Scambiatori di calore – Parte C

APPLICAZIONI AVANZATE DI FISICA

TECNICA
POLITECNICO DI TORINO

Pietro ASINARI, Eliodoro CHIAVAZZO,

Matteo FASANO
 Heat Exchangers – Summary

1. The LMTD method

2. The ε-NTU method

3. Case study 1: double-pipe heat exchanger

4. Case study 2: Shell-and-Tube heat exchanger

2
Heat exchangers types

3
The LMTD method (design method)
The logarithmic mean temperature difference (LMTD) method is very useful when
mass flow rates and inlet and outlet temperatures of the cold and hot streams are
known. Once the global heat transfer coefficient is determined, the area required to
accomplished the required heat transfer can be thus calculated.

∆𝑇1 − ∆𝑇2
Φ = 𝑈𝐴𝑆 ∆𝑇𝑙𝑚 = 𝑈𝐴𝑆
𝑙𝑛 ∆𝑇1 Τ∆𝑇2 Hypotheses:
1. The heat exchanger is insulated from its
surroundings, in which case the only
heat exchange is between the hot and cold
fluids.
2. Axial conduction along the tubes is
negligible.
3. Potential and kinetic energy changes are
negligible.
4. The fluid specific heats are constant.
5. The overall heat transfer coefficient is
constant.

Source (drawings): Y. A. Cengel, Heat Transfer: A Practical Approach 2nd Edition

4
Logarithmic mean temperature difference
(LMTD)
PARALLEL FLOW COUNTER FLOW

Tlm ,cf =
(T ci − T fi ) − (Tco − T fo )
Tlm ,cf =
(T ci − T fo ) − (Tco − T fi )
T − T fi T − T fo
ln ci ln ci
Tco − T fo Tco − T fi
Configurazione equicorrente Configurazione controcorrente

dΦ
dΦ

Temperatura
Temperatura

Tc Tc

Tf Tf

Superficie di scambio
Superficie di scambio

Legend (valid for this slide only):

c (‘caldo’) = hot stream 5
f (‘freddo’) = cold stream
Fattori di correzione per altre geometrie

Source: F. P. Incropera et al., Fundamentals of Heat and Mass Transfer, 6th Edition
6
Fattori di correzione per altre geometrie

∆𝑇𝑙𝑚 = 𝐹 × ∆𝑇𝑙𝑚,𝑐𝑓
𝐹 → correction factor to account for the different
geometries

Source (drawings): Y. A. Cengel, Heat Transfer: A Practical Approach 2nd Edition

Additional info on correction factors: http://checalc.com/solved/LMTD_Chart.html

7
 Heat Exchangers – Summary

1. The LMTD method

2. The ε-NTU method

3. Case study 1: double-pipe heat exchanger

4. Case study 2: Shell-and-Tube heat exchanger

8
The ε-NTU method (performance method)
The effectiveness-NTU method is used when mass flow rates and temperatures of
inlet streams are known, but outlet temperatures are not. In this case, the heat
exchange area is already known whereas the heat exchange rate must be calculated
along with outlet stream temperatures.

This method is used to calculate the heat transfer performance of a specified heat-
exchanger; essentially, the scope is to verify if the selected HX would do the job.

𝜀 = 𝑓(𝑁𝑇𝑈, 𝑐, 𝑓𝑙𝑜𝑤 𝑐𝑜𝑛𝑓𝑖𝑔𝑢𝑟𝑎𝑡𝑖𝑜𝑛)

𝑎𝑐𝑡𝑢𝑎𝑙 ℎ𝑒𝑎𝑡 𝑡𝑟𝑎𝑛𝑠𝑓𝑒𝑟 𝑟𝑎𝑡𝑒 Φ Φ

𝜀= = =
𝑚𝑎𝑥𝑖𝑚𝑢𝑚 ℎ𝑒𝑎𝑡 𝑡𝑟𝑎𝑠𝑛𝑓𝑒𝑟 𝑟𝑎𝑡𝑒 Φ𝑚𝑎𝑥 𝐶𝑚𝑖𝑛 (𝑇ℎ𝑖 − 𝑇𝑐𝑖 )

𝑈𝐴 𝐶𝑚𝑖𝑛
𝑁𝑇𝑈 = (Number of transfer units) 𝑐=
𝐶𝑚𝑖𝑛 𝐶𝑚𝑎𝑥

9
Effectiveness relations

10
Effectiveness graphs

PARALLEL FLOW COUNTER FLOW

11
Effectiveness graphs

12
 Heat Exchangers – Summary

13

1. The LMTD method

2. The ε-NTU method

3. Case study 1: double-pipe heat exchanger

4. Case study 2: Shell-and-Tube heat exchanger

13
Case study 1. Heat exchanger with double-pipe
and unfinned surface
A mass flow of 5000 kg/h of water must be heated from 20 °C to 35 °C. The
hot stream is water found at 140°C. The maximum allowed hot side
temperature drop is 15°C. Let assume that a double-pipe heat exchanger is
used to accomplished heat transfer between the cold and hot streams.

> Internal diameter of the external pipe 𝐷𝑖 = 0.0779 m (3 in.);

> Internal diameter of the inner pipe 𝑑𝑖 = 0.0525 m (2 in.);

> External diameter of the inner pipe 𝑑𝑜 = 0.0603 m.

Hot water properties at outlet (saturated water at 140 °C, p = 3.7 bar):

𝜌 = 932.4 kg/m3; 𝑐𝑝 = 4264 J/(kg K); 𝑘 = 0.683 W/(m K);

𝜇 = 0.209 x 10-3 Pa s.

The overall heat transfer coefficient 𝑈 has to be determined.

14
Douple-pipe heat-exchanger with bared
surface in the annulus region

15
 Overall heat transfer coefficient through a pipe

1 ln 𝑑𝑜 Τ𝑑𝑖 1
𝑅 = 𝑅𝑡𝑜𝑡 = 𝑅𝑖 + 𝑅𝑤 +𝑅𝑜 = + +
ℎ𝑖 𝐴 𝑖 2𝜋𝑘𝐿 ℎ𝑜 𝐴 𝑜

Φ = 𝑈𝐴𝑆 𝜃𝑤 = 𝑈𝐴Δ𝑇 = 𝑈𝑖 𝐴𝑖 Δ𝑇=𝑈𝑜 𝐴𝑜 Δ𝑇

1 1 1
= =
𝑈𝐴𝑆 𝑈𝑖 𝐴𝑖 𝑈𝑜 𝐴𝑜

Source (drawings): Y. A. Cengel, Heat Transfer: A Practical Approach 2nd Edition

16
Water properties

HOT-IN HOT-OUT COLD-IN COLD-OUT

Temperature, °C 140 125 20 35
Pressure, Pa 370.000 370.000 370.000 370.000
Vapor Frac 0% 0% 0% 0%
Liquid Frac 100% 100% 100% 100%
Enthalpy, J/kg -1,5E+07 -1,5E+07 -1,6E+07 -1,6E+07
Entropy, J/kg-K -7,7,E+03 -7,8,E+03 -9,1,E+03 -8,9,E+03
ρ, kg/m3 925,9 938,8 998,5 994,2
Average M.W. 18,0 18,0 18,0 18,0
cp, J/kg-K 4280 4248 4176 4171
λ, W/m-K 0,682 0,683 0,598 0,623
µ, Pa-sec 1,964E-04 2,220E-04 1,002E-03 7,196E-04
Pr (Prandtl number) 1,23 1,38 6,99 4,82

Average values (between inlet and outlet conditions) can be used, provided that the
temperature dependency of the physical property is low and/or the operating
temperature interval is rather small.

Note that hot water flows through the inner tube.

17
Heat transfer rate and Reynolds numbers
The heat transfer rate of the HX is calculated as:

Φ = 𝐺𝑐 𝑐𝑝,𝑐 𝑇𝑐,𝑜𝑢𝑡 − 𝑇𝑐,𝑖𝑛 = 𝐺ℎ 𝑐𝑝,ℎ 𝑇ℎ,𝑖𝑛 − 𝑇ℎ,𝑜𝑢𝑡 ≅ 87 𝑘𝑊𝑡ℎ

The hot stream flow rate is:

Φ
𝐺ℎ = = 4894 𝑘𝑔/ℎ = 1.36 𝑘𝑔/𝑠
𝑐𝑝 𝑇ℎ,𝑖𝑛 −𝑇ℎ,𝑜𝑢𝑡

The Reynolds number for the two fluids is respectively:

𝜌ℎ 𝑢ℎ 𝑑𝑖
𝑅𝑒ℎ 𝑖𝑛𝑛𝑒𝑟 𝑡𝑢𝑏𝑒 = = 157594
𝜇ℎ

𝜌𝑐 𝑢𝑐 𝐷ℎ
𝑅𝑒𝑐 𝑎𝑛𝑛𝑢𝑙𝑢𝑠 = = 14865
𝜇𝑐

𝐷𝑖2 𝑑𝑜2
4𝜋 −
4𝐴 4 4
𝐷ℎ = = = 𝐷𝑖 − 𝑑0 = 0.0176 𝑚
𝑝 𝜋𝐷𝑖 + 𝜋𝑑𝑜

18
Friction factor and Nusselt number
correlations

The correlations to be used for the calculation of the friction factor are
the following: (Petukhov-Kirilov, turbulent flow completely developed
in a pipe)

𝑓 = 1.58 ∙ ln 𝑅𝑒ℎ − 3.28 −2

𝑓
ℎ𝐷𝑒 𝑅𝑒𝑃𝑟
2
𝑁𝑢𝐷𝑒 = =
𝜆 1 + 8.7 𝑓 Τ2 1Τ2 (𝑃𝑟 − 1)

𝐷𝑖2 𝑑𝑜2
4𝜋 −
4𝐴 4 4 𝐷𝑖2 − 𝑑𝑜2
𝐷𝑒 = = =
𝑝 𝜋𝑑𝑜 𝑑𝑜

19
Friction factor and Nusselt number
correlations - Results

INNER TUBE ANNULUS

(HOT SIDE) (COLD SIDE)
Inner tube internal diameter (di), m 0,0525 -
Inner tube external diameter (do), m 0,0603 -
Outer tube internal diameter (Di), m - 0,0779
Hydraulic diameter for annulus, m - 0,0176
Equivalent diameter for annulus, m 0,0403
Flow area, m2 0,0022 0,0019
Mass flow, kg/s 1,36 1,39
Velocity, m/s 0,674 0,730
Reynolds number (Re) 157.594 14.865
Prandtl (Pr) 1,31 5,88
Friction factor (f) 0,0041 0,0071
Nusselt number (Nu) 376 88
Heat transfer coefficient (h), W/m2-K 4890 1326

20
Heat exchanger required length
INNER TUBE ANNULUS
(HOT SIDE) (COLD SIDE)
External convective linear resistance (Rc), m-K/W - 3,98E-03
Wall thermal conductivity, W/m-K 54
Wall linear resistance (Rm), m-K/W 4,08E-04
Overall thermal resistance (Rtot), m-K/W 5,63E-03 -
Overall heat transfer coefficient (U), W/m2-K 1077 937
LMTD, °C 104,3
Heat-exchanger surface area, m2 0,77 0,89
Heat-exchanger required length, m 4,70 4,70
Pressure loss, Pa 310 1997

1 1 𝑙𝑛 𝑑𝑜 Τ𝑑𝑖 1
Φ = 𝑈𝐴Δ𝑇𝑙𝑚 = 𝑅𝑡𝑜𝑡 = + +
𝑈𝐴 ℎ𝑖 𝐴𝑖 2𝜋𝑘𝐿 ℎ𝑜 𝐴𝑜

1 1
𝑈𝑖 = =
1 𝑙𝑛 𝑑𝑜 Τ𝑑𝑖 𝐴𝑖 𝐴𝑖 1 𝑙𝑛 𝑑𝑜 Τ𝑑𝑖 𝑑𝑖 𝑑
+ + + + 𝑖
ℎ𝑖 2𝜋𝑘𝐿 ℎ𝑜 𝐴𝑜 ℎ 𝑖 2𝑘 ℎ 𝑜 𝑑𝑜

21
Douple-pipe heat-exchanger with finned
surface in the annulus region

The heat-exchange area per unit length can be enhanced by welding thin metal fins
on the bare surface.

In our case, only the annulus region has fins longitudinal to the fluid flow.

22
Global heat transfer coefficient for a finned
surface
𝑃ℎ = 𝜋𝐷𝑖 + 𝜋𝑑𝑜 + 2𝑏𝑁𝑓

𝑃𝑒 = 𝜋𝑑𝑜 − 𝛿𝑁𝑓 + 2𝑏𝑁𝑓

𝐷𝑖2 𝑑𝑜2
4 𝜋 − − 𝑁𝑓 𝑏𝛿
4 4
𝐷ℎ =
𝜋𝐷𝑖 + 𝜋𝑑𝑜 + 2𝑏𝑁𝑓

𝐷𝑖2 𝑑𝑜2
4 𝜋 − − 𝑁𝑓 𝑏𝛿
4 4
𝐷𝑒 =
𝜋𝑑𝑜 + 2𝑏𝑁𝑓

The fin efficiency (with adiabatic tip) is:

Convection heat transfer coefficient (outer)
tanh(𝑚𝑏) 2ℎ𝑜
𝜂= with 2
𝑚 =
𝑚𝑏 𝛿𝑘 Metal thermal conductivity

23
Overall fin efficiency

𝜂𝑜𝑣 𝑆 = 𝑆𝑏 + 𝜂𝑆𝑓

𝑆𝑏 = 𝜋𝑑𝑜 − 𝛿𝑁𝑓 𝐿 Bare surface

𝑆𝑓 = 2𝑏𝑁𝑓 𝐿 Finned surface
𝑆 = 𝜋𝑑𝑜 − 𝛿𝑁𝑓 + 2𝑏𝑁𝑓 𝐿 Total surface available for heat exchange

𝜂𝑜𝑣 𝑆 = 𝑆 − 𝑆𝑓 + 𝜂𝑆𝑓
𝑆𝑓 1 − 𝜂 2𝑏𝑁𝑓 (1 − 𝜂)
𝜂𝑜𝑣 =1− =1− Overall fin efficiency
𝑆 𝜋𝑑𝑜 − 𝛿𝑁𝑓 + 2𝑏𝑁𝑓

1 1
𝑈𝑖 = =
1 𝑙𝑛 𝑑𝑜 Τ𝑑𝑖 𝐴𝑖 𝐴𝑖 1 𝑙𝑛 𝑑𝑜 Τ𝑑𝑖 𝑑𝑖 𝐴𝑖
+ + + +
ℎ𝑖 2𝜋𝑘𝐿 𝜂𝑜𝑣,𝑜 ℎ𝑜 𝐴𝑜 ℎ𝑖 2𝑘 𝜂𝑜𝑣,𝑜 ℎ𝑜 𝐴𝑜

24
Results

INNER TUBE ANNULUS

Fin height (b), m 8,00E-03
Fin width (δ), m 1,00E-03
Fins maximum number 95
Number of fins, Nf 45
Flow area, m 2 0,0022 0,0016
Hydraulic diameter for annulus, m - 0,0054
Equivalent diameter for annulus, m - 0,0072
Velocity, m/s 0,674 0,899
Reynolds number (Re) 157.576 5.592
Prandtl (Pr) 1,307 5,884
Friction factor (f) 0,0041 0,0093
Nusselt number (Nu) 376,3 39,3
Heat transfer coefficient (h), W/m2-K 4890 3344
Fin thermal conductivity, W/m-K - 54
Fin efficiency - 0,353
Overall finned surface efficiency, ηov 0,46
Ai/Ao 0,19
Overall heat transfer coefficient (U), W/m2-K 2527,0 482,3
HX surface area, m2 0,33 1,73
Heat-exchanger length, m 2,00 2,00
Pressure loss, Pa 132 5586
Pump load, kWe 0,26 10,38

25
Sensitivity analysis: variable number of fins
Lenght Ui
5,00 3000
Heat-exchanger length, m

coefficient, Ui (W/m2-K)
Overall heat transfer
4,00 2500
2000
3,00
1500
2,00
1000
1,00 500
Lenght Pumping work
0,00 0
0 10 20 30 40 50 5,00 12,0

Heat-exchanger length, m

Pumping load (kWe)

Number of fins 4,00 10,0
8,0
3,00
6,0
2,00
4,0
1,00 2,0
0,00 0,0
0 10 20 30 40 50
Number of fins

26
Heat transfer coefficients in heat exchangers

Source: Y. Cengel, Heat Transfer: A Practical Approach, 2nd Edition

27
 Heat Exchangers – Summary

28

1. The LMTD method

2. The ε-NTU method

3. Case study 1: double-pipe heat exchanger

4. Case study 2: Shell-and-Tube heat exchanger

28
Shell-and-tube heat exchanger
Shell-and-tube heat exchanger
The typology of heat-exchanger studied consists of a bundle of tubes contained in a
cylindrical enclosure or vessel. Baffles can be inserted in the vessel to yield a mixed
counter-/cross-flow configuration.
Nuclear power plant

U-tube steam generator

https://upload.wikimedia.org/wikipedia/commons/3/3f/Generic_Nuclear_PWR_Steam_Generator.svg
31
Allocation of streams and design assumptions
Generally, the following considerations apply:

✓ the more seriously fouling fluid flows through the tube side that is easier to clean;

✓ the high-pressure fluid flows through tubes;

✓ the stream with the lower heat transfer coefficient flows on the shell side, because it is
easy to design outside finned tubes.

Several possible design solutions can be also identified:

✓ straigth vs. U-tube;

✓ number of shell-side passages;

✓ baffled flow;

✓ baffle typology;

✓ etc.
32
Design methodology

Problem Identification

Selection of a Basic Heat

Exchanger Type

Selection of a Tentative Set of

Exchanger Design Parameters

Correlation for friction factors and heat

Rating and Evaluation of the
Design: Thermal Performance transfer are required to calculate fluidic and
and Pressure Drops thermal phenomena occuring iwithin the heat
exchanger

Mechanical Design, Costing,

etc.

33
TEMA standards

34
TEMA Nomenclature

http://standards.tema.org/images/HeatExchangerNomenclature.pdf
35
Basic design of an heat exchanger
The size of heat transfer can be obtained from the energy balance equation: Tc,o

Φ
𝐴0 =
𝑈0 𝐹Δ𝑇𝑙𝑚 Gc Tf,i Gf
Tc,i
Φ = 𝑚𝑐
ሶ 𝑝 𝑐
𝑇𝑐𝑜 − 𝑇𝑐𝑖 = 𝑚𝑐
ሶ 𝑝 ℎ
𝑇ℎ𝑖 − 𝑇ℎ𝑜

F is an adimensional coefficient depending on flow Tf,o

configuration and two adimensional temperature ratios.

F = f ( P, R, flow)

36
Basic design of an heat exchanger

The global heat transfer coefficient referred to the outer surface (i.e., O.D. of the
tube bundle) is:

1 𝐴𝑜 1 𝑅𝑓𝑖 𝑅𝑓𝑜 1
= + + 𝐴𝑜 𝑅𝑤 + +
𝑈𝑜 𝐴𝑖 𝜂𝑖 ℎ𝑖 𝜂𝑖 𝜂 𝑜 𝜂 𝑜 ℎ𝑜

𝑅𝑓𝑖 and 𝑅𝑓𝑜 are the internal and external fouling resistances, respectively.

37
Typical film heat transfer coefficients for
Shell-and Tube heat exchangers

38
 Basic design of an heat exchanger
In the preliminary calculation, the surface to be determined is calculated as following:

Φ
𝐴0 =
𝑈0 𝐹Δ𝑇𝑙𝑚

This area can be thus translated into sound preliminary dimensions of the heat
exchanger to be designed:

𝐴0 = 𝜋𝑑𝑜 𝑁𝑡 𝐿,
where:

𝑁𝑡 is the number of tubes;

𝑑𝑜 is the outer diameter of the tube;
𝐿 is the tube length.

39
Basic design of an heat exchanger – Shell
geometry
𝜋𝐷𝑆2 equivalent to 𝐶𝑇𝑃 𝐷𝑆2
𝑵𝒕 = (𝐶𝑇𝑃) 𝑵𝒕 = 0.785
4𝐴𝑖 𝐶𝐿 (𝑃𝑅)2 𝑑𝑜2

where: 𝐴𝑖 = (𝐶𝐿)𝑃𝑇2 (projected area of the single tube)

FLOW

°
45
FLOW 30°
𝐶𝑇𝑃 = 0.93 1 𝑡𝑢𝑏𝑒 𝑝𝑎𝑠𝑠
𝐶𝑇𝑃 = 0.90 2 𝑡𝑢𝑏𝑒 𝑝𝑎𝑠𝑠
𝐶𝑇𝑃 = 0.85 3 𝑡𝑢𝑏𝑒 𝑝𝑎𝑠𝑠
𝐶𝐿 = 1 𝑓𝑜𝑟 90° 𝑎𝑛𝑑 45°
FLOW 90° FLOW 60°
𝐶𝐿 = 0.87 𝑓𝑜𝑟 30° 𝑎𝑛𝑑 60°
𝑃𝑇 tube pitch
𝑃𝑇
𝑃𝑅 =
𝑑𝑜 do
do

FLOW 30° C PT FLOW 90° C PT

40
Basic design of an heat exchanger – Shell
geometry
Finally, the shell diameter can be obtained as:

1Τ2
2 𝐶𝐿 𝐴0 (𝑃𝑅)2 𝑑𝑜
𝑫𝒔 =
𝜋 𝐶𝑇𝑃 𝐿
1Τ2
𝐶𝐿 𝐴0 (𝑃𝑅)2 𝑑𝑜
= 0.637
𝐶𝑇𝑃 𝐿

Or
4 𝐶𝐿
𝑫𝒔 = 𝑃 𝑁
𝜋 𝐶𝑇𝑃 𝑇 𝑡

41
 Case study – Problem Definition
Stream data

Hot side (shell side) Cold side (tube side)

𝑇ℎ𝑖 = 67°𝐶 𝑇𝑐𝑖 = 17°𝐶 (raw water)

𝑝ℎ𝑖 = 0.3 𝑏𝑎𝑟 𝑇𝑐𝑜 𝑚𝑖𝑛. = 40°𝐶
𝑚ሶ ℎ = 50,000 𝑘𝑔/ℎ 𝑐𝑝,𝑐 = 4184 𝐽/(𝑘𝑔 − 𝐾)
𝑚ሶ 𝑐 = 30,000 𝑘𝑔/ℎ
𝑝𝑐𝑖 = 0.3 𝑏𝑎𝑟

Heat exchanger type: shell / tube with baffles.

Geometrical data

Tube O.D. (𝑑𝑜 ) = 19 mm 𝑃𝑅 = 1.25 (pitch ratio)

Tube I.D. (𝑑𝑖 ) = 16 mm 𝐵= 0.6 𝐷𝑆 (baffle spacing; baffle cut is 25%)
𝐿𝑚𝑎𝑥 = 5 m

42
Thermodynamic and thermo-physical data

Shell side Tube side

HOT-IN HOT-OUT COLD-IN COLD-OUT
Total Flow kg/sec 13,89 13,89 8,33 8,33
Temperature °C 67,0 53,2 17,0 40,0
Pressure Pa 30.000 30.000 100.000 100.000
Vapor Frac 0% 0% 0% 0%
Liquid Frac 100% 100% 100% 100%
Enthalpy J/kg -1,6,E+07 -1,6,E+07 -1,6,E+07 -1,6,E+07
Entropy J/kmol-K -1,53E+05 -1,56E+05 -1,65E+05 -1,59E+05
Entropy J/kg-K -8,5,E+03 -8,7,E+03 -9,2,E+03 -8,9,E+03
Density kg/cum 979,4 986,5 998,9 992,3
Average MW 18,0 18,0 18,0 18,0
CPMX J/kg-K 4181 4175 4178,8 4172
Density kg/cum 979,4 986,5 998,9 992,3
KMX Watt/m-K 0,660 0,647 0,593 0,630
MUMX Pa-sec 4,212E-04 5,188E-04 1,080E-03 6,532E-04
Pr (Prandtl number) 2,67 3,35 7,62 4,33

43
 Case study – Heat duty calculation
The heat duty of the heat-exchanger can be calculated from the energy balance on the cold
side:
Φ = 𝑚𝑐
ሶ 𝑝 𝑐
𝑇𝑐𝑜 − 𝑇𝑐𝑖 = 800 𝑘𝑊

The hot water temperature can be then calculated as:

Φ
𝑇ℎ𝑜 = 𝑇ℎ𝑖 − = 53.2 °𝐶
𝑚𝑐
ሶ 𝑝 ℎ

As first approximation, the convection heat transfer coefficients are estimated from Tables.

𝑊
ℎ𝑜 = 5000 2 (𝑠ℎ𝑒𝑙𝑙 𝑠𝑖𝑑𝑒)
𝑚 𝐾
𝑊
ℎ𝑖 = 4000 2 (𝑡𝑢𝑏𝑒 𝑠𝑖𝑑𝑒)
𝑚 𝐾

44
Case study – Global heat transfer coefficient

TUBE SIDE SHELL SIDE

Heat duty, kW 800,0
Inner diameter di, mm 0,016 -
Outer diameter, do, mm 0,019 -
Baffle spacing, m 0,2
Baffle cut 25%
Pitch ratio (square pitch) PT/do 1,25
Tube length, m 3
Assumed hi, W/m2-K 4000 -
Assumed ho, W/m2-K - 5000
Wall thermal conductivity, W/m-K 60
Fouling resistance Rft, m2-K/W 0,000176
Tentative Uo, W/m2-K - 1428,4
Tentative Ui, W/m2-K 1696 -
LMTD, °C 31,4
Assumed correction factor F 0,9
LMTD corrected , °C 28,2
Exchange area shell side Ao, m2 19,83
Shell diameter Ds, m 0,30
Number of tubes, Nt 111

45
Heat exchanger selection according to TEMA
(Tubular Exchanger Manufacturers Association)
TIPOLOGIA E

46
Vantaggi e svantaggi

http://www.hed-inc.com/shell-tube.html

47
Heat exchanger selection according to TEMA
(Tubular Exchanger Manufacturers Association)

48
 TEMA 2-P Shell-and-tube heat-exchanger –
Geometry definition
Inner diameter di, m 0,016
Outer diameter do, m 0,019
Baffle spacing B, m 0,25
Baffle cut 25%
Number of tubes, Nt 124
Number of tube passes, Np 2
Shell internal diameter Ds, m 0,39
Maximum tube length, m 5
do do

C PT FLOW 30° C PT
FLOW 90°

3
4𝐴 4(𝑃𝑇2 − 𝜋𝑑𝑜2 Τ4) 4𝐴 4(𝑃𝑇2 − 𝜋𝑑𝑜2 Τ8)
𝐷𝑒 = = 𝐷𝑒 = = 4
𝑝 𝜋𝑑𝑜 𝑝 𝜋𝑑𝑜 /2
𝐷𝑠 𝐶𝐵 𝑚ሶ
𝐴𝑠 = 𝑁𝑡 𝐶𝐵 = 𝐺𝑠 =
AAFT - 2013 𝑃𝑇 𝐴𝑠 49
 Heat transfer correlations
In the presence of baffles, due to the increased turbulence the heat transfer coefficient is
enhanced compared to the case with undisturbed flow along the axis of tubes without baffles.

Kern’s correlation can be used for the shell side:

0.55 1Τ3 0.14

ℎ𝑜 𝐷𝑒 𝐷𝑒 𝐺𝑠 𝑐𝑝 𝜇 𝜇
𝑁𝑢 = = 0.36
𝑘 𝜇 𝑘 𝜇𝑤

3
𝐺𝑠 𝐷𝑒
2 × 10 < 𝑅𝑒𝑠 = < 1 × 106
𝜇
For the tube side the following correlations can be used:
(𝑓 Τ2) 𝑅𝑒 − 1000 𝑃𝑟
𝑁𝑢 =
1 + 12.7 𝑓 Τ2 1Τ2 𝑃𝑟 2Τ3 − 1

𝑓 = (1.58 ln 𝑅𝑒 − 3.28)−2

50
Results

TUBE (cold side) SHELL (hot side)

Wall thermal conductivity, W/m-K 60
Approximated wall temperature Tw, °C 317
µw, Pa/s 6,04E-04
Equivalent diameter De, m 0,0188
Clearance C, m 0,005
Shell bundle cross-flow area As, m 0,0195
Shell mass velocity ms, kg/s-m2 712,25
Shell Reynolds number Res 2,85E+04
Shell Nusselt number, Nus 141,45
Shell heat transfer coefficient ho, W/m2-K 4916,0
Tube flow area, m2 0,0125
Tube velocity, m/s 0,67
Tube Reynolds number 1,23E+04
Tube friction factor 0,00743
Tube Nusselt number 90,7
Tube heat transfer coefficient hi, W/m2-K 3464,3
Uo, W/m2-K 1334,4
Ui, W/m2-K 1584,6
Exchange area shell side Ao, m2 21,2
Tube length, m 2,87

51
Shell side transfer – Bell-Delaware method
(alternative to Kern’s correlation)

ho = hid  J c  J l  J b  J s  J r

Leakages (≈ 0.6)

. 2/3 0.14
 ms    s   s 
hid = ji c ps         

Pure cross-flow
 
 As   c ps      s , w 
ji → Colburn j − factor
a
 1.33 
  (Re s )a2
a3
ji = a1   a=
1 + 0.14  (Re s ) 4
a
 PT / d 0 
b
 1.33 
  (Re s )b2
b3
f = b1   b=
1 + 0.14  (Re s ) 4
b
 PT / d 0 
52
Shell side transfer – Bell-Delaware method
(alternative to Kern’s correlation)

53