Types of Shell and Tube Heat Exchangers

Harlan Bengtson Updated May 21, 2010

The shell and tube heat exchanger is one of the most common types of heat exchangers. The heat transfer coefficient affects the heat transfer rate and the total heat exchanger tube area needed. There are several configuration options for flow pattern through a shell and tube heat exchanger.

Introduction
The shell and tube heat exchanger is made up of a bundle of parallel heat exchanger tubes held in place with tube sheets and placed into a shell. The heat exchange always takes place between two fluids through the heat exchanger tube wall. There are quite a variety of flow options for shell and tube heat exchangers, as discussed in the following sections. In all of the configurations for shell and tube heat exchangers, one fluid passes through the tubes (the tube side fluid) and the other passes through the shell (the shell side fluid). The choice of shell and tube heat exchanger configuration affects the overall heat transfer coefficient and thus also affects the rate of heat transfer and the heat exchanger tube surface area needed.

Terminology for Shell and Tube Heat Exchangers

The two fluids that are exchanging heat in a shell and tube heat exchanger are referred to as the tube side fluid (which goes through the heat exchanger inside the tubes) and the shell side fluid (which goes through the heat exchanger in the shell, outside the tubes). Important components of a shell and tube heat exchanger (in addition to the obviously important tubes and shell) are the tube sheets, baffles, end channels for the tube side fluid, and inlet & outlet nozzles for both the shell side fluid and the tube side fluid. These various components are shown in the diagram of a straight tube, two pass, shell and

tube heat exchanger at the left. As shown in the diagram, the tube sheets serve to hold the tubes in place in a "tube bundle" (see diagrams in next section), and also can serve as baffles to create turbulence and a more consistent residence time for the shell side fluid. The end channels distribute the tube side fluid and create either a transition to the outlet nozzle or a means to send the tube side fluid back to the other end of the heat exchanger, as in the diagram above.

U-tube or Straight tube?

O ne way of classifying shell and tube heat exchangers is U-tube or straight tube. The diagram on the left shows a schematic diagram of a U-tube, shell and tube heat exchanger and the flows in and out. The diagram on the right shows a tube bundle for a U-tube heat exchanger. The tube sheets which hold the tubes in place and serve as baffle for the flow of the shell side fluid can be seen in the tube bundle picture. With Utube heat exchangers, the tube side fluid enters and leaves at the same end of the heat

exchanger as shown in the diagram at the left. Straight tube heat exchangers are the other possibility.

The diagram at the right shows a schematic diagram of a straight tube, shell and tube heat exchanger and the diagram on the left shows a tube bundle for a straight tube heat exchanger. A straight tube heat exchanger is easier to clean than a U-tube heat exchanger, so it is better for a tube side fluid that tends to foul the tube, causing a need for regular cleaning. The U-tube heat exchanger works well if the two fluids have greatly different thermal expansion characteristics, because it can allow the tube and the shell to expand or contract independently.

How Many Passes for the Shell and Tube Heat Exchanger?
The number of passes refers to the tube side fluid. The shell and tube heat exchanger is commonly made in single pass, two pass and four pass configurations, although custom multipass heat exchangers with yet another number of passes are also available. A Utube heat exchanger is automatically a two pass heat exchanger, because of the heat exchanger tube U turn as shown in the diagram above. The first image in this article is a straight tube, two pass heat exchanger. Instead of a U-tube bundle, the end channel and an internal horizontal baffle, are used to cause the two passes. A schematic diagram for a straight tube, one pass heat exchanger is shown in the previous section.

Effects of Shell and Tube Heat Exchanger Configuration on the Overall Heat Transfer Coefficient
The choice of configuration for a shell and tube heat exchanger affects the overall heat transfer coefficient and thus affects the heat exchanger tube surface area needed. The flow pattern through most shell and tube heat exchangers is a combination of counterflow, crossflow and parallel flow. In general counterflow is the most effective configuration for minimizing the needed heat transfer surface area. See the articles, 'Fundamentals of Heat Exchanger Theory and Design,' and 'Preliminary Heat Exchanger Design Example,' for more detailed information about the basic heat exchanger design equation, and its use with the overall heat transfer coefficient and the log mean temperature difference for design of heat exchangers.

Image Credits
Straight tube, two pass, shell and tube heat exchanger: http://www.esteamboilers.com/en/shell_tube_heat_ex.asp Tube bundle for a straight tube heat exchanger: http://www.rubiconhx.com/heatexchangers.html U-tube bundle: www.hydrothrift.com/shellntub.html

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Features and Characteristics of the Flat Plate Heat Exchanger

Harlan Bengtson Updated May 24, 2010

A flat plate heat exchanger uses a metal heat exchanger plate between the two fluids. This gives it a higher overall heat transfer coefficient than shell and tube heat exchangers, the most widely used type of industrial heat exchanger. A flat plate heat exchanger disassembles for ease of cleaning.

Introduction
The plate heat exchanger is also known as a plate and frame heat exchanger or flat plate heat exchanger. In plate heat exchangers, heat is transferred from one fluid to another through a flat metal heat exchanger plate, instead of through a heat exchanger tube wall as with double pipe or shell and tube heat exchangers. There are both advantages and disadvantages of the flat plate heat exchanger, which will be discussed in the following sections.

Plate Heat Exchanger Configuration

Some flat plate heat exchangers have the plates welded or brazed together and are not easily disassembled. The type of plate heat exchanger to be considered in this article is also sometimes called a plate and frame heat exchanger. It is made up of a series of plates held together in a frame with a fixed space

between

adjacent plates. The flow pattern is set up so that the hot

fluid flows between alternate spaces between plates with the cold fluid going through the other set of spaces between plates. The general configuration and flow pattern is shown in the diagram at the left. Plate and frame heat exchangers can be taken apart for cleaning as indicated in the diagram. Gaskets are used between plates to provide a seal. A picture of a flat plate heat exchanger that is assembled and clamped together is shown at the right.

Advantages of a Flat Plate Heat Exchanger

A flat plate heat exchanger (plate and frame type) has the following advantages over the widely used shell and tube heat exchangers.
1. High value for overall heat transfer coefficient, U - For the same two fluids, a flat plate heat exchanger typically has a U value much higher than either a shell and tube heat exchanger or a spiral heat exchanger. 2. Compact design - The combination of high value for the overall heat transfer coefficient and the general compact configuration of the flat plate heat exchanger lead to its ability to have the same thermal capacity as a shell and tube heat exchanger as much as five times its size 3. Easy maintenance and cleaning - The fact that a plate and frame heat exchanger can be taken apart as discussed in the previous section, allows for easy cleaning and maintenance. A plate and frame heat exchanger can be designed to allow for easy addition or removal of plates to expand or reduce its heat transfer capacity. 4. Temperature control - A flat plate heat exchanger works well with small temperature differences between the hot fluid and the cold fluid.

Disadvantages of a Flat Plate Heat Exchanger

A flat plat heat exchanger also has some disadvantages in comparison with other types of heat exchangers as follows:
1. Potential for leakage - Although plate and frame heat exchangers are designed to allow the plates and the gaskets between them to be firmly clamped together, there is still a greater potential for leakage than with either shell and tube or spiral heat exchangers. 2. Higher pressure drop - The narrow passageways for fluid flow, which lead to a high overall heat transfer coefficient, also lead to a higher pressure drop, and thus a higher cost for pumping, than shell and tube heat exchangers. 3. Not good for large fluid temperature differences - A flat plate heat exchanger does not work as well as a shell and tube heat exchanger for cases where there is a large temperature difference between the two fluids. 4. Doesn't work well with very high fluid temperatures - The gaskets may impose temperature limitations for plate and frame heat exchangers.

Summay
Advantages of a flat plate heat exchanger over some other types of heat exchangers are due to its high overall heat transfer coefficient, leading to a compact size, and due to

its ease of cleaning. The disadvantages of a flat plate heat exchanger in comparison with other types of heat exchangers are related to its potential for leakage and relatively high pressure drop.

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