Heat Exchanger

(Alat Penukar Kalor)

MCF 41264 (4 SKS)
 Tujuan Pembelajaran

Mengenal jenis-jenis alat penukar kalor

Mengetahui jenis APK yang paling baik untuk
aplikasi industri yang ada
Mengerti parameter kunci dalam desain APK
Mampu mengestimasi ukuran dan harga APK
Memiliki latarbelakang untuk menggunakan
software komersial untuk mendesain APK
 Pendahuluan Heat Exchangers

Untuk apakah Alat Penukar Kalor?

Jenis-Jenis Alat Penukar Kalor
Bagaimana Alat penukar kalor
diklasifikasikan?
Dasar-dasar perencanaan Alat Penukar
Kalor?
 Contents
Mengapa kita membutuhkan APK
Konstruksi APK
Macam-macam APK
Proses Desain APK
 Apakah fungsi APK itu ?

Untuk memperoleh aliran fluida pada

temperatur yang tepat untuk proses
berikutnya
Untuk mengkondensasikan uap
Untuk menguapkan fluida
Untuk memanfaatkan panas buang
Untuk pembangkitan daya
Feed-effluent exchanger

Feed-effluent
Exothermic reaction
exchanger

Heat recovery
 Distillation

Reflux condenser

Top product
Feed Column

Reboiler

Bottom product
 Naphtha
and gases
Typical crude oil distillation
Top pump
Kerosene
around

Desalter E2

Distillation tower
Light
Top pump gas oil
around Heavy gas oil Bottom
pump
around
E2 E3 Heavy
E5 gas oil
Light gas oil
Kerosene
E4
E1 Bottom pump
Furnace
around
Reduced
E5 E6 crude

Storage Reduced crude

Geothermal Power cycle

Feedwater
heater
Nuclear Power Plant
Ocean Thermal Energy Conversion
 Contoh sebuah APK

Bundle for shell-and-tube exchanger

 Heat utilities

Hot utilities
Boiler generating service steam (maybe a combined
heat and power plant)
Direct fired heaters (furnace)
Electric heaters
Cold utilities
Cooling tower (wet or dry) providing service cooling
water
Direct air-cooled heat exchanger
Jenis-Jenis Alat Penukar Kalor
 KATEGORI UTAMA ALAT PENUKAR KALOR

Heat exchangers

Recuperator Regenerators
s
Wall
Wall separating
separating streams
streams Direct contact

Kebanyakan Alat Penukar Kalor memeliki 2 aliran

fluida, hot dan cold, tetapi beberapa memiliki lebih
dari dua aliran fluida
 Recuperators dan regenerators

Recuperative
Has separate flow paths for each
fluid which flow simultaneously
through the exchanger transferring
heat between the streams Rotating wheel
Regenerative
Has a single flow path which the hot
and cold fluids alternately pass
through.
 Compactness

Can be measured by the heat-transfer area

per unit volume or by channel size
Conventional exchangers (shell and tube)
have channel size of 10 to 30 mm giving
about 100m2/m3
Plate-type exchangers have typically 5mm
channel size with more than 200m2/m3
More compact types available
Compactness
 Double Pipe
Simplest type has one tube inside another - inner
tube may have longitudinal fins on the outside

However, most have a

number of tubes in the outer
tube - can have very many
tubes thus becoming a shell-
and-tube
 Shell and Tube

Alat Penukar Kalor tipe shell and tube yang biasa digunakan pada industri proses
Shell-side flow
Baffle
Fin Tube
Complete shell-and-tube
 Plate and frame

Plates hung vertically and

clamped in a press or frame.
Gaskets direct the streams
between alternate plates and
prevent external leakage
Plates made of stainless steel or
higher quality material
Plates corrugated to give points
of support and increase heat
transfer
 Plate types

Corrugations on plate
improve heart transfer
give rigidity

Many points of
contact and a
tortuous flow path

Chevron Washboard
 General view of plate
exchanger
Plate exchanger
normally refers to
a gasketted plate-
and-frame
exchanger
 Flow Arrangement within a PHE
Gaskets
arranged for
each stream to
flow between
alternate plates

Alternate plates (often same plate types inverted)

 Air-cooled exchanger

Air blown across finned tubes (forced draught

type)
Can suck air across (induced draught)

Finned tubes
ACHE bundle
 Plate-fin exchanger

Made up of flat plates (parting sheets) and

corrugated sheets which form fins
Brazed by heating in vacuum furnace
Can have many streams

7 or more streams are typical

Typical plate-fin
 Spiral (plate)

Good for streams with large solids

 Cooling Towers
Large shell with packing at the bottom over which
water is sprayed
Cooling by air flow and evaporation
Air flow driven by forced or natural convection
Need to continuously make up the cooling water lost
by evaporation
 Agitated Vessel

Used for batch heating

or cooling of fluids
An agitator and
baffles promote
mixing
A range of agitators
are used
Often used for batch
chemical reaction
 Printed circuit heat exchanger
Plates are etched to
give flow channels
Stacked to form
exchanger block
Block diffusion welded
under high pressure
and temperature
Bond formed is as
strong as the metal
itself
Printed circuit exchanger

Note that compact does not

mean small but means large
surface area per unit volume
 Distribution of types
in terms of market value in Europe

Waste Heat
Boilers Other Heat
Cooling Towers Recovery
5%
9% 10%

Air Coolers
10%
Other Proprietary
2%

Other Plate
4%

Plate & Frame Shell & Tube

13% 42%

Other Tubular
5%
 Preliminary points on selection

Tubes and cylinders can withstand higher

pressures than plates
If exchangers can be built with a variety of
materials, then it is more likely that you can
find a metal which will cope with extreme
temperatures or corrosive fluids
More specialist exchangers have fewer
suppliers, longer delivery times and must be
repaired by experts
S&Ts cannot normally give high thermal
effectiveness,
 Design sequence

Design the process flow flow-sheet

Specify the heat exchanger requirements
Select the best exchanger type for the job
Thermal design of exchanger
Mechanical design of exchanger
Looping back may be necessary at any stage
but can be difficult because of the project
timetable
 Who does what?

Processor/
end user
Design the process flow flow-
sheet
Specify the heat exchanger
requirements
Select the best exchanger type Contractor
for the job
Thermal design of exchanger
Mechanical design of exchanger
Manufacturer
 The design of a process heat exchanger usually
proceeds through the following steps:

1. Process conditions (stream compositions, flow rates, temperatures,

pressures) must be specified.
2. Required physical properties over the temperature and pressure ranges of
interest must be obtained.
3. The type of heat exchanger to be employed is chosen.
4. A preliminary estimate of the size of the exchanger is made, using a heat-
transfer coefficient appropriate to the fluids, the process,and the
equipment.
5. A first design is chosen, complete in all details necessary to carry out the
design calculations.
6. The design chosen in step 5 is evaluated, or rated, as to its ability to meet
the process specifications with respect to both heat transfer and pressure
drop.
 7.On the basis of the result of step 6, a new configuration is chosen if
necessary and step 6 is repeated. If the first design was inadequate to
meet the required heat load, it is usually necessary to increase the size of
the exchanger while still remaining within specified or feasible limits of
pressure drop, tube length, shell diameter, etc. This will sometimes mean
going to multiple-exchanger configurations. If the first design more than
meets heat-load requirements or does not use all the allowable pressure
drop, a less expensive exchanger can usually be designed to fulfill process
requirements.

8. The final design should meet process requirements (within reasonable

expectations of error) at lowest cost. The lowest cost should include
operation and maintenance costs and credit for ability to meet long-term
process changes, as well as installed (capital) cost. Exchangers should not
be selected entirely on a lowest-first-cost basis, which frequently results in
future penalties.
 Exchanger specification
Heat load (duty) along with the terminal
temperatures of the streams
Maximum pressure drop each streams
liquids - 0.5 bar
gases/vapours below 2bar - 10% of inlet pressure
Design pressures and temperatures
Size/weight constraints
Standards to apply
General standards like ISO, TEMA, ASME, API etc
Companies own standards
Other requirements
 The designer must supply an exchanger which

Meets the stated specification

Has reasonable initial costs and operating
costs (most exchangers are bought on the
basis of the cheapest tender)
Has a reasonable lifetime
no damaging vibration
no thermal fatigue
no unexpected fouling or corrosion
 Fouling may be classified by mechanism into six
basic categories:
1. Corrosion fouling. The heat transfer surface reacts chemically with
elements of the fluid stream producing a less conductive,corrosion layer on
all or part of the surface.
2. Biofouling. Organisms present in the fluid stream are attracted to the
warm heat-transfer surface where they attach, grow, and reproduce. The
two subgroups are microbiofoulants such as slime and algae and
macrobiofoulants such as snails and barnacles.
3. Particulate fouling. Particles held in suspension in the flow stream will
deposit out on the heat-transfer surface in areas of sufficiently lower
velocity.
4. Chemical reaction fouling (ex.Coking). Chemical reaction of the fluid
takes place on the heat-transfer surface producing an adhering solid
product of reaction.
5. Precipitation fouling (ex.Scaling). A fluid containing some dissolved
material becomes supersaturated with respect to this material at the
temperatures seen at the heat-transfer surface. This results in a
crystallization of the material which plates out on the warmer surface.
6. Freezing fouling. Overcooling of a fluid below the fluids freezing point at
the heat-transfer surface causes solidification and coating of the heat-
transfer surface.
 Pemilihan Heat
Exchanger
Choosing the best exchanger for a
given process application
 Langkah-langkah

Coarse filter
Buang Jenis Alat Penukar Kalor yang
tidak memenuhi ketentuan tekanan dan
temperatur operasi, fluid-material
compatibilitas, kondisi termal yang
extrem
Fine filter
Estimasi Harga
 Coarse filter

Use information on next few slides to reject

those exchangers which are clearly out of
range or are otherwise unsuitable
The information is summarised in the table
At this stage, if in doubt, include the
exchanger (poor choices are likely to turn
out expensive at the fine filter stage)
 Point-point utama

Tube /pipa dan cylinders dapat menahan tekanan

yang lebih besar dibanding dengan plates
Jika APK dapat dibangun dengan material yang
bervariasi, berarti anda dapat menentukan metal
yang dapat tahan terhadap temperatur yang extrem
dan fluida-fluida yang korosif
APK yang khusus hanya memiliki supplier yang
sangat sedikit, waktu pengiriman barang yang
lebih lama dan harus diperbaiki oleh orang yang
sangat ahli.
 Thermal effectiveness

Stream temperature rise divided by the theoretically

maximum possible temperature rise
T1,in T1,out

T1,in T2 ,in
T1,in T1,out

T2,out T2,in
 Double Pipe
Tipe APK ini adalah yang paling simpel, memiliki satu tube di
dalam dan satu tube pada bagian luar, Tube paling dalam bisa
memiliki sirip secara longitudinal pada bagian luarnya

Walaupun demikian terdapat

pula jenis APK ini yang
memeiliki beberpa tube didalam
tube luarnya.
 Double pipe

Ukuran Normal
0.25 to 200m2 (2.5 to 2000 ft2) per unit
Note multiple units are often used
Built of carbon steel where possible
 Advantages/disadvantages of double-pipe
Advantages
Easy to obtain counter-current flow
Can handle high pressure
Modular construction
Easy to maintain and repair
Many suppliers
Disadvantage
Become expensive for large duties (above 1MW)
 Scope of double pipe
Maximum pressure
300 bar(abs) (4500 psia) on shell side
1400 bar(abs) (21000 psia) on tubeside
Temperature range
-100 to 600oC (-150 to 1100oF)
possibly wider with special materials
Fluid limitations
Few since can be built of many metals
Maximum = 0.9
Minimum T = 5 K
 Shell and tube

Size per unit 100 - 10000 ft2 (10 - 1000 m2)

Easy to build multiple units
Made of carbon steel where possible
 Advantages/disadvantages of S&T
Advantages
Extremely flexible and robust design
Easy to maintain and repair
Can be designed to be dismantled for cleaning
Very many suppliers world-wide
Disadvantages
Require large plot (footprint) area - often need
extra space to remove the bundle
Plate may be cheaper for pressure below 16 bar
(240 psia) and temps. below 200oC (400oF)
 Scope of shell and tube
Essentially the same as a double pipe

Maximum pressure
300 bar(abs) (4500 psia) on shell side
1400 bar(abs) (21000 psia) on tubeside
Temperature range
-100 to 600oC (-150 to 1100oF)
possibly wider with special materials
Fluid limitations
Few since can be built of many metals
Maximum = 0.9 (less with multipass)
Minimum T = 5 K
 Plate and frame
Plates pressed from stainless steel
or higher grade material
titanium
incoloy
hastalloy
Gaskets are the weak point. Made
of
nitrile rubber
hypalon
viton
neoprene
 Advantages of plate and frame
High heat transfer - turbulence on both sides
High thermal effectiveness - 0.9 - 0.95 possible
Low T - down to 1K
Compact - compared with a S&T
Cost - low because plates are thin
Accessibility - can easily be opened up for inspection and
cleaning
Flexibility - Extra plates can be added
Short retention time with low liquid inventory hence
good for heat sensitive or expensive liquids
Less fouling - low r values often possible
 Disadvantages of plate & frame
Pressure - maximum value limited by the sealing of the
gaskets and the construction of the frame.
Temperature - limited by the gasket material.
Capacity - limited by the size of the ports
Block easily when solids in suspension unless special
wide gap plates are used
Corrosion - Plates good but the gaskets may not be
suitable for organic solvents
Leakage - Gaskets always increase the risk
Fire resistance - Cannot withstand prolonged fire
(usually not considered for refinery duties)
 Scope of plate-frame
Maximum pressure
25 bar (abs) normal (375 psia)
40 bar (abs) with special designs (600 psia)
Temperature range
-25 to +1750C normal (-13 to +3500F)
-40 t0 +2000C special (-40 to +3900F)
Fluid limitations
Mainly limited by gasket
Maximum = 0.95
Minimum T = 1 K
 Welded plates
Wide variety of proprietary types each with one or
two manufactures
Overcomes the gasket problem but then cannot be
opened up
Pairs of plates can be welded and stacked in
conventional frame
Conventional plate and frame types with all-welded
(using lasers) construction have been developed
Many other proprietary types have been developed
Tend to be used in niche markets as replacement to
shell-and-tube
Air-cooled exchangers
 Advantages of ACHEs
Air is always available
Maintenance costs normally less than for water
cooled systems
In the event of power failure they can still transfer
some heat due to natural convection
The mechanical design is normally simpler due to
the pressure on the air side always being closer to
atmospheric.
The fouling of the air side of can normally be
ignored
 Disadvantages of ACHEs

Noise - low noise fans are reducing this

problem but at the cost of fan efficiency and
hence higher energy costs
May need special features for cold weather
protection
Cannot cool to the same low temperature as
cooling tower
 Scope of Air Cooled Exchangers

Maximum pressure - tube(process) side:

500 bar (7500psia)
Maximum temperature: 600oC (1100o F)
Fluids: subject to tube materials
Size per unit: 5 - 350m2 (50 - 3500ft2 ) per
bundle (based on bare tube)
 Plate Fin Exchangers

Formed by vacuum brazing

aluminium plates separated
by sheets of finning
Noted for small size and
weight. Typically, 500
m2/m3 of volume but can be
1800 m2/m3
Main use in cryogenic
applications (air
liquifaction)
Also in stainless steel
 Scope of plate-fin exchanger
Max. Pressure 90 bar (size dependent)
Temperatures -200 to 150oC in Al
Up to 600 with stainless
Fluids Limited by material
Duties Single and two phase
Flow configuration Cross flow, Counter flow
Multistream Up to 12 streams (7 normal)
Low T Down to 0.1oC
Maximum T 50oC typical
High Up to 0.98
Important to use only with clean fluids
 Printed Circuit Exchanger
Very compact
Very strong construction
from diffusion welding
Small channels (typically
1 - 2 mm mean hydraulic
diameter)
Can be made in stainless
steel, nickel (and alloys),
copper (and alloys) and
titanium
 Scope of PCHE
Maximum Pressure 1000bar (difference 200bar)
Temperature -200 to +800oC for stainless
steel but depends on metal
Fluids Wide range
but must be low fouling
Normal Size 1 to 1000m2
Flow configuration Crossflow or counterflow
Effectiveness up to 0.98
Low T Yes
Thermal cycling Has caused problems
 Example

Which exchanger types can be used for

condensing organic vapour at -60oC and 60
bar by boiling organic at -100oC and 70
bar?
Would you modify your choice if the
boiling stream were subject to fouling
requiring mechanical cleaning?
 Heat exchanger costing - fine filter
Full cost made up of
Capital cost
Installation cost
Operating cost
The cost estimation method given here is based
only on capital cost - which is the way it is often
done
Note: installation costs can be as high as capital
cost except for compact exchangers
Installation cost considerations can predominate
on offshore plant
 Scoping
The cost estimate method given here is for the
preliminary plant design stage - scoping
Note that we are trying to estimate the cost of an
exchanger before we have designed it
Full design and cost would be done later
 Quick sizing of heat exchangers

Tb Ta

We estimate the area from

Q
A
UT
Where
T FT Tm

Ta Tb
Tm
ln(Ta / Tb )
 FT correction factor
This correction accounts for the two streams not
following pure counter-current flow
At the estimation stage, we do not know the detailed
flow/pass arrangement so we use
FT = 1.0 for counter flow which includes most compact and
double-pipe
FT = 0.7 for pure cross flow which includes air-cooled and
other types when operated in pure cross flow (e.g. shell-and-
tube)
FT = 0.9 for multi-pass
FT = 1.0 if one stream is isothermal (typically boiling and
condensation)
 Estimating U

This may be estimated for a given exchanger type

using the tables from ESDU (given below)
These tables give U values as a function of Q/T
(the significance of this group will become clear
later)
Example: high pressure gas cooled by treated
cooling water in a shell-and-tube, where
Q/T = 30 000 W/K
gives U = 600 W/m2K
This includes typical fouling resistances
 Estimating cost
This has often been done by multiplying the
calculated area, A, by a cost per unit area
But, when comparing exchangers, U and A
vary widely from type to type. It is also
difficult to define A if there is a complicated
extended surface.
Hence, ESDU give tables of C values where
C is the cost per UA - using 1992 prices
Note, from our basic heat transfer equation
UA = Q / T
 ESDU
ESDU gives tables for a range of heat
exchanger types but we can only include here
those for shell-and-tube and plate-and-frame
Full data Item 92013 is available from
ESDU International plc
27 Corsham Street
London N1 6UA
Tel 0171 490 5151 Fax 0171 490 2701
esdu@esdu.com
 Steps in calculation

Calculate Tln and hence estimate T

Determine Q/T
Look up C value from table
To determine C at intermediate Q/T, use logarithmic
interpolation - see next slide
Calculate exchanger cost from - Cost = C(Q/T)
Taking the last shell-and-tube example, C = 0.4.
Hence, Cost = 0.4 X 30 000 = 12 000
Make sure that you take account of footnotes in tables
 Logarithmic interpolation

ln(C1)
ln(C)
ln(C2)

ln(V1) ln(V) ln(V2)

Where the Vs are the values of Q/T. V1 and V2
are the values either side of the required value V
ln(C1 / C2 ) ln(V / V1 )
C exp ln(C1 )
ln(V1 / V2 )
 Desain Termal
Alat Penukar Kalor
 Harga Lokal dan harga rata-rata
Overall artinya dari the hot side ke the
cold side termasuk semua termal resistan
Titik khusus pada alat penukar kalor adalah local
Jadi kita memiliki lokal, overall coefficient
LOKAL

q UT
KESELURUHAN ALAT PENUKA KALOR

Q T U m AT Tm
 Q = U A Tk
yw

Thot

Tcold

1 1 yw 1
rcold rhot
U cold w hot
 Integral terhadap area alat penukar kalor

dQ
Persamaan Lokal q UT
dA dQ

dQ dA
Rearranging UdA
T

dQ
Integral Q T UdA
AT
Total area AT
T
 Definisi dari harga rata-rata (mean values )

Dari slide sebelumnya Q T

U m AT
Tm

dQ
Bandingkan dua sides Q T A UdA
T T

1 1 dQ

Tm Q T Q T Um
1
UdA
AT AT
 Kasus Khusus dimana Ts linear terhadap Q

Eqn. integrates to
give log. mean

Temperature
Ta
temperature
difference - LMTD

Ta Tb Q
Tm TLM Tb
ln( Ta / Tb )
Pararel Flow
Counter Flow
Cross Flow
 Multipass exchangers
T1
Untuk single-phase duties, T2
Faktor correction teoritis, FT,

Temp.
t2
sudah diturunkan (lihar
referensi) t1
Harga FT Kurang dari 1
Q
Jangan Merancang untuk FT
kurang dari 0.8

Tm FT TLM
 Typical FT correction factor curves
For shell and tube with 2 or more tube-side passes

Curves are for different values of R

t2 t1 T1 T2 T, t = Shell / tube side
P ;R 1, 2 = inlet / outlet
T1 t1 t2 t1
 Thermal effectiveness

Stream temperature rise divided by the theoretically

maximum possible temperature rise
T1,in T1,out

T1,in T2 ,in
T1,in T1,out

T2,out T2,in
 ALAT PENUKAR KALOR
Shell-and-Tube

Memilih tipe TEMA yang tepat dan

menentukan fluida kerja yang mengalir
di dalam tube
 Daftar isi
Mengapa shell-and-tube?
Scope dari shell-and-tube
Konstruksi
TEMA standards
Memilih tipe TEMA
Alokasi Fluid
Design problems
Enhancement
Improved designs
 Why shell-and-tube?

Can be designed for almost any duty with a

very wide range of temperatures and
pressures
Can be built in many materials
Many suppliers
Repair can be by non-specialists
Design methods and mechanical codes have
been established from many years of
experience
 Scope of shell-and-tube
Maximum pressure
Shell 300 bar (4500 psia)
Tube 1400 bar (20000 psia)
Temperature range
Maximum 600oC (1100oF) or even 650oC
Minimum -100oC (-150oF)
Fluids
Subject to materials
Available in a wide range of materials
Size per unit 100 - 10000 ft2 (10 - 1000 m2)
Can be extended with special designs/materials
 Construction
Bundle of tubes in large cylindrical shell
Baffles used both to support the tubes and to
direct into multiple cross flow
Gaps or clearances must be left between the
baffle and the shell and between the tubes and
the baffle to enable assembly
Shell

Tubes

Baffle
Shell-side flow
 Tube layouts

pitch
Triangul Rotated Rotate
Squar d
ar triangul e square
30o ar 90o 45o
60o
Typically, 1 in tubes on a 1.25 in pitch or 0.75 in tubes
on a 1 in pitch
Triangular layouts give more tubes in a given shell
Square layouts give cleaning lanes with close pitch
 TEMA standards
The design and construction is usually based on
TEMA 8th Edition 1998
Supplements pressure vessel codes like ASME and BS
5500
Sets out constructional details, recommended tube
sizes, allowable clearances, terminology etc.
Provides basis for contracts
Tends to be followed rigidly even when not strictly
necessary
Many users have their own additions to the standard
which suppliers must follow
 TEMA terminology

Rear
Front end Shell end
stationary head head
type type

Letters given for the front end, shell and rear

end types
Exchanger given three letter designation
Above is AEL
 Front head type
A-type is standard for dirty tube side
B-type for clean tube side duties. Use if possible
since cheap and simple.
A B

Channel and removable cover Bonnet (integral cover)

 More front-end head types
C-type with removable shell for hazardous tube-
side fluids, heavy bundles or services that need
frequent shell-side cleaning
N-type for fixed for hazardous fluids on shell side
D-type or welded to tube sheet bonnet for high
pressure (over 150 bar)

B N D
 Shell type
E-type shell should be used if possible but
F shell gives pure counter-current flow with two
tube passes (avoids very long exchangers)

Longitudinal baffle
E F

One-pass shell Two-pass

shell
Note, longitudinal baffles are difficult to seal with
the shell especially when reinserting the shell after
maintenance
 More shell types
G and H shells normally only used for horizontal
thermosyphon reboilers
J and X shells if allowable pressure drop can not be
achieved in an E shell

G H
Longitudinal
Split flow baffles Double split flow

J X

Divided flow Cross flow

 Rear head type
These fall into three general types
fixed tube sheet (L, M, N)
U-tube
floating head (P, S, T, W)
Use fixed tube sheet if T below 50oC,
otherwise use other types to allow for
differential thermal expansion
You can use bellows in shell to allow for
expansion but these are special items which
have pressure limitations (max. 35 bar)
 Fixed rear head types
L

Fixed tube sheet

L is a mirror of the A front end head

M is a mirror of the bonnet (B) front end
N is the mirror of the N front end
 Floating heads and U tube

Allow bundle removal and mechanical cleaning on the

shell side
U tube is simple design but it is difficult to clean the tube
side round the bend
 Floating heads
T S

Pull through floating head Similar to T but with smaller shell

Note large shell/bundle gap bundle gap

Split backing ring

 Other floating heads

Not used often and then with small

P exchangers W

Outside packing to give Externally sealed floating tube sheet

smaller shell/bundle gap maximum of 2 tube passes
 Shell-to-bundle clearance (on diameter)

150
T

100
Clearance, mm

P and S

50
Fixed and U-tube

0
0 0.5 1.0 1.5 2.0 2.5

Shell diameter, m
 Example

BES
Bonnet front end, single shell pass and split
backing ring floating head
Apakah ini ?
 Allocation of fluids
Put dirty stream on the tube side - easier to clean
inside the tubes
Put high pressure stream in the tubes to avoid
thick, expensive shell
When special materials required for one stream,
put that one in the tubes to avoid expensive shell
Cross flow gives higher coefficients than in plane
tubes, hence put fluid with lowest coefficient on
the shell side
If no obvious benefit, try streams both ways and
see which gives best design
 Example 1
Debutaniser overhead condenser

Hot side Cold side

Fluid Light hydrocarbon Cooling water

Corrosive No No
Pressure(bar) 4.9 5.0
Temp. In/Out (oC) 46 / 42 20 / 30
Vap. fract. In/Out 1/0 0/0
Fouling res. (m2K/W) 0.00009 0.00018
 Example 2
Crude tank outlet heater

Cold side Hot

side

Fluid Crude oil Steam

Corrosive No No
Pressure(bar) 2.0 10
Temp. In/Out (oC) 10 / 75 180 /
180
Vap. fract. In/Out 0/0 1/0
Fouling res. (m2K/W) 0.0005 0.0001
 Rule of thumb on costing
Price increases strongly with shell diameter/number of tubes
because of shell thickness and tube/tube-sheet fixing
Price increases little with tube length
Hence, long thin exchangers are usually best
Consider two exchangers with the same area: fixed tubesheet,
30 bar both side, carbon steel, area 6060 ft 2 (564 m2), 3/4 in (19
mm) tubes
Length Diameter Tubes Cost
10ft 60 in 3139 $112k (70k)
60ft 25 in 523 $54k (34k)
 Shell thickness
t
Ds p p
t
p is the guage pressure in the shell
t is the shell wall thickness
is the stress in the shell
From a force balance
pDs
2t pDs hence t
2
 Typical maximum exchanger sizes

Floating Head Fixed head & U tube

Diameter 60 in (1524 mm) 80 in (2000 mm)

Length 30 ft (9 m) 40 ft (12 m)
Area 13 650 ft2 (1270 m2) 46 400 ft2 (4310 m2)

Note that, to remove bundle, you need to allow at least as

much length as the length of the bundle
 Fouling

Shell and tubes can handle fouling but it can be reduced by

keeping velocities sufficiently high to avoid deposits
avoiding stagnant regions where dirt will collect
avoiding hot spots where coking or scaling might occur
avoiding cold spots where liquids might freeze or where corrosive
products may condense for gases

High fouling resistances are a self-fulfilling prophecy

 Flow-induced vibration
Two types - RESONANCE and INSTABILITY
Resonance occurs when the natural frequency
coincides with a resonant frequency
Fluid elastic instability
Both depend on span length and velocity
Resonance Instability
Tube displacement

Velocity Velocity
 Avoiding vibration
Inlet support baffles - partial baffles in first few
tube rows under the nozzles
Double segmental baffles - approximately halve
cross flow velocity but also reduce heat transfer
coefficients
Patent tube-support devices
No tubes in the window (with intermediate support
baffles)
J-Shell - velocity is halved for same baffle spacing
as an E shell but decreased heat transfer coefficients
 Avoiding vibration (cont.)

Inlet support Double-segmental baffles

baffles
Intermediate baffles

Windows
with no tubes Tubes

No tubes in the window - with intermediate support

baffles
 Shell-side enhancement
Usually done with integral, low-fin tubes
11 to 40 fpi (fins per inch). High end for condensation
fin heights 0.8 to 1.5 mm
Designed with o.d. (over the fin) to fit into the a
standard shell-and-tube
The enhancement for single phase arises from the
extra surface area (50 to 250% extra area)
Special surfaces have been developed for boiling
and condensation
 Low-finned Tubes

Flat end to go into tube sheet and

intermediate flat portions for baffle
locations

Available in variety of metals including

stainless steel, titanium and inconels
 Tube-side enhancement using inserts

Spiral wound wire and twisted tape

Increase tube side heat transfer coefficient but at the
cost of larger pressure drop (although exchanger can
be reconfigured to allow for higher pressure drop)
In some circumstances, they can significantly
reduce fouling. In others they may make things
worse
Can be retrofitted

Twisted tape
 Wire-wound inserts (HiTRAN)
Both mixes the core (radial mixing) and
breaks up the boundary layer
Available in range of wire densities for
different duties
 Problems of Conventional S & T
Zigzag path on shell side leads to
Poor use of shell-side pressure drop
Possible vibration from cross flow
Dead spots
Poor heat transfer
Allows fouling
Recirculation zones
Poor thermal effectiveness,
Conventional Shell-side Flow
 Shell-side axial flow
Some problems can be overcome by having axial flow
Good heat transfer per unit pressure drop but
for a given duty may get very long thin units
problems in supporting the tube
RODbaffles (Phillips petroleum)
introduced to avoid vibrations by providing
additional support for the tubes
also found other advantages
low pressure drop
low fouling and easy to clean
high thermal effectiveness
 RODbaffles
Tend to be about 10% more expensive for the
same shell diameter
 Twisted tube (Brown Fintube)

Tubes support each other

Used for single phase and condensing
duties in the power, chemical and pulp and
paper industries
 Shell-side helical flow (ABB Lummus)

Independently developed by two groups in

Norway and Czech Republic
 Comparison of shell side geometries
Twisted Segmental Helical ROD
tube baffles baffles baffles
Good p Y N Y Y
High shell N Y Y N
Low fouling Y N Y Y
Easy Y With square With square Y
cleaning pitch pitch
Tube-side Included With inserts With inserts With inserts
enhance.
Can give Y N N Y
high
Low Y With special With double Y
vibration designs helix
Designing Shell-and-Tube Exchangers

Will this exchanger do the duty?

Developing a design envelope.
Choosing the best design.
 Contents

Overview of design
Single phase rating methods used in
DEVIZE
Tube side
Shell side
Design envelope concept in DEVIZE
Demonstration of DEVIZE
 Overall design process

Decide fluid allocation (last lecture)

Decide TEMA type (last lecture)
Make some guesses about the design
Repeat until satisfied

Generate design envelope using

with design

DEVIZE
Do a rating using DEVIZE
Review the envelope and the rating in
order to improve your initial guess
Finally select the best design
 Starting point of rating
We know
The duty which we need to achieve (i.e. flow
rates and temperature changes of the two
streams)
The full exchanger geometry
The allowable pressure drops for the two streams
We are checking whether that exchanger can do
that duty within the imposed constraints
 The thermal rating

The actual heat transfer area (based on the

tube o.d.), Ao is known
We calculate the required area, Areq from
Q
Areq
U o Tm
One output of the thermal rating is the ratio
Ao
RA
Areq
 Overall coefficient
yw
yw
Thot Di

Tcold Do

We have thermal resistances in series

1 1 Do Do yw Do 1
ri ro
U o i Di Di w Dw o
1
Where Dw ( Do Di )
2
 Thermal conductivity
Typical values of thermal conductivity
Material W/m k

Stainless Steel 15

Copper 390

Aluminium 208

Carbon Steel 50

Gases 0.02 - 0.3

Liquids 0.03 - 0.7

Polystyrene foam 0.003

Pipe Lagging 0.092

 Typical values of stream coefficients

Fluid State htc W/m2.k

Water Single Phase 5000 - 7500
Water Boiling <5Bar 3000 - 10000
Steam Condensing 1 Bar 10000 - 15000

Organic Single Phase 0.5-2.5 cp 750 -1500

Organic Boiling 0.5-2.5 cp 1000 - 3500
Organic Condensing 0.5-2.5 cp 1500 - 4000

Gas 1 Bar 80 - 125

Gas 10 Bar 250 - 400
 Typical fouling resistance
Fluid State r (m2.k/W)
Water Single Phase 0.0001 - 0.00025
Water Boiling <5Bar 0.0001 - 0.0002
Steam Condensing 1 Bar 0 - 0.0001

Organic Single Phase 0.5-2.5 cp 0.0002 - 0.001

Organic Boiling 0.5-2.5 cp 0.0001 - 0.0003
Organic Condensing 0.5-2.5 cp 0.0001 - 0.0003

Gas 1 Bar 0 - 0.0001

Gas 10 Bar 0 - 0.0001
 Single phase exchangers

We will now concentrate on a single phase

in both streams
This is a limitation of DEVIZE
But the principles of the design process are
similar for boiling and condensing streams
In single phase
coefficients do not vary much and can be
treated as constant
and Tm = FT TLM
 Tube side heat transfer coefficient
Nu 0.023 Re 0.8 Pr 0.4 ,Re 8000
Re 2000
Nu 3.66, Gz 9
Nu 1.75Gz1/ 3 , Gz 9
di
Gz Re Pr
4 L
In the transition region, Nu is calculated from a
linear interpolation with Re of the values at Re =
2000 and 8000
Note: wall-to-bulk property variations and natural convection effects
are neglected
 Tube side pressure drop

General equation
L u 2
p 4 f
di 2
Laminar flow
(transition taken as
crossover with 16
f ,Re 837
turbulent equation) Re

Turbulent flow in a 0.264

f 0.0035 0.42 ,Re 837
commercial rough Re
tube
 Nozzle, tube entry and return losses

u 2
p K
2
K is taken as 1.8 per tube-side pass to allow
for tube entry, tube exit and header losses
10% of the total pressure drop is assumed to
occur in the nozzles
 Shell side - the Bell Method
DEVIZE uses the Bell-Delaware method as
set out by Taborek in HEDH
This method starts with the coefficients and
pressure drops for ideal cross flow and
then corrects these for the non-idealities
which occur in real shell-side flows
The method gives reasonable accuracy
while remaining simple
More accurate proprietary methods have
been developed based on network models
 Shell-side non-idealties

Window
effects

Tube-to-
baffle
leakage

Shell-to-baffle
Bypass leakage
 Bell method for heat transfer
Ideal JW J L JB J Lam
Where
Jw corrects for some tubes being in the window
JL corrects for leakage through and around the baffle
JB corrects for flow around the bundle
JLam corrects for special effects which occur at very
low Reynolds numbers (not applied in DEVIZE)
 What do the factors depend upon?
Jw - ratio of tubes in cross flow to tubes in windows
JL - ratio of leakage areas to cross-flow area
JB - ratio of bypass flow area to cross flow area and the
number of pairs of sealing strips

Sealing strips to reduce bypass

Example correction factor - bypass
 Ideal crossflow coefficient
2 / 3
Ideal uCp j Pr
The j-factor is given as a function of Reynolds number,
defined by

Re = umin di /

Where umin is the velocity calculated at the minimum flow

area near the equator of the bundle (assuming no leakage
and bypass)
 Shell-side pressure drop and vibration

Pressure drop
The Bell method for pressure drop is similar to
that for heat transfer but with some extra
complications in the end zones
An additional 10% is assumed for the nozzles

Vibration
DEVIZE uses the methods in ESDU Data Item
87019 for fluid-elastic instability
 Outputs of rating
Area ratio (already discussed): RA = Ao / Areq
Pressure drop ratios for the shell side and the tube
side: Rp= pcalc/ pspec
Velocity ratio for vibration ratio: Rv = u / ucrit
For an acceptable design,
RA > 1, RpT < 1, RpS < 1, Rv < 1
The closer these ratios are to 1, the tighter the
design (i.e. the lower the safety margins)
 Thermal resistance diagram

Good way of viewing where the main resistances lie

and therefore where it is best to make changes to
improve the design

1 1 yw Do Do 1 Do
ro ri
Uo o w Dw Di i Di
Shell Side Tube Side

Stream Fouling Wall

 Envelope design concept

Description of the envelope design concept

and the demonstration of DEVIZE
Starting point is to make guesses about key
geometrical features
number of passes
baffle pitch (say as factor on the shell diameter)
baffle cut (say to equalise the cross-flow and
window-flow areas)
 Tube side pressure drop
Shell diameter

For given shell diameter

DEVIZE can calc.

The tube length which
just uses up the p

Tube length
 Tube-side pressure drop limit
Shell diameter Repeating for range of shell diameters gives curve

Designs valid in this region

Not valid in this region

Tube length
 Shell-side pressure drop limit
We can do similar thing for the shell side

Shell-side p limit
Shell diameter

Tube-side p limit

Tube length
 Heat transfer limit
And then for the heat transfer

Heat transfer area limit

Shell diameter

dr op l im its
Pressure

Tube length
 Add limits on tube-side velocity
Shell diameter

Min.
Valid

Valid
Max.

Tube length
 Danger areas for vibration may also be shown
Shell diameter

Min.

Max.

Vibration

Tube length
 Highlight valid design region
Shell diameter

Min.
Design envelope

Max.

Tube length
 Rating at optimum point

Smallest diameter and shortest tubes

so likely to be the cheapest
Shell diameter

Min.

Max.

Tube length
 Preferred shell diameters and tube lengths
Shell diameter

Min.
A
B

Max.

Tube length
 Design process
Start with a set of assumptions about number of
passes, baffle configuration, etc.
Generate envelope
Change initial assumptions to obtain better
envelopes
Then Rate good geometries within the best
envelopes
Consider advantages of ratings outside the
envelope assuming constraint may be relaxed
Select the best Rating
 Hambatan Termal pada Radiator

1 1 Rf "h Rf "c 1
Rw
UA (o .h. A) h (o A) h (o A) c (o .h. A) c

1 1 1
Rw
UA (h. A) h (o .h. A)c

q h.DH l NA f tanh mL
UA Nu Rw 0 1 1
(Tlm ) k kA At mL
Nu C. Re 0.8 . Pr 0.4 1 1
hP 2 2h t f
2

C . Re h Prh
0.8 0.4
kh m 1
hh h kftf w f
kAc
DH ,h