2/27/2015

Department of Chemical Engineering

College of Engineering
University of the Philippines Diliman
Second Semester, AY 2014-2015

ChE 142: Chemical

Engineering Plant Design
Detailed Design of
Static Equipment (HEx and AFC)

Heat Exchanger Types

Devore et al recommend the
following heat exchanger types:

Outline of Lecture

Introduction
Heat Exchanger Types
Design Calculations
P&ID Representation
Cost Estimation

Heat Exchanger Types

Spiral Heat Exchanger

Spiral heat exchanger if area is

less than 2 m2.
Double-pipe heat exchanger if
area is between 2 and 50 m2.
Shell-and-tube heat exchanger
if area is greater than 50 m2.

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Heat Exchanger Types

Heat Exchanger Types

Double Pipe Heat Exchanger

Shell and Tube Heat Exchanger

Shell and tube heat exchangers are
broadly classified into two: removable
and non-removable tube bundle.
Of the two classifications, the cheapest
options are the U-tube heat exchanger
and the fixed tubesheet heat exchanger
respectively.

Heat Exchanger Types

Heat Exchanger Types

Shell and Tube Heat Exchanger

Shell and Tube Heat Exchanger

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Heat Exchanger Types

Heat Exchanger Types

Shell and Tube Heat Exchanger

Shell and Tube Heat Exchanger

Heat Exchanger Types

Heat Exchanger Types

Shell and Tube Heat Exchanger

Shell and Tube Heat Exchanger

Costlier for the same heat transfer

area, but can clean shell side.

Cheaper for the same heat transfer

area, but cant clean shell side.

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Heat Exchanger Types

Heat Exchanger Types

Shell and Tube Heat Exchanger

Shell and Tube Heat Exchanger

Design Calculations

Design Calculations
Problem Statement
Design and draw the P&ID representation of
a shell-and-tube heat exchanger with the
following information:

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Design Calculations

Design Calculations

Initial Specifications

Initial Specifications

Fluid Placement
Place the fluid on the tube side if it is:
(arranged in order of priority)
1.
2.
3.
4.
5.
6.

Corrosive
Cooling water
More fouling
Less viscous
More pressurized
Hotter

Fluid Placement
Fouling factors (refer to Table 3.3)
Crude oil
= 0.004-0.005 hr-ft2-F/Btu
Kerosene
= 0.001-0.003 hr-ft2-F/Btu
Place the crude oil and kerosene in tube
side and shell side respectively.

Design Calculations

Design Calculations

Initial Specifications

Initial Specifications

Shell and Head Type

Tube and Tubing Layout

The following guidelines are
observed in the selection of tube
dimensions and layout:
14 BWG tubes with 1
triangular pitch for straight tubes
1 14 BWG tubes with 1
square pitch for U-tubes

What shell and tube heat exchanger type

is suitable for this service, BEU or BEM?

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Design Calculations

Design Calculations

Initial Specifications

Initial Specifications

Tube and Tubing Layout

Tube and Tubing Layout

The preferred straight tube lengths are 16 ft
and 20 ft. For the same heat transfer area,
which is more economical?
Longer but thinner
heat exchanger?
Shorter but fatter
heat exchanger?

What are the advantages and disadvantages

of triangular pitch over square pitch?

Design Calculations

Design Calculations

Initial Specifications

Initial Specifications

Baffle Dimensions

Baffle Dimensions

The baffle spacing is recommended to

be between 20% and 100% of the
shell diameter. The default is 20%.

The baffle cut is recommended to be

between 15% and 45%. The default is 20%.

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Design Calculations

Design Calculations

Maximum Pressure Drop

Maximum Pressure Drop

Allowable pressure drop for shell and tube

exchangers and air coolers in pumped liquid
service may be considered as follows:

Pressure (psig)

Allowable Pressure Drop (psi)

Shell Side

Tube Side

Up to 50

2.5 per shell

Less than 1.0

5.0

10

50 and above

5.0 per shell

1.0 to 5.0

7.5

10

Viscosity (cP)

Allowable Pressure Drop (psi)

Allowable pressure drop for shell and tube

exchangers and air coolers in condensing
service may be considered as follows:

5.0 to 15.0

10

15

15.0 to 25.0

15

20

25.0 to 50.0

15

25

Design Calculations

Design Calculations

Initial Specifications

Initial Specifications

The initial specifications are as follows:

Kerosene at shell, crude oil at tube

o Kerosene
= 0.003 hr-ft2-F/Btu
o Crude oil
= 0.005 hr-ft2-F/Btu
Heat exchanger type BEU
1 14 BWG tubes with 1 square pitch
o Outer diameter (Do) = 1.000 in
o Inner diameter (Di) = 0.834 in
o Tube pitch (PT)
= 1.250 in
o Clearance (C)
= 0.250 in
Tube length of 20 ft
Baffle spacing of 20% of shell diameter
Baffle cut of 20%
Maximum shell-side P
= 5.0 psi
Maximum tube-side P
= 10.0 psi

The initial specifications are as follows:

Kerosene at shell, crude oil at tube

o Kerosene
= 5.248 x 10-4 m2-K/W
o Crude oil
= 8.806 x 10-4 m2-K/W
Heat exchanger type BEU
1 14 BWG tubes with 1 square pitch
o Outer diameter (Do) = 0.02540 m
o Inner diameter (Di) = 0.02118 m
o Tube pitch (PT)
= 0.03175 m
o Clearance (C)
= 0.00635 m
Tube length of 6.096 m
Baffle spacing of 20% of shell diameter
Baffle cut of 20%
Maximum shell-side P
= 34.46 kPa
Maximum tube-side P
= 68.93 kPa

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Design Calculations

Design Calculations

Number of Shell Passes

Number of Shell Passes

Assume that only one shell pass will suffice.

Calculate the LMTD correction factor (F).

Assume that only one shell pass will suffice.

Calculate the LMTD correction factor (F).

Design Calculations

Design Calculations

Number of Shell Passes

Estimated Area

If calculated F is less than 0.80, set the

number of shell passes to two.

Calculate the area using the equation

Q = UAFTlm
Estimate the overall heat transfer
coefficient using the individual heat
transfer coefficients (should have been
done during ChE 141).

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Design Calculations

Design Calculations

Minimum Number of Tubes

Maximum Number of Tube Passes

The heat exchanger area is equal to the

surface area of each tube multiplied by
the number of tubes:

The tube-side fluid loses pressure as it

expands at the inlet nozzle, flows inside the
tubes, and contracts at the outlet nozzle.

A = nt x (DoL)

Assume that nozzle losses are negligible.

How can the maximum number of tube

passes be calculated using the equation
above?

Design Calculations

Design Calculations

Shell Diameter

Required Overall Heat Transfer Coefficient

Given the heat exchanger type and the tubeside details, a shell diameter can be selected:

Given the selected tube length and

the tube count on the selected shell
diameter, calculate the area available
for heat exchange:

A = nt x (DoL)
Calculate the required overall heat
transfer coefficient:

Ureq = Q/AFTlm

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Design Calculations

Design Calculations

Inside Heat Transfer Coefficient

Outside Heat Transfer Coefficient

The tube-side heat transfer coefficient is

calculated using the Seider-Tate and Hausen
equations. Viscosity correction is neglected:

The shell-side heat transfer coefficient is

calculated using the following correlation.
Viscosity correction is neglected:

Design Calculations

Design Calculations

Overall Heat Transfer Coefficient

Tube-Side Pressure Drop

Calculate the overall heat transfer coefficient

using the equation below. Metal resistance is
neglected:

The tube-side fluid loses pressure as it

expands at the inlet nozzle, flows inside the
tubes, and contracts at the outlet nozzle.
Assume that nozzle losses are negligible.

The magnitude of oversize is based on the

required overall heat transfer coefficient.

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Design Calculations

Design Calculations

Shell-Side Pressure Drop

Design Assessment

The shell-side fluid loses pressure as it

expands at the inlet nozzle, flows outside the
tubes, and contracts at the outlet nozzle.
Assume that nozzle losses are negligible.

P&ID Representation

What adjustments need to be done?

Case

Is overall HTC
greater than
required?

Is tube-side
P less than
maximum?

Is shell-side
P less than
maximum?

YES

YES

YES

YES

YES

NO

YES

NO

YES

NO

YES

YES

P&ID Representation

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P&ID Representation

P&ID Representation

P&ID Representation

Cost Estimation
Towler and Sinnott (2008) expressed the
January 2006 purchased cost of heat
exchangers as a function of area.

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Air Fin Coolers

Air Fin Coolers

Because of low heat

transfer coefficient on
the air side, the tubes
are finned to increase
the area available for
heat transfer.

Air Fin Coolers

Air fin coolers are second only to shelland-tube heat exchangers in frequency
of occurrence in chemical and
petroleum processing operations.

Air Fin Coolers

Forced Draft Air Fin Coolers

Assuming no process restrictions,

when is air cooling economically
advantageous over water cooling?

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Air Fin Coolers

Air Fin Coolers

Induced Draft Air Fin Coolers

Forced vs. Induced Draft Air Fin Coolers

Differentiate the two configurations in
terms of:
1. Accessibility of tubes and fan parts
2. Fan power consumption for the same
mass flowrate of air
3. Area for the same air fin cooler duty

Air Fin Coolers

Air Fin Coolers

Forced vs. Induced Draft Air Fin Coolers

Forced vs. Induced Draft Air Fin Coolers

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Air Fin Coolers

Air Fin Coolers

Forced vs. Induced Draft Air Fin Coolers

Tube Dimensions

For inlet process fluids above 350F,

use forced draft configuration.

Tube lengths are typically from 6 ft to 50 ft,

with 40 ft commonly used. Tubes are
typically stacked from three to eight rows,
with six rows commonly used.

Air Fin Coolers

Air Fin Coolers

Tube Dimensions

Bay Dimensions
Bay widths are typically from 4 ft to 30 ft, with
14 ft commonly used. Axial-flow fans with four
or six blades and diameters of 6 ft to 18 ft are
typically employed.

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2/27/2015

Department of Chemical Engineering

College of Engineering
University of the Philippines Diliman
Second Semester, AY 2014-2015

ChE 142: Chemical

Engineering Plant Design
Detailed Design of
Static Equipment (HEx and AFC)

16