CHAPTER 5

DESIGN FOR HEAT EXCHANGER

5.1 INTRODUCTION

A heat exchanger is a device built for efficient heat transfer from one medium to
another. A solid wall may separate objects, so that they never mix, or they may be
in direct contact. They are widely used in space heating, refrigeration, air
conditioning, power plants, chemical plants, petrochemical plants, petroleum
refineries, natural gas processing, and sewage treatment. Heat exchangers are
widely used in industry both for cooling and heating large scale industrial
processes. The type and size of heat exchanger used can be tailored to suit a
process depending on the type of fluid, its phase, temperature, density, viscosity,
pressures, chemical composition and various other thermodynamic properties
(G.E, Measurement and Control).
Classification of a heat exchanger is made by their flow arrangement, and
with this there are two main flow arrangements which are parallel-flow and
counter-current-flow. As the name would goes by itself, a parallel-flow heat
exchangers; two fluids enter the exchanger at the same end, and travel in parallel
to one another to the other side, and in counter-flow heat exchangers the fluids
enter the exchanger from opposite ends. Comparing flow arrangements, counter
current design is most efficient because it can transfer the most heat from the heat
transfer medium. There are many types of heat exchanger in industry. Selecting
the most appropriate types require a understanding of each type advantage and
disadvantage as well as the environment condition in which it will operate.
 5-2

5.2 HEAT EXCHANGER CHEMICAL DESIGN

5.2.1 Selections of Heat Exchanger

Typically in the manufacturing industry, several different types of heat exchangers

are used for just the one process or system to derive the final product. In order to
select an appropriate heat exchanger, one would firstly consider the design
limitations for each heat exchanger type. Although cost is often the first criterion
evaluated, there are several other important selection criteria which include:

- High/ Low pressure limits

- Thermal Performance
- Temperature ranges
- Product Mix (liquid/liquid, particulates or high-solids liquid)
- Pressure Drops across the exchanger
- Fluid flow capacity
- Cleaning-ability, maintenance and repair
- Materials required for construction
- Ability and ease of future expansion

Table 5.1: Types and Functions of Heat Exchanger in Industry

Types Functions

Double pipe heat exchanger The simplest type. Use for heating and cooling.

Shell and tube heat exchanger Used for all application.

Plate exchanger Use for heating and cooling.

Plate-fin exchanger Use for heating and cooling.

Spiral heat exchanger Use for heating and cooling.

Air cooled Cooler and condenser.

Direct contact Cooling and quenching.

Agitated vessels Use for heating and cooling.

Fired heaters Use for heating and cooling.

Source: Chemical Engineering Design, R.K.Sinnott.

 5-3

5.2.2 Basic Principles of Design

Design Criteria
The criteria that a process heat exchanger must satisfy are easily enough stated if
we confine ourselves to a certain process. The criteria include:

1) The heat exchanger must meet the process requirements – reach the
desired temperature change with allowable pressure drop.

2) The heat exchanger must withstand the service conditions of the

environment of the plant which includes the mechanical stresses of
installation, startup, shutdown, normal operation, emergencies and
maintenance.

3) The heat exchanger must be maintainable, which usually implies choosing a

configuration that permits cleaning and replacement. In order to do this, the
limitations is the positioning the exchanger and providing clear space around
it. Replacement usually involves tubes and other components that may be
especially vulnerable to corrosion, erosion, or vibration.

4) The cost of the heat exchanger should be consistent with requirements.

Meaning of the cost here implement to the cost of installation.

5) The limitations of the heat exchanger. Limitations are on length, diameter,

weight and tube specifications due to plant requirements and process flow.

Designing a Heat Exchanger

The logical structure of the heat exchanger design procedure is shown in Figure
2.15. From the figure, a more clear view and steps of designing a heat exchanger
can be obtained.

5.2.3 Problem Identification

For this specific chapter, the heat exchanger that will be calculated for design is
the cooling utility for stream 23 to stream 24 (HE-109). The hot stream cooling is
from temperature 98.18 oC to 30 oC, and the cool stream is provided by cooled
water. The hot stream is in liquid phase condition from the down product distillation
column T-102. It consist of propanol solution of 99% purity.
 5-4

Figure 5.1: Basic Logical Structure of Heat Exchanger Design

5.2.4 Selection of Heat Exchanger

Shell and tube heat exchangers are the most widely used equipments in chemical
industry. This type is the most basic design in term of the specification design as
well as one of the lowest in capital cost. Universally, the sizes of various part of
shell and tube of heat exchangers are standardized and developed by Tubular
Exchanger Manufacturers Association, USA (TEMA).

Shell Side

Shell is the costliest part of heat exchanger. The cost sensitively changes with
change in the diameter of shell. Using TEMA standard, shell size ranges from 6 in
(152 mm) to 60 in (1520 mm). Standard pipes are available up to 24 in (608 mm).
Thus, shell greater than 24 in (608 mm) is fabricated by a rolling plate. Shell
diameter depends on tube bundle diameter. For maximum pull through floating
head heat exchanger the range is from 90 mm to 100 mm. The Required shell
diameter is determined by either;
 5-5

a) Based on the actual tube sheet layout drawing

Using computer programs with all the required parameters keyed in.

b) Use of standard tables

These tables give the maximum number of tubes that can be
accommodated in various standard sizes of shell ranging based on their
respective design criteria (tube arrangement, tube pass, and etc).

c) Use of approximate equations

Approximate equations are available in literature to find the shell diameter
or to find the tube bundle diameter.

Tube Side

Tube size ranges from ¼ in (6.35 mm) to 2.5 in (63.5 mm) in shell and tube heat
exchanger. Data for the standard tubes are given in TEMA standard. For the
standard tubes, its size is equal to outer diameter of tube. Thickness of standard
tubes is expressed in BWG (Birmingham Wire Gauge). Increase in BWG means
decrease in thickness of tube. For no phase change heat exchangers and for
condensers, ¾ in (19.05 mm) OD tube is widely used in practice. Tubes are
available in standard lengths like 6 ft (1.83 m), 8 ft (2.44 m), 12 ft (3.66 m), 16 ft
(4.88 m) and 19.67 ft (6.00 m). Tube side passes are provided to decrease the
tube side flow area and to decrease tube side velocity thereby to improve the tube
side heat transfer coefficient, at the expense of pressure drop. This is true only if
there is no phase change on tube side. Hence, more number of tube side passes
is recommended only if there is no change in phase of the tube side fluid.

Fluid Allocation Factor

Usually, common sense is a reliable guide when deciding which fluid belongs on
the shell side and which on the tube side (Price, 1999)

 Fluids which are prone to fouling belong in tubes, where the higher
velocities will reduce build-up. Cleaning is much more practical for tubes.
 Corrosive fluids are usually best in tubes, as are very high temperature
fluids that require alloy construction. Tubes are cheaper to fabricate from
exotic materials.
 5-6

 Viscous fluids require a judgment call. Placing the more viscous fluid on
the shell side will improve heat transfer, but using tube side leads to a
lower ∆P
 Toxic fluids should go inside the tubes to improve containment.
 Streams with low flow rates typically go on the tube side to increase the
velocity and turbulence.
 High pressure streams usually go inside the tubes, since they are less
expensive to build strong.
 Low allowable pressure drop stream‟s usually goes into tube side

5.2.5 Design Procedure

Basic design for most heat exchanger involves the heat transfer across the
surface;

Q = UA ∆Tm

With U = Overall heat transfer coefficient, w/m2 0C

Q = heat per unit time, W
A = Heat transfer area, m2
∆Tm = mean temperature difference, 0C

Which in this case, ∆Tm = Tlm  (T1  t2 )  (T2  t1 )

 (T  t ) 
In  1 2 
 (T2  t1 ) 

The prime objective of the design is to determine the surface area required for our
heat exchanger based on the temperature requirement and energy transfer. The
details on how the above equation is expanded are later on explained. Early
design, there would be no way of knowing the exact value for these parameters. A
trial and error approach is more suitable to be performed. The steps in a typical
design procedure are given by Chemical Engineering Design, Volume 6;

1. Define the duty, heat transfer rate, flow rates, and temperature
2. Collect together the required physical properties
3. Decide on the type of heat exchanger to be used
4. Select a trial value for the overall heat coefficient, U
5. Calculate the mean temperature difference
6. Calculate area required from assumed U
7. Decide the exchanger lay out (tube pass, shell pass)
 5-7

8. Calculate for shell and tube coefficient individually

9. Calculate overall coefficient and compare it with the trial one. If the
calculated differs significantly, substitute values and return to 6.
10. Calculate pressure drop if unsatisfied, return to step 7, or 4 or 3.
11. Optimize the design as seen fit for its duty and cost range.

The specific procedure in handling a heat exchanger design is called Kern‟s

Methods. In this, there are a few standard tolerance and will give a reasonably
satisfactory prediction of the heat transfer coefficient for standard design.

5.2.6 Design of Shell and Tube Heat Exchanger

From the fluid allocation factor, it is decided that Propanol Solution is allocated at
tube side and cooled water is at shell side:
- Propanol stream has lower mass and volume flow rate.
- Propanol is more toxic compared to water.
- Propanol is supplied at a higher pressure than the cooling water.
- Higher pressure propanol should be put at tube side to reduce ∆P

A) Physical Properties

Tube Side Fluid

Table 5.2: tube side stream properties
Properties Inlet Mean Outlet
Temperature (0C) 97.18 63.59 30
heat capacity (kJ/kg0C) 2.40E+03 2402.44 2.40E+03
Thermal conductivity (W/m0C) 0.2017 0.2064 0.2111
3
Density (kg/m ) 796.5 803.05 809.6
-2
Viscosity (N sm )x E-3 0.0008974 0.0011118 0.001326

Shell Side Fluid

Table 5.3: shell side stream properties
Properties Inlet Mean Outlet
0 20 32.5 40
Temperature ( C)
heat capacity(J/kg0C) 4193 4191.5 4190
Thermal conductivity (W/m0C) 5.87E-01 0.6202 6.54E-01
Density (kg/m3) 999.8 996.4 993
Viscosity (N sm-2) 0.001002 0.0007745 0.000547
 5-8

For the tube side, the data was taken from the simulation, which was done
previously on Design Project 1 (stream 23 to 24 based on the HYSYS
environment), the shell side data was taken from water property table for pressure
of 1 atm at www.engineeringtoolbox.com. Both side are taken at average ( [inlet +
outlet] / 2 ) condition
Table 5.4: Shell and Tube description
Heat exchanger type Shell and Tube
Design type Fixed–tube plate
Heat exchanger orientation Horizontal
To cool liquid product stream from T101 to
Description
appropriate room temperature/condition
Shell side inlet/outlet stream 1/1
Shell side stream Cooled water for cooling (supplied at 20 0C)
Tube side inlet/outlet stream 1/1
Tube side stream Stream 27 and stream 28 based on HYSYS
environment

Table 5.5: Determination for shell and tube side flow rates
Required Energy E106 Utility = 2.60E+06 kJ/h
721388.89 J/s [Watt]
Cp(∆T) for shell = 83830 J/kg
mass flow rate shell side =
(Energy Req. / Cp.∆T) 8.60538 kg/s
volume flow rate shell side = 0.00864 m3/s
mass flow rate tube side = 12290 kg/h
(from mass balance) 3.413888889 kg/sec
volume flow rate tube side = 0.004251154 m3/s
(from mass balance)

B) Area of Heat Exchanger

Tube or Shell side Tube Shell
Stream Stream 17 to Stream 18 Cooling water
Tin (C) 97.18 20

Tout (C) 30 40
 5-9

t
Figure 5.2: temperature allocation for shell-tube heat exchanger

(T1  t2 )  (T2  t1 )
Logarithmic mean temperature, Tlm 
 (T  t ) 
In  1 2 
 (T2  t1 ) 
∆Tlm = 27.0587 oC
True temperature difference is given by;
∆Tm = Ft (∆Tlm),
With Ft = Temperature correction factor.

We can determine Ft using figure 12.19 or 12.20, Chemical Engineering Design,

Vol. 6, based on the shell/tube passes that will be used. This figure is also given in
the Appendix E3.
R = (T1-T2)/(t2-t1) = 3.359
S = (t2-t1)/(T1-t1) = 0.2591

With this known, Ft = 0.90, which is for 1 shell and even number tube pass
Therefore, ∆Tm = 24.3528 oC

(Note: later in this report, it is decided that our pass will be 1 shell pass; 6 tube
pass. This is determined to coincide with our thermal coefficient, pressure drop
and fluid velocity.)
 5-10

C) Estimated Overall Coefficient

The overall heat transfer coefficient was decided to be, U = 400 W/m2.oC
For a good first estimation of this value, it can be refer at Table 6.7, Typical Overall
Coefficients for Shell and Tube Heat Exchangers, Chemical Engineering Design,
Volume 6. Of course the value obtain above is after many consideration and
recalculation of the following steps (See Design Procedure)

Q
A
Heat transfer area,
UTm
Where, Q = heat transferred per unit time (W)
U = overall heat transfer coefficient,(W/m2.oC)
∆Tm = the mean temperature difference (oC)

From equation, we can get an estimated area of, A = 74.06 m2

This will be used to calculate the tube sizing and allocation in the following section

D) Tube rating and coefficient

Material = Stainless steel

Length of tube, L (m) = 4.88 m
Outer diameter, do = 19 mm
0.019 m
Thickness = 2.1 mm
Inner diameter, di = 14.8 mm
0.0148 m

Heat transfer area of a tube, At = Lt X Dto

= 0.2914 m2
Number of tube, Nt = A/At
= 253.8929
= 254 tubes

Dti 2
Tube cross-sectional area, At 
4
= 172.1 mm2
= 0.0001721 m2
 5-11

With “n” pass at tube side and the number of tubes per pass is known by
dividing number of total tubes, Nt, to the number of passes selected
Number of tube pass = 6
*through trial and error, 2 and 4 tube pass did not give an
appropriate thermal coefficient.
Tube per pass = Nt /n
= 258/6
= 42.33 tubes per pass

Cross sectional area for each pass (Total flow area, AT)
Total flow area, AT = Nt x At
= 7285.6898 mm2
= 0.007286 m2
Referring to table 5;
From mass balance, mass flow rate tube side = 12 290 kg/hr
= 3.4139 kg/s
Volumetric flow rate on tube side (Mass FR/density) = 0.004251 m3/s
= 4.251 litre/s
Tube side velocity, ut = 0.58349 m/s
uDti
Reynolds number, Re 

= 6237.55
Cp
Prandtl number, Pr 
kf
= 12.94
L/Dti = 329.73
0.14
k f j h Re Pr 0.33   
Tube side heat transfer coefficient, hi   
Dti  w 
hi d i
 jh Re Pr 0.33
kf
(Assuming viscosity of the fluid is identical at the wall and of the bulk fluid)
With the information on Re, Pr number and L/D, we can find the heat transfer
coefficient from Figure 12.23, Chemical Engineering, Vol. 6, jh = 0.004
The other data are seen in table 3, previously. By calculation it is known;

hi = 809.975 W/m2.oC
 5-12

This value is very well above the overall coefficient of 400 W/m2.oC, thus it is an
acceptable design

E) Bundle diameter, Db and Shell Diameter

Tube pitch is the distance between tube centers and formulated as,

Pt  1.25  Dto
= 1.25(0.019 m) = 0.02375 m

For the bundle diameter, we can either put it in triangular or square arrangement.
Triangular pattern gives more efficient heat transfer with higher pressure drop. The
square pattern is usually used for heavy fouling fluid where mechanical cleaning is
required. For the sake of comparison, value of Db is calculated for both patterns,
according to Chemical Engineering Design, Vol. 6

Triangular Pitch Square pitch

Ki (for 4 pass) = 0.175 ki (for 4 pass) = 0.158
n1 (for 4 pass) = 2.285 n1 (for 4 pass)= 2.263
Bundle Diameter, Db = do (Nt/K1)1/n1 Db = do (Nt/K1)1/n1
0.45969 m 0.49606 m
Table 5.6: Determination of Bundle diameter

Figure 5.3: tube arrangement for a) triangular pitch and b) square pitch

From table 6 we can see that triangular pitch results in a smaller bundle diameter,
however the difference to the square pitch is not that significant. The selected
patterns are the triangular pitch, as it is considered a higher heat transfer methods
of arrangements. For the total shell diameter, bundle diameter will add value of
shell bundle diameter clearance. Take bundle shell clearance as 2Pt lenth
2 x 0.02375 = 0.0475 m
 5-13

For Fixed and U-tube, Ds = Db + shell bundle clearance

= 0.4597+0.0475
= 0.5072 m
Our shell diameter requirement is quite small, less than 24 in (609.6 mm) therefore
we will be using a standard 20 inched (508mm) diameter pipe. This will give a
shell of L/D=9.6, which is in the appropriate range of 5-10 for an efficient heat
exchanger design.

F) Shell Side Coefficient

First of all we need to decide the baffle spacing. The explanation on this will be
later discussed in the mechanical section of the heat exchanger. Baffle spacing is
usually estimated at 0.2 to 1.0 shell diameter. The further apart the baffles the
lower the heat transfer coefficient but it also gives a lower pressure drop.
After a few recalculations of trial and error on the system, the determined spacing
was decided at 0.8 shell diameter. This is due to the fact that we would not require
a higher heat transfer shell side and what is obtain from this is quite appropriate.

Shell diameter, Ds = 508 mm

= 0.508 m
Tube pitch, Pt = 0.02375 m
Baffle spacing, IB = Ds x 0.8
= 0.4064 m

( Pt  Dto ) Ds l B
Shell cross flow, As 
Pt
= 0.0778 m2

As determined in table 5, shell side volume flow rate is

Vs= 0.00864 m3/s
The linear velocity of shell side is then
us= 0.11101 m/s

Shell side equivalent diameter, De 

Dto

1.1 2
pt  0.917 Dto2 
= 0.01349 m
 5-14

Reynolds number, Re = Density x Velocity x Diameter x (1 / Viscosity)

= 72 549.67

Prandtl number, Pr = Cp x Viscosity / Thermal Conductivity (Kw)

= 5.234

From figure 12.29 in Chemical engineering design, volume 6, by Selecting

25% for baffle cut, and 7.2 x 104 Re value.
Heat Transfer Factor, jh = 0.0024

0.14
k f j h Re Pr1 / 3   
Shell side heat transfer coefficient, hs   
De 
 w
= 13 821.64 W/m2.C

5.2.7 Overall Heat Exchanger Coefficient

The relationship between overall coefficient and individual coefficients is given by:

 do 
d o ln . 
1 1
 
1
  di   d o  1  d o  1
Uo ho hod 2k w d i hid d i hi

Uo = the overall coefficient based on the outside area of the tube, W/m 2.

°C,

ho = outside fluid film coefficient W/m2. °C,

hi = inside fluid film coefficient W/m2. °C,

hid = inside dirt coefficient W/ m2 . oC (Refer Table 6.9 Recommended
Fouling Coefficients),
hod = outside dirt coefficient W/ m2. oC
Kw = thermal conductivity of the tube wall material W/m2.°C
di = tube inside diameter, m,
do = tube outside diameter, m.

The objective of this equation is to determine the calculated overall heat

coefficient, the shell and tube diameter is already determined, so as the fluid film
coefficient. The dirt coefficient refers to the fouling factor of the respective fluid (as
 5-15

can be seen from appendix A). The wall material that will be used is determined to
be carbon steel, and from appendix A also we can see its thermal conductivity.

Outside fluid film coefficient, ho, W/m2.oC = 13 821.64

2 o
Inside fluid film coefficient, hi, W/m . C = 809.98
2 o
Outside dirt coefficient (fouling factor), hod, W/m . C = 3000
Inside dirt coefficient, hid, W/m2.oC = 5000
Thermal conductivity of the tube wall material, kw, W/m.oC = 60

The overall heat transfer coefficient are then calculated using the above equation

Uo = 437.26 W/m2.oC

This value is well above assumed coefficient of 400 W/m2.C; the relative error is
about 8.5% error, therefore our design are determined to be feasible

5.2.8 Shell and Tube side Pressure Drop

For the tube side pressure drop, there are many methods in determining the
proper consideration on pressure drop. However it is known that there are 2 major
sources of pressure loss on the tube-side of a shell and tube heat exchanger; The
friction losses in the tube; and the losses due to the sudden contraction and
expansion, flow reversals that the fluid experience in flow through the tube
arrangement.

For a non-isothermal where there are properties changes, there is no

distinguishing method in delivering the best results. The below expression is used
widely for basic equation for flow in pipes in non-isothermal condition
𝐿 𝜌𝑢𝑡 2
∆𝑃 = 8 𝑗𝑓 ( )
𝑑𝑖 2
However in fluid with distinguish property changes it is usually only consider the
viscosity changes in the flow. This will results in the equation to be write as;
𝐿 𝜌𝑢𝑡 2 µ −𝑚
∆𝑃 = 8 𝑗𝑓 ( )
𝑑𝑖 2 µ𝑤
With m = 0.25 for laminar flow (Re<2100), m = 0.14, for turbulent flow (Re>2100).
Most liquid stream calculations neglect this as it becomes very insignificant
(caused by the very few changes in the viscosity values).
 5-16

Tube Side ∆P: For the tube side pressure drop it is considered using Kern‟s
(1950), recommendation to use 4 added velocity head per pass into this equation,
with an added 1 velocity head for inlet contraction and 0.5 head for the outlet
expansion

Tube side pressure drop,

   
m
  2
Pt  N p 8 j f ( L / Dti )   H  s

  w   2
 

Since we are at liquid phase, the viscosity correction will be neglected.

The friction factor is obtained from appendix A.12.

With Re = 6.2x103, jf = 0.0055, tube passes, Np = 6,

Tube length, L = 4.88 m, tube inlet diameter, Dti = 0.0148
Density, ρ = 803.05 kg/m3, tube side velocity, u = 0.58349 m/s
Velocity head = 4 + 1 + 0.5

∆Ptube = 16.4113 kPa

Higher than 10kPa; a satisfactory range, however, it is still quite low for the
compared to its mass flow capacity.

Shell Side ∆P: For the shell side pressure drop we would still apply the isothermal
equation mentioned before. However this time there would not be any velocity
head counts. There is however a consideration on the overall flow pattern, this is
represented by the ratio of length over baffle spacing; which indicated the number
of times the flow crosses the tube bundle.

Number of baffles, Nb = (L / lb)

= (4.88)/(0.4064)
= 12.0
For the pressure drop the expression will be as follow; as referred to chemical
engineering design volume 6;
m
 2   
Ps  8 j f ( Ds / De )( L / l B ) s  
2   w 
As we are already using water properties, the viscosity expression can be
neglected and equation can be simplified.
 5-17

From, appendix A13;

Shell side friction factor, jf = 0.038
Substituting all the data given; Ds = 0.506 m, De = 0.01349 m, and L/lb = 12

∆PS = 7627.87 Pa

Acceptable value, however, this is also quite low considering the mass flow. A few
improvements can be made to increase the pressure drop for a more sufficient
flow, such as lowering baffle spacing, reducing pitch length, and using smaller
shell pipe diameter.
 5-18

Table 5.7: List for Chemical Design Values in Heat Exchanger HE-106
Function To cool down the liquid product from
distillation column T102; which is the final
product of 99.8% Propanol
Tube Side Fluid Propanol solution in stream 23 to 24
(Hot Stream)
Flow rates (kg/hr) 12290
Inlet temperature (°C) 97.18
Outlet temperature (°C) 30
Shell Side Fluid Cooled water
Flow rates (kg/hr) 30979
Inlet temperature (°C) 20.0
Outlet temperature (°C) 40.0
Heat Duty, Q (kW) 2 600 000
Overall Heat Transfer Coefficient
(W/m2.C) 437.26
Tube Side Specification
Heat transfer area, A (m2) 74.06 Tube pass 6
Number of tubes, Nt 254 Material Stainless Steel
Tube inside diameter, di (m) 0.0148 Heat transfer
Tube outside diameter, do (m) 0.0190 Coefficient (W/m2.C) 809.96
Length of tube, L (m) 4.88 Pressure Drop (kPa) 16.411
Tube Pitch, pt (m) 0.02375
Shell Side Specification
Bundle diameter, Db (m) 564.6299
Shell diameter, Ds (m) 0.508
Tube Clearance, C (m) 0.0068
Baffle Spacing, Bs (m) 0.4064
heat transfer
coefficient, (W/ m2°C) 13821
Shell Pressure Drop (kPa) 36894.2680
 5-19

5.3 MECHANICAL DESIGN OF HEAT EXCHANGER

5.3.1 Introduction

Most of the important requirement of a heat exchanger has already been

determine in the calculation for the chemical design. This would include the shell
and tube thickness, dimensions (diameter, length, and surface area) and even the
material used has also been taken into consideration. For the mechanical design,
we are more focusing on how to build this heat exchanger to meet the chemical
requirement that is pre-determined, withstand the vessel internal pressure, and
efficiently operating it, while maintaining a stable condition and low failure rate.

Heat exchanger, either mounted on the floor or interconnected with other

devices, the structural support needs to be designed properly with proper tabs,
brackets, and other mounting features on the heat exchanger to ensure no failure
of the supporting structure due to vibration, impact loads, fatigue, and so on. In a
mechanical design, consideration is also given to maintenance requirements such
as cleaning, repairing, serviceability and general inspection. Every heat exchanger
must comply with applicable local, state, national or international codes and
standards such as ASME pressure vessel codes and TEMA standards. Heat
exchanger should be designed accordingly for good mechanical design that will
also result in good thermal design.

In this section we will carefully measure the following mechanical criteria

a) Minimum shell and tube wall thickness

b) Construction material
c) Head and closure design
d) Channel cover
e) Shell and tube nozzle design
f) Tube arrangement inside shell, baffles and tube pass
g) Vessel support and design
 5-20

5.3.2 Operating Condition and Design Condition

Before furthering into the specific design of a heat exchanger, a safe margin of
design condition needs to be established. Usually the design condition is taken at
a higher value than that of the predetermined operating value. This is obviously so
that the design can withstand a maximum operating pressure and temperature,
and also giving room to uncertainties allowance which might happen in our
equipment. For tube and shell side of a heat exchanger, the only parameter that is
considered a significant effect to the design is temperature and pressure.

Design Pressure: For vessel under internal pressure, the design pressure is taken
as the pressure at which the relief valve is set, which is normally 5-10% above the
normal operating temperature.

Propanol Solution Cooled Water

Tube Shell
Working 0.1515 0.101
Design 0.16665 0.1111
Table 5.8: Design pressure

Design Temperature: Very important to include when the stream have component
mixture that might have exothermic reaction. The pressure would also affect the
changing temperature depending on its value. In the case of this particular heat
exchanger, shell side stream is obviously very stable as it is cool water stream.
The tube side stream is also quite stable as it contains about 98% propanol.
0
Therefore we are only inserting a 5 C pressure increase for the design
temperature.

Propanol Solution Cooled water

Tube Shell
Working 98 40
Design 103 45
Table 5.9: Design temperature
 5-21

5.3.3 Mechanical design of Shell and Tube wall

A) Shell Wall
It has been decided that the main material of construction of our heat exchanger
would be carbon steel. In calculating minimum thickness of any vessel wall, the
following equation is used;

Pi D i
Minimum thickness, e =
2 J f - Pi

Design Stress (Maximum Allowable stress) = f

Internal Vessel Pressure = Pi, Internal Diameter = Di
Joint efficiency = J (refer to appendix E7)
The description for stainless steel and carbon steel material is as follow (required
data for mechanical stress can also be seen in Appendix E6:

ASTM designation = A240

Grade = Gr A
Tensile strength (N/mm2) = 310.3
2
Yield strength (N/mm ) = 165.5
Max Allowed Stress at 100°C (N/mm2) = 89
Table 5.10: Description for Carbon Steel

Using inner Pressure, Pi =0.1111 N/mm2; Inner Diameter, Di = 508 mm; and Joint
efficiency of single weld butt joint with backing strips and Spotted Radiographic
Examination, J = 0.8

For the corrosion allowance, add 4mm to the minimum thickness. Although our
stream is not actually corrosive to wall material, an extra percussion is needed.
This is considering that we are using carbon steel as our shell material, which quite
prone to a very small value of corrosion.

Shell minimum thickness, es= 0.3966

Adding corrosion allowance of 4mm, es= 4.3966
Rounding to the closest available thickness, take 5 mm as our shell thickness

B) Tube Wall
Using the same equation as for shell wall thickness we can also calculate
minimum wall thickness for tube wall. Construction materials used are stainless
steel. There is not much difference in temperature design between shell and tube;
the max allowable stress can still apply.
 5-22

ASTM designation = A240

Grade = 316
Tensile strength (N/mm2) = 515
2
Yield strength (N/mm ) = 205
2
Max Allowed Stress at 100°C (N/mm ) = 105
Table 5.11: Description for Stainless Steel

Using design stress, f = 105 N/mm2; I

Inner Pressure, Pi = 0.16665 N/ mm2;
Inner Diameter, Di = 14.8 mm;
Joint efficiency, (use double welded with full radiographic examination) J=1.
Adding corrosion allowance = 2 mm
e = 0.01175 + 2
= 2.01175 mm
Based on the chemical design, it has been decided that the tube thickness would
be 2.1mm. This is well above the minimum requirement, therefore it is acceptable.

5.3.4 Head and closure

Head/closure design relates to the parts that closes the ends of a cylindrical
vessel. The specification is the same with any cylindrical equipment including heat
exchanger. Some of the common types of head and closure are;

 Hemispherical : Very strong design, high cost, for high pressure

 Ellipsoidal: Midrange classes, most economical for operation above 15 bar
 Torispherical: Cheap, most common for cylindrical vessel
 Flat Ends: low cost: not structurally efficient, very thick plates if used for high
pressure, very simple to design

From the pressure design we can safely state that our vessel operates at low
pressure, which is less than 5 bar. From the selection that is available, there are
only 2 options that are in range of our heat exchanger: Torispherical Head or Flat
Ends. Both of which can be economically apply for low pressure vessel.
 5-23

A) Torispherical head
Minimum thickness for torispherical heads;

Pi R c C s
e=
2Jf  Pi (C s - 0.2)

Cs = Concentration factor

1  Rc 
Cs = 3 
4  Rk 

Rc = 508 mm
Rk = 0.06(RC) = 30.48 mm
Cs = 1.7706
J =1.0 (double welded with fell radiographic examination)

Ratio of knuckle to crown radii should not less than 0.06 to avoid buckling; and
crown radius should not be taken larger than the cylindrical vessel diameter. Using
data from shell design and stress allowance, the minimum thickness of the
torispherical head is:
e = 0.5609 mm
Adding corrosion allowance of 4 mm:
e = 0.5609 + 4
= 4.5609 mm
Take thickness as same as for vessel design, and take thickness as 5 mm

B) Flat Ends Head

The thickness required will depend on the degree of constraint at the plate
periphery, and the minimum thickness is shown as:

𝐶. 𝑃𝑖
𝑒 = 𝐷𝑒 𝑓. 𝐽
C = Design constant, dependant on edge constraint = 0.17
De = Nominal plate diameter = Di
f = Maximum allowable stress = 89 N/mm2
J = 1.0 (double welded with full radiographic examination)

The value of „C‟ and „De‟ varies with the plate design as closure, which follows
ASME BPV (Society of Mechanical Engineers, Boiler and Pressure Vessel) Code.
 5-24

The design that we are using is: Flanges only end at C=0.17, Corner radius is not
more than 3e and De = Di.

Flat ends minimum thickness thickness, e = 0.1078

Adding 4 mm for corrosion allowance, e = 4.1078
Take thickness same as vessel design, which is 5 mm.

Since both torispherical and flat ends closure results in the same final thickness,
choose the most economical one, which is the flat ends closure with thickness of 5
mm

5.3.5 Channel cover

For channel cover, we will still be using the equation for flat ends as previously
applied. Channel cover is removable covers that are place at one end of a heat
exchanger. Flat ends with bolted cover are usually more practical than other types
of head.

𝐶. 𝑃𝑖
𝑒 = 𝐷𝑒 𝑓. 𝐽

Where C = A design constant, depend on the edge constraint

De = Nominal plate diameter

For the edge design, use bolted cover with full face gasket: C = 0.25 and De is the
bolt circle diameter which the diameter of a circle connecting the centres of the bolt
holes. This is usually larger than the outside diameter of vessel.

Take nominal diameter at 20 mm larger than the outside diameter of cylindrical

vessel:

De = (vessel thickness) + (vessel inside diameter) + 2(20mm)

= 2(5) + 508 + 2(20)
= 558 mm
Input all the required data and we get:
Closure minimum thickness = 9.8574 mm
We don‟t have to take corrosion allowance as it has already been indirectly
calculated in the nominal diameter, De. Round up the thickness, take closure
minimum thickness as 10 mm
 5-25

5.3.6 Dead Weight on Equipment

A) Vessel Weight
The following equation can be used for calculating approximate weight of
cylindrical vessel with doomed ends and uniform wall thickness

𝑾𝒗 = 𝑪𝒗 𝛑𝛒𝐦 𝐃𝐦 𝐠 𝐇𝐯 + 𝟎. 𝟖 𝐃𝐦 𝐭

Wv = total weight of the shell, N

Mean Diameter, Dm = Di + Cylindrical thickness
= (508 + 10) x 10-3 = 0.518 m
Material Density (Carbon Steel), ρm = 7850 kg/m3
Gravitational Pull, g = 9.81 m/s2
Accounted Weight Factor, Cv = 1.15 (vessel with fittings)
Lenght Cylindrical Vessel, Hv = 4.88 m
Wall Thickness, t = 0.005 m

Total weight of shell vessel = 3.7769 kN

B) Weight of tube
The equation for the internal tubing is simpler then that of the shell side. This will
only involve the tubing dimensions and density.

Wt  N t do2  di2Lm g

Total Number of Tubes, Nt = 254

Tube Outside Diameter, do = 0.019 mm
 Tube inside Diameter, di = 0.0148 mm
Tube side length, L = 4.88 m
Tube material density, ρm = 8000 kg/m3 (Stainless Steel 316)
Total weight of tubes = 43.4013 kN

C) Weight of insulation
The insulating materials are placed at the wall of a cylindrical vessel. This is to
prevent the heat in the designated process being loss into the surrounding area.
The suitable insulation for this equipment should be the mineral wool insulation.
 5-26

Wi = π Ds L ti ρ g
Take standard insulation thickness 70 - 75 mm, ti = 0.075 m
Density of mineral wool = 130 kg/m3
Double the density for fittings, sealing and moisture
= 260 kg/m3
Length, L = 4.88 m
Shell Diameter, Ds = 0.513 m
Mineral Wool Insulation, 75 mm thick to cover 4880 mm of pipe
Weight of insulator, Wi = 1.5051 kN

D) Total weight of heat exchanger

Adding all the calculated dead weight on the heat exchanger;
WTOTAL = Ws + Wt + Wi
= 48.6833 kN

5.3.7 Tube and shell side nozzle

Nozzle design for both channel stream is important to prevent excessive pressure
drop, avoid flow restriction and to assure proper fluid getting in and out. There are
no definite expressions that are taken into this section. However, good
approximations are available as can be seen in Stanley M. Walas, Chemical Process
Equipment, as can be seen in Appendix E10.

Shell Side Nozzle

Material of construction will be using the same as shell side pipe which is carbon
steel. The following data on water stream in shell side was already calculated
previously:
Water Flow Rate, Gs = 8.605 kg/s
Water linear velocity, us = 0.111 m/s

Flow area is the minimum required area which the respective fluid flow rate needs.
Flow Area, AFS = Gs / (ρshell x us)
= 0.0778 m3
Diameters for flow are: rearrange from circular area equation:
 5-27

Nozzle Shell Diameter, DNS = (4A/π)1/2

= 0.315 m

Tube Side Nozzle

In the tube side nozzle, we will regard it as the same as for the shell. This would be
the diameter at which the hot stream (propanol mixture) enters the tubing area.

Fluid Flow Rate, GT = 3.414 kg/s

Linear velocity, ut, of tube side inlet and outlet should be taken respectively to the
total cross sectional area of tubes per pass;

Total Tube Cross Sectional Area, Flow Area, AFT

= (N Tubes per Pass) x (Cross section of tube)
= 43 x π (0.0074)2 = 0.0074 m2

Rearranging from circular area equation, Diameter for flow area;

Nozzle Tube Side Diameter, DNT = 0.307 m

Take the nozzle diameter for both shell and tube side respectively the same for its
inlet and outlet section. This should actually differ slightly as there are some
density changes throughout the process.

Tube side inlet and outlet nozzle diameter

= 0.307 m = 12.087 inch
Shell side inlet and outlet nozzle diameter
= 0.315 m = 12.401 inch
Based on nominal nozzle diameter tabulated by Stanley M. Walas, Chemical
Process Equipment, as can be seen in Appendix E10; it can be seen that both side
can be take nominal diameter of about 12 inches = 304.8 mm. This is actually is
quite smaller than that is required, thus increasing shell and tube side pressure
drop. However, referring to the pressure drop calculated previously, we conclude
that there is still room for some value to be sacrificed and running the equipment
just as efficient.
5.3.8 Flange for Nozzles

Flanged joints are used for connecting pipes and instruments to vessel, for
manholes cover and for removable vessel head when ease of access is required.
 5-28

Flanged may also be used on the vessel body, when it is necessary to divide the
vessel into sections from transport or maintenance. Flanged joints are also used to
connect pipe to the equipments such as pumps and valves. Flanges ranges size
from a few millimeters diameter for small pipes to several meters diameter for
those used as body or head flanges on vessels. Flanges dimension must be able
to withstand the hydrostatic ends loads and the bolt loads necessary to ensure
tight joint in service.
For the design of this heat exchanger, welding-neck flange are used. It is
because welding-neck flanges have a long tapered hub between the flange ring
and the welded joint. This gradual transition of the section reduces the
discontinuity stresses between the flange and branch. It is also can increase the
strength of the flange assembly. Welding-neck flanges are suitable for extreme
service conditions, where flange are likely to be subjected to temperature, shear
and vibration loads. They will normally be specified for the connections and
nozzles on process vessels and process equipment. The specification design can
be seen in Appendix E11

Table 5.12: Specification for Flange Joints (based on figure)

Type Nom. Pipe Flange Face Bolt Drilling Neck

Pipe OD D B h1 d4 f d2 k d3 h2 r

Tube 305 327.1 450 22 62 369.1 4 22 400 346.3 15 12

side
Shell 305 327.1 450 22 62 369.1 4 22 400 346.3 15 12
Side
 5-29

Figure 5.4: Design for flange joints

5.3.9 Tubing, Baffles and Passes

The internal design of this heat exchanger was actually already specified in the
chemical design section. This would consist of 2 item which is the tubing passes
design and baffles spacing. Baffles are used in the shell to direct the fluid flow
across tube and increase the fluid velocity. When the fluid velocity increases, it‟s
improving the rate of heat transfer. The assembly of baffles and tubes is hold
together by support rods and spacers. The most commonly used type of baffle is
the single-segmental baffle. Baffle cut used to specify the dimensions of a
segmental baffle. Tube passes are generally how many times the fluid will pass the
whole length from end to end before leaving the shell area.
It was decided that the baffle spacing was to be 80% shell diameter, and
25% for baffle cuts. Baffle spacing is the length between one segmental baffle to
another and baffle cuts is to specify the height of the segment remove to form
baffle.
For tube design, there are 6 passes with approximately 43 tubes per pass
(see figure 5.5) Because of this specification, it can‟t actually be use in U tube
design, therefore it is decided to use a horizontal fixed tube with closure path.
 5-30

Figure 5.5: Tube pass and allocation

a) )

b)
Figure 5.6: a) Baffle spacing and baffle cuts, b) Segmental baffle design

Front End Shell Type Rear End

Stationary Heat: One pass: 1 inlet stream and 1 Fixed tube sheet:
Channel and Removable outlet stream: 12 baffle segments stationary flat ends head
Cover Baffle Spacing: 0.4064 m
Tubesheet baffle spacing: 0.4064
Baffle Cuts: 0.127

Figure 5.7: Heat exchanger designation for front and rear end, and shell type
 5-31

5.3.10 Vessel Support

Vessel support should be design to allow easy access to the vessel for inspection
and maintenance. It also has to be strong enough to hold the total weight of the
equipment plus its operating condition, vibration and accidental force. Horizontal
vessels such as the design heat exchanger; it is usually mounted on two or more
saddle support. The saddle must be designed to withstand the load imposed by
the weight of the vessel and its contents. For support design it depends on the
weight of vessel, which is the weight of cooler itself. From the previous calculation
of cooler weight, the total weight is 48.6833 kN.. From the value of weight, the
dimensions of saddle is choosing as referred to Figure 13.26 from Coulson &
Richardson‟s, Volume 6 (Refer Appendix E12)

Vessel outside diameter (with insulation counted) = 558 mm

Approximate Total Weight = 50 kN
Support Contact Angle = 160O

Table 5.13: Specification for Saddle Support

Vessel Weight Dimensions (mm)
Diameter V Y C E J G t2 t1 Bolt Bolt
Diameter Holes
0.558 m 50kN 450 150 550 240 140 95 8 6 20 25
 5-32

Table 5.13: Mechanical Design Sheet for Heat Exchanger

Heat Exchanger Specification Sheet Equipment No HE-109

Design By: Tasneem Mohd Noor Description Cooling Propanol (S23)

Product to 30oC

Overall Specification

Type Fixed tube Shell and Tube Heat Exchanger

Tube Pass 6 Tube Count 258

Shell pass 1 Connection Type Horizontal

Shell Side Construction

Length 4880 mm Material Carbon Steel Gr A

Inside Diameter 508 mm Wall Thickness 5 mm

o
Operating Pressure 101.3 kPa Operating Temp. 40 C

Head Type Flat End Head Thickness 5 mm

Closure Type Bolted Flat End Closure Thickness 5 mm

Insulator Mineral Wool Insulator Thickness 75 mm

Tube Side Construction

Length 4880 mm Material Stainless Steel 304

Wall Thickness 2.1 mm Operating Pressure 151.3 kPa

o
Outside Diameter (OD) 19 mm Operating Temp. 40 C

Inside Diameter (ID) 14.8 mm Tube Sheet Type Stationary

Other Mechanical Design

Baffles Type Segmental, 25% cut Nozzle Type welding-neck flange

Spacing 406. 4 mm Nozzle Shell Side 305 mm OD

Diameter
Cut 127.0 mm Tube Side 305 mm OD

Support Type Saddle Total Weight 48.68 kN

 5-33

Heat Exchanger Equipment Costing

Bare module cost and material factor for heat exchanger, process vessel and
pumps

𝑪𝒃𝒎 = 𝑪𝒑 𝒐 𝑭𝑩𝑴 = 𝑪𝒑 𝒐 (𝑩𝟏 + 𝑩𝟐 𝑭𝒎𝑭𝒑)

Calculation Steps

1) Area of heat transfer, A (m2) = 74.1 m2

From figure A.5: purchase cost of heat exchangers

(Based on CEPCI Sept. 2001 = 397)

Using 74.1 m2 area and fixed tube sheet line; Cpo = 300 $/m2

Cpo = (300 $/m2) x 74.1 m2 = 22 230.00 $

2) B1 and B2 are taken from table A.4 Constant for bare module factor
For fixed tube sheet heat exchanger
B1 = 1.63, B2 = 1.66

3) Fm, material factor

Identification number for material taken from Table A.3
Carbon Steel Shell and Stainless Steel Tube
Id. Number: 4
From figure A.18, material Factor, Fm = 1.8

4) Pressure Factor, Fp
Referring to Equation (A.3); page 923 of Turton, 3rd Edition;

Log10 Fp = C1 + C2 log10P + C3 (Log10P)2

From table A.2: pressure factor for process equipment

Using fixed tube sheet at pressure < 5 barg.

C1 = 0, C2 = 0, C3 = 0;
Log10 Fp = C1 + C2 log10P + C3 (Log10P)2
Fp = Log10 (0) = 1
 5-34

5) Bare Module Cost for equipment;

𝐶𝑏𝑚 = 𝐶𝑝 𝑜 (𝐵1 + 𝐵2 𝐹𝑚𝐹𝑝)

Cpo = 22 230.00 $
B1 = 1.63, B2 = 1.66
Fm = 1.8, Fp = 1

Cbm = 102 658.14 $

(Based on CEPCI @ SEPTEMBER 2001)

Convert to Malaysian Ringgit (MYR)

1 USD = 3.1 MYR
102 658.14 USD = 318 240. 23 MYR

6) Cost Index

In terms of inflation and increase of price over time, Chemical Engineering

Plant Cost Index (CEPCI) can be used from the year 2001 and to the latest
available estimate.

At September 2001, CEPCI = 397

At March 2010, CEPCI = 645.5

𝐶𝐵𝑀@2010 𝐼2 𝐶𝐸𝑃𝐶𝐼 645.5

= =
𝐶𝐵𝑀@2001 𝐼1 𝐶𝐸𝑃𝐶𝐼 397.0

𝑪𝑩𝑴@𝟐𝟎𝟏𝟎 = 𝟔𝟒𝟓. 𝟓 𝟑𝟗𝟕. 𝟎 𝟑𝟏𝟖 𝟐𝟒𝟎. 𝟐𝟑 𝐌𝐘𝐑

= 𝟓𝟏𝟕, 𝟒𝟒𝟎. 𝟗𝟖 𝑴𝒀𝑹

 5-35

Reference

Coulson J.M. and Richardson J.F., Chemical Engineering Design,vol.6, 1999

Dr. Brian S., Orela J.T., Heat Exchanger Theory and Design Handbook, Mc Graw
Hill,1990

Perry R.H. and Green D.W., Perry’s Chemical Engineers Handbook, 7 edition, Mc
Graw Hill International editions,1997

R.M. Price. 1999. CBU Official Website. “Shell and Tube Heat Exchanger:
Introduction”. Updated on: 2nd May 2003. Accessed on: 3rd February 2011.
Available at: http://www.cbu.edu/~rprice/lectures/

Harlan Bengtson. 2010. Bright Hub. “Types of Shell and Tube Heat Exchangers”.
Accessed on 10th March 2011. Available at:
http://www.brighthub.com/engineering/mechanical