Introduction to

HEAT EXCHANGERS
Transfer of thermal energy between

two or more fluids

between a solid surface and a fluid

between solid particulates and a fluid

2 )
Types of HE
Double-pipe exchanger

Shell and tube exchangers

Plate and frame exchangers

Plate-fin exchangers.

Spiral heat exchangers.

Air cooled heat exchangers

Agitated vessels.

Fired heaters.

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Based on transfer process
Indirect Contact – Shell & Tube Heat Exchangers

Direct Contact – Cooling Towers

Based on phase of fluids

Gas-Liquid exchangers

Liquid-Liquid exchangers

Gas-Gas heat exchangers

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Based on construction
Tubular
Double pipe heat exchanger
Shell and tube heat exchangers
Spiral heat exchangers
Plate-type
Plate and frame heat exchangers
Spiral plate heat exchangers
Extended Surface
Plate-fin exchanger
Tube-fin exchanger

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Based on flow arrangements
Parallel flow / Co-current flow

Counter flow

Cross flow

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Heat Transfer Coefficient
Heat transfer rate, 𝑞  =  𝑈𝐴∆𝑇𝑚
U = overall heat transfer coefficient, W/(m2 C)
A = heat transfer surface area, m2
∆𝑇  = o
𝑚 mean temperature difference, C
Overall Heat Transfer Coefficient, Uo

ho = outside fluid film coefficient, W/(m2.oC)

hi = inside fluid film coefficient, W/(m2 .oC)
hod = outside dirt coefficient (fouling factor), W/(m2 .oC)
hid = inside dirt coefficient, W/(m2 .oC)
kw = thermal conductivity of the tube wall material, W/(m2 .oC)
d i= tube inside diameter, m
do= tube outside diameter, m
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Temperature Profile: Co-current flow

Log Mean Temperature

Difference (LMTD)

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 Temperature Profile: Counter current flow

Log Mean Temperature

Difference (LMTD)

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Temperature Correction Factor (Ft )
Mean temperature difference, ∆𝑇𝑚

∆𝑇  = 𝐹 ∆𝑇
𝑚 𝑡   𝑙𝑚

Ft depends on R & S

𝑇  − 𝑇
ℎ𝑖 ℎ𝑜
𝑅 =
𝑇  − 𝑇
𝑐𝑜 𝑐𝑖

𝑇  − 𝑇
𝑐𝑜 𝑐𝑖
𝑆 =
𝑇  − 𝑇
ℎ𝑖 𝑐𝑖

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 SHELL & TUBE
HEAT EXCHANGERS
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 Components of a STHE
Shell
Shell cover
Tubes
Channel
Channel Cover
Tubesheet
Baffles
Floating-Head Cover
Nozzles
Tie-Rods & Spacers
Pass Partition Plates
Impingement Plates
Sealing Strips & Sealing Rods

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 Classification by Construction
Fixed-tubesheet heat exchanger

Has straight tubes secured at both ends to tubesheets

welded to the shell

Low cost, simplest construction.

Bundle is "fixed" to the shell so outside of the tubes

cannot be cleaned mechanically.

Application is limited to clean services on the shell side

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 U-tube heat exchanger
Tubes are bent in the shape of a U

Only one tubesheet

Bending of tubes adds to the cost

Tube bundle is removable, outside of tubes can be

cleaned.
Because of the U-bend, inside of the tubes can’t be

cleaned mechanically
Can’t be used for dirty fluids inside tubes.

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 Floating head exchanger

Most versatile and costliest.

One tubesheet is fixed relative to the shell, and the other

is free to “float” within the shell.

Cleaning of both the insides and outsides of the tubes

Can be used for services where both the shell-side and

the tube-side fluids are dirty

Widely used in Petroleum Industry

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 U-Tube Heat Exchanger

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 Straight-Tube ( 1-Pass )

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 Straight-Tube ( 2-Pass )

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 FLUID ALLOCATION
Shell Side Tube Side
Fluids which are prone to
Viscous Fluids
fouling
Lower Flow Rates
Corrosive fluids
Cleaner Fluids
Toxic fluids to increase
containment
High pressure streams, since
tubes are less expensive to
build strong
Streams with low allowable
pressure drop
Cooling water to be put on
tube side only

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 Tubes
Tubes should be able to withstand:
Operating temperature and pressure on both sides
Thermal stresses due to the differential thermal expansion
between the shell and the tube bundle
Corrosive nature of both the shell-side and the tube-side
fluids
TUBE PITCH RATIO:
Min 1.25 times of tube OD
1.333 times of tube OD
1.5 times of tube OD
TUBE PASS: Based on pressure drop & velocity limit on tube
side

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 TUBE LAYOUT ANGLE
30o
30o Triangular 90o
90o Square
FLOW FLOW

Triangular layouts give more

tubes in a given shell Square layouts give cleaning
lanes with close pitch
60o

45o

FLOW
60o Rotated 45o Rotated
Triangular Square
FLOW

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 Feature Tube Layout Pattern

Lower ΔP on shell-side Square (effective only at low

Re number)
Shell-side fouling Square - easier cleaning

Horizontal shell-side Square

Boiling
Smaller shell size Fit 15% more tubes if
triangular pitch used

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 Tube pitch
Shortest distance between two adjacent tubes

TEMA specifies a minimum tube pitch of 1.25*(OD)

Minimum tube pitch leads to smallest shell diameter for a

given number of tubes.

To reduce shell-side pressure drop, the tube pitch may be

increased to a higher value.

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 Tubesheet
Barrier between shell-side and tube-side fluids.

Mostly circular with uniform pattern of drilled holes.

Tubes are attached to tubesheet

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 Tie rods and spacers
Tie rods and spacers are used for:
holding the baffle assembly together

maintaining the selected baffle spacing

Sliding strips
help the bundle to slide out from the shell

Can also be used as tie rods to hold the bundle in

position.

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 Sealing strips and Seal rods
Sealing strips prevent shell side fluid from bypassing the

bundle.
Sealing strips block the resulting large open area at top or

bottom of the shell.

Seal rods are also used to control the leakage streams.

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 TUBE PASS LAYOUT
Ribbon

Quadrant

H-Bend

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 TYPES OF BAFFLES
Segmental type;
Single – horizontal & vertical
Double
Triple
No-Tubes in Window (NTIW)
Orifice type
Disc and doughnut type
Rod type
Impingement type
Longitudinal (pass partitions)

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 ORIENTATION:
 Horizontal for heating or cooling with no phase change
 Vertical for shell side condensation
CUT:
 15 % to 45 % of shell ID for Single Segmental
 25 % to 35 % of shell ID for Double Segmental

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 Baffle cut
Height of the segment that is cut in a baffle to permit the shell-
side fluid to flow across the baffle.
Baffle cut should be set carefully because a baffle cut that is
either too large or too small can increase the possibility of
fouling in the shell, and moreover it would also lead in
inefficient shell-side heat transfer
CUT:
 15 % to 45 % of shell ID for Single Segmental
 25 % to 35 % of shell ID for Double Segmental

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41 Transport Phenomenon (CH 306)
Baffle/ Nozzle orientation
The orientation of the baffle cut is important for heat exchanger
installed horizontally.
When the shell side heat transfer is sensible heating or cooling with
no phase change, the baffle cut should be horizontal.
For shell side condensation, the baffle cut for segmental baffles is
vertical.
For shell side boiling, the baffle cut may be either vertical or
horizontal depending on the service.
Positioning of inlet/ outlet nozzle is also important for the proper
functioning of exchangers.
In cooling water services, the inlet nozzle should be at the bottom
and outlet nozzle should be at the top.
For condensing services exit should be from the bottom nozzle.

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 Baffle Spacing
Baffle spacing is the longitudinal or centreline-to-
centreline distance between adjacent baffles.

According to TEMA, the minimum baffle spacing should

be one-fifth of the shell inside diameter or 2 in.,

whichever is greater.

The maximum baffle spacing is the shell inside diameter.

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 Impingement devices
Impingement rod, Impingement plate, Nozzle Impingement baffle

are the various devices used in heat exchangers to trim down the
effects of high velocity at entry nozzles over tube bundle.

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 TUBE PROBLEMS
• Scaling of inside/outside of the tube surface

• Blockage of tube passage

• By passing across the baffle

• Puncture in the tube

• Leakage through the tube to tubesheet

• Leakage through gasketted joint of floating head

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 Bypass & Leakage streams:
TINKER FLOW MODEL
B stream: Main heat transfer stream, follows a path around baffles and

through tube bundle

A stream: Leakage stream, flowing through clearance between tubes and

holes in baffles

C stream: Tube bundle bypass stream in the gap between the tube bundle

and shell wall

E stream: Leakage stream between baffle edge and shell wall

F stream: Bypass stream in flow channel partitions due to omissions of

tubes in tube pass partitions.

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 FLOW FRACTIONS ALLOWABLE LIMITS
A Stream < 10 %
B Stream > 40 %
C Stream < 10 %
E Stream < 15 %
F Stream < 10 %

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Bypass & Leakage Streams
Since the flow fractions depend strongly upon the path resistances, varying any
of the following construction parameters will affect stream analysis and
thereby the shell side performance of an exchanger:

Baffle spacing and baffle cut

Tube layout angle and tube pitch

Clearance between the tube and the baffle hole

Clearance between the shell I.D. and the baffle

Location & no. of sealing strips and sealing rods

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 Temperature Cross (Co-current)
Outlet temperature of cold stream

cannot be greater than the outlet

temperature of the hot stream.

An F shell has 2 shell passes, so if

there are 2 tube passes as well, it

represents a pure counter-current
flow

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 Air cooled heat exchanger

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 Plate and Frame heat exchanger

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 Spiral heat exchanger

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