Exercises thermal installation: shell & tube heat exchangers

Exercise 6
A heat exchanger has to be designed to heat water using condensate at a temperature of
67C and a pressure of 1.2bar (cp = 4184 J/kgK). The condensate flows through the shell
of a shell&tube heat exchanger with a mass flow rate of 50000 kg/h (one pass through the
shell). The heat is transferred to the water which has a temperature of 17C and a mass
flow rate of 30000 kg/h. The fouling resistance can be assumed 0.000176 mK/W for
both sides. To avoid erosion, the velocity of the cold water has to be limited to 1.5m/s.
Due to limited space, the length is not allowed to exceed 5m. The pipe walls consist of
carbon steel ( = 60 W/mK). The water flows through tubes of (outer diameter 19
mm, inner diameter 16 mm). The tubes are packed in a parallel arrangement with a pitch
of 0.024m. The baffle spacing is 0.25m. The water temperature at the outlet has to be
40C or higher. The shell has an inner diameter of 15 ; with 124 tubes in a 2P
shell&tube in agreement with the TEMA arrangement. Calculate the length, the amount
of baffles and the pressure losses on both sides. Use the Kern method.
The pressure losses in a shell&tube heat exchanger can be calculated using:
L
v m2
pi = 4 f tube + 1
Np
di
2

With Np the amount of passes.

In the above equation the extra term +1 (compared to the flow in tubes) is added to
account for the inlet effects.

Exercise 7
Demineralised water flows through the shell of a S&T heat exchanger with a rate of
50kg/s. At the inlet the demineralised water has a temperature of 32C and 25C at the
outlet. The baffle spacing is 0.5m. The heat is transferred to tap water with a mass flow
rate of 148kg/s and a temperature of 20C. A S&T heat exchanger with one pass on the
shell side and one tube pass has to be designed. The tube diameter is (19mm outer
diameter and 16mm inner diameter). The tubes are positioned in a square layout with a
pitch of 1. The tubes consist of a Cr-alloy (( = 42.3 W/mK). The water velocity in the
tubes has to be limited to 2m/s.
Calculate the shell side convection coefficient using the Bell-Delaware method. Assume
that the product of all the correction factors equals 0.6.

Exercise 8
A S&T heat exchanger has to be designed to warm up ethanol (60000 kg/h) from 25C to
50C. For this water at 95C is available. The water mass flow rate is 75000 kg/h. The
heat exchanger consists of stainless steel ( = 26 W/mK). A S&T heat exchanger with
one pass at the shell side and two passes at the tube side is preferred. Ethanol flows
through the tubes at a maximum velocity of 1.5m/s. The employed tubes have an inner
diameter of 0.0157 m and an outer diameter of 0.0191 m ( tubes BWG 16). The tubes
are placed in a triangular layout with a pitch of 1. The baffle spacing is 0.5m and the
baffle cut is 25%. All baffles have the same size. 8 pairs of sealing strips were added.
Fouling at the water side cannot be neglected. Design the heat exchanger using the
Taborek method. To minimize the leakage flows dummy tubes are added. Also calculate
the pressure loss on the shell side.
Ethanol: = 775 kg/m; cp = 2850 J/kgK; = 0.00085 kg/ms; = 0.165 W/mK