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What are the common causes of fouling in a heat exchanger? How does
fouling affect heat transfer and pressure drop?
Ankit Malhotra, Chemical Engineer

Answered Sep 7
Common causes for fouling in a heat exchanger-
1. Low velocity
2. Dead spots in design where there is no continuous flow
3. High metal temperature
4. Film boiling
5. Nature of fluid- presence of solids, thermal sensitivity.
Fouling reduces heat transfer as it acts as an additional resistance in heat transfer. Fouling
increases pressure drop, for the same flow rate, as it increases the roughness and reduces
the flow area.
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How is heat transfer coefficient higher for a multipass shell and tube heat
exchanger than a single pass shell and tube heat exchanger?

Answered Sep 7
A multipass heat exchanger, with all other parameters remaining the same has a higher tube
side velocity than a single pass design. A higher velocity means better turbulent. Better
turbulence in co...
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0
Why is a 2-pass heat exchanger used over a 1-1 heat exchanger?

Answered Sep 7
With everything else the same, if tube passes are increased from one to two, the tube count
per pass halves (approximately). This means that the tube side velocity doubles. This results
in the heat transfer coefficient improving reducing the area required for the same heat duty.
There are sometimes other reasons of increasing the passes, such as attaining a minimum
velocity required to prevent fouling on the tube side. On the negative front it increases the
pressure drop and reduces the MTD.
The purpose is always to have a reliable, optimum design.
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How can leakage in tubes of heat exchangers can be found?

Answered Sep 7
In process industries, the sign of a leak is seen in process parameters. The leaking fluid will
pass from the high pressure side to the low pressure side, contaminating it, which will show
up in online analysers or periodic lab analysis. For example, a heat exchanger for an acid and
cooling water service with the process side having a higher pressure, if leaks will lead to a
sudden drop in pH of Cooling water at the cooling water tower. This can then be confirmed
by taking the exchanger offline and doing a hydro test.
In heat exchangers where the contamination is not easy to check, a slight amount of
radioactive tracer is used.
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How do engineers troubleshoot shell and tube heat exchangers?

Answered Jul 18, 2018
How to understand the operating parameters to understand a problem with a heat

exchanger has already been mentioned in another answer. I will try to add to that.
In my experience we come across the following type of problems and have described the
approach towards solution:
1. Inadequate duty: If an exchanger is identified to be performing lower than its

design or required duty, the next step is identifying where did we go wrong-
a. Incorrect original sizing -
i. Large leakage streams not accounted for in design such as that because if bundle
to shell gap in floating head or leakage through sealing arrangement of f type
shell
ii. Incorrect calculation of heat transfer coefficient for the controlling side
iii. Incorrect MTD calculation, especially in case of temperature cross, wide boiling
range mixture.
iv. Accumulation of condensate in exchanger because of inadequate driving head for
flow to go out
v. Fouling - Inadequate velocities, high skin temperatures, film boiling not accounted
for in design
vi. Design vs actual differences - There have been instances where not all features of
datasheet were not captured in the actual exchanger.
b. Design is adequate but Operating conditions are different because of which
exchanger is not performing-
i. Difference in temperature or composition of either fluid because of which MTD or
heat transfer coefficient is affected.
ii. Difference in actual vs design flow rates - Cooling water is a very common of this
which can lead to accelerated fouling.
iii. Presence of contaminants not accounted in design leading to accelerated fouling
2. Tube failure
i. TTSJ joint - Checking the nature of joint and scope for improvement
ii. Vibration related damage - Quantifying vibration amplitude, providing support in
design
iii. Missing impingement device and erosion of tubes in front of nozzle - Especially if
inlet is two phase
iv. Corrosion - Choice of metallurgy and presence of possible corrosion agents
depending on type of corrosion.
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How LMTD of counter flow heat exchanger is greater than parallel flow
heat exchanger?

Answered Apr 12, 2018
Temperature difference leads to heat transfer and heat transfer changes the temperature
difference.
Take a single pass shell and tube exchanger and look at how the temperature changes as
we go along the length of it in small segments.
In case of a parallel (co-current flow), if the temperature difference in the first segment is
DT1, the flow of heat reduces the temperature difference in the next segment to something
less than it as the flow of heat from hot to cold fluid brings temperatures closer to each
other. This means that the temperature difference is very high at one end and very low at
the other.
In case of countercurrent exchanger the flow of heat does change the temperature of the
two streams- hot stream cools down a bit and cold steam heats up but it does not bring
them closer to each other in the next segment. This is because the next segment is in
opposite directions. The temperature difference is a high number throughout the length.
LMTD which is a mean of the overall is better in counter current than in co-current.
5k views · View Upvoters · View Sharers · Answer requested by Pankaj Yadav
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Is multipass possible in a shell and tube heat exchanger?

Yes. Multiple tube passes are very common in shell and tube exchangers. On the tubeside it
is done to get high enough tube side velocity and 2/4/6/8 passes are very common. On the
shell side a TEMA F type is a common shell type a near equivalent to having two shells in
series, helps in applications with a temperature cross and provides for a countercurrent
arrangement if you also have 2 passes on the tubeside.
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What is the advantage of double tube heat exchangers over shell and
tube heat exchangers?

An answer I have to a similar question earlier might help you. Ankit Malhotra's answer to
What are practical applications of double pipe heat exchanger?
790 views · View Upvoters · Answer requested by Rupesh Kumar
12
0
How overall heat transfer coefficient is more for plate type heat
exchanger (PHE) than shell and tube heat exchanger?

Answered Mar 28, 2018
More turbulence.
The nature of the flow area in a PHE, which are the plate channels (small hydraulic diameter)
and the flow being subject to many more direction changes than in a normal shell and tube
heat exchanger allows for turbulence to be achieved at a much lower velocity. Higher
turbulence leads to higher heat transfer coefficients.
Ofcourse there are other advantages and disadvantages of a PHE as well.
Some information on this video by AIChE although not directly pertaining to the question
might be useful too.
721 views · View Upvoters · Answer requested by Sangeetha K
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What textbook should I follow for the optimisation of a heat exchanger?

Answered Feb 21, 2018
The one I like the most on the subject is Heat Exchanger Design Handbook by Kuppan
Thulukkanam.
178 views · View Upvoters · Answer requested by Kasi Aswin
12
What is a shell side pass partition plate?

A shell side pass partition plate is unique to a TEMA F type shell in a shell and tube heat
exchanger which allows for multiple passes on the shell side just like we have on the tube
side.
Most shel...
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56
How should I choose the shell side fluid and tube side fluid in shell and
tube heat exchanger for better efficiency?

For better efficiency I assume the question refers to getting the least area for the same heat
transfer requirement.
The idea is always to start with a design, realize its limitations - what is the controlling thing
behind it - which of the two sides is controlling the heat transfer and will that be helped if
the shell side and tubeside fluid are swapped ?
Some ideas-
1. Viscous fluids: Getting turbulence in viscous fluids is tough on tubeside and

relatively easier on the shell side. If you are using aids such as tubeside inserts to
aid turbulence, ofcourse the sides would change. This is to improve the coefficient
if one of the two fluids is very viscous.
2. Low conductivity fluids: At times it is prudent to use the low heat transfer
coefficient giving side on the shell side only because you can balance the
resistance by giving higher area on the tube outer surface using fins. This will bring
down the size of the shell significantly.For example a gas- liquid exchangers like air
coolers.
3. Temperature change and MTD: One can play with the fluid- shell side/tubeside
choice, combination of different pass configurations for a multi-pass exchanger,
the number of passes to keep, the number of shells to keep in series, to get the
best mean temperature difference keeping in mind other constraints such as
velocity.
Do note that I am assuming here you do not have any of the other limitations which usually
control tubeside/shell side fluid as it might be in a case where both shell side fluid and
tubeside fluid is similar in most aspects such as a feed bottoms exchanger in a distillation
column. Mostly the other criteria are more important in making this decision.
1.4k views · View Upvoters · Answer requested by Mohamed Tharick
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What will happen to heat transfer coefficient if prandtl number is

increased in turbulent flow?

Answered Jun 17, 2016
Originally Answered: what will happen to heat transfer coefficient if prandtl number is increased in
turbulent flow?
Can Increase or Decrease.
Dittus-Boelter equation is one of the many empirical correlations to estimate the heat
transfer coefficient h, by first calculating the Nussult number based on the Prandtl number
and Reynold’s number (Nusselt number). What it says is that Nussult number increases with
increase in Reynolds number and Prandtl number but not the heat transfer coefficient.
Prandtl number is a collection of physical properties and the only way one might be able to
change it significantly is if we are talking about two different fluids.
If we can find two fluids with all properties being the same other than specific heat, the one
with higher specific heat will have higher Pt and this correlation indicates it will have a
higher heat transfer coefficient as well.
To give you a counter example, replacing a low conductivity fluid with a high conductivity
one (with all other properties the same), will increase the heat transfer coefficient though
Prandtl number reduces.The same is predicted by this correlation as well, since there is the
thermal conductivity term in both Prandtl number and Nussult number. This effect is most
visible in cases of gases, which typically have very low heat transfer coefficients because of
the same reason except for hydrogen, which has an exceptionally high thermal conductivity
and gives a much better h.
1.1k views · View Upvoters · Answer requested by Lucky Sharma
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Which criteria limitations the Maximum length of tube in heat

exchanger?
Mostly - shell side pressure drop because of the long flow path.
Exchanger tube length is generally selected in multiples of 1.5m i.e. 1.5, 3, 4.5, 6m being the
most common ones as these are readily available tube sizes. There are exceptional cases
with much higher tube lengths as well however. There are also tubular reactors with much
higher tube lengths as well. Longer tube length typically means a greater footprint, if the
exchanger is horizontal or higher foundation costs if the exchanger is vertical. For horizontal
exchangers space might also be needed infront of the exchanger to allow for bundle
pullout, increasing the plot space requirement further. The exchanger also becomes too
heavy to be supported by the regular infrastructure constraints of a plant - cranes, bundle
pullers, trailers etc. But like everything else, there are exceptions.
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Is any heat transfer taking place between the paperweight (on the table)
and table?
Heat transfer needs a driving force. Unless the paper weight and table are at different
temperatures, there will not be any heat transfer. If the two are at different temperatures,
there will be transfer of heat from the hot body to the cold body till it achieves an
equilibrium - a temperature which is same for both objects. In this reference this means that
if you keep a hot paperweight on a table, it will heat up the table and the air around it till
the paperweight cools down. The table and air will heat up, but the change will be
insignificant considering their weight. Slowly even the table will cool down and all the heat
will be taken up by the air, with everything reaching the same temperature at which heat
transfer will stop.
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Describe the effect of no of tube passes on pressure drop and turbulence

in shell and tube heat exchangers?
Originally Answered: describe the effect of no of tube passes on pressure drop and turbulence in shell and
tube heat exchangers?
Tube passes - Changing the number of tube passes can have multiple effects on an
exchanger-
1. Pressure drop, velocity: For the same shell diameter and tube length, changing
tube-pass count means that the net flow path length and flow area for the tube
side flow changes. eg. Doubling the number of passes, approximately halves the
flow path area (doubling the velocity) and doubles the flow path length for the
tube side flow. This means that the pressure drop changes by 8 times ! This higher
velocity also means a better heat transfer coefficient, if the increase in pressure
drop is acceptable. At times a minimum velocity is a process requirement as well,
to avoid fouling of exchangers.
2. Shell side flow, heat transfer area: Changing the number of passes or even the
different arrangements in which those passes are laid out within the exchanger can
lead to changes to the shell side flow. Consider change in number of passes in an
exchanger from 1 to 2. This means that there is an additional pass- partition baffle,
which takes up some space which was otherwise occupied by tubes and therefore
the number of tubes and the net heat transfer area will reduce. This can be
significant for small exchangers but is not too much of a concern for large
exchangers. Also, depending on the number of passes and their configurations,
there can be different leakage streams which can develop. There is an additional
flow path available for the flow - the gap between tubes caused because of the
pass partition baffle. These leakage streams can reduce the overall effectiveness of
the exchanger unless addressed.
Turbulence: Increase in turbulence on shell side or tubeside, increases the heat transfer
coefficient at the cost of higher pressure drop.
3.4k views · View Upvoters · Answer requested by Lucky Sharma
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How can we mathematically prove that heat transfer is higher in

Turbulent flow as compared to Laminar flow?

I do-not know of a mathematical proof to explain this. There are only experimental
correlations to fit what we see, so that it can be used in science and engineering, most
commonly we try to fit (N...
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56
What does it look like inside a fractional distillation column?

Answered May 29, 2016
Industrial Distillation columns can be very small to very big. They can be anything from
~300mm in diameter to 15000mm which is as big as a hall. They can be very high ~ 100–
120m in height. We can ...
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34
How 100 % heat can be converted into useful work?

Originally Answered: how 100 % heat can be converted into useful work ?
It cannot be done.
In the world of thermodynamics, heat and work are not equals and work represents a higher
form of energy than heat. One can convert work into heat completely (we do this when we
rub our hands, or the famous experiment by Joule with a stirrer (DynamicMenu). The reverse
process of converting heat into work completely was attempted time and again and it was
found that it is not possible. There are always some “losses” associated with this conversion.
To allow engineers and scientists work with this fact, it was drafted as a law, famously called
the the second law of thermodynamics (it is called a law because we cannot prove it without
making other assumptions again). The law can be stated in many ways and the relevant
version here is the Kelvin Plank statement: “It is impossible to devise a cyclically operating
device, the sole effect of which is to absorb energy in the form of heat from a single thermal
reservoir and to deliver an equivalent amount of work” (Kelvin–Planck statement.)
This has huge implications in the real world, where in we attempt to make use of different
forms of heat to work - such as a steam turbine, which can never be 100% efficient.
More on second law of thermodynamics: 5.1 Concept and Statements of the Second Law
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Why is saturated steam, instead of superheated steam used as a heating

medium in the evaporator?

Because it offers a much better heat transfer coefficient and can provide a much larger
amount of heat, per unit weight/volume.
In most practical applications, steam does have some amount of super-heat to prevent its
condensation and related problems during transportation in pipelines.
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Why is the heat transfer coefficient of saturated steam higher than a

superheated steam?

The two are governed by different principles.
Super-heated steam is quite bad and saturated steam is too good at heat transfer. The
condensing steam film coefficient can be as high as 8000- 10000 kcal/hr/m2/deg-C. It is
much lower (<1000 kcal/hr/m2/degC) for super-heated steam.
In case of superheated steam, which undergoes regular heat transfer with temperature
change, the main resistance is the low thermal conductivity because of which the heat
transfer coefficient is quite low (as is for all gases other than hydrogen), which makes the
coefficient quite low, even less than liquids. Low thermal conductivity means that even
though it can be at the same bulk temperature as saturated steam (ofcource the two will
have to be at different pressures here), there will be a large thermal layer built up, acting has
a significant resistance.
In case of saturated steam there is a huge difference between the latent heat and the
specific heat, which allows for a lot more heat to be transferred by the same amount of gas,
making the calculated heat transfer coefficient much larger in this case. For example with 1
kg of steam at 4 bar, we can have ~ 500 kcal of heat. 1kg superheated steam undergoing a
typical~20deg temperature change under similar conditions would give ~10kcal or heat.
The heat transfer coefficient can be as much as 10 times higher in case of dropwise
condensation, instead of the typical film condensation, because of absence of the liquid film
resistance, which makes non-wettable heat transfer surfaces a very attractive field.
Of-course the other advantage of using saturated steam is that it can provide a lot of heat
at a constant temperature.
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What is the physical significance of convective heat transfer coefficient?

Convection is one of the ways heat gets transferred and the heat transfer coefficient is a
measure of its effectiveness. Convection dictates most of the heat transfer around us, like
the cooling system of the human body, a car, a computer, or other things like heating water,
basically everything which allows physical movement of fluid for heat transfer.
Most heat transfer is a combination of conduction and convection together. But we can
minimize the conduction resistance using highly conducting material (mostly metals), which
makes convective heat transfer coefficients the key limitation in most cases. The significance
of this coefficient lies in how it can dictate the size of the required system, say your car
radiator, or say the processing capacity of your phone (Samsung's Galaxy S7 is the first
smartphone to feature a clever liquid cooling system » TechWorm ). It is what makes us feel
better in hot weather when you turn up the fan’s speed as the coefficient goes up with
increase in turbulence.
2.6k views · View Upvoters · Answer requested by Aravind Srinivasan
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Why is ice more effective in cooling than water at same temperature?

I will just rephrase one of the answers. Ice can take in a lot of heat and still not get warm,
which will happen with water. The rate of heat transfer is directly dependent on the
temperature of the cooling medium, therefore in case of water it will gradually keep
reducing, with ice, it will remain the same for a significant time till it melts.
What is also ‘cool’ is that the degree of latent heat of ice is significant, which means it can
take in a lot of heat before it melts (otherwise it would have meant too quick melting).
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When describing a heat exchanger, why do we use log mean temperature

difference instead of mean temperature difference?

Because that is the right thing to do (based on Science and Mathematics).

This is because the temperature profiles for both hot and cold streams, even in an ideal case
of perfect co-current and coun...
(more)
4950
What is the temperature profile of a double pipe heat exchanger in

counter current?

A double pipe heat exchanger temperature profile is exactly what is taught in academia - for
a co current exchanger - two lines exponentially going towards each other .
For a counter current exchanger two curved lines which look parallel to each other.
It is not very difficult to come up with the equations of these lines, assuming a constant heat
transfer coefficient along the length of the exhanger. Link
3.2k views · View Upvoters · Answer requested by Shubham Pandey
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What is the difference between the design and rating of a double pipe
heat exchanger?

In case of rating, you are checking an existing heat exchanger design for a specific need -
say for a higher duty and thus coming with an answer specific to that need and an existing
exchanger.
In c...
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34
What is the approximate range of baffles operating in a heat exchanger?

It can vary depending on all the geometrical parameters of an exchanger. Typically one
would see a baffle spacing of the order of 450–600mm in industrial scale exchangers. Max
spacing can be about ...
(more)
01
What will happen to velocity in tube side of heat exchanger, when bundle
diameter is changed?

Increases as bundle diameter is decreased and vice-versa if everything else is constant.
As one decreases the bundle diameter, retaining the other geometrical characteristics (tube-
size, pitch, th...
(more)
12
0
What are practical applications of double pipe heat exchanger?

The decision of going for a double pipe type during designing are driven by its
characteristics:
1. Can have countercurrent flow throughout the length of the exchanger- great if you are
dealing with...
(more)
56
What are the benefits of drinking water in Copper pot?

Updated May 15, 2016
Short version: Drinking water which has been kept in a copper pot for few hours can help
you meet your daily copper requirement and also clean your water to some extent. But do-
not over do it.
Long ...
(more)
100+
What does the statement "There is a natural asymmetry between

converting heat to work and work to heat" mean?

It means that you can convert work completely into heat but you cannot convert heat
energy completely into work, thus the asymmetry. The statement is based on the first and
second law of thermodyna...
(more)
45
Why does transfer of heat take place from higher temperatures to lower
temperature? Is it due to spontaneity
Answered Jan 30, 2016
Heat transfer can happen in different ways - Conduction, convection, radiation. Each has its
way of working. In each case an excited particle tries to lose its energy by passing it on to
another.
T...
(more)
12
Why is steam fed to the shell side in heat exchangers rather than the tube
side?

The choice of which stream to keep where is always a debatable topic for any heat
exchanger design and there is never a general rule which can be applied everywhere like
saying that steam driven sh...
(more)
1920
1
0
What steam is used in shell and tube heat exchanger?

Any type of steam can be used, depending on the application. Industrial plants usually have
multiple but fixed grades of steam - Low pressure (LP), Medium Pressure (MP) & High
pressure (HP). Some p...
(more)
12
Why are shell and tube exchangers with cooling water on the shell side,
always designed to have outlet from the top of the exchanger?

I think the question is about why shell and tube exchangers with Cooling water on the shell
side have outlet from the top. It is actually to allow complete venting of the exchanger,
while taking th...
(more)
34
Credentials & HighlightsMore
Works at Reliance Industries Limited

Studied at Indian Institute of Technology, Kanpur
Lives in Mumbai, Maharashtra, India
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Heat Exchangers
33 answers
Chemical Engineering
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Distillation
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ProfileMost Recent / All-Time Views

Ankit Malhotra, Chemical Engineer

Common causes for fouling in a heat exchanger-

346 views · View Upvoters

Ankit Malhotra, Chemical Engineer

Why is a 2-pass heat exchanger used over a 1-1 heat exchanger?

Ankit Malhotra, Chemical Engineer

The purpose is always to have a reliable, optimum design.

125 views · View Upvoters

Ankit Malhotra, Chemical Engineer

366 views · View Upvoters

How do engineers troubleshoot shell and tube heat exchangers?

How to understand the operating parameters to understand a problem with a heat

1. Inadequate duty: If an exchanger is identified to be performing lower than its

Ankit Malhotra, Chemical Engineer

5k views · View Upvoters · View Sharers · Answer requested by Pankaj Yadav

Is multipass possible in a shell and tube heat exchanger?

Ankit Malhotra, Chemical Engineer

Ankit Malhotra, Chemical Engineer

790 views · View Upvoters · Answer requested by Rupesh Kumar

Ankit Malhotra, Chemical Engineer

Ofcourse there are other advantages and disadvantages of a PHE as well.

721 views · View Upvoters · Answer requested by Sangeetha K

What textbook should I follow for the optimisation of a heat exchanger?

Ankit Malhotra, Chemical Engineer

178 views · View Upvoters · Answer requested by Kasi Aswin

What is a shell side pass partition plate?

Ankit Malhotra, Chemical Engineer

Ankit Malhotra, Chemical Engineer

1. Viscous fluids: Getting turbulence in viscous fluids is tough on tubeside and

1.4k views · View Upvoters · Answer requested by Mohamed Tharick

What will happen to heat transfer coefficient if prandtl number is

Ankit Malhotra, Chemical Engineer

1.1k views · View Upvoters · Answer requested by Lucky Sharma

Which criteria limitations the Maximum length of tube in heat

1.2k views · View Upvoters

404 views · View Upvoters

Describe the effect of no of tube passes on pressure drop and turbulence

3.4k views · View Upvoters · Answer requested by Lucky Sharma

How can we mathematically prove that heat transfer is higher in

Ankit Malhotra, Chemical Engineer

What does it look like inside a fractional distillation column?

How 100 % heat can be converted into useful work?

Ankit Malhotra, Chemical Engineer

1k views · View Upvoters · Answer requested by Ranjit Shingare

Why is saturated steam, instead of superheated steam used as a heating

Ankit Malhotra, Chemical Engineer

1.6k views · View Upvoters

Why is the heat transfer coefficient of saturated steam higher than a

Ankit Malhotra, Chemical Engineer

The two are governed by different principles.

10k views · View Upvoters · View Sharers

What is the physical significance of convective heat transfer coefficient?

2.6k views · View Upvoters · Answer requested by Aravind Srinivasan

Why is ice more effective in cooling than water at same temperature?

7.6k views · View Upvoters

When describing a heat exchanger, why do we use log mean temperature

Ankit Malhotra, Chemical Engineer

Because that is the right thing to do (based on Science and Mathematics).

What is the temperature profile of a double pipe heat exchanger in

Ankit Malhotra, Chemical Engineer