26.03.

2008
Heat Exchangers
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Heat Exchangers
Shell and Tube Heat Exchanger
U-Tube Heat Exchanger
Double-Pipe Heat Exchanger
Counter current
Cocurrent
Cross current
Flat-Plate Heat Exchanger
Spiral-Tube Heat Exchanger
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Counter Flow
In a counter-flow heat exchanger fluids flow in the
opposite direction
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Counter Flow
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Parallel Flow
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Parallel Flow
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Cross Flow Air to Liquid Heat
Exchanger
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Cross Flow Heat Exchanger
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Finned-Both Fluids
Unmixed
Unfinned-One Fluid Mixed
the Other Unmixed
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Cross Flow
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Shell and Tube Heat Exchanger
Provides a comparatively large ratio of heat transfer
area to volume and weight
It provides this surface in a form which is relatively
easy to construct in wide range of sizes
It is mechanically rugged enough to withstand
normal shop fabrication stresses, field erection
stresses, and normal operating conditions
They can be reasonably cleaned, and those
components subject to failure-gaskets and tubes-
can be easily replaced
Good design method exists
Expertise and shop facilities for successful design
and construction are available throughout the world.
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Single Pass Heat Exchanger
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Shell and Tube with one shell
and One tube pass
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Basic Components of Shell and
Tube Heat Exchangers
Tubes
Tube Sheet
Shell and Shell Side Nozzles
Tube side nozzles
Channel Cover
Pass Divider
Baffles
Tie rods
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Baffles in Shells: to give high
enough shell-side velocities
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Baffles
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Baffles
Single-segmental baffles act as barriers, thus forcing the shell flow to take a
serpentine path through the shell. In this way that fluid (in this case a
condensing refrigerant) flows at nearly right angles to the tubes and the
resulting turbulence increases the shell-side heat transfer coefficient.
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Tube sheet
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Tube
Bundle
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Tube Pitch
Square pitch has advantage of easier cleaning
Triangular pitch allows more tubes in a given
shell diameter
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Tube Pass
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Range of Shell and Tube Heat
Exchangers
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One Shell Pass,
Two Tube Passes
Two Shell Passes,
Four Tube Passes
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U-Tube Heat Exchangers
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U-Tube Heat Exchangers
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Spiral Heat Exchanger
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Working of Spiral Heat Exchanger
A spiral heat exchanger is composed of two long flat plates, which are
wrapped around a center tube, to form two concentric spiral channels.
The hot flow enters the heat exchanger in the center, spirals outwards
through the long flat channel to leave the exchanger in tangential
direction. The cold fluid enters tangential, flowing through the long flat
channel to leave in axial direction. This way a counterflow is created,
which maximizes heat transfer.
good alternative for ordinary shell-and-tube heat exchangers when it
comes to fouling
the curved form of the channels will create turbulence at any point in
the flow, even with low velocities. The same curved form causes high
shear rates at the walls. These two effects can prevent particles from
clinging to the wall.
In spiral heat exchangers, there is only one channel, so when some
foulant does attach, the flow still has to go through. The velocity will
locally increase, as will the shear rate, thereby removing the foulant
again.



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Plate and Frame Heat Exchanger
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Plate and Frame Heat Exchanger
consists of plates instead of tubes to separate the hot
and cold fluids. The hot and cold fluids alternate
between each of the plates.
Baffles direct the flow of fluid between plates.
Because each of the plates has a very large surface
area, the plates provide each of the fluids with an
extremely large heat transfer area.
a plate type heat exchanger, as compared to a simi
larly sized tube and shell heat exchanger, is capable of
transferring much more heat. This is
due to the larger area the plates provide over tube.
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Plate and Frame heat Exchanger
Due to the high heat transfer efficiency of the plates, plate type
heat exchangers are usually very small when compared to a tube
and shell type heat exchanger with the same heat transfer
capacity.
Plate type
heat exchangers are not widely used because of the inability t
o reliably seal the large gaskets between each of the
plates. Because of this problem, plate type heat exchangers
have only been used in small, low pressure applications such
as on oil coolers for engines.
However, new improvements in gasket design and overall heat
exchanger design have allowed some large scale applications of
the plate type heat exchanger. As older facilities are upgraded or
newly designed facilities are built, large plate type heat exchangers
are replacing tube and shell heat exchangers and becoming more
common.
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LMTD Method
A Methodology for Heat Exchanger
Design Calculations
- The Log Mean Temperature Difference (LMTD) Method -
A form of Newtons Law of Cooling may be applied to heat exchangers by
using a log-mean value of the temperature difference between the two fluids:
1m
q U A T A =
( )
1 2
1
1 2
1n /
m
T T
T
T T
A A
A
A A

=
Evaluation of depends on the heat exchanger type.
1 2
and T T A A
Counter-Flow Heat Exchanger:
1 ,1 ,1
, ,
h c
h i c o
T T T
T T
A
=
2 ,2 ,2
, ,
h c
h o c i
T T T
T T
A
=
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LMTD Method (cont.)
Parallel-Flow Heat Exchanger:
1 ,1 ,1
, ,
h c
h i c i
T T T
T T
A
=
2 ,2 ,2
, ,
h c
h o c o
T T T
T T
A
=
Note that T
c,o
can not exceed T
h,o
for a PF HX, but can do so for a CF HX.
For equivalent values of UA and inlet temperatures,
1 , 1 , m CF m PF
T T A A >
Shell-and-Tube and Cross-Flow Heat Exchangers:
1 1 , m m CF
T F T A A =
Figures 11.10 - 11.13 F
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LMTD correction factor
Change e Temperatur Maximum
Fluid Tubeside of change Temp
t T
t t
P
_
1 1
1 2
=

=
side shell
side tube
C
C
t t
T T
R
_
_
1 2
2 1
=

=
P represents the thermal effectiveness of tube side fluid and varies from 0 to 1
R varies from 0 to . When R=0, it means that the fluid on shell side is
undergoing phase change, and when R= , the tube side fluid is undergoing a
phase change. When R=0 or infinity, the correction factor is 1.
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LMTD Correction Factor
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Typical values of heat transfer coefficients
Type Application and Conditions
U
W/(m
2
K)
U
Btu/(ft
2
F
h)
Tubular, heating
or cooling
Gases at atmospheric pressure inside and outside
tubes
5 - 35 1 - 6
Gases at high pressure inside and outside tubes 150 - 500 25 - 90

Liquid outside (inside) and gas at atmospheric
pressure inside (outside) tubes
15 - 70 3 - 15
Gas at high pressure inside and liquid outside tubes 200 - 400 35 - 70
Liquids inside and outside tubes 150 - 1200 25 - 200
Steam outside and liquid inside tubes 300 - 1200 50 - 200
Tubular,
condensation
Steam outside and cooling water inside tubes 1500 - 4000 250 - 700

Organic vapors or ammonia outside and cooling
water inside tubes
300 - 1200 50 - 200
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Tubular,
evaporation
steam outside and high-viscous liquid inside tubes,
natural circulation
300 - 900 50 - 150

steam outside and low-viscous liquid inside tubes,
natural circulation
600 - 1700 100 - 300

steam outside and liquid inside tubes, forced
circulation
900 - 3000 150 - 500
Air-cooled heat
exchangers
2)

Cooling of water 600 - 750 100 - 130
Cooling of liquid light hydrocarbons 400 - 550 70 - 95
Cooling of tar 30 - 60 5 - 10
Cooling of air or flue gas 60 - 180 10 - 30
Cooling of hydrocarbon gas 200 - 450 35 - 80
Condensation of low pressure steam 700 - 850 125 - 150
Condensation of organic vapors 350 - 500 65 - 90
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Plate heat exchanger liquid to liquid 1000 - 4000 150 - 700
Spiral heat exchanger liquid to liquid 700 - 2500 125 - 500
condensing vapor to liquid 900 - 3500 150 - 700
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According to Garrett-Price (1985) fouling is generally defined as
the forming of deposits on heat transfer surfaces, which interferes
with heat transfer and/or fluid flow. In other words, by using a
heat exchanger small layers of insulating material will be formed
on the heat transferring surfaces of that heat exchanger. The
influence of this layer is two-sided:
1) The layer has a high thermal resistance, higher then any other
part of the heat exchanger, thereby increasing the total thermal
resistance. This will decrease the amount of heat transferred
through the surfaces and reduces the efficiency of the heat
exchanger.
2) The presence of a layer will decrease cross-sectional flow area of
the medium. To achieve the same throughput through this smaller
area, theres a bigger pressure drop needed. Additional pumping
is needed, increasing to total amount of energy added to the
system, decreasing the efficiency.
So fouling is a absolutely not-wanted phenomenon.
What exactly is fouling?
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Fouling in Heat Exchangers
Types of Fouling
Precipitation fouling
Particulate fouling
Chemical reaction fouling
Corrosion fouling
Solidification fouling
Biological fouling
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Precipitation fouling
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Corrosion fouling
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Biological fouling
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Economic Considerations in Heat
Exchanger Selection
Temperatures of heating and cooling media: A
higher heating media temperature results in a smaller
heat exchanger for a given heating load. Limitations of
materials must be kept in mind here.
Pressure drops permitted by the system affect heat
exchanger size The highest allowable pressure drop
will result in substantial savings in heat exchanger size.
Length restriction sometimes affect heat exchanger
costs However, there are so many exceptions and
limiting conditions that we cannot simply say the longer
the cheaper.
Materials of construction: Corrosive tendencies and
purity requirements of fluids being handled. Often, the
choice here is based on reliable data and experience

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Heat Exchanger Design
Calculation of Heat Duty
Calculation of Mean Temperature Difference
Configuration Correction Factors for LMTD
Assume a Overall Heat Transfer Coefficient and
calculate area A.
Assume a specific number of tube and shell passes and
define the size of tube 1 or outside diameter. Select
a tube pitch and baffle spacing.
Find out the number of tubes by
A = ntdL


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Rules of Thumb for Heat
Exchangers

Take countercurrent shell-and-tube heat exchanger as a
basis.
Standard tubes are OD, triangular spacing, 16ft long.
A 1 ft OD shell accommodates 100 ft2, 2 ft OD-400 ft2, 3
ft OD-1100 ft2.
Pressure drops are 1.5 psi for boiling services and 3-9
psi for other services.
Minimum temperature approach is 20 F with normal
coolants, 5-10 F with refrigerants.
Water inlet temperature is 90 F, maximum outlet 120 F.


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Calculate the tube side flow rate based
upon the assumed number of tubes/pass
and the heat balance. The velocity should
be between 3-8 ft/s
Compute tube side coefficient (hi) using
Dittus Boelter correlation





n
k
Cp Dv
k
hiD
|
.
|

\
|
|
.
|

\
|
=

8 . 0
023 . 0
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Determine the shell side coefficient for an
assumed baffle spacing by using equation

14 . 0
3 / 1
55 . 0
36 . 0
|
|
.
|

\
|
|
.
|

\
|
|
|
.
|

\
|
=
w
s e o
k
Cp DG
k
D h

Where Gs is mass velocity based on the minimum area

Bs
pt
do pt
D A
s
) (
min

=
Ds= shell diameter
pt = tube pitch
Do= outside diameter
Bs = Baffle spacing
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Determine the tube side and shell side fouling factors. If
nothing is given assume a value of 1000 BTU/ hr ft
2

o
F.
(1 Btu/(ft2 F h) = 5.6785 W/(m2 K))
Calculate Uo and Ui
Check with assumed value
Estimate area by using equation
q= UATlm
If this area is 10-20% excess than the assumed one than
assumed one is acceptable otherwise go to step 5
(no. of tube passes)
Calculate number of tubes / pass by using
A = ntdo L
If not satisfactory go to step 5 and recalculate by
changing baffle spacing etc.
Calculate shell and tube side pressure pressure drop. If
pressure drop is too high reassume the unit in step 5.
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Allocation of Streams
more corrosive fluid goes tube-side because it is
cheaper to construct tubes from alloys rather than
the shell and tubesheet
higher pressure stream goes tube-side because
small diameter tubes handle stress better
more severely fouling fluid goes tube-side because it
is easier to clean tube-side
fluid with lower film coefficient goes shell-side
because it allows use of finned tubing to increase
A
o
h
o
fluid with low P
max
goes shell side
viscous fluid goes shell-side

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Tube Size and Pitch

The standard length of tubes in a shell-and - tube
exchanger are 8, 12, 16, and 20 ft.
Tube IDs range from 5/8 to 1 1/2 exchangers with
small-diameter tubes are less expensive than those
with large diameter tubes. However smaller tubes
are more difficult to clean
Tubes are usually laid out in a square or a triangular
pattern (1.25 O.D for triangular pitch and min. for
square pitch)
Finned tubes are preffered in condensers and while
handling gases (5/8- O.D are preffered)

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Baffles

Baffling the shell-side increases the pressure
drop and pumping costs
These disadvantages are usually more than
offset by increases fluid mixing and improved
heat transfer coefficients
Baffle spacing typically lies between 1/5 of the
shell diameter and 1 shell diameter
Baffles are provided with 20-50% cut (25%
common)

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Tie rods
For
6 15 shell 4 rods diameter
16 27 shell 6 rods 3/8 diameter
28 33 shell 6 rods diameter
34 48 shell 8 rods of diameter
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Pressure Drops

There are recommendations based on
velocity in case of liquids and operating
pressure in case of gases
With liquids of 1Cp = 5 lb/in
2
1 - 10Cp = 7 lb/in
2
> 10 Cp = 10 lb/in
2


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Applications of Heat Exchanger
Oil Coolers
Fuel Oil Pre-Heaters
Aftercoolers
Steam Converters
Condensers
Thermo-Syphon Reboilers
Falling Film Evaporators

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Single Pass Condenser
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Multi Pass Condenser
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Evaporation
Evaporation is the process of removal of volatile
solvent by vaporization, from an aqueous solution
consisting of non-volatile solute. In majority of the
cases of evaporation, the solvent is water.

Evaporation plays a major role in the manufacture of
a variety of products in chemical process industries,
including food processing, pulp & paper,
pharmaceuticals, fertilisers etc.

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Evaporation
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Classification of Evaporators
Evaporator types may be classified as
follows:
1. Short-tube evaporators (Natural Circulation)
2. Long-tube vertical evaporators
- Forced-circulation
- Upward-flow (climbing-film)
- Downward-flow (falling-film)
3. Agitated-film evaporators

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Natural Convection Horizontal
Short Tube Evaporator
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Forced Circulation Evaporators
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Falling Film Evaporators
A: Product 1: Head
B: Vapor 2: Calandria
C: Concentrate
3: Calandria,
Lower part
D: Heating Steam
4: Mixing
Channel
E: Condensate
5: Vapor
Separator
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Falling Film Evaporators

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Climbing Film
Evaporator
A : Product
B : Vapor
C: Concentrate
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Climbing Film Evaporator
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Evaporator Calandria
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Forced Circulation
Evaporators
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Forced Circulation
Evaporators
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Forced Circulation Evaporators
A Product
B Vapour
C Concentrate
D Heating steam
E Condensate