1

HEAT TRANSFER, HEAT

EXCHANGERS,
CONDENSORS AND
REBOILERS, AIR
COOLERS
Reyad Awwad Shawabkeh
Associate Professor of Chemical Engineering
King Fahd University of Petroleum & Minerals
Dhahran, 31261
Kingdom of Saudi Arabia
 Contents 2
HEAT TRANSFER LAW APPLIED TO HEAT EXCHANGERS 2
HEAT TRANSFER BY CONDUCTION 3
The Heat Conduction Equation 9
HEAT TRANSFER BY CONVECTION 12
Forced Convection 12
Natural Convection 14
HEAT TRANSFER BY RADIATION 15
OVERALL HEAT TRANSFER COEFFICIENT 18
PROBLEMS 22
DESIGN STANDARDS FOR TUBULAR HEAT EXCHANGERS 23
SIZE NUMBERING AND NAMING 23
SIZING AND DIMENSION 27
TUBE-SIDE DESIGN 32
SHELL-SIDE DESIGN 33
Baffle type and spacing 33
GENERAL DESIGN CONSIDERATION 35
THERMAL AND HYDRAULIC HEAT EXCHANGER DESIGN 37
DESIGN OF SINGLE PHASE HEAT EXCHANGER 37
Kerns Method 45
Bells method 49
Pressure drop inside the shell and tube heat exchanger 57
DESIGN OF CONDENSERS 65
DESIGN OF REBOILER AND VAPORIZERS 72
DESIGN OF AIR COOLERS9 85
MECHANICAL DESIGN FOR HEAT EXCHANGERS10 88
DESIGN LOADINGS 88
TUBE-SHEET DESIGN AS PER TEMA STANDARDS 90
DESIGN OF CYLINDRICAL SHELL, END CLOSURES AND FORCED HEAD 91
REFERENCES 95
HEAT TRANSFER LAW APPLIED TO 3

HEAT EXCHANGERS
Heat Transfer by Conduction 4

W/m2 W/m.K
Thermal Conductivity of solids 5
Thermal Conductivity of liquids 6
Thermal conductivity of gases 7
Example 8

Calculate the heat flux within a copper rod that

heated in one of its ends to a temperature of 100 oC
while the other end is kept at 25 oC. The rode length
is 10 m and diameter is 1 cm.
 Example 9

An industrial freezer is designed to operate with an internal air

temperature of -20 oC when external air temperature is 25 oC. The walls
of the freezer are composite construction, comprising of an inner layer of
plastic with thickness of 3 mm and has a thermal conductivity of 1 W/m.K.
The outer layer of the freezer is stainless steel with 1 mm thickness and
has a thermal conductivity of 16 W/m.K. An insulation layer is placed
between the inner and outer layer with a thermal conductivity of 15
W/m.K. what will be the thickness of this insulation material that allows a
heat transfer of 15 W/m2 to pass through the three layers, assuming the
area normal to heat flow is 1 m2?
 The Heat Conduction Equation 10

Rate of heat Rate of heat Rate of heat Rate of energy

conduction generation conduction
+ = + storage inside
into control inside control out of control control volume
volume volume
volume
 11
The Heat Conduction Equation
Heat Transfer by Convection 12
 13
Reynolds and Prandtl Numbers

Re < 2100 Laminar flow

Re > 2100 Turbulent flow

Values of Prandtl number for different liquids and gases

 Flow through a single smooth cylinder 14

This correlation is valid over the ranges 10 < Rel < 107 and 0.6 < Pr < 1000 where
 Flow over a Flat Plate 15

Re < 5000 Laminar flow

Re > 5000 Turbulent flow

Natural Convection 16
 Heat Transfer by Radiation 17

q = (Th4 - Tc4) Ac

Th = hot body absolute temperature (K)

Tc = cold surroundings absolute temperature (K)
Ac = area of the object (m2)

= 5.6703 10-8 (W/m2K4)

The Stefan-Boltzmann Constant
Emissivity coefficient for several selected material 18
Emissivity Coefficient
Surface Material
--
Aluminum Commercial sheet 0.09
Aluminum Foil 0.04
Aluminum Commercial Sheet 0.09
Brass Dull Plate 0.22
Brass Rolled Plate Natural Surface 0.06
Cadmium 0.02
Carbon, not oxidized 0.81
Carbon filament 0.77
Concrete, rough 0.94
Granite 0.45
Iron polished 0.14 - 0.38
Porcelain glazed 0.93
Quartz glass 0.93
Water 0.95 - 0.963
Zink Tarnished 0.25
Overall heat transfer coefficient 19

For a wall

For cylindrical
geometry
Typical value for overall heat transfer coefficient 20

Shell and Tube

Hot Fluid Cold Fluid U [W/m2C]
Heat Exchangers

Heat Exchangers Water Water 800 - 1500

Organic solvents Organic Solvents 100 - 300
Light oils Light oils 100 - 400
Heavy oils Heavy oils 50 - 300
Reduced crude Flashed crude 35 - 150
Regenerated DEA Foul DEA 450 - 650
Gases (p = atm) Gases (p = atm) 5 - 35
Gases (p = 200 bar) Gases (p = 200 bar) 100 - 300
Coolers Organic solvents Water 250 - 750
Light oils Water 350 - 700
Heavy oils Water 60 - 300
Reduced crude Water 75 - 200
Gases (p = 200 bar) Water 150 - 400
Organic solvents Brine 150 - 500
Water Brine 600 - 1200
Gases Brine 15 - 250
Heat Exchangers Hot Fluid Cold Fluid U [W/m2C]
21
Heaters Steam Water 1500 - 4000
Steam Organic solvents 500 - 1000
Steam Light oils 300 - 900
Steam Heavy oils 60 - 450
Steam Gases 30 - 300
Heat Transfer (hot) Oil Heavy oils 50 - 300
Flue gases Steam 30 - 100
Flue gases Hydrocarbon vapors 30 -100
Condensers Aqueous vapors Water 1000 - 1500
Organic vapors Water 700 - 1000
Refinery hydrocarbons Water 400 - 550
Vapors with some non
Water 500 - 700
condensable
Vacuum condensers Water 200 - 500

Vaporizers Steam Aqueous solutions 1000 - 1500

Steam Light organics 900 - 1200
Steam Heavy organics 600 - 900
Heat Transfer (hot) oil Refinery hydrocarbons 250 - 550
 DESIGN STANDARDS FOR 22

TUBULAR HEAT EXCHANGERS

Size of heat exchanger is represented by the shell inside

diameter or bundle diameter and the tube length

Type and naming of the heat exchanger is designed by

three letters single pass shell

The first one describes the stationary head type

The second one refers to the shell type
The third letter shows the rear head type
TYPE AES refers to Split-ring floating head exchanger with removable
channel and cover.
Heat exchanger nomenclatures 23
The standard nomenclature for shell and tube heat exchanger
24
1. Stationary Head-Channel 20. Slip-on Backing Flange 30. Longitudinal Baffle
2. Stationary Head-Bonnet 21. Floating Head Cover-External 31. Pass Partition
3. Stationary Head Flange-Channel or 22. Floating Tube sheet Skirt 32. Vent Connection
Bonnet 23. Packing Box 33. Drain Connection
4. Channel Cover 24. Packing 34. Instrument Connection
5. Stationary Head Nozzle 25. Packing Gland 35. Support Saddle
6. Stationary Tube sheet 26. Lantern Ring 36. Lifting Lug
7. Tubes 27. Tie-rods and Spacers 37. Support Bracket
8. Shell 28. Support Plates 38. Weir
9. Shell Cover 29. Impingement Plate 39. Liquid Level Connection
10. Shell Flange-Stationary Head End 40. Floating Head Support
11. Shell Flange-Rear Head End
12. Shell Node
13. Shell Cover Flange
14. Expansion Joint
15. Floating Tube sheet
16. Floating Head Cover
17. Floating Head Cover Flange
18. Floating Head Backing Device
19. Split Shear Ring
 25

Removable cover, one pass, and floating head heat exchanger

Removable cover, one pass, and outside packed floating head heat exchanger
 26

Channel integral removable cover, one pass, and outside packed

floating head heat exchanger
 27

Removable kettle type reboiler with pull through floating head

Tube sizing: Birmingham Wire Gage 28
(B.W.G.) (B.W.G.) (B.W.G.) (B.W.G.)
Gauge (inches) (mm) Gauge (inches) (mm)
00000 (5/0) 0.500 12.7 23 0.025 0.6
0000 (4/0) 0.454 11.5 24 0.022 0.6
000 (3/0) 0.425 10.8 25 0.020 0.5
00 (2/0) 0.380 9.7 26 0.018 0.5
0 0.340 8.6 27 0.016 0.4
1 0.300 7.6 28 0.014 0.4
2 0.284 7.2 29 0.013 0.3
3 0.259 6.6 30 0.012 0.3
4 0.238 6.0 31 0.010 0.3
5 0.220 5.6 32 0.009 0.2
6 0.203 5.2 33 0.008 0.2
7 0.180 4.6 34 0.007 0.2
8 0.165 4.2 35 0.005 0.1
9 0.148 3.8 36 0.004 0.1
10 0.134 3.4 25 0.020 0.5
11 0.120 3.0 26 0.018 0.5
12 0.109 2.8 27 0.016 0.4
13 0.095 2.4 28 0.014 0.4
14 0.083 2.1 29 0.013 0.3
15 0.072 1.8 30 0.012 0.3
16 0.065 1.7 31 0.010 0.3
17 0.058 1.5 32 0.009 0.2
18 0.049 1.2 33 0.008 0.2
19 0.042 1.1 34 0.007 0.2
20 0.035 0.9 35 0.005 0.1
21 0.032 0.8 36 0.004 0.1
22 0.028 0.7
Tube sizing: Birmingham Wire Gage 29
Tube-side design 30

Arrangement of tubes inside the heat exchanger

 Shell-side design 31

(a) one-pass shell for E-type, types of shell passes

(b) split flow of G-type,
(c) divided flow of J-type,
(d) two-pass shell with longitudinal baffle of F-type
(e) double split flow of H-type.
Shell-side design 32

Shell thickness for different diameters and material of constructions

Baffle type and spacing 33
General design consideration 34

Factor Tube-side Shell-side

Corrosion More corrosive fluid Less corrosive fluids

Fouling Fluids with high fouling Low fouling and scaling

and scaling

Fluid temperature High temperature Low temperature

Operating pressure Fluids with low pressure Fluids with high pressure
drop drop

Viscosity Less viscous fluid More viscous fluid

Stream flow rate High flow rate Low flow rate

THERMAL AND HYDRAULIC 35

HEAT EXCHANGER DESIGN

Design of Single phase heat exchanger

Design of Condensers

Design of Reboiler and Vaporizers

Design of Air Coolers

Design of Single phase heat 36

exchanger
Typical values for fouling factor coefficients 37
 38
Temperature profile for different types of
heat exchangers
 39

For counter current

For co-current
 40

one shell pass; two or more even tube 'passes

 41

two shell passes; four or multiples of four tube passes

divided-flow shell; two or more even-tube passes

 42

split flow shell, 2 tube pass

cross flow heat exchanger

Shell-side heat transfer coefficient 43
44
Shell diameter 45
46
 47

Bundle diameter clearance

Tube-side heat transfer coefficient 48
 49

Tube-side heat transfer factor

Shell and Tube design procedure 50

Kerns Method

This method was based on experimental work on commercial exchangers

with standard tolerances and will give a reasonably satisfactory prediction
of the heat-transfer coefficient for standard designs.

Bells method

This method is designed to predict the local heat transfer coefficient and
pressure drop by incorporating the effect of leak and by-passing inside the
shell and also can be used to investigate the effect of constructional
tolerance and the use of seal strip
Kerns Method 51
Bells method 52
53
54
55
 56

Figure 34 Baffle cut geometry

57
58
Pressure drop inside the shell 59
Pressure drop inside the tubes 60
Design of Condensers 61

For reactor off-gas quenching

Vacuum condenser
De-superheating
Humidification
Cooling towers

Direct contact cooler

 Condensation outside horizontal tubes 62

For Laminar flow

For turbulent flow,

Condensation inside horizontal tubes 63

stratified flow

annular flow
 Design of Reboiler and Vaporizers 64

Suitable to carry viscous and heavy fluids.

Pumping cost is high

Forced-circulation reboiler

The most economical type where there is no need for

pumping of the fluid
It is not suitable for viscous fluid or high vacuum
operation
Need to have a hydrostatic head of the fluid
Thermosyphon reboiler

It has the lower heat transfer coefficient than the other

types for not having liquid circulation
Used for fouling materials and vacuum operation with a
rate of vaporization up to 80% of the feed

Kettle reboiler
Boiling heat transfer and pool boiling 65

Nucleate pool boiling

Critical heat flux

Film boiling
 66
Nucleate
boiling heat
transfer
coefficient
 67
Critical flux
heat transfer
coefficient

Film boiling
heat transfer
coefficient
 Convection boiling 68

Effective heat transfer coefficient encounter the

effect of both convective and nucleate boiling
69
70
Design of air cooler 71
72
Mechanical Design for HE 73

A typical sequence of mechanical design procedures is summarized

by the flowing steps

Identify applied loadings.

Determine applicable codes and standards.
Select materials of construction (except for tube material, which
is selected during the thermal design stage).
Compute pressure part thickness and reinforcements.
Select appropriate welding details.
Establish that no thermohydraulic conditions are violated.
Design nonpressure parts.
Design supports.
Select appropriate inspection procedure
Design loading 74
75
76
77