1. Heat Exchangers
Tubular Exchangers
Convection
Q = U A DT
Usually the governing mechanism in most process applications
Q U A Th Tc
ro
ln ro / ri
ri
1 1 1
ro U ro h o k ri h i
Q = U A Tm
DTlm
Th Tc
T
ln h
Tc
A useful shortcut to know:
DTh/DTc 1.0 1.5 2.0 3.0 4.0
DTlm / DTc 1.0 1.2 1.4 1.8 2.2
DTgeom mean = (DTc x DTh)
DTgeom mean /DTc 1.0 1.22 1.41 1.73 2.0
Q = U A F Tlm
F is sometimes called Ft
hot out
hot in
cold out cold in
Tubular Exchangers
Into this -
Baffle assembly
Inserting
Welding the shell tubes
Final
product
Tubesheet
Source: Bos-Hatten Inc.: www.Bos-Hatten.com
2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy
Chemical Engineering Design
Tube Bundles
U-tubes
Tubesheet
Baffles
Source: UOP
A B B Type
Must break piping connections to open
exchanger
Single tube side joint
C N C Type
Channel to tubesheet joint eliminated
Bundle integral with front head
N Type
D Fixed tubesheet with removable cover
plate
D Type
Special closures for high pressure
applications
F F Type
Counter current flow obtained. Baffle leakage problems.
G
G Type
Lower pressure drop
H Type
H Horizontal thermosyphon reboilers
J Type
J Older reboiler designs
K Type
K Phase separation integral to exchanger
X Type
X Lowest pressure drop, low F factor
M Type
L M Same as B type front head
N Type
P Same as N type front head
N
P & W Types
Rarely used
S T
S Type
Floating head with backing ring
U W
T Type
Floating head pulls through shell
U Type
Removable bundle without floating head
t1 R = (T1 - T2)
T2 (t2 t1)
Most simulators
show an error if
there is a low F
factor
For example, in
UniSim Design
the exchanger
shows up
yellow
(c) E102
30 60 90 45
Sometimes use larger pitch for easier cleaning (but bigger shell,
lower shellside h.t.c.)
FEATURE USE PATTERN:
lower DP on shellside square (effective only at low Re number)
shellside fouling square - easier cleaning
horizontal shellside square - prevent vapor blanketing
boiling
decrease shell size fit 15% more tubes if triangular pitch used
2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy
Chemical Engineering Design
Baffle Types & Shell Flow Patterns
max unsupported
tube span
FULL
TUBEFIELD
max unsupported
tube span
FULL
TUBEFIELD
max unsupported
tube span
Tubular Exchangers
Vapors
Air, 10 psig 10 10
Hydrogen, 50 psig 100 100
Hydrogen, 500 psig 400 400
Hydrocarbon vapor, 50 psig 60 60
Noncondensible gas, 2 psig 5 5
Note: Coefficients are based on 3/4 inch diameter tubes. For Tube side flows, correct by
multiplying by 0.75/Actual OD. Estimated accuracy is 25%. For 50% hydrogen in
vapor, reduce h to 2/3 of pure H2 value.
2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy
Chemical Engineering Design
Approximate Fouling Factors
Fluid f (Btu/(hr.ft2.F))
Tubular Exchangers
U
tubes
Plates
Gasket
Source: Alfa-Laval, www.AlfaLaval.com
2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy
Chemical Engineering Design
Gasket Layout of Alternating Plates
Disadvantages
Lots of gaskets
Lower design pressure, temperature
External leakage if gaskets fail
Applications
Food processing, brewing, biochemicals, etc.
Source: Alfa-Laval,
Alfa-Laval www.AlfaLaval.com
2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy
Chemical Engineering Design
Welded Plate Heat Exchangers
Feed Outlet
Effluent Inlet
Vent
Advantages
Higher thermal efficiency
Hot End Bellows
Single unit can replace multiple shell &
Source: Alfa-Laval Packinox
Manhole
Feed Header
Effluent Header tube units
Bundle Support
Closer approach to hot inlet temperature
Pressure Vessel
Low pressure drop
Welded
Plate Bundle Little chance of vibration problems
Excellent distribution of two phase flows
Disadvantages
Single alloy material for plates
Bracket
(or Skirt)
Difficult to clean
Few manufacturers at large scale (Alfa
Effluent Header Laval Packinox)
Venturi
Spray Bar
Liquid Feed Used in large scale clean services that
Cold End Bellows
Recycled Gas Inlet need close temperature approach
Effluent Outlet
2012 G.P. Towler / UOP. For educational use in conjunction with
Towler & Sinnott Chemical Engineering Design only. Do not copy
Chemical Engineering Design
Questions ?