Step 1: Assume tube diameter, tube length and BWG.

Tube length
L  3 mm
Tube diameter
d o  19 mm
d i  16 mm
BWG Number
BWG  14

Step 2: Assume fouling factor based on inside and outside tubes.

1 1 m2 K
  0.0002
hd o 5000 W
1 1 m2 K
  0.00025
hd i 4000 W
Step 3: Assume material of construction for the tubes and determine its thermal conductivity
Material of construction: Carbon steel
W
k w  60
m2 K
Step 4: Assume three known temperature and use the heat duty equation to solve for the fourth
temperature
Tci  17C Tco  40C
Thi  67C Tho  ?
Using the heat duty equation,
Q  mCpT
Qh  Qc
Qc  mc Cpc Tco  Tci 
 kg 1hr  J 
Qc   40000 x  4179 313K  290 K 
 hr 3600 s  kgK 
Qc  1067966.667 W
 1067966.67  mh Cph (Thi  Tho )
 kg 1hr  J 
1067966.67   60000 x  4184 67  Tho 
 hr 3600s  kgK 
Tho  51.68C
Step 5: Based on the type of flow, calculate the Log Mean Temperature Difference, LMTD
For counter current flow, LMTD
Thi  Tco   Tho  Tci 
LMTD 
 Th  Tco 
ln  i 
 Tho  Tci 
LMTD 
67  40  51.68  17 
 67  40 
ln  
 51.68  17 
LMTD  30.68C
Step6: Based on the exchanger configuration, obtain the Temperature correction factor
For a 1-2 shell pass exchanger
 1  S  
R 2

 1 ln  
 1  RS  
 
Ft 
2  S R 1
R  1 ln 
R 2
1 
 2  S R  1  

R 2
 1 
 1  0.46  
0.67 2

 1 ln  
 1  0.460.67  
Ft 
0.67  1 ln 

 2  0.46 0.67  1  0.67 2

1 
 2  0.460.67  1  

0.67 2
 1 
Ft  0.93

Step 7: Calculate the mean temperature difference

DTm  Ft xLMTD
DTm  0.93x30.68
DTm  28.65C
Step 8: Assume overall heat transfer coefficient as initial guess from the range of overall heat
transfer coefficient from Table 12. 1 (Typical overall heat transfer coefficient)
For water-water working fluids
 W
U  800  1200
m 2 C
Assume
W
U  1100
m 2 C
Step 9: Calculate the provisional area
q
A
Tlmf
J
1067966.667
A s
1100
W
28.65C 
m 2 C
A  33.89 m 2
Step 10: Based on the assumed diameter and tube length, calculate the number of tubes
A
Nt 
d o L
34 m 2
Nt 
1m
  19 mm  3 m
1000 mm
N t  189.24
N t  190 tubes

Step 11: Calculate the tube pitch and bundle diameter

Pt  1.25d o
Pt  1.2519 mm
Pt  23.75 mm
1
N  n1
Db  Do  t  : Bundle diameter
k 
 1 
For 2 tube per pass, square pitch
k1  0.156
n1  2.291
 1
 190  2.291
Db  19 mm 
 0.156 
Db  422.28 mm
Step 12: Assume the type of floating head of the exchanger and obtain the bundle diameter
clearance, BDC.
Type of floating head
Assume split-ring floating head exchanger
Since
Db  0.422 m
BDC  56 mm
Step 13: Calculate the shell diameter
Ds  Db  BDC
Ds  422.28 mm  56 mm
Ds  478.28 mm
Step 14: Calculate the baffle spacing
Bs  0.6 Ds
Bs  0.6478.28
Bs  286.968 mm
Step 15: Calculate for the area for cross-flow
Pt  Po 
As  Ds Bs
Pt

As 
23.75  19 478.28286.968
23.75
As  27450.21101 mm 2
As  0.02745 m 2
Step 16: Calculate the shell-side mass velocity
Shell side mass velocity
 shell side flow rate
Gs 
As
kg 1 hr
60000
x
hr 3600 s
Gs 
0.02745 m 2
kg
Gs  607.16 2
m s
Shell side velocity
Gs
s 

kg
607.16
s  m2s
kg
998.53 3
m
m
 s  0.61
s
Step 17: Calculate the shell equivalent diameter

de 
1.27 2
do

Pt  0.785d o
2

de 
1.27
19

23.75 2  0.78519
2

d e  18.76 mm
Step 18: Calculate the shell side Reynold’s number
Gs d e
Re 


0.01876 m  607.16 kg 


Re   m2s 
kg
4.67  10  4
ms
Re  24391.80792
Step 19: Calculate the Prandtle number
 Cp
Pr 
k
kg  J 
4.67  10  4  4184 
ms  kgK 
Pr 
w
0.652 2
m K
Pr  3
Step 20: Obtain the shell-side heat transfer coefficient

k
1

ho   j h Re Pr 3 

de 
 
3
j h  4.0  10
w
0.652
ho  m 2 K  4  10 3 24391.80792 313 
 
18.76  10 3 m  
w
ho  4890.306 2 0
m C

Step 21: Calculate the pressure drop in the shell

  s 2   
0.14
D  L
Ps  8 j f  s   
  w 
 De  Lb  2 
j f  4.4  10  2
 kg  m 
2

 983.53  0.61  
 478.28 mm  3000 mm   

Ps  8 4.4  10  2    
m 3  s 
 18.76 mm  287 mm   2 
 
 
Ps  17.58 KPa
Step 22: Calculate the number of tubes per pass
N t 190
NTTP  
2 2
NTTP  95 tubes
Step 23: Calculate the tube-side mass velocity
 tube side flow rate
GM 
di 2
NTTP 
4
kg 1 hr
40000 x
GM  hr 3600s
2
 16 
 
95    1000 
4
kg
GM  581.71 2
sm
Step 24: Calculate the tube-side velocity
kg
581.71
GM sm 2
Vt  
 kg
998.6 3
m
m
Vt  0.583574
s
Step 25: Calculate the Reynold’s number and Prandtle number for fluids inside tubes
dVt
Re 

 kg  16 mm  m
 998.6 3   0.58374 
Re  
m  1000  s
kg
8.26 x10  4
ms
Re  11268.38
Cp
Pr 
k
kg  J 
8.26 x10  4  4179 
ms  kgK 
Pr 
w
0.61 2
m K
Pr  5.65
Step 26: Calculate the heat transfer coefficient hi using either the equation for Laminar or
Turbulent flow
 kf 1
 d  0.7
hi  0.023 Re Pr 3 1  i 
 di  L
0.7
 0 / 61
   0.016 
4  10 3 11267.925.65 3 1 
1
hi  0.023 
 0.016  3 
W
hi  17562.02 2 0
m C
Step 27: Calculate the overall heat transfer factor
1
Uo 
d 
d o ln  o 
1

1
  di   do 
do
ho . hd o 2kw d i d i ho  d i hd i 
1
Uo 
 19 
0.019 ln  
1

1
  16   19 
19
4890.306 5000 260 164000 1617562.02
W
U o  1117.14 2
m C
Step 28: Compare the calculated overall heat transfer coefficient obtained from the previous step
with that assumed. If it is close to what is assumed, then the assumption is valid. Otherwise, use
the calculated value in the previous step in step 8 and do the loop until the difference between the
calculated U between two consecutive iteration is small.
1117.14  1100
% error   100%
1100 (Satisfactory)
% error  1.5%
Step 28: Calculate the tube-side pressure drop
   8 j f L       i v 2
m

P  1.5  N t 2.5     
  di   w    2
  
m
  
   0

 w
  



P  1.5  952.5 
 2


8 4.4 x10 3000   998.60.58
2

  16   2
  
  1000 
P  22.13kPa
Design Specifications
Parameters Calculated Value
Tube length L3m
Tube diameter d o  19 mm
d i  16 mm

BWG number BWG  14

Thermal conductivity(carbon steel) W
k w  60
m2 K
Triangular pitch Pt  23.75 mm

Number of tubes N  190 tubes

Heat transfer area A  33.89 m2

Bundle diameter Db  422.28 mm

Shell inside diameter Ds  478.28 mm

Tube-side coefficient W
hdi  4000
m2 K
Shell-side coefficient W
hd o  5000
m2 K
Overall coefficient estimated W
U c  1117.14
m2 K
Overall coefficient required W
U  1100
m2 K
Fouling factors: 1 1 m2 K
  0.0002
Shell-side hd o 5000 W
Tube-side 1 1 m2 K
  0.00025
hd i 4000 W
Pressure Drops:
Required P  34.46 Kpa
Calculated Pc  22.13Kpa

Baffle Spacing Bs  286.968 mm,25% cut

Number of Baffles N b  12