1 Design of Heat Exchangers

1.1 E-101

Step (1): Taking physical properties from Aspen HYSYS for the shell side and the tube side:

Table 1: Physical Properties for E-101.

Physical Properties at the Average Temperature of the Fluid Tube Side Shell Side
𝐶𝑝 (𝑘J/𝑘𝑔) 3.731992 3.70
𝜇 (𝑁/𝑚2) 0.000852 9.59E-04
𝑘𝑓 (𝑊/𝑚 𝑘) 0.388423 3.92E-01
𝜌 (𝑘𝑔/𝑚3) 998.613017 1006.17

Step (2): Specifications of the heat exchanger:

1) Hot fluid in the shell side, cold fluid in the tube side.
2) One shell pass and two tube passes.
3) Selecting a floating-head exchanger to clean the surface of the tubes.
4) Square pitch is used to have cleaning paths through the bundle of tubes.
5) Counter-current flow.

Figure 1: Pattern of tubes

Step (3): Defining the mass flowrate of both sides:
* The value is taken from Aspen HYSYS, if it is not there, it can be calculated by the energy
balance.

m tube =106.9 kg / s
Q=16877415.2 W

For the shell side:

Q=mshell C p ∆ T

16877.415=m shell (3.7)(124.8−65.8)

mshell =74.76 kg /s

Step (4): Calculate LMTD:

( T shell ,o−T tube ,i ) −( T shell , i−T tube, o )
LMTD=
T shell , o−T tube, i
ln ⁡( )
T shell ,i −T tube , o
( 65.8−56.08 )−( 124.8−100 )
LMTD=
65.8−56.08 = 16.1 ℃
ln ⁡( )
124.8−100

To correct LMTD, R and S should be calculated:

T shell ,i−T shell ,o 124.8−65.8

R= = =1.34303
T tube ,o−T tube ,i 100−56.08
T tube ,o−T tube ,i 100−56.08
S= = =0.639
T shell ,i−T tube ,i 124.8−56.08
Figure 2: LMTD correction factor for two or more even tube passes

Using the above figure, Ft = 1.

∆ T m=F t ∆ T LMTD =(1)(16.1¿=16.1℃

Step (5): Assume a value for overall coefficient, Uo,assumed .

The assumption is based on the following table:

Table 2: Range of the overall coefficient U based on the fluids.

It is assumed 200 W/m2 ºC at the beginning, then after some iterations, it is found to be
152.445652 W/m2 ºC which is in the range in the table 100-300 W/m2 ºC.
Step (6): Calculate the number of tubes, and the shell diameter.

Q
* Surface area for all tubes = A = = 6882.164403 m2.
U ∆ Tm

Assuming the outer diameter (do) is 20 mm, the inner diameter (di) is 16 mm, and the length (L)
of the tube is 4.88 m.

* Surface area for one tube = Atube = π d o L = 0.303 m

Surface area for all tubes

* Number of tubes = Nt = =¿22713 tubes
Surface area for one tube

N t 1 /n 1

* Bundle diameter = Db = d o ( )
K1

Where Nt is the number of tubes, Db is the bundle diameter in mm, and do is the outside diameter
of tube in mm.

Table 3: Constants for Db relation for different types of pitch and passes.

Db = 3.586740 m
Pitch Length = pt = 0.025 m

To find the bundle diameter clearance (BDC), the following figure is used:
 Figure 3: Shell Bundle Diameter Clearance.

For Db = 3.586740 m and Pull-through floating head:

BDC = 0.116 m

* Shell Diameter = Ds = Db + BDC = 3.702434

Assuming a baffle spacing (Bs) is 0.6 m.

( pt −d o ) D s Bs
Shell side cross flow area = As = =0.44 m 2
pt

Step (7): Estimate the heat transfer coefficient for the tube side and the shell side.
Tube Side Calculations:

π 2
Tube cross sectional area = a = d =0.000201 m2
4 i
22713
Number of tubes per pass = =¿11357
2
Total flow area = 11357 × 0.000201 = 2.28 m2
flowrate of the tube side 106.9
Mass velocity = Gt = = =46.82 kg /m 2s
total flow area 2.28
Gt
Linear velocity = ut = =0.047 m/s
ρ
ρu t d i
Reynold number for tube side = Ret = =879.6
μ

Figure 4: Friction factor for the tube side.

jf = 0.009
* The pressure drop should be less than 7 psi, otherwise the diameter and the length of the tubes
should be changed.

μ
By assuming = 1,
μw
∆ Pt =53.68 Pa=0.007786 psi
The pressure drop is less than 7 psi, so out assumptions for the length and the diameter are
acceptable.

μC p
Prandtl Number = Pr = =8.18
kf
Where:
μ = dynamic viscosity in kg/m.s
C p= specific heat in J/kg.K
k f = thermal conductivity of the fluid in W/m.K

To calculate Nusselt Number:

Nu = 10.43
 hi d i
Nu =
kf

So, the inside film coefficient:

hi = 253.27 𝑊/𝑚2℃

Shell Side Calculations:

Shell Diameter = Ds = Db + BDC = 3.702434

flowrate of the shell side 74.76

Mass velocity = Gs = = =168.27 kg/m 2s
total flow area 0.44
Gs
Linear velocity = us = =0.167 m/s
ρ

Table 4: Equivalent diameter for the shell.

Equivalent diameter for the shell with square pitch arrangement:

de = 0.02 m
ρu s d i
Reynold number for the shell side = Res = =3464.1
μ

Assuming 25% for the baffle cut, then jf = 0.058.

Where lB is the baffle spacing, and it is assumed to be 0.6 m.

μ
By assuming = 1,
μw
∆ P s=9955.4 Pa=1.44 psi

The pressure drop is less than 7 psi, so our assumption for the baffle spacing is acceptable.

μC p
Prandtl Number = Pr = =9.04
kf

Figure 5: Friction factor for the shell side.

 Figure 6: Heat transfer factor for the shell side.

Assuming 25% for the baffle cut, then jh = 0.01.

μ
By assuming = 1,
μw
Nu = 72.2
ho d e
Nu =
kf
ho = 1434 W/m2℃

Where,
ℎ𝑑o is the outside dirt coefficient in 𝑊/𝑚2℃.
ℎdi is the inside dirt coefficient in 𝑊/𝑚2℃.
kw is the thermal conductivity for the wall of tube based on the material.

ℎ𝑑o and ℎ𝑑i both are taken as 2857.14 𝑊/𝑚2℃ from the literature.
kw for the SS material is 16 𝑊/𝑚2℃.

Uo = 152.445652 W/m2 ºC.

1.2 E-102

Assumptions:
1. The initial guess for the overall heat transfer coefficient is 300 W/m2 oC.
2. The tube length is 4.88 m.
3. The outer diameter of the tube is 25 mm.
4. The thickness is 2 mm.
5. The inner diameter is 21 mm.
6. The average value for both the inside and the outside fouling factor is 4500 W/m2.oC.
7. The material of construction for the tube is SS with kw equal to 16 W/m2 oC.
8. Baffle spacing is 600 mm.
9. Baffle cut is 25%.
10. The correction factor for viscosity is equal to 1.
11. Cooling water in the shell side.

Table 5 : Physical Properties for E-102.

Physical Properties at the Average Temperature of the Fluid Tube Side Shell Side
𝐶𝑝 (𝑘J/𝑘𝑔) 3.581784 4.31
𝜇 (𝑁/𝑚2) 0.001899 0.00
𝑘𝑓 (𝑊/𝑚 𝑘) 0.343521 0.62
𝜌 (𝑘𝑔/𝑚3) 1008.074939 999.76
Table 6 : Summary of final sizing results for E-102 after iterations.
 Parameter Value
Inlet Temperature for Tube Side in ℃ 65.803232
Outlet Temperature for Tube Side in ℃ 41.000000
Inlet Temperature for Shell Side in℃ 30.000000
Outlet Temperature for Shell Side in ℃ 40.000000
Logarithmic Mean Temperature (𝑇𝐿𝑀𝑇𝐷) in ℃ 17.362367
R 0.403173
1.3 E- S 0.692765 105
Ft 0.900000
Corrected 𝑇𝐿𝑀𝑇𝐷 (𝑇m) in ℃ 15.626130
Assumed U 38.000000
Mass Flowrate for Tube Side in 𝑘𝑔/𝑠 74.761430
Duty in W 7021610.6
Surface Area for all Tubes in 𝑚2 11825.014985
Surface Area for One Tube in 𝑚2 0.303000
Number of Tubes (𝑁𝑡) 39026.452097
Cross Sectional Area for a Tube in 𝑚2 0.000346
Number of Tubes per Pass 19513.226049
Total Flow Area for Tube Side in m2 6.758612
Mass Velocity (𝐺𝑡) for Tube Side in 𝑘𝑔/𝑚2𝑠 11.061654
Linear Velocity (𝑢𝑡) for Tube Side in 𝑚/𝑠 0.010973
Reynold Number in Tube Side (𝑅𝑒t) 122.353478
Friction Factor for Tube Side (jf) 0.065000
Pressure Drop in Tube Side (Δ𝑃t) in psi 0.002171
Prandtl Number for Tube Side (𝑃𝑟t) 19.795611
Nusselt Number for Tube Side (𝑁𝑢t) 2.881965
Inside Heat Transfer Coefficient (ℎ𝑖) in 𝑊/𝑚2℃ 47.143612
Mass Flowrate for Shell Side in 𝑘𝑔/𝑠 162.739580
Bundle Diameter (𝐷𝑏) in 𝑚 5.678305
Bundle Diameter Clearance (𝐵𝐷𝐶) in 𝑚 0.132426
Pitch Length (𝑝𝑡) in 𝑚 0.031250
Diameter for the shell (Ds) in m 5.810731
Baffle Spacing (lB) in m 0.600000
Cross Sectional Area for a Shell in 𝑚2 0.697288
Mass Velocity (𝐺𝑡) for Shell Side in 𝑘𝑔/𝑚2𝑠 233.389418
Linear Velocity (𝑢𝑡) for Shell Side in 𝑚/𝑠 0.233445
Equivalent Diameter (𝑑𝑒) in 𝑚 0.024686
Reynold Number in Shell Side (𝑅𝑒s) 7.95E+03
Friction Factor for Shell Side (jf) 0.051000
Pressure Drop in Shell Side (Δ𝑃s) in psi 3.086259
Prandtl Number for Shell Side (𝑃𝑟s) 5.001367
Heat Transfer Factor (𝑗ℎ) 0.006500
Nusselt Number for Shell Side (𝑁𝑢s) 88.416162
Outside Heat Transfer Coefficient (ℎo) in 𝑊/𝑚2℃ 2238.096964
Overall Heat Transfer Coefficient (𝑈𝑜) in 𝑊/𝑚2℃ 37.991157
Assumptions:

1. The initial guess for the overall heat transfer coefficient is 300 W/m2 oC.
2. The tube length is 4.88 m.
3. The outer diameter of the tube is 50 mm.
4. The thickness is 2 mm.
5. The inner diameter is 46 mm.
6. The average value for both the inside and the outside fouling factor is 4500 W/m2.oC.
7. The material of construction for the tube is SS with kw equal to 16 W/m2 oC.
8. Baffle spacing is 600 mm.
9. Baffle cut is 25%.
10. The correction factor for viscosity is equal to 1.
11. Cooling water in the shell side.

Table 7 : Physical Properties for E-105.

Physical Properties at the Average Temperature of the Fluid Tube Side Shell Side
𝐶𝑝 (𝑘J/𝑘𝑔) 0.950190 4.31
𝜇 (𝑁/𝑚2) 0.000019 0.00
𝑘𝑓 (𝑊/𝑚 𝑘) 0.023253 0.62
𝜌 (𝑘𝑔/𝑚3) 7.946709 999.76

Table 8 : Summary of final sizing results for E-105 after iterations.

 Parameter Value
Inlet Temperature for Tube Side in ℃ 137.833232
Outlet Temperature for Tube Side in ℃ 80.000000
Inlet Temperature for Shell Side in℃ 30.000000
Outlet Temperature for Shell Side in ℃ 40.000000
Logarithmic Mean Temperature (𝑇𝐿𝑀𝑇𝐷) in ℃ 71.260859
R 0.172911
1.4 E- S 0.536321 106
Ft 0.980000
Corrected 𝑇𝐿𝑀𝑇𝐷 (𝑇m) in ℃ 69.835641
Assumed U 68.000000
Mass Flowrate for Tube Side in 𝑘𝑔/𝑠 4.579257
Duty in W 251687.6
Surface Area for all Tubes in 𝑚2 52.999990
Surface Area for One Tube in 𝑚2 0.303000
Number of Tubes (𝑁𝑡) 174.917460
Cross Sectional Area for a Tube in 𝑚2 0.001662
Number of Tubes per Pass 87.458730
Total Flow Area for Tube Side in m2 0.145348
Mass Velocity (𝐺𝑡) for Tube Side in 𝑘𝑔/𝑚2𝑠 31.505496
Linear Velocity (𝑢𝑡) for Tube Side in 𝑚/𝑠 3.964597
Reynold Number in Tube Side (𝑅𝑒t) 7.67E+04
Friction Factor for Tube Side (jf) 0.003000
Pressure Drop in Tube Side (Δ𝑃t) in psi 0.091416
Prandtl Number for Tube Side (𝑃𝑟t) 0.772467
Nusselt Number for Tube Side (𝑁𝑢t) 170.766773
Inside Heat Transfer Coefficient (ℎ𝑖) in 𝑊/𝑚2℃ 86.322948
Mass Flowrate for Shell Side in 𝑘𝑔/𝑠 5.833353
Bundle Diameter (𝐷𝑏) in 𝑚 1.071863
Bundle Diameter Clearance (𝐵𝐷𝐶) in 𝑚 0.095575
Pitch Length (𝑝𝑡) in 𝑚 0.062500
Diameter for the shell (Ds) in m 1.167438
Baffle Spacing (lB) in m 0.600000
Cross Sectional Area for a Shell in 𝑚2 0.140093
Mass Velocity (𝐺𝑡) for Shell Side in 𝑘𝑔/𝑚2𝑠 41.639293
Linear Velocity (𝑢𝑡) for Shell Side in 𝑚/𝑠 0.041649
Equivalent Diameter (𝑑𝑒) in 𝑚 0.049371
Reynold Number in Shell Side (𝑅𝑒s) 2.84E+03
Friction Factor for Shell Side (jf) 0.060000
Pressure Drop in Shell Side (Δ𝑃s) in psi 0.011610
Prandtl Number for Shell Side (𝑃𝑟s) 5.001367
Heat Transfer Factor (𝑗ℎ) 0.012000
Nusselt Number for Shell Side (𝑁𝑢s) 58.244072
Outside Heat Transfer Coefficient (ℎo) in 𝑊/𝑚2℃ 737.172240
Overall Heat Transfer Coefficient (𝑈𝑜) in 𝑊/𝑚2℃ 68.764764
Assumptions:

1. The initial guess for the overall heat transfer coefficient is 300 W/m2 oC.
2. The tube length is 4.88 m.
3. The outer diameter of the tube is 50 mm.
4. The thickness is 2 mm.
5. The inner diameter is 46 mm.
6. The average value for both the inside and the outside fouling factor is 4500 W/m2.oC.
7. The material of construction for the tube is SS with kw equal to 16 W/m2 oC.
8. Baffle spacing is 600 mm.
9. Baffle cut is 25%.
10. The correction factor for viscosity is equal to 1.
11. Cooling water in the shell side.

Table 9 : Physical Properties for E-106.

Physical Properties at the Average Temperature of the Fluid Tube Side Shell Side
𝐶𝑝 (𝑘J/𝑘𝑔) 1.005825 4.31
𝜇 (𝑁/𝑚2) 0.000020 0.00
𝑘𝑓 (𝑊/𝑚 𝑘) 0.025698 0.62
𝜌 (𝑘𝑔/𝑚3) 23.046198 999.76

Table 10 : Summary of final sizing results for E-106 after iterations.

 Parameter Value
Inlet Temperature for Tube Side in ℃ 197.450641
Outlet Temperature for Tube Side in ℃ 80.000000
Inlet Temperature for Shell Side in℃ 30.000000
Outlet Temperature for Shell Side in ℃ 40.000000
Logarithmic Mean Temperature (𝑇𝐿𝑀𝑇𝐷) in ℃ 93.672452
R 0.085142
1.5 E- S 0.701405 107
Ft 0.980000
Corrected 𝑇𝐿𝑀𝑇𝐷 (𝑇m) in ℃ 91.799003
Assumed U 20.000000
Mass Flowrate for Tube Side in 𝑘𝑔/𝑠 4.579257
Duty in W 540068.2
Surface Area for all Tubes in 𝑚2 294.157965
Surface Area for One Tube in 𝑚2 0.303000
Number of Tubes (𝑁𝑡) 970.818365
Cross Sectional Area for a Tube in 𝑚2 0.001662
Number of Tubes per Pass 485.409183
Total Flow Area for Tube Side in m2 0.806703
Mass Velocity (𝐺𝑡) for Tube Side in 𝑘𝑔/𝑚2𝑠 5.676511
Linear Velocity (𝑢𝑡) for Tube Side in 𝑚/𝑠 0.246310
Reynold Number in Tube Side (𝑅𝑒t) 1.28E+04
Friction Factor for Tube Side (jf) 0.004500
Pressure Drop in Tube Side (Δ𝑃t) in psi 0.001281
Prandtl Number for Tube Side (𝑃𝑟t) 0.798476
Nusselt Number for Tube Side (𝑁𝑢t) 41.231662
Inside Heat Transfer Coefficient (ℎ𝑖) in 𝑊/𝑚2℃ 23.034424
Mass Flowrate for Shell Side in 𝑘𝑔/𝑠 12.517138
Bundle Diameter (𝐷𝑏) in 𝑚 2.264755
Bundle Diameter Clearance (𝐵𝐷𝐶) in 𝑚 0.105118
Pitch Length (𝑝𝑡) in 𝑚 0.062500
Diameter for the shell (Ds) in m 2.369873
Baffle Spacing (lB) in m 0.600000
Cross Sectional Area for a Shell in 𝑚2 0.284385
Mass Velocity (𝐺𝑡) for Shell Side in 𝑘𝑔/𝑚2𝑠 44.014795
Linear Velocity (𝑢𝑡) for Shell Side in 𝑚/𝑠 0.044025
Equivalent Diameter (𝑑𝑒) in 𝑚 0.049371
Reynold Number in Shell Side (𝑅𝑒s) 3.00E+03
Friction Factor for Shell Side (jf) 0.060000
Pressure Drop in Shell Side (Δ𝑃s) in psi 0.026334
Prandtl Number for Shell Side (𝑃𝑟s) 5.001367
Heat Transfer Factor (𝑗ℎ) 0.010500
Nusselt Number for Shell Side (𝑁𝑢s) 53.871010
Outside Heat Transfer Coefficient (ℎo) in 𝑊/𝑚2℃ 681.824127
Overall Heat Transfer Coefficient (𝑈𝑜) in 𝑊/𝑚2℃ 20.304956
Assumptions:

1. The initial guess for the overall heat transfer coefficient is 300 W/m2 oC.
2. The tube length is 1.83 m.
3. The outer diameter of the tube is 38 mm.
4. The thickness is 2 mm.
5. The inner diameter is 34 mm.
6. The average value for both the inside and the outside fouling factor is 3500 W/m2.oC.
7. The material of construction for the tube is SS with kw equal to 16 W/m2 oC.
8. Baffle spacing is 600 mm.
9. Baffle cut is 25%.
10. The correction factor for viscosity is equal to 1.

Table 11 : Physical Properties for E-107.

Physical Properties at the Average Temperature of the Fluid Tube Side Shell Side
𝐶𝑝 (𝑘J/𝑘𝑔) 2.846946 2.84
𝜇 (𝑁/𝑚2) 0.000016 0.00
𝑘𝑓 (𝑊/𝑚 𝑘) 0.147710 0.15
𝜌 (𝑘𝑔/𝑚3) 14.058602 13.92

Table 12 : Summary of final sizing results for E-107 after iterations.

 Parameter Value
Inlet Temperature for Tube Side in ℃ 157.680556
Outlet Temperature for Tube Side in ℃ 223.000000
Inlet Temperature for Shell Side in℃ 280.593024
Outlet Temperature for Shell Side in ℃ 210.081582
Logarithmic Mean Temperature (𝑇𝐿𝑀𝑇𝐷) in ℃ 54.956155
1.6 E- R 1.079486 108
S 0.531431
Ft 0.760000
Corrected 𝑇𝐿𝑀𝑇𝐷 (𝑇m) in ℃ 41.766678
Assumed U 311.711000
Mass Flowrate for Tube Side in 𝑘𝑔/𝑠 36.766807
Duty in W 6891737.2
Surface Area for all Tubes in 𝑚2 529.354550
Surface Area for One Tube in 𝑚2 0.303000
Number of Tubes (𝑁𝑡) 1747.044718
Cross Sectional Area for a Tube in 𝑚2 0.000908
Number of Tubes per Pass 873.522359
Total Flow Area for Tube Side in m2 0.793089
Mass Velocity (𝐺𝑡) for Tube Side in 𝑘𝑔/𝑚2𝑠 46.359013
Linear Velocity (𝑢𝑡) for Tube Side in 𝑚/𝑠 3.297555
Reynold Number in Tube Side (𝑅𝑒t) 9.95E+04
Friction Factor for Tube Side (jf) 0.002800
Pressure Drop in Tube Side (Δ𝑃t) in psi 0.082162
Prandtl Number for Tube Side (𝑃𝑟t) 0.305277
Nusselt Number for Tube Side (𝑁𝑢t) 154.877557
Inside Heat Transfer Coefficient (ℎ𝑖) in 𝑊/𝑚2℃ 672.850247
Mass Flowrate for Shell Side in 𝑘𝑔/𝑠 36.766807
Bundle Diameter (𝐷𝑏) in 𝑚 2.224398
Bundle Diameter Clearance (𝐵𝐷𝐶) in 𝑚 0.104795
Pitch Length (𝑝𝑡) in 𝑚 0.047500
Diameter for the shell (Ds) in m 2.329193
Baffle Spacing (lB) in m 0.600000
Cross Sectional Area for a Shell in 𝑚2 0.279503
Mass Velocity (𝐺𝑡) for Shell Side in 𝑘𝑔/𝑚2𝑠 131.543454
Linear Velocity (𝑢𝑡) for Shell Side in 𝑚/𝑠 9.446818
Equivalent Diameter (𝑑𝑒) in 𝑚 0.037522
Reynold Number in Shell Side (𝑅𝑒s) 3.11E+05
Friction Factor for Shell Side (jf) 0.029000
Pressure Drop in Shell Side (Δ𝑃s) in psi 3.958323
Prandtl Number for Shell Side (𝑃𝑟s) 0.304043
Heat Transfer Factor (𝑗ℎ) 0.001500
Nusselt Number for Shell Side (𝑁𝑢s) 313.686747
Outside Heat Transfer Coefficient (ℎo) in 𝑊/𝑚2℃ 1240.544677
Overall Heat Transfer Coefficient (𝑈𝑜) in 𝑊/𝑚2℃ 312.082239
Assumptions:

1. The initial guess for the overall heat transfer coefficient is 300 W/m2 oC.
2. The tube length is 4.88 m.
3. The outer diameter of the tube is 25 mm.
4. The thickness is 2 mm.
5. The inner diameter is 21 mm.
6. The average value for both the inside and the outside fouling factor is 4500 W/m2.oC.
7. The material of construction for the tube is SS with kw equal to 16 W/m2 oC.
8. Baffle spacing is 1500 mm.
9. Baffle cut is 25%.
10. The correction factor for viscosity is equal to 1.
11. Cooling water in the shell side.

Table 13 : Physical Properties for E-108.

Physical Properties at the Average Temperature of the Fluid Tube Side Shell Side
𝐶𝑝 (𝑘J/𝑘𝑔) 2.819352 4.31
𝜇 (𝑁/𝑚2) 0.000008 0.00
𝑘𝑓 (𝑊/𝑚 𝑘) 0.070127 0.62
𝜌 (𝑘𝑔/𝑚3) 20.281961 999.76

Table 14 : Summary of final sizing results for E-108 after iterations.

 Parameter Value
Inlet Temperature for Tube Side in ℃ 223.429232
Outlet Temperature for Tube Side in ℃ 35.000000
Inlet Temperature for Shell Side in℃ 30.000000
Outlet Temperature for Shell Side in ℃ 40.000000
1.7 E- Logarithmic Mean Temperature (𝑇𝐿𝑀𝑇𝐷) in ℃ 49.530778 109
R 0.053070
S 0.974151
Ft 0.950000
Corrected 𝑇𝐿𝑀𝑇𝐷 (𝑇m) in ℃ 47.054240
Assumed U 300.000000
Mass Flowrate for Tube Side in 𝑘𝑔/𝑠 38.928021
Duty in W 28301607.0
Surface Area for all Tubes in 𝑚2 2004.892462
Surface Area for One Tube in 𝑚2 0.303000
Number of Tubes (𝑁𝑡) 6616.806805
Cross Sectional Area for a Tube in 𝑚2 0.000346
Number of Tubes per Pass 3308.403403
Total Flow Area for Tube Side in m2 1.145901
Mass Velocity (𝐺𝑡) for Tube Side in 𝑘𝑔/𝑚2𝑠 33.971552
Linear Velocity (𝑢𝑡) for Tube Side in 𝑚/𝑠 1.674964
Reynold Number in Tube Side (𝑅𝑒t) 8.85E+04
Friction Factor for Tube Side (jf) 0.002900
Pressure Drop in Tube Side (Δ𝑃t) in psi 0.065125
Prandtl Number for Tube Side (𝑃𝑟t) 0.323946
Nusselt Number for Tube Side (𝑁𝑢t) 143.842506
Inside Heat Transfer Coefficient (ℎ𝑖) in 𝑊/𝑚2℃ 480.341538
Mass Flowrate for Shell Side in 𝑘𝑔/𝑠 655.945186
Bundle Diameter (𝐷𝑏) in 𝑚 2.617042
Bundle Diameter Clearance (𝐵𝐷𝐶) in 𝑚 0.107936
Pitch Length (𝑝𝑡) in 𝑚 0.031250
Diameter for the shell (Ds) in m 2.724979
Baffle Spacing (lB) in m 1.500000
Cross Sectional Area for a Shell in 𝑚2 0.817494
Mass Velocity (𝐺𝑡) for Shell Side in 𝑘𝑔/𝑚2𝑠 802.385718
Linear Velocity (𝑢𝑡) for Shell Side in 𝑚/𝑠 0.802577
Equivalent Diameter (𝑑𝑒) in 𝑚 0.024686
Reynold Number in Shell Side (𝑅𝑒s) 2.73E+04
Friction Factor for Shell Side (jf) 0.042000
Pressure Drop in Shell Side (Δ𝑃s) in psi 5.635180
Prandtl Number for Shell Side (𝑃𝑟s) 5.001367
Heat Transfer Factor (𝑗ℎ) 0.003800
Nusselt Number for Shell Side (𝑁𝑢s) 177.706752
Outside Heat Transfer Coefficient (ℎo) in 𝑊/𝑚2℃ 4498.328496
Overall Heat Transfer Coefficient (𝑈𝑜) in 𝑊/𝑚2℃ 300.870769
Assumptions:

1. The initial guess for the overall heat transfer coefficient is 300 W/m2 oC.
2. The tube length is 4.88 m.
3. The outer diameter of the tube is 20 mm.
4. The thickness is 2 mm.
5. The inner diameter is 16 mm.
6. The average value for both the inside and the outside fouling factor is 4500 W/m2.oC.
7. The material of construction for the tube is SS with kw equal to 16 W/m2 oC.
8. Baffle spacing is 1200 mm.
9. Baffle cut is 25%.
10. The correction factor for viscosity is equal to 1.
11. Low pressure steam in the shell side.

Table 15 : Physical Properties for E-109.

Physical Properties at the Average Temperature of the Fluid Tube Side Shell Side
𝐶𝑝 (𝑘J/𝑘𝑔) 2.819352 35.15
𝜇 (𝑁/𝑚2) 0.000008 0.00
𝑘𝑓 (𝑊/𝑚 𝑘) 0.070127 0.03
𝜌 (𝑘𝑔/𝑚3) 20.281961 1.85

Table 16 : Summary of final sizing results for E-109 after iterations.

 Parameter Value
Inlet Temperature for Tube Side in ℃ 29.050606
Outlet Temperature for Tube Side in ℃ 73.000000
Inlet Temperature for Shell Side in℃ 160.000000
Outlet Temperature for Shell Side in ℃ 100.000000
Logarithmic Mean Temperature (𝑇𝐿𝑀𝑇𝐷) in ℃ 78.702104
R 1.365207
S 0.335621
Ft 0.950000
Corrected 𝑇𝐿𝑀𝑇𝐷 (𝑇m) in ℃ 74.766999
1.8 Assumed U 110.000000
Mass Flowrate for Tube Side in 𝑘𝑔/𝑠 5.157865
Duty in W 1037042.1
Surface Area for all Tubes in 𝑚2 126.093812
Surface Area for One Tube in 𝑚2 0.303000
Number of Tubes (𝑁𝑡) 416.151194
Cross Sectional Area for a Tube in 𝑚2 0.000201
Number of Tubes per Pass 208.075597
Total Flow Area for Tube Side in m2 0.041836
Mass Velocity (𝐺𝑡) for Tube Side in 𝑘𝑔/𝑚2𝑠 123.287486
Linear Velocity (𝑢𝑡) for Tube Side in 𝑚/𝑠 6.078677
Reynold Number in Tube Side (𝑅𝑒t) 2.45E+05
Friction Factor for Tube Side (jf) 0.002300
Pressure Drop in Tube Side (Δ𝑃t) in psi 0.881733
Prandtl Number for Tube Side (𝑃𝑟t) 0.323946
Nusselt Number for Tube Side (𝑁𝑢t) 324.526881
Inside Heat Transfer Coefficient (ℎ𝑖) in 𝑊/𝑚2℃ 1422.371006
Mass Flowrate for Shell Side in 𝑘𝑔/𝑠 0.491715
Bundle Diameter (𝐷𝑏) in 𝑚 0.625896
Bundle Diameter Clearance (𝐵𝐷𝐶) in 𝑚 0.092007
Pitch Length (𝑝𝑡) in 𝑚 0.025000
Diameter for the shell (Ds) in m 0.717903
Baffle Spacing (lB) in m 1.200000
Cross Sectional Area for a Shell in 𝑚2 0.172297
Mass Velocity (𝐺𝑡) for Shell Side in 𝑘𝑔/𝑚2𝑠 2.853887
Linear Velocity (𝑢𝑡) for Shell Side in 𝑚/𝑠 1.541216
Equivalent Diameter (𝑑𝑒) in 𝑚 0.019749
Reynold Number in Shell Side (𝑅𝑒s) 4.10E+03
Friction Factor for Shell Side (jf) 0.058000
Pressure Drop in Shell Side (Δ𝑃s) in psi 0.021880
Prandtl Number for Shell Side (𝑃𝑟s) 17.806143
Heat Transfer Factor (𝑗ℎ) 0.009000
Nusselt Number for Shell Side (𝑁𝑢s) 96.264649
Outside Heat Transfer Coefficient (ℎo) in 𝑊/𝑚2℃ 132.402869
Overall Heat Transfer Coefficient (𝑈𝑜) in 𝑊/𝑚2℃ 110.241605