Vol-3 Issue-4 2017 IJARIIE-ISSN (O)-2395-4396

DESIGN OF A SHELL AND TUBE HEAT

EXCHANGER
Swarnotpal Kashyap
Department of Chemical Engineering, IIT Guwahati, Assam, India – 781039

ABSTRACT
Often, in process industries the feed stream has to be preheated before being sent to the process unit (reactor or
distillation column) and the product stream has to be cooled before being sent for storage. In order to minimize heat
losses and maximize energy efficiency, the heat removed from the product stream is provided to the feed stream as
preheat. This is done with the help of heat exchangers in process industries. Many different types of heat exchangers
are available depending on the need of operation; however, shell and tube heat exchangers are by far the most
commonly used heat exchangers.

In this work, the design of a counter current shell and tube heat exchanger used in nitric acid plants has been
presented. The design work has been done considering the desired capacity of the plant, which is 100 tons/day of
nitric acid. Two different methods, Kern’s method and Bell’s method, have been used for the design. Bell’s method
was found to be more accurate as the overall heat transfer coefficient calculated by Bell’s method was close to the
assumed value. Further, the design of auxiliary parts of the heat exchanger such as flanges, gaskets, bolts, supports
and saddles have also been presented.

Keywords: heat exchanger, design, process industries

NOMENCLATURE
Re Reynolds number

Pr Prandtl number

Uo Overall heat transfer coefficient

Db Bundle diameter

Ds Shell diameter

di Tube diameter

hi Tube side heat transfer coefficient

As Cross flow area

Gs Mass velocity

de Equivalent diameter

k Thermal conductivity of equipment material

Nu Nusselt number

hs Shell side heat transfer coefficient

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∆Ps Shell side pressure drop

∆Pt Total pressure drop

∆Pc Cross flow pressure drop

f Allowable stress

ro Knuckle radius

1. INTRODUCTION
Heat exchangers are typically used in process industries for the transfer of heat from a hot fluid to a cold fluid. This
helps in minimizing energy losses and maximizing energy efficiency, which further results in higher economic
returns. Many different types of heat exchangers are available such as shell and tube heat exchangers, plate heat
exchangers, spiral heat exchangers, etc. But, shell and tube heat exchangers are the most commonly used because of
their versatility, robust nature and reliability.

A shell and tube heat exchanger is an indirect contact heat exchanger in which the hot and cold fluid streams do not
come in direct contact but the heat transfer occurs through a dividing wall. There are three different classifications of
shell and tube heat exchangers such as parallel flow, cross flow and counter-current flow. Out of these three
different types, counter current flow provides the highest heat transfer rate for a given amount of time. In this work,
the design of a counter current shell and tube heat exchanger used in nitric acid manufacturing plants has been
presented. The design involves a large number of operating and geometric variables in order to match the heat duty
requirement for the corresponding plant capacity, which is 100 tons per day of nitric acid. Two different iterative
procedures, Kern’s method and Bell’s method, have been used in the design work.

2. METHODOLOGY
A reference geometric configuration of the equipment is chosen at first and a desired overall heat transfer coefficient
is chosen. The values of the design parameters are evaluated based on the initial assumptions and the assumed
design specifications. An iterative procedure is followed to arrive at a satisfactory heat transfer coefficient and a
reasonable design specification.

3. CALCULATIONS
3.1 Kern’s Method

Heat capacity of nitric oxide = 1.066 kJ/kg.K

Nitric oxide flow rate = 0.827 kg/s

Inlet temperature of nitric oxide = 150 C

Outlet temperature of nitric oxide = 50 C

Heat load = 0.827 x 1.066 x (150 - 50) KW

= 88.1582 KW

Heat capacity of water = 4.195 kJ/kgK

Water flow rate = 0.744 kg/s

∆T (water) = 88.1582/(0.744x4.195)

= 28.246 C

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LMTD = ((150-63.246)-(50-35))/ ln(86.754/15)

= 40.88

R = T1 – T2/(t2 – t1)

= 100/28.246

= 3.54

S = t2 – t1/(T1 – t1)

= 28.246/115

= 0.2456

From graph, Ft = 0.8

∆Tm = 0.8 x 40.88

We assume the value of U (overall heat transfer coefficient) to be 300 W/m2

Total area of heat transfer A Q/(Ux∆T m) = 8.98 m2

We take o.d. 20 mm, i.d. 16 mm and length 4.83 m of tube

Area of 1 tube = 3.14 x do x L = 0.303 m2

No. of tubes= A/(Area of 1 tube)

= 29.62 tubes

30 tubes

We use 1.25 triangular pitch

Bundle diameter Db = 20 * (30/K1)1/n1

= 20 * (30/0.249)1/2.207

= 175.349 mm

We use split ring floating head type

Bundle diametrical clearance = 50 mm

Shell diameter Ds = 175.349 + 50

= 225.349 mm

Tube side coefficient

Mean water temperature = (35 + 63.246)/2

= 49.123 C

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Tube cross sectional area π/ x di2

= 3.14/4 x (162)

= 201 mm2

Tubes per pass = 30/2 = 15 tubes

Total flow area = 15 x 201 x 10-6

= 3.015 x 10-3

= 0.003015 m2

Water mass velocity = 0.744/(0.003015)

= 246.766 Kg/sm2

Density of water = 995 kg/m3

Water linear velocity = 246.766/995

= 0.248 m/sec

hi = 4200 x (1.35+0.02t) x ut0.8/(di0.2)

= 4200 x (1.35+ 0.02x49.1) x 0.2480.8/(160.2)

= 1844.169 W/m2K

Shell side coefficient

Baffle spacing = Ds/5 = 225.349/5

= 45.0698 mm

Tube pitch = 1.25 x 20 = 25 mm

Cross flow area As = ((25-20)/25)x(225.349x45.0698x10-6)

= 2.03 x 10-3 m2

Mass velocity, Gs = 0.827/0.00203

= 407.389 kg/sm2

Equivalent diameter, de = 1.1/20*(252 - 0.917 x 202)

= 14.4 mm

Mean shell side temperature = (150 + 50)/2 = 100 C

Viscosity = 24 x10-6 Pa.s

= 0.024 x10-3 Pas

k = 0.04 W/m.K

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Re = Gsde/µ = 407.389 x 14.4 x 10-3/0.024 x 10-3 = 244433.4

Pr = µCp/k = 0.024 x 10-3x 1.066 x 103/ (0.04)

= 6.396 x10-4 x 103

= 0.6396

From graph, jh= 2.8 x 10-3 (Page no. 665, Coulson & Richardson [1])

Nu= hsde/kf= jhRePr1/3

hs = 0.04/0.0144 x (2.8 x 10-3 x 244433.4 x 0.63961/3)

= 1638.01 W/m2K

Estimate wall temperature

Mean temperature difference across all resistances = 100 - 49.123

= 50.877 C

Film temperature difference = U/ho x ∆T

= 300/1638.01 x 50.877

= 9.318 C

Mean wall temperature = 100 – 9.318

= 90.681 C

Overall coefficient

Thermal conductivity of cupro-nickel alloy = 50 W/m.K

Fouling coefficient for water = 3000W/m2K

Fouling coefficient for nitric oxide = 5000 W/m2K

1/U0 = 1/ho + 1/hod + (do/di) x 1/hid + (do/di) x 1/hi

1/Uo = 1/1638.01 + 1/5000 + (20x10-3 x ln(20/10))/2x50 + (20/16)x(1/3000) + (20/16) x (1/1844.169)

Uo = 513.05 W/m2K

This value is well above the assumed value of 300W/m2K. Thus, the design is satisfactory.

2nd iteration

We assume length to be 2.39 m

Area of 1 tube= 3.14 x do x L= 3.14 x 20 x 10-3 x 2.39

= 0.1539 m

No. of tubes = 60 tubes

Bundle diameter, Db = 20 x (60/0.249)1/2.207

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= 240.049 mm

Using fixed tube type

Bundle diametrical clearance = 11 mm

Shell diameter, Ds = 240.049 + 11

= 251.049 mm

Tube side coefficient

Mean water temp. = (35+63.246)/2

= 49.123 C

Tube cross sectional area = 3.14/4 x (162)

= 201 mm2

Tubes per pass = 60/2 =30 tubes

Total flow area = 30x 201 x10-6

= 6.03 x10-3

= 0.00603 m2

Water mass velocity = 0.744/(0.00603)

= 123.38 Kg/m2.s

Density of water = 995 kg/m3

Water linear velocity = 123.38/995

= 0.124 m/sec

hi = 4200 x (1.35 + 0.02t) x ut0.8/(di0.2)

= 4200 x (1.35+ 0.02 x 49.1) x 0.1240.8/(160.2)

= 1059.197 W/m2K

Shell side coefficient

Baffle spacing = Ds/5 = 251.049/5

= 50.2098 mm

Tube pitch = 1.25 x 20 = 25 mm

Cross flow area As = ((25-20)/25) x (251.049 x 50.2098 x 10-6)

= 2.521 x 10-3 m2

Mass velocity, Gs = 0.827/0.002521

= 328.044 kg/sm2

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Equivalent diameter, de = 1.1/20 x (252 - 0.917 x 202)

= 14.4 mm

Mean shell side temperature = (150 + 50)/2 = 100 oC

Viscosity = 24 x10-6 Pa.s

= 0.024 x10-3 Pas

k = 0.04 W/mK

Re = Gsde/µ = 328.044x14.4x10-3/0.024x10-3

= 196826.4

Pr = µCp/k = 0.024 x 10-3 x 1.066 x 103/(0.04)

= 6.396 x10-4 x 103

= 0.6396

From graph, jh = 3.4 x 10-3 (Page no. 665, Coulson & Richardson [1])

Nu= hsde/kf= jhRePr1/3

hs= 0.04/0.0144 x (3.4 x10-3 x 196826.4 x 0.63961/3)

= 1601.63 W/m2K

Estimate wall temperature

Mean temperature difference across all resistances = 100 - 49.123

= 50.877 C

Film temperature difference = U/ho x ∆T

= 300/1601.63 x 50.877

= 9.529 C

Mean wall temperature = 100 – 9.529

= 90.471 C

Overall coefficient

Thermal conductivity of cupro-nickel alloy = 50 W/mK

Fouling coefficient for water = 3000 W/m2K

Fouling coefficient for nitric oxide = 5000 W/m2K

1/U0 = 1/ho+ 1/hod + (do/di) x 1/hid + (do/di) x 1/hi

1/Uo = 1/1601.63 + 1/5000 + (20x10-3 x ln(20/10))/2x50 + (20/16) x (1/3000) + (20/16) x (1/1059.107)

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Uo = 405.62 W/m2K

This value is well above the assumed value of 300W/m2K

Thus, the design is satisfactory

Pressure drop
-3
Re ρudi/μ 995x 1 x16x1 /0.001

= 1974.08

Pr μ p/k

= 0.001x4.195x1000/0.59

= 7.11

jF = 3.9x10-2

∆Pt = Np(8jF(L/di) + 5)ρut2/2

∆Pt = 2 x (8 x 3.9 x 10-2 x (2.39 x 103/16) + 2.5) x 995 x 0.1242/2

= 751.26 N/m2 = 0.751 kPa

As this value is low we could consider increasing the number of passes to 6

Tubes per pass = 60/6 = 10

Total flow area = 10 x 201 x 10-6

= 201 x 10-5 m2

Water mass velocity = 0.744/201 x 10-5

= 370.149 Kg/m2s

Water linear velocity = 370.149/995 = 0.372 m/s

Re = 16x10-3 x 0.372 x 995/0.001 = 5922.24

jF = 1.5 x 10-2

∆Pt = 6 x (8 x 1.5 x 10-2 x 2.39x103/16 + 2.5) x 995 x 0.3722/2

= 8437.08N/m2

= 8.4 kPa

1/Uo = 1/1601.63 + 1/5000 +20x10-3 x ln(20/10)/2 x 50 + 20/16 x 1/3000 + 20/16 x 1/2550.18

Uo = 563.27 W/m2C

hi = 4200 x (1.35 + (0.02 x 491.23)) x 0.3720.8/160.2

= 2550.7849 W/m2 K

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Shell side

Re = 196826.4

jF = 2.9 x 10-2

∆Ps = 8 x jFx(Ds/de) x (L/lB) x (ρus2/2)

∆Ps = 8 x 2.9 x 10-2 x (251.049/14.4) x (2.39x103/50.2098) x 1.249 x 26.2642/2

= 82.93 kPa

This value is acceptable

3.2 Bell’s Method

No of tubes = 60

Bundle diameter, Db = 240.049 mm

Tube outer diameter, do = 20 mm

Tube length = 2.39 m or 2390 mm

Tube pitch = 25 mm

Baffle cut = 25 %

Shell diameter, Ds = 251.049 mm

Gas velocity in shell = 26.264 m/sec

For heat transfer coefficient (hoc)

As = ((Pt - do) x Ds x lb) / Pt)

= ((25-20) x 251.049 x 100.418) / 25)

= 5041.96 mm2 or 5.041 x 10-3 m2

Density of nitric oxide, ρ 1 9 kg/m3

Viscosity of nitric oxide, µ = 0.024x10-3 N sec/ m2

Gs = 0.827 / (5.041 x 10-3) = 164.05 kg/ m2 sec

Reynolds number, Re = Gs do / µ

= (164.05 x 20)/ 0.024

= 1.367 x 105

jh= 3.4 x 10-3 (from the graph) (Page no. 694, Coulson and Richardson [1])

Prandtl number, Pr = 0. 6396

Thermal conductivity, kf = 0.04 W/m.K

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hoc.do= kf.jh.Re.Pr0.33

hoc = (3.4 x 10-3 x 136712.29 x (0.63960.33) x 0.04) / (20 x 10-3)

hoc = 801.09 W/ m2 k

Tube row correction factor (Fn)

P’t = 0.87 x Pt = 0.87 x 25 (for equilateral triangular pitch)

= 21.8 mm

Baffle cut height, Hc = 0.25 x 251.049

= 62.762 mm

Height between the baffle tips = Db – 2 x Hc

= 251.049 – 2 x 62.726

= 125.524 mm

Ncv = 125.524 / 21.8 = 5.757

So, Fn = 0.956 (from the graph ) (Page no. 695, Coulson and Richardson [1])

Window correction factor, Fw

Hb = (Db/2) – Ds (0.5- 0.25)

= (240.049/2) – 251.049 x 0.25

= 57.26 mm

Bundle cut = 57.26/240.049 = 0.23 (23 %)

Ra’ 0.18 (from the graph) (Page no. 704, Coulson and Richardson [1])

Tubes in one window area, Nw = 60 x 0.18 = 10.8

Tubes in cross-flow area, Nc = 60 – (2 x 10.8) = 38.4

Rw = (2x10.8)/ 60 = 0.36

Fw = 1.02 (from the graph) (Page no. 696, Coulson and Richardson [1])

Bypass correction, Fb

Ab = lb(Ds – Db)

= 5.52x10-4 m2

Ab/As = (5.52x10-4/2.52x10-3)

= 0.2191

Fb = exp( -a x (Ab/Ab)(1- (2Ns/Ncv)0.33) (Ns/Ncv = 1/5)

Fb = exp(-1.35x0.2191(1- 0.40.33)

= 0.925

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Leakage correction, FL

Tube to baffle = 0.4 mm

Baffle to shell = 2.4 mm

Atb = (Ct x π x do (Nt – Nw)) / 2)

= (0.4 x 3.14 x 20(60 _10.8))/2

= 6.179 x 10-4 m2

Asb = ((Cs x Ds x ( π - ϴb)/2)

For 25% cut, ϴb= 2.1

= (2.4 x 251.049(6.28 - 2.1))/2

= 1.259 x 10-3 m2

AL = Atb + Asb

= 6.179 x 10-4 + 1.259 x 10-3

= 1.8769 x 10-3 m2

Now, AL /As = (1.8769 x 10-3 / 5.04 x 10-3) = 0.37

From graph, βL = 0.26 (Page no. 698, Coulson and Richardson [1])

FL = 1 – 0.26((6.179 x 10-4 + 2 x 1.259 x 10-3)/ 1.876 x 10-3)

= 0.56

Shell- side coeeficient

hs = 801.09 x 0.856 x 1.02 x 0.925 x 0.56 = 359.77 W/m2.K

This value is appreciably lower than predicted by Kern’s method

Pressure drop

Cross-flow zone

Reynolds number, Re = 1.367 x 105 so, jf = 3.4 x 10-2

us = 26.2624 m/ sec

∆Pi = 8jf Ncv ((ρµs2)/2)

= (8 x 3.4 x10-2 x 5.757 x 1.249 x (26.2642))/2

= 674.55 N/m2

Fb’ exp (-4 x 0.219 x (1 – 0.40.333)

= 0.524

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From graph, βL’ 7 (Page no 7 1, oulson and Richardson [1])

FL’ 1 – 0.47((6.179x10-4 + 2 x 1.259 x 10-3)/ 1.876x10-3)

= 0.214

∆Pc = 674.55 x 0.524 x 0.214 = 74.76 N/m2

Window zone

For 25% baffle cut, Ra= 0.19 (from the graph)

Aw (π Ds2 Ra/4) – (Nw π do2/4)

= 9400.268 – 3391.2

= 6.009 x 10-3 m2

uw = Ws / Aw ρ

= 0.827/(6.009x10-3 x 1.249)

= 110.18 m/ sec

uz = (uw us)0.5

= (110.18 x 26.264)0.5

= 53.79 m/sec

Nwv = Hb / Pt’ 57 6/ 1 8

∆Pw = ((FL’( + 6 Nwv)ρUz2) / 2)

= (0.217 (2 + 0.6x3)1.249 x 2893.36)/2

= 140.6245 x 2893.36

= 1489.97 N / m2

End zone

∆Pe ∆Pi((Nwv + Ncv)/Ncv)Fb’

= 674.55 x (1.52) x 0.524

= 537.59 N/ m2

Total pressure

Nb = 2390/100.418 = 23

∆Ps ∆Pe + ∆Pc(Nb – 1) + Nb∆Pw

= (2 x 537.55) + (74.76 x 22) + (23 x 1489.97)

= 36.989 kPa

In case of fouled condition ∆Ps = 1.55 x 36.989 = 57.33 kPa

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3.3 Mechanical Design

Shell side

Material of construction = Cupro – nickel alloy

Permissible stress = 110 N/mm2

Fluid: Liquid mixture from oxidation tower

Working pressure = 2.448 bar

= 2.448 x 105 N/m2

= 0.2448 N/mm2

Design Pressure, Pd = 0.26928 N/mm2

Inlet temperature = 150 C

Outlet temperature = 50 C

Shell diameter, Ds = 251.049 mm

Length = 2.39 m

Shell thickness ts= PdDs/(2fJ + Pd)

= 0.26928 x 251.049/(2 x 110 x 0.85 + 0.26928)

= 0.36 mm

Corrosion allowance = 3 mm

Minimum thickness of 8 mm is chosen

Flanges, gasket, bolts

Flange material used – ASTM A-201 grade B

Allowable stress f = 100 N/mm2

Material used for bolts – 5 % Cr Mo steel

Allowable stress fb = 138 N/mm2

Gasket material – Asbestos composition

Tube side

Tube and tube sheet material – Cupro-nickel alloy

Number of tubes = 60

Tube outer diameter = 20 mm

Tube inner diameter = 16 mm

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Length = 2.39 m

Working pressure = 1 atms

= 0.1013 N/mm2

Design pressure = 0.1114 N/mm2

Inlet temperature = 35 C

Outlet temperature = 63.246 C

Tube thickness

th= PdDo/(2fJ + Pd)

= 0.1114 x 20/(2 x 110 x 0.85 + 0.1114)

= 0.0119 mm

Saddle support

Material of construction – Carbon steel

Density – 7800 kg/m3

ro – knuckle radius = 6 % of shell diameter

= 15.06 mm

Fig. 1 Sketch showing the shell and tube heat exchanger according to design

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4. DESIGN SUMMARY

4.1 Kern’s Method

Number of tubes 60
Bundle diameter 240.049 mm
Bundle diametrical clearance 11 mm
Shell diameter 251.049 mm
Tube side coefficient 1059.197 W/m2K
Baffle spacing 50.209 mm
Tube pitch 25 mm
Equivalent diameter 14.4 mm
Shell side coefficient 1601.63 W/m2K
Mean wall temperature 90.471
Overall heat transfer coefficient 405.62 W/m2K
Shell side pressure drop 82.93 kPa
Number of passes 6
4.2 Bell’s Method
Shell side area 5041.96 mm2
Height between baffle tips 125.524 mm
Tubes in one window area 11
Heat transfer coefficient 359.77 W/m2K
Cross flow pressure drop 74.76 N/m2
Window zone pressure drop 1489.97 N/m2
End zone pressure drop 537.59 N/m2
Shell side pressure drop 36.989 kPa
4.3 Mechanical Design
Shell thickness 8 mm
Tube and sheet material Cupro-nickel alloy
Tube outer diameter 20 mm
Tube inner diameter 16 mm
Length of heat exchanger 2.39 m
Tube thickness 0.0119 mm
Saddle support material Carbon steel
Knuckle radius 15.06 mm

Table 1 Summary of the design work

5. REFERENCES

[1] oulson and Richardson’s hemical Engineering, Volume , 5th, edition, J M oulson and J F Richardson,
Butterworth-Heinemann (2002)

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