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Heat Exchanger Sizing

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40 views23 pages

Heat Exchanger Sizing

Uploaded by

JEFY JEAN A
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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SHELL AND TUBE

Heat Exchanger Sizing


Guide

A Practical Sizing Guide with Step-by-Step


Calculations & Design Best Practices

By : PROCESS ENGINEERING GUY


📘 Introduction to Heat Exchangers
A heat exchanger is a device designed to efficiently transfer heat
between two fluids without mixing them. It plays a crucial role in
thermal systems across industries—whether it's heating a process
stream, condensing vapors, or recovering waste heat from hot gases.

Heat exchangers are fundamental in chemical, petrochemical, power,


HVAC, food processing, and many other sectors where temperature
regulation is essential for safety, performance, and energy efficiency.

We use heat exchangers when:

🔄 Two process streams need to exchange heat without contact


⚡ There’s a need to recover heat to reduce utility costs
🧊 One fluid needs to be cooled before entering the next unit
🔥 A fluid must be preheated for efficient reaction or separation

Types of Heat Exchangers

Shell and Tube Heat Exchanger


Plate Heat Exchangers
Air Cooled heat Exchangers
Double pipe Heat Exchangers
Spiral Heat Exchangers
Finned Tube Heat Exchangers
1. Shell and Tube Heat Exchanger

Most widely used in industries.


Consists of a bundle of tubes inside a shell.
One fluid flows through the tubes, the other through the shell.
Suitable for high pressure, high temperature, and large heat duty.
📌 Used in refineries, chemical plants, power generation.

When to use Shell and Tube HE:

✅ 1. High Pressure and High Temperature Conditions


✅ 2. Large Heat Duty Requirements
✅ 3. Two Immiscible or Hazardous Fluids
✅ 4. Fouling or Dirty Service
✅ 5. Customizability and Flexibility
Important Concepts

Thermal Conductivity:

Thermal conductivity is the ability of a material


to conduct heat. It measures how easily heat
energy passes through a material when there is a
temperature difference across it.

Symbol: k
SI Unit: W/m·K (watts per meter per kelvin)

Fouriers law of heat conduction :

q = Heat transfer rate


k = Thermal Conductivity ( W/m·K )
A = cross-sectional Area (m2 )

= Tempearture Gradient
Important Concepts

Newtons Law of cooling

q = Heat transfer rate


A = cross-sectional Area (m2 )
h = Heat transfer coefficient ( w/ m2 . k)
Ts = Surface temperature
T∞ = fluid temperature

Reynolds no. :

Prndtl no :

Nusselt No. :
Heat Exchanger Sizing steps
1. Calculation of Heat Load

0 Energy
water 25 C water 35 0C

m = Mass flow rate (Kg/s)

Cp = Specific Heat capacity (kj/kg 0C)

= Temperature Difference ( 0C )

For Condensers and Reboilers

m = Mass flow rate (Kg/s)

λ = Latent Heat of Vaporisation

For Condensers with sub-cooling.

+
2. Sizing Equation

Q = Heat flow rate (W)


U = Overall heat transfer coefficient assumed
(W/ m2 K)
A = Heat transfer area (m2)

= Logarithmic Mean temperature difference


Log Mean Temperature Difference ΔTlm

for counter-current flow :

45 0C 35 0C

30 0C 22 0C

ΔT1 = 45-30 = 15 C 0

ΔT2 = 35 - 22= 13 0C
ft Factor : Mean correction factor based on R & S.

t1 = HOT IN t1 ’ = COLDIN
t2 = HOT OUT t2 ’ = COLD OUT

ΔTm = ΔTlm * ft

For ft, see R & S graph.


3. Calculation of Heat Transfer Area

∴ 2
(m )

4. Calculation of No. of Tubes

∴
d0 = Outer Dia of Tube (6.35 mm to 63.5mm)
l = Length of tubes (1.83 m to 6 m)
5. Selection of Tube Pitch

As per TEMA((Tubular Exchanger Manufacturers


Association)
Tube Pitch = 1.25 * Tube OD

Pt = 1.25 * d0

📐 Examples:
For 19.05 mm (3/4 inch) OD tubes:
Minimum pitch = 1.25 × 19.05 = 23.81 mm
For 25.4 mm (1 inch) OD tubes:
Minimum pitch = 1.25 × 25.4 = 31.75 mm
6. Tube Bundle Diameter

Nt = No. of tubes
K1 and n1 values are constant and taken
from chart based on no. of tube side passes.

7. Shell Inner Diameter

{
For Fixed tubes - 10 to
20 mm

for Float - 80 to 100 mm

c= clearance
**Tube Side Heat transfer Coefficient**

1. Tube Side Flow Area

2. Tube Side Mass Flow Velocity

m = Tube side mass flow


At= Tube side flow Area

3. Tube Side Total Velocity

Gt = Tube side mass velocity


ρ = Density of tube side fluid
4. Reynolds No. :

di = Tube inside Dia.


μ = viscosity (kg/m.s)

5. Prandtl No. :

cp = Specific heat Capacity


k = Thermal Conductivity (W/m.k)
μ = Viscosity

6. Nusselt No. :
Nusselt No. :

c = 0.023 for liquid


= 0.021 for gas
= 0.027 for viscous fluid

Consider , =1

Tube Side Heat Transfer Coefficient


**Shell Side Heat Transfer Coefficient (ho)**

1. Shell Side flow Area :

Pt = 1.25 * d0

d0 = Outer Dia of Tube

Di = Inside Shell Dia.

Bs = Baffle Spacing (0.20 to 1 times of Di)

2. Mass velocity of shell side fluid

m = Shell side mass flow


At= Shell side flow Area
3. Shell Side Total Velocity

ρs = Density of shell side fluid

4. Equivalent Dia of Shell

For Triangular Pitch

For Square Pitch


5. Reynolds No. :

de = Equivalent dia of shell

μs = Viscosity of shell side fluid

6. Prandtl No. :

cp = Specific heat Capacity

k = Thermal Conductivity (W/m.k)

μ = Viscosity
7. Nusselt No. :

Consider , =1

Shell Side Heat Transfer Coefficient

k = Thermal conductivity of shell side fluid


de = Equivalent Dia of Shell
Overall Heat Transfer Coefficient

here,

U0 = Overall HTC (W/m2 . 0c)

ho = Shell side HTC (W/m2 . 0c)

hod = Shell side fouling factor ( (W/m2 . 0c)

do = Outer dia. of tube

di = Inside dia. of tube

hid = Tube side fouling factor ( (W/m2 . 0c)

hi = Tube side HTC (W/m2 . 0c)

Kw = Thermal conductivity of tube material (W/m. 0c)

If the calculated HTC ≥ assumed HTC → ✅ Design is valid


If the calculated HTC < assumed HTC → ❌ Your exchanger
may be undersized
Pressure Drop Calculations

Tube Side Pressure Drop

here,

Np = No. of tube side passes

Jf = Tube friction factor

L = Length of tube

di = Inside Dia. of tube

μ and μw = Viscosity of fluid inside tube and at wall

ρ = Density of tube side fluid

Vt = Tubeside Velocity (m/s)

∆P will be in Pascal.

Allowable Pressure drop in Tube Side.

∆Pt = 10 PSI / 69 Kpa / 0.7-0.8 bar


Shell Side Pressure Drop

Jf = Tube friction factor

L = Length of Shell

de = Equivalent Dia. of Shell

Bs = Baffle Spacing

μ and μw = Viscosity of fluid inside tube and at wall

ρ = Density of Shell side fluid

Vs = Shell side Velocity (m/s)

∆P will be in Pascal.

Allowable Pressure drop in Tube Side.


For Liquid = 35 Kpa
For Viscous Fluid = 50-70 Kpa
For Gas/Vapour = 138 Kpa
Thank you
for
Reading.
By : Process Engineering Guy

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