CHEE3004 UNIT OPERATIONS

Heat transfer equipment

- Shell and tube heat exchanger
procedure
Dr Tom Rufford
School of Chemical Engineering, UQ
Contact details
Office 74-310
Email: t.rufford@uq.edu.au
Semester consultation hours:
Tue 10:00-11:30

The key equations in heat transfer fundamentals

First step in heat transfer equipment design is
a macroscopic energy balance
Need an average temperature driving force
such as log mean temperature difference
(LMTD). Has limitations, corrections.
Rate of heat transfer depends on the overall
heat transfer coefficient U, heat transfer area
& temperature driving force. F is a correction
faction for exchanger configuration.
Overall coefficients can be predicted from
individual coefficients by adding resistances
in series.
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qc q qh

eg. qc m&c H cb H ca
Eg. LMTD counter current flow
T1 T2
TL
T1
ln
T2

qT U AT F TL
1 1
1
1

fouling
U ho k
hi
B

Background reading Week 2

RATING: Required.

RATING: Recommended.

TOWLER, G. & SINNOTT, R. K. 2013. Chemical

engineering design: principles, practice, and
economics of plant and process design, Oxford;
Waltham, MA, Butterworth-Heinemann.
Chapter 19 Heat-transfer equipment
Other useful references

RATING: Interest only.

RATING: Required

RATING: Interest only.

SERTH, R.W. (2014) Process heat transfer: principles, applications and rules of thumb, 2nd ed.
Oxford, Academic Press. (online via UQ Library)
MCCABE, W. L., SMITH, J. C. & HARRIOTT, P. (2005) Unit Operations of Chemical Engineering,
7th ed. New York, McGraw-Hill.
OBRIEN, K., CORRIE, S., HOPKINS, L. & T. HOWES (2014) CHEE3002 Heat & Mass Transfer
Study Guide. The University of Queensland.

Week 6 Tasks
1. Attend Monday & Attend Wednesday lectures
o Heat-transfer equipment, no phase change (Rufford)

2. Read
o TOWLER, G. & SINNOTT, R. K. (2013). Chapter 19
o Watch LearnChemE How to Calculate Heat Duty
o Watch Learn ChemE Log Mean Temperature Difference

3. Project 1 Peer Review

o Compulsory in 2nd September tutorial class

4. Complete MBEB3
o Due 17:00 Friday in Blackboard
4

Objectives of this session

At the end of this section we should be able to:
After completing this section of CHEE3004 students
should be able to:
Quantify rates of heat transfer,
Estimate individual film and overall heat transfer
coefficients (using provided correlations in the exam, or
find appropriate correlations in a project activity)
Apply fundamentals of heat transfer to design and analyze
heat transfer equipment,
Consider energy efficiency of a heat exchanger design
within a process system.

Building on fundamentals studied in CHEE3002:

CHEE3002
Fundamentals of heat transfer
Conduction, convection,
radiation
HT resistances in series
Log mean temperature
difference
NTU method
No phase change
Design output heat transfer
area

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CHEE3004
Builds on CHEE3002
+ HT without phase change
+ Design outputs area,
length, number tubes, etc
+ Decisions about process
design in the flow sheet
+ HT with phase change:
Condensors, reboilers,
evaporators

Typical absorption process (eg. MDEA)

Source: Rufford, T. E., S. Smart, et al. (2011). "The removal of CO2 and N2 from natural gas: A review of conventional and emerging process
technologies." invited review paper in preparation for The Journal of Petroleum Science and Engineering

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Milk processing. Direct UHT steam injection plant

a) Balance tank milk; b) Balance tank water; c) Feed pump; d)

Plate heat

exchanger; e) Positive pump; f) Steam injection head; g) Holding coil; h) Expansion

chamber; i) Vacuum pump; j) Centrifugal pump; k) Aseptic homogenizer; l) Aseptic tank;
m) Aseptic filling

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Source: Ullmans Encyclopaedia of Industrial Chemistry

Common types of Heat Exchangers

Double-pipe

Plate

Forced air or fan

Shell and tube

Bath
Direct fired (furnace, kiln)
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Stages in a general
heat exchanger
design problem
CHEE3004 focuses on Stages 1-3:
thermal and hydraulic calculations
to determine heat transfer rates and
pressure drops for equipment sizing

Mechanical design concerned with

detailed equipment specification: eg.
stress and tube vibration analyses
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Most important equation for Heat Exchangers

q UAT
q
Rate of heat
transfer
[W, J.s-1]

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U
Overall Heat
Transfer
Coefficient
[W.m-2.K-1]

12

Heat Transfer
Area
[m2]

Temperature
difference
[K,C]

PRELIMINARY EXCHANGER
DESIGN EXAMPLE
1.
2.

Define the problem

Selection of basic heat exchanger type (q, A, TEMA designation)

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Example 7.1 Shell & tube exchanger design

In a petroleum refinery a kerosene stream with a flow rate of
20,000 kg/hr is to be cooled from 200 C to 120 C by heat exchange
with 70,000 kg/hr of crude oil at 40 C. A maximum pressure drop of
15 psi has been specified for each stream. Prior experience with this
crude oil indicates the oil exhibits significant fouling tendencies, and a
fouling factor of 0.0005 m2.K/W should be applied. Design a shell and
tube heat exchanger for this service.
Fluid property
Cp (kJ/kg.K)
(cP)
k (W/m.K)
Density (kg/m3)
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Kerosen
e
2.51
0.45
0.137
785
14

Crude
oil
2.05
3.60
0.130
850

1. Define the problem

What is the process objective for this unit operation?
Scale and type of process? (large, small, batch, continuous)
What heating or cooling streams are available?
Pressures?
Any hazardous, toxic, or corrosive materials?
Clean or dirty fluids?
Solids involved?
Heat integration required in process?

DRAW A DIAGRAM

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Problem definition and draw diagram(s)

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2. Selection of a basic heat exchanger type

Outputs from Stage 2 HX Design
Flowrates
Fluid properties
Temperatures (and pressures)
Heat duty (q)
Configuration: HX type, fluid placement
Initial guess of overall HT coefficient, U
Estimate of fouling factors
Estimate of required heat transfer surface
area
Allows a preliminary cost estimate

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2. Selection of a basic heat exchanger type

Calculations for Stage 2:
2a) Energy balance q and Ts
2b) Calculate log-mean temperature difference (LMTD)
2c) Calculate LMTD correction factor
2d) Estimate a UD design HT coefficient from tables of typical
values
2e) Calculate required area, A using

qT U A F TL

To complete calculations 2b,c,d we need to select an

exchanger type and configuration to evaluate.
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qT U A F TL

ENERGY BALANCES
McCabe et al. @ p329:
Quantitative attack on heat-transfer problems is
based on energy balances and estimations of rates of
heat transfer.

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Enthalpy balances across a process

q

m&= flow rate of stream

Process
stream in

A heat transfer
unit operation

Properties:
T1 = temperature fluid entering
H1 = enthalpy per unit mass of
stream entering

Properties out:
T2 = temperature fluid exiting
H2 = enthalpy per unit mass of
stream exiting

q m& H 2 H1

What is rate of heat transfer into

the process stream? q [W or J/s]
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Process
stream out

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Some assumptions you might choose if

solving this sort of problem:
No shaft work, and
Changes in mechanical, potential and kinetic
energies are small in comparison to the other
terms in the balance
Steady state
Constant and uniform thermal properties

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The simplest heat exchanger:

Double-pipe heat exchanger counter current
Hot stream out

Tha , H ha
Cold stream out
Tcb, Hcb
less cold

Cold stream in
Tca, Hca
cold

Hot stream in

Thb , H hb

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The simplest heat exchanger:

Double-pipe heat exchanger counter current
We can make 3 balances:
1.
2.

3.

Balance on fluid inside

pipe (cold stream here)
Balance on fluid in the
outside pipe (hot stream
here)

Cold stream in
Tca, Hca
cold

Overall balance
Hot out
Tha, Hha
Less hot

Outside
pipe

Heat gained by cold side is equal to heat

lost by the hot side.
A missing key assumption?
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Inside pipe

Cold out
Tcb, Hcb
less cold

qc q qh
23

Hot in
Thb, Hhb
hot

Summary: Energy Balance in Heat

Exchanger

Neglecting heat transfer to surroundings

If only sensible heat is transferred and constant
specific heats are assumed
Enthalpy balance between two streams is:

q m&h CP ,h Tha Thb m&c C P ,c Tcb Tca

specific heat capacities

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Energy balance across exchanger

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2. Selection of a basic heat exchanger type

Calculations for Stage 2:
2a) Energy balance q and Ts
2b) Calculate log-mean temperature difference (LMTD)
2c) Calculate LMTD correction factor
2d) Estimate a UD design HT coefficient from tables of typical
values
2e) Calculate required area, A using

qT U A F TL

To complete calculations 2b,c,d we need to select an

exchanger type and configuration to evaluate.
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qT FU AT TL

T
TEMPERATURE DRIVING
FORCE

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Temperature profiles in double pipe heat exchangers

co-current (parallel) flow

counter-current flow

T - approach temperature
Tha
T1

T2

Thb

Thb

Tcb

Tca
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Tca
28

T2 Tha
Tcb
T1

To determine the heat flow over entire heat exchanger

a mean T must be determined
If we focus on a differential area dA (a slice) the heat flow is given by...

dq U dA T U dA Th Tc
where T is the local temperature difference at some location

Eq. 11.9 in McCabe

et al., p331

Temperature

Th
dq

The quantity U defined

by this equation is called
the local overall heat
transfer coefficient.

dA

Tc
Distance (equivalently area)
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U is a proportionality
factor between dq/dA
and T

Some assumptions are required for

determining a mean T...
1. overall heat transfer coefficient, U, is constant
2. specific heats of hot and cold fluids are constant
3. heat exchange with ambient is negligible
4. flow is steady and either parallel or counter-current

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Logarithmic mean temperature difference, LMTD

parallel flow (co-current)

T1, T2 are approach temperatures

(co-current example)

T2 T1
TL
T2

ln

1
counter-current flow

T1 T2
TL
T1

ln

2
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TL or Tlm

31

LMTD calculation

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Most important equation for heat exchangers...

qT U A TL
1. can be used to predict the performance of a heat
exchanger
2. can be used to estimate the area for a new
exchanger when flows known and Ts specified
3. can be used to determine the overall heat transfer
coefficient from measured qT and Ts
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LMTD shouldnt be used when?...

1. U changes appreciably (assumption to LMTD is
constant U)
2. If T is not linear function of heat transferred q

For example when there is a phase change

3. If there are reactions occurring in the exchanger

4. For multipass exchangers, but we can apply correction

factors
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Correction of LMTD in multipass exchangers

qT U AF TL
F is a correction factor:
- calculate from charts
- Depends on configuration
& temperature gradients
- Rule of thumb is F>0.8 or
choose another
configuration
Temperature-length curve in 1-2
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exchanger. McCabe et al. Fig 15.5,

35

2. Selection of a basic heat exchanger type

Common heat exchanger types:
Double pipe
Shell-and-tube
Plate-and-frame
Spiral heat exchangers
Compact (plate-fin) exchangers
Air coolers (fin-fan coolers)

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Shell-and-tube heat exchangers

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Advantages of shell-and-tube exchangers

Single phase, condensation, boiling on tube or shell
side, in vertical or horizontal positions
Wide range of operating pressure & pressure drops
Construction can accommodate thermal stresses
inexpensively
Variety different materials possible on shell and tube
Equipment can be easily dismantled for repair and
cleaning
For study purposes: performance data available freely
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Components of a shell-and-tube exchanger

Bundle of tubes contained in a cylindrical shell.
Most S&T HX designed in standard of Tubular Exchanger
Manufactures Association (www.tema.org)
Fixed tube sheet or removable tube bundle (U-tube, floating head)
Baffles to control shell-side flow distribution and P

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Design choices with shell-and-tube exchangers

WHEN TO CONSIDER
Stage 2 selection design
Stage 3 Rating
Stage 3 Rating
Stage 2 selection design
Stage 2 selection design
Stage 3 Rating
Stage 4 mechanical
Stage 4 mechanical

DESIGN CHOICE
i. Fluid placement
ii. Tubing selection
iii. Tube layout
iv. Tube passes
v. Shell and head type
vi. Baffles and tubesheets
vii. Nozzles
viii.Sealing strips

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i. Guidelines for fluid placement

Criteria given in Serth (2014) Table 3.4 in order of priority:
Tube-side fluid
Corrosive fluid
Cooling water
Fouling fluid

Shell-side fluid
Condensing vapour (unless corrosive)
Fluid with large T (>55 K)

Less viscous fluid

Higher-pressure stream
Hotter fluid

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iv. Tube passes

Choose passes after tube size and
number tubes selected.

Typically 2 considerations affect number tube passes:

1. Fluid velocity to maintain fully developed turbulent flow

Turbulent flow provides most effective heat transfer

Keep velocity liquids about 0.9-2.4 m/s (3-8 ft/s). Too low could lead to
excessive fouling, too high to erosion of tube wall.

2. Except for single pass exchanger, even number

preferred to have tube-side fluid enter and exit at the
same header.
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v. Shell and head type

Choose simplest design possible to achieve heat-transfer
objective: i.e. a one pass shell (Type E).
If LMTD correction factor F<
0.8, try next:
a) Two 1-pass shells in series,
or
b) a two-pass shell with
longitudinal (Type F)
Head type: mostly about fixed
or floating for cleaning. See
Serth (2014) p 159
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TEMA 3-letter codes:

Front end stationary head
Shell type
Read end head types
See Serth (2014) Table 3.1
for features of some common
TEMA configurations.

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Example 7.2a Stage 2 Exchanger design

In a petroleum refinery a kerosene stream with a flow rate of
20,000 kg/hr is to be cooled from 200 C to 120 C by heat exchange
with 70,000 kg/hr of crude oil at 40 C. A maximum pressure drop of
15 psi has been specified for each stream. Prior experience with this
crude oil indicates the oil exhibits significant fouling tendencies, and a
fouling factor of 0.0005 m2.K/W should be applied. Design a shell and
tube heat exchanger for this service.
Fluid property
Cp (kJ/kg.K)
(cP)
k (W/m.K)
Density (kg/m3)

CHEE3004-2015

Kerosen
e
2.51
0.45
0.137
785

Crude
oil
2.05
3.60
0.130
850

45

Outputs Stage 2
Flow rates mi, T, P
Fluid properties
Heat duty, q
HX type, fluid side
Initial guess of overall HT
coefficient, U
Estimate of fouling factors
Heat transfer area, A

Specify fluid side and exchanger type

LMTD correction factor

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qT U AT F TL

HEAT TRANSFER
COEFFICIENTS

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Common process engineering example:

Fluid A | pipe wall | Fluid B

Hot fluid side

Pipe wall, copper kw=385W/m2.K

Cold fluid side

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Fig 11.8 in McCabe et al., p331

Heat Transfer by Convection, 1D

Newtons law of cooling

heat flow from a hot surface to

cold fluid

q h A T s T

Ts

q = rate of heat transferred between

surface and surrounding fluid (W)

h = heat transfer coefficient (W/m2K)
TS = surface temperature (K)

T = ambient fluid temperature (K)

viscous sub-layer

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Combined Conduction and Convection

cold fluid

hot fluid

3 Stages
convection from hot fluid to surface

T4

T3

T2

T1

q hh A T 1 T2
conduction through surface

qk

A T 2 T3

convection
q hfrom
A Tsurface
T to cold fluid
c

viscous sub-layers
most likely different values

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Heat Transfer by Conduction

Fouriers Law heat flux is proportional to temperature
gradient and opposite in sign to the direction of the
gradient.
where:
dq
dT
k
q = rate of heat flow [W]
dA
dx
A = surface area [m2]
T = temperature [C]
x = distance normal to surface [m]
k = thermal conductivity [W/m C]

Thermal conductivity is a transport property of the material.

However, k may have a weak dependence on temperature: k= a +bT
Units of k:
o Watt/(metreCelsius) [W/m.C]
o British thermal unit/(hourfootFahrenheit) [Btu/(hftF)]
o To convert Btu/(hftF) to W/m.C multiply by 1.73073.
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Thermal conductivity of various

materials

W/m.C

Btu/
(hftF)

Copper (pure)

385

223

Aluminium (pure)

202

117

Chrome-nickel steel (18% Cr, 8%

Ni)

16.3

9.4

Sandstone

1.83

1.06

Glass (window)

0.78

0.45

0.059

0.034

Water

0.556

0.327

Lubricating oil, SAE 50

0.147

0.085

0.141

0.081

Metals

Nonmetallic solids

Sawdust
Liquids

Gases
Helium

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Data from McCabe et al. Appendix

But how do I know the value to use for individual or

overall heat transfer coefficients?
i.

Use correlations for the individual coefficients

resistances of the solid and fluid layers

ii. Add the resistances in series to find the overall

resistance, which is the reciprocal of the overall heat
transfer coefficient U

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Overall Heat Transfer Coefficient

For Convection and Conduction
Defined as:

q U A ( F T )

incorporates all of...

External (alt. hot side) film coefficient (ho)
Internal (alt. hot side) film coefficient (hi)
Wall conductivity (k)
Fouling factors (more later)

additive (constant area)...

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1 1
1
1

fouling
U ho k
hi
B
54

U for cylindrical geometry (flow through pipes)

Inside surface area of pipe < outside surface area
q ho Ao T
k A T
q

through tubes
xw L
outside film

inside film

q hi Ai T

ln Do Di
xw
1
1 Do
1

Do

U c hi Di
ktube
Do Di
ho
xw is tube wall thickness
Do outside diameter
Di inside diameter pipe
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Where do I get numerical values for the coefficients?

for preliminary design use tables of typical values
wide variety of cases in practice
almost impossible to predict by theory empirical
correlations
Depends on fluid properties, flow regimes, geometry of
equipment, materials of construction.
Use dimensionless groups like
Reynolds number, Nusselt number, Prandlt number,
Peclet number, Graetz number
Project 2 requires you to find and use appropriate correlations to
estimate heat transfer coefficients.
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Estimate UD use table like 3.5 Serth (2014)

Btu
W
1
5.6783 1 2
2
h. ft . F
m .K

Preliminary estimate of heat-transfer area

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Review: Stage 2 Exchanger design

Do we have a preliminary design including?
Flow rates mi, T, P
Fluid properties
Heat duty, q
HX type, fluid side
Initial estimate of overall HT coefficient, U,
estimates fouling factors
Heat transfer area, A

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3a) Selection of tentative exchanger parameters

DESIGN CHOICES
i. Fluid placement

Stage 2: eg. tube side = crude oil

ii. Tubing selection

Use tube data tables

iii. Tube layout

Use tube layout tables

iv. Tube passes

Picked 2 in Stage 2. We check here.

v. Shell and head type

Stage 2: AES

vi. Baffles and tubesheets

Soon

vii. Nozzles

Stage 4 mechanical

viii. Sealing strips

Stage 4 mechanical

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Use these to
then pick a
shell
diameter

3. Rating design and re-specification

Inputs
Flowrates
Temperatures
Pressures
Configuration
Fluid properties
Fouling factors
Outputs
Tube length or
Outlet temperature
Pressure drops

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ii. Tubing selection

Start with selection from standard tubing available. Appendix 4 in
McCabe et al. (2005) tabulates data of standard tubing.
3 characteristics to specify or choose:
Tube diameter
o Refers to outside diameter
o Most commonly used size in HX are inch and 1 inch

Tube thickness
o 16 BWG typical choice.
o BWG = Birmingham Wire Gauge, common standard for thickness
tube, pipe

Tube length
o Standard lengths 8, 12, 16, 20 foot.
o 16ft good starting choice for most exchanger design.
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Initial tubing selection:

1 tubes, BWG16 and 16 foot length
how many tubes nt do I need?

A
nt
Do L
Do is outside tube diameter, L is length of tube

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iii. Tube layout

Square and triangular
most common with pitch:
1 inch (3/4 tubes), or
1.25 inch (1 tubes).

Square pitch
(90)

Triangular gives more

closely packed tubes
- more A in same shell
diameter
- Smaller gaps between
make cleaning shell
side more difficult

triangular (30)

pitch is the centre-to-centre distance between tubes

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Rotated
square (45)

65

Choose passes after tube size and

number tubes selected.

iv. Tube passes

Typically 2 considerations affect number tube

passes:
1. Fluid velocity to maintain fully developed
turbulent flow

Turbulent flow provides most effective heat transfer

Keep velocity liquids about 0.9-2.4 m/s (3-8 ft/s). Too
low could lead to excessive fouling, too high to
erosion of tube wall.

2. Except for single pass exchanger, even

number preferred to have tube-side fluid
enter and exit at the same header.
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Re

4m&c n p nt

Di c

Turbulent if

Re 104

Hydraulic check:

Re

&c n p nt
4m

Di c

Turbulent if

Re 10 4

Di is inside tube diameter

Must convert units of viscosity to kg/m.s
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Tube count tables

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vi. Baffles and tubesheet

Single-segmental baffles standard with spacing 0.2-1.0 shell diameters.
See guidelines on spacing, thickness, cut in references such as Serth
(2014)

For our prelim design we will choose:

single-segment baffles
Baffle cut B = 20%, Fig 5.3 Serth for example B/ds =0.3, where ds is
the shell diameter. B=
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Preliminary design specified:

i. Fluid placement

Stage 2: eg. tube side = crude oil

ii. Tubing selection

1, BWG16, 16ft long

iii. Tube layout

1.25 in square pitch

iv. Tube passes

8 tube passes

v. Shell and head type

AES. ds=23

vi. Baffles and tubesheets

20% cut, B/ds=0.3

vii. Nozzles

Stage 4 mechanical

viii. Sealing strips

Stage 4 mechanical

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Calculate overall HT coefficient required, U req

q U A ( F T )
Havent changed: q = 1116 kW or TLM=90.85K
LMTD correction factor F doesnt change significantly with
increasing number tube passes F=0.92
We now can calculate A for our specified design: 84.45 m2

U req

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158.06W/m 2 .K
A ( F Tlm )
72

Now we estimate film coefficients and check if our design would work for a
clean exchanger
Use correlations to find hi and ho
Get thermal conductivity of tubing from data tables, handbooks
etc
xw is tube wall thickness

ln Do Di
xw
1
1 Do
1

Do

U c hi Di
ktube
Do Di
ho
Heat flux-area inside vs
outside conversion
3 possible outcomes from evaluation
a.

if Uc~Ureq exchanger if thermally feasible. Add the fouling resistance and check.

b.

If Uc<Ureq need to increase A or improve U?

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c. If Uc>>Ureq thermally ok, but could be oversize

Example calculation
Assume:
hi= 1000 W/m2.K
ho=500 W/m2.K
ktube=45 W/m.K

Uc=313.6 W/m2.K
Uc/Ureq-1 = 98 %
Thermally suitable, but
oversized.

1 BWG16 tubes:
Do= 0.0254 m, Di=0.0221 m , xw=0.00165 m

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Fouling Factors
Empirical factors for reduced heat transfer due to solid
deposits
scale, corrosion, dirt, wax

Acts as additional insulation

1 1
1
1 1
1

U ho k
hi hdi hdo
B
Fouling factors:
hdi = inside fouling factor
hdo = outside fouling factor
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vii. Nozzles
Sized to meet P limitations and/or match process piping.
Eg. 2 nozzle for shell diameter 4-10.
Also consider tube vibration and erosion as fluid entering shell directly
impinges on tube bundle.
Use tabulated guidelines available to select nozzle size & check
velocity guidelines.

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viii. Sealing strips

Sealing strips are used to reduce effect of the bundle bypass stream
that flows around the outside of the tube bundle (which bypass the
heat transfer area with the tubes!)
Typically one pair sealing strips per 4-10 roes of tubes between the
baffle tips.

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APPENDIX:
SUMMARY OF SHELL & TUBE
EQUIPMENT CHOICES

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Stages in a general
heat exchanger
design problem
CHEE3004 focuses on Stages 1-3:
thermal and hydraulic calculations
to determine heat transfer rates and
pressure drops for equipment sizing

Mechanical design concerned with

detailed equipment specification: eg.
stress and tube vibration analyses
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Design choices with shell-and-tube exchangers

WHEN TO CONSIDER
Stage 2 selection design
Stage 3 Rating
Stage 3 Rating
Stage 2 selection design
Stage 2 selection design
Stage 3 Rating
Stage 4 mechanical
Stage 4 mechanical

DESIGN CHOICE
i. Fluid placement
ii. Tubing selection
iii. Tube layout
iv. Tube passes
v. Shell and head type
vi. Baffles and tubesheets
vii. Nozzles
viii.Sealing strips

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i. Guidelines for fluid placement

Criteria given in Serth (2014) Table 3.4 in order of priority:
Tube-side fluid
Corrosive fluid
Cooling water
Fouling fluid

Shell-side fluid
Condensing vapour (unless corrosive)
Fluid with large T (>55 K)

Less viscous fluid

Higher-pressure stream
Hotter fluid

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ii. Tubing selection

Start with selection from standard tubing available. Appendix 4 in
McCabe et al. (2005) tabulates data of standard tubing.
3 characteristics to specify or choose:
Tube diameter
o Refers to outside diameter
o Most commonly used size in HX are inch and 1 inch

Tube thickness
o 16 BWG typical choice.
o BWG = Birmingham Wire Gauge, common standard for thickness
tube, pipe

Tube length
o Standard lengths 8,12,16,20 foot. 16ft good starting choice for most
exchanger design.
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iii. Tube layout

Square and triangular
most common with pitch:
1 inch (3/4 tubes), or
1.25 inch (1 tubes).

Square pitch
(90)

Triangular gives more

closely packed tubes
- more A in same shell
diameter
- Smaller gaps between
make cleaning shell
side more difficult

triangular (30)

pitch is the centre-to-centre distance between tubes

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Rotated
square (45)

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iv. Tube passes

Choose passes after tube size and
number tubes selected.

Typically 2 considerations affect number tube passes:

1. Fluid velocity to maintain fully developed turbulent flow

Turbulent flow provides most effective heat transfer

Keep velocity liquids about 0.9-2.4 m/s (3-8 ft/s). Too low could lead to
excessive fouling, too high to erosion of tube wall.

2. Except for single pass exchanger, even number

preferred to have tube-side fluid enter and exit at the
same header.
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v. Shell and head type

Choose simplest design possible to achieve heat-transfer
objective: i.e. a one pass shell (Type E).
If LMTD correction factor F<
0.8, try next:
a) Two 1-pass shells in series,
or
b) a two-pass shell with
longitudinal (Type F)
Head type: mostly about fixed
or floating for cleaning. See
Serth (2014) p 159
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TEMA 3-letter codes:

Front end stationary head
Shell type
Read end head types
See Serth (2014) Table 3.1
for features of some common
TEMA configurations.

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vi. Baffles and tubesheet

Single-segmental baffles standard with spacing 0.2-1.0 shell diameters.
See guidelines on spacing, thickness, cut in references such as Serth
(2014)

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vii. Nozzles
Sized to meet P limitations and/or match process piping.
Eg. 2 nozzle for shell diameter 4-10.
Also consider tube vibration and erosion as fluid entering shell directly
impinges on tube bundle.
Use tabulated guidelines available to select nozzle size & check
velocity guidelines.

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viii. Sealing strips

Sealing strips are used to reduce effect of the bundle bypass stream
that flows around the outside of the tube bundle (which bypass the
heat transfer area with the tubes!)
Typically one pair sealing strips per 4-10 roes of tubes between the
baffle tips.

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APPENDIX:
ESTIMATING HEAT
TRANSFER COEFFICIENTS

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Where do I get values for h?

h values are most reliably calculated using empirical expressions
using dimensionless groups:
CHEE3004 used: Nusselt type expressions: Nu = f(Re, Pr)
Alternatives: Delaware method, Colburn j factors: j = f/2 = f(Re, Pr)

Reynolds number, Re is a property of fluid and flow conditions

Prandlt number, Pr is ratio viscous to thermal properties of the

boundary layer:

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Refer back to CHEE300293Study Guide (2014), page H-93.

Nusselt number, Nu
hd
Nu
k
Where
h =film heat transfer coefficient (W/m2.K)
d = characteristic length (m)
k = average thermal conductivity (W/m.K)

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Eg. From CHEE3002 Study Guide (2014), page H-103.

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