4.1.

3 Step-by-Step Calculation

Figure 2.1 Shell and tube heat exchanger diagram

The log mean temperature is given as:

∆𝑇𝑙𝑚 = (𝑇𝐻𝑖𝑛−𝑇𝐶𝑜𝑢𝑡 )−(𝑇𝐻𝑜𝑢𝑡 −𝑇𝐶𝑖𝑛 ) (195−170)−(130−80)

(𝑇𝐻𝑖𝑛 −𝑇𝐶𝑜𝑢𝑡 ) = (195−170) = 36℃
ln ln
(𝑇𝐻𝑜𝑢𝑡 −𝑇𝐶𝑖𝑛 ) (130−80)

It is important to consider the correction factor where it is correlated based on

the shell and tube fluid temperatures and the number of tube and shell passes. It is
normally correlated as a function of two dimensionless temperature ratios:

(𝑇1 −𝑇2 ) (80−170)

R= = = 1.38
(𝑡2 −𝑡1 ) (130−195)

(𝑡2 −𝑡1 ) (130−195)

S= = = 0.57
(𝑇1 −𝑡1 ) (80−195)
 The factor R is obtained through the shell side fluid flow-rate multiply with the
fluid mean specific heat; and then later divided by the tube side fluid flow-rate multiply
with the tube side fluid specific heat. As for S factor, it is a measure of the temperature
efficiency of the exchanger. Based on the temperature-driving force correction factor
the value of FT tabulated from the graph is 0.81. Thus, it is assumed as a 1 tube 4 pass
heat exchanger.

The true temperature difference is,

Tm  0.81  36  29.16 o C

The heat requirements are calculated as,

Q  UATm
Where Q is the exchanged heat duty, U is the heat transfer coefficient, Δ𝑇𝑚 is
the log-mean temperature difference and A is exchange area. The typical range of the
overall coefficient is being referred from the table data provided by Coulson and
Richardson, which is in the range of 100-300 W/m2 oC. After calculating the value of Q
is 4.29 x105 kJ/kg, and the estimated overall coefficient is 200 w/m2°C.

𝑄
𝐴=
𝑈. 𝛥𝑇𝑚

4.29 𝑥 10^5
𝐴=
200 𝑥 29.19

= 73.7 m2

4.1.4 Size and Configuration Detail of the Equipment

The chosen outside diameter of the tube is 20 mm due to its considerably

cheaper in terms of costs as well as easier cleaning purpose. As for the wall thickness,
it is taken as 2 mm in order to withstand the internal pressure of the process stream
and it is sufficient as stainless steel has higher tendency of handling high pressure.
Therefore, the inside diameter is 16 mm. The selected optimum value of the tube
length is 6 m long due to the consideration of reduction of the shell diameter as well
as the cost of the exchanger. In term of tube patterns, greater heat transfer rates can
be achievable through rotated square arrangement. Tube length is determined by heat
transfer required subject to plant layout and pressure drop constraints. The material
type of the heat exchanger is stainless steel. The thermal conductivity of stainless
steel is 16.5 W/m.

Number of tubes:

Area of one tube, 𝐴 = 𝜋 × 20 × 10−3𝑚 × 6𝑚

= 0.38m2

Number of tubes required:

N = Total Area / Area of one tube

= 73.7 / 0.38

= 194 tubes

Therefore for 4 pass tube, tube per pass = 49

𝜋
Tube cross section area= 4 ( 16𝑥10 − 3)2 = 2.0106 x10-4 m2

Thus, area per pass = 49 (2.0106 x10-4 m2) = 9.85 × 10−3𝑚2

Based on design project one the flow rate is 15067.56 kg/hr

Tube side velocity, ut

𝑉𝑜𝑙𝑢𝑚𝑒𝑡𝑟𝑖𝑐 𝐹𝑙𝑜𝑤 0.648

ut = = = 65.79 𝑚/𝑠
𝐴𝑟𝑒𝑎 𝑝𝑒𝑟 𝑝𝑎𝑠𝑠 9.85 𝑋 10^−3

Bundle and shell diameter:

The bundle diameter Db, is calculated by the below formula:- (Manfred Nitsche, 2015)

Db
By referring to the constant value in Table 2.1; 4 passes with square pitch giving the
value of K1=0.158 and n1=2.263

194 1
0.02( )2.263
0.158
= 0.464 m

Table 2.1 constant use for bundle diameter (Manfred Nitsche, 2015)

Based on shell bundle graph below, the shell diameter obtained a value of 12mm
from the selection of fixed and u-tube. Therefore, the shell inside diameter is :

𝐷𝑥 = 0.464 + 0.012 = 0.476 𝑚

Figure 2.2 Bundle diameter clearance (Manfred Nitsche, 2015)

Tube side Heat transfer coefficient

The Reynolds Number of the flow is:

Re

645.592𝑥 65.79 𝑥16

0.197 𝑥10 − 3

= 3449624.2

The Prandtl number is:

Pr =

7.998𝑥10^3(0.197𝑥10^ − 3)
=
0.124

= 12.71

Cp is the specific capacity

kf is the thermal conductivity.

Ratio of the length to pipe inside diameter is: -

Length of the tube =6 m,

L/di = 6/16×10-3

= 375

From the Reynolds number obtain above, the heat transfer of turbulence flow can be
obtain using Nusselt Number, jh value can be obtained from Figure 2.3

𝑁𝑢 = 𝑗ℎ𝑅𝑒𝑃𝑟0.33

= (2.3 ×10-3) (3449624.2) (12.71) 0.33

= 18359.8
 Figure 2.3 Tube side heat transfer factor (Manfred Nitsche, 2015)

The heat transfer coefficient for tube side is

0.124
= 18359.8𝑥
16𝑥10 − 3

= 142288.45 W/m2 0C

Calculation for shell tube side

Shell-side heat-transfer coefficient and pressure drop for a single shell pass
exchanger is calculated by using Kern’s Method. The shell diameter of the heat
exchanger is 250 mm.

Baffle spacing = 0.4 x di

= 0.4 x 250 = 100 mm

Area cross-flow As
Where pt is tube pitch, do is tube outside diameter, Ds is shell inside diameter and lb is
baffle spacing
As = (25 – 20) (476) (100) / 25
= 0.00952 m2

For square pitch arrangement, the shell side diameter is express as

1.10
= ({(25)2 − 0.8697(202 )}
20

= 15.242 mm

Volumetric flow rate:

15067.56 𝑘𝑔 1ℎ𝑟 1𝑚3

= 𝑥 𝑥
ℎ𝑟 3600𝑠 2839.301𝑘𝑔
= 1.474 x10-3 m3/s

Shell side velocity:

𝑚3 1
= 1.474 x10^ − 3 𝑥
𝑠 0.00952 𝑚^2

= 0.155 m/s

Reynold’s Number in the shell side is

Re =
𝑐𝑤

2839.301 𝑥 0.155 𝑥(16 𝑥 10^ − 3)

=
0.197 𝑥 10^ − 3

= 35743.45
Prandtl number

Pr=

2.2 𝑥 0.815
=
0.258

= 6.95

The heat transfer coefficient in the shell side is

1
(0.04) (35743.45)𝑥6.953 𝑥0.258
=
16𝑥10 − 3

= 43996.5 W/m2 0C

A baffle with a 25% cut point is selected as it would give a reasonable heat transfer
coefficient without too large of a pressure drop. The heat transfer coefficient in the
shell side is therefore,

Overall heat transfer coefficient

The overall heat transfer coefficient is given as:

hi= tube side heat transfer coefficient

ft= is tube side fouling factor
kw= is thermal conductivity for stainless steel
hs =shell side heat transfer coefficient
fs =shell side fouling factor

20
1 1 20 20(𝑙𝑛 16)
=( + 0.0002) 𝑋 + + 0.0002
𝑈0 43996.5 16 2(16)

U0= 7.145 W/m2 0C

The overall heat transfer coefficient is 7.145 W/m2 0C which is less than the initial
estimated heat transfer coefficient. Therefore, the dimension of this heat exchanger is
acceptable.

Pressure Drop

Some of the sources of pressure loss on the tube side of a shell and tube
exchanger: the friction loss in the tubes and the losses due to the sudden contraction
and expansion and flow reversals that the fluid experiences in flow through the tube
arrangement. The pressure drop across the tube is developed in equation below which
takes into consideration the pressure losses due to contraction at the tube inlets,
expansion at the exits, and flow reversal in the headers; and coupling the effect of loss
in terms of velocity heads. For the Shell side, the pressure drop equation is expressed
in the equation which takes into account the friction losses.

Tube side

∆𝑃𝑡 =tube-side pressure drop

𝑁𝑝 =is the tube-side passes
Ut= is tube side velocity
L=is the length of one tube
6 645.592(65.79)^2
4 {8(0.04) ( ) + 2.5} 𝑥
16 2

= 14642296 N/m2
Shell side

The baffle cut is estimated at 25%, the shell velocity is 0.155 m/s and the Reynold’s
number is 35743.45

476 6 645.592 𝑋 (0.155)^2

4 {8(0.04) ( )𝑥( )𝑥 }
15.242 100 2

= 18.6 N/m2
Heat exchanger sheet Equipment no.

Sheet no 1
Type of heat Shell and tube, U-tube Heat duty
exchanger

Heat transfer area Overall hear transfer coefficient 7.145 W/m2

Operating data

Tube side Shell-side

Fluid Process stream Process stream

Inlet temperature OC 80 195

Outlet temperature OC 170 130

Mass flow kh/hr 15067.56 15067.56

Density of stream kg/m³ 645.592 2839.301 kg/m³

Thermal conductivity W/m OC 0.124 0.258

Tube side mechanical data

Outside diameter 20m Inside diameter 16mm

Wall material Stainless steel Tube length 6m

Tube arrangement Rotated square pitch Number tubes 194

Exchanger type 4 passes tube, 49 tube velocity 65.79m/s

per pass

Thickness 2mm Bundle diameter 0.464m