21

ASEAN Journal for Science and Engineering in Materials 3(1) (2024) 21-42

ASEAN Journal for Science and

Engineering in Materials
Journal homepage: https://ejournal.bumipublikasinusantara.id/index.php/ajsem

How to Calculate and Design Shell and Tube-type Heat

Exchanger with a Single Heat Transfer
Risti Ragadhita, Asep Bayu Dani Nandiyanto*

Universitas Pendidikan Indonesia, Indonesia

Correspondence: E-mail: [email protected]

ABSTRACT ARTICLE INFO

Article History:
The process in the industry requires equipment with high Submitted/Received 20 Jul 2023
First Revised 02 Sep 2023
efficiency, especially energy. This is closely related to the Accepted 20 Oct 2023
need to measure the heat-transfer process in heat First Available online 23 Oct 2023
exchangers. A study of the effectiveness of a heat exchanger Publication Date 01 Mar 2024

is needed to increase the effectiveness of the heat exchanger ____________________

Keyword:
because each heat exchanger product created has different Calculation,
effectiveness. This study aims to discuss and explain the Design,
calculations in the design of shell and tube-type heat Effectiveness,
Heat exchanger,
exchangers. A step-by-step method for calculating heat Shell and tube.
exchanger designs is presented, including reviewing simple
cases regarding heat exchanger design calculations. This
research has the potential to be used as standard
information on how to do step-by-step calculations for heat
exchanger design.

© 2023 Bumi Publikasi Nusantara

 Ragdhita & Nandiyanto, How to Calculate and Design Shell and Tube-type Heat … | 22

1. INTRODUCTION

The transfer of heat from one fluid to another is a critical activity in most chemical
industries (Pordanjani et al., 2019; Muthukrishman et al., 2020). Heat transfer is most
commonly used in the construction of heat transfer equipment for exchanging heat from one
fluid to another. Heat exchangers are often used equipment for efficient heat transfer
(Thanikodi et al., 2020; Patel, 2023). The application, available floor area, available resources,
connections in the field, cost, and many other considerations all influence the selection of a
heat exchanger for a certain application. In a highly competitive context, the heat exchanger
must provide the required heat transfer while taking up less space, weighing less, and being
priced competitively (Douadi et al., 2022).
Shell and tube-type heat exchangers are the most commonly used heat exchangers in
industries such as chemical processing, power production, oil refining, refrigeration, and air
conditioning (Gupta et al., 2022; Gürses et al., 2022). More than 35-40% of heat exchangers
utilized in modern engineering sectors are shell and tube type due to their sturdy construction
geometry, ease of maintenance, and upgradeability. Shell and tube heat exchangers transmit
significant amounts of heat at a low cost, give a cost-effective tube surface while limiting floor
area, liquid volume, and weight requirements, and come in a variety of diameters and lengths
(Mohammadi et al., 2020). Heat exchangers with shell and tube construction have been
around for over 150 years. The current manufacturer's thermal technology and
manufacturing techniques are thoroughly defined and utilized.
Because of their widespread use, shell and tube heat exchangers must be improved in
performance. These heat exchangers are studied in two parts: shell side and tube side. The
research on the tube side is simple with few characteristics; on the other hand, the study of
the shell side is complicated with numerous parameters, the most essential of which are the
baffle and tube layout. Many reports explain the theory of heat exchangers (Vasiliev, 2005).
However, studies documenting how to calculate shell and tube-type heat exchanger designs
have not been well documented. This report is to discuss and explain the calculation of a shell
and tube-type heat exchanger. Here, a step-by-step method on how to calculate a shell and
tube-type heat exchanger design is presented, including a review of simple case examples of
heat exchanger calculations.

2. LITERATURE REVIEW
2.1. Shell and Tube Type Heat Exchanger
Amongst all types of exchangers, shell and tube exchangers are the most commonly used
heat exchange equipment. This type is used for higher flow rates, thus frequently used in
industry (Gupta et al., 2022; Gürses et al., 2022). Tubes are installed in parallel and many are
in one shell. Cold fluid enters the tube. Hot fluid enters from different ends to counter the
current flow in the shell (Bahiraei et al., 2021). The advantage of this type of heat exchanger
is that it has a larger heat transfer surface per unit volume, has a good mechanical
arrangement with a shape good enough for operation pressurized, is available in a variety of
construction materials, operating procedures easier, better design methods are available, and
clean-up can be done easily (Li et al., 2020). Therefore, the most common type of heat
exchanger profitable to use is a shell and tube-type heat exchanger. The common types of
shell and tube exchangers are (Saffarian et al., 2019; Saffiudeen et al., 2020):
(i) Fixed tube sheet exchanger
Fixed tube-sheet exchanger called a non-removable tube bundle. The fixed tube sheet
design is the most basic and least expensive type of shell and tube exchanger. The tube sheet
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is welded to the shell in this form of exchanger, and there is no relative movement between
the shell and tube bundle. An illustration of a fixed tube-sheet exchanger is shown in Figure
1.

Figure 1. Fied tube-sheet exchanger.

(ii) Removable tube bundle
To facilitate cleaning and replacement, the tube bundle can be detached. Floating-head
and U-tube exchangers are two types of removable tube bundle exchangers. The floating-
head exchanger is made out of a stationary tube sheet that is fastened to the shell flange. The
tubes may expand into a freely riding floating head or floating tube sheet at the other end of
the bundle. The tube sheet is affixed to a floating head cover, and the entire bundle can be
removed for cleaning and inspection of the interior. Figure 2 depicts the floating-head
exchanger. The U-tube exchanger is made up of tubes bent in the shape of a "U" and rolled
back into the tube sheet seen in Figure 3. This means that depending on the tube
configuration, it will omit some tubes in the center of the tube bundle. The tubes can freely
grow towards the "U bend end”.

Figure 2. Floating-head heat exchanger.

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Figure 3. Romovable u-tube heat exchanger.

Figures 1-3 (International Standard: 4503-1967) depict typical parts and connections,
which are summarized in Table 1.
Table 1. Typical component of shell and tube type heat exchanger.
No Component No Component
1 Shell 16 Tubes (U-type)
2 Shell cover 17 Tie rods and spacers
3 Shell flange (channel end) 18 Transverse (or cross) baffles or support plates
4 Shell flange (cover end) 19 Longitudinal baffles
5 Shell nozzle or branch 20 Impingement baffles
6 Floating tube sheet 21 Floating head support
7 Floating head cover 22 Pass partition
8 Floating head flange 23 Vent connection
9 Floating head gland 24 Drain connection
10 Floating head backing ring 25 Instrument connection
11 Stationary tube sheet 26 Expansion bellows
12 Channel or stationary head 27 Support saddles
13 Channel cover 28 Lifting lugs
14 Channel nozzle or branch 29 Weir
15 Tube (Straight) 30 Liquid-level connection

2.2 Flow Type in Heat Exchanger

Several flow types in the heat exchanger, including counter-current, co-current, and cross-
flow. Counter current flow is flow in the opposite direction, where one fluid enters at one end
of the heat exchanger, while the other fluid enters at the other end of the heat exchanger,
each fluid flows in the opposite direction. This type of counter-current flow provides better
heat compared to unidirectional or parallel flow. Meanwhile, the number of passes also
influences the effectiveness of the heat exchanger used (Bahiraei et al., 2021; Saeid and
Seetharamu, 2006). Parallel flow or co-current is unidirectional flow, where both fluids enter
at the same end of the heat exchanger and both fluids flow in the same direction towards the
other end of the heat exchanger (Saeid and Seetharamu, 2006). Cross flow often called cross
flow is fluids that flow along a surface moving in mutually perpendicular directions (Harris et
al., 2002).

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2.3 Standards and Codes for Heat Exchanger

British Standard, BS 3274, governs the mechanical design characteristics, manufacturing,
materials of construction, and testing of shell and tube exchangers. The TEMA standards,
developed by the American Tubular Heat Exchanger Manufacturers Association, are also
widely utilized. The TEMA standards cover three types of exchangers: class R for exchangers
used in the petroleum and related industries, class C for exchangers used in commercial and
general process applications, and class B for exchangers used in the chemical process
industries.
2.4 Thermal Design Consideration
A shell and tube heat exchanger's thermal design typically includes determining the heat
transfer area, number of tubes, tube length, and diameter, tube layout, number of shell and
tube passes, type of heat exchanger (fixed tube sheet, removable tube bundle, and so on),
tube pitch, number of baffles, their type and size, shell and tube side pressure drop, and so
on (Sing et al., 2019).
2.4.1 Tubes
Tube diameter sizes range from 5/8 in. (16 mm) to 2 in. (50 mm). Smaller diameters (5/8
to 1 in. (16 to 25 mm) are favored for most jobs because they result in more compact, and
thus less expensive, exchangers. Larger tubes are easier to clean mechanically and would be
chosen for highly fouling fluids. The tube thickness (gauge) is chosen to resist internal
pressure while also allowing for corrosion (Aresti et al., 2018). Steel tubes for heat exchangers
are covered by BS 3606 (metric sizes); other materials are covered by BS 3274. Table 2 shows
the standard sizes and wall thicknesses for steel tubes.
Table 2. Standard dimension for steel tubes
Outside diameter (mm) Wall thickness (mm)
16 1.2 1.6 2.0 - -
20 - 1.6 2.0 2.6 -
25 - 1.6 2.0 2.6 3.2
30 - 1.6 2.0 2.6 3.2
38 - - 2.0 2.6 3.2
50 - - 2.0 2.6 3.2

Tube lengths for heat exchangers are as follows: 6 ft (1.83 m), 8 ft (2.44 m), 12 ft (3.66 m),
16 ft (4.88 m), 20 ft (6.10 m), and 24 ft (7.32 m). Longer tubes will reduce the shell diameter
for a given surface area, resulting in a lower cost exchanger, especially at high shell pressures
(Aresti et al., 2018). The ideal tube length-to-shell diameter ratio is usually between 5 and 10.
When using U-tubes, the tubes on the outside of the bundle will be longer than the tubes on
the interior. For usage in the thermal design, the average length must be estimated. U-tubes
will be bent and trimmed to size from standard tube lengths. As a starting point for design
calculations, 3/4 in. (19 mm) is a good trial diameter.
2.4.2 Tube arrangements
Figure 4 shows how the tubes of an exchanger are typically organized in an equilateral
triangular, square, or rotating square arrangement. The triangular and rotated square
patterns give higher heat-transfer rates but at the expense of a higher pressure drop than the
square pattern. A square, or rotated square arrangement, is used for heavily fouling fluids,

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where it is necessary to mechanically clean the outside of the tubes. The recommended tube
pitch (distance between tube centers) is 1.25 times the tube outside diameter, and this will
normally be used unless process requirements dictate otherwise. Where a square pattern is
used for ease of cleaning, the recommended minimum clearance between the tubes is 0.25
in. (6.4 mm) (Kallannavar et al., 2020).

Figure 4. Tube arrangements.

2.4.3 Tube-side passes
To expand the length of the flow channel, the fluid in the tube is frequently directed to
flow back and forth in several "passes" via groups of tubes placed in parallel. The number of
passes is chosen to provide the necessary tube-side design velocity. Exchangers are
constructed with one to sixteen tube passes. By splitting the exchanger headers (channels)
with partition plates (pass partitions), the tubes are organized into the number of passes
required. Figure 5 depicts the pass partition layout for 2, 4, and 6 tube passes
(Silaipillayarputhur and Khurshid, 2019).
2.4.4 Shell
The British standard BS 3274 covers exchangers with diameters ranging from 6 in. (150
mm) to 42 in. (1067 mm), while the TEMA standards cover exchangers with diameters ranging
from 60 in. (1520 mm). Shells up to around 24 in. (610 mm) are typically made of standard,
near tolerance tubing; above 24 in. (610 mm), they are rolled from the plate. Table 3 shows
the values, which have been translated to international standard units and rounded (Abd et
al., 2018). Furthermore, the shell inside diameter is calculated by considering clearance. The
clearance between the shell inside diameter and the tube bundle can be determined from
Figure 6, assuming a pull-through floating head.
2.4.5 Tube-sheet layout
The bundle diameter is determined not only by the number of tubes but also by the
number of tube passes because spaces must be allowed in the tube sheet pattern to
accommodate the pass partition plates (Boulougouras and Besseris, 2023). Table 3 contains
the constants for use in triangular and square tube-sheet layouts.

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Figure 5. Tube arrangements, showing pass-partitions in the header.

Figure 6. Tube bundle clearance.

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Table 3. Constant for use in triangular and square tube-sheet layout.

Triangular pitch = 1.25do
No. Passes 1 2 4 6 8
K1 0.319 0.249 0.175 0.0743 0.0365
n1 2.142 2.207 2.285 2.499 2.675
Square pitch = 1. 25do
K1 0.215 0.156 0.158 0.0402 0.0331
n1 2.207 2.291 2.263 2.617 2.643

2.4.6 Shell types (passes)

Figure 7(a-e) depicts the main shell layouts. TEMA standards use the letters E, F, G, H, and
J to indicate the various varieties. The E shell is the most typical configuration. When the shell
and tube side temperature differences are too great for a single pass, two shell passes (F shell)
are employed. However, obtaining a suitable seal with a shell-side baffle is difficult, and the
same flow arrangement can be achieved by connecting two shells in series (Costa and
Queiroz, 2008). Figure 7(f) depicts one technique for sealing the longitudinal shell-side baffle.
The divided flow and split-flow arrangements (G and J shells) are utilized to reduce shell-side
pressure drop, where pressure drop, not heat transmission, is the controlling factor in the
design.

Figure 7. Shell types (pass arrangements) of (a) one-pass shell (E shell); (b) split flow (G
shell); (c) divided flow (J shell); (d) two-pass shell with longitudinal baffle (F shell); and (e)
double split flow (H shell).
2.4.7 Shell and tube designation
A common method of describing an exchanger is to designate the number of shell and tube
passes: m/n; where m is the number of shell passes and n is the number of tube passes. Thus,
1/2 describes an exchanger with 1 shell pass and 2 tube passes, and 2/4 an exchanger with 2
shell passes and 4 four tube passes (Silaipillayarputhur and Khurshid, 2019).
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2.4.8 Baffles
In the shell, baffles are employed to direct the fluid stream over the tubes, increasing the
fluid velocity and thus the rate of transfer (Abolpour et al., 2021). The single segmental baffle,
shown in Figure 8(a), is the most often used type of baffle; additional varieties are shown in
Figures 8(b, c, and d).
The baffles would restrict condensate flow if the setup depicted in Figure 8(a) was utilized
with a horizontal condenser. This issue can be solved by either rotating the baffle
arrangement through 90° or trimming the baffle's base, as shown in Figure 8. The word "baffle
cut" refers to the proportions of a segmental baffle. The baffle cut is the height of the segment
removed to construct the baffle given as a percentage of the diameter of the baffle disc.
Baffle cuts ranging from 15% to 45% are employed. In general, a baffle cut of 20 to 25% is
optimal for good heat transfer rates without excessive drop. As a clearance must be left for
assembly, there will be some fluid leakage around the baffle (Kücük et al., 2019; Abdelkader
and Zubair, 2019). The required clearance is determined by the shell diameter; typical values
and tolerances are shown in Table 4.
Another leakage path is the space between the tube holes in the baffle and the tubes.
Normally, the maximum design clearance is 1/32 in. (0.8 mm). The specifications specify the
minimum thickness for baffles and support plates. The baffle spacings employed vary
between 0.2 and 1.0 times the shell diameters. Closer baffle spacing results in higher heat
transfer coefficients but larger pressure drops. The ideal separation will be between 0.3 and
0.5 times the shell diameter.

Figure 8. Types of baffle used in shell and tube heat exchangers of (a) segmental; (b)
segmental and strip; (c) disc and doughnut; and (d) orifice types.
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Table 4. Typical baffle clearances and tolerances.

Shell Diameter, Ds Baffle Diameter Tolerance
Pipe Shells
1 1
6 to 25 in. (152 to 635 mm) Ds – 𝑖𝑛. (1.6 mm) + 𝑖𝑛. (0.8 mm)
16 32
Plate Shell
1 1
6 to 25 in. (152 to 635 mm) Ds – 𝑖𝑛. (3.2 mm) +0, - 𝑖𝑛. (0.8 mm)
8 32
3 1
27 to 42 in. (686 to 1067 mm) Ds – 𝑖𝑛. (4.8 mm) +0, - 𝑖𝑛. (1.6 mm)
16 16

3. METHOD
In the research, the heat exchanger was designed to obtain optimal performance results.
The standard used in designing shell and tube-type heat exchangers is TEMA (Tubular
Exchanger Manufactures Association). In this study, a series of calculations were carried out
to analyze the heat transfer correction coefficient values, pressure drops on the tube and
shell sides, as well as design effectiveness. The first step in designing a shell and tube type
heat exchanger is to determine several thermal design specifications and dimensional
specifications of the shell and tube heat exchanger. Several initial specifications that must be
determined and collected are presented in Tables 5 and 6. Table 5, which is a thermal
specification, must be adapted to the literature. Meanwhile, the tool dimension specifications
in Table 6 must be adjusted to TEMA standards.
Table 5. Heat exchanger operating data.
Spesifications Hot Fluida Cold Fluida
Mass flow rate (m; kg/s) ….. …..
Dynamic viscosity (µ; Kg/m.s) ….. …..
Inlet Temperature (°C) ….. …..
Outlet Temperature (°C) ….. …..
Heat Capacity (Cp; J/Kg.K) ….. …..
Tube and Shell material ….. …..
Thermal conductivity of fluid materials (K; W/m.K) ….. …..

Table 6. Initial specifications of the tool.

Dimensions Standard Tube and Shell Design International Standard
Tube outer diameter (dot) …. inchi …. m
Tube inner diameter (dit) …. inchi …. m
BWG …. ….
Tube length (L) …. inchi …. m
Tube Layout …. ….
Pass Flow (Np) …. ….
Inner diameter (dis) …. inchi …. m
Outer diameter (dos) …. inchi …. m
Baffle …. inchi …. m
Tube pitch (Pt) …. inchi …. m
Clearance (C; Pt-dot) …. inchi …. m

The next step to determine the effectiveness of heat exchanger design is to carry out
calculation steps according to equations 1-27 as presented in Table 7. The equations in Table
7 have been organized sequentially to finally calculate the effectiveness of the heat
exchanger.

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Table 7. Heat exchanger parameter calculation.

Section Parameter Equation Eq.
Basic parameters The energy transferred Qc = Qh (1)
(Q) 𝑚𝑐 × 𝐶𝑝𝑐 × ∆𝑇𝑐 = 𝑚ℎ × 𝐶𝑝ℎ × ∆𝑇ℎ

Where,
Q = the energy transferred (Wt)
m = the mass flow rate of the fluid (Kg/s)
Cp = the specific heat
∆𝑇 = the fluid temperature difference (°C).

Logarithmic mean (𝑇ℎ𝑖 − 𝑇𝑐𝑖 ) − (𝑇ℎ𝑜 − 𝑇𝑐𝑜 ) (2)

𝐿𝑀𝑇𝐷 =
temperature (𝑇 − 𝑇𝑐𝑖 )
𝑙𝑛 ℎ𝑖
differenced (LMTD) (𝑇ℎ𝑜 − 𝑇𝑐𝑜 )

Where,
𝑇ℎ𝑖 = temperature of hot fluid inlet (°C)
𝑇ℎ𝑜 = temperature of hot fluid outlet (°C)
𝑇𝑐𝑖 = temperature of cold fluid inlet (°C)
𝑇𝑐𝑜 = temperature of cold fluid outlet (°C)
Correction factor 𝑇𝑐𝑜 − 𝑇𝑐𝑖 (3)
𝑃=
𝑇ℎ𝑖 − 𝑇𝑐𝑖 (4)
𝑇ℎ𝑖 − 𝑇ℎ𝑜 (5)
𝑅=
𝑇𝑐𝑜 − 𝑇𝑐𝑖
2 1−𝑃
√𝑅 + 1 ln[1 − 𝑃𝑅 ]
𝐹=
2 − 𝑃(𝑅 + 1 − √𝑅2 + 1
(𝑅 − 1) ln ( )
2 − 𝑃(𝑅 + 1 + √𝑅2 + 1

Thus, the value of the temperature change is

∆𝑡 = 𝐹 × 𝐿𝑀𝑇𝐷

Where, (6)
𝑇ℎ𝑖 = temperature of hot fluid inlet (°C)
𝑇ℎ𝑜 = temperature of hot fluid outlet (°C)
𝑇𝑐𝑖 = temperature of cold fluid inlet (°C)
𝑇𝑐𝑜 = temperature of cold fluid outlet (°C)
P = temperature efficiency of the heat
exchanger
R = ratio of the product of fluid flow in the
shell with specific heat to fluid flow in the tube
F = correction factor
∆𝑡 = temperature change
LMTD = Logarithmic mean temperature
differenced (calculated using Eq. 2)

Heat Transfer Field 𝑄 (7)

𝐴=
Area (A) 𝑈 × (𝐿𝑇𝑀𝐷 × 𝐹)

Where,
𝑄 = the energy transferred (W)
𝑈 = the overall heat transfer coefficient
LMTD = the logarithmic mean temperature
difference.

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Table 7 (Continue). Heat exchanger parameter calculation.

Section Parameter Equation Eq.
Number of Tubes (N) 𝐴 (8)
𝑁𝑡 =
𝜋 × 𝐷𝑜 × 𝑙

Where,
N = the number of tubes
A = the area of the heat transfer area (m2),
𝜋 = 3.14
𝐷𝑜 = tube diameter (m)
𝑙 = tube diameter (m).

Tube Surface Area of Total 𝑎′𝑡 (9)

𝑎𝑡 = 𝑁𝑡
Heat Transfer in Tube 𝑛
(at) Where,
𝑎𝑡 = the total heat transfer surface area in the
tube (m2)
𝑁𝑡 = the number of tubes
𝑎′𝑡 = the flow area in the tube (m2)
n = the number of passes.

And,
𝜋 (10)
𝑎′𝑡 = × (𝐷𝑖,𝑡 )2
4

Where,
𝐷𝑖,𝑡 = inner diameter of tube
Mass Flow Rate of Fluid 𝑚𝑡ℎ (11)
𝐺𝑡 =
in Tube (Gt) 𝑎𝑡
Where,
𝐺𝑡 = the mass flow of water in the tube
(kg/m2s)
𝑚ℎ = the mass flow rate of the hot fluid (Kg/s)
𝑎𝑡 = the flow area tube (m2
Reynold number (Re,t) 𝑑𝑖𝑡 × 𝐺𝑡 (12)
𝑅𝑒𝑡 =
𝜇
Where,
𝑅𝑒𝑡 = the Reynolds number in tube
𝑑𝑖𝑡 = the inner tube diameter (m),
𝐺𝑡 = the mass flow of water in the tube (m2)
𝜇 = the dynamic viscosity (Kg/ms).
Prandtl Number (Pr,t) 𝐶𝑝 × 𝜇 1 (13)
𝑃𝑟 = ( )2
𝐾
Where,
Pr = Prandtl number
Cp = the specific heat of the fluid in the tube
𝜇 = the dynamic viscosity of the fluid in the
tube (Kg/ms)
K = the thermal conductivity of the tube
material (W/m°C).
Nusselt number (Nu,t) 𝑁𝑢 = 0.023 × 𝑅𝑒𝑡 0.6 × 𝑃𝑟 0.33 (14)

Where,
𝑅𝑒𝑡 = the Reynolds number in tube
Pr = Prandtl number

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Table 7 (Continue). Heat exchanger parameter calculation.

Section Parameter Equation Eq.
Inside coefficient (hi) 𝑁𝑢 × 𝐾 (15)
ℎ𝑖 =
𝑑𝑖 , 𝑡
Where,
ℎ𝑖 = the convection heat transfer coefficient
in the tube (W/m2°C)
K = the thermal conductivity of the material
(W/m°C)
𝑑𝑖 , 𝑡 = the inner tube diameter (m).
Shell Shell flow area (𝐴𝑠 ) 𝑑𝑠 × 𝐶 × 𝐵 (16)
𝐴𝑠 =
𝑃𝑡
Where,
𝑑𝑠 = shell diameter (m)
C = clearance (𝑃𝑡 -𝑑𝑜 )
B = Baffle spacing
𝑃𝑡 = tube pitch (1.25× 𝑑𝑜 ) (m).
Mass Flow Rate of 𝑚𝑐 (17)
𝐺𝑠 =
Water in Shell (Gs) 𝐴𝑠
𝑚𝑐 = the mass flow rate of the cold fluid
(Kg/s)
𝐴𝑠 = the shell flow area (m2).
Equivalent diameter 2 (18)
𝑃𝑡 1 𝑑
(𝑑𝑒 ) 4( × 0.87 𝑃𝑡 − 𝜋 𝑜,𝑡 )
𝑑𝑒 = 2 2 4
1
𝜋𝑑
2 𝑜,𝑡
Where,
𝑃𝑡 = tube pitch (1.25× 𝑑𝑜 ) (m)
π = 3.14
𝑑𝑜,𝑡 = tube outside diameter (m).
Reynold number (Re,s) 𝑑𝑒 × 𝐺𝑠 (19)
𝑅𝑒𝑠 =
𝜇
𝑅𝑒𝑠 = Reynold number
𝑑𝑖𝑠 = inner tube diameter (m)
𝐺𝑠 = the mass flow of water in the shell
2
(Kg/m s)
𝜇 = the dynamic viscosity (Kg/ms).
Prandtl Number (Pr,s) 𝐶𝑝 × 𝜇 1 (20)
𝑃𝑟 = ( )2
𝐾
Prs = Prandtl number
Cp = specific heat capacity (kJ/kg°C)
𝜇 = dynamic fluid viscosity (Kg/ms)
K = thermal conductivity (W/m°C).

Nusselt number (Nu,s) 𝑁𝑢𝑠 = 0.023 × 𝑅𝑒𝑠 0.6 × 𝑃𝑟 0.33 (21)

𝑅𝑒𝑠 = Reynold number
Pr = Prandtl number
Convection Heat 𝑁𝑢 × 𝐾 (22)
ℎ𝑠 =
Transfer Coefficient 𝑑𝑒
(hs) ℎ𝑜 = convection heat transfer coefficient
(W/m2°C)
K = thermal conductivity (W/m°C)
𝑑𝑒 = shell diameter (m).

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Table 7 (Continue). Heat exchanger parameter calculation.

Section Parameter Equation Eq.
Heat rate Hot Fluid Rate (tube) 𝐶ℎ = 𝑚ℎ . 𝐶𝑝ℎ (23)
(𝐶ℎ ) Where,
𝐶ℎ = hot fluid rate (W/°C)
𝐶𝑝ℎ = specific heat capacity (J/Kg°C)
𝑚ℎ = mass flow rate of hot fluid (Kg/s).
Cold Fluid Rate (shell) 𝐶𝐶 = 𝑚𝑐 . 𝐶𝑝𝑐 (24)
(𝐶𝐶 ) 𝐶𝑐 = cold fluid rate (W/°C),
𝐶𝑝ℎ = specific heat capacity (J/Kg°C),
𝑚𝑐 = mass flow rate of cold fluid (Kg/s)
Maximum Heat 𝑄𝑚𝑎𝑥 = 𝐶ℎ (𝑇ℎ𝑖,𝑡 − 𝑇𝑐𝑖,𝑠 ) (25)
Transfer Rate 𝑄𝑚𝑎𝑥 = maximum heat transfer (W)
(Qmax) Cmin = minimum heat capacity rate (W/°C)
𝑇ℎ,𝑖 = temperature of hot fluid inlet (°C)
𝑇𝑐,𝑖 = temperature of cold fluid inlet (°C).
Effectiveness Heat Exchanger 𝑄𝑎𝑐𝑡 (26)
𝜀= × 100%
Effectiveness (𝜀) 𝑄𝑚𝑎𝑥
Where,
𝑄𝑎𝑐𝑡 = actual energy transferred (W)
𝑄𝑚𝑎𝑥 = maximum heat transfer (W)
Number of Transfer 𝑈×𝐴 (27)
𝑁𝑇𝑈 =
Unit (NTU) 𝐶𝑚𝑖𝑛
Where,
𝑈 = overall heat transfer coefficient
(W/m2°C
A = heat transfer area (m2)
𝐶𝑚𝑖𝑛 = minimum heat capacity rate (W/°C).

Tube Length Tube Length (Lt) 𝑁𝑇𝑈 × 𝐶𝑚𝑖𝑛 (28)

𝐿𝑡 =
𝑈 × 𝜋 × 𝑑𝑜,𝑡 × 𝑁𝑡 × 2
Where
Lt = tube length (m)
NTU = Number of transfer unit
𝐶𝑚𝑖𝑛 =Hot fluid rate (W/K)
𝑊
U = Overall heat transfer ( 2 𝐾)
𝑚
𝑑𝑜,𝑡 = Outer tube diameter (m)
Nt = number of tube

4. RESULTS AND DISCUSSION

Here, an example of a case of designing a shell and tube-type heat exchanger is given. The
input for thermal design calculations before modeling is shown in Table 8.
After the input thermal design data is determined, calculations are carried out according
to equations (1)-(27) as follows.
(i) Determining the energy transferred (Q)
Determination of heat transfer for hot fluids and cold fluids is calculated using Eq. (1). Here,
for example, the calculation of heat transfer determination is carried out to calculate heat
transfer for hot fluids. The variable value of 𝑚ℎ , 𝐶𝑝ℎ , 𝑎𝑛𝑑 ∆𝑇ℎ ware taken from Table 8.
Qc = Q h (1)
𝑄ℎ = 𝑚ℎ × 𝐶𝑝ℎ × ∆𝑇ℎ
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𝑘𝑔 2161𝐽
𝑄ℎ = 1.5 × × (380 − 340)𝐾 = 129,660𝐽/𝑠
𝑠 𝐾𝑔.𝐾

Table 8. Heat exchanger operating data.

Specification Input Fluid
Tube Side (Hot Fluid)
Fluid Material Oil
Mass flow rate (𝑚𝑡ℎ ; kg/s) 1.5
Dynamic viscosity (µ; Kg/m.s) 6.16 × 10−4
Inlet Temperature in tube side (𝑇ℎ𝑖 ; °C) 107
Inlet Temperature in tube side (𝑇ℎ𝑖 ; K) 380
Outlet Temperature in tube side (𝑇ℎ𝑜 ; °C) 27
Outlet Temperature in tube side (𝑇ℎ𝑜 ; K) 300
Heat Capacity (Cp; J/Kg.K) 2161
Thermal conductivity of fluid materials (K; W/m.K) 0.138
Tube and Shell material Copper
Shell Side (Cold Fluid)
Fluid Material Water
Mass flow rate (𝑚𝑠ℎ ; kg/s) 1.72
Dynamic viscosity (µ; Kg/m.s) 2.54 × 10−3
Inlet Temperature in tube side (𝑇𝑐𝑖 ; °C) 27
Inlet Temperature in tube side (𝑇𝑐𝑖 ; K) 300
Outlet Temperature in tube side (𝑇𝑐𝑜 ; °C) 45
Outlet Temperature in tube side (𝑇𝑐𝑜 ; K) 318
Heat Capacity (Cp; J/Kg.K) 4174
Thermal conductivity of fluid materials (K; W/m.K) 0.640
Tube and Shell material Aluminium

(ii) Determining LMTD value, using input values in Table 8.

The logarithmic average of the temperature difference between the hot and cold feeds at
each end of the heat exchanger is used to calculate the LMTD. The greater the LMTD, the
greater the heat transfer. LMTD was calculated using Eq. (2). Where, the value of 𝑇ℎ𝑖 ,
𝑇ℎ𝑜 , 𝑇𝑐𝑖 , 𝑎𝑛𝑑 𝑇𝑐𝑖 were taken from Table 8.
(𝑇ℎ𝑖 −𝑇𝑐𝑂 )−(𝑇ℎ𝑜 −𝑇𝑐𝑖 )
𝐿𝑀𝑇𝐷 = (𝑇 −𝑇𝑐𝑂 ) (2)
𝑙𝑛 ℎ𝑖
(𝑇ℎ𝑜 −𝑇𝑐𝑖 )
(380−318)−(340−300)
𝐿𝑀𝑇𝐷 = (380−318) = 50.22 𝐾
𝑙𝑛(340−300)

(iii) Determine correction factor

Correction factors are carried out by determining the values of several variables,
including:
• Determining the temperature efficiency of the heat exchanger (P) using Eq. (3).
Where, the value of 𝑇ℎ𝑖 , 𝑇ℎ𝑜 , 𝑇𝑐𝑖 , 𝑎𝑛𝑑 𝑇𝑐𝑖 were taken from Table 8.
𝑇 −𝑇
𝑃 = 𝑇𝑐𝑜 −𝑇𝑐𝑖 (3)
ℎ𝑖 𝑐𝑖
318−300
𝑃= 38−300
= 0.225
• Determining the ratio of the product of fluid flow in the shell with specific heat to
fluid flow in the tube (R) with specific heat using Eq. (4). Where, the value of 𝑇ℎ𝑖 ,
𝑇ℎ𝑜 , 𝑇𝑐𝑖 , 𝑎𝑛𝑑 𝑇𝑐𝑖 were taken from Table 8.
𝑇ℎ𝑖 −𝑇ℎ𝑜
𝑅= (4)
𝑇𝑐𝑜 −𝑇𝑐𝑖
380−340
𝑅 = 318−300 = 2.22
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• Determining correction factor (F) using Eq. (5). Where, P and R values were taken
using calculation from Eqs. (3) and (4), respectively.
1−𝑃
√𝑅 2 +1 ln[ ]
1−𝑃𝑅
𝐹= (5)
2−𝑃(𝑅+1− 𝑅2 +1
√
(𝑅−1) ln( )
2−𝑃(𝑅+1+√𝑅2 +1
1−0.225
√2.222 +1 ln[ ]
1−0.225×2.22
𝐹= = 0.94
2−0.225(2.22+1− 2.222 +1
√
(2.22−1) ln( )
2−0.225(2.22+1+√2.222 +1
Thus, the value of the temperature change is calculated using Eq. 6. Where, F and LMTD
values were taken using calculation from Eqs. (5) and (2), respectively.
∆𝑡 = 𝐹 × 𝐿𝑀𝑇𝐷 (6)
∆𝑡 = 0.94 × 50.22𝐾 = 47.2𝐾
After calculating the thermal design calculations, the next step is to carry out calculations
on the tube side. However, before carrying out calculations on the tube side, the design and
sizes of the tube must first be determined. The data determined are dimensions such as tube
length, inner and outer diameter of the tube, and number of flow paths in the tube concerning
standard specifications for tube dimensions such as the TEMA standard. In this study, tube
dimension specifications assumtions are summarized in Table 9. The tube side calculation was
carried out from point (iv) to point (xi).
Table 9. Tube dimensions.
Dimensions Standard Tube Design International Standard
Tube outer diameter (dot) ¾ inchi 0.01905 m
Tube inner diameter (dit) 0.652 0.01656 m
BWG 18 -
Tube length (L) 2.15 m
Tube Layout Triangular pitch Triangular pitch
Pass Flow (n) 2 2

(iv) Determining the heat transfer area

To calculate the heat transfer area using Eq. (7), several parameters must be used as
references in the calculation, including the energy balance value (Q) that calculated using
Eq. 1, the average actual temperature difference or LMTD (calculated using Eq. (6)), and
the overall heat transfer coefficient value (U). For the U value, first use the assumed heat
transfer coefficient. Based on the literature, the heat transfer coefficient value for hot oil
𝑊
and cold-water fluids is 800 𝑚2 (Kern, 1965).
𝑄
𝐴= (7)
𝑈×𝐿𝑇𝑀𝐷×𝐹
129,660 𝑊
𝐴= 𝑊 = 3,43 𝑚2
800 2 ×47.2 𝐾
𝑚
(v) Determining the number of tubes
Number of tube was calculated using Eq. (8). Where, heat transfer field area (A) was
calculated using Eq. (7). Meanwhile, 𝐷𝑜 and 𝑙 tube were taken from Table 9.
𝐴
𝑁𝑡 = (8)
𝜋×𝐷𝑜 ×𝑙
3.43 𝑚2
𝑁𝑡 = 3.14×1.905×10−2 𝑚×2.15 𝑚 = 26,7 = 26
(vi) Determining surface area of total heat transfer in tube
Surface area of total heat transfer in tube was calculated using Eqs. (9) and (10).

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To calculate this variable, it is necessary to have data on the inner diameter of the tube,
number of passes, and number of tubes taken from Table 9.
𝑎′
𝑎𝑡 = 𝑁𝑡 𝑛𝑡 (9)
To calculate 𝑎′𝑡 , Eq. (10( was substituted in Eq. (9) as below.
𝜋
× (𝐷𝑖,𝑡 )2
𝑎𝑡 = 𝑁𝑡 4
𝑛
3.14
× (0.01656𝑚)2
𝑎𝑡 = 26 4 = 2.798 × 10−3 𝑚2
2
(vii) Determining mass flow rate of fluid in tube
Mass flow rate of fluid in tube was calculated using Eq. (11). Where, the 𝑚𝑡ℎ and 𝑎𝑡 were
taken from Table 8 and Eqs. (9-10), respectively.
𝑚
𝐺𝑡 = 𝑎𝑡ℎ (11)
𝑡
𝑘𝑔
1.5 𝐾𝑔
𝑠
𝐺𝑡 = = 536.097 𝑠
2.798×10−3 𝑚2 𝑚
(viii) Determining the reynolds number on the tube side
Reynolds number on the tube side was calculated using Eq. (12). Where, the 𝜇 and 𝑑𝑖𝑡
were taken from Tables 8 and 9. Meanwhile, 𝐺𝑡 was calculated using Eq. (11).
𝑑𝑖𝑡 ×𝐺𝑡
𝑅𝑒𝑡 = (12)
𝜇
𝐾𝑔
0.01656 m×536.097 𝑠
𝑚
𝑅𝑒𝑡 = 𝐾𝑔 = 14411.95
6.16×10−4 𝑠
𝑚
(ix) Determining the prandtl number of the tube side
The Prandtl number is used to determine the temperature distribution in each flow tube.
Prandtl number of tube side was calculated using Eq. (13). Where, the value of 𝐶𝑝 , 𝜇, and
K were taken from Table 8.
𝐶𝑝 ×𝜇 1
𝑃𝑟 = ( )2 (13)
𝐾
𝐽 𝐾𝑔
2161 𝐾𝑔 . 𝐾 × 6.16 × 10−4 𝑚 . 𝑠 1
𝑃𝑟 = ( )2 = 9.646
𝑊
0.138 ( 𝑚 . 𝐾)
(x) Determining nusselt number on tube side
Nusselt number on the tube side was calculated using Eq. (14). Where, 𝑅𝑒𝑡 and 𝑃𝑟 from
tube side calaculation were calculated using Eqs. (12) and (13), respectively.
𝑁𝑢 = 0.023 × 𝑅𝑒𝑡 0.6 × 𝑃𝑟 0.33 (14)
0.6 0.33
𝑁𝑢 = 0.023 × 14411.95 × 9.646 = 15.196
(xi) Determining heat transfer on the tube side
Heat transfer on the tube side was calculated using Eq. (15). Where, the 𝑁𝑢, K, and 𝑑𝑖 , 𝑡
were obtained from Eq. (13), Tables 8 and 9, respectively.
𝑁𝑢×𝐾
ℎ𝑖 = 𝑑 ,𝑡 (15)
𝑖
𝑊
15.196×0.138 ( .𝐾) 𝑊
𝑚
ℎ𝑖 = = 126.63 𝑚2 𝐾
0.01656 𝑚

The next stage is the calculation of the shell side. Before calculating the shell side, some
initial dimensional specifications can be used to simplify the calculations determined from the
standards referenced from the TEMA standard. The shell side dimension values are shown in
Table 10.

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Table 10. Shell dimensions.

Dimension Standard Shell Design International Standard
Inner diameter (dis) 12 inchi 0.3048 m
Outer diameter (dos) 12.787 inchi 0.3248 m
Baffle 0.315 inchi 0.008 m
Tube pitch (Pt) 15/16 inchi 0.0238 m
Clearance (C; Pt-dot) 0.187 inchi 0.475

(xii) Determining the flow area in the shell

Flow area in the shell was calculated using Eq. 16. Where, 𝑑𝑠 and 𝐵 were obtained from
Table 10. Where, C and Pt values were calculated using embedded equation in Eq. (16).
𝑑 ×𝐶×𝐵
𝐴𝑠 = 𝑠 𝑃 (16)
𝑡
30.48×10−2 𝑚×0.475×10−2 𝑚×0.06096 𝑚
𝐴𝑠 = = 3.7088 × 10−3 𝑚2
0.0238
(xiii) Determining mass flow velocity
Mass flow velocity was determined using Eq. (17). Where, 𝑚𝑐 was obtained from Table
8 and 𝐴𝑠 was calculated first using the Eq. (16).
𝑚
𝐺𝑠 = 𝐴 𝑐 (17)
𝑠
1.72 𝐾𝑔
𝐺𝑠 = 3.7088×10−3 = 463.76 𝑚2 . 𝑠
(xiv) Determining the equivalent diameter of shell
Equivalent diameter of shell was calculated using Eq. (18). Where, the 𝑑𝑜,𝑡 and Pt were
obtained from Tables 9 and 10, respectively.
2
𝑃𝑡 1 𝑑𝑜,𝑡
4( ×0.87 𝑃𝑡− 𝜋 )
2 2 4
𝑑𝑒 = 1 (18)
𝜋𝑑𝑜,𝑡
2

0.0238 1 0.019052
4( ×0.87× 0.0238− ×3.14× )
2 2 4
𝑑𝑒 = 1 = 0.0139 𝑚
×3.14×0.01905
2
(xv) Determining the reynolds number on the shell side
Reynolds number on the shell side was calculated using Eq. (19). Where, μ was obtained
from Table 8 and Gs was calculated first using Eq. (17).
𝑑 ×𝐺𝑠
𝑅𝑒𝑠 = 𝑒 𝜇 (19)
𝐾𝑔
0.0139 𝑚×463.76 2 .𝑠
𝑚
𝑅𝑒𝑠 = 𝐾𝑔 = 2537.89
2.54×10−3 .𝑠
𝑚
(xvi) Determining the prandtl number coefficient on the shell side
Prandtl number on the shell side was calculated using Eq. (20). Where, the value of 𝐶𝑝 ,
𝜇, and K were obtained from Table 8.
𝐶𝑝 ×𝜇 1
𝑃𝑟 = ( )2 (20)
𝐾
𝐽 𝐾𝑔
4174 .𝐾×2.54×10−3 .𝑠 1
𝐾𝑔 𝑚
𝑃𝑟 = ( 𝑊 )2 = 4.070
0.640 .𝐾
𝑚
(xvii) Determining nusselt number on the shell side
Nusselt number on the shell side was calculated using Eq. (21). Where, 𝑅𝑒𝑡 and 𝑃𝑟 from
shell side calaculation were calculated using Eqs. (19) and (20), respectively.
𝑁𝑢 = 0.023 × 𝑅𝑒𝑡 0.6 × 𝑃𝑟 0.33 (21)

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𝑁𝑢 = 0.023 × 2537.890.6 × 4.0700.33 = 4.032

(xviii) Determining heat transfer on the shell side
Heat transfer on the shell side was obtained from Eq. (22). The 𝑑𝑒 and Nu values were
calculated first using Eqs. (18) and (19). Meanwhile, 𝐾 was obtained from Table 8.
𝑁𝑢×𝐾
ℎ𝑠 = 𝑑 (22)
𝑒
𝑊
4.032×0.640 .𝐾 𝑊
𝑚
ℎ𝑠 = = 185.646 𝑚2 𝐾
0.0139 𝑚
(xix) Determining the hot fluid rate on tube side
Hot fluid rate for tube side was calculated using Eq. (23). Where, the 𝑚ℎ and 𝐶𝑝ℎ for tube
side were obtained from Tabel 8.
𝐶ℎ = 𝑚ℎ . 𝐶𝑝ℎ (23)
𝑘𝑔 2161𝐽
𝐶ℎ = 1.5 . . 𝐾 = 3241 𝑊/𝐾
𝑠 𝐾𝑔
(xx) Determining the cold fluid rate on the shell side
Hot fluid rate for tube side was calculated using Eq. (24). Where, the 𝑚ℎ and 𝐶𝑝ℎ for shell
side were obtained from Tabel 8.
𝐶𝐶 = 𝑚𝑐 . 𝐶𝑝𝑐 (24)
𝐾𝑔 𝐽
𝐶𝐶 = 1.72 . 4174 𝑘𝑔 . 𝐾 = 7179.28 𝑊/𝐾
𝑠
(xxi) Determining the maximum heat transfer rate (Qmax)
Maximum heat transfer rate was calculated using Eq. (25). Where, 𝑇ℎ𝑖,𝑡 and 𝑇𝑐𝑖,𝑠 values
were obtained from Table 8. Meanwhile, 𝐶ℎ was calculated using Eq. (23).
𝑄𝑚𝑎𝑥 = 𝐶ℎ (𝑇ℎ𝑖,𝑡 − 𝑇𝑐𝑖,𝑠 ) (25)
𝑊
𝑄𝑚𝑎𝑥 = 3241 𝐾(380−300) = 259,280 𝑊
(xxii) Determining the value of heat exchanger effectiveness (ε)
Heat exchanger apparatus effectiveness was calculated using Eq. (26). Where, 𝑄𝑎𝑐𝑡 dan
𝑄𝑚𝑎𝑥 values were calculated using Eq. (1).
𝑄𝑎𝑐𝑡
𝜀 = 𝑄𝑚𝑎𝑥 × 100% (26)
129,660 𝑊
𝜀= × 100% = 50,01%
259,280
(xxiii) Determining NTU value
The NTU value was calculated using Eq. (27). Where, U value was obtained from
literature. Meanwhile, A and 𝐶𝑚𝑖𝑛 were calculated using Eqs. (7) and (23).
𝑈×𝐴
𝑁𝑇𝑈 = 𝐶 (27)
𝑚𝑖𝑛
800×3.43
𝑁𝑇𝑈 = = 0.85
3241
(xxiv) Determining tube length
Tube length was calculated using Eq. (28). Where, U value was obtained from literature.
The 𝑑𝑜,𝑡 value obtained from Table 8. And also, 𝑁𝑡 and 𝐶𝑚𝑖𝑛 values were calculated
using Eqs. (8) and (23).
𝑁𝑇𝑈×𝐶𝑚𝑖𝑛
𝐿𝑡 = 𝑈×𝜋×𝑑𝑜, ×𝑁𝑡×2 (28)
𝑡
0.85×3241W/K
𝐿𝑡 = 𝑊 = 1.107 𝑚
800 2 𝐾×3.14×0.01905 𝑚×26×2
𝑚
In this study, the fluid used in the heat exchanger is water with a temperature of 27°C to
reduce the oil temperature to 107°C so that the calculation result of the heat transfer
𝑊
coefficient that occurs on the tube side is 126.63 𝑚2 𝐾 with a Reynolds value of 14409.11. The

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Reynolds value for flow on the tube side shows a value greater than 2300 which indicates that
the flow on the tube side is turbulent. Then, the water flowing inside the shell has a heat
𝑊
transfer coefficient of 185.646 𝑚2 𝐾 with a Reynolds value greater than 2300, namely 2537.89,
which indicates that the fluid flow on the shell side is also turbulent. The heat transfer value
of oil is quite large because high oil temperatures cause large heat transfer. Meanwhile, the
maximum heat transfer rate value from the design is 259,280 W. Meanwhile, the actual heat
transfer rate value from the design is 129,660 W, thus the effectiveness of the apparatus
obtained based on calculations of the effectiveness of the heat exchanger and NTU is 50.01%
and 0.85 respectively.
5. CONCLUSION
Calculation results in the case example of a shell and tube type heat exchanger design using
copper tubes and aluminum shell for a triangular pitch shape, with a capacity of 129,660 W,
showed that the number of tubes was 26 and tube length was 1.107 m with the effectiveness
of the designed device being 50.01%.
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