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Process Engineering Calculations (Part 1)-115

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Process Engineering Calculations (Part 1)-115

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Varatha
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3.

Shell &Tube Preliminary sizing

The preliminary sizing stage focuses on establishing initial estimates and configurations before
proceeding to detailed design calculations. During preliminary sizing, several key parameters need to be
considered. These include the heat duty or the amount of heat to be transferred, the temperature
difference between the two fluids, the flow rates of the fluids, and the physical properties of the fluids,
such as density and specific heat capacity.

The goal of preliminary sizing is to determine the approximate size and layout of the shell and tube heat
exchanger, including the number of tubes, tube diameter, tube length, and shell diameter. This is
achieved by employing empirical correlations, design guidelines, and engineering experience to estimate
the required surface area for heat transfer.

Additionally, factors like pressure drop, fouling, material selection, and construction constraints are also
taken into account during the preliminary sizing phase.

The results obtained from preliminary sizing serve as a foundation for detailed design and analysis,
where more precise calculations and considerations are made to optimize the heat exchanger's
performance, efficiency, and cost.

In preliminary sizing of shell and tube heat exchangers, there are certain aspects and considerations that
are generally not accounted for. These may include:

1. Vibration Analysis
2. Detailed Pressure Drop Calculations.
3. Thermal Stress Analysis

While preliminary sizing may not incorporate these detailed analyses and considerations, it is important
to note that they are crucial in the subsequent stages of design and engineering to ensure the heat
exchanger's reliability, performance, and longevity.

3.1 Bell-Delaware Preliminary Design: Polley et al.[4][6]


G. T. Polley developed rapid design algorithms for the design of both shell and tube heat exchangers and
compact heat exchangers. These algorithms are based on the full use of allowable pressure drops of
both of the streams being contacted as the design objective and a set of simultaneous equations. In the
case of a shell and tube heat exchanger, they assumed that the best shell-side performance can be
gained by making baffle window flow velocities and bundle cross-flow velocities equal. This in turn
results in a “similarity concept” that can be used for the derivation of simple performance equations
from shell-side models. They determined the exchanger geometry
from values as follows:
1. The tube-side film heat coefficient can be directly related to the tube-side velocity and thus to
the exchanger tube count.
2. From the tube count and total surface area, the tube length can be determined.
3. The shell diameter can be calculated from the tube count.
4. Finally, with the shell diameter known, and the shell-side velocity being determined from the
shell-side film coefficient, the number of baffles and baffle spacing required within the

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