UNIVERSITY OF CROSS RIVER STATE

FACULTY OF ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

ENG 5110: SEMINAR

DEVELOPMENT AND ANALYSIS OF A SHELL AND TUBE HEAT

EXCHANGER BASED ON TUBULAR EXCHANGER
MANUFACTURERS’ ASSOCIATION (TEMA) STANDARDS

MARCH, 2025
IN PARTIAL FULFILMENT OF THE REQUIREMENT FOR THE AWARD OF
A BACHELOR DEGREE OF ENGINEERING (B.ENG) IN MECHANICAL
ENGINEERING

WRITTEN BY

AGBELUYI OLUWADUNSIN ABRAHAM - 19/MEN/004

OKO SUNDAY WONAH - 19/MEN/124
CHUKWUDI EBUBENNA - 19/MEN/034
AKWA PROMISE ABANI - 19/MEN/014
AHUNANYA COUNCELLOR CHIDEBREM - 19/MEN/169
ESSIEN EMMANUEL GREGORY - 19/MEN/064
NWOSU CHIBUIKE CHRISTOPHER - 19/MEN/109
INAH UWOM IGNATIUS - 19/MEN/079
TERUNGWA DANIEL - 19/MEN/154

COURS TITLE:
SEMINAR

COURSE CODE:
MEC 5110

SEMINAR SUPERVISOR:
ENGR. DR. OKU EKPEYONG NYONG

MARCH, 2O24
 CERTIFICATION

This is to certify that this proposed project titled “ DEVELOPMENT AND ANALYSIS
OF A SHELL AND TUBE HEAT EXCHANGER BASED ON TUBULAR
EXCHANGER MANUFACTURERS’ ASSOCIATION
(TEMA) STANDARDS” written by AGBELUYI OLUWADUNSIN ABRAHAM
(19/MEN/004), OKO SUNDAY WONAH (19/MEN/124), CHUKWUDIEBUBENNA
(19/MEN/034), AKWA PROMISE ABANI (19/MEN/014), AHUNANYA COUNCELLOR
CHIDEBREM (19/MEN/169), ESSIEN EMMANUEL GREGORY (19/MEN/064), NWOSU
CHIBUIKE CHRISTOPHER (19/MEN/109), INAH UWOM IGNATIUS (19/MEN/079),
TERUNGWA DANIEL (19/MEN/154) has been found acceptable for the seminar
presentation and to be presented as a final year project proposal in the Department of
Mechanical Engineering.

Engr. Dr. Oku Ekpeyong Nyong SIGN: ________________ DATE: ______________

(Supervisor)

Engr. Dr. Diwa James Enyia SIGN: ________________ DATE: ______________

(Head of Department)

Examiner: SIGN: ________________ DATE: ______________

 DEDICATION

This work is dedicated to God Almighty for His unfailing love and grace to make it this far in
our academic pursuit and also, to our parents and friends for their continual support. And to
my prestigious school, the University of Cross River State for her outstanding academic
standards and excellence in Nigeria.
 ACKNOWLEDGEMENT

We would like to convey our sincere gratitude to our seminar supervisor Dr. Oku Ekpeyong
Nyong, for his invaluable suggestions, constructive criticism, and guidance for carrying out
this project. We hereby express my heartfelt thanks.
 TABLE OFCONTENT
Dedication
Acknowledgement
CHAPTERONE: INTRODUCTION
1.1 Overview
1.2 Aims and Objective
1.3 Statement of problem
1.4 Knowledge gap

CHAPTERTWO:LITERATUREREVIEW
2.1 Heat transfer media and process
2.2 Applications
2.3 Development of STHE based on TEMA standards
2.4 Analysis of STHE
2.5 Technological advancements

CHAPTERTHREE:METHODOLOGY
3.1 Heat transfer analysis/thermal design
3.2 Fluid flow analysis
3.3 Geometry design standards (TEMA)
3.4 Material selection
3.5 Design criteria
3.6 Design Parameters

References
 CHAPTER ONE

INTRODUCTION
1.1 OVERVIEW
Shell and Tube Heat Exchangers are a type of heat exchanger that consists of a shell with a
tube bundle. They have widespread use across many industries, including chemical
processing, oil refining, power generation, and HVAC, due to their efficiency, reliability, and
cost-effectiveness.
The Shell and Tube Heat Exchanger is the conventional illustration of a recuperative heat
exchanger, where the heat of a fluid is transferred to another fluid through a solid wall. The
shell side fluid flows over the outside of the tubes, and the tube side fluid flows through the
tubes. The construction offers a large heat transfer area, and therefore it is an effective and
efficient heat transfer method.
Shell and Tube Heat Exchangers have been utilized for more than a century and have evolved
substantially in terms of design over the years. Today's Shell and Tube Heat Exchangers are
developed to maximize heat transfer, reduce pressure drop, and limit fouling. They are also
developed to be in compliance with certain industry standards and codes, such as those
specified by the American Society of Mechanical Engineers (ASME) and the Tubular
Exchanger Manufacturers Association (TEMA).
Despite their widespread use, Shell and Tube Heat Exchangers still pose stringent design and
operational problems. For example, the optimal design of heat exchangers to achieve
maximum heat transfer with minimum pressure drop and fouling is a daunting task.
Additionally, ensuring the reliability and integrity of the heat exchanger during its operating
life is of utmost concern to prevent costly downtime and maintenance.

Fig1.1.Shellandtubeheat exchanger
1.2 AIMS AND OBJECTIVES
The primary aim of this work is to conduct in-depth research on existing shell and tube heat
exchanger models in an attempt to select the most suitable model for construction, and
operation. This entails testing the performance of the selected heat exchanger through
intensive testing to ensure that it is up to the standards of the Tubular Exchanger
Manufacturers Association (TEMA). Lastly, the project seeks to validate the efficacy and
efficiency of the shell and tube heat exchanger and also address the problem of non-
availability of a laboratory shell and tube heat exchanger in the University of Cross River
State that will also close the knowledge gap in the university.
The objectives of this project are as follows:
1. Baffle Design: Study the influence of baffle design (e.g., segmental, helical, or grid-
type) on shell-side flow and heat transfer.
2. Thermal Efficiency: Study the thermal efficiency of Shell and Tube Heat Exchangers
at various operating conditions.
3. Temperature Distribution: Study the temperature distribution within the heat
exchanger and its impact on performance.
4. Fabrication/Construction: Study the fabrication process (e.g., welding, brazing, or
expansion) used for Shell and Tube Heat Exchangers and also design one based on
TEMA specifications.
5. Computational Fluid Dynamics (CFD): Use of CFD to simulate the thermal as well as
hydraulic performance of Shell and Tube Heat Exchangers.
6. Data collection and analysis: For carrying out rigorous test of which data will be
accumulated and performance verified under various operation conditions.
7. Conclusion and Recommendations: Summarize conclusions based on the results of
the tests and provide recommendations for additional study or improvement wherever
necessary.

1.3 STATEMENT OF THE PROBLEM

The problem with designing and producing a shell and tube heat exchanger is finding the
balance between the pressure drop and heat transfer coefficient and determining the precise
size of the heat exchanger. The capacity of the heat exchanger must be explicitly designed for
particular requirements, i.e., temperature profile and heat transfer rate, and must account for
others such as flow rates, fluid properties, fouling, and corrosion. Budget concerns and issues
of acquiring materials to be utilized for construction are also present.

1.4 KNOWLEDGE GAP

With all the various modifications and enhancements that can be made to the shell and tube
heat exchanger, it goes even further to demonstrate that the U-tube shell and tube heat
exchanger cannot be replaced in today's world. So, all the students of Mechanical
Engineering should be familiar with heat exchangers. What better way to familiarize them
than a practical demonstration of the working principle of a shell and tube heat exchanger.
This way the students will understand and enjoy the fact that a STHE works. Such a machine
is expensive to import, and therefore the aim of this project to provide one locally made and
affordable to the department of Mechanical Engineering at the University of Cross River
State.
 CHAPTER TWO

LITERATURE REVIEW

The Shell and Tube Heat Exchangers (STHE) are widely applied in most industries for
heating and cooling processes due to their efficiency and reliability. The literature review
aims to provide an overview of Shell and Tube Heat Exchangers (STHE) with their
construction, design, and performance.

2.1 HEAT TRANSFER MEDIA AND PROCESS

Heat transfer in STHE is across two fluids, one inside the tubes and the other outside the
tubes. Heat is transferred by conduction and convection, with conduction through the solid
pipe wall and convection by means of heat transfer across flowing streams.

2.2 APPLICATIONS
STHE are used in various industries, such as:
 Space heating: Warming buildings and domestic houses.
 Refrigeration: Cooling equipment for food storage and transport.
 Air conditioning: Vehicle and building cooling systems.
 Chemical plants: Heat transfer applications in chemical process.
 Power plants: Applications of heat transfer in power plant.
 HVAC systems: Heating, ventilation, and air conditioning systems.

2.3 TEMA STANDARD-BASED DEVELOPMENT OF SHELL AND TUBE HEAT

EXCHANGERS:
Kakac et al. (2012) provided an in-depth presentation of the construction and design
of shell and tube heat exchangers based on TEMA specifications. The authors discussed
various forms of shell and tube heat exchangers, including fixed tube sheet, floating head,
and U-tube heat exchangers.
The authors have also given a detailed analysis of thermal design of shell and tube
heat exchangers, for example, calculation of heat transfer coefficients, pressure drop, and
other performance parameters. The authors described various correlations and methods for
the calculation of heat transfer coefficients and pressure drop in shell and tube heat
exchangers.
The review also covered the manufacturing and construction aspects of shell and tube
heat exchangers, such as material selection, fabrication techniques, and testing methods. The
authors described the importance of following TEMA standards and other industry standards
in the design, construction, and testing of shell and tube heat exchangers.
 Hewitt et al. (2015) reported a comprehensive study of the thermal-hydraulic
performance of shell and tube heat exchangers based on TEMA standards. The authors
discussed the various parameters that affect the thermal-hydraulic performance of shell and
tube heat exchangers, including the tube diameter, tube length, shell diameter, and baffle type.
The authors proposed a numerical model to model the thermal-hydraulic performance
of tube and shell heat exchangers. The model was developed from the mass conservation
equations, momentum, and energy and took into account the contributions of turbulence,
conduction, and radiation to the heat transfer process.
The authors also validated the numerical model by comparing the model's predictions
with experimental data from the literature. The findings showed that the numerical model
could effectively predict the thermal-hydraulic performance of shell and tube heat
exchangers, including the heat transfer coefficient, pressure drop, and fluid flow rates.
Shah et al. (2017) presented a numerical analysis of the thermal-hydraulic
characteristics of shell and tube heat exchangers as per TEMA requirements. The authors
discussed various types of shell and tube heat exchangers, i.e., fixed tube sheet, floating head,
and U-tube heat exchangers.
Authors provided a numerical model for modeling the thermal-hydraulic performance
of tube and shell heat exchangers. The model was developed on the basis of the conservation
equation for mass, momentum, and energy, and also took into consideration the impact of
turbulence, conduction, and radiation upon the heat exchange process.
The authors investigated the effect of a number of design parameters on shell and tube
heat exchanger thermal-hydraulic performance, including tube diameter, tube length, shell
diameter, and baffle configuration. The results showed that the numerical model accurately
predicted shell and tube heat exchanger thermal-hydraulic performance, including the heat
transfer coefficient, pressure drop, and fluid flow rates.

2.4 ANALYSIS OF SHELL AND TUBE HEAT EXCHANGER

Gupta et al. (2019) performed an experimental investigation of the thermal-hydraulic
performance of shell and tube heat exchangers as per TEMA standards. The authors designed
and fabricated a shell and tube heat exchanger with a fixed tube sheet and segmental baffle
arrangement.
The authors conducted experiments to investigate the effects of various operating parameters
on the thermal-hydraulic behavior of the heat exchanger, including the flow rates of the hot
and cold fluids, hot and cold fluid inlet temperatures, and heat exchanger pressure drop.
The results showed that the heat transfer coefficient increased with increased flow rates of the
hot and cold fluids, and decreased inlet temperatures of the hot and cold fluids. The authors
also proved that the pressure drop in the heat exchanger increased with increased flow rates
of the hot and cold fluids.
The authors have compared their experimental results with the predictions of a number of
correlations and models from the literature and have found good agreement between
experiment and prediction.
 Kumar et al. (2020) proposed a numerical analysis of the thermal-hydraulic
performance of shell and tube heat exchangers according to the requirements of TEMA. The
authors developed a computational fluid dynamics (CFD) model of the flow simulation and
heat transfer in a fixed tube sheet and segmental baffle arrangement in a shell and tube heat
exchanger.
The authors investigated the effect of various design parameters on the thermal-hydraulic
performance of the heat exchanger, which were tube diameter, tube length, shell diameter,
and baffle spacing. The results showed that the heat transfer coefficient was rising with the
decrease in tube diameter and increase in tube length, and with the increase in shell diameter
and decrease in baffle spacing.
The authors further confirmed that the pressure drop through the heat exchanger increased
with decreasing tube diameter and increasing tube length, and increasing shell diameter and
decreasing baffle spacing. The authors compared the numerical solutions they achieved with
predictions of various available correlations and models in the literature and reported good
correlation between the numerical values and the predicted values.
Li et al. (2020) presented a review of current advancements in design and analysis of
shell and tube heat exchangers as per TEMA standards. The authors presented the various
categories of shell and tube heat exchangers, i.e., fixed tube sheet, floating head, and U-tube
heat exchangers.
The authors discussed the various correlations and models presented in literature for the
estimation of thermal-hydraulic performance of shell and tube heat exchangers, including the
heat transfer coefficient, pressure drop, and fluid flow rates. The authors also discussed the
various numerical methods available for the simulation of flow and heat transfer in shell and
tube heat exchangers, including CFD and finite element methods.
The authors acknowledged the various limitations and challenges associated with analysis
and design of shell and tube heat exchangers, including the complexity of the heat and flow
phenomena, lack of correct design parameters, and higher accuracy and reliability in models
and correlations.

2.5 TECHNOLOGICAL ADVANCEMENTS

There has been a development of U-tube heat exchanger design as a result of recent
technological advancements and material sciences.
 Computational Fluid Dynamics (CFD): The use of CFD in the design process allows
better prediction of flow patterns and heat transfer behavior so that it is possible to
optimize geometries (Patel et al., 2020).
 Microchannel Heat Exchangers: Design of microchannel heat exchangers, which can
be integrated into U-tube designs, has been promising towards enhanced heat transfer
performance with less material usage (Khan et al., 2021).
 Additive Manufacturing: New manufacturing techniques, such as 3D printing, have
opened up possibilities for more complex and efficient U-tube heat exchanger designs
(Zhou et al., 2022)
 CHAPTERTHREE

METHODOLOGY

The design of a typical shell and tube heat exchanger considers various methods and factors
to ensure optimal performance, efficiency, and suitability for the intended application. The
following are aspects we considered before designing a shell and tube heat exchanger.
3.1 HEAT TRANSFER ANALYSIS/ THERMAL DESIGN
In this section the kern’s equation is widely recognized as the approach used for the
preliminary thermal design of a shell and tube heat exchanger which is outlined below:

Shell-Side Thermal and Hydraulic Equations: The flow velocity in the shell-side (vs)
depends on the flow area between adjacent baffles (Ar):

where 𝑚𝑠 ̂ and 𝜌𝑠 ̂ are the shell-side stream flow rate and density, respectively.
(1)

This flow area corresponds to the area delimited by the shell diameter (Ds) and baffle

A𝑟= 𝐷𝑠𝐹𝐴𝑅𝑙𝑏𝑐
spacing (lbc) multiplied by the free area ratio (FAR):
(2)

The free area ratio between baffles is given by:

(3)

where ltpis the tube pitch, dte is the outer tube diameter, and rp is the ratio between the tube
pitch and the tube diameter.

The Reynolds number associated to the shell-side velocity (Res) is given by:

Where Deq is the equivalent diameter, and 𝜇𝑠 ̂ is the shell-side stream viscosity.
(4)

The equivalent diameter present in the Reynolds number depends on the tube layout. For a
square and triangular pattern, respectively:

(5)
(6)

The Nusselt number for the shell-side flow (Nus) is a function of the Reynolds and Prandtl
Numbers( Res∧Prs ) :
(7)

Where the dimensionless groups Nusselt and Prandtl are defined by:

(8)

(9)
where hs is the shell-side convective heat transfer coefficient, 𝑘𝑠 ̂ is the thermal conductivity,
and c𝑝𝑠 ̂ is the heat capacity.
The head loss in the shell-side flow, dismissing nozzle pressure drop, can be
calculated by:
( 10)

Where ∆ Ps is the shell-side stream pressure drop, fs is the shell-side friction factor and Nb is
the number of baffles.
The expression for evaluation of the shell-side friction factor is:

f𝑠= 1.728 Res−0.188 (11)

The number of baffles is directly related to the baffle spacing and tube length:

(12)

Tube-Side Thermal and Hydraulic Equations: The flow velocity in the tube-side (vt)
depends on the number of tubes per pass (Ntp) and the inner tube diameter (dti):
(13)

Where 𝑚𝑡 ̂ and 𝜌𝑡 ̂ are the tube-side stream flow rate and density, respectively.
The equation of the Reynolds number related to the tube-side flow rate (Ret) is:
(14)

Where dti is the inner tube diameter, and 𝜇𝑡 ̂ is the tube-side stream viscosity.
The Prandtl number for the tube-side stream (𝑃𝑟𝑡 ̂) is:
(15)

Where 𝑘𝑡 ̂ and 𝐶𝑝𝑡 ̂ are the tube-side stream thermal conductivity, and heat capacity,
respectively.

The Reynolds and Prandtl numbers allow the evaluation of the tube-side Nusselt number
(Nut) through the Dittus-Boelter correlation:
(16)

Where the parameter n is equal to 0.4 for heating services and 0.3 for cooling services.
The definition of the Nusselt number is:
(17)

Where ht is the tube-side convective heat transfer coefficient.

The head loss in the tube-side flow, dismissing nozzle pressure drop and the variation
of the physical properties, is given by:
(18)

Where ∆ Pt is the tube-side stream pressure drop, and ft is the tube-side friction factor. The
first term in the RHS corresponds to the head loss in the tube bundle and the second
corresponds to the head loss in the front and rear headers. The parameter K is equal to 0.9 for
one tube pass and 1.6 for two or more tube passes.
The expression for the Darcy friction factor for turbulent flow can be expressed by:
(19)

Overall Heat Transfer Coefficient: The expression of the overall heat transfer coefficient
(U) is:
(20)

Where the 𝑘𝑡𝑢𝑏𝑒 ̂ is the thermal conductivity of the tube wall, and 𝑅𝑓𝑡 ̂ and 𝑅𝑓𝑠 ̂ are the
fouling factors of the tube-side and shell-side streams, respectively.
Heat Transfer Rate Equation: According to the LMTD method, the heat transfer rate
expression is:
(21)

Where 𝑄̂ is the heat load, Areq is the required area, 𝛥𝑇𝑙𝑚 ̂ is logarithmic mean temperature
difference (LMTD), and F is the LMTD correction factor.
The LMTD is given by:

(22)

The LMTD correction factor is equal to 1, for one tube pass and is equal to the
following expression for an even number of tube passes:

(23)

Where:
(24)

(25)

A= 𝑁𝑡𝑡𝜋𝑑𝑡𝑒𝐿
The heat transfer area (A) is represented by the sum of the area of the surface of each tube:
(26)

Where Ntt is the total number of tubes.

In order to guarantee an adequate design margin, the exchanger area must be higher
than the required area according to a certain “excess area” (𝐴𝑒𝑥𝑐 ̂), specified by the design
engineer:
(27)
Therefore, the heat transfer rate equation is reorganized using actual heat exchanger area:

(28)

Bounds on Pressure Drops, Flow Velocities and Reynolds Numbers: During the process
design,allowable pressure drops are imposed according to the pressure profile of the unit.
These parameters are related to a trade-off between capital and operating costs. The
corresponding constraints are:
(29)
(30)

Additionally, lower and upper bounds on flow velocities are also established:

(31)
(32)
(33)
(34)

Flow velocity lower bounds seek to avoid fouling susceptible conditions.

Corresponding upper bounds aims to avoid erosional conditions that could damage the heat
exchanger during its operational life.
According to the application range of the convective heat transfer coefficient
correlations, there are bounds on the Reynolds numbers in the shell-side and tube-side:

(35)
(36)

Geometric Constraints: The baffle spacing must be limited between 20% and 100% of the
shell diameter
(37)
(38)

The ratio between the tube length and shell diameter must be between 3 and 15:
(39)

(40)
3.2 GEOMETRY DESIGN STANDARDS (TEMA)

 Tube diameter layout and pitch

Tubes may be between 12.7 mm (0.5 in) and 50.8 mm (2 in), but 19.05 mm(0.75 in) and 25.4
mm (1 in) are the standard sizes. The tubes are arranged intriangular or square arrangements
in the tube sheets. See Figure 2.2.

Fig 2.2. Tube Layouts

The square arrangements are required where it is necessary to reach the tube surface for
mechanical cleaning. The triangular arrangement can hold more tubes in a given area. The
tube pitch is the smallest center-to-center tube distance. The tube spacing is represented by
the ratio of tube pitch/tube diameter, which is generally 1.25 or 1.33. Since the square tube
pattern is used for cleaning purposes, there should be a gap of not less than 6.35 mm (0.25 in)
between the tubes. Baf e types Baf es are installed on the shell side to achieve a higher heat-
transfer rate by creating more turbulence and to allow the tubes so as to reduce the risk of
damage due to vibration. There are a few different baffle types, that support the tubes and
improve ow across the tubes. Figure 2.3 shows the following baffle configurations:
 Single Segmental (this is the most common),
 Double Segmental (this is used to obtain a lower shell side pressure drop and
velocity).
 Disc and Doughnut.
 Fig. 2.3

The gap between the center of two baffles is known as the baffle-pitch and this can be
adjusted to alter the cross flow velocity. In practice, baffle pitch is not more than a spacing
equal to the inside shell diameter or less than a spacing equal to one-fifth the diameter or 50.8
mm (2 in) whichever is greater. In order to allow the fluid to flow backward and forward
between the tubes a part of the baffle is taken out. The height of the part is referred to as the
baffle-cut and is defined as a percentage of the shell diameter, say 25 per cent baffle-cut. The
size of the baffle-cut (or baffle window) has to be considered along with the baffle pitch. It is
usual to size the baffle-cut and baffle pitch to nearly equalize the velocities across the
window and in cross flow, respectively. There are two main classes of baffles which create
longitudinal flow:
 Orifice Baffle,
 Rod Baffle.

In these types of baffles, the turbulence is created as the flow passes over the baffle.

 Heat Transfer Enhancements Devices

There are three main classes.
o Special surfaces
These are typically used for inducing nucleate boiling when the driving force of temperature
is low.
 o Tube inserts
They are typically twisted tapes or wire wound inserts. They are typically utilized for
utilizing medium to high viscosity liquids for the heat transfer enhancement by causing
turbulence increase. There also appears to be proof that these reduce fouling. The exchanger,
for their use, must be well-designed for the purpose. This usually calls for an increase in shell
diameter, decreasing tube length and tube side passes to accommodate the higher pressure
loss attributes of the devices.
o Extended surfaces
These are used to increase the heat transfer area when a stream has a low heat transfer
coefficient. The most common is "low n tubing" where typically the ns are 1.5 mm high at 19
ns per inch.

 Selection Criteria
In most instances the only means of guaranteeing maximum selection is to perform a
complete design on the basis of a number of alternative geometries. In the initial case,
however, a number of significant decisions must be made regarding:
o Allocation of fluids to the shell side and tube side;
o Selection of shell type;
o Selection of front-end header type;
o Selection of rear end header type;
o Selection of exchanger geometry.
To a large extent, these will depend on each other. For instance, the allocation of a dirty fluid
to the shell side will have a direct bearing on the selection of exchanger tube configuration.

 Fluid allocation
In deciding on which side to allocate the hot and cold fluids the following need to be taken
into account, in order of decreasing priority.
o Consider any and all reliability and safety factors and distribute fluids accordingly.
Never distribute dangerous fluids so that they are bounded by anything other than
normal bolted and gasket—or welded—joints.
o Ensure the fluid distribution is according to standard engineering practices,
particularly those outlined in customer specifications.
o Having done the above, distribute the fluid most likely to cause the most severe
mechanical cleaning issues (if any) to the tube side.
o If neither of these, the division of the fluids will have to be calculated only after two
other alternative designs have been completed and the lowest cost is selected (time-
consuming if manual calculations are used but packages such as TASC from the Heat
Transfer and Fluid Flow Service (HTFS) make this a trivial task).

 Shell selection
E-type shells are used most often. If a single tube pass is utilized and provided that there are
more than three baffles, then an approximate counter-current flow is achieved. If two or more
tube passes are utilized, then pure countercurrent flow cannot be achieved and the log mean
temperature difference must be adjusted to allow combined concurrent and counter current
flow by using an F-factor.
G-type and H shells are usually only specified for horizontal thermosyphon reboilers. J shells
and X-type shells have to be selected if the maximum DP cannot be accommodated in a
reasonable E-type design. For more than one shell with removable bundles where the service
is required, F-type shells can be very cost-saving and should always be considered provided
they are not ruled out by customer specifications

 Front header selection

A-type front header is standard in dirty tube side fluids and B-type is standard in clean tube
side fluids. A-type is also the operators' preference regardless of tube side fluid cleanliness
when there is a need to go into the tubes. Apply the other types only if the following apply.
A pull-out shell C-type head should be considered for tube side dangerous fluids, heavy duty
or bundles requiring regular shell side cleaning. N-type head is used if dangerous fluids are
on the tube side. For high pressure application, a D-type head or B-type head welded on the
tube sheet is used. Y-type heads are used in single tube-pass exchangers only in their standard
application if they are installed in line with a pipeline.

 Rear header selection

For normal service a Fixed Header (L, M, N-types) can be used subject to no overstressing
due to differential expansion and the shell side shall not be subjected to mechanical cleaning.
Where thermal expansion is likely a fixed header with bellows can be used subject to the
shell side fluid not being dangerous, shell side pressure not over 35 bar (500 psia) and the
shell side shall not be subjected to mechanical cleaning.
A U-tube unit can be used to prevent thermal expansion problems and allow removal of the
bundle for cleaning. Countercurrent flow is only achievable by using an F-type shell and
mechanical cleaning of the tube side is occasionally a problem.
An S-type floating head is to be used if thermal expansion has to be taken care of and two
sides of the exchanger have to be accessed for cleaning. Other rear head designs will not
generally be used unless there are special cases.

 Selection of Exchanger Geometry

o Tube outside diameter
19.05 mm (3/4") will be most common for the process industry.
o Tube wall thickness
There must be a reference to an accepted pressure vessel code to be able to make a choice on
this.
o Tube length.
For a tube surface area, the longer the tube length the cheaper the exchanger cost, although a
long thin exchanger might not be feasible.
o Tube layout
45- or 90-degree layouts are chosen in the event of mechanical cleaning, otherwise 30-degree
layout is commonly employed, since it provides larger heat transfer and thus reduced
exchanger.
 o Tube pitch
Minimum allowable pitch of 1.25 times external tube diameter is normally used except when
more pitch is required due to mechanical cleaning or welding of tube ends.
o Number of tube passes
This is usually one or an even number (not usually more than 16). The higher the passes, the
greater will be the coefficient of heat transfer but care should be taken not to have tube side ρ
v2 greater than about 10,000 kg/m·s2.
o Shell diameter
Normal pipe is commonly used for shell diameters up to 610 mm (24\\"). Above this the shell
is built up of rolled plate. Shell diameters are generally in the range of 152 mm to 3000 mm
(6\\\" to 120\\\").
o Baffle type
Single segmental baffles are used as standard but other types are considered where pressure
drop constraints or vibration, is a problem.
o Baffle spacing
This is established on trying to achieve a compromise between the requirement for increased
cross ow velocity and tube support (lower baffle pitch) and pressure drop restriction (higher
baffle pitch). TEMA provides recommendations on the minimum and maximum baffle pitch.
o Baffle cut
This varies with the type of baffle but typically 45% for single segmental and 25% for double
segmental baffles.
o Nozzles and impingement
For shell side nozzles ρ v2 must be no greater than about 9000 in kg/m·s2.
For tube side nozzles the maximum limit ρ v2 must not be greater than 2230 kg/m·s2 for
single-phase noncorrosive, nonabrasive fluids and 740 kg/m·s2 for other fluids. Impingement
protection is always required for corrosive or abrasive gases, saturated vapors and two
phases' mixtures. Shell or bundle entrance or exit areas should be so constructed that a ρ v2
of 5950 kg/m·s2 is not exceeded.

 Materials of Construction
Shell and tube exchangers are typically constructed with metal, but in special applications
(i.e., where the process involves strong acids or pharmaceuticals), other materials such as
graphite, plastic and glass may be used

3.2 FLUID FLOW ANALYSIS

For the maximum flow arrangement for the maximum heat transfer coefficient, we will use
counter flow since it is the most efficient one. The fluid distribution is also to be considered
because the type of fluid may affect the overall efficiency of the shell and tube heat
exchanger. The following are some parameters that have been explained by Baher Elsheikh,
SABIC in his paper on "fluid allocations in shell land tube heat exchangers":
 Allowable pressure drops: Shell side flow area is larger than the tube side flow area
and resistance to flow and associated pressure drop will be less. Fluids, whose
pressure drop has to be low to satisfy the limiting plant operating conditions, need to
be allocated in the shell side.

 Fluid pressure operating and temperature: It is preferred to maintain the high-

pressure fluid on the tube side of the exchanger, rather than on the shell side, because
pressure part thickness varies linearly with its diameter. One such example is the
equation for thickness required for the cylindrical part under internal pressure
(t=PR/SE-0.6P) where 't' is required thickness and 'R' is internal radius and 'S' is
material allowable stress. The thick shell will impact the cost, design of foundation,
and could impact the fabric ability of the shell (welding, forming and inspection
requirements). In some cases, the high-pressure fluid being passed through the shell
may result in a more cost-effective unit, particularly if it reduces the diameter of the
exchanger and it is made of carbon steel. The influence of temperature is sometimes
the same as, at high temperature, the material strength reduces and thus results in the
allowable stress value ('S' in the equation). That will result in higher calculated
thickness which is to be preferred on the tube side. In sharing the higher-pressure
fluid on the tube side, it is recommended that the 10/13 rule be taken into account
while deciding the shell side design pressure, if possible. Sometimes a moderate
increase in the shell side design pressure can satisfy the 10/13 rule mentioned in the
box text.

 Fluid viscosity: In the case of viscous fluids, turbulent flow is easier to obtain at the
shell side due to the baffle effect during direction changes in flow. Higher viscous
fluid flow is desirable at shell side. Viscous fluids also experience higher pressure
drop which is advantageous in routing them to shell side to minimize the pressure
drop.

 Heat transfer rate of the fluid: It is preferable to put low heat transfer coefficient fluid
in the shell side since it can be made more flexible in order to enhance the heat
transfer by changing the flow patterns due to the support of the baffles as the heat
transfer will be much higher for the flow of turbulence. If that fluid is put on the tube
side, then increased tube passes can be used for the flow's velocity and turbulence.

 Phases of fluids (two phases or one phase): Phase-changing liquids have to be put on
the shell side. Here, a huge flow area can be accommodated to deal with the vapor
flow without introducing pressure drop. Whereas the flow that is condensed from the
heat transfer is usually put on the tube side.

 Filthy Fluids: Filthy fluids and fluids with suspended solids are preferable to be
placed in the tube side since it is easier to clean compared to the shell side. If the
filthy fluids need to be placed on the shell side due to some other reasons, then it is a
good idea to use square pitch tube and not triangular pitch (even though heat transfer
would be less) such that the bundle of tubes could be cleaned on the shell side.
  Corrosivity of fluids: The effect of corrosion in deciding on the best exchanger side
for each fluid is difficult to make conclusions with but, by general agreement, it's
practice to employ the more expensive material on the tube side. Sometimes, if the
fluid is not under high pressure and the reversal reduces the shell diameter, it will
provide a cheaper option. If the fluid on the shell side tends to form cracks, fixed tube
sheet exchangers should be avoided and all the internal welds must be made
accessible for inspection. Moreover, if a fluid tends to cause crevice corrosion it is
advisable to route it in the tube side so that crevice corrosion in tube and tube sheet at
tube sheet backside is avoided.

 Fouling Considerations: Most of the process fluids in the exchanger foul the surface
of heat transfer. The material deposited reduces the rate of effective heat transfer due
to relatively low thermal conductivity.Net heat transfer with clean surface therefore
has to be higher to compensate for loss in performance while operating. Fouling of the
exchanger costs the additional amount of:
i. Construction due to over sizing,
ii. Additional energy due to ineffective performance of the exchanger and
iii. Cleaning of the material deposited. A spare exchanger may be made available for
design to provision for maintenance services without interruption. The effect of
fouling is treated in heat exchanger design by including tube side and shell side
fouling resistances. Fouling coefficient and resistance values for regular conditions
are presented in Table 3.1

Table 3.1
3.3 MATERIALS SELECTION
Listed below are the materials used in the fabrication of the shell and tube heat exchanger
• Galvanized steel pipes(shell)
• Copper Tube
• Thermocouple
• Instant electric water heater
• Control Valves
• Wood (Work Table)
• Hose (pipes)
• Reservoirs (hot and cold)
• Flow meters.
• Surface water pumps.
• Electric cables sockets and switch

3.4 DESIGN CRITERIA

1. The tube and shell can be utilized as a multi (double) pass counter flow heat
exchanger.
2. The heat exchanger is built to a sensible size and mounted on a cart (wheeled stand)
for easy mobility.
3. The unit will be self-contained, except for the necessary connections to the cold-water
supply and the electrical service.
4. The unit will have a large reservoir of hot water with a holding capacity for a large
quantity of water. The hot water is re-circulated. Cold water is pumped directly from
the laboratory cold-water supply faucet into a second reservoir. Cold water is not re-
circulated, but rather directly to the drain.
5. The instrumentation must be sufficient to record temperatures of incoming and
outgoing hot and cold-water streams and to record flow rates of both streams.
6. Valves and pipes will be utilized for fluid flow control in the particular heat
exchanger module in use at any given time. Flow control valves shall also be
provided.
7. The instrumentation must be modern.

3.5 DESIGN PARAMETERS

Parameter Symbol Valve Unit

Cold fluid outlet temperature T c ,o 31.45 [℃ ¿
Cold fluid inlet temperature T c ,i 25 [℃ ¿
Hot fluid outlet temperature T h ,o 40 [℃ ¿
Hot fluid inlet temperature T h ,i 90 [℃ ¿
Specific heat capacity of water Cp 4183.5 J/Kg.℃
Density of water ρ 988.25 K/gm3
LMTD ∆ T lm 31.98 [℃ ¿
Assume heat transfer coefficient Ua 810 W/
2
m .℃
2
Heat transfer area A 56 m
Tube side velocity Ut 1.922 m/s
Shell side velocity Us 0.3123 m/s
Tube side Reynold’s number ℜt 43687 -
Shell side Reynold’s number ℜt 11157 -
Tube side pressure drop ∆ Ps 11485 Pa
Shell side pressure drop ∆ Pt 27117 Pa
Nusselt number Nu 85.07 -
Shell side heat transfer coefficient hs 3393 W/
2
m .℃
Tube side heat transfer coefficient ht 8029 W/
2
m .℃
Overall heat transfer coefficient U cal 950.9 W/
2
m .℃
Tube inner diameter T id 0.0189 m
Tube outer diameter T od 0.0222 m
Length of tubes Lt 4.26 m
Number of tubes Nt 128 -
Tube pitch Tp 0.02775 m
Bundle diameter Bd 0.4471 m
Shell diameter Sd 0.5151 m
Baffle spacing Lb 0.206 m
Thermal conductivity of copper Kc 395 W/m ℃
Number of baffles Nb 20 -
Mass flow rate for shell side ms 6.5 Kg/s
Mass flow rate for tube side mt 50.5 Kg/s
 REFERENCES
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