Contents

Methodology............................................................................................................................................. 2
Process and Design Specifications ........................................................................................................ 3
Problem Specifications.......................................................................................................................... 4
Advantages of Shell and Tube heat exchanger ......................................................................................... 5
Requirements from client ......................................................................................................................... 7
Equations .................................................................................................................................................. 8
FUNDAMENTALS OF HEAT TRANSFER .................................................................................................. 8
Heat Balances........................................................................................................................................ 8
Basic Heat Transfer Relations ............................................................................................................... 8
Shell and Tube Exchangers........................................................................................................................ 9
Effective Temperature Difference ........................................................................................................ 9
Nomenclature ......................................................................................................................................... 11
Methodology
Design is an activity aimed at providing complete descriptions of an engineering system,

part of a system, or just of a single system component. These descriptions represent an

unambiguous specification of the system/component structure, size, and performance, as

well as other characteristics important for subsequent manufacturing and utilization.

This can be accomplished using a well-defined design methodology.

From the formulation of the scope of this activity, it must be clear that the design

methodology has a very complex structure. Moreover, a design methodology for a heat

exchanger as a component must be consistent with the life-cycle design of a system. Lifecycle

design assumes considerations organized in the following stages.

. Problem formulation (including interaction with a consumer)

. Concept development (selection of workable designs, preliminary design)

. Detailed exchanger design (design calculations and other pertinent considerations)

. Manufacturing

. Utilization considerations (operation, phase-out, disposal)

At the initial stage, an engineer must specify requirements and define the main goal of

the system design. This must be based on a good understanding of customer needs. If the

problem is clearly formulated, an engineer evaluates alternative concepts of the system

design and selects one or more workable design solutions. Based on this analysis, detailed

sizing, costing, and optimization have to be completed. This activity leads to a proposed

design solution. Simultaneously, project engineering (construction/manufacturing)

considerations should be taken into account. The issues related to startups, transients,

steady and erratic operations, and ultimately, the retirement, should be considered as

well. Through consideration of these steps, a design team reconsiders the conclusions

and, in the light of the constraints imposed, iterates one or more steps until all the

requirements are met within the tolerable limits. Within the framework of these activities,

a particular design methodology has to be developed.

A methodology for designing a new (single) heat exchanger for compact and shell-and-tube exchangers.
This design procedure may be
characterized as a case study (one case at a time) method. Major design considerations

include:

. Process and design specifications

. Thermal and hydraulic design

. Mechanical design

. Manufacturing considerations and cost

. Trade-off factors and system-based optimization

These design considerations are usually not sequential; there could be strong interactions

and feedback among the aforementioned considerations, as indicated by doublesided

arrows, and may require a number of iterations before the design is

finalized. The overall design methodology is quite complex because of the many qualitative

judgments, in addition to quantitative calculations, that must be introduced. It

should be emphasized that depending on the specific application, some (but not necessarily

all) of the foregoing considerations of heat exchanger designs are applied in various

levels of detail during the design process. In the following, these broad considerations are

discussed in some detail, accompanied by several examples showing the main features of

the design procedures and interactions among them. Refer to appropriate blocks and

boxes in for identification of the following specific sections and subsections.

Process and Design Specifications

The process and problem specification (the top dashed block in Fig. 2.1) is one of the

most important steps in heat exchanger design. A heat exchanger design engineer can add

the most value by working together with a system design engineer to develop ‘‘smart’’

specifications for the heat exchanger that define an optimum system. The smart specifications

need to be completed based on discussions with the customer, on industry and

customer standards, and on design engineer’s own experiences.

Process or design specifications include all necessary information to design and

optimize an exchanger for a specific application. It includes problem specifications for

operating conditions, exchanger type, flow arrangement, materials, and design/manufacturing/

operation considerations. In addition, the heat exchanger design engineer provides

necessary and missing information on the minimum input specifications required.

Problem Specifications.
The first and most important consideration is to select

the design basis (i.e., design conditions). Next comes an analysis of the performance at

the design point and off-design (turndown) conditions. The design basis would require

the specification of operating conditions and the environment in which the heat exchanger
Advantages of Shell and Tube heat exchanger
1. Can be used in systems working under high temperatures and pressures
2. Pressure drop across a tube cooler is less
3. Less expensive than other types such as plate exchangers
4. Tube leaks can easily spotted and plugged since pressure test is comparatively easy
5. Easy to repair
Design input
Requirements from client
P-003 Datasheet

P-004 Datasheet

TK-210 coil geometry and material of consruction

TK-102 coil geometry and material of consruction

BL-430/440 coil geometry and datasheet

Heater FA500 data sheet

Heat exchanger 600 datasheet

Target temperature for all tanks

Time duration needed for heating process

Equations
FUNDAMENTALS OF HEAT TRANSFER
The basic definitions and equations used in heat exchanger

calculations are reviewed below:

Heat Balances
For no phase change of the hot fluid:

Q mH CpH TH1 TH2

For isothermal condensing of the hot fluid:

Q mH H 

For no phase change of the cold fluid:

Q mC CpC TC2 TC1

For isothermal boiling of the cold fluid:

Q mC C 

Basic Heat Transfer Relations

Q UA LMTDfor single-pass designs

Q = UA (CMTD) for multi-pass designs

Shell and Tube Exchangers
For tubular heat exchangers, the heat transfer area generally

referred to is the effective outside bare surface area of the

tubes, and the overall heat transfer coefficient must also be

based on this area.

Effective Temperature Difference

In most instances the local temperature difference between the hot stream and the cold stream will not have a constant

value throughout a heat exchanger, and so an effective average value must be used in the rate equation. The appropriate average
depends on the configuration of the exchanger. For simple countercurrent and co-current exchangers (in the following figure), the

Log Mean Temperature Difference (LMTD) applies.

Countercurrent Flow and Co-current Flow

LMTD chart defines LMTD in terms of Greatest Terminal Temperature

Difference (GTTD) and Least Terminal Temperature Difference (LTTD), where “terminal” refers to the first or last point of heat
exchange in the heat exchanger. For exchanger configurations with flow passes arranged to be partially countercurrent and
partially co-current, it is common practice to calculate the LMTD as though the exchanger were in countercurrent flow, and then
to apply a correction factor to obtain the effective temperature difference.

CMTD LMTDFCorrected Mean Temperature Difference

The magnitude of the correction factor, F, depends on the exchanger configuration and the stream temperatures. Values

of F are shown in Figs. 9-4, LMTD Correction Factor (2 shell passes; 4 or more tube passes), 9-6, and LMTD Correction
Factor (4 shell passes; 8 or more tube passes) for most common exchanger arrangements. In general if the value obtained for

F is less than 0.8, it is a signal that the selected exchanger configuration is not suitable, and that one more closely approaching

countercurrent flow should be sought.

Heat Exchange with Non-Linear Behavior

The above Corrected Log Mean Temperature Difference (CMTD) implicitly assumes a linear relation between duty and stream
temperature change. Some situations for which this assumption is not applicable include process streams which undergo a very
large temperature change so that the physical properties change significantly, multi-component condensing or boiling with non-
linear duty vs. temperature curves, and exchangers in which the process stream undergoes both phase
change and sensible cooling or heating. These situations may be handled by dividing the exchanger into zones which may be
treated individually with the linear assumption. The overall exchanger performance may be represented in terms of the weighted
average performance of the zones in the overall rate equation. The following equations may be taken as the rate equations for the
overall exchanger and for the nth zone of the exchanger.

QTotal Uwtd ATotal WTD

Qn Un An LMTDn

Then the weighted temperature difference may be defined

as:

In multi-component, two-phase (vapor/liquid) flow regimes undergoing heat transfer, the vapor and liquid composition changes
that occur are related to the extent of continuous contact of the two phases. If the vapor phase is maintained in contact with the
liquid, the total change in enthalpy (or other properties) that accompanies the composition change is termed “integral.” If the
vapor is continuously removed from contact with the liquid as it is formed, the property changes are termed “differential.” An
accurate representation of temperature difference and heat transfer in these cases depend on correct consideration of the phase
separation that occurs in the heat transfer equipment.

Overall Heat Transfer Coefficient

Metal Resistance for Plain Tubes

The metal resistance is calculated by the following equation:

Values of the tube metal thermal conductivity for several materials of construction at different metal temperatures.

Fouling Resistances
Fouling resistances depend largely upon the types of fluid being handled, i.e., the amount and type of suspended or dissolved
material which may deposit on the tube walls, susceptibility to thermal decomposition, etc., and the velocity and temperature of
the streams. Fouling resistance for a particular service is usually selected on the basis of experience with similar streams. Some
typical values are given in Typical Heat Transfer Coefficients, U, and Fouling Resistances, rf and in the TEMA Standards.

Film Resistances
Equations for calculating the film coefficients, ho, and hi, for the simpler common geometries, as functions of flow rate and

fluid properties, may be found in heat transfer references and in engineering handbooks. Some typical values of film resistances

are given in Fig. 9-11. Some common overall heat transfer coefficients are shown. Film coefficients, film resistances, and overall
heat transfer coefficient are related as follows: hi = 1/ri, ho = 1/ro, and

U = 1/r
Nomenclature
A = area, sq ft

BP = baffle spacing, in.

C = tube count factor

Cp = specific heat, Btu/(lb · °F)

CMTD = Corrected Log Mean Temperature Difference, °F

D = diameter, in.

F = LMTD correction factor

f = ratio of one value to another

FD = free diameter, in.

G = mass velocity, lb/(sq ft · sec)

GTTD = Greatest Terminal Temperature Difference, °F

h = film coefficient, Btu/(hr · sq ft · °F)

H = height, in.

k = thermal conductivity, Btu/[(hr · sq ft · °F)/ft]

L = length, in.

LMTD = Log Mean Temperature Difference, °F

LTTD = Least Terminal Temperature Difference, °F

m = mass flowrate, lb/hr

N = number of exchangers

Np = number of passes

DP = pressure drop, lb/sq in.

P = pressure, lb/sq in. absolute

p = temperature efficiency

PHE = plate and frame heat exchanger

Q = heat transferred, Btu/hr

R = heat capacity rate ratio

Re = Reynolds number = (123.9 DG)/m

RC = tube rows crossed

r = film resistance (hr · sq ft · °F)/Btu

SP = number of baffle spaces

T = temperature, °F

t = temperature, °F

TMTD = True Mean Temperature Difference, °F

U = overall heat transfer coefficient, Btu/(hr · sq ft · °F)

W = width, in.

WTD = weighted temperature difference, °F

X = weight fraction

l = latent heat, Btu/lb

m = viscosity, centipoise

r = density, lb/cu ft

Subscripts

b = boiling

C = cold fluid

c = condensing

f = fouling

H = hot fluid

i = inside

in = inlet

L = liquid

m = mean value

n = nth value

o = outside

out = outlet

2F = two-phase

w = wall

v = vapor