Prepared By: Mr. Harsh Panchal

PROCESS EQUIPMENT DESIGN (3170502)
Semester – V (CHEM)
Chapter Name: Process design of Heat Exchangers
Introduction:
o All chemical reaction and unit operation involve heat transfer.

o Solid liquid and gases require heating or cooling during the operation that
are performed to get the desired product.
o This transfer can be performed by in a verity of equipment called as heat
exchangers.
o Shell and tube heat exchangers are most common in the process industry.
Shell and tube heat exchangers:
o They are mostly used as heat transfer equipment but in a few cases, they
are also used as Reactors, Falling Film Absorbers, etc.
o
o Standards developed by Tubular Exchanger Manufacturers Association,
USA (TEMA) are universally used for design of shell and tube heat
exchangers. Equivalent Indian Standard is IS:4503.
shell and tube heat exchangers are classified in three categories:
1. Class R covers heat exchangers which are used for severe duties in petroleum
and related industries. Also, it covers heat exchangers that are going to handle
toxic gas, highly flammable fluid or hazardous fluid.
2. Class B covers the heat exchangers which are used in chemical process
industries not involving severe duties.
3. Class C covers the heat exchangers which are used in commercial and in le
important process applications. Example: Heat exchangers used for recovery of
energy from an effluent stream.
Prepared By: Mr. Harsh Panchal Page

Various Parts Of Shell And Tube Heat Exchangers:
1. Shell:
o Shell is the costliest part of the heat exchanger.

o Cost of shell and tube heat exchanger sensitively changes with change in
the diameter of shell. As per the TEMA standard, shell size ranges from 6
in (152 mm) to 60 in (1520 mm). Standard pipes are available up to 24 in
size (600 mm NB).
o If shell size is greater than 24 in, it is fabricated by rolling a plate.
o Shell diameter depends on tube bundle diameter.
2. Shell Side Pass Partition Plate:
o Single pass shell is used in the most of the cases. Two pass shell is rarely
used and is recommended where shell and tube temperature difference
are unfavorable for the single shell side pass.
o Shell side pass partition plate is not provided to improve shell side heat
transfer coefficient but it is provided to avoid the unfavorable
temperature difference or to avoid the cross of temperatures between hot
fluid and cold fluid.
3. Baffles:
o There are two functions of baffles

o Baffles are used in the shell to direct the fluid stream across the tubes to
increase the velocity of shell side flow and thereby to improve the shell
side heat transfer coefficient.
o In other words, baffles are used in shell to increase the turbulence in shell
side fluid.
o Baffles indirectly support the tubes and thereby reduce the vibrations in
tubes.
o Different types of baffles are used in shell and tube heat exchangers; (i)
Segmental baffle, (ii) Nest baffle, (iii) Segmental and Strip baffle, (iv) Disk
and Doughnut baffle, (v) Orifice baffle, (vi) Dam baffle, etc.

4. Tubes:
o Tube size range from 1/4 in (6.35 mm) to 2.5 in (63.5 mm) in shell and
tube heat exchanger.
o For the standard tubes, its size is equal to outer diameter of tube.
Thickness of standard tubes are expressed in BWG (Birmingham Wire
Gauge).
o Increase in the value of BWG means decrease in tube thickness.
o For no phase change heat exchangers and for condensers, 3/4 in (19.05
mm) OD tube is widely used in practice. While for reboiler 1 in (25.4 mm)
OD tube size is common.
o Tubes are available in standard lengths like 6 ft (1.83 m), 8 ft (2.44 m), 12
ft (3.66 m), 16 ft (4.88 m) and 6 m.
5. Tube Side Pass Partition Plate:
o Tube side passes are provided to decrease the tube side flow area and to
increase tube side fluid velocity thereby to improve the tube side heat
transfer coefficient at the expense of pressure drop.
o This is true only if there is no phase change on tube side.
o Hence, a greater number of tube side passes are recommended only if
there is no change in the phase of tube side fluid.

6. Spacers:
o Spacers are used to maintain the space between baffles.

o Spacers are passed over the tie rods and because of them baffles do not
slide over tie rods under the effect of the force of fluid. Hence, spacers fix
the location of baffles and maintain the space between them.
o Length of spacer is equal to space between the baffles.
7. Tube Sheet:
o Tubes and one end of tie rods are attached to tube sheet (also called tube
plate). Hence, entire load of tube bundle is transferred to one or two tube
sheets.
o In U-tube shell and tube heat exchanger (as shown in Fig. 6.1(d), type CFU
or Fig. 6.1(e), type AKT) only one tube sheet is used. While in fixed tube
sheet shell and tube heat exchanger, two tube sheets are used.
o One surface of tube sheet is exposed to tube side fluid and other surface is
exposed to shell side fluid.
8. Sealing Strip:
o It is a shell side component. Sealing strips are attached on the inside

surface of shell throughout the length of shell.
o There are two functions of sealing strips
1. Sealing strips reduce the amount of bypass stream of shell side fluid flowing
through the clearance between shell inside diameter and tube bundle diameter
and thereby improve the shell side heat transfer coefficient.
2. Sealing strips also make the removal of tube bundle from the shell easy.
Hence, they are also known as sliding strips.
GENERAL DESIGN METHOD FOR SHELL AND TUBE HEAT EXCHANGERS:
1) Calculation of Heat Duty:
1. For cooling or heating or for no phase change, heat duty is calculated by the
equation
∅ = 𝒎𝑪𝒑∆𝒕
where, = Heat duty required, kW
m = Mass flow rate of fluid, kg/s
Cp= Specific heat of fluid, kJ/(kg. °C)
∆𝒕 = Temperature difference to be affected, °C

2. For condensation with subcooling
∅ = mλ + mCL Δt
where, m = Mass flow rate of vapour, kg/s
CL = Specific heat of condensate, kJ/(kg °C)
λ=Latent heat of vaporization, kJ/kg
3. For reboilers
∅B = mVλ x 1.05 (considering 5% heat loss)
where, m = Vaporization rate, kg/s
λ=Latent heat of vaporization, kJ/kg
2) Energy Balance
Establish energy balance or heat duty balance and based on that find the mass
flow rate of heating medium or cooling medium.
ø= mCpΔt=mwCLw(t2-t1)
Here, mw = mass flowrate of cooling medium, kg/s
CLW = heat capacity of cooling medium, kJ/kgK
∆𝒕 = temperature difference, 0C
t2 = outlet temperature of cooling medium
t1 = Inlet temperature of cooling medium
3) Mean Temperature Difference
Mean temperature difference is calculated by
ΔTm=FtΔTlm
Where , ΔTlm is
∆𝑻𝟐 − ∆𝑻𝟏
∆𝑻𝒍𝒎 = ∆𝑇2
ln ( )
∆𝑇1
Here, ∆𝑇1 and ∆𝑇2 𝑎𝑟𝑒 𝑡ℎ𝑒 𝑡𝑒𝑟𝑚𝑖𝑛𝑎𝑙 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒
𝐹𝑡 = 𝑓(𝑅, 𝑆)
𝑻𝟏−𝑻𝟐 𝒕𝟐−𝒕𝟏
𝑹= 𝑺=
𝒕𝟐−𝒕𝟏 𝑻𝟏−𝒕𝟏
T1= hot fluid inlet temp. 0C
T2= hot fluid outlet temp. 0C
t1= cold fluid inlet temp. 0C
t2= cold fluid outlet temp. 0C

4) Estimation of overall HTC (U):

Assume the value of overall heat transfer coefficient U form standard table and
based on that calculate area required.
∅𝒕
𝑨=
𝑼 × ∆𝑻𝒎
For first trial calculation this, A is the heat transfer area provide
A=NtПdoL
Calculate number of tube required by above equation.
Here, do = OD of tube
L = Length of tube
Nt = number of tubes
5) Shell diameter
Ds=DB+Cl
𝑵𝒕 𝟏
𝑫𝑩 = 𝒅𝒐 ( )
𝒌𝟏 𝒏𝟏
Here, Ds= shell diameter
DB= tube bundle diameter
Cl = clearance
K1 and n1 are constants

6) Tube Side Heat Transfer Coefficient
1. For no phase change, tube side heat transfer coefficient is determined

by Sieder-Tate equation. If Reynolds number; Re is less than 2000.
𝒉𝒊𝒅𝒊 𝒅𝒊 𝟎.𝟑𝟑 𝝁 𝟎.𝟏𝟒

𝑵𝒖 = = 𝟏. 𝟖𝟔 (𝑹𝒆 ∙ 𝑷𝒓 ∙ ) ( )
𝒌𝒇 𝑳 𝝁𝒘
2. If Re>4000 then tube side HTC can be calculated by Dittus-bolter

equation
𝒉𝒊𝒅𝒊 𝟎.𝟑𝟑
𝝁 𝟎.𝟏𝟒
𝑵𝒖 = = 𝑪 𝑹𝒆𝟎. 𝟖 𝑷𝒓 ( )
𝒌𝒇 𝝁𝒘
𝑵𝒕 𝝅
𝒂𝒕 = 𝑻𝒖𝒃𝒆 𝒔𝒊𝒅𝒆 𝒇𝒍𝒐𝒘 𝒂𝒓𝒆𝒂 = × 𝒅𝒊𝟐
𝑵𝒑 𝟒
Vt=mt/atρ
𝐷𝑣𝜌 𝑑𝑖𝐺𝑡
Here, Re = Reynolds number = =
𝜇 𝜇
𝐶𝑝𝜇
Pr=Prandtl number=
𝐾
h = Tube side heat transfer coefficient, W/(m².C)
k=Thermal conductivity of fluid, W/(m. °C)
𝜇 =Viscosity of fluid pa.s
𝜇 W=Viscosity of fluid at tube wall temperature,
C=0.021 for gases
= 0.023 for non-viscous liquid

= 0.027 for viscous liquid
G₁ = Tubeside mass velocity, kg/(m²- s)m
3. Alternatively, tube side heat transfer coefficient h, can be calculated

by Kern's equation from the value of "heat transfer factor; J", for the
entire range of Reynolds number (from Re = 10 to 10%).
𝝁 𝟎.𝟏𝟒
𝑵𝒖 = = 𝑱𝒉 𝑹𝒆 𝑷𝒓 ( )
𝒌 𝝁𝒘
7) Calculation of Tube Side Pressure Drop
If there is no phase change in tube side fluid then tube side pressure drop can
be calculated by.
𝑳 𝝁 −𝒎 𝝆𝒖𝒕𝟐
∆𝑷𝒕 = 𝑵𝒑 (𝟖𝑱𝒇 ( ) ( ) + 𝟐. 𝟓)
𝒅𝒊 𝝁𝒘 𝟐

Here, m=0.25 for Re ≤ 2100

= 0.14 for Re> 2100
∆𝑷𝒕 = Tube side friction pressure drop, N/m²
Np = Number of tube side passes
Jf= Tube side friction factor
ut= Tube side fluid velocity, m/s
8) Shell Side Heat Transfer Coefficient
For no phase change shell side heat transfer coefficient can be calculated by
following procedure.
1. calculate shell side flow area by following equation.
(𝑷𝒕 − 𝒅𝒐)𝑫𝒔𝑩𝒔
𝑨𝒔 =
𝑷𝒕
where,
AS= Shell side flow area, m²
Pt= Tube pitch, m
do = Outside diameter of tube, m
BS= Baffle spacing, m
DS= Shell inside diameter, m
2. calculate shell side velocity by

𝒎𝒔
𝒖𝒔 =
𝑨𝒔𝝆𝒔
where,
us= Shell side velocity,
ms = Shell side mass flow rate of fluid, kg/s
A = Shell side flow area m2
3. Calculate the shell side equivalent diameter
• For square pitch arrangement

𝟏. 𝟐𝟕
𝒅𝒆 = (𝑷𝒕𝟐 − 𝟎. 𝟕𝟖𝟓𝒅𝒐𝟐)
𝒅𝒐
• For triangular pitch arrangement
𝟏. 𝟏
𝒅𝒆 = (𝑷𝒕𝟐 − 𝟎. 𝟗𝟎𝟕𝒅𝒐𝟐)
𝒅𝒐
4. Calculate shell side Reynolds number.

𝒅𝒆𝑮𝑺
𝑹𝒆𝒐 =
𝝁
5. Calculate shell side Prandlt number.
𝑪𝒑𝝁
𝑷𝒓𝒐 =
𝑲
6. Calculate Shell Side Heat Transfer Coefficient
𝒉𝒐𝒅𝒆 𝟎.𝟑𝟑
𝝁 𝟎.𝟏𝟒
𝑵𝒖𝒐 = = 𝟎. 𝟑𝟔 𝑹𝒆𝟎. 𝟓𝟓 𝑷𝒓 ( )
𝒌 𝝁𝒘

Alternatively, shell side heat transfer coefficient can also be found by
𝝁 𝟎.𝟏𝟒
𝑵𝒖𝒐 = = 𝑱𝒉 𝑹𝒆 𝑷𝒓 ( )
𝒌 𝝁𝒘
9) Calculation of Shell Side Pressure Drop
If there is no phase change in shell side fluid then shell side pressure drop can
be calculated by.
𝑫𝒔 𝝆𝒖𝒕𝟐 𝑳 𝝁 −𝟎.𝟏𝟒
∆𝑷𝑺 = (𝟖𝑱𝒇 ( ) ( )( )( ) )
𝒅𝒆 𝟐 𝑩𝒔 𝝁𝒘
Where
∆𝑷𝑺 = shell side pressure drop pa
de= Shell side equivalent diameter, m
L= Tube length, m
Bs= Baffle spacing, m
uv = Shell side linear velocity, m/s
μ= Viscosity of fluid (N-s)/m²
μw = Viscosity of fluid at tube wall temperature, (N-s)/m²
J= Shell side friction factor

10) Calculation of the Overall Heat Transfer Coefficients

𝟏
𝑼𝒐 = 𝑑𝑜
𝟏 𝟏 𝒅𝒐 ln 𝑑𝑖 𝒅𝒐 𝟏 𝒅𝒐 𝟏
+ + + × + ×
𝒉𝒐 𝒉𝒐𝒅 𝟐𝒌𝒘 𝒅𝒊 𝒉𝒊𝒅 𝒅𝒊 𝒉𝒊
where,
U = Overall heat transfer coefficient, W/(m². °C)
h = Shell side heat transfer coefficient, W/(m². °C)
do = OD of tube, m
di = ID of tube, m
k=Thermal conductivity of tube wall material, W/(m - °C)
hid = Fouling coefficient for tube side fluid, W/(m². °C)
hod=Fouling coefficient for shell side fluid, W/(m². °C)

Advantages of U-tube and Floating Head Heat Exchangers Over Fixed Tube
Sheet Heat Exchangers
1. Maintenance and cleaning of tube bundle is easier. In U-tube and floating

head heat exchanger, entire tube bundle can be easily taken out for
cleaning and maintenance, While the same is not possible in fixed tube
sheet heat exchanger.
2. U-tube and floating head heat exchangers permit the differential thermal
expansion or contraction between shell and tube. Therefore, use of
expansion joint is not required in U-tube and floating head heat
exchangers
Disadvantages of U-tube and Floating Head Heat Exchangers Over Fixed

Tube Sheet.
For a given heat duty, U-tube and floating head heat exchangers are costlier
than fixed tube sheet heat exchangers because of the following reasons:
(a) For the same number of tubes, tube arrangement and tube pitch, shell sizes
required by U-tube and floating head heat exchangers are higher than the same
required by fixed tube sheet heat exchangers.
In U-tube heat exchanger, minimum bend radius of U-tube is 1.5d, Hence, in

central portion of tube bundle, tubes cannot be provided.
In floating head heat exchanger more clearance between shell ID and tube
bundle diameter (50 to 100 mm) is required.

(b) In case of cooling or heating of shell side fluid (no phase change) heat
transfer coefficients obtained in U-tube and floating head heat exchangers for
the given heat duty are less than the same obtained in fixed tube sheet heat
exchangers as bypassing area is higher in case of U-tube or floating head as
compared to fixed tube sheet heat exchanger.
Advantages and Disadvantages of U-tube Heat Exchanger Over Floating

Head Heat Exchanger.
➢ Advantage
Fixed cost of U-tube heat exchanger is always less than the same of floating
head heat exchanger for the given duty.
➢ Disadvantages
1. In U-tube, tube material becomes weak in bending portion, hence use of U-

tube heat exchanger is not recommended for severe conditions. While for the
same conditions floating head heat exchanger can be used.
2. In U-tube heat exchanger number of tube side passes are fixed (two). It
reduces the flexibility in design calculations.

3. U-tube heat exchanger is not recommended for tube side dirty fluid. As it is
difficult to remove dirt from U-tube. While floating head heat exchanger can be
used where both; shell side fluid and tube side fluid are relatively dirty.
Floating Head Heat Exchangers:
There are two types of floating head heat exchangers.
1. Split-ring floating head heat exchanger
2. Pull through floating head heat exchanger
➢ Advantage
o Compared to pull through floating head heat exchanger, is required for the
shell to accommodate the same number of tubes.
o Less diameter is required for the shell to accommodate the same number
of tubes.
➢ Disadvantages
o More maintenance time is required. In maintenance, shell cover is

removed first, then the split backing ring, then floating head cover and
finally tube bundle is removed from the stationary end.
o Pull through floating head heat exchanger is the costliest type of shell and
tube heat exchanger because it requires largest shell diameter for the
given numbers of tubes. With this heat exchanger, it is possible to remove
the entire tube bundle including Boating head assembly from the
stationary end.
Fluid allocation
1. Fluid allocation in case of phase change
o Condensing or vaporizing fluid is normally taken on shell side as in the

shell, liquid and vapor phases are easily separated.
o In case of a condenser, if condensation is carried out in tube side, then the
entire liquid condensate forms a film on heat transfer surface which
provides additional resistance to heat transfer.
o In case of reboilers normally on both sides phase change take place and
hence, fluid allocation depends on other factors.
2. Fluid allocation in case of no phase change:
If there is no phase change in shell side and tube side fluid, then fluid allocation
depends on the following factors:
➢ Corrosion:
o Corrosive fluid is allocated tube side as the cheaper material like mild steel
can be used for costly shell, baffles, etc. Also, other costlier parts like tubes
and tube sheets require the use of non-corrosive or costlier material of
construction in case of corrosive fluid, whether it is on tube side or in shell
side.

o In cooling of ethyliodide, it should be taken on tube side as it requires the
use of special material (Hastelloy-B).
➢ Fouling:
o In fixed tube sheet heat exchanger inside surface of tubes can be easily
cleaned and hence, the fluid which has the greatest tendency to foul on
heat transfer surface should be placed in the tubes.
o For example, cooling water has a tendency to foul. Hence, normally it is
passed through tubes.
➢ Fluid temperature:
o At very high temperature as well as at very low temperature use of special

alloy is required. Hence, very hot or very cold fluid is placed on tube side
to avoid the use of costlier material for the shell.
➢ Operating pressure:
o High pressure stream should preferably be placed on tube side as high-

pressure tubes are cheaper than high pressure shell. Diameter of shell is
very much greater than diameter of tubes hence, its thickness is more
sensitively changed with change in pressure as compared to that of the
tubes

➢ Fluid flow rates and viscosity:
o Very low value of flow rate of fluid and high. value of viscosity of fluid give
low value of Reynolds number. Fluid which provides very low value of
Reynolds number should be placed on shell side as the dependency of
shell side heat transfer coefficient on Reynolds number is less as
compared to the same of tube side heat transfer coefficient.
CRITERIA OF SELECTION BETWEEN HORIZONTAL CONDENSER AND VERTICAL

CONDENSER
I. For film wise condensation
• Horizontal position gives higher condensation coefficient than vertical

position.
• In film wise condensation, thickness of condensate film over heat transfer

surface decides the value of condensation coefficient.
• With horizontal position and shell side condensation, the condensate

travels less distance over heat transfer surface before falling down by
gravity compared to vertical position.
• With vertical position, condensate travels over the entire tube length
before falling down by gravity.
• Hence, average condensate film thickness obtained with horizontal

position is less than the same with vertical position and hence, it can
provide higher condensation coefficient.

II. Condensation with subcooling
• In case of condensation with subcooling in a shell and tube heat

exchanger, condensation coefficient is higher with horizontal position
while subcooling coefficient is higher with vertical position.
• In case of subcooling with horizontal position, small fraction of

gravitational force is acting on the pool of condensate and hence,
condensate is flowing with almost no turbulence.
• Hence, subcooling with horizontal position is natural convection heat

transfer. While in subcooling with vertical position, entire gravitational
force is acting on pool of condensate.
• Therefore, in the case of condensation with subcooling, shell and tube

heat exchanger is designed for both positions (horizontal and vertical) and
the position that gives higher value of overall coefficient is selected.
III. Condensation with non-condensable
• Selection of position depends on the percentage of non- condensable

present in inlet vapor
• If non- condensable are < 0.5% (by mass), then the presence of non-
condensable is ignored in design calculations. Heat exchanger is designed
as a total condenser. For this case, horizontal position should be selected
as it provides the higher condensation coefficient.
• If non-condensable are > 70% (by mass), then for the entire flow rate,
without phase change correlation is applied to calculate the heat transfer
coefficient. For this case, selection of the position does not depend on
heat transfer coefficient

• Between 0.5 to 70% non-condensable, heat transfer coefficient is
determined by considering both condensation as well as cooling of non-
condensable and vapors.
• For this case horizontal position should be selected as it gives higher

condensation coefficient.
TINKER'S FLOW MODEL
• In old methods, like Kern's method, it is assumed that entire shell side fluid
is flowing across the tube bundle and between the baffles. But actually,
shell side fluid is flowing in various ways. In Tinker's flow model shell side
flow is divided in five different steams.
1. Stream A
• Stream A is the tube-to-baffle leakage stream or it is the fraction of shell

side fluid flowing through the clearance between tube hole in baffle and
tube outside diameter.
• This stream does not bypass the heat transfer area (outside area of tubes)
and hence, it does not create any adverse effect on the value of heat
transfer coefficient.
• However, it makes the significant difference in pressure drop (loss). When
stream A leaves this clearance, it forms free flowing jet. Hence, boundary
layer separation occurs and considerable friction loss or pressure drop
takes place.
• Effect of stream A must be considered in the calculation of pressure drop.
2. Stream B
• Stream B is the actual cross flow stream or it is the fraction of shell side
fluid which is flowing across the tube bundle and between the baffles.
• In Kern's method and other old methods, it is assumed that entire shell
side fluid is flowing like stream B.
3. Stream C
• Stream C is bundle to shell bypass stream or it is the fraction of shell side

fluid flowing through the clearance area between shell inside diameter
and tube bundle.
• This clearance area provides low pressure drop path for the shell side
fluid. Hence, of shell side fluid bypassed through this clearance area is
quite significant.
• Amount of stream C can be reduced considerably by using sealing strips

which are attached on inside surface of shell. They provide the partial
blockage or the additional resistance in the path of stream C.

4. Stream E
• Stream E is the baffle to shell leakage stream.
• It is a part of shell side Fluid flowing through the clearance between the
edge of baffle and shell wall.
• Like stream C, this stream is also bypassing the heat transfer area and
hence, reduces shell side heat transfer coefficient. But amount of stream E
is lesser than amount of stream C.
• Normally, the clearance between baffle outside diameter and shell inside
diameter is in the range of 1.6 to 4.8 mm while clearance between tube
bundle and shell inside diameter is in the range of 10 to 100 mm.
5. Stream F
• Stream F is the pass-partition bypass stream. In tube sheets where pass

partition plates are attached in that portion tubes cannot be provided.
• Stream F is the fraction of shell side fluid flowing through these gaps.
• If the gap is vertical, it provides low pressure drop path for fluid flow. Just
like stream C and stream E, this stream is also bypassing the heat transfer
area and reduces shell side heat transfer coefficient.

Design of Vertical Thermosyphon Reboiler
• It is installed in the perfect vertical position in which normal level of liquid

in distillation column is same as level of top tube sheet of heat exchanger.
• Inside the tubes, liquid is partially vaporized by using the heating medium
like saturated steam or hot oil on shell side.
• It decreases the density of fluid (vapor-liquid mixture) in "hot" leg

compared to the density of saturated liquid in relatively "cold" leg and
starts natural fluid circulation in the anticlockwise direction.
• In this type of reboiler, syphoning effect is created by heating (thermally),

hence it is called thermosyphon reboiler.

1. Calculation of Heat Duty For reboilers
∅𝑩 = 𝒎𝒗𝝀 × 𝟏. 𝟎𝟓
Here, mv = mass flowrate of vapor, kg/s
λ = latent heat of vaporization kJ/kg
2. Fix the value of mean temperature difference, ΔTm
It should be less than and close to critical temperature drop.
Then, average temperature of heating medium th = Δ Tm + tB
3. Select the suitable heating medium. Based on the energy balance, find the
mass flow rate of heating medium required.
4. Assume the value of overall heat transfer coefficient, U =1000 W/ (m². *C).
Find the heat transfer area based on assumed value of U

∅𝒕
𝑨=
𝑼 × ∆𝑻𝒎
5. Assume the recirculation ratio equal to 4 for the first trial.
Mass flow rate of liquid recirculated 𝑚𝐿𝑜

Recirculation ratio= =
Vaporization rate 𝑚𝑣𝑜
where, mLo=Mass flow rate of liquid at outlet of reboiler

mvo=Mass flow rate of vapour at outlet of reboiler.

6. Carry out the pressure balance. At steady state
Δpav = Pressure loss in the base of distillation column

+ Pressure loss in associated piping and nozzles
+ Pressure loss in reboiler
∆𝑷𝒂𝒗 ≅ ∆𝑷𝒕
Here ΔPt= tube side pressure loss of reboiler
∆𝑷𝒂𝒗 = 𝑳(𝝆𝑳 − 𝝆𝒂𝒗)𝒈
where, L= Length of tube
ρL= Density of liquid in cold leg. kg/m³
ρ av= Average density of liquid vapor mixture in hot leg. kg/m3
g=Acceleration of gravity-9.81 m/s²

𝑉𝑜
ln
𝑉𝑖
𝜌𝑎𝑣 =
𝑉0 − 𝑉𝑖
Vi=Specific volume of saturated liquid at the inlet of reboiler. = 1/ρL
V0=Specific volume of liquid-vapor mixture at the outlet of reboiler,

m³/kg
(𝑚𝑉𝑜⁄𝜌𝑣 ) + (𝑚𝐿𝑜⁄𝜌𝐿)
𝑉𝑜 =
𝑚𝑣𝑜 + 𝑚𝐿𝑜

7. Compare the value of available differential head Δpav, and pressure drop in
the system or tube side pressure drop, ΔPt, obtained based on assumed
value of recirculation ratio.
There are total five possibilities:
i. ∆𝑷𝒂𝒗 ≅ ∆𝑷𝒕
It implies that the assumed value of recirculation ratio (4 for first trial
calculation) is equal to the actual value of recirculation ratio.
ii. ∆𝑷𝒂𝒗 > ∆𝑷𝒕
It implies that the assumed value of recirculation ratio is less than the
actual recirculation ratio. Hence, assume higher value of recirculation
ratio, repeat the calculations and again compare the new values.
iii. ∆𝑷𝒂𝒗 ≫ ∆𝑷𝒕
It implies that the assumed value of recirculation ratio is very much less
than actual recirculation ratio. In this case also, one can find the value of
recirculation ratio for which ∆𝑷𝒂𝒗 ≅ ∆𝑷𝒕, By trial-and-error calculations
but very high recirculation ratio and hence, very high tube side pressure
drop may be obtained which cannot be permitted.
Very high tube side pressure drop will result in significant boiling point
elevation inside the tubes of the reboiler and decrease the mean
temperature difference.

iv. ∆𝑷𝒂𝒗 < ∆𝑷𝒕
It implies that the actual recirculation ratio is less then assumed or

minimum recommended value of recirculation ratio.
In this case actual recirculation ratio can be increased by electing liquid

level at the base of the distillation column above the top tube sheet of
reboiler.
This modification may increase the height of support of distillation

column.
v. ∆𝑷𝒂𝒗 ≪ ∆𝑷𝒕
It implies that the actual recirculation ratio is very low or very much less
than minimum recommended value (I.e 4)
This is possible when the viscosity of the bottom product of distillation

column is very high.

8. After finding the reciliation ratio for which available differential head
becomes nearly equal to pressure loss in the system and calculate tube
side heat transfer coefficient.
Re is less than 2000 use Sieder-Tate equation.
𝒉𝒊𝒅𝒊 𝒅𝒊 𝟎.𝟑𝟑 𝝁 𝟎.𝟏𝟒

𝑵𝒖 = = 𝟏. 𝟖𝟔 (𝑹𝒆 ∙ 𝑷𝒓 ∙ ) ( )
𝒌𝒇 𝑳 𝝁𝒘
If Re>4000 then use Dittus-bolter equation
𝝁 𝟎.𝟏𝟒
𝑵𝒖 = = 𝑪 𝑹𝒆𝟎. 𝟖 𝑷𝒓 ( )
𝒌𝒇 𝝁𝒘
9. Calculate shell side heat transfer coefficient.
If shell side fluid is saturated steam then take ho=6000 W/m20C
𝝁 𝟎.𝟏𝟒
𝑵𝒖𝒐 = = 𝟎. 𝟑𝟔 𝑹𝒆𝟎. 𝟓𝟓 𝑷𝒓 ( )
𝒌 𝝁𝒘
10. Determine overall heat transfer coefficient.
11. Find the shell side pressure drop. And it should be less than the
maximum allowable value.

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PROCESS EQUIPMENT DESIGN (3170502)

o All chemical reaction and unit operation involve heat transfer.

Shell and tube heat exchangers:

shell and tube heat exchangers are classified in three categories:

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Various Parts Of Shell And Tube Heat Exchangers:

o Shell is the costliest part of the heat exchanger.

2. Shell Side Pass Partition Plate:

o There are two functions of baffles

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5. Tube Side Pass Partition Plate:

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o Spacers are used to maintain the space between baffles.

o It is a shell side component. Sealing strips are attached on the inside

GENERAL DESIGN METHOD FOR SHELL AND TUBE HEAT EXCHANGERS:

1) Calculation of Heat Duty:

m = Mass flow rate of fluid, kg/s

Cp= Specific heat of fluid, kJ/(kg. °C)

∆𝒕 = Temperature difference to be affected, °C

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2. For condensation with subcooling

where, m = Mass flow rate of vapour, kg/s

CL = Specific heat of condensate, kJ/(kg °C)

λ=Latent heat of vaporization, kJ/kg

∅B = mVλ x 1.05 (considering 5% heat loss)

where, m = Vaporization rate, kg/s

λ=Latent heat of vaporization, kJ/kg

Here, mw = mass flowrate of cooling medium, kg/s

CLW = heat capacity of cooling medium, kJ/kgK

t1 = Inlet temperature of cooling medium

3) Mean Temperature Difference

Mean temperature difference is calculated by

Here, ∆𝑇1 and ∆𝑇2 𝑎𝑟𝑒 𝑡ℎ𝑒 𝑡𝑒𝑟𝑚𝑖𝑛𝑎𝑙 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒

T1= hot fluid inlet temp. 0C

T2= hot fluid outlet temp. 0C

t1= cold fluid inlet temp. 0C

t2= cold fluid outlet temp. 0C

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4) Estimation of overall HTC (U):

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Calculate number of tube required by above equation.

DB= tube bundle diameter

K1 and n1 are constants

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1. For no phase change, tube side heat transfer coefficient is determined

𝒉𝒊𝒅𝒊 𝒅𝒊 𝟎.𝟑𝟑 𝝁 𝟎.𝟏𝟒

2. If Re>4000 then tube side HTC can be calculated by Dittus-bolter

h = Tube side heat transfer coefficient, W/(m².C)

k=Thermal conductivity of fluid, W/(m. °C)

𝜇 =Viscosity of fluid pa.s

𝜇 W=Viscosity of fluid at tube wall temperature,

C=0.021 for gases

= 0.023 for non-viscous liquid

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G₁ = Tubeside mass velocity, kg/(m²- s)m

3. Alternatively, tube side heat transfer coefficient h, can be calculated

7) Calculation of Tube Side Pressure Drop

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