1

PROC 5071:
Process Equipment Design I

Workbooks: Shell and tube heat exchanger design

Salim Ahmed

Salim Ahmed PROC 5071: Process Equipment Design I

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1 Workbook: Calculation of LMTD

1.1 The problem

A heat exchanger is to be used to subcool con-

densate from a methanol condenser from 95oC
to 40oC. Flow rate of methanol 100, 000kg/h.
Brackish water will be used as the coolant, with
a temperature rise from 25oC to 40oC.
Considering a 1-2 shell and tube heat exchanger,
calculate the corrected log mean temperature dif-
ference (LMTD).

1.2 Notes and analysis

• We will use the notations T and t for the hot

and cold fluid temperature, respectively.
• For the ends, 1 is used for the inlet of the hot
stream.
• For countercurrent, end 2 is the inlet for the
cold fluid.
Salim Ahmed PROC 5071: Process Equipment Design I
1.3 Calculation steps 3

• Brackish water being corrosive, it’s allocated to

the tube side (why?).

1.3 Calculation steps

Step 1 : Calculate LMTD (∆lm) assuming a sin-

gle pass countercurrent flow.
Step 1.1 : Identify the temperatures.
Using the above mentioned notations, for the coun-
tercurrent flow
T1 = 95oC
T2 = 40oC
t1 = 40oC
t2 = 25oC

Step 1.2 : Calculate ∆T1 and ∆T2.

Salim Ahmed PROC 5071: Process Equipment Design I

1.3 Calculation steps 4

∆T1 = T1 − t1
= 95oC − 40oC
= 55oC

∆T2 = T2 − t2
= 40oC − 25oC
= 25oC

Step 1.3 : Calculate ∆Tlm.

(55 − 15)oC
∆Tlm = 55 oC
ln 15oC
= 30.8oC

Step 2 : Calculate the correction factor, FT .

Step 2.1 : Calculate the constants R and S

Salim Ahmed PROC 5071: Process Equipment Design I

1.3 Calculation steps 5

• R is defined as the ratio of temperature de-

crease of the hot fluid to the temperature in-
crease of the cold fluid
T1 − T2
R =
t1 − t2
(95 − 40)oC
=
(40 − 25)oC
= 3.67

• S is defined as the ratio of the temperature

increase of the cold fluid to the difference be-
tween the inlet temperatures of the two fluids
t1 − t2
S =
T1 − t2
(40 − 25)oC
=
(95 − 25)oC
= 0.21

Salim Ahmed PROC 5071: Process Equipment Design I

1.3 Calculation steps 6

Step 2.2 : From the graph find the value of the

correction factor.

Figure 1: Temperature correction factor for 1-2 shell and tube heat exchangers.

Alternatively, the following equation can be used

to calculate FT .
√ h
1−S
i
R2 + 1 ln 1−RS
FT = "  √ #
2−S R+1− R2+1
(R − 1) ln  √ 
2−S R+1+ R2+1

Salim Ahmed PROC 5071: Process Equipment Design I

1.3 Calculation steps 7

The value of FT is obtained as

FT = 0.85

Step 3 : Calculate the corrected mean tempera-

ture.

∆Tm = FT × ∆Tlm
= 0.85 × 38oC
= 26oC

Salim Ahmed PROC 5071: Process Equipment Design I

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2 Workbook: Calculation of the tube side

heat transfer coefficients

2.1 The problem

A heat exchanger is to be used to subcool con-

densate from a methanol condenser from 95oC
to 40oC. Flow rate of methanol 100, 000kg/h.
Brackish water will be used as the coolant, with
a temperature rise from 25oC to 40oC.
Considering a 1-2 shell and tube heat exchanger,
calculate the tube side heat transfer coefficient.

2.2 Additional information

• Brackish water in the tube side.

• Pipes to be used for the tube side has the spec-
ification: 3/4in, 16f t that has the following
dimensions
i.d. = 16mm, o.d. = 20mm, length = 4.88m
• Table of fluid properties at average conditions
Salim Ahmed PROC 5071: Process Equipment Design I
2.3 Problem analysis 9

Table 1: Water properties.

Property Value
ρ 995kg/m3
µ 0.8mN.s/m2
Cp 4.2kJ/kg.oC
k 0.59W/m.oC
Table 2: Methanol properties.

Property Value
Cp 2.84kJ/kg.oC
2.3 Problem analysis

First look at the equation for determining the

tube side heat transfer coefficient:
 0.14
0.33 µ
N u = jhReP r
µw
with
htdi
Nu =
kf
diutρ
Re =
µ
cp µ
Pr =
kf
Salim Ahmed PROC 5071: Process Equipment Design I
2.3 Problem analysis 10

To determine ht we need to know the following

variables
• di: inner diameter of tubes - given
• kf : conductivity of water - table
• ρ: density of water - table
• µ: viscosity of water - table
• Cp: specific heat of water - table
• µw : viscosity of water at wall temperature -
table if tw is known
• ut: velocity of water in the tube - can be cal-
culated

How to calculate ut:

• We need to know flow rate of water, which can
be calculated from heat duty
• We need to know the flow area of water.

Salim Ahmed PROC 5071: Process Equipment Design I

2.4 Solution 11

• Flow area can be calculated if the tube i.d

(given) and number of tubes are known.
• To know number of tubes, we need heat trans-
fer area.
• to know heat transfer area, we need to know
the overall heat transfer coefficient (U).
• To calculate U we need ht
This makes the calculation procedure an
iterative problem. Fortunately we know
how to solve problems iteratively!
So let’s do it

2.4 Solution

1. First let us assume a value of the overall heat

transfer coefficient based on the outside tube
area.
Uo = 0.6 kW/m2.oC
2. Calculate the heat duty. This can be done for

Salim Ahmed PROC 5071: Process Equipment Design I

2.4 Solution 12

the hot fluid.

Q = ṁCp∆T methanol
= (100000 kg/h)(2.84 kJ/kg.oC)(95 − 40)oC
= 4339 kW
3. Calculate the heat transfer area (outer surface
area of tubes) from
Q = UoAo∆Tm
∆Tm is the corrected LMTD. So we have
Q
Ao =
Uo∆Tm
4339kW
=
(0.6kW/m2.oC)(26oC)
= 278m2
4. Calculate the number of tubes
• o.d. of tubes = 20mm
• Effective length = 4.83m

Salim Ahmed PROC 5071: Process Equipment Design I

2.4 Solution 13

• Outside surface area of one tube

= πdoL
= π(20mm)(4.83m)(1m/1000mm)
= 0.3035m2
• Number of tubes
278m2
=
0.3035m2
= 916
5. Calculate the tube side flow area
• Inside flow area for one tube
π
= (16mm)2
4
= 201mm2
• Total tubes = 916. As there are 2 passes,
number of tubes per pass = (916/2) = 458.
• Total flow area inside tube per pass
= (201mm2)(458)(10−6m2/mm2)
= 0.092m2

Salim Ahmed PROC 5071: Process Equipment Design I

2.4 Solution 14

6. Calculate fluid velocity inside tube

• Mass flow rate of water can be obtained from
heat duty


Q = ṁCp∆T water
Giving
Q
ṁwater =

Cp∆T water
4339kW
=
(4.2kJ/kg.oC)(40 − 25)oC
= 68.87kg/s
• Mass flux can be obtained using the flow area
ṁwater
Gwater =
0.092m2
68.87kg/s
=
0.092m2
= 749kg/s.m2

Salim Ahmed PROC 5071: Process Equipment Design I

2.4 Solution 15

• Velocity is obtained using fluid density

Gwater
ut =
ρ
749kg/s.m2
=
995kg/m3
= 0.75m/s
7. Now calculate Re and P r
diutρ
Re =
µ
(16 × 10−3m)(0.75m/s)(995kg/m3)
=
0.8 × 10−3N.s/m2
= 14925

Cp µ
Pr =
kf
(4.2 × 103J/kg.oC)(0.8 × 10−3N.s/m2)
=
0.59W/m.oC
= 5.7
8. Obtain jh using the value of Re from the at-
tached graph. Note that you do not need L.D
Salim Ahmed PROC 5071: Process Equipment Design I
2.4 Solution 16

for this value of Re.

jh = 4 × 10−3

Figure 2: Tube side jh factor.

9. Finally calculate N u and obtain ht by neglect-

ing the viscosity correction term
htdi
= jhReP r0.33
kf
= (4 × 10−3)(14925)(5.7)0.33
= 106

Salim Ahmed PROC 5071: Process Equipment Design I

2.4 Solution 17

So we get
(106)(kf )
ht =
di
(106)(0.59W/m.oC)
=
16 × 10−3m
= 3910W/m2.oC
Are we done? Not yet!
• We started the calculation based on an assumed
value of U . So we need to check whether that
was right.
• To check that we need to estimate the shell
side coefficient which will be our task for next
workbook.
• Also we neglected the viscosity correction fac-
tor. To get that we need the wall temperature
which also a part of the next workbook.

Salim Ahmed PROC 5071: Process Equipment Design I

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3 Workbook: Calculation of the shell side

heat transfer coefficient

3.1 Problem statement

A heat exchanger is to be used to subcool con-

densate from a methanol condenser from 95oC
to 40oC. Flow rate of methanol 100, 000kg/h.
Brackish water will be used as the coolant, with
a temperature rise from 25oC to 40oC.
Considering a 1-2 shell and tube heat exchanger,
calculate the shell side heat transfer coefficient.

3.2 Additional information

• All information from the previous workbooks

are valid.

Salim Ahmed PROC 5071: Process Equipment Design I

3.3 Analysis 19

Table 3: Methanol properties.

Property Value
ρ 750kg/m3
µ 0.34mN.s/m2
Cp 2.84kJ/kg.oC
k 0.19W/m.oC
3.3 Analysis

First look at the equation for determining the shell

side heat transfer coefficient:
 0.14
0.33 µ
N u = jhReP r
µw
with
hsde
Nu =
kf
deusρ
Re =
µ
cpµ
Pr =
kf

Salim Ahmed PROC 5071: Process Equipment Design I

3.3 Analysis 20

To determine hs we need to know the following

variables
• de: equivalent diameter - calculate from tube
dimensions and pitch
• kf : conductivity of methanol - table
• ρ: density of methanol - table
• µ: viscosity of methanol - table
• Cp: specific heat of methanol - table
• µw : viscosity of methanol at wall temperature
- table if tw is known
• us: velocity of methanol in the shell - can be
calculated

How to calculate us:

• We need to know flow rate of methanol, which
is given
• We need to know the flow area of water.
Salim Ahmed PROC 5071: Process Equipment Design I
3.4 Solution 21

• Flow area can be calculated if tube dimensions,

pitch, shell dimensions and baffle configuration
are known. To know all of these, we need heat
transfer area.
• to know heat transfer area, we need to know
the overall heat transfer coefficient (U).
• To calculate U we need hs
Again this becomes an iterative problem
So let’s do it

3.4 Solution

1. From the tube side calculation, we get the num-

ber of tubes = 916.
2. Also the tube dimensions are given which are
i.d. = 16mm and 0.d. = 20mm.
3. These tubes are to be placed in the shell and
we need to know the size of the shell that can
accommodate all these tubes. The diameter of

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3.4 Solution 22

the tube bundle can be obtained from

 1
Nt n1
Db = do
K1
where, Nt is the number of tubs and n1 and K1
are constants that are given in the literature.
For 2 tube passes the values are
K1 = 0.249 n1 = 2.207
So we have
  1
916 2.207
Db = (20mm) = 825mm
0.249
For this problem we will use a split ring floating
type head for which bundle diameter clearance
is 68mm. So we get the shell diameter as
Ds = 825mm + 68mm = 893mm
4. Calculate the velocoty/mass velocity of methanol
in the shell side. For this we need to calculate
the flow area which is the area between two
baffles.
Salim Ahmed PROC 5071: Process Equipment Design I
3.4 Solution 23

Figure 3: Simplified flow pattern of liquid in the shell.

• Choose baffle spacing as 15 th of the shell di-

ameter
Ds 893mm
Baf f le spacing = = = 178mm
5 5
• Choose tube pitch as 1.25do.
pt = 1.25do = 1.25(20mm) = 25mm
• Cross flow area is obtained as
 
25 − 20
As = (893)(178)mm2 = 0.032m2
25
• Mass velocity is obtained as
ṁ 100000kg/h
Gs = =
As 0.032m2
= 868kg/s.m2

Salim Ahmed PROC 5071: Process Equipment Design I

3.4 Solution 24

• The equivalent diameter is given by

1.1  2 
de = pt − 0.907d2o
do
1.1  
= (25mm)2 − 0.907(20mm)2
20mm
= 14.4mm
5. Now calculate Re and P r
deusρ deGs
Re = =
µ µ
(14.4 × 10−3m)(868kg/s.m23)
=
0.34 × 10−3N.s/m2
= 36, 672

Cp µ
Pr =
kf
(2.84 × 103J/kg.oC)(0.34 × 10−3N.s/m2)
=
0.19W/m.oC
= 5.1
6. Obtain jh using the value of Re from the at-
tached graph. Note that we will use a 25%4

Salim Ahmed PROC 5071: Process Equipment Design I

3.4 Solution 25

baffle cut.
jh = 3.3 × 10−3

Figure 4: Shell side jh factor.

7. Finally calculate N u and obtain ht by neglect-

ing the viscosity correction term
hsde
= jhReP r0.33
kf
= (3.3 × 10−3)(36672)(5.1)0.33
= 207.7
Salim Ahmed PROC 5071: Process Equipment Design I
3.4 Solution 26

So we get
(207.7)(kf )
hs =
de
(207.7)(0.19W/m.oC)
=
14.4 × 10−3m
= 2740W/m2.oC

Salim Ahmed PROC 5071: Process Equipment Design I

 27

4 Workbook: Calculation of the overall

heat transfer coefficient

4.1 Problem statement

A heat exchanger is to be used to subcool con-

densate from a methanol condenser from 95oC
to 40oC. Flow rate of methanol 100, 000kg/h.
Brackish water will be used as the coolant, with
a temperature rise from 25oC to 40oC.
Considering a 1-2 shell and tube heat exchanger,
calculate the overall heat transfer coefficient.

4.2 Additional information

• Pipes to be used for the tube side has the spec-

ification: 3/4in, 16f t that has the following
dimensions
i.d. = 16mm, o.d. = 20mm, length = 4.88m
• The conduction heat transfer coefficient of the
wall is given by kw = 50W/m.oC
Salim Ahmed PROC 5071: Process Equipment Design I
4.3 Analysis 28

4.3 Analysis

• The overall heat transfer coefficient is given by

1 1 1 do ln(do/di) 1 do 1 do
= + + + +
Uo ho hod 2kw hi di hid di
• From the previous workbooks we got
hi = 3910w/m2.oC
ho = 2740w/m2.oC
• The value of the dirt coefficients can be ob-
tained from the following table.

Salim Ahmed PROC 5071: Process Equipment Design I

4.4 Solution 29

4.4 Solution

• From the table, for brackish water, the heat

transfer coefficient value of sea water is taken
as and for methanol, that of organic liquid can
be used.
• So we get,
hid = 3000W/m2.oC
hod = 5000W/m2.oC
• To get the overall heat transfer coefficient
1 1 1 do ln(do/di) 1 do 1 do
= = + + + +
Uo ho hod 2kw hi di hid di
1 1
= +
2740 5000
20 × 10−3 ln(20/16)
+
2 × 50
1 20 1 20
+ +
3910 16 3000 16
= 743
• The value is significantly different from the as-
sumed value. So the entire calculation needs
Salim Ahmed PROC 5071: Process Equipment Design I
4.4 Solution 30

to be repeated.

Salim Ahmed PROC 5071: Process Equipment Design I

4.4 Solution 31

References

1. G. Towler and R. Sinnott. Chemical Engineer-

ing Design: Principles, Practice and Economics
of Plant and Process Design. Butterworth-Heinemann
2008.

Salim Ahmed PROC 5071: Process Equipment Design I