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    Heat Exchanger Design Guide: A Practical Guide for Planning, Selecting and Designing of Shell and Tube Exchangers
    Heat Exchanger Design Guide: A Practical Guide for Planning, Selecting and Designing of Shell and Tube Exchangers
    Heat Exchanger Design Guide: A Practical Guide for Planning, Selecting and Designing of Shell and Tube Exchangers
    Ebook554 pages1 hour

    Heat Exchanger Design Guide: A Practical Guide for Planning, Selecting and Designing of Shell and Tube Exchangers

    By Manfred Nitsche and Raji Olayiwola Gbadamosi

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    About this ebook

    Heat Exchanger Design Guide: A Practical Guide for Planning, Selecting and Designing of Shell and Tube Exchangers takes users on a step-by-step guide to the design of heat exchangers in daily practice, showing how to determine the effective driving temperature difference for heat transfer.

    Users will learn how to calculate heat transfer coefficients for convective heat transfer, condensing, and evaporating using simple equations. Dew and bubble points and lines are covered, with all calculations supported with examples.

    This practical guide is designed to help engineers solve typical problems they might encounter in their day-to-day work, and will also serve as a useful reference for students learning about the field. The book is extensively illustrated with figures in support of the text and includes calculation examples to ensure users are fully equipped to select, design, and operate heat exchangers.

    • Covers design method and practical correlations needed to design practical heat exchangers for process application
    • Includes geometrical calculations for the tube and shell side, also covering boiling and condensation heat transfer
    • Explores heat transfer coefficients and temperature differences
    • Designed to help engineers solve typical problems they might encounter in their day-to-day work, but also ideal as a useful reference for students learning about the field
    LanguageEnglish
    PublisherElsevier Science
    Release dateSep 28, 2015
    ISBN9780128038222
    Heat Exchanger Design Guide: A Practical Guide for Planning, Selecting and Designing of Shell and Tube Exchangers
    Author

    Manfred Nitsche

    Dr. Manfred Nitsche has more than 40 years’ experience as a chemical engineer. During his career he has designed and built several chemical plants and has been giving engineering training courses for young engineers since 1980. He has written a number of books on piping design, heat exchanger design, heating and cooling systems in plants, column design and waste air cleaning (all in German). Dr. Nitsche's extensive experience includes designing and building distillation units, tank farms, stirred tank reactor facilities, air purification units and absorption and stripping units for various applications.

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    • 4/5
      It is a very good book of heat transfer design. I saw not only heat exchangers, nor evaporators, chillers, so on.
      What I did not like about this book is that I could see the pages 482 to the end.

      1 person found this helpful

    Book preview

    Heat Exchanger Design Guide - Manfred Nitsche

    Heat Exchanger Design Guide

    A Practical Guide for Planning, Selecting and Designing of Shell and Tube Exchangers

    M. Nitsche

    R.O. Gbadamosi

    With numerous practical Examples

    Table of Contents

    Cover image

    Title page

    Copyright

    Foreword

    Chapter 1. Heat Exchanger Design

    1.1. Procedure in Heat Exchanger Design

    1.2. Information about Heat Exchangers

    Nomenclature

    Chapter 2. Calculations of the Temperature Differences LMTD and CMTD

    2.1. Logarithmic Mean Temperature Difference for Ideal Countercurrent Flow

    2.2. Corrected Temperature Difference for Multipass Heat Exchanger

    2.3. Influence of Bypass Streams on LMTD

    2.4. Mean Weighted Temperature Difference

    2.5. Determination of the Heat Exchanger Outlet Temperatures

    Chapter 3. Calculations of the Heat Transfer Coefficients and Pressure Losses in Convective Heat Transfer

    3.1. Tube-Side Heat Transfer Coefficient

    3.2. Shell-Side Heat Transfer Coefficient

    3.3. Comparison of Different Calculation Models

    3.4. Pressure Loss in Convective Heat Exchangers

    3.5. Heat Exchanger Design with Heat Exchanger Tables

    Nomenclature

    Chapter 4. Geometrical Heat Exchanger Calculations

    4.1. Calculation Formula

    4.2. Tube-Side Calculations

    4.3. Shell-Side Calculations

    Chapter 5. Dimensionless Characterization Number for the Heat Transfer

    5.1. Reynolds Number Re for the Characterization of the Flow Condition

    5.2. Prandtl Number Pr, Peclet Number Pe, and Temperature Conductivity a 

    5.3. Nusselt Number Nu for the Calculation of the Heat Transfer Coefficient

    5.4. Stanton Number St for the Calculation of the Heat Transfer Coefficient

    5.5. Colburn Factor JC for the Calculation of the Heat Transfer Coefficient

    5.6. Kern Factor JK for the Calculation of the Heat Transfer Coefficient

    5.7. Graßhof Number Gr for the Calculation of the Heat Transfer Coefficient in Natural Convection

    Chapter 6. Overall Heat Transfer Coefficient and Temperature Profile

    6.1. Calculation of the Overall Heat Transfer Coefficient 

    6.2. Calculation of the Temperature Gradient in a Heat Exchanger

    6.3. Viscosity Correction

    6.4. Calculation of the Heat Transfer Coefficient from the Overall Heat Transfer Coefficient

    Nomenclature

    Chapter 7. Chemical Engineering Calculations

    7.1. Vapor Pressure Calculations

    7.2. Equilibrium between the Liquid and the Vapor Phase

    7.3. Bubble Point Calculation

    7.4. Dew Point Calculation

    7.5. Calculation of Dew and Bubble Lines of Ideal Binary Mixtures

    7.6. Flash Calculations

    7.7. Condensation or Flash Curve of Binary Mixtures

    7.8. Calculation of Nonideal Binary Mixtures

    7.9. Flash Calculations for Multicomponent Mixtures

    Chapter 8. Design of Condensers

    Construction Types of Condensers

    8.1. Condenser Construction Types

    8.2. Heat Transfer Coefficients in Isothermal Condensation

    8.3. Comparison of Different Calculation Models

    8.4. Condensation of Vapors with Inert Gas

    8.5. Condensation of Multicomponent Mixtures

    8.6. Miscellaneous

    Nomenclature

    Chapter 9. Design of Evaporators

    9.1. Evaporation Process

    9.2. Evaporator Construction Types

    9.3. Design of Evaporators for Nucleate Boiling

    9.4. Design of Falling Film Evaporators

    Chapter 10. Design of Thermosiphon Reboilers

    10.1. Thermal Calculations

    10.2. Calculation of the Heat Transfer Coefficient

    10.3. Calculation of the Two-Phase Density and the Average Density in the Reboiler

    10.4. Flow Velocity wReb in the Reboiler

    10.5. Determination of the Required Height H1 for the Thermosiphon Circulation or the Maximum Allowable Pressure Loss ΔPmax in Thermosiphon Circulation

    10.6. Design of Riser and Downcomer Diameter

    10.7. Calculation of the Pressure Losses in the Thermosiphon Circulation

    10.8. Calculation of the Required Reboiler Length or Area for the Heating up to the Boiling Temperature and for the Evaporation in Vertical Thermosiphon Evaporators

    10.9. Required Heating Length for Vertical Thermosiphon Reboilers According to Fair

    10.10. Calculation of the Pressure and Boiling Point Increase by Means of the Liquid Height H1

    10.11. Average Overall Heat Transfer Coefficient for Heating + Vaporizing

    10.12. Calculation of the Vapor Fraction x of the Two-Phase Mixture in a Vertical Reboiler

    10.13. Thermosiphon Reboiler Design Example

    Chapter 11. Double Pipe, Helical Coil, and Cross Flow Heat Exchanger

    11.1. Double Pipe and Multipipe Heat Exchangers

    11.2. Helical Coil Heat Exchanger

    11.3. Cross Flow Bundle

    Nomenclature

    Chapter 12. Finned Tube Heat Exchangers

    12.1. Why Finned Tube Heat Exchangers?

    12.2. What Parameters Influence the Effectiveness of Finned Tubes?

    12.3. Finned Tube Calculations

    12.4. Application Examples

    Index

    Copyright

    Butterworth Heinemann is an imprint of Elsevier

    The Boulevard, Langford Lane, Kidlington, Oxford OX5 1GB, UK

    225 Wyman Street, Waltham, MA 02451, USA

    Copyright © 2016 Elsevier Inc. All rights reserved.

    No part of this publication may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording, or any information storage and retrieval system, without permission in writing from the publisher. Details on how to seek permission, further information about the Publisher’s permissions policies and our arrangements with organizations such as the Copyright Clearance Center and the Copyright Licensing Agency, can be found at our website: www.elsevier.com/permissions.

    This book and the individual contributions contained in it are protected under copyright by the Publisher (other than as may be noted herein).

    Notices

    Knowledge and best practice in this field are constantly changing. As new research and experience broaden our understanding, changes in research methods, professional practices, or medical treatment may become necessary.

    Practitioners and researchers must always rely on their own experience and knowledge in evaluating and using any information, methods, compounds, or experiments described herein. In using such information or methods they should be mindful of their own safety and the safety of others, including parties for whom they have a professional responsibility.

    To the fullest extent of the law, neither the Publisher nor the authors, contributors, or editors, assume any liability for any injury and/or damage to persons or property as a matter of products liability, negligence or otherwise, or from any use or operation of any methods, products, instructions, or ideas contained in the material herein.

    ISBN: 978-0-12-803764-5

    British Library Cataloguing-in-Publication Data

    A catalogue record for this book is available from the British Library

    Library of Congress Cataloging-in-Publication Data

    A catalog record for this book is available from the Library of Congress

    For information on all Butterworth Heinemann publications visit our website at http://store.elsevier.com/

    Publisher: Joe Hayton

    Acquisition Editor: Fiona Geraghty

    Editorial Project Manager: Cari Owen

    Production Project Manager: Susan Li

    Designer: Victoria Pearson

    Typeset by TNQ Books and Journals

    www.tnq.co.in

    Printed and bound in the United States of America

    Foreword

    Dear Reader,

    This book is not an academic treatise but rather a book for solving daily practical problems easily and for the illustration of essential influencing variables in the design of heat exchangers, condensers, or evaporators.

    All calculations are explained with examples that I am using in my seminars since several years.

    In this book, you will be shown how to proceed in the design of a heat exchanger in the daily practice, how to determine the effective temperature difference for the heat transfer, and how to calculate the heat transfer coefficient using simple equations.

    The most important influence parameters for the heat transfer coefficient are introduced. Different calculation models are compared. It is shown how to calculate the required dew point and bubble point lines for mixtures.

    From the wide range of published calculation methods, I have chosen the models that can simply be calculated using the hand calculator and deliver sure results. I refer to the models which I have chosen from several existing literatures as Nitsche methods because I recommend these.

    During the time from 1966 to 2007, I designed, planned, and built several chemical plants: distillation plants with evaporators, condensers, and heat exchangers, for fatty alcohols, fatty acids, nitrochlorobenzenes, amine and hydrocarbons and tar oils; storage tanks and vessels with filling stations for tank truck, rail tank car, and barrels; stirred tank plants for reactions with decanters, centrifuges, and filters; plants for exhaust air purification and gasoline recovery, methanol and ethyl acetate etc.; stripper for of sour water purification or for methyl isobutyl ketone recovery.

    Since 1980, I report in seminars about piping, heat exchangers, and chemical plants about my practical experiences in the Design and Planning. At the latest, I realized during plant startup what I wrongly calculated or what I wrongly planed. This book should help you to minimize the mistakes in the design of heat exchangers.

    Hamburg

    Dr Manfred Nitsche

    Chapter 1

    Heat Exchanger Design

    Abstract

    How does one proceed if a new heat exchanger for a specific heat load is to be designed? Which calculations are required? A schema for the design of a heat exchanger for a given problem definition is introduced and explained with an example. After some explanations to the different tube patterns and the different baffles, the problems of bypass and leakage streams and the accommodation of different expansions at the tube and shell side are treated. Finally, a schema is given for the selection of the appropriate TEMA type for the given problem definition.

    Keywords

    Baffles; Bypass streams; Design schema; Expansion compensation; Selection schema for TEMA type; TEMA standard; Tube pattern

    Contents

    1.1 Procedure in Heat Exchanger Design 2

    1.2 Information about Heat Exchangers 12

    1.2.1 Tube Pattern 12

    1.2.2 Bypass and Leakage Streams 13

    1.2.3 Baffles 14

    1.2.4 Technical Remarks 15

    1.2.5 Selection of a Shell and Tube Exchanger 16

    1.2.5.1 Which Heat Exchanger Types Can Be Cleaned? 17

    Nomenclature 18

    References 19

    In heat exchanger design the required heat exchanger area A (m²) is determined for a certain heat load Q (W) at a given temperature gradient Δt (°C).

    The overall heat transfer coefficient, U, is calculated as follows:

    fi  =  inner fouling factor (m²  K/W)

    fo  =  outer fouling factor (m²  K/W)

    U  =  overall heat transfer coefficient (W/m²  K)

    s  =  tube wall thickness (m)

    λ  =  thermal conductivity of the tube material (W/m  K)

    αi  =  inner heat transfer coefficient in the tubes (W/m²  K)

    αo  =  outer heat transfer coefficient on the shell side (W/m²  K)

    Figure 1.1 shows which overall heat resistances have to be overcome and how the temperature profile in a heat exchanger looks like.

    The overall heat transfer coefficients and the temperature profile will be calculated in Chapter 6.

    Reference values for heat transfer coefficients and overall heat transfer coefficients are listed in Table 1.1.

    Figure 1.1  Heat transfer resistances and temperature profile.

    1.1. Procedure in Heat Exchanger Design

    In order to calculate the convective heat transfer coefficients, the Reynolds number is needed.

    The heat transfer coefficients, α, are dependent on the Reynolds number, Re, hence the flow velocity, w, on the tube and shell side, respectively.

    Therefore the cross-sectional areas must be known in order to determine the flow velocities and the Reynolds numbers. For an existing heat exchanger, this is not a problem if a drawing is available. In the case of the design of a new heat exchanger, the flow cross sections are not known. So, initially an estimation of the required area has to be done and then an appropriate equipment has to be selected.

    For the selection, the following criteria should be applied:

    • The flow velocity on both sides should be in the order of 0.5–1  m/s for liquids and in the range of 15–20  m/s for gases.

    • The required heat exchanger area should be achieved with tube length of 3–6  m.

    In Figure 1.3 the flow chart for the heat exchanger design is provided [1].

    In the following the procedure of heat exchanger design is explained in some more detail:

    1. Determine flow rates, temperatures, and the fluid property data

    2. Determination of the heat loads on tube and shell side

        For condensers and evaporators, the condensation and the vaporization enthalpies need to be considered.

    Table 1.1

    Reference values for heat transfer coefficients, α

    Table 1.2

    Geometric data of heat exchangers according to DIN 28,184, part 1, for 25  ×  2 tubes with 32  mm triangular pitch

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