HEAT TRANSFER

AND
HEAT EXCHANGERS

Slide 1
 What We Will Cover

Heat transfer theory-review

Relation of heat transfer theory to shell and tube

heat exchangers

Design of a S&T exchanger--procedure outline

Design features and parameters of shell and tube

exchangers

Slide 2
 BASIC HEAT TRANSFER CONCEPTS

Flow of heat behaves like flow of fluids and flow of

electrons

Driving Force
Rate K x Resistance (General)

Pressure Drop
QK x Resistance (Fluids)

Voltage
I = 1.0 x Resistance (Electricity)

Temperature Difference
QK x Resistance (Heat)

Slide 3
 COMPARISON WITH FLUIDS

Fluids: 2 = K x (P2 - P1) (Remember Section 3?)

Q
A fL
D
Heat: Q = 1 x (T2 - T1)
A RT

FLUIDS HEAT

Q = Volume / Second Q = Btu / Hour

P2, P1 = Higher, lower pressures T2, T1 = Higher, lower
temperatures
A = Area available for flow RT = Total specific
resistance

fL
4 * D = Number of fluid flow A = Area available for flow
resistance units of heat

Slide 4
 BASIC HEAT TRANSFER EQUATION

Q = 1 x (T2 - T1) = 1 x T
A RT RT

RT = Total Resistance, Hr x FT2 x F / Btu

I = Total Conductivity = U Btu / Hr x Ft2 x F

RT
Q = 1 x U T
A

Q = U x A x T Btu / Hr

U is Referred to as the Overall Heat Transfer Coefficient

Slide 5
 TOTAL RESISTANCE TO HEAT FLOW - HEAT EXCHANGERS

There are two areas through which heat must flow: The
inside tube area and the outside tube area. Resistance
occurs at both areas.

The Industry Standard Reference Area is the Outside Tube

Area.

Slide 6
 INDIVIDUAL COMPONENTS OF THE TOTAL RESISTANCE

Ao
Inside Film Resistance = R io = R i
Ai
Ao
Inside Fouling Resistance = r io = r i
Ai
Tube Wall Resistance = r w = w / k w

Outside Fouling Resistance = ro

Outside Film Resistance = Ro

Rio + rio + rw + ro + Ro = RT = I
U
w = Wall Thickness, Feet

Kw = Thermal Conductivity, Btu / Hr x Ft 2 x F

Ft
r = Resistances, Hr x Ft2 x F/Btu

Slide 7
 INDIVIDUAL COMPONENTS OF THE TOTAL RESISTANCE

Slide 8
 TYPICAL RESISTANCE VALUES

Very Low Typical Very High

Film Resistances (Each) 0.00050 0.004 0.04

(Inverse = h) (2000) (250) (25)

Fouling Resistance (Each) 0.001 0.002 0.01

Inverse (1000) (500) (100)

Wall Resistance 0.000030 0.00027 0.00049

Inverse (32,000) (3760) (2030)

Total Resistance 0.00303 0.01227 0.10050

Inverse (330) (81) (10)

Slide 9
 THE CONTROLLING COEFFICIENT

Frequently One of the two film coefficients determines the value of the overall
coefficient:

Out side Coefficient, h = 75 75 150

Inside Coefficient, hio = 1000 3000 1000
Ro = 0.01333 0.01333 0.00667
Rio = 0.00100 0.00033 0.00100
rw + rio + ro = 0.00070 0.00070 0.00070
RT = 0.01503 0.01436 0.00837
U = 66.5 69.6 119.5
Improvement = Base +4.6% +80%

Hence h is the Controlling Coefficient, and efforts to improve exchanger

performance should concentrate on this side of the exchanger.

Slide 10
 TEMPERATURE DROPS ACROSS THE RESISTANCES

Temperature drop across each of the resistances is

directly proportional to each resistance.
For example, If T2 = 200 and T1 = 80, then total temperature
drop = 120F, and:

Temperature Drop

Ro = 0.01333 77.6 = 0.01333 x 120

Rio = 0.00500 29.1 0.02063
rw = 0.00030 1.7
rio+ ro = 0.00200 1.6
RT = 0.02063 120F

Slide 11
 TEMPERATURE DROPS ACROSS THE RESISTANCES

A Useful Concept is Heat Flux = Q = Btu

A
Hr x Ft2

Q = U x A x (T2 - T1) = U x A x T

Q
Then T = Q = * x R = Flux x Resistance
A
UxA

Then Q = T = 120
A RT 0.02063

= 5817 Btu , and T across Ro = 5817 x 0.01333 = 77.6 F

Hr x Ft
as shown on that slide.

Slide 12
 BACK TO BASICS

Weve looked at basic theory, and discussed Q = U x A x T. In

refinery work we usually know either Q or A, and need to calculate the
other value.
How do we do it?

Either question requires calculating U or T.

Well talk about U later, first lets discuss T, the temperature driving
force.

Note that capital letter T denotes the hot stream, while lower case t
denotes the cold stream:

T1 = Hot In T2 = Hot Out

t1 = Cold In t 2 = Cold Out

Slide 13
 FLOW PATTERNS AND TEMPERATURE DRIVING FORCE

Slide 14
 FLOW PATTERNS AND TEMPERATURE DRIVING FORCE

Slide 15
 FLOW PATTERNS AND TEMPERATURE DRIVING FORCE

Slide 16
 FLOW PATTERNS AND TEMPERATURE DRIVING FORCE

Slide 17
 TEMPERATURE DRIVING FORCE

From the preceding slides, it is clear that some sort of average driving force
must be used in design calculations.
What is this average?
The average is called The Effective Mean Temperature Difference, or MTDe.
For true countercurrent and true cocurrent flow, the effective driving force
equals the log mean average of the two extreme (largest and smallest) deltas.

(T1 - t2) - (T2 - t1)

Te = LMTD = (T1 - t2)
LN (T2 - t1)

This is precisely true only when the heat release curves are straight lines.
Otherwise it is an approximation.

Slide 18
 TEMPERATURE DRIVING FORCE

What about mixed flow: Shell and Tube Exchangers?

The complex flow in these units was analyzed mathematically

many years ago, resulting in rigorous equations for a
Correction Factor, Fn. This is multiplied by the LMTD to give
the correct MTDe.

MTDe = Fn x LMTD

Equations are valid only when heat release curves are linear.

Similar relations are available for transverse flow (air fin

coolers, for example).

Slide 19
 CALCULATION OF Fn

Depends on the number of shells in series (Shell Passes)

The more shells one has in series, the closer Fn approaches 1.0

Typically the minimum acceptable value of Fn is 0.8

What exactly do we mean by shells in series or shell

passes?

Slide 20
 CALCULATION OF Fn - SHELL PASSES

Slide 21
 CALCULATION OF Fn - SHELL PASSES

Slide 22
 CALCULATION OF Fn

Complex equations simplified to charts

See TEMA Section 7, or Exxon DP IX-D
Applicable only to linear heat curves

Slide 23
 CALCULATION OF Fn

Example

T1 = 300 t1 = 85
T2 = 105 t2 = 115

P = j = 115 - 85 = 0.14
300 - 85

R = 300 - 105 = 6.5

115 - 85

R n (1 Shell) = <0.8 (unreadable on chart) - Unacceptable

Fn (2 Shell) = 0.95 Use two shells

Slide 24
 CALCULATION OF Fn

Since this technique is applicable only to the case of

straight-line heat release, how do we estimate number
of shells and MTDe for other cases?

Slide 25
 NON-LINEAR HEAT RELEASE - MTDe SUGGESTION FOR COMPLEX
CASES SUCH AS REFORMER FEED/EFFLUENT

Plot T Vs. Enthalpy

Step Off to Get Minimum Number of Shells
Calculate MTDe for Each Shell (Discuss Later)

Slide 26
 NON-LINEAR HEAT RELEASE--MTDe
SUGGESTION FOR CONDENSERS

Plot the condensing curve

Assume cold side is linear and draw in cold side flow pattern
If two shells, assume equal duties

Slide 27
 MTDe FOR CONDENSERS (Continued)

Calculate the LMTD for each zone, assuming that the cold temperature
in each zone is the average of the inlet/outlet cold temperatures of the
shell in which the zone occurs (see graph)

Then weight the overall MTDe as follows:

MTDe (Weighted) = Qtotal

Qzone1 + Qzone2 + Qzone3 + Qzone4
LMTD1 LMTD2 LMTD3 LMTD4

Slide 28
 HEAT TRANSFER COEFFICIENTS

Film coefficients are relatively easy to estimate:

They are a function of

Reynolds Number DV

Prandtl Number (Cp) ()
K

Similarly, pressure drop is a function of Reynolds number and length of

flow path.

Slide 29
 HEAT TRANSFER COEFFICIENTS (Continued)

The handouts just examined are suitable ONLY for estimates

of coefficients.

For detailed coefficients on which to base the purchase of an

exchanger, detailed computer calculations are necessary.

Detailed computer calculations examine the effects of many

other parameters, particularly shell-side effects such as
channeling and baffle leakage.

Slide 30
 Show Videotape

Slide 31
 EXCHANGER DESIGN PROCEDURE

First need to know:

Permissible tube sizes - diameter, gauge, length.

(Frequently set by refinery maintenance department)

The appropriate tube material for the service

The allowable system pressure drops for each stream.

Slide 32
 EXCHANGER DESIGN PROCEDURE (Continued)

(1) Assume an overall heat transfer coefficient (Uo) and calculate

tube surface area (A).

(2) Using the required tube size and length, calculate the number
of tubes.

(3) Using a reasonable tube-side velocity (0.6-4.5 m/s), calculate

the tubeside cross sectional area required for each tube pass:
Acs = m3/s
m/s

(4) Determine the EVEN number of tube passes which will most
closely approximate the needed flow area.
# tubes/pass= Acs / single tube cross sectional area
# passes = (# tubes/pass) / # tubes

Slide 33
 EXCHANGER DESIGN PROCEDURE (Continued)

(5) Calculate the bundle diameter.

(6) Using a reasonable value of shell-side velocity, calculate the

flow area required between shell-side baffles (gives baffle
spacing).

(7) Calculate tube-side and shell-side pressure drop. If

satisfactory, continue to step 8. If not, modify the exchanger
geometry until pressure drop requirements are met.

(8) Calculate the overall coefficient U.

(9) Compare [U(calculated) x A x MTDe ] with the required value of

Q. If it doesnt agree within about 10%, then change exchanger
geometry and repeat calculations.

Slide 34
 HEAT EXCHANGER DESIGN

There are several major types of heat exchanger used in

refineries/chemical plants:
+ Shell-and-Tube
+ Air-Fin Coolers
+ Double-Pipe
+ Plate and Frame

The vast majority are S & T.

We will briefly review usage of the minor types and then

concentrate on the features of shell-and-tube exchangers.

Slide 35
 AIR COOLED EXCHANGERS

Used for cooling high to medium temperature streams where

heat recovery is not practical

Consists of tube bundle and motor driven fans

Can be forced or induced draft

Can be countercurrent or cocurrent to air flow

Tubes are usually equipped with circumferential fins

Design outlet temperature is limited by ambient air temperature

Detailed design of air-fins is left to the individual vendors.

Process Designers simply provide duty specification.

Slide 36
 DOUBLE PIPE

Consists of one or more pipes within a larger pipe

Internal pipes can be bare surface or have longitudinal fins

True cocurrent or true countercurrent flow can be achieved

Available in standard off-the-shelf sizes

Several standard units may be connected in series or in

parallel

Not usually economical where surface requirements exceed

about 500 square feet

Especially suited for high-pressure applications

Slide 37
 PLATE AND FRAME

Consists of a series of alternating corrugated plates

pressed together in a compression frame

Process fluids flow on alternate sides of the plates in

channels formed by the corrugations

Units achieve true countercurrent flow

Slide 38
 PLATE AND FRAME (Continued)

ADVANTAGES
True countercurrent flow
Highly compact - take up much less space than an equivalent S
&T
Much less expensive than S & T
Very small holdup of process fluids
Small probability for cross contamination of the two fluids
DISADVANTAGES
Limited to moderate temperatures and pressures (up to about
300F / 150C and 300 psig / 21 barg)
Some hydrocarbon streams attack the interplate gasketing
Require great time in assembly/disassembly
Best suited to aqueous streams, e.g. amines, water

Slide 39
 SHELL AND TUBE

Most common type in refinery service

Consists of tube bundle within external shell

Not truly cocurrent or countercurrent

Slide 40
 NOMENCLATURE
Components of Shell and Tube Exchangers

1. SHELL 8. FLOATING HEAD COVER FLANGE 16. IMPINGEMENT BAFFLE

2. SHELL COVER 9. CHANNEL PARTITION PLATE 17. VENT CONNECTION
3. SHELL FLANGE 10. STATIONARY TUBESHEET 18. DRAIN CONNECTION
4. SHELL COVER END FLANGE 11. CHANNEL 19. TEST CONNECTION
5. SHELL NOZZLE 12. CHANNEL COVER 20. SUPPORT SADDLES
6. FLOATING HEAD TUBESHEET 13. CHANNEL NOZZLE 21. LIFTING RING
7. FLOATING HEAD COVER 14. TIE RODS AND SPACERS 22. SPLIT RING
15. TRANSVERSE BAFFLES
OR SUPPORT PLATES

Slide 41
 MAJOR TYPES OF S & T UNITS

Fixed tube sheet (uncommon)

Floating tube sheet

+ Pull-through floating head
+ Split ring floating head

U-Tube

Slide 42
 SHELL & TUBE EXCHANGERS

Fixed Tube Sheet

Cleanest. Consider only when shell side fouling factor 0.004
(m2*C/W) and shell side can be chemically cleaned.
Because of thermal stresses, this type is generally unacceptable if the
average shell temperature and average tube temperature differ by more
than 10C
U-Tube
Least expensive for high tubeside design pressure. Normally used
when tubeside fouling 0.004. (except for water)
Split Ring Floating Head
This type is normally specified unless very frequent mechanical
cleaning is required
Pull-Through Floating Head
Most expensive type of S & T unit; thermally inefficient because of
shell bypassing. Use when both sides must be mechanically cleaned

Slide 43
 PRELIMINARY DECISIONS:
DESIGN OF SHELL-AND-TUBE UNITS

Which fluid to put in the tubes

Tube nominal diameter, wall thickness and material

Tube length

Tube layout

Baffle orientation

Baffle pitch (spacing)

Maximum bundle diameter (bundle weight)

Slide 44
 TUBE SIDE FLUID

Between the two streams, the stream with the higher:

Pressure
Corrosion Rate
Fouling Rate
Is usually placed on the TUBE SIDE.
When these characteristics apply to both streams, the designer
uses his judgement.

In a service where one stream is changing phase, that stream is

assigned to SHELL SIDE.

In steam-heated vaporizers/reboilers, the condensing steam is

placed in THE TUBES.

Streams with very HIGH VISCOSITY are placed on the SHELL

SIDE (better coefficient).

Slide 45
 TYPICAL TUBE DIAMETERS/WALL THICKNESS

1. Oil Service - Ferrous Tubes Layout and

Severity of Service OD, In. Spacing, In. BWG Thickness, In.

Non-Fouling or Fouling 3/4 15/16 14 0.083

(<0.003), Mildly Corrosive

Non-Fouling or Fouling 3/4 1.00 or 12 0.109

(<0.003), Corrosive

Extremely Fouling 1 1.25 or 12 0.109

( 0.003), Mildly Corrosive

Extremely Fouling 1 1.25 or 10 0.134

( 0.003), Corrosive

2. General Service Alloy Tubes

Water Service--
Nonferrous Tubes 3/4 15/16 or 1.0 16 0.065

Non-Fouling or Fouling
(<0.003) 3/4 15/16 or 1.0 16 0.065

Extremely Fouling
(0.003) 1 1.25 or 14 0.083

Slide 46
 TUBE LENGTH

Refinery decision (local preference)

Most common length is 20 feet (6.1m)

Occasionally, 16 (4.9m) length is used

For special situations, 8 (2.4m) and 10 (3m) can be

considered

Longer tube bundles require more plot area for bundle

removal. Longer bundles are also more difficult to extract
from the shell and to handle.

Slide 47
 TUBE LAYOUT

3 Main Layouts--

Square 1. Use when ro > 0.004 and shellside

must be mechanically cleaned.
2. Reboilers/Vaporizers

Rotated Square Use as square, but only when flow is

laminar or for vibration problems

Triangular 30 1. Use when ro 0.004

2. Cheapest, so use when applicable

Slide 48
 TYPE OF BAFFLE

Segmental - Most common

Double Segmental (modified disk and donut) is used to

obtain very low shell-side pressure drop

Tube Supports Only - No real baffles. Occasionally used

in certain reboiling or condensing services.

Slide 49
 BAFFLE ORIENTATION AND CUT

Vertical Chord - Most Common

Condensers, vaporizers and fluids containing suspended solids
Flow is side-to-side

Horizontal Chord
Sediment-free fluids being cooled through high temperature
range (200 to 300F / 90-150 C) in one shell
Flow is over-under

Baffle Cut
This is the percent of the baffle which is cut away to permit flow
Typical cut is 25% (40% for double segmental baffles).

Slide 50
 BAFFLE PITCH

Minimum allowable spacing (pitch) is 20% of the shell ID or two

inches, whichever is greater.

Maximum allowable pitch:

+ For no change of phase, equals shell ID
+ For change of phase

Tube Size Steel Copper Alloys

30 26
1 37 32
1 50 43.5

Slide 51
 TEMA

Tubular Exchanger Manufacturers Association

This is the basic industrial standard for shell-and-tube

exchangers

Covers heavy-duty type (TEMA R) as well as the lighter

duty (TEMA C) units

Latest edition is the eighth dated 1999

Slide 52
 TEMA TYPE

TEMA Type followed by three letters refers to the type of

+ Front end (channel) arrangement
+ Shell nozzle/baffle arrangement
+ Rear end (floating head end) arrangement

These three characteristics are each identified by a single letter

of the alphabet

The result, for example, would be the entry TEMA Type AES
in the specification for the heat exchangers. The type MUST be
specified.

Slide 53
 MOST COMMON TEMA TYPES
Front End (Channel) Arrangement

A Removable channel with removable cover plate

May be used with fixed or removable tube bundles
Tube cleaning easier since no piping disassembly required
Flanged channel end is costly and prone to leakage
Most commonly used

B Removable channel with integral cover

May be used with fixed or removable tube bundles
Used for low tube side fouling services or where chemical
cleaning is specified. Mechanical cleaning requires piping
disassembly
Less costly and less prone to leakage than type A

C Channel integral with tubesheet and with removable cover

Two types: removable bundle and fixed bundle

Slide 54
 MOST COMMON TEMA TYPES (Continued)

Shell Types
E One pass shell
Most common type used
F Two pass shell with longitudinal baffle
Used to improve cross flow correction factor
Equivalent to two shells in series
Maximum shellside pressure drop of 10 PSI
Maximum shellside temperature range of 350 F
G/H Split flow arrangements
Use internal baffles to split the shellside flow
Used to minimize pressure drop
J Divided flow
Also used to minimize pressure drop
No internal baffle
K Kettle types
Used for vaporizing services (reboilers, steam generators and
refrigeration services)
X Cross flow
No baffles
Low pressure drop
Slide 55
 MOST COMMON TEMA TYPES (Continued)
Rear End Head
S Floating tubesheet sandwiched between split ring and tubesheet cover
Tubesheet assembly moves within shell cover to absorb expansion of the tubes
Requires removing rear shell cover and floating tubesheet cover for
bundle removal, but results in a smaller diameter shell for the same heat
transfer surface
Usually first choice for removable bundles if mechanical cleaning of shell side
will be infrequent
T Pull through floating head
Floating tubesheet cover bolted directly to floating tubesheet
Does not require rear head disassembly for bundle removal
Results in larger diameter shell for same heat transfer surface than Type S
Preferred where frequent mechanical cleaning of shellside is anticipated
U U-tube bundle
No floating head. Tube bundle consists of U-tubes
Not recommended where mechanical cleaning of tube side is anticipated
Good for high pressure, clean services or where chemical cleaning of
tubeside is specified

Slide 56
 TEMA HEAT EXCHANGER NOMENCLATURE
DP IX-C Figure 2

Notes: 1. Commonly referred to as channel or channel box.

2. Commonly referred to as bundle types.
3. Recommended for condensers and thermosiphons.
Slide 57 4. Recommended for thermosiphon reboilers only.
 MOST COMMON TEMA TYPES (Continued)

Therefore a TEMA AES exchanger has

A = Removable channel and removable channel cover plate

E = One pass shell (one inlet nozzle and one outlet nozzle)

S = Split ring type floating tube sheet construction

Slide 58
 HEAT INTEGRATION PRINCIPLES

Object is overall minimum surface/number of shells

Try to achieve maximum LMTDs

Avoid temperature crosses if possible

Incremental surface is cheaper than more shells

Do not match streams with large differences in

Heat content
Volume

Slide 59
 HEAT INTEGRATION PROCEDURES

Identify all heat sources and heat sinks

Prepare T-Q curves for sources and sinks

Match sources and sinks according to

principles

Try different arrangements using typical Uos to

estimate total surface

Slide 60
 Problem 5A
Heat Integration

Slide 61
 TABLE 1.01
DESIGN CONSTANTS FOR SHELL AND TUBE EXCHANGER CALCULATIONS

SHELL SIDE
Maximum Allowable Baffle Pitch Maximum Pb, Inches
Tube O.D. Inches Steel Copper, Aluminum Alloys
0.75 30.0 26.0
1.00 37.0 32.0
1.50 50.0 43.5
(For no change of phase, Pb should not exceed the shell ID.

Heat Transfer & Pressure Drop Factor B1 and B2

Baffle Position Tube Layout Transfer B1 Pressure Drop B2
Vertical to tube rows Square 0.50 0.30
On the bias (45) Square 0.55 0.40
Vertical to tube rows Triangular 0.70 0.50

Pressure Drop Fouling Factors, Fs

Fluid Fs
Liquids 1.15
Gases or condensing vapors 1.00

TUBE SIDE
Pressure Drop Fouling Factors Typical Tube Pitch
Tube O.D. Inches Ft Tube O.D. Inches Pitch In
0.75 Steel 1.50 0.75 Triangular 0.9375
1.00 Steel 1.40 0.75 Square 1.0
1.50 Steel 1.20 1.0 Square 1.25
0.75 Copper Based 1.20 1.5 Square 1.875
1.00 Copper Based 1.15
Slide 62
 TABLE 1.01
DESIGN CONSTANTS FOR SHELL AND TUBE EXCHANGER CALCULATIONS
(Continued)

TUBE SIDE (Continued)

Design Cooling Water Velocity
Most Favorable Permissible
Material Type of Water Velocity, ft/sec Range, ft/sec (4)

Carbon Steel Fresh, non-inhibited 4 3 to 6

Fresh, inhibited 6 to 8 3 to 10

Red brass All types 6 to 8 3 to 4

Admiralty (inhibited) Fresh (inhibited or not) 6 to 8 3 to 10

Salt or brackish 3 3 to 5

Aluminum brass Fresh (inhibited or not) 6 to 8 3 to 10

Salt or brackish 5 4 to 8

Cupronickel (70-30) All types 7 to 8 6 to 12

Cupronickel (90-10) All types 7 to 8 6 to 12

Monel All types 8 6 to 12

Type 316 alloy steel All types 10 8 to 15

Slide 63
 TABLE 1.02 - EXCHANGER TUBE DATA
do= O.D. of = Wall di = I.D. of Internal Cross External Surface
Tubing, In. BWG Thickness In. (3) Tubing, In. Sectional Area Sq. In. Per Foot Length Sq. Feet
12 0.109 0.532 0.223 0.1963
14 0.083 (1) 0.584 0.268 0.1963
16 0.065 (2) 0.620 0.302 0.1963
18 0.049 0.652 0.334 0.1963
1 10 0.134 0.732 0.421 0.2618
1 12 0.109 (1) 0.782 0.479 0.2618
1 14 0.083 (2) 0.0834 0.546 0.2618
1 16 0.065 0.870 0.594 0.2618
1 10 0.134 1.232 1.192 0.3927
1 12 0.109 1.282 1.291 0.3927
1 14 0.083 1.334 1.397 0.3927
GAGE EQUIVALENTS MAXIMUM RECOMMENDED NUMBER OF TUBE PASSES
Inches BWG Shell ID Inches Max. Passes
0.220 5 <10 4
0.165 8 10-19 6
0.148 9 20-29 8
0.134 10 30-39 10
0.120 11 40-49 12
0.109 12 51-59 (Rare) 14
0.095 13 Notes:
(1) Typical wall thickness for carbon steel tubes.
0.083 14 (2) Typical wall thickness for copper alloy tubes.
0.072 15 (3) Average wall thickness is typically 10% greater than the minimum wall thickness.
Tubes may be specified (and purchased) on either an average wall or minimum wall
0.065 16 basis. (Exxon normally specifies minimum wall.)
0.058 17
Slide 64 0.049 18
0.035 20
 TABLE 1.03
THERMAL CONDUCTIVITIES OF METALS AT TYPICAL HEAT EXCHANGER TEMPERATURES

Material Composition Thermal Conductivity, k,

Admiralty (71 Cu - 28 Zn - 1 Sn) 64
Type 316 Stainless Steel (17 Cr - 12 Ni - 2 Mo) 9
Type 304 Stainless Steel (18 Cr - 8 Ni) 9
Brass (70 Cu - 30 Zn) 57
Red Brass (85 Cu 15 Zn) 92
Aluminum Brass (76 Cu - 22 Zn - 2 Al) 58
Cupro-Nickel (90 Cu - 10 Ni) 41
Cupro-Nickel (70 Cu - 30 Ni) 17
Monel (67 Ni - 30 Cu - 1.4 Fe) 15
Inconel 11
Aluminum 117
Carbon Steel 26
Carbon-Moly Steel (0.5 Mo) 25
Copper 223
Lead 20
Nickel 36
Titanium 11
Chrome-Moly Steel (1 Cr - 0.5 Mo) 24
(2-1/4 Cr - 0.5 Mo) 22
(5 Cr - 0.5 Mo) 20
(12 Cr - 1 Mo) 16
Slide 65
 TABLE 1.04
TYPICAL FOULING FACTORS - CUSTOMARY

Stream Type Typical ri or ro

Vapor Overheads 0.001

Virgin Distillate liquids to tankage 0.001
Virgin Distillate liquids from tankage 0.002
Cracked distillate liquids from tankage 0.002
Reduced Crudes 0.004
Tar, bitumen 0.005
Cracked Tar 0.010
Crudes 0.0102-0.004
Steam 0.001
BFW 0.001
Cooling Water, Fresh 0.0015 - 0.0025
Cooling Water, Salt 0.0025 -0.0035

Slide 66
 TABLE 1.05
SOME TYPICAL OVERALL COEFFICIENTS - CUSTOMARY

Type of Source Typical Uo

Light Ends Liquid Coolers (Water) 120

Distillate Coolers (Water) 70-90
Light Ends Reboilers (Steam) 80
Light Ends Feed/Bottoms 100

Crudes/distillates 25-50
Condensers (Tower overheads) 90

Slide 67
 NOMENCLATURE
A - Total exchanger are, ft2 Ro - Outside film resistance to heat transfer, (Note 1).
As - Area/shell, ft. 2 Rt - Total resistance (duty) to heat transfer (Note 1).
B1 - Bundle factor for shell side heat transfer rio - Inside fouling factor corrected to outside area, (Note 1).
B2 - Bundle factor for shell side pressure drop , dimensionless ro - Outside fouling factor (Note 1).
C - Specific heat at caloric temperature, Btu/Lb -F. rw - Resistance of tube wall metal at average wall temperature(Note 1).
Cf - Specific heat of the shell side fluid at average S - Free flow area between shell baffles, in. 2
film temperature, Btu/lb-F TDS - Design temperature of the shell side, F.
D - Shell I.D., inches TDT - Design temperature of the tube side, F.
Dt - Diameter of tube bundle (outer tube limit), inches TM - Tube sheet design temperature, F.
di - Tube I.D., inches T1 - Inlet temperature of fluid being cooled, F.
do - Tube O. D., inches T2 - Outlet temperature of fluid being cooled, F.
Fn - Correction factor for log mean temperature difference t1 - Inlet temperature of fluid being heated, F.
(due to partially concurrent flow), dimensionless t2 - Outlet temperature of fluid being heated, F.
Fs - Shell side pressure drop correction factor, dimensionless tf - Average shell side film temperature, F.
Ft - Tube side pressure drop correction factor, dimensionless ts - Caloric temperature of the shell fluid, F.
G - Mass velocity, lbs/sec - ft2 tt - Caloric temperature of the tube fluid, F.
hio - Inside film coefficient corrected to outside area, Btu/hr-ft2-F. tw - Average tube wall temperature, F.
ho - Outside film coefficient Btu/hr-ft2 -F Uc - Over-all clean coefficient of heat transfer, Btu/hr-ft2-F.
k - Thermal conductivity at caloric temperature, Btu/hr-ft2-F/Ft. Uo - Over-all duty coefficient of heat transfer, Btu/hr-ft2-F.
kf - Thermal conductivity of the tube metal at average tube V - Velocity in the tubes or shell ft/sec.
temperature, Btu/hr-ft2-F/ft VN - Velocity in the nozzles, ft/sec.
kw - Thermal conductivity of the tube metal at average W - Free width between baffles, in.
tube temperature Ysh - Shell side heat transfer correlation factor.
L - Tube wall thickness, in. Ysp - Shell side pressure drop correlation factor.
L - Tube length, ft. Yth - Tube side heat transfer correlation factor.
M - Mass rate, lbs/hr. Ytp - Tube side pressure drop correlation factor.
M - Density, lbs/ft3 z - Viscosity at caloric temperature, centipoises.
NB - Number of shell baffles zf - Viscosity of the shell side fluid at average film temperature, centipoises.
NP - Number of tube passes per shell. zw - Viscosity of the tube side fluid at tube wall temperature, centipoises.
NRe- Reynolds number, inch-lbs/sec-ft2 - centipoise Ptf - Tube pressure drop due to friction, psi/tube pass.
NS - Number of shells in series. Ptr - Tube pressure drop due to turns, psi/tube pass.
NT - Number of tubes across in the bundle Pt - Total tube side pressure drop, psi.
NTC - Number of tubes across the center line of the bundle Psf - Shell side pressure drop due to friction, psi/shell.
Pb - Baffle pitch, inches. Psr - Shell side pressure drop due to friction, psi/shell.
Pt - Tube pitch, inches. PN - Nozzle Pressure drop, psi/shell.
Q - Rate of heat transfer, Btu/hr. Ps - Total shell side pressure drop, psi.
RC - Total resistance (clean) to heat transfer (Note 1) te - Long mean temperature difference corrected for non-ideal countercurrent
Rio - Inside film resistance corrected to outside area, (Note 1) flow (Effective temperature difference) F.
Slide 68 tew - Weighted effective log mean difference, F.
 FIGURE 1.01 - LMTD CORRECTION FACTORS

Slide 69
 FIGURE 1.02 - LMTD CORRECTION FACTORS

Slide 70
 FIGURE 1.03 - LMTD CORRECTION FACTORS

Slide 71
 FIGURE 2.01
FRICTIONAL PRESSURE DROP FOR FLUIDS FLOWING IN TUBES

Slide 72
 FIGURE 2.02
HEAT TRANSFER COEFFICIENT FOR FLUIDS IN TUBES

Slide 73
 FIGURE 5.01
FRICITONAL PRESSURE DROP FLUIDS FLOWING ACROSS TUBE BANKS

Slide 74
 FIGURE 5.02
HEAT TRANSFER COEFFICIENT FLUIDS FLOWING ACROSS TUBE BANKS

Slide 75
 FIGURE 5.01
VALUES OF THE THERMAL FUNCTION k(PRANDTL NO.)1/3 FOR LIQUID HYDROCARBONS

Slide 76
 FIGURE 5.02
VALUES OF THE THERMAL FUNCTION K(PRANDTL NO.)1/3 FOR HYDROCARBON VAPORS

Slide 77
 ADDENDUM 5.02
FOR FLOW INSIDE TUBES APPROXIMATE EFFECT OF VARIABLES IN THE TRANSFER OF MOMENTUM AND
HEAT

To Find P2 To Find h2
Property Changed Multiply P1 By: Multiply h1 By:

NRe > 10,000 (Note 1) Turbulent Flow

Linear Velocity (V2/V1)1.8 (V2/V1)0.8

Tube Diameter (at constant linear velocity) (D1/D2)1.2 (D1/D2)0.2

Viscosity (2/1)0.2 (2/1)0.5

Density (at constant linear velocity) (2/1)0.8 (2/1)0.8

NRe > 2,100 (Note 1) Laminar Flow*

Linear Velocity V2/V1 (V2/V1)0.33

Tube Diameter (at constant linear velocity) (D1/D2)2 (D1/D2)0.33

Tube Diameter (at constant weight rate) (D1/D2)4 D1/D2

Density (at constant linear velocity No dependence (2/1)0.33

Tube Length L2/L1 (L1/L2)0.33

Note 1: This is dimensionless Reynolds Number.

Slide 78
 Section I X-B Page HEAT EXCHANGE EQUIPMENT
DESIGN CONSIDERATIONS FOR ALL EXXON DESIGN PRACTICES
Date TYPES OF HEAT EXCHANGERS
PROPIETARY INFORMATION -For Authorized Company Use Only

TABLE 1
TYPICAL OVERALL HEAT TRANSFER COEFFICIENTS - Uo

U0(1) U0(1)
Fluid Being Cooled Fluid Being Heated BTU W

Hr ft2 F m2 C
Shell and Tube Units with Smooth Tubes

Exchangers
Atmospheric P/S Top Pumparound Crude 60 - 70 340 - 400
Atmospheric P/S No. 3 S/S Crude 48 - 58 270 - 330
Atmospheric P/S Bottom Pumparound Crude 55 - 85 310 480
Atmospheric P/S Bottoms Crude 26 45 150 - 260
Reduced Crude Flashed Crude 25 140
Lean Oil Fat Oil 60 340
Hydrocracker Effluent Hydrocracker Feed 75 430
Hydrogenation Reactor Effluent Hydrogenation Reactor Feed 51 55 290 310
Hydrofiner Effluent Hydrofiner Feed 50 68 280 390
Debutanizer Effluent Debutanizer Feed 70 400
Powerformer Effluent Powerformer Feed 50 80 280 450
Acetylene Converter Feed Acetylene Converter Effluent 22 30 120 170
Regenerated DEA Foul DEA 110 630
Catalyst-Oil Slurry Gas Oil Feed 40 230
Cracking Coil Vapors Gas Oil 30 170
Rerun Still Overhead Rerun Still Feed 50 280
Splitter Overhead Debutanizer Feed 55 310

Slide 79
 Section I X-B Page HEAT EXCHANGE EQUIPMENT
DESIGN CONSIDERATIONS FOR ALL EXXON DESIGN PRACTICES
Date TYPES OF HEAT EXCHANGERS
PROPIETARY INFORMATION -For Authorized Company Use Only

TABLE 1 - (Continued)
U0(1) U0(1)
Fluid Being Cooled Fluid Being Heated BTU W

Hr ft2 F m2 C
Coolers
Water Water 150 210 (2) 850 - 1190
Brine Sour Water 100 115 570 650
Debutanizer Bottoms Water 68 75 390 430
Debutanizer Overhead Products Water 85 90 480 - 510
Debutanizer Bottom Products Water 43 240
Vacuum P/S Bottoms Water 20 25 110 - 140
Absorber Oil Water 80 450
Lean Oil Water 70 400
Heavy Gas Oil Water 40 230
Regenerated DEA Water 110 630
Reduced Crude Water 29 32 160 180

Gas Coolers
Air, 27 psig (186 kPa gage) Water 13 70
105 psig (724 kPa gage) Water 17 100
320 psig (2206 kPa gage) Water 23 130
Primary Fractionator Gas Water 27 150
Hydrocarbon Vapors (30 M.W.) Water 38 43 220 240
Hydrocarbon Vapors (25 M.W.) Water 55 60 310 340
Propylene Water 50 280
Ethylene Water 31 180

Slide 80
 Section I X-B Page HEAT EXCHANGE EQUIPMENT
DESIGN CONSIDERATIONS FOR ALL EXXON DESIGN PRACTICES
Date TYPES OF HEAT EXCHANGERS
PROPIETARY INFORMATION -For Authorized Company Use Only

TABLE 1 - (Continued)

U0(1) U0(1)
Fluid Being Cooled Fluid Being Heated BTU W

Hr ft2 F m2 C
Condensers
Atmospheric P/S Overhead Water 80 90 450 510
Atmospheric P/S Overhead Crude 35 45 200 260
Atmospheric P/S Distillate Water 70 80 400 - 450
Vacuum P/S Overhead Water 115 130 650 740
Debutanizer Overhead Water 90 100 510 570
Deethanizer Overhead Water 110 620
Depentanizer Overhead Water 90 113 510 640
LPG Tower Overhead Water 99 560
Hydrofiner Effluent Water 91 105 510 600
Stabilizer Overhead Water 75 85 430 480
Splitter Overhead Water 85 113 480 640
Rerun Still Overhead Water 70 400
DEA Regenerator Overhead Water 100 570
Primary Fractionator Overhead Water 40 (50% cond) 230
Primary Fractionator Overhead & Products Water 60 (25% cond) 340
Powerformer Effluent Water 55 60 310 340
Hydrocracker Effluent Water 85 480
Propylene Water 120 680
Steam (3) Water 400 600 2270-3410

Slide 81
 Section I X-B Page HEAT EXCHANGE EQUIPMENT
DESIGN CONSIDERATIONS FOR ALL EXXON DESIGN PRACTICES
Date TYPES OF HEAT EXCHANGERS
PROPIETARY INFORMATION -For Authorized Company Use Only

TABLE 1 - (Continued)
U0(1) U0(1)
Fluid Being Cooled Fluid Being Heated BTU W

Hr ft2 F m2 C

Chillers
Ethylene (4) Propylene 98 560
Demethanizer Overhead (4) Ethylene 107 610
Deethanizer Overhead (4) Propylene 113 640
Depropanizer Overhead (4) Propylene 115 650
Ethylene Ethylene 99 105 560 600
Demethanizer feed Ethylene 96 113 550 640
Demethanizer Feed Propylene 100 122 570 690

Reboilers
Steam Demethanizer Bottoms 75 430
Lean Oil Demethanizer Bottoms 60 340
Steam Deethanizer Bottoms 73 86 410 490
Atmospheric P/S Top Pumparound Deethanizer Bottoms 66 370
Steam Depropanizer Bottoms 89 510
Steam Debutanizer Bottoms 74 100 420 570
Atmospheric P/S Top Pumparound Debutanizer Bottoms 65 370
Atmospheric P/S Bottoms Debutanizer Bottoms 56 320
Steam Depentanizer Bottoms 81 460
Steam Debenzenizer Bottoms 102 580
Steam Detoluenizer Bottoms 77 440
Steam Splitter Bottoms 80 450

Slide 82
 Section I X-B Page HEAT EXCHANGE EQUIPMENT
DESIGN CONSIDERATIONS FOR ALL EXXON DESIGN PRACTICES
Date TYPES OF HEAT EXCHANGERS
PROPIETARY INFORMATION -For Authorized Company Use Only

TABLE 1 - (Continued)

U0(1) U0(1)
Fluid Being Cooled Fluid Being Heated BTU W

Hr ft2 F m2 C
Reboilers (Continued)
Dowtherm Splitter Bottoms 70 400
Steam Stripper Bottoms 82 470
Steam Stabilizer Bottoms 115 650
Steam Rerun Tower Bottoms 74 420
Dowtherm Rerun Tower Bottoms 47 270
Steam LPG Bottoms 70 400
Powerformer Effluent Powerformer Stabilizer Bottoms 75 77 430 440
Steam K3PO4 Stripper Bottoms 145 820
Steam DEA Regenerator Bottoms 240 1360
Dowtherm Phenol 65 370

Preheaters
Steam Isobutane Tower Feed 82 520
Steam Rerun Tower Feed 80 100 450 570
Steam Debutanizer Tower Feed 110 620
Steam Hydrogenation Reactor Feed 75 89 430 510
Powerformer Stabilizer Bottoms Powerformer Stabilizer Feed 47 270

Slide 83
 Section I X-B Page HEAT EXCHANGE EQUIPMENT
DESIGN CONSIDERATIONS FOR ALL EXXON DESIGN PRACTICES
Date TYPES OF HEAT EXCHANGERS
PROPIETARY INFORMATION -For Authorized Company Use Only

TABLE 1 - (Continued)
U0(1) U0(1)
Fluid Being Cooled Fluid Being Heated BTU W

Hr ft2 F m2 C
Steam Generators
Vacuum P/S Bottoms Feed Water 35 200
Vacuum P/S Bottom Pumparound Feed Water 67 86 380 490
Primary Fractionator Slurry Feed Water 30 55 170 310
Flue Gas Feed Water 8 15 50 90
Reformer Effluent Feed Water 45 60 260 340

Longitudinal Fin Units (Coefficients based on total outside surface)

Heavy Naphtha Water (6 ft/sec(1.8m/s) in annulus) 25 140
Water (3 ft/sec(0.9 m/s) in annulus) 20 110
Light Naphtha Water (6 ft/sec(1.8 m/s) in annulus) 30 170
Water (3 ft/sec(0.9 m/s) in annulus) 25 140
Clean K3PO4 Water 40 230
Clean K3PO4 Foul K3PO4 42 240

Notes:

1. Coefficients given represent a range of typical coefficients. Where only one coefficient given, typical
coefficients can be higher or lower than the tabulated value.
2. Coefficient highly dependent on fouling factors.
3. Steam surface condenser. Refer to Heat Exchange Institute Standards for Steam Surface Condensers.
4. Condensing Service.

Slide 84
 Attachment IX - Safety Factor Selection

Slide 85
 Correction Factor for Non-Condensables Calculation Procedure

Slide 86
See HEXTRAN Users Guide, located in HEXTRAN program folder
 Attachment IXB - Pressure-Drop-Multiplier Selection
See also DP IX-D p. 40-41

Tubeside Pressure-Drop Multiplier (DPSCALAR)

Slide 87
 Attachment IXB - Pressure-Drop-Multiplier Selection (cont.)
See also DP IX-D p. 40-41

Shellside Pressure-Drop Multiplier (DPSCALAR)

Fluid DPSCALAR
Liquids 1.15 (1)
Gases or condensing vapors 1.0 (2)
(1) This value may be increased for extremely dirty service
(2) Use a larger number if vapors are known to be fouling.

Slide 88
 ENHANCED HEAT TRANSFER TECHNOLOGIES (EHT)

WHAT ARE THEY?

Technologies used to improve heat transfer performance and reliability of shell-
and-tube (S&T) heat exchangers, or as alternates to S&TS.

ADVANTAGES OF EHTS
Low initial cost
Low maintenance
Compact size - Save plot space, have small weight and hold-up volume
can debottleneck existing exchangers

SEVEN TYPES OF EHTS

Plate type heat exchangers (PHE)
Spiral heat exchangers (SHE)
Rod baffle exchangers (RBE)
Integral fin tubes (IFT)
Nucleate boiling tubes (NBT)
Turbulence promoters (TP)
On-line mechanical cleaning devices (OMC)

Slide 89
 Heat transfer enhancement is obtained by increasing heat transfer coefficient, surface
are per unit volume or temperature driving force

Q = U x A x MTD
PHE - Increase U by turbulence and MTD by countercurrency
SHE - Increase U by turbulence and MTD by countercurrency
RBE - Increase U by allowing higher flow rate
IFT - Increase A of tube surface; Increase U for condensing and vaporizing
NBT - Increase U by enhancing vaporizing heat transfer
TP - Increase U by enhancing HI
OMC - Increase U by reducing fouling; some types also increase HI

Slide 90
 PLATE TYPE HEAT EXCHANGERS (PHE)
WHAT DOES IT DO?
It is an alternative to shell-and-tube exchangers.
Provides a compact heat exchanger because of high surface area per unit
volume
Provides true counter current flow and high heat transfer coefficients
Typical Applications - Final product cooling (close approach
Tempered water cooling
Low temperature feed/effluent exchanger
Sea water cooling (high metallurgy)
WHAT DOES IT LOOK LIKE?
Multiple streams possible

PLATE & FRAME WELDED PLATE PLATE-FIN

Slide 91
 SPIRAL HEAT EXCHANGERS (SHE)
WHAT DOES IT DO?
It is an alternative to shell-and-tube exchangers.
Provides a compact heat exchanger because of high surface area per unit
volume
It can handle fluids with high viscosity or high solid particle content
Typical applications - Final product cooling (close approach)
Overhead condensers (tower top)
Tar cooling (high viscosity)
Slurry exchangers (solids)
WHAT DOES IT LOOK LIKE?
Two plates rolled together. Spacing maintained by studs.

Slide 92
 ROD BAFFLEHEAT EXCHANGERS (RBE)
WHAT DOES IT DO?
It eliminates tube vibration in shell-and-tube heat exchangers
It allows debottlenecking of pressure drop limited exchangers
Typical applications - To correct known vibration problems
Compressor inter/after coolers (high velocity
gas)
Reboilers (high velocity vapor or two-phase)

WHAT DOES IT LOOK LIKE?

Rod baffles replace conventional baffles on a S&T tube bundle

Slide 93
 INTEGRAL FIN TUBES (IFT)
WHAT DOES IT DO?
Provides higher heat transfer area compared to plain tubes
Enhances shell side heat transfer coefficient in two-phase applications
Typical applications - Overhead condensers
Compressor inter and after coolers
Good for single or change of phase

WHAT DOES IT LOOK LIKE?

Commonly referred to as low-fin tubes
Note that ID is smaller than plain tube of same OD and thickness
New fin geometries developed and double (inside and outside) enhanced tubes
are available.

Slide 94
 NUCLEATE BOILING TUBES (NBT)

WHAT DOES IT DO?

Increases shell side heat transfer coefficient for boiling services
Typical Applications - horizontal reboilers - shell side boiling
vertical reboilers - tubeside boiling
excellent in refrigeration systems (C3 reboilers)
WHAT DOES IT LOOK LIKE?
Coating on inside or outside tube surface (UOP high flux)
special fin geometry (Wieland)

Slide 95
 TURBULENCE PROMOTERS (TP)
WHAT DOES IT DO?
Increases tubeside heat transfer coefficient by the following mechanisms:
Thermal mixing through bulk or near-wall flow disturbance
Disruption of thermal boundary layer by changing bare tube surface
Impart swirl to mix flow, change flow direction or both

Typical Applications - Tar oil heating (high viscosity)

Lube oil cooling (high viscosity)
Tubeside condensers (increase HI and AI)
WHAT DOES IT LOOK LIKE?

BULK FLOW MIXERS NEAR-WALL MIXERS

(LAMINAR OR TRANSITION) (TURBULENT)

Slide 96
 ON-LINE MECHANICAL CLEANING (OMC)

WHAT DOES IT DO?

Keep shell-and-tube heat exchangers clean, on the run
Typical Applications - Crude preheat with crude on tube side
Hydrofiner feed on tube side
Cooling water on tubeside

WHAT DOES IT LOOK LIKE?

Devices are permanently installed in the bundle

SPIRELF TURBOTAL BRUSH & BASKET

Slide 97
 LOGIC DIAGRAM TO SELECT EHT

Slide 98
 ADVERTISEMENT
UNFIRED HEAT TRANSFER AT EMR&E

O Consulting Expertise
+ Traditional heat exchanger design practice
+ Advanced concepts with new technologies
+ Assist with redesign of problem heat exchangers
+ General heat transfer questions/problems
O Computer Programs
+ Mainframe programs for heat exchanger design/rating/simulation
+ Insulation programs
O Source of Available Outside Technology
+ HTRI/HTFS state-of-the-art heat transfer technology
+ R & D efforts to identify applications/developments of new technology
O Technical Training
+ Courses at EMR&E or affiliate location
+ Subjects include:
Advanced heat transfer
ExxonMobil computer programs

Slide 99
 HEAT EXCHANGER REFERENCES

Design Practices, Section IX (Heat Exchangers) and

XIV (Fluid Flow)
Global Practices (GPs), Section 6
Heat Exchanger Specialists:
L.A. (Lou) Curcio, (281) 834-7892,
AMERICAS(LACURCI)
R.C. Tomotaki, (281) 834-4419, AMERICAS
(LESEREB)

Slide 100
 ADDENDUM 5.01
SECTION 5 - PROCESS DESIGN COURSE - HEAT EXCHANGER DESIGN

A shortcut procedure for approximate evaluation of shell and tube exchangers with no change of phase
IMPORTANT NOTE AND WARNING:
This procedure must not be used for the definitive design of heat exchangers. It is a shortcut
technique which makes many simplifying assumptions, especially with regards to shell-side
calculations
The Reynolds Number used in this addendum is dimensional.
INDEX
DESCRIPTIVE MATERIAL
1. LMTD & Caloric Temperature/Properties
2. Shell Side, Tube Side Flowrates
3. Fouling
4. Tube Side Calculations
5. Shell Side Calculations
6. Duty & Clean Coefficients
7. Design Temperature of Tube Sheet
8. Calculation Form
9. Nomenclature Summary
TABLE
1.01 General Design Constants
1.02 Exchanger Tube Data
1.03 Thermal Conductivities of Metals
1.04 Typical Fouling Factors
1.05 Typical Overall Coefficients
FIGURES
1.01-1.03 Fn Factors
2.01-2.02 Tube Side Correlations
3.01-3.02 Shell Side Correlations
4.01-4.02 Thermal Function K (Pr)1/3
Slide 101
 SHORTCUT PROCEDURE
SCOPE
The following subsection presents an approximate procedure for evaluating shell and tube exchangers
in which there is no change of phase, (I.e., vapor/vapor, vapor/liquid or liquid/liquid exchangers). The
actual calculations can be made on the calculation form. Each Step of the procedure is explained in the
following paragraphs.
DETAILED PROCEDURE
1. Terminal Conditions and Effective Log Mean Temperature Difference
a. Determine the following temperatures
Inlet temperature of fluid being cooled, T 1
Outlet temperature of fluid being cooled, T 2
Inlet temperature of fluid being heated, t 1
Outlet temperature of fluid being heated, t 2
b. Determine the log mean temperature difference, tm
(T 1 - t 2) - (T 2 - t 1)
tm = (T1 - t 2)
ln (T2 - t 1)
c. From Figure 1.01 - 1.03, determine the minimum number of shells required
for a temperature correction factor (Fn) of at least 0.8000.

d. Determine the effective log mean temperature differences, t e

t e = Fn t m
Slide 102
 SHORTCUT PROCEDURE (Continued)

2. Caloric Temperatures

a. Decide which fluid to pass through the tubes and which through the shell
b. Calculate the caloric temperatures.
For the fluid being heated, t t or t s = 0.4(t 2 - t 1 ) + t 1
For the fluid being cooled, t s or t t = 0.4(T 1 - T 2) + T 2
3. Caloric Properties of Fluids

a. Tube Side of Exchanger

1. At the caloric temperature t t, determine the following tube side fluid

properties:

For water: density, m

For hydrocarbon liquids or vapors: density, m; viscosity, z
For other fluids: density, m; viscosity, z; specific heat, c; and thermal
conductivity, k

b. Shell Side of Exchanger

1. At the caloric temperature, determine the density, m of the shell side fluid.

Slide 103
 SHORTCUT PROCEDURE (Continued)

4. Shell Side and Tube Side Flow Rates

The values of the respective flow rates in lb/hr will normally be determined during the heat
and material balance calculations

5. Fouling Factors

a. Decide the tube side fouling factor r i (See Table 1.04)

b. Decide the shell side fouling factor ro (See Table 1.04)

6. Iteration, Tube Side

(1) The heat duty for the exchanger will normally be determined during the heat and
material balance calculations.
(2) Assume U, the over-all coefficient (See Table 1.05)
(3) Calculate total area
A = Q / U te
(4) Calculate the area per shell.
As = A / Ns
If necessary, the number of shells should be increased to meet the maximum
shell size limitations (typically 48). This will require recalculating Fn te, A, A s
(5) Decide the tube metal and determine tube thermal conductivity, kw (See Table
1.03).

Slide 104
 SHORTCUT PROCEDURE (Continued)
(6) Choose the tube length, diameter, wall thickness, pitch, and layout
(See Tables 1.01 and 1.02).

(7) Determine the number of tubes as follows:

NT = 3.82 As
(L - 0.5) do

(8) Estimate Np, the even number of tube passes per bundle which will give a reasonable tube-
side velocity (3-20 fps).

(9) Calculate the linear velocity in the tubes and in the nozzles:

(d N = Nozzle ID) Np M M
V= VN =
2 2
19.6 ;mN T d i 19.6 m dN
(10) Tube side pressure drop and heat transfer coefficient (for water).
a. Tube side heat transfer coefficient, hio for water from approximately 80F
to 180F.

1 = h io = 368 (Vd i) 0.7 tt 0.26

R io do 100

Slide 105
 SHORTCUT PROCEDURE (Continued)
b. Total tube side pressure drop, P t, for water at approximately 100F.

P t = 0.020 F t N s N p V 2 + 0.158L V 1.73 + PN

d i1.27
For PN, See Step 15 (nozzle pressure drop).

(11) For fluids other than water:

a. Calculate the tube side mass velocity, G

G = mV

b. Calculate tube side Reynolds Number, Nre (dimensional)

N Re = d i G
z

Note: At this point, check for a transition problem by calculating N Re using fluid properties
at inlet (or outlet) conditions. An Exchanger design is not valid if the type of flow conditions
changes from viscous to turbulent (or vice- versa) within the unit.

(12) From Figure 2.01 determine the tube side pressure drop correlation factor, Y tp.

Slide 106
 SHORTCUT PROCEDURE (Continued)

(13) Calculate the tube side velocity head and the nozzle velocity head.

mV 2N in the nozzles ; mV 2 in the tubes

9270 9270
(14) Calculate Ptf, the frictional pressure drop per tube pass.

Ptf = Ytp L mV2 Zw

0.14 or 0.25

d 9720 z
i

The exponent 0.14 is for turbulent flow (N Re < 30); 0.25 is for streamline flow (N Re< 30).

(15) Calculate the pressure drop per tube pass due to turns, Ptr, and the nozzle pressure
drop, PN.

mV2
P t = 3 mV2 ; PN = 2 (two nozzles)
9270 9270

Slide 107
 SHORTCUT PROCEDURE (Continued)
(16) Calculate the total tube side pressure drop, Pt
P t = F t N s N p (P tf + P tr) + PN
For : Ft , see Table 1.01.
If the pressure drop is reasonably close to the value desired, proceed to the next
step. If it seems too high or low, change number of tube passes and repeat step 9
through 16 until the pressure drop is satisfactory.

(17) From Figure 2.02, determine the heat transfer correlation factor, Y th.
a. Calculate the thermal function:

k cz 0.33

k
For hydrocarbons, refer to Figures 4.01 and 4.02.
b. Calculate the tubeside heat transfer coefficient, h io.

1 = h io = Y th k cz 0.33 z 0.14

R io d o k z w

Initially assume Z 0.14 = 1, until tube wall temperature is calculated.

ZW

Slide 108
 SHORTCUT PROCEDURE (Continued)

c. Estimate the average tube wall temperature, tw

t w = t t + U o (R io+ r io) (t s- t t)
d. At the average tube wall temperature, determine z w and calculate:

Z 0.14

zw

(18) Recalculate h io using this viscosity correction.

(19) Calculate the tube wall resistance, r w
rw =
12 kw

(See Tables 1.02-1.03)

7. Iteration, Shell Side
(1) Estimate t f, the average shell side film temperature.
tf = ( t s + t t ) + (U o) (R io + r io + r w + r o) (T s- t t)
2 2

Slide 109
 SHORTCUT PROCEDURE (Continued)
(2) At the average shell side film temperature, determine the following shell fluid properties:
a. For hydrocarbon liquids or vapors: Viscosity, z f.
b. For other fluids: Viscosity, z f; specific heat, c f; and thermal conductivity, k f.
(3) Determine the number of tubes across the centerline of the tube bundle, NTC.
For square tube layout:
N TC = 1.19 (N T) 0.5

For triangular layout:

N TC = 1.10 (N T) 0.5
(4) Determine the outer tube limit, D t.
D t = (N TC - 1)(P t) + d o
(5) Determine shell I.D. as follows:
D = D t / 0.9; except for the following limitations:
1. Minimum D = D t + 1
2. Maximum D = D t + 3
(6) Determine the free width for fluid flow normal to and around the tubes.
One shell pass, W = D - (d o N TC) ; Two shell pass, W = D - (d o NTC )
2

Slide 110
 SHORTCUT PROCEDURE (Continued)

(7) Estimate the baffle pitch Pb which will give a reasonable shell-side velocity
(3-15 fps). See Table 1.01 for maximum Pb.

(8) Calculate the number of shell side baffles, N B (always a whole number).
N B = 10L/Pb

(9) Determine the free area, S, for fluid flow across the tube bundle between each pair
of baffles.

For Calculating the For Calculating the

Film Coefficient, h Pressure drop, P
Segmental Baffles: S = W (Pb - 0.375) S = W (Pb - 0.375)
Modified Disc &
Donut Baffles: S = W (Pb - 0.375) S = 0.85 W (Pb - 0.375)
In each case, 0.375 in. represents the approximate baffle thickness.

(10) Calculate the shell side mass velocity, G.

Disc and donut baffles, G = M/50 x S; Segmental baffles, G = M/25 x S

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 SHORTCUT PROCEDURE (Continued)

(11) Calculate the shell side linear velocity, V and the shell side nozzle velocity, VN
V = G/m
Vn = M (d N = Nozzle ID)
19.6 md2N

(12) Calculate the shell side Reynolds number, N Re

N Re = d o G/Z f

(13) Calculate the ratio of the tube diameter to the tube spacing:
do
Pt-do
From Figure 5.01 determine the shell side pressure drop correlation factor, YSP.
Total Shell Side Pressure Drop

(14) Calculate the shell side velocity head and the nozzle velocity head.
mV 2 N in the nozzles ; mV 2 in the shell.
9270 9270

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 SHORTCUT PROCEDURE (Continued)

(15) Calculate Psf, the frictional pressure drop per shell. Table 1.01 gives values for B2.

Psf = B 2Ysp N TC N B mV 2
9270
(Note!: For Disc & Donut baffles, divide NTC by 2.0)
(16) Calculate the pressure drop per shell due to turns, Psr, and the nozzle pressure drop, PN.

Psr = (N B + 1) 3.5 - 2Pb mV 2 ; PN = 2 mV 2 N

D 9270 9270
(17) Calculate the total shell side pressure drop, Ps.
Ps = Fs N s (Psr + Psf) + PN

For Fs, see Table 1.01.

If the pressure drop is reasonably close to the desired value, proceed to the next step. If it seems too
high or low, change the baffle pitch Pb and repeat steps 7 through 17 until the pressure drop is
satisfactory.

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 SHORTCUT PROCEDURE (Continued)
Shell Side Heat Transfer Coefficient, ho
(18) From Figure 5.02 determine the heat transfer correlation factor, Ysh.
A. Calculate the thermal function:
k cfzf 1/3
f
kf

(For hydrocarbon liquids or vapors, refer to Figures 4.01 and 4.02)

b. Calculate the correction factor for the deviation from ideal baffle pitch.

0.1
4Pb
D
1 = h o = B 1 Ysh k c fz 1/3 4Pb 0.1
f f
Ro do kf D

See Table 1.01 for B1

8. Duty Coefficient
Calculate Uo, the over-all duty heat transfer coefficient.
1 = R t =R io +r io +R o +r w +r o

Uo

If Uo calculated does not agree with Uo assumed, repeat the calculations with a new Uo
assumed until agreement is reached (10%).

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 SHORTCUT PROCEDURE (Continued)

9. Clean Coefficient
Calculate Uc, the over-all clean coefficient.

1 =R c =R io +r w +R o + 0.001
Uc
10. Design Temperatures
Determine the following mechanical design features:
1. The design temperature and pressure of the shell and tube sides.
2. The nozzle size and flange rating for the inlets and outlets on both the shell
and tube sides.
3. The design temperature of the tube sheet, TM.
a. For coolers (water on tube side), specify the higher result
of the following equations:
R io (TDS - TDT)
TM = TDT +
RC
or
(R io + rio) (TDS - TDT)
TM = TDT +
Rt
b. For other exchangers:
(1) When the fluid being cooled is on the tube side
TM = TDT - 0.1(TDT - TDS)
(2) When the fluid cooled is on the shell side
TM = TDT + 0.3 (TDS - TDT)
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 Problem 5 B-E
Heat Exchanger Design

Slide 116