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Geometrical Details of Baffles & Shell Side Fluid

Dynamics

P M V Subbarao
Professor
Mechanical Engineering Department
I I T Delhi

Ideas to Achieve Optimal Combination of Axial &


Cross flow
Segmental Baffle Cut Geometry

Segmental baffle cut height :Lbch

Assuming that the segmental baffle is centered within


the shell inside diameter .
The small difference between the shell and baffle diameter is
called the clearance Lsb and it is important for leakage
corrections.
Selection of Baffle Cut
Baffle cut can vary between 15% and 45% of the shell inside
diameter.
Both very small and very large baffle cuts are detrimental to
efficient heat transfer on the shellside due to large deviation
from an ideal situation.
Role of Baffle Cut on Flow Distribution

If the baffle cut is too small, the flow will jet through the window
area and flow unevenly through the baffle compartment.
If the baffle cut is too large, the flow will short-cut close to the
baffle edge and avoid cross-mixing within the baffle
compartment.
A baffle cut that is either too large or too small can increase the
potential for fouling in the shell.
In both cases, recirculation zones of poorly mixed flow cause
thermal maldistribution that reduces heat transfer.
To divert as much heat-carrying flow across the tube bundle as
possible, adjacent baffles should overlap by at least one tube row.
This requires a baffle cut that is less than one-half of the shell
inside diameter.
Non-Optimal Baffle Cut & Fouling Zones

Ds

LBCH

LBCH/Ds
Too small Baffle Cut Too Large Baffle Cut
Optimal Baffle Cut

It is strongly recommended that only baffle cuts between 20%


and 35% be employed.
Reducing baffle cut below 20% to increase the shellside heat-
transfer coefficient or increasing the baffle cut beyond 35% to
decrease the shellside pressure drop usually lead to poor
designs.
Other aspects of tube bundle geometry should be changed
instead to achieve those goals.
For example, double segmental baffles or a divided-flow shell,
or even a cross-flow shell, may be used to reduce the shellside
pressure drop.
Equalize cross-flow and window velocities

Flow across tubes is referred to as cross-flow, whereas flow


through the window area (that is, through the baffle cut area) is
referred to as window flow.
The window velocity and the cross-flow velocity should be as
close as possible preferably within 20% of each other.
If they differ by more than that, repeated acceleration and
deceleration take place along the length of the tube bundle,
resulting in inefficient conversion of pressure drop to heat
transfer.
Recommended segmental baffle cut values
Orientation of Baffle Cut
For single-phase fluids on the shellside,
a horizontal baffle cut is recommended.
This minimizes accumulation of
deposits at the bottom of the shell and
also prevents stratification.
In the case of a two-pass shell (TEMA
F), a vertical cut is preferred for ease of
fabrication and bundle assembly.
Vertical Vs Horizontal Cut
Selection of Baffle Cut Orientation
For single-phase service, single-segmental baffles with a
perpendicular (horizontal) baffle-cut orientation in an E- or J-
shell are preferred to improve flow distribution in the inlet and
outlet regions.
With vertical inlet or outlet nozzles, parallel-cut (vertical) baffles
are preferred if the shellside process fluid condenses and needs a
means of drainage.
Parallel-cut baffles should also be used when the shellside fluid
has the potential for particulate fouling, and in multipass F-, G-,
or H-type shells to facilitate flow distribution.
However, parallel-cut (vertical) baffles have the potential for
significant flow and temperature maldistribution in the end zones.
This can induce local tube vibration and reduce the effective heat
transfer rate in the inlet and outlet baffle spaces
Helical Baffles
Superiority of Helical Baffling
Closing thoughts
Baffling is the most crucial shellside consideration in shell-
and-tube heat exchanger design, because baffles regulate
shellside fluid flow and improve heat transfer while offering
significant tube support.
Although TEMA baffles are easier to fabricate, they usually
have higher pressure drops than non-TEMA-type baffles.
It is equally important to consider how baffle selection affects
other shellside parameters, such as tube pitch ratio, tube layout
pattern, tube size, shell type, and shell diameter.
A basic understanding of the various baffle types and their
advantages and disadvantages is essential to choosing an
effective baffle configuration.
Basic baffle geometry relations
Basic baffle geometry relations

Dotl : Diameter of circle touching


the outer surface of outermost
tubes.

Dctl : Diameter of circle passing


through the centers of of
outermost tubes.

Lbb: Diametric clearance between


tube bundle and shell inside
diameter.

qctl: The angle intersecting Dctl due


to baffle cut.

qds: The angle intersecting Ds due


to extended baffle cut.
Historical Development of the Delaware Method
The Department of Chemical Engineering at the University of
Delaware started a comprehensive research program on shell-
side design of shell-and-tube heat exchangers in 1947.
This project is called Delaware Project and it finished in 1963.
In 1947, the project started under ASME sponsorship using
funds from:
the Tubular Exchanger Manufacturers Association,
the American Petroleum Institute,
Standard Oil Development Co.,
Andale Company, Downingtown Iron Works,
Davis Engineering Co., E.I. du Pont de Nemours and Company, and
York Corporation.
The principal investigators were Professors Olaf Bergelin and
Allan Colburn of the University of Delaware.
Methodology of Development
In 1947, the experimental program started with measurements
of heat transfer and pressure drop during flow across ideal tube
banks.
Then several baffle cut and spacing configurations were
studied inside a cylindrical shell with no baffle leakage first.
Baffle leakages between baffles and the shell and between the
tubes and baffles were added afterwards.
Finally, the bypass flow around the bundle between the outer
tube limit and the shell inner diameter was investigated.
The first report was published in 1950 and the second report,
in 1958.
In 1960, a preliminary design method for E shell heat
exchangers was issued.
In 1963, the final report was published.
Shell-side stream analysis
On the shell side, there is not just one stream.
There are essentially two models that address the flow
on the shell side.
The ideal flow and real flow models.

Ideal Shell side flow


A nearly ideal flow can only exist in a heat exchanger if it is manufactured with
the special mechanical features.
Realization of Ideal Flow : Condition - 1

Each baffle is welded to the shell inside diameter at the


contact line so that there is no possibility of leakage
between the shell and the baffle.
Realization of Ideal Flow : Condition - 2

The annular space between the tube and the baffle hole
is either mechanically closed or a bushing is inserted to
eliminate any fluid leak across the clearance between
the baffle hole and the tube.
Realization of Ideal Flow : Condition - 3

The tube bundle layout is such that there are no lands


and extra spaces for ribs and impingement plates.
Realization of Ideal Flow : Condition - 4

The outer tube limit (OTL) almost touches the inner


diameter of the shell.
Shell side Real Flow

When the tube bundle employs baffles, the velocity of fluid


fluctuates because of the constricted area between adjacent
tubes across the bundle.
Only part of the fluid takes the desired path through the
tube bundle, whereas a potentially substantial portion flows
through the leakage areas.
However, these clearances are inherent to the manufacturing
and assembly process of shell-and-tube exchangers, and the
flow distribution within the exchanger must be taken into
account.
Flow Path lines
Temperatures of Path-lines
Velocity Contours in Mid-plane
The Role of Fluid Viscosity
The shell side fluid viscosity also affects stream analysis
profoundly.
In addition to influencing the shell side heat transfer and
pressure drop performance, the stream analysis also affects the
mean temperature difference (MTD) of the exchanger.
It is important to realize that the
LMTD and F factor concept assumes that there is no
significant variation in the overall heat-transfer coefficient
along the length of the shell.
In the case of cooling of a viscous liquid as the liquid is
cooled, its viscosity increases, and this results in a progressive
reduction in the shellside heat-transfer coefficient.
In this case, the simplistic overall MTD approach will be
inaccurate, and the exchanger must be broken into several
sections and the calculations performed zone-wise.

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