design of shell & tube hx (unprotected for expert excel users)

8/11/2019 Design of Shell & Tube HX (Unprotected for Expert Excel Users)

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Organic Solvents Shell Side

11

Water Tube Side

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SHELL SIDE 1 TUBE SIDE

symbol values units SI Values symbol values units

Density of Fluid ρS = 840 kg/m3 840.00000 Density of Fluid ρT = 993 kg/m3

Viscosity μS = 0.33 cP 0.00033 Viscosity μT = 0.0008 kg/ms

Thermal Conductivity kS = 0.1156 J/s m K 0.11560 Thermal Conductivity kT = 0.623 J/s m K

Specific Heat cp,S = 2.093 KJ/kg K 2093.00000 Specific Heat cp,T = 4.175 KJ/kg K

Fouling Factor RdO = 0.00021 h m2 C / kcal 0.00018 Fouling Factor Rdi = 0.00035 h m2 C / kc

Temperature In TS,in = 135 C 408.15000 Temperature In TT,in = 30 C

Temperature Out TS,out = 40 C 313.15000 Temperature Out TT,out = 40 C

0 Mass Flow Rate 50 tonne/da

Mass Flow Rate mS = 0.57870371 kg/s Mass Flow Rate mT = 2.75608506 kg/s

Volumetric Flow Rate qS = 0.00068893 m3/s Volumetric Flow Rate qT = 0.00277551 m

3/s

Heat Duty Q = 115066.551 J/sec 115066.5512

Range: Hot Ends Temp. Diff ΔT1 = 95 K

U* = 350 kcal/h m2 C 407.05 Cold Ends Temp. Diff ΔT2 = 10 K

Correction Factor R = 9.5 S = 0.095238095 Log Mean Temp. Diff LMTD = 37.7561008 K

Auto f T = f T = 0.8 LMTD (corrected) LMTD* = 30.2048806 K

Heat Transfer Area : AHT = 9.358887 m2

Shell Diameter DS = 10 in. 0.254 Length of Tube LT = 4.5 m

Tube Clearance cT = 0.0064 m 0.0064 Outside Dia. of Tube dO = 0.75 in.

Baffle Spacing B = 0.1 m 0.1 Thickness of Tube δ = 16 BWG

Tube Pitch PT = 1 in. 0.0254 Inside Dia. of Tube di =

aST = 0.269313 m2

Pitch Type : No. of Tubes NT = 35

Triangular DH = 0.0180335 m No. of Tubes per Pass n = 9

Flow Area [= cT B DS / PT] aS = 0.0064 m2 Flow Area of Tube [inside] aT = 0.00175301 m

2

Linear Velocity of Tube [inside] uT = 1.58328889 m/s

Thermophysical Properties :

EthyleneSpecify :

Design Specifications :

[assume] Overall Heat

Transfer coefficient

250 - 750 W/m2 K

Counter-CurrentFlow Type :

Temperature ΔT:

LMTD Calculation:

Outer Surface Area [Single Tube] :

No. of TEquivalent Diameter

Ethylene Water




Mass Velocity [= mS / aS] GS = 90.4224539 kg/m2

s Mass Velocity [= mT / aT] GT = 1572.20587 kg/m2

s

Reynolds # [= DHGS/μS] ReS = 4941 Reynolds # [= ρTuTdi /μT] ReT = 30949

Prandtl # [= cp,S μS / kS] PrS = 5.975 Prandtl # [= cp,T μT /kT] PrT = 5.361

Method: NuS = 69.8380622 Method: NuT = 174.845638

Auto jH =

32 Auto jH =

85Shell Side HT Co-efficient hO,S = 447.68172 W / m K Tube Side HT Co-efficient hi,T = 6916.9947 W / m K

Udo = 338.6124 W / m K

g =

Friction Factor (use graph) f S = 0.052 Friction Factor (use graph) f T = 0.0037

Number of Baffles Nb = 44 Pressure Drop ΔPT = 537.108877 kg / m2

Pressure Drop ΔPS = 16.3676429 kg / m2 Return Loss ΔPr = 2032.04579 kg / m

2

Shell Side Pressure Drop ΔPS = 16.367643 kg / m2

Tube Side Pressure Drop ΔPT = 2569.1547 kg / m2

(

Turbulent Flow Turbulent

Pressure Drop Calculations :

Design] Overall Heat Transfer coefficien

Heat Transfer Co-efficient Calculations :



Background

A shell and tube heat exchanger, also known as the “workhorse” of industrial processheat transfer, is a class of heat exchanger designs.

processes, and is suited for higher-pressure applications. Other types of heat exchangers

are used when economical. Though the application of other types of heat exchangers is

increasing, the shell and tube heat exchanger will continue its popularity for a long time,

largely because of its versatility

Construction

vessel) with a bundle of tubes inside it. One fluid runs through the tubes, and another

fluid flows over the tubes (through the shell) to transfer heat between the two fluids.

The set of tubes is called a tube bundle, and may be composed by several types of tubes:

plain, longitudinally finned, etc.

pressure and temperature.

Requirements of Heat Exchangers

Heat exchangers have to fulfil1 the following requirements:

1. High thermal effectiveness2. Pressure drop as low as possible

3. Reliability and life expectancy

4. High-quality product and safe operation

5. Material compatibility with the process fluids

6. Convenient size, easy for installation, reliable in use

7. Easy for maintenance and servicing

8. Light in weight but strong in construction to withstand the operational pressures

9. Simplicity of manufacture

10. Low cost

11. Possibility of effecting repair to maintenance problems

Design Equations of Shell & Tube Heat Exchangers




Organic Solvents Water 250 750

Hot fluid Cold fluid

Water Water 800 1500

Organic Solvents Organic Solvents 100 300

Light Oils Light oils 100 400

Heavy Oils Heavy oils 50 300

Reduced Crude Flashed crude 35 150

Regenerated DEA Foul DEA 450 650

Gases (P = atm) Gases (P = atm) 5 35

Gases (P = 200 bar) Gases (P = 200 bar) 100 300

Organic Solvents Water 250 750

Light Oils Water 350 700

Heavy Oils Water 60 300

Reduced Crude Water 75 200

Gases (P = atm) Water 5 35

Gases (P = 200 bar) Water 150 400Gases Water 20 300

Organic Solvents Brine 150 500

Water Brine 600 1200

Gases Brine 15 250

Steam Water 1500 4000

Steam Organic Solvents 500 1000

Steam Light Oils 300 900

Steam Heavy Oils 60 450

Steam Gases 30 300

Dowtherm Heavy Oils 50 300

Dowtherm Gases 20 200

Flue Gases Steam 30 100

Flue Gases Hydrocarbon Vapours 30 100

Aqueous Vapours Water 1000 1500

Organic Vapours Water 700 1000

Reference: http://www.engineeringpage.com/technology/thermal/transfer.html

Coolers

Heaters

Condensors

U (W/m2°C)

Shell & Tube Exchangers

Typical Overall Coefficients

Page 840 | D. Q. Kern' Process Heat Transfer

Range



Refinery Hydrocarbons Water 400 550

Organics (some non-condensables) Water 500 700

Vacuum Condensors Water 200 500

Steam Aqueous Solution 1000 1500

Steam Light organics 900 1200Steam Heavy Organics 600 900

Dowtherm Refinery Hydrocarbons 250 550

Vaporisers



Index

11

FALSE

FALSE

FALSE

FALSE

FALSE

FALSE

FALSE

FALSE

FALSE

FALSE

TRUE

FALSE

FALSE

FALSE

FALSE

FALSEFALSE

FALSE

FALSE

FALSE

FALSE

FALSE

FALSE

FALSE

FALSE

FALSE

FALSE

FALSE

FALSE

FALSE

FALSE

FALSE

FALSE

FALSE

FALSE



FALSE

FALSE

FALSE

FALSE

FALSE

FALSE

FALSEFALSE

FALSE



NP Pitch Type dO (m) PT (m)

4 Triangular 0.01905 0.0254 0 44 72 96 134 180 232 294

inches 8 10 12 13.25 15.25 17.25 19.25 21.25

metres 0.2032 0.254 0.3048 0.33655 0.38735 0.43815 0.48895 0.53975

1 Triangular 0.01905 0.0238125 33 69 105 135 193 247 307 391

1Triangular 0.01905 0.0254

33 57 91 117 157 217 277 3431 Square 0.01905 0.0254 33 53 85 101 139 183 235 287

1 Triangular 0.0254 0.03175 15 33 57 73 103 133 163 205

1 Square 0.0254 0.03175 17 33 45 65 83 111 139 179

2 Triangular 0.01905 0.0238125 32 58 94 124 166 228 300 370

2 Triangular 0.01905 0.0254 28 56 90 110 154 208 264 326

2 Square 0.01905 0.0254 26 48 78 94 126 172 222 280

2 Triangular 0.0254 0.03175 16 32 52 62 92 126 162 204

2 Square 0.0254 0.03175 12 26 40 56 76 106 136 172

4 Triangular 0.01905 0.0238125 48 84 108 154 196 266 332

4 Triangular 0.01905 0.0254 44 72 96 134 180 232 294

4 Square 0.01905 0.0254 48 72 88 126 142 192 2424 Triangular 0.0254 0.03175 24 44 60 78 104 138 176

4 Square 0.0254 0.03175 24 40 48 74 84 110 142

6 Triangular 0.01905 0.0238125 80 116 174 230 294

6 Triangular 0.01905 0.0254 66 104 156 202 258

6 Square 0.01905 0.0254 54 78 116 158 212

6 Triangular 0.0254 0.03175 34 56 82 112 150

6 Square 0.0254 0.03175 44 66 88 116

8 Triangular 0.01905 0.0238125 94 140 198 258

8 Triangular 0.01905 0.0254 82 124 170 224

8Square 0.01905 0.0254

94 132 1748 Triangular 0.0254 0.03175 66 90 120

8 Square 0.0254 0.03175 74 94

Inner Diameter of

SHELL

Reference: Page 37 | Ernest E. Ludwig' Applied Process Design for Ch

Special Thanks: Muhammad Arsalan Kh

Tube

Tube Count [Fixed Tub

Shell & Tube Exchangers



35

Index

360 424 508 596 692 802 912 1024 12

23.25 25 27 29 31 33 35 37 10

0.59055 0.635 0.6858 0.7366 0.7874 0.8382 0.889 0.9398 0.254

481 553 663 763 881 1019 1143 1269 FALSE

423 493 577 667 765 889 1007 1127 FALSE355 419 495 587 665 765 865 965 FALSE

247 307 361 427 481 551 633 699 FALSE

215 255 303 359 413 477 545 595 FALSE

452 528 626 734 846 964 1088 1242 FALSE

398 468 556 646 746 858 972 1088 FALSE

346 408 486 560 644 746 840 946 FALSE

244 292 346 410 462 530 608 688 FALSE

218 248 298 348 402 460 522 584 FALSE

412 484 576 680 788 904 1024 1172 FALSE

360 424 508 596 692 802 912 1024 TRUE

308 366 440 510 590 688 778 880 FALSE212 258 308 368 422 486 560 638 FALSE

188 214 260 310 360 414 476 534 FALSE

372 440 532 632 732 844 964 1106 FALSE

322 388 464 548 640 744 856 964 FALSE

266 324 394 460 536 634 224 818 FALSE

182 226 274 338 382 442 514 586 FALSE

154 184 226 268 318 368 430 484 FALSE

332 398 484 576 682 790 902 1040 FALSE

286 344 422 496 588 694 798 902 FALSE

228 286 352 414 490 576 662 760 FALSE154 190 240 298 342 400 466 542 FALSE

128 150 192 230 280 334 388 438 FALSE

mical & Petrochemical Plants, 3rd Ed, Vol.3 (1999)

n [2010 - CH - 120]

Count

Calculated # of Tubes

s]



tonne/day 1.15740741E-02 GaugeRange Hot.Fluids

(7/0) Aqueous Vapours

kg/s 1.00000000E+00 (6/0) Dowtherm

kg/min 1.66666667E-02 (5/0) Flue Gases

kg/h 2.77777778E-04 (4/0) Gases

kg/day 1.15740741E-05 (3/0) Gases (P = 200 bar)

tonne/h 2.77777778E-01 (2/0) Gases (P = atm)tonne/day 1.15740741E-02 0 Heavy Oils

tonne/yr 3.17097921E-05 1 Light Oils

g/s 1.00000000E-03 2 Organic Solvents

g/min 1.66666667E-05 3 Organic Vapours

g/h 2.77777778E-07 4 Organics (some non-condensables)

g/day 1.15740741E-08 5 Reduced Crude

lb/s 4.53592370E-01 6 Refinery Hydrocarbons

lb/min 7.55987283E-03 7 Regenerated DEA

lb/h 1.25997881E-04 8 Steam

Mlb/h 1.25997881E-01 9 Water

lb/day 5.24991169E-06 10

M lb/day 5.24991169E-03 11 Cold.Fluids

MM lb/day 5.24991169E+00 12 Aqueous Solution

tn(short)/s 9.07184740E+02 13 Brine

tn(short)/min 1.51197457E+01 14 Flashed Crude

tn(short)/h 2.51995761E-01 15 Foul DEA

tn(short)/day 1.04998234E-02 16 Gases

tn(long)/s 1.01604691E+03 17 Gases (P = 200 bar)

tn(long)/min 1.69341152E+01 18 Gases (P = atm)

tn(long)/h 2.82235253E-01 19 Heavy Oilstn(long)/day 1.17598022E-02 20 Heavy Organics

21 Hydrocarbon Vapours

m3/sec 1.00000000E+00 22 Light Oils

m3/min 1.66700000E-02 23 Light Organics

m3/h 2.77800000E-04 24 Organic Solvents

m3/day 1.15700000E-05 25 Refinery Hydrocarbons

L/sec 1.00000000E-03 26 Steam

L/min 1.66700000E-05 27 Water

L/h 2.77800000E-07 28

L/day 1.15700000E-08 29

barrel/s 1.58987295E-01 30

barrel/min 2.64960000E-03 31

barrel/h 4.41600000E-05 32

barrel/day 1.84000000E-06 33

gallon/s [US] 3.78541200E-03 34

gallon/min [US] 6.30900000E-05 35

gallon/h [US] 1.05200000E-06 36

gallon/day [US] 4.38333333E-08 37

MGPD 4.38100000E-05 38

Mass.FR

Vol.FR



MMGPD 4.38100000E-02 39

gallon/s [UK] 4.54609000E-03 40

gallon/min [UK] 7.57681667E-05 41

gallon/h [UK] 1.26280278E-06 42

gallon/day [UK] 5.26167824E-08 43

44

4546

47

48

49

50



Process.Fluid Process.FR Fluid.Side FlowType PitchType

Ethylene Mass Flow Rate Shell Side Parallel Triangular

Water Volumetric Flow Rate Tube Side Counter-Current Square

Temp. Length Gauge Density Viscosity

K m BWG kg/m3

kg/msC cm SWG g/L P

F mm AWG g/cm3

cP

ft lb/ft3

in. lb/in.3

Thermal.Cond Heat.Capacity HT.C. Fouling.Factor

W/m K J/kg K W/m2

K m2

K / W

J/s m K KJ/kg K cal/s m2 C s m

2 C / cal

BTU/hr ft F cal/g C kcal/h m2 C h m2 C / kcal

BTU/lb F BTU/hr ft2 F hr ft

2 F / BTU



FT.Entry Phase Tube.Pitch.Values Hi.Calc

Auto Gas 15/16 Auto

Manual Liquid 1 Manual

1 1/4



inches m

(7/0) -

(6/0) -

(5/0) 0.5 0.0127

(4/0) 0.454 0.0115316

(3/0) 0.425 0.010795(2/0) 0.38 0.009652

0 0.34 0.008636

1 0.3 0.00762

2 0.284 0.0072136

3 0.259 0.0065786

4 0.238 0.0060452

5 0.22 0.005588

6 0.203 0.0051562

7 0.18 0.004572

8 0.165 0.004191

9 0.148 0.0037592

10 0.134 0.0034036

11 0.12 0.003048

12 0.109 0.0027686

13 0.095 0.002413

14 0.083 0.0021082

15 0.072 0.0018288

16 0.065 0.001651

17 0.058 0.0014732

18 0.049 0.0012446

19 0.042 0.001066820 0.035 0.000889

21 0.032 0.0008128

22 0.028 0.0007112

23 0.025 0.000635

24 0.022 0.0005588

25 0.02 0.000508

26 0.018 0.0004572

27 0.016 0.0004064

28 0.014 0.0003556

29 0.013 0.0003302

30 0.012 0.0003048

31 0.01 0.000254

32 0.009 0.0002286

33 0.008 0.0002032

34 0.007 0.0001778

35 0.005 0.000127

36 0.004 0.0001016

37 -

38 -

B.W.G



39 -

40 -

41 -

42 -

43 -

44 -

45 -46 -

47 -

48 -

49 -

50 -



No_Passes

1

2

4

6

8

10



inches m

(7/0) 0.5 0.0127

(6/0) 0.464 0.0117856

(5/0) 0.432 0.0109728

(4/0) 0.4 0.01016

(3/0) 0.372 0.0094488(2/0) 0.348 0.0088392

0 0.324 0.0082296

1 0.3 0.00762

2 0.276 0.0070104

3 0.252 0.0064008

4 0.232 0.0058928

5 0.212 0.0053848

6 0.192 0.0048768

7 0.176 0.0044704

8 0.16 0.004064

9 0.144 0.0036576

10 0.128 0.0032512

11 0.116 0.0029464

12 0.104 0.0026416

13 0.092 0.0023368

14 0.08 0.002032

15 0.072 0.0018288

16 0.064 0.0016256

17 0.056 0.0014224

18 0.048 0.0012192

19 0.04 0.00101620 0.036 0.0009144

21 0.032 0.0008128

22 0.028 0.0007112

23 0.024 0.0006096

24 0.022 0.0005588

25 0.02 0.000508

26 0.018 0.0004572

27 0.0164 0.00041656

28 0.0148 0.00037592

29 0.0136 0.00034544

30 0.0124 0.00031496

31 0.0116 0.00029464

32 0.0108 0.00027432

33 0.01 0.000254

34 0.0092 0.00023368

35 0.0084 0.00021336

36 0.0076 0.00019304

37 0.0068 0.00017272

38 0.006 0.0001524

S.W.G



39 0.0052 0.00013208

40 0.0048 0.00012192

41 0.0044 0.00011176

42 0.004 0.0001016

43 0.0036 0.00009144

44 0.0032 0.00008128

45 0.0028 0.0000711246 0.0024 0.00006096

47 0.002 0.0000508

48 0.0016 0.00004064

49 0.0012 0.00003048

50 0.001 0.0000254



inches m

(7/0) -

(6/0) -

(5/0) -

(4/0) 0.46 0.011684

(3/0) 0.4096 0.01040384(2/0) 0.3648 0.00926592

0 0.3249 0.00825246

1 0.2893 0.00734822

2 0.2576 0.00654304

3 0.2294 0.00582676

4 0.2043 0.00518922

5 0.1819 0.00462026

6 0.162 0.0041148

7 0.1443 0.00366522

8 0.1285 0.0032639

9 0.1144 0.00290576

10 0.1019 0.00258826

11 0.0907 0.00230378

12 0.0808 0.00205232

13 0.072 0.0018288

14 0.0641 0.00162814

15 0.0571 0.00145034

16 0.0508 0.00129032

17 0.0453 0.00115062

18 0.0403 0.00102362

19 0.0359 0.0009118620 0.032 0.0008128

21 0.0285 0.0007239

22 0.0253 0.00064262

23 0.0226 0.00057404

24 0.0201 0.00051054

25 0.0179 0.00045466

26 0.0159 0.00040386

27 0.0142 0.00036068

28 0.0126 0.00032004

29 0.0113 0.00028702

30 0.01 0.000254

31 0.00893 0.000226822

32 0.00795 0.00020193

33 0.00708 0.000179832

34 0.0063 0.00016002

35 0.00561 0.000142494

36 0.005 0.000127

37 0.00445 0.00011303

38 0.00397 0.000100838

A.W.G



39 0.00353 0.000089662

40 0.00314 0.000079756

41 -

42 -

43 -

44 -

45 -46 -

47 -

48 -

49 -

50 -

design of shell & tube hx (unprotected for expert excel users)

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