Sample Calculations
Selection of Heat Exchanger Type
Type: Shell and tube heat exchanger
Tube material: Copper
Shell material: Carbon steel
Layout: Square pitch
Tube passes: 2
Fluids:
Tube side: Glycol–water mixture (30:70)
Shell side: Saturated steam (3 bar)
Specification
Fluid 1 (Glycol–Water 30:70):
Flow rate = 0.55 kg/s
Supply temperature = 18 °C
Target temperature = 60 °C
Q = mCp ΔT
=( 0.55 kg/s) ( 3.7 kJ/kg·K)( 60 °C - 18 °C)
= 88.47 kW
Fluid 2 (Saturated Steam at 3 bar):
Inlet: saturated vapor
Outlet: saturated liquid
Supply temperature = 133.6 °C (steam tables at 3 bar)
Target temperature = 133.6 °C
Heat of vaporisation H fg =−2163.8 kJ/kg (steam tables)
Q −88.47 kg
msteam = = = 0.04
H fg −2163.8 s
ΔT1= Tsteam – ΔTcold,out
= 134-60
= 134 – 60 = 74 ℃
ΔT2 = Tsteam – Tcold,in
= 134 – 18
= 116 ℃
3. Physical Properties
Fluid 1 (Glycol–Water):
Density = 1047 kg/m³
Specific heat capacity = 3.7 kJ/kg·K
Thermal conductivity = 0.256 W/m·K
Viscosity = 3.5 × 10⁻³ kg/m·s
Fluid 2 (Steam/Condensate):
Density = 1.65 kg/m³
Thermal conductivity = 0.02 W/m·K
Specific heat capacity = 3.82 kJ/kg·K
Viscosity = 1.35 × 10⁻⁵ kg/m·s
Overall Coefficient (Assumed)
U ass =1000 W/m ²
5. Exchanger Type and Dimensions
Number of passes = 2
Correction factor F=1
Log mean temperature difference Δ T m=93.025 °C
Tube length = 1 m
Tube thickness = 1.6 mm
Heat Transfer Area
Q=88.47 k W
ΔT 2−ΔT 1
LMTD = ΔT 2
ln ( )
ΔT 1
=
116−74
116
ln ( )
74
= 93.43 ℃
Arequired = = = 0.9510 m2
Q 88.47 kW
U LMTD 1000(93.43)
7. Layout and Tube Size
Tube size: 20 mm (OD), 16 mm (ID)
Tube layout: Square pitch
Pt =d 0 +c=6.4 +20=26.4 m m
Tube length: 1 m
Surface Area per tube:
At=πDL=3.14(20×103) (1) =0.0628m²
Number of Tubes
Nt = = = 0.000201 m2
A required 0.9510
At 0.0628
Cross-sectional area per tube:
π
Ac , tube = ¿
4
Total tube area:
Ac , total=16 ×0.000201=0.00322 m ²
Tube velocity (one pass):
0.55
U= =0.1631 m/ s
1047 × 0.00322
Velocity after passes:
U t =2 ×0.1631=0.326 m/ s
9. Bundle and Shell Diameter
Db = 20(16/0.156)1/2.291
Clearance (floating head): 88 mm
Ds =Db +clearance=200+ 88=288 m m Ds =11.34 in≈ 12 in
Baffle spacing: 0.2 × D s=57.6 mm
Tube pitch: 1.25 ×20=25 mm
Flow area:
(Pt −d 0 )D s Lb (25−20)× 288 ×57.6
A s= = =3317.76 mm²=0.003317 m²
Pt 25
10. Tube-Side Heat Transfer Coefficient
Reynolds number:
−3
ρUD 1047× 0.326 ×16 × 10
ℜ= = −3
=1560.329
μ 3.5 ×10
Prandtl number:
−3
Cpμ 3.78 ×3.5 × 10
Pr= = =51.68
k 0.256
Nusselt number:
0.8 0.4
Nu=0.023 R e Pr =39.960
Tube-side heat transfer coefficient:
Nu ×k 39.960 ×0.256
hi = = =639.365 W/m² K
d 16 ×10
−3
11. Shell-Side Heat Transfer Coefficient
Shell-side equivalent diameter:
2 2
De =1.27 /d 0 (Pt −0.785 d 0 )=19.75 mm
Mass velocity:
0.040886
Gs = =12.36 kg/s
0.003317
Velocity:
12.36
U s= =7.49 m/s
1.65
Reynolds number:
G s D e 12.36 ×19.75
ℜ= = −5
=18082.22
μ 1.35× 10
Prandtl number:
3 −5
Cpμ 2.20 ×10 × 1.35× 10
Pr= = =1.485
k 0.02
Heat transfer factor: j h =1.35
Nusselt number:
1/ 3 −3
Nu= j h ReP r =(4.2 ×10 )(18082.22)¿
Shell-side heat transfer coefficient:
Nu × k 86.645× 0.022
h s= = =2820.2693 W/m² K
De 19.75 × 10
−3
12. Overall Coefficient (Calculated)
U= A R
1
ref eq
R=
1
hA
Rmixture = =
1 1
2
hA 639.65 W /m K A
Rsteam =
1
2
2820.2693W /m A
= 0.0004
2
m K
W
Rshell = 0.0002
2
m K
W
U=
1
A ref ( R mixture + R steam+ R tubes+ R shell)
1
= A ref (
2 2
1 1 m K m K
+ +0.0004 +0.0002 )
639.65 W 2820.2693 W W W
A A
m2 K m2 K
1
= 0.9510 m (
2 2
2 1 1 m K m K
+ +0.0004 +0.0002 )
639.65 W 2820.2693 W W W
(0.9510) (0.9510)
m2 K m2
U calc =1.65
ΔP_tube = Np[9Jf(L/di)+2.5]
= 2[9(6.6*10-1)(1/16*10-3)+2.5]*1047(0.326) ^2/2
=41.587 kPa
ΔP_shell = 8Jf(Ds/de)(L/lb) pu^2/2
= 8*4.4*10-1(288/19.75) (1/57.6*10-3)1.65(7.49) ^2/2
= 41.244 kPa
Modified Calculations
1. Selection of Heat Exchanger Type
Type: Shell and Tube Heat Exchanger
Tube Material: Copper
Shell Material: Carbon Steel
Tube Layout: Square Pitch
Tube Passes: 2
Fluids:
Tube Side: Glycol–water mixture (30:70)
Shell Side: Saturated steam (3 bar)
Specification
Fluid 1 (Glycol–Water 30:70):
Flow rate = 0.55 kg/s
Supply temperature = 18 °C
Target temperature = 60 °C
Q = mCp ΔT
= (0.55 kg/s) (3.7 kJ/kg·K) (60 °C - 18 °C)
= 88.47 kW
Fluid 2 (Saturated Steam at 3 bar):
Inlet: saturated vapor
Outlet: saturated liquid
Supply temperature = 133.6 °C (steam tables at 3 bar)
Target temperature = 133.6 °C
Heat of vaporisation H fg =−2163.8 kJ/kg (steam tables)
Q −88.47 kg
msteam = = = 0.04
H fg −2163.8 s
ΔT1= Tsteam – ΔTcold,out
= 134-60
= 134 – 60 = 74 ℃
ΔT2 = Tsteam – Tcold,in
= 134 – 18
= 116 ℃
3. Physical Properties
Fluid 1 (Glycol–Water):
Density = 1047 kg/m³
Specific heat capacity = 3.7 kJ/kg·K
Thermal conductivity = 0.256 W/m·K
Viscosity = 3.5 × 10⁻³ kg/m·s
Fluid 2 (Steam/Condensate):
Density = 1.65 kg/m³
Thermal conductivity = 0.02 W/m·K
Specific heat capacity = 3.82 kJ/kg·K
Viscosity = 1.35 × 10⁻⁵ kg/m·s
Overall Coefficient (Assumed)
U assumed =850 W/m²
5. Exchanger Type and Dimensions
Number of passes = 2
Correction factor F=1
Log mean temperature difference Δ T m=93.025 °C
Tube length = 1 m
Tube thickness = 1.6 mm
Heat Transfer Area
3
Q 88.47 ×10
Q=UA Δ T m A= = =1.122 m ²
U Δ T m 850 ×93.025
Layout and Tube Size
Do =20 mm , Di=16 m mPt =1.25 Do=25 mm At =π Do L=π (0.02)(1)=0.0628 m²
Number of Tubes
A required 1.122
Nt= = =12 tube s
Total area:
At 0.0628
Ac , total=12× 0.000201=0.00241 m²
Velocity (one pass):
ṁ 0.55
U= = =0.216 m/s
ρ A c, total 1047 × 0.00241
Velocity after 2 passes:
U t =2 ×0.216=0.432 m/s Bundle and Shell Diameter
1 /2.291
12
Db =20( ) =129 mm ≈150 m m Ds =Db +clearance=150+88=238 mm
0.156
(Pt −Do )D s Lb
Baffle spacing=0.2 Ds =47.6 mm A s= =0.00268 m²
Pt
10. Tube-Side Heat Transfer Coefficient
ρU Di 1047(0.432)(0.016) C p μ 3.7 ×103 (3.5 ×10−3)
ℜ= = −3
=206 5 Pr= = =50.5
μ 3.5× 10 k 0.256
=747.5 W/m² K Shell-Side
Nu k 46.75 (0.256)
Nu=0.023 R e Pr =46.75hi = =
0.8 0.4
Di 0.016
Heat Transfer Coefficient
2 2
ṁs 0.0409
De =1.27 /d o (Pt −0.785 d o)=19.75 m mGs = = =15.26 kg/s\cdotpm²
A s 0.00268
Gs De 15.26 (0.01975) C p , s μ s 3.82 ×103 (1.35 ×10−5)
R e s= = −5
=22322P r s = = =2.58
μs 1.35× 10 ks 0.02
0.55 0.33
N u s k s 103.6(0.02)
N us =0.36 R e s P r s =103.6 h s= = =1049 W/m² K
De 0.01975
Overall Heat Transfer Coefficient (Calculated)
U= A R
1
ref eq
R=
1
hA
Rmixture = =
1 1
2
hA 747.5W /m K A
Rsteam =
1
2
1049W /m A
= 0.0004
2
m K
W
Rshell = 0.0002
2
m K
W
U=
1
A ref ( R mixture + R steam+ R tubes+ R shell)
1
= A ref (
2 2
1 1 m K m K
+ +0.0004 +0.0002 )
747.5 W 1049W W W
A A
m2 K m2 K
1
= 1.122m (
2 2
2 1 1 m K m K
+ + 0.0004 + 0.0002 )
747.5 W 1049 W W W
(1.122) (1.122)
m2 K m2
1 W
U calc = =856 2
0.001168 m K
ΔPtube= Np[9Jf( )+2.5]
2
L Pt V
di 2
=3[9(0.0419)( )+2.5]
2
2 1047(0.7634 )
= 5132.2 Pa
0.0148 2
ΔPshell= 8Jf( )( l ) ρu2/2
Ds L
de b
=8 (0.0419)( )( )1.65(0.432)2/2
238 2
= 593.57 Pa
19.75 1