3.
1 Various Types of Heat Exchangers
Heat exchangers are devices used to transfer heat between two or more fluids at different
temperatures.
Classification:
A. Based on Flow Arrangement
1. Parallel Flow – Both fluids flow in the same direction
2. Counter Flow – Fluids flow in opposite directions (higher heat transfer efficiency)
3. Cross Flow – Fluids flow perpendicular to each other
B. Based on Construction
1. Double Pipe Heat Exchanger
2. Shell and Tube Heat Exchanger
3. Plate Heat Exchanger
4. Spiral Heat Exchanger
5. Finned Tube Heat Exchanger
C. Based on Phase Change
1. Condensers
2. Evaporators
3. Boilers
3.2 Types of Shell and Tube Heat Exchangers and Its Parts
Types of Shell and Tube Heat Exchangers
1. Fixed Tube Sheet Heat Exchanger
2. U-Tube Heat Exchanger
3. Floating Head Heat Exchanger
Main Parts of Shell and Tube Heat Exchanger
1. Shell – Outer cylindrical vessel containing shell-side fluid
2. Tubes – Carry tube-side fluid
3. Tube Sheet – Holds tubes in position
4. Baffles – Increase turbulence and heat transfer
5. Front Head – Inlet and outlet for tube-side fluid
6. Rear Head – Allows expansion or tube cleaning
7. Nozzles – Fluid entry and exit points
8. Gaskets – Prevent leakage
3.3 Advantages and Disadvantages of Different Types of Shell and Tube Heat Exchangers
1. Fixed Tube Sheet Type
Advantages:
Simple design
Low initial cost
Suitable for high pressure
Disadvantages:
Difficult to clean shell side
Not suitable for large temperature differences
2. U-Tube Type
Advantages:
Allows thermal expansion
Suitable for high temperature difference
Lower cost than floating head
Disadvantages:
Difficult tube-side cleaning
Tube replacement is difficult
3. Floating Head Type
Advantages:
Easy cleaning of both sides
Suitable for high temperature and pressure
Handles thermal expansion well
Disadvantages:
Expensive
Complex construction
3.4 Different Types of TEMA Designations
TEMA stands for Tubular Exchanger Manufacturers Association.
It standardizes shell and tube heat exchanger design.
TEMA Designation Format:
Front Head – Shell – Rear Head (e.g., BEM, AES, BEU)
Common TEMA Front Head Types
A – Channel with removable cover
B – Bonnet (integral cover)
C – Channel with removable cover and tube sheet
Shell Types
E – One-pass shell (most common)
F – Two-pass shell
G – Split flow shell
H – Double split flow shell
Rear Head Types
L – Fixed tube sheet
M – Fixed tube sheet with packing
S – Floating head with backing device
T – Pull-through floating head
U – U-tube bundle
Example: BEM
B – Bonnet front head
E – One-pass shell
M – Fixed tube sheet rear head
Fixed Tube Sheet Heat Exchanger
A Fixed Tube Sheet Heat Exchanger is a type of shell and tube heat exchanger in which the tube
sheets are rigidly fixed to the shell at both ends, and the tubes cannot move independently of the
shell.
Construction
Shell: Cylindrical outer body carrying shell-side fluid
Tubes: Straight tubes fixed permanently into the tube sheets
Tube Sheets: Welded or bolted rigidly to the shell
Baffles: Provided inside the shell to direct flow and increase heat transfer
Front Head & Rear Head: Provide inlet and outlet for tube-side fluid
Working Principle
One fluid flows through the tubes, while the other flows through the shell side.
Heat is transferred through the tube walls from the hot fluid to the cold fluid.
Since the tube bundle is fixed, thermal expansion difference between shell and tubes is
restricted.
Advantages
1. Simple construction
2. Low initial cost
3. Suitable for high-pressure tube-side operation
4. Leakage chances are minimal
5. Compact and rugged design
Disadvantages
1. Shell-side cleaning is difficult
2. Not suitable for large temperature difference
3. Thermal stress may develop
4. Tube bundle cannot be removed
5. Limited maintenance flexibility
Applications
Oil coolers
Water coolers
Heat recovery systems
Short Exam Answer
A fixed tube sheet heat exchanger is a shell and tube heat exchanger in which the tube sheets are
rigidly fixed to the shell, making the tube bundle non-removable and suitable for high pressure
applications with small temperature differences.
U-Tube Heat Exchanger
A U-Tube Heat Exchanger is a type of shell and tube heat exchanger in which the tubes are bent in the
shape of a “U” and fixed to only one tube sheet. The other end is free, allowing thermal expansion.
Construction
Shell: Cylindrical outer body carrying shell-side fluid
U-shaped Tubes: Bent tubes forming a U-shape
Single Tube Sheet: Holds both ends of U-tubes
Baffles: Direct shell-side fluid and improve heat transfer
Channel / Bonnet: Provides inlet and outlet for tube-side fluid
Working Principle
Tube-side fluid enters through one pass of the U-tube and returns through the other pass.
Shell-side fluid flows across the tubes.
Heat transfer occurs through tube walls.
Advantages
1. Allows thermal expansion
2. Suitable for high temperature difference
3. Lower cost than floating head type
4. Reduced leakage possibility
5. Simple rear-end construction
Disadvantages
1. Tube-side cleaning is difficult
2. Individual tube replacement is not possible
3. Not suitable for dirty tube-side fluids
4. Tube inspection is limited
Applications
High temperature services
Chemical and petrochemical industries
Heat recovery systems
When large temperature difference exists between fluids
Short Exam Answer
A U-tube heat exchanger is a shell and tube heat exchanger in which U-shaped tubes are fixed to a
single tube sheet, allowing thermal expansion and making it suitable for high temperature difference
applications.
Floating Head Heat Exchanger
A Floating Head Heat Exchanger is a type of shell and tube heat exchanger in which one tube sheet
is fixed and the other is free (floating). This floating arrangement allows independent thermal
expansion of the tube bundle and enables easy cleaning of both shell and tube sides.
Construction
Shell: Cylindrical outer body carrying shell-side fluid
Straight Tubes: Fixed into two tube sheets
Fixed Tube Sheet: Rigidly attached to the shell
Floating Tube Sheet (Floating Head): Free to move inside the shell
Baffles: Increase turbulence and heat transfer
Rear Head Assembly: Allows removal of tube bundle
Channel / Bonnet: Inlet and outlet for tube-side fluid
Working Principle
One fluid flows through the tubes and the other through the shell side.
Heat is transferred through tube walls.
During operation, thermal expansion of tubes occurs freely because one end is floating.
The tube bundle can be removed for inspection and cleaning.
Advantages
1. Easy cleaning of both shell and tube sides
2. Suitable for large temperature differences
3. Handles thermal expansion effectively
4. Suitable for high pressure and high temperature
5. Longer service life
Disadvantages
1. High initial cost
2. Complex construction
3. More space required
4. Higher maintenance cost
Applications
Oil refineries
Chemical and petrochemical plants
Heat exchangers handling dirty fluids
High temperature and pressure services
Short Exam Answer (2 Marks)
A floating head heat exchanger is a shell and tube heat exchanger in which one tube sheet is fixed
and the other is free to move, allowing thermal expansion and easy cleaning of both sides.
TEMA Designation Examples
AES
o A – Channel with removable cover
o E – One-pass shell
o S – Floating head with backing device
AET
o T – Pull-through floating head
TEMA stands for Tubular Exchanger Manufacturers Association.
It is an international organization that standardizes the design, construction, dimensions, materials,
and nomenclature of shell and tube heat exchangers to ensure interchangeability, safety, and
reliability.
TEMA Designation System
TEMA uses a three-letter designation to describe a shell and tube heat exchanger:
Front Head – Shell – Rear Head
1. TEMA Front Head Designations
Letter Type Description
A Channel with removable cover Allows easy tube-side cleaning
B Bonnet (integral cover) Simple, low-cost construction
C Channel with removable cover and tube sheet Used for high-pressure services
2. TEMA Shell Designations
Letter Type Description
E One-pass shell Most commonly used
F Two-pass shell Improved heat transfer
G Split flow shell Used for phase change
H Double split flow shell High heat transfer
J Divided flow shell Low pressure drop
3. TEMA Rear Head Designations
Letter Type Description
L Fixed tube sheet Simple and economical
M Fixed tube sheet with packing Allows limited expansion
Letter Type Description
S Floating head with backing device Easy maintenance
T Pull-through floating head Easy tube bundle removal
U U-tube bundle Allows thermal expansion
Suitable Example: BEM Heat Exchanger
B → Bonnet type front head
E → One-pass shell
M → Fixed tube sheet rear head
Meaning:
A BEM heat exchanger has a bonnet front head, a single-pass shell, and a fixed tube sheet rear
head, commonly used for clean fluids and moderate temperature differences.