i

Minor Project on:

Design and Optimization of Shell & Tube Heat Exchanger Using
Aspen Exchanger Design and Rating (EDR)

Report submitted in partial fulfillment of the requirement for the degree of

B.Tech.
In
Chemical Engineering

Under the Supervision of

Professor A.K Jain

By

Pravind Kumar Thakur

[Enrollment Number: 03016101420]

University School of Chemical Technology

Guru Gobind Singh Indraprastha University
Dwarka Sec- 16C, Delhi- 110078
 Certificate

This is to certify that the project report titled " Design and Optimization of Shell & Tube Heat Exchanger Using Aspen
Exchanger Design and Rating (EDR)" submitted to University School of Chemical Technology, Guru Gobind Singh
Indraprastha University, New Delhi in fulfillment of the requirements for the award of the Bachelor of Engineering in
Chemical Engineering embodies the original research work carried out by Pravind Kumar Thakur under the supervision of
Prof. A.K Jain and Asst. Prof. Shweta Gupta. This work has not been submitted in part or full for any degree or diploma to
this or any other University.

Pravind Kumar Thakur Supervisor: Prof. A.K Jain (Dean, USCT)

Enrollment No.: 03016101420
 Declaration
I hereby declare that the project report titled “ Design and Optimization of Shell & Tube Heat Exchanger Using Aspen
Exchanger Design and Rating (EDR)" is an authentic record of the research work conducted by me and is free from any
falsification and plagiarism. This work was carried out under the supervision of Prof. A.K Jain and Asst. Prof. Shweta
Gupta at University School of Chemical Technology, Guru Gobind Singh Indraprastha University, New Delhi. I assume
full responsibility for any disputes that may arise from the content of my research work.

Pravind Kumar Thakur

Enrollment No.: 03016101420

 Acknowledgment
It is both an honor and a privilege for me to express my heartfelt gratitude to those who have been instrumental in guiding
and inspiring me throughout the completion of my B. Tech project. The undertaking of this project has not only fostered a
profound sense of research within me but has also expanded my knowledge in numerous aspects.
Foremost, I extend my sincere appreciation and gratitude to Prof. A.K Jain , a distinguished Professor at the Department
of Chemical Engineering, Guru Gobind Singh Indraprastha University. His exemplary guidance and constructive criticism
during the execution of my project titled “ Design and Optimization of Shell & Tube Heat Exchanger Using Aspen
Exchanger Design and Rating (EDR)" have been invaluable. Prof.Jain’s expertise has significantly shaped my
understanding of the intricate aspects of heat exchanger design within the Aspen EDR framework.
I am particularly thankful to Dr. Shweta Gupta and the entire faculty and supporting staff of the University School of
Chemical Technology for their unwavering support, constant assistance, and the provision of departmental facilities
essential for the successful completion of my project.

Student Name: Pravind Kumar Thakur

Student enrollment No.: 03016101420
Student Signature:
 Content
Certificate
Declaration
Acknowledgement
Content
List of Figures
List of Tables
Notations
Abstract
Chapter 1: Introduction 1
Chapter 2: Design parameters
2.1 Shell
2.2 Tube
2.3 Baffles
2.4 Tube Sheets
2.5 Tube Pitch
2.6 Tube Bundles
2.7 Fouling
2.8 Allocation of Streams
Chapter 3: Design Codes
3.1 TEMA
3.1.1 TEMA Class for Channels
3.1.2 Selection of heads
3.1.3 Selection of Shell
3.2 Case Selection TEMA types
3.2.1 TEMA types involving A, B, C, D, L, M, and N
3.2.2 TEMA designations involving L, M and N as 3rd character
3.2.3 TEMA types involving F, G, and H as 2nd character
3.2.4 TEMA types with U as 3rd character
Chapter 4: Theory-Kern’s method
Chapter 5: Simulation
5.1 Evaluating Constraints
5.2 Initial Geometry
5.3 Aspen EDR
5.4 Process simulation
5.5 Problem Statement
Reference
 List of Figures
S. No. Figure Caption Page
number
1.1 Shell and Tube Heat Exchanger

2.1 Types of Baffles

2.2 Flowing Pattern in Baffles
2.3 Tube Sheet Patterns
5.1 Screen shot of the crude distillation unit with heat exchanger E-100 as the
basis for rating/checking design calculations from the PFD in the Simulation
Environment (Source: UniSim Design R443, Courtesy of Honeywell Process
Solutions).

List of Tables

S. No. Title Page

number
1.1 Representative values of overall heat transfer coefficient in heat exchanger
2.1 Value of K1 and n
2.2 Fouling Characteristics
3.1 Selection of Heads
3.2 Selection of Shell
3.3 Baffle types as per TEMA
 Notations
A Area (m2)

As Cross Flow Area (m2)

B Baffle Spacing (m)

C Specific Heat Capacity (J kg-1 K-1)

Db Bundle Diameter (m)

Di Inside diameter of shell (m)

Ds Outside diameter of shell (m)

de Equivalent Diameter (m)

di Inside diameter of tube (m)

do Outside diameter of tube (m)

F Fouling Factor.

Ft Log Mean Temperature Difference Correction Factor

h Enthalpy (J kg-1K -1 )

hi Tube side Film Heat Transfer Coefficient (W m-2 K -1 )

hs Shell side Film Heat Transfer Coefficient (W m-2 K -1 )

Jf Friction Factor

Jh Heat Transfer Factor

k Thermal Conductivity, Turbulent kinetic energy.

L Length (m) m Mass Flow Rate (kg s-1 )

N Number of tubes.

Np Number of tube side passes

Pin Pressure at inlet of the shell

Pout Pressure at outlet of the shell

∆P Pressure Drop. Pt Pitch.

Q Heat Load.

∆Tlm Log Mean Temperature Difference.

t Time.

U Overall Heat Transfer Factor.

 Abstract
This project delves into the meticulous design of a Shell & tube Heat Exchanger using Aspen EDR, with a keen focus on
its industrial implications. The paramount objective is to harness cutting-edge engineering principles and technological
advancements to optimize heat exchange processes in real-world industrial applications.
Under the expert guidance of Prof. A.K Jain, a distinguished authority in the field of Chemical Engineering at Guru
Gobind Singh Indraprastha University, the project unfolds a comprehensive exploration of heat exchanger design
methodologies. The utilization of Aspen EDR software adds a practical dimension to the endeavor, aligning theoretical
knowledge with industry-relevant tools.
The project aims to contribute novel insights and innovative solutions applicable to diverse industries, including but not
limited to petrochemical, energy, and manufacturing sectors.
Furthermore, collaboration with industry professionals and experts has been integral to this research, ensuring alignment
with contemporary industrial standards and practices. Insights gained from this project are anticipated to have a substantial
impact on the optimization of heat exchange systems within industrial settings, enhancing overall efficiency and
sustainability.
This abstract encapsulates a multifaceted approach, integrating academic rigor with practical industrial relevance, and
underscores the project's potential to advance the field of heat exchanger design within an industrial framework.
 Chapter 1

INTRODUCTION

Heat exchangers play a pivotal role in the efficient transfer of thermal energy between fluids at different temperatures,
contributing to various industrial applications. Common examples of heat exchangers include automobile radiators,
condensers, evaporators, air preheaters, and oil coolers. Their widespread use is evident in power plants, petroleum
industries, heating, ventilation, refrigeration, and air conditioning systems (HVRAC), heat recovery systems, and the
chemical process industry.

In power plants and diverse engineering processes, heat exchangers, including intercoolers, boilers, pre-heaters, and
condensers, are crucial for controlling heat energy. These devices facilitate efficient heat transfer and can be broadly
classified into recuperative and regenerative types. Recuperative heat exchangers exchange heat on either side of a
dividing wall by fluids, while regenerative heat exchangers have hot and cold fluids in the same space, employing a matrix
of materials alternately as a source for heat flow.

Optimal thermal design of shell & tube heat exchangers involves a meticulous consideration of various interacting design
parameters. The design process encompasses both process and mechanical aspects.

Process Considerations:

1. Assigning process fluids to the shell side or tube side.

2. Selecting stream temperature specifications.

3. Defining shell side and tube side pressure drop design limits.

4. Establishing shell side and tube side velocity limits.

5. Choosing heat transfer models and fouling coefficients for both shell side and tube side.

Mechanical Considerations:

1. Selecting the heat exchanger TEMA layout and determining the number of passes.

2. Specifying tube parameters, including size, layout, pitch, and material.

3. On tube length setting upper and lower limits.

4. Specifying shell side parameters such as materials, baffles cut, baffle spacing, and clearances.

5. Establishing upper and lower design limits on shell diameter, baffle cut, and baffle spacing.
The integration of these considerations ensures a comprehensive and efficient thermal design, aligning with the specific
requirements of industrial applications. This project explores the multifaceted nature of shell & tube heat exchangers,
addressing their crucial role in diverse industries and highlighting the intricate design parameters involved.

1.1. Heat Transfer Processes:

Heat exchanger is a device designed to transfer thermal energy between two or more fluids, and the heat transfer process
involves distinct stages:

Convection from Hot Fluid to Wall:

The initial stage involves the transfer of heat from the hot fluid to the wall of the heat exchanger through convection. In
this process, the high-temperature fluid near the wall imparts its thermal energy to the adjacent solid surface.

Conduction Through the Wall:

Once the heat is transferred to the wall, the thermal energy traverses through the wall material via conduction. The wall
acts as a medium, allowing the efficient flow of heat from the hot side to the cold side.

Convection from Wall to Cold Fluid:

Subsequently, the thermal energy reaches the cold side of the heat exchanger, where it is transferred to the cold fluid
through convection. The cold fluid gains heat as it absorbs the energy released by the wall, completing the heat transfer
cycle.

In essence, the combination of convection, conduction, and convection again facilitates the exchange of thermal energy
between the two fluids while maintaining a physical separation through the heat exchanger wall.

The total amount of thermal resistance involved with the heat transfer process involves two convection and one
conduction resistances. Total thermal resistance become,
 So, the heat transfer through the pipe is:

When analyzing heat exchangers, it is advantageous to consolidate all thermal resistances along the heat flow path from
the hot fluid to the cold one into a unified resistance denoted as R. This allows for the expression of the rate of heat
transfer between the two fluids.

where U is the overall heat transfer coefficient, ( unit is W/m2 · °C), which is identical to the unit of the ordinary
convection coefficient h. Canceling T, Equation reduces to

Table 1.1: Representative values of overall heat transfer coefficient in heat exchanger
 Figure 1.1: Shell and Tube Heat Exchanger

1.2. Types of Heat Exchangers:

Transfer of heat from one fluid to another is a vital process in the majority of chemical industries. The primary application
of heat transfer lies in the design of equipment dedicated to exchanging heat between two fluids, commonly referred to as
Heat Exchangers. These devices, designed for the efficient transfer of heat, are generally classified based on the specific
transfer processes occurring within them, as illustrated in Figure 1.1.

Among the various types of heat exchangers, shell & tube heat exchangers emerge as the most widely used heat
exchange equipment. The common types of shell & shell & tube heat exchangers include:

Fixed Tube-Sheet Exchanger (Non-Removable Tube Bundle):

This is the simplest and most cost-effective type of shell & shell & tube heat exchanger with a fixed tube sheet design. In
this configuration, the tube sheet is welded to the shell, preventing any relative movement between the shell & tubebundle
(refer to Figure 1.2).

Removable Tube Bundle Exchanger:

Tube bundles in these exchangers can be removed for ease of cleaning and replacement. This category includes floating-
head and U-tube exchangers.

Floating-Head Exchanger: Features a stationary tube sheet clamped with the shell flange. At the opposite end of the
bundle, tubes may expand into a freely riding floating head or floating tube sheet. The floating head cover is bolted to the
tube sheet, allowing the entire bundle to be removed for cleaning and inspection (depicted in Figure 1.3).

U-Tube Exchanger: Consists of tubes bent in the form of a 'U' and rolled back into the tube sheet, as shown in Figure 1.4.
This design may omit some tubes at the center of the tube bundle, and the tubes can expand freely towards the 'U' bend
end.

Guidelines for the mechanical design of unfired shell & tubeheat exchangers are provided by TEMA (USA) and IS: 4503-
1967 (India) standards.
 Chapter 2

Design Parameters
The Thermal design of a shell & tube heat exchanger encompasses several critical parameters, including the determination
of heat transfer area, number of tubes, tube length and diameter, tube layout, number of shell & tube passes, heat
exchanger type (fixed tube sheet, removable tube bundle, etc.), tube pitch, number of baffles, their type and size, and shell
& tube side pressure drop.

2.1. Shell: The shell serves as the container for the shell fluid, with the tube bundle positioned inside. Selection of the shell
diameter aims for a close fit of the tube bundle. The clearance between the tube bundle and the inner shell wall depends on
the type of exchanger ([2]; page 647). Shells are typically fabricated from standard steel pipe with an adequate corrosion
allowance. For operating pressures up to 300 psi and a shell ID of 12-24 inches, a shell thickness of 3/8 inch is deemed
satisfactory.

2.2. Tube: Commonly, tube outer diameters of ¾ and 1 inch are employed in designing compact heat exchangers. Optimal
heat transfer conditions involve maximizing the number of tubes in the shell to enhance turbulence. Tube thickness must
be sufficient to withstand internal pressure, considering the necessary corrosion allowance. Tube thickness is expressed in
terms of BWG (Birmingham Wire Gauge) and true outside diameter (OD). Tube lengths of 6, 8, 12, 16, 20, and 24 feet are
preferred, although longer tubes reduce shell diameter at the expense of higher shell pressure drop. Finned tubes come into
play when fluids with low heat transfer coefficients flow on the shell side. Stainless steel, admiralty brass, copper, bronze,
and copper-nickel alloys are common materials used for tubes.
2.3. Baffles: Baffles play a crucial role in supporting tubes, maintaining a desirable fluid velocity at the shell side, and
preventing tube failure due to flow-induced vibration. There are two primary types of baffles: plate and rod. Plate baffles
can be single-segmental, double-segmental, or triple-segmental.

The shell side crossflow area (as) is determined by the formula:

as = (D.C.B)/PT

Where:

(as) is the shell side crossflow area,

(D) is the shell inside diameter,

(C) is the clearance between tubes,

(B) is the baffle spacing,

(PT) is the tube pitch.

Baffle Spacing: The minimum baffle spacing (pitch) should generally not be closer than 1/5 of the shell diameter (ID) or 2
inches, whichever is greater. The maximum spacing does not normally exceed the shell diameter. Tube support plate
spacing is determined by mechanical considerations, such as strength and vibration.

Maximum Spacing: The maximum spacing is given by mechanical considerations and aims to prevent failures, especially
when the unsupported tube length is greater than 80%. Designers often limit the shell side pressure drop.

Baffle Cuts: It is a segment cut away to permit the fluid to flow parallel to the tube axis as it flows from one baffle space
to another. Baffle cuts can vary between 15% and 45% and are expressed as the ratio of segment opening height to shell
inside diameter. The upper limit ensures that every pair of baffles adequately supports each tube. Kern shell side pressure
drop correlations are commonly based on a 25% cut, standard for liquid on the shell side.

Baffle Clearances: The outer tube limit (OTL) is the diameter created by encircling the outermost tubes in a tube layout.
The actual OTL is usually 1.5 times the design pressure, used during a hydrostatic test to detect leaks at any joint on the
heat exchanger.

Example Fixed Tube-Sheet Clearances:

{Shell Inside Diameter (mm)} = {Clearance Shell I.D and OTL (mm)}

- 254 (10) to 610 (24) → 11 (7/16)

- ≥ 635 (25) → 13 (1/2)

Figure 2.1: Types of Baffles

 Figure 2.2: Flowing Patterns in baffles

2.4. Tube Sheets: Tube sheets, crucial in shell-and-tube heat exchangers, are flat, round metal pieces with precisely
drilled and reamed holes. Tubes are securely attached using methods like hydraulic pressure or roller expansion.
Machining grooves in tube holes enhances joint strength.

Purpose: Tube sheets serve as plates with holes for tube insertion.

Securing Tubes: Tubes are firmly attached to prevent fluid mixing between shell & tubesides.

2.5. Tube Pitch: The distance between tube holes, usually 1.25 times the tube diameter, optimizes arrangement for
efficient heat transfer. It is defined by PT = d0 + C

Figure 2.3: Tube Sheet Patterns

2.6. Tube Bundles: Tube bundles, also known as tube stacks, are designed to meet specific customer needs and can
replace existing units. Two common types are the Fixed Tube Sheet and U-Tube configurations.

a) Fixed Tube Sheet: Straight tubes secured at both ends by tube sheets welded to the shell.

Application: Suitable for various heat exchange applications.

b) U-Tube: Tubes bent in a U-shape with only one tube sheet in the heat exchanger.

Application: Offers versatility and efficiency in certain heat transfer scenarios.

The bundle diameter (Db) can be estimated using the formula:

Db = d0 (Nt / K1)¹⁄n

Where:

(do): Tube Outside Diameter

(Nt): Number of tubes

(K1) and (n): Constants (Value given in table below)

Figure 2.1: Value of k1 and n

2.7. Fouling: In heat exchangers, fouling, the accumulation of unwanted materials on processing equipment surfaces,
poses significant challenges impacting both performance and efficiency. The fouling layer, characterized by low thermal
conductivity, increases heat transfer resistance and diminishes the overall effectiveness of heat exchangers. This
phenomenon is particularly problematic as it necessitates additional energy consumption and maintenance costs. Frequent
fouling results in increased construction expenses due to the need for oversizing, and regular cleaning becomes imperative
for optimal functionality. Additionally, fouling is considered in the heat exchanger design by incorporating tube side and
shell side fouling resistances, mitigating the associated performance limitations.

On the other hand, vibrations induced by fluid flow in heat exchangers present practical problems that require careful
consideration. Various vibration mechanisms, including fluid elastic instability (Critical flow velocity causing instability),
vortex shedding(Periodic shedding of vortices can damage tubes) , acoustic resonance(Occurs when acoustic wave
frequency aligns with tube natural frequency), turbulent buffering(Significant in two-phase flow situations), and flow
pulsation(Periodic variations in flow become crucial in two-phase flow scenarios), can compromise the integrity of the
heat exchanger tubes. Effective strategies such as adjusting span lengths, altering tube diameter, and implementing
deresonating baffles are employed to counteract these vibration challenges. A comprehensive understanding of both
fouling and vibration issues is essential for the successful design, operation, and maintenance of heat exchangers, ensuring
prolonged and efficient functionality.

Figure 2.2: Fouling Characteristics

2.8. Allocation of Streams:

• High Pressure: When one stream operates at high pressure, it is advantageous to position that stream inside the tubes.
This design choice allows for a focus on designing only the tubes and tube-side fittings to withstand high pressure,
while the shell can be constructed with lighter-weight materials.
• Corrosion: The material selection for construction is often dictated by corrosion considerations. To minimize costs,
especially when corrosion-resistant alloys are more expensive, the corrosive fluid is typically placed inside the tubes,
avoiding the need for corrosion-resistant alloys on the shell side.
• Viscosity: Highly viscous fluids are placed on the shell side to induce turbulence by incorporating baffles in the shell.
This arrangement helps enhance heat transfer efficiency.
• Fouling: While fouling influences the design of most process exchangers, streams prone to severe fouling necessitate
design features that minimize fouling or facilitate easier cleaning.
• Low Heat Transfer Coefficient: Streams with inherently low heat transfer coefficients, such as low-pressure gases or
viscous liquids, are preferably placed on the shell side.
• Flow Rate: Generally, fluids with smaller flow rates are positioned on the shell side. This arrangement allows for the
provision of adequate turbulence by increasing the number of baffles.
• Phase of Fluid: Two-phase fluids are placed on the shell side as part of the design consideration.
 Chapter 3

Design Code
3.1. TEMA: (Standards of Tubular Exchanger Manufacturers Association) These guidelines are designed to complement
and elucidate the ASME Pressure Vessel Code specifically for shell-and-tube exchanger applications (excluding double-
pipe exchangers). While TEMA is intricately linked with ASME VIII, it serves as a valuable standard that can augment
various national codes beyond ASME. Construction recommendations are delineated in three distinct classes, with the
specific class being designated by the purchaser. It is essential to note that the design rules remain consistent across all
classes, with variations confined to dimensions and construction details.

Class R: Tailored for the rigorous requirements typically encountered in petroleum and related processing applications.

Class C: Geared towards the generally moderate requirements prevalent in commercial and general process services.

Class B: Specifically designed for chemical process service.

The numbering system employed is uniform across all classes, and TEMA references indicate whether they pertain to
Class R, C, or B of the 1978 edition. This edition marks a notable inclusion of a section titled "Recommended Good
Practice," addressing aspects not covered in the primary sections of the standard. It particularly focuses on the requisites
for exchangers featuring shell diameters ranging from 1524 to 2540 mm (60 to 100 inches). The numbering system aligns
with the three main sections of TEMA, with an asterisk (*) consistently denoting additional recommended good practices.

This comprehensive framework ensures a standardized approach to the design and construction of shell-and-tube
exchangers, offering flexibility to cater to diverse industry needs while maintaining a consistent and robust set of design
rules.

3.1.1. TEMA Class for Channels:

TEMA Class for Channels Application

R Severe requirements of petroleum and related
process applications.
C Moderate requirements of commercial and general
process applications.
B Chemical process service.

TEMA Front and Rear Ends:

 TEMA Front Head TEMA Rear Head

3.1.2. Selection of Heads (Table 3.1):

TEMA Front Head Selection

A Easy to open for tube side access. For low pressure applications.
B For Higher-pressure applications, preferred with clean tube side fluid. It is less expensive
than Type A.
C Tube side is corrosive, toxic or hazardous and when removable tube bundle is required. It is
normally used for low-pressure operations.
N For application where tube side is corrosive, toxic or hazardous and shell side fluid is clean
and any leakage possibility is to be eliminated.
D Very High-pressure applications.

TEMA Rear Head Selection

L, M, N Fixed Head, should be used when thermal differential expansion of the shell and tubes is
low and shell side fluid is clean.
L For low pressure applications.
M For Higher-pressure applications, not requiring frequent maintenance.
N For application where tube side is Corrosive, toxic or hazardous and where leakage of shell
to tube side fluid and vice versa, is to be eliminated.
U For thermal differential expansion of the shell and tubes is higher and tube side fluid is
clean. For highpressure applications or, with hazardous/ toxic fluid on shell side.
P, S, T, W Should be used when shell side fluid or both shell & tubeside fluid are Dirty.
P Pressure is low and shell side fluid is not toxic or hazardous. Where risk of internal flange
leakage is to be avoided.
S Normal Pressure requirements, relatively lesser maintenance requirements.
T High-pressure requirements, frequent need to takeout the tube bundle.
W For low-pressure application.

TEMA Shell Types:

Common TEMA type of Shell & Tube Heat Exchangers: AES, BEU, BHU, BXU, BEM, AKU, AET, AEL

3.1.3. Selection of Shell (Table 3.2):

TEMA Shell Selection

E The E shell is the most common as it is inexpensive and simple.
F F shell is rarely used in practice because there are many problems associated with the
design. It is difficult to remove/replace the tube bundle, problems of fabrication and
maintenance, internal leakage, unbalanced thermal expansion in case of large temperature
difference between inlet & outlet.
G, H To accommodate high inlet velocities. They are used as horizontal thermosiphon reboilers,
condensers, and other phase-change applications.
J Used for low pressure drop applications such as a condenser in vacuum.
K The K shell is used for partially vaporizing the shell fluid. It is used as a kettle reboiler in
the process industry and as a flooded chiller in the refrigeration industry. They are used
when essentially 100% vaporization is required.
X It is used for gas heating and cooling and for vacuum condensation. It is also used when
shell flows are large.
3.2. Case Selection of TEMA Types:
3.2.1 TEMA types involving A, B, C, D, L, M, and N (1st and 3rd character):

Selection among the types characterized by the above letters will normally be based on mechanical and operational
aspects. They will not affect the calculations performed by HEATEX87.

When dealing with high-pressure exchangers (above 80-100 kg/cm2g) only Type D must be specified. The Mechanical
Department will then select an appropriate design which may not necessarily have the appearance as shown in TEMA.

3.2.2 TEMA designations involving L, M and N as 3rd character (Fixed tube sheet):

The above refers to a design where the connections between the tube sheets and the shell are fixed. This is a relatively
cheap construction, which moreover in many cases allows true counter current flow. On the other hand, mechanical
cleaning on the shell side will not be possible. Furthermore, the fixed connection between tube sheet and shell means that
tubes and shell cannot expand independently of each other. Normally expansion bellows are not acceptable for this
purpose. During the following engineering steps, it shall therefore be verified if the allowable stresses are within allowable
limits.

3.2.3 TEMA types involving F, G, and H as 2nd character (longitudinal baffles):

These types are chosen because they often provide a greater degree of countercurrent flow than other acceptable
alternatives. However, they will only perform satisfactorily if the longitudinal baffle is properly sealed to the shell. Such
seals are very vulnerable to damage during mounting and dismantling. Furthermore, longitudinal baffles are often exposed
to pressure drops many times bigger than those of normal baffles. TEMA types with T and S as 3rd character (floating
head) These types normally allow the tube bundle to be pulled out of the shell, thus allowing. mechanical cleaning on both
shell side and tube side. At the same time, they allow greater differential expansions between shell and tubes. However, it
is a rather complicated and expensive construction, in particular in case the head shall be designed for a big differential.
pressure. Moreover, control of the internal flange tightness will not be possible during operation. The above types also
require a big space between shell & tubebundle. Efficient blocking of this space with sealing strips is in case of segmental
baffles mandatory to ensure a reasonable performance on the shell side.

3.2.4 TEMA types with U as 3rd character (U-tubes):

This type stands for U-tubes. It results in a relatively cheap construction. However, there are. certain limitations to the
application of this type. It is not possible to clean the tube side efficiently. by mechanical means. This construction should
therefore be used only for non-fouling services.

Interrelation between cross flow baffle type and TEMA type It should be kept in mind that the baffle type is to be selected
with due consideration to the TEMA type. As guidance, the following table should be used:
Table 3.3:: Baffle type as per TEMA
 Chapter 4

Theory- Kern’s Method

Codes and standards are applicable only for mechanical design/aspects of shell & tubeheat exchanger but w.r.t process
design we do not have any standards but some definite methods. The steps for designing according to this base method
are:

Define duty. Use energy balance

to compute unspecified flow rates
or temperature

Collect Physical Properties

Yes? Accept!

Assume value of Uo, ass Pressure drops within specification?

Decide number of Shell &

tubepasses. Calculate True ΔTim Estimate tube and shell side pressure
drop.

Determine Heat Transfer Area

NO YES

0 < (Uocal - Uoass) / Uoass <30%

Decide type, tube size, material
layout. Assign fluid to shell and tube. Calculate Heat tranfer co-efficient
including fouling factor, Uo, cal

Calculate number of tubes

Estimate Shell side heat transfer co-
efficient.
Compute Shell Diameter

Estimate tube-side heat transfer co-efficient. Decide Baffle Spacing

 Chapter 5

Simulation
Designing Shell & tubeHeat Exchanger in ASPEN Exchanger Design Rating (EDR):

5.1. Evaluating Constraints:

Thermal evaluation: Parting from the heat transfer developed: Convection (tube fluid) +Conduction (through pipe
thickness) + Convection (Shell fluid).

To be thermally stable, the overall co-efficient must: Uclean>UD>UReq

Thermal Evaluation Diagram Flow:

Hydraulic Assessment: It is imperative that the combined total pressure drop on the tube and shell sides remains within
thepermissible limit. Upon selecting the initial heat exchanger geometry, the subsequent equations (applicable when using
English Units) are employed to verify whether the chosen geometry aligns with the allowable pressure drop limits.
Several factors influence the pressure drop in a heat exchanger, impacting both the tube and shell sides. On the tube side,
factors such as tube length (L) and the number of tube passes (np) play crucial roles. For the shell side, baffle spacing (B)
is a significant determinant; an increase in baffle spacing enhances the flow area across the tube bundle, leading to a
reduction in shell-side pressure drop (∆Pshell). Additionally, tube pitch (PT) is considered, although it is not commonly
utilized due to its tendency to escalate heat exchanger area and, consequently, increase costs. These factors bear
significance in the design process, whether conducted manually or through computer-aided software. If the initially
selected geometry fails to meet pressure drop requirements, adjustments to these influencing factors become imperative to
achieve a suitable heat exchanger design.
5.2. Initial geometry:

Shell & tubeDesign flow Diagram:

5.3. Aspen EDR:

Aspen EDR serves as a comprehensive tool for simulating, rating, and designing heat exchangers, with a particular focus
on shell and tube heat exchangers. Upon entering the interface, the program provides an extensive range of heat exchanger
options. However, a prerequisite understanding of heat exchanger design basics is essential, as achieving a solution in your
case may be hindered by thermal and/or hydraulic constraints not aligning with the initial conditions.

Encountering cases where a solution is elusive is often attributed to the calculated pressure drop exceeding the allowed
limits. In such instances, adjusting factors influencing the pressure drop across tube and/or shell sides becomes necessary
to attain a design compliant with client-prescribed over-design limits.

Aspen EDR offers a notable feature allowing design with various constraints, including tube length, tube and shell passes,
baffle spacing, tube diameter, and more. Nevertheless, it is crucial to exercise caution when imposing stringent constraints,
as excessively tight conditions may impede the program's ability to reach a solution through its iterations.

Being part of the Aspen suite, Aspen EDR seamlessly integrates with HYSYS, facilitating the transfer of data between the
two without complications, even when certain physical properties data is not fully provided. This interoperability enhances
the overall efficiency of the design process. Notably, Aspen EDR stands out for its expeditious iteration times,
contributing to faster design outcomes.

This software serves a multifaceted purpose by offering capabilities for the design, rating, simulation, and cost prediction
of heat exchangers. Specifically, ASPEN is employed to simulate heat exchangers designed using Kern's theoretical
method. In the simulation mode, users input comprehensive data encompassing the heat exchanger's geometry, fluid
properties, flow rates, and input temperatures of fluid streams. Subsequently, the software produces outputs, including the
attained output temperatures of the streams.

One noteworthy output is the TEMA sheet, a specification sheet generated by the software. This sheet provides crucial
information such as the overall heat transfer coefficient, pressure drop in both the shell-side and tube-side, along with
various other parameters integral to heat exchanger design. Additionally, the software offers essential drawings of the heat
exchanger, contributing to a comprehensive and detailed understanding of the design. Overall, ASPEN proves to be a
valuable tool for engineers and designers involved in the intricate process of heat exchanger design, offering efficiency
and precision in various aspects of the design and simulation workflow.

Process and property data can be entered in three ways:

1. Manually

2. By using the physical property databanks provided within the program

3. By importing from a simulation case

We will enter process and property data manually for the simulation of the given problem.
5.4. Process Simulation:

Fig 5.1: Screen shot of the crude distillation unit with heat exchanger E-100 as the basis for rating/checking design calculations from the PFD in the
Simulation Environment (Source: UniSim Design R443, Courtesy of Honeywell Process Solutions).

5.5. Problem Statement: A kerosene stream with a Flow rate of 45000 lb./h is to be cooled from 390°F to 250°F by heat
Exchanger with 150000 lb./h of crude oil at 100°F. A maximum pressure drop of 15 psi has been specified from each
stream. Prior experience with this particular oil indicates that it exhibits significant fouling tendencies, and a fouling factor
of 0.003 ℎ 𝑓𝑡2°𝐹/𝐵𝑇𝑈 is recommended. Design a Shell & Tube Heat Exchanger for this process.
Solution:
1. Fluid Placement: Kerosene, being non-corrosive, is suitable for the shell, while crude oil, dependent on salt and sulfur
contents, should be placed in the tubes. At lower temperatures, corrosion concerns are mitigated if the crude oil has been
adequately desalted. The tube placement is chosen due to crude oil's higher fouling tendency, as indicated in Table 1.
Additionally, the shell is designated for kerosene owing to its substantial temperature difference of 140°F.

2. Shell and Head Types: With the recommended fouling factor for kerosene indicating significant fouling potential, a
floating head exchanger is selected to allow for mechanical cleaning of the exterior tube surfaces. The floating tubesheet
accommodates differential thermal expansion due to the substantial temperature difference between the two streams.
Consequently, a type AES exchanger is specified.

3. Tubing: Adhering to design guidelines for fouling crude oil service, 1-inch 14 BWG tubes, each with a length of 14
feet, are chosen.

4. Tube Layout: To facilitate cleaning of the tube exterior surfaces, a square pitch is specified, providing cleaning lanes
through the tube bundle. Following design guidelines for 1-inch tubes, a tube pitch of 1.25 inches is designated.

5. Baffles: The Simplified Delaware method requires segmental baffles with a 20% cut. A baffle spacing of 0.3 shell
diameters (Bs/Ds = 0.3) is chosen.

6. Sealing Strips: In line with the requirements of the Simplified Delaware method and design guidelines, one pair of
sealing strips per 10 tube rows is specified.

7. Construction Materials: Since neither fluid is corrosive, plain carbon steel is specified for tubes, shell, and other
components.

INITIAL GEOMETRY
Tube Fuel Crude Oil
TEMA Configuration AES
Tube Size(inches) 1
Tube BWG 14

Tubing Selection Tube Long (ft) 20

Tube Pitch(in) 1.25
Tube Layout Square
Baffles Cut 20%
Spacing (B/ds) 0.3
Sealing Strips Pair/10 tubes rows 1
Material Shell and tube side Carbon steel
 References

[1] Fundamentals of Heat Exchanger Design by R. K. Shah and D. P. Sekulic, published by Wiley in 2003.

[2] Heat Exchanger Design Handbook by K. Thulukkanam, published by CRC Press in 2013.

[3] Standards of the Tubular Exchanger Manufacturers Association 9th Edition by Tubular Exchanger Manufacturers
Association, Inc., published in Tarrytown, NY, in 2007.

[4] Process Heat Transfer: Principles and Applications by R. W. Serth, published by Elsevier in 2007.