Shell and tube[edit]
Main article: Shell and tube heat exchanger
A shell and tube heat exchanger
Shell and tube heat exchanger
Shell and tube heat exchangers consist of a series of tubes which contain fluid that
must be either heated or cooled. A second fluid runs over the tubes that are being
heated or cooled so that it can either provide the heat or absorb the heat required. A set
of tubes is called the tube bundle and can be made up of several types of tubes: plain,
longitudinally finned, etc. Shell and tube heat exchangers are typically used for high-
pressure applications (with pressures greater than 30 bar and temperatures greater
than 260 °C).[4] This is because the shell and tube heat exchangers are robust due to
their shape.
Several thermal design features must be considered when designing the tubes in the
shell and tube heat exchangers: There can be many variations on the shell and tube
design. Typically, the ends of each tube are connected to plenums (sometimes called
water boxes) through holes in tubesheets. The tubes may be straight or bent in the
shape of a U, called U-tubes.
Tube diameter: Using a small tube diameter makes the heat exchanger both
economical and compact. However, it is more likely for the heat exchanger to
foul up faster and the small size makes mechanical cleaning of the fouling
difficult. To prevail over the fouling and cleaning problems, larger tube
diameters can be used. Thus to determine the tube diameter, the available
space, cost and fouling nature of the fluids must be considered.
Tube thickness: The thickness of the wall of the tubes is usually determined
to ensure:
There is enough room for corrosion
That flow-induced vibration has resistance
Axial strength
Availability of spare parts
Hoop strength (to withstand internal tube pressure)
Buckling strength (to withstand overpressure in the shell)
Tube length: heat exchangers are usually cheaper when they have a smaller
shell diameter and a long tube length. Thus, typically there is an aim to make
the heat exchanger as long as physically possible whilst not exceeding
production capabilities. However, there are many limitations for this, including
space available at the installation site and the need to ensure tubes are
available in lengths that are twice the required length (so they can be
withdrawn and replaced). Also, long, thin tubes are difficult to take out and
replace.
Tube pitch: when designing the tubes, it is practical to ensure that the tube
pitch (i.e., the centre-centre distance of adjoining tubes) is not less than 1.25
times the tubes' outside diameter. A larger tube pitch leads to a larger overall
shell diameter, which leads to a more expensive heat exchanger.
Tube corrugation: this type of tubes, mainly used for the inner tubes,
increases the turbulence of the fluids and the effect is very important in the
heat transfer giving a better performance.
Tube Layout: refers to how tubes are positioned within the shell. There are
four main types of tube layout, which are, triangular (30°), rotated triangular
(60°), square (90°) and rotated square (45°). The triangular patterns are
employed to give greater heat transfer as they force the fluid to flow in a more
turbulent fashion around the piping. Square patterns are employed where
high fouling is experienced and cleaning is more regular.
Baffle Design: baffles are used in shell and tube heat exchangers to direct
fluid across the tube bundle. They run perpendicularly to the shell and hold
the bundle, preventing the tubes from sagging over a long length. They can
also prevent the tubes from vibrating. The most common type of baffle is the
segmental baffle. The semicircular segmental baffles are oriented at 180
degrees to the adjacent baffles forcing the fluid to flow upward and
downwards between the tube bundle. Baffle spacing is of large
thermodynamic concern when designing shell and tube heat exchangers.
Baffles must be spaced with consideration for the conversion of pressure
drop and heat transfer. For thermo economic optimization it is suggested that
the baffles be spaced no closer than 20% of the shell's inner diameter.
Having baffles spaced too closely causes a greater pressure drop because of
flow redirection. Consequently, having the baffles spaced too far apart means
that there may be cooler spots in the corners between baffles. It is also
important to ensure the baffles are spaced close enough that the tubes do not
sag. The other main type of baffle is the disc and doughnut baffle, which
consists of two concentric baffles. An outer, wider baffle looks like a
doughnut, whilst the inner baffle is shaped like a disk. This type of baffle
forces the fluid to pass around each side of the disk then through the
doughnut baffle generating a different type of fluid flow.
Tubes & fins Design: in application to cool air with shell-and-tube technology
(such as intercooler / charge air cooler for combustion engines), the
difference in heat transfer between air and cold fluid can be such that there is
a need to increase heat transfer area on air side. For this function fins can be
added on the tubes to increase heat transfer area on air side and create a
tubes & fins configuration.
Fixed tube liquid-cooled heat exchangers especially suitable for marine and harsh
applications can be assembled with brass shells, copper tubes, brass baffles, and
forged brass integral end hubs.[citation needed] (See: Copper in heat exchangers).
