SUMMARY OF FORMULAS

DESIGN OF HEAT EXCHANGERS

HEAT EXCHANGE AREA

Q 1 1 1 s
A= = + + + fi + fo
U × ∆t U αi αo λ

A : Heat exchange area (m2) U : Overall heat transfer coefficient (W/m2 C)

Q : Heat load (W) fi : Inner fouling factor (m2 C/W)

Δt : Temperature gradient (°C) fo : Outer fouling factor (m2 C/W)

U : Overall heat transfer coefficient (W/m2 C) s : Tube wall thickness (m)

λ : Thermal conductivity of the tube material (W/m C)

αi : Inner heat transfer coefficient in the tubes (W/m2 C)

αo : Outer heat transfer coefficient in the tubes (W/m2 C)

DESIGN OF HEAT EXCHANGERS

HEAT LOAD

SHELL SIDE TUBE SIDE

Q S = MS × cS × (T1 − T2 ) Q T = MT × cT × (t 2 − t1 )

QS : Shell heat load (W) QT : Tube heat load (W)

MS : Shell side flow rate (Kg/h) MT : Tube side flow rate (Kg/h)
cS : Specific heat capacity shell side (Wh/kg K) cT : Specific heat capacity tube side (Wh/kg K)
T1 : Inlet temperature shell side (°C) t1 : Inlet temperature tube side (°C)
T2 : Outlet temperature shell side (°C) t2 : Outlet temperature tube side (°C)
DESIGN OF HEAT EXCHANGERS

LMTD

Counter current
(T1 − t 2 ) − (T2 − t1 ) T2 t2
LMTD =
T1 − t 2
ln
T2 − t1

T1 : Shell-side inlet temperature (°C)

T2 : Shell-side outlet temperature (°C)
T1 t1
t1 : Tube-side inlet temperature (°C)
t2 : Tube-side outlet temperature (°C)
In counter current flow, the hot and cold fluids
flow in the opposite direction

LMTD : Logarithmic mean temperature difference for countercurrent (°C)

DESIGN OF HEAT EXCHANGERS

CMTD

CMTD = F × LMTD

F : Temperature efficiency factor (> 0.75)

CMTD : Corrected effective mean temperature difference (°C)
LMTD : Logarithmic mean temperature difference for countercurrent (°C)
DESIGN OF HEAT EXCHANGERS

CMTD

(1 − Pz )
√R2 + 1 ln � �
(1 − RPz )
F= × T1 : Shell-side inlet temperature (°C)
R−1 �2�P � − 1 − R + √R2 + 1
z T2 : Shell-side outlet temperature (°C)
ln � �
2 2
� �P � − 1 − R − √R + 1 t1 : Tube-side inlet temperature (°C)
z
t2 : Tube-side outlet temperature (°C)
N : Number of heat exchangers in series
1
RP − 1 N
1−� P−1 � t 2 − t1 T1 − T2
Pz = 1 P= R=
T1 − t1 t 2 − t1
RP − 1 N
R−� P−1 �

One pass shell

DESIGN OF HEAT EXCHANGERS

CMTD
MULTIPASS HX

M
CMDT (°C) =
O+M
ln O − M

O = (T1 − t 2 ) + (T2 − t1 ) M = �(T1 − T2 )2 + (t 2 − t1 )2

T1 : Shell-side inlet temperature (°C)
T2 : Shell-side outlet temperature (°C)
t1 : Tube-side inlet temperature (°C)
t2 : Tube-side outlet temperature (°C)
DESIGN OF HEAT EXCHANGERS

BAFFLES
Baffle spacing
SHELL SEGMENTAL CUT
SHELL

SEGMENTAL
HEIGHT

BAFFLE
BAFFLES

Baffle spacing, B = 0.2 × Di Segmental heigh, H = 0.2 × Di

Di : Shell internal diameter (m)

DESIGN OF HEAT EXCHANGERS

INFLUENCE OF BYPASS STREAMS ON LMTD

Baffle spacing
SHELL

TEMP CHANGE
PER SHELL PASS

BAFFLES

Baffle spacing, B = 0.2 × Di

Di : Shell internal diameter (m)

DESIGN OF HEAT EXCHANGERS

MEAN WEIGHTED TEMPERATURE DIFFERENCE

1 Determine CMTD and heat load of each zone

2 Use the above calculated values to determine WMTD

according to the following formula :

∑i Q i
WMTD =
Qi
∑i
CMTDi
DESIGN OF HEAT EXCHANGERS

DETERMINING THE HX OUTLET TEMPERATURES

(1 − R) × t h1 + (1 − B2 ) × R × Tc1 t h1 − t h2
t h2 = Tc2 = + Tc1
1 − (R × B2 ) R

Where :

Wc × cc F×U×A
R= B2 = exp � × (R − 1)�
Wh × ch Wc × cc

HOT FLUID COLD FLUID

Wh : Hot stream flow rate (kg/h) Wc : Cold stream flow rate (kg/h) A : Heat exchanger area (m2)

th1 : Inlet temperature of the hot stream (°C) Tc1 : Inlet temperature of the cold stream (°C) U : Overall heat transfer coefficient (W/m2 K)

th2 : Outlet temperature of the hot stream (°C) Tc2 : Outlet temperature of the cold stream (°C) F : Temperature efficiency factor for nonideal countercurrent

ch : Specific heat capacity of the hot stream (Wh/kg K) cc : Specific heat capacity of the cold stream (Wh/kg K)
DESIGN OF HEAT EXCHANGERS

DETERMINING HEAT TRANSFER COEFF.

TUBE SIDE SHELL SIDE

Nu × λ Nu × λ
α= Re : Reynolds number α=
di Pr : Prandtl number
w : Flow velocity (m/s)
do
wcross : cross flow velocity shell side (m/s)
V : Volumetric rate (m3/h)
B : Baffle spacing (m)
Nu : Nusselt number (Reynolds dependent), dimensionless Di : Shell inner diameter (m) Nu : Nusselt number (tube pattern dependent), dimensionless
nacr : # of tubes in cross stream
λ : Heat conductivity (W/m K) ρ : Fluid density (kg/m3) λ : Heat conductivity (W/m K)
ν : Kinematic viscosity (mm2/s)
di : Tube inner diameter (m) do : Tube outer diameter (m)

Re < 2300 2300 < Re < 8000 Re > 8000

Re × Pr × di 0.33
Nu = 1.86 × � � Nu = (0.037 × Re0.75 − 6.66) × Pr 0.42 Nu = 0.023 × Re0.8 × Pr 0.33 Nu = 0.196 × Re0.6 × Pr 0.33 Nu = 0.156 × Re0.6 × Pr 0.33
l

w × di ϑ × c × ρ × 3600 t1 + t 2 wcross × do V(m3 /h)

Re = Pr = tm = Re = wcross =
ϑ λ 2 ϑ B × (Di − nacr × do )
DESIGN OF HEAT EXCHANGERS

PRESSURE LOSS IN HX
Tubes

1 Tube side pressure drop ΔPT wT2 × ρ f×L 0.216

∆PT (Pa) = × np × � + 4� f=
2 di Re0.2

Inlet nozzle wT : Flow velocity in the tubes (m/s)

ρ : Fluid density (kg/m3)
np : # of tube passes
2
wNi ×ρ f : Friction factor
∆PNi (Pa) = L : Tube length (m)
2 di : Tube outer diameter (m)
Re : Reynolds number
wNi : Flow velocity in inlet nozzle (m/s)
wNo : Flow velocity in outlet nozzle (m/s)
Outlet nozzle

2
wNo ×ρ
∆PNo (Pa) = 0.5 ×
2
2 Shell side pressure drop ΔPS
DESIGN OF HEAT EXCHANGERS

PRESSURE LOSS IN HX
Baffle windows
2 Shell side pressure drop ΔPS
2
∆Pw (Pa) = BF × nB × ρ × ww

Tube

ρ 2
∆Pcr (Pa) = BF × (nB + 1) × f × ncross × × wcr
2
BF : Bypass factor ~0.36
Inlet / Outlet nozzles nB : Number of baffles
ρ : Fluid density (kg/m3)
ww : Window velocity (m/s)
wn2 × ρ f : Friction factor = f(Re)
∆Pn (Pa) = 1.5 ncross : Tube rows in the cross stream between both baffle cuts
2 wcr : Cross stream velocity (m/s)
wn : Nozzle velocity (m/s) 1 Tube side pressure drop ΔPT
DESIGN OF HEAT EXCHANGERS

PRESSURE LOSS IN HX – FRICTION FATCORS

Bell fBell = 2.68 × Re−0.182

−0.2
3.12
Clark-Davidson fCD = Re ×
�T�d
0

−0.16
0.47
Jakob fJ = Re × �1 + 1.08 �
�T�d − 1�
o

−0.2
3
Donohue fD = Re × 0.2
T − d0
� �
d0
DESIGN OF HEAT EXCHANGERS

PRESSURE LOSS IN HX – FRICTION FATCORS

Chopey
Shell tube
ρ 2
∆Pcr (Pa) = BF × (nB + 1) × f × ncross × × wcr
2

= f(B, Di) = f(ReCh)

−0.25
fCh = 4 × ReCh
B 0.08
BF = 0.6375 × � × Di
Di wcr × (T − d0 )
ReCh =
ϑ
DESIGN OF HEAT EXCHANGERS TUBE SIDE CALCULATIONS

TUBE SIDE FLOW CROSS SECTION

n 2 π π 2
aT = × di × a T = t p × di ×
np 4 4

aT : Tube side flow cross section (m2) aT : Tube side flow cross section (m2)
n
n : Number of tubes tp : Number of tubes per pass t p =
np
np : Number of tube passes di : Tube inner diameter (m)

di : Tube inner diameter (m)

USEFUL GEOMETRICAL CALCULATIONS

DESIGN OF HEAT EXCHANGERS TUBE SIDE CALCULATIONS

TUBE FLOW VELOCITY

VT
wT =
aT × 3600

wT : Flow velocity in the tubes (m/s)

VT : Tube side volumetric flow rate (m3/h)

n π
aT : Tube side flow cross section (m2) aT = × di 2 ×
np 4

USEFUL GEOMETRICAL CALCULATIONS

DESIGN OF HEAT EXCHANGERS SHELL SIDE CALCULATIONS

SHELL SIDE FLOW CROSS SECTION

across = B × (Di − nacr × d0 )

across : Shell side flow cross section (m2)

B : Baffle spacing (m) ~ 0.2 x Di (as per best design practice)

Di : Shell inner diameter (m)

nacr : Number of tubes in the middle across the flow direction

Number of tubes in cross stream

on the center line (nacr)

USEFUL GEOMETRICAL CALCULATIONS

DESIGN OF HEAT EXCHANGERS SHELL SIDE CALCULATIONS

SHELL SIDE FLOW CROSS SECTION

Di − sR DH
across = B × (Di − nacr × d0 ) nacr = =
sq sq

across : Shell side flow cross section (m2) DH : Outer limit diameter (m) = envelope of tube pattern

B : Baffle spacing (m) ~ 0.2 x Di (as per best design practice) sR : Edge strip (m)

Di : Shell inner diameter (m) sq : Tube middle gap across the flow direction (m)  Pitch dependent

nacr : Number of tubes in the middle across the flow direction

ROTATED
SQUARE TRIANGULAR
SQUARE

sq =T = 1.414 T T
USEFUL GEOMETRICAL CALCULATIONS
DESIGN OF HEAT EXCHANGERS SHELL SIDE CALCULATIONS

SHELL SIDE CROSS STREAM VELOCITY

VShell
wcross =
across × 3600

wcross : Shell side cross stream velocity through the bundle (m/s)

VShell : Shell side volumetric flow rate (m3/h)

across : Shell side flow cross section (m2) across = B × (Di − nacr × d0 )

USEFUL GEOMETRICAL CALCULATIONS

DESIGN OF HEAT EXCHANGERS SHELL SIDE CALCULATIONS

SHELL SIDE LONGITUDINAL STREAM CROSS AREA

2 2 π
aw = Di × C − nw × d0 ×
4 Segmental height (H)
(height of the baffle cut)

aw : Shell side longitudinal stream cross area in the baffle window (m2)

Di : Shell inner diameter (m)

C : Geometrical calculation factor

nw : Number of tubes in the baffle window Number of tubes in the baffle

window (nw) Baffle

 Segment height, H
 Distance of the tube rows from the middle

USEFUL GEOMETRICAL CALCULATIONS

DESIGN OF HEAT EXCHANGERS SHELL SIDE CALCULATIONS

SHELL SIDE LONGITUDINAL STREAM CROSS AREA

2 2 π 16x 2 − 13x 3
aw = Di × C − nw × d0 × C=
4 12√x − x 2
H
aw : Shell side longitudinal stream cross area in the baffle window (m2) x= H : Segment height (m)
Di
Di : Shell inner diameter (m)

C : Geometrical calculation factor 2

n × d0
nw : Number of tubes in the baffle window NF = 1 −
 Segment height, H Di 2
 Distance of the tube rows from the middle

USEFUL GEOMETRICAL CALCULATIONS

DESIGN OF HEAT EXCHANGERS SHELL SIDE CALCULATIONS

SHELL SIDE LONGITUDINAL STREAM CROSS AREA

2 16x 2 − 13x 3
aw = Di × C × NF C=
12√x − x 2
H
aw : Shell side longitudinal stream cross area in the baffle window (m2) x= H : Segment height (m)
Di
Di : Shell inner diameter (m)

C : Geometrical calculation factor 2

n × d0
n : Total number of tubes NF = 1 −
NF : Free room factor Di 2

USEFUL GEOMETRICAL CALCULATIONS

DESIGN OF HEAT EXCHANGERS SHELL SIDE CALCULATIONS

SHELL SIDE LONGITUDINAL STREAM CROSS AREA

2 16x 2 − 13x 3
aw = Di × C × NF C=
12√x − x 2
H
aw : Shell side longitudinal stream cross area in the baffle window (m2) x= H : Segment height (m)
Di
Di : Shell inner diameter (m)

C : Geometrical calculation factor 2

n × d0
n : Total number of tubes NF = 1 −
NF : Free room factor DH 2
DH : Outer limit diameter (m) = envelope of tube pattern

USEFUL GEOMETRICAL CALCULATIONS

DESIGN OF HEAT EXCHANGERS SHELL SIDE CALCULATIONS

DESIGN BEST PRACTICE

=
2 2 π
aw = Di × C − nw × d0 × across = B × (Di − nacr × d0 )
4

aw : Shell side longitudinal stream cross area in the baffle window (m2)
H across : Shell side flow cross section (m2)
0.2 ≤ x = ≤ 0.25 Di : Shell inner diameter (m)
Di d0 : Tube outer diameter (m)
B : Baffle spacing (m)
DH : Outer limit diameter (m) = envelope of tube pattern
nacr : Number of tubes in the middle across the flow direction
B nw : Number of tubes in the baffle window
= 0.2 C : Geometrical calculation factor
Di NF : Free room factor
DESIGN OF HEAT EXCHANGERS SHELL SIDE CALCULATIONS

LONGITUDINAL STREAM FLOW VELOCITY

VShell
ww =
aw × 3600

ww : Longitudinal stream velocity through the window (m/s)

VShell : Shell side volumetric flow rate (m3/h)

aw : Shell side longitudinal stream cross area in the baffle window (m2)

aw = Di 2 × C × NF

USEFUL GEOMETRICAL CALCULATIONS

DESIGN OF HEAT EXCHANGERS SHELL SIDE CALCULATIONS

AVERAGE SHELL SIDE FLOW CROSS SECTION

aav = �aacross × aw

across : Shell side flow cross section (m2)

across = B × (Di − nacr × d0 )

aw : Shell side longitudinal stream cross area in the baffle window (m2)

aw = Di 2 × C × NF

USEFUL GEOMETRICAL CALCULATIONS

DESIGN OF HEAT EXCHANGERS SHELL SIDE CALCULATIONS

AVERAGE SHELL SIDE FLOW VELOCITY

VShell
wav =
aav × 3600

wav : Average shell side flow velocity (m/s)

VShell : Shell side volumetric flow rate (m3/h)

aav : Average shell side flow cross section (m2)

aav = �aacross × aw

USEFUL GEOMETRICAL CALCULATIONS

DESIGN OF HEAT EXCHANGERS SHELL SIDE CALCULATIONS

NUMBER OF BAFFLES

L−B
nB =
B+a

nB : Number of baffles

L : Tube length (m)

B : Baffle spacing (m)

a : Baffle thickness (m)

USEFUL GEOMETRICAL CALCULATIONS

DESIGN OF HEAT EXCHANGERS SHELL SIDE CALCULATIONS

NUMBER OF TUBE ROWS IN CROSS STREAM

Di − 2 × H − SG × �np − 1�
ncross = +1
sl
Baffle window #1

ncross : Number of tube rows in cross stream between the windows Segmental height (H)
(height of the baffle cut)

np : Number of tube passes

SG : Strips of the pass partition plates for the pass partition

sl : Tube middle clearance longitudinal to flow direction  Pitch dependent

Number of vertical tube rows

between baffle windows (ncross)

Baffle window #2

USEFUL GEOMETRICAL CALCULATIONS

DESIGN OF HEAT EXCHANGERS SHELL SIDE CALCULATIONS

NUMBER OF TUBE ROWS IN CROSS STREAM

Di − 2 × H − SG × �np − 1�
ncross = +1
sl
ROTATED
SQUARE TRIANGULAR
SQUARE
ncross : Number of tube rows in cross stream between the windows

np : Number of tube passes

SG : Strips of the pass partition plates for the pass partition

sl : Tube middle clearance longitudinal to flow direction  Pitch dependent

sl =T = 0.707 T 0.866 T

USEFUL GEOMETRICAL CALCULATIONS

DESIGN OF HEAT EXCHANGERS SHELL SIDE CALCULATIONS

FLOW CROSS SECTION FOR LONGITUDINAL FLOW

2 π
a w = A S − n w × d0 ×
4

Segmental height (H)

aw : Flow cross section for the longitudinal flow in the baffle cut (m2) (height of the baffle cut)

AS : Area of the baffle cut (m2)

nw : Number of tubes in the baffle window

d0 : Tube outer diameter (m)

Number of tubes in the baffle
window (nw) Baffle

USEFUL GEOMETRICAL CALCULATIONS

DESIGN OF HEAT EXCHANGERS SHELL SIDE CALCULATIONS

FLOW CROSS SECTION FOR LONGITUDINAL FLOW

? 2 π
a w = A S − n w × d0 ×
4

aw : Flow cross section for the longitudinal flow in the baffle cut (m2)
H
AS : Area of the baffle cut (m2) = 0.2 → AS = 0.112 × Di 2
Di
nw : Number of tubes in the baffle window

d0 : Tube outer diameter (m) H

= 0.25 → AS = 0.154 × Di 2
H : Height of the baffle cut (m) Di
Di : Shell inner diameter (m)

USEFUL GEOMETRICAL CALCULATIONS

DESIGN OF HEAT EXCHANGERS SHELL SIDE CALCULATIONS

FLOW CROSS SECTION FOR LONGITUDINAL FLOW

2
𝐧𝐧 × d0
aw = NF × AS NF = 1 −×
Di 2

aw : Flow cross section for the longitudinal flow in the baffle cut (m2)
H
AS : Area of the baffle cut (m2) = 0.2 → AS = 0.112 × Di 2
Di
n : Total number of tubes

d0 : Tube outer diameter (m) H

= 0.25 → AS = 0.154 × Di 2
H : Height of the baffle cut (m) Di
Di : Shell inner diameter (m)

USEFUL GEOMETRICAL CALCULATIONS

DESIGN OF HEAT EXCHANGERS SHELL SIDE CALCULATIONS

NUMBER OF TOTAL VERTICAL TUBE ROWS

Di − do − SG × �np − 1�
ntv =
sl

ntv : Number of vertical tube rows

d0 : Tube outer diameter (m)

Di : Shell inner diameter (m)

np : Number of tube passes

SG : Strips of the pass partitions

sl : Tube middle clearance longitudinal to flow direction  Pitch dependent

Number of vertical tube rows (ntv)

USEFUL GEOMETRICAL CALCULATIONS

DESIGN OF HEAT EXCHANGERS SHELL SIDE CALCULATIONS

NUMBER OF TOTAL VERTICAL TUBE ROWS

Di − do − SG × �np − 1�
ntv =
sl

ntv : Number of vertical tube rows

ROTATED
SQUARE TRIANGULAR
SQUARE

d0 : Tube outer diameter (m)

Di : Shell inner diameter (m)

np : Number of tube passes

SG : Strips of the pass partitions

sl : Tube middle clearance longitudinal to flow direction  Pitch dependent sl =T = 0.707 T 0.866 T

USEFUL GEOMETRICAL CALCULATIONS

DESIGN OF HEAT EXCHANGERS SHELL SIDE CALCULATIONS

NUMBER OF TUBE ROWS IN THE CROSS STREAM BETWEEN BAFFLE WINDOWS

DH − do − 2 × H − SG × �np − 1�
ncross = +1
sl
Baffle window #1
ncross : Number of tube rows in the cross stream between the baffle windows
Segmental height (H)
d0 : Tube outer diameter (m) (height of the baffle cut)

DH : Shell inner diameter (m)

H : Height of the baffle cut (m)

np : Number of tube passes

Number of vertical tube rows
SG : Strips of the pass partitions between baffle windows (ncross)

sl : Tube middle clearance longitudinal to flow direction  Pitch dependent

Baffle window #2

USEFUL GEOMETRICAL CALCULATIONS

DESIGN OF HEAT EXCHANGERS SHELL SIDE CALCULATIONS

NUMBER OF TUBE ROWS IN THE CROSS STREAM BETWEEN BAFFLE WINDOWS

DH − do − 2 × H − SG × �np − 1�
ncross = +1
sl

ncross : Number of tube rows in the cross stream between the baffle windows

d0 : Tube outer diameter (m)

ROTATED
SQUARE TRIANGULAR
SQUARE

DH : Shell inner diameter (m)

H : Height of the baffle cut (m)

np : Number of tube passes

SG : Strips of the pass partitions

sl : Tube middle clearance longitudinal to flow direction  Pitch dependent sl =T = 0.707 T 0.866 T

USEFUL GEOMETRICAL CALCULATIONS