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How To Design Shell And Tube Heat Exchanger

Views: 0     Author: Site Editor     Publish Time: 2025-01-21      Origin: Site

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1. Define Design Specifications

Start with understanding the requirements:

  • Type of fluids: Identify the hot and cold fluids.

  • Flow rates: Determine the mass or volumetric flow rates.

  • Inlet and outlet temperatures: Define the temperature change required for each fluid.

  • Heat duty: Calculate the amount of heat to be transferred (Q = m * Cp * ΔT).

  • Pressure drop limits: Ensure pressure drops for both fluids stay within allowable limits.

  • Material constraints: Consider material compatibility with fluids and operating conditions.

  • Operating conditions: Include operating pressures, temperatures, and fouling factors.


2. Select Heat Exchanger Type

Choose the type of shell and tube heat exchanger based on:

  • Flow configuration: Counterflow, parallel flow, or crossflow.

  • Tube arrangement: Fixed tube sheet, U-tube, or floating head.

  • Tube pattern: Square or triangular pitch for tube arrangement.

  • Passes: Number of tube and shell passes (e.g., 1-2, 2-4 passes).


3. Thermal Design

Use the Log Mean Temperature Difference (LMTD) or NTU-Effectiveness method to determine the heat exchanger size.

  1. Calculate LMTD:

    How To Design Shell And Tube Heat Exchanger

    where ΔT1and ΔT2 are the temperature differences at each end.

  2. Determine overall heat transfer coefficient (U):
    Account for heat transfer through tubes, fouling factors, and fluid film resistances:

    Determine overall heat transfer coefficient

    where h1,h0 are heat transfer coefficients, is wall thickness,  is thermal conductivity, and Rf is fouling resistance.

  3. Determine required surface area (A):

    Q=U⋅A⋅LMTDQ 


4. Mechanical Design

  • Tube Design: Choose tube diameter, thickness, and length. Common sizes: 12.7–50.8 mm OD, lengths 1.2–6 m.

  • Shell Design: Decide on shell diameter and baffle spacing. Typical baffle spacing is 20–50% of shell diameter.

  • Tube Sheet Design: Ensure proper tube sheet thickness and hole arrangement.

  • Nozzles and Supports: Size inlet/outlet nozzles for both fluids, and design supports for structural integrity.


5. Pressure Drop Calculations

  • Calculate pressure drops for shell-side and tube-side:

    • Shell-side pressure drop:

      Shell-side pressure drop

    • Tube-side pressure drop:

      Tube-side pressure drop

    • Ensure the calculated values meet system requirements.



6. Material Selection

Choose materials compatible with operating conditions and fluids:

  • Tubes: Stainless steel, copper, titanium.

  • Shell: Carbon steel, stainless steel.



7. Optimization

Optimize the design for cost, weight, size, and efficiency:

  • Reduce fouling by choosing appropriate flow rates and materials.

  • Ensure proper maintenance access and cleanability.



8. Software Tools

Leverage specialized heat exchanger design software (e.g., Aspen HYSYS, HTRI) for detailed analysis and optimization.



If you're designing shell and tube heat exchangers for industries, Jiangsu Pretank Process Co., Ltd. offers high-quality, customized solutions tailored to your specific needs. With expertise in manufacturing fixed plate, U-tube, and floating head heat exchangers, we ensure optimal performance and durability for your applications. Partner with us to achieve efficient heat transfer, reliable operation, and long-term value for your processes.Contact us now!


Provide stainless steel tanks solutions for liquid processing of STORAGE,FERMENTING, HEATING,CHILLING, BLENDING, DISTILLING, MASHING AND BOILING.

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