{"id":3208,"date":"2026-10-12T18:03:18","date_gmt":"2026-10-12T10:03:18","guid":{"rendered":"https:\/\/customindustrialheatexchanger.com\/?p=3208"},"modified":"2026-10-12T18:07:10","modified_gmt":"2026-10-12T10:07:10","slug":"shell-and-tube-heat-exchanger-design","status":"publish","type":"post","link":"https:\/\/customindustrialheatexchanger.com\/pt\/shell-and-tube-heat-exchanger-design\/","title":{"rendered":"Shell and Tube Heat Exchanger Design"},"content":{"rendered":"\t\t<div data-elementor-type=\"wp-post\" data-elementor-id=\"3208\" class=\"elementor elementor-3208\" data-elementor-post-type=\"post\">\n\t\t\t\t<div class=\"elementor-element elementor-element-14c779e e-con-full e-flex wpr-particle-no wpr-jarallax-no wpr-parallax-no wpr-sticky-section-no wpr-column-slider-no wpr-equal-height-no e-con e-parent\" data-id=\"14c779e\" data-element_type=\"container\" data-e-type=\"container\">\n\t\t\t\t<div class=\"elementor-element elementor-element-a252b66 elementor-widget elementor-widget-image\" data-id=\"a252b66\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"image.default\">\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<a href=\"https:\/\/customindustrialheatexchanger.com\/our-industrial-heat-exchanger-products\/finned-tube-manufacturer\/\">\n\t\t\t\t\t\t\t<img fetchpriority=\"high\" decoding=\"async\" width=\"1920\" height=\"720\" src=\"https:\/\/customindustrialheatexchanger.com\/wp-content\/uploads\/2025\/10\/\u6362\u70ed\u5668\u5c55\u793a.jpg\" class=\"attachment-full size-full wp-image-1287\" alt=\"Industrial Heat Exchanger \u2013 Efficient Thermal Transfer\" srcset=\"https:\/\/customindustrialheatexchanger.com\/wp-content\/uploads\/2025\/10\/\u6362\u70ed\u5668\u5c55\u793a.jpg 1920w, https:\/\/customindustrialheatexchanger.com\/wp-content\/uploads\/2025\/10\/\u6362\u70ed\u5668\u5c55\u793a-300x113.jpg 300w, https:\/\/customindustrialheatexchanger.com\/wp-content\/uploads\/2025\/10\/\u6362\u70ed\u5668\u5c55\u793a-1024x384.jpg 1024w, https:\/\/customindustrialheatexchanger.com\/wp-content\/uploads\/2025\/10\/\u6362\u70ed\u5668\u5c55\u793a-768x288.jpg 768w, https:\/\/customindustrialheatexchanger.com\/wp-content\/uploads\/2025\/10\/\u6362\u70ed\u5668\u5c55\u793a-1536x576.jpg 1536w, https:\/\/customindustrialheatexchanger.com\/wp-content\/uploads\/2025\/10\/\u6362\u70ed\u5668\u5c55\u793a-18x7.jpg 18w, https:\/\/customindustrialheatexchanger.com\/wp-content\/uploads\/2025\/10\/\u6362\u70ed\u5668\u5c55\u793a-600x225.jpg 600w\" sizes=\"(max-width: 1920px) 100vw, 1920px\" \/>\t\t\t\t\t\t\t\t<\/a>\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t<div class=\"elementor-element elementor-element-134afa6 e-flex e-con-boxed wpr-particle-no wpr-jarallax-no wpr-parallax-no wpr-sticky-section-no wpr-column-slider-no wpr-equal-height-no e-con e-parent\" data-id=\"134afa6\" data-element_type=\"container\" data-e-type=\"container\">\n\t\t\t\t\t<div class=\"e-con-inner\">\n\t\t<div class=\"elementor-element elementor-element-29c9bc5 e-con-full e-flex wpr-particle-no wpr-jarallax-no wpr-parallax-no wpr-sticky-section-no wpr-column-slider-no wpr-equal-height-no e-con e-child\" data-id=\"29c9bc5\" data-element_type=\"container\" data-e-type=\"container\">\n\t\t\t\t<div class=\"elementor-element elementor-element-e7e3f30 elementor-widget elementor-widget-text-editor\" data-id=\"e7e3f30\" data-element_type=\"widget\" data-e-type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t\t\t\t\t\t<h2><span style=\"color: #000000;\"><strong>1. Introduction <\/strong><\/span><\/h2><p><span style=\"color: #000000;\">How well an industrial heat exchanger transfers heat from one fluid stream to another depends on its design.<\/span><\/p><p><span style=\"color: #000000;\">The concept seems straightforward enough.<\/span><\/p><p><span style=\"color: #000000;\">Fluid 1 runs through tubes while fluid 2 flows around the tubes inside a shell.<\/span><\/p><p><span style=\"color: #000000;\">Heat exchanger design in reality involves many interrelated decisions.<\/span><\/p><p><span style=\"color: #000000;\">Parameters such as heat duty, temperature, flow rate, fluid properties, pressure drop, allowable fouling, materials of construction, and more all play a part. Additionally, designers must choose tube diameter and length, create a tube layout pattern, decide on baffle spacing, specify shell diameter, and establish flow configuration.<\/span><\/p><p><span style=\"color: #000000;\">Often times, a change in one parameter will impact several others.<\/span><\/p><p><span style=\"color: #000000;\">Increasing fluid velocity may improve heat transfer but it will likely increase pressure drop as well.<\/span><\/p><p><span style=\"color: #000000;\">As a result, effective <a href=\"https:\/\/customindustrialheatexchanger.com\/shop\/heat-exchanger\/tubular-heat-exchanger\/tubular-heat-exchanger\/\"><strong>Shell and Tube Heat Exchanger Design<\/strong><\/a>\u00a0balances thermal performance with mechanical requirements, maintenance concerns, and cost.<\/span><\/p><p><span style=\"color: #000000;\">This article provides an overview of the major principles and factors involved.<\/span><\/p><p><span style=\"color: #000000;\"><strong><em><u><b><i><a href=\"https:\/\/customindustrialheatexchanger.com\/shop\/heat-exchanger\/tubular-heat-exchanger\/tubular-heat-exchanger\/\">Shell and Tube Heat Exchanger<\/a> <\/i><\/b><\/u><\/em><\/strong><\/span><\/p><h2><span style=\"color: #000000;\"><strong>2. What Is <\/strong><strong>Shell and Tube Heat Exchanger Design<\/strong><strong>?<\/strong><\/span><\/h2><p><span style=\"color: #000000;\">Essentially, <a href=\"https:\/\/customindustrialheatexchanger.com\/shop\/heat-exchanger\/tubular-heat-exchanger\/tubular-heat-exchanger\/\"><strong>Shell and Tube Heat Exchanger Design<\/strong><\/a>\u00a0is the process by which we engineer an exchanger\u2019s thermal and mechanical characteristics.<\/span><\/p><p><span style=\"color: #000000;\">Heat exchanger design always starts with the process requirements.<\/span><\/p><p><span style=\"color: #000000;\"><strong><b>Typical input data includes: <\/b><\/strong><\/span><\/p><p><span style=\"color: #000000;\">\u00a0Hot fluid type<\/span><\/p><p><span style=\"color: #000000;\">\u00a0Cold fluid type<\/span><\/p><p><span style=\"color: #000000;\">\u00a0Hot fluid flow rate<\/span><\/p><p><span style=\"color: #000000;\">\u00a0Cold fluid flow rate<\/span><\/p><p><span style=\"color: #000000;\">\u00a0Inlet temperatures<\/span><\/p><p><span style=\"color: #000000;\">\u00a0Outlet temperatures<\/span><\/p><p><span style=\"color: #000000;\">\u00a0Operating pressures<\/span><\/p><p><span style=\"color: #000000;\">\u00a0Fluid properties<\/span><\/p><p><span style=\"color: #000000;\">\u00a0Allowable pressure drop<\/span><\/p><p><span style=\"color: #000000;\">\u00a0Fouling tendencies<\/span><\/p><p><span style=\"color: #000000;\">\u00a0Corrosion considerations<\/span><\/p><p><span style=\"color: #000000;\">\u00a0Available space for installation<\/span><\/p><p><span style=\"color: #000000;\">Engineers use this information to calculate the heat transfer area needed to accomplish the required heat transfer.<\/span><\/p><p><span style=\"color: #000000;\">Next, they work to develop the overall physical configuration of the heat exchanger.<\/span><\/p><p><span style=\"color: #000000;\">This involves selecting items such as shell diameter, tube diameter, tube length, tube wall thickness, number of tubes, tube pitch, tube layout pattern, number of passes, baffle cut, baffle spacing, materials of construction, and nozzle sizes and dimensions.<\/span><\/p><p><span style=\"color: #000000;\">As you can see, exchanger design involves both thermal considerations and mechanical design.<\/span><\/p><h2><span style=\"color: #000000;\"><strong>3. Basic Working Principle <\/strong><\/span><\/h2><p><span style=\"color: #000000;\">A shell and tube heat exchanger exchanges thermal energy between two fluids that are separated by a solid barrier.<\/span><\/p><p><span style=\"color: #000000;\">Heat transfer occurs across the tube wall.<\/span><\/p><p><span style=\"color: #000000;\">Heat transfers from the hotter fluid to the tube wall by convection. Thermal energy then conducts through the tube wall and into the cooler fluid.<\/span><\/p><p><span style=\"color: #000000;\">As a result, the overall heat transfer rate is dependent on many resistances to heat transfer.<\/span><\/p><p><span style=\"color: #000000;\"><strong><b>These can include: <\/b><\/strong><\/span><\/p><p><span style=\"color: #000000;\">\u00a0Convection resistance on the hot side<\/span><\/p><p><span style=\"color: #000000;\">\u00a0Conductive resistance through the tube wall<\/span><\/p><p><span style=\"color: #000000;\">\u00a0Convective resistance on the cold side<\/span><\/p><p><span style=\"color: #000000;\">\u00a0Fouling resistance<\/span><\/p><p><span style=\"color: #000000;\">Note that heat exchanger area is only one factor affecting performance.<\/span><\/p><p><span style=\"color: #000000;\">Fluid properties and flow details also have a significant impact.<\/span><\/p><p><span style=\"color: #000000;\"><strong><em><u><b><i><a href=\"https:\/\/customindustrialheatexchanger.com\/shop\/heat-exchanger\/tubular-heat-exchanger\/tubular-heat-exchanger\/\">Industrial Heat Exchanger<\/a> <\/i><\/b><\/u><\/em><\/strong><\/span><\/p><h2><span style=\"color: #000000;\"><strong>4. Key Design Parameters <\/strong><\/span><\/h2><p><span style=\"color: #000000;\">Prior to beginning detailed <strong>shell and tube heat exchanger design<\/strong>\u00a0calculations, we must have a good understanding of our process data.<\/span><\/p><h5><span style=\"color: #000000;\"><strong>Heat Duty <\/strong><\/span><\/h5><p><span style=\"color: #000000;\">Heat duty is the amount of thermal energy that must be transferred per unit time.<\/span><\/p><p><span style=\"color: #000000;\">Heat duty is the starting point for thermal sizing calculations.<\/span><\/p><h5><span style=\"color: #000000;\"><strong>Fluid Flow Rates <\/strong><\/span><\/h5><p><span style=\"color: #000000;\">Fluid flow rates will affect heat capacity rates, fluid velocity, pressure drop, and convective heat transfer coefficients.<\/span><\/p><h5><span style=\"color: #000000;\"><strong>Inlet and Outlet Temperature <\/strong><\/span><\/h5><p><span style=\"color: #000000;\">These values allow us to calculate the magnitude of the temperature change that must occur. Additionally, they help us determine the maximum temperature driving force available.<\/span><\/p><h5><span style=\"color: #000000;\"><strong>Fluid Properties <\/strong><\/span><\/h5><p><span style=\"color: #000000;\">There are several fluid properties that we need to know including:<\/span><\/p><p><span style=\"color: #000000;\">\u00a0Density<\/span><\/p><p><span style=\"color: #000000;\">\u00a0Specific heat<\/span><\/p><p><span style=\"color: #000000;\">\u00a0Viscosity<\/span><\/p><p><span style=\"color: #000000;\">\u00a0Thermal conductivity<\/span><\/p><p><span style=\"color: #000000;\">Keep in mind that fluid properties can change with temperature.<\/span><\/p><p><span style=\"color: #000000;\">As a result, we should use properties that are representative of the actual operating conditions.<\/span><\/p><h5><span style=\"color: #000000;\"><strong>Operating Pressure <\/strong><\/span><\/h5><p><span style=\"color: #000000;\">Operating pressure will have a direct effect on mechanical design.<\/span><\/p><p><span style=\"color: #000000;\">Pressure can also affect the phase and properties of the process fluids.<\/span><\/p><h5><span style=\"color: #000000;\"><strong>Allowable Pressure Drop <\/strong><\/span><\/h5><p><span style=\"color: #000000;\">All piping systems have some pressure limits.<\/span><\/p><p><span style=\"color: #000000;\">As such, we must design the heat exchanger to maintain a pressure drop that is considered acceptable by plant standards.<\/span><\/p><h2><span style=\"color: #000000;\"><strong>5. Heat Duty Calculation <\/strong><\/span><\/h2><p><span style=\"color: #000000;\">Determining heat duty is typically the first major step in <strong>shell and tube heat exchanger design<\/strong>.<\/span><\/p><p><span style=\"color: #000000;\">When dealing with single phase fluids and no reactions or phase changes, we can relate heat duty to mass flow, heat capacity, and temperature change using the following relationship:<\/span><\/p><p><span style=\"color: #000000;\">The basic relationship is:<\/span><\/p><p><span style=\"color: #000000;\"><strong>Q = \u1e41 \u00d7 Cp \u00d7 \u0394T<\/strong><\/span><\/p><p><span style=\"color: #000000;\">Where:<\/span><\/p><ul><li><span style=\"color: #000000;\"><strong>Q<\/strong>= heat duty<\/span><\/li><li><span style=\"color: #000000;\"><strong>\u1e41<\/strong>= mass flow rate<\/span><\/li><li><span style=\"color: #000000;\"><strong>Cp<\/strong>= specific heat capacity<\/span><\/li><li><span style=\"color: #000000;\"><strong>\u0394T<\/strong>= temperature change<\/span><\/li><\/ul><p><span style=\"color: #000000;\">Basically, we can think of this relationship as the amount of heat a fluid can absorb or lose.<\/span><\/p><p><span style=\"color: #000000;\">For instance, a larger fluid flow will require more thermal energy to achieve the same temperature change.<\/span><\/p><p><span style=\"color: #000000;\">Similarly, the hotter we need to raise the process fluid, the greater the heat duty.<\/span><\/p><p><span style=\"color: #000000;\">Ideally, we want the amount of heat lost by the hot process stream to equal the heat gained by the cold stream.<\/span><\/p><p><span style=\"color: #000000;\">On actual heat exchanger design problems we may need to account for heat losses to the surroundings as well.<\/span><\/p><p><span style=\"color: #000000;\">Heat exchanger applications involving phase changes require special consideration.<\/span><\/p><p><span style=\"color: #000000;\">Latent heat must be accounted for when dealing with condensers, boilers, and evaporators. As a result, thermal calculations will look different than typical liquid heating applications.<\/span><\/p><h2><span style=\"color: #000000;\"><strong>6. Heat Transfer Area Design <\/strong><\/span><\/h2><p><span style=\"color: #000000;\">Once we know our heat duty, we can proceed by estimating the heat transfer area required for our heat exchanger.<\/span><\/p><p><span style=\"color: #000000;\">Assuming we know the overall heat transfer coefficient and can calculate an effective mean temperature difference, we can use the following relationship to estimate the required heat transfer area:<\/span><\/p><p><span style=\"color: #000000;\"><strong>Q = U \u00d7 A \u00d7 \u0394T\u2098<\/strong><\/span><\/p><p><span style=\"color: #000000;\">Where:<\/span><\/p><ul><li><span style=\"color: #000000;\"><strong>Q<\/strong>= heat transfer rate<\/span><\/li><li><span style=\"color: #000000;\"><strong>U<\/strong>= overall heat transfer coefficient<\/span><\/li><li><span style=\"color: #000000;\"><strong>A<\/strong>= heat transfer area<\/span><\/li><li><span style=\"color: #000000;\"><strong>\u0394T\u2098<\/strong>= effective mean temperature difference<\/span><\/li><\/ul><h5><span style=\"color: #000000;\"><strong>Overall Heat Transfer Coefficient <\/strong><\/span><\/h5><p><span style=\"color: #000000;\">The overall heat transfer coefficient U accounts for thermal resistance due to:<\/span><\/p><p><span style=\"color: #000000;\">\u00a0Convection on the tube side<\/span><\/p><p><span style=\"color: #000000;\">\u2013 Conduction through the tube wall<\/span><\/p><p><span style=\"color: #000000;\">\u2013 Convection on the shell side<\/span><\/p><p><span style=\"color: #000000;\">\u2013 Fouling on the tube side<\/span><\/p><p><span style=\"color: #000000;\">\u2013 Fouling on the shell side<\/span><\/p><p><span style=\"color: #000000;\">A small U value will require a larger heat transfer area.<\/span><\/p><h5><span style=\"color: #000000;\"><strong>Temperature Difference <\/strong><\/span><\/h5><p><span style=\"color: #000000;\">Notice that \u0394T\u2098 is not just the subtraction of the two temperatures.<\/span><\/p><p><span style=\"color: #000000;\">The temperature difference changes as we move along the length of the heat exchanger.<\/span><\/p><p><span style=\"color: #000000;\">As a result, we usually take a logarithmic mean temperature difference for appropriate heat exchanger designs. Multipass exchangers may also require a correction factor to determine actual temperature difference.<\/span><\/p><h2><span style=\"color: #000000;\"><strong>7. Shell and Tube Sizing <\/strong><\/span><\/h2><p><span style=\"color: #000000;\">Now that we have estimated the required heat transfer surface area, we can begin actual sizing of the heat exchanger.<\/span><\/p><p><span style=\"color: #000000;\">Keep in mind that the total heat transfer surface area available is a function of several variables <strong><b>including:<\/b><\/strong><\/span><\/p><p><span style=\"color: #000000;\">\u00a0Number of tubes<\/span><\/p><p><span style=\"color: #000000;\">\u00a0Tube outside diameter (OD)<\/span><\/p><p><span style=\"color: #000000;\">\u00a0Effective tube length<\/span><\/p><p><span style=\"color: #000000;\">We can increase the available heat transfer area by adding more tubes.<\/span><\/p><p><span style=\"color: #000000;\">Adding tubes will also increase the shell diameter.<\/span><\/p><p><span style=\"color: #000000;\">Tubes can be made longer in order to decrease the total number of tubes.<\/span><\/p><p><span style=\"color: #000000;\">Keep in mind that longer tubes will require more space for installation and cleaning.<\/span><\/p><p><span style=\"color: #000000;\">Plant layout may be a large deciding factor between a taller or wider heat exchanger.<\/span><\/p><h2><span style=\"color: #000000;\"><strong>8. Tube Diameter, Length, and Thickness <\/strong><\/span><\/h2><p><span style=\"color: #000000;\">Size and thickness of the heat exchanger tubes directly impacts heat transfer and mechanical design considerations.<\/span><\/p><h5><span style=\"color: #000000;\"><strong>Tube Diameter <\/strong><\/span><\/h5><p><span style=\"color: #000000;\">Decreasing the tube diameter allows us to fit more tubes inside a given shell diameter.<\/span><\/p><p><span style=\"color: #000000;\">Smaller tubes also affect fluid velocity.<\/span><\/p><p><span style=\"color: #000000;\">One disadvantage of smaller tubes is the difficulty to clean them mechanically.<\/span><\/p><h5><span style=\"color: #000000;\"><strong>Tube Length <\/strong><\/span><\/h5><p><span style=\"color: #000000;\">Increasing the length of each tube allows us to increase the surface area provided by each tube.<\/span><\/p><p><span style=\"color: #000000;\">Physical limitations from the factory, shipping, or installation may restrict tube length.<\/span><\/p><h5><span style=\"color: #000000;\"><strong>Tube Wall Thickness <\/strong><\/span><\/h5><p><span style=\"color: #000000;\">Thickness of the tube wall will impact the mechanical strength of the tubes as well as thermal resistance.<\/span><\/p><p><span style=\"color: #000000;\">Increasing the thickness of the tube wall will improve strength but it will also increase thermal resistance.<\/span><\/p><p><span style=\"color: #000000;\">As such, we should choose tube thickness based on both mechanical and thermal needs.<\/span><\/p><h2><span style=\"color: #000000;\"><strong>9. Tube Layout and Tube Pitch <\/strong><\/span><\/h2><p><span style=\"color: #000000;\">Tube layout impacts shellside flow, ability to clean, and shell diameter.<\/span><\/p><h5><span style=\"color: #000000;\"><strong>Triangular <\/strong><\/span><\/h5><p><span style=\"color: #000000;\">If we set the tubes up in a triangular layout we can fit more tubes within the shell diameter.<\/span><\/p><p><span style=\"color: #000000;\">Additionally, this layout can increase turbulence on the shellside of the heat exchanger.<\/span><\/p><p><span style=\"color: #000000;\">One drawback is that it may be more difficult to clean between the tubes.<\/span><\/p><h5><span style=\"color: #000000;\"><strong>Square <\/strong><\/span><\/h5><p><span style=\"color: #000000;\">Using a square tube layout allows us straighter lines to clean between the tubes.<\/span><\/p><p><span style=\"color: #000000;\">As a result, it can become advantageous to use this layout when shellside mechanical cleaning is a concern.<\/span><\/p><h5><span style=\"color: #000000;\"><strong>Rotated Square Pattern <\/strong><\/span><\/h5><p><span style=\"color: #000000;\">Rotating the square pattern is another way to strike a balance between tube density and flow characteristics.<\/span><\/p><h5><span style=\"color: #000000;\"><strong>Tube Pitch <\/strong><\/span><\/h5><p><span style=\"color: #000000;\">Tube pitch is defined as the center to center distance between two adjacent tubes.<\/span><\/p><p><span style=\"color: #000000;\">Tube pitch will affect many things such as:<\/span><\/p><p><span style=\"color: #000000;\">\u00a0Tube density<\/span><\/p><p><span style=\"color: #000000;\">\u00a0Shellside flow area<\/span><\/p><p><span style=\"color: #000000;\">\u00a0Pressure drop<\/span><\/p><p><span style=\"color: #000000;\">\u00a0Ease of cleaning<\/span><\/p><p><span style=\"color: #000000;\">\u00a0Mechanical layout<\/span><\/p><p><span style=\"color: #000000;\">Therefore we must choose our tube pitch wisely.<\/span><\/p><h2><span style=\"color: #000000;\"><strong>10. Tube Pass Design <\/strong><\/span><\/h2><p><span style=\"color: #000000;\">Tube passes refer to how many times the fluid on the tubeside must travel the length of the exchanger.<\/span><\/p><p><span style=\"color: #000000;\"><strong><b>Typical designs include: <\/b><\/strong><\/span><\/p><p><span style=\"color: #000000;\">Increasing tube passes will increase fluid velocity on the tubeside.<\/span><\/p><p><span style=\"color: #000000;\">This will improve our tubeside heat transfer coefficient.<\/span><\/p><p><span style=\"color: #000000;\">However, pressure drop will also increase as a result.<\/span><\/p><p><span style=\"color: #000000;\">As such, more passes does not always mean a better heat exchanger design.<\/span><\/p><p><span style=\"color: #000000;\">We must balance heat transfer enhancement with pumping power.<\/span><\/p><p>\u00a0<\/p><h2><span style=\"color: #000000;\"><strong>11. Baffle Design<\/strong><\/span><\/h2><p><span style=\"color: #000000;\">There are two main purposes of baffles.<\/span><\/p><p><span style=\"color: #000000;\">Tube Support<\/span><\/p><p><span style=\"color: #000000;\">ShellSide Flow Guidance<\/span><\/p><p><span style=\"color: #000000;\">Without proper baffles, shellside fluid can flow through lessefficient paths.<\/span><\/p><h5><span style=\"color: #000000;\"><strong>ShellSide Velocity<\/strong><\/span><\/h5><p><span style=\"color: #000000;\">Smaller baffle spacing increases shellside velocity.<\/span><\/p><p><span style=\"color: #000000;\">This increases heat transfer but pressure drop as well.<\/span><\/p><p><span style=\"color: #000000;\">Larger spacing allows lower flow resistance, but shellside heat transfer may suffer.<\/span><\/p><h5><span style=\"color: #000000;\"><strong>Baffle Cut<\/strong><\/span><\/h5><p><span style=\"color: #000000;\">The baffle cut determines shellside flow window and crossflow area.<\/span><\/p><p><span style=\"color: #000000;\">As such, baffle cut impacts heat transfer and pressure drop.<\/span><\/p><h5><span style=\"color: #000000;\"><strong>Tube Support<\/strong><\/span><\/h5><p><span style=\"color: #000000;\">Another role of baffles is limiting the unsupported length of tubes.<\/span><\/p><p><span style=\"color: #000000;\">This minimizes vibration which could damage tubes.<\/span><\/p><p><span style=\"color: #000000;\">As such, thermal and mechanical design considerations must go handinhand.<\/span><\/p><h2><span style=\"color: #000000;\"><strong>12. ShellSide and TubeSide Pressure Drop<\/strong><\/span><\/h2><p><span style=\"color: #000000;\">Allowable pressure drop is always a limiting factor of <strong>Shell and Tube Heat Exchanger Design<\/strong>.<\/span><\/p><p><span style=\"color: #000000;\">Increasing fluid velocity improves heat transfer, but results in greater friction losses.<\/span><\/p><p><span style=\"color: #000000;\">TubeSide Pressure Drop<\/span><\/p><h5><span style=\"color: #000000;\"><strong>Pressure drop on the tubeside depends on:<\/strong><\/span><\/h5><p><span style=\"color: #000000;\">\u00a0\u2013 Fluid Velocity<\/span><\/p><p><span style=\"color: #000000;\">\u00a0\u2013 Tube Diameter<\/span><\/p><p><span style=\"color: #000000;\">\u00a0\u2013 Tube Length<\/span><\/p><p><span style=\"color: #000000;\">\u00a0\u2013 Pass Count<\/span><\/p><p><span style=\"color: #000000;\">\u00a0\u2013 Fluid Viscosity<\/span><\/p><p><span style=\"color: #000000;\">\u00a0\u2013 Entrance\/Exit Losses<\/span><\/p><h5><span style=\"color: #000000;\"><strong>ShellSide Pressure Drop<\/strong><\/span><\/h5><p><span style=\"color: #000000;\">Pressure drop on the shellside depends on:<\/span><\/p><p><span style=\"color: #000000;\">\u00a0\u2013 Baffle Spacing<\/span><\/p><p><span style=\"color: #000000;\">\u00a0\u2013 Baffle Cut<\/span><\/p><p><span style=\"color: #000000;\">\u00a0\u2013 Shell Diameter<\/span><\/p><p><span style=\"color: #000000;\">\u00a0\u2013 Tube Configuration<\/span><\/p><p><span style=\"color: #000000;\">\u00a0\u2013 Fluid Velocity<\/span><\/p><p><span style=\"color: #000000;\">\u00a0\u2013 Fluid Properties<\/span><\/p><p><span style=\"color: #000000;\">\u00a0\u2013 Leakage\/Bypass streams<\/span><\/p><p><span style=\"color: #000000;\">Ideally, pressure drop should fall within allowable limits for the process system. Exceeding this may increase pumping or compression costs.<\/span><\/p><h2><span style=\"color: #000000;\"><strong>13. Flow Arrangement<\/strong><\/span><\/h2><p><span style=\"color: #000000;\">Flow direction impacts temperature driving force through the heat exchanger.<\/span><\/p><h5><span style=\"color: #000000;\"><strong>Parallel Flow<\/strong><\/span><\/h5><p><span style=\"color: #000000;\">Fluids enter on the same general end and move in the same general direction.<\/span><\/p><h5><span style=\"color: #000000;\"><strong>Counterflow<\/strong><\/span><\/h5><p><span style=\"color: #000000;\">Fluids run through the exchanger in opposite directions.<\/span><\/p><p><span style=\"color: #000000;\">Counter\u00a0flow usually allows a more favorable temperature distribution for heat transfer.<\/span><\/p><p>\u00a0<\/p><p><span style=\"color: #000000;\">Heat exchangers often use more complicated flows than these two examples.<\/span><\/p><p><span style=\"color: #000000;\">Pass arrangements on the tubeside or shellside can drastically alter true temperature profile.<\/span><\/p><p><span style=\"color: #000000;\">Engineers should evaluate entire flow arrangement when designing heat exchangers.<\/span><\/p><h2><span style=\"color: #000000;\"><strong>14. Material Selection<\/strong><\/span><\/h2><p><span style=\"color: #000000;\">Materials of Construction should be compatible with process fluids.<\/span><\/p><p><span style=\"color: #000000;\">Some common tube\/shell materials include:<\/span><\/p><h5><span style=\"color: #000000;\"><strong>Carbon Steel<\/strong><\/span><\/h5><p><span style=\"color: #000000;\">Carbon steel has decent mechanical properties and low cost when used with acceptable fluids.<\/span><\/p><h5><span style=\"color: #000000;\"><strong>Stainless Steel<\/strong><\/span><\/h5><p><span style=\"color: #000000;\">Stainless steel allows for greater corrosion resistance. Grades 304L and 316L are common in process equipment.<\/span><\/p><h5><span style=\"color: #000000;\"><strong>Copper Alloys<\/strong><\/span><\/h5><p><span style=\"color: #000000;\">Copper alloys allow for greater thermal conductivity.<\/span><\/p><h5><span style=\"color: #000000;\"><strong>Nickel Alloys<\/strong><\/span><\/h5><p><span style=\"color: #000000;\">Nickel and other highperformance materials can handle certain chemicals and high temperatures.<\/span><\/p><h5><span style=\"color: #000000;\"><strong>Titanium<\/strong><\/span><\/h5><p><span style=\"color: #000000;\">Titanium works wonders in certain applications but comes at a cost.<\/span><\/p><p><span style=\"color: #000000;\">Equipment cost should be weighed against performance requirements.<\/span><\/p><h2><span style=\"color: #000000;\"><strong>15. Fouling and Cleaning Considerations<\/strong><\/span><\/h2><p><span style=\"color: #000000;\">Fouling presents another form of thermal resistance.<\/span><\/p><p><span style=\"color: #000000;\"><strong><b>Examples of fouling include:<\/b><\/strong><\/span><\/p><ul><li><span style=\"color: #000000;\">Scale<\/span><\/li><li><span style=\"color: #000000;\">Sediment<\/span><\/li><li><span style=\"color: #000000;\">Biological growth<\/span><\/li><li><span style=\"color: #000000;\">Corrosion<\/span><\/li><li><span style=\"color: #000000;\">Process buildup<\/span><\/li><\/ul><p><span style=\"color: #000000;\">Heat transfer decreases as fouling materials buildup on surfaces.<\/span><\/p><p><span style=\"color: #000000;\">Pressure drop can increase as well. As such, engineers should anticipate fouling during the design phase.<\/span><\/p><p><span style=\"color: #000000;\">Typically fouling is defined by adding a fouling resistance to thermal calculations.<\/span><\/p><p><span style=\"color: #000000;\">One should be careful not to add too large of a design margin. Otherwise, equipment may be oversized.<\/span><\/p><p><span style=\"color: #000000;\">Can\u2019t see through your process stream? Consider how your fluid may foul over time.<\/span><\/p><p><span style=\"color: #000000;\">Include cleaning provisions if your fluid has severe fouling tendencies.<\/span><\/p><p><span style=\"color: #000000;\">Simple access to tube bundles allows for easier cleaning.<\/span><\/p><p><span style=\"color: #000000;\">Removable tube bundle heads allow cleaning on the shellside.<\/span><\/p><h2><span style=\"color: #000000;\"><strong>16. Common Shell and Tube Configurations<\/strong><\/span><\/h2><h5><span style=\"color: #000000;\"><strong>Fixed Tube Sheet<\/strong><\/span><\/h5><p><span style=\"color: #000000;\">Both shell and tube sheets are fixed relative to each other.<\/span><\/p><p><span style=\"color: #000000;\">Simple design. Beware of thermal expansion and shellside cleaning.<\/span><\/p><h5><span style=\"color: #000000;\"><strong>U Tube<\/strong><\/span><\/h5><p><span style=\"color: #000000;\">The tubes form a U shape to allow for expansion without a second fixed tube sheet.<\/span><\/p><h5><span style=\"color: #000000;\"><strong>Floating Head<\/strong><\/span><\/h5><p><span style=\"color: #000000;\">Floating head allows for expansion and sometimes removable tube bundles.<\/span><\/p><h2><span style=\"color: #000000;\"><strong>17. <\/strong><strong>Shell and Tube Heat Exchanger Design<\/strong><strong>\u00a0Process Step by Step<\/strong><\/span><\/h2><p><span style=\"color: #000000;\"><strong><b>Step 1: Define Process Conditions<\/b><\/strong><\/span><\/p><ul><li><span style=\"color: #000000;\">Temperature<\/span><\/li><li><span style=\"color: #000000;\">Pressure<\/span><\/li><li><span style=\"color: #000000;\">Flow rate<\/span><\/li><li><span style=\"color: #000000;\">Physical properties<\/span><\/li><li><span style=\"color: #000000;\">Fluid type<\/span><\/li><\/ul><p><span style=\"color: #000000;\"><strong><b>Step 2: Calculate Heat Duty<\/b><\/strong><\/span><\/p><p><span style=\"color: #000000;\"><strong><b>Step 3: Determine Temperature Driving Force<\/b><\/strong><\/span><\/p><p><span style=\"color: #000000;\"><strong><b>Step 4: Estimate Overall Heat Transfer Coefficient U<\/b><\/strong><\/span><\/p><p><span style=\"color: #000000;\">Use estimated values or thermal resistance charts to arrive at U<\/span><\/p><p><span style=\"color: #000000;\"><strong><b>Step 5: Estimate Heat Transfer Area<\/b><\/strong><\/span><\/p><p><span style=\"color: #000000;\">Calculate rough heat transfer area needed<\/span><\/p><p><span style=\"color: #000000;\"><strong><b>Step 6: Select Tube Dimensions<\/b><\/strong><\/span><\/p><p><span style=\"color: #000000;\">Tube ID, Wall thickness, and Length<\/span><\/p><p><span style=\"color: #000000;\"><strong><b>Step 7: Determine Number of Tubes<\/b><\/strong><\/span><\/p><p><span style=\"color: #000000;\">Approximate number of tubes needed<\/span><\/p><p><span style=\"color: #000000;\"><strong><b>Step 8: Select Tube Layout<\/b><\/strong><\/span><\/p><p><span style=\"color: #000000;\">Triangular? Square? Something else?<\/span><\/p><p><span style=\"color: #000000;\"><strong><b>Step 9: Estimate Shell Diameter<\/b><\/strong><\/span><\/p><p><span style=\"color: #000000;\">Find shell diameter from geometry of tube bundle.<\/span><\/p><p><span style=\"color: #000000;\"><strong><b>Step 10: Select Baffles<\/b><\/strong><\/span><\/p><p><span style=\"color: #000000;\">Type, Cut, and Spacing of baffles<\/span><\/p><p><span style=\"color: #000000;\"><strong><b>Step 11: Calculate Heat Transfer Coefficients<\/b><\/strong><\/span><\/p><p><span style=\"color: #000000;\">Evaluate Ai (tubeside), Ui(J), and hi (shellside)<\/span><\/p><p><span style=\"color: #000000;\"><strong><b>Step 12: Check Pressure Drop<\/b><\/strong><\/span><\/p><p><span style=\"color: #000000;\">Ensure tubeside and shellside pressure drop are within limits.<\/span><\/p><p><span style=\"color: #000000;\"><strong><b>Step 13: Iterate<\/b><\/strong><\/span><\/p><p><span style=\"color: #000000;\">Revise any numbers, velocities, passes, or baffles as needed.<\/span><\/p><p><span style=\"color: #000000;\"><strong><b>Step 14: Mechanical Design Details<\/b><\/strong><\/span><\/p><p><span style=\"color: #000000;\">Shell thickness, tube sheets, nozzles, supports, bolting, and more.<\/span><\/p><h2><span style=\"color: #000000;\"><strong>18. Common Design Mistakes<\/strong><\/span><\/h2><h5><span style=\"color: #000000;\"><strong>Fouling<\/strong><\/span><\/h5><p><span style=\"color: #000000;\">Maybe your heat exchanger works well enough when it\u2019s nice and clean.<\/span><\/p><p><span style=\"color: #000000;\">What about after several months of your process fluid sitting inside?<\/span><\/p><h5><span style=\"color: #000000;\"><strong>Pressure Drop<\/strong><\/span><\/h5><p><span style=\"color: #000000;\">Velocity increases heat transfer but too much velocity causes excessive pressure drop.<\/span><\/p><h5><span style=\"color: #000000;\"><strong>Material Selection<\/strong><\/span><\/h5><p><span style=\"color: #000000;\">Just because a material can handle the temperature doesn\u2019t mean your process wants to react with it.<\/span><\/p><h5><span style=\"color: #000000;\"><strong>Flow Distribution<\/strong><\/span><\/h5><p><span style=\"color: #000000;\">Maldistribution lowers true heat transfer area and creates hot spots.<\/span><\/p><h5><span style=\"color: #000000;\"><strong>Cleaning<\/strong><\/span><\/h5><p><span style=\"color: #000000;\">Can you easily clean the heat exchanger? If your process fluid fouls, you should be able to clean it.<\/span><\/p><h5><span style=\"color: #000000;\"><strong>Thermal Expansion<\/strong><\/span><\/h5><p><span style=\"color: #000000;\">Did you know the shell expands a different amount than the tubes? What about bowing of tubes?<\/span><\/p><h5><span style=\"color: #000000;\"><strong>Heat Transfer Area<\/strong><\/span><\/h5><p><span style=\"color: #000000;\">Sure you can always add heat transfer area, but what about everything else mentioned above?<\/span><\/p><h2><span style=\"color: #000000;\"><strong>19. Custom Heat Exchanger Design<\/strong><\/span><\/h2><p><span style=\"color: #000000;\">Many industrial heat exchanger projects require custom design.<\/span><\/p><p><span style=\"color: #000000;\"><strong><b>Adjustable parameters include but are not limited to:<\/b><\/strong><\/span><\/p><ul><li><span style=\"color: #000000;\">Heat transfer area<\/span><\/li><li><span style=\"color: #000000;\">Shell diameter<\/span><\/li><li><span style=\"color: #000000;\">Tube diameter<\/span><\/li><li><span style=\"color: #000000;\">Tube length<\/span><\/li><li><span style=\"color: #000000;\">Tube thickness<\/span><\/li><li><span style=\"color: #000000;\">Tube material<\/span><\/li><li><span style=\"color: #000000;\">Tube pitch<\/span><\/li><li><span style=\"color: #000000;\">Tube arrangement<\/span><\/li><li><span style=\"color: #000000;\">Number of passes<\/span><\/li><li><span style=\"color: #000000;\">Baffle cut<\/span><\/li><li><span style=\"color: #000000;\">Baffle spacing<\/span><\/li><li><span style=\"color: #000000;\">Nozzle locations<\/span><\/li><li><span style=\"color: #000000;\">Connection style<\/span><\/li><li><span style=\"color: #000000;\">Equipment orientation<\/span><\/li><\/ul><p><span style=\"color: #000000;\">Heat exchanger designs can also use finned tubes.<\/span><\/p><p><span style=\"color: #000000;\">External fin surface can improve heat transfer when your application has an issue with heat transfer on one side.<\/span><\/p><p><span style=\"color: #000000;\">Fin types can include low fin, welded fin, extruded fin, embedded fin, and more.<\/span><\/p><p><span style=\"color: #000000;\"><strong><em><u><b><i>Low Fin Tubes for Heat Exchanger<\/i><\/b><\/u><\/em><\/strong><\/span><\/p><p><a href=\"https:\/\/customindustrialheatexchanger.com\/our-industrial-heat-exchanger-products\/finned-tube-manufacturer\/\"><span style=\"color: #000000;\"><strong><em><u><b><i>High Frequency Welded Fin Tube<\/i><\/b><\/u><\/em><\/strong><\/span><\/a><\/p><p><a href=\"https:\/\/customindustrialheatexchanger.com\/our-industrial-heat-exchanger-products\/finned-tube-manufacturer\/\"><span style=\"color: #000000;\"><strong><em><u><b><i>Laser Welded Fin Tube<\/i><\/b><\/u><\/em><\/strong><\/span><\/a><\/p><p><a href=\"https:\/\/customindustrialheatexchanger.com\/our-industrial-heat-exchanger-products\/finned-tube-manufacturer\/\"><span style=\"color: #000000;\"><strong><em><u><b><i>Extruded Fin Tubes for Heat Exchanger<\/i><\/b><\/u><\/em><\/strong><\/span><\/a><\/p><h2><span style=\"color: #000000;\"><strong>20. Why Choose Bangwin Thermal?<\/strong><\/span><\/h2><p><span style=\"color: #000000;\">Bangwin Thermal specializes in industrial heat exchanger equipment and fin tubes.<\/span><\/p><p><span style=\"color: #000000;\">Different processes require different thermal solutions.<\/span><\/p><p><span style=\"color: #000000;\"><strong><b>That\u2019s why Bangwin Thermal can work with you to understand:<\/b><\/strong><\/span><\/p><ul><li><span style=\"color: #000000;\">Fluid composition<\/span><\/li><li><span style=\"color: #000000;\">Flow Rate<\/span><\/li><li><span style=\"color: #000000;\">Heat duty<\/span><\/li><li><span style=\"color: #000000;\">Inlet temperature<\/span><\/li><li><span style=\"color: #000000;\">Desired Outlet temperature<\/span><\/li><li><span style=\"color: #000000;\">Operating Pressure<\/span><\/li><li><span style=\"color: #000000;\">Material needs<\/span><\/li><li><span style=\"color: #000000;\">Allowable pressure drop<\/span><\/li><li><span style=\"color: #000000;\">Installation dimensions<\/span><\/li><\/ul><p><span style=\"color: #000000;\">With this information, Bangwin Thermal can help you determine what heat exchanger will work best for your process.<\/span><\/p><p><span style=\"color: #000000;\">Need more external surface area? Bangwin Thermal specializes fin tube technology.<\/span><\/p><p><span style=\"color: #000000;\">This includes standard tubes, low fin tubes, G fin tubes, extruded fin tubes, laser welded fin tubes, and high frequency welded fin tubes.<\/span><\/p><p><span style=\"color: #000000;\">Contact Bangwin Thermal today to see how we can help with your custom heat exchanger needs.<\/span><\/p><h2><span style=\"color: #000000;\"><strong>21. FAQ<\/strong><\/span><\/h2><h5><span style=\"color: #000000;\">l\u00a0<strong>What information should I have before Shell and Tube Heat Exchanger Design?<\/strong><\/span><\/h5><p><span style=\"color: #000000;\">You should know: Fluid Types, Flow Rate, Temperatures, Pressures, Fluid Properties, Allowable Pressure drop, Material Requirements, Fouling Details, Installation Requirements.<\/span><\/p><h5><span style=\"color: #000000;\">l\u00a0<strong>What are the steps to size a shell and tube heat exchanger?<\/strong><\/span><\/h5><p><span style=\"color: #000000;\">Determine heat duty, determine temperature driving force, estimate overall heat transfer coefficient U, and Estimate heat transfer area.<\/span><\/p><h5><span style=\"color: #000000;\">l\u00a0<strong>How do you size a heat exchanger?<\/strong><\/span><\/h5><p><span style=\"color: #000000;\">Calculate required heat transfer area then choose tube dimensions and length to produce enough surface area.<\/span><\/p><h5><span style=\"color: #000000;\">l\u00a0<strong>What layout should I use for my tubes?<\/strong><\/span><\/h5><p><span style=\"color: #000000;\">Triangular has more tube density. Square allows better access to tubes for cleaning. Consider process specifics when choosing layout.<\/span><\/p><h5><span style=\"color: #000000;\">l\u00a0<strong>Why are baffles needed?<\/strong><\/span><\/h5><p><span style=\"color: #000000;\">Without baffles, shellside fluid can bypass tubes. Baffles force fluid to flow across tubes. Baffles also support the tubes and control shellside velocity.<\/span><\/p><h5><span style=\"color: #000000;\">l\u00a0<strong>How does tube size matter?<\/strong><\/span><\/h5><p><span style=\"color: #000000;\">Changing tube diameter impacts velocity, pressure drop, heat transfer area, fouling tendencies, and cleaning access.<\/span><\/p><h5><span style=\"color: #000000;\">l\u00a0<strong>How many passes do you put in a heat exchanger?<\/strong><\/span><\/h5><p><span style=\"color: #000000;\">Depends on the exchanger. Depends on your velocity and pressure drop requirements.<\/span><\/p><h5><span style=\"color: #000000;\">l\u00a0<strong>What is the best material for a shell and tube heat exchanger?<\/strong><\/span><\/h5><p><span style=\"color: #000000;\">Depends on your process.<\/span><\/p><h5><span style=\"color: #000000;\">l\u00a0<strong>What metals are commonly used for heat exchangers?<\/strong><\/span><\/h5><p><span style=\"color: #000000;\">Carbon steel, stainless steel, copper, nickel, and titanium are common materials for heat exchangers.<\/span><\/p><h5><span style=\"color: #000000;\">l\u00a0<strong>Do finned tubes increase heat transfer?<\/strong><\/span><\/h5><p><span style=\"color: #000000;\">Yes, they increase external heat transfer area.<\/span><\/p><h5><span style=\"color: #000000;\">l\u00a0<strong>Can Bangwin Thermal design custom heat exchangers?<\/strong><\/span><\/h5><p><span style=\"color: #000000;\">Yes! Give us a call or send us an email. Send us your process information and we\u2019ll help determine your heat exchanger needs.<\/span><\/p><h2><span style=\"color: #000000;\"><strong>22. Conclusion<\/strong><\/span><\/h2><p><span style=\"color: #000000;\"><strong>Shell and Tube Heat Exchanger Design<\/strong>\u00a0is much more complicated than just attaching tubes to a shell.<\/span><\/p><p><span style=\"color: #000000;\">An engineer should understand process conditions and heat duty.<\/span><\/p><p><span style=\"color: #000000;\">Temperature driving force and required heat transfer area should be determined.<\/span><\/p><p><span style=\"color: #000000;\">Tube diameter, length, quantity, pitch, and layout determine the tube bundle configuration.<\/span><\/p><p><span style=\"color: #000000;\">Baffle configuration dictates shellside flow details.<\/span><\/p><p><span style=\"color: #000000;\">Do not forget about pressure drop limitations.<\/span><\/p><p><span style=\"color: #000000;\">Fouling tendencies, thermal expansion, cleaning provisions, and maintenance are all important to longterm success.<\/span><\/p><p><span style=\"color: #000000;\">When designing shell and tube heat exchangers, engineers must balance thermal performance, equipment costs, and maintenance requirements.<\/span><\/p><p><blockquote class=\"wp-embedded-content\" data-secret=\"NaROcQXUQd\"><a href=\"https:\/\/bangwingascylinder.com\/\">Home<\/a><\/blockquote><iframe class=\"wp-embedded-content lazyload\" sandbox=\"allow-scripts\" security=\"restricted\" style=\"position: absolute; visibility: hidden;\" title=\"\u300a Home \u300b\u2014https:\/\/bangwingascylinder.com\" data-src=\"https:\/\/bangwingascylinder.com\/embed\/#?secret=f7ReaXekVj#?secret=NaROcQXUQd\" data-secret=\"NaROcQXUQd\" width=\"500\" height=\"282\" frameborder=\"0\" marginwidth=\"0\" marginheight=\"0\" scrolling=\"no\" src=\"data:image\/svg+xml;base64,PHN2ZyB3aWR0aD0iMSIgaGVpZ2h0PSIxIiB4bWxucz0iaHR0cDovL3d3dy53My5vcmcvMjAwMC9zdmciPjwvc3ZnPg==\" data-load-mode=\"0\"><\/iframe><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t<div class=\"elementor-element 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