FIG. 11-4 LMTD correction factors for heat exchangers. In all charts, R = (T - T2)/t - ¿1) and S = (¿2 - t\)/{T\ -¿1). (a) One shell pass, two or more tube passes. (b) Two shell passes, four or more tube passes. (c) Three shell passes, six or more tube passes. (d) Four shell passes, eight or more tube passes. (e) Six shell passes, twelve or more tube passes. (f) Cross-flow, one shell pass, one or more parallel rows of tubes. (g) Cross-flow, two passes, two rows of tubes; for more than two passes, use Ft = 1.0. (h) Cross-flow, one shell pass, one tube pass, both fluids unmixed

ciency must also be known to calculate an effective outside area to use in Eq. (11-2).

Fittings contribute strongly to the pressure drop on the annulus side. General methods for predicting this are not reliable, and manufacturer's data should be used when available.

Double-pipe exchangers are often piped in complex series-parallel arrangements on both sides. The MTD to be used has been derived for some of these arrangements and is reported in Kern (Process Heat Transfer, McGraw-Hill, New York, 1950). More complex cases may require trial-and-error balancing of the heat loads and rate equations for subsections or even for individual exchangers in the bank.

Baffled Shell-and-Tube Exchangers The method given here is based on the research summarized in Final Report, Cooperative Research Program on Shell and Tube Heat Exchangers, Univ. Del. Eng. Exp. Sta. Bull. 5 (June 1963). The method assumes that the shell-side heat transfer and pressure-drop characteristics are equal to those of the ideal tube bank corresponding to the cross-flow sections of the exchanger, modified for the distortion of flow pattern introduced by the baffles and the presence of leakage and bypass flow through the various clearances required by mechanical construction.

It is assumed that process conditions and physical properties are known and the following are known or specified: tube outside diameter Do, tube geometrical arrangement (unit cell), shell inside diameter Ds, shell outer tube limit Doti, baffle cut lc, baffle spacing ls, and number of sealing strips Nss. The effective tube length between tube sheets L may be either specified or calculated after the heat-transfer coefficient has been determined. If additional specific information (e.g., tube-baffle clearance) is available, the exact values (instead of estimates) of certain parameters may be used in the calculation with some improvement in accuracy. To complete the rating, it is necessary to know also the tube material and wall thickness or inside diameter.

This rating method, though apparently generally the best in the open literature, is not extremely accurate. An exhaustive study by Palen and Taborek [Chem. Eng. Prog. Symp. Ser. 92, 65, 53 (1969)] showed that this method predicted shell-side coefficients from about 50 percent low to 100 percent high, while the pressure-drop range was from about 50 percent low to 200 percent high. The mean error for heat transfer was about 15 percent low (safe) for all Reynolds numbers, while the mean error for pressure drop was from about 5 percent low (unsafe) at Reynolds numbers above 1000 to about 100 percent high at Reynolds numbers below 10.

Calculation of Shell-Side Geometrical Parameters

1. Total number of tubes in exchanger Nt. If not known by direct count, estimate using Eq. (11-84) or (11-85).

2. Tube pitch parallel to flow pp and normal to flow pn. These quantities are needed only for estimating other parameters. If a detailed drawing of the exchanger is available, it is better to obtain these other parameters by direct count or calculation. The pitches are described by Fig. 11-5 and read therefrom for common tube layouts.

3. Number of tube rows crossed in one cross-flow section Nc. Count from exchanger drawing or estimate from

4. Fraction of total tubes in cross-flow Fc = -

Ds - 2 lc / , Ds - 2 lA „ , Ds - 2lc n + 2-sin I cos -I - 2 cos -

Fc is plotted in Fig. 11-6. This figure is strictly applicable only to split-ring, floating-head construction but may be used for other situations with minor error.

5. Number of effective cross-flow rows in each window Ncw

FIG. 11-5 Values of tube pitch for common tube layouts. To convert inches to meters, multiply by 0.0254. Not that Da, p , pp, and -pn have units of inches.
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