Shell and Tube Heat Exchangers

Shell-and-Tube Heat
Exchangers
What’s a Shell and Tube Heat
Exchanger ??!
• Consist of two main
things as it’s name
implies Shell & Tubes
• The shell is a large
vassel with a number of
tubes inside it .
Construction
• Bundle of tubes in large cylindrical shell
• Baffles used both to support the tubes and to direct
into multiple cross flow
• Gaps or clearances must be left between the baffle
and the shell and between the tubes and the baffle
to enable assembly
Shell
Tubes
Baffle
• The principle of operation is simple enough: Two fluids of
different temperatures are brought into close contact but they
are not mixing with each other.
• One fluid runs through the tubes, and another fluid flows over
the tubes (through the shell) to transfer heat between the two
fluids.
Components of STHEs
• It is essential for the designer to have a good working
knowledge of the mechanical features of STHEs and
how they influence thermal design.
• The principal components of an STHE are:

– Shell; shell cover;
– Tubes; tube sheet;
– Baffles; and nozzles.
• Other components include tie-rods and spacers, pass

partition plates, impingement plate, longitudinal
baffle, sealing strips, supports, and foundation.
There are many types of shell-tube heat exchanger but the most
common types in use are :-
• U-Tube Heat Exchanger

• Straight-Tube ( 1-Pass )
• Straight-Tube ( 2-Pass )
Straight-Tube ( 1-Pass )
Straight-Tube ( 2-Pass )
U-tube exchanger
• This type of exchangers consists of tubes
which are bent in the form of a ‘U’ and rolled
back into the tube sheet
• This means that it will omit some tubes at the
centre of the tube bundle depending on the
tube arrangement.
• The tubes can expand freely towards the ‘U’
bend end.
U-Tube Heat Exchanger
U-tube exchanger
Types of shell and tube exchangers
Fixed tube-sheet exchanger (non-

removable tube bundle):
• The simplest and cheapest type of shell and

tube exchanger is with fixed tube sheet design.
• In this type of exchangers the tube sheet is

welded to the shell and no relative movement
between the shell and tube bundle is possible
Fixed tube-sheet exchanger (non-removable
tube bundle):
Types of shell and tube exchangers
Removable tube bundle:
• Tube bundle may be removed for ease of

cleaning and replacement.
• Removable tube bundle exchangers further

can be categorized in floating head and U-tube
exchanger.
Floating-head exchanger
• It consists of a stationery tube sheet which is
clamped with the shell flange.
• At the opposite end of the bundle, the tubes

may expand into a freely riding floating-head or
floating tube sheet.
• A floating head cover is bolted to the tube sheet

and the entire bundle can be removed for
cleaning and inspection of the interior
Floating-head exchanger
Shell and Tube Heat Exchangers
Shell and Tube Exchangers
S&T Exchanger Construction
Baffle assembly
Inserting
Welding the shell tubes
Final
product
Tubesheet
Tube Bundles
U-tubes
Tubesheet
Baffles
Source: UOP
Tube layouts
pitch
Triangular Rotated Rotated
Square square
30o triangular
90o 45o
60o
• Typically, 1 in tubes on a 1.25 in pitch or 0.75 in

tubes on a 1 in pitch
• Triangular layouts give more tubes in a given shell
• Square layouts give cleaning lanes with close pitch
Heat Exchanger Design
• Heat exchange design must:
– Provide required area
– Contain process pressure
– Prevent leaks from shell to tubes or tubes to shell
– Allow for thermal expansion
– Allow for cleaning if fouling occurs
– Allow for phase change (some cases)
– Have reasonable pressure drop
• S&T heat exchangers are built to standards set by
the Thermal Exchanger Manufacturers Association
(TEMA)
TEMA standards
• The design and construction is usually based on TEMA
8th Edition 1998
• Supplements pressure vessel codes like ASME and BS
5500
• Sets out constructional details, recommended tube sizes,
allowable clearances, terminology etc.
• Provides basis for contracts
• Tends to be followed rigidly even when not strictly
necessary
• Many users have their own additions to the standard
which suppliers must follow
TEMA terminology
Rear end
Front end head type
Shell
stationary head type
• Letters given for the front end, shell and

rear end types
• Exchanger given three letter designation
• Above is AEL
TEMA Nomenclature
• Many combinations of front header, shell
and rear header can be made. The most
common combinations for an E-Type Shell
are shown below
• But other combinations are also used.
Front head type
• A-type is standard for dirty tube side
• B-type for clean tube side duties. Use if possible
since cheap and simple.
A B
Channel and removable cover Bonnet (integral cover)

More front-end head types
• C-type with removable shell for hazardous tube-side
fluids, heavy bundles or services that need frequent
shell-side cleaning
• N-type for fixed for hazardous fluids on shell side
• D-type or welded to tube sheet bonnet for high
pressure (over 150 bar)
B N D
Shell type
• E-type shell should be used if possible but
• F shell gives pure counter-current flow with two
tube passes (avoids very long exchangers)
Longitudinal baffle
E F
One-pass shell Two-pass shell
Note, longitudinal baffles are difficult to seal with

the shell especially when reinserting the shell after
maintenance
More shell types
• G and H shells normally only used for horizontal
thermosyphon reboilers
• J and X shells if allowable pressure drop can not be
achieved in an E shell
G H
Longitudinal
Split flow baffles Double split flow
J X
Divided flow Cross flow

Rear head type
These fall into three general types
• fixed tube sheet (L, M, N)
• U-tube
• floating head (P, S, T, W)
Use fixed tube sheet if T below 50oC,
otherwise use other types to allow for
differential thermal expansion
You can use bellows in shell to allow for
expansion but these are special items which
have pressure limitations (max. 35 bar)
Fixed rear head types
L
Fixed tube sheet
• L is a mirror of the A front end head

• M is a mirror of the bonnet (B) front end
• N is the mirror of the N front end
Floating heads and U tube
Allow bundle removal and mechanical cleaning
on the shell side
• U tube is simple design but it is difficult to
clean the tube side round the bend
Floating heads
T S
Pull through floating head Similar to T but with smaller shell/

Note large shell/bundle gap bundle gap
Split backing ring

Other floating heads
• Not used often and then with small exchangers
P W
Outside packing to give Externally sealed floating tube sheet

smaller shell/bundle gap maximum of 2 tube passes
Types and applications of shell & tube heat exchangers
Baffle Type & Geometry
• Baffles serve two functions:
– Support the tubes for structural rigidity, preventing tube vibration and sagging
– Divert the flow across the bundle to obtain a higher heat transfer coefficient.
• When the tube bundle employs baffles,
– the heat transfer coefficient is higher than the coefficient for undisturbed flow
around tubes without baffles.
– For a baffled heat exchanger the higher heat transfer coefficients result from
the increased turbulence.
– the velocity of fluid fluctuates because of the constricted area between

adjacent tubes across the bundle.
Baffles; (a) horizontal cut baffles; (b) Vertical cut baffles;
Types of Baffles
Segmental Baffles
• In case of cut-segmental baffle, a segment (called baffle cut) is
removed to form the baffle expressed as a percentage of the
baffle diameter.
• Baffle cuts from 15 to 45% are normally used.
• A baffle cut of 20 to 25% provide a good heat-transfer with the

reasonable pressure drop. The % cut for segmental baffle
refers to the cut away height from its diameter.
Thermal Design Considerations
• The flow rates of both hot and cold streams, their
terminal temperatures and fluid properties are the
primary inputs of thermal design of heat
exchangers.
• Thermal design of a shell and tube heat exchanger

typically includes the determination of heat transfer
area, number of tubes, tube length and diameter,
tube layout, number of shell and tube passes, type
of heat exchanger (fixed tube sheet, removable
tube bundle etc), tube pitch, number of baffles, its
type and size, shell and tube side pressure drop etc.
Selection of fluids for tube and the shell side
• The routing of the shell side and tube side fluids has
considerable effects on the heat exchanger design.
Some general guidelines for positioning the fluids
are given in Table below
Fouling Considerations
Shell
• Shell is the container for the shell fluid and the tube bundle is
placed inside the shell.
•
• Shell diameter should be selected in such a way to give a
close fit of the tube bundle.
• The clearance between the tube bundle and inner shell wall
depends on the type of exchanger
• Shells are usually fabricated from standard steel pipe with

satisfactory corrosion allowance.
• The shell thickness of 3/8 inch for the shell ID of 12-24 inch
can be satisfactorily used up to 300 psi of operating pressure.
Shell-to-bundle clearance (on diameter)
150
T
100
Clearance, mm
P and S
50
Fixed and U-tube

0
0 0.5 1.0 1.5 2.0 2.5
Shell diameter, m
Tube
• Tube OD of ¾ and 1‟ are very common to design a compact heat
exchanger.
• The tube thickness should be enough to withstand the internal

pressure along with the adequate corrosion allowance. The tube
thickness is expressed in terms of BWG (Birmingham Wire Gauge)
and true outside diameter (OD).
• The tube length of 6, 8, 12, 16, 20 and 24 ft are preferably used.

Longer tube reduces shell diameter at the expense of higher shell
pressure drop.
• Finned tubes are also used when fluid with low heat transfer
coefficient flows in the shell side.
• Stainless steel, admiralty brass, copper, bronze and alloys of copper-

nickel are the commonly used tube materials:
Tube Layouts
Tube Count & Tube Pass

Shell and Tube Heat Exchangers

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Shell-and-Tube Heat

• The principal components of an STHE are:

• Other components include tie-rods and spacers, pass

• U-Tube Heat Exchanger

Fixed tube-sheet exchanger (non-

• The simplest and cheapest type of shell and

• In this type of exchangers the tube sheet is

• Tube bundle may be removed for ease of

• Removable tube bundle exchangers further

• At the opposite end of the bundle, the tubes

• A floating head cover is bolted to the tube sheet

• Typically, 1 in tubes on a 1.25 in pitch or 0.75 in

• Letters given for the front end, shell and

Channel and removable cover Bonnet (integral cover)

One-pass shell Two-pass shell

Note, longitudinal baffles are difficult to seal with

Divided flow Cross flow

Fixed tube sheet

• L is a mirror of the A front end head

Pull through floating head Similar to T but with smaller shell/

Split backing ring

Outside packing to give Externally sealed floating tube sheet

• When the tube bundle employs baffles,

– the velocity of fluid fluctuates because of the constricted area between

• Baffle cuts from 15 to 45% are normally used.

• A baffle cut of 20 to 25% provide a good heat-transfer with the

• Thermal design of a shell and tube heat exchanger

• Shells are usually fabricated from standard steel pipe with

Fixed and U-tube

• The tube thickness should be enough to withstand the internal

• The tube length of 6, 8, 12, 16, 20 and 24 ft are preferably used.

• Stainless steel, admiralty brass, copper, bronze and alloys of copper-

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