SHELL AND TUBE HEAT EXCHANGER

Aditya Singhal, Kuldeep Danewa, Maheshwari Rajat Ajit, Mala Ram, Manoj Kumar.


Mechanical Engineering Deptt. Swami Keshvanand Institute, Jaipur, Rajasthan, India

ABSTRACT

Shell and tube heat exchanger in their various construct modifications are probably the most
spread and commonly used heat exchanger configuration in the process industries. The
reasons for this generally acceptance are several. The shell and tube heat exchanger provides
a comparatively large ration of heat transfer area to volume and weight. It provides the
surface in the form which relatively easy to constructs in wide ranges of sizes and which is
mechanically rugged enough to with stand normal shop fabrication stresses, shipping and
field erection stresses and normal operating conditions. The shell and tube exchanger can be
reasonably easily cleaned, and those components most subject to failure gaskets and tube can
be easily replaced.
Two fluids, of different starting temperatures, flow through heat exchanger. One flows
through the tubes (tube side) and the other flows outside the tubes. Heat is transferred from
one fluid to the other through the tube walls, either from tube side to shell side or vice-versa.
The fluid can be either liquids or gases on either the shell or the tube side .In order to transfer
heat efficiently the large heat transfer area should be used, leading to the use of many tubes.
In this way, waste heat can be put to use. This is an efficient way to conserve energy.
INTRODUCTION

Shell and tube heat exchangers consist of a series of tubes. One set of these tubes contains the
fluid that must be either heated or cooled. The second fluid runs over the tubes that are being
heated or cooled so that it can either provide the heat or absorb the heat required. A set of
tubes is called the tube bundle and can be made up of several types of tubes: plain,
longitudinally finned, etc.
Shell and tube heat exchangers in their various construction modifications are probably the
most widespread and commonly used basic heat exchanger configuration in the process
industries. The reasons for this general acceptance are several. The shell and tube heat
exchanger provides a comparatively large ratio of heat transfer area to volume and weight. It
provides this surface in a form which is relatively easy to construct in a wide range of sizes
and which is mechanically rugged enough to withstand normal shop fabrication stresses,
shipping and field erection stresses, and normal operating conditions. There are many
modifications of the basic configuration, which can be used to solve special problems. The
shell and tube exchanger can be reasonably easily cleaned, and those components most
subject to failure - gaskets and tubes can be easily replaced.



WORKING PRINCIPLE OF SHELL AND TUBE HEAT EXCHANGER

1. First of all fill the water in the bucket and then heat it with the help of immersion heater
2. Note down the temperature.
3. Then connect the shell with the tap from where the cold water is filled in it.
4. Note down the temperature of the cold water inlet.
5. After that make the hot water flow through the copper tube.
6. There occurs the heat exchange between them.
7. Note down the outlet temperature of hot and cold water.
It works on the principle of process of heat exchange taking between different fluids. It finds
application where high pressure is required.
There are two primary classifications of heat exchanges according to their flow arrangement.
Parallel flow- in the parallel flow heat exchanger, the two fluids enter the exchanger at the
same en, and travel in parallel to one another to the other side.
Counter flow- in this type of heat exchanger the fluid enter the exchanger from opposite ends.
The counter current design is most efficient, in that it can transfer the most heat medium. See
countercurrent exchange. In across flow heat exchanger, the fluid travel roughly
perpendicularly to one another through the exchanger.



(i) (ii) (iii)
I. SHELL AND TUBE HEAT EXCHANGER, SINGLE PASS (1-1 PARALLEL
FLOW)
II. SHELL AND TUBE HEAT EXCHANGER, 2-PASS TUBE SIDE (1-2
CROSSFLOW PARALLEL FLOW)
III. SHELL AND TUBE HEAT EXCHANGER, 2-PASS SHELL SIDE, 2-PASS TUBE
SIDE (2-2 COUNTERCURRENT)



DESIGN OF STUDY

A large number of input process parameters can be varied in the Heat Exchanging process,
each having its own impact on output parameters such as Temperature variation, Flow
Rate, and mass of water, effectiveness, no of transfer units. Various components included
in this process are:
a. Shell
b. Tube
c. Baffles
d. Insulators
e. Heating rod
f. Temperature Indicator
g. Pipe
h. Water Tank

It is also known from the previous research works that out of the above listed components,
four components i.e. tubes, water tank and shell affect the effectiveness of shell and tube
heat exchanger. Out of these components, three components have been investigated
thoroughly in this research work.

EXPERIMENTAL DESIGN

The design components used for this experimental work is as follows:

Shell
Shell is the major part of the heat exchanger. The selection of material is one of the basic
problems in this. We have to select the material which is non-corrosive and can sustain in all
the condition for this we have select steel which is highly non-corrosive and will not corrode
if used with different liquids used in industries and can also be used with coating of zinc to
prevent from corrosion. Shell has been prepared of stainless steel with dimension 20x12x12
inch. Shell has been prepared by welding stainless steel sheets.


Tubes
The tubes are the basic components of the shell and tube exchanger, providing the heat
transfer surface between one fluid flowing inside the tube and the other fluid flowing across
the outside of the tubes. The tubes may be seamless or welded and most commonly made of
copper or steel alloys. Other alloys of nickel, titanium, or aluminum may also be required for
specific applications


Baffles
Baffles serve two functions: Most importantly, they support the tubes in the proper position
during assembly and operation and prevent vibration of the tubes caused by flow-induced
eddies, and secondly, they guide the shell-side flow back and forth across the tube field,
increasing the velocity and the heat transfer coefficient

Temperature Indicator
Thermocouple are used to measure of cold water inlet, cold water outlet, hot water inlet, hot
water outlet. Thermocouples are attached with wires which lead to temperature indicator
where temperature is indicated digitally.






RESULTS AND DISCUSSIONS

The Number of Transfer Units (NTU) Method is used to calculate the rate of heat
transfer in heat exchangers (especially counter current exchangers) when there is insufficient
information to calculate the Log-Mean Temperature Difference (LMTD). In heat exchanger
analysis, if the fluid inlet and outlet temperatures are specified or can be determined by
simple energy balance, the LMTD method can be used; but when these temperatures are not
available The NTU or The Effectiveness method is used.
To define the effectiveness of a heat exchanger we need to find the maximum possible heat
transfer that can be hypothetically achieved in a counter-flow heat exchanger of infinite
length. Therefore one fluid will experience the maximum possible temperature difference,
which is the difference of t
h1
-t
c1
(The temperature difference between the inlet temperature of
the hot stream and the inlet temperature of the cold stream). The method proceeds by
calculating the heat capacity rates (i.e. mass flow rate multiplied by specific
heat) C
h
and C
c
for the hot and cold fluids respectively, and denoting the smaller one as C
min
.
The reason for selecting smaller heat capacity rate is to include maximum feasible heat
transfer among the working fluids during calculation.

Where q
max
is the maximum heat that could be transferred between the fluids. According to
the above equation, to experience the maximum heat transfer the heat capacity should be
minimized since we are using the maximum possible temperature difference. This justifies
the use of C
min
in the equation.

The effectiveness (E), is the ratio between the actual heat transfer rate and the maximum
possible heat transfer rate:

Effectiveness is dimensionless quantity between 0 and 1. If we know E for a particular heat
exchanger, and we know the inlet conditions of the two flow streams we can calculate the
amount of heat being transferred between the fluids by:

For any heat exchanger it can be shown that:

For a given geometry, E can be calculated using correlations in terms of the "heat capacity
ratio"

and the number of transfer units, NTU

Where U is the overall heat transfer coefficient and A is the heat transfer area.
For example, the effectiveness of a parallel flow heat exchanger is calculated with:

Or the effectiveness of a counter-current flow heat exchanger is calculated with:

For C
r
=1

Similar effectiveness relationships can be derived for concentric tube heat exchangers and
shell and tube heat exchangers. These relationships are differentiated from one another
depending on the type of the flow (counter-current, concurrent, or cross flow), the number of
passes (in shell and tube exchangers) and whether a flow stream is mixed or unmixed.
Note that the C
r
=0 is a special case in which phase change condensation or evaporation is
occurring in the heat exchanger. Hence in this special case the heat exchanger behavior is
independent of the flow arrangement. Therefore the effectiveness is given by:


OBSERVATIONS TABLE AND CALCULATION
S.NO Hot
Water
Temperature Cold
Water
Temperature
1
=t
h1
-t
c1

2
=t
h2
-t
c2

1
-
2

t
h1
t
h2
t
c1
t
c2

1. 70 51 30 43 40 12 28
2. 80 62 35 46 45 16 29
3. 90 73 40 56 50 17 33

t
h1
t
h2
t
c1
t
c2

1

2

1
-
2

80 62 35 46 45 16 29

m
= 28.04c
Mass flow rate for hot fluid=
m
h
= 600 kg/hr
Mass flow rate for cold fluid=
m
c
= 1500 kg/hr
Heat Exchange
= m
h
c
h
(th1-th2)
Log-rithmic mean temperature difference

Overall heat transfer coefficient
1/u =1/h
h
+ 1/h
c

Heat convective coefficient for water=h
h
=h
c
=1600
Heat exchange = q=UA
m

Heat surface area= A =q/U
m

In terms of NTU

the number of transfer units, NTU

q = m
h
c
h
(t
h1
-t
h2
)= 12540J/sec

1/u =1/h
h
+ 1/h
c
=1/1600 + 1/1600 = 1/800
Overall heat transfer coefficient= 800 W/m
2
K
Heat exchange = q = UA
m

Heating surface area= A= q/U
m
= 12540/800(28.04)
= 0.539m
2
Effective NTU Approach
Thermal capacity rates of hot and cold fluid are
C
h
= m
h
c
h
=(600/3600)*4180= 696.67 W/k
C
c
= m
c
c
c
= (1500/3600)*4180= 1741.67 W/k
C
max
= C
c
=1741.67 W/k
C
min
=696.67 W/k
Capacity ratio=

=696.67/1741.67 = 0.4
Effectiveness = E= (t
h1
-t
h2
)/(t
h1
-t
c1
)=(80-62)/(80-35)=0.4

0.4 =1-exp[-NTU(1+C)]
1+0.4
NTU= 0.580
NTU= UA/C
min

0.586=(800*A)/696.67= 0.510m
2


Conclusion
In the project we have gained complete knowledge about Heat Exchanger as well as its
effectiveness and also the advancements we can do further to help the industries and a human
being to give more benefits. During the whole process of fabrication we have learnt how to
work in a team.
We have done this project because we could analyze it financially . Sometimes this project
cost us very high and gives us very low efficiency . So we tried to focus on the purpose that
that our project is the working prototype of the commercial type shell and tube heat
exchanger.
We found that if we invest more money we could increase its efficiency and effectiveness
This is possible by increasing its heat transfer area . This heat transfer area could be increased
by fin. Therefore sometimes we are recommended to use plate and fin type heat exchanger.
Above mentioned calculation shows that LMTD approach gives more heat transfer area than
NTU approach. So we should use LMTD method for heat transfer area calculation and for the
size of heat exchanger.







REFERENCES

1. E.A.D.Saunders (1988). Heat Exchangers: Selection Design And Construction Longman
Scientific and Technical I
2. Kay J M & Nedderman R M (1985) Fluid Mechanics and Transfer Processes, Cambridge
University Press
3. Coulson, J. and Richardson, J (1999). Chemical Engineering- Fluid Flow. Heat Transfer and
Mass Transfer- Volume 1; Reed Educational & Professional Publishing LTD
4. Dogan Eryener (2005), Thermo economic optimization of baffle spacing for shell and tube
heat exchangers, Energy Conservation and Management, Volume 47, Issue 1112, Pages 1478
1489.
5. G.F.Hewitt, G.L.Shires, T.R.Bott (1994)Process Heat Transfer, CRC Press, Inc, United States
Of America.
6. Randall, David J.; Warren W. Burggren; Kathleen French; Roger Eckert (2002). Eckert animal
physiology: mechanisms and adaptations. Macmillan. p. 587.
7. Kister, Henry Z. (1992). Distillation Design (1st ed.). McGraw-Hill.