Design and Fabrication of Shell and Tube Heat Exchanger for Practical

Applications
Abdulmumuni, B*, Adedeji, M.A and Ologunye, O.B
Department of Mechanical Engineering Technology, Federal Polytechnic Ede, Osun
State, Nigeria,
*-corresponding author email: masburk1245@gmail.com or maadedeji@fptb.edu.ng
+234-08065981684

Abstract
Shell-and-tubes heat exchanger of water and water type was designed using kern’s method.
This type of heat exchangers have special and practical applications in oil refining, chemical,
petro-chemical, power generation, boilers, oil coolers, condensers, pre-heaters etc. They are
also widely used in process applications as well as the refrigeration and air conditioning
industry. Some locally available and durable materials were used in the fabrication. Data
generated from theoretical formulae were used to fabricate a shell and tube heat exchanger
for practical applications. Primarily, this research was carried out in order to assist
engineering students to acquire necessary practical experience on heat transfer and energy
conversion being the most commonly found in industrial applications and to understand the
salient factors and parameters affecting heat transfer rates. The heat exchanger was tested
under various flow conditions using the insulations of cotton wool. The results obtained were
as follows: cold water inlet temperatures of (26, 27and 27) ºC increased to (59, 35 and 47) ºC
after (10, 8 and 9) minutes, respectively. On the hand, the hot water temperatures decreased
from (100, 73 and 87) ºC to (73, 50 and 62) ºC, respectively. The results obtained proved that
the heat exchanger is effective.

Keywords: Shell and tube heat exchanger, thermal analysis, heat transfer, energy
conversion

Paper presented at the 12th UNILAG Annual Research Conference and Fair (An International
Conference of the Humanities and Sciences). Scheduled for Jelili Omotola Halls, University
of Lagos, Akoka, Yaba, Lagos, Nigeria from Tuesday 15th to Thursday 17th August, 2017.
Nomenclature
Dimensions Abbreviations Units
0
Correction factor F C

Heat transfer rate Q KW

Heat transfer by cold water Qc KJ

Heat transfer by hot water QH KJ

0
Inlet temperature of hot water Thi C
0
Inlet temperature of cold water Tci C

Inside surface area of the tube Ai m2

Inside tube fouling resistance Ri m2ºC/W

Length of the tube Lt m

Mean velocity Vm m/s

Mass flow rate M Kg/s

0
Outlet temperature of hot water tho C
0
Outlet temperature of cold water tco C

Outside surface area of the tube A0 m2

Overall heat transfer coefficient U W/m2 0C

Pitch clearance L m

Pitch length Sn m

Radius of the tube R m

Shell inside diameter Ds m

Shell outside diameter D0 m

Shell –side heat transfer coefficient ho W/m2 0C

Specific heat capacity of the fluid CP J/kg0C

Surface area of the heat exchanger A m2

Tube pitch Pt m

Tube outside diameter d0 m

2
 Tube inside diameter di m

Total flow area available per pass At m2

Tube side heat transfer coefficient hi W/m2 0C

Thermal conductivity of the material K m2 0C/W

Thermal contact resistance Rc m2 0C/W

0
Total resistance R C/W

Tube sheet thickness Lts m

Thickness of the tube Ltw m

Thickness X m

Introduction
General background
Heat exchangers are devices basically used to facilitate the exchange of heat between two or
more fluids that are at different temperatures, while keeping them away from mixing with each
other. These devices are built up in such a way that they do not mix or the medium of mixture
can come in contact with each other. Heat exchangers are commonly used in wide range of
applications ranging from households, to chemical processing, power production, chemical
industries, food industries, electronics, environmental engineering, manufacturing industry,
and many others (Dubey et al., 2014). It comes in many types and function according to its
uses. So what exactly is heat exchanger? Heat exchanger is a device that is used to transfer
thermal energy between two or more fluids, between a solid surface and a fluid at different
temperatures and in thermal contact. There are usually no external heat and work interactions.
In most heat exchangers, heat transfer between fluids takes place through a separating wall or
into and out of a wall in a transient manner (Shah and Seculik, 2003). Heat Exchanger is a
device used for efficient heat transfer from one fluid to other fluid a typical heat exchanger is
shell and tube heat exchanger. They consist of series of finned tubes in which one of the fluid
runs in the tube and the other fluid run over the tube to be heated or cooled during the heat
exchanger operation, high pressure high temperature water or steam are flowing at high
velocity inside the tube or plate system. A heat exchanger utilizes the fact that, where ever there
is a temperature difference, flow of energy occurs (Adelaja et al., 2012). So, that heat will flow
from higher temperature heat reservoir to the lower temperature heat reservoir. The flowing

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fluids provide the necessary temperature difference and thus force the energy to flow between
them (GopiChand et al., 2012). The energy flowing in a heat exchanger may be either sensible
energy or latent heat of flowing fluids. The fluid which gives its energy is known as hot fluid
(Hari et al., 2013). The fluid which receives energy is known as cold fluid. It is but obvious
that, Temperature of hot fluid will decrease while the temperature of cold fluid will increase in
heat exchanger. The purpose of heat exchanger is either to heat or cool the desired fluid (Nitesh
and Basavaraj, 2015).

Materials and Methods

Manual Designing Using Kern’s Method
Shell and tube heat exchangers are designed normally by using either Kern’s method or Bell-
Delaware method. Kern’s method is mostly used for the preliminary design and provides
conservative results whereas; the Bell-Delaware method is more accurate method and can
provide detailed results. It can predict and estimate pressure drop and heat transfer coefficient
with better accuracy. In this study we have designed a simple counter flow shell and tube type
heat exchanger to heat the water from 26ºC to 59ºC by using water at room temperature by
using Kern’s method (Dubey, et al., 2014).

Design Methods
Shell and tube heat exchanger is designed by trial and error calculations (TEMA, 1988). The
main steps of design following the Kern’ method are summarized as follows:
Step 1
We obtained the required thermo-physical properties of hot and cold fluids at the caloric
temperature or arithmetic mean temperature and perform energy balance and to find out the
heat duty (Q) of the exchanger (Andre and Queiroz, 2008; Rajput, 2008; Hari Haran, et al.,
2013), Equation 1:
𝑄 = 𝑚ℎ 𝐶𝑃 (𝑇ℎ,𝑖 − 𝑇ℎ,𝑜 ) = 𝑚𝑐 𝐶𝑃 (𝑇𝑐,0 − 𝑇𝑐,𝑖 ) 1
Step 2
We assumed a reasonable value of overall heat transfer coefficient 𝑈𝑜 , assm. Determined the
LMTD and correction factor.
Calculating the long mean temperature difference (LMTD), Equation 2 was used:
(𝑡ℎ𝑖− 𝑡𝑐𝑜 )−(𝑡ℎ𝑜− 𝑡𝑐𝑖 )
∆𝑇𝑙𝑚 = (𝑡 𝑡𝑐𝑜 )
2
ln ℎ𝑖−
(𝑡ℎ𝑜− 𝑡𝑐𝑖 )

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Correction factor (F), Equation 3:
√𝑅2 + 1 1−𝑃
( ) ln( )
𝑅−1 1−𝑃𝑅
𝐹1−2 = 3
𝐴+√𝑅2 + 1
ln( )
𝐴−√𝑅2 + 1

Step 3
Decided type of shell and tube exchanger (fixed tube sheet, U-tube etc.). Selected the tube pitch
(PT), determined inside shell diameter (Ds).
𝑃
Tube pitch 𝑃𝑇 is chosen so that the pitch ratio is 1.25 < 𝑑𝑡 < 1.5
𝑜

𝐷𝑆 = 26.7𝑑0

Step 4
In calculating heat transfer area for shell (𝐴0 ) and tube (𝐴𝑡 ) required, Equations 4a and 4b were
used:
𝑄
𝐴0 = 𝑈 4a
0,𝑎𝑠𝑠𝑢𝑚 𝐹∆𝑇𝑙𝑚

𝑚ℎ
𝐴𝑡 = 4b
𝜌𝑉

Step 5
Selecting tube material, deciding the tube diameter (ID = 𝑑𝑖 ) and (OD = 𝑑𝑜 ), its wall thickness
in terms of BWG or SWG) and tube length (L). We calculated the number of tubes (𝑁𝑡 )
Number of tubes (𝑁𝑡 ), Equations 5a and 5b were consulted:
𝐴0
𝑁𝑡 = 5a
𝜋𝑑0 𝐿

𝐷0 = 𝐷𝑆 + 𝑋𝑖 + 2𝑋𝑠 5b
where: 𝐷𝑆 = Shell internal diameter = = 26.7𝑑0
𝑋𝑖 = Thickness of insulating materials
𝑋𝑆 = Thickness of the shell materials
Step 6
In determining the effectiveness of the heat exchanger (Ʃ), Equation 6a was used:
𝐶𝑚𝑎𝑥 (𝑇ℎ𝑖 −𝑇ℎ𝑜 )
Ʃ= 6a
𝐶𝑚𝑖𝑛 (𝑇ℎ𝑖 −𝑇𝑐𝑖 )

Thermal analysis calculations

 𝑚𝑐 = Mass flow rate of cold fluid
𝑚𝑐 = 0.3112𝑘𝑔/𝑠
 𝑚ℎ = Mass flow rate of hot fluid
𝑚ℎ = 0.3274𝑘𝑔/𝑠

5
  𝐶𝑃𝑐 = Specific heat capacity of cold fluid
𝐶𝑃𝑐 = 4.186 × 103 𝐽/𝑘𝑔0 𝐶
 𝐶𝑃ℎ = Specific heat capacity of hot fluid
𝐶𝑃ℎ = 4.186 × 103 𝐽/𝑘𝑔0 𝐶
 𝑇ℎ𝑖 = Inlet temperature of hot fluid
𝑇ℎ𝑖 = 1000 𝐶
 𝑇ℎ𝑜 = Outlet temperature of hot fluid
𝑇ℎ𝑜 = 650 𝐶
 𝑇𝑐𝑖 = Inlet temperature of cold fluid
𝑇𝑐𝑖 = 250 𝐶
 𝑇𝑐𝑜 = Outlet temperature of cold fluid
𝑇𝑐𝑜 = 61.80 𝐶
 𝜌 = Density of water
𝜌 = 968.1𝑘𝑔/𝑚3
 𝑈𝑜,𝑎𝑠𝑠𝑢𝑚 = Overall heat transfer coefficient
𝑈𝑜 , 𝑎𝑠𝑠𝑢𝑚 = 1220 𝑊/𝑚2 0 𝐶
 Q = Total heat transfer
Q = 𝑚𝑐 𝐶𝑃𝑐 ∆𝑇𝑙𝑚 6b
Q = Heat gain by the cold fluid = Heat loss by the hot fluid
Q = 𝑚𝑐 𝐶𝑃𝑐 ∆𝑇𝑙𝑚 = 𝑚ℎ 𝐶𝑃ℎ ∆𝑇𝑙𝑚 6c
0.3112 × 4.186 × 103 (𝑇𝑐,0 − 25) = 0.3274 × 4.186 × 103 (100 − 65)
1302.7(𝑡𝑐,0 − 25) = 47967.4
𝑇𝑐𝑜 = 36.822 + 25 = 61.80 𝐶
Q = 𝑚𝑐 𝐶𝑃𝑐 ∆𝑇𝑙𝑚 = 0.3112 × 4.186 × 103 (61.8 − 25) = 47.939 × 103 𝑊 = 47.939𝐾𝑊
Rate of heat transfer Q = 47.939𝐾𝑊
 Logarithmic mean temperature differences for counter flow heat exchanger (LMTD)
(𝑇ℎ𝑖− 𝑇𝑐𝑜 )−(𝑇ℎ𝑜− 𝑇𝑐𝑖 )
∆𝑇𝑙𝑚 = (𝑇 𝑇𝑐𝑜 )
6d
ln ℎ𝑖−
(𝑇ℎ𝑜− 𝑇𝑐𝑖 )

(100−61.8 )−(65−25)
= (100−61.8 )
ln (65−25)

= 440 𝐶
 Correction factor (F), Equation 6e:

6
 √𝑅2 + 1 1−𝑃
( ) ln( )
𝑅−1 1−𝑃𝑅
𝐹1−2 = 6e
𝐴+√𝑅2 + 1
ln( )
𝐴−√𝑅2 + 1

𝑇𝑐𝑜− 𝑇𝑐𝑖 61.8−25

𝑃= = = 0.49
𝑇ℎ𝑖 −𝑇𝑐𝑖 100−25
𝑇ℎ𝑖 −𝑇𝑐𝑖 100−25
𝑅= = = 0.95
𝑇𝑐𝑜− 𝑇𝑐𝑖 61.8−25
2
𝐴= − 1 − 𝑅 = 2.132
𝑃

√(0.95)2 + 1
1−0.49
( ) ln( )
0.95−1 1−0.49 ×0.95
𝐹1−2 = = 0.86
2.132+√(0.95)2 + 1
ln( )
2.132−√(0.95)2 + 1

 Area of shell (𝐴0 ), Equation 6f:

𝑄
𝐴0 = 𝑈 6f
0,𝑎𝑠𝑠𝑢𝑚 𝐹∆𝑇𝑙𝑚

47.939×103
= 1220 ×0.86 × 44

= 1.0390𝑚2
where: 𝑉 = 12.6 𝑚⁄𝑠, 𝜌 = 968.1𝑘𝑔/𝑚3 and 𝑚ℎ = 0.3274𝑘𝑔/𝑠
 Area of tube (𝐴𝑡 ), Equation 6g:
𝑚ℎ 0.3274
𝐴𝑡 = = 12198.06 = 0.000027𝑚2 6g
𝜌𝑉

 Number of tubes (𝑁𝑡 )

𝐴0
𝑁𝑡 = 𝜋𝑑0 𝐿

where: 𝑑0 = 0.009525𝑚 𝑎𝑛𝑑 𝐿 = 0.7𝑚

1.0390 1.0390
𝑁𝑡 = = = 49 𝑡𝑢𝑏𝑒𝑠
𝜋 × 0.009525 × 0.7 0.021

 Shell outside diameter (𝐷0 )

Shell outer diameter (D0) is given by Equation 6h:
𝐷0 = 𝐷𝑆 + 𝑋𝑖 + 2𝑋𝑠 6h
where: 𝐷𝑆 = Shell internal diameter = 26.7𝑑0 = 26.7× 0.009525 = 0.254m
𝑋𝑖 = Thickness of insulating materials = 0.025
𝑋𝑆 = Thickness of the shell materials = 0.0015
But: 𝐷0 = 0.254 + 0.025 + 2 × 0.0015 = 0.282𝑚
 Effectiveness of the heat exchanger, Equation 6i:
𝐶𝑚𝑎𝑥 (𝑇ℎ𝑖 −𝑇ℎ𝑜 )
Ʃ= 6i
𝐶𝑚𝑖𝑛 (𝑇ℎ𝑖 −𝑇𝑐𝑖 )

7
𝐶𝑚𝑎𝑥 = max of 𝐶ℎ or 𝐶𝑐 i.e. 𝐶𝑚𝑎𝑥 = 𝐶ℎ = 𝑚ℎ 𝐶𝑃ℎ = 0.3274 × 4.186 × 103 = 1370.5
𝐶𝑚𝑖𝑛 = min of 𝐶ℎ or 𝐶𝑐 i.e. 𝐶𝑚𝑖𝑛 = 𝐶𝑐 = 𝑚𝑐 𝐶𝑃𝑐 = 0.3112 × 4.186 × 103 = 1302.7
𝐶𝑚𝑎𝑥 (𝑇ℎ𝑖 −𝑇ℎ𝑜 ) 1370.5(100−65)
Ʃ= = = 0.491
𝐶𝑚𝑖𝑛 (𝑇ℎ𝑖 −𝑇𝑐𝑖 ) 1302.7(100−25)

Results and Discussions

After construction was completed, the system was then tested and the results showed that, the
cold water inlet temperature was at 260C and the hot water at 1000C reach the boiling point
after two hours. Then the fluids were allow to exchange heat within ten minutes, the final
temperature for the hot water was noted to decrease from 100ºC down to 730C and that of the
cold water increased from 26ºC to 590C. Another test carried out showed that, at 270C of water
at room temperature and 730C of hot water, the final temperature of the cold water increased
from initial temperature of 26ºC to 350C while that of hot water decreased to 500C within eight
minutes. The last was conducted the hot water decreased from 87°C to 62°C while that of the
cold water increased from 27°C to 47°C (Nitesh and Basavaraj, 2015; Dubey, et al., 2014).
Table 1, illustrates the results obtained from the three test carried out on the heat exchanger. Degree of
cooling fluctuated from 27°C to 25°C while the degree of heating from 33°C to 20°C. Fluctuations
could linked so many factors ranging from effect of the lagging material, ambient temperature etc.
(Jayachandriah and Rajsekhar K., 2012; Kothandaraman and Subramanyan S., 2007; Shravan
et al., 2010).
Table 1: Results of the heat exchanger
S/N Hot Hot Cold water Cold Degree of Degree of Effectiveness of Heat
water water water exchanger
Inlet (OC) cooling heating
Inlet outlet outlet (OC) (OC)
(OC) (OC) (OC)

1 100 73 26 59 27 33 0.36486

2 73 50 27 35 23 08 0.50000

3 87 62 27 47 25 20 0.41667

Figures 1 and 2 displayed the relationship between degree of cooling and heating and
effectiveness of the heat exchanger (Dubey, et al., 2014).

8
 30 35
Degree of cooling(°C)/
Level of effectiveness

Degree of heeating(°C)/
Level of effectiveness
25 30
20 25
15 Degree of 20 Degree of
cooling (°C) 15 heating (°C)
10
10
5 Effectiveness of Effectiveness of
Heat exchanger 5 Heat exchanger
0 0
1 2 3 4 1 2 3 4
Number of tests Number of tests

Fig. 1: Relationship between degree of cooling and effectiveness Fig. 2: Relationship between degree of heating and effectiveness

Plate 1 is the pictorial view of the fabricated heat exchanger.

Plate 1: Shell and Tube Heat Exchanger front view

Conclusions and Recommendations

Conclusions
In conclusion, we noticed that the degree of heating and degree of cooling of the
hot water and the heating of the cold water, respectively, are found to be unequal
in each and every recording, which is contrary to what is assumed in the
assumptions of the derivation of heat exchanger’s effectiveness which can be
attributed many factors beyond the scope of this study. Hence the expression of
effectiveness also needs some improvements.
Recommendations
1. More tests is recommended using different fluids apart from water.

9
 2. Different materials used instead of mild steel with different lagging materials
3. Different range of temperatures adopted.
4. To construct and test heat exchanger under various flow conditions using the insulations
of aluminium foil, tape, foam, paper etc.

REFERENCES

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