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\
|
A
A
A A
= = A
2
1
2 1
ln
T
T
T T
LMTD T
LM
Effectiveness-NTU Method
In the thermal analysis of shell-and-tube heat exchangers by the LMTD method, an equation
(3.1) has been used. This equation is simple and can be used when all the terminal temperatures are
known. The difficulty arises if the temperatures of the fluids leaving the exchanger are not known. In
such cases, it is preferably to utilize an altogether different method known as the effectiveness-NTU
method. Effectiveness of shell-and-tube heat exchanger is defined as:
( )
( )
( )
( )
Ti Si
Ti To T
Ti Si
So Si S
T T C
T T C
T T C
T T C
=
min min
c
The group
min
C
UA
is called number of transfer units, NTU.
Effectiveness for shell-and-tube heat exchanger can also be expressed as:
|
|
.
|
\
|
=
max
min
min
,
C
C
C
UA
c c
Where
S
T
T
S
C
C
or
C
C
C
C
=
max
min
(depending upon their relative magnitudes).
Kays and London have given expressions for shell-and-tube heat exchangers. Some of their
relationships for effectiveness are given below:
For one shell pass, 2, 4, 6 tube passes
|
.
|
\
|
+ +
(
|
.
|
\
|
+ + +
+ + + =
2
min
2
min
2
min min 1
1 1 exp 1
1 1 exp 1
1 1 2
C NTU
C NTU
C C c
For two shell pass, any multiple of 4 tubes
1
min
2
1
min 1
2
1
min 1
2
1
1
1
1
1
(
(
|
|
.
|
\
|
(
(
|
|
.
|
\
|
= C
C C
c
c
c
c
c
It is essential that the designer of shell-and-tube heat exchangers becomes familiar with the
principles of the various correlations and methods in numerous publications, their advantages and
disadvantages, limitations and degrees of sophistication versus probable accuracy and other related
aspects. All the published methods can be logically divided into several groups:
1. The early developments based on flow over ideal tube banks or even single tubes.
2. The integral approach, which recognizes baffled cross flow modified by the presence of
window, but treats the problem on an overall basis without considerations of the modified effects
of leakage and bypass.
3. The analytical approach based on Tinkers multistream model and his simplified method.
4. The stream analysis method, which utilizes a rigorous reiterative approach based on Tinkers
model.
5. The Delaware method, which uses the principles of the Tinkers model but interprets them on an
overall basis, that is, without reiterations.
6. Numerical prediction methods.
LITERATURE REVIEW
Detailed design of shell-and-tube heat exchanger generally proceeds through the testing of a range of
potential exchanger geometries in order to find those that satisfy three major design objectives:
1. Transfer of required heat duty
2. Specified cold side pressure drop
3. Specified hot side pressure drop
The allowable pressure drops determine the operating cost of heat exchanger in the process; they also
determine the capital requirement of the installed heat exchanger surface area.
Different authors have long recognized the importance of considering pressure drops during heat
exchanger analysis.
MCADAMS [1] was one of the earliest workers to quantitatively demonstrate this. Analysis was simple
and based on tubular heat exchanger. By taking into account the cost of power and fixed cost of the
exchanger, per unit heat transferred, simple expressions for estimating the optimum mass velocities for
both inside tubes and outside tube fluids are developed. However, his equations are deriving on the basis
that each side of the exchanger can be treating independently of the other. It is assume that the streams
do not interact and the effect of opposing resistance is neglecting. This is an erroneous assumption.
JENSSEN [2] in an attempt to provide a quickly and general method for estimating the economic
power consumption in plate exchangers introduced the so-called J parameter (i.e. the specific pressure
drop per heat transfer unit parameter). He produced graphs showing economic optimum based on the
assumption that the streams on the either side the exchanger have the same flow rates and the same
physical properties. The use of such graphs in design only requires the knowledge of the ratio of the
capital cost influence to the power cost influence. The capital cost influence is given as the annual
investment increment for added unit heating surface area. The power cost influence is the annual unit
power cost. One major weakness in this work that has perhaps limited its practical application is the
assumption that the streams have identical fluid properties and identical geometries. These are highly
limiting assumptions. While the method may apply under restricted conditions to plate exchangers, its
extension to shell-and-tube heat exchangers appears too far from straightforward.
KEVIN M. LUNSFORD [3], Bryan Research & Engineering, his analyzing some methods for
increasing shell-and-tube exchanger performance. The methods consider whether the exchanger is
performing correctly to begin with, excess pressure drop capacity in existing exchangers, the re-
evaluation of fouling factors and their effect on exchanger calculations, and the use of augmented
surfaces and enhanced heat transfer. Three examples are provided to show how commercial process
simulation programs and shell-and-tube exchanger rating programs may be used to evaluate these
exchanger performance issues. The last example shows how novel heat transfer enhancement can be
evaluated using basic shell-and-tube exchanger rating calculations along with vendor supplied
enhancement factors.
V.HARI HARAN, G.RAVINDRA REDDY AND B.SREEHARI [4] (ISSN: 2231-2803)
In this paper, a simplified model for the study of thermal analysis of shell-and tubes heat exchangers of
water and oil type is proposed. Shell and Tube heat exchangers are having special importance in boilers,
oil coolers, condensers, pre-heaters. They are also widely used in process applications as well as the
refrigeration and air conditioning industry. The robustness and medium weighted shape of Shell and
Tube heat exchangers make them well suited for high pressure operations. In this paper we have shown
how to done the thermal analysis by using theoretical formulae for this we have chosen a practical
problem of counter flow shell and tube heat exchanger of water and oil type, by using the data that come
from theoretical formulae we have design a model of shell and tube heat exchanger using Pro-e and
done the thermal analysis by using ANSYS software and comparing the result that obtained from
ANSYS software and theoretical formulae. For simplification of theoretical calculations we have also
done a C code which is useful for calculating the thermal analysis of a counter flow of water-oil type
shell and tube heat exchanger.
NENAD RADOJKOVI, GRADIMIR ILI, ARKO STEVANOVI [5]
Experimental investigations were done to identify influence of thermal and flow quantities and shell side
geometry on STHE's heat exchange intensity. In this paper special attention was paid to segmental baffle
cut influence on apparatus efficiency.
METHODOLOGY
DESIGN OPTIMIZE
ESTABLISHMENT
ANALYSE
BACKGROUND
STUDY
Y
E
S
INCREASING
PERFORMANCE NO
A plan for increasing heat exchanger performance for shell and tube exchangers should consider
the following steps.
Determine that the exchanger is operating
correctly as designed. Correcting flaws in
construction and piping that may have a
detrimental effect on heat transfer and
pressure drop may be the solution
Estimate how much pressure drop is available.
For single phase heat transfer coefficients,
higher fluid velocity increases heat transfer
coefficients and pressure drop.
Estimate fouling factors that are not overstated.
Excessive fouling factors at the design state
result in oversized exchangers with low
velocities. These low velocities may exacerbate
the fouling problem. More liberal fouling
factors and periodic cleaning may increase the
heat exchangers performance.
Consider using a basic shell-and-tube exchanger
with enhancement or intensification such as
finning, tube inserts, modified tubes, or
modified baffles
One simple and obvious solution for increasing shell-and-tube heat exchanger performance
might be to switch the shell-and-tube fluids. The placement of the process fluids on the tube or shell
side is usually not dependent on the most efficient heat transfer area. A primary concern is pressure.
High-pressure fluids tend to be placed in the tubes rather than the shell, resulting in less construction
material and a less expensive exchanger. Handling phase changes may dictate where fluids are placed.
Switching the tube-and-shell side process streams may only be valid if the process streams have no
phase change and are approximately the same pressure.
For the first three steps, engineers can use operating data and commercial software with shell-
and-tube exchanger rating packages to perform the calculations and predict the resulting changes. For
the fourth criteria, engineers can use software programs for the base calculation but must obtain
additional information to account for the increases in film coefficients for a particular type of
enhancement.
The design process of shell-and-tube heat exchanger proceeds through the following steps:
Design and optimization algorithm is developed for shell-and-tube heat exchanger. A solution of core
velocity equation is a heart of such an algorithm.
Process conditions (stream compositions, flow rates,
temperatures, and pressures) must be specified.
The type of heat exchanger to be employed is chosen.
A preliminary estimate of the size of the exchanger is
made, using a heat transfer coefficient appropriate to
the fluids, the process, and the equipment.
A first design is chosen; complete in all details necessary
to carry out the design calculations