Applied Thermal Engineering 29 (2009) 24332438

Contents lists available at ScienceDirect

Applied Thermal Engineering

journal homepage: www.elsevier.com/locate/apthermeng

An experimental investigation of heat transfer enhancement

for a shell-and-tube heat exchanger
Simin Wang, Jian Wen *, Yanzhong Li
Department of Refrigeration and Cryogenics Engineering, School of Energy and Power Engineering, Xian Jiaotong University, Xian, Shaan xi 710049, China

a r t i c l e i n f o a b s t r a c t

Article history: For the purpose of heat transfer enhancement, the conguration of a shell-and-tube heat exchanger was
Received 6 June 2008 improved through the installation of sealers in the shell-side. The gaps between the bafe plates and shell
Accepted 15 December 2008 is blocked by the sealers, which effectively decreases the short-circuit ow in the shell-side. The results of
Available online 24 December 2008
heat transfer experiments show that the shell-side heat transfer coefcient of the improved heat exchan-
ger increased by 18.225.5%, the overall coefcient of heat transfer increased by 15.619.7%, and the
Keywords: exergy efciency increased by 12.914.1%. Pressure losses increased by 44.648.8% with the sealer instal-
Shell-and-tube heat exchanger
lation, but the increment of required pump power can be neglected compared with the increment of heat
Sealer
Bafe-shell leakage ow
ux. The heat transfer performance of the improved heat exchanger is intensied, which is an obvious
Heat transfer enhancement benet to the optimizing of heat exchanger design for energy conservation.
2008 Elsevier Ltd. All rights reserved.

1. Introduction heat exchanger tubing linear footage by 2575% compared with

Shell-and-tube heat exchangers are commonly used in petro-
chemical and energy industries for their relatively simple manu-
facture and adaptability to different operating conditions.
Although not the most compact solution, their robustness and
shape make them well suitable for high-pressure operations [1].
The bafes are primarily used in shell-and-tube heat exchangers
for inducing cross ow over the tubes, and as a result, improving
heat transfer performance. In practice this objective is not quite
achieved due to departure from cross ow and due to several leak-
ages and bypass stream.
Pressure drop and heat transfer are interdependent and both of
them essentially inuence the capital and operating costs of any heat
exchange system. The design and optimization of shell-and-tube
heat exchangers including thermodynamic and uid dynamic de-
sign, strength calculations, cost estimation represents a complex
process containing an integrated whole of design rules, calculating
methods and empirical knowledge of various elds [2]. The optimi-
zation of shell-and-tube heat exchangers requires a good knowledge
of the local and average shell-side heat transfer coefcients. In the
past few years there were realized several developments to improve
the thermal effectiveness of shell-and-tube heat exchangers. New
types of tube-side turbulence promoters (e.g. tube inserts, corru-
gated tubes) and tube supports (e.g. helical bafes) have been suc-
cessfully introduced. Thome et al. [3] put forward that the proper
application of tubular heat transfer augmentations is able to reduce
* Corresponding author. Fax: +86 29 82668725.
E-mail address: jianwen@mail.xjtu.edu.cn (J. Wen).
conventional plain tube units. Hosseini et al. [4] experimentally
investigated the effect of different types of external tube surfaces
on shell-side heat transfer coefcient and pressure drop of a shell-
and-tube heat exchanger. The results showed that the performance
of the heat exchanger greatly improved for micro-nned tubes at a
higher Reynolds number. Another feature of optimization is to select
the optimum inter-bafe spacing. Li et al. [5] found that the in-
creased bafe spacing can increase the heat transfer coefcient in
the whole bafe. The local heat transfer coefcient distribution at
an individual tube is slightly affected by the bafe spacing. Taborek
et al. [6] suggested that the space between the bafes could vary be-
tween a minimum of 20% of shell diameter and a maximum equal to
the shell diameter. Mukherjee et al. [7] pointed out that the optimum
bafe spacing normally ranges from 0.3 to 0.6 times the shell diam-
eter. Saffar-Avval et al. [8] have studied the effect of bafe spacing on
heat transfer area and pressure drop, and conclude that the bafe
spacing has a decisive effect on pumping power and noticeable effect
on required heat transfer area, where a guideline has been also
developed to calculate the optimum bafe spacing for single phase
E-type shell-and-tube heat exchanger. In a recent study, Eryener
et al. [9] analyzed the optimum ratio of bafe spacing to shell diam-
eter by applying the thermoeconomic analysis method. Although all
these investigations are able to improve the performance of the heat
exchanger to some extent, the results are not so obvious.
There are also a few researchers who have studied the effect of
leakage ow on thermal performance of shell-and-tube heat
exchangers. Roetzel and Lee [10] experimentally investigated the
leakage ow in shell-and-tube heat exchangers with segmental baf-
es. They found that the shell-bafe leakage has great inuence on

1359-4311/$ - see front matter 2008 Elsevier Ltd. All rights reserved.
doi:10.1016/j.applthermaleng.2008.12.008
2434 S. Wang et al. / Applied Thermal Engineering 29 (2009) 24332438
Nomenclature
Cp average specic heat capacity at constant
pressure (kJ/(kg K))
di internal diameter of tubes (mm)
do external diameter of tubes (mm)
E exergy (kJ/s)
Egain gained exergy (kJ/s)
Epay consumed exergy (kJ/s)
h enthalpy (kJ/kg)
Ne pump power consumption (W)
K overall coefcient of heat transfer
(W/m2 K)
Q total heat transfer in the heat exchanger
(kJ/s)
Re Reynolds number
Ri water-side fouling resistance (m2 K/W)
Ro oil-side fouling resistance (m2 K/W)
Ta air temperature (K)
U velocity (m/s)
V shell-side volume ow (m3/s)
W mass velocity (kg/s)
the apparent overall heat transfer coefcient, which is based on the
ideal plug ow model. This reduction will be even greater when the
tube-side Reynolds number increases. Roetzel and Lee [11] studied
experimentally the inuence of bafe-shell leakage ow on the
thermal performance in bafed shell-and-tube heat exchangers
with different distances between bafes. The results have shown
that bafe-shell leakage ow causes a reduction in the thermal per-
formance. This reduction increases as the tube-side Reynolds num-
ber increases, and the distance between bafes decreases. Li and
Kottke [12] performed experiments to determine the response of
the pressure drop and local heat transfer on the shell-side of shell-
and-tube heat exchangers to a change in the leakage between bafes
and shell in the fully developed regime. They found that the leakage
between bafes and shell can greatly reduce the pressure drop and
the per-compartment average heat transfer coefcient. They found
that bafe-shell leakage reduces greatly the heat transfer by 17
21% among their experimental Reynolds range.
All the above research results demonstrate that the bafe-shell
leakage is negative for the improvement of the heat transfer in
shell-and-tube heat exchangers. However, there is still an apparent
lack of literature on the topic of conguration improvements of
shell-and-tube heat exchangers to decrease the leakage ow. For
manufacturing reasons, the internal diameter of the shell is always
bigger than the external diameter of tube bundle for the successful
installation. So according to the GB151 national standards of China,
there is always a circular gap of around 37 mm between the shell
and tube bundle for the shell-and-tube heat exchangers with diam-
eter between 400 and 2000 mm. And with the development of larger
heat exchangers, the gap will increase accordingly. A part of the uid
in the shell will ow through the gap and does not participate into
heat exchange, thus diminishing thermal performance of the heat
exchangers. Hence experimental investigation is performed in this
paper to effectively decrease the shell-bafe leakage ow through
the conguration improvement of shell-and-tube heat exchanger.
2. Conguration improvement
2.1. Flow mode of conventional heat exchanger
The ow modes of the conventional shell-and-tube heat
exchangers are demonstrated in Fig. 1. There are three types of
Greek symbols
a0 oil-side heat transfer coefcient (W/m2 K)
ai water-side heat transfer coefcient (W/m2 K)
d tube thickness (mm)
D error
DP shell-side pressure drop (mmHg)
DT temperature change from inlet to outlet in the exchan-
ger (K)
DTm logarithmic mean temperature difference (K)
k heat conduction coefcient of tubes (W/m K)
gex exergy coefcient of heat exchanger
Subscripts
c cold uid
ex exergy
h hot uid
o oil
w water
1 inlet
2 outlet
ow modes in the shell. A is cross ow of uid through the tube
bundle. B is the ow through the gaps of segmental bafes and C
is the shell-bafe leakage ow (short-circuit ow).
2.2. Flow mode of improved heat exchanger
The so called conguration improvement is to install sealers on
each bafe in order to block the bafe-shell gap. The ow distribu-
tion for bafed shell-side ow of improved heat exchanger is
shown in Fig. 2. There are only two kinds of ow modes (A and
B) after the installation of sealers. The ow mode of C is prevented,
and this part of uid is forced to join modes A and B to participate
in heat exchange.
As to the shell-and-tube heat exchanger AES300-2.5-10-3/25-2
used in the experiment, the cross-sectional area of the bafe-shell
gap (circular ow passage) engages about 1/6 of the total ow area
in shell-side. At the same pressure head, the ux inside two ow
passages relates to not only the ow area but also the resistance in-
side the ow passages. The circular ow passage through the gap is
short and straight, which causes little resistance. While the ow
passage within the tube bundle is Z-shaped and long, which results
in more resistance. Thus the unit area ux in the short-circuit ow
passage is larger than that of the other one. So the sealers may
block more than 1/6 of all the ux in the shell. The effect of the
bafe-shell leakage ow on the thermal performance cannot be
C C
B
A A
C C
Fig. 1. Schematic ow distribution for bafed shell-side ow of conventional heat
exchanger.
 S. Wang et al. / Applied Thermal Engineering 29 (2009) 24332438
Sealer B Sealer
A A
Sealer
Fig. 2. Schematic ow distribution for bafed shell-side ow of improved heat
exchanger.
neglected. It is necessary to improve the conguration of shell-
and-tube heat exchangers to block the leakage ow.
3. Experimental setup
Fig. 3 shows the schematic drawing of experimental system,
which consists of water loop system, oil loop system and data
acquisition system. The arrangement of them is also illustrated in
the diagram. Water is supplied into tube-side by a pump. Oil is
heated by an electric heater and ows to the shell-side as hot uid.
The experiment is performed under the same operating conditions
for one heat exchanger with the changeable tube bundle. One is
conventional tube bundle and the other is improved with sealers,
namely conventional heat exchanger and improved, separately.
The data acquisition system consists of sensors, acquisition board,
acquisition program and PC. The effect of the sealers on the pres-
sure drop and thermal performance of the heat exchanger are then
analysed.
3.1. Experimental apparatus
Two QB-100 centrifugal pumps are used in the experiment. One
is for water and the other is for oil. There are two tanks made in-
house, one is for oil with capacity of 20 m3 and the other is for
water with capacity of 40 m3. Gear oil gauge XB-630 is used for
1. Oil pump, 2. Gear oil gauge, 3. Heat exchanger, 4. Temperature transducer,
5. Rotermeter, 6. Water tank, 7. Water pump, 8. Differential gauge, 9. Oil tank
Fig. 3. Schematic arrangement of experimental setup.
2435
measuring the oil ux, whose measurement error is less than
1.0%. A rotermeter LZB-100 is used for measuring water ux,
whose measurement error is less than 2.0%. The pressure drop is
measured by U-shaped tube and water is adopted as the working
uid. The minimum scale of the U-shaped tube is 1 mm. Within
the measurement range, the measurement error of pressure drop
is less than 1.0%.
Temperature is measured by copper-constantan thermocou-
ples. Although all of the thermocouples are calibrated (Fig. 4), mea-
surement errors still exist for their intrinsic property and
discrepancy during manufacturing process, which are as follows:
(1) D1, error caused by thermoelectric non-uniformity of the
thermocouples. There are variations between electric potential
and temperature which is mainly caused by the non-uniformity
of chemical composition during manufacture of thermocouples.
The error of electric potential , caused by thermoelectric non-uni-
formity is 1.2 lV. The electric potential is 39.1 lV per degree (C)
between 0 and 70 C. There are about 99.7% experimental results
located within l 3r according to mathematic statistics. The max-
imum error of electric potential is 3.6 lV, that is D1 = 0.092 C.
(2) D2, error caused by non-linearity of the calibration curve
(Fig. 4). The relationship between electric potential (E, lV)and
temperature of copper-constantan thermocouples can be ex-
P
pressed as a polynomial expression (E Ni0 bi ti ) within 200 to
200 C. Commonly, the measurement precision can be guaranteed
by using a binomial or trinomial. The thermocouples selected in
the experiment were calibrated and denoted as a binomial. Accord-
ing to the calibration results, D2 is less than 0.20 C.
(3) D3, error caused by the electric resistance of leading wires.
According to former experiences and the experimental conditions,
D3 is less than 0.05 C.
D4, error caused by the accuracy of secondary meter (digital
universal meter). It is Model 2000 produced by KEITHLEY Ltd.
The zero output of the digital universal meter is within 13 lV.
The maximum value of D4 is 0.076 C at 3 lV.
From above description, the measurement error of the thermo-
couples is then dened as follows [13]:
q
D D21 D22 D23 D24 0:24  C 1
The measurement error of temperature is less than 0.24 C in the
heat transfer experiment. The error is less than 2.4% within the
2436 S. Wang et al. / Applied Thermal Engineering 29 (2009) 24332438

3.5 tem has achieved a fully developed ow. Only the experimental
data indicating that the thermal leakage is within 3.0% are seen
3.0 as valid, otherwise they are discarded.

2.5
4. Results and discussion
2.0
4.1. Effect of sealer on heat transfer coefcient
E/mv

1.5
The overall heat transfer Q is as follows:
1.0 Q W h C p;h DT h W c C p;h DT c 2

0.5 The overall coefcient of heat transfer K is calculated through

the following equation:
0.0 Q
10 20 30 40 50 60 70 K 3
A  DT m
T/
The water-side heat transfer coefcient ai is expressed as
Fig. 4. Calibration curve of thermocouples.
follows:
k
measurement range, which meets the specication of less than 5%
ai 0:027 Re0:8 P 0:33
c 4
d
for measurement error in heat transfer experiment [14].
The oil-side heat transfer coefcient a0 is expressed as,

3.2. Heat exchanger 1

The tube-and-shell heat exchanger used in the experiment is
ABS300-2.5-10-3/25-2. The internal diameter of shell is 300 mm
and the external diameter of tube is 25 mm (as shown in Fig. 5).
There are 36 tubes with the length of 3000 mm. The total heat ex-
change area is 10 m2 with a bafe spacing of 120 mm and a mea-
sured gap between the tube bundle and shell is about 3 mm. The
sealers are patent products installed on the bafes. The sealers
shrink upon installation to ease installation, while they expand
to block the bafe-shell gap under the operating conditions.
3.3. Experimental method
The cold uid in tube-side is water and the hot uid in shell-
side is heat-conducting oil. The ux of water in the tubes is xed
to 18 m3/h. The ux of oil in the shell-side varies with the working
conditions. The measured data include ux and temperature both
at the inlet and at the outlet of tube-side and shell-side, and the
shell-side pressure drops. All the data are measured after the sys-
a0 1 5
K
 R0  Ri dd0  a1 d0
di
 dk d0
di
i i
In these equations, the subscripts h and c denote the hot and
cold uids, respectively; Q is total heat transfer in the heat exchan-
ger; W denotes mass velocity and Cp denotes average specic heat
capacity at constant pressure; DT denotes the temperature change
from inlet to outlet in the exchanger ; DTm is logarithmic mean
temperature difference in heat exchanger; K denotes overall heat
transfer coefcient; Ri is water-side fouling resistance; R0 is oil-side
fouling resistance; di is internal diameter of tubes and d0 is external
diameter of tubes; d denotes the tubes thickness; k is the heat con-
duction coefcient of tubes.
Figs. 6 and 7 show the effects of sealers on oil-side heat transfer
coefcient a0 and overall coefcient of heat transfer K. Heat trans-
fer performance is obviously enhanced by the conguration
improvement. The variation trends with shell-side ux are the
same for a0 and K. They all increase with the shell-side ux. All
of the values of a0 and K of improved heat exchanger increase com-
pared with that of conventional heat exchanger. Under the opera-
tion conditions, a0 and K increase by 18.225.5% and 15.619.7%,
respectively. The sealers block the bafe-shell gap, which effec-
tively forces the original short-circuit ow to participate in heat

600 50
Oil-side heat-transfer coefficient W/m K
2

with sealer
500
without sealer 40
Increase percentage (%)

400

30

300

20
200

increase percentage
100 10
100 150 200 250 300

Shell-side flux (L/min)

Fig. 5. Schematic gure of tube distribution. Fig. 6. Oil-side heat transfer coefcient a0 versus shell-side ux.
 S. Wang et al. / Applied Thermal Engineering 29 (2009) 24332438 2437

500 40 crease of ow rate. Thus the pressure drops in the improved heat
Overall heat transfer coefficient (W/m .K)

exchanger increase.
2

with sealer 35

400
without sealer 4.3. The effect of sealers on pump power consumption

Increase percentage (%)

30
Under the same operating conditions, the values of K of the im-
proved heat exchanger with sealers increase, which results in the
300 25 outlet temperature increase of cold uid and the decrease of hot
uid. The total thermal ux through the improved heat exchanger
20 with sealers increases accordingly. The increase of shell-side pres-
200 sure drop causes the increase of pump power consumption. But the
15
calculated value is very low.
increase percentage The pump power consumption is dened as [15],

100
100
Fig. 7. Overall heat transfer coefcient K versus shell-side ux.
exchange. The shell-side circulation area decreases and the
shell-side ow rate increases accordingly. Thus the shell-side heat
transfer performance of improved heat exchanger is effectively
enhanced, bringing about an obvious increase in shell-side heat
transfer coefcient a0 and overall coefcient of heat transfer K.
4.2. The effect of sealers on shell-side pressure drops
The variation of shell-side pressure drops along with ux is
demonstrated in Fig. 8. As shown in the gure, the pressure drop
4P increases with the shell-side ux. And the pressure drops of im-
proved heat exchanger are always higher than the conventional
one. When shell-side ux is 150 L/min, the shell-side pressure drop
is 7.8 mmHg before the conguration improvement and 11 mmHg
after. The pressure drop increased by about 44.8%. When ux in-
creases to 306 L/min, the pressure drop increases from 25.7 mmHg
of conventional heat exchanger to 37.2 mmHg of improved with
sealers, which increases by 48.8%. Within the operating conditions,
the pressure drops increase by 44.648.8%. The installation of seal-
ers deletes the short-circuit ow and urges this part of uid to ow
across the tube bundle and bafes to exchange heat with water in
the tubes. The pressure drop of the original short-circuit ow in-
creases for the above variation of ow passage. The shell-side cir-
culation area decreases by means of the block of sealers and the
shell-side average ow rate increases. The pressure drop caused
by the frictional resistance along the passages increases by the in-
10 N e DP  V 6
150 200 250 300
where Ne is denoted as pump power consumption. DP is shell-side
Shell-side flux (L/min) pressure drop. And V is denoted shell-side volume ow.
Fig. 9 demonstrates the effects of sealers on pump power con-
sumption. The increased thermal ux and the increased pump
power consumption all increases with shell-side ux. The operat-
ing condition of the largest shell-side pressure drop was chosen.
At this point, the increased thermal ux is 11.8 kW and the in-
creased pump power consumption is 7.8 W. This difference is
about three orders of magnitude. The increment of thermal ux
is among 6.411.7 kW and the increment of pump power con-
sumption is among 0.77.8 W under the operating conditions.
The increased thermal ux is far and away larger compared with
the increased pump power consumption. Hence the increased
pump power consumption by means of the installation of sealers
can be neglected, which is more than compensated for by the in-
crease of heat ux.
4.4. The effect of sealers on the exergy coefcient
From the former mentioned experimental results, it can be seen
that the thermal performance of the improved heat exchanger is
notably enhanced by the addition of sealers. However, there is an
increase in ow resistance, which results in the increase of irre-
versible loss in the thermodynamic process. Exergy analysis is
based on second law of thermodynamics. According to the equilib-
rium of exergy, the exergy is converted, transferred, used and lost
during the heat exchange process. The thermal performance of
heat exchanger can be analyzed and evaluated through the aspect
of energy quality. The integrative thermal performance of heat
exchangers is compared using the parameter of exergy coefcient.

20
Increment of pump power consumption (W)

40 70
12 increase of thermal flux
Increment of thermal flux (kW)

65 pump power consumption 16

Shell-side pressure drop (mmHg)

30
with sealer
without sealer
Increase percentage (%)

60
10
12
20 55

8
50 8
10

45
4
0 6
40
increase percentage
0
-10 35 100 150 200 250 300
100 150 200 250 300
Shell-side flux (L/min)
shell-side flux (L/min)
Fig. 9. Increment of pump power consumption and thermal ux versus shell-side
Fig. 8. Shell-side pressure drop versus shell-side ux. ux.
2438 S. Wang et al. / Applied Thermal Engineering 29 (2009) 24332438

Based on reference [16,17], the exergy coefcient of heat exchan- 5. Conclusions

ger can be expressed as below (water is cold uid and oil is hot
uid), The sealers installed inside the shell-and-tube heat exchanger
Exw2  Exw1 El effectively block the bafe-shell gap and decrease the circular leak-
gex 1 7 age ow. The original short-circuit ow then participates in heat
Ex01  Ex02 Ex01  Ex02
transfer, which intensies the heat transfer performance inside
The average specic heat of water is chosen as the calculated the heat exchanger. Within operating conditions, the shell-side
parameter. Then the gained exergy of water is given by, heat transfer coefcient of the improved heat exchanger increased
   by 18.225.5% and the overall coefcient of heat transfer K in-
T w2
Egain Ew2  Ew1 W w cpw T w2  T w1  T a ln 8 creased by 15.619.1%. Pressure losses increased by 44.648.8%
T w1
with the sealer installation. However, the increment of pump
The consumed exergy of oil is dened as, power consumption for the increase of pressure drop is very low
  compared with the increment of thermal ux. With respect to
T o1
Epay Eo1  Eo2 W o ho1  ho2  T a cpo 9 the energy quality, the exergy coefcient increased by 12.9
T o2
14.1% after the conguration improvement. The energy utilization
where the subscripts o and w are denoted oil and water, respec- improves, which is of signicance to the energy conservation and
tively; W is represented mass velocity, kg/s. The subscripts 1 and optimum design to the shell-and-tube heat exchanger. The sealers
2 are denoted inlet and outlet, respectively; cp is the average spe- are a novel solution settling the puzzle of the effect of bafe-shell
cic heat capacity at constant pressure, kJ/(kg K). Ta is the air tem- leakage ow in tube-and-shell heat exchangers. They are cheap,
perature, K. h is the enthalpy, kJ/kg. rm and convenient to install, guarantying safe and long lasting
Substitution of gained exergy and consumed exergy yields the operation. The sealers can be used in new heat exchangers or ret-
exergy coefcient of heat exchanger, gex, rotted into existing installations. The potential gain could be of
n h io benet to many industries using shell-and-tube heat exchangers.
T w2
Egain W w cpw T w2  T w1  T a ln T w1
gex
10
Epay W o ho1  ho2  T a cpo TT o1 Acknowledgements
o2

The exergy coefcient of heat exchanger versus shell-side ux is
shown in Fig. 10. Under the xed tube-side inlet condition, the
oil-side heat transfer coefcient a0 (Fig. 6) and shell-side tempera-
ture difference of heat transfer increase with the increase of shell-
side ux, which intensies the heat transfer within heat exchanger.
However, the increase of shell-side ux increases the ow resis-
tance and systematic irreversible loss enlarges accordingly, which
results in the decrease of exergy coefcient (as shown in Fig. 10).
The improved heat exchanger with sealers is always superior in
thermal performance to the conventional one. And the improved ef-
fect is more and more obvious as the ux increases. When the shell-
side ux is 83 L/min, the exergy coefcient gex of conventional heat
exchanger is 51.6%. And that of the improved one with sealers is
64.5%, an increment of 12.9%. When the shell-side ux increases
to 285 L/min, the exergy coefcient gex increases from 45.1% of con-
ventional heat exchanger to 59.8% of improved one, an increment of
14.1%. It can hence be concluded that the sealers can effectively en-
hance the heat transfer performance of heat exchanger.
70
65
Exergy coefficient(%)
The paper is supported by the National Natural Science Founda-
tion of China (NSFC 50676074) and grammatically revised by Dy-
lan Thorpe from RMIT of Australia, for which the authors are
thankful.
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