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Analysis study of shell and tube heat exchanger for clough company with
reselect different parameters to improve the design
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Analysis study of shell and tube heat exchanger for clough MARK
company with reselect different parameters to improve the design
⁎
Ammar Ali Abda, , Samah Zaki Najib
a
Water Resources Engineering College/Al-Qasim Green University, Iraq
b
Petroleum and petrochemical Engineering Department/Kerbala University, Iraq
AR TI CLE I NF O AB S T R A CT
Keywords: The specification design of this heat exchanger has been taken from a real project executed by
Nusselt number Clough. The process data given matches the real application exactly and was used to design the
Heat transfer coefficient heat exchanger. The Regeneration Gas Heater was manufactured in Malaysia, and was shipped to
Clough a fabrication yard in Thailand for installation within a pre-assembled module. This paper illus-
Square arrangement
trates fully thermal and mechanical design for this heat exchanger. Here, the redesign takes place
Shell and tube exchanger
to improve the design by reselect different parameters which can enhance the heat transfer
through the exchanger. As well as, new correlation is developed to predict Nusselt number for
tube side which reduces the error percent with Kern's method from 15.25% to 12.64% based on
simulation data. Where, the proposed and Kern's correlations compared against experimental
data to show that the proposed correlation is quite accurate. After many iterations, the new
design suggested that four tubes passes need to be used with 1.38 m tube length. In addition, the
tube arrangement chosen to be square type with 0.9 m shell diameter. With these parameters, the
exchanger achieves high enough heat transfer coefficient and the pressure drop within specifi-
cation.
1. Introduction
The task at hand is to design a heat exchanger that will heat dry gas (natural gas) with hot oil. Heat exchangers are a type of
process equipment in which heat is exchanged between two streams, a hot and cold one. They can be used to heat and cool streams
and even in some cases completely vaporise the process stream. There are several different types of heat exchangers which include
Double-pipe exchangers, Shell and tube exchangers, air coolers and many more. Where, 80% of the energy utilization systems uses
heat exchangers [1].
The project involved the design of a shell and tube heat exchanger with a number of specifications. Shell and tube heat exchangers
are commonly used in the chemical industries and separations processes. They are made from bundles of tubes and may be composed
of several types of tubes: plain, longitudinally finned, etc [2]. The ends of tubes are placed in sheets that divide the shell and tubes
fluids [3]. Baffles are also placed in the shells which aid in direction the shell-side fluid flow and create a more turbulent flow regime.
There are several advantages with this heat exchanger type that include a large surface area for a small volume, easy cleaning, a good
mechanical layout and well-known design procedures [3]. It is necessary to know all the parameters and data of the requested design
before starting calculations. Therefore, the design will be limited to certain specification requested by the company as shown in Table
A1 in Appendix A. These specifications will help to make the design applicable for the requested conditions. As a first step, the heat
⁎
Corresponding author.
E-mail address: ammarali@wrec.uoqasim.edu.iq (A.A. Abd).
http://dx.doi.org/10.1016/j.csite.2017.10.002
Received 2 March 2017; Received in revised form 17 September 2017; Accepted 5 October 2017
2214-157X/ © 2017 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY license (http://creativecommons.org/licenses/BY/4.0/).
A.A. Abd, S.Z. Naji Case Studies in Thermal Engineering 10 (2017) 455–467
exchanger will be designed by Hysys simulation program to find all the physical properties for both fluids as shown by Tables A2 and
A3 in Appendix A. The used procedure to design the heat exchanger in this paper is Kern's method [4]. Kern's method bases on
experimental data which can lead to reasonable prediction for Nusselt number [4]. While, the pressure drop prediction is less satisfy
because it is affected by leakage and bypassing than heat transfer [4]. Kern's method applies modified figure to find the friction factor,
and neglecting the viscosity term which lead to error percentage when calculates Nusselt number. Therefore, it would significantly
important if we can modify new correlation proportional directly to Reynold and Prandtl numbers based on Kern's method can be
reduce the error. In this work, more than seventy heat exchangers with different conditions designed by using Hysys simulation
program to calculate the Nusselt number for tube side. Simulated Nusselt numbers plotted against Reynold and Prandtl numbers to
find new correlation which can calculate the overall heat transfer coefficient with smaller error percentage.
2. Strategy
In making an energy balance of the two fluids several things will be assumed that no heat loss to the surrounds, negligible
Potential and kinetic energy changes, no phase changes, constant specific heat capacity, and steady State Conditions [5].
qcold = qhot (EnergyBalanceEquation)
The heat transfer and the flowrate can be calculated based on the above equation with the given data.
In order to start the calculations two shell pass and four tube passes will be used to start with. The LMTD-Method will be used to
evaluate the required equipment's area. Analysis will start by first calculating the mean temperature. Both fluids will be used in
counter-flow to maximise the log mean temperature difference. The temperatures for both side provided as specification by Table A1
in Appendix A.
∆T1−∆T2
∆Tlm = ∆T
ln ∆ T1
2
For a Two shell and Four tube passes the geometry correction factor (F) can be calculated using the equation show bellow. Note
the equation is valid for two shell and any even number of tube passes.
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A.A. Abd, S.Z. Naji Case Studies in Thermal Engineering 10 (2017) 455–467
2
⎡ (R +1) ⎤ ln 1 − P
( )
⎢ 2(R −1) ⎥ 1 − PR
F= ⎣ ⎦
A + B + (R2 +1)
ln ⎡ ⎤
⎢ A + B − (R2 +1) ⎦
⎣ ⎥
2 2
Where , A = −1−R, B = * (1−P )(1−PR)
P P
As the correction factor is above 0.75 it can be noted that the configuration used is valid and efficient [4]. In same vein, the
calculated mean temperature should be corrected by:
∆Tm = F .∆Tlm
∆T1 195.3℃
∆T2 20℃
∆Tlm 76.926℃
P 0.235
R 3.9
F 0.888
∆Tm 68.3
To calculate the heat exchanger area, values of mean temperature difference (∆Tm ) and overall heat transfer coefficient (OHTC, U)
should be obtained.
For this design, the range of U values depend on the fluids which are the dry gas and hot oil, therefore it can be start assuming
with overall heat transfer coefficient 375 W/m2.℃ [6].
To start with a 19.05 mm outer diameter tube and with 1.6 mm thickness will be used, both of which are standard sizes [5]. The
manufacturing material that will be used is carbon steel which can provide good thermal conductivity. Finally, the tube length was
set to 1.83 m which should be sufficient large to lower the cost and reduce the shell diameter. Where, Bisoniya reported that
increasing tube length leads to increase the heat transfer and the pressure drop at the same time [8]. Thermal conductivity of carbon
steel will be K carbon steel = 55 W/m K [3].
Factors can be considered in the allocation of the two fluids which can be illustrated below:
Fouling: The fluid with the higher fouling factor should be placed in the tubes as they are easier to clean than the shell [9]. The
deposits accumulation on the internal surface of the heat exchanger causes reducing in the heat transfer and the effectiveness of
the exchanger [10].
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A.A. Abd, S.Z. Naji Case Studies in Thermal Engineering 10 (2017) 455–467
Fluid Temperature: It is safer to allocate the cold fluid around the hot fluid, as well as, it will reduce energy loses and the overall
cost of the equipment's [9].
Pressure Drop: the pressure drop on the tube side will be higher than that on the shell side. Therefore, the lowest pressure
allowance should be allocated in the tube side [9].
However, the project flow diagram shows that the dry gas flows in the tube side because it is less dirty and the hot oil in shell side.
As well as, that the specification sheet gives that the lower fouling factor with dry gas and higher fouling factor for hot oil, therefore,
the dirtier fluid will be in the shell side which is hot oil.
In calculation of the tube area, the thickness of tube sheet will be neglected. Hence, the tube area and tubes numbers can be
calculated:
Areaof singletube = πDo L
Ao
TubesNumber =
Atube
752 Tubes will be used in total; therefore, as there are four tube passes and the number of tubes per pass will be 188.
π
crosssectionareaof tube = (Din )2
4
Nt
Tubesfor eachpass =
PassesNumbers
ṁ
Massvelocityof DryGas, Ms =
tubetotalarea
ṁ
velocity =
ρ
An estimation of the Bundle diameter (Db ) can be made using the bellow equation [3].
Db n1
Nt = K1 ( )
Do
K1 and n1 are constants that can obtained for square arrangement and four passes from Table A4 in Appendix A, which are 0.158
and 2.263 respectively [4].
Db
752 = 0.158*( )2.263Db = 0.8034m
0.01905
The shell clearance for a Pull–through floating head heat exchanger can be determined from Fig. A1 in Appendix A, by con-
sidering the bundle diameter, and a Pull-through floating head exchanger the shell clearance will be approximately 94 mm [4]. Based
on these two values the shell diameter (Ds) can be evaluated Fig. A1.
Ds = Db + clearance = 0.8034 + 0.094 = 0.9m
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A.A. Abd, S.Z. Naji Case Studies in Thermal Engineering 10 (2017) 455–467
In order to determine the tube side heat transfer coefficient, the Reynolds number must first be evaluated. We will also assume
that the flow is fully developed; therefore, the entry region does not need to be considered.
Ms *Di
Re =
μ
A turbulent flow is present and therefore the turbulent equations should be used. Eq. (1) will be used in determining the average
Nusselt number and in the calculation, it will be assumed that the viscosity factor (µ/µw)0.14 is one [4].
μ 0.14
Nu = jh × Re ×Pr 0.33 × ,
μw (1)
μcp Nu
Pr = , ht = *k
k Di
L
jh can be obtained from Fig. A2 with Di
= 115.5 which is jh = 3 × 10−3 , and Nu = jh × Re ×Pr 0.33
Re 7.7254*10 4
Pr 76.4
Nu 969.3
ht 3265.65 W/m2.°C
In the calculation of Nusselt number on the shell side, Kern's procedure will be employed to calculate the external heat transfer
coefficient. Rao and Raju concluded that as the baffle cut decreases the overall heat transfer increases [11]. For this design, the baffle
cut will be 0.3, which should provide an optimum heat transfer coefficient without result in a high pressure drop, and the baffle will
be a segmental baffle. In the calculation of shell cross flow area (As) a baffle spacing of Ds/3 will be used [4].
The first Step in calculating the external heat transfer coefficient is to determine the cross-flow area of the shell.
Pt = 1.25Do
Ds × (Pt − Do) × B
As =
Pt
The equivalent shell side diameter (de) can be calculated by using Eq. (2) for a Square arrangement of tubes [4].
1.27
De = *(pt 2 −0.785do2)
do (2)
Ms *De ṁ
Re = , velocity =
μ ρ
Pt 0.02381 m
As 0.054 m2
De 0.0188 m
Ms 190.63 kg/m2.s
velocity 0.1421 m/s
Re 2.442×10 4
Pr 4.6232
Nu 153.8
hs 744.457 W/m2.°C
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A.A. Abd, S.Z. Naji Case Studies in Thermal Engineering 10 (2017) 455–467
The overall heat transfer coefficient based on the outer area (Uo) can be calculated by considering all the thermal resistances
present in the heat exchanger.
1
=
1 r 1 r
+ R s + Rt * o + * o +
ro*ln ro
i()
r
Uo hs ri hi ri kcarbonsteel
Uo = 432.189
The assumption can be assumed fairly accurate, as Kern's limitations for difference percentage is 30% [4].
L
∆Pt = Np ⎛4 × jf ×
⎜ + 1.25⎞ × ρV 2
⎟
⎝ di ⎠
From Fig. A4 in Appendix A, the friction factor will be, jf = 3.8 × 10−3, [4].
∆Pt = 592.544 Pa
The pressure of nozzles can be added for inlet and outlet by adding 15% of the total calculated pressure [4] Fig. A4.
0.15 × 592.544 + 592.544 = 681.43 Pa
This pressure drop is well within the limit of 0.5 bars and hence is acceptable.
From Fig. A5 in Appendix A and the Reynold number on the shell side, jf can be estimated to be around 0.037, [4]:
∆Ps = 1170.73 Pa
The pressure drop in the shell nozzle significant only when dealing with gases [4]. As a result, the nozzle pressure drop may be
neglected. The obtained value of 1170.73 Pa is less than the limit of 0.5 bars and hence is acceptable Fig. A5.
4. Study the effect of increasing tube length on the overall heat transfer coefficient
Many iterations done with same procedure by using different lengths to study the change in the overall heat transfer coefficient
for the exchanger. Where, the used lengths been 1.5, 1.83, 2, 2.44, 3, and 3.66 m, check Table A5. Where, increasing tube length
increases the overall heat transfer, as shown by Fig. 1.
Where, by plotting length against overall coefficient for more than iteration, quick prediction can be showed form below
equation:
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A.A. Abd, S.Z. Naji Case Studies in Thermal Engineering 10 (2017) 455–467
Fig. 3. Nusselt number against Reynold and Prandtl based on the proposed correlation.
Fig. 4. The comparisons between the proposed and Kern's correlations with Experimental Data.
Now, this equation helps chosen new length that can reduce the error percentage between the assumed and the calculated overall
heat transfer coefficient, for this heat exchanger the best length will be 1.83 mm standard length which gives enough heat transfer
and accepted pressure drop.
In this part, effect of increasing tube length on shell diameter examined, where, as length increase shell diameter decrease.
Fig. 2, describe the change in length with shell diameter which can be demonstrated by below equation:
shelldiameter = −0. 1276*Length + 1. 1081
This equation will give more flexibility to calculate shell diameter by using the chosen length directly. Therefore, the shell
diameter with 1.83 m length will be 0.8746 m.
Internal flow can be descripted by flow of fluid surrounding by solid walls. Heat exchangers are conglomerates of internal flows.
There are two basic points should be taken in account by the designer who contemplates using an internal flow configuration. They
are heat transfer and the thermal conductivity between fluid and walls [13]. Kern's suggested correlation that considers the effect of
fluid viscosity at the wall and in tube [13]. In addition, Kern's modified a figure to calculate the friction factor for limit range of
Reynold number. The problem with Kern's correlation can be illustrated by that the viscosity term should be ignore at the beginning
of the calculating as the wall temperature is unknown. Thus, the calculation comes with an error percentage. Therefore, it is worthy
to find new correlation that can solve this problem and reach more accurate results.
Usually, most of Nusselt number correlations for fully developed flow is function of Reynold and Prandtl numbers [14]. Simu-
lation program (Hysys V8.8) used to calculate the Nusselt numbers for internal flow with different temperatures, mass flow rates,
tube dimensions, fluid type. The collected Nusselt numbers plotted against Reynold and Prandtl numbers for each case to create new
correlation based on Kern's correlation form which is proportional directly to Reynold and Prandtl numbers as shown by Fig. 3.
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A.A. Abd, S.Z. Naji Case Studies in Thermal Engineering 10 (2017) 455–467
The proposed correlation works more accurate than kern's correlation with wide range of Reynold numbers, different types of
fluids, flow rates, and different dimensions. The limitations of the new correlation are that it is applicable for fully developed
turbulent flow, and internal flow through tubes. The calculation will recompute using the new correlation for tube side to test the
proposed correlation as shown below:
Nu = 0. 0126*Re 0 . 8762 Pr 0 . 289
With, Re=7.7254*10 4 and Pr = 76.4 .
Nu = 0.0126*(7.7254*10 4)0.8762 (76.4)0.289 = 846.02
846.02
ht = × 0.0534 = 2850.313W/m2.°C
0.01585
Now, with same calculation for shell side, the overall heat transfer coefficient can be calculated to be:
1
=
1 r 1 r
+ R s + Rt * o + * o +
ro*ln ro
i ()
r
Uo hs ri hi ri kcarbonsteel
1
=
1
+ 0.00035 + 0.00018*
0.00953
+
1
*
0.00953
+
0.00953*ln ( 0.00953
0.007925 )
Uo 744.457 0.007925 2850.313 0.007925 55
1
= 0.0013432 + 0.00035 + 0.00022 + 0.000422 + 0.000032
Uo
1
= 0.0023672→Uo = 422.4
Uo
Uo − Uass 422.4 − 375
%Difference = ×100% = × 100% = 12.64%
Uass 375
The new correlation reduces the error percentage from 15.25% to 12.64% which can give better prediction than kern's equation.
The proposed correlation in this work will be compared with experimental data exist in literature suggested by Skupinski et al.
with constant wall temperature for turbulent flow part [15]. Analysis study done to study the heat transfer by forced convective
shows that the Nusselt number depends strongly on Reynolds and Prandtl at low fluid speed [16]. Based on this study, low ex-
perimental Reynolds numbers uses to study the both correlations Kern's and the proposed to test the accuracy.
The comparisons presented by Fig. 4 show that the agreement between the proposed correlation in this work and the experimental
data is quite good. As the proposed correlation gives close Nusselt numbers to the experimental data than Kern's correlation.
7. Conclusion
In conclusion, the designed heat exchanger is competent for the duty of heat transfer. It means the dry gas at 24.7 °C can be heated
to 260 °C by this exchanger with hot oil at 280 °C. Furthermore, the flow rates of fluids also can be achieved with a pressure in the
scope of demand. The presented method is Kern's method, which can provide satisfactory prediction of heat transfer coefficient. The
core concept is using a trail-and-error process to approach the feasible OHTC. However, it is criticized for its performance on the
prediction of pressure drop, which is more optimal to be examined with Bell's method. In the study, the numerical results of cal-
culation validate the correlation between fluid velocity and heat transfer coefficient. It demonstrates that the higher flow rate lead to
higher heat transfer coefficient. However, the high velocity will cause high pressure drop, which may reduce the useful life of
equipment. Therefore, it is significant to find the equilibrium between high heat transfer coefficient and proper pressure drop. In
addition, new correlation proposed based on kern's method to rich more accurate results. The proposed correlation reduces the error
percentage and can be applied easily. Moreover, four different lengths used to study the effect of increasing tube length on overall
heat transfer coefficient, and shell diameters. To sum up, the shell and tube heat exchanger is feasible for this given system and can do
the function with high performance.
Appendix A
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A.A. Abd, S.Z. Naji Case Studies in Thermal Engineering 10 (2017) 455–467
Table A1
Given specification by clough for the design.
Table A2
Dry gas properties.
Dry gas
Thermal conductivity, k, (
W
) 0.036 0.071 0.0535
m.k
Table A3
Hot oil properties.
Hot oil
Thermal Conductivity k, (
W
) 0.0875 0.095 0.091
m.k
Note: The values T1 and T2 were the lower and upper temperature bounds from the mean temperature of the respective fluids. The physical
properties of these fluids at T1 and T2 were obtained: Physical property data from the Project Sheet. The values at the mean temperature were
obtained by linear interpolation.
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A.A. Abd, S.Z. Naji Case Studies in Thermal Engineering 10 (2017) 455–467
Table A4
Constants to calculate Bundle diameter [4].
Table A5
Overall heat transfer coefficient and length.
1.5 418.2
1.83 432.189
2 489.4
2.44 500
3 601.47
3.66 669.79
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A.A. Abd, S.Z. Naji Case Studies in Thermal Engineering 10 (2017) 455–467
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