Assignment

On Shell and Tube Heat exchanger

Submitted by,
1. Md. Mahmud-Or-Rashid
S-201310163

2. Md. Jisan Fardin

S-201310130

Department of Mechanical Engineering,

Bangladesh University of Engineering and Technology

Date: 14-03-2018
Shell and tube heat exchanger

The most common application of heat transfer is in designing of heat transfer equipment for
exchanging heat from one fluid to another fluid. Such devices for efficient transfer of heat are
generally called Heat Exchanger. One type is shell and tube heat exchanger.

It may be two, four or eight passes for different application.

Design parameters:
1. Shell (diameter, length)
2. Tube (diameter, length, tube number, tube layout)
3. Baffles,
4. Transferred Heat,
5. Pressure drop

Mathematical design:
By trial and error method, with balancing energy , a heat exchanger is designed.
The calculated heat transfer area,
A=Q/(U*LMTD*FC)
At here
Q= Transferred heat=m*Cp*dT
U= Overall heat transfer co-efficient
LMTD=Logarithmic Mean Temperature Difference
FC= Correction factor for shell and tube

At here,
LMTD= (dT1-dT2)/ ln(dT1/dT2)
dT1=Th,in- Tc,out
dT2=Th,out-Tc,in

Now,
P=(t2-t1)/(T1-t1)
R=(T2-T1)/(t2-t1)
From the graph, FC can be determined
For double ,4,8 passes of shell, this chart is also available

With this area ,for given tube diameter and length ,the number of tube ,
nt =A/(π*D*L)
D= Tube diameter
L=Tube length

Pressure loss=dpf=γ*hf

Here, γ=Specific weight of our selected fluid

hf= head loss due to friction

hf=(f*L*V2)/(2*g*D)
f= friction factor
V= velocity of fluid
Factors Affecting the Performance of Shell and Tube Heat
Exchanger
1. Tube layout: There are three types of tube layout
i. Square,
ii. Triangular,
iii. Rotated square

In square layout, the heat transfer efficiency is less but frictional loss is lower. In rotated square
layout, heat transfer efficiency is better but frictional loss is more.
These are used depending upon different types of application.

Orientation of tubes and its materials:

Tube geometry has a great effect on heat transfer .If we introduce curved tube, twisted tube or
finned tube; these will increase heat transfer by increasing heat transfer area. Or Tube with rough
surface may be used.
 Fig: twisted tube and finned tubes

Stainless steel or copper may be selected as tube material. Stainless steel is applicable for wide
pH range ,low maintenance cost, durability and efficiency .Copper is used due to its high
conductivity ,good corrosion resistance etc.

Baffles inclination and cut:

The performance of a heat exchanger is dependent on baffles cut, effective spacing, height and
its inclination angle. Baffles are used to reduce the vibration of tube and to increase turbulence
mainly. The overlapped baffles and ladder-type fold baffles can effectively improve the heat
transfer performance of heat exchangers with helical baffles. Having lower inclination angle,
increases heat transfer at the cost of increased shell side pressure drop. On the other hand
increasing angle beyond certain value might result in reduced pressure drop but with lesser heat
transfer. So it is very important to have an optimum baffle angle to give minimum pressure drop
with maximum heat transfer.
Also determining effective baffle spacing and tube diameter for optimum baffle inclination.

If we use a sheet with tubes as baffles, in which tubes are used for another passage of fluid to add
cooling or heating effect, it may enhance the performance.

The different baffle cuts are

Fouling, Air pockets, Leakage:

Fouling may significantly impact the thermal and mechanical performance of heat exchangers.
Fouling increases the overall thermal resistance and lowers the overall heat transfer coefficient
of heat exchangers. Fouling also impedes fluid flow, accelerates corrosion and increases pressure
drop across heat exchangers. With proper monitoring, it may be reduced. Heat exchanger
enhancement may also decrease the effects of fouling, as described by Gibbard7. The author
describes the different methods by which fouling occurs and the ability of heat exchanger
enhancement to abate some of that fouling. Mukherjee8 and Polley and Gibbard9 describe the
use of tube inserts for dirty hydrocarbon services in crude oil refining. The inserts tend to
promote radial flow from the center to the wall. This churning motion minimizes the material
deposits on the tube wall.
Air pockets also reduce the heat transfer. This can be avoided by venting all air or gas out at
start up and periodically venting gases as required.
Most leakages occur due to gasket failure - replacement of gaskets will be necessary. Internal
leakage due to tube failure will cause contamination of the lower pressure fluid by the ingress of
higher pressure fluid. This will require tube 'plugging' or replacement. Tube failure generally
occurs due to corrosion, excessive pressure or by failure of the welded or rolled fitting of the
tubes into the tube-sheets.
Application:
A heat exchanger is a device to efficiently transfer or exchange
heat from one matter to another. The applications of shell and
tube heat exchanger are :
1. Shell and tube heat exchanger is very common heat
exchanger due to its simple geometric shape and good
thermal efficiency.
2.