CERTIFICATE

This is to certify Project Report entitled

“TUBE ELEMENT DEVELOPMENT FOR HEAT TRANSFER

OPTIMIZATION”

Submitted by
Manoj H. Lokare Pranit P. Gunjal
B150235936 B150235923

Has successfully completed their projectreport under the supervision of Prof. Mrs. S. S. Patil
for the partial fulfillment of Bachelor of Chemical Engineeringof Savitribai Phule Pune
University for academic year 2018-19. This work has not been submitted elsewhere for any
degree.

Prof. Mrs. S. S. PatilProf. P. P. SirsatDr. S. R. Shrisath

Guide Project Coordinator Head of Department

Dr. S. D. Lokhande

External ExaminerPrincipal

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 PROJECT APPROVAL SHEET

THE PROJECT REPORT ENTITLED

“SIMULATION OF DOUBLE EFFECT HEAT BASED

REFRIGERATION SYSTEM”

Submitted by

DAMINI L. PARULEKAR MANOJ C. TRIBHUWAN

B150235947 B150235964

Is approved for degree of Bachelor of Engineering in Chemical Engineering under

SAVITRIBAI PHULE PUNE UNIVERSITY

DEPARTMENT OF CHEMICAL ENGINEERING

SINHGAD COLLEGE OF ENGINEERING,

PUNE-411041

Dr. J. G. Gujar

Examiner Guide

Dr. Nilesh A. Mali

CSIR-National Chemical Laboratory (Pune)

Co-Guide
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 ACKNOWLEDGEMENT

With immense pleasure, we are representing this project report as a part of the curriculum of
B.E. Chemical Engineering. We wish to thank all the people who gave us an unending
support right from the stage the idea was conceived.

We are grateful to our project guide Prof Mrs. S. S. Patil for her support and guidance
throughout the course of our project. We also thank all those who have directly or indirectly
guided and help us in preparation of this report.

We express our deepest and sincerest thanks to our external guide Mr. Tushar Wagh,
Founder Director, and Mr. Ram Khandekar, Assistant Manager and Senior Process
Engineer, YouthCon Creative Solutions Pvt. Ltd, Pune whose encouragement and guidance
helped us in the successful completion of the project. It was our privilege to interact with
them.

We express our profound thanks to our respected Head of Department, Dr. S. R. Shrisath
whose advice and valuable guidance helped us in making this seminar interesting and
successful one.

We take this opportunity to convey our sincere thanks to our Principal, Dr. S. D. Lokhande
for his continual support and encouragement that made the Seminar a great success.

We also thanks all those who directly or indirectly guided us and helped us in preparation if
this project.

- Manoj Lokare
- Pranit Gunjal
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 ABSTRACT

Heat exchangers are widely used in thermal applications. The effectiveperformances of heat
exchangers depend on their heat transfer rate.Heat transfer augmentation Double helical coil
wire sometimes called “Turbulator” are experimentally investigated in the present work. In
this work anattempt is made to study the effect of turbulator in increasing the heat transfer
rate in a shell and tubeheat exchanger. A double pipe heat exchanger is fabricated for
experimentation purpose. The water to water system is considered with hot water on shell
sideand cold water on tube side. Furthermore the results obtained were compared
withperformance of the heat exchanger without using inserts. It was inferred that the
heattransfer rate increased with usage of inserts i.e. turbulator. The Double helical coil inserts
exhibited better performance. Design of Shell and tube heat exchanger (Condenser) was done
with the help of HTRI Xchanger Suite module ‘Xist’. Input data parameters are added in the
Software to get all the output parameters including Result Drawing.

Keywords:Turbulator, Overall heat transfer coefficient,internalheat transfer coefficient,

Nusselt Number, Reynolds Number, Turbulent flow.

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Chapter no. Descriptions Page No.
Certificate i
Project Approval Sheet ii
Acknowledgement iii
Abstract iv
Index v
List of Figures vi
List of Tables vii
List of Graphs INDEX viii
HTRI Results ix
Nomenclature x
1 Introduction 1
Literature Survey Part I - Heat Exchanger Types
2 4

3 Literature Survey Part II- Design Consideration 7

4 Design Procedure for Shell and Tube Heat Exchanger 12
5 Design of Condenser 17
6 Enhancing Heat Transfer Coefficient 20
7 Experimentation : Double Pipe Trial 27
8 Results and Discussion 30
9 Costing 43
10 Design with software tools 51
Conclusion 63
Reference 64

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 LIST OF FIGURES

Figure No. Description Pageno.

1.1 General Classification of Heat Exchanger 2
2.1 Typical Shell and Tube Heat Exchanger 5
2.2 Double Pipe Heat Exchanger 5

2.3 6
Plate and Frame Heat Exchanger
3.1 Heat Exchanger Tube Layout 8
3.2 Different Types of Heat Exchanger Baffles 9
3.3 TEMA Classification 11
6.1 24
Typical Twisted Tape Turbulator

6.2 Typical Brock Turbulator 24

6.3 Typical Wire Turbulator 25

7.1 (a) Experimental setup in Working condition - High flowrate pumps 27

(b) Experimental setup in Working condition - Low flowrate pumps
7.2 Double Helical Coil Turbulator Used for experimentation 28

7.3 (a) Inner tube with turbulator 28

(b) Turbulator inserted in the inner tube of the heat exchanger

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 LIST OF TABLES

Table No. Description Page No.

4.1 Constants for use in equation in step 11 13
8.1 Results of 1.2 – 1.2 lpm flowrate without Turbulator 30
8.2 Results of 1.2 – 1.2 lpm flowrate with Turbulator 30
8.3 Results of 10- 12 lpm flowrate without Turbulator 31
8.4 Results of 10- 12 lpm flowrate with Turbulator 31
8.5 Results of 12- 12 lpm flowrate without Turbulator 32
8.6 Results of 12- 12 lpm flowrate with Turbulator 32
8.7 Results of 20- 20 lpm flowrate without Turbulator 33
8.8 Results of 20- 20 lpm flowrate with Turbulator. 33
8.10.1 Results of 1.2 – 1.2 lpm flowrate without Turbulator 35
8.10.2 Results of 1.2 – 1.2 lpm flowrate with Turbulator 35
8.11.1 Results of 10 – 12 lpm flowrate without Turbulator 36
8.11.2 Results of 10 – 12 lpm flowrate with Turbulator 36
8.12.1 Results of 12 – 12 lpm flowrate without Turbulator 37
8.12.2 Results of 12 – 12 lpm flowrate with Turbulator 37
8.13.1 Results of 20 – 20 lpm flowrate without Turbulator 38
8.13.2 Results of 20 – 20 lpm flowrate with Turbulator 38
8.14 Overall Heat Transfer Coefficient Increment- With and without 42
8.15 Heat Transfer Area Decrement- With and without Turbulator 42
9.1 Cash flow 50

Graph No. Page no.

Description
8.1 40
Flowrate Vs Heat Load
8.2 40
Flowrate Vs LMTD
8.3 40
Flowrate Vs Overall Heat Transfer Coefficient
8.4 40
Flowrate Vs Reynolds Number
8.5 40
Flowrate Vs Internal Heat Transfer Coefficient
8.6 40
Flowrate Vs Nusselt Number
9.1 50
Cash Flow
LIST OF GRAPHS

vii
 HTRI RESULTS

Description Page no.

Input Summary : Page 1 54

Input Summary : Page 2 55

Output Summary : Page 1 56

Final Results : Page 1 57

Final Results : Page 2 58

Final Results : Page 3 59

Rating datasheet 60

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 TEMA Specification Sheet 61

Exchanger Drawing 62

Setting Plan 62

NOMENCLATURE
ID – Internal diameter
OD – Outer diameter
L – Tube length
hi – Inside heat transfer coefficient
ho – Outside heat transfer coefficient
hdi – Inside tube dirt factor
hdo – Outside tube dirt factor
mc - Mass flow rate of cold stream
mh – Mass flow rate of hot stream
Q – Heat duty / Heat Load
Cp – Specific heat
Tco – Temperature of cold stream out

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Tci – Temperature of cold stream in
Thi – Temperature of hot stream in
Tho – Temperature of hot stream out
Ft – Temperature correction factor
Uo – Overall heat transfer coefficient
Nt – Number of tubes
Pt – Tube pitch
do – Tube outside diameter
di – Tube inside diameter
Db – Bundle diameter
Ds – Diameter of shell
Bs – Baffle spacing
K1 – Constant (step 11)
N1 - Constant (step 11)
Ntpp – Number of tubes per pass
Gm – Mass velocity
δi – Density of fluid inside tube
µw – Viscosity of water
Pr – Prandtl number
k – Thermal conductivity

Re – Reynolds number

Nu – Nusselt number

Jh – Constant

ΔP – Pressure drop

de – Equivalent diameter

λ - Latent heat

A – Heat Transfer Area

At – Area of tube

As – Cross sectional area

x
Lb – Baffle spacing

Va– Current asset value

V – Original asset value

xi