DESIGN OF SHELL & TUBE TYPE HEAT EXCHANGER

OVERVIEW:-

Shell-and-tube heat exchangers are fabricated with round tubes mounted in cylindrical shells with their axes coaxial with the shell axis. The differences between the many variations of this basic type of heat exchanger lie mainly in their construction features and the provisions made for handling differential thermal expansion between tubes and shell. There are various design considerations to be taken into account such as routing of fluids (shell or tube), pressure drop especially in the case of increasing number of baffles and tube diameter and adjusting the area with the suitability of the exchanger to conduct the heat required to heat or cool a fluid with another one.

ILLUSTRATION:-

Fig- shell and tube type heat exchanger with baffles

1. Shell. 2. Floating Head Flange. 3. Shell Channel. 4. Shell Cover End Flange. 5. Shell Nozzle. 6. Floating Tube Sheet. 7. Floating Head.

8. Floating Head Flange. 9. Channel Partition 10. Stationary Tube Sheet. 11. Channel. 12. Channel Cover. 13. Channel Nozzles. 14. Tie Rods and Spacers

15. Transverse Baffles. 16. Impingement Baffle. 17. Vent Connection. 18. Drain Connection. 19. Test Connection. 20. Support Saddles. 21. Lifting Ring.

APPLICATIONS:1. Power Plants Condensers, Pre Heaters, Waste water treatment

2. Oil Refineries Inter cooling Purpose, Re-Processing Purpose, 3. Manufacturing Industries Oil coolers for Quenching Oil, Oil coolers for Lubrication Oil 4. Offshore Industry Water Makers Condensers 5. Nuclear Power Plants Chillers and Water Coolers 6. Food and Dairy Industries 7. Refrigeration systems 8. Pulp and Paper Industries 9. Wine-brewery industry 10. Plastic and Fertilizers Industries

HEAT EXCHANGER DESIGN REQUIREMENTS :-

INPUT PARAMETERS:The desired input parameters required for a shell and tube type heat exchanger are as follows:-

INLET SHELL FLUID TUBE FLUID PARAMETERS VELOCITY (m/s) PRESSURE (bars) TEMPERATURE ( C) MASS FLOW RATE (kg-m/s)

OUTLET SHELL FLUID TUBE FLUID

TABLE- INPUT VALUES FOR FLUIDS

y Type of flow pass for which the heat exchanger has to be designed. 1. single pass flow 2. double pass flow 3. four pass flow 4. multiple pass flow y Acceptable tolerance allowance for fouling.

DESIGN METHODOLOGY:Part A - Thermal Design 1. Selection of the process fluids both on shell & tube side according to the specification. 2. Selection of Required Temperature Specifications. 3. Limiting the Shell and Tube side Pressure Drop as specified. 4. Setting Shell and Tube Side Velocity Limits 5. Finding Heat Transfer Area Including Fouling Factor Part B- Mechanical Design 1. Selection of TEMA Layout Based on Thermal Design 2. Selection of Tube Parameters Size, Thickness, Layout, Pitch, material

3. Limiting the Upper and Lower Design on Tube Length 4. Selection of Shell side Parameters Material Baffle Cut, Baffle Spacing, and Clearances 5. Setting upper and Lower Design Limits on Shell Diameter, Baffle Cut, and Baffle Spacing.

PROBLEM SPECIFICATION

SELECT CONSTRUCTION TYPE, FLOW ARRANGEMENT, SURFACE SELECTION, FLUID ALLOCATION, SIZE AND SHAPE CONSIDERATION

DETERMINE SURFACE GEOMETRICAL PROPERTIES

THERMO-PHYSICAL FLUID PROPERTIES MODIFY THE VARIABLES THERMO-HYDRAULIC DESIGN & PRESSURE DROP CALCULATION

IS THE DESIGN ACCEPTABLE

NO

YES
ANALYZE FOR FLOW INDUCED VIBRATION OF SHELL SIDE

MECHANICAL DESIGN

PERFORMANCE PARAMETERS
FLUID ALLOCATION FLUID NAME FLUID QUANTITY, TOTAL TEMPERATURE (IN/OUT) F SPECIFIC GRAVITY VISCOSITY SPECIFIC HEAT (Btu/Lb F) THERMAL CONDUCTIVITY LATENT HEAT (Btu/Lb F) INLET PRESSURE (Psi) VELOCITY (Ft/s) PRESSURE DROP ALLOWANCE (PSI) FOULING RESISTANCE SHELL SIDE TUBE SIDE

COOL WATER IS INTRODUCED FROM TOP SENSIBLE HEAT TRANSFER BETWEEN HOT AIR AND COLD FLUID DUE TO MIXING IN THE BED

HOT AIR ENTERS INTO DIRECT CONTACT HEAT EXCHANGER THROUGH INLET AIR INJECTED BY A BLOWER

INJECTED AIR IS HEATED BY A HEAT SOURCE

DUE TO MIXING WITH HOT AIR THE COLD FLUID GETS HEATED UP AND COLLECTED FROM THE BOTTOM FOR FURTHER PROCESSES

Tc2

HOT FLUID

Th1

Th2

COLD FLUID

Tc1

Tc1

HOT FLUID

Th1

Th2

COLD FLUID

Tc2

TH1

HOT FLUID

TH2 TC2

TC1

COLD FLUID

COLD FLUID IN

HOT FLUID IN

HOT FLUID OUT

COLD FLUID OUT

COLD FLUID

Tc1

Tc2

Th1

Th2

HOT FLUID

HEAT TRANSFER AREA

HEAT TRANSFER (Q) TAKES PLACE FROM HOT FLUID TO COLD FLUID