SHELL AND TUBE HEAT EXCHANGER

HEAT TRANSFER LAB PROJECT

SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENT FOR THE AWARD

OF

BACHELOR OF TECHNOLOGY
(Mechanical Engineering)

SUBMITTED BY: UNDER GUIDANCE

GOBIND (1508082) Prof. RUPINDER KAUR
GURKARAN SINGH (1508087)
GURPREET SINGH (1508092)
GURWINDER SINGH 1508095)
INDERBIR SINGH (1508107)

MECHANICAL ENGINEERING DEPARTMENT

GURU NANAK DEV ENGINEERING COLLEGE, LUDHIANA
 ABSTRACT

Due to the wide range of design possibilities, simple manufactured, low maintenance and low
cost cross-flow heat exchangers are extensively used in the petroleum, petrochemical, air
conditioning, food storage, and others industries.
In this paper a mathematical model for cross-flow heat exchangers with complex flow
arrangements for determining e -NTU relations is presented. The model is based on the tube
element approach, according to which the heat exchanger outlet
Temperatures are obtained by discretizing the coil along the tube fluid path. In each cross
section of the element, tube-side fluid temperature is assumed to be constant because the heat
capacity rate ratio C*-Cmin/Cmax tends toward zero in the element. Thus, temperature is
controlled by effectiveness of a local element corresponding to an evaporator or an element.

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 ACNOWLEDGEMENT

The authors are highly grateful to the Principal, Guru Nanak Dev Engineering College
Ludhiana, for providing this opportunity to carry out the present minor project work.

The constant guidance and encouragement received from Dr. P.S Bilga, Professor and
Head, Department of Mechanical Engineering, GNDEC, Ludhiana has been of great help in
carrying out the project work and is acknowledged with reverential thanks.
The authors would like to express a deep sense of gratitude and thanks to Prof. Rupinder Kaur,
Prof. Deepak Dhand & Lab Attendant Rakesh Kumar and Lab Assistance Jasbir Singh,
Department of Mechanical Engineering, GNDEC, who was our minor project guides. Without
the wise counsel and able guidance, it would have been impossible to complete in this manner.

The authors express gratitude to other facility members of Mechanical Engineering Department,
GNDEC and Head and Staff of Workshops, GNDEC for their intellectual support throughout
the course of this work. Finally, the authors are indebted to all whosoever have contributed in
the minor project work.

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CHAPTER 1

INTRODUCTION

Transfer of heat from one fluid to another is an important operation for most of the chemical
industries. 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.

1. 1 CLASSIFICATION OF HEAT EXCHANGER

1. According to construction features

2. According to heat transfer mechanisms
3. According to flow arrangements
4. According to transfer processes
5. According to surface compactness
6. According to number of fluids

Fig 1.1; Heat Exchanger according to constructional features

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1. 2 BASIC CONSTRUCTION OF SHELL AND TUBE HEAT
EXCHANGER

This exchanger, shown in Fig.1.2 is generally built of a bundle of round tubes mounted in a
cylindrical shell with the tube parallel to that of the shell. One fluid flows inside other flows
across and along the tubes. The major components of this exchanger are tubes (or tube bundles),
shell, frontend head, rear-end head, baffles, and tube-sheet. A variety of different internal
constructions are used in shell and-tube exchangers, depending on the desired heat transfer and
pressure drop performance and the methods employed to reduce thermal stresses, to prevent
leakages, to provide for ease of cleaning, to contain operating pressures and temperatures, to
control corrosion, to accommodate highly asymmetric flows and so on.

Fig1.2: Basic components of Shell and Tube Heat Exchange

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1. 3 ASSUMPTIONS

In order to derive expression for LMTD for various types of heat exchangers, the following
assumptions are made

1. The overall heat transfer coefficient U is constant.

2. The flow conditions are steady.
3. The specific heats and mass flow rates of both fluids are constant.
4. There is no loss of heat to the surroundings. Due to the heat exchanger being perfectly
insulated.
5. There is no change of phase either of the fluid during the heat transfer.
6. The changes in potential and kinetic energies are negligible.
7. Axial conduction along the tubes of the heat exchanger is negligible.

1. 4 APPLICATION
Generally the shell and heat type heat exchanger are widely used for various purposes
having limitation to be designed for maximum up to 15000 psi, 1000 of & 30000 ft2/shell.
Beyond above given parameter special consideration is required for the design of heat
exchanger. The design is ideal for high pressure and temperature services.
1. Shell and tube heat exchanger are easy to clean for floating head type configuration so
can be used in dirty services.

2. Shell and tube type heat exchanger can be used for higher temperature difference
services as it can accommodate thermal expansion.

3. They are most suitable for gas services and phase change service.

They can be designed for special operating conditions : vibration, heavy touting, highly
viscous fluids, erosion, corrosion, toxicity, radioactivity, multi component mixtures and so
on. They are the most versatile exchangers made from a variety of metal and non-metal
materials (such as graphite, glass, and Teflon) and range in size from small [0.1m2 (1 ft2) ]
to supergiant [over 105m2( 106 ft2) ] surface area. They are used extensively as process heat
exchanger s in the petroleum-
refining and chemical industries ; as steam generators, condensers, boiler feed water heaters
and oil coolers in power plants ; as condensers and evaporators in some air-conditioning and
refrigeration applications ; in waste heat recovery applications with heat recovery from
liquids and condensing fluids ; and in environmental control.

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CHAPTER 2

LITERATURE REVIEW

Ebieto, C. E and Eke G. B.-In his experimental paper the performance analysis carried out
of shell and tube heat exchanger & analytical method was used to develop correlation for the
performance analysis. The thermal analysis of a shell and tube heat exchanger involves the
determination of the overall heat-transfer coefficient from the individual film coefficients.
Nu=0.8 Pr1/3(µ/µw) 0.14 (1)

Where, Nu-Nusselt Number-hd/k

Re-Reynold's Number-DVp/µ
Pr-Prandtl Number-cpµ/k

For calculation of heat exchanger performance, if only the inlet temperatures are known, it is
preferable to use the effectiveness-number of transfer units (e-NTU) method, which
simplifies the algebra, involved in predicting the performance of complex flow
arrangements. e-NTU relations in algebraic form are useful in computational calculations for
design and experimental studies. For compact heat exchangers the mechanism of heat
transfer and pressure drop is fairly complex and
as a result, analytical derivation of e-NTU relations is a difficult task. It should be
emphasized that the use of correct e-NTU relations should be carefully considered before
applying the appropriate heat transfer correlation to sizing or rating a heat exchanger.

Domanski (1991)-He presented a discretization model based on a tube-by-tube approach.

Each tube with associated fins works as a heat exchanger.

Bensafi et al. (1997)-Proposed a model that discretizes heat exchangers into tube elements.
Local values of properties and heat transfer coefficients are used. The authors also present a
computational procedure, which requires data on the coil geometry and circuit and
operational parameters such as temperature, mass flow rate, and pressure. In this model. The
cooling coils were analysed by a log mean temperature difference method.

Vardhan and Dhar (1998)-He proposed a model that discretizes the coil into nodes along
the tube-side path and carries out repetitive movement between the tube element entrance
and exit. While simultaneously updating the values of the air stream proper ties. Each
element uses an
effectiveness completed by mixed-umixed cross-flow e-NTU relations with the air side
Characterized by the minimum heat capacity rate.

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Corbern and Me1on (1998)-He developed a model discretizing the tube path with a UA-
log
mean temperature difference local approach to test the R 134a evaporation and condensation
correlation. A comparison of simulated with experimental data shows the most appropriate
correlation for computational simulation.

Bansal and Purkayastha (1998)-He simulated the performance of alternative refrigerants

in
heat exchangers of vapor compression refrigeration/heat pump systems.

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CHAPTER 3

PROJECT WORK

3.1 PROBLEM STATEMENT

The thermal performance of a heat exchanger depends upon so many factors. Some of them
are
thermal conductivities of involved fluids and materials, velocity of now, turbulence, quality
and
quantity of the insulation provided, ambient conditions now conditions, construction etc. To
make an exact prediction about the performance of heat exchanger under a set of loading
conditions is always a tough job. However by certain testing and experience predictions up
to
a certain level can be made. The present paper is also an attempt of analysing the
performance of shell and tube type heat exchanger under certain specified variables and
loading conditions.

3.2 OBJECTIVES

1. Determination of effectiveness of heat exchanger.

2. Determination of rate of heat transfer.

3.3 SELECTION OF MATERIAL

To be able to transfer heat well

1. The tube material should have good thermal conductivity.

2. The tube material also should be compatible with both the shell and tube side fluids for
long periods under the operating conditions (temperatures, pressures, pH, etc.) to minimize
deterioration such as corrosion.
3. The tube material should have low coefficient of thermal expansion
4. All of these requirements call for careful selection of strong, thermally conductive.
corrosion-resistant, high quality tube materials. Typically, metals, including aluminium,
copper alloy stainless steel, carbon steel, non-ferrous copper alloy. Inconel. Nickel,
Hastelloy and titanium.

Fluoropolymers such as perfluoroalkoxy alkane (PFA) and Fluorinated ethylene propylene

(FEP) are also used to produce the tubing material due to their high resistance to extreme
temperatures. Poor choice of tube material could result in a leak through a tube between the
shell and tube sides causing fluid cross-contamination and possibly loss of pressure.

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 3. 4 EQUIPMENTS USED

1. Cast iron shell.

2. U-shaped copper tubing.
3. Pressure cooker.
4. Heating Element.
5. Plastic pipes.
6. Metal pipes Joints.
7. Metallic frame.
8. Valves.
9. Thermocouples.
10. Temperature indicator.
11. Water pump.
12. Pressure Gauge.

3. 5 DESIGN AND FABRICATION

Materials

1. Casing-Cast iron
2. Piping-Copper
3. Flanges-Mild steel
4. Pipe Joints-Mild Steel
5. Valves-Stainless Steel
6. Frame-Cast iron

1. Casing specifications
Inner diameter, Di-152. 4 mm
Outer diameter, Do-157. 4mm
Length, L-650mm

2. Copper tube specifications-

Diameter, d-12. 7 mm
Length, l=3000mm

3. Flange specification
Diameter, D,-177 mm
Thickness, T-5mm

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Fabrication-First of a cast iron casing is taken and is cut to appropriate dimensions and two
holes are drilled for inlet and outlet of steam. Then copper tubing is shaped in a U spiral from
which cold water is passed. Two flanges are welded to the cast iron casing and to the ends of the
copper tubes. Plastic pipes are connected to the tubing through which water is to be passed. A
frame or base is made to which upon which whole set up is joined.
A pressure cooker is used to create steam and two holes are drilled into it. For one hole
pressure gauge is attached and to other valve arrangement which is further attached to the
steam inlet in casing.

3. 6 WORKING PROCEDURE

First of a1l liquid or water is filled inside the pressure cooker and plastic pipe is attached to the
water and outlet. Then the water is pumped into these pipes with the help of pump. The steam is
generated by heating the water inside the pressure cooker with the help of heater. The steam
generated by the pressure cooker is sent into the cast iron casing through the valve arrangement.

The cold water is inside the tubing and the steam will flow all around it inside the casing. As the
steam comes in contact with the cold water, it starts condensing we get condensed water at the
outlet of casing. Thermocouple wires are attached at the inlet and outlet of cold water and the
inlet/ outlet of steam.
By recording the values of inlet / outlet of the water and steam effectiveness can be found as per
the methods given in the calculations.

3. 7 FORMULA USED

1. Q = mhCph(th1-th2) = mcCpc (tc2-tc1)

where, thl-hot water inlet

th2-hot water outlet
tcl-cold water inlet
tc2-cold water outlet
Q = Heat transfer rate
mh-mass flow rate of hot fluid
mc-mass flow rate of cold fliud
Cph & Cpc-specific heat of hot and cold fluid

2. €= Ch (th1-th2)/ Cmin (th1-tc1)

where, € = Effectiveness of heat exchanger.

3. Logarithimic Mean Temperature Difference (LMTD)

ϴm= ϴ1-ϴ2/ ln(ϴ1/ϴ2)

4. Correction Factor, F
To know the correction factor we have to know first P (temperature ratio) and R (capacity
ratio).
P = tc2-tcl / th1-tcl
R=th1-th2 / tc2-tcl
 Figure. 3 : Correction factors plot for common cross flow heat exchangers

5. NTU method
NTU = UA/Cmin
where, U= Over all Heat Transfer Coefficient
NTU : Number of Transfer Units
A= Area of tubes=Npπd L, where Np is the number of tubes per pass

5. Reynolds Number
Re= ρVD/µ
If Re > 2300. Hence the flow is turbulent.

7. Nusselts Number
Nu=hd / k = 0. 023 (Re)0. 8 (Pr)0.4

8. Prandtls Number
Pr=µC p / k

9. Overall Heat Transfer Coefficient

U = hi ho / ho + hi

10. Rate of Heat Transfer

Q = FUAϴm
where, F = Correction Factor: U= Overall Heat Transfer Coefficient
ϴm=Logarithmic Mean Temperature Difference

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3.8 CALCULATIONS
Steam inlet, thi=1200C,

Steam outlet, th2=180C

Water inlet, tci=170c ,

Water outlet, tc2=370c

mc=0.011kg/s

Length of tube-52cm ,

Diameter of tube=12.7mm

Q=mc*cpc*(tc2-tc1)=0.011*4.14*10^3(37-17)=920.48KW

Cmax= mc*cpc=0.011*4.178*10^3=45.958W
Q=920.48=mh*cph(th1-th2)= mh*2206*10^3(120-18)
mh=0.00409Kg/s

Therefore, Cmin= mh*cph=0.00409*2.206=9.02W

Area=5πdl=5*1*3.14*0.0127*0.522=0.1033628m2

To find F, we have to find:

P(temperature ratio) and R(capacity ratio)
P= tc2-tc1/ th1-tc1=37-17/120-17=0.19417
R= th1-th2/ tc2-tc1=120-18/37-17=5.1
With the value of P=0.19147 and R=5.1, We get F=0.8

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Now we have to find ho and hi-
For hi-
mc=0.11kg/s,
Area of tube=0.1036m^2,
Dia of tube=12.7mm
Therefore Reynold’s number=4m/ πdl=1096.7
And Nu=hd/k=.023*(Re)^0.8*(Pr)^0.4

To find Pr=µcp/k=7.03
Hence, Nu=13.55
hi=k/d*Nu=0.5978/0.0127=637.8W/m^2®C

For ho,
mh=0.00409Kg/s, Dia of shell=).1574m
Re=2767.6

Since Re>2300, hence flow is turbulent

Therefore
Nu=0.023*(Re)^0.6*(Pr)*0.4
Pr=µcp/r=11.96*10^-6*2206/0.02373=1.11
Therefore Nu=13.56
Ho=k/d*Nu=0.02373/0.1577*13.56=2.04W/m^2®C
1/µ=1/hi+1/ho
µ=2.033W/m^2

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Further,LMTD is given by-
Ꝋm=Ꝋ1-Ꝋ2/Ln(Ꝋ1/Ꝋ2)= (th1-tc2)-( th2-tc1)/ln[(th1-tc2)/ (th2-tc1)]=18.55
Hence rate of heat transfer= Ꝋ=FUAꝊm=2.65W
Effectiveness-
€=Cmax(th1-th2)/Cmin(th1-tc1)=0.973
Effectiveness=97.3%

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 3.8 CALCULATIONS

Table 3.1 Effectiveness and Rate of Heat Transfer

S.No Steam Steam Water Water Effectiveness Rate of
Inlet Outlet Inlet Outlet Heat
Transfer

1 120 18 17 37 97.3% 2.65W

3.9 RESULT
1. The effectiveness of heat exchanger is 97.3 %.
2. The rate of heat transfer is 2.65 W.

3.10 CONCLUSION
Based on above study it is clear that many factors affect the performance of the heat
exchanger and the optimization obtained by the formulas depicts the cumulative effect
of all the factors over the performance of the heat exchanger. It is observed that by
changing the value of one variable the by keeping the rest variable as constant we can
obtain the different results. Based on that result we can optimize the design of the shell
and tube type heat exchanger. Higher the thermal conductivity of the tube metallurgy
higher the heat transfer rate will be achieved. Less is the baffle spacing, more is the
shell side passes, higher the heat transfer but at the cost of the pressure drop. So, while
optimization it must be taken care that the advantage in one of the output parameter can
affect the other parameters, which can lead to increase in initial or operating cost.

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CHAPTER 4

REFERENCES

1. A Gopichand, Prof. A. V. N. L. Shar ma, G. Vijay Kumar, A. Srividya, Thermal

analysis of shell and tube type heat exchanger using MATLAB and FLOEFD
software".

2. Durgesh Bhatt, Priyanka M Javhar, "Shell and Tube Heat Exchanger Performance
Analysis".

3. Dutta B. K., "Heat Transfer Principles and Applications", PHI Pvt. Ltd., New Delhi.

4. Er. R. K. Rajput "A Textbook of Heat and Mass Transfer " S. Chand & Company
Pvt. Ltd, Ram Nagar, New Delhi.

5. Ebieto, C. E and Eke G. B., Performance Analysis of shell and Tube Heat
Exchangers using Miscible System

6. Bensafi, A., Borg, S., and Parent, D., CYRANO : A Computational Model for the
Detailed Design of plate-fin-and-tube Heat Exchangers Using Pure and Mixed
Refrigerants, International Journal of Refrigeration

7. Domanski, P. A., Simulation of an Evaporator with Non-uniform One-dimensional

Air
Distribution

8. Vardhan, A. and Dhar, P. L., A New Procedure for Performance Prediction of Air
Conditioning Coils, International Journal of Refrigeration

9. Corberin, J. M. and Mel6n, M. G., Modelling oF Plate Finned Tube Evaporators and
Condensers

10. Bansal, p. K. and Purkayastha, B., An NTU-e Model for Alter native Refrigerants.
International Journal of Refrigeration

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