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CLB 21003
SECTION: L01-T1
Shell and tube heat exchanger is a class of heat exchanger design. It is the most common
type of heat exchanger in oil refineries and other large chemical processes, and is suited for high-
pressure applications. It consists of a shell with a bundle of tubes inside it. For this project, we
were required to design a shell and tube heat exchanger to transfer heat from a stream of kerosene
to a stream of water. Water will enter the exchanger on the shell side at a flow rate of 30 kg s-1 at
35 0C and 12 bars, and kerosene will enter on the tube side at a flow rate of 43 kg s-1 at 185 0C
and 8 bars. The tubes should be thin-walled with an internal diameter of not less than 1.5 cm and
outer diameter not less than 1.6 cm. The maximum length of each tube pass in the heat exchanger
cannot be more than 7.5 m. The tubes in the tube banks should be arranged in-line in the direction
of flow with a 4.5 cm square pitch minimum. The shell has an inside diameter of not smaller than
2.8 m. After that, we find the area of the shell and tube using the formula . Therefore,
the area for the tube is 0.3063m2 and for the shell is 56.5487 m2. Then, we need to find the velocity
of water stream and kerosene stream which is 0.0005 m/s and 0.1712 m/s. By finding the velocity,
we could find the Reynold’s number where the number is 125.2352 and74.239 respectively and
then we could substitute the value into the formula to determine the Nusselt number. Nu for both
water stream and kerosene stream is 7.1788 and 4.5868. Later on, we determine the thermal
resistance value before we find the LMTD. With the calculation, we get value for RT is 31.6383
o
C/W and to find the maximum effectiveness, we the find the NTU value to be 12,900,000 W.
Therefore after substituting into the formula, we get the maximum effectiveness is 90 %.
2.0 INTRODUCTION
2.1 HISTORY BACKGROUND
Heat exchanger is a device, which is used to transfer the thermal energy or enthalpy
between two or more fluids, between a solid surface and a fluid. It is important unit operation that
contributes to the efficiency and safety of many processes. Heat exchanger are classified according
to the transfer process, number of fluids, the degree of surface contact, design features, flow
arrangements, and heat transfer mechanisms. There are different types heat exchanger likes plate
and frame, compact heat exchanger, shell and tube heat exchanger, and some more.
Shell and tube have been used in industry for over 150 years, so that the thermal
technologies and manufacturing methods are well defined and applied by modern competitive
manufacturers. It was introduced in the early of 1990s to fill the needs in power plants for large
heat exchanger surfaces as condenser and feed water heaters capable of operating under relatively
high pressure. Both of the original applications of shell and tube heat exchangers continue to be
used, but the design have become highly sophisticated and specialized. The broad industrial used
to accommodate the demands of emerging oil industry.
During the 1920s shell and tube manufacturing technology became fairly well developed,
mainly because of the efforts of relatively few major manufactures. In 1930s, the designers
established many sound design principles from intuition and data emerging on ideal tube banks.
Viscous flow was one of the most difficult problems for shell side flow and was poorly understood
until the 1960s. Shell side pressure drop is not even mentioned in the literature until the late 1940s.
Condensers and reboilers were designed purely to experience derived values, often tightly guarded
secrets of the manufacturers.
Shell and tube heat exchanger are containing large number of tubes packed in the shell with
their axes parallel to the shell. There are few components inside the shell and tube. Baffles are
placed in the shell to force the shell side fluid to flow across the shell to enhance heat exchanger
and maintain uniform spacing between tubes. Then, it also used on the shell side fluid to
accomplish mixing or turbulence. Without the baffles, the fluid can become flowing in certain
parts of the shell. The used of headers is where the tube fluid accumulates before entering and
leaving the heat exchanger.
Figure 1: Example of Shell and Tube and its Components
A cylindrical shell with multiple tubes running inside the shell. One fluid passes through
the tubes and then exit the heat exchanger, and the other fluid circulates on the outside of the tubes
within the cylindrical shell. Heat is transferred from one fluid to the other through the walls of the
tubes.
Shell and tube heat exchanger are represent as the most widely used for the transfer of heat
in industrial process applications. The applications are likes process liquid or gas cooling, process
heat removal and preheating of feed water, compressor, turbine and engine cooling, oil and jacket
water, and hydraulic and lube oil cooling. It have the ability to transfer large amounts of heat in
relatively low cost, and serviceable designs. Then, it can also provide large amounts of effective
tube surface while minimizing the requirements of floor space, liquid volume, and weight.
The products will be used for this project are kerosene and water. Kerosene or also called
as paraffin or paraffin oil, is a flammable pale yellow or colourless oily liquid. Kerosene is a
refined petroleum distillate that has a flash point. In the early years of the petroleum industry
kerosene was the largest selling and most important product.
Some kerosene using devices emit substantial amounts of fine particulates, carbon
monoxide (CO), nitric oxide (NO), and sulphur dioxide (SO2). Portable kerosene room heaters
are used primarily in developed countries, and some developing countries such as Chile although
many countries have either prohibited or discouraged their used, particularly because of the risk
of carbon monoxide (CO) poisoning (Long,1997)
2.3 TYPE OF HEAT EXCHANGER
T
Q UAT U i Ai T U o Ao T
R
The Log Mean Temperature Difference Method (LMTD)
1 2
Tm
ln 1
2
3.0 TUBE BANK ANALYSIS
Tube banks are commonly-employed design elements in heat exchangers. Both plain and
finned tube banks are widely found. Tube bundles are a sub-component in shell-and-tube heat
exchangers, where the flow resembles crossflow at some places, and longitudinal flow elsewhere.
St 4.5 cm2
µ 𝑘𝑔 Pressure 12 bars
0.404𝑥10−3
𝑚. 𝑠
Assume Diameter
Tube Di = 1.5 cm @ 0.015 m
Tube Do = 1.6 cm @ 0.016 m
Lc= 6.5 m
= 127.47 ºC
𝜌(𝑉𝑚𝑎𝑥)(𝐷𝑜) (𝑉𝑚𝑎𝑥)(𝐷𝑜)
Re = =
𝜇 𝑣
𝑆𝑡 0.045 𝑚
Vmax= V= 0.1712
𝑆𝑡−𝐷𝑜 0.045−0.016 𝑠
𝑚
= 0.2657
𝑠
𝜌(𝑉𝑚𝑎𝑥)(𝐷𝑜) (𝑉𝑚𝑎𝑥)(𝐷𝑜)
Re = =
𝜇 𝑣
𝑚
(0.2657 𝑠 )(0.016𝑚)
= 𝑚2
3.394 𝑥 10−5
𝑠
= 125.2352
Nu for cylinder
= 4.5868
= 11.4548 W/m2.℃
a. Tf :
f. Pr = 0.6979 f. Pr = 2.55
Calculation analysis (Shell):
Reynold number
𝑚
𝑉𝐿𝑐 (0.0005 𝑠 )(3𝑚)
Re = = 𝑚2
= 74.239
𝑣 2.0205𝑥 10−5 𝑠
Nusselt number
1 1 5 4
0.62 𝑅𝑒2 𝑃𝑟3 𝑅𝑒
Nu = 0.3 + 1 [1 + ( )]
8 5
2 4 282000
[1 + (0.4
𝑃𝑟
3
) ]
1 1
0.62 (74.239)2 (2.55)3 74.239 5 4
= 0.3 + [ 1 ] [1 + ( )8 ]5
2 4 282000
0.4 3
[1 + (2.55 ) ]
= 7.1788
𝑤
𝑁𝑢.𝑘 (7.1788)(0.663𝑚.℃)
ho = =
𝐷𝑖 3𝑚
𝑤
= 1.5865
𝑚.℃
Overall heat transfer coefficient, U
𝑄
U = 𝐴𝑡 ∆𝑇𝑚
11,610,000 𝑤
=(
0.3063 𝑚2 )( 31.6383℃)
= 1,198,042.109𝑚2𝑤℃
𝑄
AS =
𝑈∆𝑇𝑚 𝐹𝑇
𝑇21 − 𝑇2 (185−50)℃
R= = (127.47−35)℃ = 1.46
𝑡2 − 𝑡1
𝑡 −𝑡 (127.47−35)℃
P = 𝑇2 − 𝑡 1 = (185−35)℃
= 0.62
1 1
𝑄
AS =
𝑈∆𝑇𝑚 𝐹
11,610,000 𝑊
= 𝑤
(1,198,042.109𝑚2 ℃ )( 31.6383℃)(0.5)
= 0.6126𝑚2
Number of tube
0.6126 𝑚2
=
0.3063 𝑚2
= 2 tubes
5.0 PRODUCT QUALITY ASSURANCE
Efficiency
Find Cmin
CH = 𝑚̇ x CpH
𝑘𝑔 𝐽
= (43 )( 2000 𝑘𝑔 .℃)
𝑠
𝐽
= 86,000 𝑠 .℃
CC = 𝑚̇ x Cpc
𝑘𝑔 𝐽
= (30 )( 4185 𝑘𝑔 .℃)
𝑠
𝐽
= 125,550 𝑠 .℃
Cmin = CH
Find Qmax
= 12,900,000W
𝑄 𝑎𝑐𝑡𝑢𝑎𝑙
E= X 100%
𝑄 𝑚𝑎𝑥
11,610,000 𝑊
= X 100%
12,900,000 W
= 90%
6.0 COST ESTIMATION
= RM 7130
Heat exchanger design
Tci = 35 ºC
ṁ = 43 kg/s
Tci = 185 ºC
ṁ = 50 kg/s
Tci = 50 ºC
ṁ = 50 kg/s
Tco = 127.47 ºC
ṁ = 43 kg/s
7.0 REFERENCES
Anonymous, Bengt Sunden Lund Institute of Technology, Introduction of Heat Exchanger,
(3.02 am, 16/6/2017)
Anonymous, Explore the World of Piping, Heat Transfer by Heat Exchanger, Shell & Tube
(3.56am, 16/6/2017)
J.Taborek, Volume 3- Thermal and Hydraulic Design of Heat Exchangers > Shell and Tube
Heat Exchanger Design, Objectives and Background, DOL 10.1615/hedhme.a.000247
(4.12am, 16/6/2017)
Anonymous, Omics International, (research.omicsgroup.org/index.php/Kerosene)