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PII: S2214-157X(17)30341-6
DOI: https://doi.org/10.1016/j.csite.2018.07.009
Reference: CSITE318
To appear in: Case Studies in Thermal Engineering
Received date: 24 December 2017
Revised date: 16 June 2018
Accepted date: 23 July 2018
Cite this article as: Ammar Ali Abd, Mohammed Qasim Kareem and Samah Zaki
Naji, Performance Analysis of Shell and Tube Heat Exchanger: Parametric
S t u d y , Case Studies in Thermal Engineering,
https://doi.org/10.1016/j.csite.2018.07.009
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Performance Analysis of Shell and Tube Heat Exchanger:
Parametric Study
Ammar Ali Abd1,3, Mohammed Qasim Kareem1, Samah Zaki Naji2,3
1
Water Resources Engineering College, Al-Qasim Green University, Iraq.
2
Petroleum Engineering Department, Kerbala, Iraq.
3
Chemical Engineering Department, Curtin University, Australia
(ammarali.abd@postgrad.curtin.edu.au)
(ammarali@wrec.uoqasim.edu.iq)
(mohammed.qasim.salami@wrec.uoqasi.edu.iq)
(Samah.alrashid@uokerbala.edu.iq)
Abstract
Enhancement of heat transfer through shell and tube exchangers stills taking high
attention by researchers. The present work investigated the effect of shell diameter
and tube length on heat transfer coefficient and pressure drop for shell side with
both triangular and square pitches. In addition, the effect of baffle spacing and
cutting space on heat transfer coefficient and pressure drop were studied.
Moreover, standards fouling rates used for both shell and tube sides to estimate
the reduced heat transfer. Increasing shell diameter with a triangular pitch and
pull-through floating head recorded 3% increasing in heat transfer coefficient for
only 0,05m increasing in shell diameter. While 2.8% increase in heat transfer
coefficient for shell side by 0.05m increasing in shell diameter with split-ring
floating head and square pitch. Heat transfer coefficient for shell side reduced by
15.15% by increasing baffle space by 0.2 from shell diameter and the pressure drop
by 41.25%. Increasing cutting space from 15% to 25% decreases heat transfer
coefficient by 5.56% and the pressure drop diminished by 26.3%. Increasing tube
length by 0.61m leads to enhance the heat transfer coefficient by 31.9% and
pressure drop by 14.11% for tube side. For shell side, increasing tube length by
0.61m gives 2.2% increasing in heat transfer coefficient and 21.9% increasing for
pressure drop. Fouling resistance change on shell side shows a high effect on heat
transfer more than same rate change on the tube side. Based on the result, this
study can help designers to quick understand of each parameter effect on heat
transfer into shell and tube exchangers.
Introduction
Shell and tube heat exchanger considers one of the most common types of
exchangers widely used in the industrial processes. This exchanger consists of a
vessel with different sizes contains a number of tubes inside. Heat transfers
between these tubes together and with the shell side through tube walls. Shell and
tube exchangers characterize by easy to manufacture in different sizes and flow
configurations [1]. The rate of transferred heat depends on several factors such as
feed temperature and pressure, shell diameter, a number of tubes, tube geometry,
baffle spacing and cutting spacing [2]. Abd & Naji (2017) studied design of shell
and tube heat exchanger in details and tested the effect of shell diameter on
overall heat transfer coefficient by using different bundle diameters [3]. Shinde &
Chavan, (2017) concluded that baffle spacing, and pitch type can play a vital role in
enhancing heat transfer into exchangers [4]. In the same vein, Eryener (2006)
tested the effect of baffle material on heat transfer coefficient and pressure drop by
using different materials of constructions to recommend stainless steel as the best
choice [5]. Yu, Ren, and Zeng (2018) tested the effects of distance, width, profile,
and layout of the baffle on the overall heat transfer of exchanger [6]. Dizaji,
Jafarmadar, and Asaadi (2017) investigated experimentally using a corrugated shell
and corrugated tube instead of smooth shell and tube to improve the heat transfer
through the exchanger [7]. Alimoradi and Veysi (2017) examined the effect of
geometry parameters on the heat transfer and entropy generation [8]. Gao et. al.
(2015) experimentally studied the effect of using helix angles on the performance of
shell and tube heat exchanger [9]. Each part in exchanger has a direct effect on the
total transferred heat, therefore, it is important to choose carefully all the
parameters.
This paper will design shell and tube heat exchanger by using different parameters
to study the effect of baffle spacing, cutting space, shell diameter, tube length,
fouling rate on heat transfer coefficient and pressure drop for shell and tube sides.
The properties estimated by using Hysys simulation program for dry gases in shell
side and hot oil in tube side as shown in table 1 and 2. In the design of shell and
tube exchanger cannot avoid trial and error process to reach requested result.
Therefore, study the effect of each parameter of design can lead to quick
prediction and effective design.
The simulation run with Hysys v8.8 program, where the fluid package chose to be
Peng-Robinson. The working conditions include input and output temperatures,
mass flowrate, pressure, and compositions provided from real project executed by
Clough company as shown in tables 1 and 2. The design suggested to pumped dry
gases in shell side and hot oil in tube side.
Many factors influence the fluid flow inside shell side such as tubes arrangement,
pith type, baffle space, cutting space, and shell header type. Abd & Naji (2017)
mentioned procedure to calculate shell diameter based on the bundle diameter
with triangular and square pitches [3]. Here, the calculations used three different
types of headers which are pull-through floating head, split-ring floating head, and
outside packed head. Shell diameter estimated for each type to check out the
change in heat transfer coefficient for triangular and square pitches respectively.
Generally, heat transfer coefficient for shell side increases as shell diameter
increases for both triangular and square pitches. Pull-through floating head with
triangular pitch gives 3% increasing in shell heat transfer coefficient for 0.005m
increasing in shell diameter. While split-ring floating head promotes heat transfer
coefficient on shell side by almost 1% only for 0.005m increasing in shell diameter
with a triangular pitch. Outside packed head comes with small shell diameter
compare to two other heads, and the heat transfer coefficient increases by 1.5% for
0.005m increasing in shell diameter with a triangular pitch. Controlling heat
transfer coefficient can be achieved by manipulating the header as shown in the
figure below. While square pitch creates larger shell diameter than triangular pitch
for same conditions. Where, pull-through floating head increases heat transfer
coefficient for shell side by 0.9%, 2.8% with split-ring floating head, and 1.5% with
an outside-packed head for o.005m increasing in shell diameter.
1350
1300 Hs Split-ring
floating head
1250
1200
Hs Outside-
1150 packed head
0.74 0.76 0.78 0.8 0.82 0.84 0.86 0.88 0.9
Shell Diameter (m)
Figure 1. shell diameter against heat transfer coefficient for shell side with three types of
headers and triangular pitch.
Square Pitch
Hs, Pull- 1350
Shell overall heat transfer
Through
coefficeint (w/m2.k)
Based on above figures, square pitch can be selected as best choice to increase
shell diameter for all three headers. The possible reason is the design pressure for
this heat exchanger is small, where square uses usually with small range of
pressure. On the other hand, triangular pitch gives the ability to control shell
diameter in case of high pressure drop and high overall heat transfer.
2- Effect of baffle and cutting spacing on overall heat transfer
coefficient and pressure drop
Baffles can play a vital role in enhancing heat transfer by increasing velocity and
direct the fluid stream. Single segmental considers as common baffle type. Eryener
(2006) examined the determination of optimum baffle spacing in the design of
shell and tube heat exchanger [5]. Sinnott (1993) concluded that effective baffle
spacing range is between 0.2 to 1 from shell diameter [10]. Li and Kottke (1998)
investigated experimentally the effect of baffle spacing on the performance of heat
exchanger [11]. While Saffar and Damangir (1995) developed a new correlation to
estimate the optimum baffle spacing [12]. This study uses different baffle spacing
to inspect the change in both pressure drop and heat transfer coefficient on the
shell side. Figure 3 shows that pressure drop, and heat transfer coefficient
decreases as baffle spacing increases. Where heat transfer coefficient reduces by
15.15% for 0.2 from shell diameter increasing in baffle spacing. Shell pressure drop
decreases by 41.25% to 0.2 from shell diameter baffle spacing increases as shown in
the figure below. Where, increasing baffle space leads to reduce velocity, as a
result, the pressure drop decrease and overall heat transfer as well, this finding
agrees with what was reached by Li and Kottke experimentally.
12000 1400
Pressure drop of shell side (N/m2)
2000 200
0 0
0 0.2 0.4 0.6 0.8 1
Shell Pressure Drop
Baffle spacing (m)
Figure 3. Baffle spacing against shell heat transfer coefficient and shell pressure drop.
While figure 4 illustrates that increasing cutting space reducing both heat
transfer coefficient and pressure drop of shell side. It shows that using 15%
cutting space lead to higher heat transfer coefficient and high-pressure
drop. Increasing in cutting space by 10% produces decreasing in shell heat
transfer coefficient by 5.56% and the pressure drop reduces by 26.3%.
instead of heat transfer coefficient and pressure drop decreases, however
pressure drop reduced by percent higher than heat transfer coefficient
which can be a method to reduce generated pressure into shell side.
Therefore, the cutting space and baffle spacing can be selected based on the
required specification to balance the pressure drop and high heat transfer.
16000 1600
14000 1400
12000 1200
10000 1000
(w/m2.k)
8000 800
6000 600
4000 400
2000 200
0 0
15% 25% 35% 45%
Shell Pressure Drop
Baffle Cuting (m)
Shell heat transfer coefficient
Figure 4. Cutting space against shell heat transfer coefficient and shell pressure drop.
1800 12000
1600
10000
1400
1200 8000
(w/m2.k)
1000
6000
800
600 4000
400
2000
200
0 0
1.83 2.44 3.66 4.88 6.1
Tube Length (m)
Tube pressure drop
Figure 5. Tube length against heat transfer coefficient and pressure drop for tube side.
1800 1600
1600 1550
1400 1500
1200
1450 (w/m2.k)
1000
1400
800
1350
600
400 1300
200 1250
0 1200
1.83 2.44 3.66 4.88 6.1
Tube Length (m)
Shell Pressure Drop Overall heat transfer coefficient
Figure 6. Tube length against heat transfer coefficient and pressure drop for shell side.
The reason after increases operation pressure and overall heat transfer coefficient
with tube length increasing is that cross section area directs proportion to tube
length. As a result, total heat transfer and pressure increases.
4- Effect of Fouling factor on heat transfer
2840
2800
2760
2720
2680
2640
0.0003 0.00035 0.0004 0.00045 0.0005
Fouling rate
2820
2810
2800
2790
2780
0.000175 0.00018 0.000185 0.00019 0.000195 0.0002 0.000205
Fouling Rate
Conclusion
The study investigated the effect of change some parameters on heat transfer
coefficient and pressure drop for shell and tube heat exchanger. The study
concluded that as shell diameter increases the heat transfer coefficient and
pressure drop increases. The pull-through head with triangular pitch can be the
best choice to increase heat transfer coefficient. While, baffle spacing and cutting
space reduced the heat transfer coefficient when increases. The fouling factor on
shell side can affect the heat transfer heat more than that for tube side, therefore it
is important to reduce fouling rate on shell side. The parameters selection has
direct effect on both overall heat transfer coefficient and pressure drop.
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Note: The values at the mean temperature were obtained by linear interpolation.