DESIGN OF SHELL AND TUBE

HEAT EXCHANGERS

BY -AJINKYA R SHELKE
GUIDED BY
DR. S. PAVITHRAN

OBJECTIVE OF WORK
Based on prescribed pressure drop, the starting heat exchanger
geometry was determined, that satisfies thermo hydraulic
conditions.
The shell side fluid (combustion products) flows in cross flow
direction. With a baffle in the middle along the tube length, the
shell side fluid changes its flow direction by 180 degrees and
then flows out.
The cooling water flows inside the tubes. Computations were
performed for Reynolds numbers up to 10000. Three different
turbulence models were used to predict the turbulence velocity
field. Three-dimensional simulation of the fluid flow and heat
transfer processes was carried out.

Introduction
Shell and tube heat exchangers are used
extensively throughout the process industry
and as such a basic understanding of their
design, construction and performance is
important to the practicing engineer.
The optimum thermal design of a shell and
tube heat exchanger involves the consideration
of many interacting design parameters.

Process
1. Process fluid assignments to shell side or tube
side.
2. Selection of stream temperature specifications.
3. Setting shell side and tube side pressure drop
design limits.
4. Setting shell side and tube side velocity limits.
5. Selection of heat transfer models and fouling
coefficients for shell side and tube side.

Mechanical Parameters

1. Selection of heat exchanger TEMA layout and

number of passes.
2. Specification of tube parameters - size, layout,
pitch and material.
3. Setting upper and lower design limits on tube
length.
4. Specification of shell side parameters materials,
baffle cut, baffle spacing and clearances.
5. Setting upper and lower design limits on shell
diameter, baffle cut and baffle spacing.

Introduction to CFD
Computational Fluid Dynamics, abbreviated as CFD, uses
different numerical methods and a number of computerized
algorithms in order to solve and analyze problems that involve
the flow of fluids. The calculations required simulating the
interaction of fluids with surfaces defined by boundary
conditions, and initial conditions are done by the OpenfoamThe
Navier-Stokes equations form the basis of all CFD problems.
Two equation models are used for the simulations, and different
models are discussed below.
The continuity equation, energy equation and the Navier-Stokes
momentum equation govern the flow of the fluid in the curve
tubes

Turbulence model
Turbulence is created because of the unstable nature of the fluid flow. The
flow becomes turbulent for higher Reynolds number. In this model the k-
(turbulent kinetics energy k and the turbulent dissipation ) model is
used.
The physical interpretation of the equation is,
1. Accumulation of
2. Convection of by the mean velocity
3. Production of
4. Dissipation of
5. Diffusion of
The time constant for turbulence is calculated from the turbulent kinetic
energy and dissipation rate of turbulent kinetic energy.

CFD analysis
Geometry
Heat exchanger is built in the
salome design module. It is a
counter-flow heat exchanger. First,
the fluid flow module is selected. The
design modeler opens as a new
window as the geometry is double
clicked.

Mesh
Initially a relatively coarser mesh is generated. This
mesh contains mixed cells (Tetra and Hexahedral cells)
having both triangular and quadrilateral faces at the
boundaries. Care is taken to use structured hexahedral
cells as much as possible. It is meant to reduce
numerical diffusion as much as possible by structuring
the mesh in a well manner, particularly near the wall
region. Later on, a fine mesh is generated. For this fine
mesh, the edges and regions of high temperature and
pressure gradients are finely meshed.

y+ Values

y + values play a significant role in turbulence modeling for the near wall
treatment. y+ is a non-dimensional distance. It is often used to describe how coarse
or fine a mesh is for a particular flow pattern. It determines the proper size of the
cells near domain walls. The turbulence model wall laws have restrictions on the
y+ value at the wall. For instance, the standard K-epsilon model requires a wall y+
value between approximately 300 and 100. A faster flow near the wall will produce
higher values of y+, so the grid size near the wall must be reduced. y+ values for
different wall treatments are given in table .

Standard k Turbulence Model

The k turbulence model proposed by Harlow and

Nakayama (1968) is by far the most widely used twoequations eddy-viscosity turbulence model, mainly
because the was long believed the require no extra terms
near walls. The popularity of the model, and its wide use
and testing, has thrown light on both its capabilities and
its shortcomings, which are well documented in the
practice. For high turbulent Reynolds numbers, the
standard form of the k model are applied.

 Run Calculation
The number of iteration is set to
1300 and the solution is calculated
and various contours, vectors and
plots are obtained

Results And Discussions

Contours
The temperature, pressure and velocity distribution
along the heat exchanger can be seen through the
contours.