DESIGN OF SHELL AND TUBE HEAT EXCHANGER

ASSOSA UNIVERSITY
COLLEGE OF ENGINEERING
DEPARTMENT OF MECHANICAL ENGINEERING
PROJECT TITLE: THE DESIGN AND SIMULATION OF SHELL
AND TUBE HEAT EXCHANGER IN EXHAUST GAS RECOVERY FOR
HEATING PURPOSE

A THESIS SUBMITTED TO MECHANICAL ENGINEERING DEPARTMENT IN PARTIAL

FULFILLMENT OF THE REQUIREMENT FOR THE DEGREE OF BACHELOR OF
SCIENCE IN MECHANICAL ENGINEERING

PREPARED BY:

Name of student ID Signature Date

1. Yeshiwork Gebeyehu ………0546/09 …

2. Ribika Bekele……………………..1935/09

3. Birtukan Tilahun………………..

4. Nabile Osman…………………..

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DESIGN OF SHELL AND TUBE HEAT EXCHANGER
DECLARATION
We,Yeshiwork Gebeyehu, Ribika Bekele ,Birtukan Tilahun, Nabile Oseman are 5th year mechanical
engineering students have theses on “Design of shell and tube heat exchanger by using exhaust gas
to heat water We declare that” our work is original and compiled according to the design project
guideline.

Name of student Signature Date

1. Yeshiwork Gebeyehu
2. Ribika Bekele
3. Birtukan Tilahun
4. Nabile Osman

PPROVED BY
Name of Advisor Signature Date
Mr.SERAJ
Name of Examiner Signature Date

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DESIGN OF SHELL AND TUBE HEAT EXCHANGER
ACKNOWLEDGEMENT
First of all, our deep gratitude goes to almightily GOD for ever thing he did to us then after we
would like to express our sincere gratitude to Mr.MOHAMED.A for providing
this interesting and exciting topic and then providing his guidance, assistance and encouragement
throughout the duration of the theses. Next, we really like to appreciate the continuous support of our
advisor Mr.SERAJ we appreciate his consistent support from the first day of the project to these
concluding moments. Sincere thanks to our all staff of the Mechanical Engineering
Department who helped us in many ways and providing equipment and information that assisted
our theses. Special thanks to our lovely parents for their support, love, dream and sacrifice
throughout our life. We would like to appreciate their devotion, support and faith in our ability to
attain our goals.

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DESIGN OF SHELL AND TUBE HEAT EXCHANGER
Abstract
Heat Exchangers are devices that are utilized to transfer the internal thermal energy of two or more
substances which are available at different temperatures. It is used in various different applications such
as condensers and evaporators in the HVAC industry, Automobile Radiators in the automobile industry,
and oil coolers, Food processing industry, Construction industry and many more. They can be classified
according to various classifications. This project is aimed towards a tubular heat exchanger when
classified according to construction and it is the shell and tube heat exchanger which is considered as
one of the popular heat exchanger types that is being currently used in the Industries. The project will
be focusing on designing, a shell and tube heat exchanger with an improved overall heat transfer
coefficient and also achieve an approaching counter flow fluid direction instead of a cross flow and
parallel flow fluid direction. Shell and tube heat exchangers are designed to make the contrast and
comparison between the conventional shell and tube heat exchanger with the newly proposed shell and
tube heat exchanger. The shell and tube heat exchanger model and materials used will influence the
effectiveness of heat exchanger. Comparing the different models with different materials enables us to
suggest a suitable model and material for heat exchanger. This suggested model and material can
recover more waste heat from Boiler exhaust gas waste heat recovery system. For comparing several
heat exchangers under the same boundary conditions CFD is a powerful tool So, in this context, we
have to optimize the existing design of heat exchanger by varying baffles and materials. Thus, in this
thesis, boiler plant municipal waste was characterized, detailed modeling and simulation of shell and
tubes Waste to Energy plant for Cities are performed. Various ways to maximize the energy
performance of Waste-to-Energy plants has been done.

Different data has been collected through literature. Waste gas used in water heating Thus, based on the
design analysis, the parameter are the in let temperature of shell 250 C Ois and the out let temperature is
90 ℃ and the tube in let temperature is 29℃proposed model can have out let is 61℃ bacteria can exist
at the temperature of 40℉ to 140℉ this boiler plant have exhaust flue gas temperature can generate
approximately 2.4 kW net heat power at 37 % net efficiency with waste throughout put of 19Kg/s. As a
result, the heat generation potential of was assessed by varying the parameter waste through puts.
Detailed analysis has been done by varying the input parameter input from 312.04 kg/day to 456
kg/day. Thus, based on the result, net heat power of 0.5 – 1kW can be obtained for heating water net
heat power of 1 – 1.5kW. The result also shows that fuel’s lower heating value, moisture and ash, , and
size of the plant affects the plant’s performance significantly. Thus, by adopting shell and tube heat
exchanger with a generating capacity of 2.45 W wash around 10,000 bottles within given time then this
helps to solve the economic and environmental problem. That is fuel consumption and environmentally
reduce GHE (greenhouse effect) .
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DESIGN OF SHELL AND TUBE HEAT EXCHANGER
Key words: CFD, Optimization, Shell and tube heat exchanger, GHE, Waste heat recovery.

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Contents

CHAPTER ONE
INTRODUCTION

1.1 Back ground of study

Heat lost in industries through ways such as discharge of hot combustion gases to the atmosphere
through chimneys, discharge of hot waste gas, and heat transfer from hot surfaces. This energy loss
can be recovered through heat exchangers and be put to other use such as preheating other industrial
fluids such as water.This project focuses on recovering waste gas or heat that is lost through boiler
chimney flue gas. In every aspect of life, competition has become a key factor to engineers to utilize
every bit of energy in proper manner. Stress is mainly on engineers that how to make devices which
are compatible to this era. This competition has lead the industries to work smarter and more
skillfully. The advancement in living has put a greater demand for more compact and energy saving
devices. This criterion of energy saving now-a-days has revolutionized the industrial sector. This is
because energy sources are limited and every industry wants the better use of the source it has. Waste
Heat Recovery the rising costs of energy and the global warming in recent years have highlighted the
need to develop advanced energy systems to increase the efficiency and reduce the emissions. One of
the methods that are extensively used is the waste heat recovery.
Waste heat recovery is the process of yielding energy from potential high energy sources that are lost
to the environment without any useful work usually following an industrial energy conversion
process .There is a great scope to recover waste heat from various industries and to process heat using
a heat recovery heat exchanger The technological know-how of waste heat recovery is indeed a
subject that has been subjected to extensive research and development. Some of the most widely used
waste heat recovery technologies are listed below. Thus energy conservation, conversion and
utilization can have a vital developmental role in industry. One bitter truth we faced earlier times was
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DESIGN OF SHELL AND TUBE HEAT EXCHANGER
that most of industries lacked the techniques to fully utilize any energy source. Thus energy
dissipation was a big drawback. But advancement in engineering fields leads us to develop devices
which could properly utilize the energy of a source. Among some devices was one which is used to
utilize heat energy of a source. The devices designed to allow heat to convey from a fluid kept at more
temperature to a fluid maintained at relatively low temperature than first one are termed as heat
exchangers
A heat exchanger is a device used to transfer heat between a solid object and a fluid, or between two
or more fluids. The fluids may be separated by a solid wall to prevent mixing or they may be in direct
contact. They are widely used in space heating, refrigeration, air conditioning, power stations,
chemical plants, petrochemical plants, petroleum refineries, natural gas processing and sewage
treatment. And also Heat exchangers are widely used in manufacturing and process industries for
several applications. [3]
The choice of heat exchanger for a given application is dependent on several factors such as the
application, available floor area, available resources, and connections in the field, cost, and many
more. In a highly competitive environment, it is essential that the heat exchanger must deliver the
required heat transfer, occupy less space, weigh less, and yet be priced competitively.

1.2 Idea generation and selection of the project

Our daily activity is related with heating and cooling of matter so when we see from largest industry
there is much amount of exhaust to the environment this lead to environment pollution and energy lose
particular increase fuel consumption so the design of shell and tube heat exchanger is viable to save
unwanted lose and also interest on the energy side of mechanical engineering, specially
thermodynamics and heat transfer are what made this topic for the final year project topic. When
selecting the specific topic for the final year project, the followings influenced to select this particular
project topic which is to improve the efficiency of a conventional shell and tube heat exchanger (a
heater.

1. Specific interested subject areas like heat transfer, sustainability and energy, pressure
temperature relationship involved subjects such as thermodynamics
2. The Future career after graduating as a mechanical engineer
3. Various outside influences such as field visits etc.
4. Engineering background knowledge.

Also, during the internship period was influenced on the area of thermodynamics and heat transfer due
to the exposure to a project which was based on a fire tube boiler for which an extensive research was

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carried out to monitor the monthly consumption of fuels (desile) that was spent by the specific
amount.
The heat exchanger can be classified/grouped into the following various forms.
 According to Construction.
 According to the transfer process.
 The flow arrangement.
 Pass arrangements.
 The phase of the process fluids.
 Heat transfer mechanisms.
1. Classification according to constriction
 Tubular
 Plate
 Extended surface
 Regenerative
2. According to transport process
 Indirect contact
 Direct contact
3 .According to pass arrangement
 Single pass
 Multi pass
4 .According to flow arrangement
 Parallel flow
 Counter flow
 Cross flow

In this project the heat exchanger is classified according to the construction.

1.2 Tubular Heat Exchangers

These exchangers are generally built of circular tubes, although elliptical, rectangular, or round/flat
twisted tubes have also been used in some applications. There is considerable flexibility in the design
because the core geometry can be varied easily by changing the tube diameter, length, and
arrangement. Tubular exchangers can be designed for high pressures relative to the environment and
high-pressure differences between the fluids. Tubular exchangers are used primarily for liquid-to-
liquid and liquid-to-phase change (condensing or evaporating) heat transfer applications. They are
used for gas-to-liquid and gas-to-gas heat transfer applications primarily when the operating
temperature and/ or pressure is very high or fouling is a severe problem on at least one fluid side and
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no other types of exchangers would work. These exchangers may be classified as shell-and tube,
double-pipe, and spiral tube exchangers. They are all prime surface exchangers except for exchangers
having fins outside/inside tubes [2].
Shell-and-Tube Exchangers. This exchanger, shown in is generally built of a bundle of round tubes
mounted in a cylindrical shell with the tube axis parallel to that of the shell. One fluid flows inside the
tubes, the other flows across and along the tubes. The major components of this exchanger are tubes
s(or tube bundle), shell, frontend head, rear-end head, baffles, and tube sheets, and are described
briefly later in this subsection. 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. Shell-and-tube exchangers are classified and constructed in accordance with the widely sed
TEMA (Tubular Exchanger Manufacturer Association) standards (TEMA, 1999), DIN and other
standards in Europe and elsewhere, and ASME (American Society of Mechanical Engineers) boiler
and pressure vessel codes. TEMA has developed a notation system to designate major types of shell-
and-tube exchangers.[1] .In this project, a shell and tube heat exchanger is designed for heating water.
Hot water is used for a certain process heating application and steam is the heating medium and
in our project for washing bottle. The heat exchanger shall be designed such that the hot water flows
through the tubes and steam through the shell side of the heat exchanger. It is assumed that large steam
flow rate is available to provide the required heating for the hot water in the shell and tube heat
exchanger. A LMTD approach shall be used to design the shell and tube heat exchanger. Shell and
tube heat exchangers are the most common type of waste heat exchangers used in the industry. It is a
proven and efficient heat recovery arrangement where the colder fluid is usually flowing inside the
tubes.
1.3 Types of shell and tube heat exchanger
There two general types
i. Vertical type
ii. Horizontal type
There are mainly 3 type of heat exchanger.
They are the direct transfer type, storage type and direct contact type .In many heat exchangers, the
fluids are separated by a heat transfer surface and ideally they do not leak or mix and such
exchangers are referred to as direct transfer type. Whereas, heat exchangers in which there is an
intermittent heat exchange between the hot and cold fluids via thermal energy storage and release
through the exchanger surface are referred to as indirect transfer type, or simply regenerators.

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Heat transfer takes place generally by the conduction phenomenon in the separating wall of a direct
transfer type heat exchanger. In general, the separating wall may be eliminated, if the fluids are
immiscible, and the interface between the fluids replaces a heat transfer surface, as in a direct-
contact heat exchanger.
Common examples of heat exchangers are shell-and tube exchangers, automobile radiators,
evaporators, condensers, air preheaters and cooling towers. If no phase change takes place in any
of the fluids in the exchanger, it is referred as a sensible heat exchanger. Combustion and
chemical reaction may occur within the exchanger, such as in boilers, fired heaters, and fluidized-
bed exchangers. Typical applications involve evaporation or condensation of single or multi
component fluid streams, heating or cooling of a fluid stream of concern. In other applications, the
objective may be to recover heat. The shell and tube heat exchanger is generally built by bundle of
round tubes mounted in a cylindrical shell with the tube axis parallel to that of the shell as
This heat transfer between two fluids can occur through two possible ways direct encounter between
fluids or restricting them from mixing and allowing heat to transfer by some other means. In this case
convection is and conduction is possible. that is barrier must be a good conductor of heat convection
may be natural and forced naturally without any external influence easily by density differance. While
forced is by using external force pump. [12]
1.4 The heat transfer occurs in following manner:
 Convection: it occurs when flowing hot fluid transfers its energy to the stationary barrier.
 Conduction: It occurs inside the barrier and transfers heat from one side of barrier to an other
side. Convection: It occurs at the other barrier end where from heat has to be transferred to the
other fluid maintained at varying temperature. In intercoolers, boilers, pre-heaters and
condensers inside power plants as well as other engineering processes, heat exchangers are
utilized for controlling heat energy. Heat exchangers are devices that regulate efficient heat
transfer from one fluid to another. There are two main types of heat exchangers.
The first type: of a heat exchanger is called the recuperative type, in which heat are exchanged on
either side of a dividing wall by fluids;
The second type: is regenerative type, in which hot and cold fluids are in the same space which
contain a matrix of materials which work alternately as source for heat flow.
STHX is among the type which doesn’t allow the mixing of the two fluids. In this one fluid is allowed
to pass through tubes and another fluid passes through the shell

1.5 Components of shell and tube heat exchanger

1. Tube side fluid inlet
2. Shell side fluid inlet
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3. Baffles
4 .Shell head
5. Tube side fluid out
6 .Shell side fluid out
7. Tubes
8. Shell
9. shell cover

Figure 1.1; - recuperative type

Vol.9Issue01, January-2020[ 2 ]

Figure 1. 2; - regenerative types

Types of shell and tube heat exchangers according to flow arrangement:
i). Parallel flow. (Cengel, 2002)
Both fluids (hot fluid and cold fluid) enter the heat exchanger at the same end and move in the same
direction to leave at the other end as shown in the figure below.

Fig 1.3 shows the flow regimes temperature profile

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(ii). Counter flow (Cengel, 2002)
In these types of arrangement, the cold and hot fluids enter the exchanger at opposite ends and flow in
opposite directions as shown in the figure below:

Figure 1.4 shows the flow regimes and temperature profiles.

1.6 Basic components of the tube and shell type heat exchanger are as follow;
A. Tubes

Figure1.5 Tube
The tubes are the basic components of a shell and tube type heat exchanger. Tubes may be seamless
or welded having diameters 5/8 inch, 3/ 4inch, and 1inch. Tubes materials should be highly thermal
conductive for proper heat transfer. .Most commonly it is made up of copper and Steel alloys. Other
alloys of nickel, titanium m, or aluminum may also be required for specific applications.
B. Tube sheet

Figure1.6 Tube sheet

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The tubes are fixed with tube sheet that form the barrier between the tube and shell fluids The tubes
can be fixed with the tube sheet using ferrule and a soft metal packing tube rolling‟. The tube metal is
forced to move into the grooves forming an excellent tight seal. This is the most common type of
fixing arrangement in large industrial exchangers. The tube sheet thickness should be always greater
than the tube outside diameter to make a good seal.
C. Shell

Figure 1.7 Shell

Shell is the container for the shell fluid and the tube bundle is placed inside the shell. Shell diameter
should be selected in such a way to give a close fit of bundle and inner shell wall depends on the type
of exchanger. Shells are usually fabricated from standard steel pipe with satisfactory corrosion
allowance.
D. Baffles

Figure 1.8 Baffles

Baffles are used to increase the fluid velocity by diverting the flow across the tube bundle to obtain
higher transfer co - efficient. The distance between adjacent baffles is called baffle -spacing. Baffles
are held in positioned by means of baffle spacers. Closer baffle spacing gives greater transfer co-
efficient by inducing higher turbulence. The pressure drop is more with closer baffle spacing.
E. Tube side channels and nozzles
This are made up of alloy material and it is used to control the flow of the tube side into and out of the
tubes of the exchanger.
F. Tube sheet thickness
The open end of the tubes is connected to the tube sheet. The tube sheet is fixed with the shell and
channel to form the main barrier for shell and tube side fluids. The tube sheet is attached by bolting
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(called gasket construction). Tube sheets are usually made from a round flat piece of metal with holes
drilled for the tube ends in
A precise location and pattern relative to one another. Tubes are attached to the tube sheet by
pneumatic or hydraulic pressure or by roller expansion. Tube holes are drilled and reamed and can be
Machined with one or more grooves. This greatly increases the strength of the tube joint.

Fig 1.9 Tube Sheet of Heat exchanger

G. Gaskets

Gaskets are used to make the metal to metal surfaces leak-proof. Gaskets are elastic-plastic
materials and relatively softer than the flange materials. Deformation of gaskets under load seals
the surface irregularities between metal to metal surfaces and prevents leakage of the fluid H.
H.Saddle
Horizontal drums are typically sup-ported at two locations by saddle Supports. A saddle support
spreads the weight load over a large area of the shell to prevent an excessive local stress in the
shell at the support points. The width of the saddle, among other design details, is determined by
the specific size and design conditions of the pressure vessel. One saddle support is normally fixed
or anchored to its foundation the other support is normally free to permit unrestrained longitudinal
thermal expansion of the drum.

Figure 1.10 Saddles

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I. Channel covers

Fgure1.11 channel covers

The channel covers are round plates that bolt to the channel flanges and can be removed for the tube
inspection without disturbing the tube side piping. In smaller heat exchangers, bonnets with flanged
nozzles or threaded connections for the tube side piping are often used instead of channel and channel
covers . made strong enough to withstand high pressure and high temperature. The fluids to be flown
are directed by use of pumps. One of the two fluids is passed through pipe bundles and the other fluid
is allowed to pass through shell. The fluid in shell is not allowed to follow a simple path instead some
arrangements are done to make the flow complex. The complexity in fluid flow is managed by the use
of baffles. These baffles also hold the pipes. Baffles are of different types and no fixed number of
baffles is available, so we can use baffles as per we require. The baffles also hold pipes inside shell.
We use different kinds of baffles:
1. Segmental baffles
2. Double segmental baffle
3. Helical baffles
4. De-resonating baffles
5. Orifice baffle

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Figure 1.12 Complete shell and tube heat exchanger

1.7 Project Assumptions and the project application
This project on the efficiency improvement of a shell and tube heat exchanger is mainly based on the
following studies and assumptions.

1. To study a conventional heat exchanger in a well-known organization in the indigenous

MOHA soft drink processing industry and then design &simulate efficiency improved shell
and tube heat exchanger so as to increase the production capacity without the need/requirement
of increasing the energy cost.
2. There is no heat exchange between heat exchanger and the surrounding the outer part of the
heat exchanger must be insulated (shell part).

1.8 Applications of shell and tube heat exchanger:

These are highly used to make heat transfer possible between two fluids or mediums. These are used
in industrial sectors for heating or cooling purpose.
The main applications areas are:-
 Space heating
 Refrigeration
 Air conditioning
 Power plants
 Chemical plants

1.9 Problem statement

The country is 100% dependent on expensive imported coal and oil for thermal power generation.
Therefore, it is of vital importance that the thermal power plants of make the most out of the
imported energy sources of fuel. At the same time, protecting the environment as much as possible,
by reducing the GHG emissions is very much a timely necessity.
In every day of life competition has become a key factor to engineers to utilize every bit of energy ,so
there is exhaust in power and process industry this exhaust contain heat and other pollutants carbon
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dioxide ,nitrogen dioxide etc…due to this exhaust the power and process industry need much fuel to
run their function this lead to economic crises and environmental pollution effect.
The main goal is to enhance the overall efficiency of fuel utilization through optimized waste gas
recovery for heating water by a steam bottoming cycle, thus also minimizing the release or reject of
gas to the environment.

1.10 General objective

The general objective of this thesis is to design and simulate shell and tube heat exchanger to heat
water by using exhaust gas.

1.11 specific objective

The specific objective of the project includes the following point

 To design the heat exchanger in the boiler plant and component of heat exchanger.
 To increase boiler efficiency.
 To analysis manufacturing process.
 To analysis the cost..
 To draw assembly drawing of heat exchanger.
 To draw part drawing and assembly of heat exchanger

Based on the general objective the specific objective is considering specific activities that build
up to the general objective. Due to this the specific objective of this paper is to know and
practice the kern method (log min temperature difference method LMTD and to develop
software capabilities

.1.12 The major reason why we prefer shell and tube heat exchanger is:
Shell and tube are relatively cheap.
Simple in design
Easy to maintain
It can work at high temperature and pressure
Its pressure drop is lass compare to others type
Easy to find and isolate leaking of tubes
They are less prone to fouling
Tubes can be double walled to reduce the likely hood of the shell side fluid leaking in to
the tube side fluid (vice versa)

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1.13 Expected Result
The expected result of this thesis will be to apply the engineering concepts and methodology to solve
the problems of the society related exhaust gas emission to the environment and the machines we
design are intended to reduce fuel consumption, energy losses, air pollution and used to heat the water
and the company can use this heated water to wash bottle and due to these power and process industry
will not exposed to additional cost and time loose to heat water for washing bottle

1.14 Benefits of the project

 To minimize the unnecessary cost of the company.

 To decrease the environmental pollution caused by the exhaust
 To minimize energy loss
 To heat much amount without direct steaming
 To get hot water easily
 To conduct safe and suitable working environment
 Simplify the load of boiler

1.15 Beneficiaries
 Working area
 Employees
 People which leave around the factory or industry be free from pollution

1.16 Scope of the project

This project focuses on design and analysis of horizontal shell and tube heat exchanger with saddle
frame. SE Code is construction code for shell and tube heat exchanger and contains mandatory
Requirements, specific prohibitions; and non-mandatory guidance for shell and tube heat exchanger
materials, design, welding and testing. To ensure the objective is achieved, some of the important
elements must be consideration. There is.Designing main components of shell and tube heat exchanger
by refer to ASME Code.

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CHAPTER TWO

LITERATURE REVIEW
Heat exchangers are devices that facilitate the exchange of heat between two fluids that are at
different temperatures while keeping them from mixing with each other. Heat transfer in heat
exchangers involves convection in each fluid and conduction through the wall separating the two
fluids. In order to account for the contribution of all the effects of convection and conduction, an
overall heat transfer coefficient, U, is used in the analysis. Heat transfer rate depends on the
temperature differences between the two fluids at the location and the velocity of the fluids (time
of interaction) between the fluids
HariHaran [1] proposed a simplified model for the study of thermal analysis of shell and tube type
heat exchangers of water and oil type is proposed. The robustness and medium weighted shape of
Shell and Tube heat exchangers make them well suited for high pressure operations. This paper shows
how to do the thermal analysis by using theoretical formulae and for this they have chosen a practical
problem of counter flow shell and tube heat exchanger of water and oil type, by using the data that
come from theoretical formulae they designed a model of shell and tube heat exchanger using Pro-E
and done the thermal analysis by using ANSYS software and comparing the result that obtained from
ANSYS software and theoretical formulae.
Yusuf Ali Kara and OzbilenGuraras [2] prepared a computer based design model for preliminary
design of shell and tube heat exchangers with single phase fluid flow both on shell and tube side. The
program determines the overall dimensions of the shell, the tube bundle, and optimum heat transfer
surface area required to meet the specified heat transfer duty by calculating minimum or allowable
shell side pressure drop. He concluded that circulating cold fluid in shell-side has some advantages on
hot fluid as shell stream since the former causes lower shell-side pressure drop and requires smaller
heat transfer area than the latter and thus it is better to put the stream with lower mass flow rate on the
shell side because of the baffled space.
V.K. Patel and R.V. Rao [3] explore the use of a nontraditional optimization technique; called particle
swarm optimization (PSO), for design optimization of shell-and-tube heat exchangers from economic
view point. Minimization of total annual cost is considered as an objective function. Three design
variables such as shell internal diameter, outer tube diameter and baffle spacing are considered for
optimization. Two tube layouts viz. triangle and Square are also considered for optimization. Four
different case studies are presented to demonstrate the effectiveness and accuracy of proposed

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algorithm. The results of optimization using PSO technique are compared with those obtained by
using genetic algorithm (GA). M.
M. El-Fawal, A. A. Fahmy and B. M. Taher:[4] In this paper a computer program for economical
design of shell and tube heat exchanger using specified pressure drop is established to minimize the
cost of the equipment. The design procedure depends on using the acceptable pressure drops in order
to minimize the thermal surface area for a certain service, involving discrete decision variables. Also
the proposed method takes into account several geometric and operational constraints typically
recommended by design codes, and provides global optimum solutions as opposed to local optimum
solutions that are typically obtained with many other optimization methods
JiangfengGuo etal[5] took some geometrical parameters of the shell-and-tube heat exchanger as the
design variables and the genetic algorithm is applied to solve the associated optimization problem. It is
shown that for the case that the heat duty is given, not only can the optimization design increase the
heat exchanger effectiveness significantly, but also decrease the pumping power dramatically
A.Pignotti[6] in his paper established relationship between the effectiveness of two heat exchanger
configurations which differ from each other in the inversion of either one of two fluids. This paper
provides the way by which if the effectiveness of one combination is known in terms of heat capacity
rate ratio and NTUs then the effectiveness of the other combination can be readily known.
Rajeev Mukharji[7] explains the basics of exchanger thermal design, covering such topics as: STHE
components; classification of STHEs according to construction and according to service; data needed
for thermal design; tube side design; shell side design, including tube layout, baffling, and shell side
pressure drop; and mean temperature difference. The basic equations for tube side and shell side heat
transfer and pressure drop. Correlations for optimal condition are also focused and explained with
some tabulated data. This paper gives overall idea to design optimal shell and tube heat exchanger.
The optimized thermal design can be done by sophisticated computer software however a good
understanding of the underlying principles of exchanger designs needed to use this software
effectively
In this paper researcher have done Comparison for several shell- and- tube heat exchangers with
segmental baffles. The objective of this project is to design a shell and tube heat exchanger with
segmental baffles and to study the flow and temperatures inside the shell and tubes using ANSYS
software tool for the different baffles assemblies and orientation also overall heat transfer is calculated
for each design. This project totally contains 5 designs for comparison. The process in solving
simulation consists of modeling and meshing the basic geometry of shell and tube heat exchanger
using CFD package ANSYS 14.5.In simulation it is shown how the temperature, pressure, velocity
varies in shell due to different baffles orientation. Researcher gave result which indicates that the heat

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DESIGN OF SHELL AND TUBE HEAT EXCHANGER
exchanger without any short-circuited flow has the higher heat transfer coefficient than the heat
exchanger with leakage. It is found that for 0.5 kg/s mass flow rate there is no much effect on outlet
temperature of the tube even though the baffle inclination is increased from 0° to 40°.
However the shell-side pressure difference is decreased with increase in baffle inclination angle i.e., as
the inclination angle is increased from 0° to 40°. The pressure difference is decreased by 6%, for the
heat exchanger with 20° baffle inclination angle and by 19.57% for the heat exchanger with 40° baffle
inclination angle with 36% baffle cut. It can be concluded that shell and tube heat exchanger with
40°inclination angle and 25% baffle cut results in better performance compared to 0°, 20° and 30°
inclination angle B. Sayali R.Bhandurge, Prof. A.M.Wankhade, Prof. P.K.Jadhao, Nikhil P.Talwekar
ʽʽAnalysis and Experimentation of Shell and Tube Heat Exchanger with Different Orientation of
Bafflesʼʼ In this paper, researcher have done Experimentation along with CFD analysis on single pass,
counter flow shell and tube heat exchanger containing Baffles at 0°,15°,30°,45° orientation. To study
the heat transfer rate and pressure drop of shell side fluid and compare the result with Bell-Delaware
method, Experimental setup is validated with help of Dittus- Boelter correlation. Nusselt number
obtains from Experimental set up of 0° orientation and Dittus- Boelter correlation are within 5.72%.
Experimental result of 0° orientation is also compare with CFD results in which Nusselt number are
found to be within 12.50% and pressure drop is found within 5.55%.Results obtain from CFD analysis
is also compare with Bell Delaware method and Nu in case of CFD is 3.35% of Bell-Delaware.
Pressure drop Results in case of CFD is Found within 14.99%.CFD analysis at 15°,30° & 45° baffle
orientation is also done and results are validate with help of Belle Delaware method. The overall
conclusions are as follows, heat transfer coefficient and heat transfer rate is increased by 10% to 17%
when baffle angle inclination changes from 0° to 45°,whereas pressure drop is decreased by 5% to
13.44% with change in baffle inclination from 0° to 45° which helps in reducing the pumping cost of
shell and tube heat exchanger. From this experimental, CFD and Bell Delaware analysis it is found
that as baffle angle changes from 0 to 45 degree, Nusselt no. increases that is indirectly heat transfer
rate is increase and pressure drop is reduces. Due to change in baffle inclination angle more turbulence
will be created across the shell side, because of this heat transfer coefficient is increases which results
in increase of Nusselt number and hence the heat transfer rate will increase. By varying the baffle
inclination with fixed baffle spacing and the baffle cut values of 25% for 4.84 kg/sec shell side flow
rates, the experimental results for 0° baffle inclination are compared with CFD simulation result and
then compare with Bell-Delaware result, it is observed that experimentation and CFD result for 0°
baffle inclination are in good agreement with Bell –Delaware results. The simulation results for 15°,
30°, 45° baffle inclination compared with result from Bell-Delaware method. For properly spaced
baffles, it is observed that the CFD simulation results are in good agreement with the Bell-Delaware

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DESIGN OF SHELL AND TUBE HEAT EXCHANGER
results. The results are also sensitive to baffle cut selection, for this counter flow shell and tube heat
exchanger with 10 baffles and baffle inclination of 45° gives slightly better result. C. Koorosh
Mohammadi, Wolfgang Heidemann & Hans Muller-Steinhagen ʽʽNumerical Investigation of the
Effect of Baffle Orientation on Heat Transfer and Pressure Drop in a Shell and Tube Heat Exchanger
With Leakage Flows In this research paper The commercial CFD code FLUENT is used to investigate
the effect of baffle orientation and of viscosity of the working fluid on the heat transfer and pressure
drop in a shell-and-tube heat exchanger in the domain of turbulent flow. Two baffle orientations as
well as leakage flows are considered. In order to determine the effect of viscosity on heat transfer and
pressure drop, simulations are performed for the working fluids air, water, and engine oil by using
different flow velocities at the inlet nozzle.
Results from numerically showed that by introducing a performance factor, the effects of horizontally
and vertically orientated baffles on pressure drop and heat transfer could be compared. The tube-baffle
leakage and bypass streams play an important role in the explanation of the performance factor of
segment ally baffled shell-and-tube heat exchangers. For all shell-side fluids (air, water, engine oil)
that have been considered, the vertical baffle orientation seems to be more advantageous than the
horizontal orientation and is more noticeable for gases since the dissipation rate in gases is much
higher than in liquids A study that has been specifically concentrated on the shell and tube type of
heat exchanger has been carried out to improvise the heat transfer of the considered shell and tube heat
exchanger by considering the utilization of a different type of a baffle( a typical component that can be
seen in shell and tube heat exchangers).
The study has given an introduction to the conventional shell and tube heat exchangers that has been
in the industry for a time. The researchers then have explained on various previous studies that has
been conducted using different various kinds of baffles for the conventional heat exchangers and the
resulting effects on the heat transfer improvement has been explained.
In contrast to this project the differences lies in the methodology that is being implemented to
improve/enhance the heat transfer of the conventional shell and tube heat exchanger. The research
paper has taken into account the geometrical aspects of the baffles whilst this project aims to modify
the shell side of a conventional shell and tube heat exchanger by utilizing a separation plate to make
the fluid flow an approaching counter flow instead of a cross flow fluid pattern. The similarity of both
this research and the research on the referred/cited research paper focuses to improve/enhance the heat
transfer of a conventional shell and tube heat exchanger. (Qiuwang Wang*, 2010)
Another research study conducted by two technical professionals focuses on a methodology which can
be used to enhance the design of a shell and tube heat exchanger using a special optimizing/enhancing
technique defined as particle swarm optimization technique. It is a computer-based technique utilized

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DESIGN OF SHELL AND TUBE HEAT EXCHANGER
to enhanced/optimize a certain problem/issue by conducting an algorithmic program to check for an
aspirant solution in relation to a certain measure of quality. This study is mainly based on
computational techniques to enhance the design of a conventional shell and tube heat exchanger. The
main quality variable they have considered in this particular study is the economic aspects involved in
designing a shell and tube heat exchanger. In contrast this study and the project is quite different
although both involves the same type of heat exchanger.
As described below heat exchangers are of various types and they are also classified and grouped in
many ways. So while carrying out the literature review process numerous studies and researches were
found in relation to the topic of efficiency improvement of shell and tube heat exchangers. Another
research paper found whilst carrying out the literature review was on improving the effectiveness of a
plate fin type heat exchanger using a computer based genetic algorithm. The purpose of these
computer based algorithm is to obtain values for the thermal effectiveness of the heat exchanger that is
being consider and also the annual cost required to be spent on the heat exchanger which includes both
the initial cost for the heat exchanger and the cost required for the operation of the heat exchanger.
However when comparing with the project based on this full report the type of heat exchangers are
different and also the techniques used to enhance the thermal performances and the other factors are
different. (Hajabdollahi, 2009)

As summary of the chapter 2 –Literature review on the topic of improving the heat transfer efficiency
of a conventional heat exchanger (shell and tube heat exchanger specifically) there are numerous
studies and researches that have been carried out by various different technical professionals and is a
continual growing process of finding the most efficient and the most accurate solution for improving
the thermal performances(efficiency and the heat transfer rate) of any type of heat exchangers. It will
also be a research area in which improvements will be found continuously as technology keeps
evolving day to day and after conducting different researches and studies using various technical
methodologies.

2.1 Methods to design shell and tube heat exchanger

The goal of heat exchanger design is to relate the inlet and outlet temperatures, the overall heat
transfer coefficient, and the geometry of the heat exchanger, to the rate of heat transfer
between the two fluids. The two most common heat exchanger design problems are those of
rating and sizing. We will limit ourselves to the design of recuperations only. That is, the
design of a two fluid heat exchanger used for the purposes of recovering waste heat. We will
begin first, by discussing the basic principles of heat transfer for a heat exchanger.

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DESIGN OF SHELL AND TUBE HEAT EXCHANGER
Q=mh c ph ¿¿ By conservation of energy both on hot and cold fluids are the same heat transfer.
And also using overall heat transfer method it can be deter Q=UA ∆T m

Where, ∆ T m=f (T hi , T ho , T ci ,T co )

It is now clear that the problem of heat exchanger design comes down to obtaining an
expression for the mean temperature difference. Expressions for many flow configurations, i.e.
parallel flow, counter flow, and cross flow, have been obtained in the heat transfer field. We
will examine these basic expressions later. The approaches to heat exchanger design that will
be discussed are the LMTD method and the effectiveness. Each of these methods has particular
advantages depending upon the nature of the problem specification.

2.1.1 LMTD Method

The log mean temperature difference (LMTD) is derived in all basic heat transfer texts. It
may be written for a parallel flow or counter flow arrangement. The LMTD has the form:
∆ T ¿ T1
∆ T m=
∆T2
ln
∆T1
The LMTD method assumes that both inlet and outlet temperatures are known. When this
is not the case, the solution to a heat exchanger problem becomes some- what tedious. An
alternate method based upon heat exchanger effectiveness is more appropriate for this type
of analysis. If ΔT 1 = ΔT 2 = ΔTs, then the expression for
The LMTD reduces simply to ΔT.

The following will be adopted for the completion of our project.

• Detail problem identification and definition
• Problem analysis
• Literature review
• Criteria for design
• System analysis preliminary design and calculation
• Detail analysis and design modification (if required)
Problem identification and definition
This includes pointing the extent of the problem; identify which sector is more affected by the
problem and over view the current situation of the defined problem.in this problem is wastage of much
fuel and pollution of working area affect the working area of soft drink industry.

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DESIGN OF SHELL AND TUBE HEAT EXCHANGER
2.2 Design and analysis
There are different design factors that we will consider on the design and calculation of this project. It
includes:- The optimum thermal design of a shell and tube heat exchanger involves the consideration
of many interacting design parameters which can be summarized as follows:
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:
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, baffles cut, baffle spacing and clearances.
5. Setting upper and lower design limits on shell diameter, baffle cut and baffle spacing.

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DESIGN OF SHELL AND TUBE HEAT EXCHANGER

CHAPTER THREE
MTHODOLOGY

3.1 Introduction to Material Selection

Material selection plays a very important role in machine design. For example, the cost of materials in
any machine is a good determinant of the cost of the machine. More than the cost is the fact that
materials are always a very decisive factor for a good design.

Engineering materials are mainly classified as:

1. Metal and their alloys, such as iron, steel, copper, aluminum etc.
2. Non-metals such as glass, rubber, plastic etc. metals are further classified as ferrous metals and
non-ferrous metals.
Ferrous metals are those metals which have iron as their main constituent, such as cast iron, wrought
iron and steels.
Non-ferrous metals are those which have a metal other than iron as their main constituent, such as
copper, aluminum, brass, tin, zinc etc.

3.2 Materials Selection for shell and tube heat exchanger design
The choice of the particular material for the machine depends on the particular purpose and the
material for the machine depends on the particular purpose and the mode of operation of the machine
components. Also, it depends on the expected mode of failure of the components.
The first steps are the selection of a proper material for all mechanical part designing purposes. To
select the best material for designing is depending on the following factors should be considered while
selecting the material:
 Availability of the materials,
 Suitability of the materials for the working conditions in service, and
 The cost of the materials.

Besides this factor section of material depend on some properties. The important properties, which
determine the utility of the material, are physical, chemical and mechanical properties.

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DESIGN OF SHELL AND TUBE HEAT EXCHANGER
For the purpose of this project, based on the particular working conditions machine component were
designed for only the ferrous metals have been considered. Also, certain mechanical properties of
metals have greatly influenced our decisions. These properties include:
 Strength: it is the ability of a material to resist the externally applied force without break down
or yielding the internal resistance offered without break down or yielding the internally applied
force is called stress.
 Stiffness: it is the ability of a material to resist deformation under stress.
 Elasticity: it is the property of a material to regain its original shape after deformation when the
external force is removed.
 Plasticity: it is property of a material which retains the deformation produced under load,
permanently.
 Ductility: a very important property of the material enabling it to be drawn into wire with the
application of a tensile force. A ductile material is both strong and plastic. Ductile materials
commonly used in engineering practical (in order of diminishing ductility) are mold steel,
copper, aluminum, nickel, zinc tin and lead.
 Malleability: it is a special case of ductility which permit materials to be rolled or hammered
into thin sheets. A malleable material is plastic but not 80 essentially strong. Examples include;
lead soft steel, wrought iron, copper and aluminum in order of diminishing malleability.
 Toughness: it is the property of a material to resist fracture due to high impact loads like
hammer blows, when heated. This property decreases.
 Brittleness: it is the properties of a material opposite to ductility, it is the property of breaking
of a material with little permanent deformation when subjected to tensile load, brittle materials
snap off without giving any sensible elongation. Cast iron is a brittle material.
Hardness it embraces difference properties such as resistance to water, scratching, deformation and
machinability etc. it also measure of the ability of a metal to cut another metal
It is necessary to evaluate the particular type of forces imposed on components with a view to
determining the exact mechanical properties.

3.3 CRITERIA FOR MATERIALS SELECTION

The engineer making the materials selection must know all the aspects involved in the construction,
operation and maintenance of the heat exchanger. The importance of this is illustrated with the
following examples: an operator may isolate a heat exchanger with raw water or sufficient time to
initiate a pitting corrosion; partial blockage of tubes, specially of small diameter, would result in
stagnant conditions that may cause pitting in alloys that are so prone; fouling may result in operating
the heat exchangers in throttled/part load condition. A general procedure [3] that could be used for
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DESIGN OF SHELL AND TUBE HEAT EXCHANGER
identifying the most appropriate material for a specific heat exchanger application would consist of the
following steps.
Define the heat exchanger requirements
 Establish a strategy for evaluating candidate materials
 Identify candidate materials
 Evaluate materials in depth
 Select the optimum material
For the first step, the engineer must consider the normal operating parameters (eg: nature of the fluids
on both the tube and shell side, flow rate, temperature and pressure), startup and shutdown
conditions ,upset conditions, special conditions like product purity requirements, hazardous effects of
intermixing of shell and tube side fluids, radioactivity and associated maintenance, etc. The applicable
codes and safety regulations must also be considered. The heat exchanger designer would also identify
the tube attachment method as this also affects the material selection. If the material selection is being
done by someone other than the heat exchanger designer, there must be close consultation between
these individuals.
While establishing the strategy for evaluating candidate materials, the main factors to be considered
are cost and reliability. The minimum cost strategy would mean use of less expensive materials and
rectifying the problems as they show up. Maximum reliability strategy would mean going for the most
reliable material regardless of its cost. Both strategies have to be weighed against initial cost, loss due
to possible shutdowns, repair costs, indirect loss to other industries etc.
In identifying candidate materials, it is desirable to narrow the field to a comparatively small number
of materials for more extensive evaluation. There is no hard and fast rule as to how many candidate
materials should be selected for detailed study. The initial identification and selection procedure, if
done properly, will eliminate those materials which are unsuitable and those which are excessively
expensive .This calls for use of operating experience, use of handbook data and literature on advanced
materials under development, and judgments. Special considerations which affect materials selection
include:
 Physical Properties- High heat transfer coefficient (requiring high thermal conductivity for
tube material) Thermal expansion coefficient to be low and as compatible as possible with
those of the material used for tube sheet, tube support and shell to provide resistance to thermal
cycling.
 Mechanical Properties Good tensile and creep properties (High creep rupture strength at the
highest temperature of operation and adequate creep ductility to accommodate localized strain
at notches are important).

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DESIGN OF SHELL AND TUBE HEAT EXCHANGER
 Good fatigue, corrosion fatigue and creep-fatigue behavior.
 High fracture toughness and impact strength to avoid fast fracture.
 Corrosion Resistance Low corrosion rate to minimize the corrosion allowance (and also
radioactivity control in heat exchangers for nuclear industry)
 Resistance to corrosion from off normal chemistry resulting from leak in upstream heat
exchanger or failure in the chemistry control
 Tolerance to chemistry resulting from mix up of shell and tube fluids. Manufacture
Ease of fabrication is an important aspect for selection of materials. The usual
manufacturing steps involved for heat exchangers are bending of tubes, joining of
tube to tube sheet by rolling, welding or rolling and welding, forming of shell geometry
and welding of shell plates and shell to nozzle and the heat treatments associated with
the welding steps. Operating Experience A great deal of knowledge is gained by the
operating experience of similar units. A lesson learnt from the failures of others is an
important consideration in materials selection.
 After narrowing down the list of candidate materials (for tube, tube sheet, shell), the next step
is to perform the design of heat exchanger with candidate materials so as to establish the initial
cost. Also the failure probability with each design needs to be established so as to establish the
outage cost
 Criteria for making the final selection will include an assessment of each of the following:
initial cost
- Maintenance cost, including consideration of how frequently the equipment will need to be
inspected for corrosion
Cost of loss in production
- Consequences of failure. Is failure likely to create unsafe conditions or cause discharge of an
undesirable chemical in to the environment or serious repercussions to an emerging technology.
Generally materials selection is based on qualitative comparisons of the candidate materials. However,
it is worthwhile to make the assessment based on financial.

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DESIGN OF SHELL AND TUBE HEAT EXCHANGER
Material selection Material selection (for heat exchanger) Material selection means choosing suitable
materials for the design purpose from different raw materials by considering different parameters. The
most important characteristics (parameters) to be considered with selecting materials are; the material
selected must be having sufficient strength and be easily worked. The most economical material that
satisfies both the process and mechanical requirement should be selected. These will be the material
that gives the lowest cost over the working life of the part avoiding maintenance and replacement. All
materials used construction of shell and heat exchangers for pressure parts must have the appropriate
specification. The materials of construction should be compatible with process fluids and others parts
of materials

 High chrome-Mo-Ni alloys (Cr content 12-27%) can be used for high temperature services
up to 2100ºC.
 . Use of any carbon or low alloy steel is not recommended for the construction of heat
Exchanger for the service below 0ºC.

Table1; - Material for construction of shell and tube heat exchanger

Materials of construction Allowable fluid temperature, °C (°F)

Carbon steel 540 (1004)

C-Mo steel 590 (1094)
Cr-Mo steel 650 (1202)
Low alloy steel (< 6 % Cr) 590 (1094)

The routing of the shell side and tube side fluids has considerable effects on the heat exchanger
design. Some general guidelines for positioning the fluids are given in Table below. It should be
understood that these guidelines are not ironclad rules and the optimal fluid placement depends on
many factors that are service specific

Table 2; - Guidelines for placing the fluid in order of priority and fluid selection

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DESIGN OF SHELL AND TUBE HEAT EXCHANGER

Shell-side fluid

Tube-side
fluid
Corrosive fluid Condensing vapor (unless corrosive)
Cooling water Fluid with large temperature difference
Fouling fluid
(>40°C)
Less viscous fluid
High-pressure steam
Hotter fluid

3.4 Fouling Considerations

The most of the process fluids in the exchanger foul the heat transfer surface. The material deposited
reduces the effective heat transfer rate due to relatively low thermal conductivity. Therefore, net heat
transfer with clean surface should be higher to compensate the reduction in performance during
operation. Fouling of exchanger increases the cost of (i) construction due to oversizing, (ii) additional
energy due to poor exchanger performance and (iii) cleaning to remove deposited materials. A spare
exchanger may be considered in design for uninterrupted services to allow cleaning of exchanger.
The effect of fouling is considered in heat exchanger design by including the tube side and shell side
fouling resistances. Typical values for the fouling coefficients and resistances are summarized in.

Table 3; - Typical values of fouling coefficients and resistances.

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DESIGN OF SHELL AND TUBE HEAT EXCHANGER

3.5 Thermal Design Procedure (algorism development)

The flow rates of both hot and cold streams, their terminal temperatures and fluid properties are the
primary inputs of thermal design of heat exchangers.
Thermal design of a shell and tube heat exchanger typically includes the determination of heat transfer
area, number of tubes, tube length and diameter, tube layout, number of shell and tube passes, type of
heat exchanger (fixed tube sheet, removable tube bundle etc), tube pitch, number of baffles, its type
and size, shell and tube side pressure drop etc.
1. Shell
Shell is the container for the shell fluid and the tube bundle is placed inside the shell. Shell diameter
should be selected in such a way to give a close fit of the tube bundle. The clearance between the tube
bundle and inner shell wall depends on the type of exchanger ([2]; page 647). Shells are usually
fabricated from standard steel pipe with satisfactory corrosion allowance. The shell thickness of 3/8
inch for the shell ID of 12-24 inch can be satisfactorily used up to 300 psi of operating pressure.
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DESIGN OF SHELL AND TUBE HEAT EXCHANGER

2. Tube
Tube OD of ¾ and 1‟‟ are very common to design a compact heat exchanger. The most efficient
condition for heat transfer is to have the maximum number of tubes in the shell to increase turbulence.
The tube thickness should be enough to withstand the internal pressure along with the adequate
corrosion allowance. The tube thickness is expressed in terms of BWG (Birmingham Wire Gauge) and
true outside diameter (OD). The tube length of 6, 8, 12, 16, 20 and 24 ft are preferably used. Longer
tube reduces shell diameter at the expense of higher shell pressure drop. Finned tubes are also used
when fluid with low heat transfer coefficient flows in the shell side. Stainless steel, admiralty brass,
copper, bronze and alloys of copper-nickel are the commonly used tube materials:
3. Tube pitch, tube-layout and tube-count
Tube pitch is the shortest center to center distance between the adjacent tubes. The tubes are
generally placed in square or triangular patterns (pitch) as shown in the the widely used tube
layouts are illustrated in Table 3.1.
The number of tubes that can be accommodated in a given shell ID is called tube count. The tube
count depends on the factors like shell ID, OD of tube, tube pitch, tube layout, number of tube
passes, type of heat exchanger and design pressure.
4. Tube passes

The number of passes is chosen to get the required tube side fluid velocity to obtain greater
heat transfer co-efficient and also to reduce scale formation. The tube passes vary from 1 to 16.
The tube passes of 1, 2 and 4 are common in application. The partition built into exchanger
head known as partition plate (also called pass partition) is used to direct the tube side flow.
Table 4; -- Common tube layouts.

Tube OD, in Pitch type Tube pitch, in

34 Square 1
1 1 14
34 Triangular 15
16
34 1

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DESIGN OF SHELL AND TUBE HEAT EXCHANGER

+
+ + +
+
Flow Flow Flow +

+ + + + +
Pitch

Pitch Pitch

a). Square b). Triangular c). Rotated square

Figure3. 1: Tube Patter

5. Tube sheet
The tubes are fixed with tube sheet that form the barrier between the tube and shell fluids. The
tubes can be fixed with the tube sheet using ferrule and a soft metal packing ring.
The tubes are attached to tube sheet with two or more grooves in the tube sheet wall by tube rolling‟.
The tube metal is forced to move into the grooves forming an excellent tight seal. This is the most
common type of fixing arrangement in large industrial exchangers. The tube sheet thickness should
be greater than the tube outside diameter to make a good seal. The recommended standards (IS:4503
or TEMA) should be followed to select the minimum tube sheet thickness.
6. Baffles
Baffles are used to increase the fluid velocity by diverting the flow across the tube bundle to
obtain higher transfer co-efficient. The distance between adjacent baffles is called baffle-
spacing. The baffle spacing of 0.2 to 1 times of the inside shell diameter is commonly used.
Baffles are held in positioned by means of baffle spacers. Closer baffle spacing gives greater
transfer co-efficient by inducing higher turbulence. The pressure drop is more with closer
baffle spacing. The various types of baffles are shown in Figure. In case of cut-segmental
baffle, a segment (called baffle cut) is removed to form the baffle expressed as a percentage of
the baffle diameter. Baffle cuts from 15 to 45% are normally used. A baffle cut of 20 to 25%
provide a good heat-transfer with the reasonable pressure drop. The % cut for segmental baffle
refers to the cut away height from its diameter. Figure 3.2 also shows two other types of
baffles

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DESIGN OF SHELL AND TUBE HEAT EXCHANGER
Shell

a). Cut -segmental baffle

Shell Doughnut
Disc

b). Disc and doughnut baffle

Baffle
Orifice

c). Orifice baffle

Figure3.2 Kinds of Heat Exchanger Baffles

 Process (thermal) design procedure
Shell and tube heat exchanger is designed by trial and error calculations. The main design steps of the
Kern method are summarized as follows:
S# 1. Obtain the required thermo physical properties of hot and cold fluids.
S# 2. Perform energy balance and find out the heat duty (Q) of the exchanger.
Q=mc ( ∆ T ) …………………………………………. (1)
S#3. Assume a reasonable value of overall heat transfer coefficient (U o , assume). The value
Of Uo, assume with respect to the process hot and cold fluids can be taken from the books.
S#4. Decide tentative number of shell and tube passes ( n p ). Determine the LMTD and the correction
factor Ft [1] page 48 Figs. 2.7; FT normally should be greater than 0.75 for the steady operation of the
exchangers. Otherwise it is required to increase the number of passes to obtain higher F T values.

(T 2−T )(t 2−t 1)

1
¿
LMTD (T −T 1) ……………………………………...….…. (2)
ln 2
(t 2−t 1)
Q
S#5. Calculate heat transfer area (A) required: A= LMTD−F …………..….. (3)
TU 0,assum

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DESIGN OF SHELL AND TUBE HEAT EXCHANGER

S# 6. Select tube material, decide the tube diameter ( ID=d i , OD=d o )its wall thickness (in terms of
BWG or SWG) and tube length (L). Calculate the number of tubes
A
( nt ) required to provide the heat transfer area (A) :nt = ……………… (4) Calculate
π do L

4 m(n p /nt )
tube side fluid velocity U= ………………………………… (5) .
P π d2

If u <1 m/s, fix n p so that, Re =4 m ¿¿ ≥ 104 ……………….…….. (6)

. Where, m, µ and 𝒫 are mass flow rate, density and viscosity of tube side fluid. However, this is
Subject to allowable pressure drop in the tube side of the heat exchanger.
S#7. Decide type of shell and tube exchanger (fixed tube sheet, U-tube etc.). Select the tube pitch ( PT ),
determine inside shell diameter ( Ds ) that can accommodate the calculated number of tubes ( nt ). Use
the standard tube counts table for this purpose.
Tube counts are available in standard text books [1] page 372 Table 9.3.
S#8. Assign fluid to shell side or tube side (a general guideline for placing the fluids is summarized in
[1] page 376). Select the type of baffle (segmental, doughnut etc.), its size (i.e. percentage cut, 25%
baffles are widely used), spacing (B) and number. The baffle spacing is usually chosen to be within
0.2 Ds to Ds .
Allocation of stream: The most fouling fluid flows through the tube, since the tube side is easier to
clean, especially if mechanical cleaning is required. The high pressure fluid flows through the tubes.
The corrosive fluid must flow through the tube.
S#9. Determine the tube side film heats transfer coefficient ( hi ) using the suitable form of Sieder-
Tate equation in laminar and turbulent flow regimes.
Estimate the shell-side film heat transfer coefficient ( h o ) from:
ho D e
iH = ¿ …………………(7)
k
Select the outside tube (shell side) dirt factor ( Rd ) and inside tube (tube side) dirt factor ( R¿¿ di ) [ 1 ] ¿
o

Calculate overall heat transfer coefficient (U O ,cal ) based on the outside tube area (you may neglect
the tube-wall resistance) including direct factors:

−1
1 A d −d A 1 A
U o , cal=[
ho (
Ai 2 k w) ()
+ Rdo + o o i + o + o R di ] …………… (8)
Ai hi Ai

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DESIGN OF SHELL AND TUBE HEAT EXCHANGER

U o , cal−U o ,ass
S#10. If0< <30 % , go to the next step#11. Otherwise go to the s#5,
U o ,ass
Calculate heat transfer area (A) required usingU o , cal and repeat the calculations starting
From s#5.
If the calculated shell side heat transfer coefficient ( h o ) is too low, assume closer baffle spacing

(B) close to 0.2 Ds and recalculate shell side heat transfer coefficient. However, this is subject to
allowable pressure drop across the heat exchanger.

S#11. Calculate % overdesign. Overdesign represents extra surface area provided beyond that
required to compensate for fouling. Typical value of 10% or less is acceptable.
A− Areqd
%Overdesign= × 100 % … … … … … … … .(9)
A reqd

A = design area of heat transfer in the exchanger; Areqd = required heat transfer area.

S#12. Calculate the tube-side pressure drop ( PT ¿: (i) pressure drop in the straight section of the tube
(frictional loss ∆ Pt and (ii) return loss Prt ) due to change of direction of fluid in a „multi-pass
exchanger‟.
Total tube side pressure drop:∆ PT =∆ Pt +∆ Prt … … … … … … … … … ..(10)

S#13. Calculate shell side pressure drop ( ∆ P S ) (i) pressure drop for flow across the tube bundle

(Frictional loss)∆ P S and (ii) return loss ( ∆ Prs )due to change of direction of fluid.

Total shell side pressure drop: ∆ P S=∆ P s−∆ P rs … … … … … … … … ..(11)

If the tube-side pressure drop exceeds the allowable pressure drop for the process system, decrease
the number of tube passes or increase number of tubes per pass. Go back to s#6 and repeat the
calculations steps.
If the shell-side pressure drop exceeds the allowable pressure drop, go back to s#7 and repeat the
calculations steps.

1
DESIGN OF SHELL AND TUBE HEAT EXCHANGER

Figure 3.3. Flow chart of design procedure

1
DESIGN OF SHELL AND TUBE HEAT EXCHANGER

CHAPTER FOUR
DESIGN ANALYSIS

4.1. Assumptions of design analysise

Water at the rate of 40000 ( kg /h ) enters to the tube at temperature of 29 c ofrom the water storage and
flue gas on shell side used as heating fluid have rate of50000 ( kg /h ) have inlet temperature of 250 c o
here we can say flue gas or desile.50000kgh-1 of desile (420 API*) leaves the base of desile side-
stripping column at the inlet 2500c and out let is to be 900c by exchange with 40000kgh-1 cold water
(340 API) coming from storage at 290c. The desile enters the heat exchanger at a pressure of 5bar and
the cold water at 6.5bar. A pressure drops of 0.8bar the maximum permissible on both the streams,
including nozzle losses. Assuming a pressure drop of 0.1bar for shell inlet and outlets and similarly for
tube inlet and outlet nozzles. Allowance should be made for fouling by including a fouling factor of
0.0005(wm-2k-1)-1 for the water stream and 0.001(wm-2k-1)-1 for the desile stream.

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DESIGN OF SHELL AND TUBE HEAT EXCHANGER
4.2 Design specification
Hot fluid inlet temperature (T1)= 2500c

Hot fluid outlet temperature (T2) = 900c

Cold fluid inlet temperature (t1) = 290c Cold

fluid outlet temperature (t2) =?
Fouling factor of hot fluid (Rk) = 0.0005 (for Desile)

Fouling factor of cold fluid (Rco) = 0.001 (for water)

Pinlet (for hot fluid) = 5bar

Pinlet (for cold fluid) = 6.5bar ∆pmax (for

hot fluid) = 0.8bar
∆pmax (for cold fluid) = 0.8bar.

Mass flow rate of cold fluid ( m co) = 40000kgh-1

Mass flow rate of hot fluid (mg) = 50000kgh-1

(Subscripts g-for desile, co-for cold water)

4.3 Design procedures

At mean temperature of desile, the specific heat capacity is 1.0732kj/kg.k

Hence, c p∗ (T ¿ )

¿ ( 50000/3600 )∗1.0732∗( 250−80 )=2533.9 KW

Since the outlet temperature of the cold fluid is not known we can determine using energy balance
equation.
I. Find using mean temperature of the cold water as equal to the inlet

temperature; ( 40000/3600∗4.18∗( t 2 −29 ) ) =2533 KW t 2=83.6 ℃

Stream mean temperature T m=(83.6+29)/2=56.3 ℃

II. Find using this stream mean temperature and c p =2.05 gives; t2 = 59.90c

In the second trial the mean temperature is, T m =60.90c Hence, from the
two iterations we take the value of t2, t2 = 610c

Determine fluid properties:

1
DESIGN OF SHELL AND TUBE HEAT EXCHANGER
Table5;-. physical properties of fluids

Description Unit Shell side Tube side

Inlet Outlet Inlet Outlet
Density kg/m3 750 770 1000 1000
Viscosity mn/m2s 0.22 0.80 2.4 2.6
Specific Heat kJ/kg.K 1.0732 1. 4.185 4.18

Overall heat transfer coefficient:U ass = 300W/m2k

Thermal conductivity, k = 0.135W/mk

Other specifications

Tube diameter (d o =19mm,d i=14.83mm)

Pitch = 23.81mm

Maximum permissible tube length =7m

Pitch diameter = 1.25mm

Maximum permissible tube side velocity = 2m/s

Maximum permissible shell side velocity = 1m/s

Material: carbon steel to both shell and tube.

4.4 Over all heat transfer coefficient assumption

From the given information the overall heat transfer coefficient is vary from 300 -500W/m 2oc then we
start with 300W/m2oc.

4.5 analysise of log mean temperature

Log mean temperature is the ratio of the change of temperature on one side to the other side. But the
type of fluid flow in tube and shell side plays great value (flow is from state number one to state
number two).

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DESIGN OF SHELL AND TUBE HEAT EXCHANGER

Fig4.1. counter flow arrangement

 Find log mean temperature for counter flow as;

∆ T 1=T 1−t 2=250−60=190 ℃

∆ T 2=T 2−t 1=90−29=61 ℃

T LMTD=¿

 Find log mean temperature for parallel flow as;

∆ t 1=T 1−t 2=200−29=171 ℃
∆ t 2=T 2−t 1=90−60=30 ℃

T LMTD=(∆ t 1 – ∆ t 2)/¿

From those two results we can conclude that the higher value of log mean temperature difference is
better to use because it can reduce the surface area of the exchanger. Hence counter flow is better to
use.
The value of mean temperature using counter flow is;

ΔT m=f ∗T LMTD=0.88∗91.7=80.6 ℃

Where ‘f’ can be determined from temperature correction factor graph.

Find heat transfer area
Q
A= Where
∆ T m∗U O

U o =300 W / m2 . K
1
DESIGN OF SHELL AND TUBE HEAT EXCHANGER
A=1788.4/ ( 300∗80.6 )=7.4 m2
From this we can determine diameter, D, A=(π /4 ) D2 → D=0.66 m

4.6 Layout and tube size decision Allocation of stream:

 The most fouling fluid flows through the tube, since the tube side is easier to clean,
especially if mechanical cleaning is required.
 The high pressure fluid flows through the tubes.

 The corrosive fluid must flow through the tube.

Hence the cold water is dirtier than the desile, so put the cold water throw the tubes and the desile in
the shell.
Table6; - Dimensional arrangement of triangular pitch specification for tubes from standard
table

Tube Square Pitch Triangular Pitch

Diameter
5/8”(16 7/8”(22mm) 25/32”(20 mm)
 From the tube lay out
mm) (Note=1)
¾”(19mm) 1”(25mm) 15/16”or1”(24or25mm) system lets tray to use
triangular layout
1”(25mm) 1¼”(32mm) 1¼”(32mm)
Use outside diameter, do of tube
1¼”(32mm) 19/16”(39mm) 19/16”(39mm) =19.05mm
1½”(38mm) 17/8”(47mm) 17/8”(47mm) Internal diameter, di of
tube=14.83mm

Length of tube, Lt=5m

Triangular Pitch =23.81mm

Calculate pitch to outside diameter ratio = 23.81/19.05 = 1.25 See fig below.

Table7: - factors for tube sheet calculation

Triangular
pitch
Number of 1 2 4 6 8
pass
K1 0.319 0.249 0.175 0.0743 0.0365

1
DESIGN OF SHELL AND TUBE HEAT EXCHANGER
N 2.142 2.207 2.285 2.499 2.675

Square pitch
Number pass 1 2 4 6 8
K1 0.215 0.156 0.158 0.0402 0.0331
N 2,207 2.291 2.263 2.617 2.643

4.7 Geometrical analysis of part design

 Shell diameter and thickness
 The shell thickness (ts) can be calculated from the equation below based on the maximum
allowable stress and corrected for joint efficiency.

pDs
ts= +C
fJ−0.6 p

ts =shell thickness

P= design pressure

DS= Shell D I

f=Maximum allowable stress of the material of construction

J=Joint efficiency (usually varies from 0.7 to 0.9)

C=corrosion allowance

The minimum shell thicknesses should be decided in compliance with the nominal shell diameter
including the corrosion allowance as specified by IS: 4503.

1.3 ×203.2
∴ t s= +c J=0.8,
(100.6 × 0.8 )−(0.6 ×1.3)

=3.32mm

Including corrosion allowance 6.32 mm, use 7 mm thickness selected.

 Shell cover

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DESIGN OF SHELL AND TUBE HEAT EXCHANGER
 According the IS: 4503, the minimum thickness of the shell cover should be at least equal to the
thickness of the shell.

The required thickness of a tori spherical head (th) can be determined by:

pRiW
t h= +C
2 fJ −0.2 p

1 Ri
W=
4( √ )
3+
ri

Ri=Crownradius ,ri=Knucleradius , c=corrosionallowance

Crown radius, Ri =220mm (crown radius, R i = Ds is considered)

Knuckle radius r i =0.06 of R i = 12.2 mm (knuckle radius r i =6% of D s is taken)

J=1 for trispherical head design , w=1.77

1.3 ×203.2 ×1.77

th= +c
( 2× 100.6× 1 )−( 0.2 ×1.3 )

¿ 2.33 mm

th= 2.33mm; including corrosion allowance th=5.33 mm, use same thickness as for shell, i.e., 7 mm

Inside depth of the head (mm) can be calculated as:

1
Ds Ds
hi=Ri− Ri−
[(
2
Ri+
2 )(
+2 ri ) ] 2

=76mm

Effective exchanger length

Leff = Lt +2hi

=2.2mm+2×76 mm

=2.35mm

 Tube sheet thickness

The open end of the tubes is connected to the tube sheet. The tube sheet is fixed with the shell and
channel to form the main barrier for shell and tube side fluids. The tube sheet is attached by bolting
(called gasket construction). The typical tube sheet construction is in figure .The minimum tube-sheet
thickness (TEMA standard) to ‘resist bending’ can be calculated by:
1
DESIGN OF SHELL AND TUBE HEAT EXCHANGER
FGp p
t ts =
3 kf√
Where, F=1 for fixed tube sheet;

𝐺𝑝 =diameter over which pressure is acting (for fixed tube sheet heat exchanger 𝐺𝑝 = shell ID;

𝑓 = allowable stress for the tube sheet material

Mean ligament efficiency (𝑘):

0.785
𝑘 = 1 − PT 2 for square or rotated pitch
do( )
The effective pressure, 𝑃=𝑃𝑠+𝑃𝑏 or 𝑃=𝑃𝑡+𝑃𝑏 when the tube sheet is extended as a flange for
bolting heads.

𝑃𝑠= shell side pressure, 𝑃𝑡= tube side pressure, 𝑃𝑏= equivalent bolting pressure

The effective tube sheet to ‘resist shear’ is given by:

0.31 D L p
t =
: ts
1−
do f ()
PT

Where, D L=4𝐴/𝐶 is the equivalent diameter of the perforated tube sheet

𝐶 is the perimeter measured by connecting the canter to centre of the outermost tubes of tube layout.

𝐴=Total area enclosed by 𝐶

The shear formula does not control the tube sheet thickness when:

𝑃/𝑓<1.6 (1−do/ PT )2

2
23.5
1.3/100.6¿ 1.6 1− ( 31.25 )
0.0129¿ 0.064

The tube sheet thickness is calculated based on the bending and considering the design pressure only.
It is assumed that shear does not control the design. Carbon steel is used for tube sheet material.

FGp p
t ts =
3 √kf

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DESIGN OF SHELL AND TUBE HEAT EXCHANGER
1× 203.2 1.3
=
3 √0.5 ×100.6
, F=1, k=0.5 =10.88mm ∴ t ts =11 mm

 Bolts design

The bolt design procedure is as follows:

The minimum initial bolt load (Wm 1) at atmospheric pressure and temperature is given by:

Wm 1=πbGY

=π × 2× 218.5 ×12.65

=17366.85N

The minimum bolt cross sectional area with bolt material carbon steel (fa=fb=100.6Mpa)

Am=Wm1/fa

=17366.88/100.6

=173mm2

From standard table of bolt and nut M10, pitch=1.5mm, stress area=58.3 mm2, major nominal diameter
(d=10mm), pitch diameter (d p=9.026mm), core diameter (dc=8.1mm) and number of bolt (n b=24)

Corresponding actual bolt circle area is calculated by;

π π
Ab = dc 2 × nb= ( 8.1 )2 ×24
4 4

=1236

1236≫ 173

Therefore our selection of bolt from standard is safe

 Calculation for number of tubes

Using outside diameter find the area of tube as, At 1=π∗d o∗Lt
¿ π∗19.05∗10−3∗5=0.2992 m2

Next find number of tubes, N t =A / At 1=7.34 /0.2992=24.5 5, say 24.0 this is from standard table
since the number of tube is changed the tube length must be find.
L= A /( π∗d o∗N t )=7.334/(24∗19.05∗10−3∗π )=5.04 m

Number of tubes per pass, N tpp =N t /N tp =24.0/2=12.0

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DESIGN OF SHELL AND TUBE HEAT EXCHANGER
Checks the tube side velocity at this state for reasonability from standards so the cross sectional
area of the tube using internal diameter is; ( π∗d i2 )/4=(1/4)∗π∗( 14.83∗10−3)2=0.000172m2

Find the tube cross sectional area per pass ¿ A/ N tpp =0.6073 m 3

˙ /1000=0.0194 m 3 /s ¿
Volumetric flow rate V =¿ m/ρ=(50000 /3600)∗1

Know using those two ratios find the tube side velocity and check if it is within the specification.
U t =0.0237 /0.02073=1.14 m/s Since this is less than 2m/s the assumption is acceptable. But
pressure drop will be checked.

 Calculation of bundle and shell diameter

From the standard table for two tube pass and square pitch layout tube, K1 = 0.156, n1 = 0.436, Cs

= 91 mm and the bundle diameter will be;

Dbr =d o∗( N t /k 1)n1=19.05( 24/0.156)0.436=171.5 mm

From the standard table for two tube pass and triangular pitch layout tube, K 1 = 0.249, n1 = 2.207 and
the bundle diameter will be;
Dbt =d o∗(N t /k 1)n1=19.05(24/0.249)1 /2.207=152 mm

Since bundle diameter of square pitch is greater than bundle diameter of triangular pitch the smallest
diameter is better to use.
With this concept the corresponding shell clearance for D b = 0.152m and split ring floating head. For
a split ring floating head exchanger the typical shell clearance is 56mm, so the shell inside diameter
is;
Ds =Dbt +C=152+56=208 mm

Tubes in center raw, N c =Db /Pt = 152/23.81 = 6.38

Know check the result by using length to shell diameter ratio to see it is over the reasonable limit
within the standards.
L/Ds = 5000/208 =24 this is within the standard limit 20.

 Tube side heat transfer coefficient

To determine this value first determine Re L/Di, Nu and Pr.

Re =(ρ∗u∗d i )/µ=(820∗1.14∗14.83∗10−3)/(3.2∗10−3)=4332

pr =(2.05∗3.2∗10−6)/0.134=48.96

1
DESIGN OF SHELL AND TUBE HEAT EXCHANGER

L/Di = c p*µ/k = 5000/14.83 = 337 since this value is less than 500 the value is effective comparison
with the standard.
J ht = 3.5*10-3 this value is take from table (using Re and Pr it can find from

N u=J ht∗R e∗P r 0.33=3.5∗10−3∗4332∗( 48.96)1 /3=54.8 hi=N u∗k /d i =54.8∗(0.134 /0.01483)=495 say 500 W
since the values are small we are obligated to increase hence it can be increase by increasing the tube
pass from 2 to 4 then the tube side velocity will be also double. U t =2∗1.14 m/s=2.3 m/s
Now find the values again using u value 2.3m/s gives;

Re =2∗4332=8664 ≈ 8.7∗10 3∧J ht =4∗10−3 N u

¿ 4∗10−3∗8664(48.96)0.33=125.2 hi

¿( 0.134/ 0.01483)∗125.2=1131W / m2 ℃

 Calculation of Shell side heat transfer coefficient

As the number of pass increase the shell diameter will also increase.

For 4 pass k1 =0.175 and n1 =2.285

Shell diameter can also obtain using bundle diameter as;

Db =19.05(24 /0.175)1/2.285=163.6 mm

The bundle to shell clearance is still around 56mm then shell diameter will be;

Ds =Db +C B=163.6 mm+ 56=219.6 mm

Baffle spacing is, Ds/5 say 43.9≈ 44mm this space is used for good
Heat transfer without high pressure drop.
A s=( P t−D O )∗D S∗LB / pt

A s=(23.81−19.05)∗219∗44 /23.81=1925.5 mm2

Find the equivalent diameter for the triangular pitch arrangement.

D e =4∗(0.87∗Pt 2−(π∗d o2 /4))/( π∗d o)=((23.81−0.917∗19.05 2)/19.05)∗1.1=27 mm

Volumetric flow rate on shell V s =(50000 /3600)∗1 /750=0.0184 m 3 /s

Shell side velocity,u=(0.0184 /0.0092)=0.5 m/s

1
DESIGN OF SHELL AND TUBE HEAT EXCHANGER
The next step will be to determine the Renaldo’s number R es and prandetl number Pr on shell side
flow.
Res =(750∗0.5∗13.92∗10−3/0.00043)=12139.5

Pr =(2.47∗0.43∗10 3∗10−3)/0.132=8.05
From the popular table use segmental baffles with a 25% cut. This should give a reasonable heat
transfer coefficient with less pressure drop.
Now using standard tables and graphs find out the heat transfer across shell side.
Take
J hs=4.52∗10−3 hs =N u∗k / De =(0.132 /13.52)∗10 3∗4.52∗10−3∗17214∗8.05 0.33=1505 W /m2 ℃
 Calculation of Overall heat transfer coefficients
Over all coefficients can be determined as;

1 do do do 1
Uo=
( hi )( )
+ Rq × + ln + + R w
d i 2 k d i ho

19.05
19.05 ×10−3 ln
1 19.05 19.05 ×0.0005 14.83 1
= + + + + 0.001
U o 1131× 14.83 14.83 2×55 1505

U o =401 W /m2 ℃

4.8. Check for Pressure drop

4.8.1 Tube side pressure drop

Δ Pt =N P∗(8∗J f ( L /di )+2.5)∗ρ∗(u 2 /2)

J ft =5∗10−3∗Re =8.7∗10−3 m=0.25 For laminar flow, Re <2100

M = 0.14 for turbulent flow, Re > 2100.

∆ Pt =4(8∗5∗10−3 (500/14.83)+2.5)∗(1820∗2.3 2/2)=138810 N /m2 ≈ 1.4 ¯¿

Since this is greater than the given specification pressure drop (1.4 > 0.8bar) it must be
recalculate starting from step five. Hence modification of the above data’s will continue.
 Modification
The tube velocity needs to reduce. This will reduce the heat transfer coefficient so the number of
tubes must be increased to compensate. There will be a pressure drop across the inlet and out let
nozzles. Allow 0.1bar for this, a typical figure (about 15% of the total); which leaves 0.7bar across
the tubes. Pressure drop is roughly proportional to the square of the velocity and u t is proportional to

1
DESIGN OF SHELL AND TUBE HEAT EXCHANGER
the number of tubes per pass. So the pressure drop calculated for 24 tubes can be used to estimate the
number of tubes required. Tubes needed N t =N t ¿
N t =24 ¿ Say

Hence approximate to the standard value hence, N t =30

Retain 4 passes since the heat transfer coefficient will be too low with 2 passes. Second trial design:
30 tubes 19.05mm outside diameter, 14.83mm internal diameter, 5m long, triangular pitch 23.81mm.
Tube side heat transfer coefficient
Bundle diameter, Db=DO∗¿

Db =19.05¿

Shell diameter, Ds =Db +C b

D s =180+59=239 mm

Cross sectional area per pass, Acp = Ac ∗N tpp

Acp =( 30/4)∗(14.83∗10−3 )π / 4=0.08731m 2

Tube velocity U t =m/( A cp∗ρ)=(0.0237 /0.01555)=1.524 m/s

Re =(ρc∗U t∗D I )/Z C

Re =(820∗1.524∗14.83∗10−3 /(3.2∗10−3))=5792 ≈ 5.8∗103

L/Di is the same as the first trial, 337

Heat transfer factor, J ht =3.6∗10−3 Heat

transfer coefficient, hi
hi =hi=N u∗k /di =((0.134 /14.83∗10−3 )∗3.6∗10−3∗5792∗48.990.33)=680W /m2 ℃ Next
step is to determine the pressure drop across tube side.

4.8.2 Tube side pressure drop

From the standard graph using the tube side Reynolds number the friction factor, J ft =5.5∗10−3

Δ Pt =N tp ¿

5000

Δ Pt =
(
4∗ 8∗5.5∗10−3 ( 14.83 )+2.5)∗820∗1.524 2 =66029 N /m ≈ 0.66 ¯¿ This is below
2
2
0.8bar hence it is acceptable.
1
DESIGN OF SHELL AND TUBE HEAT EXCHANGER
The total pressure drop is the sum of the pressure drop across the inlet and out let of the nozzle and
the pressure drop across the tube, i.e. ΔP= ΔP t +0.1 ¯¿
ΔP=0.66+ 0.1=0.76 ¯¿ This is acceptable; 0.67< 0.8 .̄ Keep the same baffle cut
and spacing.

4.8.3 Shell side pressure drop

( Pt−D O )∗D s∗L B∗A s ( 23.81−19.05 )∗597∗100 2
A s= = =11935 mm u s
Pt 23.81
¿ m s /( ρ∗A s)=(0.0076 / 0.01193)=0.637 m/ s∗d e =13.92mm
Res =( ρh∗U s∗D e )/ Z h

¿(730∗0.637∗13.92∗10−3 /(0.43∗10−3 ))=15057=1.5∗104 Prs =8.05 as befor

J hs=4.8∗10−3 hs=N u∗k /D e=(0.132/( 13.92∗10−3 ))∗0.0048∗15053∗8.05 0.33=1366 W /m2 ℃

This is good estimation.
Know it simply to determine the pressure drop of shell

J fs =4.6∗10−2

Δ P s=( 8∗J fs ( Ds /d e )∗( L/ LB )∗(ρ K∗U s2 /2))∗¿

Consider low viscosity then Z w =Z k

Δ P s=( 8∗4.6∗10−2 (597 /13.92)∗(5000/100)( 730∗0.638 2/2))=117243 N /m2 ≈ 1.2 Since1.2

¯ ¯¿ 0.8 ¯¿

The design of shell side is not acceptable it must be modify.

Check the overall coefficient to see if there is to modify the shell side design.

1
Uo=
1 d d d 1
( hi )( )
+ R f × o + o ln o + + Rf
d i 2 ×k d i ho

1 1 19.05
=
U o 680(+0.00035 ∗ )(
14.83
+¿ )
U o =302W /m2 ℃

U o =(Q /( A o∗ΔT ¿ ))∗A=30∗0.2992=107.7 m2 U o=(1509.4∗103 /(107.7∗68.6))=204 W /m2 ℃

The estimated overall coefficient is well above that required for design, 302compired to 204W/m 2oc
which gives scope for reducing the shell side pressure drop. Allow a drop of 0.1bar for the shell
inlet and outlet nozzles leaving 0.7bar for the shell side flow. So to keep within the specification the
shell side velocity will have to be reduced by around 0.707. To achieve this baffle spacing will need
1
DESIGN OF SHELL AND TUBE HEAT EXCHANGER
to be increased to 100/0.707 =131, say 130mm. A s=((23.81−19.05)/23.81)∗597∗130 =

15516 mm2 ≈ 0.0155 m2 u s=(0.0076/0.0155)=0.490 m/s

Res =( ρg∗U s∗d e )∗R es /Z g=(730∗0.490∗13.92∗10−3 /(0.43∗10−3 ))=11580 ≈ 1.2∗10 4

Prs =(C pg∗Z g )∗P r /k g=(1,0732∗0.43∗103∗10−3 /0.132)=8.05

J hs=5.9∗10−3 ∧J fs =5.9∗10−2 ho=(k k /d e )∗J hs ∗R es∗p rs1 /3(Z g / Z w ) 0.14

= (0.132∗103 /13.92)∗5.9∗10−3∗1.2∗10 4∗8.05 0.33=1180 W /m2 ℃

Consider Z g=Z w

Hence,Δ P s=8∗J rs ( Ds /d e )∗(L /L B)∗( ρ k∗U s2 /2) ¿∗¿

¿( 8∗2.58∗10−2 (596 /13.52)∗(5000/144)∗(730∗0.455 2/2))=47000 N /m2=0.47 ¯¿ Since

the pressure drop is within the limit (0.47bar < 0.8bar) the design on shell side is
acceptable.

CHAPTER FIVE

Cost analysis of heat exchanger

5.1 Cost estimation

5 .1.1 the factorial method cost estimation

Capital cost estimates for chemical process plants are often based on an estimate of the purchase cost
of the major equipment items required for the process, the other cost being estimated as factors of the
equipment cost. The accuracy of this type of estimate will depend on what stage the design has
reached at the time the estimate is made, and on the reliability of the data available on equipment
costs. In the later stages of the project design, when detailed equipment specifications are available
and firm quotations have been obtained, an accurate estimation of the capital cost of the project can
be made. Therefore total cost of the product is the sum of material cost manufacturing cost and other
like transportation cost. So in this the designer obligates to set the material cost as follows.
 Find volume of tube, V from surface area of tube, number of tube and thickness of tube.
1
DESIGN OF SHELL AND TUBE HEAT EXCHANGER
V ¿ A st∗N t∗t

= 0.299237m2*360*0.002m =0.21545064m3

 Find mass of the tube, m from density of material and volume of tube.

M = ρ*V

= 7804*0.21545064 = 1681.37679kg since density of material carbon steel is 7840kg/m3

• Find total cost of tube from cost of carbon steel per ton and mass of the tube
(material cost).
Total cost of tube = m*cost of carbon steel per ton

= 1681.37679kg * 500US$/1000kg

=840.68US$

• Find volume of shell

V s =π∗D∗L∗t

¿ 0.01597 m 3

• find total cost of shell(material cost)

Total cost of shell = V s *density of material*cost of carbon steel per ton

= 0.01597m3*7804kg/m3 *500US$/1000kg
= 62.3164US$

• Find total cost of the heat exchanger(material cost)

Total cost of heat exchanger = total cost of tube + total cost of shell

= 840.68 + 62.3164

= 902.9964US$

EQUIPMENT COST METHOD

5.2 Material cost for shell

The material we use in the project in each component is stainless steel as we have listed the reason in
the material selection and its density is 7.8 g/cm3. The cost estimation depends on the material volume,
mass, density, e

Volume of the shell:

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DESIGN OF SHELL AND TUBE HEAT EXCHANGER
Assumed value: length =5m, internal diameter = 210mm, thickness =10mm

The total volume of the shell is calculated as follows, total volume (VT) =

π 2 2
VT = (d −d )
4 o i

π
VT = ((220mm)2)−¿((210mm)2)*5000mm
4

VT =0.161m3

Density of the material is known 7,850 kg/m3. Now the mass of the material (M) is:

Mass (M) = density *volume

M = 7,850 kg/m3 *0.161m3 = 131.5 kg

The mass of carbon steel per kg is 18.5 birr.

The total cost of the shell is:

131.5kg *18.5 birr/ kg

= 2452.25 birr

The material cost of the shell is 2452.25birr

5.3 Cost analysis of water tube inside the shell

To calculate cost analysis of the water tube we have to know the volume of the tube.

Length of the tube (L) =2200 m, outer diameter of the tube (do) = 25.4mm and internal diameter of the
tube (di) =22mm

π 2 2
Volume of each tube (V) = (d o −d i ) *L
4

π
V= (25.42-222)*2200 = 2.78*10−4 m3
4

Total volume of all tubes inside the shell is calculated by;

V=number of tube *volume of individual tube

=32*2.78*10−4 m3

=8.91*10−3 m3

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DESIGN OF SHELL AND TUBE HEAT EXCHANGER
For same material with shell, mass of material is given by;

Mass (M) = density *volume

=7850*8.91*10−3 m 3

=69.9Kg

Total cost of water tube is

=69.9*18.5birr

=1293.15birr

5.4 Cost analysis for shell cover

In our design of shell and tube heat exchanger there are two head covers of the shell. They are; front
head and rare head covers. Similarly to calculate cost analysis of the head covers of the shell we have
to know volume of each head cover. Head cover is made from two integrated parts they are half
spherical part and cylinder part.

Total volume of head cover is calculated by;

π
VT=4/3 ¿ where,
2

r i =d i/2 and r o =d o /2

l =length of cylindrical head=76mm

4 /3(108.53−101.6 3) π
VT= + (2172−203 2)∗76
2 4

=4.78*10−4 +¿ 3.51*10−4

=8.29*10−4 m3

For same size front and rare head cover

V T =2∗8.29∗10−4 m3

=1.658∗10−4 m 3

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DESIGN OF SHELL AND TUBE HEAT EXCHANGER
For same material with the shell total mass is calculated by;

Mass=7850*1.658¿ 10−3 m3

=13.01Kg

Total cost of shell cover material cost is given by;

Cost=13.01*18.5

=240.78birr

5.5 RESULT AND DISCUTION

The objective of this project was completion of boiler chimney heat recovery heat
exchanger system that could be used to recover heat lost through flue gases. Shell and tube heat
exchanger was used in the design. The systems model was completed under free (natural)
convection conditions. From the performance of the model the optimum operating conditions
were obtained as:
Overall heat transfer coefficient U= 302W/m2K
Amount of heat recovered Q =3.4 kW
T water in = 290C, T water out = 610C, T g in = 2000C, T g out =830C the amount of heat recovered
Q increased linearly with the overall heal transfer
coefficient from values of u and Q of 1.00 kW and 300respectively. At a value of Q= 0.34kW,
the value of U reached its maximum and then remained constant for higher values of Q . The
optimum value of U was found to be 2533from Q 0.34kW and higher values of Q.
Q increased with increase in . optimum values was never reached due
to nature of the fluid
The temperatures for the above operating conditions were:
water inlet temperature Ta in = 290C
water outlet temperature T air out = 510C
Flue gas inlet temperature T gin = 2000C
Flue gas outlet temperature T gout = 830C
The optimum operating conditions can therefore be summarized as follows:
Overall heat transfer coefficient U= 2533kw / m2 k
Effectiveness ε = 40%
T water in = 290C, T water out =61 ℃ T g in = 200 ℃ C, T g out= 90 ℃

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DESIGN OF SHELL AND TUBE HEAT EXCHANGER
As we see from the project by using those specification we get the out let temperature of the water is
61 c o this is hot water that is used to wash the bottle before we rinse it in cold water we have to wash it
by hot water in order to avoid different particles for example bacteria can survive at the temperature of
40c o so by washing the bottle we can make it free from different derties
Table8; - Input and Output parameter of design analysis

Parameter Value Unit

In let temperature of shell 250 ℃
Out let temperature of shell 90 ℃
In let temperature of tube 29 ℃
Out let temperature of tube 61 ℃
Mass flow rate of shell fluid 13.8 kg / s
Mass flow rate of tube fluid 11 kg / s
In let velocity of shell 2 m/s
Out let velocity shell 1.14 m/s
In let velocity of tube 1 m/s
Out let velocity of tube 0.5 m/s
Pressure of in let fluid of shell 0.8 ¯¿
Pressure of out let in shell 0.7 ¯¿
Pressure in let of tube 6.5 ¯¿
Pressure out let of tube 0.45 ¯¿
Over all coefficient heat 300 w /m2 k
transfer

From thermal design analysis procedure there are main design step of kern method by assuming over
all heat transfer coefficient U oass=300w /m k with decide number of tube and tube of baffle is cut segment
2

by calculating tube side and shell side pressure drop can determine the flow rate in order to increase
the heat transfer the allowable pressure should greater than the tube side and shell side pressure if not
by increase the number of tube the flow is counter when taking long mean temperature difference we
take the higher because this can reduce the surface area of exchanger and tube side have higher
pressure than shell side having multi pass.

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DESIGN OF SHELL AND TUBE HEAT EXCHANGER
CHAPTER SIX

CONCULUSION AND RECOMMENDATION

6.1CONCULUSION

Recovery The objective of this project was completion and testing of boiler chimney heat recovery
heat exchangers system that could be used to recover heat lost through flue gases. Shell and tube heat
exchanger was used in the design. The systems model was completed and tested under forced
convection conditions
From the the project we conclude that the two component of heat transfer that is shell and tube are
must designed well then the heat transfers will be effective and efficient

6.2 RECOMANDATION
we recommend that the project should be continued by other in order to get more modified then it will
be interesting and helpful for our countries and for to be more economical this design can solve the
economic and social problems of the working area or surrounding especially the soft drink company.
This project should done by using software like comsul and, ansys.due lack of time cannot put or do
its simulation it is easy and simple to analyse effect of different temperatures, pressure, velocity, baffle
spacing, etc….

6.3 FUTURE WORK

The developed new heat exchanger will be further developed into a heating unit which can be utilized
on a typical water-heater air conditioning system in the air conditioning and ventilation industry.

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DESIGN OF SHELL AND TUBE HEAT EXCHANGER

REFERANCE
http://chemicalengineeringnow.com/HeatExchanger.aspx
www.engineersedge.com
http://www.calculatoredge.com
[1] Introduction to CFD Basics by Rajesh Bhasaran Lance Collins.
[2] Design of experiment using the taguchi approach by Ranjit KRoy
[3] Heat Exchangers:Selection,Rating, and Thermal Design By Sadik Kakac Anchasa
Pramuanjaroenkij, Liu
[4] Tahery, A.A., Khalilarya, S., Jafarmadar, S., 2017. “Effectively designed shell-tube heat
exchangers c nsidering cost minimization and energy management”, Heat Transfer – Asian Research,
Volume 46, Issue 8, Pages 1488-14 98.
[5] Hadidi, A., Hadidi, M., Nazari, A., 2013. “A new design approach for shell-and-tube heat
exchangers using imperialist competitive algorithm (ICA) from economic point of view”, Energy
Conversion and Management, Volume 67, Pa gas 66-74.
[6] Şencan Şahin A.,Kiliç, B., Kiliç, U., 2011. “Design and economic optimization of shell and tube
heat exchangers using Artificial Bee Colony (ABC) algorithm”, Energy Convers ion and
Management, Volume 52, Issue 11, Pages 3356-3362.
[7] Eryener, D., 2006. “Thermo economic optimization of baffle spacing for shell and tube heat
exchangers”, Energy Conversion and Management, Volume 47, Issue 11-12, Pages 1478-1489.
[8] Azar, R.T., Khalilarya, S., Jafarmadar, S., Ranjbar, F., 2017. “Modeling for Shell-Side Heat
Transfer Co efficient and Pressure Drop of Helical Baffle Heat Exchangers”, H eat Transfer
Engineering, Volume 38, Issue 2, Pages 265-277.
[9] Muralikrishna, K., Shenoy, U.V., 2000. “Heat exchanger design targets for minimum area and
cost”, Chemic al Engineering Research and Design, Volume 78, Issue 2, Pages 161-167.
[10] Qashqaei, A., & Asl, R. G. (2015). Numerical Modeling And Simulation Of Copper Oxide
Nano fluids Used In Compact Heat Exchangers. International Journal of Mechanical Engineering,
4(2), 1-8.
[11] Caputo, A.C., Pelagagge, P.M., Salini, P., 2008. “Heat exchanger design based on economic
optimization”, Applied Thermal Engineering, Volume 28, Issue 10, Pages 1151-1159.
[12] .Sserna, M., JimÉnez, A., 2004. “An efficient method for the design of shell and tube heat
exchangers”, Heat Transfer Engineering, Volume 25, Issue 2, Pages 5-16.

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DESIGN OF SHELL AND TUBE HEAT EXCHANGER
[13] Wang, Q., Chen, G., Chen, Q., Zeng, M., 2010. “Review of Improvements on shell-and-tube
heat exchangers with helical baffles”, Heat Transfer Engineering, Volume 31, Issue 10, Pages 836-
853.
[14] Bell, K.J., 2004. “Heat exchanger design for the pro cess industries”, Journal of Heat
Transfer, Volume 126, Issue 6, Pages 877-885.
[15] Owaid, A. I., Tariq, M Issa, H., Sabeeh, H., & Ali, M. The Heat Losses Experimentally in the
Evacuated Tubes Solar Collector System in Baghdad-Iraq Climate.

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APPANDIX: A
Table A 1: Nomenclature

Symbol Definition Units

Ao Heat transfer area m2
A tube The surface area of the tube m2
Ac Tube cross-sectional area m2
C p,i Heat capacity of substance i J/kg.k
Db Tube bundle diameter M
de Equivalent shell diameter M
Ds Shell diameter M
di Tube inner diameter M
do Tube outer diameter M
Tube-side heat transfer
hi W/m2.K
coefficient
Tube-side fluid Fouling
Rf ,i W/m2.K
factor
Shell-side heat transfer
ho W/m2.K
coefficient
Shell-side fluid Fouling
Rof W/m2.K
factor
jf Friction factor -
jh Heat transfer factor -
Thermal conductivity of
kf W/m.K
fluid
The thermal conductivity of
kw W/m.K
the wall
lb Baffle spacing M
K1 Bundle diameter coefficient -
𝑚̇ Mass flow rate in shell side kg/s
𝑠
𝑚̇ 𝑡 Mass flow rate in tube side kg/s
n1 Bundle diameter coefficient -
Np Number of tube passes -
Nt Total number of tubes -

𝛥𝑃 Shell side pressure drop Pa

𝑠
𝛥𝑃𝑡 Tube side pressure drop Pa
Q Heat duty W
Re Reynolds number -
Temperature of substance i
Ti ℃
in tube side
 ASSOSA UNIVERSITY

Temperature of substance i
ti ℃
in shell side
Log mean temperature
∆Tlm ℃
difference
Calculated overall heat
𝑈𝑐𝑎𝑙 W/m2.K
transfer coefficient
𝑈 Assumed overall heat
W/m2.K
𝑎s𝑠 u transfer coefficient
𝑢 Shell-side fluid velocity m/s
𝑠
𝑢𝑡 Tube-side fluid velocity m/s
Dynamic viscosity of
𝜇i Pa.s
component i
𝜌i Density of component i kg/m3
Kinematic viscosity of
𝑣i m2/s
component i
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 ASSOSA UNIVERSITY

APPANDIX: B
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ASSOSA UNIVERSITY