Heat & Mass Transfer

Project Report

Instructor: Dr M.ANWAR

Members:
M.Mubashar Hassan 220501006
Saim Javed 220501008
Mehar Mohammad Ali 220501010
Sohaib Shehzad 220501052
Muhammad Musharib 220501022
Shahzaib 2105010
Contents:
 Abstract
 Introduction of STHE
 Design of S&THE
 Design Methods
 Design Considerations for S&THE
 Calculations
 Research Papers
 References
Design of shell and tube heat exchanger
Consider the following problem and design a shell and tube heat exchanger;
20000kgh-1 of kerosene (420 API* ) leaves the base of kerosene side-stripping
column at 200 0C and is to be cooled to 90 0C by exchange with 70000kgh-1 light
crude oil (340API) coming from storage at 40 0C. The kerosene enters the heat
exchanger at a pressure of 5bar and the crude oil at 6.5bar. A pressure drop 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 0.00035(wm-2 k -1) -1 for the crude stream and 0.0002(wm-2 k -
1) -1 for the kerosene stream

a. Introduction to shell and tube heat exchanger

i. What are shell and tube heat exchanger
ii. What work is now going on related to these (include at least 10
recent research papers (published after 2015))
b. Design methods for shell and tube heat exchanger
c. Design consideration in shell and tube heat exchanger
d. Design of shell and tube heat exchange
Abstract
A shell and heat exchanger is a vital component in thermal and fluid engineering,
designed to transfer heat between two or more fluids without direct mixing. It
consists of a cylindrical outer shell enclosing a bundle of tubes, where one fluid
flows through the tubes and another fluid flows over them within the shell. This
configuration allows efficient heat exchange due to the large surface area and
controlled flow paths. Common applications include power plants, chemical
processing, refrigeration, and HVAC systems. The design and operation of shell
and heat exchangers prioritize thermal efficiency, pressure drop minimization, and
material durability to ensure reliable performance across diverse industrial
environments

Design of Shell and Tube Heat Exchanger

1. Introduction to Shell and Tube Heat Exchangers

a. What are Shell and Tube Heat Exchangers?

 Shell and tube heat exchangers are devices designed for efficient heat
transfer between two fluids.
 They consist of a shell (a large vessel) containing a bundle of tubes, where
one fluid flows through the tubes and another flows over the tubes within the
shell.
 Widely used in industries such as petrochemicals, power generation, and
chemical processing.

A shell and tube heat exchanger is a device designed to efficiently transfer heat
between two fluids, typically without allowing them to mix. It consists of a
cylindrical shell housing a bundle of tubes. One fluid flows through the tubes,
while the other circulates around them within the shell. This arrangement
facilitates heat exchange through the tube walls, driven by the temperature
difference between the two fluids.

The design of shell and tube heat exchangers offers versatility, accommodating
various applications by adjusting parameters such as tube diameter, length, and
arrangement. They are commonly used in industries like oil refining, chemical
processing, and power generation, where efficient heat transfer is essential.
Key components of a shell and tube heat exchanger include:

 Shell: The outer vessel that encases the tube bundle.

 Tube Bundle: A set of tubes through which one of the fluids flows.
 Tube Sheets: Plates that hold the tubes in place at both ends of the shell.
 Baffles: Structures within the shell that direct the flow of the shell-side fluid,
enhancing heat transfer and supporting the tubes.

The efficiency of these heat exchangers depends on factors such as the flow
arrangement (e.g., counterflow, parallel flow), the properties of the fluids involved,
and the specific design features employed. Proper design and maintenance are
crucial to ensure optimal performance and longevity of the equipment.

2. Design methods for shell and tube heat exchangers:

Designing a shell and tube heat exchanger involves a systematic approach to
ensure efficient heat transfer, mechanical integrity, and compliance with
operational requirements. The process typically includes the following steps:

1. Define Process Requirements:

o Heat Duty: Calculate the amount of heat to be transferred between
the two fluids.
o Fluid Properties: Gather data on flow rates, temperatures, pressures,
and physical properties of both shell-side and tube-side fluids.
o Allowable Pressure Drops: Determine the maximum permissible
pressure drops for both sides to ensure efficient operation.
2. Thermal Design Calculations:
o Log Mean Temperature Difference (LMTD): Compute the LMTD
based on the inlet and outlet temperatures of the fluids to drive the
heat transfer.
o Overall Heat Transfer Coefficient (U): Estimate 'U' considering
factors like fluid properties, flow arrangements, and fouling factors.
o Heat Transfer Area (A): Calculate the required surface area using
the formula: Q=U×A×LMTDQ = U \times A \times
LMTDQ=U×A×LMTD where QQQ is the heat duty.
3. Mechanical Design:
 o Tube Specifications: Select tube material, diameter, wall thickness,
length, and arrangement (e.g., triangular or square pitch) based on
thermal and mechanical considerations.
o Shell Specifications: Determine shell diameter, thickness, and
material to accommodate the tube bundle and withstand operating
conditions.
o Baffle Design: Design baffles to support tubes and direct shell-side
flow, enhancing heat transfer while controlling pressure drop.
4. Pressure Drop Calculations:
o Tube Side: Calculate the pressure drop considering factors like tube
length, diameter, fluid velocity, and viscosity.
o Shell Side: Estimate the pressure drop accounting for baffle spacing,
shell diameter, and flow characteristics.
5. Fouling Considerations:
o Incorporate fouling factors into the design to account for the expected
accumulation of deposits over time, which can impact heat transfer
efficiency.
6. Iterative Optimization:
o Adjust design parameters iteratively to balance thermal performance,
pressure drops, mechanical integrity, and cost-effectiveness.
7. Compliance with Standards:
o Ensure the design adheres to relevant industry standards and codes,
such as those from the Tubular Exchanger Manufacturers Association
(TEMA) and the American Society of Mechanical Engineers
(ASME).
c. Design Considerations in Shell and Tube Heat Exchangers
1. Thermal Performance: Ensure efficient heat transfer by selecting
appropriate materials and configurations that maximize the heat exchange
between fluids.
2. Pressure Drop: Maintain pressure drops within acceptable limits to prevent
excessive energy consumption and ensure proper fluid flow.
3. Material Selection: Choose materials compatible with the operating
environment to resist corrosion, erosion, and thermal stresses.
4. Fouling Factors: Account for potential fouling by incorporating fouling
factors into the design to maintain performance over time.
5. Mechanical Design: Ensure structural integrity under operating pressures
and temperatures, considering factors like thermal expansion and vibration.
6. Maintenance and Accessibility: Design for ease of maintenance, cleaning,
and inspection to prolong the exchanger's lifespan.

d. Design of Shell and Tube Heat Exchanger

1. Define Process Requirements: Establish the heat duty, inlet and outlet
temperatures, flow rates, and allowable pressure drops for both shell-side
and tube-side fluids.
2. Select Heat Exchanger Configuration: Choose the appropriate shell and
tube arrangement (e.g., single-pass, multi-pass) based on process
requirements and space constraints.
3. Thermal Design Calculations:
o Heat Transfer Area: Calculate the required surface area using the
heat duty and an estimated overall heat transfer coefficient.
o Log Mean Temperature Difference (LMTD): Determine the LMTD
for the chosen flow arrangement to facilitate accurate area
calculations.
o Overall Heat Transfer Coefficient (U): Estimate 'U' considering the
thermal resistances of the tube and shell materials, fouling factors, and
film coefficients.
4. Mechanical Design:
o Tube Specifications: Determine tube diameter, wall thickness, length,
and material based on thermal requirements and mechanical strength.
o Shell Specifications: Define shell diameter, thickness, and material,
ensuring it can withstand operating pressures and temperatures.
 o Baffle Design: Design baffles to support tubes and direct shell-side
flow, enhancing heat transfer while controlling pressure drop.
5. Pressure Drop Calculations: Compute pressure drops on both shell and
tube sides to ensure they are within permissible limits, adjusting design
parameters as necessary.
6. Iterative Optimization: Iteratively adjust design parameters to balance
thermal performance, pressure drops, mechanical integrity, and cost-
effectiveness.
7. Compliance and Standards: Ensure the design adheres to relevant industry
standards and regulations, such as those from the Tubular Exchanger
Manufacturers Association (TEMA) and the American Society of
Mechanical Engineers (ASME).

Calculations :
Analysis
 Hot fluid (kerosene):

 Flow rate: m˙h=20000 kg/h=5.56 kg/s

 Initial temperature: Th,in=200∘C
 Final temperature: Th,out=90∘C
 Specific heat capacity (CpC_pCp): Approx. 2.09 kJ/kg (from typical
kerosene properties)

 Cold fluid (light crude oil):

 Flow rate: m˙c=70000 kg/h=19.44 kg/s

 Initial temperature: Tc,in=40∘CT
 Final temperature: To be determined
 Specific heat capacity (Cp): Approx. 2.1 kJ/kg

 Constraints:

 Maximum pressure drop: 0.8 bar

 Fouling factors: Rf (crude oil)=0.00035 (W/m2⋅K), Rf (kerosene)} =
0.0002(W/m2.K)
  Pressure Drop Check

Verify the pressure drop on both shell and tube sides using standard correlations (e.g.,
Kern’s method or Bell-Delaware method). Adjust the design if necessary to ensure
ΔP≤0.8 bar.

Research Papers on the working heat exchangers:

Shell and tube heat exchanger optimization using
new baffle and tube configuration

Abstract
This research focus on the fluid flow and heat transfer of water inside the
segmental baffle shell and tube heat exchanger (SB-STHE) optimization using
combined baffle and longitudinal ribbed tube configuration. Triangular and
circular ribbed tubes are employed with disk baffle shell and tube heat exchanger
(DB-STHE) and combined segmental-disk baffle shell and tube heat exchanger
(CSDB-STHE). The fluid domain is simulated by SOLIDWORKS Flow
Simulation (Ver. 2015). Obtained results are compared with experimental data and
numerical results available in literature. Based on the obtained results under
maximum mass flow rates (2 kg/s), the average value of shell-side heat transfer
coefficient of DB-TR and CSDB-TR are 26.6% and 31.9% higher than DB-CR and
CSDB-CR, respectively. To evaluate the performance, Q/ΔP is selected at the same
flow rate. A 42.8%, 40.5%, 24.2% and 7.12% difference over conventional baffles
are represented by DB-TR, CSDB-TR, CSDB-CR and DB-CR respectively. In
another criterion named as Performance evaluation criterion a 39%, 37%, and 13%
performance difference over conventional baffles are represented by disk baffle
shell and tube heat exchanger with longitudinal triangular ribbed tube (DB-TR),
combined segmental-disk baffle shell and tube heat exchanger with longitudinal
triangular ribbed tube (CSDB-TR), and combined segmental-disk baffle shell and
tube heat exchanger with longitudinal circular ribbed tube (CSDB-CR)
respectively.
Introduction
Heat exchangers are an inseparable part of the industries such as: power plants,
process industries, oil refining and so on. Meanwhile, the shell and tube heat
exchangers (STHE) have 40% share apparatus of the different industry. Therefore,
focus on this apparatus is needed to improve the performance of this device.
Baffles and tube configuration and their arrangement have a profound effect on the
performance of this kind of heat exchanger. One can refer to common segmental
baffle problems as: creation of fouling in dead zone, producing high pressure drop
because of dead zones, remarkable flow streams between shell and baffle, tube and
baffle because of construction tolerance and decreasing the lifetime of the heat
exchanger due to the vibration caused by the fluid flow across the tube bundle [1],
[2].
Gao et al. [3] studied the discontinuous baffle with different angles experimentally.
Their result show that 40° helix angle is the best among the other studied helix
angles [3]. In an industrial research project in Tabriz, Zeyninejad Movassag et al.
[4], using helical baffle as an alternative of segmental baffle, improved the
performance of the conventional shell and segmental baffle STHE by reducing the
pressure drop and fouling. In another investigation, Nemati Taher et al. [5] studied
numerically the impact of baffle space for the helical baffle STHE. They used
baffles with angle of 20-degree. In the new approach by You et al. [6], they studied
the computationally based on the porosity and permeability concept in the range of
Reynolds numbers from 6,813 to 22,326. Wang et al. [7] presented flower baffled
STHE in an experimental investigations and compared its performance with
common segmental baffleThere are a number of investigation that focus on baffles
and tubes simultaneously. Liu et al. [19] presented a numerical simulation of the
shell side flow in rod-baffle heat exchangers with spirally corrugated tubes. Results
are compared with those in rod-baffle heat exchanger with plain tubes. Obtained
results showed that the thermo–hydraulic performance in spirally corrugated tubes
are much higher that the rod-baffle heat exchanger with plain tubes. Chen et al.
[20] examined the effect of surface roughness on the performance of a
conventional heat exchanger, and found that the system's performance is slightly
improved. In the study of Ibrahim et al. [21], the thermal-fluid behavior of the
elliptical tube was investigated in a crossover flow for the aspect ratio of 0.25,
0.33, 0.5 and 1. Swain et al. [22] compared the heat transfer coefficient and
pressure drop over the flat and elliptical tubes. In referred study, the elliptical tube
bundles show better performance than the flat tubes from the heat transfer
viewpoint. In a similar investigation, He et al. [23] conducted an investigation on
flow characteristic in the shell side of a vertical STHE having combined helical
baffles with elliptic tubes. Obtained results showed that the heat transfer rate,
Nusselt number, friction factor and thermal performance factor of the elliptic tubes
are 14.7–%-16.4%, 11.4–16.6%, 29.2–36.9% and 30–35%, higher than those of the
circular tubes respectively. Heat exchanger, and the shell side friction factor is
lower by 29.2–36.9%. Referred work demonstrates that the elliptic tube can
effectively improve the heat transfer performance of non-Newtonian fluid flowing
in the helical baffle heat exchanger when compared to the circular tube.
According to the presented research, it can be concluded that there are few articles
that point out to the optimization of heat exchangers by changing the baffles and
tubes simultaneously. In this research two kind of baffles and longitudinal ribbed
tube is proposed in order to improve the thermal performance of STHE. For fulfill
of this propositions the fluid flow and heat transfer in three dimensional domain
are simulated numerically using SOLIDWORKS Flow Simulation (Ver. 2015). By
numerical simulation of flow domain in the shell side of STHE the best model is
selected.

Section snippets

Geometry of the studied model

The geometric dimension of studied shell and tube is same for all models. In fact,
the tube length and diameter and shell diameter are same for all studied
configurations. To facilitate the

Governing equations

For turbulent flow modelling, the k-ε turbulence model is adopted for the
calculation process. The governing equations for continuity, momentum, energy, k
and ε in the computational domain are shown as follows:
Continuity:∂∂xiρui=0
Momentum:∂∂xiρuiuk=-∂P∂xi+∂∂xiμ∂uk∂xi
Energy:∂∂xiρuiT=∂∂xi∂T∂xikcP

Conclusion
In this research, CFD method is applied to study the thermohydraulic behavior of
STHE with the new baffles and ribbed tube in a 3D geometry. The pressure drop
decreases due to the directional movement of the fluid along the axis of the tubes.
The outputs of this study show that the DB-STHE and CSDB-STHE significantly
reduce the pressure drop of the shell side rather than common SB-STHE. With new
tubes, heat transfer is also increased due to the promoting area of heat
exchanging with this ribbed

Research Papers :
 B. Gao et al.
Experimental study of effects of baffle helix angle on shell-side
performance of shell-and-tube heat exchangers with
discontinuous helical baffles
Exp. Therm. Fluid Sci.
(2015)

 J.M. Gorman et al.

Thermal and fluid flow first-principles numerical design of an
enhanced double pipe heat exchanger
Appl. Therm. Eng.
(2016)

 A. El Maakoul et al.
Numerical design and investigation of heat transfer
enhancement and performance for an annulus with continuous
helical baffles in a double-pipe heat exchanger
Energy Convers. Manage.
(2017)

Research Papers Referneces:

1. Design and Analysis of Shell and Tube Heat Exchanger
This study examines the impact of baffle spacing and material selection on
heat transfer efficiency, utilizing CFD analysis to compare copper,
aluminum, and steel.
ResearchGate

A Comprehensive Review of Methods of Heat Transfer Enhancement

This review compiles various strategies aimed at increasing heat transfer
rates and reducing the size and cost of shell and tube heat exchangers.

Springer Link

Experimental Investigation of Heat Transfer Characteristics for a Shell

and Tube Heat Exchanger
This research presents numerical investigations on heat exchangers with
different baffle configurations, analyzing their impact on heat transfer
performance.

ResearchGate

Investigation of Heat Transfer Rates on Shell and Tube Heat Exchanger

by Numerical Modelling via CFD Analysis
This paper investigates a shell and tube heat exchanger design concerning
total heat transfer rate and temperature profile through numerical modeling,
comparing k-epsilon and k-omega models.

arXiv

Design of Metal Foam Baffle to Enhance the Thermal-Hydraulic

Performance of Shell and Tube Heat Exchanger
This study proposes replacing solid baffles with metal foam baffles to
address flow resistance and dead zones, aiming to improve thermal-
hydraulic performance.

R Discovery

Analysis of Stream Flow and Its Impact on Thermal Performance in

Shell-Side of Heat Exchangers Based on Flow Dead Zone
This research investigates the influence of different flow paths on shell-side
performance, utilizing stream classification and dead zone analysis methods.

R DiscoveryA Meta-Heuristic Approach for Reliability-Based Design

Optimization of Shell-and-Tube Heat Exchangers
This study introduces a new framework combining a control variate-based
 surrogate model and a hybrid metaheuristic algorithm for optimizing heat
exchanger layouts.

R Discovery

Hybrid Optimization Algorithm for Enhanced Performance and

Security of Counter-Flow Shell and Tube Heat Exchangers
This research develops a hybrid optimization methodology combining
Neural Fitting Tool, Particle Swarm Optimization, and Grey Relational
Analysis to optimize heat exchanger performance.

R Discovery

These papers provide insights into recent developments aimed at improving the
efficiency, design, and performance of shell and tube heat exchangers.

Sources: