TERM PROJECT:HEAT

EXCHANGER DESIGN
KM 331, 21, 22 HEAT TRANSFER



BERKAY ERKO
20823999

INSTRUCTOR: PROF. DR. ZMRYE AKSU
Introduction
The term project of heat transfer lecture includes a problem solving about a shell and
tube heat exchanger.
In the simplest of terms, the discipline of heat transfer is concerned with only two
things: temperature, and the flow of heat. Temperature represents the amount of
thermal energy available, whereas heat flow represents the movement of thermal
energy from place to place. Heat transfer is classified into various mechanisms, such as
heat conduction, convection, thermal radiation, and phase-change transfer.
Several material properties serve to modulate the heat tranfered between two regions at
differing temperatures. Examples include thermal conductivities, specific heats, material
densities, fluid velocities, fluid viscosities, surface emissivities, and more. Taken
together, these properties serve to make the solution of many heat transfer problems an
involved process.
The process of heat exchange between two fluids that are at different temperatures and
separated by a solid wall occurs in many engineering applications. The device used to
implement this exchange is termed a heat exchanger, and specific applications may be
found in space heating and air& conditioning, power production, waste heat recovery,
and chemical processing.
There are two primary classifications of heat exchangers according to their flow
arrangement. In parallel-flow heat exchangers, the two fluids enter the exchanger at the
same end, and travel in parallel to one another to the other side. In counter-flow heat
exchangers the fluids enter the exchanger from opposite ends. The counter current
design is most efficient, in that it can transfer the most heat from the heat (transfer)
medium. Common constructions for heat exchanger include shell and tube, double pipe,
extruded finned pipe, spiral fin pipe, u-tube, and stacked plate.
The driving temperature across the heat transfer surface varies with position, but an
appropriate mean temperature can be defined. In most simple systems this is the "log
mean temperature difference" (LMTD). Sometimes direct knowledge of the LMTD is not
available and the NTU method is used.
In this term shell and tube heat exchanger has been used. Shell and tube type heat
exchangers are built of tubes (round or rectangular in general) mounted in shells
(cylindrical, rectangular or arbitrary shape).One set of these tubes contains the fluid that
must be either heated or cooled. The second fluid runs over the tubes that are being
heated or cooled so that it can either provide the heat or absorb the heat required.
Inside the shell, baffles (dividers) are installed to direct the flow around the tubes,
increase velocity, and promote cross flow. They also help support the tubes. Shell and
tube heat exchangers are the most versatile type of heat exchangers. They are used in
process industries, in conventional and nuclear power stations, steam generators, etc.
They are used in many alternative energy applications including ocean, thermal and
geothermal. They provide relatively large ratios of heat transfer area to volume. They
are typically used for high-pressure applications. They can be easily cleaned.
Many variations of this basic type is available.
The differences lie mainly in the detailed features of construction and provisions
for differential thermal expansion between the tubes and the shell.

In general, the design of most heat exchangers involved initial conditions in which the
following variables are known and assumed data:
1. flow rate of fluids
2. temperature range of fluids
3. length/tube and arrangement of tubes
With this information, it must prepare a design for the optimum exchanger that will
meet the required process conditions. Ordinarily, the following results must be
determined.
1. Number of tubes and shell diameter
2. Heat transfer rate
3. Overall heat transfer coefficient
4. Tube side and shell side pressure drop
The design procedure is divided into three main steps.
1. Calculation of total number of tubes
2. Calculation and Checking of heat load and overall heat transfer coefficient
3. Calculation and Checking of pressure drop for tube and
shell side
Main Body
Problem
7.5 kg/s of pure iso-butane are to be condensed at a temperature of 331.7 K in a
horizontal tubular heat exchanger using a water inlet temperature of 301 K. The cooling
water outlet should not exceed 320 K. It is proposed to use 19 mm outside diameter
tubes of 1.6 mm wall arranged on a 25 mm triangular pitch. On the other hand, a layer of
scale 0.25 mm thick and thermal conductivity 2.0 W/m K, has formed on the inside of
the pipes. It is required to determine the number and arrangement of the tubes in the
shell.

Algoritm













Data
Mass flow rate of iso-butane: 7.5 kg/s
The latent heat of vaporisation of iso-butane: 286 kJ/kg
iso-butane inlet temperature: 331.7 K
cooling water inlet temperature: 301 K
OD: 19 mm


Calculating heat loaded for vaporization of isobutane.

Making assumptions (cooling water outlet temperature
and overall heat transfer coefficient)

Calculating log mean temperature difference

Calculating area with assumed data

Controling the assumptions

Calculating mass flow rate of cooling water

Tubes- 1.6 mm Wall arranged on a 25 mm trianglar pitch
Layer of scale formed on the inside of the pipes;
Thickness: 0,25 mm
k: 2.0 W/m.K
Cpwater: 4.18 kJ/kg.K
Equations which are used in calculations:
Q = m Hfg Q = m Cp T Q = U Ao Tlm
Tlm = (T1 T2)/ln(T1 T2)
A = D0 L Ao = n D0 L Across = Di
2
/4
u = m/( Across)
hi = 4280(0.00488T 1)u
0.8
/di
0.8

ho= 0.72[(k
3

2
g)/(jdo Tf)]
0.25

1/U =1/ho +Ri + 1/hi
Assumptions
cooling water outlet temperature: 317 K (should not exceed 320 K)
overall heat trasfer coefficient: 525 W/m
2
.K
ignore fouling and pressure drop
Calculations
the heat load: Q = 7.5 286 = 2145 kW
the mass flow of water: m = 2145/[4.18(317-301)] = 32.1 kg/s
T1: 331.7 301 = 30.7 K
T2: 331.7 317 = 14.7 K
Tlm = (30.7 14.7)/ln(30.7/14.7) = 21.7 K
the approximate area: A = (2145 10
3
)/(525 21.7) =188.3 m
2

the outside area of 0.019 m diameter tubes = ( 0.019 1.0) = 0.0597 m
2
/m
the total length of tubing = 188.3/0.0597 = 3154 m
Adopting a standart tube length of 4.9 m, number of tubes = (3154/4.90) = 644
a four tube-side pass unit is proposed
Resistance of scale = 2 0.000025 = 0.0005
Checking assumptions:
Inside
Water flow through each tube = 32.1/ (644/4) = 0.199 kg/s
The tube i.d. = 19.0 (21.67) = 15.7 mm
The cross- sectional area for flow= (/4)(0.0157)
2
= 0.000194 m
2

The Water velocity: u = 0.199/(1000 0.000194) = 1.025 m/s
hi = 4280 [(0.00488 308) 1]1.025
0.8
/0.0157
0.2
= 5040 W/m
2
. K = 5.040 kW/m
2
.K
Outside
The temperature drop across the condensate film; Tf is given by;
(Thermal resistance of water film + scale)/(total thermal resistance)= (T
lm
T
f
)/T
lm

(1/5.040 + 0.525)/(1/0.525) = (21.7 Tf)/21.7
Tf = 13.5 K
The condensate film is thus at (331.7 13.5) = 318.2 K
At 318.2 K;
k =0.13 W/m.K , =508 kg/m
3
, =0.000136 N s/m
2
, j=644=25.4(vertical rows of
horizontal tubes),
ho= 0.72[(k
3

2
g)/(jdo Tf)]
0.25
= 0.72[(0.13
3
508
2
9.81 286 10
3
)/(25.4 19
10
-3
0.000136 13.5)]
0.25
=833 W/m
2
K
Overall
1/U = (1/5.04) + (1/0.833) + 0.5 = 1.899
U = 0.526 kW/m
2
K = 526 W/m
2
K
which is very near the assumed value. For the proposed unit, the heat load:
Q = (0.526 644 4.9 0.0597 21.7) = 2150 kW
2150kW 2145kW
Therefore assumptions we made are correct.
Results and Conclusions
The purpose of this project was to was to bring an understanding of the design of a heat
exchanger. The transfer of heat from the hot fluid to the wall or tube surface is
accomplished by convection, through the tube wall or plate by conduction, and then by
convection to the cold fluid.
Even though the solution algorithm seems simple, the required calculations are hard to
apply because of many iterations and checking. To simplify the calculations, Coulson
and Richardsons Chemical Engineering book is used. Most of the equations in our
calculations belongs to it. As shown in algorithm, firstly the transferred heat value was
calculated by given heat of vaporization and mass flow rate terms. Then made an
assumption for overall heat transfer coefficient and cooling water outlet temperature
and logarithmic mean temperature difference was calculated from the values. Then the
heat transfer area required for the given heat duty is calculated. Tube diameter is
given, number of the tubes necessary for the system and flow-pass of heat exchanger is
determined. After that, inside and outside heat transfer coefficients ware calculated. At
the end the overall heat transfer coefficient was found and a heat transfer rate is
calculated again. It is obviusly clear that the values of U and Q which is calculated is very
close to the assumed ones.The assumptions were very succesful.
Assumed lenght of tubes are 4.9 meters and assumed, assumed cooling water outlet
temperature is 317 K and assumed overall heat transfer coefficient is 525 W/m
2
K. In the
end 644 tubes and 4-pass shell and tube heat exchanger was used. The steps of the
design of a heat exchanger was learned by solving this problem, efficiently. The factors
which effect the heat transfer rate and the importance of the tube arrangement, tube
length are well-understood.










References
Transport Processes and Seperation Process Principle (includes unit operation) 4th Edition
C.J.Geankoplis
Coulson & Richardsons Chemical Engineering Volume 1 Fluid Flow,Heat Transfer and Mass
Transfer 6th Edition J.M.Coulson, J.F.Richordson with J.R.Backhurst and J.H.Harker
Perrys Chemical Engineers Handbook Section 2 Physical and Chemical Data 8th Edition
B.E.Poling, G.H.Thomson, D.G.Friend, R.L.Rowley, W.V.Wilding
http://www.wlv.com/products/databook/ch2_2.pdf
http://www.wlv.com/products/databook/ch2_5.pdf
http://www.waset.org/journals/waset/v46/v46-104.pdf
http://www.chemstations.com/content/documents/Technical_Articles/shell.pdf
http://www.engr.iupui.edu/me/courses/shellandtube
http://en.wikipedia.org/wiki/Heat_exchanger
http://www.efunda.com/formulae/heat_transfer/home/overview.cfm
http://www.cheresources.com/designexzz.shtml