Submitted To:
Mr. S.K. Sharma
Associate Professor
DCRUST,Murthal
Submitted By:
Gurpreet Singh Tanwar
11001005016
Chemical Engg. 4th Year
SUPERVISORS DECLARATION
I hereby declare that I have checked this project report and in my opinion, this project is
adequate in terms of scope and quality for the award of the degree of Bachelor of Chemiical
Engineering
Signature :
Name of Supervisor : Mr. SK Sharma
Position : Asst. Professor
Date : 21 Nov.2014
ACKNOWLEDGEMENT
ABSTRACT
This project is mainly focusing on designing one type of a heat exchanger which is shell and
tube heat exchanger.Heat exchangers are most used equipments used in any chemical
industry. When it comes to the manufacturing industry, heat exchangers are used both for
cooling and heating. Heat exchangers in large scale industrial processes are usually custom
made to suit the process, depending on the type of fluid used, the phase, temperature,
pressure, chemical composition and other thermodynamic properties.
According to problem statement I have to calculate the no. of tubes per passes, No. of
passes,Length of tube. In the problem statement water is used as a hot fluid as well as a cold
fluid.The inlet and outlet temperatures of both shell and tube side fluids are given. The
maximum length of pipe is given. We have to calculate the required length of tube.It should
be less than the maximum length.
CONTENTS
1. INTRODUCTION
1.1 Project Background
1.2 Project Objectives
2. HEAT EXCHANGER
2.1 Introduction
2.2 Uses and Application of Heat Exchanger
2.3 Type of Heat Exchangers
3. Flow Arrangement
4. Thermal Considerations Design
4.1 Shell
4.2 Tubes
4.3 Baffles
5. Fluid side Designing
6. LMTD and Correction factor
7 .Problems in Heat Exchanger
8. Problem Statement
INTRODUCTION
HEAT EXCHANGER
2.1 Introduction
Heat exchanger is one of devices that is convenient in industrial and household application.
These include power production, chemical industries, food industries, electronics,
environmental engineering, manufacturing industry, and many others. It comes in many
types and function according to its uses.
So what exactly heat exchanger is? Heat exchanger is a device that is used to transfer
thermal energy between two or more fluids, between a solid surface and a fluid at different
temperatures and in thermal contact. There are usually no external heat and work
interactions. In most heat exchangers, heat transfer between fluids takes place through a
separating wall or into and out of a wall in a transient manner.
for. Brazed heat exchangers, a collection of plates which are brazed together, are used for
hydronic systems like swimming pools, floor heating, snow and ice melting. The shell and
coil heat exchanger design is best for areas with limited spaces as it can be installed
vertically. Of course, for the highly industrial process, the shell and tube heat exchanger is
the perfect solution.
3.FlOW ARRANGEMENT
Co-current (Parallel) flow- As the name suggests, the flow of the hot and the cold fluid is
taking place in the same direction in this case. As the graph shows, the temperature
difference between the hot and the cold fluid keeps on decreasing from one end to the
other.
Counter current flow- In this setup, the hot fluid enters from one end of the exchanger and
the cold from the opposite end. This results in nearly constant temperature difference
between the hot and the cold fluid. This is a significant aspect and makes counter current
exchangers preferable over co-current exchangers. We will discuss this point later when we
talk about LMTD.
Crossed flow-The cold and the hot fluid flow axis is at an angle to each other and hence, the
fluids cross each other in this arrangement. The most common type of crossed flow
exchanges has the angle between axes as 90 degrees.
4.1 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 Shells are
usually fabricated from standard steel pipe with satisfactory corrosion allowance.
4.2 Tube
Tube OD of 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 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.
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.
transfer co-efficient by inducing higher turbulence. The pressure drop is more with closer
baffle spacing. The various types of baffles are shown in the 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. Following figure also shows two other
types of baffles
Correction Factor:
If a heat exchanger other than double pipe type is used the heat transfer is calculated by
using a corrcetion factorapplied to LMTD for a counterflow arrangement problem with the
same hot and cold fluid temperature.
Fouling
Fouling is the accumulation of unwanted material on solid surfaces to the detriment of
function. The fouling material can consist of either living organismsor a non-living substance
(inorganic or organic). Fouling is usually distinguished from other surface-growth
phenomena in that it occurs on a surface of a component, system or plant performing a
defined and useful function, and that the fouling process impedes or interferes with this
function.
Some types of fouling are:
a.Corrosion fouling
b.Chemical Reaction fouling
c. Biofueling
Tube Vibrations
Vibration of tubes in heat exchangers is an important limiting factor in heat exchanger
operation. The vibration is caused by nonstationary fluid dynamic processes occurring in the
flow. These are turbulent pressure pulsations (in turbulent flow), vortex initiation and
separation from tubes in crossflow.This problem can cause damage to heat exchanger.
Leakage
Sometimes the fluid of the tube side can leak to shell side or vice versa. It may cause huge
production loss. Leaks may develop at the tube to tube sheet joints of fixed tube sheet
exchangers because differential thermal expansion between the tubes and the shell causes
overstressing of the rolled joints. Or, thermal cycling caused by frequent shutdowns or
batch operation of the process may cause the tubes to loosen in the tube holes. Floating
heads or U-bend exchangers would be considered first for this type of service. If a fixed tube
sheet unit is required, an expansion joint will be specified. An exchanger that will
be thermally cycled two or three times a day will require superior mechanical construction
such as the strength welding of tubes to the tube sheet, complete inspection of the shell
and channel welds during fabrication. Welding the tubes to the tube sheets does not
guarantee that a leak will not occur as sometimes weld failure due to porosity in the welds
or just one poorly welded tube out of the hundreds of welds can cause a leakage. The use of
double tube sheets to minimise the chances of leakage between the tube side and shell side
can be a good solution to the problem.
Dead Zones
Existing shell and tube heat exchangers suffer from the fact that they must typically use
baffles to maintain the required heat transfer. This, however, results in dead zones within
the heat exchanger where flow is minimal or even non existent. These dead zones generally
lead to excessive fouling. Other types of heat exchangers may or may not employ baffles. If
they do, the same increased fouling problem exists. Further, in heat exchangers fitted with
baffles, for example, the cross flow implementation results in the additional problem of
potential damage to tubes as a result of flow induced vibration. In the case of such damage,
processes must often be interrupted or shut down in order to perform costly and time
consuming repairs to the device.
Assumptions:
1.Steady state conditions exist.
2.Heat loss to the surroundings is negligible.
3.Kinetic and potential energy are negligible.
Solution:
Step 1: Calculation of Hot fluid exit temperature:
Here hot and cold fluids both are water. Heating fluid is entered in shell and cooling fluid is
entered in tubes.
As we know that heat lost by hot fluid is equal to heat gain by cold fluid. Let 1 represents
the hot fluid and 2 represents the cold fluid.
Now, heat lost by hot fluid =m1*c1*dT1
Heat gain by the cold fluid=m2*c2*dT2
where dT1 and dT2 are difference in Temperatures of hot and cold fluid rpt.
dT1=Th1-Th2
dT2=Tc2-Tc1
From the given values:
dT1=93-Th2
dT2=55-38=17 0C
Equating the heat lost by hot fluid to the Heat gain by the cold fluid,
We get,
Th2=93-((3.8*4.18)*17/(1.9*4.18))=59 0C
So, Th2=59 0C
Step 2: Calculation of LMTD
q=m2*c2*dT2
q: The total required heat transfer
q=3.8*4.18*17=270 kW
LMTD=((Th1-Tc2)-(Th2-Tc1))/(ln((Th1-Tc2)/(Th2-Tc1)))
=(38-21)/ln(38/21)=28.66 0C
So, LMTD=28.66 0C
Step 3:Calculation of Total Surface Area (As1)
From q=U*As*LMTD
As1=q/(U*LMTD)
=270*10**3/(1419*28.66)=6.639 m2
As1=6.639 m2
Step 4: Calculation of total flow area (Af)
Using the average water velocity in tubes and flow rate
m2=rho*Af*Vav
rho=density of water=1000 kg/m3
Af=m2/(rho*Vav)
=3.8/(1000*0.366)
=0.0104 m2
So, Af=0.0104 m2
Step 5:Calculation of number of tubes (n)
From n*At=Af
n=Af/At
=0.0104/(3.14*0.0119**2/4)
=36.7
So, n=37
Step 6: Calculation of the length of tube L
From n*3.14*Dt*L=As
L=As/(n*3.14*Dt)
=6.639/(37*3.14*0.019)
=3
So, L=3 m
This length is greater than the allowable length.
CONCLUSION
(a) The no. of tube passes.=37
(b) No. of tubes per pass=2
(c) The tubes length=1.707 m