Optimization of Shell and Tube Heat Exchanger 1 PDF

Optimization of shell and tube heat exchanger
SCHOOL OF ENGINEERING AND TECHNOLOGY
Student name: Salah Hewidi
MSc Mechanical Engineering
Msc project (interim report)

Course: EN 541
Project title: Optimization of shell and tube heat exchanger
Supervisor: Dr. Ken Leung
Year of submission: 2004
School of Engineering and Technology 1

Abstract:
Shell and tube type heat exchangers are widely used in process industries, for economic reasons;
there is a need for a new optimization approach for shell and tube type heat exchanger design
and operation.
The objective function is to achieve a minimal total annual cost of heat exchangers, Pressure
drop and heat transfer are interdependent, and both of them strongly influence capital and
operating costs of any heat transfer system.
In designing a heat exchanger, it is necessary to determine the optimal dimensions of the

exchanger with the given conditions of the equipment operation.
The goal is to obtain the most economically optimal design. An economic assessment allows a
comparable estimation of various alternatives. The total annual cost consisting of fixed and
variable costs of the heat exchanger were selected as a criterion that summarizes different factors
of influence into one objective function. Major cost components of a heat exchange system are
capital, operating.
A thermal-hydraulic model for shell and tube heat exchangers has been derived. It represents the
relationship between heat transfer, pressure drop and exchanger area, and gives the possibility to
predict heat transfer coefficients from pressure drops. It is used in the optimal design of shell and
tube heat exchangers.

Contents
. Nomenclature
1. Introduction
2. Background theory
2.1 Heat exchanger
2.2 Shell and tube heat exchanger
2.3 Heat exchanger performance
2.4 Heat exchanger performance improvement
2.5 The case study
3. Data procedures for heat exchanger optimization
4. Calculation and results
5. Conclusions
6. Future work
7. Reference:
8. Appendix

Nomenclature
A Heat transfer area, m²

b spacing between bafflers, mm
c clearance between tubes, mm
Cp heat capacity per unit mass at constant pressure, j/kgk
Cmin small thermal capacity
d diameter of tubes, mm
D diameter of shell, mm
ε effectiveness of heat transfer, dimensionless
G mass flow rate, kg/sm²
h film heat transfer coefficient, w/m²k
hf fouling factor, w/m²k
j heat transfer factor, dimensionless
k thermal conductivity, w/mk
L length of tube per pass, m
m number of rows of tubes accommodated in half the shell, dimensionless
M mass flow rate, kg/s
nd maximum number of tubes on inside diameter of shell, dimensionless
nn equivalent number of tubes for two nozzles, dimensionless
nt total number of tubes, dimensionless
np equivalent number of tubes for two passes divider, dimensionless
NTU number of transfer units, dimensionless
Pr prandtl number, dimensionless
p tube pitch, mm
P power, w
R heat capacity ratio, dimensionless
Re Reynolds number, dimensionless
T temperature, ºC
u mean linear velocity, m/s
U overall heat transfer coefficient, w/m²k

x thickness of tube wall, mm

∆p pressure drop, N/m²
μ dynamic viscosity of fluid, Ns/m²
ρ density of fluid, kg/m³
Subscripts
C referring to cooler fluid
e referring to equivalent
H referring to hotter fluid
i referring to inside
o referring to outside
s referring to shell
t referring to tube

1. Introduction
Shell and tube heat exchangers the most commonly used in process industries because of their
relatively simple manufacturing and their adaptability to different operating conditions.
The principle of operation is simple enough: Two fluids of different temperatures are brought
into close contact but are prevented from mixing by a physical barrier. The temperature of the
two fluids will tend to equalize. By arranging counter-current flow it is possible for the
temperature at the outlet of each fluid to approach the temperature at the inlet of the other. The
heat contents are simply exchanged from one fluid to the other and vice versa. No energy is
added or removed.
High primary energy consumption is typical of the chemical and process industries. Each
production is tied up with requirements for profitability and process efficiency.
Shell and tube heat exchangers distinguishes itself by low-pressure drops with high flow
velocities; the capital requirement of it, as well as the associated flow (i.e. the combined power
and capital) cost requirement due to pressure drops of the pumped streams in a unit can be very
expensive. In addition, the dependence of total cost to capital or current requirements is highly
affected by commercial policies of the company Optimization of shell and tube heat exchangers
from an economic point of view involves both capital and operating costs, those which gain
importance because of the current and future share of the market of this heat exchanger type in
various industries. Unfortunately, the known commercial design procedures and tools do not
consist of optimization strategies. However they are presented as simplified expressions
describing interactions between heat transfer and pressure drop which can be used to optimize
the design of these kinds of heat exchangers.
The objective is to illustrate the use of the transfer method for optimum size on basis of
minimum annual cost of a 1 – 2 shell and tube heat exchanger used by Jowfe oil
Technology Company at Libya, required to cool an organic liquid by using water flowing
through the shell as coolant [13].

2. Background Theory
Heat Transfer Concepts Heat is a form of energy that is transferred from one body to another
body flows due to difference in temperature, the heat transfers from the hotter body to the colder
one. This will continue until the temperatures of the bodies are the same (thermal equilibrium).
The transfer of heat occurs via one or any combination of the three modes of heat transfer -
conduction, convection and radiation. Generally, the radiation heat transfer is of little importance
for heat exchangers operating at low temperatures.
Heat Flow through a Pipe The heat transfer through a pipe is dependent on the thickness of the
pipe layer. The thickness of the pipe can be defined by the radius of layers i.e. Din, and Dout the
thermal conductivity of layer is, K The fluid within the pipe is at temperature Tin, and the heat
transfer coefficient from fluid to the wall is h in. The temperature and heat transfer coefficient
for the fluid outside the pipe are Tout and h out. By using Fourier’s law of conduction and
Newton’s law of cooling, it can be shown that for a steady state heat transfer [6]:
din
Rin Rw Rout
Tin,hin T1 T2 Tout,hout Tin T1 T2 Tout
dout
Figure (1) Pipe drawing show heat flow
·
Q = UA(Tin - Tout ) ……………………………………………………………………………... (1)
2.1 Heat exchanger.
Heat Exchanger many engineering applications involve a process of heat exchange it’s built for
efficient heat transfer from one fluid to another. Some examples of application are intercoolers,
preheaters, boilers, condensers in chemical processing, and air conditioning [6].

2.1.1 Types and classification of heat exchanger:
1. Recuperative type: In which fluids exchange heat from hot fluid to the cold fluid.
2. Regenerative type: in which hot and cold fluids works alternatively as a sink or source
for heat flow through a matrix.
3. Direct type: in which fluids direct contact in the same space.
The recuperative type of heat exchanger which is the most common in practice can be classified
according to one of the following types Parallel-flow, Counter-flow, and Cross-flow as in fig (2)
[3].
Th
Tc
Tc
Th
Figure (2) Heat exchanger classification
2.2 Shell and tube Heat exchanger
The most common type of heat exchanger used in industry contains a number of parallel tubes
enclosed in a shell and is thus called a shell and tube heat.

The shell and tube heat exchanger consists of a cylinder (shell) to pack in a large number of
tubes. The inner fluid flow through several of tubes, the outer fluid flow through the shell and
forced be buffers, which provided to support the tubes, and direct the fluid flow and increase the
turbulence, consequently improve the convection heat transfer [7].
Tube outlet Shell inlet
Baffles Shell outlet Tube inlet
Figure (3) Shell and tube heat exchanger
2.2.1 Type of shell tube exchanger
1. Fixed – tube plate.

2. U – tube.
3. Internal floating head without clamp ring.
4. Internal floating head with clamp ring.
5. External floating head packed gland.
6. Kettle reboiler with U – tube bundle [7].
2.2.2 Tube arrangements
The tubes are usually arranged in equilateral triangular or square pattern as shown in figure (4)
di
[7] do
Flow
P C P
Figure (4) Tube arrangement

2.2.3 Tube passes
The fluid in the tube is usually directed to flow back and forth in a number of passes to increase
the length of the flow path. The arrangement of the pass partition for 2, 4, and 6 tubes are shown
in figure (5) [7].
Figure (5) Tube passes
2.2.4 Baffles
Baffles are used in the shell to direct the fluid stream across the tube, to increase the fluid
velocity and so improve the rate of transfer. The most commonly used type of baffle shown in
figure (6) [7].
Figure (6) Baffles

2.3 Heat exchanger performance:
2.3.1 Heat Exchanger Effectiveness
Heat Exchanger Effectiveness is defined as the ratio of the actual rate of heat transfer Q to the
maximum theoretically possible of heat transfer Qmax [4]
e = Q Qmax …………………………………………………………………………………... (2)

2.3.2 The Number of Transfer Units
The number of transfer units (NTU) is a measure of a heat exchanger's ability to transfer heat by
consider of heat exchanger size factor [4].
NTU = UA C min ……………………………………………………………………………... (3)
2.4 Heat exchanger performance improvement
To get the most out of a heat exchanger means saving money, particularly if the process is built
for a long-term operations. Some ways to improve the performance of a heat exchanger:-
1. Heat transfer area .
2. Fluid flow velocity .
3. Temperature gradient [4].
2.4.1 Heat transfer area
As the equation (1), the heat transfer area is directly proportional to the heat transfer rate. As the
heat transfer area increases, heat transfer rate increases.
2.4.2 Fluid flow rate velocity
As the cooling fluid velocity increases, the cooling fluid is able to dissipate heat more
effectively.

2.4.3 Temperature gradient
Temperature gradient is an important factor of heat transfer. It is the driving force for heat
transfer. If we can introduce fluids with larger temperature difference into the heat exchanger,
the heat transfer rate (Q) will be higher [4] .
2.5 The case study.

To optimize the size of a 1 – 2 shell and tube heat exchanger required to cool 20 kg/s of an
organic liquid from 70°c to 50°c using water flowing through the shell as coolant. The water
enters at 20°c and leaves at a temperature not exceed 50°c. The steel tubes used of 20SWG
thickness having an outside diameter of 19 mm. the tube have a length of 2.4 and are laid out on
a 25mm triangle pitch. The shell contains 25 per cent cut segmental baffles space 15.25mm apart
[13].
Chemical Chemical
reactor N1 reactor N2
Heat exchanger
Chemical pump
To cleaning taps
Water pump
Figure (7) Plant layout

2.5.1 Equipment data for 1-2 Exchanger fig. (8) [13].
L
Shell
di do
Tubes
Di
Figure (8) Exchanger dimension describe

Data of heat exchanger an on Jowfe Oil Company [13]
b = 152.4 mm , d o =19 mm , p = 25 mm , De = 17.27 mm , L =2.4 mm , x=2 mm
c = 6 mm , d i =15 mm , d m = 17 mm , At = 8.835 ´ 10 -5 nt mm²
As = 0.036576 Ds mm² , k = 45 W/mk
2.5.2 Physical data [13].
Tube side Organic liquid [13]

µ = 0.00045 Ns/m²
ρ = 881 kg/m³
Cp = 1675 j/kgk
k = 0.1731 W/mk
Pr = 4.35
Shell side Water specification in appendix (1)

3. Data procedures for heat exchanger optimization
To optimize the heat exchanger calculations proceeded as follow:
1- One of the factors which effective on the performance of the exchanger is heat transfer area
accordingly, to optimize the exchanger five inside shell diameters selected Ds (0.25, 0.3, 0.35,
0.4,and 0.45 m) based the exchanger used by the company.
2- Tube side heat transfer calculations as in appendix (1).
3- Shell side heat transfer calculations as in appendix (1)
4- Overall heat transfer calculations as in appendix (1).
5- plot the actual and the required heat transfer coefficient vs. the heat transfer area for each
value of the water outlet temperature Tc(outlet), from these curves read off the values of area at
the point where the actual and the required overall heat transfer coefficients U are the same, at
each value of Tc(outlet)
6- plot the values of the temperatures Tc(outlet) which actual and required U are the same vs. the
area, and read off the values of the water outlet temperature Tc(outlet) which correspond to the
heat transfer areas of the 1-2 shell and tube heat exchangers with standard shell inside diameters.
7- The pressure drop, pressure drop and power calculations an in appendix (1).
8- Estimation the fixed capital cost for the equipment from figure. [11]
9- Power consuming cost calculated basis of the electrical power cost rate 0.15£/kW
10- Plot the total power cost for 5 years operating vs. the operating hours per day to select the
optimum heat exchanger according to the daily operating hours.

4. Calculation and results
4.1 tube side coefficient:
Table (1) shows an example of the results obtained for the heat transfer in the tube side
(complete results shown on table (1) appendix (2). the principles of the study are as follow:
1- As the inside shell diameter increase the number of the tubes increases consequently the
heat transfer area increase.
2- From the results the Reynolds number is > 2100 the flow is therefore well into the turbulent
region for all options.
3- Since the mass flow rate of the organic liquid is constant, therefore as the number of the
tubes increases the (Re) decreases.
Table (1) Tube side heat transfer calculations (organic liquid)

Options selected 1
Ds ( inside shell diameter(m)) 0.25
nt (corrected no. of tubes) 60
At (the cross sectional flow area(m²)) 0.00529875
u s (the mean linear velocity(m/s²)) 4.284307732
G h (the mass flow rate(kg/sm²)) 3774.475112
Re (Reynolds number) 125815.8371
j h (heat transfer factor) 0.002578794
hi (inside film heat transfer coefficients(w/m²k)) 6117.773381
As (the cross sectional flow area for the shell stream(m²)) 0.009144
A (heat transfer area(m²)) 6.7854

4.2 Shell side coefficient:
Table (2) shows an example of the results obtained for the heat transfer in the shell side.
(Complete results shown on table (2) appendix (2)). The principles of the study are as follow:
1- For different outlet temperatures the mass flow rate of water decreases as the outlet
temperatures increases.
2- As the outlet temperature, and the inside shell diameter increases, the flow forward to the
laminar flow.
Table 2 Shell side heat transfer calculations (water)

Tc(outlet(ºC)) 26
mc (mass flow rate(kg/s)) 26.69399606
Tc(mean(ºC) 23
Cp(heat capacity of water(j/kgk)) 4183.212825
µ(dynamic viscosity of water) 0.000939019
k c (thermal conductivity of water(w/mk)) 0.6146288
Pr (Prandtl number) 6.391035246
(Gc)s (mass flow rate (kg/m²s)
for Di = .25 2919.290908
(Re)s (Reynolds number)
for Di = .25 53690.26573
( j h )s (heat transfer factor)
for Di = .25 0.002611284

(hi )s (film heat transfer coefficient(w/m²k))
for Di = .25 9253.91388

4.3 Overall coefficient
Table (3) shows an example of the results obtained for the overall heat transfer in the heat
exchanger, (complete results shown on table (3) appendix (2)).
By Comparing between the required and actual overall heat transfer coefficient for each inside
shell diameter and the tube outlet temperature, the results plot on figure (9).
Table 3 Overall heat transfer calculations

Tc(outlet(ºC)) 26
mc*Cp 111666.6667
E (effectiveness of heat transfer) 0.4
R (heat capacity ratio 0.3
NTU ( number of transfer units) 0.64
UiAi (w/k) 21440
Ui(overall heat transfer coefficient (w/m²k))
required for Di = .25 3159.725293
actual for Di = .25 2341.972084
Ai (area (m²) where required U = actual U) 9.3

heat transfer coefficient vs heat transfer Area figure (9)
4600
4100
3600
3100
2600
U
2100
1600
1100
600
9.3 12.9 17.7 23.9
0.00 5.00 10.00 15.00 20.00 25.00 30.00
Area
Actual U at Tc(outlet)=26 Actual U at Tc(outlet)=32 Actual U at Tc(outlet)=38
Actual U at Tc(outlet)=44 Actual U at Tc(outlet)=50 Required U at Tc(outlet)=26
Required U at Tc(outlet)=32 Required U at Tc(outlet)=38 Required U at Tc(outlet)=44
Required U at Tc(outlet)=50
From these curves read off the values of area at the point where the actual and the required
overall heat transfer coefficients U are the same and compare with the outlet water
temperature as shown in figure (10)
heat transfer area vs cooling water temp.figure(10)
25
Area of exchanger
20 A=19.6,Di=.4
heat transfer area vs
cooling water temp.
15 A=14.7,Di=.35
A=10.4,Di=.3
10
5
26 31 36 41 46
Cooling water tempetature
- It's clearly from fig (10) that as outlet water temperature arise the heat exchanger needs
bigger.
- To find for the optimum heat exchanger power consuming must be calculate.

4.4 Pressure drop and power
Complete results shown on table (4) appendix (2). The principles of the study are as follow:
1- As the inside shell diameter increase the pressure drop in the exchanger reduced
consequently the power required to pumping the fluids though the exchanger reduced
2- As the heat exchanger area increased fixed capital cost for the heat exchanger and pumps
increase.
3- As the heat exchanger area increased the variable (operating) cost decreases.
4- the best results is the summation of all capital and operating costs for 5 years operating
and find the lower overall cost figure (11).
total cost figure (11)
35000
total power cost for 5 years operating
33000
31000
29000
27000
(£)
25000
23000
21000 Total cost =19820 £
19000
shell inside diameter0.3 m
17000
15000
shell inside diameter0.35 m
8 9 101112131415161718192021222324
operating hours per day(h) shell inside diameter0.4m

4.5 Specification for optimum exchanger
Data for the optimum 1-2 Shell and tube heat exchanger, selected on basis of minimum annul
cost, are summarized in table (4)
Table 4 specification for optimum exchanger

Inside diameter of shell Di 0.4 m
Total number of tubes nt 174
Heat transfer area A 19.677 m²
Flow rate of water through the shell mc 8.092 kg/s
Outlet temperature of water Tc 40ºC

5. Conclusions
- The most economical design of heat exchangers, depends upon an optimum balance
between the heat transfer area and the energy consumption arising because from the
pressure drop of streams on both sides of the exchanger.
- It was found that the 0.4 m inside shell diameter exchanger, gave the economical design
for 5 years operating 24hrs a day.
- Exchangers with 0.25, and .45 m inside shell diameter rejected because it's not met the
operation conditions.
- Because the owner using the outlet water for cleaning purpose not recycling, which mean
no extra energy added to the cycle, and the higher outlet water temperature 40ºC will be a
benefit for the cleaning.

6. Future work
According to the study on this project, it is necessary to enhance the overall surface heat transfer
rate. This may achieved by lowering the convective resistance by increasing the convective heat
transfer coefficient or from the lowering the conductive resistance by increasing the surface area,
the latter can be achieved by extending the surface area through the addition of fins.
Future work will be to study the fins and how it will improve the heat exchanger which is
optimized on this part of project.
Gantt chart for future task

Project part one January 04 July04 August 04 Septemer04
Task description w1 w2 w3 w4 w1 w2 W3 w4 w1 w2 w3 w4 w1 w2 w3 w4
1 Supervisor meeting ▌ ▌ ▌ ▌ ▌ ▌ ▌ ▌ ▌ ▌ ▌ ▌ ▌ ▌ ▌
▌ ▌ ▌ ▌ ▌ ▌ ▌ ▌ ▌ ▌ ▌ ▌ ▌ ▌ ▌
2 Library search for useful books ▌ ▌ ▌
▌ ▌ ▌ ▌
3 Internet search for useful website ▌
▌
4 Available source study ▌ ▌ ▌
▌ ▌ ▌ ▌
5 Data submissions ▌
▌
6 Calculation ▌ ▌ ▌ ▌
▌ ▌ ▌ ▌
7 Result analysis ▌ ▌
▌ ▌
8 Report writing ▌
▌ ▌
9 Report submission ▌
▌
▌Planning ▌Actual
Project part two October 04 November 04 December 04 January 05
Task description w1 w2 w3 w4 w1 w2 w3 w4 w1 w2 w3 w4 w1 w2 w3 w4
1 Supervisor meeting ▌ ▌ ▌ ▌ ▌ ▌ ▌ ▌ ▌ ▌ ▌ ▌ ▌ ▌ ▌ ▌
2 Library search for useful books ▌▌▌▌ ▌▌ ▌▌
3 Internet search for useful website ▌▌
4 Available source study ▌▌▌▌▌▌▌▌
5 Data submissions ▌▌
6 Calculation ▌▌▌▌▌▌▌▌
7 Result analysis ▌▌▌▌
8 Report writing ▌▌▌
9 Report submission ▌
w = weeks
4 hr daily study

7. Reference:
1. James P. Hartnett, Tomas F. Irvine, Advances in heat transfer, vol.15, Academic press,
1982.
2. J. P. Holman, Heat transfer, ed.7, McGraw-Hill, 1992
3. Christopher long, Essential heat transfer, Longman, 1999
4. Donald R. Pitts, Leighton E. Sissom, Theory and problems of heat transfer, ed 2,
schaum’s outline series, McGraw-Hill, 1997.
5. Jesse S. Doolittle, Francis J. Hale, Thermodynamics for engineers, John Wiley & sons,
1984.
6. T. D. Eastop, A. Mcconkey, Applied thermodynamics for engineering technologists, ed 5,
Longman, 1993.
7. R. K. Sinnott, Chemical engineering, Vol. 6, ed. 3, Butterworth Heinemann, 1999.
8. Howard F. rase, Chemical reactors design for process plants, Vol. 1, principles and
techniques, John Wiley & sons, 1977
9. Zhang Zhnegguo, Experimental study on heat transfer enhancement of a helically
baffled heat exchanger combined with three-dimensional finned tubes, Science direct ,
Applied thermal engineering, vol.24, issue 14-15, February 2004
10. B. Khalifeh Soltan, M. Saffar-AvvalMinimizing ,capital and operating costs of shell and
tube condensers using optimum baffle spacing Science direct , Applied thermal
engineering, June 2004
11. Thomas Aichera, Holger Martin Rayleigh–Benard convection in vertical shell and tube
heat exchangers ,Science direct, Chemical Engineering and Processing
Volume 38, Issues 4-6 , September 1999,
12. Equipment costs. www.matche.com.
13. Data source, operation manger, Jowfe Oil Technology Libya

Appendix 1(equations used for calculation)

In this appendix show all equations used to optimize the exchanger:-
1- Physical data of Water [7].

1
µ = 0.1/ [2.14819{(TºK -281.635) + [8087.4+ (TºK – 281.635)²] 2 } - 120] …...........................(1)
ρ= 1200.92 – 0.015739TºK + 0.0010824(TºK) ² …………………………………...(2)
Cp = 0.015539(TºK – 308.2) ²+4180.9 …………………………………………...(3)
k =0.34+0.0009278 TºK …………………………………………………………...(4)
2- Data procedures for heat exchanger optimization
2.1- The heat flow rate Q (w), given by: [2]
Q = m h (c p )h [Th (inlet ) - Th (outlet )] = m c (c p )c [Tc (outlet ) - Tc (inlet )] …………………...(5)

· ·
·
2.2- The flow rate of water m c (kg s ) , given by: [2]
· Q
mc =
(c p )c [Tc (outlet ) - Tc (inlet )] ……………………………………………………….(6)
2.3- The total numbers of tubes nt for several 1-2 shell and tube heat exchangers each with a
standard shell inside diameter, given by: [7]

nt = m(2nd - m ) ………………………………………………………………...............(7)
Di
nd = - 1 ……………………………………………………………………………...(8)
p
m = .577n d + .423 ………………………………………………………………………(9)
2.4- The Reynolds number Re, given by: [5]

Gd i
Re = ……………………………………………………………………………...(10)
m
2.5- Heat transfer factor jh, given by: [2]
0.027
2.5.1- For tube side Re greater than 10000 j h = ………………….........................(11)
Re 0.2

0.351
2.5.2- For shell side Re greater than 5000 j h = ………………………….............(12)
Re 0.45
2.6- The film heat transfer coefficient hi, given by: [2]
j h (c p )h G h
2.6.1- For tube inside ji = …………………………………………………….(13)
prh2 3
j h (c p )c Gc
2.6.2- For shell side ji = 2
…………………………………………………….(14)
prc 3
Where:
cpm
2.6.3- Pr is the Prandtl number = ……………………………………………………(15)
k
2.7- The cross sectional flow area As for shell side, given by: [7]
As =
( pt - d o )bDi …………………………………………………………………….(16)
pt
2.8- The heat transfer area At based on the inside diameter of the tubes, given by: [7]
At = p .d i L.nt …………………………………………………………………………..(17)
2.9- Actual overall heat transfer U, given by: [6]

æd ö
d i ln çç i ÷÷
1 1 d
= + i + è do ø + 1 ……………………………………………………(18)
U i hi hs d o 2k hf
2.10- The effectiveness of heat transfer e , search for (mc p )min given by: [2]
c h (Th,i - Th ,o ) cc (Tc ,o - Tc ,i )
e= = ………………………………………………….(19)
c min (Th,i - Tc,i ) c min (Th ,i - Tc ,i )
2.11- The of heat capacity rate ratio, given by: [7]

(mc )p min
R= ………………………………………………………………………….(20)
(mc )p max
2.12- The number of transfer units NTU, read of from the graph of e vs. NTU for each value
of e and R.
2.13- The required overall heat transfer coefficient U. since UA is the multiplication of NTU
by the (mc p )min , [7]

NTU (mc p )min

U= ……………………………………………………………………..(21)
A
2.14- The pressure drop ∆p for the tube and shell sides, given by: [7]
æ l ö ru 2
Dp = 8 j f çç ÷÷ ……………………………………………………………………(22)
è di ø 2
For tube side multiply by the number of the passes for this case 2 passes.
2.15- The electric power consumption to pumping the fluids, given by: [11]
·
Dp m
P(w ) = …………………………………………………………………………..(23)
r
2.16- Annual electric power consumption, given by: [11]
Pa = P(operating × hours ) ……………………………………………………………..(24)

Appendix 2 (results)
This is full results obtained by use of the speared sheet (excel program) as on the attached disc.
Table 1 Tube side heat transfer calculations (organic liquid)

Option selected 1 2 3 4 5
(Di)s( inside shell diameter(m)) 0.25 0.3 0.35 0.4 0.45
Nd(max. number of tubes on inside diameter of shell) 9 11 13 15 17
m(number of rows of tubes ) 5.616 6.77 7.924 9.078 10.232
nT(max. number of tubes) 70 104 144 190 244
nN(equivalent no. of tubes from two nozzles) 5 6 7 8 9
Np(equivalent no. of tubes from two pass arrangement) 5.616 6.77 7.924 9.078 10.232
nT(corrected no. of tubes) 60 92 130 174 224
At(the cross sectional flow area(m²)) 0.00529 0.00812 0.01148 0.01536 0.01978
u(the mean linear velocity(m/s)) 4.28430 2.79411 1.97737 1.47734 1.14758
GH(the mass flow rate(kg/sm²)) 3774.47 2461.61 1742.06 1301.54 1011.02
Re(Reynolds number) 125815.8 82053.8 58068.8 43384.7 33700.6
jH(heat transfer factor) 0.00257 0.00280 0.00301 0.00319 0.00335
hi(inside film heat transfer coefficients(w/m²k)) 6117.77 4345.94 3295.79 2610.20 2132.63
As(the cross sectional flow area for the shell stream(m²)) 0.00914 0.01097 0.01280 0.01463 0.01645
A (heat transfer area(m²)) 6.7854 10.4042 14.7017 19.6776 25.3321
Table 2 Shell side heat transfer calculations (water)

Tc(outlet(ºC)) 26 32 38 44 50
mC(mass flow rate(kg/s)) 26.69399 13.3501 8.90164 6.67693 5.34175
TC(mean(ºC)) 23 26 29 32 35
Cp(heat capacity of water(j/kgk)) 4183.212 4182.21 4181.49 4181.05 4180.90
µ(dynamic viscosity of water) 0.000939 0.00087 0.00082 0.00077 0.00072
kC (thermal conductivity of water (w/mk)) 0.614628 0.61741 0.62019 0.62297 0.62576
Pr(Prandtl number) 6.391035 5.93888 5.53432 5.17086 4.84312
(Gc)s(mass flow rate (kg/m²s))
for Di = .25 2919.290 1459.99 973.496 730.198 584.181
for Di = .30 2432.742 1216.66 811.246 608.498 486.817
for Di = .35 2085.207 1042.85 695.354 521.570 417.272
for Di = .40 1824.556 912.496 608.435 456.374 365.113
for Di = .45 1621.828 811.107 540.831 405.665 324.545
(Re)s(Reynolds number)
for Di = .25 53690.2 28758.7 20481.6 16367.5 13917.9
for Di = .30 44741.8 23965.6 17068.0 13639.6 11598.2
for Di = .35 38350.1 20541.9 14629.7 11691.0 9941.3
for Di = .40 33556.4 17974.2 12801.0 10229.7 8698.70
for Di = .45 29827.9 15977.0 11378.7 9093.06 7732.18
(Jh)s(heat transfer factor)
for Di = .25 0.00261 0.00345 0.00402 0.00445 0.00479
for Di = .30 0.00283 0.00375 0.00437 0.00483 0.00520
for Di = .35 0.00303 0.00402 0.00468 0.00518 0.00557

for Di = .40 0.00322 0.00427 0.00497 0.00550 0.00592

for Di = .45 0.00340 0.00450 0.00524 0.00580 0.00624
Hs(film heat transfer coefficient(w/m²k)
for Di = .25 9253.91 6435.12 5238.83 4547.73 4088.24
for Di = .30 8370.96 5821.13 4738.98 4113.82 3698.17
for Di = .35 7690.50 5347.94 4353.75 3779.41 3397.55
for Di = .40 7145.94 4969.25 4045.46 3511.79 3156.97
for Di = .45 6697.69 4657.54 3791.70 3291.51 2958.94
Table 3 Overall heat transfer calculations

Tc(outlet(ºC)) 26 32 38 44 50
Mc*Cp 111666.6 55833.3 37222.2 27916.6 22333.3
E (effectiveness of heat transfer) 0.4 0.4 0.4 0.48 0.6
R (heat capacity ratio) 0.3 0.6 0.9 0.83333 0.66666
NTU ( number of transfer units) 0.64 0.7 0.78 1 1.38
UiAi 21440 23450 26130 27916.6 30820
Ui(overall heat transfer coefficient (w/m²k))
required for Di = .25 3159.725 3455.95 3850.91 4114.22 4542.10
actual for Di = .25 2341.972 1883.23 1581.44 1360.67 1190.14
required for Di = .30 2060.690 2253.88 2511.46 2683.19 2962.24

actual for Di = .30 2293.635 1838.43 1542.66 1327.6 1161.97
required for Di = .35 1458.334 1595.05 1777.34 1898.87 2096.35

actual for Di = .35 2250.560 1798.75 1508.36 1298.33 1137.02
required for Di = .40 1089.560 1191.70 1327.90 1418.69 1566.24

actual for Di = .40 2211.622 1763.07 1477.56 1272.04 1114.58
required for Di = .45 846.3549 925.700 1031.49 1102.02 1216.63

actual for Di = .45 2176.039 1730.631 1449.59 1248.15 1094.17
Ai (area (m²) where required U = actual U) 9.3 12.9 17.7 23.9

Table 4 pressure drop and power calculation

(Di)s( inside shell diameter(m)) 0.3 0.35 0.4
Re (Reynolds number) 82053.81 58068.85 43384.77
Jh (heat transfer factor) 0.002907 0.003182 0.003434
∆p (pressure drop(N/m²) 42791.74 22641.95 13257.83
tube side theoretical power(w)/hr 971.4355 514.0057 300.9723
Tc(outlet(ºC)) 28 34.2 39.8
Tc(mean) 24 27.1 29.9
(Cp)c 4182.849 4181.92 4181.336
Mc 20.02224 11.28264 8.09272
Gs (mass flow rate 1824.715 881.3462 553.1441
µ(dynamic viscosity of water) 0.000917 0.000856 0.000805
Ρc 902.7565 899.6443 896.8334
Re (Reynolds number) 34346.68 17790.55 11864.09
Jf (heat transfer factor) 0.030241 0.034335 0.037128
Di/De 17.37116 20.26636 23.16155
∆p 122049.2 37846.31 18480.66
Shell side theoretical power(w)/hr 2706.93 474.639 166.7632
total power consumption(w/hr) 3678.365 988.6447 467.7354
Heat exchanger efficiency 43.88% 43.16% 42%

Optimization of Shell and Tube Heat Exchanger 1 PDF

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Optimization of shell and tube heat exchanger

SCHOOL OF ENGINEERING AND TECHNOLOGY

Student name: Salah Hewidi

MSc Mechanical Engineering

Msc project (interim report)

Project title: Optimization of shell and tube heat exchanger

Supervisor: Dr. Ken Leung

Year of submission: 2004

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In designing a heat exchanger, it is necessary to determine the optimal dimensions of the

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A Heat transfer area, m²

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x thickness of tube wall, mm

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Figure (1) Pipe drawing show heat flow

2.1 Heat exchanger.

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2.1.1 Types and classification of heat exchanger:

2.2 Shell and tube Heat exchanger

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Tube outlet Shell inlet

Baffles Shell outlet Tube inlet

Figure (3) Shell and tube heat exchanger

2.2.1 Type of shell tube exchanger

1. Fixed – tube plate.

2.2.2 Tube arrangements

Figure (4) Tube arrangement

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2.2.3 Tube passes

Figure (5) Tube passes

Figure (6) Baffles

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2.3 Heat exchanger performance:

2.3.1 Heat Exchanger Effectiveness

e = Q Qmax …………………………………………………………………………………... (2)

2.4.1 Heat transfer area

2.4.2 Fluid flow rate velocity

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2.4.3 Temperature gradient

2.5 The case study.

Figure (7) Plant layout

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2.5.1 Equipment data for 1-2 Exchanger fig. (8) [13].

Figure (8) Exchanger dimension describe

c = 6 mm , d i =15 mm , d m = 17 mm , At = 8.835 ´ 10 -5 nt mm²

As = 0.036576 Ds mm² , k = 45 W/mk

2.5.2 Physical data [13].

Tube side Organic liquid [13]

Shell side Water specification in appendix (1)

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3. Data procedures for heat exchanger optimization

To optimize the heat exchanger calculations proceeded as follow:

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4. Calculation and results

4.1 tube side coefficient:

Table (1) Tube side heat transfer calculations (organic liquid)

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4.2 Shell side coefficient:

Table 2 Shell side heat transfer calculations (water)

for Di = .25 0.002611284