New Microsoft Word Document 4.1
New Microsoft Word Document 4.1
New Microsoft Word Document 4.1
INTRODUCTION
Shell & tube heat exchangers are used extensively throughout the process industry and as
such a basic understanding of their design, construction and performance is important to the
practising engineer. The objective of this project is to provide a concise review of the key
issues involved in their thermal design without having to refer to the extensive literature
available on this topic.
The design of a plate & frame heat exchanger involves the consideration of many interacting
design parameters which can be summarised as follows:
Process
1. Process fluid assignments.
2. Selection of stream temperature specifications.
3. Setting plate side pressure drop design limits.
4. Setting fluid velocity limits through plates.
5. Selection of heat transfer models and fouling coefficients for.
Mechanical
1. Selection of heat exchanger TEMA layout and number of passes.
2. Specification of plate parameters - size, layout and material.
3. Setting upper and lower design limits on plate length.
There are several software design and rating packages available, including Aspen BJAC,
HTFS and CC-THERM, which enable the designer to study the effects of the many
interacting design parameters and achieve an optimum thermal design. These packages are
supported by extensive component physical property databases and thermodynamic models.
It must be stressed that software convergence and optimisation routines will not necessarily
achieve a practical and economic design without the designer forcing parameters in an
intuitive way. It is recommended that the design be checked by running the model in the
rating mode. It is the intention of this paper to provide the basic information and
fundamentals in a concise format to achieve this objective. [4]
CHATER 2
LITERATURE REVIEW
Shell and Tube-type heat exchanger have wide application in nuclear industry where they
play an important role in the transfer of heat. Their cost minimization and pressure utilization
are important targets for both designers and users. In this project a computer program for
economical design of shell and tube heat exchanger using specified pressure drop is
established. 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. The capability of the proposed model was verified
through two design examples. The obtained results illustrate the capacity of the proposed
approach through using of a given pressure drops to direct the optimization towards more
effective designs, considering important limitations usually ignored in the literatures. In
designing a shell & tube heat exchanger is designed many times by taking different variables.
So in this project it designed by taking variable tube length. The optimization is taken on
pressure drop which is 0.8 bar allowable. So in a computer programme MATLAB this
exchanger is again designed and calculated.
CHAPTER 3
Heat exchangers (STHEs) are done by sophisticated computer software. However, a good
understanding of the underlying principles of exchanger design is needed to use this
software effectively.
This article 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, shell side pressure drop, and mean temperature difference. The basic equations for
tube side and shell side heat transfer and pressure drop are well known; here we focus on the
application of these correlations for the optimum design of heat exchangers.
[9]
Shell;
shell cover;
Tubes;
Channel;
Channel cover;
Tube sheet;
Baffles and
Nozzles;
Heat exchanger: both sides single phase and process streams (that is, not a utility).
Cooler: one stream a process liquid and the other cooling water or air
Condenser: one stream a condensing vapor and the other cooling water or air.
Chiller: one stream a process fluid being condensed at sub-atmospheric
CHAPTER 4
kw (W/moC)
202
206
97
104
116
388
378
62
59
45
30
16
45
45
36
16
4. You have the option to assume three known temperature and find the fourth one or four
temperature values and find one of the shell or tube side flow rate. Use the heat duty
equation (mCP T)h AND (m CP T)C where subscripts c and h refer to cold and hot
streams. Then obtain the heat duty, q.
5. Based on the type of flow, calculate Log Mean Temperature Difference, LMTD. For
counter current.
Tln
Tc ,in Th Tc , out
T T
ln h c ,in
Th Tc ,out
6. Based on the exchanger configuration obtain the Temperature correction factor. For 1shell-2-tube pass exchanger.
6
S
R
Ttube,out Ttube,in
Tshell,in Ttube,in
Tshell,in Ttube,in
Ttube,out Ttube,in
t 2 t1
T1 t1
T T2
1
t 2 t1
Figure no. 2 Temperature correction factor: one shell pass; two or more even tube 'passes [1]
7. Calculate the mean temperature difference using DTm= Ft LMTD m
8. Assume overall heat transfer coefficient as initial guess from the table no. 02 given below.
Table no. 2 overall heat transfer coefficient [1]
Shell and tube exchanger
Hot fluid
Cold fluid
Heat exchanger
Water
Water
Organic solvent
Organic solvent
Light oils
Light oils
Heavy oils
Heavy oils
Gases
Gases
coolers
Organic solvents
water
Light oils
Water
Heavy oils
Water
Gases
Water
Organic solvent
Brine
Water
Brine
Gases
Brine
Heater
Steam
Water
Steam
Organic solvent
7
U (W/m2 oC)
800-1500
100-300
100-400
50-300
10-50
250-750
350-900
60-300
20-300
150-500
600-1200
15-250
1500-4000
500-1000
Steam
Steam
Steam
Condensers
Aqueous vapours
Organic vapours
Organics (some non-condensable)
Vacuum condensers
vaporisers
Steam
Steam
Steam
Light oil
Heavy oils
Gases
300-900
60-450
30-300
Water
Water
Water
Water
1000-1500
700-1000
500-700
200-500
Aqueous solution
Light organics
Heavy organics
1000-1500
900-1200
600-900
K1
n1
0.319
2.142
0.249
2.207
0.175
2.285
0.0743
2.499
0.0365
2.675
Squre pitch
K1
n1
0.125
2.207
0.156
2.291
0.158
2.263
0.0402
2.617
0.0331
2.643
10
Ui
1
d
d
1 1 d i ln( d o / d i )
i i
hi hdi
2k w
d o hdo d o ho
Uo
1
d
1
1 d o ln( d o / d i ) d o
o
ho hdo
2k w
d i ho d i hdi
20. Compare the calculated overall heat transfer coefficient you obtained from the previous
step with that you assumed in step 8. If it is close to what you assumed, then you had a
valid assumption, and then tabulate your results such as total surface area of tubes,
number of tubes, exchanger length and diameter, heat duty and other design specification.
Otherwise, use the calculated value in step 8 and do loop until the difference between the
calculated U between two consecutive iterations is small.
Kerosene
20000 Kg/hr.
2000C
900C
5 bar
0 .0003 m2 0C/W
(G)
Crude oil
70000 Kg/hr
400C
6.5 bar
11
0.0002 m2 0C/W
Fouling
Solution
Specification
Calculate duty
Duty = mCpdT
Duty= 200002.47(200-90)/3600 = 1509.4 kW
Crude oil outlet temperature
700002.01(t2-40) = 1509.4
t2= 77.90C
Table no. 4 physical properties of kerosene and crude oil
Kerosene
Temperature
Specific heat
Thermal
Inlet
200
2.72
.130
Mean
145
2.47
.132
Outlet
90
2.26
.135
conduct.
Density
Viscosity
Crude oil
Temperature
Specific heat
Thermal
690
.22
Outlet
78
2.09
.133
730
.43
Mean
59
2.05
0.134
770
.08
Inlet
40
2.01
0.135
Kg/m3
mNsm-2
conduct.
Density
Viscosity
800
2.4
820
3.2
840
4.3
Kg/m3
mNsm-2
C
KJ/Kg0C
W/m0C
C
KJ/Kg0C
W/m0C
LMTD
Tln = [(200-78) (90-40)]/Ln (122/50)
= 80.7 oC
Correction factor (Ft) = 0.88
Actual LMTD = 0.8880.7 = 71.0
Layout and tube size
Crude oil is viscous so taking purpose of cleaning of heat exchanger so take floating heat
exchanger. Fluid is non-corrosive and operating pressure is also not too high, so plain carbon
steel is used. Crude oil is taken in tube side. Tubes are taken in standard size of 19.05mm
12
outer diameter and 14.83mm inner diameter. Taking standard i.e. 5m long and triangular pitch
of 23.81mm.
Shell & tube specification
Tube outer diameter do = 19.05mm
Tube inner diameter di = 14.83mm
Number of tubes Nt = 360
Number of pass Np = 4 (always take even no. of pass)
Tube cross-sectional area = (14.8310-3)/4 = 0.0001727m2
Area per pass = 0.0001727360/4 = 0.01555 m2
Volumetric flow = 70000/(3600820) = 0.0237 m3/s
Tube side velocity ut = 0.0237/0.01555 = 1.524 m/s
Bundle diameter Db = do (Nt/K1)1/ n1
K1 = 0.175 & n1 = 2.285 (by table 3)
So Db = 537mm
Shell diameter Ds = 537+59 = 596mm (fig. 3)
Baffle spacing = Ds/5 = 119.2
Shell side area
As = [(pt-do) Ds lB]/pt
pt = tube pitch = 23.81mm
do = tube outer diameter = 19.05mm
Ds = shell diameter = 596mm
lB = baffle spacing = 100mm
so
As = 0.167 m2
h = 680 W/m2 0C
Shell side
Volumetric flow rate on shell side = 20000/(3600730)=0.0076m2
us = 0.0076/ As = 0.455 m/s
de = 13.52mm
Re= (u dh)/
= (730 0.45513.5210-3)/0.4310-3 = 14644
Pr = Cp /k
= 8.05
jh = 4.810-3 (by figure 4)
Nu = h dh / k
So
h = 1177 W/m2 0C
14
CHAPTER 5
Shell and Tube-type heat exchanger have wide application in various industries where they
play an important role in the transfer of heat from core to the heat sink; their cost
minimization is an important target for both designers and users. In this project 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
may provide global optimum solutions as opposed to local optimum solutions that are
typically obtained with many other optimization methods. While fulfilling heat transfer
requirements, it has anticipated to estimate the minimum heat transfer area and resultant
minimum cost for a heat exchanger for given pressure drops. The capability of the proposed
model was verified through two design examples. The obtained results illustrate the capacity
of the proposed approach through using of a given pressure drops to direct the optimization
towards more effective designs, considering important limitations usually ignored in the
literatures.
Cost minimization of Shell-and-tube heat exchangers is a key objective. Traditional design
approaches besides being time consuming, do not guarantee the reach of an economically
optimal solution. So, in this project, a new shell and tube heat exchanger optimization design
approach is developed based on a computer programme MATLAB. The MATLAB algorithm
has some good features in reaching to the global minimum in comparison to other
evolutionary algorithms. In this study technique has been applied to minimize the total cost of
the equipment shell and tube heat exchanger by varying various design variables such as tube
length, tube outer diameter, pitch size, baffle spacing, etc. Based on proposed method, a full
computer code was developed for optimal design of shell and tube heat exchangers
For our key objective economic cost optimization of shell and tube heat exchanger for a
given pressure constant for both tube and shell side. We are going to develop a computer
program for different designs of shell and tube heat exchangers.
From this program we get a design of heat exchanger for the same condition and varying tube
length and the new design is given below
15
20000
200
90
5
0.8
0.0002
70000
40
6.5
0.8
0.0003
145
1509.444444
78.62117982
59.31058991
70.86
0.41885235
280
2
0.000172644
140
0.024170186
0.023712737
0.981073833
0.249
2.207
459.510917
56
515.510917
reynold no.
prendtl no.
L/di
jh from figure
nussult no.
hi
3729
48.96
472
0.027
363.5832041
3285.242707
160
0.016489421
13.51957786
0.00761035
0.461529248
10592.94613
8.05
baffle cut
jh from figure
Nussult no.
hs
25%
0.0021
44.5828696
435.2901288
0.00338129
295.7451384
pressure drop
Tube side
Re
Jf from figure
pt
p in bar
3729
0.021
64560.03225
0.645600323
Shell side
jf from figure
Re
ps
p in bar
0.066
10592.94613
68482.25238
0.684822524
17
CHAPTER 6
CONCLUSION
70.86
70.86
268
302
280
360
14.83
14.83
19.05
19.05
Number of baffles
32
42
515.51
596
160
119.2
0.645
0.66
0.685
0.47
In this work, an optimization model for the design of a shell and tube heat exchanger has
been proposed. The optimization strategy based upon the presented analytical optimization
analysis is developed as a computer aided design package. Important additional constraints,
usually ignored in previous optimization schemes, are included in order to approximate the
solution to the design practice. Two cases for optimal design of shell and tubes heat
exchanger based upon the devised computer program were presented. In case study one the
obtained results in the present work are consistent with the corresponding values. In case two
the comparison showed that the proposed model is more efficient in terms of providing
excellent optimum solutions than standard optimization method. Also the result of the study
cases ends up with the final conclusion that the use of the model provides the best solutions
with higher quality together with short duration of real time.
18
CHAPTER 7
REFERENCES
1. Sinnott, R.K. (1993) Coulson & Richardsons Chemical Engineering Vol. 6, 3rd
edition. Page No. 634-779
2. HEAT EXCHANGER selection, rating, and thermal design by Sadik kaka, hongtan
Liu (department of mechanical engineering university of miami). Page 249-278, 323348.
3. Roy G. K. Fundamental of Heat and mass transfer operation Page No. 37-82.
4. Hewitt, G.F. et al (1994) Process Heat Transfer, (CRC Press)
5. Perry ,R.H. and Green, D. (1984) Perrys Chemical Engineers Handbook, 6th edition
6.
7.
8.
9.
(McGraw Hill)
Kern, D.Q. (1950) Process Heat Transfer (McGraw Hill)
Chemstations, Inc. CHEMCAD THERM Version 5.1 User Guide
Schlunder, E.U. (1993) VDI Heat Atlas (Woodhead Publishing)
Seider, D.S., Seader, J.D.Seader and Lewin, R.L. Process Design Principles, (John
19