HEAT AND MASS TRANSFER
PROJECT REPORT
COMPACT DESIGNING OF A SHELL AND TUBE HEAT EXCHANGER
Group Members:
• Umer Mehmood (190501015)
• Haris Irfan (190501030)
• Shahzain Zukhraf (190501008)
• Usama Ameer (190501006)
• Shehmir-ul-Hassan (190501046)
Department/Batch:
• BE Mechanical-08
Course Instructor:
• Dr. Naseem Ahmed
1
Table of Contents
Abstract: ................................................................................................................................................ 3
Problem Statement: .............................................................................................................................. 3
Introduction: ......................................................................................................................................... 3
Shell And Tube Heat Exchanger: ........................................................................................................ 3
Working: ................................................................................................................................................ 4
TEMA standard: ................................................................................................................................... 5
Flow types: ............................................................................................................................................. 5
Design Methodology: ............................................................................................................................ 7
Dependence of Heat Transfer: ............................................................................................................. 8
Selection of Changing Parameter: ....................................................................................................... 8
Important Terms: ................................................................................................................................. 9
Difference between Bare Tube & Finned Tube: .............................................................................. 10
Bare Tube Calculations: ..................................................................................................................... 11
Shell Side Calculations: ...................................................................................................................... 12
Tube Side Calculations: ...................................................................................................................... 13
Overall heat transfer coefficient: ....................................................................................................... 14
Heat transfer from Bare Tube (without fins): .................................................................................. 15
Calculations For Finned Tubes: ........................................................................................................ 16
Calculations For Overall Heat Transfer Rate After Finned Tube Surface: .................................. 17
Comparison Of Bare And Finned Tubes Heat Transfer:................................................................ 17
Cost Justification: ............................................................................................................................... 18
Conclusion: .......................................................................................................................................... 19
References:........................................................................................................................................... 20
2
Abstract:
This research covers the detail of bare tube heat transferring phenomenon with little
modification of tubes. A different method other than conventional shell and tube heat
exchangers was used for designing and calculating heat transfer and the results of this
modification on cost were also discussed. The main objective of this research project was to
develop a detail understanding of a shell and tube heat exchanger along with the minor details
like baffle cut percent and factors affecting the heat transferring in shell and tube heat
exchanger. A detailed calculations were performed on given data of fluids for finned type tubes
as well for comparison and at the end results and conclusion were discussed.
Problem Statement:
With the fascinating developments and innovations one of the most important aspects
of engineering is the improvement of already existing designs in a way that can help
industrialist and entrepreneur to come forward and produce extraordinary results. Therefore
sometime it is not possible to compromise on everything during a design process and most
important factors are cost and area coverage that hinders the development. Therefore there is a
constant desire of an optimized design and with lower financial risks so that industries can
make progress with desire area size and with adequate expenditures for a long run.
Introduction:
Shell and tube heat exchangers are compatible with both liquid and gas, giving them a
huge range of suitable applications. It’s important to remember when discussing heat
exchangers that a “fluid” can be in a gaseous or liquid state. Technically, it is not proper
terminology to call a heat exchanger a cooler because the process fluid can be warmed as well
as chilled. A cylindrical shell with multiple tubes running inside the shell. One fluid passes
through the tubes and then exits the heat exchanger; the other fluid circulates on the outside of
the tubes within the cylindrical shell. Heat is transferred from one fluid to the other through the
walls of the tubes. The flow path of the fluid within the cylindrical shell is directed through the
vessel by means of baffles, which has the effect of increasing the flow path and thus contact
time of the fluid heat transfer interchange.
Shell And Tube Heat Exchanger:
There are many design of shell and tube heat exchangers but most of them contains same main
parts that are as follows:
Shell:
3
The shell is what you would first notice when you come across a shell and tube cooler. This is
the outer portion that holds the process fluid and houses the internals.
Tubes / tube bundle:
The tubes contain and flow the cooling medium. Tubes must have excellent thermal transfer
properties, be resilient to large temperature fluctuations / differentials and resistant to
corrosion. The summation of the tubes referred to as a tube bundle or simply stated: the bundle.
In many designs, the bundle may be removable for maintenance and service purposes.
Material:
Tube material is an importance consideration when selecting the heat exchanger. The tubes see
a lot of stress due to the fact they are subject to a large temperature differential. Common tube
materials include copper, brass and various steel alloys.
Four ports:
Shell side fluid in
Shell side fluid out
Tube side fluid in
Tube side fluid out
Inlet / Outlet Plenums:
Found on the end(s) of the shell. This is the open area where the tube bundle either collects or
discharges the cooling fluid.
Baffles:
The baffle creates turbulence within the shell to improve efficiency and reduce
“concentrations” of hot or cold. Baffles are simple design considerations but essential to proper
function.
Pressure Differential:
It is common for there to be a pressure differential, so in the case of an unexpected leak, the
cross contamination damage is minimized. Typically you would see the pressure being greater
in the tube sheet / shell, so if there were to be an unexpected leak, the process fluid would flow
into the cooling medium. This design prevents the process fluid from being contaminated
leading to costly accidents and/or failures.
Working:
Put rather simply, there are two fluids of different temperatures in the cooling operation,
one being the process and the other being the cooling medium. The process fluid that is being
4
cooled generally runs through relatively small diameter tubes that are housed within the shell.
The outer shell contains and circulates the cooling medium. Both process and cooling fluid are
continuously kept in circulation for the heat exchanger to function properly. In order to be
efficient, shell and tube heat exchangers utilize round small tubes creating a large surface that
doesn’t take up unnecessary room.
TEMA standard:
TEMA stands for Tubular Exchanger Manufacturers Association. TEMA is a set of
standards that helps define the manufacturing tolerances and machining used when
constructing a shell and tube heat exchanger. TEMA helps the end user know that his heat
exchanger meets industry standards and is built in a fashion that reflects quality. There are three
common classes of ratings:
• TEMA C – General Service
• TEMA B – Chemical Service
• TEMA R – Refinery Service
When evaluated, TEMA C is the least strict and TEMA R is the most stringent set of guidelines.
Flow types:
There are three main flow types, these are parallel, counter and cross flow. Due to
design considerations and the applications of heat exchangers, it is rare that a heat exchanger
be only one of these flow types, usually they are a combination of several flow types e.g.
counter cross flow.
Parallel Flow:
Parallel flow occurs when both the shell side and tube side mediums enter the heat exchanger
from the same end of the heat exchanger and flow to the opposite end of the heat exchanger.
Figure 1: Parallel Flow Type
5
Counter Flow:
Counter flow (also known as contra-flow) heat exchangers have two flowing mediums that are
flowing in a counter direction (180° apart) to each other. Each flowing medium enters the heat
exchanger at opposite ends and is discharged at opposite ends.
Figure 2: Counter Flow Type
Cross Flow:
Cross flow heat exchangers have one medium flowing that flows perpendicular (at 90°) across
the other. Cross flow heat exchangers are usually found in applications where one of the fluids
changes state (2-phase flow).
Figure 3: Cross Flow Type
Single and Multi-Pass:
An economical and efficient way of increasing a heat exchangers efficiency is to bring the
flowing mediums into contact with each other several times. Each time one medium passes
over the other, heat is exchanged.
6
When one flowing medium passes over the other only once, it is termed a ‘single pass’ heat
exchanger.
Figure 4: Single Pass Design
When one flowing medium passes over the other more than once, it is termed a ‘multi-pass’
heat exchanger.
.
Figure 5: Multi Pass Design
Design Methodology:
Heat transfer mode in a shell-and-tube heat exchanger usually involves convection in
each fluid and conduction through the wall separating the two fluids. In the analysis of shell-
and-tube heat exchangers, it is convenient to work with an overall heat transfer coefficient that
accounts for the contribution of all these modes at heat transfer. The rate of heat transfer
between the two fluids at a location in a heat exchanger depends on the magnitude of the
temperature difference at that location, which varies along the shell-and-tube heat exchanger.
𝑄̇ = UA∆Tlm(F)
Therefore, in the heat transfer analysis of heat exchangers, it is convenient to establish
an appropriate mean value of the temperature difference between the hot and cold fluids such
that the total heat transfer rate Q ̇between the fluids, and that can be determined from.
∆𝑇1 − ∆𝑇2
∆Tlm = ∆𝑇1
ln
∆𝑇2
∆T1 = THOT,IN – TCOLD,OUT
∆T2 = THOT,OUT - TCOLD,IN
Where:
7
A is the total hot-side or cold-side heat transfer area. U is the average overall heat transfer
coefficient based on that area.
∆Tlm is a function of
∆T1 = THOT,IN – TCOLD,OUT
∆T2 = THOT,OUT - TCOLD,IN
LMTD (Log Mean Temperature Difference) method is very suitable for determining the size
of a heat exchanger to realize prescribed outlet temperatures, when the mass flow rates, the
inlet, and outlet temperatures of the hot and cold fluids are specified.
For multi pass and cross-flow heat exchangers, the log mean temperature difference
should be corrected using a correction factor (F).F is non-dimensional, it depends on the
temperature effectiveness P, the heat capacity rate ratio R, and the flow arrangement.
Figure 6: chart for one shell and two tube passes
Dependence of Heat Transfer:
Hence from the equation of heat transfer it is clear that the Q depends on
• Temperature
• Overall heat transfer coefficient
• Surface area
If we maintain our operating conditions then only options left for us for designing that is Area
and overall heat transfer coefficient. In a smaller space heat transfer surface area can be
increased by simple using a finned tube instead of conventional bare tubes. With increasing
surface area Q will be increases but at the same time U will be vary as well.
Selection of Changing Parameter:
Variations in Overall Heat Transfer Coefficient:
8
It is understood that the value of U will vary with changing areas but it is further
depends on hi and ho, since we are not changing flowrate of the fluid neither the temperature
so the values ‘h’ will not vary that much as they are dependent of Nu or Re or Pr no.
Hence the best option we have is to vary the area of structure. It provides the best and
easy method for calculations. Otherwise a complete dimensionless parameters calculations
have to be performed in order to vary the convective heat transfer coefficients. Therefore a tube
with finned surface is selected for analysis and comparison of results.
Figure 7: Finned Tubes
Important Terms:
o Pitch tube:
Tube pitch is defined as the shortest distance between two adjacent tubes. For a
triangular pattern, TEMA specifies a minimum tube pitch of 1.25 times the tube O.D.
Thus, a 25-mm tube pitch is usually employed for 20-mm O.D. tubes. The selection of
tube pitch is a compromise between a close pitch for increased shell-side heat transfer
and surface compactness, and a larger pitch for decreased shell-side pressure drop and
fouling, and ease in cleaning. In most shell and tube exchangers, the minimum ratio of
tube pitch to tube outside diameter (pitch ratio) is 1.25.
Figure 8: Triangular And Square Pitch Layout
9
o Baffle Spacing:
Baffle spacing is the centerline-to-centerline distance between adjacent baffles and
identified as the most important geometric parameter affecting both pressure drop and
heat transfer characteristics on the shell side design. It affects the velocity of the shell
side fluid which thereby affects the heat transfer. The smaller baffle spacing, the smaller
flow area, and the higher the fluid velocity. Also the maximum baffle spacing is
specified by the TEMA standards by mechanical considerations. This is because the
purpose of the baffle in addition to improve the heat transfer coefficient is to support
the tubes also.
Figure 9: Baffle Spacing/Arrangements
Difference between Bare Tube & Finned Tube:
A bare tube is one which has smooth internal and external diameter. The roughness on
each side assumes to be negligible with sometimes zero fouling on either side of a tube..
While a finned tube is one which has a finned attached to its outer surface either in
annulus formation, spiral formation or in any other form. The one we are using in our
calculations is of annular form with specific fin height and thickness.
10
Figure 10: Finned Tube Under Analysis
Bare Tube Calculations:
For bare tube calculations shell and tube side individual calculations will be performed
to find out ho and hi. It is done by finding dimensionless parameter related to this and other
parameter values.
Details of Bare Tube & Shell Design:
THOT,IN = 65˚C (shell inlet , Ti)
THOT,OUT = 40˚C (shell outlet , To)
TCOLD,IN = 30˚C (tube inlet , ti)
TCOLD,OUT = 40˚C (tube outlet , to)
ρs = 631 kg/m3 (hot fluid density)
Hear transfer surface area = 200.034m2
No of tubes = 616
Tube layout (triangular)
Tube pitch = 0.0238m
Mass flowrate of hot water = 33.33 kg/s
Specific heat capacity of hot fluid = Cpc = 2.27 kJ/kg˚C
Thermal conductivity of hot fluid = kh = 0.1279 W/m˚C
11
Viscosity of hot fluid = 𝛍h = 0.3 Ns/m2
Density of cold water = ρc = 992 kg/m3
Specific heat capacity of hot water = Cpc = 4.2 kJ/kg˚C
Viscosity of cold water = 𝛍c = 0.8 Ns/m2
Thermal conductivity of water = kw = 0.59 W/m˚C
Tube length = L = 5.426m
Tube outer diameter = 19.05mm
Tube inner diameter = 16.104mm
Tube thickness = 1.473mm
Tube material = austenitic stainless steel
Tube thermal conductivity = 16 W/m˚C
Weight of a bare tube = 0.719 kg/m for 19.05mm Outer Diameter
Friction factor for shell side = Jh = 2(10-2)
Shell Side Calculations:
Hot Fluid is present in shell side. The fluid we are using for this analysis is hot
Hexane Vapors.
Area of shell side:
(𝑃𝑡 − 𝑑𝑜 ) 𝐷𝑠 𝑙𝐵
As = = 2.552 (10-3) m2
𝑃𝑡
𝑊𝑠 33.33 𝑘𝑔/𝑠
𝑮𝒔 = = 2.552 (10−3) = 13060.34 kg/𝑚2 s
𝐴𝑠
Velocity:
𝐺 33.33 𝑘𝑔/𝑠
𝑼𝒔 = 𝜌𝑠 = 631 𝑘𝑔/𝑚3 = 20.7 m/s
𝑠
𝝆𝒔 was taken at Tavg of shell side temperature.
Equivalent Diameter:
(𝑃𝑡 2 − 𝜋𝑑𝑜 2 )
De = = 9.57(10-3) m
𝜋𝑑𝑜
Reynolds Number:
𝐺𝑠 𝐷𝑒 𝑈𝑠 𝐷𝑒 𝜌𝑠
Re = = = 416.62
𝜇𝑠 𝜇𝑠
12
Prandtl’s Number:
𝐶𝑝(𝑠) 𝜇𝑠
Pr = = 5324.47
𝑘𝑓
Nusselt Number for shell side:
1
𝜇 0.14
Nu = Jh x Re x 𝑃𝑟 3 x (𝜇 𝑠 ) = 126.832
𝑤
Jh = 2(10-2) (shell side heat transfer factor)
Convective heat transfer coefficient of shell side:
Since,
ℎ𝑠 𝐷𝑒
Nu = 𝑘𝑠
𝑁𝑢 𝑘𝑓
hs = 𝐷𝑒
(hs = ho)
ho = 1695.08 W/m2˚C
Tube Side Calculations:
Cold fluid is present in tube side. The fluid we are using in this analysis is Water.
Area of tube side:
At = Ai = πdi2/4
𝑊𝑡 33.33 𝑘𝑔/𝑠
𝑮𝒕 = = 2.035 (10−3) = 163783.78 kg/𝑚2 s
𝐴𝑡
Velocity:
𝐺 163783.78 kg/𝑚2 s
𝑼𝒕 = 𝜌𝑡 = = 165.4 m/s
𝑡 992 𝑘𝑔/𝑚3
𝝆𝒕 was taken at Tavg of shell side temperature.
Hydraulic Diameter:
di = = 16.104(10-3) m
Reynolds Number:
𝐺𝑠 𝐷𝑒 𝑈𝑡 𝑑𝑖 𝜌𝑡
Re = = = 3296.80
𝜇𝑡 𝜇𝑡
Prandtl’s Number:
13
𝐶𝑝(𝑡) 𝜇𝑡
Pr = = 5694.91
𝑘𝑡
Nusselt Number for tube side:
𝑑 0.33
Nu = 1.86 x (Re x Pr )0.33 x ( 𝑙𝑖 )
Nu = 68.50
Since,
ℎ𝑠 𝐷𝑒
Nu =
𝑘𝑠
Convective heat transfer coefficient of tube side:
𝑁𝑡 𝑘𝑡
ht = 𝑑𝑖
(ht = hi)
hi = 2509.65 W/m2˚C
Overall heat transfer coefficient:
Overall heat transfer coefficient is calculated by combining both the hi and ho along
with the fouling resistance and wall resistances etc.
Formula used:
1
U= 1 1 𝐴 1 𝐴
( + 𝑟𝑜 ) ( ) + 𝑟𝑤 + 𝑟𝑖 ( 𝑜 )+ ( )( 𝑜 )
ℎ𝑜 𝐸𝑓 𝐴𝑖 ℎ𝑖 𝐴𝑖
ro and ri are fouling resistances of outside and inside of the tube which can be neglected.
Whereas rw is the tube wall resistance that can be found using formula
𝑑 𝑑𝑜
rw = 24𝑜𝑘 (ln 𝑑 )
𝑜 −2𝑡
rw = 1.042 (10-3) m2˚𝑪/W
Ef (efficiency) = 1 (for bare tube case)
Then formula reduces to;
1
U= 1 1 1 𝐴
( ) ( ) + 𝑟𝑤 + ( )( 𝑜 )
ℎ𝑜 𝐸𝑓 ℎ𝑖 𝐴𝑖
After substituting values we get;
14
U = 455 W / m2˚C
Heat transfer from Bare Tube (without fins):
Normally the formula used for heat transfer calculation is;
𝑄̇ = UA∆Tlm(F)
U = 455 W / m2˚C
A = 200.034 m2
Where ∆Tlm is found by using LMTD method. And it will be used for the case of 1 shell
and 2 tubes with cross flow configuration of temperatures inlet and outlet.
∆𝑇1 − ∆𝑇2
∆Tlm = ∆𝑇1
ln
∆𝑇2
∆T1 = THOT,IN – TCOLD,OUT
∆T2 = THOT,OUT - TCOLD,IN
Temperatures are given as:
THOT,IN = 65˚C (shell inlet , Ti)
THOT,OUT = 40˚C (shell outlet , To)
TCOLD,IN = 30˚C (tube inlet , ti)
TCOLD,OUT = 40˚C (tube outlet , to)
Then ∆Tlm is found out to be ∆Tlm = 16.3˚C
Correction Factor:
The value of correction factor F is found by using a graph of cross values between
dimensionless parameters R and P from graph of one shell and multiple tubes.
𝑇𝑖 − 𝑡𝑜
R= = 2.5
𝑡𝑜 − 𝑡𝑖
𝑡 −𝑡
P = 𝑇𝑜− 𝑡𝑖 = 0.28
𝑖 𝑖
Then the value of F = 0.94
Finally substituting values in 𝑄̇ = UA∆Tlm(F)
𝑄̇ = (455)(200.034)(16.3)(0.94) = 1343.06 W
15
Qb = 1394.539 kW (without fins)
Calculations For Finned Tubes:
Details of finned Tube & Shell design:
Outer diameter of finned tubes = 𝑑𝐹𝑂 = 0.01905m
Inner diameter of finned tubes = 𝑑𝐹𝐼 = 0.015494m
Fin height (z) = wall thickness of finned tubes (t’) = 0.889mm
Outer diameter of bank space = 𝑑′𝐹𝑂 = 0.01905m – 2(0.000889m) = 0.017272m
Finn thickness (tf) = 0.305mm
Gap between two fins = fs = 0.607mm
Weight of a fin tube = 0.538 kg/m
Thermal conductivity (k) = 16 W/m˚C
No of Finns = 1102 Finns / meter
Afin:
𝑑𝐹𝐼 2 𝑑′𝐹𝑂 2 𝑑𝐹𝑂 2
Area of one fin surface = 2(π)[( ) − ( ) ] + 2πtf ( ) = 119.696 mm2
2 2𝑁 2
Aunfin:
Area of one unfin surface = π 𝑑′𝐹𝑂 (fs) = 32.93 mm2
Atotal fin:
The total area of unit fin with blank space = Afin + Aunfin
Atotal fin = 152.633 mm2
Atotal fin for one meter:
1102 fins are in 1 meter hence;
Atotal fin/meter x N = 0.1682m2
AFO,BUNDLE:
But total length of a tube is 5.426 therefore,
16
L x 0.1682m2 = 0.9126m2
Given total no. of tubes Nt = 616
AFO,BUNDLE = Nt x 0.9126m2 = 562.1998m2 (AFO,BUNDLE)
Calculations For Overall Heat Transfer Rate After Finned Tube Surface:
QF = UF x AFO,BUNDLE x LMTD x F
In case of finned tube only one change occurs in the U formula for rw value because of
the addition of fins which is
1
U= 1 1 1 𝐴
( ) ( ) + 𝑟𝑤 + ( )( 𝑜 )
ℎ𝑜 𝐸𝑓 ℎ𝑖 𝐴𝑖
𝑡 (𝑑𝑜 +2𝑁𝑍 (𝑑𝑜 + 𝑍 )
rw = 12𝑘 𝑑𝑜 − 𝑡
and Ef = 0.90
Where;
UF = 346.78 W/m2˚C
AFO,BUNDLE = 562.1998m2
LMTD = 16.3˚C
F = 0.94 (correction factor)
Now substitute these values we get;
Qf = 2987.171 kW (with fins)
Comparison Of Bare And Finned Tubes Heat Transfer:
Heat transfer rate of one finned tube = Qf / no of tubes
= 2987.171 kW / 616 tubes
= 4849.3 watt/tube
If we equate the heat transfer rate of finned tube to the bare tube then required no of
tubes will be ;
17
Required no of tubes = Qb / Heat transfer rate of one finned tube
= 1394.539 kW / 4849.3 watt/tube
=287 tubes
Therefore only 287 tubes are required for same amount of heat transferring as in bare
tube heat exchangers.
Total no of tubes reduce = 616 – 287 = 329 tubes
Cost Justification:
Cost of Bare Tube:
Tubes = 616
Price of single bare tube = say (280 Rs/kg)
Weight of bare tube (given) = 0.719 kg/m
Length of bare tube = 5.426m
Weight of one bare tube = (5.426 x 0.719) = 3.90 kg
Weight of total tubes = (3.90 x total tubes) = 2403.17 kg
Price of total tubes = 2403.17 kg x 280 Rs/kg = 672895 Rs
Cost of finned tube:
Tubes = 287
Price of single fin tube = say (385 Rs/kg)
Weight of fin tube (given) = 0.587 kg/m
Length of fin tube = 5.426m
Weight of one fin tube = (5.426 x 0.587) = 3.18 kg
Weight of total tubes = (3.18 x total tubes) = 914.11 kg
Price of total tubes = 914.11 kg x 385 Rs/kg = 351933 Rs
18
Conclusion:
After detail research and analysis it is clear that to increase the amount of heat transfer
amendments in the geometry of heat exchangers are required. But these changes will only be
significant when these changes giving better outputs or results than previous working
machines. Therefore by using finned tubes instead of conventional bare tube in shell and tube
heat exchangers the area can be modified for heat transfer and hence provide a compact way
of designing a heat exchanger. Similarly by making changes in geometry other parameters can
changes slightly or significantly. Therefore overall care should be taken in designing as well.
For example in our case the value of U was main factor that changers significantly from 455 to
346.78 W/m2˚C. Moreover prices were compared and hence results were came out that using
finned tubes saves
672895 – 351933 = 320962 Rs
This results shows that whenever area and costs are issues in designing, a finned tube bundle
type heat exchanger can be installed rather than a conventional shell and tube type heat
exchangers.
19
References:
[1] Comparative analysis of finned tube and bared tube type shell and tube heat exchanger,
Shiv Kumar Rathore, Ajeet Bergaley, (IJEIT), volume 2, issue 1, July 2012
[2] Optimization of a Finned Shell and Tube Heat Exchanger Using a Multi-Objective
Optimization Genetic Algorithm, Heidar Sadeghzadeh1, Mehdi Aliehyaei2, and Marc
A. Rosen3
[3] Numerical Investigation of the Effect of Variable Baffle Spacing on the Thermal
Performance of a Shell and Tube Heat Exchanger, Halil Bayram1,2 and Gökhan
Sevilgen1*
[4] Kakac, S.; Liu, H.; Pramuanjaroenkij, A. Heat Exchangers: Selection, Rating, and
Thermal Design; CRC Press: Boca Raton, FL, USA, 2012; pp. 361–425. ISBN 978-1-
4398-4991-0.
20