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Design of a Shell and Tube Heat Exchanger
Technical Report · December 2020
DOI: 10.13140/RG.2.2.22783.28329
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Bangladesh University of Engineering & Technology
Course No: ME 310
Course Title: Thermo-Fluid System Design
Design of an oil Cooler for Marine Applications
Date Of Submission: 18/12/2020
Submitted By
Group-A07
AYON MAHMUD(1610033)
KHALID MAHMUD LABIB (1610036)
MD MAHBUB TALUKDER(1610040)
MD YOUNUS ALI (1610056)
Acknowledgement:
We would like to express our special thanks of gratitude to our respected
teachers Professor Dr. Zahurul Haq Sir, Professor Dr. A.K.M. Monjur
Morshed Sir, Dr. Md. Ashikur Rahman Sir(Associate Professor), Musanna
Galib Sir(Assistant Professor), Md. Rakibul Hasan Roni Sir(Assistant
Professor) and Saif Al-Afsan Shamim Sir (Lecturer) for their whole
hearted co-operations and valuable knowledge.
Abstract:
A Shell and tube heat exchanger contains a large number of tubes packed
in a shell with its axis parallel to that of the shell. Heat transfer takes place
as one fluid flows inside the tubes while the other flows outside of the
tubes through shell. The problem that we were assigned was to design a
Shell and tube heat exchanger that can cool hot oil using cold seawater,
maintaining a definite temperature difference & pressure drop which
were also provided. The thermal design of a shell and tube heat
exchanger typically includes the determination of heat transfer area,
number of tubes, tube length and diameter, tube layout, number of shell
and tube passes, tube pitch, number of baffles, its type and size etc. We
used HTRI and solidworks softwares for our final result and mechanical
design respectively. We tried to minimize the cost and maximize the
thermal efficiency considering the required temperature difference and
pressure drop.
Design Problem:
An oil cooler for marine applications has to be desgined having the
following specifications:
Fluid SAE-30 oil Sea Water
Inlet temperature (°C) 65 20
Outlet temperature (°C) 56 32
Pressure drop limit (kPa) 140 40
Total mass flow rate (kg/s) 20 —
A shell and tube heat exchanger is to be designed and rated.
Objective:
Our main objective of this project is to get familiar with real life engineering
problem of heat transfer analysis and solve this problem with the help of
theoretical knowledge of heat transfer [Link] goal is to design a shell
and tube heat exchanger, do energy calculations and optimize the heat
exchanger through economic analysis and finding out its maximum
effectiveness. In other words, our goal is to design a compact heat
exchanger with high thermal efficiency and minimum cost.
Introduction:
A heat exchanger is a system used to transfer heat between two or more
fluids which simultaneously performs both heating and cooling functions. A
shell and tube heat exchanger is a type of heat exchanger widely used in
engineering fields specially in oil refineries and other large chemical
processes, and is suited for higher-pressure applications.
In general applications ,the designed heat exchanger should be compact
enough and have high thermal [Link] must be balance between
enhanced heat transfer and accompanied pressure drop. Another
important factor should be considered is fouling which has to be reduced as
much as possible.
We designed a Shell and tube heat Exchanger .The Exchanger consists of
one shell and double pass tube [Link] considered Counter flow,
passing hot oil in the tube and cold sea water in the shell side.
For shell geometry,we used TEMA type ‘AFL’.We also considered Horizontal
shell [Link] used single segmental perpendicular baffle .
Design Factor Considered:
Since it is a design problem, we had to select some parameters at the initial stage
for sample calculation. The following parameters were selected:
Inner Tube Diameter = 15.75 mm
Outer Tube Diameter = 19.09 mm
Pitch Ratio = 1.3
Pitch was selected 1.3 times of Outer Diameter for easy weilding. This design is similar
to two pass STHx. Tube was chosen to be square shaped for minimum pressure drop.
Also, as the heat exchanger would be compact,this shape would provide better
cleaning facilities. Tube length was chosen 2.44 m. We also selected layout angle to be
90℃ for minimum pressure drop.
CL = 1 for 90℃ layout angle
CTP = 0.9 for two pass tube
From above considerations, the shell inside diameter can be calculated using the
following formula:
ODt
Ds = 0.637 * ( CTP
Cl
) * Ao * ( PR)^2 *
L
We found Ds to be 25.75 inch. Hence, we selected 28 inch diameter standard wrought
steel pipe for its easy availability. Baffle spacing was chosen 0.5 times of shell diameter.
Lastly, we had selected carbon steel for tube and shell for cost optimization and its
easy availability in market.
Finally we considered the HTRI data for Design and drawing.
Design and Drawings:
Figure: 3D View
Figure: Sectional View
2D DRAWINGS
Figure: Side View
Figure: Top View
Figure: Top Sectional View(Front Head)
Figure: Top Sectional View(Rare Head)
Figure: Front View
Calculations:
Both hand calculations and software analyses are added to the next
pages.
Economic Analysis:
Material Used: Carbon Steel
Pumping Power Required: 3.1kW
Interest Rate: 10%
Life cycle(year) : 05 yrs.
Components initial cost(USD) initial cost(BDT) AW of cost(USD) AW(BDT)
Materials 200 16,934 52 4,402.84
Pumping 900 76,203 900 76,203
Others 100 8,467 － －
Total 1,200 1,01,604 952 80,605.84
Final Results:
Shell inside diameter = 304.80 mm = 12 inch
Tube outside diameter = 12.7 mm
Tube wall thickness = 2.11 mm
Pitch ratio = 1.3
Pitch = 16.51 mm
Tube layout: Square, Orientation Angle: 90˚
No. of passes (tube) = 2
No. of tubes, Nt = 200
Tube Length = 2 m
Mass Flow Rate: Water = 7.3457 kg/s
Oil = 20.0001 kg/s
Pressure Drop (cold shellside) = 4.594 kpa (<40 kpa)
Pressure Drop (hot tubeside) = 103.681kpa(<140kpa)
Average film coefficient: Cold Shellside,hs = 1693.50 W/(m^2.K)
Hot Tubeside,ht = 141.38 W/(m^2.K)
Effective Heat Exchange Area = 140.894 m^2
Overall heat transfer coefficient: Actual,Ua = 79.15 W/(m^2.K)
Required,Ur =77.55 W/(m^2.K)
Heat Duty = 0.3986MW
Effective Overall Temperature Difference = 33.8℃
Fouling : Cold Shellside = 0.000090 (m2-K/W)
Hot Tubeside = 0.000879 (m2-K/W)
Conclusions:
We were assigned to design an oil cooler for marine applications. Hence, we
designed a shell and tube heat exchanger for that purpose. But we did not make
the heat exchanger and perform any test. Our theoretical results are similar to
the results from HTRI software. If we had done any performance test, there
might be a deviation between the experimental results and our theoretical
results. Since in real life, there arises many other contributing factors. We
obtained a very good result in case of pressure drop in both cold shellside and
hot tubeside. Also,our heat exchanger was economically sound and not very
costly. One of our aims was to reduce fouling as much as possible which we had
been able to do successfully.
References:
1. Jensen, S. Heat Exchanger Selection, CPE-Heat Transfer Survey,1968.
2. Teertstra, P., Yovanovich, M.M., and Culham, J.R., “Analytical Forced
Convection Modeling of Plate Fin Heat Sinks,” Proceedings of 15th IEEE
Semi-Therm Symposium, pp. 34-41, 1999
3. Heat and Mass Transfer By YUNUS A. ÇENGEL & AFSHIN J. GHAJAR
4. [Link]
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