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Shell and Tube Heat Exchanger

Technical Report · January 2018

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Arnab Mustafi Arka Syed Angkan Haider

Bangladesh University of Engineering and Technology University of Illinois, Urbana-Champaign
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 Shell and Tube Heat Exchanger

Project Report
Submitted in partial fulfilment of the course of
ME 310: Thermo-Fluid System Design

Submitted to
Department of Mechanical Engineering
Bangladesh University of Engineering and Technology

Submitted by

Group: B2-04
ARNAB MUSTAFI ARKA (1010177)
FAISAL HAQUE (1410091)
SYED ANGKAN HAIDER (1410102)
RAFSUN HOSSAIN MRIDHA (1410112)

BANGLADESH UNIVERSITY OF ENGINEERING AND TECHNOLOGY

Dhaka-1000, Bangladesh
January 2018

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 DECLARATION OF AUTHORSHIP

The authors grant to Bangladesh University of Engineering and Technology the right to
reproduce, by appropriate methods, upon request, any or all portions of this project report. It is
understood that “proper request” consists of the agreement, on the part of the requesting party, that
said reproduction is for his personal use and that subsequent reproduction will not occur without
written approval of the author of this project report. Further, any portions of the thesis used in
books, papers, and other works must be appropriately referenced to this project report.

All the published work have been properly consulted and attributed. Finally, the author of
this project report reserves the right to publish freely, in the literature, at any time, any or all
portions of this report.

Arnab Mustafi Arka _____________________________

Faisal Haque _____________________________

Syed Angkan Haider _____________________________

Rafsun Hossain Mridha _____________________________

Date _____________________________

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 DEDICATION

We dedicate the aforementioned project to our beloved parents without whom this would have
been a utopian scheme. Needless to say, we are grateful to Almighty GOD for giving us strength
and endeavor to take this huge project in limited period of time.

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 ACKNOWLEDGEMENT

We would like to express our solemn gratitude to our course supervisors whose amicable and
generous guidance helped us to overcome various problems of our project and helped us by
motivating through our hard times. We are thankful to our honorable teachers- Dr. A. K. M.
Monjur Morshed (Associate Professor, Dept. f Mechanical Engineering, BUET), Dr. Md. Ashiqur
Rahman (Assistant Professor, Department of Mechanical Engineering, BUET), Md. Rakibul
Hasan Roni (Lecturer, Department of Mechanical Engineering, BUET) and Musanna Galib
(Lecturer, Department of Mechanical Engineering, BUET) for their instructive suggestions and
guidelines. Credit also goes to Dr. Md. Zahurul Haq (Professor, Department of Mechanical
Engineering, BUET) who, despite not being directly involved with the lab classes, provided the
basic knowledge and theoretical know-how in the theory class which went a long way to helping
up achieve out desired final project.
We would also like to express our thankfulness to Dr. Mohammad Ali (Head of Department of
Mechanical Engineering, BUET) for letting us use the machine shop and also the welding shops.
Moreover, we are truly grateful to Md. Rakibul Hasan Roni for his continuous support and
dedication to solve our unwanted problems which helped us in the long run. He was always there
when we were in need of guidance and any kind of help.

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 ABSTRACT

The scope of this work was to design a shell and tube heat exchanger to meet the specifications
provided in the problem statement. For a given value of heat duty, a shell and tube heat exchanger
was designed, keeping in mind the restraints of pressure drop and mass flow rates on both the
shell-side and the tube-side. The materials for the shell and tube sides, along with the inlet and
outlet temperatures were also prescribed by the problem statement. Fouling was taken into account
on both shell and tube side. The main goal was to produce a thermally and hydraulically optimized
shell and tube heat exchanger with a suitable number of tubes. For the purpose of the project, the
design with greatest achievable values of heat transfer coefficients on the shell and tube sides and
the overall heat transfer coefficient were found via iteration. For optimization and iterative
purposes the software HTRI Xchanger Suite v6.00 was used. The different dimension were chosen
in the software interface and several iterations were carried out in search of a suitable optimized
design. After selecting an optimized design, the next task was to carry out the detailed mechanical
design of the entire heat exchanger for a suitable real-life case. After finding the dimensions for
the design, the final task was to produce a 3D model of the heat exchanger and SolidWorks 2013
was used for this purpose. Finally, after a 3D drawing was prepared, a scaled down model of the
heat exchanger was made.

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 TABLE OF CONTENTS

CHAPTER NAME PAGE NUMBER

CHAPTER 1: Introduction 07

CHAPTER 2: Methodology 09

CHAPTER 3: Problems and Limitations 12

CHAPTER 4: Results and Discussions 13

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 CHAPTER 1
Introduction

1.1 Background
Heat exchangers are common systems of heat transfer and they have widespread applications in
industry. A heat exchanger is a device used to transfer heat between a solid object and a fluid, or
between two or more fluids. The fluids may be separated by a solid wall to prevent mixing or they
may be in direct contact. They are widely used in space heating, refrigeration, air conditioning,
power stations, chemical plants, petrochemical plants, petroleum refineries, natural-gas
processing, and many other areas. There are several different types of heat exchanger including
shell-and-tube, double-pipe, plate-and-frame types and many more. The project at hand demanded
the optimum design of a simple shell-and-tube heat exchanger.

1.2 Problem Statement

The problem statement was given as follows:

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1.3 Project purpose
The demand of the project was to carry out the thermal, hydraulic and mechanical designs of a
simple shell-and-tube heat exchanger, following certain restraints as provided in the problem
statement. After a series of iterations and optimization schemes, a final design was selected using
commercial software. Detailed mechanical design calculations had to be performed for
completeness. Finally, a scaled down model of the project had to be made. The purpose of the
project was to bridge the gap between theory and application and also provide insight into design
considerations. The project also taught a different strategy for design, different from that taught in
theory class, via commercial software. Several decisions had to be made regarding optimization.
Useful design experience was gained and the project was an excellent opportunity for future
engineering applications.

1.4 Contribution of the project

Heat exchangers are common in industry and they have widespread applications. This project
helped provide knowledge on the design of such a crucial and versatile engineering equipment and
on further improvement of design.

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 CHAPTER 2
Methodology

2.1 Project Design

2.1.1 Thermal Design

The thermal design was performed using the commercial software HTRI Xchanger Suite v6.00
and tedious iterations as required by hand calculations were avoided. By having the liberty of
leaving the calculations for the software to do, there was plenty of time for refining and polishing
of the optimization process. Several different combinations of design parameters were tried and
used and the best design after numerous iterations was selected. The given problem constraints
were input into the software interface and different combinations of dimension (tube dia, tube
thickness, baffle cut, baffle spacing, etc.) were tried. Throughout the thermal design, the main
target was to get the highest possible overall heat transfer coefficient (U) for a suitable number of
tubes (<1000). TEMA (Tubular Exchanger Manufacturers Association) specification was considered
and used in our design.
2.1.2 Mechanical Design
After the different fundamental dimensions were obtained from the thermal design, the next task
was to perform a detailed mechanical design of the different parts of the heat exchanger (bolts,
flanges, shell thickness, nozzle, etc.). This was achieved using TEMA specification. As this was
done, the complete design for the shell-and-tube heat exchanger was obtained. The design was
ready for manufacture somewhat.
2.1.3 Three-dimensional Design
Once the complete design was achieved, the final task was to provide the data to the manufacturer
for production. For this, detailed 3D drawings had to be provided along with different views and
sections. This was done using SolidWorks 2013. The drawing was made of a scaled down version
of the designed model.

2.2 Main Body & Production

The main body was made at a mechanical workshop with the proper guidance and vigilance of the
project members. The design data along with detailed drawings were provided to the workers and
the desired product was made. The main body was made using mild steel material.

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The photographs of the project during production are provided as follows:

Fig. 1: Tubes, tube sheet, baffles (during production) Fig. 2: Shell (during production)

Fig. 3: Shell, channel cover, torispherical head cover complete with flanges(during production

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Fig. 4: Tube sheet with tube layout, baffles and tubes (after painting, during production)

Fig. 5: Final body (after production)

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 CHAPTER 3
Problems and Limitations

3.1 Problem Analysis

A problem that was encountered was finding a proper engineering workshop with a mechanic with
the proper set of skills to make the product according to the design. Since a heat exchanger is not
something commonly made in local engineering workshops, it took a lot of searching to find a
good enough worker. Another problem was finding the right material for the model. In the end
mild steel was chosen. To cover for the rusting problem, a layer of paint was laid on both the
external and internal surfaces.

3.2 Limitations
The design chosen for the heat exchanger could still use more polishing with more iterations and
different configurations to obtain a more optimized state. And the model that was made was not a
working model, but was just made to highlight the different dimensional aspects such as tube
layout angle, flanges, torispherical head, nozzles, etc.

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 CHAPTER 4
Results and Discussions

1.1 Results
4.1.1. Thermal & Hydraulic Results
The results obtained from the HTRI Xchanger Suite v6.00 are given below:

Fig. 6: Process Conditions

Fig. 7: Exchanger Performance

Fig. 8: Shell & Baffle Geometry

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 Fig. 9: Tube and Nozzle Geometry

Fig. 10: Thermal Resistance, Velocities and Flow fractions

From the results obtained, the most important parts to notice are the values of heat transfer
coefficient and the pressure drop. The shell-side h was 469.89 W/m2 .K and that for tube-side was
10544.3 W/m2 .K. the overall heat transfer coefficient, U was 275.47 W/m2 .K. Although a U value of
269.42 W/m2 .K would be sufficient, there was a slight overdesign of 2.25% which was quite acceptable.

Fig.11: Change in local overall U with length

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 Fig.12: Change in heat transfer coefficient with length

Fig.13:Change in overall heat transfer coefficient with length

The pressure drops were 15.128 kPa and 67.534 kPa on the shell-side and tube-side respectively. The
allowable value of pressure drop was 68.948 kPa. So considering pressure drop, the design was quite well
optimized, since the pressure drop on one side is almost close to the limiting value.

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Other output from the software are also presented:

Fig. 14: Exchanger drawing

Fig. 15: Setting Plan

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 Fig. 16: Tube Layout

4.1.2 Mechanical Design

The results of mechanical design are given below:
Shell: Shell thickness = 9.5 mm
Shell Cover:
Torispherical head
Crown radius = 539.751 mm
Knuckle radius = 32.39 mm
Inside depth = 72.24 mm
Effective exchanger length = 151.19 mm
Thickness of head = 1.22 mm
Channel Cover: Shell cover thickness = 9.5 mm

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Tube Sheet: Tube Sheet thickness = 25.5 mm
Impingement plate: (not required)
Nozzle: Nozzle diameter = 101.6 mm
Nozzle thickness = 3.2056 mm
Baffle: Baffle thickness = 4.8 mm
Tie rod: Tie rod diameter = 4.5 mm
Number of tie rods = 6
Gasket: Gasket material = Asbestos
Gasket width = 2.92 mm
Bolts: Bolt diameter = 31.805 mm
Number of bolts = 10

4.1.3 Three-dimensional Design

The 3D drawings from SolidWorks are given below:

Fig.17: Solid Works Design of the HTX

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Fig. 18: Full assembly

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Fig. 19: Shell cover

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Fig. 20: Channel cover

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 4.2. Discussions
4.2.1 Costing
The costing for the different items and labor is given as follows:

Item no. Item Name Cost(in taka)

1. Pipe 2ft length 6 in diameter 900
2. Pipe 16 mm diameter (9 pieces) 670
3. 6” flange (5 pieces) 800
4. 6” flange (closed-1 piece) 1900
5. 6” cap 1 piece 750
6. 4 net (2 for baffle and 2 for tube sheets) 1200
7. Gasket 280
8. Miscellaneous (bolt, wrench, support, welding, painting) 1000
9. Labor cost 2000
Total cost 9500

4.2.2 Further work and Recommendations

Further optimization can be done by changing TEMA type, shell orientation, tube pass
arrangement, clearance, nozzle standard etc. parameters.

Conclusion:
Optimization of Shell and Tube Heat Exchanger is done with the help of thermal design by using
HTRI Xchanger Suite v6.00.The maximum overall heat transfer coefficient of 275.47 W/m2.K is
achieved with 2.25% overdesign. But still more optimization is possible by changing certain
parameters. More optimization can be done by considering further economic, thermal and
mechanical design.

References
1. Heat and Mass Transfer – Fundamentals and Applications, Y. A. Cengel, A. J. Ghajar.
2. Principles of Heat Transfer, F. Kreith, R. M. Manglik, M. S. Bohn.
3. Heat Transfer in Process Engineering, E. Cao.
4. Design of Fluid Thermal Systems, W. S. Janna.

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