An-Najah National University

Faculty of Engineering and Information Technology

Chemical Engineering Department
Computer- Aided Equipment Design (10626444)

Shell and Tube Heat Exchanger

Prepared By:
Amer Abu Hayat
Areen Alshaer
Omar Alabed
Omniya Atarah
Sara Rabaya

Group Members:
Amer Abu Hayat
Areen Alshaer
Omar Alabed
Omniya Atarah
Sara Rabaya

Submitted to:
Dr. Majd Shhadi
Eng. Maha Fuqha

Submitted on [October 9 , 2023]

Contents
List of Figures:.................................................................................................................................................
List of Equations..............................................................................................................................................
Abstract............................................................................................................................................................
Introduction:.....................................................................................................................................................
Methodology:...................................................................................................................................................
Discussion:.......................................................................................................................................................
Conclusions:.....................................................................................................................................................
References:.......................................................................................................................................................
Appendices.......................................................................................................................................................

List of Figures:
Figure 1: .....................................................................................................................................................
Figure 2:.........................................................................................................................................................
Figure 3: ......................................................................................................................................................

List of Tables

Table 1:..........................................................................................................................................................
Table 2:..........................................................................................................................................................
Table 3:..........................................................................................................................................................
Table 4:..........................................................................................................................................................

Abstract
Design Project Statement

Hot exhaust gases having roughly the same physical properties as air are used in a shell-
and-tube exchanger to heat 45 ton/hr of water from 80°C to 150 °C. The gases enter at
340°C and 81 ton/hr.

Each group should carry the following and submit a full design report before the due
date:

• Select the optimum arrangement and size of your exchanger estimating capital,
operating, and total annual cost.
• All assumptions regarding design parameters will be provided during lectures.
• Use Excel to perform your calculations and submit them separately on the excel
sheet.

At the end of the report, each group should attach a management sheet (Milestone Table)
including the actions carried out during the work with the responsible person and the time
frame of that action in addition to the difficulties the group faced during the project
progress.
 Introduction

heat exchanger is a thermal device used to transfer heat between fluids that have different
temperatures. This device is used in many different applications such as refrigeration and
air conditioning, power generation plants, chemical processes, the food industry, and
automobile radiators.

The heat exchanger design can be divided into two main categories, thermal and
hydraulic design and mechanical design. In thermal and hydraulic design, the focus is on
calculating an adequate surface area transfer a certain amount of heat, pressure dope,
pumping power work, etc. The goal of the mechanical design is to design the mechanical
integrity of the exchanger, as well as designing various pressure and non-pressure
components.

here are two types of heat transfer mechanisms employed by heat exchangers—single-
phase or two-phase heat transfer.
In single-phase heat exchangers, the fluids do not undergo any phase change throughout
the heat transfer process, meaning that both the warmer and cooler fluids remain in the
same state of matter at which they entered the heat exchanger.

On the other hand, in two-phase heat exchangers, fluids do experience a phase change
during the heat transfer process. The phase change can occur in either or both of the
fluids involved resulting in a change from a liquid to a gas or a gas to a liquid.

Common types of heat exchangers:

 Shell and tube heat exchangers.

 Double pipe heat exchangers.
 Plate heat exchangers.
 Condensers, evaporators, and boilers.
In this project the type of heat exchanger is Shell and tube heat exchangers, shell and tube
heat exchangers are constructed of a single tube or series of parallel tubes (i.e., tube
bundle) enclosed within a sealed, cylindrical pressure vessel (i.e., shell).

The principal components of shell-and-tube heat exchangers are:

Tubes.

Heat exchanger tube is a device which is used to transfer heat from one medium to
another for both cooling and heating processes. It separates the medium which is being
used. Heat is transferred through these exchanger tubes by the conduction process.[1]

Figure1: Tubes in a heat exchanger.

 Tube sheet.

A tube sheet in a heat exchanger is a plate with holes drilled in at optimal positions.
Tubes then pass through these holes. The tube sheet holds the tubes in place within the
heat exchanger to ensure effective heat transfer.[2]

Figure2: Tube sheet in a heat exchanger.

Shell and Shell-Side Nozzles.

The shell is simply the container for the shell-side fluid, and the nozzles are the inlet and
exit ports. The shell normally has a circular cross-section and is commonly made by
rolling a metal plate of appropriate dimensions into a cylinder and welding the
longitudinal joint.[3]

Tube-Side Channel and Nozzles.

The tube-side channel and nozzle are where the tube-side fluid enters and exits the heat
exchanger.[4]
 Baffles.

Baffles are components of shell and tube heat exchangers that are used to support and fix
the tubes in a defined position.[5]

Figure3: Baffle plate in heat exchangers.

Tie-rod.

Tie rods are used to hold the baffle in place with spacers, which are pieces of tubing or
pipe placed to maintain the selected baffle spacing.[6]

Figure4: shell & tube heat exchangers components.

 Discussion

 What are the shell & tube in the heat exchanger made of?
Tubes (Air) can be made of:[7]
 Stainless steel: Stainless steel tubes are popular in heat exchangers due to their
corrosion resistance, especially in applications where the fluid being processed is
aggressive or corrosive(and we have hot air which is more corrosive than water).
Common stainless steel grades include 304 and 316.
 Low Carbon Steel: Carbon steel tubes are often used in low-temperature and
low-pressure applications. They are cost-effective and offer good thermal
conductivity but are susceptible to corrosion.
 Copper: Copper tubes are known for their excellent thermal conductivity, making
them suitable for applications where efficient heat transfer is essential. They are
often used in HVAC (Heating, Ventilation, and Air Conditioning) systems.
 Aluminum: Aluminum tubes are lightweight and have good thermal conductivity.
They are often used in automotive and some air-cooled heat exchangers.
 Titanium: Titanium tubes are highly corrosion-resistant and are used in
applications where extreme corrosion resistance is required, such as in marine and
chemical processing industries.
 Inconel: Inconel is a family of nickel-chromium alloys known for their high-
temperature and corrosion resistance. They are used in heat exchangers that
operate at high temperatures and under harsh conditions.
 Copper-Nickel Alloys: Copper-nickel alloys like Cu-Ni 90/10 and Cu-Ni 70/30
are used in marine heat exchangers because of their excellent resistance to
seawater corrosion.
Shells (Water) can be made of:

 Carbon Steel: Carbon steel is often used for heat exchanger shells in low- to
moderate-temperature and pressure applications. It's a cost-effective option, but it
may require additional corrosion protection in certain environments.
 Carbon Steel with Internal or External Coatings: In cases where carbon steel
is used but corrosion protection is required, the shell may be coated with materials
like epoxy, rubber lining, or other anti-corrosion coatings.
 Copper: Copper shells are used in specialized applications, particularly in the
HVAC and refrigeration industries, where high thermal conductivity is essential.
 Aluminum: Aluminum shells are employed in certain heat exchanger designs,
especially in lightweight and compact applications.
 Titanium: Titanium is used in heat exchanger shells when exceptional corrosion
resistance is needed, often in chemical processing or marine applications.
 Other Exotic Alloys: Some heat exchanger shells are made from exotic alloys
like Inconel, Hastelloy, and Monel, especially in high-temperature or highly
corrosive environments.

The material selection depends on the specific operating conditions of the heat exchanger
and the fluids being processed. It's crucial to consider factors like temperature, pressure,
corrosion, and the overall efficiency of the heat exchange process when choosing the
appropriate tube material.

According to the above information we chose stainless steel for the tubes(since we
have hot air which is more corrosive than water). and Carbon Steel with Internal or
External Coatings for the shell.
  why we choose straight tubes instead of U-tubes?
A U-tube design finds itself in applications when the thermal difference between the fluid
flows would otherwise result in excessive thermal expansion of the tubes. Typical U-tube
bundles contain less tube surface area as traditional straight tube bundles due to the
bended end radius, on the curved ends and thus cannot be cleaned easily. Moreover, the
interior tubes on a U-tube design are difficult to replace and often require the removal of
additional tubes on the outer layer; Typical solutions to this are to simply plug the failed
tubes.
 References

[1] https://www.anandseamless.com/a-complete-guide-understanding-the-heat-
exchanger-tubes/ (25th October)
[2] https://www.sterlingtt.com/2022/05/10/heat-exchanger-tube-sheets/(25th
October)
[3] https://www.boardmaninc.com/news.html/2017/12/28/volume-xxiii-asme-
pressure-vessels/(25th October)
[4] https://www.altexinc.com/case-studies/shell-tube-heat-exchangers/how-to-
design-a-shell-and-tube-heat-exchanger/(25th October)
[5] https://tungaloy.com/industries/heat-exchangers-baffle-plate/(25th October)
[6] https://epcmholdings.com/design-of-shell-and-tube-heat-exchanger/(25th
October)
[7] https://www.shell-tube.com/Materials-and-Construction.html. Viewed
(2023, October 24)