CONTENTS

Ch. No. Title Page No.

1. INTRODUCTION 01
1.1 HEAT EXCHANGER
1.2 TYPES OF HEAT EXCHANGER

2. SHELL & TUBE HEAT EXCHANGER 06

2.1 TYPES OF SHELL & TUBE HEAT

EXCHANGER
2.2 ADVANTAGE & DISADVANTAGE
2.3APPLICATION
3. THEORY 10
4. EQUIPMENT SPECIFICATION 12
5. WORKING, PROCEDURE & RESULT 14
6. CALCULATION 16

CONCLUSION 21

TABLE OF NOMENCLATURE 22

BIBLIOGRAPHY

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 CHAPTER - 1
INTRODUCTION
Heat transfer is a science, which deals with the flow of heat from a higher temperature to
lower temperature. Heat cannot be stored and it is defined as the energy in transit due to
the difference in the temperatures of the hot and cold bodies.

The transfer of heat to and from process fluids is an essential part of most chemical
processes. There are three distinct ways in which heat transfer occurs, although most
process applications are combination of two or three. These are Conduction, Convection
and Radiation.

Mode of heat transfer:

Conduction:

Conduction is the transfer of heat in a continuous substance without any observable

motion of the matter. Thus, heat conduction is essentially the transmission of energy by
molecular motion. Consider a metallic rod being heated at the end and the other end of
the rod gets heated automatically. The heat is transported from one end to the other end
by the conduction phenomenon. The molecules of the metallic rod get energy from the
heating medium and collide with the neighboring molecules. This process transfers the
energy from the more energetic molecules to the low energetic molecules. Thus, heat
transfer requires a temperature gradient, and the heat energy transfer by conduction
occurs in the direction of decreasing temperature. Figure 1.2 shows an illustration for the
conduction, where the densely packed atoms of the rod get energized on heating and
vibration effect transfers the heat as described in fig.1.2.

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 Fig.1.2: Different stages during conduction in a metallic rod

Conduction:
When a macroscopic particle of a fluid moves from the region of hot to cold region, it
carries with it a definite amount of enthalpy. Such a flow of enthalpy is known as
convection. Convection may be natural or forced. In natural convection, the movement of
the fluid particles is due to the buoyancy forces generated due to density difference of
heated and colder region of the fluid as shown in the fig.1.3a. Whereas, in forced
convection the movement of fluid particles from the heated region to colder region is
assisted by some mechanical means too (e.g., stirrer) as shown in fig.1.3b.

Fig.1.3: Heat transfer through convection (a) natural, and (b) forced

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Radiation:
We have seen that a medium is required for the heat transfer in case of conduction and
convection. However, in case of radiation, electromagnetic waves pass through the
empty space. Electromagnetic waves travel at the velocity of light in vacuum. These
waves are absorbed, reflected, and/or transmitted by the matter, which comes in the path
of the wave. We will limit our discussion (in this NPTEL course) to the thermal
radiation. Thermal radiation is the term used to describe the electromagnetic radiation,
which is observed to be emitted by the surface of the thermally excited body. The heat of
the Sun is the most obvious example of thermal radiation.

There will be a continuous interchange of energy between two radiating bodies, with a
net exchange of energy from the hotter to the colder body as shown in the fig.1.4.

Fig.1.4: Heat transfer through radiation

1.1 HEAT EXCHANGER

Heat exchangers are devices in which heat is transferred between two fluids (one
is hotter than the other) at different temperatures without any mixing of the fluids.
We can also say that heat is transferred from the hot fluid to the cold fluid; a
device in which this happens is called a heat exchanger.

1.2 TYPES OF HEAT EXCHANGER

In industries, there are lots of heat exchanger that can be seen. There are mainly
three types of heat exchanger such as

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  Direct Transfer Type:
Type

A direct transfer type heat exchanger is one in which the cold and hot fluids
flows simultaneously through the device and heat is transferred through a wall
separating the fluids.

Hot Fluid
out

Cold Fluid Cold Fluid

in out
Hot Fluid
in

Types of Direct Type Heat Exchangers:

 Tubular Heat Exchanger

 Concentric Tube or Double

Double-pipe
pipe Heat Exchanger

 Shell & Tube Heat Exchanger

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  Plate Heat Exchanger

 Extended Surface Heat Exchanger

 Storage Type

A storage type heat exchanger is one in which the heat transfer from the hot fluid
to the cold fluid occurs through a coupling medium in the form of a porous solid
matrix. The hot and cold fluids flow alternately through the matrix, the hot fluid
storing heat in it and the cold fluid extracting heat from it.

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  Direct Contact Type:

A direct Contact type heat exchanger is one in which the two fluids are not separated.
If heat is to be transferred between a gas and a liquid, the gas is either bubbled through
the liquid or the liquid is sprayed in the form of droplets into the gas.

CHAPTER – 2

Shell & Tube Heat Exchanger:

A shell &tube heat exchanger is built of a bundle of round tubes mounted in a large
cylindrical shell with the tube axis parallel to the shell to transfer the heat between two
fluids. The fluid flows inside the tubes and other fluid flows across and along the tubes.

But for baffled shell & tube heat exchanger the shell side stream flows across between
pairs of baffles and then flows parallel to the tubes as it flows from one baffle
compartment to the next. This kind of exchanger consists of Tubes, Shells, Front-end
head, Rear-end head, Baffles and Tube sheets. The different types of shell & tube heat
exchanger depend on different application.

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 1.1 TYPES OF SHELL & TUBE HEAT EXCHANGER

The most common types of shell-and-tube heat exchanger are

 Fixed tube sheet design,

In a Fixed tube sheet exchanger, the tube sheet is welded to the shell. This result in a
simple and economical construction and the tube bores can be cleaned mechanically or
chemically. However, the outside surfaces of the tubes are inaccessible except to
chemical cleaning. If large temperature differences exist between the shell and tube
materials, it may be necessary to incorporate an expansion bellows in the shell, to
eliminate excessive stresses caused by expansion. Such bellows are often a source of
weakness and failure in operation. In circumstances where the consequences of failure
are particularly grave U-Tube or Floating Header units are normally used.
This is the cheapest of all removable bundle designs, but is generally slightly more
expensive than a fixed tubes sheet design at low pressures.

 U-tube design

In a U-Tube exchanger any of the front header types may be used and the rear
header is normally a M-Type. The U-tubes permit unlimited thermal expansion,
the tube bundle can be removed for cleaning and small bundle to shell clearances
can be achieved. However, since internal cleaning of the tubes by mechanical
means is difficult, it is normal only to use this type where the tube side fluids are
clean.

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  Floating-head type

In this type of exchanger the tube sheet at the Rear Header end is not welded to the
shell but allowed to move or float. The tube sheet at the Front Header (tube side
fluid inlet end) is of a larger diameter than the shell and is sealed in a similar
manner to that used in the fixed tube sheet design. The tube sheet at the rear
header end of the shell is of slightly smaller diameter than the shell, allowing the
bundle to be pulled through the shell. The use of a floating head means that
thermal expansion can be allowed for and the tube bundle can be removed for
cleaning. There are several rear header types that can be used but the S-Type Rear
Head is the most popular. A floating head exchanger is suitable for the rigorous
duties associated with high temperatures and pressures but is more expensive
(typically of order of 25% for carbon steel construction) than the equivalent fixed
tube sheet exchanger.

1.2 ADVANTAGES & DISADVANTAGES

Advantages

1. Less expensive as compared to Plate type coolers

2. Can be used in systems with higher operating temperatures and
pressures
3. Pressure drop across a tube cooler is less
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 4. Tube leaks are easily located and plugged since pressure test is
comparatively easy
5. Tubular coolers in refrigeration system can act as receiver also.
6. Using sacrificial anodes protects the whole cooling system against
corrosion.
7. Tube coolers may be preferred for lubricating oil cooling because of the
pressure differential

Disadvantages

1. Heat transfer efficiency is less compared to plate type cooler

2. Cleaning and maintenance is difficult since a tube cooler requires
enough clearance at one end to remove the tube nest
3. Capacity of tube cooler cannot be increased.
4. Requires more space in comparison to plate coolers.

1.3 APPLICATIONS

o Shell and tube heat exchangers are most commonly used in heating or
cooling process fluids and gasses.
o It is most commonly used in space heating such as in power plants and even
in air conditioning. It is also used in the radiator in a car using an antifreeze
engine cooling fluid.
o But the fact is that there are heat exchangers even in the circulation system
of fishes and whales. The veins of these animals are intertwined such that
one side is carrying cold blood and the other has cold blood. As a result,
these species can prevent heat loss especially when they are swimming in
cold water.
o For instance, heat exchangers are used as oil coolers, transmission and
engine coolers, boiler coolers, waste water heat recovery, condensers and
evaporators in refrigeration systems.
o In residential homes, heat exchangers are used for floor heating, pool
heating, snow and ice melting, domestic water heater, central, solar and
geothermal heating.

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 CHAPTER -3
THEORY

The theory behind the operation of a shell-and-tube heat exchanger involves the
consideration of both convective and conductive heat transfer. The treatment presented
in this report is based on the work done by Incropera and Dewitt (1996).

The determination of the overall heat transfer coefficient is one of the most important,
and often most uncertain, quantities in the analysis of heat exchangers. This coefficient
primarily accounts for all of the conductive and convective resistances (k and h,
respectively) between fluids separated by a wall (or tube), and further takes into account
thermal resistances caused by fouling on the wall (i.e., rust, scaling, etc.) by means of
fouling factors on both sides. For an unfinned tubular heat exchanger the overall heat
transfer coefficient, U, can be expressed as

U= (1)
∗∆

where:
Q is the rate of heat transfer between the two fluids in the heat exchanger in Btu/hr,

U is the overall heat transfer coefficient in BTU/hr-m2-oF,

A is the heat transfer surface area in m2, and
ΔTm is the true temperature difference in oC, calculated from the inlet and outlet
temperatures of both fluids.
Another important quantity in heat exchanger analysis is the total rate of heat transfer
between the hot and cold fluid. Several different expressions for this heat transfer rate
can be developed, relating the heat transfer rate to quantities such as the inlet and outlet
fluid temperatures and the overall heat transfer coefficient. When these expressions are
developed, care must be taken to ensure that the appropriate mean temperature

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expressions are used. Several assumptions can be made to simplify these expressions. In
this case, we assume: negligible heat transfer between the system and its surroundings,
negligible potential or kinetic energy changes, constant specific heats, and that the fluids
are not undergoing any phase change. In this case, the total heat transfer rate, q, becomes

q = ms*Cps*∆ (2)

= mt*Cpt*∆

where,

Ts  Ti  To (3)

and

Tt  ti  t o . (4)

When the total heat transfer rate is related to the overall heat transfer coefficient, another
expression develops. This time

q  U d AFTLM 5

Where, A is the area for heat transfer, F is the correction factor for flow, and TLM is the
log mean temperature difference between the inlet and outlet temperatures. In a shell-
and-tube heat exchanger, the area for heat transfer is

A  nt d o L .
(6)

The correction factor, F, is needed due to the fact the theory was originally developed for
the case of pure counter flow. In a shell-and-tube heat exchanger, there is usually one
shell pass and some multiple of two tube passes. The shell-and-tube heat exchanger used
in experimentation has one shell pass and two tube passes. For this

case, the correction factor, F, becomes

 1 P 
a ln 
F  1  RP  7 
1  R ln 2  Pb  a  
 2  Pb  a  
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where the equations for each of the variables in the equation are

a  R2 1 8

b  R 1 9 

Ti  To
R  10 
to  ti

to  ti
P  . 11 
Ti  T o

Finally, the log mean temperature difference is defined as the mean between the inlet and
outlet temperatures for both the shell-and-tube. The equation for the log mean
temperature difference is

T o  t i   T i  to 
 T LM  . 12 
 T  ti 
ln  o 
 Ti  t o 

CHAPTER -4
EQUIPMENT SPECIFICATION:
The following is a list of all pieces of equipment and their specifications for the shell and
tube heat exchanger:

 Shell
Material PVC (Poly Venyl Chloride) Pipe
Length 1.706 ft
Outer diameter 011 cm
Inner diameter 010.5 cm

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The shell is simply a container for the shell side fluids and the nozzles are the inlet and
exit ports. The shell normally a circular cross section & is commonly made by rolling a

metal plate of appropriate dimensions of a cylinder and welding the longitudinal joint.
The roundness of shell is important in fixing the maximum diameter of the baffles that
can be inserted and therefore to effect of shell to baffle leakage

 Tube
Material Copper
Length 1.45 ft (44 cm)
Outer diameter 01cm
Inner diameter 0.8cm
No. of tubes 09

Tubes are the basic component of shell and tube heat exchanger, providing the heat
transfer surface from inside tube to the outside of the tube. The tubes may be seamless or
welded or most commly made of copper and steel alloys. Other commonly alloys are
nickel, titanium and aluminium are used for specified applications.

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  Baffles

Material: Aluminium

No of baffles used: 4

Baffles serve two function :most importantly, they support the tubes in the proper
positions during assembly and operations and prevent vibration of tubes caused by flow
inducing eddies and secondly they guide ,the shell side flow back and forth across the
tube field increasing the velocity and heat transfer coefficient.

 Pump ( Cooler Pump) & Submersible Pump (used in water coolers)

 Water Heater & Adhesive ( m- Seal, Fevistick & Electric Tape)

CHAPTER-5

WORKING:

A hot fluid (shown in red) flows through a tube coiled inside a larger shell through
which another, colder fluid (shown in blue) is running in the opposite direction. Heat is

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exchanged by the fluids: the hot fluid cools down and the cold fluid warms up, without
them actually coming into contact or mixing.

Procedure:

 Take two bucket or a container that can hold at least 15-20 lit. Water and measure
the temp. of water.
 Heat one of the water containing bucket with the help water heater, after sufficient
heating (45°C ) remove it from the bucket.
 Now put the hot pump in hot water bucket and cold pump in cold water bucket
&connect it with electricity.
 Note down the both inlet and out temp. of hot & cold water by thermometer.
 The hot water fluid flows through the shell side & cold fluid flows through the
tube side in counter current flow.
 Note down the flow rate of the system in g/s.
 Now calculate the log mean temp. difference with the help of LMTD equation.
 Then calculate the heat transfer area and efficiency of heat exchanger.

Hot water
inlet

Cold water Cold water

outlet inlet

Hot water
outlet

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 CHAPTER-6

CALCULATION:
Calculate Logarithmic Mean Temperature Difference (LMTD)

T1 = 45 °C t1 33 °C
=

T2 =40°C t2 35 °C
=

Δ T1 = T1 - t2 Δ T2 = T2 - t1
=(45-35) =(40-33)
=10°C = 7°C

LMTD = (Δ T1 - Δ T2)/ln ( Δ T1 / Δ T2)

= (10-7)/ln (10/7)
= 3/0.35
= 8.5°C
Now,
Calculate Logarithmic Mean Temperature Difference (LMTD),
CORRECTION FACTOR

R =(T1 - T2 ) / (t1 - t2) P= (t2 - t1)/(T1 - t1)

=(45-40)/(35-33) = (35-33)/(45-33)
= 2.5°C = 0.16°C
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  1 P 
a ln 
 1 RP
F
1 Rln 2  Pb  a 
 2  Pb  a 

a= ( + 1)

a = 2.7

.
.
.
.
.
.

Now,

Calculate True Mean Temperature Difference, ΔTm

ΔT = LMTD ∗ F
= (8.5*0.96) °C
= 8.16°C

Calculate efficiency,ῃ

( )
ῃ = %
( )

( − )
= % = %
( − )
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 ( − )
ῃ = %
( − )
( )
= %( )
= %

⁖ ῃm = (ῃ + ῃ )/

( + )
= = %

Calculate heat transfer area, A

A= n*π*di*l

= (9*3.14*0.008*0.440) m2

= 0.1 m2

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Flow Diagram of Design Procedure for Shell & Tube Heat Exchanger
Source: Chemical Engineering Design, Coulson & Richardson’s by
R.K. Sinnott

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Result
We done our design on the basis of above flow diagram and after that we are
able to design a shell and tube heat exchanger. Then we successfully find the
following:

Flow Rate = 67g/s

LMTD = 8.5°C

Correction Factor (F) = 0.96

True Mean Temperature Difference (ΔT ) = 8.16

Efficiency (ῃm) = 35%

Heat Transfer Area = 0.1m2

No. Of Tubes = 12

Shell Diameter = 0.1028m

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 CONCLUSION

This project shows that the shell & tube heat exchanger follow the basic law
of thermodynamics. The shell & tube heat exchanger is the simplest form of
heat exchanger, consisting of one shell & more than 2 tubes, one carrying the
hot fluid and the other carrying the cold fluid. Heat is transferred from the hot
to the cold fluid without mixing of the two streams. In the current lab setup,
four segments of shell & heat exchangers are arranged in series, where
temperatures are measured at the inlet and outlet of each segment. A series of
bypass tubes are used to allow the operation of one, two, three, or four
segments, in parallel or counter flow setups, as required by the specific lab
exercises. This project shows that when the flow rate of one stream increases,
the rate of heat transfer will also increases.

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 TABLE OF NOMENCLATURE

T1 = Hot water outlet temperature, °C

T2 = Hot water inlet temperature, °C
t1 = Cold water outlet temperature, °C
t2 = Cold water inlet temperature, °C
ΔT1 = Temperature difference between hot water outlet and cold
water inlet temperature, °C
ΔT2 = Temperature difference between hot water inlet and cold
water outlet temperature, °C
F = Correction Factor
Δ Tm = True mean temperature difference
ῃ1 = Temperature efficiency of the hot stream
ῃ2 = Temperature efficiency of the hot stream
ῃm = Mean Temperature efficiency of the hot stream
A = Heat transfer area, m2

BIBLIOGRAPHY:

 Shell and tube Wikipedia

 STU shell and tube .pdf
 Chemical Engineering Design, R.K Sinnot (Volume 6)
 www.google.com

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