Chapter Two

LITERATURE REVIEWS
2.1 Introduction

the purpose of this chapter is to provide a literature review of past research effort such as
journals or articles related to shell and tube heat exchanger, review of others relevant
research studies is made to provide more information in order to understand more on this
research.

2.2 Literature Reviews

•Shubham Sharma, Shalab Sharma, Mandeep Singh, Parampreet Singh
,Rasmeet Singh, Sthitapragyan Maharana, Nima Khalilpoor , and Alibek
Issakhov (1 June 2021) [3]
The heat transfer performance of shell-and-tube heat exchangers (STHXs) has been
compared for two different tube arrangements. STHX having 21 and 24 tubes arranged in
the inline and staggered grid has been considered for heat transfer analysis. Shell-and-tube
heat exchanger with staggered grid arrangement has been observed to provide lesser
thermal stratification as compared to the inline arrangement. Further, the study of variation
in the mass flow rate of shell-side fluid having constant tube-side flow rate has been
conducted for staggered grid structure STHX. The mass flow rate for the shell side has
been varied from 0.1 kg/s to 0.5 kg/s, respectively, keeping the tube-side mass flow rate as
constant at 0.25 kg/s. The influence of bulk mass-influx transfer rate on heat transfer
efficiency, effectiveness, and pressure drop of shell-tube heat exchangers has been
analyzed. CFD results were compared with analytical solutions, and it shows a good
agreement between them. It has been observed that pressure drop is minimum for the flow
rate of 0.1 kg/s, and outlet temperatures at the shell side and tube side have been predicted
to be 40.94°C and 63.63°C, respectively.

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S. Shinde, (2017) [4] Enhancement of heat transfer through shell and tube exchangers
stills taking high attention by researchers. The present work investigated the effect of
shell diameter and tube length on heat transfer coefficient and pressure drop for shell
side with both triangular and square pitches. In addition, the effect of baffle spacing
and cutting space on heat transfer coefficient and pressure drop were studied.
Moreover, standards fouling rates used for both shell and tube sides to esti mate the
reduced heat transfer. Increasing shell diameter with a triangular pitch and pull-through
f loating head recorded 3% increasing in heat transfer coefficient for only 0,05m
increasing in shell diameter. While 2.8% increase in heat transfer coefficient for shell
side by 0.05m increasing in shell diameter with split-ring floating head and square
pitch. Heat transfer coefficient for shell side reduced by 15.15% by increasing baffle
space by 0.2 from shell diameter and the pressure drop by 41.25%. Increasing cutting
space from 15% to 25% decreases heat transfer coefficient by 5.56% and the pressure
drop diminished by 26.3%. Increasing tube length by 0.61m leads to enhance the heat
transfer coefficient by 31.9% and pressure drop by 14.11% for tube side. For shell side,
increasing tube length by 0.61 m gives 2.2% increasing in heat transfer coefficient and
21.9% increasing for pressure drop. Fouling resistance change on shell side shows a
high effect on heat transfer more than same rate change on the tube side. Based on the
result, this study can help designers to quick understand of each parameter effect on
heat transfer into shell and tube exchangers.
Bergelin, O. (1958) [5] The effect of baffle orientation on the heat transfer and pressure
drop of shell and tube heat exchangers in the domain of turbulent flow is investigated
numerically using the commercial CFD code FLUENT. The segmentally baffled shell
and tube heat exchangers considered follow the TEMA standards and consist of 76 and
660 plain tubes respectively, with fixed outside diameter and arranged in a triangular
layout. Air, water and engine oil with Prandtl numbers in the range of 0.7 to 206 are
used as shell-side fluids. For horizontally and vertically orientated baffles, simulations
are performed using different flow velocities at the inlet nozzle. A shell-side gain factor
suitable for the assessment of shell and tube heat exchangers is introduced as ratio of
the shell side heat transfer coefficient to the shell-side pressure drop. To facilitate the
decision between horizontal and vertical baffle orientation, a performance factor Φ is
used as ratio of the gain factor for horizontally orientated baffles to the gain factor for
vertical baffle orientation.
L. Shi, V. (2017) [6] shell and tube heat exchanger (MC-STHE) designed and
manufactured using Kern’s method. A shell with
an inner diameter of 30 mm and four horizontally oriented transverse baffles with a
25% baffle cut wer used in the mini-channel heat exchanger. Using rotated triangular
layout, the tube bundle was composed of 13 mini-channel copper tubes with an outer
diameter of 3 mm and a length of 240 mm. The shell-sideReynolds numbers ranged
from 250 to 2500 while the tube-side Reynolds number was kept constant at 5900
based on the experimental surface flow area goodness factor (j/f) results. The shell side
convective heat transfer coefficients and total pressure drop results were compared with
correlations for macrotubes commonly used in the literature.
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Mane VN, (2012) [7] Shell and tube heat exchangers (STHEs) are the most common
type of heat exchangers and are applicable for wide range of operating temperatures
and pressures. Numerical analyses on thermal hydraulic performance of three sets of
shell and tube heat exchangers (STHEs) with different geometrical tube layout
patterns variations namely; triangular (30º, STHE_T), rotated triangular (60º,
STHE_RT) and the combined (STHE_C) patterns were carried out in this study. The
results from solving the governing continuity, momentum and energy equations
showed that bulk of the heat transfer and pressure drop occur during the cross-flow of
shell-fluid through the tube bundles. Evaluation of the performances of the heat
exchangers showed that the STHE_T is more desirable followed by the STHE_C as
they exhibit higher heat transfer coefficient than the STHE_RT for the same pressure
drop in the shell-side.
Zhang J, (2009) [8] Shell and tube heat exchangers are used in various industrial
processes, and are one of the most commonly used heat exchang ers. A shell and tube
heat exchanger with a 25% baffle cut was used in this study. Tubes of different cross-
sections (circular, elliptical with an attack angle of 90° and elliptical with an attack
angle of 0°) were studied. A combined model of a shell and tube heat exchanger with
elliptical tubes with an attack angle of 90° and circular tubes was introduced. A heat
exchanger with ellipsoidal tubes near the shell with an attack angle of 90° and circular
tubes in the center of the shell showed the highest heat transfer compared with the
shell and tube heat exchangers with circular tubes and elliptical tubes with an attack
angle of 90° and 0°. The pressure drop in the tube and shell side was also investigated
for all five cases in this study. The effect of the location of tubes on heat transfer was
investigated. It was shown that tubes located near the shell have a greater impact on
heat transfer compared with tubes located in the center of the shell .

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• Thundil Karuppa Raj et al [9]
Attempts were made to investigate the impacts of various baffle inclination angles on fluid
flow and the heat transfer characteristics of a shell-and-tube heat exchanger for three
different baffle inclination angles namely 0°, 10° and 20°. The simulation results for
various shell and tube heat exchangers, one with segmental baffles perpendicular to fluid
flow and two with segmental baffles inclined to the direction of fluid flow are compared
for their performance. The shell side design has been investigated numerically by
modeling a small shell-and-tube heat exchanger. The study is concerned with a single
shell and single side pass parallel flow heat exchanger. The flow and temperature fields
inside the shell are studied using noncommercial CFD software tool ANSYS CFX 12.1.
For a given baffle cut of 36 %, the heat exchanger performance is investigated by varying
mass flow rate and baffle inclination angle. From the CFD simulation results, the shell
side outlet temperature, pressure drop,

Recirculation near the baffles, optimal mass flow rate and the optimum baffle inclination
angle for the given heat exchanger geometry are determined. The shell side of a small
shell-and-tube heat exchanger is modelled with sufficient detail to resolve the flow and
temperature fields .The shell side of a small shell-and-tube heat exchanger is modelled
with sufficient detail to resolve the flow and temperature fields .For the given geometry
the mass flow rate must be below 2 kg/s, if it is increased beyond 2 kg/s the pressure drop
increases rapidly with little variation in outlet temperature .The pressure drop is decreased
by 4 %, for heat exchanger with 10° baffle inclination angle and by 16 %, for heat
exchanger with 20° baffle inclination angle. The maximum baffle inclination angle can be
20°, if the angle is beyond 20°, the center row of tubes are not supported. Hence the baffle
cannot be used effectively. Hence it can be concluded shell and tube heat exchanger with
20° baffle inclination angle results in better performance compared to 10° and 0°
inclination angles.

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•Arjun K.S. and Gopu K et al [10]
The Outlet temperature of shell side was much affected while the baffle inclination angle
was increased from 0 to 20. This was because of decrease in shell side pressure decline.
The pressure decline was found to decrease by 4 per cent with 10 and 16 percent with 20
baffle inclination. The outlet velocity also increases with increase in baffle inclination
and cause a further increase in heat transfer. The prediction of pressure decline and heat
transfer of the mode was found to be with an average error of 20 per cent. Rapid mixing
and change in flow direction was observed in inlet and outlet region and found to be the
only exception for the assumption in geometry and meshing. Reliable results were
observed with the model by considering the standard k-e and wall function. It could also
be seen that the mass flow rate when increased beyond 2kg/s; the pressure decline
suddenly increases with practically nil variation in outlet temperature for the given
geometry. The unsupported behavior of center row of tubes makes the baffle use
ineffective when the baffle angle is above 20. Hence, the helix baffle inclination angle of
20 makes the best performance of shell and tube heat exchanger.

•Sachin k.Patel , A.R.Patel(March -2015)[11]

The different major analysis done by several researchers in the topic of Shell and tube
type of heat exchanger. To increase the capacity of heat exchanger is invite the
optimization problem which seeks to identify the best parameter combination of heat
exchangers .In order to tackle such an optimization problem in present work the
optimization technique is applied to perform screening of experiments and to identify the
important significant parameters which are affecting the effectiveness of shell and tube
type heat exchanger. According to our review we find that majority of the researches
used The prefix parameters (tube diameter, mass flow rate and pitch length, baffle angle
etc.)are used as input variable and the output parameter is maximum temperature
difference of shell and tube heat exchanger

Conclusion
Experimentation Results it is confirmed that the Performance of a Tubular Heat
Exchanger can be improved by Helical Baffles instead of Segmental Baffles. Use of
Helical Baffles In Heat Exchanger Reduces Shell side Pressure drop, pumping cost,
weight, fouling... etc. as compare to Segmental Baffle for a new installation .The shell
and tube heat exchanger with 20° baffle inclination angle results in better performance
compared to 10° and 0°.

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 Inclination angles .There is increase in pressure drop with increase in fluid flow rate in
shell and tube heat exchanger which increases pumping power. Tube length, tube layout
as well as baffle spacing ratio were found to be important design parameters which has a
direct effect on pressure drop and causes a conflict between the effectiveness and total
cost. The unsupported behavior of center row of tubes makes the baffle use ineffective
when the baffle angle is above 20. Hence, the helix baffle inclination angle of 20 makes
the best performance of shell and tube heat exchanger.

• E. Ms.VanditaThantharate, Dr.D.B.Zodpe (2013). [12]

Heat exchangers various active and passive techniques have been used over plain tubes
to enhance heat transfer. Twisted tube is a passive technique. The main aim of this study
is to determine its feasibility for use in applications like automobile radiators, air
conditioners or similar type of multi pass applications. In present study, twisted tube is
compared with plain tube in multiple tube pass (4 passes) of 0.3 m length each pass for
four flow rates of 1.5 lpm, 1.37 lpm, 0.5 lpm and 0.24 lpm resulting in Reynolds number
of Re 625 to 7000 covering turbulent and laminar range. The comparison is done
analytically, experimentally and numerically. The results showed that for the given mass
flow rates and inlet temperature, the performance of plain tube is better than twisted tube
in low flow rates .For high Reynolds number range the performance of twisted tube is
better, the reason is attached flow through tubes. Thus this study concludes that for multi
pass configuration one should always select twisted tubes according to the required flow
rate.
• Jan Havlik1,*, Tomas Dlouhy1 (2017) [13]
Determination of heat transfer coefficients. The calculation of heat transfer coefficients
constitutes a crucial issue in design and sizing of heat exchangers .The Wilson plot
method and its modifications based on measured experimental data utilization provide
an appropriate tool for the analysis of convection heat transfer processes and the
determination of convection coefficients in complex cases. A modification of the Wilson
plot method for shell-and-tube condensers is proposed. The original Wilson plot method
considers a constant value of thermal resistance on the condensation side. The heat
transfer coefficient on the cooling side is determined based on the change in thermal
resistance for different conditions (fluid velocity and temperature). The modification is

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 Based on the validation of the Nusselt theory for calculating the heat transfer coefficient
on the condensation side. A change of thermal resistance on the condensation side is
expected and the value is part of the calculation. It is possible to improve the
determination accuracy of the criterion equation for calculation of the heat transfer
coefficient using the proposed modification. The criterion equation proposed by this
modification for the tested shell-and-tube condenser achieves good agreement with the
experimental results and also with commonly used theoretical methods.
• Anil Kumar Samal, Prof. Basudeb Munshi[14]
the design of shell and tube heat exchanger with helical baffle and study the flow and
temperature field inside the shell using ANSYS software tools. The heat exchanger
contains 7 tubes and 600 mm length shell diameter 90 mm. The helix angle of helical
baffle will be varied from 00 to 200. In simulation will show how the pressure varies in
shell due to different helix angle and flow rate. The flow pattern in the shell side of the
heat exchanger with continuous helical baffles was forced to be rotational and helical due
to the geometry of the continuous helical baffles, which results in a significant increase in
heat transfer coefficient per unit pressure drop in the heat exchanger. The study model
predicts the heat transfer and pressure drop with an average error of 20%. Thus the model
can be improved. The assumption worked well in this geometry and meshing expects the
outlet and inlet region where rapid mixing and change in flow direction takes place. Thus
improvement is expected if the helical baffle used in the model should have complete
contact with the surface of the shell, it will help in more turbulence across shell side and
the heat transfer rate will increase. If different flow rate is taken, it might be help to get
better heat transfer and to get better temperature difference between inlet and outlet.
Moreover the model has provided the reliable results by considering the standard k-e and
standard wall function model, but this model

Over predicts the turbulence in regions with large normal strain. Thus this model can also
be improved by using Nusselt number and Reynolds stress model, but with higher
computational theory. Furthermore the enhance wall function are not use in this project,
but they can be very useful. The heat transfer rate is poor because most of the fluid passes
without the interaction with baffles. Thus the design can be modified for better heat
transfer in two ways either the decreasing the shell diameter, so that it will be a proper
contact with the helical baffle or by increasing the baffle so that baffles will be proper
contact with the shell. It is because the heat transfer area is not utilized efficiently. Thus
the design can further be improved by creating cross flow regions in such a way that flow

7
Doesn’t remain parallel to the tubes. It will allow the outer shell fluid to have contact
with the inner shell fluid, thus heat transfer rate will increase.
•Dawid Taler ,* and Jan Taler (2017) [15] .
three power-type correlations of a simple form, which are valid for Reynolds range from
3·103 ≤ Re ≤ 106, and for three different ranges of Prandtl number: 0.1 ≤ Pr ≤ 1.0, 1.0 <
Pr ≤ 3.0, and 3.0 < Pr ≤ 103. Heat transfer correlations developed in the paper were
compared with experimental results available in the literature. The comparisons
performed in the paper confirm the good accuracy of the proposed correlations. They are
also much simpler compared with the relationship of Gnielinski, which is also widely
used in the heat transfer calculations.

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2.3 Summary
Shell and tube heat exchanger:
The shell and tube heat exchanger consists of a bundle of tubes and a shell. Heat transfer
occurs when one fluid that needs to be heated or cooled flows through the tubes, while the
second fluids pass over the tubes that provide heat or absorb the heat that is needed
In this paper, the performance of the shell-and-tube heat exchanger when the flow rate is
changed will be studied and the results obtained will be compared.

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2.4 References:

[1] S. Shinde, U. Chavan, Numerical and experimental analysis on shell side thermos
hydraulic performance of shell and tube heat exchanger with continuous helical FRP
baffles, Therm. Sci. Eng. Prog. (2017), https://doi.org/10.1016/j.tsep.2017.11.006.
[2] Bergelin, O. P., Leighton, M. D., Lafferty, W. L., Pigford, R. L. [1958], Heat Transfer
and Pressure Drop During Viscous and Turbulent Flow Across Baffled and Unbaffled Tube
Banks, Bulletin No. 4, University of Delaware Engineering Experiment Station, Newark,
Delaware.
[3] L. Shi, V. Gudjonsdottir, C.A.I. Ferreira, G. Rexwinkel, A.A. Kiss, Absorption of
CO2-NH3-H2O mixture in mini-channel heat exchangers, in: 12th IEA Heat
Pump Conf. 2017, 2017, pp. 1–12.
[4] Mane VN, Bagi JS. Improvement in quality dimensions of shell and tube type heat
Exchanger by using design software. IJAET. 2012;3(1):22-24.
[5] Zhang J, He Y, Tao W. 3D numerical simulation on shell-and-tube heat exchangers
with middle-overlapped helical baffles and continuous baffles - Part II: Simulation results
of periodic model and comparison between continuous and noncontinuous helical baffles.
International Journal of Heat and Mass Transfer. Elsevier. 2009;52:5381-5389.
[6] https://en.wikipedia.org/wiki/Shell_and_tube_heat_exchanger.
[7] Heat Transfer Principles and Applications by Charles H.forsberg.
[8] Computational Fluid Dynamics Analysis of Flow Patterns,Pressure Drop, and Heat
Transfer Coefficient in Staggered and Inline Shell-Tube Heat Exchanger.
[9] Thundil Karuppa Raj, Srikanth Ganne. Shell side numerical analysis of a shell and tube
heat exchanger considering the effects of baffle inclination angle on fluid flow using CFD
.journal of science direct.
[10] Arjun K.S. and Gopu K.B. Design of Shell and Tube Heat Exchanger Using
Computational Fluid Dynamics Tools .journal of Research Journal of Engineering
Sciences.
[11] Sachin k.Patel. , A.R.Patel "INVESTIGATION OF PERFOMANCE FOR SHELL
AND TUBE HEAT EXCHANGER".
[12] Ms.Vandita Thantharate ,.D.B.Zodpe Experimental and Numerical Comparison of
Heat Transfer Performance of Twisted Tube and Plain Tube Heat Exchangers. (2-4).
[13] Experimental determination of the heat transfer coefficient in shell-and-tube
condensers using the Wilson plot method.
[14] Anil Kumar Samal “Shell and tube heat exchanger design using CFD tools.
[15] Simple heat transfer correlations for turbulent tube flow.

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