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EXCHANGER DESIGN
CLB21003 PROCESS HEAT TRANSFER
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SHELL AND TUBE HEAT EXCHANGER DESIGN
SECTION 2: INTRODUCTION
2.1 Product
Shell and Tube Heat Exchangers are one of the most popular types of exchanger due to
the flexibility the designer has to allow for a wide range of pressures and temperatures. A shell
and tube exchanger consists of a number of tubes mounted inside a cylindrical shell. Two fluids
can exchange heat, one fluid flows over the outside of the tubes (shell) while the second fluid
flows through the tubes. The essential principle of a heat exchanger is that it transfers the heat
without transferring the fluid that carries the heat.
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SHELL AND TUBE HEAT EXCHANGER DESIGN
b) Steam Condensation
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SHELL AND TUBE HEAT EXCHANGER DESIGN
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SHELL AND TUBE HEAT EXCHANGER DESIGN
For the first step in calculating the heat transfer in the shell and tube heat exchanger,
the fluid for the tube side and shell side are determine with each physical properties for the
calculation needed througout designing the heat exchanger. It is decided from the description
given. Hot fluid (palm oil) enter the tube side and the cold fluid (water) enter the shell side.
The properties needed are in the Table 1.
The Q, rate of heat transfer for both side of shell and tube are calculated and to be equal with
each other. The Th,out, temperature out for hot fluid are estimated in order to calculate the Qh,
rate of heat transfer of hot fluid.
Qh = mhCp,h(Th,in-Th,out)
= 35 (2.042) (150-65) C
.
= 6074.95
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SHELL AND TUBE HEAT EXCHANGER DESIGN
Qc = mcCp,c(Tc,out-Tc,in)
6074.95 = 23 (4.2035) (Tc,out-25) C
.
(Tc,out-25) = 62.84 C
Tc,out = 87.84 C
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SHELL AND TUBE HEAT EXCHANGER DESIGN
Vmax = (V)
Where,
ST = tube pitch (m)
OD = outer diameter of tube (m)
V = velocity of hot fluid (m/s)
.
Vmax = (1.9877 )
..
= 9.9385 m/s
Density, (kg/m3) 857.25
Dynamic viscosity, (kg/ms) 0.008521
Maximum velocity, Vmax (m/s) 9.9385
Diameter of tube (m) 0.1650
Re =
Where,
= density (kg/m3)
= dynamic viscosity (kg/ms)
V = maximum velocity (m/s)
Lc = diameter (m)
. (. )(.)
Re =
.
= 164976.3591
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SHELL AND TUBE HEAT EXCHANGER DESIGN
= 104.191
Specific heat capacity, Cp (kJ/s) 2.249
Dynamic viscosity, (kg/ms) 0.003469
Thermal conductivity, k (W/m.) 0.1627
= 47.95
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SHELL AND TUBE HEAT EXCHANGER DESIGN
= 3380.7941
hi =
Where,
Nu = Nusselt number
L = diameter (m)
k = thermal conductivity (W/m.C)
...
hi=
.
= 3421.7734
.
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SHELL AND TUBE HEAT EXCHANGER DESIGN
Ay=
Where,
LMTD = log mean temperature difference
Us = assumed overall heat transfer coefficient
Ay =
.
= 120.850 m2
No of tube, :
=
120.850
=
1.969
= 61
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SHELL AND TUBE HEAT EXCHANGER DESIGN
= 42338.93
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SHELL AND TUBE HEAT EXCHANGER DESIGN
The Reynolds number and Prandtl number are needed to calculate the Nusselt number.
Reynolds number, Re 42338.93
Prandtl number, Pr 2.00
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SHELL AND TUBE HEAT EXCHANGER DESIGN
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SHELL AND TUBE HEAT EXCHANGER DESIGN
Material Selection
In order to create heat exchanger, the material selection is the most crucial aspects. The
heat exchanger that created must be long lasting and low in maintenance. Other than that the
material selection is also crucial to identify and to make sure the efficiency is high. Quality
assurance includes on how to manage with the quality of materials used, products formed and
the composition as well as the inspection process done. For the design of shell tube heat
exchanger, two types of fluid substance is used which is water and oil. The oil will pass through
the tubes in shell.
Some of the problems that could arise result from improper selection of materials for
tubes are corrosion. Since the shell side are flowed with water and exposed to air that consists
oxygen. The corrosion can occur because these two things is the important element for the
formation of rust, so suitable material should be suitable in order to prevent this problem. Other
than that, penetration of oil also can occur thus leakage of oil entering the shell of heat
exchanger that is filled with water. Last but not least the inefficiency of heat transfer from hot
liquid which is oil to cold liquid which is liquid.
In order to prevent this problem some specification is identified for the heat exchanger.
The specification consists of;
High thermal conductivity
Low specific heat capacity, Cp
Corrosion resistance
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SHELL AND TUBE HEAT EXCHANGER DESIGN
Material of Shell
For the shell side carbon steel is chosen as the material. This is because its physical
properties and mechanical properties. Steel with a low carbon content has the same properties
as iron, soft but easily formed. As carbon content rises the metal becomes harder and stronger
but less ductile and more difficult to weld. Higher carbon content lowers steel's melting point
and its temperature resistance in general. Carbon steel is a metal alloy of carbon and iron that
has a relatively low tensile strength whose surface hardness can be increased through
carburizing. The amount of carbon used is usually less than 2 percent and no other metal
elements are added. Carbon steel is the most abundantly produced of all steel products. It has
a wide range of applications in the motor and electrical appliances sector due to its
ferromagnetic nature
On the other hand it has good thermal conductivity. The thermal conductivity is high
and it absorbs the heat from the oil and cool down by water. This type of material will get hot
faster and can be cooled down faster. Next, it is impermeable. It will prevents the texture of
substance which is in this case the oil and the water to mix together even though the wall is
thin.
Lastly, due to the specific volume it can be considered as light in terms of weight. It is
way lighter than steel or iron. It can be easily designed and handle. Due to all this point it can
be conclude that this material low in maintenance and easy to replaces if there is any damages
occur.
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SHELL AND TUBE HEAT EXCHANGER DESIGN
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SHELL AND TUBE HEAT EXCHANGER DESIGN
PRESSURE FACTOR, Fp
Fp shell = 0.9803 + 0.018(/100) + 0.0017(/100)
=0.9803 + 0.018(130.534/100) + 0.0017(130.534/100)
=1.0067
FLOATING HEAD,Cb
Cb = { 11.6670.8709(ln())+0.09005(ln())}
= { 11.6670.8709(ln(12.20))+0.09005(ln(12.20))}
= 23202.14
= 2.0054
Shell = carbon steel
Tube = brass
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SHELL AND TUBE HEAT EXCHANGER DESIGN
PURCHASE COST,Cp
Cp = Fp x Fm x Fl x Cb
=(2.0024)(2.0054)(1.11)(23202.14)
= 103419.60 USD
= 448841.06 MYR
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SHELL AND TUBE HEAT EXCHANGER DESIGN
We estimate that the cost of designing the shell and tube exchanger for the
specifications is about RM 448841.06. We estimate by using formula of purchase cost which
is :
Purchase cost = pressure factor x material factor x tube length factor x floating head
CP = Fp x Fm x Fl xCb
We design the shell with material of carbon steel and the tube by the brass. For the material
factor, we obtain the and B from the table of material construction shell and tube which the
value are 1.08 and 0.05 respectively. For the tube length factor, our tube length is 3.8 meters
which need to convert to 12.467 ft and we obtain the value of Fl by interpolate of table tube-
length correction factor between 1.12 for 12 ft and 1.05 for 16 ft which is 1.11.
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SHELL AND TUBE HEAT EXCHANGER DESIGN
SECTION 7: REFERENCES
Blackwell, W. W. and Haydu. L. (1981) Calculating the Correct LMTD in Shell-and-Tube
Heat Exchangers, Chemical Engineering, 101-106.
Jegeda, F. O., Polley, G. T. (1992) Optimum Heat Exchanger Design, Transactions of the
Institute of Chemical Engineering, 133-141.
J.P. Holman. (2002) Heat Transfer, 9th Edition, McGraw-Hill.
Kakac, S. (1981) Heat Exchangers: Thermal-Hydraulic Fundamentals and Design,
Hemisphere Publishing Corporation, New York.
Kern, D. Q. (1950) Process Heat Transfer, McGraw Hill.
Peters, M.S., Timmerhaus, K. D., and West, R. E. (2003) Plant Design and Economics for
Chemical Engineers, McGraw-Hill, New York.
Schlunder, E. V. (1983) Heat Exchanger Design Handbook, Hemisphere Publishing
Corporation, New York.
Smith, R. (2005) Chemical Process Design and Integration, Wiley.
Taborek, J. (1983) Shell-and-Tube Heat Exchangers, Section 3.3, Heat Exchanger Design
Handbook, Hemisphere.
Tubular Exchanger Manufacturers Association, (1998) Standards of Tubular Exchanger
Manufacturers Association, 7th Edition, New York.
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SHELL AND TUBE HEAT EXCHANGER DESIGN
APPENDIX
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