Design optimization of shell-and-tube heat exchangers

Andre L.H. Costa, Eduardo M. Queiroz

Applied Thermal Engineering 28 (2008) 1798–1805

Andre L.H. Costa, Eduardo M. Queiroz (2008) formulated problem

consisting of the minimization of the thermal surface area for a certain
service, with discrete decision variables for optimization of shell and
tube Heat exchanger. They also represented more constraints on
geometrical features and velocity conditions which must be complied
in order to reach a more realistic solution for the process task.
The optimization algorithm is based on a search along the tube count
table where the established constraints and the investigated design
candidates are employed to eliminate non optimal alternatives, thus
reducing the number of rating runs executed. They explored
performance of the algorithm and its individual components e through
two design examples. Their obtained results illustrate the capacity of
the proposed approach to direct the optimization towards more
effective designs, considering important limitations usually ignored in
the literature.
Their paper approached the optimization of the design of shell-and-
tube heat exchangers. The formulation of the problem seeks the
minimization of the thermal surface of the equipment, for certain
minimum excess area and maximum pressure drops, by considering
discrete decision variables. In order to approximate the solution to the
design practice they have included important additional constraints,
usually ignored in previous optimization schemes. Their optimization
algorithm applied to the formulated problem involves a tube count
table search based on a controlled path along the decision variable
space. The definition of variable bounds, feasibility tests and
fathoming procedures allow a sensible reduction of computational
costs. The algorithm can be associated to any desired rating code for
the necessary thermal and hydraulic evaluations.

Entransy dissipation-based thermal resistance method for heat

exchanger performance design and optimization
Qun Chen
International Journal of Heat and Mass Transfer 60 (2013) 156–162

Qun Chen presented a paper based on entransy theory from which the
formula of entransy dissipation-based thermal resistance (EDTR) was
deduced. For diferent types of heat exchangers, he analyzed the
factors influencing heat exchanger performance and, more
importantly, developed an alternative EDTR method for the design
and optimization of heat exchanger performance. His results indicate
that the EDTR of parallelflow, counterflow and TEMA E-type shell-
and-tube heat exchangers have a general formula, which without
introducing any phenomenological non-dimensional parameter
directly relates heat exchanger performance to heat capacity rates of
fluids, thermal conductance and flow arrangement of heat exchanger.
From this formula, it is clear that there are three factors influencing
heat exchanger performance, including finite thermal conductance,
different heat capacity rates of hot and cold fluids, and non-counter
flow arrangement of heat exchangers. Furthermore, based on the
relation among heat transfer rate, arithmetical mean temperature
difference and EDTR, the total heat transfer rate in a heat exchanger
can be easily calculated by the thermal conductance of heat exchanger
and the heat capacity rates of fluids. Therefore, the EDTR method can
analyze, compare and optimize heat exchanger performance
conveniently.
Based on the definition of EDTR of heat exchangers and its relation
to heat exchanger effectiveness and NTU, the formulas of EDTR
and the corresponding EDTR method were developed for
parallelflow, counterflow, and TEMA E-type shell-and-tube
exchangers. EDTR directly connect the heat exchanger performance
to the heat capacity rates and flow arrangements of fluid and the
thermal conductance of heat exchanger without introducing any
phenomenological non-dimensional parameters different from the
existing design method, e.g. the e-NTU, P-NTU, w-P methods, where
some phenomenological non-dimensional parameters, e.g. correction
factor u, heat exchanger effectiveness e, and temperature
effectiveness P, should be introduced. The EDTR for parallelflow,
counterflow and one shell and any integral multiple of two tube
passes TEMA E-type shell-and-tube exchangers have a general
formula. From this general formula, it is clear that there are three
factors influencing heat exchanger performance including finite
thermal conductance, different heat capacity rates of hot and cold
fluids, and non-counterflow arrangement of heat exchangers. In
addition, the total heat transfer rate in a heat exchanger can be easily
calculated through the thermal conductance of heat exchanger and the
heat capacity rates of fluids. Therefore, the EDTR method contributes
to the analysis, comparison and optimization of heat exchanger
performance from the viewpoint of irreversibility of heat transfer.