GRD Journals- Global Research and Development Journal for Engineering | Volume 3 | Issue 6 | May 2018

ISSN: 2455-5703

Study the Effect of Single Segmental Baffle cut

on Overall Heat Transfer Coefficient in Shell and
Tube Heat Exchanger
Er. Satvirpal Singh Grewal Er. Kulwinder Singh Brar
M.Tech Scholar Assistant Professor
Department of Mechanical Engineering Department of Mechanical Engineering
North-West Institute of Engg. and Tech., Dhudike, Moga, North-West Institute of Engg. and Tech., Dhudike, Moga,
Punjab, India Punjab, India

Er. Didar Singh Er. Karanjeet Singh

Assistant Professor M.Tech Scholar
Department of Mechanical Engineering Department of Mechanical Engineering
North-West Institute of Engg. and Tech., Dhudike, Moga, North-West Institute of Engg. and Tech., Dhudike, Moga,
Punjab, India Punjab, India

Abstract
To figure out the best baffle cut to obtain the maximum overall heat transfer coefficient for the better performance of shell and
tube heat exchanger. Methods: To identify the best relation between the baffle cut and overall heat transfer coefficient, six
different baffle cut varies from 15% to 40% were taken at the same mass of fluid. To analyze thermal design and overall heat
transfer coefficient HTRI was used. To find out the relation between the baffle cut to overall heat transfer coefficient, we
generated 2d profile corresponding to length and 3d profile for local heat transfer coefficient. We compared all six design
variations to analyze the variation in overall heat transfer coefficient. After comparison of all six variations we figured out
optimum relationship between Baffle cut and Overall Heat Transfer Coefficient. Result shows that at a particular cut the rate of
heat transfer is the maximum. We found that 25% baffle cut is the optimum cut for single segmental baffle, this provides best
combination of shell side velocity and B stream and generate enough turbulence for better heat transfer coefficient. It is also
demonstrating good distribution of heat transfer in all localities of heat exchanger. If we decrease the baffle cut, it may increase
turbulence but leads to decrease the shell side velocity and B stream, this results the less heat transfer coefficient. Similarly, by
increasing the baffle cut there is increase in shell side velocity and B stream, but due to less turbulence less heat transferred. So
there is less heat transfer coefficient. Thus for beat the performance of heat exchanger and optimum heat transfer coefficient,
there should be best combination of all effective variables.
Keywords- Shell and Tube Heat Exchanger, Baffle, Segmental Baffle, Helical Baffle, Overall Performance

I. INTRODUCTION
In this modern world, heat exchangers are indispensible part of oil refining, electric power generation, environmental protection,
chemical industry and many others. Although, there is much type of types of heat exchangers, but shell and tube heat exchanger
is the most suitable type, because of its suitability at high pressure, robust construction and easy maintenance. Heat exchangers
can be classified in many different ways like: i). Recuperates and Regenerators. ii). Transfer process: Direct contact and Indirect
contact. iii) Geometry of construction: tubes, plates and extended surfaces. iv) Heat transfer mechanisms: single phase and two
phase. V) Flow arrangements: parallel, counter and cross flows. In this paper we will majorly focus on shell and tube heat
exchanger and its performance. Although there are many factors on which the performance of shell and tube depends, but we
will majorly discuss about the baffle cut and its effect on the overall heat transfer coefficient.

II. LITERATURE SURVEY

H. Reza Tasouji Azar, Shahram Khalilarya, Samad (2016) calculated data pressure drop and overall average heat transfer
coefficient of shell side in helix baffles and segmental baffles and concluded for the common rete of mass flow and code and
EXPRESS was used to compare this data. Results show that to improve the performance of heat transfer in helix baffles over
segmental baffles, helix bundle achieved up to three times longer operational time.

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 Study the Effect of Single Segmental Baffle cut on Overall Heat Transfer Coefficient in Shell and Tube Heat Exchanger
(GRDJE/ Volume 3 / Issue 6 / 001)

Fig. 1: Operating and maintenance costs; Bundle replacement

From the above results we can calculate that initial and installation cost of helix baffles is higher than segmental baffles
but the maintenance and operating cost is low.
Yonghua You, Aiwu Fan, Suyi Huang, Wei Liu (2016) solved the numerical method of Reynolds numbers ranging from
6813 to 22,326 at shell side for a shell and tube heat exchanger with flower baffles and to demonstrate the reasonable accuracy
comparison is done by test data. After all results we calculated that after the installation of flower baffles the velocity magnitude
of fluid and coefficient of connective heat transfer vary in periodical way.

Fig. 2: Overall performance index hs,m /Dp on the shell side between CFD results and test data for the heat exchanger with flower
baffles

B. Mayank Vishwakarma, K. K. Jain (2013) develop the arrangement of tilt baffle angle to increase the heat transfer and
to reduce the pressure drop in shell and tube heat exchangers.

Fig. 3: Graph plot between shell-side mass flux and helical angle

Using the Kern’s method, the thermal analysis provides the clear results that ratio of coefficient of heat transfer is the
maximum in helical baffles sell and tube heat exchanger as compared to segmental baffles shell and tube heat exchanger.

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 Study the Effect of Single Segmental Baffle cut on Overall Heat Transfer Coefficient in Shell and Tube Heat Exchanger
(GRDJE/ Volume 3 / Issue 6 / 001)

III. METHODOLOGY

A. Development of a General Design Problem

A problem was developed as per industrial practical conditions. We took water as hot and cold fluid on the both sides of heat
exchanger. Hot water was on shell side and cold fluid was on tube side. Problem is detailed in result section.

B. Add values in HTRI

For thermal designing of heat exchanger, we put all geometrical and conditional values in HTRI software.

C. Change in Baffle Cut

We changed baffle cut from 15% to 40% and analyze the variation in results.

D. Generation of 2D & 3D Profiles for Every Baffle Cut Value

To find out the relation between the baffle cut to overall heat transfer coefficient, we generated 2d profile corresponding to
length and 3d profile for local heat transfer coefficient.

E. Analyze the Variation in Overall Heat Transfer Coefficient

We compared all six design variations to analyze the variation in overall heat transfer coefficient.

F. Figure Out the Optimum Relationship between Baffle Cut and Overall Heat Transfer Coefficient
After comparison of all six variations we figured out optimum relationship between Baffle cut and Overall Heat Transfer
Coefficient. Result shows that at a particular cut the rate of heat transfer is the maximum.

IV. RESULTS

A. General Design Problem

From the literature review we identified that water is the standard fluid to study such kind to heat exchanger problems. We
developed a design problem detailed below for our study. We took atmospheric pressure with suitable flow rate. Geometric
values that we selected also most common values used in manufacturing of shell and tube heat exchanger.

B. Problem
Fluid = Water
Flow Rate = 20000 kg/hour
Hot Fluid Temperature (inlet/outlet) = (42/38) Degree Celsius
Cold Fluid Temperature (inlet/outlet) = (32/36) Degree Celsius

1) Geometry of Heat Exchanger

Shell ID = 254 mm
Tube OD = 12.7 mm
Tube Length = 1000 mm
Tube Thickness = 0.711 mm
Tube material = Carbon Steel

Fig. 4: Profile of Local Overall U with 15% baffle cut

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Study the Effect of Single Segmental Baffle cut on Overall Heat Transfer Coefficient in Shell and Tube Heat Exchanger
(GRDJE/ Volume 3 / Issue 6 / 001)

Fig. 5: Profile of Local Overall U with 20% baffle cut

Fig. 6: Profile of Local Overall U with 25% baffle cut

Fig. 7: Profile of Local Overall U with 30% baffle cut

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Study the Effect of Single Segmental Baffle cut on Overall Heat Transfer Coefficient in Shell and Tube Heat Exchanger
(GRDJE/ Volume 3 / Issue 6 / 001)

Fig. 8: Profile of Local Overall U with 35% baffle cut

Fig. 9: Profile of Local Overall U with 40% baffle cut

Fig. 10: Final Results

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 Study the Effect of Single Segmental Baffle cut on Overall Heat Transfer Coefficient in Shell and Tube Heat Exchanger
(GRDJE/ Volume 3 / Issue 6 / 001)

The final results are showing that exchanger with 15% baffle may provide good turbulence but due to low shell side velocity and
low B stream, the value of overall heat transfer coefficient is only 2598.38 kcal/m^2-hr-c. By increasing the baffle cut with 5%,
there is a small increase in shell side velocity and B stream. This further leads to increase the overall heat transfer coefficient.
25% baffle cut is best solution. It gives the optimum efficiency and best combination of shell side turbulence, shell side velocity
and B stream. The overall heat transfer coefficient is maximum with 25% baffle cut i.e. 2673.78 kcal/m^2-hr-c. If we increase
baffle cut further due to less turbulence less heat transferred by the fluid. So there is decrease in overall heat transfer coefficient
with increment in baffle cut.

V. CONCLUSION
The objective of the thesis is to figure out the optimum relation between baffle cut and overall heat transfer coefficient. We
developed a practical design problem of shell and tube heat exchanger. We put problem values in HTRI to figure out the
solution. We developed six cases with six variations of baffle cut. After the comparison of all six cases results we found that 25%
baffle cut is the optimum cut for single segmental baffle, this provides best combination of shell side velocity and B stream and
generate enough turbulence for better heat transfer coefficient. It is also demonstrating good distribution of heat transfer in all
localities of heat exchanger. If we decrease the baffle cut, it may increase turbulence but leads to decrease the shell side velocity
and B stream, this results the less heat transfer coefficient. Similarly, by increasing the baffle cut there is increase in shell side
velocity and B stream, but due to less turbulence less heat transferred. So there is less heat transfer coefficient. Thus for beat the
performance of heat exchanger and optimum heat transfer coefficient, there should be best combination of all effective variables.

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 Study the Effect of Single Segmental Baffle cut on Overall Heat Transfer Coefficient in Shell and Tube Heat Exchanger
(GRDJE/ Volume 3 / Issue 6 / 001)

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