UNIVERSITI KUALA LUMPUR

MALAYSIAN INSTITUTE OF CHEMICAL AND BIOENGINEERING

TECHNOLOGY

HEAT EXCHANGER DESIGN

MINI PROJECT
PROCESS HEAT TRANSFER

CLB 21003

DATE: 24 JUNE 2017

SECTION: L01-T1

NAME: FATIN NOR FARHANA BINTI MOHD AZRAEI 55218116222

NOOR FAIZAH BINTI ABDUL MALEK 55218116221
AMIR LOKMAN BIN MOHD ZULKIFLEE 55213116230
MUHAMAD LUQMAN HAKIM BIN MAT LAZIM 55216116231
NURUL EMILIA HUSNA BINTI MOHD HASHIM 55218116036

LECTURER: MDM AIZA SYUHANIZ BINTI SALLEH

 TABLE OF CONTENTS

1.0 EXECUTIVE SUMMARY ....................................................................................................1

2.0 INTRODUCTION ............................................................................................................................. 4
2.1 HISTORY BACKGROUND .................................................................................................... 5
2.2 INTRODUCTION OF PRODUCT AND HISTORY BACKGROUND .................................. 5
2.3 INDUSTRIAL APPLICATION AND USES .......................................................................... 5
2.4 TYPE OF HEAT EXCHANGER ............................................................................................. 5
2.4.1 TUBULAR HEAT EXCHANGER ....................................................................... 5
2.4.1.1 SHELL-AND-TUBE HEAT EXCHANGER ........................................... 5
2.5 FUNCTION OF HEAT EXCHANGER .................................................................................. 5
2.6 CALCULATION METHOD OF EQUIPMENT ...................................................................... 5
3.0 TUBE BANK ANALYSIS ......................................................................................................1
3.1 TUBE BANK DESIGN ........................................................................................................ 5
3.2 MATERIAL SELECTION FOR TUBE BANK ....................................................................... 5
3.3 ASSUMPTION ......................................................................................................................... 5
4.0 SHELL AND OVERALL HEAT TRANSFER COEFFICIENT ANALYSIS ..................1
5.0 PRODUCT QUALITY ASSURANCE ....................................................................................4
6.0 COST ESTIMATION ...............................................................................................................4
7.0 REFERENCES AND APPENDICES .............................................................................................. 4
1.0 EXECUTIVE SUMMARY

Shell and tube heat exchanger is a class of heat exchanger design. It is the most common
type of heat exchanger in oil refineries and other large chemical processes, and is suited for high-
pressure applications. It consists of a shell with a bundle of tubes inside it. For this project, we
were required to design a shell and tube heat exchanger to transfer heat from a stream of kerosene
to a stream of water. Water will enter the exchanger on the shell side at a flow rate of 30 kg s-1 at
35 0C and 12 bars, and kerosene will enter on the tube side at a flow rate of 43 kg s-1 at 185 0C
and 8 bars. The tubes should be thin-walled with an internal diameter of not less than 1.5 cm and
outer diameter not less than 1.6 cm. The maximum length of each tube pass in the heat exchanger
cannot be more than 7.5 m. The tubes in the tube banks should be arranged in-line in the direction
of flow with a 4.5 cm square pitch minimum. The shell has an inside diameter of not smaller than

2.8 m. After that, we find the area of the shell and tube using the formula . Therefore,
the area for the tube is 0.3063m2 and for the shell is 56.5487 m2. Then, we need to find the velocity
of water stream and kerosene stream which is 0.0005 m/s and 0.1712 m/s. By finding the velocity,
we could find the Reynold’s number where the number is 125.2352 and74.239 respectively and
then we could substitute the value into the formula to determine the Nusselt number. Nu for both
water stream and kerosene stream is 7.1788 and 4.5868. Later on, we determine the thermal
resistance value before we find the LMTD. With the calculation, we get value for RT is 31.6383
o
C/W and to find the maximum effectiveness, we the find the NTU value to be 12,900,000 W.
Therefore after substituting into the formula, we get the maximum effectiveness is 90 %.
2.0 INTRODUCTION
2.1 HISTORY BACKGROUND
Heat exchanger is a device, which is used to transfer the thermal energy or enthalpy
between two or more fluids, between a solid surface and a fluid. It is important unit operation that
contributes to the efficiency and safety of many processes. Heat exchanger are classified according
to the transfer process, number of fluids, the degree of surface contact, design features, flow
arrangements, and heat transfer mechanisms. There are different types heat exchanger likes plate
and frame, compact heat exchanger, shell and tube heat exchanger, and some more.
Shell and tube have been used in industry for over 150 years, so that the thermal
technologies and manufacturing methods are well defined and applied by modern competitive
manufacturers. It was introduced in the early of 1990s to fill the needs in power plants for large
heat exchanger surfaces as condenser and feed water heaters capable of operating under relatively
high pressure. Both of the original applications of shell and tube heat exchangers continue to be
used, but the design have become highly sophisticated and specialized. The broad industrial used
to accommodate the demands of emerging oil industry.
During the 1920s shell and tube manufacturing technology became fairly well developed,
mainly because of the efforts of relatively few major manufactures. In 1930s, the designers
established many sound design principles from intuition and data emerging on ideal tube banks.
Viscous flow was one of the most difficult problems for shell side flow and was poorly understood
until the 1960s. Shell side pressure drop is not even mentioned in the literature until the late 1940s.
Condensers and reboilers were designed purely to experience derived values, often tightly guarded
secrets of the manufacturers.
Shell and tube heat exchanger are containing large number of tubes packed in the shell with
their axes parallel to the shell. There are few components inside the shell and tube. Baffles are
placed in the shell to force the shell side fluid to flow across the shell to enhance heat exchanger
and maintain uniform spacing between tubes. Then, it also used on the shell side fluid to
accomplish mixing or turbulence. Without the baffles, the fluid can become flowing in certain
parts of the shell. The used of headers is where the tube fluid accumulates before entering and
leaving the heat exchanger.
 Figure 1: Example of Shell and Tube and its Components

A cylindrical shell with multiple tubes running inside the shell. One fluid passes through
the tubes and then exit the heat exchanger, and the other fluid circulates on the outside of the tubes
within the cylindrical shell. Heat is transferred from one fluid to the other through the walls of the
tubes.

Figure 2: The Flow of Fluid through the Tubes

Shell and tube heat exchanger are represent as the most widely used for the transfer of heat
in industrial process applications. The applications are likes process liquid or gas cooling, process
heat removal and preheating of feed water, compressor, turbine and engine cooling, oil and jacket
water, and hydraulic and lube oil cooling. It have the ability to transfer large amounts of heat in
relatively low cost, and serviceable designs. Then, it can also provide large amounts of effective
tube surface while minimizing the requirements of floor space, liquid volume, and weight.
 The products will be used for this project are kerosene and water. Kerosene or also called
as paraffin or paraffin oil, is a flammable pale yellow or colourless oily liquid. Kerosene is a
refined petroleum distillate that has a flash point. In the early years of the petroleum industry
kerosene was the largest selling and most important product.

Kerosene is a combustible hydrocarbon liquid widely used as a fuel in industry and

households. Its name is derived from Greek (Keros) meaning wax and registered as a trademark
by Abraham Gesner in 1854. It has been an important household fuel since the 19th century.
However, in developing countries, kerosene use for cooking lighting remains widespread. It is
often advocated as a cleaner alternative to solid fuels, biomass and coal, for cooking, and kerosene
lamps are frequently used hen electricity is unavailable.

Some kerosene using devices emit substantial amounts of fine particulates, carbon
monoxide (CO), nitric oxide (NO), and sulphur dioxide (SO2). Portable kerosene room heaters
are used primarily in developed countries, and some developing countries such as Chile although
many countries have either prohibited or discouraged their used, particularly because of the risk
of carbon monoxide (CO) poisoning (Long,1997)
2.3 TYPE OF HEAT EXCHANGER

2.3.1 TUBULAR HEAT EXCHANGER

The tubular types are consists of circular tubes. One fluid flows inside the tubes and the
other flows on the outside of the tubes. The parameters of the heat exchanger can be
changed like the tube diameter, the number of pitch, tube arrangement, number of tubes
and length of the tube can be manipulate. The common type of heat exchangers lie under
this categories are double-pipe type, shell-and-tube type and spiral tube type. The tubular
heat exchangers can be designed for high pressure relative to the environment and high
pressure difference between the fluids. These exchangers are used for liquid-to-liquid and
liquid-to-vapor phase. But when the operating temperature or pressure is very high or
fouling on one fluid side, it will used gas-to-liquid and gas-togas heat transfer applications.

2.3.1.1 SHELL-AND-TUBE HEAT EXCHANGER

This 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 the two
fluids. The fluid flows inside the tubes and other fluid flows across and along the
tubes. But for baffled shell-and-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 tubesheets. The different type of shell-
and-tube heat exchangers depends on different application. Usually in chemical
industry and process application, it is used as oil-coolers, power condensers,
preheaters in power plants and also steam generators in nuclear power plants.
 Figure 1

2.4 FUNCTION OF HEAT EXCHANGER

Heat exchanger are used to transfer heat from one fluid to another. This transfer of
exchange of heat maybe between one liquid & another, a liquid & a gas or two gases.

2.5 CALCULATION METHOD OF EQUIPMENT

The Overall Heat Transfer Coefficient

T
Q  UAT  U i Ai T  U o Ao T
R
The Log Mean Temperature Difference Method (LMTD)
1   2
Tm 
 
ln  1 
 2 
3.0 TUBE BANK ANALYSIS
Tube banks are commonly-employed design elements in heat exchangers. Both plain and
finned tube banks are widely found. Tube bundles are a sub-component in shell-and-tube heat
exchangers, where the flow resembles crossflow at some places, and longitudinal flow elsewhere.

3.1 TUBE BANK DESIGN

3.2 MATERIAL SELECTION FOR TUBE BANK

Aluminium – Bronze has been chosen as the material for making as the tube for the heat
exchanger. It has been chosen because of it physical and mechanical properties. It is because of it
high specific heat capacity compare to copper – nickel (10%). This properties are needed because
usually the tube are moving the cold fluid which is will be used to cold down the hot fluid in the
shell. Therefore, the tube must be cold at a long time. So, the hot fluid can reach almost at 100%
efficiency after started the heat exchanger after a long time. It is cause by the high specific heat
capacity. Aluminium – bronze also has the strength to resist any corrosion and also high thermal
conductivity. High thermal conductivity are used to conduct the cold temperature of the cold fluid
to high temperature of the hot fluid in shell. Aluminium – bronze also has a low density. The tube
bank is being built with 19 more inner tube inside the outer tube.
3.3 ASSUMPTION
3.3.1. Properties of kerosene
Hot fluid (Kerosene) Tube

Tf 125 ºC Mass / Flowrate 43 kg/s

Cp 2000 J/kg.ºC Thin / Thout 185 ºC / 65 ºC

µ 2.559 x 10-5 kg/m.s Pressure 8 bars

ρ 810.352 kg/m3 Fouling Factor 0.0005 m2.ºC.W-1

v 3.394 x 10-5 m2/s Internal Diameter 0.015 m

Pr 0.6979 Outer Diameter 0.016 m

k 0.03746 W/m.K Length 6.5 m

St 4.5 cm2

3.3.2. Properties of water

Cold fluid (H2O) Shell

Tf 70 Mass / Flowrate 30 kg/s

Cp 4185 J/kg.ºC Tcin / Tcout 35 ºC / 105 ºC

µ 𝑘𝑔 Pressure 12 bars
0.404𝑥10−3
𝑚. 𝑠

ρ 977.5kg/m3 Fouling Factor 0.0004 m2.ºC.W-1

v 2.0205 x 10-5 m2/s Internal Diameter 3m

Pr 2.55 Outer Diameter -

k 0.663 W/m.K Length 6m

Baffle cut 30%

Assume Diameter
Tube Di = 1.5 cm @ 0.015 m
Tube Do = 1.6 cm @ 0.016 m
Lc= 6.5 m

Assume the Tcout and Thout

Tcout= 50 ºC (assumed)
Thin= 185 ºC
Q = [mHCpHΔT]KEROSENE
= (43 kg/s) x (2000 J/kg. ºC) x (185 - 50) ºC
= 11,610,000J/s

Assume that Qc/Qh =1 @ Qc =Qh

Q = [mHCpHΔT]WATER
𝑄
Tcout = Tcin - 𝑚.𝐶𝑝
11,610,000 J/s
= 35 ºC + (30 kg/s)(4185 J/kg.ºC)

= 127.47 ºC

Determine LMTD, ΔTm

Knowing the inlet and outlet temperature of both fluids, the logarithmic mean temperature
differences for this counter-flow heat exchanger becomes
1  185  127.47  57.53 ºC
 2  50  35  15 ºC
57.53  15
Tm 

ln 57.53
15

Tm  31.6383 ºC
Area of tube = πDiL
= π (0.015 m) (6.5 m)
= 0.3063 m2

Velocity of kerosene stream

V = ṁ/ ρ A
V = (43 kg/s) / (820 kg/m3) x (0.3063 m2)
= 0.1712 m/s

Reynold number using tube bank

𝜌(𝑉𝑚𝑎𝑥)(𝐷𝑜) (𝑉𝑚𝑎𝑥)(𝐷𝑜)
Re = =
𝜇 𝑣
𝑆𝑡 0.045 𝑚
Vmax= V= 0.1712
𝑆𝑡−𝐷𝑜 0.045−0.016 𝑠
𝑚
= 0.2657
𝑠
𝜌(𝑉𝑚𝑎𝑥)(𝐷𝑜) (𝑉𝑚𝑎𝑥)(𝐷𝑜)
Re = =
𝜇 𝑣
𝑚
(0.2657 𝑠 )(0.016𝑚)
= 𝑚2
3.394 𝑥 10−5
𝑠

= 125.2352

Nu for cylinder

In-line flow (2𝑥105 − 2𝑥106 )

Pr
Nu = 0.27𝑅𝑒 0.63 𝑃𝑟 0.36 (𝑃𝑟𝑠)0.25
0.6979
= 0.27(125.2352)0.63 (0.6979)0.36 ( 0.965 )0.25

= 4.5868

Heat transfer coefficient

 𝑤
𝑁𝑢.𝑘 (4.5868)(0.03746𝑚.℃)
hi = =
𝐷𝑖 0.015𝑚

= 11.4548 W/m2.℃

4.0 SHELL AND OVERALL HEAT TRANSFER ANALYSIS

a. Tf :

Tube (oil) Shell (water)

185+65 35+105
Tf = ◦c Tf = ◦c
2 2
= 125 ◦c = 70 ◦c
b. Properties

Properties of oil Properties of water

𝑘𝑔 𝑘𝑔
a. µ = 2.559𝑥10−5 𝑚.𝑠 a. µ = 0.404𝑥10−5 𝑚.𝑠
𝐽 𝐽
b. Cp = 2000 b. Cp = 4185
𝑘𝑔 .℃ 𝑘𝑔 .℃
𝑊 𝑊
c. k = 0.03745 𝑚.𝐾 c. k = 0.663 𝑚.𝐾
𝑘𝑔 𝑘𝑔
d. ρ = 810.352 𝑚2 d. ρ = 977.5 𝑚2
𝑚2 𝑚2
e. ѵ= 3.394 𝑥 10−5 𝑠
e. ѵ= 2.0205𝑥 10−5 𝑠

f. Pr = 0.6979 f. Pr = 2.55
Calculation analysis (Shell):

Area of tube = πDiL

= π (3 m) (6 m)
= 56.5487 m2

Velocity of water stream

V = ṁ/ ρ A
V = (30 kg/s) / (977.5 kg/m3) x (56.5487 m2)
= 0.0005 m/s

Reynold number

𝑚
𝑉𝐿𝑐 (0.0005 𝑠 )(3𝑚)
Re = = 𝑚2
= 74.239
𝑣 2.0205𝑥 10−5 𝑠

Nusselt number
1 1 5 4
0.62 𝑅𝑒2 𝑃𝑟3 𝑅𝑒
Nu = 0.3 + 1 [1 + ( )]
8 5
2 4 282000
[1 + (0.4
𝑃𝑟
3
) ]

1 1
0.62 (74.239)2 (2.55)3 74.239 5 4
= 0.3 + [ 1 ] [1 + ( )8 ]5
2 4 282000
0.4 3
[1 + (2.55 ) ]

= 7.1788

Heat transfer coefficient,hi (shell)

𝑤
𝑁𝑢.𝑘 (7.1788)(0.663𝑚.℃)
ho = =
𝐷𝑖 3𝑚
𝑤
= 1.5865
𝑚.℃
Overall heat transfer coefficient, U

𝑄
U = 𝐴𝑡 ∆𝑇𝑚

11,610,000 𝑤
=(
0.3063 𝑚2 )( 31.6383℃)

= 1,198,042.109𝑚2𝑤℃

Total surface area, AS

𝑄
AS =
𝑈∆𝑇𝑚 𝐹𝑇

The value of FT is based on the graph:

𝑇21 − 𝑇2 (185−50)℃
R= = (127.47−35)℃ = 1.46
𝑡2 − 𝑡1

𝑡 −𝑡 (127.47−35)℃
P = 𝑇2 − 𝑡 1 = (185−35)℃
= 0.62
1 1

Based on the graph FT = 0.5

𝑄
AS =
𝑈∆𝑇𝑚 𝐹

11,610,000 𝑊
= 𝑤
(1,198,042.109𝑚2 ℃ )( 31.6383℃)(0.5)

= 0.6126𝑚2
Number of tube

𝑇𝑜𝑡𝑎𝑙 𝑎𝑟𝑒𝑎 𝑜𝑓 𝑡𝑢𝑏𝑒

Ntube =
𝑎𝑟𝑒𝑎 𝑜𝑓 1 𝑡𝑢𝑏𝑒

0.6126 𝑚2
=
0.3063 𝑚2

= 2 tubes
5.0 PRODUCT QUALITY ASSURANCE

Efficiency

Find Cmin

CH = 𝑚̇ x CpH
𝑘𝑔 𝐽
= (43 )( 2000 𝑘𝑔 .℃)
𝑠
𝐽
= 86,000 𝑠 .℃

CC = 𝑚̇ x Cpc
𝑘𝑔 𝐽
= (30 )( 4185 𝑘𝑔 .℃)
𝑠
𝐽
= 125,550 𝑠 .℃

Cmin = CH

Find Qmax

Qmax = Cmin (Thi – Tci )

𝐽
= 86,000 𝑠 .℃ (185- 35)℃
𝐽
= 12,900,000 𝑠

= 12,900,000W

Find the efficiency

𝑄 𝑎𝑐𝑡𝑢𝑎𝑙
E= X 100%
𝑄 𝑚𝑎𝑥
11,610,000 𝑊
= X 100%
12,900,000 W

= 90%
6.0 COST ESTIMATION

Material Price Quantity Total price

Aluminium -
Bronze
Inner tube RM 120 36 RM 4320
Outer tube RM 230 4 RM 920
Copper - Nickel
Inner shell RM 150 2 RM 300
Outer shell RM 200 2 RM 400
Screw and RM 10 1 RM 10
Washer
TOTAL PRICE RM 5930

Total Cost = Base Cost + Operational and maintenance

Operational and maintenance cost = RM 1200

Total Cost = RM 5930 + RM 1200

= RM 7130
Heat exchanger design

Tci = 35 ºC
ṁ = 43 kg/s

Tci = 185 ºC
ṁ = 50 kg/s

Tci = 50 ºC
ṁ = 50 kg/s

Buffle cut = Pitch square =

30% 0.045 m

Tco = 127.47 ºC
ṁ = 43 kg/s
7.0 REFERENCES
 Anonymous, Bengt Sunden Lund Institute of Technology, Introduction of Heat Exchanger,
(3.02 am, 16/6/2017)
 Anonymous, Explore the World of Piping, Heat Transfer by Heat Exchanger, Shell & Tube
(3.56am, 16/6/2017)
 J.Taborek, Volume 3- Thermal and Hydraulic Design of Heat Exchangers > Shell and Tube
Heat Exchanger Design, Objectives and Background, DOL 10.1615/hedhme.a.000247
(4.12am, 16/6/2017)
 Anonymous, Omics International, (research.omicsgroup.org/index.php/Kerosene)