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INTRODUCTION
Shell-and-tube heat exchangers are commonly used in oil refineries
and other large-scale chemical processes. A heat exchanger is a device that
is used to transfer thermal energy between transfer thermal energy between
two or more fluids, between a solid surface and a fluid a fluid, or between
solid particulates and a fluid at different temperatures and in thermal contact
In this model, two separated fluids at different temperatures flow through the
heat exchanger: one through the tubes (tube side) and the other through the
shell around the tubes (shell side). Several design parameters and operating
conditions influence the optimal performance of a shell-and-tube heat
exchanger. The main purpose of this model is to show the basic principles for
setting up a heat exchanger model. It can also serve as a starting point for
more sophisticated applications, such as parameter studies or adding
additional effects like corrosion, thermal stress, and vibration.
The heat exchanger is made of structural steel. The participating fluids
are water flowing through the tube side and air flowing through the shell
side. The baffles introduce some cross-flow to the air and such increasing the
area of heat exchange. Another advantage is that baffles reduce vibration
due to the fluid motion.(Comsol,2013).
Transfer process
Number of fluids
Degree of surface contact
Design features
Flow arrangements
Heat transfer mechanisms
Shell and tube heat exchanger is the most common type of heat
exchanger in industrial applications.It contain a large number of tubes
(sometimes several hundred) packed in a shell with their axes parallel to that
of the shell. Heat transfer takes place as one fluid flows inside the tubes
while the other fluid flows outside the tubes through the shell. Shell-and-tube
heat exchangers are further classified according to the number of shell and
tube passes involved.(Cengel,2011).
Figure 2: Schematic shell and tube heat exchanger(open shell pass and one
tube pass).
stream, storing heat, and then through the cold stream, rejecting this
stored heat.
Condenser: One of the fluids is cooled and condenses as it flows
OBJECTIVE
To evaluate and study the heat balance, LMTD and overall heat
transfer coefficient.
To measure and determine the shell and tube side pressure drop.
THEORY
In most heat exchangers, two fluids are exchanging their heat without
direct physical contact to avoid mixing. This is called indirect heat transfer.
Cooling water temperature in a hot area is normally above 25 degrees
centigrade, and it depends on the atmospheric and climate condition. To
reach the range of 1 to 5 degrees centigrade, we need to use chilled water,
which is already cooled by a refrigerant. For heating purposes, the
mechanism is similar to the cooling. We can use hot intermediate fluid such
as hot water or steam and even other hot process streams.
To proceed on the heat exchanger theory we need to know that the meaning
of the following terminologies:
The overall heat transfer rate in a heat exchanger
The overall heat transfer coefficient can be used to calculate the total
heat transfer through a wall or heat exchanger construction. The overall heat
transfer coefficient depends on the fluids and their properties on both sides
of the wall, and the properties of the wall and the transmission surface.
Q = U A T
and
)
=
)
=
where:
is closest to
can be calculated
Where:
Heat rate with respect to the flow rate of water
Theoretically Q above is equal to
or
or
Reynolds Number
Shell-side Re(s) for CW
Where:
Pitch = 0.81inch
Tube outside diameter, inch
Viscosity, taken at average fluid temperature in the shell, lbmft-1hr-1
(lbmft-2hr-1)
Flow rate in (lbmhr-1)
Tube-side Re (t) for HW
Where:
Viscosity, taken at average fluid temperature in the tube, lbmft-1hr-1
And
Where:
Thermal conductivity at mean temperature with respect to fluid
position
Fluid viscosity at mean temperature with respect to fluid position
Fluid viscosity for different value of hot and cold water stream
Energy being transfer in the system
value :
Where:
and
Pressure drop
This part would determine the following:
: The measured tube-inside pressure drop DP (tube) which will be
corrected and is expected to be more than calculated tube-side pressure
drop.
: The measured shell-inside pressure drop DP (shell) which will be
corrected and is expected to be more than calculated tube-side pressure
drop.
APPARATUS
FT (C)
DPT
Pressure
TE1 to TE5 :
0-1000C.
PG-H, PG-C :
TG2
TSV3A, TSV3B
FI (H), FI (C)
USPGM
TI3 (T1)/TIC3
i.e. T1.
TIC5
DPI
of
Panel-Mount
Portable
FTDPR
PROCEDURE
Preparation procedures
Start the following preparation procedures step-by-step.
i)
Tanks T1 and T2 was filled with water to their maximum level define by their
overflow drain pipes D.
ii) At tank T1, the discharge valve (HV) was shut fully, but open fully its by-pass
valve (BVH). The HW pump PH was start for the water to recirculate around
its tank T1, via only BVH. The suction valve of pump PH must remained
open at all times.
The heaters at the front of the panel was switch on and the water was
allowed in tank T1 to be heated to its maximum temperature 70
/ 158
(see T1C5), which will took about 20 minutes. Whilst waiting, proceed
to (iii) below. The heaters in tank T1 was automatically switch off by the
on/off temperature controller T1C5 when the heated water temperature
exceeds its preset High Limit (say 70 ), and when the temperature drops
below switch them on again, say of its preset High Limit (i.e. below 69.5
).
With BVC1 was fully opened, the CW flowrate {FC at FI(C*)} was
noted,drop the pressure (PG-C) and shell-side (at DPI*). To read DP
(shell), the signal to DPI* was selected used the DP Selector Switch
provided at the panel, to the DP (shell) position and wait till the
reading at DPI* was almost steady.
The by-passvalve ( BVC1) was shut fully and the increase in FC, PG-C
and (shell) was noted. The CW temperatures was noted at the Heat
Exchanger inlet (T1 at TI3*) oulet (T2 at TI4*). The Heat Exchanger
pressure drop increases with flowrates was noted.
f) Pump PC2 was switch on whose suction was from tank T2. Opened fully
its manual discharge valve CV2 and by-pass valve (BVC2). The CW
flowrate {FC at FI(C*)} was note, pressure (PG-C) and shell-side
pressured drop (at DPI*).
g) BVC2 was opened fully but CV2 was shut fully so that pump PC2 now
operates only as be mixing pump for tank T2. The drop in FC, PG-C and
DP(shell)was noted. Only pump PC1 was now pumped through the Heat
Exchanger. Shut BVC1 fully maximum flow from PC1 through the Heat
Exchanger. Both the CW pumps PC2 and PC1 was swith off. The DP
Selector Switch was switch to the equalising (vertical or 0) position.
iv)
(158
(b). The discharge valve (HW) was noted, the HW pump PH was still
shut but its by-pass valve (BVH) was fully opened.
b) The by-pass(BVH) was gradually shut fully and simultaneously opened
its discharge valve (HV) sully so that the maximum HW flows into the
Heat Exchanger and return into tank T1. The HW flowrate {FH at
FI(H*)} was read, pressure (PG-H) and Tube-side pressure drop (at
DPI*). Select the DP signal to DPI* to read used the DP Selector Switch
provided at the panel, to the DP (Tube) position. Wait till the DP (Tube)
HW, FH : 25 USGPM
b) Please refered to table 1, Three (3) sets of readings were taken for every
RUN.
position.
DP (Tube) at DPI*, with the DP Selector Switch at the DP (Tube)
position.
Exchanger.
c) The HW temperature in tank T1 drops (note TIC5) was noted when the
heater input was inadequate to meet with the heat (QC) removed by CW.
Hence the second and third sets of temperature readings may be taken at
decreasing heat load, but the water temperature at tank T1 must be at
least 60 .
d) Concentrated on taking the three (3) sets of temperature, flowrate and
pressure drop readings. The pressure drop readings DP( shell) and
DP(Tube) were taken at the panel-mount DPI*, used the DP signal Selector
Switch provided. The pressure drop depends on the flowrate and not on
the temperature was noted.
e) The above procedure for other RUNS (II, III, etc) was repeated at the
following CW and HW recommended nominal flowrates. A deviation of
HW, FH
15 USGPM
10USGPM
With a good overview of the experiment plan detailed in C1, proceed with
RUN I as follows:
i)
All the pump suction valves (for PH, PC1, PC2) were checked and fully
Opened BVC2 fully but shut CV2 fully so chat that PC2 shall operated as
a back-mixing pump for r tank T2 in the next experiment. CV1 BVC1 was
opened fully. To pump CW into the Heat Exchanger in
the next
experiment used PC1 shall. Did not switch on any CW pumps (PC1, PC2)
yet.
To circulate around tank T1 via only BVH was started pump PH for HW.
The heaters was started and noted TIC5. When the HW in tank T1 was
almost 70 /158 (see TIC5), opened HV fully. The HW flowrate
was quickly adjusted to abouat 25 USGPM by regulating its by-pass
valve BVH.
CW pumps PC1 and PC2 was switched on. The CW flowrate was quickly
adjusted to about 10 USGPM by regulating the by-pass valve BVC1.
ii)
a) First set of temperature and flowrate readings was took:
CW: Temperature- inlet/oulet, TI3* (T1), TI4* (T2):
Flowrate FC at FI(C*).
HW: Temperature- inlet/oulet, TI1*(t1), Ti2* (t2):
Flowrate FH at FI(H*)
The CW inlet temperature (T1) was increased gradually was noted. The CW
oulet temperature (T2) varies together with the HW inlet/oulet tenperature
t1/t2. All the temperature and flowrate readings was important and be taken
almost simultaneously.
Readings appropriately in table 1 was recorded:
The respective inlet pressure and pressure drop of the CW and HW flow
streams was recorded. For the pressure drop readings, DP (Shell), DP
(Tube) at the panel-mount DPI*, used the DP signal Selector Switch
With the HW pump PH still running, shut fully the discharge valve HV
but opened fully the by-pass valve BVH.
v) Analyst the data by computing the QC and QH values for each of the three(3)
sets of readings for the previous RUN I whilst waited for the HW in tank T1
to be heated to about 70 /158
a) For each set of readings in RUN I, the heat load QC and QH was
calculated for the CW and the HW as per the formula in section (E)
calculation.
b) The three (3)b calculated values of QC and QH for RUN I was
compared. Select the set of readings where QC was closest to QH and
noted them down in table 1 and table 2, as the selected QC and QH
for RUN I. At the same time, noted down their corresponding
II)
Checked all the pumps (PH, PC1, PC2) were switched off
III)
IV)
The main power supply was switched off to the plant at the front of
the panel/cubical. All the pumps suction valves, discharge valves
(HV, CV1, CV2) and by-pass valves (BVH, BVC1, BVC2) was opened
RESULT
Table 1 : experimental data for RUN III
RUN III
Nominal Flow,
USGPM
Actual Flow, USGPM
SET 1
CW
FC: 10
FC: 9.8
HW
FH: 15
FH: 15.3
SET 2
CW
PG-H: 4.7
SET 3
CW
HW
15
10
15
15.3
9.9
15.2
4.5
2.5
4.5
10
Temp, C, Inlet
PG-C: 2.5
HW
9.9
DP:1454(TU 2.5
BE)
621
* Temp change, C
23.7
13.2
18.8
11.8
16.1
9.9
59.6
37.7
54.1
36.35
50.55
QC/QH
1.168
1.122
1.288
Select QC/QH
nearest to 1.0
SELECTED
NOT SELECTED
NOT SELECTED
Selected set,
194429.45
HW
FH: 10
FC: 9.8
HW
SET 3
CW
HW
10
10
10
10
9.8
10.4
9.8
10.4
2.0
2.5
2.0
FH: 10.5
Temp, C, Outlet
PG-C: 2.5
SET 2
CW
PG-H: 2.0
2.5
DP:
564(TUBE) 620
* Temp change, C
21.1
16.1
16.6
14.1
15.2
13.0
58.75
37.7
54.15
37.00
52.3
QC/QH
1.22
1.109
1.101
Select QC/QH
nearest to 1.0
NOT SELECTED
NOT SELECTED
Selected set,
SELECTED
128140.53
RUN
III
IV
QC
(BTU/hr)
QH
(BTU/hr)
0.5(QC+
QH)
(BTU/hr)
209472.9
7
134345.5
3
179385.9
2
121935.5
3
194429.4
5
128140.5
3
U
LMTD*FT
(F)
( hr BTU
. ft . )
2
20.14
504.81
25.50
332.70
RUN
III
IV
Re (s)
Re (t)
389.31
12833.12
364.46
7753.94
ho
hi
hio
Uc
Ud
Rd
BTU
BTU
BTU
BTU
( hr BTU
)
(
)
(
)
(
)
(
. ft .
hr . ft .
hr . ft .
hr . ft .
hr . ft . ) (x10 )
2
III
IV
1598.82
1620.18
721.68
604.95
571.57
479.12
421.05
263.63
504.81
332.70
-3
3.94
0.664
RUN
III
IV
Pressure Drop
Shell-side (mmH2O)
Calcula Measur Correct
ted
ed
ed
4937.73 560
65.05
4484.88 564
69.05
Tube-side (mmH2O)
Calcula Measur Correct
ted
ed
ed
89.891
1093
353.72
18.79
563.32
191.88
CALCULATION
Sample calculation
RUN III, Set 1
Heat Load and Heat Balance
FC= 9.8 USPGM
m3/Hr
4.4 USGPM
kg
FH = 15.3 USPGM
FH = 15.3 USGPM
m3/Hr
4.4 USGPM
m3
kg
FH = 7666.065Ibm/hr
CP= 1 Btu/Ibm oF
QH= FH X CP X (t1 - t2)
209472.97
179385.92
= 1.168
Calculations above were repeated for each set in RUN IV. The set which
gives the ratio of QC/QH nearest to 1 is then used for the next part of the
calculation for each respective RUN.
( 137.84114.44 )(112.2884.92)
( 137.84114.44 )
ln
(112.2884.92)
LMTD =
= 25.33
BTU
1
1
=194429.45 (
x
x
)
( hr BTU
)
hr
. ft .
31.5 ( ft ) 12.2271
504.81
BTU
hr . ft 2 .
All calculations involving LMTD and U were repeated again for the selected
set on RUN IV. The results of calculation are tabulated in table .
4
d e=
Gs
Pt
1 d
x 0.87 P t o
2
2 4
do
2
Given,
do
)
= 0.625 ins
Pt
= 0.8125 ins
Ws
= 4910.29 lbm/hr
As
= 0.029 ft2
= 1.584 lbm/ft.hr
Gs
de
De
= 0.0443/12 = 0.003642ft
Re (s)
Gt
Given,
= 0.04125 ft
Wt
= 7666.065 lbm/hr
At
= 0.02139
= 1.152 lbm/ft.hr
Gt
De
= 0.003733 ft
Cp
= 1.001 btu/lbm..F
= 1.584 lbm/ft.hr
Twall
=( 40.45+59.6)OC/2=50.030C
wall
9.85
ho
= 1598.82
( hr BTU
. ft . )
2
= 0.04125 ft
Cp
= 1.001 btu/lbm..F
= 1.152 lbm/ft.hr
hi = 721.68
( hr BTU
. ft . )
2
U c=
hio x ho
h io + ho
0.495
0.625
= 571.57
= 421.05
BTU
hr . ft 2 .
BTU
hr . ft 2 .
BTU
hr . ft 2 .
Uc
= 421.05
BTU
hr . ft 2 .
Rd
Ud
504.81421.05
504.81 X 421.05
= 3.94x 10-4
Ps =
Given,
Ps =
Ds
= ID = 6.065ins = 0.50541 ft
= 23
De
= 0.003733 ft
Gs
= 169320.34 lbm/ft2.hr
SG
= 1.01167
= 9.2550 psi
Since SG = 0.9931,
1psi = 703.72 x 0.9931 = 698.86 mmH2O
Ps = 9.2550 psi x 698.86 mmH2O / 1 psi = 4937.73 mmH2O
Correction to the measured pressure drop for Shell side, CW (RUN III, Set 1)
Pressure drop read at 560 mmH2O and flow rate CW of 9.8 USGPM,
Calculated piping pressure drop DP(s) = 494.95 mmH2O
Pt =
Given,
f x Gt 2 x L x n
2 x g x x D x t
D
= 0.04125 ft
L x n = 12
Pt =
Gt
= 358394.81 lbm/hr.ft2
SG
= 0.9893
0.00012 x 358394.812 x 12
2 x (4.17 x 108) x 61.392 x 0.04125 x 0.9893
= 0.1295 psi
Since SG = 0.98671,
1psi = 703.72 x 0.9871 = 694.14 mmH2O
Pr =
V
2 g'
V2
2g'
( )( 62.5
144 ) = 0.02 (at G = 358394.81 from figure 27 in appendices)
Where
Pr =
( )( )( 62.5
144 )
4n
SG
4 (2)
( 0.98671
)x
mmH2O
Pt = P' t + P r
Correction to the measured pressure drop for Tube side, HW (RUN III, Set 1)
Pressure drop read at 1093 mmH2O and flow rate CW of 15.3USGPM,
Calculated piping pressure drop, DP (t) = 739.28 mmH2O
DISCUSSION
The objective of the experiment is to evaluate and study the
performance of shell and tube heat exchanger at various operating condition.
Besides that, evaluate and study the heat balance, LMTD and overall heat
transfer coefficient. We need also calculate Reynoldss number at the shell
and tube heat exchanger and measure and determine the shell and tube side
pressure drop. During the experiment, we carried out Run III and Run IV
experiment. Every run consist of three set of data which need to be
considered.
Firstly, set up equipment according to the variable we need to
investigate which are pressure and temperature. The ideal temperature for
this heat exchanger is between 50
C and 70
when the ideal temperature is achieve. For run III the flow rate is set to the
10 USGPM
experiment was run until the value of flow rate was stable. Then, all the data
was record for set 1.The experiment were repeated three times to get best
result. The calculation was made from data recorded to identify which set of
Run III have better result.
The heat load was calculated for all sets of data. The ratio of Q C/QH
which nearest to 1.0 is selected to continue the calculation. Then, for RUN III,
set 1 is selected. The QC is 209472.97 Btu/hr ,QH is 179385.92 Btu/hr and
0.5(QC+QH) is 194429.45 Btu/hr. Next, the corrected LMTD was 20.14 0F
( hr BTU
. ft . )
2
. The
Reynolds number for shell is 389.31 and for tube is 12833.12.Other than
( hr BTU
. ft . )
2
( hr BTU
. ft . )
2
and 571.57
( hr BTU
. ft . )
( hr BTU
. ft . )
and UD is 504.8
, 721.68
( hr BTU
. ft . ) .The value of R is 3.94 x x10
2
-3
.Next,
for the pressure drop at shell-side the calculated value, measured and
corrected are 4973.73 mmH2O,560 mmH2O and 65.05 mmH2O respectively.
For the pressure drop at tube-side the calculated value, measured and
corrected are 89.891 mmH2O,1093 mmH2O and 353.72mmH2O respectively.
For RUN IV, the flow rate was set up to 10 USGPM for both cold water
(CW) and hot water (HW).The instrument is run for a while until the ideal
temperature is achieved. For RUN IV, set 3 is selected. This is because the
ratio of QC/QH is nearest to 1.0 which is 1.101. The QC is 134345.53 Btu/hr ,QH
is 121935.53 Btu/hr and 0.5(QC+QH) is 128140.53 Btu/hr. Next, the
corrected LMTD was 25.5 0F while the overall heat transfer coefficient is
332.7
BTU
hr . ft 2 .
7753.94.Other than that, for part III the h o, hi and hi0 are 1620.18
604.95
( hr BTU
. ft . )
2
and 479.12
( hrBTU
. ft . )
2
BTU
hr . ft 2 .
),
263.63
( hr BTU
. ft . )
2
and UD is 332.70
( hr BTU
. ft . )
2
x10-3 .Next, for the pressure drop at shell-side the calculated value,
measured and corrected are 4484.88mmH 2O,564mmH2O and 69.05 mmH2O
respectively. For the pressure drop at tube-side the calculated value,
measured and corrected are 18.79mmH 2O,563.32mmH2O and 191.88mmH2O
respectively.
From the result above, the pressure drop depends on the flow rate not
the temperature. As we can see that the pressure drop for Run III which used
10USGPM and 15USGPM was higher than pressure at Run IV which used
10USGPM. From the calculation, we conclude that the number of QC is
decreasing from Run III to Run IV and same pattern goes to QH and
0.5(QC+QH).Other than that,U is also decreasing from RUN III to Run IV. The
overall heat transfer coefficient, U, Reynolds number and flow rates of hot
water are also decreasing from Run III to Run IV.
CONCLUSION
The objective is achieved for Run III and Run IV. Based on evaluate and
study the performance of shell and tube heat exchanger at various operating
condition was determined. Besides that, the heat balance, LMTD and overall
heat transfer coefficient also determined. The Reynoldss number at the shell
and tube heat exchanger was identified. Moreover, the shell and tube side
pressure drop also determined. From the result , the pressure drop depends
on the flow rate not the temperature. As we can see that the pressure drop
for Run III which used 10USGPM and 15USGPM was higher than pressure at
Run IV which used 10USGPM. From the calculation, we conclude that the
number of QC is decreasing from Run III to Run IV and same pattern goes to
QH and 0.5(QC+QH).Other than that,U is also decreasing from RUN III to Run
IV. The overall heat transfer coefficient, U, Reynolds number and flow rates
of hot water are also decreasing from Run III to Run IV.
RECOMMENDATION
The water to the tube side should be the first and last flow rate to be
turned on.
The steam should be turned on only after the water is flowing through
the tube side
and the water should be turned on only after the steam has been
turned on.
Fully drain system after each use of water on tube side and steam
condensate on
shell side in order to avoid corrosion build-up during down-times.
REFERENCE
APPENDIX
SG
(1.0 at
60F)
71.1
65
0.985
60
54.5
0.9872
48.9
0.9901
DENSITY
lbm/ft3
DENSITY
lbm/USG
61.00
8.156
61.30
8.182
61.38
8.207
8.227
61.71
8.253
61.94
8.289
62.06
8.296
48
40
35
0.995
VISCOSITY
lbm/ft. sec
2.6947 x
10-4
2.9272 x
10-4
3.1503 x
10-4
3.430 x 104
3.7565 x
10-4
3.8223 x
10-4
4.4083 x
10-4
4.8572 x
10-4
HEAT
CAPACI
TY
BTU/lb
m. F
THERMAL
CONDUCTIV
ITY
BTU/hr.ft2.
F/ft
0.3840
1.00
0.3830
0.3790
0.3710
0.999
0.3605