Objective:

The use of spiral tube alternative to parallel tube increases the effectiveness by 10%.The fluid
flowing through the tube will have to pass through an helix angle of 30˚through turns and
increases the fluid flow timing inside the shell which causes the heat transfer rate to increase
because the cold water has enough time to absorb the heat from the hot fluid. Thus the heat
transfer effectiveness is increased.

Introduction:
Heat exchangers are one of the mostly used equipment in the process industries. Heat
exchangers are used to transfer heat between two process streams. One can realize their usage
that any process which involve cooling, heating, condensation, boiling or evaporation will
require a heat exchanger for these purpose. Process fluids, usually are heated or cooled before
the process or undergo a phase change. Different heat exchangers are named according to their
application. For example, heat exchangers being used to condense are known as condensers,
similarly heat exchanger for boiling purposes are called boilers. Performance and efficiency of
heat exchangers are measured through the amount of heat transfer using least area of heat
transfer and pressure drop. A more better presentation of its efficiency is done by calculating
over all heat transfer coefficient. Pressure drop and area required for a certain amount of heat
transfer, provides an insight about the capital cost and power requirements (Running cost)
of a heat exchanger. Usually, there is lots of literature and theories to design a heat exchanger
according to the requirements.

Heat exchangers are of two types:-

Where both media between which heat is exchanged are in direct contact with each other is
Direct contact heat exchanger.
Where both media are separated by a wall through which heat is transferred so that they never
mix, Indirect contact heat exchanger.

A typical heat exchanger, usually for higher pressure applications up to 552 bars, is the shell and
tube heat exchanger. Shell and tube type heat exchanger, indirect contact type heat exchanger. It
consists of a series of tubes, through which one of the fluids runs. The shell is the container for
the shell fluid. Generally, it is cylindrical in shape with a circular cross section, although shells
of different shape are used in specific applications. For this particular study shell is considered,
which is generally a one pass shell. A shell is the most commonly used due to its low cost and
simplicity, and has the highest log-mean temperature-difference (LMTD) correction factor.
Although the tubes may have single or multiple passes, there is one pass on the shell side, while
the other fluid flows within the shell over the tubes to be heated or cooled. The tube side and
shell side fluids are separated by a tube sheet.

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 Baffles are used to support the tubes for structural rigidity, preventing tube vibration and
sagging and to divert the flow across the bundle to obtain a higher heat transfer coefficient.
Baffle spacing (B) is the centre line distance between two adjacent baffles, Baffle is provided
with a cut (Bc) which is expressed as the percentage of the segment height to shell inside
diameter. Baffle cut can vary between 15% and 45% of the shell inside diameter. In the present
study 36% baffle cut (Bc) is considered. In general, conventional shell and tube heat exchangers
result in high shell-side pressure drop and formation of recirculation zones near the baffles. Most
of the researches now a day are carried on helical baffles, which give better performance then
single segmental baffles but they involve high manufacturing cost, installation cost and
maintenance cost. The effectiveness and cost are two important parameters in heat exchanger
design. So, In order to improve the thermal performance at a reasonable cost of the Shell and
tube heat exchanger, baffles in the present study are provided with some inclination in order to
maintain a reasonable pressure drop across the exchanger. The complexity with experimental
techniques involves quantitative description of flow phenomena using measurements dealing
with one quantity at a time for a limited range of problem and operating conditions.
Computational Fluid Dynamics is now an established industrial design tool, offering obvious
advantages. In this study, a full 360° CFD model of shell and tube heat exchanger is considered.
By modelling the geometry as accurately as possible, the flow structure and the
temperature distribution inside the shell are obtained.

Fig1- Simple Shell & Tube Heat Exchanger

Classification of Heat Exchanger:

Heat exchanger may be classified according to the following main criteria.
1. Recuperators and Regenerators.
2. Transfer process: Direct contact and Indirect contact.

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3. Geometry of construction: Tubes, plates and extended surfaces.
4. Heat transfer mechanisms: single phase and two phase.
5. Flow arrangements: parallel, counter and cross flows.

Large ratio of heat transfer area to volume is provided by the shell and tube heat exchanger and
weight and they can be easily cleaned. Great flexibility is always provided by the shell and tube
heat excahngers to meet almost any service requirement. Shell and tube heat exchanger can be
designed for high pressure relative to the environment and high pressure difference between the
fluid streams.

Figure 2- Classification of Heat Exchanger

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Components Required:
• Heater
• Valves
• Hose pipes
• Shell
• Helical Tube
• Containers
• Bolts and nuts
•Thermometers

Material selection:

Shell Material: Sheet Metal (MS) Sheet metal/PVC pipe is thinner and flat. It’s tougher and easy
to weldor joint. It has good electrical conductivity and less brittle and flexibility. Steel cools as it
is rolled, with a typical rolling finish temperature of around 750°C.
Tube material: Copper (Cu) Shape: Spiral type Copper has good Thermal Conductivity and it is
electrically conductive. It is corrosion resistance and has bio fouling resistance capability. It has
good machinability and it can retend its mechanical and electrical properties at the cryogenic
temperature. The thermal conductivity of copper is 385W/mK.

Methodology:
Fabrication of this type heat exchanger was a challenging process and although we have stated
our work as follows: After the materials were purchased, as per the design parameters the
dimensions on the materials have to make. Initially we marked the dimensions of the shell on the
sheet metal. Then the sheet metal is cutted to that shape. It’s then rolled into a cylindrical shape
of diameter 200mm. To join the ends the TIG welding is done. The shell of the heat exchanger is
ready to process. The copper tube which is of parallel type has to be folded to a helical shape
which is considered to be tedious process. The spiral tube is placed by the supported enclosures
on the both sides of the shell. The holes for inlet and outlet passage were also provided. The
problems were faced in the bending of the spiral copper tube where the projections created due to
improper bending may cause the blockage of water inside the tube. A heater is provided to raise
the temperature of the hot water and a pump is provide to circulate the water inside the tube and
it is also coupled into the cold water supply circulation.

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 Figure 3 –Helical Tube
Flow calculation Methodology:
Shell and tube heat exchangers are designed normally by using either Kern’s method or Bell-
Delaware method. Kern’s method is mostly used for the preliminary design and provides
conservative results whereas, the Bell-Delaware method is more accurate method and can
provide detailed results. It can predict heat transfer coefficient with better accuracy. In this paper
we have designed a simple counter flow shell and spiral tube type heat exchanger to cool the
water from 85 to 55 by using water at room temperature by using Kern’s method. 1. First we
consider the energy balance to find out the values of some unknown temperature values. The
energy balance equation may be given as:
1. Q = m1c1(T1-T2) =m2c2(T2-T1)
2. Then we consider the LMTD expression to find its value:
LMTD or Δ Tm= (ΔT1 – ΔT2) / ln(ΔT1/ΔT2) Where ΔT1= T1-T2 , ΔT2= T2-T1
3.Then by using the amount of heat transfer formula we can get the heat transfer quantity:
Q=UA(ΔTm)
4. Then we intended to find the Effectiveness of heat transfer by the following:
Δ = Q/(Cmin*(T1-T2).

Working:
A heat exchanger is a device that allows heat from a fluid (a liquid or a gas) to pass to a second
fluid (another liquid or gas) without the two fluids having to mix together or come into direct
contact. If that's not completely clear, consider this. In theory, we could get the heat from the gas
jets just by throwing cold water onto them, but then the flames would go out! The essential
principle of a heat exchanger is that it transfers the heat without transferring the fluid that carries
the heat.
Process heat transfer with conventional shell and tube heat exchangers is familiar to many
engineers in many industries. Their use and performance is well-documented. Helically coiled
heat exchangers, although they have been around for many years, are not as well known.

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Helically coiled exchangers offer certain advantages. Compact size provides a distinct benefit.
Higher film coefficients—the rate at which heat is transferred through a wall from one fluid to
another—and more effective use of available pressure drop result in efficient and less-expensive
designs. True counter-current flow fully utilizes available LMTD (logarithmic mean temperature
difference). Helical geometry permits handling of high temperatures and extreme temperature
differentials without high induced stresses or costly expansion joints. High-pressure capability
and the ability to fully clean the service-fluid flow area add to the exchanger’s advantages.
Although various configurations are available, the basic and most common design consists of a
series of stacked helically coiled tubes. The tube ends are connected to manifolds, which act as
fluid entry and exit locations. The tube bundle is constructed of a number of tubes stacked atop
each other, and the entire bundle is placed inside a casing, or shell. Multiple pass design, which
increases tubeside velocity, thereby increasing the heat transfer rate. With this configuration,
there is an increase in tubeside pressure drop.
• Vaporizer design for liquid vaporization and droplet disengagement.
• Condenser design, which comes in three typical configurations. Each depends on the process
and vessel’s discharge connection.
• Weld-seal designs for completely welded units often are specified when cross-contamination
must be prevented, or fluids are hazardous or incompatible with gasket materials.
As with any heat exchanger, the flow rate, allowable pressure, physical properties of the fluid,
and construction material control final design.
No matter the design, helical heat exchangers offer several distinct advantages to the user.
High film coefficients are achieved on both the coil and casing side. The helical flow path
imparts higher shear rates and turbulence at a given pressure drop, which can result in film
coefficients
Bundle for a water vaporizer in a supercritical water-extraction process up to 40% higher than
those achieved with many comparable shell and tube units. Departure from laminar floss and
fully developed turbulent flow occur at lower Reynolds numbers.
The 100% counter-current flow allows full use of the available LMTD and makes temperature
cross—when the hot side outlet temperature is cooled below the cool side outlet temperature—
possible without multiple units in series. The flow geometry of a helical unit is such that a
temperature cross is managed within a single unit. This is possible because 100% counter-current
flow permits closer temperature approaches and improved heat recovery.
Cleaning the casing-side flow area is easily managed. The casing can be unbolted and the entire
bundle assembly removed for cleaning, inspection or replacement. Fully welded designs
(weldseal) though, do not have this feature.
The coil arrangement’s compactness also provides advantages, because the exchanger requires
minimal floor space.
The heat exchanger’s spring-like coil eliminates thermal expansion and thermal shock problems
that often occur during startup or during cryogenic or high-temperature service.

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High operating pressures are easily handled on the coilside, and without the need for the
tubesheet of a shell and tube unit, required thicknesses are minimal, even at high operating
pressures. Pressures exceeding 10,000 psi are possible.
The high shear stresses and induced turbulence of helically coiled exchangers reduce the
tendency for fouling. This results in longer operating cycles between scheduled cleaning
intervals. Additionally, the lower fouling tendency permits the use of less conservative safety
margins at the initial design Stage. Conventional designs allow casing-side access for cleaning
and inspection.
Economical unit selection is possible due to approved film coefficients, full use of available
LMTD and minimal required thicknesses.

Fig-4 Type of shell

Cross Baffles:

Baffles serve two purposes:

• Divert (direct) the flow across the bundle to obtain a higher heat transfer coefficient.
• Support the tubes for structural rigidity, preventing tube vibration and sagging.
• When the tube bundle employs baffles,
• The heat transfer coefficient is higher than the coefficient for undisturbed flow around
tubes without baffles.
• For a baffled heat exchanger the higher heat transfer coefficients result from the
increased turbulence.
• The velocity of fluid fluctuates because of the constricted area between adjacent tubes
across the bundle.

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Types of Baffle Plates: Segmental Cut Baffles:

• The single and double segmental baffles are most frequently used.
• They divert the flow most effectively across the tubes.
• The baffle spacing must be chosen with care.
• Optimal baffle spacing is somewhere between 40% - 60% of the shell diameter.
• Baffle cut of 25%-35% is usually recommended.

Figure 5- Type Baffle Plates

Application :

You can see heat exchangers in all kinds of places, usually working to heat or cool buildings or
helping engines and machines to work more efficiently. Refrigerators and air-conditioners, for
example, use heat exchangers in the opposite way from central heating systems: they remove
heat from a compartment or room where it's not wanted and pump it away in a fluid to some
other place where it can be dumped out of the way.
In power plants or engines, exhaust gases often contain heat that's heading uselessly away into
the open air. That's a waste of energy and something a heat exchanger can certainly reduce
(though not eliminate entirely—some heat is always going to be lost). The way to solve this
problem is with heat exchangers positioned inside the exhaust tail pipes or smokestacks. As the
hot exhaust gases drift upward, they brush past copper fins with water flowing through them.
The water carries the heat away, back into the plant. There, it might be recycled directly, maybe
warming the cold gases that feed into the engine or furnace, saving the energy that would
otherwise be needed to heat them up. Or it could be put to some other good use, for example,
heating an office near the smokestack.
In buses, fluid used to cool down the diesel engine is often passed through a heat exchanger and
the heat it reclaims is used to warm cold air from outside that is pumped up from the floor of the
passenger compartment. That saves the need for having additional, wasteful electric heaters
inside the bus. A car radiator is another kind of heat exchanger. Water that cools the engine
flows through the radiator, which has lots of parallel, aluminum fins open to the air. As the car
drives along, cold air blowing past the radiator removes some of the heat, cooling the water and

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heating the air and keeping the engine working efficiently. The radiator's waste heat is used to
heat the passenger compartment, just like on a bus.

Fig 6- Application

Work completed till date

 Arrangement of tubes
 Arrangement of shells and motor
 Arrangement of hot water rod
Work to be completed
 Assemble the parts of the heat exchanger
 Testing of the heat exchnager

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 References
[1]. K.S. Bharuka, D.Y. Kasture(1984), Flow through a helically coiled annulus, Applied Science
Research, 41, 55–67.

[2]. Dawit Bogale(2014) , AJER, e-ISSN : 2320-0847 p-ISSN : 2320-0936 Volume-03, Issue-
10, pp-99109 (Design and Development of Shell and Tube Heat Exchanger for Harar Brewery
Company Pasteurizer Application (Mechanical and Thermal Design).

[3]. Durgesh Bhatt, Priyanka M Javhar,IJSR,ISSN(2011):23197064,researh paper on Shell and

Tube Heat Exchanger Performance Analysis.

[4]. Kevin.L.Luthersford conducted a experiment to increase the heat exchanger performance It

may be feasible to consider enhanced heat transfer through the use of finned tubes, inserts,
twisted tubes, or modified baffles.(1998) .

[5]. Ramesh K shah and Dusan P. Sekulic(2013), “Fundamental of heat exchanger design”,
Rochester Institute of Technology, Rochester New York.

[6]. Sandeep K. Patel, Professor Alkesh M. Mavani (2012)ISSN2249–8974IJAERS/Vol. II/ Issue

I/130135, Research Paper on Shell and tube heat exchanger thermal design with optimization of
mass flow rate and baffle spacing.

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