Thesis Abstract

Abstract
Shell and tube heat exchangers are widely used in various industries for efficient heat transfer between two fluids. This research project focuses on the design and operation of a shell and tube heat exchanger, aiming to optimize its performance and energy efficiency. The design aspect involves determining the appropriate dimensions, materials, and configuration of the heat exchanger to meet specific heat transfer requirements. Factors such as fluid properties, flow rates, temperature ranges, and pressure drop limitations are considered during the design process to ensure optimal performance. The operation of the heat exchanger is crucial for maintaining efficient heat transfer between the two fluids. Proper installation, monitoring, and maintenance are essential to prevent fouling, corrosion, and other issues that can affect the heat exchanger's performance. Additionally, the project explores the use of advanced technologies such as heat exchanger simulation software and sensors for real-time monitoring and control of the heat exchanger operation. Furthermore, the research project investigates different heat transfer enhancement techniques that can be applied to the shell and tube heat exchanger to improve its efficiency. These techniques include the use of extended surface tubes, surface treatments, and flow control mechanisms to enhance heat transfer rates and reduce energy consumption. The project also considers the environmental impact of the heat exchanger operation and explores ways to make the system more sustainable. This includes optimizing the design for energy efficiency, using eco-friendly materials, and implementing waste heat recovery strategies to minimize energy waste and reduce greenhouse gas emissions. Overall, this research project provides valuable insights into the design and operation of shell and tube heat exchangers, with a focus on improving performance, energy efficiency, and sustainability. The findings of this study can benefit industries that rely on heat exchangers for various processes, helping them optimize their systems for better performance and reduced environmental impact.

Thesis Overview

INTRODUCTION

The most common type of heat exchanger used in industry contains a number of parallel tubes enclosed in a shell and is thus called a shell and tube heat exchanger. These heat exchangers are employed when a process required large quantities of fluid to be heated or cooled. Due to their compact design, these heat exchangers contain a large amount of heat transfer area and also provide a high degree of heat transfer efficiency.

Over the years, many different types of shell and tube heat exchangers, have been designed to meet various process requirements. In the industry today, heat exchangers are most often designed with the aid of software program. Given the required specifications for a heat exchanger, these simulators perform the appropriate calculations.

In this project, we try to use a computer approach in designing a shell and tube heat exchanger. We started by designing an algorithm that covers the chemical engineering design such as the estimation of fluid and material properties, film and overall heat transfer coefficient, exchanger surface, tube layout and pressure drop. It also covers the mechanical engineering design of calculating the shell and channel thickness, shell cover thickness, channel cover thickness e.t.c.
These algorithm was translated into a program using a microsoft visual basic 6.0, an object oriented computer programming language.

With this program, the computer takes over and automatically per for all the complex computations with little or no human effort and gives an output which is the design information needed.