Thesis Abstract

Abstract
Shell and tube heat exchangers are widely used in various industrial processes for efficient heat transfer between two fluids. This research project focuses on the design and operation of a shell and tube heat exchanger to optimize heat transfer performance while considering factors such as pressure drop, material selection, and overall efficiency. The design aspect involves determining the appropriate dimensions of the heat exchanger, including the tube length, diameter, and arrangement within the shell to maximize heat transfer. Factors such as the heat exchanger configuration, tube layout, and baffle design are critical in achieving the desired heat transfer rate. Additionally, the selection of materials for the shell and tubes is crucial to withstand operating conditions and prevent corrosion or fouling, which can reduce heat transfer efficiency. The operation of the shell and tube heat exchanger involves understanding the flow patterns of the two fluids, which can be co-current or counter-current. The choice of flow arrangement significantly impacts the overall heat transfer coefficient and effectiveness of the heat exchanger. Proper monitoring of inlet and outlet temperatures, flow rates, and pressure drops is essential to ensure efficient operation and troubleshoot any issues that may arise during the heat exchange process. The thermal performance of the heat exchanger is evaluated by calculating the overall heat transfer coefficient, heat transfer area, and effectiveness of the heat exchanger. These parameters help in assessing the efficiency of the heat exchanger design and identifying areas for improvement. Computational fluid dynamics (CFD) simulations can also be utilized to optimize the heat exchanger performance by analyzing flow distribution, temperature gradients, and pressure profiles within the exchanger. In conclusion, the design and operation of a shell and tube heat exchanger require a comprehensive understanding of heat transfer principles, fluid dynamics, and material selection. By optimizing the design parameters and operational conditions, the heat exchanger can achieve high thermal efficiency, minimize energy consumption, and enhance the overall performance of industrial processes that rely on heat exchange mechanisms. Further research can explore advanced heat exchanger designs, innovative materials, and improved operational strategies to meet the growing demands for sustainable and energy-efficient heat transfer solutions in various industries.

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 unto a program using a micro soft 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.