Thesis Abstract

Abstract
Shell and tube heat exchangers are widely used in various industrial applications 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 efficiency while considering factors such as pressure drop, temperature profiles, and material selection. The design process involves determining the heat duty required for the exchanger based on the flow rates and temperature differences of the hot and cold fluids. Various design parameters, such as the number of tubes, tube diameter, tube length, and shell diameter, are considered to meet the specified heat transfer requirements. Computer-aided design software is utilized to simulate the thermal performance of the heat exchanger and optimize its configuration. The operation of the shell and tube heat exchanger is crucial for maintaining efficient heat transfer. Proper fluid flow management, including the arrangement of baffles inside the shell, helps enhance heat transfer by promoting turbulence and reducing fouling. Monitoring the temperature profiles at different points along the heat exchanger allows for adjustments to optimize performance and ensure uniform heat distribution. Furthermore, material selection for the heat exchanger components is essential to withstand the operating conditions and prevent corrosion or degradation over time. Factors such as fluid properties, temperature, pressure, and compatibility with the process fluids are considered when selecting materials for the tubes, shell, and tube sheets to ensure the long-term reliability of the heat exchanger. Overall, the design and operation of a shell and tube heat exchanger require a comprehensive understanding of heat transfer principles, fluid dynamics, and thermodynamics. By optimizing the design parameters, fluid flow patterns, and material selection, the efficiency and performance of the heat exchanger can be maximized to meet the desired heat transfer requirements in industrial processes. This research project aims to provide valuable insights into the design and operation considerations for shell and tube heat exchangers to enhance their effectiveness in various industrial applications.

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.