Construction of sheel and tube heat exchanger

Project Abstract

The construction of shell and tube heat exchangers involves the design and assembly of a key component in various industrial processes that require efficient heat transfer. These heat exchangers consist of a cylindrical shell with numerous tubes running through it, allowing for the exchange of heat between two fluid streams. The design and construction of shell and tube heat exchangers require careful consideration of factors such as heat transfer requirements, fluid properties, operating conditions, and material selection. The construction process typically involves several stages, starting with the design phase where the heat exchanger size, layout, and tube configuration are determined based on the specific application requirements. Material selection is a crucial step in the construction process, considering factors such as corrosion resistance, thermal conductivity, and cost-effectiveness. Common materials used for shell and tube heat exchangers include stainless steel, carbon steel, and copper alloys. The assembly of shell and tube heat exchangers involves the fabrication of the shell, tube bundles, baffles, and tube sheets, followed by the welding or brazing of these components to ensure a leak-tight construction. Proper tube sealing is essential to prevent fluid leakage and ensure efficient heat transfer between the two fluid streams. Additionally, the construction process includes the installation of headers, nozzles, and other accessories to facilitate the connection of the heat exchanger to the process system. Quality control measures are essential throughout the construction process to ensure the reliability and performance of the shell and tube heat exchanger. Non-destructive testing methods such as pressure testing, visual inspection, and ultrasonic testing are commonly used to detect any defects or imperfections in the construction, ensuring the integrity of the heat exchanger. In conclusion, the construction of shell and tube heat exchangers is a critical aspect of various industrial applications where efficient heat transfer is essential. Careful consideration of design, material selection, assembly processes, and quality control measures is necessary to ensure the reliability, performance, and safety of these heat exchangers in operation. The successful construction of shell and tube heat exchangers requires a comprehensive understanding of thermal dynamics, fluid mechanics, and materials engineering to meet the specific heat transfer requirements of each application.

Project Overview

<p> </p><p><strong>INTRODUCTION</strong></p><p>In large industrial processes, it is necessary to transfer heat between the system and its surrounding and the device whose primary objective to do it efficiently and effectively is the heat exchanger.</p><p>Therefore heat transfer is defined as the rate of exchange of heat between one body (hot) and another cold.</p><p>The most important aim in the chemical engineering sector of any plant is to control the flow of thermal energy between two terminals. It there existing temperature gradient of change.</p><p>In industrial process, the heat exchange is a very important unit in all the processing industries that their design has been highly developed. Designers of heat exchanger must be constantly aware of the difference between the idealized conditions for and under which basic knowledge was obtained and the real conditions of the mechanical expressions of their design and it’s environment.</p><p>The design must satisfy process operational requirement such as availability and maintainability.</p><p>Heat transfer or thermo-kinetics is another chapter of the theoretical fundamentals of heat engineering dealing with the processes of heat propagation. In nature and engineering, the most diverce process of heat propagation are observed and also heat flow from bodies (or their section) of a lower temperature. During the process of heat transfer, from one body to another heat flow continues till their temperature became equal be come to equilibrium state of temperature.</p><p><strong>MODES OF HEAT TRANSFER</strong></p><p>Heat is transferred by conduction, convection and thermal radiation. In practice, heat is usually transmitted by two or all the three modes of heat transfer concurrently.</p><p><strong>CONDUCTION</strong></p><p>Heat conduction of simply conduction is the transfer of heat by a direct contact between the elementary particles of a body, Viz molecules, atoms, free electrons, when the bodies involved are at rest.</p><p>Pure conduction takes place in opaque or non transpired solid.</p><p>In goses, conduction occurs due to random motion of the molecules (the diffuse from high concentration region to lower region. In this made of heat transfer, it is very common with metals and thus call for high thermal conductivity. Also the heat transfer per unit area is proportional to normal temperature gradient given as:</p><p>Q &nbsp; &nbsp; &nbsp; = &nbsp; &nbsp; &nbsp; dt &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp;= &nbsp; &nbsp; &nbsp; (1)</p><p>A &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp;dx</p><p>Fourier postulated an expression for heat transferred by conduction called fouriers law gives by:</p><p>Q &nbsp; &nbsp; &nbsp; = &nbsp; &nbsp; &nbsp; KA dt &nbsp; &nbsp; &nbsp; &nbsp; = &nbsp; &nbsp; &nbsp; (2)</p><p>Dx</p><p>Where Q rate of flow of heat J/S or welts</p><p>K &nbsp; &nbsp; &nbsp; = &nbsp; &nbsp; &nbsp; Fourier’s constant</p><p>A &nbsp; &nbsp; &nbsp; = &nbsp; &nbsp; &nbsp; Area of heat transfer perpendicular to the direction of heat flow (M2).</p><p>dt/dx temperature gradient (0C or K &nbsp;).</p><p><strong>CONVECTION</strong></p><p>This involves the transfer of heat from one body to another by the mobile particles of liquid, gas or coarse solids during their relative motion in space. Convection heat transfer can be illustrated by the transfer of heat by heated air from a stove to the upper layers of the room air. Convection consist of forced and natural convection. Forced convection is widely used in chemical processing industries. The expression below shows heat transfer by convection.</p><p>Q &nbsp; &nbsp; &nbsp; = &nbsp; &nbsp; &nbsp; KA (Ti – To) &nbsp; &nbsp; &nbsp; &nbsp;= &nbsp; &nbsp; &nbsp; (3)</p><p>= &nbsp; &nbsp; &nbsp; hA (Ti – To) &nbsp; &nbsp; &nbsp; &nbsp; = &nbsp; &nbsp; &nbsp; (4)</p><p>where h k/x</p><p>Q &nbsp; &nbsp; &nbsp; = &nbsp; &nbsp; &nbsp; heat transfer rate J/S or welts</p><p>K &nbsp; &nbsp; &nbsp; = &nbsp; &nbsp; &nbsp; Proportionality constant</p><p>X &nbsp; &nbsp; &nbsp; = &nbsp; &nbsp; &nbsp; Distance over which heat is transferred (m)</p><p>A &nbsp; &nbsp; &nbsp; = &nbsp; &nbsp; &nbsp; Area (M2)</p><p>Ti and To &nbsp; &nbsp;= &nbsp; &nbsp; &nbsp; Temperature at different point (0C or K)</p><p>h &nbsp; &nbsp; &nbsp; &nbsp;= &nbsp; &nbsp; &nbsp; Convection heat transfer co-efficient (w/m2k)</p><p><strong>RADIATION</strong></p><p>This is a process of heat transferred by electromagnetic waves through a machines which is transparent to thermal radiation. During this process, a fraction of the thermal energy of a hot body is converted into radiant energy which, when encountering an opaque body again turns partly into heat.</p><p>From the second law of thermodynamics, STEFANBOLTZ MANU prop</p><p>Proposed that heat is directly proportional to the fourth power of the temperature and the surface area.</p><p>Thus given as:</p><p>Q &nbsp; &nbsp; &nbsp; = &nbsp; &nbsp; &nbsp; såAT – 4 &nbsp; &nbsp; &nbsp;= &nbsp; &nbsp; &nbsp; (5)</p><p>Where &nbsp;s &nbsp; &nbsp; = &nbsp; &nbsp; &nbsp; Stefan – Boltman constant</p><p>å &nbsp; &nbsp; &nbsp; = &nbsp; &nbsp; &nbsp; Emissivity surface</p><p>T &nbsp; &nbsp; &nbsp; = &nbsp; &nbsp; &nbsp; Absolute temperature (0C or K)</p><p>A &nbsp; &nbsp; &nbsp; = &nbsp; &nbsp; &nbsp; Area of heat transfer (M2)</p><p>Q &nbsp; &nbsp; &nbsp; = &nbsp; &nbsp; &nbsp; Heat transfer rate J/S or welt</p><p><strong>HEAT TRANSFER EQUIPMENT</strong></p><p>There are various types of heat exchange equipment generally defined by the function it performs in a chemical industry. Generally, heat exchange is the equipment whose primary objective is to transfer heat energy between two fluids. These equipment are classified into three categories mainly:-</p><p>(a) &nbsp; &nbsp; Regenerators</p><p>(b) &nbsp; &nbsp; Open type heat exchangers and</p><p>(c) &nbsp; &nbsp; &nbsp;Closed type bread exchanger or recuperations</p><p><strong>a. &nbsp; &nbsp; &nbsp; REGENERATORS</strong></p><p>These are heat exchangers in which the hot and cold fluid flow through the same space alternatively with a little physical mixing as possible occurring between the two streams. The amount of heat transferred depends on the fluid and flow properties of the fluid streams as well as the geometry and thermal properties of the surface.</p><p><strong>b. &nbsp; &nbsp; &nbsp;OPEN TYPE HEAT EXCHANGERS</strong></p><p>These are devices where by fluid stream flow into an open chamber and there the complete mixing occurs. Hot and cold fluid enter the exchanger separately and will at the other end leaves as single fluid stream.</p><p><strong>c. &nbsp; &nbsp; &nbsp; RECUPERATORS OR CLOSED TYPE HEAT EXCHANGERS</strong></p><p>They are those in which the heat transfer occurs between the two fluid stream that do not physical contact each other. The fluid streams involved are separated from one another by a tube wall or a pipe. Heat transfer occurs by convection from the hot fluid to the solid surface, by conduction through the solid surface and then by convection through solid surface to the cooler fluid.</p><p>Another classification is based on relative flow direction of the two fluid streams. They include:-</p><p><strong>i. &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; </strong><strong>Parallel Flow:</strong>&nbsp;When the fluid stream flow in the same direction.</p><p><strong>ii. &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; </strong><strong>Counter Current Flow: </strong>The fluid streams flow in opposite direction.</p><p><strong>iii. &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp;</strong><strong>Cross Flow:</strong>&nbsp;If the fluid stream flow at right angle to one another.</p><p>The other classification is based on tube construction:-</p><p>i. &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; Double – pipe heat exchanger</p><p>ii. &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; Shell and tube heat exchanger</p><p>iii. &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp;Extended – surface exchangers</p><p>iv. &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp;Spiral plate exchanger</p><p>v. &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; Graphic block heat exchangers</p><p>vi. &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp; &nbsp;Scrap surface exchanger.</p> <br><p></p>