Thesis Abstract

Abstract
Shell and tube heat exchangers are widely used in various industries for transferring heat 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 efficiency. The project includes the theoretical analysis of heat transfer principles, fluid flow dynamics, and material selection to ensure the proper functioning of the heat exchanger. The design process involves determining the heat duty required, selecting appropriate materials for the tubes and shell, calculating the required surface area for heat transfer, and deciding on the tube layout and baffle configuration. Various design considerations such as pressure drop, fouling factor, and overall heat transfer coefficient are taken into account to improve the heat exchanger's effectiveness. Furthermore, the project explores the operational aspects of the shell and tube heat exchanger, including startup and shutdown procedures, maintenance practices, and performance monitoring. Proper operation and maintenance are crucial for ensuring the longevity and efficiency of the heat exchanger. Experimental validation of the design is conducted to compare the theoretical calculations with the actual performance of the heat exchanger. This involves measuring parameters such as inlet and outlet temperatures, flow rates, and pressure drops to evaluate the heat exchanger's effectiveness in transferring heat between the two fluids. The results of the experimental testing are analyzed to assess the heat exchanger's thermal efficiency, heat transfer rate, and overall performance. Any discrepancies between the theoretical and experimental results are investigated to identify potential areas for improvement in the design and operation of the heat exchanger. Overall, this research project provides valuable insights into the design and operation of shell and tube heat exchangers, highlighting the importance of proper design considerations, material selection, and operational practices in maximizing heat transfer efficiency. By optimizing the performance of the heat exchanger, industries can enhance their energy efficiency, reduce operating costs, and improve overall process productivity.

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.