Design and Thermal Analysis of Shell and Tube type Heat Exchanger
Heat exchangers have been observed from the smallest electronic devices to the space shuttles. It transfers heat from one medium to another by means of direct or indirect contact. There are so many types of heat exchangers available but due to wide range of design possibilities, simple
2025-06-28 16:26:26 - Adil Khan
Design and Thermal Analysis of Shell and Tube type Heat Exchanger
Project Area of Specialization Mechanical EngineeringProject SummaryHeat exchangers have been observed from the smallest electronic devices to the space shuttles. It transfers heat from
one medium to another by means of direct or indirect contact. There are so many types of heat exchangers available
but due to wide range of design possibilities, simple manufacturing, low maintenance cost, cross flow and counter
flow heat exchanger extensively used in petroleum, petrochemical, air conditioning, food storage and other
industries. The shell and tube heat exchanger is widely used in industries as a chiller plant for transfer waste heat
from the injection molding machine to the cooling water for improve the efficiency of the injection molding
machine. The transformations of the waste heat from the injection molding machine to the cooling water are
dependent on the heat exchange capacity of heat exchangers. To increase the heat exchange capacity of heat
exchanger optimization is done which seeks to identify the best parameter combination of heat exchangers. The
prefix parameter (tube diameter) is used as an input variable and the output parameter is the maximum temperature
difference of shell and tube heat exchanger. Nine models are made on the basis of taguchi method in NX 10.00 and
CFX analysis is carried out in ANSYS 14.5. Result obtained from that gives the best dimension of heat exchanger
for minimum outlet temperature of water
Project ObjectivesThe objective of work is to increase the efficiency of the shell and tube heat exchanger. The efficiency of the heat
exchanger basically depends on the geometric parameters (tube diameter, pitch length, types of the baffles, angle of
the baffles etc.) as well as on operating parameters (mass flow rate, inlet and outlet temperature of the cooling water
etc.) of heat exchangers.
So the objective is to optimize some of parameters for improving the efficiency of the heat exchanger. Those are as
follow:-
Tube diameter Pitch length Mass flow rate
The steps needs for perform optimization of parameters:-
Modelling of shell and tube heat exchanger.
CFD analysis of shell and tube heat exchanger in ANSYS.
Experimental reading for validation of ANSYS result.
Optimization of parameters by using Taguchi method.
Project Implementation MethodLarger ratios of heat transfer area to volume and weight, as compared to other types because of the enhanced area provided by tubes.
High design flexibility to meet wide range of heat duty requirements by changing the pressure and temperature affecting elements such as tubes, baffles, number of passes etc. In addition the design flexibility allows to reduce the thermal expansion effects.
Ability to withstand high operating pressure differences relative to the environment and between the hot and cold fluids, therefore for same heat duty smaller shell and tubes heat exchanger are used as compared to other heat exchanger types.
Reliable, convenient and plenty of design methods are available for designing and construction, custom designs can be made for any specific capacity and operating conditions.
Easier to clean compared to other heat exchanger types, as both the shell and tube bundles can be inspected mechanically for cleaning process.
Cost effective due to comparatively simple design and fabrication procedure
Benefits of the Project1. High Heat transfer
2. Compact in structure, small in size
3. Convenient for maintenance and repair
4. Applicable to various complications
5. Wide scope of application
The hardest thing in this project is to design this project. Because it is needed to be first designed on reliable software, then part by part, the whole equipment of the manually operated, and then its assembly will be done, and the analysis and all the calculations will be done.
Then potential risks are age when welding the frame when cutting the steel for the frame. These are some potential risks that we need to be very careful of because we can cut our hand or much more.
So we need to take precautions in welding and cutting the frame and the other parts.
Final Deliverable of the Project Hardware SystemCore Industry OthersOther Industries Energy , Manufacturing Core Technology OthersOther TechnologiesSustainable Development Goals No Poverty, Good Health and Well-Being for People, Quality Education, Industry, Innovation and InfrastructureRequired Resources| Item Name | Type | No. of Units | Per Unit Cost (in Rs) | Total (in Rs) |
|---|---|---|---|---|
| Total in (Rs) | 78150 | |||
| Tanks | Equipment | 4 | 2550 | 10200 |
| Rods | Equipment | 10 | 540 | 5400 |
| Cutting of rods | Miscellaneous | 10 | 15 | 150 |
| Pumps | Equipment | 2 | 11000 | 22000 |
| Frame | Equipment | 1 | 8000 | 8000 |
| Shell | Equipment | 1 | 7000 | 7000 |
| Baffles | Equipment | 8 | 800 | 6400 |
| Pipes | Miscellaneous | 10 | 200 | 2000 |
| Panel | Equipment | 1 | 10000 | 10000 |
| Tools | Miscellaneous | 1 | 5000 | 5000 |
| Others | Miscellaneous | 1 | 2000 | 2000 |