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Shell and Tube Heat Exchanger Thermal Design Optimization with flow pressure
drop due to fouling

Thesis · January 2012

DOI: 10.13140/RG.2.1.2651.6241

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2 authors:

Nirmal Parmar Adil Khan

The Czech Academy of Sciences School of Engineering and Technology, Navrachana University,Vadodara, India
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 SHELL & TUBE HEAT EXCHANGER THERMAL DESIGN WITH
OPTIMIZATION OF FLOW PRESSURE DROP DUE TO FOULING

SUBMITTED BY
Parmar Nirmal S.

SUPERVISED BY
Prof. Adil A. Khan

WORK PLACE
Charisma Careers Pvt. Ltd.
Akota, Vadodara.

ABSTRACT

The Shell and Tube Heat Exchangers are most commonly used in industries. The
shell-and-tube heat exchanger which is the majority type of liquid-to-liquid heat
exchanger is used as feed water cooler in process industries, refineries, chemical
plants and power plants. It is necessary to operate heat exchanger at optimum
condition which serves high thermal efficiency in allowable condition and low
running cost.

This research is about Shell and tube heat exchangers optimal thermal design,
construction and performance. In practical applications pressure drop due to fouling in
heat exchanger is the major factor which directly affects the performance of the heat
exchanger. The optimal values of pressure drop at various mass flow rates and related
heat transfer with respect to fouling factor in heat exchanger, with trial and error
method optimal performance condition is estimated. The effect of mass flow rate and
fouling variation on other thermal parameters such as overall heat transfer coefficient,
fouled heat transfer coefficient, film heat transfer coefficient, heat exchanged and
over design is analyzed. Efficient Thermal Design is achieved by controlling fouling
amount and pressure drop in operating limits.
 In this dissertation attempt is made to overcome some major theoretical assumptions
and serve practical approach as much as possible for shell tube heat exchanger design
and optimization. Number of iteration and their comparisons as well sd analysis is
performed in software. The cause of minor error is theoretical assumptions made in
manual calculations. The final results are helpful to run shell and tube heat exchanger
water cooler at optimal flow pressure drop and fouled condition.

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