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2nd International Conference on Materials Manufacturing and Design Engineering
2nd International Conference on Materials Manufacturing and Design Engineering
Study of Shell and Tube Heat Exchanger with the Effect of Types of
Study of Shell and Tube Heat Exchanger Baffles with the Effect of Types of
Manufacturing
PranitaEngineering
Bichkar*, OjasSociety
Dandgaval, Baffles
International
Pranita Dalvi,Conference 2017,and
Rhushabh Godase MESIC 2017,
Tapobrata Dey*28-30 June
Pranita Bichkar
Department *
of Mechanical 2017, Vigo
, Ojas Dandgaval,
Engineering, D. Y. (Pontevedra),
Pranita
PatilDalvi, Spain
CollegeRhushabh Godase
of Engineering, and
Akurdi, Tapobrata
Pune- Dey*
411044, India
Savitribai
Department of Mechanical Engineering, D. Phule Pune
Y. Patil University,
College India
of Engineering, Akurdi, Pune- 411044, India

Costing models for capacity optimization in Industry 4.0: Trade-off

Savitribai Phule Pune University, India

Abstract
Abstractbetween used capacity and operational efficiency
For evaluation of shell and tube heat exchanger, thermal performance and pressure drop are considered as major factors. Both,
For evaluation
thermal of shelland
performance A. heat
andpressure
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exchanger,
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are adependent , A.ofZanin
thea,*path
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fluidpressure
flow Wernke
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orientations
thermal performance
respectively. Increasing andthepressure dropofare
complexity dependent
baffles on the
enhances heatpath of fluid
transfer which flow
alsoand typesin of
results baffles
higher in different
pressure orientations
drop which means
respectively.
higher pumping Increasing
power isthe complexity
required. This of
a
bafflesthe
reduces
University enhances
Minho, heat
ofsystem transfer
efficiency.
4800-058 which
This paper
Guimarães, also results the
presents
Portugal in higher pressure
numerical drop which
simulations means
carried out
higher pumping
on different power
baffles is required.
i.e. single segmental,
b
Unochapecó,
This reduces
double segmental 89809-000
the system and Chapecó,
efficiency.
helical ThisSC,
baffles. Brazil
paper
This presents
shows the theeffect
numerical simulations
of baffles carried
on pressure dropout
in
on different
shell and tubebaffles
heat i.e. single segmental,
exchanger. double segmental
Single segmental baffles showandthehelical baffles.ofThis
formation deadshows
zonesthe effectheat
where of baffles
transferoncannot
pressure
takedrop in
place
shell and tube
effectively. heat exchanger.
Double Single reduce
segmental baffles segmentalthe baffles showdamage
vibrational the formation of dead
as compared to zones
single where heat baffles.
segmental transfer The
cannot
use take place
of helical
effectively.
baffles shows Double segmental
a decrease bafflesdrop
in pressure reduce
duethe vibrational
to the damage
elimination as compared
of dead zones. The toless
single
deadsegmental baffles.
zones result The use
in better heatoftransfer.
helical
Abstract
baffles shows a decrease in pressure droppumping
due to the elimination of turn
deadincreases
zones. The
The lower pressure drop results in lower power, which in theless deadsystem
overall zones result in better
efficiency. The heat transfer.
comparative
The lower
results show pressure drop baffles
that helical results are
in lower
more pumping power,
advantageous which
than otherintwo
turnbaffles.
increases the overall system efficiency. The comparative
Under the concept
results show that helicalofbaffles
"Industry 4.0",
are more productionthan
advantageous processes
other two will be pushed to be increasingly interconnected,
baffles.
information based on a real time basis
© 2017 The Authors. Published by Elsevier B.V. and, necessarily, much more efficient. In this context, capacity optimization
©
goes2018 The
beyond Authors.
the
© 2017 The Authors. Published
traditional aimby Elsevier
of capacity
Published byofElsevier B.V.maximization,
B.V. committee of the 2nd also
contributing for organization’s profitability and value.
Peer-review under responsibility the scientific International Conference on Materials
Peer-review under responsibility of the scientific committee of the 2nd International Conference on Materials Manufacturing and
Indeed,
Peer-reviewlean under
Manufacturing management
and responsibility
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the
Engineering. improvement
scientific committee approaches
of the 2nd suggest capacity
International optimization
Conference on instead of
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maximization. and study
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capacity optimization and costing models is an important research topic that deserves
contributions
Keywords: Shell from both
and tube heatthe practical
exchanger, and
CFD, theoretical
baffle perspectives.
types, pressure Thisrate.
drop, mass flow paper presents and discusses a mathematical
Keywords:
model forShell and tube
capacity heat exchanger,based
management CFD, on
baffle types, pressure
different costingdrop, mass flow
models rate. and TDABC). A generic model has been
(ABC
developed and it was used to analyze idle capacity and to design strategies towards the maximization of organization’s
1. Introduction
value. The trade-off capacity maximization vs operational efficiency is highlighted and it is shown that capacity
1. Introduction
optimization might hide operational inefficiency.
HeatThe
© 2017 exchangers are usedby
Authors. Published forElsevier
transferring
B.V. thermal energy between two or more fluids, or solid particulates and a
Heat
fluid, at exchangers
different are used
temperature for
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Keywords: Cost Models; The
according heat
to transfer
ABC; TDABC;transfer occurs
processes,
Capacity number mainly
Management; due
ofIdle
fluids, toand
conduction
Capacity; and convection.
degree of Efficiency
Operational surface compactness,The construction
heat exchangers are
features,
classified accordingand
flow arrangements, to transfer processes,
heat transfer number [1].
mechanisms of fluids, and degree of
Heat exchangers aresurface compactness,
extensively construction
used in many features,
engineering
flow arrangements, and heat transfer mechanisms [1]. Heat exchangers are extensively used in many engineering
1.*Introduction
Corresponding author. Tel.: +91–20–27653058 ; fax: +91–20-27653057.
* Corresponding
E-mail address: pranitabichkar@yahoo.com , tapobrata.dey@gmail.com
author. Tel.: +91–20–27653058 ; fax: +91–20-27653057.
The cost
E-mail of idle
address: capacity is a fundamental
pranitabichkar@yahoo.com information for companies and their management of extreme importance
, tapobrata.dey@gmail.com
in modern production systems. In general, it is defined as unused capacity or production potential and can be measured
2351-9789 © 2017 The Authors. Published by Elsevier B.V.
in several ways:
Peer-review tons
underThe
2351-9789 © 2017
of production,
responsibility of theby
Authors. Published
available
scientific hours of
Elsevier committee
B.V.
manufacturing,
of the etc.Conference
2nd International The management of Manufacturing
on Materials the idle capacity
and
* PauloEngineering.
Design Afonso.
Peer-review Tel.:
under +351 253 510 of
responsibility 761;
thefax: +351 253
scientific 604 741 of the 2nd International Conference on Materials Manufacturing and
committee
E-mail address:
Design Engineering.psafonso@dps.uminho.pt

2351-9789 © 2017 The Authors. Published by Elsevier B.V.

Peer-review
2351-9789 © under
2018responsibility
The Authors. of the scientificbycommittee
Published Elsevier of the Manufacturing Engineering Society International Conference 2017.
B.V.
Peer-review under responsibility of the scientific committee of the 2nd International Conference on Materials Manufacturing and
Design Engineering.
10.1016/j.promfg.2018.02.028
196 Pranita Bichkar et al. / Procedia Manufacturing 20 (2018) 195–200
P. Bichkar et al. / Procedia Manufacturing 00 (2017) 000–000

applications such as chemical engineering processes, power generation, petroleum refining, refrigeration, air
conditioning, food industry and so on. Among different types of heat exchangers, shell and tube heat exchangers are
relatively easy to manufacture and have multipurpose application possibilities for gaseous as well as liquid media in
large temperature and pressure ranges [2].
In shell and tube heat exchanger, two fluids of different temperature flow through the heat exchanger. One flows
through the tubes (the tube side) and other flows outside the tubes but inside the shell (the shell side). Heat is transferred
from one fluid to the other through the tube walls, either from tube side to shell side or vice versa. The fluids can either
be liquids or gases on either the shell or the tube side. In order to transfer heat efficiently, a large heat transfer area is
used, leading to the use of many tubes. This is an efficient way to use energy and avoid wastage of thermal energy.
B.I. Master et al. in 2006 found that more than 30% heat exchangers are used of shell and tube type [3]. Shell and
tube heat exchangers can be custom designed by considering its operability, maintainability, flexibility and safety.
This makes it very robust and serves major reason to be used widely in industries [4]. For efficient heat transfer process,
heat exchanger should have low pressure drop, high shell side mass flow velocity, high heat transfer coefficient, and
no or very low fouling and so on. Heat transfer also depends on the amount of turbulence created in shell side. This
turbulence can be created by using baffles. Various types of baffles are enlisted in literature. Some of the commonly
used are segmental, double segmental, triple segmental, doughnut type, helical type, double helical and flower type.
When traditional segmental baffles are used in shell and tube heat exchanger, higher pumping power is often needed
to offset higher pressure drop under same heat load. The problems of SG-STHX mentioned above were improved or
solved by helical baffles. The shell and tube heat exchanger with discontinuous helical baffle was firstly proposed by
Lutcha and Nemcansky [5] and commercially produced by ABB Lummus [6] heat transfer. Lei et al. [7] carried out a
numerical investigation to study the impact of various baffle inclination angles on fluid flow and heat transfer of
continuous helical shell and tube heat exchangers by using periodic model. From the results computed, it was observed
that the best-integrated performance occurs approximately 45° helix angle. Performance of heat exchanger also
depends on pressure drop. Leakage can reduce pressure drop and thus per compartment average heat transfer
coefficient. Gaddis and Gnielinsk [8] proposed a procedure to evaluate pressure drop and its comparison with
experimental data. Based on flow arrangement, shell and heat exchangers are classified into parallel (co-current) and
counter (concurrent). In a counter-flow or counter-current exchanger, the two fluids flow parallel to each other but in
opposite directions within the core (The temperature variation of the two fluids in such an exchanger may be idealized
as one dimensional). As shown later, the counter-flow arrangement is thermodynamically superior to any other flow
arrangement. It is the most efficient flow arrangement, producing the highest temperature change in each fluid
compared to any other two fluid flow arrangements for a given overall thermal conductance (UA), fluid flow rates
(actually, fluid heat capacity rates), and fluid inlet temperatures. Moreover, use of helical; baffles has proved better
heat transfer efficiency than original segmental shell and tube heat exchanger in same shell structure and same mass
flow rate. Wang et al. [9] proposed maximal velocity design method for continuous helical shell and tube heat
exchanger.
The objective of the present work is to reduce the pressure drop of fluid in shell side of shell and tube heat exchanger
by variation and application of different types of baffles i.e. segmental (SG-STHX), double segmental (DSG-STHX)
and continuous helical (CH-STHX) baffles for changed mass flow rate for heat exchanger with same dimensional
parameters.

2. CFD as a tool:

2.1. Mathematical modelling

Any physical problem can be converted into a mathematical domain which now is solved using a CAE based solver
like Fluent. It is basically based on Numerical methods which are solved either iteratively or using some empirical
relations. In this way, this complex system is modelled into simplified numerical equations and solved accordingly.
Computational Fluid Dynamics (CFD) is analysis of the system involving fluid flow, heat transfer and associated
phenomenon such as chemical reactions by means of computer based simulations. CFD is used to visualize how fluid
flows as well as how fluid behaves under certain circumstances. Computational Fluid Dynamics is based on the
Navier-Stokes equation which is given in general format as:
 P. Pranita
BichkarBichkar
et al. / Procedia Manufacturing
et al. / Procedia 00 (2017)
Manufacturing 20000–000
(2018) 195–200 197

𝜕𝜕⍴𝜙𝜙 𝜕𝜕⍴𝑢𝑢𝑢𝑢 𝜕𝜕⍴𝑣𝑣𝑣𝑣 𝜕𝜕⍴𝑤𝑤𝑤𝑤 𝜕𝜕2 𝜙𝜙 𝜕𝜕2 𝜙𝜙 𝜕𝜕2 𝜙𝜙

( )+( + + ) = 𝛤𝛤 ( + + ) + 𝑆𝑆(𝜙𝜙) (1)
𝜕𝜕𝜕𝜕 𝜕𝜕𝜕𝜕 𝜕𝜕𝜕𝜕 𝜕𝜕𝜕𝜕 𝜕𝜕𝑥𝑥 2 𝜕𝜕𝑦𝑦 2 𝜕𝜕𝑧𝑧 2

where, ϕ= 1, V (u, v, w), T for mass, momentum and energy equations respectively.
These equations are used to solve the equations for conservation of mass, momentum and energy for the required
system.

2.2. Physical modelling

A shell and tube heat exchanger was modelled in CATIA V5 (CAD software). The geometrical specifications used
in shell and tube heat exchanger are as follows:

Table 1: Geometrical specifications

Parameters Specifications
Material Stainless steel
Tube internal diameter 4 mm
Tube external diameter 6 mm
Tube arrangements Triangular
Number of tubes 7
Tube effective length 184 mm
Shell internal diameter 44 mm
Baffle number 4
Baffle cut ~22%

The baffle spacing for all the three types of baffles is kept same which ensures that all the other geometrical
parameters remain the same. This leads to a comparison between the three baffles types. The working fluid in shell
side is water with a specific heat of 4185 J/kgK. Water being a Newtonian and incompressible fluid, its thermo-
physical properties remains constant over a considerable range of temperature. The heat exchanger is assumed to be
newly built and thus has negligible fouling resistance and leakage between parts in contacts is very small.

(a) (b) (c)

Fig. 1: Types of baffles (a) Segmental baffles, (b) Double segmental baffles, (c) Helical baffles

2.3. Computational domain, mesh and boundary conditions

The heat exchanger is modelled using three different types of baffles. In these models, only shell side fluid domain
is modelled and meshed using a tetrahedral type of grid. The meshes are generated using ANSYS Meshing tool. The
element quality and skewness are checked to keep them within the limits. Three grids with a total cell count of ~2.1
million, ~3.7 million and ~4.3 million are computed. The pressure drop for all the three cases are monitored and it is
found that difference between ~3.7 million and ~4.3 million is less than 0.5%. Taking into consideration the solution
accuracy and computation time, a grid with ~3.7 million is opted.
198 Pranita Bichkar et al. / Procedia Manufacturing 20 (2018) 195–200
P. Bichkar et al. / Procedia Manufacturing 00 (2017) 000–000

The flow in shell and tube heat exchanger is observed to be highly turbulent. Owing to the merits of k-ε turbulence
model, it is preferred for turbulence modelling in shell and tube heat exchanger. This simulation uses realizable k-ε
turbulence model with scalable wall function. The scalable wall functions enable solutions on arbitrarily fine near-
wall grids, which is a significant improvement over standard wall functions. The realizable k-ε model is often used to
capture boundary effects with somewhat coarse mesh. The solid walls are set with momentum boundary condition of
no slip. The inlet to the shell is set as mass flow inlet. Mass flow rates are varied from 0.0104 kg/s to 0.032 kg/s. The
shell outlet is said to be a pressure outlet with pressure so that the inlet pressure is equal to the pressure drop. All the
governing equations are solved with a second order of accuracy and the residuals limit was set to 10 -4. SIMPLE
algorithm was used to solve the pressure linked equations.

3. Results and discussions

Pathlines show the path of fluid flow and it is dependent on the types and orientation of baffles. For single segmental
baffles (SG-STHX), fluid follows a zigzag pattern which causes dead zones, eddy formation and back mixing of fluid
particles. So the heat transfer cannot take place effectively. This also causes an increase in pressure drop leading to
excess of pump work. This problem is solved by usage of double segmental baffles (DSG-STHX). In this case, there
is an improvement in the elimination of dead zones. Due to this improvement, thermal performance increases to a
greater extent but increases pressure drop to certain level. In case of continuous helical baffles (CH-STHX), the path
followed by the fluid particles is helical in nature. So there is complete elimination of dead zones and back mixing of
fluid particles results in reduction in pressure drop and thus reduces pumping power. This proves that use of helical
baffles improves thermal efficiency.

(a) (b)

(c)
Fig. 2: Pathlines of (a) Segmental baffles, (b) Double segmental baffles, (c) Helical baffles

3.1. Pressure drop:

The pressure drop is very important factor in the design of shell and tube heat exchanger as it directly related to
operating cost and efficiency. Lower the pressure drop results in lower pumping power, which in turn increases the
overall system efficiency. From the above pressure contours, it can be observed the trend in pressure drop and seen
that higher pressure is required at the inlet for the fluid to reach the outlet. By comparing the three types of baffles, it
can be seen that the pressure drop for segmental baffles is more as compared to other two and it goes on reducing
towards helical baffles. Fig. 3 shows pressure contours for the heat exchangers with three baffle types respectively.
 Pranita Bichkar et al. / Procedia Manufacturing 20 (2018) 195–200 199
P. Bichkar et al. / Procedia Manufacturing 00 (2017) 000–000

(a) (b)

(c)
Fig. 3: Pressure contours of (a) Segmental baffles, (b) Double segmental baffles, (c) Helical baffles

3.2. Mass flow rate:

From the pressure contours, it is observed that pressure drop varies with varying mass flow rate. The following
graph shows a variation of shell side pressure drop for various mass flow rates ranging from 0.0104 kg/s to 0.032 kg/s.
It can be seen that the variation in pressure drop for all the three baffles is very less for low mass flow rate. As the

Fig 4: Shell side pressure drop versus mass flow rate

mass flow rate is increased, variation in pressure drop is increased to a greater extent. Thus it is suggested that the
heat exchangers working at higher mass flow rates should prefer the use of helical baffles over segmental or double
segmental baffles.
200 Pranita Bichkar et al. / Procedia Manufacturing 20 (2018) 195–200
P. Bichkar et al. / Procedia Manufacturing 00 (2017) 000–000

The obtained numerical results from table 2 are successfully compared with the experimental data obtained by
Anas El Maakoul [10] and are found to be acceptable. The results are within the error limits of 5% which is an
acceptable limit.

Table 2: Comparative results of pressure drop in shell side at mass flow rate 0.032kg/s

Types of baffle Single segmental Double segmental Helical

Pressure at inlet (Pa) 239.54122 196.19764 127.2102
Pressure at outlet (Pa) 0 0 0
Pressure drop (Pa) 239.54122 196.19764 127.2102

These errors are results of discretization error, truncation error and round-off errors. This verifies that the obtained
CFD results successfully match with the experimental data. Further improvisations can be done in order to minimize
the errors.

4. Conclusion:

In the present study, a numerical model is used to compute and compare the shell side fluid performance of shell
and tube heat exchanger. Numerical simulations are carried out on different baffles i.e. segmental, double segmental
and helical baffles which show the effect of baffles on pressure drop in shell and tube heat exchanger. Increasing the
number of baffles beyond certain number gives serious effects on pressure drop. So by changing the types of baffles
without hampering the other dimensions suggested that single segmental baffles show the maximum pressure drop
while it reduced when helical baffles are used.
Single segmental baffles show the formation of dead zones where heat transfer cannot take place effectively. This
problem is solved by usage of double segmental baffles. It also reduces the vibrational damage as compared to single
segmental baffles. But the use of helical baffles over other two lowers the pressure drop which in turn increases the
overall system efficiency. So it is proved that helical baffles are more advantageous than other two types of baffles.

References

[1] R.K. Shah and Dušan P. Sekulic, Fundamentals of Heat Exchangers, John Wiley and Sons.
[2] B.B. Gulyani, Estimating number of shells in shell and tube heat exchangers: a new approach based on temperature cross, Trans. ASME J. Heat
Transfer 122 (3) (2000) 566–571.
[3] B.I. Master, K.S. Chunangad, A.J. Boxma, D. Kral, P. Stehlík, Most frequently used heat exchangers from pioneering research to worldwide
applications, Heat Transfer Eng. 27 (6) (2006) 4– 11.
[4] K.J. Bell, Heat exchanger design for the process industries, transactions of the ASME, Trans. ASME J. Heat Transfer 126 (6) (2004) 877–885.
[5] J. Lutcha, J. Nemcansky, Performance improvement of tubular heat exchangers by helical baffles, Chem. Eng. Res. Des. 68 (3) (1990) 263–
270.
[6] B.I. Master, Heat exchanger, United States, US 6827138 B1, 2004.
[7] Y.G. Lei, Y.L. He, R. Li, Y.F. Gao, Effects of baffle inclination angle on flow and heat transfer of a heat exchanger with helical baffles, Chem.
Eng. Process. 47 (12) (2008) 2336–2345.
[8] E.S. Gaddis, V. Gnielinski, Pressure drop on the shell side of shell-and-tube heat exchangers with segmental baffles, Chem. Eng. Process. 36
(2) (1997) 149–159.
[9] Q.W. Wang, G.D. Chen, J. Xu, Y.P. Ji, Second-law thermodynamic comparison and maximal velocity ratio design of shell-and-tube heat
exchangers with continuous helical baffles, Trans. ASME J. Heat Transfer 132 (10) (2010) 101801–101809.
[10] Anas El Maakoul, Numerical comparison of shell side performance for shell and tube heat exchangers with trefoil-hole, helical and segmental
baffles, Applied Thermal Engineering (2006).