Analysis of Heat Transfer Coefficient of Shell and Tube On Heat Exchanger Using Heat Transfer Research Inch (HTRI) Software

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Formosa Journal of Sustainable Research (FJSR)

Vol.2, No.5, 2023: 1175-1184

Analysis of Heat Transfer Coefficient of Shell and Tube on Heat


Exchanger Using Heat Transfer Research Inch (HTRI) Software
Alif Gita Arumsari1*, Petrus Junake Ginting2
Chemical Engineering, Al-Kamal Institute of Science and Technology, Jakarta
Corresponding Author: Alif Gita Arumsari [email protected]
ARTICLEINFO ABSTRACT
Keywords: Heat Exchanger, The heat transfer process in the industrial world
Heat Transfer, Shell and Tube, is the most important thing to pay attention to,
Software
especially in industrial equipment that works at
Received : 4 April high temperatures, one of the heat exchangers
Revised : 18 April commonly used in the industrial world is a heat
Accepted: 19 May exchanger which is used to exchange heat
©2023 Arumsari, Ginting: This is an between fluids of different temperatures.
open-access article distributed under Therefore, it is necessary to pay attention to the
the terms of theCreative Commons performance of the heat exchanger. In the shell
Attribution 4.0 International. and tube type heat exchanger, apart from using
baffles which aim to direct the flow on the shell
side, it also aims to increase the rate of heat
transfer that occurs between the working fluids
by causing flow turbulence on the shell side. The
results of this study are to obtain the heat transfer
that occurs in the shell and tube in the heat
exchanger, and to obtain the total heat transfer
coefficient

DOI: https://doi.org/10.55927/fjsr.v2i5.4271 1175


( ISSN-E: 2830-6228
https://journal.formosapublisher.org/index.php/fjsr
Arumsari, Ginting

INTRODUCTION
Heat transfer is the transfer of energy due to a temperature difference
between two different places. In the industrial world, especially in energy
conservation, heat exchangers or heat exchangers are one of the most important
tools. A tool used to transfer a certain amount of energy in the form of heat from
one fluid to another that has a different temperature and keeps the fluids from
mixing with each other. Hear exchanger tools are generally widely used in the
process industry, because they can be designed to run at higher pressures and
temperatures as found in the process industry. This Heat Exchanger can also be
constructed from various materials. (Kreith, Frank & Prijono, Arko, 1994).
Heat exchangers have a variety of uses in a variety of industries and
applications. Here are some common uses of heat exchangers:
Heat Exchange: The main use of a heat exchanger is to transfer heat from one
fluid to another without any interference between the two. This helps in heating,
cooling or condensing fluids depending on the type of heat exchanger used.
Examples include heating water in industry, cooling air in HVAC systems, and
condensing steam in industrial processes.
Energy Efficiency: Heat exchangers are used to increase energy efficiency
in systems. For example, in a power plant, a heat exchanger is used to heat water
using the residual heat from exhaust gases or steam produced by the combustion
engine. This helps in generating more energy from the same heat source.
Heat Recovery: Heat exchangers can be used for heat recovery from flue gas or
waste heat in industrial processes. The heat released by a system or process can
be reused to heat other fluids or produce steam. By recovering previously wasted
heat, heat exchangers help improve energy efficiency and reduce operating costs.
Calculating heat transfer in a heat exchanger has a significant influence on
the design, performance and efficiency of the heat exchanger. Like an Optimal
Design, Energy Efficiency, Performance Prediction, Identification of Potential
Problems, and Design Optimization. In all, heat transfer calculations in heat
exchangers provide important insights into heat exchanger performance,
efficiency, and design. Using these calculations, heat exchangers can be designed
and operated more efficiently and effectively, resulting in significant benefits in
a variety of industrial applications.
In this study the heat exchanger used was of the shell and tube type,
counterflow was chosen and used heating water fluid while for cold fluids it also
used water. The baffle plate used was modified using copper. Shell and Tube
Heat Exchanger consists of a shell (outer sleeve) and inside there are tubes (small
tubes). Fluids that have different temperatures flow inside the shell and inside
the tubes where the two fluids do not mix with each other. The flow direction of
the two fluids can occur in parallel, counter, cross or mixed. Parallel flow occurs
when both fluids enter from the same direction, flow in the same direction and
exit in the same direction. for counter flow occurs when the two fluids enter from
opposite directions, flow in opposite directions, and flow with opposite outlets,
whereas for cross flow occurs when one of the fluids flows perpendicular to the
other fluid. And for mixed flow, it is a combined flow of several types of these
flows.

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Jormosa Journal of Sustainable Research (FJSR)
Vol.2, No.5, 2023: 1175-1184

LITERATURE REVIEW
The following is a cross-sectional image of the shell and tube type heat
exchanger that will be used in this study.

Figure 1. Shell and Tube Type Heat Exchangers

This type of heat exchanger is a type of heat exchanger which according to


its construction is characterized by the presence of a set of tubes attached to a
cylindrical shell where two types of fluids exchange heat. This type is often used
in the chemical industry.
The type of shell and tube type heat exchanger has components that are
very influential in its construction. The components of this type of heat exchanger
are:

Figure 2. Components of a Shell and Tube Type Heat Exchanger

a. Tubes
b. Tube sheets
c. Shell and shell side nozzles
d. Tube side channels and nozzles
e. Channel covers
f. Divider pass
Before designing a heat exchanger, flow rate data (flow rate), inlet
temperature and outlet temperature, and the pressure of the two fluids are
needed. The calculation factor for the heat exchanger is the heat transfer problem,
if the heat released is equal to Q per unit time, then the heat it is received by the
cold fluid of Q, with the equation:
Q = UAΔQ
Where :
Q = Heat released/received (W)
U = Overall heat transfer coefficient (W/m2 0C)
A = Heat transfer area (m2)
ΔT = Difference in average temperature (0C)

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Arumsari, Ginting

Before determining the heat surface area (A), the value of LMTD must first
be determined. This is based on the difference in temperature of the fluid entering
and leaving the heat. The LMTD approach with a heat exchanger is useful when
the inlet and outlet temperatures can be determined easily, so that the LMTD can
be easily calculated. Furthermore, the heat flow, surface area, and overall heat
transfer coefficient can be determined. If we determine the inlet or outlet
temperature, the analysis will involve an iterative procedure because the LMTD
corresponds to a logarithmic function. The analysis will be easier to carry out by
using a method based on the effectiveness of the heat exchanger in transferring a
certain heat con.
To determine the maximum heat transfer rate in a heat exchanger, it must
first be understood that the maximum value will be obtained if one of the fluids
experiences a temperature change equal to the maximum temperature difference
contained in the heat exchanger.

METHODOLOGY
This research was conducted by analyzing shell and tube type heat
exchangers with manual calculations and HTRI (Heat Transfer Research Inch)
software until accurate analysis results were obtained regarding the working
conditions of the desired heat exchanger.
HTRI (Heat Transfer Research, Inc.) is a company and software package
that provides tools and methods of calculating heat transfer for the design and
analysis of heat exchangers.
The stages of the research to be carried out are:
1. Collect theory and data covering research such as literature studies on heat
exchangers and specifications of heat exchangers.
2. Processing the data includes calculating LMTD, calculating the shell,
calculating the pipe, impurities factor in the heat exchanger, and the
effectiveness of the heat exchanger
In this study we used the HTRI program, then we only need to enter known
data such as mass flow rate of fluid, pressure, temperature, as well as design
assumptions based on standards from TEMA, Perry's hand book from Pustaka
kern.

RESULT
Manual Calculation
1. Heat transfer rate
The amount of heat transfer from the hot fluid to the cold fluid can be
calculated by the equation:
Q = Qh = Qc
Qh = mh . (h1 – h2)
Qh = 3.6124 kj/s . (1736.56 -1579.01) kj
= 569.1335 kj/s = 569133.6 h/s
= 569,133.6 W

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Jormosa Journal of Sustainable Research (FJSR)
Vol.2, No.5, 2023: 1175-1184

It is assumed that the heat released by the hot fluid of ammonia gas is
completely absorbed by the water so that we can know the magnitude of
the mass flow rate of water:
Qc = mc. Cpc.ΔT
𝑄𝑐 569.133,6 𝑗/𝑠
mc =𝐶𝑝𝑐 .𝛥𝑇= = 10.48 kj/s4178,7 𝑥 (45−32)

2. Logarithmic mean temperature difference (LMTD)


𝛥𝑇1− 𝛥𝑇2
LMTD = 𝛥𝑇1 = ΔT1 =Th1 – Tc0 = 120 - 45 = 75°C
𝐼𝑛
𝛥𝑇2
ΔT2 = Th0 – Tc1 = 50 -32 = 18°C

(75−18)°𝐶 57
LMTD == = 39.94 75 °C
𝐼𝑛 𝐼𝑛 1,427
18

For the type of heat exchanger type 1 shell fitting and 1 tube fitting
where the correction factor (F) = 1

3. Design overall heat transfer coefficient (ud)


𝑄
Equality :𝑢𝑑 = 𝐴 𝑥 𝐿𝑀𝑇𝐷 A = Heat transfer area (m2)
=Nt x L xπ x Do, t
569.133,6 𝑤
𝑢𝑑 = =235 x 4.877 x 3.14 x 0.001905
68,56 𝑚2 𝑥 39,94°𝐶
= 68.56 m2
=207.84 w/m2 °C

4. Tube side calculation


- Total heat transfer surface area (at)
𝑎𝑓 2,154.10−4 𝑚2
𝑎𝑡 = 𝑁𝑡 𝑛
=235 𝑥 1
= 0.05m2

Ammonia mass flow rate (Gt)


𝑚ℎ 3,6124 𝐾𝑔/𝑠
𝐺𝑡 = = 72,248 𝑘𝑔/𝑚2 𝑠 di,t = Tube OD – wool thickness
𝑎𝑡 0,05 𝑚2

- Reynolds number (Re,h) =19.05mm – 1.245mm

𝑑𝑖,𝑡 . 𝐺𝑡
𝑅𝑒, ℎ = =17.805 mm
𝑚

17,805.10−3 𝑥 72,248 𝑘𝑔/𝑚𝑠


= = 17.805 . 10-3m
12,33.10−6 𝐾𝑔/𝑚𝑠

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Arumsari, Ginting

= 104,328.92
So, the type of flow that occurs in the tube is turbulent flow because Re,
h > 2300 (Incopera; 1996)

- Convection heat transfer coefficient (hi)


Nuselt Equation (Nu)
ℎ. 𝑑𝑖,𝑡
𝑁𝑢 = = 0,0214(Re,h0,8 - 100) Pr,t 0,4
𝑘

Nu = 0.0214 ( 104,328.92 0.8 – 100 ) 0.87560.4


= 207.89
𝑁𝑢 .𝐾 207,89 𝑥 0,031 𝑤/𝑚𝑠
So that :ℎ𝑖 = = = 361.95 w/m2c
𝑑𝑖.𝑡 17,805.10−3 𝑚

5. Shell side calculation


- Total heat transfer surface area (as)
𝑑𝑖, 𝑠 . 𝑐𝐹 . 𝑚 438,15 𝑚𝑚 𝑥 6,35 𝑚𝑚 𝑥 219 𝑚𝑚
𝑎𝑠 = =
𝑝𝑡 25,4 𝑚𝑚
=23988.7125 mm2
= 0.024 m2

- Mass flow velocity of water (Gs)


𝑚 .𝑐 10,48 𝐾𝑔/𝑠
𝐺𝑠 = = =436.67 Kg/m2 s
𝑎𝑠 0,024 𝑚2

Reynolds number (Re,c)

𝑑𝑒 . 𝐺𝑠
𝑅𝑒, 𝑐 =
𝑚

𝑘𝑔
32,35.10 − 3𝑚 𝑥 436,67
𝑅𝑒, 𝑐 = 𝑚2 𝑠
𝑘𝑔
0,637 . 10 − 3 𝑚. 𝑠

= 22,176.26

Where de = hydraulic diameter


1
1
𝑝𝑡 . 0,86 𝑝𝑡 − 2 𝜋𝑑0, 𝑡
𝑑𝑒 = 4(2 4 )
1
2 𝜋𝑑0, 𝑡

1
1 𝑥 3,14 𝑥 19,052
( 𝑥 25,4 𝑥 0,86 𝑥 25,4 )−(2 )
2 4
=4 1
𝑥 3 ,14 𝑥19,05
2

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Vol.2, No.5, 2023: 1175-1184

(12,7 𝑥 21,84)−142,44
=4 29,91

= 32.35 mm = 32.35 . 10-3m

So the type of flow in the tube is also turbulentRe.c > 2300

- The convection heat transfer coefficient (h0) can be found by the Nusselt
equation (Nu):

ℎ.𝑑𝑒
𝑁𝑢 = = 0.012 ( Re.c 0.87 - 280) Pr.t 0.4
𝐾

= 0.012 (22,176.26 0.87 - 280) 4.473 0.4

= 125.81
So that :
𝑤
𝑁𝑢 . 𝐾 125,81 𝑥 0,6286 𝑚°𝑐
ℎ𝑜 = =
𝑑𝑐 32,35 . 10−3 𝑚

= 2444.64 W/m2°C
Software Calculation
In this study we used the HTRI program, then we only need to enter known
data such as mass flow rate of fluid, pressure, temperature, as well as design
assumptions based on standards from TEMA, Perry's hand book from the Kern
Library.
Because shell and tube is the most widely used type, it is necessary to
standardize it in its manufacture. The standardization was made by the Tubular
Exchanger Manufactures Association (TEMA) using a numbering system. The
numbering system is made with 3 (three) letters of the alphabet. Each letter
represents a part of the shell and tube where the first letter indicates the front
header type, the second letter indicates the shell type, and the third letter
indicates the end header type. (Gede, Tahdid, Candra, 2019)
From this standardization, several types of shell and tube combinations
can be created. However, there are 3 (three) main combinations that are
often used, including fixed tube sheet heat exchangers, U-tube heat
exchangers, and floating header heat exchangers.
The Process of Entering Data
In this process, we only enter the data needed by the HTRI program based
on design assumptions, different from manual calculations, we don't have to
enter all the data into the HTRI calculation process. The program only gives signs
for data that must be entered and the rest of the program will process data
automatically. As seen in the image below.

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Arumsari, Ginting

Figure 3. Data Input Process


Data Processing Results
If the data processing process is complete, the data will be processed
automatically by the program and it will be known whether the planning is
successful or not. If planning fails, the program will give an error message and
improvements must be made in entering data. If successful, the program will
provide results in the form of a table as shown in the picture.
Contains how data is collected, data sources and methods of data analysis, along
with the flow of research conducted.

Figure 4. Results of Data Processing

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Vol.2, No.5, 2023: 1175-1184

DISCUSSION
This study focuses on data collection on variations in baffle distances and
variations in mass flow rates, to obtain optimum heat transfer conditions. The
results of the calculations will be reviewed between the relationship between
variations in baffle distance and the value of ΔPs and heat transfer effectiveness
and a graph of the relationship between variations in mass flow rate and ΔPt and
efficiency. Each will be discussed and reviewed for any trends trends and
theories that support the graph results.

Table 1. Comparison of Manual Calculations and HTRI Calculations


Parameter Manual Calculation of
Calculation HTRI
Heat Transfer Rate (Q) 569.134w 567,373w
LMTD 39.94°C 39.80°C
Design Heat Transfer Coefficient 207.84 w/m2 °C 204.63 w/m2 °C
(Ud)
Net Heat Transfer Coefficient (Uc) 289.61 w/m2 °C 292.00 w/m2 °C
Number of Baffles 22 21
Shell pressure drop 8.37 Kpa 15,998 Kpa
Tube pressure drop 25.61 Kpa 11.492 Kpa
Impurity Factor 0.00136 m2 °C/w 0.00146 m2 °C/w

CONCLUSION
From the results of the comparison of the manual calculation and the HTRI
calculation, a close value is obtained, only in the calculation of the pressure drop,
a slightly different comparison value is obtained, this is due to the suspicion that
there are different setups that need to be entered and changed in the HTRI
software as well as differences in the reference values used in the calculations.
manuals.
Calculation of heat transfer makes it possible to evaluate the energy
efficiency of the heat exchanger. By understanding the magnitude of heat transfer
that occurs, it can be identified how much heat is transferred and how well the
heat energy is utilized. This helps in increasing energy efficiency and reducing
unnecessary energy consumption

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REFERENCES
Anggareza., & Djatmiko. 2013. Performance Simulation of Shell and Tube Type
Heat Exchanger with Double Segmental Baffles Against Helical Baffles.
November 10th Institute of Technology. Surabaya.

Bizzy, Setiadi. 2013. Calculation Study of Shell and Tube Type Heat Exchanger
with Heat Transfer Research Inc (HTRI) Program. Sriwijaya University.
Palembang.

Burmawi., Mulyadi., & Angga. 2021. Performance Analysis of a Shell and Tube
Type Heat Exchanger Using Water as a Hot and Cold Fluid. Bung Hatta
University. Padang.

Light, 2021. Analysis of Shell and Tube Type Heat Exchanger with Single Pass
System. Jakarta Muhammadiyah University. Jakarta.

Gede, Tahdid, & Chandra. 2019. Shell and Tube Type Heat Exchanger Prototype
in terms of Baffle Distance and Hot Air Mass Flow Rate. Sriwijaya State
Polytechnic. Palembang.

Kreith, Frank & Prijono, Arko, 1994. Principles of Heat Transfer

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