Final Year Project Heat Exchanger Design Software

CHAPTER ONE
1 .Introduction to Heat Exchangers
A heat exchanger is a device in which heat is transferred from a fluid at a high temperature to a fluid at
low temperature. The usual objective of this transfer is to control the temperature of one of the fluids
for a technological purpose. Heat transfer from one fluid to another can be accomplished by mixing
the fluids directly or if mixing is un desirable, through a partition between the fluids. Almost all
technological heat exchange problems require a partition because of the need to keep one fluid
separated from the other. The heat transfer between the two fluids takes the form of convection on the
fluid side and conduction through the partition walls.

1.1. Types of Heat Exchanger

Heat exchangers can be classified as
1. Regenerators: - are heat exchangers in which the hot and cold fluids flow alternatively
through the same space open type heat exchanger are devices were physical mixing of the two
streams occur.
2. Closed type heat exchangers:- are those in which heat transfer occurs between fluids streams
that do not mix or physically contact with each other
According to the flow of one fluid relative to that of the other heat exchanger can be classified into
three types.
1. Parallel flow Heat Exchanger: - In this exchanger, both fluids flow in the same direction.
2. Counter Flow Heat Exchanger :-both fluids flow in opposite directions
3. Cross Flow Heat Exchanger :- the fluid flow at right angles to each other
Heat exchanger may also be classified based on their construction as-
1. Double Pipe Heat Exchanger:-the fluids may flow in either parallel or counter flow. The
double pipe heat exchanger is extremely useful because it can be assembled in any pipe fitting
shop from standard parts and provides in expensive heat transfer surface
2. Shell and Tube Heat Exchanger: - shell and tube equipment involves expanding a tube into a
tube sheet and forming seal, which does not leak under reasonable operating conditions.
3. Compact Heat Exchangers: - they are primarily used in gas flow systems were the
over all heat transfer coefficients are low and it is desirable to achieve a large

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Final Year Project Heat Exchanger Design Software

surface area in small volume. These exchangers generally have surface area grater
than 650m2/cubic meter of volume.

1.2. Heat Exchanger Design Considerations

In the processes and power industries or related activities, many heat exchangers are
purchased as of the shelf and the selection is made on the basis of cost and specifications
furnished by the various manufacturers. In more specialized applications such as
aerospace and electronics, Industries particular design is frequently called for. Whether
the heat exchanger is selected as of the shelf item or design especially for the application,
the following factors are always considered.
1. Heat transfers requirements
2. Cost
3. Physical size
4. Pressure drop characteristics
The heat transfer requirements must be mate in selection or design of any heat exchanger.
By forcing the fluids through the heat exchanger at higher velocities, the overall heat
transfer coefficient may be increased, but this higher velocity results in large pressure
drop through the exchanger and correspondingly large pumping cost. If the surface area
of the exchanger is increased the overall heat transfer coefficient and hence the pressure
drop, need to be solved; however their may be limitations on the physical size which can
accommodated and a large physical size results in higher cost for the heat exchanger.

1.3. Computer Aided Design of Heat Exchanger

It is widely known that computers are contributing a lot in various aspects of field
studies. There are many computer programs, which are being used in developing different
kinds of software for multi purpose applications. In the development of a software design
of heat exchanger, the program visual basic 6 is used.

When performing the design of a heat exchanger, our main objective is surely minimizing

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Final Year Project Heat Exchanger Design Software

the tire some tasks of computing various data.

While developing the soft ware for a heat exchanger, it is known that the soft ware needs
a user who is aware of the terms, the tables and other factors which are used in the
design.
Now days there are various soft wares developed for various heat exchangers .out this
software’s the double pipe and the shell and tube type are included. Most of the soft
wares takes inlet and out let temperatures, fouling factor, specific heat ,shell in let
diameter and soon as a given conditions and produce the following parameters as an out
put LMTD ,total over all heat transfer coefficient ,flow area, length of tube, and the
change in pressure .
the developed soft ware, in our case include both the double pipe and the shell and tube
types .some of the input data are similar to both cases while there are some additional in
put data for the shell and tube type heat exchanger; some of the given data are shown as
arrow data for the user to made a selection.

1.3.1. Instructional Capability

Indirect heating/ cooling by transfer of heat from one fluid stream to another when
separated by a solid wall.
Energy balance determination (heat balance) using the flow rates and temperature
changes in the hot and cold fluid streams.
By using the mean temperature determination of the standards values (density, specific
heat capacity, thermal conductivity, prandatal numbers) from the data base
Using the Logarithmic Mean Temperature Difference (LMTD) in heat transfer
calculations.
Calculation Overall Heat Transfer Coefficient (U).
Calculation of the heat transfer area
Calculation of length of the tube
Determination of change pressure in the tube and annulus side
Compare the results with the allowable pressure value.
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CHAPTER TWO

2. Double pipe Heat Exchanger

2.1. Counter flow: Double pipe exchanger
The principal parts are two sets of concentric pipes, two connecting tees and a return head
and a return bend.
The inner pipe is supported with in the outer pipe by packing glands and the fluid enters
the inner pipe thorough threaded connection located out side the exchanger section
proper.
The tees have nozzles or screwed connections attached to them to permit the entry and
exit of the annulus fluid which crosses from one leg to the other through the return head.
The two lengths of the inner pipe are connected by a return bend. When arranged in two
legs the unit is a hair pin.
Double pipe exchangers are usually assembled in 12, 15, 20 ft effective length. The
principal disadvantage to the use of double pipe exchanger lies in the small amount of
heat transfer surface contained in a single hair pin. Each double pipe exchanger
introduces no fewer than 14 points at which leakage might occur. The time and expense
for dismantling and periodically cleaning is prohibitive.
The double pipe exchanger is of greatest use where the total required heat transfer surface
is small 9.3m to 18.6m or less. Pipes are rougher than tubes and produce more
turbulence for equal Reynolds numbers.

2.2. Relation between parallel flow and counter flow

Both kinds of flow are possible in a double pipe heat exchanger. Except where one fluid is isothermal
such as condensing steam there is a distinct thermal disadvantage to use the parallel flow.
The LMTD for the same process temperatures in parallel flow is lower than for counter flow

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2.3. Basic Design Procedure

Heat exchanger must satisfy the

1 Heat transfer requirements (design or process needs)

2 Allowable pressure drop (pumping capacity and cost)

Steps in designing a heat exchanger can be listed as:

1 Identify the problem

2 Select a heat exchanger type

3 Calculate/Select initial design parameters

4 rate the initial design.

5 Calculate thermal performance and pressure drops for Annulus and tube side

2.3.1. Heat Balance

When the process temperatures of the two respective streams are given, the total heat
transfer Q is also given, being computed from

Where

= Mass flow rate

c = Specific heat
q = Heat Capacity

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Final Year Project Heat Exchanger Design Software

2.3.2. Size of Heat Exchanger

The initial size (surface area) of a heat exchanger can be estimated from

Where
Ao = Outside tube surface area
q = Heat duty – heat exchange between tube and shell side
Uo = Overall heat transfer coefficient
F = Correction factor F=1.0 for cross flow heat exchanger
Tlm = Log mean temperature difference

2.3.3. Over all Heat Transfer coefficient

In case of two concentric pipes, the inner pipe being very thin the resistance in countered
are the pipe fluid resistance, the pipe wall resistance Lm/Km and the annulus fluid film
resistance.
If the out side area A of the inner pipe is used then hi must be multiplied by Ai/Ao give
the value that hi would have.
For a pipe with a thick wall

Thin wall pipe wall resistance is negligible.

Where
U =Overall heat transfer coefficient
h = Tube side heat transfer coefficient
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Final Year Project Heat Exchanger Design Software

h = Annulus side heat transfer coefficient

d = Tube outer diameter
d = Tube inner diameter

2.3.4. Annulus side Heat Transfer Coefficient

Where
h = heat transfer coefficient for the fluid in annuli
R = Reynolds number for the fluid in annuli
P = Prandtal number for the fluid in annuli
K = Thermal Conductivity of the fluid in annuli
d = Equivalent diameter
2.3.5. Equivalent Diameter:
When a fluid flows in a conduit having other than a circular cross-section, such as an
annulus, it has been found advantageous to employ equivalent diameter De to heat
transfer coefficients and friction factors by the same type of equations and curves
used for pipes and tubes.

Where
De = Equivalent Diameter
D =Annulus inner diameter
D = Tube outer diameter

2.3.6 .Tube side Heat Transfer Coefficient

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Final Year Project Heat Exchanger Design Software

Where
h = heat transfer coefficient for the fluid in Tube
R = Reynolds number for the fluid in tube
P = Prandatal number for the fluid in tube
K = Thermal Conductivity of the fluid in tube
d = Equivalent diameter

h is the value of the hi referred to the outside diameter of the tube

2.3.7. Overall Clean Heat Transfer Coefficient

Where

U = Overall Clean Heat Transfer

2.3.8. Fouling Factor

The additional resistance reduce the original values of U, and the required amount of heat is no longer
transferred by the original surface A; T rises above and t falls below the desired outlet temperature,
although hi and ho remain substantially constant. To overcome this eventually, it is customary in
designing equipment to anticipate the deposition of dirt and scale or fouling resistance.

Where
R = Fouling factor

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2.3.9. Pressure Drop in Annuli

The pressure – drop allowance in an exchanger is the static fluid pressure which may be
expanded to dive the fluid through the exchanger. The pump selected for the circulation
of a processes fluid is one which develops sufficient head at the desired capacity to
overcome the frictional losses caused by connecting piping, fitting, control regulator, and
the pressure drop in the exchanger itself.

Where
f = friction factor
L = length of the tube
G = mass velocity of the fluid in the annulus side
ρ = density of the fluid in the annulus side
g = gravitational acceleration
d =equivalent diameter

2.3.10. Friction factor

Where
R - Annulus side Reynolds numbers

2.3.11. Equivalent diameter

In the pressure drop calculation the friction not only results from the resistance of the
outer pipe but is also the outer pipe but is also affected by the outer surface of the inner
pipe.

2.3.12 Pressure Drop in Tubes

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Where

R = Tube side Reynolds numbers

L = length of the tube
G = mass velocity of the fluid in the tube side
ρ = density of the fluid in the tube side
g = gravitational acceleration
de = equivalent diameter

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CHAPTER THREE
3. Shell and tube heat exchanger.
Shell & tube heat exchangers are the most versatile type of heat exchanger. They are used in
process industries, in conventional and nuclear power Stations, steam generators, etc
They are used in many alternative energy applications including ocean, thermal and
geothermal. Shell & tube heat exchangers provide relatively large ratios of heat transfer area
to volume. They can be easily cleaned.
Shell & tube type heat exchangers are built of tubes (round or rectangular in general)
mounted in shells (cylindrical, rectangular or arbitrary shape).
Heat exchanger tubes are also referred to as condensed tubes and should not be confused
with steel pipes or other types of pipes which are extruded to iron pipe sizes. Heat
exchanger tubes are available in a variety of metals which include steel, copper,
aluminum, stainless steels. They are obtainable in a number of different wall thickness
defined by the Birmingham wire gage, which is usually referred to as the BWG or gage
of the tube. The sizes of the tubes which are generally available are ¾ outside diameter
and 1 in.OD are most common in heat exchanger design.
Many variations of this basic type are available. The differences lie mainly in the detailed
features of construction and provisions for differential thermal expansion between the tubes
and the shell.

3.1. Shell types

TEMA (the Tubular Exchangers Manufacturers Association) publishes standards defining
how shell and tube exchangers should be built. They define a naming system that is
commonly used. Shells are also typically purchased in standard sizes to control costs.

One pass shell Two pass shell Split flow

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Double split flow Cross flow Cross flow

Two pass shell Three pass shell

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Mixed flow

3.2. Tube to header plate connection

Tubes are arranged in a bundle and held in place by header plate (tube sheet). The number
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of tubes that can be placed within a shell depends on Tube layout, tube outside diameter,
pitch, number of passes and the shell diameter. When the tubes are to close to each other,
the header plate becomes too weak. Methods of attaching tubes to the header plate.

Header plate

Tube

3.3. Baffle Type and Geometry

Baffles (dividers) are installed in the shell to direct the flow around the tubes, to increase
velocity, and to promote cross flow. They also help to support the tubes. The baffle cut is
the ratio of the baffle window height to the shell diameter. Typically, baffle cut is about20
percent. It affects both heat transfer and pressure drop. Designers also need to specify the
baffle spacing; the maximum spacing depends on how much support the tubes need.
Baffles have two functions:
1. Support the tubes for structural rigidity, preventing tube vibration and sagging
2. Divert the flow across the bundle to obtain a higher heat transfer coefficient.
The single and double segmental baffles are most frequently used. They divert the flow
most effectively across the tubes. The baffle spacing must be chosen with care Optimal
baffle spacing is somewhere between 40% - 60% of the shell diameter. Baffle cut of 25%-
35% is usually recommended. The triple segmental baffles are used for low pressure
applications.
Disc and ring baffles are composed of alternating outer rings and inner discs, which direct the
flow radially across the tube field. The potential bundle-to-shell bypass stream is eliminated.
This baffle type is very effective in pressure drop to heat
transfer Conversion
In an orifice baffle shell-side-fluid flows through the
clearance between tube outside diameter and baffle-hole
diameter.
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3.4. Number of Tubes

The number of tubes in an exchanger depends on the
1 Fluid flow rates
2 Available pressure drops.
The number of tubes is selected such that the tube side velocity for water and similar liquids
ranges from 0.9 to 2.4 m/s and for the shell-side velocity from 0.6 to 1.5 m/s.
The lower velocity limit corresponds to limiting the fouling, and the upper velocity limit
corresponds to limiting the rate of erosion. When sand and silt are present, the velocity is kept
high enough to prevent settling.

3.5. Tube pass

A pass is when liquid flows all the way across from one end to the other of the exchanger.
We will count shell passes and tube passes. An exchanger with one shell pass and two tube
passes is a 1- 2 exchanger. Almost always, the tube passes will be in multiples of two (1-2,
1-4, 2-4, etc.). Odd numbers of tube passes have more complicated mechanical stresses, etc.
An exception: 1-1 exchangers are sometimes used for vaporizers and condensers.
A large number of tube passes are used to increase the tube side fluid velocity and heat
transfer coefficient and minimize fouling. This can only be done when there is enough
pumping power since the increased velocity and additional turns increases the pressure drop
significantly.
The number of tube passes depends on the available pressure drop. Higher velocities in the
tube result in higher heat transfer coefficients, at the expense of increased pressure drop.
Therefore, if a higher pressure drop is acceptable, it is desirable to have fewer but longer
tubes (reduced flow area and increased flow length).
Long tubes are accommodated in a short shell exchanger by multiple tube passes. The
number of tube passes in a shell generally range from 1 to 10. The standard design has one,
two, or four tube passes. An odd number of passes is uncommon and may result in

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mechanical and thermal problems in fabrication and operation.

3.6. Tube Materials

Materials selection and compatibility between constructions
Materials and working fluids are important issues, in particular with regard to corrosion and
/or operation at elevated temperatures. Requirement for low cost, light weight, high
conductivity, and good joining characteristics often leads to the selection of aluminum for the
heat transfer surface. On the other side, stainless steel is used for food processing or fluids
that require corrosion resistance. In general, one of the selection criteria for exchanger
material depends on the corrosiveness of the working fluid.

3.7. Tube Wall Thickness

The wall thickness of heat exchanger tubes is standardized in terms of Birmingham Wire
Gage BWG of the tube. Small tube diameters (8 to 15mm) are preferred for greater area to
volume density but are limited for the purposes of cleaning. Large tube diameters are often
required for condensers and boilers.

3.8. Tube Outside Diameter

The most common plain tube sizes have 15.88, 19.05, and 25.40 mm. From the heat transfer
viewpoint, smaller-diameter tubes yield higher heat transfer coefficients and result in a more
compact higher heat transfer coefficients and result in a more compact. However, larger-
diameter tubes are easier to clean and more rugged. The foregoing common sizes represent a
compromise. For mechanical cleaning, the smallest practical size is 19.05 mm and for
chemical cleaning, smaller sizes can be used provided that the tubes never plug completely.

3.9. Tube Length

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Tube length affects the cost and operation of heat exchangers.

Longer the tube length (for any given surface area),
• Fewer tubes are needed, requiring less complicated header plate with fewer holes drilled
• Shell diameter decreases resulting in lower cost
Typically tubes are employed in 2.4m, 3.7m, 4.6m, and 6.1m lengths
Mechanical cleaning is limited to tubes 6.1m and shorter; although standard exchangers can
be built with tubes up to 12.2 m. Shell-diameter-to-tube-length ratio should be within limits
of 1/5 to 1/15

3.10. Tube layout

Tube layout is characterized by the included angle between tubes and there are two standard
types of tube layouts, the square and the equilateral triangle type.
• Triangular pitch (30 layout) is better for heat transfer and surface area per unit
length (greatest tube density.)

• Square pitch (45 & 90 layouts) is needed for mechanical cleaning.

Note that the 30°, 45° and 60° are staggered, and 90° is in line.

Triangular Pitch Square Pitch

For the identical tube pitch and flow rates, the tube layouts in decreasing order of shell-side
heat transfer coefficient and pressure drop are: 30°, 45°, 60°, and 90°. The 90° layout will
have the lowest heat transfer coefficient and the lowest pressure drop. The square pitch (90°
or 45°) is used when jet or mechanical cleaning is necessary on the shell side. In that case, a

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minimum cleaning lane of ¼ in. (6.35 mm) is provided. The square pitch is generally not
used in the fixed header sheet design because cleaning is not feasible. The triangular pitch
provides a more compact arrangement, usually resulting in smaller shell, and the strongest
header sheet for a specified shell-side flow area. It is preferred when the operating pressure
difference between the two fluids is large.

3.11. Tube Pitch

The selection of tube pitch is a compromise between a close pitch (small values of ) for

increased shell-side heat transfer and surface compactness, and an open pitch (large values

of ) for decreased shell-side plugging and ease in shell-side cleaning. Tube layout and

tube locations are standardized for industrial heat exchangers.

3.12. Fluid Allocation

Tube side is preferred under these circumstances
Fluids which are prone to foul
• The higher velocities will reduce buildup
• Mechanical cleaning is also much more practical for tubes than for shell
Corrosive fluids are usually best in tubes
• Tubes are cheaper to fabricate from exotic materials
• This is also true for very high temperature fluids requiring alloy constructions
Streams with low flow rates to obtain increased velocities and turbulence;
High pressure streams since tubes are less expensive to build strong Streams with a low
allowable pressure drop.
Viscous fluids go on the shell side, since this will usually improve the rate of heat transfer.
On the other hand, placing them on the tube side will usually lead to lower pressure drops.

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3.13. Basic Design Procedure

Heat exchanger must satisfy the
1 Heat transfer requirements (design or process needs)
2 Allowable pressure drop (pumping capacity and cost)
Steps in designing a heat exchanger can be listed as:
1 Identify the problem
2 Select a heat exchanger type
3 Calculate/Select initial design parameters
4 Rate the initial design.
5 Calculate thermal performance and pressure drops for shell and tube side

3.13.1. Size of Shell and Tube Heat Exchanger

The initial size (surface area) of a heat exchanger can be estimated from

Where
A = Outside tube surface area
q = Heat duty – heat exchange between tube and shell side
U = Overall heat transfer coefficient
F = Correction factor
Tm = Log mean temperature difference

3.13.2. Overall Heat Transfer Coefficient

Estimated from the individual heat transfer coefficients (h) Shell wall, outside & inside tube
diameter.

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Where
U =Overall heat transfer coefficient
h = Tube side heat transfer coefficient
h = Shell side heat transfer coefficient
d = Tube outer diameter
d = Tube inner diameter

3.13.3. Heat Balance of Shell & Tube Heat Exchanger

Heat load of a heat exchanger can be estimated from heat balance

Where

= Mass flow rate

c = Specific heat
q = Heat Capacity

If three of the temperatures are given, the fourth can be calculated using the above equation.

3.13.4. Total Number of Tubes

Once the total tube outside surface area A is estimated a cost effective heat exchanger
configuration needs to be calculated. Number of tubes N is dependent on tube side flow

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conditions.

Where
N = Number of tubes
L = Length of the tube
d = Tube outer diameter
It is related to the shell diameter (Ds), tube length (L) and tube diameter (do) together with
the allowable pressure drop and the total tube side flow rate hence the heat transfer
coefficient. The total number of tubes can be predicted as a function of the shell diameter by
taking the shell circle Ds and dividing it by the projected area of the tube layout pertaining
to a single tube A1

3.13.5. Rating an exchanger means to evaluate the thermo-hydraulic

Performance of a fully specified exchanger Input to the rating process is heat exchanger
geometry (constructional design parameters), process conditions (flow rate, temperature,
and pressure) and material/fluid properties (density, thermal conductivity)
First output from the rating process is either the outlet temperature for fixed tube length or
the tube length itself to meet the outlet temperature requirement.
Second output from the rating process is the pressure drop for both fluid streams hence the
pumping energy requirements and size.

3.15.5.1. Insufficient Thermal Rating

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If the output of the rating analysis is not acceptable, a geometrical modification should be
made. If the required amount of heat cannot be transferred to satisfy specific outlet
temperature, one should find a way to increase the heat transfer coefficient or increase
exchanger surface area .One can increase the tube side heat transfer coefficient by increasing
the fluid velocity - Increase number of tube passes One can increase the shell side heat
transfer coefficient by decreasing baffle spacing and/or baffle cut. One can increase the
surface area by
1 Increasing the heat exchanger length
2 Increasing the shell diameter
3 Multiple shells in series

3.15.5.2. Insufficient Rating Pressure Drop

If the pressure drop on the tube side is greater than the allowable pressure drop, then the
number of tube passes can be decreased or the tube diameter can be increased which may
result to
• decrease the tube length – (Same surface area)
• increase the shell diameter and the number of tubes
If the shell side pressure drop is greater than the allowable pressure drop then baffle spacing,
tube pitch, and baffle cut can be increased or one can change the baffle type

3.13.6. Equivalent Shell Diameter - De

The equivalent diameter of the shell is taken as four times the net flow area as layout on the
tube sheet (for my pitch layout) divided by the wetted perimeter

Rectangular Pitch Square Pitch

Where
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Final Year Project Heat Exchanger Design Software

Pt= Pitch of the tube

do= Outside diameter of the tube

3.13.7. Tube side Heat Transfer Coefficient

It is the same as the double pipe heat exchanger tube side heat coefficient. And it is
given as

Where
h = heat transfer coefficient for the fluid in Tube
R = Reynolds number for the fluid in tube
P = Prandatal number for the fluid in tube
K = Thermal Conductivity of the fluid in tube
d = Equivalent diameter

h is the value of the hi referred to the outside diameter of the tube

3.13.8. Shell Side Heat Transfer Coefficient

Baffled Flow
When the tube bundle employs baffles, the heat transfer coefficient is higher than the
coefficient for undisturbed flow around tubes without baffles.
For a baffled heat exchanger the higher heat transfer coefficients result from the increased
turbulence. The velocity of fluid because of the constricted area between adjacent tubes
across the bundle fluctuates.

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3.13.9. Shell Side Heat Transfer Coefficient without Baffles – Flow along
the Tube Axis

The heat transfer coefficient outside the tube bundle is referred to as the shell-side heat
transfer coefficient. If there are no baffles, the flow will be along the heat exchanger inside
the shell. Then, the heat transfer coefficient can be based on the equivalent diameter, De
(Same as a double-pipe heat exchanger)

Where
h = Heat transfer coefficient in the shell side
d = Equivalent shell diameter
R = Reynolds Number
Prs = Prandtal Number
b = Bulk fluid temperature
w = Wall temperature

3.13.10. Clean Overall Heat Transfer Coefficient

Where

U = Overall Clean Heat Transfer

3.13.10. Fouling Factor

= Fouling factor
If Rd equals or exceeds the required dirt factor proceed under the pressure drop

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3.13.11. Baffle Spacing

It is the centre to centre distance between baffles, and dependant on the values of shell
inner diameter.

Where
B baffle spacing
D = Shell inner diameter

3.13.12. Shell Side Mass Velocity - Gs

There is no free-flow area on the shell side by which the shell-side mass velocity, Gs, can be
calculated for this reason; fictional values of Gs can be defined based on the bundle cross
flow area at the hypothetical tube row possessing the maximum flow area corresponding to
the center of the shell.

Where
Ds = Shell diameter
C = Clearance between adjacent tubes
Pt= Pitch size
B = Baffle spacing

Clearance between tubes

3.13.13. Shell Side Pressure Drop

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The shell-side pressure drop depends on the number of tubes the fluid passes through in the
tube bundle between the baffles as well as the length of each crossing. If the length of a
bundle is divided by four baffles, for example, all the fluid travels across the bundle five
times. A correlation has been obtained using the product of distance across the bundle, taken
as the inside diameter of the shell, Ds and the number of times the bundle is crossed.
L is the heat exchanger length, B is the baffle spacing.

Where,
f = friction factor

f= ,

Shell inside diameter of shell side

g = acceleration due to gravity
= density of water
= equivalent diameter of shell side

Number of baffles and is given by

3.13.14. Tube Side Pressure Drop

The tube-side pressure drop can be calculated by knowing the number of tube passes, Np
mean fluid velocity inside the tube, um, and length of the heat exchanger, L.
The change of direction in the passes introduces an additional pressure drop, Pr due to
expansions and contractions that the tube fluid sudden experiences during a return.

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Where,
f = friction factor
N = Number of tube pass
L = length of tube pass
G t= Mass flow

3.13.13Mass Flow Rate in the Tube Side

Where is number of tube

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CHAPTER FOUR

5. FLOW CHART
Using the flow chart is an essential part to both understand and show the working
principle of the software. The program has many declared values, defined
functions and loops which perform different tasks which are made easier to
understand. The flow chart here shows the overall performance of the software.

STARTING UP THE
SOFTWARE

START UP FORM
It shows up and stays visible for 3 seconds
and after that it hides leaves calling the
next form to show up

OPTION FORM
It provides the option for the user to choose two
types of heat exchanger. And from the selected one
it gives standard and user defined option.
Then automatically continues to the next form

SPECFICATION FORM
Select the kind and type of the fluid for both the tube and annulus
side. On this form the designer asked to enter the inlet and outlet temperatures of
both tube and annulus side. And the designer asked to enter the mass flow rates for
both fluids. The designer must enter all the temperatures or the three of the
temperatures values. If one of them is undetermined, he must enter the specific
heat for both fluids to calculate the unknown temperature values. Clicking the next
button will hide this form and shows the next form

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PHYSICAL PROPERTIES FORM

This form gives two options for the designer. Either designer can fill the
properties of the fluids or clicking on the database using the mean temperature of
the fluids can fill the values. Whatever the designer use, he must enter the fouling
factor for both cases. Clicking the next button will hide this form and shows the
next form.

HAET CAPACITY FORM

On this form the heat capacity is calculated by clicking the calculate button. The
form also provides option to calculate the LMTD either counter flow or parallel
flow. In addition, it acquaints the designer to select one of the standard tube
lengths. Clicking the next button will hide this form and shows the next form.

For the double pipe case if he TYPE AND PARAMETERS FORM

selects user defined case he has On this form, the designer is asked to select for
to fill the tube inlet and outlet standard case the exchanger type, exchanger layout,
diameter and annulus inner the type of the tube arrangement, shell inner diameter,
diameter number of shell and tube passes and the tube length.
But for user defined case the designer is supposed to
enter his own values or values of the standard table of
the tube outer diameter, inner diameter and annulus
inner diameter. Clicking the next button will hide this
form and shows the next form.

RESULTS OF PROPOSED DESIGN FORM

The result form it gives the required data that are
displayed

BAFFLE CUT AND TYPE FORM

In this form the designer asked to select baffle cut and
type. Baffle spacing and number of baffles. Clicking the
next button will hide this form and shows the next form.

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HEAT EXCHANGER REQUIREMENT FORM

It gives an option for the designer to select either the
pressure drop or heat transfer requirements. Clicking the
next button will hide this form and shows the next form.

RESULTS OF PROPOSED DESIGN FORM

The result form it gives the required data that are displayed

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CHAPTER FIVE
6. HOW TO USE THE PROGRAM

6.1. Getting Started

Go to the start menu and click on the program and you will find “Heat Exchanger
Design”. Clicking it will run the program.

6.2. Option Form

On the selection from the two options of Shell & Tube and Double Pipe heat exchanger
are provided. In addition you are required to select either a standard or user defined case.
Then it will automatically take you to the next form.

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6.3. Specification Form

The specification form takes information from the designer. It takes the inlet and outlet temperatures,
and the mass flow rates of the two fluids. The designer must at least inter the three required
temperatures of fluids. If the designer enters only three of the four temperatures then he must enter
specific heat capacities of the two streams.

Click on the button to select the

Click on the component name button to type of fluids
select the type of component

Click on this button to select the type of

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6.4. Material Properties Form

The material property form takes information either from the designer or from the database. If it is
from the data base it selects values from the standard table based on the mean bulk temperature.

Enter the Fouling Factor

Click on the database button to select

values from the standard table
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6.5. Database Form

It is a form acquainted with the material property form and it is essential to load all the
properties of a selected fluid stream from the data base.
For simplicity of considering various fluids steams one by one the add button which is
provided here makes the task possible by adding fluids of the required type from the data
base.

Click on the load button to

load material from the
database

It displays the material loaded

from the database

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6.6. Heat Capacity Form

The form calculates the heat capacity from the values entered in the specification and material
property forms.
Click on the calculate button to
It also calculates the log mean temperature difference. calculate the heat capacity

It give an option for the user to

select standard tube length

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Click on the counter flow or parallel
Mekelle university By: Aklilu A.
flow to calculate the LMTD based on
& Fasil M.
your selection
Final Year Project Heat Exchanger Design Software

6.7. Tube Parameter Form

This form lets the user to enter values based on either his requirement or from the standard table.

Enter the tube inner and

outer diameters

Select tube inner and outer

Enter the annulus inside diameters values from the table
diameter

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Select annulus inner diameter from
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the table
Final Year Project Heat Exchanger Design Software

6.8. Result Form

It displays the results of the proposed design of the double pipe heat exchanger.
It also provides the minimum Tube side and Annulus side pressure drop based on the recommended
intervals.

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6.9. Heat Exchanger Parameter Form for User Defined

This form it gives an option for the user to select in addition to standard case the tube
outer diameter when he select from the standard table .If he enter his own values he has
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to enter in addition tube inner diameter ,pitch and number of tubes

Click on this button to Enter your own outer and

select tube outer diameter inner tube diameter, pitch and
from the table number of tubes

6.10. Parameter Form for Standard Case

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This form displays the types of exchangers, exchanger layout, shell inner diameter, tube
arrangement, and tube length.

Insert number of tube pass and

shell pass
Click on the DS button to select the
standard shell inner diameter

Click on this button to Click on this to select the tube

select the tube length arrangement

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6.11. Baffle Cut and Type Form

This form it give an option for the user to select baffle cut, baffle type.

Click on this button to Click on the calculate button to

select baffle spacing calculate the number of baffles

6.12. Heat Exchanger Requirement Form

This form gives an option for the user to select either the pressure drop requirement or
heat transfer requirement.

Click on this button to

select heat transfer
requirement

Click on this button to

select pressure drop
requirements

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6.13. Shell and Tube Result Form

It displays the proposed design parameters based on the heat transfer requirement we
select.
The result sheet is especially essential to provide all the data’s which are essential for the
manufacturing purpose and also for selection of the heat exchanger type.

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CHAPTER SIX
7. Future work
The soft ware developed here is not acquainting with graphics because of the lake of time. Including
of the method makes the soft ware more accurate especially for manufacturing purpose.
The graphic representation of the soft ware can be made with the knowledge of AutoCAD and the
results of the design.

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CHAPTER SEVEN
8. Conclusion and Recommendation
Now days, most of the design are supported by computers. Computer aided design help in providing
better accuracy along with simplicity of the design by reducing the tire some tasks.
The visual basic programming language along with the concept of heat exchangers design made the
soft ware possible. In the program both types of heat exchangers the double pipe and the shell and
tube type are included.
To increase the essentiality of the program, the soft ware developed provides an option of selecting
either the standard or the user defined one. Hence a designer can have all his calculations based on the
standard table only or based on his own values along with values of the standard table.
At the end of the program, the result sheet provides the designer with the values of the essential
parameter, which are especially necessary for manufacturing purpose.

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Bibliography
1. ASHRAE Hand book CD, 1999
2. Thermal engineering
3. Donald Q.Kern. Process Heat Transfer. McGraw – Hill Inc.
4. Frank Kreith and Mark S. Bohn. Principle of Heat Transfer. PWS Publishing
Company, 5th edition.
5. Frank P.Incropera and David P.Dewitt. Introduction to heat Transfer. John
wiley and sons.3rd edition.
6. G.R.Nagpal. Machine design. Khama publishers
7. J.B Jones and R.E Dugan. Engineering thermodynamics .A Simon and
Schuster Company.
8. J.P.Holman. Heat Transfer. United State of America. 8th edition.
9. Keith E.Herold, Keinhard, Radermacher and Sanfrord A.klein. Absorption
chillers and Heat Pumps. United state of America.
10. R.F.Boehm. Design Analysis of Thermal system. United state of America
11. S.C.Arora and S.Domkundwar Anand V.Domkundwar. A course In Heat
and mass Transfer.Gagan kapur for Dhanpat Rai and Co. (P).Ltd.Delhi-
110006.

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Appendix

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