DESIGN OF HEAT EXCHANGER

A Project Report for Industrial Internship Project

Submitted by

PRIYA

In the partial fulfillment for the award of the degree of

B.Tech
In the

CHEMICAL DEPARTMENT

UNIVERSIYTY INSTITUTE OF ENGINEERING AND TECHNOLOGY

(CSJMU)

at

Ardent Computech Pvt. Ltd.

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 CERTIFICATE FROM SUPERVISOR

This is to certify that Priya, University Registration No:

CSJMA17001390201 have successfully completed the project titled
"Design of Heat Exchanger" under my supervision during the period from
“07/07/2020” to “01/09/2020” which is in partial fulfilment of
requirements for the award of the B.Tech degree and submitted to the
Department of “CHEMICAL” of “UNIVERSIYTY INSTITUTE OF
ENGINEERING AND TECHNOLOGY (CSJMU)”.

___________________________
Signature of the Supervisor

Date: 22/09/2020
Name of the Project Supervisor:
Soumyadip Sarkar

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 CONTENTS:

 ACKNOWLEDGMENT 04

 INTRODUCTION 05

 DESIGN CHARACTERISTICS 06

 TYPES OF HEAT EXCHANGER 11

 PRACTICAL EXAMPLES 13

 PROJECT 16

 REFERENCE 20

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 ACKNOWLEDGEMENT

The achievement that is associated with the successful completion of any task
would be incomplete without mentioning the names of those people whose
endless cooperation made it possible. Their constant guidance and
encouragement made all my efforts successful.

We take this opportunity to express our deep gratitude towards our project
mentor, Soumyadip Sarkar for giving such valuable suggestions, guidance and
encouragement during the development of this project work.

Last but not the least we are grateful to all the faculty members of Ardent
Computech Pvt. Ltd. for their support.

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 INTRODUCTION
A heat exchanger is a device used to transfer heat between two or more fluids.
The fluids can be single or two phase and, depending on the exchanger type,
may be separated or in direct contact.

Depending on the type of heat exchanger used the heat transfer process can
be from liquid-liquid, gas-gas, liquid-gas. The designing of heat exchanger can
be based on many factors; it could depend upon the construction material and
component or on the heat transfer mechanism or flow configurations. Based
on above configuration heat exchangers are designed accordingly. In this
report we will go through all the types of heat exchangers based on above
configuration then we would learn some real applications, advantages and
disadvantages of it in the industries. We will also design a heat exchanger using
AUTOCAD software for our final project.

The design of a heat exchanger is an exercise in thermodynamics, which is the

science that deals with heat energy flow, temperature, and the relationships to
other forms of energy. To understand heat exchanger thermodynamics, a
sound knowledge about the three ways in which heat can be transferred –
conduction, convection, and radiation is prerequisite to know

Regardless of the type and design, all heat exchangers operate under the same
fundamental principles—namely the Zeroth, First, and Second Laws of
Thermodynamics—which describe and dictate the transference or “exchange”
of heat from one fluid to another. Altogether, these principles dictate the
underlying mechanisms and operations of heat exchangers; the Zeroth law
establishes temperature as a measurable property of thermodynamic systems,
the First Law describes the inverse relationship between a system’s internal
energy (and its converted forms) and that of its surrounding environment, and
the Second Law expresses the tendency for two interacting systems to move
towards thermal equilibrium. Thus, heat exchangers function by allowing a
fluid of higher temperature (F1) to interact—either directly or indirectly—with
a fluid of a lower temperature (F2), which enables heat to transfer
from F1 to F2 to move towards equilibrium. This transfer of heat results in a
decrease in temperature for F1  and an increase in temperature for F2.

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 DESIGN CHARACTERISTICS

As described earlier heat exchanger can be broadly characterized on the basis of

flow configuration, heat transfer mechanism and construction method.

A. Flow Configuration
 Cross-flow
In crossflow heat exchangers, fluids flow at an angle of 900 to one
another.

 Co-current flow
Cocurrent flow heat exchangers, also referred to as parallel flow
heat exchangers, are heat exchanging devices in which the fluids
move parallel to and in the same direction as each other.

 Counter-current flow
Counter-flow exchangers are in which the two fluids flow
parallel to each other but in opposite directions. This type

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 of flow arrangement allows the largest change in
temperature of both fluids and is therefore most efficient.

 Hybrid flow
In industrial heat exchangers, hybrids of the above flow types are
often found. It exhibit some combination of the characteristics of
the previously mentioned flow configurations. These types of heat
exchangers are typically used to accommodate the limitations of an
application, such as space, budget costs, or temperature and
pressure requirements.

To give more clear idea about the applications, the countercurrent offers the
greatest efficiency among all, co-current results in lower efficiencies than a
counter flow arrangement, although it allows the greatest thermal uniformity
across the walls of the heat exchanger. The efficiencies of hybrid heat
exchangers falls between that of countercurrent and cocurrent heat exchangers.

B. Heat transfer mechanism

There are two types of heat transfer mechanisms employed by heat
exchangers—single-phase or two-phase heat transfer.

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 In single-phase heat exchangers, the fluids do not undergo any
phase change throughout the heat transfer process, meaning that
both the warmer and cooler fluids remain in the same state of
matter at which they entered the heat exchanger. For example, in
water-to-water heat transfer applications, the warmer water loses
heat which is then transferred to the cooler water and neither
change to a gas or solid.
On the other hand, in two-phase heat exchangers, fluids do
experience a phase change during the heat transfer process. The
phase change can occur in either or both of the fluids involved
resulting in a change from a liquid to a gas or a gas to a liquid.
Typically, devices that employ a two-phase heat transfer
mechanism require more complex design considerations than ones
that employ a single-phase heat transfer mechanism. Some of the
types of two-phase heat exchangers available include boilers,
condensers, and evaporators.

C. Construction method

 Recuperative vs. regenerative

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 Heat exchangers can be classified as recuperative heat exchangers
and regenerative heat exchangers.

The difference between recuperative and regenerative heat

exchanger systems is that in recuperative heat
exchangers (commonly called recuperators), each fluid
simultaneously flows through its own channel within the heat
exchanger. On the other hand, regenerative heat exchangers, also
referred to as capacitive heat exchangers or regenerators,
alternately allow warmer and cooler fluids to flow through the
same channel. Both recuperators and regenerators can be further
separated into different categories of exchangers, such as direct or
indirect and static or dynamic, respectively. Of the two types
indicated, recuperative heat exchangers are more commonly
employed throughout industry.
 Direct vs. indirect

Recuperative heat exchangers employ either direct contact or

indirect contact transfer processes to exchange heat between fluids.

In direct contact heat exchangers, the fluids are not separated

within the device and heat transfers from one fluid to another
through direct contact. On the other hand, in indirect heat
exchangers, the fluids remain separated from one another by
thermally conductive components, such as tubes or plates,
throughout the heat transfer process. The components first receive
heat from the warmer fluid as it flows through the heat exchanger,
and then transfer the heat to the cooler fluid as it flows through.
Some of the devices which employ direct contact transfer processes
include cooling towers and steam injectors, while devices that
employ indirect contact transfer processes include tubular or plate
heat exchangers.
 Static vs. dynamic

There are two main types of regenerative heat exchangers—static

heat exchangers and dynamic heat exchangers. In static
regenerators (also known as fixed bed regenerators), the heat
exchanger material and components remains stationary as fluids
flow through the device, while in dynamic regenerators the
material and components move throughout the heat transfer
process. Both types are at risk of cross-contamination between
fluid streams, necessitating careful design considerations during
manufacturing.

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  Types of components and materials employed

There are several types of components which can be employed in

heat exchangers, as well as a wide range of materials used to
construct them. The components and materials used depend on the
type of heat exchanger and its intended application.
While metals are highly suitable—and commonly used—for
constructing heat exchangers due to their high thermal
conductivity, as in the case of copper, titanium, and stainless
steel heat exchangers, other materials, such as graphite, ceramics,
composites, or plastics, may offer greater advantages depending on
the requirements of the heat transfer application.

TYPES OF HEAT EXCHANGER

Based on the above configurations heat exchangers are of following types:

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 Shell and tube heat exchangers

This equipment can be found in any Petroleum refinery unit. It consists of

a cylindrical shell inside which number of tubes are mounted. Two fluids
can exchange heat, one fluid flows over the outside of the tubes while the
second fluid flows through the tubes. The fluids can be single or two
phase and can flow in a parallel or a cross/counter flow arrangement.

 Double pipe heat exchangers

A form of shell and tube heat exchanger, double pipe heat

exchangers employ the simplest heat exchanger design and configuration
which consists of two or more concentric, cylindrical pipes or tubes (one
larger tube and one or more smaller tubes).

 Plate heat exchangers

It consists of two rectangular end members which hold together a number

of embossed rectangular plates with holes on the corner for the fluids to

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 pass through. Each of the plates is separated by a gasket which seals the
plates and arranges the flow of fluids between the plates. This type of
exchanger is widely used in the food industry because it can easily be
taken apart to clean. If leakage to the environment is a concern it is
possible to weld two plate together to ensure that the fluid flowing
between the welded plates cannot leak.

 Condensers, evaporators, and boilers

Boilers, condensers, and evaporators are heat exchangers which employ a

two-phase heat transfer mechanism. As mentioned previously, in two-
phase heat exchangers one or more fluids undergo a phase change during
the heat transfer process, either changing from a liquid to a gas or a gas to
a liquid. Condensers are heat exchanging devices that take heated gas or
vapor and cool it to the point of condensation, changing the gas or vapor
into a liquid. On the other hand, in evaporators and boilers, the heat
transfer process changes the fluids from liquid form to gas or vapor form.

PRACTICAL EXAMPLES

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Heat exchangers are devices used throughout industry for both heating and
cooling processes. Several variants of heat exchangers are available and find
application in a wide range of industries, including:
 ASME heat exchangers
 Automotive heat exchangers (typically as car radiators)
 Brewery heat exchangers
 Chemical heat exchangers
 Cryogenic heat exchangers
 Marine heat exchangers
 Power generation heat exchangers
 Refrigeration heat exchangers

Furnaces—the process fluid passes through the furnace in straight or helically

wound tubes and the heating is either by burners or electric heaters.
Air Cooled Heat Exchangers consist of bundle of tubes, a fan system and
supporting structure. The tubes can have various type of fins in order to provide
additional surface area on the air side. Air is either sucked up through the tubes
by a fan mounted above the bundle (induced draught) or blown through the
tubes by a fan mounted under the bundle (forced draught). They tend to be used
in locations where there are problems in obtaining an adequate supply of
cooling water.

Type of Heat Common Industries and Applications

Exchanger
Shell and Tube  Oil refining
 Preheating
 Oil cooling
 Steam generation
 Boiler blowdown heat recovery

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  Vapor recovery systems
 Industrial paint systems
Double Pipe  Industrial cooling processes
 Small heat transfer area requirements
Plate  Cryogenic
 Food processing
 Chemical processing
 Furnaces
 Closed loop to open loop water
cooling
Condensers  Distillation and refinement processes
 Power plants
 Refrigeration
 HVAC
 Chemical processing
Evaporators/Boilers  Distillation and refinement processes
 Steam trains
 Refrigeration
 HVAC
Air Cooled/Fan  Limited access to cooling water
Cooled
 Chemical plants and refineries
 Engines
 Power plants
Adiabatic Wheel  Chemical and petrochemical
processing
 Petroleum refineries

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  Food processing and pasteurization
 Power generation
 Cryogenics
 HVAC
 Aerospace
Compact  Limited space requirements (e.g.,
aircrafts and automobiles)
 Oil cooling
 Automotive
 Cryogenics
 Electronics cooling

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 PROJECT

The following heat exchanger is created using the software AUTUCAD , below
is the 2D figures of the model from every angle which was necessary for the
production of final 3D model. The below 2D diagrams have all the dimensions
in meters only.

This gives the clear

idea about the inner
and outer radius of
the shell. Also gives
the measurements
for bolting.

This part show the length of the heat

exchanger and also specifies the dimensions
for inlet and outlet knob.

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It shows the number of tubes to be mounted and its
diameter. The right side of the diagram shows the
placement of baffles.

The left diagram gives the basic 2D sketch which

can be revolved to make the shell cover and the
right side shows its cross section which have holes
for bolting.

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 This shows the dimensions for head cover, the
cover for knobs and the heat exchanger stand.
The head cover and knob cover are the basic 2D
sketch which can be revolved in Autocad to get
required 3D model.

The all the above information presented is sufficient to make the 3D model of
the shell and tube heat exchanger. In the next page the whole look of 3D model
is presented with its cross-sectional view.

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Final 3D model of shell and tube heat exchanger.

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 REFERENCES

1. https://www.thomasnet.com/articles/process-
equipment/understanding-heat-exchangers/#register

2. http://www.thermopedia.com/content/832/

3. https://www.sacome.com/en/heat-exchanger-advantages-
uses-applications/

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