Modeling and Optimization of the Performance Parameters of a Single Pass Shell and Tube Heat Exchanger—An Approach Using Response Surface Methodology

Abstract

The objective of this research work is to obtain optimum values of the parameters, namely mass flow rate of hot and cold fluids, hot fluid inlet temperature so as to maximize heat transfer rate, number of transfer unit or NTU, and effectiveness of a one shell one tube pass counter-flow shell and tube heat exchanger. A statistical data analysis tool, namely the response surface methodology is applied to model, analyze, and optimize the heat transfer performance parameters. A second-order Box-Behnken design is used for the experimental design and to study the main factor effects as well as interaction effects of the controllable variables on responses. Analytical calculations are performed on three factors, two levels with Box-Behnken design matrix with full replication. The developed regression models for heat transfer rate, NTU and effectiveness fit well with the expetimental data as R-square and adjusted R-square value is above 90%. The optimum settings for mass flow rates of hot and cold fluids and hot fluid inlet temperature as obtained from the analysis are, respectively, 50 l/h, 200 l/h, and 80 °. With the optimum settings, the maximized values of heat transfer rate, NTU and effectiveness are found to be 5820.01 J/s, 1.262, and 0.701, respectively.KeywordsShell and tube heat exchangerResponse surface methodologyHeat transfer