Shell Exchanger Research Articles

Prediction of transient melt fraction in metal foam - nanoparticle enhanced PCM hybrid shell and tube heat exchanger: A machine learning approach

Phase change materials (PCMs) have gained popularity in storing thermal energy due to their high energy storage capacity per volume. However, the low performance of the PCM heat exchanger (HX) is primarily due to poor thermal conductivity. The performance of these systems can be improved by using metal foams, nanoparticles, fins, etc. In the present work, the melt fraction (MF) in PCM shell and tube (ST) heat exchanger (HX) with a hybrid combination of metal foam + Graphene nanoplatelets (GNP) nanoparticles (NPs) is predicted using the Machine learning (ML) algorithms. This study analyzes 0.93, 0.95, and 0.97 porosity copper metal foams and 0.5% and 1% volume fraction GNP NPs considering the orientation (0°, 30°, 45°, 60° and 90°) effects of HX. Numerical simulations are carried out to collect the data, to train, cross-validate, and testing. Linear regression (LR), support vector regression (SVR), XGBoost (XGB), and K nearest neighbor (K NN) ML algorithms are used to predict the MF of the PCM in HX with respect to time. MF is predicted during both the melting and solidification processes. Among the ML models selected, the LR model has predicted the transient variation of MF with the highest accuracy during both melting and solidification.

Thermal analysis and performance investigations of shell and tube heat exchanger using numerical simulations

The steam condenser is a crucial component in power plants, playing a vital role in influencing the overall performance of steam power plants. This paper delves into a detailed assessment of the thermal aspects and evaluation of steam surface condensers. To conduct this rigorous evaluation, we meticulously crafted a three-dimensional (3D) model of a multi-tube single-pass counter-flow heat exchanger using ANSYS Design-Modeller. Within this model, a multiphase mixture model was harnessed to replicate the condensation process that takes place within the condenser. After the model’s development, a series of computational fluid dynamics (CFD) simulations were expertly executed utilizing ANSYS Fluent Workbench. The simulations encompassed diverse cooling water flow rates and steam inlet velocities. Notably, two sets of CFD simulations were carried out: the initial set featured a velocity inlet in the condenser, while the second set involved CFD simulations with a pressure steam inlet. The findings derived from these simulations unveiled a noteworthy correlation between the condensation rate within the shell and both the rate of circulating water flow and the operational pressure of the condenser. Additionally, it was discerned that the condensation rate could be further influenced by the specific geometry of the condenser. In sum, this study concludes that optimizing the geometrical configuration and baffle arrangements holds promise for increasing the condensation rate and overall performance of steam condensers employed within steam power plants.

Thermo-hydraulic rating of a shell and tube heat exchanger for acetone cooling using bell-delaware method

Shell and tube heat exchangers are becoming the most popular devices for the transfer of heat in industrial process applications. In the present work, the thermo-hydraulic rating of a shell and tube heat exchanger proposed to cool an acetone stream was carried out using the Bell-Delaware methodology. An overall heat transfer coefficient value of 426.70 W/m2.K, a calculated heat transfer area of 121.46 m2, and a percent excess area of 20.83% were obtained. Both the pressure drop of acetone and water had values of 1,622.36 Pa and 3,020.46 Pa, respectively. The proposed shell and tube heat exchanger can be used satisfactorily for the required application, since the percent excess area does not exceed the 25%, and the pressure drops of both fluid streams are below the limit values established by the process.

Thermo-hydraulic design of a horizontal shell and tube heat exchanger for ethanol condensation

Horizontal shell and tube condensers are widely used in several industrial applications due to its versatility and heat transfer efficacy. In the present work, the thermo-hydraulic design of a horizontal shell and tube heat exchanger intended to condense 25,000 kg/h of a pure ethanol stream was carried out. Several key design parameters were calculated such as the number of tubes, heat transfer area, overall heat transfer coefficient, shell internal diameter, baffle spacing, as well as the pressure drop for both streams. The heat exchanger type is of pull-through floating head, and will present a number of tubes of 731, a heat transfer area of 223.68 m2, an overall heat transfer coefficient of 499.36 W/m2.ºC, a shell internal diameter of 1.684 m and a baffle spacing of 0.674 m. Around 157 kg/s of chilled water will be required for this heat transfer service. The values of both the shell side (10,069.25 Pa) and tube side (42,192.63 Pa) pressure drop are below the maximum values set by the process.

Thermal analysis of PCM magnesium chloride hexahydrate using various machine learning and deep learning models

The heat storage through Phase change material (PCM) is important for sustainable development. Previously a set of experiments were carried out on 14.5 kg of PCM, Magnesium chloride hexa hydrate in a shell and tube heat exchanger. The results are used to build machine learning and deep learning models such as Support vector machine, Random forest, Extreme gradient boost, Catboost and Artificial neural network to replicate the experiment virtually. The input variables are heat transfer fluid’s inlet and outlet temperature and time elapsed while PCM’s temperature is predicted in both charging and discharging cycles. The hyperparameter tuning is done using hyperband. Catboost model outperformed all other models with highest variance in both the cycles (0.9945 and 0.9299) and highest score: 0.993 and 0.9466. It has got the lowest MAPE (0.2% and 0.1 %). Hence this model can be recommended over these other models for doing system simulation of problems involving both charging and discharging cycles of the PCM.

Large eddy simulation-based analysis of the flow-induced noise characteristics of shell and tube heat exchanger

The energy sectors and chemicals depend heavily on shell & tube heat exchangers, which are also employed extensively in the modern manufacturing industry. Flow-induced noise has an important impact on how heat exchangers function. and should not be overlooked. Computational Fluid Dynamics (CFD) and acoustic-solid coupling are used in this paper to investigate the fluidic and vibration noise of tubes in shell & tube heat exchangers. In order to study the characteristic law of noise caused by flow, the flow and acoustic fields are combined in this research, with the flow field being estimated by accepting a large eddy simulation. A combination methodology of theoretical analysis and numerical simulation is utilized to analyze the influence of pipe type, pipe spacing, flow direction outside the pipe, flow velocity outside the pipe, and pipe length on noise. The results indicate that as the diameter of the pipe increases, the noise level rises, and with increasing pipe spacing, the noise decreases. The noise increases as the incidence angle of the fluid inflow increases. When flow rate accelerates, so does the noise. The study presented in this paper can serve as a theoretical and computational foundation for the design of shell & tube heat exchangers.

Pigmented Antifouling Coatings for Improved on-Site Inspection

Sol-gel derived antifouling coatings for use in crude oil heat exchangers have been successfully utilized for years. The combination of a very thin and heat conductive coating with low surface energy and low surface roughness in an inert glass ceramic matrix has proven very effective in preventing fouling accumulation and maintaining sustained production. A challenge using very thin and transparent sol-gel coatings is reassuring that the items are actually coated and are correctly applied. For plate heat exchangers, that may only be single side coated, it is important that the unit is assembled correctly, so that the coated side of the heat exchanger plates face the crude oil. Also, for inspection purposes and for estimation of residual lifetime, it is important to be able to establish the quality of the coating efficiently and quickly – also inside individual tubes of a shell and tube heat exchanger. Here we present ongoing coating development of Thermo Coat 200 (TC200), an antifouling coating stable up to 300 °C/572 °F, which is provided with inert and heat stable pigments that allow quick inspection of coating integrity, both before and after operation. Together with procedures for testing coating repellency and substrate adhesion, the pigmented TC200 coating may facilitate the industrial transition to antifouling coatings.

Enhancement of heat transfer in a vertical shell and tube heat exchanger using air injection and new baffles: Experimental and numerical approach

Vertical shell and tube heat exchangers play a critical role in many industrial processes, and their importance lies in their high heat transfer efficiency, versatility, compact size, easy maintenance, and longevity. To improve the hydrothermal performance, this research investigates the influences of air bubbles injection inside the shell with disc and ring baffles with circular holes, which is the first time to be addressed. The experiments used a fixed oil mass flow rate with 0.23 kg/s inside the tube sides and various cold water flow rates on the shell side within the 0.15–0.23 kg/s range. Three baffles’ configurations, such as single segmental (SSB), disc and ring (DRB), and disc and ring with circular holes (DRCHB), were investigated with different volume flow rates of air bubbles injection in the shell experimentally. A numerical model is performed and validated for the three baffles shapes. The performance parameters such as number of transfer units, effectiveness, heat transfer coefficient, pressure drop, and performance evaluation criterion are studied. The experimental findings showed that efficacy improved with the increase of the cold-water mass flow rates, whereas the DRCHB baffle shape with air injection)10 × 10−5 m3/s(achieved the highest effectiveness with an enhancement rate of 202% to 231%. The DRCHB configuration with maximum air injection has the highest values of the number of transfer units, heat transfer coefficient, and performance evaluation criterion compared to the other baffles configurations moreover, the pressure drop is the smallest in this case DRCHB without air injection. The numerical results showed that both novel configurations (DRB and DRCHB) have more uniform velocity and temperature distributions compared to the segmental baffles, which may effectively increase the hydrothermal performance.

Numerical Simulation of Thermo-hydraulic Behaviour of Shell and Tube Heat Exchanger Equipped with Segmental Baffle and Helical Baffle

The baffle type and structure are critical to enhancing the comprehensive thermo-hydraulic behavior of shell-and-tube heat exchangers (STHX). In the study, Solidworks software was used to establish three-dimensional mesh models of STHX equipped with the segmental baffle and the continuous helical baffle, respectively. ANSYS software was adopted to study the effects of the baffle type and the baffle geometric parameters on the thermo-hydraulic characteristic of STHXs using the pressure drop of the shell side, the coefficient of heat transfer and isobaric JFP factor as the evaluation characteristics. For segmental baffles, better thermo-hydraulic performance could be obtained with a baffle spacing of 200 mm and a gap height of 0.4 D. For helical baffles, an optimized thermo-hydraulic performance could be obtained with a baffle pitch of 150 mm. By comparing the comprehensive thermo-hydraulic performances of STHXs equipped with two different baffles, it could be concluded that the isobaric JFP factor of STHX equipped with the helical baffle was 1.18 times that of STHX equipped with the segmental baffle under the different suitable flow rate.

Enhancement of Heat Transfer Rate with a Low-Pressure Drop in Shell and Tube Heat Exchanger through Optimal Spacing of Helical Baffle

Enhancement of Heat Transfer Rate with a Low-Pressure Drop in Shell and Tube Heat Exchanger through Optimal Spacing of Helical Baffle

Experimental and Numerical Investigation of Al2O3 Nanofluids Based Crude Oil in Shell and Tube Heat Exchanger

Experimental and Numerical Investigation of Al2O3 Nanofluids Based Crude Oil in Shell and Tube Heat Exchanger

A predictive method for pipe in pipe, cylindrical modules and spherical packed bed latent thermal energy storage systems

Due to the transient operation of latent thermal energy storage (LTES) heat exchangers, methods from classical heat exchanger theory such as the effectiveness number of transfer unit method are not applicable. As a result, the study of these systems lacks a general theoretical framework. Recently, an approximate analytical solution method was developed which integrates phase fraction under a constant boundary condition to an LTES heat exchanger with a varying heat transfer fluid temperature. In this paper, the method is applied to three geometries: pipe in pipe, cylindrical modules and spherical packed bed geometries. The resulting model predicts the phase change fraction and effectiveness as a function of time, based on one-dimensional solutions for the movement of the phase change front. The predictions of the analytical model are compared to results of a simplified numerical method of an LTES heat exchanger. The average deviation of the predicted phase change fraction is 3.3 10−2 %, 4.6 10−1 % and 3.7 10−1 % for the pipe in pipe, cylindrical and spherical module respectively. The difference in model performance stems from the description of the fundamental heat transfer behavior. In a second validation step, the outlet temperature predicted by the model is compared to an experimental dataset for a LTES shell and tube heat exchanger. The predictions of the model can be improved further by including sensible heat, heat losses and allowing time-varying inlet conditions.

Simulation of shell and tube type heat exchanger for square geometry using computational fluid dynamics method

Heat exchangers have various types of design models, one example is the shell and tube type heat exchanger. This tool is useful for raising or lowering the temperature. One of its uses is in the hydroelectric power generation industry, namely as an oil cooler bearing. This study aims to design and simulate a shell and tube type heat exchanger with tube inner diameters of 20 mm and 25 mm and also tube arrangement square and rotated square. From the design results obtained a total length of 1318.59 mm, 300 mm outer diameter of the shell and 320 mm inner diameter of the shell. The simulation results show that variations in tube diameter and tube arrangement greatly affect the performance of the heat exchanger, the highest value for the overall heat transfer coefficient is found in the tube square arrangement variation with the number of tubes 61 of 112.15 W/m2.K and the lowest value in the tube arrangement variation square with the number of tubes 55 is 106.48 W/m2.K, the highest value of pressure drop on the shell side is found in the variation of the tube square arrangement with the number of tubes 55.

Thermal-economic optimization design of shell and tube heat exchanger using an improved sparrow search algorithm

Optimal design of heat exchangers is challenging, since complex non-linear relationship exists among the various design parameters. This study aims to construct a full-dimensional thermal-economic model for shell-and-tube heat exchanger using two commonly (i.e., Kern and Bell-Delaware) methods based on Logarithmic-Mean-Temperature-Difference (LMTD) or ε-Number-of-Transfer-Units (ε-NTU) method and proposes a novel solving mechanism based on improved sparrow search algorithm to achieve thermal-economic optimization design of heat exchanger. The improved method organically combines nonlinear gradient descent weight factor, elite reverse strategy, selection-mutation operator to maintain population diversity, enhance convergence speed and avoid being stuck in local optima. Firstly, the constructed model’s accuracy is verified by numerical analysis. Then, the improved sparrow search algorithm is applied to four examples after algorithm parameter tuning, and the results show that the area decreases by 15.62%∼49.30% and total annual cost is reduced by 27.93% compared to the literature. It can also identify feasible solutions at a lower total cost than the metaheuristic method, with reductions of 7.56%∼59.42%(Kern) and 6.26%∼60.19%(Bell-Delaware). Moreover, a multi-objective optimization algorithm is obtained by adding fast non-dominated sorting mechanism and archival gene pool, and the superiority is verified by standard test functions. Finally, a multi-objective optimization scheme with the higher effectiveness-economic benefit is conducted to achieve cost-effectiveness tradeoff for two real-world cases. The results show that total cost of the most economic-efficient scheme decreases by 53.73% and effectiveness increases by 2.33%, while the runtime decreases by 35%. Furthermore, sensitivity analysis of effectiveness and total cost varying with crucial variables is performed and discussed.

An improved equilibrium optimizer for numerical optimization: A case study on engineering design of the shell and tube heat exchanger

The accurate design of the shell-and-tube heat exchanger (STHE) model is crucially important for industries such as process industries, oil refining, thermic devices, and power plants. However, determining its parameters is a challenging task due to the multimodality and nonlinearity of the cost function. Due to such nature, performing algorithms face the challenges of sluggish convergence speed and the proneness to local optima, making it difficult to reach satisfactory solutions. In line with the above challenges, this paper aims to contribute by developing an improved optimization algorithm that can effectively deal with such optimization issues. The proposed algorithm, named Levy-Opposition- Equilibrium Optimizer (LOEO), combines the Equilibrium Optimizer (EO) and the strategies of opposition learning (OL) and Levy flight learning (LFL) to overcome the dilemma of early convergence and getting trapped in local optima. It does this by employing the OL and LFL strategies after performing the EO phase to explore the search space in opposite directions and exploit the search space by means of the Levy distribution pattern, respectively. The proposed LOEO approach aims to enhance the algorithm's ability (provides enhanced exploration capability, effective search space exploitation, and enhanced convergence speed) and reach higher quality solutions to optimization problems. To assess the performance of the suggested LOEO, three stages of analysis are carried out. In the first stage, the performance of the proposed algorithm is investigated on some benchmark problems, including CEC 2005 and CEC 2020, using statistical verifications, convergence behavior, and the boxplot paradigm. The second stage involves the non-parametric Friedman test to assess the significance of results, where the results indicate that the LOEO outperforms the best existing one (equilibrium whale optimization algorithm (EWOA)) by an average rank of the Friedman test greater than 28% for CEC 2005 benchmark functions while outperforming enhanced EO (EEO) by 24% for CEC 2020. Finally, the LOEO's applicability is realized through determining the optimal design structure of the STHE model. The reported results indicate that the LOEO algorithm offers accurate performance compared to competing algorithms as it saves the cost of the device by 39.81% compared to the best existing results, and thus, it is commended to adopt for new applications.

Analisa Pemanfaatan Energi Terbuang (Wasted Energy) pada Perencanaan Heater di PT Samudera Windu Cold Storage

One type of heat exchanger that is widely used is the shell and tube type heat exchanger. The feasibility of making this heat exchanger is seen from the use of heating fluid and heated fluid, how much economic value is obtained. From the data obtained, that in the process of making ice cubes using cold storage which is in the cooling process in the condenser using river water and has a high enough temperature, so that it can be used as a heating source. Through the concept of the Energy Management Program (PME) a heat exchanger with utilizing residual heat as a preheater for the use of water consumption for bathing, washing, and so on.
 

Global optimization of the design of intensified shell and tube heat exchanger using tube inserts

AbstractThis paper investigates global optimization of the detailed design of intensified shell and tube heat exchangers using two tube inserts: twisted tape and coiled wire. Three objectives, including heat exchanger area, total annualized cost, and environmental impact, are respectively minimized. All the design variables are considered as the ones that have discrete values based on their physical nature or manufacturing standards. We present, for the first time, a tailored global optimization approach for the design of intensified shell and tube heat exchanger: Set trimming procedure. We compare the computational performance of our set trimming procedure, exhaustive enumeration, and commercial solvers. The proposed three objectives have certain competitive relationships and multi‐objective optimization is performed to analyze the conflicts among them. Two literature examples are tested for illustration purposes. The solution results indicate that the intensified heat exchanger designed using tube inserts compares well to the regular heat exchanger using plain tube. Compared with commercial solvers, set trimming procedure runs fast and can converge to global optimum without initial value. The pareto‐optimal solutions of multi‐objective optimization provide holistic trade‐offs between different objectives, hence helping the process designer make proper decisions for the design of intensified shell and tube heat exchangers.

Efficiency Enhancement of Heat Transfer Fluids by Using Carbon Dots Nanoparticles Derived From Aloe Vera

Modern technological progress in transportation, medical, electronics and HVAC systems has resulted in an extreme need for a performance-enhanced heat transfer system. Heat transfer employing a flowing fluid is most used, and the thermal properties of liquids play a decisive role in heating and cooling applications in industrial processes. The thermal conductivity of a liquid is an important physical property that decides its heat transfer performance. Conventional heat transfer fluids have inherently poor thermal conductivity, making them inadequate for ultra-high heat transfer applications. Nanofluids are a new class of liquids whose properties are controllable by adding nanoparticles. A great deal of attention has been drawn to their enhanced heat transfer characteristics relative to that of pure fluid. This paper synthesizes three various Nano Fluids and experimentally compares their heat transfer capabilities using a shell and tube heat exchanger setup. An attempt is made to suggest applications for enhanced heat transfer. Al2O3 Nanofluid is compared with Nanofluid containing carbon dots derived from Aloe vera, and it has been found that carbon. Aloe vera yields more heat transfer

Innovative method for heat transfer enhancement through shell and coil side fluid flow in shell and helical coil heat exchanger

Innovative method for heat transfer enhancement through shell and coil side fluid flow in shell and helical coil heat exchanger

Investigation on chlorella Sp. HS2 microalgae growth using CO2 from engine exhaust to study carbon sequestration

A functional method of exploiting engine exhaust waste has been explored in current investigation. In experimentation, a direct injection (DI) 4-stroke diesel engine has been considered. The engine was operated at varying injection pressures and injection timings. The exhaust emissions such as CO2, NO, HC, and CO were determined at different engine load conditions. To capture CO2 emissions at an optimal temperature desired for microalgae cultivation within a designed photobioreactor (PBR) tank, a shell and tube type heat exchanger was designed and operated to cool exhaust gases. Highest volume of CO2 produced through the engine exhaust was used to cultivate Chlorella sp. HS2 microalgae. The results of biomass productivity and growth rate were compared for photobioreactor tanks, one with CO2 supplementation and the other without any external CO2 supply. The results derived in this study depict the effective usage of exhaust gases to harness CO2 in the form of microalgae.