PRESENTED BY SUPERVISED BY

NIDHI YADAV MR.YASHWANT VERMA

M.TECH 1ST YEAR ASST. PROFESSOR

15001505007

PRESENTATION

ON

HELICAL BAFFLE HEAT

EXCHANGER

Content1- Introduction of Heat Exchanger

2- Introduction of Helical Baffle Heat Exchanger / Helixchanger

i- Helical Baffle Heat Exchanger(Diagram)

ii- Tube Arrangement (Diagram)

3-

4- Designing of Helixchanger

i- Thermal Analysis of Helical Baffle

ii- Thermal Analysis of Tube Side

iii-Hydrodynamics Analysis of Shell Side

iv-Overall Heat Transfer Coefficient

5- Advantage of Helixchanger

6- Future Aspects

7- References

Comparison of shell and tube heat exchanger & Helixchanger

Introduction of Heat Exchanger

Heat exchangers are one of the mostly used equipment in process industries. Heat

exchanger is a device specially designed for efficient transformation of heat from one

fluid to another fluid over solid surface.

Ref1

Introduction of Helical Baffle Heat

Exchanger/HelixchangerThe Helical Baffle heat Exchanger is otherwise known as a Helixchanger. Shell and

tube heat exchanger with helical baffles is superior to that with segmental baffles in

reducing pressure drop, eliminating dead zone and lowering the risks of vibration of

tube bundle. The Helical flow provides the necessary characteristics to reduce flow

dispersion and generate near plug flow conditions. Helixchanger Increases process

capacity up to 40% while reducing maintenance cost.(Ref. TEMA INDIA LTD.).

Helical baffle Segmental Baffle

Ref1 Ref5

Helical Baffle Heat Exchanger

Ref2

Tube Arrangement

Ref1

Comparison of Shell and Tube Heat

Exchanger & Helixchanger

Helixchanger Shell and Tube Heat Exchanger

It have higher Heat transfer coefficient It have lower Heat transfer Coefficient

Higher Efficiency Lower Efficiency

Low Operating Cost Higher Operating Cost

Low Maintenance Cost High Maintenance Cost

Designing of Helixchanger

By Using Kerns Method, which has been modified to suit the changed geometry of

the Heat exchanger.

It based on four analysis-

1- Thermal Analysis of Helical Baffle

2- Thermal Analysis of Tube Side

3- Hydrodynamics Analysis of Shell Side

4- Overall Heat Transfer Coefficient

Thermal Analysis of Helical Baffle

I. Tube Clearance (C)

C=Pt-Dot

II. Baffle Spacing (Lb)

Lb=∏.Dis.tanΦ

III. Cross Flow Area (As)

As=(Dis.C.Lb)/Pt

IV. Equivalent Diameter (DE)

DE=4[{(Pt2 3 )/4} −{dot

2 . ∏/8}]/{∏. dot/2}]

Pt = Prandtl No.

Dot =Tube outer Diameter

Dis =Shell inner diameter

Φ =Helix angle

V. Maximum Velocity (Vmax)

Vmax=Qs/As

VI. Reynolds Number (Re)

Re=ρ. Vmax. DE/μs

VII. Prandtl Number (Pt)

Pt=5.767 at 250c(standard)

VIII. Heat transfer Coefficient (h0)

h0= (0.36Ks.Re0.55.Pr1/3)/DE

Qs =Flow rate(Shell Side)

Vmax =Maximum inter-tube

velocity

ρ =Density

μs =Viscosity (Shell side fluid)

Thermal Analysis of tube side

I. Tube Clearance (C)

C=Pt-Dot

II. Reynolds Number (Re)

Re= ρ.Vt.di / μt

III. Nusselts Number (Nu)

Nu=0.023 Re0.8 Pr0.4

IV. Heat Transfer Coefficient (ht)

ht = Nu.kt/di

Vt =Tube Side Velocity

di =Tube inner diameter

μt =Tube side viscosity

kt =Tube Thermal conductivity

Hydrodynamics Analysis of Shell Side

I. Number of Baffles

Nb=Ls/(Lb+ΔBT)

II. Pressure Drop

Δps=[fs.Gs2.(Nb+1)Ds]/2. ρs.DE. Φs

fs=𝑒(0.576−0.19𝐼𝑛 𝑅𝑒)

Gs=ms/As

Ls =Shell Length

ΔBT =Baffle Thickness

fs =Shell side Friction factor

Ds =Shell Dia.

ms =Shell Side Mass Flow Rate

Overall Heat Transfer Coefficient

1/U0=1/h0+[(1/hi).(d0/di)]+[r0ln(r0/ri)/kt]

h0 =Baffle side Heat Transfer

coefficient

hi =Tube side Heat Transfer

coefficient

d0 =Shell outer diameter

di =Shell Inner diameter

r0 =Shell outer Radius

ri =Shell inner Radius

kt =Tube Thermal

Conductivity

Advantage of Helixchanger

I. Reduced bypass effects

II. Reduced shell side fouling

III. Prevention of flow induced vibration

IV. Reduced maintenance

V. Reduced Pumping Cost

Ref4

Future Aspects

Designing and optimization of Helixchanger by CFD for cost effectiveness.

CFD analysis for knowing velocity and pressure flow patterns over helical baffle in

STHE.

CFD analysis for knowing velocity and pressure in tube side.

References

Ref1,Improved Performance Of Helixchanger Over Segmental Baffle Heat Exchanger USING

KERN’S Method, sunil kumar shinde, mustan hatim pancha and S. Pavithran, international

journal of advances in engineering & technology, nov. 2012. Issn: 2231-1963.

Ref2,Design of helical baffle in shell andtube heat exchanger and comparingwith segmental

baffle using kern method, dr.B.Jayachandriah and V.Vinay kumar, international journal of

emerging technology in computer science & electronics (IJETCSE).ISSN:0976-1353

volume 13 issue 2 –MARCH 2015

Ref3,Thermal analysis of helical baffle in heat exchanger mayank vishwakarma, K. K. Jain,

international journal of science and research (IJSR), india online ISSN: 2319-7064

Ref4,Gang yong lei, ya-ling he, ruili, ya-fu gao, effects of baffle inclination angle on flow and

heat transfer of a heat exchanger with helical baffles, sciencedirect-chemical engineering and

processing, (2008), 1-10.

Ref5,http://www.google.com/baffle/segmental baffle/image.

Thank You