Title Page

Table of Contents
1. Introduction...........................................................................................................................................3
1.1. Background and importance of heat exchangers in steam power plants....................................3
1.2. Objective..........................................................................................................................................3
2. Steam Power Plant Overview...............................................................................................................3
2.1. Working principle of a steam power plant....................................................................................4
2.2. Working of Steam Turbine.................................................................................................................5
2.3. Role of heat exchangers in steam power plants............................................................................7
3. Heat Exchanger Fundamentals.........................................................................................................7
3.1. Basic principles of heat transfer....................................................................................................7
3.2. Types of heat exchangers................................................................................................................8
3.3. Application of heat exchangers....................................................................................................11
3.4. Advantages and disadvantages of shell and tube heat exchangers............................................12
4. Shell and Tube Heat Exchanger Design.............................................................................................12
4.1. Construction and components of a shell and tube heat exchanger...........................................12
4.2. Flow arrangement.........................................................................................................................13
4.3. Fouling in Heat Exchanger..........................................................................................................14
4.4. Performance Consideration.........................................................................................................15
4.5. Selection of Heat Exchanger........................................................................................................15
6. Conclusion............................................................................................................................................15
References................................................................................................................................................16

List of Figures
Figure 1. Basic component of Steam power Plant.......................................................................................4
Figure 2. ideal Rankine Cycle.......................................................................................................................5
Figure 3.Working of Steam Power Plant......................................................................................................7
Figure 4. Conduction...................................................................................................................................8
Figure 5. Convection....................................................................................................................................8
Figure 6. Radiation.......................................................................................................................................8
Figure 7. parallel flow..................................................................................................................................9
Figure 8. Counter Flow.................................................................................................................................9
Figure 9. Compact Heat exchanger..............................................................................................................9
Figure 10. shell and Tube Heat exchanger.................................................................................................10
Figure 11. Plate type HX............................................................................................................................11
Figure 12. Finned tube HX.........................................................................................................................11
Figure 13. Configuration of shell and tube heat exchanger.......................................................................13
Figure 14.One-shell pass and two-tube passes..........................................................................................13
Figure 15.Two-shell passes and four-tube passes......................................................................................14
Figure 16. Fouling Heat exchanger.............................................................................................................14

List of Tables
Table 1. Advantages and disadvantages of HX...........................................................................................12
1. Introduction
1.1. Background and importance of heat exchangers in steam power plants
The main source of electricity generation for decades is steam power plants, that use expansive
energy of steam to drive turbines blades and produce electrical power. The efficient transfer of
heat is crucial to optimize energy conversion and overall plant performance. We can achieve this
goal by using shell and tube heat exchangers.

Heat exchangers has been using for many years, but due advancement in engineering and
materials, shell and tube heat exchangers have become a widely used solution in steam power
plant due their effectiveness and reliability.

1.2. Objective
This report's main goal is to examine a shell and tube heat exchanger utilized in steam power
plants in terms of its design, operation, and performance characteristics. This study attempts to
offer a thorough understanding of the critical role played by this heat exchange equipment in the
overall performance of steam power production systems by looking at the concepts underpinning
its operation and analyzing its efficiency.

Specifically, the objectives of this report are as follows:

1. To examine the theories governing heat transfer in a shell and tube heat exchanger, as
well as the various forms of heat transfer involved and their importance in steam power
plant applications.

2. To investigate the design factors and variables, such as tube arrangement, tube material,
shell geometry, flow rates, and operating circumstances, that affect a shell and tube heat
exchanger's performance.

2. Steam Power Plant Overview

Steam power plant is also known as thermal Power Plant that generates electricity by using heat
energy extracted from fossil fuels, such as coal, natural gas, or oil, to produce steam. The steam
is then used to drive a steam turbine which in turn drive a generator to produce electrical power.

There are four basic components of steam turbine.

 Boiler
 Turbine
 Condenser
  Pump

Figure 1. Basic component of Steam power Plant

2.1. Working principle of a steam power plant.

Steam power plant operate on Rankine Cycle. There are four processes in ideal Rankine cycle.
1-2 Isentropic compression in a pump
2-3 Constant-pressure heat addition in a boiler
3-4 Isentropic expansion in a turbine
4-1 Constant-pressure heat rejection in a condenser
 Figure 2. ideal Rankine Cycle

Pump (q=0) : Wpump, in= h2-h1

Boiler (w=0) : qin= h3-h2

Turbine (q=0) : Wturbine= h4-h3

Condensor (w=0) : Wout= h4-h1

q¿
Thermal efficiency, η=1−
q out

2.2. Working of Steam Turbine

working of steam power plant is discussed below,

Boiler: The process begins in the boiler, where fuel such as coal, natural gas, or oil is burned to
produce high-pressure steam. The heat generated from the combustion process converts water
into steam in the boiler. The steam generated is superheated to a high temperature and pressure to
maximize its energy content.

Turbine: The high-pressure steam produced in the boiler is directed to the turbine. The turbine
consists of a series of blades mounted on a shaft. As the high-pressure steam passes through the
turbine blades, it imparts its energy to the turbine, causing the shaft to rotate at high speed.
Condenser: After passing through the turbine, the low-pressure steam is directed to the
condenser. The condenser is a heat exchanger that cools down the steam by transferring its heat
to a cooling medium, typically water from a nearby lake or river. As the steam loses heat, it
condenses back into water, forming condensate.

Pump: The condensate, which is now in the liquid state, is pumped back to the boiler using a
pump. The pump increases the pressure of the condensate, allowing it to be fed back into the
boiler for reheating and conversion back into steam. This process helps to maintain a continuous
cycle of steam generation.

Generator: The rotation of the turbine shaft, driven by the high-pressure steam, is used to rotate
a generator. The generator consists of a rotor and a stator, which together convert the mechanical
energy from the turbine into electrical energy. The rotation of the turbine shaft induces an electric
current in the generator windings, producing electricity.

Power Transmission: The electricity generated by the generator is then transmitted through a
network of power lines to homes, industries, and other consumers. Transformers are used to step
up the voltage for long-distance transmission and step it down again for distribution to end-users.

Cooling Water: In a steam power plant, cooling water from a lake or river is used in the
condenser to extract heat from the steam. After absorbing heat from the steam, the cooling water
is discharged back into the lake or river, ensuring that the plant does not excessively heat the
surrounding environment.
Figure 3.Working of Steam Power Plant

2.3. Role of heat exchangers in steam power plants

One of the most important heat exchangers in a steam power plant is the steam condenser. After
the steam passes through the turbine, it enters the condenser, where it is exposed to a cooling
medium (usually water or air). The heat exchanger facilitates the transfer of heat from the steam
to the cooling medium, causing the steam to condense into water. This condensed water is then
pumped back into the boiler to be reheated and converted into steam again. The condensation
process allows the steam to release its latent heat, which increases the overall efficiency of the
power plant.

3. Heat Exchanger Fundamentals

3.1. Basic principles of heat transfer
There are three basic principles of heat transfer which are discussed below,
Conduction: Heat is transported when a hot fluid comes into direct contact with a solid wall that
separates the two fluids. The heat is transferred from the hot fluid to the cold fluid through the
solid wall.
 Figure 4. Conduction

Convection: Heat is transported because of fluid motion. As the hot fluid passes through the
tubes or channels, it heats up the surrounding cold fluid through convective heat transfer.

Figure 5. Convection

Radiation: In some cases, heat exchange can also occur through thermal radiation between the
hot fluid, the cold fluid, and the solid wall.

Figure 6. Radiation

3.2. Types of heat exchangers

There are three types of heat exchangers commonly used.
Double pipe heat exchangers the simplest type of heat exchanger consists of two concentric
pipes of different diameters, as shown in Figure 13–1, called the double-pipe heat exchanger.
One fluid in a double-pipe heat exchanger flows through the smaller pipe while the other fluid
flows through the annular space between the two pipes. Two types of flow arrangement are
possible in a double-pipe heat exchanger: in parallel flow, both the hot and cold fluids enter the
heat exchanger at the same end and move in the same direction. In counter flow, on the other
hand, the hot and cold fluid.

Figure 7. parallel flow Figure 8. Counter Flow

Compact heat exchangers It has larger surface area per unit volume. The ratio of the heat
transfer surface area of a heat exchanger to its volume is called the area density. A heat
exchanger with 700 m2/m3 is classified as being compact. It gives us high heat transfer rate
between two fluids in a small volume. They are used in such a place where there is a restriction
on weight and volume.

Figure 9. Compact Heat exchanger

Shell and tube heat exchangers

Shell-and-tube heat exchangers contain many tubes (sometimes several hundred) packed in a
shell with their axes parallel to that of the shell. Heat transfer takes place as one fluid flows
inside the tubes while the other fluid flows outside the tubes through the shell. Baffles are
commonly placed in the shell to force the shell-side fluid to flow across the shell to enhance heat
transfer and to maintain uniform spacing between the tubes. Despite their widespread use, shell
and-tube heat exchangers are not suitable for use in automotive and aircraft applications because
of their relatively large size and weight. Note that the tubes in a shell-and-tube heat exchanger
open to some large flow areas called headers at both ends of the shell, where the tube-side fluid
accumulates before entering the tubes and after leaving them.

Figure 10. shell and Tube Heat exchanger

Plate Type Heat exchanger

A plate type heat exchanger is a type of heat exchanger that transfers heat between two fluids by
means of a sequence of metal plates. It is a versatile, efficient instrument that is frequently
utilized in industrial and commercial application.
 Figure 11. Plate type HX

Finned Tube Heat exchanger

To improve heat transmission between fluids, a finned tube heat exchanger uses tubes with
expanded surfaces known as fins. When working with fluids that have poor heat transfer
coefficients or when there is a requirement for greater heat transfer efficiency, it is frequently
used.

Figure 12. Finned tube HX

3.3. Application of heat exchangers

Heat exchangers are widely used in number of applications, some of them are mentioned below:
  Heat exchangers are widely used in heating, ventilation, and air conditioning (HVAC)
systems.
 Power Generation
 Process industries
 Automotive industry
 Waste heat recovery
 renewable energy system
 Chemical and Petrochemical Industries
3.4. Advantages and disadvantages of shell and tube heat exchangers
The advantages and disadvantages of heat exchangers are discussed below.
Table 1. Advantages and disadvantages of HX

Advantages Disadvantages

Efficient heat transfer Initial cost

Energy-saving Space requirements
Temperature control Fouling and maintenance
Versatility Pressure limitations
Environmentally friendly Limited to compatible fluids

4. Shell and Tube Heat Exchanger Design

4.1. Construction and components of a shell and tube heat exchanger
Shell-and-tube heat exchangers contain many tubes (sometimes several hundred) packed in a
shell with their axes parallel to that of the shell. Heat transfer takes place as one fluid flows
inside the tubes while the other fluid flows outside the tubes through the shell. Baffles are
commonly placed in the shell to force the shell-side fluid to flow across the shell to enhance heat
transfer and to maintain uniform spacing between the tubes.
 Figure 13. Configuration of shell and tube heat exchanger

4.2. Flow arrangement

Shell-and-tube heat exchangers are further classified according to the number of shell and tube
passes involved. Heat exchangers in which all the tubes make one U-turn in the shell, for
example, are called one-shell-pass and two tube-passes heat exchangers. Likewise, a heat
exchanger that involves two passes in the shell and four passes in the tubes is called a two-shell-
passes and four-tube-passes heat exchanger.

Figure 14.One-shell pass and two-tube passes.

Figure 15.Two-shell passes and four-tube passes.

4.3. Fouling in Heat Exchanger
As deposits build up on heat transfer surfaces over time, heat exchanger performance often
degrades with time. The layer of deposits adds to the heat transfer resistance and lowers the rate
of heat transmission in a heat exchanger. A fouling factor Rf, a measurement of the thermal
resistance brought on by fouling, depicts the overall impact of these accumulations on heat
transport.

Figure 16. Fouling Heat exchanger

4.4. Performance Consideration

Efficiency and performance of shell and tube heat exchangers in steam power plants depend on
various factors, including:

a) Temperature difference between the hot and cold fluids.

b) Fluid flow rates and velocities.

c) Surface area of the tubes and overall heat transfer area.

d) Thermal conductivity and fouling characteristics of the fluids.

e) Proper maintenance and cleaning to prevent fouling and scaling.

4.5. Selection of Heat Exchanger

The enhancement of heat transfer in heat exchangers is usually accompanied by increased
pressure drop and higher pumping power. Therefore, any gain from the enhancement in heat
transfer should be weighed against the cost of the accompanying pressure drop. The fluid with a
greater pressure is better suited for the tube side and the fluid with a higher viscosity for the shell
side (bigger passage area and smaller pressure drop). selection of heat exchanger depends upon
following factors.

 Heat transfer rate

 Cost
 Pumping Power
 Size and weight
 Material

6. Conclusion
In conclusion, shell and tube heat exchangers play crucial roles in energy efficiency and heat
transfer, making them key parts of steam power plants. These heat exchangers make it possible
to transfer thermal energy reliably and effectively between various fluid streams, such as steam
and water.

Shell and tube heat exchangers are built to satisfy the unique operating conditions and
specifications of steam power plants. To achieve ideal heat transfer and long-term performance,
factors such tube diameter, length, material selection, and shell parameters are carefully
considered. The efficiency and durability of the heat exchanger are improved using materials
with exceptional thermal conductivity, corrosion resistance, and mechanical strength.

The difference in temperature between the hot and cold fluids, fluid flow rates, surface area, and
fouling characteristics all have an impact on how well shell and tube heat exchanger’s function.
In order to avoid fouling and scaling, which can have a negative impact on heat transfer
efficiency, proper maintenance and cleaning are essential. The performance and dependability of
the heat exchangers are maintained through routine inspections and cleaning operations.
Overall, shell and tube heat exchangers are essential parts of steam power plants and
considerably increase the performance and efficiency of these facilities. Research and
development are continually improving these heat exchangers' construction, use, and upkeep in
order to increase heat transfer effectiveness, lessen fouling, and lengthen their useful lives. Shell
and tube heat exchangers will continue to be essential to the development of steam power plants
in the future due to their crucial role in promoting heat exchange and energy conservation.

References
[1]."Heat and Mass Transfer: Fundamentals and Applications" by Yunus A. Cengel and
Afshin J. Ghajar.
[2]."Heat Transfer" by J.P. Holman.