Heat Transfer Coefficient Estimation and Performance Evaluation of Shell and Tube Heat Exchanger Using Flue Gas

In the past few decades, water and air were commonly used as working fluid to evaluate shell and tube heat exchanger (STHE) performance. This study was undertaken to estimate heat transfer coefficients and evaluate performance in the pilot-scale twisted tube-based STHE using the flue gas from biomass co-combustion as working fluid. Theoretical calculation along with experimental results were used to calculate the specific heat of flue gas. A simplified model was then developed from the integration of two heat transfer methods to predict the overall heat transfer coefficient without tedious calculation of individual heat transfer coefficients and fouling factors. Performance including water and trailer temperature, heat load, effectiveness, and overall heat transfer coefficient were jointly investigated under variable operating conditions. Results indicated that the specific heat of flue gas from co-combustion ranging between 1.044 and 1.338 kJ/kg·K while specific heat was increased by increasing flue gas temperature and decreasing excess air ratio. The developed mathematical model was validated to have relatively small errors to predict the overall heat transfer coefficient. A flue gas mass flow rate of 61.3–98.8 kg/h, a water flow rate of 13.7–14.1 L/min, and a parallel arrangement of two water-to-air heaters in an empty trailer were found to be optimal conditions for space heating purpose. In addition, a lower poultry litter feeding rate decreased heat loss of flue gas and increased heat gain of water, while a lower water flow rate also provided a lower maximum possible heat transfer rate with a higher actual heat transfer rate to quickly achieve heat equilibrium that ultimately improves the performance. This study demonstrates the possibility of collecting residual heat from the flue gas using the pilot-scale STHE system while outlining a systematic approach and process for evaluating its performance.