Design and Performance Analysis of Shell and Tube Intercooler used in Double Acting Two Stage Reciprocating Compressor

A Compressed air system is the source of process and service air to be used for various applications such as Pneumatic instruments, cooling of shut-off rods, masking of air, drying of fuel and other in-pile assemblies, etc. An Intercooler acts as a Heat Exchanger between the multiple stages of the working compressor and helps transfer thermal energy between fluids at different temperatures. This article is concerned with the design and study of calculations involved in the performance of an Intercooler. Various parameters are responsible for the performance review under different operating conditions. Performance analysis parameters such as overall heat transfer coefficient, fluid velocity, pressure drop, and others are calculated using standard operating values. Further, considering the given operating conditions, the effectiveness of the Intercooler has been evaluated.