Purdue School of Engineering and Technology

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Purdue School of Engineering and Technology Heat Exchanger Design Project Department of Mechanical Engineering ME 414 Thermal / Fluid System Design Final Project December 13, 2005 Group Members: David Langenderfer Rishi Govalakrishnan Dan Langenderfer Vincent Liaw Professor: Mr. John Toksoy Purdue School of Engineering and Technology

Purdue School of Engineering and Technology Problem Statement Design a heat exchanger flowing a chemical at 80,000 kg/hr to drop the fluid temperature from 35°C to 25°C Cooling chemical is city water flowing at 20°C The shell may not exceed 2 meters in diameter and 7 meters in length Weight, pressure drop, and cost should be minimized Purdue School of Engineering and Technology

Purdue School of Engineering and Technology Assumptions Process and cooling fluid have minimal corrosive properties Properties of fluid are similar to water Counter flow to improve effectiveness Tube pitch set at 90 degrees Pitch ratio of 1.25 (rule of thumb) Shell side mass velocity set to 140,000 kg/hr Purdue School of Engineering and Technology

Matlab Implementation Initially used to determine possible dimensions of an acceptable heat exchanger Output from Matlab was inputted into Minitab for optimization Compared results from Matlab output and Minitab optimization Purdue School of Engineering and Technology

Purdue School of Engineering and Technology Funneling Effect Tube OD, Shell ID, Length, Number of Passes, Tube Material, Baffles, Baffle Spacing 7 Factors 3 Factors Tube OD, Shell ID, Length Purdue School of Engineering and Technology

Purdue School of Engineering and Technology Optimization Obtained results with 7 parameters from Matlab Using DOE Factorial Response in Minitab we reduced the parameters by utilizing Main Effects plots Purdue School of Engineering and Technology

Purdue School of Engineering and Technology

Determining Effects on Heat Exchanger Key variables for an effective heat exchanger Tube OD Shell ID Tube Length Purdue School of Engineering and Technology

Decisions from Main Effects Two pass on tube side: Minimal foot print on shop floor Minimize leak points Increases pressure drop Allows for independent expansion of tubes and shell1 Purdue School of Engineering and Technology

Purdue School of Engineering and Technology Decisions Cont’d Counter flow is desirable for a two tube pass exchanger to increase effective temperature difference1 Aluminum minimized weight with no effect on heat transfer No baffles due to large increase in pressure drop on shell side Purdue School of Engineering and Technology

Purdue School of Engineering and Technology Optimization Plots Purdue School of Engineering and Technology

Purdue School of Engineering and Technology Results Tube OD: 0.0095 m Shell ID: 0.3874 m Length: 3.0 m Tube velocity: 1.54 m/s (Range 0.9 - 2.4 m/s) Turbulent flow promoting high heat exchange on shell and tube Heat transfer is 6% over desired heat transfer to accommodate for future fouling Purdue School of Engineering and Technology

Purdue School of Engineering and Technology Results (cont’d) ΔP Shell: 2,513 Pa ( 0.365 PSI) ΔP Tube: 38,450 Pa (5.577 PSI) Weight: 496 kg (1094 lbs) Number of Tubes: 750 Purdue School of Engineering and Technology

Purdue School of Engineering and Technology Lessons Learned Optimization using interaction between Minitab and Matlab How to work as a team Lots of decisions to make when given an open ended question Many solutions to a simple problem Finish projects early (12/4/2005) Purdue School of Engineering and Technology

Purdue School of Engineering and Technology References Heat Exchangers Selection, Rating, and Thermal Design Kakaç and Liu CRC Press, 2nd Edition, 2002 ME 414 Lecture Notes Professor John Toksoy, 2005 Purdue School of Engineering and Technology

Purdue School of Engineering and Technology Questions Purdue School of Engineering and Technology