Heat Exchange Design and Optimization Project Presented: May 6 th, 2010 Professor: Mr. Toksoy Group Members: Nathan Dart Andrew Kinney Paul Thompson Joe.

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Presentation transcript:

Heat Exchange Design and Optimization Project Presented: May 6 th, 2010 Professor: Mr. Toksoy Group Members: Nathan Dart Andrew Kinney Paul Thompson Joe Sullivan Christian Watness

Problem Statement: Design Criteria/Assumptions:  Mass flow rate = 220,000 kg/hr  Material properties of this chemical product can be approximated as water  Cooling of the chemical product will be achieved by using treated city water  City water is available at 20 ⁰ C  Exit temperature of city water from the heat exchanger is a function of the selected mass flow rate Using a heat exchange reduce a liquid chemical by 20 ⁰ C via city water.

Design Optimization Goals:  Chemical must be cooled from 45 ⁰C to 25 ⁰C.  Length of heat exchanger must not exceed 7 meters.  Diameter of shell must not exceed 2 meters.  Minimize heat exchanger weight.  Minimize heat exchanger pressure drop.

Initial Parameters: Funnel Effect  Tube OD  City Water Flow  Tube Length  Tube Thickness  Tube Layout & Angle  Tube Material  Tube Pitch  Shell Mass Flow Rate  Shell Material  Shell Thickness  City Water Flow Rate  Counter or Parallel Flow  Shell ID  Baffles – Yes or No  Baffle Spacing

Main Effects Plot: Weight

Main Effects Plot: Δ P Shell

Main Effects Plot: Δ P Tube

Main Effects Plot: Q Calculated

Pareto Chart: Weight

Standardized Effects: Weight

Pareto Chart: Δ P Shell

Pareto Chart: Δ P Tube

Pareto Chart: Q Calculated

Standardized Effects : Q Calculated

Optimized Results: HE Pressure Drop ====================================== Shell Side Delta-P = Pa Shell Side Delta-P = kPa Tube Side Delta-P = Pa Tube Side Delta-P = 2.41 kPa ====================================== Shell Side Pump Power = 0.31 kW Tube Side Pump Power = 0.11 kW Heat Exchanger Weight ====================================== Shell Weight = kg Tube Weight = kg Shell Fluid Weight = kg Tube Fluid Weight = kg Total HE Weight = kg Heat Exchanger Inlet & Outlet Temperatures (Celsius) ========================================== Inlet Outlet Delta Bulk Wall Tube Shell Overall Heat Transfer Coefficient ====================================== U (Tube Outside Area) = W/m2.C Heat Transfer Rate ====================================== Desired Heat Transfer Rate = W Calculated Heat Transfer Rate = W Difference = W Desired-to-Calculated Ratio = 1.00

Material Selection Reasoning: Cost of Shell (96.79 kg = lbs)… Stainless Steal 1.04/lb = $ Total Aluminum.84/lb = $ Total Cost of Tubes (N = 8,142)… Aluminum $1,117,489.50$ Stainless Steal $1,384, Therefore, Aluminum was chosen for the tube material due to its low weight. In addition, Stainless steal was chosen as the shell material to provide a longer shell life.

Referenced:  Toksoy, John. ME 414 Thermal-Fluid Systems Design. Department of Mechanical Engineering, IUPUI, Indianapolis, IN, Spring  OnlineMetals.com. (n.d.). Retrieved May 6, 2010, from htttp://

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