ME T HERMAL F LUID S YSTEM D ESIGNS Heat Exchanger Final Project

P ROBLEM STATEMENT Parameters of Heat Exchanger Mass flow rate = 220,000 kg/hr Working fluid is treated as water Working fluid enters at 45 ºC Working fluid exits at 25 ºC Design Limits of Heat Exchanger Cooling fluid is city water Cooling fluid enters at 20 ºC Max length is 7 meters Max shell diameter is 2 meters

G OALS OF DESIGN OPTIMIZATION Achieve Heat Transfer Requirements 5.11 MW Minimize Pressure Drop This increases the efficiency of the heater exchanger Direct result is lower energy requirements, which means lower energy costs Minimize Weight This is directly proportional to the cost More material = more money

F UNNEL EFFECT Design Requirements All variables available Run OFATS 12 variables Run DOE 1 and DOE 2 6 variables Run DOE 3 4 variables Optimize Pareto Charts

D ESIGN OF E XPERIMENT V ARIABLES DOE 1 Shell Internal Diameter Tube Outside Diameter Tube Length Tube Thickness Mass Flow Rate of Cooling Fluid Number of Tube Passes DOE 2 Use of Baffles Baffle Spacing Baffle Cut Counter Flow versus Parallel Flow Shell Material Tube Material

R ESULTS OF DOE 1

R ESULTS OF DOE 2

R EMAINING V ARIABLES Shell Internal Diameter Tube Outside Diameter Tube Length Tube Thickness Counter Flow Shell Material

R ESULTS OF DOE 3

P ARETO P LOTS

O PTIMIZATION

B EFORE OPTIMIZATION Variables Shell Internal Diameter = 0.5 m Tube Outside Diameter = m Tube Length = 5.95 m Tube Thickness = 0.002m Characteristics q = 5.11 MW Weight = 2473 kg Tube Side Pressure Drop = 3680 Pa Shell Side Pressure Drop = 2321 Pa

A FTER OPTIMIZATION Variables Shell Internal Diameter = 0.52 m Tube Outside Diameter = m Tube Length = 4.87 m Tube Thickness = 0.04m Characteristics q = 5.11 MW Weight = 1365 kg Tube Side Pressure Drop = 163 Pa Shell Side Pressure Drop = 1344 Pa

C ONCLUSION Engineers can benefit greatly from optimization. The combination of Matlab and Minitab can save time and money in design.

QUESTIONS ?