1. 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

2. 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.

3. 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.

4. 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

5. Main Effects Plot: Weight

6. Main Effects Plot: Δ P Shell

7. Main Effects Plot: Δ P Tube

8. Main Effects Plot: Q Calculated

9. Pareto Chart: Weight

10. Standardized Effects: Weight

11. Pareto Chart: Δ P Shell

12. Pareto Chart: Δ P Tube

13. Pareto Chart: Q Calculated

14. Standardized Effects : Q Calculated

16. Optimized Results: HE Pressure Drop ====================================== Shell Side Delta-P = 12330.12 Pa Shell Side Delta-P = 12.33 kPa Tube Side Delta-P = 2412.77 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 = 96.79 kg Tube Weight = 887.29 kg Shell Fluid Weight = 1363.08 kg Tube Fluid Weight = 873.20 kg Total HE Weight = 3220.36 kg Heat Exchanger Inlet & Outlet Temperatures (Celsius) ========================================== Inlet Outlet Delta Bulk Wall Tube 45.00 25.00 20.00 35.00 30.55 Shell 20.00 32.22 -12.22 26.11 Overall Heat Transfer Coefficient ====================================== U (Tube Outside Area) = 815.25 W/m2.C Heat Transfer Rate ====================================== Desired Heat Transfer Rate = 5106263.80 W Calculated Heat Transfer Rate = 5105087.64 W Difference = 1176.16 W Desired-to-Calculated Ratio = 1.00

17. Material Selection Reasoning: Cost of Shell (96.79 kg = 213.385 lbs)… Stainless Steal 1.04/lb = $221.92 Total Aluminum.84/lb = $179.24 Total Cost of Tubes (N = 8,142)… Aluminum $1,117,489.50$ Stainless Steal $1,384,615.20 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.

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

19. Questions ?