Heat Exchange Design and Optimization Project
Presented: May 6th, 2010
Professor: Mr. Toksoy
Group Members: Nathan Dart
Andrew KinneyPaul 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 C⁰Exit 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 C via ⁰city water.
Design Optimization Goals: Chemical must be cooled from 45⁰C 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 ODCity Water FlowTube LengthTube ThicknessTube Layout & AngleTube MaterialTube PitchShell 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: ΔP Shell
Main Effects Plot: ΔP Tube
Main Effects Plot: Q Calculated
Pareto Chart: Weight
Standardized Effects: Weight
Pareto Chart: ΔP Shell
Pareto Chart: ΔP Tube
Pareto Chart: Q Calculated
Standardized Effects : Q Calculated
Standardized Effects : Q Calculated
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 WCalculated Heat Transfer Rate = 5105087.64 W Difference = 1176.16 WDesired-to-Calculated Ratio = 1.00
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.
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
Questions?