Heat Exchange Design and Optimization Project Presented: May 6th, 2010 Professor: Mr. Toksoy Group Members: Nathan Dart Andrew Kinney Paul Thompson Joe Sullivan Christian Watness Problem Statement: Using a heat exchange reduce a liquid chemical by 20⁰C via city water. 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 ⁰C Exit temperature of city water from the heat exchanger is a function of the selected mass flow rate 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 OD Shell Material City Water Flow Shell Thickness Tube Length City Water Flow Rate Tube Thickness Counter or Parallel Tube Layout & Angle Flow Tube Material Shell ID Tube Pitch Baffles – Yes or No Shell Mass Flow Baffle Spacing Rate 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: 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 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 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 ?