DESIGN AND MANUFACTURING OF A HEAT EXCHANGER

DESIGN PROJECT REPORT

HEAT TRANSFER (MEL3212)

GROUP-02

NAME-ANKIT KUMAR (1641018370)

SHUBHAM KUMAR (1641018383)

MANISH PRASAD (1641018371)

ANISH KUMAR SINGH (1641018371)

Change the logo –DEEMED TO BE UNIVERSITY

DEPARTMENT OF MECHANICAL ENGINEERING

INSTITUTE OF TECHNICAL EDUCATION & RESEARCH
SOA UNIVERSITY

2018
1
 ABSTRACT

This project tells us about what is heat exchanger made of in terms of thermal analysis. The important tools and
factors which play vital role in designing them are the concepts learnt from heat transfer and fluid mechanics.
All the calculations are done with respect to Tubular Exchanger Manufacturers Association (TEMA). The main
objective in this project is to design a heat exchanger model for a swimming pool. The purpose of this project is
to design a shell and tube heat exchanger which is the majority type of liquid to liquid heat exchanger and to
study its flow and the temperature field using flow analysis in solid works. The overall heat transfer coefficient
is based on the requirement of amount of heat energy. It is to be determined by considering the useful factors
like area, length and also the type materials to be used in heat exchanger. It is found that the overall heat
transfer can be maximized and minimized by changing the dimensions and other parameters.

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 TABLE OF CONTENT
Contents Page No
1. CHAPTER-1 Introduction
1.1 Literature of Heat Exchanger
1.2 Types of Heat Exchanger
1.3 Selection Criteria
1.4 Sizing & Rating
2. CHAPTER-2 Problem Statement
3. CHAPTER-3 Theory
3.1 Energy Balance Equation.
3.2 LMTD Approach
3.3 Overall Heat Transfer Coefficient
3.4 NTU method
3.5 Effectiveness
3.6 Pressure Drops
4. CHAPTER-4 Design Analysis
4.1 Calculation
5. CHAPTER-5 Numerical Modelling of the Designed Heat Exchanger
5.1 Steps
5.2 Graphical model
5.3 Graphs (temperature, pressure, flow trajectory)

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6. CHAPTER-6 Manufacturing
6.1 Bills of Materials and costs
7. CHAPTER-7 Experiment
7.1 Description of Experimental Set up
7.1 Experimental Results
7.2 Result Analysis
8. CHAPTER-7 Results and Discussions
8.1 Thermal model results
8.2 Geometrical model results
8.3 Experimental testing results
9. CHAPTER-8 Conclusion
Reference
Appendix
Plagiarism

LIST OF SYMBOLS

h Heat transfer coefficient

k Thermal conductivity

Pr Prandlt Number

Nu Nusselt Number

Do Outer Diameter

Di Inner Diameter

Cp Specific Heat

A Area

L Length

F Fouling Factor

U Overall Heat Transfer Coefficient

ṁ Mass flow rate

4
Re Reynold’s number

LIST OF TABLES AND FIGURES

All the Figures and Tables included in the report are listed below

SL. NO. FIGURES DESCRIPTIONS

SL. NO.
1
TABLES
1.1
DESCRIPTIONS
SHELL AND TUBE HEAT EXCHANGER
1 2.1 SPECIFICATION OF INLET AND OUTLET
2 1.2 PLATE HEAT
TEMPERATURES WITHEXCHANGER
MASS FLOW RATES
3 1.3 PLATE AND SHELL HEAT EXCHANGER
24 1.4
4.1 PLATE AND FIN
FINDINGS HEAT EXCHANGER
OF DESIGN ANALYSIS
35 1.5
6.1 TYPICAL KETTLE
MATERIAL REBOILER
COSTS USED FOR
AND BILLS
4 C1 INDUSTRIAL DISTILLATION TOWERS
PROPERTIES OF WATER AT REGULAR
6 1.6 TEMPERATURE SURFACE
TYPICAL WATER-COOLED INTERVALSCONDENSER
7 3.1 SCHEMATIC GRAPH OF LMTD
8 5.1 FLOWCHART OF MODELLING
9 5.2 BOUNDARY CONDITIONS OF THE INLET AND
OUTLET
10 5.3 2D VIEW OF SHELL AND BAFFLER
11 5.4 PRESSURE VARIATION INSIDE THE HEAT
EXCHANGER
12 5.5 TEMPERATURE VARIATION INSIDE THE HEAT
EXCHANGER
13 5.6 MANUFACTURED HEAT EXCHANGER MODEL

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 CHAPTER-1

INTRODUCTION
This chapter is going to give the idea of what this project is all about. The basic knowledge of what a heat
exchanger is and how does a heat exchanger works? What are the selection criteria etc?

LITERATURE OF HEAT EXCHANGER

The subject of shell and tube heat exchanger (STHE) has a wide variety of process and phenomena. A vast
amount of the material is published regarding STHE which depicts various factors affecting the thermal
efficiency of the STHE. On the basis of that a brief summary is reviewed as follows:

This paper gives overall idea to design optimal shell and tube heat exchanger. The optimized thermal
design can be done by sophisticated computer software however a good understanding of the underlying
principles of exchanger designs needed to use this software effectively [1].

It studied that, increased fluid velocities result in larger heat transfer coefficients and, consequently, less
heat-transfer area and exchanger cost for given rate of heat transfer. On the other hand, the increased fluid
velocities cause an increase in pressure drop and greater pumping power cost [2].

It concluded that circulating cold fluid in shell-side has some advantages on hot fluid as shell stream since
the former causes lower shell-side pressure drop and requires smaller heat transfer area than the latter and
thus it is better to put the stream with lower mass flow rate on the shell side because of the baffled space
[3].

A new chart method is presented to calculate single-phase shell side heat transfer coefficient in a typical
TEMA style single segmental shell and tube heat exchanger. A case study of rating water-to-water
exchanger is shown to indicate the result from this method with the more established procedures and
software available in the market [4].

The experimental data has been compared with theoretical data available. Experimental work shows higher
Nusselt number and pressure drops with respect to theoretical correlation based on Bell’s method [5].

Applied genetic algorithms (GA) for the optimal design of shell-and-tube heat exchanger by varying the
design variables: outer tube diameter, tube layout, number of tube passes, outer shell diameter, baffle
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 spacing and baffle cut. From this study it was concluded that the combinatorial algorithms such as GA
provide significant improvement in the optimal designs compared to the traditional designs. GA application

for determining the global minimum heat exchanger cost is significantly faster and has an advantage over
other methods in obtaining multiple solutions of same quality [6]. Guo- yanZhon et al. (2014) proposed a
simple model to predict the temperature distribution in the shell and Tube heat exchanger by using the basis
of differential theory. Based on the baffle arrangements and number of tube passes, the heat exchanger has
been divided into number of small elements. The tube side current is considered series and shell side
current is parallel. Two heat exchangers (AES and BEU) are considered for analysis by using the Cell
model and Heat Transfer Research Incorporations (HTRI) method. From this paper, it is seen that the HTRI
method used for predicting temperature of heat exchangers is more accurate. This model agrees for the heat
exchangers with straight tubes or U-tubes while the Cell model is limited for the cases of straight tubes [7].

Rajagapal THUNDIL KARUPPA RAJ and Srikanth GANNE made the attempts to investigate the impacts
of various baffle inclination angles on fluid flow and the heat transfer characteristics of a shell-and-tube
heat exchanger for three different baffle inclination angles namely 0°, 10°, and 20°. The simulation results
for various shell and tube heat exchangers, one with segmental baffles perpendicular to fluid flow and two
with segmental baffles inclined to the direction of fluid flow are compared for their performance. The shell
side design has been investigated numerically by modelling a small shell-and-tube heat exchanger. The
study is concerned with a single shell and single side pass parallel flow heat exchanger [8].

1.2 TYPES OF HEAT EXCHANGER

The different types of Heat Exchangers are listed below with their respective figures and proper
specifications.

1. Shell and tube heat exchanger

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Shell and tube heat exchangers (FI GURE 1.1) consist of series of tubes. One set of these tubes contains the
fluid that must be either heated or cooled. The second fluid runs over the tubes that are being heated or cooled
so that it can either provide the heat or absorb the heat required. A set of tubes is called the tube bundle and can
be made up of several types of tubes: plain, longitudinally finned, etc. Shell and tube heat exchangers are
typically used for high-pressure applications (with pressures g reater than 30 bar and temperatures greater than
260 °C). This is because the shell and tube heat exchange rs are robust due to their shape.

Several thermal design features must be considered when designing the tubes in the shell and tube heat
exchangers: There can be many variations on the shell and tube design. Typically, the ends of each tube are
connected to plenums (sometimes called water boxes) through holes in tube sheets. The tubes may be straight or
bent in the shape of a U, called U-tubes.

2. Plate heat exchangers

Another type of heat exchanger is the plate heat exchanger (FIGURE 1.2). These exchangers are composed of many
thin, slightly separated plates that have very large surface areas and small fluid flow passages for heat transfer.
Advances in gasket and brazing technology have made the plate-type heat exchanger increasingly practical. In
HVAC applications, large heat exchangers of this type are called plate-and-frame; when used in open loops, these
heat exchangers are normally of the gasket type to allow periodic disassembly, cleaning, and inspection. There are
many types of permanently bonded plate heat exchangers, such as dip-brazed, vacuum-brazed, and welded plate
varieties, and they are often specified for closed-loop applications such as refrigeration. Plate heat exchangers
also differ in the types of plates that are used, and in the configurations of those plates. Some plates may be
stamped with "chevron", dimpled, or other patterns, where others may have machined fins and/or grooves.

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 3. Plate and shell heat exchanger

A third type of heat exchanger is a plate and shell heat exchanger (FIGURE 1.3), which combines plate heat
exchanger with shell and tube heat exchanger technologies. The heart of the heat exchanger contains a fully
welded circular plate pack made by pressing and cutting round plates and welding them together. Nozzles carry
flow in and out of the plate pack (the 'Plate side' flow path). The fully welded plate pack is assembled into an
outer shell that creates a second flow path(the 'Shell side'). Plate and shell technology offers high heat transfer,
high pressure, high operating temperature, uling and close approach temperature. In particular, it does
completely without gaskets, which provides security against leakage at high pressures and temperatures.

9
 4. Plate and fin heat exchanger
This type of heat exchanger uses "sandwiched" passages containing fins to increase the effectiveness of the unit.
The designs include cross flow and counter flow coupled with various fin configurations such as straight fins,
offset fins and wavy fins.

Plate and fin heat exchangers (FIGURE 1.4) are usually made of aluminum alloys, which provide high heat
transfer efficiency. The material en able the system to operate at a lower temperature difference and reduce
the weight of the equipment. Plate and fin heat exchangers are mostly used for low temperature services
such as natural gas, helium and oxygen liquefaction plants, air separation plants and transport industries
such as motor and aircraft engines5.

FIGURE-

5. Tabular heat exchanger

These kind of heat exchangers are mainly made up of cellular coils whereas many different shapes are also
used for different applications. They provide flexibility because the geometric parameters such as length,
diameter can be modified easily.These are used for phase change such as condensation,evaporation kind of
operations.again it is classified in three different categories i.e.double pipe heat exchanger,spiral tube heat
exchanger and shell and tube heat exchanger.

1.3 SELECTION CRITERIA

The basic criteria for heat exchanger selection from various available types are:
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 1. The heat exchanger must satisfy the process specification; it must continue to the next scheduled shut
down of the plant for maintenance.
2. The heat exchanger must withstand the service conditions of the plant environment. It must also resist
corrosion by the process and service streams as well as the environment. The heat exchanger should also
resist fouling.
3. The exchanger must be maintainable, which usually implies choosing a configuration the permits
cleaning and replacement of any components that may be especially vulnerable to corrosion, erosion, or
vibration. This requirement will dictate the positioning of the exchanger and the space requirement
around it.
4. The heat exchanger should be cost effective. The installed operating and maintenance cost, including
the loss of production due to exchanger unavailability, must be calculated and the exchanger should cost
as little as possible.

1.3 SIZING AND RATING

There are two basic types of thermal design problems, namely, rating and sizing. In a rating problem, the
geometry and size of the heat exchanger are fully specified. Entering flow rates and fluid temperatures are
known. The job is to calculate the thermal effectiveness (heat transferred) and pressure drop of each stream.
This is a quite straightforward problem, with one exception. Because the exit stream temperatures are not
known, the average temperatures at which the fluid properties are evaluated are not known.
In a sizing problem, the heat exchange requirement is specified and the designer must calculate the heat
exchanger size. Normally, pressure drop limits are given for each fluid stream. Since the entering flow rates,
temperatures, and pressures are given, and the heat duty (or leaving temperatures) is specified, the thermal
effectiveness ε and NTU (number of transfer units) are directly calculable. A true sizing problem is
considerably more complex than the rating problem. A number of decisions must be made prior to making
the thermal performance calculations. These include the selection of the following.
1. Heat exchanger flow arrangement, e.g., counter flow, cross flow, etc.
2. Heat exchanger materials, as influenced by fluid temperatures and corrosion potential.
3. Fin geometry and fin thickness, as influenced by design pressure requirements.
4. The type of surface geometry and fin spacing and height. Fouling considerations influence the type of
surface geometry and fin spacing that may be selected.
5. Heat exchanger frontal area. This key decision establishes the Reynolds number for each flow stream.
The pressure drops are directly dependent on this decision. Use of high-performance surfaces (high j-value)
will tend to require a larger frontal area and less core depth (and less core volume) for a specified pressure
drop. If a small frontal
So in this chapter the various types of heat exchanger and the criteria that were needed to be satisfied to
make an ideal heat exchanger were discussed. Also the aspects that must be kept in mind while giving the
dimensions. [9]

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 CHAPTER-2

PROBLEM STATEMENT

This chapter gives the detail description of the problem statement. To design a heat exchanger model with the
following specifications as mentioned in Table 2.1.

Fluid Hot water Cold Water

Inlet temperature (0C) 60 35
Outlet temperature (0C) 40 25
Mass flow rate (kg/sec) 0.1 -

TABLE 2.1 SPECIFICATIONS OF INLET AND OUTLET TEMPERATURES WITH MASS FLOW RATES

A shell and tube heat exchanger must be designed and rated. Single shell and single tube pass is preferable.
Proper layout of the tubes should be chosen with appropriate pitch. Maximum length of the heat exchanger of
1m is required because of space limitation. Proper tube material and size of tube (di = 4.25 mm & d0 = 6.25 mm)
must be selected. Fouling resistance may be taken to be 0.0002 m2K/W. Maximum flow velocity through the
tube is 0.75 m/sec. Perform thermal analysis. Note that surface over design should not exceed 50%. The entry
and exit temperatures of the hot water are 600C and 400C respectively, were as for cold water these are 35 0C to
250C respectively as shown in the Table 2.1. The mass flow rate of hot water is given to be 0.1 kg/sec.
It is required to determine the mass flow rate of cold water to have the required end temperatures along with the
determination of length and diameter of the shell side of the heat exchanger.

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13
 CHAPTER-3

THEORY
Heat exchangers allow control over the dynamics of heat transfer between fluids. Below are
parametric thermodynamic equations that define the nature of heat exchange and performance
of a heat exchanger for any given application. Once these thermal parameters are determined
they can be used to calculate heat exchanger performance in order to select the most suitable
product based on the specific application. The first important aspect discussed in this chapter is
the energy balance equation followed by the discussion of log mean temperature difference and
effectiveness NTU method for the determination of design parameters. The pressure drop is also
important design parameters for heat exchanger.

-----------------------

3.1 Energy Balance Equation

While designing heat exchanger energy balance calculation is mainly done to determine the
missing operating parameters.

For hot fluid side of a heat exchanger let,

mH : mass flow rate of the hot fluid in kg/hr CpH : mass heat capacity of the hot fluid in
Joules/kg0C THi and THo : Inlet and outlet temperatures on exchanger hot side in 0C

mC : mass flow rate of the cold fluid in kg/hr CpC : mass heat capacity of the cold fluid in
Joules/kg0C TCi and TCo : Inlet and outlet temperatures on exchanger cold side in 0C

Heat lost by the hot fluid = q= mH × CpH × (THo - THi)

(1)

Heat gained by the cold side = q = mC × CpC × (TCo - TCi)

(2)

Comparing equations (1) and (2),

mH × CpH × (THi - THo) = mC × CpC × (TCo - TCi)

(3)

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This energy balance equation can be solved for one variable for any given case. Out of total six
variables in the equation (3), five should be fixed to determine the unknown variable.

3.2 Log Mean Temperature Difference Approach

Log Mean Temperature Difference (LMTD)

LMTD=

3.3 Overall Heat Transfer Co-efficient

The heat transfer can be calculated by

q = UA∆Tmean

Here ‘U’ is the overall heat transfer coefficient. It can calculated by taking into consideration
both Inner and outer cross-sectional area.

Where:

Uo=Overall heat transfer coefficient(

Ao=Outer area(m2)

Ai=inner area (m2)

ho=heat transfer coefficient at the outer fluid (W

hi=heat transfer coefficient at the inner fluid(W

l=length of the tube used in heat exchanger(m)

k=thermal conductivity(W/mK

3.4 ε-NTU Approach

The Number of Transfer Units (NTU) Method is used to calculate the rate of heat transfer in
heat exchangers based on counter flow. This method is used when two parameters of
15
temperature are missing out either from the inlet or outlet part. NTU method is used by
referring to standardized chart. NTU determines the size of heat exchanger i.e. more the size of
heat exchanger, the more is the NTU value.

NTU=

Where

m=mass flow rate(kg/s)

cp=specific heat capacity(J/kg.K)

3.5 Effectiveness of Heat Exchanger

It is defined as the ratio of actual heat transfer to maximum heat transfer

€=

qactual = mh-cph(Thi-Tho) = mc-cpc(Tco-Tci)

= UA(LMTD) qmax = (m-cp )min- (Thi-Tci)

3.6 Pressure Drops

. Pressure drop is a major constraint in thermal design of shell and tube heat exchangers. Overall heat
transfer coefficient can be maximized by maximizing shell side and tube side flow velocities, which, in
turn, is governed by the allowable pressure drop as higher velocity means higher pressure drop.

The parameters discussed above are very essential for the calculation of the dimensions of the inside tube
as well as the shell diameter of the heat exchanger.

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 CHAPTER-4

DESIGN ANALYSIS
Now using the parametric thermodynamic equations such as energy balance equation (calculation of mass flow
rate of the cold water), the logarithmic mean temperature and the overall heat transfer coefficient the length of
the tubes will be calculated and by NTU method number of tubes that would be required can be found out. All
the calculations are done considering Tubular Exchanger Manufacturer Association (TEMA) standards

4.1 CALCULATION

The calculations related to the number of tubes, mass flow rate, overall heat transfer coefficient and shell
diameter is given below-

PROPERTIES OF HOT WATER AT 50ᵒc

ρ = 987.7 kg/m3

µ = 0.547×10-3 Pa.s

Pr = 3.56

Cp = 4181 J/ kg.K

k = 0.6435 W/m.

PROPERTIES OF HOT WATER AT 30ᵒc

ρ = 990.2 kg/m3

µ = 0.596×10-3 Pa.s

Pr = 4.34

Cp = 4178 J/ kg.K

k = 0.57 W/m.K

k=398 W/m.K ( for copper – tube material)

As it is a counter flow heat exchanger so ∆To = 25c & ∆TL = 15c

So the LMTD ( log mean temperature difference) is 19.57c.

LMTD =

17
 ! " #$% #$&

So the LMTD ( log mean temperature difference) is 19.57c.

During calculation a set of construction standard are necessary. The popular standard is Tabular Exchanger
Manufacturers Association (TEMA).

4.1 CALCULATION OF NUMBER OF TUBES

Inside tube → hot fluid

ꝭ VDi
Re= µ

988.1× 0.75 ×( 4.25 ×10−3 )

= 5757.89
0.547× 10−3

Nu=0.023Re^0.8 Pr^0.4 Pr=3.65

=38.097

hiD Nukf
Nu= =>hi=
kf D

=>hi=5895.55w/m^2k

ho =0.6hi

=3537.35w/m^2k

4.2 CALCULATION OF LENGTH OF THE TUBE & SHELL DIAMETER

Diameter of shell →
CL Af PR 2 × Do
Ds=0.637 [ ¿^0.5
CTP L

CTP=Count tube pass

CL=Tube layout constant(0.87)

PR=Pitch ratio
L=1m
Do=0.00625
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4.3 CALCULATION OF OVERALL HEAT TRANSFER COEFFICIENT

1
ro
UoAo= ln ( )
1 ri 1
+ + + Rfo+ Rfi
hoAo 2 πLk hiAi

Ao=2ℼroL

Ai=2ℼriL

1
ro
=>Uo= roLn( )
1 ri ro
+ + + AoRfo + AiRfi
ho k rihi

1
ro
=>Uo= roLn( )
1 ri ro AoFi
+ + + Fo+
ho k rihi Ai

1
ro
=>Uo= roLn( )
1 ri ro ro
+ + + Fo+ Fi
ho k rihi ri

=345.423

Without fouling factor

1
ro
Uo = roLn( )
1 ri ro
+ +
ho k rihi

1
6.25 6.25
= ×10−3 ln ⁡( )
2 4.25 6.25
2.82× 10 +
−4
+
398 4.25 × ꝭ

=1868.57

With fouling factor

Uo=971.54
19
 q·=m·hCp,h (Thi-Tho)

= m·cCp,h (Tci-Tco)

=0.2kgs^-1

m·h=ꝭAVn

=>n=9.51⁓10

Total heat loss in the heat exchanger is

q=UoA∆Tm

q
=>A=
Uo∆ Tm

∆ T 1−∆ T 2
∆Tm= ∆T 1
ln ⁡( )
∆T 2

( 60−35 )−( 40−25)

= 25
ln ⁡( )
15

∆Tm=19.57ºC

q =8356

Now for clear tube (without fouling factor)

L =

For tube with fouling

L =

4.4 CALCULATION FOR SHELL DIAMETER

The length of the Heat Exchanger has been calculated using with and without fouling factors keeping the
view that oversize should not exceeds 50%. After a number of iterations the final dimensioning of the Heat
Exchanger has been obtained.

So, the obtained results are shown in Table 4.1

Sl. No. PARAMETERS DIMENSION

1 Tube length without fouling factor 1.16m
2 Tube length with fouling factor 2.23m

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 3 Shell diameter 0.103631m

TABLE-4.1 FINDINGS OF DESIGN ANALYSIS

CHAPTER-5
NUMERICAL MODELLING

In this chapter the various step of modeling and verifying the model virtually is going to be discussed as shown
in the Figure 5.3 and graphically in Figure 5.1 respectively. After getting the dimensions correctly all the
components were made in the solidworks 2016 (Laboratory CAD/CAM/CAE-I, B116). First for the tube a
rectangular structure was drawn and was then revolved along the centre line to get a cylindrical structure. The
obtained cylindrical structure was then multiplied using certain functions after which it was aligned in a circular
manner to get the structure of a cylinder. Then an end plate was made at one of the tube for which a circle was
drawn at one end after which it was mirrored at another end. Then four bafflers were designed choosing another
plane and were fitted between the two end plated for a uniform water flow which would eventually help in
uniform heat transfer.

Then the outer shell was designed. For this first he right plane was chosen and a circle was made after which
was extruded out and a cylindrical structure was obtained. Then using the cross sectional view a semi-circle was
made on the front view and was revolved along the center line. The same thing was mirrored on to another end.
These would act as end cups and make sure that the shell was covered from all directions.

21
Then in the final step of modeling the inlet and outlet were made. For this, first two holes were made ----

After the completion of the modeling part it was turn for simulation. The main objective for simulation is to ---

First the flow simulation add in was added into the solid works then the boundary conditions were added as
shown in the Figure 5.2 such as ---

Then the wall parameters were added such as there would be no slip condition at the walls which means the
velocity at the walls would be zero.

After this the flow trajectory was obtained which showed many corrections were needed in the modeling. Then
the modifications were made in the model and the model was tested in the simulation. The boundary conditions
were given and then the flow trajectory was successfully obtained.

After this the pressure plot was obtained as shown in the Figure 5.4. This graph shows the variation of pressure
across the heat exchanger, and then the temperature plot was obtained which shows the temperature variations
inside the heat exchanger shown in the Figure 5.5. Figure 5.6 shows the heat exchanger manufactured in Design
and Manufacturing Studio III.

CREATING PARTS USING

SOLIDWORKS

MODELLING OF SHELL

MODELLING OF TUBES

MODELLING OF BAFFLERS

MODELLING OF END CAPS

22

ASSEMBLY OF
5.2 GRAPHICAL MODEL

23
FIGURE 5.2 BOUNDARY CONDITIONS OF THE INLET AND OUTLET( insert color photographs)

24
FIGURE 5.5 TEMPERATURE VARIATIONS INSIDE THE HEAT EXCHANGER( insert color photographs)

FIGURE 5.6- MANUFACTURED HEAT EXCHANGER MODEL

25
The Table 5.1 describes the temperature obtained through theoretical and as well as simulated through
solidworks.

Results Th in Th Tc Tc out
out in
Theoreti 600 400 35 25C
cal C C C
Simulati
on

TABLE 5.1 THEORETICAL AND SIMULATION RESULTS FOR TEMPERATURES.

All the results obtained through theoretical and using solidworks have been taken for final manufacturing in
Design and Manufacturing Studio – III as described in Chapter - 6

26
 CHAPTER-6
MANUFACTURING

All the Materials were purchased from the Vendors and the manufacturing was carried out in the Design
and Manufacturing Studio - III as per the specific design and calculations in Chapter 4 and 5. In the
workshop various steps have been followed and different tools have been used for the manufacturing of
heat exchanger.

6.1 STEPS FOR THE MANUFACTURING

o As designed 10 numbers of copper tubes of length 2.39 meter having diameter 4.25 mm has been taken. o
The ends of the tube are ground to remove the sharp edges

o The tubes are straightened using wooden hammer.

o Six numbers of baffles are taken.

o The tubes are attached to the baffles with an angular separation of 360.

o The shell made of PVC pipe is taken as per the specified length 2.50 meter and diameter 57 mm. o The
detailed assembly of the heat exchanger is shown in Figure 6.1

6.2 TOOLS AND EQUIPMENTS USED

*HACKSHAW- To cut the PVC pipes and copper tubes.

• FILING TOOLS- FLAT FILE: To make the sharp edges of copper tubes smooth.
ROUND FILE: Used for the baffle holes and copper tubes.

• GRINDING MACHINE-Used for making the baffle round.

• DRILLING MACHINE- Using proper drill bids holes were done in the baffler.

• SHEARING MACHINE- To cut the large Mild steel sheets to obtain the baffler

• BENCH VICE- To straighten the cut out baffles

. • C-CLAMP- To hold all the baffles together while grounding

. • M-SEAL- For sticking purpose

. • MILLING MACHINE- Used in the making of baffles.

• HAMMER- Wooden hammer was used to straighten the copper pipes

. • SCALE- For measurement purpose.

• PUNCH- Dot punch was used in the baffles before drilling.

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6.3 BILLS OF MATERIALS

The cost of all the materials used for the manufacturing of heat exchanger has been cited in Table 6.1

TABLE 6.1- MATERIAL COSTS AND BILLS

SL. NO MATERIALS COST

1 COPPER TUBES 850/-
(QUARTER INCH)
2 PVC PIPES-1.5 METERS(2.5”) 600/-
0.5 METERS (0.5”)
3 PVC GUM AND M-SEAL 100/-
4 T-CONNECTORS AND VALVES 920/-
TOTAL 2470/-

Proper safety precautions have been considered during the entire manufacturing processes. It was instructed
to follow the following safety norms:

 Full shoes
 Safety goggles
 Aprons
 Hair net
 Gloves

28
 CHAPTER-7

EXPERIMENTAL METHOD

Analysis Goals

Goals

ame Unit Value Progress Use in Delta Criteria

Convergence

G Max ºC 50.00 100 On 0.109636532 0.14022768

mperature(Fluid) 1

G Max ºC 48.27 100 On 0.172780475 0.89039395

mperature(Solid) 1

Global Min-Max Table

Min/Max Table

Name Min Max

Pressure(pa) 101184.89 127065.34
Temperature(ºC) 30.00 50.00
Density 987.45 994.80
Velocity 0 1.692
Velocity(X) -0.369 0.562
Velocity(Y) -0.384 0.369
Velocity(Z) -1.691 0.402
Temperature(Fluid) 30.00 50.00
Temperature(Solid) 30.88 48.27
Density(Solid) 8960 8960
Velocity(1/s) 0.024 737.424
Shear Stress 0 36.20
Relative Pressure -140.11 25740.34
Heat Transfer Coefficient 4.168e-005 6335.297
Surface Heat Flux -105627.82 69263.276
Heat Flux 139.755 2.569e+007
Overheat above Melting -1052.165 -1034.779
Temperature
29
Material Data

Engineering Database

Liquid

Water

Path: Liquids Pre-Defined

Density

Interpretation:

Cooling a substance causes molecule to slow down and get slightly closer together, occupying a smaller volume
that results in an increase in density. Hot water is less dense and will float on room temperature water. Cold
water is more dense and will sink in room temperature water.

Dynamic Viscosity

Interpretation :

The temperature dependence of liquid viscosity is the phenomenon b which liquid viscosity tends to decrease
(or, alternatively, its fluidity tends to increase) as its temperature increases.

As the temperature increases, the thermal viscosity increases. However, much more important is the rapid
decrease of the mean free path with temperature.

Specific heat (Cp)

30
Interpretation :

Water’s high heat capacity is a property caused by hydrogen bonding among water molecule. When heat is
absorbed, Hydrogen bonds are broken and water molecules can move freely. When the temperature of water
decreases, the hydrogen bonds are formed and release a considerable amount of energy. Water has highest
specific heat capacity of any liquid. Specific heat is defined as the amount of heat 1gm of substance must absorb
or lose to change its temp by 1ºC or 4.184J. as a result, it takes water a long time to heat and a long time to cool.

Thermal Conductivity

Interpretation:

Thermal conductivity is a transport property which provides information about the rate of energy transferred in
the process of conduction.it depends on the molecular structure of the material.

The general trend for non metallic liquids is that the thermal conductivity decreases with increasing temperature
with exception being water, Glycerine and Engine Oil.

31
Cavitation Effect: Yes

Temperature : -273.15ºC

Saturation Pressure: 0 pa

Solids

Copper

Path: Solids pre-defined\Metals

Density: 8960.00 kg/m3

Specific Heat

Conductivity Type: Isotropic

Thermal Conductivity

Electrical Conductivity : Conductor

Resistivity

32
Interpretation:

Water shows a property where as the temperature increases the resistivity also increases .

Radiation Property: No

Melting Temperature: Yes

Temperature:1083.05 ºC

CHAPTER-8

RESULTS AND DISUSSIONS

All the design parameters and calculations are based on TEMA. The thermal and geometrical model analysis is
done based on the given parameters using specified software. During manufacturing proper safety precaution
have been taken. The results obtained through design calculations and geometrical model analyses are discussed
as follows.

8.1 Thermal Model Results

Comparing the numerical calculations and the thermal model we found that the temperatures at the inlet
and the outlet were almost equal in both the cases

We can observe the temperature plot and the contours provided that inlet of hot fluid temperature is nearly
equal to 333K and the outlet temperature is nearly 313K .Similarly for the cold fluid the temperature
contour turned light blue from dark blue as there is a little deviation of 10 degree in temperature.
Secondly we observe that the pressure is maximum at the inlets and it goes on decreasing towards the
outlet.

8.2 Geometric Model Analysis

For the solid modelling of the product SOLIDWORKS 2016 version 24.4.0.0086 was used.
The assembly and the flow simulation feature was used to analyse all the parameters

33
  Shell: The shell was made by first sketching two concentric circles and extruding it. After that the cut
extrudes were made after sketching two circles in the reference planes. After that cylinders were
extruded to make the extension.
 Caps:
 Tubes: Tubes were made by ---------------
 Bafflers:
At last the assembly was done to mate the parts.

Later using the SOLIDWORKS FLOW SIMULATION the inlet mass flow rate of the fluids were provided. A
computational domain was created for the boundary layers control. Fluid was selected as water. The
thermodynamic parameter such as temperature was specified at the inlet. The heat transfer coefficient was also
provided to the walls. Later the flow trajectories and the cut plots were shown along with the point parameters
showing the temperature, pressure and velocities at the inlet and outlet.

All the design and simulated parameters are shown in Table 8.1.

Sl.No Parameters Numerical Values

.
1 Number of Tubes 10
2 Length of Tube without fouling 1.32 m
3 Length of Tube with fouling 2.89 m
4 Length of Shell 1.5 m
5 Diameter of the Tube 6.25 mm
6 Diameter of the Shell 2.5 in
7 No. of Baffles 6
8 Exit Temperature of hot fluid 400C
9 Exit Temperature of cold fluid 250C
10 Heat Transfer Coefficient of tube side 5192 W/m2K
11 Heat Transfer Coefficient of Shell side 3115 W/m2K
12 Mass flow rate of cold fluid 0.20 kg/s

TABLE 8.1 Designed Parameters

34
 CHAPTER-9

CONCLUSION
After performing the analysis and design of heat exchanger, a precise dimensioning for the counter flow heat
exchanger consisting of 10 tubes with hot water flowing inside it was found out. The materials used such as
copper tubes, PVC pipes; mild steel served the purpose of inner tube, outer shell and baffles respectively. Using
the help of SOLIDWORKS 2016 we could design the solid model of the heat exchanger and later using flow
simulation feature the flow trajectory and the temperature, pressure plots were made.

35
36
 APPENDIX
Table C-1 presents information at regular intervals of temperature. This table was generated using EES with the
substance R134a which implements the fundamental equation of state developed by R. Tillner -Roth and H.D.
Baehr,An International Standard Formulation for the Thermodynamic Properties

37
 REFERENCES

[1] Ramesh K shah and Dusan P. Sekulic, “Fundamental of heat exchanger design”, Rochester Institute of
Technology, Rochester New York, 2003.

[2] Rajeev Mukharji, “Effective design of shell and tube heat exchanger”, American Institute of Chemical
Engineering, 1988.

[3] Yusuf Ali Kara, Ozbilen Guraras, “A computer program for designing of Shell and tube heat
exchanger”, Applied Thermal Engineering 24(2004) 1797–1805.

[4] R. Hosseini, A. Hosseini-Ghaffar, M. Soltani, “Experimental determination of shell side heat transfer
coefficient and pressure drop for an oil cooler shell and tube heat exchanger with three different tube
bundles”, Applied Thermal Engineering 27 (2007) 1001–1008

[5] M.Serna and A.Jimenez, “A compact formulation of the Bell Delaware method for Heat Exchanger
design and optimization”, Chemical Engineering Research and Design, 83(A5): 539–550.

[6] B.V. Babu, S.A. Munawarb, “Differential evolution strategies for optimal design of shell and tube heat
exchanger”, Chemical Engineering Science 62 (2007) 3720 – 3739.

[7] (Guo-yan Zhou, Ling-Yun Zhu, Hui Zhu, Shan-tungTu and Jun-jie Lei, “Prediction of temperature
distribution in shell-and-tube heat Exchangers”, Energy Procedia, Vol. 61, pp. 799 – 802, 2014.for
refernce).

[8] Rajagapal THUNDIL KARUPPA RAJ and Srikanth GANNE, “Shell side numericalanalysis of a shell
and tube heat exchanger considering the effects of baffle inclination angle on fluid flow”, Thundil
Karuppa Raj, R., et al.: Shell Side Numerical Analysis of a Shell and Tube Heat Exchanger ,THERMAL
SCIENCE: Year 2012, Vol. 16, No. 4, pp. 1165-1174.
[9] Sadik kakac, “Heat Exchangers Selection, Rating and Thermal Design”, 2002.

[10] Frank P. Incropera, Davis P. Dewitt, Theodore L. Bergman, Adrienne S. Lavine, “Principles of HEAT
AND MASS TRANSFER”2016.

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PLAGIARISM REPORT

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