WOLDIA UNIVERSITY

INSTITUTE OF TECHNOLOGY

SCHOOL OF MECHANICAL & CHEMICAL ENGINEERING

5TH MECHANICAL ENGINEERING THESIS PROPOSAL

PROPOSAL TITLE: WASTE HEAT RECOVERY FOR WATER HEATING
PURPOSE

NAME ID
Misge chekole …………..1271/08
Haymanot asmamaw……..1077/08
Samuel bekele……………1374/08

Advisor Name; Mr Yoftahe T.

Co advisor; Mr Mebratu

Submission date 03/07/2012 E.C

 STUDENT DECLARATION
From this proposal we declare that our work is original and compiled according to the proposal
writing guide line given by mechanical engineering department. We assure that this proposal
contains the actual study that we have done and the contents of the proposal are our own and have
not been copied from others.

Advisors Name

Yoftahe T. Signature _________________date____________________

Mr.Mebratu. Signature _________________date____________________

Examiner Name

Signature _________________date____________________

THESIS PROPOSAL
 ACKNOWLEDGMENT
Before each one we would like in the direction of thanks to God who provide our great ideas and
strength. After that we would like to thanks our parents they facilitated to us any necessary things.
Next we would like to thanks our advisors Mr. Yoftahe T. &Mr. Mebratu who has informed us
the correct approach of our work.

THESIS PROPOSAL
 ABSTRACT
Waste heat refers to energy that is generated in industrial processes without being put to practical
use which can be recovered by a means of recovering heat discharged as a byproduct of one
process to provide heat needed by another process. It is methods include capturing and transferring
the waste heat from a process with a gas or liquid back to the system as an extra energy source
which can be used to create additional heat or to generate energy. This thesis proposal deals with
the energy conservation and auditing from wasted heat of fire wood in which this energy is
recovered with shall and tube heat exchangers so as to heat water, in this proposal latest related
works to our work, design analysis of heat exchanger from properly selected materials have been
included. 2D and 3D modeling of the machine and its components with affordable cost estimation
are also part of this study.

THESIS PROPOSAL
TABLE OF CONTENT

CONTENTS
STUDENT DECLARATION.....................................................................................................................i
ACKNOWLEDGMENT................................................................................................................................ii
ABSTRACT..................................................................................................................................................iii
TABLE OF CONTENT................................................................................................................................iv
LIST OF FIGURES....................................................................................................................................v
LIST OF TABLE.......................................................................................................................................v
1. INTRODUCTION.....................................................................................................................................1
1. 1.Back ground........................................................................................................................................1
Types of waste heat recovery mechanisms.................................................................................................1
Waste heat boilers......................................................................................................................................1
Heat exchangers.........................................................................................................................................2
Double Pipe Heat Exchanger.....................................................................................................................2
Shell and Tube heat exchanger...................................................................................................................1
Cross flow Heat exchanger (Compact heat exchanger)..............................................................................1
Plate and Frame (Plate type) Heat Exchanger............................................................................................1
2. LITERATURE REVIEW...........................................................................................................................2
4. OBJECTIVES............................................................................................................................................4
5. METHODOLOGY.....................................................................................................................................5
6. SCOPE OF THE STUDY......................................................................................................................6
7. SIGNIFICANT OF THE PROJECT......................................................................................................6
8. WORK PLAN OF THE PROJECT........................................................................................................7
9. BUDGET...............................................................................................................................................8
10. Expected results.......................................................................................................................................9
REFERENCE...............................................................................................................................................10

THESIS PROPOSAL
LIST OF FIGURES
Figure 1; Schematic of shell and tube heat exchanger (one-shell pass and one tube pass............................8
Chart 1; Methodology flow chart...............................................................................................................13

LIST OF TABL

Table 1; work plan table............................................................................................................................14

THESIS PROPOSAL
1. INTRODUCTION
1. 1.Back ground
Waste heat is the heat generated in a process by method of fuel combustion or chemical reaction
and then. Large amount of hot flue gases is generated from Boilers, Kilns, Ovens and Furnaces. If
some of this waste heat could be recovered, a significant amount of primary fuel could be saved.
The energy lost in waste gases cannot be fully recovered. However, much of the heat could be
recovered and loss can minimized. [ CITATION DAR79 \l 1033 ]
Waste heat recovery is the method of capturing and transferring the waste heat from a process with
a gas or liquid back to the system as an extra energy source the energy source and to generate
energy. Waste heat can be rejected at any temperature; conventionally, the higher the temperature,
the higher the quality of the waste heat and the easier optimization of the waste heat recovery
process. It is therefore important to discover the maximum amount of recoverable heat of the
highest potential from a process and to ensure the achievement of the maximum efficiency from a
waste heat recovery system.[ CITATION MdA12 \l 1033 ]

Types of waste heat recovery mechanisms

There are many different heat recovery technologies available which can be used for capturing and
recovering the waste heat and they mainly consist of energy recovery heat exchangers in the form
of waste heat recovery unit. These are;
Regenerative and recuperative burners
A recuperative burner has heat exchanger surfaces as part of the burner design, which captures
energy from the heated gas that passes through the body of the burner The burner uses the energy
of waste gas from the exhaust to preheat the combustion air before it gets mixed with the fuel. The
burners consist of an internal heat exchanger with various features such as grooves; counter
current flow and fins, which are used to establish thermal contact between. The waste exhaust
gases and the combustion air coming from the supply pipe. [ CITATION sad12 \l 1033 ]

Waste heat boilers

Waste heat boilers consist of several water tubes that are placed in parallel to each other and in the
direction of the heat leaving the system. The system is suitable to recover heat from medium to
high temperature exhaust gases and is used to generate steam as an output[ CITATION DAR79 \l
1033 ].

Economizers
Economizers are used to recover low - medium waste heat are mainly used for heating liquids. The
system is located in the duct carrying the exiting exhaust gases and it absorbs the waste heat by
letting the hot gases pass through different sections covered by the finned tubes [ CITATION
MdA12 \l 1033 ].

Air preheaters
Air preheaters are mainly used for exhaust-to-air heat recovery and for low to medium temperature
applications which results in heat being absorbed at the hot section of the pipe, and transferred to
the cold section, heating the cold moving air over the pipes[ CITATION sad12 \l 1033 ].

Heat exchangers
Heat exchangers devices that facilitate the exchange of heat between two fluids that are at
different temperatures while keeping them from mixing with each other. In heat exchangers, there
are usually no external heat and work interactions. Heat exchangers are commonly used in practice
in a wide range of applications, from heating and air conditioning system in household, to
chemical processing and power production in large plants. Heat exchangers differ from mixing
chambers in that they do not allow the two fluids involved to mix. Heat transfer in a heat
exchanger usually involves convection in each fluid and conduction through the wall separating
the two fluids. In the Analysis of a heat exchanger, it is convenient to work with an overall Heat
transfer co-efficient that accounts for the contribution of all these effects on heat transfer heat
exchanger[ CITATION sad12 \l 1033 ].
Types of heat exchanger
There are different classifications of heat exchangers based on some criteria’s, but we focus on the
classification of heat exchanger based on the geometry of construction[ CITATION sad12 \l 1033 ].
Generally, four types of heat exchangers are in common use:
 Double pipe heat exchangers  Plate and frame (plate type) heat
 Cross flow heat exchangers exchanger
 Shell and tube heat exchangers

THESIS PROPOSAL
Double Pipe Heat Exchanger
This is the simplest type of heat exchanger which consists of two concentric pipes of different
diameters, One fluid flows through the smaller pipe while the other fluid flows through the
annular space between the two pipes. It has parallel and counter flow arrangements are possible in
a double-pipe heat exchanger[ CITATION sad12 \l 1033 ].

Shell and Tube heat exchanger

It is the most common type of heat exchanger in industrial applications is the shell-and-tube heat
exchanger. Shell-and-tube heat exchangers contain a large number of tubes (sometimes several
hundred) packed in a shell with their axes parallel to that of the shell. Heat transfer takes place as
one fluid flows inside the tubes while the other fluid flows outside the tubes through the shell.
[ CITATION sad12 \l 1033 ]

Figure 1; Schematic of shell and tube heat exchanger (one-shell pass and one tube pass[ CITATION
sad12 \l 1033 ]

Baffles are commonly placed in the shell to force the shell-side fluid to flow across the shell to
enhance heat transfer and to maintain uniform spacing between the tubes. The tubes in a shell-and-
tube heat exchanger open to some large flow areas called headers at both ends of the shell, where
the tube-side fluid accumulates before entering the tubes and after leaving them. [ CITATION sad12 \l
1033 ]

Cross flow Heat exchanger (Compact heat exchanger)

This type of heat exchanger is specifically designed to realize a large heat transfer surface area per
unit volume. The ratio of the heat transfer surface area of a heat exchanger to its volume is called
the area density . A heat exchanger with  > 700 m2/m3 is classified as being compact..

THESIS PROPOSAL
Plate and Frame (Plate type) Heat Exchanger
It is one type of heat exchanger that has found widespread use is the plate and frame heat
exchanger which consists of a series of plates with corrugated flat flow passages. The hot and cold
fluids flow in alternate passages and thus each cold fluid stream is surrounded by two hot fluid
streams, resulting in very effective heat transfer.

2. LITERATURE REVIEW
Kabir et al (2010) have conducted thermal energy audit analysis on the cement processing unit and
found that the fuel combustion provides 95.48% of the total energy input to the unit. Fuel
consumption and energy cost are crucial for the clinker production energy management. The kiln
exist gases and kiln shell are the major sources of thermal energy losses, amounting to 27.9% and
10.84 % respectively. The thermal efficiency of the unit is 41%; however this recovered heat not
sufficient enough to implement thermal energy conservations measures.[ CITATION psb \l 1033 ]

Augustine et al (2007) have studied the district heating systems using residual industrial waste
heats to provide an efficient method for residential water heating and reported that the proper
resources utilization in the sense that this ‘‘waste to heat’’ technique is thermodynamically more
useful than the current practice of converting natural gas with high energy content into flue gas at
very high temperature and then using it to heat water for space heating; However the wasted heat
energy is not that much sufficient so as to heat this residential water than using natural gas to heat
the water.[ CITATION dha16 \l 1033 ]

I. E. Smith (1970) has carried out an experimental study on a heat recovery system installed in an
industry which showed a 10 per cent of energy saving in the total energy utilization. In his system,
a small storage tank was situated inside the bigger waste collection tank. The ascending cold water
running in the small tank was preheated by the descending hot waste water in the big tank; but this
large amount recovered heat can able to preheat small amount of water. [ CITATION RB \l 1033 ]

Wong et al (2010) made an investigation on the potential for shower water heat recovery from
bathrooms equipped with instantaneous water heaters in high-rise residential buildings. A simple
single-pass counter-flow heat exchanger installed horizontally beneath the shower drain is
employed as a localized heat recovery measure for preheating cold water going to a water heater.

THESIS PROPOSAL
The results indicate that 4–15% shower water heat can be recovered through a 1.5 m long single-
pass counter-flow heat exchanger for a drainage pipe of diameter 50 mm. however only small
amount of heat is recovered from this hot shower water.[ CITATION Lok12 \l 1033 ]

3. PROBLEM STATEMENT

Energy is one of the most important things in our day to day activities. However, it is not properly
utilized. Global energy crisis, as well as high cost of fuel, charcoal and fire wood resulted in more
activities to be consume energy to maximum extent. In woldia university cafeteria retains a record
of large amount of heat energy is being wasted in the form of smoke and flue gases. In this
cafeteria for baking Injera a huge amount of fire wood is consumed as a result after the fire in the
oven smoke and flue gases removed to the surrounding in the form of waste. In addition at
working process the wood after it becomes burned can produce toxic gases; these causes serious
health risk. So in order to reduce this energy wastage and health risk those wasted heat should be
recovered. So these waste heat recovery technology can be used to enhance energy saving for our
university cafeteria as well as for all other sectors of industrial and residential applications.

THESIS PROPOSAL
 4. OBJECTIVES

General objective

The main objective of this project is waste heat recovery for heating purpose

Specific objective

 To design heat exchanger

 To design the components of heat exchanger that are incorporated in the system with
suitable materials and data
 To determine geometrical analysis and modeling of the components of the machine.
 To draw 2D and 3D modeling of the system.

THESIS PROPOSAL
 5. METHODOLOGY

Chart 1; Methodology flow chart

THESIS PROPOSAL
6. SCOPE OF THE STUDY

In this proposal from collecting of relevant data from different data sources up to designing and
modeling of each components of the system have been included.

7. SIGNIFICANT OF THE PROJECT

Benefit of the project

 Reduction in air pollution and greenhouse gas emissions.

 Reduction in fuel and auxiliary energy consumption
 Reduces energy cost and cost of capital equipment
 Reduces cost of capital equipment
 Reduces operating costs
 Reduces environmental impact
 May reduce air emission treatment costs
 improve efficiency of combustion and production quality
Beneficiaries

Woldia university cafeteria workers are all the Beneficiaries by this project.

THESIS PROPOSAL
8. WORK PLAN OF THE PROJECT
Table 1; work plan table
Activity MONTHS(2012 E.C)
February March April May June
W4 W1 W2 W3 W 4 W1 W2 W3 W 4 W1 W2 W3 W 4 W1
Data
collection
Searching
previous
work
Identifying
problem,
Prepare
proposal
Material
selection
Design
analysis
Cost analysis
Model by
software
Documentati
on
Proto type
Making
Final
presentation

THESIS PROPOSAL
9. BUDGET
Cost estimation
To estimate the investment cost of heat recovery; the cost of pump, heat exchanger& insulated
container, transport, labor worker, wilding, grinding and duct. Currently, the costs of the above
listed materials are estimated as below:-

Fixed cost

Cost of Feed water pump 12400birr

Cost of heat exchanger 31000birr

Cost of insulated container 20400birr

Cost of insulated duct 11300birr

Cost of duct 3500birr

Variable cost

Transport 500birr

Labor worker 1000birr

Wilding 350birr

Grinding 200birr
Total investment cost=80650birr

THESIS PROPOSAL
10. Expected results
This proposal work is about waste heat recovery for heating purpose. It is completed in successful
manner by designing all the components of heat exchanger with their necessary dimensions and
geometry. The machine is going to be designed so as to keeps wise use of energy and avoid
wastage of energy. In addition, the machine is used to create additional energy source or to
generate energy. This proposal is significant for woldia university cafeteria and it plays a vital role
for reducing of air pollution, greenhouse gas emissions, Reduction in fuel and auxiliary energy
consumption Proper use of energy,

THESIS PROPOSAL
REFERENCE
1. D.A. Reay, E & F.N.Span,. London : S.N., 1079.

2. International Journal Of Scientific & Engineering Research. Md A.A.Mamun, Subrato Biswas. 10,
S.L. : Md A.A.Mamun, Subrato Biswas, October 2012, Vol. 3.

3. Sadik Kakac, Hongtan Liu. Geat Exchangers Selection Rating,Abd Thermal Design. 2012.

4. Sustanable Development Through Waste Heat Recovery. Bundela, P.S.

5. Review On Waste Heat Recovery Application And Scope Of Heat Pipe Heat Exchanger Charged With
Nanofluid. Dharmadhikari, Mr Makarand. 2, 2016, Vol. 2, Pp. 794-799.

6. Waste Heat Recovery Through Air Conditioning System. Lokapure.J.D.Joshi, R.B. 3, India : S.N.,
December 2012, International Journal Of Engineering Research And Development, Vol. 5, Pp. 87-92.

7. Design And CFD Investigation Of Exhaust Gas Recovery System For 4ss Diesel Engine. Bibin P
Varghese, V Hariganash, Ajish Soman. 5, May 2015, International Journal Of Science And Technology
Research, Vol. 4, Pp. 1577-1583.

THESIS PROPOSAL
THESIS PROPOSAL