NED UNIVERSITY OF

ENGINEERING AND TECHNOLOGY

COMPLEX ENGINEERING PROBLEM

HEAT & MASS TRANSFER ME-315

MUHAMMAD ABDULLAH BIN SALEEM

AU-18015
B.E. (FALL)
AUTOMOTIVE ENGG.

SUBMITTED TO: DR.-ING. S. MUSHAHID HASHMI

 UNDERSTANDING OF THE PROBLEM
This problem requires the design of a heat exchanger which would efficiently transfer heat from the flue
gas to the combustion stream by applying the laws of thermodynamics and engineering calculations
using 1st principle approach

APPROACH TO THE PROBLEM

 Acquiring proper assumptions
 Developing a schematic diagram
 Making a mathematical model
 Performing engineering calculations
 Developing relevant charts
 Market survey
 Final design

ASSUMPTIONS
1) Kinetic and potential energy changes are assumed to be negligible.
2) There is no heat loss by the heat exchanger HX (i.e 𝑞𝑛𝑒𝑡=0).
3) Combustion air is at atmospheric conditions prior to utilizing in HX.
4) There is no mechanical or moving devices associated with the HX, therefore there would be no
work-done (i.e.; Ẇ= 0).
5) Mass flow rate of the inlet air and mass flow rate of the flue gas is equal (i.e.;𝑚̇𝑎𝑖𝑟 = 𝑚̇𝑓𝑙𝑢𝑒).

Schematics:
Schematic diagram of a typical furnace heat exchanger

HEAT EXCHANGER

FURNACE
 CALCULATIONS:
Given information
𝜂 = 75%, 𝑄𝑖𝑛 = 15𝑀𝑊
As we know that:
𝑄𝑜𝑢𝑡
𝜂 = 1−
𝑄𝑖𝑛
𝑄𝑜𝑢𝑡 = 𝑄𝑖𝑛 – 𝜂𝑄𝑖𝑛
Using first law of thermodynamics: (first principle approach)

As we know;

𝜕𝑞 − 𝜕𝑤 = 𝑑𝑢
Or we can write as:
𝑉𝑒2 𝑉𝑖2
𝑄̇ − 𝑊̇ = 𝛴 𝑚̇𝑒 (ℎ𝑒 + + 𝑔𝑍𝑒) − 𝛴 𝑚̇𝑒 (ℎ𝑖 + + 𝑔𝑍𝑖)
2 2
Assumption 4 and 5 will reduce the above eqn into:

𝑄̇ = 𝛴 𝑚𝑒
̇ (ℎ𝑒) − 𝛴 𝑚̇𝑖 (ℎ𝑖)

For combustion air:

From assumption 2,

𝑄̇ = 𝛴 𝑚̇𝑎𝑖𝑟 (ℎ𝑒 − ℎ𝑖) – (1)

We know that the enthalpy change is:

ℎ𝑒 − ℎ𝑖 = 𝐶𝑝(𝑇𝑒 − 𝑇𝑖)
Therefore; eqn 1 will become:

𝑄̇ = 𝑚̇𝑎𝑖𝑟 𝐶𝑝 (𝑇𝑒 − 𝑇𝑖)

Since volumetric flow rate is equal to V̇ = ṁ/ ρ or we can write as ṁ = ρ V̇

Therefore we can write:

𝑄̇ 𝑎 = 𝜌 𝑉̇ 𝐶𝑝 (𝑇𝑖𝑛 − 𝑇𝑎𝑡𝑚) – (2)

First we have to calculate Q̇ :

For Actual heat transfer energy (𝑄̇𝑎):

𝐻𝑒𝑟𝑒 𝑄𝑜𝑢𝑡 = 𝑄𝑎 (𝑄𝑎𝑐𝑡𝑢𝑎𝑙)

𝑄𝑎 = 15 – 15 𝑥 0.75
𝑄𝑎 = 3.75 𝑀𝑊 = 3750 𝑘𝑊
Now calculating the thermal properties of air at 20 °C

From table 28 of appendix 2:

We can get the density of water at room temp i.e 20 °C

𝜌 20°𝐶 = 1.164 𝑘𝑔/𝑚3

similarly the specific heat of the air is:

𝐶𝑝 = 1.012 𝑘𝐽/𝑘𝑔 𝐾
The volumetric flow rate of the combustion air is given in the problem:

𝑉̇ = 96 𝑓𝑡3/𝑠𝑒𝑐 = 2.76258 𝑚3/𝑠𝑒𝑐

Now substituting values in eqn 2 we get:

3750𝑘𝑊 = (1.164 𝑘𝑔/𝑚3)( 2.76258 𝑚3/𝑠𝑒𝑐)(1.012 𝑘𝐽/𝑘𝑔 𝐾)(𝑇𝑎𝑖𝑟𝑖𝑛 @ 20°𝐶)

𝑇𝑎𝑖𝑟_𝑖𝑛 = 1152°𝐶 = 1425𝐾

Now,

For temperature of the flue gas leaving the furnace before the heat exchanger is installed (T flue_exit):

To calculate the temperature of the flue gas leaving the furnace , eqn 1 can be re-modified as:

0.75𝑥𝑄𝑖𝑛 = 𝜌 𝑉̇ 𝐶𝑝𝑓𝑙𝑢𝑒 (𝑇𝑓𝑙𝑢𝑒𝑒𝑥𝑖𝑡 − 𝑇𝑎𝑖𝑟 𝑖𝑛 ) – (3)

Here, density of the flue gas can be determined from the flue gas properties table:

We can calculate specific heat of the flue gas at Tair in =1152°C (linear interpolation)

Cpflue = 1.3315 kJ/kgK

Now putting all the values in eqn (3) to calculate Tflueexit :

0.75𝑥15𝑥1000
𝑇𝑓𝑙𝑢𝑒𝑒𝑥𝑖𝑡 = + 1152°C
1.164𝑥2.76258𝑥1.3315

𝑇𝑓𝑙𝑢𝑒𝑒𝑥𝑖𝑡 = 3812.47°C = 4085K

This is the required temperature of the flue gas leaving the furnace before the heat exchanger is
installed.
FOR OUTLET TEMPERATURES OF THE STREAM:
The outlet temperature of the cold stream coming from HX will equal to the inlet temperature of the
furnace (𝑇𝑐𝑜𝑢𝑡 = 𝑇𝑎𝑖𝑟𝑖𝑛 = 1152°𝐶)

To calculate the outlet flue gas temperature coming from HX, we can again use the first law of
thermodynamics

Here,

𝑇𝑐𝑖𝑛 = 20°𝐶
𝑇𝑐𝑜𝑢𝑡 = 1152°𝐶
𝑇ℎ𝑖𝑛 = 4022.02°𝐶
𝑇ℎ𝑜𝑢𝑡 =?
0.75𝑥15𝑥1000
𝑇ℎ𝑜𝑢𝑡 = + 20°C
1.164𝑥2.76258𝑥1.34

𝑇ℎ𝑜𝑢𝑡 = 2630.83°C

As we know mass flow rate: ṁ = 𝜌 𝑉̇

Therefore; ṁ = (1.164)(2.7625)

ṁ = 3.2155 𝑘𝑔/𝑠

FOR LOG-MEAN TEMPERATURE DIFFERENCE:

As we know:
ΔT1 − ΔT2
ΔT𝐿𝑀 =
ΔT
ln( ΔT1 )
2

Here ΔT1 = 4022 − 2630

ΔT1 = 1392°C
Now ΔT2 = 1152 − 20

ΔT2 = 1132 °C
Now log-mean temperature would be
1392 − 1132
ΔT𝐿𝑀 =
1392
ln(1132)

ΔT𝐿𝑀 = 1257.52 °C
CORRECTION FACTOR:
T1 − T2
R =
t 2 − t1
t 2 − t1
P =
T1 − T2

Therefore
4022 − 2630 1152 − 20
R = P =
1152 − 20 4022 − 2630

R= P=

A = Area of Heat exchanger = Q/Overall heat transfer coefficient X logirthmic mean

tempertaure

𝑄𝑖𝑛 = 15𝑀𝑊

U = overall heat transfer co-efficient = 7.9 w/m^2 K for air

ΔT𝐿𝑀 = 1257.52 °C

Since
𝑄 = 𝑈𝐴(ΔT𝐿𝑀 )
Therefore
15 𝑥 106 = 7.9(𝐴)(1257.52)

 𝐴 = 31.41 m2
PRESSURE DROP:
Assuming some dimensions
Internal Diameter of tube 𝐼𝑑 = 19 mm
Outer Diameter of tube 𝑂𝑑 = 35 mm
Length of tube 𝐿 = 2.5 m
Now the no of tubes needed in shell and tube Exchanger can be calculated as
𝐴
𝑁𝑇 =
𝜋(𝑂𝑑)(𝐿)
46
𝑁𝑇 =
(3.142)(0.0354)(2.5)
𝑁𝑇 = 165.37
Now finding the fluid velocity;
𝑁𝑝
4(ṁ)(𝑁𝑇)
𝑉𝑇 =
𝜋(𝜌)(𝐼𝑑)2
1
4(3.21)( )
𝑉𝑇 = 230.55
𝜋(1.164)(0.01905)2
𝑉𝑇 = 58 𝑚/𝑠

Now the Reynolds number;

𝑁𝑝
4(ṁ)(𝑁𝑇)
𝑅𝑒 =
𝜋(𝜇)(𝐼𝑑)
1
4(3.21) ( )
𝑅𝑒 = 230.55
𝜋(1.6 𝑥 (10)−5 )(0.01905)
m2
Since 𝜇 (𝑘𝑖𝑛𝑒𝑚𝑎𝑡𝑖𝑐 𝑣𝑖𝑠𝑐𝑜𝑠𝑖𝑡𝑦 𝑜𝑓 𝑎𝑖𝑟)@ 20°C = 1.6 𝑥 (10)−5 s

𝑅𝑒 = 5.8 𝑥 104 i.e. Turbulent flow

We can calculate the friction factor form the mood chart for turbulent flow
Therefore @ 𝑅𝑒 = 5.8 𝑥 104
𝑓 = 0.042

now the pressure drop would be approximately:

𝑙 1
ΔP = 𝑓 𝑥 𝜌(𝑉)2
𝐷 2
2.5 1
ΔP = 0.042 𝑥 1.164(58)2
0.019 2

ΔP = 10.819𝐾𝑃𝑎
PLOTS ACQUIRED FROM MODER TOOLS:
 MARKET SURVEY & COST CALCULATIONS
COST MODEL FOR SHELL AND TUBES The starting point is an expression for the capital cost (CC) of a
single heat exchanger. If “A” is the surface area, then a simple cost law typically has the form:

𝑐 𝐶𝐶 = 𝑎 + 𝑏𝐴
Where;
A,b,c are the cost law coefficients:

Selecting shell and tube of SS (stainless steel)

𝐶 = 30800 + 1644(31.41)0.81
Therefore Capital cost of heat Exchanger with cross flow would be

𝐶𝑐𝑐 = 57617.28 $
 REFERENCE
https://www.ijcce.ac.ir/article_8143_9657d43468e7907c528006792017aefb.pdf

https://www.researchgate.net/figure/Fig-Flue-gas-Property-Table_fig2_275643214

https://upload.wikimedia.org/wikipedia/commons/d/d9/Moody_EN.svg

https://homex.com/ask/what-is-correction-factor-in-heat-exchanger