Case 1:

Title: Design of a Heat Exchanger for a Coffee Shop

Background:
A small coffee shop is looking to optimize its hot water system for brewing coffee. The
current system is inefficient, and the shop owner wants to improve energy efficiency by
designing a more effective heat exchanger system.

Case Study Description:

Part A
Students will be tasked with designing a heat exchanger system for the coffee shop,
considering specific technical parameters. The primary aim is to swiftly assess and enhance
the heat exchanger's overall operational effectiveness and efficiency within a one-hour
timeframe.

Technical Parameters:
Daily hot water demand: 500 liters
Initial hot water temperature: 60°C
Desired hot water temperature for coffee brewing: 90°C
Coldwater supply temperature: 20°C
Specific heat capacity of hot water: 4.18 kJ/kg°C
Specific heat capacity of cold water: 4.18 kJ/kg°C
Heat exchanger type: Shell-and-tube
Number of tubes: 20
Tube diameter: 15 mm
Tube length: 1 meter
Flow rate of hot water: 5 liters per minute
Flow rate of cold water: 10 liters per minute

Part B
Could you provide your opinion on whether adjusting the flow rates of hot water and cold
water enhances efficient heat transfer, supported by your analysis? How do you believe this
variability in flow rates affects the heat exchanger's efficiency, and can you offer any data or
reasoning to back your view?
Case 1:
Design Elements and Activities for Students (Simplified):
Part A

Heat Load Calculation:

Calculate the daily heat load based on the hot water demand, initial temperature, and desired
temperature for coffee brewing.
Temperature Differences:

Determine the required temperature difference between the hot water supply and the cold
water inlet for effective heat exchange.
LMTD Calculation:

Calculate the Log Mean Temperature Difference (LMTD) for the shell-and-tube heat
exchanger.
Heat Exchanger Duty:

Calculate the heat exchanger duty based on the LMTD and the known flow rates and specific
heat capacities of the fluids.
Energy Efficiency:

Estimate the energy savings that the new heat exchanger design will bring compared to the
existing system.
Presentation:

Prepare a brief presentation summarizing the design, calculations, and expected energy
savings, focusing on the technical parameters and calculations.

Heat Load Calculation:

Heat load = (Daily hot water demand) x (Specific heat capacity of water) x (Desired
temperature - Initial temperature)
Heat load = 500 liters x 4.18 kJ/kg°C x (90°C - 60°C) = 62,700 kJ or 62.7 MJ
Temperature Differences:
Temperature difference for hot water = Desired temperature - Initial temperature = 90°C -
60°C = 30°C
Temperature difference for cold water = Cold water supply temperature = 20°C
LMTD Calculation:

ΔT1 = Temperature difference for hot water = 30°C

ΔT2 = Temperature difference for cold water = 20°C
LMTD = (ΔT1 - ΔT2) / (ln(ΔT1 / ΔT2)) = (30°C - 20°C) / (ln(30°C / 20°C)) = 25.71°C

Heat Exchanger Duty:

Q = m * C * ΔT, where Q is the heat duty, m is the mass flow rate, C is the specific heat
capacity.
For hot water: Q_hot = 5 L/min * 60 min/hour * 4.18 kJ/kg°C * 30°C = 37,350 kJ/hour or
37.35 MJ/hour
For cold water: Q_cold = 10 L/min * 60 min/hour * 4.18 kJ/kg°C * 20°C = 50,160 kJ/hour or
50.16 MJ/hour
Total heat exchanger duty = Q_hot - Q_cold = 37.35 MJ/hour - 50.16 MJ/hour = -12.81
MJ/hour
Energy Efficiency:
The new heat exchanger design will save 12.81 MJ of energy per hour compared to the
existing system, leading to improved energy efficiency.

Part B
Higher Heat Transfer Rate: The rate of heat transfer (Q) in a heat exchanger is directly
proportional to the mass flow rate (m) of the fluid. The formula for heat transfer is Q = m * C
* ΔT, where C is the specific heat capacity of the fluid, and ΔT is the temperature difference
between the hot and cold fluids. By increasing the mass flow rate, you can increase the
amount of heat transferred per unit of time, thus improving performance.

Increasing Flow Rate:

Advantages: Increasing the flow rate of one of the fluids can lead to a higher heat transfer
rate. This is because a greater flow rate can result in a higher Reynolds number, which
promotes turbulence and enhances heat transfer coefficients.
Disadvantages: However, increasing the flow rate might also increase pressure drop and
energy consumption. It's important to strike a balance to avoid excessive energy use.
Decreasing Flow Rate:
Advantages: Reducing the flow rate of one of the fluids can help achieve a higher
temperature difference, which can enhance heat transfer efficiency. Lower flow rates may
also reduce pressure drop and energy consumption.
Disadvantages: Decreasing the flow rate too much can lead to reduced heat transfer rates,
especially if the flow becomes laminar and less turbulent.