Design & Analysis Of Heat Exchanger P resented by MOHAMMED SAIF ANSARI (13ME13)

A SEMINAR ON Design & Analysis Of Heat Exchanger • Presented by MOHAMMED SAIF ANSARI (13ME13) ZUZER CHOUGLE (13ME19) KULDEEP MISHRA (13ME27) Under Guidance Prof. Rahul R Thavai Department of Mechanical Engineering Anjuman-I-Islam’s Kalsekar Technical Campus, School of Engineering & Technology, New Panvel University Of Mumbai

DESIGN & ANALYSIS OF HEAT EXCHANGER TABLE OF CONTENT BE MECHANICALPROJECT-2

DESIGN & ANALYSIS OF HEAT EXCHANGER 1. INTRODUCTION • WHAT IS HEAT EXCHANGER. • PRINCIPLE OF HEAT EXCHANGER. • WHY IT IS USED. BE MECHANICALPROJECT-2

DESIGN & ANALYSIS OF HEAT EXCHANGER 2. LITERATURE SURVEY BE MECHANICALPROJECT-2

DESIGNING & ANALYSIS OF HEAT EXCHANGER SHELL & TUBE HEAT EXCHANGER A shell-and-tube heat exchanger comprises a shell which houses a tubular core, with an array of heat transfer tubes uniformly spaced between the shell walls and the core. BE MECHANICALPROJECT-2

DESIGNING & ANALYSIS OF HEAT EXCHANGER DIFFERENT PARTS OF SHELL & TUBE HEAT EXCHANGER BE MECHANICALPROJECT-2

DESIGN & ANALYSIS OF HEAT EXCHANGER 3. PROBLEM STATEMENT • A particular Chemical Processing Company has a requirement for manufacturing a Shell and Tube Heat Exchanger for raising the temperature of Ethane Gas. The temperature of Ethane Gas at inlet of heat exchanger is 25.6˚C and is to be raised up to 53˚C. The fluid that is used to raise the temperature of Ethane is Quenched Water which is supplied to the Heat Exchanger at 74.6˚C and leaves the Heat Exchanger at 63.9˚C. The Operating Pressure inside the shell is 10.11 kgf/cm2 and inside the Tube is 7.80 kgf/cm2. BE MECHANICALPROJECT-2

DESIGN & ANALYSIS OF HEAT EXCHANGER 4. METHODOLOGY The design of Heat Exchanger is a very complex procedure to follow. The core classification for the designing is; • Thermal Design • Mechanical Design BE MECHANICALPROJECT-2

DESIGN & ANALYSIS OF HEAT EXCHANGER 4.1 THERMAL DESIGN Thermal Design of a Shell and Tube Heat Exchanger typically includes the determination of • Heat Transfer Area, • Number of Tubes, • Tube Length and Diameter, • Tube Layout, • Number of Shell and Tube Passes, • Type of Heat Exchanger, • Tube Pitch, • Number of Baffles, its Type and Size, • Shell Tube side Pressure Drop, etc. BE MECHANICALPROJECT-2

DESIGN & ANALYSIS OF HEAT EXCHANGER 4.2 MECHANICAL DESIGN Mechanical design of heat exchangers includes design of various pressure and non-pressure parts. It is generally performed according to the design standards and codes. • TEMA (United States), • IS: 4503-1967 (India), • BS: 3274 (United Kingdom), • BS: 20414 (United Kingdom), • ASME Section 2A, • ASME Section 8, Division 1. BE MECHANICALPROJECT-2

DESIGN & ANALYSIS OF HEAT EXCHANGER 4.3 PREREQUISITES OF MECHANICAL DESIGN BE MECHANICALPROJECT-2

DESIGN & ANALYSIS OF HEAT EXCHANGER BE MECHANICALPROJECT-2

DESIGN & ANALYSIS OF HEAT EXCHANGER 4.4 DESIGN CONSIDERATIONS According to Indian Standards IS: 4503, 1967 for Design of Heat Exchangers there are some considerations to be considered. 𝐷𝑒𝑠𝑖𝑔𝑛 𝑃𝑟𝑒𝑠𝑠𝑢𝑟𝑒 = 10% 𝑒𝑥𝑐𝑒𝑠𝑠 𝑜𝑓 𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑊𝑜𝑟𝑘𝑖𝑛𝑔 𝑃𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝐷𝑒𝑠𝑖𝑔𝑛 𝑇𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒= 𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑊𝑜𝑟𝑘𝑖𝑛𝑔 𝑇𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒+10℃ Hence, Design Pressure that is calculated is 19.25 𝑘𝑔𝑓/𝑐𝑚2 and Design Temperature is 115˚C. 𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑊𝑜𝑟𝑘𝑖𝑛𝑔 𝑇𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 = 105˚𝐶 BE MECHANICALPROJECT-2

DESIGN & ANALYSIS OF HEAT EXCHANGER 5. CALCULATIONS • Selection of Materials • Selection of Arrangement • Heat transfer area • Tube Design • Shell Thickness • Design of Baffles • Design of Tube-Sheet • Design of Channel and Cover • Design of Gaskets • Design of Nozzle • Design of Bolts • Design of Flange. BE MECHANICALPROJECT-2

DESIGN & ANALYSIS OF HEAT EXCHANGER 5.1 SELECTION OF MATERIAL BE MECHANICALPROJECT-2

DESIGN & ANALYSIS OF HEAT EXCHANGER G10: Prolonged exposure to temperatures above 800°F, the carbide phase of carbon steel may be converted to graphite. S1: Stress values at temperatures of 455°C and above are permissible but, except for tubular products 3 in. O.D. or less enclosed within the boiler setting. T2: Allowable stresses for temperatures of 400°C and above are values obtained from time–dependent properties. BE MECHANICALPROJECT-2

DESIGN & ANALYSIS OF HEAT EXCHANGER Design Temperature is 115°C BE MECHANICALPROJECT-2

DESIGN & ANALYSIS OF HEAT EXCHANGER Now depending on the Design Temperature that is 115˚C, The Maximum Allowable Stress for the Material is 138MPa for 125˚C. BE MECHANICALPROJECT-2

DESIGN & ANALYSIS OF HEAT EXCHANGER 5.2 SELECTION OF ARRANGEMENT AJL Type BE MECHANICALPROJECT-2

DESIGN & ANALYSIS OF HEAT EXCHANGER 5.3 HEAT TRANSFER AREA BE MECHANICALPROJECT-2

DESIGN & ANALYSIS OF HEAT EXCHANGER 5.4 TUBE DESIGN BE MECHANICALPROJECT-2

DESIGN & ANALYSIS OF HEAT EXCHANGER 5.5 SHELL THICKNESS BE MECHANICALPROJECT-2

DESIGN & ANALYSIS OF HEAT EXCHANGER 5.6 DESIGN OF BAFFLE PLATES BE MECHANICALPROJECT-2

DESIGN & ANALYSIS OF HEAT EXCHANGER Type of Baffle BE MECHANICALPROJECT-2

DESIGN & ANALYSIS OF HEAT EXCHANGER 5.7 DESIGN OF TUBESHEET BE MECHANICALPROJECT-2

DESIGN & ANALYSIS OF HEAT EXCHANGER Taking thickness as 30mm as per the above calculations and adding the corrosion allowance Of 3mm to the both side of the Tube-Sheet (i.e. Channel Side and Shell Side). Therefore, the total Nominal Thickness of the Tube-Sheet will be 36mm. BE MECHANICALPROJECT-2

DESIGN & ANALYSIS OF HEAT EXCHANGER 5.8 DESIGN OF CHANNEL & COVER BE MECHANICALPROJECT-2

DESIGN & ANALYSIS OF HEAT EXCHANGER 5.9 DESIGN OF GASKET BE MECHANICALPROJECT-2

DESIGN & ANALYSIS OF HEAT EXCHANGER 5.10 DESIGN OF NOZZLE BE MECHANICALPROJECT-2

DESIGN & ANALYSIS OF HEAT EXCHANGER 5.11 DESIGN OF BOLTS BE MECHANICALPROJECT-2

DESIGN & ANALYSIS OF HEAT EXCHANGER 5.12 DESIGN OF FLANGE BE MECHANICALPROJECT-2

DESIGN & ANALYSIS OF HEAT EXCHANGER 6. CONCLUSION After Designing 10 Components of Shell and Tube type Heat Exchanger for the specifications given by the customer, the calculations were verified by GeecyEngineering Pvt. Ltd. Company by using Design Software known as PV Elite and our Project Guide Prof. Rahul Ramesh Thavai has also verified the calculations. BE MECHANICALPROJECT-2

DESIGN & ANALYSIS OF HEAT EXCHANGER 7. FUTURE SCOPE • According to the approach that is selected, there are chances of enhancing the method which is described above. • Can Increase efficiency of heat exchangers. • Reduce the size of heat exchangers in order to use less material and make it compact for same efficiency. • Further research can be done for the simplification of the solution to the problem given. • Apart from the standard procedure of TEMA, one can design Heat Exchanger by using non standard procedure and can come to same results. BE MECHANICALPROJECT-2

DESIGN & ANALYSIS OF HEAT EXCHANGER 8. REFERENCES • SadikKakac & HongtanLiu“Heat Exchangers Selection, Rating & Thermal Design 2ndEdition” University of Miami. • Heat Exchanger Selection & Sizing by www.klmtechgroup.com • John E. Edwards “Design & rating Shell & tube Heat Exchanger”. • NPTEL module1&2 on Chemical Engineering Design2 ( Process-Design of Heat-Exchangers & Mechanical Design of HX). • M.V. JOSHI “Process Equipment Design”. BE MECHANICALPROJECT-2

Design & Analysis Of Heat Exchanger P resented by MOHAMMED SAIF ANSARI (13ME13)