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HE Design Optimization ME414 – Thermal Fluid System Design Professor John Toksoy Final Project

HE Design Optimization ME414 – Thermal Fluid System Design Professor John Toksoy Final Project. Team Members: Kaela Hlaulani Prince Bedell William Broaddus Derek Vleck Trever Zike Seth Simonson. Project Definition. Design heat exchanger to reduce fluid by 20 degrees Celsius.

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HE Design Optimization ME414 – Thermal Fluid System Design Professor John Toksoy Final Project

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  1. HE Design OptimizationME414 – Thermal Fluid System Design Professor John ToksoyFinal Project Team Members: Kaela Hlaulani Prince Bedell William Broaddus Derek Vleck Trever Zike Seth Simonson

  2. Project Definition • Design heat exchanger to reduce fluid by 20 degrees Celsius. • Mass flow rate at the inlet of tube side is fixed at 220,000 kg/hr. • Inlet flow rate of shell is a design parameter. • Inlet temperature of shell fluid is 20 degrees Celsius. • Both fluids are considered as water.

  3. Design Optimization Goals • System must cool fluid from 45 C to 25 C • Length of Heat Exchanger cannot exceed 7 m • Shell Diameter cannot exceed 2 m • Shell and Tube weight must be minimized • Pressure drop of Shell and Tube must also be minimized

  4. Introduction • MATLAB is used to perform DOE runs. • Minitab is used to evaluate the importance of the variables according to the DOE runs (Main Effect Plots). • Relatively unimportant variables are selected and eliminated (fixed). • Most important variables are optimized using Minitab.

  5. Design – Funneling Process Single Factor Runs: I_Counter Flow Mdot shell Tube Length Baffle Space Tube Thickness # Tube Passes Baffle Cut Shell ID Shell Thickness Shell Material Tube OD • 1st Step: Analyze all 11 variables • 2nd Step: Two Factor DOE’s • 3rd Step: Critical Variables Optimization 2 Factor DOE Runs: Tube Length Baffle Space # Tube Passes Shell ID Shell Material Tube OD 4 Critical Variables: Tube Length Baffle Space Shell ID Tube OD Optimization

  6. Variable Analysis • Each design variable is analyzed while everything else is kept constant

  7. 1st run Main Effect Plots (11 Variables) • Effect of each variable on q_calc

  8. 1st run Main Effect Plots (11 Variables) • Effect of each variable on DP_tube

  9. 1st run Main Effect Plots (11 Variables) • Effect of each variable on DP_shell

  10. 1st run Main Effect Plots (11 Variables) • Effect of each variable on weight_HE

  11. 1st run Main Effect Plots (11 Variables) • Following variables were eliminated as a result of 1st DOE • I counter flow (We chose counter flow to Increase LMTD correction factor and heat exchanger effectiveness) • Baffle cut (We chose 84.15 mm) • Shell thickness (Only affects the weight, so we chose a reasonably thin shell) • Tube thickness (We chose a thickness of 0.559 mm) • mdot _shell (We chose a value of 64 Kg/m3 to minimize Dp_Shell.)

  12. 2nd run Main Effect Plots (6 Variables) • Effect of each variable on q_calc

  13. 2nd run Main Effect Plots (6 Variables) • Effect of each variable on DP_tube

  14. 2nd run Main Effect Plots (6 Variables) • Effect of each variable on DP_shell

  15. 2nd run Main Effect Plots (6 Variables) • Effect of each variable on weight_HE

  16. 2nd run Main Effect Plots (6 Variables) • Variables Eliminated: • Number of tube passes • We sacrificed some amount of heat transfer, however, we minimized the pressure drop, which implies that we can use less powerful pump. • Shell material • We chose pure aluminum because: • It has a high thermal heat coefficient • low weight. • Fluid has same properties as water, therefore there is no corrosion hazard.

  17. 3rd run Main Effect Plots (4 Variables) • Effect of each variable on q_calc

  18. 3rd run Main Effect Plots (4 Variables) • Effect of each variable on DP_tube

  19. 3rd run Main Effect Plots (4 Variables) • Effect of each variable on DP_shell

  20. 3rd run Main Effect Plots (4 Variables) • Effect of each variable on weight_HE

  21. Minitab Optimization Critical Variables: • Tube Length • Baffle Space • Shell ID • Tube OD

  22. Final Design Specifications • Tube Length = 6.06 m • Baffle Space = 0.1616 m • Shell ID = 0.2693 m • Tube OD = 6.3 E-3 m • Weight = 547.9 kg • DP Shell = 238 MPa • DP Tube = 45.44 KPa • Q_Calc = 5,227 KW

  23. Conclusion • The Shell Pressure is high because we selected baffles • Baffles induce turbulence which increases heat loss. • We chose a low Fouling factor of 3E-5: • The chemical has water like properties which minimizes the likelihood of fouling. • We chose a 90° square pitch: • makes cleaning of the tubes easier

  24. Questions ?

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