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Problem Statement

Heat Exchanger Design Project Department of Mechanical Engineering ME 414 Thermal / Fluid System Design Final Project December 13, 2005 Group Members: David Langenderfer Rishi Govalakrishnan Dan Langenderfer Vincent Liaw Professor: Mr. John Toksoy. Problem Statement.

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Problem Statement

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  1. Heat Exchanger Design ProjectDepartment of Mechanical EngineeringME 414 Thermal / Fluid System DesignFinal ProjectDecember 13, 2005Group Members:David LangenderferRishi GovalakrishnanDan LangenderferVincent LiawProfessor: Mr. John Toksoy Purdue School of Engineering and Technology

  2. Problem Statement • Design a heat exchanger flowing a chemical at 80,000 kg/hr to drop the fluid temperature from 35°C to 25°C • Cooling chemical is city water flowing at 20°C • The shell may not exceed 2 meters in diameter and 7 meters in length • Weight, pressure drop, and cost should be minimized Purdue School of Engineering and Technology

  3. Assumptions • Process and cooling fluid have minimal corrosive properties • Properties of fluid are similar to water • Counter flow to improve effectiveness • Tube pitch set at 90 degrees • Pitch ratio of 1.25 (rule of thumb) • Shell side mass velocity set to 140,000 kg/hr Purdue School of Engineering and Technology

  4. Matlab Implementation • Initially used to determine possible dimensions of an acceptable heat exchanger • Output from Matlab was inputted into Minitab for optimization • Compared results from Matlab output and Minitab optimization Purdue School of Engineering and Technology

  5. Funneling Effect Tube OD, Shell ID, Length, Number of Passes, Tube Material, Baffles, Baffle Spacing 7 Factors 3 Factors Tube OD, Shell ID, Length Purdue School of Engineering and Technology

  6. Optimization • Obtained results with 7 parameters from Matlab • Using DOE Factorial Response in Minitab we reduced the parameters by utilizing Main Effects plots Purdue School of Engineering and Technology

  7. Purdue School of Engineering and Technology

  8. Determining Effects on Heat Exchanger • Key variables for an effective heat exchanger • Tube OD • Shell ID • Tube Length Purdue School of Engineering and Technology

  9. Decisions from Main Effects • Two pass on tube side: • Minimal foot print on shop floor • Minimize leak points • Increases pressure drop • Allows for independent expansion of tubes and shell1 Purdue School of Engineering and Technology

  10. Decisions Cont’d • Counter flow is desirable for a two tube pass exchanger to increase effective temperature difference1 • Aluminum minimized weight with no effect on heat transfer • No baffles due to large increase in pressure drop on shell side Purdue School of Engineering and Technology

  11. Optimization Plots Purdue School of Engineering and Technology

  12. Results • Tube OD: 0.0095 m • Shell ID: 0.3874 m • Length: 3.0 m • Tube velocity: 1.54 m/s (Range 0.9 - 2.4 m/s) • Turbulent flow promoting high heat exchange on shell and tube • Heat transfer is 6% over desired heat transfer to accommodate for future fouling Purdue School of Engineering and Technology

  13. Results (cont’d) • ΔP Shell: 2,513 Pa ( 0.365 PSI) • ΔP Tube: 38,450 Pa (5.577 PSI) • Weight: 496 kg (1094 lbs) • Number of Tubes: 750 Purdue School of Engineering and Technology

  14. Lessons Learned • Optimization using interaction between Minitab and Matlab • How to work as a team • Lots of decisions to make when given an open ended question • Many solutions to a simple problem • Finish projects early (12/4/2005) Purdue School of Engineering and Technology

  15. References • Heat Exchangers Selection, Rating, and Thermal Design Kakaç and Liu CRC Press, 2nd Edition, 2002 • ME 414 Lecture Notes Professor John Toksoy, 2005 Purdue School of Engineering and Technology

  16. Questions Purdue School of Engineering and Technology

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