Heat Exchange Design and Optimization Project Presented: May 6 th , 2010

1. Heat Exchange Design and Optimization Project Presented: May 6th, 2010 Professor: Mr. Toksoy Group Members: Nathan Dart Andrew Kinney Paul Thompson Joe Sullivan Christian Watness

2. Problem Statement: Using a heat exchange reduce a liquid chemical by 20⁰C via city water. • Design Criteria/Assumptions: • Mass flow rate = 220,000 kg/hr • Material properties of this chemical product can be approximated as water • Cooling of the chemical product will be achieved by using treated city water • City water is available at 20 ⁰C • Exit temperature of city water from the heat exchanger is a function of the selected mass flow rate

3. Design Optimization Goals: • Chemical must be cooled from 45⁰C to 25 ⁰C. • Length of heat exchanger must not exceed 7 meters. • Diameter of shell must not exceed 2 meters. • Minimize heat exchanger weight. • Minimize heat exchanger pressure drop.

4. Initial Parameters: Funnel Effect • Shell Material • Shell Thickness • City Water Flow Rate • Counter or Parallel Flow • Shell ID • Baffles – Yes or No • Baffle Spacing • Tube OD • City Water Flow • Tube Length • Tube Thickness • Tube Layout & Angle • Tube Material • Tube Pitch • Shell Mass Flow Rate

5. Main Effects Plot: Weight

6. Main Effects Plot: ΔP Shell

7. Main Effects Plot: ΔP Tube

8. Main Effects Plot: Q Calculated

9. Pareto Chart: Weight

10. Standardized Effects: Weight

11. Pareto Chart: ΔP Shell

12. Pareto Chart: ΔP Tube

13. Pareto Chart: Q Calculated

14. Standardized Effects : Q Calculated

15. Standardized Effects : Q Calculated

16. Optimized Results: HE Pressure Drop ====================================== Shell Side Delta-P = 12330.12 Pa Shell Side Delta-P = 12.33 kPa Tube Side Delta-P = 2412.77 Pa Tube Side Delta-P = 2.41 kPa ====================================== Shell Side Pump Power = 0.31 kW Tube Side Pump Power = 0.11 kW Heat Exchanger Weight ====================================== Shell Weight = 96.79 kg Tube Weight = 887.29 kg Shell Fluid Weight = 1363.08 kg Tube Fluid Weight = 873.20 kg Total HE Weight = 3220.36 kg Heat Exchanger Inlet & Outlet Temperatures (Celsius) ========================================== Inlet Outlet Delta Bulk Wall Tube 45.00 25.00 20.00 35.00 30.55 Shell 20.00 32.22 -12.22 26.11 Overall Heat Transfer Coefficient ====================================== U (Tube Outside Area) = 815.25 W/m2.C Heat Transfer Rate ====================================== Desired Heat Transfer Rate = 5106263.80 W Calculated Heat Transfer Rate = 5105087.64 W Difference = 1176.16 W Desired-to-Calculated Ratio = 1.00

17. Material Selection Reasoning: • Cost of Shell (96.79 kg = 213.385 lbs)… • Stainless Steal • 1.04/lb = $221.92 Total • Aluminum • .84/lb = $179.24 Total • Cost of Tubes (N = 8,142)… • Aluminum • $1,117,489.50$ • Stainless Steal • $1,384,615.20 Therefore, Aluminum was chosen for the tube material due to its low weight. In addition, Stainless steal was chosen as the shell material to provide a longer shell life.

18. Referenced: • Toksoy, John. ME 414 Thermal-Fluid Systems Design. Department of Mechanical Engineering, IUPUI, Indianapolis, IN, Spring 2010. • OnlineMetals.com. (n.d.). Retrieved May 6, 2010, from htttp://www.onlinemetals.com/basket.cfm

19. Questions ?