ME 4226 Energy and Thermal Systems Analysis AY2010/2011 Semester 1

Design of a Cross Flow Heat Exchanger

ME4226 Design Project

Chai Kwan Chen Lai Zhenwei Ooi Min Jia Elaine Tan Mu Ling Nathaniel

U084803E U080471L U076725M U076649A

IntroductionIndividual ReportsIndividual Reports 2

Contents
Introduction ................................ ................................ ................................ ................................ ...... 3 Objective ................................ ................................ ................................ ................................ ........... 5 Design Parameters................................ ................................ ................................ ............................. 5 Determination of Fluid Properties................................ ................................ ................................ ...... 7 Design Calculations ................................ ................................ ................................ ............................ 9 Heat Transfer Coefficient ................................ ................................ ................................ ................. 12 Fin effectiveness and heat transfer area: ................................ ................................ ......................... 12 Total Surface Area and Size of Heat Exchanger................................ ................................ ................. 14 Verification of Design Calculations ................................ ................................ ................................ ... 16 Computation of Reynolds Number................................ ................................ ............................... 16 Computation of Stanton Number, Friction Factor and Heat Transfer Coefficients......................... 17 Determination of Fin Effectiveness and Overall Heat Transfer Coefficients................................ ... 17 Determination of NTU and Heat Exchanger Effectiveness and Outlet Temperatures .................... 18 Determination of The Pressure Loss In The Heat Exchanger ................................ ......................... 19 Discussion................................ ................................ ................................ ................................ ........ 20 Conclusion ................................ ................................ ................................ ................................ ....... 21 Individual Reports................................ ................................ ................................ ............................ 23

IntroductionIntroductionIndividual Re ortsIndividual Re orts 3

Int odu tion

Heat e c angers are devices built for efficient heat transfer from one medium to another. They are widely used in s ace heating, refrigeration, air conditioning, power plants, chemical plants, petrochemical plants, petroleum refineries and natural gas proc essing. s There are different types of heat e changer and one such is the shell-and-tube (also known as cross-flow) as seen from Figure 1 below.

Figure 1: Shell-and-tube Heat Exchanger This type of heat exchanger consists of a series of tubes. One set ofthese tubes contains fluids that must be either heated or cooled. The second fl runs over the tubes being uid heated or cooled so that it can either provide heat or absorb the heat required. As the shelland-tube (also known as cross-flow) heat exchangers are robust due to their shape, they are typically used for high pressure applications. Pipes, tubes, and cast tubular sections with external transverse high fins have beenused extensively for heating, cooling, and dehumidifying air and other gases. The fins are preferably called transverse rather than radial because they need not be circular, as the latter term implies, and are often helical. The air-fin cooler is a device in which hot-process fluids, usually liquids, flow inside extended surface tubes a atmospheric air is circulated nd outside the tubes by forced or induced draft over the extended surface. High-fin tubes can also be extruded directly from the tube -wall metal, as in the case of integral low-fin tubing. However, it becomes increasingly difficult to extrude a high fin from ferrous alloys as hard as those required for high -temperature services, which are often

IntroductionIntroductionIndividual ReportsIndividual Reports 4

amenable to work hardening while the fin is being formed. Whether fins are attachedby arc welding or resistance welding, the fin-to-tube attachment for all practical design considerations introduce a negligible bond or contact resistance.

Figure 2: Various Shapes of Finned Tubes

The large majority of applications are for transferring heat to atmospheric air. Finnedtubes may be used in: water cooling of product, and air cooling of product, oil air exchangers and oil, industrial and residential air heaters using burned gas heat, steam, hotwater or resistance heating elements rolled inside finned tube, cooling and food processingindustry and automotive industry.

For efficiency, heat exchangers are designed to maximize the surface area of the wall between the two fluids, while minimizing the resistance to fluid flow through the exchanger. The exchanger s performance can also be affec by the addition of fins in one or both ted directions which increase surface area and may channel fluid flow or induce turbulence.

ObjectiveIntroductionIndividual ReportsIndividual Reports 5

Objective
The objective of this assignment is to design a cross-flow, finned tube gas to li uid heat exchanger, installed to a Capstone C60 Microturbine. The purpose of the heat exchanger is to recover heat from the turbine exhaust and thence supply hot water to the guest rooms and kitchens of a major hotel. The selected heat exchanger for use is CF-8.7-5/8J (b).

Design Parameters
For the turbine exhaust gas:
Exhaust Gas Mass Flow Rate, mg Maximum Exhaust Gas Temperature Maximum Pressure Drop (Turbine Back Pressure) Table 1 0.43 kg/s 370 C 8 Water (inches) = 2kPa

For heat exchanger (water) characteristics:

Inlet Water Temperature, tw,i Outlet Water Temperature, tw,o Tube Diameter Table 2 30 C 80 C 5/8 inch = 1.5875 x 10 -2 m

Design ParametersIntroductionIndividual ReportsIndividual Reports 6

Flow-Passage Hydraulic Diameter Flow-Passage Hydraulic Radius, rh,g Total Gas Side Transfer Area/Total Volume, Fin Area/Total Area Free-Flow Area/ Frontal Area, Fin Metal Thickness, Fin Length, l Fin Pitch Table 3
g g g

Fin Material Copper, kg

F r

E c

r(

Fin Diameter (inclusive of tube) Outside Diameter Of Tube Inside Diameter, di Spacing: S Spacing: L Frontal Area Associated With 1 Tube: S*L Free Flow Area Of 1 Tube, Ac,tp Inside Perimeter Of 1 Tube Free-Flow Area/ Frontal Area,
w w

Water-Side Transfer Area/Total Volume,

Water-Side Flow Passage Hydraulic Radius, rh,w Table 4

  

 
0.01167 m 0.0029175 m 216 m2/m3 0.865 0.628 0.000254 m 389.5 W/mC 0.0060452 m 342.519685 per m

F r

E c

r(

 

id )

r id )

0.0284734 m 0.016383 m 0.015875 m 0.0469392 m 0.03429 m 0.001609545 m2 0.000197933 m2 0.049872783 m 0.122974249 30.98563766 m2/m3 0.00396875 m

Determination of Fluid PropertiesIntroductionIndividual ReportsIndividual Reports 7

Determin tion of Fluid Properties

Given that situations are seldom ideal, we choose an inlet gas temperature significantly lower than the specified temperature the microturbine manufacturer suggests.

T/

Gas Wat x

Temperature Values Exhaust Gas Temperature Outlet Water Temperature Outlet Exhaust Gas Temperature Inlet Water Temperature Inlet 120C 80C 280C 30C

Bulk average temperature of water, tw = (30+80) = 55 C Log Mean Temperature Difference, LMTD = [(280-80) (120 30)] / ln[(280-80) / (120 30)] = 137.757 C Bulk Average Temperature of Exhaust Gas, tg = 55 + 137.757 = 192.757 C

Determination of Fluid Properties IntroductionIndividual ReportsIndividual Reports 8

Properties of water:
At tw = 55 C, from the Rogers and Mayhew Steam Tables, Prandlt Number, Pr w Density,
w

3.23 985.22 kg/m3 4.183 kJ/kg.K 0.000501 kg/ms 0.648 W/mK Tabl 5

Specific Heat Capacity, cp,w Dynamic Viscosity,

w

Thermal Conductivity, k w

Properties of xhaust Gas:

As the composition of exhaust gas is very similar to that of dry air, we can assume the properties of exhaust gas to be similar to the properties of air.

At tg = 192.757 C = 465.757 K, Prandlt Number, Prg Density,

g

0.68 0.706 kg/m3 1.0295 kJ/kg.K 0.0000297 kg/ms Tabl 6

Specific Heat Capacity, cp,g Dynamic Viscosity,

g

Data taken from: http://www.engineeringtoolbox.com/water-thermal-properties-d_162.html

 

Design CalculationsIntroductionIndividual ReportsIndividual Reports 9

Design Calculations
As turbulent flow is re uired as a guiding principle, we assumed that the gas should flow at a velocity for its Reynolds number to be more than 2300. The flow velocity of gas, w g is assumed to be at 8.2 m/s. The flow velocity of water, w w is assumed to be at 0.208 m/s.

For the gas side

Heat Transfer, Qg = (0.30358 x 1029.5)(280 -120) = 50005.7 W Mass Velocity, Gg = 0.706 x 8.2 = 5.7892 kg/m2s Reynolds Number, Re g = 4 x (2.907 x 10-3) x 5.7892 / 0.0000267 = 2521.582 > 2300

For the water side

Mass Flow Rate, m w = 50005.7 / [4183(80 -30)] = 0.23909 kg/s Mass Velocity, G w = 985.22 x 0.208 = 204.93 kg/m2s Reynolds Number, Re w = 4 x (3.94 x 10-3) x 204.93 / 0.000501 = 6446.367 > 2300

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At Reg = 2521.582, StgPrg2/3 = 0.0125 and f g = 0.066 Stanton Number, St g = 0.0125 / 0.68 2/3 = 0.016165

Figure 4: Friction Factors for Smooth Tubes

F gu

3: Geometry o F nned Circular Tubes

"

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Figure 5: Nusselt Numbers for Turbulent Tube Flow

At Re w = 6446.367, Friction Factor, f w = 0.079(6446.367) -0.25 = 0.008817 (from Figure 4) Nusselt Number, Nu w = 0.023(6446.367) 0.8(3.23)0.4 = 41.00727 (from Figure 5)

Heat Transfer CoefficientIntroductionIndividual ReportsIndividual Reports 12

Heat Transfer Coefficient

For the gas side
hg = StgGgcp,g = 0.016165 x 5.7892 x (1029.5) = 96.342 W/m2K

For the water side

hw = Nu wkw/4rh,w = (41.00727 x 0.648) / (4 x 3.94 x 10 -3) = 1686.068 W/m 2K

Fin effectiveness and heat transfer area:

m = [(2 x hg) / (k x )]

= [(2 x 96.342) / (389.5 x 0.000254)] = 39.947 m(ro-ri) = 39.947(6.06 x 10-3) = 0.242 ro/ri = 28.5/16.38 = 1.7399

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Figure 6 Effectiveness/efficiency of thin fins From Figure 6, Fin Effectiveness,

f

= 0.97
a

Overall Surface Effectiveness,

=1

g(1- f)

= 1 0.628(1-0.97) = 0.97414 Overall Coefficient Of Heat Transfer (Gas Side Area), U g = {(1/
ahg)

+ 1 / [hw (

w/

-1 g)]}

= 67.4875 W/m 2K

Total Surface Area and Size of Heat ExchangerIntroductionIndividual ReportsIndividual 14 Reports

Total Surface Area and Size of Heat Exchanger

Heat Transfer Area, A = Q / (U x LMTD) = 50005.7 / (67.4875 x 137.757) = 5.3788 m 2 Matrix Frontal Area, A fr,g = mg / (
g

x Gg)

= 0.43 / (0.628 x 5.7892) = 0.0835 m 2 Tube Matrix Length, L tm = A / (A fr,g x

g)

= 5.3788 / (0.0835 x 216) = 0.2982 m Number of Tube Passes, N tb = Ltm / L = 0.2982 / (1.35 x 0.0254) = 8.6944

As a conservative design, this value is rounded to 9 tube passes, New Matrix Length, L tm = 9 x 1.35 x 0.0254 = 0.3087 m Mass Flow Rate Per Tube Passage, mtp = Ac,tpGw = (0.195 x 10 -3) x 204.93 = 0.04 kg/s Number of Tube Passages Re uired, N tp = 0.23909 / 0.04 = 5.9808

Total Surface Area and Size of Heat ExchangerIntroductionIndividual ReportsIndividual 15 Reports As a conservative design, this value is rounded to 6 tube passages.

Height of Matrix Inlet Face, H fr,g

= 6 x 46.9 = 0.281 m

Width of Matrix Inlet Face, L fr,g

= Afr,g / Hfr,g = 0.0835 / 0.281 = 0.297 m

The design of the gas-to-water, cross-counter flow heat exchanger is now complete. The proposed heat recovery unit is a finned-tube exchanger of length 0.3087 m and crosssection 0.281 m X 0.297 m. Water flows through 6 finned, copper tube banks of diameter 5/8 inch BWG gauge in a staggered arrangement with 9 passes. Copper fins of thickness 0.1 mm and height 6.054 mm are installed along the tube at a pitch of 343 fins per metre. Water flows through the tubes and makes 9 passes before exiting at the inlet section of the heat exchanger.

Verification of Design Calculations IntroductionIndividual ReportsIndividual Reports 16

Verification of Design Calculations

Heat xchanger Dimensions:
%
Gas side frontal area, Water side frontal area, Total heat exchanger volume,


Computation of Reynolds Number

For the gas side:


For the water side:



6425.79

Figure 7: Effectiveness-NTU Curves

Verification of Design Calculations IntroductionIndividual ReportsIndividual Reports 17

Computation of Stanton Number, Friction Factor and Heat Transfer Coefficients

For the gas side:
From Figure 3, for surface CF-8.7-5/8J(B) with Reg=6425.79,

0.066

For the water side:

From Figures 7 and 8 in lecture notes,

Determination of Fin ffectiveness and Overall Heat Transfer Coefficients

For the gas side:

From Figure 6,

0.97

The overall surface effectiveness,

Verification of Design Calculations IntroductionIndividual ReportsIndividual Reports 18

Neglecting wall resistance, the overall heat transfer coefficient on the gas side is computed by:

Determination of NTU and Heat xchanger ffectiveness and Outlet Temperatures

Heat capacity for the gas side, Heat capacity for the water side, 312.5356 1003.317

From Figure 9 in lecture notes, for a cross -flow heat exchanger with one fluid mixed and the other unmixed,

The effectiveness of the heat exchanger,

Determination of the gas outlet temperature:

Verification of Design Calculations IntroductionIndividual ReportsIndividual Reports 19

Determination of water outlet temperature by energy-balance considerations:

The values of the oil and exhaust gas outlet temperatures from the heat exchanges agree with the values assumed for the design and thus validate the size of the heat exchanger.

Determination of The Pressure Loss In The Heat xchanger

For the gas side

The pressure loss on the gas side is less than the maximum allowable pressure drop of the microturbine. Thus, the design i s fine.

For the water side

DiscussionIntroductionIndividual ReportsIndividual Reports 20

Discussion
The design of our heat exchanger is based on circular fins of surface designation CF -8.7-5/8 J(B). Our group further explored the possibility of an alternative design which uses the surface designation of CF-8.7-5/8 J(A). Such circular fins have smaller traverse tube spacing and hydraulic diameter. Calculations have shown that the alternative design is able to increase the compactness of the heat exchanger while achieving similar performance in terms of effectiveness and temperatures. The drawback of this design is its significant increase in the pressure drop of gas. Besides design parameters, fouling can also affect the design of the heat exchanger. Heat exchangers are subjected to fouling over prolonged period of use which leads to the corresponding effects of reduction in thermal efficiency, decrease in heat flux and increase in pressure drop. Provisions for fouling sh ould be made in the design stage by providing an allowance for fouling such as having an excess in surface area for heat transfer. However since this is an academic design and design for fouling allowance is beyond the scope of our stusdy, we will be assuming the clean surface condition. Our main objective of the project is to recover the heat from the turbine exhaust to supply hot water to the guest rooms of a major hotel. By assuming that each guest s daily consumption of hot water is 100L/day and at a fu ll occupancy rate of 200, there will still be an allowance of 5% in the water flow rate. In Singapore, the average hotel occupancy rate is 75.8% (from Key Annual Indicators 2009). This means that our system will normally operates at about 80% of its full l oad and the supply is more than sufficient in meeting the consumption rate at any time of the year. In addition, the hot water produced will be stored in an insulated tank to ensure continuous steady flow of water all day even when the turbine is running at part load. Heat losses to the surroundings will be inevitable even with a well insulated tank and piping. Hence, the outlet temperature of the water supplied to the guests rooms may be slightly below 80 C. However, this may not be much of a concern since average bath water temperature lies between 30 - 50 C which means that cold water will have to be mixed with the hot water before coming out of the taps. Therefore, slight temperature drop in the water temperature should be accommodated.

ConclusionIntroductionIndividual ReportsIndividual Reports 21

Conclusion
Design Parameter Exhaust Gas Inlet Temperature Exhaust Gas Outlet Temperature Water Inlet Temperature Water Outlet Temperature Our Design Data 280 oC 120 oC 30 oC 80 oC

Tube Type Tube Size Number Of Tubes Number Of Passes

CF-8.7-5/8 J(B) 5/8 BWG Gauge 16 6 9

Gas Side Heat Transfer Coefficient

67.49 W/m2oC

Maximum Turbine Back Pressure Water Side Pressure Drop Gas Side Pressure Drop

2 kPa 126.653 kPa 0.0998 kPa

Summary Table

ConclusionIntroductionIndividual ReportsIndividual Reports 22

We chose the surface type CF-8.7-5/8 J(B). CF-8.7-5/8 J(B) s finned tube configuration is ideal for heat exchange between a li uid and a gas and has a good
g

(Total Heat Transfer

Area to Total Volume ratio). It was also chosen because the tubes and fins are uite well spaced apart, therefore the expected pressure drop across the heat exchanger is low and will not exceed the maximum allowable backpressure drop specified by the turbine manufacturer. In this assignment, design parameters are tested repeatedly, and changed accordingly and reasonably so as to achieve the desired final condition. At the same time, given the numerous types of heat exchangers, we are also aware of how the sizing problem is interconnected with the rating problem. To conclude, our gr oup has learnt and understood the concepts and procedures re uired for designing of heat exchangers.

&

&

&

Individual ReportsIntroductionIndividual ReportsIndividual Reports 23

Individual Reports
Lai Zhenwi U080471L

Learning Points The design exercise was a good learning experience. It was an understanding of the complexity in designing a heat exchanger. We made a significant number of iterations before we managed to achieve the desired results. With the excel sheet, this iteration is done with more ease as the beginning parameters can be changed without having the calculations done another time. I also realised that there are other considerations that we have not researched in detail. Firstly, fouling was not considered as we assumed a clean surface. Secondly, the price of the heat exchanger designed by us was not calculated. Price is an important factor in the design as factors such as durability and material degradation will have to be considered. It would be interesting to be able to manufacture and test the actual heat exchanger. Contribution I drawn up the excel sheet, which includes getting the property data as well as the design calculations. The calculations were checked through many times as one mistake was affecting the results of the whole project. I contributed to the first uarter of the report writing. Peer Grading All members contributed their fair share and were willing to help each other out throughout the project. This project was done in a very fair and cooperative f ashion and I have enjoyed doing this project with them.

'

Individual ReportsIntroductionIndividual ReportsIndividual Reports 24

Ooi Min Jia laine U076725M

(

The design exercise was a good learning experience. It was an understanding of the complexity in designing a heat exchanger. We made a significant number of iterations before we managed to achieve the desired results. In the initial stage of the design process, each group member built his or her own spreadsheet from scratch. Rather than choosing the easier and less taxing way of assigning one member to come up with the wh ole spreadsheet, we insisted on having everyone draw up their own calculation spreadsheet as we believe by designing your own heat exchanger from scratch allows us to gain a more holistic understanding of the limitations and problems present. There were many variables to consider in the design process. The complicated and laborious nature of the work definitely caused some frustration. It was important to be precise in our calculations and derivation since any error in the numbers would result in unrealist ic and erroneous specifications (as we found out). The design process led to a concretization and understanding of the heat exchanger design process up without attempting to design one ourselves. It was also a lesson in realism, given that reality often differs from the perfect measurements we derive. We gave a great margin to account for less than ideal workings. The contributions of my group mates were commendable. They were full of initiative and support. Their organisation made my task very easy. I really enjoyed working with them. Full marks for them in every aspect! something which we would not pick

Individual ReportsIntroductionIndividual ReportsIndividual Reports 25

Tan Mu Ling Nathaniel U076649A

From this design assignment, I have a better understanding of the procedures of designing a heat exchanger. As there may be many dependent variables, we need to consider its various implications such that at the end of the day, we are able to obtain the desired results. I have also understood why certain assumptions have to be made in the design process. I am more also more appreciative of the different values calculated as they reflect the various properties of the design. It was not easy troubleshooting the discrepancies in our calculations, and necessary adjustments to the design parameters had to be made for the design to function properly and efficiency. This exercise has also strengthened my knowledge and understanding on the application of heat exchangers. In addition, working with my group mates has proved to be a rewarding experience. Their willingness to share and troubleshoot during our group discussions has helped me to learn more effectively and cleared my misconceptions. While I was in the midst of formatting and preparing this written report, I have also helped to cross-check the calculations and done research on the theory of heat exchangers. This design report is a compilation of all our efforts.

Individual ReportsIntroductionIndividual ReportsIndividual Reports 26

Chai Kwan Chen

)

U084803

I have produced an excel spreadsheet independantly by following the design steps as shown in the course material in order to compare the calculations with others so that to confirm that there weren t any mistakes. In the process of doing so, I realized that there was a slight mistake in the steps which actually ignored the effect of the assumed water velocity in the tube. In the course material, it wasn t shown how to obtain the correct velocity through iteration and modifications to the design steps have to be made in order to achieve that. In addition, I con tributed the design and verification part of the report. Throughout the process of designing, we have to be clear what is the objective or goal we would like to achieve in our design such as maximum water flowrate which is a result of efficient heat transfer and minimum dimension which is dependant on the tubes characteristics and turbine s pressure drop limitation. It is however, hard to achieve every single objective in one shot and is best to be realized by modifying the design to achieve one at a time as we have done so by maximizing the flowrate before substituting the design with smaller spaced tubes to achieve a much more compact design, all while keeping the pressure drop within the turbine s limit. It is inspiring to work in my group especially duri ng the discussion when we challenged each other s understanding on the topic and procedure, which greatly inspired me to think further and deeper into the respective issues.