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
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
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.

Initial Parameters:
Funnel Effect
Tube OD  Shell Material
City Water Flow  Shell Thickness
Tube Length  City Water Flow Rate
Tube Thickness  Counter or Parallel
Tube Layout & Angle Flow
Tube Material  Shell ID
Tube Pitch
 Baffles – Yes or No
Shell Mass Flow
 Baffle Spacing
Rate
Main Effects Plot: Weight
Main Effects Plot: ΔP Shell
Main Effects Plot: ΔP Tube
Main Effects Plot: Q Calculated
Pareto Chart: Weight
Standardized Effects: Weight
Pareto Chart: ΔP Shell
Pareto Chart: ΔP Tube
Pareto Chart: Q Calculated
Standardized Effects : Q Calculated
Standardized Effects : Q Calculated
Optimized Results:
Heat Exchanger Inlet & Outlet Temperatures (Celsius) HE Pressure Drop
========================================== ======================================
Inlet Outlet Delta Bulk Wall Shell Side Delta-P = 12330.12 Pa
Tube 45.00 25.00 20.00 35.00 30.55 Shell Side Delta-P = 12.33 kPa
Shell 20.00 32.22 -12.22 26.11 Tube Side Delta-P = 2412.77 Pa
Tube Side Delta-P = 2.41 kPa
======================================
Overall Heat Transfer Coefficient Shell Side Pump Power = 0.31 kW
====================================== Tube Side Pump Power = 0.11 kW
U (Tube Outside Area) = 815.25 W/m2.C
Heat Exchanger Weight
Heat Transfer Rate ======================================
====================================== Shell Weight = 96.79 kg
Desired Heat Transfer Rate = 5106263.80 W Tube Weight = 887.29 kg
Calculated Heat Transfer Rate = 5105087.64 W Shell Fluid Weight = 1363.08 kg
Difference = 1176.16 W Tube Fluid Weight = 873.20 kg
Desired-to-Calculated Ratio = 1.00
Total HE Weight = 3220.36 kg
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.
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
Questions
?