CME 8056 Manufacturing,

Materials and Processes

Module Leader : Dr Charles,
Herschel Bldg. 5
th
floor, Rm 5.03

Email : e.a.charles@ncl.ac.uk

1
CME 8056 Processes
Module Outline
6 topics presented by 6 staff :
Dr Charles, heat exchange
Prof Bull, surface engineering
Dr Novakovic, polymer processing
Dr Oila, composites
Dr Siller, chemical sensors
Dr Frankel, bio-materials

2
Timetable
There are three lecture slots (Monday,
Thursday & Friday)
One tutorial slot
Two Seminar slots (spare)

Lecture slots will be used but tutorial and
seminar slots will only be used when you are
told
3
CME 8056
Module Assessment :

70% for written exam (sections A and B)

10% for group presentation

20% for technical report
4
Presentations
Each lecturer will give five / six lectures over
two weeks and the following week during the
tutorial / seminar slots as agreed, groups of
three students will give 15 minute
presentations on topics assigned to them

Presentation topics may appear in the exam

5
Presentations
Marked on presentation quality, clarity of
message, technical background & discussion

Lecturer and two randomly selected student
judges will each mark the presentations on a
topic
6
Reports
Each student will be allocated to a lecturer to
get a topic and discuss any issues
Students should have contacted their lecturer
to get their topics before the Spring Vacation
(before 15th of March)
The submission date is Wednesday 8
th
of May
Hand to the CEAM general office, 3
rd
floor,
Merz Court before 4pm

7
Reports
Must be no more than 2000 words
Will be marked on presentation quality,
technical content and clarity
Report materials will not appear in the exam
Students may be allocated similar or different
topics but we will be checking for originality !

8
Topic 1. Heat Transfer Technology
Dr Charles
9
Heat Transfer Economics
Compare energy consumption before and after
heat recovery

Calculate financial saving and then determine the
rate of return on the capital investment of
installation

Costs can be related to cost of prime energy
source eg. barrel of oil equivalent ~ 1700 kWh

10
Heat transfer economics
11
Heat Exchangers
Increasing applications in all industry / energy
related activities
European market is growing and worth over 4
billion dollars a year
Aim to exchange heat, recover waste heat or
transport heat energy
12
Life Cycle Costing, LCC
Materials selection effects life and capital cost

Software packages for life-time costing and
comparison of different starting material costs

13
Life Cycle Costing
Total Cost :
material
fabrication and installation
future maintenance
plant down-time
future replacement
estimate for inflation / interest rate changes

14
Life Cycle Costing
Evidence shows investment in high quality
materials provides long-term savings on
operation / maintenance

15
CME8056
16
Life Cycle Costing
Further factors such as,

safety of operators

environmental impact

may also need to be costed

17
Typical Life-Cycle Costs
18
Heat Transfer a reminder
Transfer may be achieved by,
Conduction transfer through a stationary
medium
Convection transfer in a moving medium in
contact with a surface
Radiation transfer between two surfaces
19
Types of Heat Exchanger
Shell & tube - common in industry

Recuperators - recovers flue gas heat
eg. balanced flue appliances
20
Types of heat Exchanger
Direct Contact hot and cold fluids / gases pass
each other power station cooling towers

Regenerators a heat retaining core which
alternates the hot and cold fluids
Smaller scale :
Compact-Plate heat exchangers
Heat Pipes transfer and transport



21
The Heat Pipe
Special case of heat transfer / transport

Applications are high tech. but becoming more
common
Advantages :
Light Weight
No moving parts
Enclosed system
No maintenance

22
Cross-section of a heat pipe
23
How a heat pipe works
24
Characteristics
Very high thermal conductivity using two
phase heat transfer

Silent operation with capillary pumping

Light weight and compact size suitable for
space constrained applications up to 3m
length
25
Characteristics
Low thermal gradient required
High reliability / life
Limitations on pipe length :
capillary volume,
sonic vibrations,
liquid viscosity,
Other limitation :
boiling point limits

26
Types of Heat Pipes
Wickless system thermosyphon

gravity
Heat in
Heat out
Vapour going-up
Condensate returning
27
CME8056
gravity
Heat in
Heat out
Vapour going-
up
Condensate
returning
28
Heat Recovery from gases
Rotating heat pipe and the thermal wheel
Regenerators for heat recovery from foundry
and furnace air streams

29
Rotating Heat Pipe

Heat in
Heat out
Vapour flow
Condensate flow
30
Types of heat pipe
Wicked systems allow for tilting
Design of wick :
Grooved, up to 10 W /cm
2

Mesh up to 15 W /cm
2

Powders > 15W /cm
2
( 200 W /cm
2
possible)


31
Selection of heat pipes
Identify operating temperature range,
orientation, dimensions
Select working fluid eg.
water 5 to 200 Deg. C
methanol -4 to 120 Deg. C
liquid nitrogen to -100 Deg C.
liquid lithium metal to ~ 1500 Deg C.
32
Selection of heat pipes
Design pipe cross-section eg. circular, flattened
pipe or semi-circular
Select pipe cross-sectional area :
up to 10 mm od. < 50W
10 to 20 mm od. up to 500W
> 20 mm od. > 500 W

Larger diameters suffer from convection /
thermals across tube

33
Applications
Electronic industry
Space applications for temperature
stabilisation
Solar energy collection
Waste heat recovery
Process industry reaction control
34
Applications
Transfer rates enhanced by
Using multiple tubes
Adding external fins to tubes

Can be used for general heat transfer ie. heating
or cooling or heat recovery
35
Electronic industry example
Ideal: compact, no noise, no power needed, no maintenance
36
Development trends
Trend of Power Level in Computer, Telecom and Power Electronics
0.1 1 10 100 1000
Power - W/cm
2
Jan - 85 Jan - 89 Jan - 93 Jan - 97 Jan - 01 Jan - 05
T
h
e
r
m
a
l

R
e
s
i
s
t
a
n
c
e

-

c
m
2
/
W
1,000
100
10
1
0.1
0.01
Natural Convection
Stampings
Extrusions
Heat Pipe Assemblies
Single & Two Phase Liquid Cooling, Refrigeration
Folded Fin Assemblies
Loop Heat Pipes & Pulsating Heat Pipes Assemblies
Advanced & Emerging
Technologies
Mature Technologies
37
Recuperators
Transfer across a barrier wall
Single or bank of tubes to transfer heat
Pressure drop along tubes is low so particulate
matter does not collect in pipes
Some system incorporate a continuous
mechanical scraper to remove deposits /
oxidation scale
38
Simple Recuperator
39
Compact-plate heat exchangers
Large surface area for transfer
High heat transfer efficiency
Suitable for small temperature differences
Hot and cold fluids pass between alternate
plates
Ribs on plates provide mechanical strength
and also fluid turbulence to improve transfer
40
Compact-plate heat exchangers








Design allows easy addition of extra plates,
external lagging
41
Compact-plate heat exchangers

42
Compact-plate heat exchangers
Plate materials often stainless steel pressings
Since 1990s polymer film plates
eg. PEEK (polyether ether ketone) thermoplastic
Plates can be down to 100um thick
Operate up to 250 Deg C. (Mpt. 343 Deg C.)
Corrosion resistant
Fouling resistant hydrophobic / smooth
finish mouldings
43
Compact-plate design
44
Compact-Plate heat Exchangers
Applications :
air conditioners, portable systems (cars,
cooled containers)

design allows easy capacity adjustment



45
Compact-Plate heat exchangers
Pros :
good temperature control
compact and lighter weight
easy to strip for cleaning / repair
Cons :
seals can leak
higher pumping P required
solutions should be silt free
46
Shell & Tube Heat Exchangers
Large exchangers used industrially
Heat transfer across barrier wall using conduction and
convection processes

Simplest for is a tube inside a tube / shell

Three main types :
Fixed tube plates cheap / simple
hard to clean tube o/d
U bend form hard to clean tube i/d
Floating head expensive but easy to clean




47
CME 8056 Shell & Tube Heat Exchanger Types
48
Types of Shell & Tube Exchanger
Fixed tube
49
Types of Shell & Tube Exchanger
U tube
50
Types of Shell & Tube Exchanger
Floating head
51
Flow in the exchanger
Tube end plate / or tube sheet Tube support plates / baffles
52
Shell & Tube Exchangers
Flow may be parallel
counter
cross-flow
Cross-flow often achieved using baffle plates
Applications : liquid/liquid heat exchange,
gas/liquid heat exchange

53
Shell & Tube Exchangers
Aim for thin-walled barrier
Aim for large surface area of interface
Limit stagnant layer on tube wall by controlled
pumping cost / maintenance versus
efficiency
Control fouling of surfaces
54
Shell & Tube Exchangers
Shell is often a pressure vessel

Tubes also have to withstand pressure
differential
Hot fluid pressurised to prevent boiling
Cold fluid often at lower pressure


55
Applications of recuperators
Special cases :
Automotive Radiators where air cools hot
water
condensers where a cold fluid causes
condensation from a gas

steam generators where hot fluid is used to
convert water to steam

56
Automotive Radiators
Design improvements / savings


57
Tube Materials Selection
Properties required :
Good mechanical strength
Ease of fabrication /ductility
Reasonable heat transfer
Good creep resistance
Resistance to corrosion
Resistance to fouling
Acceptable cost
58
Materials Used
Many carbon steel shells with alloy steel tubes
this can lead to galvanic issues
In hostile environments shell is also alloy
Corrosion problems from impurities in fluids
Today also specialist polymers and ceramics
applications


59
Carbon steel / alloy applications
60
Materials Selection
61
Alloy materials for tube bundles
In order of usage :
300 stainless steels
nickel
monel
copper
aluminium alloys
inconel alloys
400 series alloys
62
Corrosion Risks
Drawn / stressed tubing may fail by stress
corrosion cracking
Deposition of impurities causes sludge piles
under which low oxygen, occluded cell
corrosion
General surface oxidation due to heat or fluid
attack
63
Steam Generators
Specific type of shell and tube exchanger used
in power stations to convert water to steam to
drive turbine operation
Provides isolation between primary and
secondary water circuits - safety
Operating temperature ~ 300 Deg. C.





64
Steam Generators in Nuclear Power
Plant
Pressurised Water Reactors, PWR, common US
and EU designs
Older boiling water reactors, BWR, less safe


65
PWR Layout
66
Nuclear Power Factoids
Over 440 plants worldwide
Producing over 360,000 MW
US has most plants
France has highest % nuclear power provision


67
Nuclear Power in the UK
Last PWR plant commissioned 1995 at
Sizewell, East Anglia
PWR output >1000 MW
Over 1000 heat exchangers on site !
Four steam generators
68
Steam Generators
Has same features as other heat exchangers
tube bundle, tube-sheet, tube support plates

At Sizewell : each has 5,600 alloy tubes giving
a heat transfer area of 5000 m
2




69
Steam Generators
The vertical tube steam generators run two
turbines each
The primary circuit input is ~ 315 Deg C. at
16 MPa
The secondary side steam is ~ 270 Deg C. at
6 MPa
Theoretical transfer efficiency is 99 %
70
Development of Steam Generators
Initially tube bundles made from 316 stainless
steel
Failures led to selection of a more corrosion
resistant alloy : Inconel 600
Eventually (17 years later) Inconel 690
purpose designed alloy developed

71
PWR Failures in the US
72
BWR Failures in the US
73
Steam Generator Plant
74
Steam Generator Operation
75
Steam Generator Failure Modes
76
Why use seamless tubing ?
Risk of cracking at welds :
77
Heat-affected zone, HAZ
78
How do you make seamless tube ?
79
U bend tube failures
80
Tube support-plate denting
81
Sludge
pile build
-up

Force of
Oxide
growth


Sludge Piles in many systems
82
Cross-section
of domestic
radiator
Showing
sludge pile and
localised
pitting
corrosion
Dealing with leaking tubes in SG
Plug during shut-down -> efficiency loss

Monitor losses :
Failure rate = Number Plugged
Total No. tubes x Operating time

Replace bundle when performance
unacceptable



83
Design Solutions to TSP denting
84
Tube-sheet expansions
85
Partial expansion
Full expansion
Roller expansion or explosive
welding
86
In many shell and tube exchangers tubes are
brazed or welled to the tube sheet
In SG the tubes are either roller expanded or
explosively welded
Minimise diffusion / micro-structural changes
Explosive Welding
87
Conclusions
Heat exchangers essential to all modern
industry

Designs / material selection still improving

Life-cycle costing and pay-back economics
important
Monday 3pm student presentations

88

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