Second Law Analysis of Plate Heat Exchange

Submitted by: Waleed Zaki Al-Jumaydi Sami Farag Al -Refai

Supervised by: Dr. Mohamed Al-Odat

Outline
Introduction Types of Heat Exchanger Plate type heat Exchanger Experimental Work Test Setup Test Procedure Results and Discussion Conclusion and Recommendation

Introduction to heat exchangers

Modes of heat transfer 1. Conduction 2 .Convection 3. Radiation

Classification of heat exchangers

Classification based on 1. Transfer process a) Direct contact b) Indirect contact 2. Flow arrangement a) Parallel Flow b) Counter Flow c) Cross flow

According to Construction

Shell and tube heat exchanger Plate heat exchanger Plate fin heat exchanger Pillow plate heat exchanger Double Pipe Heat Exchanger

COMPARISON BETWEEN PHE AND STHE

FEATURES Multiple duty Hold up volume Gaskets modifications PHE Possible Low On each plate Easy by adding or removing plates STHE Impossible High On flanged joints impossible

FEATURES
Repair

PHE

STHE

Easy to replace Requires tube plates and gaskets plugging

Detection of leakage
Time reqd. for opening Sensitivity to vibrations Fouling

Easy to detect

Difficult to detect

15 min Not sensitive 15 to 20 % of STHE

60 to 90 min sensitive

Plate Heat Exchanger

The word meaning of Plate Heat Exchanger is "Heat Exchangers". Heat exchanger transfer the heat continuously from one fluid to another without using any energy. Two fluids are separated from each other by an obstacle completely

Different types of plate heat exchangers

1.

Spiral type plate exchanger Plate-fin and tube type exchanger

2.

3.

Brazed plate-fin type exchanger

Plate-fin and tube type exchanger

4.

Different types of plate heat exchangers

Brazed Plate-fin type

Plate-fin and tube type

Spiral plate type exchanger

Plate-frame type

PHE - main components

Carrying bar

Frame plate

Pressure plate

Tightening bolts

Plate pack

Frame
Carrying bars

Support column s Guiding bars

Carryings bar in Aluminium or Painted carbon steel Support columns in Aluminium or Painted carbon steel

Tightening bolts to allow easy opening

Bolt head
Bearing box Plastic cover Lock washer Nut Rolled thread

Frame

Easy maintenance

One man can open and close a large PHE using standard tools Serviceability Less downtime Safety Longer lifetime

smaller
Round carrying bar

Support column

Round guiding bar

Carryings bar, Support columns and Guiding bar in Aluminium No roller needed due to low weight pressure plate

The Plate Pack

Plate sizes

Plate geometries

Plate - corrugation and channels

We have two plate corrugations (L and H) These form three different channels (L, M and H)
L: Low theta H: High theta

L + L = L channels

L + H = M channels

H + H = H channels

We choose between L, M and H channels Tailor-make it for the specific duty

Plate - main components

Suspension Inlet / outlet Passing through Leak chamber Distribution area Gasket in gasket groove

Main heat transfer area

Thin sheet design, cold formed in single step hydraulic pressing (up to 40000 tons)

Plate - materials

Relative Price

Standard materials and thicknesses

AISI 304 (stainless steel)

Usually 0.4 or 0.5 mm thickness Cheapest possible solution

100%

AISI 316 (stainless steel)

115%

Always 0.5 and 0.6 mm Some with thicker plates (high-pressure applications)

254 SMO (high-alloy stainless steel)

250%

Usually in 0.6 mm to allow stock-keeping

Titanium

300%

Always 0.5 and 0.6 mm

Some with thicker plates (high-pressure applications) Some PHEs with 0.4 mm (low-pressure applications)

600%

Alloy C-276 (Nickel alloy)

Usually in 0.6 mm to allow stock-keeping

Gasket - advanced sealing system

Homogeneous rubber gasket made in one piece Gasket material from certified suppliers Supporting and protecting gasket groove Roof-top gasket profile

Two component ovencured epoxy glue ...or glue-free gasket that do not mix sealing and fastening function

Gasket material

The choice of rubber material depends on

Fluids - chemical attack or not

The combination of temperature and pressure

Rubber materials change properties due to

Time - the rubber relaxes

Temperature - the rubber deteriorates Hardening by attack of oxidising agents (e.g., oxygen in air) Swelling or softening by absorption of chemicals in the fluids

Gasket material

Commonly used gasket materials:

1.
2. 3.

4.
5. 6.

7.

Natural rubber Styrene-butadiene-SBR Nitrile Butyl Ethylene propelene rubber Flourinated rubber Compressed asbestos fibre

Stacking of plates

Operation

Channels are formed between the plates and corner ports are arranged so that the two media flow through alternate channels. The heat is transferred through the thin plate between the channels, and complete counter current flow is created for highest possible efficiency. No intermixing of the media or leakage to the surroundings will take place as gaskets around the edges of the plates seal the unit.

End Plate II

Channel plates

Single Pass, concurrent Flow

End Plate I

Working principle

Hot out

Cold in

Cold out Hot in

Only 2 plates that do not transfer heat - the endplates

Multi-Pass, concurrent Flow

Pass/Channel: Hot Side Cold Side

APPLICATIONS

3 major applications (1)liquid-liquid services (2)condensing and evaporative (3)Central cooling

LIQUID-LIQUID SERVICES

It is well-suited to liquid/liquid duties in turbulent flow, i.e. a fluid sufficiently viscous to produce laminar flow in a smooth surface heat exchanger may well be in turbulent flow in PHE. It has major applications in the food industry.

CONDENSATION AND VAPORIZATION

Condensation of vapor (including steam) at moderate pressure, say 6 to 60 Psi, is also economically handled by PHEs, but duties involving large volumes of very low pressure gas or vapor are better suited to other forms of heat exchangers

CENTRAL COOLING

It is the cooling of a closed circuit of fresh noncorrosive and non-fouling water for use inside a plant, by means of brackish water. Central coolers are made of titanium, to withstand the brackish water

ADVANTAGES of Plate Type HEX

Compactness Flexibility. Very high heat transfer coefficients on both sides of the exchanger. Close approach temperatures and fully counter-current flow. Ease of maintenance. Heat transfer area can be added or subtracted with out complete dismantling the equipment. Ease of inspection on both sides. Ease of cleaning. Savings in required flow area. Low hold-up volume. Low cost. No Local over heating and possibility of stagnant zones is also reduced. Fouling tendency is less.

Limitations Of Plate Type HEX

Low Pressure up to 300 psi Low temperature up to 300 F Limited capacity Limited plate size 0.02 sq.m to 1.5 sq.m Large difference b/w flow rates cant be handled High pressure drop Potential for leakage

Testing procedure of PHE

Equipments Test procedures Examination Acceptance standard Reports

The First Law of Thermodynamics Analysis

Qc mc Cpc (Tci Tco ) Qh mh Cp h (Thi Tho )

the heat capacity rate and is defined for the hot and cold fluid streams as

C c mc Cp c
Q C c (Tci Tco )
Q UA Tlm

C h m h Cp h

Q C h (Thi Tho )
Where U is the overall heat transfer coefficient, A is the heat transfer area Tlm is an appropriate average temperature difference between the two fluids.

The rate of heat transfer in a heat exchanger can also be expressed in an analogous manner to Newtons law of cooling as

the temperature rise of a cold fluid is equal to the temperature drop of the hot fluid is when the heat capacity rates of the two fluids are equal to each other

hot and cold water variation with heat exchanger length in counter flow configuration

The second low analysis

Case I: The hot-side capacity rate is lower than that of the cold fluid. Therefore, the minimum capacity rate is replaced by the capacity , an be given : rate of the hot fluid. The heat exchanger effectiveness ()

Entropy generation number, , can be gien :

Case B: The capacity rate of the hot fluid, is higher than that of the cold fluid, therefore, the minimum capacity rate , is replaced by the capacity rate of the cold water. The heat exchanger effectiveness obtained from

Experimental
1 Objective of the experiment To demonstrate indirect heating or cooling by transfer of heat from one fluid stream to another when separated by a solid wall (fluid to fluid heat transfer). In this an HT32 unit (Plate Heat Exchanger) are used for this laboratory. The HT32 is test devices created for use in physics and engineering laboratories by Armfield Limited,.

Equipment: HT32 Heat Exchanger -Volume: 0.03m3 - Gross weight: 6 kg - Plate overall dimensions: 75mm x 115mm - Projected heat transmission area: 0.008m2 per plate - Maximum water temperature to 85C Hot fluid outlet Hot fluid inlet Cold fluid inlet Cold fluid outlet effective plaes Thermocouples resolution 0.1C. Conditioning circuits Fig. 3.1: Photo of the plate type heat exchanger used in this SDP

Procedure:
switch on the mains switch . (if the temperature controller does not illuminate check the RCD and circuit breakers at the rear of the support plinth, all switch at the near should be up) Set the temperature controller to a set point approximately 30 above the cold water inlet temperature ( ) (e.g. if then set controller to 45 ) then switch on the hot water circulator. Set the flow indicator switch to then adjust the cold water control valve1 litter / min Set the flow indicator switch to then adjust the cold water control valve 2 litter /min

Allow the temperature to stabilize (monitor the temperature using the switch or temperature meter). When the temperature are stable recorded. Repeat and record the data in the tables. Close the cold water flow control valve then reverse the cold water connections to the shell of the heat exchanger.

Note: the connections to the heat exchanger are now configured for concurrent operation where the hot and cold fluid streams flow in the same direction across the heat transfer surface.

Open the cold water flow control valve and adjust it to give a reading .set the flow indicator switch to then adjust the hot water control valve . Set the temperature controller to a set point approximately above the cold water inlet temperature. Repeat the same procedure for co current operation as that of countercurrent flow . Switch off the equipment and allow the cold water to flow through the heat exchanger to cool it down to room temperature, and then close the cold water supply to the equipment.

List of Formulas used to obtain the results reported in this project.

Parallel flow operation Counter flow operation

Logarithmic Mean Temperature Difference (LMTD)

The equation for LMTD is the same for both counter and parallel flow because the temperature measurement points are fixed on the exchanger.

Arithmetic mean diameter

Heat transmission area

Overall heat transfer coefficient

The heat exchanger effectiveness

the temperature ratio

the capacity rate ratio

The second law analysis is focused on entropy generation

Result and discussion

Illustrates the variation of the effectiveness value with inlet hot water temperature for 0.90 volume flow rate. as you can see , the effectiveness value increase with increase inlet hot temperature.
35% 30% 25% 20% 15% effectiveness 10% 5% 35% 31% 24% 30% 25% 20% 15%effectiveness 10% 2% 50.3 44.9 40.2 34.7 5% 0%

33%

0%
50.0 49.9 44.8 39.9 35.1

inlet hot water

inlet hot water

Counter flow

Parallel flow

Illustrates the variation of the heat transfer rate with inlet hot water temperature for 0.90

volume flow rate.

600.00

800.00 700.00 600.00 500.00 400.00 300.00 200.00 100.00 0.00 50.0 49.9 44.8 39.9 35.1 50.3 44.9 40.2 34.7

500.00
400.00 Heat Power emitted Qe [W] 300.00 200.00 100.00 0.00 Heat Power emitted Qe [W]

inlet hot water temperature

inlet hot water temperature

Illustrates the variation of the heat transfer rate with inlet cold water temperature for 1.20 volume flow rate.
800.00 700.00 600.00 500.00 400.00 300.00 200.00 100.00 0.00 29.8 29.8 29.7 29.6 29.5 29.2 29.0 29.1 29.1 Heat Power emitted Qe [W] 600.00 500.00 400.00 Heat Power emitted Qe [W]

300.00
200.00 100.00 0.00

Counter flow

inlet cold water temperature

inlet cold water temperature

Parallel flow

Illustrates the variation of overall heat transfer coefficient with cold mass flow rate for 1.20 volume flow rate.
2500.000 2000.000 1500.000 Overall Heat Transfer Coefficient 1000.000 U 500.000 0.000 0.020 0.020 0.020 0.020 0.020 0.020 0.021 0.020 0.020 1400.000 1350.000 1300.000 Overall Heat Transfer Coefficient 1250.000 U 1200.000 1150.000

cold mass flow rate

2500.000

cold mass flow rate

1400.000

2000.000
1350.000 1500.000 Overall Heat Transfer Coefficient U 1300.000 1250.000 1200.000 1150.000 0.000 0.015 0.015 0.015 0.015 0.015 0.009 0.010 0.010 Overall Heat Transfer Coefficient U

1000.000

500.000 0.009

hot mass flow rate

hot mass flow rate

Illustrates the variation of effectiveness with LIMTD for 1.20

volume flow rate.

35% 30% 25% 20% 15% 10% 5% 0% 11.5 11.4 8.6 5.8 effectiveness

35% 30% 25% 20% 15% 10% 5% 0% 10.3 8.0 5.7 effectiveness

LIMTD

3.1

LIMTD

3.1

Illustrates the variation of effectiveness with temp efficiency for hot fluid
35% 30% 25% 20% 15% 10% 5% 0% 53.8 54.1 57.1 64.9 60.9 60.5 63.5 71.1 effectiveness 20% 15% 10% 5% 0% effectiveness 35% 30% 25%

temp efficiency for hot flow

temp efficiency for hot

Illustrates the variation of effectiveness with temp efficiency for cold fluid
35% 30% 25% 20% 15% effectiveness 35% 30% 25% 20% 15% 10% 5% 0% 31.9 31.8 effectiveness

10%
5% 0% 31.9 31.8 30.3 26.3 16.4

temp efficiency for cold flow

30.3

26.3

16.4

temp efficiency for cold flow

Illustrates the variation of

with hot mass flow rate

0.05 0.045 0.04 0.035 0.03 0.025 0.02 0.015 0.01 0.005 0 0.015 0.015 s

0.06 0.05 0.04 0.03 0.02 0.01 0 0.009 0.010

hot mass flow rate

0.015

0.015

0.015

hot mass flow rate

0.010

0.009

Illustrates the variation of

0.05 0.045 0.04 0.035 0.03 0.025 0.02 0.015 0.01 0.005 0 s

with cold mass flow rate

s
0.048 0.0475 0.047 0.0465 0.046 0.0455 0.045 0.0445 0.044 0.0435 0.043 0.0425

0.020

0.020

cold mass flow rate

0.020

0.020

0.020

cold mass flow rate

Illustrates the variation of

0.05 0.045

with hot temperature inlet

0.048 0.0475 0.047 0.0465 0.046 0.0455

0.04
0.035 0.03 0.025 0.02 0.015 0.01 s

0.045 0.0445 0.044 0.0435 0.043 0.0425 50.03735352 49.875 44.84204102 39.87402344 35.10083008

0.005
0 50.0 49.9 44.8 39.9 35.1

hot mass flow rate

Conclusion
Plate heat exchanger has an advantages as : Movable pressure plates Versatility Lower liquid volume Expandable Durability Reliablity