Department of Mechanical Engineering, IUPUI ME 414 Thermal-Fluid Systems Design Fall 2004 Project 2: Heat Exchanger Design

Transcription

1 Department of Mechanical Engineering, IUPUI ME 44 Thermal-Fluid Systems Design Fall 24 Project 2: Heat Exchanger Design Team : Michael Armbrester Andrea Geyer Joel Gray Mark Svendsen Justin Zenn

2 Problem Introduction Shell and tube heat exchanger to remove.2mw from process water through use of city water Process Water Inlet Temperature 25 C Exit Temperature C City Water Inlet Temperature 25 C

3 Deliverables Thermal energy removed Pressure drops Shell Side Tube Side Cost Measured by heat exchanger weight and material costs Heat exchanger volume Measured by.5*tube Length*Shell Cross-Sectional Area

4 Deliverables Thermal energy removed:.22mw Pressure drops: Shell Side = 9.5 kpa Tube Side = 5.9 kpa Cost: Total Cost = $753.9 Total Weight = 8.84 kg Heat exchanger volume: 6.93 L

5 Problem Definitions m dot dot for turbulent flow: Shell Side: 2 kg/sec Tube Side:.34 kg/sec Fluid allocation: Process Water on Tube Side (Hot) City Water on Shell Side (Cold) Fouling factors: Tube Side =.4 m2 K/Wm Shell Side =.3 m2 K/Wm

6 Initial Aspects of the Design Made Initial Guesses in Matlab Changed code until.2mw was achieved

7 DOE Factors 7 Factors Tube Length Tube Outer Diameter Shell Inner Diameter Shell Mass Flow Rate Tube Material Shell Material Tube Pitch 2 Level Full Factorial Design Helps Determine Weighting of the Factors

8 Main Effects Plots Main Effects Plot (data means) for Weight T_Len T_OD SH_ID 5 Mean of Weight 5 M.SH T_MA T SH_M AT T_Pch Main Effects Plot (data means) for Shell Press 5 5 T_Len T_OD SH_ID 5 Mean of Shell Press 5 5 M.SH T_M AT SH_MA T 5 T_Pch 5

9 Main Effects Plots Main Effects Plot (data means) for Tube Press 2 T_Len T_O D SH_ID Mean of Tube Press 2 M.SH T_MAT SH_MA T 2 T_Pch Main Effects Plot (data means) for Q-Calc T_Len T_OD SH_ID Mean of Q-Calc M.SH T_MA T SH_MA T T_Pch 8 2 6

10 Main Effects Plots Main Effects Plot (data means) for Cost 5 T_Len T_O D SH_ID 3 Mean of Cost 5 3 M.SH T_MA T SH_MA T 5 T_Pch 3

11 Interaction Plots Interaction Plot (data means) for Shell Press T_Len T_OD SH_ID T_Len T_OD SH_ID T_Len T_OD Interaction Plot (data means) for Weight T_Len T_OD M.SH T_MAT SH_MAT M.SH T_MAT SH_MAT SH_ID 6 8 SH_ID T_Pch M.SH 6 8 M.SH T_MAT 6 8 T_MAT SH_MAT 6 8 SH_MAT T_Pch

12 Interaction Plots Interaction Plot (data means) for Tube Press T_Len T_OD SH_ID T_Len T_OD SH_ID T_Len T_OD Interaction Plot (data means) for Q-Calc T_Len T_OD M.SH T_MAT SH_MAT M.SH T_MAT SH_MAT SH_ID 3 5 SH_ID T_Pch M.SH 3 5 M.SH T_MAT 3 5 T_MAT SH_MAT 3 5 SH_MAT T_Pch

13 Interaction Plots Interaction Plot (data means) for Cost T_Len T_OD T_Len T_OD SH_ID 8 4 SH_ID M.SH 8 4 M.SH T_MAT 8 4 T_MAT SH_MAT 8 4 SH_MAT T_Pch

14 Response Optimizer

15 Steps Toward Final Design Take the results of the response optimizer and use the parameters in MATLAB Adjust key parameters to further refine the design Tube Length Shell Inner Diameter

16 Final Results Heat Exchanger Inlet & Outlet Temperatures (Celsius) Inlet Outlet Delta Bulk Tube Shell Tube Side Heat Transfer Parameters Number of Tubes = 237. Number of Passes = 2. Tubes OD =.95 m Tubes ID =.84 m Tube Length =.454 m Tube Flow Area =.66 m 2 Tube Pitch =.9 m

17 Final Results Shell Side Heat Transfer Parameters Shell ID =.232 m Shell Cross Sec Area =.324 m 2 Shell Flow Area =.6 m 2 Baffle Space =.5 m Number of Baffles = 2. m

18 Deliverables Thermal energy removed:.22mw Pressure drops: Shell Side = 9.5 kpa Tube Side = 5.9 kpa Cost: Total Cost = $753.9 Total Weight = 8.84 kg Heat exchanger volume: 6.93 L

19 Project Management - RACI

20 Project Management WBS Shell and Tube Heat Exchanger Design System Modeling Optimize Design Project Reports Develop analysis tools Review MATLAB code Revise and develop code Learn basics of MINITAB Analyze critical tube parameters Vary flow rate Vary tube passes Vary tube sizes Vary tube pitch Vary tube layout Vary number of tubes Vary flow arrangement Vary materials Analyze critical shell parameters Vary flow rate Vary shell cross-section Vary baffle configuration Vary materials Determine optimal design Construct Main Effects plots Construct Interaction plots Finalize optimal design Select proper material Calculate pressure drops Determine material cost Determine total volume Prepare Status Report 2. Write Statement of Work Create RACI Chart Create Gantt Chart Create Work Breakdown Structure Prepare Status Report 2.2 Revise Statement of Work Revise RACI Chart Revise Gantt Chart Revise Work Breakdown Structure Compile preliminary results Outline subsequent steps Prepare Final Report Revise Statement of Work Revise RACI Chart Revise Gantt Chart Revise Work Breakdown Structure Compile final results Prepare Final Presentation Create PowerPoint slides Practice group presentation

21 Project Management - SOW Project Title: Heat Exchanger Design Project Purpose: To design a process water vs. city water shell and tube heat exchanger that will remove.2 MW from the process water for an undisclosed process. collaboration Customers and Approvals: The customer for this project is the engineering corporation which operates the undisclosed process. Deliverables: Status Report 2., which consists of Statement of Work Work Breakdown Structure Gantt Chart RACI Chart Status Report 2.2, which consists of Statement of Work Work Breakdown Structure Gantt Chart RACI Chart Preliminary Results Outline of Subsequent Steps

22 Project Management SOW cont. Final Report, consisting of Statement of Work Work Breakdown Structure Gantt Chart RACI Chart System Results: Minimized pressure drops on shell and tube sides of exchanger Minimized material cost as measured by the weight of the exchanger Minimized heat exchanger volume Demonstration of fulfillment of required heat transfer rate Final group presentation Customer Support: To complete this project we will need access to the following information or items: Cost of all potential construction materials and their properties Purity of process water and city water supplies Access to MINITAB and MATLAB, as well as all relevant subroutines Allowable range of mass flow rates for process water and city water

23 Questions?