Design of waste heat recovery system for a Hieza boiler in a Soap Industry

12
Department of Mechanical Engineering , SIT, Mangalore
Mass flow rate of Furnace oil is found out by using the calibrated burette and is
found to be 5.5 GPH which is 0.0281286 kg/s.
6.3 .To calculate the stoichoimetric air required for the fuel
We know that 282.336 gms of C
20
H
42
consumes 976gms of O2. So
0.0281286kG of C
20
H
42
consumes 0.4065513 kG of air. Similarly for Sulphur,
32.065 gms of Sulphur combines with 32 Gms of O2 stoichiometrically.
Therefore the rest 3% of the fuel which contains sulphur, i.e 0.03* 0.028128kG
of fuel combines with 0.0036297 kg of air. Therefore the total amount of air
required for burning 0.0281286 is 0.4065513+0.0036299 = 0.410181 kg of air.
We know that Mass flow rate of exhaust gases (M
e
) is the sum of mass flow
rate of air(M
a
) and mass flow rate of fuel(M
f
)

.
M
e
= M
a
+M
f
M
e
= 0.41081+0.0281286
M
e
= 0.4383096 kg/sec.
Now Total heat supplied in the heater is the sum of heat taken by the thermic
fluid and heat taken by the exhaust gases.
Therefore total heat supplied is M
f
* CV. Where Cv is the calorific value of the
furnace oil which is 41.85MJ/kg. Heat taken away by the fluid is sensible heat
taken by the fluid and is given by M
t
*Cp* (283-241)kJ. Calculating for the mass
flow rate of thermic fluid,
M
f
* CV kJ = M
t
*Cp* (283-241)kJ + Me Cp *(616-308)kJ
(0.0281286*41.85*10
3
) = Mt *2.84012 * (42) + 156.59
Mt =8.55kg/s.





Design of waste heat recovery system for a Hieza boiler in a Soap Industry
12
Department of Mechanical Engineering , SIT, Mangalore
6.4. Calculation of LMTD
For all the heat recovery system from flue gases cross flow arrangement is used.

Now heat lost by exhaust gases is equal to the heat gained by the thermic fluid.
Me* Cpe* (616-453) = Mt Cpt *( T-309)
0.43830906*1.16*(616-453) = 8.55*1.954* (T-309)
T= 313.960 K
LMTD is given by ( Thi- Tco) (Tho Tci) / In [ (Thi-Tco)/(Tho-Tci)]
LMTD = (616-313.9605)- (453-309) / ln [(616-313.9605)/(453-309)]
LMTD= 213.365 K
6.4.1. Assumptions
a. Steady flow
b. single phase flow as there is no change in the state of either of the fluids.
c. Constant thermophysical properties.
d. Constant heat transfer co efficients
e. Negligable longitudinal wall conduction as the magnitude is less and length
of the tube is more.


Design of waste heat recovery system for a Hieza boiler in a Soap Industry
12
Department of Mechanical Engineering , SIT, Mangalore
CHAPTER 7
Design Methodology
[4
]


Fig 7.1 Design methodology flow chart
7.1 Selection of appropriate heat exchanger type
Generally the goal should be the cheapest overall solution that achieves
the required thermal performance within described limits (i.e. maximum
allowable pressure drop, size, weight, dimensions, etc.). To ensure reliable
operation and not only low investment, but low overall operating costs, also
issues such as fouling propensity and cleanability, and corrosion resistance must
be considered. In practice, various plate-type heat exchangers tend to provide
lowest total costs (if not necessarily always lowest purchasing cost per heat
Design of waste heat recovery system for a Hieza boiler in a Soap Industry
12
Department of Mechanical Engineering , SIT, Mangalore
transfer area) where conditions permit their use, while tubular exchanger types
offer the most versatile applicability for more challenging operating conditions.
7.2 Fluid pressures and temperatures
If the fluids are liquids at less than approximately 150 200 C
temperature and 1 Mpa pressure, the gasketed PHE is usually the most
economical choice. Since the main limitation here is not the heat transfer
surface itself, but the gasket material, somewhat higher temperature ranges can
be achieved by welded or brazed construction, although this obviously comes at
the expense of easy disassembly. (Shah 2003, pp.26 and 674- 675) For gas-gas
heat exchangers a plate-type heat exchanger is also usually the best choice, but
instead of a gasketed PHE, a compact heat exchanger of either brazed plate-fin
or laser-welded primary-surface construction is often preferable. If one of the
fluids is at too high pressure for plate-type heat exchangers, a finned-tube
construction, with high-pressure fluid on the tube side, can be used. A tube-fin
construction is also inherently stronger and allows slightly higher temperatures
to be achieved with the same materials, although at the cost of larger size,
weight and cost for a given performance. Tubular heat exchangers can be built
to tolerate very high temperatures and pressures, as well as corrosive or
hazardous fluids, provided that suitable materials are chosen. The high-pressure
and/or high-temperature fluid should be placed into the tubes: this allows only
the tubes to be constructed from expensive materials, and minimizes insulation
expenses and heat losses through the shell. For very high temperatures,
regenerative instead of recuperative heat exchangers must be used - static
ceramic matrices can tolerate gas temperatures of up to 2000 K.
7.3 Fouling
If fouling is expected to be significant on one or both fluids, both
minimizing the foulant accumulation and ease of cleaning should be considered.
If temperature, pressure and corrosion considerations permit, the gasketed plate
heat exchanger is usually ideal from both points of view. Foulant accumulation
in a plate heat exchanger tends to be much less than in a tubular exchanger for
given fluids, and disassembly of the plate stack for periodic cleaning is simple
and fast. A spiral heat exchanger is also a potential candidate for applications
where fouling effects are significant. If the foulant is such that it can be
removed from the heat transfer surface by the increased shear stress of an
accelerated fluid flow, the spiral heat exchanger tends to be self-cleaning:
significant growth of foulant layer thickness in any location of the spiral
Design of waste heat recovery system for a Hieza boiler in a Soap Industry
12
Department of Mechanical Engineering , SIT, Mangalore
channel will contract the channel, thereby locally increasing fluid velocity and
shear stress. Particularly fouling by crystallization may create too strong foulant
layers to be removable in this manner, however. If a plate heat exchanger is not
possible, a shell-and-tube heat exchanger allows also reasonably easy cleaning.
Ideally the fluid undergoing heaviest fouling should be placed on the tube side
to permit easy access for mechanical cleaning and the length of the tubes should
be short enough to allow easy extraction from the shell given the physical
restriction at the installation site. For ease of cleaning, straight tubes should be
used instead of U-tubes. If fouling is a concern also on the shell side, the tube
layout should be either 45 or 90 square pitch with at least 6 to 7 mm clearance
between tubes, in order to allow cleaning lanes for mechanical cleaning.
(Taborek 1983c) (Mller-Steinhagen 1997) and (Hammo 1994) provide
additional information on the topics of fouling and cleaning of shell-and-tube
heat exchangers.

7.4 Material choices
The material chosen for the heat exchanger must be suitable for the type
of physical construction, be compatible with the fluid temperature ranges
expected, and not be corroded by the fluids. Cost is a significant concern as
well, while thermal conductivity is rarely a significant issue. In plate-type heat
exchangers the heat transfer surfaces are currently still metallic, although
ceramic materials are being developed to achieve higher temperature ranges.
Aluminum is a common material in compact heat exchangers, but cannot be
used or in high-temperatures applications (maximum temperature is
approximately 200 C). Also use with food fluids or highly corrosive fluids
necessitates the use of other materials, often stainless steel. Aluminum is,
however, useful down to very low (cryogenic) temperatures. (Shah 2003,
pp.678) Temperatures of up to approximately 650 C are achievable with
welded stainless steel plate heat exchanger constructions, most commonly Type
347 stainless steel (Aquaro and Pieve 2007). High-temperature superalloys such
as Inconel can further increase the achievable temperature range up to 750
800 C (McDonald 2003), but only at a considerably increased cost. Material
and construction issues related to high temperature gas heat exchangers are
covered in more detail in for example (Aquaro and Pieve, 2007), as well as
numerous publications by Colin McDonald and Ulf Sundstrm. Particularly in
highly corrosive use, titanium is also a common plate heat exchanger material.
Design of waste heat recovery system for a Hieza boiler in a Soap Industry
12
Department of Mechanical Engineering , SIT, Mangalore
Tubular heat exchangers can be constructed from a variety of materials, most
commonly carbon steel unless corrosion or temperature considerations require
other materials. Ordinary carbon steel can be used within a temperature range of
0 to 500 C with non-corrosive or mildly corrosive fluids. Impact-tested carbon
steel is still useful down to -45 C, below which special steels or aluminum
must be used. Refractory lining permits temperatures higher than 500 C. (Shah
2003, pp.679) If one of the fluids is highly corrosive, that fluid should be placed
on the tube side to allow cheaper shell material to be used, and only tubes be
constructed of the corrosion resistant material. Depending on the fluid, that
material could be aluminum (only mildly corrosive fluids), a suitable steel type,
titanium, or a copper alloy. Also glass or carbon can be used for corrosive
duties, or more conventional materials can be protected by suitable linings, for
example austenitic Cr-Ni steel for general corrosion resistance, refractory
materials for high-temperature applications, or lead and rubber for seawater.
(Shah 2003, pp. 679)
7.5 Cost
Other considerations permitting, the goal is of course always to minimize
the overall total cost of the heat exchanger. This total overall cost is the sum of
manufacturing, installation and operating costs. The manufacturing cost is often
roughly one third of total installed cost, although the ratio obviously depends
much on the type, construction material and size of heat exchanger. The
operating costs consist of pumping cost to overcome the pressure drop
associated with the heat exchanger, maintenance, cleaning and repair costs, and
often also the energy costs related to the usage of the heat exchanger. Most heat
exchanger manufacturers have their own proprietary methods for cost
estimation and analysis; publically available information can be described as
sketchy at best. Table 3.3, based on original cost data from 1994 in Great
Britain, gives a comparison of heat transfer area cost per square meter,
normalized against a 10m2 shell-and-tube heat exchanger (relative cost 1.0).
The costs of gasket or welded plate heat exchangers are not available for
comparison, but as a general rule, plate-type heat exchangers are the cheapest
option when other considerations such as pressures and temperatures of the
fluids permit. For a rough guideline of actual costs, at the time of writing (2009)
the total installed costs of large shell-and-tube heat exchangers were measured
in hundreds of Euros per m2, obviously depending on the exact construction
and materials used.
Design of waste heat recovery system for a Hieza boiler in a Soap Industry
12
Department of Mechanical Engineering , SIT, Mangalore
With all the above information and assumptions we use bare tube heat
exchanger and assume it be cross flow heat exchanger. Material of the tube is
assumed to be carbon steel which sustains temperature upti 500
O
C.
As given in the Design of Heat transfer Equipments for Thermal Power plants
for Heat exchanger and condenser tube data we consider 1 inch, 1
1/4
inch, 11
/2
inch OD carbon steel tubes of 14 BWG, 16BWG, 18BWG thicknesses.
A table is drawn and the respective calculations for designing the heat
exchanger such as velocity of flow in the tubes, Reynolds number, inside heat
transfer co efficient , overall heat transfer co efficient, surface area required ,
dimensions , friction factors, pressure drop ,and outside heat transfer co
efficient.
The final decision on the on the heat exchanger design in done by the that tube
which gives us less variation in the overall heat transfer co efficient and lesser
pressure drop.

















Design of waste heat recovery system for a Hieza boiler in a Soap Industry
12
Department of Mechanical Engineering , SIT, Mangalore
CHAPTER 8
CALCULATIONS
8.1 Calculation of velocities through each tube.
Mass flow rate of thermic fluid= 8.55kg/s
We know = m/ Q
Where Q is the volumetric flow rate
is the desity of thermic fluid and equal to 900 kg/m
3
Q= 8.55/900
Q=0.095m
3
/sec


For1 inch OD 14BWG tube
Flow area=0.546 in
2

1 inch
2
=0.00064 m
2

Flow area= 0.546 *0.00064 = 0.0003494m
2

Therefore velocity of thermic fluid through 1 inch OD 14BWG tube is
V= Q/A =0.0095/0.0003494= 27.189 m/sec.


For 1 inch OD 16BWG tube
Flow Area =0.594 in
2
1 inch
2
=0.00064 m
2
Flow area =0.594*0.00064=0.0003802m
2

Therefore velocity of thermic fluid through 1 inch OD 16BWG tube is
V=Q/A= 0.0095/0.0003802= 24.986m/sec.

For 1 inch OD 18BWG tube
Flow Area =0.639in
2
Design of waste heat recovery system for a Hieza boiler in a Soap Industry
12
Department of Mechanical Engineering , SIT, Mangalore
1 inch
2
=0.00064 m
2
Flow area =0.639*0.00064=0.000409 m
2
.
Therefore velocity of thermic fluid through 1inch OD 18 BWG tube is
V=Q/A=0.0095/0.000409 =23.227 m/sec.

For 1
1/4
inch 14 BWG tube
Flow area= 0.923in
2

Flow area =0.923*0.00064=0.0005907m
2

Therefore velocity of thermic fluid through 1
1/4
inch 14 BWG tube is
V= Q/A=0.0095/0.0005907 =16.08m/sec.

For 1
1/4
inch 16 BWG tube
Flow area=0.985in
2

Flow area=0.985*0.00064=0.0006304m
2

Therefore velocity of thermic fluid through 1
1/4
inch 16 BWG tube is
V=Q/A=0.0095/0.0006304=15.06m/sec.

For 1
1/4
inch 18 BWG tube
Flow area=1.04in
2

Flow area=1.04*0.00064=0.0006656m
2

Therefore velocity of thermic fluid through 1
1/4
inch 18 BWG tube is
V=Q/A=0.0095/0.0006656=14.272m/sec.

For 1 inch OD 14 BWG tube
Flow area=1.40in
2

Flow area=1.40*0.00064=0.000896m
2

Therefore velocity of thermic fluid through 1
1/2
inch 14 BWG tube is
V=Q/A=0.0095/0.000896=10.602m/sec.
Design of waste heat recovery system for a Hieza boiler in a Soap Industry
12
Department of Mechanical Engineering , SIT, Mangalore

For 1 inch OD 16 BWG tube
Flow area=1.47in
2

Flow area=1.47*0.00064=0.000948m
2

Therefore velocity of thermic fluid through 1
1/2
inch 16 BWG tube is
V=Q/A=0.0095/0.000948=10.021m/sec.

For 1 inch OD 18 BWG tube
Flow area=1.54in
2

Flow area=1.54*0.00064=0.0009856m
2

Therefore velocity of thermic fluid through 1
1/2
inch 18 BWG tube is
V=Q/A=0.0095/0.0009856=9.638m/sec.

8.2 Calculation of Reynolds number for flow through each tube
We have Kinematic viscosity at 200
0
C = 1.1mm
2
/sec=1.1*10
-6
m
2
/sec.
We know that Reynolds Number = VD/ .


For 1 inch OD 14 BWG tube
VD/ = 27.189*1*0.0254/1.1*10
-6
= 627818.7
For 1 inch OD 16 BWG tube
VD/ = 24.986*0.0254/ 1.1*10
-6
=576949.5
For 1 inch OD 18 BWG tube
VD/ = 23.227*0.0254/1.1*10
-6
=536332.5

For 1
1/4
inch OD 14 BWG tube
VD/ = 16.08*1.25*0.0254/1.1*10
-6
= 464127.3
For 1
1/4
inch OD 16 BWG tube
Design of waste heat recovery system for a Hieza boiler in a Soap Industry
12
Department of Mechanical Engineering , SIT, Mangalore
VD/ = 15.06*1.25*0.0254/1.1*10
-6
= 434686.4
For 1
1/4
inch OD 18 BWG tube
VD/ = 14.272*1.25*0.0254/1.1*10
-6
=411941.8

For 1

inch OD 14 BWG tube

VD/ = 10.602*1.5*0.0254/1.1*10
-6
=367214.7
For 1

inch OD 16 BWG tube

VD/ = 10.021*1.5*0.0254/1.1*10
-6
=347091
For 1

inch OD 18 BWG tube

VD/ = 9.638*1.5*0.0254/1.1*10
-6
=333825.3

8.3 Calculation of convective heat transfer co efficient inside the tube for all
the velocities.
For a smooth surface and fully developed flow conditions
For 1inch OD 14 BWG
Nu
d
= 0.023 Re
4/5
Pr
0.4
.
K= 0.111W/mK
[1]

Pr = 9
[1]

Nu
d
= hD/K.
Nu
d
= 0.023 Re
4/5
Pr
0.4
Nu
d
=0.023 (627818.7)
0.8
* (9)
0.4
=2408.199
Therefore h = 2408.199*0.111/0.0211 =12668.71W/m
2
K
For 1inch OD 16 BWG
Nu
d
=0.023 (576949.5)
0.8
* (9)
0.4
=2250.790
Therefore h = 2250.790*0.111/0.022098=11305.898 W/m
2
K
For 1inch OD 18 BWG
Nu
d
=0.023 (536332.5)
0.8
* (9)
0.4
=2123.0864
Therefore h = 2123.0864*0.111/0.02291=10286W/m
2
K.

Design of waste heat recovery system for a Hieza boiler in a Soap Industry
12
Department of Mechanical Engineering , SIT, Mangalore
For 1
1/4
inch OD 14 BWG
Nu
d
=0.023 (464127.3)
0.8
* (9)
0.4
=1891.167
Therefore h=1891.167*0.111/0.027432=7652.3634W/m
2
K.
For 1
1/4
inch OD 16 BWG
Nu
d
=0.023 (434686.4)
0.8
* (9)
0.4
=1794.573
Therefore h=1794.573*0.111/0.028448=7002.16W/m
2
K.
For 1
1/4
inch OD 18 BWG
Nu
d
=0.023 (411941.8)
0.8
* (9)
0.4
=1719.05
Therefore h=1719.05*0.111/0.02921=6532.516W/m
2
K.

For 1
1/2
inch OD 14 BWG
Nu
d
=0.023 (367214.7)
0.8
* (9)
0.4
=1568.037
Therefore h=1568.037*0.111/0.03378=5152.52W/m
2
K.
For 1
1/2
inch OD 16 BWG
Nu
d
=0.023 (347091)
0.8
* (9)
0.4
=1498.908319
Therefore h=1498.908319*0.111/0.033782=4934.128W/m
2
K.
For 1
1/2
inch OD 18 BWG
Nu
d
=0.023 (333825.3)
0.8
* (9)
0.4
=1452.900
Therefore h=1452.900*0.111/0.03556=4535.205W/m
2
K.
Reynold,s number for the flow of exhaust gases.
Kinematic Viscosity of flue gases is given by = (0.1335+0.925*10
-3
*t)10
-4

[2]
m
2
/sec, Where t is the temperature of exhaust gases
Therefore = (0.1335+0.925*10
-3
*343)10
-4
= 0.0000450775 m
2
/sec.
Velocity of flue gases is taken as from the range of 6m/s to 25 m/s
[2]
.
For all the tubes the condition is that the flow of exhaust gases in oner the
cylinder and perpendicular to the axis of the tubes.
For 1 inch OD tubes
Re = VD/ = 10*0.0254/0.0000450775
Re=5634.7401.
Design of waste heat recovery system for a Hieza boiler in a Soap Industry
12
Department of Mechanical Engineering , SIT, Mangalore

For 1
1/4
inch OD tubes
Re = VD/ = 10*1.25*0.0254/0.0000450775
Re=7043.425.

For 1

inch OD tubes
Re = VD/ = 10*1.5*0.0254/0.0000450775
Re=8452.1102.
8.4 Calculation of heat transfer co efficient outside the tubes.
We use the relation for Nusselt number from Heat and Mass transfer Data Hand
Book
[3]
,for flow across cylinders, N
u
= C (Re)
m
*(P
r
)
0.333
.
The corresponding values of C and m for corresponding Reynolds number are
given in Heat and mass transfer Data Hand Book
[3]
.
For 1 inch OD tube
N
u
=0.193 * (5634.7401)
0.618
*(0.74)
0.333
=36.31196
K= 0.02442+(0.6992*10
-4
t)W/mK
[2]

=0.02442+(0.6992*10
-4
*343)
=0.0484025W/mK

h
o
=36.31196*0.0484025/0.0254=69.1965W/m
2
K

For 1
1/4
inch OD tube
N
u
=0.193 * (7043)
0.618
*(0.74)
0.333
=41.6754
h
o
=41.6754*0.0484025/0.03175=63.5336 W/m
2
K

For 1
1/2
inch OD tube
N
u
=0.193 * (8542)
0.618
*(0.74)
0.333

h
o
= 47.0010*0.0484025/1.5*0.0254=59.70861 W/m
2
K

Design of waste heat recovery system for a Hieza boiler in a Soap Industry
12
Department of Mechanical Engineering , SIT, Mangalore
8.5 Calculation of Overall heat transfer coefficient for all the tubes.
For 1 inch OD 14 BWG tube
We have 1/U= 1/h
i
+1/h
o
U=12668.71*69.1965/(12668.71+68.1965)=68.820604 W/m
2
K
For 1 inch 16BWG tube
U=11305.898*69.1965/(11305.898+69.1965)=68.77557 W/m
2
K
For 1inch OD 18 BWG tube
U=10286*69.1965/(10286+69.1965)=68.734112 W/m
2
K

For 1
1/4
inch OD 14BWG tube
U=7652.3634*63.5336/(7652.3634+63.5336)=63.01145 W/m
2
K
For 1
1/4
inch OD 16BWG tube
U=7002.16*63.5336/(7002.16*63.5336)=62.9633 W/m
2
K
For 1
1/4
inch OD 18BWG tube
U=6532.516*63.5336/(6532.516+63.5336)=62.9216 W/m
2
K

For 1
1/2
inch OD 14BWG tube
U=5152.52*59.7689/(5152.52+59.7689)=59.0835 W/m
2
K
For 1
1/2
inch OD 16BWG tube
U=5934.128*59.7689/(5934.128+59.7689)=59.173 W/m
2
K
For 1
1/2
inch OD 18BWG tube
U=4535.206*59.7689/(4535.206+59.7689)=58.9927 W/m
2
K

Calculation of Surface Area (A) required for each tube.
We know that Q= UA LMTD
For 1inch OD 14 BWG tube
156.89*10
3
=68.8216*(A)*213.365
A=10.6639m
2

Design of waste heat recovery system for a Hieza boiler in a Soap Industry
12
Department of Mechanical Engineering , SIT, Mangalore
For 1inch OD 16 BWG tube
156.89*10
3
=68.7755*(A)*213.365
A=10.670 m
2

For 1inch OD 18 BWG tube
156.89*10
3
=68.734112*(A)*213.365
A=10.677 m
2

For 1
1/4
inch OD 14 BWG tube
156.89*10
3
=63.01145*(A)*213.365
A=11.647 m
2
For 1
1/4
inch OD 16 BWG tube
156.89*10
3
=62.9633*(A)*213.365
A=11.656102 m
2

For 1
1/4
inch OD 18 BWG tube
156.89*10
3
=62.9226*(A)*213.365
A=11.663642 m
2


For 1
1/2
inch OD 14 BWG tube
156.89*10
3
=59.0845*(A)*213.365
A=12.421 m
2
For 1
1/2
inch OD 16 BWG tube
156.89*10
3
=59.0845*(A)*213.365
A=12.4025 m
2
For 1
1/2
inch OD 18 BWG tube
156.89*10
3
=58.9927*(A)*213.365
A=12.440 m
2


Design of waste heat recovery system for a Hieza boiler in a Soap Industry
12
Department of Mechanical Engineering , SIT, Mangalore
8.6 Calculation of Tube length for all the tubes.
For 1inch OD tubes 1m length of a tube has 0.07979m
2
of surface area.
Therefore inch OD 14BWG tube has 10.639/0.07979=133.6495m.
For 1 inch 16 BWG tube=10.670/0.07979=133.72603m
For 1 inch 18 BWG tube=10.677/0.07979=133.81376m
For all the above lengths the standard length is 144m
[2].


For 1
1/4
inch OD tubes 1m length of a tube has 0.0997008m
2
of surface area.
Therefore inch OD 14BWG tube has 11.647/0.0997008m
2
=116.8264m
For1
1/4
inch 16 BWG tube=11.656102/0.0997008m
2
=133.72603m
For 1
1/4
inch 18 BWG tube=11.663642/0.0997008m
2
=133.81376m
For all the above lengths the standard length is 120m
[2].


For 1
1/2
inch OD tubes 1m length of a tube has 0.119634m
2
of surface area.
Therefore inch OD 14BWG tube has 12.421/0.119634m
2
=116.8264m
For1
1/2
inch 16 BWG tube=12.4025/0.119634m
2
=133.72603m
For 1
1/2
inch 18 BWG tube=12.440/0.119634m
2
=133.81376m
For all the above lengths the standard length is 120m
[2].

8.7 Calculation of new surface area (A*) based on standard tube lengths.
For 1 inch =144*0.07979=11.489m
2
For 1
1/4
inch =120*0.0997008=11.964m
2
For 1
1/2
inch =120*0.119634=11.964m
2

8.8 Calculation of new Overall heat transfer coefficient(U*) for all the
tubes.
We know that Q= UA LMTD
Based on the new heat transfer surface area (A*), new values of overall heat
transfer coefficient (U*) can be found out.
Design of waste heat recovery system for a Hieza boiler in a Soap Industry
12
Department of Mechanical Engineering , SIT, Mangalore
For 1 inch OD tubes(14 ,16,18 BWG)
Q=U* A* LMTD
156.89*103= U* 11.489*213.365
U* =63.879W/m
2
K

For 1
1/4
inch OD tubes(14 ,16,18 BWG)
Q=U* A* LMTD
156.89*103= U* 11.964*213.365
U* =61.46W/m
2
K

For 1
1/2
inch OD tubes (14 ,16,18 BWG)
Q=U* A* LMTD
156.89*103= U* 14.35*213.365
U* =51.24W/m
2
K.

8.9 Calculation of percentage change in overall heat transfer co efficient for
all the tubes.
For 1 inch 14 BWG tube
(68.8216-63.879/68.8216)*100=7.18%

For 1 inch 16 BWG tube
(68.7755-63.879/68.7755)*100=7.12%
For 1 inch 18 BWG tube
(68.734112-63.879/68.734112)*100=7.06%

For 1
1/4
inch 14 BWG tube
(63.01145-61.46/63.01145)*100=2.4%
For 1
1/4
inch 16 BWG tube
(62.9633-61.46/62.9633)*100=2.38%
Design of waste heat recovery system for a Hieza boiler in a Soap Industry
12
Department of Mechanical Engineering , SIT, Mangalore
For 1
1/4
inch 18 BWG tube
(62.9266-61.46/62.9266)*100=2.32%

8.10 Calculation Friction factor for all the tubes.
The Darchy Friction factor for all the tubes are calculated assuming that all the
tubes are smooth and the formula used to calculate the friction factor is given by
Swamee-Jain
[5]
formulae

For a smooth tube the relative roughness is taken as zero and thus e/D=0
The f values for all the tubes are calculated for corresponding Reynolds number
and are:
For 1inch OD 14 BWG tube=0.0023741.
For 1inch OD 16 BWG tube=0.00240.
For 1inch OD 18 BWG tube=0.0.002438.
For 1
1/4
inch OD 14 BWG tube=0.00250.
For 1
1/4
inch OD 16 BWG tube=0.002531.
For 1
1/4
inch OD 18 BWG tube=0.002556.

For 1
1/2
inch OD 14 BWG tube=0.002611.
For 1
1/2
inch OD 16 BWG tube=0.002638.
For 1
1/2
inch OD 18 BWG tube=0.00265.

8.11 Calculation of Pressure drop for flow through all the tubes.
We have P= f L V
2
/( 2D) N/m
2

For 1 inch OD 14 BWG tube
P=0.002371*144*27.189
2
*900/(2*0.834*0.02540)=5.361MPa.
For 1 inch OD 16 BWG tube
Design of waste heat recovery system for a Hieza boiler in a Soap Industry
12
Department of Mechanical Engineering , SIT, Mangalore
P=0.002371*144*24.986
2
*900/(2*0.870*0.02540)=4.403MPa.
For 1 inch OD 16 BWG tube
P=0.002371*144*23.227
2
*900/(2*0.902*0.02540)=3.85MPa

For 1
1/4
inch OD 14 BWG tube
P=0.00250*120*16.08
2
*900/(2*1.08*0.02540)=1.271MPa
For 1
1/4
inch OD 16 BWG tube
P=0.002531*120*15.06
2
*900/(2*1.12*0.02540)=1.089MPa
For 1
1/4
inch OD 18 BWG tube
P=0.002556*120*14.272
2
*900/(2*1.15*0.02540)=0.9624MPa

For 1
1/2
inch OD 14 BWG tube
P=0.002611*120*10.602
2
*900/(2*1.33*0.02540)=0.46912MPa
For 1
1/2
inch OD 16 BWG tube
P=0.002638*120*10.021
2
*900/(2*1.37*0.02540)=0.41108MPa
For 1
1/2
inch OD 18 BWG tube
P=0.002651*120*9.638
2
*900/(2*1.40*0.02540)=0.373MPa











Design of waste heat recovery system for a Hieza boiler in a Soap Industry
12
Department of Mechanical Engineering , SIT, Mangalore
Table 8.1 Summary of Calculations.


OD
inch
BWG V
m/s
Re Hi

U A L A* U* F(10-3) %U P
(MPa)
Ro ho
1
14 27.1 627818.7 12668.7 68.8 1.6639 133.6 11.4 63.8 2.3 7.18 5.3 5631.7 69.1
16 24.9 576949.5 11305.8 68.7 10.670 133.726 11.48 63.8 2.4 7.12 4.4
18 23.2 536332.5 10286 68.4 10.677 133.81 11.4 63.8 2.43 7.06 3.7
1
1/4

14 16.08 464127.3 7652.3 63.1 11.647 116.82 11.964 61.4 2.5 2.4 1.27 7043.4 63.5
16 15.06 434686.4 7002.1 62.9 11.6 116.9 11.964 61.4 2.531 2.38 1.089
18 14.27 411941.8 6532.5 62.98 11.66 116.986 11.964 61.4 2.556 2.32 0.962
1
1/2

14 10.60 367214.7 5152.5 59.08 12.5 103.8 14.35 51.24 2.6 13.27 0.46 8452.4 59.7
16 10.02 347091 4934.1 59.1 12.4 103.6 14.35 51.24 2.63 13.4 0.41
18 9.063 333825.3 4535.2 58.9 12.44 103.98 14.35 51.24 2.65 13.4 0.37













Design of waste heat recovery system for a Hieza boiler in a Soap Industry
12
Department of Mechanical Engineering , SIT, Mangalore
CHAPTER 9
Results and Discussions
.
From the table 8.1 we can see the trend of P and A* with the velocity of
flow of thermic fluids through the tube. Generally we desire the value of overall
heat transfer co efficient to be higher so that minimum surface area is required
for the heat exchanger. So in order to do this we increase the velocity of flow so
that turbulence is increased and by the virtue of which heat transfer co efficient
inside the tube increases. The similar trend is seen above in the table 8.1. But as
the turbulence increases the pressure drop ion the tube also increases. So we
need to strike a balance between the pressure drop, and the surface area( which
is eventually U*). So a graph was plotted and and point of interference of
graphs V v/s P and V v/s A is marked and optimum value of A*, P, and
velocity through the tubes noted. The corresponding values of dimensions of the
heat exchanger are
Velocity through the tubes=21.5m/s
Resulting P=2.8MPa
Optimum surface area A*=11.6m
2
Optimum length of the tube=125.799m
OD=0.9063inch*0.0254=0.0244602m.
Thickness of the tube=0.136969inch*0.0254=0.0034709m.










Design of waste heat recovery system for a Hieza boiler in a Soap Industry
12
Department of Mechanical Engineering , SIT, Mangalore
Conclusion



























Design of waste heat recovery system for a Hieza boiler in a Soap Industry
12
Department of Mechanical Engineering , SIT, Mangalore




























Design of waste heat recovery system for a Hieza boiler in a Soap Industry
12
Department of Mechanical Engineering , SIT, Mangalore




























Design of waste heat recovery system for a Hieza boiler in a Soap Industry
12
Department of Mechanical Engineering , SIT, Mangalore




























Design of waste heat recovery system for a Hieza boiler in a Soap Industry
12
Department of Mechanical Engineering , SIT, Mangalore