PAPER PRESENTATION ON

OPTIMUM THERMAL DESIGN OF ETHYL ALCOHOL HEAT EXCHANGER

USING SOFTWARE

SUBMITTED BY:CHIRAG MEHTA (B.E. MECH.)

SALMAN DABIR (B.E. MECH)

GUIDED BY:PROF. S.S. PAWAR

(ASST. PROF. MECH. ENGG.)

DEPARTMENT OF MECHANICAL ENGINEERING

LOKMANYA TILAK COLLEGE OF ENGINEERING
NAVI-MUMBAI.
2005- 2006

ABSTRACT

Optimum design of heat exchanger is more effective in thermal design stage as compared to
mechanical design. The thermal design is a trial and error method of design i.e. iterative. The
application of computer in such design method gives very fast and optimum design by comparing all
the possible resource.

The objective of this project is to do optimum design of ethyl alcohol heat

exchanger using C++ language for thermal design and for checking parameters like pressure drop,
velocity drop, dirt factor etc by using area based and required flow condition.
At last the conclusive remark and results are discussed by comparing required output.

CONTENTS
1. INTRODUCTION
2. OBJECTIVE AND NECESSITY OF OPTIMUM THERMAL DESIGN
3. PROBLEM
4. NOMENCLATURE
5. RESULTS OF 1-4 PASS - FIXED TUBESHEET SHELL AND TUBE HEAT EXCHANGER
6. OPTIMUM THERMAL DESIGN BASED ON MINIMUM AREA

PASS 1-1

PASS 1-2

PASS 1-4

7. RESULTS AND CONCLUSIONS

8. REFERENCES

INTRODUCTION:A device used for transferring or exchanging energy in the form of heat between two fluids is
known as heat exchanger. This heat exchanger can be either by direct or indirect method. In direct
method heat exchanger heat transfer between two fluids takes place without mixing. Two fluids are
separated by a surface metallic or non- metallic through which heat transfer takes place in the direction
perpendicular to the flow direction.
TYPES OF HEAT EXCHANGER:1. fixed tube sheet
2. outside packed floating head.
3. internal floating head
4. U- tube type.
5. Reboiler (with internal floating head or U- tube type).

COMPONENTS OF HEATEXCHANGER:1. Shell

2. Shell cover
3. Tubes
4. tube sheet
5. tie rods or spacer.
6. baffles
7. channel
8. channel cover
9. pass partition
10. nozzles
11. flanges
12. support
type of heat exchanger we have selected for given specification is a fixed tube sheet shell and tube due
to following reasons.:
to prevent corrosion in the shell, water is taken inside the tube. There is a possibility of fouling
and hence clogging of tubes. This will reduce heat transfer capability of heat exchanger. To avoid
clogging it is recommended that velocity of fluid flowing on the tube side should be more then 3 fps.

Since there is low temperature difference on shell side and tube side and material of
construction is also same, there will be practically no thermal expansion, therefore u tube heat
exchanger will not be suitable choice.

Among the heat exchanger configuration 1-1,1-2, 1-4 pass , we have selected 1-4 pass heat
exchanger, which will satisfy the above criteria of increase in tube side fluid velocity

Also we have selected fixed tube sheet configuration, because it will be suitable for this
application as there is no problem of thermal stresses and there are no internal joints in this, thus
eliminating leakage of one fluid into another.

OBJECTIVE:The application of the principle of heat transfer to the design of equipment to accomplish a
certain engg. Objective is of extreme importance. For applying the principles to the design, individual
is working towards the important goals of product development for economic gain.
The objective of this project is to do optimum design of ethyl alcohol heat exchanger using C++
language for thermal design and for checking parameters like pressure drop, velocity drop, dirt factor
etc by using area based and required flow condition.

NECESSITY OF OPTIMUM THERMAL DESIGN:Economics play a key role in the design and selection of heat exchanger equipment. The weight
and size of heat exchanger used in space or aeronautical applications are very important parameters.
The weight and size are important cost factor in the overall application in the chemical process
industries and thus may still be considered as economic variables.
Optimum design of heat exchanger is more effective in thermal design stage as compared to
mechanical design. The thermal design is a trial and error method of design i.e. iterative. The
application of computer in such design method gives very fast and optimum design by comparing all
the possible resource.

PROBLEM:Ethyl alcohol is manufactured by m/s Krishna Sahakari Sakar Karakhana Ltd. Rethare BK. Tal.. Karad
at the rate of 30kl/day. The ethyl alcohol is condensed in condenser operating at atmospheric pressure,
which gives condensing temp. as 78 c . the hot ethyl alcohol is to be cooled from 78 c to 45 c coming
with pressure 3.5 kg/cm2 using cooling water available at 30 c and pressure 3.5 kg/cm2 with 5 c as
approach
Design suitable cooler (heat exchanger) with dirt coefficient = 0.002 (hr)(ft2)(F)/Btu and
allowable pressure drop as 10 psi(g) on both sides of the cooler .

SOLUTION:
This problem is solved by theoretical calculation which is very long lengthy , tedious and time
consuming. The various formulas used for calculation are as follows:
LMTD = (t2 t1)
Ln [t2 / t1]
R = (T1 T2) / (t2 t1) and S = (t2 t1) / (T1 t1)
True Temperature Difference, t = LMTD x FT
a) For viscosity at Ta and ta, referring from graph from Donald Q.kern
Viscosity of water at 90.5 F is = 0.80 cp
Viscosity of ethyl alchohol at 143.0 F is al = 0.62 cp
b) For Thermal conductivities, refer table 4 from Donald Q.kern
Kal at 122 F = 0.087
Kal at 68 F = 0.105
c) Prendtal number :- (c / K) al
Surface Area, A = Q / (UD x t)
Mass velocity, Gt = Mt / at
Water velocity V = Gt / (3600 x w)
Reynold number, Ret = D x Gt / w
hi = JH x (k / D) x (c / K)1/3 x t

hio / t = (hi / t ) x (ID / OD)

pt = (f x Gt2 x L x n) / (5.22 x 1010 x D x s x t)
Return pressure loss :pr = (4 x n/s) x (V2 / 2 x g)
Total pressure loss from tube side:
PT = (pt + pr)
Shell side calculation :
Flow area as = (ID x C x B) / (144 x PT )
Mass velocity Gs = W / as
Shell side Reynold number: Res = De x Gs / al
ho = JH x (K / De) x (c / K)1/3 x s

Number of crosses,
N + 1 = 12 x L/B
Ps =

(f x Gs2 x Ds x (N + 1)
(5.22 x 1010 x De x s x s)

Clean overall coefficient Uc :

Uc = hio x ho
hio + ho
Dirt factor Rd :
Rd = Uc - Ud
Uc x Ud

NOMENCLATURE:
A = heat transfer surface
a = flow area, ft2
a = external surface per linear foot, ft
B = baffle spacing, in.
C = clearance between tubes, in.
C = specific heat of fluid, Btu/ (lb) (F)
D = Inside diameter of tube, ft.
Ds = Inside diameter of shell, ft
De, De1 = equivalent diameter for heat transfer and pressure drop, ft
d = inside diameter of tubes, in.
FT = temperature- difference factor, dimensionless
f = friction factor, ft2 / in2.
G = mass velocity, lb / (hr) (ft2)
g = acceleration of gravity, ft / hr2
G = acceleration of gravity, ft / sec2.
H, hi, ho = heat transfer coefficient in general, for inside fluid, and for outside
Fluid respectively, Btu / hr (ft2) (F / ft).
hio = value of hi when referred to tube outside diameter, Btu / hr (ft2) (F / ft)
jH = factor for heat transfer, dimensionless.
k = thermal conductivity, Btu / hr (ft2) (F / ft)
L = tube length, ft.
LMTD = Log mean temperature difference, F.
N = number of shell side baffles.
Nt = number of tubes.
n = number of tube passes
Pt = tube pitch, in.
Q = heat flow, Btu / hr.
R = TEMPERATURE GROUP (T1-T2)/ (t2-t1), dimensionless.
Rd = dirt factor, (hr) (ft2) (F) / Btu.
Re = Reynolds no for heat transfer,), dimensionless
S = temperature group, (t2-t1) / (T1 t1),), dimensionless.
T1, T2 = inlet and outlet temperature of hot fluid, F.
Ta = average temperature of hot fluid, F
ta = average temperature of cold fluid, F
Uc, Ud = clean and design overall coefficient of heat transfer, Btu / hr (ft2) (F / ft)
V = Velocity, fps
W = weight flow of hot fluid, lb / hr
Mt = weight flow of cold fluid, lb / hr
s = shell
t = tube.

As it is seen that the thermal design is a trial and error i.e. iterative method of design, therefore it is
very difficult, tedious and time consuming method to get optimum design. Hence it is proposed to
prepare general program in C++ language to get quick, accurate and optimum thermal design
parameters to reduce the weight to achieve cost effectiveness. So we solve the above problem using
C++ software
We obtain the following results as shown below for all the three passes (C++ program is not shown
here as it is lengthy)

RESULTS OF 1-4 PASS

FIXED TUBESHEET SHELL AND TUBE HEAT EXCHANGER
INSTRUCTION: - in this program you feed the data such that, T1>T2, t2>t1 otherwise it will
give wrong results.
Now enter the values of following parameters:
Enter tube od in inches
.75
Enter triangular pitch in inches
1
Enter clearance in inches
.25
Enter surface per linear feet value ft square from kern book
.1963
Enter flow area per tube value inch sqr
.302
Enter inner diameter of tube di in ft
.502
Enter mass flow rate on shell side (lb / hr)
2200
Enter shell side inlet temp (deg F) T1
173
Shell side outlet temperature (deg F) t2
113

Enter tube side inlet temperature t1 (deg F)

86
Tube side outlet temperature t2 (deg F)
95
Enter shell side fluid specific gravity SG_s
.81
Enter tube side fluid specific gravity SG_t
1
Enter shell side fluid specific heat (Btu/Lb deg F)
.78
Enter tube side fluid sp. Heat (Btu/Lb deg F)
11
Enter viscosity of shell side fluid
1.5
Enter tube side fluid viscosity
1.936
Enter shell side fluid thermal conductivity
0.08
Enter tube side fluid thermal conductivity
0.358
Enter the term fay_s
1

Enter the term fay_t

1
Enter lower (limit of Ud-1) in British units so that it will start from lower limit
74
Enter upper limit of Ud
150
Enter final limit of tube length, ft
6

ENTER THE LOWER LIMIT OF TUBE SIDE PASSES AS FOLLOWS

For np=1, enter 0
For np=2, enter 1
For np=4, enter 2
2
Now enter upper limit of no of passes which you want
But remember this upper limit >= lower limit
4
Enter the minimum tube side velocity which you want (ft/sec)
1.5
Enter lower limit of dirt factor in British units
0.002
Enter upper limit of dirt factor in British units
0.002
Heat transferred =102960
Mt=11440
LMTD=46.0198
Ud lower limit=74
Enter tube length lower limit (i.e. suppose 816 then enter 8)
6
Lower limit of tube length selected=6
No of passes before beginning of loop =2
Press any key!
RESULTS:/
Rd
/ Ps / Pt / TU / TBLN / B / SH_ID / Ud / N_P / cnt / EPC / EPD /
/ 0.002264 / 0.31 / 3.46 / 24 / 6.0 / 1.60 / 8.0 / 75 / 4 / 1 /0.62 / 0.53/
/ 0.002264 / 0.31 / 3.46 / 24 / 6.0 / 1.60 / 8.0 / 76 / 4 / 1 /0.62 / 0.53 /
/ 0.002264 / 0.31 / 3.46 / 24 / 6.0 / 1.60 / 8.0 / 77 / 4 / 1 /0.62 / 0.53 /
/ 0.002264 / 0.31 / 3.46 / 24 / 6.0 / 1.60 / 8.0 / 78 / 4 / 1 /0.62 / 0.53 /

hence optimum thermal design based on minimum area for the passes 1-1, 1-2 and 1-4 is as
shown below:-

OPTIMUM THERMAL DESIGN BASED ON MINIMUM AREA

FOR 1-1 PASS
PARAMETERS

MAGNITUDE

Area
UD
LMTD
TUBE LENGTH
TUBES
SHELL ID
As
Gs
Re_s
Friction Factor
On shell side
Pressure drop
On shell side
At
Gt
Tube velocity
Re_t
Friction factor
On tube side
Pressure drop
On tube side
Jho
Ho
Hio
Uc
Rd
No of passes
EPC_Uc
EPC_Ud

43.5
51.34
46.02
6.00
37.0
8.00
0.0319
68869.58
2755.42
0.002868

ft sqr
Btu/hr ftsqr deg F
deg F
ft
number
inches
ft sqr
Lb/hr ft sqr
dimensionless
dimensionless

0.11

psi

0.0776
147427.97
0.66
3959.84
0.000345

ft sqr
Lb/hr ft sqr
ft/sec
dimensionless
dimensionless

0.03

psi

27.41
89.34
159.24
57.23
0.002006
1.0
0.58
0.53

UNITS

Btu/hr ftsqr deg F

Btu/hr ftsqr deg F
Btu/hr ftsqr deg F
hr ft sqr deg F/Btu
number

OPTIMUM THERMAL DESIGN BASED ON MINIMUM AREA

FOR 1-2 PASS

PARAMETERS

MAGNITUDE

UNITS

Area
UD
LMTD
TUBE LENGTH
TUBES
SHELL ID
As
Gs
Re_s
Friction Factor
On shell side
Pressure drop
On shell side
At
Gt
Tube velocity
Re_t
Friction factor
On tube side
Pressure drop
On tube side
Jho
Ho
Hio
Uc
Rd
No of passes
EPC_Uc
EPC_Ud

35.33
63.32
46.02
6.00
30.0
8.00
0.0319
68869.58
2755.42
0.002868

ft sqr
Btu/hr ftsqr deg F
deg F
ft
number
inches
ft sqr
Lb/hr ft sqr
dimensionless
dimensionless

0.1100

psi

0.0315
363655.62
1.62
9767.61
0.000271

ft sqr
Lb/hr ft sqr
ft/sec
dimensionless
dimensionless

0.31

psi

27.41
89.35
392.80
72.79
0.002055
2.0
0.59
0.53

Btu/hr ftsqr deg F

Btu/hr ftsqr deg F
Btu/hr ftsqr deg F
hr ft sqr deg F/Btu
number

OPTIMUM THERMAL DESIGN BASED ON MINIMUM AREA

FOR 1-4 PASS

PARAMETERS

MAGNITUDE

Area
UD
LMTD
TUBE LENGTH
TUBES
SHELL ID
As
Gs
Re_s
Friction Factor
On shell side
Pressure drop
On shell side
At
Gt
Tube velocity
Re_t
Friction factor
On tube side
Pressure drop
On tube side
Jho
Ho
Hio
Uc
Rd
No of passes
EPC_Uc
EPC_Ud

28.27
79.15
46.02
6.00
24.0
8.00
0.0200
99000.0
3960.92
0.002672

ft sqr
Btu/hr ftsqr deg F
deg F
ft
number
inches
ft sqr
Lb/hr ft sqr
dimensionless
dimensionless

0.31

psi

0.0126
909139.06
4.04
24419.03
0.000211

ft sqr
Lb/hr ft sqr
ft/sec
dimensionless
dimensionless

3.46

psi

33.43
108.98
837.03
96.42
0.002264
4.0
0.62
0.53

UNITS

Btu/hr ftsqr deg F

Btu/hr ftsqr deg F
Btu/hr ftsqr deg F
hr ft sqr deg F/Btu
number

RESULTS AND CONCLUSION:The thermal design of the heat exchanger is carried out as per D.Q. Kern. The manual design
procedure is found tedious and time consuming. Therefore computer program in C++ language is
prepared and results obtained are compared for different pass arrangements. The optimum thermal
design parameters are selected on the basis of minimum area. The key parameters are tabulated as
shown below:Pass
arrangement

Area

No. of
Tubes

Sheet ID

Uc

UD

Rd

Tube
Velocity

Total pressure
drop

1-1

43.58

37

57.23

51.34

0.002006

0.66

0.14

1-2

35.33

30

72.79

63.32

0.002055

1.62

0.42

1-4

28.27

24

96.42

79.15

0.00226

4.04

3.77

From the result mention in table it can be concluded that 1-4 pass arrangement is the best optimum
design. Further 1-6 pass arrangement is not possible because pressure drop from tube side increases
eight times which crosses the limit of allowable pressure drop 10psi. also the tube velocity and dirt
factor crosses the allowable limit for next pass arrangement.

REFERENCES:

Donald Q Kern. process heat transfer Tata McGraw Hill.

Let us C ++ by Yashwant Kanitkar.