HE Design Optimization

ME414 Thermal Fluid System Design

Professor John Toksoy
Final Project

Team Members:
Kaela Hlaulani
Prince Bedell
William Broaddus
Derek Vleck
Trever Zike
Seth Simonson

CUMMINS CONFIDENTIAL
 Project Definition

Design heat exchanger to reduce fluid by 20

degrees Celsius.
Mass flow rate at the inlet of tube side is fixed at
220,000 kg/hr.
Inlet flow rate of shell is a design parameter.
Inlet temperature of shell fluid is 20 degrees
Celsius.
Both fluids are considered as water.

CUMMINS CONFIDENTIAL
 Design Optimization Goals

System must cool fluid from 45 C to 25 C

Lengthof Heat Exchanger cannot
exceed 7 m
Shell Diameter cannot exceed 2 m
Shell
and Tube weight must be
minimized
Pressuredrop of Shell and Tube must
also be minimized
CUMMINS CONFIDENTIAL
 Introduction
MATLAB is used to perform DOE runs.
Minitab is used to evaluate the importance of the
variables according to the DOE runs (Main Effect
Plots).
Relatively unimportant variables are selected and
eliminated (fixed).
Most important variables are optimized using
Minitab.

CUMMINS CONFIDENTIAL
 Design Funneling Process
1st Step: Analyze all 11 variables
2nd Step: Two Factor DOEs
3rd Step: Critical Variables Optimization
Single Factor Runs: 2 Factor DOE Runs: 4 Critical Variables:

I_Counter Flow
Mdot shell

Optimization
Tube Length Tube Length
Baffle Space Tube Length
Baffle Space
# Tube Passes Baffle Space
Tube Thickness
Shell ID Shell ID
# Tube Passes Tube OD
Shell Material
Baffle Cut
Tube OD
Shell ID
Shell Thickness
Shell Material
Tube OD CUMMINS CONFIDENTIAL
 Variable Analysis
Each design variable is analyzed while everything
else is kept constant

q_calc (W) Mass (kg) DP_Shell (Pa) DP_Tube (Pa)

variable Name 20% 20% 20% 20% 20% 20% 20% 20%

I_counter_flow 1.83E+07 5.22E+06 711.06 711.06 2.38E+08 2.38E+08 1.31E+05 1.31E+05

mdot_shell 2.43E+06 6.69E+06 710.77 711.24 1.58E+08 3.32E+08 1.31E+05 1.31E+05
Tube_length 4.17E+06 6.26E+06 568.85 853.28 1.89E+08 2.86E+08 1.07E+05 1.55E+05
Baffle_space 5.36E+06 5.09E+06 711.06 711.06 4.45E+08 1.44E+08 1.31E+05 1.31E+05
Tube_Thickness 5.17E+06 5.28E+06 684.28 748.57 2.38E+08 2.38E+08 1.05E+05 1.88E+05
N_tube_pass 2.59E+06 705.87 2.38E+08 9.48E+05
baffle_cut 5.22E+06 5.22E+06 711.06 711.06 2.38E+08 2.38E+08 1.31E+05 1.31E+05
Shell_id 4.05E+06 6.23E+06 456.96 1020.2 2.87E+08 2.04E+08 2.89E+05 6.95E+04
Shell_thickness 5.22E+06 5.22E+06 707.63 714.5 2.38E+08 2.38E+08 1.31E+05 1.31E+05
Shell_material 5.22E+06 5.22E+06 743.8 750.66 2.38E+08 2.38E+08 1.31E+05 1.31E+05
Tube_OD 6.75E+06 4.22E+06 745.51 686.69 3.08E+08 1.92E+08 2.37E+05 8.67E+04

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 1st run Main Effect Plots
(11 Variables)
Effect of each variable on q_calc

Main Effects Plot for qCalc Main Effects Plot for qCalc
Data Means Data Means
I _counte_flow mdot_shell Tube_length baffle_cut Shell_id Shell_thickness
16000000
5200000
12000000 5150000

8000000 5100000

5050000
4000000
5000000
Mean

Mean
0
0 2 51.2 76.8 4.8 7.2 0.06732 0.10098 0.26928 0.40392 0.0008 0.0012
Baffle_space Tube_Thickness N_tube_pass Shell_material Tube_OD
16000000
5200000
12000000 5150000

8000000 5100000

5050000
4000000
5000000
0
0.107712 0.161568 0.0004472 0.0006708 0 1 21 41 0.0041856 0.0062784

CUMMINS CONFIDENTIAL
 1st run Main Effect Plots
(11 Variables)
Effect of each variable on DP_tube

Main Effects Plot for DPTube Main Effects Plot for DPTube
Data Means Data Means

I _counte_flow mdot_shell Tube_length baffle_cut Shell_id Shell_thickness

1000000
480000
800000
360000
600000
240000
400000
120000
200000

Mean
0
Mean

0 2 51.2 76.8 4.8 7.2 0.06732 0.10098 0.26928 0.40392 0.0008 0.0012
Baffle_space Tube_Thickness N_tube_pass Shell_material Tube_OD
1000000
480000
800000
360000
600000
240000
400000
120000
200000
0
0.107712 0.161568 0.0004472 0.0006708 0 1 21 41 0.0041856 0.0062784

CUMMINS CONFIDENTIAL
 1st run Main Effect Plots
(11 Variables)
Effect of each variable on DP_shell

Main Effects Plot for DPShell Main Effects Plot for DPShell
Data Means Data Means
I _counte_flow mdot_shell Tube_length baffle_cut Shell_id Shell_thickness
320000000
400000000

280000000
300000000

240000000
200000000

200000000
Mean

Mean
100000000
0 2 51.2 76.8 4.8 7.2 0.06732 0.10098 0.26928 0.40392 0.0008 0.0012
Baffle_space Tube_Thickness N_tube_pass Shell_material Tube_OD
320000000
400000000

280000000
300000000

240000000
200000000

200000000
100000000
0.107712 0.161568 0.0004472 0.0006708 0 1 21 41 0.0041856 0.0062784

CUMMINS CONFIDENTIAL
 1st run Main Effect Plots
(11 Variables)
Effect of each variable on weight_HE

Main Effects Plot for Weight_ HE Main Effects Plot for Weight_ HE
Data Means Data Means
I _counte_flow mdot_shell Tube_length baffle_cut Shell_id Shell_thickness

800 900
750
800
700
700
650
600
600
Mean

Mean
500
0 2 51.2 76.8 4.8 7.2 0.06732 0.10098 0.26928 0.40392 0.0008 0.0012
Baffle_space Tube_Thickness N_tube_pass Shell_material Tube_OD

800
900
750
800
700
700
650
600
600
500
0.107712 0.161568 0.0004472 0.0006708 0 1 21 41 0.0041856 0.0062784

CUMMINS CONFIDENTIAL
 1st run Main Effect Plots
(11 Variables)
Following variables were eliminated as a result of
1st DOE

I counter flow (We chose counter flow to Increase LMTD

correction factor and heat exchanger effectiveness)
Baffle cut (We chose 84.15 mm)
Shell thickness (Only affects the weight, so we chose a
reasonably thin shell)
Tube thickness (We chose a thickness of 0.559 mm)
mdot _shell (We chose a value of 64 Kg/m3 to minimize
Dp_Shell.)

CUMMINS CONFIDENTIAL
 2nd run Main Effect Plots
(6 Variables)
Effect of each variable on q_calc

Main Effects Plot for qCalc

Data Means
Tube_length Baffle_space N_tube_pass
4500000

4000000

3500000

3000000

2500000
Mean

4.8 7.2 0.107712 0.161568 0 1

Shell_id Shell_material Tube_OD
4500000

4000000

3500000

3000000

2500000

0.26928 0.40392 21 41 0.0041856 0.0062784

CUMMINS CONFIDENTIAL
 2nd run Main Effect Plots
(6 Variables)
Effect of each variable on DP_tube

Main Effects Plot for DPTube

Data Means
Tube_length Baffle_space N_tube_pass
2000000

1500000

1000000

500000
Mean

0
4.8 7.2 0.107712 0.161568 0 1
Shell_id Shell_material Tube_OD
2000000

1500000

1000000

500000

0
0.26928 0.40392 21 41 0.0041856 0.0062784

CUMMINS CONFIDENTIAL
 2nd run Main Effect Plots
(6 Variables)
Effect of each variable on DP_shell

Main Effects Plot for DPShell

Data Means
Tube_length Baffle_space N_tube_pass
50000000

40000000

30000000

20000000
Mean

4.8 7.2 0.107712 0.161568 0 1

Shell_id Shell_material Tube_OD
50000000

40000000

30000000

20000000

0.26928 0.40392 21 41 0.0041856 0.0062784

CUMMINS CONFIDENTIAL
 2nd run Main Effect Plots
(6 Variables)
Effect of each variable on weight_HE

Main Effects Plot for Weight_ HE

Data Means
Tube_length Baffle_space N_tube_pass

900

800

700

600
Mean

500
4.8 7.2 0.107712 0.161568 0 1
Shell_id Shell_material Tube_OD

900

800

700

600

500
0.26928 0.40392 21 41 0.0041856 0.0062784

CUMMINS CONFIDENTIAL
 2nd run Main Effect Plots
(6 Variables)
Variables Eliminated:
Number of tube passes
We sacrificed some amount of heat transfer,
however, we minimized the pressure drop, which
implies that we can use less powerful pump.

Shell material
We chose pure aluminum because:
It has a high thermal heat coefficient
low weight.
Fluid has same properties as water, therefore there is no
corrosion hazard.

CUMMINS CONFIDENTIAL
 3rd run Main Effect Plots
(4 Variables)
Effect of each variable on q_calc

Main Effects Plot for qCalc Pareto Chart of the Standardized Effects
Data Means (response is qCalc, Alpha = 0.05)

Tube_length Baffle_space 2.20

6000000

5500000
Tube_length
5000000

4500000
Shell_id

Term
4000000
Mean

4.8 7.2 0.107712 0.161568

Shell_id Tube_OD
6000000 Baffle_space

5500000

5000000 Tube_OD

4500000

4000000 0 10 20 30 40 50 60 70 80
0.26928 0.40392 0.0041856 0.0062784 Standardized Effect

CUMMINS CONFIDENTIAL
 3rd run Main Effect Plots
(4 Variables)
Effect of each variable on DP_tube

Main Effects Plot for DPTube Pareto Chart of the Effects

Data Means (response is DPTube, Alpha = 0.05)
Tube_length Baffle_space Factor Name
A Tube_length
480000 D Tube_OD

360000 D
240000

120000

Term
0 A
Mean

4.8 7.2 0.107712 0.161568

Shell_id Tube_OD
480000

360000 AD
240000

120000

0 0 100000 200000 300000 400000 500000

0.26928 0.40392 0.0041856 0.0062784 Effect

CUMMINS CONFIDENTIAL
 3rd run Main Effect Plots
(4 Variables)
Effect of each variable on DP_shell

Main Effects Plot for DPShell Pareto Chart of the Standardized Effects
Data Means (response is DPShell, Alpha = 0.05)

Tube_length Baffle_space 2.31

500000000 Factor Name
A Tube_length
B
400000000 B Baffle_space
C Shell_id
D D Tube_OD
300000000

200000000 A

Term
Mean

4.8 7.2 0.107712 0.161568 C

Shell_id Tube_OD
500000000 BD

400000000 AB

300000000
BC
200000000
0 5 10 15 20
0.26928 0.40392 0.0041856 0.0062784 Standardized Effect

CUMMINS CONFIDENTIAL
 3rd run Main Effect Plots
(4 Variables)
Effect of each variable on weight_HE

Main Effects Plot for Weight_ HE Pareto Chart of the Standardized Effects
Data Means (response is Weight_HE, Alpha = 0.05)
Tube_length Baffle_space 2.2
Factor Name
900 A Tube_length
C Shell_id
800 C D Tube_OD

700
600
A
500

Term
Mean

4.8 7.2 0.107712 0.161568

Shell_id Tube_OD
AC
900

800

700 D

600

500 0 20 40 60 80 100 120

0.26928 0.40392 0.0041856 0.0062784 Standardized Effect

CUMMINS CONFIDENTIAL
Minitab Optimization

Critical Variables:

Tube Length
Baffle Space
Shell ID
Tube OD

CUMMINS CONFIDENTIAL
 Final Design Specifications
Tube Length = 6.06 m
Baffle Space = 0.1616 m
Shell ID = 0.2693 m
Tube OD = 6.3 E-3 m
Weight = 547.9 kg
DP Shell = 238 MPa
DP Tube = 45.44 KPa
Q_Calc = 5,227 KW

CUMMINS CONFIDENTIAL
 Conclusion
The Shell Pressure is high because we selected
baffles
Baffles induce turbulence which increases heat loss.
We chose a low Fouling factor of 3E-5:
The chemical has water like properties which
minimizes the likelihood of fouling.

We chose a 90 square pitch:

makes cleaning of the tubes easier

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Questions ?

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