Design of Compact Plate Fin Heat Exchanger: Jainender Dewatwal
Design of Compact Plate Fin Heat Exchanger: Jainender Dewatwal
Design of Compact Plate Fin Heat Exchanger: Jainender Dewatwal
Bachelor of Technology
In
Mechanical Engineering
By
JAINENDER DEWATWAL
(ROLL.NUMBER: 10503059)
1
DESIGN OF COMPACT PLATE
FIN HEAT EXCHANGER
JAINENDER DEWATWAL
(ROLL.NUMBER: 10503059)
Under the Guidance of
PROF. R.K.Sahoo
2
National Institute of Technology
Rourkela
CERTIFICATE
This is to certify that the project entitled, “Design of compact plate fin
heat exchanger ” submitted by Jainender Dewatwal in partial fulfilment of the
requirements for the award of Bachelor of Technology, Rourkela (Deemed
University) is an authentic work carried out by him under my supervision and
guidance.
To the best of my knowledge, the matter embodied in the project has not
been submitted to any other University / Institute for the award of any Degree or
Diploma.
Rourkela – 769008
Signature: India
3
National Institute of Technology
Rourkela
ACKNOWLEDGEMENT
I would like to articulate my deep gratitude to my project guide Prof.
R.K.Sahoo who has always been my motivation for carrying out the project.
An assemblage of this nature could never have been attempted without
reference to and inspiration from the works of others whose details are
mentioned in reference section. I acknowledge my indebtedness to all of them.
Rourkela – 769008
Signature: India
4
INDEX
1. Certificate 3
2. Acknowledgement 4
3. Abstract 6
4. Introduction 7-18
5
ABSTRACT
Plate fin heat exchangers, because of their compactness, low weight and high
effectiveness are widely used in aerospace and cryogenic applications. This
device is made of a stack of corrugated fins alternating with nearly equal
number of flat separators known as parting sheets, bonded together to form a
monolithic block. Appropriate headers are welded to provide the necessary
interface with the inlet and the exit streams. While aluminum is the most
commonly used material, stainless steel construction is employed in high
pressure and high temperature applications.
6
INTRODUCTION
• Plate Fin Heat Exchangers
• Fin Geometries
• Flow Friction and Heat Transfer Characteristics
1
7
2 Figure 1.1: Plate fin heat exchanger assembly and detailsSide bars
Plates or Parting Sheets FinsFluid 1 Fluid 2 Cap Sheet Header
8
Steam exchanges heat by flowing along the passege
corrugations between the parting sheets. The edges of the corrugated
layers are sealed by side-bars. Corrugations and side-bars are brazed to
the parting sheets on both sides to form rigid pressure-containing voids.
The first and the last sheets, called cap sheets, are usually of thicker
material than the parting sheets to support the excess pressure over the ambient
and to give protection against physical damage. Each stream enters the block
from its own header via ports in the side-bars of appropriate layers and leaves in
a similar fashion. The header tanks are welded to the side-bars and parting
sheets across the full stack of layers
9
Merits and Drawbacks
Plate fin heat exchangers offer several advantages over competing designs.
(2) Large heat transfer surface area per unit volume (Typically 1000
2 3
m /m ),
(4) Multi-stream operation (Up to ten process streams can exchange heat
in a single heat exchanger.), and
(5) True counter-flow operation (Unlike the shell and tube heat
exchanger, where the shell side flow is usually a mixture of cross and
counter flow.).
Materials
Plate fin heat exchangers can be made in a variety of materials. Aluminium is
preferred in cryogenic and aerospace applications because of its low density,
high thermal conductivity and high strength at low temperature. The maximum
design pressure for brazed aluminium plate fin heat exchangers is around 90
bar. At temperatures above ambient, most aluminium alloys lose mechanical
strength. Stainless steels, nickel and copper alloys have been used at
0
temperatures up to 500 C. The brazing material in case of aluminium
exchangers is an aluminium alloy of lower melting point, while that used in
stainless steel exchangers is a nickel based alloy with appropriate melting and
10
.
Manufacture
Applications
11
(1) exchange of heat between gases, liquids or both,
(3) boiling,
Flow Arrangement
A plate fin heat exchanger accepts two or more streams,
which may flow in directions parallel or perpendicular to one another. When the
flow directions are parallel, the streams may flow in the same or in opposite
sense. Thus we can think of three primary flow arrangements – (i) parallel flow,
(ii) counterflow and (iii) cross flow. Thermodynamically, the counterflow
arrangement provides the highest heat (or cold) recovery, while the parallel flow
geometry gives the lowest. The cross flow arrangement, while giving
intermediate thermodynamic performance, offers superior heat transfer
properties and easier mechanical layout. Under certain circumstances, a hybrid
cross – counterflow geometry provides greater heat (or cold) recovery with
superior heat transfer performance. Thus in general engineering practice, plate
fin heat exchangers are used in three configurations: (a) cross flow, (b)
counterflow and (c) cross-counter flow.
(a) Cross flow (Fig. 1.2(a))
In a cross flow heat exchanger, usually only two
streams are handled, thus eliminating the need for distributors. The header tanks
are located on all four sides of the heat exchanger core, making this
arrangement simple and cheap. If high effectiveness is not necessary, if the two
streams have widely differing volume flow rates, or if either one or both streams
are nearly isothermal (as in single component condensing or boiling), the cross
flow arrangement is preferred. Typical applications include automobile
radiators and some aircraft heat exchangers.
(b) Counter flow (Fig. 1.2 (b))
The counterflow heat exchanger provides the most
thermally effective arrangement for recovery of heat or cold from process
streams. Cryogenic refrigeration and liquefaction equipment use this geometry
almost exclusively. The geometry of the headers and the distributor channels is
complex and demands proper design.
(c) Cross-Counter flow (Fig.1.2 (c))
The cross-counterflow geometry is a hybrid
of counterflow and cross flow arrangements, delivering the thermal
effectiveness of counterflow heat exchanger with the
12
Figure 1.2: Heat exchanger flow arrangements(a) Cross Flow (b)
Counter flow(b) Cross counter flow
13
the smaller value of allowable pressure drop flows through the straight channel,
while the other stream takes the zigzag path. For example, in a liquid-to-gas
heat exchanger, the gas stream with a large volume flow rate and low allowable
pressure drop is assigned the straight path, while the liquid stream with a high
allowable pressure drop flows normal to it over a zigzag path. This arrangement
optimises the overall geometry.
1.2 Fin Geometries
The performance of a plate fin heat exchanger is determined,
among other things, by the geometry of the fins. The most common fin
configurations are – (1) plain (straight and uninterrupted) fins with rectangular,
trapezoidal or triangular passages, (2) uninterrupted wavy fins and (3)
interrupted fins such as offset strip, louvered, perforated and pin fins. The
details of each fin type are given below.
Plain Fins
These are straight fins that are continuous in the fluid flow
direction (Fig.1.3(a, b). Although passages of triangular and rectangular cross
section are more common, any desired shape can be given to the fins,
considering only manufacturing constraints. Straight fins in triangular
arrangement can be manufactured at high speeds and hence are less expensive
than rectangular fins. But generally they are structurally weaker than
rectangular fins for the same passage size and fin thickness. They also have
lower heat transfer performance compared to rectangular fins, particularly in
laminar flow
Plain fins are used in those applications where core pressure drop is critical. An
exchanger with plain fins requires a smaller flow frontal area than that with
interrupted fins for specified pressure drop, heat transfer and mass flow rate. Of
course, the required passage length is higher leading to a larger overall volume.
Wavy Fins
Wavy fins are uninterrupted fin surfaces with cross-sectional
shapes similar to those of plain fins, but with cyclic lateral shifts perpendicular
to the flow direction (Fig.1.3 (c)). The resulting wave form provides effective
interruptions and induces a complex flow field. Heat transfer is enhanced due to
creation of Goertler vortices. These counter-rotating vortices form while the
fluid passes over the concave wave surfaces, and produce a corkscrew-like flow
pattern.
The heat transfer and pressure drop characteristics of a wavy fin surface lie
between those of plain and offset strip fins. The friction factor continues to fall
with increasing Reynolds number. Wavy fins are common in the hydrocarbon
industry where exchangers are designed with high mass velocities and moderate
thermal duties. Unlike offset strip fins, the thickness of wavy fins is not limited
at high fin densities. Therefore, wavy fins are often used for streams at high
pressure, particularly those which can tolerate somewhat poor heat transfer
coefficient.
14
Offset Strip Fins
This is the most widely used fin geometry in high
performance plate fin heat exchangers. It consists of a type of interrupted
surface, which may be visualised as a set of plain fins cut normal to the flow
direction at regular intervals, each segment being offset laterally by half the fin
spacing (Fig. 1.3 (d)). Surface interruption enhances heat transfer by two
independent mechanisms. First, it prevents the continuous growth of thermal
boundary layer by periodically interrupting it. The thinner boundary layer offers
lower thermal resistance compared to continuous fin types. Above a critical
Reynolds number, interrupted surfaces offer an additional mechanism of heat
transfer enhancement. Oscillations in the flow field in the form of vortices shed
from the trailing edges of the interrupted fins enhance local heat transfer by
continuously bringing in fresh fluid
15
The heat transfer performance of offset strip fin is often as much as 5 times that
of a plain fin surface of comparable geometry, but at the expense of higher
pressure drop. For specified heat transfer and pressure drop requirements, the
offset strip fin surface demands a somewhat higher frontal area compared to
those with plain fin, but results in a shorter flow length and lower overall
volume. An undesirable characteristic of this type of fin is that at high Reynolds
numbers the friction factor remains nearly constant (because of the higher
contribution of form drag), while the heat transfer performance goes down.
Therefore, offset strip fins are used less frequently in very high Reynolds
number applications. On the other hand, they are extensively used in air
separation and other cryogenic applications where mass velocities are low and
high thermal effectiveness is essential.
The louvered fin geometry shown in Fig. 1.3 (e) bears a similarity to
the offset strip fin. Instead of shifting the slit strips laterally, small segments of
the fin are slit and rotated 20 to 45 degrees relative to the flow direction. The
base surface of the louvered fin geometry can be of triangular or rectangular
shape, and louvers can be cut in many different forms.
The multilouvered fin has the highest heat transfer enhancement
relative to pressure drop in comparison with most other fin types. Flow over
louvered fin surfaces is similar in nature to that through the offset strip fin
geometry, with boundary layer interruption and vortex shedding playing major
roles. An important aspect of louvered fin performance is the degree to which
the flow follows the louver. At low Reynolds number the flow is nearly parallel
to the axial direction (duct flow), whereas at high Reynolds number the flow is
in the direction of the louvers (boundary layer flow). Louvered fins are
extensively used in automotive heat exchangers.
Perforated fins shown in Fig.1.3 (f) are made by punching a pattern of
spaced holes in the fin material before it is folded to form the flow channels.
The channels may be triangular or rectangular in shape with either round or
rectangular perforations. While this geometry, with boundary layer
interruptions, is a definite improvement over plain fins, its performance is
generally poorer than that of a good offset strip fin. Furthermore, the perforated
fin represents a wasteful way of making an enhanced surface, since the material
removed in creating the perforations is thrown out as scrap. Perforated fins are
now used only in limited number of applications such as turbulators in oil
coolers.
In a pin fin exchanger, a large number of small pins are sandwiched
between plates in either an inline or staggered arrangement. Pins may have a
round, an elliptical, or a rectangular cross section. These types of finned
surfaces are not widely used due to low compactness and high cost per unit
surface area compared to multilouvered or offset strip fins. Due to vortex
shedding behind the pins, noise and flow-induced vibration are produced, which
16
are generally not acceptable in most heat exchanger applications. The potential
application of pin fin surfaces is at low flow velocities (Re < 500), where
pressure drop is negligible. Pin fins are used as electronic cooling devices with
free-convection flow on the pin fin side.
J=h(Pr)^(2/3)/GCp
P=4fLG^2/(2Dhρ)
2
where, h = heat transfer coefficient (W/m K)
2
G = mass velocity (kg/m s) [on the basis of minimum free flow area]
L = length of flow passage (m)
Dh = hydraulic diameter (m), and
3
ρ = mean density of fluid (kg/m ).
The friction factor f takes both viscous shear (skin friction) and pressure forces
(form drag) into consideration. This approach is somewhat arbitrary since
geometric variables, other than the hydraulic diameter, may have a significant
effect on surface performance. It also becomes necessary to present j and f data
separately for each surface type. The j and f data so presented are applicable to
surfaces of any hydraulic diameter, provided a complete geometric similarity is
maintained.
One of the earliest and the most authoritative sources of experimental j and f
data on plate fin surfaces is the monograph Compact Heat Exchangers by Kays
and London [1]. Although nearly two decades have passed after the latest
edition, there has not been any significant addition to this database in open
literature. Attempts have been made towards numerical prediction of heat
transfer coefficient and friction factor; but they have generally been unable to
match experimental data. Several empirical correlations, however, have been
generated from the data of Kays and London, which have found extensive
application in industry, particularly in less-critical designs. For critical
applications, direct experimental determination of j and f factors for each fin
geometry remains the only choice.
17
In a plate fin heat exchanger, the hydraulic diameter of the
flow passage is generally small due to closely spaced fins. Operation with low
density gases leads to excessive pressure drop unless the gas velocity in the
flow passage is kept low. These factors imply operational Reynolds number less
than 10,000, the common range being between 500 and 3000 for most ground
based applications
18
RECTANGULAR OFFSET STRIP FIN
SURFACES
The offset strip fin is one of the most widely used finned surfaces,
particularly in high effectiveness heat exchangers employed in cryogenic and
aircraft applications. These fins are created by cutting a set of plain rectangular
fins periodically along the flow direction, and shifting each strip thus generated
by half the fin spacing alternately left and rightward. The flow is thus
periodically interrupted, leading to creation of fresh boundary layers and
consequent heat transfer enhancement. Interruption of flow also leads to greater
viscous pressure drop, manifested by a higher value of effective friction factor.
In addition to the effect of wall shear, resistance to flow also increases due to
form drag over the leading edges of the fin sections facing the flow, and due to
trailing edge vortices. The effective heat transfer coefficient and friction factor
are composite effects of the above mechanisms.
Figure
19
20
Design of compact plate fin heat exchanger using
Magahanic correlation
(1) Heat transfer data specification
a. fin thickness (t)=.2 mm
b. fin frequency(f) =714.25 fin per meter
c. fin length (l)=1.5 mm
d. fin height (h)=9.3 mm
e. fin spacing (s)=(1/f)-t
= (1/714.25)-.2
= 1.2 mm
f. plate thickness(b)= h + t
= 9.3+.2
=9.5 mm
g. free flow area (Aff) =(s-t)h
=(1.2-.2)*9.3
=9.6*10-6 m2
h. frontal area (A ) =(h+t)(s+t)
=(9.3+.2)(1.2+.2)
=.0000133 m2
i. heat transfer area (As)=2*h*l+2*s*l+2*h*l
=2*9.3*1.5+2*1.2*1.5+9.3*.2*2
=35.22 mm2
n. α =h/s=9.3/1.2=7.75
o. δ =l/s=1.5/1.2=1.25
p. ν = t/s=.2/1.2=.166
21
(2.) DATA INPUT
material of the fin =Al
conductivity of the fin material(Kf)=150 W/mK
end plate of thickness=6 mm
end bars thickness=6 mm
hot fluid cold fluid
inlet temp 310 k 99.716 K
Outlet temp 124.26 K 301.54 K
Mass flow rate .0822 Kg/s .07791 Kg/s
Pressure inlet 8 bar 1.15 bar
Allowable pressure drop .05 bar .05 bar
Density at avg. temp 1.583 1.711
(3) ASSUMPTION
avg. wall temp 200 K
width(w) .115 mm .115 mm
no of layers 5 4
area between plate .0054625 m2 .00437m2
A=(wbn)
For hot fluid =.115*9.5*.5
For cold fluid =.115*9.5*4
Free flow area .003819643 m2 .003055714 m2
( Aff=A*ζ)
For hot fluid =.0054625*.699
For cold fluid=.00437*.699
22
(c) core mass velocity(G)=mff /Aff
G=(.0822/.003819643)
=21.5203 Kg/sm2 (hot fluid)
=(.07791/.003055714)
=25.4964 Kg/sm2 (cold fluid)
=1077.7424
Since Re> Re*
F=.32(Re)(h/s).221(l/s)-0.185(t/s)-0.023
=.053 (hot fluid)
F= .02039 (cold fluid)
-0.42 .288 -0.184 -0.05
J=.18(Re) (h/s) (l/s) (t/s)
=.012 (hot fluid)
J=.01164 (cold fluid)
2
Pressure drop /length=(.5fG )Deq
=(.053*21.52032*1000)/(2*1.583*1.58)
=4931.727799 N/m3
h=jc p l/pr(2/3)
=344.704 (hot fluid)
=374.129 (cold fluid)
fin parameter
M=√2h/kft=√(2*344.704*1000)/(150*.2)
=151.5925 (hot fluid)
=√2*374.129*1000/(150*.2)
= 157.930 (cold fluid)
Mlf =Mb/2
=151.5925*9.5/2=.7200644
=157.930*9.5/2=.75016
nf =tanh(ml)/ml
=tanh(.7200644)/.7200644=.856797 (hot fluid)
=tanh(.75016)/.75016=.84680918 (cold fluid)
Overall efficiency=№ =1-(Af/As)(1- nf )
=1-.8977(1-.856797)
=.871434 (hot fluid)
=1-.8977(1-.84680)
23
=.862467 (cold fluid)
24
EFEECT OF LONGITUDNAL HEAT CONDUCTION
Heat conduction area = Aw=core width*total height-free flow area of hot side
- free flow area of cold side
=115*104.7-3819-3055
=5165 mm2
Cmin = .07791*1043=81.26
FOS = 2.47
UA = UAo*FOS
= 1088*2.47=2687.36
NTU = UA/Cmin
= ( 2687.36 )/81.26=33.071
λ = (KWAW)/LCmin
=(150*.005165)/( 2.022 *81.26)=.011641
Y = λ*NTU*CR
=.0116*33.071*.947
=.3649
γ=(1-CR)/(1-CR)(1+Y)
=(1-.9478)/(1+.9478)(1+.3649)
=.0196
Ψ=(1+ Ф)/(1- Ф)
=1.0076
r1=(1-CR)*NTU/(1+ λNTUCR)
=1.264
1-ε=(1-CR)/(Ψer1-CR)
=.0199
ε =.9800
Heat exchanger area=15.605m2
Required length = 2.022 m
25
RATING OF HEAT EXCHANGER
pressure drop
p /L=(fG2/2ρDeq)
=4038.829 Pa (hot fluid)
=4948.206647 Pa (cold fluid)
26
Design of compact plate fin heat exchanger using
Wieting correlations
(2) Heat transfer data specification
a. fin thickness (t)=.2 mm
b. fin frequency(f) =714.25 fin per meter
c. fin length (l)=1.5 mm
d. fin height (h)=9.3 mm
e. fin spacing (s) =(1/f)-t
= (1/714.25)-.2
= 1.2 mm plate thickness
n. α =s/h=1.2/9.3=.129
o. δ =t/l=.2/1.5=.133
27
p. ν = t/s=.2/1.2=.166
(2.) DATA INPUT
material of the fin =Al
conductivity of the fin material(Kf)=150 W/mK
end plate of thickness=6 mm
end bars thickness=6 mm
hot fluid cold fluid
inlet temp 310 k 99.716 K
Outlet temp 124.26 K 301.54 K
Mass flow rate .0822 Kg/s .07791 Kg/s
Pressure inlet 8 bar 1.15 bar
Allowable pressure drop .05 bar .05 bar
Density at avg. temp 1.583 1.711
(3) ASSUMPTION
avg. wall temp 200 K
width(w) .115 mm .115 mm
no of layers 7 6
area between plate .007647 m2 .006555m2
A=(wbn)
For hot fluid =.115*9.5*7
For cold fluid =.115*9.5*6
Free flow area .005347 m2 .004583 m2
( Aff=A*ζ)
For hot fluid =.007647*.699
For cold fluid=.006555*.699
28
(c) core mass velocity(G)=mff /Aff
G=(.0822/.005347)
=15.37166Kg/sm2 (hot fluid)
=(.07791/.004583)
=16.9976Kg/sm2 (cold fluid)
29
=.9048 (hot fluid)
=1-.8977(1-.8894)
=.9007 (cold fluid)
30
EFEECT OF LONGITUDNAL HEAT CONDUCTION
Heat conduction area = Aw=core width*total height-free flow area of hot side
- free flow area of cold side
=115*104.7-3819-3055
=6810 mm2
Cmin = .07791*1043=81.26
FOS = 2.5
UA = UAo*FOS
= 1088*2.5=2720W/K
NTU = UA/Cmin
= (2720 )/81.26=33.4727
λ = (KWAW)/LCmin
=(150*.005165)/( 2.72 *81.26)=.0119
Y = λ*NTU*CR
=.0119*33.4727*.94
=.3794
γ=(1-CR)/(1-CR)(1+Y)
=(1-.9478)/(1+.9478)(1+.3794)
=.0194
Ф=γ(Y/(1+Y)).5((1+ γ)Y/(1- γ(1+ γ)Y))
=.0039
Ψ=(1+ Ф)/(1- Ф)
=1.0079
r1=(1-CR)*NTU/(1+ λNTUCR)
=1.2666
1-ε=(1-CR)/(Ψer1-CR)
=.0199
ε =.98000
Heat exchanger area=22.64
Required length=2.62 m
31
Design of compact plate fin heat exchanger using
Joshi & Webb correlation
32
n. α =h/s=9.3/1.2=7.75
o. =l/s=1.5/1.2=1.25
p. ν = t/s=.2/1.2=.166
(2.) DATA INPUT
material of the fin =Al
conductivity of the fin material(Kf)=150 W/mK
end plate of thickness=6 mm
end bars thickness=6 mm
hot fluid cold fluid
inlet temp 310 k 99.716 K
Outlet temp 124.26 K 301.54 K
Mass flow rate .0822 Kg/s .07791 Kg/s
Pressure inlet 8 bar 1.15 bar
Allowable pressure drop .05 bar .05 bar
Density at avg. temp 1.583 1.711
(3) ASSUMPTION
avg. wall temp 200 K
width(w) .115 mm .115 mm
no of layers 6 5
area between plate .00655 m2 .00546m2
A=(wbn)
For hot fluid =.115*9.5*.5
For cold fluid =.115*9.5*4
Free flow area .00458m2 .003819 m2
( Aff=A*ζ)
For hot fluid =.00655*.699
33
Properties
Hot fluid cold fluid
Sp. Heat (cp ) 1043 J/Kg-K 1043 J/Kg-K
Viscosity( μ ) .0000134 N/m2-s .00001295 N/m2- s
Predelt number .74767 .75
=(.07791/.0038)
=(20.39*1.58)/.0000134
J =.21(2120.35)-0.4(1.5/1.58)-0.24 (.2/1.58)0.02
34
J=.00893 (cold fluid)
h=jc p l/pr(2/3)
= 216.537 (hot fluid)
=√2*230.26*1000/(150*.2)
Uo = 110.688W/m2 K
35
(6) heat transfer area m/m2
UA for heat exchanger = 1088 W/K
Required heat transfer area = 9.829 m2
Required heat transfer area /length
A/L=9.6435 =4Amin(ff)/Deq
Required length of heat exchanger
L=1019 m
(7) pressure drop
p /L=(fG2/2ρDeq)
=3385.008 Pa (hot fluid)
=3821.286 Pa (cold fluid)
(8) final dimensions
Core length =1019 mm (without longitudinal heat conduction)
Core width =115 mm
Total width =115+2*6=127 mm
no of HP side =6
no of LP side =5
core height =(nc+nh)*b+(nc+nh)*a
=113.14mm
Total height =113.14+2*6=125.14 mm
36
EFEECT OF LONGITUDNAL HEAT CONDUCTION
Heat conduction area = Aw=core width*total height-free flow area of hot side
- free flow area of cold side
=115*104.7-3819-3055
=5987 mm2
Cmin = .07791*1043=81.26
FOS = 2.41
UA = UAo*FOS
= 1088*2.41=2622.08W/K
NTU = UA/Cmin
= (2622.08 )/81.26=32.26
λ = (KWAW)/LCmin
=(150*.005987)/( 2.41 *81.26)=.0108
Y = λ*NTU*CR
=.0108*32.26*.94
=.3314
γ=(1-CR)/(1-CR)(1+Y)
=(1-.9478)/(1+.9478)(1+.3314)
=.0201
Ψ=(1+ Ф)/(1- Ф)
=1.006
r1=(1-CR)*NTU/(1+ λNTUCR)
=1.265
1-ε=(1-CR)/(Ψer1-CR)
=.0199
ε =.98
Heat exchanger area = 23.688 m2
Heat exchanger length=2.45 m
37
Design of compact plate fin heat exchanger using
Deepak & Maity correlations
(4) Heat transfer data specification
a. fin thickness (t)=.2 mm
b. fin frequency(f) =714.25 fin per meter
c. fin length (l)=1.5 mm
d. fin height (h)=9.3 mm
e. fin spacing (s)=(1/f)-t
= (1/714.25)-.2
= 1.2 mm plate thickness
n. α =h/s=9.3/1.2=7.75
o. δ =l/s=1.5/1.2=1.25
38
p. ν = t/s=.2/1.2=.166
(2.) DATA INPUT
material of the fin =Al
conductivity of the fin material(Kf)=150 W/mK
end plate of thickness=6 mm
end bars thickness=6 mm
hot fluid cold fluid
inlet temp 310 k 99.716 K
Outlet temp 124.26 K 301.54 K
Mass flow rate .0822 Kg/s .07791 Kg/s
Pressure inlet 8 bar 1.15 bar
Allowable pressure drop .05 bar .05 bar
Density at avg. temp 1.583 1.711
(3) ASSUMPTION
avg. wall temp 200 K
width(w) .2 m .2m
no of layers 10 9
area between plate .019 m2 .0171m2
A=(wbn)
For hot fluid =.2*.0095*10
For cold fluid =.2*.0095*9
Free flow area .0132 m2 .0119 m2
( Aff=A*ζ)
For hot fluid =.019*.699
For cold fluid=.0171*.699
39
(c) core mass velocity(G)=mff /Aff
G=(.0822/.0132)
=6.187 Kg/sm2 (hot fluid)
=(.07791/.0119)
=6.58 Kg/sm2 (cold fluid)
J=.18Re-0.42(α)0.288(δ )-.184(γ)-.05
=.02350 (hot fluid)
=.02209 (cold fluid)
Re*=648.23*(α)-.06 *(δ).1*(γ)-.196
=832.874(hot fluid)
=832.874(cold fluid)
F=.32Re-0.286(α)0.221(δ )-.185(γ)-.023
=.08118 (hot fluid)
=.07523 (cold fluid)
Pressure drop /length=(4fG2)/2ρDeq
=312.95 N/m3 (hot fluid)
=2201.312 N/m3 (cold fluid)
Pressure drop =387.061N/m2 (hot fluid)
=2722.59 N/m2 (cold fluid)
h=jc p l/pr(2/3)
=194.118 (hot fluid)
=190.447 (cold fluid)
fin parameter
M=√2h/kft=√ (2*194.118*1000)/(150*.2)
=113.75 (hot fluid)
=√ (2*190.447*1000)/(150*.2)
= 112.67 (cold fluid)
Mlf =Mb/2
=113.75*9.5/2=.5289 (hot fluid)
=112.67*9.5/2=.5239 (cold fluid)
nf =tanh(ml)/ml
40
=tanh(.5289)/.5289=.9161 (hot fluid)
=tanh(.5239)/.5239=.9175 (cold fluid)
Overall efficiency=№ =1-(Af/As)(1- nf )
=1-.8977(1-.9161)
=.9246 (hot fluid)
=1-.8977(1-.9175)
=.9259 (cold fluid)
41
EFEECT OF LONGITUDNAL HEAT CONDUCTION
Heat conduction area = Aw=core width*total height-free flow area of hot side
- free flow area of cold side
=115*104.7-3819-3055
=5165 mm2
Cmin = .07791*1043=81.26
FOS = 1.91
UA = UAo*FOS
= 1088*1.91=3479.92 W/K
NTU = UA/Cmin
= ( 3479.92 )/81.26=42.27
λ = (KWAW)/LCmin
=(150*.005165)/( 1.236 *81.26)=.023
Y = λ*NTU*CR
=.023*42.27*.94
=.9413
γ=(1-CR)/(1-CR)(1+Y)
=(1-.9478)/(1+.9478)(1+.9413)
=.0172
Ψ=(1+ Ф)/(1- Ф)
=1.0236
r1=(1-CR)*NTU/(1+ λNTUCR)
=1.4084
1-ε=(1-CR)/(Ψer1-CR)
=.019
ε =.98
42
PLATE FIN HEAT EXCHANGER DESIGN USING MANGAHANIC CORRELATION
1) Heat Exchanger Design Specifications
a) Type of heat exchanger : Plain plate fin heat exchanger
b) Fin type Offset Serrated
c) Fin thickness, t 0.0002 m 0.2 mm 0.0002 m 0.2 mm
d) Fin frequency, f 714.25 fpm 714.25 fpm
e) Fin length, Lf 0.0015 m 1.5 mm 0.0015 m 1.5 mm
f) Fin height, h 0.0093 m 9.3 mm 0.0093 m 9.3 mm
g) Plate thickness, a 0.0008 m 0.8 mm 0.0008 m 0.8 mm
h) Fin spacing, s 0.0012 m 1.2 mm 0.0012 m 1.2 mm
i) Plate Spacing, b 0.0095 m 9.5 mm 0.0095 m 9.5 mm
2 2
j) Free flow area per fin , a ff 0.0000093 m 0.0000093 m
2
k) Frontal area per fin, a fr 0.0000133 m 0.0000133 m2
2) Data input:
hot fluid: cold fluid:
Inlet temperature, 310 K 99.716 K
Outlet temperature, 124.26 K 301.54 K
Mass flow rate, 0.0822 kg/s 0.07791 kg/s
Pressure at inlet, 8 bar 1.15 bar
Allowable pressure drop 0.05 bar 0.05 bar
3
Density at a verage temperature, 1.583 Kg/m 1.711 Kg/m 3
3) Assumptions:
a) Average wall temperature, Tw = 200 K
b) Width, W 0.115 m 115 mm 0.115 m
c) Number of Layers 5 4
a) Area between plates 0.0054625 m2 0.00437
2
b) Free flow area , Aff 0.003819643 m 0.003055714
43
b) The mean film temperature,Tm 208.565 K 200.314 K
c) Properties at the mean film temperature
Specific heat, Cp 1043 J/Kg-K 1043 J/Kg-K
Viscocity, μ 0.0000134 N/m -s
2
0.00001295 N/m2-sec
Prandtl number, Pr 0.74767 0.75
2
d) Core mass velocity, G 21.52033661 kg/s-m 25.49649369 kg/s-m2
e) The Reynold's number, Re 2544.421806 3119.288461
f) Critical Reynold's number Re*j 1077.742419 1077.742419
g) Critical Reynold's number Re*f 832.8747012 832.8747012
h) J 0.01265 0.01161
i) F 0.05341 0.05039
j) Pressure drop per length, Δp/L 4931.722799 6042.142505
k) Convective Heat transfer Coefficient, h 344.7043956 374.129065
l) The fin parameter,M 151.592523 157.9301671
m) MLf 0.720064484 0.750168294
n) The fin effectiveness, ηf 0.856797214 0.846809108
The surface effectiveness, ηo 0.871434637 0.862467461
Remarks Design is OK
9) Effect of logitudnal heat conduction
Aw 0.005165143 m2
Cmin 81.26013
FOS 2.47
UA 2687.36 W/K
44
NTU 33.0710768
Λ 0.011641587
Cr 0.9478
Y 0.364902822
Γ 0.019634706
Ф 0.00380512
Ψ 1.007639308
r1 1.264786167
1-ε 0.019911533
Ε 0.980088467
heat exchanger area 15.60564439 m2
length of heat exchanger 2.022804065 m2
45
PLATE FIN HEAT EXCHANGER DESIGN USING WIETING CORRELTION
1) Heat Exchanger Design Specifications
a) Type of heat exchanger : Plain plate fin heat exchanger
b) Fin type Offset Serrated
c) Fin thickness, t 0.0002 m 0.2 mm 0.0002 m 0.2 mm
d) Fin frequency, f 714.25 fpm 714.25 fpm
e) Fin length, Lf 0.0015 m 1.5 mm 0.0015 m 1.5 mm
f) Fin height, h 0.0093 m 9.3 mm 0.0093 m 9.3 mm
g) Plate thickness, a 0.0008 m 0.8 mm 0.0008 m 0.8 mm
h) Fin spacing, s 0.0012 m 1.2 mm 0.0012 m 1.2 mm
i) Plate Spacing, b 0.0095 m 9.5 mm 0.0095 m 9.5 mm
2 2
j) Free flow area per fin , aff 0.0000093 m 0.0000093 m
2 2
k) Front al area per fin, af r 0.0000133 m 0.0000133 m
2 2
l) Heat transfer area, A s 0.00003522 m 0.00003522 m
2 2
m) Fin area , Af 0.00003162 m 0.00003162 m
n) Equivalent diameter,De 0.002125714 m 2.12571429 mm 0.002125714 m 2.126 mm
Fin area /total surface area, A f
2 2 2 2
o) /As 0.897785349 m /m 0.897785349 m /m
2 2 2 2
p) Front al area ratio,ζ =Aff / Afr 0.69924812 m /m 0.69924812 m /m
q) α = s/h 0.129032258 0.129032258
r) δ = t/l 0.133333333 0.133333333
s) γ=t/s 0.166666667 0.166666667
t) Conductivity of fin material, Kf 150 W/m-K 150 W/m-K
u) End Plate Thickness 6 Mm
v) End Bars/ End Bars Thickness 6 Mm
2) Data input:
hot fluid: cold fluid:
Inlet temperature, 310 K 99.716 K
Outlet temperature, 124.26 K 301.54 K
Mass flow rate, 0.0822 kg/s 0.07791 kg/s
Pressure at inlet, 8 Bar 1.15 bar
Allowable pressure drop 0.05 Bar 0.05 bar
Density at average
1.583 3 3
temperature, Kg/m 1.711 Kg/m
3) Assumptions:
A verage wall temperature, Tw
a) = 200 K
b) Width, W 0.115 M 115 mm 0.115 m
c) Number of Layers 7 6
a) Area between plates 0.0076475 m2 0.006555
2
b) Free flow area , Aff 0.0053475 m 0.004583571
46
side
A verage or bulk
a) temperature, Tavg 217.13 K 200.628 K
b) The mean film temperature, Tm 208.565 K 200.314 K
c) Properties at the mean film temperature
Specific heat, Cp 1043 J/Kg-K 1043 J/Kg-K
2
Viscocity, μ 0.0000134 N/m -s 0.00001295 N/m2-sec
Prandtl number, Pr 0.74767 0.75
2
d) Core mass velocity, G 15.371669 kg/s-m 16.99766246 kg/s-m2
e) The Reynold's number, Re 2438.490776 2790.12926
f) Critical Reynold's number Re1 1000 1000
g) Critical Reynold's number Re2 2000 2000
h) j 0.01244 0.01184
i) f 0.09012 0.08775
j) Pressure drop per length, Δp/L 3164.2519 3485.41642
Convective Heat transfer
k) Coefficient, h 242.0763791 254.2087757
l) The fin parameter,M 127.037102 130.1816105
m) MLf 0.603426234 0.61836265
n) The fin effectiveness, ηf 0.894033241 0.889424648
The surface effectiveness, ηo 0.904864596 0.900727069
47
Design i s
Remarks OK
9) Effect of logitudnal heat conduction
Aw 0.006810629 m2
Cmin 81.26013
FOS 2.5
UA 2720 W/K
NTU 33.4727498
λ 0.011961847
Cr 0.9478
y 0.37949523
γ 0.019427009
Ф 0.003971804
Ψ 1.007975284
r1 1.266606438
1-ε 0.019853256
Ε 0.980146744
heat transfer area 22.64433405 m2
length of heat exchanger 2.625430034 m
48
PLATE FIN HEAT EXCHANGER DESIGN USING JOSHI &WEBB CORRELATION
1) Heat Exchanger Design Specifications
a) Type of heat exchanger : Plain plate fin heat exchanger
b) Fin type Offset Serrated
c) Fin thickness, t 0.0002 m 0.2 mm 0.0002 m 0.2 mm
d) Fin frequency, f 714.25 fpm 714.25 fpm
e) Fin length, Lf 0.0015 m 1.5 mm 0.0015 m 1.5 Mm
f) Fin height, h 0.0093 m 9.3 mm 0.0093 m 9.3 Mm
g) Plate thickness, a 0.0008 m 0.8 mm 0.0008 m 0.8 Mm
h) Fin spacing, s 0.0012 m 1.2 mm 0.0012 m 1.2 Mm
i) Plate Spacing, b 0.0095 m 9.5 mm 0.0095 m 9.5 Mm
2 2
j) Free flow area per fin , a ff 0.0000093 m 0.0000093 m
2
k) Frontal area per fin, a fr 0.0000133 m 0.0000133 m2
2) Data input:
hot fluid: cold fluid:
Inlet temperature, 310 K 99.716 K
Outlet temperature, 124.26 K 301.54 K
Mass flow rate, 0.0822 kg/s 0.07791 kg/s
Pressure at inlet, 8 bar 1.15 bar
Allowable pressure drop 0.05 bar 0.05 bar
Density at a verage temperature, 1.583 Kg/m 3 1.711 Kg/m 3
3) Assumptions:
a) Average wall temperature, Tw = 200 K
b) Width, W 0.115 m 115 mm 0.115 m
c) Number of Layers 6 5
a) Area between plates 0.006555 m2 0.0054625
b) Free flow area , Aff 0.004583571 m2 0.003819643
49
c) Properties at the mean film temperature
Specific heat, Cp 1043 J/Kg-K 1043 J/Kg-K
Viscocity, μ 0.0000134 2
N/m -s 0.00001295 N/m2-sec
Prandtl number, Pr 0.74767 0.75
2
d) Core mass velocity, G 17.93361384 kg/s-m 20.39719495 kg/s-m2
e) The Reynold's number, Re 2120.351505 2495.430769
f) Critical Reynold's number Re1 681.1382467 690.9666918
g) Critical Reynold's number Re2 2000 2000
h) J 0.00954 0.00893
i) F 0.05180 0.04885
j) Pressure drop per length, Δp/L 3321.485567 3748.892456
k) Convective Heat transfer Coefficient, h 216.5340502 230.267632
l) The fin parameter,M 120.1482557 123.8998606
m) MLf 0.570704215 0.588524338
n) The fin effectiveness, ηf 0.903929313 0.898575355
The surface effectiveness, ηo 0.913749145 0.90894244
5) Overall heat transfer coefficient,W/m2-K
a) Total area/seperating surface (wall) area,Ao/Aw 8.385784167 m 2/m2 8.385784167 m 2/m2
2
b) Ovearall thermal resistance,1/Uo 0.009034333 m K/W
c) Overall heat transfer coefficient,Uo 110.6888519 W/m 2-K
Remarks Design is OK
effect of logitudnal heat conduction
Aw 0.005987886
Cmin 81.26013
FOS 2.41
UA 2622.08
NTU 32.2677308
Λ 0.010836451
Cr 0.9478
Y 0.331415035
50
Γ 0.020128559
Φ 0.003418493
Ψ 1.006860439
r1 1.265101793
1-ε 0.019923945
Ε 0.980076055
Area 23.68874513
Length 2.456428648
51
PLATE FIN HEAT EXCHANGER 1 DESIGN (Deepak corelation)
1) Fluid Data input:
Working Fluid Pres Temp Dens H Cp Viscosity Prandtl#
Nitrogen bar K kg/m3 KJ/kg KJ/kg K Pa-s
HP Inlet 8 310.00 8.70041 320.436 1.0507 0.0000185 0.71675
HP Exit 7.95 120.45 24.59257 114.67011 1.21522 0.0000084 0.7680636
HP Mean 7.975 215.225 12.64345 220.14748 1.0706 0.0000139 0.7181032
LP Inlet 1.15 100.74 3.93202 102.49171 1.0705 0.0000068 0.7254834
LP Exit 1.1 305.80 1.21202 317.47858 1.04036 0.0000182 0.7162658
LP Mean 1.125 203.27 1.86879 210.59691 1.04589 0.0000131 0.7136091
1.1 310 1.19555 321.84803 1.04033 0.0000184 0.7163585
Mass
Mass Flow Flow
rate rate Ch Cc Cmin Cmax Cr
kg/ s
kg/ s (HP (LP
Side) side) W/K W/K W/K W/K
0.0822 0.0787 88.00332 82.311543 82.311543 88.00332 0.93532316
NTU, UA,
ε UA, W/K LMTD Q, Watts
Req LMTD
0.9801 22.1348 1821.94954 10.032072 16913.95616 1685.9884
52
r) δ = l/s 1.25 1.25
s) γ=t/s 0.166666667 0.166666667
Conductivity of fin material,
t) Kf 150 W/m-K 150 W/m-K
u) End Plate Thickness 6 mm
End Bars/ End Bars
v) Thickness 6 mm
3) Assumptions:
a) Width, W 0.2 m 200 mm 0.2 M
b) Number of Layers, n 10 9
53
Required heat trans fer area
2 2
per length , A /L 30.18857143 m /m 30.18857143 m /m
The required length of the
heat exchanger, L 1.23680429 m 0.647541513 m
7) Pressure drop,Δp
Critical Reynold's number
a) Re*f 832.8747012 832.8747012
f factor 0.08188 0.07523
Pressure drop per length,
2
Δp/L=4f G /(2 De) 312.9525781 2201.312508
pressure drop,Δp 387.0610911 Pa 2722.592753 Pa
0.003870611 bar 0.027225928 bar
Longitudinal heat
9) conduction
Conduction area 0.016157143
λ=KwAw/LCmin 0.02380642
Y=λNtuCr 0.941379538
γ=(1-Cr)/((1+ Cr)*(1+Y) 0.017214122
Φ=γ (Y/(1+Y))^0.5*Y*(1+γ)/(1-
γ(1+γ)) 0.011670991
Ψ=(1+ Φ)/(1-Φ) 1.023617623
r1=(1-Cr)Ntu/(1+λ*Ntu*Cr) 1.408469158
1-ε=(1-Cr)/ (Ψexp(r1)-Cr) 0.019894718
ε 0.980105282
54
55
56
CONCLUSION
58
affordability of most heat exchanger designers. Under these
circumstances the approach taken in this design provides a workable
solution.
59
REFERENCES
60
11. Shah, R. K. and Webb, R. L. Compact and Enhanced Heat
Exchangers, in J. Taborek, G. F. Hewitt and N. Afgan (Eds), Heat
Exchangers – Theory and Practice McGraw Hill, New York, 425-468
(1983)
12. London, A. L. Compact Heat Exchangers – Design Methodology
in S. Kakac, R. K. Shah and A. E. Bergles (Eds), Low Reynolds
Number Flow Heat Exchangers, Hemisphere Publishing Corp.
Washington DC, 21-27 (1983)
61