Transcript ME 414 Project 2 Heat Exchanger Design

ME 414 Project 2
Heat Exchanger Design
Date: - May 6, 2009
Instructor: - John Toksoy
Member: - Rahul Patel
Hesam Nouri
Atoosa Solhkonan
Juan Tapia
Appendix
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Problem Defined
Objective and Specification
Design Heat Exchanger
Results Summary
Conclusion
Problem Defined
• Chemical temperature must be cooled by at least
20 degrees Celsius
• Mass flow rate is 220,000 kg/hr.
• Material properties must be defined as water.
• City Water Temperature must be 20 C.
• Length of the heat exchanger can not exceed 7
meters.
• Minimize pressure drop, shell and tube weight.
• Shell Diameter should not exceed 2 meters.
Objective
• Calculate the heat transfer ratio between 0.95
and 1.
• Minimize the weight of the Heat Exchanger.
• Minimize the pressure drop for the shell and
tube side.
Design Heat Exchanger
• First use notes and your experience to
eliminate the variables.
• Use matlab and Minitab to run the DOE on the
variable to see their effect.
• Find the final 4 or 5 variables that effect the
heat exchanger design.
Variables
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Shell and Tube Fluid
Mdot Shell and Tube
Temperature of Shell in and Out
Temperature of Tube in and Out
Rf of Tube in
Rf of Tube Shell side
Shell tube side fluid reversed
Type of Flow
Number of shell and tube pass
Type of baffle
Baffle space and cut
Shell ID and thickness
Nusselt Shell and Tube
Pressure shell and Tube
Tube OD and thickness
Tube length and number of tubes
Tube Pithch and layout angle
Input Variables
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Shell and Tube Fluid: Water
Temperature of Shell in: 20 C
Temperature of Tube in: 45 C
Temperature of Tube Out: 25 C
Type of flow: Counter flow
Number of tube pass: 1
Number of Shell pass: 1
Design of Experiment (DOE)
• Total variables: 32
• Eliminated 22 variables including the inputs
using notes and experiences.
• 10 Variables so 2 DOE for 5 variables in each
• Reduced 6 variables using DOE
• Final Variables: Mdot shell, Shell ID, Tube OD
and length,
First DOE: Main Effect Plots
Data Means
Data Means
Data Means
I_counter_flow
Main Effects Plot for q Calc
Main Effects Plot for q Desired
Main Effects Plot for q (des - calc)
mdot_shell
I_counter_flow
Tube_Len
1000000
mdot_shell
I_counter_flow
Tube_Len
5500000
mdot_shell
Tube_Len
6000000
5250000
0
5000000
5000000
1.25
300
Baffle_Space
500
4.875
8.125
Tube_th
Mean
Mean
0.75
4500000
0.75
1.25
300
Baffle_Space
500
4.875
8.125
Mean
4750000
-1000000
4.875
8.125
4000000
4750000
0.390525
0.650875
0.0006668
0.390525
0.390525
0.0011113
0.650875
0.650875
mdot_shell
I_counter_flow
Tube_Len
0.0006668
0.0011113
0.0011113
Main Effects Plot for Weight_HE
Data Means
Data Means
Data Means
I_counter_flow
0.0006668
Main Effects Plot for DP shell
Main Effects Plot for DP Tube
mdot_shell
Tube_Len
16000
I_counter_flow
mdot_shell
Tube_Len
12000000
14000
10000000
280
8000000
12000
6000000
10000
0.75
1.25
300
Baffle_Space
500
4.875
8.125
Mean
4000000
200
0.75
1.25
Baffle_Space
Tube_th
300
500
Tube_th
12000000
4.875
8.125
Mean
240
Mean
500
Tube_th
5000000
4500000
320
300
5000000
-1000000
320
1.25
Baffle_Space
6000000
5250000
0
0.75
Tube_th
5500000
1000000
4000000
0.75
16000
1.25
Baffle_Space
300
500
Tube_th
14000
10000000
280
12000
8000000
6000000
240
10000
4000000
0.390525
200
0.390525
0.390525
0.650875
0.0006668
0.0011113
0.650875
0.0006668
0.0011113
0.650875
0.0006668
0.0011113
4.875
8.125
First DOE: Pareto Charts
Pareto Chart of the Standardized Effects
Pareto Chart of the Standardized Effects
Pareto Chart of the Standardized Effects
(response is DP shell, Alpha = 0.05)
(response is Weight_HE, Alpha = 0.05)
(response is DP Tube, Alpha = 0.05)
2.06
2.05
F actor
B
C
D
D
2.05
N ame
mdot_shell
Tube_Len
Baffle_S pace
B
Tube_Len
BD
Term
Term
Term
Tube_Len
C
Tube_th
CD
Tube_th
BC
0
0
10
20
30
40
50
Standardized Effect
60
70
10
80
Pareto Chart of the Standardized Effects
20
30
Standardized Effect
40
0
50
Pareto Chart of the Standardized Effects
(response is q Calc, Alpha = 0.05)
(response is q (des - calc), Alpha = 0.05)
2.1
2.1
F actor
B
C
D
E
C
Tube_Len
E
Term
Term
Tube_th
B
Baffle_Space
D
mdot_shell
BC
0
20
40
60
80
100
Standardized Effect
120
140
160
0
50
100
Standardized Effect
150
200
N ame
mdot_shell
Tube_Len
Baffle_S pace
Tube_th
10
20
30
Standardized Effect
40
50
First DOE: Optimization
mdot_sheTube_Len Baffle_S
Optimal
High
500.0
8.1250 0.6509
D
Cur [302.0202][4.8750] [0.3905]
0.93553 Low
300.0
4.8750 0.3905
Composite
Desirability
0.93553
Weight_H
Targ: 8400.0
y = 8451.2000
d = 0.96800
DP shell
Targ: 5150000.0
y = 5.236E+06
d = 0.97762
DP Tube
Targ: 185.0
y = 188.270
d = 0.78200
q Calc
Targ: 3800000.0
y = 3.781E+06
d = 0.98511
q (des Targ: 1300000.0
y = 1.303E+06
d = 0.98300
Tube_th
0.0011
[0.0007]
0.0007
Second DOE: Main Effect Plots
1000000
Data Means
Data Means
Data Means
Baffle_Cut
Main Effects Plot for q Calc
Main Effects Plot for q Desired
Main Effects Plot for q (Des - calc)
Shell_ID
Baffle_Cut
I_Shell_mat
Shell_ID
Baffle_Cut
I_Shell_mat
5500000
5000000
0.495300
0.74295
Tube_OD
1000000
1.23825
1.5
2.5
Shell_th
4500000
4500000
0.371475
0.495300
Tube_OD
0.74295
1.23825
1.5
2.5
Shell_th
Mean
0.371475
Mean
Mean
5000000
4750000
-1000000
I_Shell_mat
6000000
5250000
0
Shell_ID
6500000
5500000
0.371475
0.495300
Tube_OD
0.74295
0.0142875
0.0165
1.23825
1.5
2.5
Shell_th
6500000
5500000
6000000
5250000
0
5500000
5000000
5000000
4750000
4500000
-1000000
4500000
0.0142875
0.0142875
0.0238125
0.0165
0.0275
0.0238125
0.0275
Main Effects Plot for Weight_HE
Main Effects Plot for DP Shell
Data Means
Data Means
Data Means
Shell_ID
I_Shell_mat
Baffle_C ut
Shell_ID
Baffle_Cut
I_Shell_mat
1000
8000000
14000
750
7000000
12000
500
6000000
250
5000000
Shell_ID
I_Shell_mat
0.371475
0.495300
0.74295
Tube_OD
1.23825
Shell_th
1.5
2.5
4000000
0.371475
0.495300
Tube_OD
1000
8000000
750
7000000
500
6000000
250
5000000
0
0.0142875
0.0238125
0.0165
0.0275
0.74295
1.23825
Shell_th
1.5
2.5
Mean
10000
0
Mean
Mean
0.0165
0.0275
Main Effects Plot for DP Tube
Baffle_C ut
0.0238125
8000
0.371475
0.495300
0.74295
Tube_OD
1.23825
Shell_th
14000
12000
10000
8000
4000000
0.0142875
0.0238125
0.0165
0.0275
0.0142875
0.0238125
0.0165
0.0275
1.5
2.5
Second DOE: Pareto Charts
Pareto Chart of the Standardized Effects
(response is DP Tube, Alpha = 0.05)
(response is DP Shell, Alpha = 0.05)
2.1
2.05
F actor
B
C
D
E
B
C
N ame
S hell_ID
I_S hell_mat
Tube_O D
S hell_th
Term
E
Term
Tube_OD
D
Term
Pareto Chart of the Effects
Pareto Chart of the Standardized Effects
(response is Weight_HE, Alpha = 0.05)
CE
Tube_OD
Shell_ID
BC
BE
0
50
100
150
Standardized Effect
200
0
5
Pareto Chart of the Standardized Effects
10
15
20
Standardized Effect
25
30
Pareto Chart of the Standardized Effects
(response is q Calc, Alpha = 0.05)
(response is q (Des - calc), Alpha = 0.05)
2.0
2.0
Tube_OD
Term
Term
Tube_OD
Shell_ID
Shell_ID
0
20
40
60
Standardized Effect
80
100
0
20
40
60
Standardized Effect
80
100
0
200
400
600
Effect
800
1000
1200
Second DOE: Optimization
Baffle_C Shell_ID I_Shell_ Tube_OD Shell_th
Optimal
High
0.4953 1.2383
2.50
0.0238 0.0275
D
Cur [0.3715] [0.9631] [1.50] [0.0194] [0.0179]
0.84011 Low 0.3715 0.7430
1.50
0.0143 0.0165
Composite
Desirability
0.84011
Weight_H
Targ: 11500.0
y = 1.150E+04
d = 0.99949
DP Shell
Targ: 6500000.0
y = 6.496E+06
d = 0.99223
DP Tube
Targ: 625.0
y = 579.8636
d = 0.63891
q Calc
Targ: 5500000.0
y = 5.411E+06
d = 0.82195
q Desire
Targ: 5150000.0
y = 5.106E+06
d = 0.70843
q (Des Targ: -300000.0
y = -3.05E+05
Final: Main Effect Plots
Main Effects Plot for Weight_HE
Main Effects Plot for DP Shell
Data Means
mdot_shell
20000
Main Effects Plot for DP Tube
Data Means
Tube_len
mdot_shell
10000000
18000
Data Means
mdot_shell
Tube_len
1800
8000000
16000
1200
6000000
225
375
4.5
Shell_ID
20000
7.5
Tube_OD
600
4000000
225
375
10000000
18000
4.5
Shell_ID
7.5
Tube_OD
Mean
12000
Mean
225
375
4.5
7.5
Shell_ID
Tube_OD
1800
8000000
16000
0
2400
1200
14000
6000000
12000
4000000
0.74295
1.23825
0.0142875
0.0238125
600
0
0.74295
1.23825
0.74295
0.0238125
Main Effects Plot for q desired
Main Effects Plot for q calc
Tube_len
5250000
6000000
mdot_shell
1000000
5500000
7000000
0.0142875
0.0238125
Data Means
mdot_shell
Tube_len
1.23825
Main Effects Plot for q (des - calc)
Data Means
Data Means
mdot_shell
0.0142875
Tube_len
0
5000000
5000000
-1000000
4000000
225
375
4.5
Shell_ID
7.5
Tube_OD
Mean
4750000
4500000
225
375
4.5
Shell_ID
7.5
Tube_OD
5250000
6000000
-2000000
225
375
4.5
Shell_ID
1000000
5500000
7000000
Mean
Mean
14000
Mean
Tube_len
2400
7.5
Tube_OD
0
5000000
-1000000
4750000
5000000
4500000
4000000
0.74295
0.74295
1.23825
0.0142875
0.0238125
1.23825
0.0142875
0.0238125
-2000000
0.74295
1.23825
0.0142875
0.0238125
Final: Pareto Charts
Pareto Chart of the Standardized Effects
Pareto Chart of the Standardized Effects
Pareto Chart of the Standardized Effects
(response is DP Shell, Alpha = 0.05)
(response is Weight_HE, Alpha = 0.05)
(response is DP Tube, Alpha = 0.05)
2.201
2.20
F actor
B
C
D
B
N ame
Tube_len
S hell_ID
Tube_O D
2.16
mdot_shell
Tube_OD
Term
Term
Term
Tube_OD
C
Tube_len
D
Tube_len
Shell_ID
BC
0
0
5
10
15
20
Standardized Effect
25
1
2
30
5
6
7
(response is q (des - calc), Alpha = 0.05)
(response is q (des - calc), Alpha = 0.05)
3.2
2.31
F actor
A
B
C
D
B
D
F actor
A
B
C
D
B
N ame
mdot_shell
Tube_len
S hell_ID
Tube_O D
D
BD
A
C
Term
BD
A
AD
CD
AB
C
BC
ABD
AD
BCD
AC
CD
0
0
0
Pareto Chart of the Standardized Effects
Pareto Chart of the Standardized Effects
Term
3
4
Standardized Effect
10
20
30
40
50
Standardized Effect
60
70
80
50
100
150
200
Standardized Effect
250
300
N ame
mdot_shell
Tube_len
S hell_ID
Tube_O D
2
4
6
8
10
12
Standardized Effect
14
16
18
Final: Optimization
Final Variables Calculated
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Desired/Calculated Heat Transfer Rate = 1.00
Overall System Weight = 14382.27 kg
Tube-side Pressure Drop = 417.46 Pa
Shell-side Pressure Drop = 3092917.05 Pa
Questions