DESIGN OF COMPACT PLATE FIN HEAT EXCHANGER

A THESIS SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE DEGREE OF

Bachelor of Technology In Mechanical Engineering By

JAINENDER DEWATWAL (ROLL.NUMBER: 10503059)

Department of Mechanical Engineering National Institute of Technology Rourkela 2009

DESIGN OF COMPACT PLATE FIN HEAT EXCHANGER

A THESIS SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE DEGREE OF Bachelor of Technology In Mechanical Engineering By

JAINENDER DEWATWAL (ROLL.NUMBER: 10503059)

Under the Guidance of PROF. R.K.Sahoo

Department of Mechanical Engineering National Institute of Technology Rourkela 2009

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.

Date:

Prof. R.K.Sahoo Dept. of Mechanical Engineering National Institute of Technology Rourkela 769008

Signature:

India

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.

Date:

Jainender Dewatwal Dept. of Mechanical Engineering National Institute of Technology Rourkela 769008

Signature:

India

INDEX

Sl .No 1. 2. 3. 4. 4.1 4.2 4.3 5. 6. 6.1 6.2 6.3 6.4 7. 8. 9. 10. Certificate

Topic

Page 3 4 6 7-18 7-14 14-17 17-18 19-20 21-42 21-26 27-31 32-37 38-42 43-54 55-56 57-59 60-61

Acknowledgement Abstract Introduction Plate fin heat exchangers Fin geometries Flow friction and heat transfer characteristics Rectangular offset fin surface Design of rectangular offset compact plate fin heat exchanger Design calculation by Mangahanic correlation Design calculation by Wieting correlation Design calculation by Joshi & Webb correlation Design calculation by Deepak & Maity correlation Design of heat exchanger in MS Excel sheet Diagram of heat exchanger in solid work Result & conclusion Reference

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. 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) rectangular or trapezoidal fins (2) uninterrupted wavy fins and (3) interrupted fins such as offset strip, louver and perforated fins. The interrupted surfaces provide greater heat transfer at the cost of higher flow impedance. Here I have designed rectangular offset plate fin heat exchanger. I have assumed some data and based on them I have designed heat exchanger . The flowing fluid in heat exchanger is liquid nitrogen and material of heat exchanger is Al. After designing the heat exchanger, rating is also necessary . The heat transfer and flow friction characteristics of plate fin surfaces are presented in terms of the Colburn factor j and the Fanning friction factor f vs. Reynolds number Re, the relationships being different for different surfaces. The laminar flow model under predicts j and f values at high Reynolds number, while the 2-Layer k-e turbulence model over predicts the data throughout the range of interest. Because most industrial heat exchangers operate with Re less than 3000, and because the j and f data predicted by the laminar and the 2-layer k-e turbulence model differ little from each other at low Reynolds numbers, we have used the laminar flow model up to Reynolds number of 10,000, which is considered to be the limit for plate fin heat exchangers operating with gases. Velocity, pressure and temperature fields have been computed and j and f factors determined over appropriate range of Reynolds number and geometric dimensions.

INTRODUCTION
Plate Fin Heat Exchangers Fin Geometries Flow Friction and Heat Transfer Characteristics
1

Plate fin heat exchangers are widely used in automobile, aerospace, cryogenic and chemical industries. They are characterized by high effectiveness, compactness (high surface area density), low weight and moderate cost. Although these exchangers have been extensively used around the world for several decades, the technologies related to their design and manufacture remain confined to a few companies in developed countries. Recently efforts are being made in India towards the development of small plate fin heat exchangers for cryogenic and aerospace applications.

Plate Fin Heat Exchangers

A plate fin heat exchanger is a form of compact heat exchanger consisting of a block of alternating layers of corrugated fins and flat separators known as parting sheets. A schematic view of such an exchanger is given in Fig. 1.1. The corrugations serve both as secondary heat transfer surface and as mechanical support against the internal pressure between layers.

2 Figure 1.1: Plate fin heat exchanger assembly and detailsSide bars Plates or Parting Sheets FinsFluid 1 Fluid 2 Cap Sheet Header

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

Merits and Drawbacks

Plate fin heat exchangers offer several advantages over competing designs. (1) High thermal effectiveness and close temperature approach. (Temperature approach as low as 3K between single phase fluid streams and 1K between boiling and condensing fluids is fairly common.), (2) Large heat transfer surface area per unit volume (Typically 1000 m /m ), (3) Low weight, (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.). The principal disadvantages of the plate fin geometry are : (1) Limited range of temperature and pressure, (2) Difficulty in cleaning of passages, which limits its application to clean and relatively non-corrosive fluids, and (3) Difficulty of repair in case of failure or leakage between passages
2 3

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

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Manufacture
The basic principles of plate fin heat exchanger manufacture are the same for all sizes and all materials. The corrugations, side-bars, parting sheets and cap sheets are held together in a jig under a predefined load, placed in a furnace and brazed to form the plate fin heat exchanger block. The header tanks and nozzles are then welded to the block, taking care that the brazed joints remain intact during the welding process. Differences arise in the manner in which the brazing process is carried out. The methods in common use are salt bath brazing and vacuum brazing. In the salt bath process, the stacked assembly 0 is preheated in a furnace to about 550 C, and then dipped into a bath of fused salt composed mainly of fluorides or chlorides of alkali metals. The molten salt works as both flux and heating agent, maintaining the furnace at a uniform temperature. In case of heat exchangers made of aluminium, the molten salt removes grease and the tenacious layer of aluminium oxide, which would otherwise weaken the joints. Brazing takes place in the bath when the temperature is raised above the melting point of the brazing alloy. The brazed block is cleansed of the residual solidified salt by dissolving in water, and then thoroughly dried. In the vacuum brazing process, no flux or separate pre-heating furnace is required. The assembled block is heated to brazing temperature by radiation from electric heaters and by conduction from the exposed surfaces into the interior of the block. The absence of oxygen in the brazing environment is ensured by application of high vacuum (Pressure 10 mbar). The composition of the residual gas is further improved (lower oxygen content) by alternate evacuation and filling with an inert gas as many times as experience dictates. No washing or drying of the brazed block is required. Many metals, such as aluminium, stainless steel, copper and nickel alloys can be brazed satisfactorily in a vacuum furnace.
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Applications
Plate-fin and tube-fin heat exchangers have found application in a wide variety of industries. Among them are air separation (production of oxygen, nitrogen and argon by low temperature distillation of air), petrochemical and syn-gas production, helium and hydrogen liquefiers, oil and gas processing, automobile radiators and air conditioners, and environment control and secondary power systems of aircrafts. These applications cover a wide variety of heat exchange scenarios, such as:
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(1) exchange of heat between gases, liquids or both, (2) condensation, including partial and reflux condensation, (3) boiling, (4) sublimation, and (5) heat or cold storage

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
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Figure 1.2: Heat exchanger flow arrangements(a) Cross Flow (b) Counter flow(b) Cross counter flow

superior heat transfer characteristics of the cross flow configuration. In this arrangement, one of the streams flows in a straight path, while the second stream follows a zigzag path normal to that of the first stream. Up to six such passes have been employed. While negotiating the zigzag path, the fluid stream covers the length of the heat exchanger in a direction opposite to that of the direct stream. Thus the flow pattern can be seen to be globally counterflow while remaining locally cross flow. Cross-counter flow PFHEs are used in applications similar to those of simple cross flow exchangers, but allow more flexibility in design. They are particularly suited to applications where the two streams have considerably different volume flow rates, or permit significantly different pressure drops. The fluid with the larger volume flow rate or that with
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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.
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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

towards the heat transfer surfaces. This enhancement is accompanied by an increase in pressure drop.

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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
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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. Heat Transfer and Flow Friction Characteristics The heat transfer and flow friction characteristics of a heat exchanger surface are commonly expressed in non-dimensional form and are simply referred to as the basic characteristics or basic data of the surface. These characteristics are presented in terms of the Colburn factor j and Friction factor f vs. Reynolds number Re, the relationships being different for different surfaces. The Colburn and Friction factors are defined by the relations: J=h(Pr)^(2/3)/GCp P=4fLG^2/(2Dh) 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 = 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.
3 2

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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

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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. 2.1 The Offset Strip Fin Geometry The geometry of the offset strip fin surface is described by the following parameters: (i) fin spacing (s), excluding the fin thickness, (ii) fin height (h), excluding the fin thickness, (iii) fin thickness (t), and (iv) the strip length (_), in the flow direction. The lateral fin offset is generally uniform and equal to half the fin spacing (including fin thickness). Figure 3.1 shows a schematic view of the rectangular offset strip fin surface and defines the geometric parameters. The following are some commonly used secondary parameters derived from the basic fin dimensions. Figure

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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 j. Fin area (Af) =2*h*l+2*h*l =2*9.3*1.5+9.3*2*.2 =31.62 mm2

k. eq. Dia. =Dh =((2lh(s-t))/(ls+hl+ht) =(2*1.5*9.3(1.2-.2))/(1.5*1.2+9.3*1.5+9.3*.2) =1.58 mm l. fin area/total surface area=(Af /As )=31.62/35.22=.8977 m. frontal area ratio ( )=Af /As=9.3/13.3=.69924 n. =h/s=9.3/1.2=7.75 o. =l/s=1.5/1.2=1.25 p. = t/s=.2/1.2=.166
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(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 inlet temp 310 k Outlet temp 124.26 K Mass flow rate .0822 Kg/s Pressure inlet 8 bar Allowable pressure drop .05 bar Density at avg. temp 1.583 (3) ASSUMPTION avg. wall temp 200 K width(w) .115 mm no of layers 5 area between plate .0054625 m2 A=(wbn) For hot fluid =.115*9.5*.5 For cold fluid =.115*9.5*4 Free flow area .003819643 m2 ( Aff=A*) For hot fluid =.0054625*.699 For cold fluid=.00437*.699 (4) CONVECTIVE HEAT TRNSFER CO-EFFICIENT (a) bulk temp =(inlet temp+outlet temp)/2 =(310+124.26)/2 =217.13 = (301.54+124.26)/2 =200.628 (b) mean film temp.=(wall temp+bulktemp)/2 = (200+217.13)/2 =208.56 k =(200+200.628)/2 =200.314 Properties Hot fluid Sp. Heat (cp ) 1043 J/Kg-K Viscosity( ) .0000134 N/m2-s Predelt number .74767
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cold fluid 99.716 K 301.54 K .07791 Kg/s 1.15 bar .05 bar 1.711

.115 mm 4 .00437m2

.003055714 m2

(hot fluid ) (cold fluid)

(hot fluid) (cold fluid) cold fluid 1043 J/Kg-K .00001295 N/m2- s .75

(c) core mass velocity(G)=mff /Aff G=(.0822/.003819643) =21.5203 Kg/sm2 =(.07791/.003055714) =25.4964 Kg/sm2

(hot fluid) (cold fluid)

(d) Reynolds no. (R e ) =GD/ =(21.5203*1.58)/.0000134 =2544.421806 (hot fluid) =(25.4964*1.58)/.0000134 =3119.288461 (cold fluid) -.06 .1 -.196 Ref*=648.25(h/s) (l/s) (t/s) =832.874 * Rej =1568.58(h/s)-.217(l/s)-1.433(t/s)-.217 =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)
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=.862467

(cold fluid)

(5)overall heat transfer coefficient(w/m2-k) (a) total area/separating wall area(A0/Aw)=(1-ft)/(1-Af/Aw) =(1-.71425*.2)/(1-.8977) =8.3857 m2/m3 (b) overall thermal resistance (1/U0)=(ncwc/nh wh(hhh))+(aAo/KwAw)+(1/c hc) =.005807 m2 K/W Uo =172.204 W/m2K (6) heat transfer area m/m2 UA for heat exchanger = 1088 W/K Required heat transfer area = 6.318074 m2 Required heat transfer area /length A/L=7.714857 m2/m =4Amin(ff)/Deq Required length of heat exchanger L=.81894 m (7) pressure drop p /L=(fG2/2Deq) =4038.829 Pa (hot fluid) =4948.206647 Pa (cold fluid) (8) final dimensions Core length =819 mm (without longitudinal heat conduction) Core width =115 mm Total width =115+2*6=127 mm no of HP side =5 no of LP side =4 core height =(nc+nh)*b+(nc+nh)*a =92.7 mm Total height =92.7+2*6=104.7 mm

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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 = (KWAW)/LCmin =(150*.005165)/( 2.022 *81.26)=.011641 Y = *NTU*CR =.0116*33.071*.947 =.3649 =(1-CR)/(1-CR)(1+Y) =(1-.9478)/(1+.9478)(1+.3649) =.0196 =(Y/(1+Y)).5((1+ )Y/(1- (1+ )Y)) =.0038 =(1+ )/(1- ) =1.0076 r1=(1-CR)*NTU/(1+ NTUCR) =1.264 1-=(1-CR)/(er1-CR) =.0199 =.9800 Heat exchanger area=15.605m2 Required length = 2.022 m
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RATING OF HEAT EXCHANGER

free flow area (Aff) =9.6*10-6 m2 heat transfer area (As)= 35.22 mm2 l=1.5 mm Deq =1.58 mm frontal area ratio ( )=Af /As=9.3/13.3=.69924 mean film temp. =(wall temp+bulktemp)/2 = (200+217.13)/2 =208.56 k =(200+200.628)/2 =200.314 UA for heat exchanger = 1088 W/K Chot=85.73 Ccold=81.26 C*=Cmin/Cmax=81.26/85.73=.94 NTU=UA/Cmin=13.38 =(1-e-NTU(1-C*))/(1-c* e-NTU(1-C*)) =.95 Th,o =Th,I - Cmin/Cmax (Th,I Tc,I ) =310-.95(81.26/85.73(310-99.7156) =121 K Tc,o=Tc,I + Cmin/Cmax (Th,I Tc,I ) =99.716+.94(310-99.716) =300 K Q= Cmin(Th,I Tc,I ) =.95*81.26(310-91.716) =16233.29 J pressure drop p /L=(fG2/2Deq) =4038.829 Pa =4948.206647 Pa

(hot fluid) (cold fluid)

(hot fluid) (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 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 j. Fin area (Af) =2*h*l+2*h*l =2*9.3*1.5+9.3*2*.2 =31.62 mm2

k. eq. Dia. =Dh =(2sh)(s+h) =(2*1.2*9.3)(1.2+9.3) =2.125 mm l. fin area/total surface area=(Af /As )=31.62/35.22=.8977 m. frontal area ratio ( )=Af /As=9.3/13.3=.69924 n. =s/h=1.2/9.3=.129 o. =t/l=.2/1.5=.133
27

p. = 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 inlet temp 310 k Outlet temp 124.26 K Mass flow rate .0822 Kg/s Pressure inlet 8 bar Allowable pressure drop .05 bar Density at avg. temp 1.583 (3) ASSUMPTION avg. wall temp 200 K width(w) .115 mm no of layers 7 area between plate .007647 m2 A=(wbn) For hot fluid =.115*9.5*7 For cold fluid =.115*9.5*6 Free flow area .005347 m2 ( Aff=A*) For hot fluid =.007647*.699 For cold fluid=.006555*.699 (4) CONVECTIVE HEAT TRNSFER CO-EFFICIENT (a) bulk temp =(inlet temp+outlet temp)/2 =(310+124.26)/2 =217.13 = (301.54+124.26)/2 =200.628 (b) mean film temp.=(wall temp+bulktemp)/2 = (200+217.13)/2 =208.56 k =(200+200.628)/2 =200.314 Properties Hot fluid Sp. Heat (cp ) 1043 J/Kg-K Viscosity( ) .0000134 N/m2-s Predelt number .74767
28

cold fluid 99.716 K 301.54 K .07791 Kg/s 1.15 bar .05 bar 1.711

.115 mm 6 .006555m2

.004583 m2

(hot fluid ) (cold fluid) (hot fluid) (cold fluid) cold fluid 1043 J/Kg-K .00001295 N/m2- s .75

(c) core mass velocity(G)=mff /Aff G=(.0822/.005347) =15.37166Kg/sm2 =(.07791/.004583) =16.9976Kg/sm2 (d) Reynolds no. (R e ) =GD/ =(15.37166*2.125)/.0000134 =2438.49 =(16.9976*2.125)/.0000134 =2790.12 Re<1000 J=.483Re-0.536(l/Dh )-0.162()-0.184 F=7.661Re-0.712(l/Dh)-.384()-0.092 Re>2000 J=.242Re-0.368(l/Dh )-.322(t/Dh)0.089 F=1.136Re-0.198(l/Dh)-0.781(t/Dh).534 Since Re>2000 F=1.136(2438.49)-0.1998(1.5/2.125)-0.781(.2/2.125).534 =.09012 F= .08775 J=.242Re-0.368(l/Dh )-.322(t/Dh)0.089 =.242(2438.49)-0.368(1.5/2.125)-.322(.2/2.125)0.089 =.01244 J=.011184 fluid) h=jc p l/pr(2/3) =242.076 =254.2087 fin parameter M=2h/kft= (2*242.076*1000)/(150*.2) =127.0371 = (2*254.20*1000)/(150*.2) = 130.181 Mlf =Mb/2 =127.0371*9.5/2=.6034 =130.181*9.5/2=.6183 nf =tanh(ml)/ml =tanh(.6034)/.6034=.8940 =tanh(.6183)/.6183=.8894 Overall efficiency= =1-(Af/As)(1- nf ) =1-.8977(1-.8940)
29

(hot fluid) (cold fluid)

(hot fluid) (cold fluid)

(hot fluid) (cold fluid) (hot fluid) (cold (hot fluid) (cold fluid)

(hot fluid) (cold fluid) (hot fluid) (cold fluid) (hot fluid) (cold fluid)

=.9048 =1-.8977(1-.8894) =.9007

(hot fluid) (cold fluid)

(5)overall heat transfer coefficient(w/m2-k) (a) total area/separating wall area(A0/Aw)=(1-ft)/(1-Af/Aw) =(1-.71425*.2)/(1-.8977) =8.3857 m2/m3 (b) overall thermal resistance (1/U0)=(ncwc/nh wh(hhh))+(aAo/KwAw)+(1/c hc) =.008325 m2 K/W Uo =120.118 W/m2K (6) heat transfer area m/m2 UA for heat exchanger = 1088 W/K Required heat transfer area = 6.057 m2 Required heat transfer area /length A/L=(4*.0045)*(.002125) m2/m =8.625=4Amin(ff)/Deq Required length of heat exchanger L=1.051 m (7) pressure drop p /L=(fG2/2Deq) =3323.829 Pa (hot fluid) =3666.487 Pa (cold fluid) (8) final dimensions Core length =1051 mm (without longitudinal heat conduction) Core width =115 mm Total width =115+2*6=127 mm no of HP side =7 no of LP side =6 core height =(nc+nh)*b+(nc+nh)*a =133.58mm Total height =133.58+2*6=145.58 mm

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 = (KWAW)/LCmin =(150*.005165)/( 2.72 *81.26)=.0119 Y = *NTU*CR =.0119*33.4727*.94 =.3794 =(1-CR)/(1-CR)(1+Y) =(1-.9478)/(1+.9478)(1+.3794) =.0194 =(Y/(1+Y)).5((1+ )Y/(1- (1+ )Y)) =.0039 =(1+ )/(1- ) =1.0079 r1=(1-CR)*NTU/(1+ NTUCR) =1.2666 1-=(1-CR)/(er1-CR) =.0199 =.98000 Heat exchanger area=22.64 Required length=2.62 m
31

Design of compact plate fin heat exchanger using Joshi & Webb correlation
(3) 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

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 j. Fin area (Af) =2*h*l+2*h*l =2*9.3*1.5+9.3*2*.2 =31.62 mm2

k. eq. Dia. =Dh =2*(s-h)/((s+h)+(th/l)) =2*(1.2-.2)/((1.2+9.3)+(.2*9.3/1.5)) =1.58432 mm l. fin area/total surface area=(Af /As )=31.62/35.22=.8977 m. frontal area ratio ( )=Af /As=9.3/13.3=.69924

32

n. =h/s=9.3/1.2=7.75 o. =l/s=1.5/1.2=1.25 p. = 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 inlet temp 310 k Outlet temp 124.26 K Mass flow rate .0822 Kg/s Pressure inlet 8 bar Allowable pressure drop .05 bar Density at avg. temp 1.583 (3) ASSUMPTION avg. wall temp width(w) no of layers area between plate A=(wbn) For hot fluid =.115*9.5*.5 For cold fluid =.115*9.5*4 Free flow area ( Aff=A*) For hot fluid =.00655*.699 For cold fluid=.00546*.699 (4) CONVECTIVE HEAT TRNSFER CO-EFFICIENT (a) bulk temp =(inlet temp+outlet temp)/2 =(310+124.26)/2 =217.13 = (301.54+124.26)/2 =200.628 (b) mean film temp.=(wall temp+bulktemp)/2 = (200+217.13)/2 =208.56 k =(200+200.628)/2 =200.314
33

cold fluid 99.716 K 301.54 K .07791 Kg/s 1.15 bar .05 bar 1.711

200 K .115 mm 6 .00655 m2

.115 mm 5 .00546m2

.00458m2

.003819 m2

(hot fluid ) (cold fluid) (hot fluid) (cold fluid)

Properties Sp. Heat (cp ) Viscosity( ) Predelt number Hot fluid 1043 J/Kg-K .0000134 N/m2-s .74767 cold fluid 1043 J/Kg-K .00001295 N/m2- s .75

(c) core mass velocity(G)=mff /Aff G=(.0822/.004583) =17.9333Kg/sm2 =(.07791/.0038) =20.39Kg/sm2 (d) Reynolds no. (R e ) =GD/ =(17.93*1.58)/.0000134 = 2120.35 =(20.39*1.58)/.0000134 = 2495.33 Re<Re*(laminar flow) J=.53Re0.5(l/Dh)-0.15()-0.14 F=8.12Re-0.74(l/Dh )-0.41()-0.02 Re>Re* +1000(turbulent flow) J=.21Re-0.4(l/Dh)-0.24(t/Dh )0.02 F=1.12Re-0.36(l/Dh )-0.65(t/Dh)0.17 Where Re*=257(l/s)1.23(t/l)0.58 Dh(t+1.328(Re/lDh)-0.5)-7 =678.484 Since Re> Re* F=1.12(2120.35)-0.36(1.5/1.58)-0.65 (.2/1.58)0.17 =.05180 F=0.04885 J =.21(2120.35)-0.4(1.5/1.58)-0.24 (.2/1.58)0.02 =.00954
34

(hot fluid)

(cold fluid)

(hot fluid)

(cold fluid)

(hot fluid) (cold fluid)

(hot fluid)

J=.00893 h=jc p l/pr(2/3) = 216.537 =230.26 fin parameter M=2h/kft=(2*216.537*1000)/(150*.2) = 120.148 =2*230.26*1000/(150*.2) = 123.89 Mlf =Mb/2 =120.148*9.5/2=.0570 =123.89*9.5/2=.0588 nf =tanh(ml)/ml =tanh(.0570)/.0570=.9039 =tanh(.0588)/.0588 =.8985 Overall efficiency= =1-(Af/As)(1- nf ) =1-.8977(1-.9060) =.9137 =1-.8977(1-.90) =.9089

(cold fluid) (hot fluid) (cold fluid)

(hot fluid)

(cold fluid) (hot fluid) (cold fluid) (hot fluid) (cold fluid) (cold fluid)

(hot fluid) (cold fluid)

(5)overall heat transfer coefficient(w/m2-k) (a) total area/separating wall area(A0/Aw)=(1-ft)/(1-Af/Aw) =(1-.71425*.2)/(1-.8977) =8.3857 m2/m3 (b) overall thermal resistance (1/U0)=(ncwc/nh wh(hhh))+(aAo/KwAw)+(1/c hc) =.0092 m2K/W 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=(fG2/2Deq) =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 = (KWAW)/LCmin =(150*.005987)/( 2.41 *81.26)=.0108 Y = *NTU*CR =.0108*32.26*.94 =.3314 =(1-CR)/(1-CR)(1+Y) =(1-.9478)/(1+.9478)(1+.3314) =.0201 =(Y/(1+Y)).5((1+ )Y/(1- (1+ )Y)) =.003 =(1+ )/(1- ) =1.006 r1=(1-CR)*NTU/(1+ NTUCR) =1.265 1-=(1-CR)/(er1-CR) =.0199 =.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 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 j. Fin area (Af) =2*h*l+2*h*l =2*9.3*1.5+9.3*2*.2 =31.62 mm2

k. eq. Dia. =Dh ==((2lh(s-t))/(ls+hl+ht) =(2*1.5*9.3(1.2-.2))/(1.5*1.2+9.3*1.5+9.3*.2) =1.58 mm l. fin area/total surface area=(Af /As )=31.62/35.22=.8977 m. frontal area ratio ( )=Af /As=9.3/13.3=.69924 n. =h/s=9.3/1.2=7.75 o. =l/s=1.5/1.2=1.25
38

p. = 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 inlet temp 310 k Outlet temp 124.26 K Mass flow rate .0822 Kg/s Pressure inlet 8 bar Allowable pressure drop .05 bar Density at avg. temp 1.583 (3) ASSUMPTION avg. wall temp width(w) no of layers area between plate A=(wbn) For hot fluid =.2*.0095*10 For cold fluid =.2*.0095*9 Free flow area ( Aff=A*) For hot fluid =.019*.699 For cold fluid=.0171*.699 200 K .2 m 10 .019 m2

cold fluid 99.716 K 301.54 K .07791 Kg/s 1.15 bar .05 bar 1.711

.2m 9 .0171m2

.0132 m2

.0119 m2

(4) CONVECTIVE HEAT TRNSFER CO-EFFICIENT (a) bulk temp =(inlet temp+outlet temp)/2 =(310+124.26)/2 =217.13 = (301.54+124.26)/2 =200.628 (b) mean film temp.=(wall temp+bulktemp)/2 = (200+217.13)/2 =208.56 k =(200+200.628)/2 =200.314 Properties Hot fluid Sp. Heat (cp ) 1043 J/Kg-K Viscosity( ) .0000134 N/m2-s Predelt number .74767
39

(hot fluid ) (cold fluid) (hot fluid) (cold fluid) cold fluid 1043 J/Kg-K .00001295 N/m2- s .75

(c) core mass velocity(G)=mff /Aff G=(.0822/.0132) =6.187 Kg/sm2 =(.07791/.0119) =6.58 Kg/sm2 (d) Reynolds no. (R e ) =GD/ =(6.18*.00158)/.0000139 =705.207 =(6.58*.00158)/.0000131 =796.014 Re *=1568.58*()-.217*()-1.433*()-.217 =1077.74 = 1077.74 J=.18Re-0.42()0.288( )-.184()-.05 =.02350 =.02209 Re*=648.23*()-.06 *().1*()-.196 =832.874(hot fluid) =832.874(cold fluid) F=.32Re-0.286()0.221( )-.185()-.023 =.08118 =.07523 Pressure drop /length=(4fG2)/2Deq =312.95 N/m3 =2201.312 N/m3 Pressure drop =387.061N/m2 =2722.59 N/m2 h=jc p l/pr(2/3) =194.118 =190.447 fin parameter M=2h/kft= (2*194.118*1000)/(150*.2) =113.75 = (2*190.447*1000)/(150*.2) = 112.67 Mlf =Mb/2 =113.75*9.5/2=.5289 =112.67*9.5/2=.5239 nf =tanh(ml)/ml
40

(hot fluid) (cold fluid)

(hot fluid) (cold fluid)

(hot fluid) (cold fluid)

(hot fluid) (cold fluid) (hot fluid) (cold fluid) (hot fluid) (cold fluid)

(hot fluid) (cold fluid)

(hot fluid) (cold fluid) (hot fluid) (cold fluid)

=tanh(.5289)/.5289=.9161 =tanh(.5239)/.5239=.9175 Overall efficiency= =1-(Af/As)(1- nf ) =1-.8977(1-.9161) =.9246 =1-.8977(1-.9175) =.9259

(hot fluid) (cold fluid)

(hot fluid) (cold fluid)

(5)overall heat transfer coefficient(w/m2-k) (a) total area/separating wall area(A0/Aw)=(1-ft)/(1-Af/Aw) =(1-.71425*.2)/(1-.8977) =8.3857 m2/m3 (b) overall thermal resistance (1/U0)=(ncwc/nh wh(hhh))+(aAo/KwAw)+(1/c hc) =.0107 m2K/W Uo =93.20 W/m2K (6) heat transfer area m/m2 FOS=1.91 UA for heat exchanger = 3479.92 W/K Required heat transfer area =37.33 m2 Required heat transfer area /length A/L=(4*.0035)*(.002125) m2/m =30.188=4Amin(ff)/Deq Required length of heat exchanger L=1.237 m 2 (7) Pressure drop /length=(4fG )/2Deq =312.95 N/m3 (hot fluid) 3 =2201.312 N/m (cold fluid) 2 Pressure drop =387.061N/m (hot fluid) 2 =2722.59 N/m (cold fluid) (8) final dimensions Core length =1237 mm Core width =200 mm Total width =200+2*6=212 mm no of HP side =10 no of LP side =9 core height =(nc+nh)*b+(nc+nh)*a =195 mm Total height =195+2*6=207 mm

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 = (KWAW)/LCmin =(150*.005165)/( 1.236 *81.26)=.023 Y = *NTU*CR =.023*42.27*.94 =.9413 =(1-CR)/(1-CR)(1+Y) =(1-.9478)/(1+.9478)(1+.9413) =.0172 =(Y/(1+Y)).5((1+ )Y/(1- (1+ )Y)) =.0116 =(1+ )/(1- ) =1.0236 r1=(1-CR)*NTU/(1+ NTUCR) =1.4084 1-=(1-CR)/(er1-CR) =.019 =.98

42

PLATE FIN HEAT EXCHANGER DESIGN USING MANGAHANIC CORRELATION

1) a) b) c) d) e) f) g) h) i) j) k) l) m) n) o) p) q) r) s) t) u) v) 2)

Heat Exchanger Design Specifications Type of heat exchanger : Fin type Fin thickness, t Fin frequency, f Fin length,
Fin height, h Plate thickness, a Fin spacing, s

Plain plate fin heat exchanger

Offset Serrated 0.0002 714.25 m fpm m m m m m m m
2 2

0.2 1.5 9.3 0.8

mm mm mm mm mm mm

0.0002 714.25 0.0015 0.0093 0.0008 0.0012

m fpm m m m m m m
2

0.2 1.5 9.3 0.8

mm mm mm mm mm mm

Lf

0.0015 0.0093 0.0008 0.0012

1.2 9.5

1.2 9.5

Plate Spacing, b
Free flow area per fin , a ff Frontal area per fin, a fr Heat transfer area, As Fin area , Af

0.0095
0.0000093

0.0095
0.0000093

0.0000133 0.00003522 0.00003162 0.001584327 0.897785349

0.69924812 7.75 1.25 0.166666667 150 6 6

0.0000133 0.00003522 0.00003162 1.58432709 mm 0.001584327 0.897785349

0.69924812 7.75 1.25 0.166666667
2

m2 m2 m2 m m /m
2 2

m2 m2 m m /m
2

Equivalent diameter,De
Fin area /total surface area, Af /As Frontal area ratio, =Aff / Afr

1.584

mm

m 2/m 2

m 2/m 2

= h/s = l/s =t/s

Conductivity of fin material, K f

W/m-K

150

W/m-K

End Plate Thickness End Bars/ End Bars Thickness Data input:
hot fluid: Inlet temperature, Outlet temperature, Mass flow rate, Pressure at inlet, Allowable pressure drop Density at a verage temperature,

mm mm

cold fluid: 310 124.26 0.0822 8 0.05 1.583

K K
kg/s

99.716 301.54 0.07791 1.15 0.05

3

K K
kg/s

bar bar
Kg/m

bar bar
Kg/m 3

1.711

3) a) b) c) a) b)

Assumptions:
Average wall temperature, Tw = Width, W Number of Layers Area between plates Free flow area , Aff 200

K
m m2 m
2

0.115
5

115

mm

0.115
4

0.0054625 0.003819643

0.00437 0.003055714

4)

Convective heat transfer coefficients hot fluid side cold fluid side K 200.628 K

a)

Average or bulk temperature,Tavg

217.13

43

b) c)

The mean film temperature,Tm Properties at the mean film temperature Specific heat, Cp Viscocity, Prandtl number, Pr

208.565
1043 0.0000134 0.74767

K J/Kg-K
N/m -s kg/s-m
2 2

200.314
1043 0.00001295 0.75

K J/Kg-K N/m2-sec kg/s-m2

d) e) f) g) h) i) j) k) l) m) n)

Core mass velocity, G The Reynold's number, Re Critical Reynold's number Re*j Critical Reynold's number Re*f J F Pressure drop per length, p/L Convective Heat transfer Coefficient, h The fin parameter,M MLf The fin effectiveness, f The surface effectiveness, o

21.52033661 2544.421806 1077.742419 832.8747012 0.01265 0.05341 4931.722799 344.7043956 151.592523 0.720064484 0.856797214
0.871434637

25.49649369 3119.288461 1077.742419 832.8747012 0.01161 0.05039 6042.142505 374.129065 157.9301671 0.750168294 0.846809108
0.862467461

5) a) b) c) 6)

Overall heat transfer coefficient,W/m2-K Total area/seperating surface (wall) area,Ao/Aw Ovearall thermal resistance,1/Uo Overall heat transfer coefficient,Uo Heat transfer surface area,m2

8.385784167
0.005807054

m 2/m2 m K/W W/m 2-K

2

8.385784167

m 2/m2

172.2043597

UA for heat exchanger

required heat transfer area, A Required heat transfer area per length , A /L The required length of the heat exchanger, L 7) a) 8) Pressure drop,p pressure drop,p Final Dimension Core Length Core Width Total Width No .of Layers HP side No .of Layers LP side Core Height Total Height Remarks 9) Effect of logitudnal heat conduction Aw Cmin FOS UA

1088

W/K
m2 m /m
2

6.318074651 7.714857143 0.818949014 4038.829524 0.040388295 819 115 127 5 4 92.7 104.7
Design is OK

m Pa
bar

4948.206647 0.049482066

Pa
bar

mm mm mm

mm mm

0.005165143 81.26013 2.47 2687.36

m2

W/K

44

NTU Cr Y r1 1- heat exchanger area length of heat exchanger

33.0710768 0.011641587 0.9478 0.364902822 0.019634706 0.00380512 1.007639308 1.264786167 0.019911533 0.980088467 15.60564439 2.022804065 m2 m2

45

PLATE FIN HEAT EXCHANGER DESIGN USING WIETING CORRELTION

1) a) b) c) d) e) f) g) h) i) j) k) l) m) n) o) p) q) r) s) t) u) v) 2)

Heat Exchanger Design Specifications Type of heat exchanger : Plain plate fin heat exchanger Fin type Offset Serrated Fin thickness, t 0.0002 m Fin frequency, f 714.25 fpm Fin length, Lf 0.0015 m
Fin height, h a 0.0093 0.0008 0.0012 m m m m 2 m m m m m m /m m /m
2 2 2 2 2 2 2

0.2 1.5 9.3 0.8

mm mm mm mm mm mm

0.0002 714.25 0.0015 0.0093 0.0008 0.0012

m fpm m m m m m 2 m m m m m m /m m /m
2 2 2 2 2 2 2

0.2 1.5 9.3 0.8

mm mm mm mm mm mm

Plate thickness, Fin spacing, s

Plate Spacing, b
Free flow area per fin , aff Front al area per fin, af r Heat transfer area, A s Fin area , Af

0.0095
0.0000093

1.2 9.5

0.0095
0.0000093

1.2 9.5

Equivalent diameter,De
Fin area /total surface area, A f

0.0000133 0.00003522 0.00003162 0.002125714 0.897785349

0.69924812 0.129032258 0.133333333 0.166666667 Kf 150 6 6

2.12571429

mm

0.0000133 0.00003522 0.00003162 0.002125714 0.897785349

0.69924812 0.129032258 0.133333333 0.166666667

2.126

mm

/As
Front al area ratio, =Aff / Afr

= s/h = t/l =t/s

Conductivity of fin material,

W/m-K

150

W/m-K

End Plate Thickness End Bars/ End Bars Thickness Data input:
hot fluid: Inlet temperature, Outlet temperature, Mass flow rate, Pressure at inlet, Allowable pressure drop Density at average temperature,

Mm Mm

cold fluid: 310 124.26 0.0822 8 0.05 1.583

K K
kg/s

99.716 301.54 0.07791 1.15 0.05

3

K K
kg/s

Bar Bar
Kg/m

bar bar
Kg/m
3

1.711

3) a) b) c) a) b)

Assumptions:
A verage wall temperature, Tw = Width, W Number of Layers Area between plates Free flow area , Aff 200

K
M m2 m
2

0.115
7

115

mm

0.115
6

0.0076475 0.0053475

0.006555 0.004583571

4)

Convective heat transfer coefficients hot fluid side 46

cold fluid

side
a) b) c) A verage or bulk temperature, Tavg The mean film temperature, Tm Properties at the mean film temperature Specific heat, Cp Viscocity, Prandtl number, Pr d) e) f) g) h) i) j) k) l) m) n) Core mass velocity, G The Reynold's number, Re Critical Reynold's number Re1 Critical Reynold's number Re2 j f Pressure drop per length, p/L Convective Heat transfer Coefficient, h The fin parameter,M MLf The fin effectiveness, f The surface effectiveness, o 5) a) b) c) 6) 1043 0.0000134 0.74767

217.13 208.565

K K J/Kg-K 2 N/m -s
kg/s-m
2

200.628 200.314
1043 0.00001295 0.75

K K J/Kg-K N/m2-sec kg/s-m2

15.371669 2438.490776 1000 2000 0.01244 0.09012 3164.2519 242.0763791 127.037102 0.603426234 0.894033241
0.904864596

16.99766246 2790.12926 1000 2000 0.01184 0.08775 3485.41642 254.2087757 130.1816105 0.61836265 0.889424648
0.900727069

Overall heat transfer coefficient,W/m2-K Total area/seperating surfac e 8.385784167 (wall) area,Ao/A w Ovearall thermal resistance,1/Uo 0.008325123 Overall heat transfer 120.1183481 coefficient,Uo Heat transfer surface area,m2

m /m
2

8.385784167

m /m

m K/W W/m -K
2

UA for heat exchanger

required heat trans fer area, A Required heat trans fer area per length , A /L The required length of the heat exchanger, L 7) a) 8) Pressure drop,p pressure drop,p Final Dimension Core Length Core Width Total Width No .of Layers HP side No .of Layers LP side Core Height Total Height

1088

W/K
m
2 2

9.057733619 8.625 1.050172014 3323.00879 0.033230088 1051 115 127 7 6 133.58 145.58

m /m

m Pa
bar

3660.286781 0.036602868

Pa
bar

mm mm mm

mm mm

47

Remarks 9) Aw Cmin FOS UA NTU Cr y r1 1- heat transfer area length of heat exchanger

Design i s OK

Effect of logitudnal heat conduction

0.006810629 81.26013 2.5 2720 33.4727498 0.011961847 0.9478 0.37949523 0.019427009 0.003971804 1.007975284 1.266606438 0.019853256 0.980146744 22.64433405 2.625430034

m2

W/K

m2 m

48

PLATE FIN HEAT EXCHANGER DESIGN USING JOSHI &WEBB CORRELATION

1) a) b) c) d) e) f) g) h) i) j) k) l) m) n) o) p) q) r) s) t) u) v)

Heat Exchanger Design Specifications Type of heat exchanger : Fin type Fin thickness, t Fin frequency, f Fin length,
Fin height, h Plate thickness, a Fin spacing, s

Plain plate fin heat exchanger

Offset Serrated 0.0002 714.25 m fpm m m m m m m m
2 2

0.2 1.5 9.3 0.8

mm mm mm mm mm mm

0.0002 714.25 0.0015 0.0093 0.0008 0.0012

m fpm m m m m m m
2

0.2 1.5 9.3 0.8

mm Mm Mm Mm Mm Mm

Lf

0.0015 0.0093 0.0008 0.0012

1.2 9.5

1.2 9.5

Plate Spacing, b
Free flow area per fin , a ff Frontal area per fin, a fr Heat transfer area, As Fin area , Af

0.0095
0.0000093

0.0095
0.0000093

0.0000133 0.00003522 0.00003162 0.001584327 0.897785349

0.69924812 0.129032258 0.133333333 0.166666667 150 6 6

0.0000133 0.00003522 0.00003162 1.58432709 mm 0.001584327 0.897785349

0.69924812 0.129032258 0.133333333 0.166666667
2

m2 m2 m2 m m /m
2 2

m2 m2 m m /m
2

Equivalent diameter,De
Fin area /total surface area, Af /As Frontal area ratio, =Aff / Afr

1.584

Mm

m 2/m 2

m 2/m 2

= s/h = t/l =t/s

Conductivity of fin material, K f

W/m-K

150

W/m-K

End Plate Thickness End Bars/ End Bars Thickness

mm mm

2)

Data input:
hot fluid: Inlet temperature, Outlet temperature, Mass flow rate, Pressure at inlet, Allowable pressure drop Density at a verage temperature, 310 124.26 0.0822 8 0.05 1.583 cold fluid:

K K
kg/s

99.716 301.54 0.07791 1.15 0.05 1.711

K K
kg/s

bar bar
Kg/m 3

bar bar
Kg/m 3

3) a) b) c) a) b)

Assumptions:
Average wall temperature, Tw = Width, W Number of Layers Area between plates Free flow area , Aff 200

K
m m2 m2 115

0.115
6

mm

0.115
5

0.006555 0.004583571

0.0054625 0.003819643

4) a) b)

Convective heat transfer coefficients hot fluid side

Average or bulk temperature,Tavg The mean film temperature,Tm

cold fluid side K K 200.628 200.314 K K

217.13 208.565

49

c)

Properties at the mean film temperature Specific heat, Cp Viscocity, Prandtl number, Pr 1043 0.0000134 0.74767

J/Kg-K
N/m -s kg/s-m
2 2

1043 0.00001295 0.75

J/Kg-K N/m2-sec kg/s-m2

d) e) f) g) h) i) j) k) l) m) n) 5) a) b) c) 6)

Core mass velocity, G The Reynold's number, Re Critical Reynold's number Re1 Critical Reynold's number Re2 J F Pressure drop per length, p/L Convective Heat transfer Coefficient, h The fin parameter,M MLf The fin effectiveness, f The surface effectiveness, o Overall heat transfer coefficient,W/m2-K

17.93361384 2120.351505 681.1382467 2000 0.00954 0.05180 3321.485567 216.5340502 120.1482557 0.570704215 0.903929313
0.913749145

20.39719495 2495.430769 690.9666918 2000 0.00893 0.04885 3748.892456 230.267632 123.8998606 0.588524338 0.898575355
0.90894244

Total area/seperating surface (wall) area,Ao/Aw Ovearall thermal resistance,1/Uo Overall heat transfer coefficient,Uo Heat transfer surface area,m2

8.385784167
0.009034333

m 2/m2 m K/W W/m 2-K

2

8.385784167

m 2/m2

110.6888519

UA for heat exchanger

required heat transfer area, A Required heat transfer area per length , A /L The required length of the heat exchanger, L 7) a) 8) Pressure drop,p pressure drop,p Final Dimension Core Length Core Width Total Width No .of Layers HP side No .of Layers LP side Core Height Total Height

1088

W/K
m2 m /m
2

9.829354825 9.643571429 1.019264999 3385.473984 0.03385474 1020 115 127 6 5 113.14 125.14
Design is OK

m Pa
bar

3821.114866 0.038211149

Pa
bar

mm mm mm

mm mm

Remarks effect of logitudnal heat conduction Aw Cmin FOS UA NTU Cr Y

0.005987886 81.26013 2.41 2622.08 32.2677308 0.010836451 0.9478 0.331415035

50

 r1 1- Area Length

0.020128559 0.003418493 1.006860439 1.265101793 0.019923945 0.980076055 23.68874513 2.456428648

51

PLATE FIN HEAT EXCHANGER 1 DESIGN (Deepak corelation)

1) Fluid Data input: Working Fluid Nitrogen HP Inlet HP Exit HP Mean LP Inlet LP Exit LP Mean Pres bar 8 7.95 7.975 1.15 1.1 1.125 1.1 Temp K 310.00 120.45 215.225 100.74 305.80 203.27 310 Mass Flow rate kg/ s (LP side) 0.0787 NTU, Req 22.1348 Dens kg/m3 8.70041 24.59257 12.64345 3.93202 1.21202 1.86879 1.19555 H KJ/kg 320.436 114.67011 220.14748 102.49171 317.47858 210.59691 321.84803 Cp KJ/kg K 1.0507 1.21522 1.0706 1.0705 1.04036 1.04589 1.04033 Viscosity Pa-s 0.0000185 0.0000084 0.0000139 0.0000068 0.0000182 0.0000131 0.0000184 0.71675 0.7680636 0.7181032 0.7254834 0.7162658 0.7136091 0.7163585 Prandtl#

Mass Flow rate kg/ s (HP Side) 0.0822 0.9801

Ch

Cc

Cmin

Cmax

Cr

W/K 88.00332 UA, W/K 1821.94954

W/K 82.311543 LMTD 10.032072

W/K 82.311543 Q, Watts 16913.95616

W/K 88.00332 UA, LMTD 1685.9884 0.93532316

2) a) b) c) d) e) f) g) h) i) j) k) l) m) n) o) p) q)

Heat Exchanger Fin Specifications Type of heat exchanger : Fin type Fin thickness, t Fin frequency, f Fin lengt h, Fin height, h a Plate thickness, Lf

H.P Side Plain plate fin heat exchanger Offset Serrated 0.0002 714.25 0.0015 0.0093 0.0008 0.0012 0.0095 0.0000093 0.0000133 0.00003522 0.00003162 0.001584327 0.897785349 0.69924812 7.75 m fpm m m m m m m m m m m m /m m /m
2 2 2 2 2

L.P. Side

0.2 1.5 9.3 0.8 1.2 9.5

mm mm mm mm mm mm

0.0002 714.25 0.0015 0.0093 0.0008 0.0012 0.0095 0.0000093

M Fpm M M M M M m m m m M m /m m /m
2 2 2 2 2

mm mm 0.2 1.5 mm 9.3 mm 0.8 mm 1.2 mm 9.5 mm

Fin spacing, s= (1-ft)/ f Plate Spacing, b=h+t Free flow area per fin , aff =(s-t)h Front al area per fin, af r=(s+t)(h+t) Heat transfer area, as =2hl+2ht+2sl Fin area , af =2hl+2ht Equivalent diameter,De=2(st)hl/(2hl+2ht+2sl) Fin area /total surface area, af /as Front al area ratio, =aff / af r = h/s

0.0000133
2

2 2

0.00003522
2

0.00003162 1.58432709 mm 0.001584327 0.897785349 0.69924812 7.75

1.58432709 mm

52

r) s) t) u) v) 3) a) b)

= l/s =t/s Conductivity of fin material, Kf End Plate Thickness End Bars/ End Bars Thickness Assumptions: Width, W Number of Layers, n Total Area between plates Af r= b*n*W Total Free flow area aff = * Af r Convective heat transfer coefficients Core mass velocity, G= mf /Aff The Reynold's number, Re=G*De / Critical Reynold's number Re*j j factor Convective h t c ,h = (j Cp (2/3) G)/pr The fin parameter,M =sqrt(2 h/Kf t) MLf The fin effectiveness, f=tanhML /ML The surface effectiveness, o

1.25 0.166666667 150 6 6 W/m-K mm mm

1.25 0.166666667 150 W/m-K

0.2 10

200

mm

0.2 9

a) b)

0.0190 0.013285714

m m

0.0171
2

m m

0.011957143

4) d) e) f) g) h) i) j) k) l)

6.187096774 705.2075546 1077.742419 0.02350 194.1181841 113.7594492 0.528981439 0.91610419 0.924679571

kg/s-m

6.581839904 796.0142933 1077.742419 0.02209 190.4474043 112.6787186 0.523956041 0.917534073 0.925963299

kg/s-m2

5) a) b) c)

Overall heat transfer coefficient,W/m2-K Total area/seperating surfac e (wall) area,Ao/A w Ovearall thermal resistance,1/Uo Overall heat transfer coefficient,Uo Heat transfer surface area,m2 Factor of Safety Design Ntu for heat exchanger Design UA for heat exchanger Required heat trans fer area, A

8.385784167 0.01072936 93.20220081

m /m
2

8.385784167

m /m

m K/W W/m -K
2

6)

Without Longitudinal Conduction 1.91 42.277468 3479.923625 37.33735464 W/K m

2

22.1348 1821.949542 19.54835322 W/K m

2

53

Required heat trans fer area per length , A /L The required length of the heat exchanger, L 7) a) Pressure drop,p Critical Reynold's number Re*f f factor Pressure drop per length, 2 p/L=4f G /(2 De) pressure drop,p

30.18857143 1.23680429

m /m m

30.18857143 0.647541513

m /m m

832.8747012 0.08188 312.9525781 387.0610911 0.003870611 Pa bar

832.8747012 0.07523 2201.312508 2722.592753 0.027225928 Pa bar

8)

Final Dimension Core Length Core Width Total Width No .of Layers HP side No .of Layers LP side Core Height Total Height Longitudinal heat conduction Conduction area =KwAw/LCmin Y=NtuCr =(1-Cr)/((1+ Cr)*(1+Y) = (Y/(1+Y))^0.5*Y*(1+)/(1(1+)) =(1+ )/(1-) r1=(1-Cr)Ntu/(1+*Ntu*Cr) 1-=(1-Cr)/ (exp(r1)-Cr) 0.016157143 0.02380642 0.941379538 0.017214122 0.011670991 1.023617623 1.408469158 0.019894718 0.980105282 1237 200 212 10 9 195 207 mm mm mm mm mm

Without Longitudinal Conduction 648 mm

9)

54

55

56

CONCLUSION
Dimension of heat exchanger is given by (1) By Mangahic correlation
Core length =2022 mm Core width =115 mm Total width =115+2*6=127 mm No. of HP side =5 No. of LP side =4 Core height =92.7 mm Total height =92.7+2*6=104.7 mm

(2) By Wieting correlation

Core length =2625 mm Core width =115 mm Total width =115+2*6=127 mm No. of HP side =7 No. of LP side =6 Core height =133.58mm Total height =133.58+2*6=145.58 mm

(3) By Joshi & Webb correlation

Core length =2456 mm Core width =115 mm Total width =115+2*6=127 mm No. of HP side =6 No. of LP side =5 Core height =113.14mm Total height =113.14+2*6=125.14 mm

(4) By Deepak & Maity correlation

57

Core length =1237 mm Core width =200 mm Total width =200+2*6=212 mm No. of HP side =10 No.of LP side =9 Core height =195 mm Total height =195+2*6=207 mm

Contribution of this Design Possibilities of Future Work

Contribution of this Design Plate Fin heat exchangers have already made a mark on the technology of the twentieth century. A variety of equipment from automobiles to aircrafts, considers them essential, while others are adopting then for their superior performance. Still, the technology has remained largely proprietary. Driven by industrial needs and international sanctions, our country has initiated a multipronged research programme on this challenging subject. This design constitutes a small component of this effort. Issues related to materials, manufacturing techniques and design approaches remain crucial to widespread application of plate fin heat exchangers. Heat transfer and flow friction characteristics of plate fin surfaces , however, will play the most vital role in its success. There is a shortage of experimental data and all existing correlations essentially represent the same basic information. The primary contribution of this design is to developing design of compact heat exchanger by combining computational and experimental data. Experiments on heat transfer over plate fin surfaces are expensive and difficult Direct numerical simulation (DNS) and comparable numerical techniques need computing resources beyond the
58

affordability of most heat exchanger designers. Under these circumstances the approach taken in this design provides a workable solution. 4.2 Possibilities of Future Work With physical constraints on time and resources, we have not been able to address to some aspects of the problem which have a strong symbiotic relationship with the material covered in this design. Among the most obvious topics are: 1. Plain fins of non-rectangular geometry triangular, trapezoidal and comparable shapes, 2. Offset strip fin in hard way configuration 3. Herringbone fins 4. Other fin types such as perforated plain fins and louver fins. The louver fin, particularly, can offer substantial computational challenges. Availability of better heat transfer and flow friction correlations and increased confidence in the results are expected to stimulate the application of these fin geometries .

59

REFERENCES
1. Maity, Dipak Heat Transfer and Flow Friction Characteristics of Plate Fin Heat Exchanger Surfaces A Numerical Study 2. Kays, W. M. and London, A. L. Compact Heat Exchangers, McGraw-Hill, New York (1984) 3. Wieting, A. R. Empirical Correlations for Heat Transfer and Flow Friction Characteristics of Rectangular Offset-Fin Plate-Fin Heat Exchangers ASME J. Heat Transfer 97 488-490 (1975) 4. Joshi, H. M. and Webb, R. L. Heat Transfer and Friction of the Offset Strip-fin Heat Exchanger Int. J. Heat Mass Transfer 30(1) 6984 (1987) 5. Manglik, R. M. and Bergles, A. E. Heat Transfer and Pressure Drop Correlations for the Rectangular Offset Strip Fin Compact Heat Exchanger Exp. Thermal Fluid Sc. 10 171-180 (1995) 6. Muzychka, Y. S. and Yovanovich, M. M. Modeling the f and j Characteristics of the Offset Strip Fin Array J. Enhanced Heat Transfer 8 243-259 (2001) 7. London, A. L. A Brief History of Compact Heat Exchanger Technology, in R. K. Shah, C. F. McDonald and C. P. Howard (Eds), Compact Heat Exchanger History, Technological Advancement and Mechanical Design Problems, HTD, 10, ASME, 14, (1980) 8. Panitsidis, H., Gresham, R.D. and Westwater, J. W. Boiling of Liquids in a Compact Plate-Fin Heat Exchanger, Int. J. Heat Mass Transfer, 18, 37-42, (1975) 9. Robertson, J.M., Boiling Heat Transfer with Liquid Nitrogen in Brazed Aluminium Platefin Heat Exchangers, American Institute of Chemical Engineers Symposium Series, San Diego, 75, 151-164 (1979) 10. Lenfestey, A. G. Low Temperature Heat Exchangers, in Progress in K. Mendelsson (Ed) Cryogenics 3, 25-47, (1961)

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