ABSTRACT

A heat exchanger is a piece of equipment built for efficient heat transfer from one

medium to another. Heat exchangers are devices where two moving fluid streams

exchange heat without mixing. Heat is transferred from the hot fluid to the cold

one. Under steady operation, the mass flow rate of each fluid stream flowing

through a heat exchanger remains constant. Heat exchangers are intended for heat

transfer between two fluids within the device. Here we introducing concept of with

a single hot fluid source, the two different cold fluids are been heated.

1
 INTRODUCTION
HEAT EXCHANGER

A heat exchanger is a piece of equipment built for efficient heat transfer from
one medium to another. The fluids separated by a solid wall to prevent mixing or
they may be in direct contact. They are widely used
in spaceheating, refrigeration, airconditioning, powerplants, chemicalplants,Petro
chemical plants, petroleum refineries, natural gas processing. The classic example
of a heat exchanger is found in an internal combustion engine in which a
circulating fluid known as engine coolant flows through radiator coils and air flows
past the coils, which cools the coolant and heats the incoming air.

TYPES OF HEAT EXCHANGER

Double pipe heat exchanger

Double pipe heat exchangers are the simplest exchangers used in

industries. On one hand, these heat exchangers are cheap for both design and
maintenance, making them a good choice for small industries. On the other hand,
their low efficiency coupled with the high space occupied in large scales, has led
modern industries to use more efficient heat exchangers like shell and tube or
plate. However, since double pipe heat exchangers are simple, they are used to
teach heat exchanger design basics to students. As the fundamental rules for all
heat exchangers are the same. To start the design of a double pipe heat exchanger,
the first step is to calculate the heat duty of the heat exchanger. It must be noted
that for easier design, it’s better to ignore heat loss to the environment for initial
design. The heat duty can be defined as the heat gained by cold fluid which is
equal to the heat loss of the hot fluid.

2
 LIST OF ABBREVIATION

S.NO CONTENT

1 LMTD – Logarithmetic Mean Temperature Difference

2 CPVC – Chlorinated Polyvinyl chloride
3 PVC – polyvinyl chloride
4 M-seal – metalloid seal

3
 LIST OF SYMBOLS
S.NO CONTENT

1 = – Equal to
◦
2 C – Degree Celsius
◦
3 F – Degree Fahrenheit

4 T1 – Inlet Temperature of Hot fluid

5 T2 – Outlet Temperature of Hot fluid
6 t1 – Inlet Temperature of cold fluid
7 t2 – Outlet Temperature of cold fluid
8 Q – Heat transfer
9 U – Over all heat transfer
10 A – Area

4
 CONSTRUCTION DETAILS

Shell and tube heat exchanger

Shell and tube heat exchangers consist of series of tubes. One set of
these tubes contains the fluid that must be either heated or cooled. The second fluid
runs over the tubes that are being heated or cooled so that it can either provide the
heat or absorb the heat required. A set of tubes is called the tube bundle and can be
made up of several types of tubes: plain, longitudinally finned, etc. Shell and tube
heat exchangers are typically used for high-pressure applications (with pressures
greater than 30 bar and temperatures greater than 260 °C).This is because the shell
and tube heat exchangers are robust due to their shape. Several thermal design
features must be considered when designing the tubes in the shell and tube heat
exchangers, There can be many variations on the shell and tube design. Typically,
the ends of each tube are connected to plenums (sometimes called water boxes)
through holes in tube sheets. The tubes may be straight or bent in the shape of a U,
called U-tubes.

5
 WORKING PRINCIPLE

Generally heat exchanger is used to transfer the heat from hot fluid
to cold fluid. The fluid may be liquid or gas. Depending upon the material of shell
and tube and size determines the amount of heat transferred. There are two
methods to find out the efficiency of heat transferred. One method is logarithmetic
mean temperature difference method and other is no of transfer units. Here we
using log arithmetic mean temperature difference.

We introducing a technique of using single hot fluid source we can

able to heat two different cold fluid. Depending upon the thermal coefficient the
cold fluids are heated. Here copper tubes are used because copper can conduct the
heat in effective manner next to gold and silver and we use chlorinated poly vinyl
chloride which resist corrosion and withstand at high operating heat.

6
 ADVANTAGES AND APPLICATIONS

ADVANTAGES

 Compact in size and simple in construction

 Shell is corrosion resistant
 Copper has high thermal coefficient
 Shell is heat resistant
 It deals with triple fluid based heat exchange

LIMITATIONS

Cleaning of heat exchanger after the process is somewhat difficult.

APPLICATIONS

Power plants, Radiators

7
PART DRAWING

8
 ASSEMBLY DRAWING

Single flow and multi flow Heat Exchanger

9
PHOTOGRAPH

Heat Exchanger

10
 DESIGN CALCULATIONS
LMTD METHOD

We assume that a generic heat exchanger has two ends (which we

call "A" and "B") at which the hot and cold streams enter or exit on either side;
then, the LMTD is defined by the logarithmic mean as follows:

LMTD = {(67-45)-(50-30)}/ ln {(67-45)/ (50-30)}

where ΔTA is the temperature difference between the two streams at end A,
and ΔTB is the temperature difference between the two streams at end B. With this
definition, the LMTD can be used to find the exchanged heat in a heat exchanger:

In a cross-flow, in which one system, usually the heat sink, has the same
nominal temperature at all points on the heat transfer surface, a similar relation
between exchanged heat and LMTD holds, but with a correction factor. A
correction factor is also required for other more complex geometries, such as a
shell and tube exchanger with baffles.

LENGTH OF COPPER TUBE USED

L=2.5m

DIAMETER OF COPPER TUBE USED

D=0.5 inch=0.0125m

11
 AREA= π*D*L

=0.0125*2.5

AREA = 0.03125

CONSIDERED FACTS:

 All fluids taken is water

 Mass flow rates of all fluids are same

• INLET CONDITIONS ARE

Hot fluid -67˚C

Cold fluid – 30˚C

• OUTLET CONDITION CALCULATED IS

Hot fluid – 50˚C

Cold fluid – 45˚C

For counter flow,

LMTD = {(T1-t2)-(T2-t1)}/ ln {(T1-t2)/ (T2-t1)}

LMTD = {(67-45)-(50-30)}/ ln {(67-45)/ (50-30)}

LMTD = 20.98°C

12
We know that heat transfer,

Q=U*A*LMTD

U=340-455W/sq.M K

(for water-copper-water)

APPLYING,

Q=400*0.03125*20.98

Q=262.25W (AMOUNT OF HEAT TRANSFERRED)

13
 CONCEPT OF COUNTER FLOW

Counter flow, as illustrated in Figure 4, exists when the two fluids flow in
opposite directions. Each of the fluids enters the heat exchanger at opposite ends.
Because the cooler fluid exits the counter flow heat exchanger at the end where the
hot fluid enters the heat exchanger, the cooler fluid will approach the inlet
temperature of the hot fluid. Counter flow heat exchangers are the most efficient of
the triple types. In contrast to the parallel flow heat exchanger, the counter flow
heat exchanger can have the hottest coldfluid temperature greater than the coldest
hot-fluid temperature.

Counter flow produces standard and custom designed heat exchangers,

intercoolers and after coolers, fabricated in accordance with codes. Available
heat exchanges include gas-to-air, gas-to-liquid, or liquid-to-liquid.
Exchangers may be stand-alone, packaged as a console, or installed in your
process system .For shell and tube heat exchangers, standard shell material is
steel. Material for tubes, baffles and tube sheets is selected as appropriate for
the product, temperatures, pressures and condensate content.

14
 LITERATURE REVIEW

John William Fenton (1978) etal evaluted Counter fluid flow was
preferable because smaller temperature differences were present at the inlets
and outlets, thus minimizing heat leakage and improving overall
performance. Smaller temperature differences inside the exchangers and
consequently higher efficiencies are possible with counter fluid flow, but
longitudinal heat conduction due to longitudinal fins in addition to the fin
plate results in near isothermal exchangers, nullifying the potential
advantage of counter-flow.

Kevin J (1989) etal told a large tube surface area is necessary for
effective heat transfer and the surface area increases with tube length and
tube diameter. However, the advantage gained from a larger tube diameter is
offset by a decreased heat exchange which results from a fluid inside of the
large tubes tending to flow through the middle area of the tube where heat
transfer is lowest rather than adjacent the peripheral tube wall where heat
exchange is greatest.

15
 DESCRIPTION OF EQUIPMENTS

COPPER CHARACTERISTICS

Copper, silver and gold are in group 11 of the periodic table, and
they share certain attributes: they have one s-orbital electron on top of a filled d-
electron shell and are characterized by high ductility and electrical conductivity.
The filled d-shells in these elements do not contribute much to the interatomic
interactions, which are dominated by the s-electrons through metallic bonds.
Unlike in metals with incomplete d-shells, metallic bonds in copper are lacking
a covalent character and are relatively weak. This explains the low hardness and
high ductility of single crystals of copper. At the macroscopic scale, introduction
of extended defects to the crystal lattice, such as grain boundaries, hinders flow of
the material under applied stress, thereby increasing its hardness. For this reason,
copper is usually supplied in a fine-grained polycrystalline form, which has greater
strength than monocrystalline forms.

CPVC CHARACTERISTICS

Chlorinated polyvinyl chloride shares most of the features and properties of

PVC. It is also readily workable, including machining, welding, and forming.
Because of its excellent corrosion resistance at elevated temperatures, CPVC is
ideally suited for self-supporting constructions where temperatures up to 200 °F
(90 °C) are present. The ability to bend, shape, and weld CPVC enables its use in a
wide variety of processes and applications. It exhibits fire-retardant properties

16
COMPARISON OF POLYVINYL CHLORIDE (PVC)
Heat resistance

CPVC can withstand corrosive water at temperatures greater than PVC,

typically 40°C to 50°C (104°F to 122°F) or higher, contributing to its popularity as
a material for water piping systems in residential as well as commercial
construction.

Mechanical properties

The principal mechanical difference between CPVC and PVC is that CPVC
is significantly more ductile, allowing greater flexure and crush resistance.
Additionally, the mechanical strength of CPVC makes it a viable candidate to
replace many types of metal pipe in conditions where metal's susceptibility
to corrosion limits its use.

Fire properties

CPVC is similar to PVC in resistance to fire. It is typically very difficult to

ignite and tends to self-extinguish when not in a directly applied flame.Due to its
chlorine content, the incineration of CPVC, either in a fire or in an industrial
disposal process, can result in the creation of chlorinated dioxins.

17
FABRICATION

COMPONENT USED

1) Shell material = CPVC PIPE

2) Tube material = COPPER TUBE
3) CPVC RESINS
4) M-SEAL BOND
5) FUNNELS

18
 PROCESS CHART
S.NO TASK DESCRIPTION START END NO OF
DATE DATE DAYS

1 Research Study about the 02.02.2015 10.02.2015 9 Days

concept of heat
exchanger
2 Design Creating 2D 24.02.2015 28.02.2015 5 Days
layout of the
heat exchanger
3 Purchasing
Copper tube Purchasing the 03.03.2015 03.03.2015 1 Day
copper tube in
ANNAI
corporation in
Trichy.
CPVC pipes Purchasing the 03.03.2015 03.03.2015 1 Day
and materials CPVC pipes and
materials in
RAMESH
enterprises in
Trichy
4 Fabrication Fabrication of 16.03.2015 22.03.2015 7 Days
the heat
exchanger in the
workshop.
5 Testing The heat 28.03.2015 28.03.2015 1 Day
exchanger is
tested for its
efficiency.
6 Documentation Creating the 02.04.215 13.04.2015 12 Days
report on
performance of
heat exchanger.
19
 COST ESTIMATION

NAME OF THE Rs
COMPONENT
CPVC PIPE 1000
COPPER TUBE 900
UPVC COUPLING 400
TEFLON TAPE AND 200
SOLUTION
LABOUR COSTING 250
TOTAL 2750

20
 CONCLUSION

In today’s world heat exchanger plays a vital role in power generation. Using
our triple fluid heat exchanger we can reduce work time. It has a greater efficient
in terms of heat exchange. In future it will have huge scope when the shell and tube
is replaced by materials made up of composites and alloys.

21
 BIBLIOGRAPHY

1) R.S Kurumi, HMT Databook, New Age International,(2005)

2) C.P kodhandaraman, Heat and Mass Transfer, New Age International (2004)
3) John William Fenton, Jerry Stevenson Lee and Richard James Buist,
Counter-flow thermoelectric heat pump with discrete sections, US4065936
A, (1978)
4) Kevin J. and Sulzberger, Shell and tube heat exchanger, US4871014 A,
(1989).

5) Stephen U.S. Choi and J.A.Eastman, enhancing thermal conductivity of

fluid with nanoparticles, Argonne National Laboratory,(1995).

22