FACULTY OF ENGINEERING

DEPARTMENT OF MECHANICAL AND PRODUCTION ENGINEERING

DESIGN OF A HEAT RECOVERY SYSTEM

(A CASE STUDY AT CROWN BEVERAGES LIMITED)

BY

KATO FREDRICK

16/U/205/EMD/GV

FINAL YEAR PROJECT REPORT SUBMITTED TO THE DEPARTMENT OF

MECHANICALAND PRODUCTION ENGINEERING IN PARTIAL FULFILLMENT OF
THE REQUIREMENTS FOR THE AWARD OF BACHELORS DEGREE IN MECHANICAL
AND MANUFACTURING ENGINEERING OF KYAMBOGO UNIVERSITY

SUPERVISOR
……………………………….

MAY 2020
DECLARATION

I hereby declare that this report is an original copy of my work. It has not been submitted elsewhere to any tertiary institution
or university for the award of any degree or diploma
Student: Date
…………………………… …………………………..
KATO FREDRICK

APPROVAL

This is to approve that this report was done by this student under my supervision and is hereby
submitted for examination to the Department of Mechanical and Production Engineering
Supervisor: Date
…………………………… ……………………………

2
ACKNOWLEDGEMENT
This final year project report has posed both excitement and a challenge to my academic and general life. However, it is true
that for every beautiful piece of work there is always a team of committed and hardworking people that invest their time to
make it a success.
I therefore wish to extend my sincere appreciation to my supervisor Mr.…………… who guided me in coming up with the
idea of this topic, building it up, and making it as original as it is right now. He has worked so devotedly to ensure that my
final year project report is a success.
I extend my sincere gratitude to the different people that spared some time to avail information to me and responded to my
questions. I thank my friends Lubega Herbert and Guma for the support they rendered while I was working on this project.

I also extend my gratitude to my parents Mr. ……. and Mrs.……. who have enabled me reach this far in my engineering
course through devoted payment of my hostel and supported me all throughout this period

3
Above all, I thank the almighty God for the wisdom, courage, strength and mercy He vested in me during this whole period.

Acronyms

ABSTRACT
A lot of dust is generated during the course of various mine operations and also other economic activities most especially due
to rock fragmentation. The dust is usually beyond allowable concentrations hence causing negative effects to both human life
and the environment. Wet suppression has been tried out but it interferes with the mine operations. This is why I came up with
an idea for a dust collection system which couldn’t interfere with operations and yet affordable.

The dust collection system was designed to avoid the circulation of dust from point sources and the case study was limestone
dust in Dura limestone Quarry. The designed dust collection system comprises of the hood for capturing the dust from a point
source, a cyclone for separating dust using centrifugal force, a hopper for breaking the vortex and an airtight container for
collecting the dust. The machine was tested to examine its efficiency and this efficiency was dependent on the length and
diameter of the cyclone.

Conclusions and recommendations were drawn from the discussed results got after testing. The designed machine had an
efficiency of 78% total dust and replaceable filters will be recommended for further cleaning of the air. The major costs to be
incurred by the dust collection system designed are the power costs since it has no movable parts. The designed system is the
best to be used in all areas whether arid or not, but only needs availability of power.

4
CHAPTER ONE
INDUSTRIAL WASTE HEAT.
This is heat lost in industries through ways such as discharge of hot combustion gases to the atmosphere through chimneys,
discharge of hot waste water, heat transfer from hot surfaces. This energy loss can be recovered through heat exchangers and
be put to other use such as preheating other industrial fluids such as water or air. Most of the manufacturing companies in third
world countries are facing high operational costs making their objectives and goals uncertain. Research has shown that one of
the most area to maintain in the manufacturing companies is fluid and energy department (utilities department) due to high cost
of fuels used in its operation.
In Uganda, Pepsi cola is one of the soft drink manufacturing company established in 29 th march 1950. The company has been
facing high cost of maintaining its utilities department due to decreasing energy efficiency of the boiler, increasing thermal and
air pollution dramatically, high consumption of furnace oil, high KPIs, corrosion, thermal cracking, low quality steam which
has affected other departments as well according to the utilities department manager report (……….). In 2015, 2016 and 2017
the company’s KPIs were very high which affected the annual production projections according to production data clerk report
(…….) . 5- why, 5s, FFA and cost containment committee was formed and results showed that utilities was the leading
departments in terms of high operation costs which needed immediate intervention to mitigate its high costs of operation
The aim of this project was to recover heat lost through flue gases exhaust at the chimney stage taking a keen consideration of
the effect of fouling especially at the core of the heat exchanger. Some research will be done and the exchanger system will be
designed to see its effectiveness as far as cost reduction is concerned. It will nevertheless be tested specifically to determine its
heat exchange effectiveness. However critical factors such as fouling will keenly observed. The small plate spacing of the
exchange core will allow for a substantial heat recovery. This obviously means the core will undergo fouling at a higher rate as
compared to boiler tubes. This will make the exchanger to require less frequent maintenance than the normal boiler
maintenance.
another objective will be to review the design ensuring that fouling will reduce and that the maintenance practice on the
exchanger does not adversely interfere with the normal operation of the boiler.

1.2 PROBLEM STATEMENT

Constant complaints by operations manager about the gradual increase in the operating costs of the utilities department
according to daily statistical data chart for the period of three years (2015-2018) and this was as a result of high fuel
consumption, emissions, poor quality steam, cold starting problems, there by the need to design the heat recovery system
which will crop down the increasing operation costs.

5
1.3 PROJECT OBJECTIVES
1.3.1 MAIN OBJECTIVE
To design a boiler chimney heat recovery system against fouling

1.3.2 SPECIFIC OBJECTIVES

1. To study the root causes of high cost of utility operation.
2. To select and size various components of the proposed system.
3. To select and test the appropriate system layout.
4. To carry out performance and cost analysis of the designed system.
1.4 RESEARCH QUESTIONS
1. What are the various real causes of high consumption of boilers?
2. How is the selection and sizing the required components of heat exchangers?
3. How are the components assembled?
4. What are the cost implications of the designed heat recovery system?

1.5 JUSTIFICATION
The rampant increase in the cost of operating utilities department at CBL is majorly affecting the operations of other
departments as well as reduction in company profit margin. Increase in cost of operation is as a result of high cost of fuel,
leakages, low boiler efficiency, use of partially open loop system, high temperature emissions, low temperature generated at
preheating unit hence a need to mitigate and crop down the operating costs.

1.6 SIGNIFICANCE
At the end of this project, the following were realized;

1. Production downtime will be reduced

2. Boiler efficiency will be increased
3. Quality of steam will be improved
4. Fuel consumption will be improved
5. Cracking of the nozzles will be minimized
6. Heat escaping in emissions will be reduced and quality of fouling gas will improve
7. Leakages will be minimized

1.7 SCOPE
This project was focused on the design of heat recovery system against fouling gases and it was conducted at crown beverages
limited located in nakawa industrial area kampala.

6
 CHAPTER TWO
LITERATURE REVIEW
INTRODUCTION
Heat exchangers are devices that facilitate the exchange of heat between two fluids that are at different temperatures while
keeping them from mixing with each other. Heat transfer in heat exchangers involves convection in each fluid and conduction
through the wall separating the two fluids. In order to account for the contribution of all the effects of convection and
conduction, an
overall heat transfer coefficient, U, is used in the analysis. Heat transfer rate depends on the
temperature differences between the two fluids at the location and the velocity of the fluids (time of interaction) between
the fluids.
2.2TYPES OF HEAT EXCHANGERS
Due to the different types of applications for heat exchanges, different types of hardware and different configurations of
heat exchanges are required. This has resulted to different designs of heart exchangers which includes and not limited to.
2.2.1Double pipe heat exchanger (simplest heat exchanger)
Consists of two concentric pipes of different diameter. In application, one fluid passes through the pipe of smaller diameter
while the other flows through the annular space between the two pipes. The flow of fluids can be arranged into:

i). Parallel flow. (Cengel, 2002)

Both fluids (hot fluid and cold fluid) enter the heat exchanger at the same end and move in the same direction to leave at
the other end as shown in the figure below.

7
Fig a. (i) shows the flow regimes while fig a (ii) shows the associated temperature profiles.

(ii). Counter flow (Cengel, 2002)

In these types of arrangement, the cold and hot fluids enter the exchanger at opposite ends and flow in opposite directions as
shown in the figure below:

Figure b (i) shows the flow regimes and figure b (ii) shows the associated temperature profiles.
2.2.2 The compact heat exchanger
This type of heat exchanger is designed to allow a large heat transfer surface area per unit volume. The ratio of the heat
transfer surface area of a heat exchanger to its volume is called the area density β. Heat exchangers with β >700 is
classified as compact heat exchanger e.g. car radiator, human lung am0ongest others. They allow high heat transfer rates
between fluids in a small volume. They are therefore best suited for applications with strict limitations on the weight and
volume of heat exchanger. They are mostly used in gas-to-gas and gas-to-liquid heat exchanger to counteract the low
heat transfer coefficient associated with fluid flow with increased surface area. The two fluids in this type of heat
exchangers move in directions perpendicular to each other, a flow configuration referred to as cross-flow. This type of
flow may be classified as unmixed or mixed.
i). Unmixed flow
Plate fins force the fluid to flow through a particular inter-fin spacing and prevent it from moving in the transverse
direction.
ii). Mixed flow
The fluid is free to move in the transverse direction. The presence of mixing can have adverse and significant effects on
the heat transfer characteristics of a heat exchanger.

8
 Fig c. compact heat exchangers
2.2.3 Shell and tube heat exchanger
Contains a large number of tubes packed in a shell with their axes parallels to that of the shell. One fluid flow through
the tubes while the other flows through the shell but outside the tubes. Baffles’ placed in the shell increases the flow
time of the shell-side fluid by forcing it to flow across the shell thereby enhancing heat transfer in addition to
maintaining uniform spacing between the tubes. These baffles are also used to increase the turbulence of the shell fluid.
The tubes open to some large flow areas called header at both ends of the shell. These types of heat exchanger can
accommodate a wide range of operating pressures and temperatures. They are easier to manufacture and are available at
low costs. Both the tube and shell fluids are pumped into the heat exchanger and therefore heat transfer is by forced
convection. Since the heat transfer coefficient is high with the liquid flow, there is no need to use fins. They can also be
classified into parallel and counter flow types.

Fig d. shell and tube heat exchanger with one shell pass and one tube pass (cross-counter flow configuration)
2.2.4 Plate heat exchangers (Ozisk, 1985)
They are usually constructed of thin plates which may be smooth or corrugated. Since the plates cannot sustain as high
pressure and or temperatures as circular tubs, they are generally used for small and low to moderate
pressure/temperatures. Their compactness factor is also low compared to other types of heat exchangers. The plates can
be arranged in such a way that there is cross- flow i.e. the hot and cold fluids flowing in directions perpendicular to each
other to enhance the heat transfer characteristic.

9
 Fig e. plate type compact heat exchanger (cross flow)
2.2.5 Other technologies applied to waste heat recovery
Regenerators
This is a type of heat exchanger where heat from the hot fluid is intermittently stored in a thermo storage medium before
it is transferred to the old fluid. In this type of heat exchanger can be the same fluid. The fluid may go through an
external processing step and then it is flowed back through the heat exchanger in the opposite direction for further
processing
Recuperators.
It is a counter-flow energy recovery heat exchanger used in industrial processes to recover waste heat.
Thermal wheel.
A rotary heat exchanger consists of a circular honeycomb matrix of heat absorbing material which is slowly

rotating within the supply and exhaust air streams of an air handling system.
Economizer.
In case of process boilers, waste heat in the exhaust gas passed along a recuperator that carries the inlet fluid for boiler
and thus decrease energy intake of the inlet fluid.
Run around coil.
Comprises 2 or more multi-raw finned tube coils connected to each other by pumped pipe work circuit.
2.3 OVERALL HEAT TRANSFER COEFFICIENT
In analysis of heat transfer in heat exchangers, various thermal resistances in the path of heat flow from the hot to cold
fluid are combined.
Heat is first transferred from the hot fluid to the wall by convection, through the mass by conduction and from the wall
to the cold fluid by convection. Any radiation effects are usually included in the convection heat transfer coefficients.
The total thermal resistance, R, for the whole system is given by:
thermal resistance of inside flow + thermal resistance of the systems material + thermal resistance of outside flow
2.4 FOULING FACTOR
The performance of heat exchangers usually deteriorates with time due to accumulation of deposits on the heat transfer
surface. The accumulation of deposits leads to increased resistance to heat transfer and causes the rate of heat transfer in
a heat exchanger to decrease. This accumulation of deposits on the heat transfer surface is known as fouling and the net
effect of fouling is represented by a fouling factor, R, introduced by a fouling f, which is a measure of the thermal
resistance.

10
 CHAPTER THREE:
METHODOLOGY
3.1 Introduction
The methodology explains the methods that were used to fulfill the objectives of the study. This also shows a design procedure
that targeted towards the achievement of the project objectives.
RESEARCH DESIGN
Research design is the one which describes the nature and pattern, which the research followed for example whether
longitudinal or cross-sectional, qualitative or quantitative, descriptive, explanatory or experimental, case based or
representative.
SOURCES OF DATA
A combination of primary and secondary was collected from the sources.
Primary data
This was collected from individuals dealing in spare parts of the heat exchanger systems and machine tool shops. Some other
data was obtained from pepsi cola uganda.
Secondary data
This was collected through a review of literature on heat exchanger technologies. The sources for this secondary data were the
internet, written information from library about the subject matter, previous studies done in areas of study, publication
documents from the heat exchanger industries. This reviewing literature provided supportive evidences to fulfill the objectives
of the study so as to address the problem stated by the study.
Tools
The following tools were used towards achieving the study started specific objectives
1. Internet
2. Textbooks

11
 3. Library
4. CAD software such as solid works, Auto cad
5. Inventory journals
6. MATLAB
7. oracle software

Summary of Methodology

s/n Specific objective Methods Description of method Data that was

obtained

1 To study the root Site visit and All sub-sections of utilities the most likely root
causes of high cost document cause of high
department were observed and
of utility operation reviews operational costs was
assessed for their effectiveness and obtained
the consumption ratings results were
reviewed.
2 To select and size Desk search The research involved calculations Required size of
various components and reviewing literature of the plates, sealings, bolts
of the proposed different researchers, stages of the and flow paths were
system. design process were conducted identified

3 To select and test the Desk search, Document review and consultations Engineering drawing,
appropriate system document
from different people who have layout and assembly
layout. reviews and
Consultations. knowledge concerning different heat of the heat exchanger
recovery techniques, carried out system.
measurements of surface areas and
volumes, compared different heat
exchanger systems, Cost and
maintainability.
4 To carry out Desk search, Mathematical calculations Prices
performance and consultations concerning different component Total costs
cost analysis of the and site visits were obtained Breakeven point
designed system.

12
 CHAPTER FOUR
DATA PRESENTATION, DISCUSION AND ANALYSIS OF FINDINGS

4.0 INTRODUCTION:
This chapter contains the findings and the results of the research that was carried out. It gives the detailed description and
discussion of the data acquired during the research in the line with the specific objectives and therefore conclusions in the next
chapter were drawn accordingly.
4.1 Studying the root causes of high cost of utility operation.
The tables below summaries the root causes of high operational costs of utilities department for the period of two years and
corresponding current status of the department after implementation of designed strategies.

Analyzing the average current status of Utilities department 2017 per month

period usages Expected Actual rejects Actual variance Root causes

output output output %
%
January Water
Compress
ed air
Furnace
oil
Power

February
march
April
may
June
July
August
Septembe
r
October
Novembe
r
December

Analyzing the average current status of utilities department 2018 per month

period usages Expected Actual rejects Actual variance Root causes

output output output %
%
13
 January Water
Compress
ed air
Furnace
oil
Power

February
march
April
may
June
July
August
Septembe
r
October
Novembe
r
December

4.2. Selection and sizing of components of the heat recovery system

4.2.1Selection of materials
Different components of the machine were selected from materials whose properties are suitable for the conditions of
operation. The factors that were considered when selecting the materials to be used in the design include; mechanical
properties, availability and cost.

4.2.1.1Mechanical properties of the materials

The mechanical properties that were considered are; strength of a material, its ductility, toughness and machinability of the
material. The material is strong and tough enough to with stand forces but also easy to bend and to be machined.

4.2.1.2Availability and cost of material

The materials which were readily available on market, efficient and relatively cheaper in terms of cost were used in the design
of the system such that the cost of the completed system is affordable to the user.

Selection of material

Component Possible material Selection criteria Material

selected
plates Mild steel, Strength, wear Mild steel
galvanized iron resistance,
availability, cost
Involute inlet Mild steel Cost, strength, wear Mild steel
galvanized iron resistance,
14
 availability,
Fan Mild steel, Strength, wear Mild steel
galvanized iron resistance,
availability, cost

Main frame Aluminium, Cost, strength, wear Mild steel

wood, mild steel resistance,
availability,

Ducts Mild steel, Cost, strength, wear Mild steel

rubber, plastic resistance,
availability,
Cyclone body Mild steel, Strength, bend ability, Mild steel
galvanized iron cost
Hopper Mild steel, Cost, strength, wear Mild steel
resistance,
availability,

4.2.2Product design specification for the heat recovery system

Performance: The system has support flange at an angle of 850 to the main frame for stability.

Maintenance: The system is easy to maintain using simple maintenance methods like oiling.

Size:

Cost: Ugandan shillings

Market: Heat recovery system

Ergonomics: The system is easy to use since it has an on and off power button, it is portable therefore it can transfer from one
point to another.

Safety: The machine is stable on frame, well insulated to avoid electric shocks, and has round edges to avoid bruises that are
caused by sharp ends.

Customer: industries and factories

4.2.3DESIGN ANALYSIS AND CALCULATIONS

4.2.3.1 Determination of power requirements of the system
The researcher obtained the power required by the system to suck the dust from the point source during operation in other
words the power to run the fan. As started in an international journal of emerging trends in Engineering and Development
ISSN 2249-6140 Issue 2, Vol.4 (May 2012) :

15
 Qρ
Power requirement by the machine P =
ὴ

Q× 450
=
0.75

Design Horse Power, H P

HP = Rated power x Service factor

THE HEAT EXCHANGER SYSTEM DESCRIPTION

COMPONENTS AND PROPERTIES

Every part of the system is described and explained in this section, the system was designed to have the following
characteristics

DESIGN PARAMETERS OF THE HEAT EXCHANGER.

Core dimensions L1 0.3m

0.2m
L
0.3m
2
Plate spacing mm 3
Air temperature at inlet °C 26
Air temperature at outlet °C 200

Gas temperature at inlet °C 450

Gas temperature at outlet °c 200

Aft. m2 0.06
Afr m2 0.09
Core volume m3 0.018
Plate thickness b mm 1.83
αa m- 615.555
1αg m- 613.888
1
Aa m2 11.08
Ag m5 11.05
Effectiveness 0.75
Ua W/m2K 3.683
R 0.96
Number of passages Air side 23

23
Gas side
16
Funnel shaped duct
This is a short cone shaped duct that is welded of the entry to the flue gas duck upstream of the exchanger core.

It provides an end that can be covered by alid during cleaning to prevent water from entering the boiler.
Small holes are left at its joint to the gas duct to allow water out.

During normal boiler operation gas filler can be put at this narrow end to trap carbon particles from
reaching the exchanger core. It was constructed from mild steel sheet (16 gauge)

Fig f. Funnel shaped duct

Ducts
The system has four ducts which are

a) Air inlet duct made from galvanized iron sheet (32 gauge)

b) Air outlet duct also made from galvanized iron sheet (32gauge) and is connected to the

air fan.

c) Gas inlet duct constructed from mild steel sheet (16gauge) to be able to support the whole

system and the rest of the chimney above.

d) Gas outlet duct: also constructed from mild steel sheet (16gauge) so as to hold the rest of

the chimney above the exchange.

17
Air duct Flue gas duct

18
Heat exchanger core:
It consists of 134 parallel aluminum plates (32gauge) of dimensions 0.3m by
0.2m enclosed in a mild steel flanged rectangular frame.

The plates were sealed alternately using silicon sealant. The sealant has good heat
resistance properties. The sealant also has good elastic properties that ensure
sealing even during plate expansion. Galvanized binding wires were used to
hold the exchange core fit in the frame and at the centre by aluminum spacers
that ensured even spacing between plates.

Flue gas side

L2

L1

Air side L3

Heat exchanger core.

Draught system
If consists of a electric motor driven (centrifugal) fan which operate at constant speed of 1389,
rpm. This fan was driven by a single-phase synchronous motor.

Design of the frame

The frame has four legs which are 85̊ to the ground, this enable it to support the entire weight of
the system. The total weight carried by the stand includes the weight of; cyclone, hopper, hood,
ducts, involute casing, fan and the motor.

The compressive stress on each machine leg is

=1134.486N

19
Bolts

The joining of the parts was done using connections that can be disassembled without destruction
methods. The joints used were strong enough to resist both external tensile loads and shear loads
or a combination. The bolts used were in various sizes these included M6, M10, M12and M16.

 M6 was used to fasten the fan housing to the cover.

 M10 was used to fasten the motor frame onto the cover.
 M12 was used to fasten the motor frame onto the mainframe.

The following stresses in the screwed fastening due to static loading are important from the
subject point of view;

 Internal stresses due to screwing up forces

 Stresses due external forces and
 Stress due to combination of stresses at (1) and (2)
 Internal stress due screwing up forces

The following stresses are induced in a bolt, screw or stud when it is screwed up tightly.

a) Tensile stress due to stretching of bolt

Since none of the above-mentioned stresses are accurately determined, therefore bolts are
designed on the basis of direct tensile stresses with a large factor of safety in order to account for
the indeterminate stresses. The initial tension in a bolt based on experiment may be found by the
relation P=2840 dN

Where;

P = initial tension in a bolt and

D = Nominal diameter of bolt in mm

The above relation is used for making a joint fluid tight like steam engine cylinder cover joints
etc. when the joint is not required as tight as fluid- tight joint, then the initial tension in a bolt
may be reduced to half of the above valve. In such cases P=1420 N

20
The small diameter bolts may fail during tightening, therefore bolts of smaller diameter ( less
than M 16 or M 18 ) are not permitted in making fluid tight joints. If the bolts is not intially
stressed, then the maximum safe axial load may be applied to it , is given by

P=Permissible stress × cross−sectional area at the bottom of thethread (stress area)

The stress area may be obtained using the relation

2
π d p +d c
stress area=
4 (2 )
Where;

dp = pitch diameter

dc = minor diameter

b) Torsional shear stress caused by the frictional resistance of the threads during its
tightening.

The torsional shear stress caused by the frictional resistance of the threads during its tightening
may be obtained by using the torsional equation known as;

T τ
=
J r

16T
τ=
π ( d c )3

τ =Torsional shear stress

T =Torque applied

c) Shear stress across the threads

The average thread shearing stress for the screw τ s is obtained by using the relation:

21
 P
τ s=
π d c ×b × n

Where b = width of the thread section at root.

P
τ n=
πd ×b × n

Where d = major diameter

According to table 11.1 (machine design) the corresponding value of stress area are given for

various bolt sizes.

Table 2:Safe tensile load calculation in different bolts.

Size of the bolt Stress area (mm2) Safe tensile load on the bolt (kN)

M6 20.1 844.2

M10 58.6 2461.2

M12 84.0 3536.4

Assuming a safe tensile stress of 42N/mm2

d) Compression or crushing stress on threads.

The compression or crushing stress between the threads ( σ c )may be obtained by using the
relation:

P
σ c=
π [ d −( d c )2 ] n
2

Where n = number of threads in engagement.

22
Bending stress if the surface under the head or nut are not perfectly to the bolt axis. When the
outside surface of the parts to be connected are not parallel to each other, then the bolt will be
subjected to bending action . the bending stress(σ b) induced in the shank of the bolt is given by

X .E
σ b=
2l

Where X = Difference in height between the extreme corners of the nut or head,

L = length of the shank of the bolt

E = Youngs modulus for the material of the bolt

MODEL TESTS, RESULTS AND ANALYSIS

The tests carried out were

1. Forced convection test with varying air flow

2. Transient test

FORCED CONVECTION TEST FOR DIFFERENT AIR FLOW RATES

 The heat exchanger was connected to the air inlet fan and the furnace.
 The air flow control flap was set at 750
 Room temperature was measured and recorded as Tr.
 Air inlet fan was switched on and the air velocity was measured by use of an air velocity
 meter.
 The furnace was fired and temperatures of the gas at inlet and outlet were measured and
 recorded.
 The air control damper was then changed to 600, 450, 300, 150 and 00 and their respective
 temperature readings and air velocities taken and recorded.
 The results were recorded in table 3.1

TRANSIENT TESTS

The objective here was to determine the time it took for the exit temperature to reach a constant

value. (Time response)

Procedure

23
  The air control valve was set at 00 and the air inlet fan switched on.
 Stop watch was set at 0.
 The air inlet fan was switched on and the furnace lit.
 Temperature readings in each duct were taken at 2minutes interval until the temperatures
 reached a steady value.
 The readings were recorded in table 5.3
Table 1: Flow rate against temperatures

Air control Average T air inlet (0C) T air outlet (0C) T flue gas T flue gas
damper angle velocity Inlet(0C) Outlet(0C)
of air
750 0.3 22.7 205 480 249
600 0.395 22.7 194 482 253
450 0.49 22. 190 483 255
300 0.58 22.7 184 483 256
150 0.70 22.7 171 483 25
00 0.95 22.7 170 483 260

Table 2: Air flow rate

Velocity near duct Velocity at the duct Angle of air control Average velocity
wall(m/s) center (m/s) flap (m/s)
0.15 0.45 75 0.3
0.19 0.60 60 0.395
0.26 0.72 45 0.49
0.32 0.84 30 0.58
0.44 0.96 15 0.70
0.60 1.30 0 0.95

Other results.
Flue gas velocity =3.7m/s
Flue gas supplier duct diameter =15.24cm

24
 Time (s) T g in T g out Ta in Ta out
0 _ _ 22.7 22.7
2 400 250 22.7 200
4 490 260 22.7 205
6 500 265 22.7 202
8 500 266 22.7 207
10 500 270 22.7 210
Table 3: Transient Test

Analysis

Calculation of volume flow rate

Flue gas volume flow rate = r2.V

R2 x3.142 × 10-4×3.7 =6.749 × 10-2 m3/s

Volume flow rate of air =AxV

Area of duct = (20 × 21) × 10-4

4.20 × 10-2 m2

Maximum volume flow rate of air

= Area of duct × velocity at Ѳ=00

= 4.2 × 10-2 × 0.95

= 3.99 × 10-2 m3/s

As the air flow rate at fully open duct is still low compared to the flue gas flow
rate, it was decided that the subsequent test be carried out at flap angle of 00 in the
air duct.

Major parameters of interest

1. Overall heat transfer rate Q

2. Effectiveness ε
3. Overall heat transfer coefficient U
Overall heat transfer rate (Q)
25
Q= ṁCp (T aout - Tain)

Where M- Mass flow rate of air

Cp-Specific heat capacity of air at constant pressure

Taout&Tain- Temperatures of air at outlet and inlet of the heat exchanger respectively

NOTE: Cp was taken at average/mean temperature

[(Taout+ Tain) ÷ 2]

Mass flow rate of air is given by;

ṁ= density of air ρa× Duct area A. × Air velocity

Mass flow rate of flue gases is given by

ṁ= density of gas ρg×duct area Ag× gas velocity Vg

Density of gas ρg=Type equation here .

Ambient conditions were: pressure=24.4 in Hg

Temperature=22.7 0C.=295.7K

Pressure in meters of mercury= 0.61976mHg

Pressure in Pa is: 0.61976× 13600× 9.81= 82685.9Pa

Density of gas=0.9743kg/m3

Overall heat transfer coefficient (u)

Effectiveness ε

26
Transient Test

Important parameters include

Dwell time Ѳd

Normalized time Ѳ*

Time to reach steady state Ѳ

Dwell time is the time air is in contact with the heat transfer surface from entry to exit of
exchanger core. It is given by: Ѳd= where L= length of heat exchanger from inlet to outlet to
exit.

Sample calculations

Mass flow rate ṁ= ρAV

=0.9743× 0.042 × 0.95

=0.04724 kg/s

Q for flap angle =00

=ṁCp (Taout-Tain)

=0.03887× 1.005 (170-22.7)

=5.7542kW/m2

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 Table 4: DETERMINING CROSS-FLOW CORRECTION FACTORS

ṁ=ρUA Ta in 0C Ta out 0C T g in 0C T g out 0C p R F LMTD

kg/s
0.01228 22.7 205 480 249 0.40 1.27 0.93 249.8595
0.01616 22.7 194 482 253 0.37 1.34 0.925 258.0758
0.02005 22.7 190 483 255 0.36 1.36 0.92 261.4768
0.02373 22.7 184 483 256 0.35 1.41 0.93 264.7929
0.02864 22.7 171 483 257 0.32 1.52 0.935 271.2981
0.03887 22.7 170 483 260 0.32 1.51 0.935 275.0789

Table 5: DETERMINED VALUES OF Q AND U

ṁ=ρUA Ta in 0C Ta out Mean CPkJ/kg K ∆T Aair Q kW U

kg/s 0C Temp K kW/m2K

0.01228 22.7 205 386.85 1.01534 182.3 0.042 2.2730 0.7966

0.01616 22.7 194 381.35 1.01300 171.3 0.042 2.8042 0.7269
0.02005 22.7 190 379.35 1.01234 167.3 0.042 3.3958 0.7041
0.02373 22.7 184 376.35 1.01114 161.3 0.042 3.8703 0.6623
0.02864 22.7 171 369.85 1.01011 148.3 0.042 4.2903 0.6749
0.03887 22.7 170 369.35 1.01006 147.3 0.042 5.7832 0.5369

Table 6: DETERMINATION OF EFFECTIVENESS

Ta Ta
Mea Cp Tg in Tg Mean Cp gas ṁ of ṁCp ṁ of ṁCp
Effecti
in n air out temp air kg/s of air gas -
out temp 0C kJ/Kg.
kJ/K for kW/K kg/sveness,
0C 0C K
0C . K g gas K ε
22.7 205 386.8 1.015 480 249 637.5 1.05995 0.01492 0.01515 0.03193 0.03384 0.3969
2
22.7 194 381.4 1.013 482 253 640.5 1.06066 0.01964 0.01990 0.03193 0.03386 0.3730
4
28
22.7 190 379.3 1.012 483 255 642.0 1.06101 0.02437 0.02467 0.03193 0.03387 0.3635
6
22.7 184 376.4 1.011 483 256 642.5 1.06113 0.02884 0.02912 0.03193 0.03387 0.3504
9
22.7 171 369.8 1.010 483 257 643.0 1.06125 0.03481 0.03516 0.03193 0.03388 0.3222
3
22.7 170 369.3 1.010 483 260 644.5 1.06160 0.04724 0.04772 0.03193 0.03389 0.3200
4

Table 7: DETERMINATION OF DWELL AND NORMALIZED TIME

ṁof air kg/s Mass/passage velocity Dwell time θd (s) Ta out 0C Time θ θ*(θ/θd)

0.04724 0.002054 0.95 0.316 205 0 0

0.04724 0.002054 0.95 0.316 194 2 379.7468
0.04724 0.002054 0.95 0.316 190 4 759.4937
0.04724 0.002054 0.95 0.316 184 6 1139.2405
0.04724 0.002054 0.95 0.316 171 8 1518.9873
0.04724 0.002054 0.95 0.316 170 10 1898.7342

Table 8: DETERMINATION OF PERCENTAGE HEAT RECOVERED

ṁ=ρUA Q air kW Total Q flue gas Fraction of heat Percentage heat

kg/s (At exit) kW (at inlet) recovered recovered

0.01492 2.7616 25.4830 0.1084 10.84

0.01964 3.4081 25.5673 0.1333 13.33
0.02437 4.1274 25.6103 0.1612 16.12
0.02884 4.7037 25.6125 0.1836 18.36
0.03481 5.2145 25.6155 0.2036 20.36
0.04724 7.0285 25.6239 0.2743 27.43

Table 9: Transient test

Time (s) Ta in Ta out Q kW U kW/m2K

0 22.7 22.7 0 0
2 22.7 200 8.4780 0.74852

29
 4 22.7 205 8.7171 0.76964
6 22.7 206 8.7919 0.77698
8 22.7 207 8.8128 0.77809
10 22.7 207 8. 8128 0.77809

Graphs

Graph of U vs Q

Graph of Q vs ṁ.

Graph of ε vs ṁ.

Graph of Ta out vs θ.

Graph of Ta out vs θ*.

30
4.3Developed layout of the sized and selected components.

4.4.1 Economic analysis

The system is economically friendly to the user, only power cost to run the machine will be the
cost most incurred. Since the system has no moving parts, maintenance cost is very minimal and

31
no operational cost because there is no operator needed. The system benefits the user by
minimizing expenditures on correcting the effects caused by dust (e.g. medical bills, cleaning
costs and maintenance costs of the equipment)

32