Executive Summary

PERFORMANCE ANALYSIS OF SHELL AND TUBE AS A PREHEATER

FUEL FOR BIODIESEL

STUDENT
Name : Hafid Rafi Noviantoro
Registry Number : 04211541000052

SUPERVISOR
Supervisor 1:
Name : Prof. Semin, S.T., M.T., ph.D.
Registry Number : 1971 0110 1997 02 1001

Supervisor 2:
Name : Irfan Syarief Arief, S.T., M.T.
Registry Number : 1969 1225 1997 02 1001
 CHAPTER I
INTRODUCTION
I.1 Background
I. Introduction
Fuel engine consumed more than 60% of fossil fuel. Scarcity of fossil fuel
requires optimal management of energy use to ensure stability energy for now as
well as for the future. Internal combustion engine until now is the major consumer
of fossil foil, but only about 30%-40% of energy could transformed into useful
mechanical energy (Hoang, 2018) (Ivan Arsie, 2014). The other energy transformed
into waste energy such as exhaust gases and water cooling, this energy has
approximately 25%-35%. This waste heat energy very unfortunate if is not used as
well as possible. Waste heat energy recovery could be increase heat efficiency of
engine. Moreover, using waste heat energy also reduced the toxic pollution
(Aladeyleh, 2015).
An engine produced waste energy while running by combustion process,
which wasted in vain into environment. In the time of engine run through sources of
waste heat such as exhaust gas, cooling water, lube oil, and turbocharger. Heat that
has best quality is the value not only about amount of the heat (Shewa Bhawan,
2015). In the moment engine run, there are four waste heat from the angina e such
as exhaust gas, cooling water, lube oil and turbocharger. Temperature of cooling
water not only the one that important to waste heat, but also mass flow rate of
cooling water (Janak Rathavi, 2012). In the diesel engine can produce temperature
of high temperature freshwater reaches 70-80°C. As seen in the figure 1, heat loss in
diesel engine for cooling water is 25%-35% of total heat loss (Shuaijun Wang,
2018).
This kind of waste heat energy can be used to heat fuel such as biodiesel.
Biodiesel is bioenergy or biofuels made from vegetable oils, derivatives of plants
that are widely grown in Indonesia such as oil palm, jatropha curcas, coconut,
candlenut and many more plants that can produce ingredients vegetable oil. The
potential for biodiesel oil production in Indonesia from 6 types of biodiesel raw
materials includes jatropha curcas, 557842 thousand barrels of biodiesel oil.
Followed by oil palm 438876, algae 258867 thousand barrels, coconut 238455
thousand barrels, used cooking oil 45515 thousand barrels, and rubber 3989.7
thousand barrels. With biodiesel supplements, Indonesia will be able to overcome
the energy crisis until 210 (Kuncahyo, Fathallah, & Semin, 2013). Bio diesel has
some differences in properties with regular diesel oil such as higher viscosity,
density and lower of flash point. These differences of properties can cause problem
in the atomization, corrosion in the injector and dirtier of fuel filter. To avoid this
happening some improvement should be taking such as preheat. Therefore, in this
study will utilize waste heat from water cooling using heat exchanger to preheat bio
diesel with simulation model using software engineering (A, 2014).
This study has aim to analyze the performance of preheater biodiesel which
is use shell and tube type of heat exchanger while utilize waste heat energy from
high temperature cooling water from the engine. The heat exchanger will be
simulated using software engineering to analyze the heat distribution, pressure drop
and to determine which heat exchanger has a better heat distribution, because there
will be variations on the baffle inside shell and tube

I.2 Problem Statement

The statements of problem that will be discussed are:
1. Analyze how the performance of shell and tube application in preheater
process for biodiesel fuel?
2. Determine how the best shell and tube application in preheater process for
biodiesel fuel?
I.3 Research Limitation
Limitation of the problem is made so that the scope of this research is more focused,
specifically:
1. This simulation only focusing on waste heat from cooling water
2. Heat exchanger type to be used is shell and tube
3. Biodiesel type to be analyze is B20 by Pertamina

I.4 Research Objective

The objectives of this study are as follows:
1. Knowing the performance of shell and tube application in preheater process
for biodiesel fuel
2. Knowing the best shell and tube application in preheater process for
biodiesel fuel

I.5 Research Benefit

The benefits of this research are as follows:
1. Give effect on the efficiency of combustion process
2. Reducing in energy consumption for auxiliary device such as boiler
CHAPTER II
LITERATURE STUDY

II.1 Previous Research Review

Research about preheat biodiesel using waste heat from diesel engine has
been done by Tushar R. Mohod with title Preheating of Biodiesel for the
Improvement of the Performance Characteristics of Di Engine: A Review. Preheater
used in this research is tube utilize waste heat from exhaust gas. The mechanism is
flow of exhaust gas is controlled with the help of an electronically controlled bypass
valve. When required fuel temperature is reached, bypass valve automatically
switch off and cut off supply in order to maintain constant temperature of fuel.
About analysis of biodiesel characteristics, Amir Khalid made research on
comparisons between biodiesel and straight vegetable oil with research title The
Comparison of Preheat Fuel Characteristics of Biodiesel and Straight Vegetable Oil.
The properties were tested at 27.5°C, 40°C, 50°C and 60°C. Characteristics he
examined were changes of the density, kinematic viscosity, flash point, water
contents, and acid value.
Jian Wen in the title of journal Experiment Investigation on Performance
Comparison for Shell and Tube Heat exchanger with Different Baffles has been
done the research shows that different configuration of baffles can effectively
improve the heat transfer of heat exchanger. Jian Wen using simulation or CFD and
experimental in his research. The results of this research are effect on heat transfer
coefficient and effect on pressure drop.

II.2 Bio Diesel

Diesel engines have different ignition, emission and injection characteristic;
therefore, the use of biodiesel is restricted. The treatment of biodiesel is needed to
make biodiesel usable for diesel engine (Mohod, 2014). The high viscosity, density
of vegetable oil interferes with injection process and leads poor fuel atomization.
The viscosity of fuels has important effects on fuel droplet formation, atomization,
evaporation and fuel-air mixing process, thus influencing the exhaust emission and
performance parameters of the engine (Khalid , et al., 2014).
 Palm oil biodiesel has a better efficient than biodiesel produced from
another vegetable oils. The lower of energy content of biodiesel make diesel engine
consumed more fuel then regular diesel oil. The lowering of power can be to 5-
10%, it depends on type of biodiesel, engine speeds and loads (M, O, & FJ, 2018).
Preheating process of the vegetable oils will make viscosity reduce and making the
biodiesel more likely to petroleum diesel. By reducing Viscosity make the biodiesel
suitable for diesel engine because high viscosity causing fuel flow and ignition
problems (McCarthy, Rasul, & Moazzem, 2011).
Biodiesel that used in this study is biodiesel from with 20% contamination
of palm oil or B20
No Characteristics Unit Min Max
.
1 Cetane Number 45
2 Density @15°C kg/m³ 815
3 Viscosity @40°C mm²/sec 2.0 4.5
4 Flash Point °C 52
5 Pour Point °C 18
6 Water Content mg/kg 500
7 Ash Content % 0.01
8 Carbon Residue % 0.1

II.3. Waste Heat Recovery

Waste heat is heat which is produced due to chemical reaction or fuel
combustion which expelled into the environmental. This heat could still be reused
for some useful and economic purpose, in this study waste heat from the cooling
water will be used to preheat fuel. The amount of heat is not essential quality
otherwise is its value. The way to recover the heat is relay on the temperature of the
waste heat. (Bhawan & Puram, 2015)
Technology of heat recovery could be reducing the operating cost while
increasing energy productivity. This technology also many are already good and
proven developed. There are two ways to recovered waste heat energy such as
indirect and direct. Direct heat recovery is often the cheaper option, but its use is
limited by location and combination considerations. In indirect heat recovery, the
two fluid streams are separated by a heat transfer surface, which can be categorized
as either a passive or active heat exchanger. Passive heat exchanger requires no
external energy input, while active heat exchanger do. (Bhawan & Puram, 2015)
There is some factor that influence to waste heat recovery such as:
a. Heat quantity is how much energy useful from waste heat. Waste heat
quantity are including temperature and mass flow rate of the stream.
b. Heat quality / waste heat temperature is factor that determine whether
temperature of waste heat can be useful.
c. Waste stream composition is the composition of heat stream that will
influence thermal conductivity and heat capacity. This composition will impact the
effectiveness of heat exchanger.
d. Minimum allowed temperature is the minimum limit of temperature that
permissible. It is also connected to corrosion of the material. The method that
usually used is designing heat exchangers with exhaust temperature above dew
point temperature.

II.4. Heat Exchanger

Heat exchanger is a device which used for transfer of internal thermal
energy between two or more fluids at different temperature. Commonly the fluids in
heat exchanger are separated by a heat transfer surface, and ideally, they do not mix.
Heat transfer in heat exchanger involving convection between different fluids and
conduction along the surface which separated between fluids. Common examples of
heat exchangers familiar day to day use are automobile radiators, condensers,
evaporators, air preheaters, and oil coolers
Heat transfer rate between two fluids depend on different temperature along
the heat exchanger. In analysis of heat exchanger, commonly using Logarithmic
Mean Temperature Difference (LMTD) which mean difference temperature
between two fluids that come in into the heat exchanger. There are many variations
of heat exchanger, in general heat exchangers have been divided by construction,
transfer processes, degrees of surface compactness, flow arrangements, pass
arrangements, phase of the process fluids, and heat transfer mechanism.

II.5. Calculation
In order to design the heat exchanger, calculation is needed to get the size of the
heat exchanger. There is some calculation needed to determine the heat exchanger:
a. Heat duty
The equation to determine heat that can be transferred from hot fluid to cool fluid
in the heat exchanger: (Kakac, 2012)
Q = mh. Cp. ΔT

b. Logarithmic Mean Temperature Difference (LMTD)

Difference temperature between two fluids that come in into the heat exchanger,
the equation can be write: (Kakac, 2012)
 LMTD =(Δth- Δtc)/(ln Δth/Δtc)

c. Caloric temperature
Caloric temperature is the temperature correspond with each stream. Caloric
temperature can be calculated by this equation: (Kakac, 2012)
• Hot fluid
Tc = T2 + Fc (T1 – T2)
• Cold fluid
Tc = t1 + Fc (t2 – t1)

d. Flow area
Flow area is area which flow by each fluid. This can be calculated by following
this equation: (Kakac, 2012)
Hot fluid
as = (IDs.C.B)/(144 Pt)
Cold fluid
at = (Nt.At)/(144 n)

e. Mass flow rate

Mass flow rate can be calculated by bay following this equation: (Kakac, 2012)
Hot fluid
Gs = ms/as
Cold fluid
Gt = mt/at
 CHAPTER III
RESEARCH METHODOLOGY

III.1 Methodology Flow Chart

 Journal
 Book
 Website
 Start

Problem Statement

Literature Sudy

Data Collecting
 Engine
Specification
Calculation Size of Heat  Engine
Exchanger Operating Data
 Fuel
Specification
Designing model of
Heat Exchanger

Failed

Simulation of
Heat Exchanger

Yes

Performance
Conclusion and End
analysis of
Recomendation
Bsiodiesel

III.2 Definition of Methodology Flow Chart

1. Problem Statement
 The research will start determining the problem that related with
the topics. The problems will be discussed are how to utilize waste
heat from diesel engine to preheat biodiesel and how characteristics
biodiesel such as viscosity and density after preheating.

2. Literature Review
Literature review will help author in conducting research by
studying theories regarding problems in chapter 1. The theories
used in this research sources from books, journals, and trusted
website. This research mostly refers to the literature about biodiesel
specifically B20 characteristics such as viscosity and density. The
other literatures also learn about designing heat exchanger or
preheater, in this case heat exchanger will be used is shell and tube.
The literature review about heat exchanger also include calculation
the of heat exchanger such as LMTD, heat duty, mass flow, etc.

3. Collecting Data
Data that will be used in this research are engine specification,
engine operating data, and fuel characteristic. In this study,
biodiesel was heated by using cooling water from a small diesel
engine. Engine that will be used in this study is Mitsubishi 4D30.
The technical parameters were briefly featured as Table.
Paramete
Description Unit r

Power, Nc PS 90
Revolution, n rpm 3500

Bore, D mm 100
Stroke, S mm 105

Displacement cc 3298
Table 1. Engine Specification

Another data will support this research is operating data of the

engine such as water-cooling temperature, flow rate of water
cooling and amount of cooling water. Biodiesel to be analyzed for
 the characteristics after preheating is B20 from Pertamina with the
characteristics before preheat show in table below.
Limitation ATSM
No. Characteristics Unit
Min Max Method

1 Cetane Number   45   D 613

D 1298/D
2 Density @ 15°C kg/m³ 815   4052

mm²/se
3 Viscosity @ 40°C c 2.0 4.5 D 445

4 Flash Point °C 52   D 93
5 Pour Point °C   18 D 97

6 Water Content mg/kg   500 D 6304

7 Ash Content %   0.01 D 482

D 4530/D
8 Carbon Residue %   0.1 189
Table 2. B20 Characteristics

4. Calculation Size of Heat Exchanger

After the data was completed next step is calculation. The
calculation is to determine estimated size of heat exchanger that
would be design. In the calculation of heat exchanger include:
a. Heat duty
b. LMTD (Log Mean Temperature Difference)
c. Caloric temperature
d. Flow area
e. Mass flow rate

5. Designing a Model of Shell and Tube

Designing a model is done by inputting data from the calculation.
In this stage is where the real dimensional drawn using 3D
modelling. The software used in this study is Solidworks 2018. The
first step in designing Shell and Tube by drawing parts such as
shell, tube, head cover, etc.
 Figure 1. Part of Shell

Figure 2. Part of Tubes

After all the parts have been done drawn, the next step is to
assemble the parts by using assembly command. The assembly
result shown as figure 3.
 Figure 3. Assembly of Shell and Tube

Modelling shell and tube with two variation, there are without fin
on the baffle and finned baffle. Model of these shell and tube can
be seen below:

Figure 4. Baffle without Fin

Figure 5. Baffle with Fin

6. Simulation of Heat Exchanger
The simulation process will use CFD (Computational Fluid
Dynamic) software. The software that will be used to simulate the
model of heat exchanger is Solidworks Flow Simulation.

7. Performance Analysis of Heat exchanger

From the simulation will be received data obtained heat transfer
coefficient, pressure drop, etc. This data will become analyzed how
the comparison of finned tube and straight tube.
 NEXT PROGRESS
The next stage after modelling process is simulation process. In the
simulation will be shown the performance of shell and tube. The
simulation process will be look like as the figure below: