NESTLE TECHNICAL TRAINING CENTRE,

FLOWERGATE FACTORY, SAGAMU OGUN

STATE.

UNIT 419 ENGINEERING DESIGN

ASSIGNMENT SUBMITTED

BY

EMMANUEL ISIAYINEKIFE
IBF0354

TO

ENGR THOMAS AKINTAN

10 DECEMBER 2023.
 TABLE OF CONTENT

Abstract

1.0 Introduction

1.1 Classifications of heat exchanger by flow configuration

1.2 Classifications of heat exchanger by construction

1.3 Plate heat exchanger

1.4 Components of plate heat exchanger

1.5 Working principles of plate heat exchanger

1.6 Performance factor and consideration of plate heat exchanger

1.7 Answers to question

1.8 Conclusion

1.9 Recommendation
ABSTRACT

"This comprehensive report delves into the pivotal role of heat exchangers across industries,
exploring their diverse types, working principles, and critical applications. The report navigates
through factors influencing performance, technological advancements, and environmental
considerations, shedding light on efficiency optimization and maintenance strategies.
Furthermore, it outlines market trends, future prospects, and real-world case studies, providing a
holistic understanding of heat exchangers' significance in modern engineering and their
promising role in shaping the future of thermal management."
1.0 INTRODUCTION

Heat exchanger

A heat exchanger is a device used to transfer heat between two or more fluids. The fluids can be
single or two phase and, depending on the exchanger type, may be separated or in direct contact.
Devices involving energy sources such as nuclear fuel pins or fired heaters are not normally
regarded as heat exchangers although many of the principles involved in their design are the
same.

A heat exchanger may be defined as an equipment which transfers the energy from a hot fluid to
a cold fluid, with maximum rate and minimum investment and running cost. The rate of transfer
of heat depends on the conductivity of the dividing wall and convective heat transfer coefficient
between the wall and fluids. The heat transfer rate also varies depending on the boundary
conditions such as adiabatic or insulated wall conditions. Some examples of heat exchangers are:

i. Intercoolers and pre heaters;

ii. Condensers and boilers in refrigeration units;

iii. Condensers and boilers in steam plant;

iv. Regenerators;

v. Oil coolers and heat engines;

vi. Automobile radiators etc.

1.1 CLASSIFICATION OF HEAT EXCHANGERS BY FLOW CONFIGURATION

There are four basic flow configurations:

1. Counter Flow

counter flow exchanger in which the two fluids flow parallel to each other but in opposite
directions. This type of flow arrangement allows the largest change in temperature of both fluids
and is therefore most efficient (where efficiency is the amount of actual heat transferred
compared with the theoretical maximum amount of heat that can be transferred).
2. Concurrent Flow

In concurrent flow heat exchangers, the streams flow parallel to each other and in the same
direction as shown in Figure 2, This is less efficient than countercurrent flow but does provide
more uniform wall temperatures.

3. Crossflow

Crossflow heat exchangers are intermediate in efficiency between countercurrent flow and
parallel flow exchangers. In these units, the streams flow at right angles to each other as shown
in Figure 3.

4. Hybrids such as Cross Counterflow and Multi Pass Flow

In industrial heat exchangers, hybrids of the above flow types are often found. Examples of these
are combined crossflow/counterflow heat exchangers and multi pass flow heat exchangers. (See
for example Figure 4.)
1.1 CLASSIFICATION OF HEAT EXCHANGERS BY CONSTRUCTION

Regenerative heat exchangers

Regenerative heat exchangers are devices that capture and store heat from a hot fluid stream and
transfer it to a cold fluid stream, typically within a cyclic process. These heat exchangers are
designed to improve energy efficiency by preheating or precooling fluids using the heat retained
from previous cycles.

Key features and concepts of regenerative heat exchangers include:

Storage Media: They employ a storage medium, often a solid material like ceramics, metal
matrix materials, or phase change materials, to store and release heat efficiently.

Cyclic Operation: The process involves alternating periods of heat absorption and release as the
fluids pass through the storage medium, allowing for efficient heat transfer between the two
streams.

Applications: Common applications include industrial processes, such as in rotary kilns, gas
turbines, and regenerative furnaces, where they help improve thermal efficiency by recovering
waste heat.

Efficiency Gains: Regenerative heat exchangers can significantly enhance energy efficiency by
preheating incoming fluids using the heat stored from the outgoing fluid, thereby reducing the
energy required to reach the desired temperature.

Types: Examples include rotary regenerators, which involve rotating heat storage matrices, and
fixed-bed regenerators, where the storage medium remains stationary while fluids pass through
it.
These heat exchangers play a vital role in various industries where heat recovery and energy
conservation are crucial, enabling processes to operate more efficiently by utilizing waste heat
that would otherwise be lost.

Recuperative heat exchangers

Recuperative heat exchangers are devices that transfer heat between two fluid streams, typically
without mixing them, in order to recover waste heat and improve energy efficiency. These heat
exchangers work by using a solid separator or a wall between the two fluid streams, allowing
heat to transfer through the barrier.

Key features and characteristics of recuperative heat exchangers include:

1. Separated Fluid Streams: They involve two separate fluid streams, often a hot fluid and a
cold fluid, flowing in adjacent or counter-flow directions.

2. Heat Transfer Surface: The heat exchange occurs through a solid surface or barrier, such
as plates, tubes, or coils, ensuring minimal mixing of the two fluids while facilitating
efficient heat transfer.

3. Types: Recuperative heat exchangers can be categorized based on their construction, such
as shell and tube, plate, or finned-tube designs, allowing for different levels of heat
transfer efficiency and adaptability to various applications.

4. Applications: Commonly used in HVAC systems, industrial processes, power generation,

and automotive applications to recover waste heat, preheat fluids, or maintain
temperature levels within systems.

5. Efficiency Improvement: By recovering heat that would otherwise be lost, these heat
exchangers enhance energy efficiency, reducing the energy required to heat or cool fluids
in a system.

6. Design Variations: They come in various configurations, including parallel flow, counter-
flow, and cross-flow designs, allowing for optimization based on specific heat transfer
requirements and spatial limitations.

Recuperative heat exchangers play a crucial role in energy conservation and are widely
employed in numerous industries where heat recovery and temperature control are essential
for optimizing processes and reducing energy consumption.

1.2 PLATE HEAT EXCHANGER

A plate heat exchanger is a type of heat exchanger that uses a series of metal plates to
transfer heat between two fluids. The plates are typically made of stainless steel or titanium
and are arranged in a pattern that allows the fluids to flow through them in alternating
channels. As the fluids pass through the channels, heat is transferred from one fluid to the
other through the plates. Plate heat exchangers are commonly used in HVAC systems,
industrial processes, and in the food and beverage industry for pasteurization and
sterilization. They are known for their high efficiency, compact size, and ease of
maintenance.

1.3 COMPONENTS OF A PLATE HEAT EXCHANGER

The main components of a plate heat exchanger include:

1. Plates: The plates are the primary component of the heat exchanger and are typically
made of stainless steel or titanium. They are designed to provide maximum surface
area for heat transfer.

2. Gaskets: The gaskets are used to seal the plates together and prevent any leakage
between the fluids. They are typically made of rubber or other flexible materials.

3. Frame: The frame holds the plates in place and provides support for the heat
exchanger. It is typically made of stainless steel or carbon steel.

4. Connections: The connections allow the fluids to enter and exit the heat exchanger.
They are typically made of metal and can be flanged or threaded.

5. Bolts: The bolts are used to tighten the plates and gaskets together. They are typically
made of stainless steel or carbon steel.

6. Pressure plates: The pressure plates are used to apply pressure to the plates and
gaskets, ensuring a tight seal and efficient heat transfer.

7. Insulation: Insulation is used to reduce heat loss from the heat exchanger and improve
its efficiency. It is typically made of materials such as fiberglass or foam.

8. pressure control valve: A pressure control valve is an essential component used in

various systems to regulate and control the pressure of a fluid within a specific range.
Its primary function is to maintain a set pressure level, ensuring stability and safety
within a system. It performs the following function,

a. Pressure Regulation: These valves manage fluid pressure by either

restricting flow or diverting it to maintain a specified pressure level within a
system.

b. Safety and Stability: They prevent pressure from exceeding safe limits,
safeguarding equipment and ensuring consistent operation.
9. Temperature control valve: A temperature control valve is a crucial component in
systems where maintaining a specific temperature range of a fluid is essential. Its
primary function is to regulate the flow of a liquid or gas to control the temperature
within a designated range. These valves respond to changes in temperature by
adjusting the flow of the medium to maintain the desired temperature level. Functions
include

a. Temperature Regulation: These valves manage the temperature of a fluid by

adjusting the flow rate based on temperature changes.

b. Temperature Stability: They help maintain a consistent temperature within a

system, preventing overheating or excessive cooling.

10. Pressure inlet transmitter: A pressure inlet transmitter is an instrument used to

measure and convert the pressure of a fluid at the inlet of a system into an electrical
signal, typically a voltage or current, which can be utilized for monitoring, control, or
data acquisition purposes. Functions include

a. Pressure Sensing: The transmitter contains a pressure sensor or transducer

that detects the pressure of the incoming fluid.

b. Signal Conversion: It converts the sensed pressure into an electrical signal

proportional to the measured pressure.

c. Transmission and Output: The transmitter sends this electrical signal to a

control system, data logger, or display device for monitoring or control
purposes.

11. Temperature inlet transmitter:

A temperature inlet transmitter is an instrument designed to measure and convert the

temperature of a fluid at the inlet of a system into an electrical signal, typically a
voltage or current, for monitoring, control, or data recording purposes.it performs the
following functions

a. Temperature Sensing: The transmitter employs a temperature sensor, such as

a thermocouple, resistance temperature detector (RTD), or thermistor, to
measure the temperature of the fluid at the inlet.

b. Signal Conversion: It converts the measured temperature into an electrical

signal, often a standardized output like 4-20mA or 0-10V, proportional to the
temperature reading.
 c. Transmission and Output: The converted electrical signal is transmitted to a
control system, data acquisition system, or display for monitoring, recording,
or control purposes.

12. Pumps:

This is an electromechanical machine that is used to drive water to and from the heat
exchanger. It helps in circulation water effectively to where it is needed.

1.4 WORKING PRINCIPLE OF PLATE HEAT EXCHANGER

The working principle involves the following steps:

1. Flow Configuration:

Fluid Circulation: The two fluids, known as the hot fluid and cold fluid, flow through alternate
channels formed between the plates.

Countercurrent Flow: Generally, the fluids flow in a countercurrent arrangement, maximizing the
temperature difference and heat transfer efficiency.

2. Heat Transfer:

Contactless Transfer: The corrugated design of the plates creates a large surface area for heat
exchange between the fluids without direct mixing.

Conduction: Heat transfers through the thin metal plates from the hot fluid to the colder fluid due
to the temperature difference between them.

3. Fluid Interaction:

Turbulence Creation: The corrugated plates induce turbulence in the fluid flow, enhancing heat
transfer by preventing the formation of boundary layers.

Thermal Efficiency: The close proximity of the fluids allows efficient heat transfer, enabling
rapid temperature changes in both fluids.

4. Plate Design and Construction:

Gasketed Plates: Some plate heat exchangers have gaskets between the plates, ensuring a tight
seal and preventing fluid intermixing.

Welded Plates: In some cases, the plates are welded together, eliminating the need for gaskets
and enhancing durability.
Working Process:

Fluid Introduction: Hot and cold fluids enter the heat exchanger through their respective inlet
ports. S2 is the inlet for hot water at 73.4 ⁰C and S3 is the inlet for cold water at 54.2 ⁰C

Fluid Separation: The fluids flow through alternate channels between the plates, never mixing
but transferring heat through the plate material.

Heat Exchange: Heat from the hot fluid is transferred through the plates to the cold fluid, raising
its temperature while lowering the temperature of the hot fluid.

Fluid Exit: The now-heated cold fluid exit via outlet S1 at 62 ⁰C and the cooled hot fluid exit
through S4 outlets.
1.5 PERFORMANCE FACTOR AND CONSIDERATION OF PLATE HEAT
EXCHANGER

The performance factor of a plate heat exchanger is determined by several factors, including the
size and shape of the plates, the flow rates and temperatures of the fluids, and the material
properties of the plates and gaskets

Some important considerations when selecting a plate heat exchanger include:

1. Heat transfer efficiency: The heat transfer efficiency of a plate heat exchanger is
determined by the design and size of the plates, as well as the flow rates and temperatures
of the fluids. A higher heat transfer efficiency will result in a more effective heat
exchange between the two fluids.

2. Pressure drop: The pressure drop across a plate heat exchanger is determined by the
flow rates and frictional resistance of the fluids as they pass through the channels. A
higher pressure drop can result in increased energy consumption and reduced efficiency.

3. Corrosion resistance: The materials used in the construction of a plate heat exchanger
must be resistant to corrosion and chemical attack from the fluids being processed. This
is especially important in applications where aggressive or corrosive fluids are being
used.

4. Maintenance requirements: Plate heat exchangers require regular maintenance to

ensure optimal performance. This includes cleaning and inspection of the plates and
gaskets, as well as replacement of any worn or damaged components.

5. Cost: Plate heat exchangers can vary widely in cost depending on their size, materials,
and design. It is important to consider both the upfront cost and the long-term operating
costs when selecting a plate heat exchanger.

1.6 ANSWERS TO QUESTIONS

1. Identify the components and functions of some noted part within the hard wear of the
heat exchanger.

2. Trace the path of fluid flow in the system and record the values of T's. 3

3. Evaluate the effectiveness of the heat exchanger within the temperature range recorded.

4. Discuss parameters or features that can enhance heat exchange within the heat exchanger
under specified conditions.
Answers

1. The components of a typical heat exchanger include:

a. Tubes or channels: These are the pathways through which the fluid flows.

b. Fins: These increase the surface area for heat transfer.

c. Shell or casing: It encloses the tubes and directs the flow of fluids.

d. Baffles: These are plates or rods that enhance fluid mixing and increase heat transfer.

e. Inlet and outlet connections: These allow the entry and exit of fluids.

f. Fans or pumps: These provide the necessary flow rate for efficient heat transfer.

The functions of these components are as follows:

a. Tubes or channels: They provide a pathway for the fluid to flow, allowing heat transfer
between the fluid and the surrounding environment.

b. Fins: They increase the surface area available for heat transfer, enhancing the efficiency
of the heat exchanger.

c. Shell or casing: It encloses the tubes and directs the flow of fluids, ensuring efficient heat
transfer.

d. Baffles: They promote fluid mixing, which improves heat transfer by preventing stagnant
regions.

e. Inlet and outlet connections: They allow the entry and exit of fluids into and out of the
heat exchanger.

f. Fans or pumps: They provide the necessary flow rate for efficient heat transfer by
ensuring proper fluid circulation.

2. The path of fluid flow in a heat exchanger depends on the specific design and configuration.
Generally, one fluid (known as the hot fluid) enters the heat exchanger through an inlet
connection, flows through the tubes or channels, and exits through an outlet connection. The
other fluid (known as the cold fluid) enters through a separate inlet connection, flows around the
tubes or channels, and exits through a separate outlet connection. The two fluids exchange heat
through the walls of the tubes or channels.

The values of T's refer to the temperatures of the hot and cold fluids at various points within the
heat exchanger. These temperatures are typically measured at the inlet and outlet connections of
each fluid to determine the heat transfer that occurs.

3. The effectiveness of a heat exchanger within a temperature range can be evaluated by

comparing the temperature difference between the hot and cold fluids at the inlet and outlet
connections. A higher temperature difference indicates more efficient heat transfer. The
effectiveness can be calculated using the formula:

Effectiveness = (Actual heat transfer rate) / (Maximum possible heat transfer rate)

Effectiveness = (66.2 – 58 ) / (73.6 – 58)

= 8.2 / 15

= 0.5467

= 54.67%

4. Parameters or features that can enhance heat exchange within a heat exchanger under specified
conditions include:

a. Increasing the surface area of the heat transfer surfaces, such as using fins or
extended surfaces.

b. Increasing the flow rate of the fluids to promote better heat transfer.

c. Using materials with high thermal conductivity for the heat transfer surfaces.

d. Optimizing the design and arrangement of tubes or channels to maximize heat

transfer.

e. Implementing proper insulation to minimize heat loss.

f. Controlling the flow direction and pattern of the fluids to ensure efficient heat
transfer.

g. Using heat transfer enhancement techniques like turbulators or inserts to disrupt

laminar flow and increase heat transfer.
1.7 CONCLUSION

it is clear that plate heat exchangers are an effective way to transfer heat between two fluids. The
components of the heat exchanger, such as the plates, gaskets, frame, and connections, all play a
crucial role in ensuring efficient heat transfer. Plate heat exchangers are an essential component
in many industrial processes, providing an efficient method for transferring heat between two
fluids. The efficiency of the heat exchanger can be improved by adjusting flow rates, using
corrugated plates, selecting materials with high thermal conductivity, and maintaining clean
surfaces. By implementing these parameters and features, the heat exchanger can operate at
optimal levels, leading to improved performance and energy savings. Overall, plate heat
exchangers are a reliable and effective solution for heat transfer in various industrial
applications.

1.8 RECOMMENDATION

To enhance heat exchange within the heat exchanger, it is recommended to increase flow rates,
use corrugated plates, use materials with high thermal conductivity, and maintain clean surfaces.
These parameters or features can improve heat transfer efficiency and ensure that the heat
exchanger operates at optimal levels.

Overall, plate heat exchangers are a reliable and efficient way to transfer heat between fluids and
can be used in a variety of industrial applications. By implementing the recommended
parameters and features, the effectiveness of the heat exchanger can be further enhanced, leading
to improved performance and energy savings.

1.9 REFERENCES

1. "Plate Heat Exchanger Maintenance." Alfa Laval. Accessed August 26, 2021.
https://www.alfalaval.com/globalassets/documents/services/maintenance-and-support/
heat-transfer/plate-heat-exchanger-maintenance.pdf.
2. "Plate Heat Exchanger Material Selection." Tranter. Accessed August 26, 2021.
https://www.tranter.com/plate-heat-exchanger-material-selection/.
3. "Optimizing Flow Rates for Plate Heat Exchangers." Heat Exchanger Design, Inc.
Accessed August 26, 2021. https://www.hed-inc.com/blog/optimizing-flow-rates-for-
plate-heat-exchangers.
4. "Corrugated Plate Heat Exchanger." Kelvion. Accessed August 26, 2021.
https://www.kelvion.com/products/heat-exchangers/plate-heat-exchangers/corrugated-
plate-heat-exchanger/.
5. "Heat Exchanger Monitoring." SPIRAX SARCO. Accessed August 26, 2021.
https://www.spiraxsarco.com/global/en-US/steam-training-center/technical-information/
heat-exchangers/heat-exchanger-monitoring.