Basic Considerations in Design

 considerations of fluid flow, thermodynamics, and heat and mass transfer

 interaction between the various components and sub systems: overall system
 non technically basis

2.1 Formulation oF the Design Problem

 determine what is required of the system, what is given or fixed, and what may be varied
 constraints or limitations due to safety, environmental, economic, material, and other
considerations.
 parameters that may be varied in the system

2.1.1 Requirement and specifications

 a water flow system is needed to obtain a specified volume flow rate Ro

 a water cooler is being designed, the flow rate Ro and the desired temperature To at the
outflow become the requirements.

 thermal annealing process for materials such as steel

 It is critical to determine the main requirements of the system and to focus our efforts on
satisfying these.
a refrigeration system has been designed to provide the specified temperature and heat
removal rate, effort may be exerted to find a substitute for the refrigerants R-11 and R-12,
both of which are chlorofluorocarbons, or CFCs; to replace the compressor with one that
is more efficient; to vary the dimensions of the freezer; or to improve the temperature
control arrangement.
 Spesifikasi: performance characteristics; expected life of the system; recommended
maintenance, weight, size, safety features; and environmental requirement.
a water chilling system: these could be the lowest attainable temperature and the
corresponding flow rate and power consumption
 specifications of the system are, thus, the means of communication between the consumer
and the designer/manufacturer.
2.1.2 Given quantities
These items cannot be changed and, as such, are not varied in the design process. For system
design, the mold and the injected material may be kept fixed, while the melting and injection
processes are varied. Similarly, the mold, as well as the material, may be varied while keeping
the rest fixed.

2.1.3 Design variables

Therefore, the variables in the design problem may be classified as:
 hardware
components of the system, dimensions, materials, geometrical configuration, and other
quantities that constitute the hardware of the system.
 operating Conditions
to quantities that can often be varied relatively easily, over specified ranges, without
changing the hardware of the given system, such as the settings for temperature, flow
rate, pressure, speed, power input

e.g. plastic screw extrusion system

consists of the following main parts: barrel, heating/cooling arrangement, screw, die, feed
hopper, and the drive mechanism, which includes the motor, bearings, and gear system.
 hardware variables can be listed as
1. Geometry, material, and dimensions of the hopper
2. Geometry, material, and dimensions of the barrel
3. Dimensions, energy requirements, and configuration of heating/cooling arrangement
4. Diameter and material of the screw
5. Shape, height, thickness, and pitch of screw flights
6. Geometry, material, and dimensions of the die
7. Physical characteristics of the drive, motor, and gear system
 operating Conditions
1. Plastic flow rate or throughput
2. Speed (revolutions/minute)
3. Temperature distribution at the barrel
4. Material used
2.1.4 Limitations or constraints
These constraints generally arise due to material, weight, cost, avail ability, and space
limitations.
 The pressure rise in a thermal system is constrained by the strength of the materials
at the operating temperature levels.

 Such constraints arise from the expected application of the system.

 Constraints also arise due to conservation principles.

2.1.5 additional considerations

Considerate safety and environmental concerns, availability of raw materials, national interests,
import and export concerns, waste disposal problems, f inancial aspects, existing technology, and
so on.

e.g.
An air-conditioning system is to be designed for a residential building. The inte rior of the
building is to be maintained at a temperature of 22 ± 5°C. The ambient temperature can go as
high as 38°C and the rate of heat dissipated in the house is given as 2.0 kW. The location,
geometry, and dimensions of the building are given. Formulate the design problem and give the
problem statement. The problem statement for the given system design may, thus, be
summarized as

 Given: Building geometry, location, and dimensions. Maximum ambient tem perature as
38°C. Rate of heat dissipated inside the house as 2.0 kW.
 Requirements: Temperature inside the building must be maintained within 17 and 27°C.
In typical cases, the rate of cooling or response time τr is also a requirement.
 Constraints: Limitations on size, volume, weight, and cost of air conditioner. Also on
maximum air flow rate circulating in the house.
 Design variables: Systems parts, such as condenser, evaporator, compressor, and
throttling valve. Also, the refrigerant may be taken as a design variable.
2.3 stePs in the Design ProCess
2.3.1 physical system
2.3.2 modelinG
2.3.3 simulation
2.3.4 evaluation: acceptable design
2.3.5 optimal design
2.3.6 safety featuRes, automation, and control
2.3.7 communicatinG the design
2.3.8 patents and copyRiGhts

2.4 ComPuter-aiDeD Design

2.4.1 main features
2.4.2 computeR-aided desiGn of theRmal systems

2.5 material selection

2.5.1 diffeRent mateRials
2.5.2 mateRial pRopeRties and chaRacteRistics foR theRmal systems
2.5.3 selection and substitution of mateRials
Final Comments

2.6 summary