DESIGN AND FABRICATION OF “PA” CHANNEL

HEAT EXCHANGER

JERMIA VASANTHAN J (211419114125)

CHARAN A (211419114064)

JEEVANANDHAM D (211419114122)

HEMKUMAR S (211419114107)

DR. A SATYAMOORTHI M.E., PH.D PROFESSOR /

HEAD PROFESSOR
 INTRODUCTION:

A Heat exchanger is device used for effecting the process of heat exchanger between the two fluid that are at different temperature. The
heat exchanger are used in the many process like refrigerating and air-conditioning, food processing system, chemical reactors and
aeronautical applications The heat exchanger process in heat exchanger can be designed by the principle of
• Conduction
• Convection
• Radiation
• Evaporation or condensation
A heat exchanger in which two fluid exchanger heat by coming into direct cont is called a direct contact heat exchanger

EXAMPLE :
• Open feed water heater
• Desuperheaters
• Jet condensor
 TYPE OF HEAT EXCHANGER:

The heat exchanger can be classified by several ways. One classification is according by the fluid flow arrangement or the relative direction
of the hot and cold fluid.
The fluid may be separated by a plane wall also but it can be most commonly done by the concentric tube ( DOUBLE PIPE), They are
namely classified as :
i) Concentric Tube Heat Exchanger
a)Parallel flow
b)Counter flow
ii)Cross Flow Heat Exchanger
a)Both Fluid Unmixed
b)One Fluid Unmixed
iii)Shell-and-Tube Heat Exchanger
a)Two tube pass, One Shell pass Type
b)Four Tube Pass, Two Shell Pass Type
• One Shell Pass Heat Exchanger
• Two Tube Pass Shell-and Tube Heat Exchange
• Concentric Tube Heat Exchanger
Parallel flow: In the parallel-flow arrangement the Hot and Cold fluid entre at the same, flow in the same direction, and leave at the
same end.

Counter flow: In the counter floe arrangement the two fluids entre at the opposite ends, flow in opposite direction and leaves at the
opposite direction
 • Cross Flow Heat Exchanger
(a) Both Fluid Unmixed: The gas flow across the finned -tube bundles and is thus unmixed as it is confined in separated channels between the fins. Similarly the other
fluid passing through the tube is also unmixed

(b) One Fluid Unmixed: The tube are without fins the gas flowing across the tube is saud to be mixed because it can move about freely in the exchanger as it exchabges heat.
Shell-and-Tube Heat Exchanger

Two Tube pass, one shell pass type

a)Four Tube Pass, Two Shell Pass Type

 ABSTRACT

A heat exchanger is a heat transfer device that exchanges heat between two or more process fluids. Heat exchangers have widespread
industrial and domestic applications. Many types of heat exchangers have been developed for use in steam power plants, chemical
processing plants, building heat and air conditioning systems, transportation power systems, and refrigeration units. The actual design
of heat exchangers is a complicated problem. It involves more than heat-transfer analysis alone. The cost of fabrication and
installation, weight, and size play important roles in the selection of the final design from a total cost of ownership point of view. In
many cases, although cost is an important consideration, size and footprint often tend to be the dominant factors in choosing a design.
There is a wide application of coiled heat exchanger in the field of cryogenics and other industrial applications for its enhanced heat
transfer characteristics and compact structure. Lots of researches are going on to improve the heat transfer rate of the heat exchanger.
Here, we have fabricated the shell and tube heat exchanger with selecting the materials on the primary objective of enhancing the heat
transfer effectiveness. We casted the tube in the spiral shape with the helical angle of 30˚.Then we intended to perform calculation on
the heat transfer Effectiveness. We are intended to show the merits of spiral coiled heat exchanger to that of the conventional parallel
type heat exchangers.
 LITERATURE SURVEY

(1) Heat exchangers has been widely used in power plants and industries for heating or cooling applications. Heat is transferred from
one medium to another medium by using heat exchangers. Helical coil heat exchangers with two different shell configurations are
designed. First shell configuration with a central core and second without a central core. Both the configurations has a copper helical
coil. Designing of heat exchangers is done with counter flow arrangement by using CATIA V5 R2015. The performance of both the
configurations are analysed and compared by using Fluid flow (Fluent) in ANSYS WORKBENCH 18.1for CFD simulations. Further
the helical tube materials Copper and Aluminium which are widely used in heat exchangers are also analysed in shell with core
configuration and heat transfer rates are also compared using CFD (Fluent) analysis.
Kewin Titus. A1
, Khaja Fareedudeen Ahmed. K. S2

(2) There are several systems that produce energy from low grade heat sources such as Stirlingengines, thermoelectric generators, and
ORC (Organic Rankine Cycle) systems. This paper shows the heat recovery from exhaust gases of a 1400 cc Diesel engine, to vaporize the
working fluid of a small (<10 kW) ORC system. The main objective is to have a system as compact as possible, to make it suitable for
transport applications such as cars, ships, trains, etc. Three fluids were studied for this application: water and two refrigerant fluids: R134a
and R245fa, which were found to be more appropriate than water at certain pressure and temperature values. Afterwards, a design
procedure was proposed, then the heat exchanger was modeled and finally a steady-st…
Giacomo Bonafoni 1
, Roberto Capata
Heat exchangers are the important engineering equipments used for transferring heat from one fluid to another. Heat exchangers are
widely used in various kinds of application such as power plants, nuclear reactors, refrigeration and air-conditioning systems, heat
recovery systems, petrochemical, mechanical, biomedical industries. Helical coil heat exchangers are gaining wide importance now-a-
days because it can give high heat transfer coefficient in small footprint of surface area. This paper focuses on the designing of shell
and helical coil heat exchanger and its thermal evaluation with counter flow configuration. The thermal analysis is carried out
considering the various parameters such as flow rate of cold water, flow rate of hot water, temperature, effectiveness and overall heat
transfer coefficient.
Amitkumar S. Puttewar1
, A.M. Andhare2

Helical Coil Heat Exchanger (HCHE) is a type of heat exchanger which has a shell called annulus and inside it, there is a helical coil. It
occupies less space and provides more surface area for effective heat transfer as compared to shell and tube heat exchanger. HCHEs
find their use in compact nuclear reactors, e.g., Small Modular Reactors (SMR). With the help of our project work, the industry will
become familiar with the benefits of HCHE. That’s why, HCHE is designed by taking essential parameters like heat load, inlet and exit
temperatures of both coil and the annulus and the velocity inside the coil from industry (Altern Energy Ltd). In the present work, an
HCHE with a heat load of 25kW is designed and developed. Pressurized hot fluid in the a…
Muhammad Usman Sikandar
The RODbaffle heat exchanger concept was conceived in 1970 as a means of eliminating the destructive, flow-induced tube vibrations
that exist in conventional, plate-baffle heat exchangers. The early RODbaffle design utilized elliptically shaped baffle rings oriented at
45{degrees} angles from the tube bundle axis; intersecting pairs of baffles contained either horizontal or vertical support rods located
between each tube row. In addition to solving the existing tube vibration problem, this early RODbaffle exchanger exhibited reduced
shellside pressure losses and increased thermal performance. Subsequent research efforts have resulted in a simplified RODbaffle
design concept and have established thermal-hydraulic predictive methods. This paper describes various aspects of current RODbaffle
heat exchanger technology.

RODbaffle heat exchanger technology

Cecil C Gentry
 METHODOLOGY

Shell and tube heat exchangers are designed normally by using either Kern’s method or Bell-Delaware method. Kern’s
method is mostly used for the preliminary design and provides conservative results whereas, the Bell-Delaware method is more accurate
method and can provide detailed results. It can predict heat transfer coefficient with better accuracy. In this paper we have designed a simple
counter flow shell and spiral tube type heat exchanger to cool the water from 85 to 55 by using water at room temperature by using Kern’s
method.

• First we consider the energy balance to find out the values of some unknown temperature values. The energy balance equation may be
given as:

Q = m1c1(T1-T2) = m2c2(T2-T1)

• Then we consider the LMTD expression to find its value:

LMTD or ΔTm= (ΔT1 - ΔT2) / ln(ΔT1/ΔT2) Where ΔT1= T1-T2, ΔT2= T2-T1

• Then by using the amount of heat transfer formula we can get the heat transfer quantity:

Q=UA(ΔTm)

• Then we intended to find the Effectiveness of heat transfer by the following:

Δ = Q/(Cmin*(T1-t1)
 SELECTION OF MATERIAL
OUTER SHELL
STAINLESS STEEL (304) :

Type 304 stainless steel is a T 300 Series Stainless Steel austenitic. It has a minimum of 18% chromium
and 8% nickel, combined with a maximum of 0.08% carbon. It is defined as a Chromium-Nickel austenitic alloy.

Grade 304 is the standard "18/8" stainless that you will probably see in your pans and cookery tools.

These are some of its characteristics:

- Forming and welding properties

- Corrosion/ oxidation resistance thanks to the chromium content
- Deep drawing quality
- Excellent toughness, even down to cryonegic temperatures which are defined as very low temperatures
- Low temperature properties responding well to hardening by cold working
- Ease of cleaning, ease of fabrication, beauty of appearance

Applications

It is used for a wide variety of home and commercial applications, this is one of the most familiar and most frequently used alloys in the
stainless steel family.
 INNER SHELL

COPPER PIPE :

Copper pipes are commonly used in the construction industry for water supply lines and refrigerant lines in HVAC (heating,
cooling, and air- conditioning) systems.

Copper pipes can be manufactured as soft or rigid copper and offer excellent corrosion resistance and reliable connections. While flexible PEX
(cross-linked polyethylene) is now the more common choice for new installation and upgrades, copper pipe still has its place.

It is a sturdier building material that has a longer lifespan—lasting up to 70 years. However, copper is about 60 percent more expensive than
PEX, and can be susceptible to cracking if the water inside the pipes is subject to freezing temperatures.

Copper plumbing pipes have proven to be incredibly durable. This piping material is able to handle pressure of up to 1000 psi.
 WORKING PRINCIPLE OF HEAT EXCHANGER

A heat exchanger is a device which allows for fast and efficient transfer of heat from one medium to another. It is used to heat or
cool a particular medium using another in the vicinity. The process works based upon the basic science of flow of heat; from hot
to cool medium. While anybody can decrease or increase the temperature of a medium; using physical contact or intermixing with
another medium. A heat exchanger allows for the transfer of heat without actual contact in between.
It basically consists of segregated elements with high thermal conductivity to act as an element for heat transfer. They keep the
two fluids separated from each other; while allowing efficient transfer of heat. Irrespective of the and shape of the exchanger; the
actual heat transfer happen in response to the relative flow of liquid in these segregated elements. A heat exchanger can have
concurrent, counter or cross flow arrangement; for effective heat exchange between the medium.

In an counter flow arrangement the two medium flows in opposite direction to one another in separate tubes or segments. Due to
their opposite but parallel flow direction it is also termed as parallel flow type. While the method is well known for its high
efficiency; it is used where we need to bring a large change in temperature in record time. A concurrent flow on another hand
have counter flow with one medium flowing left to right; while the other moving top to bottom.
Due to its flow direction its is also termed as counter flow type. Similarly when a heat exchanger have arrangement where; the
two medium exchange heat crossing each other at 90 degree. The flow method is called to be cross flow type with an efficiency;
in between that of the other two methods.
2D DESIGN OF “PA” CHANNEL HEAT EXCHANGER
 MERITS AND DEMERITS
MERITS

1. Adaptable
Many modern heat exchangers, such as the plate heat exchanger, are very adaptable, which makes them suited for a wide variety
of tasks. Heat exchangers have also become compact, which makes them useful in smaller and smaller items. Although early heat exchangers
were often as large as a refrigerator, heat exchangers as of 2011 can even be used for small portable heaters or room air conditioners.

2. Cost and Maintenance

The fabrication costs of heat exchangers have fallen as technology has progressed. Modern plate heat exchangers use
pressed plates, which are less expensive than the welded plates used on early models. Pressed plates are also more resistant to corrosion and
chemical reactions that would weaken the heat exchanger and require more frequent replacement. Many heat exchanges have even been
modified with ease of cleaning in mind.

3. Industrial Applications
The heat exchanger as a piece of equipment is a simple model and therefore, has many applications in industry. The
coolant in radiator coils in an internal combustion engine is one example of a heat exchanger. In addition, heat exchangers are also used in
chemical plants, petroleum refineries

DEMERITS

Leakage and Pressure

Leakage and pressure drops in the system are two possible disadvantages of heat exchangers. Leakage in the process of
heat transfer is difficult to prevent and repair. In fact, many heat exchangers need to be taken apart entirely in order to fix a leak. Similarly, a
drop in pressure across a plate heat exchanger requires checking every plate for the fault.
 REFERENCE

[1]. K.S. Bharuka, D.Y. Kasture(1984), Flow through a helically coiled annulus, Applied Science Research, 41, 55–67.
[2]. Dawit Bogale(2014) , AJER, e-ISSN : 2320-0847 p-ISSN : 2320-0936 Volume-03, Issue-10, pp-99109 (Design and
Development of Shell and Tube Heat Exchanger for Harar Brewery Company
Pasteurizer Application (Mechanical and Thermal Design))
[3]. Durgesh Bhatt, Priyanka M Javhar,IJSR,ISSN(2011):23197064,researh paper on Shell and Tube Heat Exchanger Performance
Analysis.
[4]. Kevin.L.Luthersford conducted a experiment to increase the heat exchanger performance It may be feasible to consider
enhanced heat transfer through the use of finned tubes, inserts, twisted tubes, or modified baffles.(1998)
[5]. Ramesh K shah and Dusan P. Sekulic(2013), “Fundamental of heat exchanger design”, Rochester Institute of Technology,
Rochester New York.
[6]. Sandeep K. Patel, Professor Alkesh M. Mavani (2012)ISSN2249–8974IJAERS/Vol. II/ Issue I/130135, Research Paper on
Shell and tube heat exchanger thermal design with optimization of mass flow rate and baffle spacing.