6.

2 Mathcad sheet for Heat exchanger design

Compact Hex Type: Flat plate finned tube Hex
6.2.1 Geometry of Unit cell of The heat exchanger.
air side:
s
p
3.175mm := D
ha
0.003633m :=
a
587
m
2
m
3
:=
p
0.3302mm :=
k
f
250
W
m K
:= k
wall
k
f
:=

a
0.534 := p
gi
1atm :=
X
t
0.0254m := X
l
0.021m := d
i
0.009525m := d
o
0.0102m :=
A
f_rat
0.839 :=
water side:
D
hw
d
i
:=
w

d
i
2
4

X
l
X
t

0.13359 = :=
w
d
i

X
l
X
t

56.09987
1
m
= :=
6.2.2 Heat Analysis
T
w1
53 C 326.15 K = := Q
pd
45.7kW := T
a1
15 C 288.15 K = := m'
a
2.5
kg
s
:=
S
sat
2.6 10
4
:=
kg
m
3
(Equivalent of 30% salt by weight solution in water)
c
pw
4180 4.396 S
sat
+ 0.0048 S
sat
+
( )
J
kg K
4.18 10
3

J
kg K
= := m'
w
0.3
kg
s
:=
T
w2
T
w1
Q
pd
c
pw
m'
w

289.70663 K = := T
wav
0.5 T
w2
T
w1
+
( )
307.92831 K = :=
6.2.3 Fluids properties
air properties at 300K:
c
pa
1007
J
kg K
:=
a
1.84 10
5 ( )
Pa s :=
a
1.1616
kg
m
3
:=
k
a
0.0263
W
m K
:= Pr
a
0.713 :=
water properies at 310K:

w
998.0 0.65 S
sat
+ 0.4
T
wav
K
20
|

\
|
|
.

(
(

kg
m
3
882.82884
kg
m
3
= :=
k
w
0.5553 0.0000813 S
sat
0.0008
T
wav
K
20
|

\
|
|
.
+

(
(

W
m K
0.78564
W
m K
= :=

w
0.695 10
3
Pa s :=
w
361.9 10
6

1
K
:= Pr
w
1.735 :=
6.2.4 Determination of NTU value
T
a2
T
a1
Q
pd
c
pa
m'
a

+ 306.30293 K = := Average air T

av
T
a1
T
a2
+
2
297.22646 K = :=
T
av
is close to 295K, so no need for iteration

ntu
Q
pd
min c
pa
m'
a
c
pw
m'
w
,
( )
T
w1
T
a1

( )
0.95904 = :=
C
0
min c
pa
m'
a
c
pw
m'
w
,
( )
max c
pa
m'
a
c
pw
m'
w
,
( )
0.49811 = := C
min
min c
pa
m'
a
c
pw
m'
w
,
( )
1.254 10
3

W
K
= :=
Guess: NTU
1
1 :=
Given
1 e
NTU
1

e
1 C
0
+
( )
NTU
1

C
0
NTU
1
( )
2

2
C
0
2
2 NTU
1
3
0.5 NTU
1
4
+
|
\
|
.
6
+

(
(
(

ntu
=
we neglected terms with powers of C
0
greater than 2
NTU Find NTU
1
( )
:=
NTU 4.34769 = UA NTU C
min
5.45201 10
3

W
K
= :=
6.2.5 Air heat transfer coefficient
Reynolds number of air is taken as
known (Re
a
)
Re
a
5000 := G
a
Re
a

a

D
ha
:= Re
a
5 10
3
=
From fig 9.4:
j 0.0055 := f 0.022 :=
Aa_min
m'
a
D
ha

a
Re
a

:=
h
a
j G
a

c
pa
Pr
a
2
3
:=
6.2.6 Water heat transfer coefficient
Take number of tubes to be N
t
1 2 , 1000 .. :=
N
t
1
2
3
4
5
6
7
8
9
10
11
12
...
=
G
w
N
t
( )
m'
w
N
t
0.25 d
i
2

:=
Re
w
N
t
( )
G
w
N
t
( )
D
hw

w
:= h
w
N
t
( )
0.05 Re
w
N
t
( ) ( )
0.8
Pr
w
0.33

k
w
d
i
:=
Re
w
N
t
( )
4
5.7700810
4
2.8850410
4
1.9233610
4
1.4425210
4
1.1540210
3
9.6167910
3
8.2429710
3
7.212610
3
6.411210
3
5.7700810
...
= h
w
N
t
( )
4
3.1859910
4
1.8298710
4
1.3229610
4
1.0509810
3
8.791610
3
7.5984210
3
6.7168510
3
6.0363210
3
5.4935110
3
5.0494510
...
kg
K s
3

=
0 50 100 150
0
1 10
4

2 10
4

3 10
4

4 10
4

h
w
N
t
( )
N
t
6.2.7 Resulting Areas
A
fr_a
m'
a

a
G
a

:= A
fr_w
N
t
( )
m'
w

w
G
w
N
t
( )

:=
6.2.8 Fin and Overall Efficiency:
We are going to use an equivalent straight fin
l
f
0.0254m 0.0102m
2
7.6 10
3
m = := fin length
ml
f
2 h
a

k
a

p

l
f
:=
f
tanh ml
f
( )
ml
f
0.02068 = :=

o
1 A
f_rat
1
f

( )
0.17835 = :=
6.2.9 Overall heat transfer areas
neglecting fouling since constant maintenance should keep the heat exchanger clean.
U
o
N
t
( )

a
h
w
N
t
( )

w

ln
d
o
d
i
|

\
|
|
.

a
d
i

k
wall

w

+
1

o
h
a

+
|

\
|
|
|
|
.
1
:=
U
o
N
t
( )

a
h
w
N
t
( )

w

ln
d
o
d
i
|

\
|
|
.

a
d
i

k
wall

w

+
1

o
h
a

+
|

\
|
|
|
|
.
1
:=
0 200 400 600 800 1 10
3

0
10
20
30
40
U
o
N
t
( )
N
t
6.2.10 Area Calculations
A
o
N
t
( )
UA
U
o
N
t
( )
:= V
hex
N
t
( )
A
o
N
t
( )

a
:=
L
3
N
t
( )
V
hex
N
t
( )
A
fr_a
:= L
1
N
t
( )
V
hex
N
t
( )
A
fr_w
N
t
( )
:=
L
2
N
t
( )
V
hex
N
t
( )
L
1
N
t
( )
L
3
N
t
( )

:=
6.2.11 Verification of assumption: N
t
N
t2
N
t
( )
L
3
N
t
( )
X
t
L
2
N
t
( )
X
l
1 +
2

L
3
N
t
( )
X
t
1
|

\
|
|
.
L
2
N
t
( )
X
l
1
2
+ := Number of tubes given by Shah
Number of fins per meter
N
f
1

p
s
p
+
|

\
|
|
.
285.29043
1
m
= :=
84 86 88 90
84
86
88
90
Nt2
Nt
N
t2
N
t
( )
N
t
N
t
84 86 88 90
84
86
88
90
Nt2
Nt
N
t2
N
t
( )
N
t
N
t
Intersections from both curves seem to conform for N
t
close to 1900. A more accurate result
will be found using mathcad numerical solution below
Guess Value for N
t
as n
n 90 :=
Given
N
t2
n ( ) n 0 =
Soltn Find n ( ) 86.1038 = :=
NOTE: The value N
t2
is from geometric constraint for the Heat Exchanger whose size
L
1
,L
2
and L
3
are determined by assuming Nt values at start. So we expect the values to be
equal at a possible point of design.
Hence we have:
N
t
=87
N
t0
ceil Soltn ( ) 87 = :=
6.2.12 Values of parameters at Design point
Aa_min 0.09872 m
2
= h
a
175.73364
W
m
2
K
= G
a
25.32342
kg
m
2
s
=

f
0.02068 =
o
0.17835 = A
fr_a
0.18487 m
2
=
Re
w
N
t0
( )
663.2272 = h
w
N
t0
( )
894.59971
W
m
2
K
= A
fr_w
N
t0
( )
0.04641 m
2
=
G
w
N
t0
( )
48.39296
kg
m
2
s
= N
t0
87 =
U
o
N
t0
( )
22.92052
W
m
2
K
= A
o
N
t0
( )
237.86579 m
2
= V
hex
N
t0
( )
0.40522 m
3
=
L
1
N
t0
( )
8.73216 m = L
2
N
t0
( )
0.02117 m = L
3
N
t0
( )
2.19188 m = L
1
and L
3
are the core lengths
L
2
will be increased to cover a complete unit matrix
6.2.13 Pressure requirements
Presure Drop on Air side:
From kakac textbook equation 9.15

ai
1.2709
kg
m
3
:=
ao
1.185
kg
m
3
:= Taking ideal air assumptions P
i
/P
o
=T
i

o
/(T
o

i
)
P
a
G
a
2
2
ai

f
A
o
N
t0
( )
Aa_min

ai

a
1
a
2
+
|
\
|
.
T
a1

ao

T
a2

ai

1 +
|

\
|
|
.
+

(
(

1.45919 10
4
Pa = :=
Presure Drop on Water side:
Since the flow in pipes are in parallel, the water flow rate is divided among the pipes
neglecting entrance and exit pressure drops since flow rate is low
f
w
64
Re
w
N
t0
( )
0.0965 = := since flow in pipes are laminar in order not to mix water solution in the pond
P
w
G
w
N
t0
( )
2
2
w

f
L
1
N
t0
( )
d
i
26.75082 Pa = :=
Presure Drop on Water side:
P P
w
P
a
+ 1.46186 10
4
Pa = :=
6.2.13 Pumps Power Requirements
P
a
P
a
m'
a

a
3.14047 10
4
W = := The power of air is assumed to come from an industrial process
P
w
P
w
m'
w

w
9.09038 10
3
W = := This power needed to pump water to the heat exchanger is small compared to the heat energy
extracted