PROJECT DESCRIPTION

Design and preparing a working model of Double Pipe Heat Exchanger (Counter flow) for heating water from 20C to 35C.

INTRODUCTION
A heat exchanger is a device built for efficient heat transfer from one medium to another. The media may be separated by a solid wall, so that they never mix, or they may be in direct contact. They are widely used in space heating, refrigeration, air conditioning, power plants, chemical plants, petrochemical plants, petroleum refineries, natural gas processing, and sewage treatment. One common example of a heat exchanger is the radiator in a car, in which the heat source, being a hot engine-cooling fluid, water, transfers heat to air flowing through the radiator.

FLOW ARRANGEMENT
There are two primary classifications of heat exchangers according to their flow arrangement. In parallel-flow heat exchangers, the two fluids enter the exchanger at the same end, and travel in parallel to one another to the other side. In counter-flow heat exchangers the fluids enter the exchanger from opposite ends. The counter current design is most efficient, in that it can transfer the most heat from the heat (transfer) medium. In a cross-flow heat exchanger, the fluids travel roughly perpendicular to one another through the exchanger. For efficiency, heat exchangers are designed to maximize the surface area of the wall between the two fluids, while minimizing resistance to fluid flow through the exchanger. The exchanger's performance can also be affected by the addition of fins or corrugations in one or both directions.

Figure: 1

DOUBLE PIPE EXCHANGER: COUNTER FLOW

1. 2. 3. 4. 5. 6. 7. 8.
Figure: 2

Flange Cold Water inlet/outlet Inner Pipe Tee Gland Outer pipe Return Head Return bend

The principal parts are two sets of concentric pipes, tees and a return head and return bend. The inner pipe is supported within the outer pipe by packing glands and the fluid enters the inner pipes through a threaded connection located outside the exchanger section proper. The tees have nozzles or screwed connection attached to them to permit the entry and the exit of the annulus fluid which crosses from one leg to other through the return head. The two length of inner pipe are connected by return bend which is usually exposed and does not provide effective heat transfer surface. The double pipe exchanger is extremely useful because it can be assembled in any pipe fitting shop from standard part and provides inexpensive heat transfer surface.

INDUSTRIAL USE:
Heat exchangers are widely used in industry both for cooling and heating large scale industrial processes. The type and size of heat exchanger used can be tailored to suit a process depending on the type of fluid, its phase, temperature, density, viscosity, pressures, chemical composition and various other thermodynamic properties. In many industrial processes there is waste of energy or a heat stream that is being exhausted, heat exchangers can be used to recover this heat and put it to use by heating a different stream in the process. This practice saves a lot of money in industry as the heat supplied to other streams from the heat
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exchangers would otherwise come from an external source which is more expensive and more harmful to the environment. Heat exchangers are used in many industries, some of which include: Waste water treatment Refrigeration systems Wine-brewery industry Petroleum industry.

In the waste water treatment industry, heat exchangers play a vital role in maintaining optimal temperatures within anaerobic digesters so as to promote the growth of microbes which remove pollutants from the waste water. The common types of heat exchangers used in this application are the double pipe heat exchanger as well as the plate and frame heat exchanger.

DESIGN PROBLEM : To Design a Double pipe (Counter Flow) Heat

Exchanger to heat water at 20oC to 35oC at the rate of 0.0415 kg/s using hot water cooled from 80oC to 60oC. The Pipe used should be of following specification: Inner Pipe: Outer Diameter, do = 0.021 m Inner diameter, di = 0.018 m Outer Pipe: Outer Diameter, Do = 0.034 m Inner Diameter, Do = 0.031 m

SELECTION OF MATERIAL:
The selection of proper material for better heat transfer rate is necessary for the designer to choose. The best material is one, which serves the desired objective at minimum cost. The following factor should be considered while selecting the material. Availability of material. Cost of the Material. Suitability of the material for the working condition Comparison of different material that can be used are: Metal Aluminium Copper G.I M.I Brass Conductivity, k W/m C 204 386 48 54 111 Table: 1 Cost High High Low Low High Corrosion factor Low Low Low Medium Low

From the above table, Copper is most suitable for manufacturing of pipes but due to high cost is not preferred. So, Galvanized Iron Pipes (G.I Pipes) are used due to its low cost and highly resistive to corrosion. Taking G.I. pipes for design, its properties are: Density, = 7801 kg/m3 Specific Heat, Cp = 0.473 kJ/kg C Thermal Conductivity, k = 54 W/m C

CALCULATION:
Water Properties: Density, = 995 kg/m2 Specific Heat, Cp = 4.187 kJ/kg K Thermal conductivity, k = 0.615 W/m K Viscosity, = 4.18 10-7 m2/s (1) Heat Balance: Cold Fluid, tav = (35 + 20)/2 = 27.5C Q = 0.053 4.187 (35 - 20) = 3.4707 kW Hot Fluid, Tav = (80 + 60)/2 = 50C Wc = 3.4707/ (4.187(80 - 60)) = 0.0415 kg/s (2) Logarithmic Mean temperature Difference (LMTD): Hot fluid 80 60 Higher temp. Lower temp. Cold fluid 35 20 Diff. 45 40 5 LMTD, m = = 5 / (ln (45/40)) = 42.45C t2 - t1 Cpc=4.187 kJ/Kg K Cph = 4.187 KJ/Kg K

Hot fluid: annulus (3) Flow Area: Flow area, aa =

Cold fluid: inner pipe

Flow area, ap = = (0.018)2 = 2.54 10-4 m2

= (0.0312 0.0182) = 4.08 10-4 m2

(4) Velocity of water: Velocity of water in outer Pipe, Vo = Q/a0 = 0.0415 / 995 (1 / 4.0810-4) = 0.102 m/s. Velocity of water in Inner pipe, Vi = Q/ai = 0.053 / 995 ( 1/ 2.54 10-4 ) = 0.2097 m/s. (5) Reynolds No.: For Cold Fluid : Inner pipe Re = = 40.0415 / ( 0.018 995 4.18 10-7 ) = 2454.37 For Hot Fluid : Outer Pipe Re = = 4 0.053 / ( (0.021 + 0.031) 995 4.18 10-7 ) = 21727.5 (6) Heat Transfer Coefficient, h : For Cold fluid : Pr = = = 0.00283

Nu = 0.023 (Re)0.8 (Pr)0.4 = 0.023(2454.27)0.8(0.00283)0.4 = 45.096 Also, Nu = = 44.096

Hence, hi = 1540.8 W/m2 K

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For Hot fluid : Pr = = = 0.00283

Nu = 0.023 (Re)0.8 (Pr)0.4 = 0.023 (18604.11)0.8 (0.00283)0.4 = 40.46 Also, Nu = = 40.46

Hence, ho = 1673.86 W/m2 K (7) Overall Heat transfer Coefficient: Overall heat transfer coefficient referred to outer diameter of inner tube is given by neglecting fouling factor.

Hence, U0 = 802.12 W/m2 K (8) Surface Area: The heat transfer rate is given by Q = Uo Ao m Ao = = = 0.1022 m2 (9) Length of Pipe Required: We know that, A = do L
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So,

L= = = 1.55 m

RESULT OF DESIGN:
Inner Pipe: Outer Diameter, do = 0.021 m Inner diameter, di = 0.018 m Outer Pipe: Outer Diameter, Do = 0.034 m Inner Diameter, Do = 0.031 m Required Length of pipe, L = 1.55 m