DESIGN OF EXHAUST GAS HEAT EXCHANGER

TEAM MEMBERS
ANKIT SAXENA ADITYA BHUSAN VISHWAKARMA HARSH SHARMA SANDEEP KUMAR GAUR

 Introduction Objective Selection of heat exchanger Problem statement Design consideration of exhaust gas heat exchanger Method employed for design Design procedure Obtained results from design cost estimation Payback period Conclusion

CONTENTS

INTRODUCTION
Present energy scenario has stimulated active research in alternative fuels such as bio-diesel etc. It pose some problem while in use. These properties can be successfully treated by heating. External heating might cost some amount. Diesel engines exchange approx. 30% unused heat in the form of exhaust to environment. This much amount of heat can be utilised by means of a heat exchanger. The thermal design of heat exchanger is directed to calculate an

OBJECTIVE
It is evident that only 3040% energy available at the crankshaft in the mechanical form and about 30% lost as exhaust. The objective is to use this much of heat by designing a compact and economic heat exchanger so that the energy of exhaust can be utilized to heat bio-diesel up to a certain desired

SELECTION OF HEAT EXCHANGER

Double-pipe heat exchanger-It creates problem at high temperature and also when the fluid used is of high viscosity. Spiral tube heat exchanger-Thermal expansion is no problem, cleaning is almost impossible. Plate type heat exchanger- clogging, maldistribution on cooling are main problem and mostly used for evaporation of non-low vapour densities. Extended surface heat exchanger-The heat transfer coefficient is quite low than that of unfinned surfaces.

 Heat pipe heat exchanger-mostly prefer in gas- to gas heat transfer application. Shell& tube heat exchanger with counter flow-Easy to Maintain & Sensitive to the heat transfer rates, Easy to design and Availability of various methods to design, it can also handle fluids of higher viscosity as well as it have a compact design also.

PROBLEM STATEMENT

DESIGN CONSIDERATIONS OF EXHAUST GAS HEAT EXCHANGER Fluid Allocation: shell or tubes
Following factors determines the allocation are Corrosion Fouling Fluid temperature Pressure drop viscosity

Shell and tube fluid velocities

For liquids-1.5 to 2.5 m/s. Shell-side: 0.3 to 1 m/s
For vapoursVacuum 50 to 70 m/s Atmospheric pressure 10 to 30 m/s High-pressure 5to10m/s

METHOD EMPLOYED FOR DESIGN methods for The first attempts to provide
calculating shell-side pressure drop and heat transfer coefficient were those in which correlations were developed based on experimental data for typical heat exchangers. One of these methods is the well-known Kern method, which was an attempt to correlate data for standard exchangers by a simple equation analogous to equations for flow in tubes. However, this method is restricted to a fixed baffle cut

Obtained results from design

Mass flow rate of exhaust gases (meg) 12.05 kg/hr Mass flow rate of fluid (mf) 13.50 kg/hr Exhaust gas inlet temperature (T1 600 K Bio-diesel inlet temperature (t1) 308K Bio-diesel outlet temperature (t2) 364K Cp of exhaust gas in KJ/KgK

OBTAINED RESULTS FROM DESIGN

Viscosity of gases () 0.02998103 kg/ms Viscosity of Biodiesel () 0.0004 kg/ms Thermal conductivity of gases (Keg) 0.1233 W/mC Thermal conductivity of Biodiesel (Kf) 0.154 W/mC Density of the gas (eeg) 2.496 kg/m3 Density the biodiesel (ef) 736.8 kg/m3

OBTAINED RESULTS FROM DESIGN

Heat transfer area A 0.2066 m2 (D0) External diameter of the tube 20 mm (Di) Internal diameter of the tube 16.8 mm Length of heat exchanger 600 mm Number of tube 6 Tube side velocity ut 1.01 m/s

OBTAINED RESULTS FROM DESIGN

Pitch Pt 25 mm Heat transfer Coefficient for tubes, hi 133.20 W/mC Equivalent diameter De 17.25 mm Overall Heat Transfer Coefficient Uo 20.00 w/m2 Heat transfer coefficient at shell side 359.49 W/mC Tube Side Pressure Drop Pt 22.82 N/m2

Wireframe view of heat exchanger

Solid view of heat exchanger

COST ESTIMATION
Raw material:
S.S pipe 1001650 mm. qty 1 1760 Rs 20 1.5 3900 mm. qty 1 3276 Rs M.s plate 150150 15 qty 2 220 Rs Nut and bolt M6 1.5 inch (1kg) 100 Rs Nozzle inch qty 2 50 Rs Baffle plate 200 Rs Other parts 500 Rs Total amount 6316 Rs

Machining cost: 1. Lathe at Rs 100/hr 200 Rs 2. Drill machine at Rs 80/hr 160 Rs 3. Brazing 250 Rs 4. Assemble cost 150 Rs 5. Over heads (10% of total cost) 707.60 Rs 6. Cost of heat exchanger 7783.60 Rs NOTE: Cost is taken on the basis of market survey Cost of product and machining may vary Cost of heat exchanger is

not actual

PAYBACK PERIOD
The payback period is how long it will take to recover money invested in a project, and the socalled straight-payback-period calculation is the simplest way of determining the projects investment potential.

Saving per year = 2522.6 Rs

Simple payback period = 3.09 year

Cost without HE
Energy consumption in heating without shell and tube : Electrical energy consumption 0 .750 kwh/hr No. of operating shift 250 No. of hr/shift 18 Cost of electricity 3.80 Rs/kwhr Annual cost of energy without heat exchanger 12825 Rs

Cost with HE
Energy consumption in heating with shell and tube : Electrical energy consumption 0 .544Kwh/hr No. of operating shift 250 No. of hour/shift 18 Cost of electricity 3.80 Rs/kwhr Annual energy cost with heat exchanger 9302.4 Rs

CONCLUSION
From the above it is found that the exhaust gases at a very high temperature can be utilised to reduce the viscosity of biodiesel through heat exchanger.
The use of shell and tube type heat exchanger for this application is also economic than any other type of heat exchanger as mentioned in this report. The design of such type of heat exchanger is compact and might be facilitate at the exhaust of an diesel engine.

The problem might be its length and its compactness from the point of view of manufacturing. But if all these