2.0 INTRODUCTION 2.

1 HEAT TRANSFER IN ENGINEERING: The study of temperature distribution and heat transfer is of great importance to engineers because of its almost universal occurrences in many branches of science and engineering. The first step in the optimal design of heat exchangers such as boilers, refrigeration and radiators is a detailed analysis of heat transfer. This is essential to determine the feasibility and cost of the undertaking, as well as the size of the equipment required to transfer a specified amount of heat in a given time. Modem electric and electronic plants require efficient dissipation of heat. A thorough heat transfer analysis is most important for the proper sizing of fuel elements in nuclear reactor cores to prevent bum out. The performance of aircraft also depends upon the ease with which the structure and engines can be cooled. An accurate heat transfer analysis is necessary for refrigeration and air-conditioning application to calculate the heat loads and determine the thickness of insulation and to avoid excess in heat gains or losses. It is clear that engineers and scientists must have a thorough knowledge of the science of heat transfer to employ in various applications. 2.2 MECHANISMS OF HEAT TRANSFER: The energy transfer as heat takes place by three distinct modes: Conduction, Convection and Radiation. Heat conduction is the mode of heat transfer via two mechanisms. By molecular interaction were by the energy exchange takes place by kinetic motion or direct impact of molecules. Molecules at a relatively high energy level (temperature) impart energy to adjacent molecules at lower energy levels.

This type of energy transfer always exists so long as there is a temperature gradient in a system comprising molecules of a solid, liquid or gas. By the drift of free electron as in the case of metallic solid. The metallic alloys have a different concentration of free electrons, and their ability to conduct heat is directly proportional to the concentration of free electrons in them. The free electron concentration of non-metals is very low. Hence materials that are good conductors (pure metals, viz., '~copper, silver etc.) are good conductors of heat too. Pure conduction is found only in solids. Fourier's Law of Heat Conduction, Q = -kA(oT/ox) Convection is possible only in the presents of a fluid medium. When a fluid flows inside a duct or over a solid body and the temperature of the fluid and the solid surfaces are different, heat transfer between the fluid and the solid surface will take place. This is due to the motion of fluid relative to the surface this type of heat transfer is called convection. The transport of heat here is inseparably linked with the movement of fluid itself. If the fluid motion is setup by buoyancy effects resulting from density variation caused by the temperature difference in the fluid, the heat transfer is set to be free or natural convection. On the other hand if the fluid motion is artificially created by means of an external agency like a blower or fan, the heat transfer is termed as forced convection. For convection the heat transfer rate is given by, Q = hA(T1 - T2) As the energy transfer between the solid surface and the fluid at the surface can take place only by conduction, the heat transfer by convection is always accompanied by conduction.

If two bodies at different temperatures are placed

111

an evacuated adiabatic

enclosure so that they are not in contact through solid or fluid medium, the temperature of the two bodies will tend to become equal. The mode of heat transfer by which this equilibrium is called thermal radiation. Radiation is an electromagnetic wave phenomenon, and no medium is required for its propagation. In fact the energy transfer by radiation is maximum when the two bodies exchanging energy are separated by a p'erfect vacuum. Thermal radiation depends only on the temperature and on the optical properties of the emitter. Most of the heat that reaches us when we sit in front of a fire is radiant

The various classifications of heat exchangers are given III below flow charts.

Indirect contact type

Direct contact type

1.

I
Plate type

I I

I
Regenerative Fixed matrix

Tubular

I
Spiral

I
Welded

I
Pipe coils

Extended surface

Gasketed

I
Classification according to surface compactness

Rotary

Parallel to tubes

separating wall Cross flow to tubes

I
Ordinary

Heat pipe wall

Compact (surface area density >700m2/m3)

Non Compact (surface area density <700m2hn3)

The two major categories of heat exchangers are 1. Shell and tube exchangers. 2. Compact heat exchangers. 2.4.1 Shell and Tube Exchangers: Shell and tube heat exchangers are fabricated with round tubes mounted in cylindrical shells with their axes coaxial with the shell axis. The differences between the many variations of this basic type of heat exchanger lie mainly in their construction' features and the I?rovisions made for handling differential thermal expansion between tubes and shell. The shell and tube heat exchangers are classified based up on the number of passes, number of baffles, type of head, type of flow, type of tube, cross section of tube, etc

2.4.2 Compact heat exchangers: Compact heat exchangers have a large heat transfer surface area per unit volume of the exchanger, resulting in reduced space, weight, support structure and footprint, energy requirement and cost, as well as improved process design, plant layout and processing conditions, together with low fluid inventory compared with shell-and-tube exchangers. From the operating condition and maintenance point of view, compact heat exchangers of different constructions are used for specific applications, such as for high temperature applications (up to about 850C or 1550 OF), high pressure applications (over 200 bars), and moderate fouling applications. However, applications do not involve both high temperature and pressure simultaneously.

Classification of Compact Heat Exchangers: Compact heat exchangers may be classified by the kinds of compact elements that they empl,oy. The compact elements usually fall into five classes, 2. Circular and flattened circular tubes 3. Tubular surfaces 4. Surfaces with flow normal to banks of smooth tubes 5. Plate fin surfaces 6. Finned-tube surfaces 7. Matrix surfaces

In this project an heat exchanger similar to the shell and tube heat exchanger, without the shell is designed. The heat exchanger is fully immersed , in the fluid to remove the heat generated. This idea was obtained from the heat exchanger used to cool lubricant oil in automobile engines, where the heat exchanger used to cool the lubricant oil is immersed in the coolant used for cooling the engine.

Coil Buildup Line (CBL) is one of the units of Cold Rolling Mill Il1 Salem Steel Plant. The coil buildup line is used prepare the sheet materials before passing in to the annealing line. It also has a notching unit which is used to cut samples for testing sheet metal. It has a MIG welding unit for building up of the coils.

The main functions of coil build-up line are, 1. Add leader end (7 to 8m) in coils for full rolling of Z-Mill

3. Rewinding of coils 4. Joint smaller coils and make bigger coils. In this line stainless steel coils of thickness 2.5 to 8mm are used. Below 3mm thickness sheets are not attached leader ends. The speed of the CBL is 5 to 50m/min. Width of coil is 1000 mm to 1250 mm. Coil Build up Line (fig3.1) works in 3 different modes. For welding of two coils or the sheet metal with the ends of the coils, we have Arc welding machine in which argon gas is used after this welding portion should be annealed by Annealing system. So the coil buildup line prepares the coils for annealing process and it can also prepare the sheet metals for market directly as per the requirements, as the CBL has the capacity for various operations to be done.

8.

Fig 3.1 Process Flow ~ Coil Buildup Line

The coil buildup line has an uncoiler, entry shear, MIG welding unit, notching unit, side trimmer and a coiler. The entry shear functions to cut the wavy edges of the sheet metal and prepare the strip for welding operation. The coiler and uncoiler has roller cars that are used to load and unload the coils. The chucks are used to hold the coils in position while winding and unwinding the coils. The coil buildup line has magnetic plates that are used to place the leader ends in position, i.e. on the rollers before welding them to the coils. The notching unit is placed next to the welding machine, its function is to notch the ends of the weld. The notched portion is used to test the grade of the sheet metal, also the notching prevents the peeling off of the welded region,
18

thus enhancing the strength of the weld. Pits are present below the coil buildup line, they collect the trimmed and sheared metallic pieces of the sheet metal. The collected metalic wastes can be recycled by sending them to the hot rolling mill. The MIG welding welds the leader ends to the head and tail of the sheet metal, the notching unit notches the end of the welded region to avoid peeling of the welded region. The side trimmer is used to redu~e the width of the sheet metal. The exit shear is used to cut the sheet metal to required lengths.

4.0 PROBLEM IDENTIFICATION 4.1 SHEARING UNIT:

There are two shearing units at coil buildup unit. The entry shear functions to prepare the strip for welding, the exit shear is used to cut the sheet metals into smaller sheets. The shears are operated by a piston and cylinder arrangement which operate by using hydraulic power. The hydraulic actuation system uses hydraulic oil SSU 46 supplied by Indian Oil Corporation Limited. The hydraulic system is actuated by means of two axial piston pumps, the pressure is maintained by using two pressure relief valves. The oil that returns to the tank as the piston retracts is cooled by means of a shell and tube heat exchanger. But the oil that returns to the tank through the relief val ves of the two motors and the pressure relief valves are not cooled this generates in the tank, when the piston is not in operation for long time. It was found at the rate of temperature rise was 5 C per hour. When the piston is in operation the oil is cooled by the shell and tube heat exchanger. But when the piston is not in operation for long time heat generates in the tank. So idle strokes of the piston were made to cool the hydraulic oil. As per specification of the oil SSU 46 the oil should not be used above 60C. If the oil SSU 46 is used above 60C the viscosity of the oil reduces and which results increased friction and it results in noisy operation. So the wear and tear of the linings is more and hence reduced life of the piston & cylinder. To cool the oil when the exit and entry shear are not in use, idle strokes were made, so that oil flows through the shell and tube heat exchanger and get cooled. This cools the oil, but wastes energy and disturbs the normal operation of the coil build up line