HEAT EXCHANGER DESIGN AND MATERIALS SELECTION

AND MANUFACTURING

SEMINAR REVIEW REPORT

SUBMITTED TO B V RAJU INSTITUTE OF TECHNOLOGY NARSAPUR

IN PARTIAL FULFILMENT FOR THE AWARD OF BACHELOR OF
TECHNOLOGY IN PHARMCEUTICAL ENGINEERING

BY
Gada Shriram (21211a3127)
Under the Supervision of
Dr.B.Ravi
ASSISTANT PROFESSOR

DEPARTMENT OF PHARMACEUTICAL ENGINEEERING

B.V. RAJU INSTITUTE OF TECHNOLOGY (UGC–AUTONOMOUS)
VISHNUPUR, NARSAPUR, MEDAK DISTRICT, TELANGANA STATE

2024

I
 B.V. RAJU INSTITUTE OF TECHNOLOGY
(UGC–AUTONOMOUS)
Vishnupur, Narsapur, Medak District.
Department of Pharmaceutical Engineering

CERTIFICATE

This is to certify that the seminar entitled Heat Exchanger Design and Materials and
Manufacturing is given by GADA SHRIRAM, Roll No.21211A3127, a bonafide student
of IV year in partial fulfillment for the award of Bachelor of Technology in Pharmaceutical
Engineering, during the year 2024. It is certified that all corrections/suggestions indicated for
internal assessment have been incorporated in the report deposited in the departmental library. The
seminar report has been approved as it satisfies the academic requirements in respect of seminar
prescribed for the said degree.

DR.B.RAVI DR. VISHNU PULAVARTHY

Supervisior Professor& HOD

Date:12/12/24
Place:B.V.Raju Institute of Technology
Narsapur
 B.V. RAJU INSTITUTE OF TECHNOLOGY
(UGC–AUTONOMOUS)
Vishnupur, Narsapur, Medak District
Department of Pharmaceutical Engineering

DECLARATION

I hereby declare that the work presented in this internship report entitled Heat Exchanger
Design and Materials selection And Manufacturing is the outcome of my own bonafide
work and is correct to the best of my knowledge and this work has been undertaken taking care of
engineering ethics. It contains no material previously published or written by another person nor
materials which has been accepted for the award of any other degree or diploma of the university
or other institute of higher learning, except where due acknowledgement has been made in the
text.

BY
GADA SHRIRAM
Roll No. 21211A312
 B.V. RAJU INSTITUTE OF TECHNOLOGY
(UGC–AUTONOMOUS)
Vishnupur, Narsapur, Medak District
Department of Pharmaceutical Engineering

ACKNOWLEDGEMENT

First and foremost, we offer our sincere gratitude to the Principal Dr. Sanjay Dube
for providing us with all the resource in the college to make our Report a success we
thank him for his valuable suggestions at the time of presentation which encouraged
us to give my best in the Seminar .
We are also grateful to Dr. Pulavarthy Vishnu Professor & Head of the
Department of Pharmaceutical engineering for his support and valuable suggestions
during the dissertation Work.
We are also thankful to Dr.B.Ravi , assistant Professor, Seminar coordinator for his
valuable guidance and encouragement during our dissertation work.
We would also like to thank all the supporting staff of the department of pharmaceutical
engineering and all other departments who have been helpful directly or indirectly in
making the project successful lastly. We would like to acknowledge the numerous
researchers and authors whose work We have cited in my project. Their contributions
have formed the foundation of my research and We are grateful for the knowledge they
have shared with the academic.

By:
Gada Shriram(21211A3127)
TABLE OF CONTENTS

CHAPTER PAGE

ABSTRACT i

LIST OF FIGURES 1

CHAPTER 1 – INTRODUCTION 2

CHAPTER 2 – LITERATURE REVIEW 3

CHAPTER 3 – COMPACT HEAT EXCHANGER 4

3.1. Compact heat exchanger 5

3.2. Types of heat exchanger design 6

3.3. Flat plate exchanger designs 7

CHAPTER 4- METHODOLOGY

4.1 Tubular Heat Exchanger Design – Double Flow 9

4.2 Tubular Heat Exchanger Designs 9

4.3 Material Selection 10

CHAPTER 5 – CONCLUSION 11
REFERENCES 12
 ABSTRACT
Heat Integration with heat exchanger network (HEN) is a widely used way to save energy and
improve efficiency. Varied types of heat exchanger and materials would influence the investment
cost and affect the design of HEN retrofit. This paper critically reviews the features of various types
of heat exchanger, their working conditions and investment costs, as well as the state-of-the-art of
the current methods for HEN synthesis and retrofit, to introduce a framework for HEN retrofit
which considers heat exchanger and material selection. The proposed framework divides the retrofit
design process into two stages, diagnosis and optimisation. In the diagnosis stage, two graphical
decision-making tools, the Shifted Retrofit Thermodynamic Grid Diagram with Shifted Heat
Exchanger Temperature Range (SRTGD-SHTR) and Shifted Material Temperature Range
(SRTGD-SMTR) are proposed for analysis and diagnosis of the existing HEN to determine feasible
retrofit plans with pre-selected heat exchangers and materials. In the optimisation stage, the
constrained particle swarm optimisation algorithm is applied to optimise the plans made in the first
stage and minimise the total annual cost. A case study demonstrates a possible implementation of
the proposed framework. The suitable types for new heat exchangers and their materials are
selected, and the retrofitted design can reduce the utility cost by 8.9% compared with the existing
HEN. This framework can be applied easily with a sound solution for HEN retrofit.
The present work aims to critically analyze the designs, materials, and manufacturing methods of
heat exchangers used for solid desiccant coating and look into recent developments in regular heat
exchangers, potentially deployed as a substrate for DCHE applications. A comprehensive literature
review of publications regarding solid desiccant materials, heat exchangers, manufacturing and
coating methods, binder materials, and the performance of heat exchangers has been developed.
Alternative heat exchangers are described as better options than fin and tube heat exchangers that
have been considered thus far for DCHE applications. Additionally, the heat exchanger's
manufacturing process and materials over their thermal and mass exchange performance have been
analyzed. Despite the widespread use of fin and tube heat exchangers for solid desiccant coating,
recent developments in heat exchanger design, and related fields such as manufacturing methods
and materials, open the possibilities for their application in solid desiccant dehumidification
systems.

i
S.no List of Figures Page num
Figure -1 : Types, Designs, Applications and
1 Selection Guide
3
2 Figure – 2: Static Equipment: Understanding Heat Exchangers 5

3 Figure – 3 : Tubular Heat Pipe configuration of Inner Tubes 7

4 Figure – 4 : Managing Pressure Drop In The Design Of 7

Shell And Tube Heat Exchangers – Equinox

5 Figure – 5 : Heat Exchanger Material Selection | 8

Fictiv
Figure – 6 : Straight-Tube Heat Exchanger
6 9
Figure - 7 : Optimal design of plate heat
7 exchangers with and without pressure drop.
10

1
 CHAPTER –1
INTRODUCTION

Air humidity affects human thermal comfort and health (1). Vapor compression systems (VCSs) are
commonly used to control temperature and provide dehumidification capabilities, also called
sensible and latent cooling, respectively. For latent cooling, VCS relies on the under cooling of
process air below its dew point, which leads to the removal of excessive moisture by condensation.
This process requires cooling the air below comfortable supply temperatures. Therefore, a reheating
process must follow the over cooling process before supplying air to the building, as the process of
1-4-5-2 is shown in Fig.1. This process, therefore, is energy inefficient. To overcome the weakness
of the VCS, researchers have sought alternative de humidification processes with better energy
efficiency. One promising alternative is the solid-desiccant-based dehumidification (SDD)

system.In solid desiccant- based dehumidification processes, capillary condensation happens due to
increased water vapor concentration inside the pores of the desiccant material. The adsorption
process gives off heat, which heats the desiccant material (the process from states 3 to 2 shown in
Figure 1), and the adsorption capability of the system drops. It is necessary to dry the solid desiccant
material for sustaining the operation. The addition of heat is the most common process method to
remove the adsorbed moisture in the saturated solid desiccant material.
The adiabatic SDD needs simple cooling (the process from state 3 to 2, as shown in Figure 1) to
remove both the sensible heat of process air and the adsorption heat. Desiccant Coated Heat
Exchanger (DCHE) system, a type of SDD system, uses internally cooled heat exchangers coated with

solid desiccant material to remove the adsorption heat dehumidifying.

2
 CHAPTER – 2
LITERATURE REVIEW

1. An extensive review of the recent progress in heat transfer enhancement using longitudinal
vortex generation has been done by Jacobi and Shah. The review given below is focused on
articles that are particularly relevant to current research.

2. As described by Fiebig [4], when the attack angle is small, the generated vortices are
mainly longitudinal, when the attack angle is 90°, transverse vortices are generated. Jacobi
and Shah
[3] and Fiebig [4] noted that longitudinal vortices show less flow losses and better heat
transfer characteristics than transverse vortices. In recent years, the third generation of
enhanced surface designed with longitudinal vortex generators (LVGs) is receiving more
attention.
3. The first report on longitudinal vortices in boundary layer control was presented in 1960
by Schubauer and Spangenberg [5]. Johnson and Joubert [6] early reported the impact of
vortex generators on the heat transfer performance in 1969. Since then, the use of LVGs in
channel flow application has received considerable attention. Lee et al numerically simulated
heat transfer characteristics and turbulent structure in a three-dimensional turbulent boundary

layer with delta wing type longitudinal vortices.

Figure -1 : Types, Designs, Applications and Selection Guide

3
 CHAPTER – 3
Compact Heat Exchanger

The ratio of the heat transfer surface area of a heat exchanger to its volume is called the area
density β. A heat exchanger with β = 700 m2 /m3 (or 200 ft2 /ft3 is classified as being compact. A
compact heat exchanger is generally defined as one which incorporates a heat transfer surface having
a high "area density". In other words, it possesses a high ratio of heat transfer surface area to volume.
This does not necessarily mean that a compact heat exchanger is of small mass or volume. However,
if compact heat exchangers did not incorporate a surface of such high area density, the resulting units
would be much bulkier and more massive than their compact counterparts [7]. Compact surfaces are
used to yield a specified heat exchanger performance q/∆Tmean, within acceptable mass and volume
constraints, where. TiO2/water Nano-fluid Nano fluids are a new class of fluids engineered by
dispersing nanometer-sized materials (nanoparticles, Nano fibers, nanotubes, nanowires, Nano rods,
Nano sheet, or droplets) in base fluids. Common base fluids include water, organic liquids (e.g.,
ethylene, tri-ethylene-glycols, refrigerants, etc.), oils and lubricants, bio-fluids, and other common
liquids. Titanium dioxide (TiO2) is one of the promising materials for heat transfer enhancement
purpose due to its excellent chemical and physical stability. In addition, TiO2 particles are cheap and
commercially available. TiO2 nanoparticles suspended in conventional fluids were extensively
utilized in various forms of heat exchangers, including circular tube, a double tube and a shell and
tube.

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 Figure – 2: Static Equipment: Understanding Heat Exchangers

Thermal design for recuperators

Four methods are used for the recuperator thermal performance analysis: log-mean temperature
difference (LMTD), effectiveness-number of transfer units (ε−NTU−NTU), dimensionless mean
temperature difference (Ψ−P) and (P1 – P2) methods.

Parallel and counter flow heat exchanger

Two types of flow arrangement are possible in a double-pipe heat exchanger: parallel flow and
counter flow. In parallel flow, both the hot and cold fluids enter the heat exchanger at the same end
and move in the same direction, as shown in Figure 1. In counter flow, the hot and cold fluids enter
the heat exchanger at opposite end and flow in opposite direction.

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Types of Heat Exchanger Design

1. Tubular and Shell Heat Exchanger Design

2. Double Pipe or Hairpin Exchanger Design

3. Flat Plate and Fin Exchangers

4. Radiators and Solar Exchangers

5. Spiral Heat Exchangers

6. Air Coolers, Chillers and Condensers

7. Wet Cooling Towers

Tubular Heat Exchanger Designs

Tubular heat exchanger are by far the simplest design. The primary fluid circulates through straight
or concentric pipes in the form of U-shaped tube design. These primary tubes are encased within an
outer sealed tube that circulates the secondary fluid.

Their usual application is in small heat water-to-water transfer applications. The advantage of this
type of design is flexibility since tubular heat exchangers can be added or removed as required. Also
any number of heat exchangers can be connected together in series or parallel combinations.

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 Tubular Heat Exchanger Design – Double Flow

Figure – 3 : Tubular Heat Pipe configuration of Inner Tubes

+
Flat Plate Exchanger Designs
Flat plate heat exchangers are another common type of design which offer improved
efficiencies for their size compared to tubular designs. These types of heat exchanger provide a
relatively large heat transfer surface in a small space and can also operate at higher fluid
pressures.

Generally, they are made from lots of thin metal plates joined or “stacked” together, with a
small amount of space between each plate to allow the heat transfer fluid to circulate, extracting
heat from the plates as it flows. These individual plates are usually joined together using rubber
gaskets and seals to prevent leakage and direct the thermal fluids through alternate flow
passages. Other types of flat plate heat exchangers include brazed or welded exchanger designs.

Figure – 4 : Managing Pressure Drop In The Design Of Shell And Tube Heat Exchangers – Equinox
7
Plate-fin and tubular-fin heat exchangers are another more common type of thermal heat
exchanger categorised as “compact heat exchangers”.

Heat exchangers get their name from the fact that their construction results in a very large
thermal surface area within a small physical size. The compactness of the exchanger is usually
given in so many m2/m3 of physical size, with surface area densities of over 1000m 2/m3 now
common.

Compact heat exchangers are commonly used as automotive water and oil cooling radiators,
air conditioning applications, process and waste heat recovery, Ocean Thermal Energy
Conversion (OTEC), Geothermal and Solar Thermal systems. In fact anywhere where there is
a need for a small compact light-weight, space-saving, and economical heat exchanger.

Figure – 5 : Heat Exchanger Material Selection | Fictiv

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 CHAPTER 4
METHODOLOGY
A methodology is developed that simulates an existing HEN considering all the
complexities associated with its operation.

Therefore, the HEN unit operation concept is introduced to include this methodology into
the operational workflow. An example of a crude preheat train is presented to show two
important features of the HEN unit operation.

One of these features makes possible the analysis of the result of the HEN variables when
changes in the operating conditions are performed in a single.

Figure – 6 : Straight-Tube Heat Exchanger

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Material Selection

The choice of material for construction in heat exchangers is usually influenced by the process
fluids and operating conditions such as temperature and pressure. An ideal material for
construction is desired to have low corrosion rate, high tensile strength, high thermal
conductivity, less cost and high reliability (Lancaster, 1983). From the spectrum of steels
available in the market, (Lancaster, 1983) stated that carbon steel and Austenitic chromium-nickel
steel are the most used materials for general purpose heat exchangers. In the temperature range of –
500 °C, both materials give satisfactory results, and for temperatures above 500 °C, refractory-
lined Austenitic steel is typically employed (Lancaster, 1983).Carbon steel is mostly considered for
less corrosive fluids such as hydrocarbons while Austenitic steel may also be considered for use
in mildly corrosive fluids such mercaptan hydrocarbons mostly found in the oil and gas
industries (Lancaster, 1983). In general, Austenitic steel is classified as high-grade steel, thus
more costly and reliable compared to carbon steel. Moreover, due to the presence of chromium in
Austenitic steel, corrosion effects are reduced significantly.

Figure - 7 : Optimal design of plate heat exchangers with and without pressure drop.

10
 CHAPTER 5
CONCLUSION

This paper gives a detailed description of certain types of geometries that can be used
to enhance heat transfer. Also, various methods of comparing the performance
achieved by different types of enhanced surfaces applicable to compact heat
exchangers were summarized. Several plate-fin enhancement geometries have been
developed in order to make heat exchangers more efficient and compact. Currently,
plate-fin heat exchangers are very common in cryogenic systems and gas-liquefaction
plants. Increased demand for smaller and better heat exchange devices will
undoubtedly lead to more widespread use of plate-fin heat exchangers in other
applications as well. This paper gives a detailed description of certain types of
geometries that can be used to enhance heat transfer. Also, various methods of
comparing the performance achieved by different types of enhanced surfaces
applicable to compact heat exchangers were summarized. Several plate-fin
enhancement geometries have been developed in order to make heat exchangers more
efficient and compact. Currently, plate-fin heat exchangers are very common in
cryogenic systems and gas-liquefaction plants. Increased demand for smaller and
better heat exchange devices will undoubtedly lead to more widespread use of plate-
fin heat exchangers in other applications.

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REFERENCES

1. Admiraal, D.M. and C.W. Bullard, 1993, "Heat Transfer in Refrigerator Condensers and
Evaporators," Air Conditioning and Refrigeration Center TR-48, 'The University of Illinois,
Urbana, ll
2.Webb, R. L., 1987, ''Enhancement of Single-Phase Heat Transfer," in Handbook of Single-
Phase Convective Heat Transfer, edited by Kakac, et al., Wiley Interscience, New York, NY.
3.A.M. Jacobi, R.K. Shah, Heat transfer surface enhancement through the use of longitudinal
vortices: a review of recent progress, Experimental Thermal and Fluid Science 11 (1995)
295– 309.
4.M. Fiebig, Embedded vortices in internal flow: heat transfer and pressure loss
enhancement, International Journal of Heat and Fluid Flow 16 (1995) 376–388.
6.G.B. Schubauer, W.G. Spangenberg, Forced mixing in boundary layers, Journal of Fluid
Mechanics 8 (1960) 10–31.
[6T.R. Johnson, P.N. Joubert, the influence of vortex generators on drag and heat transfer
from a circular cylinder normal to an airstream, ASME Journal of Heat Transfer 91 (1969)
91–99.
7.S.H. Lee, H.S. Ryou, Y.K. Choi, Heat transfer in a three-dimensional turbulent boundary
layer with longitudinal vortices, International Journal of Heat and Mass Transfer 42 (1999)
1521–1534
8.M.C. Gentry, A.M. Jacobi, Heat transfer enhancement by delta-wing vortex generators on a
flat plate: vortex interactions with the boundary layer, Experimental Thermal and Fluid
Science 14 (1997) 231–242.
9.M.C. Gentry, A.M. Jacobi, Heat transfer enhancement by delta-wing-generated tip vortices
in flat-plate and developing channel flows, ASME Journal of Heat Transfer 124 (2002)
1158– 1168.
10.A. E. Bergles, R. L. Webb and G. H. Junkan, Energy Conservation Via Heat Transfer
Enhancement, Energy, Vol. 4, pp. 193-200, 1979.
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