A

REPORT

ON

DESIGN OF HEAT EXCHANGER

SUBMITTED TO FACULTY OF CHEMICAL ENGINEERING
BHARATIVIDYAPEETH (DEMMEND TO BE UNIVERSITY)
COLLEGE OF ENGINEERING, PUNE

RATI

VIDZ
UNIVEI
RSIT
& PUNE
SUBMITTED BY:
DEVASHISH SATIAND RAJAN GUPTA
PRN: 1500000889&1500000778

Under the Guidance of:

PROF. SAGAR.CBANDPATTE
DEPARTMENT OF CHEMICAL ENGINEERING
BHARATIVIDYAPEETH (DEEMED TO BE UNIVERSITY)
COLLEGE OF ENGINEERING, PUNE-43
 BHARATIVIDYAPEETH (DEEMED TO BE
UNIVERSITY)
COLLEGE OF ENGINEERING, PUNE-43
DEPARTMENT OF CHEMICAL ENGINEERING

RATITIDA

VERSIT
8R PUNE 8

CERTIFICATE
This is to be certify that the work of report topic "DESIGN OF HEAT
EXCHANGER" is
carried out under my guidance in partial fulfilment for the degree of "Bachelor Of
Techno logy In Chemical Engineering" ."Bharti Vidyapeeth (Deemed to Be
University)",
Pune during the academic year 2018-2019

PROF. S BANDPATTE
Department
(SUBJECT TEACHER) Engneering
ti YBPRRRRREd Universi
rge ofEngíneering.
Ndi Pune - 411
 BHARATI VIDYAPEETH (DEEMED TO BE UNIVERSITY)
COLLEGE OF ENGINEERING, PUNE-411043
DEPARTMENT OFCHEMICAL ENGINEERING

VERSI
PUNE S

Certificate of
Conduction of Examination

This is to certify that viva-voce examination of DEVASHISH SATI & RAJAN GUPTA with
dissertation title DESIGN OF HEAT EXCHANGER" has been held on Monday, 17h
June 2019 at Department of Chemical Engineering, Bharati Vidyapeeth Deemed To Be
University, College of Engineering, Pune-43.

Time: 08:30AM
Date: 17/06/2019
Place: BVDUCOE, PuDe -43

H.O. D.
Internal Examiner DonataDochegnitanggineering External Examiner
fiVidyapeeth Deemed Universit
(-eottegeof Engineering.
nala-Dhankawadi Pune - 411
 ACKNOWLEDGEMENTS
It gives us great pleasure in presenting the report of our topic DESIGN OF
HEAT
EXCHANGER. We would like to take this opportunity to thank our guide Prof.
s.C.Bandpatte for giving us all the help and guidance we needed. We are really grateful to
his for his kind support throughout the analysis and design
phase .his valuable criticism and
suggestion were very helpful.
We are grateful to Dr.
P.V.CHAVAN, Head of Department of Chemical Engineering,
and Bharati Vidyapeeth (Demmed to Be University) College Oof Engineering, Pune for
his support.
 TABLE OF CONTENT

SR TOPIC PAGE NO.

NO.

1. ABSTRACT

2. INTRODUCTION 1

3. LITRETURE SURVEY 3

4. WORKING PRINCIPLE 4

5. CLASSIFICATION 5

6. DESGIN AND OPERATION 6

7 ADVANTAGES, LIMITATION, APPLICATION 12

8 DESIGN METHODOLOGY FLOW 14

9. RESULT 24

10. CONCLUSION 25

11. REFERNCES 26
 ABSTRACT
Plate heat exchangerS are used regularly in the heating, ventilating, air conditioning, and
refrigeration industry. There is an urgent need for detailed and systematic research regarding
heat transfer and the fluid flow characteristics of these types of exchangers. As an initiative
in this respect, a literature search is presented on plate heat exchangers. New correlations for
evaporation heat transfer coefficient and friction factor are introduced, which are applicable
tovarious sy[tem pressure conditions and plate chevron angles. The correlations are based on
actual field data collected during several years of installation and operation of chillers, and
they are intended to serve as design tools and perhaps as a starting point for future research.
Plate heat exchangers are commonly used in hygienic applications as well as in chemical
processing and other industrial applications. Pertinent information on plate exchangers from
a designer's point of view is summarized to provide a basic insight into performance behavior
of chevron plates. Basic design methods are presented and a method of coupling between
heat transfer and pressure drop is introduced. A step by step design procedure for rating and
sizing problems is outlined.
 INTRODUCTION
Heat transfer in the simplest term is the
movement of heat from one place to another and the
process of transferring heat between two or more fluid streams at
different temperatures is
achieve by specialized designed equipment known as heat
exchangers. There are several
types of heat exchangers, which are generally classified based on
their heat transfer
mechanism, size and shape.
This work is about plate heat exchangers, which is frequently used in
the manufacturing and
process industries. The main purpose of this study is to achieve an efficient
method used in
the construction and installation of plate heat exchangers that will
take into consideration all
parameters related to the construction and design of plate heat exchangers.

This will give a general idea of the problem field associated

with the design and application.
The thermal-hydraulic design of the plate heat
exchanger and other physical properties is
mention in this study.

In the study, a design method is presented which calculates several parameters such as the
pressure drop, total effective heat transfer area of plate, Reyno lds, Nusselt numbers
and the
optimum number of plates in plate heat exchangers operating with a given fluid
stream and
different operating conditions.
To analyses the effects of the hot/cold fluid streams,
several iteration is made with the flow
rates, temperatures, and physical properties. The plate material will be changed and the
hot
fluid wil be kept constant in order to get a proper
comparison between the different type of
fluid stream used on the given plate material to obtain the
combination that will yield the
efficient thermal hydraulic design of plate heat exchangers. The design
process is done on
parallel and counter-current flow arrangement whereby the log mean
temperature difference
is calculated for the different arrangement where
possible. Furthermore, the data obtained by
using the simulation and iteration methods are compared and the
accuracy of the result is
determined, which takes into consideration the thermal hydraulic parameters of the fluid
streams. The simulated design data is used to compare the values from literature.
Basic features of plate heat exchangers

Plate Heat exchangers are heat transfer devices that are employed to
transfer heat between
diverse fluid streams at different temperatures. Heat exchangers are
usually classified as
direct contact or indirect contact heat exchangers. The direct
contact heat exchanger there is
no intervening surface between fluids and due to this fact, they
could achieve closer approach
temperatures, while the indirect contact heat exchanger is a device that employs the transfer
of heat between two fluids or between a
surface and a fluid.
The plate heat exchanger is a perfect example of indirect contact heat
exchanger and it is
composed of a series of corrugated plates, which forms the core that enhances and conduct
heat transfer through the plates. The thermal plates consist of gaskets confined in a
formed
groove around the perimeter of the plate that contains the fluid between the plates.
(API
2010)

Plate heat exchangers have several advantages because of their

respective design
methodology, which is relatively inexpensive and easy to dismantle during maintenance.
Furthermore, plate heat exchangers can accommodate a wide range of fluids and the
specialized surface area enhancement due to the many corrugations of the plate implies that a
great deal of surface can be packed into a small volume which makes the design co mpact.
This implies that plate heat exchangers are perfect example of compact heat exchangers
because of its efficient heat transfer surface having a surface area density above about
700m/m3
/m. Other example of indirect contact exchanger is the shell and tube heat exchangers
that have a large hydraulic diameter with small surface area to volume ratios.
 Literature review

Plate heat exchangers (PHES) are not a new concept or techno logy. One of the first patents
was issued in 1890 to Langem and Hundhanssen, a German company. In the past, thís type of
exchanger has been successfully used in industries such as dairy, process, paper/pulp, and
heating, ventilating, and air conditioning (HVAC). The main purpose of this article is to
direct potential researchers to the subject of PHE, because current industries lack
fundamental information about them. These types of evaporators are being used in the
heating, ventilating, air conditioning, and refrigeration (HVAC&R) industry on a regular
basis, yet there is no guidance whatsoever. The objective here is to present the current status
of industrial practice and methods after considering years of fieldwork and real world" data.
Early usage of the PHE was in the dairy industry, but innovative designs and improvements
in its mechanical integrity and sealing aspects allowed application into new areas. These
developments included several unique plate designs and complicated stamping techniques.
Plates with high and low chevron angles began to be used in mixed configurations, which
eventually resulted in a single mixed chevron plate. With the advent of ast computers, one
could precisely distribute different chevron patterns in order to optimize the surface area at
minimum pumping power. Since plate exchangers use gaskets for sealing, the air
conditioning and refrigeration industry did not readily adopt this techno logy due to concerns
over refrigerant leakage. However, the industry was aware of the extraordinary performance
and compactness of PHEs. With the advent of the ozone-depletion issue in the mid-1980s.
some companies started seriously considering the introduction of plate exchangers because
their compactness would result in a low refrigerant charge. Obviously, a low charge meant
lower environmental impact an lower inventory costs.
 Working principle
Plate heat exchangers works with the same basic working
principle of any other heat
exchanger in which there is transfer of heat between two or more fluid
streams through a
separating wall. In the case of a plate heat exchanger, heat transfer occurs
through the
separating wall or plate with no intermixing of the liquids flowing through the plates or
leakages to the surrounding because of the aid of gaskets placed around the
edges of the
plates, which seals each unit. Furthermore, the corrugated nature of
plates provides a
suitable passage of fluids flow between plates and thus there is
maximum

Working principle ofa Plate heat exchanger

The above figure shows the flow principle of plate heat exchangers whereby the hot and cold
fluid streams flows in different pathways in opposite direction without intermixing with each
other. This illustration gives a flow arrangement whereby the hot and cold stream flows
entering and leaving the plate heat exchanger through the portholes on the plate where heat
transfer takes place between the hot fluid and the cold fluid stream.
CLASSIFICATION OF PLATE HEAT EXCHANGERS
Gasketed plate heat exchangers
Gasketed plate heat exchangers are made up of a series of
alloy plates, which the edges are specifically scaled by
rcctangular corrugated metal or
gaskcts and held firmly together in a
frame as shown below. The design is well tailorcd in such a way that the
frame has a fixed
end cover that is fitted with connecting ports and a
movable end cover that can be a pressure
plate or a tailpiece. Plates are usually
suspended in the frame from an upper carrying screw
bar that is securely guided by a
bottom-carrying bar, which supports and enables proper
alignment of equipment.

Support Inspecction Roller Afovable

Column Cover
Assembly Cover Gasket
Carrying Bar

Plato Pack

Stud Bolt

Support
Foot Fixed CSver
Guide Bar
Tightening
Nut
Lock
Washer
Tigh tening Beari ng Frame Faol
Bolt Box Sh roud
DESIGN AND OPERATION PROCEDURE OF PLATE HEAT
EXCHANGERS

The primary objective in the design of plate heat exchangers is the estimation of the
minimunm heat transfer area required for a given heat duty as this is an important factor to
estimate the overall cost of designing the plate heat exchanger. In the previous section of this
work was discussed briefly the different types of plate heat exchangers that are used for
different applications in the manufacturing industries but since one design principle and
methodology is used for all of them therefore we are going to extensively use the Gasketed
plate heat exchanger as our case study in this research.

In the working of Gasketed plate heat exchanger was described briefly to consist of a series
of rectangular corrugated metal or alloy plates, which are sealed by gaskets and clamped
firmly together in a frame with the aid of bolts. The contact of the fluid stream with the
corrugated plate causes a turbulent flow, which increases heat transfer between the hot and
cold fluid streams respectively. Furthermore,the hot and cold fluid streams flows in and out
the corrugated plate via the circular ports located in each corner of the plate. The gaskets are
wellinterlocked and embedded in the plates, which helps to direct the fluid flow. In practice,
a single unit of plate heat exchangers can use up to 700 plates, which gives a total heat
2
transfer area of approximately 2500m.

Material used for plate design

The materials used in the fabrication of the plates in plate heat exchangers are mainly
stainless steel, aluminum, titanium, hastelloy, incoloy, tantalum, Monel and nickel based
alloy are commonly used. To achieve an efficient heat transfer area which during design it is
an important factor to estimate the cost of designing the plate heat exchanger. The plate
material must be closely checked to be compatible with the fluid stream in order to avoid
fouling and untimely damage of the equipment, which will incur more maintenance cost as
well as low output in the end.
 Furthermore, the material selection for plate heat exchangers also depends on the heat duty,
mode of heat transter and the type of fluid stream as mentioned earlier which has to be
compatible with the plate material. The principal factor that determines the selection of the
plate material is the compatibility of the fluid and heat duty, the manufactures choice of
material can also be considered as a factor, which also influences the material selection
because in most cases they take into consideration the thermal design optimization to achieve
better results.

The plate materials can be categorized into four groups as follows.

*Alloys of nickel which includes C-276, C-22, C-2000, G-30, D-205, 59, 31, 28, 3033, 825,
686, 400 and nickel 200/201 etc.

*Stainless steel and alloys which includes 304, 316, 316Ti, 254SMO, 904L, 317, 317LN, 6
XN etc.

*Titanium, which includes alloys in the following, grades ASTM Grl,Gr 1letc.
*Alloys and non-metal like graphite, copper, tantalum, aluminum etc.

In considering the compatibility between the fluid stream and plate material, the thermal
hydraulic design of the respective plate heat exchanger must be taken as an important factor.
This is because the thermal resistance of the plate wall has a very important role to play when
considering the thermal conductivity values of the plate materials, which indicates that plate
materials with higher thermal conductivity values are most preferred in the design of plate
heat exchangers. Practically the plates are massed produced with varying thickness within the
range of 0.4to 1.2 mm and are pressed with different design pattern or corrugations, which
indicates that they are only available in a limited number with varying sizes and designs.This
design pattern of the plates shows that each plate has its own clearly defined specification
with regard to the operating conditions and parameters.
TABLE 1. Plate material selection

Plate Material
Compatible fluid stream

Stainless steel
Natural cooling water, demineralized water, (< 200ppm)
diluted chloride solution, copper sulphate solutions, food
products, Pharmaceutical media brews, etc.

Nickel Caustic (50-70%) solutions

Inco loy Hydrogen gas/water vapour with mercury carryovers, and

acids (S70°c)
Hastelloy Sulphuric and nitric acids

Titanium Brackish or sea water, (>20Oppm) chloride solutions,

chlorinated brines and dilute acids(<70°c)

Titanium-palladium alloys Dilute nitric and Sulphuric acids (10% concentration and<
70°C )

Table shows the type fluid that is compatible with the selected plate material, which can be
used as a simple selection guide when choosing the design material for the plate heat
exchanger. There are severaltypes of corrugated plate design in plate heat exchangers but the
most common design is the chevron type with chevron angle that varies between 25 to 65°,
The pressure drop and heat transfer characteristics of the plate is determined by the chevron
angle on the plate as well.
 Materialused for gasket design
The efficiency of the plate heat exchanger highly depends on the gaskets used in the design
hecause its fünctions are numerous which when absent will pose a challenge for the smooth
runnìng of the equipment. Gaskets, which are usually made from single picce elastomers,
determine the safety and lifetime leakage proof of the plate hcat exchanger. It also determines
the flow direction of the fluid stream when in contact with the corrugated plate which avoid
intermixing of the hot and cold fluid streams.

The mechanical stress and chemical environment are important factors to consider when
selecting the gasket material for the design of a plate heat exchanger. Gaskets are
manufactured from diferent polymers such as Nitrile Butadiene Rubber (NBR),
Hydrogenated Nitrile (HNBR), Neoprene (CR), Butyl Rubber (BR), Silicone Rubber (SiR)
and Ethylene Proplylene Diene Monomer (EPDM) etc. In addition, some gaskets are made
With asbestos fibre which indicates that selection and manufacturing process involved in
obtaining the right material for gasket is quite complex. Other materials that are also used
Can contain some vulcanization chemical and additives, which promotes manufacturing.
 Operation and selection

There is no discrepancy in the operation ofa plate heat exchanger that it functions with the
same principle as any other type of heat exchanger. The size, hold up volume and operating
condition play a very important role in the operation of plate heat cxchangers because both
the steady state and transient responses so lely depends on these parameters. The working
principle of plate heat exchangers clearly indicates that a single pass plate heat exchanger
operates like apure counter flow exchanger because its relative compactness and optimum
convective characteristics gives a small approach temperature during operation. This
characteristic is very important and useful because it prevents the process fluid media to
undergo thermal debasement because they are temperature sensitive.

Plate heat exchangers due to their compact design and optimum performance are mostly
preferred to shell and tube and any other heat exchangers. Furthermore, there is some restrain
in the selection, application and operation because the operating temperature and pressure are
within a limit of l60 250C and 25 30 bars. Due to the malleable nature of the plates,
there is deformation that is caused by high presures of the fluid streams, and the retention
capacity of the gasket has to be greatly considered during selection.

In the selection of plate heat exchangers, some factors that restrain the smooth operation are
mentioned below.

*The complexity of the inter-plate flow channel transmits a high shear rate and shear
sensitivity of the media which may cause degradation.

* The effect of very low flow rate can cause flow mal-distribution in handling very viscous
liquids.
* Pressure drop becomes excessive because plate manufacturers place an upper limit on the
size, which restricts applications that requires a very high flow rate in the process industry.
 Dme to very high-pressure drop, plate heat exchangers are unsuitable for air-cooling, gas
to-gas heat exchange and low operating pressure condensation application.

Neverthe less, plate heat exchangers are still considered a better option than the other types
of heat exchangers because of their compact design, which makes inspection, maintenance
and cleaning easy. In addition, the design methodology varies from very small size to big
sized plate heat exchangers depending on the application also the optimum thermal
hydraulic performance recompenses for any drawbacks and limitations encountered during
operation.
 18

TABLE 2. Operating range of Gasketed plate heat exchangers

Operating range Gasketed plate heat exchanger

Maximum operating 25 bar (30 bar with specialconstruction)
Pressure

Maximum operating 160°c (2s0°C with special gaskets)

Temperature

Maximum flow rate 3600 m'h

Heat transfer coefficient Up to 7500 W/m. K

Heat transfer area 0.1 2500 m

Maximum connection size 450 mm

Approach Temperature Low as 0.25°C

Difference

Heat recovery Up to 95 %

Number of plates Upto 2500

Port size Up to 435 mm

Plate thickness 0.4 to 1.2 mm

 Advantages of plate heat exchangers

The advantages of plate heat exchangers are numerous due to their compact design whereby
the components can be casily disassenmbled for inspection, cleaning and maintenance. The
flexibility of the design makes it possible to alter or rearrange the heat transfer area during
optimization for an expected load or heat duty change, which may be done by altering the
plate size, corrugation patterns, and the pass arrangement respectively. A brief comparison
between the shell-tube exchangers and plate heat exchangers shows that fouling can be
reduced from 25 to 10 % when a plate heat exchanger is used because the high shear rates,
stresses, high turbulent flow pattern and proper mixing are all attributed to the plate
corugation patterns in plate heat exchangers.
Plate heat exchangers usually have a high heat transfer coefficient because the plates are very
thin with large surface area and due to the activities taking place on the fluid boundary layers,
which leads to achieving a small hydraulic diameter flow passage. Fouling is at a reduced
rate compared to shell-tube exchangers, flow arrangement are usually counter flow that aids
the approach temperature to reach up to 1°C and ahigher heat transfer coefficient is achieved
due to the absence of bypass and leakages. Furthermore, this minimizes the design cost and
due to the compact design, the equipment can be portable which will occupy less space.
Thermal performance is usually high which favors strict temperature control, which is
advantageous when using heat sensitive materials because this can optimize the quality of the
product.
 Limitations of plate heat exchangers
There are several advantages to use the plate heat
exchangers but there are also some
limitations as well. The use of plates and gaskets imposes the main
limitations, which sets an
upper limit on the operating temperature and pressure. In addition, the
nature of the type of
fluid it can handle is also a limitation because gaskets cannot
withstand the use of corrosive
or aggressive fluid streams. Fluids with very high viscosity pose a
problem, which is because
of the flow distribution effects.
 Industrial application
As mentioned briefly this research work which the earliest development that introduced the
use of plate heat exchanger was used in the dairy industry for milk pasteurization. The use of
plate heat exchangers in recent innovative technological processes have expanded greatly
because several heat transfer techniques that enhances the development of more optimum
compact heat exchangers. This is widely applied today by the refrigeration, air conditioning,
petrochemical, food industries etc.

Turbine

Generator

>Electricity

Fuel
Boiler

Condenser

Water
Plate Heat Exchanger

Building

Atypical industrial application of plate heat exchangers in heat and power generat ion plant.
 BASICDESIGN METHODOLOGY

employed
The same design methodology used in designing other type of heats exchanger is
when designing the plate heat exchangers as well. In the design process, five important steps
includes
that determine an efficient design of plate heat exchangers may be considered. This
the folloving as numbered below:

* Design/process or problem specification

* Thermal hydraulic design

* Structural/mechanical design which includes operation and maintenance constraints

* Cost and manufacturing considerations

* System based optimization and trade-off factors

The stipulated process/design problem for a particular application plate heat exchanger
provides all the necessary information needed in achieving an efficient design, which is
required for the optimization of the heat transfer process. This implies that the specified
streams,
process or design challenges must include the type of material used, heat load, fluid
and pressure drop constraints. The mechanical or structural integrity of the heat
exchanger
in the
that the operating condition is under a steady and transient state must be included
mechanical design process of the plate heat exchanger. In addition, several international,
national and relevant local codifications or standards can be strictly adhered to in the
mechanical design. In order to carry out an efficient system based optimization which the
manufacturer can estimate the required cost to enable an appropriate trade-offs can be

considered as well.
Process specifications
Problem
Pate heat echanger constrectlen. Specifieation
Nes arrangement, arehltecturat
nnciderations, mnterisl and surfsce Operating conditions
sclextion, uid sclection

Surface
characteristics Heat transfer &
nnd pressure drop analysis Thermo-physieaf
properties of
geometrical and optimization fuids anf
properties materials

Thermal and Hydraulic Design

Fluid
distribution
devices
Heat Mechanical/Structuraldesign, jncluding
Cxchangcr operation and maintenance
core considerations

Support
and
mounting
Mechanical Design

Optimized optional solution

Manufacturing
Equipment considerations and cost costing
processing estimates

Trade-off
factors

System
based
optimization

Optimum solution
Cost Analysis and Processing

Overview of plate heat exchanger design methodo logy

Thermal hydraulic design

The thermal hydraulic design of heat exchangers takes into consideration some specific
auantities like the detailed dimensional size, flow arrangement, thermal hydraulic properties
and the optimum operating conditions of the fluid stream. which includes the flow rates,
inlet/outlet temperatures, fouling factors, pressure drop etc. In the construction of plate heat
exchangers, the thermal hydraulic design methodology faces two important problem
specifications, which includes the rating and sizing of the exchanger. The sizing problem
may be solved by taking into consideration the type of
construction, flow arrangements,
detailed dimensional size of the exchanger. In addition, the operating conditions of the
fluid
streams must be analyzed which includes the inlet/outlet temperatures and flow
rates
respectively. Furthermore, the heat load or duty and pressure drop constraints must be
determined as well in other to achieve an optimal design.

Flow arrangement of the fluid stream

In the design of plate heat exchangers considering the

thermal hydraulic parameters, three
different type of flow arrangement are employed for the hot and cold fluid streams, which
includes the following below:

* Parallel flow arrangement with two fluid streams flowing in the same direction.
* Counter flow arrangement with two fluid stream flowing in opposite
directions.
* Multiarrangement whereby the path ofone fluid stream is reversed through the flow length
two or more times if possible.
 Hot in

Cold in

Hot out

Cold out

* Parallel flow arrangement in a two fluid plate heat exchanger

Hot in

Cold out

Hot out

Cold in

*Counter flow arrangement in a two fluid plate heat exchanger