Hot in

Cold out
Cold in

Hot out

* Typical multipass arrangement in a two fluid plate heat exchanger

5.3 Temperature distribution

The temperature of the fluid streams in the plate heat exchanger varies along their flow path
because of the temperature gradient and the type of flow distribution, which usually varies
across the plate during heat transfer. In the parallel flow arrangement, whereby two fluid
streams flowing in the same direction it is observed that the final temperature of the cold
fluid stream is always less than the outlet temperature of the hot fluid stream. While in the
case of the counter flow arrangement, the temperature of the cold fluid stream may be
observed to be higher than the outlet temperature of the hot fluid stream because of the
favorable temperature gradient. This implies that there is a great thermodynamic advantage
over the parallel flow arrangement.

The illustration on graph 1 and 2 below shows the inlet/outlet temperatures of the fluid
stream plotted against the heat transfer area for a single-phase flow of two fluid streams using
two different flow arrangements, which is the parallel flow, and the counter flow
arrangement respectively. As shown on the graph the heat transfer area is represented on the
X-axis and the fluid streams temperature is on the y-axis.
T ot in
Chot

ATI AT AT2

Cçold
T cold in

A
Area

GRAPH 1. Temperature distribution in parallel flow arrangement

Chot
T pt in
ATI
AT

T bot out

AT2

Cold
YT cold in

0 A

Area

GRAPH2. Temperature distribution in counter flow arrangement

5.4 Design equations and energy balances

The overall energy balance of a plate heat exchanger can be determined by the application of the
first law of thermodynamics whereby the total heat transfer rate in the hot and cold fluid streams
are equal. Therefore, this implies that the total heat transfer rate can be calculated from either the
hot or the cold fluid streams respectively. (Kakaç & Liu 2002.)

Q=Ch (Thí - Tho)

Q=Co(Te, o-Tc,)
Qr =m,Cp, hATh= m,CpcAe

Where Te, iand Te, oare the inlet/outlet temperatures of the cold fluidstream, and m; is the
Mass flowrate of the hot fluid stream and Cph is the specific heat capacity of the hot fluid
Stream. The temperature difference between the inlet and outlet hot fluid stream is
The logarithmic mean temperature difference LMTD gives the appropriate average temperature
difference between the hot and cold fluid streams over the entire length of the heat exchanger. This
method will be used extensively in this research in the design of plate heat exchangers and can be
obtained using the LMTD equation as expressed below:

LMTD =(Thi- Teo) -(Iho -Toi CThi-Too)/(Tho- Ta)

U= Q/A,LMTD
Uf-Q/AFLMTD
Where is the overallheat transfer coefficient, A, is the nominal heat transfer surface area and
Qis the rate of heat transfer. Equation 5 can be used conveniently to calculate the overall
heat transfer coefficient when the total surface area is known. In addition equation
(6) Shows the overallheat transfer coefficient Ufunder fouled condition whereby a
correction factor F is must be applied in parallel flow arrangement.
Toestimate the total number of effective plates is illustrated in the equation below.

N=N, - 2

The hydraulic diameter Dh in plate heat exchangers arises as a result of the corrugation in
plates which form a three dimensional flow path with a nominal opening twice the pressing
depth of the plate.
The size of the hydraulic diameter in plate heat exchangers usually ranges from 5-10mm and
this is can be calculated using the equation below:

Where A is the area of cross sectional flow channel, Pe is wetted perimeter of the periphery
of the exchanger. The symbols b, are the channel spacing and wetted surface or
enlargement factor, which is usually issued by the manufacturer.

Drop for an application with a single -phase flow. The channel mass velocity Ge, can be
calculated from the expressions below:

Ge=m/Nepblw
Nep- Nr-1/2N,
bp-Ap
Lw LntDp
 Design method

The design method used in this research work employs a systematic design approach, which
is developed for the simulation of plate heat exchangers operating in steady state with
generalized configuration. The approach used in this work take into consideration the
calculation of all the parameters needed for the design and construction of the plate heat
exchanger, which the results are closely compared with the results from literature using the
same parameters with the design equations. The approach or method with the best optimum
design parameters is recommended for the design .The calculated parameters include the
number of plates, plate dimensional properties, the inlet/outlet temperatures for the hot and
cold fluid stream is usually given. However, inachieving the required heat transfer surface
area the plate amount used is closely checked since it plays an important role in obtaining the
required area and the flow channel velocities, physical properties of the hot/cold fluid
streams. The schematic diagram below show the design methodology used in this research
work for the optimum design of the plate heat exchanger.
 Input design data

Calculate Q

Calculate A, NTU,
ALMTD,

Calculate
N,Np,p,Lc, Dh, Ach,
AT

Hot side: Calculate, Cold side :Calculate,

hh, Re, Nu, U, mass flow, hc, Re, Nu, U, mass flow,
velocity velocity

Calculate
Clean Uo, Fouled Uo,
Clean Qo, Fouled Qo

Calculate
APh, APc

APcal < APmax

Yes
End

Diagrammatic design methodo logy

The methodology above is based on the fact that one variable either the total effective area or
the number of plates must be defined or assumed in order for the design program to calculate
the other variables. However to calculate the overall heat transfer coefficient the fouled and
cleaned must also be assumed. In addition to this, the maximum pressure drop must be
considered as wellbecause the calculated pressure must be less than the maximum assumed
pressure. Furthermore, when the calculated pressure drop exceeds the value of the maximum
pressure drop, it is suggested that the designer must increase the number of plate in order to
meet up with the design specification and heat duty demands.

The major priority we have to consider when designing the plate heat exchanger is the
determination of the surface area required for the specified heat duty by employing the given
temperature difference and taking into consideration the maximum pressure drops allowed in
the design specification. The following parameters are calculated by employing the design
methodology above:
I. Heat load required clean or fouled
II. Duty clean/dirty calculations
III. Totaleffective area
IV, Surface area calculations

V. Number of plates
VI. Overall heat transfer coefficient (clean /dirty)
VII. Total Pressure drop for hot fluid and cold fluid streams respectively
VIII. Dimensions of the plate are calculated as well
IX. Calculation of velocity through ports, mass velocity through channels and ports
X. Calculation of Reyno lds Re and Nusselt Nu numbers
XI. Calculation of heat transfer coefficients etc.
 Test of the system
The main problems usually encountered with heat exchangers are as follows:

1. Fouling: This is caused by deposits of scale, dirt, sand and/or other solid particles on the
conducting surfaces. Coke formation in furnace tubes and other causes of semi-blockage of
tubes will drastically decrease efficiency in an exchanger. Such problems will result in
shutdown for cleaning and possible tube and other parts replacements. Many of these
problems can be avoided by proper operation and fluid treatment - filtration, corrosion
inhibition, and furnace firing control.
2. Air pockets: The formation of air pockets in exchanges due to improper venting at start up, or
build of gas from light materials, will affect the heat transfer rate. This can be avo ided by
venting all ir or gas out at start-up and periodically venting gases as required.

3. Leakage: Most leakages occur due to gasket failure - replacement of gaskets might be
necessary after some time of operation. Tube failure generally occurs due to corrosion,
Cxcessive pressure or by failure of the welded or rolled fitting of the tubes into the tube
sheets.
 RESULTS

In this section, the results from the simulation design and literature are compared
closely with
emphasizing more on the key parameters since the values obtained are numerous during
design. The simulation model was applied in such a way that the configuration and design
methodology shows that it can be effectively used in optimizing the plate heat exchanger
design while targeting the most important factors like minimal operational and capital cost of
running the equipment. The practical case study in this work was to design a plate heat
exchanger, which is capable of transferring heat from the hot fluid stream to the cold fluid
stream by effectively achieving similar results from simulated design program. In addition,
theoretical results were obtained by mathematical iterations and analysis from literature by
employing design equations.

Furthermore, the results obtained from simulation software and theoretical iteration shows
that the materials and parameters employed in the design process were effective because it
gave similar results from both metho ds. Hence, the mass flow rate and the heat load were
estimated by the simulation method and when compared to the values in literature gave a
very close solution, it shows that the stimulation method can be effectively used in the design
process.

The method employed take into consideration some parameters such as the heat transfer
coefficient, pressure drop, as well as the heat transfer area. The results obtained illustrates
that the iteration made are valid and can be relied on during consequent design. Table 6
shows that the results obtained from the stream properties between the hot and cold fluid of
the simulation and theoretical iteration were accurate when compared. However, the pressure
drop analyses there were some slight diferences between the simulation and iteration
methods due to the complexity to deduce the parameters required to achieve the result using
iteration method. Thus, the plate properties gave accurate results using the simulation and
iteration method.
 CONCLUSION

The research study was based on plate heat exchanger design methodo logy in the
manufacturing and process industries. It employed the use of stimulation and iteratíon
methods to compare the accuracy of the result obtained during the design application.
The objective of this research study was to design a plate heat exchanger, which is capable of
transferring heat from the hot fluid stream to the cold fluid stream by effectively achieving
similar results from simulated design program and to achieve an efficient method used in the
construction and installation of plate heat exchangers.
However, the results obtained during the research shows the design application is effective
and can be used as a guide for future optimization purposes. The maximum pressure drop
allowed in the design is one of the impotant parameters or specifications employed and it
must be noted that this maximum pressure drop is always higher than the calculated values in
both design methods employed in this research work. Hence, it is required to note that when
the calculated pressure drop exceeds the maximum allowable pressure, the design must be
optimized by adding more plates in order to increase the heat transfer area and correct the
necessary design errors.

The simulation method is widely used nowadays and during the course of the research
studies, it should be noted that several design simulation software were widely explored but it
was observed that due to the fact that most of them are still undergoing future development
and cannot be totally relied on.

In suggestion for further research, the iteration method should be encouraged to crosscheck
the simulat ion results in order to minimize and control design errors.
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