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Effects of Temperature Differences in Optimization of Spiral Plate Heat Exchangers

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Abstract

In this research, three aspects of modeling, analyzing, and optimizing spiral plate heat exchangers (SPHEs) are studied. The main objective of this work is to pave the way for comparing manufacturers’ designed SPHEs with theoretical designed SPHEs without involving designers in using computational methods. To begin, with assumption of constant overall heat transfer coefficient and specific heat capacities, a mathematical modeling of SPHE based on energy balance equations is developed to model the SPHE as a network of series-connected equivalent internal heat exchangers to determine the temperature distribution in spiral turns. This modeling can facilitate the usage of temperature-enthalpy diagram in SPHEs’ analysis and design. Furthermore, a new algorithm for thermal design optimization of SPHEs has been proposed. The proposed algorithm is based on maximizing pressure drops at channels, considering geometric proportion of SPHE and minimizing the total cost simultaneously. To show the proposed method applicability in analyzing thermal and hydraulic design parameters, a single-phase counter-current SPHE is assessed and optimized for different design cases with temperature approach variations. Results of comparing manufacturers’/standard designed SPHEs and research/theoretical designed SPHEs by defining appropriate geometric proportion ranges confirmed that temperature approach variations can improve SPHE performance to a higher extent, such as finding temperature approach ranges for optimized SPHEs with higher compactness to reduce the manufacturing cost. This fact is revealed by introducing compactness-temperature approach diagram which depicts the geometric optimization of SPHEs and the effects of temperature differences in SPHE’s optimization.

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Abbreviations

A :

Heat transfer area (m2)

A c :

Free flow area (m2)

b :

Channel plate spacing (m)

c p :

Specific heat capacity (J/kg K)

C :

Heat capacity rate ratio

C e :

Energy cost (USD/KW hr)

C i :

Capital cost (USD)

C od :

Operational cost (USD)

C tot :

Total cost (USD)

CS :

Carbone steel

D h :

Hydraulic diameter (m)

D i :

Core or Inside diameter (m)

D s :

Outer diameter of SPHE (m)

F T :

Temperature difference correction factor

GP :

Geometric proportion

h :

Heat transfer coefficient (W/m2 K)

H :

Channel plate width (m)

Hw :

Work hours (hr/yr)

HX :

Heat exchanger

i :

Annual discount rate

k :

Thermal conductivity (W/m K)

L :

Plate length (m)

M :

Mass flow rate (kg/s)

M weight :

Molecular weight

n :

Year (yr)

N :

Number of spiral turns of the stream

NTU :

Number of heat transfer units

ny :

Equipment life year (yr)

p :

Plate thickness (m)

P :

Pressure (KPa)

Pr :

Prandtl number

Q :

Heat transfer rate (W)

R fouling :

Fouling factor resistance (m2 K/W)

Re:

Reynolds number

Recr :

Critical Reynolds number

s :

Relative density (relative to water at 20 °C)

SPHE :

Spiral plate heat exchanger

SS :

Stainless steel

T :

Temperature (°C)

U :

Overall heat transfer coefficient (W/m2 K)

V :

Total volume of SPHE (m3)

V f :

Fluid mean velocity (m/s)

b :

Bulk fluid properties

c :

Cold stream

cr :

Critical

f :

Fluid

h :

Hot stream

HX :

Heat exchanger

i :

Inlet

j :

Counter

l :

Liquid

max :

Maximum

min :

Minimum

o :

Outlet

s :

Scale or fouling material

w :

Wall plate material or at wall temperature

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Greek Letters

β Compactness factor or surface density (m2/m3)

ΔP Pressure drop (KPa)

ΔTLM Logarithmic mean temperature difference-LMTD (K)

ΔTmax Greater terminal temperature difference (K)

ΔTmin Smaller terminal temperature difference (K)

ε Thermal effectiveness per turn

εtot Thermal effectiveness of heat exchanger

η Pumping efficiency

μ Viscosity (kg/m s)

μb Fluid bulk viscosity (kg/m s)

μw Fluid viscosity at the wall temperature (kg/m s)

ρ Density (kg/m3)

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Authors and Affiliations

  1. Mechanical Department, Petrochemical Industries Design and Engineering Company (PIDEC), Shiraz, Iran

    A. H. Sabouri Shirazi

  2. Research Institute of Petroleum Industry (RIPI), Tehran, Iran

    M. R. Jafari Nasr

  3. School of Engineering and Information Technology, UNSW Canberra, Canberra, ACT, 2612, Australia

    M. Ghodrat

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  1. A. H. Sabouri Shirazi
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  2. M. R. Jafari Nasr
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  3. M. Ghodrat
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Correspondence to M. Ghodrat.

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Sabouri Shirazi, A.H., Jafari Nasr, M.R. & Ghodrat, M. Effects of Temperature Differences in Optimization of Spiral Plate Heat Exchangers. Process Integr Optim Sustain 4, 391–408 (2020). https://doi.org/10.1007/s41660-020-00128-5

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