Thermal Energy Conservation of a Stenter Machine

THERMAL ENERGY CONSERVATION OF A
STENTER MACHINE
Final Year Project Report

Group: 39
Batch: 2009-2010
M. Shahzaib Shakaib
ME-09150
Atif Mehmood
ME-09175
Daniyal Riaz
ME-09181
Moiz Khan
ME-09313
Internal Advisor:
Syed Mohammad Rizwan Azeem

Associate Professor
Department of Mechanical Engineering
Reference#: 39/2013
DEPARTMENT OF MECHANICAL ENGINEERING

NED UNIVERSITY OF ENGINEERING AND TECHNOLOGY
CERTIFICATE
It is to certify that the following students have completed their project Thermal Energy
Conservation of a Stenter Machine satisfactorily.
Group: 39
Batch: 2009-2010
Name
Seat No.
M. Shahzaib Shakaib
ME-09150
Atif Mehmood
ME-09175
Daniyal Riaz
ME-09181
Moiz Khan
ME-09313
Internal Advisor
Projects Coordinator
Mr. Syed Mohammad Rizwan Azeem
Dr. Muhammad Shakaib
Associate Professor
Associate Professor
NED University of Engg. & Tech.
NED University of Engg. & Tech.
DEPARTMENT OF MECHANICAL ENGINEERING

NED UNIVERSITY OF ENGINEERING AND TECHNOLOGY
ACKNOWLEDGEMENTS
Above and before all we thank Almighty Allah, it is due to His Benevolence that this
project reached completion.
The next most important acknowledgement is to Prof. Sir. Syed Mohammad Rizwan
Azeem, (Associate Professor). His kind advice and generously given support have
made invaluable contribution, to which these few words will hardly do justice.
We want to present our heartiest thanks to the following persons also, who have
contributed in making this project reached completion.
Ms. Asma Adeel

Assistant Professor, Mechanical Engineering Department.
Mr. Umair Bin Asim

Lecturer, Mechanical Engineering Department.
Mr. Muhammad Aqeel

Technical Manager, Afroze Textile Industries.
II
ABSTRACT
The purpose of our project is to study and propose various means for effective
utilization of thermal energy in the operation of a stenter machine commonly used in
textile industries. The stenter machine is mostly used to dry the textile fabric. The heat
required in fabric drying process in the stenter is obtained from combustion of natural
gas. Since stentering is an energy intensive process, this study aims to reduce the energy
requirement either by re-utilization of exhaust gases or by some other means.
One goal of this project is to apply waste heat recovery system to operation of a stenter
machine in a textile mill in order to optimize its energy consumption. The heat recovery
is accomplished by re-utilization of exhaust air from stenter machine by means of a heat
exchanger. Research has been carried out on the theory and design of simple plate heat
exchanger and plate-fin heat exchangers, especially their use for energy recovery and
reduction of air pollution. Comparison between the two designs is also done in order to
select the best heat exchanger that meets our objectives. As a result of this study,
significant thermal energy saving have been achieved since the heat recovery process
reduces the amount of natural gas needed for drying process in stenter machine. Also,
pre-filtering is used in the heat recovery system thereby minimizing the air pollution
caused by the stenter machine.
Usually fabrics are mechanically de-watered up to some extent before going into the
stenter machine for drying process. Energy used in mechanical dewatering is only 1%
of the energy used to evaporate the same quantity of water. Therefore, wherever
possible, mechanical dewatering techniques should be employed. Squeezing mangle,
vacuum slot extraction device and centrifugal extractors are the different dewatering
techniques which have been studied for this project and a comparison is done between
them on the basis of their energy consumption.
III
TABLE OF CONTENTS
1.
2.
Introduction to Stenter Machine .................................................................... 1

1.1
Sections of a stenter range .......................................................................... 2
1.2
Types of heat source used in stenter machine ............................................ 3
1.2.1
Steam ................................................................................................... 3
1.2.2
Steam and electrical heating ................................................................ 3
1.2.3
Thermic fluid or hot oil ....................................................................... 3
1.2.4
Direct heating by oil burning ............................................................... 4
1.2.5
Direct gas firing ................................................................................... 4
1.3
Hot air dryer stenter .................................................................................... 4
1.4
Components of hot air dryer stenter & their working ................................ 5
1.4.1
Trough ................................................................................................. 5
1.4.2
Padders ................................................................................................ 5
1.4.3
Entry mahlo unit .................................................................................. 5
1.4.4
Chain drive .......................................................................................... 6
1.4.5
Heating section .................................................................................... 6
1.4.6
Delivery roller ..................................................................................... 6
1.4.7
Exit mahlo unit .................................................................................... 6
1.5
Industrial visits ........................................................................................... 6
1.6
Energy conservation of a stenter machine .................................................. 7
1.6.1
Waste heat recovery system ................................................................ 8
1.6.2
Mechanical dewatering techniques...................................................... 8
Fundamentals of Waste Heat Recovery ......................................................... 9

2.1
Introduction ................................................................................................ 9
2.2
Quality of waste heat .................................................................................. 9
2.3
Sources of waste heat ............................................................................... 10
2.3.1
High temperature heat recovery ........................................................ 10
2.3.2
Medium temperature heat recovery ................................................... 11
2.3.3
Low temperature heat recovery ......................................................... 11
2.4
Benefits of waste heat recovery................................................................ 12

i
2.4.1
Direct benefits ................................................................................... 12
2.4.2
Indirect benefits ................................................................................. 12
2.4.2.1 Reduction in pollution................................................................ 12

2.4.2.2 Reduction in equipment sizes .................................................... 13
2.4.2.3 Reduction in auxiliary energy consumption .............................. 13
2.5
Applications of waste heat recovery ........................................................ 13
2.6
Energy savings in stenters ........................................................................ 14
2.7
Device for waste heat recovery ................................................................ 15
2.8
Classification of heat exchangers ............................................................. 15
2.8.1
Direct contact heat exchanger ........................................................... 15
2.8.2
Indirect contact heat exchanger ......................................................... 16
2.8.3
Recuperators ...................................................................................... 17
2.8.3.1 Radiation recuperators ............................................................... 17

2.8.3.2 Convection recuperators ............................................................ 17
2.8.3.2.1 Shell and tube recuperators ........................................... 17
2.8.3.2.2 Tubular type recuperators .............................................. 17
2.8.3.2.3 Plate type recuperators .................................................. 17
2.8.4
Regenerators ...................................................................................... 18
2.8.4.1 Swing type regenerators ............................................................. 18

2.8.4.1.1 Checker brick regenerators ............................................ 18
2.8.4.1.2 Pebble bed regenerators ................................................. 18
2.8.4.2 Thermal wheel............................................................................ 18
3.
Heat Recovery Device-Selection ................................................................... 19

3.1
Introduction .............................................................................................. 19
3.2
Air to air heat exchanger .......................................................................... 19
3.2.1
Plate-fin recuperator .......................................................................... 20
3.2.2
Heat pipe heat exchanger ................................................................... 21
3.2.3
Thermal wheel ................................................................................... 22
3.2.4
Run-around coil ................................................................................. 23
3.3
4.
Selection criteria ....................................................................................... 24
Properties Evaluation and Design Constraints ........................................... 26

4.1
Properties evaluation ................................................................................ 26

ii
5.
4.1.1
Properties of hot air ........................................................................... 26
4.1.2
Properties of cold air ......................................................................... 28
4.1.3
Properties of aluminum ..................................................................... 29
4.2
Design constraints .................................................................................... 30
4.3
Heat transfer constraints ........................................................................... 30
4.4
Dimensional constraints ........................................................................... 31
4.5
Cost constraints ........................................................................................ 31
Plate-Fin Heat Exchanger ............................................................................. 32

5.1
Introduction .............................................................................................. 32
5.2
Salient features of plate-fin heat exchanger ............................................. 33
5.3
Advantages of plate-fin heat exchanger ................................................... 33
5.4
Limitations of plate-fin heat exchanger .................................................... 34
5.5
Flow arrangement ..................................................................................... 35
5.5.1
Counter flow ...................................................................................... 35
5.5.2
Cross flow .......................................................................................... 35
5.6
6.
Fin geometry............................................................................................. 36
5.6.1
Plain fins ............................................................................................ 36
5.6.2
Louvered fins ..................................................................................... 37
5.6.3
Offset strip fins .................................................................................. 39
5.6.4
Wavy fins........................................................................................... 40
5.7
Relative merits of plate-fin geometries .................................................... 41
5.8
Material of construction ........................................................................... 41
5.9
Relation between heat transfer rate and heat transfer area ....................... 42
5.10
Heat exchanger effectiveness ................................................................... 43
5.11
Number of transfer units........................................................................... 43
5.12
Applications of plate-fin heat exchanger in waste heat recovery ............. 45
5.12.1
Application to air conditioning system.............................................. 45
5.12.2
Application to industrial dryers ......................................................... 45
Qualitative Thermal Design .......................................................................... 46

6.1
Simple plate heat exchanger ..................................................................... 46
6.1.1
Range of no. of gaps between plates - selection ................................ 47
6.1.2
Calculation of dimensions of flow passage ....................................... 47

iii
6.1.3
Calculation of hydraulic diameter of flow passage ........................... 47
6.1.4
Calculation of exterior dimensions of heat exchanger ...................... 48
6.1.5
Calculation of all geometrical quantities for hot and cold side fluid 49
6.1.6
Calculation of all the dimensionless quantities for hot and cold side
fluid ................................................................................................... 49
6.1.7
Calculation of overall heat transfer coefficient ................................. 50
6.1.8
Calculation of log mean temperature difference ............................... 51
6.1.9
Calculation of height of flow passage ............................................... 51
6.1.10
Calculation of all quantities ............................................................... 51
6.1.11
Calculation of number of transfer units and overall effectiveness .... 52
6.1.12
Calculation of overall pressure drop on both sides ........................... 53
6.1.13
Calculation of cost of heat exchanger ............................................... 54
6.1.14
Selection of heat exchanger ............................................................... 54
6.2
Plate fin heat exchanger ........................................................................... 55
6.2.1
Range of no. of parting sheets - selection.......................................... 55
6.2.2
Geometrical parameters of the fin ..................................................... 56
6.2.3
Calculation of dimensions of flow passage ....................................... 56
6.2.4
Calculation of exterior dimensions of heat exchanger ...................... 56
6.2.5
Calculation of all geometrical quantities for hot and cold side fluid 58
6.2.6
Calculation of all the dimensionless quantities for hot and cold side
fluid ................................................................................................... 59
6.2.7
Calculation of fin effectiveness ......................................................... 60
6.2.8
Calculation of overall heat transfer coefficient ................................. 61
6.2.9
Calculation of number of transfer units and overall effectiveness .... 61
6.2.10
Calculation
of
effectiveness
of
heat
exchanger
considering
longitudinal wall conduction............................................................. 62

6.2.11
Calculation of amount of heat transferred and the outlet temperatures

for hot and cold side fluids................................................................ 63
7.
6.2.12
Calculation of overall pressure drop on both sides ........................... 64
6.2.13
Calculation of cost of heat exchanger ............................................... 66
6.2.14
Quantitative Thermal Design........................................................................ 68

7.1
Simple plate heat exchanger ..................................................................... 68

iv
7.1.1
Range of no. of gaps between plates - selection ................................ 68
7.1.2
Dimensions of flow passage .............................................................. 68
7.1.3
Hydraulic diameter of flow passage .................................................. 69
7.1.4
Exterior dimensions of heat exchanger ............................................. 69
7.1.5
All geometrical quantities for hot and cold side fluid ....................... 69
7.1.6
All dimensionless quantities for hot and cold side fluid ................... 71
7.1.7
Overall heat transfer coefficient ........................................................ 72
7.1.8
Log mean temperature difference ...................................................... 73
7.1.9
Height of flow passage ...................................................................... 73
7.1.10
Calculated values of all quantities ..................................................... 74
7.1.11
Number of transfer units and overall effectiveness ........................... 74
7.1.12
Overall pressure drop on both sides .................................................. 75
7.1.13
Cost of heat exchanger ...................................................................... 76
7.1.14
7.2
Plate fin heat exchanger ........................................................................... 79
7.2.1
Range of no. of parting sheets - selection.......................................... 79
7.2.2
Geometrical parameters of the fin ..................................................... 79
7.2.3
Dimensions of flow passage .............................................................. 79
7.2.4
Exterior dimensions of heat exchanger ............................................. 80
7.2.5
All geometrical quantities for hot and cold side fluid ....................... 80
7.2.6
Dimensionless quantities for hot and cold side fluid......................... 82
7.2.7
Fin effectiveness ................................................................................ 84
7.2.8
Overall heat transfer coefficient ........................................................ 85
7.2.9
Number of transfer units and overall effectiveness ........................... 86
7.2.10
Effectiveness of heat exchanger considering longitudinal wall

conduction ......................................................................................... 87
7.2.11
Amount of heat transferred and the outlet temperatures for hot and cold
side fluids .......................................................................................... 89
8.
7.2.12
Overall pressure drop on both sides .................................................. 90
7.2.13
Cost of heat exchanger ...................................................................... 91
7.2.14
Advantages, Savings & Comparison .......................................................... 113

8.1
Advantages ............................................................................................. 113

v
8.2
Principle of waste heat recovery system ................................................ 113
8.3
Energy requirement and savings ............................................................ 115
8.3.1
Energy requirement without pre-heater ........................................... 115
8.3.2
Energy requirement with pre-heater ................................................ 117
8.3.2.1 Simple plate heat exchanger .................................................... 117

8.3.2.2 Plate fin heat exchanger ........................................................... 120
8.4
9.
Comparison of both heat exchanger designs .......................................... 123
Mechanical Dewatering ............................................................................... 124

9.1
Introduction ............................................................................................ 124
9.2
Squeezing mangle................................................................................... 125
9.3
Vacuum slot extraction device ............................................................... 125
9.3.1
Equipment used for vacuum slot extraction .................................... 125
9.3.2
Mechanism of vacuum extraction ................................................... 126
9.3.3
Importance of airflow in vacuum slot extraction device ................. 127
9.3.4
Applications ..................................................................................... 129
9.4
Centrifugal extractors ............................................................................. 129
9.5
Comparison of dewatering machines ..................................................... 130
Conclusion
Nomenclature
References
Appendix
vi
LIST OF FIGURES
A typical direct gas fired stenter machine ..................................................1
Inside view of heating chamber of a typical stenter machine ....................6
Classification of various heat exchangers ................................................16
Schematic of a stenter with and without air to air heat recovery unit .....19
Flow arrangements of plate-fin recuperator heat exchanger ..................20
Components and mechanism for a heat pipe containing a wick ..............21
Typical arrangement of heat pipe exchanger ...........................................22
Diagrammatic operation of a thermal wheel ...........................................22
Run-around coil installation, serving air handling units on the roof of an
office building ...........................................................................................23
Basic elements and two types of flow arrangements in plate-fin heat
exchanger .................................................................................................32
Different types of plate-fin surfaces .........................................................36
Plain rectangular fins ...............................................................................36
Louvered fins ............................................................................................37
Offset strip fins .........................................................................................39
Wavy fins ..................................................................................................40
Different drawing views of simple plate heat exchanger .........................48
Different drawing views of plate-fin heat exchanger ...............................57
Entrance & exit pressure loss coefficients for a multiple square-tube heat
exchanger core with abrupt- contraction entrance and abrupt-expansion
exit. ...........................................................................................................65
Detailed schematic diagram of waste heat recovery system ..................114
Squeezing mangle ...................................................................................125
Arrangement of a typical vacuum slot extraction device .......................126
Centrifugal extractor ..............................................................................129
vii
LIST OF TABLES
Stenter machine specifications ...................................................................7
Waste heat source & its quality ................................................................10
Waste heat temperatures in high temperature range. ..............................11
Waste heat temperatures in medium temperature range..........................11
Waste heat temperatures in low temperature range ................................12
Weighted decision matrix for heat exchangers ........................................25
Design constraints ....................................................................................30
Relative merits of plate-fin geometries .....................................................41
Design parameters of simple plate heat exchangers for different values of
N ...........................................................................................................78
Design parameters of plain plate fin at each NT ......................................93
Design parameters of louvered plate fin at each NT ................................97
Design parameters of offset strip plate fin at each NT ...........................101
Design parameters of wavy plate fin at each NT ....................................108
Final list of design parameters for each type of fin satisfying all the
constraints at each NT ............................................................................112
Components of waste heat recovery system ...........................................115
Comparison of heat exchanger designs..................................................123
Energy cost of dewatering machine .......................................................130
viii
CHAPTER #1
1. Introduction to Stenter Machine
Textile industry is one of the important and biggest industrial sectors in Pakistan. It
plays a major role in country economy and has steadily grown over years. When
compared with other industrial sectors, the textile industry requires usage of large
amount of water and energy.
The energy used in the textile

industry is generally in forms of
fuel and electricity. Since this
industry is energy-intensive, it
is very important to minimize
the energy consumption. Textile
process consists of wide variety
of production sections such as
spinning,
weaving,
dyeing,
drying, finishing, knitting etc.

Among them, drying process is
often one of the most energyintensive
Furthermore
operations.
this
A typical direct gas fired stenter

machine
process
exhausts large amounts of warm and moist air
Polymeric materials, such as polyester, are thermoplastics, become soft itself when
heated and harden when cooled. During production, the fabrics are subjected to various
deformations which cause shrinkage in the process of wetting and washing. In fabric
made of synthetic fiber deformation can be reversed by heating the fabric, while kept
under dimensional control.
Mostly stenter machines are used for drying process in various textile industries. It is a
machine or apparatus for stretching and stabilizing the fabric by heating while it is in
stretched condition. The purpose of the Stenter machine is to bring the length and width
to pre-determined dimensions. It is also used for heat setting and for applying finishing
chemicals.
1.1 Sections of a stenter range

The main sections of the stentering range can be classified as follows:
1. The entrance zone of the stenter in which the width equalizing and adjusting
take place. It is narrower at the actual entrance and tapers into a wider width till
the end of the section i.e. up to the heating chambers. The fabric is pulled during
the passage of the fabric in this section.
2. The intermediate zone, consisting of the fabric compensating device, weft
correcting system, crease removing and selvedge uncurling devices, fabric
selvedge guiding and introduction zone.
3.
The finishing zone, consisting of the finishing padder and its component parts.
The fabric is introduced into the finishing padder, squeezed to a planned
retention percentage.
4. The drying zone, consisting of the number of drying chambers according to the
drying process planned. Each of the drying chambers consists of suitable
positioned blower fans with fan motors, nozzle sets for blowing the hot air on
the fabric and heating registers which heat the air coming from blower fans and
achieve the desired effect.
5. The delivery zone, consisting of fabric releasing system, cooling device, plaiting
device and the type of batching system which may have been selected. This
zone permits the cooling of the fabric before it is stripped off the pins or clips
at the takeoff point. In some stenters air blower is arranged after the drying
section for adequate cooling of the fabric. Fresh air to bring down the
temperature is blown onto the fabric with the help of suitable ducting and
nozzles.
1.2 Types of heat source used in stenter machine

A variety of heat energy sources are used to heat the drying medium from which the
heat is distributed through heating registers or heat exchangers.
1.2.1 Steam
High pressure steam from the boiler mains is fed to the heat exchangers located in the
drying chambers. The steam pressure is regulated at a point, which is in the vicinity of
the stenter in order to maintain a continuous and consistent supply of steam at the
desired pressure and temperature to the heating registers. The temperature reached by
steam at reasonably high pressures is around 165C, which is adequate for drying,
curing and cross-linking the chemical reactants. Therefore the use of steam is limited
to drying purposes only. Circulation of hot air, which follows the exchange of heat, is
effected by means of suitably designed, motor driven blower fans. Highly superheated
steam is usually not used due to operational difficulties at higher pressures.
1.2.2 Steam and electrical heating

Electrical heating systems for attaining higher temperatures required for heat setting of
fabrics are also used. These systems are used along with pressurized steam for normal
drying purposes. The main problem with this system is cumbersome design features
and maintenance of both type of heating arrangements. However, exclusive electrical
heating arrangements are made in small production houses where boilers could not be
installed. This process is slightly costlier because of high cost of the electrical energy
compared to gas and oil.
1.2.3 Thermic fluid or hot oil

Hot oils or thermic fluids are also circulated through heating registers when higher
temperatures are required. One of the most redeeming features of this system is that the
same thermic fluid can be heated and recirculated through the stenter or any other
drying machines. The whole circulation is effected under normal pressure, with suitable
control valves for each of the drying chambers. After flowing through the hot oil
registers throughout the dry and heating zones, the oil is pumped back to the storage
together with expansion tank. From the expansion tank, it flows to the oil-heating tank,
where it is brought to the required temperature and is then again circulated through the
drying machine.
1.2.4 Direct heating by oil burning

In this system, each stenter chamber has its own oil burner arrangement. The flames are
discharged on one side of the heat exchanger. The oil burner design and position is
arranged in such a manner that the system can impart sufficient heat recovery for one
standard drying chamber, along with necessary oil spray, air mixing device, and igniting
device. Sometimes, oil combustion products are directly fed into the chamber but are
not preferred because of oil spots and soot formation owing to incomplete combustion.
1.2.5 Direct gas firing

Some stenter chambers are designed to be heated by direct gas firing with natural gas
being used as the fuel. The heat in the gas flame is taken up by the air from the blower
fans and passed on to the fabric surfaces. It is possible to control the gas flame in such
a manner that the hot medium temperature is adequate for drying, and when needed, for
the thermo-setting process, as the case may be. Indirect firing though a heat exchanger
can also be used for gas-produced heat but it is usually avoided because the arrangement
is very costly and the drying efficiency goes down by 20 to 30 %.
1.3 Hot air dryer stenter

In this project we are focusing only on direct gas fired hot air dryer stenter. The hot air
stenter is a gas fired oven, with the fabric passing through on a chain drive, held in place
by either clips or pins. Air is circulated above and below the fabric, before being
exhausted to atmosphere. As well as for drying processes, the stenter is used for pulling
fabric to width, chemical finishing and heat setting and curing. It is a very versatile
piece of equipment. It is usually the most expensive, largest and important machine in
finishing section.
Controlling width of the fabric is necessary because practically in all processing stages
the fabric is subjected to longitudinal or warps wise tension to varying degrees. Hence
the fabric shrinks widthwise to varying extent at different sections along its length.
There are a number of heating chambers dedicated to perform drying of the fabric inside
the stenter machine. Each of the heating chambers has a pair of air blowers attached to
a pair of air ducts. Drying of the fabric is achieved while the fabric passes through this
chamber.
By the time the fabric is about to get out of the stenter machine, almost all water in the
fabric has already been absorbed by the air inside the chamber. Thereafter the dried
fabric is rolled or pleated in the fabric receiving system
1.4 Components of hot air dryer stenter & their working

Following are the components of gas fired hot air dryer stenter.
1.4.1 Trough
A trough is installed below the padder. The fabric is first dipped in the trough which
contains chemicals. Chemicals are used to enhance the properties of fabric such as
whitening or stretching strength.
1.4.2 Padders
They are also called squeezers. The fabric then passes through these squeezers which
mechanically removes water from the fabric up-to some extent. The efficiency of these
squeezers plays an important role in removing the moisture from the fabric and can also
reduce the cost of the process.
1.4.3 Entry mahlo unit

This particular unit is installed to straighten the fabric. It controls 75% of bowing and
crossing. It only straightens out the weft of the fabric, not the warp.
In weaving the weft or woof is the term for the yarn which is drawn through
the warp yarns to create cloth. Sensors are installed to measure how much the fabric
should be straightened.
1.4.4 Chain drive

After mahlo unit, the fabric passes through the chain drive in which it is gripped by
rolling chains. The chains were designed in such a way that they can accommodate the
width setting of the fabric.
1.4.5 Heating section

The fabric then passes through the heating section. A number of burners are installed
in this section. This section also contains the blower fans which blows the hot air
through the nozzles onto the fabric.
Inside view of heating chamber of a typical stenter machine
1.4.6 Delivery roller

After heating section, the fabric then passes through the delivery roller.
1.4.7 Exit mahlo unit

This unit controls the remaining 25% of bowing and crossing. The fabric is then
collected in a bucket.
1.5 Industrial visits

A couple of visits have been carried out to get a better understanding of the stentering
range. Afroze Textiles, is the industry which we visited. The textile factory has 4 gas
fired hot air stenter for drying the fabric, each equipped with 8 burners in the heating
section. One of the objectives of the visit is the collection of data necessary for our
calculations. Table 1 lists the parameters of the stenter machine installed at Afroze
Textiles for which we have collected the data during our visits.
6
Serial No.
Parameters
Data
1.
Electrical power of machine
195 kW
2.
Machine roller width
3m
3.
Machine speed
40 m/minute
4.
No. of heating chambers
5.
No. of exhaust duct
6.
Heat source
Natural gas
7.
Maximum temperature of chamber
200 C (473 K)
8.
Temperature of exhaust air
120 C (393 K)
9.
Volume flow rate of intake air
31,000 m3/h
10.
Volume flow rate of exhaust air
31,000 m3/h
11.
Inlet wet fabric
0.75 kgwater / kgfabric
12.
Outlet wet fabric
0.07 kgwater / kgfabric
13.
Holding form
Clips
14.
Chain type
Pin chain horizontal
Stenter machine specifications
1.6 Energy conservation of a stenter machine

In textile industries, the energy used to dry the fabric corresponds to 50% of energy
consumed in the process of finishing the fabric, with 25% of that total going to the
stenters. The reason for this high energy consumption is the need for high air exchange
rates inside the stenter for the elimination of substances released during the process that
may compromise the fabric coloration. It is during this process that the heat losses are
the most. At exhaustion there is a huge waste of thermal energy, due to discharge of hot
gases exhausted. Energy expended in raw, 60 to 80% is lost in this disposal.
In this study, we are focusing ourselves on two alternatives to reduce the thermal load
of the stenter machine. The two alternatives are:
1. Use of Waste heat recovery system

2. Study of mechanical dewatering techniques
1.6.1 Waste heat recovery system

The goal of this study is to apply waste heat recovery system to operation of a stenter
machine in a textile mill in order to optimize its energy consumption.
One of the ways to reduce energy consumption is to reuse waste energy generated
during production processes. In the textile industry, this waste energy can be generally
recovered in the form of heat and be used in other processes of production.
The heat required in fabric drying process in the stenter is obtained from a hot gas
burner. The heat recovery is accomplished by re-utilization of exhaust air from stenter
machine by means of a heat exchanger. As a result of this study, significant thermal
energy savings are to be achieved since the heat recovery process reduces the amount
of energy needed to operate the hot gas burner.
Heat recovery system also involves pre-filtering and therefore air pollution caused by
the stenter machine is also minimized.
1.6.2 Mechanical dewatering techniques

Moisture is introduced to the dryer by the feed, the process air and, in certain instances,
by reaction, such as combustion. Reducing this loading allows the energy to be better
utilized on the drying process. To reduce this loading, mechanical dewatering is often
used because of lower energy requirements. Our goal is limited to the study of
techniques involved in dewatering and their comparison with each other.
CHAPTER #2
2. Fundamentals of Waste Heat Recovery
2.1 Introduction
Waste heat is a necessity generated by machines that do work or by processes which
requires energy. Rejecting heat is fundamental to the laws of thermodynamics for
operational systems. However it has lower utility i.e. higher entropy than the original
energy source. Most operational systems dump this waste heat to the environment even
though it could be recycled for useful and economic purpose.
The temperature of waste heat fluids and the economics involved governs the strategy
of how to recover this heat.
The waste heat can be rejected at almost any temperature depending upon the type of
process. Usually the higher the temperature, higher the quality and more cost effective
is the heat recovery. In any heat recovery situation it is essential to know the amount of
heat recoverable and also how it can be used.
2.2 Quality of waste heat

In considering the potential for heat recovery, it is useful to note all the possibilities,
and grade the waste heat in terms of potential value as shown in Table 2.
Source
Heat in flue gases.
Quality
The higher the temperature, the greater the
potential value for heat recovery
Heat in vapour streams.
As above but when condensed, latent heat also

recoverable.
Convective and radiant heat Low grade if collected may be used for space
lost from exterior of equipment heating or air preheats.
Heat losses in cooling water.
Low grade useful gains if heat is exchanged with

incoming fresh water.
9
Heat losses in providing chilled a) High grade if it can be utilized to reduce demand
water or in the disposal of for refrigeration.
chilled water.
b) Low grade if refrigeration unit used as a form of

heat pump.
Heat stored in products leaving Quality depends upon temperature.

the process
Heat in gaseous and liquid Poor if heavily contaminated and thus requiring
effluents leaving process.
alloy heat exchanger.
Waste heat source & its quality
2.3 Sources of waste heat

The sources of waste heat on the basis of their temperatures can be divided into three
temperature ranges. The high temperature range occurs between 620C to 1650C,
medium temperature range occurs between 230C to 650C and low temperature range
refers to the temperature between 27C to 230C.
2.3.1 High temperature heat recovery

Table 3 lists the temperatures of waste gases from industrial process equipment in the
high temperature range. All of these results are obtained from direct fuel fired
processes.
Source
Temperature, C
Nickel refining furnace
1370 1650
Aluminum refining furnace
650-760
Zinc refining furnace
760-1100
Copper refining furnace
760- 815
Steel heating furnaces
925-1050
Copper reverberatory furnace
900-1100
Open hearth furnace
650-700
Cement kiln (Dry process)
620- 730
Glass melting furnace
1000-1550
10
Hydrogen plants
650-1000
Solid waste incinerators
650-1000
Fume incinerators
650-1450
Waste heat temperatures in high temperature range.
2.3.2 Medium temperature heat recovery

Table 4 lists the temperatures of waste gases from process equipment in the medium
temperature range. Most of the waste heat in this temperature range comes from the
exhaust of directly fired process units.
Source
Temperature, C
Steam boiler exhausts
230-480
Gas turbine exhausts
370-540
Reciprocating engine exhausts
315-600
Reciprocating engine exhausts
230- 370
(turbo charged)
Heat treating furnaces
425 - 650
Drying and baking ovens
230 - 600
Catalytic crackers
425 - 650
Annealing furnace cooling systems
425 - 650
Waste heat temperatures in medium temperature range.
2.3.3 Low temperature heat recovery

Table 5 lists some heat sources in the low temperature range. In this range it is usually
not practical to extract work from the source. Low temperature waste heat may be useful
in a supplementary way for preheating purposes. Waste heat temperatures for our
project lies in low temperature heat recovery.
11
Source
Temperature, C
Process steam condensate
55-88
Cooling water from:

Furnace doors
32-55
Bearings
32-88
Welding machines
32-88
Injection molding machines
32-88
Annealing furnaces
66-230
Forming dies
27-88
Air compressors
27-50
Pumps
27-88
Internal combustion engines
66-120
Air conditioning and refrigeration condensers
3243
Liquid still condensers
32-88
Drying, baking and curing ovens
93-230
Hot processed liquids
32-232
Hot processed solids
93-232
Waste heat temperatures in low temperature range
2.4 Benefits of waste heat recovery

Benefits of waste heat recovery can be broadly classified in two categories:
2.4.1 Direct benefits

Recovery of waste heat has a direct effect on the efficiency of the process. This is
reflected by reduction in the utility consumption & costs, and process cost.
2.4.2 Indirect benefits

2.4.2.1 Reduction in pollution
A number of toxic combustible wastes such as carbon monoxide gas, sour gas, carbon
black off gases, oil sludge, Acrylonitrile and other plastic chemicals etc., releasing into
the atmosphere if/when burnt in the incinerators serves dual purpose i.e. recovers heat
and reduces the environmental pollution levels.
12
2.4.2.2 Reduction in equipment sizes

Waste heat recovery reduces the fuel consumption, which leads to reduction in the flue
gas produced. This results in reduction in equipment sizes of all flue gas handling
equipments such as fans, stacks, ducts, burners, etc.
2.4.2.3 Reduction in auxiliary energy consumption
Reduction in equipment sizes gives additional benefits in the form of reduction in
auxiliary energy consumption like electricity for fans, pumps etc.
2.5 Applications of waste heat recovery

Some applications of waste heat are as follows:
1. Medium to high temperature exhaust gases can be used to preheat the

combustion air for:
a. Boilers using air preheaters
b. Furnaces using recuperators
c. Ovens using recuperators
d. Gas turbine using regenerators
e. Gas fired stenter machines using air preheaters
2. Low to medium temperature exhaust gases can be used to preheat boiler feed
water or boiler make up water using economizers which are simply gas to liquid
water heating devices.
3. Exhaust gases and cooling water from condensers can be used to preheat the
liquid and/or solid feed stocks in industrial processes. Finned tubes and shell &
tube heat exchangers are used.
4. Exhaust gases can be used to generate steam in waste heat boilers to produce
electrical, mechanical power, process steam and any combination of above.
5. Waste heat can be transferred to liquid or gaseous process units directly
through pipes and ducts or indirectly through a secondary fluid such as steam
or oil.
6. Waste heat can be transferred to an intermediate fluid by heat exchangers ot
waste heat boilers, or it can be used by circulating the hot exit gas through pipes
13
or ducts. Waste heat can be used to operate an absorption-cooling unit for airconditioning or refrigeration.
2.6 Energy savings in stenters

One of the milestones of our project is to use waste heat recovery system for a stenter
machine in a textile mill in order to optimize its energy consumption. One of the ways
to reduce energy consumption is to reuse waste energy generated during production
processes. In the textile industry, this waste energy can be generally recovered in the
form of heat and be used in other processes of production.
The heat required in fabric drying process in the stenter is obtained from a hot gas
burner. The heat recovery is accomplished by re-utilization of exhaust air from stenter
machine by means of a heat exchanger. As a result, significant thermal energy savings
can be achieved since the heat recovery process reduces the amount of energy needed
to operate the hot gas burner.
Heat recovery system also involves pre-filtering and therefore air pollution caused by
the stenter machine is also minimized. Waste heat recovery from the stenter is possible
in two ways:
1. Waste heat recovery from the hot condensate and flash steam
2. Waste heat recovery from the exhaust gasses
Waste heat recovery from the condensate is easier. As the condensate comes from steam
traps, flash steam is produced. The flash steam may be condensed in a direct contact
condenser where cold water will extract its heat. Whereas the hot condensate may be
returned to the boiler feed water tank, by using a centrifugal pump. On the other hand,
recovering heat from the exhaust air probably offers the greatest potential reducing fuel
consumption. Our scope is limited to use waste heat recovery from the exhaust gases
because we are focusing on hot air dryer stenters.
14
2.7 Device for waste heat recovery

The backbone of heat recovery systems are the Heat Exchangers. It is an equipment
in which a hot fluid exchanges heat with a cold fluid. It is mostly used to obtain the
following results.
1. To get fluid streams to the right temperature for the next process
2. To condense vapors
3. To evaporate liquids
4. To recover heat to use elsewhere
5. To reject low grade heat
6. To drive a power cycle
The equipment for waste heat recovery can be classified in a number of way, but since
our project is based on gas to gas heat recovery, we will present the classification
according to gas to gas heat recovery systems.
2.8 Classification of heat exchangers

Figure 3 shows the tree structure that lists the classification of gas to gas heat
exchangers. They are initially classified as direct or indirect systems.
2.8.1 Direct contact heat exchanger

In Direct Contact type heat Exchanger, heat is directly transferred between hot and cold
fluids. There is no separating wall between the hot and cold fluids. Most direct contact
heat exchangers fall under the Gas- Liquid category, where heat is transferred between
a gas and liquid in the form of drops, films or sprays.
It utilizes the waste heat carrying gases by either mixing them with process streams to
augment their energy content, or by employing them independently as the process
stream itself. The former type is termed as Mixing Type heat recovery systems
whereas the latter is termed as Serial Type heat recovery system.
15
Gas to Gas Heat

Recovery Systems
Direct
Contact HX
Mixing
Type
Serial
Type
Indirect
Contact HX
Rotary
Regenerators
Swing
Regenerators
Checker
Brick
Radiation
Convection
Shell and Tube
Plate Type
Run-around
coil
Regenerators
Recuperators
Heat Pipe HX
Pebble Bed
Mix mode
Tubular
Classification of various heat exchangers
2.8.2 Indirect contact heat exchanger

In an indirect contact type heat exchanger, the fluid stream remains separated. There is
separating wall between the hot and cold fluids. The heat transfer in this type of heat
exchanger takes place continuously through a dividing wall. Most indirect contact heat
16
exchangers fall under those gases and liquids that are soluble in nature. They are further
sub-divided into three categories.
2.8.3 Recuperators
Recuperators are heat exchangers utilizing heat conduction through walls separating
the waste heat stream and the heated fluid stream. The recuperators can be classified
into radiation and convection types based on the mode of heat transfer between the heat
transfer surface and the waste heat stream.
2.8.3.1 Radiation recuperators
They have one large passage for the waste gas stream, with radiation as the primary
heat transfer mode on the waste gas side and convection on the cold side. Such
exchangers can be used with flue gas temperatures of up to 1500C.
2.8.3.2 Convection recuperators
They consist of banks of plates or tubes in the passage of waste heat stream, with
convection as the principal heat transfer mode on both the hot and cold side. The usage
of such recuperators is limited to 800C to 1100C waste gas inlet.
2.8.3.2.1 Shell and tube recuperators
They have an arrangement such that the hot gases are carried through a number of small
diameter parallel tube, while the cold stream enters a shell surrounding the tubes. The
cold gases are passed over the outside of the hot tubes one or more times in a direction
normal to the tubes.
2.8.3.2.2 Tubular type recuperators
They consist of banks of tubes placed in the hot waste stream duct. The cold gas flows
through the tubes, while the hot gas flows across the tube banks.
2.8.3.2.3 Plate type recuperators

They use metal plates as the primary heat transfer surface. They are made up of a series
of plates arranged within an enclosure. The hot gases pass through the plate recuperator
transferring their heat to the plates. Simultaneously, cold stream is drawn into the
17
recuperator in either cross flow or counter flow direction to the hot gas flow, in alternate
plate passages absorbing heat from the plates.
2.8.4 Regenerators
In a regenerator, heat from the waste heat gas stream is conducted to and stored in a
solid matrix. Cold gas stream subsequently flows over the same solid matrix to absorb
the stored heat. The hot and cold streams alternatively share the same heat transfer
surfaces and are switched either by means of a flow reversing valve of by rotating the
heat storage matrix. Following are few different types of regenerator.
2.8.4.1 Swing type regenerators
They consist of two or more solid storage matrices arranged in parallel. While hot gas
passes into one, cold gas flows through the other. Gas flows are switched at appropriate
times.
2.8.4.1.1 Checker brick regenerators
They have storage matrix constructed of fireclay, chrome, or silica brick shapes. Such
kind of regenerators are used in high temperature corrosive environments such as those
in coke oven, glass furnaces, open hearth furnaces and soaking pits.
2.8.4.1.2 Pebble bed regenerators
They have a mass of small refractory particles, enclosed in a brick-lined steel shell, to
work as a heat storage medium.
2.8.4.2 Thermal wheel
It is a rotary type of regenerator, which uses Ljungstrom principle of heat regeneration.
It consists of a cylindrical rotor containing the heat transfer surfaces, which rotates at 1
to 3 rpm inside a housing divided into two sections. Waste heat is absorbed from the
hot gas stream and transferred to incoming cold gas by means of continuously rotating
heat transfer surfaces.
18
CHAPTER #3
3. Heat Recovery Device-Selection
3.1 Introduction
In the previous chapter, a couple of heat exchangers were briefly discussed that were
the potential heat recovery devices for energy conservation. In this chapter however,
we will list down all of these devices that are used to recover heat from stenter machine
exhaust gases.
Additionally a comparison between them will be conducted so as to select the most

appropriate heat exchanger that will be suited to our goals.
3.2 Air to air heat exchanger

The hot stenter exhaust gas at up to 140C is transported by the existing waste air fans
through the heat exchanger and into the atmosphere. The cold, clean fresh air
(approximately 50% of the waste air volume) is drawn in by the fresh air fan through
the heat exchanger and into the stenter. As it passes through the heat exchanger, this air
is preheated to approximately 100C. This hot air can be used in the burner of the stenter
itself so as to lessen the requirement of fuel in the burner. The only problem is that the
burners will have to be modified in order that they are capable of accepting the air at
high temperature. This process is illustrated in Figure 4.
Schematic of a stenter with and without air to air heat recovery

unit
19
Presently, there are several kinds of heat recovery systems which are using waste heat
from stenter exhaust gases to preheat combustion air for the stenter. The existing
systems are discussed below.
3.2.1 Plate-fin recuperator

A plate-fin recuperator energy recovery heat exchanger positioned within the supply
and exhaust air streams of an air handling system, or in the exhaust gases of an industrial
process, in order to recover the waste heat. In many types of processes, combustion is
used to generate heat, and the recuperator serves to recuperate, or reclaim this heat, in
order to reuse or recycle it.
They are commonly used to reuse waste heat from exhaust air
normally expelled to atmosphere.
Devices typically comprises a
series
of
parallel
plates
of
aluminum, plastic, stainless steel,

or synthetic fibre, with extended
surfaces(fins), alternate pairs of
which are enclosed on two sides
to form twin sets of ducts at right
Flow arrangements of plate-fin
recuperator heat exchanger
angles to each other, and which

contain the supply and extract air
streams. In this manner heat from the exhaust air stream is transferred through the
separating plates, and into the supply air stream. Manufacturers claim gross efficiencies
of up to 80% depending upon the specification of the unit.
The characteristics of this device are attributable to the relationship between the
physical size of the unit, in particular the air path distance, and the spacing of the plates.
For an equal air pressure drop through the device, a small unit will have a narrower
plate spacing and a lower air velocity than a larger unit, but both units may be just as
efficient.
20
3.2.2 Heat pipe heat exchanger

A heat pipe is a heat-transfer device that combines the principles of both thermal
conductivity and phase transition to efficiently manage the transfer of heat between two
solid interfaces.
Heat pipe transmits thermal

energy
by
evaporation
and
condensation of the working

fluid. The working fluid inside
the heat pipe is in equilibrium
with its own vapour as the
container tube is sealed under
vacuum. Thermal energy applied
to the external surface of the heat
pipe causes the working fluid
near the surface to evaporate
instantaneously. The vapour thus
formed absorbs the latent heat of
Components and mechanism
for a heat pipe containing a
wick
vaporization and this part of the

heat pipe becomes an evaporator
region. Due to the pressure gradients thus created within the heat pipe by the rapid
generation of vapour near the surface, the excess vapour is forced to a remote area
within the heat pipe having low temperature and pressure. The vapour then travels to
the other end of the pipe where the thermal energy is removed causing the vapour to
condense into liquid again, thereby giving up the latent heat of the condensation. This
part of the heat pipe works as the condenser region. The condensed liquid then flows
back to the evaporator region to be reused, thus completing a cycle.
Heat is removed from the external surface of the condenser region by conduction,
convection or radiation. The heat pipe works continuously in a close-loop
condensation/evaporation cycle and thus, the capillary pumping force is established
within the wick structure that returns the working fluid from the condenser region to
21
the evaporator region. Heat pipes are often positioned in the exhaust gases of an
industrial process, in order to recover the heat energy.
Because of the characteristics of

the device, better efficiencies are
obtained
when the unit
positioned upright
with
is
the
supply air side mounted over the

exhaust air side, which allows
the liquid refrigerant to flow
quickly back to the evaporator
aided by the force of gravity.
Typical arrangement of heat

pipe exchanger
Generally, gross heat transfer
efficiencies of up to 75% are claimed by manufacturers.
3.2.3 Thermal wheel

A thermal wheel, also known as a rotary heat exchanger, or rotary air-to-air enthalpy
wheel, or heat recovery wheel, is a type of energy recovery heat exchanger positioned
within the supply and exhaust air streams of an air handling system, or in the exhaust
gases of an industrial process, in order to recover the heat energy.
A thermal wheel consists of a

circular honeycomb matrix of
heat-absorbing material, which
is slowly rotated within the
supply and exhaust air streams of
an air handling system. As the
thermal wheel rotates, heat is
picked up from the exhaust air
stream in one half of the rotation,
Diagrammatic operation of a
thermal wheel
stream in the other half of the rotation. Thus waste heat energy from the exhaust air
and given up to the fresh air
stream is transferred to the matrix material and then from the matrix material to the
22
fresh air stream, raising the temperature of the supply air stream by an amount
proportional to the temperature differential between air streams, or 'thermal gradient',
and depending upon the efficiency of the device. Heat exchange is most efficient when
the streams flow in opposite directions, since this causes a favorable temperature
gradient across the thickness of the wheel.
Because of the nature of thermal wheels in the way that heat is transferred from the
exhaust air stream to the supply air stream without having to pass directly through or
via an exchange medium, the gross efficiencies are usually much higher than that of
any other air-side heat recovery system. The shallower depth of the heat exchange
matrix, as compared to that say for a plate heat exchanger, means that the pressure drop
through the device is normally lower in comparison.
3.2.4 Run-around coil

A run-around coil is a type
of
energy
recovery
heat
exchanger most often positioned

within the supply and exhaust air
streams of an air handling
system, or in the exhaust gases of
an industrial process, to recover
the heat energy. Generally, it
refers to any intermediate stream
used to transfer heat between two
streams that are not directly
connected for reasons of safety
Run-around coil installation,

serving air handling units on
the roof of an office building
or practicality.
A typical run-around coil system comprises two or more multi-row finned tube coils
connected to each other by a pumped pipework circuit. The pipework is charged with a
heat exchange fluid, normally water, which picks up heat from the exhaust air coil and
gives up heat to the supply air coil before returning again. Thus heat from the exhaust
23
air stream is transferred through the pipework coil to the circulating fluid, and then from
the fluid through the pipework coil to the supply air stream.
The use of this system is generally limited to situations where the air streams are
separated and no other type of device can be utilized since the heat recovery efficiency
is lower than other forms of air-to-air heat recovery. Gross efficiencies are usually in
the range of 40 to 50%, but more significantly seasonal efficiencies of this system can
be very low, due to the extra electrical energy used by the pumped fluid circuit.
3.3 Selection criteria

Now that a general understanding is created about the possible heat recovery devices,
its time to select one satisfying our objective. Due to the many variables involved,
selecting optimal heat exchangers is challenging. In order to select an appropriate heat
exchanger, we have establish the selection criteria for the listed heat exchangers.
Although cost is often the first criterion evaluated, there are several other important
selection criteria which include:
1. Application
2. Size or compactness
3. Weight
4. Heat losses
5. Cost
6. Maintenance requirements, reliability and safety
The above figure of merits has been used to screen different types of heat exchangers.
Each figure of merit is assigned a weightage factor that will dictate the importance of
the criteria. The weightage factor is chosen according to the need of our objective.
Finally a weighted decision matrix has been created which will identify the most
probable choice of heat exchanger that meets the requirements of our objective. The
decision matrix is shown below:
24
Type of heat Exchanger

Figure of
merit
Application
Compactness
Weight
Heat losses
Cost
Maintenance
Total
Weight
factor
10
20
10
10
30
20
100
Plate-fin
recuperator
Heat
pipe
Thermal
wheel
Run-around
coil
Scoring
1
1
1
0
1
0
1
0
0
0
0
1
-1
1
1
0
1
0
-1
-1
-1
1
0
0
70
30
60
-30
Weighted decision matrix for heat exchangers

The plate-fin heat exchanger has the highest score among others because of its
compactness, lower weight and cost. Thermal wheel has a higher score too but it also
recovers the moisture from the exhaust fluid stream in addition to heat and therefore, is
an energy recovery device rather than heat recovery device and is not suitable for our
application. If the moisture content in the combustion air is higher, it will damage the
burner. Heat pipe has an average score because of its relatively higher weight and less
compactness compared to plate-fin recuperator. Therefore plate-fin heat exchanger is
the most suitable type for our objective.
25
CHAPTER #4
4. Properties Evaluation and Design Constraints
4.1 Properties evaluation
Following are the properties that needs to be evaluated to carry out the design process
of the heat exchanger.
1. Density ()
2. Specific heat (Cp)
3. Absolute viscosity ()
4. Dynamic viscosity ()
5. Thermal conductivity (k)
6. Prandtl no. (Pr)
4.1.1 Properties of hot air

The following properties are evaluated at mean temperature of the hot air coming out
of the stenter.
Thi = Inlet temperature of hot air = 120C = 393 K
Tho,design = Design outlet temperature of hot air = 50C = 323 K
Thm = Mean temperature of hot air at which properties are evaluated
Thm =
Thi + Tho,design
2
Thm = 358 K
All properties are obtained from table A-1, Ref 1. Linear interpolation is done where
necessary.
Density (h):
0.995 kg/m3 at 350 K
0.871 kg/m3 at 400 K
0.975 kg/m3 at Thm = 358 K
26
Specific heat (Cph):
1.009 kJ/kg/K at 350 K

1.014 kJ/kg/K at 400 K
1.009 kJ/kg/K at Thm = 358 K
Absolute viscosity (h):
208.200e10-7 Pa-s at 350 K

230.100e10-7 Pa-s at 400 K
211.704e10-7 Pa-s at Thm = 358 K
Dynamic viscosity (h)
20.920e-6 m2/s at 350 K

26.410e-6 m2/s at 400 K
21.798e-6 m2/s at Thm = 358 K
Thermal conductivity (kh):
30.000e-3 W/m/K at 350 K

33.800e-3 W/m/K at 400 K
30.608e-3 W/m/K at Thm = 358 K
Prandtl no. (Prh):
0.700 at 350 K
0.690 at 400 K
0.698 at Thm = 358 K
27
4.1.2 Properties of cold air

The following properties are evaluated at inlet temperature of the cold air coming from
the environment.
Tci = Inlet temperature of cold air = 30C = 303 K
All properties are obtained from table A-1, Ref 1. Linear interpolation is not done.
Density (c):
1.162 kg/m3 at Tci = 303 K
Specific heat (Cpc):
1.007 kJ/kg/K at Tci = 303 K
Absolute viscosity (c):
184.600e10-7 Pa-s at Tci = 303 K
Dynamic viscosity (c)
15.890e-6 m2/s at Tci = 303 K
Thermal conductivity (kc):
26.300e-3 W/m/K at Tci = 303 K
Prandtl no. (Prc):
0.707 at Tci = 303 K
28
4.1.3 Properties of aluminum

The following properties are evaluated at mean temperature of the hot and cold air going
into the heat exchanger.
Thi = Inlet temperature of hot air = 120C = 393 K
Tci = Inlet temperature of cold air = 30C = 303 K
Tm = Mean temperature of hot and cold air at which properties are evaluated.
Tm =
Thi + Tci
2
Tm = 348 K
All properties are obtained from table A-2, Ref 1. Linear interpolation is done where
necessary.
Density (p):
2770 kg/m3 at Tm = 348 K
Thermal conductivity (kp):
163.000 W/m/K at 200 K

186.000 W/m/K at 400 K
180.000 W/m/K at Tm = 348 K
29
4.2 Design constraints

The following data has been obtained from Afroze textiles for the design of a proposed
heat exchanger for waste heat recovery from the exhaust air of the stenter machine.
Parameters
Volume flow rate
Units
m3/hr
Hot Air Side

31000
Cold Air Side

31000
Mass flow rate (Calculated)
kg/s
8.397
10.001
Inlet Temperature
393
303
Outlet Temperature (Design)
323
To be calculated
Inlet Pressure
Pa
151,987.5
151,987.5
Allowable pressure drop
3.0
3.0
Effectiveness: Must be greater than 70%
Design constraints
4.3 Heat transfer constraints

The design must satisfy the following heat transfer constraints.
Q = Heat transfer rate of the heat exchanger
Q = m Cph (Thi Tho,design)

Q = 8.397 x 1.009e3 x (393-323)
Q = 593.521 kW
Tco,design =
Tco,design =
Q
+ Tci
m Cpc
593.521e3
+ 303
10.001 1.007e3
Tco,design = 361.935 K
Although if the design has better heat transfer rates than the constraints with slightly
lower added cost than it will be selected as the proposed design.
30
4.4 Dimensional constraints

The following are the constraints imposed on the size of the heat exchanger as per the
exterior dimensions of the stenter machine installed at Afroze textiles.
Maximum length: 2 m
Maximum height: 2m
Maximum width: 2m
4.5 Cost constraints

Cost is one of the most important factors in the selection of heat exchanger. The total
cost of the heat exchanger should not be greater than Rs. 1 million. It is assumed in
order to narrow down the selection of various configuration of fins used in the heat
exchanger which will be discussed later.
31
CHAPTER #5
5. Plate-Fin Heat Exchanger
5.1 Introduction
Plate-fin heat exchangers are a
form of compact heat exchanger
consisting of a stack of alternate
flat plates called parting sheets
and fin corrugations brazed
together as a block. Separate hot
and cold fluid streams flow
through alternating layers of the
heat exchanger and are enclosed
at the edges by side bars. Heat is
transferred from one stream
through the fin interface to the
parting sheets and through the
next set of fins into the adjacent
fluid. The fins also serve to
increase the structural integrity
of the heat exchanger and allow
Basic elements and two types

of flow arrangements in platefin heat exchanger
it to withstand high pressures

while providing an extended
surface area for heat transfer.
In a plate-fin heat exchanger, the fins are easily able to be rearranged. This allows for
the two fluids to result in cross flow, counter-flow, and cross-counterflow or parallel
flow arrangement, though parallel flow is mostly not used. If the fins are designed well,
the plate-fin heat exchanger can work in perfect counterflow arrangement which
permits the exchanger to satisfy duties requiring a high thermal effectiveness.
32
A high degree of flexibility is present in plate-fin heat exchanger design as they can
operate with any combination of gas, liquid, and two-phase fluids. Heat transfer
between multiple process streams is also accommodated, with a variety of fin heights
and types as different entry and exit points available for each stream.
5.2 Salient features of plate-fin heat exchanger

The essential features of plate-fin heat exchangers are as follows:
1. Plate-fin surfaces are commonly used in gas-to-gas exchanger applications.

They offer high area densities (up to about 6000 m2/m3).
2. The passage height on each side could be easily varied. Different fins (such as
rectangular or triangular fin either plain or with louver or perforation, offset
strip fin and wavy fin) can be used between plates for different applications.
3. They are generally designed for low pressure applications, whose operating
pressures are limited to about 1000 kPa.
4. The maximum operating temperatures are limited by the type of fin-to-plate
bonding and the materials employed. Plate-fin exchangers have been designed
from low cryogenic operating temperatures to about 800C.
5. Fluid contamination (mixing) is generally not a problem since there is
practically zero fluid leakage from one side to the other side of the exchanger.
5.3 Advantages of plate-fin heat exchanger

The principal advantages of plate-fin heat exchanger over other forms of heat
exchangers are summarized as follows:
1. Plate-fin heat exchangers, in general are superior in thermal performance to

those of the other type of heat exchangers employing extended surfaces.
2. They can achieve temperature approaching as low as 1C between single-phase
streams and 3C between multiphase streams. Typically, overall mean
temperature differences of 3C to 6C are employed in aluminum plate-fin heat
exchanger applications.
33
3. With their high surface compactness, the ability to handle multiple streams, and
with aluminum's highly desirable low temperature properties, brazed aluminum
plate-fins are an obvious choice for cryogenic applications.
4. Very high thermal effectiveness can be achieved; for cryogenic applications,
effectiveness of the order of 95% and above is common.
5. Provided the streams are reasonably clean, plate-fin heat exchanger can be used
to exchange heat in most processes, for the wide range of stream compositions
and pressure/temperature envelopes.
6. Large heat transfer surface per unit volume is possible.
7. Low weight per unit heat transfer.
8. Possibility of heat exchange between many process streams.
9. Provided correct materials are selected, the plate-fin heat exchanger can be
specified for temperatures ranging from near absolute zero to more than 800C,
and for pressures up to at least 140 bar. Usually the plate-fin heat exchanger do
not involve both high temperature and high pressure together.
10. The plate-fin heat exchanger offers about 25 times more surface area per
equipment weight than the shell and tube heat exchanger.
5.4 Limitations of plate-fin heat exchanger

Following are the limitations of plate-fin heat exchanger excluding fouling.
1. With a high effectiveness heat exchanger and/or large frontal area, flow
distribution becomes important.
2. Due to short transient times, careful design of control is required for startup
compared with shell and tube exchangers.
3. Flow oscillations could be a problem.
34
5.5 Flow arrangement

A plate fin heat exchanger can have two or more streams, which may flow in directions
parallel or perpendicular to one another. When the flow directions are parallel, the
streams may flow in the same or in opposite sense. So there are three primary flow
arrangements for a plate fin heat exchanger.
1. Parallel flow
2. Counter-flow
3. Cross flow
Thermodynamically, the counter-flow arrangement provides the highest heat (or cold)
recovery, while the parallel flow geometry gives the lowest. The cross flow
arrangement, gives an intermediate thermodynamic performance, by offering superior
heat transfer properties and easier mechanical layout.
5.5.1 Counter flow

In a counter flows heat exchanger the two fluids flow parallel to each other but in opposite
directions. The counter-flow heat exchanger provides the most thermally effective arrangement
for recovery of heat or cold from process streams. A counter flow arrangement is
thermodynamically superior to any other flow arrangement. It is the most efficient flow
arrangement, producing the highest temperature change in each fluid compared to any other
two-fluid arrangement for a given overall thermal conductance (UA), fluid flow rates and fluid
inlet temperatures. Cryogenic refrigeration and liquefaction equipment use this geometry
almost exclusively. But these type of heat exchangers demand proper design because of the
complex geometry of headers.
5.5.2 Cross flow

In cross flow heat exchangers, the fluids flow in directions normal to each other.
Thermodynamically the effectiveness for cross flow heat exchangers falls in between that for
the counter flow and parallel flow arrangements. The largest structural temperature difference
exists at the corner of the entering hot and cold fluids. Only two streams are handled in a cross
flow type of a heat exchanger which eliminates the need for distributors. For this type of heat
exchangers the header tanks are located on all four sides of the heat exchanger core, making
this arrangement simple and cheap. If high effectiveness is not necessary, and if the two fluid
35
streams have widely differing volume flow rates, or if either one or both streams have constant
temperature, the cross flow arrangement should be preferred. Typical applications include
automobile radiators and some aircraft heat exchangers.
5.6 Fin geometry

Plate-fin surfaces have plain
triangular,
louver,
plain
offset
rectangular,
strip,
wavy,
perforated, or pin fin geometries.

Fin density varies from 120 to
700 fins/meter, thickness from
0.005 to 0.25 mm, and fin heights
may range from 2 to 25 mm. Due
to the lack of data for perforated
Different types of plate-fin

surfaces
and pin fin geometries, we have
discarded it in our design process and will only consider plain, louver, offset strip and
wavy fins for the design of heat exchanger.
5.6.1 Plain fins

Plain fin corrugation is the
simplest type of fins. These
surfaces are straight fins that are
uninterrupted (uncut) in the fluid
flow direction. Triangular and
rectangular passages are more
common. The triangular fin is
generally not
structurally as
strong as the rectangular fin for

the same passage size and fin
thickness. When the fins are
Plain rectangular fins
straight along the flow length, the boundary layers tend to be thick resulting in lower
values of the heat transfer coefficient. When they are wavy or off-set strip fin along the
36
flow length, the boundary layers are thinner or the growth of boundary layers is
disrupted periodically, respectively, resulting in a higher heat transfer coefficient.
Plain fin surfaces have pressure drop and heat transfer characteristics similar to flow
through small-bore tubes, i.e., relatively low pressure drop and heat transfer, but a high
ratio of heat transfer to pressure drop. For a flow channel with rectangular or triangular
cross section, under turbulent flow conditions, standard equations for turbulent flow in
circular tubes may be used to calculate j and f, provided the Reynolds number (Re) is
based on the hydraulic diameter Dh. If the (Re) based on hydraulic diameter is less than
2000, one may use theoretical laminar flow solutions for j and f.
Plain fins are preferred for very low Reynolds number applications and in applications
where the pressure drop is very critical. Condensing duties require minimal pressure
drop or else the heat release curve can significantly alter and the overall duty may not
be met. Therefore, for condensation, plain fins are normally specified.
5.6.2 Louvered fins

The
louvers
are
essentially
formed by cutting the sheet metal

of the fin at intervals and by
rotating the strips of metal thus
formed out of the plane of the fin.
Louvers can be made in many
different geometries. Note that
the parallel louver fin and offset
strip fin both have small strips
aligned parallel to the flow. The
louvered fin geometry bears a
similarity to the offset strip fin.
Louvered fins
Rather than offsetting slit strips,
the entire slit fin is rotated 20- 60 relative to the airflow direction. As such, they are
similar in principle to the offset strip fin. Louvered fins enhance heat transfer by
37
providing multiple flat plate leading edges with their associated high values of heat
transfer coefficient. Salient features of louver fins are as follows:
1. The louvered fin strip length is usually longer than that of offset strip fin, e.g. 6
to 18 mm, versus 3 to 9 mm for the offset strip fin. The louvered fin gage is
generally thinner than that of an offset strip of the fin.
2. The fin corrugations normally form a triangular passage. Hence, it is generally
not as strong as an offset strip fin, since the latter has a large flat area for
brazing, thus providing strength.
3. The louver fins may have a slightly higher potential of fouling compared to the
offset strip fins.
4. The louvered fin can provide heat transfer coefficients comparable to the offset
strip fin. However, the ratio of j/f tends to be lower because of the considerable
form drag on the bent fins.
5. Louver fins can enhance heat transfer by a factor of two or three compared with
the equivalent un-louvered surfaces.
6. A wide range in performance can be achieved by varying the louver angle,
louver width and louver form.
The operating Reynolds number range is 100-5000, depending upon the type of louver
geometry employed.
Their attractive thermal performance characteristics in terms of compactness, light

weight, and low pumping power for a given heat transfer duty make louver fins a
potential candidate for aerospace applications. They are recognized as very effective
heat transfer surfaces leading to compact solutions to cooling problems. Louvered fin
surfaces are now used widely for engine cooling equipment, air-conditioning heat
exchangers (evaporators and condensers), and aircraft oil and air coolers. They share
this quality with the offset strip fin surfaces. The louvered surface is the standard
geometry for automotive radiators. For the same strip width, the louvered fin geometry
provides heat transfer coefficients comparable to the offset strip fin.
38
5.6.3 Offset strip fins

The offset strip fin (OSF) is the
commonly used geometry in
plate-fin heat exchangers. The fin
has a rectangular cross section; it
is cut into small strips of length L,
and every alternate strip is offset
by about 50% of the fin pitch in
the
transverse
direction.
Fin
spacing, fin height, fin thickness,

Offset strip fins
and strip length in the flow

direction are the major variables of OSF.
OSF geometry is characterized by high heat transfer area per unit volume, and high heat
transfer coefficients. The heat transfer mechanism in OSFs is as follows. The heat
transfer enhancement is obtained by periodic growth of laminar boundary layers on the
fin length, and their dissipation in the fin wakes. This enhancement is accompanied by
an increase in pressure drop because of increased friction factor. A form drag force, due
to the finite thickness of the fins, also contributes to the pressure drop. Fluid interchange
between channels is possible. OSFs are used in the approximate Reynolds number
range of 500-10,000. Salient features pertaining to thermal performance include the
following:
1. Commonly used in air separation plants where high thermal effectiveness at low
mass velocities is required.
2. The heat transfer performance of OSFs is increased by a factor of about 1.5 to
4 over plain fins or similar geometry, but at the expense of higher pressure drop.
3. At high Reynolds numbers, the j factor decreases, while the friction factor
remains constant because of the high form drag. Therefore, offset fins are used
less frequently for very high Reynolds number applications.
4. They are used at low Reynolds number applications calling for accurate
performance predictions, such as some aerospace applications; other fin
performance data are not as repeatable.
39
5.6.4 Wavy fins

Since
wavy
fins
have
non-
interrupted walls in each flow

channel, they are less likely to catch
particulates and foul than are
OSFs.
Their
performance
is
competitive with that of the OSF

but the friction factor continues to
rail
with
increasing
Reynolds
numbers.
Wavy fins
The waveform in the flow direction provides effective interruptions to flow and induces
very complex flows. The augmentation is due to Goertler vortices, which form as the
fluid passes over the concave wave surfaces. These are counter-rotating vortices, which
produce a corkscrew-like pattern and probable local flow separation that will occur on
the downstream side of the convex surface. In the low- turbulence regime (Re of about
6000-8000), the wall corrugations increase the heat transfer by about nearly three times
compared with the smooth wall channel. Therefore, wavy fins are often a better choice
at the higher Reynolds numbers typical of the hydrocarbon industry; the smooth surface
allows the friction factor to fall with increasing Reynolds number.
40
5.7 Relative merits of plate-fin geometries

The following table lists the commonly used plate-fin geometries and their relative
merits.
Type of
Fin
Plain
Description
Application
Straight fins
(rectangular or
triangular)
Low Reynolds number

applications and in
applications where the
pressure drop is very
critical, e.g.
condensation.
Louvered The louvers are
Radiators, air
formed by cutting
conditioning heat
the sheet metal of the exchangers (evaporators
fin at intervals & by and condensers), and
rotating the strips
aircraft oil and air
thus formed out of
coolers.
the plane of the fin.
Offset
Straight but offset by Air separation plants and
strip
half a pitch (usually
low Reynolds number
about every 3 to 4
applications calling for
mm)
accurate performance
predictions, e.g.
aerospace applications.
Wavy
Straight fin with
For general purpose use.
small holes Smooth
but wavy.
Features
Heat
Pressure
transfer
drop
Lowest
Lowest
Highest
Highest
Highest
Highest
High
High
Relative merits of plate-fin geometries
5.8 Material of construction

Plate-fin heat exchangers are made in a variety of materials to suit a wide range of
process streams, temperatures and pressures. Material specifications should comply
with the appropriate section of the ASME or to other applicable codes.
Aluminum is preferred for cryogenic duties, because of its relatively high thermal
conductivity, strength at low temperatures, and low cost. For cryogenic services,
aluminum alloy 3003 is generally used for the parting sheets, tins, and edge bars that
41
form the rectangular plate-fin heat exchanger block. Headers and nozzles are made from
aluminum alloy 3003, 5154, 5083, 5086, or 5454. Above ambient temperature, with
increase in temperature, most aluminum alloys rapidly lose their strength.
Stainless steels and most nickel alloys are also used for plate-fin heat exchangers,
particularly for high-temperature services. Stainless steels have poor thermal
conductivity but their higher strength allows thinner parting plates and fins than with
aluminum, which offsets some of the reduction in heat transfer. We are using aluminum
as the material of construction for our design because of low temperature application.
5.9 Relation between heat transfer rate and heat transfer
area
The heat transfer rate Q to or from a fluid is equal to its rate of change enthalpy, and is
given by:
Q = m x Cp x T
(5.1)
Where, m is the fluid mas flow rate, T is the fluid temperature change during
heating or cooling, and Cp is the fluid specific heat at constant pressure.
The product of m x Cp is equal to the rate of heat transfer to or from the fluid per unit
temperature change and is called heat capacity rate C. The heat capacity rate of the
cold side fluid is designated as Cc, and that of the hot side fluid as Ch. The smaller
heat capacity is referred to as Cmin and the larger heat capacity rate as Cmax. It is
convenient to define the unit thermal capacity ratio as:
(5.2)
The values of C lie in the range between 0 and 1.
The maximum possible heat transfer Qmax occurs when the temperature of the fluid with
Cmin changes from its inlet value to the inlet value of the other fluid. If that fluid were
the cold side fluid, it would be heated from Tci to Thi, where Tci, is the inlet temperature
42
of the cold side fluid and Thi is the inlet temperature of the hot side fluid. If the fluid
with Cmin were the hot side fluid, it would be cooled from Thi to Tci Thus,
Qmax = Cmin x (Thi Tci)
(5.3)
Since the heat transfer rate is the same for the fluid with Cmax, its temperature change
at Qmax is less than (Thi Tci).
5.10 Heat exchanger effectiveness

The heat exchanger effectiveness is defined as the ratio of the actual heat transfer Q
to the maximum possible heat transfer rate Qmax. Mathematically,
m x Cp x T
Cmin x (Thi Tci)
Where, the terms in the numerator refer to either the hot side or the cold side. If
mc x Cpc = Cmin it follows that,
(Tco Tci)
(Thi Tci)
Where, Tco is the outlet temperature of the cold side fluid. If mh x Cph = Cmin, it follows
that,
(Thi Tho)
(Thi Tci)
Where, Tho is the outlet temperature of the hot side fluid. If mc x Cpc = mh x Cph, it
follows that,
(Tco Tci)
(Thi Tho)
=
(Thi Tci)
(Thi Tci)
The latter condition is approximated reasonably well in a gas turbine recuperator.
5.11 Number of transfer units

Before defining the number of transfer units, additional concepts involved in the
definition must be introduced.
43
The total resistance to the flow of heat between a hot fluid and a cold fluid is equal to
the sum of the resistances in the hot and cold fluids plus the resistance of the heat
transfer path (usually a wall) between the fluids. The resistance of the heat transfer path
(usually a wall) between the fluids. The resistance of the heat transfer path between the
fluids is usually small compared to the fluid thermal resistance. We may then write for
the total thermal resistance Rt.
1
1
1
1
1
=
=
=
+
+
Where hc is the heat transfer coefficient of the cold side fluid, hh, is the heat transfer
coefficient of the hot side fluid, Ac is the cold side heat transfer area, Ah is the hot side
heat transfer area, Uc is the heat transfer coefficient based on the cold side area, Uh is
the heat transfer coefficient based on the hot side area, kp is the thermal conductivity of
aluminum plates and tp is the thickness of plates. In our design the cold side heat transfer
area and the hot side heat transfer area are same such that ATc = ATh = AT.
The heat transfer rate between the fluids can be expressed in terms of UAT as,
Q = U x AT x Tm
(5.4)
Where, Tm is the log mean temperature difference between the hot side and cold side
fluids. Mathematically,
Tm =
( ) ( )
( )

( )
The heat transfer rate given by Eq. (5.4) is also equal to the heat transfer rate to or from
either fluid, as given by Eq. (5.1).
A reference heat transfer area Aref will now be defined as,
Aref =
Tmax
(5.5)
Where, Tmax = Thi Tci

44
As it is evident from Eq. (5.4), the reference area is equal to the area that would be
needed to transfer heat between the hot and cold side fluids at the maximum rate if the
log mean temperature difference were equal to the maximum temperature difference
between the fluids.
With the aid of Eq. (5.5), the number of transfer units NTU can now be defined as,
Tmax
=
(5.6)
Substituting for Qmax from, Eq. (5.3), NTU assumes the final form as,
The magnitude of NTU can be less than, equal to, or greater than unity.
5.12 Applications of plate-fin heat exchanger in waste heat
recovery
Following are the few applications of plate-fin heat exchanger as a waste heat recovery
device.
5.12.1 Application to air conditioning system

The temperature of exhaust gas from the air conditioning system is as low as
approximate 20C, but the high efficiency and compactness of plate-fin heat exchanger
proves to be the best choice for waste heat recovery at such a low temperature.
5.12.2 Application to industrial dryers

Because of relatively low temperature, the heat from the exhaust gas of industrial dryer
is suitable to recover by the usage of plate-fin heat exchanger. Therefore, inquiries are
most frequently concentrated on this field. It was conventionally considered that the
recovery of exhaust gas of low temperature of approximately 150 C was not so
profitable, but in recent years, the investment in the equipment has been recovered for
about one year due to the rise in energy prices, and troubles in the recovery from dryers
are fewer than in the recovery of heat from the combusted gas. Thus, it has been
common to recover heat from the exhaust of dryers.
45
CHAPTER #6
6. Qualitative Thermal Design
Previous chapter describes in detail, the working and types of fin surfaces used in plate
fin heat exchanger. In this chapter however, we describe the sequential steps, we will
follow in conducting the design calculations for our heat exchanger. We have chosen
counterflow arrangement for our proposed heat exchanger because of higher heat
transfer rates and greater effectiveness of the heat exchanger.
Design calculations are also done of a simple plate heat exchanger with no extended
surfaces (simple metal plates arranged parallel to each other, alternate gaps of which
contain the hot and cold fluid) in order to compare the two designs and study their
effects on the cost, size and heat transfer rates. The sequential steps for both heat
exchangers are described as follows:
6.1 Simple plate heat exchanger

We have considered a compact counterflow plate type heat exchanger consisting of
aluminum plates separated by N gaps. The hot and cold air are moving in opposite
direction within alternating gaps. The stack of the heat exchanger is considered to be of
cubical geometry. The assumptions of the design are as follows:
1. Negligible heat loss to the surroundings.

2. Negligible kinetic & potential energy changes.
3. Constant properties.
4. Negligible fouling factors.
5. Fully developed conditions.
6. Identical gap to gap heat transfer coefficients.
7. Heat exchanger exterior dimensions are larger compared to gap width.
8. All units are in S.I system.
46
6.1.1 Range of no. of gaps between plates - selection

The metal plates are separated by a finite no. of gaps of finite height. Let them be
represented by:
No. of gaps between metal plates = N
We have defined a range of assumed no. of gaps that satisfies our design, heat transfer,
dimensional and cost constraints. All the quantities mentioned below will contain this
as a variable until a relationship is developed between height of flow passage and no.
of gaps.
6.1.2 Calculation of dimensions of flow passage

Height of gap between metal plates = Plate spacing = b
Thickness of metal plates = tp
Total number of metal plates = NT = N-1
Height of flow passage = Hf
= ( ) + ((N 1) )
Length of flow passage = Lf = Hf
Width of flow passage = Wf = Hf
6.1.3 Calculation of hydraulic diameter of flow passage

The hydraulic diameter of the flow passage is given by:
Where, Dh is the hydraulic diameter, Av is the cross-sectional area of flow passage and
P is the wetted perimeter of the flow passage. Simplifying above we get,
4 Wf
2 ( + Wf)
Assuming that b << Wf, we get:
= 2
47
6.1.4 Calculation of exterior dimensions of heat exchanger

Since the stack is of cubical geometry, each side of the heat exchanger will be of same
dimension. Let them be represented as,
Thickness of end plates = tep

Height of heat exchanger = H = Hf + (2 x tep)
Length of heat exchanger = L = Hf
Width of heat exchanger = W = Hf
Figure 16 shows the arrangement of our proposed heat exchanger.
Different drawing views of simple plate heat exchanger

48
6.1.5 Calculation of all geometrical quantities for hot and cold

side fluid
Frontal area of hot air side = Afr = Afr,h = Wf x Hf
Frontal area of cold air side = Afr = Afr,c = Wf x Hf
Hot air side heat transfer area i.e. the total surface area of the metal plates on the hot air
side is given by:
= = (N 1)
Similarly, cold air side heat transfer area,
= = (N 1)
Minimum free-flow area of hot air side is given by,
= =
Similarly, minimum free-flow area of cold air side,

= =
Mass velocity of hot air,
Mass velocity of cold air,
6.1.6 Calculation of all the dimensionless quantities for hot and

cold side fluid
Now the following dimensionless quantities need to be calculated for both the hot and
cold side fluid.
49
Reynolds number,
Reynolds number of hot air side,
Reynolds number of cold air side,
Nusselt number,
Nusselt number for hot air side,
Nusselt number for cold air side,
By using table A-3, Ref 1, we have calculated the Nusselt no. for hot and cold air.
Now we can calculate the heat transfer coefficients for hot and cold air side by using
the above relations.
6.1.7 Calculation of overall heat transfer coefficient

Since the heat transfer area is same for hot and cold side, the overall heat transfer
coefficient will also be same and is given by,
= = =
50
1
1
+ +

6.1.8 Calculation of log mean temperature difference

The log mean temperature difference is given by:
(, ) ( , )
(, )
( , )
6.1.9 Calculation of height of flow passage

Now a relationship is developed between the height of flow passages and the no. of
gaps between metal plates. The relationship derived below:
2 ( 1)
1
1
+ +

2 =
1
1
( + + )
( 1)
The above relationship will contain the variable N and by using the defined range
all quantities will be calculated.
6.1.10 Calculation of all quantities

Now that the no. of gaps has been defined, all quantities will be calculated as in the
following order:
1. b
2. NT
3. Dh
4. H, L & W
5. Afr
6.
51
7.
8. &
9. &
10. &
11.
6.1.11 Calculation of number of transfer units and overall

effectiveness
The number of transfer units and heat exchanger effectiveness will computed by using
the following steps.
Heat capacity rate,
=
Heat capacity rate for hot air side,
= =
Heat capacity rate for cold air side,
= =
The thermal capacity ratio is given by:
Number of transfer units is given by:
Hence the effectiveness of heat exchanger is,
1 ((1
))
1 ( ((1 )) )
52
6.1.12 Calculation of overall pressure drop on both sides

The pressure drop is calculated by using the following relation.
2
64
Pressure drop of hot air side,
2
64
=
2
Pressure drop of cold air side,
2
64
=
2
The percentage pressure drop is given by:
% =
Percentage pressure drop of hot air side,
% =
100
Percentage pressure drop of cold air side,

% =
100
The symbols in above equation have the following definitions. Pinlet is the inlet
pressure and P is the net pressure drop.
53
6.1.13 Calculation of cost of heat exchanger

The cost of the heat exchanger is calculated as follows:
Volume of metal plates: Vp = Hf x Lf x tp x NT
Volume of end plates: Vpe = (2 x Lf x H x tep) + (2 x Lf x W x tep)
Total volume aluminum used: Va = Vp + Vpe
Mass of aluminum used: Ma = Va x p
Cost of aluminum: Costa = Ma x 200 (Market price of aluminum in Rs. / kg)
Cost of heat exchanger: CostHX = 7.5 x Costa

The constant 7.5 is taken from Ref 6.
6.1.14 Selection of heat exchanger

All calculations are performed at the defined range of no. of gaps and the results were
tabulated. The tabulated results are shown in this section. Now the most suitable design
satisfying all the constraints will be selected.
54
6.2 Plate fin heat exchanger

We have considered a compact counterflow plate-fin heat exchanger whose core is built
by stacking the layer of fins separated by parting sheets made of aluminum having N
gaps. The hot and cold air are moving in opposite direction within alternating gaps. The
stack of the heat exchanger is considered to be of cubical geometry.
The data regarding different types of fin geometry is obtained from Ref 2, compact heat
exchangers by W. M. Kays and A. L. London. The book serves the basis of the design
and most of the geometrical and dimensional parameters are obtained from this book.
Plain, Louvered, Offset strip and wavy are the types of fin geometries which we have
considered for the design. The assumptions of the design are as follows:
1. Negligible heat loss to the surroundings.

2. Negligible kinetic & potential energy changes.
3. Constant properties.
4. Negligible fouling factors.
5. Fully developed conditions.
6. Identical gap to gap heat transfer coefficients.
7. Heat exchanger exterior dimensions are larger compared to gap width.
8. All units are in S.I system.
6.2.1 Range of no. of parting sheets - selection

The no. of parting sheets are separated by a finite no. of gaps of finite height. Let them
be represented by:
Total no. parting sheets = NT
No. of gaps between parting sheets = N = NT + 1
We have defined a range of assumed no. of parting sheets based on the availability of
data from Ref 2. The range is actually dictated by the Reynolds no. at which the
dimensionless parameters such as Stanton no. and friction factor are obtained from the
book. The Reynolds no. however is controlled by the no. of parting sheets in the heat
exchanger core.
55
6.2.2 Geometrical parameters of the fin

Following are the geometrical parameters which are obtained from table A-4, Ref 2. At
each NT, all the quantities mentioned below are calculated for a particular type of fin
and then the geometrical parameters are changed for another fin to repeat the above
mentioned process. The parameters are,
Type of fin
Surface designation
Plate spacing = b
Fin thickness =
Hydraulic diameter = Dh
Fin frequency = F
Total heat transfer area on one side / volume between the plates on that side =
Fin area/ Total Heat transfer area =
6.2.3 Calculation of dimensions of flow passage

Thickness of metal plates = tp
Height of flow passage = Hf
= ( ) + ((N 1) )
Length of flow passage = Lf = Hf
Width of flow passage = Wf = Hf
6.2.4 Calculation of exterior dimensions of heat exchanger

Since the stack is of cubical geometry, each side of the heat exchanger will be of same
dimension. Let them be represented as,
Height of heat exchanger = H = Hf + (2 x tep)

Length of heat exchanger = L = Hf
Width of heat exchanger = W = Hf
Thickness of end plates = tep
56
Figure 17 shows the arrangement of our possible design of heat exchanger.
Different drawing views of plate-fin heat exchanger

57
6.2.5 Calculation of all geometrical quantities for hot and cold

side fluid
Frontal area of hot air side = Afr = Afr,h = Wf x Hf
Frontal area of cold air side = Afr = Afr,c = Wf x Hf
Total volume of heat exchanger core = Vtotal = Hf x Wf x Lf
The ratio of total heat transfer area on one side and total volume of heat exchanger core
designated by is calculated as follows:
(2 ) + (2 )
Hot air side heat transfer area i.e. the total surface area of metal plates on the hot air
side is given by:
= =
Similarly, cold air side heat transfer area,
= =
The ratio of minimum free flow area and frontal area designated by is calculated
as follows:
=
Minimum free-flow area of hot air side is given by,
= =
Similarly, minimum free-flow area of cold air side,
= =
58
6.2.6 Calculation of all the dimensionless quantities for hot and

cold side fluid
Now the following dimensionless quantities need to be calculated for both the hot and
cold side fluid.
Mass velocity of hot air,
Mass velocity of cold air,
Reynolds number,
Reynolds number of hot air side,
Reynolds number of cold air side,
Stanton number,
Stanton number for hot air side,
Stanton number for cold air side,
By using table A-5, Ref 2, we have obtained the Stanton no. for hot and cold air side at
the calculated Reynolds number.
59
Now we can calculate the heat transfer coefficients for hot and cold air side by using
the above relations.
6.2.7 Calculation of fin effectiveness

Now the calculations for effectiveness of the fin are done in this section.
Fin effectiveness parameter,
Fin effectiveness parameter for hot air side,
Fin effectiveness parameter for cold air side,
The fin length from root to center is given by:
Fin effectiveness,
tanh( )
tanh( )

Fin effectiveness for hot air side,
60
Fin effectiveness for cold air side,
tanh( )

Total surface effectiveness,
= 1 ( (1 ))
Total surface effectiveness for hot air side,
= 1 ( (1 ))
Total surface effectiveness for cold air side,
= 1 ( (1 ))
6.2.8 Calculation of overall heat transfer coefficient

Since the heat transfer area is same for hot and cold side, the overall heat transfer
coefficient will also be same and is given by,
= = =
1
1
+ +

6.2.9 Calculation of number of transfer units and overall

effectiveness
The number of transfer units and heat exchanger effectiveness will computed by using
the following steps.
Heat capacity rate,
=
Heat capacity rate for hot air side,
= =
61
Heat capacity rate for cold air side,
= =
The thermal capacity ratio is given by:
Number of transfer units is given by:
Hence the effectiveness of heat exchanger is,
6.2.10 Calculation
of
1 ((1
))
1 ( ((1 )) )
effectiveness
of
heat
exchanger
considering longitudinal wall conduction

Longitudinal heat conduction along the separating surfaces of hot and cold fluids causes
serious performance deterioration. The effect of longitudinal heat conduction is to
reduce the effectiveness of heat exchanger. The decrease in the effectiveness of heat
exchanger is found out by using Kroegers equation found in Ref 4.
Longitudinal wall conduction area,
Longitudinal wall conduction area of hot air side,
= = ,
Similarly, wall conduction area of cold air side,
= = ,
62
Wall conduction parameters are given by,
=(
1
(1 + )(1 + )
(1 + )
1
)2 (
)
1+
1 (1 + )
1 =
1+
1
(1 )
1 + ( )
Now the corrected heat exchanger effectiveness is calculates as:
= 1
1
1
6.2.11 Calculation of amount of heat transferred and the outlet

temperatures for hot and cold side fluids
The maximum possible heat transfer rate by the heat exchanger is,
= ( )
The actual heat transfer rate by the heat exchanger is given by:
=
The outlet temperature of hot air is,
, =
63
Similarly, the outlet temperature of cold air is,
, = +
6.2.12 Calculation of overall pressure drop on both sides

The hot and cold side fluids undergo a drop in pressure while flowing through the heat
exchanger. Since a decrease in fluid pressure can adversely affect the performance of
the system of which the flowing fluids are apart, there is generally a limit on the
allowable hot and cold side fluid pressure drops. In a gas turbine recuperator for
example, a representative requirement might be that the sum of the hot and cold side
pressure drops does not exceed 6%.
The same factors that act to increase heat transfer coefficient and reduce heat exchanger
size, such as an increase in the flow velocity or a decrease in the hydraulic diameter of
flow passages, also act to increase the pressure drop. Therefore, the minimum size of a
heat exchanger with a specified effectiveness will generally be determined by the
allowable overall (hot side plus cold side) pressure drop.
The fractional pressure drop of a fluid flowing through one side of a heat exchanger can
be expressed as:
2 1
[( + 1 2 ) + 2 ( 2 1) + ( )
=
2
1
1
(1 2 ) (
2
)]
1
The symbols in above equation have the following definitions. Pinlet is the inlet
pressure, P is the net pressure drop, 1 is the specific volume at the core inlet, 2 is
the specific volume at the core exit, m is the mean specific volume in the core, G is
the mass velocity in the core, Kc is the entrance loss coefficient, Ke is the exit loss
coefficient, f is the friction coefficient and g is the acceleration due to gravity.
The variables f, Kc, and Ke depend on the core geometry and the Reynolds number.
64
The first term in the brackets of above equation accounts for entrance losses due to
both the momentum increase associated with the increase of velocity as the fluid
enters the heat exchanger core (1-2) and the irreversible losses associated with the
abrupt contraction of flow area (the entrance loss coefficient Kc). The second term
accounts for the pressure change due to momentum change in the core as the fluid
density changes during heating or cooling. The third term accounts for the core
friction pressure loss. The last term accounts for the increase in exit pressure due to
the momentum loss associated with the deceleration of fluid leaving the heat
exchanger core [-(1-2 )] and the irreversible pressure loss associated with abrupt
expansion (the exit loss coefficient Ke).
The entrance and exit loss coefficients are obtained from Figure 18 which is taken
from Ref 2.
Entrance & exit pressure loss coefficients for a multiple

square-tube heat exchanger core with abrupt- contraction
entrance and abrupt-expansion exit.
65
For gaseous hot and cold fluids, the perfect gas law can be used to obtain following
relationships:
2 2 1
=
1 1 2
Similarly,
m 1
=
1
1
Since the allowable percentage pressure drop is small in most cases,
2 2
=
1 1
m
=
1
1
Where, subscript 1 & 2 corresponds to inlet and outlet properties of fluids. Therefore,
by use of all the above mentioned substitutions, the equation for fractional pressure
drop reduces to,
2 R 1
2

2
[
=
(
+
1
)
+
2
1)
+
(
1
1
2 2
2
(1 2 ) ( )]
1
6.2.13 Calculation of cost of heat exchanger

The cost of the heat exchanger is calculated as follows:
Total fin area on both sides: Af = 2 x x AT
Total volume of fins: Vf = Af x
Volume of parting sheets: Vp = Hf x Lf x tp x NT

66
Total volume aluminum used: Va = Vp + Vpe + Vf
Cost of aluminum: Costa = Ma x 200 (Market price of aluminum in Rs. / kg)

The constant 7.5 is taken from Ref 6.

All calculations are performed at the defined range of no. of parting sheets for each type
of fin geometry included in plain, louvered, offset strip and wavy fins. The results are
tabulated at each NT and are shown in this section. The most appropriate design is
selected from each table and design results are once again tabulated. Out of the initial
heat exchanger designs, the most suitable design satisfying all the constraints is
selected.
67
CHAPTER #7
7. Quantitative Thermal Design
Having gone through a number of designs, we end up with the final design of both the
heat exchangers in all of the design constraints are successfully satisfied. All the designs
of both (Simple plate and plate-fin) heat exchanger are also tabulated and are shown in
this chapter.
7.1 Simple plate heat exchanger

Following calculations have been done in the order described in the qualitative
thermal design. These calculations are of the design that is selected among all the other
proposed design.
7.1.1 Range of no. of gaps between plates - selection

The defined range of assumed no. of gaps ranges from 500 to 600 i.e.
500 600
7.1.2 Dimensions of flow passage

Following are the internal dimensions of heat exchanger.
b = to be calculated later
tp = 0.08e-3 m
NT = N-1
= ( ) + ((N 1) )
= ( ) + ((N 1) 0.08e 3)
= + ((N 1) 0.08e 3)
=
( ((N 1) 0.08e 3))

N
Lf = = + ((N 1) 0.08e 3)
Wf = = + ((N 1) 0.08e 3)
68
7.1.3 Hydraulic diameter of flow passage

Hydraulic diameter of the flow passage:
= 2
= 2
( ((N 1) 0.08e 3))

N
7.1.4 Exterior dimensions of heat exchanger

Following are the exterior dimensions of heat exchanger.
tep = 1e-3 m
= + (2 )
= ( + ((N 1) 0.08e 3)) + (2 1e 3)
= ( + ((N 1) 0.08e 3)) + 2e 3
L = = + ((N 1) 0.08e 3)
W = = + ((N 1) 0.08e 3)
7.1.5 All geometrical quantities for hot and cold side fluid
Frontal area:
= , =
= 2
= , =
= 2
69
Heat transfer area:
= = (N 1)
= 2 (N 1)
= = (N 1)
= 2 (N 1)
Minimum free-flow area:
= =
2
=
2
= =
2
=
2
Mass velocity:
=
=
8.397
2
2
16.794
2
70
=
=
10.001
2
2
20.002
2
7.1.6 All dimensionless quantities for hot and cold side fluid
Reynolds number:
=
=
211.704 7
1586.554812e3 ( ((N 1) 0.08e 3))

N 2
=
=
( ((N 1) 0.08e 3)) 16.794
N
2
( ((N 1) 0.08e 3)) 20.002
N
2
184.600 7
2167.063922e3 ( ((N 1) 0.08e 3))

N 2
Nusselt number (using table A-3, Ref 1)
= 7.54
= 7.54
71
Value of h
( ((N 1) 0.08e 3))

N
7.54 =
30.608e 3
0.11539216
=
( ((N 1) 0.08e 3))
2
( ((N 1) 0.08e 3))

N
7.54 =
26.300e 3
0.099151
=
( ((N 1) 0.08e 3))
2
7.1.7 Overall heat transfer coefficient

Overall heat transfer coefficient:
= = =
1
1
+ +

=[
1
0.11539216
( ((N 1) 0.08e 3))
+
72
1
0.099151
( ((N 1) 0.08e 3))
0.08 3 1
]
180
=[
( ((N 1) 0.08e 3))

0.11539216
+
( ((N 1) 0.08e 3))
0.099151
0.08 3 1
+
]
180
7.1.8 Log mean temperature difference

Log mean temperature difference:
(, ) ( , )
(, )
( , )
(323 303) (393 361.935)

(323 303)
(
393 361.935)
= 25.128
7.1.9 Height of flow passage

The height of flow passage is calculated as follows:
2 =
( 1)
2 =
( ((N 1) 0.08e 3))

593.5213
[
( 1) 25.128
0.11539216
+
( ((N 1) 0.08e 3))

0.099151
0.08 3
]
180
Now a relationship has been developed between the height of flow passage and the
number of gaps. We will calculate the quantities at N = 550, because it is our selected
design of heat exchanger from all the values of N. After hit & trial the height of flow
passage is calculated to be:
= 1.432 m
73
7.1.10 Calculated values of all quantities

1. Plate spacing: b = 2.508e-3 m
2. Total number of metal plates: NT = 549
3. Hydraulic diameter: Dh = 5.015e-3 m
4. Height of heat exchanger: H = 1.4251 m
Length of heat exchanger: L = 1.432 m
Width of heat exchanger: W = 1.432 m
5. Frontal area of both side fluids: Afr = 2.051 m
6. Heat transfer area of both side fluids: AT = 1111.842 m
7. Minimum free flow area of both side fluids: Ac = 1.0126 m
8. Mass velocity of hot air: Gh = 8.292 kg/m2/s
Mass velocity of cold air: Gc = 9.876 kg/m2/s
9. Reynolds no. of hot air side: Reh = 1964
Reynolds no. of cold air side: Rec = 2683
10. Heat transfer coefficient of hot air side: hh = 46.017 W/m2/K
Heat transfer coefficient of cold air side: hc = 39.540 W/m2/K
11. Overall heat transfer coefficient of both side fluids: U = 21.266
7.1.11 Number of transfer units and overall effectiveness

Heat capacity rate:
= =
= 8.397 1.00983
= 8479 W/K
= =
= 10.001 1.0073
= 10,071 W/K
74
Thermal capacity ratio:
=
=
8479
10,071
= 841.925 3
Number of transfer units:
=
=
21.266 1111.842
8479
= 2.789
Effectiveness of heat exchanger:
1 ((1
))
1 ( ((1 )) )
1 (2.789(1841.9253))
1 (841.925 3 (2.789(1841.9253)) )
= 778.004 3
7.1.12 Overall pressure drop on both sides

Pressure drop through heat exchanger:
2
64
=
2
=
64
8.2922 1.432
1964 0.9751 2 0.0050152
= 325.950 Pa
75
2
64
=
2
64
9.8762 1.432
=
2683 1.1614 2 0.0050152

= 284.219 Pa
Percentage pressure drop:
% =
=
325.9497818
100
151987.5
= 0.214 %
% =
=
284.2191442
100
151987.5
= 0.187 %
7.1.13 Cost of heat exchanger

Volume of metal plates: Vp = Hf x Lf x tp x NT
= 1.432 x 1.432 x 0.08e-3 x 549
= 88.947e-3 m3

= (2 x 1.432 x 1.4251 x 1e-3) + (2 x 1.432 x 1.432 x 1e-3)
= 81.066e-3 m3
Total volume aluminum used: Va = Vp + Vpe

= 88.947e-3 + 81.066e-3
= 97.054e-3 m3
76

= 97.054e-3 x 2770
= 268.839 kg
Cost of aluminum: Costa = Ma x 200

= 268.839 x 200
= Rs. 53.768e3

= 7.5 x 53.768e3
= Rs. 403.259e3

The tabulated results are shown in table 9. All of the designed heat exchangers satisfied
the constraints that we had established. Since it is difficult to choose among them now,
we selected the design with number of gaps equal to 550. In this design, the cost is well
within the limits, the flow seems to be laminar and the use of equation for pressure drop
is justified because we have consider the formula of friction factor for laminar flow.
The design with number of gaps greater than 550 have lies roughly in the transition
zone.
77
Number of gaps N
Parameters
500
510
520
530
540
550
560
570
580
590
600
499
509
519
529
539
549
559
569
579
589
599
1.736
1.666
1.600
1.538
1.479
1.423
1.370
1.320
1.272
1.227
1.184
AT
Ac
Gh
Gc
Rh
Rc
hh
1.504e3
1.413e3
1.329e3
1.251e3
1.179e3
1.112e3
1.049e3
991.426
937.255
886.612
839.428
1.507
1.388
1.280
1.183
1.094
1.013
938.724e-3
871.200e-3
809.374e-3
752.642e-3
700.691e-3
5.570
6.047
6.557
7.099
7.677
8.292
8.945
9.638
10.374
11.156
11.983
6.635
7.203
7.810
8.456
9.144
9.876
10.654
11.479
12.356
13.288
14.273
1.785e3
1.821e3
1.857e3
1.893e3
1.928e3
1.964e3
2.000e3
2.036e3
2.072e3
2.107e3
2.143e3
2.439e3
2.487e3
2.536e3
2.585e3
2.634e3
2.683e3
2.732e3
2.781e3
2.830e3
2.879e3
2.927e3
34.011
36.200
38.494
40.890
43.396
46.017
48.752
51.608
54.591
57.707
60.953
hc
U
29.224
31.105
33.076
35.134
37.288
39.540
41.890
44.344
46.907
49.585
52.374
15.718
16.730
17.790
18.897
20.055
21.266
22.530
23.850
25.229
26.669
28.169
778.010e-3
778.017e-3
778.006e-3
778.014e-3
778.012e-3
778.004e-3
779.008e-3
778.012e-3
778.012e-3
778.003e-3
778.012e-3
%Ph
%Pc
Ma
Costa
0.961e-3
1.133e-3
1.334e-3
1.567e-3
1.835e-3
2.144e-3
2.500e-3
2.908e-3
3.376e-3
3.912e-3
4.523e-3
0.837e-3
0.988e-3
1.164e-3
1.366e-3
1.600e-3
1.870e-3
2.180e-3
2.536e-3
2.944e-3
3.411e-3
3.944e-3
366.787
344.004
322.930
303.519
285.526
268.839
253.385
239.020
225.645
213.165
201.558
73.357e3
68.801e3
64.586e3
60.704e3
57.105e3
53.768e3
50.677e3
47.804e3
45.129e3
42.633e3
30.311e3
550.181e3
516.006e3
484.395e3
455.278e3
428.290e3
403.259e3
380.078e3
358.530e3
338.468e3
319.748e3
302.336e3
NT
Hf
CostHX
Design parameters of simple plate heat exchangers for different values of N
78
7.2 Plate fin heat exchanger

Following calculations have been done in the order described in the qualitative
thermal design. These calculations are of the design that is selected among all the other
proposed design.
7.2.1 Range of no. of parting sheets - selection

The defined range of no. of parting sheet ranges from 70 to 130 i.e.
70 130
For NT < 100, the data is not available for plain and louvered type of fins and the
calculations have only been done for offset strip and wavy fins for N T < 100. The
calculations listed here are performed at NT = 110.
7.2.2 Geometrical parameters of the fin

Following are the geometrical parameters of the fin.
Type of fin: Offset strip fin

Surface designation: 1/4-15.4(D)
b = 5.2324e-3 m
= 1.524e-4 m
Dh = 1.605e-3 m
F = 606.300 fins per meter
= 2106.300
= 0.816
7.2.3 Dimensions of flow passage

Following are the internal dimensions of heat exchanger.
tp = 0.08e-3 m
N = NT + 1 = 110 + 1 =111
= ( ) + (N )
= (5.2324e 3 111) + (110 0.08e 3)
79
= 589.5964 3 m
Lf = = 589.5964 3 m
Wf = = 589.5964 3 m
7.2.4 Exterior dimensions of heat exchanger

Following are the exterior dimensions of heat exchanger.
tep = 1e-3 m
= + (2 )
= 589.5964 3 + (2 1e 3)
= 591.596 3 m
L = = 589.5964 3 m
W = = 589.5964 3 m
7.2.5 All geometrical quantities for hot and cold side fluid
Frontal area:
= , =
= 589.5964 3 589.5964 3
= 347.624 3 m
= , =
= 589.5964 3 589.5964 3
= 347.624 3 m
80
Total volume of heat exchanger core:
=
= 589.5964 3 589.5964 3 589.5964 3
= 204.958 3 m
Ratio of total heat transfer area on one side & total volume of heat exchanger core:
(2 ) + (2 )
=
=
5.2324e 3 2106.300
(2 5.2324e 3) + (2 0.08e 3)
m2
= 1037.291 3
m
Heat transfer area:
= =
= 1037.291 204.958 3
= 212.601 m2
= =
= 1037.291 204.958 3
= 212.601 m2
Ratio of minimum free flow area & frontal area:
=
=

4
1037.291 1.605e 3
4
= 416.213 3
81
Minimum free-flow area:
= =
= 416.213 3 347.624 3
= 144.686 3 m2
= =
= 416.213 3 347.624 3
= 144.686 3 m2
Mass velocity:
8.397
144.686 3
= 58.036 kg/m2 /s
=
=
10.001
144.686 3
= 69.122 kg/m2 /s
7.2.6 Dimensionless quantities for hot and cold side fluid

Reynolds number:
=
=
1.605e 3 58.036
211.704 7
= 4.4003
82
=
=
1.605e 3 69.122
184.600 7
= 6.0103
Stanton number (using table A-5, Ref 2)
2
= 5.578 3 3
2
= 5.578 3 0.69843
= 7.086 3
2
= 5.108 3 3
2
= 5.108 3 0.7073
= 6.437 3
Value of h
7.086 3 =
58.036 1.00983
= 415.273 W/m2 /K
6.437 3 =
69.122 1.0073
= 448.053 W/m2 /K
83
7.2.7 Fin effectiveness

Fin effectiveness parameter:
2 415.273
180 1.524e 4
= 174.002 1/m
2 448.053
180 1.524e 4
= 180.737 1/m
Fin length:
2
5.2324e 3
=
2
= 2.616 3
Fin effectiveness:
=
=
tanh( )

tanh(174.002 2.616 3)
174.002 2.616 3
= 936.215 3
84
=
=
tanh( )

tanh(180.737 2.616 3)
180.737 2.616 3
= 931.594 3
Total surface effectiveness:
= 1 ( (1 ))
= 1 (0.816 (1 936.215 3))
= 947.951 3
= 1 ( (1 ))
= 1 (0.816 (1 931.594 3))
= 944.181 3
7.2.8 Overall heat transfer coefficient

Overall heat transfer coefficient:
= = =
1
1
+ +

1
1
0.08e 3
1
+
+
947.951 3 415.273
180
944.181 3 448.053
= 203.893 /2 /
85
7.2.9 Number of transfer units and overall effectiveness

Heat capacity rate:
= =
= 8.397 1.00983
= 8479 W/K
= =
= 10.001 1.0073
= 10,071 W/K
Thermal capacity ratio:
=
=
8479
10,071
= 841.925 3
Number of transfer units:
=
=
203.893 212.601
8479
= 5.112
Effectiveness of heat exchanger:
1 ((1
))
1 ( ((1 )) )
86
1 (5.112(1841.9253))
1 (841.925 3 (5.112(1841.9253)) )
= 887.224 3
7.2.10 Effectiveness
of
heat
exchanger
longitudinal wall conduction

Longitudinal wall conduction area:
= = ,
= 347.624 3 144.686 3
= 202.938 3 m2
= = ,
= 347.624 3 144.686 3
= 202.938 3 m2
Wall conduction parameters are given by:
=
=
2

180 2 202.938 3
589.5964 3 8479
= 14.614 3
=
= 14.614 3 5.112 841.925 3
= 62.897 3
1
=
(1 + )(1 + )
=
1 841.925 3
(1 + 841.925 3)(1 + 62.897 3)
87
considering
= 80.742 3
=(
(1 + )
1
)2 (
)
1+
1 (1 + )
62.897 3 1
)2
1 + 62.897 3
(1 + 80.742 3) 62.897 3
(
)
1 80.742 3 (1 + 80.742 3) 62.897 3
= 80.742 3 (
= 1.342 3
1+
1
1 + 1.342 3
=
1 1.342 3
= 1.003
1 =
=
(1 )
1 + ( )
(1 841.925 3) 5.112
1 + (14.614 3 5.112 841.925 3)
= 760.261 3
Corrected heat exchanger effectiveness is calculated as:
= 1
=1
1
1
1 841.925 3
(1.003 760.2613 ) 841.925 3
= 878.714 3
88
7.2.11 Amount of heat transferred and the outlet temperatures

for hot and cold side fluids
Maximum possible heat transfer rate:
= ( )
= 8479 (393 303)
= 763.098 kW
Actual heat transfer rate:
=
= 878.714 3 763.0983
= 670.545 kW
Outlet temperature of hot air:
, =
= 393
670.545e3
8479
= 314.000 K
Outlet temperature of cold air:
, = +
= 303 +
670.5453
10071
= 369.582 K
89
7.2.12 Overall pressure drop on both sides

Pressure drop through the heat exchanger:
2 R 1
2
2
[
=
1) + (
2 ( + 1 ) + 2 (
1
2

2
) (1 2 ) ( )]
1
1
Entrance and exit loss coefficients (using Figure 18, Ref 2)

For hot air side:
, = 0.49
, = 0.30
For cold air side:
, = 0.47
, = 0.32
Friction factor (using table A-5, Ref 2)
= 0.0182
= 0.0167
Pressure drop for hot air side:
58.036 2 287.1 393

[(0.49 + 1 0.4162132 ) + 2
=
2 9.81 151987.52
314
212.601
353.5
1) + (0.0182
)
393
144.686 3
393
314
(1 0.4162132 0.30) (
)]
393
(
= 2.026 %
90
Pressure drop for cold air side:
69.122 2 287.1 303

[(0.47 + 1 0.4162132 ) + 2
=
2
2 9.81 151987.5
370
212.601
337
1) + (0.0167
)
303
144.686 3 303
370
(1 0.4162132 0.32) (
)]
303
(
= 2.566 %
7.2.13 Cost of heat exchanger

Total fin area on both sides: Af = 2 x x AT
= 2 x 0.816 x 212.601
=346.965 m2
Total volume of fins: Vf = Af x
= 346.965 x 1.524e-4
= 52.877e-3 m3
Volume of parting sheets: Vp = Hf x Lf x tp x NT

= 589.596e-3 x 589.596e-3 x 0.08e-3 x 110
= 3.060e-3 m3

= (2 x 589.596e-3 x 591.596e-3 x 1e-3) + (2 x 589.596e-3 x
589.596e-3 x 1e-3)
= 1.393e-3 m3
Total volume aluminum used: Va = Vp + Vpe + Vf

= 3.060e-3 + 1.393e-3 + 52.877e-3
=57.330e-3 m3
91

= 57.330e-3 x 2770
= 158.804 kg
Cost of aluminum: Costa = Ma x 200

= 158.804 x 200
= Rs. 31.761e3

= 7.5 x 31.761e3
= Rs. 238.208e3

The tabulated results are shown in Table 10, 11, 12 & 13. The calculations are
performed at the defined range of no. of parting sheets for each type of fin geometry.
However for plain and louvered fins, there was not enough data available in the book
to perform the calculations for NT ranging from 70 to 90. Therefore no calculations are
shown in that range for both fins.
Initially the pressure drops are not computed for each and every type of fin at each NT
because of tedious work involved. Therefore at first, the pressure drop constraint is not
imposed on selecting the design for each fin at each NT. A total of 20 designs of heat
exchangers are selected with each satisfying the constraints imposed. The 20 designs
are shown in Table 14. The pressure drops are then computed for the 20 designs and
the prime design is selected with features having lower cost, better heat transfer rates,
smaller size and lower pressure drop.
The best design is at NT =110 of offset strip fin having surface designation 1/4-15.4(D).
The design is well within the constraints and has better heat transfer rate than any other
at a lower cost. The pressure drops are somewhat higher than the others but is well
within the constraints.
92
Design parameters of plain plate fin at each NT

Total Number of Plates, NT = 100
Surface Designation
Parameters
Hf
Afr
Vtotal
AT
Ac
Gh
Gc
Reh
Rec
Sth
Stc
hh
hc
fh
fc
oh
oc
U
Qcalculated
Ma
Costa
CostHX
Data
Availability
5.3
6.2
9.03
11.11
11.11(a)
14.77
15.08
19.86
10.27T
11.94T
12.00T
16.96T
25.79T
30.33T
1.216
1.049
2.121
651.350e-3
1.241
856.582e-3
1.082
651.350e-3
1.406
648.785e-3
651.350e-3
666.742e-3
895.063e-3
1.478
1.100
4.500
424.000e-3
1.541
733.733e-3
1.171
424.257e-3
1.976
420.921e-3
424.000e-3
444.000e-3
801.000e-3
1.794
1.152
9.537
275.491e-3
1.910
627.035e-3
1.266
275.49e-3
2.773
272.245e-3
275.000e-3
295.000e-3
715.000e-3
306.346
332.063
398.736
594.544
508.475
682.463
674.055
908.826
472.820
636.632
636.170
984.920
1321
549.563
382.562
3803
163.792
971.171
427.928
853.060
250.373
1311.000
173.320
175.260
291.050
944.970
470.762e-3
459.675e-3
462.845e-3
457.950e-3
447.191e-3
441.590e-3
450.282e-3
425.903e-3
453.364e-3
456.810e-3
456.490e-3
424.040e-3
403.410e-3
695.795e-3
505.814e-3
2.083
194.288e-3
689.145e-3
324.015e-3
527.485e-3
180.692e-3
895.680e-3
192.283e-3
193.660e-3
188.500e-3
323.190e-3
12.068
14.373
16.600
19.772
4.031
4.802
43.210
51.470
12.180
14.510
25.910
30.860
15.910
18.950
46.460
55.340
9.374
11.165
43.660
52.010
43.350
51.630
44.540
53.050
25.980
30.940
3.504e3
4.786e3
4.342e3
5.931e3
884.165
1208
6290
8591
2025
2765
3168
4328
2009
2744
4115
5620
1698
2320
5920
8087
5878
8029
3623
4949
1499
2048
6.299e-3
5.723e-3
4.217e-3
4.099e-3
8.165e-3
6.261e-3
4.480e-3
4.125e-3
4.760e-3
4.660e-3
5.238e-3
4.811e-3
4.465e-3
3.977e-3
4.589e-3
4.299e-3
6.252e-3
5.313e-3
4.092e-3
3.886e-3
4.108e-3
3.805e-3
3.483e-3
3.541e-3
5.310e-3
4.448e-3
76.760
82.837
70.694
81.622
33.241
30.275
195.510
213.820
58.590
68.200
137.060
149.520
71.7690
75.9370
215.360
239.600
59.180
59.730
180.420
203.520
179.830
197.870
156.680
189.160
139.310
138.590
938.441e-3
933.953e-3
973.593e-3
969.659e-3
938.677e-3
943.779e-3
954.700e-3
950.710e-3
962.110e-3
956.230e-3
945.320e-3
940.710e-3
953.580e-3
951.040e-3
950.370e-3
945.160e-3
960.750e-3
960.390e-3
958.340e-3
953.300e-3
958.150e-3
954.180e-3
961.600e-3
954.080e-3
939.700e-3
939.990e-3
955.739e-3
952.512e-3
980.776e-3
977.912e-3
945.545e-3
950.076e-3
965.750e-3
962.730e-3
967.640e-3
962.620e-3
953.850e-3
949.960e-3
959.610e-3
957.400e-3
957.870e-3
953.440e-3
966.120e-3
965.820e-3
967.960e-3
964.090e-3
967.650e-3
964.580e-3
966.940e-3
960.460e-3
944.040e-3
944.310e-3
38.015
37.103
15.019
98.482
30.423
68.075
35.367
108.397
28.717
92.397
91.024
82.611
65.600
572.928e3
501.450e3
704.493e3
526.072e3
627.884e3
625.932e3
630.989e3
615.394e3
660.502e3
524.701e3
523.974e3
596.412e3
711.418e3
750.792e-3
657.124e-3
923.201e-3
689.39e-3
822.940e-3
820.25e-3
826.878e-3
806.441e-3
865.553e-3
687.593e-3
686.64e-3
781.56e-3
932.276e-2
382.606
428.362
3.951e3
118.576
984.744
329.230
665.424
193.500
1658
126.450
128.413
226.282
766.926
76.521e3
85.672e3
790.150e3
23.715e3
196.94e3
65.846e3
133.085e3
38.7e3
331.542e3
25.290e3
25.683e3
45.250e3
153.385e3
573.909e3
642.543e3
5.926e6
177.865e3
1.477e6
493.845e3
998.136e3
290.250e3
2.487e6
189.775e3
192.619e3
339.423e3
1.150e6
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
No
Yes
93

Parameters
Surface Designation
5.3
6.2
9.03
11.11
11.11(a)
14.77
15.08
19.86
10.27T
11.94T
12.00T
16.96T
25.79T
30.33T
Hf
1.336
1.153
2.331
715.650e-3
1.364
941.202e-3
1.189
715.650e-3
1.544
712.831e-3
715.650e-3
732.566e-3
980.674e-3
Afr
1.785
1.329
5.434
512.155e-3
1.861
885.861e-3
1.414
512.155e-3
2.386
508.127e-3
512.155e-3
536.653e-3
961.721e-3
Vtotal
AT
Ac
Gh
Gc
Reh
Rec
Sth
Stc
hh
hc
fh
fc
oh
oc
U
2.381
1.529
12.657
365.499e-3
2.535
832.86e-3
1.679
365.499e-3
3.680
361.192e-3
365.499e-3
392.061e-3
941.211e-3
306.346
332.063
398.736
594.544
508.475
682.463
674.055
908.826
472.820
636.632
636.178
984.929
1.321e3
729.291
507.653
5.047e3
217.305
1.289e3
567.811
1.132e3
332.175
1.740e3
229.947
232.523
386.152
1.243e3
470.762e-3
459.675e-3
462.84e-3
457.95e-3
447.19e-3
441.598e-3
450.282e-3
425.903e-3
453.364e-3
456.815e-3
456.490e-3
424.042e-3
403.403e-3
840.158e-3
610.733e-3
2.515
234.54e-3
832.13e-3
391.194e-3
636.904e-3
218.128e-3
1.082
232.120e-3
233.793e-3
227.563e-3
387.961e-3
9.994
11.903
13.748
16.375
3.338
3.976
35.8
42.64
10.09
12.018
21.464
25.565
13.183
15.702
38.494
45.848
7.763
9.247
36.173
43.085
35.915
42.776
36.898
43.947
21.643
25.778
2902
3964
3596
4912
732
1000
5210
7117
1677
2290
2624
3584
1664
2273
3408
4656
1406
1921
4904
6699
4869
6651
3001
4100
1249
1706
6.592e-3
6.028e-3
4.177e-3
4.161e-3
9.303e-3
7.25e-3
4.683e-3
4.324e-3
5.133e-3
4.711e-3
5.469e-3
5.05e-3
4.728e-3
4.229e-3
4.754e-3
4.450e-3
6.982e-3
5.762e-3
4.112e-3
4.013e-3
4.249e-3
3.975e-3
3.341e-3
3.541e-3
5.980e-3
4.945e-3
66.528
72.25
57.99
68.62
31.359
29.009
169.298
185.661
52.304
57.009
118.546
129.964
62.940
66.869
184.806
205.452
54.738
53.657
150.197
174.122
154.083
171.240
124.495
156.695
130.687
128.367
946.116e-3
941.804e-3
978.213e-3
974.34e-3
941.907e-3
945.978e-3
960.49e-3
956.87e-3
966.02e-3
963.1e-3
952.292e-3
947.984e-3
959.013e-3
956.587e-3
957.057e-3
952.532e-3
963.567e-3
964.256e-3
965.029e-3
959.727e-3
963.887e-3
960.058e-3
969.201e-3
961.601e-3
943.488e-3
944.425e-3
961.258e-3
958.157e-3
984.139e-3
981.32e-3
948.41e-3
952.03e-3
970.13e-3
967.4e-3
970.978e-3
968.483e-3
959.735e-3
956.098e-3
964.341e-3
962.231e-3
963.541e-3
959.700e-3
968.558e-3
969.153e-3
973.101e-3
969.030e-3
972.085e-3
969.125e-3
973.482e-3
966.938e-3
947.557e-3
948.426e-3
33.242
30.891
14.320
85.787
26.453
59.391
31.233
93.563
26.252
78.315
78.724
67.332
61.389
597.741e3
520.716e3
722.964e3
552.827e3
647.8e3
646.354e3
652.555e3
635.192e3
682.757e3
546.550e3
549.527e3
608.810e3
726.617e3
787.308e-3
682.371e-3
947.4e-3
724.450e-3
848.909e-3
847.012e-3
855.139e-3
832.386e-3
894.717e-3
716.224e-3
720.126e-3
797.813e-3
952.193e-3
55.833
567.016
5.238e3
156.777
1305
435.910
881.509
256.179
2.197e3
167.227
169.827
299.649
1.008e3
101.167e3
113.403e3
1.047e6
31.355e3
260.964e3
87.182e3
176.302e3.
51.236e-3
439.477e3
33.445e3
33.965e3
59.93e3
201.592e-3
CostHX
758.750e3
850.523e3
7.856e6
235.165e3
1.957e6
653.866e3
1.322e6
384.269e3
3.296e6
250.841e3
254.741e3
449.474e3
1.512e6
Data
Availability
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
No
Yes
Qcalculated
Ma
Costa
94

Surface Designation
Parameters
5.3
6.2
9.03
11.11
11.11(a)
14.77
15.08
19.86
10.27T
11.94T
12.00T
16.96T
25.79T
30.33T
Hf
1.456
1.256
2.541
779.950e-3
1.487
1.026
1.296
779.950e-3
1.683
776.877e-3
779.950e-3
798.390e-3
638.574e-3
1.072
Afr
2.120
1.578
6.457
608.322e-3
2.211
1.052
1.680
608.322e-3
2.834
603.537e-3
608.322e-3
637.427e-3
407.776e-3
1.149
Vtotal
AT
Ac
Gh
Gc
Reh
Rec
Sth
Stc
hh
hc
fh
fc
oh
oc
U
3.083
1.980
16.394
473.244e-3
3.282
1.077
2.175
473.244e-3
4.766
467.667e-3
473.244e-3
507.641e-3
259.580e-3
1.229
306.346
332.063
398.736
594.544
508.475
682.463
674.055
908.826
472.820
636.632
636.178
984.929
1382
1.321e3
944.468
657.411
6.537e3
281.364
1.699e3
735.271
1.466e3
430.096
2.253e3
297.732
301.067
499.990
358.792
1.624e3
470.762e-3
459.675e-3
462.845e-3
457.950e-3
447.191e-3
441.598e-3
450.282e-3
425.903e-3
453.364e-3
456.815e-3
456.490e-3
424.042e-3
397.598e-3
403.413e-3
998.120e-3
725.532e-3
2.988
278.581e-3
988.591e-3
464.698e-3
756.629e-3
259.086e-3
1.285
275.705e-3
277.693e-3
270.296e-3
162.131e-3
463.530e-3
8.412
10.02
11.573
13.784
2.810
3.346
30.140
35.899
8.493
10.116
18.069
21.521
11.097
13.218
32.408
38.6
6.534
7.783
30.455
36.274
30.237
36.014
31.064
36.999
51.789
61.684
18.114
21.575
2442
3336
3027
4135
616.22
841.71
4386
5992
1411
1928
2209
3017
1401
1913
2870
3920
1184
1617
4129
5640
4099
5599
2527
3452
2815
3845
1045
1428
6.826e-3
6.328e-3
4.228e-3
4.191e-3
10.157e-3
8.412e-3
4.866e-3
4.487e-3
6.401e-3
5.128e-3
5.681e-3
5.248e-3
4.928e-3
4.501e-3
4.896e-3
4.593e-3
7.781e-3
6.360e-3
4.181e-3
4.062e-3
4356e-3
4.113e-3
3.371e-3
3.416e-3
3.601e-3
3.118e-3
6.741e-3
5.457e-3
57.985
63.852
49.49
58.17
28.87
28.34
148.10
162.22
54.899
52.237
103.662
113.742
55.227
59.911
160.219
178.537
51.346
49.847
128.572
148.371
133.010
149.160
105.748
127.292
188.329
193.655
123.299
118.572
952.643e-3
948.150e-3
981.366e-3
978.148e-3
346.313e-3
947.132e-3
965.229e-3
962.066e-3
964.402e-3
966.059e-3
957.980e-3
954.119e-3
963.818e-3
960.893e-3
962.513e-3
958.441e-3
965.732e-3
966.693e-3
969.882e-3
965.436e-3
968.640e-3
964.992e-3
973.692e-3
968.535e-3
970.371e-3
969.563e-3
946.187e-3
948.121e-3
965.950e-3
962.720e-3
986.434e-3
984.092e-3
952.326e-3
953.053e-3
973.713e-3
971.322e-3
969.6e-3
971.014e-3
964.535e-3
961.277e-3
968.522e-3
965.977e-3
968.174e-3
964.716e-3
970.427e-3
971.256e-3
976.839e-3
973.421e-3
975.759e-3
972.939e-3
977.349e-3
972.908
973.808e-3
973.094e-3
950.061e-3
951.857e-3
29.307
26.325
13.614
75.295
25.973
52.225
27.797
81.613
24.555
67.175
68.511
56.336
92.939
57.480
618.367e3
539.244e3
735.762e3
545.327e3
677.055e3
662.919e3
670.001e3
651.622e3
701.668e3
565.340e3
570.720e3
620.977e3
644.852e3
738.255e3
810.337e-3
706.650e-3
964.177e-3
753.935e-3
887.244e-3
868.720e-3
878.001e-3
853.915e-3
919.498e-3
740.849e-3
747.898e-3
813.758e-3
845.044e-3
967.44e-3
653.024
732.759
6777
202.408
1.688e3
563.455
1.140e3
331.113
2843
215.943
219.305
387.373
283.067
1315
130.605e3
146.552e3
1.355e6
40.482e3
337.534e3
112.691e3
227.988e3
66.223e3
568.612e3
43.189e3
43.861e3
77.475e3
56.613e3
263.069e3
CostHX
979.536e3
1.099e6
10.166e6
303.612e3
2.531e6
845.812e3
1.710e6
496.669e3
4.265e6
323.915e3
328.958e3
581.060e3
424.600e3
1.973e6
Data
Availability
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Qcalculated
Ma
Costa
95

Surface Designation
Parameters
5.3
6.2
9.03
11.11
11.11(a)
14.77
15.08
19.86
10.27T
11.94T
12.00T
16.96T
25.79T
30.33T
Hf
1.576
1.360
844.250e-3
1.609
1.110
1.403
844.25oe-3
1.822
840.923e-3
844.250e-3
864.214e-3
691.190e-3
1.160
Afr
2.458
1.850
712.758e-3
2.591
1.233
1.969
712.250e-3
3.321
707.151e-3
712.758e-3
746.866e-3
477.743e-3
1.346
Vtotal
3.911
2.512
600.320e-3
4.165
1.367
2.759
600.320e-3
6.047
593.245e-3
600.320e-3
643.959e-3
329.255e-3
1.560
306.346
332.063
594.544
508.475
682.463
674.055
908.826
472.820
636.632
636.178
984.929
1382
1321
AT
1.198e3
834.057
356.917
2.118e3
932.790
1860
545.587
2.859e3
377.679
381.911
634.254
455.098
2060
470.762e-3
459.675e-3
457.950e-3
447.191e-3
441.598e-3
450.282e-3
425.903e-3
453.364e-3
456.815e-3
456.490e-3
424.042e-3
397.598e-3
403.413e-3
Ac
Gh
Gc
Reh
Rec
Sth
Stc
hh
hc
fh
fc
oh
oc
U
1.170
850.211e-3
326.408e-3
1.158
544.526e-3
886.659e-3
303.566e-3
1.506
323.037e-3
325.367e-3
316.702e-3
189.949e-3
543.164e-3
7.178
8.550
9.876
11.763
25.724
30.639
7.248
8.638
15.420
18.366
9.470
11.279
27.660
32.944
5.576
6.641
25.993
30.959
25.806
30.737
26.512
31.578
44.204
52.650
15.49
18.412
2084
2847
2583
3528
3744
5114
1204
1645
1855
2575
1195
1633
2449
3345
1010
1380
3524
4813
3499
4779
2157
2946
2402
3282
892.117
1219
6.629e-3
6.566e-3
3.801e-3
4.149e-3
5.026e-3
4.664e-3
6.401e-3
5.128e-3
5.907e-3
5.447e-3
5.085e-3
4.713e-3
5.035e-3
4.731e-3
7.615e-3
6.826e-3
4.114e-3
4.086e-3
4.408e-3
4.227e-3
3.395e-3
3.317e-3
3.785e-3
3.366e-3
7.597e-3
6.010e-3
48.053
56.536
37.902
49.150
130.557
143.913
46.847
44.575
91.976
100.744
48.629
53.529
140.627
156.994
42.887
45.650
107.971
127.397
114.877
130.822
90.882
105.488
1168.945
178.458
118.560
111.442
960.370e-3
953.762e-3
985.631e-3
981.461e-3
969.197e-3
966.174e-3
969.432e-3
970.863e-3
962.504e-3
959.105e-3
967.974e-3
964.883e-3
966.916e-3
963.246e-3
971.189e-3
969.394e-3
974.561e-3
970.148e-3
972.776e-3
969.137e-3
977.290e-3
973.755e-3
973.232e-3
971.871e-3
948.126e-3
951.058e-3
971.506e-3
966.755e-3
989.539e-3
986.504e-3
976.713e-3
974.427e-3
973.895e-3
975.117e-3
968.354e-3
965.485e-3
972.138e-3
969.448e-3
971.911e-3
968.796e-3
975.136e-3
973.587e-3
980.437e-3
877.043e-3
978.956e-3
976.143e-3
980.446e-3
977.403e-3
976.417e-3
975.134e-3
951.861e-3
954.582e-3
25.178
21.147
66.784
22.259
46.492
24.738
71.974
21.544
57.205
59.797
47.796
84.682
54.759
Qcalculated
630.989e3
542.744e3
595.005e3
686.071e3
677.098e3
683.528e3
665.622e3
710.902e3
578.675e3
587.980e3
631.673e3
663.358e3
746.684e3
826.878e-3
711.237e-3
779.723e-3
899.060e3
887.301e-3
895.728e-3
872.263e-3
931.6e-3
758.323e-3
770.516
827.773e-3
869.295e-3
978.489e-3
Ma
826.307
928.008
256.130
2139
713.725
1444
419.395
3604
273.304
277.565
490.736
358.627
1667
Costa
165.261e3
185.602e3
51.226e3
427.783e3
142.745e3
288.900e3
83.879e3
720.848e3
54.661e3
55.513e3
98.147e3
71.725e3
333.503e3
CostHX
Data
Availability
1.239e6
1.392e6
394.195e3
3.208e6
1.071e6
2.167e6
629.093e3
5.406e6
409.957e3
416.348e3
736.105e3
537.941e3
2.501e6
Yes
Yes
No
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
96
Design parameters of louvered plate fin at each NT

Surface Designation
Parameters
3/8-6.06
3/8(a)-6.06
1/2-6.06
1/2(a)-6.06
3/8-8.7
3/8(a)-8.7
3/16-11.1
1/4-11.1
1/4(b)-11.1
3/8-11.1
3/8(b)-11.1
1/2-11.1
3/4-11.1
3/4(b)-11.1
Hf
651.350e-3
651.350e-3
651.350e-3
651.350e-3
651.350e-3
651.350e-3
651.350e-3
651.350e-3
651.350e-3
651.350e-3
651.350e-3
651.350e-3
651.350e-3
Afr
424.257e-3
424.257e-3
424.257e-3
424.257e-3
424.257e-3
424.257e-3
424.257e-3
424.257e-3
424.257e-3
424.257e-3
424.257e-3
424.257e-3
424.257e-3
Vtotal
AT
Ac
Gh
Gc
Reh
Rec
Sth
Stc
hh
hc
fh
fc
oh
oc
U
275.491e-3
275.491e-3
275.491e-3
275.491e-3
275.491e-3
275.491e-3
275.491e-3
275.491e-3
275.491e-3
275.491e-3
275.491e-3
275.491e-3
275.491e-3
414.723
414.723
414.723
414.723
497.343
497.343
594.544
594.544
594.544
594.544
594.544
594.544
594.544
114.252
114.252
114.252
114.252
137.014
137.014
163.792
163.792
163.792
163.792
163.792
163.792
163.792
461.651e-3
461.651e-3
461.651e-3
461.651e-3
453.823e-3
453.823e-3
458.328e-3
458.328e-3
458.328e-3
458.328e-3
458.328e-3
458.328e-3
458.328e-3
195.858e-3
195.858e-3
195.858e-3
195.858e-3
195.538e-3
195.538e-3
194.449e-3
194.449e-3
194.449e-3
194.449e-3
194.449e-3
194.449e-3
194.449e-3
42.871
51.061
42.871
51.061
42.871
51.061
42.871
51.061
43.610
51.942
43.610
51.942
43.181
51.432
43.181
51.432
43.181
51.432
43.181
51.432
43.181
51.432
43.181
51.432
43.181
51.432
9017
12316
9017
12316
9017
12316
9017
12316
7519
10270
7519
10270
6290
8591
6290
8591
6290
8591
6290
8591
6290
8591
6290
8591
6290
8591
7.262e-3
6.943e-3
8.729e-3
8.039e-3
7.447e-3
7.157e-3
8.184e-3
7.535e-3
7.580e-3
6.829e-3
8.187e-3
7.686e-3
9.058e-3
8.392e-3
9.557e-3
8.833e-3
8.102e-3
7.260e-3
8.147e-3
73434e-3
7.586e-3
7.018e-3
6.369e-3
5.710e-3
6.403e-3
5.802e-3
314.377
356.994
377.901
413.362
322.375
368.009
354.281
387.446
333.822
357.220
360.520
402.037
394.965
434.631
416.730
457.472
353.268
376.015
355.242
385.034
330.805
363.498
277.707
295.716
279.217
300.477
929.492e-3
920.839e-3
916.666e-3
909.691e-3
927.853e-3
918.635e-3
921.385e-3
914.776e-3
925.520e-3
920.794e-3
920.132e-3
911.905e-3
913.293e-3
905.570e-3
909.036e-3
901.194e-3
921.588e-3
917.041e-3
921.191e-3
915.253e-3
926.133e-3
919.536e-3
937.096e-3
933.343e-3
936.780e-3
932.357e-3
954.875e-3
949.337e-3
946.666e-3
942.202e-3
953.826e-3
947.926e-3
949.686e-3
945.457e-3
952.332e-3
949.308e-3
948.885e-3
943.619e-3
934.450e-3
928.611e-3
931.231e-3
925.302e-3
940.721e-3
937.283e-3
940.421e-3
935.931e-3
944.157e-3
939.169e-3
952.445e-3
949.607e-3
952.206e-3
948.862e-3
159.177
186.452
163.420
175.361
164.072
179.869
192.767
202.442
171.029
173.348
163.095
136.198
137.569
Qcalculated
Ma
Costa
548.344e3
576.271e3
553.109e3
565.560e3
585.361e3
600.373e3
637.395e3
644.094e3
620.160e3
622.161e3
612.982e3
584.076e3
585.750e3
718.576e-3
755.172e-3
724.819e-3
741.254e-3
767.084e-3
786.757e-3
835.272e-3
844.051e-3
812.687e-3
815.309e-3
803.280e-3
765.401e-3
767.594e-3
75.766
75.766
75.766
75.766
88.065
88.065
118.576
118.576
118.576
118.576
118.576
118.576
118.576
15.153e-3
15.153e-3
15.153e-3
15.153e-3
17.613e3
17.613e3
23.715e3
23.715e3
23.715e3
23.715e3
23.715e3
23.715e3
23.715
CostHX
113.650e3
113.650e3
113.650e3
113.650e3
132.098e3
132.098e3
177.865e3
177.865e3
177.865e3
177.865e3
177.865e3
177.865e3
177.865e3
Data
Availability
Yes
Yes
Yes
Yes
Yes
Yes
No
Yes
Yes
Yes
Yes
Yes
Yes
Yes
97

Surface Designation
Parameters
3/8-6.06
3/8(a)-6.06
1/2-6.06
1/2(a)-6.06
3/8-8.7
3/8(a)-8.7
3/16-11.1
1/4-11.1
1/4(b)-11.1
3/8-11.1
3/8(b)-11.1
1/2-11.1
3/4-11.1
3/4(b)-11.1
Hf
715.650e-3
715.650e-3
715.650e-3
715.650e-3
715.650e-3
715.650e-3
715.650e-3
715.650e-3
715.650e-3
715.650e-3
715.650e-3
715.650e-3
715.650e-3
715.650e-3
Afr
712.758e-3
512.155e-3
512.155e-3
512.155e-3
512.155e-3
512.155e-3
512.155e-3
512.155e-3
512.155e-3
512.155e-3
512.155e-3
512.155e-3
512.155e-3
512.155e-3
Vtotal
AT
Ac
Gh
Gc
Reh
Rec
Sth
Stc
hh
hc
fh
fc
oh
oc
U
365.499e-3
365.499e-3
365.499e-3
365.499e-3
365.499e-3
365.499e-3
365.499e-3
365.499e-3
365.499e-3
365.499e-3
365.499e-3
365.499e-3
365.499e-3
365.499e-3
414.723
414.723
414.723
414.723
497.343
497.343
594.544
594.544
594.544
594.544
594.544
594.544
594.544
594.544
151.181
151.181
151.181
151.181
181.779
181.779
217.305
217.305
217.305
217.305
217.305
217.305
217.305
217.305
461.651e-3
461.651e-3
461.651e-3
461.651e-3
453.823e-3
453.823e-3
458.328
458.328
458.328
458.328
458.328
458.328
458.328
458.328
236.437e-3
236.437e-3
236.437e-3
236.437e-3
232.428e-3
232.428e-3
234.735e-3
234.735e-3
234.735e-3
234.735e-3
234.735e-3
234.735e-3
234.735e-3
234.735e-3
35.513
42.298
35.513
42.298
35.513
42.298
35.513
42.298
36.126
43.028
36.126
43.028
35.770
42.605
35.770
42.605
35.770
42.605
35.770
42.605
35.770
42.605
35.770
42.605
35.770
42.605
35.770
42.605
7469
10202
7469
10202
7469
10202
7469
10202
6228
8508
6228
8508
5210
7117
5210
7117
5210
7117
5210
7117
5210
7117
5210
7117
5210
7117
5210
7117
8.548e-3
7.716e-3
8.983e-3
8.039e-3
7.854e-3
7.157e-3
8.427e-3
7.535e-3
8.026e-3
7.215e-3
8.656e-3
7.215e-3
9.267e-3
8.694e-3
9.680e-3
8.737e-3
10.059e-3
9.167e-3
8.585e-3
7.726e-3
8.699e-3
7.768e-3
8.237e-3
7.280e-3
6.74e-3
7.51e-3
6.75e-3
6.13e-3
221.186
236.174
322.140
342.419
281.667
304.849
302.188
320.951
292.789
312.611
315.760
343.957
334.747
373.012
349.64
374.83
363.339
393.27
310.11
331.47
314.21/333
.27
297.53
312.33
243
322
243
263
949.119e-3
945.894e-3
927.901e-3
923.776e-3
936.268e-3
931.453e-3
932.003e-3
928.144e-3
933.951e-3
926.855e-3
929.092e-3
923.465e-3
925.332
917.638
922.317e-3
917.275e-3
919.568e-3
913.625e-3
930.369e-3
925.997e-3
929.525e-3
925.631e-3
932.966e-3
929.912e-3
944e-3
927e-3
944e-3
940e-3
967.436e-3
965.372e-3
927.901e-3
923.776e-3
959.212e-3
956.130e-3
956.482e-3
954.012e-3
953.435e-3
950.547e-3
950.092e-3
946.043e-3
943.551
937.734
941.272e-3
937.460e-3
939.193e-3
934.701e-3
947.359e-3
944.053e-3
946.721e-3
943.77e-3
949.323e-3
947.014e-3
957e-3
945e-3
957e-3
954e-3
110.378
158.102
140.203
148.674
143.927
156.081
165.964
169.931
176.952
151.518
152.873
144.473
132
121
Qcalculated
Ma
Costa
572.665e3
595.879e3
575.865e3
585,775e3
609.775e3
622.053e3
655.103e3
658.086e3
663.087e3
643.143e3
644.345e3
636.604e3
623.837e3
610.630e3
808.91e-3
780.867e-3
754.640e-3
767.627e-3
799.078e-3
815.167e-3
858.477e-3
862.38e-3
868.80e-3
842.805e-3
844.380e-3
834.23e-3
817e-3
800e-3
99.980
99.980
99.980
99.980
126.273
126.273
156.777
156.77
156.77
156.77
156.77
156.77
156.77
156.77
19.996e3
19.996e3
19.996e3
19.996e3
25.2255e3
25.2255e3
31.355e3
31.355e3
31.355e3
31.355e3
31.355e3
31.355e3
31.355e3
31.355e3
CostHX
149.970e3
149.970e3
149.970e3
149.970e3
189.410e3
189.410e3
235.165e3
235.165e3
235.165e3
235.165e3
235.165e3
235.165e3
235.165e3
235.165e3
Data
Availability
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
98

Surface Designation
Parameters
3/8-6.06
3/8(a)-6.06
1/2-6.06
1/2(a)-6.06
3/8-8.7
3/8(a)-8.7
3/16-11.1
1/4-11.1
1/4(b)-11.1
3/8-11.1
3/8(b)-11.1
1/2-11.1
3/4-11.1
3/4(b)-11.1
Hf
779.950e-3
779.950e-3
779.950e-3
779.950e-3
779.950e-3
779.950e-3
779.950e-3
779.950e-3
779.950e-3
779.950e-3
779.950e-3
779.950e-3
779.950e-3
779.950e-3
Afr
608.322e-3
608.322e-3
608.322e-3
608.322e-3
608.322e-3
608.322e-3
608.322e-3
608.322e-3
608.322e-3
608.322e-3
608.322e-3
608.322e-3
608.322e-3
608.322e-3
Vtotal
AT
Ac
Gh
Gc
Reh
Rec
Sth
Stc
hh
hc
fh
fc
oh
oc
U
473.244e-3
473.244e-3
473.244e-3
473.244e-3
473.244e-3
473.244e-3
473.244e-3
473.244e-3
473.244e-3
473.244e-3
473.244e-3
473.244e-3
473.244e-3
473.244e-3
414.723
414.723
414.723
414.723
497.343
497.343
594.544
594.544
594.544
594.544
594.544
594.544
594.544
594.544
196.265
196.265
196.265
196.265
235.365
235.365
281.364
281.364
281.364
281.364
281.364
281.364
281.364
281.364
461.651e-3
461.651e-3
461.651e-3
461.651e-3
453.823e-3
453.823e-3
458.328e-3
458.328e-3
458.328e-3
458.328e-3
458.328e-3
458.328e-3
458.328e-3
458.328e-3
280.832e-3
280.832e-3
280.832e-3
280.832e-3
276.071e-3
276.071e-3
278.811e-3
278.811e-3
278.811e-3
278.811e-3
278.811e-3
278.811e-3
278.811e-3
278.811e-3
29.899
35.611
29.899
35.611
29.899
35.611
29.899
35.611
30.415
36.226
30.415
36.226
30.116
35.869
30.116
35.869
30.116
35.869
30.116
35.869
30.116
35.869
30.116
35.869
30.116
35.869
30.116
35.869
6288
8590
6288
8590
6288
8590
6288
8590
5244
7163
5244
7163
4386
5992
4386
5992
4386
5992
4386
5992
4386
5992
4386
5992
4386
5992
4386
5992
8.164e-3
7.316e-3
10.057e-3
8.973e-3
8.229e-3
7.259e-3
8.944e-3
7.953e-3
8.495e-3
7.646e-3
9.150e-3
80255e-3
9.884e-3
8.699e-3
10.216e-3
9.177e-3
10.576e-3
9.593e-3
9.539e-3
8.131e-3
9.269e-3
8.195e-3
8.44e-3
7.61e-3
7.12e-3
6.40e-3
7.09e-3
6.42e-3
246.487
262.355
259.147
274.617
248.463
261.589
270.044
285.185
260.914
278.943
281.012
301.124
300.591
314.227
310.67
331.496
321.636
346.501
290.105
293.705
281.871
295.999
256
275
216
231
215
232
943.691e-3
940.325e-3
941.003e-3
937.744e-3
943.27e-3
940.487e-3
938.705e-3
935.533e-3
940.630e-3
936.838e-3
936.405e-3
932.223e-3
932.33e-3
929.52e-3
930.25e-3
925.992e-3
928.004e-3
922.952e-3
934.50e-3
933.76e-3
936.50e-3
933.28e-3
941e-3
937e-3
950e-3
946e-3
950e-3
946e-3
963.962e-3
961.808e-3
962.242e-3
960.156e-3
963.693e-3
961.912e-3
960.771e-3
958.741e-3
958.144e-3
955.471e-3
955.165e-3
952.217e-3
948.844e-3
946.71e-3
947.272e-3
944.05e-3
945.571e-3
941.751e-3
950.48e-3
949.92e-3
951.78e-3
949.563e-3
955e-3
952e-3
962e-3
959e-3
962e-3
959e-3
122.368
128.152
122.685
133.118
128.989
138.628
145.601
151.656
157.406
138.671
137.255
126.720
107.531
107.491
Qcalculated
Ma
Costa
596.224e3
618.869e3
596.643e3
609.559e3
631.881e3
641.911e3
670.622e3
675.286e3
679.418e3
664.852e3
663.610e3
653.640e3
631.392e3
631.339e3
781.320e-3
837.170e-3
781.869e-3
798.794e-3
828.047e-3
841.191e-3
878.81e-3
884.926e-3
890.342e-3
871.34e-3
869.62e-3
856e-3
827e-3
827e-3
128.868
128.868
128.868
128.868
162.912
162.912
202.408
202.408
202.408
202.408
202.408
202.408
202.408
202.408
25.774e-3
25.774e-3
25.774e3
25.774e3
32.582e3
32.582e3
40.482e3
40.482e3
40.482e3
40.482e3
40.482e3
40.482e3
40.482e3
40.482e3
CostHX
193.302e3
193.302e3
193.302e3
193.302e3
244.369e3
244.369e3
303.612e3
303.612e3
303.612e3
303.612e3
303.612e3
303.612e3
303.612e3
303.612e3
Data
Availability
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
99

Surface Designation
Parameters
3/8-6.06
3/8(a)-6.06
1/2-6.06
1/2(a)-6.06
3/8-8.7
3/8(a)-8.7
3/16-11.1
1/4-11.1
1/4(b)-11.1
3/8-11.1
3/8(b)-11.1
1/2-11.1
3/4-11.1
3/4(b)-11.1
Hf
844.250e-3
844.250e-3
844.250e-3
844.250e-3
844.250e-3
844.250e-3
844.250e-3
844.250e-3
844.250e-3
844.250e-3
844.250e-3
844.250e-3
844.250e-3
844.250e-3
Afr
712.758e-3
712.758e-3
712.758e-3
712.758e-3
712.758e-3
712.758e-3
712.758e-3
712.758e-3
712.758e-3
712.758e-3
712.758e-3
712.758e-3
712.758e-3
712.758e-3
Vtotal
AT
Ac
Gh
Gc
Reh
Rec
Sth
Stc
hh
hc
fh
fc
oh
oc
U
600.320e-3
600.320e-3
600.320e-3
600.320e-3
600.320e-3
600.320e-3
600.320e-3
600.320e-3
600.320e-3
600.320e-3
600.320e-3
600.320e-3
600.320e-3
600.320e-3
414.723
414.723
414.723
414.723
497.343
497.343
594.544
594.544
594.544
594.544
594.544
594.544
594.544
594.544
248.966
248.966
248.966
248.966
298.565
298.565
356.917
356.917
356.917
356.917
356.917
356.917
356.917
356.917
461.651e-3
461.651e-3
461.651e-3
461.651e-3
453e-3
453e-3
458e-3
458e-3
458e-3
458e-3
458e-3
458e-3
458e-3
458e-3
329.045e-3
329.045e-3
329.045e-3
329.045e-3
323e-3
323e-3
326e-3
326e-3
326e-3
326e-3
326e-3
326e-3
326e-3
326e-3
25.518
30.393
25.518
30.393
25.518
30.393
25.518
30.393
25.958
30.918
25.958
30.918
25.703
30.614
25.703
30.614
25.703
30.614
25.703
30.614
25.703
30.614
25.703
30.614
25.703
30.614
25.703
30.614
5367
7331
5367
7331
5367
7331
5367
7331
4475
6113
4475
6113
3744
5114
3744
5114
3744
5114
3744
5114
3744
5114
3744
5114
3744
5114
3744
5114
8.164e-3
42.042e-3
10e-3
8.97e-3
8.6e-3
7.83e-3
9.4e-3
8.4e-3
8.49e-3
7.64e-3
9.67e-3
8.65e-3
10.5e-3
9.25e-3
10.72e-3
9.65e-3
10.56e-3
10.024e-3
10.133e-3
8.56e-3
9.82e-3
8.68e-3
8.83e-3
8.01e-3
7.49e-3
6.72e-3
7.42e-3
6.72e-3
210.371
1287
259.147
274.617
221.667
239.770
243.2
/257.65
222.684
238.072
253.577
269.360
272.626
285.238
278.43
297.59
274.07
309.032
262.99
263.97
254.95
267.63
229.192
247.013
194.479
207.313
192.738
207.401
951.46e-3
771e-3
941e-3
937e-3
949.01e-3
945e-3
944.379e-3
941.321e-3
948.79e-3
945e-3
942e-3
938e-3
938e-3
935e-3
936e-3
932e-3
937.85e-3
930.59e-3
940e-3
939e-3
941e-3
939e-3
947e-3
943.57e-3
954e-3
952e-3
955.312e-3
952.10e-3
968e-3
853e-3
962e-3
960e-3
967.000e-3
964.88e-3
964.403e-3
962e-3
963e-3
961.56e-3
959e-3
956e-3
953e-3
951.3e-3
952e-3
949e-3
953.32e-3
947.52e-3
954.78e-3
954.62e-3
956.78e-3
954.04e-3
960.22e-3
957.346e-3
965.928e-3
963.808e-3
966.21e-3
963.79e-3
171.911
128.152
111.280
120.544
110.772
125.135
132.734
136.772
138.045
125.766
124.699
113.985
96.819
96.405
Qcalculated
Ma
Costa
675.527e3
638.843e3
618.505e3
630.235e3
643.745e3
659.544e3
686.597e3
689.664e3
690.597e3
680.882e3
679.957e3
669.813e3
649.581e3
649.018e3
885e-3
837.17e-3
810e-3
825e-3
843e-3
864e-3
899e-3
903e-3
904e-3
892e-3
891e-3
877e-3
851e-3
850e-3
162.843
162.843
162.843
162.843
206.029
206.029
256.130
256.130
256.130
256.130
256.130
256.130
256.130
256.130
32.569e3
32.56e3
32.56e3
32.56e3
41.206e-3
41.206e-3
51.226e-3
51.226e-3
51.226e-3
51.226e-3
51.226e-3
51.226e-3
51.226e-3
51.226e-3
CostHX
244.265e3
244.265e3
244.265e3
244.265e3
309.044e3
309.044e3
384.195e3
384.195e3
384.195e3
384.195e3
384.195e3
384.195e3
384.195e3
384.195e3
Data
Availability
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
100
Design parameters of offset strip plate fin at each NT

Surface Designation
Parameters
1/4(s)-11.1
3/32-12.2
1/8-15.2
1/8-13.95
1/2-11.94(D)
1/4-15.4(D)
1/6-12.18(D)
1/7-15.75(D)
1/8-20.06(D)
1/8-19.82(D)
1/8-16.12(D)
1/816.0(D)
1/8-16.12(D)
Hf
882.249e-3
754.208e-3
683.875e-3
644.200e-3
573.868e-3
Afr
778.363e-3
568.829e-3
467e-3
414e-3
329e-3
Vtotal
AT
Ac
Gh
Gc
Reh
Rec
Sth
Stc
hh
hc
fh
fc
oh
oc
U
685e-3
427e-3
318e-3
266e-3
188e-3
554.145
678.890
619.794
686.135
1056
379.674
290.482
197.654
182.861
198.817
472.58e-3
449.20e-3
415.21e-3
45.18e-3
41.36e-3
367.83e-3
255.51e-3
194.19e-3
18.75e-3
13.62e-3
22.822
27.188
32.861
39.139
43.239
51.50
447.815
433.374
616.434
734.208
3678
5024
4108
5611
5473
7476
5572
7610
4563
6233
11.909e-3
10.416e-3
12.096e-3
10.936e-3
14.503e-3
13.104e-3
7.747e-3
6.811e-3
8.491e-3
6.804e-3
274.513
285.165
401.395
431.018
633.232
679.607
3503
3658
5286
5031
738e-3
731e-3
796e-3
784e-3
832e-3
822e-3
357e-3
350e-3
398e-3
407e-3
774e-3
768e-3
821e-3
812e-3
859e-3
851e-3
455e-3
449e-3
469e-3
477e-3
107.955
169.841
280.363
810.023
1220
Qcalculated
Ma
Costa
670.682e3
690.729e3
701.801e3
755.047e3
761.773e3
878.893e-3
905.164e-3
919.673e-3
989.449e-3
998.264e-3
204.837
229.168
246.009
98.160
156.762
40.967e3
45.834e3
49.202e3
19.632e3
31.352e3
CostHX
307.256e3
343.753e3
369.014e3
147.240e3
235.143e3
Data
Availability
No
Yes
Yes
Yes
No
No
Yes
No
No
No
No
No
Yes
101

Surface Designation
Parameters
1/4(s)-11.1
3/32-12.2
1/8-15.2
1/8-13.95
1/2-11.94(D)
1/4-15.4(D)
1/6-12.18(D)
1/7-15.75(D)
1/8-20.06(D)
1/8-19.82(D)
1/8-16.12(D)
1/816.0(D)
1/8-16.12(D)
Hf
1.006
860.164e-3
779.925e-3
734.662e-3
633.850e-3
654.424e-3
Afr
1.012
739e-3
608e-3
539e-3
401e-3
428e-3
Vtotal
AT
Ac
Gh
Gc
Reh
Rec
Sth
Stc
hh
hc
fh
fc
oh
oc
U
1.017
634e-3
473e-3
395e-3
253e-3
279e-3
554.144
678.890
619.794
686.135
854.013
1056
563.459
431.054
293.286
271.324
216.796
294.972
472.57e-3
449.20e-3
415.21e-3
45.18e-3
44.19e-3
41.361e-3
478.49e-3
332.35e-3
252.56e-3
24.38e-3
17.75e-3
17.714e-3
17.54
20.90
25.264
30.091
33.245
39.596
344.322
410.108
472.862
563.206
474.015
564.579
2827
3862
3158
4314
4208
5748
4284
5852
4624
6316
3509
4793
13.138e-3
11.564e-3
13.049e-3
11.835e-3
15.668e-3
14.177e-3
7.591e-3
7.529e-3
8.550e-3
7.686e-3
9.380e-3
8.134e-3
232.813
243.394
332.906
358.604
525.992
565.290
2639
3109
4086
4359
4490
4624
767e-3
759e-3
823e-3
812e-3
856e-3
847e-3
408e-3
378e-3
383e-3
371e-3
429e-3
423e-3
799e-3
793e-3
845e-3
836e-3
879e-3
871e-3
499e-3
473e-3
470e-3
460e-3
496e-3
491e-3
94.757
146.264
238.514
694.978
980.461
1125
Qcalculated
Ma
Costa
698.381e3
712.237e3
720.664e3
759.420e3
760.768e3
762.850e3
915.191e-3
933.349e-3
944.392e-3
995.179e-3
996.946e-3
999.674e-3
302.459
338.952
364.119
144.833
116.336
231.934
60.492e3
67.790e3
72.824e-3
28.967e3
23.267e3
46.387e3
CostHX
453.688e3
508.428e3
546.178e3
217.249e3
174.504e3
347.900e3
Data
Availability
No
Yes
Yes
Yes
No
No
Yes
Yes
No
No
No
No
Yes
102

Surface Designation
Parameters
1/4(s)-11.1
3/32-12.2
1/8-15.2
1/8-13.95
1/2-11.94(D)
1/4-15.4(D)
1/6-12.18(D)
1/7-15.75(D)
1/8-20.06(D)
1/8-19.82(D)
1/8-16.12(D)
1/816.0(D)
1/8-16.12(D)
Hf
1.130
966.120e-3
875.975e-3
825.124e-3
711.866e-3
734.980e-3
Afr
1.277
933e-3
767e-3
680e-3
506e-3
540e-3
Vtotal
AT
Ac
Gh
Gc
Reh
Rec
Sth
Stc
hh
hc
fh
fc
oh
oc
U
1.441
899e-3
670e-3
560e-3
359e-3
395e-3
554.144
678.890
619.794
686.135
854.013
1056
798.643
610.931
415.652
384.515
307.211
418
472.57e-3
449.20e-3
415.21e-3
45.18e-3
44.19e-3
41.361e-3
603.67e-3
419.27e-3
318.60e-3
30.76e-3
22.39e-3
22.343e-3
13.909
16.566
20.026
23.852
26.354
31.389
272.962
325.113
374.896
446.523
375.802
447.602
2241
3061
2504
3420
3336
4556
3396
4639
3666
5007
2782
3800
14.444e-3
12.644e-3
14.101e-3
12.676e-3
16.892e-3
15.190e-3
9.481e-3
8.261e-3
9.482e-3
8.178e-3
10.080e-3
9.005e-3
202.869
210.937
285.160
304.466
449.530
480.141
2613
2704
3590
3667
3825
4081
789e-3
783e-3
844e-3
835e-3
873e-3
866e-3
410e-3
403e-3
406e-3
402e-3
460e-3
448e-3
818e-3
813e-3
863e-3
856e-3
893e-3
887e-3
500e-3
495e-3
490e-3
486e-3
524e-3
513e-3
84.408
126.67
206.851
661.556
887.159
1024
Qcalculated
Ma
Costa
717.957e3
727.524e3
733.860e3
762.039e3
762.345e3
763.057e3
940.844e-3
953.381e-3
961.684e-3
998.612e-3
999.013e-3
999.946e-3
427.008
479.158
515.023
204.354
164.185
327.956
85.402e3
95.832e3
103.005e3
40.871e3
32.837e3
65.591e-3
CostHX
640.512e3
718.737e3
772.535e3
306.531e3
246.278e3
491.934e3
Data
Availability
No
Yes
Yes
Yes
No
No
Yes
Yes
No
No
No
No
Yes
103

Surface Designation
Parameters
1/4(s)-11.1
3/32-12.2
1/8-15.2
1/8-13.95
1/2-11.94(D)
1/4-15.4(D)
1/6-12.18(D)
1/7-15.75(D)
1/8-20.06(D)
1/8-19.82(D)
1/8-16.12(D)
1/816.0(D)
1/8-16.12(D)
Hf
651.350e-3
1.254
1.072
972.025e-3
618.000e-3
538.472e-3
915.586e-3
789.882e-3
664.177e-3
815.536e-3
Afr
424e-3
1.573
1.149
944e-3
381e-3
289e-3
838e-3
623e-3
441e-3
665e-3
Vtotal
AT
Ac
Gh
Gc
Reh
Rec
Sth
Stc
hh
hc
fh
fc
oh
oc
U
275e-3
1.970
1.230
916e-3
235e-3
155e-3
765e-3
491e-3
292e-3
541e-3
594.544
554.144
678.890
619.794
746.315
1037
686.135
854.013
891.223
1056
163.792
1092
834.958
568.048
175.582
161.352
525.482
419.807
260.332
571.211
458.328e-3
472.577e-3
449.201e-3
415.216e-3
422.728e-3
416.285e-3
45.182e-3
44.197e-3
41.48e-3
41.361e-3
194.449e-3
743.394e-3
516.288e-3
392.309e-3
161.450e-3
120.703e-3
37.876e-3
27.575e-3
18.299e-3
27.509e-3
43.181
51.432
11.295
13.453
16.263
19.371
21.403
25.492
52.007
61.944
69.564
82.855
221.688
264.043
304.497
362.673
458.85
546.517
305.228
363.544
6290
8591
1820
2486
2033
2777
2709
3700
5566
7603
5275
7205
2758
3767
2977
4067
4035
5512
2259
3086
7.267e-3
6.615e-3
15.758e-3
13.647e-3
14.896e-3
13.498e-3
17.922e-3
16.204e-3
6.099e-3
5.695e-3
6.728e-3
6.426e-3
10.398e-3
13.256e-3
10.38e-3
8.93e-3
10.619e-3
9.803e-3
10.784e-3
9.666e-3
316.868
342.615
179.726
184.881
244.635
263.293
387.335
415.972
320.313
355.265
472.583
536.172
2328
3525
3192
3261
4920
5395
3324
3539
928e-3
923e-3
808e-3
804e-3
862e-3
854e-3
888e-3
881e-3
934e-3
928e-3
928.160e-3
919.42e-3
432e-3
356e-3
429e-3
425e-3
494e-3
475e-3
489e-3
476e-3
946e-3
942e-3
834e-3
831e-3
880e-3
872e-3
906e-3
900e-3
948e-3
943e-3
941e-3
934e-3
519e-3
454e-3
509e-3
506e-3
573e-3
556e-3
549e-3
538e-3
155.456
75.917
111.139
181.271
159.299
235.595
689.146
819.198
1454
932.619
605.543e3
731.731e3
737.962e3
742.917e3
619.931e3
661.683e3
762.957e3
762.900e3
762.994e3
763.093e3
793.532e-3
958.895e-3
967.06e-3
973.553e-3
812.386e-3
867.101e-3
999.815e-3
999.74e-3
999.863e-3
999.992e-3
118.576
581.765
653.509
702.740
130.628
120.741
278.285
223.628
200.319
447.380
23.715e3
116.353e3
130.702e3
140.548e3
26.126e3
24.148e3
55.657e3
44.726e3
40.064e3
89.476e-3
CostHX
177.865e3
872.648e3
980.263e3
1.054e6
195.942e3
181.112e3
417.427e3
335.442e3
300.478e3
671.071e3
Data
Availability
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
No
No
No
Yes
Yes
Qcalculated
Ma
Costa
104

Surface Designation
Parameters
1/4(s)-11.1
3/32-12.2
1/8-15.2
1/8-13.95
1/2-11.94(D)
1/4-15.4(D)
1/6-12.18(D)
1/7-15.75(D)
1/8-20.06(D)
1/8-19.82(D)
1/8-16.12(D)
1/816.0(D)
1/8-16.12(D)
Hf
715e-3
1.378
1.178
1.068
678e-3
591e-3
1.006
867e-3
577e-3
588e-3
591e-3
729e-3
Afr
512e-3
1.899
1.388
1.141
461e-3
349e-3
1.012
753e-3
333e-3
346e-3
349e-3
532e-3
Vtotal
AT
Ac
Gh
Gc
Reh
Rec
Sth
Stc
hh
hc
fh
fc
oh
oc
U
365e-3
2.614
1.632
1.216
312e-3
206e-3
1.016
652e-3
191e-3
203e-3
206e-3
387e-3
594.544
554.144
678.890
619.794
746.315
1037
686.135
854.013
1127
1099
1066
891.223e-3
217.305
1449
1108
753.770
232.941
214.045
697.271
557.016
216.374
223.469
220.047
345.391
458.328e-3
472.577e-3
449.201e-3
415e-3
422.728e-3
416.285e-3
45.182e-3
44.197e-3
42.021e-3
42.206e-3
41.374e-3
41.482e-3
234.735e-3
897.641e-3
623.383e-3
473e-3
194.894e-3
145.694e-3
45.73e-3
33.291e-3
14.041e-3
14.631e-3
14.480e-3
22.091e-3
35.770
42.605
9.354
11.141
13.469
16.043
17.72
21.113
43.03
51.31
57.623
68.642
183.613
218.693
252.214
300.402
599.142
713.613
573.891
683.538
579.866
690.654
380.097
452.717
5210
7117
1507
2059
1684
2300
2244
3065
4611
6298
4370
5969
2284
3120
2466
3369
4220
5764
4166
5690
4251
5806
3343
4566
7.77e-3
6.92e-3
16.871e3
14.831e-3
15.675e-3
14.324e-3
18.749e-3
17.164e-3
6.398e-3
5.863e-3
7.086e-3
6.437e-3
11.308e-3
9.717e-3
11.542e-3
9.779e-3
10.862e-3
10.773
11.179e-3
11.088e-3
12.539e-3
12.437e-3
11.32e-3
10.131e-3
280.646
296.941
159.359
166.392
213.2
231.409
335.607
364.935
278.366
302.986
412.380
444.930
2097
2140
2940
2958
6571
7742
6479
7632
7342
8650
4365
4619
936e-3
933e-3
825e-3
819e-3
877e-3
868e-3
902e-3
894e-3
942e-3
938e-3
936e-3
932e-3
453e-3
449e-3
445-e3
444e-3
450e-3
418e-3
445e-3
413e-3
500e-3
466e-3
519e-3
507e-3
951e-3
949e-3
849e-3
844e-3
893e-3
885e-3
917e-3
911e-3
954e-3
950e-3
948e-3
944e-3
536e-3
533e-3
523e-3
522e-3
536e-3
509e-3
533e-3
506e-3
588e-3
560e-3
594e-3
584e-3
137.165
68.952
98.707
159.902
138.217
202.544
566.667
771.096
1860
1823
2283
1322
629.252e3
741.541e3
745.464e3
749.102e3
640.092e3
677.064e3
763.022e3
763.058e3
763.032e3
763.038e3
763.088e3
763.74e3
824.601e-3
971.749e-3
976.891e-3
981.658e-3
838.806e-3
887.257e-3
999.900e-3
999.947e-3
999.913e-3
999.92e-3
999.986e-3
999.968e-3
156.777
770.009
865.724
931.287
172.816
159.804
368.187
295.921
114.424
118.004
165.239
265.207
31.255e3
154.002e3
173.145e3
186.257e3
34.563e3
31.961e3
73.637e3
59.184e3
22.885e3
23.601e3
33.048e3
53.041e3
CostHX
235.165e3
1.155e6
1.299e6
1.0397e6
259.224e3
239.706e3
552.281e3
443.881e3
171.636e3
177.006e3
247.859e3
397.810e3
Data
Availability
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
No
Yes
Qcalculated
Ma
Costa
105

Surface Designation
Parameters
1/4(s)-11.1
3/32-12.2
1/8-15.2
1/8-13.95
1/2-11.94(D)
1/4-15.4(D)
1/6-12.18(D)
1/7-15.75(D)
1/8-20.06(D)
1/8-19.82(D)
1/8-16.12(D)
1/816.0(D)
1/8-16.12(D)
Hf
779e-3
1.502
1.284
1.164
739e-3
644e-3
1.096
945e-3
629.000e-3
641e-3
644e-3
795e-3
Afr
608e-3
2.257
1.649
1.355
547e-3
415e-3
1.202
894e-3
396e-3
411e-3
415e-3
632e-3
Vtotal
AT
Ac
Gh
Gc
Reh
Rec
Sth
Stc
hh
hc
fh
fc
oh
oc
U
473e-3
3.385
2.113
1.575
404e-3
267e-3
1.316
844e-3
248e-3
263e-3
267e-3
501e-3
594.544
554.144
678.890
619.794
746.315
1037
686.135
854.013
1127
1099
1066
891.223
281.364
1876
1435
976.112
301.602
277.118
902.932
721.273
280.130
289.318
284.888
447.212
458e-3
472e-3
449e-3
415e-3
422e-3
416e-3
45e-3
44e-3
42e-3
42.e-3
41.e-3
41e-3
278e-3
1.006
740e-3
562e-3
231e-3
173e-3
54e-3
39e-3
16e-3
17e-3
17e-3
26e-3
30.116
35.869
7.874
9.378
11.338
13.504
14.922
17.773
36.273
43.202
48.525
57.796
154.566
184.097
212.326
252.893
504.480
600.864
483.213
575.535
488.243
581.525
320.006
381.145
4386
5992
1269
1733
1417
1936
1889
2580
3882
5302
3679
5026
1923
2627
2076
2836
3553
4853
3507
4791
3579
4889
2814
3844
8.258e-3
10.687e-3
18.168e-3
15.937e-3
16.306e-3
14.976e-3
20.057e-3
18.004e-3
8.503e-3
6.119e-3
7.433e-3
6.754e-3
12.111e-3
10.563e-3
12.450e-3
10.614e-3
11.179e-3
11.088e-3
12.539e-3
12.437e-3
12.129e-3
10.73e-3
251.148
386.029
144.447
150.499
186.696
203.655
32.231
322.218
311.471
266.234
364.213
393.102
1890
1958
2669
2703
5533
6519
5455
6426
6182
7283
3919
4118
942e-3
915e-3
838e-3
833e-3
890e-3
882e-3
910e-3
905e-3
936e-3
945e-3
943e-3
939e-3
474e-3
467e-3
464e-3
462e-3
484e-3
451e-3
479e-3
446e-3
536e-3
501e-3
542e-3
532e-3
956e-3
935e-3
861e-3
856e-3
904e-3
897e-3
925e-3
920e-3
949e-3
956e-3
953e-3
950e-3
554e-3
548e-3
540e-3
538e-3
565e-3
537e-3
562e-3
534e-3
618e-3
590e-3
613e-3
604e-3
10.86e-3
10.77e-3
144.285
63.291
87.780
143.917
136.820
180.017
530.486
723.934
1653
1620
2021
1222
669.564e3
748.576e3
750.565e3
753.733e3
671.464e3
691.835e3
763.083e3
763.091e3
763.077e3
763.79e3
763.096e3
763.094e3
877.428e-3
980.97e-3
983.575e-3
987.727e-3
879.917e-3
906.614e-3
999.979e-3
999.991e-3
999.972e-3
999.975e-3
999.997e-3
999.994e-3
202.408
995.019
1119
1205
223.229
206.495
475.622
382.321
147.761
152.381
213.532
342.781
40.482e3
199.004e3
223.905e3
240.936e3
44.646e3
41.299e3
95.124e3
76.464e3
29.552e3
30.476e3
42.706e3
68.556e3
CostHX
303.612e3
1.492e6
1.679e6
1.807e6
334.843e3
309.743e3
713.434e3
573.482e3
221.641e3
228.572e3
320.298e3
514.172e3
Data
Availability
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
No
Yes
Yes
Qcalculated
Ma
Costa
106

Surface Designation
Parameters
1/4(s)-11.1
3/32-12.2
1/8-15.2
1/8-13.95
1/2-11.94(D)
1/4-15.4(D)
1/6-12.18(D)
1/7-15.75(D)
1/8-20.06(D)
1/8-19.82(D)
1/8-16.12(D)
1/816.0(D)
1/8-16.12(D)
Hf
844e-3
1.626
1.390
1.260
800e-3
697e-3
1.187
1.024
681e-3
694e-3
697e-3
860e-3
Afr
712e-3
2.644
1.932
1.588
641e-3
487e-3
1.409
1.048
464e-3
482e-3
486e-3
741e-3
Vtotal
AT
Ac
Gh
Gc
Reh
Rec
Sth
Stc
hh
hc
fh
fc
oh
oc
U
600e-3
4.295
2.681
1.998
512e-3
339e-3
1.669
1.071
315e-3
334e-3
338e-3
636e-3
594.544
554.144
678.890
619.794
746.315
1037
686.135
854.013
1127
1099
1066
891.223
356.917
2380
1820
1238
382.582
351.503
1145
915.009
355.319
366.977
361.359
567.303
458e-3
472e-3
449e-3
415e-3
422e-3
416e-3
45e-3
44.e-3
42e-3
42e-3
41e-3
41e-3
326e-3
1.250
867e-3
659.000e-3
271e-3
202e-3
63e-3
46e-3
19e-3
20e-3
20e-3
30e-3
25.703
30.614
6.719
8.002
9.675
11.524
12.734
15.167
30.959
36.874
41.418
49.332
131.904
157.106
181.204
215.824
430.6
512.869
412.445
491.245
416.736
496.357
273.115
325.296
3744
5114
1083
1479
1210
1652
1612
2202
3313
4526
3141
4290
1641
2242
1772
2420
3033
4142
2994
4089
3055
4173
2402
3281
8.928e-3
7.742e-3
19.291e-3
16.873e-3
16.832e-3
15.620e-3
20.972e-3
18.971e-3
7.730e-3
6.379e-3
7.754e-3
7.062e-3
13.057e-3
11.296e-3
13.372e-3
11.552e-3
10.862e-3
10.773e-3
11.275e-3
11.088e-3
12.539e-3
12.437e-3
12.966e-3
11.347e-3
231.730
238.668
130.879
135.972
164.456
181.264
269.680
289.744
241.659
236.849
324.306
350.804
1739
1787
2447
2511
4723
5564
4696
5485
5276
6216
3576
3717
946e-3
945e-3
851e-3
846e-3
902e-3
893e-3
919e-3
914e-3
949e-3
950e-3
949e-3
945e-3
491e-3
485e-3
482e-3
477e-3
517e-3
483e-3
510e-3
478e-3
570e-3
535e-3
562e-3
553e-3
959e-3
958e-3
871e-3
867e-3
914e-3
907e-3
932e-3
927e-3
960e-3
961e-3
958e-3
955e-3
569e-3
564e-3
555e-3
551e-3
593e-3
564e-3
588e-3
561e-3
646e-3
617e-3
629e-3
622e-3
112.779
58.001
78.565
129.910
114.892
161.283
499.492
685.438
1481
1456
1804
1141
668.565e3
753.270e3
754.193e3
756.825e-3
678.590e3
703.839e3
763.096e3
763.097e3
763.092e3
763.093e3
763.098e-3
763.098e3
876.119e-3
987.120e-3
988.330e-3
991.779e-3
889.257e-3
922.344e-3
999.996e-3
999.999e-3
999.991e-3
999.992e-3
999.999e-3
999.999-3
256.130
1260
1419
1527
282.599
261.496
602.153
484.086
187.013
192.860
270.421
434.175
51.226e3
252.015e3
283.726e3
35.388e3
56.520e3
52.299e3
120.430e3
96.817e3
37.403e3
38.572e3
54.084e3
86.835e3
CostHX
384.195e3
1.890e6
2.182e6
2.290e6
423.899e3
392.244e3
903.229e3
726.130e3
280.520e3
289.290e3
405.632e3
651.262e3
Data
Availability
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
No
Yes
Yes
Qcalculated
Ma
Costa
107
Design parameters of wavy plate fin at each NT
Parameters

Surface Designation
11.48-3/8W
11.5-3/8W
17.8-3/8W
Hf
752.404e-3
683.875e-3
752.404e-3
Afr
566e-3
467e-3
Vtotal
AT
Ac
Gh
Gc
Reh
Rec
Sth
Stc
hh
hc
fh
fc
oh
oc
U
424e-3
Parameters

Surface Designation
11.48-3/8W
11.5-3/8W
17.8-3/8W
Hf
858.106e-3
779.925e-3
858.106e-3
566e-3
Afr
736e-3
608e-3
736e-3
318e-3
424e-3
630e-3
473e-3
630e-3
571.430
564.485
836.794
242.751
461.55e-3
180.016
426.55e-3
355.481
444.22e-3
571.430
360.224
461.55e-3
564.485
267.113
426.55e-3
836.794
527.507
444.221e-3
261.29e-3
199.49e-3
251.47e-3
339.86e-3
259.46e-3
327.10e-3
32.135
38.274
42.09
50.131
33.38
39.76
24.70
29.42
32.36
38.54
25.67
30.57
4904
6699
6009
8208
3349
4575
3770
5150
4620
6311
2575
3517
10.83e-3
9.64e-3
10.552e-3
9.321e-3
10.18e-3
8.85e-3
11.99e-3
10.56e-3
11.69e-3
10.30e-3
11.309e-3
9.902e-3
351.677
371.690
448.48
470.56
343.443
354.58
299.229
312.964
382.091
399.955
293.157
304.881
816.48e-3
808.42e-3
874.04e-3
868.81e-3
819.85e-3
815.30e-3
838.58e-3
832.65e-3
890.24e-3
885.81e-3
841.23e-3
836.13e-3
844.56e-3
837.73e-3
896.46e-3
892.16e-3
839.31e-3
835.25e-3
Vtotal
AT
Ac
Gh
Gc
Reh
Rec
Sth
Stc
hh
hc
fh
fc
oh
oc
U
863.28e-3
858.25e-3
909.78e-3
906.13e-3
858.38e-3
853.82e-3
131.673
686.720e3
177.417
686.631e3
127.945
718.046e3
899.91e-3
899.79e-3
940.96e-3
278.736
326.417
418.405
55.747e3
65.282e3
83.681e3
152.003
205.352
146.06
657.990e3
658.220e3
695.743e3
862.262e-3
862.563e-3
911.73e-3
188.586
220.601
282.708
37.717e3
44.120e3
56.542e3
Qcalculated
Ma
Costa
CostHX
282.879e3
330.901e3
424.062e3
CostHX
418.103e3
489.625e3
627.607e3
Data
Availability
Yes
Yes
Yes
Data
Availability
Yes
Yes
Yes
Qcalculated
Ma
Costa
108
Parameters

Surface Designation
11.48-3/8W
11.5-3/8W
17.8-3/8W
Hf
963.808e-3
875.975e-3
963.803e-3
Afr
928e-3
767e-3
928e-3
Vtotal
AT
Ac
Gh
Gc
Reh
Rec
Sth
Stc
hh
hc
fh
fc
oh
oc
U
893e-3
670e-3
893e-3
571.430
565.585
836.794
510.543
461.55e-3
378.560
426.55e-3
747.633
444.22e-3
428.75e-3
327.30e-3
412.64e-3
19.58
23.32
25.65
30.55
20.34
24.23
2989
4082
3663
5003
2041
2788
13.042e-3
11.516e-3
12.781e-3
11.214e-3
12.390e-3
10.869e-3
257.921
270.496
331.082
345.053
254.575
265.254
857.06e-3
851.33e-3
903.20e-3
899.60e-3
858.60e-3
853.71e-3
878.93e-3
874e-3
920.43e-3
917.47e-3
873.87e-3
869.50e-3
115.725
155.262
113.234
Qcalculated
Ma
Costa
707.427e3
706.983e3
732.978e3
927.04e-3
926.46e-3
960.52e-3
393.820
461.591
591.772
78.764e3
92.318e3
118.354e3
CostHX
590.730e3
692.387e3
887.658e3
Data
Availability
Yes
Yes
Yes
Parameters
11.48-3/8W
11.5-3/8W
17.8-3/8W
Hf
1.069
972.025e-3
1.069
Afr
1.144
944e-3
1.144
Vtotal
AT
Ac
Gh
Gc
Reh
Rec
Sth
Stc
hh
hc
fh
fc
oh
oc
U
1.221
916e-3
1.221
571.430
564.485
836.794
697.758
517.356
1022
461.55e-3
426.55e-3
444.22e-3
527.95e-3
403.02e-3
508.12e-3
15.904
18.943
20.83
24.81
16.52
19.68
2427
3315
2975
4063
1657
2264
14.141e-3
12.5e-3
13.731e-3
12.159e-3
13.503e-3
11.828e-3
227.104
238.417
288.886
303.832
225.326
234.429
871.52e-3
866.14e-3
914.27e-3
910.31e-3
872.37e-3
868.03e-3
891.17e-3
886.62e-3
929.53e-3
926.27e-3
886.15e-3
882.28e-3
103.390
137.406
101.591
722.838e3
721.809e3
743.271e3
947.240e-3
945.892e-3
974.018e-3
536.883
629.717
807.424
107.377e3
125.943e3
161.485e3
CostHX
805.324e3
944.576e3
1.211e6
Data
Availability
Yes
Yes
Yes
Qcalculated
Ma
Costa
109

Surface Designation
Parameters

Surface Designation
Parameters

Surface Designation
11.48-3/8W
11.5-3/8W
17.8-3/8W
11.48-3/8W
11.5-3/8W
17.8-3/8W
Hf
1.175
1.068
1.175
Hf
1.281
1.164
1.281
Afr
1.381
1.141
1.381
Afr
1.641
1.355
1.641
Vtotal
AT
Ac
Gh
Gc
Reh
Rec
Sth
Stc
hh
hc
fh
fc
oh
oc
U
1.620
1.216
1.620
2.098
1.575
2.098
571.430
564.485
836.794
571.430
564.485
836.794
925.917
686.504
1356
1199
889.005
1756
461.55e-3
426.53e-3
444.22e-3
461.555e-3
426.553e-3
444.221e-3
637.46e-3
486.60e-3
613.52e-3
757.292e-3
578.059e-3
728.851e-3
13.17
15.68
17.25
20.55
13.68
16.30
11.08
13.20
14.52
17.30
11.52
13.72
2010
2746
2464
3365
1373
1875
1692
2311
2074
2833
1155
1578
15.094e-3
14.787e-3
14.744e-3
13.079e-3
14.355e-3
12.745e-3
16.135e-3
14.289e3
15.809e-3
13.899e-3
14.517e-3
13.629e-3
200.771
233.603
256.910
270.676
198.383
209.212
180.649
190.024
231.888
242.145
168.881
188.311
888.43e-3
868.42e-3
922.88e-3
919.15e-3
885.54e-3
880.19e-3
894.48e-3
889.73e-3
929.26e-3
926.93e-3
900.543e-3
890.597e-3
902.05e-3
888.55e-3
936.61e-3
933.54e-3
897.90e-3
893.13e-3
Vtotal
AT
Ac
Gh
Gc
Reh
Rec
Sth
Stc
hh
hc
fh
fc
oh
oc
U
910.63e-3
906.60e-3
942.26e-3
939.93e-3
911.54e-3
902.41e-3
84.147
111.473
80.757
96.714
123.248
91.190
736.098e3
732.946e3
749.964e3
964.618e-3
960.486e-3
982.788e-3
710.969
834.390
1070
142.194e3
166.878e3
213.995e3
Qcalculated
Ma
Costa
CostHX
1.066e6
1.252e6
1.605e6
Data
Availability
Yes
Yes
Yes
Qcalculated
Ma
Costa
110
742.005e3
741.176e3
753.976e3
972.358e-3
971.272e-3
988.045e-3
919.122
1079
1384
183.824e3
215.840e3
276.807e3
CostHX
1.379e6
1.619e6
2.076e6
Data
Availability
Yes
Yes
Yes
Parameters

Surface Designation
11.48-3/8W
11.5-3/8W
17.8-3/8W
Hf
1.387
1.260
1.387
Afr
1.923
1.588
1.923
Vtotal
AT
Ac
Gh
Gc
Reh
Rec
Sth
Stc
hh
hc
fh
fc
oh
oc
U
2.662
1.998
2.662
571.430
1521
461.55e-3
564.485
1128
426.55e-3
836.794
2228
444.22e-3
887.43e-3
677.38e-3
854.10e-3
9.46
11.26
1444
1972
16.954e-3
15.086e-3
161.983
171.203
904.139e-3
899.340e-3
918.806e-3
914.741e-3
76.307
747.763e3
12.39
14.76
1770
2417
16.825e-3
14.717e-3
210.597
218.797
935.71e-3
933.41e-3
947.15e-3
945.26e-3
101.535
747.258e3
9.83
11.70
986.058
1347
16.503e-3
14.315e-3
163.828
168.795
903.17e-3
900.58e-3
913.63e-3
911.32e-3
75.860
757.739e3
979.903e-3
979.242e-3
992.977e-3
1164
1368
1754
232.877e3
273.550e3
350.845e3
CostHX
1.747e6
2.052e6
2.631e6
Data
Availability
Yes
Yes
Yes
Qcalculated
Ma
Costa
111
Final list of design parameters for each type of fin satisfying all the constraints at each NT
Serial No.
Type of Plate
fin
Surface
Designation
No. of parting
sheets (NT)
Hf
Qcalculated
CostHX
%Pressure drop
(Hot side)
%Pressure drop
(cold side)
1.
Plain
19.86
100
651.350e-3
615.394e3
290.250e3
676.521e-3
874.456e-3
2.
Plain
19.86
110
715.650e-3
635.192e3
384.269e3
529.602e-3
680.415e-3
3.
Plain
25.79T
120
638.574e-3
644.852e3
424.600e3
1.181
1.496
4.
Plain
25.79T
130
691.190e-3
663.358e3
537.941e3
991.048e-3
1.215
5.
Louvered
3/8-11.1
100
651.350e-3
620.160e3
177.865e3
968.849e-3
1.223
6.
Louvered
1/4(b)-11.1
110
715.650e-3
663.087e3
235.165e3
1.001
1.304
7.
Louvered
1/4(b)-11.1
120
779.950e-3
679.418e3
303.612e3
802.716e-3
1.032
8.
Louvered
1/4(b)-11.1
130
844.250e-3
690.597e3
384.195e3
643.298e-3
835.322e-3
9.
Offset-Strip
1/8-13.95
70
683.875e-3
701.801e3
369.014e3
2.808
3.718
10.
Offset-Strip
1/8-13.95
80
779.925e-3
720.664e3
546.178e3
1.950
2.587
11.
Offset-Strip
1/8-13.95
90
875.975e-3
733.860e3
772.535e3
1.418
1.881
12.
Offset-Strip
1/4-15.4(D)
100
538.472e-3
661.683e3
181.112e3
2.566
3.407
13.
Offset-Strip
1/4-15.4(D)
110
591.596e-3
677.064e3
239.706e3
2.026
2.566
14.
Offset-Strip
1/4-15.4(D)
120
644.720e-3
691.835e3
309.743e3
1.636
2.073
15.
Offset-Strip
1/4-15.4(D)
130
697.844e-3
703.839e3
392.244e3
1.343
1.704375
16.
Wavy
11.44-3/8W
70
752.404e-3
657.990e3
282.879e3
943.604e-3
1.146
17.
Wavy
11.44-3/8W
80
858.106e-3
686.720e3
418.103e3
701.478e-3
850.729e-3
18.
Wavy
11.44-3/8W
90
963.808e-3
707.427e3
590.730e3
536.005e-3
661.325e-3
19.
Wavy
11.44-3/8W
100
1.069
722.838e3
805.324e3
419.985e-3
522.806e-3
20.
Wavy
11.44-3/8W
110
1.175
736.098e3
1.066e6
344.740e-3
422.980e-3
112
CHAPTER #8
8. Advantages, Savings & Comparison
8.1 Advantages
Following are the advantages of the designed air pre-heater.
1. There is no mixing of both fluids because of parting sheets, thus resulting in the
prevention of leakage between supply and exhaust air.
2. Since the structure is simple, the design can be easily made according to
environment conditions for use and allowable pressure drop.
3. The air pre-heater is easy to install. Ductwork and support structures are less
complex than those needed for conventional tubular or regenerative air preheaters. Therefore it can be easily and economically incorporated to any existing
system.
4. The air pre-heater has lower pressure than regenerative or tubular air preheaters.
5. There are no moving parts, no electrical connections, no complex gear drives to
align lubricate, or maintain, and no spare parts to worry about.
6. Natural gas consumption of the hot air stenter machine is reduced significantly.
7. The air pollution caused by the stenter machine is decreased significantly.
8.2 Principle of waste heat recovery system

In this project, Waste heat recovery system is applied to the stenter machine in textile
plant by using a heat exchanger. A schematic diagram of the waste heat recovery system
is shown in Figure 19. In this diagram, all of the system components and
interconnections with each other are shown in detail. Table 15 indicates all parameters
and their corresponding explanations.
The exhaust waste air contains high amount of moisture and generally contaminated
with fibre fragments, dust and chemical materials. For this reason, the exhaust air
cannot be directly used as a supplementary source of the inlet fresh air but it could be
113
used to preheat the inlet fresh air. In order to cause less air pollution, the exhaust air is
cleaned thoroughly before being sent to preheating process. A pre-filter is installed just
before the heat exchanger to achieve above mentioned cleaning of exhaust air. Air is
easily flowed through the filter, but impurities are collected on the surface of the filter.
The pre-filter is equipped with a proper cleaning device with pressurized water which
is supplied from a pool with the help of a water pump having an electrical power of 2.3
kW.
Detailed schematic diagram of waste heat recovery system

114
Components of waste heat recovery system

Number
1
2
3
4
5
6
7
Description
Number
Fabric inlet
Fabric outlet
Stenter machine
Blower fan
Pre-filter
Drainage system
Pump
8
9
10
11
12
13
14
Description
Pool
Valve
Heat Exchanger
Blower fan
Blower fan
Exhaust duct
Duct
Components of waste heat recovery system

After pre-filtering, the cleaned air is sent to the air-to-air heat exchanger. Heat of the
cleaned exhaust air is transferred by the heat exchanger to the cold fresh air coming
from outside. Thus, the temperature of the fresh air is raised while that of the waste air
is decreased. The cooled waste air is exhausted to the atmosphere by using a blower fan
motor. The pre-heated fresh air is supplied to the burner of the stenter itself so as to
lessen the requirement of fuel in the burner located in each of the 8 chambers of the
stenter machine. Fresh air and waste exhaust air is processed with a blower fan motor
separately each having an electrical power of 11 kW.
8.3 Energy requirement and savings

8.3.1 Energy requirement without pre-heater
Without the use of the pre-heater, the combustion air entering the burner is at ambient
temperature i.e. at 303 K. The maximum temperature for the given moisture loading in
the stenter machine is 473 K. Thus, the energy requirement of the stenter machine
fulfilled by the burners is given as,
= (1 2 )
Where,
m = mass flow rate of the ambient air entering the burners = 10.00 kg/s
T1 = Maximum temperature in the stenter machine = 473 K
T2 = Temperature of the ambience = 303 K
115
Cp = Specific heat of the air at mean temperature, Tm
1 + 2
2
473 + 303
=
2
= 388 K
The specific heat at mean temperature is,
Cp = 1.013 kJ/kg/K
The energy requirement is therefore,
Q = 10 1.0133 (473 303)

= 1722.1 kW
The energy requirement of the stenter machine is also given as,
=
Where,
= Burner efficiency for natural gas = 85%
mfuel = mass flow rate of the natural gas (kg/s)
LHV = Lower heating value of natural gas = 47.141 MJ/kg
The mass flow rate of fuel is therefore calculated as,
1722.13 = 0.85 47.1416

= 0.0430 kg/s
The volume flow rate of natural gas is given as,
Where,
fuel = density of natural gas = 0.70 kg/m3
116
Therefore,
0.0430
0.70
= 0.0614 m3 /s
= 0.0614 3600 20 300
= 1326.243 m3 /year
The cost of natural gas for industrial consumers in Pakistan is Rs. 17.424 per m3.
Hence, the annual price of consumed natural gas is,
= 17.424
= 1326.243 17.424
= . 23.11 million per year
8.3.2 Energy requirement with pre-heater

Since two heat exchanger designs have been proposed, we conducted the calculations
for both the designs and have compared it at the end of this chapter.
8.3.2.1 Simple plate heat exchanger
With the use of the pre-heater, the combustion air entering the burner is at outlet
temperature of pre-heater i.e. at 362 K. The maximum temperature for the given
moisture loading in the stenter machine is 473 K. Thus, the energy requirement of the
stenter machine fulfilled by the burners is given as,
= (1 2 )
Where,
m = mass flow rate of the outlet air from the preheater = 10.00 kg/s
T2 = Outlet temperature of air from the pre-heater = 363 K
1 + 2
2
117
473 + 362
2
= 417.5 K
Cp = 1.016 kJ/kg/K
Q = 10 1.0163 (473 362)

= 1127.76 kW
=
Where,
= Burner efficiency for natural gas = 85%
1127.763 = 0.85 47.1416

= 0.0282 kg/s
Where,
Therefore,
0.0282
0.70
= 0.0402 m3 /s
118
= 0.0402 3600 20 300

= 868.4703 m3 /year
Hence, the annual cost of consumed natural gas is,
= 17.424
= 868.4703 17.424
= Rs. 15.132 million per year
The additional power requirement imposed the water pump and two blower fans per
year is given as,
= ((2 11) + 2.3) 20 300

= 145.8e3 kWh/year
The electricity tariff for industrial consumers in Pakistan is Rs. 14 per kWh.
Hence, the annual cost of additional consumed electricity is,
= 145.8e3 14
The total annual cost is therefore given by:
Total annual cost = 15.132 + 2.0412

Therefore the savings in energy is calculated is follows:

Total annual saving = 23.11 17.173
119
The payback period for the proposed heat exchanger is then given as,
Payback period =
Cost HX
Total annual saving
0.404
5.937
= 0.0680 years
= 0.0680 300
= 20.4 21 days
8.3.2.2 Plate fin heat exchanger
With the use of the pre-heater, the combustion air entering the burner is at outlet
temperature of pre-heater i.e. at 370 K. The maximum temperature for the given
moisture loading in the stenter machine is 473 K. Thus, the energy requirement of the
stenter machine fulfilled by the burners is given as,
= (1 2 )
Where,
m = mass flow rate of the outlet air from the preheater = 10.00 kg/s
T2 = Outlet temperature of air from the pre-heater = 370 K
1 + 2
2
473 + 370
=
2
= 421.5 K
Cp = 1.017 kJ/kg/K
Q = 10 1.0173 (473 370)

120
= 1047.51 kW
=
Where,
= Burner efficiency of natural gas = 85%
1047.513 = 0.85 47.1416

= 0.0261 kg/s
Where,
Therefore,
0.0261
0.70
= 0.0373 m3 /s
= 0.0373 3600 20 300
= 806.6713 m3 /year
Hence, the annual cost of consumed natural gas is,
= 17.424
= 806.6713 17.424
121
The additional power requirement imposed the water pump and two blower fans per
year is given as,
= ((2 11) + 2.3) 20 300

= 145.8e3 kWh/year
The electricity tariff for industrial consumers in Pakistan is Rs. 14 per kWh.
Hence, the annual cost of additional consumed electricity is,
= 145.8e3 14
The total annual cost is therefore given by:
Total annual cost = 14.055 + 2.0412

Therefore the savings in energy is calculated is follows:

Total annual saving = 23.11 16.097
The payback period for the proposed heat exchanger is then given as,
Payback period =
Cost HX
Total annual saving
0.238
7.013
= 0.0340 years
= 0.0340 300
= 10.181 11 days
122
8.4 Comparison of both heat exchanger designs

The following table lists the design parameters of heat exchangers.
Parameters
Simple plate
heat exchanger
-
Offset-strip plate
fin heat exchanger
1/4-15.4(D)
550
110
1.432
0.590
1111.842
212.601
Overall heat transfer coefficient (W/m2/K)
21.266
203.893
Heat transfer rate (kW)
593.521
670.545
Effectiveness of HX (%)
77.800
87.871
Pressure drop for both fluids (Hot/Cold) (%)
0.214 / 0.187
2.026 / 2.566
Cost of HX (Rs.)
0.404 million
0.238 million
Annual saving (Rs.)
5.937 million
7.013 million
21
11
Surface designation
Number of parting sheets
Length of flow passage (m)
Heat transfer area (m2)
Payback period (Days)
Comparison of heat exchanger designs

As we can see the offset-strip fin has higher heat transfer rates at a lower cost and
smaller size but at the expense of higher pressure drop within the heat exchanger core.
Although the simple plate heat exchanger has lower pressure drop, its heat transfer rate
is relatively less with greater size of the heat exchanger core. Moreover, the cost of
offset-strip fin HX is lower than that of simple plate HX. The offset-strip fin HX has
also greater annual saving with payback period of only 11 days compared to simple
plate HX which has less annual saving with payback period of 21 days.
Therefore, the offset-strip fin heat exchanger with a surface designation of 1/4-15.4(D)
offers the greatest potential for our goal as to recover the waste heat from exhaust air
of a stenter machine.
123
CHAPTER #9
9. Mechanical Dewatering
9.1 Introduction
Mechanical dewatering of fabrics before going for thermal drying is of considerable
interest (in an ecological and economic sense) due to a high efficiency and relative low
energy consumption.
Energy used in mechanical dewatering is only 1% of the energy used for evaporate the
same quantity of water. Wherever possible, mechanical dewatering techniques should
be employed.
The minimization of the moisture content in the textile goods allows shorter curing
times. Stentering is an energy intensive process, so it is important to remove as much
water as possible before the fabric enters the oven. Up to 15% energy savings in the
stenter (depending on the type of fabric) can be obtained if the moisture content of the
fabric is reduced from 70% to 60% before it enters the stenter machine. This can be
achieved using the following methods.
1. Squeezing mangle
2. Vacuum Slot Extraction device
3. Centrifugal extractors
124
9.2 Squeezing mangle

A mangle or wringer is a
mechanical
laundry
aid
consisting of two rollers in a

sturdy frame, connected by cogs.
Most often these mangles are
used to reduce the moisture
loading at the entry of the stenter
machine. The mangles are used in
2
or
bowl
combinations.
machine
Reduction
in
moisture loading is accomplished

by passing the fabric between a
pair of rollers and is by far the
least
expensive
method
Squeezing mangle
for
dewatering fabrics. The energy requirements of water removal are only approximately
58 kJ/kg. Little data is available for squeezing mangles therefore we cannot discuss this
in detail.
9.3 Vacuum slot extraction device

Vacuum slot extraction device remove excess liquid as it passes over a narrow slot in a
tube connected to a vacuum pump. The pressure differential across the fabric forces
mobile liquid from the interior spaces of fabric into the slot, and then the resulting
airflow penetrates into the yarns and removes much of the liquid adhering to the surface
of the fibers. Although mechanical removal of water from textiles is much cheaper than
thermal drying, the vacuum technique was not widely used in the past because of poor
reproducibility of the final water content.
9.3.1 Equipment used for vacuum slot extraction

A simple vacuum extractor can be made by cutting a narrow slot along the length of a
steel pipe connected to a vacuum pump. The orifice, however, is preferably formed
from two parallel plates, mounted on top of the slot in the vacuum tube. The use of a
material with low friction and the actual shape of the orifice formed between the two
125
plates are important factors for

minimizing accumulation of lint
(an accumulation of
fluffy
fibers that collect on fabric)

sucked from the cloth surface
and for ensuring good contact
and fit of the fabric with the slot.
The vacuum tube should have a
diameter large enough to avoid
any pressure drop in the air
flowing through it. The tube
may have a plastic lining to
avoid adhesion of lint.
Arrangement of a typical
vacuum slot extraction device
The exposure time to the pressure differential is a key factor determining the efficiency
of water removal. It is determined by the slot width, geometry and the fabric speed.
9.3.2 Mechanism of vacuum extraction

In discussing vacuum extraction, it is important to distinguish between bound and
unbound water. Bound water is that absorbed by the fiber and held between the polymer
chains in the amorphous zones by intermolecular forces such as hydrogen bonds. The
amount of bound water depends on the hydrophilic or hydrophobic nature of the
particular fiber. Many textile materials can be vacuum extracted down to moisture
levels close to the water retention values determined by centrifugation
Unbound water is held by surface tension in the interyarn and interfiber spaces. Such
water can migrate easily and the bulk of it can be removed by vacuum extraction. This
involves two steps: suction of water from the yarn interstices because of the pressure
differential between the two faces of the fabric, and subsequent elimination of most of
the interfacial water by the high velocity airflow through the yarns. The viscous drag
of the air creates shear forces sufficiently powerful to overcome the interfacial tension
holding water to the fiber surfaces. When the pressure drop decreases as the fabric
leaves the vacuum slot, relaxation of residual distorted water drops results in retention
126
of a small amount of unbound interfacial water, held predominantly at fiber

intersections.
Effective liquid removal depends on generating the maximum shear force by having
the highest possible air speed through the yarns and ensuring an adequate exposure to
the vacuum. There is little evaporative drying caused by the airflow at ambient
temperatures. Well extracted fabrics do not demonstrate any significant decrease in
moisture content on repeated extraction.
9.3.3 Importance of airflow in vacuum slot extraction device

Vacuum extraction can be considered in terms of airflow through a mesh screen or thin
porous sheet as a consequence of the pressure differential across the layer. Fluid flow
through such materials follows irregular patterns precluding exact solutions of the
equations of motion used in fluid dynamics. Correlations of experimental data based on
theoretical models for flow through screens or thin porous layers have been published.
These are generally based on equations including both laminar (viscous) and turbulent
(inertial) flow for idealized structures, and they could be useful for correlation of air
flow data in vacuum slot extraction.
These correlations are based on Eq. (9.1) relating the pressure drop, DP, and the fluid
approach velocity, v. The two constants, d and e, depend on the characteristics of the
layer material (thickness, porosity) and the moving fluid (viscosity, density). Equations
of this form can also be expressed in terms of the two dimensionless parameters, the
friction factor, f and the Reynolds number, Re (proportional to v) and two constants,
A and B Eq. (9.2), related to the viscous and inertial resistance to flow, respectively.
P
= + ( )
(9.1)
(9.2)
127
As the flow rate increases, the value of Re increases and the friction factor approaches
a constant value of B as the inertial resistance to flow becomes dominant. The actual
values of the constants A and B depend on the theoretical model used to represent the
structure of the fibrous web.
An empirical relationship describing the airflow through a textile web as a function of

the vacuum level, the orifice area and the permeability of the fabric has been published.
It has been called the Albany airflow equation. Its application is difficult because of
uncertainties in the mathematical signs and the units of some of the variables. As with
all the existing airflow correlations, it is not of general validity but limited to the
materials and conditions used in developing it.
The flow of air through a textile fabric is through a series of small orifices in parallel.
Consideration of a simple orifice meter allows development of some important basic
principles applicable to vacuum slot extraction. As the pressure differential is increased,
the airflow through the fabric increases, as does the velocity of the air in the channels.
Once the air reaches a velocity equal to that of sound in air, its flow rate and velocity
through the channels cannot be increased further. This is the critical flow condition.
Even if the pressure downstream can be decreased further, this will not be registered in
the actual channels because the pressure wave in a compressible fluid can only travel
at sonic velocity and the pressure drop cannot be transmitted upstream.
For passage of air from an open face through a narrow section of fabric over a vacuum
slot, the critical pressure ratio, rc (i.e., the ratio of the absolute pressure in the orifices
in the fabric and of the entering air) is given by Eq. (9.3), with a value of 0.528 for air,
which has a specific heat ratio, k. of 1.40 at 25 C.
= (
2
)1
(1 + )
(9.3)
128
9.3.4 Applications
The major applications of vacuum extraction during textile finishing are:
1. Dewatering of fabrics before drying.

2. Dewatering before wet-on-wet pad application of chemicals to eliminate
exchange of the water in the incoming fabric with the bath solution.
3. Removal of unwanted chemicals in washing during preparation and after
dyeing.
4. Low add-on finishing with good penetration.
5. Lint removal.
9.4 Centrifugal extractors

Hydro extraction may be carried
out in a common box form of a
centrifuge
which
consists
essentially of a perforated cage

of copper or galvanized iron
mounted on a central spindle
and contained in steel casing.
The steel casing has an outlet for
the water.
The wet fabric is placed in the
cage in which the fabric is in
completed and crushed state.
Centrifugal extractor
The cage is then rotated at high
speed, developing centrifugal pressure which forces the cloth to the inner wall of the
cage; the excess water passes through the perforations and the water is drained away.
Centrifuges of this type are available of various sizes from 36 to 72 inches in diameter
and developing speeds from 1000 to 600 rpm respectively; the drive may be belt,
friction or directly by electric motor. Depending on the size of the machine and the type
of fabric, the centrifugal action may require from 2 to 10 minutes to remove the excess
water.
129
With some goods particularly smooth fabrics there is a danger of the perforation of the
cage marking the outer layer of the fabrics where they are forced against the walls by
centrifugal force. This method of removing excess water from fabrics is not much
favored since it is very slow and it requires much labor. The machine extract water from
the cloth in a discontinuous manner, but continuous extractors may be used where the
fabric is treated at full width and the water is removed by a vacuum pump.
9.5 Comparison of dewatering machines

The following table lists the relative energy cost of the three machines we have studied
so far.
Dewatering machine
Energy cost
Squeezing mangle
1.5
Vacuum slot extraction device
4.5
Centrifugal extractors
2.5
Energy cost of dewatering machine

When the three mechanical methods of removing excess water are compared, it is found
that the mangle is the cheapest, and the suction extractor the most expensive. The
centrifuge is useful on account of its versatility, but the output is low.
Although vacuum slot extraction device is somewhat less efficient than squeezing
mangle, the technique is of considerable merit. Its use results in considerable savings
in drying and in recovered chemicals. It can play a key role in improving the efficiency
of drying operations. The success of the vacuum technique in dewatering and in
finishing has led to its almost universal use in American finishing mills.
130
CONCLUSION
In this project, we have established waste heat recovery system into a textile plant.
Waste heat recovery system reutilizes the hot exhaust air of stenter machine and uses it
to preheat the inlet fresh air of the machine. For this two configurations of plate heat
exchangers are considered, one with fins and the other one without fins. Design
calculations are performed using maple for different fin geometries and by varying the
number of parting sheets between the two fluid streams which results in two hundred
& two designs and out of these, the two designs best matched to our constraints have
been selected. Both designs are then compared and the one with greatest monetary gain
and lowest payback period is selected for goal.
In short, the following conclusions are drawn from the study of waste heat recovery
system.
1. A waste heat recovery system which utilizes an offset-strip fin heat exchanger
with a surface designation of 1/4-15.4(D) has been applied to textile plant.
2. Hot air produced by the system has been re-utilized in the same machine.
3. Natural gas consumption of the burners used in stenter machine is reduced
significantly.
4. Thermal and monetary gain has been obtained from the system.
5. The air pollution caused by the plant is decreased significantly.
Three mechanical dewatering techniques are also studied but due to the lack of data no
significant conclusions are drawn aside from that mechanical dewatering techniques
should be employed whenever possible as energy savings of up to 15% can be obtained
by the usage of proper mechanical dewatering techniques.
131
NOMENCLATURE
AT
= Total heat transfer area for one side
ATh
= Total heat transfer area for hot air side
ATc
= Total heat transfer area for cold air side
Av
= Cross-sectional area of flow passage
Ac
= Minimum free flow area for one side
Ach
= Minimum free flow area for hot air side
Acc
= Minimum free flow area for cold air side
Afr
= Frontal area for one side
Afr, h
= Frontal area for hot air side
Afr, c
= Frontal area for cold air side
Aw
= Longitudinal wall conduction area
Awh
= Longitudinal wall conduction area for hot air side
Awc
= Longitudinal wall conduction area for cold air side
Af
= Total fin area on both sides
Aref
= Reference heat transfer area
= Plate spacing
Cp
= Specific heat
Cph
= Specific heat of hot air
Cpc
= Specific heat of cold air
= Heat capacity rate
Ch
= Heat capacity rate of hot air
Cc
= Heat capacity rate of cold air
= Thermal capacity ratio
Costa
= Cost of aluminum used
CostHX
= Cost of heat exchanger
Dh
=Hydraulic diameter of flow passage
= Fin frequency
= friction coefficient
fh
= friction coefficient for hot air side
fc
= friction coefficient for cold air side
Gh
= Mass velocity of hot air
Gc
= Mass velocity of cold air
= Acceleration due to gravity
hh
= Heat transfer coefficient of hot air
hc
= Heat transfer coefficient of cold air
Hf
= Height of flow passage
= Height of heat exchanger
Kc
= Entrance loss coefficient
Kc,h
= Entrance loss coefficient for hot air side
Kc,c
= Entrance loss coefficient for cold air side
Ke
= Exit loss coefficient
Ke,h
= Exit loss coefficient for hot air side
Ke,c
= Exit loss coefficient for cold air side
kh
= Thermal conductivity of hot air
kc
= Thermal conductivity of cold air
kp
= Thermal conductivity of aluminum
= Specific heat ratio
Lf
=Length of flow passage
= Length of heat exchanger
= Fin length from root to center
LHV
= Lower heating value of natural gas
= Fin effectiveness parameter
Mh
= Fin effectiveness parameter for hot air side
Mc
= Fin effectiveness parameter for cold air side
Ma
= Mass of aluminum used
= Mass flow rate
mh
= Mass flow rate of hot air
mc
= Mass flow rate of cold air
mfuel
= mass flow rate of natural gas
= No. of gaps between metal plates or parting sheets
NT
=Total no. of metal plates or parting sheets
Nuh
= Nusselt no of hot air
Nuc
= Nusselt no of cold air
NTU
= No. of heat transfer units
Sth
= Stanton no. for hot air side
Stc
= Stanton no. for cold air side
Prh
= Prandtl no. of hot air
Prc
= Prandtl no. of cold air
= Wetted perimeter of flow passage
Pinlet
= Inlet pressure of heat exchanger
DP
= Pressure drop
DPh
= Pressure drop of hot air side
DPc
= Pressure drop of cold air side
fuel
= Volume Flow rate of natural gas
Qdesign
= Design heat transfer rate of heat exchanger
Qmax
= Maximum possible heat transfer
Qcalculated
= Actual heat transfer rate
= Universal gas constant
Reh
= Reynolds no. of hot air
Rec
= Reynolds no. of cold air
Rt
= Total thermal resistance
Thi
= Inlet temperature of hot air
Tho, design
= Design outlet temperature of hot air
Tho, calculated
= Calculated outlet temperature of hot air
Thm
= Mean temperature of hot air
Tci
= Inlet temperature of cold air
Tco, design
= Design outlet temperature of cold air
Tco, calculated
= Calculated outlet temperature of cold air
Tm
= Mean temperature of hot and cold air
DTm
= Log mean temperature difference
tp
= Thickness of metal plate or parting sheets
tep
= Thickness of end plate
= Overall heat transfer coefficient
Uh
= Overall heat transfer coefficient for hot air side
Uc
= Overall heat transfer coefficient for cold air side
Vtotal
= Total volume of heat exchanger core
Vf
= Total volume of fins
Vp
= Volume of metal plates or parting sheets
Vpe
= Volume of end plates
Va
= Total volume of aluminum used
= Fluid approach velocity
Wf
= Width of flow passage
= Width of heat exchanger
= Total heat transfer area on one side / total volume of exchanger core
= Total heat transfer area on one side / volume between the plates on
that side
= Fin thickness
= Density of hot air
= Density of cold air
= Density of aluminum
fuel
= Density of natural gas
= Fin area / total heat transfer area
= Absolute viscosity of hot air
= Absolute viscosity of cold air
= Dynamic viscosity of hot air
= Dynamic viscosity of cold air
= Minimum free flow area / frontal area
= Fin effectiveness
fh
= Fin effectiveness for hot air side
fc
= Fin effectiveness for cold air side
= Total surface effectiveness
oh
= Total surface effectiveness for hot air side
oc
= Total surface effectiveness for cold air side
= Burner efficiency for natural gas
= Heat exchanger effectiveness
= Corrected heat exchanger effectiveness
REFERENCES
[1]
Frank P. Incropera. Fundamentals of heat and Mass

transfer (Theodore L. Bergman, Adrienne S. Lavine &
David P. Dewitt).
[2]
W. M. Kays. Compact Heat Exchangers (A. L. London).
[3]
Kuppan
Thulukkanam.
Heat
Exchanger
Design
Handbook
[4]
Sidramappa Alur., (2012). Experimental Studies on Plate

Fin Heat Exchangers
[5]
Mustafa Sekkeli., (2012). Scada Based An Energy Saving

Approach To operation Of Stenter Machine In A Textile
plant Using Waste Heat Recovery System
[6]
R. K. Shah., (2005). Compact Heat Exchangers for Micro

turbines
[7]
Arthur D. Broadbent., (1990). Basic principles of vacuum

slot extraction, Textile Chemist and Colorist, Vol. 22, No.
8.
[8]
Bureau of Energy Efficiency. , (2004). Waste heat recovery
[9]
Mohit S. Ishar (2013, Jan 22). Stenter exhaust heat

recovery for combustion air preheating. Retrieved from
http://www.slideshare.net/mohitishar/stenter-exhaustheat-recovery-for-combustion-air-preheating
[10]
Abhinav Chittora (2009, May 28). Heat Exchanger.

Retrieved
from
http://www.slideshare.net/Abhinav2006/heat-exchanger
APPENDIX
Table A-1
From Ref. 1
Table A-2
From Ref. 1
Table A-3
From Ref. 1
Table A-4
Geometrical parameters of different fins
(a) Plain fins
(b) Louvered fins
Table A-4 (continued)

Geometrical parameters of different types of fins
(c) Strip fins
(d) Wavy fins
From Ref. 2
Table A-5
Heat transfer & friction factor data for plain fin surfaces

Heat transfer & friction factor data for plain plate-fin surfaces (continued)

Heat transfer & friction factor data for louvered plate-fin surfaces

Heat transfer & friction factor data for strip plate-fin surfaces

Heat transfer & friction factor data for strip plate-fin surfaces (continued)
Heat transfer & friction factor data for wavy plate-fin surfaces
From Ref. 2

Thermal Energy Conservation of a Stenter Machine

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Thermal Energy Conservation of a Stenter Machine

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THERMAL ENERGY CONSERVATION OF A

Final Year Project Report

Syed Mohammad Rizwan Azeem

DEPARTMENT OF MECHANICAL ENGINEERING

Mr. Syed Mohammad Rizwan Azeem

Dr. Muhammad Shakaib

Department of Mechanical Engineering

Department of Mechanical Engineering

NED University of Engg. & Tech.

NED University of Engg. & Tech.

DEPARTMENT OF MECHANICAL ENGINEERING

Ms. Asma Adeel

Mr. Umair Bin Asim

Mr. Muhammad Aqeel

Introduction to Stenter Machine .................................................................... 1

Sections of a stenter range .......................................................................... 2

Types of heat source used in stenter machine ............................................ 3

Steam and electrical heating ................................................................ 3

Thermic fluid or hot oil ....................................................................... 3

Direct heating by oil burning ............................................................... 4

Direct gas firing ................................................................................... 4

Hot air dryer stenter .................................................................................... 4

Components of hot air dryer stenter & their working ................................ 5

Entry mahlo unit .................................................................................. 5

Chain drive .......................................................................................... 6

Heating section .................................................................................... 6

Delivery roller ..................................................................................... 6

Exit mahlo unit .................................................................................... 6

Industrial visits ........................................................................................... 6

Energy conservation of a stenter machine .................................................. 7

Waste heat recovery system ................................................................ 8

Mechanical dewatering techniques...................................................... 8

Fundamentals of Waste Heat Recovery ......................................................... 9

Quality of waste heat .................................................................................. 9

Sources of waste heat ............................................................................... 10

High temperature heat recovery ........................................................ 10

Medium temperature heat recovery ................................................... 11

Low temperature heat recovery ......................................................... 11

Benefits of waste heat recovery................................................................ 12

Direct benefits ................................................................................... 12

Indirect benefits ................................................................................. 12

2.4.2.1 Reduction in pollution................................................................ 12

Applications of waste heat recovery ........................................................ 13

Energy savings in stenters ........................................................................ 14

Device for waste heat recovery ................................................................ 15

Classification of heat exchangers ............................................................. 15

Direct contact heat exchanger ........................................................... 15

Indirect contact heat exchanger ......................................................... 16

2.8.3.1 Radiation recuperators ............................................................... 17

2.8.4.1 Swing type regenerators ............................................................. 18

Heat Recovery Device-Selection ................................................................... 19

Air to air heat exchanger .......................................................................... 19

Plate-fin recuperator .......................................................................... 20

Heat pipe heat exchanger ................................................................... 21

Thermal wheel ................................................................................... 22

Run-around coil ................................................................................. 23

Selection criteria ....................................................................................... 24

Properties Evaluation and Design Constraints ........................................... 26

Properties evaluation ................................................................................ 26

Properties of hot air ........................................................................... 26

Properties of cold air ......................................................................... 28

Properties of aluminum ..................................................................... 29

Design constraints .................................................................................... 30