Shell and tube heat exchangers and their use in cooling processes are the major topic of this thesis. The theoretical part of the thesis starts with the mechanisms of heat transfer and then deals with shell and tube heat exchangers. Their position, design specifications and equations for calculations are given. In the experimental part, the heat transfer on semi-operating shell and tube heat exchangers with baffles and glass or silicon carbide heat exchange surface is examined by cooling the humid air by 50% propylene glycol in tubes. For four or five coolant flows and three airflows, input and output flow temperatures including relative air humidity were measured. Differences in exchanged heat between the exchangers were negligible due to the low local air heat transfer coefficient, although silicon carbide has two orders of magnitude better thermal conductivity than glass. Much higher efficiency was performed by the carbide heat exchanger because the difference between air outlet temperature and liquid inlet temperature was one and half times higher for the glass heat exchanger. That was reflected in a decrease in mean temperature difference, which resulted in a 16 % higher experimental heat transfer coefficient compared with the glass surface. The theoretical model using the j factor, the correction factors for the baffles, and the correction for air humidity condensation have proven to be appropriate. For the glass surface, for the highest air flow rates the model gives an appropriate heat-transfer coefficient; at lower flow rates it gives slightly higher values. For the silicon carbide surface, it gives a lower heat-transfer coefficient because the model failed to consider a lower mean temperature difference. The results also evaluate the heat loss through the shell and the heat exchanged in addition by air humidity condensation.

This diploma thesis deals with the design of a feedwater heater. The aim of the work is to perform thermal, hydraulic and stress analysis. A preliminary technical documentation is also part of this work. The first part contains a summary of basic types of heat exchangers and processes of heat transfer. The main part is focused on thermal analysis to determine the main parameters of the heat exchanger. Next part is followed up by hydraulic analysis to determine the pressure drop of the heating water. After that is created design of heat exchanger with stress analysis of the proposed wall thicknesses of the shell, water chambers and tubesheet. Achieved results are summarized and evaluated at the end of the diploma thesis.

Ce projet porte, dans un souci d’efficacité énergétique, sur la récupération d’énergie des rejets thermiques à basse température. Une analyse d’optimisation des technologies dans le but d’obtenir un système de revalorisation de chaleur rentable fait objet de cette recherche. Le but sera de soutirer la chaleur des rejets thermiques et de la réappliquer à un procédé industriel. Réduire la consommation énergétique d’une usine entre habituellement en conflit avec l’investissement requis pour les équipements de revalorisation de chaleur. Ce projet de maitrise porte sur l’application d’optimisations multiobjectives par algorithme génétique (GA) pour faciliter le design en retrofit des systèmes de revalorisation de chaleur industrielle. L’originalité de cette approche consiste à l’emploi du «fast non-dominant sorting genetic algorithm» ou NSGA-II dans le but de trouver les solutions optimales entre la valeur capitale et les pertes exergétiques des réseaux d’échangeurs de chaleur et de pompes à chaleur. Identifier les solutions optimales entre le coût et l’efficacité exergétique peut ensuite aider dans le processus de sélection d’un design approprié en considérant les coûts énergétiques. Afin de tester cette approche, une étude de cas est proposée pour la récupération de chaleur dans une usine de pâte et papier. Ceci inclut l’intégration d’échangeur de chaleur Shell&tube, d’échangeur à contact direct et de pompe à chaleur au réseau thermique existant. Pour l’étude de cas, le projet en collaboration avec Cascades est constitué de deux étapes, soit de ciblage et d’optimisation de solutions de retrofit du réseau d’échangeur de chaleur de l’usine de tissus Cascades à Kinsley Falls. L’étape de ciblage, basée sur la méthode d’analyse du pincement, permet d’identifier et de sélectionner les modifications de topologie du réseau d’échangeurs existant en y ajoutant de nouveaux équipements. Les scénarios résultants passent ensuite à l’étape d’optimisation où les modèles mathématiques pour chaque nouvel équipement sont optimisés afin de produire une courbe d’échange optimal entre le critère économique et exergétique. Pourquoi doubler l’analyse économique d’un critère d’exergie? D’abord, parce que les modèles économiques sont par définition de nature imprécise. Coupler les résultats des modèles économiques avec un critère exergétique permet d’identifier des solutions de retrofit plus efficaces sans trop s’éloigner d’un optimum économique. Ensuite, le rendement exergétique permet d’identifier les designs utilisant l’énergie de haute qualité, telle que l’électricité ou la vapeur, de façon plus efficace lorsque des sources d’énergie de basse qualité, telles que les effluents thermiques, sont disponibles. Ainsi en choisissant un design qui détruit moins d’exergie, il demandera un coût énergétique moindre. Les résultats de l’étude de cas publiés dans l’article montrent une possibilité de réduction des coûts en demande de vapeur de 89% tout en réduisant la destruction d’exergie de 82%. Dans certains cas de retrofit, la solution la plus justifiable économiquement est également très proche de la solution à destruction d’exergie minimale. L’analyse du réseau d’échangeurs et l’amélioration de son rendement exergétique permettront de justifier l’intégration de ces systèmes dans l’usine. Les diverses options pourront ensuite être considérées par Cascades pour leurs faisabilités technologiques et économiques sachant qu’elles ont été optimisées.

O presente trabalho descreve e introduz uma metodologia numérica de simulação térmica de trocadores de calor de fluxo cruzado e de casco e tubo. A metodologia computacional é utilizada para simular doze configurações de arranjos de escoamento de trocadores de calor de fluxo cruzado com número de passes e tubos por passe arbitrários, assim como diversas condições de mistura de ambos os fluidos. O procedimento computacional é desenvolvido, baseado em diversos trabalhos da literatura, para calcular a efetividade de temperatura e o fator de correção da diferença média logarítmica de temperatura para trocadores de calor de fluxo cruzado em escoamentos contracorrente e paralelo. Novos dados da efetividade de temperatura e do fator de correção para configurações complexas de trocadores de calor são apresentados em diversas tabelas e figuras. As condições de mistura do fluido interno depois de cada passe são analisadas e caracterizadas por três configurações: misturado, não misturado com uma ordem idêntica das fileiras e não misturado com uma ordem inversa das fileiras. A influência da mistura do fluido externo entre os tubos do trocador de calor também é analisada. A metodologia computacional também é utilizada para trocadores de calor de casco e tubo tipo TEMA E com um passe de ambos os fluidos (fluidos do casco e dos tubos) em escoamentos contracorrente e paralelo de acordo com as entradas do trocador de calor. O algoritmo é baseado em diversas hipóteses e considerações de modelagem adotadas em diversos trabalhos de trocadores de calor de fluxo cruzado e de casco e tubo. Cada seção entre as chicanas é idealizada como um trocador de calor não misturado - não misturado. Além disso, este estudo fornece um sumário de correlações matemáticas exatas e aproximadas para algumas configurações de trocadores de calor de fluxo cruzado e de casco e tubo, que são muito apropriadas para análises computacionais e que facilitam o cálculo de efetividade de temperatura e do fator de correção. Os resultados encontrados são comparados com o algoritmo HETE e com soluções e relações matemáticas disponíveis em outras literaturas e mostram a capacidade dos algoritmos desenvolvidos. / The present thesis describes and introduces the numerical simulation methodologies for thermal modeling of crossflow and shell-and-tube heat exchangers. The computational methodology is used for simulating twelve general flow arrangement configurations of crossflow heat exchangers with arbitrary number of passes and tubes per pass, as well as, several mixture conditions of both fluids. The computational procedures are developed, based on some works from literature, to calculate the temperature effectiveness and the mean logarithm temperature difference (MLTD) correction factor for crossflow and parallel and counter-crossflow heat exchangers. New temperature effectiveness and correction factor data for the treated complex flow arrangements configurations are provided and showed in various tables and plots. Tube fluid mixing conditions after each pass, characterized by three types of configuration: tube fluid mixed; tube fluid unmixed keeping identical order of the rows; and tube fluid unmixed with inverted order of the rows, are analyzed. The influence of external fluid mixing between tube rows along the heat exchanger configurations is also addressed. The computational methodology is also addressed to TEMA E shell-and-tube heat exchangers type with one-pass of both fluids (in-tube and shell side) flowing in counterflow and parallel regarding the heat exchangers inlets. The algorithm is based on various assumptions and modelling considerations adopted in several works of crossflow and shell-and-tube heat exchangers. Each section between two baffles is idealized as an unmixed-unmixed crossflow heat exchanger. In addition, this study provides a summary of exact and approximate correlations for some configurations of crossflow and shell-and-tube heat exchangers, that are very appropriate for computerized analysis and that facilitate the computation of both parameters, the temperature effectiveness and the mean logarithmic temperature difference correction factor. The results found are compared to algorithm HETE and with available relations and solutions of other works and show the capability of the developed algorithm.

O presente trabalho descreve e introduz uma metodologia numérica de simulação térmica de trocadores de calor de fluxo cruzado e de casco e tubo. A metodologia computacional é utilizada para simular doze configurações de arranjos de escoamento de trocadores de calor de fluxo cruzado com número de passes e tubos por passe arbitrários, assim como diversas condições de mistura de ambos os fluidos. O procedimento computacional é desenvolvido, baseado em diversos trabalhos da literatura, para calcular a efetividade de temperatura e o fator de correção da diferença média logarítmica de temperatura para trocadores de calor de fluxo cruzado em escoamentos contracorrente e paralelo. Novos dados da efetividade de temperatura e do fator de correção para configurações complexas de trocadores de calor são apresentados em diversas tabelas e figuras. As condições de mistura do fluido interno depois de cada passe são analisadas e caracterizadas por três configurações: misturado, não misturado com uma ordem idêntica das fileiras e não misturado com uma ordem inversa das fileiras. A influência da mistura do fluido externo entre os tubos do trocador de calor também é analisada. A metodologia computacional também é utilizada para trocadores de calor de casco e tubo tipo TEMA E com um passe de ambos os fluidos (fluidos do casco e dos tubos) em escoamentos contracorrente e paralelo de acordo com as entradas do trocador de calor. O algoritmo é baseado em diversas hipóteses e considerações de modelagem adotadas em diversos trabalhos de trocadores de calor de fluxo cruzado e de casco e tubo. Cada seção entre as chicanas é idealizada como um trocador de calor não misturado - não misturado. Além disso, este estudo fornece um sumário de correlações matemáticas exatas e aproximadas para algumas configurações de trocadores de calor de fluxo cruzado e de casco e tubo, que são muito apropriadas para análises computacionais e que facilitam o cálculo de efetividade de temperatura e do fator de correção. Os resultados encontrados são comparados com o algoritmo HETE e com soluções e relações matemáticas disponíveis em outras literaturas e mostram a capacidade dos algoritmos desenvolvidos. / The present thesis describes and introduces the numerical simulation methodologies for thermal modeling of crossflow and shell-and-tube heat exchangers. The computational methodology is used for simulating twelve general flow arrangement configurations of crossflow heat exchangers with arbitrary number of passes and tubes per pass, as well as, several mixture conditions of both fluids. The computational procedures are developed, based on some works from literature, to calculate the temperature effectiveness and the mean logarithm temperature difference (MLTD) correction factor for crossflow and parallel and counter-crossflow heat exchangers. New temperature effectiveness and correction factor data for the treated complex flow arrangements configurations are provided and showed in various tables and plots. Tube fluid mixing conditions after each pass, characterized by three types of configuration: tube fluid mixed; tube fluid unmixed keeping identical order of the rows; and tube fluid unmixed with inverted order of the rows, are analyzed. The influence of external fluid mixing between tube rows along the heat exchanger configurations is also addressed. The computational methodology is also addressed to TEMA E shell-and-tube heat exchangers type with one-pass of both fluids (in-tube and shell side) flowing in counterflow and parallel regarding the heat exchangers inlets. The algorithm is based on various assumptions and modelling considerations adopted in several works of crossflow and shell-and-tube heat exchangers. Each section between two baffles is idealized as an unmixed-unmixed crossflow heat exchanger. In addition, this study provides a summary of exact and approximate correlations for some configurations of crossflow and shell-and-tube heat exchangers, that are very appropriate for computerized analysis and that facilitate the computation of both parameters, the temperature effectiveness and the mean logarithmic temperature difference correction factor. The results found are compared to algorithm HETE and with available relations and solutions of other works and show the capability of the developed algorithm.

Subject of this work is a development of an integrated software environment for mechanical design and check of shell and tube heat exchangers. Processes of mechanical design and checks well as software which perform these processes are broken down to basic methods and parts. Mechanical design is usually performed according to some standards. In this work, ČSN EN 13445 is used. This standard describes mostly design check calculations which can be easily algorithmized. On the contrary, design calculations are described to some extent in few simple cases and mechanical design of shell and tube heat exchanger has not been fully algorithmized yet. Subject of this work is design of software, which will be capable of automatically performing mechanical design from datasheet as an input. Based on breakdown of design and check processes, requirements for key software features are derived. Important part of presented work is design and implementation of key modules – data model of shell and tube heat exchanger, module for mechanical design check according to ČSN EN 13445. These modules form basis of the software which will be developed further in future work.

The proposed master´s thesis looks into the aspects of tubular heat exchangers modeling using available software tools. In the first – theoretical part there is a description of distribution and types of heat exchangers, including a detailed description of the industrial heat exchanger solved in this thesis. Another chapter is devoted to the main computational relations and calculation methods used in the context of thermo-hydraulic calculation. The main part of thesis consists of chapters, which are devoted to selected available software and perform calculations using the software in the specific industrial case. Finally, there is summary of the various software and a recommendation for the specific program for the need.

Cette étude concerne la compréhension des mécanismes de transfert de chaleur et le développement d’un système de stockage pour la valorisation de la chaleur fatale industrielle. L’utilisation de Matériaux à Changement de Phase (MCP) permet d’atteindre une densité énergétique élevée et de restituer la chaleur à température constante. Cependant, leur faible conductivité thermique impose d’améliorer les transferts thermiques, notamment par l’utilisation d’échangeurs à surface augmentée. Le but est de comprendre le comportement de tels échangeurs en régime transitoire au contact de MCP. Une étude expérimentale à basse température, où quatre échangeurs de type tube-calandre ont été testés avec différentes orientations (horizontale/verticale) et injections (haut/bas), a mis en évidence des phénomènes de transfert thermique importants, comme la convection naturelle à la charge et la contraction volumique à la décharge. Ces observations ont été validées par un modèle CFD tridimensionnel. Une méthode de comparaison des performances basée sur un calcul d’énergie par le biais d’un maillage expérimental est proposée et permet de sélectionner un échangeur selon les critères de densités énergétiques, de temps caractéristique et de coût. Trois MCP, envisagés pour l’application, ont alors été testés à température réelle (100-200 °C) au contact d’un échangeur tube inox à ailettes transverses en aluminium pour évaluer leur cyclabilité et comparer leur comportement. Le mélange de sels, H105 (Tfusion = 122 °C), n’est pas retenu pour l’application à cause de sa faible densité énergétique (≈ 56 kWh/m3) et sa plage de fusion trop étalée. L’acide sébacique (Tfusion = 132 °C) a un comportement répétable au cours des cycles et une densité énergétique plus élevée (≈ 66 kWh/m3). L’alcool de sucre, l’érythritol (Tfusion = 118 °C), présente de bonnes thermo-physiques (128 kWh/m3) mais la maîtrise de sa cristallisation est un point clé pour l’utiliser en tant que MCP. / This PhD thesis deals with the understanding of the heat transfer mechanisms and with the development of thermal energy storage system for the industrial waste heat recovery application. The use of Phase Change Materials (PCM) is attractive for its high storage density and its possibility to deliver heat at constant temperature. However, the PCM low thermal conductivity leads to develop heat transfer improvement methods, such as heat exchangers with increased heat transfer surface. The goal is to characterize the behavior of such heat exchangers An experimental study, where four several heat exchangers have been tested with different orientations (horizontal/vertical) and injection types (upward/downward), highlighted the impact of natural convection during the melting process and the volume contraction one during the solidification. These results have been validated through a 3D numerical model. A performance comparison method based on an energy calculation through an experimental mesh is proposed and enables to select a heat exchanger on criteria such as the storage density, the characteristic time and the cost. Three PCM, adapted to our application, have been tested at the intended temperature (100-200 °C) by integrating them into a storage system made of a stainless steel tube with aluminum circular fins. Their ability to resist to repeated cycles has been assessed and their behavior has been compared. The salts mixture, H105 (Tmelting = 122 °C), is not selected for the application because of it low storage density (≈ 56 kWh/m3) and its large melting area. The sebacic acid (Tmelting = 132 °C) has a repeatable behavior with cycles and a higher storage density (≈ 66 kWh/m3) and is appropriate as storage material. The sugar alcohol, erythritol (Tmelting = 118 °C), has good thermo-physical properties (128 kWh/m3) but the crystallization control is a key point to use it as a PCM.

The aim of diploma thesis is creating calculation algorithms off single types unconventional heat transfer equipment and their aplication in thermal - hydraulic calculations in the industrial aplication . The main attention is paid to shell and tube heat exchangers with ROD and disc baffle system and radiation heat exchanger. All of these exchangers are used mainly in process of waste thermic destruction. The theoretical part of the work describes construction details of each heat exchanger and calculation algorithms of these equipments. The practical part of the work applies theoretic calculation alghortims in the industrial aplication which is design and rating. In the final part advantages and disadvantages of results have been assessed for construction and process aspects.

This thesis is devoted to thermal-hydraulic design and rating of heat exchangers with the specialized commercial software HTRI. These heat exchangers are solved for real high-temperature applications, where the hot fluid is a flue gas with high temperature (above 500 °C). In the thesis is made a brief analysis of the conventional design of heat exchangers usable for high-temperature aplications, description of the basic relations, description and brief user manual of software HTRI. Further, work includes a comparative study of methods for calculation of pressure drop of the fluid at 180° elbows, as support analysis for solution of required applications characterized by low pressure drop of process fluids.