Project Overview: In this advanced heat exchanger design project, you will engage in a
comprehensive exploration of heat and mass transfer principles, experimental techniques, computer
simulations, and industry-standard design practices. Each student will work independently to design,
simulate, and analyse a Plate Heat Exchanger using FreeCAD with the OpenFOAM add-in. The
project integrates theoretical understanding, hands-on simulation, and virtual experimentation to
achieve optimal heat exchanger performance according to design standards.
Project Objectives:
- Demonstrate the ability to identify and solve complex heat and mass transfer problems
individually.
- Independently design a practical plate heat exchanger using FreeCAD and OpenFOAM.
- Effectively communicate simulation outcomes through a comprehensive written report submitted
via the Jotform platform and articulate them verbally.
- Utilise advanced computer skills to simulate heat and mass transfer scenarios using simulation
and design software.
- Formulate hand calculations and simulation results to optimise the heat exchanger design.
- Engage in investigative work, simulation analysis, and data interpretation to make informed
engineering decisions.
Full Answer Section
Project Objectives:
This project will address the following objectives:
- Identify and solve complex heat and mass transfer problems: A thorough theoretical understanding of heat transfer principles, including conduction, convection, and radiation, will be applied to design and analyze the PHE.
- Design a practical plate heat exchanger: FreeCAD will be used to create a 3D model of the PHE, considering its geometry, material properties, and operating conditions.
- Simulate heat and mass transfer using OpenFOAM: OpenFOAM will be employed to simulate fluid flow and heat transfer within the PHE, generating visualizations and quantitative data for analysis.
- Optimize the heat exchanger design: Based on simulation results and hand calculations, the PHE design will be optimized to improve its efficiency and performance.
- Communicate findings effectively: A comprehensive report will be submitted through Jotform, clearly explaining the design process, simulation results, and optimization strategies. A concise verbal presentation will also be delivered to communicate the findings effectively.
Methodology:
The project will be conducted in the following stages:
1. Design and Geometry:
- Define the desired heat transfer duty and operating conditions (flow rates, temperatures, fluids).
- Select appropriate plate material and corrugation pattern based on thermal conductivity, pressure drop, and fouling resistance.
- Design the plate geometry using FreeCAD, including plate dimensions, corrugation specifications, and channel configurations.
2. Meshing and Pre-processing:
- Generate a high-quality computational mesh using OpenFOAM tools like snappyHexMesh or blockMesh.
- Define boundary conditions and initial values for temperature, pressure, and velocity.
- Set up solver parameters and control settings for accurate and efficient simulations.
3. Simulation and Analysis:
- Run OpenFOAM simulations to predict fluid flow, temperature distribution, and heat transfer rate within the PHE.
- Analyze the generated data (pressure drop, heat transfer coefficients, efficiency) to evaluate the PHE performance.
- Visualize the results using OpenFOAM post-processing tools like ParaView to gain insights into fluid behavior and heat transfer mechanisms.
4. Optimization and Design Improvement:
- Identify areas for improvement based on simulation results and hand calculations.
- Modify the design parameters (plate geometry, corrugation pattern, flow rates) to optimize the PHE performance.
- Conduct iterative simulations and analysis to refine the design and achieve the desired heat transfer goals.
5. Reporting and Presentation:
- Prepare a comprehensive report outlining the design process, simulation methodology, results, analysis, and optimization strategies.
- Deliver a clear and concise presentation summarizing the project findings and key takeaways.
Expected Deliverables:
- A 3D model of the PHE designed in FreeCAD.
- OpenFOAM scripts and settings used for simulation.
- Simulated data and visualizations of fluid flow and temperature distribution.
- Hand calculations and analysis of heat transfer performance.
- A comprehensive report documenting the entire project process and findings.
- A concise verbal presentation summarizing the project and key outcomes.
Project Tools and Resources:
- FreeCAD: Open-source 3D modeling software
- OpenFOAM: Open-source Computational Fluid Dynamics software
- ParaView: Open-source visualization software
- Reference materials on heat transfer and PHE design
- Online tutorials and documentation for FreeCAD and OpenFOAM
Project Timeline:
- Week 1-2: Literature review, design specifications, and selection of materials and corrugation patterns.
- Week 3-4: FreeCAD modeling of the PHE geometry.
- Week 5-6: OpenFOAM meshing, pre-processing, and solver setup.
- Week 7-8: Simulation and analysis of heat transfer performance.
- Week 9-10: Design optimization and iterative simulations.
- Week 11-12: Report writing and presentation preparation.
- Week 13: Project submission and presentation.
Sample Answer
Plate Heat Exchanger Design and Analysis using OpenFOAM
Introduction: Plate heat exchangers (PHEs) are widely used in various industrial and domestic applications due to their compact size, high efficiency, and ease of maintenance. They utilize corrugated plates to increase surface area and enhance heat transfer between two fluids flowing in alternate channels. This project aims to design and analyze a PHE using FreeCAD (Computer-Aided Design software) and OpenFOAM (Computational Fluid Dynamics software) to optimize its performance for specific operating conditions.