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Efficient Heating System Design for NASA North Pole Project

Delivering a cost-effective heating system for a North Pole housing with specific constraints and calculations for optimal performance and comfort. The project involves heat loss calculations, insulation cost analysis, fresh air vs oxygen tank utilization, furnace and blower specifications, and material costs.

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Efficient Heating System Design for NASA North Pole Project

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  1. ME 414 : Project 1 May 5, 2006 Heating System for NASA North Pole Project Team Members Alan Benedict Jeffrey Jones Laura O’Hair Aaron Randall

  2. Problem Statement Your job as a Thermal Fluid Systems engineer is to deliver the housing heating system in the North Pole. 4 occupants Oxygen supply tank or circulating fresh air from outside The outside temperature in North Pole is -40C and the desired temperature inside the housing is 25C. You have a space of 12” in the outside walls and 8” in the interior walls.

  3. Deliverables • Lowest blower cost measured by the least system pressure drop • Least material cost measured by the number of sheets used • Least labor cost per the labor rates given • Least operating cost measured by the cost of maintenance items and monthly natural gas, oxygen, electricity, etc usage. • Most comfort to occupants measured by the least flow rate variation between registers

  4. Supply Air System

  5. Return Air System

  6. Heat Loss Calculation Assumptions • All heat loss occurs through exterior walls and roof. • The structure is perfectly sealed. No transfer of air. • There is no heat transfer between rooms. • There is not heat transfer to or from the basement.

  7. Interior Temperature 25˚C Exterior Temperature -40˚C Thermal Conductivity of Wall 0.8W/m˚C Convection Coefficients Interior surfaces Walls 4.2W/m2˚C Roof 5.17W/m2˚C Exterior All surfaces 34W/m2˚C Heat Loss Calculations

  8. Used Resistance Network Results Roof Walls Heat Loss Room 1 7791.5W Room 2 10118.9W Room 3 6269.2W Room 4 7380.7W Room 5 8457.8W Total 40018.1W Heat Loss Calculations

  9. Resistance Network Insulation Conductivity k=0.043W/m2˚C Results Roof Walls Heat Loss Room 1 489.9W Room 2 634.3W Room 3 394.4W Room 4 466.7W Room 5 534.8W Total 2520.1W = 8598.9Btu/h Heat Loss CalculationsWith Insulation Added

  10. Heat Loss Rates • Heat loss rate through walls and roof: • 2520W • Heat loss rate through heating of outside air: • 72W

  11. Insulation Cost Benefit Analysis • Cost to add insulation: • 12 inches in walls and roof • Total of 3501.1 ft3 insulation required • Cellulose insulation cost $0.387 per ft3 • Total cost to add insulation: $1354.07

  12. Insulation Cost Benefit Analysis • Heat loss rate without insulation: • 40,018.1W • Heat loss rate with insulation: • 2,520.1W • Heat loss rate reduction: • 37,498W or 93.7%

  13. Insulation Cost Benefit Analysis • 4 month cost to heat house without insulation • $20,903.11 • 4 month cost to heat house with insulation • $1,316.35 • 4 month savings: • $19,586.75 • Time to recover cost of insulating: • 8.4 days

  14. Fresh Air or Oxygen Tank? • 4 month analysis of using bottled O2 • 5.3592 x 10-4 m3/s O2 consumption rate • 3000L volume of O2 in tank at 1atm • $1,050 per bottle material • $75 per bottle labor • COST • $2,112,750

  15. Fresh Air or Oxygen Tank? • 1.6 ft3/min addition of outside air to interior • 5.3592 x 10-4 m3/s occupants • 7.7794 x 10-4 m3/s burning gas • -40°C air temperature • $0.045/ft3 cost for natural gas • COST • $32.28

  16. Furnace and Blower • Gibson KG6RA Series Specifications • 45000 Btu/h • 80% Efficiency • Cost of $543

  17. Furnace and Blower Blower Electrical Consumption and Cost for 4 months • Electricity Consumption • 1/5 hp = 149.14W • 149.14W*2880hrs = 429.5kWhrs • Operational Cost • 429.5kWhrs*$0.4/kWhr = $171.80

  18. Materials • Duct Diameter • 7.43 inches • 3 ducts per each 90” X 70” sheet

  19. Materials • Total sheets • 9 • 90 degree bends • 6 • Branches • 9 • Registers • 9

  20. CIRCULAR DUCTS Material: $2,250.00 Labor: $2,400.00 Total $4,650.00 SQUARE DUCTS Material: $3,250.00 Labor: $2,600.00 Total $5,850.00 Material and Labor Costs

  21. Problems not Overcome • Flowmaster • Flow rates in pump do not coincide with branch flow rate • Flow rates don’t produce results as expected

  22. Flow Output of Pump Lower than First Branch

  23. Register size vs. output discrepancy

  24. Conclusion • Least Pressure Drop not achievable through Flowmaster • Least material cost calculated at $4147 • Least labor cost calculated at $2400 • Least operating cost calculated at $1488 • Flow rate variation between registers not achievable through Flowmaster

  25. Questions?

  26. ME 414 : Project 2 May 5, 2006 Heat Exchanger Optimization Team Members Alan Benedict Jeffrey Jones Laura O’Hair Aaron Randall

  27. Problem Statement Design a heat exchanger to meet the customer requirements for heat transfer and maximum dimensions, while optimizing the weight and pressure losses in both the tube and shell sides.

  28. Project Definition • Chemical Specifications: • Temperature must be reduced from 35°C to 25°C • Mass flow rate is 80,000 kg/hr • Material properties closely approximate that of water • Cooling Water Specifications: • Treated city water at 20°C • Mass flow rate is not fixed • Exit temperature is function of design

  29. Customer Requirements • Must cool the chemical from 35 C to 25 C • Heat exchanger length can not exceed 7m • Heat exchanger shell diameter can not exceed 2m • Minimize heat exchanger shell and tube weight • Minimize heat exchanger pressure drop

  30. Initial Design Specifications

  31. Initial Results • Desired heat transfer rate of 928,502W • Calculated heat transfer rate of 924,068W • Difference of 4,434W • Desired-to-calculated ratio 0.995

  32. First DOE Results

  33. Initial Design Specifications

  34. Final DOE Pareto Charts

  35. Final DOE Optimization Without Baffles With Baffles

  36. Specifications for Optimized Heat Exchanger • Counter flow design • Stainless steel material for shell and tube • Single pass shell • Single pass tube • Tube OD of 2.22cm (standard size) • Tube length of 3.06m • Tube thickness of 2.40mm • Tube pitch of 3.18cm • Square tube configuration with 90° layout angle • Shell ID of 1.90m • No baffles

  37. Final Results

  38. Conclusion • Met requirement to cool the chemical from 35 C to 25 C • Tube length of 3.06m 3.06m<7m • Shell diameter of 1.9m 1.9m<2m • Minimized heat exchanger shell and tube weight 26,150 kg • Minimized pressure drop • Shell side 16.72 Pa • Tube side 22.36 Pa

  39. Questions?

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