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Manufacturing cost model for heat exchangers optimization.

Author(s) : CAPUTO A. C., PELAGAGGE P. M., SALINI P.

Type of article: Article

Summary

In the field of shell and tube heat exchangers traditional costing methods rely on simple parametric functions. Such correlations are usually based on the sole overall heat transfer surface, and are applicable to traditional equipment configurations only, and in limited size ranges, to estimate the equipment purchase price. This makes them unsuitable for utilization as an economical design tool, particularly when the equipment configuration is not standard, or when the manufacturer uses proprietary manufacturing processes, and in case computerized design optimization procedures are adopted. In order to provide a more precise costing approach, to be used during the design phase, in this paper an analytical-generative cost estimation procedure for shell and tube heat exchangers is developed, based on detailed geometrical features and manufacturing processes of the equipment. It can also be used for precise cost estimation during competitive bidding in make-to-order manufacturing context. In the paper existing cost estimation methods are reviewed and criticized at first. The new mathematical model for heat exchanger manufacturing cost estimation is developed and a parametric analysis is carried out showing that an optimal length-to-diameter ratio exists. Then numerical examples are included detailing the relative magnitude of cost items and showing the superiority of the suggested method in optimized design of heat exchangers when compared to traditional methods. Results show that exchangers configurations obtained according to this new costing procedure are cheaper than optimal configurations obtained resorting to traditional parametric costing methods.

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