Thermal Systems Design E-Book

Richard J. Martin

• Herausgeber: John Wiley & Sons
• Kategorie: Fachliteratur
• Sprache: Englisch

Seitenzahl: 1155

Veröffentlichungsjahr: 2022

Beschreibung

Thermal Systems Design

Discover a project-based approach to thermal systems design

In the newly revised Second Edition of Thermal Systems Design: Fundamentals and Projects, accomplished engineer and educator Dr. Richard J. Martin offers senior undergraduate and graduate students an insightful exposure to real-world design projects. The author delivers a brief review of the laws of thermodynamics, fluid mechanics, heat transfer, and combustion before moving on to a more expansive discussion of how to apply these fundamentals to design common thermal systems like boilers, combustion turbines, heat pumps, and refrigeration systems.

The book includes design prompts for 14 real-world projects, teaching students and readers how to approach tasks like preparing Process Flow Diagrams and computing the thermodynamic details necessary to describe the states designated therein. Readers will learn to size pipes, ducts, and major equipment and to prepare Piping and Instrumentation Diagrams that contain the instruments, valves, and control loops needed for automatic functioning of the system.

The Second Edition offers an updated look at the pedagogy of conservation equations, new examples of fuel-rich combustion, and a new summary of techniques to mitigate against thermal expansion and shock. Readers will also enjoy:

• Thorough introductions to thermodynamics, fluid mechanics, and heat transfer, including topics like the thermodynamics of state, flow in porous media, and radiant exchange
• A broad exploration of combustion fundamentals, including pollutant formation and control, combustion safety, and simple tools for computing thermochemical equilibrium when product gases contain carbon monoxide and hydrogen
• Practical discussions of process flow diagrams, including intelligent CAD, equipment, process lines, valves and instruments, and non-engineering items
• In-depth examinations of advanced thermodynamics, including customized functions to compute thermodynamic properties of air, combustion products, water/steam, and ammonia right in the user’s Excel workbook

Perfect for students and instructors in capstone design courses, Thermal Systems Design: Fundamentals and Projects is also a must-read resource for mechanical and chemical engineering practitioners who are seeking to extend their engineering know-how to a wide range of unfamiliar thermal systems.

Leseprobe

Thermal Systems Design

Fundamentals and Projects

Second Edition

Richard J. Martin

Martin Thermal Engineering, Inc.

California Polytechnic State University, San Luis Obispo

Santa Clara University, Santa Clara

California, USA

This edition first published 2022© 2022 John Wiley & Sons, Inc.

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The right of Richard J. Martin to be identified as the author of this work has been asserted in accordance with law.

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Library of Congress Cataloging‐in‐Publication Data applied for:

ISBN: 9781119803478

Cover design by WileyCover images: © AnitaVDB/Getty Images; © Photographee.eu/Shutterstock; © Derek Pinkston/Getty; © leungchopan/Shutterstock; © momente/Shutterstock; © Mint Images/Getty; © Grant Faint/Getty; © Mechanical Engineering/Shutterstock; © Andrii Stepaniuk/Shutterstock; © artpartner-images/Getty; © mikulas1/Getty

Preface to the First Edition (A Most Practical Guidebook)

The theme and structure of this textbook arose from the author's 16 semesters instructing mechanical and chemical engineering students at the University of Southern California (USC), and much of the specialized content incorporated here arose from investigations the author performed for clients of Martin Thermal Engineering, Inc. The author (in parallel with several colleagues) considered numerous published texts and found that none contained the focus or breadth necessary for a comprehensive class in thermal systems design – hence, the need for this tome was clear.

The intended audience is mechanical or chemical engineering students seeking capstone design guidance for thermal‐fluid systems, including heating, drying, boiling, refrigeration, air‐conditioning, compression, expansion, combustion, and power generation. Practitioners of thermal engineering design may also find this to be a helpful reference work – one that offers breadth, clarity, and simplicity.

The overarching goal of this textbook is to help students visualize the landscape of a thermal system design project and to equip their intellectual “toolkits” with a wide variety of techniques for applying solid engineering theory toward a useful and successful design, while exposing them to predictable stumbling blocks that will require ingenuity to overcome.

Thermal systems design students should enter this course having successfully completed math and science prerequisites such as advanced calculus, differential equations, chemistry, and physics, as well as intermediate engineering courses in thermodynamics, fluid mechanics, and heat transfer. Prior study of combustion is helpful, but not required. The book adopts use of a technique called “Think Stop,” which triggers a pause for reflection whenever the author sees an opportunity for “extracurricular learning” about a subject.

The course can be taught in a 15‐week semester with 3‐lecture hours per week or in a 10‐week quarter with 4‐lecture hours per week. Expectations for student projects and homework should be reduced a bit for the 10‐week course. Chapters 16–18 may be excluded without a loss of continuity, but students should be encouraged to digest this content in their spare time.

Acknowledgments

Inspiration for much of the material developed here would not be possible without contributions from my colleagues at USC and elsewhere. I am indebted to Larry Redekopp and Geoff Spedding for bringing me into the fold of the Aerospace & Mechanical Engineering Department as a part‐time faculty member and for numerous discussions about teaching philosophy and technique. I also thank my colleagues Fokion Egolfopoulos and Paul Ronney for their encouragement and advice about subject matter for which our fondness is kindred. It is with deep gratitude that I acknowledge my classroom colleagues Manny Dekermenjian and Leslie King, without whom the teaching and learning elements that embody the soul of this book would not have been possible. The original illustrations were expertly crafted by Ed Thielen, one of the world's finest creators of clear and compelling courtroom demonstrative exhibits. The editor was Alison Martin, a rising star in the field of composition, rhetoric, and news analysis. The delightful cover art was created by Nik Hallin and Cara Koenig of Motion Squared Design. Brian Martin, John Taber, John McArthur, and Zuhair Ibrahim attended lectures and provided helpful comments, as did numerous students from my Fall 2017 class, who studied from a draft version of this book. Finally, to Dawn Martin, my CFO, my cheerleader, and my more‐than‐equal partner in all things nonengineering, I give a Tom Hanks‐to‐Meg Ryan smile of gratitude and love.

Preface to the Second Edition (Fundamentals and Projects)

Where the prior edition claimed to be “most practical,” the current edition attempts to earn recognition for having the “coolest” (and the “hottest”) projects. The principal changes in this edition relate to the inclusion of many new design projects for the student teams, but it also includes new analytical tools for students to employ as they undertake their design projects. We continue our prior themes of motivating good engineering habits by applying the laws of thermodynamics, fluid mechanics, and heat transfer to create a functional design – while also insisting students demonstrate a higher level of design acumen than required by most other textbooks in the design category. This distinction appears in the projects by the inclusion of phase change (vaporization, condensation, humidity), chemistry (combustion, multiphase thermochemistry), and/or flow in porous media – to go beyondthe more elementary p‐T‐h analyses found in less‐thorough works.

With this edition, the author has adopted an augmented mission: to convince students that they can analyze thermal systems without spending tens of thousands of dollars per year to license a process/flow simulation software package. The outcome we seek is for students to first understand the fundamentals and then approach their design projects with confidence and creativity. If our instruction is successful, students will begin their careers with an unsurpassed breadth of knowledge and a stout collection of engineering design tools in their toolkits.

The most practical way we attempt to further this mission is with a new appendix that contains VBA scripts for customized Excel functions that compute values for thermodynamic properties of fluids and other complex engineering equations. If readers (i.e. students or engineering practitioners) invest a small amount of time copying the scripts and pasting them into VBA modules within Microsoft Excel, their toolkits will be augmented with powerful tools that would cost a small fortune elsewhere. In addition, the property tables from the first edition were relocated to a separate appendix and new property tables for propane, ammonia, and ammonia/water mixtures were added.

Eight projects were presented in the first edition (as end‐of‐chapter problems in Chapters 5 and 14), and they remain prominent in the second edition, even as new projects are presented via new homework questions. The new projects include: a hot air balloon, an exothermic gas generator, a tenter‐frame drying oven, an espresso machine, an ammonia/water/hydrogen absorption refrigeration system with no moving parts, and a thermally assisted air filtration system for destruction of biohazard particles.

The companion website for this book includes a substantial collection of supplementary tools to assist instructors and students. Included in this resource cache are PowerPoint slides with content organized for a 15‐week lecture course, “customer specifications” that provide necessary sizing and operating parameters that form the bases for the project designs, and solution keys for most of the homework problems. The solution keys also are repositories for several important derivations and project examples that were too long for the published text.

The new projects are intended to be executed in the same manner as the old projects. First, students create a schematic of the system with major equipment (unit operations) connected by lines (process streams). Then they compute thermodynamic details at each state and prepare a process flow diagram (PFD) withstream table. Next, they determine sizes for pipes/ducts and major equipment using applicable rules for heat transfer, fluid mechanics, phase change, and combustion. And finally, they complete the overall process design by selecting sensors (instruments) and valves (final control elements) and adding feedback control loops and safety interlocks – all of which are communicated via a piping andinstrumentation diagram (P&ID). If the PFD and P&ID drawings are prepared using commercial software, those exercises can provide a “laboratory” experience for design students.

The approach taken here is for students to complete a process design package, not a mechanical design package. Consequently, no emphasis is placed on detailed structural or mechanical design of equipment beyond basic sizing (D, L, # tubes) of piping, vessels, and heat exchangers, along with sizing/selection of commodity items such as blowers, pumps, and burners. Economic analyses and cost optimization may be added by instructors, but these topics are excluded from the chapter content here to help ensure the coverage remains manageable for a 45‐lecture‐hour semester or a 40‐lecture‐hour quarter.

In addition to the new projects, extensive new content is provided in several chapters: Chapter 4 has a new analytical method for computing equilibrium in fuel‐rich combustion and an improved method of estimating destruction efficiency for thermal oxidation based on VOC properties; Chapters 6 and 10 provide a thorough discussion of dew points and bubble points for two‐component refrigerant mixtures. Chapter 13 is broadened to include engineering methods for protection of materials against thermal shock and thermal expansion; Chapter 17 contains a more rigorous development of statistical methods for quality and efficiency.

Finally, we wish to call attention to a concern we have encountered regarding the nomenclature of conservation, and why we elected to invent a pedagogically preferred symbology – even though it modestly disrespects scientific orthodoxy. As described in Chapters 1–4, we use a nomenclature shortcut to illuminate the four elements of conservationin a control volume for any arbitrary property B: production , inflow , outflow , and storage .

Strictly speaking, the superdot symbol should apply only to the two flow terms, and the production and storage terms should be expressed as time derivatives (without any superdot). Certainly, this orthodoxy offers the only valid mathematical way to construct a conservation equation and this book carefully embraces these conventions in Chapters 2–4. The orthodox math is valid because (i) it is senseless to think of inflows and outflows as being derivatives of something else (hence the need for a superdot symbol to denote quantity flowing per unit time) and (ii) it is completely sensible to apply differentiation (with respect to time) to extensive fluid properties such as mass, momentum, and energy – because they can and do change with time.

Despite the obvious validity of the long‐accepted orthodoxy, we introduce our unorthodox superdot symbology for production and storage in Chapter 1 for its descriptive simplicity, and we believe this approach greatly helps students understand the contrasting concepts of production and storage. This approach protects the integrity of the physics by employing the mathematical rigor of the Reynolds transport theorem when presenting the detailed conservation equations, while it also highlights the bright line distinguishing production and storage in a simple way.

Acknowledgments

Many thanks are due to Professors Betta Fisher (Cornell University), Mahboobe Mahdavi (Gannon University), and Zuhair Ibrahim (University of Southern California) for identifying minor errors in the first edition and suggesting sections where additional clarity was needed. Special thanks to Brian Kaiser for lengthy discussions about principles of multicomponent, multiphase mixtures, to Jay Hudson for fluid heater sizing and safety know‐how, to Craig Schuler for helpful discussions on iteration techniques, and to Gabriel Gundling for a tutorial on ballooning technologies and practices. Special thanks are due again to Ed Thielen for compelling new artwork and to Dawn Martin for side‐by‐side assistance with table prep and the key word index.

The author is indebted to the Wiley team, especially Lauren Poplawski, Gabby Robles, Jenny Seward, Amudhapriya Sivamurthy, and Becky Cowan, for adopting this second edition textbook as their project and for numerous helpful editorial and pedagogic discussions along the way.

About the Author and the Textbook

Dr. Richard J. Martin played major roles in the design, commissioning, operation, and testing of combustion and heat transfer equipment in the 1980s and 1990s. During this time he became a named inventor on 24 utility patents. In the two decades of the current century, he investigated hundreds of failures (e.g. fires, explosions, thermal equipment failures) – the majority of which originated within thermal systems employed in many fields of commerce. He has been a volunteer leader of technical committees that write safety standards for industrial heating equipment.

In addition to teaching thermal systems design and heat transfer at University of Southern California, he has also taught courses in air pollution, fluid mechanics, heat transfer, programming applications in engineering, and thermal systems design at the California Polytechnic State University (Pomona and San Luis Obispo). Dr. Martin will be starting a new engagement at Santa Clara University shortly after the publication of this textbook, where he will teach Heat Transfer and Thermal Systems Design.

The primary purpose of this textbook is to encourage and exemplify high quality, accurate, well‐communicated, engineering design. A design may be amazing, but if it is poorly communicated to those who build and use it, horrible consequences could ensue. Similarly, a design that is communicated with accuracy and clarity may be equally problematic if it was produced using erroneous principles or insufficient forethought.

Another important purpose of this textbook is to motivate engineering students to enhance their: (i) knowledge of scientific fundamentals that govern human interactions with the environment; (ii) habits of observing, investigating, and analyzing engineering successes and failures; and (iii) desire to apply engineering know‐how to the service of humankind.

The author's unique background, comprising equal tenures in innovative design and technology failure investigation, gives this textbook a perspective different from most others. Not only are students given valid tools and methods to solve real‐world engineering design problems, but they are also cautioned about numerous ways the tools may be misunderstood or accidentally misapplied. By detailing both “right and wrong” approaches, students are better equipped to adopt the right, while rejecting the wrong.

The author encourages feedback from readers if any part of this textbook contains inaccurate or confusing information or could benefit from additional technical content that was omitted.

About the Companion Website

This book is accompanied by a companion website:

   www.wiley.com/go/Martin/ThermalSystemsDesign2

This website includes:

Instructor site

Homework Solutions

All figures from the print book downloadable in color in PowerPoint

All tables from the print book downloadable in PowerPoint

Course schedules for instructors

Project specifications

Student site

All figures from the print book available in color in PDF