This is a model of temperature distribution across a star shaped tube of a specialised shell and tube heat exchanger.

The model was prepared to demonstrate to management the likely magnitude of possible efficiency gains with a small change in tube design. The model assisted the justification for further expenditure of funds on a more detailed investigation.

The overall modelling of such a heat exchanger is of course quite complex, and in this model, complicating factors have been ignored. Early results indicate that the addition of extra fins may increase the heat transfer of the cross section by as much as 43%.

Australian Paper's Wesley Vale Mill was recently upgraded with the addition of an infra-red drying section. The dryer uses several hundred infra-red lamps, each with its own set of stainless steel cooling shrouds and quartz glass cover. Unfortunately, unpredictable thermal deflections within the shroud of each lamp was causing the quartz glass covers to break, causing serious production down time. FEA modelling was used to simulate the thermal deflections and to successfully evaluate modification proposals. This allowed Australian Paper to speed up and improve confidence in the proto-typing process and eased them through a serious and costly commissioning problem.

Finite Elements were involved with all facets of this project from the initial design concept right through to installation. This included detailed design development using FEA for; Thermal Analysis, Stress Analysis and Deflection Analysis to ensure all design requirements were achieved.

In addition to design, Finite Elements were also responsible for:

• Engineering Procurement
• Installation management over 5 day 24 hour shutdown.
• Completed to total a budget of $400 000

For more details on this project, click on the image above....