It was required to design a heat exchanger with tubes having 50 mm diameter and 3 mm wall thickness. The temperature difference across the length of the tube is 100 C and the heat transfer rate is 500 kW. The copper tubes with 50 mm diameter costs $ 40/m and its thermal conductivity was measured to be 391.889 W/mk. The Aluminium tubes with 50mm diameter costs $22/m and its thermal conductivity was measured to be 209.145 W/mk. The task was to select the most cost-effective material for the tube of the heat exchanger from either Copper or Aluminium.
To compare the cost of both materials, first, it was required to find out the length of tube needed in both cases. Thus the length of the copper tube and aluminium tube required to transfer 500 kW at 100 C temperature difference across the of 50 mm diameter tube was calculated.
It was found from the calculations that if we use the copper tube for the heat exchanger it will cost us 91.99 $ with a tube length of 2.3 meters and if we use aluminium pipe for the heat exchanger it will cost us 94.81$ with a tube length of 4.31 meters.
It can be observed from the results that copper tubes are more cost-effective for our heat exchanger compares to aluminium tubes, as with the copper tubes, the cost will reduce as well as it will require almost half the length of aluminium tube required for same heat transfer, thus reducing the required space.
In the design of the new refrigerator, it was required to select a pair of magnets and find out the thickness of the rubber seal needed to adjust the separation between the magnets. There are four combination of the magnets available 25mm-25mm, 12.7mm-12.7mm, 12.7mm-10mm and 10mm-10mm. The task was to select the most cost-efficient combination of magnets and thickness of the rubber seal out of these four options.
The thickness of the rubber seal required for all the four pairs of the magnets were calculated from the experimental data available for each combination. The cost of the rubber seals were calculated based on their thickness and this cost was combined with the cost of the related pair of magnets to calculate the total cost of the combination.
It was found that to maintain 12N of pull force with 25mm-25mm magnets, the thickness of the rubber seal required is 16.83 mm and the total cost of this combination is 111.34 $. For 12.7mm-12.7mm magnets, the thickness of the rubber seal required is 7.46mm and the total cost of this combination is 60.41$. 10mm-12.7mm magnets requires 4.54 mm thickness of the rubber seal and the total cost of this combination is of 74.64 $. 10mm-10mm magnets requires 3.62 mm thickness of the rubber seal and the total cost of this combination is of 81.35$.
It can be observed form the results that 12.7mm-12.7mm pair of neodymium magnets are the most cost-efficient option with a combined cost of magnets and rubber seal 60.41$.
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