Liquid-Liquid Heat Transfer in Spray Column

LIQUID-LIQUID HEAT TRANSFER IN A
SPRAY COLUMN
THESIS
Submitted by
SUDHANYA KARMAKAR
Class Roll No- 001310302001
Exam Roll No-M4CHE15-01
Registration No-124698 of 2013- 2014
Under the Guidance of

Prof. (Dr.) Avijit Bhowal
in partial fulfillment for the award of the degree of

MASTER OF ENGINEERING IN CHEMICAL ENGINEERING
DEPARTMENT OF CHEMICAL ENGINEERING

JADAVPUR UNIVERSITY
Jadavpur, Kolkata-700032
MAY 2015
Declaration of Originality and Compliance of Academic Ethics

I hereby declare that this thesis contains literature survey and original research work by
the undersigned candidate, as part of his Master of Engineering in Chemical
Engineering studies.
All information in this document have been obtained and presented in accordance with
academic rules and ethical conduct.
I also declare that, as required by these rules and conduct, I have fully cited and
referenced all material and results that are not original to this work.
Name: Sudhanya Karmakar

Class Roll No-001310302001
Exam Roll No- M4CHE15-01
Registration No- 124698 of 2013- 2014
Thesis Title : LIQUID LIQUID HEAT TRANSFER IN A SPRAY COLUMN
Date:
Sudhanya Karmakar
FACULTY OF ENGINEERING AND TECHNOLOGY

DEPARTMENT OF CHEMICAL ENGINEERING
JADAVPUR UNIVERSITY
CERTIFICATE OF RECOMMENDATION
This is to certify that Ms. Sudhanya Karmakar, final year student of Master of
Engineering in Chemical Engineering, Jadavpur University, has completed the Project
work titled Liquid Liquid Heat Transfer in a Spray Column under the guidance of
Prof. Dr. Avijit Bhowal during his Masters Curriculum. This work has not been reported
earlier anywhere and can be approved for submission in partial fulfillment of the course
work.
--------------------------------------------
Dr . Avijit Bhowal
Project Supervisor
Professor
Department of Chemical Engineering
Jadavpur University , Kolkata 32
Approval
The following thesis is hereby approved as a credible study of a Engineering subject and
presented in a manner satisfactory to warrant its acceptance as a perquisite to the degree
for which it has been submitted. It is to be understood that by this approval, the
undersigned do not necessarily endorse or approve any statement made, opinion
expressed or conclusion drawn there in, but approve the thesis only for thr purpose for
which it has been submitted.
Department of Chemical Engineering
Jadavpur University
-------------------------------------------------HOD (Department of Chemical Engineering)
--------------------------------------------------Dean (FET)
Committee of final examination for evaluation of thesis
--------------------------------------------
--------------------------------------------
--------------------------------------------
ACKNOWLEDGEMENT
Though the following project is an individual work, I could never have reached the
heights or explored the depths without the help, support, guidance and efforts of a lot of
people. Firstly, I would like to thank my Project Guide, Prof. Dr. Avijit Bhowal
(Chemical Engineering) for instilling in me the qualities of being a good researcher. His
infectious enthusiasm and unlimited zeal have been major driving forces through my post
graduate career at the Jadavpur University, Kolkata. I would also like to thank my
laboratory co-researcher Aritra Das for her support during the project work. I would like
to take this opportunity to thank Mr. Jayant Modak , for his constant encouragement and
helpful advice. I also extend my gratitude to Ms. Chandana Das for her support. My very
special thanks to my parents whom I owe everything I am today, my father Mr. Subodh
Karmakar and my mother Mrs. Tapashi Karmakar. Their unwavering faith and
confidence in my abilities and in me is what has shaped me to be the person I am today.
Thank you for everything. Finally, I would like to take the opportunity to thank all my
teachers and support staff of the Chemical Engineering Department, Jadavpur University,
Kolkata.
Sudhanya Karmakar
22st May, 2013
Contents
Chapter No
1.
Topics/Subtopics
Page No
Introduction
1-26
1.1 Cooling Tower
1.2 Evaporator
1.3 Heat Exchanger
4-23
1.3.1 Classification according to
9-17
contact type
18-19
flow type
19-23
construction type
23
number of fluids
23
surface compactness
1.4 Spray Column
24-26
2.
Literature Review
27-36
3.
Aim & Objective
37-39
4.
Experimental Section
40-44
4.1 Experimental Setup
41-42
5.
4.2 Experimental Procedure
42-43
Results & Discussion
45-65
5.1 Study of heat loss in counter-flow
46-48
Spray-Column
5.2 Calculation of thermal efficiency
49
5.3 Calculation of heat transfer coeff
49
-icient
5.4 Effect of water flow rate on h &
50-55
5.5 Effect of variation in water inlet
56-58
temperature on h &
5.5 Effect of variation in column height 59-61
on h &
5.5 Effect of variation in phase ratio on 62-65
6.
Conclusion
66-67
NOMENCLATURE
68
REFFERENCES
69-70
List of Figures
Fig No.
Figure Name
Page No.
Fig 1.1
Classification of heat exchangers
Fig 1.2
Shell and tube heat exchanger
Fig 1.3
Plate and Frame heat exchanger
10
Fig 1.4
Turbulent pipe contact
13
Fig 1.5
Typical mechanically agitated towers
14
Fig 1.6
Baffle tray column
15
Fig 1.7
A possible configuration of a packed bed condenser
15
Fig 1.8
Schematics of a Spray Column
16
Fig 1.9
Schematic of a sieve tray column
17
Fig 1.10
Schematic of a Parallel flow & a Counter Flow Heat Exchanger
18
Fig 1.11
Schematic of a Cross Flow Heat Exchanger
19
Fig1.12
Tubular Heat Exchanger
19
Fig1.13
Plate-Type Heat Exchanger
20
Fig1.14
Extended Surface Heat Exchanger
21
Fig1.15
Regenerator
22
Fig1.16
Typical countercurrent-flow spray tower
26
Fig 1.17
Crosscurrent-flow spray tower
26
Fig 4.1
Overall Experimental Set Up
43
Fig 4.2
Schematic of experimental set up
44
Fig 5.1
Effect of water flow rate on thermal efficiency at water
51
bath temperature550C & Column Height 105cm

Fig 5.2
Effect of water flow rate on thermal efficiency
51
at water bath temperature 640C & Column Height 105cm

Fig 5.3
52
at water bath temperature550C & Column Height 80cm

Fig 5.4
52
at water bath temperature640C & Column Height 80cm

Fig 5.5
Effect of water flow rate on heat transfer coefficient

at water bath temperature 550C & column height 105cm
54
Fig No.
Figure Name
Page No.
Fig 5.6
54

Fig 5.7
55

Fig 5.8
55

Fig 5.9
Effect on thermal efficiency with change in water
57
bath temperature at a height 105cm

Fig 5.10
Effect on thermal efficiency with change in water
57

Fig 5.11
Effect on heat transfer coefficient with change in water
58

Fig 5.12
Effect on heat transfer coefficient with change in water
58

Fig 5.13
Effect on thermal efficiency with change in column height
60
at a water bath temperature 550C

Fig 5.14
Effect on thermal efficiency with change in column height
60
at a water bath temperature 640C

Fig 5.15
Effect on overall heat transfer coefficient with change in
61
height at a water bath temperature 55 C

Fig 5.16
61
height at a water bath temperature 640C

Fig 5.17
Effect on Thermal Efficiency with change in phase ratio at
63
a Column Height 105cm

Fig 5.18
Effect on Thermal Efficiency with change in phase ratio at
63

Fig 5.19
64
phase ratio at a Column Height 105cm

Fig 5.20

64
Fig 5.21
Effect on Kerosene Outlet temperature with change in
65

Fig 5.22
Effect on Kerosene Outlet temperature with change in
65
List of Tables
Table No.
Table Name
Page No
Table1
Heat loss at Water Bath Temperature-55 0C &
46
Column Height- 105 cm

Table2
Heat Loss at Water Bath Temperature- 64 0C &
47

Table3
Heat Loss at Water Bath Temperature- 55 0C &
47
Table4
Heat loss at Water Bath Temperature- 64 0C &

48
Chapter 1
IntroductIon
Most of the industries use water for their production and this water often requires
particular properties such as solubility, transportability and heat exchanging potential.
Water in industry is used for boiler make up, processing, product treatment and cleaning,
cooling etc.
The quantity of water consumption differs between types of industries. The steel,
chemical, oil, petrochemical, pulp and paper industries are major users of large quantities
of water per unit price of products because they use fresh water for cooling, cleaning and
product processing. Cooling water comprise the majority of consumption of industrial
water. Due to huge water consumption in each plant, cooling water is generally reused in
order to save the acquisition cost & the water resource.
So, a huge amount of water is necessary to re-circulate in many industries such as:
thermal power plant, oil industries, petrochemical industries etc. In thermal power plant,
large amount of superheated steam is produced by using soft water. This steam is used to
rotate the impeller of the turbine so that it can generate power. This used steam is
condensed by passing it through a condenser. For this purpose, a water stream is passed
through the condenser coil to transfer the heat energy from steam to water. Therefore, the
water temperature rises. The temperature of the water must be reduced to make the water
fit for recycling.
In oil and petroleum industries, steam is used to raise the temperature of oil and
petroleum product to maintain the flowability. For this reason a huge steam is used in
steam jacket in storage tanks, process lines, columns, reboilers etc. in all over the process.
That steam passed through the condenser where water recirculation is necessary. Besides
condenser there are many heat exchanger equipments in those industries where water is
used as coolant. There also water recycling process is essential. Again, it should also be
noted that for the environmental friendly discharging of the waste water in some
industries the temperature of the water should be brought down or else it may have
several effects on the aquatic or marine life by causing abnormal increase in the
temperature of the water body. The sharp increase in water temperature inhibits the
growth of microorganisms which are very essential for the maintenance of aquatic
symbiosis. So cooling of process hot water stream is an important operation in process
industries. There are various equipment used for cooling hot water such as heat
exchanger, cooling towers, evaporators etc. The different equipment used for cooling
water is:
1.1 Cooling Tower
When warm liquid is brought into contact with unsaturated gas, part of the liquid
evaporates and the liquid temperature drops. The most important application of this
principle is in the use of cooling towers to lower the temperature of recirculated water
used for condensers and heat exchangers in chemical plants, power plants. Cooling
towers are large-diameter columns with special type of packing designed to give good
gas-liquid contact with low pressure drop. Warm water is distributed over the packing by
spray nozzles or a grid of notched troughs or pipes. Air is passed through the packing by
forced-draft or induced-draft fan or in some designs it is drawn through by natural

convection.
1.2 Evaporator
An evaporator is a device used to turn the liquid form of a chemical into its
gaseous form. The liquid is evaporated, or vaporized, into a gas. It is used in air
conditioning system to evaporate gas from liquid while absorbing heat in the process. It
can also be used to remove water or other liquids from mixtures. In the concentration
process, the main objective of evaporation is to vaporize most of the water from a
solution which contains the desired product. The general types of evaporator used in
todays world are open kettle or pan evaporator, agitated film evaporator, pan solar
evaporator, natural circulation type and forced circulation type. Natural circulation type
evaporators are classified into horizontal tube evaporator, vertical short tube or calandria
evaporator, long tube vertical rising film type, long tube vertical falling film type. Open
kettle or pan evaporators are the simplest evaporator consists of an open kettle in which
the liquid is boiled. The heat supplied by condensation of steam in a jacket in the liquid.
these are inexpensive and simple to operate but the steam economy is very poor.
1.3 Heat Exchanger
A heat exchanger is a device that is used to transfer thermal energy (enthalpy)
between two or more fluids, between a solid surface and a fluid, or between solid
particulates and a fluid, at different temperatures and in thermal contact. In heat

exchangers, there are usually no external heat and work interactions.
Heat exchangers are commonly used in practice in a wide range of applications,
from heating and air-conditioning systems in a household, to chemical processing and
power production in large plants. Heat exchangers differ from mixing chambers in that
they do not allow the two fluids involved to mix. In a car radiator, for example, heat is
transferred from the hot water flowing through the radiator tubes to the air flowing
through the closely spaced thin plates outside attached to the tubes.
Heat transfer in a heat exchanger usually involves convection in each fluid and
conduction through the wall separating the two fluids. In the analysis of heat exchangers,
it is convenient to work with an overall heat transfer coefficient U that accounts for the
contribution of all these effects on heat transfer. The rate of heat transfer between the two
fluids at a location in a heat exchanger depends on the magnitude of the temperature
difference at that location, which varies along the heat exchanger. In the analysis of heat
exchangers, it is usually convenient to work with the logarithmic mean temperature
difference LMTD, which is an equivalent mean temperature difference between the two
fluids for the entire heat exchanger.
In a few heat exchangers, the fluids exchanging heat are in direct contact. In most
heat exchangers, heat transfer between fluids takes place through a separating wall or into
and out of a wall in a transient manner. In many heat exchangers, the fluids are not
separated by a heat transfer surface, and ideally they do not mix or leak. Such exchangers
are referred to as direct transfer type, or simply recuperators. In contrast, exchangers in
which there is intermittent heat exchange between the hot and cold fluidsvia thermal
energy storage and release through the exchanger surface or matrix are referred to as
indirect transfer type, or simply regenerators. Such exchangers usually have fluid leakage
from one fluid stream to the other, due to pressure differences and matrix rotation/valve
switching. Common examples of heat exchangers are shell-and tube exchangers,
automobile radiators, condensers, air preheaters. If no phase change occurs in any of the
fluids in the exchanger, it is sometimes referred to as a sensible heat exchanger. There
could be internal thermal energy sources in the exchangers, such as in electric heaters and
nuclear fuel elements. Combustion and chemical reaction may take place within the
exchanger, such as in boilers, fired heaters, and fluidized-bed exchangers. Mechanical
devices may be used in some exchangers such as in scraped surface exchangers, agitated
vessels, and stirred tank reactors. Heat transfer in the separating wall of a recuperator
generally takes place by conduction. However, in a heat pipe heat exchanger, the heat
pipe not only acts as a separating wall, but also facilitates the transfer of heat by
condensation, evaporation, and conduction of the working fluid inside the heat pipe. In
general, if the fluids are immiscible, the separating wall may be eliminated, and the
interface between the fluids replaces a heat transfer surface, as in a direct-contact heat
exchanger. There are different types of heat exchangers as follows.
Fig 1.1: Classification of Heat Exchangers
1.3.1 Classification according to contact type:

1.3.1(a) Indirect contact heat exchanger involves heat transfer between hot and cold
streams of two phases in the presence of a separating solid wall.
Shell and tube heat exchangers:

As shown in fig.1.2 shell and tube heat exchanger has two sides. One is tube side
and another is shell side. Tube side has series of tubes called tube bundle. Tube bundle
can be made of different types of tubes: plain, longitudinally finned, etc .The fluid
contains tube side can be heated or cooled by transferring heat with shell side fluid. The
shell and tube heat exchanger can be used at temperature >2500 C and pressure at>30 bar.
Fig.1.2: Shell and tube heat exchanger.
Plate and Frame heat exchanger:

For many applications at moderate temperature and pressure, an alternative to the
shell and tube exchanger is the gasketed plate exchanger (fig.1.3), which consists of
many corrugated stainless-steel sheets separated by polymer gaskets and clamped in a
steel frame. Inlet portals and slots in the gaskets direct the hot and cold fluid to alternate
spaces between the plates. The corrugation induces turbulence for improved heat transfer
and each plate is supported by multiple contacts with adjoining plates, which have a
different pattern or angle of corrugation. The space between plates is equal to the depth of
the corrugations and is usually 2 to 5 mm.
Fig.1.3: Plate and Frame heat exchanger
10
1.3.1(b) Direct Contact Heat Exchanger

In a direct-contact exchanger, two fluid streams come into direct contact,
exchange heat, and are then separated. Common applications of a direct-contact
exchanger involve mass transfer in addition to heat transfer, such as in evaporative
cooling and rectification; applications involving only sensible heat transfer are rare. The
enthalpy of phase change in such an exchanger generally represents a significant portion
of the total energy transfer. The phase change generally enhances the heat transfer rate.
Advantages and Disadvantages in Utilizing Direct Contactors

The exchange of heat between two fluid streams can, in general, be accomplished
using either direct contact or surface-type heat exchangers. There are, however, several
limitations to the use of direct contactors. First, if two fluid streams are placed in direct
contact, they will mix, unless the streams are immiscible. Thus, stream contamination
will occur depending on the degree of miscibility. The two streams must also be at the
same pressure in a direct contactor, which could lead to additional costs. The advantages
in utilizing a direct contactor include the lack of surfaces to corrode or foul, or otherwise
degrade the heat transfer performance. Other advantages include the potentially superior
heat transfer for a given volume of heat exchanger due to the larger heat transfer surface
area achievable and the ability to transfer heat at much lower temperature differences
between the two streams. Still another advantage is the much lower pressure drop
11
associated with direct contactors as compared to their tubular counterparts. A final

advantage is the much lower capital cost as direct contact heat exchangers can be
constructed out of little more than a pressure vessel, inlet nozzles for the fluid streams,
and exit ports. Of course, it is sometimes advantageous to provide internals,
Varieties of Direct Contact Heat Exchangers

A typical direct contactor provides heat transfer between two fluid streams. The
processes include the simple heating or cooling of one fluid by the other; cooling with the
vaporization of the coolant; cooling of a gas-vapor mixture with partial condensation;
cooling of a vapor or vapor mixture with total condensation; and cooling of a liquid with
partial or complete solidification. Most of the direct-contact applications can be
accomplished with the following devices: a) Spray columns, b) Baffle tray columns, c)
Sieve tray or bubble tray columns, d) Packed columns, e) Pipeline contactors, and f)
Mechanically agitated contactors. There are also some other direct contactors like
evaporator, cooling tower , bubble column reactor.
Fig1.4 to 1.9 - illustrate the general configurations of a) through f), respectively.
Except for the turbulent pipe contactor, all of the devices are countercurrent devices and
depend upon the relative buoyancy of the dispersed phase through a continuous phase.
While the figures illustrate a less-dense dispersed phase being introduced at the bottom of
12
the column, it is possible for the dispersed phase to be denser and introduced at the top,
with the configuration internals appropriately revised.
The turbulent pipe contactor is a parallel-flow device and has the limits of
efficiency of all such systems, whether they be direct contact or surface-type heat
exchangers. That is, the maximum temperature
achieved by the cool stream is that of the
mixing cup temperature. The size of the
turbulent pipe contactor is dictated by the
relative mass flow rate and the nature of the
Fig 1.4: Turbulent pipe contactor
turbulence.Turbulence promoters can be
installed to enhance the turbulence and, thereby, reduce the length of contactor necessary
to essentially obtain the mixing cup temperature. If separation of the streams is desired,
the contactor must be followed by a separation device such as a settler, a cyclone
separator, or other mechanisms. While the turbulent pipe conductor is very inexpensive,
if separation is desired, the cost of the settler will in all probability dictate the economics
of the process.The remaining apparatus all have the heat transfer take place between a
continuous phase and a clearly defined disperse phase in the form of drops, bubbles, jets,
sheets, or thin supported films in the case of packed beds.
13
Heat
mechanical
exchangers
agitators
with
(Fig 1.5),
while often superior as heat or

mass transfer equipment, are more
difficult to design as the dispersed
phase may have a wide range or Fig 1.5: Typical mechanically agitated towers
drop or bubble sizes. Thus, empirical data from the manufacturer to establish
performance is necessary.Further, problems may result in seals at the penetration point of
the drive shafts. Special designs may therefore be necessary.
Baffle tray columns may have similar problems in defining the nature of the
curtain of the dispersed phase. Depending on flow rates and battle design, the dispersed
phase may be a sheet, a series of rivulets or defined streams, which can break up into
drops. If the baffles are, in fact, trays with serrated or notched rims, the dispersed phase
can be designed to be a series of well-defined streams and the heat transfer is more easily
analyzed. The baffles/trays then result in mixing of the dispersed phase and enhance the
internal-to-the-dispersed phase mixing.
14
Fig 1.6: Baffle tray column
Fig1.7: A possible configuration of a packed bed condenser
15
The spray column shown in Fig 1.8 is an open column whose only internals are
the inlet nozzles for the dispersed and continuous
phase. Ideally, such columns are capable of pure
counter flow operation, with the dispersed phase made
up of nearly uniform diameter drops. While it is
possible to design the dispersed phase inlet nozzle to
achieve the desired characteristics, providing a Fig1.8: Schematics of a Spray Column
uniform flow in the continuous phase is more difficult. Great care must be taken or
maldistribution of the continuous phase may lead to diminished heat transfer. Thus, the
design of continuous phase inlet nozzles is sometimes proprietary, or patented.
The bubble column or sieve tray column (see Fig 1.9) enhances the internal heat
transfer coefficient by repeatedly reforming the drops at each tray. Proper tray or baffle
design can lead to shorter columns, and potentially small heat exchanger volume for the
same service. Their major disadvantage is fouling, corrosion or blockage of some of the
holes in the sieve tray.
16
Fig 1.9: Schematic of a sieve tray column

A liquid to liquid heat exchanger designed for highly efficient heat transfer
covering a wide variety of liquid types. The heavy duty design makes it ideal for
demanding commercial, industrial and residential applications where high performance
and low maintenance are important. Here transfer coefficients are greater than
conventional shell and tube or plate exchangers because of the enhanced heat exchange
surface and counter flow design.
17
1.3.2 Classification according to flow type:

1.3.2(a) Parallel flow Heat Exchanger The hot and cold fluids enter the same end,
flow in the same direction and leave at the same end.
Fig 1.10: Schematic of a Parallel flow & a Counter Flow Heat Exchanger
1.3.2(b) Counter flow Heat Exchanger The hot and cold fluids enter at opposite ends,
flow in opposite direction and leave at opposite ends.
1.3.2(c) Cross flow heat exchanger The flow of one fluid is perpendicular to the other
fluid.
18
Fig 1.11: Schematic of a Cross Flow Heat Exchanger

1.3.3 Classification according to Construction Type
1.3.3(a) Tubular Heat ExchangersThese exchangers are generally built of
circular
tubes,
although
elliptical,
rectangular, or round/flat twisted tubes

have
Fig1.12: Tubular Heat Exchanger
also
been
used
in
some
applications. There is considerable flexibility in
the design because the core geometry can be varied easily by changing the tube diameter,
length, and arrangement. Tubular exchangers can be designed for high pressures relative
to the environment and high-pressure differences between the fluids. Tubular exchangers
are used primarily for liquid-to-liquid and liquid-to-phase change (condensing or
evaporating) heat transfer applications. They are used for gas-to-liquid and gas-to-gas
19
heat transfer applications primarily when the operating temperature and/ or pressure is
very high or fouling is a severe problem on at least one fluid side and no other types of
exchangers would work. These exchangers may be classified as shell-and tube, doublepipe, and spiral tube exchangers. They are all prime surface exchangers except for
exchangers having fins outside/inside tubes.
1.3.3(b) Plate-Type Heat Exchangers-Plate-type
heat exchangers are usually built of thin plates (all
prime surface). The plates are either smooth or have
some form of corrugation, and they are either flat or
wound
in
exchangers
an
exchanger.
cannot
Generally,
accommodate
very
these
high
pressures, temperatures, or pressure and Fig1.13 Plate-Type Heat Exchanger

temperature differences. Plate heat exchangers (PHEs){ can be classified as gasketed,
welded (one or both fluid passages), or brazed, depending on the leak tightness required.
Other plate-type exchangers are spiral plate, lamella, and platecoil exchangers.
20
1.3.3(c) Extended Surface Heat

Exchangers- The tubular and
plate-type exchangers described
previously are all prime surface
heat exchangers, except for a shelland-tube
finned
exchanger
tubing.
with
Their
low
heat
exchanger effectiveness is usually
Fig1.14: Extended Surface Heat Exchanger
60% or below, and the heat transfer surface area density is usually less than 700 m2 /m3
(213 ft2 /ft3). In some applications, much higher (up to about 98%) exchanger
effectiveness is essential, and the box volume and mass are limited so that a much more
compact surface is mandated. Also, in a heat exchanger with gases or some liquids, the
heat transfer coefficient is quite low on one or both fluid sides. This results in a large heat
transfer surface area requirement. One of the most common methods to increase the
surface area and exchanger compactness is to add the extended surface (fins) and use fins
with the fin density ( fin frequency, fins/m or fins/in.) as high as possible on one or both
fluid sides, depending on the design requirement. Addition of fins can increase the
surface area by 5 to 12 times the primary surface area in general, depending on the
design. The resulting exchanger is referred to as an extended surface exchanger. Flow
21
area is increased by the use of thin gauge material and sizing the core properly. The heat
transfer coefficient on extended surfaces may be higher or lower than that on unfinned
surfaces. For example, interrupted (strip, louver, etc.) fins provide both an increased area
and increased heat transfer coefficient, while internal fins in a tube increase the tube-side
surface area but may result in a slight reduction in the heat transfer coefficient, depending
on the fin spacing. Generally, increasing the fin density reduces the heat transfer
coefficient associated with fins. Flow interruptions (as in offset strip fins, louvered fins,
etc.) may increase the heat transfer coefficient two to four times that for the
corresponding plain (uncut) fin surface. Plate-fin and tube-fin geometries are the two
most common types of extended surface heat exchangers.
1.3.3(d)
Regenerators-
The
regenerator is a storage-type heat

exchanger, as described earlier.
The heat transfer surface or
elements are usually referred to
Fig1.15:Regenerator
as a matrix in the regenerator.
To have continuous operation, either the matrix must be moved periodically into and out
of the fixed streams of gases, as in a rotary regenerator , or the gas flows must be
diverted through valves to and from the fixed matrices as in a fixedmatrix regenerator.
22
The latter is also sometimes referred to as a periodic-flow regenerator, a swing

regenerator, or a reversible heat accumulator.
1.3.4 Classification According to Number of Fluids
Most processes of heating, cooling, heat recovery, and heat rejection involve transfer of
heat between two fluids. Hence, two-fluid heat exchangers are the most common. Threefluid heat exchangers are widely used in cryogenics and some chemical processes (e.g.,
air separation systems, a heliumair separation unit, purification and liquefaction of
hydrogen, ammonia gas synthesis). Heat exchangers with as many as 12 fluid streams
have been used in some chemical process applications.
1.3.5 Classification According to Surface CompactnessCompared to shell-and-tube exchangers, compact heat exchangers are characterized by a
large heat transfer surface area per unit volume of the exchanger, resulting in reduced
space, weight, support structure and footprint, energy requirements and cost, as well as
improved process design and plant layout and processing conditions, together with low
fluid inventory. A gas-to-fluid exchanger is referred to as a compact heat exchanger if it
incorporates a heat transfer surface having a surface area density greater than about 700
m2 /m3. In case of heat transfer surface having a surface area density less than about 700
m2/m3 then it is called non-compact heat exchanger.
23
1.4 Spray Column

1.4.1 Spray Column
In this study of liquid liquid heat transfer Spray Column is used as a heat
exchange equipment. A Spray Column is a two phase contactor used to achieve the mass
& heat transfer between a continuous phase & a dispersed phase. It consists of empty
cylindrical vessel made of steel or plastic & nozzles that spray liquid in the vessel. The
light phase usually enters the bottom of the tower and moves upward while the heavy
phase moves downward.
A spray is a dynamic collection of drops dispersed in a gas. The process of
forming a spray is known as atomization. A spray nozzle is the device used to generate a
spray. The two main uses of sprays are to distribute material over a cross-section and to
generate liquid surface area. There are thousands of applications in which sprays allow
material to be used most efficiently. The spray characteristics required must be
understood in order to select the most appropriate technology, optimal device and size.
It is mainly considered as a gas liquid contactor. But it also works on liquid-liquid
contact. The common design consists of an empty cylindrical shell through which the gas
flows upwards against a downflowing spray of the absorbing liquid .Here the gas is the
continuous phase & the liquid is the dispersed phase. The liquid is dispersed in the form
of fine droplets near the top by forcing it through spray nozzles. Spraying should be
uniform over the cross-section of the vessel for the sake of better gas liquid contact. The
liquid droplets have a distribution of size. The contact time between the droplets & the
gas has also a distribution. A fraction of the droplets unavoidably strike the wall of the
tower and the liquid flows down as a film. Backmixing of the gas remains small in a
24
spray tower. The raining droplets are collected at the bottom and liquid leaves through a
nozzle. A demister is invariably used to prevent entrainment of droplets in the exit gases.
The Spray tower can handle a large volumetric gas flow rate at a low pressure drop. The
HTU is substantially large. Pumping the liquid at a high pressure to the spray nozzles
involves substantial power consumption. The absence of any moving parts is also an
advantage of the spray Column. The device is particularly suitable for a. corrosive liquids
& gases, b. liquids containing suspended solid, c. gas streams may contain dust, d. low
gas pressure drop application, e. scrubbing various waste gas stream, f. liquid-liquid
extraction.
1.4.2 Spray formation
Spray atomization can be formed by several methods. The most common method
is through a spray nozzle which typically has a fluid passage that is acted upon by
different mechanical forces that atomize the liquid. The first atomization nozzle was
invented by Thomas A. DeVilbiss of Toledo, Ohio in the late 1800s His invention was
bulb atomizer that used pressure to impinge upon a liquid, breaking the liquid into a fine
mist. Spray formation has taken on several forms, the most common being, pressure
sprayers, centrifugal, electrostatic and ultrasonic nozzle.
25
1.4.3 Flow Patterns in a Spray Column
Fig 1.16: Typical countercurrent-flow spray tower
Fig1.17: Crosscurrent-flow spray tower
26
Chapter-2
Literature review
27
Letan & Kehat (1967) studied the mechanics of a Spray Column. Local & average
hold up & drop size distribution as function of flow rates which were measured for
kerosene drops and water in a counter current , 15cm I.D., 160cm long Spray Column.
The range of flow rates was 5 to 40 liters/min of kerosene & 0 to 50 liters/min of water.
At the same pairs of flow rates of the dispersed and the continuous phases in spray
columns, three modes of drop packing can be obtained. These are termed, in order of
increasing average hold up and increasing regularity of flow patterns, dispersed,
restrained, and dense packing. For dispersed packing, at low flow rates of the two phases,
the hold up and the drop size are constant along the column. At high flow rates the drop
size increases from bottom to top of the column & hold up increases from top to bottom
of the column. The range of flow rates for the operation of a spray column is extended by
use of a conical entry section (Elgin design) at the bottom of the column, by the
formation of an equilibrium region in the conical section. The average hold up increases
with flow rates of both phases for dispersed & restrained packing, and restrained packing
and with decreased flow rates of both phases for dense packing. The best definitions of
flooding in a spray column are either the point of maximum average specific area of the
drops, which corresponds to the onset of coalescence in the column, or the start of
rejection of drops from the column proper.
Siqueiros & Bonilla (1999) did an experimental study of a three-phase, directcontact heat exchanger. An experimental pilot scale three-phase, direct-contact heat
exchanger was constructed and tested. The DCHE (Direct Contact Heat Exchanger) is a
spray column of 0.61 m (24 in) nominal diameter carbon steel, 3.3 m height with two
distributors. The water (continuous phase) distributor is on the top of the column. The
28
pentane (discontinuous phase) distributor is on the bottom of the column. It has six
viewing windows along its length. The column has two flanges. On the upper flange the
pentane vapour exit and the security valve were installed. On the lower flange the cool
brine exit and the liquid pentane inlet were installed. Steady-state conditions were
reached between 30 and 60 min after the pentane was fed into the column. The main
parameters of control for each experimental test were the pentane and water mass flowrates. The inlet water temperatures ranged from 75 C to 88C, and the inlet pentane
temperatures varied from 23 C to 38C. The volumetric heat transfer coefficient, hold-up
and heat flow-rate are functions of pentane mass flow-rate. For high pentane/water
volumetric flow ratios flooding was reached. Before reaching flooding conditions,
accumulation of liquid pentane at the top of the active volume was found. The volumetric
heat transfer coefficient was achieved in between 4.5-8 KW m 1 K 1 .
Peng et.al, (2001) studied heat transfer in gasliquidliquid three-phase directcontact exchanger. The heat transfer to dispersed droplets in an immiscible continuous
phase is studied for the n-pentanewater system. The gasliquidliquid three-phase
section of the exchanger is divided into two stages, where the volumetric heat transfer
coefficients are developed, respectively. These models take into account the evaporation
of continuous phase water into the dispersed phase and the two-phase droplets break-up.
The calculated results showed good agreement with the experimental values. This paper
studies the heat transfer in a parallel flow exchanger and discusses the effects of some
operational parameters on the volumetric heat transfer coefficient. Some expressions take
account of the possible coalescence and break-up of the droplets. The expressions may
improve our insight into the dependencies of the total heat transfer performance of
29
exchangers on individual operational parameters and, indirectly, on the exchanger design.

The exchanger is made of plexiglass with an inside diameter of 90mm and a length of
2000 mm. On both sides of the exchanger there are 20 holes with a diameter of 8mm each
and which are used for measuring the temperature and pressure. n-Pentane is used as the
dispersed fluid. It is injected into the exchanger from a distributor located at the bottom
of the exchanger. Hot water is supplied to the exchanger from the bottom when it is
heated to the given temperature in the heater. The water flow rate is measured by using a
rotameter. A volumetric heat transfer coefficient was achieved in between the range of
20-120 KW m 3 K 1 for variation in column elevations (0-2m) at different flow rates of
dispersed & continuous phase.
Pierce et.al (1959) studied heat transfer and fluid dynamics in mercury-water
spray columns. Heat transfer and fluid dynamics were studied in columns in which hot
mercury was sprayed into a rising stream of water. Volumetric and area heat transfer
coefficients are presented which were found to be lower than those reported for heat
transfer from fixed spheres. It was observed that considerable water bypassed the stream
of drops, while some surrounding the drops flowed downward. This behavior resulted in
water temperatures at the base of the column which were considerably higher than the
inlet water temperatures. Consequently the outlet mercury temperature did not approach
the inlet water temperature as a limit. The very unconventional flow pattern of the water
was unexpected and is believed to be an important factor in spray-column heat transfer
and mass transfer kinetics. Six different columns were used, but the same steel end
assemblies were used with each. The columns were fabricated from 1- and 2-in. I.D.
Pyrex pipe. The enlarged ends of the columns were 6 in. I.D. to accommodate the end
30
assemblies. Measurements of temperatures, mercury flow rate, water flow rate, drop
sizes, drop velocities, water phase movements were measured & varied during the
experiment. The volumetric heat transfer coefficient observed in between the range of
19.3*103 B.T.U/hr-cubic ft-0F to 48.3*103 B.T.U/hr-cubic ft-0F for a column of 1 inch
diameter, 13.25 inch length where water flow rate were maintained at 54.8 to 109.8
gal/min-sq ft & mercury flow rate were maintained at 2000 to 5000 lb/min-sq ft.
Hanna et.al presented investigation deals with experimental and theoretical
phenomenological study of three phase direct-contact heat exchanger, for n-pentane
water system. The test section consisted of a cylindrical perspex column 17.2cm I.D. and
1m long, in which, distilled water, was to be confined. Liquid n-pentane drops were
injected into the hot water filled column, through a special design of two distributors. A
study of speed and high resolution camera films taken during the heat transfer process
rendered information regarding the bubble shape, bubble size, and evaporation rates of npentane drops evaporating in hot water. The study was devoted to express the effect of
process variables on heat transfer coefficient, and volumetric heat transfer coefficient and
effectiveness. From this parametric analysis of this countercurrent column it was found
that The volumetric heat transfer coefficient values fall with an increase in the inlet
temperature of water. Small-diameter nozzles associated with faster nozzle velocities, and
smaller droplets, yield higher volumetric heat transfer coefficient, and larger heat transfer
coefficients gave higher values of volumetric heat transfer coefficient .It was found that
volumetric heat transfer coefficient varied in between 0.5 KW/m3 0C to 4 KW/m3 0C for
the water flow rate 5 cm3/s to 55 cm3/s and n-pentane flow rate 0.8 cm3/s to 2 cm3/s.
31
Mahood & Sharif et. Al (2013) developed a model for temperature distribution of
a spray column, three-phase direct contact heat exchanger. This study is for the relative
velocity and the drag coefficient of the evaporation swarm of drops in an immiscible
liquid, using a convective heat transfer coefficient of those drops. They assume a constant
holdup ratio (range 0.14 to 0.165) along the direct contact column. From this study it is
been evaluated that the variation of dispersed and continuous phase temperatures and the
spray column height at different initial phases temperatures and flow rates, with an initial
drop radius equal to 2mm and 1.6mm. At the phases entrance, at the fist zone where the
temperature difference is at its maximum between the phases. In this region a high
increase in dispersed temperature occurs, while nearly a constant temperature in the
continuous phase. This zone covers a very short length of the column (about 1m), and it
seems independent of the operational column parameters. In the second zone, a slow heat
exchange occurs between the phases and this region cover a wide range of the column
height. At the final zone the temperature difference decreases to minimum. The results
have shown that the rate of heat transfer increases with decreasing drops size. And the
heat exchange is influenced by the vaporization ratio.
Letan & Kehat(1968) studied the mechanism of heat transfer in a Spray Column
Heat Exchanger. Temperature profiles of water in a Spray Column Heat Exchanger 15cm
in diameter and 150cm long operating with a dense packing of kerosene drops were
measured. The range of superficial velocities was 0 to 0.8 cm/s for water and 0.5 to 1.7
cm/s of kerosene. The bottom of the dense packing was either slightly above or 15 cm
below the bottom of the column proper. The mathematical equations for dispersed
packing of drops were modified to take into the account of the reduction of wake size at
32
the interface of the two packings and the difference in the mixing patterns at the top of
the column.This operation was controlled by the fluid mechanics of the system and not
by the resistance to heat transfer inside or at the surface of the drops. The thermal
performance of the small diameter column was reduced significantly by the effect of
bypassing and was also reduced if the bottom of the dense packing of drops was
maintained within the conical bottom entry section.
Sathiyan (2011) et.al studied heat transfer for water-diesel two-phase system in a
Spiral Heat Exchanger. In this study, the main objective was to evolve a correlation to
predict liquid-liquid two-phase heat transfer coefficients in a spiral plate heat exchanger.
Experimental studies were conducted in a spiral plate heat exchanger using the liquidliquid two-phase system of water-diesel in different volume fractions and flow rates as
the cold fluid. Experiments were conducted by varying the volumetric flow rate and
temperature, keeping the volumetric flow rate of hot fluid constant. The two-phase heat
transfer coefficients were correlated with Reynolds number, Prandtl number and volume
fraction in the form Nu = a (Re) b (Pr) c () d. The data obtained from fresh experiments
were compared with the predictions of the obtained correlation. The predicted
coefficients showed a spread of 12 % in the laminar range, indicating the potential use
for practical applications. For 40% water + 60% diesel mixture it was found that the
overall heat transfer coefficient varied in the range of 162.22 - 766.06 W/m2 K.
Zabulok et.al studied experimental investigation of direct contact heat transfer in
Isopentane-water system. The test section consisted of a cylindrical perspex column, in
which distilled water was to be confined. Liquid isopentane drops were injected into the
hot water filled column through special distributors located at the bottom of the column.
33
Various operating and design parameters were investigated and their effects on the
overall performance of the heat transfer process were deduced. The experimental runs
were planned using the central composite rotatable design method. It has been found that
the volumetric heat transfer coefficient values fall with an increase in the inlet
temperature of water, also small-diameter nozzles associated with faster nozzle velocities,
and smaller droplets, yield higher volumetric heat transfer coefficient. In addition, isopentane was found to yield a slightly higher volumetric heat transfer coefficient
compared with n pentane. The inlet water temperature was maintained in between 300C
to 380C & the volumetric flow rate of water & Iso pentane was maintained in between
9.8-49 cm3/s and 0.96 to 1.92 cm3/s, respectively. The volumetric heat transfer coefficient
varies in the range between 3-7 KW/m3 0C.
Ming Yeh (2010) performed an analysis of heat transfer in the heat exchangers of
cocurrent and countercurrent flows with external recycle. It has been carried out by heattransfer theory. Considerable improvement is achievable by recycle operation if the
increase in heat-transfer coefficient by applying the recycle effect to enhance the fluid
velocity can compensate for the decrease in the driving force (temperature difference) of
heat transfer due to the remixing of inlet fluid. As expected, the heat-transfer rate
obtained in the countercurrent-flow heat exchangers with or without recycle is superior to
those in the cocurrent-flow devices. However, the space for the improvement in
performance by recycle in the countercurrent-flow device is smaller than that in the
cocurrent-flow one.
34
Terasaka and Tsuge (Terasaka & Tsuge, 1993) studied the bubble volumes and
shapes formed from a constant-flow nozzle submerged in a liquid. They photographed
the bubble shapes during bubble formation with a high-speed video camera, using
different liquids in N2 gas such as tap water and 68 Wt % glycerol.
Sideman et al. (1965) investigated the spray column with fixed dispersed phase
flow rates and different diameters of orifices using the n-pentane / sea water system. The
results show that the smaller the droplets, the smaller the optimal volume, and the larger
the volumetric heat transfer coefficient.
Sideman and Gat. (1966) measured the volumetric heat transfer coefficient and
column heights required to vaporize pentane in water. Volumetric heat transfer
coefficients were in the range of 8,000 to 20,000 kJ/m hr. C, and the results show that the
coefficients decrease with increasing driving force.
Brickman and Boehm (1994) studied the liquid-liquid direct-contact heat
exchangers for the purpose of finding the design that brings the temperature difference
between the two fluids to as a small value as possible, using oil-water system. They
confirmed that a longer column and smaller droplet size yield an increase in
effectiveness.
Shahidi & Ozbelge et. Al (1995) investigated direct contact heat transfer between
water and a heat transfer oil under non-boiling conditions in co-current turbulent flow
through a horizontal concentric annulus. The ratio of the inner pipe diameter to the outer
pipe diameter (aspect ratio) K = 0.730-0.816; total liquid velocity (mixture velocity)
0.42 1.1 m/s; inlet oil temperature
mixture
= 38 94C; oil volume fraction in the flowing
= 0.25 0.75 were varied and their effects on the overall volumetric heat
35
transfer coefficient
were determined at constant interfacial tension of 48 dynes/cm. It
was found that, in each concentric pipe set, the overall volumetric heat transfer
coefficient increased with increasing dispersed phase volume fraction at each constant
mixture velocity and reached a maximum at around
0.5. The maximum U v
values increased with increasing total liquid velocity and decreasing aspect ratio of the
annulus. The volumetric heat transfer coefficient was also found to increase with
increasing inlet oil temperature and increasing total liquid velocity but to decrease with
length along the test section keeping all other parameters constant. Empirical expressions
for the volumetric heat transfer coefficient were obtained within the ranges of the
experimental parameters.
Mori (1991) studied the evaporation of drops of a volatile liquid sprayed upward
in an immiscible liquid flowing down in a vertical column, and derived an expression for
the volumetric heat transfer coefficient in a counter flow spray column. The expression of
the volumetric heat transfer coefficient was used to predict its values under some
particular column operating conditions, which were then compared with relevant
experimental data found in the literature.
Rasheed (1999) studied the direct-contact evaporation of a drop moving in a
stagnant column of an immiscible liquids, using n-pentane-water, 2-methyl pentanewater, and n-pentane/2-methyl pentane-water systems. A theoretical analysis of
evaporating droplets in an immiscible liquid was developed by solving the governing
equations of the motion and heat transfer numerically by Runge-Kutta method, assuming
a spherical drop in a column of stagnant immiscible liquid at uniform temperature.
36
Chapter 3
Aim & objectives
37
It reveals from the literature survey that Direct Contact Heat Exchangers (such as
Spray Column, Mechanically agitated Column, Packed Column etc.) between two
immiscible fluids have shown many advantages because of higher effective heat transfer
coefficients, a relatively simple design that provides cost effective performance and
absence of surface scaling.
Ming Yeh (2010) in his study reported that heat-transfer rates obtained in the
countercurrent-flow heat exchangers with or without recycle, are superior to those in the
cocurrent-flow device, the space for the improvement by recycle in the countercurrentflow device is also smaller than that in the cocurrent-flow one. This fact will be more
obvious when the devices are operated under higher temperature difference and/or low
flow rate and/or smaller reflux ratio
With respect to liquid/liquid countercurrent studies in these devices, Letan and
Kehat (1967) gave a theoretical model in which heat transfer in a spray column is
controlled by the fluid dynamics of the system, and not by the resistance to heat transfer
inside or at the surface of the drops. Siqueiros & Bonilla(1999) did an experimental study
of heat transfer in a countercurrent Spray Column. The experimental study resulted in
enhancement of heat transfer coefficient, thermal efficiency etc. The volumetric heat
transfer coefficient found to be in the range of 4.5-8 KW m 1 K 1 . Again from the heat
transfer study in between mercurywater in a counter-current spray column done by
Pierce et.al (1959) desirable heat transfer effects were found. Mercury flow rate, water
flow rate, drop sizes, drop velocities, water phase movements were measured & varied
during the experiment. The volumetric heat transfer coefficient observed in between the
range of 19.3x103 B.T.U/hr-cubic ft-0F to 48.3x103 B.T.U/hr-cubic ft-0F for a column of 1
38
inch diameter, 13.25 inch length where water flow rate were maintained at 54.8 to 109.8
gal/min-sq ft & mercury flow rate were maintained at 2000 to 5000 lb/min-sq ft.
Extremely rapid heat transfer was experienced between the dispersed phases in the
mercury-water columns. The major heat transfer resistance was within the bulk of the
water phase. Heat transfer results did not vary appreciably with minor change in column
design nor between 1 and 2 inch diameter columns, but the column efficiencies decreased
markedly with increased column length. This study has illustrated that flow patterns can
greatly limit the efficiency of liquid-liquid spray columns.
Because of the disadvantages reported in cross flow heat exchanger as stated above and the
positive aspects of counter flow Spray Column reported by Pierce et al. ( 1959 ), project aims
liquid to liquid heat transfer in a counter flow Spray Column. By the application of this
contactor, the performance is expected to enhance the heat transfer coefficient with reduced
heat loss. Therefore a project aimed to study heat transfer performance of spray column with
water-kerosene system.
The objectives of the proposed project include:

1. To determine the heat transfer coefficient in a counter flow Spray Column.
2. To study the effect of water & kerosene flow rate on heat transfer characteristics
& thermal efficiency.
3. To reduce the heat loss.
39
Chapter 4
ExpErimEntal sEction
40
4.1 Experimental set up

A schematic diagram of apparatus is given in Fig 4.2. It consists of a stainless
steel oil tank, a spray column, oil & water pump, a stainless steel water bath equipped
with a 400V electrical heater, an electrical stirrer & a thermocouple connected to the
digital temperature controller to keep the inlet water temperature constant at the desired
value.
The heat transfer section is a vertical column made up of stainless steel and has a
provision to change its height. A stationary distributor of 76 mm diameter, located at the
bottom of column, consisting of number of 1 mm diameter holes on its surface was used
to spray kerosene around the heat transfer zone. The casing on which the unit along with
the distributor is installed was cylindrical in shape, with a diameter of 80 mm and axial
length of 120 cm. For another column this height was 95 cm.
A magnetic pump is used to feed warm water from a storage tank of capacity
around 100 liters, maintained at a constant temperature to the heat transfer unit. Kerosene
is sprayed against the vertically down flowing hot water, in the cylindrical column and
flow vertically upward. There is a by pass system in the storage tank to maintain uniform
temperature of the water bath, also there are two stirrers in the water tank to maintain
constant mixing. Kerosene used for cooling the warm water was fed to the column, by a
pump, in the reverse direction of gravity or in the upward direction. One control valve is
provided at the water outlet for maintaining the water level in the column. The spray
column provides a counter-flow contact of kerosene and warm water.
41
The water and kerosene flow rates were measured by previously calibrated
rotameter of capacity 0.1-1 LPM and 0.2-2 LPM respectively. The temperature of the
water entering and leaving the column was measured by thermocouple connected to a
digital display. Also, the entering and exit kerosene temperature was measured by
thermocouple connected to the digital display. Flow rates of liquids were controlled by
the valves on the bypass line of the pumps and adjusting the indivisual rotameters.
To reduce the heat loss the total heat transfer unit was covered with two layers of nylon
rope .
4.2 Experimental Procedure

Distilled water was heated in a constant temperature bath with the temperature
fixed at 55 C. After the temperature reaches to 55 C, the stirrers along with the
recirculation in the bath was switched on to maintain complete mixing and uniform
temperature of the water bath. In the mean time the water pump was switched on with the
water flow rate fixed at the desired value, made to pass through the column for 5-7 min
so that a steady state is attained. The water flow rates used are 0.2, 0.3, 0.4, 0.5 LPM. The
water level was fixed in the column by adjusting the control valve at the water outlet.
The kerosene flow rate is switched on now and the desired flow rate is maintained by the
rotameter. The kerosene flow rates used are 0.2, 0.3, 0.4, 0.5 LPM. The hot water flows
downward & kerosene was sprayed at the bottom & flows in the upward direction.
Now keeping the water flow rate, kerosene flow rate fixed it is allowed to reach a
steady state. Subsequently after reaching the steady state in 7 to 8 minutes, few sets of
reading for inlet water temperature, outlet water temperature, inlet kerosene temperature,
outlet kerosene temperature, was noted down at a regular interval of 4 minutes for 20 to
42
24 minutes and the most steady state of the readings is reported among those noted. Also
the actual water & kerosene outlet flow rate were noted. Then the water bath temperature
was increased to 64 0C and the above procedure was repeated with the same kerosene and
water flow rate.
The whole experimental procedure was performed by varying the height of the
column from 80 cm to 105 cm. Each set of run last for about approximately 40 min. After
each set of run the machine was given rest for around 1 hr. In the entire set of run for the
two sets of height the kerosene inlet temperature was found to vary from 26.5 C to 32.9
C.
Fig 4.1: Overall Experimental Set Up
43
Fig 4.2: Schematic of Experimental Set Up

A-Water Bath, B-Valve, C-Magnetic Pump, D- Gear Pump, E-Rotameter, FKerosene Bath, G-Spray Column, H-Water Inlet, I-Water Outlet, J-Kerosene
Inlet, K-Kerosene Outlet, L- Stirrer, M-Heating Coil
44
Chapter 5
Results & Discussion
45
As stated earlier, this heat transfer study was performed for two column heights in
counter flow mode between two liquid phases i.e. water and kerosene.
Value/Range of Operating Parameters in the study
qw=0.2LPM-0.5LPM ,
qk =0.2LPM-0.5LPM
Water bath Temperature- 550C -650 C
H=95cm-120cm, d= 8cm, t=2mm
w = 988.1 Kg/m3 at 550C, 983.2 Kg/m3 at 640C
k = 800 Kg/m3
C pw= 4.1806 KJ/ Kg-K at 550C, 4.1843 KJ/Kg-K at 640C
C kw= 2.01 KJ/ Kg-K
5.1 Study of Heat Loss in counter-flow Spray Column
Preliminary experimentation for calculation of heat loss in the equipment was conducted
in the beginning so as to consider it during the calculations of heat transfer coefficient for
accuracy purpose. The data for heat loss in Spray Column in Watt is as given below
Table1: Heat loss at Water Bath Temperature-55 0C & Column Height- 105 cm
Water Flow Rate (LPM)
0.2
0.3
0.4
0.5
0.2
19.12
16.47
10.10
19.62
0.3
10.76
5.88
8.74
16.21
0.4
6.33
14.29
17.75
5.58
0.5
15
18.4
11.58
4.98
Kerosene Flow Rate (LPM)
46
Table2: Heat Loss at Water Bath Temperature- 64 0C & Column Height- 105 cm
Water Flow
Rate (LPM)
0.2
0.3
0.4
0.5
0.2
20.87
21.71
26.05
26.33
0.3
2.30
18.53
24.94
16.6
0.4
1.4
14.1
22.8
16.96
0.5
2.61
17.93
8.76
8.67
Kerosene Flow
Rate(LPM)
Table3: Heat Loss at Water Bath Temperature- 55 0C & Column Height- 80 cm

Water Flow
Rate (LPM)
0.2
0.3
0.4
0.5
0.2
14.14
2.34
25.72
0.62
0.3
0.74
6.96
2.49
0.63
0.4
22.20
25.10
10.81
7.99
0.5
29.22
23.86
14.70
5.71
Kerosene Flow
Rate (LPM)
47
Table4: Heat loss at Water Bath Temperature- 64 0C & Column Height- 80 cm

Water Flow
Rate (LPM)
0.2
0.3
0.4
0.5
0.2
26.98
4.37
1.60
0.98
0.3
49.38
29.45
4.28
23.25
0.4
33.98
27.46
28.44
14.17
0.5
12.48
29.45
5.89
0.94
Kerosene Flow
Rate (LPM)
It can be seen a certain amount of heat loss in each of the cases does exists. So,
the heat loss term, being considerable, was added in heat transfer coefficient calculations
for the sake of accuracy in the governing equation.The amount of kerosene coming out
from water outlet is negligible. 1 L of kerosene content in a 50 L of water bucket was
measured.
From the above experimental data thermal efficiency & overall heat transfer coefficient
of the column were determined.
48
5.2 Calculation of Thermal Efficiency

Thermal efficiency for both height of the column & varying water bath
temperature were determined. The simultaneous heat transfer of the spray Column was
presented in terms of thermal efficiency defined as
= Actual heat transfer/ Maximum possible heat transfer

=
T
T
WI
T WO
WI
T KI
The effectiveness lies in between 0 to 1.
5.3 Calculation of Heat Transfer Coefficient

To calculate the overall heat transfer co-efficient (h) a model equation is
developed and represented as
.
dT
A Q
mw c pw dxw ha (Two Tko ) l l
49
5.4 Effect of Water flow rate on h
&
Fig 5.1 and Fig 5.2 illustrates the variation of thermal efficiency with water flow
rate, at kerosene flow rates of 0.2, 0.3, 0.4 & 0.5 LPM for water bath temperature 55 0C
& 640 C respectively and the column height of 105 cm. It can be seen that the thermal
efficiency increased as the water flow rate decreased & increased with increase in the
kerosene flow rates. For example, at a constant kerosene flow rate of 0.2 LPM, the
thermal efficiency for the column decreased from 0.21 to 0.10 with an increase in water
flow rate from 0.2 LPM to 0.5 LPM for water bath temperature 55 0C, whereas in case of
constant water flow rate of 0.2 LPM thermal efficiency increases from 0.21 to 0.43 with
an increase in kerosene flow rate from 0.2 LPM to 0.5 LPM for water bath temperature
64 0C.
Fig 5.3 and Fig 5.4 plots the variation of thermal efficiency with water flow rate
for kerosene flow rates of 0.2, 0.3, 0.4 & 0.5 LPM, water bath temperature 550C & 640C
and the column height 80 cm. It was found that the thermal efficiency decreased as the
water flow rate increased & increased with increase in the kerosene flow rates which are
quite clear from the plots. For example, at a constant kerosene flow rate of 0.2 LPM, the
thermal efficiency for the column decreased from 0.21 to 0.11 with an increase in water
flow rate from 0.2 LPM to 0.5 LPM for water bath temperature 55 0C. Where as in case
of constant water flow rate of 0.2 LPM thermal efficiency increases from 0.22 to 0.39
with an increase in kerosene flow rate from 0.2 LPM to 0.5 LPM for water bath
temperature of 64 0C.
50
T h erm al E fficien c y
0.5
0.45
0.4
0.35
0.3
Qk=0.2LPM
Qk=0.3LPM
0.25
0.2
0.15
0.1
Qk=0.4LPM
Qk=0.5LPM
0.05
0
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
Qw(LPM)
Fig 5.1: Effect of water flow rate on thermal efficiency at water bath
temperature 55 0C & Column Height 105 cm
0.45
0.4
T h erm al E fficien cy
0.35
0.3
Qk=0.2LPM
0.25
Qk=0.3LPM
0.2
Qk=0.4LPM
0.15
Qk=0.5LPM
0.1
0.05
0
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
Qw(LPM)
51
0.45
T h e rm a l E ffi c i e n c y
0.4
0.35
0.3
Qk=0.2LPM
0.25
Qk=0.3LPM
0.2
Qk=0.4LPM
0.15
Qk=0.5LPM
0.1
0.05
0
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
Qw(LPM)
0.45
T herm al E fficiency
0.4
0.35
0.3
Qk=0.2LPM
0.25
Qk=0.3LPM
0.2
Qk=0.4LPM
0.15
Qk=0.5LPM
0.1
0.05
0
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
Qw(LPM)
52
Fig 5.5 and Fig 5.6 depicts the variation of heat transfer coefficient with water
flow rate for kerosene flow rates of 0.2, 0.3, 0.4 & 0.5 LPM, water bath temperature 550C
& 640 C and the column height of 105 cm. It was found that the heat transfer coefficient
increased as the water flow rate increased & decreased with increase in the kerosene
flow. For example, at a constant kerosene flow rate of 0.2 LPM, the heat transfer
coefficient for the column increased from 360 to 730 W/m2 K with an increase in water
flow rate from 0.2 LPM to 0.5 LPM for water bath temperature 55 0C. Where as in case
of constant water flow rate of 0.2 LPM heat transfer coefficient decreases from 442 to
232 W/m2 K with an increase in kerosene flow rate from 0.2 LPM to 0.5 LPM for water
bath temperature 64 0C.
Fig 5.7 and Fig 5.8 plots the variation of heat transfer coefficient with water flow
rate, at kerosene flow rates of 0.2, 0.3, 0.4 & 0.5 LPM for water bath temperature 550C &
640 C respectively and the column height is 80 cm. It can be seen from figures that the
heat transfer coefficient
increased as the water flow rate increased & decreased with
increase in the kerosene flow rates. For example, at a constant kerosene flow rate of 0.2
LPM, the heat transfer coefficient for the column increased from 465 to 775 W/m2 K with
an increase in water flow rate from 0.2 LPM to 0.5 LPM for water bath temperature
550C. Whereas in case of constant water flow rate of 0.2 LPM, heat transfer coefficient
decreases from 478 to 295 W/m2 K with an increase in kerosene flow rate from 0.2 LPM
to 0.5 LPM for constant water bath temperature of 640C.
53
K)
H eat T ran sfe r C o e fficie n t(W /m
800
700
600
Qk=0.2LPM
500
Qk=0.3LPM
400
Qk=0.4LPM
300
Qk=0.5LPM
200
100
0
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
Qw(LPM)
Fig 5.5: Effect of water flow rate on heat transfer coefficient at water bath
H eat T ran sfer C o efficien t(W /m
K)
temperature 550C & column height 105cm
900
800
700
600
Qk=0.2LPM
500
Qk=0.3LPM
400
Qk=0.4LPM
300
Qk=0.5LPM
200
100
0
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
Qw(LPM)
54
K)
Heat T ransfer Co efficien t(W /m
900
800
700
600
Qk=0.2LPM
500
Qk=0.3LPM
400
Qk=0.4LPM
300
Qk=0.5LPM
200
100
0
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
Qw(LPM)
1000
H e a t T r a n s fe r C o e ffi c i e n t(W /m
K)
900
800
700
600
Qk=0.2LPM
Qk=0.3LPM
500
Qk=0.4LPM
400
300
Qk=0.5LPM
200
100
0
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
Qw(LPM)
55
5.5 Effect of variation in Water Inlet Temperature on
h&
Fig 5.9 & 5.10 shows the variation of thermal efficiency with change in the water
inlet temperature at constant water flow rate and kerosene flow rates which are
maintained in between the range of 0.2 to 0.5 LPM for column height of 105 cm & 80 cm
respectively . Water bath temperature was maintained at 550C & 640C. It was found that
there is not much variation in thermal efficiency with change in temperature. It remains
almost same. In some cases thermal efficiency decreased as the water bath temperature
increased. For example, at a constant kerosene flow rate of 0.3 LPM and 0.2 LPM water
flow rate, the thermal efficiency for the column at 550C is 0.27 decreased to 0.25 at 640C
for the column height 105 cm.
Fig 5.11 & 5.12 plots the variation of heat transfer coefficient with water flow
rate, at kerosene flow rates of 0.2, 0.3, 0.4 & 0.5 LPM for water bath temperature 550C
& 640C for the column height is 105 cm & 80cm respectively . It was found that the heat
transfer coefficient increased as the water bath temperature increased which is revealed
by the plots. For example, at a constant kerosene flow rate of 0.2 LPM & 0.2LPM water
flow rate, the heat transfer coefficient for the column at 550C is 360W/m2 K increased to
408 W/m2 K at 640C for 105 cm column height.
56
T herm al E fficiency
0.5
0.45
Qk=0.2LPM, Temp=55C
0.4
0.35
Qk=0.3LPM, Temp=55C
Qk=0.4LPM, Temp=55C
0.3
0.25
0.2
Qk=0.5LPM, Temp=55C
Qk=0.2LPM, Temp=64C
Qk=0.3LPM,Temp=64C
0.15
0.1
Qk=0.4LPM,Temp=64C
Qk=0.5LPM,Temp=64C
0.05
0
0
0.2
0.4
0.6
0.8
Qw(LPM)
Fig 5.9: Effect on thermal efficiency with change in water bath temperature at
a height 105cm
T h e rm al E fficien cy
0.45
0.4
Qk=0.2LPM,Temp=55C
0.35
Qk=0.3LPM, Temp=55C
0.3
Qk=0.4LPM, Temp=55C
0.25
Qk=0.5LPM, Temp=55C
0.2
Qk=0.2LPM, Temp=64C
0.15
Qk=0.3LPM, Temp=64C
0.1
Qk=0.4LPM, Temp=64C
0.05
Qk=0.5LPM, Temp=64C
0
0
0.2
0.4
0.6
0.8
Qw(LPM)
Fig 5.10: Effect on thermal efficiency with change in water bath temperature at
a height 80cm
57
K)
H e a t T r a n s fe r C o e ffi c i e n t(W / m
900
800
Qk=0.2LPM, Temp=55C
700
Qk=0.3LPM, Temp=55C
600
Qk=0.4LPM, Temp=55C
500
Qk=0.5LPM, Temp=55C
400
Qk=0.2LPM, Temp=64C
300
Qk=0.3LPM,Temp=64C
200
Qk=0.4LPM,Temp=64C
100
Qk=0.5LPM,Temp=64C
0
0
0.2
0.4
0.6
0.8
Qw(LPM)
Fig 5.11: Effect on heat transfer coefficient with change in water bath
1000
H eat T ran sfer C o efficien t(W /m
K)
temperature at a height 105cm
900
800
Qk=0.2LPM,Temp=55C
700
600
Qk=0.4LPM, Temp=55C
500
400
Qk=0.2LPM, Temp=64C
Qk=0.3LPM, Temp=55C
Qk=0.5LPM, Temp=55C
Qk=0.3LPM, Temp=64C
300
200
Qk=0.4LPM, Temp=64C
Qk=0.5LPM, Temp=64C
100
0
0
0.2
0.4
0.6
0.8
Qw(LPM)
Fig 5.12: Effect on heat transfer coefficient with change in water bath
temperature at a height 105cm
58
5.5 Effect of Variation in Column Height

Fig 5.13 & 5.14 present the variation of thermal efficiency with water flow rate, at
kerosene flow rates of 0.2, 0.3, 0.4 & 0.5 LPM for column height 105 cm & 8 0cm for
water bath temperature 550C & 640C respectively. It was found that the thermal
efficiency
increased as the column height decreased. For example, at a constant
kerosene flow rate of 0.2 LPM & 0.4 LPM water flow rate, the thermal efficiency for the
column height 105 cm at 550C is 0.10 increased to 0.12 at 550C for the 80 cm height. But
in most of the cases thermal efficiency does not vary too much with column height.
Fig 5.15 & 5.16 plots the variation of heat transfer coefficient with water flow
rate, at kerosene flow rates of 0.2, 0.3, 0.4 & 0.5 LPM for column height 105 cm & 80
cm for water bath temperature 550C & 640C respectively. It was found that the overall
heat transfer coefficient increased as the column height decreased. For example, at a
constant kerosene flow rate of 0.3LPM & 0.3LPM water flow rate, the heat transfer
coefficient for the column height 105 cm at 550C is 403 W/m2 K increased to 440 W/m2 K
at 550C for the 80 cm height.
59
T h e rm a l E ffi c ie n c y
0.5
0.45
0.4
Qk=0.2LPM,H=105cm
0.35
0.3
Qk=0.4LPM,H=105cm
Qk=0.3LPM,H=105cm
Qk=0.5LPM,H=105cm
0.25
Qk=0.2LPM,H=80cm
0.2
0.15
Qk=0.3LPM,H=80cm
Qk=0.4LPM,H=80cm
0.1
0.05
Qk=0.5LPM,H=80cm
0
0
0.2
0.4
0.6
0.8
Qw(LPM)
Fig 5.13: Effect on Thermal Efficiency with change in height at a water bath
temperature 550C
0.6
Qk=0.2LPM,H=105cm
Therm al E fficiency
0.5
Qk=0.3LPM,H=105cm
0.4
Qk=0.4LPM,H=105cm
Qk=0.5LPM,H=105cm
0.3
Qk=0.2LPM,H=80cm
Qk=0.3LPM,H=80cm
0.2
Qk=0.4LPM,H=80cm
0.1
Qk=0.5LPM,H=80cm
0
0
0.2
0.4
0.6
0.8
Qw(LPM)
Fig 5.14: Effect on Thermal efficiency with change in height at a water bath
temperature 640C
60
H e a t T ra n s fer C o e ffic ie n t(W /m 2 K )
900
800
Qk=0.2LPM,H=105cm
700
Qk=0.3LPM,H=105cm
600
Qk=0.4LPM,H=105cm
500
Qk=0.5LPM,H=105cm
400
Qk=0.2LPM,H=80cm
300
Qk=0.3LPM,H=80cm
200
Qk=0.4LPM,H=80cm
100
Qk=0.5LPM,H=80cm
0
0
0.2
0.4
0.6
0.8
Qw(LPM)
Fig 5.15: Effect on overall heat transfer coefficient with change in height at a
Heat Transfer Coefficient(W/m2K)
water bath temperature 550C
1000
900
800
Qk=0.2LPM,H=105cm
700
600
Qk=0.4LPM,H=105cm
Qk=0.3LPM,H=105cm
Qk=0.5LPM,H=105cm
500
Qk=0.2LPM,H=80cm
400
300
Qk=0.3LPM,H=80cm
Qk=0.4LPM,H=80cm
200
100
Qk=0.5LPM,H=80cm
0
0
0.2
0.4
0.6
0.8
Qw(LPM)
Fig 5.16: Effect on overall heat transfer coefficient with change in height at a
water bath temperature 640C
61
5.6 Effect of Phase Ratio

Fig 5.17 & 5.18 shows the variation of heat transfer coefficient with variation in
kerosene-water phase ratio for column height
105 cm & 80 cm and water bath
temperature 550C & 640C respectively at different water flow rates. It was found that the
thermal efficiency increased as the phase ratio increased which means that increase in the
kerosene mass flow rate is a result of increasing thermal efficiency.
Fig 5.19 & 5.20 indicates the variation of heat transfer coefficient with variation
in kerosene-water phase ratio for column height 105 cm & 80 cm varying water bath
temperature 550C & 640C respectively at different water flow rate. It was found that the
overall heat transfer coefficient decreased as the phase ratio increased.
Fig 5.21 & 5.22 shows change in kerosene outlet temperatures with the change in
phase ratio for two different column heights varying the water bath temperature. It was
found that with increasing phase ratio the kerosene outlet temperature marginally varied.
But with increasing water inlet temperature it markedly changed.
62
Therm al Efficiency
0.5
0.45
0.4
0.35
0.3
Temp=55C
0.25
0.2
Temp=64C
0.15
0.1
0.05
0
0
0.2
0.4
0.6
0.8
1.2
1.4
Phase Ratio
Fig 5.17: Effect on Thermal Efficiency with change in phase ratio at a Column
Height 105cm
0.45
Therm al Efficiency
0.4
0.35
0.3
0.25
Temp=55C
0.2
Temp=64C
0.15
0.1
0.05
0
0
0.2
0.4
0.6
0.8
1.2
1.4
Phase Ratio
Fig 5.18: Effect on Thermal Efficiency with change in phase ratio at a Column
Height 80cm
63
K)
2
Heat Transfer Coefficient(W /m
900
800
700
600
500
Temp=55C
400
Temp=64C
300
200
100
0
0
0.2
0.4
0.6
0.8
1.2
1.4
Phase ratio
Fig 5.19: Effect on overall heat transfer coefficient with change in phase ratio
Heat transfer coefficient(W/m 2K)
at a Column Height 105cm
1000
900
800
700
600
Temp=55C
500
400
Temp=64C
300
200
100
0
0
0.2
0.4
0.6
0.8
1.2
1.4
Phase Ratio
Fig 5.20: Effect on overall heat transfer coefficient with change in phase ratio
at a Column Height 80cm
64
70
60
Tko (0C)
50
40
Temp=55 C
30
temp=64C
20
10
0
0
0.2
0.4
0.6
0.8
1.2
1.4
Phase Ratio
Fig 5.21: Effect on Kerosene Outlet temperature with change in phase ratio at
70
60
T ko (0C)
50
40
Temp=55C
30
Temp=64C
20
10
0
0
0.2
0.4
0.6
0.8
1.2
1.4
Phase Ratio
Fig 5.22: Effect on Kerosene Outlet temperature with change in phase ratio at
65
Chapter 6
ConClusion
66
The performance of a Spray Column at two different column heights of 105 cm & 80 cm
were studied for heat transfer in between Kerosene-Water. The heat loss in the counter
flow Spray Column found, were not small enough to be negligible. So, a term consisting
of heat loss was added to the governing equation for the calculation of heat transfer
coefficient. The thermal efficiency of the 80 cm column height varied in the range of 0.78
to 0.96 and found to be higher by maximum of 6 % than that of 105 cm column height.
So, it can be said that variation in column characteristics does not affect thermal
efficiency. The value of overall heat transfer coefficient (h) reported in the range of 200
W/m2 K to 900 W/m2 K. It increased as the water flow rate was varied from 0.2 LPM to
0.5 LPM and decreased with increase in kerosene flow rate to 0.5 LPM. This could be
because as the water working here as a warm liquid so at higher flow rate the amount of
heat flow in the column increases thus providing higher amount of heat to be transferred.
It was also found that h increases markedly with increase in water bath temperature &
decrease in column height.
The volumetric heat transfer coefficient reported in mechanically agitated column at
similar operating conditions varied between 150 W/m2 K to 600 W/m2K. Thus it can be
concluded that due to improved heat transfer coefficient along with less heat loss, counter
flow Spray Column can be used as a replacement of mechanically agitated column.
Further work can be performed by changing the column diameter, increasing or
decreasing the nozzle diameter of the kerosene distributor or by changing the no of holes
or nozzles in the kerosene distributor.
67
Nomenclature
mw= mass flow rate of water
mk= mass flow rate of kerosene
qw = volumetric flow rate of water
qk =volumetric flow rate of kerosene
Cpw= specific heat of water
w = Density of water
k= Density of Kerosene
C kw= Specific heat of Kerosene
dTw= Temperature change in water flow
ha= heat transfer coefficient
Two= Water outlet temperature
Tko= Kerosene outlet temperature
T
T
WI
KI
= Water inlet temperature or inlet temperature of the hot fluid in the column
= Kerosene inlet temperature or inlet temperature of the cold fluid in the column
A= Area of heat transfer

l= Length of the column
d=Diameter of the column
t= Thickness of the column
Q= Amount of heat loss
H= Height of the column
68
REFFERENCES
1.
Ruth Letan, Ephraim Kehat, The Mechanics of a Spray Column, AIChE Journal
13(3) (1967) 443-448.
2.
J. Siqueiros, O. Bonilla, An experimental study of a three-phase, direct-contact

heat exchanger , Applied Thermal Engineering 19 (1999) 477-493.
3.
Zhang Peng , Wang Yiping , Guo Cuili, Wang Kun, Heat transfer in gasliquid
liquid three-phase direct-contact exchanger, Chemical Engineering Journal 84
(2001) 381388.
4.
R. D. PIERCE, O. E. DWYER, and J. J. MARTIN, Heat Transfer & Fluid

Dynamics in a Mercury-Water Spray Column, AIChE Journal 5 (2) (1959) 259267.
5.
Fadi Zakariya Hanna, A.A.Kendoush, M.A.Zablouk, DIRECT-CONTACT HEAT

EXCHANGER WITH PHASE CHANGE: THEORETICAL EXPRESSION FOR
HEAT TRANSFER COEFFICIENT AND VOLUMETRIC HEAT TRANSFER
COEFFICIENT OF A TWO-PHASE BUBBLE, 1-8.
6.
Ho-Ming Yeh, Effect of External Recycle on the Performance in Parallel-Flow

Rectangular Heat-Exchangers, Tamkang Journal of Science and Engineering, 13
(4) (2010) 405-412.
7.
M.K.Shahidi, T.A.Obalge, Direct contact heat transfer between two immiscible

liquids flowing in a horizontal concentric annulus, Int.J.Multiphase flow,21 (6)
(1995) 1025-1036.
8.
S. SATHIYAN, M. Rangarajan, and S. Ramachandran ., Studies of Heat Transfer

for Water-Diesel Two-Phase System , Chem. Biochem. Eng. . 25 (2) (2011) 195
201.
9.
Mori, Y.H. , An analytic model of directcontact heat transfer in spray-column

evaporators, American Institute Chemical Engineering Journal 37(4) (1991) 539546.
10.
Rasheed, F. S.. Ph.D. Thesis, Department of Chemical Engineering University of

Technology, Baghdad(1999).
69
11.
Ruth Letan, Ephraim Kehat, The Mechanism of heat transfer in a Spray Column
Heat Exchanger, AIChE Journal 14(3) (1968) 398-405.
12.
Hameed B. Mahood, Adel O. Sharif, Seyed Ali Hosseini, and Rex B. Thorpe,
Analytical Modelling of a Spray Column Three-Phase Direct Contact Heat
Exchanger, ISRN Chemical Engineering Volume 2013 (2013), Article ID 457805,
9 pages.
13.
S. Sideman and Y. Gat, Direct contact heat transfer with change of phase: spray
column studies of a threephase heat exchanger, AIChE Journal, 12(2), (1966)
296303.
14.
R. A. Brickman and R. F. Boehm, Maximizing three-phase direct-contact heat

exchanger output, Numerical Heat Transfer A, 26(3), (1994), 287299.
15.
Terasaka K. and H. Tsuge ,Bubble formation under constant-flow conditions,

Chemical Engineering Science 48 (1993) 3417-3422.
16.
Introduction to Heat Exchangers.pdf.
70

Liquid-Liquid Heat Transfer in Spray Column

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LIQUID-LIQUID HEAT TRANSFER IN A

Under the Guidance of

in partial fulfillment for the award of the degree of

DEPARTMENT OF CHEMICAL ENGINEERING

Declaration of Originality and Compliance of Academic Ethics

Name: Sudhanya Karmakar

Thesis Title : LIQUID LIQUID HEAT TRANSFER IN A SPRAY COLUMN

FACULTY OF ENGINEERING AND TECHNOLOGY

-------------------------------------------------HOD (Department of Chemical Engineering)

Committee of final examination for evaluation of thesis

1.1 Cooling Tower

1.3 Heat Exchanger

1.3.1 Classification according to

Aim & Objective

4.1 Experimental Setup

4.2 Experimental Procedure

Results & Discussion

5.1 Study of heat loss in counter-flow

5.3 Calculation of heat transfer coeff

5.5 Effect of variation in water inlet

Classification of heat exchangers

Shell and tube heat exchanger

Plate and Frame heat exchanger

Turbulent pipe contact

Typical mechanically agitated towers

Baffle tray column

A possible configuration of a packed bed condenser

Schematics of a Spray Column

Schematic of a sieve tray column

Schematic of a Parallel flow & a Counter Flow Heat Exchanger

Schematic of a Cross Flow Heat Exchanger

Tubular Heat Exchanger

Plate-Type Heat Exchanger

Extended Surface Heat Exchanger

Typical countercurrent-flow spray tower

Crosscurrent-flow spray tower

Overall Experimental Set Up

Schematic of experimental set up

Effect of water flow rate on thermal efficiency at water

bath temperature550C & Column Height 105cm

Effect of water flow rate on thermal efficiency

at water bath temperature 640C & Column Height 105cm

Effect of water flow rate on thermal efficiency

at water bath temperature550C & Column Height 80cm

Effect of water flow rate on thermal efficiency

at water bath temperature640C & Column Height 80cm

Effect of water flow rate on heat transfer coefficient

Effect of water flow rate on heat transfer coefficient

at water bath temperature 640C & column height 105cm

Effect of water flow rate on heat transfer coefficient

at water bath temperature 550C & column height 80cm

Effect of water flow rate on heat transfer coefficient

at water bath temperature 640C & column height 80cm

Effect on thermal efficiency with change in water

bath temperature at a height 105cm

Effect on thermal efficiency with change in water

bath temperature at a height 80cm

Effect on heat transfer coefficient with change in water

bath temperature at a height 105cm

Effect on heat transfer coefficient with change in water

bath temperature at a height 80cm

Effect on thermal efficiency with change in column height

at a water bath temperature 550C

Effect on thermal efficiency with change in column height