Process Heat Group

Process Heat Group
Major Challenges
Lecture 2
22.033/22.33 Nuclear Engineering Design Project
September 14, 2011
MIT Dept. of Nuclear Science and Engineering

22.033/22.33 Nuclear Design Course
Dr. Michael P. Short, 2011

Page 1
The Three Challenge Problems
Heat exchanger (Hx) design

Heat transport
Heat storage (if necessary)


Page 2
First, Some Nomenclature
Sensible heating temperature change

.
Q = mcp T
Latent heating phase change
.
Q = m hfg
Bond energy storage enthalpy of chemical
reactions


Page 3
Where Do We Find Them?
Courtesy of the Generation IV International Forum. Used with permission.
Source: http://www.gen-4.org/Technology/systems/gfr.htm


Page 4
Heat Exchangers Fundamental

Parameters
Hx effectiveness ()
Measures how
much heat is
transferred
compared to how
much is possible
=1 is ideal, but
practically
Source: Dean Bartlett. The Fundamentals of Heat
impossible (big Hx)
Exchangers The Industrial Physicist, AIP, p. 20 (1996)
American Institute of Physics. All rights reserved. This content is excluded from our
Creative Commons license. For more information, see http://ocw.mit.edu/fairuse.


Page 5

Parameters
Diagram of heat exchanger removed due to copyright restrictions. See lecture video for details.
***Source: Ramesh K. Shah, Dusan P. Sekulic. Fundamentals of Heat Exchanger Design. John Wiley &
Sons, Inc. p. 102 (2003).


Page 6

Parameters
Q = UAFTlm
Q = Heat transfer rate (W)
U = Thermal conductance (W/m2K)
A = Heat transfer area (m2)
Tlm = Log mean temperature difference (K)
F = Factor (for flow configuration)


Page 7
Heat Exchangers Log Mean

Temperature Difference (LMTD)
Tlm =
( TH
TC )
TH
ln
TC
LMTD is a good measure of the effectiveness of simlar heat
exchangers of different designs
Often, LMTD (counter flow) > LMTD (parallel flow)


Page 8
Heat Exchangers Finding Key

Parameters
Figure 1 A big,
complicated heat
exchanger chart
Source: Wolverine Tube Heat Transfer

Data Book, p. 93 (2001), accessed at
http://www.wlv.com/products/databook
/ch2_5.pdf
Courtesy of Wolverine Tube, Inc. Used with permission.


Page 9

Parameters
For all flow configurations
Hx is balanced when C* = 1
NTU = Number of Transfer Units
John Wiley & Sons, Inc. All rights reserved. This content is excluded from our Creative
Commons license. For more information, see http://ocw.mit.edu/fairuse.
***Source: Ramesh K. Shah, Dusan P. Sekulic. Fundamentals of Heat Exchanger Design. John Wiley &
Sons, Inc. p. 116, 118-119 (2003).


Page 10
Hx Flow Types
Heat Exchanger Classification by

Flow Arrangement
Multi-pass
Single-pass
Counter-flow
Parallel-flow
Cross-flow
Split-flow
Extended surface
Divided-flow
Shell-and-tube
Plate
Fluid 1 m passes
Crosscounter-flow
Crossparallel-flow
Compound
flow
Parallel
counter-flow
m-shell passes
n-tube passes
Split-flow
Divided-flow
Fluid 2 n passes
Image by MIT OpenCourseWare.
***After Ramesh K. Shah & Dusan P. Sekulic. Fundamentals of Heat Exchanger Design. John Wiley &
Sons, Inc. (2003).


Page 11
Parallel Flow vs. Counterflow
Counter-flow
Temperature
Temperature
Parallel-flow
tpi
tpi
ti
tpo
ti
to
tso
tpo
tso
tsi
to
tsi
See http://www.engineeringtoolbox.com/arithmetic-logarithmic-mean-temperature-d_436.html


Page 12
Hx Flow Configurations
Heat Exchanger Classification by Construction
Plate-type
Tubular
PHE
Gasketed
Spiral
Welded
Plate coil
Extended surface
Printed
circuit
Brazed
Plate-fin
Double-pipe
Shell-and-tube
Cross flow
to tubes
Spiral tube
Regenerative
Tube-fin
Rotary
Fixed-matrix
Pipe coils
Parallel flow
to tubes
Rotating
hoods
Ordinary
separating
wall
Heat-pipe
wall
After Ramesh K. Shah, Dusan P. Sekulic. Fundamentals of Heat Exchanger Design. John Wiley &
Sons, Inc. (2003).


Page 13
Hx Flow Configurations - Tubular
Courtesy of Wikipedia User:H Padleckas. Used with permission.
Courtesy of Harlan Bengtson. Used with permission.
Source: Wikimedia Commons


Page 14
Hx Flow Configurations Plate

Plate (brazed) type
Alfa Biz Limited. All rights reserved. This content is excluded from our Creative
Source: http://www.alfa-biz.com/Gasketed-Plate-Heat-Exchanger.asp

Spiral type
Jooshgostar Equipments Manufacturing Company (JEMCO). All rights

reserved. This content is excluded from our Creative Commons license.
For more information, see http://ocw.mit.edu/fairuse.
Source: http://www.hiwtc.com/photo/products/16/02/14/21470.jpg

Page 15
Hx Heat Transfer Mechanisms
Other design parameters should largely

determine this choice
Heat Exchanger Classification by
Heat Transfer Mechanism
Single-phase convection
on both sides
Single-phase convection
on one side, two-phase
convection on other side
Two-phase convection
on both sides
Combined convection and

radiative heat transfer
After Ramesh K. Shah, Dusan P. Sekulic. Fundamentals of Heat Exchanger Design. John Wiley &
Sons, Inc. (2003).


Page 16
Heat Exchangers - Questions
What type to use?
What working fluids?
What geometry? Flow considerations? Laminar or
turbulent?
Where is the tradeoff between cost & performance?
Materials concerns?
See also: T. Kuppan. Heat exchanger design handbook.
and Som, Introduction To Heat Transfer.

Page 17
Heat Transport
Main problem: Get process heat from the

reactor to the hydrogen & biofuels plants
How? Must consider:
Temperatures
Losses
Flow rates
Flow transients


Page 18
Heat Transport Long Distance
How to model it?

Thermal resistances
FEM
Loop analysis
How to pump it? Forced? Gravity?

Distance from Rx to H2, biofuel plant is one
of the most important parameters

Page 19
Heat Transport - Questions
What are the constraints? (TH-Rx, TC-H2, TC-bio)

How far does the heat have to go?
Where to take the heat from?
How to transport it?
How to model it? What/where are losses?
Should some of it be stored...

Page 20
Heat Storage
Heat storage is a way to balance out load

instabilities (capacitive effect)
Store some heat to run turbines and/or
product factories during transients
Can help avoid or delay plants loaddumping or load-following
Must balance benefits gained vs. heat lost by

storage

Page 21
Heat Storage Electrical Analogy
Source
switch
Load, losses
(transport,
dissipative,
hydraulic)
I
Reactor
Heat storage
system
Power (current)
Courtesy of Prof. Eric C. Toolson. Used with permission.
Image source: http://www.unm.edu/~toolson/rc_circuit.html


Page 22
Heat Storage Technologies
Sensible heat storage

Simply apply hot fluid to a material, reverse
flow when required
Latent heat storage

Uses phase change materials (PCMs)
Dependent on melting point, heat of fusion
Bond energy storage

Dependent on reaction temperature, enthalpy

Page 23
Heat Storage Sensible Heat

Example: Hot gas on alumina fluidized bed
Prof. Reuel Shinnar. All rights reserved. This content is excluded from our Creative
Source: R. Shinnar et al. A novel storage method for

concentrating solar power plants allowing operation at high temperature. DoE Presentation, Boulder, CO (2011).


Page 24
Heat Storage Sensible Heat
Other proposed & demonstrated storage
media: Molten salt, concrete
Thermocline test at Sandia National Laboratories
NREL. All rights reserved. This content is excluded from our Creative
Sandia National Labs. All rights reserved. This content is excluded from our
Concrete TES at U. Stuttgart
See http://www.nrel.gov/csp/troughnet/thermal_energy_storage.html


Page 25
Heat Storage Phase Change

Materials
Source: M. Demirbas.
Thermal Energy Storage
and Phase Change
Materials: An Overview.
Energy Sources, Part B,
1:8595, 2006.
More compact
Layout can be more
complicated
Salts can be corrosive
Graphite foils have
been used to
improve heat
spreading
Taylor and Francis Group, LLC. All rights reserved. This content is excluded from our


Page 26
Heat Storage Bond Energy
Absorb/Release chemical energy by shifting

chemical equilibrium reactions
Change temperature, pressure
Examples: hydration, hydriding,
ammonia/salt reactions
Chemical reaction should be reversible


Page 27
Heat Storage Questions
What temperature(s) is/are required?
What materials to use?
What capacity to use? (kWh, MWh, Gwh)
How does cost scale with size?
What are loss rates & pathways?
When would it be used, if at all?
Where would it be located?


Page 28
MIT OpenCourseWare
http://ocw.mit.edu
22.033 / 22.33 Nuclear Systems Design Project

Fall 2011
For information about citing these materials or our Terms of Use, visit: http://ocw.mit.edu/terms.

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Process Heat Group

22.033/22.33 Nuclear Engineering Design Project

September 14, 2011

MIT Dept. of Nuclear Science and Engineering

Dr. Michael P. Short, 2011

The Three Challenge Problems

Heat exchanger (Hx) design

MIT Dept. of Nuclear Science and Engineering

Dr. Michael P. Short, 2011

First, Some Nomenclature

Sensible heating temperature change

MIT Dept. of Nuclear Science and Engineering

Dr. Michael P. Short, 2011

Where Do We Find Them?

Courtesy of the Generation IV International Forum. Used with permission.

MIT Dept. of Nuclear Science and Engineering

Dr. Michael P. Short, 2011

Heat Exchangers Fundamental

MIT Dept. of Nuclear Science and Engineering

Dr. Michael P. Short, 2011

Heat Exchangers Fundamental

MIT Dept. of Nuclear Science and Engineering

Dr. Michael P. Short, 2011

Heat Exchangers Fundamental

U = Thermal conductance (W/m2K)

A = Heat transfer area (m2)

Tlm = Log mean temperature difference (K)

F = Factor (for flow configuration)

Dr. Michael P. Short, 2011

Heat Exchangers Log Mean

LMTD is a good measure of the effectiveness of simlar heat

exchangers of different designs

Often, LMTD (counter flow) > LMTD (parallel flow)

MIT Dept. of Nuclear Science and Engineering

Dr. Michael P. Short, 2011

Heat Exchangers Finding Key

Source: Wolverine Tube Heat Transfer

MIT Dept. of Nuclear Science and Engineering

Dr. Michael P. Short, 2011

Heat Exchangers Fundamental

MIT Dept. of Nuclear Science and Engineering

Dr. Michael P. Short, 2011

Heat Exchanger Classification by

Image by MIT OpenCourseWare.

MIT Dept. of Nuclear Science and Engineering

Dr. Michael P. Short, 2011

Parallel Flow vs. Counterflow

Image by MIT OpenCourseWare.

MIT Dept. of Nuclear Science and Engineering

Dr. Michael P. Short, 2011

Heat Exchanger Classification by Construction

Image by MIT OpenCourseWare.

MIT Dept. of Nuclear Science and Engineering

Dr. Michael P. Short, 2011

Hx Flow Configurations - Tubular

Courtesy of Wikipedia User:H Padleckas. Used with permission.

Courtesy of Harlan Bengtson. Used with permission.

Source: Wikimedia Commons

MIT Dept. of Nuclear Science and Engineering

Dr. Michael P. Short, 2011

Hx Flow Configurations Plate

MIT Dept. of Nuclear Science and Engineering

Jooshgostar Equipments Manufacturing Company (JEMCO). All rights

Dr. Michael P. Short, 2011