ENQ0247 - Unit Operations II - 2008 / 4 - Prof. C.

Lisete Scienza heat exchanger

s are devices that perform the heat exchange between two fluids, usually separat
ed by a solid wall, through the mechanisms of conduction and convection. CLASSIF
ICATION FOR USE Cooler - cools a fluid through water or air. Refrigerator - cool
s a fluid at temperatures below those obtained when using water. As refrigerants
are commonly employs ammonia and freon. Condenser - cools the steam until its p
artial or total condensation. Heater - heats a fluid process, often through wate
r vapor. Reboiler - a term particularly used for the vaporizer that works attach
ed to the bottom of fractionation towers, re-evaporating the waste accumulated t
here. Evaporator - are used to concentrate a solution by vaporization of water.
Beyond the vaporization of water occurs and any other fluid unit called a vapori
zer. Exchanger - although this term is used for almost all equipment exchange is
best applied to cases in which the two effects, a cooling fluid and heating the
other, are desired in the process. CLASSIFICATION FOR CONSTRUCTION
Recuperative: fluids are separated by an intermediate wall, which represents the
true surface heat transfer. Ex: tubular exchangers.
Regenerative: its operation is characterized by the inner surfaces (heating elem
ent), which are alternately exposed to the two fluids, ie, the hot fluid transfe
rs heat to the heating element to flow through it, get cold, the heat stored in
the thermal element is then transferred to the cold fluid when it flows to the e
quipment. Ex: Ljungstron (thermal rotating wheel).
1
Diagram of the regenerative heat exchanger
Basket items
Operation: A hot gas flows over the surface of metal components, increasing its
temperature. As the rotor turns, at about 1 rpm, heated components move into the
cold gas stream, increasing its temperature. The rotary heat exchangers are pro
duced in various sizes, depending on the application, but can be up to 20 meters
in diameter, weighing over 800 tons. Different elements are specifically design
ed for fuel or specific applications, with performance reflecting a compromise b
etween resistance to erosion or soot and efficiency of heat transfer. To move la
rge quantities of gas or air, the rotary regenerative heat exchangers are an ext
remely efficient and compact. The reason is that both surfaces of each plate ele
ment is used both to heat transfer, to rotate through both the gas side as the a
ir heat exchanger.
2
CLASSIFICATION FOR THE FILE TRANSFER Exchangers direct contact - the transfer of
heat occurs between two immiscible fluids, such as a gas and a liquid coming in
to direct contact. Eg cooling towers.
Exchangers indirect contact - no mixing of two fluids. The hot and cold fluids a
re separated by a surface heat exchange. Eg multi-tubular heat exchanger.
3
CLASSIFICATION Compacting ratio of the heat transfer area on one side of the exc
hanger and the volume of equipment can be used as a measure of the compactness o
f the exchanger. A heat exchanger with a density of surface area on one side, la
rger than 700m2/m3 is classified arbitrarily as compact heat exchanger. Ex: heat
exchanger plates.
4
HEAT EXCHANGER TUBE OF DOUBLE combine the flow in a tube with a flow void. The a
rrangement of parallel streams will be both fluids seep into the same direction,
and counter-current to dispose the fluid in opposite directions. How to have an
area of heat transfer considerably limited, are employed only in cases where a
moderate or low heat exchange is required.
Cold fluid, hot fluid t1, T2, T2 <T1
Hot fluid T1
x dx cold fluid, t2 t2> t1 L
5
The increased application of double tube type heat exchangers is the exchange of
sensible heat - heating or cooling - where the area of heat exchange is not req
uired untrapassa 20 m2. Its main advantage is the ease of pipe fittings to and e
ase of cleaning. They also allow a good control of fluid distribution on both si
des. Its main disadvantage is its high cost per unit area of heat exchange. Exch
angers multitubular constitiuem design standard for most services. The main adva
ntages are the low cost per unit area of heat exchange and gande variety of size
s and types available.€The main disadvantage is its relative inflexibility in co
nstructive, ie it is practically impossible to change in one piece ready. The mu
lti-tubular construction is the most important in the process industry, and, the
refore, the most studied. Plate exchangers are used in services where corrosion,
cleaning and sterilization are problems. The geometric arrangement of the plate
s allows high heat transfer coefficients, resistance to deposits and ease of cle
aning. The main disadvantage is the limitation of the moderate range of pressure
drop and high capacity requirement témbicas similar on both sides. These exchan
gers have calculation methods which are generally owned by companies that manufa
cture this equipment and are inclusive of possession of methods that optimize th
e Equipment to a particular service.
EVALUATION, SELECTION AND DESIGN OF A HEAT EXCHANGER The evaluation of a system
is to determine the flow of heat transfer and temperature distribution under cer
tain operating conditions (type of fluid, mass flows and temperatures of entry d
efined), providing bases for : a) establishing changes in operating conditions t
o optimize the existing process, b) determining when an existing unit should be
cleaned, inspected changed or exchanged, c) select a new device that performs a
new task. The selection of new equipment is usually made by considering standard
ized units by manufacturers, in situations where the working conditions permit.
In situations in which the standard units do not meet adequately the demands of
the system, it is necessary to design modifications to a standard unit or provid
e specifications for the construction of a heat exchanger to measure for the pro
cess in question. The purpose of a thermal design is to determine the area requi
red for heat exchange to a specific heat flux transferred between two fluids wit
h specific flow rates and temperatures. Mechanical and economic criteria must be
considered.
6
PROFILE OF TEMPERATURES IN HEAT EXCHANGERS
CONDESA CONDENSER / EVAPORATOR CONDENSERS CONDESA / HEATER
Boiling point T1
Condensation temperature T
t1
Temperature condensation temperature t1
t2
T1 t1
Temperature
T t1 t2
ΔT = constant
x = distance through the exchanger
x = distance through the exchanger
EVAPORATOR / COOLER evaporation temperature t
T1
T2
Temperature
T1 T2 t
x = distance through the exchanger
EXCHANGER HEAT FLOW PARALLEL T1
Heat exchanger countercurrent flow T1
dT dt T2 T1 t1 t1 = distance x through the exchanger T2 t2
t2
T2 T2 T1 t1 x t1 = distance through the exchanger
t2
Temperature
Temperature
t2
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Topics Heat Transfer Three principles are fundamental in analyzing the processes
of heat transfer: (a) Second Law of Thermodynamics: it provides the definitive
conclusion that heat moves toward the temperature down. (2) Principle of Dimensi
onal Continuity: Requires that all equations are dimensionally consistent. (3) E
quation of State: provide information in the form of equations, tables or charts
on the thermodynamic properties in any state. FUNDAMENTAL CONCEPTS OF HEAT TRAN
SFER individual coefficient h = convective heat transfer ratio (film) U = overal
l coefficient of heat transfer fouling factor = Rd LMTD = logarithmic mean tempe
rature difference caloric temperature Tc = Tw = wall temperature of NTU or equiv
alent diameter = NUT = Number of Global Transfer Coefficient Heat Transfer
R =
Thermal Resistance Current
R = 1 and Ai + 1 + hi kan A0 h0
+
Thermal Resistance of the material
+
Thermal Resistance of current
Ai, A0 = areas of internal and external surface An = cross-sectional area and th
ickness of the pipe = R = resistance to heat transfer p / tube
clean
U0 = 1 (D0
R 1 1 = A0 (A0 Ai) (1 hi) + (A0 An) (k) + 1 h0 Ui = 1 Ai 1 = DD + R 1 [1] D ln (
0) + (i) (1) hi Di D0 h0 (2k) i Coef. heat transfer based on the inner surface
U0 =
D) (1) + [1] D0 ln (0) + 1 2k Di Di hi h0 Coef. transf erênciade of heat based o
n the external surface
"If the wall thickness is small and the thermal conductivity of the tube is high
, in the absence of fouling, the above equation can be simplified as:
Ui =
January 1 +1 hi h0
'Whereas tubes with inlay on both surfaces:
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R =
R = total resistance to heat transfer considering the buildup Rdo, Rdi = resista
nce due to fouling on external and internal tube, respectively.
Rd and Rd 0 1 1 + + + + i Ai Ai kan hi h0 A0 A0
Ud = (
D0
D) (1) + (0 hi Di Di
Di = UC
1 D) Rd + i [0
hio hio × h0 + h0
2k
] Ln (
D0
Di
) + 0 + 1 Rd
h0
Rd =
Uc - Uc Ud Ud ×
hi = hio
1 1 = i + Rd + Rd Uc Ud 0
Uc, Ud = coef. global heat transfer when the tube is clean and when the tube is
with inlay, respectively.
Calculation of Coefficients of Film
•
For Laminar flow:
Hi Di
κ
v Di Di Cpμ = 1.86 γ κ L
1
3
μ μ w

0, 14
•
For Turbulent Flow:
Hi Di
κ
Di v 0.8 Cpμ 13 = 0.027 γ κ
μ μ w
0, 14
μ w = viscosity of the fluid at the temperature of wall κ = thermal conductivity
of the fluid μ = viscosity of the fluid in the heat transfer
Cp = specific heat L = len th of tube properties of fluids can be obtained usin
the avera e temperature of fluid in the exchan er when: 1 - The viscosity at lo
wer temperature is low (~ 5 cP) 2 - The temperature is moderate ( ~ 100 º F) and
the temperature difference is low (~ 75 ° F). For many fluids the relation (
μ
μw)
DH vρ
can be assumed as unity.
Additional Equations - Fluid flow
Re =
DH = hyd
aulic diamete
=
v DH
γ
=
μ
v =
ρA ω
4 A → P → floing area etted perimeter
Re <2100: Laminar flo Re> 104: Turbulent Flo 2100 <Re <104: Transition beteen
to regimes v = average velocity of flo (m / s)
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ω
•

γ = kinematic viscosity = μ ρ (m2 / s) μ = dynamic viscosity ( / ms) ρ = densi
ty (k /m3)
= Mass
ate (k / s) fo
the inne
tube:
=>
μ = γ ρ
Re i =
Di v
γ
=
ω ω Di Di = A i Di μ π 2
4
⇒ ω = ρ A v
μ
•
For the fluid flowin in the annular space:
Re o =
From ω ω (D 2 - D1) = 4ω 2 2 (D - D1) μ π (D 2 + D1) 2 When μ μπ
4
D1 = outside diamete
of the inne
tube D2 = inside diamete
of the oute
tube (
shell) fo
fluid flow the equivalent diamete
(De) is iven by De = D2 - D1 Exam
les: 1) Ai
at 27 º C and 1 atm with a mass flow
ate of 0.8 K /m2s will be hea
ted in a CT bitubula
, with tube diamete
s co

esondin to 3 and 5 cm and 2.5 m
in len th. Wate
heated to 98 ° C is inside the tube at a
ate of 0.01 k / s.
The coefficient of convective heat t
ansfe
to the ai
that sees into the annul
a
a
ea can be conside
ed equal to 138 W/m2 º C. To estimate the ove
all ave
a e
coefficient of heat t
ansfe
fo
this alication, dis
e a
din the effects of
foulin and
esistance of the tube mate
ial. P
oe
ties of wate
: ρ = 961 k /m3
0,294.10-6 m2/sk = γ = 0.68 W / m º C c = 4.21 kJ / k º C Conside
μ / μw = 1.
0 2) determine the overall transfer coefficient external heat (Udo) of a steel t
ube with internal diameter (Di) of 2.5 cm and outer diameter (Do) of 3.34 cm, a
material of thermal conductivity of 54 W / m ° C. Some properties are considered
as follows: hi = 1800 W/m2 º C ho = 1250 W/m2 º C Rdi Rdo = = 0,00018 m2 ° C /
W Determine which would be the clear lobal coefficient (UC).
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CALCULATION OF HEAT EXCHANGERS METHOD OF EFFECTIVENESS
ε =
qc qc max
qcmax = maximum flow rat of hat transfr will b chckd whn th outlt tmp
ratur of th fluid has a lowr hat capacity (C), C Cp = ω, is equal to the inl
et temperature of another fluid. The maximum possible flo of heat transfer for
both thermal flos (parallel, counter) can be expressed as follos: qc max = Cmi
n (T1 input - input t1) C min = minimum flo of heat capacity in absolute value
(ω min Cp )
T2 T1 t1 t2
T2 T1 t1 t2
Number of Transfer Units (NTU, NUT, N): represents an index of the size of the e
xchanger. In the design of a heat exchanger is necessary to establish conditions
that result in moderate values of NTU, so as not to overestimate or undersized
equipment.
NTU =
The U C min
U = overall coefficient of heat transfer medium As = surface heat exchange capac
ity C min = minimum temperature Thus, the efficiency of heat transfer can also b
e expressed by:
ε =
C min ΔTb qc = qc min max min C (T1 input - input t1)
ε =
ΔTb min T1 input - input t1
ΔTbmin = absolute value of the difference in fluid temperature associated with m
inimal thermal capacity. The usefulness of the analysis through efficiency in as
sessing the performance of heat exchangers is important when: 1 - They are the u
nknown fluid temperatures at the exit, 2 - In situations where you know the temp
erature of input and output of fluids, and unknown heat capacity;
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3 - Analysis of a heat exchanger that was tested in a given condition but that w
ill be used under different specification. The equations of efficiency can also
be written in terms of NTU: Parallel Yield:
1 - exp - NTU C min 1 + Cmax ε = Cmin + 1 Cmax
Countrcurrnt Flow in:
1 - xp - NTU 1 - C max C min ε = C xp - 1 NTU - C 1 mi
n - min C max C max
Condnsr / vaporator: Cq / Cf = 0 => ε = 1 - -NTU To Cq / Cf = 1 =>
(Also valid for cross flow).
1 + NTU NTU
ε =
Cq Cf = hat capacity of th hot fluid and cold fluid, rspctivly. Exampls: 3
) Fron 12 to -20 º C, flowing in innr tub of a hat xchangr bitubular at a
rat of 0.265 kg / s, will b hatd by watr at 98 º C, which sps into th an
nular ara with a rat of 0.035 kg / s. Th xchangr is mad of coppr tubs of
thin thicknss, 2 and 3 cm in diamtr and 3 m in lngth. Whras cof. Global
h at transfr is about 534 W/m2 º C, stimat th total hat transfr rat (qc).

cp (fron) = 0.907 kJ / kg º C cp (watr) = 4.21 kJ / kg º C) Considr a parall
l arrangmnt b) Considr arrangmnt in countr 4) A hat xchangr oprating
in countr with a thrmal xchang ara of 12, 5 m2, to cool oil (cp = 2000 J /
kg º C) using watr (cp = 4.21 kJ / kg ° C) as cooling fluid. Th oil ntrs at
100 º C to 2 kg / s whil th watr ntrs at 20 ° C with a rat of 0.48 kg / s.
Th cof. Global hat transfr is 400 W/m2 º C. Calculat th outlt tmpratur
 of th oil and th total rat of hat transfr. METHOD OF LMTD LMTD's approach
is vry convnint in trms of dsign. Enrgy balanc ar: • For th fluid tub
: qc = wi CPI (T1 - T2)
Cp i = w i
qc T1 - T2
12
•
In th fluid shll:
qc = Cpo wo (t2 - t1) qc = U. Airs LMTD
w o = Cp
qc t 2 - t1
Hat transfr quation:
LMTD =
ΔTq - ΔT ΔT f ln (q ΔT f)
IF A => countercurrent flow
LMTD =
(T1 - t 2) - (T2 - t1) T-t ln (1 2) T2 - t1
T1
The fluid T2 fluid B
t2
t1
Terminal cold
Terminal hot
CASE B => current flow in parallel
T2 T1 t1 t2
Terminal Terminal hot cold
LMTD =
(T1 - t1) - (T2 - t 2) ln (T1 - t1) T2 - t 2
As =
q U x LMTD
As (heat exchange) = π D L
When a multiass exchan e
oe
ates o
c
oss flow, the LMTD should be co

ected
by a facto
(Ft) since we no lon e
have a sin le di
ection of flow (a
allel o

counte
cu

ent) Then: ΔTefetiva = Ft x LMTD
Examples of using the LMTD method for exchangers bitubulares: 5) A heat exchange
r double pipe is used to cool 55 lb / min of oil with specific heat of 0,525 Btu
/ lb ° F to 122 º F to 104 º F. The coolant enters the heat exchanger to 68 ° F
and leaves at 77 º F. The coef. overall average heat transfer is 88 º F. Btu/hf
t2 Determine the area of heat exchange (As) for the arrangement in parallel and
in counter.
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6) A heat exchanger double pipe is used to heat 10 kg / s of water, 15 º C to 33
º C. The fluid heating with thermal capacity of 25 kW / C enters the exchanger
at 75 º C. The coef. Global transf. Heat is 1570 W/m2 º C. Determine the area of
heat exchange for the operation in countercurrent and parallel flow. (Cp water
= 4.21 kJ / kg ° C). Considering the diameter of the inner tube of 2 cm and a le
ngth of 4 m, determine the number of tubes that would be required to perform the
service. CASES IN NEED OF A FIX LMTD
For example exchangers shell and tube: A heat exchanger shell and tubes heat wat
er 1:2 at 15 ° C flowing at a rate of 0.796 kg / s. The heating fluid is an oil
(cp = 2.5 kJ / kg º C) entering the tubes of this exchanger to 80 ° C and leaves
at 35 º C at a rate weight of 0.4 kg / s. Determine the area of the exchanger i
f the coef. overall average heat transfer for this system is 300 W/m2 º C.
Examples for cross flow heat exchangers:
A cross flow heat exchanger without mixing, will be used to heat 2.5 kg / s of a
ir (cp = 1.01 kJ / kg º C) 15 ° C to 30 º C. The heating fluid is water, which c
omes in tubes at 55 ° C. Since the overall average coefficient of heat transfer
equal to 300 W/m2 º C, determine the surface area needed for the water temperatu
re at the outlet of the exchanger is equal to 24 º C.
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Examples of using the LMTD method for shell-tube heat exchangers:
1) A steam condenser shell and tube 1:1, with tubes of outer diameter of 2.5 cm,
a vapor condenses at 54 ° C. The cooling water enters the tubes at 18 ° C with
a rate of 0.7 kg / s and leaves at 36 º C.€The coefficient of heat transfer over
all (based on the external surface of the tubes) is 3509 W/m2 º C. Determine the
length of the tubes and the amount of heat involved in the process using the me
thod and the effectiveness of the LMTD method. (Cpágua = 4.17 kJ / kg º C) Equat
ions: qc max = Cmin (T1 input - input t1)
NTU =
ε =
Th U C min
qc = qc max
(T1 input - input t1)
ΔTb min
P / capacitors => Cq / Cf = 0 =>
ε = 1 - -NTU
2) Krosn to 43,800 lb / hr with 42 º API laks in th hull of a multi-tubular
hat xchangr. This fluid ntrs th xchangr at 390 ° F and is coold to 200
º F for 149,000 lb / hr of crud oil with 34 API, from a rsrvoir at 100 ° F a
nd is hatd to 170 º F insid th xchangr. Th quipmnt is a 1:2 xchangr t
ubs 13 BWG OD 1in. Th rlations (ho / φs) and (hio / φt) are known and equal t
o 135 and 169 º F Btu/h t2 respectively. Determine: a) The real change in the te
mperature exchanger (ΔTreal) ΔTreal LMTD = Ft x b) Temperature caloric fluids ho
t or cold (Tc and tc)
ΔTf ΔTq
Figure 17 (it uses the largest kc) Fc tc = t1 + (t2 - t1) Tc = T2 + Fc (T1 - T2)
(T1 - T2) => kc (t2 - t1) => kc
c) The temperature of wall (tw)
tω ho = t + c hio
φs φs
hio
φt
+ Ho
(Tc - tc) or
ω t = Tc -
φt φs
hio
φt
+ Ho
(Tc - tc)
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