ASSIGNMENT No.

: 3 Course Code: BTY 378

Course Instructor: Mr. Himanshu Date of submission: 29/3/11

Student’s Roll No. 10 Section No. : A7803

Declaration:

I declare that this assignment is my individual work. I have not copied from any other student’s work or from any
other source except where due acknowledgment is made explicitly in the text, nor has any part been written for me
by another person.

Student’s Signature: Nishit Kumar

Evaluator’s comments: __________________________________________________________________

Marks obtained: ___________ out of ______________________

 PART-A
1. Draw the temperature profile for co current and counter –current flow.

Temperature profile for cocurrent flow

2. Derive the expression for the LMTD.

SOLUTION-
Assume heat transfer is occurring in a heat exchanger along an axis z, from generic coordinate A to B, between two
fluids, identified as 1 and 2, whose temperatures along z are T1 (z) and T2 (z).
The temperature differences are ΔT(A) at point A and ΔT(B) at point B, having defined ΔT(z)=T2 (z)-T1 (z).

. Since LMTD is the average temperature difference of the two streams between A and B, it is defined by the
following formula:

Assumption
The rate of change of the temperature of the two fluids is proportional to the temperature difference
between them:

This gives:

where K=k a +k b.

We can now express dz as a function of ΔT:

Substituting this expression back into our formula for LMTD, we can remove dz from it:

K is constant and can be simplified. Integration is at this point trivial, and finally gives:
3. Describe the working of a shell and tube condenser with neat diagram.
Shell and tube heat exchangers are the most widespread and commonly used basic heat exchanger configuration in
the process industries. The reasons for this general acceptance are following.
-The shell and tube heat exchanger provides a comparatively large ratio of heat transfer area to volume and weight.
-It provides this surface in a form which is relatively easy to construct in a wide range of sizes and which is
mechanically rugged enough to withstand normal shop fabrication stresses, shipping and field erection stresses,
and normal operating conditions.

Working of a shell and tube condenser-

Diagram of a shell and tube condenser

Component of Shell and tube condenser

TUBES- The tubes are the basic component of the shell and tube exchanger, providing the heat transfer surface
between one fluid flowing inside the tube and the other fluid flowing across the outside of the tubes. The tubes
may be seamless or welded and most commonly made of copper or steel alloys. Other alloys of nickel, titanium, or
aluminum may also be required for specific applications.

TUBE SHEETS-. The tubes are held in place by being inserted into holes in the tube sheet and there either
expanded into grooves cut into the holes or welded to the tube sheet where the tube protrudes from the surface.
The tube sheet is usually a single round plate of metal that has been suitably drilled and grooved to take the tubes
(in the desired pattern), the gaskets, the spacer rods, and the bolt circle where it is fastened to the shell. However,
where mixing between the two fluids (in the event of leaks where the tube is sealed into the tube sheet) must be
avoided, a double tube sheet such as is shown in Figure may be provided.

SHELL AND SHELL SIDE NOZZLES-. The shell is simply the container for the shell-side fluid, and the nozzles
are the inlet and exit ports. The shell normally has a circular cross section and is commonly made by rolling a
metal plate of the appropriate dimensions into a cylinder and welding the longitudinal joint ("rolled shells"). Small
diameter shells (up to around 24 inches in diameter) can be made by cutting pipe of the desired diameter to the
correct length ("pipe shells"). The roundness of the shell is important in fixing the maximum diameter of the
baffles that can be inserted and therefore the effect of shell-to-baffle leakage. Pipe shells are more nearly round
than rolled shells unless particular care is taken in rolling, In order to minimize out-of-roundness, small shells a are
occasionally expanded over a mandrel; in extreme cases, the shell is cast and then bored out on a boring mill.

CHANNEL COVERS- The channel covers are round plates that bolt to the channel flanges and can be removed
for tube inspection without disturbing the tube-side piping. In smaller heat exchangers, bonnets with flanged
nozzles or threaded connections for the tube-side piping are often used instead of channels and channel covers.

PASS DIVIDER. A pass divider is needed in one channel or bonnet for an exchanger having two tube-side passes,
and they are needed in both channels or bonnets for an exchanger having more than two passes. If the channels or
bonnets are cast, the dividers are integrally cast and then faced to give a smooth bearing surface on the gasket
between the divider and the tube sheet. If the channels are rolled from plate or built up from pipe, the dividers are
welded in place.

BAFFLES- Baffles serve two functions: Most importantly, they support the tubes in the proper position during
assembly and operation and prevent vibration of the tubes caused by flow-induced eddies, and secondly, they
guide the shell-side flow back and forth across the tube field, increasing the velocity and the heat transfer
coefficient.

PART-B

4. Describe the various methods for measuring KLa

There are three methods generally used to measure KLa.
1. Sampling Method
2. Gassing out method
3. Sulfite Oxidation
1. Sampling Method- In the sampling method, a value of CL is obtained by quickly plaaing a sample from the
actual fermentation in a polarographic cell and then noting the concentration of dissolved oxygen at various times.
A graph of the results is extrapolated to zero time, i.e., the time of sampling. Knowing CL and Qo, (from the slope
of the above-mentioned plot), Equation 3 is used to find KLa. In a modified procedure, Hixson and Gaden
sampled with a nitrogen- flushed hypodermic syringe which also contained a small amount of phenol to "kill" the
respiration. Initial readings on the polarograph then gave CL directly.
Either broth or a dilute salt solution is placed in the fermentation vessel, and after a preliminary gassing-
out with nitrogen,aeration is begun at constant flow rate. At convenient intervals ther eafter, the value of CL is
measured voltammetrically by a sampling technique. The time rate of increase in the concentration of dissolved
oxygen may be written dCL/dG, and therefore equation 3 becomes

dCL - La(C* -CD )

This means that the unsteady-state absorption of oxygen follows a logarithmic course, for upon integration
equation 5 yields

ln (C* - CL) = -KLaO + constant of integration (6)

To evaluate KLa it is convenient to plot log(C* - CL) against the time, 0, whence

KLa = -2.303 (slope of straight line) (7)

SULFITE OXIDATION-
A third method of measuring KLa is indirect.It involves the carrying out of a sulfite oxidation in the
fermentation apparatus. In the presence of copper or cobalt sts, which act as catalysts, the reaction with oxygen or
air proceeds rapidly and irreversibly to completion in the liquid phase.The reaction rate is not only much more
rapid than the absorption rate, but it is independent of sulfite ion concentration at molarities above 0.015. These
features attracted Cooper, Fern- strom, and Miller used sulfite oxidation as a test system for evaluating gas liquid
contactors. To find KLa it is necessary only to titrate the sulfite solution with iodine at intervals during aeration.
The rate of absorption found in this manner is KLaC* since CL, the concentration of dissolved oxygen, is zero at
all times.

5. Describe the effect of gas velocity on the mass transfer rate in fermentation broth.

SOLUTION-

The effect of gas velocity on the mass transfer rate in fermentation broth is discussed below-
(i) Fermenter operating conditions, increasing the stirrer speed improves the value of kLa. In contrast, except at
very low sparging rates, increasing the gas flow is generally considered to exert only a minor influence on kLa.

(ii) If the agitator speed N i is low and the gas feed rate Fg is high, gas envelopes the impeller without dispersion
and the flow pattern is dominated by air flow up the stirrer shaft. Impeller flooding is said to occur; this
means that the gas-handling capacity of the stirrer is smaller than the amount introduced.

6. Describe the various types of gas spargers you come across in bio processing.
SOLUTION-
The various type of spargers used in bioprocessing is discussed below-

1. Porous sparger: Made of sintered glass, ceramics or metal. It is used only in lab scale-non agitated vessel. The
size of the bubble formed is 10-100 times larger than pore size. There is a pressure drop across the sparger
and the holes tend to be blocked by growth which is the limitation of porous sparger.

2. Orifice sparger: Used in small stirred fermenter. It is a perforated pipe kept below the impeller in the form of
crosses or rings. The size should be ~ ¾ of impeller diameter. Air holes drilled on the under surfaces of the
tubes and the holes should be at least 6mm diameter. This type of sparger is used mostly with agitation. It is
also used with out agitation in some cases like yeast manufacture, effluent treatment and production of SCP.

3. Nozzle sparger: Mostly used in large scale. It is single open/partially closed pipe positioned centrally below
the impeller. When air is passed through this pipe there is lower pressure loss and does not get blocked.

4. Combined sparger agitator: This is air supply via hallow agitator shaft. The air is emitted through holes in the
disc or blades of agitator.