HT2.

ppt

Basic Revision of Overall Heat-
Transfer Calculations
Components of Course: What
Stage are We Up To?
Types of exchangers, revision of
OHTCs, fouling factors.
Heat exchanger selection.
Thermal performance analysis (NTUs) for
co- & counter-current exchangers.
Multi-pass exchangers (S&T).
Condensation & boiling.
Radiation.
Overview
Problem statement
Approaches to problem solving
Basic concepts & assumptions
revision of heat-transfer resistances & overall
heat-transfer coefficient
neglect of tube wall resistance
heat-transfer coefficients for condensation
Solution to problem statement
Learning Aims and Outcomes
- Re-familiarise yourself with key
dimensionless groups in heat transfer.
- Apply the concepts of heat-transfer
resistances to heat exchanger problem
analysis.
Apply these principles to a design problem
(decide on the size of a heat exchanger
given the outlet temperature(s), rather than a
performance problem, where you assess
the performance, here the outlet
temperatures, of existing equipment).
Problem Statement
Water flowing at a rate of 4 m
3
hr
-1
must be
heated from 15 to 50
o
C in a double-pipe
heat exchanger. The water is flowing
within the inner tube, with steam
condensing at 110
o
C on the outside.
Draw the situation first.
Questions
Calculate the heat load (Q in kW) & mean
temperature difference (in K) for this
exchanger
For a pipe diameter (D) of 5 cm, calculate
the inside heat-transfer coefficient (o
i
) &
hence the overall heat-transfer coefficient
(U), both in Wm
-2
K
-1

What dont you know about this situation?
Using these two results, calculate the heat-
transfer area required (A in m
2
) & hence the
length of the exchanger (L in m)
Approach to Problem Solution
Diagram
What assumptions are justified & why?
Structure of problem solution
Layer 1:
Heat balance / energy equation
Design equation

mean
T A U Q A =
Layer 2: Design Equation
Overall heat-transfer coefficient
Heat transfer area
Mean temperature difference (may not be
log mean)
Layer 3: The Details
Overall heat-transfer coefficient
Film heat-transfer coefficients
Fouling resistances
Mean temperature difference
Sketch temperature profile through exchanger
Layer 4: Film Heat-Transfer
Coefficients
Identify geometry
Fluid properties
Re, Pr, Nu
Check that numbers make sense (e.g. Re >
10,000 for full turbulence)
Basic Concepts & Assumptions
Overall heat-transfer coefficient = 1/(overall
heat-transfer resistance)
Overall heat-transfer resistance = sum of
series resistances = inside film resistance
(heating water) + inside fouling resistance +
tube-wall resistance + outside fouling
resistance + outside film resistance
(condensing steam)
o
fo fi
i
R
L
R
U o o
1 1 1
+ + + + =
Assumptions
In the absence of further information:
What assumption might you make about the
tube-wall resistance & why?
What assumption might you make about the
heat-transfer coefficient on the condensing
steam side & why?

Tube-Wall Resistance
This can often be neglected
Why?
Need to revise heat-transfer resistances:
central concept for calculating
overall heat-transfer coefficients in all heat
exchangers
calculating energy losses in energy utilising
devices (furnaces, boilers, engines,
refrigerators, distillation columns)
Basic Concept of Heat-Transfer
Resistance
( )
resistance sfer) (heat tran
force driving re) (temperatu
flux heat) (
T
q
A
= =
Conduction: Linear temperature profile
for constant thermal conductivity
| |
resistance transfer - heat
force driving
m W
flux heat
2 1
2 -
=

=
=
= =
=
L
T T
dx
dT
A
Q
q

| |
| |
| |
1 - 2
2 -
2 1
K W m
m W flux, heat
K force, driving
conduction for
resistance transfer - Heat
= =

L
q
T T
Convection
Heat-transfer coefficient incorporates both
convection & conduction in fluids (e.g. air)
| |
1 - 2
K W m
1
convection for
resistance transfer - Heat
= =
o
Some Numbers
Heat-transfer coefficients (o)
lowest: around 2 Wm
-2
K
-1
for natural
convection, normally around 10 Wm
-2
K
-1

highest: 20,000 Wm
-2
K
-1
for small passages,
two-phase (boiling & condensation)
Thermal conductivities (): 50 Wm
-1
K
-1
for
iron, 400 Wm
-1
K
-1
for copper
Wall thicknesses: 1-10 mm in pipes &
process equipment
Relative Resistances
Iron pipe, 1 mm wall thickness
L/ = 0.001 m / 40 Wm
-2
K
-1
= 2.5 x 10
-5
m
2
KW
-1

= tube-wall resistance, smaller than either

For o = 2 Wm
-2
K
-1
, film resistance = 0.5 m
2
KW
-1

(if natural convection)
or
For o = 20,000 Wm
-2
K
-1
, film resistance = 5 x 10
-5

m
2
KW
-1
(if condensation)

Neglect wall conduction in overall resistance /
coefficient
Assumptions
In the absence of further information:
What assumption might you make about the
tube-wall resistance & why? Done.
What assumption might you make about the
heat-transfer coefficient on the condensing
steam side & why?

Heat-Transfer Coefficient for
Condensing Steam
Heat-transfer coefficients for condensation
typically large (~10,000 Wm
-2
K
-1
) cf (cf=
compared with) those for single-phase heat
transfer (~2,000 Wm
-2
K
-1
)
because latent heat of phase change transferred
(for water, about 2000 kJkg
-1
cf specific heat
capacity of liquid, 4 kJkg
-1
K
-1
)
implies that film resistance on condensing
steam side is small cf on side heating liquid
water
Overall Resistance to Heat
Transfer
Here, most of resistance is on water heating
side
Hence overall heat-transfer coefficient is
nearly equal to inside (water) film heat-
transfer coefficient
If inside heat-transfer coefficient is 2,000
Wm
-2
K
-1
& outside coefficient is 10,000
Wm
-2
K
-1
, then (no fouling) overall coefficient
is 1,670 Wm
-2
K
-1
Assumptions
In the absence of further information:
What assumption might you make about the
tube-wall resistance & why? Done.
What assumption might you make about the
heat-transfer coefficient on the condensing
steam side & why? Done.
Other Assumptions
Steady-state: time derivatives are zero,
implies no accumulation of heat, etc
as well as
Adiabatic: no heat loss or gain, heat loss or
gain is small relative to heat-transfer rates
These assumptions are not the same
Review Point
Have reviewed assumptions & approach to
problem solving
No fouling, so neglect R
fi
& R
fo

Have reviewed why 1/o
o
& L/ should be
neglected here

ely approximat
so
1 1 1
i
o
fo fi
i
U
R
L
R
U
o
o o
~
+ + + + =
Worked Example
Physical properties
Scope of problem
heat duty
mean temperature difference
Reynolds number, heat-transfer coefficient
Check resistances to heat transfer
Area & length

Physical Properties
For water, from a reference source (cite the
reference, e.g. from tutorial sheet, but you
must give the reference)
Density () = 1000 kg/m
3

Viscosity () = 10
-3
kg/(ms)
Thermal conductivity (k or ) = 0.6 W/(mK)
Specific heat capacity (C
P
) = 4200 J/(kgK)
Scope of Problem
Heat duty
Mean temperature driving force
pure parallel flow (co/counter)
log mean
( )( )
kg/s 11 . 1
s 3600 hr / 1 kg/m 1000 /hr m 4
m 05 . 0
3 3
=
=
=
m
D

Heat Duty & Driving Force
K 2 . 76
50 110
15 110
ln
) 50 110 ( ) 15 110 (
=
|
.
|

\
|

= A
LM
T
( )
kW 163
K 15) - (50 J/(kgK) 4200 kg/s 11 . 1
=
=
A = T C m Q
P

Heat balance
Transport (Heat-Transfer)
Coefficient
Related to momentum transfer parameter
(Reynolds number, Re) & fluid properties
(ratio of molecular diffusion of momentum
to molecular diffusion of heat = Prandtl
number, Pr)
Reynolds number = inertial/viscous forces
Inertia mass flux (kg/(m
2
s))
If we know the mass flowrate, then we do
not need the density to calculate Re
Mass Flux
( )
1 - 2 -
2
mean
sectional cross
s m kg 566
m 05 . 0
4
kg/s 11 . 1
=
=
= =
t
u
A
m
G

Reynolds & Prandtl Numbers
( )( )
( )( )
7
K m W 6 . 0
s m kg 10 K kg J 4200
28300
s m kg 10
m 05 . 0 s m kg 566
1 - 1 -
1 - 1 - 3 1 - 1 -
1 - 1 - 3
-1 -2
=
=
=
=
= =

P
C
Pr
D G
Re
Heat-Transfer Correlation (Inside
Tube)
Re over 10,000, turbulent flow, so the Dittus-Boelter equation
can be used (recall that Nusselt number Nu = D o
i
/)

( ) ( )
( )
1 - 2 -
1 - 1 -
3 . 0 8 . 0
3 . 0 8 . 0
K m W 1800
m 05 . 0
K m W 6 . 0 150
150
7 28300 023 . 0
023 . 0
=
= =
=
=
=
D
Nu
Pr Re Nu
i

o
Check Inside & Outside
Resistances
Inside resistance 1/1,800 m
2
K W
-1

Outside coefficient ~ 10,000 W m
-2
K
-1

Outside resistance 1/10,000 m
2
K W
-1

small compared with inside resistance
Hence, overall heat-transfer coefficient ~
1,500 W m
-2
K
-1


Area & Length
( )
( )
m 94 . 8
m 05 . 0
m 40 . 1
m 40 . 1
K 2 . 76 K m W 530 , 1
W 000 , 163
2
2
1 - 2 -
m
= =
=
=
A
=
t
L
T U
Q
A
Design equation
Conclusions
Check assumptions & heat-transfer
resistances first
Try to get a feel for the significant
resistances
Heat-transfer resistances add, not
coefficients (adding coefficients will result
in marks being halved for any item of
assessment)