ChemicalEngineering Science, 1964, Vol. 5, pp. 215 to 297.

Pergamon Press Ltd.

Approximation

methods for designing

R. C. CAIRNS
of Technology,

cooler-condensers

School

of Chemical

Engineering,

N.S.W.

University

High Street,

Kensington, Sydney, Australia.

Summary-The need for a general approximation method for the design of cooler-condensers is discussed and the recent papers on the condensation of vapour in the presence of a non-condensable gas are reviewed. The various approximation methods that can be used for design are presented including the COLBURN [5] method, in which enthalpy is assumed as the driving force. A new approximation method is given for obtaining the mean value of the heat flux, ( UAt),
which is based cooler-condenser, on the assumption that a plot of the heat flux point values throughout the against the heat transferred per unit time, q, is a parabola.

The areas calculated by the use of the various approximation methods are compared with the areas obtained for cooler-condensers designed by the rigorous COLBURN and HOUGEN [7]
method, for six examples that have been fully worked out in the literature. the mean value of (UAt) is considerably more accurate simpler than the and is also generally It is concluded that the method involving COLBURN approximation varied from 0.7% 2.0%, 0.7% to f

to use than the COLBURN and HOUGEN method to + 95%.

method for the cases studied.

The error in the use of the COLBURN method 42%. values are shown to lead

The error in the use of the mean heat flux method varied from means of the terminal

except for one case which gave an error of various logarithmic

The methods to serious errors. RBsumB-Lauteur

involving

ins&e

sur le besoin dune m&hode 11 pr&ente

&n&ale

dapproximation r&entes

pour le calcul pour ce

des r6frig&ants-condenseurs. calcul, y compris la m&hode 11 donne une nouvelle

11 passe en revue les publications les m&hodes de COLBURN dans laquelle lenthalpie

sur la condensation valables

dune vapeur en pr6sence dinertes.

dapproximation

est prise comme force mot&e.

approximation pour obtenir la valeur moyenne du flux de chaleur ( UAt), approximation qui assimile ir une parabole la courbe des valeurs ponctuelles du flux de cbaleur dun bout B lautre du r&rig&ant-condenseur en fonction de al chaleur transmise par unit6 de

temps, q. 11 compare les surfaces calcult!es en se servant des diverses mkthodes dapproximation et les surfaces obtenues en appliquant la m&hode rigoureuse de COLBURN et HOUGEN, dans le cas de
six exemples dkj& compl&ement la m&hode 6tudi6s dans la litterature. la valeur moyenne En conclusion, de COLBURN utilisant

de (Uht)

est beaucoup

plus simple

que celle de COLBIJRN et HOUGEN et, g&&ralement,

plus pr&ise que la m&hode

dappmximation

dans les cas &ud& Lerreur commise en utilisant Is m&hode de COLBURN varie de - 0,7% B + 95%. Avec la mkthode du flux de chaleur moyen, elle varie de - 0,7% B + 2%, except6 pour un exemple qui donne une erreur de - 42%. Lauteur montre que les m&hodes introduisant diverses moyennes logarithmiques des valeurs aux extr&mit&s conduisent ir de graves erreurs.

The several papers appearing in the literature in recent years on the condensation of vapdurs from mixtures with non-condensable gases has reflected the growing interest in this subject. The method of COLBURN and HOUGEN [7]
has generally from been of accepted as the basis to for the rigorous vapour design cooler-condensers remove

a gas-vapour

mixture.

This method has the disadvantage of being tedious in that it involves successive trial and error substitutions and because of this there is a need for an investigation of approximation methods. A method involving preferably only the terminal conditions which at least would always give a reasonable conservative design area is greatly desired. The nature of the problem makes the

215

R. C. CAIRN :

Approximation methods for designing cooler-condensers

Where (U,/c,) is evaluated as the arithmetic attainment of an approximation method difficult mean of the two terminal values. The terminal since in a cooler-condenser both the temperature values of (U,/eJ are found from drop from cooling medium to the gas-vapour mixture and the overall coefficient may vary c,lu, = c,lh, + Who (4) widely throughout the condensation process. where m = di*/dt The stepwise procedure of COLBURNand HOUGEN allows for the variation of the temperature drop = slope of the enthalpy saturation and overall coefficient by evaluating their product line. at several points in the cooler-condenser from COLBURNobtained very good agreement between equation (1) and graphically or otherwise integratthis approximate method and the COLBURNand ing equation (2), HOUGEN method. (uA.t) = h, (tg - $) + KM, h (P, - P,) = In order to apply the COLBURNand HOUGEN (1) &I(4 -4J method to the cooling of an unsaturated mixture, it is necessary firstly, to evaluate the operating IT dq A= __ (2) line, as vapour is removed from the mixture. o (Uht) This in itself is a difficult procedure. BRAS [l] SMITH and ROBSON [lo] working with a water has used the relationship, jacketed vertical condenser tube 10.23 feet long and 1.231 inch. I.D., condensed benzene (5) from a superheated benzene-air mixture for fit . both upward and downward flow of the mixture, previously proposed by COLBURN [5], to evaluate with the cooling water countercurrent in the the operating line for the cooling of an unsaturated jacket. The degree of superheat was from 18F mixture of converter gases and water vapour in to 27F. They applied the COLBURN and HOUGEN an ammonia oxidation unit. He evaluates the method of calculation to their experimental slope of the pressure-temperature operating line results assuming that the benzene-air mixture at the inlet of the condenser from equation [5] was at its saturation temperature. and follows the slope for a short distance. The In the case of turbulent flow throughout slope is again evaluated at the new point and the condenser and downward flow, the COLBURN followed again. By continuing this procedure he and HOUGEN method gave an area within 6% finds the operating line on the pressure-temperaof the actual area used. For other cases where and ture curve. The stepwise method of COLBURN turbulent flow was not maintained throughout HOUGEN is applied simultaneously for condensacondensation, the COLBURNand HOUGENmethod tion occuring along this derived operating line. gave conservative results when downward flow CAIRNS [2] has shown that for the systems was used. An oversize area was also obtained chloroform-air and steam-air which were studied, for all but one case of upward flow. the COLBURN and HOUGEN method agrees to COLBURN [5] has recently introduced an within 5% of the area used experimentially. approximate procedure which is an application The gas-vapour mixtures were introduced very to indirect contact equipment of MERKELS [2] close to saturation and turbulent flow existed total heat method for direct contact equipment. throughout the condensation process. The water The method presupposes that enthalpy is the jacketed condenser tube used was 6 feet long and driving force for the transfer of heat. It is 1.081 in. I.D., with cooling water in the jacket much simpler to use than the rigorous method countercurrent to the downward flow of the since it involves only the terminal conditions. mixtures. CAIRNS also compared the approxiCOLBURN writes :mate method of COLBURNto the systems and found that the areas were approximately 90% (Ai), greater than used experimentally.

dp=

A = (L&J

216

R. c. In all of the above

CAIRNS

Approximation methods for designing cooler-condensers sensible heat mean temperature difference. The accuracy

cases

the

carried by the diffusing vapour has been neglected in the calculations. COLBURN and DREW [6] give a theoretical method for estimating the increase in sensible heat transfer obtained, when simultaneous heat and mass are transferred in the same direction, as in a cooler-condenser. These have not been used since the sensible heat transfer is only a small fraction of the total heat transfer. Further, CAIRNS and ROPER [3] have shown, in an experimental study of a wetted wall tower, that the theoretical method of COLB~JRNand DREW cannot explain the data for the case of simultaneous heat and mass work in the in this methods heat transfer transfer in opposite directions. In the absence of further experimental on simultaneous same paper do not direction of the include heat the the available and mass transfer comparisons effect of the made approximation on the heat

of this method decreases as the difference between inlet and outlet overall coefficients increases. Also the use of a logarithmic mean temperature difference theoretically requires that both the specific heat of the mixture and the overall coefficient remain constant. However in cases where the coefficient slightly this method The approximation and specific heats vary only is of value. method of COLBURN has

been shown by COLBURN to give good agreement with the COLBURN and HOUGEN method in certain cases. It has also been shown to give as much as 20% oversize in other cases. In some cases the use of the following method

can be quite helpful. If the heat flux, (UAt), can be shown or can be predicted to be linear or approximately to evaluate

q, then the logarithmic

A from

linear with the heat transferred, mean (UAt) can be used equation (6),

sensible

of the vapour

transferred

rates. There have been a sufficient number of examples of the application of the COLBURN and HOUGEN method, and various modifications of it, to enable comparisons to be made with this method methods that chosen in this of physical a and the several approximation are available. The six examples work cover a considerable procerties of similarly wide

A = (UE),
A disadvantage of this method

(6)
is that, unless

the conditions for which the method is applicable are approximately met, i.e. (UAt) linear in q, then either an undersize or oversize area will be obtained depending on the curvature. Another method, which suggests itself, is to evaluate the logarithmic mean of the products of the driving force at one end and the overall coefficient at the other. This involves the assumption that the overall coefficient is linear in the temperature drop, as well as the temperature drop being linear in q. The foregoing approximation methods involve

range

gas-vapour mixtures under range of terminal conditions.

APPROXIMATION METHODS The problem of designing resolved itself into two is the method cooler-condensers has main issues. Firstly

of COLBURN and HOUGEN generally

applicable and secondly is there an approximation method which can be used safely? On the basis of present experimental results [2], [lo], accurate turbulent the COLBURN and HOUGEN method is to within 10% for fully developed flow at least. Hence this method

only the use of terminal conditions and thus simplify the design procedure considerably. However, none of the methods are generally applicable under all conditions since each has its own definite limitations, which are very often exceeded. The most promising results appear to be in a general method for obtaining a mean value of and using this to find the heat flux, (UAt), the area. A mean value of (UAt) is desired since as previously throughout 217 stated both

can be used as a standard of comparison with the approximation methods. The simplest and hence the most usual approximation method is to evaluate the terminal overall coefficients and use the arithmetic average overall coefficient in conjunction with the logarithmic

U and At vary

the cooler-condenser.

R. c. CAIRNS : Approximation methods for designing cooler-condensers

In searching for a general approximation method it has been noticed that when the (UAt) point values are plotted against q the curve so obtained approaches very closely part of a parabola in shape, as in Fig. 1 for example, for

then from (8), or from equations (2) and (7), A= & IT 0 (%I2 + b!l + 4 s

(11)

Integration of equation (11) gives ;

2aq + b db2 4ac QT 11 o

A=

Z/b21aac1n

( ?aq+b+.\/b2--4ac

when b2 > 4 UC, (12) A = d4gt _ b2 tan- (;:SY-J]:

(13) (14)

when b2 < 4 ac, when b2 = 4 ac.

When b2 > ac the extrapolated parabola of (UAt) versus q would cut the axis at two places. When b2 < 4ac the parabola does not cross the q axis. When b2 = 4ac there is only one value of q when (UAt) is made equal to zero. The solution of these integrals is simple, once values of a, 6 and c are found. This may be done as follows :0 2 pxto 4 -6 b 8 IO

Bt.u/hr

Let (UAt)

= (UAt),,

at q = at q = 0

iqT

Fig. 1. (t7At) vs.p for the COLBURN example. the COLBURN

and HOUGEN [7]

( UAt) = (UAt)mid (UAt) = (UAt),

at Q = + &q, the

and HOUGEN problem. This means that the relationship between (UAt) and q can be represented approximately by a second order equation of the form, (UAt) = up2 + bq + c
(7)

Where (UAt),, (UAt),,

= The heat tlux at gas-vapour outlet,

On this basis it is possible to evaluate to use in equation (8),

= the heat flux at a point in the cooler-condenser where half the total heat has been transferred and = the heat flux at the gasvapour inlet.

(UAt), (UAt),

A = (u!&m
From equations (2) and (8),

(8)

Then from equation (7) When q = 0

(UAt), = qrr
Subsitituting (vat), (7), = qT

/s /s
0
PT 0

qT dq

(UAt)

(9)

c = ( UAt),,

(15)

When q=
(UN, When

-&qT bqT/2 f (U&,,~,-J (16)

= aqT2j4 q= +*qT

dq h2 + b!J+ c)

(10)
218

(UW,

= aqT2/4 f

bqT/2 -k- (vat),,

(17)

R. C.

CAIBNS : Approximation methods for designing cooler-condensers

are greater than about half and less than 1.65

(17)-W) ; ( UAt), - (UAt), = bq, b = [VW,

(17)+ (13); (UAt), + (UAt),, = $qT2 + 2(UAt)mid

times the mid value. The graph is also based on the assumption that the relationship between

- (UW,]/q,

(18)

their driving

force

and the amount

transferred

is a parabola. In order to give a comparison

of the approxima-

tion methods mentioned here, they have been compared with the COLBURN and HOUGEN a = 2 [(UAt),+ (UA.t), -2 (UA&&J/P~2* (19) method for those cases that have been fully For these values of a, b and c, equation (11) worked out in the literature. becomes APPLICATION OF APPROXIMATION METHODS
riqTJ2

Table

gives

the

conditions

known

for

the

(20)
(IT/2

examples ture for

that have been chosen from the literathis comparison. All but one case,

ie-A =
A =

d/b2 :

&c

In aq +

aq+b

2/b2-4ac

b + d$=iii$ for b2 > 4ac.

)I
_qT

the BRAS example, are for the removal of vapour from saturated mixtures where the pressuretemperature operating line is immediately known.

+qT

Table II gives the results of the application of the COLBURN approximation method which is (21) as the driving force. The based on enthalpy value was of m for each case, except evaluated at the temperature that of BRAS, of the gas

for b2 < 4ac.

and A =
Hence

[ aq +b knowing

-2

vapour mixture, tg, at inlet and outlet, by the (22) method outlined previously [2]. The SMITH

+QT

-qT

when

b2 = 4ac

(23)
at each

the values

of (UAt)

and ROBSON example for the benzene-air mixture is shown, and in this example, it was necessary to correct the heat transfer coefficient at the gas-vapour outlet since the SCHMIDT number here was greater than the PRANDTL number. For the case of the unsaturated mixture of

end of the cooler-condenser and a third value at a point in the cooler-condenser when half the total heat removed has been transferred, it is possible to calculate the values of the constants a, b and c in equation (26). The appropriate integrated on whether equation is then used, gives depending directly the b2 $ Pm, which specified.

BRAS, where water vapour is removed from ammonia converter gases, difficulties arise as to the value of m to use. In this example m at the top of the cooler-condenser cannot be evaluated as the slope of the saturation line at tg, as suggested by COLBURN. It is therefore necessary to assign a position at which to evaluate m, which was taken as the point (t,, i,*). The correct slope to use will actually be greatei still than that at (t,, i,*) but if the area obtained in using the slope at (t,, i,*) is greater thar the area obtained by the COLBURN and HOUGE~ method, any increase in m will over design thf cooler-condenser further. As is shown later ar oversize area is obtained by the COLBURE approximation method even when m is evaluated at (t,, i,*) for the top of the cooler-condenser.

area the conditions

The only limitation on this method is that (Uht) when plotted against q approaches a part of a parabola. CAREY and WILLIAMSON [P] have recently published a graph, but without a mathematical development, for obtaining their mean driving force in direct contact air-water systems. This graph gives values of a factor, f with which to multiply the midpoint driving force in order to obtain the mean driving force, but it is limited to those values of the mean driving force which

219

R. C. CAIRNS :

Approximation

methods for designing cooler-condensers

Table I.
COL~~RN and HOUGEN example SMITH and ROBSON example BRAS example
CAIRNS CAIRNS

example No. 1 Saturated air-chloroform vapour

120.2 94.0

example
No. 2

KERN example

-system .
Satzcrated nitrogen-steam

__
Saturated
air-benzene Unsaturated converter gas-steam 278.0 85.0

Saturated air-steam

vapour

Satwated carbon-dio;n&steam

_Gas-vapour temp. tn F -~Cooling water temp. t, F -II_ Gas rate lb. moles/hr. In out 203.0 169.7 90.3 168.3

__
267.0

-104.0

-_
120.0

-_
In out 77.0 85.6 88.0 67.0 73.2 58.5 80.0

-140.0

-_
115.0

-_
lOO*O 0.0576 246.68 35

-_
Cooling water rate Ib./hr. 154,000 2760 1 Single tube vertical. 172,000

-.
137,000

-Total pressure atm. 1 1

-.
3.05

-_
Exchanger type Shell and tube, l-l. Gas on shell side. Shell and tube, l-l. Gas on tube side. Vertical Downwards and countercurrenl Downwards

-.
Shell and tube, 1-4. Gas on shell side.

-_
Gas-vapour flow Countercurrent Downwards and countercurrent

t 1
-.

The value of m at the gas-vapour outlet in this case although unsaturated was taken as the slopes of the enthalpy curve at tg = %F, as before, which is safe. The recalculated values of CAIRNS for chloroform and air, and steam and air are also shown in Table II together with the example of KERN [a] on the removal of steam from carbon dioxide. In this case, since the condensation is carried out under pressure, allowance is made for the absolute pressure in evaluating m from the equation previously presented [2]. In Table III the results are shown of the application of the method based on the assumption that a plot of (Ubt) versus p is a parabola, in which the area is obtained directly by integration. The values of (UAt) at each end of the

cooler-condensers were taken from the references, as was the mid-point for the saturated cases. This midpoint value can be obtained of course without knowing all the (UAt) point values for these cases. Figs. 1 to 6 show the relationship between the calculated point values of (UAt) and q for each of the examples. Fig. 3 plots the point values of BRAS using the (UAt) values as calculated by BRAS. The deviation from the straight line in the chloroform-air example of CAIRNS is due to the exclusion of the condensate resistance at the point of the gas-vapour inlet. The dotted line indicates approximately the relationship between ( UAt) and q at this end of the coolercondenser.

220

R. C. CAIRNS : Approximation methods for designing cooler-condensers Tabk 2. SMITEand BFi.W

I I

_-

ROBSON

CAIRNS No. 1

CAIRNS

KEEN

No. 2

I _.
Bottom

Top

Top 120.2 Bottom 1 Top

_ __ ~~
Bottom Top 267.0

__ ~~____20.3 ~~___~ 85.6

Bottom

Top 278.0

Bottom

-.
94.0 1683

_.
120.0

Gas-vapour temp. ir F Cooling water temp. tw F Vapour pressure

169.7

85.0

-_
78.2 67.0 80.3 58.5 70.3

__ ___~

129.9

__
115.0 80.0

88.0

._--~~

66.4

-0.151 0.038 ___~ 40.3 24.1 16.2 1.24 10.0 0.2% 0.6%b
-.

_.
-0.382 0.391 0.151 2.68

__
0.115

p, atm.
Enthalpy, & above 82F B.t.u./lb. i,

0.883

0.178

..
4787 126.4 4661 at t# m 5,
h, corrected for SC. es h0

..
485 26.6 458 17.7 -

__
147 23.5 123 4.13 355% 36.8

136.8

193.3 29.8 163.5 094 10.8 0.30 118

_.~~___118.2

. .PPP___
18.6 a.98

. .~~_______
737 4.81
-

_.~~~~
at tW -

. .~~______
0.694

333 F___ 101 105 -. ~232 965 -. -123 66.1 -. ~~ -. -302 5.37 1070
-. -.

. .~~ . .~._-~

..
32.8 15.1

..
3523 21.2

_.
494 0.72

. .~___ ._~-

..
-

._
5.74 18.9 5.7

8.18

_.~~~~
0.46% -

._~~

_.
-

-.

0.42 159 6.1

_.-~~~
634 985 0.42 ~________ _150

.____~
O-60

__
1.58 0.22

1.38
-.

-98 ~~ 3.08

_.~~ . .-~

0.29

_.
92% 92%

_.
0.48 7189 0.78 840 1.08

( U,lc,) gr B.t.u./bour

113 ~___ 27.7 27.2 1,077,400 27.5 63.0

179
-_

159 13.1

__
1.62 25.4

l*%O pp 3781
--

_.-~~~

_______ __
I

__
4,802,OOO 13.5 685

7795 9.6 255

(U,/c,) arith. avg. (W,

Calculated area A sq. ft. Area by COLBURN and
HOUGEN Error method

2.34 515

10.9

613

a.14

8.18

519

5.95 + 33%

561 + 9.3%

1.68 + 37%

1.63 + 95%

379 + 37%

Fig. 6, for KERNS example, illustrates clearly the existence of a point of inflection. As is seen 222

the curve that

for this example

does

not

approach

of a parabola.

EL C.

CAIRNS : Approximation

methods

for designing

cooler-condensers

2
qx10

4
-3 -

pd
Fig.

Rtujhr
[l] example.

B.t u /hr
ROBSON [IO] example.

3. (UAt) vs. q for the &us

Fig. 2. ( UAt) vs. p for the SMITHand

For the midpoint value in the BRAS example, where the operating line is initially unknown, it is necessary to make the simplifying assumption that the operating line between inlet and outlet points is a straight line on the humidity chart.

It is also necessary to assume that the outlet is the same composition and temperature as was assumed by BRAS. For the purpose of comparing the methods on the same basis this second assumption is justified, although where the outlet concentration is not known for the cooling of an unsaturated mixture, it would be necessary to assume the mixture left saturated. The temperature and humidity at the point cooler-condenser where half the total

4 / / I : 0 x u

_vl 1 i---i
0
I I
I

I
2 qxKi3--+

I
3

I
0
Fig. 5. ( UAt) 222
2 4 6 8

B.t u./hr

Fig. 4. (UAr)

vs.

for the

example.

CAIIINS

[2] chloroform-air

qxrc?-

B.tu/hr

vs. p for the CAIRNS [2] steam-air example.

R. C. CAIRNS:

Approximation methodsfordesigning cooler-condensers Tabk III

COLBURN and HOUGEN

Snrru and ROBSON

BUS

CAIRNS No. 1

CAIRNS

KJnlN

No. 2

Gas-vapour
outlet (UA%), 1629 23.0 462 loo0 2QM 651

Gas-vapour
inlet (UAl),

18,540
C

9704 4632 7139

4295 2650 1,077,400

5030 2600 3781

8120 5380 7795

97,956 54,000 4,802,006 - 8.15x lo-lo 2.026x lo-= 4.105x 10-d - 1.76x lo4 (21)

(UAt),id=

23,500 9,706,OOO - 5.696x lo-lo 1.742x

1O-8

qT B.t.u./hr. a b b2 4ac Use equation Calculated area A sq.ft. Error

6525 x 1O-5 - Q-35x lo-lo 1.356 l-839 1.052 (21) 3.558x 10-s 1.266x 1O-5 - 9.91x 1O-6 (21)

1.161x 1O-4 - 9.875x 1O-6 1.066 1.136 l-207 (22) 0.742 0.551 - O-213 (21)

3.035x 10-s - 5.353x 10-s (21)

690 - 0.7%

5.92 - 0.5%

572 + 20%

l-70 + 1.2%

164 + 0.6%

226 - 42%

heat

has been

transferred

were calculated the sensible

by an heat in

the

condensate,

and

from

the

assumed The trial and

linear of error

enthalpy

balance,

neglecting

relationship

between

H and ts.

value

by ( At)mid was then found substitution in equation (1).

The value of ( UAt),id 2650 as compared by ture

6

obtained of 2720. found method

in this way was by BRAS, temperaThe to be

to the value was of this be

obtained

rigorous of the

calculation, mixture

184F as

compared The the area

to 175F can best

by BRAS. of evaluating the following shown by

application

calculation Values and

of the COLBURN and HOUGEN example: previously calculated by COLBURN

HOUGEN

;
(sq. ft.) (sq. ft.) sq. ft.)

(UAt),
(Ubt), (UAt),,

= 1,629 B.t.u./(hr.)
= = 18,540 23,500 B.t.u./(hr.) B.t.u./(hr.)

* i 10-6 Fig. 6.

B.t u./hr

qT = 9,706,OOO B.t.u./(hr.)
from 223 equations (19), (18) and (15)

(UAt) vs.q forthe KEBN

[8] example.

R. C. CAIRNS : Approximationmethodefor designingcooler-condensers a = 2 (18,540 + 1629 - 2 x 23,500)/ (9.706 x 106) 5.696 X lo- x 106) b = (18,540 1 1629)/(9706 = 17.42 x lo4 c = 2.35 X 10 bS = 3.035 x 10-S and 4ac = =. *. use equation (21) db2 - 4ac = 7521 x lo-
by/y/b2

From Fig. 8 reference (4), f = 0.595 (UAt), = 0.595 X 23,500 = 13,980 A = 9,706,000/13,980 = 694 sq. ft. Table IV gives the results of the method using the graph of CAREY and WILLIAMSON, which enables solution of the appropriate integral to be read off graphically. Table V compares the various other methods involving logarithmic means of the terminal values only. In Tables II to V the percent error is expreSsed as the difference between the areas obtained by the COLBURN and HOUGEN method and the approximation methods, divided by the area obtained from the COLBURN and HOUGENmethod, all multiplied by 100. COMPARISON OF APPROXIMATION METHODS

4 X 5.696 X lo-lo X 2.35 x lo4 5.353 x 10-J

4ac = -

57.79 x 10-4

b + l/b2 A=

- 4ac = + 92.63 x lo4

1

75.21 x lo4

In

5.696 x lo-I0 x q - 57.79 x lo- +*r - 5.696 X lo-lo x q + 92.63 x lOA 11 _pT

= 690 sq. ft. Using the chart WILLIAMSON,

(uht)micl =

presented

by

CAREY and

14.4

(VA% (UAt) (uA;; . = 1.27

Table

Table II shows that the COLBURN approximation gives an oversize area varying from 9.3% to 95 %. The area obtained by COLBURN using his approximation method for the COLBURN and HOUGEN example was 690 sq. ft., an error of - 0.70/,, the COLBURNand HOUGEN method giving 695 sq. ft. On the basis of the examples compared here, the COLBURN approximation IV CAIRNS No. 1
2.60 0.52 0.855 2,223

COLBURN and HOUGEN ( ~%nrd/( UAt),

( ~A&,,/( UW, 14.4 1.27 0,595 13,980

SMITE arzd ROBSON

175 0.42

BRAS

CAIRNS No. 2
2.30 0*66 0.88 4,734

KERN

5.74 0.62 0.715 1,895

32.9 0.55 Not on graph -

Factor, f, Fig. 8 [4]

( UW,,, Calculated areas A sq. ft. Error -

Not on graph
-

694 O-l%

569 + 1.4%

1.70 + 1.2%

1.65 + 1.2%

224

R. C. CAIRN :

Approximation methods for designing cooler-condensers. Tabk V

CAIRNS

COLB~N and HOUGEN ~~ TOP ______ u ~~ At Area by 6&O ___1290 (+ 27.0 294 Bottom

SMITE and ROBSON -. ___~

BRAS

No. 1

-- ___TOP ___20.6

CAIRNS No. 2 dTOP 82.9 98.0 Bottom 36.9 63.5

KERN

-BottomL
--

-.
60

TOP 118.8

Bottom

TOP 84.0

Bottom -28.2 a5.5

I 4.91 -- -4.68

30.8
--

-_ -___
81.7

208.0

_.___~
86%)* 4.29 ( 28%)

15.0
--

59.9

-- ~571 (+ 1.8%)

~m4Athm
Area by log. mean of (U, At,) and ~u,At,) Area by ( UAt), *

_-

_-

--

1733 (+

140%) -

15.1 (+

154%)

536 (-4.5%)

1.66 (--

1.2%)

1.78 (+ 9,279

483 ( +27%)

_.
4.46 ( 25%)

_-

--1.68 (+ 3.1%) 247 ( 35%)

1396 (+

101%)

Percentage in brackets is the percent error based on the area obtained by the COLBURN and HOIJ~ENcalculation.

627 (+

12%)
-

method appears to yield on oversize area rather than undersize and is thus conservative from a design viewpoint. However a cooler-condenser with 95o/o more area than is required is an expensively designed cooler-condenser. As
COLBURN points to give a rough In Table on and of the the III out the method approximation the results relationship and HOUGEN is only intended for the true area. based (UAt) + 2.0% in gives all a the this the BRAS between method which exception, by to

of the method

parabolic COLBURN

turn is due to the plot of the heat flux due to latent heat transfer against q giving a point of inflection. In all other examples this quantity shows the normal parabolic relationship. It is difficult at this stage to predict when the nonparabolic relationship would occur, since only one out of the six examples shows this tendency. Table IV gives the areas as obtained by the graph of CAREY and WILLIAMSON for those cases
where with where to the the Table the graph III graph ratios can is be used. The agreement and good. The CAREY (Uht)

q is seen to give areas from - 0.7%

cases except the KERN example, - 42% error. Apart from this agreement in the is remarkable of method HOUGEN error considering as + volume and calculations

WILLIAMSON

is recommended mid-point

for the cases values

of the

the reduction

afforded compared 2%

approximation COLBURN The example small

value can be plotted. This procedure eliminates the necessity of solving equations (21), (22) or (23) and reduces further
terminal

(UAt)

method. for the made in order of 2720

the

amount

of

calculations. graph from equations of the

Where (21),

the

CAREY

of only

and WILLIAMSON can be obtained logarithmic

cannot

be used the area (22) or (23). the various

supports

the assumptions method. value

to apply the approximation figure for the is mid-point

If the actual

The results of the methods means

involving terminal

of (UAt)

used the exact area is obtained, which would be expected by inspection of Fig. 3. The reason the method gives a 42% undersize area for the example of KERN is due to the nonparabolic relationship between (UAt) and q, This in as has been previously mentioned.
225

values are shown in Table V. The correlation of areas by these methods is shown to be generally poor. The use of these methods must be treated with considerable caution as either an unreasonably undersize or oversize area can be obtained. It is seen from Tables II and III that the

R. C.

CAIRNS

Approximation

methods for designing cooler-condensers

is generally better than method using (UAt), the COLBURN approximation method, except for the example of KERN. It must be emphasised however that three point values of (UAt) are required involving three trial and error subsitutions, whereas the COLBURN method does not require any trial and error substitutions and operates entirely on the terminal conditions. The use of only three point values of (UAl) in the mean heat flux method however means a considerable reduction in the amount of calcula-

COLBURN and HOUGEN method and it is more accurate in five out of the six cases studied than the COLBURN method of approximation. More examples need to be solved however before its limitations could be fully determined. ACKNOWLEDGMENT The author wishes to acknowledge advice received from Professor J. of Chemical School University of Technology, interest in this work Engineering, the helpful P. BAXTER, N.&W.

tion compared to the usual six to ten point values. It must be mentioned that the evidence offered here is not conclusive but would have to be augmented by further worked examples before it could be definitely shown that the mean heat flux method is more suitable in all cases than the COLBURN approximation method. On the basis of the present work it appears five out of the six cases. An attempt approximation was made to modify method by obtaining to be so in the COLBURN a mean

and for his continued

NOTATION a = constant
A b c es dq = = = = = defined by equation (19). cooler-condenser surface area, sq. ft. constant defined by equation (19). constant defined by equation (15). humid heat, B.t.u./(lb.) (OF). increment of the total heat transferred, coefficient, B.t.u./(hr.) (sq.

B.t.u./hour. h = heat transfer

value of the product of the enthalpy heat transfer coefficient and the enthalpy driving force, in the same manner as (VAt),. (us/c, x A%,,,,, This was based on the assumption that this product showed a parabolic relationship with q. In the case of the COLBURN and HOUGEN example the area obtained 695 sq. ft. actual, was rejected. CONCLUSION An approximation method has been presented for the design of is based on the point values of The method has cooler-condensers. This method assumption that a plot of the (Uht) against q, is a parabola. been shown to give good agreewas 3,240 sq. ft. compared to and consequently this method

ft.) (OF), ha = the combined conductames the gas lllm, h, = the gas fihn. H = humidity of the gas-vapour lb./(lb. dry gas). i = enthalpy of the gas vapour

other than

mixture, mixture,

B.t.u./lb. i,* = the saturation enthalpy at 1,. is = the enthalpy at &, i,* = the saturation enthalpy at to,, (Af)r, = the overall logarithmic mean enthalpy driving force. K = mass transfer coefficient, lb.moles/(hr.) m = = M, = p = (sq. ft.) (atm.). slope of the enthalpy saturation line. di*/dl. molecular weight of the vapour. partial pressure, atm., pBM = the logarithmic mean of pg and

ment with the COLBURN and HOUGEN method in all the cases studied except one. The nonagreement in this case is discussed. In applying the method the graph of CAREY and WILLIAMSON is recommended. When this graph cannot be used the appropriate integrated equation can be used which gives the area the 226 directly. This method

(P-P,), pc = the vapour pressure at t,, pg = the non-condensable gas in the main
stream, pressure in the main stream, Aps = the partial pressure driving force across the gas film. P = total pressure, atm. Pr = Prandtl No. Q = heat transferred per unit time, B.t.u./hour,

p, = the vapour

is less tedious

to use than

R. C. CAIRNS :

Approximation methods for designing cooler-condensers (U,/c,) = overall heat transfer ccefllcient per unit enthalpy difference, B.t.u./(hr.) (sq. ft.) (B.t.u./lb.). (UAl) = heat flux B.t.u./(hr.) (sq.ft.) (UAt), = the true mean (UAL). (UA.t)lm = the logarithmic mean of the (UAr) terminal values, (UAi?),id = (UAt) at the point when half the total heat has been transferred. X = latent heat of vaporisation, B.t.u./lb. Subscripts : 1 = gas-vapour outlet, 2 = gas-vapour inlet.

QT = total heat transferred. SC = Schmidt No. t = temperature, F, tc = condensate surface, tg = gas-vapour mixture, & = water, At = overall temperature driving force. A$ = temperature driving force across the gas film. U = overall heat transfer coefficient, B.t.u. /(hr.) (sq. ft.) (OF). IJ,,. = arithmetic average of U, and U,.

[I] Buns, G. H. [2] [3] [4] [5] [6]

CAIRNS, R. C.

; Chem. Eng. 1953 60 223-26, 238-240. ; Chem. Eng. Sci. 1953 2 127-138,228.
G. J.

CAIRNS, R. C. and ROPER, G. H. CAREY, W. F. and WILL-SON, COLB~N, A. P. 1951 l-11.

; Chem. Eng. Sci. 1954 3 97-109. ; Inst. Mech. Engrs. Steam Group Proc. 1959 163 41-53.

; General Discussion on Heat Transfer, Inst. Mech. Engrs. and Amer. Sot. Mech. Engrs.

; Trans. Amer. Inst. Chem. Engrs. 1937 33 197-212. [7] COLBUXN, A. P. and HOUGEN, 0. A. ; Ind. Eng. Chem. 1934 26 1178-82.
COLBURN, A. P. and DREW, T. B. KERN,D.Q. MERKEL, F. ; Process HeatTransfer. McGraw-Hill Book Co. Inc., First edition, 1950, 346-51.

[8] [9] [lo]

; Forschungsarb, 1925 275 l-48. SMITE, J. C. and ROBSON, H. T. ; General Discussion on Heat Transfer.

Inst. Mech. Engrs. and Amer.

Sot. Mech. Engrs. 1951 38-42.