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Calculation procedure
Material for courses DPE and PRO III (remember part 3). Prepared by: Pavel Hoffman
1. Given data
Cooled solution (syrup):
Amount of incoming solution Temperature of incoming solution Required (or calculated) temperature of outgoing syrup Incoming solution concentration MS (kg/s) tS0 (C) tS1 (C) xS0 (%)
(W/mK)
Fouling thickness (incrustation) on side of cooling water Thermal conductivity of fouling on side of cooling water Fouling thickness (incrustation) on side of cooled syrup Thermal conductivity of fouling on side of cooled syrup Max. allowable pressure loss on side of cooling water Max. allowable pressure loss on side of cooled syrup Max. allowable pressure in plates Minimal economical temperature difference in HE
sWi (mm)
Wi
(W/mK)
sSi (mm)
Si
(W/mK)
cW (J/kgK)
W
S S S
cS (J/kgK)
S
PrS (-)
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(all parameters are found from tables etc. for average temperatures) Fig. 1.: Example of chart of plate HE with 2 sections 1.section cooling water 2.section cooling water
syrup
syrup
cooling water
tS
tS twfS twS twW twfW
tW
tW
sSi ;
S i
S cooling of syrup
sw;
w
sW ; i
W i
tW 1
tHEm in
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Specification of outgoing temperature of heated cooling water (if we have given the outgoing temperature of cooled syrup) For heat loss QL= 0
(C)
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If we take into account heat loss in HE QL (W) or z (in % of transferred heat) owing to heat loss we have to transfer less heat from the hot syrup to the cooling water (it is that tW1 will be lower than for the case without heat loss)
(C) (C)
Specification of outgoing temperature of cooled syrup (if we have given outgoing temperature of cooling water) For heat loss Qz = 0
(C)
If we take into account heat loss in HE QL (W) or z (in % of transferred heat) owing to heat loss the hot syrup will be cooler for needed outgoing temperature we will transfer less heat to the cooling water
(C)
(C)
These outgoing temperatures we have to compare with a reality of heat transfer (depending on given data). It is that for example we compare the calculated temperature of cooled syrup with the given temperature of cooling water. If it is
(C)
given data are unreal (see fig. 2 and 3) and it is necessary to design the cooler for this new outgoing temperature of cooled syrup
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(C)
Otherwise, with regard of temperature drops on the cooling water side, in the fouling layer, in plate material and on the syrup side (again with fouling layer), it would not be economical or real to transfer the needed amount of heat (or the heat transfer area would be too large). Then we can specify the mean logarithmic temperature difference in the HE (counter flow) see fig.3
(tS0 tW1) (tS1 tW0 ) (t t ) ln S0 W1 (tS1 tW0 )
tL =
(K)
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various liquids from points of views of heat passage coefficient heat transfer area capital cost and pressure loss pump consumption running costs). Then we calculate new values of heat transfer coefficients and a new value of the coefficient of heat passage. If there is a difference we repeat the procedure. Simultaneously we must check pressure losses in the HE. If they are too high we must use a solution with lower losses (it is to increase a number of parallel connected channels for a liquid in question). On the contrary if are the pressure losses too low it is good to reduce number of parallel connected channels and so increase speed. Thus increase coefficient of heat passage and decrease needed heat transfer area (cheaper HE). More see example about effect of speeds on a HE size.
4.1. Estimation of coefficient of heat passage and preliminary calculation of cooler (coolers)
Estimation of coefficient of heat passage
kest = ? (W/m2K)
(m2)
nPT = ATC / AP
(-)
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Q = k * A * tL * F
where F is a factor with values usually in range from 0.8 to 1.0. A HE with factor F < 0.8 is not acceptable as it is not stable in operation. For our case of a pure counter flow is the F = 1.0. Similarly it is for pure parallel flow, evaporators and condensers. Fig. 5.: Examples of temperature profiles and their F factors:
F=1
Evaporator
F<1
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P = (tC1 tC0) / (tH0 tC0) = heating of cool liquid / max. possible heating R = (tH0 tH1) / (tC1 tC0) = cooling of hot liquid / heating of cool liquid Note 2: Another variant very often used for plate HE design. According experiences speeds of both liquids in interplate channels are in the 1st iteration estimated. On the basis of these speeds we can specify a flow pattern. It is numbers of parallel channels in 1 pass. From it we can specify exact speeds of both liquids wi and for this iteration Rei, Nui and ki. Then we can specify the heat transfer area A and from it number of passes connected in series. Next procedure is analogous to the previous case. This procedure is used in the examples prepared in Excel. Choice of HE arrangement Number of parallel channels in 1 pass and number of passes in HE we choose from a point of view of optimal speeds of liquid in channels it is that coefficient of heat passage and pressure losses must be optimal. Criterion of a proper choice (design) is a HE size (mass, total heat transfer area) of the cooler and total pressure losses on both liquids economic appraisal.
Choice of a number of parallel interplate channels in the cooler syrup side (with regard to the recommended speed)
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npcScalc = MS / ( npcS = ?
* fP *wSrec)
(-)
Choice of a number of parallel interplate channels in the cooler cooling water side (with regard to the recommended speed)
npcWcalc = MW / ( npcW = ?
* fP *wWrec)
(-)
Choice of a number of passes connected in series in HE (section) syrup side (one half of channels is for cooled syrup, the second one is for cooling water)
(-) (-)
(-)
(-)
A maximal difference between products npcS*npsS and npcW*npsW can be +/- 1 (ev. max. 2) else it is impossible to set plates together according calculated values of numbers. (for = 2 in 1 pass is not the same number of parallel channels as in others for one liquid) see fig. 6b.
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Total number of plates in the cooler (section) again it must be a whole number
(-)
(m2)
Both end plates close interplate channels and they do not participate on heat transfer (see fig. 6.).
Fig.6.: Example of a flow pattern in a plate HE (plates arrangement) a) Flow pattern: syrup 1 x 4; cooling water 2 x 2 Flow pattern on this example:
cooling water
cooling water npcW = 2; npsW = 2 syrup npcS = 4; npsS = 1 = npcS*npsS npcW*npsW =4*1 2*2 = 0 O.K. nPTreal = 1 * 4 + 2 * 2 + 1 = 9
syrup 1 2 3 4 5 6 7 8 9
f1pW = 2 * fP
f1pS = 4 * fP
nPTHEreal = nPTreal 2 = 9 2 = 7 Cross section clear areas in 1 pass: cooling water f1pW = 2 * fp (m2) syrup f1pS = 4 * fp (m2)
cooling water
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Print date: 8 / 2007 P. Hoffman
f1pW = 2 * fp
f1pS = 5 * fp
cooling water npcW = 2; npsW = 2 syrup npcS = 5; npsS = 1 = npcS*npsS npcW*npsW =5*1 2*2 = 1 O.K. nPTreal = 1 * 5 + 2 * 2 + 1 = 10 nPTHEreal = nPTreal 2 = 10 2 = 8
Specific heat flux in the HE (cooler) through plates = heat transfer area
QHE = QCW
(W/m2)
f1pW = npcW * fp
Cooling water speed in cannels
(m2)
wW = MW / (
* f1pW)
(m/s)
The speed we compare with a recommended one and ev. change a number of parallel channels or parallel HE. Cross section clear area in one pass of the HE (section) cooled syrup side
f1pS = npcS * fp
Cooled syrup speed in channels
(m2)
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wS = MS / (
* f1pS)
(m/s)
The speed we compare with a recommended one and ev. change a number of parallel channels or parallel HE. For next calculations we will use equations from literature, e.g. criteria equations that are valid for the type of plates. Cooling liquid side Determination of Reynolds criterion
ReW = wW * de /
(-)
Determination of Nusselt criterion for turbulent flow Analogous to tubular HE is for the Nusselt criterion following equation used
(-)
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= NuW *
/ de
(W/m2K)
ReS = wS * de /
(-)
Again as in previous we use the criteria equation designed for the used type of plates
(-)
= NuR *
/ de
(W/m2K)
(W/m2K)
This value we compare with the estimated one (see chap. 4.1.) and if there is a difference we repeat these calculations till
kcalc kest
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Pressure loss in plate HE depends among others on speed, character of corrugation of plates and their arrangement. Analogous to the heat transfer we use criteria equation derived from our experiments for used type of plates.
Eu =
pL * w2
(-)
Note: This equation is valid for common working conditions, it is with common fouling layer and directions changes, inlet and outlet necks etc. Pressure loss in one interplate channel
pW1 = EuW *
*wW2
(Pa; Pa, -)
(-)
Note: Like for previous the equation is valid for working conditions, it is with common fouling on plates. Pressure loss in one interplate channel
pS1 = EuS *
m/s)
*wS2
(Pa; -, kg/m3,
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(Pa; Pa, -)
These pressure losses we compare with given maximal allowable and according situation (for corresponding liquid) repeat this calculation with a new number of parallel channels npci and from it calculated number of passes connected in series npsi. Too low pressure loss in HE results in low value of heat passage coefficient and consequently too large heat transfer area = too expensive HE. Therefore it is important to optimize capital and running costs of a designed HE.
Note: Calculation for tubular HE Specification of roughness of tubes kT = ? Coefficient of friction losses for turbulent flow in tubes
k = 0,169 T * dTi
0,319
(-)
(-)
Where
nPS = number of passes on the syrup side in a HE nHES = number of HE connected in series LT = tubes lenght dTi = internal tubes diameter wST = syrup speed in tubes
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where n is number of sudden enlargements. Pressure loss owing to sudden contraction (from chamber to tubes) For the case it is possible to use following equation
(-; m, m)
where Dvalve is diameter of seat of valve and Zvalve is valve stroke above the seat.
pLvalve = valve* w2 valve * S 2
wvalve=
Note: For valves, flap valves (butterfly valves), spherical valves, slide valves etc. it is better to calculate pressure losses according characteristics given by a manufacturer. Total pressure loss on the syrup side
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D=
4* M * * wrec * n
where is
mass flow of a fluid (steam, vapour, inerts, solution, condensate ...) number of necks for the fluid reccomended speed for the fluid
Reccomended speeds (according my practical experiences) These speeds are valid for common cases of evaporators and heat exchangers in food and chemical industries. Steam (vapour) in inlet necks Condensate in outlet necks (tubes) 10 - 25 m/s 0,2 - 0,5 m/s
(condensate is on boundary line vapour/water) if pressure decreases owing to pressure losses condensate starts superheated and vapour forms (in valves, steam traps, pipelines etc.,) two-phases flow in pipeline >> volume)
Solution inlet or outlet for HEs Solution outlet for evaporators Inerts outlet
5.
As the real number of plates and their configuration are little different from calculated values we want to know what is the real maximal performance of this HE. Analogical is a calculation if we want to use an existing HE for other application etc. In our case we want to know what the lowest attainable
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temperature of cooled syrup is or what the maximal attainable temperature of cooling water is. Select number of parallel channels on side of cooled syrup
npcS = ?
Select number of parallel channels on side of cooling water
(-)
npcW = ?
Speed in channels side of syrup
(-)
wS = MS / (
* fP * npcS)
(m/s)
wW = MW / (
* fP * npcW)
(m/s)
npsS = ?
Select number of passes connected in series side of water
(-)
npsW = ?
Total number of plates in the cooler (section)
(-)
(-)
(m2)
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Heat transfer for forced convention in channels On the basis of our previous results we estimate outlet temperatures of syrup and cooling water - (i iteration) and from them physical properties. The next procedure is similar to the previous.
tS1i = ?
- Side of cooled syrup
and
tW1i = ?
ReSi = wSi * de /
Si
(-) (-)
Si
= NuSi *
Si
/ de
(W/m2K)
ReWi = wWi * de /
Wi
(-) (-)
Wi
= NuWi *
Wi
/ de
(W/m2K)
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kcalci =
1 1 sWi sP sSi 1 + + + + Wi Wi P Si Si
(W/m2K)
tLi =
(K)
Maximal value of heat transfered from cooled syrup in cooling water (without heat loss)
(W)
(C)
(C)
Now we compare these temperatures with previous i iteration. If there is a difference we repeat these calculations till are temperatures the same. In supplement are results of several variants calculated in Excel file. Here you can see for example an effect of a variant with 2 sections or higher pressure loss on heat transfer area of HE.
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In a case of HE where is a phase change (condensation, boiling) is the procedure similar, it is that we firstly estimate heat passage coefficient = big iteration loop (1st iteration level). Because for condensation heat transfer coefficient depends on a temperature difference between condensing steam and wall (that is unknown), we must estimate it too = small iteration loop in the big one (2nd iteration level). When is the calculated wall temperature on the condensing steam side equal to the estimated one we can continue in calculations in the big iteration loop. Therefore is this procedure more complicated. Our calculations (temperatures specification) go from this standpoint: Specific heat flux through all interfaces must be the same (from condensing steam to incrustation, through incrustation, through wall, through incrustation and from incrustation to boiling liquid). In this way we can specify temperatures on single interfaces (see fig. 2 there are other indices).
q = s * (ts tis) = =
ib
is
/ sw * (tws twb) =
* (tib tb)
In the equation is: s steam; is incrustation on steam side; ws wall on steam side; wb wall on boiling side; ib incrustation on boiling side; b boiling liquid
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t21
M2 - syrup
syrup
water
t12
M1 - water Temperatures in 1 section
t22 t11
t21 t122
M2 - syrup
syrup
syrup
t112
M1 - water
t221 t121
t222 t111
Temperatures in 2 sections
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Parameter
1 section < p
Q (kW) k (W/m2K)
191,0 257
AHET (m2) number of plates mass of cooler (kg) temperatures (C) - syrup - cooling water
30,9 73 394
pressure loss (kPa) - syrup - cooling water 77 15 203 50 184,6 12,3 14,1
Approximate economical appreciation of 3 variants with 1 and 2 sections (both for higher pL)
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Costs for salaries will be the same for both variants. Costs of maintaining, depreciation etc. will be supposed as some percent of capital costs. Therefore we can neglect them and we can calculate only with these two costs. Syrup pre-cooled in the HE must be after-cooled in another cooler with refrigerant to a needed temperature 10 C with ice water from a cooling circuit e.g. with an ammonia compressor.
Additional costs for heat transfer area for variant with 2 sections CCA = A * CA = (42,7 30,9) * 8000 = 94 400,- K
This value represents higher capital cost.
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We assume a depreciation time 12 years. Corresponding depreciation rate is c. 8 %. Cost for maintaining we assume as c. 4 % of acquisition cost. Then these additional costs for maintaining and depreciation are
CMD = CCA * (D + M) = 94 000 * (8 + 4) / 100 = 11 330,- K/year Amount of energy saved for 2nd step of syrup cooling QCOOL = Q2 Q1 = 205,0 190,3 = 14,7 kW Amount of saved energy (cool) per year
Line working time
QCOOLY = QCOOL * QCOOLY = 14,7 * 4800 * 3600 / 1 000 000 = 254,0 GJ / year Cost of saved cool per year CCCOOLY = QCOOLY * CCOOL = 254,0 * 250 = 63 500,- K/year
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AP = CCCOOLY - CMD = 63 500 11 330 = 52 170,- K/year Simple rate of return of the investment SRR = CCA / AP = 94 400 / 52 170 = 1,81 years
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Design o
Given data: Specify:
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HE CALCUL
1. Specificati
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3. Liquids (m
calculated numb
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Medium 2
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Note: Maxim c
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Pressure lo
Medium 1
Eu1 = 418,6*(R
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pressure loss in
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GIVEN DAT
Medium 1 - he
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CALCULAT
Medium 1
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Design o
Given data: Specify:
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Note:
Order:
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Made by:
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HE CALCUL
1. Specificati
- Medium 1:
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3. Liquids (m
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calculated num
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calculated num
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maximal allowa
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Note: Maxi c
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Temperature o Temperature o
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Pressure lo
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Print of results
GIVEN DAT
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CALCULAT
Medium 1
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Design o
Given data: Specify:
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HE CALCUL
1. Specificati
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3. Liquids (m
calculated numb
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5. Specificati
tlog = abs((t22
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Note: Maxim c
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Temperature o Temperature o
Pressure lo
Medium 1
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GIVEN DAT
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CALCULAT
Medium 1
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