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2012
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The over-all heat transfer coefficient in a jacketed agitated vessel system can be
determined from the energy balance equation and empirical correlations. This
course will use one-dimensional flow of heat across the radial direction (Assumption
#1). The energy balance equation is composed of a series of resistances which
relate the bulk stream temperatures of the agitated liquid batch and the
cooling/heating medium through the vessel wall. Figures 1 and 2 are common
industrial examples of a jacketed vessel used to heat or cool a liquid batch. (Figures
used in this course are located in the following pages.)
In both examples, the volume of batch liquid is well mixed by an internally mounted
mixing device. Typically this device is a propeller or turbine blade connected to a
shaft that is usually driven by an electric motor at a fixed speed. The result of the
“well mixed” volume of liquid is that this allows us to assume that the liquid physical
properties, i.e., temperature, heat capacity, viscosity etc., of the liquid are uniform
throughout the entire liquid batch volume, (Assumption 2). The transport
mechanism assumed for heat transfer from the jacket wall to the agitated liquid
batch is convective heat transfer (Assumption 3).
The rate of convection heat transfer, -QA, from the hot fluid to the vessel wall is
defined as equal to the temperature driving force divided by the resistance to
exchange heat. The temperature driving force is the difference between the hot fluid
bulk temperature, TA, and the vessel wall temperature on the hot fluid side, TwA.
Note that a negative value indicates heat being released. The resistance to heat
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Page 1 of 32 PDH Course K102 www.PDHcenter.com
Over-all Heat Transfer Coefficients in Agitated Vessels
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Vessel Data:
Volume= 5,500 gals
Diameter = 9 feet
Agitator Motor
Speed = 45 rpm
Saturated
Steam
150 psig
366 deg F Liquid Level
Vessel Jacket
Liquid Volume = 5,000 gals
Fluid = Water
Condensate
Cp = 1.0 Btu/lb.-F
150 psig
Density = 8.3 lbs./gal
366 deg F
Tinitial = 70 F
Vessel Jacket
Agitator Blades
Diameter = 3.5 feet
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Vessel Data:
Volume= 5,500 gals
Diameter = 9.0 feet
Agitator Motor
Speed = 45 rpm
Liquid Level
Vessel Jacket
Chilled
Liquid Volume = 5,000 gals Water
Fluid = Water
50 psig
Cp = 1.0 Btu/lb.-F
48 deg F
Density = 8.3 lbs./gal
Tinitial = 170 F
Vessel Jacket
Chilled
Water
50 psig
Agitator Blades
40 deg F
Diameter = 3.5 feet
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Page 3 of 32 PDH Course K102 www.PDHcenter.com
Over-all Heat Transfer Coefficients in Agitated Vessels
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Vessel Wall
of thickness DX
TA
Bulk
Temperature
Temperature TWA
TWB TB
Bulk
Temperature
Hot Fluid
Cold Fluid
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exchange, RA , is the reciprocal of the product terms area, AA, and heat transfer
coefficient, hA. Expressed mathematically, the temperature driving force is:
RA = 1 / ( hA * AA ) (2)
RB = 1 / ( hB * AB ) (3)
The heat transfer through the vessel wall is based on conduction through the vessel
material of thickness ΔX, with a material thermal conductivity of kW (Assumption #5).
The conduction transport mechanism for heat transfer is based on the physical
contact of one substance to another. The resistance equation for conduction
includes a thickness term, ΔX, of the material transferring heat as well as the wall
material thermal conductivity term:
RW = ΔX / ( kW * AW ) (4)
The quantity of heat being transferred by the hot fluid A is obtained by combining
equations (1) and (2) yields the convective form of the steady-state heat transfer
rate equation:
QA = - ( TWA – TA ) / ( 1 / ( hA * AA ) ) (5)
Likewise for the cold fluid heat gain and the vessel wall heat transfer:
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QB = - ( TB – TWB ) * RB
B (6)
Equations (5), (6), and (7) are the Fourier form of the steady-state heat transfer
equations which assume a constant temperature driving force across each
resistance. If we rearrange equation (5) using its basis equations, (1) and (2), we
get:
- ΔTA = QA / RA (8)
- ΔTB = QB / RB (9)
- ΔTW = QW / RW (10)
At steady state, by definition, the heat transfer through each mechanism is equal
and can be represented by Q Over-all, the over-all heat transfer rate (Assumption #6):
QA = QB = QW = Q Over-all (12)
Substituting equation (1) back into the left-hand side of equation (11) for ΔTA , along
with the respective equivalents for ΔTB and ΔTW results in the wall temperature
terms cancelling out. Using equation (12) in equation (11) results in:
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which implies that the heat transfer rate is equal to the temperature difference
divided by the sum of the individual resistances:
where each resistance is calculated as the reciprocal of the product term of area
and individual heat transfer coefficient (Assumption #7).
∑ R Over-all = ∑ 1 / ( hi * Ai ) (15)
Equation (13) can also be restated as relating the over-all heat transfer to the over-
all temperature difference divided by the over-all system resistance.
In most cases agitated batches, however, are not constant temperature driving
force processes, and heat transfer must be calculated using a transient, non-steady
state application equation. An example of this situation follows.
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A jacketed vessel is supplied with condensing steam to heat an agitated liquid batch
from 70 to 150 deg F. While the steam can be assumed to be at its constant
saturation temperature, the liquid batch temperature is changing throughout the
heating time. The driving force during this time is not constant, but variable.
The important concept from the steady-state rate equation derivation is the
definition of the over-all resistances as the sum of the individual resistances. This
course will use Assumption #7 in developing the application equation for over-all
heat transfer coefficients in agitated vessels.
Normally the bulk fluid streams temperatures, TA and TB, are easiest to measure.
The temperature difference between the two bulk streams, the agitated liquid batch
and the heating/cooling medium, will represent the temperature driving force across
all the resistances encountered between the two fluids. This ΔT is referred to as the
over-all or total driving force. Accordingly, an over-all coefficient, U Over-all may be
defined as a function of the total resistance, ∑ R Over-all, and transfer area, A,
consistent with the definition of U Over-all as:
From Figure 3, Equation (17) becomes for the agitated liquid batch and
heating/cooling medium convective resistances, along with the jacket wall
conductive resistance,:
where:
U Over-all = over-all heat transfer coefficient, Btu/hr-sq. ft-deg F. This course will
assume that it is constant (Assumption #6). It is understood, however, that the
coefficient does in fact vary with the temperature of the fluids. It is assumed
that its change with temperature is gradual, so that when the temperature
ranges are moderate the assumption of constancy is not in error significantly.
Based on this, all individual coefficients will be calculated by determining the
fluid properties at an average temperature (Reference 1).
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Two additional resistance terms can be added to equation (18) to include the effects
of equipment fouling by the process fluid on both sides of the vessel wall. The terms
are strictly empirical. Table 1 contains selected values used in industry.
Equation (19) then defines the general over-all heat transfer coefficient for agitated
liquid batches:
where:
ADC or ADH = transfer area of the hot and cold fouling deposits, sq. ft.
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For the case where the vessel wall is composed of a material such as iron, steel,
copper or aluminium, and the operating pressures are not high, the vessel wall
thickness will be relatively small and the thermal conductivity will be relatively high.
This ratio of thickness to thermal conductivity will be almost a magnitude smaller
than the other resistances and can be assumed negligible (Assumption #8).
ΔX/(KW*AW) = 0 (20)
Another simplifying assumption can be made relative to the heat transfer areas. For
vessels operating at 150 psig jacket pressures with a 3-foot diameter or larger, the
ratio of outside-to-inside heat transfer surface areas for 3/8” thick vessel wall is less
than 2 percent difference. For a 9-foot vessel, the difference drops to less than
0.7%. This analogy will also be extended to the fouling deposit areas.
Therefore it will be assumed that the relative areas are equal (Assumption #9):
Agitated vessels are typically designed and operated so that the internal wetted
vessel surface is essentially “clean” at the start of each operation. The vessel side
fouling coefficient will be assumed to be zero and therefore the only fouling
consideration will be the heating or cooling media. Fouling deposit coefficient
subscript for the media will be represented by 1/hDM , this further simplifies equation
(19) to:
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Application Equations
Over-all heat transfer coefficient for the Agitated Batch Liquid general case:
Over-all heat transfer coefficient for the simplified case in agitated vessels:
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Notation for jacket side heat transfer coefficients, hJ , will utilize the subscript “J”.
Heat transfer coefficients for condensing vapors, such as steam, can be calculated
from a Nusselt type correlation (Reference 2). The condensing vapors in the jacket
side of a jacketed vessel are typically introduced at a nozzle along the top of the
jacket. The vapor droplets collect as a film layer as they condense on the vertical
jacket-vessel wall and eventually run down to the bottom of the jacket. The
condensed phase is then collected and removed through a nozzle located at the
bottom of the jacket. A steam trap is typically used to maintain the jacket at
saturation conditions and minimize the amount of uncondensed steam from leaving
the jacket. An empirical correlation which is based on the condensate film for
vertical tubes is given in equation (25). This correlation utilizes the physical
properties of the liquid condensate to predict the heat transfer coefficient. Equation
(25) is valid for condensate film Reynolds numbers from 2,100 to 100,000. Equation
(24) defines the condensate film Reynolds number:
where:
where:
hJ = jacket heat transfer coefficient of the condensate film, Btu/
hr-sq. ft- deg F.
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Typical jacket side liquids used are: water, brine, oils, and organic solvents. The
benchmark for predicting heat transfer coefficients for flow in circular tubes is the
Dittus-Boelter correlation (Reference 3). This correlation relates the Nusselt number
to the jacket fluid Reynolds and Prandlt numbers and utilizes physical properties at
the bulk fluid temperature. For Reynolds numbers greater than 10,000, and Prandlt
numbers less than 700:
where:
Rearranging to solve for the individual jacket fluid heat transfer coefficient yields:
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Notation for liquid batch side heat transfer coefficients, hB , will utilize the subscript
“B”.
The Chilton, Drew, and Jebens benchmark correlation for determining the heat
transfer coefficient of the agitated liquid batch to/from the jacketed vessel wall is
equation (28) relating the Nusselt number to the agitated liquid batch Reynolds and
Prandlt numbers. A correction for viscosity is also included (Reference 4). The
assumptions required for this correlation include no phase changes or loss of
material for the liquid being agitated.
where:
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Rearranging to solve for the individual agitated liquid batch heat transfer coefficient,
hB ,and yields:
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AGITATOR A2 M RANGE OF
BLADE TYPE REYNOLD’S NUMBER
3-Blade marine 0.54 0.14 2,000 (one data point )
Propeller
Paddle 0.36 0.21 300-300,000
Disk, Flat-Blade 0.54 0.14 40-300,000
Turbine
Pitched-blade 0.53 0.24 80-200
turbine
Anchor 0.36 0.18 300-40,000
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Example #1
Equipment Data:
Vessel Diameter = 9.0 ft.
Agitator Diameter = 3.5 ft.
Agitator type = Flat blade disk turbine
Agitator speed = constant 45 rpm
Vessel jacket height = 8.0 ft.
Vessel jacket flow depth = 1.0 in
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Page 21 of 32 PDH Course K102 www.PDHcenter.com
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NPr = 3.52
Viscosity Ratio = ( μB / μw B)
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Page 22 of 32 PDH Course K102 www.PDHcenter.com
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Tavg = 44 deg F
Viscosity Ratio = ( μ / μw ) = 1
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Page 23 of 32 PDH Course K102 www.PDHcenter.com
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where:
ACS = 1.0 * 8 * 12
Wetted = ( 1.0 * 2 ) + ( 96 * 2 )
Wetted = 194 in
DJ = 4 * 96 / 194
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AEquivalent = ( π /4 ) * DJ 2
AEquivalent = (π /4 ) * ( 0.165) 2
Volumetric Flow = 100 gal/min * min/60 sec * cu. ft/ 7.48 gals
NRe = 114,926
NPr = 10.6
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Example #2
Equipment Data:
Vessel Diameter = 9.0 ft.
Agitator Diameter = 3.5 ft.
Agitator type = Flat blade disk turbine
Agitator speed = constant 45 rpm
Vessel jacket height = 8.0 ft.
Vessel jacket flow depth = 1.0 in
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NPr = 3.52
Viscosity Ratio = ( μB / μw B)
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where:
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