A STUDY OF THE HEAT TRANSFER BETWEEN A FALLING

DROP OF LIQUID AND A RISING STREAM OF GAS

A Thesis
Presented to
the Faculty of the Department of Chemical Engineering
The University of Southern California

In Partial Fulfillment
of the Requirements for the Degree
Master of Science in Chemical Engineering

by
Charles T. Foy
January 1950
 UMI Number: EP41725

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This thesis, w ritten by

Charles Terrance Foy

under the guidance o f hT.?.... F a c u lty C om m ittee,

and ap p ro ved by a l l its members, has been
presented to and accepted by the C o u n cil on
G ra d u ate S tudy and Research in p a r t ia l f u l f i l l ­
ment of the requirements f o r the degree of

Master of Science in

Chemical Engineering

D ate..

Faculty Committee

Chairman
 TABLE OF CONTENTS

CHAPTER PAGE

I. THE PROBLEM AND DEFINITIONS OFTERMS USED. . . . 1

The problem................................. 1
Statement of the problem ........ 1
Importance of the study.................... 1
Nomenclature and definitionsof terms used , . 2
Thesis organization. . . . ............ ... 2
II. REVIEW OF THE LITERATURE 3 .
Limitations of previous study................ 4
III.. EQUIPMENT AND EXPERIMENTAL PROCEDURE ......... 5
Apparatus ................... 5
Materials................. 8
Experimental procedure ..................... 9
IV. EXPERIMENTAL R ESULTS......................... 12
Heat balances............................... 12
Correlation of the data............... 15
V. SUMMARY AND CONCLUSIONS....................... 24
Summary..................................... 24
Discussion................................. 24
Conclusions................................. 27
BIBLIOGRAPHY..................... 28
APPENDIX A. ORIGINAL D A T A ................... 30
APPENDIX B. SAMPLE CALCULATIONS................... 39
APPENDIX C. SAMPLE DESIGN CALCULATIONS............. 46
 CHAPTER I

THE PROBLEM AND DEFINITIONS OF TERMS USED

For quite- sometime engineers in the field of heat

transfer have been faced with the problem of heating gases.
The problem has always presented a great deal of difficulty
because of the low coefficients obtained when attempting to
transfer heat to or from a gaseous medium. Since these co­
efficients are so small, large heat transfer areas are re­
quired for this service. These large exchangers cost a
great deal of money. Hence engineers have attempted in
various ways to reduce the size of these exchangers YriLthout
reducing their efficiency. A notable example of this is
the finned-tube units.

THE PROBLEM

Statement of the problem. It was the purpose of this

investigation (l) to construct an apparatus to study the
heat transfer between a falling drop of liquid and a rising
stream of gas, (2) to correlate the data collected on the
apparatus, and (3) to obtain heat transfer coefficients for
the design of heat exchangers.

Importance of the study. Except in large installa­

tions, no effort is made to utilize the sensible heat of hot
gases for the BTU content alone. The extremely low heat
transfer coefficients obtained in gas to liquid or gas to
gas exchangers makes it economically unsound to do so.
Therefore vast amounts of heat are wasted by industry.
An exchanger of the type proposed herein makes re­
covery of this heat more feasible. This- might result in a
substantial saving of fuel.

nomenclature and definitions of terms used. The

nomenclature and definitions will conform to the standard
system of Nomenclature for Chemical Engineering Unit Oper­
ations as defined in the Transactions of the American Insti­
tute of Chemical Engineer s,-*- except as noted.

Thesis organization. The first chapter.will cover

the problem and the definitions of the terms used. There
will be four other chapters. The second chapter will be a
review of the literature. The third chapter will cover the
experimental work with a description of the apparatus and
the method of its utilization. Chapter four will contain
the experimental results. Finally, chapter five will con­
tain the summary and conclusions.

"Standard System of Nomenclature for Chemical En­

gineering Unit Operations," Transactions of the American In­
stitute of Chemical Engineers. 40:251-67 X1944-) •
 CHAPTER II

REVIEW OF THE LITERATURE

A review of the literature indicated that a great

deal of research has been done in the phase of the heat
transmission field which concerns itself with the transfer
of heat between gases and liquids. The greatest amount of
work has been on heat transfer through metal surfaces where
the liquid and gas do not come into contact with each other.
Also, a considerable number of articles have been written
on the subject of simultaneous heat and mass transfer. In
this case the liquid and the gas are in direct contact with
each other. The problem is complicated, however, by the
fact that this simultaneous transfer is taking place. Al­
though an exhaustive search of the literature was made, no
articles could be found on the subject of heat transfer be­
tween liquids and gases in direct contact with each other,
and where the vapor pressure of the liquid was sufficiently
low to insure negligible simultaneous mass transfer.
One article was found, however, where the transfer of
heat was studied betv/een gases and streamlined solids having
the same shape as a falling drop of liquid. This investi­
gation was carried out by Hughes'and Coy.^ They tested in

p
J. A. Hughes and E. Coy, !,0n the Cooling of Cylinders
in a Stream of Air," Philosophical Magazine. (6) 31:118, 1916.
a wind tunnel a steamheated copper model having a stream­
lined contour similar to that of a tear drop. The inlet and
exit air temperatures were measured and the gas film heat
transfer coefficients were calculated over a wide range of
air velocities. Their data was correlated by plotting
ht% vs on log—log paper. De is the effective diameter,
equal to the total perimeter divided by If . It was found
that lower coefficients were obtained v/hen the model was
reversed so that the air approached the pointed end of the
tear.

LIMITATIONS OF PREVIOUS STUDY

The greatest limitation of this study by Hughes and

Coy3 is that it only holds true for metal streamline shapes.
The results of the investigation presented herewith indicate
that their correlation cannot be used to compute gas film
coefficients when liquid droplets are employed. In the
latter case, higher coefficients were obtained due to the
violent mixing of the liquid in the droplet.

3
J. A. Hughes and E. Coy, loc. cit.
 CHAPTER III

EQUIPMENT AND EXPERIMENTAL PROCEDURE

APPARATUS

The equipment used in this investigation is shown in

Figure 1. It consisted essentially of a drop forming mecha­
nism, an enclosed space through which the liquid droplets fell
counter-current to the rising stream of gas, and a liquid
reservoir. Details of the drop forming mechanism are shown
in Figure 2.
The liquid from the reservoir was pumped through a
one-half inch iron pipe directly to the drop forming mechanism
where it flowed through the small stainless steel capillary
tubes, 0.05 inch O.D. The liquid emerged from these tubes
in the form of droplets. Within the drop forming mechanism,
the liquid was kept at a constant level by using an overflow
pipe, thus insuring a constant rate of flow.
The droplets fell through a six inch diameter stove
pipe lagged with one sixteenth inch asbestos. The height of
the column could be varied by adding or subtracting sections
of pipe. The bottom of the column tapered to one inch in
diameter and, at this point, the exit temperature of the
droplets was measured by a calibrated thermometer. Approxi­
mately six inches above the tapered section, a trough was
 6

Thermometer-; exitgas
Thermometer} faJet h<fo/<t-

Drop forming mechanism

V / ,y
6 Store p ip e - asbestos ta g g in g

'-fayt/icL oferf/ow /me

7roi/y/7 to catch /ipaicf running

e/oxrn the inflate of the store /npe

Gas distributor

tine used to frteasure

A ig u/ct through mp u t

V v V AAAI S/ectr/c heaters

f/yare /
Fxper/ m e n t a l Apparatus
 Orerf/ovr Pjpe
£ S£4.

f / g v r e £.
Drop for/n/ng
Afec/?ar/sm
placed on the inside of the column which collected the
liquid flowing down the sides of the pipe. This liquid was
carried off by a quarter inch copper tube. A calibrated
thermometer in the line measured its temperature. .
In order to determine the rate of flow, a two way
valve was placed directly below the tapered section. By
means of this valve, the stream of liquid flowing through
the apparatus could be diverted into a side arm and col­
lected in a suitable weighed container.
The liquid reservoir had a fifteen gallon capacity. ,
It was equipped with electric heaters capable of supplying
heat at the rate of 5200 BTU/hr. Constant agitation was
provided by an electric mixer.
The gas entered the column through a star type gas
burner, hereafter called the distributor, located directly
beloY/ the trough. The gas rate was measured by means of
an orifice and its temperature was recorded before entering
the column. The gas passed upward countercurrent to the
falling drops, flowed around and through the three-quarter
inch copper tube in the drop forming mechanism, and out the
top of the column. Its temperature was measured just be­
fore leaving.

MATERIALS

The two materials used in this investigation were

Dowtherm and air. Air was chosen because of its availa­
bility and Dowtherm because of its extremely low vapor
pressure. It was calculated that the average vapor pres­
sure of the Dowtherm in the column was 0.032 psia. Since
this is such a small value it was assumed there was no mass
transfer. Calculations to support this assumption are pre­
sented in Appendix B.

EXPERIMENTAL PROCEDURE

At the advent of the problem, it was realized that

there were two possible methods of approach. The first one
that could have been employed was to use the air as the hot
fluid and the Dowtherm as the cold. In this procedure, the
hot air would transfer heat to the cold Dowtherm droplets.
This method had an obvious disadvantage in that it would
have required extensive heat transfer apparatus to heat
the air. The second approach, and the one that was used,
was the exact opposite of this. The hot Dowtherm droplets
transferred the heat to the cold air.
At the .start of a run, the heaters in the reservoir
were turned on and the temperature allowed to become con­
stant at approximately ten degrees above the desired inlet
Dowtherm temperature. The compressor, which was used to
force air through the column, was then turned on. In be­
tween the compressor and the column there was a by-pass
 10

valve located in the air line, which opened to the atmos­

phere. This gave better control over the air rate.
With the air going through the column, the Dowtherm
was circulated, using a one-half inch gear pump. A variac,
in series with the electric heaters, was-then adjusted to
bring the inlet Dowtherm to the desired temperature of
200° F. or 175° F., depending on the conditions under which
the run was being carried out. The equipment was allowed to
run until equilibrium was attained. This was indicated by-
constant temperature readings in the air and Dowtherm
streams. While awaiting for equilibrium, samples of Dow­
therm were removed through the two way valve and the copper
tube from the trough. These samples indicated the amount of
Dowtherm passing through and down the sides of the apparatus.
When equilibrium conditions were attained, the fol­
lowing temperatures were recorded: (l) the inlet Dowtherm
temperature, (2) the exit Dowtherm temperature, (3) the
trough temperature, (4) the inlet air tempera-ture, and (5)
the exit air temperature.
The air rate was then changed and the apparatus again
allowed to come to equilibrium. The required data was then
recorded. For any one run of a constant Dowtherm rate, the
air rate was varied from 24-5 #/hr. to 375 #/hr. as measured
by a calibrated orifice. To convert these rates to pounds
of air per hour per square foot of cross sectional area, the
 11

values should be divided by 0.196. To convert them to

ft/sec, the values should be multiplied by 0.0207.
Three runs were made at an inlet Dowtherm temperature
of 200° F. The Dowtherm rate was different for each run.
At approximately the same Dowtherm rates, three more rims
Y/ere made at an inlet Dowtherm temperature of 175° F. The
lower Dowtherm rates were achieved by blocking off some of
the capillary tubes. The higher Dowtherm rates were
achieved by increasing the liquid head over the ends of the
tubes. The three rates used were approximately 100 #/hr.,
150 #/hr., and 200 #/hr. To convert these rates to pounds
of Dowtherm per hour per square foot of cross sectional area
the values should be divided by 0.196.
The above six runs were carried out at a distance of
forty-four inches between the ends of the capillary tubes
and the air distributor. An analogous procedure was re­
peated with an increased distance of sixty-four inches.
 CHAPTER IV

EXPERIMENTAL RESULTS

Heat balances. Data were collected on the apparatus

for a total of twelve runs. The validity of the data was de­
termined -by calculating heat balances using the following
equation:

<1 = wcp (t2 - ti)

where: q = heat gained or lost, BTU/hr.
w = weight of substance, lb.
Cp = specific heat of substance, BTU/°F.
tp = inlet temperature, °F.

t£ = exit temperature, °F.

If there were no heat losses, the ”q n calculated for the air
using the inlet and exit air temperatures should equal the
’’q” calculated for the Dowtherm, providing, of course, no
errors were made in the weight and temperature measurements.
In an attempt to eliminate such errors in this inves­
tigation, calibrated thermometers were used which could be read
to within a quarter of a degree Fahrenheit. During a parti­
cular run, the Dowtherm and air rates v/ere constantly re­
corded, thus assuring accurate weights of each. These
recorded weights could not have been more than several per­

cent in error.
The heat balances for one run are given in Table I,
 13

TABLE I
HEAT BALANCES RUN NO. 1

Heat Transferred Heat Transferred Losses

From Dowtherm To Air BTU/hr.
BTU/hr. BTU/hr.

2674 2670 — 4
2946 2950 / 4
3193 3170 -23

H
3334 3320

1
3440 3440 0
3550 3520 -30
 14

while heat balances for all the runs are tabulated in Appendix
A, The method used in their calculation is presented in
Appendix B.
An examination of these heat balances shows that the
heat losses, in most cases, were extremely low. Since cal­
culations, presented in Appendix B, indicate that these
losses should have been approximately 45 BTU/hr., it is be­
lieved that compensating errors existed which made the heat
balances appear better than they actually were.

Drop size. Before any correlation of the results of

this investigation could be attempted, the size of a droplet
had to be determined. This was done by weighing a known
number of droplets which were formed by capillary tubes the
same size as those in the drop forming mechanism. Six tubes
were used in this determination. By dividing the number of
droplets thus formed into the total weight, the weight of a
single droplet was found. The volume of the drop was cal­
culated by dividing this weight by the density of the Dowtherm
at 187.5° F. (the average of the two operating temperatures,
200° F. and 175° F.). The assumption was then made that the
droplet was a perfect sphere and the diameter and surface
area was calculated. It was realized that under operating
conditions this area was not the true area, but it xvas pro­
portional to it. These calculations are presented in
 15

Appendix B while the results of the weight determinations are

given in Table II.

CORRELATION OF THE DATA

One of the objects of this investigation was to corre­

late thedata in such a manner that the heat transfer
coefficients obtained could be used to design other heat
transfer equipment. In any design problem, one of the main
considerations is how large to make the exchanger so that it
will be capable of doing the job for which it is intended.
The size is usually determined by calculating the area re­
quired to transfer the necessary amount of heat using the
following equation:

<1 = UAAtm

where: H ~ Amount of heat transferred.

U = Overall heat transfer coefficient.
A = Surface area required.
At m - Correct mean temperature difference.
The terminal conditions of both streams are obtainable
as well as the amount of heat to be transferred. The value of
U, the overall heat transfer coefficient, hoT/ever, can only be
obtained from experiments made on similar equipment or cal­
culated using some correlation to be found in the literature.
For this reason, any correlation presented in this thesis will
 16.

TABLE II
DROPLET SIZE

Trial Number Weight Ifeight

No. of of per
Droplets Droplets Droplet
grains grains

Capillary No. 1
1 20 0.2470 0.0124
2 20 0.2449 0.0122
3 20 0.2452 0.0123
Capillary No. 2
1 20 0.2501 0.0125
2 20 0.2447 0.0122
3 20 0.2316 0.0115
Capillary No. 3
1 11 0.1296 0.0118
2 10 0.1196 0.0120
3 10 0.1247 0.0125
Capillary No. 4
1 20 0.2336 0.0117
2 20 0.2397 0.0120
3 20 0.2347 0.0117
Capillary No. 5
1 20 0.2405 0.0120
2 10 0.1193 0.0119
3 10 0.1206 0.0121
Capillary No. 6
1 10 0.1211 0.0121
2 10 0.1156 0.0116
3 10 0.1097 0.0110
Average Droplet Size: 0.0120 grains/droplet
 17

contain U so that the drop type heat exchanger can more

easily be designed.
From the above equation, it is apparent that UA= q/Atm .
Since both q andZsfcm can be calculated from variables that
were measured in the experiment, it was decided to plot UA
against some other measured variable such as the air rate as
a first attempt at a correlation. The results of this are
presented in Figure 3. A q based on the weight and terminal
conditions of the air stream was used in this attempted
correlation.
It is obvious that this does not correlate the data
very well. The reason for this is that unlike conventional
exchangers, the drop type does not have a fixed surface area
available for heat transfer, but a variable one depending on
the rate of liquid throughput, the velocity of the gas
stream, and the distance the droplets fall. This surface
area can be varied over a wide range without altering the
physical make-up of the exchanger. This is a most unusual
case, and as such, requires an unusual correlation. There­
fore another was sought which still contained the variable
U.
If the area, A, in the above correlation, is trans­
ferred from the ordinate to the abscissa, a plot of U versus
area/air rate results. Since the effect of the velocity of
the gas stream on the surface area is small, for all
 $

II
§
 19

practical purposes it can be said that the Dowtherm rate is

directly proportional to the area for any definite column
height. Therefore the Dowtherm rate can he substituted for
it in the above ratio. As a second attempt at correlation,
this ratio, the Dowtherm rate/the air rate, was plotted
against a calculated or apparent overall heat transfer co­
efficient, U. This'is definitely a second approximation when
the data collected on the apparatus is plotted in this
manner.
Before this apparent coefficient could be obtained,
the surface area available for heat transfer had to be cal­
culated. As mentioned above, this area is dependent upon
the rate of liquid throughput, the velocity of the gas
stream, and the distance the droplet falls. The latter two
can be combined by calculating the time required for a
droplet to fall through a countercurrent gas stream from the
end of the capillary in the drop forming mechanism at the
top of the column to the gas distributor at the bottom of
the column. This time is defined as the residence time.
Once the residence time is determined, the amount of
liquid present in the column at any instant can be found.
By dividing this amount by the weight of one droplet, the
number of droplets in the column is obtained. If the
assumption is made that the droplets are perfect spheres,
their surface area can easily be calculated by using the
 20

theorems of solid geometry as presented in any mathematics

handbook.
One other assumption was made at this point. It was
assumed that the liquid collected in the trough at the bottom
of the column existed as droplets for three quarters of the
distance betv/een the drop forming mechanism and the gas dis­
tributor. Therefore, to the liquid rate that was measured by
diverting the liquid stream into the side arm at the bottom
of the column was added three, quarters of the liquid rate that
was measured from the trough. This amounted to a correction
of about ten per cent addition to the measured stream.
The residence time was calculated using the following
equation presented in a Master’s thesis by Marines and Wilson^
of the University of Southern California.

Sg= (V1 2/g) In cosh g/V'Ct-C-jJ / C2-VQt

W w d /cd4jpaSd
cl= (~V,/g)tanh -1V o A T
C2= (-V»2/g) In cosh ( g A T)Ci
where:
Sg— Distance drop falls in ft.

g = Acceleration due to gravity in ft./sec./sec.

4 Robert Marines and George Wilson, "Behavior of liquid

Droplets Falling into an Up?/ard Moving Air stream."- Master’s
Thesis Presented to the Faculty of the Department of Mechani­
cal Engineering, The University of Southern California (194,9).
 21

t = Time of fall in sec.

VQ= Velocity of the air stream in ft./sec.

Wa.= Weight of the drop in lbs.

CcL= Drag coefficient.

fsP Density of the air stream in slugs/cu.ft.

S<3= Surface area of the drop in ft.2

This equation was solved and the distance of fall was
plotted against time for drops falling in still air and
counter-current to 2/5 lbs. of air/hr. and 37/ lbs. of air/hr.
through the six inch stove pipe. The latter two values
represent the least and the greatest amount of air used in
this investigation. The results of such a plot are pre­
sented in Figure 5 and the method of calculation is given
in Appendix B.
The apparent coefficient, U, was then calculated from
the equation q= UAAtm and the result was plotted against the
ratio of the Dowtherm rate to the air rate. This was done
for each set of conditions in all twelve runs. The final
results are reproduced in Figure 4 and tabulated in
Appendix A.
It will be noted that a better correlation was ob­
tained and that this correlation can easily be used to
design similar exchangers as illustrated by the sample
problem presented in Appendix C.
22

1
1

S*
SO X SO bEB IMCH
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Aa
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M3DU3 HOMl 513s* OS X OS

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 CHAPTER V

SUMMARY AMD CONCLUSIONS

Summary. Experiments were conducted using a drop

type heat exchanger. Two column heights were used in the
investigation, 44 inches and 64 inches respectively. With
the column in the lower position, three runs were made with
the Dowtherm inlet temperature at 200°F and three at 175°F.
The liquid rate was varied with each run and the air rate
was varied from approximately 245 lb./hr. to 375 lb./hr.
during each run. With the column in the higher position,
the procedure v/as repeated.
Inlet and exit air and Dowtherm temperatures were
taken and the amount of heat transferred ascertained. The
surface area avails,ble for heat transfer was calculated and
the apparent overall heat transfer coefficient computed. A
smooth curve was obtained when this coefficient was plotted
against the ratio of the Dowtherm rate to the air rate.
This curve is well adapted for design calculations.

Discussion. From the data presented in this thesis,

it is apparent that extremely high heat transfer coeffici­
ents are obtained in the drop type exchanger. It is be­
lieved this is due to the violent mixing within the droplets
as they fall through the exchanger. If this mixing did not
 25

occur, the heat from the central portion of the droplets

would have to be transferred, by means of conduction, to the
surface of the droplet before it could be transferred to the
air. Thus we would have two temperature drops, one from the
center of the droplets to the surface, and, one from the
surface to the air. When mixing takes place within the
droplets, however, the temperature is constant throughout
each droplet, therefore one of these temperature drops is
eliminated. This, in effect, reduces the resistance to
heat transfer and results in high heat transfer coeffi­
cients.
Another fact which explains these high coefficients
is that no stagnent gas film is built up around the liquid
droplet. As droplets fall through the exchanger there is
a constant movement of gas past them. The resistance to
heat transfer is much less through a moving gas film than
through a stagnent one. These facts also explain why higher
coefficients are obtained when the ratio of the Dowtherm
rate to the air rate is decreased. If the air rate is in­
creased, the gas film surrounding the droplets is reduced
and, at the same time, the amount of mixing within the
droplet is increased. This reduces the resistance to heat
transfer which, of course, increases the overall coefficient.
Since the overall heat transfer coefficients are so
high in the drop type exchanger, it lends itself well to
liquid to gas or gas to gas heat exchange. Design calcula­
tions for the latter are given in Appendix C. It is interest­
ing to note the effect of .increasing or decreasing the
Dowtherm rate in these claculations. As mentioned above, if
this rate be decreased, the overall coefficient is increased.
This means that a lower column could be used but only a
percentage of the heat available for transfer could be re­
covered. If the Dowtherm rate is Increased, all of the heat
available for transfer could be recovered, but much higher
columns would have to be used. It might be pointed out that
the limiting factor is the coefficient, not the surface
area, since it changes more rapidly with changes in the
ratio, R. It will‘be noted that increasing or decreasing
the Dowtherm rate has exactly the opposite effect on the
surface area, but this effect is small when compared to the
changes in the overall coefficient.
It is also interesting to note that the coefficients
obtained in this type exchanger are independent of the
diameter of the exchanger, but dependent only on the ratio.,.
R. •
Further investigations should be made to determine
the effect of increasing and decreasing the drop size. The
procedure followed in this ‘investigation should also be re­
peated using the air to heat the Dowtherm droplets. This can
easily be done by installing heaters in the air lines to the
exchanger.
In the calculations presented in this thesis, the
log mean temperature difference was used. It is recognized
that this is not the correct mean temperature difference,
hut for the purpose of these calculations the log mean is
sufficiently accurate. In a'more exhaustive study, of course,
this would not he true and a more exact mean temperature dif­
ference would have to he used.

Conclusions.
(1) High heat transfer coefficients are obtained in
the drop exchanger.
(2) The heat transfer coefficients obtained are de­
pendent only on the ratio, B and increase as B decreases.
(3) The drop type heat exchanger could he used to
advantage to transfer heat to and from gases.
BIBLIOGRJPHY
 BIBLIOGRAPHY

Hughes, J. A. and E. Coy, ”On the Cooling of Cylinders in a

Stream of Air," Philosophical Magazine. (6) 31:118,
1916.
McAdams, William H., Heat Transmission. New York: McGraw-
Hill Book Company, Inc., p. 360.
Mannes, Robert and George Wilson, ’’Behavior of Liquid
Droplets Falling into an Upward Moving Air Stream,n
Master*s Thesis Presented to the Faculty of the De­
partment of Mechanica.1 Engineering, The University of
Southern California, (1949)•
’’Standard System of Nomenclature for Chemical Engineering
Unit Operations,11 Transactions of the American Insti­
tute of Chemical Engineers. 46:251-67, (1944)•
Appmvn a
 TABLE I
EXPERIMENTAL DATA

Air Inlet Exit Heat Droplet Inlet Exit Trough Trough Heat
Rate Air Air Transferred Rate Droplet Droplet Liquid Liquid Transferred
Temp. Temp. to Air Temp. Temp. Rate Temp. From Dowtherm
lb./hr. op Op BTU/hr. lb./hr. Op Op lb./hr. °p BTU/hr.
Run'#l

2/5 104.0 149.9 2670 118.1 199.4 158.0 22.05 152.6 2674
276 lO/.O 149.0 2950 116.0 199.4 152.6 22.30 149.0 2946
303 105.8 149.9 3170 115.3 199.4 149.0 22.80 143.6 3193
330 100*4 142.7 3320 118.2 199.4 147.2 22.05 143.6 3334
354 99.5 140 •4 3440 118.5 199.4 145.4 21.60 141.8 3440
37/ 100.4 140.0 3520 117.5 199.4 143.6 21.85 140.0 3550
Run #2

248 98.6 155.3 3350 I64.8 199.4 158.9 21.00 159.8 3374
278 100.4 156.2 3690 163.6 199.4 155.3 21 *40 154.4 3683
304 104.0 157.1 3880 I64.7 199.4 151.7 21.45 152.6 3993
328 107.0 157.1 3940 165.5 199.4 151.7 21.50 152.6 4001
350 109.4 156.2 3940 165.0 199.4 151.7 21.50 152.6 3991
371 113.0 157.1 3930 165.0 199.4 151.7 22 •20 152.6 4007
Run #3
245 100.4 137.8 2180 129.3 175.0 140.9 21.90 143.6 2242
275 101.3 137.3 2358 128.0 175.0 138.7 22.00 140.9 2375
304 103.1 136.8 2440 127.2 175.0 137.3 22.2.0 140.0 2452
330 104.0 135.9 2500 125.2 175.0 135.5 22.20 136.4 2555
353 104.9 135.9 2602 127.3 175.0 135.5 22.30 136.4 2644
374 105.8 135.9 2680 128.8 175.0 135.5 22.60 136.4 2682
 TABLE I (Con*t)

Air Inlet Exit Heat Droplet Inlet Exit Trough Trough Heat
Bate Air Air Transferred Bate Droplet Droplet Liquid Liquid: Transferred
Temp. Temp. to Air Temp. Temp. Bate Temp. From Dowtherm
lb./hr. °F °F BTU/hr. lb./hr. °F °F lb./hr. °F • BTU/hr.

Bun #4-
24.4 102.2 14*0.4 2220 73.0 199.4 141»8 19.80 151.7 2265
274 104.0 140.9 2405 72.7 199.4 140.0 20.05 149.0 2397
302 105.8 142.7 2655 81.0 199.4 137.4 20.35 149.0 2722
327 107.6 143.1 2755 80.7 199.4 134.6 20.65 149.0 2818
350 105.8 140.0 2850 80.2 199.4 132.8 20.80 145.4 2910
375 107.6 140.7 2950 80.8 199.4 131.9 21.05 143.6 2978
Run #5
*
244 102.2 127.4 1360 70.1 175.0 134.6 15.12 138.6 1488
274 102.2 126.5 1583 69.8 175.0 131.4 15.27 134.6 1609
302 102.2 125.6 1681 70.0 175.0 129.2 15.68 131.9 1708
327 102.2 125.6 1822 69.9 175.0 126.5 16.08 127.4 1826
350 102.2 125.6 1942 70.7 175.0 123.8 16.30 125.6 1946
372 102.2 125.6 2082 70.5 175.0 121-.0 16.61 123.8 2048
Run #6

243 100.8 132.4 1830 87.8 175.0 131.9 19.9 138.2 1987
274 100.4 131.4 2020 88.4 175.0 130.1 19.8 138.2 2067
302 102.2 131.0 2070 87.9 175.0 129.2 19.9 137.3 2100
327 , 100.4 129.2 2240 87.9 175.0 126.5 20.0 136.4 2213
346 100.4 128.3 2300 88.2 175.0 123.8 20.2 134.^ 2335
370 104.0 131.0 2380 87.4 175.0 121.1 20.3 132.8 2447
 TABLE I (Con’t)

Air Inlet Exit Heat Droplet Inlet Exit Trough Trough Heat
Rate Air Air Transferred Rate Droplet Droplet Liquid Liquid Transferred
Temp. Temp. to Air Temp. Temp. Rate Temp. From Dowtherm
lb./hr. OF °F BTU/hr. lb./hr. op °F lb./hr. °F BTU/hr.

Run #7

2/5 95.0 141.8 2727 83.0 200 138.2 18.38 136.4 2831
276 95.5 141.8 3040 83.3 200 135.5 18.70 132.8 2980
303 95.5 139.1 3140 82.8 200 131.9 18.91 127.4- 3157
329. 96.5 138.2 3265 82.8 200 127.4 19.10 124.7 3352
350 97.0 138.2 3400 82.7 200 122.0 19.24 121.1 3582
37/ 97.5 138.2 3620 82.6 200 118.4 19..32 118.4 3739
Run #8

246 97.0 129.6 1910 85.1 175 129.2 18.13 128.3 2088
276 98.0 129.2 2050 85.2 175 127.4 18.21 126.5 2174
303 97.0 128.3 2255 84.4 175 124.7 18.21 123.8 2280
330 97.0 126.9 2350 84.O 175 122.9 18.30 122.0 2355
350 97.0 126.5 2460 84.2 175 120.2 18.53 - 120.2 2460
373 98.0 126.5 2530 84.5 175 117.5 18.45 117.5 2607
Run #9
245 99.0 154.4 3230 121.3 200 145.4 20.45 145.4 3406
276 99.0 152.6 3520 122.1 200 143.6 20.65 143.6 3542
304 100.0 150.8 3675 121 •1 200 140.9 20.90 l/O.O 3707
329 100.0 149.0 3840 122.0 200 138.2 21.15 138.2 3895
352 100.0 149.0 4110 121.3 200 132.8 21.40 134.6 4206
374 100.0 148.1 4280 122.2 200 131.0 21.55 132.8 4347
 TABLE I (Con't)

Air Inlet Exit Heat Droplet Inlet Exit Trough Trough Heat
Bate Air Air Transferred Bate Droplet Droplet Liquid Liquid Transferred
Temp. Temp. to Air Temp. Temp. Bate Temp. From Dowtherm
°F BTU/hr. lb./hr. Op op lb./hr. °F ' BTU/hr.
lb./hr. °F
Bun #10

245 94.0 •133.7 2305 117.8 175 134.6 18.90 140.0 2386
275 94.0 131.9 2A80 117.0 175 132.4 19.15 138.2 2500
305 95.5 131.9 2640 116.0 175 130.1 20.25 136.4 2634
328 96.0 131.0 2730 115.1 175 127.8 20.60 134.0 2756
350 97.0 131.0 2835 114.5 175 125.6 20.90 132.8 2878
373 99.0 131.9 2920 113.5 175 123.4 21.05 131.0 2920

i #11 »

246 96.0 154-4 3420 178.5 200 162.5 19.30 148.1 3461
277 96.5 153.5 3760 176.0 200 158.0 19.86 147.2 3797
305 99.0 155.3 4080 175.0 200 154-4 20.40 146.3 4078
330 101.0 154.0 4160 169.O 200 151.7 20.90 145.4 4183
354 102.5 152.6 4220 168.8 200 149.9 21.45 143.6 4349
374 104.0 152.6 4320 168.8 200 148.1 22.20 143.6 4403
. #12
246 97.5 137.8 2136 169.0 175 149.9 20.10 • 132.8 2234
276 97.0 136.4 2590 168.0 175 145.4 20.60 132.8 2567
305 98.0 136.4 2790 167.0 175 141.8 20.90 131.9 2836
330 101.5 137.8 2850 170.0 175 140.0 21.10 131.9 3020
351 104.0 139.1 2935 169.0 175 138.2 21.15 131.0 3143
375 105.0 138.2 2965 168.0 175 138.2 21.15 131.0 3128 -
 TABLE II

CALCULATED DATA
EVALUATION OF THE APPARENT OVERALL HEAT
TRANSFER COEFFICIENT

75%
Droplet Trough Trough .Effective Resident Resident Number Effective Heat AT__ U
Rate Liquid Liquid Liquid Time Liquid Surface Transferred 111
Rate Rate Rate of Area to Air BTU/hr.
lb./hr. lb./hr. lb./hr. lb./hr. Sec. lb. Drops sq.ft. BTU/hr. °F ft.2ojp
Run #1 *
118.4 22.05 16.5 ■ 134.9 0.54 0.0202 769 0.2065 2670 51.6 276
116.0 22.30 16.8 132.8 0.547 0.0200 762 0.205 2950 49.5 291
115.3 22.80 17.1 132.4 0.55 0.0202 769 0.2065 3170 46.3 318
118.2 22.05 16.5 134-7 0.555 0.02075 789 0.212 3320 51.6 302
118.5 21-.60 16.2 134-7 0.565 0.02115 804 0.216 3440 52.0 304
117.5 21.85 16.4 133.9 0.57 0.0212 807 0.217 3520 51.0 313
Rim #2
I64.8 21.00 15.1 179.9 0.54 0.027 1028 0.276 3350 51.8 223
163.6 21.40 15.4 179.4 0.547 0.02715 1031 0.2775 3690 48.7 271
164.7 21.45 16.1 180.8 0.55 0.0276 1050 0.282 3880 45.0 313
165.5 21; 50 16.2 181.7 0.555 0.02795 1062 0.2.86 3940 43.5 316
165.0 21.50 16.2 181.2 0.565 0.0284 1080 0.2905 3940 42.7 314
165.0 22.20 16.6 181.6 0.57 0.0287 1091 0.2935 3930 40.5 331
Run #3

129.3 21.90 I6.4 145.7 0.54 0.02185 831 0.2235 2180 38.7 251
128.0 -22.00 16.5 ■144.5 0.547 0.02195 835 0.2245 2358 37.6 279
127.2 22.20 16.6 143.8 0.55 0.02200 836 0.2250 2440 36.2 299
125.2 22.20 16.6 141.8 0.555 0.02795 831 0.2235 2500 35.3 316
127.3 22.30 16.7 144*0 0.565 0.02260 860 0.2310 2602 34-7 322
128.8 22.60 16.9 145.7 0.57 0.02305 878 0.2360 2680 34.2 330
 TABLE II (Con’t)

75^
Droplet Trough Trough Effective Resident Resident Number Effective Heat ATm U
Rate Liquid Liquid Liquid Time Liquid Surface Transferred
Rate Rate Rate Area to-Air n BTU/hr.
lb./hr. lb./hr. lb./hr. lb./hr. Sec. lb. Drops sq.ft. BTU/hr. F ft.2 °F
Run #4.

73.0 19.8 14.8 87.8 0.54 0.01318 501 0.1348 2220 48.7 338
72.7 20.05 15.0 87.7 0.547 0.01332 507 0.1362 2405 46.4 380
S1.0 20.35 15.3 96.3 0.55 0.0147 559 0.1505 2655 43.0 410
80.7 20.65 15.5 "96.2 0.555 0.01482 564 0.1518 2755 •4O.O 454
80.2 20.80 15.6 95.8 0.565 0.01503 572 0.1538 2850 41.1 451
80.8 21.05 15.8 96.6 0.57 0.0153 582 0.1564 2950 39.1 472

Run #5
70.1 15.12 11.3 81.4 0.54 0.0122 464 O.I248 1360 39.4 276
69.8 15.27 11.4 81.2 0.547 0.01232 468 0.126 1583 37.1 339
70.0 15.68 11.7 81.7 0.55 0.0125 475 0.1278 1681 37.1 355
69.9 16.08 12.0 81.9 0.555 0.01261 480 0.129 1822 35.4 399
70.7 16.3 12.3 83.0 0.565 0.0130 494 0.133 1942 34.1 428
70.5 16.61 12.4 ' 82.9 0.57 0.0131 498 0.134 2082 31.6 491
Run #6
87.8 19.9 14.9 102.7 0.54 0.0154 586 0.1575 1830 36.5 318
88.4 19.8 14.8 103.2 0.547 0.0157 597 0.1605 2020 36.2 348
87.9 19.9 14.9 102.8 0.55 0.0157 597 0.1605 2070 34.8 370
87.9 20.0 15.0 102.9 0.555 0.01585 603 0.1621 2240 35.0 394
88.2 20.2 15.1 103.3 0.565 0.01622 617 0.166 2300 33.6 412
87.4 20.3 15.2 102.6 0.57 0.01624 618 0.166 2380 28.5 514
 TABLE II (Con’t)

••

75$
Droplet Trough Trough Effective Resident Resident Humber Effective Heat AT U
Bate Liquid Liquid Liquid Time Liquid Surface Transferred m
Bate Rate Rate of Area to Air BTU/hr.
lb./hr. lb./hr.lb./hr. lb./hr. Sec. lb. Drops sq.ft. BTU/hr. °F ft.^oF
Run #7
83.0 18.38 13.7 96.7 0.675 0.01812 690 0.1854 2720 50.2 292
83.3 18.7 14.0 97.3 0.683 0.01843 701 0.3.888 3040 48.6 332
82.8 18.91 14.2 97.0 0.689 0.01859 707 0.1900 3140 47.6 347
82 •8 19.10 14.3 97.1 0.698 0.01883 717 0.1928 3265 44 •8 380
82.7 19.24 14*4 97.1 0.703 0.01898. 722 0.194 3400 40.7 430
82.6 19.32 14.5 97.1 0.71 0.01917 730 0.196 3620 37.7 490
Run #8

85*1 18.13 13.6 98.7 0.675 0;0185 704 0.1892 1910 38.4 263
85.2 18.21 13.7 98.9 0.683 -0.01875 714 0.192 2050 36.9 290
8/.4 18.21 13.7 98.1 0.69 0.0188 715 0.1922 2255 36.4 322
84.O 18.3 13.7 98.1 0.698 0.01893 720 0.1937 2350 35.9 338
84.2 18.53 13.9 98.1 0.703 0.0195 729 0.196 246O 34.3 366
84.5 18.45 13.8 98.3 0.71 0.01938 736 0.198 2530 31.9 400
Run #9

121.3 20.45 15.3 136.6 0.675 0.0256 973 0.262 3230 46.0 268
122.1 20.65 15.5 137.6 0.683 0.0261 993 0.268 3520 46.0 287
121.1 20.90 15.7 136.8 0.69 0.0262 996 0.268 3675 44.7 307
122.0 21.15 15.9 137.9 0.698 0.02675 1016 0.2735 3840 44 •5 316
121.3 21.4 16.1 137.4 0.703 0.02685 1020 0.2745 4110 41.3 362
122.2 21.55 16.2 138.4 0.71 0.02725 1036 0.279 4280 40.6 378
 TABLE II (Con«t)

Droplet Trough Trough Effective Resident Resident Number Effective Heat AT D

Rate Liquid Liquid Liquid Time Liquid - Surface Transferred
Rate Rate Rate Area to Air BTU/hr.
lb./hr, lb./hr,1b,/hr. , lb./hr. Sec._____ lb. Drops sq.ft. BTU/hr._____F ft.2 °F
Run #10
117.8 18.9 1/. 2 132.0 0.675 0.02/75 9/2 0.253 2305 /1.2 221
117.0 19.15 14*. 131 »/ 0.683 0.02/9 9/8 0.255 2/80 /O.S 238
116.0 20.25 15.2 131.2 0.69 0.0251 955 0.257 26/0 38.8 265
115.1 20.6 15.4- 130.5 0.698 0.0253 96/ 0.259 2730 37.7 282
11/. 5 20.9 15.7 130.2 0.703 0.025/5 968 0.260 2835 35.8 30/
113.5 21.05 15.8 129.3 0.71 0.0255 970 •0.261 2920 32.9 3/0
Run #11

178.5 19.3 "1/.5 193.0 0.675 0.0362 1375 0.370 3/20 55./ 167
176.0 19.86 1/.9 190.9 0.683 0.0362 13*75 0.370 3760 53.7 189
175.0 20./ 15.3 190.3 0.69 0.0365 1387 0.373 /080 50.0 219
I69.O 20.9 15.7 18/. 7 0.698 0.0358' 1360 0.366 /160 /8.0 237
168.8 21./5 16 ;i 18/. 9 0.703 0.0361 1371 0.369 /220 Z7./ 2/2
168.8 22.2 16.6 185./ 0.71 0.03655 1390 0.37/ /320 Z5.7 253
Run #12

169.0 20.1 15.1 18/. 1 0.675 0.03/5 1312 0.353 2360 //. / 151
168.0 20.6 15./ 183./ 0.683 0.03/8 1322 0.356 2590 • Z3.2 168
167.0 20.9 15.7 182.7 0.69 0.035 1330 0.358 2700 /1.2 189
170.0 21.1 15.8 185.8 0.698 0.036 1368 0.368 2850 37.9 20/
169.0 21.15 15.9 18/. 9 0.703 '0.0361 1371 0.3695 2935 35.0 227
168.0 21.15 15.9 183.9 0.71 0.03625 1378 0.3705 2965 35.0 229
APPENDI2 B
 SAMPLE CALCULATIONS

Heat Balances

q = wcpO^-ti)
where:
q ss Amount of heat transferred, BTU/hr.
w = Weight of material, lbs./hr.
cp = Specific heat, BTU/lb. °F.
t]i_ = Inlet temperature, °F.
t2 = Exit temperature, °F.
Data for Trial #1, Run #1:
For Air:
w = 2/5 lbs./hr
cp = 0.238 BTU/lb. °F.
tx = 104.0 OF.
t2 = 149.9 °F.
q = (245) (0.238) (149.9 - 104)
q r 2670 BTU/hr.
For Dowtherm:
Droplets (that part of the Dowtherm that existed
as droplets throughout the apparatus.)
w - II8.4 lbs./hr.
cp = 0.45 BTU/hr. °F.
t± = 199.4 °F.
 41

t2 = 158.0 °F.

qd = (118.4) (0.45) (158.0 - 199.4)

qd = -2210 BTU/hr. Heat lost by droplets.

Trough liquid (that part of the Dowtherm that ran
down the inside surface of the stove pipe and
was collected in the trough.)
w = 22.05 lbs./hr.
cp = 0.45 BTU/hr op.
t = 199.4 °F-
t2 = 152.6 °F.

qt = (22.05) (0.45) (152.6 - 199-4)

q^. =-464 BTU/hr. Heat lost by trough liquid,

q aqd/ qt- (-2210) / (-464) = -2674 BTU/hr.

Heat loss:
(2670) / (-2674) = -4 BTU/hr.

Drop Size

Weight of one droplet (Table II) = 0.012 gms. =

0.0000264 lbs.
V = WV

where:
V ssVolume of one drop, cu. ft.
w =Weight of one drop, lbs.
v = Specific volume of Dowtherm at 187.5 °F.,
cu. ft./lb.
 V = (0.0000264) (0.01592)
V = 4*2 x 10“ ^ cu. ft.
V = (1/6) Tt D3
where:
V = Volume of a sphere, cu. ft.
D = Diameter of the sphere, ft.
D = V6V/TT
D = v w T T o .00000042)/3.14
D » 9.256 x 10“3 ft. Diameter of a droplet.
S = jfD2
where:
S = Surface area of a sphere, sq. ft.
D as Diameter of the sphere, ft.
S = (3 .14) (0 .009256)2
S = 2.69 x 10-4 sq. ft. Surface area of a droplet

Residence Time
Sg = (V«2/g)ln cosh g/V'Ct-Ci) / C2-V0t

v' = V V c a « ! k sd
C]_ =: (-V»/g) tanh--*- V0/Vf
c2 = (-V,2/g) In cosh (g/V1) ^
where:
Sg = Distance drop falls, ft.
g = Acceleration due to gravity, ft./sec./sec.
t = Time of fall, sec.
 43

VQ = Velocity of the air stream* ft./sec.

Wd = Weight of the drop* lhs.
Cd = Drag coefficient.
_X =
< Density of the air stream in slugs/eu. ft.
Sd = Surface area of the drop* sq. ft.
Air Rate = 245 lbs./hr. Ave. Air Temperature = 120 °F

■v = p r
Wd « 2.64 x 10“5 IDs.
Cd = 0.75
= 2.13 x 10“5 slugs/cu. ft.
Sd = 2.69 x 10“4 sq. ft.
V* = /2.64 x 10-5/(0.75)(|)(2.13 x 10-3)
(2.69 x 10“4)J s
V* » 22.1 ft./sec.
C-l = (-V»/g) tanh-1 VQ/V«
V ’ = 22.1 ft./sec.
g = 32.2 ft./sec./sec.
VQ =* 5.06 ft./sec.
= (-22.1/32.2) tanh-1 5.06/22.1
C-j_ = -0.16 sec.
C2 = (-V*2/g) In cosh ( g / V O ^
C2 = (- 22.1 2/32.2) In cosh (32.2/22.1)(-0.16)
c2 = -0.409 ft.
Sg = (V*2/g)ln cosh g/V» (t-^) /C2 - VQt
 44

Sg = (22.1)(22.1)/32.2 In cosh 32.2/22.1(0.5/0.16)

-O.4.O9- (5 .06) (0.5)
S = 3.IB ft. Distance drop falls in 0.5 sec.
©

Apparent Heat Transfer Coefficient

Data for Trial #1, Hun #1:

Weight of droplets =■ 118.4- lbs./hr.
Weight of trough liquid = 22.05 lbs./hr.
75$ of trough liquid =16.5 lbs./hr.
Weight of droplets effective throughout apparatus =
134--9 lb./hr.
Residence time from Figure 4- = 0.54 se° feu* a
distance of fall of 44 inches.
Residence Dowtherm = (134*9 lb./hr.) (0.54 sec.)/
3600 sec./hr.
Residence Dowtherm = 0.0202 lbs.
Weight per drop = 2.64 x 10~5 lbs.
Humber of droplets = 0.0202/2.64 x 10~5 = 769
Surface area of one droiolet = 2.69 x 10“4 sq. ft.
Effective area available for heat transfer
(769)(2.69 x 10“4) = 0.2065 sq. ft.
Amount of heat transferred calculated from the con­
ditions of the air stream = 2670 BTU/hr.
Log - mean temperature difference = 46.8 °F.
U = q/AAbm
U = 2670/(0.2065)(46.8)
U = 276 BTU/hr. sq. ft. °F.
Since the temperature drops in the apparatus are not
large, U will be constant throughout, and, therefore
the use of the log-mean temperature difference is
justified.
APPENDIX C
 SAMPLE DESIGH PROBLEM

One possible, application of this type heat exchanger

is in gas to gas heat exchange. For this application, two

exchangers similar to the one used in this investigation are

required as shown in Figure 6. Hot gases enter the first ex­

changer and transfer their heat to the cold liquid droplets.

The heated liquid is then pumped to the second exchanger where

it exchanges heat with the gases to be heated. The cooled

liquid is then pumped back to the first exchanger and the

cycle is repeated.

The problem. It is desired to transfer heat from hot

flue gas to cold air using the drop type heat exchanger with

DoYrtherm as the intermediate fluid. Find the percentage of

heat that will be transferred at various column heights if

the exchangers used are similar to the one described in this

thesis

Flue gas rate 300 #/hr

Flue gas temperature 300 °F.

.Air rate 400 #/hr

Air temperature 100 °F.

The solution. A calculation of this type requires a

trial and error solution since the cold Dowtherm temperature

is not known. The first step to¥/ards a solution is to assume

 48

a cold Dowtherm temperature. The calculations are then made

and the temperature of the Dowtherm leaving the second ex­
changer is compared with the assumed temperature. This pro­
cedure must he repeated with a new assumed temperature if
the two values don’t nearly coincide.
The complete solution to this problem is presented
in the accompanying graph (Figure 7) while sample calcula­
tions for a column height of 10 ft. are given below,
q - wCpCtg-ti)
where:
w = Weight of flue gas = 300 lb./hr.
Cp = Specific heat of flue gas = 0.25 BTU/lb. °F.
t^ = Base temperature= 100 °F.
t2 - Inlet flue gas temperature = 300 °F.
q = (300)(0.25)(300-100)
q = 15,000 BTU/hr. = Amount of heat transferred in
a column of infinite height
w - qApC^-t-^
where:
q = Amount of heat transferred = 15,000 BTU/hr.
Cp = Specific heat of Dowtherm = 0.44 BTU/lb. °F.
t-^ = Minimum inlet Dowtherm temperature = 100°F.
t^ - Maximum exit Dowtherm temperature = 300 °F.
w = 15,000/(0.44)(300-100)
 49

w =: 170.5 lb./hr. = Amount of Dowtherm required to

transfer 15,000 BTU/hr.
B = Dowtherm rate/flue gas rate
B = 170.5/300
B = 0.569
From Figure 4*
U = 2/2 BTU/hr. ft.^ °F. in the first exchanger.
B = Dowtherm rate/air rate
B = 170.5/400
B = O.4.26
U = 302 BTU/hr. ft.^ °F. in the second exchanger.
Besident time = 1 . 1 sec.
Area available for heat transfer = 0.534 Scl* ft*
Assumed inlet Dowtherm temperature = 138 °F.
By using the following formulae^ the exit temperatures in
the first exchanger can be calculated.
t'2 = t ’(i_z!) / (a5-l)-t* / (a^-Z1)
a = UAF (l-Z*)/w*c’
5 e
_ I _ T T / JJ It
Z - w c /w c
where:
t^ = Inlet flue gas temperature — 300 °F.

t ’ = Exit flue gas temperature.

t ” = Inlet Dowtherm temperature = 138 °F.

t?
William H. McAdams, Heat Transmission. . (Nexv York:
McGraw-Hill Book Company, Inc.), p. 360.
 50

COLD GAS COLD DOWT/fERM M O T AlA

>—

EXCHANGER & / E X C H A N G E R ** £

---to
HOT GAS HOT DOiTTHEffM COLD AIR

Figure 6
Jam jo /e Gas to Gas Exchanger
iimvimtv
fj _r. f l

b
u

►u
.s
bO
.n
ch
s“

IS
°W
bl
C
C
J
Lit

U
S

M3QS T3I O
37
t
i
l
J
?
0
w
X
o

OS*
V5

±1

0*£
.OH
 52

U =. Overall heat transfer coefficient =

242 BTU/hr. ft.^ °F. in the first exchanger.
A = Urea available for heat transfer = 0.534- sq. ft.
F = Correction factor = 1
w! = Yfeight of flue gas stream = 300 lb./hr.
w lf = Weight of Dowtherm stream = 170.5 lb./hr.
e1 = Specific heat of gas stream = 0.25 BTU/lb. °F.
c" = Specific heat of Dowtherm stream =
O.44. BTU/lb. °F.
Z1 = (300)(0.25)/(l70.5)(0.44)
Z* = 1
If the ratio, Z 1, is unity, t is constant through the
exchanger and the terminal overall temperature differences
are equal and one obtains:

t2 " (tI/a6tl ) / ^ a6)

a^ = UAF/w1c 1

a6 = (242)(0.534)(l)/(300)(0.25)
a^ — 1.722
t^ = 300/(1.722)(138) /(1/1.722)
t^ = 198 °F. = Temperature of the flue gas leaving
the first exchanger.

q - wVftJ-tp
q = (300) (0.25)(300-198)
q = 7,650 BTU/hr. Heat lost by the flue gas.
t"-t" = q/w"c»
 t” = (7650)/(170.5) (0.44-) / 138
t” = 240 °F. = Temperature of exit Dowtherm stream
from first exchanger.
In the second exchanger:

tZ - * (a5-l)t^ /(a5- Z r)
a, - eUAF (l-Z')/w'C
where:

t^ = Inlet temperature of the air stream = 100 °F.

t^ = Exit temperature of the air stream
t” = Inlet temperature of the Dowtherm stream =
24.O °F.
U = Overall heat transfer coefficient =

302 BTU/hr. ft.2 °F.

A = Area available for heat transfer = 0.53/ sq. ft.

F = Correction factor = 1
w 1 = Weight of the air stream = 4-00 lb./hr.
w n = Weight of the Dowtherm stream = 170.5 lb./hr.
c ' = Specific heat of air stream = 0.238 BTU/lb. °F.
cn = Specific heat of Dowtherm = 0.4-4- BTU/lb. °F.
Zf = w fc 7 w f,cn
Zf = (4-00) (0.238)/(170.5) (0 .44)
Z* = 1.269
a5 = e (302) (°«534) 0-)(1-1.269)/(400) (O.44)
a5 = 0.635

t^ = (100)(1-1 .269)/(0 .635-1)(240) /(0.635-1.269)

 54

t2 = 180/5 °F.
q =» w|c ’

q = (400)(0.238)(180.5-100)
q = 7,660 BTU/hr.
t^-t^ = q/w,!c"
, !t _ , 11 / f t n
= t - q/w c

t£ = 240 - 7660/(170.5)(O.44)

t” = 138 °F. Exit temperature of the Dowtherm stream

from the second exchanger.
This temperature is equal to the assumed temperature, there­
fore the assumed temperature was correctly chosen. If they
had differed, another trial would have to he made.
At a column height of 10 feet, 7,660/15,000 = 51$ of
the available heat transferred.

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