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    Process Heat Transfer Donald Q Kern 1

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    PROCESS HEAT TRANSFER BY DONALD Q. KERN D. Q. Kern Ansociatr, and Professorial Lalarer in Chemical Pegineeing ‘Case Institute of Techwlony McGRAW-HILL BOOK COMPANY - Auckland Bogoté Guatemala Hamburg Lisbon London Madrid Mexico New Delhi Panama’ Paris San Juan Sio Paulo Singapore Sydney Tokyo Kt PROCESS HEAT TRANSFER INTERNATIONAL EDITION 1965 mar Te si se Mer Bo Cosp Te consigned by 10 123456789 20 FSP9543, CCopyrighs 1980, by the McGraw-Hill Book Cov:ps, Ig. All rigs sesered Rete af tht pueden mayb repre sed ante ‘or wnamitd, i any form oF by any mete, clonic, mechanical, phosocopying, ‘cording, ov echereln, without the free wisen permiocn ofthe pabtaer ‘When ordering this title use ISBN 0-07-085353-3 Printed in Singapore fel PREFACE tis the object of this text to provide fundamental instruction in heat transfer while employing the methods and language of industry. This treatment of the subject has evolved from a course given at the Poly- techni Institute of Brooklyn over a period of years. The possibilities of collegiate instruction patterned after the requirements ofthe practicing pprovess engineer were suggested and encouraged by Dr. Donald F. Othmer, Head of the Department of Chemical Engineering. The inclu- sion of the practical aspects of the subject as an integral part of the pedagogy Was inteuded tw serve as a supplement cather thaz = substitute for a strong foundation in engineering fundamentals. These points of view have been retained throughout the writing of the book. ‘Yo provide the rounded group of heat-transfer tools required in process ‘engineering it has been necessary to present a numberof erapirical calcula tion methods which have not previously appeared in the engineering literature. Considerable thought has been given to these methods, and the author has discussed vhem with numerous engineers before accepting. and including them in the text. It has been a further desire that all the calculations appearing in the text shall have been performed by an experienced engineer in conventional manner. On several occasions the author has enlisted the aid of experienced colleagues, and their assistance is acknowledged in the text. In presenting several of the methods some degree of accuracy has been sacrificed to permit the broader application of fewer methods, and it is hoped that these simplifications will cause neither inconvenience nor criticism. tbecame apparent in the early stages of waiting this book that it could readily become too large for convenient use, and this has affected the plan of the book in several important respects. A. portion of the material ‘which is included in conventional texts is rarely if ever applied inthe solu- tion of run-of-the-mill engineering problems. Such material, as familiar ‘and accepted as it may be, has been omitted unless it qualified as impor- tant fundamental information. Secondly, it was not possible to allocate space for making bibliographic comparisons and evaiuacions and ct the ‘same time present industrial practice. Where no mention has been made of a recent contribution to the literature no slight was intended ‘Most of the literature references cited cover methods on which the author bas obtained additional information from industrial appl viii PREFACE ‘The author has been influenced in his own professional development by the excellent books of Prof. W. H. MeAdams, Dr. Alfred Schack, and ‘others, and it isfelt that their influence should be acknowledged separately in addition to their invidence in the text as bibliography. For assistance with the manuseript indebtedness is expressed to Thomas HL Miley, John Blizard, and John A. Jost, former associates at the Foster Wheeler Corporation. "For checking the numerical calculations credit is due to Krishnabhai Desai and Narendra R. Bhow, graduate students at the Polytechnic Institute. For suggestions which led to the ine!sion or exclusion of certain material thanks are due Norman E. Anderson, Charles Bliss, Dr. John F. Middleton, Edward L. Pfeiffer, Oliver N. Prescott, Everett N. Sieder, Dr. George E. Tait, and to Joseph Me'sler for assistance with the proof. ‘The Tubular Exchanger Manufacturers Association has been most generous ia granting permission for the repro- duction of a number of the graphs contained in itsStandard. Thanks ere also extended to Richard L. Cawood, President, and Arthur E, Kempler, Vice-President, for their personal assistance and for the cooperation of ‘The Patterson Foundry & Machine Company. Donar Q. Kens New Your, NY. Apri, 1950 CONTENTS Pazrace. Ivonx ro rue Provcrrat Arranarus CaLeutanoss. 1. Proces Heat Transfer. 2. Conduction 2. Convection 4 Radtion 5 Temperature - = = 6 Counterfow: Dooble pipe Exchangers 17. 12 Parallel counterfow: Shell-and-Tube Exchanges. Flow Arrangements for Increased Heat Recovers 8. Gases 10. Streamline Flow and Free Convection 11, Caleultions for Process Conditions 12, Condensation of Single Vapors 18. Condenastion of Mined Vapors 14. Evaporation 16, Vaporizer, Evaporators, and Reborn, 16, Brtended Burfacet. . 117, Direct-contact Transfer: Cooling Tower. 18, Batch and Unsteady State Processes 19, Furnace Calculations. 2, Additional Applications 21, The Contre of Temperature and Ralated Process Variables ‘Arrexor oF Cascotamion Dath ‘Aornon Inox. Sunsecr Inoex. INDEX TO THE PRINCIPAL APPARATUS CALCULATIONS Exenasorne ‘Double;pipe counteriow exchanger (bensene-tlvene) ‘Double pipe serics-parallel exchanger (ube el-erade ol) ‘Tubular exchanger (keosene-erude oi) ‘Tubular exchanger (water-wate) ‘Tabuler cooler (KsPO«solution-water) ‘obstretr, abated slam) ‘Tubular 24 cooler (35° APL oll-water) Core tube heater (as oil-eenm) - ‘Tank beater (enline-steama) ‘Tubular eschanger(traw ol-napitha) ‘Tubular 48 exchanger Jean oil-rich ci) ‘Tubular cooler (N4OH votutionrater) ‘Tubular heater (aleobo-steam). ‘Tubular plt-fow cooler (Bue gas-water) ‘Jacketed veel (aqueotssolution-weam) ‘Tube cil (aqueous slution-steaz Pipe col cooler (alurry-rates) ‘Trombone cooler (80s gue-water) Atmospheric eoler Gacket water-eate) Electric resitance hester Cospessens (Tenuta) Condenser, horizontal (propancl-rater) Condenser, horisodtal (hydrocarbon mistur, gu, stoam-water) Braronerons (Tencian) ‘Raw water evaporator. Power plant makeup evsporsior us ae geeegueyss INDEX TO THE PRINCIPAL APPARATUS CALCULATIONS Process multiple effet evaporatir. . Hat trancormer evaporator SaS8888 geege Bae eRat a8 CHAPTER 1 PROCESS HEAT TRANSFER Heat Transfer. ‘The science of thermodynamics deals with the quant tative transitions and rearrangements of energy asheat in bodiesof matter. ‘Heat transfer is the science which deals with the rates of exchange of heat between hot and cold bodies called the source and receiser. When a ound of water apes condoned, the energy change in er ‘identical. ‘The rates at which either process can be made to Progrese with an independent source or receiver, however, ars iaberentiy different. Vs * ‘ary filfeentVapriation i generally a much more rapid phenome- ‘Heat Theories. The study of heat transfer would be greatiy enhanced by asound understanding of the nature of heat. Yet thisis an advantage which is not readily available to students of heat transfer or thermo- dynamics because'so many manifestations of heat have beer discovered ‘that no simple theory covers them all. Laves which may apply to snass transitions may be inapplicable to molecular or atomic transitions, and those which are applicable at low temperatures may not apply at high ‘temperatures. For the purposes of engineering it is necessary tu under- take the study with basic information on but a few of the many phe- nomena. The phates of a single substance slid, liquid, and gnseous, are associated with its energy content. In the solid phase the molecules or stoma are close together, gving it rigidity. "In the Liquid phase euficien ‘thermal energy is present to extend the distance of adjacent molecules such that rigiity is lost. In the gas phase the presence of additional thermal energy has resulted in a relatively complete separation of the atoms of molecules so that they may wander anywhere in a confined space. It is also recognised that, whenever a change of phase occurs outside the critical region, a large amount of energy is involved in the ‘transition. For the same substance in its different phases the various therma! properties have diferent orders of magnitude. As an example, the spe- ‘ilo heat per unit mass is very low for solide, high for liqusa, and wmually intermediate for gases, Similarly in any body sboorbing or loing heat, special consideration must be given whether the change is one of sensible Grlatent heat or both. Stil further, tis also known that hot source is i 2 ‘PROCESS HEAT TRANSFER ‘capable of such grest subatomic excitement that it emits energy without tty direct contact with the reosiver, aud this nthe underiying principle ‘Gf radiation. Each type of change exhibit ita own peculiarities, Mechanisms of Heat Tranafer..'There ae thre distinct ways in which heat may pass from a source to a receiver, although most engineering spplications are combinations "f two or thee. Theee are edition, tonsecton, and radiation. ‘Conduction. Conduction is the transfer of heat through fixed material such ot the stationary wall chown ‘Fig. 1. Tho direction of beat flow willie stright angles tothe wall H the wall urfaces are isothermal tnd the body homogencou and i ‘tropic. Assume that a scurce of heat exiat on the left face of the vrll and a receiver of heat exists on ‘the right face. It has been known and later it will be confirmed by derivation that the flow of heat per hour is proportional to the change Tak paeES im temperature through the wall and Fea Lt, Haalfow tweuewa the area ofthe wall A. Itt the temperatre st any poiat inthe wall snd zn the thickness ofthe wall inthe direction of eat flow, the quantity of heat flow dQ is given by ao=4(-2) veo an ‘The term ~di/de is called the temperature grodient and has « negative sign ifthe temperature has been assumed higher at the face of the wall where = = O and lower at the face where == X._ In other words, the instantaneous quantity of heat transfer is proportional to the area’ and temperature difference di, which drives the heat through the wall of thickness dz. The proportionality constant k is peculiar to conductive ‘heat transfer and is known as the ermal Tt is evaluated ‘experimentally and is basically defined by Bq. (1.1). ‘The thermal con- ductivites of solids have a wide range of numerical valves depending ‘upon whether the slid is relatively good conductor of heat such as & ‘metal or 2 poor conductor such as sabestos. ‘The latter serve as énru- llors, Although heat conduction is unally sociated with heat transfer through solids, it is aso applicable with limitations to gases and liquids. Convection. Convection is the transfer of heat between relatively hot and cold portions of a Suid by mixing. Suppose a can of liquid were PROORSS HEAT TRANSFER 3 placed over a hot fame, The liquid at the bottom of the can becomes heated and lees dense than before o-ing to its thermal expansion, ‘The liquid adjacent to the bottom is also less dense than the cold upper portion and rises through it, transfering its heat oy mizing an it ries. The transfer of heat from the hot liquid at the bottom of the can to the remainder is natural or fre coutecion, If any other agitation occurs, such as that produood by w stirrer, it is forced convection. This type of hheat transfer may be describea in ‘an equatiou which imitates the form. of the conduction equation and is given bz" dQ = haat a2) “The proportionality constant his term whichis infuence by the nature of the fd and the nature ofthe agitation and must be evalua‘ exper- ‘mentally. It is called the heat-transfer coeficient. When Eq. (1.2) is ‘written in integrated form, Q'= hd Ai, itis called Newton's law of coking Radiation. Radiation involves the transfer of radiant energy from souree to a receiver. When radiation isms from a source to a receiver, part of the energy is absorbed by the receiver and part reflected by it. ‘Based on the second lw of thermodynamics Boltsmann estab that the rate at which a source gives off heat is dQ = oedA 7 aay ‘Thisis known asthe fourth-power la in which T'is the absolute tempera ture. ¢ isa dimensional constant, but «isa factor peculiar to radiation and is called the emissivity. ‘The emissivity, ike the thermal condue- tivity F or the hest-transfer coefficient A, must also be determined experimentally. Process Heat Transfer. Heat transfer has been described as the study of the rates at which heat is exchanged between heat sources and receivers usually treated independently. Process heat transfer deals with the rates of heat exchange as they occur in the heat-transfer equipment of the engineering and. chemical processes. This approach brings to better focus the importance of the temperature difference between the source and receiver, which is, aftr all, the driving force whereby the transfer of heat is accomplished. A typical problem of process heat transfer is ‘concerned with the quantities of heats to be transferred, the rates at which they may be transferred because of the natures of the bodies, the driving potential, the extent and arrangement of the surface separating ‘the source and receiver, and the amount of mechanical energy which max ‘be expended to facilitate the transfer. Since heat transfer involves an exchange in a metem, the loa of heat by the one body will equal the heat abeorbed by another within the confines ofthe acme ayslem. CHAPTER 2 conDUCTION ‘The Thermal Conductivity. The fundamentals of heat conduction were established over a century ago and are generally attributed to Fourier. In numerous systems involving flow such as heat flow, fid flow, of electricity flow, it has been observed that the flow quantity is directly proportional to a driving potential and inversely proportional to the resistances applying to the eystem, or potential Flow « ey In a simple hydraulic path the presure slong the path is the driving potential and the roughness of the pipe is the flow resistance. In an ‘electric circuit the simplest applications are expressed by Ohm's law: ‘The voltage on the circuit is the driving potential, and the difficulty with which electrons negotiate the wire isthe resistance. In heat flow through a wall, low is eflected by a temperature uifference between the hhot and cold faces. Conversely, from Eq. (2.1) when the two faces of a wall are at different temperatures, s flow of heat and a resistance to heat, flow are necessarily present. The conductance is the reciprocal of the resistance to heat flow and Eq. (2.1) may be expressed by Flow « conductance X potential 2 ‘To make Eq. (2.2) an equality the conductance must be evalusted in such 1 way that both sides will be dimensionally and numerically correct. Suppose a measured quantity of heat Q’ Btu has been transmitted by a ‘wall of unknown size in a measured time interval @ br with a measured temperature difference A¢ °F. Rewriting Eq. (22) @ =F = conductance x At Blu/he @3) ‘and the conductance has the dimensions of Btu/(hr)("F). ‘The conduct ‘ance is s measured property of the entire wall, although it has also been found experimentally that the flow of heat is influenced independently by the thickness and the area of the wall. If tis desired to design a wall to have certain heat-low characteristics, the conductance obtained above ° conpuoriox 7 is not useful, being applicable only to the experimental wall. ‘To enable 1a broader use of experimental information, it has become conventions) ‘to report the conductance only when all the dimensions are referred to unit values, When the conductance is reported fora quantity of material 1 ft thick with heat-fow area 1 £0, time uni I hr, and temperature differ- ‘ence 1°F, itis called the thermal conductivity. The relationship between the thermal conductivity and the conductance of an entire wall of thickness L and area A is then given by Conductance = kf and ontha oo where & has the dimensions resulting from the expression QU /a At or Beu/(hr) (fof flow area)(F of temperature differ cence)/({t of wall thickness) * “apparatus for the determination of the thermal conductivity of nonmetal solids is shown in Fig. 2A, Te consists of an electrical Iheating plate, two identical tot ‘specimens through which heat 7% 24+ Guarded pastes, and two water jackets which remove heat, ‘The temperatures st both feces of the specimens and at their sides are measured by thermo- couples. A guard.ing is provided to assure that all the measured heat input to the plate passes through the specimens with a negligible loss from their sides. ‘The guard ring surrounds the test assembly and con- sists of an auriliry heater sandwiched between ploces ofthe material ‘being tested. While current enters the heating plate, the input to the nthe mae tem ti lo pot he thermal oduct a lee (ea9¢C/em). * An exllent review of experimental methods wil be found in Sha and Srivastava, “Trenton Heat," Te fnian Prem, Coletta 158," Laterrfreoat ar Bate, ©. ey Jad. Bag. Chen, 36, 52 (103); 8, 4041008); 8, 57504); 8,196 (145). Tolland, JL and H.W. Afelvie, Trane Faraday Se, 38,1918 (1987). ‘otchinoo, EE, Trans, Forday So, 41,87 (108). 8 ‘PROCESS HEAT TRANSFER ‘surilary beater is adjusted ust no temperature differences exit between the specimens and sdjecent points in the guard ring. Observations are made when the heat input and the temperatures on both faces of each ‘specimen remain steady. Since half of the measured electrical beat {input to the plate flows through each specimen and the temperature difference and dimensions of the specimen are known, k can be computed directly from Eq. (2.4). . Liquids and Gases. ‘There is greater dificulty in determining the conductivities of liquide and gatet. Ifthe heat flows through a thick layer of liquid or gas, it cause free eon- veetion and the conductivity is decep- tively high. To reduoe convection it is necessary to use very thin films and small ‘temperature differences with attendant cerors of measurement. A method appli- ‘able to viscous fuids consinta ofa bare ‘electric wire passing through « horizontal tube filed with tet liquid. ‘The tube is ‘immersed ins constant-temperatare bath ‘The resistance of the wire ia calibrated against its temperature.” Fora given rate of heet input and for the temperature of ‘the wire obtained from resistance measure- meats the conductivity can be calculated by suitable equations. A more exact method, however, i that of Bridg- man and Smith,! consisting of a very thin fluid annulus between two Fig. 22. Heat supplied to the inner eylinder by areistance wire flows ‘arough the film to the outer cylinder, where itis removed by the bath. ‘This apparatos, through the use of a reservoir, assures that the annulus is full of liquid and is adaptable to gases. The film is 344 in. thick, and ‘the temperature difference is kept very small. Tnfluence of Temperature and Pressure on E. ‘The thermal conductivi- toe of solide are greater than thore of liquide, which in turn are greater than those of gases. It is easier to transmit heat through a solid than a liquid and through aliquid than a gat. Some solids, ouch as metals, have high thermal conductivities and are called conducora. Others have low conductivities and are poor conductorsof sai. ‘These areineulalore. Ta experimental determinations of the type described above the thermal conductivity has boen assumed independent of the temperature at any ‘point in the test material. The reported values of I are consequently Bath FD. Tad. Bag, Chem, #4, 1246 (130); Trane, ASME, 88, 719 1086) conpucrio 9 the averages for the entire specimen, and the error introduced by this assumption can be estimated by an examination of Tables 2 to 5 in the Appendix. The conductivities of solida may either increase or decrease ‘with temperature and in some instances may even reverse their rate ‘of change from a decrease to an increase. For the most practical prob- ems there is no need to introduce « correction for the variation of the thermal conductivity with temperature. However, the variation ‘can usually be expressed by the simple linear equation kektat where ky is the conductivity at OF and 7 is a constant denoting the change in the conductivity per degree change in temperature. ‘The con- ductivities of most liquids decrease with increasing temperature, although water is a notable exception. For all the common gases and vapors there is an increase with increasing temperature. Sutherland! deduced ‘an equation from the kinetio theory which is applicable to the variation of the conductivity of gases with temperature 492 + Cy Ey era where Cy = Sutherland constant 7 aboacte temperatare ofthe gs, x= conéactivity ofthe gas at 37 ‘The influence of pressure on the conductivities of solids and liquids appears to be wegligible, and the reported data on gases are too inexact cing othe eet of free convection and radiation to permit generalina- tion From the Kinetie theory of ge it can be concluded tha the influence of preamre should be small except where a ery low vacuum is encountered Contact Resistance, One ofthe factors which urs err the deter sinaion of th thermal conductivity isthe nature ofthe bod formed between the eat pource and the Sui o aid wecinea which contacta it and transmits heat. If a solid receives heat by contacting a solid, it is smoot impossible to exclude th presence of ai or other fd frm the contact. Even when a liquid contacts « metal, the presence of minute pits or surface roughness may permanently trap infinitesimal bubbles of air, and it will be seen presently that these may cause considerable error. Derimtion ofa General Pondaction Bqurtin. Tn qe (21) £0 (24) a picture of heat conduction was obtained from an unqualified observation of the relation betwen heat Sow, potential, and resstance. Tt now feasible to develop an equation which will have the broadest applicability *utbman, W, PAL Mop 6 27 180 10 PROCESS HEAT TRANSFER and from which other equations may be deduced for epocal applications Brquation (24) may be written in differentia form Ba-rad @s) In this stetment fis the only property ofthe matter and itis astumed to’be independent ofthe other variables. Refering to Fig. 23, an ele- santa cube of volume de = ds dy de receives a diferential quantity of Theat dQ Btu through ita left yo face in the tine interval da. Aamume al but the left and right ye faces are inmulted. Inthe same interval the quanity of heat 4 leaves at the right face. Tes apparent that any of three eflecte may oocur: dO tay be greater than dQ; 00 that the elemental volume :tores heat, increasing the ooeraye temperature of the cube; dQ; may be greater than Qj so that the cube loses heat; and lastly, dQ; and oj may be equal so that the heat wll simply through the cube without afeting the storage of heat. Taking either of the frat two ease aa being more general, storage or depletion term dQ’ can be defined as the diference betwoen the heat entering and the heat leaving or AQ’ = dQ ~ 20% @8) According to Bq, (2.5) the heat entering onthe left face may be given by i raa(-2 an The tamper pdt ~ 2 may vy wth oh tie and pion i ‘the cube. ‘The variation of — 2 an f(s) only is ~ 2/22). Over the distance ds from z to = + de, if 4G, > a0, the total change in the tem- peratregradieat wil bo — 22082 gs og 2 ae Then at «the rect in — and ats de th emptor gt am eee conpucrion u dQ; out of the cube at the right face and in the same form as Eq. (2.7) is given by BY -raya(-2- Ba) a) from whica 2B -B-S -cya(M) ac es) ‘The cube will have changed in temperature by ~dt deg, The change in temperature per unit time will be di/d@ and over the time interval dit in given by (21/40) d0 deg. Bice the analy has been based on an

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