BRAUWEIT INTERNATIONAL Programme for dimensionin areas at cylindro hhofact that these tanks are not series: produced highlights the problem in- volved in dimensioning ther cooling zones correctly. ‘The problems encoun: tered in this eontest become even more evident when one remembers that at each brewery aflerent parameters. apply for ‘computation ofthe eooling zones, Another consideration exacerbating the problems involved in calculating the cool ing areas at CCTs is the fact that until re cently the everyday practice for dimen- sioning cooling zones was to use feedback values from existing tank sys- tems, or to perform rule-ofsiiumb ealeula- tions and (due to the uncertainty inevitably entailed by this approach) to add to the caleulated figures a more or less sizeable ‘markup to be on the sale side, In almost all eases, this kind of approach tocalculation will result lathe tanks mostly being operated with an overlimensioned cooling area, which in turn entails several disadvantages: 4 The line is not run continuously, whieh means the cooling medium flow is re peatedly interrupied: the solenoid valves ate permanently in action, 4 The yeast may suffer a cold shock during fermentation, causingit to losefermenta- tion activity, U There isa risk of the young beer freezing atthe tank jacket. 1 Procedure for compting the cooling zones Design specification The design specification mainly involves lining various key data, The author. Peter Gross, Gross Rehiter und Aulagetibuu, D-78238 Stltingen 152 BRAUWELINTERRONAL 19881 TECHNICAL FEATURE Cylindro-conical ferment. ing tanks (CCFs) and cylin- dro-conical storage tanks (CCSs), also referred to as unitanks, are an integral part of every modern-day brewery all over the world. These tanks have proved their worth many times over, offering as they do both great advantages in terms of handling and a high degree of dependabili- ty with regard to beer qual- ity as well. Only perhaps in regard to the dimensioning of capacities, diameters, heights and the question of cooling have they given rise to debate. 4 Key data of the tank: diameter, eylindr: cal height, overall height, mean wall Uhickness, cone angle, knuckle radius an! useful eapacities Key data of the cooling zones: hal diameter, pte, slit stip width, e00 profile area, cooling medium, and (de- pending on the coolant involved) fer NH, the evaporation temperature, and forthe ‘otters the inlet and outfet temperatures, U Key dataot the wortthe beer: beer start ingaid final temperatures, cooling durae tion, and extract breakdown, Key data ofa general nature are: material used, thermal conductivity, soiling fa tor, additional thermal restitivty, heat transmission cocfticient (k-value) of the Insulation, ambient air temperature. Scat the cooling tanks Computation ical value forthe heat transmission coefficient Is now used to perform a first rough computation, which bs necessary since for the precise etermination of the heat transmission co- clliecient (So important in this compu tion) other data are also required, like flow velocities, the dimensions of certain assem biies and their interrelationships. is first rough computation and the re sultant heat exchange areas are taken as the basis for precise computations of the Iieat transfer coeffieetents atthe individual points. For these fatter computations, for- ‘mula are used which have all been taken from the VDI Heat Atlas (sixth enlarged edi- tion, published in 1991) (VDI = Assoctation of German Et The accurate heat exchange areas ob- ined from these. computations should ‘not differ trom that calculated. on. the basis of the design dimensions by more than approx. 5 per cent. If deemed neces- sary, a safely markeap may be included in the computations. I there isa risk of cool ingzone soiling, vg. due to deposits, the temperature lay! and the thickness of the + mist also be allowed for when ng the lest transmisssion coctt- For the vast majority of practical cases, the surface temperatures of the walls are not known, enly the temperatures of those ‘media involved in the heat exchange pro- oss. However, these values are important of obtaining an accurate compulaton pecially in the case of free convection. Th Is why an assumption must be made be- forehand, which tias to be confirmed at the end af the computation process con cerned Once you have computed the heat transmission coefficients. resulting from the specified design, a decision must be made aslo whether Ue cooling areas which, the programme us dimensioned oder or need to be modified, If this case, thee computations must be mpeated until the computed and designed cooling areas satisfy the actual requirements volvedCustomers’ wishes Since customers frequently, out of fina ‘lal considerations, want to install very ‘sizeable tanks with unfavourable diameter- height ratios and very short cool-down s, it may happen that the tank surface is not sufficiently ange to accomaodate the cooling areas required. I this is the ease, the key data specified for performance de ation must be modified after prior ‘consultation with the customer (Fig. 1) Summary Its already quite obvious at this point that precise determination of cooling areas “by hand!” constitutes an extremely labori- ‘us process and is hardly feasible in prac- tice, even it the formulas stated in the VDI Heat Atlas are meticuloulsy applied, Against this background, a computation programme has been developed, which has been in use at the Gross company for same years now and permits precise computa- tions to be made, taking all the individual application data into account 1m Programme assumptions The iterative computation approach has been selected for computing the fundamen- tal values, like heat transfer coelfcient and heat transmission coefficient, In this case, precise computation is not possible, abso hte accuracy restricted since some as- ‘sumptions were made in advance. ‘These are as follows: Neglect ofthe tank manufacturing toler- ances; neglect of il evel tolerances inside the tank; the assumption that free convection will, set in immediately: areas without cooling atthe tank are ne- gleeted inthe computaiton of convection (eddying); @ convection inside the tank is assumed to be a completely formed eddy flow; U Counterflow is assumed for the first cooling-area computation 15 Computation sequence in the programme For computing the heat exchanger area, the following basic formula apples: Q=k-A-Adm @n Validity range ofthis formula: Form applies forthe circumstances of stationary hheat transfer and of plane heat exchange BRAUWELT INTERNATIONAL TECHNICAL FEATURE Fig. 1 Example of a cylindroconical tank between the surfaces. Empirical feedback from the use of this formula with instation- ary heat transfer at curved surfaces per- mitsa concomitantextension ofthe validity, range for the problems discussed here, To compute the total heat flow of the tank, ll that is needed isa simple addition, following the formula: Q=Qr + Qe4Qv G6) where Q = total heat fow (is, W) Qu ~ heat flow to he transferred (/,W) Qo = fermentation heat flow (Us, W) Qy = outside heat flow (is, W) K- ~ heat transmission coefficient (Wim, K) A ~ cooling area, from design-related factors (mn) ‘Adm mean logarithmic temperature dliferential “ ‘To determine the mean logarithmic tem- perature differential, two values are need- cd: firstly, the great temperature clferen- tial, and secondly, the small. temperature Alifferential between the heat-exchanging media, The following formula is used for computation: (0 pr — ABA) Ader Adu 40m an m Aeery where Adm = mean logarithmic temperature differential Cs) AD gy ~ differential between the starting temperature of the medium and the inlet temperature of the cook ing medium « AD) ~ diflerential betweew the nal tem- perature of the medium and the ‘outlet temperature ofthe cooling medium ®) ——— Rule-ofthumb dimensioning of the cool- ing zones in the first part of the computa- tions is followed by a design-based dimen- sioning routine, proceeding from the tank dimensions specilied beforehand. In this, design-based specification, the number of zones together with the corresponding ber of ducts or turns are quantified, into which the overall cooling area is to be subdivided. This is laid down firstly for process-engineering brewingrrelated rea ‘sons and secondly in order to avotd an ex- cessive pressure loss in the cooling zones, ‘The nature, size and shape of the cooling zone profiles lies within the responsibility, of the tank manufacturer, who works with standard profiles which are precisely, matched of the individual applications i volved, eg. to the type of cooling mediun used. Customer: Sample brewer Represented by: Mr. Samy Sample tank = Data andl results are per tank — ‘Tank diameter (inner) — = 4,200 mm Cooling zone —eylindrical tank height = 11,500 mm Mean wall thickness = 4.5 mm Cone angle ars ‘Knuckle radius at the cone = 20mm Useful capacity up to f upper edge of frame = 1,700 hi Cooling performance: = beer starting temperature = G0 beer final temperature = ~1.0°C cooling duration 960 ~extract breakdown = 0400% 1096) ARRUWELT WMERUTONAL — 153BRAUWELT sO TECHNICAL FEATURE Toble 1 Coolng-area computation fr cyindro-cnical tanks ~ cooing area per zon (beer side) oneno.| Naber olducts [Turns perduct | Pressure oss pert (ar) 1 T = aor 2 2 To aor a z 1 ToT 0 Cooling medium: v=—Yn 3.10) = evaporation " temperature = -30°C where Heat . ‘Total heat flow = 14469 kealfh Vx — volume flow of cooling NH, quantity (Hold) = 904 kwh medium (mrs) ‘4, ~ free transition area lak! down inthe cooling profile (mn) Desigu-based specification of the cooling zones with pressure loss (see Table i) The heat transfer areas computed as fol lows: = Depeztenex 9) where F ~ heat transfer area (m D tank diameter (inner) (ny 2 = number of cooling zones oO ty —pitch of cooling zones @ fa Sumber of turns per duct oO x ~ number of ducts per cooling zone(-) You now use the cooling area specified con the basis of the design-elated dimen- sioning routine, with its subdivision into zones, ducts and number of spirals, for the subsequent computations asi this cooling area were the binding one. ‘The resultant heat transmission coetti- clentis compared tothe one assumed at the beginning of computations, and corrected appropriately. This corrective computation routine must be repeated until assumption and recomputed value coincide, apart from mini eror. Peay te cging medio ‘To be able to precisely compute the flow ‘conditions in the cooling zones, itis neces- sary to determine the free transition area which has been laid down for the cooling ‘medium in the cooling profil. This has ready been done by the tank manufacturer, who by designing the cooling profile has determined the size and nature of the cook. ing zone. ‘This is used 1o compute the velocity of the cootng medium as follows: 154 BRM TERATONAL 1998/1 ‘Validity range ofthis formula: the cooling. ‘medium does not change its phase, a (umber of cooling zones) is used only wi parallel flow. IW The heat transmission coefficient ‘The formula given below is used for com- putation of the heat transmission coeffi- Cieat, which describes te heat transfer tak- ing place betwen two fluids separated by a wall hear eer etre avert LaLa gto eehee GD where k= heat transinission coefficient (Wark) ‘41 ~ heat transfer coefficient on the product side (Wwnrk) (2 ~ heat transfer coefficient on the cooling mediuin sile (Win'K) Sa mean wall thickness (n) 24 ~ coefficient of thermal conduction for the basie material (Wark) corrective factors dependent ‘onthe cooling profile o Heat transfer: of fr coneronl Vet sates od cis at Heat transfer with free convection is ‘mostly produced as a consequence of tem- perature differential, due to differences in density, With free convection, the density in the motion equation is assumed to be a lin- ear function of the temperature only inthe uplift term, while all other material values, are assumed to be constant. The determi- ‘material property varlable is the iso baric thermal coefficient of expansion “B", which can be taken from tables. The mean dimensionless heat transmission coeffi- cient for the laminar and also for the eddy flow range of Ra 10" to Ra = 10 (the prod uct Gr Pr is also referred to as Rayleigh number Ra) is described. by the Nusselt number and the Grashof number. for the Naselt umber the following formula ap mes Nun=fog25 4 — 9987 Ral | [rvroseayr lf Pr 8.20) Formula 320, which was researched a the literature, is regarded as not uncontest edly applicable for RA > 10. In the VDI Heat Alls (Gth ed, 1951, chapter Fa 2), however, allow range ofRA- 10" to Ra=10#is stated. as the validity spectrum, which shows that here the restricted applicability for RA > 1? Ismeglected in favour of applicability overa greater range. ‘The forula given below for the vertical cylinder is used to determine the Nusselt number of a vertical plate of the same hheightand of the ratio between height h and tank diameter D: Nu 40.978 3.20a) 4 (.20a) ‘Computation of the Nusselt number ena bles the productsside heat transmission ccoelfieclent which describes the heat trans- ferbetween movingliquid or gas and a fixed ‘wall to be determined on the basis of mate lal values taken from tables. mi Heat transfer with direct NH, ‘evaporation in clled tubing ‘The heat fax density must be determined from the specified cooling area A and the {otal heat flow involved. Q 3.26) q ae 3.26) fee @ = total neat how 5.) G — heat flux density Wim’) A =cooling area (m’) The theoretical NH, quantity is computed from the heat flow to be dissipated, using the following formula: G29)BRAUWELT Os ‘The circulating NH, quantity Is deter- mined from empirical data, using the fol- lowing formula: Fiiynnuini = 4o myn B30) where mixin, theoretically required! ammonia mass flow (kes) tiny jut actually required ammonia mass flow (kg/s) r evaporation enthalpy of the ammonia cede) ‘The velocity inside the cooling coil can be computed from the circulating NH, quan- tity, using the following formula @30) ‘The pressure loss, which is of major im- portance in the cooling zones, is computed using the following formula: p= GotSeiby PE aan) wt 2-108 where Ap ~ pressure loss in the olin eo (oar) Length of the cooing coil ¢n) v__~ velocity of the cooling medium in the coll (vs) & ~ drag coefficient of the cooling coll oe Ex ~ drag coetfcient at entry into and exit from the cooling profile) fpr ~ density ofthe NH, fluid (kam) ya hydraulic transition diameter (mn) Validity range of the formula: bar$ 4p £02 bar iricgteatazso When a cooling agent flows through coiled tubing, the same criteria apply (for ‘computation of the pressure loss using the {orimulas deseribed) as for direct NH, evap- ‘oration in the coiled tubing. As with the design-based speeification of the cooling zones, frst the velocity in these is ascertained. This velocity is important {or determining the type of flow: laminar or eddy {In this context, please note that with very viscous cooling agents in particular it may easily happen that the flow, in spite of high, TECHNICAL FEATURE flow velocities, will bein the laminar range. If this isthe case, the coolingzone design aust be modified soas to ensure operation ‘vith ewer ducts and/or with redueed heat- up Gincrease in troughllow). However due tothe quay nce tise tells, this also means @ rise in oper crate, The coolingagent value Now is termined by means ofthe following formu- la: Q (3.3) pr-AdK ae From this, the velocity inthe cooling zones ‘can be computed, using the following for- mula: G3) where v= velocity in the cooling zone (1s) ep ~ specie heat (ayy: K) a = free transition area laid down: in the cooling profile ny 2 ~ number fooling zones) % = numberof ducts per cooling zone Vx ~ volume flow of cooling agent(m'/s) Q = heat flow Wis. W) Pr - density of cooling agent (kg/m') loss in the cooling zones is of grea in tance. It is computed using the follow formula Ape Gerber by. VP aay hyt 2-10" ‘where Ap ~ pressure ss in the cooling col (ba) L = length of the cootingeoil —(m) y= velocity ofthe cooting medium inthe col (js) & ~ drag coelicient of the cooling medium in the coil oO Sx = drag coelficient at entry into and eat from the eooling profile. pe = density ofa cooling agent fi kg/n’y iyo hydraulic transition diameter (m) 15 Where do we go from here? ‘The paragraphs below are intended to briefly outline the direction in which devel. ‘opment is being progressed; the steps are: 1. To conduct design-elated research and development on the type of cooling zones used and on inlet/outlet areas of ‘cooling zones, so as to achieve a redue- tion in material consumption and an opti- mized cooling perlormance, e.g. by re= «lucing the pressure loss involved; 2. to extend the cooling programme to in- clude the heating field as well, so that cooling zones can also be utilized for heating purposes; 3. to Incorporate forced convection (by blowing CO, gas into the fermentation process) into the computation pro: ‘gramme. 4. Lo implement the solutions found by ~ developinga cell mod, whieh means modelling based on existing numeri= cal solutions; the cooling zones by ite difusion, which means solving the coupled dilferential equa- tions inthe liquid. ‘This step-by-step approach minimized the costs involved since here one step builds on the preceding one, and if prob Jems oecur, these ean immediately be coun tered by the correct response. Summary ‘To sum up, itcan be stated that today the ‘know-how is available, and the skill to im- plement it, to meet in full the ongoing re- ‘quirements of breweries for cost-efficiency, ‘optimized process control and eco-compat- ibility. The result will be al the better, the more ‘closely customers’ wishes can be: faitully dovetailed with product-specific exper ‘ence, in order to ereate a properly custom. ized system designed! to ensure a top-quall- ty produ, It is hore that the great diffence lies be- ‘tween a qualified completesystem vendor and atank supplier pure and simple, il 189 ERUWELTINERIATONAL 15,