hanger Hot & cold fluid flows simultaneously & Q is transferred through wall 1) bula 1. Concentric tube (or) double pipe I. Shell-tube HE (100-500 m2/m3) Ill. Spiral tube 2) Plate 3) Extended surface Flow arrangement 1) Single-Pass (parallel, counter, cross) 2) Multi-Pass (parallel, counter, cross) eae Storage ( or regenerative) type : @ (Hot — cold) through coupling meaum s solid matrix), hot & cold d flows altematively through matrix (hot fluid stores Q & cold fluid extracts Q from it) Q EX: Single matrix HE Direct contact type : (2 fluids are not separated , Q (gas— liquid) ; gas is either bubbles through liquid (or) id is sprayed in the form of droplets into the gas Surface compactness 1) Non-compact (surface area density < @ area 700 m?/m*) 2) Compact (surface area density > 700 m?/m?)ise in HE analysis ‘et temp of the hot & cold fluids are known (or) can be determined from an EB. & Uare available, HI ¢ area of the HE can be determined 7 q = VAT EMTD method is very suitable for determination of size of a HE Specified outlet temp , rit & inlet & outlet temp (hot & cold fluids) Using LMTD method, select a HE to meet the prescribed HT requirements© {ypes of HE problems size of a HE for a specified performance es, inlet & exit temp aster areal) req he performance of a specific HE exchanger & wo given fluids, & flow rates are specified SRIREHBf the two fluidsRate of FFECTIVENESS Effectiveness = oe Actual Q in the HE (.q) = (capycity cate) * (change of temp of the fluid) Max. possible Q ( ke of the two capacity rates, (7HC,),1 * [max possible rise (or) fa Tn = Ta) J te Use smaller ca :. pacity F . temp tise ( If larger capacity rate (1itCy), Is ; the np © Tee > Tri (0t) Tr GHG —T max — (aly), Tri MC < teCye & (Equilavent when mC,» TinGpn > TheCpc t = telpstead of ritnCyy = (1hCp)., that TieCpe = (mhCp),, : =1~exp[-(1 fomncebe) UA V+ MnCpn) MeCpe ubscript b : larger of the two capacity rates(highest) th fluids unmixed) + parallel Capacity NTU values (<0.3) min ( 1) + 0 corresponds t0 Crux > 2 (Ad process : con ciler) egardless of the (ype of HE ), reduce to € = 1 — exp! boiling fluid remains constant Coax? 1 i.e heat capacity r meas| Double Pipe HE desigr alk de) & h, (inside) (0 obtain overall clean “U: { f ance to obtain dirty overall “U": { atcul ausing, Q = UpAATy, In the calculation procedu ! nid fluid temp : upper & lower case letter 1 Fluid properties : lower case letters ‘acess conditions req uid: ( inside &outside dir le fluid itn, Cp, Hy k, AP, inside Koutside dirt Fact | Diameter of each pipe : given (or) assume1 t balar Q from T,, T,, t, & using Cy @ Tyo, (Ty) & tonean (ten) LMTD (counter flow arrangement, AT},,,) MTD) ==li) Calculate physical properties : hot & cold fluid @ arithmetic mean of (T, & T,) & (t, & t) prnon-viscous fluids,(~) ~ 1 ) Obtain C,, 11, k G raluate Nain value of hy (inside HTC) using Seider-Tate (or) Dit t t Inside HTC referred to OD Annulus, C ii) Flow area = Ay =~ (D3 — D?), m? OD of inner pipe ID of outer pipeObtain jt @ T,,, (or) t,, [take mean temp] Calculate Nz.pute Dittus verall clear 3oelter (or) Sieder-Tate equation (take (—) $ (heating) & a = 0.3 (cooling) efficient]ympute U,, (Dirty overall heat ? Up = Ue t Ra Ra = Ra, + Ray ¥) Compute heat transfer area, Q = UpAAT in tain length of pipe (L) using, A = mDoL Jere! etal wall resistance is to be consic yeti Sew 2.) PL OMe MK ANDY) Shell & tube HE design Shell side coefficient Evaluate all proper ‘Shell side mass velocity ide side or bundle cross area (a), —/DXCXB _ Shell IDX as velocity, G, je spacing or baffle pitch : ce loved within the sbell of a HE and also as struc ‘Sneles to the i equivalers di ity and turbulence of the use the fluid to flow thnShell side equivalent diameter (D.) flow area wetted perimeter quare pitch, ingular pitch, (05 + 0.86)P? D. = 4+ (/2)rdg lp = OD of the tube IP, = Pitch of the tube ‘Square pitchconcn of solution through vaporization to solvent (residue : thick liquor, solute : non volatile) on the surface of the liq (surface phenomena) & occurs @ any temp where AT emoval of solvent by vaporization from soln (non-volatile solute + volatile solvent) Concentrate a non-volatile solute: organic compounds, inorganic salts, acids (or) bases from a solvent & tile solvent Common solutes : caustic soda, caustic potash, sodium sulfate, sodium chloride, phosphoric acid & urea Common solvent : water. Similar to vaporization (takes place in the bulk : boiling) : bulk phenomena Takes place only @ a particular temp where liquid reaches to its BP Important unit operation : considered an individual operation If evaporation process continues, residual matter —> solid (drying) © not to dry but to concentrate weak solution © Crystallization (evaporation)—+ formation of crystal in the solution. 1m the difference between evaporator, crystallization & drying. ‘© Evaporation (vs) drying (vs) crystallization [Evaporation is followed by crystallisation & drying]Vaporation (vs) Drying eS = atin Weak solnis ¢ ance in presses the solvent of a hot gas stream (entire solvent vapourise! Heat Transte Mass transfer operation Removal of H,O asa wapauv (@ its BP) Removal of H,O as a vapour (below @ ns BP) Pat : concentrate ion (thie Rquor i.e viscous) Pdt : Solid residue (spray drying of milk to produce (ii) Detergent powder Weak solns are handled Wet solids & solns are handled Heating medium : Steacu Heating medium : Hot air/hot gas Long tube & Short tube Bxaporaror, HZ tube Tray, Rotary and Spray drierVaporator Evaporator: HE (boiling the solution with special provisions for separation of L & V) Evaporators : tubular heating surfaces (Hz or vertical, long or short; liquid may be inside or outside the tubes. Equipment, in which evaporation is performed. Evaporators (chemical industries) are heated by steam & have tubular surface. : Solution is circulated in the tube & tubes are heated by steam (saturated steam ) a © itcondenses on the outer tube surface to heat the tube. Tae Circulation of the solution (tube) : reasonable velocity (to remove of scales on the inner surface of the tube) Steam heated tubular evaporators © Natural & forced circulation evaporators.Qa Q Q cation of evaporator Evaporator : S-T-HE (boiling soln) + special provisions for separation of L & V phases. Industrial evaporators : tubular heating surfaces. > Tubes : horizontal or vertical, long or short; liquid may be inside or outside the tubes Steam heated tubular evaporators : 1) Natural circulation evaporators © Calandria type or short tube evaporator © Basket-type Vertical Evaporators © Long tube vertical evaporator 2) Forced circulation evaporators © Long tube vertical recirculation 3) Others: © Falling film evaporator © Climbing(or) Rising film evaporator Folling-film —. Long-Tube Vertical Calandria ypeuid is fed to top of the tubes & flows down the walls as a thin fil ‘nd periphery of inner tubes) Steam (shell side) & vaporization tak € Pour-liquid separation usually takes place @ the bottom (V-L mixture available) Liquid contacts steam only once & hence used for concentrating heat sensitive mat Adv ‘antages : concentration of caustic, brine solns & evaporation of corrosive solruptl concentrating solr jetach entraif od droplets)ii) Degradation due to high temperature (sensitivity) Products (Fine , food, pharmaceutical) , enzymes etc. are very te mp sensitive. ets damage during evaporation. “Special case or technique is required for concentrating solution \Woid long exposure @ higher temp V) Scale formation O Solution have tendency to deposit the scale on the heating surface O Scales extra thermal resistance. Increases Q resistance (dissolved solutes) i.e salting out effect k of solutes is low (decreases *h’) Q ~., Ignore scaling (equipment) : (de-scaling important & routine matter).) Equipment material of construction Q Chose by considering the solution properti¢ Usually made of some kind of steel Solution ; neither be contaminated nor react with the equipment material. For highly corrosive fluids : Cu,Ni, Alumina, impervious graphite ete (costly) > Maintain high HTC to reduce surface area (or) size Y Capital cost of investment | (less consumption of mat, S/A)] i) Other characterization Q Specific heat, heat of concentration , freezing , gas liberation, toxicity level , explosion hazard, radioactivity etcJ Capacity (vaporization capacity) no of kilograms of water vaporized /hour. J Economy (steam economy ) Number of kg of water vaporized (from all the effects) for each kg of steam fed to the 1* effect Steam Consumption Steam Consumption = Capacity / Economy (kg/h) OTE For single effect : steam economy <1 (~0.8) For n-effect : capacity = n* single effect unit Total Steam economy = 0.8 ntultiple (double) effect evaporators E-1 (Saturated vapor) —> steam in E-2 (for heating) E-1 (partially concentrated soln) —> feed to the E-2 (desired final coen) lote Vapour leaving (E-1) @ boiling temp of the liquid leaving the 1* effect, TD (ransfer heat{condensing vapor (E-1) —+ boiling liquid (E-2)], © Liquid (E-2) must boil @ temp < condensation temp of vapour (reasonable driving force) © Method : maintain suitable low *P’ (E-2) : Liquid boils @ a lower temp. If E-1 operates @ atm pressure, E-2 should be operated @ same suitable vacuum nefit Multiple reuse of heat supplied to the E-1 is possible & results in improved steam economy.' kg of steam (supply)—» 1 kg of H,0 in each of the 2 evaporators (series) Steam economy ~ double (single effect) > triple / quadruple : suitable piping [one effect + next in series) partially concentrated in each effect (improves steam economy) Extend Solution epee vs Pasay Csingle (vs) Multiple Low capital cost High steam cost Low “U" Only feed pump Scaling problem: high Simple piping High capital cost Low steam cost High to low “h” (feed arrangement) ‘Two (or) several pumps (feed arrangement) Scaling problem : low to high (fced arrangement) Complex piping‘apour recompression (self study) MEE is used to increased economy : Evaporation of solution @ moderate temp © MEE cannot be used poration of orange juice < 55°C) Similar economy can be maintained in SEE. Q_ _Vopour coming out from top which is discarded & it has to be recompressed & recirculate back to SEE Compression needed becos pressure of vapour Is low than the saturated steam (entering Into the evaporator from ext sapply) G__During compression, temp of vapour gets increased which is recirculated bock as well Increases “P™ O Alternative for SEE with highest economy (substitute to MEE) Vapour recompression system : good steam economy © Thermal recompression: { (i) steam jet ejector to increase T & P (li) Mix (motive fluid (HP steam) & LP steam(load) to generate steam (intermediate characteristics) in the form of PT (tea ‘P ) recirculate to SEE © Mechanical recompression : Use mechanical device for compression (For lange steam flow = centrifugal compressor & small volume steam flow : +Ve displacement compressor) ; compression ratio is 2:1 TE © Vapour recompression unit associated with SEE to improve ‘economy & alterative to MEEawback: When evaporator operates @ large driving force , vapour recompression may not be economical When evaporator operates @ low driving force , large area is needed (may not be desirable ) ‘Trade of b/w these 2 opposing factor needs to be considered as while deciding on type of evaporator to be used By vapour recompression multiple effect economy in a single effect © Vapour recompression works on temp drop = 10°F (MEE: 100°F) ‘© Compression equipment is expensive © If soln BPE :appreciable —-energy needed for compression }iling point elevation Evaporators > concentrated soln [ higher BP than that of the solvent (of the soln) @ prevailing P) Increase in BP over that of water : boiling point elevation (BPE) of the solution. As the concn increases the BP of the solution also increases. To get the real AT (or driving force) between the steam temp & solution temp, ¥ BPE must be subtracted from the temperature drop. Y BPE may be predicted from the steam table (in case water is a solvent). An empirical rule (Dithring rule) : Estimating the BPE of strong solution. Boiling point rise cannot be calculated from physical data (liquor) An empirical rule (Dohring rule) : change in BPR with pressure (for strong solution). | BP (solution) > BP (water) @ prevailing | BPR/BPE = BP (soln)- BP (pure water) @tihring Chart BP (solution) is linear function of the BP of the pure water @ same pressure. © BP (solution) (vs) BP (water) @same pressure => straight line (non-volatile solute , salt : NaCl) © Different lines can be obtained @ different concns. © find out BP (solution). Non-volatile solute inwater a) i mf of solute in the soln (a) 0.1 (b) 0.2 (c) 0.25 (d) 0.39 (e) 0.35 (f) 0.45 (g) ¢ [os os(wo7 iimperature profile in an evaporator ab = 45> Ty : BP (liquid) in the evaporator @ P (vapour chamber) = Mp of the surface liquid in the vapour chamber) t fl emp of the recycled liquid entering the tubes : Th, (a little less if the feed pid) hen the liquid flows up the tube, its temp rises it Local “P @ any position (1ube pr chamber pressure + hydrostatic pressure + frictional head loss quid stants boiling @ a level where its temp rises to its sat temp @ under local sure of the liqui 1 iquid temp profile (tube) = (i) for low velocity (ti)high liquid velocity. } @ low liquid velocity, liquid temp rises in the tube up to a certain height { I jefore it starts boiling. The temp gradually drops thereafter (loss of superheat) * i) Liquid flows @ higher velocity, temp raise is less & liquid does not oil until it reach near the top of the tube (ii) i): shell side temp profile (steam is heating the tube) If steam enters the shell @ top with a little superheat (looses the heat along line segment “u” ) If there is sub cooling of the condensate @ lower end of the shell, change in the condensate temp “I” Along most of the tube length , shell side temp remains @ 7 (saturation temp of steam @ shell pressure) )) : Boiling temperature of the water @ pressure in the vapor chamber : Ty ¢ BPR of the liquid =T,-T, ‘True temp driving force : Difference between the curve (iil) & liquid temp curve (i) or (li). [steam ys liquid) O Driving force varies along the tube length. However, it is practically not easy to determine the temp variation in the tube. CO Design calculations ; consider T,-Typ as temp difference (or) driving forceTESS Salem [eat transfer coefficient oe “h” for condensation of steam (shell): very high © Liquid side “h” controls the rate of HT & difficult to predict © Entering liquid velocity is low, Liquid side “h” is remains low © This “h” increases greatly when liquid stars boiling after reaching certain height in the tubes Evaporator operates @ very high liquid velocity (tubes) & no bolling occurs in the tubes (boiling occurs @ top end of the tube), “ = 0.023 Rep* Pret D- inner diameter of the tube ; k - thermal conductivity of the solution. ‘There is no practically useful method of estimation of tube side “h” if there is boiling in tubes of an evaporator Fouling of the inside tube surface is major problem in most evaporators. ‘© Tubes required periodic cleaning © Scale thickness (fouling resistance grows with time) & account in the evaporator design (fouling resistance) o Change in U with time, sew =—3+ wath