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Evaluate flow and heat transfer in agitated jackets

Article · August 2005

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 Heat Transfer

Evaluate
Flow and Heat Transfer
in Agitated Jackets
Use these correlations to compute
John Garvin
Manford Technical Consultants
swirl flowrate and jacket heat-transfer
coefficients as functions of
agitation nozzle flow.

R
eactor vessels with conventional jackets are nor- length (L), flow height (z) and jacket flow area (At) can
mally fitted with jacket nozzles (often termed agi- be calculated. To completely define the system, it is nec-
tation nozzles) that impart circumferential momen- essary to know the effective outlet diameter (dn) and area
tum to the jacket fluid. This causes a swirling motion, (a n) of the nozzle.
which enhances the heat transfer in the jacket. Generally, values of dn or an for proprietary nozzles
Vendors of agitation nozzles provide design informa- are not explicitly available. (Values of dn are related to,
tion that is adequate for the selection of suitable nozzles but not the same as, the nozzle throat diameter). In all
for particular applications. This vendor-supplied informa- cases, however, pressure drop vs. flowrate data are avail-
tion, however, is neither adequate for computing the varia- able (1–4), and design performance data are also often
tion in the induced swirl flow with changes in nozzle flow, available in a variety of formats. From these data and a
nor for computing heat-transfer coefficients as a function momentum balance around the jacket (Eq. 1), it is possi-
of nozzle flow. Quantitative information on jacket flows ble to derive accurate values of dn and an from the total
and heat transfer at variable nozzle flows is useful for swirl flow in the jacket:
dealing with heat transfer at low flows (e.g., during main-
tenance heating or cooling) and at high flows (e.g., during rq = –j + [j2 + j(ra + 1)]0.5 (1)
exotherm control or emergency cooling), as well as for
process validation and batch timing. where j is a friction parameter, defined as de/2fL.
This article presents general relationships (based on a Two types of agitation nozzles are available. The
review of proprietary nozzles from a variety of manufac- nozzle enters the jacket wall radially and incorporates
turers) for calculating jacket swirl flows and heat-transfer either a deflector plate or a smooth right-angle elbow to
coefficients using only published proprietary (i.e., vendor- send the nozzle flow in a circumferential direction
supplied) data. It also gives details of how to calculate the around the jacket.
process efficiency of agitation nozzles. From published nozzle pressure drop (∆pn) vs. flowrate
(qn) data for water, the flow coefficient, K , can be calculated:
Swirl flow and heat-transfer coefficient
Heat transfer area (Aht), jacket volume (Vt) and vessel K = ∆pn/ρqn2 (2)
outside diameter (dv) are normally available for propri-
etary vessels. From these, the flow width (w), flow Equations 3 and 4, derived from published flow data

CEP www.cepmagazine.org August 2005 1

Heat Transfer

provided by four suppliers, are then used to calculate dn The friction factor in straight flow is calculated by:
for smooth-elbow nozzles and deflector-plate nozzles, (4fs)1/2 = –1.1513/ln[e/(3.7de) + 2.51/(Re(4fs)1/2 (10)
respectively:
and in curved flow is:
dn = 0.393 Dn0.62 K–0.069 (3)
fc = fs + 0.01(de/dv)1/2 (11)
dn = 0.781 K–0.221 (4)
Finally, the heat transfer coefficient is calculated from:
The average absolute error associated with Eqs. 3 and 4
is about 2–3%. This error can be expected to result in an Nu = h de/k = 0.023 Re0.80 Pr0.33 (12)
error of about 2% in the film coefficient and about 1% in
the overall heat-transfer coefficient.
Sample calculation
Process efficiency of agitation nozzles A DIN BE6300 reactor is fitted with three 40-mm
The process efficiency of an agitation nozzle is defined as: smooth-elbow nozzles. Proprietary information for the
nozzle gives a pressure drop of 0.562 bar at a flowrate of
η = Ej/En (5) 9.0 m3/h. Calculate the jacket velocity and heat-transfer
coefficient at a flowrate of 12 m3/h per nozzle. Assume
where: water at 20°C (ρ = 998.3 kg/m3, µ = 1.036 cP = 0.001036
Pa-s, specific heat, c = 4,188 J/kgK, k = 0.5872 W/m-K,
Ej = Qt(p2 – p1) = Qtρut2(ra – 2rq + 1)/rq2 (6) Pr = 7.39). Available proprietary information is: Vt = 744
L = 0.744 m3; Aht = 18.1 m2; and dv = 2 m.
En = Qn∆pn = (Nnqn)(ρqn2K) (7) The flow coefficient for the nozzle is calculated from
Eq. 2: K = ∆pn/ρqn2 = (0.562 ×105)/(998.3)(9.0/3,600)2 =
so that 9.0 × 106 Pa/(kg/m3)(m3/s)2.
The nozzle outlet diameter is given by Eq. 3: dn =
η = (ra – 2rq + 1)rq/(ra2an2K) (8) 0.393 (0.040)0.62 (9.0 × 106)–0.069 = 0.0177 m.
Outlet area per nozzle = an = πdn2/4 = π(0.0177)2/4 =
0.0002461 m2.
Heat transfer and nozzle power Total nozzle outlet area = An = 3 × 0.0002461 =
Bondy and Lippa (5) have suggested as a rule of thumb 0.000738 m2.
that to achieve a heat-transfer coefficient of 400 Btu/ft2-h- Flow width = w = Vt/Aht = 0.744 m3/18.1 m2 = 0.041 m.
°F in agitated vessels, it is necessary to have a minimum Flow length = L = πdv = π × 2.00 = 6.42 m.
of 0.01 hp of nozzle power per square foot of heat transfer Jacket equivalent diameter = de = 2 w = 0.082 m.
area. This is equivalent to achieving 2,270 W/m2-K with Flow area = At = Vt/L = (0.744 m3)/(6.42 m) = 0.116 m2.
nozzle power of 80 W/m2. Using a roughness value of e = 0.0000457 m, Eq. 10
Nozzle power is given by: gives a first approximation of the straight-flow friction
factor of fs = 0.0055. Correcting for curvature with Eq. 11
qn∆p = ρKqn3 (9) gives fc = 0.00752
The friction parameter j = de/2fL = (0.082) ÷
This rule of thumb has been checked for a wide [(2)(0.00752)(6.42)] = 0.8515. The area ratio, ra, = A t/An =
range of vessel and nozzle configurations. The average 0.116/0.000738 = 157.
heat-transfer coefficient calculated for a nozzle power Equation 1 gives the flow ratio rq = –j + (j2 + j[ra +
of 80 W/m2 is 2,287 W/m2-K (403 Btu/ft2-h-°F), with 1])0.5 = –0.8515 + (0.85152 + 0.8515[157 + 1])0.5 = 10.8.
values ranging from 2,076 to 2,649 W/m2-K. It appears The total flowrate in the jacket is Qt = rq × Qn = 10.8 ×
that the rule of thumb is valid, on average, and subject 3 × (12.0/3,600) = 0.108 m3/s.
to a mean variation of about 6%. The primary limitation The jacket velocity is ut = Qt/At = 0.108/0.116 = 0.931 m/s.
is that this generalization is applicable to water at ambi- With this value of jacket velocity, the Reynolds number
ent temperatures, and any significant variation in vis- Re = deρut/µ = (0.082)(998.3)(0.931)/(0.001036) = 73,564.
cosity, density or conductivity from ambient water val- Substituting this value for Re into Eq. 9 gives fs =
ues invalidates it. 0.0054, which is close to the approximation of fs = 0.0055.

2 www.cepmagazine.org August 2005 CEP

 The heat-transfer coefficient is calculated using Eq. 12, Nomenclature
and results in h = (0.5872/0.082)(0.023)(735640.80)(7.390.33)
= 2,493 W/m2-K. an = effective flow area of a nozzle, m2
The table lists values of heat-transfer coefficients and Aht = heat transfer area, m2
other parameters for this choice of vessel and nozzles for a An = total nozzle outlet area, m2
range of nozzle flowrates. At = jacket flow area, m2
The practical upper limit on achievable heat-transfer rates c = fluid specific heat, J/kg-K
is set by possible erosion and noise problems that occur at de = equivalent diameter of jacket, m
high nozzle velocities. It is not normally recommended to dn = effective outlet diameter of nozzle, m
exceed a nozzle exit velocity of un = 15 m/s. CEP dv = vessel outside diameter, m
Dn = nominal/inlet size of nozzle, m; the following nominal
values should be used for Dn: 1 in. = 0.025 m; 1.25 in. =
0.032 m; 1.5 in. = 0.040 m; 2 in. = 0.050 m; 3 in. =
0.075 m; and 4 in. = 0.100 m
e = roughness factor, m
Table. Jacket heat-transfer coefficients and other data
Ej = energy delivered to jacket, W
for BE6300 fitted with three 40-mm nozzles
(details per sample calculation).
En = energy input into the nozzles, W
f = Fanning friction factor
Flow per Heat-Transfer Total Nozzle Nozzle fs = friction factor in straight flow
Nozzle, Coefficient, Velocity, Pressure Velocity, fc = friction factor in curved flow
m3/h W/m2-K m/s Drop, bar m/s h = jacket film heat transfer coefficient, W/m2-K
k = fluid thermal conductivity, W/m-K
3 766 0.21 0.06 3.4
K = nozzle flow coefficient, Pa/(kg/m3)(m3/s)2
6 1,393 0.45 0.25 6.8
L = total flow length, m
9 1,966 0.69 0.56 10.2 Nn = number of inlets with nozzles
12 2,493 0.93 1.00 13.5 Nu = Nusselt Number = hde/k
15 3,022 1.18 1.56 16.9 p = pressure, Pa
∆pn = nozzle pressure drop, Pa
Pr = Prandtl Number = cµ/k
qn = flowrate from one nozzle, m3/s
Qn = flowrate from all nozzles, m3/s
Literature Cited
Qs = swirl flowrate in jacket, m3/s = Qt – Qn
1. Pfaudler Reactor Systems, “Agitating Nozzle for Qt = total flowrate in jacket, m3/s
Jacketed Reactors,” Data Sheet DS65-700-5. ra = area ratio = At/An
2. De Dietrich USA, “Capacity of Agitating Nozzles in De rq = flowrate ratio, Qt/Qn
Dietrich Jacketed Glass Lined Reactors,” Bulletin 773 Re = Reynolds Number = deρut/µ
(1991). un = nozzle exit velocity, m/s
3. Pfaudler-Werke GmbH, “Agitating Nozzles in the Jacket ut = total fluid velocity in jacket, m/s
of Glass-Lined Reactors,” Ref. 235-2e. Vt = total volume of jacket, m3
4. De Dietrich Zinswiller France, “Cooling Water Flowrates w = flow width or mean jacket gap, m
Recommended on Standard Reactors,” “Pressure Drop z = effective jacket height = flow height, m
Due to Agitating Nozzles,” and “Jacket Nozzle Detail,” = Vt/(wL) = Aht/L
DEC-C2-009.
5. Bondy, F., and S. Lippa, “Heat Transfer in A g i t a t e d Greek Letters
Vessels,” Chem. Eng.,pp. 62–71 (Apr. 4, 1983). η = efficiency
ρ = density of fluid, kg/m
µ = viscosity of fluid, Pa-s
JOHN GA RV I N is a director of Manford Technical Consultants (Wexford, j = friction parameter = de/2fL
Ireland; E-mail: john_garv i n @ p rochem.ie), a firm that specializes in
chemical engineered design, technology development and pro j e c t Subscripts
management. He has over 25 years of experience in project design and 0 = point immediately upstream of the nozzle(s)
management for a broad range of process industries, and has worked
1 = point immediately downstream of the nozzle(s)
with companies in the U.S. and Ireland. He has undertaken technology
d e velopment in heat transfer, reactor design, and physical pro p e rties,
2 = point downstream of Point 1; any point sufficiently
including software applications. downstream of the nozzle for mixing of the nozzle
stream with the swirl flow to be effectively complete

CEP www.cepmagazine.org August 2005 3

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