ISAT 413 - Module V: Industrial Systems

Topic 3: Run-around Coil Systems,

Regenerative Heat Exchangers,
Pinch Technology

 Run-around Coil Systems:

• Definition of Run-Around Coil Systems
• Design Factors
• Examples

1
Run-around coil system of heat recovery
A run-around coil heat recovery system is the name
given to a linking of two recuperative heat exchangers
by a third fluid which exchanges heat with each fluid
in turn as shown diagrammatically below.

2
Run-around coil system
 A run-around coil would be used in cases where the two
fluids which are required to exchange heat are too far
apart to use a conventional direct recuperative heat
exchanger. It is also desirable to use such an indirect
system if there is a risk of cross-contamination between
the two primary fluids (e.g. when a particularly corrosive
fluid is involved, or when there is a risk of bacterial
contamination as in a hospital).
 Advantage would be free choosing of working fluid.
 Disadvantage would be low effectiveness of the HX.
 Typical applications are recovery of energy from the air
leaving a room or building to pre-heat the air entering;
and recovery of energy from a corrosive gas for water
heating.
3
Run-around coil heat recovery between fluids
with the same thermal capacity
 m c  C   m c  H

Q Q Q
    t S1  t S 2    t C 1  t C 2    t H 1  t H 2 
 m c  S  m c  C  m c  H
i.e.  m c  S   m c  C   m c  H
and  t H 1  t S1    t H 2  t S 2  ;  t S1  t C1    t S 2  t C 2 
4
Run-around coil heat recovery between fluids
with the same thermal capacity  m c    m c  C H
Assume the two heat exchangers are identical :
Q Q t H 1  tC1
 UA H   UA C    t S1 
 t H 1  t S1   t S1  t C 1  2
Q Q t H 2  tC 2
  
and UA H  UA C     tS2 
 t H 2  t S 2   t S 2  tC 2  2

thus, Q   UA H  t H 1  t S1    UA C  t S1  tC1  

  UA H  t H 1  tC 1 
2
Q
and since tC 1  tC 2 
 m c  C
hence the heat recovery can be expressed as Q    UA H  t H 1  t C 2 
2
 UA H
 m c  C
5
Example
A run-around coil heat recovery system similar to that on
slide 4 is used for a room in which the presence of bacteria
rules out any possibility of air re-circulation or a direct
recuperative heat exchanger. Air enters the room at 24 oC
and leaves at 20oC; the average outside air temperature
during the annual period of use is 5oC. Assuming that the
mass flow rate of air is 2 kg/s, mean specific heat 1.005
kJ/kg-K, that (UA)H = (UA)C = 4 kW/K, and that the
specific heat of the secondary fluid is 2.5 kJ/kg-K,
calculate:
(i) the required mass flow rate of secondary fluid;
(ii) the temperature of the air leaving the run-around coil;
(iii) the percentage energy saving by using the run-around
coil.
6
Example
(i)  m c  S   m c  H   m c  C  2 1.005  2.01 kW / K

 m s 
 m c  S 2 .01
  0.804 kg / s
cS 2 .5

(ii) Q 
  UA H  t H 1  tC 2  4 20  5
  15.04 kW
2
 UA H
2
4
 m c  C 2.01
Q 15.04
and tC 1  tC 2   5  12.5o C
 m c  C 2.01
(iii) Without the heat recovery the air must be heat
from 5o C to 24o C hence the percentage energy saving
is given by :
% saving 
 m c  C 12.5  5
 100%  39.4%
 m c  C  24  5 7
Round-around coil heat recovery between
fluids of different thermal capacity
 m c  C   m c  H

8
Round-around coil heat recovery between
fluids of different thermal capacity
 m c  H   m c  S   m c  C

9
Round-around coil heat recovery between
fluids of different thermal capacity
 m c  H   m c  S   m c  C

10
Idealized run-around coil system

Required secondary fluid m S 

 m c  H  m c  C   UA H   UA C 
c S   m c  H  UA C   m c  C  UA H 
11
Example 5.7
(use - NTU method to analyze run-around coil
heat recovery system)

12
Example 5.7
A corrosive gas at a flow rate of 30 kg/s from a process at
300oC is to be used to heat 20 kg/s of water entering 10oC
using a run-around oil as shown on slides 8 & 12. Calculate
using the data given:
(i) the mass flow rate of secondary fluid required;
(ii) the effectiveness of the overall heat transfer;
(iii) the exit temperature of the water;
(iv) the temperatures of the secondary fluid.
Data: Mean specific heat of gases, 1.2 kJ/kg-K; mean
specific heat of water, 4.2 kJ/kg-K; mean specific heat of
secondary fluid, 3.8 kJ/kg-K; (UA) for the gas to secondary
fluid heat exchanger, 40 kW/K; (UA) for the secondary
fluid to water heat exchanger, 200 kW/K.
13
 Example 5.7
(i) The required mass flow rate of secondary fluid is given by
mS 

 m c  H  m c  C   UA H   UA C 
c S   m c  H  UA  C   m c  C  UA H 


 30 1.2   20  4.2 40  200  18.09 kg
3.8  20  4.2  40    30  1.2  200  s
1 1 1 1 1 3
(ii) Since     
 UA overall  UA H  S  UA S _ C 40 200 100
since NTU 
 UA overall 33.333
  0.926;
 m c  min 36

and R 
 m c  min 36
  0.429
 m c  max 84
1  e  NTU 1 R  1  e 0.9260.571
Hence HX effectiven ess,    NTU  1 R 
  0.9260.571
 0.55
1  Re 1  0.429e
14
Example 5.7
(iii) Since the definition of HX effectiveness is given by
Q H or Q C  m c  H  t H 1  t H 2   m c  C  t C1  tC 2 
  
 m c  min  t max  t min   m c  H  t H 1  tC 2   m c  H  t H 1  tC 2 
   0.55 
 30 1.2  H   300  t H 2 
 t H 2  140.5o C
 30 1.2 H   300  10
   0.55 
 20  4.2  C   t C1  10 
 tC 1  78.4o C
 30 1.2 H   300  10
(iv) Since the heat transfer is given by
@ station 1 :  UA H  t H 1  t S1    UA C  t S1  t C1 
 40 H  300  t S1    200 C  t S1  78.4  t S1  115.3o C
@ station 2 :  UA H  t H 2  t S 2    UA C  t S 2  t C 2 
 40 H 140.5  t S 2    200 C  t S 2  10  t S 2  31.8o C
15
Temperature changes for Example 5.7

16
 Regenerative Heat Exchangers:
• Definition of Regenerative HX
• Design Factors
• Examples
In a regenerative heat exchanger (sometimes
called a capacitance heat exchanger) the hot
and cold fluids pass alternately across a
matrix of material; the matrix is heated up by
the hot fluid then cooled down by the cold
fluid so that the process is cyclic.

17
Stationary Regenerative Heat Exchanger

In (a) matrix B is hot and heats up the cold fluid

while matrix A is heated by the hot fluid; in (b) the
cold fluid is now heated by matrix A while the hot
fluid re-heats matrix B; the valves are then switched
over and the cycle commences again as in (a) .
18
Rotary Regenerator or Thermal Wheel

A matrix of material is mounted on a wheel which is

rotated slowly through the hot and cold fluid
streams as shown above. It is known as the thermal
wheel, and Ljungstrom rotary regenerator after its
Danish inventor.
19
Influence of Matrix Rotational
Speed on Effectiveness

 
 
 1 
E  E c 1  1.93 
   m c  M  
 9    
   m c  min  

where, E c 
1  e  NTU 1 R 
;R
 m c  min
1  Re  NTU  1 R 
 m c  max
Mc M
and  m c  M   NMc M


20
Example 5.8 (A rotary regenerator)
A rotary regenerator is used to recover energy from
a gas stream leaving a furnace at 300oC at a mass
flow rate of 10 kg/s. Heat is transferred to a mass
flow rate of air of 10 kg/s entering at 10oC. The
wheel has a diameter 1.5 m, giving an approximate
face area of 1.6 m2, and a width of 0.22 m; the matrix
has a surface area to volume ratio of 3000 m2/m3 and
a mass of 150 kg; the rotational speed of the wheel is
10 rev/min. The heat transfer coefficient for both
fluid streams is 30 W/m2-K and the mean specific
heats at constant pressure for the gas and air are
1.15 kJ/kg-K and 1.005 kJ/kg-K; the specific heat of
matrix material is 0.8 kJ/kg-K.
Calculate:
21
 Example 5.8 (A rotary regenerator)
(i) the effectiveness of the heat exchanger;
The overall heat transfer coefficienct is given by
1 1 1 hC hH 30  30 W
  U    15 2
UA hH A hC A hH  hC 30  30 m .K
 A
Heat transfer area, A  V     1.6  0.22  3000  1056 m 2
V 
NTU 
UA

15 1056
 1.576; R 
 m c  min 10 1.005
  0.874
 m c  min 10 1.0051000  m c  max 10 1.15
1  e  NTU 1 R  1  e 1.5760.126 10 kW
Ec   NTU  1 R 
 1.5760.126
 0.636;  m c  M  150  0.8  20

1  Re 1  0.874e 60 K
 
 
 1   1  kW
E  Ec 1  1.93 
 0.6361  1.93 
 0.617 Where  mc  min  10.05

   m c  M    91.99  K
 9  m c   
  min  
22
Example 5.8 (A rotary regenerator)
(ii) the rate of heat recovery and the temperature of
the air at exit;
From the definition of heat exchanger effectiveness
Q
E  0.617
 m c  min  t H 1  tC 2 
 Q  0.617  10 1.005   300  10  1799 kW
Also, Q   m c   t  t   10 1.005   t  10  1799 kW
min C1 C2 C1
1799
 exit temperature of air, t C1  10   189o C .
10.05

23
Example 5.8 (A rotary regenerator)
(iii) the air temperature at exit if the rotational speed
of the wheel is increased to 20 rev/min;
rev . rev . 1 min
Given N  20  20 
min min 60 sec
  m c  M
20
 NMc M  150  0.8  40
kW

 m c  M  40  3.98
60 K  m c  min 10 1.005
 
 
 1   1 
E  Ec 1  1.93 
 0 .636 1  1.93 
 0.631
   m c  M    9 3.98 
 9   m c   
  min  
Therefore E 
Q

 m c  min  tC1  tC 2   0.631
 m c  min  t H 1  tC 2   m c  min  t H 1  tC 2 
 tC1  10  0.631  300  10  193o C

24
Example 5.8 (A rotary regenerator)
(iv) the air temperature at exit if the rotational speed
of the wheel is reduced to 5 rev/min;
rev . rev . 1 min
Given N  5 5 
min min 60 sec
  m c  M
5
 NMc M  150  0.8  10
kW

 m c  M  10  0.995
60 K  m c  min 10 1.005
 
 
 1   1 
E  E c 1  1.93 
 0 . 636 1  1.93 
 0.565
   m c  M    9 0.995 
 9   m c   
  min  
Therefore E 
Q

 m c  min  tC1  tC 2   0.565
 m c  min  t H 1  tC 2   m c  min  t H 1  tC 2 
 tC1  10  0.565   300  10  173.8o C

25
 Gas-Fired Regenerative Burners

In (a) the hot gases are fed back through the burner
and through a matrix to exhaust; while in (b) air is
drawn through the matrix and supplied with gas to
the burner where combustion takes place; two
burners are used in tandem so that continuous
combustion can take place.
26
Magnetic Heat Pump research
at Oak Ridge National Laboratory

27
Problem 5.9
Double Accumulator Regenerative Heat Exchanger

A double accumulator as shown above is to be

installed to recover energy from the air leaving a
building. The air leaves the building at 20oC at a rate
of 2 kg/s and the mean outside air temperature for
the heating season is 5oC. Calculate the rate of the
recovery, etc...
28
 Pinch Technology Concepts:
• Basic Concepts
• Design Factors
• Examples
For many years the approach to a large network of heat
exchangers was either by ‘rule of thumb’ or a
systematic mathematical examination of all possible
configurations to try to achieve the best layout.

Another approach to network design is given the name

Process Integration, or Pinch Technology.

29
Heat Exchanger Temperature Profiles

The design of the

heat exchanger is
based on the
minimum allowable
temperature
difference between
the two streams
being 20K.
Additional heating
and cooling are
required to achieve
the desire
temperatures.

30
Simple Heat Recovery Scheme
Additional/External heating :
Q external , heating
 C C  130 - 110 
 2  20  40 kW

Additional/External cooling :
Q external , cooling
 C H   60 - 30
 1 30  30 kW

31
Temperature-Heat Load representation
of Heat Recovery scheme
The two lines
representing the
streams are positioned
so as to show a region
of overlap which
represents the action of
the HX in transferring
140 KW. The minimum
temperature difference
occurs where the two
lines are nearest
together - this point is
called the Pinch point.
32
Effect of ‘Moving’ the Cold Stream
The effect of
increasing the Pinch
temperature
difference is twofold;
the amount of heat
exchange between the
two fluids is reduced
and the external
duties are increased.
Note that the slope of
the cold stream line is
determined by the
value of CC, which is
1/CC = 0.5 K/kW.
33
Effect of ‘Moving’ the Hot Stream
 The same argument could be used for positioning the hot
stream line. Thus we can say that the lines can be moved
horizontally within the limits of temperature and gradient
until the nearest points are separated by the minimum
allowable temperature difference, that is the Pinch
temperature difference.
Also
 To achieve the target for the external cooling duty of the
hot stream, there must be no external cooling of the hot
stream above the pinch.
 A similar argument applies to the external heating of the
cold stream below the pinch: there must be no external
heating of the cold stream below the Pinch.
34
 Stream Netwroks:
• Stream Network Concepts
• Design Factors
• Examples

Considering the design of a system of heat recovery

between two (or more) hot streams and two (or
more) cold streams to illustrate some fine points of
Pinch Technology.

35
Example 6.1 (Pinch Technology)
The heat flow capacities and temperatures of four streams are
shown in the table below. For the purpose of definition, a hot
stream is defined as one which requires cooling to reach its final
temperature and a cold stream is one which requires heating to
reach its final temperature. The minimum allowable
temperature difference between the streams is 20 K.
Stream Type Thermal Initial Final Rate of
number capacity temp. temp. enthalpy
rate, C (oC) (oC) increase
(kW/K) (CT)
(kW)
1 Hot 2 200 60 -280
2 Hot 4 170 70 -400
3 Cold 3 40 175 +405
4 Cold 4.5 100 150 +225
- 50 36
Composite Stream Heat Flow Capacities
(Hot Stream Composite)

37
Composite Stream Heat Flow Capacities
(Cold Stream Composite)

38
Hot and Cold Composite Curves

39
Combined Hot and Cold Composite Curves
From the graph the
following information can
be derived:
 hot stream temperature
at the Pinch: 120oC
 cold stream
temperature at the Pinch
= 100oC
 target external heating
load = ? kW
 target external cooling
load = ? kW
Cooling load will exceed the heating load by ? kW.
40
 Calculations of External Cooling and
Heating Loads  target external
200 200 heating load = 90 kW
170 175

150 150
Temperature (o C)

120 148
140
90
100
70 100
60
 target external
50
40 cooling load = 140 kW

0
0 200 400 600 800
Heat Load (kW)
Cooling load will exceed the heating load by 50 kW.
41