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DESALINATION
il
ELSEVIER Desalination 152 (2002) 195-200
www.elsevier.com/locate/desal

Comparison of heat transfer coefficient correlations for thermal

desalination units

Javier Uche*, Javier Artal, Luis Serra

Centre of Research for Power Plant Efficiency (CIRCE), Centro Polit~cnico Superior, Edificio C.,
University of Zaragoza, C/ Maria de Luna 3. 50015 Zaragoza, Spain
Tel. + 34 (976) 762584/2036; Fax + 34 (976) 732078; emails: javiuche@posta, unizar.es, serra@posta.unizar.es

Received 30 March 2002; accepted 8 April 2002

Abstract

This paper presents several simulator models allowing studying the behavior of different types of thermal
desalination plants [ 1]. Three types of evaporators have been distinguished in thermal desalination plants: horizontal
falling film evaporators (HFF), vertical falling film evaporators (VFF) and vertical rising film evaporators (VRF).
An in depth study of the correlations adopted to calculate the heat transfer coefficients (HTC) of the selected
evaporator/condenser has been made," in order to predict the plant performance of dual-purpose plants. Once the
sensitivity analysis of the possible HTC has been done, the selected HTC has been implemented in a complex
simulation model of MSF and MEDNC/TVC desalination units. Validation (if possible) of the calculated HTC was
also done with the real data encountered in the literature.

Keywords: Heat transfer coefficients; Correlation; Distillation; Simulator

1. Introduction The type and configuration of the evaporators/

The reliability of the thermal desalination
simulators strongly depends on the calculation of
the heat transfer coefficients (HTC) used to model
the heat transfer phenomena in the desalting process.
*Corresponding author.
condensers also implies the application of different
correlations and methodologies to deal with the
heat transfer phenomena inside or outside of the
tubes. The scope of the analysis includes three types
of evaporators: horizontal falling film evaporators
(HFF), vertical falling film evaporators (VFF) and

Presented at the EuroMed 2002 conference on Desalination Strategies in South Mediterranean Countries:
Cooperation between Mediterranean Countries of Europe and the Southern Rim of the Mediterranean.
Sponsored by the European Desalination Society and Alexandria University Desalination Studies and Technology
Center, Sharm El Sheikh, Egypt, May 4-6, 2002.

0011-9164/02/$- See front matter 2002 Elsevier Science B.V. All rights reserved
PII: S0011-9164(02)01063-9
196 ~ Uche et al. / Desalination 152 (2002) 195-200

vertical rising film evaporators (VRF). Flow pattern
corresponding to each type of evaporator/condenser
has also been taken into account in the analysis.
An extensive comparison of different correlations
applied to those configurations has been studied:
normally, six or seven correlations have been tested
for the water and/or vapor side of the evaporator/
condenser included in the thermal desalination unit.
The use of the appropriate HTC correlation is
essential to provide a reliable set of performance
results when a new configuration is being designed.
The analysis performed in this work is valid for
selecting the best correlation in more complex
models including heat, mass and salt balances, and
thermodynamic and thermophysical properties.
Due to the extension of the work, the equations
describing the correlations are not included in the
next, but all of them are described in detail in [1].
2. Horizontal tube failing film evaporator (HFF)
Horizontal falling film evaporators have gained
widespread acceptance in the desalination industry
due to some inherent advantages. Brine is sprayed
and distributed as a film over the outside of a
horizontal tube bundle and the heating steam
condenses inside the tubes. High heat transfer
coefficients are achieved (the liquid is in the form
of a very thin film), and this design has a number
of distinctive practical advantages.
2.1. Evaporation
Evaporation can either take place with or without
controlled evaporation without boiling under
turbulent regime.
Barba and Di Felice's correlation [3] for non-
boiling conditions and turbulent film flow.
Modified Nusselt, Kutateladze and Labuntsov's
correlation [4--6] for gravity controlled con-
densation (or evaporation without boiling) in
laminar, wavy and turbulent regime for falling
films onto a planar surface.
Han and Fletcher's correlation [7] for falling
films in boiling conditions.
Several comparisons of the HTC calculated from
those correlations have been made with respect
to the brine saturation temperature (see Fig. 1), mass
flow per unit length and wall superheat. Finally,
according to the given stability over a wide range
of conditions, we have selected the Parken corre-
lation for non-boiling conditions, and Han and
Fletcher's correlation when boiling occurs.
2.2. Condensation
There are many possible correlations in the
literature for this purpose. But before using any
correlation, it is necessary to check the experi-
mental test fluid. In condensation there are two
extreme situations, i.e. shear-controlled flow
(annular flow) and gravity-controlled flow (or
stratified flow). The analyzed correlations are the
following:
7000
6000 / Barbaand Di Felice
/

boiling. Usually boiling does not occur since high 5000 ~rk~_
superheat in the tube wall is necessary, and in ~ 4 0 0 0 ~Han and Fl.e.tc~r.,2.*C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
desalination units it is interesting to maintain a ~ 3 0 0 0 ~ Nussett
low temperature difference between condensing 2000 ~ Han and Fletcher,5C
brine and evaporating brine. Evaporation with 1000 ~,_
boiling achieves high heat transfer ratios and is 0 " ~ -- --7 ~ r . . . . . . . 7

50 60 70 80 90 I00
defined by different correlations than just evapo- Temperature (C)
ration. We found four possible correlations for
calculating the HTC of a falling film on the outside Fig. 1. Influence of evaporation temperature on the outside
of horizontal tubes: HTC in HFF; Mass flow per unit length 0.1 kg/m.s; salt
Parken and Fletcher's correlation [2] for gravity concentration 5%.
 d. Uche et al. / Desalination 152 (2002) 195-200
Boyko and Kruzhilin [8]: for annular turbulent
flow.
Chen [9]: for combined nucleate boiling and
forced convection for condensation inside tubes.
Also a new one for annular turbulent flow [ 10].
Coolier and Pulling [11]: similarto Chen's one
for annular flow expression.
Shah [12]: for annular turbulent flow valid for
many fluids, also for water.
Akers et al. [13]: this correlation is valid for
annular flow in turbulent and laminar regime.
Cavalini and Zecchin [14]: for turbulent annular
flow.
Traviss et al. [15]: it works properly for every
regime (laminar, wavy or turbulent), in annular
flow.
Chaddok and Chato [16]: it is derived from
Nusselt's gravity controlled condensation, the
film at the top of the tube will be very thin,
causing high heat transfer coefficients.
For the different correlations presented, a
graphical comparison is made to determine which
correlation should be used. The running conditions
cover a wide range (see Fig. 2. for the title of the
two-phase mixture). It can be clearly seen that the
correlation for annular flow provides very different
results. We selected for our simulation models the
Traviss correlation, because it gives approximately
the mean value.
.... Akers ......
Cavallini and Zecchin ....
- - Chen 2 - -
100000 . . . . Turbulent film
.... Traviss
el
10000 "- . . . . . . . . . . . . . .
r..; 1000 - ~
m
I00 !
0 0.2 0.4
Fig. 2. Influenceof the title in HTC for internalcondensation
in HFF. Saturation temperature is 70C, mass flow 5 g/s
and wall sub cooling 2C.
197
3. Vertical tube falling film evaporator (VFF)
In this type of heat exchanger, evaporation
takes place inside vertical tubes, and condensation
outside them. The seawater is sprayed into the
inner tube wall of the vertical tube, and it flows
down as a film. Therefore, the brine has to be
pumped from the bottom to the top of each effect
before being sprayed.
Different methods available for finding out
heat transfer coefficients for evaporation and for
condensation are described below. The flow
regime is very important to calculate the evapo-
ration heat transfer coefficient for non-boiling
conditions, which is the usual case and also for
condensation. All the formulae mentioned in the
following subsection were developed for non-
boiling conditions and for condensation.
3.1. Evaporation a n d condensation
Six correlations have been studied in evaporation
and condensation in this type of evaporators.
These correlations are compared here.
Nusselt analysis for laminar films [4]: the velo-
city profile in the film as well as the film thick-
ness and the different heat transfer coefficients
are studied.
Correlation proposed by Kutateladze [5] for
wavy falling films causing enhanced heat
transfer.
Correlation proposed by Labuntsov [6] for
turbulent falling films.
Boyko and Kruzhilin
Chen I
Chun and Seban's correlation [ 17] for vertical
Laminar film heated tubes at atmospheric and vacuum pres-
Shah
Chaddock and Chato ~
sures.
~ . _ . ~ : :-.~_, Sandall et al.'s correlation for turbulent falling
films [18].
Correlation proposed by Alhusseini, Tuzla and
Chen [19] that takes into account the effects
0.6 0.8 on the Prandtl number in the heat transfer
Title x coefficients in the laminar region.
The comparison between all the correlations
has been made depending on the flow regime
(Reynolds number, see Fig. 3) and temperature.
198 J. Uche et al. / Desalination 152 (2002) 195-200
.... Chor, and Scban .... Alhusscini, Tuzla and Chcn
. . . . . Sandall Nusscll
..... Kutateladzc -- -- -- Labuntsov
15000
~E 10000
5000 ~ :~=~
~., Evaporation
0 r i
I0 I O0 1000
Re
Fig. 3. Influenceof the Reynoldsnumberin the evaporation
HTC (VFF evaporators).Temperature70C.
The selected correlation has been the Alhusseini,
Tuzla and Chen correlation for wavy-laminar and
turbulent regime. For laminar regime, there is only
the Nusselt correlation that works very well.
However the laminar region is only found at the
top of the tubes in the condensation side, not being
representative of the mean flow in the tube.
The values for evaporation and condensation
are similar since the only difference is the pro-
perties calculation for condensate and for the brine
and the tube diameter. HTCs obtained with the
selected correlation have been compared with real
data from VFF evaporators (1 mm thickness, and
yorcalbro-aluminium brass material). This is the
reason for taking the Alhusseini, Tuzla and Chen
correlation (their values are very close to the
experimental ones).
4. Vertical tube rising film evaporator (VRF)
This type of heat exchanger was widely used
in the seventies, but it is not so efficient as the
vertical tube falling film or the horizontal tube
falling film. The brine enters the vertical tubes at
the bottom o f the heat exchanger. Steam con-
densing on the outside of the vertical tubes con-
taining brine, at a predetermined level, causes the
brine to boil, vapor to be released and a film of
brine to be established on the tube wall. This film
rises through the tubes being evaporated at the
same time. At the end of the tubes, separation of
both phases vapor and brine takes place. The brine
flows to the next stage as vapor does.
* 4.1. E v a p o r a t i o n
The flow patterns are bubbly, plug, churn,
annular. There is a non-boiling zone in the bottom
section and a boiling zone above. The four more
10000 t 00000
used correlations to calculate boiling heat transfer
inside tubes are those from Chen [9] (widely used
and considered as general, reliable in a wide range
of conditions), Shah [20] (for vertical up-flow, is
currently the most widely accepted one for
horizontal tubes), Gting6r-Winterton [21 ] (like the
Chen's correlation consists of two terms - - one
for the convective contribution and the other one
for the boiling heat transfer) and Kandlikar [22]
(divides the flow into the nucleate boiling dominant
region and the convective boiling dominant region).
Other possible correlation specific for annular
flow like Steiner-Taborek's [23] (in terms o f flow
quality and liquid to vapor density ratio) or Collier-
Pulling's [ 11] (only valid for non-boiling conditions
and annular flow) are also tested. To compare the
correlations, the HTC has been plotted vs. some
parameters: wall superheat temperature, critical
wall superheat, mass velocity (Fig. 4), saturation
temperature, title. The correlation chosen to
calculate the HTC for evaporation in vertical
rising flow is the Chen's one, since it extrapolates
correctly to the extreme cases and it is valid for
70000 .... Chen
xr~nnn Collier and Pulling / / t ."~
. . . . . GungOr and Wintertor~ J .'#r
50000 . . . . . . Kandlikar / /".'j7
40000 I -- -- --Steiner and Taborek/ ; .-"7
~300o^ i .... shah / /,:Y
,oooo / .,;Y
10000 ~ . < .-..i
0 ~
10 100 1000 10000
G (kg/(m2"s))
Fig. 4. Influenceof the mass velocity in the HTC for VRF
distillers.Annularflow over 120 kg/m2.s,salt concentration
5%, saturationtemperature70C, and title 0.05.
 J. Uche et aLI Desalination 152 (2002) 195-200 199

all the flow pattems. The correlations developed by here. The selected correlation has been considered
Kandlikar or Gting6r and Winterton were also valid. the best alternative to include in the models
describing the performance of MSF/VC/TVC/MED
4.2. Condensation plants. The most conflictive case is the evaporation
in VRF tubes, due to the diversity of flow regimes
The HTC for condensation can be calculated
occurring in the process. Those correlations provide
just as for the VFF already explained, using the
enough stability (operation range and flow regime)
correlation ofAlhusseini, Tuzla and Chen [19].
for finding out reliable solutions in complex simu-
lators. At least, the trends of the calculated HTC
4.3. Comparison with real data
by these correlations are very similar to the experi-
Our calculated HTC values have been compared mental data available in the literature. The con-
with those measured in a real plant [24] (Fig. 5). venient adjustment is needed to approach more
The graph shows the differences obtained for real and calculated values.
three different saturation temperature differences
between outside condensing vapor and inside
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