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Heat Transfer File

Page 1

Heat Transfer

Submitted by:
Zeeshan Zaki
Muzammil Ali

Submitted to:
Sir Adnan

 Index

No. Detail Page


1. Dirt factor in double pipe heat exchanger (co current flow) 2
2. Dirt factor in double pipe heat exchanger (counter current flow) 11
3. Heat losses of insulation 20
4. Heat Transfer through bricks 23
5. Loading factor of cooling tower 25
6. Number of Turns of cooling coil 27
Heat Transfer File
Page 2
Experiment Number 1
Object:
To determine the dirt factor of double-pipe heat exchanger when cooling
water is flowing co-current

Formulae:
1. T1  THI  TCI Approach 1
2. T2  THO  TCO Approach 2
T  TCO
3. TCBM  CI
2
T  THO
4. THBM  HI
2
T2  T1
5. TLMTD 
ln T2  ln T1
6. THOT  THI  THO Range 1
7. TCOLD  TCO  TCI Range 2
8. m HOT  P   AI
9.  COLD  VCOLD  
m
10. 
Q HOT m  C T HOT W HOT

COLD  m
11. 
Q  COLD CW TCOLD
12. 
Q LOSSQ  Q 
HOT COLD

D 2
13. AI  1

14. AO 

 D32  D22  DQ Kern Process Heat Transfer (text) page 105
4
15. AIS    D1  L (Area of cylinder formula)
D D2 2

16. De  3 2
DQ Kern Process Heat Transfer page 105 equation 6.3
D2
V
17. vCOLD  COLD
AO
V HOT
18. v HOT 
AI
1 0.14

 0.027  Re  0.8  C P    
k 3 
19. h 
D  k   W 
Sieder–Tate equation for turbulent flow DQ Kern Process Heat Transfer page 103
equation 6.2 & Coulson & Richardson’s Chemical Engineering volume 1 page 369
1
k
 0.027  Re  0.8  C P    k  0.027 Re  0.8  Pr  3
3 1
20. h
D  k  D
C  
Prandl Number Pr   P 
 k 
1

21. 2.1482  281.435 

8078.4    281.435    120
2 ( in Poise)
Heat Transfer File
Page 3
Correlation for viscosity of water in Poise (P) for  in Kelvin table 6, page 683
Coulson and Richardson Chemical Engineering, Volume 1, Fifth Edition
1
 
22. 21.482 T  8.285 

8078.4   T  8.285    1200
2

(Rearranged formula for  in Ns/m2 for T in Celsius)


vD GD
23. Re   where G  m / A
 
ID D
24. hio  hi   hi  1 DQ Kern Process Heat Transfer page 105
OD D2
equation 6.5
h  ho
25. U C  io DQ Kern Process Heat Transfer page 106 equation 6.7
hio  ho
QLOSS
26. UD  DQ Kern Process Heat Transfer page 107 equation 6.11
AIS  TLMTD
U UD
27. RD  C DQ Kern Process Heat Transfer page 108
U C U D
equation 6.13
Legend:
T1 and T2 are called approach. THI, THO, TCI and TCO are the temperature at the hot
inflow and outflow, cold inflow and outflow respectively.
TCBM and THBM are the bulk mean temperature of cold and hot streams
THOT = Temperature decrease of hot fluid
TCOLD = Temperature increase of cold fluid
TLMTD = Log mean temperature difference
CW, CP = heat capacity of water = 4.184 J/kg = 1 Btu/lb
  
Q LOSS , Q HOT , QCOLD = heat flow rates for heat loss, hot and cold water respectively

 = mass flow rate with subscripts for hot and cold water
m
P  = pressure reading on the meter for the hot fluid in psi (lb/in2) or kg/cm2
AI, AO = Area of cross section of inner pipe and outer pipe/annulus respectively
AIS = Internal Surface area of the pipe
 = Density of water taken as 1g/cc =1000kg/m3= 62.382 lb/ft3
D1 and D2 are the inner and outer diameter of inner pipe respectively
D3 and D4 are the inner and outer diameter of outer pipe respectively
De is the equivalent diameter used for calculating Reynolds Number and heat transfer
coefficient for hot fluid flow in the annulus
v = Fluid velocity k = Thermal conductivity Re = Reynolds Number
h = Heat transfer coefficient or film coefficient (subscript “i" for inner coefficient, “o”
for outer and “io” for inner biased on outer diameter)
G = Mass flow rate per unit area (proportional to P’)
UC = Clean Overall heat transfer coefficient
UD = Dirty Overall heat transfer coefficient
RD = Dirt Factor or resistance to heat flow in heat exchangers due to scaling
D in Re and h is called characteristic diameter which is De for outer and D 1 for inner
pipe
Heat Transfer File
Page 4
Conversion factors between MKS and FPS
Length: 1 in = 2.54 cm 1 ft = 0.3048 m (1)
Area: 1 in2= 6.451 6 cm2 1 ft2= 0.0929 m2 (2)
3 3
Volume: 1 ft = 28 316.85 dm (3)
Mass: 1 lb = 453.9237 g (4)
Viscosity dynamic: 1 dyn s/cm2 (poise P) = 0.1 Ns/m2 or Pa s (5)
1 lbm/ (ft h) = 4.133 789x10–4 Ns/m2 (6)
1 lbm / (ft s) = 1.488 164 Ns/m2 (7)
10 Poise P = 1 Pa. s = 1 Ns/m2 (8)
1 cP (centi poise) = 1 mNs/m2 (9)
Velocity: 1 ft/s = 0.3048 m/s (10)
Fluid velocity: 1 ml/s = 0.127133 ft3/h = 3.5315 x10–3 ft3/s (11)
Thermal Conductivity: 1 Btu/ (h ft °F) = 1.730 735 W/ (m K) (12)
Heat transfer Coefficient: 1 Btu/ (h ft2 °F) = 5.678 263 W/ (m2 K) (13)
Pressure: 1 Psi (lb/in2) = 0.07035831 kg/cm2 (14)
1 kg/cm2 = 14.213 Psi (15)
Density: 1 g/cm3 = 62.382 lb/ft3 (16)
 9
Temperature:
o
F   o C    32 (17)
 5
K = °C + 273.15 (18)

Table 1–4, page 1–4 to 1–10 Perry’s Chemical Engineer’s Handbook

Observations:
Pipe Symbol Cm in ft m
Outer
D4 4.84 1.906 0.159 0.0484
Outer diameter
pipe Inner
D3 4.10 1.616 0.135 0.0410
diameter
Outer
D2 2.09 0.823 0.069 0.0209
Inner diameter
Pipe Inner
D1 1.54 0.605 0.050 0.0154
diameter
Equivalent diameter De 5.966 2.349 0.196 0.060
Length L 560 220.472 18.373 5.60
Parameter cm 2
in 2
ft2
m2
AI 1.854 0.287 0.00200 1.85x10–4
AO 9.794 1.518 0.01054 9.79 x10–4
AIS 3677 570 3.958 0.368
AI, AO, AIS, De were calculated by formulae 13, 14, 15, 16 respectively. The outer
diameter of pipes was noted and standard thickness of schedule 40 pipes was
subtracted to get inner diameter of the pipes. The inner pipe is called a ½ inch pipe
and outer pipe is 1½ inch designation. The data for pipes can be obtained from
Perry’s Chemical Engineer’s Handbook (7th edition) table 10–18 page 10–72, Plant
Design and Economics for Chemical Engineers by Max S Peters (4th edition) table 13
page 888, Process Heat Transfer by Donald Q Kern table 11 page 844, Unit
Operations for Chemical Engineers by McCabe Smith sixth edition appendix 3 page
1068.
Heat Transfer File
Page 5
Temperature for water streams (Celsius):
Hot Cold
Outle Outle THBM TCBM TCOLD THOT T1 T2 TLMTD
Inlet Inlet
t t
50.00 46.00 29 35 48.0 32.0 6.0 4.0 21.00 11.00 15.46
50.00 46.50 30 35.5 48.3 32.8 5.5 3.5 20.00 11.00 15.05
50.00 46.25 30 34 48.1 32.0 4.0 3.8 20.00 12.25 15.81
49.50 46.50 31 36 48.0 33.5 5.0 3.0 18.50 10.50 14.12
48.50 46.00 31 35 47.3 33.0 4.0 2.5 17.50 11.00 14.00
48.75 46.00 31 36 47.4 33.5 5.0 2.8 17.75 10.00 13.51
47.50 45.00 31 36 46.3 33.5 5.0 2.5 16.50 9.00 12.37
48.00 45.50 31 36 46.8 33.5 5.0 2.5 17.00 9.50 12.89
47.75 45.50 31 36 46.6 33.5 5.0 2.3 16.75 9.50 12.78

Temperature for water streams (Fahrenheit):


Hot Cold
Outle Outle THBM TCBM TCOLD THOT T1 T2 TLMTD
Inlet Inlet
t t
122.00 114.80 84.2 95.0 118.4 89.6 10.8 7.2 37.80 19.80 27.84
122.00 115.70 86.0 95.9 118.9 91.0 9.9 6.3 36.00 19.80 27.10
122.00 115.25 86.0 93.2 118.6 89.6 7.2 6.8 36.00 22.05 28.46
121.10 115.70 87.8 96.8 118.4 92.3 9.0 5.4 33.30 18.90 25.42
119.30 114.80 87.8 95.0 117.1 91.4 7.2 4.5 31.50 19.80 25.20
119.75 114.80 87.8 96.8 117.3 92.3 9.0 5.0 31.95 18.00 24.31
117.50 113.00 87.8 96.8 115.3 92.3 9.0 4.5 29.70 16.20 22.27
118.40 113.90 87.8 96.8 116.2 92.3 9.0 4.5 30.60 17.10 23.20
117.95 113.90 87.8 96.8 115.9 92.3 9.0 4.1 30.15 17.10 23.01

T1, T2, TCBM, THBM, TLMTD, THOT, T COLD calculated by formulae 1, 2, 3, 4, 5, 6


& 7 respectively. Temperature converted to Fahrenheit by conversion relation number
17.

Flow Observation:

Hot Cold
MKS FPS MKS FPS
P m 
V m 
V V Time V m m V
kg/cm2 kg/s (ml/s) lb/s ft3/h ml s (ml/s) kg/s lb/s ft3/h
0.06 0.11122 111.22 0.245 14.14 1000 14.2 70.42 0.0704 0.1551 8.95
0.06 0.11122 111.22 0.245 14.14 1000 14.2 70.42 0.0704 0.1551 8.95
0.06 0.11122 111.22 0.245 14.14 1000 14.2 70.42 0.0704 0.1551 8.95
0.06 0.11122 111.22 0.245 14.14 1000 17.1 58.48 0.0585 0.1288 7.43
0.06 0.11122 111.22 0.245 14.14 1000 17.1 58.48 0.0585 0.1288 7.43
0.06 0.11122 111.22 0.245 14.14 1000 17.1 58.48 0.0585 0.1288 7.43
0.06 0.11122 111.22 0.245 14.14 1000 22.1 45.25 0.0452 0.0997 5.75
0.06 0.11122 111.22 0.245 14.14 1000 22.1 45.25 0.0452 0.0997 5.75
0.06 0.11122 111.22 0.245 14.14 1000 22.1 45.25 0.0452 0.0997 5.75
The values of m HOT, m COLD calculated by formulae 8 & 9 respectively. MKS values
are converted to FPS by conversion relations 4 & 11.
Heat Transfer File
Page 6
Heat Loss Calculation:

MKS
Q HOT Q COLD Q LOSS
m HOT m COLD
kJ/s kJ/s kJ/s
kg/s kg/s
0.11122 1861.37 0.0704 1767.89 93.49
0.11122 1628.70 0.0704 1620.56 8.14
0.11122 1745.04 0.0704 1178.59 566.45
0.11122 1396.03 0.0585 1223.39 172.64
0.11122 1163.36 0.0585 978.71 184.65
0.11122 1279.69 0.0585 1223.39 56.30
0.11122 1163.36 0.0452 946.61 216.75
0.11122 1163.36 0.0452 946.61 216.75
0.11122 1047.02 0.0452 946.61 100.42

FPS
Q HOT Q COLD Q LOSS
m HOT m COLD
Btu/s Btu/h Btu/s Btu/h Btu/h
lb/s lb/s
0.245 1.764 6350.88 0.1551 1.6755 6031.88 319.00
0.245 1.544 5557.02 0.1551 1.5359 5529.23 27.80
0.245 1.654 5953.95 0.1551 1.1170 4021.26 1932.70
0.245 1.323 4763.16 0.1288 1.1595 4174.11 589.05
0.245 1.103 3969.30 0.1288 0.9276 3339.29 630.01
0.245 1.213 4366.23 0.1288 1.1595 4174.11 192.12
0.245 1.103 3969.30 0.0997 0.8972 3229.74 739.56
0.245 1.103 3969.30 0.0997 0.8972 3229.74 739.56
0.245 0.992 3572.37 0.0997 0.8972 3229.74 342.63

Q HOT, Q COLD & Q LOSS calculated by formula 10, 11 and 12 respectively.

Overall Dirty Heat Transfer Coefficient:

AIS = 0.368 m2 = 3.958 ft2


MKS FPS
UD UD
2
W/m K Btu/(h ft2 °F)
16.44 2.90
1.47 0.26
97.44 17.16
33.24 5.85
35.87 6.32
11.34 2.00
47.64 8.39
45.74 8.05
21.36 3.76
UD is calculated by formula 26.
Heat Transfer File
Page 7
Thermal Conductivity and Viscosity DATA:
MKS FPS
T Kelvin T Celsius k W/m K T Fahrenheit k Btu/(h ft °F)
303 30 0.616 85.73 0.356
333 60 0.659 139.73 0.381
The equations for linear interpolation using the above data are:
Equation Range
3
k  1.433  10 TC  0.5732 30–60°C
4
k  4.63  10 TF  0.3163 86–140°F
 This data was obtained from Coulson and Richardson’s Chemical Engineering,
Volume 1, Fifth Edition page 346. Data for thermal conductivity can also be
obtained from Process Heat transfer by D Q Kern Table 4 page 800 and in detail
from Plant Design and Economics for Chemical Engineers by Max S Peter and
Timmerhaus (table 4 Page 876). Equations for linear interpolation are used and
developed to give a routine and simple correlation rather than interpolating
between different values from the references.
 The Viscosity can be correlated by formula 22 and can be converted to FPS using
conversion relation 6.
 The thermal conductivity and viscosity will be calculated at the bulk mean
temperatures.
Calculation:
Thermal Conductivity Viscosity
K k k k  
HOT COLD HOT COLD HOT COLD
W/(m K) Btu/(h ft °F) Ns/m2 lbm/ft h Ns/m2 lbm/ft h
0.6420 0.6191 0.3578 0.3711 0.000567 1.371 0.000766 1.852
0.6424 0.6201 0.3584 0.3713 0.000564 1.365 0.000754 1.824
0.6422 0.6191 0.3578 0.3712 0.000566 1.368 0.000766 1.852
0.6420 0.6212 0.3590 0.3711 0.000567 1.371 0.000742 1.796
0.6409 0.6205 0.3586 0.3705 0.000574 1.389 0.000750 1.814
0.6411 0.6212 0.3590 0.3706 0.000573 1.386 0.000742 1.796
0.6395 0.6212 0.3590 0.3697 0.000584 1.413 0.000742 1.796
0.6402 0.6212 0.3590 0.3701 0.000579 1.401 0.000742 1.796
0.6400 0.6212 0.3590 0.3700 0.000580 1.404 0.000742 1.796

Fluid Velocity:
MKS FPS
v HOT v COLD v HOT v COLD
m/s ft/s ft/h ft/s ft/h
0.6 0.072 1.969 7086.7 0.2359 849.3
0.6 0.072 1.969 7086.7 0.2359 849.3
0.6 0.072 1.969 7086.7 0.2359 849.3
0.6 0.060 1.969 7086.7 0.1959 705.2
0.6 0.060 1.969 7086.7 0.1959 705.2
0.6 0.060 1.969 7086.7 0.1959 705.2
0.6 0.046 1.969 7086.7 0.1516 545.7
0.6 0.046 1.969 7086.7 0.1516 545.7
0.6 0.046 1.969 7086.7 0.1516 545.7
Fluid Velocity is calculated by formula 17 and 18. Be careful in the units of volume
and area! The units must match.
Heat Transfer File
Page 8
Reynolds Number:
MKS
HOT COLD
 v  D1  v  De
Re Re
kg/m3 m/s Ns/m2 m kg/m3 m/s Ns/m2 m
1000 0.60 0.000567 0.015 16260 1000 0.072 0.000766 0.060 5604
1000 0.60 0.000564 0.015 16330 1000 0.072 0.000754 0.060 5691
1000 0.60 0.000566 0.015 16295 1000 0.072 0.000766 0.060 5604
1000 0.60 0.000567 0.015 16260 1000 0.060 0.000742 0.060 4799
1000 0.60 0.000574 0.015 16052 1000 0.060 0.000750 0.060 4750
1000 0.60 0.000573 0.015 16087 1000 0.060 0.000742 0.060 4799
1000 0.60 0.000584 0.015 15776 1000 0.046 0.000742 0.060 3713
1000 0.60 0.000579 0.015 15914 1000 0.046 0.000742 0.060 3713
1000 0.60 0.000580 0.015 15880 1000 0.046 0.000742 0.060 3713
FPS
HOT COLD
 v  D1  v  De
Re Re
lb/ft3 ft/h lb/ft h ft lb/ft3 ft/h lb/ft h ft
62.382 7086.7 1.371 0.050 16249 62.382 849.3 1.852 0.196 5600
62.382 7086.7 1.365 0.050 16318 62.382 849.3 1.824 0.196 5687
62.382 7086.7 1.368 0.050 16283 62.382 849.3 1.852 0.196 5600
62.382 7086.7 1.371 0.050 16249 62.382 705.2 1.796 0.196 4795
62.382 7086.7 1.389 0.050 16041 62.382 705.2 1.814 0.196 4747
62.382 7086.7 1.386 0.050 16075 62.382 705.2 1.796 0.196 4795
62.382 7086.7 1.413 0.050 15765 62.382 545.7 1.796 0.196 3710
62.382 7086.7 1.401 0.050 15903 62.382 545.7 1.796 0.196 3710
62.382 7086.7 1.404 0.050 15868 62.382 545.7 1.796 0.196 3710
Reynolds Number has been calculated by formula 23. The Reynolds number for MKS
is very close to that of FPS this shows precision in calculation. The precision is lost
because of recursive conversions and propagation of error.
Reynolds Number is greater than 2100 showing that the flow is turbulent in both inner
and outer tubes so that equation
C  
Prandl Number: Pr   P 
 k 
MKS
HOT COLD
Cp  k Cp  k
Pr Pr
J/kg K Ns/m2 W/m K J/kg K Ns/m2 W/m K
4184 0.000567 0.6420 3.694 4184 0.000766 0.6191 5.174
4184 0.000564 0.6424 3.677 4184 0.000754 0.6201 5.086
4184 0.000566 0.6422 3.686 4184 0.000766 0.6191 5.174
4184 0.000567 0.6420 3.694 4184 0.000742 0.6212 5.000
4184 0.000574 0.6409 3.749 4184 0.000750 0.6205 5.057
4184 0.000573 0.6411 3.739 4184 0.000742 0.6212 5.000
4184 0.000584 0.6395 3.823 4184 0.000742 0.6212 5.000
4184 0.000579 0.6402 3.785 4184 0.000742 0.6212 5.000
4184 0.000580 0.6400 3.795 4184 0.000742 0.6212 5.000
Heat Transfer File
Page 9

FPS
HOT COLD
Cp  k Cp  k
Pr Pr
Btu/lb lb/ft h Btu/(h ft °F) Btu/lb lb/ft h Btu/(h ft °F)
1 1.371 0.3578 3.833 1 1.852 0.3711 4.990
1 1.365 0.3584 3.810 1 1.824 0.3713 4.911
1 1.368 0.3578 3.825 1 1.852 0.3712 4.988
1 1.371 0.3590 3.819 1 1.796 0.3711 4.839
1 1.389 0.3586 3.873 1 1.814 0.3705 4.897
1 1.386 0.3590 3.861 1 1.796 0.3706 4.846
1 1.413 0.3590 3.937 1 1.796 0.3697 4.858
1 1.401 0.3590 3.903 1 1.796 0.3701 4.853
1 1.404 0.3590 3.911 1 1.796 0.3700 4.854

Heat transfer coefficient, overall Heat transfer coefficients:


ID/OD = D1/D2= 0.735
Heat transfer coefficients MKS
Dirt Factor
HOT COLD Overall Clean Overall Dirty
hi hio ho UC UD RD
2 2
W/(m K) m K/W
4078 2998 483.2 416.12 16.44 0.0584
4088 3005 487.2 419.26 1.47 0.6778
4083 3001 483.2 416.19 97.44 0.0079
4078 2998 423.4 371.02 33.24 0.0274
4049 2977 421.1 368.91 35.87 0.0252
4054 2980 423.4 370.75 11.34 0.0855
4011 2948 344.9 308.75 47.64 0.0178
4030 2962 344.9 308.91 45.74 0.0186
4025 2959 344.9 308.87 21.36 0.0436

Heat transfer coefficients FPS


Dirt Factor
HOT COLD Overall Clean Overall Dirty
hi hio ho UC UD RD
2 2
Btu/(h ft °F) (h ft °F)/Btu
701 515 87.2 74.56 2.90 0.3320
703 517 87.8 75.08 0.26 3.8451
702 516 87.2 74.59 17.16 0.0449
703 516 76.2 66.42 5.85 0.1558
698 513 75.8 66.02 6.32 0.1432
699 514 76.1 66.32 2.00 0.4858
693 509 61.9 55.20 8.39 0.1011
696 511 62.0 55.27 8.05 0.1061
695 511 62.0 55.25 3.76 0.2477
The values of hi and ho were calculated by formula 20 in which the characteristic
diameter D was D1 for inner pipe and De for outer pipe. The value of hio and UC were
calculated by formula 24 and 25 whereas values of UD were already calculated. The
approximation of (/W) = 1, made in equation 20, is done because water is
incompressible in the short temperature range.
Heat Transfer File
Page 10
Result:
The mean value of dirt factor RD calculated when water was flowing co-current in the
double pipe heat exchanger is found to be:
RD = 0.1069 m2K/W
RD = 0.6068 (h ft2 °F)/Btu

Verification:
1 m2K/W = 5.678 263 (h ft2 °F)/Btu (from conversion factor 13)
The value of RD FPS calculated by converting the value of RD MKS is found to be:
RD CONVERTED = 0.1069 x 5.678 263 = 0.6070 (h ft2 °F)/Btu which is very close to the
value of RD calculated [0.6068 (h ft2 °F)/Btu]. This shows that the calculation in the
experiment has been consistent.
Heat Transfer File
Page 11
Experiment Number 2
Object:
To determine the dirt factor of double-pipe heat exchanger when cooling
water is flowing counter-current
Formulae:
1. T1  THI  TCO Approach 1
2.  T2  T HO  TCI Approach 2
T  TCO
3. TCBM  CI
2
THI  THO
4. THBM 
2
T2  T1
5. TLMTD 
ln T2  ln T1
6. THOT  THI  THO Range 1
7.  TCOLD  T CO  TCI Range 2
8.  
m HOT  P  AI
9.  COLD  VCOLD  
m
10. 
Q HOTm  C T HOT W HOT

COLD  m
11. 
Q  COLD CW TCOLD
12. 
Q Q
LOSS
 Q 
HOT COLD

D 2
13. AI  1

14. AO 

 D32  D22  DQ Kern Process Heat Transfer page 105
4
15. AIS    D1  L (Area of cylinder formula)
D D2 2

16. De  3 2
DQ Kern Process Heat Transfer page 105 equation 6.3
D2
V
17. vCOLD  COLD
AO
V HOT
18. v HOT 
AI
1 0.14

 0.027  Re  0.8  C P    
k 3 
19. h 
D  k   W 
Sieder–Tate equation for turbulent flow DQ Kern Process Heat Transfer page 103
equation 6.2 & Coulson & Richardson’s Chemical Engineering volume 1 page 369
1
k
 0.027  Re  0.8  C P    k  0.027 Re  0.8  Pr  3
3 1
20. h
D  k  D
C  
Prandl Number Pr   P 
 k 
1

21. 2.1482  281.435 

8078.4    281.435    120
2 ( in Poise)

Correlation for viscosity of water in Poise (P) for  in Kelvin table 6, page 683
Coulson and Richardson Chemical Engineering, Volume 1, Fifth Edition
Heat Transfer File
Page 12
1
 
22. 21.482 T  8.285 

8078.4   T  8.285    1200
2

(Rearranged formula for  in Ns/m2 for T in Celsius)


vD GD
23. Re   where G  m / A
 
ID D
24. hio  hi   hi  1 DQ Kern Process Heat Transfer page 105
OD D2
equation 6.5
h  ho
25. U C  io DQ Kern Process Heat Transfer page 106 equation 6.7
hio  ho
QLOSS
26. UD  DQ Kern Process Heat Transfer page 107 equation 6.11
AIS  TLMTD
U UD
27. RD  C DQ Kern Process Heat Transfer page 108
U C U D
equation 6.13
Legend:
T1 and T2 are called Approach. THI, THO, TCI and TCO are the temperature at the hot
inflow and outflow, cold inflow and outflow respectively.
TCBM and THBM are the bulk mean temperature of cold and hot streams
THOT = Temperature decrease of hot fluid
TCOLD = Temperature increase of cold fluid
TLMTD = Log mean temperature difference
CW, CP = heat capacity of water = 4.184 J/kg = 1 Btu/lb
  
Q LOSS , Q HOT , QCOLD = heat flow rates for heat loss, hot and cold water respectively

 = mass flow rate with subscripts for hot and cold water
m
P  = pressure reading on the meter for the hot fluid in psi (lb/in2) or kg/cm2
AI, AO = Area of cross section of inner pipe and outer pipe/annulus respectively
AIS = Internal Surface area of the pipe
 = Density of water taken as 1g/cc =1000kg/m3= 62.382 lb/ft3
D1 and D2 are the inner and outer diameter of inner pipe respectively
D3 and D4 are the inner and outer diameter of outer pipe respectively
De is the equivalent diameter used for calculating Reynolds Number and heat transfer
coefficient for hot fluid flow in the annulus
v = Fluid velocity k = Thermal conductivity Re = Reynolds Number
h = Heat transfer coefficient or film coefficient (subscript “i" for inner coefficient, “o”
for outer and “io” for inner biased on outer diameter)
G = Mass flow rate per unit area (proportional to P’)
UC = Clean Overall heat transfer coefficient
UD = Dirty Overall heat transfer coefficient
RD = Dirt Factor or resistance to heat flow in heat exchangers due to scaling
D in Re and h is called characteristic diameter which is De for outer and D 1 for inner
pipe
Heat Transfer File
Page 13
Conversion factors between MKS and FPS
Length: 1 in = 2.54 cm 1 ft = 0.3048 m (1)
Area: 1 in2= 6.451 6 cm2 1 ft2= 0.0929 m2 (2)
3 3
Volume: 1 ft = 28 316.85 dm (3)
Mass: 1 lb = 453.9237 g (4)
Viscosity dynamic: 1 dyn s/cm2 (poise P) = 0.1 Ns/m2 or Pa s (5)
1 lbm/ (ft h) = 4.133 789x10–4 Ns/m2 (6)
1 lbm / (ft s) = 1.488 164 Ns/m2 (7)
10 Poise P = 1 Pa. s = 1 Ns/m2 (8)
1 cP (centi poise) = 1 mNs/m2 (9)
Velocity: 1 ft/s = 0.3048 m/s (10)
Fluid velocity: 1 ml/s = 0.127133 ft3/h = 3.5315 x10–3 ft3/s (11)
Thermal Conductivity: 1 Btu/ (h ft °F) = 1.730 735 W/ (m K) (12)
Heat transfer Coefficient: 1 Btu/ (h ft2 °F) = 5.678 263 W/ (m2 K) (13)
Pressure: 1 Psi (lb/in2) = 0.07035831 kg/cm2 (14)
1 kg/cm2 = 14.213 Psi (15)
Density: 1 g/cm3 = 62.382 lb/ft3 (16)
 9
Temperature:
o
F   o C    32 (17)
 5
K = °C + 273.15 (18)

Table 1–4, page 1–4 to 1–10 Perry’s Chemical Engineer’s Handbook

Observations:
Pipe Symbol cm in ft m
Outer
D4 4.84 1.906 0.159 0.0484
Outer diameter
pipe Inner
D3 4.10 1.616 0.135 0.0410
diameter
Outer
D2 2.09 0.823 0.069 0.0209
Inner diameter
Pipe Inner
D1 1.54 0.605 0.050 0.0154
diameter
Equivalent diameter De 5.966 2.349 0.196 0.060
Length L 560 220.472 18.373 5.60
Parameter cm 2
in 2
ft2
m2
AI 1.854 0.287 0.00200 1.85x10–4
AO 9.794 1.518 0.01054 9.79 x10–4
AIS 3677 570 3.958 0.368
AI, AO, AIS, De were calculated by formulae 13, 14, 15, 16 respectively. The outer
diameter of pipes was noted and standard thickness of schedule 40 pipes was
subtracted to get inner diameter of the pipes. The inner pipe is called a ½ inch pipe
and outer pipe is 1½ inch designation. The data for pipes can be obtained from
Perry’s Chemical Engineer’s Handbook (7th edition) table 10–18 page 10–72, Plant
Design and Economics for Chemical Engineers by Max S Peters (4th edition) table 13
page 888, Process Heat Transfer by Donald Q Kern table 11 page 844, Unit
Operations for Chemical Engineers by McCabe Smith sixth edition appendix 3 page
1068.
Heat Transfer File
Page 14
Temperature for water streams (Celsius):
Hot Cold
Outle Outle THBM TCBM TCOLD THOT T1 T2 TLMTD
Inlet Inlet
t t
42.00 41.00 32 35.5 41.5 33.8 3.5 1.0 6.50 9.00 7.68
42.00 41.00 31.5 35 41.5 33.3 3.5 1.0 7.00 9.50 8.19
42.00 41.00 31.5 35 41.5 33.3 3.5 1.0 7.00 9.50 8.19
42.00 40.50 32 34 41.3 33.0 2.0 1.5 8.00 8.50 8.25
41.50 40.00 32 34 40.8 33.0 2.0 1.5 7.50 8.00 7.75
41.50 40.00 32 34 40.8 33.0 2.0 1.5 7.50 8.00 7.75
40.50 39.50 32 34.5 40.0 33.3 2.5 1.0 6.00 7.50 6.72
40.50 39.50 32 34.5 40.0 33.3 2.5 1.0 6.00 7.50 6.72
40.00 39.00 32 34.5 39.5 33.3 2.5 1.0 5.50 7.00 6.22

Temperature for water streams (Fahrenheit):


Hot Cold
Outle Outle THBM TCBM TCOLD THOT T1 T2 TLMTD
Inlet Inlet
t t
107.60 105.80 89.6 95.9 106.7 92.8 6.3 1.8 11.70 16.20 13.83
107.60 105.80 88.7 95.0 106.7 91.9 6.3 1.8 12.60 17.10 14.74
107.60 105.80 88.7 95.0 106.7 91.9 6.3 1.8 12.60 17.10 14.74
107.60 104.90 89.6 93.2 106.3 91.4 3.6 2.7 14.40 15.30 14.85
106.70 104.00 89.6 93.2 105.4 91.4 3.6 2.7 13.50 14.40 13.95
106.70 104.00 89.6 93.2 105.4 91.4 3.6 2.7 13.50 14.40 13.95
104.90 103.10 89.6 94.1 104.0 91.9 4.5 1.8 10.80 13.50 12.10
104.90 103.10 89.6 94.1 104.0 91.9 4.5 1.8 10.80 13.50 12.10
104.00 102.20 89.6 94.1 103.1 91.9 4.5 1.8 9.90 12.60 11.20

T1, T2, TCBM, THBM, TLMTD, THOT, T COLD calculated by formulae 1, 2, 3, 4, 5, 6


& 7 respectively. Temperature converted to Fahrenheit by conversion relation number
17. Note that the formula of T1 & T2 are different in co-current and counter current
flow.

Flow Observation:

Hot Cold
MKS FPS MKS FPS
P m 
V m 
V V Time V m m 
V
kg/cm2 kg/s (ml/s) lb/s 3
ft /h ml s (ml/s) kg/s lb/s ft3/h
0.06 0.11122 111.22 0.245 14.14 1000 35.81 27.93 0.0279 0.1551 3.55
0.06 0.11122 111.22 0.245 14.14 1000 35.81 27.93 0.0279 0.1551 3.55
0.06 0.11122 111.22 0.245 14.14 1000 35.81 27.93 0.0279 0.1551 3.55
0.06 0.11122 111.22 0.245 14.14 1000 12.03 83.13 0.0831 0.1288 10.57
0.06 0.11122 111.22 0.245 14.14 1000 12.03 83.13 0.0831 0.1288 10.57
0.06 0.11122 111.22 0.245 14.14 1000 12.03 83.13 0.0831 0.1288 10.57
0.06 0.11122 111.22 0.245 14.14 1000 26.00 38.46 0.0385 0.0997 4.89
0.06 0.11122 111.22 0.245 14.14 1000 26.00 38.46 0.0385 0.0997 4.89
0.06 0.11122 111.22 0.245 14.14 1000 26.00 38.46 0.0385 0.0997 4.89
The values of m HOT, m COLD calculated by formulae 8 & 9 respectively. MKS values
are converted to FPS by conversion relations 4 & 11.
Heat Transfer File
Page 15
Heat Loss Calculation:

MKS
Q HOT Q COLD Q LOSS
m HOT m COLD
kJ/s kJ/s kJ/s
kg/s kg/s
0.11122 465.34 0.0279 408.94 56.41
0.11122 465.34 0.0279 408.94 56.41
0.11122 465.34 0.0279 408.94 56.41
0.11122 698.02 0.0831 695.59 2.42
0.11122 698.02 0.0831 695.59 2.42
0.11122 698.02 0.0831 695.59 2.42
0.11122 465.34 0.0385 402.31 63.04
0.11122 465.34 0.0385 402.31 63.04
0.11122 465.34 0.0385 402.31 63.04

FPS
Q HOT Q COLD Q LOSS
m HOT m COLD
Btu/s Btu/h Btu/s Btu/h Btu/h
lb/s lb/s
0.245 0.441 1587.72 0.0615 0.3876 1395.26 192.47
0.245 0.441 1587.72 0.0615 0.3876 1395.26 192.47
0.245 0.441 1587.72 0.0615 0.3876 1395.26 192.47
0.245 0.662 2381.58 0.1831 0.6593 2373.31 8.27
0.245 0.662 2381.58 0.1831 0.6593 2373.31 8.27
0.245 0.662 2381.58 0.1831 0.6593 2373.31 8.27
0.245 0.441 1587.72 0.0847 0.3813 1372.64 215.08
0.245 0.441 1587.72 0.0847 0.3813 1372.64 215.08
0.245 0.441 1587.72 0.0847 0.3813 1372.64 215.08

Q HOT, Q COLD & Q LOSS calculated by formula 10, 11 and 12 respectively.

Overall Dirty Heat Transfer Coefficient:

AIS = 0.368 m2 = 3.958 ft2


MKS FPS
UD UD
2
W/m K Btu/(h ft2 °F)
19.97 3.52
18.74 3.30
18.74 3.30
0.80 0.14
0.85 0.15
0.85 0.15
25.50 4.49
25.50 4.49
27.56 4.85
UD is calculated by formula 26.
Heat Transfer File
Page 16
Thermal Conductivity and Viscosity DATA:
MKS FPS
T Kelvin T Celsius k W/m K T Fahrenheit k Btu/(h ft °F)
303 30 0.616 85.73 0.356
333 60 0.659 139.73 0.381
The equations for linear interpolation using the above data are:
Equation Range
3
k  1.433  10 TC  0.5732 30–60°C
4
k  4.63  10 TF  0.3163 86–140°F
 This data was obtained from Coulson and Richardson’s Chemical Engineering,
Volume 1, Fifth Edition page 346. Data for thermal conductivity can also be
obtained from Process Heat transfer by D Q Kern Table 4 page 800 and in detail
from Plant Design and Economics for Chemical Engineers by Max S Peter and
Timmerhaus (table 4 Page 876). Equations for linear interpolation are used and
developed to give a routine and simple correlation rather than interpolating
between different values from the references.
 The Viscosity can be correlated by formula 22 and can be converted to FPS using
conversion relation 6.
 The thermal conductivity and viscosity will be calculated at the bulk mean
temperatures.
Calculation:
Thermal Conductivity Viscosity
K k k k  
HOT COLD HOT COLD HOT COLD
W/(m K) Btu/(h ft °F) Ns/m2 lbm/ft h Ns/m2 lbm/ft h
0.6327 0.6216 0.3592 0.3657 0.000636 1.539 0.000739 1.787
0.6327 0.6209 0.3588 0.3657 0.000636 1.539 0.000746 1.805
0.6327 0.6209 0.3588 0.3657 0.000636 1.539 0.000746 1.805
0.6323 0.6205 0.3586 0.3655 0.000639 1.546 0.000750 1.814
0.6316 0.6205 0.3586 0.3651 0.000645 1.560 0.000750 1.814
0.6316 0.6205 0.3586 0.3651 0.000645 1.560 0.000750 1.814
0.6305 0.6209 0.3588 0.3645 0.000654 1.582 0.000746 1.805
0.6305 0.6209 0.3588 0.3645 0.000654 1.582 0.000746 1.805
0.6298 0.6209 0.3588 0.3640 0.000660 1.597 0.000746 1.805

Fluid Velocity:
MKS FPS
v HOT v COLD v HOT v COLD
m/s ft/s ft/h ft/s ft/h
0.6 0.029 1.969 7086.7 0.0935 336.8
0.6 0.029 1.969 7086.7 0.0935 336.8
0.6 0.029 1.969 7086.7 0.0935 336.8
0.6 0.085 1.969 7086.7 0.2785 1002.5
0.6 0.085 1.969 7086.7 0.2785 1002.5
0.6 0.085 1.969 7086.7 0.2785 1002.5
0.6 0.039 1.969 7086.7 0.1288 463.8
0.6 0.039 1.969 7086.7 0.1288 463.8
0.6 0.039 1.969 7086.7 0.1288 463.8
Fluid Velocity is calculated by formula 17 and 18. Be careful in the units of volume
and area! The units must match.
Heat Transfer File
Page 17
Reynolds Number:
MKS
HOT COLD
 v  D1  v  De
Re Re
kg/m3 m/s Ns/m2 m kg/m3 m/s Ns/m2 m
1000 0.60 0.000636 0.015 14490 1000 0.029 0.000739 0.060 2303
1000 0.60 0.000636 0.015 14490 1000 0.029 0.000746 0.060 2280
1000 0.60 0.000636 0.015 14490 1000 0.029 0.000746 0.060 2280
1000 0.60 0.000639 0.015 14423 1000 0.085 0.000750 0.060 6752
1000 0.60 0.000645 0.015 14290 1000 0.085 0.000750 0.060 6752
1000 0.60 0.000645 0.015 14290 1000 0.085 0.000750 0.060 6752
1000 0.60 0.000654 0.015 14092 1000 0.039 0.000746 0.060 3140
1000 0.60 0.000654 0.015 14092 1000 0.039 0.000746 0.060 3140
1000 0.60 0.000660 0.015 13960 1000 0.039 0.000746 0.060 3140
FPS
HOT COLD
 v  D1  v  De
Re Re
lb/ft3 ft/h lb/ft h ft lb/ft3 ft/h lb/ft h ft
62.382 7086.7 1.539 0.050 14479 62.382 336.8 1.787 0.196 2301
62.382 7086.7 1.539 0.050 14479 62.382 336.8 1.805 0.196 2278
62.382 7086.7 1.539 0.050 14479 62.382 336.8 1.805 0.196 2278
62.382 7086.7 1.546 0.050 14413 62.382 1002.5 1.814 0.196 6747
62.382 7086.7 1.560 0.050 14280 62.382 1002.5 1.814 0.196 6747
62.382 7086.7 1.560 0.050 14280 62.382 1002.5 1.814 0.196 6747
62.382 7086.7 1.582 0.050 14082 62.382 463.8 1.805 0.196 3138
62.382 7086.7 1.582 0.050 14082 62.382 463.8 1.805 0.196 3138
62.382 7086.7 1.597 0.050 13950 62.382 463.8 1.805 0.196 3138
Reynolds Number has been calculated by formula 23. The Reynolds number for MKS
is very close to that of FPS this shows precision in calculation. The precision is lost
because of recursive conversions and propagation of error.
Reynolds Number is greater than 2100 showing that the flow is turbulent in both inner
and outer tubes so that equation
C  
Prandl Number: Pr   P 
 k 
MKS
HOT COLD
Cp  k Cp  k
Pr Pr
J/kg K Ns/m2 W/m K J/kg K Ns/m2 W/m K
4184 0.000636 0.6327 4.207 4184 0.000739 0.6216 4.972
4184 0.000636 0.6327 4.207 4184 0.000746 0.6209 5.028
4184 0.000636 0.6327 4.207 4184 0.000746 0.6209 5.028
4184 0.000639 0.6323 4.229 4184 0.000750 0.6205 5.057
4184 0.000645 0.6316 4.273 4184 0.000750 0.6205 5.057
4184 0.000645 0.6316 4.273 4184 0.000750 0.6205 5.057
4184 0.000654 0.6305 4.341 4184 0.000746 0.6209 5.028
4184 0.000654 0.6305 4.341 4184 0.000746 0.6209 5.028
4184 0.000660 0.6298 4.386 4184 0.000746 0.6209 5.028
Heat Transfer File
Page 18

FPS
HOT COLD
Cp  k Cp  k
Pr Pr
Btu/lb lb/ft h Btu/(h ft °F) Btu/lb lb/ft h Btu/(h ft °F)
1 1.539 0.3592 4.284 1 1.787 0.3657 4.886
1 1.539 0.3588 4.289 1 1.805 0.3657 4.936
1 1.539 0.3588 4.289 1 1.805 0.3657 4.936
1 1.546 0.3586 4.311 1 1.814 0.3655 4.964
1 1.560 0.3586 4.351 1 1.814 0.3651 4.969
1 1.560 0.3586 4.351 1 1.814 0.3651 4.969
1 1.582 0.3588 4.410 1 1.805 0.3645 4.953
1 1.582 0.3588 4.410 1 1.805 0.3645 4.953
1 1.597 0.3588 4.451 1 1.805 0.3640 4.958

Heat transfer coefficient, overall Heat transfer coefficients:


ID/OD = D1/D2= 0.735
Heat transfer coefficients MKS
Dirt Factor
HOT COLD Overall Clean Overall Dirty
hi hio ho UC UD RD
2 2
W/(m K) m K/W
3827 2813 235.0 216.93 19.97 0.0455
3827 2813 233.8 215.83 18.74 0.0487
3827 2813 233.8 215.83 18.74 0.0487
3818 2806 557.9 465.39 0.80 1.2506
3798 2792 557.9 464.99 0.85 1.1746
3798 2792 557.9 464.99 0.85 1.1746
3769 2771 302.0 272.31 25.50 0.0355
3769 2771 302.0 272.31 25.50 0.0355
3750 2756 302.0 272.17 27.56 0.0326

Heat transfer coefficients FPS


Dirt Factor
HOT COLD Overall Clean Overall Dirty
hi hio ho UC UD RD
2 2
Btu/(h ft °F) (h ft °F)/Btu
666.0 489.6 41.9 38.58 3.52 0.2584
665.5 489.2 41.7 38.41 3.30 0.2770
665.5 489.2 41.7 38.41 3.30 0.2770
663.8 487.9 99.5 82.64 0.14 7.0915
660.9 485.8 99.4 82.53 0.15 6.6607
660.9 485.8 99.4 82.53 0.15 6.6607
656.9 482.9 53.7 48.35 4.49 0.2020
656.9 482.9 53.7 48.35 4.49 0.2020
654.0 480.7 53.7 48.29 4.85 0.1853
The values of hi and ho were calculated by formula 20 in which the characteristic
diameter D was D1 for inner pipe and De for outer pipe. The value of hio and UC were
calculated by formula 24 and 25 whereas values of UD were already calculated. The
approximation of (/W) = 1, made in equation 20, is done because water is
incompressible in the short temperature range.
Heat Transfer File
Page 19
Result:
The mean value of dirt factor RD calculated when water was flowing counter-current
in the double pipe heat exchanger is found to be:
RD = 0.4274 m2K/W
RD = 2.4239 (h ft2 °F)/Btu

Verification:
1 m2K/W = 5.678 263 (h ft2 °F)/Btu (from conversion factor 13)
The value of RD FPS calculated by converting the value of RD MKS is found to be:
RD CONVERTED = 0.4274 x 5.678 263 = 2.4268 (h ft2 °F)/Btu which is very close to the
value of RD calculated [2.4239 (h ft2 °F)/Btu]. This shows that the calculation in the
experiment has been consistent.
Heat Transfer File
Page 20
Experiment Number 3
Object:
To calculate and compare the heat losses of different insulations
Formulae:
T  THO
1. THBM  HI
2
V HOT
2. v HOT 
AI
3. T1  THI  TR
4. T2  THO  TR
T2  T1
5. TLMTD 
ln T2  ln T1
D12
6. AI 
4
7. AIS  2    r1  L
1
 
8. 21.482 T  8.285 

8078.4   T  8.285    1200
2

9. k  1.433  10 3 TC  0.5732 30–60°C


1
0.8

10. hi  k  0.023  vD   C P    k  0.023 Re 0.8  Pr  3


3 1

D     k  D
ln(r2 r1 )
11. RT  PIPE  
2k P L
ln(r3 r2 )
12. RT  INSULATION  
2k I L
1
13. RT (FILM)  h A
i IS

TLMTD
14. Q P 
RT  PIPE   RT  FILM
TLMTD
15. QI 
RT  INSULATION   RT  PIPE   RT  FILM 
Legend:
THBM = Bulk mean temperature of hot water, THI, THO, TR are the temperature of
inlet, outlet and the room.
v HOT = fluid velocity of hot water
hi = internal film transfer coefficient
k = thermal conductivity subscript “I" for insulation and “P” for pipe
QP and QI are the heat losses through pipe and insulations.
AIS = Internal surface area  is the viscosity
r1, r2, r3, r3’, are the inner, outer radius of pipe, and radius of glass wool and rock
wool respectively. RT is the thermal resistances in K/W
Heat Transfer File
Page 21
Thermal Conductivity Data:
Material k [Btu /(h ft °F)] k [W/(m K)]
Steel Pipe 26.00 45.00
Glass Wool 0.024 0.042
Rock Wool 0.033 0.057
Data for thermal conductivity of Glass Wool and Steel Pipe was obtained from
Coulson and Richardson Chemical Engineering Volume 1, table 9.1, page 346 and
the thermal conductivity for Rock Wool was obtained from Example 2.5 page 19
Process Heat Transfer by DQ Kern.

Units Basis: MKS system will be used


Pipe Symbol cm m Length
Rock wool
D3” 9.27 0.0927 2.95 m
diameter
Insulation
Glass wool
D3 8.4 0.084 2.74 m
diameter
Outer
D2 3.34 0.0334
diameter
Inner Pipe 2.95 m
Inner
D1 2.64 0.0264
diameter
Area Parameter cm2 m2
AI 5.47 0.000547
AIS 2446.67 0.2447
AI, AIS calculated by formula 6 and 7. The given pipes are of standard (schedule 40)
1-inch designation pipes.

Room Temperature: TR = 30°C



V Temperatures
Pipe V ml T sec State Mean
ml/sec °C
Inlet 60.00 61.00 62.00 61.00
280 17 16.47
Outlet 58.00 57.00 58.50 57.83
Glass Inlet 62.00 62.00 61.50 61.83
570 17 33.53
Wool Outlet 58.50 58.50 59.00 58.67
Inlet 62.00 61.50 61.00 61.50
420 8 52.50
Outlet 58.50 59.50 59.50 59.17
Inlet 61.50 61.00 60.50 61.00
250 65 3.85
Outlet 48.50 49.00 49.50 49.00
Rock Inlet 60.00 60.50 61.00 60.50
265 14 18.93
Wool Outlet 49.50 49.00 50.50 49.67
Inlet 60.50 60.50 60.00 60.33
430 16 26.88
Outlet 52.50 54.00 55.00 53.83
Inlet 59.00 59.00 58.50 58.83
235 38 6.18
Outlet 32.00 32.50 32.50 32.33
Bare Inlet 58.50 58.50 58.50 58.50
300 17 17.65
Pipe Outlet 34.50 41.00 46.00 40.50
Inlet 58.50 58.00 58.00 58.17
570 20 28.50
Outlet 49.00 52.00 54.00 51.67
Heat Transfer File
Page 22
T Inlet T Outlet T Bulk
Material V ml/s
(mean) (mean) Mean
T1 T2 LMTD
16.47 61.00 57.83 59.42 31.00 27.83 29.39
Glass
33.53 61.83 58.67 60.25 31.83 28.67 30.22
Wool 52.50 61.50 59.17 60.33 31.50 29.17 30.32
3.85 61.00 49.00 55.00 31.00 19.00 24.51
Rock
18.93 60.50 49.67 55.08 30.50 19.67 24.69
Wool 26.88 60.33 53.83 57.08 30.33 23.83 26.95
6.18 58.83 32.33 45.58 28.83 2.33 10.54
Bare
17.65 58.50 40.50 49.50 28.50 10.50 18.03
Pipe 28.50 58.17 51.67 54.92 28.17 21.67 24.77
Thermal resistances:
Material RT K/W
Glass Wool 1.1979
Rock Wool 0.9643
Bare Pipe 0.000282
Thermal resistances are calculated by formula 11 & 12
Viscosity, Velocity, Thermal Conductivity and Film Coefficient:
Viscosity K Velocity hi RT FILM
Material THBM
Ns/m2 W/(m K) m/s W/(m2K) K/W
59.42 0.000472 0.6584 0.030 370.01 0.0110
Glass
60.25 0.000466 0.6596 0.061 658.05 0.0062
Wool 60.33 0.000465 0.6597 0.096 942.66 0.0043
55.00 0.000505 0.6520 0.007 111.22 0.0367
Rock
55.08 0.000504 0.6522 0.035 398.28 0.0103
Wool 57.08 0.000489 0.6550 0.049 536.54 0.0076
45.58 0.000591 0.6385 0.011 149.04 0.0274
Bare
49.50 0.000553 0.6441 0.032 357.92 0.0114
Pipe 54.92 0.000506 0.6519 0.052 551.74 0.0074
Viscosity, Velocity, Thermal Conductivity & Film Coefficient were calculated by
formulae 9, 2, 10 & 11 respectively. Be careful in calculating fluid velocity as the
units of volume flow rate should be in m 3/s and internal area AI in m2. The film
coefficient was calculated by formula 10 on the assumption that fluid flowing in all
pipes at all temperature was turbulent. The Film resistance was calculated by formula
13.
Heat Loss through Pipes:
Material Q LOSS (W) Mean Q LOSS (W)
24.304
24.870
Glass Wool 25.094
(1.45% of 1714.259)
25.213
24.481
25.844
Rock Wool 25.326
(1.51% of 1714.259)
27.724
380.4
Bare Pipe 1540.6 1714.259
3221.8
The heat losses were calculated by formulae 14 and 15.

Result:
The results show 98.55% decrease in heat loss for glass wool and 98.49% decrease in
heat loss for rock wool.
Heat Transfer File
Page 23
Experiment Number 4
Object:
To determine the heat flow rate through different types of bricks
Data:
Length Width Thickness Area k
Brick
cm cm cm m cm 2
m 2 W/(m K)
Detrolite 19 9 4 0.04 171 0.0171 0.7
Alumina 22 10 6 0.06 220 0.022 0.2
Fire Brick 21 10 5 0.05 210 0.021 1.4

Formula:
kA TH  TC 
Q
x
Legend:
TH and TC are the temperature of hot face and cold face respectively
x = Thickness of brick
k = Thermal conductivity of brick
A = Area exposed to heat
Q = Heat flow across the brick

Observation:
Furnace Temperature Temperature Mean
Brick Q (W)
Temperature Hot face Cold Face Q (W)
106 38 20.349
100 105 39 19.751
102 40 18.554
114 42 21.546
Detrolite 200 156 44 33.516 35.677
178 48 38.903
255 61 58.055
300 253 66 55.960
252 70 54.464
110 35 8.250
100 108 36 7.920
107 35 7.920
196 48 16.280
Alumina 200 200 47 16.830 16.353
204 47 17.270
234 49 20.350
300 283 50 25.630
295 52 26.730
102 37 38.220
100 107 37 41.160
104 37 39.396
164 42 71.736
Fire
200 167 41 74.088 74.088
Brick 169 41 75.264
243 63 105.840
300 247 60 109.956
248 59 111.132
Result:
Heat Transfer File
Page 24
The average heat flow across the bricks is as follows:

Detrolite: 35.677 W
Alumina: 16.353 W
Fire-Brick: 74.088 W
Heat Transfer File
Page 25
Experiment Number 5
Object:
To calculate the loading factor of cooling tower

Formula:
1. T= TWI – TWO
m  CW  T
2. Q  W
A
3. m W  V  
Q
LO 
4.  H 2  H1 
   CW TO
 X 2  X1 
Page 584 equation 17.53 Process Heat Transfer By D Q Kern
Legend:
T = temperature difference of water inlet and outlet
TWI & TWO are the water inlet and outlet temperature respectively
Q = heat lost by hot water per unit area of flow of cooling tower
A = Internal ground area of the tower
LO = flow rate of makeup water needed per unit area of flow of cooling tower
TO = Room Temperature CW = Heat capacity of water taken as 1 Btu/ (lb °F)
H1 and H2 are the enthalpy of entering and exiting air
X1 and X2 are the values of humidity of exiting and entering air
m W = mass flow rate,  = density of water =1000kg/m3 =62.382 lb/ft3
Given:
Internal ground area of cooling tower or area of flow = 715 in2 = 4.9653 ft2
Observations:
Room temperature = 30°C = 86°F
Air Inlet Air Outlet
V temperature temperature Water Temperature
ml/sec Dry Wet Dry Wet
Bulb Bulb Bulb Bulb Inlet Outlet
29.5 28.5 29 27 61 46
116.7 30.5 27.5 29 27 55 45.5
30 27 29 26 49 40.5
30 26.9 28.75 25.5 36 35
87.0 29.5 26.5 28 25 37 32.5
29 26.5 28 26 38 31.5
30 26.5 29 26 43.5 29
88.5 30 29 29 26 43.75 29
30 27 29 26 44 29

Correlations for humidity and enthalpy (75–90°F):


1. H  1.08  TWB  42.52 (Btu/lb dry air)
2. X  0. 00096  TWB  0 .00023  T DB  0. 03594 (lb water / lb air)
Here TWB and TDB are the wet bulb temperatures in degrees Fahrenheit. These
correlations are developed using interpolation schemes from psychrometric charts.
They have an expected error of less than 2% and can be verified by data from
psychrometric chart. Range of application is 75–87°F for TDB.
Heat Transfer File
Page 26
Basis: FPS system is used as psychrometric chart has data in FPS notation

FPS values:
Air Inlet Air Outlet

V temperature temperature Water Temperature
3
ft /hr Dry Wet Dry Wet
Bulb Bulb Bulb Bulb Inlet Outlet
85.10 83.30 84.20 80.60 141.80 114.80
7.20 86.90 81.50 84.20 80.60 131.00 113.90
86.00 80.60 84.20 78.80 120.20 104.90
86.00 80.42 83.75 77.90 96.80 95.00
7.50 85.10 79.70 82.40 77.00 98.60 90.50
84.20 79.70 82.40 78.80 100.40 88.70
86.00 79.70 84.20 78.80 110.30 84.20
6.69 86.00 84.20 84.20 78.80 110.75 84.20
86.00 80.60 84.20 78.80 111.20 84.20
1 ml/s = 0.127133 ft3/h

X1 X2 Loading
H1 H2
m Q lb lb Factor
Btu/lb dry Btu/lb dry
lb/hr Btu/(h ft2) water/lb water/lb LO
air air
dry air dry air lb/(h ft2)
2440.9 47.4 44.5 0.02446 0.02207 2.147
448.9 1545.9 45.5 44.5 0.02231 0.02207 0.395
1383.2 44.5 42.6 0.02166 0.02034 0.993
169.6 44.3 41.6 0.02148 0.01958 0.126
467.9 763.3 43.6 40.6 0.02100 0.01903 0.548
1102.6 43.6 42.6 0.02121 0.02076 0.532
2192.8 43.6 42.6 0.02079 0.02034 1.057
702.1 2230.6 48.4 42.6 0.02511 0.02034 1.962
2268.4 44.5 42.6 0.02166 0.02034 1.628
The value of Q is calculated by formula 2 and that of Lo by formula 4.

Result:
The mean loading factor for the cooling tower is determined to be:
1.043 lb water /h ft2
Heat Transfer File
Page 27
Experiment Number 6
Object:
To calculate the number of turns of coil in a helical coil agitator

Formula:
TWI  TWO
1. TWBM 
2
2. T  TWO  TWI
3. T1  TOIL  TWI
4. T2  TOIL  TWO
T2  T1
5. TLMTD 
ln T2  ln T1
VW
6. vW 
AI
D12
7. AI 
4
ID D
8. hio  hi   hi  1
OD D2
9. AN  4 2  L   r2  2 2  L   D2
1
W 
10. 21.482  T  8.285 

8078.4   T  8.285    1200 2

11. kW  1.433  10 3 TC  0.5732 30–60°C


0.62 1 0.14
 CP     
 0.87   L N 
k  2  3
12. ho     
DV     k   W 
Chilton-Drew-Jebens correlation for outside film coefficient for agitated vessel in
Coulson and Richardson’s Chemical Engineering Volume 1 page 497
2 1 0.14

 0.87   L N   C P    
k  2 3 3 
13. ho  
DV     k   W 
Chilton-Drew-Jebens correlation for outside film coefficient for agitated vessel in
Process heat transfer by D Q Kern, page 722 equation 20.4
0.8 0.3
 CP  
14. hi PIPE 
k
 0.023  vD   
D     k 
Dittus Boelter equation for cooling water equation 9.54 page 367 Coulson and
Richardson’s Chemical Engineering Volume 1 fifth edition (other editions have
different page number and equation number)
 D 
15. hi COIL  hi PIPE 1  3.5 1 
 L 
Jeschke Correction Factor page 426 Coulson and Richardson’s Chemical Engineering
Volume 1 fifth edition & page 721 D Q Kern Process Heat Transfer
h  ho
16. U C  io
hio  ho
U  hD
17. UD  C
U C  hD
Heat Transfer File
Page 28
LOSS  mW CW T
18. 
Q 
Q LOSS
19. A
U D  TLMTD
A
20. n
AN
Legend:
AN = Surface area per turn of a helix by considering one turn of helix as a torus. The
formula is for area of a torus with radius D2/2 rotated at a distance L from a fixed line
or the axis of rotation. Look for formula at page 3-11 Perry’s Chemical Engineer’s
Handbook, 7th Edition. W = Viscosity of water kW = thermal conductivity of
water L = Paddle length, D1 = Inner diameter of helical tube DV = Inner
diameter of tank. TWI and TWO are water inlet and outlet temperatures. For calculating
the coefficients, the value of characteristic diameter will be D 1 for inner coefficient
and DV for external coefficients.
Data given for 28° API oil at 80°C:
 = 4.04x10-4 lb/(ft/s) =0.0006012 Ns/m2
 = 53.19 lb/ft3 = 852.6 kg/m3
k = 0.08 Btu/ (h ft °F) = 0.1385 W/ (m K)
CP = 0.509 Btu/ (lb °F) = 2129.7 J/ (kg K)
For apparatus:
Inner diameter of coil = D1 = 0.018046 ft =0.00550 m
Outer diameter of coil = D2 = 0.024476 ft = 0.00746 m
Length of Paddle = L = 0.2875 ft = 0.08763 m
Inner diameter of tank DV = 0.9625 ft = 0.29337 m
Outer diameter of tank = DE = 1.000 ft = 0.3048 m
Number of Rotations = N = 720 rpm =12 rps
AI = 0.2376 cm2 (by formula 7)
AN = 0.0129 m2 /turn (by formula 9)
ID /OD = D1/D2 = 0.7373 (for use in formula 8)
Observations:
Temperature Celsius

V Mass QLOSS
Water Oil
ml/sec T WBM T1 T2 TLMTD T Kg/s (W)
In Out
28.4 26 35 66 30.50 31.00 40.00 35.31 9 0.0284 1069.43
28.4 26 34 59 30.00 25.00 33.00 28.82 8 0.0284 950.60
28.4 26 31 54 28.50 23.00 28.00 25.42 5 0.0284 594.13
22.2 26 40 76 33.00 36.00 50.00 42.62 14 0.0222 1300.39
22.2 26 39 68 32.50 29.00 42.00 35.10 13 0.0222 1207.50
22.2 26 38 62 32.00 24.00 36.00 29.60 12 0.0222 1114.62
14.2 26 50 74 38.00 24.00 48.00 34.62 24 0.0142 1425.91
14.2 26 44 68 35.00 24.00 42.00 32.16 18 0.0142 1069.43
14.2 26 41 62 33.50 21.00 36.00 27.83 15 0.0142 891.19
Mass is calculated by multiplying the volume by density. QLOSS is calculated by
formula 17. TWBM, T1, T2, T, TLMTD are calculated by formula 1, 2, 3, 4, 5
respectively.

Calculated Physical properties of water:


Velocity Viscosity k hi pipe hi coil hio
m/s Ns/m2 W/(m K) W/(m2 K) W/(m2 K) W/(m2 K)
1.1952 0.000790 0.6169 6177 7534 5555
Heat Transfer File
Page 29
1.1952 0.000798 0.6162 6142 7491 5523
1.1952 0.000824 0.6140 67036 7363 5428
0.9343 0.000750 0.6205 5216 6362 4691
0.9343 0.000758 0.6198 5187 6327 4665
0.9343 0.000766 0.6191 5159 6292 4639
0.5976 0.000679 0.6277 3850 4696 3462
0.5976 0.000720 0.6234 3729 4548 3353
0.5976 0.000742 0.6212 3669 4475 3299
The Jeschke correction factor has a value of 1.22. The values are calculated by using
formulae 6, 10, 11, 14, 15 & 16 respectively. The value of C P taken is 4184 J/kg K,
density = 1000 kg/m3, characteristic diameter = D1 = 0.0550 m. The value of viscosity
and thermal conductivity are calculated at bulk mean temperature.
The value of ho by using the values provided in formula number 12 is found to be:
ho = 1281 W/(m2 K)

UC UD A AN A
n Mean
W/(m2 K) W/(m2 K) m2 2
m /turn AN
1040.827 259.759 0.117 0.0129 9.0
1039.714 259.690 0.127 0.0129 9.8
1036.310 259.477 0.090 0.0129 7.0
1006.112 257.541 0.118 0.0129 9.2
1004.914 257.463 0.134 0.0129 10.4 9.9
1003.706 257.383 0.146 0.0129 11.3
934.951 252.620 0.163 0.0129 12.6
926.834 252.023 0.132 0.0129 10.2
922.630 251.711 0.127 0.0129 9.9
The value of overall clean heat transfer and dirty heat transfer coefficient is calculated
by formula 16 and 17. The value of area required for cooling is calculated by formula
19 and the number of turns by formula 20.

Result:
The number of turns of cooling coils comes out to be 10.

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