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CONTENTS
SECTION
INTRODUCTION/PURPOSE
SCOPE
FIELD OF APPLICATION
DEFINITIONS
3.1 units
5.1
5.2
Assumptions
Basic Equations
6
6
10
6.1
6.2
10
10
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APPENDICES
12
WORKED EXAMPLES
26
FIGURES
1
CASES CONSIDERED
TABLES
1
DEFINITIONS OF FUNCTIONS
NOMENCLATURE
29
30
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INTRODUCTION/PURPOSE
This Process Engineering Guide is one of a series on heat transfer produced for
GBH Enterprises. It is intended to provide guidance in the estimation of batch
heating and cooling times and the design of heat transfer equipment for this
purpose.
SCOPE
This Guide gives methods for estimating the batch heating or cooling times for
cases where the heat transfer performance of the system may be estimated.
Alternatively, it may be used to specify the required heat transfer performance of
the system in order to meet a given heating or cooling time.
It does not give detailed advice on the estimation of heat transfer coefficients nor
the design or rating of heat transfer equipment. Information on this topic may be
found in other guides in the GBH Enterprises heat transfer series. Ratings are
usually performed with the aid of computer programs. See GBHE-PEG-HEA-502
for information on recommended computer programs.
FIELD OF APPLICATION
This Guide is intended for process engineers and plant operating personnel in
GBH Enterprises world-wide, who may be involved in the specification, design
or operation of batch equipment with cyclic variations in temperature, such as
batch reactors.
DEFINITIONS
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3.1
Units
All equations in this guide are in coherent units. Base units for the SI system are
used.
However, the equations are, in general, equally valid if the individual terms are
expressed in any other coherent set of units.
A full list of symbols, with the appropriate base S.I. units, is given at the end of
the Guide.
There are several different cases that can be identified. These lead to related,
but not identical, solutions. The different cases which need to be considered
depend on:
(a)
(b)
(2)
(3)
whether the service fluid is single phase (e.g. cooling water) or isothermal
two phase (e.g. condensing steam).
Case 2
Direct use of a single phase service fluid, e.g. cooling water, in the
vessel jacket and/or internal coil.
Case 3
Case 4
Case 5
Case 6
Case 7
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Case 8
Some of these cases are covered in the book 'Process Heat Transfer' by D Q
Kern. However, this coverage is not as comprehensive as given here. Moreover,
there are errors in Kern's treatment.
FIGURE 1
CASES CONSIDERED
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5.1
Assumptions
In order to simplify the problem, a number of assumptions are made. The validity
of some of these may open to question, particularly for systems whose properties
vary dramatically with temperature. The magnitude of any likely errors may be
checked by comparing the results of detailed heat transfer calculations at the
start and end of the batch with the estimated performance based on the
approach given in this Guide. In extreme cases it will be necessary to perform a
series of detailed calculations to obtain an accurate picture, but the methods in
this Guide may still be useful to obtain a simple over-view of the problem.
(a)
(b)
(c)
The thermal masses of the external heat exchanger and the intermediate
circuit, if used, are negligible.
(d)
There are no time lags in the system, so that the instantaneous rate of
heat transfer between the vessel and the intermediate fluid is equal to that
between the intermediate fluid and the service fluid.
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(e)
The thermal mass of the vessel can be included with the thermal mass of
its contents. (This implies also that all resistance to heat transfer in the
jacket/coils is on the service side.)
5.2
Basic Equations
The basic equations which describe the thermal performance of the system are
the same for all cases considered. They involve the use of certain intermediate
functions denoted by the letters B, E and D which are functions of the different
systems, but, provided that the assumptions listed above hold, these functions
are constant for any given system. Details of the derivations of these equations
are given in Appendix A, where appropriate sub-scripts are used for the different
systems.
The batch time is related to the initial and final temperatures of the batch by the
equation:
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Note:
For these equations, the heat load is positive if the vessel contents are being
cooled, and negative if they are being heated.
For cases where there is an intermediate fluid between the batch and the service
fluid, the temperature of this intermediate fluid entering the service (external)
exchanger is given by:
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For the batch fluid circulated through an external exchanger, the outlet
temperature from the external exchanger is given by:
The functions B and D are functions of the flow rates and specific heats of the
various fluids and the heat transfer coefficients. They are defined for the various
cases in Table 1. In order to simplify the equations, in many cases further
intermediate functions E are also defined. Provided that the assumptions listed in
5.1 apply, these functions are constant for a given system.
The various terms in Table 1 are as follows:
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TABLE 1
DEFINITIONS OF FUNCTIONS
6.1
Determine the performance of the heat transfer equipment at the start and
end of the temperature cycle. For an external heat exchanger, either used
directly on the process fluid or as part of an intermediate system, this can
usually be done using a suitable computer program, following the
recommendations of GBHE-PEG-HEA-502. For heat transfer between the
vessel contents and a jacket or coil, the best recommendations available
at present are given in the HTFS Design Report. The situation is rather
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If the values of the heat transfer coefficients for the jacket/coil and the
external heat exchanger are reasonably constant over the cycle, calculate
the value of B for the appropriate case from Table 1. If the values are not
constant, go to (d).
(c)
Calculate the heating or cooling time from Equation 5.1 and the variation
of heat load and temperatures with time, if required, from Equations 5.2 to
5.7.
(d)
6.2
Often, when designing a batch system, the desired time to heat or cool the
vessel contents is fixed, and it is required to specify the heat exchanger that will
enable this time to be achieved.
The suggested procedure for specifying the exchanger is as follows:
(a)
Determine the thermal mass of the vessel and contents, W, the required
cycle time, S, and the initial and final temperatures, 0 and S. Then, using
Equation 5.1 determine the required value of the function B.
(b)
Determine the mean temperature of the batch fluid, m. As the batch fluid
temperature falls towards the service inlet temperature with an exponential
decay, as shown by Equation 5.2, the best value to use for this is that
corresponding to the LMTD between the start and end of the cycle:
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(c)
Calculate the heat duty at this temperature from Equation 5.3, using
the value of B calculated in (a).
(d)
(e)
(f)
(g)
(h)
If the estimated cycle time differs from the desired value, estimate a
new value of the heat duty at mean conditions by scaling the
original value in the ratio of estimated cycle time/desired cycle time,
and repeat from (d).
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APPENDIX A
Note:
The equation numbering system in this section is such that similar equation
numbers are used for the same process in each case. This means that in some
cases, the numbering is not contiguous.
A1
For heat transfer in the jacket or coil, the heat duty is given by:
Note that If the vessel has both a jacket and coil, in general both the areas and
the coefficients of these will differ. However, as these items always occur as their
product a compound value may be used which is given by:
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Re-arranging and integrating, with the boundary conditions that the batch
temperature is 0 at time zero and S at time S, gives the batch time:
A2
For heat transfer in the jacket or coil, the heat duty is given by:
The heat duty is also related to the change in temperature of the service fluid:
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Rearranging and integrating with the boundary conditions that the batch
temperature is 0 at time zero and S at time S, gives the batch time:
A3
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Rearranging and integrating with the boundary conditions that the batch
temperature is 0 at time zero and S at time S, gives the batch time:
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A4
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Hence, re-arranging and integrating with the boundary conditions that the batch
temperature is 0 at time zero and S at time S, gives the batch time:
A5
If the flowing thermal masses of the process and service fluids, M.C and m.c are
equal, i.e. r = 1, the approach of Case 4 breaks down, as certain terms become
undefined.
As for Case 4, the heat duty of the exchanger may be defined in three different
ways:
For the service fluid:
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For the exchanger, the temperature difference is constant along the length, so
the log mean temperature difference becomes the temperature difference at
either end. Thus:
Re-arranging and integrating with the boundary conditions that the batch
temperature is 0 at time zero and S at time S, gives the batch time:
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Note:
For Cases 6 - 8, the terms M and C refer to the intermediate fluid, whereas in
Cases 3 - 5 they refer to the process fluid.
A6
Using assumption (d) in 5.1, the instantaneous heat loads on the vessel
jacket/coil and the external heat exchanger are the same, and will equal the heat
duty associated with the change in temperature of the intermediate fluid passing
through the jacket/coil and exchanger. The heat loads are:
For the jacket/coils:
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Re-arranging:
Hence, re-arranging and integrating with the boundary conditions that the batch
temperature is 0 at time zero and S at time S, gives the batch time:
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A7
Using assumption (d) in 5.1, the instantaneous heat loads on the vessel
jacket/coil and the external heat exchanger are the same, and will equal the heat
duty associated with the change in temperature of the intermediate fluid passing
through the jacket/coil and exchanger and that associated with the service fluid.
The heat loads are:
For the jacket/coils:
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A8
If the flowing thermal masses of the intermediate and service fluids, M.C and m.c
are equal, i.e. r = 1, the approach of Case 7 breaks down, as certain terms
become undefined.
Using assumption (d) in 5.1, the instantaneous heat loads on the vessel
jacket/coil and the external heat exchanger are the same, and will equal the heat
duty associated with the change in temperature of the intermediate fluid passing
through the jacket/coil and exchanger and that associated with the service fluid.
The heat loads are:
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For the external heat exchanger, the temperature difference is constant along the
length, so the log mean temperature difference becomes the temperature
difference at either end.
Thus:
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Hence, re-arranging and integrating with the boundary conditions that the batch
temperature is 0 at time zero and S at time S, gives the batch time:
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APPENDIX B
B1
WORKED EXAMPLES
EXAMPLE 1
(a)
5000 kg
1000 kg
3500 J.kg-1K-1
500 J.kg-1K-1
15000 kg.h -1
21C
20000 kg.h-1
4817 J.kg-1K-1
(b)
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Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
B2
EXAMPLE 2
The contents of a jacketed vessel are to be cooled by circulating an
intermediate fluid between the jacket and an external heat exchanger,
cooled using cooling water. Estimate the time to cool the vessel contents
from 80C to 40C. Also, in order to check the assumed heat transfer
coefficients, estimate the temperatures of the various fluids at the start of
the cooling process. The relevant data are as follows:
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
OTHER DOCUMENTS
HTFS Design Guide
Vessels
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com