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A counterflow, concentric tube heat exchanger is designed to heat water from 20 to \(80^{\circ} \mathrm{C}\) using hot oil, which is supplied to the annulus at \(160^{\circ} \mathrm{C}\) and discharged at \(140^{\circ} \mathrm{C}\). The thin-walled inner tube has a diameter of \(D_{i}=20 \mathrm{~mm}\), and the overall heat transfer coefficient is \(500 \mathrm{~W} / \mathrm{m}^{2} \cdot \mathrm{K}\). The design condition calls for a total heat transfer rate of \(3000 \mathrm{~W}\). (a) What is the length of the heat exchanger? (b) After 3 years of operation, performance is degraded by fouling on the water side of the exchanger, and the water outlet temperature is only \(65^{\circ} \mathrm{C}\) for the same fluid flow rates and inlet temperatures. What are the corresponding values of the heat transfer rate, the outlet temperature of the oil, the overall heat transfer coefficient, and the water- side fouling factor, \(R_{f,}^{n}\) ?

Short Answer

Expert verified
In short, for a counterflow concentric tube heat exchanger with the given conditions, the length of the heat exchanger is approximately 1.59 m. After 3 years of operation, the performance is degraded due to fouling on the water side, resulting in corresponding values of: 1. Heat transfer rate: \(Q^{'} \approx 1687.5 W\) 2. Outlet temperature of the oil: \(T_{o_o}^{'} \approx 149.55^{\circ}C\) 3. Overall heat transfer coefficient: \(U^{'} \approx 262.6 W/m^2 K\) 4. Water-side fouling factor: \(R_{f}^{n} \approx 0.0006438 m^2 K/W\)

Step by step solution

01

(a) Finding Length of the Heat Exchanger

First, we'll find the length of the heat exchanger using the given data. For this, we'll use the following heat transfer equation: \(Q = U * A * \Delta T_{lm}\) where: \(Q\) = total heat transfer rate (3000 W), \(U\) = overall heat transfer coefficient (500 W/m²·K), \(A\) = heat transfer area, \(\Delta T_{lm}\) = log mean temperature difference. To find the log mean temperature difference we will use: \(\Delta T_{lm} = \frac{(\Delta T_2 - \Delta T_1)}{ln(\Delta T_2 / \Delta T_1)}\) where: \(\Delta T_1\) = temperature difference at the inlet, \(\Delta T_2\) = temperature difference at the outlet. \(\Delta T_1 = T_{i_o} - T_{i_w} = 160 - 20 = 140^{\circ}C\) \(\Delta T_2 = T_{o_o} - T_{o_w} = 140 - 80 = 60^{\circ}C\) Now, finding the log mean temperature difference: \(\Delta T_{lm} = \frac{(60 - 140)}{ln(60 / 140)} = -94.47^{\circ}C\) The minus sign is due to the countercurrent flow; the actual temperature difference is positive. Now, we have: \(Q = U *\ A *\ \Delta T_{lm}\) Since the exchanger is a concentric tube type, the heat transfer area per unit length can be expressed as: \(A_{exchanger} = 2 \pi * D_{i} * L\) where \(D_{i}\) = diameter of the inner tube (0.02 m), \(L\) = length of the exchanger. Putting the values into the equation and solving for length, we get: \(3000 = 500 * 2 \pi * 0.02 * L * 94.47\) \(L = \frac{3000}{500 * 2 \pi * 0.02 * 94.47} \approx 1.59 m\) So, the length of the heat exchanger is approximately 1.59 m.
02

(b) Finding the Heat Transfer Rate, Outlet Temperature of the Oil, Overall Heat Transfer Coefficient, and the Water-side Fouling Factor

Let's use the data after degradation due to fouling and find the corresponding values. Given the following conditions after degradation: \(T_{o_w}^{'} = 65^{\circ}C\) (new outlet temperature of water) Now, let's calculate the new values of heat transfer rate, ΔT1', and ΔT2': \(Q^{'} = 500 * 2 \pi * 0.02 * L * \Delta T_{lm}^{'}\) So, we need to find \(\Delta T_{lm}^{'}\) for the degraded case: \( \Delta T_1^{'} = T_{i_o} - T_{i_w} = 160 - 20 = 140^{\circ}C\) \(\Delta T_2^{'}\) = temperature difference at the outlet for the degraded case = \(T_{o_o}^{'} - T_{o_w}^{'}\) To calculate this, we need to know \(T_{o_o}^{'}\), the new oil outlet temperature. Let's first find \(Q^{'}\) value by using the given water outlet temperature, \(T_{o_w}^{'}\). \(Q^{'} = m_w * c_w * (T_{o_w}^{'} - T_{i_w})\) \(Q^{'} = m_o * c_o * (T_{i_o} - T_{o_o}^{'})\) We know the initial condition of heat transfer rate, \(Q = 3000 W\), and we can deduce: \(m_w * c_w * (80 - 20) = m_o * c_o * (160 - 140)\) Thus, the ratio \(\frac{m_w * c_w}{m_o * c_o} = \frac{160 - 140}{80 - 20} = 0.5\) Now let's use it to find \(T_{o_o}^{'}\): \(Q^{'} = 0.5 * (T_{i_o} - T_{o_o}^{'}) * (T_{o_w}^{'} - T_{i_w})\) \(Q^{'} = 0.5 * (160 - T_{o_o}^{'}) * (65 - 20)\) Now, solving for the new heat transfer rate and the new oil outlet temperature, we get: \(Q^{'} \approx 1687.5 W\) \(T_{o_o}^{'} \approx 149.55^{\circ}C\) Next, we find \(\Delta T_2^{'}\): \( \Delta T_2^{'} = T_{o_o}^{'} - T_{o_w}^{'} = 149.55 - 65 = 84.55^{\circ}C\) Now, find \(\Delta T_{lm}^{'}\): \(\Delta T_{lm}^{'} = \frac{(\Delta T_2^{'} - \Delta T_1^{'})}{ln(\Delta T_2^{'} / \Delta T_1^{'})} = \frac{(84.55 - 140)}{ln(84.55 / 140)} \approx -107.5^{\circ}C\) Now, let's find the new overall heat transfer coefficient, \(U^{'}\): \(Q^{'} = U^{'} * A * \Delta T_{lm}^{'}\) \(U^{'} = \frac{Q^{'}}{A * \Delta T_{lm}^{'}} = \frac{1687.5}{2 \pi * 0.02 * 1.59 * 107.5} \approx 262.6 W/m^2 K\) The water-side fouling factor, \(R_{f}^{n}\), can be found using the relation: \( \frac{1}{U^{'}} = \frac{1}{U} + R_{f}^{n}\) \( R_{f}^{n} = \frac{1}{U^{'}} - \frac{1}{U} \approx \frac{1}{262.6} - \frac{1}{500} = 0.0006438 m^2 K/W\) The corresponding values are: 1. Heat transfer rate: \(Q^{'} \approx 1687.5 W\) 2. Outlet temperature of the oil: \(T_{o_o}^{'} \approx 149.55^{\circ}C\) 3. Overall heat transfer coefficient: \(U^{'} \approx 262.6 W/m^2 K\) 4. Water-side fouling factor: \(R_{f}^{n} \approx 0.0006438 m^2 K/W\)

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Key Concepts

These are the key concepts you need to understand to accurately answer the question.

Log Mean Temperature Difference (LMTD)
Understanding the Log Mean Temperature Difference (LMTD) is crucial in analyzing heat exchangers. It's a key factor that defines the driving force for heat transfer when there's a temperature gradient. In the context of your textbook exercise, the LMTD method is applied for a counterflow heat exchanger, where two fluids flow in opposite directions. The formula for LMTD is:
\[\begin{equation}\Delta T_{lm} = \frac{(\Delta T_2 - \Delta T_1)}{\ln(\Delta T_2 / \Delta T_1)}\end{equation}\]where \(\Delta T_1\) and \(\Delta T_2\) represent the temperature differences at the inlet and outlet, respectively. What's important to remember is that, due to the nature of the logarithmic mean, the actual temperature difference used in calculations is always positive, even if the equation gives a negative result, which can happen in systems with countercurrent flow like in the exercise.
To make the concept easier to grasp, picture the LMTD as a sort of 'average' temperature difference that remains relatively constant along the length of the heat exchanger. This is especially helpful in complex systems where inlet and outlet temperatures aren't uniform, something not unusual in real-world applications.
Overall Heat Transfer Coefficient (U)
The Overall Heat Transfer Coefficient, denoted as \(U\), encapsulates the total resistance to heat flow through the heat exchanger. This resistance might come from the conducting walls as well as convection at both the hot and cold fluid surfaces. The formula to find the heat transfer rate using the overall heat transfer coefficient is:
\[\begin{equation}Q = U * A * \Delta T_{lm}\end{equation}\]In your exercise, \(U\) is initially provided, but it changes after the heat exchanger experiences fouling. The decreased performance is then reflected in the new, lower value of \(U\) calculated from the reduced heat transfer rate and LMTD. Understanding that \(U\) can change over time due to factors like fouling is key to maintaining efficiency in a heat exchanger system.
Furthermore, when you come across this coefficient in your studies, remember that a high value of \(U\) signifies an efficient heat exchanger—something that allows substantial heat transfer with minimal size and cost.
Fouling in Heat Exchangers
Fouling refers to the accumulation of unwanted material on the heat exchanger surfaces, which impairs heat transfer and reduces efficiency. In the exercise example, the performance degradation is caused specifically by fouling on the water side. This accumulation adds an extra layer of resistance to heat flow, causing the overall heat transfer coefficient to drop over time.
Once fouling occurs, it can be quantified using a fouling factor, \(R_{f}\), which increases the overall thermal resistance. The relation between the initial and degraded overall heat transfer coefficients is:
\[\begin{equation}\frac{1}{U^{'}} = \frac{1}{U} + R_{f}^{n}\end{equation}\]Here, \(U^{'}\) represents the decreased overall heat transfer coefficient after fouling, and \(R_{f}^{n}\) is the water-side fouling factor. By computing these values, engineers can determine the extent of fouling and make informed decisions about cleaning or replacing parts of the heat exchanger.
Regular monitoring and maintenance are crucial to mitigate the effects of fouling. Implementing effective cleaning schedules and choosing appropriate materials for construction can help to prolong the life of heat exchangers and maintain optimal performance.

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Most popular questions from this chapter

A boiler used to generate saturated steam is in the form of an unfinned, cross-flow heat exchanger, with water flowing through the tubes and a high- temperature gas in cross flow over the tubes. The gas, which has a specific heat of \(1120 \mathrm{~J} / \mathrm{kg} \cdot \mathrm{K}\) and a mass flow rate of \(10 \mathrm{~kg} / \mathrm{s}\), enters the heat exchanger at \(1400 \mathrm{~K}\). The water, which has a flow rate of \(3 \mathrm{~kg} / \mathrm{s}\), enters as saturated liquid at \(450 \mathrm{~K}\) and leaves as saturated vapor at the same temperature. If the overall heat transfer coefficient is \(50 \mathrm{~W} / \mathrm{m}^{2} \cdot \mathrm{K}\) and there are 500 tubes, each of \(0.025-\mathrm{m}\) diameter, what is the required tube length?

A shell-and-tube heat exchanger with one shell pass and 20 tube passes uses hot water on the tube side to heat oil on the shell side. The single copper tube has inner and outer diameters of 20 and \(24 \mathrm{~mm}\) and a length per pass of \(3 \mathrm{~m}\). The water enters at \(87^{\circ} \mathrm{C}\) and \(0.2 \mathrm{~kg} / \mathrm{s}\) and leaves at \(27^{\circ} \mathrm{C}\). Inlet and outlet temperatures of the oil are 7 and \(37^{\circ} \mathrm{C}\). What is the average convection coefficient for the tube outer surface?

A liquefied natural gas (LNG) regasification facility utilizes a vertical heat exchanger or vaporizer that consists of a shell with a single-pass tube bundle used to convert the fuel to its vapor form for subsequent delivery through a land-based pipeline. Pressurized LNG is off-loaded from an oceangoing tanker to the bottom of the vaporizer at \(T_{c, i}=-155^{\circ} \mathrm{C}\) and \(\dot{m}_{\mathrm{LNG}}=150 \mathrm{~kg} / \mathrm{s}\) and flows through the shell. The pressurized LNG has a vaporization temperature of \(T_{f}=-75^{\circ} \mathrm{C}\) and specific heat \(c_{p l}=4200 \mathrm{~J} / \mathrm{kg} \cdot \mathrm{K}\). The specific heat of the vaporized natural gas is \(c_{p, v}=2210 \mathrm{~J} / \mathrm{kg} \cdot \mathrm{K}\) while the gas has a latent heat of vaporization of \(h_{f g}=575 \mathrm{~kJ} / \mathrm{kg}\). The LNG is heated with seawater flowing through the tubes, also introduced at the bottom of the vaporizer, that is available at \(T_{h, i}=20^{\circ} \mathrm{C}\) with a specific heat of \(c_{\mu \mathrm{Sw}}=3985 \mathrm{~J} / \mathrm{kg} \cdot \mathrm{K}\). If the gas is to leave the vaporizer at \(T_{c o}=8^{\circ} \mathrm{C}\) and the seawater is to exit the device at \(T_{\text {hot }}=10^{\circ} \mathrm{C}\), determine the required vaporizer heat transfer area. Hint: Divide the vaporizer into three sections, as shown in the schematic, with \(U_{\mathrm{A}}=150 \mathrm{~W} / \mathrm{m}^{2} \cdot \mathrm{K}\), \(U_{\mathrm{B}}=260 \mathrm{~W} / \mathrm{m}^{2} \cdot \mathrm{K}\), and \(U_{\mathrm{C}}=40 \mathrm{~W} / \mathrm{m}^{2} \cdot \mathrm{K}\).

A shell-and-tube heat exchanger consists of 135 thinwalled tubes in a double- pass arrangement, each of \(12.5\) - \(\mathrm{mm}\) diameter with a total surface area of \(47.5 \mathrm{~m}^{2}\). Water (the tube-side fluid) enters the heat exchanger at \(15^{\circ} \mathrm{C}\) and \(6.5 \mathrm{~kg} / \mathrm{s}\) and is heated by exhaust gas entering at \(200^{\circ} \mathrm{C}\) and \(5 \mathrm{~kg} / \mathrm{s}\). The gas may be assumed to have the properties of atmospheric air, and the overall heat transfer coefficient is approximately \(200 \mathrm{~W} / \mathrm{m}^{2} \cdot \mathrm{K}\). (a) What are the gas and water outlet temperatures? (b) Assuming fully developed flow, what is the tubeside convection coefficient? (c) With all other conditions remaining the same, plot the effectiveness and fluid outlet temperatures as a function of the water flow rate over the range from 6 to \(12 \mathrm{~kg} / \mathrm{s}\). (d) What gas inlet temperature is required for the exchanger to supply \(10 \mathrm{~kg} / \mathrm{s}\) of hot water at an outlet temperature of \(42^{\circ} \mathrm{C}\), all other conditions remaining the same? What is the effectiveness for this operating condition?

A shell-and-tube exchanger (two shells, four tube passes) is used to heat \(10,000 \mathrm{~kg} / \mathrm{h}\) of pressurized water from 35 to \(120^{\circ} \mathrm{C}\) with \(5000 \mathrm{~kg} / \mathrm{h}\) pressurized water entering the exchanger at \(300^{\circ} \mathrm{C}\). If the overall heat transfer coefficient is \(1500 \mathrm{~W} / \mathrm{m}^{2} \cdot \mathrm{K}\), determine the required heat exchanger area.

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