DIMENSIONING OF HEAT EXCHANGERS IN HEAT EXCHANGER STATION

Ivan Stojanovi 1, Mladen Stojanovi 2, Ana Nenadov3

1

The University of Belgrade, The Faculty of Mechanical Engineering, Serbia, ivanstojanovic1987@gmail.com 2 The University of Belgrade, The Faculty of Mechanical Engineering, Serbia, mladiv@open.telekom.rs 3 The University of Belgrade, The Faculty of Mechanical Engineering, Serbia, anenadov@yahoo.com

This paper considers the problem of dimensioning the group of heat exchangers in heat exchanger station for large flows of transmitters and receivers with different parallel and serial connections by the flow of heat transmitters and receivers. Usage of heat transmitters is presented within the system of remote heating and also some constructive solutions are suggested. Keywords: shell and tube heat exchanger, heat receiver, heat transmitter, serial and parallel connection.

1. INTRODUCTION
Urban areas are grouped around the district heating stations. Besides combined heat and power (CHP) as a heat source, there are heat-only boiler stations used as an additional source of heat in urban areas. This paper considers hot-water system where hot water is distributed to the city area via magistral network. CHP covers a consumer base, but during the period when outdoor temperature is constantly below 0oC, greater thermal power is needed and then boiler stations are activated. Water from magistral network is transported to the boiler stations where is heated in boilers if needed, and transported to the district network and forward to substations by pipe system. Circulator pumps are part of the boiler station. This hotwater system is unique hydraulic system which may be disturbed due to pumps failure, resulting transmission of unbalanced pressure to the consumers in the distribution network. The main problem in hot-water system is that there are no heat excharges that separate the city distribution network from buildings network, so the pump failure may directly cause serious damage to heaters (radiators) in buildings because of transmitted pressure wave. In order to overcome the problem, indirect connection between the CHP and the city distribution network should be made. One of the possible solutions would be to place heat exchanges in the main heat exchanger station where circulator pumps are.

Fig. 1 Indirect connection sheme in main heat exchanger station (two parallel flows on the sides of heat transmitters and four parallel flows in heat exchanger station )

3. DRUM HEAT CALCULATION

EXCHANGER

Drum heat exchangers consist of two main parts: external part (shell, front and back head) and internal part (pipe register or tubular beam).

2.

INDIRECT CONNECTION SHEME

The task of this paper is to analyze dynamic work conditions, to dimension heat exchangers and to determine number of heat exchangers that would look like in Figure 1. There would be two parallel flows on the sides of heat transmitters and four parallel flows in heat exchanger station. Water from city distribution network would be transported into 4 flow lines where heat exchangers are in serial configuration. One flow line from CHP heat exchanger would transmit heat to the first two flow lines in heat exchanger station and the other flow line from CHP heat exchanger would transmit heat to the other two flow lines in heat exchanger station.

Fig. 2 Drum heat exchanger

Calculation will determine dimensions of heat exchanger, dynamic work conditions will be analysed and number of heat exchangers for one flow line of heat transmitters and for two flow lines of heat receivers will be determined. Parameters that are known are temperature and pressure of water from CHP on the heat exchanger inlet and temperature on heat exchanger outlet, temperature and pressure of water from district network on the heat exchanger inlet, heat transfer coefficient k=1200 [W/m2*K]. Pipe length is 6 mm and outer diameter of the pipe is 20 mm. Later it will be calculated mass flow rate of water from CHP as well as temperature of water from heating district network at the outlet of both parallel lines of the heat exchanger.

Temperature of water from CHP at the heat exchanger outlet will be fluctuated and in the end of this paper it will be analysed how total area and number of heat exchangers depends of different temperatures.

Q 250000000 m1 = = =906,9 [kg/s] . c p1 (t 1ul -t 1iz ) 4241 (150-85) Heat equivalent for the heat transmitter is calculated:

(8)

4.

HEAT BALANCE EQUATIONS

Heat exchanges between the working fluids as well as between the working fluids and environment. According to the law of conservation of mass, the total mass of working fluid at the inlet and outlet of the device is constant:

. (9) W1 = m1 c p1 =4241 906,9=3846154 [W/K] When mass flow of water from heat transmittor is calculated and specific heat capacity of water is determined, volume flow rate can be calculated:
V1 =

m1 m1 = = m 1 1 1 1

= 9 0, 0010579053 906,

(10a)

m1u = m1i = m 1 ,
m 2u = m 2i = m 2 .

(1) (2)

According to the law of conservation of energy, it can be written:

(10b) V1 =0,959414044 [m3 /s]=3453 [m3 /h] . Mass flow of water from district network for both parallel flows of heat receivers can be calculated by multiplying volume flow rate of water and its density:

m1 c p1t1ul + m2 cp2 t 2ul = m1 cp1 t1iz + m2 cp2 t 2iz + Qg1 + Qg2 . (3)
If the system is ideally thermally isolated, than losses are
Qg1 = Q g2 = 0 , and equations are:

c p2 =4,224 [kJ/kgK] - specific heat capacity of water with

average temperature of 107,5oC,

1 =0,0010579053 [m3 /kg] - specific volume of water with

average temperature of 107,5oC and pressure of p1=10[bar], 1 2400 1 m 2 = V = V 2 = =635,51 [kg/s] . (11) 2 2 2 3600 0, 0010490336 Heat equivalent for the heat reciever is calculated: . (12) W2 = m2 c p2 =4224 635,53=2684479 [W/K] The effective temperature divergence (logarithmic temperature) for the case of parallel flow in opposite directions can be obtained usin the following equation: t tlower (t1ul t 2iz ) (t1iz t 2ul ) t e = t m = higher = thigher (t ) t . (13) ln 1 ul 2 iz ln (t1iz t 2 ul ) tlower Second important equation for dimensioning heat exchanges is equation of heat exchange. This equation represent connection between thermal and geometric parameters:
Q = q A=k At
m

Q1 = m1 cp1 (t1ul -t1iz )=W1 t1,

(4) (5) (6)

Q 2 = m 2 c p2 (t 2ul -t 2iz )=W2t 2 ,

Q1 = Q2 = Q ,

where:
Q1 , Q 2 [W] - thermal power (energy) which CHP transmits and heating district network recieves,

m1 , m2 [kg/s] - mass flow of water from CHP and heating district network, c p1 , cp2 [kJ/kgK] - specific heat capacity,

W1 ,W2 [W/K] - heat equivalent, it is a multiplication of mass flow and specific heat capacity. First group of heat exchangers on the outlet will be dimensioned for temperature of 85oC, where: t1ul = 150o C - water temperature on the inlet of the heat exchanger, t1iz = 85o C - water temperature on the outlet of the heat exchanger, t sr1 - average water temperature, and is calculated:
t sr1 = t1ul +t1iz 235 = = 117, 5o C . 2 2

(14)

(7)

If :

c p1 =4,241 [kJ/kgK] - specific heat capacity of water with

average temperature of 112,5oC,

1 =0,0010579053 [m3 /kg] - specific volume of water with

average temperature of 112,5oC and pressure of p1=5[bar],
Q =250 000 000 W ,

where: k [W/m 2 K] - heat transfer coefficient, A [m 2 ] - external area of heat exchange register, t m [K] - effective temperature difference. Computer program is used to calculate values for: total area and number of heat exchangers (one flow for heat transfer and two flows for heat reciever), temperature of water from heating district network (two groups of heat exchangers for two parallel flows for heat transfer) and temperatures on the input and output of every exchanger separately. For heat exchanger with oposite direction flow, temperature variables of heated and cooled fluid are calculated, respectively: t1ul -t1iz = (t1 ul t2 ul ) (15)

t 2iz -t 2ul = (W1 / W2 ) ( t1 ul t2 ul)

Transmitted heat energy is calculated:
Q = W1 (t1ul t1iz ) ,

(16) (17)

than, from equation (4), mass flow for one heat transmittor can be calculated:

or:

Q = W1 (t1ul t2 ul ) .

(18)

Auxiliary function is calculated:

-(1-

= 1-

1-e W1 W2

W1 ) kA/ W W2

-(1-

W1 ) kA/ W W2

(19)

On the Figure 3, heat exchanger configuration is presented. Temperature of heat transmitter on the otlet of the last heat exchanger is 85oC, and temperature of heat receivers on the inlet of the last two heat exchangers is 70oC. Area (surface) of one heat exchanger is 760 m2, and it is the same for all 12 of them. This value meets the requirement: if pipe length is 6 m (this is a setpoint), than diameter of pipe group should not be higher than 1,31 m. Number of pipes can be determined:

First step in calculation is to determine auxiliary function for presumed area for one heat exchanger, and than for all of them, starting from last to first. There are 6 pairs (12 heat exchangers) on one flow of heat transmitter. After is determined, input and output temperatures can be calculated, as well as transmitted heat energy. If total summary of transmitted heat energy is more than 1% higher than total required heat energy ( Q =250 MW ), than different area (surface) value must be presumed. This process repeats until the required term is fulfilled. Areas of all heat exchangers are the same.

nC =

A' 760 = = 2016 d CS lC 0, 02 6

(20)

Diameter of pipe group is calculated:

D = 4 n C s 2 / = 4 2016 0, 0262 / = 1,31 [m] . (21)

External diameter of pipe is 20 mm.
Table 1. Results illustration

m 2 = 635,51 [kg/s] m1 = 906,9 [kg/s] k =1200 [W/m 2 K] n C = 2016

W 2 = 2684479 [W/K] W1 = 3846154 [W/K] A' = 760 [m 2] A = 9120 [m 2] D = 1,31 [m] = 0,183913

t2iz 1 2 3 4 5 6 7 8 9 10 11 12
116,5 115,5 106,3 105,0 96,97 96,12 89,09 87,1 81,76 81,29 75,93 74,84

t2ul
105,0 106,3 96,1 96,97 87,1 89,09 81,29 81,76 74,84 75,93 70 70

t1iz
141,2 134,8 127,7 122,06 115,79 110,88 105,44 101,08 96,26 92,52 88,38 85

t1ul
149,4 141,2 134,8 127,71 122,06 115,79 110,88 105,44 101,08 96,26 92,62 88,38 31354620 24703912 27374357 21740466 24090569 18889029 20931783 16751574 18562387 14376854 15930964 13001325

Fig. 3 Heat exchanger configuration

Heat energy of 250 MW transfers through 12 heat exchangers with exchange areas (surfaces) of 760 m2 and temperature of t1iz=85oC. Requirements are respected: D1,31 m and water flow velocity value is between 1,2 m/s and 2,2 m/s. This calculation demanded a computer model which will not be a part of this paper. Further, only chosen solutions will be presented. Computer program uses equations for temperature divergences of heating fluid (heated and cooled), heat flux exchange and auxiliary functions, and calculates every single temperature and heat energy of every heat exchanger in line separately. Intire calculation is repeated for the other two temperature values (80oC and 75o). Results are presented in Table 2 and 3.

Table 2. Results illustration for temperature of 80oC

t1iz,16 = 80 o C

t 2ul,16 = 70 o C

t 2ul,15 = 70 o C

m1 = 842,9 [kg/s] m 2 = 635,51 [kg/s] = 0,179326

W1 = 3571429 [W/K] W 2 = 2684479 [W/K] A' = 675 [m 2]

t2iz 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
116,7 115,66 107,48 106,49 99,44 98,67 92,63 91,85 86,62 86,11 81,64 80,90 77,10 76,83 73,54 72,91

t2ul
106,4 107,48 98,67 99,44 91,85 92,63 86,11 86,62 80,98 81,64 76,83 77,10 72,91 73,54 70,00 70,00

t1iz
141,7 135,60 128,98 123,68 117,97 113,43 108,53 104,60 100,36 97,01 93,39 90,47 87,32 84,85 82,19 80,00

t1ul
149,4 141,74 135,60 128,98 123,68 117,97 113,43 108,53 104,60 110,36 97,01 93,39 90,47 87,32 84,85 82,19 27512480 21940928 23648452 18916613 20388774 16231848 17495070 14032303 15124349 11989768 12922856 14034081 11246100 8822549 9509153 7803919

CONCLUSION
Water temperature of heat transmitter at the outlet from heat exchanger was varied for three values: 75oC, 80oC and 85oC. Using this three different values, total areas (surfaces) of heat exchangers was determined respectively: 14040 m2, 10800 m2 and 9120 m2, as well as number of heat exchangers: 20, 16 and 12 (by one flow of heat transmitter). Comparing volume flow rate for three different temperature values, it can be concluded that when temperature divergence of water that transmits heat from CHP at the inlet and outlet of heat exchangers is decreasing, volume flow rate is increasing. This means that highest value of volume flow rate is obtained for water temperature of 85oC, and lowest value for temperature of 75oC. Because of higher flow velocity around the pipe, water flow is separated in two streams: one stream is transported through heat exchangers placed into two parallel lines on heat riciever sides, and the second stream is transported through other two parallel lines on heat exchangers sides. If the flow is separated into more that two streams (for example 4), water flow velocity around pipe in group would be lower.

Table 3. Results illustration for temperature of 75oC

t1iz,20 = 75 o C
m1 = 788, 02 [kg/s] m 2 = 635,51 [kg/s] = 0,196888

t 2ul,20 =70 o C

t 2ul,19 = 70 o C

W1 = 3333333 [W/K] W 2 = 2684479 [W/K] A' = 702 [m 2]

REFERENCES
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