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CHAPTER 4
4.1 INTRODUCTION
Th1 Th 2 T Tc1
Ph = ; Pc = c 2 (4.1)
Th1 Tc1 Th1 Tc1
The model applies only for the middle part of a spiral plate heat
exchanger, where heat is transferred to cold fluid from both walls.
Therefore the model works better for a spiral heat exchanger with
a large number of turns. In this study, the number of turns n = 60,
large enough for end-effects to be neglected.
b
r= ( m ) + rm, (4.2)
58
Hot fluid enters the exchanger in the centre of the apparatus and
cold fluid flows in at the outermost channel.
Figure 4.1. Both temperature differences are positive in the spiral plate heat
exchanger. Further, these differences of temperature depend upon each
other; however, for convenience they will be separately derived as two
different quantities and will later be combined with each other.
Let the heat capacity of the hot fluid be Ch. For the part of the
channel between the radii r 1 and r, the hot fluid flows in the counter
clockwise direction. Since is also measured counterclockwise, the flow
direction of the hot fluid is the positive direction of . This hot fluid loses
heat to the cold fluids in the channels between r 1 and r 2, and r and
r + 1. Denoting the channel between r 1 and r as j, the above statement
may be rewritten as: the hot fluid in j loses heat to the cold fluid in j 1 and
j + 1. Let the temperature of the hot fluid be denoted Th and that of the cold
fluid be denoted TC. In order to indicate the temperature dependence on the
60
position of the fluid in the exchanger, the temperature of the hot fluid in j is
denoted as Th (r (1 2)) , and that of the cold fluid in j + 1 is denoted as
Th (r + (1 2)) . Thus, the rate of change of heat transfer from the hot fluid in j
to the cold fluid in j + 1 with respect to the angle is given by:
1 1
q j, j+1 = hA T = hrw Th r Tc r + (4.3)
2 2
1
d hc r
Ch 2 =q + q (4.4)
j, j1 j, j+1
d
1
dTc r +
Cc 2 =q + q (4.5)
j, j+1 j+1, j+ 2
d
with respect to the angle , one may convert this into the change with
respect to r. From Equation 4.2, we have d = dr .Thus, in the new
b
notations, Equations 4.4 and 4.5 become:
dTh (r ) r[Th (r ) Tc (r )]
Ch = kWb
dr + (r 1)[Th (r ) Tc (r 2) ]
dTc (r ) r[Th (r ) Tc (r )] +
Cc = kWb (4.6)
dr (r + 1)[Th (r + 2) Tc (r ) ]
The boundary conditions are obtained from the inlet and outlet
temperatures of the hot and cold fluids, respectively in the centre of the
exchanger. These two equations contain two kinds of temperature
differences (see Figure 4.1):
Ch
2 A c h / C , the heat capacity ratio as R = , and rearranging, the two
Cc
Equations in 4.6 may be recast as:
62
dTh ( r )
2 R + r (r ) + ( r 1)(r 1) = 0
dr
dTc ( r )
2 R + r( r ) + (r + 1)( r + 1) = 0 (4.7)
dr
To obtain the energy balance of the main and side spirals in terms
of the above defined local temperature differences, the derivatives have to be
converted to those in (r) and (r). This involves algebraic manipulation of
the two Equations in 4.7, and expanding terms in Taylors series to second
derivative (Bes and Roetzel 1993). It turns out to be convenient to define a
new independent variable x which depends on r, as
R +1
x= r (4.8)
2 R
d ( x ) d[x(x )]
x [ (x ) + (x )] =0
dx dx
d ( x ) d[x (x )]
x [(x ) + (x )] + =0
dx dx (4.9)
= constant
63
(
d (1 + x 2 )[(x ) + (x )] )
2x[(x ) + (x )]
dx
= [ i i x i ( i + i )] (4.11)
Gi
(x ) + (x ) = ( i + i ) (4.12)
(1 + x )
2 1
2
where, G i = (1 + x i )1 is a constant computed for the radius ri at
the inlet to the exchanger.
T h ,i T h , o
Ph = (4.13)
T h ,i T c ,i
64
1 exp[(R 1) NTU]
Ph = (4.14)
1 R exp[(R 1) NTU]
1 + x o 2
1 exp ln
2
Ph = 1 + x i
(4.15)
( )
1 + x o ( R 1) x i 2
1 R exp ln
2
2
+
(
1 + x i ) 1+ xi
2
( )
Here the term is given by
2
=
( R 1 R )( R +1 R )
2
(4.16)
= (R 1) NTU h CN 2
where,
CN = ( R +1 )
R NTU ( A c A)
A c (4.17)
CN (NTU h + NTU c )
A
(1 + x ) (1 + x ) = 1 + (x
o
2
i
2
o
2
xi
2
) (1 + x )
i
2
and
1
2 2
1+
xo xi
= CN 2 n 21
1 + x i2 1 + xi
For realistic heat capacity ratios (R) and small inlet radius, the
1 2
ln 1 + 1 + CN
(n 1)
F= 2
(4.18)
CN
1 exp[(R 1) NTU F]
Ph = (4.19)
1 R exp[(R 1) NTU F]
Ch
Pc = Ph = Ph R (4.20)
Cc
66
on the heat capacity ratio and F. The experiments performed, however, have
been conducted for fixed hot fluid flow rates and varying cold fluid flow
rates. This implies that, as the cold fluid flow rate increases, its heat capacity
increases. Therefore, the heat capacity ratio R decreases continuously, even
as the NTU increases and the effectiveness increases. This preliminary study
has investigated the NTU range of practical relevance and the values of
thermal effectiveness range for the cold fluid, and the hot fluid is listed in
the Table 4.1.
Table 4.1 Ranges of NTU, thermal effectiveness of hot and cold fluid
NTU Ph Pc
System
Min Max Min Max Min Max
Octane - Water 1.86 4.31 0.07 0.29 0.83 0.97
Kerosene - Water 0.28 3.93 0.07 0.59 0.23 0.97
Dodecane -Water 0.44 3.93 0.07 0.66 0.34 0.97
Diesel - Water 2.30 6.83 0.07 0.22 0.89 1.00
Nitrobenzene - Water 0.49 3.93 0.07 0.49 0.38 0.97
that the cold side has laminar flow while the hot side has
turbulent flow. Therefore, the reduction in R is insufficient to
reverse the trend. In other words, this is a limitation on the use of
a purely thermal model in the prediction of heat transfer in
laminar convection processes.
Pure Water
1.2
Pure Octane
1 Pure Kerosene
Pure Dodecane
0.8 Pure Diesel
Pc,exp
0.4
0.2
0
0 2 4 6 8
NTUc
Figure 4.2 Thermal effectiveness with number of transfer units,
when pure cold fluids are used: From experiments
Pure Water
1.2
Pure Octane
1 Pure Kerosene
Pure Dodecane
0.8 Pure Diesel
Pc,pred
0.4
0.2
0
0 2 4 6 8
NTUc
1
0.9
0.8
0.7 Pure Water
Pure Octane
0.6
Pure Kerosene
Pc,exp
1.0
Temperature effectiveness Ph, pred
0.9
0.8
0.7
0.6
0.5 Pure Water
0.4 20% Octane
0.3 40% Octane
60% Octane
0.2
80% Octane
0.1 Pure Octane
0.0
0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
Temperature effectiveness Ph, exp
Pure Water
1.0 Cold Fluid 20% Octane
Temperature effectiveness Pc, exp 40% Octane
0.8 60% Octane
80% Octane
Pure Octane
0.6
0.4
0.2
0.0
0 1 2 3 4 5
Number of transfer units NTUc
Figure 4.8 Thermal effectiveness with number of transfer units
in cold fluid for octane-water system: From experiments
Pure Water
0.9
20% Octane
40% Octane
60% Octane
80% Octane
Pure Octane
0.8
1.5 2.0 2.5 3.0 3.5 4.0
Number of transfer units NTUc
1.0
Temperature effectiveness Pc, pred 0.9
0.8
0.7
0.6
0.5 Pure Water
0.4 20% Octane
0.3 40% Octane
60% Octane
0.2
80% Octane
0.1 Pure Octane
0.0
0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
Temperature effectiveness Pc, exp
0.2
0.1
0.0
0.0 0.5 1.0 1.5
Number of transfer units NTUh
0.35
0.25
0.15
0.05
0.15 0.65 1.15 1.65
Number of transfer units NTUh
1.0
Temperature effectiveness Ph, pred
0.9
0.8
0.7
0.6
0.5
Pure Water
0.4 20% Kerosene
0.3 40% Kerosene
0.2 60% Kerosene
80% Kerosene
0.1 Pure Kerosene
0.0
0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
Temperature effectiveness Ph, exp
Figure 4.13 Thermal effectiveness comparison of model
vs. experiments in hot fluid for kerosene-water system
78
Pure Water
Cold Fluid
Temperature effectiveness Pc, exp
1.2
20% Kerosene
40% Kerosene
1.0 60% Kerosene
80% Kerosene
0.8 Pure Kerosene
0.6
0.4
0.2
0.0
0 2 4 6
Number of transfer units NTUc
Figure 4.14 Thermal effectiveness with number of transfer units in
cold fluid for kerosene-water system: From experiments
0.8
0.0
0 1 2 3 4
Number of transfer units NTUc
1.0
20% Dodecane
0.6 40% Dodecane
0.5 60% Dodecane
80% Dodecane
0.4 Pure Dodecane
0.3
0.2
0.1
0.0
0.0 0.5 1.0 1.5 2.0
Number of transfer units NTUh
0.2
0.0
0.0 0.5 1.0 1.5 2.0
Number of transfer units NTUh
1.0
Temperature effectiveness Ph, pred
0.9
0.8
0.7
0.6
0.5 Pure Water
0.4 20% Dodecane
40% Dodecane
0.3
60% Dodecane
0.2 80% Dodecane
0.1 Pure Dodecane
0.0
0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
Temperature effectiveness Ph, exp
Pure Water
1.0 Cold Fluid
Temperature effectiveness Pc, exp
20% Dodecane
40% Dodecane
0.8 60% Dodecanel
80% Dodecane
Pure Dodecane
0.6
0.4
0.2
0 2 4 6
Number of transfer units NTUc
Figure 4.20 Thermal effectiveness with number of transfer units in
cold fluid for dodecane-water system: From experiments
20 % Dodecane
0.9 40 % Dodecane
60 % Dodecane
0.8
80 % Dodecane
0.7 Pure Dodecane
0.6
0.5
0.4
0.3
0.0 2.0 4.0 6.0
Number of transfer units NTUc
1.0
Temperature effectiveness Pc, pred
Pure Water
0.9
20% Dodecane
0.8
40% Dodecane
0.7 60% Dodecane
0.6 80% Dodecane
0.5 Pure Dodecane
0.4
0.3
0.2
0.1
0.0
0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
Temperature effectiveness Pc, exp
20% Diesel
40% Diesel
0.4 60% Diesel
80% Diesel
0.3 Pure Diesel
0.2
0.1
0.0
0.0 0.5 1.0 1.5
Number of transfer units NTUh
Figure 4.23 Thermal effectiveness with number of transfer units
in hot fluid for diesel-water system: From experiments
83
0.10
0.05
0.1 0.3 0.5 0.7 0.9
Number of transfer units NTUh
1.0
Temperature effectiveness Ph, pred
0.9
0.8
0.7
0.6
0.5 Pure Water
20% Diesel
0.4
40% Diesel
0.3 60% Diesel
0.2 80% Diesel
0.1 Pure Diesel
0.0
0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
Temperature effectiveness Ph, exp
Pure Water
1.0 Cold Fluid
Temperature effectiveness Pc, exp
20% Diesel
40% Diesel
0.8 60% Diesel
80% Diesel
0.6 Pure Diesel
0.4
0.2
0.0
0 2 4 6 8
Number of transfer units NTUc
Figure 4.26 Thermal effectiveness with number of transfer units
in cold fluid for diesel-water system: From experiments
40 % Diesel
60 % Diesel
80% Diesel
0.95 Pure Diesel
0.90
0.85
2 4 6 8
Number of transfer units NTUc
Figure 4.27 Thermal effectiveness with number of transfer units
in cold fluid for diesel-water system: From Bes and
Roetzel Model
85
1.0
Temperature effectiveness Pc, pred
0.9
0.8
0.7
0.6
0.5 Pure Water
0.4 20% Diesel
0.3 40% Diesel
60% Diesel
0.2
80% Diesel
0.1 Pure Diesel
0.0
0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
Temperature effectiveness Pc, exp
20% Nitrobenzene
0.6
40% Nitrobenzene
0.5 60% Nitrobenzene
0.4 80% Nitrobenzene
Pure Nitrobenzene
0.3
0.2
0.1
0
0 0.5 1 1.5
Number of transfer units NTUh
Figure 4.29 Thermal effectiveness with number of transfer units
in hot fluid for nitrobenzene-water system: From
experiments
86
1.0
Pure Water
Temperature effectiveness Ph, pred
0.9
20% Nitrobenze
0.8
40% Nitrobenzene
0.7
60% Nitrobenzene
0.6
80% Nitrobenzene
0.5
Pure Nitrobenzene
0.4
0.3
0.2
0.1
0.0
0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
Temperature effectiveness Ph, exp
Figure 4.31 Thermal effectiveness comparison of model
vs. experiments in hot fluid for nitrobenzene-water
system
87
0.2
0.0
0 2 4 6
Number of transfer units NTUc
Figure 4.32 Thermal effectiveness with number of transfer units
in cold fluid for nitrobenzene-water system: From
experiments
0.9
0.8 Pure Water
0.7 20 % Nitrobenzene
40 % Nitrobenzene
0.6
60 % Nitrobenzene
0.5
80 % Nitrobenzene
0.4 Pure Nitrobenzene
0.3
0.0 1.0 2.0 3.0 4.0
Number of transfer units NTUc
1.0
0.9
Temperature effectiveness Pc, pred
0.8
0.7
0.6
0.5
0.4
Pure Water
0.3 20% Nitrobenze
40% Nitrobenzene
0.2 60% Nitrobenzene
80% Nitrobenzene
0.1 Pure Nitrobenzene
0.0
0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
Temperature effectiveness Pc, exp