Compact heat exchangers for transfer intensification _ low grade heat and fouling mitigation
Contents
Foreword....................................................................................................................xi
Preface.................................................................................................................... xiii
Authors....................................................................................................................xvii
Chapter 1
Introduction.................................................................................................................1
Acknowledgments.......................................................................................................8
References...................................................................................................................9
Chapter 2
Low-Grade Heat: Issues to Be Dealt With............................................................... 11
2.1 Waste Heat from Industry.............................................................................. 11
2.2 Waste Heat from Buildings............................................................................ 12
2.2.1 Sewage Waters.................................................................................. 12
2.2.2 Ventilation Air Exhaust.................................................................... 14
2.3 Waste to Energy............................................................................................. 16
2.4 Renewable Sources of Heat Energy............................................................... 18
2.4.1 Solar Heating.................................................................................... 18
2.4.1.1 Solar Ponds � 19
2.4.1.2 Solar Collectors................................................................. 19
2.4.2 Geothermal Heat...............................................................................20
2.5 Heat Pumps to Increase Heat Potential.......................................................... 21
2.5.1 Vapour-Compression Heat Pumps....................................................22
2.5.1.1 Mechanical Compressor Heat Pump Systems..................24
2.5.1.2 Ejector Compression Heat Pump Systems........................26
2.5.2 Chemical Heat Pumps......................................................................27
2.5.2.1 Absorption Heat Pump......................................................27
2.5.2.2 Adsorption Heat Pump......................................................28
2.6 Storage and Transport of Thermal Energy....................................................29
2.7 Low-Grade Heat to Power.............................................................................. 33
2.7.1 Organic Rankine Cycle.....................................................................34
2.7.2 Supercritical Rankine Cycle............................................................. 35
2.7.3 Kalina Cycle � 35
2.8 Requirements for Heat Transfer Equipment When Utilising
Low-Grade Heat.............................................................................................36
2.8.1 Small Temperature Differences........................................................ 37
2.8.2 Close Temperature Approach...........................................................38
2.8.3 Fouling Mitigation............................................................................38
2.8.4 Compactness and Limited Cost When Using Expensive
Materials for Heat Transfer Surface �38
References................................................................................................................. 39
© 2016 by Taylor & Francis Group, LLC
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Chapter 3
Compact Heat Exchangers........................................................................................ 41
3.1 Main Developments in Compact Heat Exchangers........................................ 41
3.2 Basic Principles and Terminology of Compactness....................................... 42
3.3 Heat Transfer Aspects of Compactness.........................................................44
3.4 Thermal and Hydraulic Performance of Different Heat Transfer Surfaces....... 49
3.5 Influence on Compactness of Heat Transfer Surface Geometrical Form
and Its Scaling Factor.....................................................................................54
3.6 Classification of Recuperative Compact Heat Exchangers............................65
3.6.1 According to the Hydraulic Diameter of Channels..........................65
3.6.2 According to Flow Arrangements of Heat Exchanging
Streams through the Unit �66
3.6.3 According to the Aggregate State of Heat Carriers..........................66
3.6.4 According to the Number of Streams in One Unit........................... 67
3.6.5 According to Construction Principles of Heat Transfer Surface...... 67
3.7 Examples of Industrial Compact Heat Exchangers........................................ 67
3.7.1 Compact Shell and Tube Heat Exchangers....................................... 67
3.7.2 Plate Heat Exchangers...................................................................... 72
3.7.2.1 Plate-and-Frame PHE....................................................... 73
3.7.2.2 Welded PHE � 79
3.7.2.3 Semiwelded PHE with Twin Plates...................................87
3.7.2.4 Special Design PHEs for Condenser
and Evaporator Duties.......................................................89
3.7.2.5 Brazed PHE �90
3.7.2.6 Fusion-Bonded PHE..........................................................92
3.7.2.7 Nonmetallic PHE..............................................................93
3.7.3 Plate-and-Fin Heat Exchanger..........................................................94
3.7.4 Tube-and-Fin Heat Exchanger..........................................................97
3.7.5 Spiral Heat Exchanger......................................................................98
3.7.6 Lamella Heat Exchanger................................................................. 100
3.7.7 Microchannel Heat Exchanger........................................................ 101
3.7.7.1 Printed Circuit MCHE.................................................... 101
3.7.7.2 Matrix MCHE................................................................. 104
3.7.7.3 Miniscale MCHE............................................................ 105
3.7.8 Non-Metal Compact Heat Exchangers........................................... 107
3.7.8.1 Polymer Compact Heat Exchangers................................ 107
3.7.8.2 Ceramic CHEs................................................................ 110
References............................................................................................................... 111
Chapter 4
Heat Transfer Intensification................................................................................... 115
4.1 Intensification of Heat Transfer for Single-Phase Flows inside Tubes
and Channels................................................................................................ 115
4.1.1 Artificial Roughness on the Channel Wall..................................... 115
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Contents vii
4.1.1.1 Flow Structure and Main Features of
Intensification Mechanism.............................................. 115
4.1.1.2 Evaluation of Enhanced Heat Transfer Surfaces
Performance in Compact Heat Exchanger Design.......... 123
4.1.1.3 Correlations for Heat Transfer and Friction Factor......... 128
4.1.2 Tubes with Inserts........................................................................... 137
4.1.3 Twisted Tubes................................................................................. 139
4.1.4 Extended Heat Transfer Surfaces.................................................... 142
4.1.5 Channels of PHEs........................................................................... 142
4.1.5.1 Flow Structure and Main Features of Heat Transfer
Intensification Mechanism in PHE Channels................. 144
4.1.5.2 Hydraulic Resistance of PHE Channels.......................... 147
4.1.5.3 Heat Transfer in PHE Channels...................................... 152
4.1.5.4 Analogy of Heat and Momentum Transfer in PHE
Channels and Accounting for the Influence of the
Prandtl Number on Heat Transfer................................... 161
4.2 Intensification of Heat Transfer for Two-Phase Flows................................. 174
4.2.1 Condensation Enhancement............................................................ 174
4.2.1.1 Film Condensation of Slow-Moving Saturated
Vapour on a Smooth Surface........................................... 176
4.2.1.2 Enhancement of the Film Condensation with
Vapour Action................................................................. 180
4.2.1.3 Enhanced Condensation Heat Transfer Surfaces............ 184
4.2.1.4 Condensation of Vapour from Mixture
with Non-Condensable Gas............................................. 187
4.2.1.5 Condensation Pressure Drop........................................... 189
4.2.2 Boiling in Compact Heat Exchangers............................................. 193
4.2.2.1 Heat Transfer at Flow Boiling in Compact
Heat Exchangers.............................................................. 195
4.2.2.2 Pressure Drop at Flow Boiling in Compact
Heat Exchangers.............................................................. 201
References...............................................................................................................203
Chapter 5
Advanced and Compact Heat Exchangers for Specific Process Conditions..............211
5.1 Influence of Geometrical Parameters on Heat Exchanger Performance..... 211
5.2 Parameter Plots for the Preliminary Design of Compact Heat Exchangers.....215
5.3 Influence of Plate Corrugations Geometry on Plate Heat Exchanger
Performance in Specific Process Conditions............................................... 216
5.3.1 Mathematical Modelling and Design of Industrial PHEs.............. 219
5.3.2 Prediction of Heat Transfer and Pressure Drop in Channels
Formed by Commercial Plates........................................................228
5.3.3 Best Geometry of Plate for Specific Process.................................. 231
5.3.4 Illustrative Example of Plate Geometry Selection..........................234
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viii Contents
5.3.5 Illustrative Examples of Plate Heat Exchanger Design
with Available Range of Plates....................................................... 237
5.3.5.1 Case Study 1 �238
5.3.5.2 Case Study 2 �240
5.A Appendix: Identification of Mathematical Model Parameters
for PHE Design....................................................................................................... 241
References...............................................................................................................246
Chapter 6
Fouling and Heat Transfer Intensity.......................................................................249
6.1 Effect of Fouling on Heat Exchanger Performance.....................................249
6.2 Forms of Fouling.......................................................................................... 251
6.3 Fouling Deposition Mechanisms.................................................................254
6.4 Fouling Models............................................................................................ 257
6.4.1 Reaction and Transport Models...................................................... 258
6.4.2 Initiation Period Models................................................................. 259
6.4.3 Ageing Models................................................................................260
6.5 Threshold Fouling Mechanism.................................................................... 261
6.6 Pressure Drop Associated with Fouling......................................................264
6.7 Fouling on Enhanced Heat Transfer Surfaces.............................................265
6.7.1 Fouling in Tubes with Artificial Roughness...................................266
6.7.2 Fouling in Tubes with Inserts......................................................... 267
6.7.3 Fouling in Channels of PHEs.........................................................268
6.7.4 Cooling Water Fouling in Channels of PHEs................................. 270
References............................................................................................................... 279
Chapter 7
Integration of Intensified Compact Heat Exchangers in a Heat Exchanger
Network...................................................................................................................283
7.1 Process Integration for the Synthesis of Energy-Efficient HENs................283
7.2 Superstructure Approach for Energy-Efficient HEN Design....................... 291
7.3 Hybrid Approach for HEN Design..............................................................292
7.4 HEN Design with Compact and Enhanced Heat Exchangers..................... 293
7.5 Estimation of Enhanced Heat Transfer Area Targets.................................. 295
References...............................................................................................................296
Chapter 8
Economical Consideration......................................................................................299
8.1 Energy–Capital Trade-Off...........................................................................299
8.2 Capital Cost Estimation...............................................................................303
8.3 Energy Prices...............................................................................................308
References............................................................................................................... 312
© 2016 by Taylor & Francis Group, LLC
Contents ix
Chapter 9
Industrial Examples................................................................................................ 315
9.1 Food Industry: Integration of a Heat Pump into the Heat Supply
System of a Cheese Production Plant........................................................... 315
9.1.1 System Description......................................................................... 316
9.1.2 Data Extraction............................................................................... 317
9.1.3 Heat Integration.............................................................................. 317
9.1.4 Heat Integration with Additional Compression.............................. 319
9.1.5 Economic Efficiency.......................................................................324
9.1.6 Conclusion ����� 324
9.2 Chemical Industry: Use of Intensified Heat Exchangers to Improve
Energy Efficiency in Phosphoric Acid Production...................................... 325
9.2.1 Process Description........................................................................ 325
9.2.2 Placement of Heat Exchangers in the Wet Process
of Phosphoric Acid Production....................................................... 327
9.2.3 Calculation for PHEs for Use in Phosphoric Acid Production....... 327
9.2.4 Closed Circuit Circulation for Barometric Condenser................... 332
9.2.5 Conclusion ���� 336
9.3 Heat Integration of Ammonia Refrigeration Cycle into Buildings’
Heating System............................................................................................ 337
9.3.1 System Description and Modelling................................................. 337
9.3.2 Heat Integration of Existing Refrigeration Cycle........................... 338
9.3.3 System with Additional Compression of Ammonia.......................340
9.3.4 Conclusion ���������������� 344
References............................................................................................................... 345
Index �347
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