Lecture 16 - Enhancement of Heat Transfer compact Heat Exchangers

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Kind: captions
Language: en

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Hello everyone. So, we are again back to the
course Heat Exchangers Fundamentals and Design
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analysis. Now if you recall ah we have given
some introduction and after that we have tried
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to have a ah have an overview of different
type of heat exchangers we are having, and
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I you should appreciate that this is a very
wide variety. And in that variety we have
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got different classification of heat exchangers
and one of the classification is based on
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the compactness of the heat exchangers.
So, heat exchangers can be ah divided into
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two groups compact heat exchangers and non
compact heat exchangers based on surface area
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per unit volume of the heat exchanger. Some
details I will ah or any of these factors
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we will try to provide as the course proceeds,
but this is one of the important classification
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of heat exchanger and then then ah we have
also seen that the compactness or the ah threshold
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of compactness based on some magnitude of
ah amount of surface area per unit volume
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of the heat exchanger, that varies whether
depending on whether our fluid is a gas or
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a liquid.
What we will do? We will ah explain some principles
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of ah of mentation heat transfer and then
some typical ah method of getting compact
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heat exchanger ah and design and analysis,
that is getting some sort of ah compactness
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in the heat exchanger with the use of extended
surfaces or fields that we will try to describe
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in few lectures to come.
So, today is the beginning this lecture is
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the beginning of that. At the beginning we
like to have an overview of ah what is what
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are the different methods of augmentation
of heat transfer.
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So, before that let us see what are the desirable
features of a good heat exchanger. The there
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are number of points, I do not claim that
the the points I have mentioned here are ah
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kind of ah flow. So, there could be some other
attributes or some other quality, but definitely
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I have ah jot it down the most important features
most important ah features we we expect from
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a good heat exchanger design like high heat
duty.
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Heat exchanger should have a high heat duty
of course, it should be qualified that for
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a given volume ah or given envelop say of
a heat exchanger, it should have the highest
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heat heat duty ah as far as ah possible as
far as practically by the ah technology available.
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Then low temperature difference. Basically
we are transferring heat between two streams,
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and the potential for this transfer process
is the temperature difference of the two streams.
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So, it is obvious that more the temperature
difference more will be the heat transfer,
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but can we have very large heat transfer with
a small temperature difference. So, that is
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the goal or that is the desirable feature
of the heat exchanger.
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Then compact size and less weight. Compact
size and less weight it is I mean always it
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is some ah goal of any engineering design,
ah because you see ah because you see that
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we have got restriction of this, we have got
cost of material, we have also the restriction
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for weight. Particularly if a system is a
mobile system we have got different implication
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if we go overweight ah. So, for all these
things compactness is one point; apart apart
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from that what we want to have? We want to
have less pressure drop.
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Generally what happens pressure drop depends
on many parameters, one of the ah most important
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parameter is the fluid velocity, but along
with this if the fluid within the heat exchanger
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has to pass a very long pathway, then there
will be high pressure drop. So, we have to
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also see that the pressure drop should be
low and up to these I have given different
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color because at the beginning or somewhere
in the course we are going on mentioning,
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that we you will look into the thermal hydraulic
aspects of heat exchanger may not be the other
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design aspects, other ah manufacturability
aspect. So, these four points are very important
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for us.
But on totality for an exchange for an engineer
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who is designing heat exchanger or ah working
on heat exchanger, see other points are also
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important these points could be less prone
to fouling ease of cleaning and maintenance,
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that is the serviceability of the heat exchanger
and over and above for any engineering system
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for any manmade system cost is a prime factor.
So, whatever we design our economy should
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allow that. So, we should have the lowest
cost of the heat exchanger.
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So, four points the for ah um point at ah
mentioned at the top, though those are very
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important as far as the thermal hydraulics
of heat exchanger is concerned. So, we have
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to have high duty high heat duty, we we ah
desire to have a low temperature difference
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between the two streams we; obviously, wants
to have our heat exchanger to be small and
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less weight light weight and there should
be less pressure drop.
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So, with these four points let us proceed.
So, how we can have it? So, basically we can
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have this four points we have told out of
that at least the first three points; that
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means, high heat duty, ah low temperature
difference and ah lesser lesser ah volume
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or weigh of the heat exchanger that we can
have with a very good ah or very effective
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way of heat transfer. And we can also argue
that if our heat transfer ah process is very
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effective ah very good very efficient, then
also we land up with a design where there
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will not be excessive pressure drop. So, this
comes that whatever normal heat heat transfer
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is there, we will try to enhance the rate
of heat transfer or augment the rate of heat
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transfer. This is very important particularly
for the heat exchanger industry, and also
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for other places like electronic component
cooling heat sink design etcetera.
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So, augmentation of heat transfer or enhancement
of heat transfer is a very special topic and
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very useful branch of heat transfer in general.
Now in heat exchanger normally there are three
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modes of heat transfer conduction conviction
and radiation, but as we are transferring
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heat in most of the cases from a moving fluid
to another fluid stream conviction is the
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main mechanism of heat transfer and if we
can improve the improve convictive heat transfer,
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then we have improved the heat transfer process
.
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So, first I have written augmentation of heat
transfer primarily give saving of material
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and energy whenever we are talking about advance
heat exchanger compact heat exchanger; obviously,
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one of the main goal is to reduce the size
of the heat exchanger. So, the basic energy
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balance equation the basic energy balance
equation what we can get ah ah the basic energy
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balance equation what we can get ah is that
let me highlight it. So, this is the basic
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energy balance equation for convictive heat
transfer.
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Q dot is equal to hA T w minus Tf. I have
shown it ah with the help of a hm ah ah with
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the help of an ah illustration, which is very
common to you this is some sort of a solid
00:09:17.530 --> 00:09:24.260
surface on which ah there is a flow of liquid
ah sorry flow of a fluid and the solid surface
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is kept at a surface temperature let us say
that is equal to ah T T valve and the fluid
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is flowing over ah the surface with a velocity
T infinity. So, on the solid surface there
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will be a velocity gradient ah due to formation
of boundary layer, there will be a temperature
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gradient due to the formation of thermal boundary
area.
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And heat transfer we depend on the difference,
that T infinity that is the temptrue of the
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fluid outside the thermal boundary layer and
T w is the temperature of the fluid ah T w
00:10:00.800 --> 00:10:09.420
is the temperature of the fluid on the surface.
So, Q will be ha T w minus T f. So, you see
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in this equation we want to maximize let us
say we want to maximize Q, our T w and T s
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are fixed, then we have got this quantities
hA h is the transfer coefficient and A is
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the surface area.
So, when we are going to augmentation of heat
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transfer particularly we are having single
phase fluid and the mode of heat transfer
00:10:37.920 --> 00:10:45.500
is convection, convection from the ah between
the wall and the ah fluid stream then we have
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to concentrate on h A; either separately or
as a combination . So, augmentation technique
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aim at modifying h A by improving h or A ah
if we go to the next slide ah well ah.
00:11:06.650 --> 00:11:19.410
So, before that let me tell you h A let let
me go back to our ah previous slide and sorry
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sorry let me go back to the previous slide
ok ah sorry for this small ah problem. So,
00:12:31.740 --> 00:12:38.250
ah what we see that here we are having h A
A is the area and h is the heat transfer coefficient.
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So, h depends on ah various thing that depends
on the ah course on the fluid property fluid
00:12:46.880 --> 00:12:52.390
velocity and the surface geometry.
Particularly the features which available
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on the surface. So, there are many ways of
increasing or ah sorry there are many ways
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of enhancing h, and there are ways of ah enhancing
a area or A also. There are some ways by which
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the combination can be improved; that means,
both h and A can be improved. So, you will
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see some of them ah. So, techniques of heat
transfer augmentation ah ah a class of technique,
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that those are known as passive techniques.
As the name suggest in this technique we do
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not need any power. ah We have some design
modification and with the design modification,
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we can have the ah heat transfer augmentation.
Like we can have treated surface, um there
00:13:45.020 --> 00:13:49.720
is some sort of a ah surface treatment. So,
that there are microscale features on the
00:13:49.720 --> 00:13:55.800
surface ah ah in case of ah phase change heat
transfer there could be the chemical features
00:13:55.800 --> 00:14:01.779
of the surface that could also be different.
Surface can be rough end ah there could be
00:14:01.779 --> 00:14:08.930
extended surface. While rough surface ah or
the ah treated surface gives feature of very
00:14:08.930 --> 00:14:17.290
small scale, extended surfaces or fields which
are as as they are known very ah popularly.
00:14:17.290 --> 00:14:25.600
So, these are large features present on the
surface and that increases the surface area.
00:14:25.600 --> 00:14:34.300
Then inserts and swirl devices ah which can
be ah put in the ah put e e inside the flow
00:14:34.300 --> 00:14:40.010
passage, then additives for liquids and gases
and then rib roughened surface ok.
00:14:40.010 --> 00:14:45.640
So, some of the then let us see we will have
a look and we will have some appreciation
00:14:45.640 --> 00:14:54.580
of some of this devices.
Ah Before that let us see ah this small illustration,
00:14:54.580 --> 00:14:59.580
here we have a corrugated surface which is
an I mean I have shown an exaggerated view.
00:14:59.580 --> 00:15:54.660
So, in this we have got this is the direction
sorry again we ah went forward. So, in this
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ah the features I have shown in an exaggerated
manner. So, basically there is not much change
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on the surface area, but due to the placement
of this feature, there will be change in the
00:16:06.050 --> 00:16:12.700
velocity field very near the ah wall and we
will have some increase in h.
00:16:12.700 --> 00:16:18.779
Ah . So, this is where we are increasing h
without increasing the area here I have shown
00:16:18.779 --> 00:16:24.630
one extended surface or field. So, basically
it is increase in the surface area and here
00:16:24.630 --> 00:16:31.480
there are offset strip fin ah. So, it is like
this that small small fins are ah placed in
00:16:31.480 --> 00:16:36.710
the staggered manner on the flow field or
in the path of the flow. So, on the field
00:16:36.710 --> 00:16:41.150
there will be boundary layer development,
but as the fins are small the boundary layer
00:16:41.150 --> 00:16:48.459
cannot develop infinitely, and cannot reduce
the ah rate of heat transfer that side of
00:16:48.459 --> 00:16:53.940
the field there will be vertex formation.
So, boundary layer will get some sort of an
00:16:53.940 --> 00:16:59.990
obstacle for further growth heat transfer
coefficient will start increasing, and at
00:16:59.990 --> 00:17:05.930
the same time the small fields they are giving
an increase in area. I would ah like to show
00:17:05.930 --> 00:17:13.409
you some other example as we proceed.
Here ah we have shown techniques for heat
00:17:13.409 --> 00:17:21.120
transfer ah augmentation, ah basically passive
augmentation. The a first one you see this
00:17:21.120 --> 00:17:26.030
is a tube, but the tube surface has been given
some sort of a shape so, that the boundary
00:17:26.030 --> 00:17:34.620
layer is disturbed and gives more heat transfer.
ah In ah the second one that is b ah or um
00:17:34.620 --> 00:17:42.330
b. So, there are some sort of micro field
over the ah um um over the tube surface. In
00:17:42.330 --> 00:17:50.130
ah c there are fin inside the tube different
kind of fins small small fins inside the tube,
00:17:50.130 --> 00:17:56.000
and these fins as they are small they are
not only they are not only ah and ah particularly
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when they are inside. So, they are not only
increasing the surface they are also ah giving
00:18:01.929 --> 00:18:07.560
a rise in the heat transfer.
D there is again ah on the tube geometry there
00:18:07.560 --> 00:18:14.340
are some variation so, that will give some
enhancement in ah heat transfer. ah Below
00:18:14.340 --> 00:18:22.520
what we can see ah below what we can see that
here ah we have got some sort of a tape insert
00:18:22.520 --> 00:18:28.450
here in this diagram, we have got a tape insert
inside the tube. So, the heat transfer will
00:18:28.450 --> 00:18:34.480
increase here ah the last one here we have
got some sort of wire insert inside the tube
00:18:34.480 --> 00:18:37.820
which will give good mixing and better heat
00:18:37.820 --> 00:18:46.150
And then active techniques; active techniques
means that we have to spend some energy more
00:18:46.150 --> 00:18:52.190
than what, we are spending for the fluid flow
additionally we have to spend certain amount
00:18:52.190 --> 00:18:59.160
of energy. So, there could be mechanical aids
like scraping or agitation, ah in case of
00:18:59.160 --> 00:19:05.820
many chemical reactors where heat exchanger
is also integrated with the reactor we have
00:19:05.820 --> 00:19:10.600
got this agitators.
Ah For viscous fluid we have got ah scrap
00:19:10.600 --> 00:19:15.280
surface heat exchange as I have mentioned
in some of the lectures earlier, then there
00:19:15.280 --> 00:19:22.280
could be surface vibration. So, all these
thing two goals are there, either we are trying
00:19:22.280 --> 00:19:30.200
to disturb the ah boundary layer, which gives
the main resistance to heat transfer and which
00:19:30.200 --> 00:19:36.420
falls on the wall. So, either we are trying
to disturb that or we are trying to give a
00:19:36.420 --> 00:19:41.520
good mixing to the bulk of the fluid. So,
by passive technique also we try to do that,
00:19:41.520 --> 00:19:46.880
and by active technique also we try to do
that. By passive technique we try to do another
00:19:46.880 --> 00:19:51.540
thing more that we sometimes try to provide
more surface area .
00:19:51.540 --> 00:19:58.820
So, surface vibration is one thing, as surface
vibration can give ah good amount of mixing
00:19:58.820 --> 00:20:05.260
then similarly fluid pulsation can give good
amount of mixing then electrostatic field
00:20:05.260 --> 00:20:11.820
this is very unique. So, if there is a dielectric
ah fluid, then we can provide some sort of
00:20:11.820 --> 00:20:19.720
a electro electrostatic field and with the
help of electrostatic field we can have ah
00:20:19.720 --> 00:20:29.300
we can have ah ah a ah good ah kind of transport
of the particles and that will give higher
00:20:29.300 --> 00:20:34.500
heat transfer.
Again these are particles which are micro
00:20:34.500 --> 00:20:42.220
scale particle fluid ah I mean ah the molecules
of the fluid, when they had a movement due
00:20:42.220 --> 00:20:48.500
to the electrostatic field so obviously, at
the microscopic level they produce some sort
00:20:48.500 --> 00:20:53.870
of agitation. When we are providing some sort
of mixer insert etcetera, that is providing
00:20:53.870 --> 00:20:59.170
agitation at the macroscopic level, but this
is at the microscopic level.
00:20:59.170 --> 00:21:09.570
Now, many cases we go for hybrid technique
and compound enhancement. ah Like ah ah two
00:21:09.570 --> 00:21:14.352
techniques are combined together, let us say
two passive techniques can be can be can be
00:21:14.352 --> 00:21:20.330
combined one passive and one active technique
can be combined and two active technique can
00:21:20.330 --> 00:21:27.009
be combined. Let me give one example and with
this example we can probably end our discussion
00:21:27.009 --> 00:21:37.900
So, here this is kind of a think of a fin
00:21:37.900 --> 00:21:45.390
tube ah ah. So, heat exchanger. So, first
what one can think that tubes are used for
00:21:45.390 --> 00:21:51.450
circulating some sort of a liquid and this
liquid has to be either cooled or heated.
00:21:51.450 --> 00:21:59.440
So, what we can provided that on on the on
on the outer surface of the tubes we can circulate
00:21:59.440 --> 00:22:05.410
some amount of gas.
But gas side heat transfer is small. So, what
00:22:05.410 --> 00:22:15.280
we can do to improve the gas side heat transfer,
we can provide ah extended surface ah or fin
00:22:15.280 --> 00:22:20.380
which is shown by this trick. So, now, you
can understand the arrangement. These are
00:22:20.380 --> 00:22:27.830
showing the tube cross section through which
your some liquid is passing; surrounding the
00:22:27.830 --> 00:22:35.179
tube we have got plate thin plate which will
act as an extended surface or fin, this will
00:22:35.179 --> 00:22:41.830
give augmentation of heat transfer and this
is a passive augmentation of heat transfer.
00:22:41.830 --> 00:22:50.240
So, this is the basic design and on this basic
design what I have done here we have provided
00:22:50.240 --> 00:22:58.880
rectangular inlet ah for alternatives. So,
when the fluid flow will take place. So, there
00:22:58.880 --> 00:23:05.850
some sort of a vortex will be created behind
this v inlet. So, fluid flow is ah taking
00:23:05.850 --> 00:23:12.750
from this side and behind this v inlet, we
will have some sort of a vortex which will
00:23:12.750 --> 00:23:18.590
give higher heat transfer due to the change
in the heat transfer coefficient.
00:23:18.590 --> 00:23:25.150
So, one passive technique is increasing the
surface area, the another passive technique
00:23:25.150 --> 00:23:30.780
is increasing the heat transfer coefficient.
Two different passive technique we have used
00:23:30.780 --> 00:23:40.380
and with that we are getting a much larger
heat transfer. So, ah . So, this is one way
00:23:40.380 --> 00:23:47.530
how we can combine two ah different augmentation
techniques together. Let me give some sort
00:23:47.530 --> 00:23:55.940
of ah concluding note for ah whatever we have
summary and concluding note for whatever we
00:23:55.940 --> 00:24:03.660
have discussed. Though we are calling passive
technique does not meet any kind of hm auxiliary
00:24:03.660 --> 00:24:11.000
power, but most of the passive technique we
have increase in pumping power. We have not
00:24:11.000 --> 00:24:18.750
to provide any kind of auxiliary device auxiliary
arrangement for power supply, new power supply
00:24:18.750 --> 00:24:26.130
obviously, but the ah fluid pumping power
that generally increases. So, this is one
00:24:26.130 --> 00:24:32.559
point people have to be careful when we are
selecting a particular augmentation technique
00:24:32.559 --> 00:24:37.000
that is one thing.
Second thing generally augmentation techniques
00:24:37.000 --> 00:24:44.720
when you adopt augmentation technique. So,
you have increase in initial cost, increase
00:24:44.720 --> 00:24:52.970
in weight and volume of the volume of the
heat exchanger or heat transfer device. So,
00:24:52.970 --> 00:25:02.540
this is also one point which needs to be considered.
Here again I like to mention one thing that,
00:25:02.540 --> 00:25:10.380
first what I have ah informed that either
we have to use auxiliary power or if we are
00:25:10.380 --> 00:25:17.320
using passive technique, then what we have
to do then what we have to do that we have
00:25:17.320 --> 00:25:26.710
to go for excess of pressure drop that pressure
drop penalty we have to admit.
00:25:26.710 --> 00:25:34.799
So, if we are admitting excess pressure drop
then what is happening? We are again spending
00:25:34.799 --> 00:25:44.240
some more amount of power ah. So, here some
reference from thermodynamics may be drawn,
00:25:44.240 --> 00:25:51.030
that we want to enhance the rate of heat transfer
for that we have to spend some amount of power.
00:25:51.030 --> 00:25:59.419
ah When we are trying to have more heat transfer
we are giving with a low grade energy, but
00:25:59.419 --> 00:26:04.650
when we are spending pumping power we are
dealing with a high grade energy.
00:26:04.650 --> 00:26:11.600
So, this is like this, ah it is like this
that we have to be very careful our heat transfer
00:26:11.600 --> 00:26:18.110
should be much more or from the energy point
of view, magnitude of energy point of view
00:26:18.110 --> 00:26:25.450
our ah ah ah rate of heat transfer enhancement
should be much more compared to the amount
00:26:25.450 --> 00:26:32.000
of pressure ah work we are spending for the
changing design. So, this is the one point
00:26:32.000 --> 00:26:41.710
you have to be very careful .
Performance evaluation of augmented surfaces.
00:26:41.710 --> 00:26:49.690
So, first thing what we can see that reduction
of size keeping delta tm and Q constant. So,
00:26:49.690 --> 00:26:56.460
this could be one way that suppose we are
keeping Q and delta tm constant that is the
00:26:56.460 --> 00:27:03.850
total amount of heat transfer and the hm and
the ah ah the ah mean temperature difference
00:27:03.850 --> 00:27:06.470
between the two fluid stream we are keeping
constant.
00:27:06.470 --> 00:27:12.960
So, whether we can reduce the size of the
heat exchanger by ah the augmentation techniques
00:27:12.960 --> 00:27:19.470
adopted. So, this could be one. Then then
the second one could be that reduction of
00:27:19.470 --> 00:27:26.549
ah delta tm keeping Q and size constant for
heat exchanger. So, let us say that earlier
00:27:26.549 --> 00:27:32.100
my process I have designed with a large temperature
difference between the two fluid streams now
00:27:32.100 --> 00:27:39.799
what I will do, I will have the same amount
of heat transfer I will have the same area
00:27:39.799 --> 00:27:48.950
ah ah rather same volume of the heat exchanger
ah, but I will be ah I have gone for ah augmentation
00:27:48.950 --> 00:27:53.650
technique. So, I will have lesser amount of
delta T m.
00:27:53.650 --> 00:28:01.320
So, this this could be also one goal and it
may be possible not in all cases, that by
00:28:01.320 --> 00:28:08.690
all these process as I have made my heat exchanger
very small. As I have made my transfer processes
00:28:08.690 --> 00:28:14.700
very efficient that I may achieve this with
a lesser pressure drop. So, this may happen
00:28:14.700 --> 00:28:21.360
this may not happen. So, it may be possible
to reduce delta p keeping q constant; however,
00:28:21.360 --> 00:28:26.450
compact heat exchanger generally aim at a
reduction in size. So, this is one thing we
00:28:26.450 --> 00:28:31.970
have to ah remember, that whenever we are
talking about compact heat exchanger generally
00:28:31.970 --> 00:28:36.820
we mean that there is a reduction in size
00:28:36.820 --> 00:28:43.920
Ah Let us quickly see that augmentation of
heat transfer during phase change boiling
00:28:43.920 --> 00:28:50.400
and condensation. So, this is initially I
have discussed ah what we should do for single
00:28:50.400 --> 00:28:57.750
phase flow, but when there is a phase change
ah the the principles are ah completely different.
00:28:57.750 --> 00:29:03.700
In case of boiling generally what we try to
do that some sort of a degree of super heat
00:29:03.700 --> 00:29:12.030
is needed between the solid surface and the
fluid for um ah for initiate nucleation. So,
00:29:12.030 --> 00:29:18.600
our surface design should be such that this
delta super fit is reduced; that means, basically
00:29:18.600 --> 00:29:25.039
we are we are reducing the effective temperature
difference between the surface and the fluid.
00:29:25.039 --> 00:29:30.200
The generation of more nucleation site, we
need to have more evaporations ah or more
00:29:30.200 --> 00:29:37.770
ah vapor formation. So, from much more many
more places there should be formation of vapor.
00:29:37.770 --> 00:29:43.730
Then increase in the range of nucleate boiling
ah actually ah I will touch up on boiling,
00:29:43.730 --> 00:29:51.170
but this is as we are discussing ah augmentation.
So, this point I want to tell, that nucleate
00:29:51.170 --> 00:29:57.570
boiling is a very high rate of heat transfer
and safe rate of safe ah method of heat transfer
00:29:57.570 --> 00:30:03.440
during boiling.
So, we want to increase its range ah temperature
00:30:03.440 --> 00:30:09.360
range basically and we want to increase the
magnitude of critical heat flus. Critical
00:30:09.360 --> 00:30:15.480
heat flux is again one heat flux probably
most of the you know it, because ah as the
00:30:15.480 --> 00:30:21.210
prerequisite of this course probably all of
you have attended heat transfer course and
00:30:21.210 --> 00:30:28.200
there you are familiar with different regimes
are ah of boiling. So, maximum heat flux that
00:30:28.200 --> 00:30:34.250
we can allow ah in many industrial equipment
is the critical heat flux, then if there is
00:30:34.250 --> 00:30:40.020
any excessive vapor formation. So, there should
be immediate removal of vapor .
00:30:40.020 --> 00:30:46.120
Condensation in condensation if we can have
ah drop wise condensation that is good and
00:30:46.120 --> 00:30:50.870
quick removal of condensate filed if we are
having film wise condensation. So, these are
00:30:50.870 --> 00:30:56.081
the method of augmentation in boiling and
condensation, probably we will revisit and
00:30:56.081 --> 00:31:02.800
ah see closely some of them when we will ah
ah learn about the phase change heat exchangers.
00:31:02.800 --> 00:31:10.620
. So, with this I like to come to an ah end
come to an end of this lecture and let us
00:31:10.620 --> 00:31:15.220
see some augmentation technique in detail
in our next lecture.
00:31:15.220 --> 00:31:15.830
Thank you.
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