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Home Resources Steam Engineering Tutorials Steam Engineering Principles and Heat Transfer
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Vessels can be heated in a number of different ways. This tutorial will deal with indirect heating. In these systems, the heat is transferred across a heat transfer surface. Options include: Submerged steam coils - A widely used form of heat transfer involves the installation inside a tank of a steam coil immersed in a process fluid. Steam jackets - Steam circulates in the annular space between a jacket and the vessel walls, and heat is transferred through the wall of the vessel.
Related Content
Tank Coil Heating
Browse a drawing and component sheet for a typical tank coil application.
Equation 2.5.3 The heat transfer area calculated is equivalent to the surface area of the coil, and will enable an appropriate size and layout to be specified.
Steam Tables
A comprehensive set of steam tables is available here.
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tanks, a significant pressure drop occurs along the length of the coil. To acheive the mean coil temperature, an average steam pressure of approximately 75% of the inlet pressure may be used. In extreme cases the average pressure used may be as low as 40% of the inlet pressure. Another variable is the coil material itself. The thermal conductivity of the coil material may vary considerably. However, overall heat transfer is governed to a large extent by the heat resistant films, and the thermal conductivity of the coil material is not as significant as their combined effect. Table 2.10.1 provides typical overall heat transfer coefficients for various conditions of submerged steam coil application. 'U' values for steam pressures between 2 bar g and 6 bar g should be found by interpolation of the data in the table.
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The range of figures shown in Table 2.10.1 demonstrates the difficulty in providing definitive 'U' values. Customary figures at the higher end of the scale will apply to installations that are supplied with clean dry steam, small coils and good condensate drainage. The lower end is more applicable to poor quality steam, long coils and poor condensate drainage. The recommended overall heat transfer coefficients will apply to typical conditions and installations. These recommended rates are empirically derived, and will generally ensure that a generous safety margin applies to the coil sizing. In the case of fluids other than water, the heat transfer coefficient will vary even more widely due to the way in which viscosity varies with temperature. However, the values shown in Table 2.10.2 will serve as a guide for some commonly encountered substances, while Table 2.10.3 gives typical surface areas of pipes per metre length.
Example 2.10.1
Continuing from Example 2.9.1 determine: Part 1. The average steam mass flowrate during start-up. (Mean heat load = 367 kW)
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Part 3. A recommended coil surface area. Part 4. The maximum steam mass flowrate with the recommended heat transfer area. Part 5. A recommendation for installation, including coil diameter and layout. The following additional information has been provided: Steam pressure onto the control valve = 2.6 bar g (3.6 bar a). A stainless steel steam coil provides heat. Heat transfer coefficient from steam/coil/liquid, U = 650 W/mC Part 1 Calculate the average steam mass flowrate during start-up Steam pressure onto the control valve = 2.6 bar g (3.6 bar a) Critical pressure drop (CPD) will occur across the control valve during start-up, therefore the minimum steam pressure in the heating coil should be taken as 58% of upstream absolute pressure. An explanation of this is given in Block 5.
Part 3 A recommendation for coil surface area Because of the difficulties in providing accurate 'U' values, and to allow for future fouling of the heat exchange surface, it is usual to add 10% to the calculated heat transfer area.
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Part 4 The maximum steam mass flowrate with the recommended heat transfer area Maximum heat transfer (and hence steam demand) will occur when the temperature difference between the steam and the process fluid is at its maximum, and should take into consideration the extra pipe area allowed for fouling. (a) Consider the maximum heating capacity of the coil Using Equation 2.5.3: = UAT
(coil)
Part 5 A recommendation for installation, including coil diameter and layout (a) Determine coil diameter and length
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From Table 2.10.3, a 100 mm pipe has a surface area of 0.358 m/m run. This application will require:
It may be difficult to accommodate this length of large bore heating pipe to install in a 3 m 3 m tank. One solution would be to run a bank of parallel pipes between steam and condensate manifolds, set at different heights to encourage condensate to run to the lower (condensate) manifold. The drain line must fall from the bottom of the condensate manifold down to the steam trap (or pump-trap). See Figure 2.10.1 for a suggested layout.
Fig. 2.10.1 Possible layout of coils in a rectangular tank Note the steam supply is situated at one end of its manifold, whilst the trap set is at the other end. This will help steam to flow and push condensate through the coils. In the application, the steam and condensate headers would each be 2.8 m long. As the condensate manifold is holding condensate, the heat from it will be small compared to the steam manifold and this
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The steam manifold should be 100 mm diameter as determined by the previous velocity calculation. This will provide a heating area of: 2.8 m x 0.358 m/m = 1.0 m Consequently 7 m - 1 m = 6 m of heat transfer area is still required, and must be provided by the connecting pipes. Arbitrarily selecting 32 mm pipe as a good compromise between robustness and workability:
CHECK It is necessary to confirm the steam velocity through the connecting tubes: On the basis of proportionality of heat transfer area, the steam header will condense:
This leaves 86% of the 850 kg/h = 731 kg/h of steam which must pass through the 18 connecting pipes and also into the lower (condensate) manifold.
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Fig. 2.10.2 Tank with a rising discharge pipe The seal arrangement allows a small amount of condensate to collect to act as a water seal, and prevents the occurrence of steam locking. Without this seal, steam can pass over any condensate collecting in the bottom of the pipe, and close the steam trap at the top of the riser. The condensate level would then rise and form a temporary water seal, locking the steam between the bottom of the riser and the steam trap. The steam trap remains closed until the locked steam condenses, during which time the coil continues to waterlog. When the locked steam condenses and the steam trap opens, a slug of water is discharged up the riser. As soon as the water seal is broken, steam will enter the rising pipe and close the trap, while the broken column of water falls back to lie at the bottom of the heating coil. The small bore dip pipe will only allow a very small volume of steam to become locked in the riser. It enables the water column to be easily maintained without steam bubbling through it, ensuring there is a steady and continuous condensate flow to the outlet. When the seal is ultimately broken, a smaller volume of water will return to the heating coil than with an unrestricted large bore riser, but as the water seal arrangement requires a smaller volume of condensate to form a water seal, it will immediately re-form. If the process involves articles being dipped into the liquid, it may not be convenient to install the coil at the bottom of the tank - it may be damaged by the objects being immersed in the solution. Also, during certain processes, heavy deposits will settle at the bottom of the tank and can quickly cover the heating surface, inhibiting heat transfer. For these reasons side hung coils are often used in the electroplating industry. In such cases serpentine or plate-type coils are arranged down the side of a tank, as shown in Figure 2.10.3. These coils should also have a fall to the bottom with a water seal and a small bore dip-pipe. This arrangement has the advantage that it is often easier to install, and also easier to remove for periodic cleaning if required.
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Fig. 2.10.3 Side hung coils If articles are to be dipped into the tank, it may not be possible to use any sort of agitator to induce forced convection and prevent temperature gradients occurring throughout the tank. Whether bottom or side coils are used, it is essential that they are arranged with adequate coverage so that the heat is distributed evenly throughout the bulk of the liquid. The diameter of the coil should provide sufficient length of coil for good distribution. A short length of coil with a large diameter may not provide adequate temperature distribution. However a very long continuous length of coil may experience a temperature gradient due to the pressure drop from end to end, resulting in uneven heating of the liquid. Whilst the next two headings, 'Sizing the control valve' and 'The condensate removal device' are included in this Tutorial, the new reader should refer to later Tutorials for full and comprehensive information, before attempting sizing and selection of equipment.
pass 850 kg/h of steam with a pressure of 2.6 bar g at the inlet of the control valve, and Critical Pressure Drop (CPD) across the valve. (Tutorial 6.4 will show how the valve size can be determined by calculation). A DN40 control valve with a larger K
vs
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If one valve is to be used, this valve must ensure the maximum heat load is catered for, while maintaining the required steam pressure in the coil to assist the drainage of condensate from it at start-up. However,
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The running load is 52 kW and with the coil running at 1.1 bar g, the running steam load:
The steam valve sizing chart shows a K of 2 is required to pass 85 kg/h with 3.6 bar upstream, operating
v
vs
cater for the start-up load. When approaching the control temperature, the larger valve would be set to shut down, allowing the smaller valve to give good control.
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Steam jackets
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the the the the
The most commonly used type of steam jacket consists simply of an outer cylinder surrounding vessel, as shown in Figure 2.10.4. Steam circulates in the outer jacket, and condenses on the wall of vessel. Jacketed vessels may also be lagged, or may contain an internal air space surrounding jacket. This is to ensure that as little steam as possible condenses on the outer jacket wall, and that heat is transferred inwards to the vessel.
Fig. 2.10.4 A conventional jacketed vessel The heat transfer area (the vessel wall surface area), can be calculated in the same manner as with a steam coil, using Equation 2.5.3 and the overall heat transfer coefficients provided in Table 2.10.4. Although steam jackets may generally be less thermally efficient than submerged coils, due to radiation losses to the surroundings, they do allow space for the vessels to be agitated so that heat transfer is promoted. The U values listed in Table 2.10.4. are for moderate non-proximity agitation. Commonly the vessel walls are made from stainless steel or glass lined carbon steel. The glass lining will offer an additional corrosion resistant layer. The size of the steam jacket space will depend on the size of the vessel, but typically the width may be between 50 mm and 300 mm.
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