BULGARIAN CHEMICAL COMMUNICATIONS

Volume 25, Number I, 1992

A SIMPLIFIED METHOD FOR DETERMINATION OF THE HEAT
TRANSFER AREA IN CASE OF HEAT INTEGRATION
OF TWO BATCH TANKS
Krasimira L. Peneva, Boyan B. Ivanov,
Natasha G. Vaklieva-Bancheva*
Institute of Chemical Engineering, Bulgarian Academy
of Sciellces, 1040 Sofia, Bulgaria
Received December 12th, 1991
A simplifed method is proposed for determination of heat exchange
parameters in cases of heat exchange between fluids in batch processing
tanks available simultaneously. Three versions of heat integration are
considered. A two-step procedure for determination of the heat par-
ameters is discussed and an example is given to illustrate the application
of the method proposed.
Kew words: batch processing tanks, heat integration, heat transfer area.
INTRODUCTION
Batch systems are wide-spread in food-processing and pharmaceutical industries
in the varnish and paint production, etc. Until recently attention has been directed
mainly on the development of design methods and optimum performance techniques
for batch-processing plants with the objective to minimize investment costs and pro-
duction expenses [1].
The deepening of the energy crisis during the last decade put forward the problem
of designing energy-conserving chemical plants. One way to solve this problem is
to develop technologies which ensure maximum heat utilization. In the past years,
due to the large relative part' of energy regarding the total costs by continuous pro-
duction, most of the numerous research and design projects treated predominantly
problems associated with continuous processes. During recent years, however, papers
appeared in the literature regarding the benefits of heat integration by batchwise pro-
cessing, Kem p and 0 e a kin, [2-4], Linn h 0 ff et a1. [!), 6], GI a vi c et a1. [7).
These studies are based on the wide-spread methods of analysis developed for con-
tinuous processes by Gun de r s e nand N a e s s [8].
Three configurations of tanks subject to heating and cooling with and without
fluid recirculation have been investigated by Vas e Ie n a k et a1. [9J. An analysis of fluid
temperature variation in time in the various units has been carried out. A heuristic
has been proposed to determine the coupling order for maximum heat utilization in
the studied system.
73
Considering various heat integration schemes, the present study presents an analy-
sis of heat exchange between fluids in two batch-processing tanks available simulta-
neously in time. A simplified method for determination of the main parameters of
the heat exchange equipment required is proposed, in a way to ensure maximum heat
recuperation for a predetermined time.
THE PRINCIPLES OF THE METHOD
1. Mathematical models in systems comprising hot and cold tanks
The systim under consideration includes two batch-processing units and an external
heat exchanger. Three basic schemes of heat transfer between hot and cold tanks are
considered, as illustrated in Figs la, 1b, and 1c, respectively. Vessell contains
a fluid, called hot !fluid, which has to be cooled from the initial temperature T~ to
the final temperature T~'. Similarly, tank 2 contains a fluid, indicated as the cold one,
which has to be heated up from the initial temperature T~ to the temperature T~'.
The difference between the schemes is that, according to one of them, the fluid is
returned to the starting tank forming a recycle, while in the other scheme, the fluid
is fed into another tank following the heat exchanger.
The following assumptions are valid in the analysis. (I) The tanks are well-mixed.
(2) Fluid heat capacities and flow rates as well as the overall heat transfer coefficient
are assumed constant. (3) Heat is exchanged in external countercurrent heat exchanger.
(4) The minimumdifference in temperature ATmln is known. (5) The heat loses are
negligible.
Accordingly, fluid temperature variation in time within the tanks is described
by the following relationships, Vas e I en a k et a1. [9J:
(l) With regard to the scheme illustrated in Fig. la.
Depending on the relationship of the heat contents per degree per time (Wh, We),
two cases are possible:
Case (a): At Wh>We
(1)
(2)
Th(T)=h1+h2exp(-k1 WeT),
Te(T)=CI-C2eXp(-k1 WeT).
HOT
-=1
COLD
2
no
Fig. 1a. Heat integration between two tanks including hot
and cold fluid recycle
74
HOT
~HOT
, -,- -i~
III
11
~.
I
I
o:;:n COLD
COLD
2
Fig. I b. Heat integration between two tanks without recycle
COLD
(HOT)
COLD
(HOT)
-- -
2
(1)
/'
HOT
(COLD)
, 1
(2)
Fig. Ie. Heat integration betweentwo tanks with single fluid
recycle
75
Case (b): At Wh<Wc,
(3)
(4)
ThCr)=h1+h2exp(-k1 Wh'r)'o
TcCr)= C1-C2 exp (-k1 Wh'r).
In these equations,
(VCp)P~ +~ T~~n)+(VCp)hT~
h1 = (VC ) +(VC). ,
peP h
(VCp)e(T~-T~-A T~n)
h2 = (VC ) +(VC ) ,
peP h
(VCp\ T~+(VCp)h(T ~-A T~in)
C1 = (VC ) +(VC )
,
peP h
(VCp)h(Til-T~-A T~~n)
c2=
(VC)+(VC )
,
peP h
(VCp) e+ (V Cp)h
k1 = (VC) (VC) .
PcP h
(2) With regard to the scheme illustrated in Fig. lb.
At the steady state, fluid temperatures in the supply and receiving tanks are con-
stant in time which renders the system analogous to the case of countercurrent heat
exchange in continuous units.
(3) With regard to the scheme in Fig. 1c.
Case (a). Cold fluid recyc1e.
The hot fluid temperature at the heat exchanger inlet is constant and equal to the in-
itial fluid temperature in the tank. The cold fluid temperature at the heat exchanger
inlet is equal to the fluid temperature in the tank at time 'r. Consequently,
(10) Te('r)= Th-~ Tmin-(Th- T~-A Truin)exp{- (V~:)eIt"},
at Wh> We,
while by Wb-s;;,Wc>
(5)
(6)
(7)
(8)
(9)
(11)
Te('r)=Til-ATmin-(T~-T~-ATmin)exP{-(~:)e 'r}.
Case (b). Hot fluid recycle.
The temperature of the cold fluid entering the heat exchanger remains constant
and equal to the initial fluid temperature in the tank. The temperature of the hot one
at the heat exchanger inlet is equal to the fluid temperature in the tank at time 'ro
For Wh>Wc:
,
ThC'r)= T~+A Tmiu+(Th- T~-A Tmin)exp {-(V~;)h 'r} 0
For Wh<We:
(13) ThC'r)= T~+ ATmin+ (Th- T~ - ATmin)oexp{'-:(~~:)h 'r}.
(12)
76
2. Determination of the heat transferred
within the system
In order to determine the heat which could be' recuperated in the two. fluid
systems, it is necessary to find the possible final temperatures (which are generalIy dif-
ferent from the desired values).
It is known that the limits, within which heat can be transferred physically in
a countercurrent heat exchanger, are as foIlows:
th-t~>A I~in
1
to-ti>A Tex
h c- min'
Ih- I~>A I~~n
In case of heat integration according to Scheme la with I~in =AI min, the following
limit temperatures can be obtained by using Eqs. (1, 2) or Eqs. (3, 4) at 1'->-co:
(14)
IUm- (VCp)c(T~+A Tmin)+(VCp)hT~
h - (VCp)c +(VCp)h .
TlIm- (VCp)cT~+(VCpMTh-A Tmin)
c - (VCp)c+(VCp)h .
In the case of heat integration according to Scheme 1b, the limit temperatures
which can be attained, are defined according to the relationship between heats Qh
and Qc' as well as according to the heat contents of the assigned fluxes (Wh' Wc),
regarding restrictions (14). Analysis of the relationships, reported in the literature by
Z h e 1e van d Boy a d j i e v [10], brings about those which are most suitable for use
in the case of Scheme lb. They are listed in Iable 1.
For the case of heat integration according to Scheme lc, the following limit tem-
peratures are valid.
a) By cold fluid recycle:
(15)
(16)
(20)
I
Um-
I
I A
T
(T
I
I
I A
I
)
J (VCp)h
}
c - h-ti min- h- c-timineXPt-(VCp\'
1
'lim
I
I (VCp)c
(T
I
T
I '.' A
I
)
{
1
(
(VCp)h
)} h = h-(VCp)h h- c-ti min -exp -(VCp)c .
(b) By hot fluid recycle:
'
T
I'
I
I A
T
(T
I
I
I A
T
)
{
(VCp)c
}
;m= c+ti min+ h- c-ti min exp -(VCp)h '
T
lim
I
I (VCp)l1
(I
I
I
I A
I
)
{I (
(VCp)c
)} c = c + ~VCp)c 11-;- c-ti min -exp - (VCp)l1 .
Ihe final temperatures, denoted as I~ for each hot tank, and I~ for each cold one,
which can be actually obtained, are defined according to the relationship between
the calculated limit temperatures, Ihimand Iiim, and the desired temperatures, Ih* and T~*,
as follows:
(17)
(18)
, (19)
(21a)
(21 b)
At I~'<T~m, Ig=I~m+(\.
At Th*>I~m, I~ = Ih".
77
Table 1
Relation
of Qho Qc
t~' t~ T~ - T~ T~ - T~
Qh = Qc
Qh>Qc
Qh< Qc
2
2: ATOlin
<ATmin
2:ATmin
<AT Olin
2: AT Olin
< ATOlin
2:ATmin
<ATmin
2:ATmin
3
2: AT Olin
2: AT Olin
<ATOlin
<ATmin
2:ATmin
?ATmin
<ATmin
< ATOlin
2:ATmin
4
t~ = T~ . t~ = T~
t~...T~-ATmin; t~ = T~- ~: (t~-T~)
Wh<Wc
t~= T~ + ATmin; t~ =0 T~ + ~: (T~- tb)
Wh =Wc
t~... T~ - ATmin:
Wh<Wc
t~ = T~ + ATmin
t~ = T~ + ATOlin:
to = TI + Wh (To - to)
0 0 We 0 II
Wh>Wc
t~= T~-ATmin: t~- T~-~: (t~-T~)
I ~
to = To : t~ "" Th- \Vh
0 0
Wh> Wc
t~= T~-ATmin; t~= T~- ~~ (T~-T~)
Wh<We
I Qc
t~=Th-Wh
at (t~- T~)2:ATmin:
t
o
T
O.
t
o -
T
I Qc
0 = 0 . h - h - Wh
at (t~ - T~ )<ATmin:
t~= T~+ATmln; t~= T~+ ~:(T~- t~)
Wh=We
t~= T~-ATmin;
Wh<We
t~ = T~ + ATmin
t~ = T~+ ATmin ;
t~= T~ + ~: (T~ - t~)
Wh>We
t~= T~- ATOlin ; t~ = T~- ~: (t~- T~)
t~... T~ ;
I Qh
to = To+ We
0
Table 1 (continued)
2 3
4
<~Tmin 2o~Tmin
t~ = T~ ;
I Qh
t~ = Te+ We
2o~Tmin < ~TmiD
t~ = T~+ ~Tmin ; t~ = T~+ ~h (T~- t~)
e
<~Tmin <~Tmn
Wh=We
t~ = T~ - ~Tmin ;
Wh<We
t~ = T~+ ~Tmin ;
t~= T~+~Tmin
to = TI+ Wh (
TI
h e We h
t~)
Wh>We
t~ = T~ -~Tmin ;
t~ = T~- We (to- TI)
Wh e e
(21c)
(2Id)
At To">TUm p>Tlim-o
e - e' e- e 2'
At To"< TUrn To = To'
e c' e e .
01 and 02 in Eqs. (21), are sufficiently small numbers.
The heats, Qh and Qe' required for cooling/heating of the fluids from temperatures
T~(TD to temperatures T~(T~). are
(22) Qh=(VCp)h(T~- T~).
and
(23) Qe= [VCp]e. (T~- T~).
respectively.
The maximum heat recuperation in a system, including both hot and cold fluids,
regardless of the heat exchange arrangement, is:
(24)
Q = min (Qh' Qe)'
3. Determination of the heat transfer area
Heat exchangers design proceeds in one of the following two ways. It requires
to determine:
- the heat transfer area, F, given the heat contents, Wh and We, and the inlet and
outlet fluid temperatures,}. e. t~, t~, t~, and t~, or
- the actual heat flux, q, realized in a heat exchanger if the heat transfer area
and the other parameters are known.
Given the initial temperatures and the final ones, defined in Section 2, the heat
contents of one or both fluids can be determined, in a way to ensure the heat Q,
accordingto Eq. (24), to be exchangedat time "Cf'
Where it is possible to determine only one of the heat contents (Wh or We), the
second one can be obtained from the equation
(25)
W TJim-TI
---E-- e e .
W -
T
I
T
Urn
e h- h
79
Table 2
I
Relation of
I
Scheme Wh and We
la
Whc:We
Wh:o;We
Ib
Equation
1
(
h2
)
We =-In ----
kI't1 T~ - bI
( T~im- TJ)
Wh = We (T~- T~im)
I
(
h2
)
Wh=--In 0
kI't1 Th - hI
We = Wh
(
TI - TUrn
)
h h
( T~im- T~)
Wh = (VCp)h
'tl
We = (VCpl<:
'tl
Ic
(a) Cold fluid recycle
Wh= (VCp)h
'tl
WhC: We
Wh<We
We = (VCp)e In
(
T~ - T~ - LlTm in
)
'tl T
I
I -- To - LlT .
] e mln
(
I TUrn
)
Th- h-
We = Wh 0~im- iD
(b) Hot fluid recycle We= (V<::p)e
'tl
Wh:o;We
Wh>We
Wh= (VCp)hln
(
T!,- T~-I1Tmin
)
'tl T~-T~-LlTmin
( T~im-TlL
Wh = We -CfI,--- T~im)
* Note: Coefficients kl> hI and h2> are determined according
and (6). respectively. .
Table 2 contains the equations for determination of the fluids heat contents in
the cases under consideration.
At known heat contents, inlet temperatures and overall heat transfer coefficient,
the heat transfer rate, q, in a countercurrent heat exchanger with surface area F is
determined as follows, Gel per i n [11]:
AtW =kW =W
(
ti_ti
)
(l-exp(-mKF)) ,
h, cog hh C
(
W
)
1- ~ exp (-m KF)
Wc
where "m" for a countercurrent heat exchanger, is defined by the equation
(26)
80
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
(11)
to Eqs. (9). (5).
(27)
(28)
1 1
m==w-w'
h c
At Wh=Wc, q=Wh(t~-t~).
The total heat, transferred at time 'tl' is determined by the following simple integral:
T,
Q= .f qd't.
0
A distinctive feature of the considered schemes is the time variation of fluid tem-
peratures at the heat exchanger inlet. In order to use Eqs. (26, 27, 29), it is necessary
to represent t~ and t~ as functions of time. Thus
(29)
t~=ThC'r) and t~=Tc('t),
where, depending on the scheme, ThC'r)is determined by Eqs. (1), (3), (12), or (13), and
Tlr) is determined by Eqs. (2), (4), (10), or (11).
At Wh= Wco(Eqs. 27, 29), the final temperature of the hot fluid can be deter-
mined, Ka n eve t z [12], by means of the equation .
(
30
)
. to-tl_
(
tl-tl
)
<I>e
h- h h c '
where the heat efficiency function <I>eis defined by
S
(31) <I>e= 5+1 '
whereas S is the number of transfer units given by
(32) S= KWF .
h
Substituting Eqs. (31) and (32) into Eq. (30) yields
to_tl
(
t' tl
)
K.F
(33) h- h- h- c' (K.F+Wh) .
Integrating Eq. (29) and after some transformations. the
tionships are obtained as follows:
1
(
Wh(WC-a
)
(34) F=mK In W (W -a) .
. c h /
heat transfer area rela-
at Wh=f:Wc'and
(35)
a.W
F= K.(W-a) .
at Wh= Wc= W, respectively.
Depending on the kind of heat exchange scheme employed, the value of "a" can
be determined by some of the following expression. Regarding Scheme 1a,
at Wh>Wc
(36) Q ,
a =
(
(T~- TIc-ilT~n
) ilT~nt,+(1-exp-(klW ct, kl Wc
6 Bulgarian chemical communications, 1
81
while
(37)
a= Q
(
AT~~n'rf+(I-exp (-k ~ 'r) (T\,- T~-AT~~n)
)
,
1 hi k W
1 h
at Wh<Wc'
With regard to Scheme 1b
(39)
a=
(ATmln'rl+
Q
a=~I
)
.
(Th -Tc 'rl
I c, by hot fluid recycle
Q
(T~- T~-ATmln)
(W c/( VCp)h)
where Wh>Vc'
(38)
Finally, regarding Scheme
(l-exp( -(V~;)h TI))) ,
(40)
whereas by Wh<Wc'
Q
a=
(
(T~ - T~-ATmln)
(
~--
(
Wh
)))
'
AT T I-ex - T
mln 1+ (Wh/(VCp)h) p - (VCp)b 1
At cold fluid recycle
(41)
Q
a-
(
I I
( (
W
)))
(Th-Tc-ATmln) c
ATmin Tf+ (Wc/(VCp)c) l-exp - (VCp)c TI
for Wh>Wc, and
(42)
Q
a
(
I 1
W
(Th-Tc-ATmin) h
ATmln'rf+ (Wh/(VCp)c) (l-exP( -(VCp)c Tf)))
for Nh<Wc'
Ill. APPLICATION OF THE METHOD
Byusing the described method, the parameters of an external heat exchanger can be
obtained regarding the various heat recuperation schemes shown in Figs la, Ib, lc.
EXAMPLE
Consider a scheme of two batch tanks: Vessell, containing hot fluid, character-
ized by the parameters, T~= 105C, T~*=25C, Vh=3.65 ms, Cp= 1448315J/ms deg;
and Vessel 2, filled with cold fluid, characterized by Ve=5.03ms, Cp=2031940 J/ms deg,
TI=20C To*=60C
c ' c .
For each scheme in Figs. 1a, band c, the following parameters can be deter-
mined: (1) the maximum amount of heat, Q, subject to recuperation, (2) the value of
heat transfer area, F, which ensures a predetermined recuperation heat. The overall heat
transfer coefficient, K, is assumed constant and equal to 250 W1m2 deg. The minimum
temperature differences are AT~~n=ATmiD = lOoc.. The time required for heat transfer,
'tf>is I h.
Table3
Following a check up of the heat exchange physical feasibility by using Eqs. (14)
the following parameters are determined consecutively by means of the suggested
method:
- The limit temperatures T~imand T~!m.
- The final fluid temperatures T~ and T~.
- The maximum heat, Q, that can be recuperated in a system considered and
- The heat contents ratio Wh/Wc'
These data are used to calculate the heat transfer area, F, which ensures the ex-
change of a predetermined heat Q.
The results obtained, regarded to the schemes in Figs la, 1b, Ie, are summarized
in Table 3. It can be seen that the maximum heat recuperation is ensured in the case
of Scheme 1b. When this arrangement cannot be realized practically, it is recommended
Scheme 1c.
CONCLUSIONS
A method is proposed for determination of the parameters of heat exchange equip- .
ment involved in heat transfer between fluids in batch-processing tanks. The heat
supply and heat receiving tanks are available simultaneously.
Three versions of heat integration are considered.
A two-step general procedure for determination of the relevant heat parameters
is proposed, including: (I) Determination of the recuperated heat and the correspond-
ing final temperatures of the system, and (2) Determination of the area required for
heat transfer.
An example is given to illustrate the application of the method, and it is shown
that best heat integration can be obtained by the arrangement shown in Fig. 1b.
The suggested method of heat integration in batch vessels is suitable for solving
.design and reconstruction problems in batch-processing plants in view of their maximum
internal heat utilization.
T~. T~
T~*.T~
T~m . T~!m
To To
h' c
Th('t)
Tc ('t)
11Tmill
NOTATION
- initial temperatures of the hot and cold tanks, deg
- desired final temperatures of the hot and cold tanks, deg
- limit temperatures of the hot and cold tanks, deg
- final temperatures of the hot and cold tanks, deg
- temperature of the hot tank at time 't, deg
- temperature of the cold tank at time 't, deg
- minimum difference in tank temperature, deg
83
Tl Tr
T T*
Q.lO-s
T T F
Scheme
----
-
C C C c J c
c m2
1a 105 25 20 60 2.466 58.3 44.1 18.1
Ib 105 25 20 60 4.088 27.7 60.0 21.5
(a)
105 25 20 60 3.391 40.8 53.2 15.7
Ic
(b)
105 25 20
60 3.096 46.4 50.3 16.3
t~. t~ - hot and cold fluid temperatures at the heat exchanger inlet, deg
t~. t~ - hot and cold fluid temperatures at the heat exchanger outlet, deg
V - fluid volume in a tank, m3 ~ -
Cp - specific heat capacity of fluid, Jjm3 deg
(VCph - heat content per degree for the hot tank, Jjdeg
(VCp)c - heat content per degree for the cold tank, Jjdeg
v - fluid flow rate, m3js
Wh=(v . Cp)h - heat content per degree per time for the hot tank, Jjdeg. s
Wc=(V. Cp)T - heat content per degree per time for the cold tank, Jjdeg. s
.1T~~n - minimum temperature difference in the heat exchanger, deg
K - overall heat transfer coefficient, Wj(m2. deg)
F - heat transfer area, m2
q - heat flux, W
Q - heat exchanged between fluids, J
Qh - heat suppliedby the hot fluid, J
Qc - heat received by the cold fluid, J
'tf - final time, s
't - time, s.
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