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*For identical temperature equalization in the egg the Fourier number must be Fo = atfd 2 =
constant, i.e. for all eggs:
boiling time x (mass)- 213= constant
is valid. Knowing the optimal bojling time for one species of egg, we can thus predict the boiling
time for other eggs, even ostrich eggs.
Contents
INDEX 296
CHAPTER I
r--1--------,I
I
<l>v, out
I
V, r
1
I I
L-----------J
Figure J.l Macrobalance
The accumulation per units of volume and time can now be denoted by dX/dt ;
hence, the accumulation in the system per unit of time is given by VdX/dt.
A flow at a rate cf>v, containing a volumetric concentration X of the considered
quantity, represents a flow rate <l> vX of this quantity. Hence, our formulation of
the conservation law reads as follows:
(1.2)
We will now apply this law to the following quantities: money, mass, energy
and momentum.
T he money balance
Let us start with the most common daily practice, the conservation law fo r
pocket money (the pocket being defined as the system, although some operate
is very unsystematically). The number of pence in the system is given by X
( J = 1), and equation (1.2) can be read as follows: the accumulation of pence
*In order to be com pletely exact we have to write this eq uation as :
- u
dX - 1 -1
vdt = cl>u, inxin- rPu,oulxOUI + Vr
""'here - . ndic.ltes a volume average a nd -!a fl ow a verage.
5
in my pocket pt;r week (which may prove to be negative!) equals the difference
between the number of pence I have taken in during this week and the number
I have spent in this time, increased by the number of pence I produced in the
meantime. The last contribution sounds somewhat cryptic or even illegal, but
an honest production of pence would be to change other coins into pence.
Similar laws can be expressed for the other coins, as well as for the overall
contents of the pocket (moneywise). From all these statements it follows that
the sum of all the production terms r must equal zero (expressed as an intrinsic
value and not as numbers) or, to put it in another way, changing in its own
currency never results in a positive gain. To find out how simple these statements
might be, try and see what happens to your thinking when X no longer stands
for money, but for mass, energy or momentum!
The mass balance
The mass balance still looks familiar and comes close to the money balance.
Here X = cA, the volumetric concentration of component A in a mixture; the
units in which cA is measured are kg/m 3 *
Hence, in a rayon factory, for instance, where NaOH (in the form of viscose)
and HCl (in the form of the spinning bath) are used, the conservation law for
NaOH {A) reads as follows: the accumulation of NaOH on the site in a month
(or any other chosen time unit) is equal to the delivery ofNaOH to the factory
in that time, subtracting the amount of NaOH distributed from the site in that
unit of time as NaOH and adding the amount ofNaOH produced in the factory
during that time (a production which is negative where NaOH is used as a
reactant).
A similar mass balance can be set up for the other reactant, HO (B), as well
as for the products NaCl (C) and H 2 0 (D). Again, the sum of all individual
production rates must be zero: r A + r 8 + rc + r0 = 0 (Lavoisier:t. More olten
than not, the accountants of a factory are more aware of the implications of the
conservation laws and the dynamic consequences of varying inflows and out-
flows of a factory than the engineers in charge of production.
v c
The wellstirred continuous flow tank reactor of Figure I.2 gives an example
of the applications of the mass balance. By 'wellstirred' we mean that the
* F rom the onset, we will accept kg, m, s, oc as the basic units for comparing physical phenomena
(paragraph 1.4).
6
concentration c of a certain compound (e.g. salt) is the same at all. places in the
vessel so that the salt concentration in the effluent stream equals the con-
centration in the vessel. Let us assume that the salt concentration in the vessel
at time t = 0 is c 0 and that, from t = 0 on, a continuous stream of pure water
(salt concentration c = 0) is passed through the vessel. The question is then
how does the salt concentration in the vessel change with time?
We can now set up two mass balances, one for the water and one for the salt.
The first balance says that, if the liquid volume in the reactor is constant, the
flow rate of liquid out of the reactor must equal the flow rate into the .reactor,
<l>v,out = <l>v.in . The second balance says that the decrease in the amount of salt
in the vessel (Vc) per unit of time must equal the mass flow rate of salt from the
vessel (</>vc). Thus :
d(Vc) =
0 _ c
dt v
or:
de c
- =
dt r
where r = V f4>v is the mean residence time of the fluid in the vessel. Integration
between t = 0, c 0 and t, c yields:
.:_ = exp
Co
(!)
T
f/ T -
Figure 1.3 Change of salt concentration in
stirred vessel
This function is shown in Figure 1.3, which shows that at the time t = 't still
3"" per cent of the initial salt is present in the reactor. For t = ir and ~r these
values are 65 and 22 per cent respectively. Apparently, the liquid in the reactor
has a large distribution of residence time.
7
The energy balance
Before we can attempt to interpret equation (1.2) in terms of an energy
balance, we must define the meaning of X as ' the volumetric concentration of
energy' Er. This quantity will contain internal energy and potential energy.
Internal energy again comprises perceptible and latent heat and pressure
energy. Pressure energy per unit of volume is nothing but an elaborate expres-
sion for merely the pressure inside the volume. Perceptible and latent heat per
unit of volume (U) may be expressed as :
(1.3)
in which p is the specific gravity, cP the heat capacity per unit of mass, T the
temperature, T, a reference temperature for calculating U, !J.H the latent heat
per firstorder phase transition (melting, evaporation) per unit mass and La
symbol to indicate that the contributions of all phase transitions between T,.
and T have to be taken into account. If the process studied does not show phase
transition, the reference temperature T,. can be chosen high enough to keep
latent heats out of the analysis. If, furthermore, the heat capacity per unit of
volume (p cp) is independent of temperature, U = pcP (T - T,).
The kinetic energy per unit of volume is fpv 2 , when v is the velocity of this
volume. If different elements o f the volume flow have different velocities, then
the flow average of the squared velocity has to be used for calculating the flow
of kinetic energy, <Pv !p(v 2 ) , with
1 1f pv 2 v dA
2p <v ) =
2
2 f v dA (1.4)
(1.7)
where I Fx indicates the sum of all forces acting in the x-direction. The balances
for the y- and z-directions can be written analogously. The dimension of all
terms in the above balance is the Newton (N).
L,
Figure 1.4 Pipe corner
dE,
V dt = Q = <l>v.inEr,in - v,outr ,out + </>A - </> H (1.8)
dpvx
V dt = 0 = pv 1 A 1v 1 - pv 1 A 2 0 + '-
"
Fx (1.10)
The second term on the right-hand side of this equation expresses the fact that
no momentum in the x-direction is taken away with the fluid. The forces acting
in the x-direction on the liquid are the pressure force p 1A 1 and the reaction
10
force the wall exerts on the liquid, Fx,w- 1 , thus:
L Fx = P1A1 + Fx,w- f (1.11)
and combining equations (1.10) and (I.ll) we find for the momentum balance
in the x-direction :
dpvx 2
vdt = 0 = pv1A 1 +PIAl+ Fx,w- J
Thus the wall has to produce a force in the negative x-direction and withstand
a force Fx.J- w ( = - Fx,w- 1 ) in the positive x-direction (action equals reaction-
first law of Newton). This force equals the sum of the pressure force and the
force which is caused if all the momentum of the flowing liquid is taken up by
the wall*:
Fx,w- f = - Fx,J-w = - pvtAt - P1A1 (I.12a)
Analogously to the above, we can develop a momentum balance for the y-
direction and find that the force the liquid exerts on the wall in the y-direction
is given by :
(I.l2b)
- - -- -
Fy,fw=-pv~A2-p2~ i /
L_ J~:LA~ -
2
y I
With this information the resulting force of the fluid on the wall can be con-
structed as shown in Figure 1.5. The pipe corner must be fixed in such a way
that these forces can be taken up by the holding structure.
In the above example we have assumed that the velocity distributions of
the liquid entering and leaving the pipe are uniform and that there are no
velocity differences over the cross-section. In that case, the momentum of the
inf.owing liquid is indeed pvi A 1 . If the above assumption of uniform flow
P:a~ :ca! technical flow velocities in pipes are 1 m/s for liquids and 15 m/s for gases. The reader
rna~ check that the momentum force on a pipe comer is mostly negligible as compared to pressure
forcu
11
vr
velocities is not allowed, we have to write p(vT)A 1 , indicating that must be
averaged over the cross-section. Since pA 1 (vr) = <Pm<v~)/(v 1 ) we say that the
momentum per unit mass is given by (vi)/(v 1 ). For the same reason we write
(v 3 )/2(v) for the kinetic energy per unit mass. Such expressions for physical
.quantities averaged over the flow will be found regularly in our discipline.
In the foregoing paragraph we have defined the various terms in the balances
based on the three laws of conservation. In so doing we-have concentrated on
transport with the flowing fluid, the so-called convective transport caused by
movement of the molecules, and neglected the statistical transport. We have
mentioned briefly the conduction of heat through the boundaries of a system
as a means of heat transport, viscous friction as a means of momentum transport
and viscous dissipation as a possible contribution to heat transport.
The opportunity of introducing diffusion of matter through the system
boundaries as a means of transporting a component has been missed until now.
Together with heat transport by conduction and momentum transport due to
viscosity, diffusion of matter is the third molecular process which is of interest
to us.
It might be imagined that a difference in the concentration of a component
on both sides of a boundary enhances a net mass flux through that boundary
because of the Brownian (heat) movement of the molecules of this component:
the bruto flux from the side of the higher concentration will override the bruto
flux from the other side, simply because more of the specific molecules are
present on that side while each has an equal chance to pass the boundary at a
given uniform temperature. Brownian motion also explains the conduction of
heat: a temperature gradient over the system boundary produces a net flux of
energy, because the molecules on the hotter side move faster and carry a
higher energy.
Molecular movement again is a reason for stress in a flow field with a velocity
gradient. Due to Br:ownian movement molecules are exchanged in all directions
and hence also in the direction of the gradient. Those coming from the faster
moving side have a higher velocity in the direction of flow and, hence, carry a
bigger momentum "th~ those coming from the slower moving side. This
results in a net flux of momentum from the faster flowing area to the slower
moving parts or, in other words, slow neighbours try to decelerate fast nt:igh-
bours and vice versa. So, a net transversal transport of momentum-in-the-
direction-of-flow can be interpreted as stress. It is good to notice again the
vectorial character of momentum flow: both the direction of transport
(transversal) and the direction of the quantity transferred (longitudinal) are
important. This means that in an arbitrary plane, stresses in all three directions
can be found when velocity gradients in all these directions are present.
Transport of heat, mass or momentum by molecular processes is sometimes
called statistical transport because it is caused by the random Brownian
12
movement of the molecules.* Statistical transport is usually much smaller than
convective transport, unless very low flow velocities occur. For this reason
statistical transport in the direction of flow can mostly be neglected.
Our elaboration of the conservation concept has to account for mass, energy
and momentum fluxes due to processes on a molecular scale. Generally, these
fluxes are found to be proportional to the gradient dX/dn, where n denotes the
coordinate in the direction perpendicular to the considered plane. The pro-
portionality constant between the flux and the driving force dX jdn is known as :
the mass diffusivity, [},in the case of mass transfer (Fick's law),
the thermal diffusivity, a = 2/ pc 9 , with 2 being the heat conductivity, in the
case of heat transfer (Fourier's law)t and
the kinematic viscosity, v = 11/ p, with 17 being the dynamic viscosity (Newton's
law).
The dimension of each of these constants is m 2 /s.
When " denotes the flux (the flow rate per m 2 ) of the quantity X due to
molecular movement in a gradient of X, we thus writet:
dX
</>" = - (0 or a or v)- (I.l3)
dn
The minus sign denotes that the net flux is positive in the direction of diminishing
concentrations of X. Thus the mass, beat and momentum fluxes in the positive
direction of n are given by :
Figure 1.6 illustrates the above relations for mass and heat transport caused by
a concentration or temperature gradient.
* Besides statistical molecular transport there can also occur statistical transport
by eddies (para-
graphs 11.2, 111.3.2 and IV.3.3). We speak of laminar flow if there is only statistical molecular
transport.
t Here, heat transfer has been used deliberately as a description which is not completely s1rnilar
to energy transfer. Heat transfer accounts only for the transport of perceptible and latent heat,
not fo: the transport of other forms of energy.
! The :-elation between momentum flux and velocity gradient discussed here is restricted to New-
tamar. llquids. For non-Newtonian liquids more complicated relations exist which will be
discussed i:n the next chapter.
13
.~... I
't"m orH "
= _ ( "'
" ora
) d ( c or pcp T)l
, "o dn no
...
0
Q
"o
___ ,
Figure 1.6 Diffusion and heat con-
duction
In the case of momentum transport there is the extra complication that we
have not only to specify the plane through which the transport occurs (e.g.
x = x 0 ) but also the direction of the momentum considered (e.g. y). The cor-
responding momentum flux is then written as F; 1 , indicating that there is
transport of y-momentum in the x-direction at the plane x = x 0 caused by a
velocity gradient dvy/dx. In other words, viscous shear is transversal transport
oflongitudinal momentum, as indicated in Figure I. 7. This momentum transport
represents itself as shear which, per unit of surface, is called the shear force -r.
Thus the momentum flux F~Y corresponds with a shear force txy in they-direction
r; I x
Y
= - "d IP vy l
dx
I .t0
0
r xy I xo =- " d ( p Vy )
dx
I
j
X0
- - x
Figure 1.8 Shear in terms of shear forces
14
at x = constant. This is illustrated in Figure I.8. The exact definition of the shear
force needs, therefore, a statement of the plane and direction considered, e.g. :
d(pv)
-rxy = - v dx
The shear force is defined in such a way that the force the left-band fluid exerts
on the right-hand fluid is positive if the gradient {from left to right) is negative.
We have seen in the foregoing that the statistical molecul~r transport through
a plane can be described quantitatively with equation (1.13) if the proportionality
constant([), a or v) and the gradient at that plane is known. In practice we are
interested in transport through a plane fonning the boundary of a system
(e.g. a wall, an interface, etc.), but, alas, often the concentration gradient at the
boundary is not known beforehand and a practical approach has to be followed
when qualifying the flux. In these cases, empirical phenomenological transfer
coefficients are used, which are defined as follows :
_[) de
4>~ = = k(coo - cw) (1.14a)
dn w
d(pcPT )
</>"n-
- - a =~Teo- T..,) (1.14b)
dn w
d{pv)
rw = - v dn
-- w = (;pv)(v- Vw) {l.14c)
The velocity at a solid wall is zero, which is one of the hypotheses on which hydrodynamics rests;
~ence vw nearly always equals zero.
15
where ii is the mean velocity of the molecules ( ~ -)2RfiM) and I the mean free
path of the molecules (--Mf p = RTj p). At normal pressure and temperature
for gases. D. a and v are of the order 05-2 x lo-s m 2 f s. The kinetic theory
further
predicts that 11 and .A (the thermal conductivity = a . pc p) for ideal gases
are mdependent of pressure and that they are approximately dependent on the
square root of absolute temperature.
For the diffusion coefficients of liquids at room temperature we find values
of the order 0) = 10- 8 -10- 9 m 2 js ; for other temperatures diffusivities can be
estimated by means of the Einstein- Nemst- Eyring relation D17/ T = constant,
where 11 is the viscosity of the solvent. The viscosity 11 of liquids varies widely
(e.g. at 20C for water '1 = 10- 3 Ns/m 2 , for glycerol 11 = 15 Ns/m 2 ) and is
strongly dependent on temperature ; in the first approximation t7 - exp {1/ T).
The termal diffusivity of liquids is about a ~ 10- 7 m 2 js with the exception of
molten salts and liquid metals, which show considerabTy higher thermal
diffusivities.
The diffusion coefficients of solid materials at room temperature are of the
order I!)~ 10 - 11 - 10 - 13 m 2 js. The thermal diffusivity of non-metallic solids is
roughly a ~ 10- 7 m 2 js, while metals belong (because of the effective heat
transport by the free electrons) to the best heat conductors (a ~ 5-100 x 10- 6
m 2 f s). Also, solid materials have a very high viscosity. The ratio of the viscosity
and the elasticity modulus (having the dimension of time) gives an impression
of the time necessary before an initially elastic deformation can be observed as
flow. On the other hand, many liquids (e.g. molten polymers) show elastic
behaviour. For these liquids the time necessary before flow is observed is
generally much greater than 01 sand it is therefore not possible to describe the
flow of these materials by means of a simple shear stress- velocity gradient
relationship, because the previous history of each particle has to be included in
the description. These problems belong to the area of rheology and we will not
go into more detail here.
1.3. Microbalances
In some cases th~ concentration, temperature and flow velocity distributions
in a system can be cal~ulated by starting with the principle of conservation and
applying this principle to every small volume element of the system. This leads
to the so-called micrQ.balances, as compared to the macrobalances of the
foregoing section (I.l .) which give no insight into the distribution of the quantity
over the system. These microbalances can be formulated in a general way, as
will be shown below. However, the partial differential equations which will
emerge from this microconcept can be solved only for relatively simple situ-
ations. Therefore, dependence on equations (I.14) is daily practice, but the idea
behind a practical correlation for the transfer coefficients is often based on a
fundamental analysis of a somewhat simplified and idealized situation which
can still be treated analytically. Let us, therefore, see how we arrive at a micro-
balance.
16
Let us consider a Cartesian element (Figure 1.9) of volume dx dy dz, where
x, y and z are the three coordinates in space. The accumulation of the quantity
X considered per time interval dt in the system is now given by :
dX
dt dx dy d2 (115)
(1.16)
where :is the flux of the quantity X in the x-direction. Similar expressions hold
for the net flow into the system in the y- and z-directions. We can therefore
write equation (1.1) for an infinitesimal volume element as :
dX d" dq/' de/>"
-dxdydz
dt
= --"
dx
dxdydz-
dy
dx dydz- _ z dxdydz + r dxdydz
_Y
dz "
or
dX d; d; dtp;
- = - -----+ r (1.17)
dt dx dz
dy
Equation (117) is the basic microbalance which can be further evaluated When
doing so, we have to realize that the flux of X on this microscale consists of a
convective transport term and a statistical transport term. These fluxes in the
n-direction are therefore given by* :
dX
4>~ = -([}or a or v) dn + v,X (1.18)
dp d(t.'xP)
-=--- (1.20)
dt dx
(1.22)
which is valid for all rheologies. Here X stands for pv. The momentum pro-
duction term in the n-direction is the sum of the pressure and gravity forces
acting in that direction-on the control volume:
dp
rn = - -dn + pgn (1.23)
With the above expressions we obtain from equation (I.17) for the micro-
momentum balance in the x-direction :
dt
(1.24)
18
With the aid of the continuity equation (1.20) this expression can be simplified
to :
d vx dvx d v.x dvx dT.x.x dTy.x dT:x dp )
P dt = - pv - - pv - - pv - - - - - - - - - + pg {1.25
x dx , dy z dz dx dy dz dx x
and
dvz dvz dvz dvz d-rxz d-ryz dtzr dp (l. 27)
p - - = - pv - - pv - - pv - - - - -- - - - - + pgz
dt x dx Y dy z dz dx dy dz dz
If, instead of a Cartesian volume element in rectangular coordinates, we had
considered a volume element in cylindrical coordinates-, as indicated in Figure
1.10, we would have obtained the following micromomentum balances in the
' z
r-direction :
p dv, = _ p {v dv, + v dv, _ vi + v dv,}
6 _ ~ d(rt,) _ ~ d-r,6 + -r80
dt ' dr r d8 r z dz r dr r d8 r
d-r,% dp
- - - - +pg (1.28)
dz dr r
in the 8-direction :
2
p d v 8 = _ p {v d v 8 + v 8 d v8 + v,v6 + v dv 0 } _ ~ d(r -r,9) _ ~ dt89
dt 'dr r d8 r z dz r 2
dr r d9
d-r8 ~ 1 dp
- dz. - ~ d8 + pge (1.29)
19
and in the z-direction:
dv: { dv: v8 dv: dv:} 1 d(r't"rz) 1 dr 8 % d -rn dp
p dt = - p Vr dr +-;: d9 + Vz dz - ; dr +; d9 + dz - dz + pg.
(1.30)
Introducing this expression into the above microbalances we obtain, for rect-
angular coordinates, in the x-direction :
dvx _ { dvx
p dt - - P Vx dx - l'y
dvx dvx}
dy - v. dz +v
{d (pvx) + ddy(pv,) +
2
dx 2
2
2
2
d (pvx) }
dz 2
dp
- dx
- + pg x (1.31)
- ~~ + pgz (1.33)
(1.34)
20
Introducing this into the general microbalance in terms of shear stresses we
obtain in the r-direction :
dv,. _
p-- - p v-
{ dv,. v8 -
+- v~ + vdv,.}
dv,.- - - + v {-d (-1 ___:.____:_
d(prv,.))
dt ,. dr r dO r z dz dr r dr
(1.36)
1.4. SI units
Different systems of units are applied at the moment in different countries in
industry, research and development. The most important systems are :
the c.g.s. system , based on the centimeter (em), gramme mass (g), second (s)
and degree Celcius (C). F or the amount of heat the calory (cal) is u sed
(d erived unit);*
the SI system, based on the metre (m), kilo gramme (kg), second (s) and degree
K elvin (K). The amount of heat (derived unit) is expressed as Joule (J),
which is identical to the unit for mechanical or electrical energy (1 J =
1 kgm 2 js 2 = 1 Nm = 1 Ws, where N =Newton, W = Watt) ;
the metric system , based on the metre (m), kilogramme force (kgf), second (s)
and degree Celsius (C). The amount of heat is expressed in kilocalories (kcal) ;
the foot-pound-second system, based on the foot (ft), pound mass (lb),
second (s) and degree Fahrenheit (F). The derived un it for the amount of
h eat is the British Thermal Unit (BTU) ;
The units for electric current and for luminous intensity will not be discussed here because they
play no role in this book.
21
the British engineering system, based on the foot (ft), pound force (lbf),
second (s) and degree Fahrenheit (F ).
For scientific research the c.g.s. system is used all over the world. Engineers in
Anglo-Saxon countries generally use the British engineering system ; in other
countries the metric system is generally used.
In the last few years the SI system (Systeme International d 'Unites) has been
more and more applied. This system has been adopted by the International
Organization for Standardization and is recommended by a large number of
national standard organizations. For that reason we will use SI units throughout
this book. In Table I.l a survey of the basic and derived SI units important for
us is given. The reader is advised to use one consistent system of units, preferably
the SI units.
Length metre m
Mass kilogram me kg
Time second s
Temperature degree Kelvin4 OK
Force Newton N = kgm/s 2
Work, energy, quantity of heat Joule J =Nm
Power Watt W = Jjs
Pressure N j m2
Dynamic viscosity Nsf m 2
Kinematic viscosity m2/s
Surface energy or tension Jj m 2 or N/m
Enthalpy Jjkg
Heat capacity Jjkg C
Heat transfer coefficient Wjm 2 C
Mass transfer coefficient m/s
Thermal conductivity W/ m C
4
Temperature difference is commonly expressed in degrees Celsius instead of degrees Kelvin.
from one system to the other. In order to facilitate this, Table 1.2 gives a collection
of conversion factor$. Table !.3 provides some information giving orientation
about the approximate values of some common properties of gases, liquids and
solids, which can be useful for rough calculations.
Multiply by
Magnitude Expressed in Divide by In SJ units
Multiply by
Magnitude Expressed in Divide by In SI units
====*==> Diffusion
c(l)
Convection c<::=::=t=:= V
1-----x x =constant
Under stationary conditions the rate of diffusion into the pipe equals the rate
of discharge of A with the flow. This situation occurs, for example, in pneumatic
control equipment where a small gas leak is applied (bleeding) in order to
prevent dust or water vapour entering the apparatus. The concentration
distribution c of the gas A in the pipe as a function of the distance x from the
opening is easily calculated if we realize that in the stationary state the amount
diffusing through each cross-section x = constant into the pipe equals the
amount of A removed with the flow, thus:
de
</>"m = 0 = - []l- - vc (1.38)
dx
25
with c = c:r:: at x = 0. The solution is:
~
c~
= exp (- vx)
U)
(1.39)
!__ =
Co
!(vx)
[ll
(1.41)
This is in agreenlent with the result obtained earlier. That the function f is an
exponential function cannot be found from dimensional considerations, this
result can only be obtained from a complete analysis. Dimensional analysis
has resulted in reducing the problem with initially five variables to a problem
with only two paiameters. Furthermore, comparisons between analogous
situations are possible without the complete solution. If we consider, for ex-
ample, two situations where the gas velocities differ by a factor 2, we find tire
same relative concenlratlons at distances which differ by a factor~ (i.e. the term
vx stays constant).
As a second illustration of the procedure followed during dimensional
analysis, we will consider the force F acting on a sphere which is placed into a
flowing fluid with velocity v, relative to the sphere (see also paragraph 11.5.2).
Based on physical considerations we can state that tb e force on the sphere will
be given by:
F = f(D, v, , p, 17) (1.42)
where D is the diameter of the sphere, p the specific gravity and 11 the viscosity
of the fluid. This relation must be dimensionally homogeneous, i.t:. the dimen
26
sions occurring on the left-hand side must equal the dimensions on the right-
hand side of the equation. This must also be the case if we write :
F = D"v:pc1J4 constant
The dimensions of these quantities can be expressed in length (L), time (T) and
mass (M) and we obtain:
LT- 2 M = L 4 (L1 1 )b(L - 3 M)'(L - l T - 1 M )d constant
The condition of homogenity leads thus to the following three expressions (one
for each dimension) between the exponents a, b, c and d :
L= L 0 L"L - 3 cL - d or 1 =a+ b - 3c- d
r -2 = T 0 T -"T 0 T-d or -2 = - b- d
M = M 0 M 0 j"A' M d or 1 = _c +d
Solving these equations for a, b and c we find :
a=2-d
b=2-d
c =l - d
The following expression for the force F is thus dimensionally homogeneous:
F = D<2 - 4 >v~2 - 4>p 0 - 4>
tr4 constant
or, also :
~
4
pv,.D 2
= (- 11
-) constant
pv,.D
(I.43)
Since both F1pv; D2 and 11/ pv,.D are dimensionless combinat~s of the variables,
any relation between these two groups is also dimension;llfy homogeneous. We
can therefore conclude that : /
F ( 17. ) ( 1) (1.44)
pv;D 2 =f pv,.D =f Re
Here Re = pv,.D/ 11 is the Reynolds number, which can be interpreted as the
ratioof momentum transport by convection ("'"' pv,v,.) and by internal friction
("' 1]V,./ D).
Again, the number of variables in this problem of initially five has been
reduced to two. In most cases the number of dimensionless groups obtained by
dimensional analysis equals the number of variables occurring in the problem
minus the number of independent dimensional equations which can be set up.
In flow and mass transport problems the number of dimensional equations is
three (L, T and M) and in heat transport problems four {L, T, M and tempera-
ture).
27
The function fin the result obtained is again unknown and can only be found
from a complete analysis of the problem. Sometimes the .result obtained from
dimensional analysis can be simplified further by making use of former physical
experience. In the case of the sphere, for example, experience tells us that at very
low flow velocities the force F on the sphere is independent of the specific
gravity of the fluid. Thus the relation between the two dimensionless groups
must be :
F '1
2 D 2 = -D constant
pv,. pv,
or
F
-- = constant (1.45)
17v,D
This equation represents Stokes's law. That the numerical value of the constant
is 3n can only be found by solving the micromomentum balances for this
problem.
As a last example we will discuss the droplets formed, for example, during
condensation of water vapour at the underside of a horizontal surface. The
hanging droplets grow until they reach a critical volume ~r and fall down. A
dimensionally homogeneous relation for ~r follows from the consideration
that ~-r depends on the density of the liquid p, the gravitational acceleration g,
the surface tension (J of the liquid and the degree to which the surface is wetted
by the liquid. For the great number of cases where the surface is well wetted by
the liquid we can write : ..
~r = f(p, g, a) (1.46)
The numerical value of the constant follows only from an exact analysis or
from experimental results. Analysis yields here constant = 666. The problem
with initially four variables has been reduced to one dimensionless group, the
Laplace number which represents the ratio oft he weight of the droplet (- pg ~r)
and the capillary force (-a VtJ
If dimensional analysis is applied all relevant variables have to be included
in the considerations. If we had, for example, forgotten the gravitational
acceleration in the analysis of the hanging droplet, we would no t have fou nd a
solution. If, on the other hand, we include too many variables, the result becomes
unnecessarily complicated. Most profit is obtained if besides dimensional
analysis a fragmentary piece of physical experience is applied, as illustrated in
the above examples.
28
1.6. Problems
In the following the reader will find a number of exercises. These problems
form an important part of the book a ..1d the reader is asked to solve as many of
them as possible. They provide a check on the understanding of the principles
discussed, they illustrate the practical application of these principles and
sometimes they extend the matter presented. In the three chapters which
follow each paragraph will end with a collection of problems. The answers to
these problems are given in order to enable the reader to check his own result.
On a few problems (marked with an asterisk) we have also included some
comments in order to illustrate an important point or to show that the solution
is really not very difficult if the basic principles are applied in the right way.
When solving a problem, the most important thing is to establish the physical
mechanism that governs the situation studied (e.g. is convection, conduction
and radiation of heat important or can one or two ofth~se transport mechanisms
be neglected in this special case?}. Secondly, we have .to decide over which
control volume the balance is made (e.g. over a microscopic volume if informa-
tion about the temperature distribution is required; over a pipe or heat exchanger
or over a total reactor with overall transfer coefficients if only information
about the mean temperature is required). Next, we have to determine whether the
situation is in steady state or not (sometimes a situation can be made steady
state by assuming the observer to move with the system, e.g. the flowing fluid).
Having come so far we are now in a position to solve the problem with the help
of the basic information provided in this book. This all sounds very difficult-
and it is- but the best way to solve any difficulties is to try very hard.
1. A tank is filled with a liquid having a specific gravity of p = 8 lb/ US gal.
What is the pressure difference between the top of the liquid and a point
4ft below the liquid level? Answer in psi, bar, Njm 2 , atm and kgfjcm 2
Answer : 167psi = 0115bar = 115 x 104 N/m 2 = 0113atm = 0117
kgf(cm 2
2. The temperature increase into earth is approx. 0025C/m. If the thermal
conductivity of earth is i.. = 186 W jm C, what is the heat loss per unit
surface area?
Answer : ~ = 00465 W / m 2
*3. 11/s water is pressed through a horizontal pipe. The pressure difference
over the length of the pipe is 2. 10 5 N/m 2 .
(a) What is the amount of power A necessary and what is the temperature
increase of the water ll. T if there is no beat exchange with the surround-
ings?
(b) What are 4> A and ll T if the water flow is doubled and if the pressure
drop is determined by momentum forces (and not by friction forces)?
X y X y
Comments on problems
Problem 3
A macroscopic energy balance over the entire pipe acco rding to equations
(1.5) and (1.6) yields for the stationary state and with Jlii = 0 (no phase transi-
tion), v 1 = v2 (constant cross-section of pipe}, h 1 = h2 (horizontal pipe),
cPv, in = </Jv,out and cPH = 0 (no heat losses) :
Now, the power necessary to bring the liquid to the initial pressure of
2 x 105 N/ m 2 is (no temperature change, d T = 0) :
p ~p = 200 W
</>A = - </> vb.p = - </>m
This power is converted into heat in the pipe (where <P A = 0), thus:
If the water flow is doubled, the pressure drop which is proportional to the
momentum (dp .- .v ,..., v 2 ) is increased by a factor 4. Thus 4>,. ("' </J,/lp - v 3 )
is increased by a factor 8 and ~ T (,...., Ap ,..., v2 ) by a factor 4.
Problem 6
The sketch shows the situation of the kettle on the fire. We will set up our
balances over the entir:e kettle. During heating up no mass leaves the kettle,
thus the mass and momentum balances reduce to :
d(pv) .
vdPL =0 and V dt = 0 respecttvely
dt
31
d(pv)
momentum: Vdt = 0 =IF
where the force in the y-direction is given by FY = Mg + <f>mvy and the force in
the x-direction by Fx = 4>mvx; and:
Problem 7
A macromomentum balance over the entire droplet will provide the answer
we are looking for. Because the flow velocities are very low we can neglect the
momen tum of the fluid and our momentum balance becomes a force balance:
~ow, the forces acting are the weight fo rce of the droplet and the surface
tension of the liquid in contact with the capillary as shown in the drawing.
Thus the force balance becomes:
'L F = 0 = -d
n 3 pg - 2nra
6
32
t
I
F=21TfCT
and thus :
d=
ru;:;
\}pg = 44mm
Problem 11
This problem is easily solved by application of the law of conservation of
matter. The complication here is that the composition (Y) of the vapour phase
changes as the distillation proceeds, because of the changing composition (X)
of the residue. Apparently, the right thing to do therefore is to set up an unsteady-
state material balance for a short time interval dt and to integrate the result
found over the total process time te . The mass balance (equation 1.1) for this
case becomes (no flow into the system, no production of methanol but variable
contents of the evaporator):
d(NX) dN
dt = -4>molY = dt Y
where the symbols have the meaning given in the figure. After partial differentia-
tion we can write:
d(NX) = NdX + XdN
dt dt dt
dN
=- - = constant
't'mo1 d/
.L
fi
Mole fraction CH30H
in vapour= Y
N kmole
mole fraction
CH 3 0H =X
ott =0, x0 , No
33
and combinin~ these two equations we obtain:
dX dN dN
N - = - Y- - X = - </> (Y- X)
dt dt dt mol
or:
dX lPmol dt dN
Y- X.
- = -
N N
which yields after integration between t = 0, x 0 and t, x:
N= No exp ( s:, y d: X)
This equation gives the relation between the total number of moles in the
evaporator and the methanol content of this residue. We are, however, interested
in the average composition of the distillate < Y) which is given by :
-ft.. d(NX) - (NX)I'x..
( Y) = f t.0 mol Y dt = 0 = O.Xo
mol te No - N No - N
= -No {xex (Jx dX )} ~- x~ = X 0 - Xeexp(J~~dX/Y- X)
N 0 -N P x 0 Y-X . Xo 1-exp(J~~ dX/Y-X)
This is the desired result ; all that remains is for us to evaluate graphically the
integral, as shown in the figure. We find for the area under the curve :
f
x~ dX = 117
Xa Y- X
x-
and thus :
045 - 005 exp (- 117) 0435
( Y) = = - - = 631 per cent
1 - ex p (- 117) 069
34
The amount of distillate is found as:
We see that sometimes the solution of a simple mass balance can be quite
involved. There is, however, a much simpler way to solve this problem approxi-
mately by carrying out the distillation stepwise. We start with 100 kmol of a
mixture containing a mole fraction of X 0 = 0-45 methanol. Let us distil off so
much distillate that X drops t~ X 1 = 0-35. Apparently,in this range the average
mole fraction of methanol in the vapour phase will be Y0 = 073 and thus we
can find the total number of moles distilled off from a simple mass balance as
follows:
xl = NoXo- (No- N)Yo = 0-35 = 100 X 045- 073(No- N)
N 0 - (N 0 - N) 100 - (N 0 - N)
We find N 0 - N = 263 kmol, containing 192 kmol of methanol. Now we
repeat this exercise as stated in the following table until we reach the desired
methanol fraction of X = 005 in the liquid phase.
Thus we find that 685 kmol were distilled off, containing 435 kmol of
methanol, i.e. 635 per cent. There is a residue of 315 kmol, containing
45 - 435 = 15 kmol of methanol, which is near enough to the desired 5 mol
per cent.
The reader will realize that the principal considerations in this approximate
solution are the same as for the exact solution given before. Instead of infinitesi-
mal steps dX or dt which made integration necessary, we just used bigger steps
which enabled us to obtain an approximate analytical solution a fter a reasonable
amount of additions and multiplications.
Flow Phenomena
In this chapter the transport of momentum is studied and wewill discuss the
prediction of flow resistance in pipe systems and of the resistance due to
obstacles placed in a flow field.
The analysis of pipe flow is divided into two sections, laminar and turbulent
flow, the difference being that in the first case shear stresses in the fluid are pre-
dictable from velocity gradients (deformation rates) but in the latter they are
not. This means that the 'theory' of turbulent pipe flow relies strongly on
empirical knowledge; however, this knowledge can be made generally applicable
by scientific reasoning.
In stationary flow through pipes of a uniform cross-section the momentum
balance degenerates to a balance between shear forces and pressure forces, but
this is no longer the case in flow systems in which the cross-section available
for flow changes. H ence, in that case a more general and practical approach
will be n eeded.
A class of flow problems, in which the enery dissipation due to shearing is
small in comparison to the amount of mechanical energy which is transformed,
e.g. from kinetic energy into potential energy, will be dealt with separately.
This will lead us to the design and use of flow meters.
F low around obstacles will not only be extended to flow through beds of
particles but also to stirrers. This brings us to the problem of mixing and of the
non-uniform distribution of residence time of the fluid elements which pass
through a continuous flow system.
In all hydrodynamic theory we will make use of the three fundamental
conservation laws which were introduced in chapter I. The idea of conservation
of mass, momentum and energy provides us with five relationships for a three-
dimensional flow field, from which the velocity distribution (v,.., v,. and vz) and
the temperature and pressure distributions can be obtained in principle, as
soon as :
these quantities are defined at the boundaries of the system and
relationships between shear stresses and deformation rates are known.
The whole problem in using the concepts of conservation of mass, energy and
momentum in predicting flow fields and flow resistances is to define the control
,olume in such a way that it facilitates the analysis and to make clever guesses
about the order of magnitude of the several terms in the balances in order to
37
make them amendable for an algebraic treatment. Hence, although the whole
theory on transport phenomena does not go beyond the concepts which are
already introduced in chapter I, the professional engineer needs considerable
experience before he is able to tum these concepts into practical use. Therefore~
this chapter has been written. It treats a number of problems in an elementary
way in order to illustrate the practical application of the basic principles and
it provides a number of elementary solutions which can be the starting point
to the solution of more complex problems.
ll.I. Laminar Oow
John looked at the spoon in his hand. Syrup dripped from it
into his porridge at a decreasing rate. H e thought about
writing a criminal story in which someone was imprisoned
until the very last drop of syrup would leave the spoon. John
had a feeling that this would last very long, months, perhaps,.
or years. Being a scientific story writer and working effici-
ent ly, he read the following introduction and found out that
the thickness of the syrup layer on his spoon decreased about
100 times in 25 minutes. Consequently, he thought, this layer
would diminish to molecular dimensions in about 3 x 105
years-a long sentence indeed.
Dtlring laminar flow, fluid elements move along parallel streamlines. Con-
sider, for example, the flow of a liquid film (e.g. syrup) on a vertical plane surface.
Here the weight of the fluid constitutes the driving force, resulting (if the vis-
cosity of the fluid is not too low) in laminar flow. At the wall, flow velocity will
be zero and there will be a velocity gradient over the thickness of the film. Thus,
adjacent fluid elements will have different flow velocities, causing shear forces
between the fluid elements.
A great number of laminar flow problems can be solved with the aid of the
balances discussed in the foregoing chapter if, for the fluids used, the relation
between shear forces and the velocity gradient is known. This relation reads
for unidirectional flo.w of Newtonian fluids :
d(pvx)
r = - vdy
-- (II.la)
yx
-
and if the fluids are non-compressible:
dvx
"[ y x = -11-
dy
(Il.Ib)
ryx is the shear force in the x-direction in a plane xz normal to they-axis. This
relationship is shown, together with two other possible relations between ryx
and the velocity gradient, in Figure 11. 1.
To solve a flow pro blem we start with a momentum balance which, for
channels with constant cross-section, takes the form of a force balance, from
which we find a relation between the shear force at any place and the pressure
drop. No assumption about the type of liquid or flow has been made until this
38
dv )"-I .::..:.!.
dv
Tyx : - K ( _dy dy
point. This relation is always valid for any kind of flow and for any type of
rheology. Using the shear force-velocity gradient relation for the fluid con-
cerned (e.g. equation ILl a for Newtonian liquids) we obtain after integration an
expression for the velocity distribution in laminar flow. From this velocity
profile the mean velocity and the volumetric flow rate can be determined as a
function of the driving force. We will illustrate this procedure in the following
paragraphs.
----
-
i'l'
Figure 11.2 Flow between two flat plates
39
and we find that the momentum balance reduces to a force balance I Fx = 0.
This is the case in all situations where compressibility of the liquid can be
neglected and where the flow channel has a constant cross-section.
The forces in the x-direction per unit of width acting on the control volume
are the following if, at the two cross-sections, the pressures are p 1 and p 2
respectively:
F
pressure force at ' 1': 'dt h =
Wl
p1 y (positive, because it acts in the
positive x-direction)
F
at '2'. x - - .PzY (acts in the negative x-direction)
width
~ Fx
Width
=0= PtY - PzY - T1 xL
or
(II.2)
Thus we see that the shear force is maximal at the wall (y = + d/2) and zero
in the centre (y = 0). Applying equation II.lb we obtain for a Newtonian non-
compressible fluid flowing in a two-dimensional slit of constant width :
- Pz
- = - Pt
dvx
-y
dy 11L
Integrating with the boundary conditions vx = 0 at y = + d/2 (flow velocity is
zero at the wall) we ~nd the velocity distribution :
We notice that the velocity profile is parabolic, the maximum velocity being
(at y = 0):
. _ Pt - P2d2
~max - 8rfL
lf>v =
width
f + df 2
-d;z
v dy = Pl - P2 d3
x 1211L
= d( v) (II.4)
------------------------------------------------ -----
40
and we see that the maximum velocity is given by
timax = f(v)
In Figure Il.3 the shear force and velocity distribution found for laminar flow
in a narrow slit are shown. The reader is asked to work out on his own the
I
I
I
Pt-P2 vmox = 3/2 <v>
L
Figure 0.3 Shear force and velocity distribution for laminar flow
in a narrow slit
solution to a similar problem of a film falling on a vertical plane surface {prob-
lem 2 on page 52).
We could also have solved the flow problem just discussed by means of the
general micromomentum balance developed in paragraph 1.3. Using equation
(!.25) and realizing that there is no flow velocity in the y- and z-directions
(v1 = 0, vz = 0), no velocity gradient in the x- and z-directions (dvxf dx = 0,
dvjdz = 0), no shear force in the x- or z-directions (d-rxxfdx = 0, dtzjdz = 0)
and that the plates are horizontal (thus pgx = 0), we find for steady-state
conditions (dv:.:f dt = 0):
{}+. ' L X
I I
I - 1
P xz -x. P2
Figure 11.4 Flow through a circular tube
W'riting down the force balance for steady-state conditions we obtain :
I Fx = 0 = nr2 p 1 - nr 2 p 2 - r~.x2nr(x 2 - x 1)
or:
vx = -1(~-
dp) (R 2 - r2) (11.6)
4~ dx
Thus, again, the velocity distribution is parabolic, with maximum flow velocity
at r = 0:
Vmax
1 (
= 4'7 - dx R
dp) . 2
The flow rate at a given' pressure gradient is found from th e velocity distribution
as:
4
<P ,. =
f o
2nrv x dr = -nR
R
8rr
( dp)
- = nR 2 (v)
-dx (II. 7)
Combining equations (Il.6) and (11.7) we find for the velocity distribution :
v = 2(v) 1 - - ( r2) = -R
2
(
-- dp) ( r2)
1 -- (11.8)
x R2 4'1 dx R 2
I I
I I
I I
r (PJ-P2l = 2<v>
2 -L-
vmax
Figure 11.5 Shear fo~ce and velocity distribution for laminar flow
in a circular pipe
The velocity gradient at the wall can be found by differentiating equation
(11.8) and by determining the value of the first derivative for r = R. We obtain:
where rw is the shear stress at the wall. We will need this result later on, when we
develop equations to predict pressure drop during flow of liquids in pipes. The
reader may check that equation (II.5)" could also have been obtained from the
appropriate microbalance, equation (1.30), and that equation (11.6) can be
derived from equation (1.37):
I
---.1
b -- rr
r !
1 I
I I
I I
I :
- - - L - -I
1
...-x 1
P1 P2
r =Pt-P2r + C1 (11.10)
rx 2L r
(11.11)
/ 1/ - (-ba) z 2
Pt - Pz
r
u
= 2L r
!
b
(II.12)
2ln -
, =
vx
Pt - Pz bl 1 _
4~L
(~) b
2
+
1
- (WIn
In(~)
(~) b
(IL 13)
In Figure Il.7 the shear stress and the velocity distribution for laminar flow
in an annulus are shown. The reader may check that, indeed:
r,.x = 0 at
and:
vx = vmax at the same value of r2 jb2
For a = 0, equations (II.l2), (II.13) and (II.14) reduce to the corresponding
relations for flow through a circular tube. For a very narrow annulus, thus for
a = b - d (d a) and r = a + y (y a), the corre-sponding relations for flow
in a narrow slit between two flat plates are obtained (problem 1).
- vx
+ Trx
Figure ll.7 Shear stress and velocity distribution for laminar flow
in a horizontal annulus
The shear stress and the velocity distribution for flow in a circular pipe can,
of course, also be found fro m equation (11.11) by applying the proper boundary
conditions Yx = 0 at r = Rand vx = oo at r = 0. The last boundary condition
leads to C 1 = 0, which we would have also found from equation (II.lO) by
realizing that at r = 0, r,.x = oo. The reader may check that equation (11.10) can
also be derived from the proper micromomentum balance, equation (1.30).
Coming back to laminar flow in an annulus it is interesting to compare the
shear force at the inner and outer wall. From equation (II.l2) we find the force
at the wall as :
I
45
The sum of the two forces is then (ra.x acts in the negative x-direction !) :
Fa + Fb = -2naLrwla + 2nbLrwlb = n(b2 - a2 )(pt - p 2 )
i.e. the total shear force at both walls equals the pressure force on the cross-
section of the annulus, as should be the case.
The ratio of the forces at the inner and outer wall is:
b 2 /a2 - 1
- - -- -1
- arax 2ln (bja)
b2/a2 - 1
-------~~~--
2 2
b ja - 21n (bi a)
This relation is shown graphically in Figure II.8. We see that for the limiting
case bja ...,. 1 the two forces become equal. The ratio of the force on the inner
cylinder to the total force is given by:
Fa -arax 1 1
----=--- - - - --'---- - - - - -
Fa + Fb -arax + btbx 2ln (bja) (bj a) 2 - 1
This relation is also shown in Figure II.8. If the ratio of the surfaces of the
outer to the inner cylinder is 5:1, then 27 per cent of the total force still acts on
the smaller cylinder ! Considerations of this kind are of importance during the
extrusion of, fo r example, plastic pipes.
bl a-
The first relation shows that the forces on both surfaces are equal, as should be
the case:
1tYfVo
Fa = nar:,.aL = Fb = nbr:,~ = In (b/a) L
In Figure 11.9 both relations are shown graphically. The reader may check
that for bj a-+- 1 both expressions reduce to the proper relations for two parallel
flat plates (see also problem 4).
v8 =--
cl c2
-r
2w 11
and, applying the boundary conditions v 8 = v 0 at r = a, v 8 =0 at r = b, we
find (using v 0 = na) : .-
(II.17)
and:
2na 2b2ry
r,e = (bl - a2)r2 (II.18)
As should be the case, the torque at the inner and at the outer wall Fr = 2nr-r,rL
is the same. The shear stress and the velocity distribution are shown in Figure
II. ll.
48
o~----------------------~
a r b
Figure 11.11 Shear stress and velocity distribution
in an annulus with inner moving cylinder .
Values for the correction factor M 0 can be found from Figure II.12.
49
Rectangle
0 1
!2:{ 8-----1
Isosceles triangle
d/8
Figure 11.12 The flow coefficient lvf 0 for stationary flow of Newtonian
liquids in cross-sectjons of various geometries
which will be treated in more detail in chapters III and IV. There, also, the exact
solution of this differential equation will be discussed.
In Figure II.14 the velocity distribution for the system of Figure 11.13 is shown
for two short times. As can be seen, the distribution can be approximated by
straight lines which cut the abscissa at y = foi. This distance foi is called
the penetration depth, i.e. the distance over which momentum has penetrated.
This solu tion is applicable as long as the penetration depth is smaller than the
depth of the liquid.
We can now estimate the velocity gradient as:
or, since V 00 = 0:
d v"' Vo17
r = -1]-=-- (II.20)
w dy Fvi
51
j;;t( ;-;;-;-; X
v
y
= gp (dx
11
- 1x2 )
cPv = (v ) d = pgd3
w )' 311
(b) On a vertical plane {width B = 1m) 1200 kg/ h water flows downwards.
What is the mean velocity, the film thickness and the maximum velocity?
Answer : <v) = 0725 m/ s
d = 046 X 10- 3 m
Vm a)l = 109 m/s
*3. In a rotary viscosimeter filled with paint (a Bingham liquid) the shear
velocities are measured as a function of shear foree :
15 6
18 12
21 18
53
If this paint is smeared on a vertical wall, how thick can the layer be before
the paint starts tc drip (p = 1200 kgfm 3 )?
Answer : d < 10- 3 m
4. The slit (width 1 m m) between two horizontal flat plates is filled with a
viscous Newtonian liquid ('1 = 100 Nsjm 2 ). If the surface of the plates is
10 - 2 m 2 , which force has to be applied under steady-state conditions to one
plate in order to move it parallel to the other p late at a velocity of 1 crnfs?
Calculate and draw the shear force and the velocity distribution between
the plates. After what time is the stationary state reached?
Answer : F = 10 N,t~3x10 - 6 s
YJ = YJo dvx'
dr
where '7o is a constant. Find the volumetric flow rate of this liquid in a
'
horizontal pipe (diameter 2R) under laminar and isothermal conditions.
2n , {!;P
Answer : <l> v = 7 Ri ...j~
6. Viscous oil ('7 = 01 Nsjm 2 ) is pumped through a horizontal pipe (diameter
1 em, length 10m) into an open vessel. The absolute pressure just behind
the pump is 3 x 10 5 N j m 2 .
{a) Determine the volumetric flow rate of t he liquid.
(b) What would be the flow rate if a pipe with rectangular cross-section
(05 x 20 em) was used?
Answer : (a) 4>v = 4-9 x 10- 5 m 3 js
(b) ., = 3-47 x lo-s m3 /s
*7. Check John 's calculations about the syrup dripping from the spoon,
reported at the beginning of this paragraph.
Assume: YJ = 1 000~, p = 2000 kgjm 3 , initial thickness 5 mm, height of
spoon 5 em
Comments on problems
Problem 3
For a liquid with Bingham characteristics the following relation between
shear force and velocity gradient is valid if we use the coordinates shown in
the small drawing overleaf:
54
B
The size of the yield value t 0 for this paint can be determined from the experi-
mental results as t 0 = 12 N j m 2
A force balance will lead to the maximum possible layer thickness before
dripping takes place :
pghdB < -r 0 hB
and thus:
to
d <-
gp
and we find d < 10- 3 m.
cP = pgd3W = WHdd
v 3~ dt
1[ 1 1] pgt
-2 d~ - d 2 = J17H
or:
d
-=
55
\
\
-w- l
\
':-do
I
H J
I
I
J
For long times :
2pgtd~
_:_:::__..::.. 1
3t7H
and we can simplify the above relation to:
d/3riH
do="'>/~
For djd 0 = 001 we find t = 1500 s = 25 minutes. The period to diminish the
syrup layer to molecular dimensions is found by substitution of
d 5 x 10- 10
d = 5 x 10- 3 = 10 - 7
0
as 15 x 1012 s.
11.2. Turbulent flow
John stood at the edge of a circular sewer channel of 4 m
diameter and contemplated that the dead body had been
found floating in the channel 72 km downstream, in a fisher
village, at 11.45 p.m. The suspect had a watertight alibi for
the time before 9.15 p.m. The channel was now half-filled and
a piece of wood passed John at a speed of 1 mjs. One of the
sewage plant operators had informed him that until the time
che body was found the water height had been less than one-
quarter of the diameter of the channel. Th inking about one
of his college courses, of which you will .find a brief outline
below, he made a quick calculation and ordered to sec the
suspected man free.
The turbulence of the flow field makes the effective viscosity (from a macro-
scopic viewpoint) larger than the molecular viscosity 17, because neighbouring
layers of different mean velocity not only transmit momentum to each other by
molecule interaction but also by cross-currents (eddies). These cross-currents
decrease in intensity the nearer they are to the wall. Because of this varying
effective viscosity (which can be supposed to be composed of the t7 and the 'eddy'
viscosity pE) the velocity distribution differs from that in laminar flow. The eddy
viscosity just introduced is, of course, not a physical property of the liquid but
is dependent on the place and on the type of flow. The dimension of the eddy
viscosity pE is kg/ms ; thus the term E has the same dimension as the kinematic
viscosity v (m2 js).
Figure Il.17 shows an example of the velocity profile in a pipe with a circular
cross-section for laminar (parabolic) and turbulent flow (more flattened).
r Vmox"' 2<v > Vmox = I I to I 2 < v > 1
I
I
I I
<v > i <V > I
I
I
I
I
I
I I
---r---
I
----r---
I
X I I
I I
I I
I I
I
I
If we want to know something about the frictional force exerted on the wall
by a liquid flowing at a velocity (vx), the shear force -rw at the wall must be
known. Since for incompressible Newtonian liquids :
dv.x
!w = r[ dr
r=R
holds (no turbulence at the wall, pEat wall = 0), we must know the velocity
distribution in order to calculate -rw . For turbulent flow this is not possible by
momentum balances, because with turbulence their solution presents insur-
mountable difficulties. However, on the basis of physical intuition it can be
posed that :
-rw = f (p, rJ, (vx), D, geometry)
from which, with dimensional analysis, it follows that the quotient of -rw and
p(vx) 2 for geometrically similar pipes only depends on the Reynolds number
(= p( vx ) D/tt). This is usually written as:
(1 1.22)
57
With this equation the constant f, the so-called friction factor is defined: on
account of the above it is a function of the geometry and of Re. For turbulent
flow this function can be obtained only from experiments on friction losses in
pipes and channels. Conversely, these friction losses are, in practice, calculated
using this friction factor f, the value of which is well known for widely divergent
conditions (see paragraph Il.4.).
Equation (II.22) can be read as follows: the quotient of -rw and p<v,) which2
2o,ooo(~r ,
32
The fact that turbulence decreases towards the wall has led to the concept
of the laminar boundary layer. No definite thickness can be assigned to such
a layer because the turbulence changes gradually. For the qualitative insight
:t can be useful to scliematize the flow field by a laminar boundary layer, .with
thickness ~h in which the velocity gradient is constant, and an adjacent turbulent
~ow region, with the mean velocity <vx> in which the velocity gradient is
;>ractically zero. The shear force at the wall is then given by:
( vx)
rw='f'/T (II.24)
and the thickness (J h can be estimated with the help of equation (11.22) as soon
as the friction factor is known.
With the aid of the laminar boundary layer thickness b1, we can give a new
mterpretation on the physical meaning of theRe number. The ratio of the tube
58
diameter and thickness of the laminar boundary layer is found to be :
From the definition of o11 , this means that eddy momentum transfer overrides
viscous transfer if:
pE = pC 1 y 3 ~ 11 . or E = C 1y3 ~ 11/P =v
Hence:
{II.27)
b: = (v)t = set
{>
II) (11.30)
where Sc is the Schmidt number. For gases Sc ~ 1 and ~, ~ l>c and for liquids
Sc ~ 1000 and b" ~ lObe. We see that in these cases the thickness of the hydro-
dynamic boundary layer is greater than those of the respective thermal and
concentration boundary layers, b11 > bT, oc.
We have .already stated at the beginning of this chapter that it is impossible
to derive theoretically a relation for the velocity distribution during turbulent
Bow. We can, however, construct a relation between velocity and the friction
factor and see whether we can determine the coefficients in this relation by ex-
perimental results. Analogously to the devdopment of equation (II.22), we
assume that the mean velocity is a function of the shear stress at the wall, the
specific gravity and the kinematic viscosity of the fluid and of the pipe diameter ;
so:
(11.33)
60
Thus, maximum flow velocity occurs in the centre of the tube at r = 0 and we
can write :
_2_ =
Vmax
(l _2r)-+
D
(II.34)
In order to find the ratio between mean and maximum velocity we can calculate
( v) from equation (II.34) as :
,CY 0
0
,..t ~
I >< /
c;/ 0\
'o
\
0
E ~0 >
"' 5l ~
'"' 'o
v6 ' r;\
0
i I /
~
0 5 0 0 5
_ . 1-2r/D
Figure ll.18 Measured velocity distribution for
turbulent flow
From this equation, which is named after Fanning, it is clear that A/S is the
characteristic dimension of the channel cross-section, so that it is obvious to
call A/ S the hydraulic diameter* of the channel. If the numerical factor 4 is
introduced in the above relation, which is done for historical reasons, fS/ A can
be written as 4fS/4A and it is still general practice to state the value of 4f
instead of the value off
The problem of predicting the pressure drop in straight channels can thus be
reduced to predicting friction factors. We shall now collect data on the friction
factors for Newtonian flow in circular pipes. The Hagen- Poiseuille formula
(II.7) valid in the laminar field yields, together with equation (11.22), for the
friction factor :
'7 64
64 (II.36)
4f = p(v)D = -Re
In the turbulent region the friction factor is considerably less dependent on Re,
notably proportional to- .Re- 0 25-0. As a consequence, the pressure drop is
proportional to (v) 1 . 75- 2 , so that for a given pipe the pressure drop increases
:nuch more strongly with ( v) than in the laminar field, but the viscosity of the
9ow has less influence.
For pipes with a smooth wall the experimentally found relation proposed b y
Blasius:
4f = 0316 Re- o:z.s (4000 < Re < 105 ) (11.37)
gives a good description of the dependency off on Re.
The quotient A /S is also called the hydraulic radius, with the consequence that the hydraulic
diameter is four times the hydraulic radius!!!
0 06
---~,----------------------10 025
" "'
----_::~------------------~001
1 "-..
-----"'-.::::...,o:::-----------------J5xl0-~
u
'-
0
.E
' ........
.........
u
c:
.Q
.:
.. .. ----------~"~~----------~to- 3'
LL j
Laminar Turbulent ..........
(circular . ~--------=.:..:a...-:- . ,-----~5x 10- 4
cross- section! ..........
only l Roughness of wall x .( m l :-------=.::::::.....:----t2x 10- 4
...........
Drown tube 2xto-6 :::-----....::::~ to- 4
Steel tube 40xlo- 6
Galvanized iron t50xlo-6 --.::--._-------15x 10-5
Cost iron 03 x10-3
Wood,concrete 0 2-2ltl0-3
0007~~-L---~-L-L--~~L---L--L-~-L~-L---~-L~--~~~--~-~~-L~~--~
56 s 103 2 3 4 G s 104 2 3 4 6 a to5 2 3 4 6 8 106 2 3 4 6 8 107 2
Re= <~ 4A
II S
'
63
In the case of turbulent flow the roughness of the wall surface also influences
the friction losses. When the mean height x of these irregularities (roughness)
becomes of the same order of magnitude as the thickness of the laminar bound-
ary region (either in the case of great roughness or at high Renumbers), part of
the resistance will be caused by direct momentum transmission between the
turbulent core of the flow and the protuberances of the wall. In extreme cases
(very great roughness or high Re) this causes a pressure loss proportional to the
kinetic energy of the flow, so that the friction factor no longer depends on Re.
The wall roughness is allowed for by the dimensionless quantity i / D = relative
roughness. Consequently, the friction factor is in general a function of Re and
i j D.
In Figure II.l9 the relation between 4f and Re is shown for various values of
the relative roughness. It appears that in the turbulent region two parts can be
distinguished : at high Re numbers, the so-called completely turbulent region
where f only depends on the roughness, and at lower Re, a turbulent transition
region where both Re and roughness play a part. The mean roughness of a
number of materials is also given in Figure 1119.
For pipes with non-circular cross-section the friction factor in the laminar
region is proportional to 1/ Re. The proportionality constant depends on the
form of the cross-section and is known for a number of cases (see paragraph
11.1.5 and figure II.12).
If the flow is turbulent, approximately the same values of the friction factor
apply as in tubes with circular cross-section if, in the Fanning equation (II.35)
and in the Reynolds number, use is made of the hydraulic diameter. Hence the
advantage of using the hydraulic diameter is that (only for turbulent flow) with
one graph for the relation between the friction factor and Re the pressure drop
a
-0E}r
Cir;cu lo r pipe
Concentri c pipe or sl it
D
0 2 -01 = 28
r.
4
o2
2 0 z>
-.,. ( Dz- I
8 4
CJe
w
R ect a ngu la r p i pe
2 WB
W+ B
WB
for ( v), which can be done by a trial and error procedure. Rearrangement of
equation (!1.35) yields:
A = lPm (pl ~ P2) = lf>v(pl - P2) = 4>m; (v)2 S(x2; X1) (11.40)
This means that the dissipated mechanical energy per unit of volume equals the
undergone pressure difference. Thus, for laminar flow 4> AI v is proportional to
(v) and for turbulent flow to (v) 1 ' 7 5
10 6 1....-...1...-.A..LM'-L.J.___.J~.L_..L..L..L..--L---"'--L-,.u_---L...--L-L.oU--__..J
10 3 104 10 5 10 6 10 7
Re--
Figure ll.ll The relation ofJRe2 andRe for turbulent flow
Err in this equation is the amount of mechanical energy which per unit of mass
is converted into heat owing to internal friction. This constant is always positive
because the dissipation is a result of statistical transport, which according to
thermodynamics is attended by degradation of energy (entropy production).
66
Hence we may conclude from equation (II.41 ) that owing to friction the total
mechanical potential (the first four terms of the equation) decreases in the direc-
tion of the flow, so that here we can speak of the law of 'non-conservation'
of mechanical energy. The readers should realize that the Bernoulli equation
is not a new balance but rather a summary of the three momentum balances.
If the amount of energy added to the system per unit of mass 4>A = 0 and the
energy loss due to friction is negligible, equation (II.41) can be written for any
point in the flow field as :
1
- dp + g dh + v dv = 0 (11.42)
p
or, also, if at the same time the specific gravity is constant:
These are two forms of the well-known equation of Bernoulli, which can also
be derived in a simple way by using the momentum balance for a frictionless
fluid (Newton's first law). The more general equation (11.41), which plays a
very important role in the technical flow theory, is furt her referred to as the
extended Bernoulli equation.
On account of what we know about the pressure drop and the energy dis-
sipation in a straight channel we can relate the constant Err for such a channel
(length L) to the friction factor and the mean velocity (v) in that channel
(equation II.40):
1 2SL (11.44)
Err= f2.(v) A
Local pressure losses are mainly due to a sudden increase in the cross-section
of the pipe. According to Bernoulli's law in such a diverging flow the velocity
downstream decreases and the pressure increases. This pressure gradient may
cause the fluid near the wall to flow upstream. This results in systematic eddies
(not the same a~ turbulence!). In these eddies part of the kinetic energy is
destroyed by internal friction. Only if the diameter is carefully widened (e.g.
via a diffuser with a vertical angle of at most 8) do these eddies not occur.
The dissipation per unit of mass in a fitting is described with a friction loss
factor K w which is defined as :
(II.45)
In practical cases K w is only a function of local geometry and is for not too
low Renumbers independent of Re. For (v) the mean velocity in the pipe on
the downstream side of the local resistance is usually taken.
To calculate the resistance of a pipe having various pieces of different dia-
meter, bends, valves and other local resistances, both equations (II.44) and
(II.45) should be introduced in the extended Bernoulli equation (11.41), via
67
the lost frictional energy Err. The latter constant integrated over the entire
pipe then becomes :
Err =~ (ft(v)
I
2
s:).+ 2;:
I J
(K...,t (v) 2 )j (11.46)
where the first sum is taken over all pieces of straight pipe and the second over
all local resistances. In air conditioning channels, often short bends have to
be made owing to lack of space. However, the K..., values then become un-
permissibly high so that frequently guide vanes are built in to lower these values
(avoidance of eddies, streamlines).
Empirical correlations between K..., values and the geometry of the pipe
system are known for a great number of situations. A few K..., values are listed
in Table IL L In some cases it is possible to derive K ..., values theoretically.
Consider the situation shown in Figure II.22. For the calculation of the energy
dissipation three equations are available, viz.:
I
I
I
1 I
l I
I
I
..
Figure 11.22 Flow in a channel with changing cross-section
u: ; f f
0 P1A1 + mvt -
+ </>A - Err</>m
The latter equation simplifies for horizontal pipes, no energy input and incom-
;>ressible fluids to:
Pt - Pz
Err= + 1((v
1
l) 2 - (vz) 2 )
p
using the above three balances it is possible to estimate the amount of dissipated
!nergy Err if we can find an expression for the force the liquid exerts on the
~aUF w We will illustrate the procedure to be applied in four examples.
68
Table II.l Some values of the friction Joss factor
K k{ ~~
2
I - }
A2 fr =
Kw
to l 2o 130 140 !so I so jmo 1800 1
=0 16 020 024 028_ 031 032 0 34 0 35
..:
Az Kw =( __ ,
A2
A I
) 2
02 0 3 04 0 5 0 6 07 08 0 9
Ao Ao
A, A2 A, 0 1 02 03 04 0 5 0 6 0 7 0 8 0 9 1 0
Kw ,. 232 51 20 9 6 5 3 3 1 I 9 12 0 73 04 8
A1 > 20A 2
~
~~----:-1--
..J- = 20. 140 16o lao 19o. j'oo. lt2o
1'40
Kw = OD5 0 14 0 36 0-74 0 98 I 26 186 2-43
j
K
w
=
{
0131 + 0163 ( -R0 ) 35} ,j-
-goo
69
5
Kw (referring to downstream velocity for Re > 10 )
, ; 15 3()0 45 60 900 I
K,= (}02 10 II 10 26 10 50 1 120
- - Kw =- 2 - - - Kw-0 75
tPm2
.ml
K.,
= 0 0 2
OJ6
= 0 95 0 88 0 89 095 110 128
0 8 1 0
+- s---~
~: 20 30 600 7QO
80 185
400 150
K," 751 118 33 II 4 15 0 52 0 24
Kw = 4 86 206 53 17 55 16 0 29 0 05
Sieve plate :
061 051 0 2
Fraction- free space i Kw 0 7 I 5 2 0
Cyclone Kw 10 to 20
K =JSL
w A
18 i2
'I
I
I
I
I
I
Fw = (A2 - At)PB
where p8 is the pressure just behind the expansion in plane 'B'. This pressure
will be p 1 < p8 < p2 . Only experimental results can show which pressure bas
:o be used.
-\. Let us assume p 8 ~ p 2 , thus Fw = p 2 (A 2 - A 1 ). Then we find from the
momentum balance :
Pt - Pz = - c/>m(v1 - Vz)
= - pv2- -
2 Az(A2 - 1)
A1 A1 A 1
We see that the momentum balance predicts correctly that p2 > p 1 . Sub-
stituting p 1 - p 2 in the Bernoulli equation:
E rr -_ Pt - P2 + li 2
2\vl -
2)
Vz
p
we find after some sorting and applying of the momentum balance :
2
K
...,
=
( At
A~
_::_1 )
F = Pt + P2(A _ A )
w 2 1 2
I I 12
I
I I
I
I
'
I
I
I I
I I
- - - +---------------+---
--
1 I
_ P1
E fr -
Now (A 1 + A2 )/2 is the mean cross-section, where the mean flow velocity
(v 1 + v2 )/2 is present. Thus:
A.. _ v1 + v2 A1 + A2
'+'m - p 2 2
4. Develop an expression for the friction factor for laminar flow in a falling
film and for flow between h. ~~ .fiat plates.
6 12
Answer: f ;= Re (film); f = Re (plates)
*5. Through a smooth horizontal tube 1 kg/s water is pressed (Re ~ 2 x 104 ).
The pressure difference over the tube is 2 x 10 5 N j m 2 What energy Pis
needed and what is the temperature rise .1 T of the water if there is no heat
exchange with th:e environment? What will be the values for P and aT:
(a) if the water fiow_is doubled?
(b) if 1 kg/ s W(\ter is pressed through a tube 15 times as narrow?
6. Calculate the pressure drop over a capillary flow meter with a smooth
wall if the gas velocity is 5 m/ s. 50 mj s and 100 mj s respectively.
5
capillary length 10 em 1Jair = 2 x 10- Ns/ m2
3
capillary diameter 1 mm Pair= 12 kg/m
Answer : 45 m j s; 520m 3 fh
Answer : H = 47 m
Answer : (a) = 2 N
(b) = 196 w
77
*12. A strong fireman sends up a jet of water of 2 m 3 jmin at an angle of 45.
The maximum height he can reach is 20m. What is the force with which
he is pressed against the ground as a result of spouting?
Answer : 66 7 N
Answer : (a) 23 m js
(b) 147 m js
14. At least how high can a pole vaulter jump if he can run at a speed of
10 m j s?
Answer : 50 m
15. On the Mons St. Nicolas (Luxemburg) lies an artificial lake with a capacity
of 7-6 X 10 6 m 3 . For twelve hours (mainly during the night) the lake is
filled with water from the Our, 500 m lower. During the next twelve hours
turbines on the Our are driven with water from the lake in order to generate
electric power. The water supply from the lake to the turbines takes place
through two parallel circular concrete tubes, 650 m long and 6 m in
diameter.
(a) What power could this station deliver, apart from losses, if it is in
continuous operation for 12 out of 24 hours?
(b) What are the .fri~on losses expressed as a percentage of the theoreti-
cally possible power? Let the resistance value for the entry and exit
losses, each related to the velocity in the tubes, be 25.
(c) Calculate that, if the pump delivery and the turbine efficiency are
75 per cent, this way of energy storage makes the electric power 18
times as expensive : the engineering works as such may be considered
as being fully written off.
16. Show that, in the case discussed at the beginning of this paragraph, John
was right in letting the suspected man go.
78
Comments on problems
Problem 3
(a) An increase in throughput will affect, amongst others, the Re number and
therefore also the friction factor. (See Figure Il.19.)
(b) Here again you should not forget the change in f due to the changing Re
number.
Problem 5
This problem has been included to show you bow widely Figure 11.19 can
be used, provided that you base your Re number on the proper hydraulic
diameter. Don't forget the hydrostatic head pressure!
Problem 10
A sketch of the chimney with an expression for tlie pressures at the bottom
and top will help you to find an expression for the height of the chimney using
the Bernoulli equation. It turns out that the losses due to friction are negligible.
p , -250
Problem 12
With the substitution of the maximum height h in the Bernoulli equation
you will find the vertical velocity component Vy of the nozzle. The force in the
y-direction can be calculated from the mass flow and vr Do you find the same
answer when you calculate the weight of water the poor fellow has to carry?
v2 = v1 ) Dh 1/D112
For a half-filled sewer channel Dhl = D, but if the channel is filled to one-
quarter of its diameter :
360 2
Dh 2 = nR8
= 059D
180
if we use cos 8/2 = (R - tR)/R = f.
Since v 1 = 1 m/s (half-filled channel) we find v 2 = 077 m/s and the time
necessary for the body to arrive at the fisher village is :
t = ~ = 9360 s = 2 h 36 min
vl
(or longer, if the water level was lower than iD~ Thus the corpse must have
been dropped into the channel at 909 p.m. or earlier, and John came to the
right conclusion.
For a great number of flow situations the energy dissipation Err is zero or
negligibly small with resp-ect to the amount of mechanical energy which changes
from one form into the other (see example 3 of the previous paragraph). In those
cases the relation between velocity and driving force is simply given by
Bernoulli's law (in the form of equations 11.42 or II.43). This equation can also
be written in such a way that the terms acquire the dimension of a length :
p ti2
- + h +- = constant along a streamline (11.47)
pg 2g
The three terms are then called pressure head, static head and velocity head
respectively ; the sum total of these terms remains constant if there is no energy
80
---- --
------y- r---------- ~
..-
-----
- - - f=-=-
-- p v2
..
--
-- -
p
- - +
11 + .1!...
--
pg 2g
-
-pg
--
pg 1 --
-- -- - -T - -- - ,___~- - v
vzO -
hI h
1 h=O
Figure 11.26 Static head, pressure head and velocity head
change due to friction or mechanical work. These heads also have physical
significance, as can be seen from Figure II.26. _.
With the left manometer tube only the pressure prevailing in the liquid i~
measured. The lower opening of the right-hand. tube is opposing the stream.
Right in front of this opening the velocity is negligible so that all kinetic energy
is converted into pressure and causes a thrust equal to !pv 2 This thrust is used
when measuring velocities with a Pitot tube. .
We will treat here two well-known examples of flow with negligible ener~n
dissipation, the flow from orifices and the flow over a sharp-edged weir.
ll.3.1. Flow of a liquid from an orifice
Friction hardly plays a role in this type of problem. For calculation of the
outflow velocity use is made of the mass balance and the Bernoulli equation.
Using this mass balance it appears that some distance before the orifice the
velocity is negligible .compared with the velocity in the orifice. Next, with
equation (11.41) it can be derived that for a sharp-edged orifice (Figure II.27)
the volume flow v becomes :
Po
( 0 ) (b ) (c )
Figure 11.27 Flow of liquids through holes
c = 0 96
d c = 0 82
.-
d--
;Iff d/ 2
c ; 0 53
'1
82
11.3.2. Flow of gases through orifices
The approach followed in the last section can also be applied to the flow
of compressible gases through orifices. Friction losses can be neglected, and we
can assume that the change of. state takes place adiabatically. However, due to
the adiabatic expansion, the pressure in the jet will be different from the initial
pressure p 1 and the final pressure p0 outside the gas jet (see Figure Il.28).
In the stationary state the Bernoulli equation (11.41) reads in its differential
form (g dh = 0, </>.,. = 0, E rr = 0) for this situation :
0 = dU + pd(~)
or, realizing that (if there is no change of state) dU = c" dT :
0 = c. dT + pd(~) (II.52}
Applying the ideal gas law for a number of moles nina volume V , p V = nRT
(R =gas law constant = 831 J/mol K), we find with M = molecular weight
of the gas (kg/mol) :
p = nM and p d (~) = _L d V = R T d V
V . p nM MV
83
R = M(cp- c") and K = cJcr: we now obtain from equation (II.52):
dT dV
0 = T + (K - l)y- (II.53)
Returning to the Bernoulli equation (II.50) for the flow of gases through
.nfices under steady-state conditions :
1
0 = -dp + v dv
p
V
2 -
-
2K
-
p ) (K- 1}/IC}
p 1 {l -(- (II.54)
K - 1 Pt Pt
the mass flow rate at any place of the variable cross-section A of the gas jet
.,...,p,p_ the pressure is p is given by:
= pvA =
p ) 1/IC
m ( Pt p 1vA
p/pl - - -
Figure 11.29 Flow of gas through an orifice
At this point the critical conditions Ac, Po vc and Pc are present. For the critical
velocity vc we find with equation (II.55):
Vc = (
K
2K P1)t
+ 1 Pt
= (KPc)t
Pc
= (KRT)t
M
(11.56)
which is the velocity of sound at Pc and Pc (for air at 0C, vc = 331 m js). For gases
consisting of two atoms, K = 14 and consequently pcfp 1 = 0527.
The expression developed for the mass flow rate (equation JI.55) can be sim-
plified for a number of conditions.
(II. 57)
(b) Pc < Po < p 1 (for air, Pt = 053pt). Equation (11.55) is valid, A being given
by CA 1 with 06 < C < 07.
Diameter (m)
400 x 10-3
Reference 300xlo-3
line
250x lo- 3
Mass flow rote
(kg/s) 200 xl0-3
:soo Friction loss
zoo foetor}:; Kw 150xl0-3
I
IOOxi0-3
2 80 X 10- 3
sol( ro- 3
10 X 10-3
8 X 10 - 3
s x ro-3
4xlo- 3
3x lo-3
25)( I0- 3
..
. .
A weir can be used for measuring liquid streams with a free surface area
Besides the rectangular weir there are differently shaped weirs. Figure II.32
gives a survey of the relations applicable to the various weirs.
Occasionally a viscous liquid is passed over a narrow-crested weir. In this
case, the flow rate is given by:
I !.3.4. Problems
1. The trough of the rotating cell filter from problem 8 in paragraph II.2.4
has a weir edge which is 285 m broad. The level of the cellulose slurry is,
as a rule, 25 em above the edge. Calculate the amount of slurry flowing
over the edge.
Answer : 76m 3 jh
2. A free-falling liquid jet contracts owing to acceleration in the field of
gravitation. For a given jet a 20 per cent contraction is attained at a distance
of 8 em from the outlet opening. Calculate at what distance 20 per cent
contraction is found if the outftowing liquid flows 15 times as fast.
Answer : 18 em
89
Rectangular weir ( L > 2h 0 )
;-;;g-
Triangular notch
0 44
tong <P
Comments on problems
Problem 3
For the volumetric flow rate from the drum, with equation (II.48a) :
P1 =Po+ pgH
Expressing p 1 in p 1 with the help of the ideal gas law and integrating between
l = Q, p 1 = 200 x 10 N/m and t = te, Pe = 10 x lOs N/m , we can find
5 2 2
> = 2CA = 1t 2 dh
--D -
4 dt
1le IJ
To measure the flow or the flow rate (volume flow rate l/>,_ or mass flow
e m) of a fluid one can distinguish between:
Displacement meters which divide the gas or liquid stream into known
volume units and give the number of these units which have flown through
during a certain time interval (e.g. wet and dry gas meters, various types of
petrol gauge).
92
B. Flow meters with which the mean velocity of the flow can be
in various ways, e.g. :
(a) dynamic: the indication is based on the flow laws (constriction in
pipe-orifice plate~ venturi tube, rotameter and also the weir and
Pitot tube (see the previous paragraph)).
(b) kinematic : the velocity is measured with a mechanical system
mill, blade whee4 water meter).
(c) thermic : the increase in temperature of the How as a result of a
input of electric energy is determinative of the velocity.
We confine ourselves here to treatment of group B(a) and discuss in
the venturi tube, the orifice plate and the rotameter. These apparatus
designed in such a way that the pressure drop i~ as low as possible (Err ~
I/.4.1. Venturi tube
This tube consists of a gradual constriction (angle 25- 30) and an even
gradual widening (angle maximal 8) ; s~e Figure II.33. With this
we can be sure that the stream follows the boundary lines and eddy
is excluded. p 1 is measured before (or behind!) the constriction and p 2 in
narrowest cross-section (cross-sectional area A2 ) . For the relation
tPm and (p 1 - p 2 ) use is made of the mass balance :
,. = p (v 1) A 1 = p(v 2 ) A 2
and of the Bernoulli equation:
Pt + !p(v t ) 2 = P2 + !p(v2) 2
from which follows :
J ~p
Figure 1133 The Venturi meter
--
-
---~~~~~~~~~mm~~mm~
fb) A considerable energy dissipation is given because the flow separates from
the wall and eddying occurs on the side of the orifice.
The relation between the mass flow and the pressure d ifference measured is
expressed b y equation (I1.35), in which A 2 has been replaced by ,uA 0 The
factor ,u(l - ,u 2 AUA~) -t times the correction factor for the energy dissipation
is called the flow coefficient rJ. for the orifice plate. If necessary, for the transport
of gases allowance can be made with the compressibility of the medium by
mtroducing, in addition to rJ., another correction factor which lies between 09
and 10 for the usual orifice plates. The flow coefficient <X depends on Re 1 =
94
( v) 1Dtfv, on the ratio A 0 / A 1 , on the shape of the orifice and the way in which its
edge has been finished and on the places where p 1 and p 2 are measured.
The finish of the orifice has been normalized in many countries. If tabulated
values of a are used it should be noted that the prescribed dimensioning is
accurately maintained and that the orifice plate is kept at a distance of at least
50 D 1 behind and 10 D 1 before an irregularity (bend, valve, change in diameter).
In the case of careful construction the calibration curve can thus be predicted
to within + 1 per cent. Orifice plates are preferably dimensioned in such a way
that the flow coefficient in the working range is constant (high Re numbers).
(See Table 11.3.)
Table 11.3 Flow coefficient o: fo r orifices with sharp edges and corner taps
A o/A 1 005 01 02 03 04 05 06 07
Re > 10 4 > 2 X 10 4 >6 X 10 4 >8 X 104 > 105 > 105 >2 X 105 >4 X 10 5
(X 0598 0603 0617 0635 0660 ().693 0740 0805
Kw 1000 240 52 19 85 4 2 l
I I .4.3. Rotameter
A rotameter is a tapered vertical tube (usually made of glass) containing a
float (Figure Il.35). The greater the upward fluid flow, the higher the level where
the float remains. The rotameter can be considered as an orifice plate with .
variable free cross-section A 0 (dependent on the position of the float in the
tube) and a constant pressure drop which is determined by the dimensions and
the weight of the fto~t. The latter can be explained as follows: the pressure on
p,<v>,p
I 1
Accurate instructions for the design and use of orifice plates can be found in : V Dl-Durchfluss-
messregeln (DIN, 1952) and R. F. Streams and others, Flow M easurements with Orifice M eters,
Kostrand, New York, 1951.
95
the underside of the float is everywhere almost p 1 and on the upper surface
p2 ,so the force on the float which is in equilibrium with the apparent weight of
the float G1 = Vg(p1 - p) is (p 1 - p 2 )A1 ~ where Af is the greatest cross-section
of the float. Using this in equation (11.35) leads to the pressure drop/flow rate
characteristic of the rotameter :
4>. = oe(A,- Ar)J 2p(pf ~ p)gV (11.63)
-
I
! R
Db
Da = 0105 m ma =
D')2 =
(D: 0345
m, = (~:) = 0065
*4. Through a pipe (Di = OlOm) flows an amount of water (T = 20C) from
12 x 10- 3 to 24 x 10- 3 m 3 fs. The flow must be acc urately m easured with
a sharp-edged orifice plat e with corner taps'. The following requirements
should be met :
(i) The flow coefficient of the orifice plate should be constant over the
entire range.
(ii) The pressure difference to be measured should not exceed 68 em Hg.
Determine the limits between which the opening ratio m should be
chosen.
Answer : 03 ~ m ~ 05.
*5. Show that John gave the greedy alcohol manufacturer the right answer to
the problem described at the beginning of this paragraph (palcohol = 790
kg/m 3 ) .
Comments on problems
Problem 4
Calculate the Re number for volume flow :
Re = pvl D I = P 08 Vt D f - . <f>v~ P l
'1 08 17D 1 08 17D 1
= 12 X 10 - 3 x . 103 = 15 X 105 (for minimum flow)
Re 08 x 10- 3 x 10- 1
In this story (Ab - A1) is. fixed. If we assume for a moment that p1 p we find:
cP m alcohol cPmwater
-
J Pal~hol JP::::r
c/>malcobol = 089 <f>mwate r
Here we see the 11 per cent claimed.by the manufacturer!
However, the manufacturer admits that the reading of the flow meter is not
affected by temperature variations. This information can be used to find a
relation between p1 and p:
d{p(pf - pJ} I = 0
, dp p=pw
He also informs us th.a t the float was selected in such a way that the ex value
was independent of the Re number. Now we have:
- - - - - -- - - - -- - - - -- - - - - -
98
n.s. Flow arOlmd obstacles
Inspector John relaxed for a moment and read a report of an
inventor about a gun which fired almost spherical tear gas
grenades at a muzzle velocity of 45 mfs. The report claimed
that the grenades could travel about 180 m. John observed
that the terminal freefall .velocity of these grenades was
25 mjs and wrote the following text in the margin, before he
turned co work again: 'I am afraid that when fired at a
distance of 200 m from a crowd, they will drop dead just in
between the crowd and the police force.' It took his superior
one night of studying the following text, before he decided
that again John was right.
(a} In the extreme case of flow along a fiat plate (Figure II.37), the force is
only caused by the friction resistance. This figure shows that the disturbance of
v,
/Jh = 3R:x
li r
(II.64)
This result is somewhat different from what we found in paragraph II.1.6, when
we discussed the penetration of momentum for a stagnant liquid and a moving
plate (see page 50). There we had found that:
op =fiW = Rvx v
r
99
Apparently, at a given distance~, > br This is due to the fact that in the case
of the moving liquid there is also a velocity component in the y-direction which
increases the thickness of the boundary layer. This velocity component is zero
in the case of the moving plate.
The presence of a velocity component vy in the flowing liquid is illustrated
by Figure 11.38, where the mean velocities averaged over a constant boundary
v, x=O
2 /v
!yxly=O
v,.
= 1Jbh = 3.Y;; 1
2PV,
2
(1 1. 65)
and the total force on the plate (both sides, length L , width B) is given by:
1
F = 2B Jo
L
Tw dx
,L)-tBLtpv;
= 266 ( vv (II.66)
(b) If a fiat plate with surface area A is placed perpendicular to the flow
{Figure Il.39) an eJqtrem-e case of geometric resistance is attained. Before the
plate a pressure builds up of the order of magnitude of the thrust (!pv;). At the
\tP
r ~ Cw .. 14
~ Cw.,. 0 4
---- ~ --
-- fJ
Ver tical plote L>D c.... 2 Sphere ell( .. 0 43
---- ~
Cy linder L>D Cw 1 2
---
Cylinder L
8 ~D Cw 0 62
--- ---
- ~ c0 f I ~
I o-:J
--- s:;;d~oOd --
- ffiCJ~j
0 0
Steam enoine c...... 1 Bus Cw 06
101
where A.t is the largest cross-sectional area of the obstacle perpendicular to v,.
( = surface area of the projection perpendicular to the flow) and C w is dependent
on Re = vxDfv, with D characteristic dimension of the obst acle. Hence
equation (11.67) has been adapted to the mechanism for the geometric resistance
(b).
At high values of Re this effect predominates the friction resistance so that
Cw is constant. In Table II.4 a survey is given of the C 141 values of a number of
obstacles in the turbulent range. In the extreme case that the total momentum
flux is used for building up the force on the obstacle, this force is given by
F = 4>vPV
Comparing this with equation (1!.67) we see that always Cw ~ 2.
The flow field round one single sphere depends on the Reynolds ' number,
which is here defined as Re = v,Djv, D being the external diameter (see F igure
Il.40). At highly viscous flow (Re < 1) no inertia effects at all occur and the
streamlines converge again behind the sphere. In this particular case Stokes'
law (which can be derives theoretically) applies:
F = 3nrrDv,
or, with the definition of C.., in (II.67):
3 1td2 1 2
(;dP(pp- p)g = Cw4 p"fPVs
7t
The solution for v5 is found by solving this equation-together with the relation
for C..., as a function of Re. This can only take place analytically in the Stokes
range (Re < 1) : '
(pp- p)gdp2
vs = 1817 (Re < 1) (IL68)
In the intermediate range (1 < Re < 103 ) which is often encountered, only a
numerical solution is possible. The force balance is then written as follows:
The right-hand term of this equation is a known constant for a given problem.
With the help of Figure II.41 the relevant Renumber can now be found, from
which the stationary rate of fall can .be calculated according to :
17 Re
v =--
s pdp
The relations (11.68), (II.69) and (II.70) are also valid for gas bubbles rising in
a liquid if they have a rigid surface. Because of the upward direction of the force,
instead of (p P - p) of course (p - Pb) has to be used. Gas bubbles with diameters
< 08 mm are spherical and the drag coefficients for spheres ca n be applied.
Bubbles with diameters 08 < db < 15 mm form oblate spheroids, the drag
coefficient of which is approximately two-thirds of the C.., value of a sphere
with the same volume.
Gas bubbles in liquids have a rigid surface as long as:
d, < ~ (11.71)
103
I
I
I
//
N t/
0: "'
it /;
1
u /
/
I /
-c... =24
-
Re
to'~--~~~-L~LU---~~-L~~~--~~~~~L~
I 2 4 6 8 tO 2 4 6 8 100 2 3 4 6 8 103
--Re
Figure 11.41 Drag coefficient and related functions for spherical particles
If surface active agents or dirt are present in the liquid. the mobility of the
surface is decreased and equation (II.71) gives too low values of the critical
value of db. Thus, air bubbles in water are rigid if db < 26 mm. F or bubbles
with a mobile surface the flow resistance is lower. The stationar y rate of rise is
then given by :
(11.72)
Figure II.42 il!ustrates the rising velocity of air bubbles of various diameters
in water. According to equation (II.72) bubbles with diameters of db = 2ja/g ~p
104
5r--------------------------------------,
I
Equation ( U . 70)
Rigid Mobile
- - d11 (mrn }
have the minimum rate of rise. F or very large bubbles (for air in water if d >
15 mm) equation (II. 72) is simplified to: b
The rising gas bubbles then have the form of spherical caps. Comparison of
equations (If.73) and (li.70) written for half a sphere shows that for these con-
ditions C"' = ~at aRe value of > 12,000 (air in water). This C..., value is compar-
able with that of a circular fiat plate {Ta ble II.4).
1t 21 2
friction force C.., 4 dP1 p 8 v C d _ 2
- - - - -- - ---..,...- - = w p{JgV ~ 1
surface tension nadP 8v -
105
In the dimensionless group we recognize the Weber number, the critical va)ue
of which should then be of the order of magnitude of:
pgdpmuvz 8
W e c r-- ~- ~ 19 (II.74)
(J cw
(assuming turbulent conditions). Hence free-falling droplets can only be stable
for diameters smaller than or equal to d pmax .
Experimental results have shown that We ~ 22 for free fall and We ~ 13 if
the droplets are sudden] y exposed to drag forces.
v
= exp (2gt)
1 +-
' V5 (II. 77)
1- ~ Vs
vs
In Figure II.43 vjv 5 has been plotted against the dimensionless factor 2gtfvs.
It appears that the velocity is stationary if2gtjv5 > 5. For 2gtfvs < 1 the velocity
can be represented with good approximation by:
1; gt
- = -
i.e. v = gt ; the relation applies to free fall in vacuum (no friction losses). This
means that up to a timet < v5/ 2g friction loss may be neglected, which justifies
our as~umption of a constant drag coefficient in equation (JI.76).
Velocities of free fall are often measured by measuring the time for free fall
over a distance L. In that way, the m1e an velocity ( v) = L/ t is determined. The
106
10
o-s
I
..
0 6 v /~f I
vs=7 v5
0
""
......
!>
0-4
0 2
0
0 10 12 0 14 16 18
2gl
v
Figure 0 .43 N on-statjonary fall of spherical particles
+ exp (
2
2 ~t) + exp (-
2
gt)'}
< >=
-
.V
-
Vs 1
n { Vs Vs
- (II.78)
Vs 2gt 4
This function is also shown in Figure II.43. lt can be used to c alculate(via trial
and error, see problem 4) the stationary velocity of free fall from a measured
mean velocity.
In this equation v~ is the rate of settling of one single particle of the system
question (e = 1) and n a value. dependent on v~4/v = Re~ and on the rei
of the particle diameter and the diameter of the vessel D, in which they
107
For dJD 1 < 01 the authors give the following values of n :
Equation (II. 79) has the advantage that the exponent n is given as a function of
a Re number defined for the free settling velocity of a single particle and not,
as .h appens in most liteliture, as a function of a Re number based ori the un
known swarm velocity.
\\\\\\\\\\\\\~
- -ooool
0000 -~""6\\ll'b
0 0 \\\\\'
v0 - 0 0 0 0 F v0 - 0 0 0 F
0 0 0 0 .
-oooo -0 0 0
0 0
0.\\'\\m\.\%' . \\\\'V\\\\\\
{0 ) ( b )
In case (a) most pipes are in the 'wake' of thei( .p redecessor, in case (b) they
are not. Owing to this shielding the resistance of arrangement (a) is lower than
that of (b) and so is the heat transfer. For case (b), as a rule of thumb, we can use
the fact that the resistance coefficient of a tube (related to the superficial velocity)
in the range 30 < Re < 2000 is about 15 times as high as for a single t ube in
the flow if the distance between two neighbouring tubes equals the tube dia-
meter.
Naturally it also occurs quite often that, for example, in the case of heat
exchang~rs the resistance for flow aiong a bank of tubes must be calculated.
For turbulent flow use is then made of th~ Fanning equa ti on (II.35) and the
hydraulic diameter.
108
ll.5.7. Problems
1. What is the maximum diameter of a rain droplet at 20C?
Answer : d P = 66 mm
*2. When driving his car {16 m wide, 13 m high, 9 50 kg) at a steady 105 kmjh
on a highway on a windless day, Klaus notices that, if he pushes the clutch
down, it takes 5 seconds for the car to decelerate to 95 kmfh.
(a) Estimate the maximum value of the drag coefficient.
(b) Driving steadily, which percentage of the petrol used (101/ 100 km) is
converted into mechanical energy, if the heat of combustion is 11000
kcalfkg (p = 700 kgfm 3 )?
Answer : (a) Cw < 055
(b) l 55 per cent
3. Two metal spheres of equal weight but of different diameter fall through air.
Calculate the relationship of their stationary rate of fall if the ratio of their
diameter is 3 and the flow round the spheres is dynamically similar. Is this
supposition correct?
Answer : 1; yes
4. The ' Euromasr tower in Rotterdam bas a height of 104m. It takes a cherry
(diameter 17 em) 65 seconds to fall from the top of the tower to the pleasant
park below.
(a) What would be the velocity of stationary free fall?
(b) What is the drag coefficient?
Assume: (i) that both in Mexico City and at sea level he develops
the same power.
109
(ii) that he runs at constant speed.
(iii) that the time necessary to pick up speed is negligible.
(c) His actual time in Me::dco City is. however. likewise 10 s.
What is your conclusion?
Answer : (b) 92 s
(c) Assumptions (ii) and (iii) are wrong.
6. The gas bubbles formed at the bottom of a glass of beer are released as soon
as their diameter is ca. 1 mm.
(a) Calculate their stationary rate of rise.
(b) How many times more rapidly would an equally large water drop faJJ
in air?
Answer : (a) 0105 mj s; (b) 35 times
*7. A horizon tal air duct with rectangular cross-section (H x B = 30 x 30 em 2 ;
L = lOm;xj Dh = 2 x 10- 3 ) containsanairbeatingelement. This element
consists of six rows of fifteen tubes placed transversely to the direction of
flow. The rows are installed in a staggered position (Figure fl.27b). The
external diameter of the tubes is D = 2 em, the mean temperature in the
duct is 80Cand the mean pressure is 13 x 105 N/m2 . Calculate the pressure
drop in this duct at a mean air velocity of 20 m/s.
Answer: 2860 N j m 2
*8. Show that John indeed gave the right answer to the problem of the gas
grenade treated at the beginning of this paragraph.
Comments on problems
Problem 2
Klaus' data collected in a quiet hour on the ElO motorway will help us to
calculate a drag coefficient that includes not only air resistance effects but also
friction losses. The actual C..., value will therefore be smaller than the value we
calculate from the unsteady-state momentum balance:
dv
-M-
dt
= Cw A-21 pzr'
dv = 10 kmfh = 0-555 mj s2
dr 5 min
and we find :
Problem 7
The pressure drop in the channel is caused by friction along the wall and by
the flow resistance of the pipes, and we can assume that these two resistances
are additive. The pressure drop in the empty channel is then found to be (using
Dh = 03 m, Reh - 3 x 105 , 4f = 0024, equation Il.35):
tlp 1 = 200 N/ m 2
The drag coefficient for one single pipe would be (with Re =2 x 104, Table
II.4) :
Cw = 12
Thus, for staggered tubes C~ = 15 C..., = 18. Thus the force on one pipe is:
F = CwAtPV 2 = 266 N
The force on all pipes together is then F.ot = 615 F = 239 N and the pressure
drop:
t:.p 2 = 239/009 = 2660 N j m 2
l -:... ---- v/
/ / -----' "'-..
~
I
::0... II I
I
I
I
I
'
x.-
111
which yields after integration between t = 0, vxo and t, vx:
1 l
(2)
Now vx = dx/ dl and after substituting vx from equation (2) and integration
between t = 0, x = 0 and te, Xe we find :
and thus:
2MfCwpA = v;fg (4)
So, for y = 0 :
te = 2vy0 /g
Introducing this expression and equation (4) into equation (3)' we obtain~
xe = v; In ( 1 + 2~~~Vyo)
g vs
Now :
2 .
v"'0 Vy 0 = v0 sm a cos ex
which is maximum for rx 45, i.e. v.xo = v>' 0 = 071 v0 , and so the maximum
distance is :
If you , as d id the poor inventor, neglect the air friction, you find for the maximum
distance:
2 2 .
Xe = -V0 SID 0: COS f1.
g
which yields for Xemax = 202m!
112
11.6. Flow through beds of particles
The police doaor rose and stared chac the man had died by
town gas poisoning not longer than 10 hours ago. 'Remark-
able', John thought. The room where they found the body
was locked from Ihe inside and there was no smell of gas at
all, although concentrations above one-thousandth of the
lethal level can be smelt quite easily. The gas valve was open
but due to an explosion at the gas works the supply ceased
8 hours before. A small fan in one of the windows pressed air
into che room so thaz lhe pressure was 80 mm water column
higher than outside the room. The room had a volume of
80 m 3 and t'J-.ere was about 50m2 of wall (20 em thick'h the
porosity of the material being approximately 20 per cent and
the particles which constituted most of the material having
a diameter of ca. 0-3 mm. Lighting a cigarette, John con-
cluded that the man had died at another place.
The fiow through a bed of particles is of gre~t importance for all branches of
technology; in chemical engineering for filtrationycatalytic processes, separation
processes in columns with packing materials, etc., and also for petroleum
production, soil mechanics and hydraulics. A great deal of theoretical and
experimental work has been done by various groups. Outwardly the various
formulae we encounter often differ, but on second thoughts they have much in
common
Two types of particle bed are of great technical imponance : the fixed bed and
the fluidized bed. ln the former bed the particles rest on each other and are not
moved by the fluid. If in this bed the velocity of the fluid js increased, a situation
is created in which the force on the bed becomes equal to the apparent weight
of the particles. The flow lifts the bed, as a result of which the particles become
suspended. This is called the fluidized state which is characterized by a thorough
mixing, especially of the particl~s. The result is that temperature- and/ or
concentration differences in the fluidized bed are rapidly eliminated, so that in
the bed uniform conditions prevail which are often desired. If the velocity of
the fluid is increased still further. the particles are ultimately blown out of the
bed and we enter the field of pneumatic transport. We shall now discuss some
essential points of the flow in the two types.
The drag coefficient in this relation is self-evidently another from that which is
found for one sphere in an infinite fluid. From the force F we can now calculate,
by multiplication by (v), the energy whic4 is dissipated round one sphere. The
total number of spheres in tbe bed is subsequently calcu1ated from the volume
the spheres take up in the bed, (1 - s) AL, where Lis the height of the bed So:
= ErrPVoA =
(1 - e)AL 1t H 3
ErlPm Cw dp,;p(v)
4
~d3
6 p
or:
_J. .!. 2 1-c;L
Err - 2Cw2Vo t3 d
p
At a sufficiently high velocity in the bed (high Renumber) the flow is turbulent
and, as we know, Cw is constant. Ergun found for this range Cw = 23.
At low velocities in the bed the flow is no longer turbulent, but shows eddy
currents. In this region (which is also called laminary') Cw is expected to be
inversely proportional to the Re n~mber. The difficulty here is to define the
Re number which is characteristic of this flow. The .c haracteristi.c velocity is,
of course, (v). However, the characteristic cross-sectional dimension oftheflow
between the particles is not so much -d etermined by the particle diameter as by
the space remaining between the particles. Now it appears that the hydraulic
radius A/ S of the cavities between the particles can be used for correlating Cw
as a function of Re11 (= 4p( v) R nf'1S) for all packed beds. This hydraulic radius
R11 is connected withe a~d the specific surface area of the particles Sp:
The specific surface area is, in turn, again a function of e and the particle dia-
meter, namely:
_ 6(1 - e)AL nd2 _1_ _ 6(1 - e)
S., - nd3p PAL - dp
114
so that :
Re&= ~ PVodp
3 '1(1 - e)
Now it appears that for Re,. < 1, Cw = 152/Re,.. This relation is known as the
Carman formula, but is also named after Blake and Kozeny.
According to Ergun a good description of the flow resistance in the entire Re
range is obtained by adding the relations for laminar and turbulent conditions,
with the result :
Err
fj,p v~ 1 - e ( v )
-=- = - 3 170- (1- e)+ 1-75 (11.80)
pL L dP e v0 d11
It appears that the flow may be considered as tl,lrbulent if Reh > 700. The
constant v 0 dJv is again a Reynolds number and is often used in the case of flow
through fixed beds, although somewhat incorrectly. Restrictions in the use of
equation (11.80) are that the particles must not deviate too much from the
sphere shape and that the diameter of the particles must be considerably
smaller than the diameter of the bed ( < 210 ) .
For a number offorms of nonspberical particles Efr has also been determined
a,
In such a case, instead of d, in equation (1180) tbe diameter of a sphere having
the same volume/ diameter ratio a s the combined particles in the bed should be
used, and the pressure drop so found should be multiplied by a correction
factor k. In Table 11.5 the correction factors for a number of agricultural and
horticultural products are given.
Product k
Peas 105
Rapeseed 12
Potat~ beans 14
Clover seed. wheat 17
Rye, summer barley 27
Maize 32
Sugar beets. carrots 35
Oats 38
F or asparagus rather divergent k values are found , just as, for example, for
flow through yarn packets and yarn filters. Here it is important to find out
whether these cylinder-shaped bodies lie mainly in the direction of flow
(k ~ 075) or mainly perpendicular to the flow (k :::::: 11). In these cases there is
hardly ever a question of 'random' arrangement.
115
IJ.62. Filtration through a bed ofparticies
Equation (II.80) can also be used for an idealized description of the filtration
process. which is practically always carried out under laminar flow conditions.
Rearrangement yields, if Vis the amount of filtrate at timet:
dV s3 ~pAd 2
vA-A.
0 --- P (ll.80a)
- '+' II - dt - 170(1 - s) 2 Yf L
During filtration, the suspended particles will collect on the filter medium (e.g.
filter paper, cloth) and form a cake. If we neglect the flow resistance of the filter
medium, the term Lin equation (II.80a) is t he thickness of the filter cake, which
is a function of the weight fraction f of solids in the suspension and the amount
of filtrate V already produced. A material balance shows:
A.
'+'u =
dV
dt = dPA
J e
3
ll.ppP
340(1 - e) Yfp,Jt
(II.83)
The derivation of equations (II.82) and (II.83) was based on the following
assumptions:
(a) constant e, i.e. the filter cake is incompressible;
(b) constant ~p. i.e. the filtration is carried out at constant pressure ;
(c) spherical particles; and
(d) no How resistance of !tlter medium.
In practice, these assumptions are not always permissible. For a gjven system
the influence of the flow resistance of the filter medium ca n be allowed fo r by
adding, in equation (Il.80a), to the resistance of the filter cake which is repre-
sented by:
(1!. 84)
2 A
V)
-1 ( -
2
fR + ( -
c
Y) R
A m
6pr(
=-l (11.87)
or :
(II.87a)
Thus a plot of (A/ V)t versus J1A should yield a straight line with slope
-!<ttfllp)fRr:, whereas the extrapolated value of (F/ V)t fo r V/F = 0 yields
(71/llp)R"n which enables us to detemrine the resistances of the filter cake and
the filter medium Rc and R,..
The maximal velocity at which the fluidized bed can just exist occurs in a
highly dilute bed (e--+ 1) and is equal to the stationary rate of fan vs of a single
particle.
The expansion of the bed as a function of v 0 is more difficult to predict
because the flow condition in the fluidized bed is in principle unstable. A gas
stream, particularly. tends to move rapidly in large bubbles through the bed
(aggregative flujdization). A bed fluidized with liquid (provided its length is not
117
much greater than its diameter) is, as a rule, fairly uniform (particulate fluid-
ization). In the latter case the bed expansion can be calculated by using the
relation of Richardson and Zaki for the rate of settling of a swarm of particles .
(paragraph 11.5.5). It should be borne in mind that in the fluidized bed the
relative velocity between the fluid and the particles is (v) = v0 jc.
The relative velocity between the phases in a. settling test (in a vessel with a.
bottom) must be calculated from the velocity of the swarm (vs)s. The settling
particles displace liquid upwards, so that on settling the relative velocity vr is
equal to the velocity of the swarm plus the velocity of the liquid. Since the
volume of particles which settles per unit of time equals the volume of liquid
which is displaced per unit of time, the velocity of the liquid on settling is equal
to (1 - e)(v.s)Je. So, the relative velocity between fluid and particles is:
1- e (vs)s .
v, = (vs)s +- - (vs)s = -
e e
Hence the expansion of a uniformly fluidized bed is given by Richardson and
Zaki as follows :
/ <V) \ l f(n- 1 )
e = \ v; }
_
or e- ~Vol
- l /n
v~
I 1.6.4. Problems
*1. Equation (II.80) can, apart from numerical factors, also be derived from
the Fanning equation (II.35) by regarding the bed as a complex of irregular
channels with total length Land hydraulic diameter 4Aj S. Check this and
calculate that for the bed applies: 4fL'/L = 152/Reh for Reh < 1 and
4fL'jL = 23 for Reh > 700.
*2. In a vertical tube (Di = 10 em, L = 25 em) almost spherical anthracite
particles are fluidized with air. The particle size distributi~n is :
dp(mm)
Mass( %)
from to
100 (}84 20
0 -84 (}71 29
0 71 (}59 23
059 (}50 25
050 042 3
(b) At which mass flow rate are the particles with 0.42 mm diameter blown
out of the bed?
(c) What is therefore the range of mass flow rates suitable for fluidization?
Answer : (a) 0.40 kg,lm 2 s
(b) 35 kgfm 2 s
(c) 1 < c/>';, < 3 kgfm2 s
3. A suspension is filtered at a constant pressure difference 6p over the filter.
At t = 0 the filtration begins (the cake thickness is then 0) and after a time
t a volume V has been filtered . The following results are fo und :
t !lp
(s) (at)
100 20 02
14l 40 Q-2
173 60 Q-2
Predict the filtered volume after 20 s if the test is repeated under the following
conditions :
(a) at a pressure difference of 0-4 at ;
(b) with a second material, the particles of which are of the same form as
the first but with the linear dimensions smaller by a factor of 2 (at
6p = 02at).
Answer : (a) 141 m 3
{b) 05 m 3
4. A mixture of oil and bleaching earth is filtered over a plate and frame press
of 20m 2 filtering surface. After 4 minutes 1m3 and after 10 minutes 2m3
of filtrate are collected. How long does it take to filter one charge of
20m 3 ?
Answer : t = 460 min.
5. At reguJar intervals the filter press of problem 4 must be cleaned. This
cleaning operation takes t 0 minutes, irrespective of the amount of cake to
be removed. If the flow resistance of the filter cake is neglected (R m RJ,
how long should the filtration last in order to obtain the maximum filtration
capacity over a complete cycle (filtration and cleaning time)?
Answer : t = t0
*6. Show that John reached the right conclusion in the problem stated at the
beginning of this paragraph.
l19
Comments on problems
Problem I
With equation (11.35) we have:
L'
!J.p = 4f-!p( v) z
D,
4A 4edP Vo _ 2 pv 0 dP
(v) = - and Reh - - ~...;:;........!=---
Dh = S = 6{1 - e)' e 3 '1(1 - c:)
..,-e find :
and :
llp = Err = 4JL'v~(l - e)3
pL L Ldpe 34
Comparing th is with the expression developed in paragraph 1!.6. 1 :
Err-~ 1 zl- e
L - 2 w"'iVo d e3
p
Problem 2
Since we are dealing here with a mixture of particles of different size we must
be careful which diameter to use in equation (II.88). The derivation of this and
of the Ergun equation was based on the specific wall surface Sp given as:
S = surface of cavity = 6(1 - e)
" yolume of particles dP
For a mixture of particles of different size we must therefore use :
a= 6 X volume of particles = L nidt = I Mi
P surface of particles L nflf L M 1
d;
where M ; = mass fraction of particles with diameter d;. Thus we find :
10
ap= 020 029 023
025 003 = 0- 69 mm
092 + 078 + 065 + 055 + 0-46
120
Estimating c ~ 0-4, we now find from equation (11.88) (17 = 17 x 10- 6 Ns/m2,
p = 13 kgfm 3}:
Assuming the gas in the room to be perfectly mixed the material balance :
de
vdt=- c 11
Mixing and stirring are two conceptions which partly overlap. Mixing is the
uniform distribution to a certain scale of inhomogeneities over a certain space.
M ixing can be attained by stirring. The object of stirring can also be to promote
heat or mass transfers or to make a suspension or emulsion. Three transport
mechanisms generally occur during mixing :
(a) convection, i.e. the material present is moved ;
(b) dispersion, i.e. different parts of the material move at different speeds; and
(c) diffusion.
I I
{0 ) ( b) lc) (d)
Flat blade turbtne Flat blade paddle Propeller Inclined blade turbine
flow in both directions. Figure II.46 shows the flow patterns obtained for two
type s or impellers.
I
I
------ I ------
{I
I
Radial flow type impeller Axial flow type impeller
where A is the crosssectional area of the object and Cw the drag coefficient
Since A - d 2 , and v corresponds to the tip speed of the blade (xnd) multiplied
by a slip factor, the force on the blade is proportional to pn2 d4.. The powe:
needed to overcome this force is equal to force x arm x number of revolutions
per unit time, or -Fnd. Therefore, the power number P0 = P/ pn3 tP is pro-
portional to the drag coefficient Cw. The shape of the power curve is similar to
that of the drag coefficient versus the R eynolds number. F or Re > 104 the
power number P0 becomes a constant. In this turbulent region P0 is only a
function of the geometry of the system. At values of Re < 10, P 0 is proportional
to 1/ Re, thus the power consumption is given b y :
P = P0 pn 3 d 5 (Re > 104)
(Re < 10)
Table 11.6 gives a survey of some approximate values for P0 and P'o for variolA
impellers.
123
150
With baffles
2 Wtthout baffles
10 10 2 103
- - - pnd2./"f/
Figure ll.47 Power consumption curve for turbine stirrer
where dis the stirrer diameter,ftbe weight percentage of the particles and C
a constant of the order 1 (for turbines approximately 15) which depends on the
geometry. The power consumption then is:
p = Popn*3ds
where pis the mean specific gravity of the suspension.
Re < lO Re > 1~
Impeller Po K,
Flat blade turbine
six blades, width/ diameter-1 / 5 70 6 13
four blades. djtto 70 45 06
.
123
Wi th baffles
W1thout baffles
10 . 10 2 10~ 10 4 10 5
2
- -- pnd !')
where dis the stirrer diameter,/ the weight percentage of the particles and C
a constant of the order I (for turbines approximately 15) which depends on the
geometry. The power consumption then is:
p = Popn*3ds
where pis the mean specific gravity of th e suspension.
.
124
I1.7.3. Pumping capacity and mixing time
If we consider only the biggest velocity component of the liquid flowing from
the impeller, the pumping capacity is given by the product of the mean velocity
of the liquid leaving the impeller and the area described by the blade tips. For
the propeller this leads to (d - diameter of impeller) :
ntm = constant
holds, for geometrically similar situations.
The mixing time is about four times the circulation time of the vessel contents.
Thus, if no dead spaces are present:
v
tm ~ 4 tPc
I ~ 0, C = Co Somphng point
tracer cone. C
Figure D .48 Measurement of the F curve
Consider the continuous flow system shown in Figure Il.48. From a time
t = .o on, we replace the feed stream by a fluid containing a tracer material
(e.g. colouring agent) at a concentration C 0 . If we measure th e mean concentra-
126
T irne 1 -
tion of the tracer material in the effluent streamwe will find that the tracer
concentration (and also <C) / C 0 , its dimensionless concentration) increases with
time, as illustrated in Figure 1149. Now F(t) is defined as the volumetric part
of the e:fHuent stream which had a residence time in the apparatus of less than
the timet. Since we know that all untraced fluid in the effluent stream has been
in the apparatus for a time t, F(t) is represented by the fraction of traced fluid
( C )/C 0 in the effluent. Consequently 1 - F(t) is the fraction of untraced fluid
in the effluent
The F function (and also ( C ) ) is averaged over a small volume taken from
the flow (mean cup values). For measuring, part of the flow is collected, mixed
and subsequently analysed. If concentration gradients or velocity profiles are
present over the cross-section (as is the case during laminar flow) we must be
careful to measure the correctly averaged value.
The F function bas a number of properties, the most important of which are:
F(t} = 0 for t =0
(i.e. no fluid remains infinitely in the apparatus) or, formulated more precisely,
F(t) = 1 for l = oc
(i.e. no fluid remains infinitely in the apparatus) or, formulated more precisely.
mathematically :
lim (1 - F(t)) =0
(i.e. all fluid originally present in the apparatus will have left it ultimately).
Funhermore. from a mass balance we find:
t--
Figure 11.50 Determinat ion o f T
The mean residence time thus can be determined from experimentally found
F(t) curves, as illustrated by Figure II. 50. A line at t = t 1 = constant creates
the areas A 1 , A 2 and A 3 such that :
rl = A t + A3
Because:
.T = Lro (1 - F) dt = A2 + A3
f oCX) (1 - F) d8 = 1
f oO() E d8 =1
The fraction of effiuent material younger than 8 1 ) which is also represented by
the F function, is then given by:
(11.93)
127
t---
Figure 11.50 Determination of -r
The mean residence time thus can be determined from experimentally found
EU) curves, as illustrated by Figure II.50. A line at t = t 1 = constant creates
the areas A 1 , A 2 and A 3 such that:
Because :
f 00
0
(1- F )d8 = 1
Jo:o Ed6 = 1
The fraction of efiluent material younger than 8 1 , which is also represented by
the F function, is then given by:
(11.93)
128
G
Figure 0.51 The E curve
The E curve can be measured by injecting a tracer material into a flow system
for a very short time and by measuring its concentration as a function of time
at a downstream point. A typical plot of these concentrations versus time is
shown in Figure II .52. The area under the curve :
Area ; 0 : total
amount of lf'ljected
tracer materlol
t -
Since 9 = t/ t and E{8) = ~E(t) we are now able to construct the actual E curve
in dimensionless parameters.
As we will see later, it is often desirable to know the variance of the distribution
curve, which can be calculated according to :
2
U2 = Jco (8- 1)2 E d8 ~ L 8 E il8- 1 = L t
2 ( C> L\t- 1 (II.97)
o r2 L <C>L\t
11.8.3. Simple applications ofF and E functions
l/.8.3.1. Perfect mixer. A perfect mixer is a vessel in which stirring is so
effective that the composition of its contents is identical at all places. Naturally
the effluent from this vessel has the same composition as its contents.
Keeping in mind that Cout = C a mass balance over this vessel reads :
dC
A. C
o/~ 0
- A.
o/v
C = V-
dt (Il98)
For the determination of the F curve from timet= 0 on, the tracer concentra-
tion of the feed stream is changed from Cin = 0 to Cin = C 0 Integration of
equation (II.98) therefore yields, via:
c - dC
--- l/J dt
--! Jr
Jo Co - C- o V
F = 5:._ = 1 - e -e (ll.99)
Co
For the determination of the E curve at time c = 0, a tracer is injected into the
vessel for a short time. The amount of tracer added would, when well mixed,
give a concentration C 0 . Integration of equation (13) for this case yields
. (C,n = Ol) :
fc dC = - (' lf>a: dt
Jc C 0
Jo V
E = C = e -8 (11.100)
Co
As can be seen, the results obtained agree with equation (Il.93), which can be
written as E = dF/d8.
I /.8.3.2. Plug .flow. During plug flow all parts of the fluid move at the same
speed and there is no axial dispersion and no residence time distribution.
130
Therefore, the F curve is described by :
F = 0 fort < -r
F = 1 fort > -r
and for the E curve :
E = 0 for t # T
I 1.8.3.3. Laminar flow in circular tube. Here, the residence time distribution
is caused by the differences in velocity and by diffusion. If we neglect diffusion,
we can write for any streamline with velocity v and residence time t :
Because the maximum velocity at the centre is twice the mean velocity, both
the F and the E functions are zero for:
v .
(v) < 2 and tf 'C < ! respecuvely
For times > r/ 2 we find for the F curve :
Lommor flow
oreo = 1
112 -e oo~--~--~------8
112
~
-~---J
11.8.4.1. Dispersion model. The dispersion model is based on the plug ftow
of a fluid with a certain amount of intermixing in axial direction. This inter-
mixing can be due to diffusion by Brownian motion or by turbulence (Figure
11.54).
dx
I I
X I I
::
~I
fdeol plug f low Dis~rsed plug
f low
If we assume the mass flow rate for dispersion in the x-direction to be pro-
portional to t he concentration gradient a mass balance over a length dx shows:
Adx dC =
dt
(vxCA- DAdC)
dx
- (vx CA- DAdC)
dx JC x+dx:
g
For the case of an instantaneous tracer injection (at timet = 0, place x = 0)
this differential equation .can be solved to yield :
(Levenspiel, Chern. Eng. Sci. , 6, 227, 1957). Equation (II.105) describes the
distribution of the tracer concentration as a function of time 8 and distance
from the point of injection x = vxt. Figure 11.55 shows E curves for various
*This model description holds only when the convective veiocity is higher than the velocity of
diffusion (i.e. vx > 20/L). The reason for this lim itation is that for lower velocities the diffusion
against the direction of flow presents a problem which can only be solved by specifying the flow
and the dispersion mechanism in detail for the area x < 0.
132
o/v}( L =
e
Figure ll.55 Dispersion modeL E curves
which is the normal Gauss distribution. For low values of D fvxL the maximum
of E occurs at(}= 1. For higher values ofDfvxL (>001) the maximum occurs
at fJ < 1.
In order to fit an experimentally determined E curve to one of the possible
theoretical curves the variances of the curves can be compared. For a flow
system with negligible entrance effects {ie. for small values of D/v'J:L), the variance
can be calculated from equation (II.105) via:
J~ (x - x)f(x) dx
2
a = J~f(x)dx
to be :
(11.107)
133
which is simplified for low Dfv;rL to :
D
.,-2 = 2 - (II.107a)
v:r;L
The F curve can be obtained from theE curve by integration according to:
F = s: E(O) dO =I E AO (II.108)
Integration of equation (Ill OS) is not possible, but the F curve can be constructed from
theE curve by graphical integration of the latter. Equation (11.106), which is valid in the
case of very little dispersion [(DfvxL) 0.01], can be integrated directly. The corresponding
F curve is then :
F =
J
6
0
E(O) d8 = 1 f
1
2n: _!!_ 0
8
exp
{
-
(1 -
4-
8)2} d9
D (II.109)
v~ v%L
which can be solved to yield:
(II.llO)
I 1'.8.4.2. Tanks in series model. For a number n of perfect mixers in series with
w tal residence time -r the E function can be shown to be :
(C) 'lffY" -1
E = -- = e- "' (Illll)
C0 (n - 1)!
For large n (n > 5) the .expression n! ~ -,r: e-"fon is valid and equation
(11. 111) becomes :
(n > 5) (Il.llla)
Figure II.56 shows E curves according to equations (11.111) and (II.llla) for
various numbers of stirred tank reactors in series.
The variance of the E curve for n stirred vessels in series is given by :
(II.112)
134
H~r------------------------;---,
8
Figure ll.56 Tanks in series model, E curves
F -
-
1-e!'e {1 +n(] +2!
(nB)2 (n0)3 (n9Y' -
+ 3J + ... +(n-1)!
1 }
(II.113)
10
e--
Figure ll.57 Tanks in series model, F curves
(dF)
d8 8= 1 ~ (E)e..,l =
n"
(n- 1)! e-n
The relation between this slope and the number of stirred vessels in
series is shown in Figure ll.58.
30.------- - - - - -- -- - -- ----,
-..
With <1:} = l ju;, the variance and hence the number of ideal mixers can be
determined using equation II.ll2.
2
8--
Figure U.59 Comparison of models
137
bich becomes for small dispersion numbers :
Figure 11.59 shows an Ecurve calculated for both models on the basis of identical
~ariance (equation Il.115). As can be seen the E curve of the tanks in series
model yields a higher proportion of material staying only for a short time in
the system, whereas the E curve of the dispersion model (which shows also a
smaller maximum E value at higher 0) shows a greater p ortion of liquid staying
for a longer time in the system.
It is evident from the above that on analysing and presenting the residence
time distribution of a continuous reactor system the model must be selected
carefully in order to present the reactor system as well as possible. If, for example,
the reactor system consist s of a series of vessels or compartments in which
mixing occurs, the tanks in series model should be chosen, whereas in the case
of a tubular reactor the dispersion model will generally represent the system
more satisfactorily.
l0_,(v~) + 0
2
D =5x ( if Re < 2000and ReSc <dO~; Sc = ~) (II.lJ6)
1
Lommor f low
Re Sc
r r
r,..
3 0L/d1
r o 2 L-~-L~~u__J~~~~--L-~~~
6
104 105 10
- Re Sc ~ d,lv 11/D ~ ~~d, IO
Turbulent flow
- - Re
Figure ll.60 Dispersion number for flow in tubes
138
whereas for turbulent flow :
D ~ Q. 2v ;xtl1 (if Re > 10 5) (IJ.117)
Figure 11.60 shows more detailed information about the dispersion coefficient
for flow in tubes.
In the literature the degree of fluid dispersion is often not described by the
dispersion coefficient but by stating the height of a mixing urut, HMU. For the
tanks in series model this length is given by:
L
HMU= - (11.118)
n
and states the length of pipe that is equivalent to one perfect mixer. For the .
dispersed plug Bow model, applying equation (II.llS), we find:
For fully developed flow through beds of particles (e.g. fixed beds, packed
columns) the height of a mixing unit is found to be equal to one particle diameter:
HMU ~ dP
in the range 01 < Re < 2000. This relation also applies for flow around
cylinders (e.g. in heat exchangers), as shown in Figure II.27, if instead of dP the
cylinder diameter ~ is used. Since for packed columns and fixed beds mostly
dP L , the number of mixers in series is so big that plug flow is approximated.
Knowledge of the dispersion coefficients in pipe flow enables us, for instance. to calculate
the degree of mixing in pipelines, if one fluid is followed by another Jiquid miscible with
the first. The situation is schematically drawn in Figure ll.61. At t = 0 (entrance of tube)
thert~ is no mixing at all, whereas at t = 't some intermixing has occurred. The problem
is now to determine the volume of liquid leaving the pipe, in which the concentration of A
and Bare lower than the preset values C~ and Cl. This volume often has to be considered
as a loss.
This problem is most easily solved by using the definition of the F curve: C 8 == F(O) and
CA = 1 - F({}). Hence, the considered volume, which leaves the pipe between 81 and 92 ,
c*\
I
:
e
Equotion{llIIO)
I
I : 0 02 I = T G,
0=0 0 =I
Figure ll.61 Mixing in pipelines
139
can be calculated from :
c; = F(8 1) and C~ = 1- F(8 2 )
If we concur to the model of pipe flow with axial dispersion and if CA and q are nor too
low, we might use a linearization of the F curve around the mean residence time :
F~ !2 + (dF)
dO s=t
(9 - 1) "" _!_
2
+ E(8 = 1)(8 - 1)
(II.l20)
L ~
- 2(1- C*A ,.....)lff2trd
--
1
Lo
- '--B
L0
~
-.1
-o ro-
1
30-~40-60
~
e
Q
c:
c0
0
20-80
v
tl)
=
'ii
0.
\ Peent contommoHon
5.
0 5-95 10-9 0
c:
g
uc
ct
i0 - 4
10-6 10-3 10-2
Dlvx L = ( Dlvx d1 Hd1 /L)
11.8.6. Problems
1. De.velop an expression for the E and F functions of two perfect mixers in
series (each with a residence time r:/2) and show that the results are in
agreement with equations (II.lll) and (11.115).
2. The feed stream to a continuous deodorizer (a vacuum steam stripper
applied for rendering edible oils tasteless) is at time t = 0 changed from
bean oil to coconut oil and the refractive index of the effluent stream is
recorded. From the refractive index the percentage of coconut oil is deter-
mined:
Time (min) Percentage of coconut oil Time (min) Percentage of coconut oil
30 0 60 705
40 5 65 83
45 165 70 92
50 345 80 99
55 52
1 100 10,000
Air 0-Sd, d,
Water SOOd, d,
4. A relatively small waste water fiow from a factory is bled into a big effiuent
stream of 0.1 m 3 /s and discharged in to the sea. If the waste water flow is
stopped, the concentration of impurities in the effluent stream at the end
of the drain appears to fall alniost exponentially to nil. The concentration
at the outlet is then halved every 100 minutes. If t he plant is running and
1 kg of very harmful material, uniformly distributed over 10 minutes,
enters the waste water flow, calculate the maximal concentration of this
material at the outlet.
Answer : 114 gjm 3
s. In order to determine the mixing efficiency in a cascade of six stirred vessels
the following experiment is carried out. A continuous stream of water is
passed through and at time r = 0 an amount of acid is injected into the
first reactor. At regular intervals samples from the effiuent of the last
reactor are taken and analysed :
0 0 30 300
5 0-10 35 212
10 163 40 139
15 323 50 051
20 396 60 010
25 371 70 0
or :
(dF)
de 8= 1
= (dF)
dt z=t
r = 196
From Figure 1158 this leads to n ~ 25 perfect mixers in series. The dispersion
number is then found via
D 1
()'2 = 2- =-
v;cL n
10-~
S: ~
v
~
0
~
I
ll.
0' 1. ~~,~ ~~
~ ~ ~
04
-1
- - - Slope =00357 mrn
0-2~
~
i~
~""""'~ J I I I I I
00 20 40 60 eo 100
r ( min)
143
Problem 5
With equations (11.96) and (11.97) we find:
cr = rL:l:cllt
2
~c ~t- 1 = o-t8t
_Q_ = 010
v;xL
The amount of tracer injected is found as:
or 60 per cent. However, John .neglected to realize that be was looking for one
man only, whereas the concept of residence time distribution is applicable only
to a very great number of elements!
ep( ifl hob/em Sclv1n9 4. ft: my\lie ftlf L "'Jn ll ~~ !f,Cit!l!. ('r II. 11
~ We have taJcen here for the heat capacity the vaJue which is correct if the process proceeds
constant pressure. F undamentally, this is not q uite accurate, because the presence of a flow
that there are presf.u re differences.. In mcst cases this is not a great problem because either cp
c. are almost equal to each other (e.g. when solid substances and in compressible liquitts
involved) or the process is almost isobaric If we want to proceed in a p recise manner, we
read, instead of c,, .c. + T(6p/f>n9 !JVj ()T, this constant o nly being calculated for every"'"".;_
meot if it is known which change in the volume per un it of mass ()()takes place within the
at which the temperature changes witb ~T.
145
Since cp''g is positive in the direction of decreasing temperature, the minus
sign has been added.
ln many correlations for heat transport the beat conductivity A. is found in
the combination AjpcP which, because of its analogy with the diffusion co-
efficient, is called thermal diffusivity a (m 2 /s). In Table 111.1 approximate
values for the heat conductivity and for the thermal diffusivity are collected.
a (m 2 / s)
</>" - ). Tt - To (IIL2a)
H- d
Methods for measuring the heat conduction of solid substances are bas
on this equation. If the wall consists of more ta yers (Figure II I.l ), for the sanie
reasons as in the foregoing~ rf>'H must be constant in every cross-section in every
layer and so in every layer dT/d.x must be constant (and inversely proportional
to the conductivity of that layer!). If for every layer we write equation (JII.2a)
as follows:
A,.H
H
'f'
~d;)
A. = flT:I = T:-
I
T:IT. l
I
--K
Figure ill.l Stationary heat conduc-
tion through walls
The terms (x2 - x .}/ }..., etc., can be considered as heat resistances, and the
above equation says that the total temperature difference (T1 - TJ equals the
heat flux multiplied by the sum total of the resistances placed between .x 1 and
x 4 (Compare this with Ohm's law in electricity.) The sum total of all partial
resistances. which are also called the partial heat resistances, is described as the
147
total heat resistance for which usually (and also here) the symbol 1/ U is used.
'U' is then the total heat transfer coefficient.
. -
ll1.1.2. Heat conducti9.n)hr.ough, cylindrical walls
.
The next example is the stationary heat conduction in the thick wall of a
cylindrical tube (see Figure 111.2). In this case the heat flows ~ (per unit of
. tubt:: length) through the surfaces r- = R 1 and r = R 2 and through all surfaces
in between must be equal:
A-' ,dT
2
dr 1_tr
'PH :::; '"7 1. = constant (III.4)
{ntegraHon
. yields:
.
T = constant ln r + c;,
and with tlte boundary conditions indicated in the figure we find for the. tern-
. perature distribution in the wa:Il:
a
0;:- kd
- .J / dr
A (IIL5)
' .
This result is again sufficient for calculating the heat flow which is transferred
between sphere and medium at a given temperature :
(III.9)
149
Newton described the cooling of bodies of any form with a pragmatic cooling
law in wh.ich he put the heat flow proportional to the outer surface of the body
and to the prevailing temperature difference (T1 - Tee,). The proportionality
constant, which is a purely phenomenological quantity and contains all that
we do not know of the transfer process, be called the heat transfer coefficient a.
For the sphere from the previous example this cooling Jaw is therefore for-
mulated as follows :
(III.lO)
It follows that in this case !X = J..R. In our j argon this is summarized to Nu = 2.
where the Nusselt number Nu is defined as a2R/ A.. The Nu number represents
the relation between the heat resistance which is estimated on account of a
characteristic dimension of the body {in the above example 2Rj ).) and the actual
heat resistance (1/ a). We may also consider this quantity as the relatio n between
the dimension of the body (2R) and the thickness of the Jayer over which the
drop in temperature takes place (/.fa).
Analogously for a fiat plate and for a cylinder we find Nu = rxdjl = 1 and
Nu = a2Rj ). = 2/ln R 2 j R 1 respectively. IJu hD ) rth tr -H.11 l,caJ -lr:ntrrttr!d
- ~~ tnltt f. ~Whlenl lronrr rt ~
K~ h~n~cd ~i ~ill ,,. lu 1 (lllJ 11
I I I .].4. General approach for the calculation of temperature distributions It ' 1..,. . (i (Q
tc "'' rill
dT dT
pep ( dt + vr dr +
v8 dT
dOr dT)
+ v, dz = )..
(' 1
T
d( r~n 1 d'T d'Tl)
dr + r d8 + dz + q
2 2 2
(Ill.l2)
The reader may check that the Simple cases treated in the first three sections
of this paragraph can be derived from these equations. !n the case of conduction
. through a cylindrical wall treated in paragraph .JII.l.2, for example, q = 0,
vx = v>' = vz = 0 , dT/dt = 0 (stationary state), dTjdfJ = 0 (constant tem-
perature in all radial directions) and dT/d2 = 0 (constant temperature in axial
direction). So we find from equation (III.12) :
~ +~l
r dr
= 0 r
'
ddTr = constant
which is identical with equation flll.4).
,~.,." q . cl
'PH= lT ;-7
'H = ~r = -).~T
2 dr
. T = _!i.,.:z + c2
4).
(III.15)
152
The average temperature is given b y:
( T) =
foR 2nrT dr
fR -
s: Tor dr + J.R <R 2- r2)dr
tR
Jo 2w dr
(Ill.16)
</JH = dT I _ = nR 2 Lq
-2rcRLJ.-d
T r"'R
which is in agreement with the overall balance equation (III.l3) set up for steady-
state conditions.
It is interesting to compare the results just obtained with the equations
developed for the shear force and flow velocity distribution for laminar flow
in a circular pipe (paragraphs IIJ.2 and 111.3). The microenergy balance
applied here is analogous to the micromomentum balance of paragraph Il.l.3
and the correlations for Jarrunar flow found in paragraph 111.2 can be translated
into the temperature distributions just developed if we use the conversions
given in Table 111.2. Apparently, the processes of laminar fiow through pipes
and of uniform heat production in a cylinder are analogous.
Table m.l Analogy between laminar How and uniform heat production
Trz ~/to ]
2
4>11 (W/ m2]
~ [In/s] T- To rCJ
'1 [Ns/m2 ] A. [W/m 0 C]
P 1- PlfL = - ~[N/m 3] q [W/m 3]
Ill.l.6. Problems
1. An oven wall consists in succession of a layer of firebricks (Ar = 121
J/ m oc s), a layer of lagging bricks {111 = 0.080 1/m oc s) and a layer of
bricks (),b = 069 J/ m oc s). Each layer is 10 em thick. The temperature on
the inside of the wall is 87rC, on the outside 32C.
(a) If the surface area of the wall is 42m 2 , calculate how much heat is lost
by conduction every 24 hours.
(b) Calculate the temperature T'" in the middle of the layer oflagging bricks.
Answer : (a) 21 x 109 J ;
153
2. The Chemisch Weekblad of 30 September 1966 gave the following news
item:
In Elsa, a mining settlement in the Yukon district, situated only 290 km south of
the polar circle where the temperature sometimes falls to - 70C. the water supply
was seriousJy hampered by freezing. This pro blem has been solved by putting a
floating pumping engine in the nearby lake. The construction is such that the water
inlet tube is well below the level of the ice. The 125 an thick pipe connecting the
pumping engine with the storage tank in town-a distance of ca. 5 Jan-was
insulated with a 5 em thick layer of urethane foam. The flow rate of the water in the
pipe is on an average 6751/min Even at extremely low temperatures water of 2SC
can be pumped from the lake to tbe town without heating being necessary.
What follows from these data for the heat conductivity of urethane
foam?
Answer : 003 W/m C
3. A management considers installation of double windows in a large office
building. According to the bookkeeper the fixed costs (depreciation,
maintenance, insurance) are Dfl. lOOOper year more than for single windows.
Natural gas costs 2 cents per decamega joule (107 J ), a year has 2 x 10 7
heating seconds and the average temperature difference inside-outside
is l0C. The heat transfer coefficients inside and outside are both
20 w/ m 2 C, a pane is 3 mm thick (l glass = 1 w/ m C) and betweeii the
double windows there is a 5 mm air space (). air = 0025 w/ m C).
(a} Calculate the loss of energy per year for the single and the double
windows.
(b) What would the total window surface area be if the additional expenses
of double windows could be paid for from the saving in heating costs?
Answer : (a) single windows : 194 x 107 J/rr/; double windows:
7
65 x 10 J/m 2
(b) at least 388m 2
4. A length of steam pipe (outer diameter 005 m) bas to be insulated. Depend-
ing on the thickness of the glass wool insulation a Dutch firm in November
1970 quoted the following prices (including glass wool insulation, outer
layer of aluminium plate 1 mm thick, labour, transport and tax) :
10 1350
20 15-00
30 1700
40 1950
50 2250
;:)
1! : 1/Jj Mft!l..J'6. The hydrogenation of edible oils is carried out with a suspended catalyst.
~.~~~:1 What is the maximum temperature difference between the catalyst surface
and the oil? '1,{~-t.tt.- 411 rl ~ ; . ,3) 'li m1 'h ",v,r~tr&
01
' 13 .-u'
J ;.r 1 ~f
, ' r ~ ~ 1 .. t-
spherical particles, dp = 2.5 X 10 - 6 m ~ '-;4' n )
I I'!' 1l /
1~ ('.,'"'-' 1':1 .
. Datil :
" ~ (I J 'i 1
,_ ... apparent specific gravity= 1750 kg/m 3
it f..,} ' rr ~ .. ~r 02 per cent by weight of catalyst applied <ltt dH I n : h!l vT
sH ~., lfl~ o Jhydrogenation rater= 13 x 10- 3 kmoljm 3 s .P h ~ k
i.v1- liPJ 1: , , ,,~,.. 11 ,.v! heat of reaction Ali = 25 kcal/mol
2
_ 1.. .
_ ~ molecular weight of the oil M = 880 gjmol
_ r.
1 h ~ ( 1 P . )(1..,, )
0
; < ':' C)~;;-q '~
J
1
off f
3 x 10- 4 oc
-
= 360( ~
2
Answer : T - x2 ) c
*8. Show that John d rew the right conclusion in the case of the deep frozen
body, treated at the beginning of tllis paragraph.
155
Comments on problems
Problem 6
A heat balance over one catalyst particle reads:
rAH
<f>H=--=aA~T
n
where n =number of catalyst particles per m 3 oil = 125 x 1014 Now for
these small particles Nu ~ 2; thus a ~ 2ld and &T can be calculated.
Problem 7
A beat balance over a length of pipe dx reads :
dT q dT
r/>8 =-A).- + -dx = - A).-
dx x L dx x+dx
dJI
or :
Integration yields:
. dT q
dx = - J..LA x + C 1
= 2A.LA x 2 + C 2
-q
T
T =
q
2J.LA
{L4 2
- x
2}
156
Problem 8 John and the frozen body
If we regard the body as a cylinder (L R) we can set up the following heat
balance per unit length :
A.' T - T,. = _McpdT
'+'H = ln R / R 1 L dt
2 1 + - --
2nA. 2nR 2 cx 0
or, collecting aU constant values into one constant C :
(T d T =- C f' dt; In T - Ya - - Ct
JroT - 1: Jo To - 1:
The information that T0 = 8C at t = 0 and T = ooc at t = 1 hat T'g =:= - 30C
allows us to calculate the value of the constant C as C = 0236 h - I .
So, assuming the poor fellow had no fever, his temperature was 37C when
still alive but ooc after t hours and we find, using the same equation, that death
must have occurred 34 h ago.
1 r, ~-------t_=ex:._ _ _ _ __
0 X
Figure m..s Penetration of heat into a semi-infinite
medium
Equation (Ill.l 8) can now be solved by anticipating that the temperature dis-
tribution can be described b y two dimensionless variables:
() = T - To and ~ = x
T1 - T0 ..j4cU
Via :
de dB d~ 1 x de
dt = d~ dt = -2 4ar3 cte
158
and :
d B= d B(de)
2 2 2
de d 2 ~ _ d e2 _t_ .
1
dx 2 2 d~ dx + d~ dx2 - d~ 4at
equation (111.18) is simplified to:
d2 B dB 8 = 0 for ~ = oo} (111.19)
d( 2 + 2~ d~ = 0 with B = 1 for = 0 e
Integration yield s:
and:
e= c,J: .-<' d~ + c,
With the boundary conditions we find C 2 = 1 (since f~ e- ~, d~ = 0) and:
(111.21}
..1. cl .. /c
or: ,/IC.p
2
The right-hand term of this. equation is called the error function, which is often
represented by the symbol erf, defined by:
~-T 2 JY
TJ - Ja erf Y = .fi. o e - ~2 cte
In Table III.3 a few values of this integral are tabulated ; complete tables can
be found in the handbooks.
Equation (III.22) enables us to calculate the temperature distribution in the
medium at any time t and in any place x. The type of curve found is illustrated
in Figure III.6, which shows the temperature penetration into a semi-infinite
slab of stainless steel (a= 7-5 x 10- 6 mz/s) at t 1 = 40, t 2 = 1 and t 3 = 01 s
for T1 - T0 =
l0C. It appears that, for small penetration depths x, the tem-
perature curves can be represented by straight lines. The slope of these tina
159
Table 111.3 The error function
y erfy
0 0
0.1 011 f/J: = (1r T.)J--~~L,
02 022 J." 1 '.l.IV~Jata
I IJ t
04
~ - u.. lrr-rq)/I-
().43
06 0-60
08 074 If~
~~---L----------~------------~~
0 lrrct1 /rrat, )rrat3
x-
Figure Ifi.6 Temperature distribution in a semi-infinite
medium
dT dO (T1 - T0 ) d8
= (:(1 - ToF. - !A:: --;
dx x=O dx x=O y 4at d"> ( =0
dT 2 T1 - T0 T1 - T0
(III.23)
dx x=O - - ,fi .J4Qi = - Fa
showing that the tangent to the temperature curve at x = 0 goes through the
point T = T0 , x = Fat.
The distance x = ~ is called the penetration
depth, which represents the distance x over which the temperature difference
T1 ~ T0 at x = 0 has dropped to 20 per cent of its original value. The last state-
ment can be checked by substituting x =~into equation (III.22).
160
The heat flux through the wall. of the medium (x = 0) is found, using equation
(III.23), as :
(III.24)
The heat fl ux through the plane x = 0 (equation 111.24) can also be described
with a heat transfer coefficient tX:
(III.26)
Thus:
(IIl26a)
If the penetration process lasts a time te , the mean beat transfer coefficie:tit
is given by :
( a ) = -1 --f i'
f'a dt = !ffPC 1r. dt = 2 !f:PCp
- (Ill.27)
te 0 Jtle 0 V L 1tt,
161
Applications of this fonriula are numerous ; see, for example, problems 2, 4, 6
and 7 at the end of this paragraph.
To t--~---"""'t""''----........---1
The proportionality constant (which is of the order of 1 and here equals 4/n)
cannot bC found in this way. A complete analysis is necessary (it is this weighing
factor which reminds us of the previous rustory oft = 0). It is, however, sufficient
for practical purposes to know that it is almost 1 ; the cumbersome full analysis
is seldom required. For times in the range oft = 0 (F o > 01) it yields a poorly
converging series of cosine terms as solution. A better usable solution for short
times is .already available (see the previous paragraph).
For longer times we are also often interested not so much in the actual tem-
perature distribution as in the heat transfer coefficient ex, which we define
on the basis of the mean temperature difference :*
dT
d x = - C t(Tt -
( 1t
2
To} exp - 4R2 2R sm 2R
at) tt . 1tX
(111.32)
and at x = R :
(IIL32a)
163
The mean temperature ( T ) is given by:
A._::_
2R n 2 ).
et.=--= - - (IIL34)
2 4 R
or:
cx2R 1t2
Nu = - = - = 4-93 (Fo > 01) (ill.34a)
l 2
Due to the fact that for Fo > 01 the shapes of the temperature distributions
do not change with time, the Nu values become constant. The value of the
Nusselt number depends only on the form of the body. For a flat plate we found
Nu = 493 and for a sphere Nu = 66. For bodies which can be enclosed by a
sphere we can estimate the Nu numbers by applying NUsphcre = a.D tfA. = 66
and taking for D 1 the diameter of the sphere having the same volume as the
body. For a cube (with side D) we find:
1t aD
V = D 3 = 6- D 31 Nucube =.. -
66 = 66 ~7t
).
= -D
Dl 6- = 53
(exact solution 49). For a cylinder with L = D we find analogously:
I
Nu
cy
1 = 6-6 {f
\}3
58
(exact solution 5.6). Since for Fo > 01 the -Nu anaa values .are constant a heat
balance over the total body becomes:
d (1)
pc P V dt = et.A(T1 - ( T )) (IIL3S)
1-0
..._-
I
----
.......
-..
..._
......
I
-Fo=at/0 2
Figwe JD.8 Mean temperature during non-stationary heat con-
duction d..
._o
...-
I
Flat plote
\---+---+--- -+----+--Sphere
10- 3 ~~~~~~~~~~~~~-L-A~-L~~
0 0 1 0 2 0 3 0 4 0 5
Fo-=at (D 2
Figure Ill.9 Centre temperature during non-stationary heat
conduction
---
cxuAt
pcpV
(III.38)
166
If both heat transport resistances, the outside (1/cx11) and the inside (1/<Xi "' Df J.),
are important, it is possible to construct graphs like Figures IIL8 and III.9
for a series of values ofcc.,. These graphs can be found in a number of handbooks
(e.g. VDI Wlirmeatlas). We can, however, approximate the exact solution by
assuming that also during non-stationary conduction the heat resistances
are additive (as is the case during stationary beat conduction).
For the region with constant Nu values (Fo > 01; i.e. long penetration times)
we can then write instead of equation (11!.36):
-ln Tl - ( T )
T1 - T0
= ~{_!_ + ~}-t
pcPV ~i au
= Nu ~{1 + t
D a 11
}-1 (III.39)
ln Tt - ( T)
T 1 - T0
= f{ a~(l + ~ )
D~ Ciw
-t} (III.40)
Apparently, we can also use Figure II18 to solve problems with an outside
heat resistance if we use instead of at./02 the corrected parameter
at (
Dz 1 + cr:.j !Xu)- 1
i.e. the times necessary to reach the same relative temperatu re equalization
with and without an external heat resistance form a ratio of (1 + a) aj : 1.
In equations (IIL39) and (IIL40) T 1 is the outside temperature and not the
surface temperature T! of the medium. Because of the resistance 1/t:~.u, T1 is
be
lower than T1 The surface temperature can calculated from a heat balance:
(III.41)
Equation (III.41) appears to be in good agreement with the known exact
solutions. The heating or cooling times calculated with the above procedure
arc! within 10 per cent of the exact solutions. In the literature other cases are
also known where an exact analysis showed that place- or time-dependent
resistances in series are not exactly additive, but that only a small error is made
by assuming additiveness. We can therefore extend the approach applied to
cases where the internal heat resistance is time-dependent, i.e. to short pene-
tration times, F o < 01. The times needed to reach a certain temperature
equalization with and without external resistance form a ratio of(l + ( a.;)/'XJ: L
In this equation ( !X) is the mean internal beat transfer coefficient averaged
over the time of the heat transfer process te (eq uation III.27).
We can, of course, also use the relations :
1
_!_ = - - + _!_ and 'li = U(T1 - T0 ) (III.42)
U ( a i) ctu
where ( o:i) is the mean inside heat transfer coefficient, in order to calculate the
heat flux into the medium.
167
111.2.4. Problems
1. A packet of butter of 250 g has a temperature of 20C. It is put in a re-
frigerator of 4C After 120 min the centre of the packet appears to have a
temperature of 6C.
(a) After bow many minutes (from the beginning) is this temperature
5C?
(b) How long does it take for the interior of a 500 g packet (equal in geo-
metry to the former) to reach a temperature of 6C?
Answer : (a) 160 min; (b) 190 min
2. Check that if two conducting media a and b with uniform temperatures
T: and 7b are brought into contact with each other, immediately a constant
temperature 7~ (contact temperature) prevails at the surface, which is
given by:
T, - 7; ~ J<~pce),
T:: :- ~ (Apcp)a
*3. A cooling drum (external diameter D 11 = 1m) has a surface temperature of
20C and rotates a t an angular velocity of2n min - t. A bituminous product
with a temperature of 80C (at this temperature the bitumen is just liquid)
is brought as a layer onto the drum and after a half-revolution is scraped
off again. The requirement is that the temperature of the cooled bitumen
3
does not exceed 25C. Properties of bitumen: c, = 920 J/kg oc ; p == 10
oc.
kgjm 3 ; J.. == 017 W/ m
(a) What is the maximum thickness of the layer which still fulfils this
requirement under the con<litions mentioned?
(b) By which factor is the capacity of.th e drum increased if the angular
speed of 6 tt/rnin is chosen?
Heat exchange between the layer and the surroundings is neglected.
On cooling no latent beat is liberated.
Answer : (a) 22 mm ; (b) 173
4. Objects are submerged in a hot fluidiz~d bed to warm them up. The par-
ticles (diameter 1 mm, ). = 1 W/m oc, cp = 4 X 10 6 J jm 3 0 C} remain
on an average for 03 son the surface of these objects and ca. 60 per cent
of the surface is occupied by particles. Calculate the heat transfer coefficient
between the fluidized bed and the objects. Assume that every particle
remains on the surface equally long, that the gas with which the particles
are fluidized does not contribute to the heat transfer and that the objects
are submerged in the bed much longer than 03 s.
Answer : 2400 W jm 2 oc.
5. Elsevier's Culinary Encyclopedia recommends the following boiling times
for obtaining hard-boiled, non-crumbly eggs from various birds:
168
Turkey 95 850
Goose 85 780
Duck 70 620
Chicken (category 2) 60 500
Guinea fowl 40 420
Partridge, pewit 36 390
Pheasant 30 350
Pigeon 24 300
1 in the pan. Water is added to keep the temperature around the pan at
nr.:.r ~ <n 1)1 10C. There are two ways of cooling: .
Ci-t (a) Allow the pan with custard to cool gently.
~ ht1 (r, -<r))Cb) Stir the pan regularly and use a pan scraper to scrape the custard off
the cylindrical pan wall and mix it with the bulk. Each part of the wall
- - <T))" P~ Vc'/~ ,surface should be scraped once every minute.
1
dt
:n ~ hA 1 ehlculate the times necessary to cool the custard down to a mean tern-
-,, ;lpV ;t perature of 20C according to both methods.
\ AC. c Data : Thermal diffusivity oftae custard is 10- 7 m 2 j s and .l = 05 Wf m cc .
_ ;:{1) },A ] i. over the entire temperature range. The custard is so viscous that
' - -Fip;l t free convection is fully suppressed. Heat transport through the
l<lj 0
bottom is neglig1ble. The pan diameter is 20 em.
Answer : (a) 146 min ; (b) 12 min
8. 1f water droplets (temperature 20C) fall from a given height onto a hot
plate, the droplets will no longer moisten the plate above a certain plate
temperature (Tp) (Leidenfrost phenom~non~ In th~ foJJowing table this
_ ) f A \ ! . - ,,.., :.4 !., r~ J~ Zr> :::c - ( s ,J r t. 1 m (' -
'I ! r ( 7[' J
VI
01. 1
-
1
~- 'ol
1
- --;--
r~Qi\lll )i"
.1
\.
169
temperature is given for four materials. Determine whether. this pheno-
menon occurs at a contact temperature characteristic for the droplet.
25"C
SO'"C
170
(a) The temperature equalization after a half-revolution (at time c = nf 2n =
t min == 30 s) is :
T1 - T,. = 20- 25 = 0 _0833
T 1 - T0 20-80
and Figure 11!.9 yields a corresponding value (flat plate, since heating only
on one side, 2d must be used instead of D) for the Fourier number of:
at at
Fo = 0-27 = -2 = -2
D 4d
from which we find d = 22 x 10- 3 m.
(b) Fo stays con stant, but c2 = !t 1 ; thus:
Problem 9
The figure shows the temperature distribution in the spinach tins during
non-stationary heating.
(a) The heat transfer resistance in the tin after a short time is oj A-spinach, with
o= JMt. We can assume that the inside resistance determines theoverall
heat transfer resistance as soon as :
f1j =1 200C
1-
\
\ ,,
T. =zooc ~~'--"""-!roc-~"--~
0 I: 0
~---L-------1
R 0 R
- x
171
(c) Temperature equalization :
_T,.=,. m = Q.l
l_-_T...:;..:
Tl ~To
and Figure Ill.9 yields :
at
Fo = 009 = D2
and we find:
t = 2-Sh.
- - -- --
X=O X=L
Figure ID.lO Heat transport during laminar flow
172
theory cannot be applied as such, because the flowing fluid transports heat as
well.
Consider the situation shown in Figure IIl.lO. A viscous liquid passes as a
laminar flow through a circular tube. At x < 0 the liquid and the pipe wall have
uniform temperatures T0 . At x ~ 0, the temperature of the pipe wa11 is
Tw (Tw > T0 ). Because of this temperature gradient there will be a heat flux q
from the wall into the liquid by conduction in the radial direction. Since there
is also a temperature gradient in the x -direction, there will be conductive heat
transport in the x-direction as well and, furthermore, heat is produced by
viscous dissipation and heat is transported in the x-direction by the flowing
liquid An energy balance over a ring-shaped control volume 2rrr dx dr consists
of the following expressions :
conduction in radial direction: + qrlr21tr ~ - q~lr+dr21t(r + dr) dx
conduction in axial direction: + qxlx 2nr dx - qxlx +d:r 2nr dx
2
heat produced by viscous dissipation : -21t dr dxrrx ddxvx = 11 d vx2tu dr dx
dx2
energy transported by fluid :
pcpvx(T- T0 )lx21tr dr - pcPvx(T- T0 )1x+d.r2nr dr
Equating heat input and beat output over the control volume, neglecting heat
conduction in the x-direction and beat production b y viscous dissipation
(which is allowed in the majority of cases), we find:
or:
d(rq,.) . dT
--T-rpc v - = 0 (111.43)
dr P x dx
-.A -
dT)
~ d ( r - + rpc lix-
dT = 0 (III.44)
dr dr P dx
v, =2( v) ( I - ; : )
.173
Introducing this expression into equation (Ill.44) we .find:
~ d ( d T) ( r )
- J. dr r dr . + 2rpcP<v> 1 .... . R2
2
d T
dx = 0. (III.45)
This differential equation (the so-called Graetz equation) has been solved
f9r a number of bound,ary ~onditions. For the conditions st'lt~ in Figure 111.9
the solution is, for great distances from the pipe entrance :.
aD ax
Nu = T = 366 for <v>D 2 > 01 (III.46a)
(Nu) = -
1 ixe Nu dx = 162 (<ax)~2) -t
for <Vax>~2 < 005 (III.46c)
r:. ~ Xe 0 ( 1 = _:. ) V
U:z "' p< )j 1 , '1 )!
The term axf(v) D 2 is called the Graetz number (Gz); it has here the same
funcfion as the Founer number for non-stat10nary conduction In the entrance
region of the pipe (short contact time) the thermal boundary layer is built up
and therefore Nu "'x--t. At great distances from the entrance the temperature
distributions will not change with x and the Nu number becomes constant
The above Nu values and beat transfer coefficients are related to a mean
fluid temperature .(T) which is defined as being proportional to the heat flux
transported by the liquid. Thus:
1t rD/2
<T> D 2 (v) = Jo 2nrv,T,.dr . . (III.47)
4
) This is the temperature we would measure if the fiow was collected in a vessel
r
and mixed (mean cup temperature).
Equations (Ill.46a) and (lll.46c) can also be written as:
as the reader m ay check. The reader may also check tha1 for laminar flow the
Nu numbers for pipes of varying diameter and the same length are equal if the
volumetric flow rate through the pipes is equal. The ratioS' of the heat transfer
coefficients are then ff.Ifoc2 = D 2jD 1 , whereas the total beat fiows in both pipes
are equal.
n
The Prandtl number is defined by Pr = vja = Cp7f/A and represents the ratio
of the rate of momentum and beat transport.
For other types of velocity distributions and other pipe geometries tempera-
ture distributions and heat transfer coefficients have also been calculated
174
theoretically. The results can alwa)'S be presented by an equation like equation
(Ill.46b), but the numeric constants change with the geometry of the flow and
the rheology of the fluid Generally, we can state that the greater the velocity
gradient near the wall the greater the heat transfer coefficient will be. For that
reason, under laminar conditions non-Newtonian (pseudoplastic) liquids often
show higher heat transfer coefficients than Newtonian fluids. Measurements
about temperature distributions and temperature equalization in laminar flow
are scarce. Practical experience indicates that, especially in laminar flow, the
temperature dependence of the physical properties of the fluid (especially
viscosity) has great influence on the rate of heat transport. During heating up
of a liquid the warmer liquid near the wall will have a lower viscosity than the
liqutid near the centre of the tube. Since the shear stress distribution is fixed.
(see paragraph II.1.2), this means that due to the heat transfer process the
temperature distribution will be flattened (more uniform). This increases the
heat transport.
Differences in specific gravity caused by temperature differences may cause
extra flow (free convection) and also tend to increase the heat transfer. An
experimentally checked relation for the heat transfer during laminar flow of
Newtonian liquids is given by Siedt;r and Tate as :
( Nu)min = 366
where 11 is the viscosity of the fluid at mean fluid temperature (7: - T )/2 and
0
YJ,., the fluid Viscosity at wall temperature Tw.
or:
(III.SO)
(Jh = Prt
br
Combined with eq uation (III.SO) we obtain :
Nu =f Re P rt (III.Sl)
2
and using the Blasius equation (11.37) to substitute for the friction factor we
finally obtain for turbulent flow in pipes with smooth walls:
Nu = 004 Re0 . 75 Pr+
which is quite similar to equation (III.49) if we add again the Sieder and Tate
correction for the influence of the radial viscosity gradients.
During turbulent ftow there is also an entrance region where higher heat
transfer coefficients occur. We can c9rrect for this effect by m ultiplying equation
(111.49) by (1 + 07 D/L). Since for most practical heat exchangers L D, this
correction term is rarely necessary, however. Equation (IJ T.49) will yield
approximate values for heat transfer in pipes of other than circular cross-
section if instead of the pipe diameter the hydraulic diameter of the channel
is used
176
If a circular pipe is wound to a spiral (diameter 2R) the heat transfer co-
efficient compared to that in a straight tube is increased by a factor of:
h ~ L oyer of d i r t
h
._ "" dw A\ ~ j. T
- 'l'-!1 -
r,.J 7- Fluid I Wa ll F lu!d 2
tr ~ ( ~ ~\~ ~ 1~ (Ti -, I
)
1~II ~ () )
~~~ I:J ha )j -
",; P.lil
al x,..
d~t
'Ad
dd
Tor ..
t -1 _! _
:=
~
h4 A~t
-----
A\ -\ Ao
:2
AL- Av
l<'vrA~ t('dA, ~ ~ A5
<T2 ) - - - - --- -
-- ~ 1--.
1 - - - 1- -
az To/l-
~Ai
Ao
~
Lli
K Di stance ..
1T =
Llr
-- Figure ID.12 Heat resistances in series
1
x 1JCJ
Ll1~1
< <
where T1) and T2 ) are the mean temperatures of the flowing liquids. 1ust as
_, with heat conduction through various solid layers {Figure III .1 ), here in the one-
dimensional case the total resistance 1/ U equals the sum total of the partial
resistances. Thus :
(III. 54)
Table 111.4 Survey of heat transfer coefficients (W/m2 C) 0
Heat flow - to: Gas (free convection) Gas (jl owing) Liquid (free convection) Liquid (flowing) Boiling liquid
1 ~ = 5- 15 IX= 10-JQo C( = 50-1000 water water
from : (x = 3000-10,000 C( = 3500-~,000
other liquids other liquids
(J. = 500-2000 C(
= HJ00-20,000
- - - - - ----- - - - - - - - - -
Gas (free convection) Room/outside air Superheaters
~ = 5- 15 through glass u= 3-10 .
u = t- 2 Oven Boiler
- - - - - - - - - - - - - - ' - - ----- ... .. ---- . - - - - - - - - u = 10-40 + u= 10::-40 +
Gas (flowing) Heat exchangers Gas boiler radiation radiatioll
{X= 10-100 for gases u = t0-50
u =: 10-30
--------- --- -'--., - - - ~-----~--------- ----
Liquid (jree convection) Oil bath for heating Cooling coil
(): = 50-10000 u = 25-500 u = 500-1500
Radiator central if stirred
heating
Liquid (flowing) u = 5---15 . Gas coolers Heating coil in vessel Heat exchanger Evaporators of cooling
water u = 10-50 waterfwater waterfwater units, hrine coolers
0: = 3000-10,000 withO\!-t stirring -u = 9oo--.zsoo u = 300-1000
other liquids u = 5o-250 water/other
0: = 500-3000 with stirring liquids
=
u 500-2000 u = 200-1000
- - - - - - - - - - - - - - - - - - - . . , . . . . . - - - - - , . . . - - - - - - - - - - - - -------
Condensing vapour Steam radiators Air heaters Steam jackets around Condensers Evaporators
water u = 5-20 u= 1()-50 vessels with stirrers. - .steamjwater steamfwater
0: = 500(}-30,000 water u = 1000-4000 u= l5()(H)()QO
other liquids u = 300- 1000 other v,apour/water steam/other liquids
0: = 1000-4000 otlier liquids iJ = 300-1000 : u = 300-200()'
u = 150--500
178
When the various surface areas are not of the same size, e.g. in the case of thick-
walled cylinders, the varying size of inner and outer surface areas should be
taken into account.
The value of U is mainly determined by the greatest resistance in series-by
the lowest value of oc or ).j d. In metal apparatus mostly ).wfdw oc (A. steel ~
45 Wfm ac). However, if a dirt layer is present, A.Jd4 can have a considerable
influence on the overall U (e.g. in water-cooled heat exchangers A.4 jd4 ~
03/ 5 x 10- 4 = 600). The partial heat transfer coefficients increase in the order
gas (free convection), gas (forced convection), liquid (free convection), liquid
(forced convection), condensing vapour and boiling liquid. Table III.4 gives a
rough survey of values for the partial heat transfer coefficient occurring ~n
practice and the consequences for the overall coefficient if two partial coefficie~ts
are combined.
In the case of laminar flow equation (III.54) yields only approximate results.
For an exact solution ofthis problem equation (Ill.45) should be solved applying
the correct boundary conditions.
III.3.4. Problems
L A very long horizontal heat exchanger for warming up liquids consists of
internally smooth pipes which are kept at constant temperat ure ~ the flow
through the pipes is turbulent
(a) If the pressure drop is doubled per unit of length of the pipes, by which
factor does the heat transfer coefficient increase?
(b) By which factor should the pipe length be increased in order to attain
the same heating up as in the former case?
Now answer the same questions for a laminar flow if the entrance region is
negligibly short with respect to the total pipe length.
Answer: turbulentflow (a) oc 1-39 times as large
(b} L 1-08 times as large
Laminar flo w (a) a constant
(b) L 12 times as large
*2. On the outside of a steel tube (outside diameter 1 in, wall thickness 312 in)
steam condenses, whereas there is a turbulent fiow of cooling water at a
rate v through the tube. From meas urements it is found that on variation
of v the total heat transfer coefficient U can be represented by :
1 0004
- = 0001
u + -vos-
where U is expressed in BTUj ft 2 h oy and based on the external pipe dia-
meter ; v is expressed in ft/s. Using the same tube some time later the same
experiments are carried out and it is then found that :
~
U
= 00025 + 0vos
"
004
179
The difference should be ascribed to a deposit layer on the cooling water
side. Determine the heat resistance caused by the condensate layer, tube
wall and dirt layer and a relation for the a on the cooling water side. Find
out whether the latter relation agrees approximately with the existing
empirical correlations for this case. The ..l. of steel is 26 BTU/ft 2 h F .
Answer : dirt layer 00015 ft 2 b FJBTU
tube wall 00001 ft 2 h FJBTU
condensate layer 00009 ft 2 h FjBTU
ex = 250 v 0 8 ; agrees within 10 per cent
3. For a completely turbulent gas flow (Re = 10 6 ) in a rough pipe (D = 0.10 m,
relative roughness 10- 2 ) the following relation is valid between the N u
number and the friction factor:
Nu = f Re
2
Calculate a., if the heat conductivity of the gas is 0.02 W/m oc and of the
pipe material 200 W/m oc.
This rough pipe (wall thickness 2 mm) is surrounded by a steam jacket
which keeps the temperature of the outside at 120. The inlet temperature
of the gas is 20C, the outlet temperature 30C. What will be the outlet
temperature if the gas throughput is doubled, and b y which factor is the
total amount of heat, which the pipe transfers per unit of time, increased?
Discuss the (very simple) answer.
Answer : ex = 950 W jm 2 oc; 4>w = twice as large; ~u' = 30C
A-" ( )
'fJH t ~
{(
-1 +-
~s
d1
.A.l
+ -1 )
<X~t
2
2c ~ T
+ -.,-------
).z
t}- t AT
u
where :
a. - the partial heat transfer coefficient on the steam side,
d 1 = thickness of the tube wall,
i. 1 = heat conductivity of the tube wall,
cxk = the partial heat transfer coefficient on the hydrocarbon side,
c = volume of deposit per unit of heat transferred,
). 2 = heat conductivity of the deposit,
ll T = the difference between the mean temperatures of the steam and of
the hydrocarbon.
180
5. A heat exchanger must be designed for heating oil from 40 to 60C. The
beating medium is condensing steam of l00C. For this situation we can
assume that the heat resistance is entirely on the oi1 side. The oil flow
through the pipe is laminar (Gz > 0-1). For an oil flow of 10m3jh.100 pipes
with an internal diameter of 2-2 em and a length of 1m are found to be
necessary.
(a) If 100 pipes with an internal diameter of 3-3 em are chosen, what should
be the pipe length?
(b) If 15 m 3/h of oil must be heated in the original heat exchanger from 40
to 60C, what should be the pipe length?
Answer: (a) 1 m ; (b) 15 m
*6. For a .flow through a circular pipe (steady-state condition) the velocity
distribution and the temperature distribution are measured to be parabolic
functions of the radius. Calculate the Nusselt number for this flow.
Answer : Nu =5
*7. Show that John took the right steps in the case of the boiling water discussed
at the beginning of this paragraph.
Comments on problems
Problem 2
The overall heat transfer coefficient is given by :
1 t 1 ds d4
- =-+ -+ - + -
u rxt' rx.., ~~s A..,
For the steel wall we find d3 j). 3 = 00001 ft 1 h oF/BTU. .J"l:te first measurement
(dd = 0) yielded:
1 - 0-004 1 1 d
- = 0001 + -08
-= - + - + -' 5
U V !Xc !Xw As
Now only ~w is dep endent on the fluid velocity. Thus!Xw = 250 v0 ' 8 BTU/ ft 2 b 0
F.
Further:
i.e. :
..:_
o:c
= 00009 ft 2 h F/BTU.
The second measurement analogously yields :
dd = 00015 ft 2 h F!BTU
;(d I
181
We can calculate ocw with equation (111.49) as :
V - Vm., ( 1- ~~)
We now know, furthermore, that the temperature distribution is parabolic,
i.e. T- r 2 j R 2 Defining that T = Tw at r = Rand T = T.. at r = 0, the tempera-
ture distribution is therefore given by:
T-_T;.;:_ = 2
_
T.,.,-1; R
..____ ..
The mean temperature of the flow in' the pipe can be calculated from:
to be:
4>H = ~ ~ T = 157 w
- 4>n
4>Ill - --
- J.A l!:.T -- \.e.g
r x l o- s kgjs
!1H d!l.H
In 4 hours. therefore, only about 1 kg of water will evaporate.
Heat exchangers play an important role in technology, not only for condition-
ing liquid ftows but also for attaining a favourable heat economy. On the basis of
tbe demands made on the heat exchange (the amount of heat rPHwhich must be
t ransferred per unit of time and the available temperature difference) and of
data on the beat resistances, the required exchanger area A of a heat exchanger
can be calculated from the formula:
l/>8 = UA~T (111.55)
Usually both U and ..1 Tare dependent on the place in the heat exchanger, so that
the formula for the entire heat exchanger should read :
(111.56)
1
c:- ---_..:...__----Jil! ~
Liquid - _ r. '
.P 'm' c~, To'--.Noc---!-:;I::::::::::::::::::::::::X::::_.-7,7"!-- L
I 1 JJ I
I Liquid I
x=o x =L
"'..~,11
m ' c"
pt
r,lf
o
0 -x -x L L 0
Figure Ill.l3 Heat exchanger and temperature gradients for co- and
countercurrent flow
d6TT1).
=
u
(A 1i. H- .1 T 0) S
dx (II 1.60)
~or a few special cases the integration can be carried out easily.
(a) If U is independent of x or T (often the case with gases). Then integration ~f
equation (II 1.60) leads to:
!!.TL- ~To
</>y = USLinf!..TJll.To = USL(!!.T'hog (IIL61)
2
10
9
e
7
6
5
4
1 5
r
~
()
0
1-..J
10
9 <J
8
7
6
5
4
15
ld! 8 6 5 4 3 2 15 10 8 6 5 4 3 2 1 5
l!. To[oc] - - -
Finally, we have to add that most heat exchangers applied in practice do not
belong to the simple 'single pass' type discussed here but to the 'multiple pass'
principle illustrated in Figure III.l5. Also, for these apparatus a mean tempera-
ture difference can be calculated. In practice, however, we prefer to use the
r"
~ 0
I
r.=================~ ---~
~========~- ro'
r"
0
r"
L.
-L
Figure 111.16 Correction factor t/J for multiple pass heat exchangers (one
shell, even number of tube passes) as a function of R and X
__\\
........
-
.......
1
.... TL '
Tube material
~~------- Hastelloy C
-
N
E
' Shell Tube
D 20 atm 6 2
1..-J
d)
30 aim 16 7
.2
... 40 atm 29 14
60 atm 44 23
0.
Figure m.t8 Costs in 1970 of standard carbon steel shell and tube heat exchanger (3/4 in diameter, 15/ 16 in
pitch, L0/10 atm) in Dfl/m2 for all materials; cost index CS 65 per cent/year, all others 45 per centjyear-
189
pipes in the shell. F or the solution of this problem two momentum balances
are available which restrict the applicable velocities, diameters and lengths
due to limits put on pressure drops in the pipes and in the shell. Furthermore,
we have an economic balance which is used to find the cheapest design for
a given problem. Once we have -chosen the type of heat exchanger these three
balances determine N , L and D, and geometric considerations then further
determine shell diameter, etc.
If we realize that, besjdes the solutions of the above problems, questions
on construction material and a great number of constructional details must
be solved, we can understand why big engineering firms often have departments
specialized in designing heat exchange equipment.
For a rough estimation of the costs of a heat exchanger Figure II1.18 can
be used This figure shows, for instance, that a heat exchanger of 100m2 with
stainless steel 316 pipes and aSS 304 shell, suitable for 300 psi in the-shell and
600 psi in the tubes, and with a pipe lengtb of 10 feet will cost per rn 2 surface
in 1973:
445 + (9 + 6 + 14 +9+ 15)% =Oft. 683/m 2
Finally, in Table III.5 some heat transfer correlations are summarized,
which are useful when designing heat exchangers. A few of these relations have
already been discussed in paragraph 111.3 ; others will be treated in following
paragraphs.
III.4.4. Problems
1. Through a horizontal smooth pipe (internal diameter 18 mm) water of
90C is forced up at a rate of 08 m/s. Determine the distance from the
entrance at which the water begins to boil if the pressure drop is negligible
and the pipe wall over its entire length is kept at l10C.
Answer : L = 15 m
2 A closed vessel filled with 86 1 of water which is stirred thoroughly bas a
temperature of l00C whereas the air temperature is 20C. If the total
outer surface area of _the vessel is I m 2 and the mean heat transfer co-
efficient U over this area is 25 Wfm2 oc, how long does it take for the tem-
perature to fall to 50C ?
Answer : 4h
3. In a double-tube beat exchanger benzene is heated from 20 to 60oC counter-
currently with water, which during this process cools down from 88 to 48C.
During an overhaul the direction of the water flow is accidentally reversed.
Determine the final ~emperature of the benzene. (The beat transfer co-
efficient is independent of 6. T.)
Answer: 52C
190
Table IU.S Heat transfer correlations for heaL exchangers
Flow siluotioll Heat transfer correlation Rtmorks
-
Flow throu9fl S1r119ht Re" I'<~>O < 2300. 2 5< Pr <4000 Physical properties ot thnds
circular pipes I I I I
at <T> > T,~-+ To~t
<Nu>:~DIS& Re'j Pr! (hr { ~.) y
0
~~
r
.
<Nu>,.,n3 66
z
f'or cor~~oon for spiralled
p1pe see equottcn II 52
Ftc-., along c.rculor popes 2300<Re< 10~, Pr > 07
I I
without bofflts <Nu>~0 OOa7 0
Re " Pr
3 (.!. )7
Flow o!Qng circular dp
' 4
" n number of pipes
pipes witt. bofflts 3 < Re <A>.,
-- < 2 lliO , 0 5 < Pr < 500
2 2
fm
OptniiWJo mi'm Physico properties 01 -r,.+ Tovt
s - 2-
uiT -o....
f)"' 0 25
I ! Mton orto ovolloble for flow
-'s j p
L <Nu>" <";fl Q-22 Reo.n Pr 3 (t )' {Sd
<A> -;s!O d l4r P( Ond
2 2 lo }!
I
:
~
R
f
~<">21
---- ., In prae11ce 4< a< 6 mm
I I for rough es11male (within
3
<0 ~2 8 c 'le Pr ( ~.. )"
0
<Nu > foetor 2 ) toke c OS ond
0 57
c 011<1 a <ltpendtnl an type and mal<e of plates
FCIII1119 film on
/
~ttcot won Re .F<r.>CII < 1600
' ' {
a
\ om
t+..Ji
r'w,..zg
-;;z} !
-1 ~z'A:; l
<a>20 5 Rt
0 2
:::: a,.,,b 0 2 a tom Re
~ -.! Re>3200
:: {~,2,~3} s r.tr.
I !
::::f
3 Phvsl col properties at ~
<> 00087 Re
0 4
' Pr 2
.,.
. {).pt., nN}~
I
Sc:~ surface htot number at rows al s.c raper blodes
-. t If
<a> I 13
N numbe r d revolut1ons
~.~ CofrtciiCn foetor i' I for wa ter
02 < oy< Q-6 for viscous ll q11ids
*4. A turbulent liquid stream of 25C flows through a straight p ipe, the wall
temperature of which is lOOoC. At 3m distance from the entrance the mean
liquid temperature is 50C.
(a) Determine at what distance from the entrance the liquid has a mean
temperature of 90C.
(b) To what degree does this distance change if the flow rate is doubled?
Answer : (a) 15m ; (b) increases by 15 per cent
191
Table IlLS (cont) Heat transfer correlations for heat exchangers
Flow Slf\XIliOf'l Heo: tronsfer correlation Remarks
l
Natural COllvediOn on 1700<Gr Pt l g 11' < Wle
venrcol swfoces ""
Pr}4
I
l nflu ~~nCe o f c ombined roatural /
<Nu>=<~L.o-55 {Gr fa tc.ed corovectrOt\ on < a > su
m.s
Gt Pr > i0 8
poroqroph
I
<Nu><~Lo t3 { Gr Pt} )
Ccndensotion
nor tzonto l prpe
en
I <a> o-n{t;/'Dt}AT
13AH}4 lnfl~nce
condensotron see
of lnett CiQS oe
~110'1 m79
Ccnd.nsotton o~
PllySICOI prOperties of fh.ildS
ver11col ptpe
ot T ~ -1 AT
*5. A gas stream of 10,000 m 3 jh must be cooled from 200C to 50C. Use is
made of a bank of steel tubes installed in the open air. The gas flows through
the pipes. Water is sprayed onto the bank of tubes and wind blows between
the pipes. In this way the outer wall of each tube is kept at a constant
temperature of 20C. Design the most economical heat exchanger for the
job for the case where the pressure drop over the tubes must b e less than
01 atm. State the length, number and inner diameters of the tubes and the
approximate 1970 price of the unit.
Data : aair = 10- 5 m 2/s
a1r = 10-
v. 5
m2/2
material of construction = stainless steel 316
Answer : L -. 4-8 m ; N = 87; D = 005 m ; Dfi. 33,00000
192
*6. Show that John drew the right conclusion regarding his cup of coffee dis-
cussed at the beginning of this paragraph.
Comments on problems
Problem 4
A heat balance in the stationary state reads :
'"
1
,._------~----~----------
L2
L
1
= L tlll:
ll1;og I A'Ji = 149
AT.1 m
log2
(b) Now the fluid velocity v varies and with it 4>v "' v and a "' v 0 8 . Using the
same procedure we find :
T - 1'air = exp (-
UAt)
-
To - Yair .M cP
~
'' / Sugar addition after
-
' , visit to bos-s
.........
I ..... .......
.........
.......
J....
7a l r
0 _,
The decrease in temperature is shown in the neighbouring graph. If John had
left the coffee without milk and sugar, the temperature difference, T - T,1p
would be bigger. Thus the total system would lose more heat and the final
temperature after addition of milk and sugar would be lower.
194
m.s. Heat t!'amfer by fOI'ced convection around obstacles
The body was lying aLa draughty corner. The police doctor
stated that theman could only have been dead for 20 minutes
and that death was due to a stab in the heart with a pQinted
weapon of approximately 3 em diameter. The murder
weapon had not yet been found. John noticed that the jacket
and shirt of the victim were wet. He estimated the air
temperature tc be 20 C and the wind velocity at the comer
tc be 8 mfs. He made a quick calculation and concluded that
the man could have been stabbed with an 'icicle.
l/1.5.1. Flow along ajlat plate
This situation is drawn in Figure 1!.37. A thermal boundary layer is present,
the thickness f>r of which increases in the x-direction. This causes the local heat
transfer coefficients to decrease in the positive x-direction. For the calculation
of the heat transfer coefficients we can apply the same technique as used
in paragraph 111.3 for the calculation of heat transfer coefficients for turbulent
flow in pipes.
We first calculate the thickness of the hydrodynamic boundary layer from
equation (11.64):
Using our knowledge about the ratio of the hydrodynamic and the thermal
boundary layer thickness (equation 11.29):
~ = (~) t = Prt
oT a
we can now calculate the Nusselt number as:
This equation is valid for Re = vxf v < 3 . 10s.. At higher Revalues the boundary
layer is of constant thickness.
= '{31jf. = J3~(v)~
0
vi>iW pg
we find, after some rearrangement :
- 7~2~f<~~r {g~:A'f
Thus the heat transfer coefficient to a falling film is :
a = 205 {
p(v)4b} - t{gp2 J..3}t (III.66a)
2
17 tT
for :
( )D11
a ). = 20 + 13 ( ~)Ols + 066(VrvD loso( ~)033 (1
11
< Re < 104 ) (111.68)
In both equations the physical properties of the fluid should be taken at the
average film temperature unless the correction term (tt/ t7w)0 . 14 is added. The
extra term containing the Pr number is connected with the curved shape of these
bodies. At Re >ca. 104 the exponent of Re is slightly higher than (}5. More
detailed information can be found in various handbooks.
At Re = 0 we findfor a sphere Nu = 2, the value for pure conductive trans-
port. At high flow velocities the convective transport is much greater than the
conductive transport. For this situation we can estimate the thickness of the
hydrodynamic boundary layer on the basis of the penetration of momentum
{paragraph 11.1.6) as :
O~r = foi
Further, reafuing that lJJ !Jr = Prt and that the timet available for creating the
boundary layer is r ~ Djv we find:
Nu = -rxD -= -D ~ 056~v
- Prt
A lJT v
which is in complete agreement with equation (III.68).
The same argumentation applied to cylinders perpendicular to the dircx:tion
of flow will yield equation (III.67). For cylinders parallel to the direction of
fiow the boundary layer will have a constant thickness at any place and we can
apply the relations for heat transfer in laminar and turbulent flow in pipes
discussed in paragraph III.3. In the latter case we can apply equation {111.43)
~we use the hydraulic diameter D11 instead o f the pipe diameter D.
Tbe two given relations (equations III.67 and III.68) are applicable in situa-
tiom v.here the heat transport by convection (in the x-direction) is much more
imponant than the conductivity in that direction, which means:
dT .d 2 T
pcpvr dx /, dxl
'I.e .._
197
The left-hand side of this inequality is a dimensionless constant which is called
the Peclet number (Pe = v)Jja~ The right-hand term is a value which follows
from the temperature distribution_ This value differs for spheres and cylinders
but is of the order of 1. So it could be said that the above relations hold if
Pe : .: . 1.
Both equations must be applied with care at low flow velocities. In these cases
we have to check whether heat transfer by free convection participates sig-
nificantly (see paragraph II1.6}.
( a ) Dh _ ~ ( u.) eDu _
).
( 2v0 Du
- 3 (l _ e)). - constant x 3 v(l _ e)
)t Pr
t {111.69)
For the constant for which approximately the value 066 is expected, a value
of (075 + 015) is found in the range 10 < Reh = 2v0 D.,/3v(l -e) < 10 3 .
Many authors state that for them~ Nu number of a packed bed (e = 040):
applies, pro,ided 30 < v0 DJv < 3 x 10 3 and Pr ~ 1. The reader may ascertain
that this corresponds with the above more fundamental result So it is again
advisable when reading the literature to ascertain which definition o f the
Reynolds number is used (just as in paragraph 11.6.1 for the pressure drop
relations in fixed beds the choice is: Rehor v 0 Djv, of which the first is fundamen-
tally correct)-
The heat transfer between the tube wall and the fixed bed (i.e. particles+
fluid~ which, for example, is important for catalytic reactions in this type of
reactor, can still only poorly be described. The problem is that of the total
-temperature difference between the wall and the centre of the bed an appreciable
part is found in the outer layer of particles (thus at the wall) but that consider-
able temperature differences a lso occur over the diameter of the bed_ It is there-
fore obvious to try a model description in which two heat resistances occur :
one in the boundary layer at the wall and one in the bed itself. The resistance
at the wall {1/(a.)) can, in principle, be described with the same relation as that
between particles and fluid (equations III.69 or III.69a) because the-wall can
be considered as a (somewhat large and strange) particle. In practice this
appears to be the case, only the constant is ca. 30 per cent lower than in equations
(III.69) or (111.69a). The reason is that the mean dimension of the channels at
the wall is slightly larger than in the heart of the bed, where the particles lie
198
closer to each other. The resistance in the bed is usually described with the
aid of an effective heat conductivity. Regarding the heat transfer the bed
(particles + fluid) is taken as a solid body with a heat capacity equal to
(1 - e)(pc~rticle.s + t(pcJnuid
and an effective ).en This heat conductivity is then, of oourse, dependent on the
porosity of the bed, the ~ of the particles, the ~ of the ftuid and of the flow
situation in the bed. A well~known rule of thumb for the effe.c tive heat conduc-
tivity is :
(III.70)
where ;.:r is the effect ive conductivity of the bed if no flow occurs. It can be:
.calculated with the help of Figure llt19 in which J.:cr/A.r has been plotted against
J...,JA.r for various values of r..
-
* ';
-<
111.5.6. Problems
* 1. A stirrer (power consumption 4 kW) stirs a fluid in a horizontal cylindrical
vessel (D = 1 m, L = 3 m) with an insulated bottom Air is blown at a rate
of 9 m/s perpendicular to tb~ axisof the vessel. If the vessel is completely
filled with water, how will the temperature of the water change with the
temperature if at t = 0, T = T0 = 'Fair?
Answer : T - T0 = 415 {1 - exp ( -98 x 10- 6 t)}
*2. Lead shot is made by allowing drops of melted lead (p = 11,340 kgjm 3 )
to fall from a height L through air. The temperature of the air is 20C.
What should L be to ensure that drops of 2 mm diameter reach the bottom
completely solidified? The drops reach the stationary rate of fall very soon
after being released The heat conductivity of lead is so high that in the drops
a uniform temperature can be assumed equal to the melting temperature
(Ys = 327C) oflead (melting heat of lead 23-5 x 103 Jjkg).
Answer : 148 m
3. T wo equally heavy metal spheres of good heat cond uctivity fall stationary
through air. The ratio of the diameters of the spheres is 2: 1. With the help
of dimension analysis it can be proved that the product of the stationary
ra te of fall and the diameter of the one sphere is equal to that of the other
sphere (vD = constant). lithe initial temperature of the spheres is T1 and that
of the air Teo, calculate the ratio between the distances the spheres s hould
travel to be cooled to temperature T2 The product of the density and the
specific heat is the same for both spheres.
Distance large sphere =
Answer : 2
Distance small sphere
200
4. If a thermometer with temperature T0 is suddenly put in a flowing fluid with
a temperature 1f, the mean temperature T of the thermometer will, in course
of time, approach the value T,. The time constant 1: of a thermometer is
defined as the time necessary to reach a value of (1f - T), which is equal to
(1f - T0 )j e, where e = the base of the natural logarithms. If the ther-
mometer conducts the heat infinitely well, has an external surface area A
and a total heat capacity c (Jr C), and if the heat transfer coeffi~ent between
the flow and the thermometer is o:, tben derive that :
c
7: =-
A~
that of Hg is :
cP = 13 x 10 2 JikgC
Answer : (a) clean: 1 = 150 s; dirty : -r:::;: 159 s
'
*5. Show that John drew the right conclusion in the case of the wet body dis-
cussed at the beginning of this paragraph.
Comments on problems
Problem 1
The outside heat transfer coefficient can be calculated with equation (III.67)
to be a = 1026 W jm C. A heat balance over the entire system reads:
dT
<f>H = 4 x 103 = vpcP dt + e>:A(T - T0 )
1t
l/>Hl = (;d!p Ml&=and; !l Tt
from which we find t = 0616 sand L = 148 m.
f
I
/
/
/
/ -Y
applies, where A., a and v should be taken at the mean boundary layer temperature
and the coefficient of expansion pat the ambient temperature T':X> This relation-
ship shows that ex decreases with increasing x because the boundary layer thick-
ness increases with greater x.
For a vertical surface with height L , the mean heat transfer coefficient ( ex)
can be represented by :
The dimensionless group which determines the heat transfer can then be written
as:
-z- ti(Hot)te 1rrn ;nk:j .J.ltJ Y'fl
G, .: p
.9 X iJT
)J.$ - --
203
Gr is the dimensionless Grashof number* which is often encountered when
describing transport phenome~during- fiow caused by d ensity differences
(although in heat transfer to liquids (Pr ~ 1) the product Gr Pr almost always
occurs).
For vertical surfaces applies (theoretically and experimentally):
( a)L
- - = <Nu) = ().55(Gr Pr)-l (103 < Gr Pr < 10 8 ) (111.71)
1
By approximation this relation can also be used for horizontal pipes, if L is
replaced by D. Equation (III.71) can be understood by realizing that the force
per surface area (gc5h J1p) in the positive x-direction (Figure fii.20) must be in
equilibrium with the shear force at the wall, which can be estimated to be:
Thus:
-
gbh &p = rJ
Vm.ax
!>, (I1I.72)
bh = y c::;
/LV =
/2vx
-
Vma:tt
(lll.7~)
Substituting vmax using equation (III.72), we find for tbe thickness of the hydro-
dynamic boundary layer~" :
[) = {7tV2Xp}*
h llp g
Remembering that the ratio of the thermal and hydrodynamic boundary layer
thickness (see paragraph !1.2.1) is given by {equation II.29):
------- - - - - - -
204
If Gr Pr becomes > 108 the flow along the surface is turbulent and ex no
longer depends on x and by approximation (ex) no longer depends on L. It is
clear that in this case in a relation of the type of equation (111.71) the exponent
of Gr Pr must be equal to ! . For this case has been found :
( Nu) = 013 {Gr Pr)t (III.74)
A similar situation occurs on cooling a horizontal plate. Above the plate
thermally generated eddies occur. If the dimension of the plate Lis great with
respect to the size of the eddies (condition: Gr Pr. > 107) (ex) is no longer
dependent on L . In that case:
( Nu) = 0-17 (Gr Pr)t (111.75):
During heat transfer by forced convection, in principle free convection is
always involved, because there are temperature differences in the medium.
The combination of both effects is very complicated and as yet little is known
about it. The effect of free convection on heat transfer is negligible compared to
that of forced convection if the liquid flow velocities are :
Vrrce coovcc:tion < Vcorced convection
From equations (III.72) and {III.72a) the maximum ftuid velocity can be
calculated and we find:
Vcreeconvc:ction = VfiitilP
-p < Vrorccd conwclion
~<
yp;r-
XVrorced convection
y
or:
.jitGr < Re (III.76)
So we see that free convection heat transfer effects can be neglected if Re > for
but that convective heat transport is most important if Re for.
In the
region Re ~for we can add the fluid velocities due to free and forced con-
vection and use the sum total to calculate N u as a function of the Re number.
111.6.2. Problems
1. Water of 50C is passed through a non-insulated horizontal pipe in air
of 20C. Through the wall an am.oun t of heat of 100 W is lost. The heat loss
is completely controlled by free convection. Later on water of 80C is
passed through the pipe. Calculate the heat loss.
Answer : 024 kW
205
2. Liquid condenses in an air-cooled pipe of 10 em diameter and 2m length.
Calculate the ratio of the condensation capacities if the pipe '1s put in the
horizontal and vertical positiQns respectively and if
(a) g ~P =3 x 106
vpwa
and
(b) g Ap = 3 X 108
vpwa
Answer : (a) horizontal : vertical = 212 : 1
(b) horizontal : vertical= 27:1
*3. A metal thermometer well (see F igure III.21) (outside diameter D , wall
thickness b) is inserted over a length L into a gas . pipe t~rough which a
warm gas with temperature Yg flows. The tempe_rature T~ of the well ~ear
the wall is lower than T,, so that by conduction through the metal (A.nJ heat
flows through the well to the wall. In the stationary state this beat is supplied
by the gas (heat transfer coefficient ex). Show that for the temperature of the
206
sleeve applies :
d 2 6.T a
dx 2 - Ab AT = 0, !iT = T - T,
X= 0, d !iT= 0
dx
X = L, /i Tw = Tw - ~
"T _ u",..,..cosh
u 1.
px
"'cosh pL
w h e re p = jfg -
A.<5
Comments on problems
Problem 3
A heat balance over a short length dx of the thermometer well reads in the
stationary state :
Now th e heat ftux in the x -direction is also given by 'H = - A. dT/ dx. Thus:
2
d !:iT __ a fl.T __
dx 2 ...t<S p
2 "T
u , where p
fa
= "V M
207
This differential equation must now be integrated between the boundary
conditions :
X = L, T = T..., ' 6 T = T..., - T,
X = o. c/J'H = 0, d T
11
= 0
dx
Multiplying through with d 11 T /dx yields :
---ax-Tl
2 2
d 11 T d 0. T _ d (d ~ d llT d
2 dX dx2 - dx = 2 (IXP 2 aT = dx(p 6T)
2
ctaT
- -=
dx
+p6.T
-
and thus :
LlT = Aepx + Be - P"
Using the boundary conditions stated, the values of the constants A and B
can be found to be :
A = B and T.,., - T.8 = A ePL + B e - pL
So we find, finally, for the temperature distribution along the thermometer
well :
T - T, + e- px cosh px ~
----::.. =
T., - T,
epx
e PL
=
+ e- pL cosh pL
.
With p = -
.At5
and with the data given we finally find for the temperature measured
T0 = 9265C instead of the actual gas temperature T, = l00C
This example shows that considerable mistakes can be made in temperature
measurement if thermometer wells are applied The deviations increase with
decreasing p and thus with decreasing beat transfer coefficients (gases, free con-
vection) and increasing heat conductivity and wall thickness of the well material.
Air
lee
Woter
For setting up a heat balance over a thin layer dd we can neglect the specific
heat of the ice formed because at most:
~'IIceCpice :::::; 42 X 10
4
61fice = 335 X 10 5 Jjkg
Thus our heat balance becomes:
Wolf
x=O Conde ... sate
Vapour
L -f - df.ll
l! .,7~
- - --~---'
X =L
liL
Now it is assumed that for each value of x the -relation between 4J., and ~ is
given by:
. J 3q( v)lJ
0
pg
(see problem 11.1.2) although strictly speaking this equation applies only to
laminar vertical films of constant thickness. So :
2
cf>v = pgb 3 W/371, and dcf>v = pgb W db
17
- -- - - -- - - - - -
210
Substitution into the energy balance gives:
2 03
!lT l dx = llH 11 p g db
71
After integration over x between 0 and Land over b between 0 and OL we get:
J.llT L = AHoplgo1_
4'7
.
The average heat transfer coefficient (a) is defined by:
Miup 2 gWo1.
( ex) AT WL = MlvP4>r:lx =L =
371
From the last two equations we find:
4 A.
<(1.>= --
3 c5L
but in this form the solution is hardly usable because oL is not an easily measur-
able constant. Elimination of bL from the three previous equations gives :
( a ) = (}94[AHuPl
LYf6T
).3gJ * (111.77)
'*The constants p, rr and ~ should be taken at a mean temperature T1 o f the condensate film which
equals 1f = Tc - f ~T.
211
{ l!.H,:'i3}'
14
r.,:r.-~t::.T
c 4 r Lt:.T
ntXlT
-30 1
0
.30
. ~0
go
120
ISO
180
210
10
liquid
( I ) HzO
( 2) CH30H
( 3) C2 H 50 H
. ,.
'(4) c 6 H6
(5) NH
3 . :
. ~100
' .
Figure ffi.23 Nomograph for the calculation of heat transfer coefficients of
condensing liquids if 4(v) oLfv = 4cpnJW1] < 1000
. .
I I 1.7.2. Drop wise condensation
[f the cooled surfac.e is poorly wettable by .the condensate, so-called dropwise
condensation occurs. Parts of the surface are then almost dry and have a very
.h igh local ~ea.t. transfer coefficient..As s,oon as so~~ condensate has formed a
drop collects which after having grown sufficiently rolls down and sweeps
part of the surface clean. The average heat transfer coefficients can be up to
ten times higher than on film condensation.
212
I 11. 7.3. Boiling
The boiling phenomenon is complex. There are eight principal situations,
as shown by the following table of possibilities (a), (b) and (c):
(a) J.Y all (b) Liquid (c) M edium
horizontal a t boiling temperature flowing
vertical undercooled stagnant
Most is known of the heat transfer from horizontal walls to a stagnant medium
at boiling temperature (water kettle on the fire), the so-called rree boiling'.
The greater part of the literature deals with this situation. Dependent ~n the
degree of superheating (6T with respect to the 1ocal boiling point) four boiling
regimens can be distinguished : ,
( I ) Low superheating (6 T < ca. 2C), free convection (with or without forced
convection), no bubble formation yet. A slight superheating (and consequent-
ly overpressure) is necessary to form bubbles because of the following
effects:
tlp due to surface tension (=Zaf R and so tlp is rugh for small bubbles),
ll.p so that the growing bubble can displace the liquid, tlT to trans-
port the heat of evaporation through the liquid to the bubble and-
if no allowance has been made on selecting the boiling temperature
(reference for \T)-a !lp due to the hydrostatic pressure on the immersed
wall.
(2) Nucleate boiling (for water : 2 < l'iT < 25 - 75C) : in certain 'active'
places (small indentations in the wall)vapour bubbles (nuclei) are formed.
which in an undercooled liquid 'collapse' because of condensation-as soon
as the tops of the bubbles reach into the cold liquid as a result of growing
(very high <XS). In a liquid at boiling temperature they grow until, because of
their buoyancy and momentum, they become detached from the indentation.
Every active place yields bubbles of a size characteristic thereof. At low
/'iTs those places first become active which yield relatively large bubbles.
If superheating is increased the frequ~ncy at which nuclei are formed in
these places becomes higher until the maximum rate of discharge of the
bubbles formed has been attained for the relative active place. Next, smaller
indentations which produce smaller bubbles are produced at a higher
frequency an d bring about more 'agitation' in the interface, so that a
increases rather strongly with ll T (approximately proportional to ~ T 3).
It appears from the foregoing that in this regime the s urface conditions of the
wall (nature and size of the irregularities, wettability) play an important
role. It is therefore difficult to carry out reproducible exp eriments, particular-
ly because when a wall has been exposed to boiling once its surface changes
(ageing).
213
-
(3) Leidenfrost regime: the bubbles of neighbouring active places coalesce and
form a closed vapour layer. As soon as this takes place the heat transfer
coefficient decreases considerably with respect to the values which were
obtained in reginie (2), because the vapour layer has a fair heat resistance.
If instead of a given wall temperature a given thermal load is applied (electric
heating element, nuclear reactor), the temperature of the wall rises con-
siderably on transition from regime (2) to (3), as a result of which the heat
transfer coefficient decreases further until finally the heating element melts.
In these cases one should therefore stay at a safe distance from the critical
~ T where the Leidenfrost phenomenon occurs.
(4) A stable vapour layer has formed from which bubbles with a dimension
characteristic of the liquid are released (for stagnant, clean water approx-
imately of 15 mm) ; in the vapour layer _the heat transfer takes place by con -
duction and particularly by radiation (tiT for water > 500C).
1
u
0
N
....E
3
.........
0
II 1.7.5. Problems
*1. A chemical reaction is carried out. in ethanol solution under r~flux. The
reflux condenser consists of a straight inner glass tube (A.,ta.ss = 1 W/m C)
of 12 mm diameter arid 2 mm wall thickness and an outer pipe of 30 mm
inner diameter and 40 em length.
(a) If 15 1/min cooling water of l5C are available, calculate the amount of
heating energy that can be supplied to the reaction mixture so that just
no vapour leaves the condenser.
(b) What would be the amount if chemists could be persuaded to use stain-
Jess steel equipment?
Comments on problems
Problem 1
The maximum amount of heat that can be removed is given by cPH = U_A llT.
Now AT and A are known. Thus, after determining the overall heat transfer co-
efficient U , 8 can be calculated.
For the various partial heat transfer coefficients we find <lwater = 2220
W /m 2 C, a 1.tass = 500 W / m 2 C, acondeMate = 950 W/ m 2 oc {from Figure ITI.23).
Thus, U = 286 W /m2 oc and <Pn = 315 W . If the inner pipe is made from stain-
less steel listed = 13,000 Wj m 2 oc and U = 630 W/ m 2 oc , so 8 = 700 W.
or :
.~. ~fv)tfv) +
Nu '""Re~ Pr>\d \x
where the diameter ofthe stirrer d and the diameter of the vessel Dare introduced
because ex is independent of v.
For relatively high Renumbers-the momentum transport between the core of
the eddy and the boundary layer determines the boundary layer thickness which
is practically uniform (analogous to the boundary layer thickness during tur-
bulent pipe flow) if the flow situation in the vessel is completely turbulent. This
results in (see paragraph 111.3.2):
Nu - Re
0 8
'
/D]OS
Prt \d
~
0 !
---o
1. :
I
0 de D 3
0
H 0
H
~
. I
" 0 "i" : l
5
( 6 blades )
l 0'
0 d
I
4
~ 1
6 - I
0 - m ( 4 baffles)
Figure ID.25 Standard configuration of stirred vessel
218
In the following, a few .experimental correlations for heat transfer to a 'stan-
dard turbine stirred vessel' are given (see Figure III.25).
The average beat transfer c~fficient to the wall Qf a standard vessel according
to Figure III.25 is:
( Nu) = -
(rx)D
- = 101 -
(nd2lt Prt ('-7w)014(d)013(L)Ol2
- - (III.80a)
A. v t1 D D
can be used (017 < d/D < 075; 01 < L/D < 07). For the standard coli;.
figuration equation (III.80a) yields equation (111.80) with a constant of 077.
Local heat transfer data to the wall can be calculated from the relation
-(standard configuration with h= vertical distance from stirrer):
Nu = ~ = 017Re+Pr('1:)"'..(~)"'" if ~ < 15
or:
014
D
Nu = 15 Ret Pr~ ( : )
if - > 15
17 h
if 103 < Re < 106
Figure Ill.26 illustrates the dependence of the ratio of rx1ocaJ(a.) on the height
of the vessel. The average heat transfer .values calculated from the local values by
integration over the vessel height are in agreement with the values found from
Height of
,--- stirrer
0
a/(a) - - --
( Nu ) = <a.A.) d ' .
= 017 Re 0 . 67 Pr 0 ~ 7 ( Dd) 0 1 (d; )
0 5
(III.81 }
for
d d ' .
D 015 and 400 < Re < 2 x 10
025 < -D < 058 , 003 <...!. < 5
lll.8. 1. Problem
1. Two water! ike liquids which react instantaneously with each other are pumped
through a continuously stirred tank reactor. Pilot plant experiments with
a double-walled tank (diameter of vessel = height of double wall = D
= 04 m ; stirring speed n = 360 rpm) according to Figure 111.25 showed
that the production capacity of the reactor is determined by the rate of
removal of the heat of reaction. It appeared that the heat transfer coefficient
was independent of the cooling water flow rate.
(a) By wha t factor would the production capacity per unit volume of the
pilot plant reactor be increased if additional cooling by means of a coil
(O.J m diameter. 001 m tube diameter. 15 turns) was applied?
(b) T he reaction is to be carried out on a factory scale in a double-walled
reactor, according to Figure. III.25, of 3 m diameter. By what factor is
the production capacity per unit reactor volume increased if the scaling-
up rule of constant stirrer power consumption per unit reactor volume
is applied?
220
(c) What stirring speed would have to be applied in situation (b) if the same
production capacity per unit volume as in the pilot plant reactor is
desired?
(d) The chief engineer of the factory wants to use a vessel with a cooling
coil instead of a double wall A coil of 25 m diameter, made from pipe
of 5 em diameter, is available. How many loops of coil are needed to
assure the same production capacity per unit volume as obtained with
the reactor of situation (b) if again the scalingup rule of constant power
consumption per unit reactor volume is applied?
(e) What is the ratio of the cooling surfaces of cases (b) and (d)?
Answer : (a) 213 x ; (b) 011 x ; (c) 2700 rpm ;
(d) ca. 15 turns ; (e) AwarJAcoil = 16.
*Other exampl~ of electromagnetic waves are radio waves (.4 > J<t Jllll)l, visible light (04 < ). <
o-8 Jllll), X-rays (J. ;:::: 10- 4 .um) and 1-rays {i. R: w-6 pm).
221
certain wavelength range preferential absorption occurs, then just as in the
case of visible light the surface is 'coloured'; -
In engineering, mean absorption coefficients over the entire wavelength
range will often suffice. In other words, such surfaces are considered as ~grey
between the extremes 'black' -and 'white'. Of most non-metallic surfaces
a > 08, so they are almost black for the infrared radiation. Metals reflect the
heat rays only satisfactorily if polished and clean; the absorpt~on coefficient a
lies then between 005 and 020. Oxidation and contamination increase a.
Figure 111.27 shows absorption coefficients fo_r a. number of differ~nt
.. .
ma~erial~.
.. '
I . , . I. . ..
Pol ished metals I Oxidized metals I Non-.me!als ~
f-
rr1-----;---~---..,.-----+-~
: I{ ~~~~~linin~
Asbestos
I'
1-l- l
I I Gypsum
08 r I Soot
1---:----.:._-41- - - - - - . . . J .I _ Refractor y bricks
1 r-- -- - ---+----[ron
_ ___.__Cu I
I
., 0 6 Bross I -,
r-------+1-AI paint I
r I I
04 r
r--------r:- Ni I
I
~Cost iron .1
I
02- I
!""--Cu Ni
1 I
!=====~~---1---A t
F-==~A~l- Pt,Zn
t- 1 I
0 -Ag 1 I
'
The amount of heat which is transported between two or' m<?re surf~ces
' '
(I II.85a}
(IU.85b)
using Kircbhotrs law. The practical course of calculation is then that with
equation (lli.8Sb) for each wall the total radiation is expressed as a function of
the temperature of that wall (l/>~ = .aT 4 ) and of the still unknown net transport
4>~- With the relations for the total radiation of each wall thus obtained the
foreign radiation f>'( on each waiJ can be calculated. These ;' values used in
equation (UI.85a) then give the net energy fluxes t/>~ for each wall as functions of
the wall temperatures.
In order to calculate the foreign radiation </>'(" for a wall with number k, we
must know the fractions Ejk which indicate which part of the total radiation of
wall j directly reaches wall k. These view factors Fare calculated by cumbersome
integrations (summation o~er small surface elements) and we have to take into
account that the radiation intensity depends on the angle cjJ between the direc-
tion of the radiation and the norm~ to the surface (approximately proportional
to cos </J, Lambert's law). However,for a number of geometrically simple cases-
to which we shall restrict ourselves-the view factors F can be found in a simple
way. The reader may check that for infinite parallel walls with numbers 1 and
2 F 1 2 = F21 = 1. In general, it can be proved that for two walls with surfaces
A 1 and A 2 A1 F12 = A 2 F21 applies. This can be understood by realizing that
in equilibrium the wall energy flux from 1 to 2 between these two planes
( = A 1 F12 ~) must be equal to the total energy flux from 2 to 1 (=A 2 F21 </J';J
It follows that if wall 2 fully endoses wall! and walll does not emit radiation
(e.g. concentric cylinders or ~pheres) F 21 = A 1 / A 2 , because F 12 shouJd be equal
to 1 (all radiation emitt~d by wall 1 should reach wall 2. but only a fractioa
223
A 1/ A 2 of the radiation which is emitted by wall 2 reaches wall 1 ;the fraction
(1 - AdA 2 ) again reaches walll).
With these data we can now calculate the net radiation transport between
two bodies of which the one (1) is completely enclosed by the other (2). The
foreign radiation over wall 1 ( =A 1 </>f'1 ) is then equal to F21 times the total
radiation of wall 2 ( = F21 A 2 cf>;). It follows that the energy flux of the radiation
Qn the smallest wall ( = rfJi'1 ) equals the total energy flux of the radiation emitted
by the larger surface ( = cf>;). So, using equation (III.85):
cp;1A1 + </>~2A2 = 0
because the energy lost by wall 1 most be taken up by wall 2 (law of energy
conservation). From the two latter relations we find for the net radiation
transport from body 1 :
This means that at room temperature a,. is about 6 Wjm 2 oc and can therefore
not be neglected with respect to free convection. At higher temperatures a,.
~ increases considerably and hence so does the radiation contribution to the total
heat transport.
II 1.9. I. Problems
1. A long rod (diameter l l em, emission coefficient 08) with a temperature
of 327C is suspended in quiet air of 2rc. Calculate the contribution of
free convection and radiation to the total heat transfer coefficient. Assume
the air to be an ideal gas with a density of lOkgjm3 at 27C.
Answer : horizontal rod: 46 % free convection
54 % radiation
vertical rod : 29 % free convection
71% radiation
224
*2. A small ceramic sphere (diameter 1 em), e.g. of a thermocouple holder, is
situated in the middle of a long tube with a diameter of 20 em. Air of l50C
is passed through the tube at a mean velocity of 20 m/s. The temperature
of the tube wall is l00C. Calculate the temperature of the sphere.
Answer : l47C
3. Check that if between two large flat walls with equal emission coefficients
a third equal waU is placed the net heat transport by radiation is halved.
An example of this type of radiation shield is the layers of aluminium foil
in the walls of refrigerators and cold store rooms.
4. The maximum intensity of sunlight occurs at a wavelength of approximately
05 x 10- 6 m. Calculate the surface temperature of the sun.
Comments on problems
Problem 2
In steady-state conditions, heat transport by radiation from the sphere must
equal convective transport to the sphere. Thus : -
( ex) (T, - TJ = a.,(7; - Tw)
Now Re = 7000, thus ( a ) = 183 Wfm 2 oc (equation 111.68). Assuming
7; ~ T, , 'f = (T, + TJ/2 = 125C ~ 400K. Thus,employingequation(lll.86a)
we find (a 1 = 09, A1/A2 1):
CHAPTER IV
Mass Transport
In this chapter the transport of matter will be treated. The starting point of
our analysis is the law of conservation of matter, which reads for a substance A
(see paragraph 1.1):
(IV.l)
':rrA,:r =- [)AB :A
dps
= - 0
A.."
'f'w.B,x BA dx
where ':nA.x is the mass flux of A (kgjm 2 s) in the x-direction for a net mass
flow = 0 ; PA is the mass concentration of A (kgfm )).
Because the conditions have been such that:
,/,."
"f'rnA.x + A-,1
'f'mB .x =
0
whereas :
PA + p8 = p =constant or dpA + dp8 = 0
it follows from these relations that DAB . DnA. In other words, the definitions
have been determined in such. a way that the diffusion coefficients of A in B
and of B in A have the same numerical value. These definitions are used for
describing the dlffusion transport in solid substances and liquids ; here, in the
227
case of not too high concentrations of, for example, A in B the density may be
assumed to be constant.
sub B . Net mole ftux = o. the total concentr~tion c =constant (kmoljm 3 )
Now we can write for the mole flux. (kmol/m 2 s) in the x-direction: ~
A." n dcA
'f'mol A..x = - 11..11 AB dx
and :
= -:- 0)BA dc
A." 8
'YmolB.x dx
cA and cB are molar concentrations (lcmoljm 3); for ideal gases and constant
pressure and temperature their sum total is constant and equals c. These defini-
tions are very suitable for describing the diffusion transport in gases. In the case
of equimolar diffusion :
B,;r =
A."
'f'mol A.x + '#'mol
A." 0
Also, here, the diffusivities have been defined in such a way that :
_[]) AB = . O)BA
According to the two definitions the dimension of II) is (length)2/ time, so that
Din the MKS system is expressed in (m2 /s). This was likewise the case for the
two other transport coefficients v (kinematic viscosity) and a (thermal diffusivity).
However, in the case of diffusion it is .advisable to distinguish between two
cases: p = constant and c = constant For these cases []) has to be defined
using respectively the gradient of the mass or of the molar concentration. .
. ' ;~
I ij'
,,
228
,
I .
unequal to zero. AI~() guring a chemical reaction e.g. at a catalyst s urface, the
mole fluxes of-the re~9.~~t$ ~o be f~d. ~n(:i the mole fluxes of the product to be
It
~
~
discharged are usu~UY y~~gll~ <~~g, in ~ 9.tm~ri~tign).
When describing q}~ m~ ifi:iil~f~r til th~~ ~@.~s ~!lgw~Qc~ ll1l!st b~ m~qe for
the entrain~ent of &pbstilP.f~1i fP ~h~ ~PW ~~~q b.Y th~ ma-s~ tnm&fer as SIJCh.
Fqr ~ biJl~ry mi~tl.q-e J1lO.Vliig wit~ fl velocity v relative to .a plane X = constant,
t}le steady-state diffusion flux of component A relative to this velocity is:
de A
(vA - v)cA = - 0 dx
Th~ first right-hand teqn in these equations repre~nts the mass flux resulting
from diffusio'n, whereas the secopd is a. m~a~!ll'~ the mass flux result~ng term of
fro~ ~o~~~ mola~ flow, Equations (11I~3a) and (IIIJb) can only be solved if the
rel.atio~ b.~twe~n' Hi~'fripl~at ff.~x~s of Aand B;s kl}gwn. We cari di~tinguish two
exJreJ11~ s~wat1ons: . .. . i I
. '
or ':nolA,;= coqstant for every plane =constant. Solution' of this X
.e quation yields, ; with the boundary conditions cA= cA; at x ' x 1 and
! .
229
c:
.~
~c:
&I
u
c:
0
u
- - Distance
Figure IV.l Concentration profile during equimolar diffusion (drawn
line) and during diffusion through a stagnant fluid (dotted line)
(IV.6)
So, during equimolar diffusion the mole flux (and analogously also 'the mass
flux) is directly proportional to the concentration gradient llcjAx. We
notice that mass transport by equimolar diffusion is analogous to the trans-
port of heat by conduction. For one--dimensional beat conduction we had
found in paragraph 111.1 .1 (equation II1.2a):
peP~ - pcPT2
A-"
'+-' H = - /, T2 - T1
=- Q--"' - - - - - . _ _ _
x 2 - Xt x2- xl
(IV.7)
Application of the mass balance (equation IV.l) yields, again, that under
stationary conditions and no production of A the molar flux of A through aU
planes x =constant must be the same. So :
de A
- = constant
dx
The above equation can be integrated and, applying the boundary conditions
x 1 , cA 1 and x 2, cA2, we find for ~he concentration distribution:
C - CA =,1 C- CA>) (x-.xl)/(xl -.x!)
(IV.lO)
C- CAl \c- CAl
This concentration distribution is also shown in Figure IV.l for materials
A (e.g. solvent) and B (e.g. solute). With the aid of equation (IV.lO) we find
from equation (IV.9) for the molar flux for diffusion through a stagnant
body :
,~,.,. _ Oc In c - cA 2
(IV.ll)
'f'moiA,x - X2 - X1 C - CAl
If cA is at all places much smaller than the total concentration c, the logar-
ithmic factor in this relation can be approximated by :
}n C - CA2 ~ _ CA2 - CA l
C - CAL C
and we find :
(IV.12)
A.."
'+'mol,A _ _ rn.
dx xO
kA = - !LJIA (IV.l3)
cAo - (cA) cA, - (cA)
Here, 4>':no1A is the mass flux o f A into phase Band cA, - ( cA) is the difference
between the concentration at the interface and the average concentration of A
in phase B (mean cup concentration). For diffusion from a sphere into an
infu1ite stagnant medium we find, combining equations (IV.13) and (IV.8)
(the latter for the case D 2 ~ ex:>):
The dimensionless number kAD/ 0 is called the Sherwood number Sh, which
plays the same role in mass transfer as the Nusselt number in heat transfer. For
diffusion from a sphere into a stagnant infinite fluid Sh = 2, analogous to
Nu = 2 for heat conduction. The dimension of the mass transfer coefficient
is the same as that of velocity, distance{unit of time.*
If a certain component is exchanged between two mobile phases (e.g. gas
absorption, extraction, distillation, etc.) we encounter an overall mass transfer
coefficient K which is composed of the partial transfer coefficients in the different
* In mass transfer with gases the partial pressure instead of the molar concentration is often used
for calculations. A mass transfer coefficient is theo defined as:
4J:C<>1A = kr{pA.w - PA.r)
since for ideal gases c = p/ RT, k, = kJ R T.
232
phases. Contrary to heat transfer (paragraph111.2.2), however, in the case of
mass transfer it is not possible to calculate the overall coefficient by summing
up the partial resistances (1/ k) to the total resistance (1/ K). This is due to the
fact that the concentrations in both pbases are generally not equal if the two
phases are in equilibrium.
Figure IV.2 shows an interface between two fluid phases through which a
stationary mass flux </l' of a certain component occurs ; the mole concentration
distributions drawn on either side of this interface are representative of the
mass exchange between two turbulent flows. According to the definition of the
mass transfer coefficient k we can write :
<f>~ol A = k'(c~.w - C~.J) = k"(c;._.J - c~.w) (IV.l4) :
It may now be assumed that there is equilibrium between the two phases at the
interface, so that c:...wand cA,ware related according to the equilibrium relation
for this system.
~ i'-lnterfaee
0...
c I
uc
Phase
1 c'A,w .
P nose
10
u
0
I I
cA,f
I
~ A,w
Distance
Fig..e IV.2 Concentration profiles near the
interface of two liquid phases
In principle, with this equilibrium relation cA,w and c;.,w can be eliminated
from the previous relations, so that a relationship between <P;o, A, k' , k", c'A./
and c}.J remains. An analytically simple relation is only obtained if the equi-
librium can be represented by means of a relation of the form:
A."
If' mol A
= (2_ + _
k" mk'
1_)- (c" - cA,JJ
1
m A ,f
= K"('c"
A,f
- ci.JJ
m (IV.l5a)
t Henry's law for gas-liquid and Nernst's distribution law for liquid-liquid systems: the relation
between the distribution coefficient m and the Henry coefficient He is m = HefRT.
233
or also :
II -
m 1) -t
+ k' !I ! t If I
(IV.15b)
moi A -
l k (meA,/ - cA./)= K (meA./ - c,..,1)
It appears that the total mass transfer resistance (1/ K", if related to the phase J'
and 1/ K' is related to the phase ') is composed additively of the partial resist-
ances 1/lt and 1/ kH, but that at the same time the relation of the equilibrium
concentrations is involved. The reader may check that the partial resistance
of the phase in which the equilibrium concentration is lowest is relatively of
the most importance.
Further. it appears from these relations forK that the concentration difference,
or 'the driving force' with the help of which k 11 and k' have been defined, rep-
resents the deviation from the equilibrium between the two phases. If we write
instead of cA..rfm., c~~f (i.e. the concentration phase " would have if it was in
equilibrium with cA..r ), and instead of meA./ , cA:1 , we get the more general
definition for k' and k" :
A."
'f'mol A = K '(c'*
A./ - c'A,/ ) = K "(c"A,/ *)
- c"A./
where K and c are related to one of the two phases. If K does not vary too
much over the apparatus, in the case of cocurrent or countercurrent flow of both
phases, for ( cA- c~) the logarithmic mean between the driving forces at the
inlet and outlet of the apparatus can be taken (see also paragraph IV.4~
IV.l.3. General approach for the calculation of concentration distributions
The partial differential equation which forms the basis for calculating con-
centration distributions is obtained if the law of conservation of matter is
applied to a small (e.g. Cartesian) volume element of the medium. If the fiow
which may come from the diffusion itself is neglected, so that Fick's law
(equation IV.2) can be used for a fixed surface element in the medium, the deriva-
tion is completely analogous to that of the general differential equation for the
heat transport (see paragraph III.1.4~
The resulting equations which we can now derive are for a component A :
(IV.16a)
234
where r A = production of A in kg/m3 s (barocentric system) and :
dcA dcA dcA dcA
dt + Vx d x + Vy dy + V: dz =
2 2
d c }
ff)Al dx;
(d c d c 2
(IV.l7)
CA -CAl = 1- X
(IV.l8)
CAo-CAI 8,
235
---x
Figure IV.3 Film theory eoncentration distribution
With the aid of this concentration distribution we can now calculate the mass
transfer coefficient for which we find:
deA l
k = - DA dX x=O [)A (IV.l9)
CAO - ( CA) = tJ~
Thus, the Sherwood number is given by :
kD D
Sh= - = - (IV.20)
[)A ~c
and we see the formal analogy between the Shand the Nu number (Nu = D/ br)
and the dimensionless expression jJRe ( = D/ll,J, which .all represent the ratio
between geometrical scale and the thickness of the boundary Layer for the
transport process concerned We may not conclude from equation (TV 20) that
the mass transfer coefficient is linearly dependent on the diffusivity because
!Jc is also dependent on [)1, as will be discussed later.
The thickness of~' of the mass transfer boundary layer cannot be determ.i ned
directly but can be calculated if the mass transfer coefficient is known. So,
the film theory does not actually help us to predict k values. The advantage of
this theory is the simplicity of the model and the possibility to estimate the
order of magnitude of the film thickness over which the mass transfer process
occurs. A further advantage of this theory is the fact that the influence of a
chemical reaction on the mass transfer process can easily be studied: We will
therefore use the film model extensively in paragraph IV.5 when treating mass
transfer with chemical reaction.
236
I V.l .5. Problems
*1. The vapour pressure of naphthalene at room temperature is approximately
005 mm Hg. If a mothball (diameter 1 em) consisting of this material
is suspended in still air, calculate the initial rate of vaporization. How long
does it take before the diameter of the mothball is reduced to half its initial
value([)) Of naphthalene in air = 0-7 X 1o- S m 2/ S, p - 1150 kg/m3 )?
Attswer : 4>m = 115 x 10- 10 kgfs; t = 23 years
2. If in a gas phase a reactant A diffuses to a catalyst surface for dimerization,
the mole flux of A is given by:
de A
..1,.11
'f'molA,.;>~' = _[])A 2c
2c- cA dx
Prove this.
3. If in a desiccator a wet plate is at a distance of L = 0.1 m fTom a layer
of a drying agent, calculate the drying time if:
total concentration c = 4-5 x 10- 2 kmoljm 3 ;
equilibrium vapour concentration of water under the prevailing condi-
tions C = 11 X 10- J k:Jnolfm 3 ;
diffusion coefficient of water vapour 0 = 25 x 10- 5 m 2 /s;
surface area of the plate = 12 x 10- 4 m 2 ;
amount of water to be evaporated = 12 x 10- 3 kg.
The desiccator can be considered to be isothermal and convective :flow
can be neglected.
Answer: 56 h
4. In a closed gas burette two equal volumes of a pure gas and a pure liquid
are brought into contact with each other under atmospheric pressure and at
room temperature. After shaking vigorously for some time the pressure
appears to have become two-thirds atmospheric, whereas the temperature
has not change<l Calculate the distribution coefficient of the gas in the
liquid
Answer : m = (concentration in liquid/concentration in gas phase) = 0.5
* 5. Small bubbles (original diameter d 0 ) of a pure gas are brought into a liquid
in which they ascend very 'Slowly. During ascending the bubbles disappear
by absorption (Sh = 2). It appears that the time of solution t and the
original bubble diameter satisfy the relation d~ = ~nstant x t where the
constant has the value.2S x 10- 9 m 2 / s. Give a theoretical explanation for
this -relation and calculate from the constant the diffusion coefficient of the
I
000052 3-14
013 0.0116
0-37 ().0042
0.63 0.0032
t-35 ().0046
226 00053
Calculate the diffusion coefficient of water in this oil and explain the results.
The solubility of water in the oil at 20C is 0004 i>er cent by weight ; p
oil = 880 kgfm 3
Answer : 0 = 14 x 10- 9 m2/s
238
*9. Show that John drew the right conclusion in t he case of the missing lawyer
discussed at the beginning of this paragraph.
Comments on problems
Problem I
Since the air is stagnant. Sh = 2 is valid (paragraphs IV.l.2 and IV. l.4-)_ We
can assume the partial pressure of naphthalene to be equal to zero at a great
distance from the mothball and be equal to the saturation pressure p* at the
surface of the ball (no resistance at the interface). So, the molar flow rate is
given by :
..l..
'l'mo1
= kAc* = 2
D
nD _.!!_
2
RT
which leads to mol = l- 18 x 10- 12 kmoljs and, with the molar weight of
naphthalene being M = 106 kg/kmol :
Problem 5
The concentration of the pure gas A in the bubbles is cA.t = 1 m3/m 3 and
we can assume the concentration in the bulk of the liquid to be cA,L = 0. We
further assume the concentration at the in terface cA..i to equal the equilibrium
concentration c! = cA.Jm (no resistance of interface, pure gas, therefore no gas
phase resistance)_ The volumetric flow rate of A from the bubble is then :
dV
,~. = Akc* = - -
'l' v - A dt
[0=
constant m
- x l o- 9 m 21s
=25
8[}cA,g 16
239
Problem 6
We can assume diffusion of ether vapour through stagnant air and equation
(IV.ll) can be applied. The partial vapour pressure of ether at the liquid surface
is the equilibrium pressure p* (no transport resistance at the interface); at the
end of the tube the partial pressur~ is zero. In order to roughly estimate the
time before the vapour starts to leave the tube we assume a sharp interface
ether vapour/air which moves at a velocity dL/dt. A material balance then shows :
r~. * A dL
o/mol = C dt
..
and after combining this with equation (IV.ll) and integrating between t :::; 0,
L = 0 and t, L we find t = 121 minutes.
A mass balance, on the other hand, gives for the mass flow of water vapour:
_ dV dL
<f>m = PCft = pAdc
Bc~cause of the analogy between the micro balances for mass transfer (equation
IV.16) and that for the heat transport (equation III.4) the non-stationary
penetration of matter into a medium can be treated easily and shortly. If in a
rigid medium the concentration is cAo and at time t = 0 the interfacial con-
centration is brought to cAh the mass transfer is given as a function of the time
with the solutions of paragraph II12 if the following substitutions are made :
a = ).Jpc P --+ I!) A
(pcpT)-+ CA
(pcpTo)-+ cAo
(pcPTl)-+ cAi
,/,.11 .~,. ,
'Y H -+ o/mol A
For shorter times (Fo = 'D AtfD 2 < 005) the penetration theory applies and
we find for the mole flux:
(IV.21)
(analogous to equation Ill.24). For longer times (Fo = 'OAtfD2 > 01) Sh =
constant applies and Figures 1Il8 and 111.9-after the correct substitutions-
can be used. (It is customary to indicate the characteristic number for non-
stationary heat (and for mass penetration) as the Fourier number, Fo.) We see
that in the case of short times (equation IV.21) the mass transfer coefficient
kat any timet is g]ven by :
(lV.22)
If the total mass transfer operation lasts a time te the average mass transfer
coefficient is found as:
(IV.23)
241
Since the penetration depth for mass transfer ( = jrl)i) is usually very small,
because of the low values for the diffusion coefficient and the short contact
times characteristic of mass transfer (usually 1 s), the penetration theory is
even more frequently used for the description of mass transfer than for heat
transfer.
Especially in cases where the interface (because it flows) is refreshed, the
penetration theory is usable. For ascending bubbles in a liquid the maximal
contact time of the surface elements is given b yte = d/v (d = bubble diameter,
v ~ rate of ascension, the 'jacket' of the bubble is renewed every time it has
moved a diameter). For a C0 2 bubble.which ascends in water at a rate of05 m/s
and which has a diameter of 10- 2 m, te = 2, x 10- 2 s. Further. fflco 2 = 2 x
10- 9 m 2 /s (20C, 1 atm). so in this case the m~an mass transfer coefficient in the
liquid phase (k) = 2~ = 36 X 10- 4 mjs (mass transfer coefficients for
aqueous solutions under normal conditions are invariably in this order of
magnitude).
Based on the idea that in many apparatus for liquid- liquid or gas-liquid
contact the interface is refreshed because there is flow, it has been proposed to
introduce an age distribution for surface elements in the apparatus, and on this
basis to calculate mean mass transfer coefficients ( k) with the penetration theory.
If 1/f(t) dt is the fraction of the surface with ages between t and t + de, according
to this theory :
( k) = f <Xlt/J(t)
Jo y;t
(0 dt (IV.24)
Usually the age distribution t/l(t) is unknown. In the literature two theories
about f/l(t) can be found. Higbie assumed that the probability to nnd a surface
element of age t for all times between t = 0 and t = te (the maximum possible
age) is equally great, so: ..
dt
t/l(t) dt = - for 0 ~ t ~ t,
te
and :
t/l(t) = 0 for t > te
This is a supposition which is correct for, for example, the absorption of a gas
in jets of liquid, in laminar liquid films and in swarms of falling, rigid liquid
droplets.
In these cases the mean mass transfer coefficient is :
as we had already found with equation (IV.23 ). Danckwerts supposed that every
surface element, independent of its previous history, has at any moment a
242
chance s dt to disappear in the subsequent period of time dt. In this case:
-dlfr(t) = t/t(t)s dt
which in words means : 'The chance that the surface element disappears in the
time between t and t + dt equals the chance that it is still there at timer multiplied
by s dt. ' Using this supposition we find with equation (IV.24):
The constants is called the surface renewal frequency (unit : s- 1 ) . The practical
use of Danckwerts theory is restricted to those cases where a priori something
can be said about the renewal frequency; those cases are rare, unfortunately.
This theory can be applied, for example, for calculating the mass transfer
. coefficients for liquids flowing over a packing material. If the liquid has at any
contact place between two packings a chance p to be completely mixe~ the
frequency s is given by the ratio of p and the residence time on one piece of
packing.
The same is valid for a dispersion of small, separate droplets which have a
certain chance (independent of their previous history) to leave the dispersion.
The droplets must stay in the continuous phase for a short time only, so that they
are not completely extracted. For small droplets staying in the continuous phase
for a long time, k = 2rJ/dP describes the mass transfer coefficient in the continu-
ous phase;
IV.2.1. Problems
1. A jet of water (diameter 2 mm, temperature 20C) with uniform velocity
distribution (v = 5 mjs) falls vertically through practically pure C0 2 gas
under atmospheric pressure. How much 00 2 is absorbed per unit of time
by the first 10 em of the jet? The solubility of C02 in water at 20C and
1 atm C0 2 pressure is 173 kg C0 2 / m 3 . The diffusion coefficient D = 17
x 10- 9 m2 fs.
Answer : 36 x 10- 1 kgjs
2 A waJl is coated on one side with a 02 mm thick layer of paint consisting
of a very volatile component and a heavier, non-volatile component.
The paint is aUowed to dry, i.e. the volatile component is caused to evaporate.
(a) Calculate with a simple physical model how long it takes before the
drying front has reached the interface paint wall.
(b) How long does it take before 99 per cent of the volatile component has
evaporated?
243
The diffusion coefficient of the volatile component in the paint is. D = 22
x 10- 11 m2 /s.
Answer : (a) 10 min
(b) 57 h
*3. A layer of water and a layer of toluene are brought together at time t = 0.
Both layers contain 10.kg/m3 of an iodine compound. The ratio of the
equilibrium concentrations of this iodine GOmpound in toluene and in water
is 10 : 1 ; the ratio of the diffusion coefficients of the iodine compound
in water and in toluene is 4. In what direction is the iodine compound
transported? Calculate for relatively short times the concentration at the
interface for both phases, assuming that the transport takes place by diffu-
sion only. Sketch the concentration distribution in both phases. .
Answer: ciw = 24 kgfm 3 ; cit= 25 kgjm 3
*4. A short laminar jet of pure water (temperature 20C) falls through pure
S02 . The gas has a temperature of20C and a pressure of 1 atm. With what
theory can the rate of absorption of the gas be described?
(a) Calculate the surface temperature of the Vfater jet if under the prevailing
conditions the solubility of so2 in water is 154kmolfm 3, the heat of
solution Is 67 kcal/ mole and the Lewis number (Le = aj D) is 90. In
this calculation neglect the heat transpon to the gas phase.
(b) How much higher wi11 the rate of absorption be if the jet falls twice as
fast?
(c) What is the influence of the jet diameter on the rate of absorption?
(In practice it appears that the jet contracts because it is accelerated by
gravity. What will be the influence of the contraction on the rate of
absorption considering the answer to the p revious,question?)
v,. = iJgf)
244
Prove that the mass transfer coefficient for the free-ftowing interface of
these bubbles is given by :
( k) = !6,f!!f
7. A water droplet with a diameter of 2 mm falls 4 m through surrounding air
(20C). Originally the droplet contains no oxygen. What is its mean oxygen
concentration after 4 m? If it contains originally 5 mg 0 2 / l, what would
have been its mean oxygen concentration after 4 m? The distribution co-
efficient of 0 2 in H 2 0 is 0033 (20C).
Answer: 085 mg 0 2 /1; 534 mg O J.!]
*8. The liquid hold-up H, in a packed column at very low gas velocities (below
loading point) can be estimated from the relations for a free-falling liquid
film to be :
H, = af;~T
13
(mfm
3 3
)
Comments on problems
Problem 3
Since ctfcw at equilibrium = 10, the iodine compound is transported into the
toluene phase. For short times we can apply the penetration theory and we find :
Assuming equilibrium a t the interface, thus c;Jc;. . . = 10, we fi nd with the given
ratio of diffusion coefficients :
cil = 25 k gjm 3 ; c,.,., = 25 kgfm 3
Problem 4
Applying the penetration theory the mass flux of S0 2 into the jet at any time
is given by:
If we assume that :
aU heat o f solution is produced at the surface of the jet ;
there is no heat loss into the gas phase ;
the temperature in the centre of the jet: remains constant
we can describe the transport of heat into the jet by the penetration theory :
and we find :
ci ~Hs
4T =
pc, va{[ . 109C
The total mass flow into the jet is given by (using t = L/v) :
Problem 8
For the thickness of a falling laminar film we found in paragraph II.l :
d = f 3y(v)d}t
.. g
where :
cPv <f>vL <f>vL Vo
<v)d = width= -A- = -aV
- =a-
- - -- -- -- - - -- -
246
Since H 1 = ad we find :
_
H ~-a--0 {3v v}'i
ga
If we assume the probability t hat the liquid .is completely mixed after each
packing particle to be p = 1 we find for the frequency of surface renewal:
1 L v0 1 {v~ga} !
s= -r:P = dpTL = Hrdp = adP ~ . = 1 77s- l .
pcPT
i./peP = a
~
a/peP
247
Thus, if for a certain geometric case of heat transfer with forced convection it is
concluded that, for example:
Nu = f 1(Re,Pr, Gr, Fo, Gz, ... )
it follows from the above that for the same case with the sam e type of b oundary
conditions applies:
Sh = / 2 (Re, Sc, G r, F o, G z, ... )
Sh = C Re'" Sen
The exponent m varies from ca. j (for the laminar entrance region in a pipe)
via 05 (in the case of flow around spheres) to ca. 08 (for turbulent flow in
pipes), but in all these cases (excep t with liquid metals) the exponent n of P r
(and he~ce also o f Sc) is about equal to t. Chilton and Colburn have used
this for representing the analogy between heat and mass transfers in the following
- -- -- - - - -
248
form. They defined a heat transfer v~l'\lt; :
j 8 = N~ ~~- 1 Pr-t
and a mass transfer value:
....
j D = Sh Re- 1 sc-i
Using these definitions the analogy for geometrically similar cases and not too
low values of Re becomes :
(IV.27)
For turbulent flow through pipes and along fia t plates this analogy can be
extended to:
)g = }D = 2
. . 1j (IV.28)
where f is the so-called Fanning friction factor (see paragraph 11.2, equation
11.22). This analogy with momentum transfer, however, applies only in those
cases where f is caused by wall friction. The flow resistance of a body caused by
eddies which can be an important part of the overall flow resistance is not
a ttended by analogous effects in t:he. beat or mass transfers. So fo r these cases
equation (IV.28) does not apply, but equation (lV.27) does.
The analogy between heat and mass transfers also applies to free convection.
The density difference ap which occurs in the Grashof number (see paragraph
Ill.6) might originate from concentration d ifferences as well as from temperature
differences. If there are differences both in concentration and in temperature
(combined heat and mass transfers) the influence of both on Gr can be ~aken
into account.
JC
Case 2.
Case 3.
v.., =wy+v;
Vy:: 0
case 5.
ro;;;
k =
v(0-:m =
-.J-;;
or :
kx = Sb =
[j) X
--( v;x)t(~)t
1
Jnv [) = 0-565 Ret Set
X
(IV.30)
= 0539(wx
1
kx
-0 = Sh X - )t (IV.31)
[)
and :
( k ) = ~kL
For a laminar, Newtonian pipe flow (diameter D) :
W=-
dv;
-
s<vx>
dy y= O D
The reader can compare this result with the analogous heat transfer problem
of Graetz (equation III.46b). For mass transfer this case is not so important
but it is a borderline case of the following case in which both an interface
velocity (vi) and a velocity gradient (w = dvJd yly=o) p lay a role.
Case 4. Stationary iitterface and a velocity vx ~ Vex; sufficiently far from the
intelface
. For the velocity and shear stress distribution~ along the interface the following
appllies, according to SGhlichting's boundary layer theory :
Also applies :
where ~his the thickness of the hydrodynamic boundary layer. Further applies:
Sh = kx = x
:r [[} (J
t:
Jf the mass transfer boundary layer {Jc is much thinner than the hydrodynamic
boundary layer ~h for the relation of the two boundary layer thicknesses applies:
06 0 0 . - - - - - - - - - - - - - - - -- -----,
Cow 1. wi1h v,-="co
Cose 1. wi th cttOI'octeristic
velocity v;
Figure IV .5 The mass transfer coefficient in the flow sit uatio n for
case 5
If the laminar boundary layer exceeds a certain thickness, the boundary layer
flow becomes turbulent (approximately for VxlJJv > 5 X 10 4 ). The eddies then
penetrate into the area where the mass transfer takes place. The {statistical)
velocity components in the y-direction contribute, together with the diffusion,
to the transport perpendicular to the interface. Quite near the interface where
the eddies hardly penetrate (laminar sublayer) transport takes place exclusively
as a result of diffusion. At larger distances from the interface the {statistical)
transport prevails by entrainment In between lies an area where both processes
are equally imponant.
Since the transport by turbulent motion is statistical, just as the diffusion,
this transport is described by means of an eddy mass diffusivity E which depends
on y. Equation (IV.30) then becomes:
The next thing to do is to measure vx(Y); to assume t in all layers near to the
interface to be constant and equal to the shear stress on the wall ; to determine
E(y) using equation (1V.34) and then to use this result for calculating k using
equation (1V.33). To this end equation (IV.33} is written as follows:
1
Sh = kx = x;~ol,y = x{~ IX) dy }- (IV.35)
X [J) ro
[) J o de A . o \1
~l
+ tO} .
A drawback to this method, of course, is that particularly close to the wall
where the resistance to the mass transfer is found v:x:{y) is difficult to measure.
As a consequence the E(y) values derived from the velocity distribution are
inaccurate, which causes errors in the estimationof Shx by this route.
Most data are known about steady-state turbulent flow along a solid flat wall.
The number of suggestions for E(y) is large. All these suggestions can be sum-
marized a s follows:
_k = St = _ _f_/_
2 -== (IV.36)
v:n 1 + g(ScVJ72
where :
St (Stanton number)= Sh/Re Sc
f = Fanning friction factor for the solid wall = 2tw/ pv~
g(Sc) = function of Sc
254
In the case wbere Sc = l , g == 0 applies and 2k = fvr:t> (Reynolds' analogy).
Further, g is the following function of Sc :
The greater error in the function g for higher values of Sc is mainly caused
by the various approximations of E(y) near the wall DeissJer, for example,
finds g = 90 Sc~ (Sc > 200); Reichardt finds in the same Sc range g = 88 Sc-i
and Ling = 18 Sc~.
These results can be used in the description of mass transfer between a pipe
wall and a turbulent flow (e.g. the free space in a packed bed can be considered
as a system of irregular channels). The friction factor fin equation (IV.36)
should then exclusively describe the friction resistance and not the form resis-
tance. This factor should also be related to a Reynold s n umber in which the
hydraulic diameter of the channels occurs as the characteristic length.
I V.3.4. Problems
1. An air freshener is suspended vertically in still air. Calculate the thickness
which evaporates each day.
Data: molecular weight : 200 vapour pressure: 10- 3 atm
v = 15 x lo- s m 2j s L = 25cm
10 = 0.5 x to- 5 m2/s p = 1500 kgjm 3
A nswer: 01 mmjday
2. The inner wall of a tube has, in the course of time, been caked with a solid
layer of brine of 2 m.m. The heat transfer coefficient ~ at the wall is
1000 Wj m 2 0 C. Calculate the time necessary to dissolve the salt if the tube
is fi usbed under the same conditions with dis tilled water. (PsaJt = 2500 kglm3 ,
the Lewis number under these conditions is Le = a/ fD = 100 and the
solubility of the sa1t is 300 kgjm 3 .)
Answer: 25 min
3. A metal foil has t o be etched. To this end it is drawn through an etching
liquid which flows at the samespeed (1 m/s)with the foil. The etching process
is fully determined b y mass transfer. By what factor does the velocity of
the etching process change if the foH is stopped and the liquid continues
to flow (Sc = 10 3 )?
Answer : 02 times
*4. The Obersalzberg, a mountain in the G erman/ Austrian Alps near Salzburg,
consists of rela tively pure sea salt.. The salt is m ined by drilling and digging
255
out chambers of about 60 x 60 m and 1 m height some hundreds of
metres deep into the mountain. These chambers are filled with water.
Fresh water is added and a 90 per cent saturated salt solution is withdrawn
continuously. Part of the mines can be visited and the guide will tell you that
the height ofthese chambers increases at a rate of approximately 1 em/day.
Wha t speed of solution of the. salt would you predict1 (p5111 = 2165 kg/m 3 ,
solubility = 300 kg/m 3 Psaturated solution = 1200 kg/m 3, [}Nact = 15 X lO - 9
I
--- -- - - - - -
256
Comments on problems
Prob~m. 4
Estimating p co :
p<XJ = 1000 + ().9 x 200 = 1180 kg/m 3
we find:
( k) = 123 X 10- 5 m js
A material balance shows that :
and we find :
dH
-dt
- = 148 em/day
The salt contains small amounts ofgypsum and iron oxide which do not dissolve
but settle at the bottom of the chamber. Apparently, these insoluble impurities
slightly lower the speed of dissolution.
Problem 5
The drawings show the flow situations around the stagnant and the mobile
droplet. These flow situations were discussed in paragraph IV.3.2 (Figure
IV.4, cases 4 and 5). So for the stagnant droplet equation (IV.32) is valid:
sb = ().332("~"dr Set
Consequently :
k stagnant
--'--- 0332(v"") t Sc-t = 037
= -- -
kmobile 0565 Vj
because V; = !vco
Problem 8
We assume that all heat of solution produced at the interface crystal-liquid
is transported .into the liquid with uniform bulk temperature T00 A simple
heat balance shows :
'H = ct(J; - . T~) ,.._4>'/n b.Hs = kci AHs
Now, because of the analogue transport mechanism of heat and mass :
~: = (~;r or ~ = ~(~r
so:
John put down his cup of tea with distaste and thought about
the detrimental effect of water pollution on his drinking
habits. He knew that his secretary used a coal filter to
decrease the concentration of impurities in the water by a
factor of10. Remembering chat because ofthe long dry period
the level of impurities had increase_d by afactor 3 he advised
his secretary to i_ncrease the length of the coal column by
48 per cent.
258
The calculation of mass exchangers in which no chemical reactions occur
proceeds analogously to the calculation of beat ex<:hangers. Mass transfer
usually takes place in apparatus in which the two exchanging phases are brought
into close contact with each other. To this end, the one phase is finely dispersed
in the other so that a Jarge exchange area is formed
For selecting the correct type of mass transfer apparatus and for determining
the main dimensions, the following data are of importance :
(a) the thermodynamic equilibrium between the phases in question under the
prevailing condition s (temperature and pressure) ;
(b) the rate of mass transport in the chosen apparatus as a functio n of the
operational variables (e.g. flow rate, stirring intensity, etc.).
Gas m
Air 0 018
Ammonia 685
Carbon dioxide 086
Chlorine 225
Hydrogen 0.01 8
Hydrogen chlonde 430
Nitrogen 0015
Oxygen 0031
Sulphur d ioxide 386
c=---
co
(.JV.37)
l + m</h
c/>g
To ensure the highest possible outlet concentration in the liquid, the ratio
mJJ 4>8 , which is called the extraction factor, should be as small as possible.
. e.g. >, = IOm<f>L The desired ratio between the flows r/>8/t/>L is therefore deter-
mined by the distribution coefficient. For poorly soluble gases such as oxygen
it is sufficient to choose r/>g/c/>L ~ 03. For readily soluble gases such as C02 ,
<P:/<PL should be ~ 10. .
These statements which are based on thermodynamics apply irrespective
of whether absorption or desorption is involved; . r
with readily soluble gases
. .
a
high Q>g/<PL ratio is necessary in order: ', .
(a) not to exhaust the gas too much and.;. .
(b) in the case of desorption not to build up too high a back pressure of the com-
ponent to be desorbed in the gas phase.
Table IV.2 Some approximate values for gas-liquid contact apparatus. The flow rate is
v0 L= 2 x J0- 2 m3/m2 s
Distillation stage
(with bubble caps)
().3 75 >06 25
Stirred tanlc
reactor 0.15 1000 >0.5 6
Sieve plate 1 150 > 015 l
Packed column
(two phases) l 250 < 005 15
I
j l4>v1
- -- ~-r------
0
___ _
. Q dx
---0 _ 1 ........ .. 0
I
Figure IV.6 Contact between two phases in a column j f 4> v2 .
(IV.44)
x+ HETP
4>v 1 ;c(x}
1
In order to determine the correlation berween HETP and HTU use is made
of the definition equation (1V.40) of the HTU:
-
HETP -- Jr+ HETP de 1
(IV.46}
HTU x c1 - mc 2
The integral on the right-hand side of equation (IV.46) can be calculated if it
is borne 'in mind that a relation between c 1 and c2 can be found from a mass
balance. For the case of plug flow this mass balance reads:
- tPv 1C1 + <f>v2C2 = COnstant
Equation (IV.46) can then be elaborated to :
H ETP
HTU
1 In /(1 - E)c1(x + HETP)- mc (x + HETP) + Ec (x + HETP))
2 1
1- E \ (1 - E)c 1(x)- mc 2 (x + HETP) + Ec 1(x + HETP)
and using the definition of the HETP, c 1(x) = mc2(X + HETP), that can be
reduced to:
HETP _ 1 Jn {.!..
c 1(x + HETP) - mc2 (x + HETP)} _ ln E (IV.47)
HTU - 1 - E E c1 (x + HETP) - mcz(x + HETP) - E- 1
So only if the extraction factor approaches the value of 1, which will be chosen
in many practical cases, will HETP ~ HTU.
For packing materials such as Raschig rings and Berl saddles the HTU is of
the order of magnitude of 6-60 em, 15 em being a good average. The reader
may check for himself what this means for the HETP if E is respectively 025,
050, 075 and 1-5.
265
Because the HETP is a stronger function of the extraction factor E than the
HTU, the Ia tter should be considered as a funclC!J!Ientall y more correct expression
for describing the operation of an extraction column.
IV.4.5. Problems
1. A column is filled with a layer of silica gel to a height of 30 em. Air with a
moisture content of 1000 ppm is passed through. When the air flows very
slowly the moisture content after passing the column is 01 ppm, while
under working conditions the moisture content of the air after passing
the column is 10 ppm. Calculate the layer of silica gel necessary to obtain
air with a moisture content of 2 ppm.
Answer: 4~ em
- 2. A H 2S-containing water stream (concentration of H 2 S is 50gjm 3 , tem-
perature 25C) is treated countercurrently with air in order to desorb
the H 2 S. At 25C the distribution coefficient of H 2 S (=concentration
in air: concentration in water) is 0-44.
(a) Calculate the m inimum amount of air necessary for fully degassing
1m 3 water.
(b) What is the lowest concentration of H 2 S which can be achieved in the
discharged water if 1m 3 air is used per m 3 water?
Answer: (a) 23 m 3/ m 3
(b) 28 gfm 3
3. Ajr flows th rough a column filled with benzoic acid spheres. The outgoing
flow appears to be for 90 per cent saturated with benzoic acid vapour.
Now, instead of air, water is passed through the column in such a way that
the Reynolds number is the same .for both flows. What is the .degree of
saturation of the effluent water with benzoic acid?
Data:
Answer : 2-3 %
*4. A water stream of 1000 1/h must be freed from Ca2 + ions. The initial con-
centration is 500 mgjl while the required final concentration is 10 mgfl.
This process is carried out in a column filled with ion exchanger consisting
of almost spherical particles. The Ca2 + ion concentration which is in
equilibrium with the exchanger is negligibly small. The rate~determining
step during ion exchange is the mass transfer from liquid to the particles.
266
Determine the product of length and diameter of the column required for
this process.
Data: dp = 2 X w- 3 m, volume fraction voids e = 0-4
DeaH l ollS = 10- 9 m 2 is, v = 10- 6 m 2/s
Answer : DH = 012mz
5. An extraction is carried out by causing droplets of water to descend
through an oil layer. The resistance to mass transfer is entirely in the oil
phase. The mass transfer can be described with the penetration theory by
introducing as contact time the time a droplet needs to cover a distance
equal to twice its own diameter. The flow around the droplets can be
considered as a laminar flow round a rigid sphere (Stokes' law applica"Qle).
(a) By what factor dQes the mass transfer coefficient increase or decrease
when the droplets are made twice as small?
(b) How much does the product kS (i.e, the product of transfer coefficient
and total surface area of all droplets in 1 m3 of the extraction column)
increase or decrease if at this droplet size reduction the total water
flow (m 3/ s) remains unchanged?
Answer : (a) 071 times as great
(b) 56 times as great
*6. An organic liquid has to be saturated to 90 per cent with a certain substance
A However, only a saturated solution of A in water is available. The
organic liquid which is insoluble in water is now caused to ascend in small
rigid droplets (diameter : d11 = 2 mm) through the saturated solution of
A in water (rate of rise : v = 10"" 2 m/s). What should be the height of the
water column to attain a 90 per cent saturation of the organic liquid with
A? The diffusion of A both in water and in the organic liquid is 10- 9 m 2/s
and the solubility of A in the organic liquid is 200 t imes as low as in water.
The continuous water phase is present in excess a nd is not exhausted.
The initial concentration of A in the droplets is zero.
Answer : 2m
7. In order to saturate an air stream with water vapour, the air is passed
through a wash bottle filled to a height of 10 em with pure water of 2SOC.
The air is divided through a sieve plate into bubbles with a diameter of
3 mm. The bubbles behave as rigid spheres. The volume fraction of water
in the dispersion is 08.
(a) Calculate the rate of rise of the swarm of bubbles using the relation of
Richardson and Zaki (paragraph II.S.5).
(b) What liquid height is necessary to ensure a relative humidity of 999
per cent in the outflowing air'?
(c) If the water is originally air-free how long does it take to saturate the
\iqui.d for 99 \)et: cent of air.
267
Data : [)) H10 inair = 25 X w- 5 m 2/ s
DairinH1 o = 5 x 10- 9 m1 /s
Answer : (a} 0 -175 m/ s
(b) 11 em
(c) 121 s
8. A dry air stream must be saturated with 99 per cent water vapour. This
bas to be attained by passing the air flow through a wetted wall column
(a pipe in which a liquid film fiows downwards along the inside wall).
The thickness of the liquid film is very small compared with the column
diameter.
Data : <f>oair = 69 X 10- ID3 / S, D internalc:otumn
3
=5 X I o -z m
Pair = 1 kgjml, 'lair = 17 X 10 Ns/m 6 2
5 2
D HzOioair = 25 X 10 - m /s
For the mass transfer coefficient in wetted wall columns applies, according
to Gilliand and Sherwood (Ind. Eng. Chem, 26, 516, 1934) :
Problem 4
A mass balance over a short height dx of the column yields after integration
(c = c0 at H = 0) :
2
-c =exp { - -~-
kanD H}
Co 44>"
With cjc0 = 0.02 and a = 6(1 - s)/dp = 1800 m 2/ m 3 we find :
kD 2 H = 765 x 10- 7 m 4 /s (1)
The mass transfer process is analogous to bea.t transfer during flow through
a packed bed, so we can adapt equation (III.69a) for the estimation of the mass
transfer coefficient :
and we find :
kD = 6-3 x 10- 6 m 2/s (2)
Combining this with equation (1) we obtain for the desired product :
DH = 012m2
So a small column of, for example, D = 02 m and H = 06 m would be suitable
for this purpose.
Problem 6
The only difficulty of this problem is to decide which mass transfer coefficient
is important. This problem has already been discussed in paragraph 1V.1.2,
so we can be very brief here. The figure shows the concentrations that play a
c*
2
cf>" = mc 2 - c 1
nc m 1
-+-
k2 kl
Since the diffusion coefficient of the transported compound is the same in both
phases k 1 = k2 , but because m = cf!c; = 1/200 the mass transport in the drop-
let is rate-determining and equation (1) becomes :
cf>':n = k 1(mc 2 - c 1)
The concentration equalization in the droplets is :
c1 - ( c)= c~- 09 c! = Ol
c 1 - c0 c~
and we find from Fi~e III.8 that Fo = Otfd; = 005 and L = vt =2m.
Problem 9
The rate of absorption is determined by the gas phase mass transfer resistance
because the S0 3 vapour pressure of concentrated H 2 S04 is practically zero. The
gas phase mass transfer coefficient can be calculated with the help of the bound-
ary layer theory (equation IV.32; see . .paragraph IV.3.2, case 5) by using
instead of vCX) the sum V; + vCX). Here we can assume v, V 00 and we find
(vCX) = vj = 218 rnjs) :
k = 0765 x 10- 2 .m2/s and . ( k) = 153 x 10- 2 m/s
A mass balance over the differential height dx of the column yields after iii
tegration (c = c0 at H = 0):
we find H = 405 m.
~
c0
= exp (- kmtDz)
4 0
= exp (- _!!_)
HTU
The height of a transfer unit stays constant and from the information about the
normal operation of the column (c = 001 c0 ) we find that H 1 = 23 HTU.
With the impure water, for the same final concentration (now c = 00033 c0 )
a column height of H 2 = 34 HTU is required~ i.e. 48 per cent more.
/CAi
I
I
I
I
I
I.
I
1
1,)
I CA
-x
Figure IV.8 Concentration distribution
during mass transfer with slow homogeneous
first-order chemical reaction
272
amount transported through the film (""' AkAcAi) is much bigger than the
amount of A converted in the film by chemical reaction (,.., Aok,.cAJ} Thus, if:
(IV.52)
where A is the size of the interface and V the bulk volume. Eliminating the un-
known bulk concentration we find for the mass flux through the interface:
(IV.53)
If the reaction is very slow, i.e. Vk, AkA or AkAfY k,. >> 1, the bulk concen-
tration will be almost equal to the concentration at the interface, cA ~ cAI.
From equation (IV.53) we find, then, that the mass flux is given by:
n V (JV.54)
cf>A = Ak,cAi
This means that under these conditions the rate of the transport process is
completely determined by the rate of the {slow) chemical reaction.
If, on the other hand, the chemical reaction is very fast, Vk, AkA or
A kAfli k, l, we find:
(IV.55)
273
because the bulk concentration cA is now very small (due to the fast conversion
of A~ The rate of the transport process is in this case determined by the ma.Ss
transport through the boundary layer.
where RA = - k,c A. The solution of this differential equation with the boundary
conditions cA = cA; at x = 0 and cA = 0 for x = ro is:
is
This concentration distribution shown in Figure IV.9. From equation (IV. 56)
we find for the mass flux through the boundary layer :
(IV.57)
.I
CAi I
I
I
I.
I
t I
I l
~
I
~A. =exp:{-
AI I
x~} l\
l
I
-----X
In this case the mass transfer coefficient is given by~ and is solely depen-
dent on the diffusion coefficient and the reaction rate constant k, . The ratio
jD Ak,fk! which represents the ratio between the mass transfer coefficients
with and without chemical reaction is called the Hatta (Ha) number, which
plays an importan t part in mass transfer with chemical reaction.
----==~~====~--------------~--
274
From the concentration distribution, equation (IV.56}, we see that the pene-
tration depth ~r of the concentration distribution with chemical reaction is
given approximately by :
(IV.58)
Consequently, the ratio of the thickness b = 'JJfkA of the boundary layer and the
penetration depth b, is given by :
!__= ~=Ha
8,. ~~
which shows another physical meaning of the Ha number.
ff the reaction occurs partly in the boundary layer and partly in the bulk of
is
the liquid (Figure IV.lOd) (where. because of the fast reaction, cA very Jow),
we can show that the mass flux is given by:
(1V.59)
If the reaction is very fast, i.e. Ha = j k,.IO Afk~ 1 (for all practical purposes
Ha > 3), equation (IV.59) can be simplified to equation (IV.57), which we have
already derived In this case the total reaction occurs in the boundary layer.
If the reaction is relatively slow, Ha = J krDAik! 1 (Ha < 03), we find from
equation (IV.59) the relation for simple physical adsorption :
lj>A = kACA i
and only a negligible part of the reaction occurs in the boundary layer.
The Ha number is therefore the criterion for whether the reaction occurs
completely in the bulk of the liquid (Ha < 03) or completely in the boundary
layer (Ha > 3). If 03 < Ha < 3, reaction in both the bulk and the film is
important. Figure IV.lO shows the five possible cases of mass transport with
homogeneous first-order chemical reaction which we have discussed. If we
want to determine to which class a certain problem belongs we start by cal-
culating the Ha number. If Ha < 03, as a second criterion the expression
Ak.JVk, has to be determined (compare equation IV.53).
Equation (IV.59} and Figure IV.IO also show that the rate of physical absorp-
tion is increased by a factor :
(IV.60)
by the occurrence of a homogeneous first-order chemical reaction. This increase
J
in adsorption rate by a factor 1 + Ha 2 in the case of a chemical reaction is
valid under all flow conditions. The thickness b, of the boundary layer where the
chemical reaction occurs is so small that it is not influenced by the flow con-
ditions. Also. during turbulent flow, the eddies cannot penetra te this thin layer.
The enhancement factor Fe= j 1 + Ha2 is therefore universally applicable.
275
_,...-cAi
~
: CA-.::.CAi Ak
Ha < 0.3 ; ~ >> l
Vk,
t I
-
(0 ) u I
I
I
J No reaction in boundary layer
Ak
Ha < 0.3 ~ ~ I
' Vk,
Ak
Ha < 03; _ A J
Vk,
( c)
Ak
0.3 < Ha < 3 ; ~ 1
Vk,
(d)
'A = kAcA;j i + Ha2
Reaction partly in boundary layer
AkA
Ha < 3 ; - k 1
v ,
(e) ;. = kAcAIHa
Reaction c:Omp1etely in boundary layer
Figme IV.JO Five cases of mass transfer witb homogeneous irreversible first-order
reaction
(IV.61)
Ha = -
1 2 krCAt
n- l
[)A. (IV.62)
kA n + 1
With the above Ha number, the relations developed in paragraphs IV.5.1
and IV.5.2 for first-order reactions also describe nth-order reactions. There is
one important practical difference: for first-order reactions b, and Ha are only
(through k,) dependent on temperature, but for nth-order reactions these para-
meters are also dependent on the concentration of A at the interface.
The solution to this problem has already been treated in paragraphs IV.S.l
and IV.5.2. There are two conditions under which the assumption of a pseudo
first-order reaction is justified :
(a) If rhe reaction takes place in the bulk so hat :
-~
H a- -~OA _
k2- -A
(b) If the reacta nt B can be transported quickly enough into the film where the
reaction occurs so that the concentration of B in the film can be assumed
to equal the bulk concentration (see Figure IV.ll), i.e. if:
(IV.64)
277
~, 8 - -x
Fieure IV.11 Concentratjon distribution during
mass transfer and second-order reaction if Ha > 3,
kBcsaJfkAcAi > 10 Ha
(IV.65)
the reaction is so fast that A and B cannot exist without reacting instantly.
A reaction front is formed at x = xR (see Figure IV.l2) where cA = c8 = 0.
The film theory yields for the transport rates of both components to the reaction
front :
(IV.67)
Hence, the chemical acceleration factor is fo und to be, bearing in mind the
definition of the H a number given in paragraph IV.5.2 and realizing tha t for this
278
0
-x
Figure IV.12 Concentration distribution during
mass transfer with secondorder reaction if Ha > 3,
kaescrlkAcAi < 01 Ha
(IV.68)
where f>A and <58 are the thicknesses of the boundary layers during physical
absorption only. The penetration theory predicts that :
bA- SbB -
f>a - ShA -
(OA)t
lOa
. (IV.69)
(see case 1 of paragraph IV.3.2) whereas the boundary l ay~r and the Leveque
theory (cases 2 and 4) predict a relation of the form :
{)A= (0 A) -t (IV.70)
<>a De
If D A and 0 8 are of the same order of magnitude (which is often the case) the
enhancement factor Fe is only slightly dependent on the physical model chosen
and we can use equation (IV.68), together with equation (1V.69) or (IV. 70) to
produce a reasonably accurate estimate of Fe-
In the in termediate area between a fast reaction (k 8 c8 d kAcA1 > 10 Ha)
and an instantaneous reaction (k8 c8 a>f kAcAi < 01 Ha), so in the area where
(see Figure IV.l3) :
kaeaa> ~ Ha
kAcA
the F, value is a function of the Ha number and of
279
-x
Figure IV.13 Concentration distribution during
mass transfer with second-order reaction ifHa > 03
k8 c8 .,jkAcAi ~ Ha
10
10 100 1000
Ha
Figure IV.14 Values for the enhancement factor Fe for second-order reactions if
Ha > 0.3, k8 c8 J/kAcA1 ~ H a
280
Table IV.3 Summary of mass transfer situations with irreversible second-order reactions
kacaao
Ha kACAc Solution
~~ = {( ~:r + ( ~;
where!< m <!
r-l C;:}kACAO
the material ba,lance for any of the five flow situations discussed in paragraph
IV.3.2 becomes:
(IV.71)
(IV.73)
We will now discuss the special cases of first- and second-order reactions.
(a) First-order reaction. Equation (IV.73)for tbis case reads :
(IV.75)
Apparently, here the quotient kAfk~ fulfils the role the expression Ak.JVk,
played during homogeneous reactions (paragraph IV.S.i). We can distinguish
three principal situations :
A.
The reaction is so slow compared. with the mass transfer process that mass
transfer does not decrease the reaction rate and the concentration of A is
uniform and equals cA-:c
B. k~ kA, CAi ~ 0, tP~ = kACAoo
* In the case of heterogeneous catalysis often a microkinetic reaction rate constant k; related to
the total pore surface of the catalyst is used; 'K,. is related to k;. and k, by :
k r = ap k"r = ak'r
2 3
where a = outer specific surface of catalyst particles and aP = specific pore area of catalyst (m /m ).
282
c.
Both chemical reaction and mass transfer determine the overall conversion
rate.
Figure IV.lS gives a summary of these three situations and shows the con-
centration distributions which occur. The reader should compare this figure
with the first three cases of Figure IV.lO, which refer to ho mogeneous first
order reactions.
A.
-)(
B.
c.
</>~ = kAcAco
where:
283
Calculation of c,.JcAoo from equation (lV.76) enables 'us to find the rate o_f
conversion as :
= kACAo ( 1 -
cf>~ CA)
- ' (IV.77)
CAo
The reader may check that for rjJ-+ 0 second-order heterogeneous reactions
can be regarded as pseudo first-order reactions.
At this stage, the authors had Gonsidered inserting -a section on the design of
simple chemical reactors. This would have been logical in the lay-out of the
book The main features of the .design of a heat exchanger (paragraph ITI.4)
fo-Ilowed the fundamental considerations on heat transfer in the preceding
sections and the design of a mass exchanger (paragraph IV.4) concluded the
theory of mass transfer without chemical reaction 1n the beginning of this
chapter. However, simple and isothermal chemical reactors seldom occur in
practice and we prefer to refer the reader to a more elaborated text on the subject
of chemical reactors, e.g. Levenspiel 's Chemical Reaction Engineering. Simple
calculations can already be made on the basis of what is offered here, as the
following problems will show-it is only and again applying the law of mass
conservation.
IV ..5.6. Problems
1. On the bottom of a cylindrical vessel (diameter D = 1 m, height H = l m)
with stirrer is a 1 em layer of solid substance. To remove this layer the
vessel js filled with a liquid in which the solid dissolves. In solution the
solid decomposes according to a first-order chemical reaction.
Data : mass transfer coefficient (without chemical reaction) k = 10- 4 mfs
solubility of the solid substance in the liquid = 50 kgjm 3
density of the solid substance p = 2000 kgjm 3
diffusivity [} = 10- 9 m 2 js
reaction rate constant kr = 10- 2 s- 1
(a) Show that the mean concentration of the dissolved solid in the liquid
is much lower than the solubility of the solid substance.
(b) Show that the conversion by chemical reaction in the .boundary layer
is negligible.
(c) How long does it take for the layer of solid substance to be ~issolved
completely?
(d) A chemist states that the process can no doubt be accelerated by adding
a catalyst which makes the reaction rate constant 1000 times as great.
Demonstrate quantitatively whether his statement is correct.
Answer : (a) c = 001 c,
(b) be = lo-s m ~ <0-3 per cent of the total conversion in film
(c) 4000 s
(d) j2 times as fast
284
2. If under otherwise equal conditions pure oxygen or oxygen -from the
surrounding air is absorbed in a strong Na2 S0 3 solution to which a
large amount of cobalt salts have been added, the difference in rate of
adsorption appears to be a factor of 10. Determine the order of the reaction
between 0 2 and Na2 S0 3 with respect to the oxygen (the reaction is very
fast, Ha > 3).
Answer: 2
3. In a laminar liquid film (c~ntact time Ol s) C0 2 (m = l) is absorbe~ from
the pure gas (20C. I atm). The liquid film contains 004 kmolfm 3 NaOH.
Under the prevailing conditions the second-order reaction rate constant
between C0 2 and NaOH is 6 x 103 m 3 jkmol s. Calcula te the chemical
enhancement factor and the mole flu x in this situation and draw the oon-
c~ntration distribution in the film. Assume []lc02 = DoH- ~ 2 x 10 - 9 rn 2 /s;
because 1 mole C02 uses two moles NaOH, for CsQ) in this "case
tcNaOH must be used.
Answer : 0376 m
*6. During fat hydrogenation pure H 2 is absorbed in liquid fat containing
catalyst particles at which the reaction between H 2 and unsaturated fatty
acid takes place. The rate of conversion per unit liquid volume related to
H 2 is independent of the degree of conversion of the oil and appears to be
linearly proportional to the solubility of H 2 In a certain experiment
the ratio between these two constants appears to be 0.03 min-
1
285
If the interface between gas and liquid is increased by a factor of 2, the
specific rate of conversion will be 20 per cent higher. If the catalyst con-
centration is increased b y a factor of :2. the specific rate of conversion will
be 50 per cent higher. Calculate for this experiment the gas- liquid inter-
facia] area per unit liquid volume and the {macro)reaction rate constant
o f the reaction between H 2 and unsaturated fat.
Data : the partial mass transfer coefficients in the liquid at the interface
with gas kl = 1o- 4 m/s and at the interface with the catalyst k2 =
w-s mfs
the interface of the catalyst per unit volume of liquid = 150 m 2 fm3
Answer: 15 m 2 /m 3 ; lo -s m/s
L tPm
(m) . (kg/s)
Answer : 154 m
*1 1. Show that John drew the right conclusion in the case o f the burning hay-
sta ck related at the beginning of this paragraph.
Comments on problems
Problem 5
A material balance over a short height dh of the packed column reads (A =
cross-sectional area of column):
- cf>L del..= ka(cL - ci)A dh = krac;A dh
287
and isolating and substituting the unknown interface concentration ci we
obtain :
}
CL
cLo
{
= exp . (~
Vo
!)
- ah
k+ k
r
We find the mass transfer coefficient with the aid of equation (III.69a) (making
use of the analogy between heat and mass transfer) to be k = 114 x 10- 4 mjs
and with a = 6(1 - e)jdP = 3600 m 2 fm 3 we finally obtain h = 0376m.
Problem 6
The reaction rate between hydrogen and fat~ given by a relation of the form
(cL = H 2 concentration in liquid phase):
Now it is stated that the reaction rate is linearly dependent on the hydrogen
concentration, so ex = 1, and independent of the degree of conversion of the
fat, hence f3 = 0, i.e. the reaction is of the pseudo first-C?rder type. We can write :
(kmoljm 3 s)
Hydrogen has to be transported from the gas phase (con~ntration mass c,.
transfer coefficient k,. specific interface a, ) to the liquid phase (concentration
cL) and from there to the surface of the catalyst particles (concentration c;,
mass transfer coefficient kL , specific interface ai) where it reacts chemically.
Under steady-state conditions all these mass transfer steps proceed at the
same rate (no accumulation of H 1 in any phase) and we can write (k; = a!<,,
where k, = mascroscopic rate constant in m/s and k; = chemical rate constant
in s - 1 ) that:
(1)
288
From this equation we isolate and eliminate the unknown concentrations cL
and c; and obtain :
_c/J_m_ol = _ _ _m_c.!!..~--- (2)
V 1 1 1
- +--+ -
kgag kLai k,.a1
This equation completely describes the overall hydrogenation process. With the
aid of the information given we can evaluate the various terms of this equation
as follows:
1
given : 4>mol =003 min - 1 = 5 x 10- 4 s- 1 = (3)
~~ _1_ + _1_+_1_
k 8 a8 kLa 1 k,a,
given: if a~ is doubled, 4>mor increases by 20 per cent~ so:
1 1 1
--+-+-
12 = k,ag kLai k,.a1 ( 4)
1 1 1
-- + -+ -
2kgag kLai k,.a;
given : if~ is doubled (via catalyst concentration), aw1 increases by 50 per cent,
so:
1 1 1
- + -- + - -
15 = k,ag k Lat k,.ai (5)
1 1 1
- + --+--
kgag 2kLai 2k,a1
When this equation is worked out it appears to be identical with equation (4),
so the information given is consistent.
From equa~ions (3) and (4) k 8 a, can be calculated and is found to be k 8a, =
15 x 10- 3 s- 1, so that with the given k8 value we find a8 = 15 m 2 /m 3 (which
is very low for a gas liquid reactor). Using the values given forkLand ai we find
from equation (4) that the macroscopic rate constant kr = 5
w-
m/s, so the
chemical rate constant is given by k; = 15 x 10- s-
3 1
Problem 8
Sodium sulfite is oxidized in solution to sodium sulfate by oxygen if cobalt
ions which act as catalysts are present:
0 2
+ 2S0 3 2 - ~ 2S04 2 -
At a pH of 7-8 and 15-35C the reaction is :
first-Order in C0 2 + if 3 10- 6 < CeoH < 10 - 3 km.olj m 3 ,
X
second-order in 0 2 (see problem 2),
first-order in S0 3 2 - if c503 ~- < 04 kmol/m 3 ,
zero-order in SQ3 2 - if Cso3 2- > 04 kmo}jm 3
For the above range of Co2 - concentrations and c503 2 ~ > 04 kmolfm 3 the
pseudo second-order reaction rate constant is :
2 x 10$ < k, < 108 m 3 fkmol s
The only explanation of the phenomenon Reith measured is segregation of the
gas bubbles which influences the driving force of the mass transfer process.
H we neglect the concentration decrease in the gas bubbles we can write for
Ha > 3 :
>mol = Ac;Jik,c;ID = Am~ c't
In Reith's first experiment c, = 50 per cent by volume in all bubbles, so all A.
In the second experiment c, = 100 per cent by volume in half of the bubbles.
so 50 per cent of A if complete segregation occurs. The ratio of the two mass
flux rates would be :
4>
mol sepuate streams = I;
1
1 =
23
J2 = 141
4>mol mi~lure {1) X 1
Theoretically for complete segregation of the bubbles we would expect a 41
per cent higher absorption rate during the second experiment, which indeed
was measured. This strong segregation (no coalescence of bubbles) is caused by
the high ion concentration of the sulfite system. In distilled water and in most
organic solvents considerable coalescence and redispersion of bubbles would
occur.
Problem 10
The sketch of the absorption column shows the gas and liquid flows and the
corresponding concentrations in all streaii?-s. To begin with we assume that the
reaction between C0 2 and MEA proceeds in the boundary layer, i.e. that
Ha > 3. We will check this assumption later on, when we calculate the Ha
number.
P =0 56 kg / m3
9
3
r#JL =3 0 m /h .P9 =507 ~ 3/h (7 ot m l
3 3
cL =3 0 kmol/m Cg =00 I vol % = 28 x 10- 5 kmol 1m
1
t
'
t P = 2 3 1 kg / m3
9
1/>9 =635 m3 /h ( 7 otm )
c9 = 20 vol % =0 056 xmol/m3
290
Since the .Qeight of the col~ will be greater than 10 packing particles, we
can assume countercurrent plug tlow of both fluids and the mass flow rate of
C0 2 into the MEA solution is given by equation (IV .53) as:
since the mass transport is enhanced by chemical reaction. The partial gas
pha.se mass trans.fer coeffici,ent kg is fou~d with the aid of the boundary layer:
theory (case 5 of paragraph IV.3.2; see also problem 9 of paragraph IV.4) to be
(with v0 = 0 20 mjs, v = 166 x lo-s m 2 js):
kL = 11 x 10- 4 m/ s
We shall now determine the enhancement factor F,. For the Ha number we
find using the mean MEA concentration :
1 1
Ha = -
K
.jk Cs a:> [)A=
r l l X 10- 4 V /7500 x 153 x 2 x 10- 9 = 435
L
This confirms our initial assumption that Ha > 3 was correct and the reaction
proceeds in the boundary layer.
291
At the column entrance (~ottom) .(see 'p,aragraph tV.5.4):
4 to-
3 ....
.
', ' ' ~ ' ' J' I,
Problem .11 .,
Let us assume that the'haystack has the form of a half-sphere of radius r tthat
all burning occurs at the surface. of thestack and that the rate of .burning is
completely controlled by transfer of oxygen froin theair. With these assump-
tions the rate of volume d ecrease of.the haystack is dependent on the oxygen
transport from the air :
dV dr
- = 4r 2 - ,_ k 2nr 2(c - c.)
dt dt g g I
IV.6.1. Drying
A special case of combined heat and mass transfer is obtained if, for example,
a drop of liquid (or an inert object moistened with liquid) is put in a gas flow
which has not been saturated with the vapour of the liqwd Assume that the
liquid originally has the same temperature as the gas. Because the gas is not
saturated at that temperature, evaporation occurs from the liquid surface
(mass transfer). As a result~ heat of evaporation is withdrawn from the liquid
so that its temperature begins to fall The lower the temperature of the liquid)
the greater the temperature difference between gas and liquid and the more
heat will be transported) from the gas to the liquid phase. Aft~r some time a
stationary state is reached in which the temperature and hence also the heat
content of the liquid no longer changes with time; all heat required for the
evaporation is then supplied. by tile passing gas. In this situation of dynamic
equilibrium the following energy balance applies (see Figu.re IV.16) :
'JJ = t/J':nol AflHe,A (IV.78)
.
II
4> 1r \ ~ c;mol A
H \ \
\ \
'__,.~"--
Go$ flow
A,. ll k (p
'PmolA = RT A,w - PA,g) (IV.79)
where (or Ttbe mean between T; and T., can be taken. By substitution of these
equations for 4>~ and ~oJA in the energy balance {equation IV.78) we find :
PA,w- PA.t = RT ~ (IV.80)
~ - Tw tllfe,A k
In this relation PA,w and Tw are coupled via the vapour pressure curve of liquid A.
If the evaporating drop is so small that the values of PA.r and T, do not change
appreciably, rxj k in this relation can be replaced by the quotient of the mean
transfer coefficients over the entire area ( rx)/(k). The value of this quotient can
now be calculated with the help of the analogy between heat aDd mass transports.
Both ( ex} and ( k) refer to the same geometric situation and to the same flow
condition (the same value of Re). If Re is not too small, the analogy relation
(paragraph IV.3.1) can be applied, which leads to:
where the product Cp!J must be taken at the mean temperature T and Le =
aj D = ScjPr is the dimensionless Lewis number. For gas mixtures the value of
Le lies between 05 and ca. 2 and for liquids, appreciably higher than 1.
With this relation is found as ultimate result:
PA,w - P~g - RTcpP
(IV.82)
~ - J:, ~ flli e ,A
The temperature Tw is called the wet-bulb temperature because this temperature
is reached by a moist sphere if it is placed in a gas flow.*
This temperature is an important constant in the description and calculation
of drying of materials in an air stream. Another application is found in spray-
drying towers in which hot s,olutions in the form of droplets or liquid layers are
brought countercurrently irito contact with the outside air; the droplets cool
down because of evaporation but their outlet temperature cannot be lower
than the wet-bulb temperature, belonging to the temperature and the partial
water vapour pressure of the ambient air.
The wet-bulb tempera ture takes its name from psychrometry, according to
which T, and Tw are measured with a 'dry' and a 'wet' thermometer respectively
*In principl~ the same effect occurs in Jt}ass transfer in a liquid flow, e.g. on dissolving crystals.
Ascertain that jn this case usually very 'small" temperature differences occur.
- -- -- -
294
in a gas stream. Using equation (IV.82) PA,g can then be calculated. The psychro-
meter is usually used for the system air/ water, but application to other liquids is
in principle also possible. The method is particularly useful because T.., is
independent of the gas rate. However, in such a measurement we should make
sure that the heat flow to the 'wet' sphere by conduction or radiation is small
with respect to the heat flow from the gas.
The wet-bulb temperature must not be confused with the so-called adiabatic
saturation temperature ~- This is the temperature a gas (e.g. air with a tem-
perature T, and water vapour pressure PA.J a ttains if it is saturated with vapour,
the gas itself supplying the required heat of evaporation by cooling from Yg
to J;. The calculation of 7:; is based on an energy balance over a unit of mass
of the gas, in which. tb.e transport of heat and mass does not play a role. Derive
that for 7; (and the relevant equilibrium -vapour pressure PA,s) applies :
PA,s- PA,g _ RTcPp
(IV.83)
~ - 1; - filie,A
Except for the factor (Le)i, (69) corresponds with (68). For all gas mixtu~es
Le lies near 1 and for the system air/water vapour (Le)i = 095. Therefore,
sometimes (wrongly) no distinction is made between Tw and 7,, although with
regard to mechanism, they are of completely different origin.
IV.6.2. Problems
*1 . Air of20C and atmospheric pressure with a relative humidity of79 per cent
is heated to 50C. What will be the partial pressure of the water vapour
and the relative humidity?
2
This warm air flo~s along a completely moist ma~erial, r:t being 35 W /m C.
How much water </>';,.' evaporates per unit of a;rea of the . material if the
heat of evaporati.o n is entirely supplied .bY ~he a1r?
20-0 238
22-0 269
25.0 323
27.0 364
'30.0 433
340 513
37.() 642
400 750
50-0 12-33
Problem 1
The partial water vapour pressure in air at 20C and 79 per cent saturation is
PH2 o = 0-79 x 238 x 10 = 188 x 10 N /m . If this air is heated to 50C,
3 3 2
PJi 1 o stays constant, but the saturation becomes 188 x 10 3 / 1233 x 103 = 15
per cent The wall temperature is found via:
Pw- Pg = Pw- 186 x 103 = RTcPp Let= 69
T, - Tw 50 - Tw !lHe
by trial and error to be Tw = 26C and Pw = 337 x 103 N/m 2 The mass flux
of the evaporating water is given by equation (IV.79)and with the aid of equation
(IV.81) we find :
/11 .rb- .
h
r
"
\ ()_
(I
nlt ...-i)eJl J'ic/f Gj+l'cl tnttrf l"oi tii ; OL rJ
l,l ,v
I
.,. r f ,, q ' '
l
I
""-- T -
Index .' 0
7 11 op
-"() r...
'I 'I
DT1 =
\l _( LJ 1, - L1h)/ In ( LJY, f A17 ) ~11t- '' = q,l- c ;::.- 2- '3
=-- 1 (?O~ -qo) - {tH-~g)] /I~ K70S-qo)/(44 - 7~] =- lJ -qqoC
\
{jh ) . (
Crt-dtd ~ )/J!JTrll :. o.q ,nqq'c) ==- 1~.qq
Absorption coefficient for heat radiation, Condensation
221 ' effect of peonanent gas,.i11
Absorption of gases, 258, 269, 285 heat transfer coefficients, 210
Analogy Conservation laws. 3 .
between heat and mass transfer, 240 Conversion factors. 22
between heat and momentum transfer,
152 Diffusion
Annulus coefficients, 12, 15, ~~5, 227
laminar flow in, 42 equimolar, 228
with moving inner cylinder, 46 through stagnant fluid, 230
with rotating inner cylinder, 47 Dimensional analysis, 21
Average temperature difference, 182 Dispersion, 131, 137
Average velocity Distillation, binary, 32
in annulus, 43 Distribution coefficients, 232, 258
in falling fitms, 40 Drag coefficient, 100
in tube ftow, 41 Droplets, 104
r l'"r
..: r
I
J
!LlL'lGl ! "r
li1.(.L I L! M 1-
r 't 1- em rhrCJc
I
.rerw af a pd j_
~
'- -
{~W~
j
~t- kt ~lu- d/1 1 bvtt- ~J tJ>+. uJe4 tktW.9~'*- 1h~ r~m!q~ ~ 14 J 411 11~ ~m ~
then Mil a~+ 2:rc . M :"- ~ o.r prfl .Jik. ~wt- pet~ttra+td through fh.t;
1-)wv dtt.~ ~o4
tnal- a.rrum;nj -1-httl-- -1~ kellle~ bcrlbrr1 vva! hf~' aJIJhmt e 9~ r ! .r~ -~-~(.!
l 't- 4J ~tl~r 1J tJ. llJ 'fll/ '~ ~ r (J-= str kJ f'I J C?t1 a Sp. ~a+ I~ :!._
(91<
~c,~h,
(
(
Xp ;:: ) . 6'f w
d.. ==. L
P4
==
---
o IT3
(>-rt) (!o)