Designing Heat Exchanger for Production of Tomato Paste

EPF 3403: Heat Transfer Sem 2 2010/2011

EMM3602 Sem 2 2010/2011 Industrial Management 1

Nor Waheda Binti Shamsudin ( 154070) qNur Fatin Awanis Mohd Zin ( 154332 ) 4/25/12 qMastura Mohd Samadi EPF3403 Sem 2 2010/2011 Heat Transfer
q

.:. FOOD PRODUCT.:. * Why use tomato?

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Tomato is a rich source of vitamin A & C. Recent research also indicates that processed tomatoes are good for human health due to a high content of lycopene. Tomato has a shorter shelf life in normal temperature. Tomato Paste provides a way out with extremely positive outcome both commercially and financially. Tomato paste have potential demand with local fruit processors as well as the retail market. Establishment of tomato processing can 4/25/12 EMM3602 Sem 2 2010/2011 Industrial Management 1 the dependence of local contribute in reducing

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.:. FLOW Process involve in production of PROCESS .:. tomato

*

paste

EPF3403 Sem 2 2010/2011 Heat Transfer EMM3602 Sem 2 2010/2011 Industrial Management 1

Process involve in production of tomato paste

EPF3403 Sem 2 2010/2011 Heat Transfer EMM3602 Sem 2 2010/2011 Industrial Management 1

EPF3403 Sem 2 2010/2011 Heat Transfer EMM3602 Sem 2 2010/2011 Industrial Management 1

4. Sorting * Type of machine being used: The sorting machine * It is designed with mesh chain conveying and roller conveying. * The tomatoes can tumble freely on the roller by the rotation and revolution designing. * The washed tomatoes are dumped on the conveyer and the workers
EPF3403 Sem 2 2010/2011 Heat Transfer EMM3602 Sem 2 2010/2011 Industrial Management 1

EPF3403 Sem 2 2010/2011 Heat Transfer EMM3602 Sem 2 2010/2011 Industrial Management 1

6. Crushing * Type of machine being used: Tomatoes Crusher * The washed and sorted tomatoes is crushed to form the pulp which, after removal of the skins and seeds and refining to reduce particle size, constitutes the raw tomatoes for concentration. * The braking of tomatoes are made to pass between two rollers with roughness surface

8. Screw pumping * From storage tank, the screw pumping is used to pump the tomatoes pulp before it is distribute into tubular heaters for preheating process. * Screw pumping is design in order to remove the tomatoes pulp more easier and
EPF3403 Sem 2 2010/2011 Heat Transfer EMM3602 Sem 2 2010/2011 Industrial Management 1

efficient by pumping it out from the storage tank.

10. Double finishing * The Pulping Machine is a perfect device used . * Tomatoes pulp, roughly broken and pre-heated, is pumped to a series of two or three cyclones for the removal of skins and seeds. * The adjustment of cyclones are consists of setting the beaters into correct position as
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13. Prepared paste * All the evaporated tomato paste is now ready to be balanced to mix them well.

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14. Sterilizing * The tomato paste is being sterilized by using Double Pipe Heat Exchanger * To destroy any organisms likely to bring about spoilage of the 15. Filling product (such as Clostridium pasteurianum and Bacillus coagulans). * Type of machine being used: Aseptic Bag Filling Machine * After sterilization, the tomato paste undergo (Ultra High * Aseptic filling process forms the basis of UHT filling process. Temperature) processing. * The processed and sterilized tomato paste is filled into can and sealed immediately. * The filling volume of the is controlled by imported flow meter and electric weighing sensor. EMM3602 Sem 2 2010/2011 Industrial Management 1 cans is cooled. * EPF3403 holding for a short time, the After Sem 2 2010/2011 Heat Transfer

16. End product * The cooled and labeled cans containing tomato paste are now finished being processed.

17. Warehouse * The finish products of tomato are put in boxes and are now ready to be distributed to the customers

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* * * *

.:. THE Why sterilization? PROCESS .:. How sterilization is done?

Heat Transfer process Type of heat exchanger used?

EPF3403 Sem 2 2010/2011 Heat Transfer EMM3602 Sem 2 2010/2011 Industrial Management 1

Why sterilization?

Sterilization process is one type of heating process. Most suitable process for production of tomato puree

because the pH value of the tomato puree is naturally 4.4 (high pH products expose easily to pathogen need extreme sterilization temperature)

In pre-heating process, the microorganism is not yet

being killed. So, sterilization is very useful to reduce any pathogens and extend the shelf life of the products also making the distribution process easier.
EPF3403 Sem 2 2010/2011 Heat Transfer EMM3602 Sem 2 2010/2011 Industrial Management 1

*
1.

How sterilization entersdone?in the double pipe is into a tube The tomato puree prepared earlier
tubular heat exchanger. At the same time, hot water begins to flow in a different an external tube across the flow of the puree (counter flow = tomato puree and hot water flow in opposite direction.

2.

3.

The process of heat transfer occurs between the hot water and the puree. During the heat transfer process, the hazardous microbiology present in tomato puree is killed to prolong the self storage of the puree.

4.

5.

After completing the flow of cool water and the sterilized puree in the heat exchanger, they leave the exit stream at the opposite end.

6.

At the end of the process, the hot water becomes cold water as there is decrease in temperature, whereas the sterilized tomato puree has increased in temperature and the quality such as color is maintained. 4/25/12

EPF3403 Sem 2 2010/2011 Heat Transfer EMM3602 Sem 2 2010/2011 Industrial Management 1

Heat Transfer process

* Use indirect contact heat exchanger. * The heat energy is exchanged between hot
and cold fluids through a heat transfer surface such as a wall separate the fluids. * Cold and hot fluids flow simultaneously while transferring heat energy through a separating wall. * Both the fluids are not mixed. * Tubular heat exchanger is one of example of indirect contact heat exchanger.

EPF3403 Sem 2 2010/2011 Heat Transfer EMM3602 Sem 2 2010/2011 Industrial Management 1

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Double-pipe Heat Exchanger

*

Type of heat exchanger used?

larger diameter with appropriate fittings. *One fluid (tomato puree) flows through the inner pipes (tube side) and the other (hot water) flows through the annular space (annulus). *The major use of double-pipe heat exchanger is for sensible heating Click edit Master subtitle style or cooling of toprocess fluids where small heat transfer areas 0.3m2 are required. *This configuration is very suitable for one or both of the fluids at high pressure because of the smaller diameter of pipes. *Structure of this heat exchanger is simple and heat transmission is large. Easy to clean also convenient to disassemble and assemble. *The pipes are doubled back multiple times in order to make the overall unit more compact. 4/25/12

*We used DOUBLE-PIPE HEAT EXCHANGER *Consists of one pipe placed concentrically inside another pipe of a

EPF3403 Sem 2 2010/2011 Heat Transfer EMM3602 Sem 2 2010/2011 Industrial Management 1

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* Also called hairpin heat exchanger when one stream is

a viscous liquid as our product that need to be sterilized is tomato puree.

* Double pipe heat exchanger are based on modular

principles, individual hairpins sections arranged in proper series to achieve the required duty.

* Also, hairpin and double pipe heat exchangers can

handle high pressures and temperatures well.

* Double pipe heat exchanger have outer pipe inside

diameter of 50-400 mm at a nominal length of 1.5EPF3403 Sem 2 2010/2011 Heat Transfer EMM3602 Sem 2 2010/2011 Industrial Management 1

12.0 4/25/12m

per hairpin.

* Flow Pattern

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Use the counter flow pattern. Two fluids stream flow in opposite direction. This is an advantageous flow pattern as it is an efficient flow pattern. Gives the highest overall heat transfer coefficient. Can operate with temperature cross (cold side outlet temperature is higher 4/25/12 than Sem 2 2010/2011 Heat Transfer temperature). EPF3403 hot side outlet

The cold side outlet temperature, T1out, can approach the hot side entering temperature, T2in, which is higher than the hot side outlet temperature, T1out.

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For the parallel flow shown beside, T1out can only 4/25/12 approach T2out; it could not EPF3403 Sem 2 2010/2011 Heat Transfer

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.:. CONDITIONS .:.

* * *

Heat exchanger condition Tomato paste condition Steam condition

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Heat exchanger condition

Concentric (double-tube heat exchanger), counterflow, heating Di = 0.1 m Do = 0.3 m Dh = 0.3 m 0.1 m = 0.2 m Reference length, L = 1m Ao = DhL = (0.2 m)(1 m) = 0.626 m2 Stainless steel A304 tube

Ai = DiL = (0.1 m)(1 m) = 0.314 m2

EPF3403 Sem 2 2010/2011 Heat Transfer EMM3602 Sem 2 2010/2011 Industrial Management 1

Ksteel 4/25/12 = 16.6 W/m.K

Tomato paste condition

Tc,i = 65oC Tc,o = 95oC

Steam condition
Th,i vc = 157oC = 20 m/s

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.:. PROPERTIES .:.

* *

Properties of tomato paste Properties of steam

EPF3403 Sem 2 2010/2011 Heat Transfer EMM3602 Sem 2 2010/2011 Industrial Management 1

Properties of tomato paste

Cp,c = 3.98 x 103 J/kg.K c c kc = 10.144 kg/m3 = 0.3 N.s/m2 = 0.647 W/m.k

Properties of steam
**Taken at Tbar,h 430K Cp,h = 2.369 x 103 J/kg.K h h kh = 3.0211 kg/m3 = 14.14 x 10-6 N.s/m2 = 30.4 x 10-3 W/m.k Ph Pr,h = 5.699 x 105 N/m2 = 1.1

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.:. Assumptions needed for the .:. ASSUMPTIONS calculations.

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Assumptions needed for the calculations.

1. 2. 3. 4. 5. 6. 7.

Negligible heat loss to the surroundings Negligible kinetic and potential energy changes Constant properties Radiation is negligible Negligible tube wall thermal resistance and fouling factor Friction is negligible Negligible thickness of the tube

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* *

.:. Material balance calculations.:. CALCULATIONS Heat transfer calculations

EPF3403 Sem 2 2010/2011 Heat Transfer EMM3602 Sem 2 2010/2011 Industrial Management 1

Material balance calculations

FOR TOMATO PASTE, mc = 100 tonnes/day x 1day/86400s x 1000kg/1 tonne = 1.1574 kg/s Cross sectional area, Ac,i = /4D2 = /4(0.1 m)2 = 0.00785 m2 Velocity, vc = mc/cAc,I = 1.1574/(10.144 x 0.00785) = 14.5 m/s
4/25/12 Th,i Tc,o Th,o Water
Tomato paste Tc,i

EPF3403 Sem 2 2010/2011 Heat Transfer EMM3602 Sem 2 2010/2011 Industrial Management 1

Material balance calculations

FOR STEAM, Cross sectional area, Ah,o = /4D2 = /4(0.3 m)2 = 0.0707 m2 Know that Ac,i = 0.00785 m2,thus cross sectional area for steam Ac = Ah,o - Ac,I = 0.0707 0.00785 = 0.06285 m2 mh = hAh,ovh = 3.0211 kg/m3 x 0.06285 m2 x 20 m/s = 3.798 kg/s 4/25/12
Th,i Tc,o Th,o Water
Tomato paste Tc,i

EPF3403 Sem 2 2010/2011 Heat Transfer EMM3602 Sem 2 2010/2011 Industrial Management 1

Material balance calculations

Since we used double-tube heat exchanger, both fluids of steam and tomato paste are unmixed. Moreover, there are no changes in terms of phase and capacity of steam and tomato paste throughout the heat exchanger. In addition, there is no heat loss since the double-tube heat exchanger is insulated. Hence, mass in = mass out. For steam flow mh,i = mh,o= 3.798 kg/s mc,i = mc,o= 1.1574 kg/s For tomato paste flow

Th,i Tc,o

Th,o Water
Tomato paste Tc,i

EPF3403 Sem 2 2010/2011 Heat Transfer EMM3602 Sem 2 2010/2011 Industrial Management 1

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Heat transfer calculations

ANALYSIS: The required heat transfer rate may be obtained from the overall energy balance for the cold tomato paste, q = qc = mcCp,c(Tc,i - Tc,o) = 1.1574 x 3.98 x 103 x (95 - 65) = 138,194 W To get the steam outlet temperature, q = qc = qh = mhCp,h(Th,i - Th,o) 138,194 W = 3.798 x 2.369 x 103 x (157 - Th,o) Th,o = 142oC 4/25/12

EPF3403 Sem 2 2010/2011 Heat Transfer EMM3602 Sem 2 2010/2011 Industrial Management 1

Heat transfer calculations

Calculating Tbar,h from Th,o that we obtained equals to: Tbar,h = (157 + 142) / 2 = 149.5oC + 273 = 422.5 K 430 K The required heat exchanger length may now be obtained by using log-mean temperature differences (LMTD). From equation, q = UATlm Where Tlm = = (Th,i - Tc,o) - (Th,o - Tc,i) ln [(Th,i - Tc,o) / (Th,o - Tc,i)] (157 - 95) - (142 - 65) ln [(157 - 95) / (142 - 65) ]

EPF3403 Sem 2 2010/2011 Heat Transfer EMM3602 Sem 2 2010/2011 Industrial Management 1

4/25/12 = 69.23oC

Heat transfer calculations

Overall heat transfer coefficient is U= 1 (1/hi )+ (1/ho ) FOR STEAM FLOW THROUGH THE TUBE, ReD,h = hvhDh = 3.0211 kg/m3 x 20 m/s x 0.2 m 14.14 x 10-6 N.m/s = 854,625.2 turbulent flow From table 8.4, we used the correlation NuD,h = 0.0233 ReD,h4/5 Prn 4/25/12 = 0.0233 (854,625.2)4/5(1.1)0.4 EPF3403 Sem 2 2010/2011 Heat Transfer

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Heat transfer calculations

Note: (Page 493) Turbulent, fully developed, 0.6 Pr 160, ReD 1000, n = 0.4 for Ts > Tm Ts,i Tm ,I steam flow tomato paste flow

ho = NuD,h . k Dh = 1329.6 x 30.4 x 10-3 0.2 = 202.1 W/m2.K 4/25/12

EPF3403 Sem 2 2010/2011 Heat Transfer EMM3602 Sem 2 2010/2011 Industrial Management 1

Heat transfer calculations

FOR TOMATO PASTE FLOW THROUGH THE TUBE, ReD,c = 4mc Dc,i . c = 4 x1.1574 kg/s x 0.1 x 195 x10-3 = 75.57 laminar flow Assuming uniform temperature along the inner surface of the annulus and a perfectly insulated outer, the convection coefficient at the outer surface may be obtained from Table 8.2 Di = 0.1 Dh 0.2 = 0.5

Thus, from the table 8.2, interpolate to get Nui = 5.74. Hence, 4/25/12 EPF3403 Sem EMM3602= Nui.k 2 2010/2011 Heat Management 1 hi Sem 2 2010/2011 Industrial Transfer

Heat transfer calculations

hi = Nuik Di = 5.74 x 0.647 0.1 = 37.1378 Thus, U = 1 (1/hi) + (1/ho) = 1 (1/37.1378) + (1/202.1) = 31.37 W/m2.K LT = q UDiTlm

q = UATTlm AT = 138149 31.37 W/m2.K x (69.23 + 273) K = 12.87 m2

Each pipe per hairpin = 40.97m / (8x2) = 2.56m Stage for double pipe = 8 stages Since we used backflow at each

= 138194 W (31.37 W/m2.K)(0.1 m)(69.23 + 273)K 4/25/12 EPF3403 Sem 2 = 40.97 2010/2011 Industrial Transfer EMM3602 Sem 2 m 2010/2011 Heat Management 1

Cc = mcCp,c = (1.1574kg/s)(3.98 x 103J/kg.K) = 4606.452W/K Ch= mhCp,h = (3.798kg/s)(2.369 x 103J/kg.K) = 8997.462W/K qmax = Cmin (Th,i-Thc,i) = 4606.452(157-65) = 423793.584 W =q qmax 4/25/12 = 138194 W x Management 1 EMM3602 Sem 2 2010/2011 Industrial 100%

* Disscussion.
The overall efficiency of our heat exchanger is relatively low that is 33% can be increased by: 1. Firstly, qmax need to be increase by increasing the difference between the inlet temperature of steam and outlet temperature of tomato paste. 2. Next, increase the production rate (capacity) of tomato paste per day more 4/25/12 EPF3403 Sem 2 2010/2011 Heat Transfer days. than 100 tonne per

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1.

2. 3. 4.

Double heat exchanger is made up of stainless steel A304 tube because: Can withstand high temperature up to 380oCcan Can resist corrosion and oxidation. Low maintenance costs for cleanliness. Able to maintain the purity of food materials which come In contact with stainless.
4/25/12

EPF3403 Sem 2 2010/2011 Heat Transfer EMM3602 Sem 2 2010/2011 Industrial Management 1

Both the temperature for inlet and outlet of both steam and tomato paste product has been decided. The material balance value has been decided so that we can calculate for the required heat transfer rate for the cold tomato paste and outlet steam. Then, we use log-mean temperature differences (LMTD) to find for the total length and the total area our of double-pipe heat exchanger by using all the given conditions and properties. The length that we obtained which is 40.97m is suitable in our heat exchanger design because by using the backflow design we state that each pipe per hairpin is 2.56m as we design it in the arrangement of 8 stages. Each stage consist of double back multiple time 4/25/12 EPF3403 Semeach pipe per hairpin EMM3602and 2010/2011 Industrial Management 1 is around 16. Sem 2 2 2010/2011 Heat Transfer

* Conclusions :

EPF3403 Sem 2 2010/2011 Heat Transfer EMM3602 Sem 2 2010/2011 Industrial Management 1

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we choose the sterilization process in the production of tomato paste. We design the double-pipe heat exchanger as a machine to sterilize that food product because it has many advantages. The flow pattern occur during the process is counter-flow as it is an efficient flow pattern. We have succeed in designing the heat exchanger as we have found the total area and total length used for the creation of the double-pipe.

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