Introduction to API Process Simulation, Example 1
Heat Transfer Through Jacket
Objective
The objective of this example is to analyze heat transfer in a pilot plant using
simulation models. The first step is to use pilot plant data to calculate heat transfer
parameters. The second part involves using simulation models to examine the trade-off
between jacket parameters and heating times.
bulk
jacket
Process Description
Assumptions: The stirred tank is assumed to be perfectly mixed. The contributions of
agitator work, heat loss to environment, and evaporation to the energy and mass
balances are assumed to be negligible.
Variables and Parameters: M bulk , Mass of bulk liquid; c p ,bulk , heat capacity; Tbulk ,
Temperature of bulk liquid; F jacket , flow rate of heat transfer fluid in jacket; c p , jacket ,
heat capacity of heat transfer fluid in jacket; T jacket ,in , jacket inlet temperature; T jacket,out ,
jacket outlet temperature, UA , overall heat transfer coefficient times area.
Balance Equations:
F jacket c p , jacket T jacket ,out  T jacket ,in   (UA)Tlm  q
where, Tlm  T jacket ,out  T jacket ,in  ln Tbulk  T jacket ,in  Tbulk  T jacket ,out 
M bulk c p ,bulk
d
Tbulk   q
dt
Pilot Plant Data: The following data relating bulk liquid temperatures to the jacket
temperature is available from pilot plant tests.
Introduction to API Process Simulation, Example 1
Jacket and Bulk temperature profiles
120
see legend
100
80
Jacket
Temperature C
60
Bulk liquid
Temperature C
40
20
0
12/8/06 6:57 AM
12/8/06 7:04 AM
12/8/06 7:12 AM
12/8/06 7:19 AM
12/8/06 7:26 AM
12/8/06 7:33 AM
Time, min
We want to use this information to determine the UA values for the stirred tank and to
study the impact of jacket parameters on heating times.
Process Parameters
The process parameters and initial conditions for Example 1 are given in the table
below.
Tbulk (initial bulk liquid temperature)
27.2
C
c p ,bulk (heat capacity)
2.516
kJ/kg K
M bulk (mass of bulk liquid in vessel)
329
kg
c p , jacket (heat capacity)
1.65
kJ/kg K
F jacket Jacket flow rate
257
5
W/K
kg/s
UA (initial guess)
Model Summary
DynoChem provides several utilities for characterizing vessels. These include a
template for fitting heat transfer coefficients to test data. A customized template for this
example is provided in the file TemplateFitUA.xls. The following information is
entered under the Components tab, Process tab and Scenarios tab.
Components. Two components are defined for this example, the solvent in the vessel
and the heat transfer fluid in the jacket.
Process Definition (Statements). The process statements define the bulk liquid phase
and heat transfer with a jacket.
Scenarios (Initial Values and Parameters). The values from the table above are entered
under the scenarios tab for the model. The pilot plant data is specified on the data sheet.
Introduction to API Process Simulation, Example 1
Fitting the UA Value to the Plant Data
The simulation runs below show the calculated temperature profile of the bulk liquid
using various guessed values for the UA parameter. These trial runs show a mismatch
with the experimental data.
120
Jacket Temperature (Imp)
100
80
Bulk liquid Temperature (Exp)
60
40
Bulk liquid Temperature
(UA=400)
20
Bulk liquid Temperature
(UA=100)
0
0
5
10
15
20
25
30
35
DynoChem provides a fitting tool which uses least squares regression to fit simulation
parameters to experimental data. The output from the fitting exercise is shown below.
The UA value from the fitting tool can then be incorporated into the simulation tool and
used for design exercises.
Introduction to API Process Simulation, Example 1
Scenarios
Once the heat transfer parameters have been determined the simulation model can be
used to estimate the heating times for different values of the jacket temperature as
shown by the plots below. Variations in other parameters such as the jacket flow rate
can be studied in a similar manner.
Heating time
Temperature (C)
70
60
Jacket Temperature=104
50
Jacket Temperature=120
40
Jacket Temperature=88
30
20
0
10
20
30
Time (minutes)
40
50
60