Heat Transfer to a Fluid in a Stirred Tank University of Illinois Heat Transfer to a Fluid in a Stirred Tank The heat transfer coefficient of the wall of a tank of water and a jacket of steam is found in this laboratory. Heat Transfer is measured in two sections. The first section is at steady state, when the temperature inside is time independent. The second section is at unsteady state and the temperature is increasing. 1 Unit Operations ChE 382 Group 5 Damo, Duffy, Guerrero, Hsu, Kosak, Qamar, Tyska Spring 2011 3/1/2011 Heat Transfer to a Fluid in a Stirred Tank University of Illinois Lab Prep Report Unit Operations II Lab 2 March 1, 2011 Group 5 Andrew Duffy Daniyal Qamar Jeff Tyska Bernard Hsu Ryan Kosak Tomi Damo Alex Guerrero 2 Unit Operations ChE 382 Group 5 Damo, Duffy, Guerrero, Hsu, Kosak, Qamar, Tyska Spring 2011 3/1/2011 Heat Transfer to a Fluid in a Stirred Tank University of Illinois Contents 1. Introduction .......................................................................................................................................... 4 2. Literature Review/Theory ..................................................................................................................... 5 3. Experimental ....................................................................................................................................... 13 3.1. Apparatus .................................................................................................................................... 13 3.2. Materials and Supplies ................................................................................................................ 18 3.3. Experimental Procedure ............................................................................................................. 19 4. Anticipated Results ............................................................................................................................. 20 5. References .......................................................................................................................................... 21 6. Appendix I: Job Safety Analysis ........................................................................................................... 22 3 Unit Operations ChE 382 Group 5 Damo, Duffy, Guerrero, Hsu, Kosak, Qamar, Tyska Spring 2011 3/1/2011 Heat Transfer to a Fluid in a Stirred Tank University of Illinois 1. Introduction Stirred tanks are probably one of the most used pieces of chemical engineering equipment that come is a wide variety for chemical processing applications. No two tanks are alike and have to be designed specifically for the proper application. This involves looking into the materials and operating parameters to ensure that the desired results occur in the safest and most efficient way possible. The most common uses are for chemical reactions, leaching, blending, and dispersing. Typically when looking into the system from a theoretical point of view the tank is assumed to have perfect mixing or constant bulk properties. This is done to make the calculations around the tank more manageable. The main purpose of this lab is to determine the effects of heating and cooling on a continuously stirred tank with multiple processes. Heating is performed by a steam jacket which allows heat to be transferred to the internal liquid and as for the case of cooling the tank there is an internal cooling coil system which uses cold water to remove the heat. There is also a secondary system to cool the tank which directly pumps the liquid out of the bottom through a heat exchanger that is also fed with cold water and then sends the cooled liquid back to the top of the tank. Another aspect to this experiment is the use of baffles on the effect of mixing which are implemented to enhance it. The heat transfer coefficient between the fluid and the walls of the vessel will be the main focus for calculations in this experiment based on its dependence of the impeller speed, fluid properties, and the baffles. Heat transfer coefficient values are functions of the fluid flow field and molecular transport properties of the fluid. Since a mixing tank has a very intricate flow pattern the heat transfer coefficient would be too complex to determine. Therefore the coefficient 4 Unit Operations ChE 382 Group 5 Damo, Duffy, Guerrero, Hsu, Kosak, Qamar, Tyska Spring 2011 3/1/2011 Heat Transfer to a Fluid in a Stirred Tank University of Illinois must be determined experimentally by correlating it with dimensionless groups. In convective flow the Reyonlds number (Re), Prandtl number (Pr), and geometric factors are needed to do so. Four cases will be studied in this experiment. The first is a steady state case and the second is also at steady state with the baffles placed in the tank. The third and fourth cases are both unsteady state cases with increasing temperature where one is with the baffles. 2. Literature Review/Theory Constant stirred tank reactors (CSTR) are widely used reactors in the industry. They are used to carry out reactions that require intense agitation, such as the addition of gaseous reactants in a liquid, a solid reactant in a liquid, or polymerization reactions. (Rawlings 5) Heat exchange in CSTR reactors is a very important and well-studied division. A highly exothermic reaction or a highly endothermic reaction both require that heat be taken out or put into the reactor respectively. Heat is the transfer of energy from one substance to another. There are three types of heat transfers; conduction, convection, and radiation. Heat conduction is the energy transfer at the molecular level. As molecules collide and bounce off of each other they exchange energy, the high energy particles loose energy to the low energy ones. Heat convection is the energy transfer as the bulk fluid moves and radiation is the transfer of energy without a medium, it does not required molecules or a bulk fluid to be transferred. In this lab we will be mainly studying conduction and convection. (Bird 266) 5 Unit Operations ChE 382 Group 5 Damo, Duffy, Guerrero, Hsu, Kosak, Qamar, Tyska Spring 2011 3/1/2011 Heat Transfer to a Fluid in a Stirred Tank University of Illinois The rate of heat conducted depends on the thermal conductivity (k) of a substance. This constant is a measure of a substance’s resistance to heat conduction. The higher the k value the easier it is to transfer heat through this substance. Temperature is the measure of energy a substance holds and heat always transfers from a high temperature region to a low temperature region. Heat is transferred according to the following law, known as Fourier’s Law (Bird 266332). ππ π/π΄ = π ππ₯ (1) Q is the Heat transferred A is the area this heat transfers through K is the thermal conductivity T is temperature x is the distance this heat is transferred through This law states that the heat flow per unit area is proportional to the temperature decrease dT over a distance dx. The heat transfer, at a boundary, that takes place between a fluid and a solid goes through a thin film. This heat transfer is not defined directly by the Fouriers law but is defined by the Newton’s Law of cooling which is defined as follows: (Bird 266-332) 6 Unit Operations ChE 382 Group 5 Damo, Duffy, Guerrero, Hsu, Kosak, Qamar, Tyska Spring 2011 3/1/2011 Heat Transfer to a Fluid in a Stirred Tank University of Illinois π13 = βπ΄(π0 − ππ )π΄ (1a) Q13 is the heat transferred h is the heat transfer coefficient T0 is the temperature of the surface Tb is the temperature of the bulk fluid A is the area of heat transfer In this lab we will be studying the heat transfer through three different regions. 1) Heat transfer across the internal fluid to the wall of the stirred tank 2) Heat transfer across the tank wall 3) Heat transfer from the condensing steam to the tank wall Since these three regions include the heat transfer through several different mediums a collective heat transfer coefficients (U) can be derived. U is defined as the following for this lab: π= 1 (2) 1 1 + βπ βπ βπ is the heat transfers coefficient from the fluid in the CSTR to the tank wall. (W/π2 − πΎ) βπ is the heat transfer coefficient from the tank wall to the surrounding steam. (W/π2 − πΎ) With the overall heat transfer coefficient, Newton’s law of cooling becomes: π13 = π(π1 − π3 )π΄ (1b) 7 Unit Operations ChE 382 Group 5 Damo, Duffy, Guerrero, Hsu, Kosak, Qamar, Tyska Spring 2011 3/1/2011 Heat Transfer to a Fluid in a Stirred Tank University of Illinois U is the overall heat transfer coefficient (accounting for heat resistance of all three boundaries listed above and described by equation 2) (W/π2 − πΎ) π1 is the temperature of the steam surrounding the CSTR (K) π3 is the temperature of the fluid in the CSTR (K) A is the heat transfer area (π2 ) Some assumptions that are needed to simplify the heat transfer are that the wall thickness is thin compared to the tank so area is same for both values and that the tank wall has a very high k value so it has no resistance to heat transfer. The following picture can help to understand the derivation of the overall heat transfer coefficient: Q Figure 1: Temperature profile As the heat transfer from the right to the left it first goes through a thin film with heat transfer coefficient h0 then it flows through the solid with heat transfer coefficients kscale and kwall finally 8 Unit Operations ChE 382 Group 5 Damo, Duffy, Guerrero, Hsu, Kosak, Qamar, Tyska Spring 2011 3/1/2011 Heat Transfer to a Fluid in a Stirred Tank University of Illinois comes out on the left side where the heat transfer coefficient is hi. The heat transfer through in the solid-fluid interface is described the equations: Q = hiAi(t4 – t5) = h0A0(t1 – t2) (3) h0 is the heat transfer coefficient across the solid-fluid boundary where temperature difference is t1 – t2 hi is the heat transfer coefficient across the solid-fluid boundary where temperature difference is t4 – t5 The heat transfer across the solids follows the Fourier law and is defined as follows: Q = Ascalekscale(t2-t3)/xscale = Ascalekscale(t3-t4)/xwall (4) Since the heat transfer is the same across all the walls at steady state, the x, h, and A values can be combined to give an overall heat transfer coefficient: 1 ππ 1 π₯π ππππ π ππ ππππ =β + βπ΄ π΄π π ππππ π₯ + ππ€πππ β π΄ π€πππ π΄π π€πππ + 1 π΄π βπ π΄0 (5) The amount of heat lost or gained by a substance depends on its heat capacity C. Q=mC(T-T0) (6) This equation determines how much heat is gained or lost by a substance as the temperature drops or is raised (Packet). 9 Unit Operations ChE 382 Group 5 Damo, Duffy, Guerrero, Hsu, Kosak, Qamar, Tyska Spring 2011 3/1/2011 Heat Transfer to a Fluid in a Stirred Tank University of Illinois Heat transfer coefficients can be theoretically estimated using the following correlations: Outer Wall Heat Transfer Coefficient Estimation This estimates the h value on the outside of the vessel wall where steam condensation takes place. βπ πΏπ π πΏ3 π2 π = 0.925 ( ππ 1/3 ) (6) Where: βπ is the heat transfer coefficient through film of condensing steam. (W/π2 − πΎ) πΏπ is the vertical length of the tank. (m) k is the thermal conductivity of the fluid. (W/K-m) ρ is the density of the fluid. (kg/π3 ) g is the gravitational constant. (m/π 2 ) μ is the viscosity of the fluid. (kg/s-m) M is the mass rate of steam condensed per wetted perimeter described by: π π = ππ·π π‘ (6a) ππ ππ π‘ is the mass rate of steam condensation. (kg/s) 10 Unit Operations ChE 382 Group 5 Damo, Duffy, Guerrero, Hsu, Kosak, Qamar, Tyska Spring 2011 3/1/2011 Heat Transfer to a Fluid in a Stirred Tank University of Illinois Saturated Steam Heat Transfer Coefficient βπ = 2960(π·ππ /ππ π‘ )1/3 (7) Estimation Inner Wall Heat Transfer Coefficient Estimation This system falls into the category of an unbaffled CSTR with Newtonian fluid. The heat transfer correlation can be estimated using the following correlations. βπ π·π π 2/3 πΆπ µ 1/3 π·π2 ππ = 0.36 ( βπ π·π π πΆπ µ 1/3 π 0.14 ( ) ( ) π ππ€ π ) ( µ ) π·π2 ππ = 0.36 ( µ (3) 2/3 ) (9) Where: βπ is the heat transfer coefficient of the inner CSTR tank wall. (W/π2 − πΎ) π·π is the diameter of the tank (m) μ is the viscosity of the fluid. (kg/s-m) πΆπ is the specific heat of the reactor fluid (J/kg-K) k is the thermal conductivity of the fluid. (W/K-m) ρ is the density of the reactor fluid. (kg/π3 ) π·π is the diameter of the impeller. (m) n is the rate of revolution of the impeller. (RMP) 11 Unit Operations ChE 382 Group 5 Damo, Duffy, Guerrero, Hsu, Kosak, Qamar, Tyska Spring 2011 3/1/2011 Heat Transfer to a Fluid in a Stirred Tank University of Illinois Correlation (3) can also be expressed in terms of dimensionless numbers: ππ’π‘ = 0.36(π ππππ ) 2/3 (ππ)1/3 (4) Where: ππ’π‘ is the tank Nusselt number described by: ππ’π‘ = βπ·π (4a) π π ππππ is the impeller Reynolds number described by: π ππππ = π·πΌ2 ππ (4b) π ππ is the fluid Prandtl number described by: ππ = πΆπ µ (4c) π In this lab the convective heat transfer coefficient at the inner surface of the tank will be experimentally determined. This value will then be compared with theoretically calculated values using the equations listed above. 12 Unit Operations ChE 382 Group 5 Damo, Duffy, Guerrero, Hsu, Kosak, Qamar, Tyska Spring 2011 3/1/2011 Heat Transfer to a Fluid in a Stirred Tank University of Illinois 3. Experimental 3.1.Apparatus 1 3 2 17 6 8 4 9 7 5 Figure 2: Top Half of CSTR Apparatus 13 Unit Operations ChE 382 Group 5 Damo, Duffy, Guerrero, Hsu, Kosak, Qamar, Tyska Spring 2011 3/1/2011 Heat Transfer to a Fluid in a Stirred Tank University of Illinois 10 16 15 12 13 11 14 Figure 3: Bottom Half of CSTR Apparatus The figures above depict the “Heat Transfer in a Stirred Tank” lab apparatus. It consists of a constantly stirred tank that is equipped with a cooling coil and lined with a steam jacket. After filling the tank with water, the pump located underneath continuously pumps water out of the tank and into the shell side of a heat exchanger where cooling water removes heat. The cooled tank water flows through the flowrator to display its flow rate and then re-enters 14 Unit Operations ChE 382 Group 5 Damo, Duffy, Guerrero, Hsu, Kosak, Qamar, Tyska Spring 2011 3/1/2011 Heat Transfer to a Fluid in a Stirred Tank University of Illinois the tank. Dial thermometers are located at the inlet and outlet of the heat exchanger. The cooling coils within the tank are fed with incoming cooling water. The flow rate of the cooling water can be set and adjusted using a flowrator. The temperature of the cooling water is displayed on dial thermometers located near the inlet and outlet of the cooling coils. Steam is fed into the steam jacket of the tank to allow heat transfer into the system. Steam condensate exits the steam jacket and enters a condenser, where cooling water flows through it. The impeller, which stirs the water in the tank, is controlled using a variable power supply. A strobotac is used to measure and display the speed of the impeller. The impeller speed and the flowrate of water through the external heat exchanger will be studied in three different experiments: 1) unbaffled stirred tank, 2) baffled stirred tank, and 3) unsteady-state heat transfer in an unbaffled tank. # 1 Equipment Strobotac Description Manufacturer Operating Range Displays rotational speed (RPM) of motor which powers N/A N/A the impeller. 2 Electric Motor Powers the impeller. 3 Variable Transformer Controls the speed of the electric motor. 4 Cooling Coil Inlet Displays the flow Flowrator Tube rate of the cooling Eastern Industries Powerstat F & P CO. 1/4 HP 0-140 V 0-100% Max of 0.810 GPM coil water. 15 Unit Operations ChE 382 Group 5 Damo, Duffy, Guerrero, Hsu, Kosak, Qamar, Tyska Spring 2011 3/1/2011 Heat Transfer to a Fluid in a Stirred Tank 5 University of Illinois Cooling Water Inlet Controls the flow rate Valve of the cooling coil N/A Crane CO. water. 6 Recycle Water Displays the flow Flowrator rate of the recycle 0-100% Max of F & P CO. 0.810 GPM MFG CO. 15-105 oC water. 7 Recycle Water Displays the Thermometer temperature of the recycle water. 8 Cooling Water Inlet Displays the Thermometer temperature of the cooling coil water at Moeller Instrument CO. 0-250 oF the inlet. 9 Tank Thermometer Displays the temperature of the Trend Instruments INC. 50-300 oF fluid in the tank. 10 Tank Contains the fluid, as well as the impeller N/A N/A and steam jacket. 11 Tank Outlet Displays the Thermometer temperature of the Trend Instruments INC. condensate exiting 16 Unit Operations ChE 382 Group 5 Damo, Duffy, Guerrero, Hsu, Kosak, Qamar, Tyska Spring 2011 3/1/2011 Heat Transfer to a Fluid in a Stirred Tank University of Illinois 0-200 oF the steam jacket before it enters the condenser. 12 Condenser Cools the steam N/A condensate. 13 Pump Continually reDayton Electric MFG circulates water 1/3 Hp CO. through the tank. 14 N/A Condenser Displays the Thermometer temperature of the cooling water Trend Instruments INC. 0-200 oF entering the condenser 15 Recycle thermometer Displays the temperature of the water that exits the MFG CO. 15-105 oF tank before it enters the heat exchanger. 16 Heat Exchanger Cools the recycled water before it re- N/A N/A enters the tank. 17 Unit Operations ChE 382 Group 5 Damo, Duffy, Guerrero, Hsu, Kosak, Qamar, Tyska Spring 2011 3/1/2011 Heat Transfer to a Fluid in a Stirred Tank 17 Pump Power Switch University of Illinois Appleton Electric Turns on the pump. Products N/A 3.2.Materials and Supplies Material/Supply Water Description Used throughout the system where measurements will be taken from. Graduated Cylinder Used to measure amount of water collected from the condenser. Baffles Directs the flow of fluids for maximum efficiency in stir tank. Mop Used to clean up any liquid spills. Stop Watch Time the amount of fluid exiting the condenser. 18 Unit Operations ChE 382 Group 5 Damo, Duffy, Guerrero, Hsu, Kosak, Qamar, Tyska Spring 2011 3/1/2011 Heat Transfer to a Fluid in a Stirred Tank University of Illinois 3.3.Experimental Procedure Begin the steady state experiment 1. Open the main water valve 2. Open the valve to the tank, and fill it up to around 2 inches from the top of the tank. 3. Measure the height of the water in the tank. 4. Turn on the impellor, and try to adjust it’s speed to 100 rpm, +- 50 rpm 5. Turn on the cooling water to the heat exchanger and the cooling coils inside the tank. Note the flowrate of cooling water. 6. Make sure the pump bypass valve and pump suction valve is on, and turn on the pump. 7. Open the valve so that the cooling water goes to the steam condenser. 8. Open the steam inlet valve, and wait for the process to reach steady state. 9. Measure the temperatures, flow rates, and impellor speed. 10. Increase the impellor speed to a different rpm 11. Measure the same variables as in part 9 12. Increase the temperature inside the tank 13. Measure the same variables as in part 9 14. Turn off the impellor, and put baffles inside the tank, being careful not to get burnt. 15. Repeat steps 9 through 13. 16. Turn off the cooling water and steam 17. Drain the tank Note – This ends the steady state portion of the experiment, the unsteady state procedure is now started. 19 Unit Operations ChE 382 Group 5 Damo, Duffy, Guerrero, Hsu, Kosak, Qamar, Tyska Spring 2011 3/1/2011 Heat Transfer to a Fluid in a Stirred Tank University of Illinois 18. Add fresh water, whose temperature should be less than 40 degrees C. 19. Run cooling water through the steam condenser. 20. Open the condenser water valve 21. Partially open the steam valve. 22. Turn the impellor on, and adjust it’s speed to 100 rpm. 23. Open the steam valve completely 24. Measure the temperature around every 20 seconds (time intervals must be constant, but intervals need not be 20 seconds) 25. Record this data until the water reaches 85 degrees Celsius 26. Turn off the steam, and record the temperature of the water as it cools down with the same time intervals. 27. Repeat steps 22-26 with different impellor speeds (same ones as used in step 10). 4. Anticipated Results The objective of this lab is to measure the heat transfer coefficient of the wall of a tank of water and a jacket of steam. The heat transfers will be measured in two sections: first as steady state, when the temperature inside has leveled off, and second during unsteady state, when the temperature is still increasing. The first section will measure the heat transfer coefficient with baffles and without baffles. These baffles are anticipated to increase the transfer of heat between the walls because the area of tank water exposed to the hot steam is increase therefore more of the water will pick 20 Unit Operations ChE 382 Group 5 Damo, Duffy, Guerrero, Hsu, Kosak, Qamar, Tyska Spring 2011 3/1/2011 Heat Transfer to a Fluid in a Stirred Tank University of Illinois up the heat as it is exposed to the heat. The baffles do this by increasing the agitation in the tank without the need for increasing the impeller speed. It is anticipated that the heat transfer coefficient for the baffle runs will be larger than the one without. All the temperatures and flow rates will be collected in order to do an energy balance and use equation 8 and 1a to figure out the overall heat transfer coefficient. As high as possible transfer coefficient is desired in order to transfer heat more rapidly but one thing that will slow this down is fouling. The wall inside the tank is lined will water build up than will inhibit heat transfer this will lower the transfer coefficient and make the tank take longer to heat. During the unsteady state the tanks temperatures are measure when the heating begins not when it has reached the desired value. In this section the goal is to determine the relationship between temperature and the heat transfer coefficient. It is anticipated that initially this will be high due to the larger temperature gradient (sink) between the two streams. 5. References Bird, R. B., Warren E. Stewart, and Edwin N. Lightfoot. Transport Phenomena. 2nd ed. New York, NY: Jonh Wiley & Sons, Inc., 2002 Packet, Heat transfer to a Fluid in a Stirred Tank 21 Unit Operations ChE 382 Group 5 Damo, Duffy, Guerrero, Hsu, Kosak, Qamar, Tyska Spring 2011 3/1/2011 Heat Transfer to a Fluid in a Stirred Tank University of Illinois 6. Appendix I: Job Safety Analysis What is the purpose of this experiment? The purpose of this experiment is to determine the effects of mixing with and without baffles on a stirred tank system. Four cases will be studied: steady state without baffles, steady state with baffles, unsteady state without baffles, and unsteady state with baffles. What are the hazards associated with the experiment? Since high temperature steam is used to heat the tank it is necessary to be aware of which pieces of the equipment will be at high temperatures. Another hazard is the impeller which should be avoided when in use. Water is continuously passed through the system therefore there is a spilling and slipping hazard. How will the experiment be conducted in a safe manner? The experiment will be constantly monitored to ensure that everything is running properly and safety. When filling the tank it will be necessary to be sure that it doesn’t overflow and cause slipping hazard. It will also be necessary to ensure that all the cooling water is draining properly and not spilling on the floor. Since electricity is used around a system that uses a lot of water it will be necessary to be aware this to avoid any electric shocks. As always, close-toed shoes and safety goggles will be worn at all times in the experiment area to decrease the chance of potential hazards. 22 Unit Operations ChE 382 Group 5 Damo, Duffy, Guerrero, Hsu, Kosak, Qamar, Tyska Spring 2011 3/1/2011 Heat Transfer to a Fluid in a Stirred Tank University of Illinois What safety controls are in place? The stirred tank is warped with insulation to ensure no one gets burned by accidently touching the side when moving around the apparatus. There is a recycle system for the pump. Most importantly, the laboratory area around the experiment will be kept dry using paper towels and a mop to clean any spilled liquid promptly to avoid wet working conditions. The water levels will be monitored to ensure that the water does not overflow and cause a spill in the laboratory. Safety goggles will be worn at all times to ensure eye protection. Describe safe and unsafe ranges of operations. Since steam is used it would be unsafe to run the system at very high temperatures so the vessel should be kept below 85°C at all times. The impeller should not exceed 200 rpm during the duration of the experiment. Never run the pump dry. I have read relevant background material for the Unit Operations Laboratory entitled: “Heat Transfer to a Fluid in a Stirred Tank” and understand the hazards associated with conducting this experiment. I have planned out my experimental work in accordance to standards and acceptable safety practices and will conduct all of my experimental work in a careful and safe manner. I will also be aware of my surroundings, my group members, and other lab students, and will look out for their safety as well. 23 Unit Operations ChE 382 Group 5 Damo, Duffy, Guerrero, Hsu, Kosak, Qamar, Tyska Spring 2011 3/1/2011 Heat Transfer to a Fluid in a Stirred Tank University of Illinois Electronic Signatures: Bernard Hsu Daniyal Qamar Jeff Tyska Alex Guerrero Tomi Damo Ryan Kosak Andrew Duffy 24 Unit Operations ChE 382 Group 5 Damo, Duffy, Guerrero, Hsu, Kosak, Qamar, Tyska Spring 2011 3/1/2011