Baffles heat transfer

Stirrer design D/Dr (m/s) (Pas) Baffled Heat transfer Wall Coil Gas-liquid dispersion Liquid-solid dispersion... 

For simple jackets without baffles, heat transfer will be mainly by natural convection and the heat transfer coefficient will range from 200 to 400 Wm 2oC 1. 

Need for very tall vessel small scale CFB processes are therefore seldom viable Substantial backmixing of solid particles Internals (e.g., baffles, heat transfer surfaces) not viable because of wear/attrition Wall wastage sometimes a serious problem Suspension-to-surface heat transfer less favorable than for low-velocity fluidization Lateral gradients can be considerable Losses of particles due to entrainment. 

Most actual reactors deviate from these idealized systems primarily because of nonuniform velocity profiles, channeling and bypassing of fluids, and the presence of stagnant regions caused by reactor shape and internal components such as baffles, heat-transfer coils, and measurement probes. Disruptions to the flow path are common when dealing with heterogeneous systems, particularly when solids are present. To model these actual reactors, various regions are compartmentalized and... 

Another design, shown ia Figure 5, functions similarly but all components are iaside the furnace. An internal fan moves air (or a protective atmosphere) down past the heating elements located between the sidewalls and baffle, under the hearth, up past the work and back iato the fan suction. Depending on the specific application, the flow direction may be reversed if a propeUer-type fan is used. This design eliminates floorspace requirements and eliminates added heat losses of the external system but requires careful design to prevent radiant heat transfer to the work. 

From 760 to 960°C, circulating fans, normally without baffles, are used to improve temperature uniformity and overall heat transfer by adding some convection heat transfer. They create a directional movement of the air or atmosphere but not the positive flow past the heating elements to the work as in a convection furnace. Heating elements ate commonly chrome—nickel alloys in the forms described previously. Sheathed elements are limited to the very low end of the temperature range, whereas at the upper end silicon carbide resistors may be used. In this temperature range the selection of heating element materials, based on the combination of temperature and atmosphere, becomes critical (1). 

Fypass Flow Effects. There are several bypass flows, particularly on the sheUside of a heat exchanger, and these include a bypass flow between the tube bundle and the shell, bypass flow between the baffle plate and the shell, and bypass flow between the shell and the bundle outer shroud. Some high temperature nuclear heat exchangers have shrouds inside the shell to protect the shell from thermal transient effects. The effect of bypass flow is the degradation of the exchanger thermal performance. Therefore additional heat-transfer surface area must be provided to compensate for this performance degradation. 

This implies that the LMTD or M I D as computed in equations 20 through 26 may not be a representative temperature difference between the two heat-transferring fluids for aU tubes. The effective LMTD or M ID would be smaller than the value calculated, and consequentiy would require additional heat-transfer area. The tme value of the effective M I D may be determined by two- or three-dimensional thermal—hydrauUc analysis of the tube bundle. Baffle—Tube Support PlateXirea. The portion of a heat-transfer tube that passes through the flow baffle—tube support plates is usuaUy considered inactive from a heat-transfer standpoint. However, this inactive area must be included in the determination of the total length of the heat-transfer tube. 

The sheU-and-tube exchanger is the workhorse of power, chemical, refining, and other industries (Fig. 8). One fluid flows on the inside of the tubes whereas the other fluid is flowing through the sheU and over the outside of the tubes. Baffles are used to ensure that the sheUside fluid flows across the tubes, thus inducing high heat transfer. 

Commonly used heat-transfer surfaces are internal coils and external jackets. Coils are particularly suitable for low viscosity Hquids in combination with turbine impellers, but are unsuitable with process Hquids that foul. Jackets are more effective when using close-clearance impellers for high viscosity fluids. For jacketed vessels, wall baffles should be used with turbines if the fluid viscosity is less than 5 Pa-s (50 P). For vessels equipped with cods, wall baffles should be used if the clear space between turns is at least twice the outside diameter of the cod tubing and the fluid viscosity is less than 1 Pa-s (10... 

P). Otherwise the baffles should be located iaside the cod helix. A conventional jacket consists of a vessel outside the main vessel with a gap for the flow of heat-transfer fluid. Half-pipe jackets are usefld for high pressures up to 4 MPa (600 psi). They are better for Hquid than for vapor service fluids and can be easdy 2oned. Dimple jackets are suitable for larger vessels and process conditions up to 2 MPa (300 psi) and 370°C. Internal cods can be either hehcal or baffle cods (Fig. 34). 

Fig. 34. Internal cod configurations for heat-transfer surfaces (a) hehcal cod where = 0.02T, = 0.15T, and = 0.65Z (b) baffle cod...

Fig. 35. Correlations for calculating heat-transfer coefficients for (a) turbine external jackets, internal cods, and baffle cods, and (b) for close-clearance...

High Temperature. The low coefficient of thermal expansion and high thermal conductivity of sihcon carbide bestow it with excellent thermal shock resistance. Combined with its outstanding corrosion resistance, it is used in heat-transfer components such as recuperator tubes, and furnace components such as thermocouple protection tubes, cmcibles, and burner components. Sihcon carbide is being used for prototype automotive gas turbine engine components such as transition ducts, combustor baffles, and pilot combustor support (145). It is also being used in the fabrication of rotors, vanes, vortex, and combustor. 

It is assumed that process conditions and physical properties are known and the following are known or specified tube outside diameter D, tube geometrical arrangement (unit cell), shell inside diameter D shell outer tube limit baffle cut 4, baffle spacing and number of sealing strips N,. The effective tube length between tube sheets L may be either specified or calculated after the heat-transfer coefficient has been determined. If additional specific information (e.g., tube-baffle clearance) is available, the exact values (instead of estimates) of certain parameters may be used in the calculation with some improvement in accuracy. To complete the rating, it is necessary to know also the tube material and wall thickness or inside diameter. 

Spiral baffles, which are sometimes installed for hquid services to improve heat transfer and prevent channeling, can be designed to serve as reinforcements. A spiral-wound channel welded to the vessel wall is an alternative to the spiral baffle which is more predictable in performance, since cross-baffle leakage is eliminated, and is reportedly lower in cost [Feichtinger, Chem. Eng., 67, 197 (Sept. 5, I960)]. 

Baffles are provided for heat-transfer purposes. When shell-side baffles are not required for heat-transfer purposes, as may be the case in condensers or reboilers, tube supports are installed. 

Maximum shell-side heat-transfer rates in forced convection are apparently obtained by cross-flow of the flmd at right angles to the tubes. In order to maximize this type of flow some heat exchangers are built with segmental-cut baffles and with no tubes in the window (or the baffle cutout). Maximum baffle spacing may thus equal maximum unsupported-tube span, while conventional baffle spacing is hmited to one-h f of this span. 

One device uses four baffles in a baffle set. Only half of either the vertical or the horizontal tube lanes in a baffle have rods. The new design apparently provides a maximum shell-side heat-transfer coefficient for a given pressure drop. 

Circulation of air at velocities of I to 10 m/s is desirable to improve the surface heat-transfer coefficient and to eliminate stagnant air pockets. Proper air flow in tray dryers depends on sufficient fan capacity, on the design of ductwork to modify sudden changes in direction, and on properly placed baffles. Nonuniform airflow Is one of the most serious problems in the operation of tray di yers. 

The baffle plate operates with liquid dispersed and gas as the continuous phase and is used primarily in heat-transfer apphcations. 

The most comprehensive correlation for heat transfer to vertical baffle-type coils is for a disk flat-blade turbine over the Reynolds number range lO to (2)(10 ) ... 

A basic stirred tank design is shown in Fig. 23-30. Height to diameter ratio is H/D = 2 to 3. Heat transfer may be provided through a jacket or internal coils. Baffles prevent movement of the mass as a whole. A draft tube enhances vertical circulation. The vapor space is about 20 percent of the total volume. A hollow shaft and impeller increase gas circulation (as in Fig. 23-31). A splasher can be attached to the shaft at the hquid surface to improve entrainment of gas. A variety of impellers is in use. The pitched propeller moves the liquid axially, the flat blade moves it radially, and inclined blades move it both axially and radially. The anchor and some other designs are suited to viscous hquids. 

Activities associated with bioreactors include gas/hquid contacting, on-hne sensing of concentrations, mixing, heat transfer, foam control, and feed of nutrients or reagents such as those for pH control. The workhorse of the fermentation industry is the conventional batch fermenter shown in Fig. 24-3. Not shown are ladder rungs inside the vessel, antifoam probe, antifoam system, and sensors (pH, dissolved oxygen, temperature, and the like). Note that coils may lie between baffles and the tank wall or connect to the top to minimize openings... 

Figure 1.7 Simple detail of shell-and-tube heat exchanger. The water box may be designed for as many as eight passes, and a variety of configurations of shell-side baffles may be used to improve heat transfer, (a) Several water box arrangements for tube-side cooling, (b) Assembly of simple two-pass exchanger with U-tubes. [Fig. 38.2, The Nalco Water Handbook, 1st ed. (1979), reprinted with permission from McGraw-Hill, Inc.)...

Coolant flow is set by the designed temperature increase of the fluid and needed mass velocity or Reynolds number to maintain a high heat transfer coefficient on the shell side. Smaller flows combined with more baffles results in higher temperature increase on the shell side. Reacting fluid flows upwards in the tubes. This is usually the best plan to even out temperature bumps in the tube side and to minimize temperature feedback to avoid thermal runaway of exothermic reactions. 

There are many text books that describe the fundamental heat transfer relationships, but few discuss the complicated shell side characteristics. On the shell side of a shell and tube heat exchanger, the fluid flows across the outside of the tubes in complex patterns. Baffles are utilized to direct the fluid through the tube bundle and are designed and strategically placed to optimize heat transfer and minimize pressure drop. 

These high velocities occur at the bundle entrance and exit areas, in the baffle windows, through pass lanes and in the vicinity of tie rods, which secure the baffles in their proper position. In conjunction with this, the shell side fluid generally will take the path of least resistance and will travel at a greater velocity in the free areas or by-pass lanes, than it will through the bundle proper, where the tubes are on a closely spaced pitch. All factors considered, it appears a formidable task to accurately predict heat transfer characteristics of a shell and tube exchanger. 

The dummy tubes do not pass through the tubesheets, and can be located close to the inside of the shell. The seating strips extend from baffle to baffle in a longitudinal direction and effectively channel the fluid across the tubes to minimize turbulence and heat transfer. On some fixed tubesheet designs, the outer tubes are in close proximity to the inside of the shell so that by-pass is minimal and no by-pass elimination is necessary. There are a number of... 

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