Flow and pressure drop on the shellside of cylindrical heat exchangers

This work presents pressure distributions and fluid flow patterns on the shellside of a cylindrical shell-and-tube heat exchanger. The apparatus used was constructed from glass enabling direct observation of the flow using a dye release technique and had ten traversable pressure instrumented tubes permitting detailed pressure distributions to be obtained. The `exchanger' had a large tube bundle (278 tubes) and main flow areas typical of practical designs. Six geometries were studied: three baffle spacings both with and without baffle leakage. Results are also presented of three-dimensional modelling of shellside flows using the Harwell Laboratory's FLOW3D code. Flow visualisation provided flow patterns in the central plane of the bundle and adjacent to the shell wall. Comparison of these high-lighted significant radial flow variations. In particular, separated regions, originating from the baffle tips, were observed. The size of these regions was small in the bundle central plane but large adjacent to the shell wall and extended into the bypass lane. This appeared to reduce the bypass flow area and hence the bypass flow fraction. The three-dimensional flow modelling results were presented as velocity vector and isobar maps. The vector maps illustrated regions of high and low velocity which could be prone to tube vibration and fouling. Separated regions were also in evidence. A non-uniform crossflow was discovered with, in general, higher velocities in the central plane of the bundle than near the shell wall._The form of the isobar maps calculated by FLOW3D was in good agreement with experimental results. In particular, larger pressure drops occurred across the inlet than outlet of a crossflow region and were higher near the upstream than downstream baffle face. The effect of baffle spacing and baffle leakage on crossflow and window pressure drop measurements was identified. Agreement between the current measurements, previously obtained data and commonly used design correlations/models was, in general, poor. This was explained in terms of the increased understanding of shellside flow. The bulk of previous data, which dervies from small-scale rigs with few tubes, have been shown to be unrepresentative of typical commerical units. The Heat Transfer and Fluid Flow Service design program TASC provided the best predictions of the current pressure drop results. However, a number of simple one-dimensional models in TASC are, individually, questionable. Some revised models have been proposed.

Variations of local heat transfer coefficient in piped flow of viscous liquids

Measurements were carried out to determine local coefficients of heat transfer in short lengths of horizontal pipe, and in the region of an discontinuity in pipe diameter. Laminar, transitional and turbulent flow regimes were investigated, and mixtures of propylene glycol and water were used in the experiments to give a range of viscous fluids. Theoretical and empirical analyses were implemented to find how the fundamental mechanism of forced convection was modified by the secondary effects of free convection, temperature dependent viscosity, and viscous dissipation. From experiments with the short tube it was possible to determine simple empirical relationships describing the axial distribution of the local 1usselt number and its dependence on the Reynolds and Prandtl numbers. Small corrections were made to account for the secondary effects mentioned above. Two different entrance configurations were investigated to demonstrate how conditions upstream could influence the heat transfer coefficients measured downstream In experiments with a sudden contraction in pipe diameter the distribution of local 1u3se1t number depended on the Prandtl number of the fluid in a complicated way. Graphical data is presented describing this dependence for a range of fluids indicating how the local Nusselt number varied with the diameter-ratio. Ratios up to 3.34:1 were considered. With a sudden divergence in pipe diameter, it was possible to derive the axial distribution of the local Nusse1t number for a range of Reynolds and Prandtl numbers in a similar way to the convergence experiments. Difficulty was encountered in explaining some of the measurements obtained at low Reynolds numbers, and flow visualization techniques wore used to determine the complex flow patterns which could lead to the anomalous results mentioned. Tests were carried out with divergences up to 1:3.34 to find the way in which the local Nusselt number varied with the diameter ratio, and a few experiments were carried out with very large ratios up .to 14.4. A limited amount of theoretical analysis of the 'divergence' system was carried out to substantiate certain explanations of the heat transfer mechanisms postulated.

Computer simulation of liquid flow patterns on distillation trays

This thesis describes work carried out to improve the fundamental modelling of liquid flows on distillation trays. A mathematical model is presented based on the principles of computerised fluid dynamics. It models the liquid flow in the horizontal directions allowing for the effects of the vapour through the use of an increased liquid turbulence, modelled by an eddy viscosity, and a resistance to liquid flow caused by the vapour being accelerated horizontally by the liquid. The resultant equations are similar to the Navier-Stokes equations with the addition of a resistance term.A mass-transfer model is used to calculate liquid concentration profiles and tray efficiencies. A heat and mass transfer analogy is used to compare theoretical concentration profiles to experimental water-cooling data obtained from a 2.44 metre diameter air-water distillation simulation rig. The ratios of air to water flow rates are varied in order to simulate three pressures: vacuum, atmospheric pressure and moderate pressure.For simulated atmospheric and moderate pressure distillation, the fluid mechanical model constantly over-predicts tray efficiencies with an accuracy of between +1.7% and +11.3%. This compares to -1.8% to -10.9% for the stagnant regions model (Porter et al. 1972) and +12.8% to +34.7% for the plug flow plus back-mixing model (Gerster et al. 1958). The model fails to predict the flow patterns and tray efficiencies for vacuum simulation due to the change in the mechanism of liquid transport, from a liquid continuous layer to a spray as the liquid flow-rate is reduced. This spray is not taken into account in the development of the fluid mechanical model. A sensitivity analysis carried out has shown that the fluid mechanical model is relatively insensitive to the prediction of the average height of clear liquid, and a reduction in the resistance term results in a slight loss of tray efficiency. But these effects are not great. The model is quite sensitive to the prediction of the eddy viscosity term. Variations can produce up to a 15% decrease in tray efficiency. The fluid mechanical model has been incorporated into a column model so that statistical optimisation techniques can be employed to fit a theoretical column concentration profile to experimental data. Through the use of this work mass-transfer data can be obtained.

Clogging in horizontal subsurface flow constructed wetlands

Horizontal Subsurface Flow Treatment Wetlands (HSSF TWs) are used by Severn Trent Water as a low-cost tertiary wastewater treatment for rural locations. Experience has shown that clogging is a major operational problem that reduces HSSF TW lifetime. Clogging is caused by an accumulation of secondary wastewater solids from upstream processes and decomposing leaf litter. Clogging occurs as a sludge layer where wastewater is loaded on the surface of the bed at the inlet. Severn Trent systems receive relatively high hydraulic loading rates, which causes overland flow and reduces the ability to mineralise surface sludge accumulations. A novel apparatus and method, the Aston Permeameter, was created to measure hydraulic conductivity in situ. Accuracy is ±30 %, which was considered adequate given that conductivity in clogged systems varies by several orders of magnitude. The Aston Permeameter was used to perform 20 separate tests on 13 different HSSF TWs in the UK and the US. The minimum conductivity measured was 0.03 m/d at Fenny Compton (compared with 5,000 m/d clean conductivity), which was caused by an accumulation of construction fines in one part of the bed. Most systems displayed a 2 to 3 order of magnitude variation in conductivity in each dimension. Statistically significant transverse variations in conductivity were found in 70% of the systems. Clogging at the inlet and outlet was generally highest where flow enters the influent distribution and exits the effluent collection system, respectively. Surface conductivity was lower in systems with dense vegetation because plant canopies reduce surface evapotranspiration and decelerate sludge mineralisation. An equation was derived to describe how the water table profile is influenced by overland flow, spatial variations in conductivity and clogging. The equation is calibrated using a single parameter, the Clog Factor (CF), which represents the equivalent loss of porosity that would reproduce measured conductivity according to the Kozeny-Carman Equation. The CF varies from 0 for ideal conditions to 1 for completely clogged conditions. Minimum CF was 0.54 for a system that had recently been refurbished, which represents the deviation from ideal conditions due to characteristics of non-ideal media such as particle size distribution and morphology. Maximum CF was 0.90 for a 15 year old system that exhibited sludge accumulation and overland flow across the majority of the bed. A Finite Element Model of a 15 m long HSSF TW was used to indicate how hydraulics and hydrodynamics vary as CF increases. It was found that as CF increases from 0.55 to 0.65 the subsurface wetted area increases, which causes mean hydraulic residence time to increase from 0.16 days to 0.18 days. As CF increases from 0.65 to 0.90, the extent of overland flow increases from 1.8 m to 13.1 m, which reduces hydraulic efficiency from 37 % to 12 % and reduces mean residence time to 0.08 days.