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SteamEngineeringTutorials>CondensateRemoval

Calculationsforheatexchangeapplicationsincludingthedesignloadsandthesteampressure/flowraterequirements.

TheHeatLoad,HeatExchangerandSteamLoadRelationship
Saturatedsteamisusedtoprovideprimaryheattoaprocessfluidinaheatexchanger.Thetermheatexchangerisusedtodescribealltypesofequipment
whereheattransferispromotedfromonefluidtoanother.Forconvenience,thisbroaddefinitionwillbeappliedtothetermheatexchanger.Whileshellandtube
heatexchangersandplateheatexchangerswillbeprincipallyreferredto,stallmayalsoberelevanttoapplicationsincludingairheaterbatteries,submerged
tankcoils,jacketedvesselsandstoragecalorifiers.

Temperaturecontrolledapplications
Inatemperaturecontrolapplication,theinlettemperatureofthesecondaryfluidtotheheatexchangermaychangewithtime.Thismeansthatinorderto
maintainaconsistentsecondaryfluidoutlettemperature,theheatsuppliedtotheheatexchangermustalsovary.Thiscanbeachievedbyusingacontrolvalve
ontheinlettotheprimarysideoftheheatexchanger,asshowninFigure13.2.1.

Acontrolvalveisusedtovarytheflowrateandpressureofthesteamsothattheheatinputtotheheatexchangercanbecontrolled.Modulatingthepositionof
thecontrolvalvethencontrolstheoutlettemperatureofthesecondaryfluid.Asensoronthesecondaryfluidoutletmonitorsitstemperature,andprovidesa
signalforthecontroller.Thecontrollercomparestheactualtemperaturewiththesettemperatureand,asaresult,signalstheactuatortoadjustthepositionof
thecontrolvalve.

Foraconstantheatingareaandheattransfercoefficient,therateatwhichheatistransferredfromthesteamtothesecondaryfluidforaparticularheat
exchangerisdeterminedbythemeantemperaturedifferencebetweenthetwofluids.Alargerdifferenceinmeantemperatureswillcreatealargeheattransfer
rateandviceversa.Onpartiallyclosingthecontrolvalve,thesteampressureandthetemperaturedifferencefall.Conversely,ifthecontrolvalveisopenedso
thatthesteammassflowandhencepressureintheheatexchangerrise,themeantemperaturedifferencebetweenthetwofluidsincreases.

Alteringthesteampressurewillalsoslightlyaffecttheamountofheatenergyavailableinthecondensingsteamastheenthalpyofevaporationactuallyfalls
withincreasingpressure.Thismeansthatthelatentheatavailableperkgofsteamreducesasthesteampressureincreases.Ifsteamflowaccuracyis
required,thismustbeaccountedfor.

Exam
ple13.2.1

Amanufactureristodesignaheatexchangerinwhichthespecificationcallsforsteamat4bargtoheatsecondarywaterfrom10Cto60C.Thewaterflowis
tobeconstantatallloadsat1.5L/s.Itisassumedthat1litreofwaterhasamassof1kg,sothemassflowrate=1.5L/sx1kg/L=1.5kg/s.
ThemanufacturerusesaheattransfercoefficientUfortheheatexchangerof2500W/mC.Takethespecificheatofwateras4.19kJ/kgC.
Det
ermine:

(A)Thedesignheatload.
(B)Thecorrespondingsteamflowrate.
(C)Theminimumheatingarearequired.
Also,ifthecustomersminimumheatloadoccurswhentheinletwatertemperaturerisesto30C,determine:
(D)Theminimumheatload.
(E)Thecorrespondingsteampressureintheheatexchanger.
(F)Thecorrespondingsteamflowrate.

Calculations:

(A)Findthedesignheatloadusingtheheattransferflowrateequation(Equation2.6.5):

Tocalculatethecorrespondingsteamflowrate,itisfirstnecessarytodeterminethesteamtemperatureattheminimumloadcondition.
Itispossibletousethe TLMdesignfigurestoaccuratelypredictthesteamtemperatureforanyloadcondition,butthisrequirestheuseoflogarithmic
calculations.However,oncetheexchanger
sizeisfixedandthedesigntemperaturesareknown,itismucheasiertopredictoperatingtemperaturesusingwhatcouldbetermedaheatexchanger
TemperatureDesignConstant(TDC).
TheTDCmethoddoesnotrequirelogarithmiccalculations.Pleasenote:TDCcannotbeusedonthoseapplicationswherethesecondaryflowratevariesor
wherecontrolisachievedbyvaryingthecondensatelevelinthesteamspace.
Note:Whensizingaheatexchangeritisnormalforheatexchangermanufacturerstousethe TLMmethod.Oncesized,byknowingtheheatingareaandthe
fullloadoperatingtemperatures,TDCcanbeusedtoaccuratelypredictalloperatingtemperaturesresultingfromchangesinload,ascanbeseeninthe
followingtext.
OperatingtemperaturescanalsobepredictedgraphicallybyusingwhatistermedaStallChart.ThismethodisdiscussedinModules13.5,13.6,and13.7.

TemperatureDesignConstant(TDC)
Foranytypeofsteamheatedexchangerwiththesecondaryliquidflowingataconstantrate,TDCcanbecalculatedfromthetestfiguresquotedbythe
manufacturerforfullload.Ifthesedatasetsarenotavailableandtheheatexchangerisalreadyinstalledinservice,TDCcanbecalculatedbyobservingthe
steampressure(andfindingthesteamtemperaturefromsteamtables)andthecorrespondingsecondaryinletandoutlettemperaturesatanyload.
TDCistheratioofthesteamtowatertemperaturesattheinletandoutletandisshowninEquation13.2.2.

TheTDCequationcanbetransposedtofindanyonevariableaslongastheotherthreevariablesareknown.ThefollowingequationsarederivedfromtheTDC
equation(Equation13.2.2).
TofindthesteamtemperatureatanyloaduseEquation13.2.3:

TofindthesecondaryfluidinlettemperatureatanyloaduseEquation13.2.4:

TofindthesecondaryfluidoutlettemperatureatanyloaduseEquation13.2.5:

Foranyheatexchangerwithaconstantsecondaryflowrate,theoperatingsteamtemperaturecanbecalculatedforanycombinationofinlettemperatureand
outlettemperature.
InExample13.2.1thesecondaryoutlettemperatureremainsat60C,andminimumloadoccurswhentheinlettemperatureis30C.Whatisthesteam
temperatureatminimumload?
Inlettemperature=30C
Outlettemperature=60C

(E)Findthecorrespondingheatexchangersteampressureandenthalpyatminimumload
Fromsteamtables:
Asteamtemperatureof115.2Ccorrespondswithasteampressureof0.7barg.
Thespecificenthalpyofevaporationat0.7barg(hfg)=2215kJ/kg

(F)Findthesteamflowrateatminimumload:
 From(D)theminimumheatloadis188.5kW.
From(E)thehfgis2215kJ/kg.
UsingEquation2.8.1:

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