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63 views113 pages

Mass and Heat Transfer Analysis of Mass Contactors and Heat Exchangers 1st Edition T. W. Fraser Russell PDF Version

Scholarly document: Mass and Heat Transfer Analysis of Mass Contactors and Heat Exchangers 1st Edition T. W. Fraser Russell Instant availability. Combines theoretical knowledge and applied understanding in a well-organized educational format.

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Mass and Heat Transfer Analysis of Mass Contactors

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CUFX282-pre CUFX282/Russell 978 0 521 88670 3 March 7, 2008 11:4

MASS AND HEAT TRANSFER

This book allows instructors to teach a course on heat and mass transfer that will equip
students with the pragmatic, applied skills required by the modern chemical industry. This
new approach is a combined presentation of heat and mass transfer, maintaining mathe-
matical rigor while keeping mathematical analysis to a minimum. This allows students to
develop a strong conceptual understanding and teaches them how to become proficient
in engineering analysis of mass contactors and heat exchangers and the transport theory
used as a basis for determining how the critical coefficients depend on physical properties
and fluid motions.
Students will first study the engineering analysis and design of equipment important
in experiments and for the processing of material at the commercial scale. The second
part of the book presents the fundamentals of transport phenomena relevant to these
applications. A complete teaching package includes a comprehensive instructor’s guide,
exercises, design case studies, and project assignments.

T. W. Fraser Russell is the Allan P. Colburn Professor of Chemical Engineering at the


University of Delaware. Professor Russell is a member of the National Academy of
Engineering and a Fellow of the American Institute of Chemical Engineering (AIChE).
He has been the recipient of several national honors, including the AIChE Chemical
Engineering Practice Award.

Anne Skaja Robinson is an Associate Professor of Chemical Engineering at the Uni-


versity of Delaware and Director of the National Science Foundation (NSF) Integra-
tive Graduate Education and Research Traineeship program in biotechnology. She has
received several national awards, including the NSF Presidential Early Career Award for
Scientists and Engineers (PECASE/Career).

Norman J. Wagner is the Alvin B. and Julia O. Stiles Professor and Chair of the Depart-
ment of Chemical Engineering at the University of Delaware. His international teaching
and research experience includes a Senior Fulbright Scholar Fellowship in Konstanz, Ger-
many, and a sabbatical as a Guest Professor at ETH, Zurich, as well as at “La Sapienza,”
Rome, Italy.

i
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ii
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CAMBRIDGE SERIES IN CHEMICAL ENGINEERING

Series Editor:
Arvind Varma, Purdue University

Editorial Board:
Alexis T. Bell, University of California, Berkeley
Edward Cussler, University of Minnesota
Mark E. Davis, California Institute of Technology
L. Gary Leal, University of California, Santa Barbara
Massimo Morbidelli, ETH, Zurich
Athanassios Z. Panagiotopoulos, Princeton University
Stanley I. Sandler, University of Delaware
Michael L. Schuler, Cornell University

Books in the Series:


E. L. Cussler, Diffusion: Mass Transfer in Fluid Systems, Second Edition
Liang-Shih Fan and Chao Zhu, Principles of Gas–Solid Flows
Hasan Orbey and Stanley I. Sandler, Modeling Vapor–Liquid Equilibria: Cubic
Equations of State and Their Mixing Rules
T. Michael Duncan and Jeffrey A. Reimer, Chemical Engineering Design and Anal-
ysis: An Introduction
John C. Slattery, Advanced Transport Phenomena
A. Varma, M. Morbidelli, and H. Wu, Parametric Sensitivity in Chemical Systems
M. Morbidelli, A. Gavriilidis, and A. Varma, Catalyst Design: Optimal
Distribution of Catalyst in Pellets, Reactors, and Membranes
E. L. Cussler and G. D. Moggridge, Chemical Product Design
Pao C. Chau, Process Control: A First Course with MATLAB®
Richard Noble and Patricia Terry, Principles of Chemical Separations with
Environmental Applications
F. B. Petlyuk, Distillation Theory and Its Application to Optimal Design of
Separation Units
L. Gary Leal, Advanced Transport Phenomena: Fluid Mechanics and
Convective Transport
T. W. Fraser Russell, Anne Skaja Robinson, and Norman J. Wagner, Mass and Heat
Transfer

iii
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Mass and Heat Transfer


ANALYSIS OF MASS CONTACTORS
AND HEAT EXCHANGERS

T. W. FRASER RUSSELL
University of Delaware

ANNE SKAJA ROBINSON


University of Delaware

NORMAN J. WAGNER
University of Delaware

v
CAMBRIDGE UNIVERSITY PRESS
Cambridge, New York, Melbourne, Madrid, Cape Town, Singapore, São Paulo

Cambridge University Press


The Edinburgh Building, Cambridge CB2 8RU, UK
Published in the United States of America by Cambridge University Press, New York
www.cambridge.org
Information on this title: www.cambridge.org/9780521886703

© T. W. Fraser Russell, Anne Skaja Robinson, and Norman J. Wagner 2008

This publication is in copyright. Subject to statutory exception and to the provision of


relevant collective licensing agreements, no reproduction of any part may take place
without the written permission of Cambridge University Press.
First published in print format 2008

ISBN-13 978-0-511-38683-1 eBook (EBL)

ISBN-13 978-0-521-88670-3 hardback

Cambridge University Press has no responsibility for the persistence or accuracy of urls
for external or third-party internet websites referred to in this publication, and does not
guarantee that any content on such websites is, or will remain, accurate or appropriate.
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This book is dedicated to our families:


Shirley, Bruce, Brian, Carey
Clifford, Katherine, Brenna
Sabine

vii
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Contents

Preface page xiii


To the Student xv
Acknowledgments xix
Instructors’ and Readers’ Guide xxi

PART I
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
References 19

2 Chemical Reactor Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20


2.1 The Batch Reactor 21
2.1.1 Chemical Equilibrium 25
2.2 Reaction Rate and Determination by Experiment 26
2.2.1 Rate Expression 26
2.2.2 Approach to Equilibrium 32
2.3 Tank-Type Reactors 33
2.3.1 Batch Reactors 34
2.3.2 Semibatch Reactors 34
2.3.3 Continuous Flow 37
2.4 Tubular Reactors 42
2.5 Reactor Energy Balance 47
References 51
Problems 51

3 Heat Exchanger Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55


3.1 Batch Heat Exchangers 56
3.1.1 Level I Analysis 57
3.1.2 Level II Thermal Equilibrium 58
3.2 Rate of Heat Transfer and Determination by Experiment 60
3.2.1 Rate Expression 61
3.2.2 Approach to Equilibrium 65

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3.3 Tank-Type Heat Exchangers 67


3.3.1 Batch Heat Exchanger 68
3.3.2 Semibatch Heat Exchanger 68
3.3.2.1 Mixed–Mixed Fluid Motions 69
3.3.2.2 Mixed–Plug Fluid Motions 72
3.3.3 Continuous-Flow Tank-Type Heat Exchangers 74
3.3.3.1 Mixed–Mixed Fluid Motions 74
3.3.3.2 Mixed–Plug Fluid Motions 78
3.4 Tubular Heat Exchangers 79
3.4.1 Cocurrent Flow 81
3.4.2 Countercurrent Flow—Double-Pipe Heat Exchanger 88
3.5 Technically Feasible Heat Exchanger Design 94
3.5.1 Design Procedure 96
References 102
Problems 103
Appendix. Energy Balance 109

4 Mass Contactor Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114


4.1 Batch Mass Contactors 118
4.1.1 Level I Analysis 119
4.1.2 Level II Analysis, Phase Equilibrium 120
4.2 Rate of Mass Transfer and Determination by Experiment 125
4.2.1 Rate Expression 127
4.2.2 Approach to Equilibrium 132
4.3 Tank-Type Two-Phase Mass Contactors 134
4.3.1 Batch Mass Contactors 135
4.3.2 Semibatch Mass Contactors 137
4.3.2.1 Mixed–Mixed Fluid Motions 138
4.3.2.2 Mixed–Plug Fluid Motions 139
4.3.3 Continuous-Flow Two-Phase Mass Contactors 143
4.3.3.1 Mixed–Mixed Fluid Motions 144
4.3.3.2 Design of a Continuous Mixed–Mixed Mass Contactor 146
4.3.3.3 Mixed–Plug Fluid Motions 153
4.4 Tubular Two-Phase Mass Contactors 156
4.4.1 Cocurrent Flow 158
4.4.2 Countercurrent Flow 159
4.4.3 Gas–Liquid Countercurrent Contactors 164
4.5 Continuous-Flow Mass Contactor Design Summary 168
References 175
Problems 175
Appendix A. “Log-Mean” Concentration Difference 178
Appendix B. Equivalence Between Heat and Mass Transfer
Model Equations 180

Nomenclature for Part I . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181


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Contents xi

PART II
5 Conduction and Diffusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
5.1 Rate of Thermal Conduction 187
5.1.1 Experimental Determination of Thermal Conductivity k and
Verification of Fourier’s Constitutive Equation 187
5.1.2 Definition of the Biot Number for Heat Transfer 195
5.1.3 Definition of the Nusselt Number 199
5.2 Rate of Molecular Diffusion 201
5.2.1 Experimental Determination of Binary Diffusivities DAB and
Verification of Fick’s Constitutive Equation 201
5.2.2 Definition of the Biot Number for Mass Transfer 206
5.2.3 Definition of the Sherwood Number 208
5.3 Geometric Effects on Steady Heat Conduction and Diffusion in
Solids and Quiescent Fluids 209
5.3.1 One-Dimensional Heat Conduction in Nonplanar Geometries 209
5.3.2 One-Dimensional Diffusion in a Conical Geometry 211
5.4 Conduction and Diffusion Through Composite Layered Materials
in Series 212
5.4.1 Overall Heat Transfer Coefficient for Composite Walls:
Resistance Formulation 212
5.4.2 Overall Heat Transfer Coefficient for a Tubular Exchanger 217
5.4.3 Overall Mass Transfer Coefficient for Diffusion Through a
Composite Wall 220
5.5 Molecular Conduction and Diffusion with Generation 222
5.5.1 Radial Heat Conduction with Generation 222
5.5.2 Diffusion with Chemical Reaction 224
5.6 Diffusion-Induced Convection: The Arnold Cell 225
5.7 Basics of Membrane Diffusion: The Sorption–Diffusion Model 230
5.8 Transient Conduction and Diffusion 231
5.8.1 Short-Time Penetration Solution 233
5.8.2 Small Biot Numbers—Lumped Analysis 235
Nomenclature 236
Important Dimensionless Groups 238
References 239
Problems 240

6 Convective Heat and Mass Transfer . . . . . . . . . . . . . . . . . . . . . . . . 246


6.1 The Differential Transport Equations for Fluids with Constant
Physical Properties in a Laminar Boundary Layer 247
6.1.1 Mass Conservation—Continuity Equation 248
6.1.2 Momentum Transport—Navier–Stokes Equation 249
6.1.3 Energy Conservation 250
6.1.4 Species Mass Conservation 252
6.2 Boundary-Layer Analysis and Transport Analogies 254
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xii Contents

6.2.1 Laminar Boundary Layer 254


6.2.2 Reynolds Transport Analogy 257
6.2.3 Effects of Material Properties: The Chilton–Colburn Analogy 260
6.2.4 Turbulent Boundary Layers 263
6.3 Transport Correlations for Specific Geometries 264
6.4 Models for Estimating Transport Coefficients in Fluid–Fluid Systems 273
6.4.1 Film Theory 273
6.4.2 Penetration Theory 273
6.4.3 Surface Renewal Theory 278
6.4.4 Interphase Mass Transfer 279
6.5 Summary of Convective Transport Coefficient Estimations 281
6.5.1 Heat Exchangers 281
6.5.2 Mass Contactors 284
Nomenclature 286
References 287
Problems 287
Appendix A. Derivation of the Transport Equations 293
Appendix B. Vector Notation 299

7 Estimation of the Mass Transfer Coefficient and Interfacial


Area in Fluid–Fluid Mass Contactors . . . . . . . . . . . . . . . . . . . . . . . . 301
7.1 Estimation of Bubble and Drop Size 304
7.2 Tank-Type Mass Contactors 307
7.2.1 Mixed–Mixed Interfacial Area Estimation 307
7.2.2 Mixed–Mixed Km Estimation 309
7.2.3 Mixed–Plug Area Estimation 309
7.2.4 Mixed–Plug Km Estimation 313
7.3 Tubular Contactors 316
7.3.1 Cocurrent Area Estimation 316
7.3.2 Cocurrent Km Estimation 318
7.3.3 Countercurrent Area Estimation 318
7.3.4 Countercurrent Km Estimation 320
Nomenclature 320
References 321
Problems 322
Appendix. Bubble and Drop Breakage 323

8 Technically Feasible Design Case Studies . . . . . . . . . . . . . . . . . . . . 327


8.1 Technically Feasible Design of a Heat Exchanger 328
8.2 Technically Feasible Design of a Countercurrent Mass Contactor 335
8.3 Analysis of a Pilot-Scale Bioreactor 345
Nomenclature 353
References 354
Problems 354
Index 363
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Preface

Chemical engineers educated in the undergraduate programs of departments of


chemical engineering have received an education that has been proven highly effec-
tive. Chemical engineering educational programs have accomplished this by manag-
ing to teach a methodology for solving a wide range of problems. They first did so
by using case studies from the chemical process industries. They began case studies
in the early part of the 20th century by considering the complete processes for the
manufacture of certain chemicals and how they were designed, operated, and con-
trolled. This approach was made much more effective when it was recognized that
all chemical processes contained elements that had the same characteristics, and the
education was then organized around various unit operations. Great progress was
made during the 1940s and 1950s in experimental studies that quantified the analysis
and design of heat exchangers and equilibrium stage operations such as distillation.
The 1960s saw the introduction of reaction and reactor analysis into the curriculum,
which emphasized the critical relationship between experiment and mathematical
modeling and use of the verified models for practical design. We have built upon this
approach, coupled with the tools of transport phenomena, to develop this text.
Our approach to teaching mass and heat transfer has the following goals:

1. Teach students a methodology for rational, engineering analysis of problems in


mass and heat transport, i.e., to develop model equations to describe mass and
heat transfer based on the relationship between experimental data and model.
2. Using these model equations, teach students to design and interpret laboratory
experiments in mass and heat transfer and then to effectively translate this knowl-
edge to the operation and design of mass and heat transfer equipment.
3. Develop the students’ molecular understanding of the mechanisms of mass and
heat transfer in fluids and solids and application in the estimation and correlation
of mass and heat transfer coefficients.

To achieve these goals we use the following methods:


r Emphasize the critical role of experiment coupled with the development of an
appropriate model.
r Focus attention on analysis and model development rather than on mathemati-
cal manipulation of equations. This is facilitated by organization of the analysis
method into levels.
xiii
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