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MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION

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WINTER-22 EXAMINATION
Model Answer
_____________________________________________________________________________________________________

Subject: Heat Transfer Operation Subject code: 22510 Page 1 of 24

Important Instructions to examiners:

1) The answers should be examined by key words and not as word-to-word as given in the
model answer scheme.
2) The model answer and the answer written by candidate may vary but the examiner may try
to assess the understanding level of the candidate.
3) The language errors such as grammatical, spelling errors should not be given more
Importance (Not applicable for subject English and Communication Skills.
4) While assessing figures, examiner may give credit for principal components indicated in the
figure. The figures drawn by candidate and model answer may vary. The examiner may give credit for
any equivalent figure drawn.
5) Credits may be given step wise for numerical problems. In some cases, the assumed constant
values may vary and there may be some difference in the candidate’s answers and model
answer.
6) In case of some questions credit may be given by judgement on part of examiner of relevant
answer based on candidate’s understanding.
7) For programming language papers, credit may be given to any other program based on equivalent
concept.

8) As per the policy decision of Maharashtra State Government, teaching in English/Marathi and Bilingual
(English + Marathi) medium is introduced at first year of AICTE diploma Programme from academic year
2021-2022. Hence if the students in first year (first and second semesters) write answers in Marathi or
bilingual language (English +Marathi), the Examiner shall consider the same and assess the answer
based on matching of concepts with model answer.
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Subject: Heat Transfer Operation Subject code: 22510 Page 2 of 24

Q Sub Answer marks


No Q.N
1 Answer any five 10
1 a Thermal conductivity: It is a measure of the ability of the substance to 1
conduct heat. It is the amount of heat passing through a material of a unit
thickness with a unit heat flow area in unit time when a unit temperature
difference is maintained across the opposite faces of the material.
Unit: W/ (m.K) 1
1 b Film heat transfer coefficient: Film heat transfer coefficient h is defined 1
as the quantity of heat transferred in unit time through unit area at a
temperature difference of 10 between the surface and surrounding.
Formula & Unit:
h=Q/AΔT 1
Unit: W/m2K
1 c Reynold’s Number :
Mathematical formula:
Reynold’s Number NRe = Duρ/ µ 1
Significance:
Reynold’s number is used to decide the nature of flow- whether the flow is 1
laminar or turbulent
OR
Reynold’s no. Inertia force/ viscous force
1 d Single pass and multi pass shell and tube heat exchanger: (Any 2 1 mark
points) each
Single pass Multi pass
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Subject: Heat Transfer Operation Subject code: 22510 Page 3 of 24

Simple in construction complex in construction


Flow may be parallel or counter Flow is parallel as well as counter
current current
Inexpensive expensive
Heat transfer coefficients are low Heat transfer coefficients are high
Frictional losses are low Frictional losses are high
Heat transfer rates are low Heat transfer rates are high
Floor space requirement is large Floor space requirement is low
1 e Classification of heat transfer equipment: ½ mark
Heat transfer equipments: each for
1. Cooler: To cool process fluid by means of water or atmospheric air. any 4
2. Condenser: To condense a vapour or mixture of vapours.
3. Chiller: To cool a process fluid to a temperature below that can be
obtained by using water as a cooling media
4. Heater: Which imparts sensible heat to process fluid.
5. Vaporiser: Which vaporizes part of liquid.
6. Reboiler: Employed to meet latent heat requirement at the bottom of
distillation column.
7. Evaporator: To concentrate a solution by evaporating water.
1 f 1
The capacity of an evaporator is defined as the number of kilogram of
water evaporated per hour.

The economy of an evaporator is defined as the number of kilogram of


1
water evaporated per kilogram of steam fed to the evaporator.

1 g The Sider –Tate equation for laminar flow is 2


h D/k = 1.86[ (NRe) (Npr) (D/L)]1/3 (µ/µw)0.14
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Subject: Heat Transfer Operation Subject code: 22510 Page 4 of 24

2 Answer any three 12


2 a Modes of heat transfer are: 2 marks
1. Conduction for
2. Convection explanati
3. Radiation on, 2
1) Conduction : If a temperature gradient exist in a continuous marks for
substance, heat can flow unaccompanied by any observable motion examples
of mater. Heat flow of this kind is called conduction.
Example: Heat flow in the metal wall of tube
2) Convection : When a macroscopic particle of fluid crosses a
specific surface, it carries with it a definite quantity of enthalpy.
Such a flow of enthalpy is called convection.
There are two types of convection- natural and forced. If the currents
are the result of buoyancy forces generated by differences in density
and the differences in density are in turn caused by temperature
gradient the action is called natural convection.
Example: heating of water by hot surface
Forced convection : If the currents are set in motion by the action
of a mechanical device such as a pump or agitator, the flow is called
forced convection
Example: heat flow to a fluid pumped through a heated pipe
3) Radiation: Radiation is transfer of energy through space by
electromagnetic waves.
Example: Loss of heat from unlagged pipe.
2 b Wilson Plot:
It is based on the separation of the overall thermal resistance into the inside
convective thermal resistance and the remaining thermal resistances
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Subject: Heat Transfer Operation Subject code: 22510 Page 5 of 24

participating in the heat transfer process.

1
1/U = 1/hi + C (Where C is constant as C = 1/ho + Xw/k)
Where c is a constant.
For turbulent flow we can write Nnu α NRe0.8
hi α v0.8
hi= a . v0.8
therefore 1/U=1/ a . v0.8 +C 1
where u is the linear velocity of the cold fluid. A plot of 1/U vs 1/ v0.8
results in a straight line with the slope equal to 1/a and intercept equal to
Xw/K +1/h0. The values of h0 is obtained from the intercept and a 1
represents the value of film coefficient hi for a unit velocity of cold fluid.
Use: To evaluate the convection coefficients in shell and tube condensers
for the case of a vapour condensing outside by means of a cool liquid flow
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inside.
2 c Multiple effect evaporator method to improve economy of evaporators:
Multiple effect evaporation: In this system, evaporators are arranged in
series so that the vapour produced in first effect is fed to the steam chest of 2
second effect as heating medium in which boiling takes place at low
pressure and temperature and so on.
Increasing the number of effects between steam supply and condenser
increases the amount of evaporation per kg of steam fed to the first effect
and also the operating cost will be less, but capital cost, maintenance and
repair charges increases with increase in number of effects.
Methods of feeding multiple effect evaporation system: 2
1. Forward feed arrangement: In this, the liquid feed flows in the same
direction as the vapour flows. Fresh feed and steam are fed to the
first effect. For effectively utilizing temperature potentials, this
arrangement is preferable.
2. Backward feed arrangement: In this arrangement, the feed solution
and vapour flow in opposite direction. Fresh feed is admitted to the
first effect and steam to the last effect. If the liquid is very viscous,
then we adopt backward feed arrangement.
3. Mixed feed arrangement: In this feed arrangement, steam is
admitted to the first effect. Feed solution is admitted to an
intermediate effect and flows to the first effect from where it is fed
to last effect for final concentration. This is adopted for best overall
performance.
2 d Stefan-Boltzmann Law :
It states that the total energy emitted (emissive power) by a black body is 2
proportional to fourth power of its absolute temperature.
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Subject: Heat Transfer Operation Subject code: 22510 Page 7 of 24

Wb ἀ T4
Mathematical expression: 2
Wb = σ T4 where σ is Stefan Boltzman constant=5.67*10-8 (W/m2K4)
3 Answer any three 12
3 a Rate of heat transfer by radiation
e1= 0.85 e2 =0.75 = 5.67*10-8 W/(m2.K4) 1
T1 = 703 K T2 = 513 K
The net radiation rate per 1 m2 is 1
Q/ A= (T14- T24) / [(1/e1)+(1/e2)-1]
= × 5.67 × 10-8 (7034 – 5134) / [(1/0.85)+(1/0.75)-1] 1
Qr / A = 6571 W/m2 1
3 b Kettle/ Reboiler type Heat Exchanger:
Diagram

Construction and Working:


It is either provided with an internal floating head arrangement or a U-tube
2
bundle. To provide a vapour space above the tube bundle, a shell is made
larger in diameter.
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It consists of a enlarged shell containing a relatively small tube bundle. At


one end of the bundle, the tubes are expanded into a stationary tube sheet
clamped between shell and channel flange.
In a channel, pass partition is incorporated so that inlet and outlet for the
tube side fluid is provided on the same channel. At opposite end of the
bundle, tubes are expanded into a freely riding floating tube sheet. The
tubes are free to expand. The shell is provided with liquid inlet and outlet
connections at the bottom as shown in figure. A vapour outlet is provided at
the top. A weir is incorporated in the shell to maintain a pool of liquid in the
shell so that the tube bundle remains submerged in the liquid.
The heating medium, usually steam, flows through the tubes and the
condensate is removed through a steam trap The liquid to be vaporised is
introduced in the enlarged shell through a liquid inlet. The tube bundle is
always submerged in a pool of boiling liquid and for this purpose an over-
flow weir is incorporated in the shell, which is set aside of the tube bundle.
Heat transfer to boiling liquid takes place from a submerged surface.
The shell is of a large diameter mainly for vapour-liquid separation. The
vapours, are generated, disengaged and removed from the top, and
unvaporised liquid spills over the weir, and is withdrawn as the bottom
product, through a liquid outlet provided at the bottom of the shell.
3 c Plate type heat exchanger:
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Subject: Heat Transfer Operation Subject code: 22510 Page 9 of 24

Construction:
It consists of a series of rectangular, parallel plates held firmly together
between head frames. The plates have corner ports and are sealed by
1
gaskets around the ports and along the plate edges. The plates are having
corrugated faces. These plates serve as heat transfer surfaces and are of
stainless steel.. It is provided with inlet and outlet nozzles for fluids at ends.
Working:
The hot fluid passes between alternate pairs of plates, transferring heat to
cold fluid in the adjacent spaces. The plates can be readily separated for
1
cleaning and heat transfer area can be increased by simply adding more
plates.
3 d Calendria type(Short tube) evaporator:
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Subject: Heat Transfer Operation Subject code: 22510 Page 10 of 24

Working: Thin liquor is introduced to the tube side and steam into steam
chest . The liquor covers top of tubes. Heat transfer to boiling liquid inside 1
the tubes take place from condensing steam on outside of tubes. Vapours
formed will rise through the tubes, come to the liquid surface from which
they are disengaged into the vapour space and removed from the vapour
outlet. Thick liquor is removed from the bottom of the evaporator.
Application:
1. For non corrosive liquor 1/2 mark
2. Clear liquor for any 2
3. Non crystallising liquor
4. widely used in sugar industry in evaporation of cane-sugar juice.
4 Answer any three 12
4 a Kirchoff’s law of radiation:
Kirchoff’s law: It states that at equilibrium temperature, the ratio of total 1
emissive power of any body to absorptivity depends only upon the
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temperature of the body.


Thus when any body is at equilibrium temperature with its surrounding, its
emissivity and absorptivity are equal.
Consider that the two bodies are kept into a furnace held at constant
temperature of T K. Assume that, of the two bodies one is a black body& 1
the other is a non-black body i.e. the body having ‘a’ value less than one.
Both the bodies will eventually attain the temperature of T K & the bodies
neither become hotter nor cooler than the furnace. At this condition of
thermal equilibrium, each body absorbs and emits thermal radiation at the
same rate. The rate of absorption & emission for the black body will be
different from that of he non-black body.
Let the area of non-black body be A1 and A2 respectively. Let ‘I’ be the
rate at which radiation falling on bodies per unit area and E1 and E2 be the
emissive powers ( emissive power is the total quantity of radiant energy
emitted by a body per unit area per unit time)of non-black & black body
respectively.
At thermal equilibrium, absorption and emission rates are equal, thus,
a1 A1 = A1 E1 ………………..(1.1)
a1 = E1 …………….(1.2)
And ab A2 = A2 Eb……………..(1.3) ab = Eb………….(1.4)
From equation (1.1) and (1.4).we get

= ………….(1.5) 1

Where a1,ab= absorptivity of non-black & black bodies respectively.


If we introduce a second body (non-black) then for the second non-black
body,we have :
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Subject: Heat Transfer Operation Subject code: 22510 Page 12 of 24

A3 a2 = E2 A3 ………….(1.6)
a2 = E2 …………..(1.7)
Where a1 = E2 are the absorptivity and emissive power of the second non-
black body. 1
Combining equations (1.2),(1.4) and(1.7) we get,

= Eb ………..(1.8)

4 b The equation to be used is:


=   1

Where U = overall heat transfer coefficient


ho = outside heat transfer coefficient
= 1750 W/(m2.K)
hi = inside heat transfer coefficient
= 5800 W/(m2.K)
1
k = thermal conductivity of metal wall
= 46.52 W/(m.K)
x = thickness of metal wall of tube
= (O.D. – I.D.) / 2

= = 5mm = 0.005m
1
= + +
1
U = 1175 W/(m2.K)
4 c Rate of heat transfer through sphere:
Consider a hollow sphere of inner radius r1 and outer radius r2. Let T1 1
be the temp. at the inner surface and T2 be the temp. at the outer
surface. Heat will flow from outside to inside.
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Subject: Heat Transfer Operation Subject code: 22510 Page 13 of 24

Consider a spherical element at radius r and thickness dr. the rate of


heat flow can be written as Q= -kA dT/dr
= -k4Пr2 dT/dr
dr/r2 = -k4П dT/Q 1
Integrate the eqn (ii) between the limits
When r = r1, T = T1
When r = r2, T = T2

∫ =- ∫ …..(iii)

r2 [-1/r]
r1 = -k (4π)/Q ( T2 - T1)…..(iv) 1
[1/r1 – 1/r2] = k (4π)/Q ( T1 - T2) ……(v)
Rate of heat flow through sphere is :
... Q = k (4π) ( T1 - T2) / [1/r1 – 1/r2] vi)
It can be put into more convenient form by expressing the rate of heat flow
as :
1

Where rm is the geometric mean radius & is given by

rm = √(r1.r2)
rm2= r1.r2

Am = 4πrm2….(ix)
Am is called as geometric mean area.
Equation (viii) becomes
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Subject: Heat Transfer Operation Subject code: 22510 Page 14 of 24

Where

4 d To derive Q=UA ΔTlm

Consider an elementary area dA( =B.dx). The rate of heat transfer across it
is given by
dq= U (Th-Tc) B dx -------------(1)
Since there are no losses to the surroundings, the heat transfer rate is also
equal to the rate of change of enthalpy on either side. Therefore,
dq= -mh Cph dTh-------------------(2)
= mc Cpc dTc ----------------------(3)
Now ΔT = Th- Tc -----------------(4)
On differentiating

d(ΔT) =dTh- dTc -------------------------------------(5)


1
substituting for dq, dTh and dTc from equations (1), (2) and (3) into
equation (5) , we obtain
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d(ΔT)/ ΔT= - ( 1/(mh Cph) + 1/(mc Cpc)) U B dx

ΔTe

∫ ΔTi d(ΔT)/ ΔT = - ( 1/(mh Cph) + 1/(mc Cpc)) U B∫0 L dx

ln (ΔTe/ ΔTi) = - ( 1/(mh Cph) + 1/(mc Cpc)) U A ---------------------------(6)

where ΔTe = The-Tce


1
ΔTi= Thi – Tci

Now if q is the total rate of heat transfer in the heat exchanger, then

q = mhCph (Thi-The) -----------------------------(7)

= mc Cpc (Tce- Tci) --------------------------(8)

Substituting equations (7) and (8) into equation (6),

ln (ΔTe/ ΔTi) = -1/q[ (Thi-The) + (Tce- Tci)]U A

q= U A (ΔTi- ΔTe)/ ln (ΔTi/ ΔTe) -----------------------------(9)


1
Equation (9) is the performance equation for a parallel-flow heat exchanger.

Q= U A ΔTlm

Where ΔTlm= (ΔTi- ΔTe)/ ln (ΔTi/ ΔTe)

4 e Material balance equation for single effect evaporator:


Consider that the evaporator is fed with mf kg/h of weak solution containing
w1 % solute & thick liquor is withdrawn at m’ kg/h containing w2 % solids
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Subject: Heat Transfer Operation Subject code: 22510 Page 16 of 24

by weight. Let mv be the kg/h of water evaporated. Then : 2

Overall material balance :


mf = mv +m….(i)

Material balance of solute :


Solute in feed = Solute in thick liquor
W1 x mf /100 = w2 m’ / 100
W1 x mf =w2 m’……(ii)

Knowing three out of five quantities ,we can find the values of other two
with the help of above two equations.
Energy balance equation for single effect evaporator: 2
Let Tf , T and Ts be the temperatures of feed entering the evaporator ,
solutions in the evaporators and condensing steam respectively.
Let ‘λs’ be the latent heat of condensation of steam at saturation
temperature and assume that only latent heat of condensation is used. Then,
rate of heat transfer through heating surface from steam is :
Qs = msλs….(iii)
Where ms is mass flowrate of steam to the evaporator in kg/h.
Heat transfer rate on steam side = Heat transfer rate on liquor side.
Enthalpy balance can be written in terms of specific heats & temperatures of
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solutions , in case of solutions having negligible heats of dilution.


Heat transfer to solution in evaporator by condensing steam (in absece of
heat losses) is utilised to heat the feed solution from Tf to T and for
vaporisation of water from solution.
Qs = Q
= mfCpf (T – Tf) +(mf – m’) λv…….(vii)
ms .λs = mf Cpf (T – Tf) +(mf – m’) λv…..(viii)

where Cpf = specific heat of feed solution


λv = latent heat of evaporation from thick liquor
For negligible boiling point rise λv = λ
Where λ =latent heat of vaporisation of water at pressure in the
Vapour space& can be read from steam tables.
Above equation (viii) becomes :
msλs = mf Cpf (T – Tf) +(mf – m’) λ……(ix)
msλs = mfCpf (T – Tf) + mv λ…..(x)
5 Answer any two 12
5 a
Derivation for relation between overall and individual heat transfer
coefficients:
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Subject: Heat Transfer Operation Subject code: 22510 Page 18 of 24

Consider a hot fluid is flowing through a circular pipe and cold fluid is
flowing on the outside of the pipe. The heat will flow from hot fluid to cold
fluid through a series of resistances.
In the diagram the lines Y1 Y2 and Z1 Z2 represent the boundaries of think
films. The flow to the left of Y1 Y2 and right of Z1 Z2 is turbulent. T1 is
the average temperature of hot fluid and T4 is the average temperature of 1
cold fluid. The temperature change from T1 to T2 is taking place in the hot
fluid film of thickness x1 . The rate of heat through this film is given by
Q=hiAi(T1-T2) ………….(1)
The overall resistance to heat flow from hot fluid to cold fluid is made up of
three resistances in series. They are
1) Resistance offered by film of hot fluid
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2) Resistance offered by metal wall. 1


3) Resistance offered by film of cold fluid
Heat transferred through metal wall
Q=kAw(T2-T3) / xw …… (2)
The rate of heat transfer through cold fluid film
Q=h0A0(T3-T4) ………….(3) 1
T1-T2 =

T2-T3 =

T3-T4 =

T1-T2+ T2-T3 + T3-T4 = Q[ + + ]……(4)


1
But Q = U0A0(T1-T4) ……(5)
Equating (4) and (5)
= + +

= + +
1

5 b
633K------- 573K 1

400K---303K

LMTD for counter current flow,


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1
∆T2 = Tho – Tci = 573 – 303 = 270 K

1
∆T1 = Thi – Tco= 633 – 400 = 233 K

LMTD = (270-233) / ln (270/233) =251K 1

Q = m Cp ∆T = U A ∆T 1
LM

1.2*2083 (633-573) = A*500*251


1

A=1.196 m2
for counter current flow
5 c Basis : 10,000 Kg/h of weak liquor entering the evaporator. 1
Let m be the kg/h of thick liquor leaving the evaporator.
Material balance of caustic soda: 1
Caustic soda in feed = Caustic soda in thick liquor
0.04  10000 = 0.25 m 1
m = 1600kg/h
Overall material balance:
kg/h of feed = kg/h evaporated + kg/h of thick liquor 1
1000 = kg/h water evaporated + 1600
water evaporated = 10000 – 1600 1
= 8400 kg/h
 capacity of evaporator = 8400kg/h 1

6 Answer any two 12


6 a Basis: 1 m length
r1 = 0.0325m r2 = 0.0825m
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Subject: Heat Transfer Operation Subject code: 22510 Page 21 of 24

rL1= (r2-r1) / ln(r2/r1) = 0.0537m 1

AL1 = 2πrLL = 0.3371 m2


K1= 0.14 W/mK
R1= B1 / K1AL1 1
= 0.05/0.14* 0.3371
= 1.059 K/W
r2= 0.0825m r3 = 0.1225m 1
rL= (r3-r2) / ln(r3/r2) = 0.101m
AL2 = 2πrLL = 0.6355 m2
K2= 0.035 W/mK 1
R2= B2 / K2AL2
= 0.04/0.035* 0.6355
= 1.798 K/W
1
R= R1+ R2
= 2.857 K/W
Temp.drop ∆T= 115 K
1
Heat loss Q= ∆T / R
= 115 / 2.857
= 40.3 W
6 b Dropwise and Filmwise condensation:
The change from liquid to vapour state is known as vapourisation and
that from vapour to liquid is known as condensation. In either case, the
latent heats involved are identical. In the condensation of a pure vapour, 1
it is necessary to remove the latent heat of vapourisation. Condensation
is a convection process that involves a change of phase from vapour to
liquid and it occurs whenever a saturated vapour comes into contact of a
cold surface, for example In surface condenser, heat transfer from the
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Subject: Heat Transfer Operation Subject code: 22510 Page 22 of 24

vapour to the surface takes place and the vapour gets condensed on the
surface.
The process of condensation which is the reverse of boiling,occurs
by two distinct mechanism and that too at very different rates of heat
transfer, The two distinct mechanism are 1) Dropwise condensation 2)
Filmwise condensation
Dropwise condensation: When a saturated vapour comes into contact
with a cold surface, it condenses and if condensate does not wet the
surface, the droplets are formed on the surface.. The droplets grow and 2
ultimately fall from or fall down under the influence of gravity leaving
behind the bare metal surface on which further condensation takes
place.The condensation occurring by this mechanism is known as
dropwise condensation.
Filmwise condensation:
When a saturated vapour comes into contact with the cold surface, it
condenses and if condensate wets the surface it formes a continuous 3
film of condensate through which heat mass be transferred. The
additional vapour is then required to condense into the liquid film rather
than directly on the surface. The condensate ultimately flows down the
surface under the influence of gravity.
In Filmwise condensation, the film covering the acts as a resistance
to heat transfer while in dropwise condensation a large portion of a surface
is directly exposed to the vapour. Because of this the rate of heat transfer
and heat transfer coefficient in dropwise condensation is larger than
filmwise condensation.
6 c Double pipe heat exchanger:
It is the simplest type of heat exchanger. It is used when the heat transfer
MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2005 Certified)

WINTER-22 EXAMINATION
Model Answer
_____________________________________________________________________________________________________

Subject: Heat Transfer Operation Subject code: 22510 Page 23 of 24

area required is relatively small.


Diagram:

OR

Construction:-It consist of concentric pipes, connecting trees, returns


heads and return bends. The packing glands support the inner pipe within
2
the outer pipe. A double pipe heat exchanger arranged in two legs. Tees are
provided with nozzles or screwed connections for permitting the entry and
exit of the annulus fluid which crosses from one leg to the other through the
return head. The return bend connects two legs of the inner pipes to each
other. These exchanger are usually assembled in effective legths of 3.65,
4.57, 6 m.
Working:- This exchanger can be very easily assembled in any pipe-fitting
MAHARASHTRA STATE BOARD OF TECHNICAL EDUCATION
(Autonomous)
(ISO/IEC - 27001 - 2005 Certified)

WINTER-22 EXAMINATION
Model Answer
_____________________________________________________________________________________________________

Subject: Heat Transfer Operation Subject code: 22510 Page 24 of 24

shop as it consists of standard parts and it provides inexpensive heat transfer 2


surface. In this exchanger, one of the fluids flows through the inside pipe
and the other fluid flows through the annular space created between two
concentric pipes either in co-current or counter-current fashion. It is usually
employed for decreasing the temperature of a hot fluid with the help of cold
fluid when flow rates are low.

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