ORC Condenser Heat Exchanger Design and Modelling

ORC Condenser Heat Exchanger Design and Modelling

Shadreck M. Situmbeko University of Botswana, Gaborone, Botswana; University of KwaZulu-Natal, Durban, RSA;

Freddie L. Inambao University of KwaZulu-Natal, Durban, RSA;

Abstract- The paper presents work done on the development of a condenser heat exchanger model suitable for incorporation into a low temperature solar thermal power cycle based on the organic Rankine cycle (ORC); it presents the mathematical and computer models of a flow of vapour over a bundle of horizontal tubes. Although the process of condensation finds application in a lot of industrial systems, the concept itself is still not yet well defined as a scientific notion and is still a subject of investigation; a number of empirical correlations that have been proposed are reviewed in this research and are to be evaluated against the results of experimental investigations. The working fluid is modelled from five organic fluids being R123, R134a, R245fa, n-butane and isobutene; the cooling liquid is placed on the tube side and consists of ethylene glycol at 50 % concentration. The condenser model is implemented on the engineering equation solver platform. The current study presents the preliminary results of the mathematical and computer analyses. The results are in the form of condensation heat transfer coefficients and rate of heat transfer for each tube in a vertical tire tube bundle.

Keywords: Condensation heat transfer coefficients, bundle of horizontal tubes, engineering equation solver

Nomenclature:

Roman Symbols

A surface area at nominal diameter (m2)

Af fin surface area (m2)

Ar tube surface area at the base of the fins (m2)

D tube diameter (m)

Dr diameter at fin root (m)

F a constant accounting for the effect of physical properties

hfg latent heat of condensation (J/kg) g gravitational acceleration (m/s2)

h heat transfer coefficient (W/m2.K)

k thermal conductivity of condensate (W/m2)

Lc Lc is the characteristic length (m)

N number of tubes

Nu Nusselts number

T Temperature (oC)

Greek Symbols

fin efficiency

dynamic viscosity (kg/m.s) Density (kg/m3)

Subscripts

G vapour phase

i inside

L liquid phase

o outside

sat saturation state

w tube wall

1. INTRODUCTION

   Condensation is the heat transfer process by which a saturated vapour is converted into a saturated liquid by means of removing the latent heat of condensation; it occurs when the enthalpy of the vapour is reduced to the state of saturated liquid.

   Condensation occurs through one or a combination of four basic mechanisms of drop-wise, film-wise, direct contact, and homogeneous [1]. Drop-wise refers to a situation whereby the vapour condenses as liquid drops at particular nucleation sites on the cooling surface and remains as drops until carried away by gravity or vapour shear; in film-wise condensation, the liquid drops coalesce into a continuous thin liquid film; and in direct contact condensation, the vapour condenses directly onto the coolant liquid that has been sprayed into the vapour; whilst in homogenous condensation the super-saturated vapour condenses in space away from any macroscopic surfaces similar to the formation of fog possibly on dust or other particles acting as nucleation sites [2]; refer to figure 1.

   The majority of industrial condensation processes are considered to be based on the film-wise mode of condensation. In this research work the study of the condenser is particularly directed towards the development of a low temperature solar thermal power plant as depicted in figure 2, below:

   1. drop-wise (c) homogeneous

   2. film-wise (d) direct-contact

      Figure 1: four condensation mechanisms

      Thome J.R. [1] and this theory forms the basis for the condenser model presented in this chapter; derivations of the formulae are considered outside the scope of this work and thus only the key equations are shown here.

      Comparison of condensation heat transfer correlations for flow of refrigerants in horizontal smooth tube bundles has been presented by Sánta Róbert [4].

      A detailed comparison of condensation heat transfer correlations for different flow configurations including flow

      Figure 2: solar thermal power plant concept [3]

      (HTF: heat transfer fluid; WF: working fluid; CF: cooling fluid)

2. THE THEORY OF CONDENSATION The theory of film condensation based on the Nusselt

   (1916) integral model for film condensation on a vertical plate and later extended to cover condensation on a horizontal bundle of tubes has been well documented by

   inside and outside of horizontal, vertical and inclined tubes has also been presented by Fang Xiande et al [5].

   Two correlations can be identified for flow outside a single horizontal tube and these are the Nusselt (1916) and the Dhir and Lienhard (1971) correlations; these are similar in every respect and only differ in the prefix multiplier constant (number):

   The correlation due to Nusselt (1916) is given as:

   1

   L(L-G)ghfgk3 4

   h=0.725 L

   [ ] (1)

   LDo(Tsat-Tw)

   The correlation given by Dhir and Lienhard (1971) proposed the following average heat transfer coefficient:

   The flow over a bundle is affected by condensate inundation; condensate inundation refers to the effect of condensate falling onto a tube from upper tubes in the tube bank. Condensate inundation modes include droplet, column and sheet; at higher inundation rates the inundation may progress into a spray mode which may involve side drainage, splashing and ripples on the lower tubes; see figure 3, below, [6].

   h=0.729 [

   1

   L

   L(L-G)ghfgk3 4

   ]

   LDo(Tsat-Tw)

   (2)

   1. droplet (b) column (c) sheet

      Figure 3: condensate inundation modes

      Three correlations can be identified for flow outside a bundle of horizontal smooth tubes; these are Nusselts (1949), Kerns (1958) and Eissenbergs (1972).

      Nusselts correlation gives the mean heat transfer

      staggered arrangement of vertical tubes; the correlations are expressed as, [8]; [9]:

      Nu 0.5

      0.5

      G

      G

      =0.416 [1+ (1+9.47 gDLhfg ) ] (7)

      coefficient as well as a coefficient for each of the tubes based on the coefficient for the first tube, as expressed by (1); the two equations for this correlation are as follows in

      Re12

      h

      u2 kL(Tsat-Tw)

      -1

      (3) and (4):

      =N- (3)

      h 1

      4

      h(N=1)

      h(N) 3 3

      h(N=1)) =0.6+0.42N 4 (8)

      Beatty and Katz (1948) correlation provides for condensation on low-finned tubes and their correlation together with supporting equations is given as: [5].

      r

      c

      h(N=1)

      =N4-(N-1)4 (4)

      h=0.689F0.25 [Ar

      1 +1.3 Af 1 ] (9)

      Incropera and DeWitt (2002) also proposed a similar average heat transfer coefficient for vertically aligned

      2gk3hfg

      A D0.25

      A L0.25

      horizontal tube bundles; their correlation, however, suggests

      F= ( L L ) (10)

      using the Dhir and Lienhard (1971) correlation for the reference heat transfer coefficient, [7].

      The correlation due to Kern (1958) gives:

      L(Tsat-Tw)

      Lc= o r

      (D2-D2)

      4Do

      (11)

      6

      h =N-1 (5)

      h(N=1)

      h(N) 5 5

      6

      A = Ar + Af(4d) (12)

      where is the fin efficiency, A is the tube surface area at nominal diameter (m2), Ar is the tube surface area at the

      base of th fins (m2), A is the fin surface area (m2), D is the

      h(N=1) =N6-(N-1)

      (6) f r

      The Butterworth and Eissenbergs (1972) correlations are only for the mean heat transfer coefficient and for a

      diameter at fin root, F is a constant accounting for the effect of physical properties, and Lc is the characteristic length.

3. MATHEMATICAL MODELLING

   The governing equations used in this model are as

   r3k 3(T

   T )3(

   14

   )g

   = 1.924 [ L

   sat w

   L G ]

   (16)

   follows: The overall heat transfer coefficient for each tube is given by:

   hfg3 L

   L

   o

   U[i]Ao= 1

   for i=1 to N

   where is the condensate mass flow rate on one side of

   1 +R“

   fi+

   D

   ln[ Di ]

   + 1 +R“fo

   the tube, per unit length of the tube, (kg/m.s); from this equation the overall heat transfer for a single tube can be

   hCFAi

   Ai 2kwLtube

   hWF[i]Ao Ao

   (13)

   expressed as:

   where hWF[i] is determined from the correlations of section 3 and hCF is determined from the Gnielinsk correlation given by:

   h D fCF(ReDCF1000)PrCF

   Q = 2Ltubehfg (17)

   where hfg is the latent heat of condensation, (J/kg)

4. COMPUTER SIMULATIONS

   CF i = 8

   (14)

   8 ]

   kCF 1+12.7[fCF 1 2

   (PrCF

   23

   1)

   Four sets of simulations have been performed as follows:

   These are used to determine the heat transfer for each tube; total heat exchange is then given as:

   = []

   (15)

   =

   Where N is the number of tubes in each column and M is the number of columns. The logarithimic mean temperature difference (LMTD) method is used together with the number of transfer units (NTU) method to determine the heat transfer for each tube.

   The input conditions are taken as:

   • The working fluid is any of: R123, R134a, R245fa, n-butane and isobutene;

   • The cooling fluid is ethylene glycol at 50% concentration;

   • TWF = 50oC as the condensate temperature; TCF,i = 25oC as the cooling fluid inlet temperature;

   • Copper tubing is used for the tube bundles: inside diameter 16.5 mm, outside diameter 19 mm and length 2.85 m

   Equations that are also useful in formulating the mathematical models are those obtained from Nusselts Integral method and may be expressed as:

   1. The first simulations are based on Nusselts correlations for the heat transfer coefficient for the first tube, for the mean heat transfer coefficient for a column of N tubes, and the heat transfer coefficients for tubes 2 up to N.

   2. The second set of results use Nusselts correlations for the first tube; and then uses Kerns method for the mean heat transfer coefficient as well as for the tubes 2 to N.

   3. The third set of simulations uses the Dhir and Lienhard correlation for the first tube and then uses the Nusselts correlations for the mean and for tubes 2 to N.

   4. The fourth set uses the Dhir and Lienhard correlation for the first tube and then uses the Kerns method for the mean and for tubes 2 to N.

      Working fluids used are R245fa, R134a, R123, n-butane and isobutene. The results are compiled for each working fluid and compared on the basis of the correlations.

      The simulations were done for only the 10 kWe concept cycle plant; sizing is based on the thermal load of 84.2 kWth determined from cycle efficiencies in the range 10-15% obtained from the initial system model thus giving an average cycle efficiency of 12.5% [3].

5. RESULTS

   • Condensate Heat Transfer Coefficients

     The results for the condensate heat transfer coefficients based on different correlations are shown in the charts of figures 4 to 7.

     2000

     1800

     1600

     1400

     1200

     1000

     800

     R 123

     R134a

     R245fa

     n-butane isobutane

     1 2 3 4 5 6 7 8

     Tube Number

     600

     Condensate Heat Transfer Coefficient

     (W/m2.C)

     Condensate Heat Transfer Coefficient

     (W/m2.C)

     Figure 4: tube heat transfer coefficients based on Nusselts Correlations

     2000

     1800

     1600

     1400

     1200

     1000

     R 123

     R134a

     R245fa

     n-butane isobutane

     800

     1 2 3 4 5 6 7 8

     Tube Number

     Condensate Heat Transfer Coefficient

     (W/m2.C)

     Figure 5: tube heat transfer coefficients based Nusselts and Kerns Correlations

     2000

     1800

     1600

     1400

     1200

     1000

     800

     R 123

     R134a

     R245fa

     n-butane isobutane

     1

     2

     3 4

     5 6

     7

     8

     Tube Number

     600

     Figure 6: tube heat transfer coefficients based on Dhir and Lienhard, and Nusselts Correlations

     2000

     800

     1

     2

     3 4

     5 6

     7

     8

     Tube Number

     Nusselts and Kerns

     method

     1200

     1400

     Nusselts Correlations

     1600

     1800

     1000

     R 123

     R134a

     R245fa

     n-butane isobutane

     1400

     1200

     1600

     1800

     Condensate Heat Transfer Coefficient

     (W/m2.C)

     Condensate Heat Transfer Coefficient

     (W/m2.C)

     Figure 7: tube heat transfer coefficients based on Dhir and Lienhard, and Kerns Correlations

     1 2 3 4 5 6 7 8

     Tube Number

     Dhir and Lienhard

     correlation and Nusselts

     Dhir and Lienhard correlation and Kerns method

     1000

     800

     600

     Figure 8: Condensate Heat Transfer Coefficient for R134a based on different combinations of Correlations

   • Heat Transfer Rates

     The total thermal loads per column data is captured for each working fluid and for each combination of correlations and the results are presented in the following table 1.

     The overall heat exchanger thermal loads for each working fluid are shown in figure 9.

   • Cooling Fluid Outlet Temperature

   The average outlet temperatures of the ethylene glycol cooling fluid for each of the working fluids are shown in figure 10; the inlet temperature is assumed as 25oC whilst the condensation temperature is taken as 50oC.

   Overall Thermal Load (W)

   TABLE 1: THERMAL LOADS PER COLUMN FOR EACH WORKING FLUID AND FOR EACH CORRELATIONS COMBINATION

   WORKING FLUIDS	R 123	R134a	R245fa	n-butane	isobutane
   CORRELATIONS	(W)	(W)	(W)	(W)	(W)
   Nusselts	14199	14585	14374	15402	14189
   Nusselts & Kerns	15470	15851	15643	16647	15461
   Dhir and Lienhard & Nusselts	14242	14628	14418	15444	14231
   Dhir and Lienhard & Kern's	15512	15892	15685	16687	15502

   130000

   120000

   110000

   100000

   90000

   80000

   R134a

   R123

   R245fa

   n-butane isobutane

   70000

   1

   2

   4

   6

   8

   cooling fluid mass flow rate (kg/coulmn-s)

   R 123

   R245fa

   27.00

   Average Exit Temperature (oC)

   Figure 9: Overall Thermal Load versus cooling fluid column mass flow rate (based on Dhir and Lienhard, and Kerns Correlations)

   29.00

   28.00

   R134a

   25.00

   1

   2

   4

   p>6

   8

   cooling fluid mass flow rate (kg/column-s)

   n-butane

   isobutane

   26.00

   Figure 10: average cooling fluid exit temperature versus cooling fluid column mass flow rate (based on Dhir and Lienhard, and Kerns Correlations)

6. DISCUSSIONS

   Figure 4 to 7 show that for all combinations of correlations two observations can be made: condensate heat transfer coefficient varies from a high on the first tube to a minimum on the last tube; and condensate heat transfer coefficients are highest with n-butane, followed by R134a, R245fa, and are lowest for R123 and isobutene; plots of values for the latter two appear superimposed.

   .

   Figure 8 shows that Kerns method gives higher values of the condensate heat transfer coefficient, varying from about 900 to 1900 W/m2.oC, as compared to the Nusselts correlation, where corresponding values vary from about 700 to 1900 W/m2 oC. The heat transfer coefficient for the first tube is almost the same regardless of whether the Nusselts or the Dhir and Lienhard correlation is used.

   In terms of thermal loads, table 1 and figure 9 show that n-butane gives the highest value followed by R134a, R245fa, and R123, with the lowest being obtained with isobutene.

   The average outlet temperatures of the ethylene glycol cooling fluid for each of the working fluids, figure 10, show a continuous decline with increases in cooling fluid mass flow rate; also n-butane gives the highest outlet temperatures; all the other fluids show superimposed plots of the outlet temperatures; outlet temperatures vary from a maximum of about 28.5oC to a minimum of about 25.8oC.

7. CONCLUSIONS

The paper has presented a condenser heat exchanger model suitable for incorporation into a low temperature solar thermal power cycle. The model consists of a flow of vapour over a bundle of horizontal tubes. The simulations have shown the effect of condensate inundation in reducing the heat transfer capacity of tubes low down in a column of horizontal tubes. The simulations have also shown that Nusselts correlations give more conservative values when compared to the Kerns method. All the working fluids depict similar device thermal exchange characteristics; n-

butane performs better than the other fluids whilst R123 and isobutene give the worst performance. Sizing of the heat exchanger is determined by the number of tube rows and columns; in this case, the simulations showed that 8 rows by 6 columns would be adequate for the given heat exchanger configuration and thermal load. These results are to be compared with the results of the on-going experiments.

ACKNOWLEDGMENTS

The authors would like to thank the Centre for Engineering Postgraduate Studies (CEPS) at University of KwaZulu-Natal for providing funds for certain aspects of the research as well as all colleagues, postgraduate students and staff of the section.

REFERENCES

1. Thome J.R. Engineering Data Book III; chapter 7: Condensation on External Surfaces, Laboratory of Heat and Mass Transfer, Swiss Federal Institute of Technology. Lausanne, Switzerland.

2. Thome J.R. Engineering Data Book III, Chapter 7, Fundamentals of Condensation on Tubes and Tube Bundles, Laboratory of Heat and Mass Transfer. Swiss Federal Institute of Technology. Lausanne, Switzerland.

3. Situmbeko SM., Inambao FL, Heat Exchanger Modelling for Solar Organic Rankine Cycle, paper accepted for publication in the International Journal of Thermal and Environmental Engineering,

   August, 2014

4. Sánta Róbert, The Analysis of Two-Phase Condensation Heat Transfer Models Based on the Comparison of the Boundary Condition in Acta Polytechnica Hungarica, Vol. 9, No. 6, 2012

5. Wei Xiaoyong, Fang Xiandel, and Shi Rongrong, A Comparative Study of Heat Transfer Coefficients for Film Condensation, Energy Science and Technology, Vol. 3, No. 1, 2012, pp. 1-9

6. http://www.thermopedia.com/content/1210/

7. Incropera FP, DeWitt DP. Fundamentals of heat and mass transfer (6th Ed.) Wiley.

8. Butterworth D. Developments in the design of shell and tube condenser. ASME; 1977. Paper 77-WA/HT-24.

9. Eissenberg DM. An investigation of the variable affecting steam condensation on the outside of a horizontal tube bundle. PhD thesis, University of Tennessee, Knoxville; 1972.

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