I am in the process of redesigning a cooling loop for a expanded polystyrene extruder. I would like to develop a better understanding of the cooling loop especially under differing process variables.
Here is a brief description. There are two loops, the process loop and the cooling loop.
The process loop is water circulated through the extruder to control the extruder's temperature. It consists of a reservoir (open to atmosphere) a pump, a flat brazed heat exchanger and control valves to meter the process water through different extruder zones as needed.
The cooling loop will supply cooled water to one side of the heat exchanger to remove heat from the process water running through the other side. The cooling loop consists of a water to air fluid cooling unit with a pump and temperature controls.
The design assumes a max steady state heat transfer of 3.5 tons (42000 BTU/hr). The lower temp process water leaving the heat exchanger and traveling to the extruder is required to be held to 110°F. The process water flow is 10 gpm. This equates to a 8.4°F delta T on the process side.
My first goal is to determine what happens as I change the cooling loop flow rate.
Please bear with me.
Let's simplify the effects of the heat exchange by assuming it is oversized and requires a minimal log mean temperature difference (LMTD)between the process and the cooling water. Assume under 1°F. The heat exchanger is plumbed for counter flow. The hot process water enters on same end as the "cold" cooling water. The heat exchanger is so oversized that the lower temp process water leaving the heat exchanger is almost the same temperature as the "cold" cooling water entering it. Let's say its 1°F warmer. By the same token the "warm" chilled water leaving the heat exchanger is almost the same temperature as the hot process water entering the heat exchanger. Again let's say 1°F.
In my prior calculations it appeared that the LMTD is pretty close to the difference of the average temperature of the process flow and cooling flow across the heat exchanger. We will use this average difference to keep things simple.
Here are one set of steady state conditions: Heat transfer 42000 BTU/Hr Cooled Cooling Water entering heat exchanger 110°F Requirement Cooled Process Water leaving heat exchanger 111°F Assumed with oversized heat exchanger Process Water flow 10 gpm Typical actual value Delta T for Process Water 8.4°F Calculated from previous values. Hot Process Water temperature 119.4°F 111+8.4
"Warm" cooling water temperature 118.4°F Assumed with oversized heat exchanger Cooling Water flow 10 gpm Same heat transfer and delta T so same flow
Any problems yet with what I have done so far?
NOW INCREASE COOLING WATER FLOW RATE WHILE STILL MAINTAINING 110°F AT "COLD" COOLING WATER INLET AT HEAT EXCHANGER.
Cooling Water flow increased. Same heat transfer, initially at least. "Cold" Cooling Water temp maintained at same 110°F Delta T on cooling loop must decrease. This decreases "warm" cooling water temperature. This decreases average of cooling water temperatures and increases LMTD. I would expect that increasing LMTD will increase heat transfer. BUT The Cooled Process Water temp is still 111°F as the "Cold" cooling water is held at 110°F and heat exchanger is oversized. The heat load on the process side has not changed. It is still
42000BTU/Hr. The process loop flow is not changed. Still 10 gpm. Therefore the "Hot" Process Water temperature must remain the same.The apparent paradox is that increasing cooling loop flow should transfer more heat at least for a period of time and alter the process temperatures. But the process temps are set by load, flow rate, and the assumed 111°F temp at process exit from heat exchanger.
I appreciate all who persevered through this long post. I have faith that someone will see the flaw(s) in my analysis.
Dave Miller snipped-for-privacy@rochester.rr.com