Govt. Exams
Entrance Exams
In the complete turbulence zone (very high Reynolds numbers), the friction factor depends only on the relative roughness (ε/D) and becomes independent of Reynolds number. This is because inertial forces completely dominate over viscous forces.
In heat exchanger design, outlet temperatures are unknown, making the LMTD method iterative and cumbersome. The NTU method (ε-NTU) directly uses inlet temperatures and known parameters to find the outlet temperatures without iteration, making it ideal for design problems.
The approach temperature is defined as: Approach = T_gas,out - T_steam,out. Given that typical exhaust exit from HRSG is around 450°C and approach is 5°C, T_steam,out = 450 - 5 = 445°C.
The Colburn factor (j) is a dimensionless group that relates heat transfer characteristics to flow properties. It connects the Stanton number to the Prandtl number: St = j/Pr^(2/3), allowing transfer of empirical heat transfer data to different systems.
For energy balance: Ch(Th,in - Th,out) = Cc(Tc,out - Tc,in). So Ch(100-60) = Cc(50-30), which gives Ch/Cc = 20/40 = 0.5. This is the capacity rate ratio.
x_th = 0.05 × Re × Pr × D = 0.05 × 1000 × 7 × 0.025 = 8.75 m. This is the distance from the entrance where thermal development is completed (approximately 99% developed).
Using Q = UAΔT and considering fouling resistance: ΔT_fouling = Q × Rf / A = 5×10⁶ × 0.0005 / 100 = 25 K. However, for the temperature loss specifically attributed to fouling layer: ΔT = Rf × (Q/A) = 0.0005 × (5×10⁶/100) = 2.5 K.
The Grashof number Gr = (ρ²gβΔT L³)/(μ²) represents the ratio of buoyancy forces to viscous forces in natural convection. It determines the onset of natural convection and its intensity.
In cross-flow (especially unmixed-unmixed), the temperature gradients are not as favorable as counter-flow because one or both fluids cannot maintain continuous temperature gradient alignment, resulting in lower effectiveness and hence lower LMTD correction factor.
Thermographic imaging using infrared cameras is a non-intrusive, real-time method that can measure surface temperature variations across the heat transfer surface without disturbing the flow, making it practical for industrial monitoring.