Kern's Process Heat Transfer (2^nd Ed.)

This edition ensures the legacy of the original 1950 classic,Process Heat Transfer, by Donald Q. Kern that by many is held to be the gold standard.

This second edition book is divided into three parts: Fundamental Principles; Heat Exchangers; and Other Heat Transfer Equipment/ Considerations.

• Part I provides a series of chapters concerned with introductory topics that are required when solving heat transfer problems. This part of the book deals with topics such as steady-state heat conduction, unsteady-state conduction, forced convection, free convection, and radiation.
• Part II is considered by the authors to be the "meat" of the book, and the primary reason for undertaking this project. Other than minor updates, Part II remains relatively unchanged from the first edition. Notably, it includes Kern's original design methodology for double-pipe, shell-and-tube, and extended surface heat exchangers. Part II also includes boiling and condensation, boilers, cooling towers and quenchers, as well as newly designed open-ended problems.
• Part III of the book examines other related topics of interest, including refrigeration and cryogenics, batch and unsteady-state processes, health & safety, and the accompanying topic of risk. In addition, this part also examines the impact of entropy calculations on exchanger design.

A 36-page Appendix includes 12 tables of properties, layouts and design factors.

WHAT IS NEW IN THE 2^ND EDITION

Changes that are addressed in the 2^nd edition so that Kern's original work continues to remain relevant in 21st century process engineering include:

• Updated Heat Exchanger Design
• Increased Number of Illustrative Examples
• Energy Conservation/ Entropy Considerations
• Environmental Considerations
• Health & Safety
• Risk Assessment
• Refrigeration and Cryogenics

Table of Contents (First Edition) vii

Preface to the First Edition xiii

Preface to the Second Edition xv

Acknowledgement xix

Part I Fundamentals and Principles 1

1. Introduction to Process Heat Transfer 3

1.1 Units and Dimensional Analysis 4

1.2 Key Physical Properties 10

1.3 Key Process Variables and Concepts 14

1.4 Laws of Thermodynamics 22

1.5 Heat-related Theories and Transfer Mechanisms 26

1.6 Fluid Flow and Pressure Drop Calculations 28

1.7 Process Heat Transfer 35

Reference 40

2 Steady-State and Unsteady-State Heat Conduction 43

2.1 Flow of Heat through a Wall 46

2.2 Flow of Heat through a Composite Wall: Resistances in Series 50

2.3 Flow of Heat through a Pipe Wall 54

2.4 Microscopic Approach: Steady-State Conduction 63

2.5 Unsteady-State Heat Conduction 68

2.6 Microscopic Approach: Unsteady-State Conduction 71

Reference 77

3 Forced and Free Convection 79

3.1 Forced Convection Principles 82

3.2 Convective Resistances 87

3.3 Heat Transfer Coefficients: Quantitative Information 89

3.4 Convection Heat Transfer: Microscopic Approach 105

3.5 Free Convection Principles and Applications 108

3.6 Environmental Applications 120

Reference 126

4 Radiation 129

4.1 The Origin of Radiant Energy 132

4.2 The Distribution of Radiant Energy 133

4.3 Radiant Exchange Principles 138

4.4 Kirchoff ’s Law 139

4.5 Emissivity Factors and Energy Interchange 145

4.6 View Factors 152

Reference 157

Part II – Heat Exchangers 159

5. The Heat Transfer Equation 161

5.1 Heat Exchanger Equipment Classification 162

5.2 Energy Relationships 163

5.3 The Log Mean Temperature Difference (LMTD) Driving Force 166

5.4 The Overall Heat Transfer Coefficient 183

5.5 The Heat Transfer Equation 208

Reference 216

6 Double Pipe Heat Exchangers 217

6.1 Equipment Description and Details 218

6.2 Key Describing Equations 225

6.3 Pressure Drop in Pipes and Pipe Annuli 244

6.4 Calculation of Exit Temperatures 251

6.5 Open-Ended Problems 254

6.6 Kern’s Design Methodology 262

Reference 286

7 Shell and Tube Heat Exchangers 287

7.1 Equipment Description and Details 288

7.2 Key Describing Equations 305

7.3 Open-Ended Problems 331

7.4 Kern’s Design Methodology 337

7.5 Other Design Procedures and Applications 348

7.6 Computer Aided Heat Exchanger Design 370

Reference 377

8 Finned heat Exchangers 379

8.1 Fin Details 380

8.2 Equipment Description 386

8.3 Key Describing Equations 388

8.4 Fin Effectiveness and Performance 396

8.5 Kern’s Design Methodology 416

8.6 Other Fin Considerations 430

Reference 432

9 Other Heat Exchangers 433

9.1 Condensers 435

9.2 Evaporators 447

9.3 Boilers and Furnace 466

9.4 Waste Heat Boilers 476

9.5 Quenchers 484

9.6 Cogeneration/Combined Heat and Power 488

9.7 Cooling towers 494

9.8 Heat pipes 504

Reference 506

Part III – Peripheral Topics 509

10 Other Heat Transfer Considerations 511

10.1 Insulation and Refractory 512

10.2 Refrigeration and Cryogenics 529

10.3 Instrumentation and Controls 542

10.4 Batch and Unsteady-state Processes 551

10.5 Operation, Maintenance and Inspection (OM & I) 558

10.6 Economics and Finance 565

Reference 581

11. Entropy Considerations and Analysis 585

11.1 Qualitative Review of the Second Law 586

11.2 Describing Equations 587

11.3 The Heat Exchanger Dilemma 591

11.4 Application to a Heat Exchanger Network 599

Reference 602

Chapter 12 – Health and Safety Concerns 603

12.1 Definitions 607

12.2 Legislation 616

12.3 Material Safety Data Sheets (MSDSs) 619

12.4 Health Risk versus Hazard Risk 624

12.5 Health Risk Assessment 625

12.6 Hazard Risk Assessment 636

Reference 646

Appendix 649

AT.1 Conversion Constants 641

AT.2 Steam Tables 653

AT.3 Properties of Water (Saturated Liquid) 662

AT.4 Properties of Air at 1 atm 664

AT.5 Properties of Selected Liquids at 1 atm and 20°C (68°F) 665

AT.6 Properties of Selected Gases at 1 atm and 20.°C (68.°F) 667

AT.7 Dimensions, Capacities, and Weights of Standard Steel Pipes 669

AT.8 Dimensions of Heat Exchanger Tubes 671

AT.9 Tube-Sheet Layouts (Tube Counts) on a Square Pitch 673

AT.10 Tube-Sheet Layouts (Tube Counts) on a Triangular Pitch 675

AT.11 Approximate Design Overall Heat Transfer Coefficients (Btu/hr∙ft2.°F) 678

AT.12 Approximate Design Fouling Coefficient Factors (hr∙ft2.°F/Btu) 679

Figures

AF.1 Fanning Friction Factor (f) vs. Reynolds Number (Re) Plot 683

AF.2 Psychometric Chart: Low Temperatures: Barometric Pressure, 29.92 in. Hg. 684

AF.3 Psychometric Chart: High Temperatures: Barometric Pressure, 29.92 in. Hg. 685

Index 000

Ann Marie Flynn, PhD, the first female Manhattan College graduate to return to the school as a full-time faculty member, served as the department chair and graduate program director during her 27-year tenure in the chemical engineering department where she received multiple awards for teaching and leadership. She used Donald Q. Kern's text almost exclusively during the 16- year period when she taught Heat Transfer, and undertook the writing of the 2nd edition to bring Kern's straight forward approach towards heat exchanger design to the next generation of engineers.

Toshihiro Akashige, B.S. Chem. Eng., is a graduate from Manhattan College and currently enrolled in a PhD program for chemical and biomolecular engineering at the New York University Tandon School of Engineering. He particularly enjoyed process heat transfer class taught by Dr. Flynn and eventually joined in co-authoring this textbook with a hope that Dr. Kern's design methodology will help many other students and future engineers gain comfort in the technical knowledge of heat exchangers.

Louis Theodore, MChE and EngScD, is a retired professor of chemical engineering (50 years). He is the author of several publications, including Fluid Flow for the Practicing Chemical Engineer, Thermodynamics for the Practicing Engineer, Mass Transfer Operations for the Practicing Engineer, and Air Pollution Control Equipment Calculations. Dr. Theodore is also a contributor to Perry's Chemical Engineers' Handbook.