Energy Management in Industry

(sECOND SEMESTER)
Palembang, March 25
th
, 2014

DOUBLE MASTER DEGREE
ENERGY/ENVIRONMENTAL TECHNOLOGY AND
MANAGEMENT
MAGISTER OF CHEMICAL ENGINEERING
2014

CRITICAL RADIUS OF INSULATION
Adding more insulation to a wall or to the attic
always decreases heat transfer.
The thicker the insulation, the lower the heat
transfer rate. This is expected, since the heat
transfer area, A, is constant, and adding insulation
always increases the thermal resistance of the insu-
lation without increasing the convection resistance.
Adding insulation to a cylindrical pipe or a spherical
shell, however, is a different matter.
The additional insulation increases the conduction
resistance of the insulation layer but decreases the
convection resistance of the surface due to the
increase in the outer surface area for convection.

The heat transfer from the pipe may increase or
decrease, depending on which effect
dominates.
The critical radius of insulation, r
cr, cyl
for a
cylindrical body can be calculated by using the
following equation:
r
cr, cyl
=


where:
k
i
= the thermal conductivity of the insulation
h = the external convection heat transfer
coefficient .

h
k
i
The rate of heat transfer from the cylinder increases
with the addition of insulation for r
2
< r
cr, cyl
,
reaches a maximum when r
2
= r
cr, cyl
, and starts to
decrese for r
2
> r
cr, cyl
.
Thus, insulating the pipe may actually increase the
rate of heat transfer instead of decreasing it when
r
2
< r
cr, cyl .

Worked Example
3. A pipeline system is used for distributing steam in a
factory. The total length of the pipeline is 80 (m)
with the thickness of 3 mm and the inside diameter
of 74 (mm). Thermal conductivities of the pipe are
52 (W/m.C) at 200 C and 50 (W/m.C) at 300 C. The
pipe is covered with an insulation having thermal
conductivity of 0.2184 (W/m.C). The temperature at
inner surface of the pipe is 260 C while the room
temperature in which the pipeline located is 86 F.
The convection heat transfer coefficient
between insulation and room air is 5.20
(W/m
2
.C) and the convection heat
transfer coefficient between steam and
inside surface of the pipe is 10.5
(W/m
2
.C). With consideration of thermal
conductivity of the pipe at inside surface
temperature, determine:
a). Heat flow rate if the insulation
thickness is equal to critical insulation
thickness.
b). Heat flow rate of the naked pipe if the
convection heat transfer coefficient between
outside surface of the pipe and the room air
is the same as convection heat transfer
coefficient between outside surface of the
insulation and the room air.
c). The temperature at outer surface of the pipe
at point a).
d). Insulation thickness needed to decrease heat
loss as much as 20 % from the heat loss
without insulation.
e. Heat energy released by steam in 1.5 hours at
point a). and point d).

Solution:
Pipe length, L = 80 (m)
Pipe thickness, t = 3 (mm) = 0.003 (m)
Room temperature, T
r
= 86F = (86-32)/1.8 = 30 C
Temperature at inside surface of pipe, T
p,i
= 260 C
Convection heat transfer coefficient between the
insulation and the room air, h
o
= 5.2 (W/m
2
.C)
Convection heat transfer coefficient between the
steam and inside surface of pipe, h
i
=10.5 (W/m
2
.C)

The inside diameter of the pipe, d
p,i
= 74 (mm)
The inside radius of the pipe, r
p,i
= 37 (mm) = 0.037 (m)
The outside radius of the pipe, r
p,o
= 40 (mm) = 0.040 (m)

At 200 C: thermal conductivity of the pipe, k
p
=52 (W/m.C)
At 300 C: thermal conductivity of the pipe, k
p
=50 (W/m.C)

By interpolation, thermal conductivity of the pipe at 260 C:
(W/m.C) 50.8 ) 52 (50
200 300
200 260
52 kp
(260C)
=

+ =
Critical radius of insulation,
where :
k
i
= thermal conductivity of insulation = 0.2184 (W/m.C)
h
o
= 5.2 (W/m
2
.C)

Therefore:

a). Heat flow rate if the insulation thickness is equal to
critical insulation thickness:

o
i
c
h
k
r =
(m) 0.042
5.2
0.2184
r
c
= =
h x r
1
ki
) /r ln(r
k
) /r ln(r
) T - (T L 2
Q
o c
o p, c
p
i p, o p,
r i p,
c
+ +
=



a). Q
c
= 24054.85 (W)

b). Heat flow rate of the naked pipe (Q
naked
):

5.20 x 0.042
1
0.2184
.040) ln(0.042/0
50.8
.037) ln(0.040/0
30) - (260 80 x 3.14 x 2
Q
c
+ +
=
5.20 x 0.040
1
50.8
.037) ln(0.040/0
30) - (260 80 x 3.14 x 2
Q
h x r
1
k
) /r ln(r
) T - (T L 2
Q
naked
o o p, p
p,i o p,
r p,i
naked
+
=
+
=
b). Q
naked
= 24,027.15 (W)

c). Determination of the temperature at outer
surface of the pipe at point a).


p
p,i o p,
o p, p,i
a).
k
) /r ln(r
) T - (T L 2
Q =
p
p,i o p,
o p, p,i
k
) /r ln(r
) T - (T x 80 x 3.14 x 2
24054.85 =



Tp,o = 259.9 C
c). The temperature at outer surface of the
pipe at point a). is, Tp,o = 259.9 C

d). Determination of insulation thickness
needed to decrease heat loss as much as
20 % from the heat loss without
insulation.





p
p,i o p,
o p, p,i
k
) /r ln(r
) T - (T x 80 x 3.14 x 2
24054.85 =
Q
0.8naked
= 0.8 x Q
naked
= 0.8 x 24027.15 = 19221.72 (W)
h . r
1
ki
) /r ln(r
k
) /r ln(r
) T - (T L 2
Q
o x
o p, x
p
p,i o p,
r p,i
0.8Qnaked
+ +
=
5.20 . r
1
0.2184
/0.040) ln(r
50.8
.037) ln(0.040/0
30) - (260 x 80 x 3.14 x 2
19221.72
x
x
+ +
=
r 5.20
1
0.2184
/0.040) ln(r
001534676 . 0
115552
19221.72
x
x
+ +
=







For: r
x
= 0.080 X = 1.218147181
r
x
= 0.098 X = 1.324659453

009998111 . 6
r 5.20
1
0.2184
/0.040) ln(r
x
x
= +
009998111 . 6
r 5.20
1
0.2184
/0.040) ln(r
x
x
= +
X 312583587 . 1
r
0.042
040 . 0
r
ln
x
x
= = +
|
.
|

\
|
) 080 . 0 098 . 0 (
1 1.21814718 - 3 1.32465945
1 1.21814718 - 7 1.31258358
0.080 r
x
+ =
r
x
= 0.0960 (m)
Insulation thickness, ti = 0.0960 0.040 = 0.056 (m)
d). The insulation thickness needed, ti = 56.0 (mm)

e). Determination of Heat energy released by steam in
1.5 hours at point a). and point d).

Heat energy released by steam in 1.5 hours at point a).:
Q
a) in 1.5 h
= 24054.85 (J/s) x 1.5 x 3600 (s) = 129896190 (J).

Heat energy released by steam in 1.5 hours at point d).:
Q
d) in 1.5 h
= 19221.72 (J/s) x 1.5 x 3600 (s) = 103797288 (J).



HOMEWORK

Subject : Energy Management in Industry
Delivered : Tuesday, March 25
th
, 2014
Collected : Tuesday, April 1
st
, 2014
Lecturer : Dr. Riman Sipahutar
Problem:
1 Steam at T
h
= 572 F flows in a cast iron pipe (k = 80 W/m.C) whose inner and outer
diameters are D
1
= 60 mm and D
2
= 66 mm, respectively. The pipe is covered with 35-mm
thick glass wool insulation with k = 0.05 W/m.C. Heat is lost to the surroundings at T
c
=
77 F by natural convection and radiation, with a combined heat transfer coefficient of h
c

= 16 W/m
2
.C. Taking the heat transfer coefficient inside the pipe to be h
h
= 60 W/m
2
.C.
Determine:
a. The rate of heat loss from the steam for the pipe length of 10 m.
b. The temperature drops across the pipe shell and the insulation in degree C.
c. The temperatures at inner and outer surfaces of the pipe in degree C.
d. The temperatures at inner and outer surfaces of the insulation in degree C.
e. The rate of heat loss from the steam for the pipe length of 10 m, without insulation.
f. The percentage of energy saving for the system by using 35-mm thick glass wool
insulation with k = 0.05 (W/m.C) compared with the system without insulation.





Thank You

and

See you next week