Lecture 4 - Process Applications
Lecture 4 - Process Applications
Wei Yan
Flow processes
Introduction
Duct flow of compressible fluids
Turbines (expanders)
Compressors and pumps
Power generation
Introduction
Steam power plan
Internal combustion engine
Jet engines
Refrigeration and liquefaction
Introduction
Carnot refrigerator
Adsorption refrigeration
Heat pump
Liquefaction processes (Linde, Claude…)
2
Introduction: Application of thermodynamics
to flow processes
The thermodynamics of flow is based on the mass, energy, and entropy balances.
The discipline underlying the study of flow is fluid mechanics, which encompasses
not only the balances of thermodynamics but also a momentum balance that arises
from the laws of classical mechanics (Newton’s laws). This makes fluid mechanics a
broader field of study. The distinction between thermodynamics problems and fluid-
mechanics problems depends on whether this momentum balance is required for
solution. Those problems whose solutions depend only on mass conservation and on
the laws of thermodynamics are commonly set apart from the study of fluid
mechanics and are treated in courses on thermodynamics. Fluid mechanics then deals
with the broad spectrum of problems which require application of the momentum
balance.
3
Duct flow of compressible fluids
Sizing of pipes and shaping of nozzles require application of the momentum balance
of fluid mechanics, and therefore are not part of thermodynamics.
Thermodynamics does provide equations that interrelate the changes in pressure,
velocity, cross sectional area, enthalpy, entropy, and specific volume of a flowing
stream.
We consider here the adiabatic, steady-state, one-dimensional flow of a
compressible fluid in the absence of shaft work and of changes in potential energy.
u 2
Energy balance H 0
2
dH udu (differential form) (7.3)
4
Duct flow of compressible fluids
V V
dV dS dP
S P P S
V V T VT
1st term on RHS:
S P T P S P CP
V V V2
2nd term on RHS: c V
2 2
2
P S P S c
dV T V
dS 2 dP (7.5)
V CP c
5
Duct flow of compressible fluids
With the above 4 equations, we treat dS and dA as independent and develop equations
that express the remaining differentials as functions of these two.
u2 2
C M
2
1 u
udu P TdS
2
dA 0
1 M 2
1 M A (7.8)
Equation (7.8) relates du to dS and dA. Combined with Eq. (7.3) it relates dH to dS
and dA, and combined with Eq. (7.4) it relates dV to these independent variables. 6
Duct flow of compressible fluids
For fluid traversing a differential length dx of its path, Eqs. (7.7) and (7.8) become
dP u 2 dS u 2 dA
(1 M )V
2
1 T 0 (7.9)
dx CP dx A dx
u2 2
du CP dS
M
2
T 1 u dA
u 2
0 (7.10)
dx 1 M 2
dx 1 M A dx
According to the second law, we have for adiabatic flow
dS irreversible
0
dx reversible
7
Duct flow: Pipe flow
For the case of steady-state adiabatic flow of compressible fluids in a horizontal pipe
of constant cross-sectional area, dA/dx=0, and Eqs. (7.9) and (7.10) reduce to
u2 u2 2
1 C dS
T CP dS
M
dP du
u T P
dx V 1 M dx
2
dx 1 M dx
2
For subsonic flow, M2<1 and we have
dP du
0 and 0
dx dx
The pressure decreases and the velocity increases in the direction of flow.
The velocity cannot exceed the sonic value. Otherwise the above inequalities would
reverse.
The equations for pipe flow indicate that when flow is supersonic the pressure
increases and the velocity decreases in the direction of flow. However, such a flow
regime is unstable. When a supersonic stream enters a pipe of constant cross section,
a compression shock occurs, the result of which is an abrupt and finite increase in
pressure and decrease in velocity to a subsonic value 8
Duct flow: Nozzles
Nozzles have changing cross-sectional area available for flow that results in the
interchange of internal and kinetic energy of a fluid.
The design of effective nozzles is a problem in fluid mechanics, but the flow through
a well-designed nozzle is susceptible to thermodynamic analysis
In the limit of reversible flow, dS/dx=0 and Eqs. (7.9) and (7.10) become:
dP u 2 1 dA du 1 u dA
2
dx 1 M A dx
dx VA 1 M 2 dx
For subsonic flow in a converging nozzle, the velocity increases and the pressure
decreases as the cross-sectional area diminishes. The maximum obtainable fluid
velocity is the speed of sound, reached at the exit.
Supersonic velocities are readily attained in the diverging section of a properly
designed converging/diverging nozzle. With sonic velocity reached at the throat, a
further increase in velocity and decrease in pressure requires an increase in cross-
sectional area, a diverging section to accommodate increasing volume of flow.
P2
P1
The speed of sound is attained at the throat of a converging/diverging nozzle only when
the pressure at the throat is low enough that the critical value of P2/P1 is reached. If
insufficient pressure drop is available in the nozzle for the velocity to become sonic,
the diverging section of the nozzle acts as a diffuser (i.e., the pressure rises and the
velocity decreases)
10
Duct flow: Nozzles
The relation of velocity to pressure in an isentropic nozzle for ideal gas with
constant heat capacities.
Combine Eqs. (6.9) and (7.3): udu VdP
Integration, with nozzle entrance and exit conditions denoted by 1 and 2, yields:
( 1)/
2 PV P
u2 u1 2 VdP
P2
2 2 1 1
1 2 (7.11)
P1 1 P1
Here we have used PV γ = const. for adiabatic process.
Equation (7.11) may be solved for the pressure ratio P2/P1 for which u2 reaches the
speed of sound, i.e. where
P 2 P2
u22 c 2 V22 V2 PV
V S ,V V2
2 2
V2
If we set u1=0, solution for the pressure ratio at the throat gives
/( 1)
P2 2
P1 1 11
Duct flow: Throttling process
When a fluid flows through a restriction, such as an orifice, a partly closed valve, or
a porous plug, without any appreciable change in kinetic or potential energy, the
primary result of the process is a pressure drop in the fluid.
Such a throttling process produces no shaft work, and in the absence of heat transfer,
the energy balance becomes
H 0 or H 2 H1
The enthalpy of an ideal gas depends on temperature only, a throttling process does
not change the temperature of an ideal gas.
For most real gases at moderate conditions of temperature and pressure a reduction
in pressure at constant enthalpy results in a decrease in temperature.
The system can be in a two-phase state after throttling.
12
Duct flow: Throttling process
13
Duct flow: Throttling process
H S V
V T V T
P T P T T P
Here we have used the Maxwell relation (∂S/∂P)T = - (∂V/∂T)P . Substituting V=ZRT/P
allows this equation to be rewritten in terms of Z as
H RT 2 Z
P T P T P
14
Duct flow: Throttling process
15
Duct flow: Turbines (Expanders)
16
Duct flow: Turbines (Expanders)
Energy balance
WS H H 2 H1 WS mH m( H 2 H1 )
Usually, the inlet conditions T1 and P1 and the discharge pressure P2 are fixed.
Therefore, only H1 is known; both H2 and WS are unknown.
If the fluid in the turbine expands reversibly and adiabatically, the process is
isentropic, and
S2 S1
This second equation fixes the final state of the fluid and determines H2.
WS (isentropic) (H ) S
The shaft work 𝑊𝑆 (isentropic) is the maximum that can be obtained from an
adiabatic turbine with given inlet conditions and given discharge pressure.
Actual turbines produce less work due to irreversibility. The turbine efficiency is
defined by WS
WS (isentropic)
17
Duct flow: Turbines (Expanders)
Apparently,
H
(H ) S
Values of η often fall in the range from 0.7 to 0.8. The following HS diagram
illustrates an actual expansion in a turbine and a reversible expansion for the same
intake conditions and the same discharge pressure.
18
Duct flow: Compressor
WS H H 2 H1
WS mH m( H 2 H1 )
19
Duct flow: Compressor
In a compression process, the isentropic work is the minimum shaft work required
for compression of a gas from a given initial state to a given discharge pressure.
The compressor efficiency
WS (isentropic)
WS
It can also be given by
(H ) S
H
20
Duct flow: Pumps
Liquids are usually moved by pumps, which are generally rotating equipment.
The same energy balance equation Ws = ΔH applies. Since the values of the enthalpy
of compressed (subcooled) liquids are seldom available, some further derivations
may be made:
dH VdP (const S )
P1
Also we can utilize the following equations
dT
dH CP dT V (1 T )dP dS CP VdP
T
Considering temperature changes in the pumped fluid are very small and the properties
of liquids are insensitive to pressure, we have
T
H CP T V (1 T )P S CP ln 2 V P
T1
21
Introduction: Production of power from heat
22
Steam power plant
23
Steam power plant: Carnot cycle
The Carnot cycle has severe practical difficulties in steps 23 and 41. Step 2-3
requires a turbine to take in saturated steam and produce an exhaust with high liquid
content (severe erosion problems). Step 41 needs a pump that takes in a mixture of
liquid and vapor (cavitation problems) and discharge a saturated liquid.
An alternative cycle is taken as the standard, at least for fossil-fuel-burning power
plants.
Step 12: A constant-pressure heating
process in a boiler.
Step 23: Reversible, adiabatic (isentropic)
expansion of vapor in a turbine to
the pressure of condenser.
Step 34: A constant-pressure, constant-
temperature process in a condenser.
Step 41: Reversible, adiabatic (isentropic)
pumping to the pressure of the boiler.
Point 1: Subcooled liquid
Point 2: Superheated vapor
Point 3: Two-phase mixture with a modest moisture content
25
Point 4: Saturated liquid
Steam power plant: Rankine cycle
Power plants actually operate on a cycle that departs from the Rankine cycle due to
irreversibilities of the expansion and compression steps. Steps 23 and 41 are
affected by these irreversibilities. The lines on the TS diagram are no longer vertical
but tend in the direction of increasing entropy.
The turbine exhaust is normally still wet, but with sufficiently low moisture content.
Slight subcooling in the condenser may occur, but the effect is inconsequential.
For the boiler and the condenser, the energy balance neglecting kinetic- and
potential-energy changes is Q H Q mH
26
Steam power plant: Rankine modifications
27
Steam power plant: Regenerative cycles
28
Steam power plant with feedwater heating
29
Internal-combustion engines
In a steam power plant, the steam is an inert medium to which heat is transferred
from an external source. It is therefore characterized by large heat-transfer surfaces
(both for the absorption of heat and for the rejection of heat). The ability of the walls
to withstand high temperatures and pressures imposes a limit on the temperature of
heat absorption.
In an internal-combustion engine, a fuel is burned within the engine itself, and the
combustion products serve as the working medium. No heat-transfer surfaces are
needed.
The analysis for internal-combustion engine is however more complicated. There is
no working medium undergoes a cyclic process. Usually, one imagines cyclic
engines with air as the working fluid. The combustion step is replaced by the addition
to the air of an equivalent amount of heat. By assuming ideal-gas state for the air, a
quantitative analysis of an ideal cycle for each internal-combustion engine is possible.
30
The Otto engine
Four strokes:
01: an intake stroke
123: All valves closed; Fuel/air mixture
compressed approximately adiabatically (12);
Ignition, combustion, rapid pressure increase at
nearly constant volume (23)
341: Approximately adiabatic expansion (34);
The exhaust value opens and the pressure falls
rapidly at nearly constant volume (34)
10: The piston pushes the remaining combustion
gases from the cylinder.
The effect of increasing the compression ratio—the ratio of the volumes at the
beginning and the end of compression from point 1 to point 2—is to increase the
efficiency of the engine, i.e., to increase the work produced per unit quantity of fuel.
31
Internal-combustion engines
The thermal efficiency increases with r: more rapidly at low values of r but more
slowly at high values of r.
Compression ratios in automobile engines are usually not much above 10.
32
The Diesel Engine
constant pressure 1/ re 1/ r
re VBig / VAig is the expansion ratio
For the same compression ratio, the Otto engine has a higher efficiency than the Diesel
engine. But the Diesel engine operates at a higher compression ratios, and consequently
at higher efficiencies. Compression ratios can exceed 20 in Diesel engines employing
indirect fuel injection.
33
The gas turbine engine
Turbines are more efficient than reciprocating engines. This is utilized in the gas-
turbine engine.
The higher temperature of the combustion gases entering the turbine, the higher the
efficiency of the unit. The limiting temperature is determined by the strength of the
metal turbine blades and is generally much lower than the theoretical flame
temperature of the fuel. Sufficient excess air must be supplied to keep the
combustion temperature at a safe level.
34
The gas turbine engine
( 1)/
T T P
1 D A 1 A
TC TB PB
35
Introduction: Refrigeration and liquefaction
The word refrigeration implies the maintenance of a temperature below that of the
surroundings.
Best known for its use in the air conditioning of buildings and in the
preservation of foods and chilling of beverages
Large-scale commercial processes requiring refrigeration: the manufacture of ice
and solid CO2, the dehydration and liquefaction of gases, and the separation of
air into oxygen and nitrogen
36
The Carnot refrigerator
A refrigerator is a heat pump that absorbs heat from a region at a temperature below
that of the surroundings and rejects heat to the surroundings. It operates with the
highest possible efficiency on a Carnot refrigeration cycle, the reverse of the Carnot
engine cycle (see (b))
37
The Carnot refrigerator
A refrigerator is a heat pump that absorbs heat from a region at a temperature below
that of the surroundings and rejects heat to the surroundings. It operates with the
highest possible efficiency on a Carnot refrigeration cycle, the reverse of the Carnot
engine cycle (see (b))
38
The Carnot refrigerator
5 273.15
11.13
(30 273.15) (5 273.15)
The calculation is valid only for a refrigerator operating on a Carnot cycle
It corresponds to the maximum possible COP
COP is often greater than 1
39
The vapor-compression cycle
40
The vapor-compression cycle
Energy balance:
QC H 2 H1 QH H 4 H 3 W H3 H 2 H 4 H1
COP H 2 H1
H3 H 2
42
The choice of refrigerant
The COP of a Carnot refrigerator does not depend on the working medium
(refrigerant). The irreversibilities have somewhat dependence on the refrigerant.
The choice of refrigerant is based on the characteristics such as toxicity,
flammability, cost, corrosion properties, and vapor pressure. Environmental concerns
strongly constrain the choice of refrigerant.
Industrial refrigerants: ammonia, methyl chloride, carbon dioxide, propane, and
other hydrocarbons
Halogenated hydrocarbons: came into common in 1930s; too stable and destroy
stratospheric ozone; replaced by less-than-fully halogenated hydrocarbons or
hydroflurocarbons.
TS TC
A Carnot refrigerator W QC
TC QH TH TS TC
A Carnot engine QH W
TH QC TH TS TC
TH TS
The value of QH/QC given by the above equation is a minimum limiting value for
absorption refrigeration 44
Absorption refrigeration
The heat pump, a reversed heat engine, is a device for heating houses and
commercial buildings during the winter and cooling them during the summer. In the
winter it operates so as to absorb heat from the surroundings and reject heat into the
building. In the summer the flow of refrigerant is simply reversed, and heat is
absorbed from the building and rejected through underground coils or to the outside
air.
47
Heat pump
Solution:
The minimum power requirements are provided by a Carnot heat pump. For winter
heating, the house coils are at the higher-temperature level TH, and the heat requirement
is QH = 30 kJ⋅s−1. Application of Eq. (5.4) gives:
T 10 273.15 1
QC QH C 30 28.02 kJ s
TH 30 273.15
This is the heat absorbed in the ground coils. By Eq. (9.1),
TH TC 25 5 1
W QC 60 4.31 kJ s
TH 5 273.15
The power requirement here is therefore 4.31 kW. Actual power requirements for
practical heat pumps are likely to be more than twice this lower limit. 48
Liquefaction processes
Widely used liquefied gases : liquid propane, liquid oxygen, LNG, liquid nitrogen
Three ways to liquefy gases:
1. Heat exchange at const. P
2. Isentropic expansion
3. Throttling
The change from state A to A′ may be accomplished by compression of the gas to the
pressure at B and constant-pressure cooling to A′. For air at 160 K, the pressure must
be greater than around 80 bar for any liquefaction to occur along the path of constant
enthalpy.
A more efficient process liquefaction process would replace the throttle valve with
an expander, but operating such a device into the two-phase region is impractical. 50
Claude liquefaction process
In the Claude process, gas at an intermediate temperature is extracted from the heat-
exchange system and passed through an expander from which it exhausts as a
saturated or slightly superheated vapor. The remaining gas is further cooled and
throttled through a valve to produce liquefaction as in the Linde process.
51
Claude liquefaction process
Methane is compressed to 60 bar, and then cooled and throttled to 1 bar. It is known
that 10 % methane has been liquefied after throttle. Calculate the temperature before
the throttle using the PR EoS. Draw schematically the process in a PH diagram
Use the following ideal gas Cp coefficients.
53
Example: Methane liquefaction through
throttling
Methane
54
Exercise: Linde process
Methane is liquefied through a Linde process shown in the figure. We know that P1,
P5-P8 are 1 bar, P2-P4 are 60 bar, T3 is 25 oC , T1 and T8 are 20 oC. We further
assume that the compressor has an isentropic efficiency of 0.8 and a mechanic
efficiency of 1.0. Use the PR EoS to calculate
H3 and H8 in J/mol
Equilibrium temperature T5
H6, H7
The fraction of liquefaction z
H4, T4
Compression work (J/mol) and COP
55