2012년 7월 26일 안박사님과 랩미팅하면서 배운 점 정리.

 

1) Cooling system

공장에서 고온의 물체를 열교환기를 통해 냉각시킬때, 보통 열교환기에 냉각수를 흘려보내 냉각시키는데, 이 냉각수는 쓰고 버리는 것이 아니라, 쿨링타워라는 곳에서 냉각시킨다. 실제로 공장에 가보니까 한 3~4층 되는 높이에서 물을 폭포처럼, 떨어뜨려 냉각시키는 걸 볼 수 있었다.

한국의 여름 낮 평균기온은 한 33~34도라고 치고, 재순환한 물이 떨어지며 식는 온도가 그보다 3도 정도 높은 37도라고 하자.  결국, 37정도의 물이 다시 열교환기로 흐르게 되는데, 예를들면 한 300도 되는 hot stream을 이 냉각수를 이용해서 냉각시킨다고 했을때, 최대

 

Cooling tower에서 냉각되는 냉각수 는 한국 여름기준 기온이 32~33도 정도이므로, 기온으로부터 최대 3도까지 근접한 37까지 밖에 식힐 수 없다. 열교환기에서 최대로 줄일 수 있는 hot과 cold의 온도차를 10~12도로 정한다면, 결국, 300도짜리를 냉각시킬 수있는 최저 온도는 50도 정도라는 소리가 된다.

 

즉, 시뮬레이션을 할 때 보면, 뭐 10도씨 이렇게 입력하는것은 클릭 몇번이면 되니까 아주 아무렇지 않게 생각하고 하게되는데, 이런 현장감각을 항상 기억하고 시뮬레이션에 임하자!

 

2) 실제 유닛이 어떻게 설치될 것인지 고려할 것.

예를들면 온도를 크게 높여야 하는 것이면, 열교환기를 따로 설치할 것이고,

뭐 반응 도중에 온도를 유지하는 정도면 코일을 감아서 히팅하면 되는것이고,

이런 것을 시뮬레이션에 반영하여서 열교환기를 따로 그릴 것인지, 아니면 반응기의 온도조건만 바꿀 것인지를 정한다.

 

3) 액체는 펌프, 기체는 콤프레서. 이건 알고 있었지만,

기체가 응축되서 액상이 되면 이건 펌프로 보내야한다.

 

4) Flash나 Decanter는 보통 duty를 0으로 두는 Adiabatic조건을 많이 한다.

여기에 온도를 급격히 낮춘다던가, 급격히 높히는 것은 힘든 일이다.

 

5) 고압으로 응축된 기체에 온도를 낮출때는, 구지 열교환기를 안써도,

트로틀 벨브로 압력을 낮추는 방법으로 쉽게 냉각시킬 수 있다.

고압 혼합기체를 기액분리할 때 이렇게 하더라.

요 원리가 Joule-Thomson effect였던걸로 기억함.

 

 

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<기초이론>

U0=the overall coefficient based on the outside area of the tube, W/m^2℃

h0=outside fluid film coefficient, W/m^2℃

hi=inside fluid film coefficient, W/m^2℃

hod=outside dirt coefficient (fouling factor), W/m^2℃  역수로 쓸때가 많다.

hid=inside dirt coefficient, W/m^2℃

di=tube inside diameter, m

do=tube outside diameter, m

 

wall temperature 구해야 하는 이유 :  h=c Re^0.8 Pv^0.3 (u/uv)^0.14 에서 마지막 term 이게 점도 비율인데, 보통은 무시. 만일 온도변화에 따라 점도가 달라진다면, h값이 바뀌게 되므로, wall temperature를 구해서 점도 고려해야함.

 

온도차 -> LMTD구하기 -> U값은 table에서 찾기 -> 전열면적 계산.

 

fouling factor는 깨끗한 정도.

열교환기의 reboiler의 경우 녹 등이 다 밑으로 떨어지기 때문에 더럽다. hod 값이 작다.

 


 

<shell and tube 열교환기 설계>

1. Baffle

Baffle의 설치 : Tube plate에 환봉(rod)을 돌려서 고정하고 -> spacer를 끼운 다음 -> baffle을 하나 넣기 -> 다시 spacer -> 다시 baffle.... 이런 순서로 고정. 마지막에 환봉을 고정할때는 double nut를 써야함(single nut는 spacer를 압착하는 효과가 생겨버림)

 

Baffle의 역할 : ① Tube의 지지역할(tube가 1.2m이상 길어지면 축 늘어짐. 그리고 유체가 흐를때 진동발생)

② 유속을 빠르게 해줌.

 

Baffle 간격에 따라 열전달 계수 바뀜

Baffle 너무 많이 넣으면 Baffle 틈새로 유체 흐를경우 생김 -> 전열계수 오히려 떨어짐.

 

Baffle 종류 : (a) Segmental, (b) Segmental and strip, (c) Disc and doughnut, (d) Orifice

(a)를 많이 쓴다. (d)방법은 tube의 support역할을 못해주므로, 잘 안씀.

열교환기 내에서 응축이 발생할 경우 baffle의 하단에 구멍을 내어 응축액이 흐를수있게 해준다.

 


2. 열교환기 구조

Fixed-tube plate : 분해가 불가능하므로 shell이 한번 오염되면 청소불가

 

U-tube : 분리가능하므로 tube사이 청소가능

 

청소를 용이하게 하기 위해 front, rear side를 분리할 수 있게 만든다.

단, clamp ring이 없는 경우, wall과 tube의 간격이 너무 멀어져서 tube 사이사이로 유체가 흐르지 않고 주위로만 돌 경우, 전열이 잘 안될수있다.

clamp ring을 이용하여 wall과 tube사이의 간격을 줄이면 위의 단점을 극복할 수 있다. (아직 정확한 차이점 모르겠음)

 

Tube 배열 방법 : 3각, 4각, 있는데, 3각은 솔이 들어갈 틈이 없으므로 청소하기 힘들다. 청소 고려한다면 4각으로 할 것. 단 집적율 떨어짐.

 


3. Tube

BWG로 두께 얘기함.

두께 클수록, 내경 좁아지고, 그럼 청소하기 어렵다.

TEMA R:원자력 등 위험물 다룰때 , TEMA C:값이싸고 안위험할때, TEMA B:일반화학공정

3/4이하는 잘 쓰지 않음.

3인치 이상은 잘 쓰지 않음.

 

Tube sheet에 tube를 고정하기 위해 (a)welding(용접) (b)홈이 파인 틈 을 이용하는데,

용접의 경우는 주의할 점이 있다.

열교환기 특성상 온도차가 많이 발생하고, 100℃차이시 1m당 1.2mm의 수축팽창 일어남. 따라서 만일 용접을 할 경우 그 부위에 10000kg/m2의 응력이 발생 --> 용접부위 쉽게 터진다.

따라서 홈이 파인 곳에 tube를 넣고, tube속에 롤러를 넣어 돌리면서 힘을가하면 홈으로 밀리면서 고정이 된다. 만일 tube속의 물질이 매우 위험하여 절대로 세면 안된다고 한다면, 홈으로 고정을 하고, 주위에 welding을 살짝만 하도록 한다.

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요즘 기웃거리고 있는 연구전문 소셜네트워크인 Research gate에서 재미있는 질문을 발견했다.

 

"What is a major difference among science, engineering and technology?"

 

다양한 답들이 올라왔는데, 답들이 재밌다.

 

Michael Dickman (ㅋㅋ 이름이 웃기구만)

Technology : 불은 음식을 조리할때 쓰일 수 있다.

Science : 나무를 연소시키면 열과, 수증기와, 이산화탄소가 발생한다. 이때 발생하는 열은 음식의 단백질을 변성시킨다.

Engineering : 손쉽게 요리를 할 수 있도록 화로와 굴뚝을 만든다.

 

Robert Baber

Science asks the question, why?

Engineering asks the question, why not?

Technology tries to answer the question, how?

 


그밖에 다양한 의견들.

debate 중에 새롭게 알게되는 것도 많다

 

Jeffon Liao

Science: It is to know why. First, It tries to ask question. It is to simplify question, ignoring the relatively umimportant details. It is to continue to find the relative correct answer (but ever can not reach the absolutely correct answer). It normally can not bring profits instantly and directly. It cares about repeatability, does not care about reliablity.
For a top scientist / researcher, it may be more important to at ask good/simple questions rather than find a answers. Innovation is more important than proficency.

Technology: It is to know how. It tries to present feasible solutions for a kinds of application/situation. For example, IC technology can teach you how to make an IC from sands.
Normally, Technology is a combine of several Science research results. For example, while developing IC technology, you shall learn chemistry and physics, you shall research why and how semiconductor can control current, and you shall research how to purify silicon, how to photoengrave, how to make a copper trace on silicon, etc.
Comparing with Research, a valuable Technology shall consider more practical issue, such as cost, timing, skill capability, environment, etc.

Engineering: It is to implement and earn profit. It implement Technologies for a certain products/application. Good Engineering shall take more constraints into account comparing with Technology, such as marketing/custom requirements, project schedule, cost/profit, process, documentation, rule and law, etc. Reliability is extremely important, Engineering shall ensure result matchs 99.9999% expect (6 Sigma).
A good engineer shall be good at implementing existing mature Technology, seldom to use inchoate technology. Proficency is more important than innovation for most Engineering (For some certain areas it is reverted. iPhone is an example).

Engineering implements Technologies, and Technologies are from Science.

 

Merab Zukhbaia

@Jeffon Liao How do you think, does today technology comes only from science ? I ask this question, because during the history there were developed several technologies like fire, for example, which wasn't the product from science...

 

Behnido Calida

@ Merab: There are several other examples (like the fire example) perhaps throughout our history about technological knowledge that came about by chance (e.g. as others have referred to as serendipitous discoveries). While I do not discount that possibility, I still believe that our understanding of "fire" was later enhanced as the relevant science was discovered, evolved or matured. Take note that the overlapping systems of processes for both science and technology are dynamic and continuously evolving.

I have my thoughts about science and technology (and later on with engineering) which I can trace back to even more lengthy philosophical debates involving the history of science and knowledge. Over the years, it has become cumbersome to delineate the boundary between science and technology. From my research, the consensus understanding is that science can be further categorized as either basic science and applied science. While it is true that basic science overlaps with applied science, which in turn overlaps with technology, the overlap still does not imply that the concept of science and technology are one and the same. There IS such a thing as basic science(e.g. such as set theory, quantum theory, particle physics, etc.) which until recently have only started to find its own niche of practical application. But the main take away points are that, 1) knowledge from basic science were cultivated for their own sake by people who are yet unable to come up with any definitive practical ideas, and 2) science is a public good whereas technology is (sad but true), to a large extent a private good. The latter being my main distinction between the difference between science and technology.

Now, how do I relate this to the concept of engineering? In my view, science and technology interact,...and in one of the many possible ways of interaction, I would define "engineering" in relation to a formal practice or discipline of deploying certain knowledge, theories, methods and techniques based on a bounded set or configuration of science and technology to solve a given problem. Before the main knowledge flow was typically initiated within the basic sciences and outward to produce technological artifacts. As evidence for these, we see the birth of various engineering disciplines such as chemical,electrical, telecommunications and nuclear engineering among many others. But nowadays, it is quite common as well to find practitioners push for their own engineering disciplines as a result of their common technological practice (to later back track towards the sciences) such as the case of biotechnology, genetic engineering, etc. Either way, engineering refers to the actual practice or deployment of science and technology

 

Deogratias Nurwaha

"Engineering is quite different from science. Scientists try to understand nature. Engineers try to make things that do not exist in nature. Engineers stress invention. To embody an invention the engineer must put his idea in concrete terms, and design something that people can use. That something can be a device, a gadget, a material, a method, a computing program, an innovative experiment, a new solution to a problem, or an improvement on what is existing. Since a design has to be concrete, it must have its geometry, dimensions, and characteristic numbers. Almost all engineers working on new designs find that they do not have all the needed information. Most often, they are limited by insufficient scientific knowledge. Thus they study mathematics, physics, chemistry, biology and mechanics. Often they have to add to the sciences relevant to their profession. Thus engineering sciences are born

 

Matthew Hartline

As per my professor:
scientists make no assumptions.

Engineers state assumptions, then go from there.

 

James Tadaro

Well, if your Professor is a scientist, and thinks that scientists make no assumptions, he has not examined even his own thought processes. If he is an Engineer, then he is likely trying to provoke, in classic Greek tradition, thoughtful debate among his students.

All science begins with someone noticing 'Something' he doesn't understand. The next step is that he creates an hypothesis about what (and why) that 'Something' is, or is doing, or has done, or will do. Thus 'Hypothesis' is simply another word for 'Assumption', dressed up in a suit for its job interview, and which needs to be tested.

Scientists then move on to 'Interview" the candidate 'Hypothesis' , aided by whomever they call upon as experts from other departments. All of this is aimed at Accepting or Rejecting each candidate Hypothesis for a position in their Intellectual Organization.

Regardless of what the Good Professor may claim, ALL Science started with one or more assumptions, which were to then tested.

The Engineer takes each of Science's successful candidates and puts them to work on various projects, and is quietly grateful that he has Scientists to do the boring drudge-work , while he gets to do the really cool, interesting stuff that has never, ever, been done before, and was always considered impossible. Like going to the Stars.

 

 

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