Heat Transfer Surface

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9124121, 248 PM Heating with Cols and Jackets | Sprax Sarco Globat} [Search | [ Navigation + covip. + Aboutus * Global Locations + Careers + Loam about steam + Resources and Design Tools » Contact Head Office Search Search Search } Looking for Spirax Sarco produets and services? Select yourlocation )— Steam Engineering Principles and Heat Transfer Home / Learn about steam Heating with Coils and Jackets Contents Heat Transfer Methods of Estimating Steam Consumption Measurement of Steam Consumy ‘Thormal Rating ‘Energy_ Consumption of Tanks and Vats Heating with Coils and Jackets eating Vats and Tanks nttopy -a basic understanding + Entropy ts practical use ‘Back1o Leam about steam Heating with Coils and Jackets Indirect heating of fluids is covered inthis tutorial including layouts, control and drainage of coils and jackets, and heat transfer calculations, Vessels can be heated in a number of different ways. This module will deal with indirect heating. In these systems, the heat is transferred across a heat transfer surface. Options include: ‘+ Submerged steam coils - A widely used form of heat transfer involves the installation inside a tank of steam coil immersed in a process fluid, + Steam jackets - Steam circulates in the annular space between a jacket and the vessel walls, and heat is transferred through the wall of the vessel Submerged steam coils ‘The use of tank coils is partcterty common in marine application where cargoes of enue ol edie ail tallow and molasses ar heated in deep tanks. Many ofthese gus ave dificult to handle at ambient temperatures de to tet viscosity Steam heated cols ae used to tase the temperature ofthese iid, lowering thei viscosity so that they become eater fo pump. hitpshwuw spiaxsarco.comileatn-about-eteamisteam-engin ring-prncios-and:e: Lransterineatng-witycols-andjackets 1s. 9124121, 248 PM Heating with Cols and Jackets | Sprax Sarco ‘Tank coils ate also extensively used in electroplating and metal treatment. Electroplating involves passing articles through several process tanks so that metallic coatings can be deposited on to their surfaces. One of the first stages in this process is known as pickling, where ‘materials such as steel and copper are treated by dipping them in tanks of acid or caustic solution to remove any scale or oxide (e.g. rust) which may have formed, Steam coll sizing Having determined the energy required (previous Module), and with knowledge of the steam pressureltemperature in the coil, the heat transfer surface may be determined using Equation 2.5.3: Equation 2.5.3 Q=UAAT ‘The heat transfer area calculated is equivalent to the surface area of the coil, and will enable an appropriate size and layout to be specified Determining the ‘U” value ‘To calculate the heat transfer area, a value for the overall heat transfer coefficient, U, must be chosen. This will vary considerably with the thermal and transport properties of both fluids and a range of other conditions. (On the product side ofthe coil a thermal boundary layer will exist in which there is a temperature gradient between the surface and the bulk fluid. Ithis temperature difference is relatively large, then the natural convective currents will be significant and the heat transfer coefficient will be high. Assisted circulation (such as stirring) that will induce forced convection, will also result in higher coefficients. As convection is partially dependent on the bulk motion of the fluid, the viscosity (which varies with temperature) also has an important bearing on the thermal boundary layer. Additional variations can also oceur on the steam side of the coil, especially with long lengths of pipe. The coil inlet may have a high steam velocity and may be relatively free from water, However, further along the length ofthe coil the steam velocity may be lower, and the coil may be running partially full of water. In very long coil, such as those sometimes found in seagoing tankers or in large bulk storage tanks, a significant pressure drop occurs along the length of the coil. To achieve the mean coil temperature, an average steam pressure of approximately 75% of the inlet pressure may be used, In extreme eases the average pressure used may be as low as 40% of the inlet pressure, Table 2.10.1 Heat emission rates for steam colls submerged in water Customary overall heat transfer coefficients U(wim?*c) ‘Mean steam/water temperature difference around 30 °C 550-1300 Mean steam/water temperature difference around 60 °C 1000 - 1 700 Mean steamiwater temperature difference around 110°C 1300-2 700 Recommended rates U (Wim? °C) Lower pressure coils | (<2 bar g) with natural circulation of water 550 Higher pressure coils | (+6 bar g) with natural circulation of water 4100 Lower pressure coils | (<2 bar g) with assisted circulation of water | 100 Higher pressure cails_| (6 barg) with assisted circulation of water 1700 ‘The range of figures shown in Table 2.10.1 demonstrates the difficulty in providing definitive ‘U’ values. Customary figures atthe higher end of the scale will apply to installations that are supplied with clean dry steam, small cols and good condensate drainage. The lower end is more applicable to poor quality steam, long coils and poor condensate drainage. ‘The recommended overall heat transfer coefficients will apply to typical conditions and installations, ‘These recommended rates are empirically derived, and will generally ensure that a generous safety margin applies tothe coil sizing. Ii the ease of fluids other than water, the heat transfer coefficient will vary even more widely due to the way in which viscosity vaties with temperature. However, the values shown in Table 2.10.2 will serve as a guide for some commonly encountered substances, while Table 2.10.3 gives typical surface areas of pipes per metre length. hntpssiwww spiraxsarco, comeam-about-stoamistearn-engineoring-prncipes-and:-noat-transfertheating-with-cols-and jackets 216 9124121, 248 PM Heating with Cols and Jackets | Sprax Sarco Table 2.10.2 Heat emission rates for steam coils submerged in miscellaneous liquids Medium pressure steam | (2-6 bar g) with natural liquid convection | _U (Wim? °C) Light oll, 170 Heavy oils 80-110 Fats" 30-60 Medium pressure steam | (2-6 bar g) with forced liquid convection | _U (Wim? *C) Light oils (200 sec Redwood at 38 °C) 850 Medium oils (1.000 sec Redwood at 38 °C) 340 Heavy oils (8 500 sec Redwood at 98 °C) 170 Molasses (10 000 sec Redwood at 38 °C) 85 Fats * (50 000 see Redwood at 38 °C) 55 * Certain materials such as tallow and margarine are solid at normal temperatures but have quite low viscosities in the molten state. ** Commercial molasses frequently contains water and the viscosity is nmuch lower. Table 2.10.3 Nominal surface areas of steel pipes per meter length Nominal bore(mm) | 15 | 20 | 25 | 32 | 40 | 50 | 65 | #0 | 100 Surface area (mim) | 0.067 | 0.085 | 0.106 | 0.134 | 0.152 | 0.189 | 0.239 | 0.279 | 0.358 Example 2.10.1 Continuing from Example 2.9.1 determine: + Part 1. The average steam mass flowrate during start-up. (Mean heat load + Part 2. The heat transfer arca required, + Part 3, A recommended coil surlace area. 67 KW) Part 4, The maximum steam mass flowrate with the recommended heat transfer area Part S. A recommendation for installation, including coil diameter and layout, ‘The following additional information has been provided: + Steam pressure onto the control valve + A stainless stel steam coil provides heat. ‘+ Heat transfer coefficient from steamy/coil/liqu 6 bar g (3.6 bar a). U=650 Wim? °C Part 1 Calculate the average steam mass flowrate during start-up ‘Steam pressure onto the control valv 2.6 bar g (3.6 bar a) Critical pressure drop (CPD) will occur across the control valve during start-up, therefore the minimum steam pressure in the heating coil should be taken as 58% of upstream absolute pressure, An explanation of ths is given in Block 5. Minimum steam pressure = 3.6 bar ax 58% Minimum steam pressure = 2.4 bar a (1.1 bar g) Enthalpy of evaporat jon (hy) at 1.1 bar g= 2 197 kilkg (fram steam tables) 367 KW Average steam flowrate = > — 2197 kites Average steam flowrate = 0.167 kgis or 602 kg/h Part 2 Calculate the heat transfer area required htpsswww spiraxsarco, comeam-about-stoamistearn-engineoring-prncipes-and:-noat-transfertheating-with-cols-and jackets 36 9124121, 248 PM Heating with Cols and Jackets | Sprax Sarco Using Equation 2.5.3: Q=UAaT Where = 367 KW (Example 28.1) 650 Wim °C (given) Mean temperature diffe a Steam pressure = 2.1 bar a (see above) Therefore: Steam temperature in the coil, T, = 122 *C (from steam tables) 8+ 60 ‘Mean liquid temperature, T,, = 2 650 Wime*C x Am? x 88°C Therefore 367 kN herefore 367 or 367 x 1000 650 x 88 A616 m? Part 3 A recommendation for coil surface area ACE ATy Because of the difficulties in providing accurate “U" values, and to allow for future fouling ofthe heat exchange surface, itis usual to add 10% to the calculated heat transfer are. Recommended heat transfer area (A) = 6.418 m2+ 10% A=Tme Part 4 The maximum steam mass flowrate with the recommended heat transfer area Maximum heat transfer (and hence steam demand) will occur when the temperature difference between the steam and the process fluid is at its maximum, and should take into consideration the extra pipe area allowed for fouling. @) Consider the maximum heating capacity of the coil Q(coil) Using Equation 2.6.3: Where AAT 650 jim *G (given) Time a initial temperature difference Initial quid temperature T, = 8 °C Steam pressure ‘Steam temperature in the coil, T, = 122°C tbarg 1,2 122-8°C aT=114°C 050 x 7x 114 eon = 7 000 519 kW oo htpsskwww spiraxsarco, comeam-about-stoamistearn-engineoring-prncipes-and:-noat-transfertheating-with-cols-and jackets ans. 9124121, 248 PM Heating with Cols and Jackets | Sprax Sarco (b) Steam flowrate to deliver S19 kW. S19 KW x 9600 Jo, gat 11 barg Maximum steam flowrate ((h,) SI9KW x 9.600 55 2197 kikg 1h, = 850 kg/h Part § A recommendation for installation, including coil diameter and layout (@) Determine coil diameter and length ‘Steam pressure = 1.1 bar g (v, = 0.841 m®ikg - from steam tables) Maximum steam flowrate = 850 kg/h Maximum recommended steam velocity = 25 mis, Volume flowisecond Steam velocity = mis Gross sectional area of pipe ‘Mass flow (kg/h) x Specitic volume (m2 Volume flow per second = eee into) 3 600 (s/h) Cross sectional area of pipe = B 850 kgm x 0.861 mikg x 4 2600 x x x DP Therefore: 25 mis = pre B50 x 08H x 4 3600 x x 25 [e50 x 08st x 4 Diameter = V3600 x a x 25 Diameter = 0.1 m or 100 mm. From Table 2.10.3, a 100 mm pipe has a surface area of 0.368 m"/m run. This application will require is 19.6 metr of 100 Baer pg = 19.8 metres of 100 mm pipe Ieay be difficult to accommodate this length of large bore heating pipe to install in a 3 mx 3 m tank. One solution would be to run a bank of parallel pipes between steam and condensate manifolds, stat different heights to encourage condensate to run to the lower (condensate) manifold. The drain line must fall from the bottom of the condensate manifold down tothe steam trap (or purnp- trap). See Figure 2.10.1 for a suggested layout. htpsskwww spiraxsarco, comeam-about-stoamistearn-engineoring-prncipes-and:-noat-transfertheating-with-cols-and jackets 515 9124121, 248 PM Heating with Cols and Jackets | Sprax Sarco Fig. 2.10.1 Possible layout of coils in a rectangular tank ‘Note the steam supply is situated at one end of its manifold, whilst the rap set is at the other end, This will help steam to flow and push condensate through the coil, In the application, the steam and condensate headers would each be 2.8 m long. As the condensate manifold is hol bacat from it will be small compared tothe steam manifold and this can be ignored in the calculation, condensate, the ‘The stoam manifold shouldbe 100 mm diameter as determined by the previous velocity calculation. ‘This will provide a heating area of 2.8 mx 0.388 milm= 1.0." Consequently 7-1? = 6s of eat ransfer area is il required, and must be provided by the connecting pipes Arbitrarily selecting 32 mm pipe asa good compromise between robustness and workability 6m? Taste 745 mettes of 32 mm pipe is required The lengths of the connecting pipes are 2.6 m. 45m Therefore, the number of connecting pipes = 3 =™ = 18 Cheek It is necessary to confirm the steam velocity through the connecting tubes: (On the basis of proportionality of heat transfer area, the steam header will condense: hitpssiwww.spiraxsarco,comleam-abou-steamisteam-engineering-prnciles-and-he Lransterineatng-witycols-andjackets 65 9124121, 248 PM Heating with Cols and Jackets | Sprax Sarco iim | 100 Fm x 100 = 14 % of the steam con sed in the whole coil assembly This leaves 88% of the 850 kg/h = 731 kg/h of steam which must pass through the 18 connecting pipes and also into the lower (condensate) manifold Volume flowisecond Steam velocit Cross sectional area of pipe 731 kghh x 0.841 mPrkg x4 Steam velocity = ——— "3 _ 3.600 x 18 pipes x x x 0.0322 ‘Steam velocity = = 12 mis per connecting pipe Other steam coil layouts ‘The design and layout of the steam coil will depend on the process fluid being heated, When the process fluid to be heated is a corrosive solution, itis normally recommended that the coil inlet and outlet connections are taken over the lip ofthe tank, a it is not normally advisable to dill through the corrosion resistant linings of the tank side. This will ensure that there are no weak points inthe tank lining, where there is a tisk of leakage of corrosive liquids. In these cases the col itself may also be made of corrosion resistant material such as lead covered steel or copper, of alloys such as titanium, However, where there is no danger of corrosion, lifts over the tank structure shoul be avoided, and the steam inlet and outlet connections ‘may be taken through the tank side. The presence of any lift will result in waterlogging of a proportion of the coil length, and possibly ‘waterhammer, noise and leaking pipework. ‘Steam heating coils should generally have a gradual fell from the inlet to the outlet to ensure that condensate runs toward the outlet and does not collect in the bottom of the coil, Where a lift is unavoidable, it should be designed to include a seal arrangement atthe bottom of the lif and a small bore dip pipe, as shown in Figure 2.10.2 Fig. 2.10.2 Tank with a rising discharge pipe r : Condoneate outlet stan in a Dip pipe ‘The seal arrangement allows a small amount of condensate to collect to act as a Water seal, and prevents the occurrence of steam locking. Without this seal, steam can pass over any condensate collecting in the bottom of the pipe, and close the steam trap atthe top of the riser “The condensate level would then rise and form a temporary water seal, locking the steam between the bottom ofthe riser and the steam trap. The steam trap remains closed until the locked steam condenses, during which time the coil continues to waterlog. hntpsskwww spiraxsarco, comleam-about-stoamistear-engineoring-prncipes-and:-neat-transfertheating-with-cols-and jackets m6 9124121, 248 PM Heating with Cols and Jackets | Sprax Sarco ‘When the locked steam condenses and the steam trap opens, a slug of water is discharged up the riser. As soon as the water seal is broken, steam will enter the rising pipe and close the trap, while the broken column of waterfalls back to lie atthe bottom of the heating coil, ‘The small bore dip pipe will only allow a very small volume of steam to become locked in the riser. It enables the water column to be casily maintained without steam bubbling through it, ensuring there is « steady and continuous condensate flow to the outlet. ‘When the sca is ultimately broken, a smaller volume of water will return to the heating coil than with an unrestricted large bore riser, but as the water seal arrangement requires a smaller volume of condensate to form a water seal, it will immediately re-form. Ifthe process involves articles being dipped into the liquid, it may not be convenient to install the coil atthe bottom of the tank - it may be damaged by the objects being immersed in the solution, Also, during certain processes, heavy deposits will settle atthe bottom of the tank and can quickly cover the heating surface, inhibiting beat transfer. For these reasons side hung coils are often used in the electroplating industry. In such cases serpentine or plate-type coils are arranged ddown the side ofa tank, as shown in Figure 2.10.3, These coils should also have a fall to the bottom with a water seal and a small bore dip- pipe.This arrangement has the advantage that i is oflen easier to install, and also easier to remove for periodie cleaning if required. steam in Condensate ot t Bip pine Fig. 2.10.3 Side hung coils articles are to be dipped into the tank, it may not be possible to use any sort of agitator to induce forced convection and prevent temperature gradients occurring throughout the tank. Whether bottom or side coils are used, it is essential that they are arranged with adequate coverage so thatthe heat is distributed evenly throughout the bulk ofthe liquid. ‘The diameter of the coil should provide sufficient length of coil for good distribution, A short length of coil with a large diameter may not provide adequate temperature distribution, However a very long continuous length of coil may experience a temperature gradient due to the pressure drop from end to end, resulting in uneven heating of the liquid. Whilst the next two headings, ‘Sizing the control valve’ and “The condensate removal device’ are included in this Module, the new ader should refer to later Blocks and Modules in The Learning Centre for full and comprehensive information, before ‘empting sizing and selection of equipment. Control valve arrangement ‘The control valve set may be either one or two valves in parallel. A single control valve, large enough fo cope with the maximum flowrate encountered at star-up, may be unable to control flow accurately at the minimum expected flowrate. This could cause erratic temperature contro, An alternative isto fit two temperature control valves in parallel: + One valve (running valve) sized to control at the lower flowrate. + A second valve (stating valve) to pass the difference between the capacity ofthe first valve, and the maximum flowrate. ‘The starting valve would have a set-point slightly lower than the running valve, so it would close first, leaving the running valve to control at Tow loads. hntpsskwww spiraxsarco, comleam-about-stoamistear-engineoring-prncipes-and:-neat-transfertheating-with-cols-and jackets ans 9124121, 248 PM Heating with Cols and Jackets | Sprax Sarco Sizing the control valve Sizing the control valve The control valve set (either one valve or two valves in parallel). The coil hes been sized on mean heat transfer values. However, it may be better to size the control valve to supply the maximum (start-up) load. With large coils in tanks, this will help to maintain a degree of steam pressure throughout the length of the coil when the steam is tumed on, helping to push condensate through the coil to the steam trapping device. Ifthe control valve were sized on mean values, steam pressure in the coil at start-up will end to be lower and the coil may flood, Using one valve Continuing with Example 2.10.1 the maximum steam load is 850 kg/h and the coil is designed to deliver this at a pressure of 1.1 bar g. A steam valve sizing chart would show that a Ky of about 20 is required to pass 850 keh of steam with pressure of 2.6 bar g atthe inlet of the control valve, and Critical Pressure Drop (CPD) across the valve, (Module 6.4 will show how the valve size can be determined by calculation), A.DN40 control valve with a larger Ks of 25 would therefore a ed to be selected for the application, fone valve isto be used, this valve must ensure the maximum heat load is catered for, while maintaining the required steam pressure in the coil to assist the drainage of condensate from it at start-up. However, for reasons previously explained, two valves may be better The running load is 52 kW and withthe coil running at 1.1 bar g, the running steam load: 2 kW sient 2197 kulkg = 0.0297 ka/s = 85kgh The steam valve sizing chart shows a Kv of 2 is required to pass 85 kg/h with 3.6 bar upstream, operating at critical pressure drop. ADNIS KE type valve (Kvs = 4) and a DN25 piston actuated valve (Kvs = 18.6) operating together will cater for the start-up load. When approaching the control temperature, the larger valve would be set to shut down, allowing the smaller valve ta give good control ‘The condensate removal device ‘The selection and sizing of the condensate removal device will be very much influenced by the condensate backpressure, For the purpose of this example, itis assumed the backpressure is atmospheric pressure. The device should be sized so itis able to satisfy both of the following conditions: 1. Pass 850 kg/h of condensate with 1.1 ber g in the col, ie. the full-load condition. 2. Pass the condensate load when steam pressure in the coil equals the condensate backpressure, ie, the stall load condition, If the steam trap is only sized on the first condition, itis possible that it may not pass the stall load (the condition where the product approaches its required temperature and the control valve modulates to reduce steam pressure). The stall load may be considerable. With respect to non-ilow type applications such as tanks, this may not be too serious from a thermal viewpoint because the contents of the tank will almost be atthe required temperature, and have a huge reservoir of heat Any reduction in heat transfer at this part of the heating process may therefore have litle immediate effect on the tank contents. However, condensate will back up into the coil and waterhammer will occur, along with its associated symptoms and mechanical stresses, Tank coils in lange circular tanks tend to be of robust construction, and are often able to withstand such stresses. Problems can however, ‘occur in rectangular tanks (which tend to be smaller), where vibration in the coil will have more of an effect on the tank structure. Here, the energy dissipated by the watethammer eauses vibration, which can be detrimental to the life of the col, the tank, and the steam trap, as well as creating unpleasant noise. With respect to flow-type applications such as plate heat exchangers, a feilure to consider the stall condition will usually have serious implications. This is mainly due to the small volume in the heat exchanger. For heat exchangers, any unwanted reduction in the heating surface area, such as that eaused by condensate backing up into the steam space, can affect the flow of heat through the heating surface, This can cause the control system to become erratic and unstable, and processes requiring stable or accurate control ean suffer with poor performance. hitpshwww.spiaxsarco,comleam-abou-steamisteam-engineering-prnciples-and:-neat-raneferineating-wih-cols-andjackets 95 9124121, 248 PM Heating with Cols and Jackets | Sprax Sarco I?heat exchangers are oversized, sufficient heating surface may remain when condensate backs up into the steam space, a thermal performance may not always occur. reduction of However, with heat exchangers not designed to cope with the effects of waterlogging, this can lead to corrosion of the heating surface, inevitably reducing the service life ofthe exchanger. Waterlogging can, in some applications, be costly, Consider a waterlogging sir heater frost coil. Cold air at 4 °C flowing at 3 mis can soon freeze condensate Tocked inthe coils, resulting in premature and unwarranted failure Proper drainage of condensate is essential to maintain the service life of any heat exchanger and air heater. ‘Steam traps are devices which modulate to allow varying amounts of condensate to drain trom applications under varying conditions. Float tuaps are steam traps designed to modulate and release condensate close to steam temperature, offering maximum plant performance, ‘maximum plant life, and maximum return on plant investment. When stall conditions occur, and a steam trap cannot be used, an automatic pump-trap or pump and trap in combination will ensure correct, condensate drainage at all times, thus maximising the thermal capability and lifetime costs of the plant. Steam jackets ‘The most commonly used type of steam jacket consists simply of an outer eylinder surrounding the vessel, as shown in Figure 2.10.4 Steam circulates in the outer jacket, and condenses on the wall ofthe vessel. Jacketed vessels may also be lagged, or may contain an internal air space surrounding the jacket. This is to ensure that as little steam as possible condenses on the outer jacket wall, and that the heat is transferred inwards to the vessel ‘eam sraner + Condensate Fig. 2.10.4 A conventional jacketed vessel ‘The heat transfer area (the vessel wall surface area), can be calculated in the same manner as witha steam coil, using Equation 2.5.3 and the overall heat tansfer coefficients provided in Table 2.10.4, Although steam jackets may generally be less thermally efficient than submerged coils, due to radiation losses to the surroundings, they do allow space for the vessels to be agitated so that heat transfer is promoted. The U values listed in Table 2.10.4. are for moderate ‘nonproximity agitation. Commonly the vessel walls are made from stainless stee! or glass lined carbon steel, The glass lining will offer an additional corrosion resistant layer. The size ofthe steam jacket space will depend on the size of the vessel, but typically the width may be between 50 mm and 300 mm, hntpsskwww spiraxsarco, comleam-about-stoamistear-engineoring-prncipes-and:-neat-transfertheating-with-cols-and jackets 1015 9124121, 248 PM Heating with Cols and Jackets | Sprax Sarco Table 2.10.4 Overall heat transfer coefficients for steam Jackets Process fluid or product Wall material U (Wim? “c) Stainless steel 860-1700 Water a Glass-lined Carbon steel ‘400 - 570 Stainless steel! 460-1140 Aqueous solution Glass-lined carbon steel 285 - 480 Stainless steel 285 - 850 Organics Glass-lined carbon steel 470-400 Stainless steel 340 - 910 Light oi! Glass lined carbon steel 230 - 425 Stainless steel 57-285 Heavy oll es Glass lined carbon steel 57-230 ‘Top Of The Page ‘Previous ~ Encrgy Consumption of Tanks and Vats Next - Heating Vats and Tanks by Steam Injections Investors Privacy Policy Legal Not kie Notice International Page {© 2021 Spirax Sarco Limited. All Rights Reserved Linked In_ Twitter Instagram Facebook You Tube VIEW SPIRAX SARCO OFFICES BY REGION Europe Nowth America Latin America Middle Fast and Africa Spirax Sarco locations: » Belgium (Francais) + Belgium (Nederlands) Bosnia & Hi ‘CaschiSlovak Republic (Cesko/Slovensko} ‘Denmark (Danmark) inland (Finnish Suomi) Ezance ‘Germany (Deutschland) Greece Hungary (Magyarorszis) Italy. alia) Kazakhstan (Kasaxcran) ‘Netherlands Nonway- (Norge? 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