Jacketed Vessel Design

Reference: http://www.cheresources.com/content/articles/heat-transfer/jacketed-vessel-design?pg=1

Jacketing a process vessel provided excellent heat transfer in terms of efficiency, control and product quality. All
liquids can be used as well as steam and other high temperature vapor circulation. The temperature and velocity of
the heat transfer media can be accurately controlled.

The various types of jackets used in process industry are :

1. Spirally baffled jackets/ conventional jackets

2. Dimple jackets
3. Partial-pipe coil /limpet jacket
4. Panel type/ plate type coil jackets
Commonly used heat transfer medias include water, steam (various pressures), hot oil (such as Therminol™), and
Dowtherm™ vapor.

Matching Jacket Types to Heat Transfer Media

Water: Depending on the process temperature, stress corrosion cracking can sometimes be a concern due to the
chlorides usually found in water. In some cases, dimple jackets may requires the use of high-nickel alloys which are
very expensive. The half-pipe coil can use 1/4'' thick carbon steel for the jacketing but their economy versus
conventional jackets must to be considered. With services involving large volumes of water (used to maintain a high
temperature difference) the conventional jacket usually offers the best solution.

Steam: Both dimple and half coil jackets are well suited use with high pressure steam. The dimple jackets are
generally limited to 300 psig design pressure while half-coil jackets can be used up to a design pressure of 750 psig.
For half-pipe coil jacket, the higher heat flux rate may require multiple sections of jackets to avoid having condensate
covering too much of the heat transfer area. For low pressure steam services convention jackets are a much more
economical choice.

Hot Oils and Heat Transfer Fluids: Although pressures are usually low when using oils or heat transfer fluids, the
temperatures are usually high. The result is low allowable stress values for the inner-vessel material. Therefore both
half-pipe jackets and dimple jackets can provide good solutions. Conventional jackets require a greater shell
thickness along with expansion joints to eliminate stresses induced by the difference in thermal expansion when the
jacket is not manufacturered from the same material as that of shell.

Dowtherm™ Vapors:The ability to vary the distance between the outer and innver vessel walls makes conventional
jackets ideally suited to handle Dowtherm™ vapors. Also since Dowtherm vapor has a low enthalpy (1/10 that of
steam) a large jacket space is needed for given heat flux. The jacket must be designed in accordance with ASME
Code specifications. The maximum allowable space is limited by section UA-104 Paragraph c and s.

Conventional Jackets
 Figure 1: Conventional
Jacket
"Conventional jackets" can be divided into two (2) main categories: baffled and non-baffled. Baffled jackets often
utilize what is known as a spirally wound baffle. The baffle consist of a metal strip wound around the inner vessel wall
from the jacket utility inlet to the utility outlet. The baffle directs the flow in a spiral path with a fluid velocity of 1-4 ft/s.
The fabrication methods does allow for small internal leakage or bypass around the baffle. Generally, bypass flows
can exceed 1/3 to 1/2 of the total circulating flow.

Conventional baffled jackets are usually applied with small vessels using high temperatures where the internal
pressure in more than twice the jacket pressure.

Spirally baffled jackets are limited to a pressure of 100 psig because vessel wall thickness becomes large and the
heat transfer is greatly reduced. In the case of an alloy reactor, a very costly vessel can result. For high temperature
applications, the thermal expansion differential must be considered when choosing materials for the vessel and
jacket. Design and construction details are given in Division 1 of the ASME Code, Section VIII, Appendix IX,
"Jacketed Vessel".

Heat Transfer Coefficients: Conventional Jackets without Baffles

(hj De / k) = 1.02 (NRe) 0.45 (NPr) 0.33 (De/ L) 0.4 (Djo/ Dji) 0.8 (NGr) 0.05 Eq. (1)

Figure 2: Schematic of Conventional

Jacket
Where:
hj = Local heat transfer coefficient on the jacket side
De = Equivalent hydraulic diameter
NRe = Reynolds Number
NPr = Prandtl Number
L = Length of jacket passage
Djo = Outer diameter of jacket
Dji = Inner diameter of jacket
NGr = Graetz number

The Reynolds Number is defined as:

 NRe = DVρ/μ
Where D is the equivalent diameter, V is the fluid velocity, ρ is the fluid density, μ and is the fluid viscosity.

The Prandtl Number is defined as:

NPr = Cp μ / k
Where Cp is the specific heat, μ is the viscosity, and k is the thermal conducitivity of the fluid.

The Graetz Number is defined as:

NGr = (m Cp) / (k L)
Where m is the mass flow rate, Cp is the specific heat, k is the thermal conducitivity, and L is the jacket passage
length.

The equivalent diameter is defined as follows:

De = Djo-Dji for laminar flow

De = ((Djo)2 - (Dji)2)/Dji for turbulent flow

Conventional Jackets with Baffles

For conventional jackets with baffles, the following can be used to calculate the heat transfer coefficient:

hj De/k= 0.027(NRe)0.8 (NPr)0.33 (µ/µw)0.14 (1+3.5 (De/Dc) ) ( For NRe > 10,000) Eq. (2)

0.33 0.14
hj De/k = 1.86 [ (NRe) (NPr) (Dc/De) ]   (µ/µw)  ( For NRe < 2100 ) Eq. (3)

Figure 3: Schematic of Conventional Jacket

with Baffle

Two new variables are introduced. Dc is defined as the centerline diameter of the jacket passage. It is calculated as
Dji + ((Djo-Dji)/2). The viscosity at the jacket wall is now defined as µw. When calculating the heat transfer cofficients,
an effective mass flow rate should be taken as 0.60 x feed mass flow rate to account for the substantial bypassing
that will be expected. De is defined
at 4 x jacket spacing. The flow cross
sectional area is defined as the
baffle pitch x jacket spacing.

Half Pipe Coil Jackets

Figure 4: Half Pipe

Coil Jacket
Half pipe coils provide high velocity and turbulence. The velocity can be closely controlled to achieve a good film
coefficient. The good heat transfer rates, combined with the structural rigidity of the design, make half-pipe coils a
good choice for a wide range of applications. A good design velocity for liquid utilities is 2.5 to 5 ft/s.

The maximumspacing between coils should be limited to 3/4". Half-pipe coils are ideally suited for high temperature
applications where the utility fluid is a liquid.
There are no limitations of the number of inlet and outlet nozzles, so the jacket can be divided in multipass zones for
maximum flexibility. The rigidity of the half-pipe coil design can also minimize the thickness of the inner vessel wall
which can be especially attractive when utilizing alloys.

Half-pipe coil jackets are not covered in Section VIII, Division I of the ASME code. Generally, they are limited to 600
psig design pressure and a design temperature up to 720 °F. A carbon steel half-pipe jacket can be applied to a
stainless steel vessel up to 300 °F. Over 300 °F, the jacket should be stainless steel as well.

Heat Transfer Coefficients: Half-Pipe Coil Jackets

Half-pipe coil jackets are generally manufactured with either 180° or 120° central angles (Dci):
 Figure 5: Depiction of Center Angles

Figure 6: Half-Pipe Coil

to Tank Details
For a 180° central angle:

Equivalent Heat Transfer Diameter, De = Π / (4 Dci)

Cross Section Area of Flow, Ax = Π / (8 (Dci2))

For a 120° central angle:

Equivalent Heat Transfer Diameter, De = 0.708 Dci

Cross Section Area of Flow, Ax = 0.154 (Dci2)

Using the same nomenclature as previous, the heat transfer coefficients are calculated as follows:

hj De/ k= 0.027(NRe)0.8 (NPr)0.33 (µ/µW)0.14 (1+3.5 (Dc/De) ) (For NRe>10,000) Eq. (7)

hj De/ k = 1.86 [ (NRe) (NPr) (Dc/De) ] 0.33 (µ/µW)0.14 (For NRe<2,100) Eq. (8)
Do not confuse Dci  with Dc. Dc is defined as Dji + ((Djo-Dji)/2).

Hydraulic Radius: Half-Pipe Coil Jackets

Figure 7: Hydraulic Radius

Dimensions
Referring to Figure7:

Eq. (9)
 Dimple Jackets or Plate Coils
The design of dimple jackets permits construction from light gauge metals without sacrificing the strength required to
withstand the specified pressure. This results in considerable cost saving as compared to convention jackets. Design
calculation begin with an assumed flow velocity between 2 and 5 ft/s. As a rule of thumb the jacket pressure will be
governing when internal pressure of vessel is less than 1.67 times the jacket pressure.

At such conditions, dimple jackets are typically more economical than other choices. However in small vessels (less
than 10 gallons) it is not practical to apply dimple jackets.
The design of dimple jackets is governed by the National Board of Boiler and Pressure Vessel Inspectors and can be
stamped in accordance with ASME Unfired Pressure Vessel Code. Dimple jackets are limited to a pressure of 300 psi
by Section VIII, Div.I of the ASME Code. The design temperature is limited to 700 °F. At high temperatures, it is
mandatory that jacket be fabricated from a metal having same thermal coefficient of expansion as that used in inner
vessel.

Figure 8: Vessel with Dimple

Figure 9: Dimple Jacket Details
Jacket Installed
Heat Transfer Coefficients: Dimple Jackets
hj Do/k= j (NRe) (NPr)0.33 (For 1000 < NRe < 50,000) Eq. (10)
Where:

j = 0.0845 (w/x)0.368 (Amin/Amax)-0.383 NRe-0.305

w = center-to-center distance between dimples

x = center-to-center distance between dimples parallel to flow
Note: (w/x) is equal to one for square spacings as is often the case
Do = (d1 + d2)/2
Amin = z (w-Do)
Amax = zw

All other variables are as previously defined. Garvin (CEP Magazine, April 2001)  reports an average error of 9.8%
with manufacturers data for the above correlation and a maximum error of 30% over 116 data points. This results in
average deviations in the heat transfer coefficient of 15-20% most of which was at velocities below 2 ft/s. Good
agreement with manufacturers data was found between 3 and 6 ft/s. A recommended excess area of 15% should be
used in this velocity range.

The correlation above is for integrally welded jackets (ie. jackets welded directly to the vessel). If a dimple jacket

is clamped onto an existing vessel and adhered with heat transfer mastic, the overall heat transfer coefficient of
 the system will be very low. Mastic is used to try to minimize air pocket resistances between the vessel wall and

the jacket. Historically, this arrangement results in poor heat transfer. A recommended overall heat transfer

coefficient of 10-15 Btu/h ft2 °F should be used for such systems regardless of the utility used.

Pressure Drop: Dimple Jackets

The pressure loss in a dimple jacket can be estimated from the following for water or water-like fluids:

Pressure Loss in Jacket = (Total Lenght of Flow, ft) x ((0.40 x Velocity, ft/s) - 0.35)

Pressure Loss Across Entire Jacket (including inlets and outlets) = Pressure Loss in Jacket + (0.10)(Pressure Loss in
Jacket)

The above estimates should be used for velocities ranging from 1.5 to 6 ft/s.

This method is based on a graph found on page 217 of the Encyclopedia of Pharmaceutical Technology by James
Swarbrick.

For detailed design, it is advisable to rely on manufacturer's data for pressure drop calculations.

Heat Transfer Coefficients Inside Agitated Vessels

In order to complete the overall heat transfer coefficient calculation, an estimate must also be made inside the
process vessel. The following estimate should yield reasonable results:

Eq. (11)

Where:

Ad = agitator diameter

N = agitator speed, rev/s
All other variables as previously defined
a is defined by the table below:

Table 1: Dimension "a" for Use with Equation 11

Agitator Surface "a"

Turbine Jacket 0.62

Turbine Coil 1.50

Paddle Jacket 0.36

Paddle Coil 0.87

Anchor Jacket 0.46

Propeller Jacket 0.54

Propeller Coil 0.83

Calculating the Overall Heat Transfer Coefficient

When calculating the overall heat transfer coefficient for a system, the vessel wall resistance and any jacket fouling
must be taken into account:

Eq. (12)

Notice that the thermal conducitivity of the vessel wall and the wall thickness are included in the calculation. A typical
jacket fouling factor is around 0.001 h ft2 °F/Btu. When calculating the overall heat transfer coefficient, use a
"common sense" analysis of the final value. The tables below will give some guidance to reasonable final values:

Table 2: Estimated Overall

Heat Transfer Coefficients
for Jacketed Tank Systems
(Imperial Units)

References
1. Heat Transfer Design Methods by 'John J. McKetta'
2. Hand Book of chemical Engineering Calculation 3rd Edition by 'Micclas P. Chopey'.
3. Applied Process Design for Chemical and Petrochemical Plants by 'Ludwig' Volume 3.
4. Estimate Heat Transfer and Friction in Dimple Jackets, 'John Garvin', CEP Magazine, April 2001, p. 73
5. Heat Transfer in Agitated Jacketed Vessels, 'Robert Dream', Chemical Engineering, January 1999, p. 90
6. Encyclopedia of Pharmaceutical Technology, 'James Swarbrick', p. 217
7. Tranter Plate Coil Product Manual