International Journal of Heat and Mass Transfer: Ahmad Fakheri
International Journal of Heat and Mass Transfer: Ahmad Fakheri
International Journal of Heat and Mass Transfer: Ahmad Fakheri
a r t i c l e i n f o a b s t r a c t
Article history: The concept of heat exchanger efficiency eliminates the need for charts, or complicated performance
Received 23 February 2014 expressions, providing a convenient approach for solving heat exchanger rating, and sizing problems,
Received in revised form 10 April 2014 as well as network of heat exchangers. The efficiency of all heat exchangers is determined from a single
Accepted 10 April 2014
algebraic expression. This paper is comprehensive, and streamlined presentation of the approach. It also
Available online 14 May 2014
provides a new expression for solving sizing problems, provides a closed form expression for determining
the minimum number of heat exchangers needed when one cannot meet the design specifications,
Keywords:
presents a new methodology for analyzing network of heat exchangers connected in series, and provides
Heat exchangers
Efficiency
closed form expressions for determining the size and the rate of heat transfer in individual heat
Heat exchanger efficiency exchangers of a network.
LMTD Ó 2014 Elsevier Ltd. All rights reserved.
Effectiveness-NTU
Heat exchanger networks
1. Introduction the ratio of the actual rate of heat transfer in the heat exchanger,
q, and the optimal rate of heat transfer, qopt,
Consider a heat exchanger where the hot fluid with capacity Ch q q
enters at T1 and leaves at T2. The cold fluid with capacity Cc enters g¼ ¼ ð1Þ
qopt U AðT tÞ
at t1 and exits at t2. The heat exchanger area is A, and the overall
average heat transfer coefficient is U, and is assumed to be a The optimum (maximum) rate of the heat transfer is the product of
constant, independent of temperature. Traditionally, two different UA of the heat exchanger under consideration and the Arithmetic
methods have been used for analyzing heat exchangers: the Mean Temperature Difference (AMTD) in the heat exchanger
Log Mean Temperature Difference (LMTD); and Effectiveness
T 1 þ T 2 t1 þ t2
NTU-method (e-NTU) [1,2]. The LMTD method is generally used AMTD ¼ T t ¼ ð2Þ
2 2
for solving heat exchanger problems where the inlet and the exit
temperatures are known and the size of the heat exchanger is to which is the difference between the average temperatures of hot
be determined (sizing problems). The reverse problem is called and cold fluids. The optimum heat transfer rate takes place in a
the rating problem where the size of the heat exchanger and the balanced counter flow heat exchanger [4]. The rate of heat transfer
inlet temperatures are known and the heat transfer rate and the in any heat exchanger for the same UA and AMTD is always less than
fluid exit temperatures are sought. The rating problem is typically the optimum value of the heat transfer rate ðg 6 1Þ.
analyzed using e-NTU approach. Fakheri [3] recently proposed a The heat transfer in a heat exchanger can be calculated from
third method for analyzing heat exchangers by defining the
q ¼ gNTUC min ðT tÞ ð3Þ
concept of heat exchanger efficiency.
Heat exchanger efficiency can be used to conveniently analyze The amount of heat transfer is also equal to
different heat exchanger design problems, including the network q ¼ C min DT max ¼ C max DT min ð4Þ
of heat exchangers without the need for charts, or complicated
performance expressions. Efficiency provides a clear and intuitive Note that some authors use DT min and DT max to refer to the temper-
measure of how well a system is performing by showing how close ature changes of the fluids with smaller and larger capacities,
it comes to the best that it can be and if further improvements are respectively, which is opposite of how it is used here.
feasible and justified. The heat exchanger efficiency is defined as The efficiency of all heat exchangers can be expressed as [2]
tanh½Fa
⇑ Tel.: +1 3096772719. g¼ ð5Þ
Fa
E-mail address: ahmad@bradley.edu
http://dx.doi.org/10.1016/j.ijheatmasstransfer.2014.04.027
0017-9310/Ó 2014 Elsevier Ltd. All rights reserved.
100 A. Fakheri / International Journal of Heat and Mass Transfer 76 (2014) 99–104
Nomenclature
A surface area, m2 qopt optimum heat transfer rate qopt ¼ UAðT tÞ
AMTD Arithmetic Mean Temperature Difference; AMTD T1 hot fluid inlet temperature
¼ ðT 1 þT
2
2
t1 þt 2
2 Þ ¼ ðT tÞ T2 hot fluid exit temperature
Cc _ p Þc
heat capacity of the cold fluid C c ¼ ðmC t1 cold fluid inlet temperature
Ch _ p Þh
heat capacity of the hot fluid C h ¼ ðmC t2 cold fluid exit temperature
Cmin =min[Ch, Cc] T average temperature of the hot fluid T ¼ T 1 þT2
2
and simplifying, results in This simple equation provides the overall efficiency of a system
" 1n # composed of two or more heat exchangers. As the number of heat
1 DT nmax þ mDT nmin exchangers is increased, the efficiency of the individual heat
Fa ¼ tanh ð16Þ
2ðT tÞ exchangers approaches one, and the overall system becomes equiv-
alent to using a single counter flow heat exchanger.
Therefore, when inlet and exit temperatures are known, the Fin The minimum number of heat exchangers needed to have a fea-
analogy number can be obtained from Eq. (16), and the efficiency sible design is the next integer higher than the value on the right
can be calculated from Eq. (5). Since the heat transfer is known, hand side of Eq. (20) [7].
the area of the heat exchanger can be calculated.
Thus both types of heat exchanger problems can be directly and Fa 2 1 DT max ð1 C r Þ
N> tanh ð20Þ
conveniently solved using the concept of heat exchanger efficiency, NTU ð1 C r Þ T t 2
without any need to charts or complicated equations, using the
same general expression for efficiency. The steps for solving both Using Eqs. (6) and (4), Eq. (20) can be written in terms of design
problems are shown in Table 2, and an example for each problem temperatures
type is given in Appendix. 1 " #
ðDT nmax þ mDT nmax Þn 1 DT max DT min
N> tanh ð21Þ
DT max DT min 2ðT tÞ
4. Heat exchangers connected in series
This provides only the minimum number of heat exchangers
There are instances, when one heat exchanger will not be able needed for a feasible solution and not necessarily an optimum solu-
to meet the design specifications. From Eq. (16), in order for a fea- tion. In fact, the system with the overall minimum area would
sible solution to exist require more than the minimum.
1n To determine the size of individual heat exchanger, consider the
DT nmax þ mDT nmin
<1 ð17Þ network shown in Fig. 1. If DT i and Dti are the temperature changes
2ðT tÞ of hot and cold fluids across the ith heat exchanger, then
If this condition is not met, the design will require the use of more qi ¼ C h ðDT i Þ ¼ C c ðDti Þ ð22Þ
than one heat exchanger. If N identical heat exchangers are con-
nected in series, as shown in Fig. 1, then the overall efficiency of
the system is given by [7]
qi ¼ U i Ai gi ðT i ti Þ ð23Þ
( )N Substituting for average temperatures and noting that
1 NTUð1C
2N
rÞ
g1
1
2 1 þ NTUð1C rÞ
g1 T iþ1 ¼ T i DT i
g¼ (
2N
)N ð18Þ ð24Þ
NTUð1 C r Þ NTUð1C r Þ t iþ1 ¼ t i Dti
1 2N g1
1þ
1 þ NTUð1C
2N
rÞ
g1 Then Eq. (23) becomes
T1 T3 Ti TN-1 TN+1 This procedure can be repeated for each assumed value of num-
ber of heat exchangers, and Example 3 of Appendix is a spread-
Fig. 1. A network of heat exchangers connected in series. sheet implementation of the approach for a number of different
102 A. Fakheri / International Journal of Heat and Mass Transfer 76 (2014) 99–104
shells, and as expected as the number of shells increases, the total Appendix A
heat exchanger area decreases.
A direct solution procedure is presented below that provides an The three examples in this appendix demonstrate how heat
explicit equation for determining U i Ai gi needed in step 2, directly, exchanger efficiency is used for sizing, rating and network
avoiding the iterative process. Multiplying both sides of Eq. (26) by problems.
Ch results in
A.1. Example 1 – sizing problem
Ch
qi ¼ ðT i t i Þ ð28Þ
ci Water at a rate of 1.5 kg/s is heated from 25 °C to 100 °C in a
For the i + 1 heat exchanger, this equation becomes finned-tube cross-flow heat exchanger using exhaust gases that
enter at 250 °C and leave at 120 °C. The exhaust gases specific heat
Ch Ch is 1080 J/kg K, and that of water is 4200 J/kg K, and the overall heat
qiþ1 ¼ ðT iþ1 t iþ1 Þ ¼ ðT i DT i ti þ Dti Þ ð29Þ
ci ci transfer coefficient based on the gas side surface area is 150 W/
m2 K. Determine the gas side heat exchanger area.
which can be rearranged as
Heat exchanger efficiency is a convenient approach for heat ðDT nmax þ mDT nmin Þn
1
Fa ¼ tanh
exchanger analysis, and can be used to solve rating and sizing 2ðT tÞ
problems, as well as network of heat exchangers without the need
for charts, or complicated performance expressions. The efficiency C r ¼ 0:58
of all heat exchangers is determined from a single algebraic expres-
For cross-flow heat exchanger with both unmixed
sion. A new expression for direct solution of the sizing problems is
presented. A closed form expression for determining the required tanh½Fa
minimum number of heat exchangers is derived. The paper also
g¼ ¼ 0:938
Fa
presents a new methodology for analyzing network of heat
exchangers connected in series, that allows the direct determina- q
A¼ ¼ 27:42 m2
tion of the size of individual heat exchangers, and the rate of heat U gðT tÞ
transfer in them, which shows the heat transfer rate in consecutive
heat exchangers connected in series increases geometrically.
A.2. Example 2 – sizing problem
Conflict of interest Hot exhaust gases, with a thermal capacity of 3634.62 W/K
enter a finned-tube cross-flow heat exchanger at 250 °C and are
None declared. used to heat water with a thermal capacity of 6300 W/K entering
A. Fakheri / International Journal of Heat and Mass Transfer 76 (2014) 99–104 103
Table 3
Spreadsheet results for calculating the areas of 3 to 7 shell and tube heat exchangers connected in series using the above algorithm.
the heat exchanger at 20 °C. The overall heat transfer coefficient T 1 t1 250 20
T t ¼ ¼
based on the gas side surface area is 150 W/m2 K, and the heat 1 þ NTU g ð1þC rÞ
1 þ 1:13 0:938 ð1þ0:58Þ
2 2
exchanger area is 27.42 m2. Determine the rate of heat transfer.
q ¼ NTU gC min ðT tÞ ¼ 1:13 0:938 3634:62 ¼ 472; 500 W
tl 25
mc 1.5 q
t2 ¼ t1 þ
cpc 4200 Cc
T1 250
Cc 6300 q
T2 ¼ T1
cph 1080 Ch
U 150 which are the same as Example 1.
Ch 3634.62
A 27.42
A.3. Example 3 – heat exchanger networks
NTU 1.13
m 0.1
Consider a 106 W of heat is to be removed from a hot stream to
n 0.37
cool it from 410 °C to 110 °C by another stream entering at 0 °C and
Cr 0.58
leaving at 360 °C in a shell and tube heat exchanger. This problem
Fa 0.45
is traditionally solved by trial and error, or by the graphical
g 0.938
approach of ‘‘stepping off’’ [8] which results in a feasible solution
T t 122.50
requiring three shells.
q 472500
Using Eq. (21)
t2 100
1 " #
T2 120 DT max n þ mDT nmax n 1 DT max DT min
N> tanh ¼ 3:08
DT max DT min 2ðT tÞ
This is the reverse problem, and an example of a heat exchanger and therefore the minimum number of heat exchangers for which a
rating problem. feasible solution exists is 4.
1 1 The direct solution for 4 shells results in
ð1 þ mC nr Þn ð1 0:1 0:580:37 Þ0:37 h i1=4
Fa ¼ NTU ¼ 1:13 ¼ 0:45 1 1
2777:78
2 2 2 1 106 3333:33
410360
þ1
TanhðFaÞ U i Ai g i ¼ 1 1 h i1=4 ¼ 3274:64
g¼ ¼ 0:938 3333:33
2777:78 1
1 þ 106 3333:33
1
2777:78
þ 1
Fa 410360
104 A. Fakheri / International Journal of Heat and Mass Transfer 76 (2014) 99–104
3333:33
From Eq. (27) ci ¼ 3274:64 þ 12 ð1 3333:33
2777:78
Þ ¼ 0:918 respectively. As can be seen, 3 heat exchangers is not a feasible
solution, and in fact the minimum number of heat exchangers for
410 360
DT i ¼ ¼ 54:47 which a solution exists is 4. As the number of heat exchangers is
0:918
increased the total area decreases and asymptotes to the limiting
Ch value of UA = 13141 W/°C which is for a single counter flow heat
Dt i ¼ DT i ¼ 65:36
Cc exchanger.