HEAT EXCHANGERS

1
 Heat Exchangers
• A heat exchanger is used to exchange heat between two fluids of different
temperatures, which are separated by a solid wall.
• Heat exchangers are ubiquitous to energy conversion and utilization. They
encompass a wide range of flow configurations.
• Applications in heating and air conditioning, power production, waste heat
recovery, chemical processing, food processing, sterilization in bio-processes.
• Heat exchangers are classified according to flow arrangement and type of
construction.

2
 Concentric Tube Construction

Parallel Flow Counterflo

• - :

Parallel Flow Counterflow

3
Parallel Flow

4
Counter Current Flow

5
 Heat Exchanger Analysis
• Expression for convection heat transfer for flow of a fluid inside a tube:

qconv  m c p (Tm,o  Tm,i )

• For case 3 involving constant surrounding fluid temperature:

q  U As Tlm

To  Ti
Tlm 
ln(To / Ti )

6
 Heat Exchanger Analysis

In a two-fluid heat exchanger, consider the hot and cold fluids separately:

qh  m h c p ,h (Th ,i  Th ,o )
qc  m c c p ,c (Tc,o  Tc,i )

q  UA Tlm
7
Tlm: 1. Parallel-Flow Heat Exchangers

T1 T2
q  UA Tlm

T  T1
Parallel Flow Tlm  2
Counterflow
ln(T2 / T1 )
where

T1  Th,i  Tc,i

T2  Th,o  Tc,o

8
Tlm: 2. Counter-Flow Heat Exchangers

T1 T2
q  UA Tlm
T2  T1
Tlm 
Counterflow ln(T2 / T1 )

where

T1  Th,i  Tc ,o
T2  Th,o  Tc ,i

9
 Example
In a double pipe counter flow heat exchanger, water at the rate of 60 lbm/min is heated from
65OF to 95OF by an oil having a specific heat of 0.36 Btu/lbm.OF. The oil enters the heat
exchanger at 200OF and leaves at 140OF. Determine the heat exchanger area for an overall
heat transfer coefficient of 50 Btu/h.ft2.OF.

q = ṁCpΔT = (60lbm/min)(60min/h)(1.0 Btu/lbm.OF)[(95 – 65) OF]

q = 108,000 Btu/h
Assume CpH2O = 1Btu/lb·°F
T1  Th,i  Tc ,o = 140 – 65 = 75 OF = 4.184 kJ/kg·K
T2  Th,o  Tc ,i = 200 – 95 = 105 OF @ Tave = 20 - 30°C
T2  T1
Tlm  75 – 105 = -30 = 89.16OF
ln(T2 / T1 ) =
ln (75/105) - 0.336
A= q = 108,000 Btu/h = 24.23 ft2
UΔTlm (50 Btu/h.ft2.O)(89.16OF)

10
 Example
• Hot oil (Cp = 2.09 kJ/kg.K) flows through a counterflow heat exchanger at the
rate of 0.63 kg/s. It enters at 193OC and leaves at 65OC. Cold oil (Cp = 1.67
kJ/kg.K) exits at 149OC at the rate of 1.0 kg/s. What area is required to
handle the load if the overall heat transfer coefficient based on the inside
area is 0.7 kW/m2.K?

• A given heat exchanger can be designed to have a U value of 2270 W/m2.OC

with a variety of different configurations (double pipe parallel; double pipe
counterflow). Find the heat transfer surfaces for each case if equal flow rates
of water (1.26 kg/s) are used and one fluid is cooled from 94OC to 72OC while
the other fluid is initially at 38OC. Cp of the cold fluid is 4.196 kJ/kg.OC and
the Cp of hot fluid is 4.176 kJ/kg.OC.

11
 Total Condensers
CASE 1 If the vapor enters as vapor and condensate leaves at the
condensing temperature (saturated vapor) without being
further cooled;

Tha = Thb = condensing temperature of the vapor

Then
qc  m c c p ,c (Tc ,o  Tc ,i ) = ṁh λ

CASE 2 If the vapor enters as saturated vapor and condensate

leaves at temperature Thb (condensate is subcooled)
which is less than Thb, the condensing temperature
Then
qc  m c c p ,c (Tc ,o  Tc ,i ) = ṁh[λ + Cphliquid condensate (Th – Thb)]

12
 Total Condensers
CASE 3 If the vapor enters superheated and condensate leaves at
condensing temperature

Then
qc  m c c p ,c (Tc ,o  Tc ,i ) = ṁh[λ + Cphsuperheated vapor(Tha – Th)]

CASE 4 If the vapor enters as superheated and condensate

leaves at temperature Thb (condensate is subcooled)
which is less than Th, the condensing temperature

Then
qc  m c c p ,c (Tc ,o  Tc ,i )

= ṁh[λ + Cphsuperheated vapor(Tha – Th) + Cphliquid condensate(Th – Thb)]

13 13
 Overall Heat Transfer Coefficient

• For tubular heat Flow

Parallel exchangers we must take into account the conduction
Counterflow
resistance in the wall and convection resistances of the fluids at the inner
and outer tube surfaces.
1 1 1
  Rcond 
UA hi Ai ho Ao
ln(Do / Di )
Rcond 
2kL
1 1 1 where inner tube surface Ai  Di L
 
UA U i Ai U o Ao outer tube surface
Ao  Do L
14
 Fouling
• Heat exchanger surfaces are subject to fouling by fluid impurities,
rust formation, or other reactions between the fluid and the wall
material. The subsequent deposition of a film or scale on the surface
can greatly increase the resistance to heat transfer between the fluids.

• An additional thermal resistance, can be introduced: The Fouling

factor, Rf.

➢ Depends on operating temperature, fluid velocity and length of service of

heat exchanger. It is variable during heat exchanger operation.

15
 Overall Heat Transfer Coefficient
•The overall heat transfer coefficient can be written:

1 1 1 1 Rf",i Rf",o 1
     Rcond  
UA U i Ai U o Ao hi Ai Ai Ao ho Ao

1
Uo  "
Ao Ao R 1
  Ao Rcond  Rf ,o 
f ,i "

hi Ai Ai ho

➢Need to determine hi and ho

16
 Example
Methyl alcohol in the inner pipe of a double pipe exchanger is cooled with water flowing in
the jacket. The inner pipe is made from 1-in Schedule 40 steel pipe. The thermal
conductivity of steel is 26 Btu/ft.h.OF (45 W/m.OC). The individual coefficients and fouling
factors are given in the table below. What is the overall coefficient, based on the outside
area of the inner pipe?
coefficient
Btu/ft2.h.OF W/m2.OC
Alcohol coefficient, hi 180 1020
water coefficient, ho 600 1700
inside fouling factor, hfi 1000 5680
outside fouling factor, hfo 500 2840

17
 Example
A counterflow, concentric tube heat exchanger is used to cool the lubricating
oil for a large industrial gas turbine engine. The flow rate of cooling water
through the inner tube (Di=25 mm) is 0.2 kg/s, while the flow rate of oil through
the outer annulus (Do=45 mm) is 0.1 kg/s. The oil and water enter at
temperatures of 100 and 30°C respectively. How long must the tube be made if
the outlet temperature of the oil is to be 60°C?

18
 Determination of ho
• Approach 1: Using correlations Approach 2: Using chart by Kern

➢Typical values of baffle cuts 20-25% for liquids and 40-45% for vapor
19
Determination of tube side film coefficient, hi
• Approach 1: Using correlations Approach 2: Sieder and Tate

20
 Determination of Conduction Resistance

• Recall that ln(Do / Di )

Rcond 
2kL
D
Ao Rcond  o ln(Do / Di )
2k

• or

Do
rw  Ao Rcond  ln(Do / Di )
2k w

21
• LAMINAR FLOW
Smooth streamlines
Highly- ordered motion
(highly viscous fluids in small pipes)
• TURBULENT FLOW
Velocity fluctuations
Highly-disordered motion
• TRANSITIONAL FLOW

22
 REYNOLDS NUMBER

Flow Regime: Ratio of the inertial forces to

viscous forces in the fluid
Geometry
Surface roughness m D
 m D
Re  
Flow velocity v 
Surface temperature
m Mean flow velocity
type of fluid
D Characteristic length of
the geometry
v/ Kinematic viscosity

23
• Critical Reynolds number (Recr) for flow in a round pipe
Re < 2300  laminar
2300 ≤ Re ≤ 4000  transitional
Re > 4000  turbulent

• Note that these values are approximate.

• For a given application, Recr depends upon
– Pipe roughness
– Vibrations
– Upstream fluctuations, disturbances (valves, elbows, etc. that
may disturb the flow) 24
HYDRAULIC DIAMETER

• For non-round pipes,

• the hydraulic diameter
Dh = 4Ac/P
Ac = cross-section area
P = wetted perimeter

25
 THERMAL BOUNDARY LAYER
Flow region over the
surface in which the
temperature variation
in the direction
normal to the surface
Velocity profile
influences
temperature profile

26
 VELOCITY
A flow field is best characterized by the velocity distribution, and
velocity may vary in three dimension
 
 ( x, y, z ) in rectangular  (r , , z ) in cylinderical coordinates

One dimensional
flow in a circular
pipe

27
NUSSELT NUMBER
(Dimensionless number)

hLc
Nu 
k
• T
q cond k
L
•
q conv  hT
•
q conv hT hL
•
   Nu
q cond kT / L k
28
 PRANDTL NUMBER

• Boundary layer theory

molecular diffusivity of momentum
 C p
Pr   
 k
molecular diffusivity of heat

Pr<<1 heat diffuses very quickly in liquid metals, tbl thicker

Pr>>1 heat diffuses very slowly in oils relative to momentum, tbl thinner than vbl

29
 FORCED CONVECTION: LAMINAR FLOW

The primary resistance to heat transfer by convection is normally

controlled within a thin layer of the fluid, adjacent to the
immersed body, in which viscous effects are important. The
quantity of heat transferred is highly dependent upon the fluid
motion within this boundary layer, being determined chiefly by
the thickness of the layer.
 FORCED CONVECTION: LAMINAR FLOW

Prandtl’s Boundary Layer Equation

By applying Newton’s second law and the continuity
equation to an infinitesimal, two dimensional control
volume within the boundary layer, and assuming that
1. Fluid viscosity is constant
2. Shear in the y-direction is negligible
3. The flow is steady, and the fluid is incompressible
4. The vertical pressure gradient is negligible
 THERMAL BOUNDARY LAYER: FLAT PLATE
When a fluid at one temperature flows along a surface which is at
another temperature, a thermal boundary layer develops. The
thermal boundary layer thickness is defined as the distance
required for the temperature T to reach 99% of its free-stream
value T∞. And assuming,
1. steady, incompressible flow
2. Constant fluid properties evaluated at film temperature:
Tw = Ts + T∞
2
3. Negligible body forces, viscous heating, and conduction in the
flow direction
 PRANDTL NUMBER

Pr = ν = Cp μ
α k

Pr is unity, which is approximately the case for most gases

(0.6<Pr<1.0). The Prandtl number for liquids however, varies widely,
ranging from large values for viscous oils to very small values for
liquid metals which have high thermal conductivities.
Heat Exchangers Chee 318 34
 Example
A stainless steel tube (k = 45 W/m.K) of inner and outer
diameters of 22 mm and 27 mm respectively, is used in a
cross flow heat exchanger. The fouling factors for the inner
and outer surfaces are estimated to be 0.0004 and 0.0002
(m2.K)/W respectively. Determine the overall heat transfer
coefficient based on the outside surface area of the tube.

Water at
75OC & Di = 22 mm Do = 27 mm
0.5 m/s

Air at 15OC & 20 m/s

35 35
Properties of water at 75OC
k = 0.6715 W/m.K
ν = 0.39 x 10-6 m2/s
Pr = 2.38

Re = u D = 0.5 m/s (0.022 m) = 28205.13 (turbulent)

ν 0.39 x 10-6 m2/s
Nu = hiDi = 0.023 Re0.8 Pr0.4
k = 0.023 (28205.13)0.8 (2.38)0.4
= 118.2
hi = 118.2 (0.6715) = 3608 W/m2.K
0.022

36
Properties of air at 15OC
k = 0.0255 W/m.K
ν = 14.16 x 10-6 m2/s
Pr = 0.704

Re = u D = 20 m/s (0.027 m) = 38135.59

ν 14.16 x 10-6 m2/s
Nu = hoDo = [0.04 Re0.5 + 0.06 Re0.67] Pr0.4 (μ/μw)0.25
k
= [0.04(38135.59)0.5 + 0.06(38135.59)0.67 ](0.704)0.4(1)0.25
= 139.3021
ho = 139.3021 (0.0255) = 131.5631 W/m2.K
0.027
37 37
 1 1 1 1 Rf",i Rf",o 1
     Rcond  
UA U i Ai U o Ao hi Ai Ai Ao ho Ao

1
Uo  "
Ao Ao R 1
  Ao Rcond  R 
f ,i "
f ,o
hi Ai Ai ho

38
Ro = 1 = 1 = 0.0896
hoAo (131.5631 W/m2.K)(П)(0.027) (1)

Ri = 1 = 1 = 0.00401
hiAi (3608 W/m2.K)(П)(0.022) (1)

Rfi = Fi = 0.0004 = 5.787 x 10 -3

Ai (П)(0.022) (1)
Rfo = Fo = 0.0002 = 2.358 x 10 -3
Ao (П)(0.027) (1)
Rcond = ln Do/Di = ln (0.027/0.022) = 7.24 x 10 -3
2ПkL 2 П (45) (1)
39
 1 1 R "f ,i 1 R "f ,o
   Rcond  
U o Ao hi Ai Ai Ao ho Ao
1
 0.00401  5.787 x 10 - 3  7.24 x 10 - 3  2.358 x 10 - 3  0.0896
U o Ao

1
1
 0.102489  Uo
U o Ao 0.102489 Ao

U o  115.0296 W/m2.K

40
 Shell-and-Tube Heat Exchangers

One Shell Pass and One Tube Pass

Baffles are used to establish a cross-flow and to induce turbulent mixing

of the shell-side fluid, both of which enhance convection.
➢ The number of tube and shell passes may be varied

41
Shell-and-Tube Heat Exchangers

One Shell Pass,

Two Tube Passes

Two Shell
Passes,
Four Tube
Passes

42
Multipass and Cross-Flow Heat Exchangers
To account for complex flow conditions in multipass, shell and tube
and cross-flow heat exchangers, the log-mean temperature difference
can be modified:

Tlm  FTlm,CF

where F = correction factor

43
Correction Factor

where t is the
tube-side fluid
temperature

44
 Example
In a heat exchanger, hot fluid enters at 60OC and leaves at
48OC, where as the cold fluid enters at 35OC and leaves at
44OC. Calculate the mean temperature difference for
a) parallel flow,
b) counter flow,
c) single pass cross flow (both fluids unmixed)
d) single pass cross flow (hot side fluid mixed, cold side
fluid unmixed)

45
 Parallel Flow
Thi = Tha = 60OC Tho = Thb = 48OC
Tci = Tca = 35OC Tco = Tcb = 44OC

T1  Th,i  Tc,i T2  T1

Tlm 
T2  Th,o  Tc,o ln(T2 / T1 )

T1  48  44  4 25  4
Tlm 
T2  60  35  25 ln(25 / 4)

Tlm  11.5C
46
 Countercurrent Flow
Thi = Tha = 60OC Tho = Thb = 48OC
Tci = Tca = 35OC Tco = Tcb = 44OC

T1  Th,i  Tc ,o T2  T1

Tlm 
T2  Th,o  Tc ,i ln(T2 / T1 )

T1  48  35  13 16  13
Tlm 
T2  60  44  16 ln(16 / 13)

Tlm  14.45OC
47
 Cross Flow
Thi = Tha = 60OC Tho = Thb = 48OC
Tci = Tca = 35OC Tco = Tcb = 44OC
Single pass cross flow; both fluids unmixed

Z = Thi – Tho = 60 – 48 = 1.33

Tcb – Tci 44 – 35

ŋH = Tco – Tci = 44 – 35 = 0.36

Thi – Tci 60 – 35

From Figure 15.7 (b), F = 0.94

LMTD = (0.94)(14.45OC) = 13.583OC

48
 Cross Flow
Thi = Tha = 60OC Tho = Thb = 48OC
Tci = Tca = 35OC Tco = Tcb = 44OC
Single pass cross flow; hot fluid mixed, cold fluid unmixed

Z = Thi – Tho = 60 – 48 = 1.33

Tcb – Tci 44 – 35

ŋH = Tco – Tci = 44 – 35 = 0.36

Thi – Tci 60 – 35

From Figure 15.7 (a), F = 0.98

LMTD = (0.98)(14.45OC) = 14.16OC

49 49
 Example
A 1-2 heat exchanger containing one shell pass and two tube
passes heats 2.52 kg/s of water from 21.1 to 54.4OC by using
hot water under pressure entering at 115.6 and leaving at
48.9OC. The outside surface area of the tubes in the exchanger
is Ao = 9.30 m2.
a) Calculate the mean temperature difference LMTD in the
exchanger and the overall heat transfer coefficient Uo.
b) For the same temperature but using a 2-4 exchanger, what
would be the LMTD?

Thi = Tha = 115.6OC Tho = Thb = 48.9OC

Tci = Tca = 21.1OC Tco = Tcb = 54.4OC

50
 Example
q = mCp,c (Tco –Tci) = 2.52 kg/s (4184 J/kg.K)(54.4 – 21.1OC)
q = 351104.54 W
LMTD for crossflow;
LMTD = (Tha – Tcb ) – (Thb – Tca)
ln (Tha – Tcb )
(Thb – Tca)
LMTD = (115.6 – 54.4) – (48.9 – 21.1) = 42.3261OC
ln (115.6 – 54.4)
(48.9 – 21.1)
For multipass and crossflow heat exchangers

Tlm  FTlm,CF
51
 Example
a) Single pass, shell fluid mixed, other fluids unmixed, use
Figure 15.7 a ( 1 – 2 Heat Exchangers)

Z = Thi – Tho = 115.6 – 48.9 = 2.00

Tcb – Tci 54.4 – 21.1

ŋH = Tco – Tci = 54.4 – 21.1 = 0.352

Thi – Tci 115.6 – 21.1

From Figure 15.7 (a), F = 0.74

LMTD = (0.74)( 42.3261) = 31.3213OC

Uo = q = 351104.54 W = 1205.351 W/m2.K

Ao (LMTD) (9.30 m2)(31.3213OC)

52
 Example
b) Single pass, both fluids unmixed, use Figure 15.7 b
( 2 – 4 Heat Exchangers)

Z = Thi – Tho = 115.6 – 48.9 = 2.00

Tcb – Tci 54.4 – 21.1

ŋH = Tco – Tci = 54.4 – 21.1 = 0.352

Thi – Tci 115.6 – 21.1

From Figure 15.7 (b), F = 0.94

LMTD = (0.94)( 42.3261) = 33.60693OC

Uo = q = 351104.54 W = 1123.375 W/m2.K

Ao (LMTD) (9.30 m2)(33.60693OC)

53 53
 Heat Transfer Coefficients
The heat transfer coefficient hi for the tube side fluid in a shell
and tube exchanger can be calculated using equations in
chapter 12. the coefficient for the shell side ho cannot be
calculated because the direction of flow is partly parallel to the
tubes and partly across them. An approximate but general
useful equation for predicting shell side coefficients is the
Donohue equation.

hoDo = 0.2 DoGe 0.6 Cpμ 0.33 μ 0.14

k μ k μw

Ge = √ Gb Gc Gb = ṁ / Sb Gc = ṁ / Sc
Mass velocity Mass velocity for
parallel with tubes crossflow
54
 Sb = ƒb π Ds2 – Nb π Do2
4 4
Total area of Total area
baffle window occupied by
the tubes

ƒb = fraction of cross-sectional area of shell occupied by baffle

window
Ds = inside daimeter of shell
Nb = number of tubes in baffle window
Do = outside diameter of tubes

Sc = P Ds ( 1 – Do/ƿ)

P = center to center distance between tubes

Ƿ = baffle pitch
55
 Heat Transfer Coefficients
ho Cpμ 2/3 μw 0.14 = jH = 0.2 DoGe -0.4

CpGe k μ μ

j - factor form

Crossflow Exchangers

hoDo = 0.287 DoG 0.61 Cpμ 0.33 Fa

k μ k

56
 Example
A tubular exchanger with 35-in (889-mm) ID contains eight
hundred and twenty eight ¾ -in (19-mm) OD tubes 12 ft (3.66-mm)
long on a 1-in (25-mm) square pitch. Standard 25 percent baffles
are spaced 12-in (305 mm) apart. Liquid benzene at an average
bulk temperature of 60OF (15.6OC) is bing heated in the shell side
of the exchanger at the rate of 100,000 lb/h (45,360 kg/h). If the
outside surfaces of the tubes are at 140OF (60OC), estimate the
individual heat transfer coefficient of the benzene.
Do = 0.75 / 12 = 0.0625 ft Ds = 35 / 12 = 2.9167 ft
Ƿ = 1/ 12 = 0.0833 ft P = 1 ft
Sc = P Ds ( 1 – Do/ƿ)
Sc = 1 x 2.9167 1 – 0.0625
0.0833
57
 Nb = 0.1955 x 828 = 161.8 ≈ 161 tubes

Sb = ƒb π Ds2 – Nb π Do2
4 4
Sb = 0.1955 π (2.9167)2 – 161 π (0.0625)2
4 4
Sb = 0.8123 ft2

Ge = √ Gb Gc Gb = ṁ / Sb Gc = ṁ / Sc

Gc = 100,000 = 137,137 lb/ft2.h Gb = 100,000 = 123,107 lb/ft2.h

0.7292 0.8123

58
 Ge = √ (137,137)(123,107) = 129,933 lb/ft2.h

Properties:
μ @ 60OF = 0.70 cP μ @ 140OF =m0.38 cP
Cp = 0.41 Btu/lb.OF k = 0.092 Btu/h.ft.OF

hoDo = 0.2 DoGe 0.6 Cpμ 0.33 μ 0.14

k μ k μw

ho = 0.2 0.0625(129,933) 0.6 (0.41)(0.70)(2.42) 0.33 0.70 0.14 0.092

0.70 (2.42) 0.092 0.38 0.0625

ho = 101 Btu/h.ft2.OF (573 W/m2.OC)

59
Heat Exchanger Applications

60
Finned Exchangers

61
 Heat Transfer Units
Transfer units can be based on either stream, but generally
the stream with the lower capacity is chosen. (𝑪𝒄 = 𝑪𝒑𝒄 𝒎ሶ 𝒄 )
Generally, the cold fluid undergoes a greater temperature
change, hence CC will be the minimum heat capacity, Cmin

𝑇𝑐𝑏 − 𝑇𝐶𝑎
𝑁𝐻 =
∆𝑇𝑙𝑚

𝑄 = 𝑚𝐶
ሶ 𝑝 𝑇𝑐𝑏 − 𝑇𝑐𝑎 = 𝑈𝐴∆𝑇𝑙𝑚

𝑼𝑨 𝑼𝑨
𝑵𝑯 = =
ሶ 𝒑 𝑪𝒎𝒊𝒏
𝒎𝑪

Heat Exchangers 62
 In a multipass or crossflow exchanger, the effective
driving force is less than the logarithmic mean difference.
𝑇ℎ − 𝑇𝑐𝑏 = (𝑇ℎ − 𝑇𝑐𝑎 )𝑒 −𝑁𝐻

If the hot and cold streams have equal capacity, the

driving force is equal to Tha - Tcb
𝑇𝑐𝑏 − 𝑇𝑐𝑎
𝑁𝐻 =
𝑇ℎ𝑎 − 𝑇𝑐𝑎

𝑻𝒄𝒃 − 𝑻𝒄𝒂 𝑵𝑯
𝜺= =
𝑻𝒉𝒂 − 𝑻𝒄𝒂 1 + 𝑵𝑯

Heat Exchangers 63
 Heat Exchanger Effectiveness

Effectiveness is defined as the as the ratio of actual

rate of heat transfer in a given exchanger to the
maximum possible amount of heat transfer if an infinite
heat transfer area were available, then Tcb = Tha.

64
 Heat Exchanger Effectiveness
Actual heat
transfer

𝐶ℎ (𝑇ℎ𝑎 − 𝑇ℎ𝑏 ) 𝐶𝑐 (𝑇𝑐𝑏 − 𝑇𝑐𝑎 )

𝜀= =
𝐶𝑚𝑖𝑛 (𝑇ℎ𝑎 − 𝑇𝑐𝑎 ) 𝐶𝑚𝑖𝑛 (𝑇ℎ𝑎 − 𝑇𝑐𝑎 )

𝑸 = 𝜺𝑪𝒎𝒊𝒏 (𝑻𝒉𝒂 − 𝑻𝒄𝒂 )

𝑄 = 𝐶𝑐 𝑇𝑐𝑏 − 𝑇𝑐𝑎 = 𝑈𝐴∆𝑇𝑙𝑚

65
 Heat Exchanger Effectiveness
Counter current flow

1 − 𝑒 −𝑁𝐻(1−𝑅𝑠)
𝜀=
1 − 𝑅𝑠 ∙ 𝑒 −𝑁𝐻 (1−𝑅𝑠)

𝐶𝑚𝑖𝑛
𝑅𝑠 =
𝐶𝑚𝑎𝑥

Parallel flow

1 − 𝑒 −𝑁𝐻(1+𝑅𝑠)
𝜀=
1 + 𝑅𝑠
66
 Example
Water flowing at a rate of 0.667 kg/s enters a counter current heat
exchanger at 308 K and is heated by an oil stream entering at 383
K at a rate of 2.85 kg/s (Cp = 1.89 kJ/kg.K). The overall U = 300
W/m2.K and the area A = 15.30 m2. Calculate the heat transfer rate
and the exit water temperature.

Assuming Tco = 370 K; Tave = (308 + 370 K)/2 = 339 K

Cp,C = 4.192 kJ/kg.K

ṁ Cp,h = Ch = 2.85 kg/s ( 1.89 x 103 J/kg.K) = 5386.5 W/K

ṁ Cp,c = Cc = 0.667 kg/s ( 4.192 x 103 J/kg.K) = 2796.06 W/K

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Cmin = 2796.06 = 0.5191
Cmax 5386.5

NH = UA = 300 (15.0) = 1.6094

Cmin 2796.06
For counter current flow exchanger,
using Figure 15.8 [Mccabe 7th Ed] ε = 0.71

q = ε Cmin (Thi – Tci)

= 0.71(2796.06)(383 – 308) = 148890.4 W

q = 148890.4 W = 2796.06 (Tco – 308)

Tco = 361.25 K

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 Example
A double pipe, parallel flow heat exchanger uses oil (Cp=1.88
kJ/kgOC) at an initial temperature of 205OC to heat water, flowing at
225 kg/h, from 16OC to 44OC. The oil flow rate is 270 kg/h
a) what heat exchanger area is required fro an overall heat transfer
coefficient of 340 W/m2.K
b) determine the number of transfer units
c) calculate the effectiveness of HE
Q = (225 kg/h)(4.18 kJ/kg.OC)(44 – 16) OC
= 26,334 kJ/h

26, 334 kJ/h = (270 kg/h)(1.88 kJ/kg.OC) (205 – Tho) OC

Tho = 153.12OC

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LMTD for crossflow;
LMTD = (205 – 44 ) – (153.12 – 16) = 148. 7406OC
ln (205 – 44 )
(153.12 – 16)

A = 225 (4.18 x 103) (44 – 16) (1/3600) = 0.1446 m2

340 (148.7406OC)

LMTD for parallel;

LMTD = (205 – 16 ) – (153.12 – 44) = 145.4218OC
ln (205 – 16 )
(153.12 – 44)

A = 26,334 kJ/h (1h / 3600s) (1000J/kJ) = 0.1479 m2

340 W/ m2 K (145.4218 K)
70
Cmin = (mCp)H = 270 (1.88 x 103) = 507,600 J/h.OC
Cmax = (mCp)C = 225 (4.18 x 103) = 940,500 J/h.OC

NTU = UA = 340 (0.1479) = 0.3568

Cmin 507,600 (1/3600)

1 − 𝑒 −𝑁𝐻(1+𝑅𝑠)
𝜀=
1 + 𝑅𝑠
ε = 0.2698 = 26.98 %
71
 HEAT TRANSFER IN AGITATED VESSELS
Heat transfer surfaces, which may be in the form of heating or
cooling jackets or coils of pipe immersed in the liquid, are often
used in the agitated vessels.

With helical coil and turbine impeller

hcDc = 0.17 Da2nρ 0.67 Cpμ 0.37 Da 0.1 Dc 0.5 μ 0.24

k μ k Dt Dt μw

To or from the jacket of a baffled tank

hjDi = 0.76 Da2ŋρ 2/3 Cpμ 1/3 μ 0.24

k μ k μw

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Anchored agitators for viscous liquid

hjDt = K Da2ŋρ a Cpμ 1/3 μ 0.18

k μ k μw

K = 1.0
a =½ for 10 < Re < 300

K = 0.36
a = 2/3 for 300 < Re < 40,000

73
 Example
A turbine agitated vessel 3 m in diameter contains 6600 kg of a
dilute aqueous solution. the agitator is 0.75 m in diameter and
turns at 150 rev/min. the vessel is jacketed with steam condensing
at 38 psig; the heat transfer area is 16 m2. the steel walls of the
vessel are 10-mm thick. If the heat transfer coefficient of the steam
is 12 kW/m2.OC, what is the rate of heat transfer between the
steam and liquid and the time to heat the vessel contents from
30OC to 90OC?

P = 52.7 psia Ŋ = 150 rev/min δ = 10 mm

Ts = 284.216OF A = 16 m2 hc = 12 kW/m2.OC
= 140.12OC Ta = 30OC Tb = 90OC

74
 hjDi = 0.76 Da2ŋρ 2/3 Cpμ 1/3 μ 0.24

k μ k μw

Properties at Tf = 30 + 90 = 60OC = 140 OF

2
k = 0.378 Btu/ft.h.OF
μ = 0.470 cP = 0.47 x 10-3 kg/m.s
ρ = 61.38 lb/ft3
μw = 0.196 cP

hj (3) = 0.76 0.7522.5(983.65) 2/3 4184(4.7x10-3) 1/3 0.47 0.24

0.6542 4.7 x 10-3 0.6542 0.196

75
hj = 6061.436 W/m2.OC

Ui = 1
1 + 1 3 + 10/1000 3
6061.436 12000 3.02 45 3.01

Ui = 2131.093 W/m2.OC

tT = 6600 (4184) ln (140.12 – 30)/(140.12 – 90)

2131.093 (16)
tT = 637.487 sec = 10.63 min

q = 2131.093 W/m2.OC (16 m2) ( 140.12 – 60)OC

76
 Example
A shell-and-tube heat exchanger must be designed to heat 2.5 kg/s of water
from 15 to 85°C. The heating is to be accomplished by passing hot engine
oil, which is available at 160°C, through the shell side of the exchanger. The
oil is known to provide an average convection coefficient of ho=400 W/m2.K
on the outside of the tubes. Ten tubes pass the water through the shell.
Each tube is thin walled, of diameter D=25 mm, and makes eight passes
through the shell. If the oil leaves the exchanger at 100°C, what is the flow
rate? How long must the tubes be to accomplish the desired heating?

77