UNIT-3: HEAT EXCHANGER

PART – A
 UNIT-3 PHASE CHANGE HEAT TRANSFER AND HEAT EXCHANGERS

PART B

1. Water is boiled at the rate of 24 kg/h in a polished copper pan, 300 mm in diameter, at atmospheric
pressure. Assuming nucleate boiling conditions calculate the temperature of the bottom surface of the
pan.

Given :
m = 24 kg / h
24 kg

3600 s
m  6.6  103 kg / s
d = 300 mm = .3m

Solution:

We know saturation temperature of water is 100C

i.e. Tsat = 100C

Properties of water at 100C

From HMT data book Page No.13
Density l = 961 kg/m3
Kinematic viscosity v = 0.293  10-6 m2 / s
Pr andtl number Pr  1.740
Specific heat Cpl = 4.216 kj/kg K = 4216 j/kg K
Dynamic viscosity l = l  v
= 961 0.293  10-6
L  281.57  10 6 Ns/m2

From steam table (R.S. Khumi Steam table Page No.4)

At 100C

Enthalpy of evaporation hfg = 2256.9 kj/kg

hfg  2256.9  103 j/kg
Specific volume of vapour
Vg = 1.673 m3/kg
Density of vapour
 1
v 
vg
1
1.673
 v  0.597 kg/m3
For nucleate boiling
3
Q g  ( l   v ) Cpl  T
Heat flux  l  hfg 
A  Csf  hfgPr1.7
We know transferred Q = m  hfg
Heat transferred Q = m  hfg.
Q mhg

A A
Q 6.6  10 3  2256.9  103

A  2
d
4
6.6  10-3  2256.9  103
=

(.3)2
4
Q
 210  103 w / m2
A
  surface tension for liquid vapour interface

At 100C (From HMT data book Page No.147)

  58.8  103 N/ m

For water – copper – Csf = Surface fluid constant = 013

Csf  .013 (From HMT data book Page No.145)

Q
Substitute, l, hfg, l,  v,  , Cpl, hfg, and Pr values in Equation (1)
A
 (1)  210  103  281.57  10 6  2256.9  103
0.5
9.81 961  597
58.8  10 3
3
4216  T
.013  2256.9  103  (1.74)1.7
4216  T
  0.825
75229.7
 T(.56)3  .825
 T  .056 = 0.937
T - 16.7
We know that
Excess temperature T = Tw  Tsat
16.7 = Tw  100C.
Tw  116.7C

2. i) Explain about fouling factors.

ii) Hot oil with a capacity rate of 2500 W/K flows through a double pipe heat exchanger. It enters at
360 °C and leaves at 300 °C. Cold fluid enters at 30 °C and leaves at 200 °C. If the overall heat
transfer coefficient is 800 W/m2K, determine the heat exchanger area required for 1) parallel flow
and 2) Counter flow. [NOV DEC 14]

heat capacity rate Ch = 2500 W/K

U = 800 W/m2K
Thi = 360 °C, Tho= 300 °C
Tci= 30 °C Tco= 200 °C

Find A=?

Q = U A (LMTD)
Also Qhot fluid = Ch*del T = 150000 W

Calculate Lmtd for parallel and counter flow

LMTD for parallel flow = 192.64 K

LMTD for counter flow = 210.2 K

the heat exchanger area required for

1) parallel flow

A = 0.973 m2

2) Counter flow

A = 0.892 m2
3. a) A vertical tube of 50 mm outside diameter and 2 m long is exposed to steam at atmospheric
pressure. The outer surface of the tube is maintained at a temperature of 84 °C by circulating cold
water through the tube. Determine the rate of heat transfer and also the condensate mass flow rate.
[NOV DEC 14]

Properties at film temperature 80+100 /2 = 90 C

The modified latent heat vaporization

Hfg = 2314 * 103 J/kg

Re = 1287

h = 5848 W/m2 K

As = 0.31416 m2

Q = 36.7 kW

m = 0.0158 kg/s

4. A Nickel wire carrying electric current of 1.5 mm diameter and 50 cm long, is submerged in a water
bath which is open to atmospheric pressure. Calculate the voltage at the burn out point, if at this
point the wire carries a current of 200A.

Given :
D = 1.5mm = 1.5  10-3 m; L = 50 cm = 0.50m; Current I = 200A
Solution

We know saturation temperature of water is 100C

i.e. Tsat = 100C

Properties of water at 100C

(From HMT data book Page No.11)
l = 961 kg/m3
v  0.293  10 6 m2 / s
Pr - 1.740
Cpl = 4.216 kj/kg K = 4216 j/kg K

l= l  v  961 0.293  106

l  281.57  106 Ns/m2
From steam Table at 100C

R.S. Khurmi Steam table Page No.4

hfg  2256.9 kj / kg
hfg = 2256.9  103 j/kg
v g  1.673m3 / kg
1 1
v    0.597 kg/m3
g 1.673
 = Surface tension for liquid – vapour interface
At 100C

  58.8  103 N/m (From HMT data book Page No.147)

For nucleate pool boiling critical heat flux (AT burn out)

Q    g  (l -  v)0.25 
 0.18  hfg   v      1
A  v2 
(From HMT data book Page No.142)

Substitute hfg, l,  v,  values in Equation (1)

Q
(1)   0.18  2256.9  103  0.597
A
0.25
 58.8  10 3  9.81 (961  .597) 
 
 .5972 
Q
 1.52  106 W/m2
A
 We know
Heat transferred Q = V  I
Q V I

A A
V  200
1.52  106  A =  dL
 dL
V  200
1.52  106 =
  1.5  10-3  .50
V  17.9 volts

5. Water is boiling on a horizontal tube whose wall temperature is maintained ct 15C above the
saturation temperature of water. Calculate the nucleate boiling heat transfer coefficient. Assume the
water to be at a pressure of 20 atm. And also find the change in value of heat transfer coefficient
when
i) The temperature difference is increased to 30C at a pressure of 10 atm.
ii) The pressure is raised to 20 atm at  T = 15C

Given :

Wall temperature is maintained at 15C above the saturation temperature.

Tw  115C. Tsat  100C Tw  100  15  115C

= p = 10 atm = 10 bar
case (i)
T  30C; p  10 atm = 10 bar
case (ii)
p = 20 atm = 20 bar; T - 15C

Solution:

We know that for horizontal surface, heat transfer coefficient

h = 5.56 (T)3 From HMT data book Page No.128

h = 5.56 (Tw – Tsat)3
= 5.56 (115 – 100)3

h  18765 w/m2K

Heat transfer coefficient other than atmospheric pressure

hp = hp0.4 From HMT data book Page No.144

= 18765  100.4

Heat transfer coefficient hp  47.13  103 W / m2K

 Case (i)

P = 100 bar T = 30C From HMT data book Page No.144

Heat transfer coefficient

h  5.56 ( T)3 = 5.56(30)3
h  150  103 W / m2K

Heat transfer coefficient other than atmospheric pressure

hp = hp0.4
 150  103 (10)0.4
hp  377  103 W / m2K

Case (ii)
P = 20 bar; T = 15C

Heat transfer coefficient h = 5.56 (T)3 = 5.56 (15)3

h  18765 W/m2K

Heat transfer coefficient other than atmospheric pressure

hp = hp0.4
= 18765 (20)0.4
hp  62.19  103 W/m2K

6. A vertical flat plate in the form of fin is 500m in height and is exposed to steam at atmospheric
pressure. If surface of the plate is maintained at 60C. calculate the following.
i) The film thickness at the trailing edge
ii). Overall heat transfer coefficient
iii). Heat transfer rate
iv). The condensate mass flow rate.
Assume laminar flow conditions and unit width of the plate.

Given :
Height ore length L = 500 mm = 5m
Surface temperature Tw = 60C
Solution
We know saturation temperature of water is 100C
i.e. Tsat = 100C
(From R.S. Khurmi steam table Page No.4

hfg = 2256.9kj/kg
hfg = 2256.9  103 j/kg

We know
Tw  Tsat
Film temperature Tf 
2
60  100

2
Tf  80C

Properties of saturated water at 80C

(From HMT data book Page No.13)

 - 974 kg/m3
v  0.364  106 m2 / s
k = 668.7  10-3 W/mk
 = p  v= 974  0.364  10-6

  354.53  106 Ns / m2

1. Film thickness x

We know for vertical plate

Film thickness
0.25
 4K  x  (Tsat  Tw ) 
x   
 g  hfg   2
 
Where
X = L = 0.5 m
4  354.53  106  668.7  103  0.5  100  60
x 
9.81 2256.9  103  9742
 x  1.73  104 m

2. Average heat transfer coefficient (h)

For vertical surface Laminar flow

0.25
 k 3   2  g  hfg 
h  0.943  
   L  Tsat  Tw 

The factor 0.943 may be replace by 1.13 for more accurate result as suggested by Mc Adams
 0.25
 (668.7  103 )3  (974)2  9.81 2256.9  103 
1.13  
 354.53  106  1.5  100  60 
h  6164.3 W/m k. 2

3. Heat transfer rate Q

We know

Q  hA(Tsat  Tw )
= h  L  W  (Tsat  Tw )
= 6164.3  0.5  1 100-60
Q = 123286 W

4. Condensate mass flow rate m

We know
Q  m  hfg
Q
m
hfg
1.23.286
m
2256.9  103
m  0.054 kg/s

7. A condenser is to design to condense 600 kg/h of dry saturated steam at a pressure of 0.12 bar. A
square array of 400 tubes, each of 8 mm diameters is to be used. The tube surface is maintained at
30C. Calculate the heat transfer coefficient and the length of each tube.

Given :

600
m  600 kg/h = kg / s  0.166 kg/s
3600
m = 0.166 kg/s

Pressure P – 0.12 bar No. of tubes = 400

Diameter D = 8mm = 8  10-3m

Surface temperature Tw  30C

Solution

Properties of steam at 0.12 bar From R.S. Khurmi steam table Page No.7
Tsat  49.45C
hfg  2384.3 kj/kg
hfg = 2384.9  103 j / kg

We know

Tw  Tsat
Film temperature Tf 
2
30  49.45

2
Tf  39.72C  40C

Properties of saturated water at 40C

From HMT data book Page No.13

 - 995 kg/m3

 = .657  10-6 m2 / s

k  628.7  10 3 W/mk

 =   = 995  0.657  10-6

 = 653.7  10-6 Ns/m2

with 400 tubes a 20  20 tube of square array could be formed

i.e. N  400  20

N  20

For horizontal bank of tubes heat transfer coefficient.

0.25
 K 3  2g hfg 
h = 0.728  
  D (Tsat  Tw ) 

From HMT data book Page No.150

0.25
 (628  10-3 )3  (995)2  9.81 2384.3  103 
h = 0.728  6 3 
 653.7  10  20  8  10  (49.45  30) 
h = 5304.75 W/m2K
 We know

Heat transfer

Q  hA(Tsat  Tw )
No. of tubes = 400
Q = 400  h    D  L  (Tsat  Tw )
Q  400  5304.75    8  10 3  1 (49.45-30)
Q = 1.05  106  L........1

We know

Q  m  hfg
= 0.166  2384.3  103
Q = 0.3957  106 W
= 0.3957  106  1.05  106 L
L  0.37 m

8. Steam at 0.080 bar is arranged to condense over a 50 cm square vertical plate. The surface
temperature is maintained at 20C. Calculate the following.
i) Film thickness at a distance of 25 cm from the top of the plate.
ii)Local heat transfer coefficient at a distance of 25 cm from the top of the plate.
iii)Average heat transfer coefficient.
iv)Total heat transfer
v)Total steam condensation rate.
What would be the heat transfer coefficient if the plate is inclined at 30C with horizontal plane.

Given :

Pressure P = 0.080 bar

Area A = 50 cm  50 cm = 50  050 = 0.25 m2

Surface temperature Tw = 20C

Distance x = 25 cm = .25 m

Solution

Properties of steam at 0.080 bar

(From R.S. Khurmi steam table Page no.7)

Tsatj / kg  41.53C
hfg  2403.2kj/kg = 2403.2  103 j / kg

We know

Tw  Tsat
Film temperature Tf 
2
20+41.53
=
2
Tf  30.76C

Properties of saturated water at 30.76C = 30C

From HMT data book Page No.13

  997 kg/m3
  0.83  10-6 m2 / s
k  612  10-3 W / mK
  p  v  997  0.83  10 6
  827.51 10 6 Ns / m2

a. Film thickness

We know for vertical surfaces

0.25
 4 K  x  (Tsat  Tw ) 
x   
 g  h   2
 fg 
(From HMT data book Page No.150)
4  827.51 10 6  612  10 3  .25  (41.53  20)100
x 
9.81 2403.2  103  997 2
 x  1.40  104 m

b. Local heat transfer coefficient hx Assuming Laminar flow

 k
hx 
x
612  10 3
hx 
1.46  10 4
hx  4,191 W/m2K

c. Average heat transfer coefficient h

(Assuming laminar flow)

0.25
 k 3   2  g  hfg 
h  0.943  
   L  Tsat  Tw 

The factor 0.943 may be replaced by 1.13 for more accurate result as suggested by Mc
adams

0.25
 k 3  2g hfg 
h  0.943  
   L  Tsat  Tw 

Where L = 50 cm = .5 m
0.25
(612  103 )3  (997)2  9.81 2403.2  103
h  1.13
827.51 106  .5  41.53  20
h  5599.6 W/m2k

d. Heat transfer (Q)

We know

Q = hA(Tsat – Tw)

h  A  (Tsat  Tw )
 5599.6  0.25  (41.53  20
Q  30.139.8 W

e. Total steam condensation rate (m)

We know Heat transfer

Q  m  hfg
Q
m
hfg

30.139.8
m
2403.2  103
m  0.0125 kg / s

f. If the plate is inclined at  with horizontal

hinclined  hvertical  sin 1/ 4

hinclined  hvertical  (sin30)1/ 4

 
1/ 4
hinclined  5599.6  1
2
hinclined  4.708.6 W/m2k

Let us check the assumption of laminar film condensation

We know

4m
Reynolds Number R e 
w
where
W = width of the plate = 50cm = .50m
4  .0125
Re 
0.50  827.51 10 6
Re  120.8  1800

So our assumption laminar flow is correct.

9. Derive an expression for LMTD in Parallel flow and Counter flow heat exchangers.
10. Explain nucleate boiling and solve the following.
A wire of 1mm diameter and 150 mm length is submerged horizontally in water at 7 bar. The wire
carries current of 131.5 ampere with an applied voltage of 2.15 Volt. If the surface of the wire is
maintained at 180 °C, calculate the heat flux and boiling heat transfer coefficient. [MAY-JUN 14]
11. Classify heat exchangers, draw temperature distribution in a condenser and evaporator and derive the
Expression for effectiveness of parallel flow heat exchanger by NTU method. [MAY-JUN 14]
Temperature distribution of Condenser and Evaporator
12. (i) Explain the various regions of flow boiling in detail.
(ii) The outer surface of a vertical tube, which is 1m long and has an outer diameter of 80mm, is
exposed to saturated steam at atmospheric pressure and is maintained at 50 °C by the flow of cool
water through the tube. What is the rate of heat transfer to coolant and what is the rate at which
steam is condensed at the surface? [NOV-DEC 13]
Ref problem 3