Heat and Mass Transfer

Heat Exchanger Design

Dr. Muhammad Ali Kamran
• These handouts are in no way,
whatsoever, a replacement of the
lectures or the book.

Dr. Muhammad Ali Kamran, Deptt. of Mech

2
Engg., UET Peshawar
 Objectives of this Study
• To understand the design process of a heat
exchanger
• To introduce parameters for assessing the
performance of a heat exchanger under prescribed
conditions

Dr. Muhammad Ali Kamran, Deptt. of Mech

3
Engg., UET Peshawar
 Introduction
• The process of heat exchange between two fluids
that are at different temperatures and separated
by a solid wall occurs in many engineering
applications.
• The device used to implement this exchange is
termed a heat exchanger
• Applications are
– space heating and air-conditioning
– power production
– waste heat recovery etc
– cooling systems
Dr. Muhammad Ali Kamran, Deptt. of Mech
4
Engg., UET Peshawar
 Cold and Hot Fluids
• The fluid that gains energy within a heat
exchanger is termed as Cold Fluid

• The fluid that loses energy within a heat

exchanger is termed as the Hot Fluid

Dr. Muhammad Ali Kamran, Deptt. of Mech

5
Engg., UET Peshawar
 Nomenclature
• Tci: Temperature of Cold Fluid at Inlet of Heat Exchanger

• Tco: Temperature of Cold Fluid at Outlet of Heat Exchanger

• Thi: Temperature of Hot Fluid at Inlet of Heat Exchanger

• Tho: Temperature of Hot Fluid at Outlet of Heat Exchanger

• ṁc: mass flow rate of Cold Fluid

• ṁh: mass flow rate of Hot Fluid
Dr. Muhammad Ali Kamran, Deptt. of Mech
6
Engg., UET Peshawar
 The Design Process
• At the start of the design process, the
following is known
• Fluid Types
• Tci, Thi
• Mass flow rate of both the fluids (In some cases,
mass flow rate of only one fluid is known)
• The objective i.e. One of the following three
– Temperature of the cold fluid at outlet Tco
– Temperature of the hot fluid at outlet Tho
– Desirable heat transfer q

Dr. Muhammad Ali Kamran, Deptt. of Mech

7
Engg., UET Peshawar
Important equations
q= ṁhcp ( Thi - Tho )

q= ṁc cp ( Tco - Tci )

q= U A ∆T

Dr. Muhammad Ali Kamran, Deptt. of Mech

8
Engg., UET Peshawar
Overall Heat Transfer Coefficient

Dr. Muhammad Ali Kamran, Deptt. of Mech

9
Engg., UET Peshawar
Dr. Muhammad Ali Kamran, Deptt. of Mech
10
Engg., UET Peshawar
 Concentric Tube Heat Exchanger

Parallel Flow

Counterflow

Dr. Muhammad Ali Kamran, Deptt. of Mech

11
Engg., UET Peshawar
Shell and Tube Heat Exchanger

One Shell Pass with One Tube Pass

Dr. Muhammad Ali Kamran, Deptt. of Mech
12
Engg., UET Peshawar
 Shell and Tube Heat Exchanger
One Shell Pass with Two Tube Passes

Dr. Muhammad Ali Kamran, Deptt. of Mech

Two Shell Passes with Four Tube Passes
Engg., UET Peshawar
13
 Cross Flow Heat Exchanger

UnFinned with one Fluid Mixed,

the other unmixed

Finned with both Fluids unmixed

Dr. Muhammad Ali Kamran, Deptt. of Mech

14
Engg., UET Peshawar
Overall Heat Transfer Coefficient U;

Dr. Muhammad Ali Kamran, Deptt. of Mech

15
Engg., UET Peshawar
 U; With Fouling

• During heat exchanger operation, surfaces are often

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.
• This effect can be treated by introducing an additional
thermal resistance, termed the fouling factor, Rf.
• Its value depends on the operating temperature, fluid
velocity, and length of service of the heat exchanger.
Dr. Muhammad Ali Kamran, Deptt. of Mech
16
Engg., UET Peshawar
Dr. Muhammad Ali Kamran, Deptt. of Mech
17
Engg., UET Peshawar
Representative Fouling Factors

Dr. Muhammad Ali Kamran, Deptt. of Mech

18
Engg., UET Peshawar
Parallel Flow Heat Exchanger

Dr. Muhammad Ali Kamran, Deptt. of Mech

19
Engg., UET Peshawar
 Parallel Flow Heat Exchanger

     


  
      
 
      


     
    
 

        
 
 



  
 






 

  
 
a  

Dr. Muhammad Ali Kamran, Deptt. of Mech

20
Engg., UET Peshawar
Parallel Flow Heat Exchanger

Log Mean Temperature Difference

Dr. Muhammad Ali Kamran, Deptt. of Mech
Engg., UET Peshawar
(LMTD) 21
Counterflow Heat Exchanger

Dr. Muhammad Ali Kamran, Deptt. of Mech

22
Engg., UET Peshawar
 PARALLEL FLOW HEAT EXCHANGER

COUNTER FLOW HEAT EXCHANGER

Dr. Muhammad Ali Kamran, Deptt. of Mech

23
Engg., UET Peshawar
Important equations
q= ṁhcp ( Thi - Tho )

q= ṁc cp ( Tco - Tci )

q= U A ∆T

Dr. Muhammad Ali Kamran, Deptt. of Mech

24
Engg., UET Peshawar
Dr. Muhammad Ali Kamran, Deptt. of Mech
25
Engg., UET Peshawar
 Comparison of LMTD for Same
Temperatures
Inlet (°C) Outlet (°C)

Hot Fluid 140 100

Cold Fluid 30 90

Dr. Muhammad Ali Kamran, Deptt. of Mech

26
Engg., UET Peshawar
 Comparison of LMTD for Same
Temperatures
Inlet (°C) Outlet (°C)

Hot Fluid 140 100

Cold Fluid 30 90

For Parallel Flow,  = 41.7°C

For Counterflow,  = 59.4°C

Find Corresponding Values in Kelvin

What would be the effect on size for the same U value?

Dr. Muhammad Ali Kamran, Deptt. of Mech
27
Engg., UET Peshawar
Dr. Muhammad Ali Kamran, Deptt. of Mech
28
Engg., UET Peshawar
Dr. Muhammad Ali Kamran, Deptt. of Mech
29
Engg., UET Peshawar
 LMTD: Special Case
Inlet (°C) Outlet (°C)

Hot Fluid 120 70

Cold Fluid 30 80

Is Parallel Flow arrangement possible?

For Counterflow arrngement, determine  , and q for
U=700W/m2K and A=2m2

Dr. Muhammad Ali Kamran, Deptt. of Mech

30
Engg., UET Peshawar
Boiler/ Evaporator

Dr. Muhammad Ali Kamran, Deptt. of Mech

31
Engg., UET Peshawar
 Condenser

Dr. Muhammad Ali Kamran, Deptt. of Mech

32
Engg., UET Peshawar
 LMTD, Other Heat Exchangers
• For all other Heat Exchangers, the following
Methodology is employed
• Assume the heat exchanger to be a
Counterflow Heat Exchanger, and calculate the
 .
• Apply the correction factor F using the graphs
to obtain the  for the given heat
exchanger
  ,

Dr. Muhammad Ali Kamran, Deptt. of Mech
33
Engg., UET Peshawar
Dr. Muhammad Ali Kamran, Deptt. of Mech
34
Engg., UET Peshawar
Dr. Muhammad Ali Kamran, Deptt. of Mech
35
Engg., UET Peshawar
 Cross Flow Heat Exchanger

UnFinned with one Fluid Mixed,

the other unmixed

Finned with both Fluids unmixed

Dr. Muhammad Ali Kamran, Deptt. of Mech

36
Engg., UET Peshawar
Dr. Muhammad Ali Kamran, Deptt. of Mech
37
Engg., UET Peshawar
Dr. Muhammad Ali Kamran, Deptt. of Mech
38
Engg., UET Peshawar
Dr. Muhammad Ali Kamran, Deptt. of Mech
39
Engg., UET Peshawar
Dr. Muhammad Ali Kamran, Deptt. of Mech
40
Engg., UET Peshawar
Dr. Muhammad Ali Kamran, Deptt. of Mech
41
Engg., UET Peshawar
Dr. Muhammad Ali Kamran, Deptt. of Mech
42
Engg., UET Peshawar
Dr. Muhammad Ali Kamran, Deptt. of Mech
43
Engg., UET Peshawar
Dr. Muhammad Ali Kamran, Deptt. of Mech
44
Engg., UET Peshawar
Cold Water at 20°C (Cp=4180 J/kgK) and
5000kg/hr is to be heated by Oil supplied at
100°C and 7000kg/hr (Cp=2200 J/kgK). You
select from a manufacturer’s catalog a shell and
tube heat exchanger (1 shell, 2 tube passes)
having a UA value of 11600W/K. Determine the
expected hot water outlet temperature.

Dr. Muhammad Ali Kamran, Deptt. of Mech

45
Engg., UET Peshawar