NTU-Effectiveness Method to Replace LMTD Method for Shell & Tube Heat Exchanger Design.

Introduction
Heat exchanger used to transfer heat from one medium to another. These media may be a gas, liquid,
or a combination of both. Heat exchangers are required to provide heating and/or cooling to meet a
process requirement. Heat exchangers also improve a system’s energy efficiency by transferring heat
from systems where it is not needed to systems where it can be used. Heat exchangers are used to
exchange heat between two or more process streams or between process stream(s) & a utility stream,
which can be either hot or cold utilities.
Heat exchanger applications:
1. Waste heat recovery in exhaust of an electricity-generating gas turbine.
2. Utilizing process heat recovery
3. Using a utility water, steam, hot oil, and molten salt, to provide heat duty to a process stream.
4. Using a utility air, cooling water, and refrigerant, to provide cooling duty to a process stream.
Selection of type of hot utility mainly depends on inlet & outlet target temperatures required by process
stream. Other factors for consideration include specific heat capacity, cost of utility & process safety.
Application of technology
Heat exchangers are available in many types of construction
1. Pipe-in-pipe
2. Shell-and-tube
3. Spiral-plate
4. Plate-and-frame
5. Printed-circuit

Shell-and-tube heat exchanger working principles

 most common heat exchanger design type consists of a parallel arrangement of tubes in a she ll. One
fluid flows through tubes and other fluid flows through shell over tubes.
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 Tubes arranged in shell to allow for parallel flow, Counterflow, crossflow, or both.
 tube layouts are single-pass, multipass, or U-tube arrangements.
 have one or two heads on shell & multiple inlet, outlet, vent, & drain nozzles
Advantages
 Reliability – more resistant to scale formation
 Potential for same shell to be used and duty improved by changing internals
 Long service life
 High efficiency but less efficient compared with plate-and-frame
 Can withstand high operating pressures due to its tubular construction
Disadvantages
 Dimensions: generally large
 Plot space: double space needed for cleaning (i.e. to pull out bundle)
 Maintainability: difficult to clean shell side
 Potential for metal corrosion due to vulnerability of outer part of case as a result of manufacturing
method
Heat exchanger key parameters
Description
Efficiency Moderate
Range of applicability (temperature, pressure) high
Footprint High but not as high as air fin cooler
Suitability to be used in fouling service Yes

Heat exchanger flow configurations

Heat exchangers have three primary flow configurations:
 Parallel flow:
Two fluids enter at same end of heat exchanger & flow in same direction, parallel to one another
 Counterflow: two fluids enter at opposite ends of heat exchanger and flow counter to one another
 Crossflow: The two fluids flow perpendicular to one another.
Heat Exchangers:
Transferring heat from one fluid to another

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Methods used analysis of heat exchangers:
log mean temperature difference (or LMTD) method, which is best suited for the first task
‐ The effectiveness-NTU method, which is best suited for second task
Analysis of Heat Exchangers (cont.)
• Heat exchangers operate with minimal change in their operating conditions for long periods of time
and thus can be modeled as steady-flow devices
• Applying overall energy balances to the hot and cold fluids:

Heat Transfer Surface Area Section of a Parallel Flow Heat Exchanger

We can obtain an expression relating the total heat transfer rate 𝑞 to the temperature difference Δ𝑇
between the hot and cold fluids, where Heat Transfer Surface Area Section of a Parallel Flow Heat
Exchanger

Since Δ𝑇 varies with position in the heat exchanger, we need a rate equation of the form:
where Δ𝑇𝑚 is the appropriate mean temperature difference

Log Mean Temperature Difference

The temperature difference between the hot and the cold fluid varies along the heat exchanger and
thus, for heat transfer analysis, we need a mean temperature difference Δ𝑇𝑚
• Let's consider a parallel-flow double-pipe heat exchanger. Applying an energy balance to a differential
element of thickness 𝑑𝑥 in the hot and cold fluids as shown:

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Heat Exchanger Basic Analysis:
heat exchangers energy equations:
Hot fluid: q = m h(hh,i-hh,o)
for liquids or ideal gases this becomes: q = m hCp,h(Th,i-Th,o)
Cold fluid: q = m c(hc,o-hc,i) or q = m cCp,c(Tc,o-Tc,i)
First Law for Heat Exchanger: Assume that the heat exchanger is insulated to the outside:
There are two models: LMTD Model& -NTU model:
Understanding both LMTD Model & -NTU model helps engineers create efficient thermal systems.
These methods are essential for designing & optimizing heat exchangers.

Logarithmic Mean Temperature Difference

(LMTD) is a logarithmic average of temperature difference between hot & cold fluids at each end of
heat exchanger

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LMTD is more accurate representation of average temperature difference in a heat exchanger
compared to arithmetic mean temperature difference because it accounts for logarithmic nature of
temperature profile
LMTD Definition and Equation
Derivation and Assumptions
Derivation assumes constant specific heats for both fluids, no phase change occurring within heat
exchanger, and negligible heat loss to surroundings
These assumptions simplify analysis & make LMTD equation applicable to a wide range of heat
exchanger problems
usually used for design when temperatures are known
q = UA Tlm F
where: Tlm = log mean temperature difference
UA = overall heat transfer coefficient, and
F = account for geometry (IF necessary)
-NTU model: usually used when size (UA) is known for performance calculations
∆T1 and ∆T2 are temperature differences between hot and cold fluids at two ends of heat exchanger
(inlet and outlet) T1 = T on left side, and T2 = T on right side
To calculate heat transfer in a heat exchanger using LMTD: q = (UA) ΔTlm (F)

T 1  T2
LMTD 
T1
ln
T2

To get q, you’ll need a value for U (A will depend on size of the heat exchanger--U will account for
convective heat transfer coefficients on both side. Rwall fouling
You can use the circuit resistance model for U:
hc hh
1 1 1
  R f , i  R wall  R f , o 
U hc hh

where:hc = convective coefficient on the cold side

hh = convective coefficient on the hot side

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 Rf,i and Rf,o are resistances due to “fouling” on inside & outside of wall
R = conductive resistance of wall (usually very small).
F=1 for single pass parallel or counter flow &For multi-pass or cross-flow use Figures
LMTD and ε-NTU methods for heat exchanger analysis
LMTD method helps analyze simple exchangers (simple flow arrangements (parallel flow or
Counterflow)
LMTD is great for known temperatures (suitable for heat exchangers with known inlet & outlet
temperatures
ε-NTU method tackles complex ones.
Both use temperature differences & flow rates to determine heat transfer performance.
ε-NTU used when outlet temps are unknown.
Determining Heat Transfer Rates & Outlet Temperatures

To find the outlet temperatures, use the energy balance equations for the hot and cold
fluids: Q=m˙hcp,h(Th,in−Th,out)=m˙ccp,c(Tc,out−Tc,in)Q=m˙hcp,h(Th,in−Th,out)=m˙ccp,c(Tc,out−Tc,in),
where m˙m˙ is the mass flow rate, cpcp is the specific heat, and TT represents the temperatures
Effectiveness and NTU in Heat Exchangers
Effectiveness (ε)

Effectiveness is usually denoted by ε (epsilon), and it is ratio of actual heat transfer to maximum possible
heat transfer (when 100% of heat is transferred between fluids).
ε-NTU method is particularly useful when outlet temperatures are unknown or heat exchanger has a
complex flow arrangement
Effectiveness (ε) is a dimensionless parameter that represents ratio of actual heat transfer rate to
maximum possible heat transfer rate in a heat exchanger
It is related to NTU & heat capacity rate ratio (Cr) through empirical relations that depend on heat
exchanger flow arrangement (parallel flow, counterflow, cross-flow, etc.)
The heat capacity rate ratio is defined as: Cr=Cmin/CmaxCr
where CminC and Cmax are smaller and larger heat capacity rates of two fluids, respectively
Maximum possible heat transfer rate (Qmax) occurs when fluid with smaller heat capacity rate (Cmin)
undergoes maximum temperature change, which is equal to inlet temperature difference between hot
& cold fluids
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effectiveness is given by: ε=Q/Qmax, Q is actual heat transfer rate and

Qmax=Cmin(Th,in−Tc,in)
For a counterflow heat exchanger, effectiveness relation is given by:
ε=(1−exp[−NTU(1−Cr)])/(1−Crexp[−NTU(1−Cr)]) for Cr<1Cr<1,
and ε=NTU/(1+NTU)ε=NTU/(1+NTU) for Cr=1
Number of Transfer Units (NTU)

(NTU) is a dimensionless quantity used to evaluate effectiveness of heat exchangers by considering

factors such as heat transfer coefficient, heat transfer surface area, and mass flow rate.
NTU value is a crucial parameter in assessing effectiveness and efficiency of a heat transfer system.
NTU a dimensionless parameter represents heat exchanger size relative to its heat transfer capacity
NTU method is primarily used in heat exchangers to determine effectiveness of system, which measures
how well the heat exchanger transfers heat from one fluid to another.
NTU is defined as:
NTU=UA/Cmin,
U = overall heat transfer coefficient,
A = heat transfer surface area, and Cmin = smaller heat capacity rate of two fluids
heat capacity rate (C) is product of mass flow rate & specific heat of a fluid: C=m˙cp
A higher NTU value indicates a larger heat exchanger or a higher overall heat transfer coefficient
relative to the heat capacity rate, which generally results in a higher effectiveness.
Significance of NTU method
NTU method is utilized to optimize number of transferred units in process of exchange of heat.
NTU Applied in case of insufficient data gathered from calculation of LMTD.
NTU is helpful in case of unavailability of specific temperatures.
NTU to be utilized in the evaluation of rate of mass exchange.
NTU building a relationship between performances of heat, as well as mass transfer.
NTU measure heat exchange capacity of system & has a direct impact on its effectiveness.
A higher NTU value usually implies a more efficient heat transfer system (means that system is designed
for more efficient heat transfer since there is an adequate heat transfer surface area, a suitable heat
transfer coefficient, and/or sufficient mass flow rate.

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NTU is affected by factors such as design & materials of heat exchanger, heat transfer coefficient, & mass
flow rate of the fluids. In this case, the effectiveness of the system is also likely to be high, indicating that
the heat exchanger is capable of transferring a large amount of heat between the fluids.
Large NTU values suggest a higher heat transfer capacity and likely higher effectiveness and higher
values might lead to increased costs and complexity in design and maintenance.
Small NTU values indicate a relative lower heat transfer capacity & may result in limited effectiveness
This could be due to a small heat transfer surface area, a low heat transfer coefficient, or a low mass flow
rate. As a result, effectiveness of heat exchanger will be limited, and it may not be able to achieve a high
level of heat transfer between the fluids. However.
A small NTU value does not necessarily mean that system is poorly designed or inefficient; it may simply be
appropriate for specific application for which it was designed.
Assumptions and Limitations
The flows are single-phase. The heat transfer is strictly one of sensible heat. The transfer is limited to
interior of the exchanger, with the environment neither gaining heat from nor providing heat to the
flows—the heat exchanger is an adiabatic component.
Distinguishing factors between LMTD and NTU methods
LMTD method, it is suitable in determination of overall amount of heat transfer on basis of obtained
inlet, & outlet temperatures of concerned fluid.
LMTD is a simple
LMTD In case of specific heat changes this method is not found to be accurate.
LMTD method is used for liquids in a steady-state and hence is not applicable in the case of dynamic
evaluation. There is no change in passes during transfer of heat.
LMTD avoidance of kinetic energy, as well as potential energy may be a barrier in providing an accurate
solution.
NTU method, it is convenient for predicting temperature of outlet of concerned fluid.
NTU effective in cases where coefficient of heat transfer & inlet temperature of fluid, is provided.
NTU method is effective in providing accurate results.
In process of LMTD, whenever data is insufficient to execute calculation, NTU method acts as a savior
and completes the steps of the calculation.
Data obtained in NTU is also helpful in LMTD method.
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Efficiency Of A Shell And Tube Heat Exchanger Calculation using effectiveness-NTU
1. Determine heat capacity rate (C) of hot fluid and cold fluid:
For hot fluid: Chot = mhot * Cphot
where mhot =mass flow rate of hot fluid & Cphot is its specific heat capacity.
For the cold fluid: Ccold = mcold Cpcold where mcold is mass flow rate of cold fluid and Cpcold is its specific
heat capacity.
2. Calculate the overall heat transfer coefficient (U): The overall heat transfer coefficient represents
combined thermal resistance of shell & tube sides of heat exchanger. It is usually provided by
manufacturer or can be estimated based on design parameters & heat transfer correlations.
3. Determine minimum heat capacity rate (Cmin) & maximum heat capacity rate (Cmax): Compare Chot
and Ccold to identify fluid with smaller heat capacity rate (Cmin) and fluid with larger heat capacity rate
(Cmax).
4. Calculate heat capacity ratio (Cr): Cr=Cmin/Cmax
5. Determine number of transfer units (NTU):
It is calculated using the following formula: NTU = (UA)/Cmin
6. Determine heat exchanger effectiveness (ε):
The effectiveness is a measure of how effectively the heat exchanger transfers heat. It depends on the
NTU and the heat capacity ratio (C_r). The effectiveness can be calculated using the appropriate
equation based on the flow configuration (parallel flow, Counterflow, or crossflow) and the arrangement
of the fluid streams within the exchanger.
7. Calculate the efficiency (n):
The efficiency of the heat exchanger is given by the equation: η = (ε - 1) / (Cr -1)
CONCLUSION
Effectiveness-NTU method is commonly used for parallel-flow and counterflow heat exchangers. The
calculated efficiency represents fractional effectiveness of heat exchanger in transferring heat from hot
fluid to old fluid
Actual calculations may involve additional considerations based on specific heat exchanger
configurations & assumptions.

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