INTERCAMBIADOR

DE CALOR
 HEAT EXCHANGER
A heat exchanger is a device that is used to transfer thermal energy (enthalpy) between
two or more fluids, between a solid surface and a fluid, or between solid particulates
and a fluid, at different temperatures and in thermal contact. In heat exchangers, there
are usually no external heat and work interactions. Typical applications involve heating
or cooling of a fluid stream of concern and evaporation or condensation of single- or
multicomponent fluid streams. In other applications, the objective may be to recover or
reject heat, or sterilize, pasteurize, fractionate, distill, concentrate, crystallize, or control
a process fluid.
Common examples of heat exchangers are shell and tube exchangers, automobile
radiators, condensers, evaporators, air preheaters, and cooling towers. If no phase
change occurs in any of the fluids in the exchanger, it is sometimes referred to as a
sensible heat exchanger.
 CLASSIFICATION

Heat Exchangers may be classified according to the following criteria.

 Recuperators/ regenerators
 Transfer process: direct and indirect contact
 Geometry of construction; tubes, plates, and extended surfaces.
 Heat transfer mechanism: single phase and two phase
 Flow arrangement: Parallel, counter, cross flow.
CLASSIFICATION
CLASSIFICATION
 CLASSIFICATION

■ Tubular heat exchangers—double pipe, shell and tube.

■ Plate heat exchangers (PHEs)—gasketed, brazed, welded, spiral,
■ Extended surface heat exchangers—tube-fin, plate-fin
■ Regenerators—fixed matrix, rotary matrix
 Tubular heat exchangers
Double pipe
A double-pipe heat exchanger has two concentric pipes, usually in the
form of a U-bend design. Double pipe heat changers with U-bend design
are known as hairpin heat exchangers. The flow arrangement is pure
countercurrent. A number of double-pipe heat exchangers can be
connected in series or parallel as necessary. Their usual application is for
small duties requiring, typically, less than 300 ft2 and they are suitable
for high pressures and temperatures and thermally long duties.
Double pipe
Application. When the process calls for a temperature cross (when the hot fluid outlet
temperature is below the cold fluid outlet temperature), a hairpin heat exchanger is the
most efficient design and will result in fewer sections and less surface area. Also, they
are commonly used for high-fouling services such as slurries and for smaller heat
duties.
Multitube heat exchangers are used for larger heat duties. A hairpin heat exchanger
should be considered when one or more of the following conditions exist:
■ The process results in a temperature cross
■ High pressure on tube side application
■ A low allowable pressure drop is required on one side
■ When an augmentation device to enhance the heat transfer coefficient is desired
■ When the exchanger is subject to thermal shocks
■ When flow-induced vibration may be a problem
■ When solid particulates or slurries are present in the process stream
Hairpin heat
exchanger
 Tubular heat exchangers
Shell and Tube
In process industries, shell and tube heat exchangers are used in great
numbers, far more than any other type of exchanger. More than 90% of
heat exchangers used in industry are of the shell and tube type. STHEs
are the “workhorses” of industrial process heat transfer. They are the
first choice because of well-established procedures for design and
manufacture from a wide variety of materials, many years of satisfactory
service, and availability of codes and standards for design and
fabrication. They are produced in the widest variety of sizes and styles.
There is virtually no limit on the operating temperature and pressure
Shell and
tube
 Plate Heat Exchangers
PHEs are less widely used than tubular heat exchangers but offer certain
important advantages. PHEs can be classified into two principal groups:
1. Plate and frame or gasketed PHEs used as an alternative to tube and
shell exchangers for low- and medium-pressure liquid–liquid heat
transfer applications
2. Spiral heat exchanger used as an alternative to shell and tube
exchangers where low maintenance is required, particularly with fluids
tending to sludge or containing slurries or solids in suspension
Plate Heat
Exchangers
 RECUPERATION/REGENERATION HE

Conventional heat exchangers with heat transfer

between 2 fluids. The heat transfer occurs thro a
separating wall or an interface.
In regenerators or storage type heat exchangers, the
same flow passage alternately occupied by one of the
two fluids. Here thermal energy is not transferred thro’
a wall as in direct transfer type but thro’ the cyclic
passage of 2 fluid thro the same matrix.
Example is the ones used for pre heating air in large
coal fired power plant or steel mill ovens.
 Classification According to Flow
Arrangement
The basic flow arrangements of the fluids in a heat exchanger are as follows:
■ Parallelflow
■ Counterflow
■ Crossflow
The choice of a particular flow arrangement is dependent upon the required exchanger
effectiveness, fluid flow paths, packaging envelope, allowable thermal stresses,
temperature levels, and other design criteria.
These basic flow arrangements are discussed next.
 Parallelflow Exchanger
In this type, both the fluid streams enter at the same end, flow parallel to each other in
the same direction, and leave at the other end. This arrangement has the lowest
exchanger effectiveness among the single-pass exchangers for the same flow rates,
capacity rate (mass × specific heat) ratio, and surface area. Moreover, the existence of
large temperature differences at the inlet end may induce high thermal stresses in the
exchanger wall at inlet. Parallelflows are advantageous. (a) In heating very viscous
fluids, parallelflow provides for rapid heating.
Although this flow arrangement is not used widely, it is preferred for the following
reasons:
1. When there is a possibility that the temperature of the warmer fluid may reach its
freezing point.
2. It provides early initiation of nucleate boiling for boiling applications.
 Counterflow Exchanger

In this type the two fluids flow parallel to each other but in opposite directions, and its
temperature distribution may be idealized. Ideally, this is the most efficient of all flow
arrangements for single-pass arrangements under the same parameters. Since the
temperature difference across the exchanger wall at a given cross section is the lowest,
it produces minimum thermal stresses in the wall for equivalent performance compared
to other flow arrangements.
Counterflow
Exchanger
 Crossflow Exchanger

In this type the two fluids flow normal

to each other. Important types of flow
arrangement combinations for a
single-pass crossflow exchanger
include the following:
• Both fluids unmixed
• Both fluids mixed
 SELECTION OF HEAT EXCHANGERS
Selection is the process in which the designer selects a particular type of
heat exchanger for a given application from a variety of heat exchangers.
There are a number of alternatives for selecting heat transfer equipment,
but only one among them is the best for a given set of conditions. The
heat exchanger selection criteria are discussed next.
Selection criteria are many, but primary criteria are type of fluids to be
handled, operating pressures and temperatures, heat duty, and cost. The
fluids involved in heat transfer can be characterized by temperature,
pressure, phase, physical properties, toxicity, corrosivity, and fouling
tendency. Operating conditions for heat exchangers vary over a very wide
range, and a broad spectrum of demands is imposed for their design and
performance. All of these must be considered when assessing the type of
unit to be used.
Materials of construction
Operating pressure and temperature, temperature program, and temperature driving
force
Flow rates
Flow arrangements
Performance parameters—thermal effectiveness and pressure drops
Fouling tendencies
Types and phases of fluids
Maintenance, inspection, cleaning, extension, and repair possibilities
Overall economy
Fabrication techniques
Mounting arrangements: horizontal or vertical
Intended applications
REQUIREMENTS OF HEAT EXCHANGERS
Heat exchangers have to fulfill the following requirements:
■ High thermal effectiveness
■ Pressure drop as low as possible
■ Reliability and life expectancy
■ High-quality product and safe operation
■ Material compatibility with process fluids
■ Convenient size, easy for installation, reliable in use
■ Easy for maintenance and servicing
■ Light in weight but strong in construction to withstand the operational pressures and vibrations
■ especially heat exchangers for military applications
■ Simplicity of manufacture
■ Low cost
■ Possibility of effecting repair to maintenance problems
 Design of heat
exchangers
A heat exchanger typically involves two flowing fluids
separated by a solid wall. Heat is first transferred from
the hot fluid to the wall by convection, through the wall
by conduction, and from the wall to the cold fluid again
by convection. Any radiation effects are usually included
in the convection heat transfer coefficients.
We discuss the two methods used in the analysis of
heat exchangers. Of these, the log mean temperature
difference (or LMTD) method is best suited for the first
task and the effectiveness–NTU (the number of transfer
units) method for the second task. But first we present
some general considerations.
The first law of thermodynamics requires that the rate of
heat transfer from the hot fluid be equal to the rate of heat
transfer to the cold one, that is:
where the subscripts c and h stand for cold and hot fluids,
respectively, and
𝑚ሶ 𝑐 , 𝑚ሶ ℎ mass flow rates
𝐶𝑝𝑐 , 𝐶𝑝ℎ specific heats
𝑇𝑐,𝑜𝑢𝑡 , 𝑇ℎ,𝑜𝑢𝑡 outlet temperatures
𝑇𝑐,𝑖𝑛 , 𝑇ℎ,𝑖𝑛 inlet temperatures
In heat exchanger analysis, it is often convenient to
combine the product of the mass flow rate and the specific
heat of a fluid into a single quantity. This quantity is called
the heat capacity rate and is defined for the hot and cold
fluid streams as:
The heat capacity rate of a fluid stream represents the rate
of heat transfer needed to change the temperature of the
fluid stream by 1 C as it flows through a heat exchanger.
Note that in a heat exchanger, the fluid with a large heat
capacity rate experiences a small temperature change, and
the fluid with a small heat capacity rate experiences a large
temperature change. Therefore, doubling the mass flow
rate of a fluid while leaving everything else unchanged will
halve the temperature change of that fluid.
Two special types of heat exchangers commonly
used in practice are condensers and boilers. One
of the fluids in a condenser or a boiler undergoes
a phase-change process, and the rate of heat
transfer is expressed as
𝑚ሶ rate of evaporation or condensation of
the fluid
ℎ𝑓𝑔 enthalpy of vaporization of the fluid at the
specified temperature or pressure.
The rate of heat transfer in a heat exchanger can
also be expressed in an analogous manner to
Newton’s law of cooling as
U overall heat transfer coefficient,
𝐴𝑠 heat transfer surface area.
∆𝑇𝑚 appropriate mean temperature difference
between the two fluids.
 THE LOG MEAN
TEMPERATURE
DIFFERENCE METHOD

∆𝑇1 , ∆𝑇2
represent the temperature difference between
the two fluids at the two ends (inlet and
outlet) of the heat exchanger
 Temperature distributions
for a parallel-flow heat exchanger
 Temperature distributions
for a counterflow heat exchanger
Examples
■ Hot oil with a specific heat of 0.5 Btu/lbm°F flows through a heat exchanger of flow
found at a rate of 50000lbm/h with a input temperature of 380°F and an exit
temperature of 150°F. Cold oil with a specific heat of 0.4 Btu/lbm°F flows inside at
a rate of 80000 lbm/h and comes out at a temperature of 300°F. Determine the
area of the heat exchanger necessary to maintain the load if the total heat transfer
coefficient based on the interior area is 135 Btu/h·ft2·°F
An essential, and often the most uncertain, part of any
heat exchanger analysis is determination of the overall
heat transfer coefficient. Recall that this coefficient is
defined in terms of the total thermal resistance to heat
transfer between two fluids. The coefficient was
determined by accounting for conduction and
convection resistances between fluids separated by
composite plane and cylindrical walls, respectively. For
a wall separating two fluid streams, the overall heat
transfer coefficient may be expressed.
Note that calculation of the UA product does not
require designation of the hot or cold side
(UcAc =UhAh). However, calculation of an overall
coefficient depends on whether it is based on the cold
or hot side surface area, since Uc ≠ Uh if Ac ≠ Ah.
During normal 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 in termed the fouling factor, Rf. Its
value depends on the operating temperature,
fluid velocity, and length of service of the heat
exchanger.
Where subscripts i and o refer to inner and
outer tube surfaces
 When the wall thickness of the tube is small and
the thermal conductivity of the tube material is
1
𝑈= high, as is usually the case, the thermal
1 𝐿 1
+ + resistance of the tube is negligible (Rwall≈0)
ℎ𝑖 𝑘 ℎ0
and the inner and outer surfaces of the tube are
almost identical (Ai≈Ao ≈ As).
Examples
■ A long thin-walled double-pipe heat exchanger with tube and shell diameters of 1.0
cm and 2.5 cm, respectively, is used to condense refrigerant-134a by water at 20 C.
The refrigerant flows through the tube, with a convection heat transfer coefficient of
hi= 4100 W/m2K. Water flows through the shell at a rate of 0.3 kg/s. Determine the
overall heat transfer coefficient of this heat exchanger.
■ Repeat problem by assuming a 2-mm-thick layer of copper forms on the outer
surface of the inner tube.
■ 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?
Multipass and Cross-Flow Heat Exchangers:
Use of a Correction Factor
The log mean temperature difference DTLM relation
developed earlier is limited to parallel-flow and
counter-flow heat exchangers only. Similar relations
are also developed for cross-flow and multipass shell-
and-tube heat exchangers, but the resulting
expressions are too complicated because of the
complex flow conditions.
The correction factor F for common cross-flow
and shell-and-tube heat exchanger
configurations is given versus two
temperature ratios P and R defined.
Where the subscripts 1 and 2 represent the
inlet and outlet, respectively. Note that for a
shell-and-tube heat exchanger, T and t
represent the shell- and tube side
temperatures, respectively.
The correction factor for a condenser or
boiler is F=1
A counter-flow double-pipe heat exchanger is to heat water from 20°C to 80°C at a rate
of 1.2 kg/s. The heating is to be accomplished by geothermal water available at 160°C
at a mass flow rate of 2 kg/s. The inner tube is thin-walled and has a diameter of 1.5
cm. If the overall heat transfer coefficient of the heat exchanger is 640 W/m2·K,
determine the length of the heat exchanger required to achieve the desired heating.
A 2-shell passes and 4-tube passes heat exchanger is used to heat glycerin from 20°C
to 50°C by hot water, which enters the thin-walled 2-cm-diameter tubes at 80°C and
leaves at 40°C. The total length of the tubes in the heat exchanger is 60 m. The
convection heat transfer coefficient is 25 W/m2K on the glycerin (shell) side and 160
W/m2K on the water (tube) side. Determine the rate of heat transfer in the heat
exchanger (a) before any fouling and (b) after fouling with a fouling factor of 0.0006
m2K/W occurs on the outer surfaces of the tubes.
 Heat Exchanger Analysis: The
Effectiveness–NTU Method
It is a simple matter to use the log mean temperature difference (LMTD) method of heat
exchanger analysis when the fluid inlet temperatures are known and the outlet
temperatures are specified or readily determined from the energy balance expressions.
However, if only the inlet temperatures are known, use of the LMTD method requires a
cumbersome iterative procedure. It is therefore preferable to employ an alternative
approach termed the effectiveness–NTU (or NTU) method.
To define the effectiveness of a heat exchanger, we must first determine the maximum
possible heat transfer rate, qmax, for the exchanger. This heat transfer rate could, in
principle, be achieved in a counterflow heat exchanger of infinite length.
The determination of 𝑄ሶ 𝑚𝑎𝑥 requires the
availability of the inlet temperature of the
hot and cold fluids and their mass flow rates,
which are usually specified. Then, once the
effectiveness of the heat exchanger is
known, the actual heat transfer rate 𝑄ሶ can
be determined from.
Effectiveness relations of the heat
exchangers typically involve the
dimensionless group UAs/Cmin. This
quantity is called the number of
transfer units NTU and is expressed
as:
In heat exchanger analysis, it is also
convenient to define another
dimensionless quantity called the
capacity ratio c as:
The value of the capacity ratio c ranges
between 0 and 1. For a given NTU, the
effectiveness becomes a maximum for c=0
and a minimum for c=1. The case
c=Cmin/Cmax 0 corresponds to
Cmax ∞ which is realized during a phase-
change process in a condenser or boiler. All
effectiveness relations in this case reduce
to:
A shell-and-tube exchanger (two shells, four tube passes) is used to heat 10,000 kg/h
of pressurized water from 35 to 120C with 5000 kg/h pressurized water entering the
exchanger at 300C. If the overall heat transfer coefficient is 1500 W/m2 K, determine
the required heat exchanger area.