Department of Mechanical Engineering: Heat Transfer

DEPARTMENT
OF MECHANICAL ENGINEERING
HEAT TRANSFER
-By Chhagan Kharol

 Parallel Flow
 Counter Current Flow
 Shell and Tube with baffles
 Cross Flow
ΔT = Approach Temperature
Q=U A F ΔTlm-counter
 1  S  
R 2  1 ln 
1  RS 
 
F
 2  S R 1 R2 1 
 R  1 ln 

 2  S R  1  R  1 
2


Thot in  Thot out Tcold out  Tcold in

R S
Tcold out  Tcold in Thot in  Tcold in
 Series of Resistances
 Basis
Inside
 Inside Tubes
 Outside
1
 Ao 
U o   R f ,i   Do Di  (1 hi )  1  2k w   Do ln(Do Di )  1 ho   R f ,o 
 Ai 
Rf=fouling factors, inside and outside
See table 18.5 for range of U values for different cases.

0.14
hD 1/ 3   b 
Nu   0.027 Re Pr  
0.8
kf  w 
L / D  60, smooth tube
Cp
0.7  Pr   16,700
kf
Re  10,000 Turbulent
Also other correlations valid over wider ranges
0.25
hD 0.4   b 
Nu   (0.4 Re  0.06 Re ) Pr 
0.5 2/3

kf  w 
b
0.25   5.2
w
Cp
0.67  Pr   300
kf
40  Re  100,000
Also other correlations valid over wider ranges

 Heuristic 26.
 Near-optimal minimum temperature approaches in
heat exchangers depend on the temperature level as
follows:
 10°F or less for temperatures below ambient,
 20°F for temperatures at or above ambient up to 300°F,
 50°F for high temperatures,
 250 to 350°F in a furnace for flue gas temperature above inlet
process fluid temperature.
Where are the Heat Exchangers?
What is happening in each
Octane Reaction
2C2H4 + C4H10  C8H18
P= 20 psia, T=93C,
X=98% Conversion
TBP
C2H4 −103.7 °C
C4H10 +0.5 °C
C8H18 +125.52 °C
Where are the Heat Exchangers?
 Tricky Problems
 Examples
 Reboiler on Distillation Unit
 Condenser on Distillation Unit
 Flash Units
 Boilers
 Simulator Assumptions
 Inlet – Saturated Vapor
 Pressure
 100% Vapor
 Outlet – Saturated Liquid
 Liquid Only Leaves via steam trap
 Pressure = Pin- ΔP (1.5 psi, Heuristic-31)
 100% Liquid
Where are the Tricky
Heat Exchangers?
 Drop Wise Condensation
 Special Case
 Very High Heat Transfer
 5 to 10 x Film Condensation
 Film Condensation
 Laminar
1/ 4
hx x  g l (  l   v )H vap kl 
3
Nu x   
kl  4  l (Tv  Tw ) x 
Highest Heat
Transfer Coef.
But hard to
control HX
operating here
Various correlations depending upon boiling mechanism

 Boil a pure liquid or close-boiling liquid mixture
in a separate heat exchanger, using a maximum
overall temperature driving force of 45 F to
ensure nucleate boiling and avoid undesirable
(low h) film boiling.
 Heuristic 29.
 When cooling and condensing a stream in a heat exchanger, a zone
analysis, described in Section 18.1, should be made to make sure that the
temperature difference between the hot stream and the cold stream is equal
to or greater than the minimum approach temperature at all locations in the
heat exchanger. The zone analysis is performed by dividing the heat
exchanger into a number of segments and applying an energy balance to
each segment to determine corresponding stream inlet and outlet
temperatures for the segment, taking into account any phase change. A
process simulation program conveniently accomplishes the zone analysis.
 Laminar vs. Turbulent
 Heuristic 31.
 Estimate heat-exchanger pressure drops as follows:
 1.5 psi for boiling and condensing,
 3 psi for a gas,
 5 psi for a low-viscosity liquid,
 7-9 psi for a high-viscosity liquid,
 20 psi for a process fluid passing through a furnace.
 Shell side
 Nozzle diameter
 Inlet and Outlet
 Number of Baffles
 Tubes
 Number, diameter, pitch, No. passes
 Tube side
 Nozzle diameter
 Inlet and Outlet
 Tubes
 Number, diameter, pitch, No. passes
Note interactions!
 See ProMax Help/index “Shell, types”
 Size Factor HX Area
 CBase(6-2000)=exp[11.0545-0.9228*ln(A)+0.09861*ln(A) ]
2
 Purchase Price
 CP-fob=FP(P)*FMaterial(A)*FL(L)*CBase*(CPI/394)
 C =F *C
BM BM P-fob
 C =3.17*C
BM P-fob
 Cost depends on HX Area
 Pumping Cost
 Work = Q*ΔP
 A = Ntubes π Dtubes Ltubes
 Shell
 Shell Diameter and pitch determines Ntubes
 Tubes
 Dtubes
 Ltubes
 Tube pitch-The transverse pitch is the shortest distance from
the center lines of two adjacent tubes.
 Tube pitch ratio 1.25 to 1.5 typically
 For a given heat duty and geometry - U determines the HX area
 Steps
 Identify the controlling heat transfer resistance
 ho-Manipulate the shell side Reynolds number
 Shell diameter
 Tube pitch
 Number of baffles
 hi-Manipulate the tube side Reynolds number
 Tube diameter
 Number of tubes (shell diameter and tube pitch)
 Number of passes
 If odd things happen check to see that you have the same controlling heat transfer
resistance
Note interactions!
 Materials of Construction
 Strength at temperature, life time, heat conduction,
fouling
 Design layout
 Tube pitch, baffles, tube and shell diameters
 Temperatures Cross Each
Other
 Non-functioning Exchanger
 To solve increase approach ΔT
 Condensation/Evaporation
 Heat transfer with multiple
heat transfer coefficients in a
single apparatus
 Various regimes of boiling
 Various regimes of condensation

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DEPARTMENT

-By Chhagan Kharol

Thot in  Thot out Tcold out  Tcold in

Rf=fouling factors, inside and outside

See table 18.5 for range of U values for different cases.

Also other correlations valid over wider ranges

Various correlations depending upon boiling mechanism

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