Module Code: NG3H237

[THERMODYNAMICS 3 - HEAT EXCHANGER DESIGN]

Introduction
Heat exchangers are devices that facilitate heat transfers between two or more fluids at different temperatures (Ozisik, 1985). Heat exchangers may be classified (Bejan and Kraus, 2003) according to transfer processes, number of fluids, construction, heat transfer mechanisms, surface compactness, flow arrangement, number of fluid passes and types of surface. Various types of heat exchangers have been developed for use at such varied levels of technological sophistication and sizes such as steam power plant, chemical processing plants, building heating and air conditioning, household refrigerators, car radiators, radiators for space vehicles, and so on (Bejan and Kraus, 2003). Fraas (1989) suggested that in common types of heat exchangers such as double-pipe and shell-andtube, heat transfer is primarily by conduction and convection from a hot to a cold fluid, which are separated by a metal wall. Double-pipe and shell-and-tube heat exchangers are available in a variety of materials, and are suitable for a wide range of pressures and temperatures. Their construction (Ozisik, 1985) allows a wide variation in design as factors such as tube size, number of tubes and tube length can all be varied. Foumeny and Heggs (1991) justified that this allows the flexibility in adapting designs to suit particular requirements; it also means that design optimisation is required to achieve cost-effective designs. Bejan and Kraus (2003) expressed that the design of heat exchangers is a complicated matter. Ozisik (1985) evaluated that heat transfer and pressure drop analysis, sizing and performance estimation, and the economic aspects play important roles in the final design of heat exchangers. For example, although the cost considerations are very important for applications in large installations such as power plants and chemical processing plants, the weight and size considerations become the dominant factor in the choice of design for space and aeronautical application (Ozisik, 1985).

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Module Code: NG3H237 Background Theory

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Double Pipe Heat Exchangers are a form of Tubular Heat Exchanger. A typical double pipe heat exchanger (Kuppan, 2000) has two concentric pipes, usually in the form of a U-bend design as illustrated in figure 1. The flow arrangement is pure counter-current (Ozisik, 1985). Kuppan (2000) and Fraas (1989) suggested that a number of double pipe heat exchangers can be connected in series or parallel as necessary and their usual application is for a small duties requiring, typically, less than 300 ft2 (27.87 m2). They are suitable for high pressures and temperatures, and thermally long duties. This contain the advantages of flexibility since units can be added or removed as required, and the design is easy to service and requires low inventory of spares due to its standardization (Kuppan, 2000). Kuppan (2000) added, either longitudinal fins or circumferential fins within the annulus on the inner pipe wall are required to enhance the heat transfer from the inner pipe fluid to the annulus fluid.

Figure 1: Double pipe heat exchanger. (a) Single pass with counter-flow; and (b) multi-pass with counter-flow (Kuppan, 2000, p. 4)

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Heat Exchanger Analysis with the use of the Log Mean Temperature Difference Incropera and DeWitt (2002) suggested that in order to design or to predict the performance of a heat exchanger, it is necessary to relate the quantities such as the inlet and outlet fluid temperatures, the overall heat transfer coefficient, and the total surface area for heat transfer. Two such relations may be obtained by applying overall energy balances to the hot and cold fluids as illustrated in figure 2.

Figure 2: Overall Energy balances for the hot and cold fluids of a two-fluid heat exchanger (Incropera and DeWitt, 2002, p. 587) The parallel-Flow Heat Exchanger The hot and cold fluid temperature distributions associated with a parallel-flow heat exchangers are illustrate in figure 3. It is important to note that, for such an exchanger, the outlet temperature of the cold fluid never exceeds that of the hot fluid (Incropera and DeWitt, 2002). In figure 3, the sub scripts 1 and 2 designate opposite ends of the heat exchanger. The energy balances and the subsequent analysis are subject to the following assumptions (Incropera and DeWitt, 2002). 1. The heat exchanger is insulated from its surroundings, in which case the only heat exchange is between the hot and cold fluids. 2. Axial conduction along he tubes is negligible. 3. Potential and kinetic energy changes are negligible. 4. The fluid specific heats are constant. 5. The overall heat transfer coefficient is constant. The specific heats may change as a result of temperature variations, and the overall heat transfer coefficient may change because of variations in fluid properties and flow conditions (Incropera and DeWitt, 2002). Incropera and DeWitt (2002) added, in many applications such variations are not significant, and it is reasonable to work with average values of Cp,c , Cp,h , and U for the heat exchanger.

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Figure 3: Temperature distributions for a parallel-flow heat exchanger (Incropera and DeWitt, 2002, p. 588) The Counter-flow Heat Exchanger The hot and cold fluid temperature distributions associated with a counter-flow heat exchangers are illustrated in figure 4. In contrast to the parallel-flow exchanger, this configuration provides for heat transfer between the hotter portions of the two fluids at one end, as well as between the older portions at the other (Incropera and DeWitt, 2002). Hence, the outer temperature of the cold fluid may exceed the outlet temperature of the hot fluid (Incropera and DeWitt, 2002). Incropera and DeWitt (2002) added, for the same inlet and outlet temperatures, the log mean temperature difference for cunter-flow exceeds that for parallel flow. The surface area required to effect the heat transfer rate q is smaller for the counter-flow than for the parallel-flow arrangement, assuming the same value of U.

Figure 4: Temperature distributions for a counter-flow heat exchanger (Incropera and DeWitt, 2002, p. 590) Daniel James Watkins 09032266 Page 4

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Aims and Objectives Aims Fully develop the understanding of Heat Exchangers Design Fully develop the understanding of different Heat Exchangers Calculation methods

Objectives Design a double-pipe water-to-water heat exchangers to meets the specifications provided Evaluate the design by identifying what features and configurations could be explored with the customer in order to develop more complete specifications Design Assumptions 1. The fluid velocity is not greater than 5 m/s 2. The tube length should not exceed 12 m 3. The flow is a fully developed turbulent flow 4. The system kinetic and potential energy is dynamic 5. The heat exchanger is a Counter-flow system 6. The thermal resistance is negligible 7. The surrounding heat lost is negligible 8. Constant thermal-physical properties throughout the system Design Approaches 1. Compute all calculations required to obtain the value of UA 2. Assume ranges of overall coefficient (U) in order to estimate the heat transfer area (A) 3. Once area (A) is obtained, estimate the tube diameters. 4. Determine the overall coefficient (U) of the selected tube diameters. Hence, Correlation of cold and hot convection coefficient can be used. 5. Once the UA products of all the selected diameters are obtained, compare it to the required (original) UA value. 6. If UA value from the first sets of selected diameters did not satisfy the required UA value, Interpolation of the ranges of the tubes against the original UA value can be compute to obtain the necessary tube diameter.

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Calculations and Results Table 1: Given Data for the Design

Fluid Hot Cold Mass Flow Rate (kg/s) 28 27 Inlet Temperature Ti (C) (K) 90C = 363 K 34C = 307 K Outlet Temperature TO (C) (K) 65C = 338 K 60C = 333K

Step 1:
Determination of the Average Mean Temperature (AMT): Average Mean Temperature for Hot Fluid (AMTh) = Average Mean Temperature for Cold Fluid (AMTC) = From table A1 (Appendix 1), determine the CP, h value: At, AMTh = 350.5 K, Interpolate to obtain Value of CP, h as illustrate in figure 5. = 350.5 K = 320 K

Figure 5: Graphical interpolation method to obtain CP, h

CP,h = x = 4.1954

103 J/kg K

and at AMTC = 320 K Daniel James Watkins 09032266 Page 6

Module Code: NG3H237 CP, C = 4.180

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103 J/kg K (Obtained directly from table A1 without interpolation)

Determinations of the Heat Capacity (C) for both fluids: Heat Capacity of hot fluid (Ch) = Heat Capacity of hot fluid (Ch) = 117.4712 =( ) ( )

103 W/K

____________________________________________ Heat Capacity of cold fluid (CC) = Heat Capacity of hot fluid (CC) = 112.86 = (27) 103 W/K (4.180 103)

____________________________________________ Determination of Heat Transfer Effectiveness( ): ( )

( (

( (
) ) ( (

) )
) )

( )=

= 0.464

Determination of Heat Capacity Ratio (Cr): ( ) ( )

( ( ) )

= 0.96 Cr 1

Since the Heat Capacity Ratio (Cr) is determined to be lesser than 1, therefore, this state that the counter flow arrangement must be apply. Determination for Number of Transfer Units (NTU) with counter flow arrangement:
( )

( NTU = 0.851

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Determination of the Maximum Heat Transfer Rate (qmax): ( ( W Determination of the Heat Transfer Rate (q): ( ) ( ) ( ) Determination of the UA Value: ( W/K ) ) ) ( )

W/K

Step 2: Estimate the area (A). The typical range of U for Water-to-Water exchangers is 850-1700 W/m2K as illustrated in table A2. Therefore, with UA = 96.04 103 W/K, the ranges for Area (A) are as follow: ( )

Now, consider:

Ranges for the Number of Tubes can be obtained.

Where, L = the length of the tube and N = Number of Tubes

Trial 1: Assuming that Di = 0.025 m and L = 10 m From,

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Trial 2: Assuming that Di = 0.045 m and L = 10 m

Trial 3: Assuming that Di = 0.075 m and L = 10 m

Table 2: Dimensional properties and number of tubes results Trial 1 2 3 Di (m) 0.025 0.045 0.075 L (m) 10 10 10 N 72 144 40 80 24 48 A (m2) 56.5 113 56.5 114 56.5 115

Step 3: Estimate the overall coefficient, U. With the inner (hot) and outer (cold) fluids in the concentric tube arrangement, the overall coefficient is:

Where, hi = coefficient of hot side and ho = the coefficient of cold side

The h are estimate using the Dittus-Boelter correlation assuming fully develop turbulent flow.

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value. as illustrate in figure 6.

From table A1, determine the viscosity,

At, AMTh = 350.5 K, Interpolate to obtain Value of

Figure 6: Graphical interpolation method to obtain

and at AMTC = 320 K, (Obtained directly from table A1 without interpolation) From table A1, determine the Prandtl number (Pr)
At, AMTh = 350.5 K, Interpolate to obtain Value of Pr, h as illustrate in figure 7.

Figure 7: Graphical interpolation method to obtain Pr, h Daniel James Watkins 09032266 Page 10

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and at AMTC = 320 K (Obtained directly from table A1 without interpolation) From table A1, determine the Thermal Conductivity, k (W/m.K)
At, AMTh = 350.5 K, Interpolate to obtain Value of kh as illustrate in figure 8.

Figure 8: Graphical interpolation method to obtain kh

W/m.K and at AMTC = 320 K W/m.K (Obtained directly from table A1 without interpolation)

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Table 3: Results of Prandtl Number (Pr), Viscosity () and Thermal Conductivity (k) for both Hot/Cold fluids at Average Mean Temperature (AMT). Fluids Hot Cold AMT (K) 350.5 320 Pr 2.28 3.77 (NS/m2) 362.8 106 577 106 k (W/.K) 668.3 103 640 103

Study 1 Consider, Di = 0.025 m 1.

2.

( ) ( )

3.

Cooling

( )

4.

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5.

6.

( ) ( )

7.

Heating

8.

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Study 2 Consider, Di = 0.045 m 1.

2.

( ) ( )

3.

Cooling

( )

4.

5.

6.

( ) ( )

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7.

Heating

8.

Study 3 Consider, Di = 0.075 m 1.

2.

( ) ( )

3.

Cooling

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( )

4.

5.

6.

( ) ( )

7.

Heating

8.

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Table 4: Obtained physical properties from the studies

Study 1 2 3 Di (m) 0.025 0.045 0.075 A (m2) 56.5 56.5 56.5 N 72 40 24 hi (W/m2.K) 5867.67 3251.95 1955.89 ho (W/m2.K) 2354.1 1271 617.01 U (W/m2.K) 1680.06 913.83 469.04 UA (W/K) 94.92 103 51.63 103 26.5 103

The value of UA obtained from the 3 studies did not meet the original required UA value (96.04 103 W/K). Since the results of UA values increases as the diameter decrease, assumption for the suitable diameter can be made. From table, at the diameter of 0.025 m, its UA value is the closest to the Original UA value. Therefore, lets consider a new diameter to be studied. Study 4 Assuming, Di = 0.02 m and L = 10 m
From,

-------------------------------------------------------------1.

2.

( ) ( )

3.

Cooling

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( )

4.

5.

6.

( ) ( )

7.

Heating

8.

9.

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[THERMODYNAMICS 3 - HEAT EXCHANGER DESIGN] , from here, interpolation

With Di = 0.02 m, the value of UA obtain is

between Di = 0.025 m and Di = 0.02 m in order to gain the required diameter to meet the required UA value can be carried out as follow:

Figure 9: Graphical interpolation method to obtain required Di

required to satisfy the original UA value.

Study 5 Check obtained result

Where, Di = 0.0248 m and L = 10 m

From,

-------------------------------------------------------------1.

2.

( ) ( )

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[THERMODYNAMICS 3 - HEAT EXCHANGER DESIGN] Cooling

3.

( )

4.

5.

6.

( ) ( )

7.

Heating

8.

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9.
Discussion of Results Firstly, all the calculations were conducted to obtain the value of UA (94.04 10 3 W/K). These calculations include the determination of the Average Mean Temperature (AMT) for both fluids, CP, h value, Heat Capacity (C) for both fluids, Heat Transfer Effectiveness( ), Heat Capacity Ratio (Cr), Number of Transfer Units (NTU counter flow arrangement), the Maximum Heat Transfer Rate (qmax) and the Heat Transfer Rate (q). The Heat Capacity Ratio (Cr) obtained was lesser than 1, this state that counter flow arrangement must be apply. From here, the ranges for the area (A) can be determined. With the ranges of Area (A), the length (L) and the number of tubes (N) can then be determined according to the ranges of diameter assumed (0.025m, 0.045m and 0.075m). Hence, the viscosity ( ), Prandtl number (Pr) and Thermal Conductivity (k) can be determine from the table of

satisfied the required UA value.

thermal-physical properties for saturated water. When all the properties are obtained, the studies for all the selected diameters can then be compute. The studies for each case are divided into 8 steps to obtain the UA value for each case as shown previously in the calculation section. From the 3 assumed diameters, the obtained UA value did not satisfy the required UA value. As mentioned earlier, from observation, the results of the UA values increases as the diameter decrease, therefore

assumption for the suitable diameter is then made. From here, a new study is then conducted with the diameter value of 0.02m. The UA obtained is , then interpolation

between Di = 0.025 m and Di = 0.02 m was conducted in order to gain the required diameter to meet the required UA value. The required diameter obtained to satisfy the original UA value is 0.0248m. Determination for the length (L) and number of tubes (N) required for this diameter is then conducted. With the use of 0.248m diameter tube, the minimum requirement for the number of tubes is 73. Therefore, the specification for the heat exchanger design that meets the requirement is Di =0.0248 m, Do = 0.0351 m, L = 10 m and N = 73 tubes.

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Conclusion Double Pipe Heat Exchangers are a form of Tubular Heat Exchanger. A typical double pipe heat exchanger has two concentric pipes. A number of double pipe heat exchangers can be connected in series or parallel as necessary. The required UA value was obtain through all the necessary calculations. Several trials were conducted using different diameter sizes. The UA values for each diameter were then obtained. The calculation shows that with the physical properties of Di =0.0248

m, Do = 0.0351 m, L = 10 m and N = 73 tubes, the design will be able to achieve the necessary UA value that satisfy with the customer requirement.
Reference Bejan, A. and Kraus, A. (2003) Heat Transfer Handbook. Toronto: John Wiley & Sons, p.797-822. Foumeny, E. and Heggs, P. (1991) Heat Exchange Engineering. Chichester: Ellis Horwood Limited, p.58,67-77. Fraas, A. (1989) Heat Exchanger design. 2nd ed. Toronto: John Wiley & Sons, Inc., p.2, 22, 54. Incropera, F. and Dewitt, D. (2002) Introduction to Heat Transfer. 4th ed. New York: John Wiley & Sons, p.606-643 Ozisik, M. (1985) Heat Transfer - A basic Approach. Singapore: McGraw-Hill, p.524-571. Kuppan, T. (2000) Heat Exchanger Design Handbook. 2nd ed. New York: Marcel Dekker, Inc, p.2-4.

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Appendix Table A1: Thermophysical Properties of Saturated Water

Source: Incropera, F. and Dewitt, D. (2002) Introduction to Heat Transfer. 4th ed. New York: John Wiley & Sons, p.844.

Table A2: Representative value of the overall Heat transfer coefficient

Source: Incropera, F. and Dewitt, D. (2002) Introduction to Heat Transfer. 4th ed. New York: John Wiley & Sons, p.586

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