Topic 4

Heat Exchangers

1
Last Lecture ?
Convection
Empirical equations for convective heat transfer
Natural convection Grashof Number (for flow velocity)
Convection with phase change
Condensation (wave effects cause large deviations)
Film
Droplet (~10 times better)
Horizontal pipes better in most cases
Boiling
Sub-cooled pool boiling (free convection)
Saturated boiling (bubble boiling) (max)
Film boiling (min)
Burn out sudden temp. changes over thresholds heat flux
Surface structure important, agitation, vibration
Rohsenow Correlation
Practical Equations with large differences h
c
= C q
n
4 general cases


2
Learning Objectives
Heat Exchanger Types (HE)
Recuperators
Regenerators
Parallel Flow
Counter Flow
Cross Flow
LMTD: Log Mean Temperature Difference
For simple double pipe HE
Correction Factor F for more complex HE
Iterative process to calculate temperatures for a given surface area
Capacity rate C = c
p
x mass flow
Effectiveness : NTU method (Number of Transfer Units)
Minimum Fluid: C = minimum
Capacity ratio c = C
min
/C
max

Awareness of Fouling



3
When do we need Heat
Exchangers ?

Typical examples ?
4
Heat Exchanger (HE)
In many technical applications fluid streams need to be heated or cooled.
In most of these cases apparatuses are used that are called heat exchangers.
If heat needs to be transferred between different streams of fluid in technical
applications a mixture between these fluids is normally not wanted.
Recuperators separate the fluid streams with a wall.
Regenerators separate the fluid streams while they pass through the HE
alternately in different turns. They store heat intermittently and recover it to the
cold fluid later. Hot and cold fluid medium an be the same.
The application field for Regenerators is much smaller that for Recuperators. The
thermodynamic calculation of Regenerators is very complex due to the unsteady
conduction.
Tube bundle HE and plate HE are the most important group of Recuperators.
The application of mixing heat exchangers where fluid streams are mixed and
separated - is only possible and reasonable in exceptions.
The ideal HE: should have a large area for heat transfer and small thermal
capacity itself and small pressure drop.

5
6
Systematic
Heat exchangers can be classified into a certain groups according to attributes like
design, application field, intended usage, type of fluids to be used, etc.
A significant influence towards the heat exchange performance is the
flow direction of the fluids
Depending on the angle the following types
can be distinguished:
1. In-line or uni-directional flow exchanger
a. Parallel flow = 0
b. Counter flow = 180
2. Cross flow HE
a. Rectangular cross flow = 90
b. Generic 0 < < 180

7
Systematic
The following assumptions are made to derive the equations for HEs:

1. The HE is an open and adiabatic system with steady flow
2. The heat conduction in the heating surfaces and in the fluids in the flow
direction are often neglected
3. The heat transfer can be described by an average heat transfer coefficient h
Also the following assumptions are made:
- The fluid with the higher temperature has the Index h (for hot) the colder
fluid has the Index c
- The state parameter gets the number 1 on the inlet side and 2 on the outlet
side
- The product between mass flow and specific heat capacity is named C -
the heat capacity rate.
8
Temperature distribution in HE:
Only for a counter flow HE the outlet temperature of the cold fluid (to be heated) can
be higher than the outlet temperature of the warm (heating) fluid.

9
2 Cross-flow heat exchangers
Cross-flow heat exchangers

Multi-pass, mixed-flow heat exchanger

Source: Cengel, 2007
10
Dynamic-type regenerator:
rotating drum and
continuous flow of the hot and cold
fluid through different portions of
the drum
so that any portion of the drum
passes periodically through the
hot stream, storing heat, and then
through the cold stream, rejecting
this stored heat.
Condenser: One of the fluids is cooled
and condenses as it flows through the
heat exchanger.
Boiler: One of the fluids absorbs heat
and vaporizes.
Source: Cengel, 2007
11
Variation of
fluid
temperatures
in a heat
exchanger
when one of
the fluids
condenses or
boils.
is the rate of evaporation or condensation of the fluid, .
h
fg
is the enthalpy of vaporization of the fluid at the specified temperature or pressure.
The heat capacity rate of a fluid during a phase-change process must approach infinity since the
temperature change is practically zero.
T
m
is an appropriate mean (average)
temperature difference between the two fluids.
Source: Cengel, 2007
12
Heat transfer in HE

q =
T
a
T
b
R
a
+ R
c
+ R
b

where: R
a
is the convective thermal resistance in stream a side.
R
b
is the convective thermal resistance in stream b side.
R
c
is the conductive thermal resistance of the wall between streams a and b.
T
a
and T
b
are the mean temperatures for streams a and b.

For plane wall:



q =
T
a
T
b
1
h
a
A
+
x
k A
+
1
h
6
A
b
13
For tube:

q =
T
a
T
b
1
h
i
A
i
+
n r
0
/ r
i
( )
2kL
+
1
h
0
A
0

Figure 4.7

The overall heat transfer coefficient U is dominated
by the smaller convection coefficient. When one of
the convection coefficients is much smaller than the
other (say, h
i
<< h
o
), we have 1/h
i
>> 1/h
o
, and thus U
h
i
. This situation arises frequently when one of the
fluids is a gas and the other is a liquid. In such
cases, fins are commonly used on the gas side to
enhance the heat transfer on that side.
14
General:

q = U A T
m

where: U: overall heat transfer coefficient =

1
R
a
+ R
c
+ R
b
.
A: surface area for heat transfer.


T
m
suitable mean temperature difference across the heat exchanger.

It is now important to find out the proper

T
m
in various heat exchanger cases.
The overall heat transfer coefficient ranges from
about 10 W/m
2
C for gas-to-gas heat exchangers
to about 10,000 W/m
2
C for heat exchangers that
involve phase changes.
15
Fouling Factor
The performance of heat exchangers usually deteriorates with time as a result of
accumulation of deposits on heat transfer surfaces. The layer of deposits represents
additional resistance to heat transfer. This is represented by a fouling factor R
f
.
The fouling factor increases with the operating temperature and the length of
service and decreases with the velocity of the fluids.
Source: Cengel, 2007
16



Parallel Flow case:

( ) dA T T U dT c m dT c m dq
c h c c
c
h h
h = = =



mass spec.
flow heat


dT
h
=
dq
m

h
C
h
and dT
c
=
dq
m

c
C
c

17


( )
|
|
|
.
|

\
|

+ = =

pc
c
ph
h
c h c h
c m c m
dq T T d dT dT
1 1


( )
dA
c m c m
U
T T
T T d
pc
c
ph
h
c h
c h

|
|
|
.
|

\
|

+ =

1 1



1
2

=
1
2

|
|
|
.
|

\
|

pc
c
ph
h
c h
c h
c m c m
UA
T T
T T
n
1 1
1 1
2 2

(Equation 4.1)
18
( )
2 1 h h ph
h T T c m q =

2 1 h h
ph
h
T T
q
c m

( )
1 2 c C pc
c T T c m q =

1 2 c c
pc
c
T T
q
c m

Substituting in equation 4.1:

q = U A
T
h2
T
c2
( )
T
h1
T
c1
( )
n T
h2
T
c2
( )
/ T
h1
T
c1
( )
| |


T
m
is LMTD
The LMTD is Log Mean Temperature Difference:
19
Note, it means that in the heat exchanger calculation, the LMTD is the proper mean
temperature difference we are looking for and the one that should be used.

For Parallel flow:


LMTD=
T
h2
T
c2 ( )
T
h1
T
c1 ( )
n T
h2
T
c2
( )
/ T
h1
T
c1
( )
| |


For Counter flow: LMTD =

T
h2
T
c1
( )
T
h1
T
c2
( )
n T
h2
T
c1
( )
/ T
h1
T
c2
( )
| |

Counter flow HE


T
20

Note: LMTD is obtained under the assumptions:
1 fluid specific heat does not change
2 convective heat transfer coefficient is constant throughout the HE

The LMTD can also be expressed as:
LMTD =

0

i
n

i
|
\

|
.
|

Where:
i
is temperature difference in the inlet of hot fluid side.

0
: is temperature difference in the outlet of hot fluid side.
21
Note: the LMTD expression above is for both parallel and counterflow simple (double-
pipe) HE, as Figure 4.11.
For other HE structure:

q = U A LMTD
( )
c
F


counter correction
flow factor
LMTD
Figure 4.11

The correction factor F is given in the textbook for various structures of the HE.
22
The LMTD method is very suitable for determining the size of a
heat exchanger to realize prescribed outlet temperatures when
the mass flow rates and the inlet and outlet temperatures of the
hot and cold fluids are specified.
With the LMTD method, the task is to select a heat exchanger that
will meet the prescribed heat transfer requirements. The procedure
to be followed by the selection process is:
1.Select the type of heat exchanger suitable for the application.
2.Determine any unknown inlet or outlet temperature and the heat
transfer rate using an energy balance.
3.Calculate the log mean temperature difference T
lm
and the
correction factor F, if necessary.
4.Obtain (select or calculate) the value of the overall heat transfer
coefficient U.
5.Calculate the heat transfer surface area A
s
.
The task is completed by selecting a heat exchanger that has a
heat transfer surface area equal to or larger than A
s
.
Effectiveness - NTU method for HE
NTU Number of Transfer Units
When inlet and outlet temperatures of HE are known or are
easily determined, using LMTD method is convenient.
The effectivenessNTU method is easier to use in cases
where the inlet or outlet temperature may not be known.

Definition
Effectiveness of HE =

= Q/Q
max


23
24
or ( )
1 2 c c c p
c T T C M Q =

with the capacity rate
pc
c C M

= M

h C
p h
T
h1
T
h2 ( )



q
max
= MC
( )
min
T
h1
T
c1 | |


hot or cold maximum possible temperature
whatever is difference in the HE
smaller



h
=
M
h
C
h
T
h1
T
h2
( )
M
h
C
h
T
h1
T
c1
( )
=
T
h1
T
h2
T
h1
T
c1
if hot flow MC is smaller

c
=
M
c
C
c
T
c2
T
c1
( )
M
c
C
c
T
h1
T
c1
( )
=
T
c2
T
c1
T
h1
T
c1
if cold flow MC is smaller
Q
max
.
.
.
.
.
.
.
25
We know for parallel flow:

n
T
h2
T
c2
T
h1
T
c1
= UA
1
M
h
C
h
+
1
M
c
C
c
|
\

|
.
|
(Equation 4.1)

T
h2
T
c2
T
h1
T
c1
= exp
UA
M
c
C
c
1+
M
c
C
c
M
2
C
h
|
\

|
.
|




(

(
(

(Equation 4.2)
From energy balance:

T
h2
= T
h1
+
M
c
C
c
M
h
C
h
T
c1
T
c2
( )

We want to substitute the left side of Equation 4.2 so we:
- subtracting T
c2
on both sides
- Divide both sides by T
h1
T
c1
:

T
h2
T
c2
T
h1
T
c1
=
T
h1
+
M
c
C
c
M
h
C
h
|
\

|
.
|
T
c1
T
c2
( )
T
c2
T
h1
T
c1

h
.
.
.
.
.
.
. .
.
26
If cold stream is minimum MC flow:

c
=
T
c2
T
c1
T
h1
T
c1

By adding T
c1
T
c1
(=0) we obtain:

c
h h
c c
c h
c c c c h h c c c h
C M
C M
T T
T T T T C M C M T T
) 1 ( 1
) (
) ( ) ( ) / ( ) (
1 1
2 1 2 1 1 1

+ =

+ +

substitute back into 4.2 gives
(
(
(

=
|
.
|

\
|

+
h h
c c
c c
c
h h
c c
C M
C M
C M
UA
C M
C M
1 exp ) 1 ( 1

resolved to (by subtracting 1 and dividing by
) 1 (
h h
c c
C M
C M

+
:

r
=
1exp
UA
M
c
C
c
|
\

|
.
|
1+
M
c
C
c
M
h
C
h
|
\

|
.
|



(

(
1+
M
c
C
c
M
h
C
h
|
\

|
.
|

c
27
If C
c
=C
min
or C
h
=C
min
the above equation can be expressed for both cases
(hot fluid is minimum or cold fluid is minimum fluid) as:


=
1exp
UA
C
min
|
\

|
.
|
1+
C
min
C
max
|
\

|
.
|



(

(
1+
C
min
C
max


For parallel flow HE.
28
For counter flow:

=
1exp
UA
C
min
|
\

|
.
|
1+
C
min
C
max
|
\

|
.
|



(

(
1
C
min
C
max
|
\

|
.
|
exp
UA
C
min
|
\

|
.
|
1
C
min
C
max
|
\

|
.
|




(

(
(

The

UA
C
min
is known as Number of Transfer Units (NTU),

C
min
C
max
is known as Capacity ratio: C.

For counter flow:

=
1exp NTU 1C
( )
| |
1C expNTU 1 C
( )
| |
=
T
min i flow
T
h1
T
c1


For specified values of U
and C
min
, the value of
NTU is a measure of the
surface area A
s
.

Thus, the larger the NTU,
the larger the heat
exchanger.
29
For parallel flow:

=
1exp NTU 1+ C
( )
| |
1+C
=
T
mini flow
T
h1
T
c1

Simplify when:
1 condensing or boiling case C =0 (all HE) :
(

= NTU c exp 1
2
M
h
C
h
= M
c
C
c
C =1, for counter flow:

=
NTU
NTU + 1

For various structured HE, the corresponding graphical plots of as a function of NTU
and C have been established (seen textbook).
In practice, for HE design, we have to consider:
1 Heat transfer requirements - performance
2 Cost (material, manufacturing, installation,
operation, repair.)
3 Physical size, weight, durability, corrosion
4 Pressure-drop characteristics pumping
power

30
31
SELECTION OF HEAT EXCHANGERS
The uncertainty in the predicted value of U can exceed 30 percent.
Thus, it is natural to tend to overdesign the heat exchangers.
Heat transfer enhancement in heat exchangers is usually accompanied by
increased pressure drop, and thus higher pumping power.
Therefore, any gain from the enhancement in heat transfer should be
weighed against the cost of the accompanying pressure drop.
Usually, the more viscous fluid is more suitable for the shell side (larger
passage area and thus lower pressure drop) and the fluid with the higher
pressure for the tube side.
Annual cost of electricity associated with the
operation of the pumps and fans:
Australian Industry, examples
http://www.airradiators.com.au/
http://www.aithermalsystems.com/
http://www.denso.com.au/
http://www.adrad.com.au/home.htm


32
Summary
Different Heat Exchanger Types
Counter flow the most effective
LMTD: Log Mean Temperature Difference
For simple double pipe HE
Correction Factor F for more complex HE
Iterative process to calculate temperatures for a given
surface area
Capacity rate C = c
p
x mass flow
Effectiveness : NTU method (Number of Transfer Units)
Minimum Fluid: C = minimum
Capacity ratio c = C
min
/C
max

Economical viable borderline
Importance of Fowling
Design Considerations/Trade-Offs




33
Next Lecture
Radiation


Reading:
Textbook Chapter 12







34
35
Example 4.1
In a simple counter flow HE 0.2 kg/s alcohol to be cooled from 75 C to 35 C. Cooling
water enters at 12 C at a flow rate of 0.16 kg/s.
Convective h between alcohol and tube, h
at
=0.34 kW/m
2
K
Convective h between water and tube, h
wt
=0.225 kW/m
2
K
C
p
for alcohol is 2.52 kJ /kgK, for water is 4.187 kJ /kgK,
The wall of tube is thin enough to be neglected.
Calculate the area of the HE required.
42.1
36
Example 4.2
To cool oil, a counterflow HE is used.
Oil inlet temperature =130 C, at a rate of 0.5 kg/s
Cooling water inlet =15 C, at a rate of 0.3 kg/s
HE area =2.4 m
2
and overall U =1.53 kW/m
2
K.
Determine effectiveness and outlet temperature of oil and water.

C
p,oil
= 2.22
kJ
kgK
, C
pw
= 4.182
kJ
kgK


37
Example 4.3
A Counter flow double-pipe HE will be used to heat water from 35 C 80 C at a rate
of 1.25 kg/s and cool oil from 150 C 85 C. The overall heat transfer coefficient U =
850 W/m
2
K.

C
p
for oil= 2
kJ
kg

C


Compare different designs a) one big HE, or b) 2 small HE ?
Oil 150 C oil 150 C


Water 35 C
80 C water
35 C 80 C


85 C
85 C

Manufacturing costs per unit are: bigger: 100 $/m
2

smaller: 120 $/m
2

Which design results in lower costs ?