Chapter 10

Heat Exchangers

Heat Exchangers

Chee 318

Heat Exchangers
A heat exchanger is used to exchange heat between two fluids of different temperatures, which are separated by a solid wall. Heat exchangers are ubiquitous to energy conversion and utilization. They encompass a wide range of flow configurations. Applications in heating and air conditioning, power production, waste heat recovery, chemical processing, food processing, sterilization in bio-processes. Heat exchangers are classified according to flow arrangement and type of construction.

All principles that we have learned previously apply. In this chapter we will learn how our previous knowledge can be applied to do heat exchanger calculations, discuss methodologies for design and introduce performance parameters.
Heat Exchangers Chee 318 2

Concentric Tube Construction

Parallel Flow

Counterflow

Heat Exchangers

Chee 318

Cross-Flow Heat Exchangers

Finned-Both Fluids Unmixed

Unfinned-One Fluid Mixed the Other Unmixed

Heat Exchangers

Chee 318

Shell-and-Tube Heat Exchangers

Baffles are used to establish a cross-flow and to induce turbulent mixing of the shellside fluid, both of which enhance convection. The number of tube and shell passes may be varied One Shell Pass and One Tube Pass

One Shell Pass, Two Tube Passes

Heat Exchangers Chee 318

Two Shell Passes, Four Tube Passes

5

Compact Heat Exchangers

Widely used to achieve large heat rates per unit volume, particularly when one or both fluids is a gas. Characterized by large heat transfer surface areas per unit volume (>700 m2/m3), small flow passages, and laminar flow.
Chee 318 6

Heat Exchangers

Heat Exchanger Analysis

Expression for convection heat transfer for flow of a fluid inside a tube:

& c p (Tm,o Tm,i ) qconv = m

For case involving constant surrounding fluid temperature:

q = U As Tlm

Tlm

To Ti = ln(To / Ti )

Heat Exchangers

Chee 318

Heat Exchanger Analysis

In a two-fluid heat exchanger, consider the hot and cold fluids separately:

& h c p ,h (Th ,i Th ,o ) qh = m & c c p ,c (Tc ,o Tc,i ) qc = m

and

q = UA Tlm

Need to define U and Tlm

Heat Exchangers Chee 318 8

Overall Heat Transfer Coefficient

For tubular heat exchangers we must take into account the conduction resistance in the wall and convection resistances of the fluids at the inner and outer tube surfaces.

1 1 ln( Do / Di ) 1 = + + UA hi Ai 2kL ho Ao
Note that:

1 1 1 = = UA U i Ai U o Ao
Heat Exchangers

where inner tube surface outer tube surface

Chee 318

Ai = Di L Ao = Do L
9

Fouling
Heat exchanger surfaces are 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. An additional thermal resistance, can be introduced: The Fouling factor, Rf.
Depends on operating temperature, fluid velocity and length of service of heat exchanger. It is variable during heat exchanger operation. Typical values in Table 10.2.

The overall heat transfer coefficient can be written:

ln( Do / Di ) 1 1 1 = + + + + UA hi Ai Ai 2kL Ao ho Ao
Heat Exchangers Chee 318 10

R "f ,i

R "f ,o

Fin (extended surface) effects

Fins reduce the resistance to convection heat transfer, by increasing surface area. Expression for overall heat transfer coefficient includes overall surface efficiency, or temperature effectiveness, o, of the finned surface, which depends on the type of fin (see also Ch. 3.6.4)

1 1 1 = = = UA U c Ac U h Ah 1 1 = + + Rconduction + + (o hA) c (o A) c (o A) h (o hA) h

where c is for cold and h for hot fluids respectively

R "f ,c

R "f , h

(11.3c)

Heat Exchangers

Chee 318

11

Tlm: 1. Parallel-Flow Heat Exchangers

T1 T2

q = UA Tlm
T2 T1 = ln(T2 / T1 )

Tlm

where

T1 = Th,i Tc,i T2 = Th,o Tc,o

Heat Exchangers

Chee 318

12

Tlm: 2. Counter-Flow Heat Exchangers

T1 T2

q = UA Tlm
T2 T1 = ln(T2 / T1 )

Tlm

where

T1 = Th,i Tc ,o T2 = Th,o Tc,i

Heat Exchangers

Chee 318

13

Example
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 30C respectively. How long must the tube be made if the outlet temperature of the oil is to be 60C?

Heat Exchangers

Chee 318

14

Special Operating Conditions

Condenser: Hot fluid is condensing vapor (eg. steam)

Heat Exchangers

Evaporator/boiler: Cold fluid is evaporating liquid

Chee 318 15

Multipass and Cross-Flow Heat Exchangers

To account for complex flow conditions in multipass, shell and tube and cross-flow heat exchangers, the log-mean temperature difference can be modified:

Tlm = FTlm,CF
where F=correction factor (Figures 11.10-11.13) and

T1 = Th,i Tc,o T2 = Th,o Tc,i

Heat Exchangers

Chee 318

16

Correction Factor

where t is the tubeside fluid temperature

Heat Exchangers

Chee 318

17

Example 2
A shell-and-tube heat exchanger must be designed to heat 2.5 kg/s of water from 15 to 85C. The heating is to be accomplished by passing hot engine oil, which is available at 160C, through the shell side of the exchanger. The oil is known to provide an average convection coefficient of ho=400 W/m2.K on the outside of the tubes. Ten tubes pass the water through the shell. Each tube is thin walled, of diameter D=25 mm, and makes eight passes through the shell. If the oil leaves the exchanger at 100C, what is the flow rate? How long must the tubes be to accomplish the desired heating?

Heat Exchangers

Chee 318

18