HEAT EXCHANGERS

Y. Bultel 2015-2016
SEM/IEN 2A
 I. INTRODUCTION

• 1. Heat Exchanger description

– Heat exchangers are devices that facilitate the exchange of heat
between two fluids that are at different temperatures with or without
mixing both fluids.
– Heat exchangers can be described as a black box including two inlets
and two outlets.
– Heat exchangers are commonly used in practice in a wide range of
applications, from heating and air-conditioning in buildings, to
chemical processing and power production in large plants.

Cold fluid Cold fluid

inlet outlet

Hot fluid Hot fluid

outlet inlet
 I. INTRODUCTION

• 1. Heat Exchanger description

– Each stream can be described by:
• State: gas or liquid
• Mass flow rate (Kg/s)
• Temperatures for hot and cold streams
• Pressures of the hot and cold streams

ṁc ṁc
c,in c,out
Pc,in Pc,out

ṁh ṁh
h,out h,in
Ph,out Ph,in
 I. INTRODUCTION

• 2. Heat Transfer description

– Heat transfer depends on the properties of the fluid and the wall:
• Specific Heat capacity (J/Kg/K)
• Density (Kg/m3)
• Viscosity (Pa/s)
• Thermal conductivity (W/m/K)

c,in c,out
c,in c,out
Cpc Cpc


h,out h,in
h,out h,in
Cph Cph
 I. INTRODUCTION

• 2. Heat Transfer description

– Heat transfer in a heat exchanger usually involves convection in each
fluid and conduction through the wall separating the two fluids. In the
analysis of heat exchangers:

• It is convenient to work with an overall

heat transfer coefficient U that accounts for
the contribution of all these effects on
heat transfer.

– The rate of heat transfer between the two fluids at a location in a heat
exchanger depends on the magnitude of the temperature difference at
any location, which varies along the heat exchanger.
 II. DIFFERENT TYPES OF
HEAT EXCHANGER

• 1. Heat Exchanger technologies:

– Different heat transfer applications require different types of hardware
and different configurations of heat transfer equipment.
• The attempt is to match the heat transfer hardware to the heat transfer
requirements with the specified constraints.

Cold fluid Cold fluid

inlet outlet

Hot fluid Hot fluid

outlet inlet
 II. DIFFERENT TYPES OF
HEAT EXCHANGER

• 2. Double-pipe heat exchanger:

– The simplest type of heat exchanger consists of two concentric pipes of
different diameters, called the double-pipe heat exchanger.
• One fluid in a double-pipe heat exchanger flows through the smaller pipe
while the other fluid flows through the annular space between the two
pipes
 II. DIFFERENT TYPES OF
HEAT EXCHANGER

• 2. Double-pipe heat exchanger:

– Two types of flow arrangement are possible in this heat exchanger:
• In parallel/co flow, both the hot and cold fluids enter the heat exchanger at
the same end and move in the same direction.
• In counter flow, on the other hand, the hot and cold fluids enter the heat
exchanger at opposite ends and flow in opposite directions.
 II. DIFFERENT TYPES OF
HEAT EXCHANGER

• 3. Compact heat exchanger:

– Compact heat exchangers are commonly used in gas-to-gas and gas-to
liquid (or liquid-to-gas).
– Compact heat exchangers are used to counteract the low heat transfer
coefficient associated with gas flow by increasing surface area.
– For example, in water-to-air compact heat exchanger, it is no surprise that fins
are attached to the air side of the tube surface.

A gas-to-liquid compact heat

exchanger for a residential air-conditioning
system.
 II. DIFFERENT TYPES OF
HEAT EXCHANGER

• 3. Compact heat exchanger:

– The large surface area in compact heat exchangers is obtained by
attaching closely spaced thin plate or corrugated fins to the walls
separating the two fluids.
– In compact heat exchangers, the two fluids usually move perpendicular
to each other, and such flow configuration is called cross-flow.
 II. DIFFERENT TYPES OF
HEAT EXCHANGER

• 3. Compact heat exchanger:

– The cross-flow is further classified as unmixed and mixed flow,
depending on the flow configuration:
• the cross-flow is said to be unmixed since the plate fins force the fluid to
flow through a particular interfin spacing and prevent it from moving in
the transverse direction (i.e., parallel to the tubes).
• The cross-flow is said to be mixed since the fluid now is free to move in
the transverse direction.
 II. DIFFERENT TYPES OF
HEAT EXCHANGER

• 3. Compact heat exchanger:

– Compact heat exchanger is specifically designed to realize a large heat
transfer surface area per unit volume.
– The ratio of the heat transfer surface area of a heat exchanger to its volume is
called the area density 
• Compact heat exchangers enable us to achieve high heat transfer rates
between two fluids in a small volume, and they are commonly used in
applications with strict limitations on the weight and volume.
• Car radiators ( =1000 m2/m3)

A gas-to-liquid compact heat

exchanger for a residential air-conditioning
system.
 II. DIFFERENT TYPES OF
HEAT EXCHANGER

• 4. Shell-and-tube heat exchanger:

– The most common type of heat exchanger in industrial applications is
the shell-and-tube heat exchanger.
• Shell-and-tube heat exchangers contain a large number of tubes packed in
a shell with their axes parallel to that of the shell.

The schematic of a shell-and-tube

heat exchanger (one-shell pass and one-tube pass)
 II. DIFFERENT TYPES OF
HEAT EXCHANGER

• 4. Shell-and-tube heat exchanger:

– Baffles are commonly placed in the shell to force the fluid to flow
across the shell to enhance heat transfer and to maintain uniform
spacing between the tubes.
– Note that the tubes in a heat exchanger open to some large flow areas
called headers at both ends of the shell, where the fluid accumulates
before entering the tubes and after leaving them.

Principle of operation
II. DIFFERENT TYPES OF
HEAT EXCHANGER
II. DIFFERENT TYPES OF
HEAT EXCHANGER
 II. DIFFERENT TYPES OF
HEAT EXCHANGER
Front head
Type shell Rear head
 II. DIFFERENT TYPES OF
HEAT EXCHANGER

• 4. Shell-and-tube heat exchanger:

– Shell-and-tube heat exchangers are further classified according to the
number of shell and tube passes involved
• Heat exchangers in which all the tubes make
one U-turn in the shell, for example, are called
one-shell-pass and two tube-passes heat
exchangers.

• a heat exchanger that involves two passes in

the shell and four passes in the tubes is called a
two-shell-passes and four-tube-passes heat
exchanger
 II. DIFFERENT TYPES OF
HEAT EXCHANGER

• 5. Plate and frame heat exchanger:

– An innovative type of heat exchanger is the plate and frame (or just
plate) heat exchanger, which consists of a series of plates with
corrugated flat flow passages.
Exploded view of a typical plate and frame
heat exchanger and flow pattern

Gasket

Typical plates in plate and frame heat exchanger (a) Intermating

or washboard type and (b) Chevron or herringbone type.
 II. DIFFERENT TYPES OF
HEAT EXCHANGER

• 5. Plate and frame heat exchanger:

– The hot and cold fluids flow in alternate passages, and thus each cold
fluid stream is surrounded by two hot fluid streams, resulting in very
effective heat transfer.

– They are well suited for

liquid-to-liquid heat exchange
applications, when the hot and
cold fluid streams are at about
the same pressure.

Principle of operation
 III. HEAT TRANSFER

• 1. Heat Transfer into Heat Exchangers

– Hypothesis:
• Stationary conditions
• The two fluids are physically separated from each other by a sealing wall
• Enthalpy lost by the hot fluid is instantly won by the cold fluid
– No energy is lost to the outside
– Thermal Behaviour:
• 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
 III. HEAT TRANSFER

• 2. Thermal resistances
– The thermal resistance network associated
with this heat transfer process involves:
- one conduction resistance:
e.g. Plate and
e
R cond  frame heat
A exchanger
T  R cond ln o  e.g. Double-pipe
r
R cond   ri 
heat exchanger
2L

- and two convection resistances:

1
R conv 
hA
 III. HEAT TRANSFER

• Reminders: Convective heat transfer coefficient

– They are obtained from the Nusselt correlations:

uL Cp
 f Re, Pr  with Re 
hL
Nu  and Pr 
  
– Correlations depend on the flow regime (laminar or turbulent) and the
geometry
– Example: External flow perpendicular to a tube
Nu  1.11ARem Pr 0.31
 III Évaluation des performances thermiques

• Reminders: Convective heat transfer coefficient

L/D  0.05RePr D L de di
– Re<2100 0.14 Re<2100 1/ 3
 D  
1/3
   d  de  
Nu  1.86 RePr  . moyen  Nu  1.86 Re . Pr i  
 L    paroi    L 
– 2100<Re<10 000 2100<Re<10 000
0.14

1/3  moyen
   D 1/ 3 
 
0.14
  moyen 
0.15

Nu  0.116 Re  125 Pr . d 
1    
2/3
 Nu  0.031 Re d e . Pr1/ 3  i 
0.8
 
  paroi    L    de 
 
 paroi 

– Re>10 000 Re>10 000

  D 
0.7
 0.14
Nu  0.023Re Pr 1     L/D  60
0.8 1/3
 
  L   Nu  0.027 Re 0.8 . Pr1/ 3  moyen 
 
 paroi 
Nu  0.023Re0.8Pr1/3 L/D  60 Colburn
 III. HEAT TRANSFER

• 3. Thermal resistance Network

– Combined Conduction and Convection into Heat Exchangers:

Ti  To 
R
 1 e 1 
• Case of a Plane wall: R     
 h i A A h o A 
• Case of a hollow cylinder:
 1 ln( ro / ri ) 1 
R     
 2 ri h i L 2 L 2 ro h o L 
• Case of a finned surface:

 1 e 1 
R     
 E i h i A i A E o h o A o 
 III. HEAT TRANSFER

• 3. Overall heat transfer coefficient

– Combined Conduction and Convection into Heat Exchangers:
  UA Ti  To 
1 1 e 1 
• Case of a Plane wall:     
U  hi  ho 
• Case of a hollow cylinder:
1  1 ri ln( ro / ri ) 1 ri 
    
Ui  hi  h o ro 
• Case of a finned surface:

1  1 e 1 Ai 
    
U i  E i h i A E o h o A o 
 III. HEAT TRANSFER

• 4. Heat Transfer from finned surfaces

– There are two ways to increase the rate of heat transfer by convection:

  h A Tw  T 

– to increase the convection heat transfer coefficient h:

• Increasing h may require the installation of a pump or fan, or replacing the
existing one with a larger one, but this approach
may or may not be practical
– or to increase the surface area A:
• The alternative is to increase the surface area by
attaching to the surface extended surfaces called fins
made of highly conductive materials such as aluminium
 III. HEAT TRANSFER

• 4. Heat Transfer from finned surfaces

– Fin efficiency:  fin
fin 
 fin ,max
– Examples:
Fin efficiency relations are developed for fins of various profiles and are
plotted in this figure for fins on a plain surface.

For the case of a fin with constant cross section

and insulated tips, the fin efficiency can be

Tanh aL 
expressed as:
fin 
aL
hP
with a 
A c
 III. HEAT TRANSFER

• 4. Heat Transfer from finned surfaces

– Overall effectiveness for a finned surface:
• The performance of the finned surface is judged on the basis of the
enhancement in heat transfer relative to the no-finned case.
• The performance of finned surface expressed in terms of the overall
effectiveness is defined as:
 total,fin hA unfin  fin A fin Tb  T 
E fin  
 total,no fin hA no fin Tb  T 
• Remarks:
– An effectiveness Efin<1 indicates that the fin actually acts
as insulation, slowing down the heat transfer from the surface
– An effectiveness of Efin>1 indicates that fins are enhancing
heat transfer from the surface, as they should
 III. HEAT TRANSFER

• D. Overall effectiveness for a finned surface: Example

 III. HEAT TRANSFER

• D. Overall effectiveness for a finned surface: Example

 III. HEAT TRANSFER

• 5. Overall Heat Transfer Coefficient

 III. HEAT TRANSFER

• 6. Overall Heat Transfer Coefficient: 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 and causes
the rate of heat transfer in a heat exchanger to decrease.
Precipitation fouling of
– The net effect of these accumulations ash particles on superheater tubes
on heat transfer is represented by a
fouling factor Rf, which is a measure of
the thermal resistance
introduced by fouling.
 III. HEAT TRANSFER

• 7. Overall Heat Transfer Coefficient

 IV. ANALYSIS OF HEAT
EXCHANGERS

• 1. Introduction
– an engineer often has to :
• 1 select a heat exchanger that will achieve a specified temperature change
in a fluid stream of known mass flow rate,
• 2 predict the outlet temperatures of the hot and cold fluid streams in a
specified heat exchanger.
– We will discuss the two methods used in the analysis of heat
exchangers:
• The log mean temperature difference (or LMTD) (method is best suited for
the first task)
• and the effectiveness–NTU (method for the second task as just stated)
– Hypothesis:
• Axial heat conduction along the tube is usually insignificant and can be
considered negligible
• The outer surface of the heat exchanger is assumed to be perfectly
insulated, so that there is no heat loss to the surrounding medium
 IV. ANALYSIS OF HEAT
EXCHANGERS

• 1. Introduction
dm
 in  m
– Mass balance equation for system: m  out 
dt

– Energy balance equation for system:

   W
 in ĥ in  k̂ in  gz in  Q
m  m   ĥ  k̂ gz


dm û  k̂  gz
 p
dV
ext out out out out
dt dt
 IV. ANALYSIS OF HEAT
EXCHANGERS

• 1. Introduction
– The rate of heat transfer from the hot fluid be equal to the rate of heat
transfer to the cold one:
 cC pc Tc ,out  Tc ,in   m
m  h C ph Th ,in  Th ,out 
– This quantity is called the heat capacity rate and is defined for the hot
and cold fluid streams as:

Cc  m
 cCpc and Ch  m
 hCph
– The rate of heat transfer in a heat
exchanger can also be expressed from the
heat exchange between the hot and cold
fluids
  U A Tlm
 IV. ANALYSIS OF HEAT
EXCHANGERS

• 2. The Log Mean Temperature Difference Method:

– Differential energy balance equation:

     U2     U 2

   n dS   T n dS     ĥ   gz U n dS 
V 
  û   gz dV
    2  t 2 
 
 IV. ANALYSIS OF HEAT
EXCHANGERS

• 2. The Log Mean Temperature Difference Method:

– The rate of heat transfer in a heat exchanger can also be expressed:
  U A Tlm
T2  T1
– Where Tlm is the log mean temperature difference: Tlm 
 T2 
ln 
 T1 
Parallel-flow heat exchangers Counter-flow heat exchangers
 IV. ANALYSIS OF HEAT
EXCHANGERS

• 2. The Log Mean Temperature Difference Method:

– The rate of heat transfer in a heat exchanger can also be expressed:
  U A F Tlm ,CF
– Where F is a correction factor for common cross-flow and shell-and-
tube heat exchanger configurations given versus two temperature ratios
P and R

t 2  t1
P
T1  t1
T1  T2 m Cp tubeside
R 
t 2  t1 m
 Cp shell side
 IV. ANALYSIS OF HEAT
EXCHANGERS

• 2. The Log Mean Temperature Difference Method:

– C. Multipass and Cross-Flow Heat Exchangers
 IV. ANALYSIS OF HEAT
EXCHANGERS

• 2. The Log Mean Temperature Difference Method:

– C. Multipass and Cross-Flow Heat Exchangers
 IV. ANALYSIS OF HEAT
EXCHANGERS

• 2. The Log Mean Temperature Difference Method:

– C. Multipass and Cross-Flow Heat Exchangers
 IV. ANALYSIS OF HEAT
EXCHANGERS

• 2. The Log Mean Temperature Difference Method:

– C. Multipass and Cross-Flow Heat Exchangers
 IV. ANALYSIS OF HEAT
EXCHANGERS

• 2. The Log Mean Temperature Difference Method:

– 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.
– 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 Tlm 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 or the heat flow rate 
 IV. ANALYSIS OF HEAT
EXCHANGERS

• 2. The Log Mean Temperature Difference Method:

– D. Example: Heating of Glycerin in a Multipass Heat Exchanger
 IV. ANALYSIS OF HEAT
EXCHANGERS

• 2. The Log Mean Temperature Difference Method:

– E. Example: Heating of Glycerin in a Multipass Heat Exchanger
 IV. ANALYSIS OF HEAT
EXCHANGERS

• 3. The Effectiveness–NTU Method:

– The Effectiveness–NTU method is based on a dimensionless
parameter called the heat transfer effectiveness , defined as:
 Actual heat transfer rate
 
 max Maximal possible heat transfer rate

– Where:  max  C min Tmax  C min Th ,in  Tc ,in 

Th ,in
Parallel Counter- Th ,in
flow Th ,out flow Tc ,out
Tc ,out Th ,out
  50%   100%
Tc ,in Tc ,in
 IV. ANALYSIS OF HEAT
EXCHANGERS

• 3. The Effectiveness–NTU Method:

– Effectiveness relations of the heat exchangers:   function NTU, c 
U A c  C min
NTU 
Cmin C max
 IV. ANALYSIS OF HEAT
EXCHANGERS

• 3. The Effectiveness–NTU Method:

– Effectiveness relations of the heat exchangers:   function NTU, c 
U A c  C min
NTU 
Cmin C max
 IV. ANALYSIS OF HEAT
EXCHANGERS

• 3. The Effectiveness–NTU Method:

– Effectiveness relations of the heat exchangers:   function NTU, c 
 IV. ANALYSIS OF HEAT
EXCHANGERS

• 3. The Effectiveness–NTU Method:

– Effectiveness relations of the heat exchangers:   function NTU, c 