1

HEAT EXCHANGERS 1
Heat exchanger may be defined as equipment which transfers the energy from a 2
hot fluid to a cold fluid most efficiently. 3
4
MEAN TEMPERATURE DIFFERENCE FOR PARALLEL FLOW HEAT 5
EXCHANGER 6
7
8
9
10
Consider an element of length dx at a distance x from LHS of heat exchanger. Let 11
the corresponding elemental heat transferring area is dA. 12
If the hot fluid travels from x to (x+dx) 13
Then let decrease in temperature of hot fluid is dT
h
and 14
Let increase in temperature of cold fluid is dT
c
15
So, net change of temperature is: 16
(1)
h c
dT dT dT = 17
Now, 18
Heat lost by hot fluid due to travel of distance dx = Heat gained by cold fluid due to 19
travel of distance dx 20
& THIS IS EQUAL TO 21
Heat transferred from the hot fluid to cold fluid by an elemental heat transferring area dA 22
. .
h c
ph h pc c
dQ m c dT m c dT UdA T = = + = A 23
h h c c
dQ C dT C dT UdA T = = = A 24
(If temperature increases with increase in length then the sign should be taken as 25
positive & If temperature decreases with increase in length then the sign should be 26
taken as negative). 27
2
&
h c
h c
UdA T UdA T
dT dT
C C
A A
= =

1
Putting these values in equation (1) 2
h c
h c
UdA T UdA T
dT dT dT
C C
| | | | A A
= =
| |

\ . \ .
3
1 1
c h
dT UdA T
C C
| |
= A
|

\ .
4
1 1
c h
dT
UdA
T C C
| |
= +
|
A
\ .
5
Integrating 6
0
1 1
o
i
T A
c h T
dT
U dA
T C C
A
A
| |
= +
|
A
\ .
} }
7
1 1
log
o
i
T
e
T
c h
T U A
C C
A
A
| |
A = +
|
\ .
8
1 1
log (2)
o
e
i c h
T
UA
T C C
| | | | A
= +
| |
A
\ . \ .
9
Now to eliminate C
h
and C
c
10
Heat lost by hot fluid = Heat gained by cold fluid 11
( ) ( )
. .
h c
ph h pc c
Q m c T m c T = A = A 12
( ) ( )
h h c c
Q C T C T = A = A 13
( ) ( )
h hi ho c co ci
Q C T T C T T = = 14
( ) ( )
&
h c
hi ho co ci
Q Q
C C
T T T T
= =

15
Putting these values in equation (2) 16
1 1
log (2)
o
e
i c h
T
UA
T C C
| | | | A
= +
| |
A
\ . \ .
17
( ) ( )
log
hi ho co ci o
e
i
T T T T T
UA
T Q Q
| | | | A
= +
| |
A
\ . \ .
18
( ) ( ) log ( )
i
e hi ci ho co
o
T UA
T T T T Seediagram
T Q
| | A
= (
|

A
\ .
19
| | log
i
e i o
o
T UA
T T
T Q
| | A
= A A
|
A
\ .
20
21
3
( ) ( )
log log
i o i o
lm
i i
e e
o o
UA T T T T
Q UA UA T
T T
T T
(
(
A A A A
(
= = = A
(
| | | | A A
(
| |
A A
(
\ . \ .
1
MEAN TEMPERATURE DIFFERENC FOR COUNTER-CURRENT FLOW 2
HEAT EXCHANGER 3
4
5
6
Consider an element of length dx at a distance x from LHS of heat exchanger. Let the 7
corresponding elemental heat transferring area is dA. 8
If the hot fluid travels from x to (x+dx) 9
Then let decrease in temperature of hot fluid is dT
h
and 10
Let increase in temperature of cold fluid is dT
c
11
So, net change of temperature is: 12
(3)
h c
dT dT dT = 13
Now, 14
Heat lost by hot fluid due to travel of distance dx = Heat gained by cold fluid due to 15
travel of distance dx 16
& THIS IS EQUAL TO 17
Heat transferred from the hot fluid to cold fluid by an elemental heat transferring area dA 18
. .
h c
ph h pc c
dQ m c dT m c dT UdA T = = = A 19
h h c c
dQ C dT C dT UdA T = = = A 20
(If temperature increases with increase in length then the sign should be taken as 21
positive & If temperature decreases with increase in length then the sign should be 22
taken as negative). 23
4
&
h c
h c
UdA T UdA T
dT dT
C C
A A
= =

1
Putting these values in equation (3) 2
h c
h c
UdA T UdA T
dT dT dT
C C
| | | | A A
= =
| |

\ . \ .
3
1 1
c h
dT UdA T
C C
| |
= A
|
\ .
4
1 1
c h
dT
U dA
T C C
| |
=
|
A
\ .
5
6
Integrating 7
8
1 1
log
o
i
T
e
T
c h
T U A
C C
A
A
| |
A =
|
\ .
9
1 1
log
o
e
i c h
T
UA
T C C
| | | | A
=
| |
A
\ . \ .
10
1 1
log (4)
i
e
o c h
T
UA
T C C
| | | | A
=
| |
A
\ . \ .
11
Now to eliminate C
h
and C
c
12
Heat lost by hot fluid = Heat gained by cold fluid 13
( ) ( )
. .
h c
ph h pc c
Q m c T m c T = A = A 14
( ) ( )
h h c c
Q C T C T = A = A 15
( ) ( )
h hi ho c co ci
Q C T T C T T = = 16
( ) ( )
&
h c
hi ho co ci
Q Q
C C
T T T T
= =

17
Putting these values in equation (4) 18
1 1
log
i
e
o c h
T
UA
T C C
| | | | A
=
| |
A
\ . \ .
19
( ) ( )
log
hi ho co ci i
e
o
T T T T T
UA
T Q Q
| | | | A
=
| |
A
\ . \ .
20
( ) ( ) log ( )
i
e hi co ho ci
o
T UA
T T T T See diagram
T Q
| | A
= (
|

A
\ .
21
| | log
i
e i o
o
T UA
T T
T Q
| | A
= A A
|
A
\ .
22
5
( ) ( )
log log
i o i o
lm
i i
e e
o o
UA T T T T
Q UA UA T
T T
T T
(
(
A A A A
(
= = = A
(
| | | | A A
(
| |
A A
(
\ . \ .
1
( )
( )
0
0
log
2
&
i o
i o
i
e
o
i o
mean
mean
If T T
UA T T
ThenQ Undefined
T
T
T T
Thentake MeanTemperature Difference T
Q UA T
A = A
A A
= = =
| | A
|
A
\ .
A + A
= A =
= A
2
3
FOR CROSS FLOW & MULTIPLE PASS HEAT EXCHANGER 4
( )
lm lm
counter flow
T for cross flow F T A = A 5
Where F is the correction factor. 6
| | ( ); ( )& F f Tempeffectiveness P Heat capacity rateratio R the flowarrangement = 7
F< 1 for cross flow and multiple pass arrangement. 8
F =1 for true counter flow arrangement. 9
The correction factor (F) represents the degree of departure of true MTD from the 10
LMTD for a counter flow arrangement. 11
The values of F for various cross flow arrangements can be seen from graphs 12
between P and R. 13
Where
.
.
c pc pc
ph
h ph
m c C
Heat capacity rateof cold fluid
R Capacity ratio
C Heat capacity rateof hot fluid
m c
= = = = 14
Now, ( ) ( )
. .
h c
ph hi ho pc co ci
m c T T m c T T = 15
( )
( )
.
.
c
pc hi ho
co ci
h
ph
m c T T
T T
m c

16
( )
( )
.
.
c
pc hi ho
co ci
h
ph
m c T T
Tempdifference of hot fluid
R
T T Tempdifference of cold fluid
m c

= = =

17
& P = Temperature ratio which indicates cooling or heating effectiveness. 18
( )
( )
co ci
hi ci
T T
Riseintempof cold fluid Riseintempof cold fluid
P
T T Difference ininlet temp Maximum possibletempdifference

= = =

19
20
21
EFECTIVENESS OF HEAT EXCHANGER 22
6
max
actual
imum
Q
Q
e= 1
Now Q
max
is achieved if a fluid with minimum heat capacity rate (mc
p
) undergoes 2
a temperature change equal to the maximum possible temperature difference available. 3
4
Maximum value of temperature in heat exchanger = T
hi
5
Minimum value of temperature in heat exchanger = T
ci
6
Therefore, maximum temperature difference available = (T
hi
-T
ci
) 7
( ) ( )
max min min hi ci
Q C Maximumavailable tempdifference C T T = = 8
9
min c h
WhereC C or C whichever is smaller = 10
( ) ( )
actual h h c c
Q C T C T = A = A 11
( ) ( )
actual h hi ho c co ci
Q C T T C T T = = 12
13
( )
( )
( )
( )
max min min
h hi ho c co ci actual
imum hi ci hi ci
C T T C T T Q
Q C T T C T T

e= = =

14
In case of LMTD method, the equation ( )
lm
Q UA F T = A can be used in the design 15
of heat exchangers, when all the terminal temperatures are known. 16
The difficulty arises if the temperatures of fluids leaving the heat exchangers are 17
not known. In such cases effectiveness by NTU method is used for the determination of 18
heat transfer and this method does not involve any of the outlet temperatures. 19
20
EFFECTIVENESS OF PARALLEL FLOW HEAT EXCHANGER BY NTU 21
METHOD: 22
We will eliminate outlet temperatures from equation (2) 23
To find outlet temperatures 24
( )
( )
( )
( )
max min min
h hi ho c co ci actual
imum hi ci hi ci
C T T C T T Q
Q C T T C T T

e= = =

25
( ) ( )
min h hi ho hi ci
C T T C T T = e 26
( ) ( )
min
hi ho hi ci
h
C
T T T T
C
= e 27
( )
min
ho hi hi ci
h
C
T T T T
C
= e 28
& ( ) ( )
min c co ci hi ci
C T T C T T = e 29
( ) ( )
min
co ci hi ci
c
C
T T T T
C
= e 30
( )
min
co ci hi ci
c
C
T T T T
C
= + e 31
From equation (2) 32
7
1 1
log
o
e
i c h
T
UA
T C C
| | | | A
= +
| |
A
\ . \ .
1
1 1
c h
UA
C C
ho co
hi ci
T T
e
T T
| |
+
|
\ .
| |
=
|

\ .
2
Putting the values of outlet temperatures 3
( ) ( )
( )
min min
1 1
c h
hi hi ci ci hi ci
UA
C C h c
hi ci
C C
T T T T T T
C C
e
T T
| |
+
|
\ .
| | | | | |
e + e
| | |
\ . \ . |
=
|

|
|
\ .
4
( ) ( )
( )
1 1
min
1 1
c h
hi ci hi ci
UA
C C c h
hi ci
T T C T T
C C
e
T T
| |
+
|
\ .
| | | |
e +
| |
\ . |
=
|

|
|
\ .
5
( )
( )
1 1
min
1 1
1
c h
UA
C C c h
hi ci
hi ci
C
C C
T T e
T T
| |
+
|
\ .
| | | |
e +
| |
\ . |
=
|

|
|
\ .
6
1 1
min
1 1
1
c h
UA
C C
c h
C e
C C
| |
+
|
\ .
| |
e + =
|
\ .
7
1 1
min
1 1
1
c h
UA
C C
c h
C e
C C
| |
+
|
\ .
| |
e + =
|
\ .
8
1 1
min
1
1 1
c h
UA
C C
c h
e
C
C C
| |
+
|
\ .
(
(

(
e=
(
| |
+
(
|
(
\ .
9
c h
If C C < 10
min max
&
c h
Then C C C C = = 11
min max
1 1
min
min max
1
1 1
UA
C C
e
C
C C
| |
+
|
\ .
(
(

(
e=
(
| |
+
(
|
(
\ .
12
8
min
min max
1
min min
min max
1
1
C UA
C C
e
C C
C C
| |
+
|
\ .
(
(

(
e=
(
| |
+
(
|
(
\ .
1
h c
Similarly if C C < 2
min max
&
h c
Then C C C C = = 3
We will get the same result. 4
The term 5
min
&
UA
The term NTU Number of transfer units ADimensionless parameter is ameasureof size
C
of heat exchanger
= = =
6
7
min
max
&
C Minimum heat capacity rate
C Capacity Ratio
C Maximum heat capacity rat
= = = 8
9
10
11
( )
( )
1
1
1
NTU C
e
C
+
(

e=
(
+

12
When NTU 13
( )
max
1 1
1 1
e
Then
C C

e = =
(
+ +

14
For boilers and condensers (i.e. in case of phase change), 0 C ~ 15
1
NTU
e

e= 16
For gas turbine, 1 C ~ 17
( )
( )
1 1 2
1 1
1 1 2
NTU NTU
e e
+
(
(
e= =
(
(
+


18
19
EFFECTIVENESS OF COUNTER CURRENT FLOW HEAT EXCHANGER BY 20
NTU METHOD: 21
We will eliminate outlet temperatures from equation (4) 22
(A) To find outlet temperatures 23
( )
( )
( )
( )
max min min
h hi ho c co ci actual
imum hi ci hi ci
C T T C T T Q
Q C T T C T T

e= = =

24
( ) ( )
min h hi ho hi ci
C T T C T T = e 25
( ) ( )
min
hi ho hi ci
h
C
T T T T
C
= e 26
9
( )
min
ho hi hi ci
h
C
T T T T
C
= e 1
& ( ) ( )
min c co ci hi ci
C T T C T T = e 2
( ) ( )
min
co ci hi ci
c
C
T T T T
C
= e 3
( )
min
co ci hi ci
c
C
T T T T
C
= + e 4
From equation (4) 5
1 1
log
i
e
o c h
T
UA
T C C
| | | | A
=
| |
A
\ . \ .
6
1 1
c h
UA
C C
i
o
T
e
T
| |

|
\ .
| | A
=
|
A
\ .
7
1 1
c h
UA
C C
hi co
ho ci
T T
e
T T
| |

|
\ .
| |
=
|

\ .
8
Putting the values of outlet temperatures 9
( )
( )
min
1 1
min
c h
hi ci hi ci
UA
C C c
hi hi ci ci
h
C
T T T T
C
e
C
T T T T
C
| |

|
\ .
| | | |
+ e
| |
\ . |
=
|
e
|
|
\ .
10
( ) ( )
( ) ( )
min
1 1
min
c h
hi ci hi ci
UA
C C
c
hi ci hi ci
h
C
T T T T
C
e
C
T T T T
C
| |

|
\ .
| |
e
|
| =
|
e
|
\ .
11
min
1 1
min
1
1
c h
UA
C C
c
h
C
C
e
C
C
| |

|
\ .
| |
e
|
| =
|
e
|
\ .
12
1 1
min min
1 1
c h
UA
C C
c h
C C
e
C C
| |

|
\ .
| |
e= e
|
\ .
13
1 1 1 1
min min
1
c h c h
UA UA
C C C C
c h
C C
e e
C C
| | | |

| |
\ . \ .
e= e 14
1 1 1 1
min min
1
c h c h
UA UA
C C C C
c h
C C
e e
C C
| | | |

| |
\ . \ .
e e = 15
10
1 1 1 1
min min
1
c h c h
UA UA
C C C C
c h
C C
e e
C C
| | | |

| |
\ . \ .
| |
|
e =
|
\ .
1
1 1
1 1
min min
1
c h
c h
UA
C C
UA
C C
c h
e
C C
e
C C
| |

|
\ .
| |

|
\ .

e=
| |
|

|
\ .
2
1 1
1 1
min
1
1 1
c h
c h
UA
C C
UA
C C
c h
e
C e
C C
| |

|
\ .
| |

|
\ .

e=
| |
|

|
\ .
3
4
5
6
c h
If C C < 7
min max
&
c h
Then C C C C = = 8
min max
min max
1 1
1 1
min
min max
1
1 1
UA
C C
UA
C C
e
C e
C C
| |

|
\ .
| |

|
\ .

e=
| |
|

|
\ .
9
min
min max
min
min max
1
1
min min
min max
1
1
C UA
C C
C UA
C C
e
C C
e
C C
| |

|
\ .
| |

|
\ .

e=
| |
|

|
\ .
10
( )
( )
( )
1
1
1
1
NTU C
NTU C
e
Ce

e=

11
12
h c
Similarly if C C < 13
min max
&
h c
Then C C C C = = 14
We will get the same result. 15
When NTU 16
( )
max
1 1 0
1
1 0 1
e
Then
Ce

(

( e = = ~

(

17
For boilers and condensers (i.e. in case of phase change), 0 C ~ 18
1
NTU
counter current
e

e = 19
1
NTU
parallel
Also e

e = 20
11
Therefore, when a phase change occurs on one side of the heat exchanger surface, it does 1
not matter which flow arrangement is used. That is why parallel and counter flow gave 2
same results. 3
4
CONCEPT OF OVEALL HEAT TRANSFER COEFFICIENT 5
If U
i
& U
o
are the OAHTC based on unit area of inside and outside surfaces of the 6
inner tube. 7
(5)
i i lm
Q U A T = A 8
& (6)
o o lm
Q U A T = A 9
If we consider fouling at the inner side and outer side of the inner tube. Due to fouling 10
(scaling) the value of OAHTC also changes and this scaling (fouling) is due to impurities 11
in the fluid, chemical reaction between fluid and wall material and rust formation etc. 12
Let h
i
and h
o
are the heat transfer coefficients of the scale (fouling) on the inside 13
and outside surface of the inner tube respectively. 14
log
1 1 1 1
2
lm lm lm
Total fi i w o oi o
e
i
fi i i i w o o fo o
T T T
Q
R R R R R R r
r
h A h A LK h A h A t
A A A
= = =
+ + + + ( | |
|
(
\ .
+ + + +
(
(

15
Where A
i
= Inside surface area of inner tube = 2
i
r L t 16
A
o
= Outside surface area of inner tube = 2
o
r L t 17
K
w
is the thermal conductivity of the inner tube wall (W/m
o
C) 18
1
i
i i
R
Ah
= ;
1
fi
i fi
R
Ah
= ; 19
( )
log
2
o
e
i
w
r
r
R For bare tube wall
KL t
| |
|
\ .
= 20
1
o
o o
R
A h
= ;
1
fo
o fo
R
A h
= 21
From (5) and (7) 22
log
1 1 1 1
2
lm
i i lm
o
e
i
fi i i i w o o fo o
T
Q U A T
r
r
h A h A LK h A h A t
A
= A =
( | |
|
(
\ .
+ + + +
(
(

23
1
log
2
i
o
i e
i i i i i
fi i i i w o o fo o
U
r
A
r A A A A
h A h A LK h A h A t
=
( | |
|
(
\ .
+ + + +
(
(

24
12
( )
( )
( )
( )
( )
( )
( )
( )
( )
1
2 log
2 2 2 2
2 2 2 2 2
i
o
i e
i i i i i
fi i i i w o o fo o
U
r
r L
r r L r L r L r L
h r L h r L LK h r L h r L
t
t t t t
t t t t t
=
( | |
|
(
\ .
+ + + +
(
(

1
( )
( )
( )
( )
( )
1
log
1 1
i
o
i e
i i i
fi i w o o fo o
U
r
r
r r r
h h K h r h r
=
( | |
|
(
\ .
+ + + +
(
(

2
1
1 1 1 1
log
i
i o i i
e
fi i w i o o fo o
U
r r r r
h h K r h r h r
=
(
| | | | | | | |
+ + + +
( | | | |
( \ . \ . \ . \ .

3
Similarly, From (6) and (7) 4
log
1 1 1 1
2
lm
o o lm
o
e
i
fi i i i w o o fo o
T
Q U A T
r
r
h A h A LK h A h A t
A
= A =
( | |
|
(
\ .
+ + + +
(
(

5
1
log
2
o
o
o e
i o o o o
fi i i i w o o fo o
U
r
A
r A A A A
h A h A LK h A h A t
=
( | |
|
(
\ .
+ + + +
(
(

6
( )
( )
( )
( )
( )
1
2 log
2 2
1 1
2 2 2
o
o
o e
i o o
fi i i i w o fo
U
r
r L
r r L r L
h r L h r L LK h h
t
t t
t t t
=
( | |
|
(
\ .
+ + + +
(
(

7
( )
( )
( )
( )
( )
1
log
1 1
o
o
o e
i o o
fi i i i w o fo
U
r
r
r r r
h r h r K h h
=
( | |
|
(
\ .
+ + + +
(
(

8
1
1 1 1 1
log
o
o o o o
e
fi i i i w i o fo
U
r r r r
h r h r K r h h
=
(
| | | | | | | |
+ + + +
( | | | |
( \ . \ . \ . \ .

9
10
A multipass exchanger gives a higher heat transfer coefficient than a single pass 11
because of larger fluid velocity. 12
13
NOTE: In heat exchanger application, the OAHTC is usually based on 1
outside surface area of the inner wall. 2
3
DESIGN OF HEAT EXCHANGER: 4
The primary function of heat exchanger is to transfer heat from hot fluid to cold 5
fluid most efficiently. 6
When the heat exchanger is to be designed for a particular application, the 7
following considerations are almost taken into account. 8
(i) Thermal Analysis and Heat Transfer Requirements: 9
Thermal analysis is primarily concerned with determination of heat transfer 10
surface area required to transfer heat at a specified rate for the given flow rates and 11
temperatures of the fluids. 12
lm
Q UAF T = A 13
The value of U is INDEPENDENT of flow direction and is 14
( ) U f Flow velocity only = 15
Therefore, by forcing the fluids through the heat exchanger at higher velocities, 16
the OAHTC and hence Q may be increased. Therefore, by increasing the flow rate, the 17
size of the heat exchanger can be decreased. 18
BUT this higher velocity results in larger pressure drop through the heat 19
exchanger and corresponding larger pumping cost. 20
( ) ( )
2
Pressure drop P mass flowrate A 21
22
( )( )
( )
.
& ( ) Pumping power Steady State Volumetric flowrate P
m
P

= A
| |
|
= A
|
\ .
}
}
23
3
.
( ) Pumping power Steady State m
| |

|
\ .
24
Therefore, by decreasing diameter of pipe (i.e. size of heat exchanger), the value of mass 25
flow rate
.
m
| |
|
\ .
increases and hence pumping cost also increases. 26
Therefore, heat exchanger having small diameter pipes have less initial cost but it 27
results in higher pumping cost for life of heat exchanger. 28
If the surface area of heat exchanger is increased, the increase in OAHC and 29
hence pressure drop need not be so large, BUT, there may be limitation of the physical 30
size as for as installation of heat exchanger are concerned. 31
(ii) MECHANICAL DESIGN : The mechanical design involves considerations of the 32
operating temperatures and pressures, the corrosive characteristics of fluids, the relative 33
thermal expansion and accompanying thermal stresses, and the relation of the heat 34
exchanger to other equipment concerned. 35
(iii) DESIGN FOR MANUFACTURER: The design for manufacturer requires the 36
translation of physical characteristics and dimensions into a unit which can be built at a 37
low cost. 38
14
Prejudgment and a consideration of all these factors will result in the proper 1
design 2
For the optimization of heat exchanger size 3
( ) 0 Cost should be
D
c
=
c
4
Where D is the diameter of tubes. 5
If we consider other parameter like density, velocity, viscosity etc. 6
Then ( ) 0
Re
Cost should be
c
=
c
7
Where Re is the Reynolds number of fluid flowing through pipes. 8
However, the methodology of arriving at an optimum design of heat exchanger 9
involves the consideration of various factors like: 10
1. Fluid temperature 11
2. Flow rates 12
3. Tube size and layouts 13
4. Dirt factors and fouling considerations 14
5. Mechanical design consideration 15
6. Cost of heat exchanger 16
17