FE-HEAT EXCHANGERS

CHAPTER 4: HEAT EXCHANGERS

1. THE OVERALL HEAT TRANSFER COEFFICIENT

1.1 For Plane Wall

T A − TB
q= = U . A.ΔToverall
1 Δx 1
+ +
h1 A kA h2 A

from which U, the overall heat transfer

coefficient is :
1
U=
1 Δx 1
+ +
h1 k h2

1.2 For Circular Tubes

Clean double pipe (Concentric Tube)heat exchanger

1 1 1 ln(ro / ri )
UA = = , Q Ri = , Rtube =
( Ri + Rtube + Ro ) 1
+
ln(ro / ri )
+
1 hi Ai 2πkL
hi Ai 2πkL ho Ao

• In most practical situations the conduction resistance is small

compared with convection resistance.

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• with time deposits and corrosion on the heat transfer surfaces increase
resistance to heat flow. A fouling factor or fouling resistance must
1 1
then be introduced; it is defined by : Rf = − .
U dirty U clean

• Hence effect of internal and external fouling factors on U overall:

1 1
UA = = ,
( Ri + R fi + Rtube + R fo + Ro ) 1 R fi ln(ro / ri ) R fo 1
+ + + +
hi Ai A 2πkL A ho Ao

2. TYPES OF HEAT EXCHANGERS

2.1 Double-pipe H.E.: either parallel flow or counter flow

a) Parallel Flow b) counter-flow

2.2 Shell and Tube H.E.:

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2.3 Cross-Flow H.E.

a) one fluid mixed, other unmixed b) both fluids unmixed

3. THE LOG MEAN TEMPERATURE DIFFERENCE

q= U A ΔTm , what is value of ΔTm?

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− dq dq
dT h = , dT c =
m& h c h m& c c c
− dq dq 1 1
∴ d (Th − Tc ) = dT h − dT c = − = − dq ( + )
m& h c h m& c c c m& h c h m& c c c
but dq = U (Th − Tc ).dA
1 1
d (Th − Tc ) = −U (Th − Tc )( + ).dA
m& h c h m& c c c
hence
d (Th − Tc ) 1 1
= −U ( + ).dA
(Th − Tc ) m& h c h m& c c c
assuming c and U are constant, integration yields:
Th 2 − Tc 2 1 1 1 1 − UA
ln( ) = −UA( + ) = −UA( + )= {(Th1 − Th 2 ) + (Tc 2 − Tc1 )}
Th1 − Tc1 m& h c h m& c cc q q q
(Th1 − Th 2 ) (Tc 2 − Tc1 )
Therefore: q = U A {(Th2 –Tc2) – (Th1-Tc1)} / ln[(Th2-Tc2)/(Th1-Tc1)]

Comparing with : q= U A ∆Tm

Where ∆Tm is a suitable mean T difference across heat exchanger, yields :
(Th 2 − Tc 2 ) − (Th1 − Tc1 )
ΔTm =
⎡ (T − T ) ⎤
ln ⎢ h 2 c 2 ⎥
⎣ (Th1 − Tc1 ) ⎦
∆Tm is called the “Log Mean Temperature Difference”, LMTD for short.
• Above eqn yields:
for parallel flow H.E.:
(Tho − Tco ) − (Thi − Tci )
ΔTm =
⎡ (T − T ) ⎤
ln ⎢ ho co ⎥
⎣ (Thi − Tci ) ⎦
for counter flow H.E.:
(Tho − Tci ) − (Thi − Tco )
ΔTm =
⎡ (T − T ) ⎤
ln ⎢ ho ci ⎥
⎣ (Thi − Tco ) ⎦

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• If a heat exchanger other than the double pipe type is used , the heat
transfer is calculated by using a correction factor “F” applied to
LMTD for the same hot and cold fluid temperatures in a double pipe
counter-flow H.E., i.e. q = U A F ∆Tm
• For boiling or condensation of one fluid: F=1.0
Ex Water at the rate of 68 kg/min is heated from 35 to 75oC by an oil having a
specific heat of 1.4 kJ/kg oK. The fluids are used in a counter-flow pipe heat
exchanger, and the oil enters the exchanger at 110oC and leaves at 75oC. Given
U=320 W/m2 oK, calculate the heat exchanger area.
Sol :
q = m& w .c w .ΔTw = 68×4180×(75-35)=11.37 MJ/min = 189.5 kW
(110 − 75) − (75 − 35)
ΔTm = = 37.44 o C
ln[(110 − 75) /(75 − 35)]

Since q=U .A .∆Tm → A = q / (U.∆Tm) = 1.895×105/(320×37.44) =15.82 m2

4. THE EFFECTIVENESS – NTU METHOD

actual heat transfer
Effectiveness(ε) ≡
max imum possible heat transfer

•
Defining heat capacity C ≡ m c p , then:
actual heat transfer(q)= Ch(Thi – Tho)= Cc(Tco –Tci)
maximum heat transfer(qmax) = Cmin (Th,in – Tc,in)
where Cmin is smaller of Ch and Cc.
Ch (Thi − Tho ) C (T − T )
∴ε = = c co ci
Cmin (Thi − Tci ) Cmin (Thi − Tci )

Number of transfer units, NTU

(NTU) ≡ (U.A / Cmin); is indicative of H.E. size.

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Effectiveness-NTU Relations
Cmin
Defining heat capacity ratio Cr = ,
Cmax

for parallel flow concentric tube heat exchanger it can be shown that:
1 − e [ − NTU (1 + C r )]
ε =
1 + C r

ln[1 − ε (1 + Cr )]
NTU = −
1 + Cr

for counter-flow it can be shown:

1 − e [ − NTU ( 1 − C r )]
ε = (Cr <1)
1 − C r e [ − NTU ( 1 − C r )]
NTU
ε= (Cr = 1)
1 + NTU

1 ⎛ ε −1 ⎞
NTU = ln⎜⎜ ⎟ (Cr < 1)
Cr − 1 ⎝ Cr ε − 1 ⎟⎠

ε
NTU = (Cr = 1)
1− ε

• Table(10-3) summarizes the effectiveness relations

• Table(10-4) gives NTU explicitly in terms of ε and C.
• for boilers and condensers: Cmin/Cmax → 0 hence :

ε = 1-e-NTU

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 FE-HEAT EXCHANGERS

* n=number of shell passes, εp is effectiveness of each shell pass.

Table(10-3):Heat Exchanger Effectiveness Relations

N≡NTU=UA/Cmin , C = Cmin/Cmax

Flow Geometry Relation

Parallel flow 1 − exp[− N (1 + C )]

ε=
Double 1+ C
pipe Counter-flow 1 − exp[− N (1 − C )]
ε =
1 − C. exp[− N (1 − C )]
Counter-flow, C=1 N
ε =
N +1
both fluids exp(− N .C.n) − 1
unmixed ε = 1 − exp[ ] , where n = N −0.22
C.n
both fluids mixed 1 C 1
ε =[ + − ] −1
Cross-flow 1 − exp(− N ) 1 − exp(− NC ) N
Cmax mixed, 1
Cmin unmixed ε = {1 − exp[−C (1 − e − N )]}
C
Cmax unmixed, 1
Cmin mixed ε = 1 − exp{−( )[1 − exp(− NC )]}
C
One shell pass, ⎧
−1
2 1 / 2 ⎛ 1 + exp[− N (1 + C )
2 1/ 2
] ⎞⎫
2,4,6, tube passes ε = 2⎨1 + C + (1 + C ) ⎜⎜ ⎟
2 1 / 2 ⎟⎬
⎩ ⎝ 1 − exp[− N (1 + C ) ] ⎠⎭
Multiple shell [(1 − ε p C ) /(1 − ε p )] n − 1
Shell and passes,2n,4n,6n ε=
tube tube passes* [(1 − ε p C ) /(1 − ε p )] n − C
special case for nε p
C=1 ε =
1 + (n − 1)ε p

All exchangers with C=0 ε = 1 − e−N

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Table(10-4): NTU Relations for Heat Exchangers

N≡NTU=UA/Cmin , C = Cmin/Cmax , ε=effectiveness
Flow Geometry Relation
Parallel flow − ln[1 − (1 + C )ε ]
N=
Double 1+ C
pipe Counterflow 1 ⎛ ε −1 ⎞
N= ln⎜ ⎟
C − 1 ⎝ Cε − 1 ⎠
Counterflow, C=1 ε
N=
1− ε
Cmax mixed, 1
N = − ln[1 + ln(1 − Cε )]
Cross-flow Cmin unmixed C
Cmax unmixed, −1
Cmin mixed N= ln[1 + C ln(1 − ε )]
C
One shell pass, ⎡ 2 / ε − 1 − C − (1 + C 2 )1 / 2 ⎤
2,4,6, tube passes N = −(1 + C 2 ) −1 / 2 . ln ⎢ 2 1/ 2 ⎥
Shell and ⎣ 2 / ε − 1 − C + (1 + C ) ⎦
tube
All exchangers with C=0 N = − ln(1 − ε )

Ex. The H.E. of last example is used for heating water as described in the
example. Using the same entering fluid temperatures, calculate the exit
water temperature when only 40 kg/min of water is heated but the same
quantity of oil is used. Also calculate the total heat transfer under these new
conditions.
Sol.
ṁ h .ch. ΔTh = ṁc .cc. ΔTc
from previous example → ṁh = 68×4180×(75-35)/[1900×(110-75)]
=170.97 kg/min (oil)
ṁh ch = (170.97/60) ×1900 = 5414 W/ K, ṁccc=(40/60)×4180=2787 W/ K
Cmin/Cmax =2787/5414 =0.515, NTU= U A/Cmin = 320×15.82/2787=1.816
Table(10-3) → ε = 0.744 = ΔTcold/ΔTmax = ΔTcold/(110-35) →
ΔTcold = 55.8oC. (ΔTcold corresponds to min C)

Hence Tw,e = 35 + 55.8= 90.8oC

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and q = ṁc cc ΔTc = (40/60)×4180×55.8= 155.5 kW

Ex. Hot oil at 100oC is used to heat air in a shell-and-tube heat exchanger.
The oil makes 6 tube passes and the air makes one shell pass; 2.0 kg/s of air
are to be heated from 20 to 80oC. The specific heat of the oil is 2100 J/kg K,
and its flow rate is 3 kg/s. Calculate the area of the H.E. for U=200 W/m2 K.
Sol.
ṁo co ΔTo = ṁa ca ΔTa
3×2100×(100-Toe) = 2.0×1009×(80-20) → Toe =80.78oC
ṁh ch = 3.0×2100 = 6300 W/ K, ṁc cc = 2.0×1009=2108 W/ K =(ṁc)min
C= Cmin/Cmax = 2018/6300 = 0.3203, ε=ΔTc/ΔTmax = (80-20)/(100-20)=0.75

2 −1 / 2 ⎡ 2 / ε − 1 − C − (1 + C 2 )1 / 2 ⎤
Table(10-4): N = −(1 + C ) . ln ⎢ 2 1/ 2 ⎥
⎣ 2 / ε − 1 − C + (1 + C ) ⎦

⎡ 2 / 0.75 − 1 − 0.3203 − (1 + 0.32032 )1 / 2 ⎤

∴ N = −(1 + 0.32032 ) −1 / 2 . ln ⎢ 2 1/ 2 ⎥
= 1.99
⎣ 2 / 0.75 − 1 − 0.3203 + (1 + 0.3203 ) ⎦
A= (NTU).Cmin /U = 1.99×2018/200 = 20.09 m2

Ex: A shell and tube heat exchanger is used as an ammonia condenser with
ammonia vapor entering the shell at 50oC as a saturated vapor. Water enters
the single pass tube arrangement at 20oC and q=200 kW, U=100 W/m2 K.
Determine the area to achieve ε=60 % with an exit water temperature of
40oC. What percent reduction in heat exchange would result if the water
flow is reduced in half while keeping the heat exchanger area and U the
same?
Sol .
q= 200 kW = ṁw cw ΔTw → ṁw = 200/[4.18×(40-20)] = 2.39 kg/s
since it is a condenser, water is the minimum fluid:
Cmin=ṁw cw =2.39×4.18=10 kW/ K
and: N=-ln(1-ε) = -ln(1-0.6) =0.916;
A=Cmin.N/U=10000×0.916/1000=1.832

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when flow rate is reduced in half: N=UA/Cmin=1000×9.16/(10000/2)=1.832

and: ε = 1 – e-N = 0.84; ΔTw= ε ΔTmax =0.84(50-20)=25.2oC
q = Cmin ΔTw = (1000/2) (25.2) =126 kW

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