CHE 408:

HEAT AND MASS TRANSFER

LECTURE 1:
HEAT EXCHANGERS

Lecturer:
Engr. Michael Allan G. Ramos
Chemical Engineering Department
Technological Institute of the Philippines
Summer 2019
Heat Exchanger Applications

Methanol Synthesis from Syngas (source: www.chemsep.org)

Heat Exchanger Applications

An engineer should be able to:

• Define the heat exchanger duty

• Collect necessary fluid properties: physical & chemical
• Decide on type of heat exchanger
• Select the specific configuration of heat exchanger
• Estimate the size of the heat exchanger
• Optimise the over-all design of heat exchanger

PERFORMANCE/EFFECTIVENESS
vs.
ECONOMICS
 TYPES OF HEAT EXCHANGER EQUIPMENT
TUBULAR HEAT EXCHANGER: Double-Pipe Heat Exchanger

• Simplest type
• Easy to install and clean
• Can be used at severe fouling
condition
• Can achieve pure concurrent
or countercurrent flow
• Good for high pressure flows

• Bulky and expensive

(source: gireeshheatexchangers.com) (source: sunriseequipments.com)

 TYPES OF HEAT EXCHANGER EQUIPMENT
TUBULAR HEAT EXCHANGER: Shell-and-Tube Heat Exchanger

• Larger surface area in a small volume

• Well-established fabrication techniques
• High efficiency
• High operating pressure flows

• Double-space needed for cleaning (source: gireeshheatexchangers.com)

• Difficult to clean shell side

(source: brighthubengineering.com)
 TYPES OF HEAT EXCHANGER EQUIPMENT
PLATE HEAT EXCHANGER: Plate-and-Frame Heat Exchanger

• Highest heat transfer coefficients

• Low pressure drop
• Easier to clean than STHE
• Small size
• Expandable capacity
• Closer approach temperature

• Low operating pressure flows

• More prone to fouling

(source: researchgate.net)
 TYPES OF HEAT EXCHANGER EQUIPMENT
DIRECT-CONTACT HEAT EXCHANGER: Vertical Quench Tower

• Large flow rates

• Low pressure drop
• High efficiency
• Less fouling

• Large size
• Requires make-up water
• Limited application

(source: monroeenvironmental.com)
RECALL: Principles of Heat Transfer
Rate of Heat Transfer, q
! = # $ %&
Temperature
Over-all heat transfer difference [K or Co]
coefficient [W/m2-K] Heat transfer
Area [m2]

Over-all Heat Transfer Coefficient, U

'
#) = -
' $) +, . Based on the inside area
#$ = ' -) $)
- + +
+, . () /0 1 2 (. $.
' -) '
+ + '
() $) /0 1 2 (. $.
#. = -.
$. +, Based on the outside area
$. -) '
+ +
() $) /0 1 2 (.
Typical Heat-Transfer Coefficients
See Chemical Engineers’ Handbook (Perry et al.): Tables 11-3 to 11-8 (8th ed.)
Typical Heat-Transfer Coefficients
See Chemical Engineers’ Handbook (Perry et al.): Tables 11-3 to 11-8 (8th ed.)
Typical Heat-Transfer Coefficients
See Chemical Engineers’ Handbook (Perry et al.): Tables 11-3 to 11-8 (8th ed.)
Fouling Factor or Fouling Resistance, Rf
$
!" = +
)* +,
$ $ ' $ $
+ + + +
%&' "' %' "' -. / 0 %, ", %&, ",
Additional resistances due to fouling or dirt

(source: manufacturing.net)
(source: tempco.it)

$ $
12 = −
!3'+45 !789:;

• Estimate the percent reduction in the over-all heat

transfer coefficient for Cutback asphalt – water.
(Ans. 15%)
Shell-and-Tube Heat Exchanger

(source: sbs.co.id) (source: Perry et al.)

• Made of casing or shell with tubes arranged inside

• Shell fluid and tube fluid flowing
• Baffles on the shell side to direct flow
Shell-and-Tube Heat Exchanger

• Results to complex flow patterns, which depends on

the configuration (no. of shell & no. of tube passes)

Nomenclature: “no. of shell” - “no. of tube passes” Heat Exchanger

i.e. 1-2 Heat Exchanger à 1 shell – 2 tube pass STHE

2-4 Heat Exchanger à 2 shell – 4 tube pass STHE

 Shell-and-Tube Heat Exchanger
Utility Fluid in
t1
T1 ∆"$ t2
Process Fluid in T2
t1
Temperature ∆"#
t2
Process Fluid out T1
T2
Utility Fluid out Length

• Use of correction factor for the LMTD based on counter-current flow

% = ' ( )"*+ ," • FT depends on temperatures in/out and STHE configuration
LMTD Correction Factor, FT
See Chemical Engineers’ Handbook (Perry et al.): Figure 11-4 (8th ed.)
LMTD Correction Factor, FT
See Chemical Engineers’ Handbook (Perry et al.): Figure 11-4 (8th ed.)

#$ − #&
!=
'& − '$
'& − '$
(=
# $ − '$
ILLUSTRATIVE PROBLEM 1
A 1-4 exchanger is used to heat 800 kg/hr of a liquid (Cp = 1600 J/kg-K)
from 30oC to 70oC. The heating medium (Cp = 3200 J/kg-K) enters the
shell at 100oC and leaves at 72oC. Determine:

a) mass rate of heating medium

b) Length per pass if hi = 450 and ho = 2000 W/m2-K and tubes are
1"Sch 40 steel
ILLUSTRATIVE PROBLEM 2
An STHE is to be designed to heat 3.80 kg/s of water from 38oC to 54oC.
Hot water entering at 93oC is to flow (one-pass) thru the shell side at a
rate of 1.90 kg/s. Assume an over-all heat transfer coefficient of 1420
W/m2-oC. Using a tube of 1.90 cm ID, the tube-side average velocity is
0.37 m/s. Due to space constraint, the tube length must not exceed
2.50 m. Determine:

a) Number of tube passes

b) Number of tubes per pass
c) Length of the tube
SEAT WORK (Group of 2 max.)
Water flows through the tubes of a 2-8 exchanger at 20oC and 1 m/s. The
water is heated by nitrogen gas entering the shell at 100oC and leaving at
30oC. The mass rate of the gas is 200 kg/hr. The exchanger is composed
of 1” Sch. 40 steel pipes. Determine the length of the exchanger needed
and the exit temperature of the water.

Assume ho = 4000 and hi = 1000 W/m2-K

Heat Transfer thru Bank of Tubes
Square Pitch Triangular Pitch

(source: thermopedia.com)

(source: Perry et al.)

S = pitch or center-to-center distance between tubes

SL = longitudinal pitch
ST = traverse pitch
ILLUSTRATIVE PROBLEM 3
160 m3/min of air will be heated at 1 atm from 15oC to 45oC by passing it normally
through a bank of vertical tubes that are 1.5 m long. Each bank is 6 rows wide and 4
rows deep and the casing is 39 cm wide. Outside tube diameter is 3 cm and A
triangular pitch of twice the outside diameter is used. Steam at 225oC flows inside
the tubes. Assume no leakage. How many banks of tubes are needed? Assume FT = 1 .
ILLUSTRATIVE PROBLEM 3
- END -