Heat Exchangers:

Design Considerations
Chapter 11
Sections 11.1 through 11.3
Types

Heat Exchanger Types

Heat exchangers are ubiquitous to energy conversion and utilization. They involve
heat exchange between two fluids separated by a solid and encompass a wide
range of flow configurations.

• Concentric-Tube Heat Exchangers

Parallel Flow Counterflow

¾ Simplest configuration.

¾ Superior performance associated with counter flow.

Types (cont.)

• Cross-flow Heat Exchangers

Finned-Both Fluids Unfinned-One Fluid Mixed

Unmixed the Other Unmixed

¾ For cross-flow over the tubes, fluid motion, and hence mixing, in the transverse
direction (y) is prevented for the finned tubes, but occurs for the unfinned condition.

¾ Heat exchanger performance is influenced by mixing.

Types (cont.)

• Shell-and-Tube Heat Exchangers

One Shell Pass and One Tube Pass

¾ Baffles are used to establish a cross-flow and to induce turbulent mixing of the
shell-side fluid, both of which enhance convection.
¾ The number of tube and shell passes may be varied, e.g.:

One Shell Pass, Two Shell Passes,

Two Tube Passes Four Tube Passes
Types (cont.)

• Compact Heat Exchangers

¾ Widely used to achieve large heat rates per unit volume, particularly when
one or both fluids is a gas.
¾ Characterized by large heat transfer surface areas per unit volume, small
flow passages, and laminar flow.

(a) Fin-tube (flat tubes, continuous plate fins)

(b) Fin-tube (circular tubes, continuous plate fins)
(c) Fin-tube (circular tubes, circular fins)
(d) Plate-fin (single pass)
(e) Plate-fin (multipass)
Overall Coefficient
Overall Heat Transfer Coefficient
• An essential requirement for heat exchanger design or performance calculations.

• Contributing factors include convection and conduction associated with the

two fluids and the intermediate solid, as well as the potential use of fins on both
sides and the effects of time-dependent surface fouling.

• With subscripts h and c used to designate the hot and cold fluids, respectively,
the most general expression for the overall coefficient is:

1 = 1 = 1
UA (UA )c (UA )h

1 R′′f , c R′′f , h 1
= + + Rw + +
(ηo hA)c (ηo A)c (ηo A)h (ηo hA)h
Overall Coefficient

¾ R′′f → Fouling factor for a unit surface area (m ⋅ K/W)

2

→ Table 11.1
¾ Rw → Wall conduction resistance (K/W)

¾ ηo → Overall surface efficiency of fin array (Section 3.6.5)

⎛ Af ⎞
ηo,c or h = ⎜1 − (1 − η f ) ⎟
⎝ A ⎠c or h

A = At → total surface area (fins and exposed base)

A f → surface area of fins only

Assuming an adiabatic tip, the fin efficiency is

⎛ tanh ( mL ) ⎞
η f , c or h = ⎜ ⎟
⎝ mL ⎠c or h

mc or h = ( 2U p / k wt )c or h

⎛ ⎞
U p , c or h = ⎜ h ⎟ → partial overall coefficient
⎜ 1 + hR′′ ⎟
⎝ f ⎠ c or h
LMTD Method
A Methodology for Heat Exchanger
Design Calculations
- The Log Mean Temperature Difference (LMTD) Method -
• A form of Newton’s Law of Cooling may be applied to heat exchangers by
using a log-mean value of the temperature difference between the two fluids:
q = U A Δ T1m
Δ T1 − Δ T2
Δ T1m =
1n ( Δ T1 / Δ T2 )

Evaluation of Δ T1 and Δ T2 depends on the heat exchanger type.

• Counter-Flow Heat Exchanger:

Δ T1 ≡ Th,1 − Tc ,1
= Th ,i − Tc , o

Δ T2 ≡ Th ,2 − Tc ,2
= Th , o − Tc ,i
LMTD Method (cont.)

• Parallel-Flow Heat Exchanger:

Δ T1 ≡ Th,1 − Tc ,1
= Th ,i − Tc ,i

Δ T2 ≡ Th ,2 − Tc ,2
= Th , o − Tc , o

¾ Note that Tc,o can not exceed Th,o for a PF HX, but can do so for a CF HX.
¾ For equivalent values of UA and inlet temperatures,
Δ T1m,CF > Δ T1m , PF

• Shell-and-Tube and Cross-Flow Heat Exchangers:

Δ T1m = F Δ T1m ,CF
F → Figures 11S.1 - 11S.4
Energy Balance

Overall Energy Balance

• Application to the hot (h) and cold (c) fluids:

• Assume negligible heat transfer between the exchanger and its surroundings
and negligible potential and kinetic energy changes for each fluid.
q = m h ( ih ,i − ih , o )
⋅

q = m c ( ic , o − ic ,i )
⋅

i → fluid enthalpy
• Assuming no l/v phase change and constant specific heats,
q = m h c p , h (Th ,i − Th , o ) = Ch (Th ,i − Th , o )
⋅

q = m c c p , c (Tc , o − Tc ,i ) = Cc (Tc , o − Tc ,i )
⋅

Ch , Cc → Heat capacity rates

Special Conditions

Special Operating Conditions

¾ Case (a): Ch>>Cc or h is a condensing vapor ( Ch → ∞ ) .

– Negligible or no change in Th (Th , o = Th ,i ) .
¾ Case (b): Cc>>Ch or c is an evaporating liquid ( Cc → ∞ ) .

– Negligible or no change in Tc (Tc , o = Tc ,i ) .

¾ Case (c): Ch=Cc.
– Δ T1 = Δ T2 = Δ T1m
Problem: Overall Heat Transfer Coefficient

Problem 11.5: Determination of heat transfer per unit length for heat recovery
device involving hot flue gases and water.

KNOWN: Geometry of finned, annular heat exchanger. Gas-side temperature and

convection coefficient. Water-side flowrate and temperature.

FIND: Heat rate per unit length.

SCHEMATIC:

Do = 60 mm
Di,1 = 24 mm
Di,2 = 30 mm
t = 3 mm = 0.003m
L = (60-30)/2 mm = 0.015m
Problem: Overall Heat Transfer Coefficient
(cont.)

ASSUMPTIONS: (1) Steady-state conditions, (2) Constant properties, (3) One-dimensional

conduction in strut, (4) Adiabatic outer surface conditions, (5) Negligible gas-side radiation,
(6) Fully-developed internal flow, (7) Negligible fouling.

PROPERTIES: Table A-6, Water (300 K): k = 0.613 W/m⋅K, Pr = 5.83, μ = 855 × 10-6
N⋅s/m2.

ANALYSIS: The heat rate is

(
q = ( UA )c Tm,h − Tm,c )
where

1/ ( UA )c = 1/ ( hA )c + R w + 1/ (ηo hA )h

Rw =
(
ln Di,2 / Di,1 )= ln ( 30 / 24 )
= 7.10 ×10−4 K / W.
2π kL 2π ( 50 W / m ⋅ K ) lm
Problem: Overall Heat Transfer Coefficient
(cont.)

With
&
4m 4 × 0.161 kg / s
Re D = = = 9990
π Di,1μ π ( 0.024m ) 855 × 10−6 N ⋅ s / m 2

the internal flow is turbulent and the Dittus-Boelter correlation gives

⎛ 0.613 W / m ⋅ K ⎞
( )
h c = k / Di,1 0.023 Re 4D/ 5 Pr 0.4 = ⎜
⎝ 0.024m
⎟ 0.023 ( 9990 )
⎠
4/5
( 5.83)0.4 = 1883 W / m 2 ⋅ K

( )
−1 −1
( hA )c = 1883 W / m ⋅ K × π × 0.024m × 1m
2 = 7.043 × 10−3 K / W.

The overall fin efficiency is

ηo = 1 − ( A f / A )(1 − ηf )
A f = 8 × 2 ( L ⋅ w ) = 8 × 2 ( 0.015m × 1m ) = 0.24m 2

( )
A = A f + π Di,2 − 8t w = 0.24m 2 + (π × 0.03m − 8 × 0.003m ) = 0.31m 2 .

From Eq. 11.4,

tanh ( mL )
ηf =
mL
Problem: Overall Heat Transfer Coefficient
(cont.)
where
1/ 2
m = [ 2h / kt ] = ⎡⎢ 2 × 100 W / m 2 ⋅ K / 50 W / m ⋅ K ( 0.003m ) ⎤⎥ = 36.5 m−1
1/ 2
⎣ ⎦

mL = ( 2h / kt ) L = 36.5 m −1 × 0.015m = 0.55

1/ 2

tanh ⎡( 2h / kt )
1/ 2 ⎤
L = 0.499.
⎣⎢ ⎦⎥

Hence
ηf = 0.499 / 0.55 = 0.911
ηo = 1 − ( A f / A )(1 − ηf ) = 1 − ( 0.24 / 0.31)(1 − 0.911) = 0.931

( )
−1 −1
(ηo hA )h = 0.931×100 W / m ⋅ K × 0.31m
2 2 = 0.0347 K / W.

It follows that

( UA )c−1 = ( 7.043×10−3 + 7.1×10−4 + 0.0347 ) K / W

( UA )c = 23.6 W / K
and
q = 23.6 W / K ( 800 − 300 ) K = 11,800 W <
for a 1m long section.
Problem: Overall Heat Transfer Coefficient
(cont.)

COMMENTS: (1) The gas-side resistance is substantially decreased by using the fins
( )
A′f >> π Di,2 and q is increased.

(2) Heat transfer enhancement by the fins could be increased further by using a material of
larger k, but material selection would be limited by the large value of Tm,h.
Problem: Ocean Thermal Energy Conversion

Problem 11S.8: Design of a two-pass, shell-and-tube heat exchanger to supply

vapor for the turbine of an ocean thermal energy conversion
system based on a standard (Rankine) power cycle. The power
cycle is to generate 2 MWe at an efficiency of 3%. Ocean
water enters the tubes of the exchanger at 300K, and its desired
outlet temperature is 292K. The working fluid of the power
cycle is evaporated in the tubes of the exchanger at its
phase change temperature of 290K, and the overall heat transfer
coefficient is known.

FIND: (a) Evaporator area, (b) Water flow rate.

SCHEMATIC:
Problem: Ocean Thermal
Energy Conversion (cont)

ASSUMPTIONS: (1) Negligible heat loss to surroundings, (2) Negligible kinetic and
potential energy changes, (3) Constant properties.

PROPERTIES: Table A-6, Water ( Tm = 296 K): cp = 4181 J/kg⋅K.

ANALYSIS: (a) The efficiency is

&
W 2 MW
η= = = 0.03.
q q
Hence the required heat transfer rate is
2 MW
q= = 66.7 MW.
0.03
Also
Δ Tlm,CF =
( 300 − 290 ) − ( 292 − 290 ) °C = 5°C
300 − 290
ln
292 − 290
and, with P = 0 and R = ∞, from Fig. 11S.1 it follows that F = 1. Hence

q 6.67 × 10 7 W
A= =
U F Δ Tl m,CF 1200 W / m 2 ⋅ K × 1 × 5 °C

A = 11,100 m 2 .
Problem: Ocean Thermal
Energy Conversion (cont)

b) The water flow rate through the evaporator is

q 6.67 ×107 W
&h =
m =
(
c p,h Th,i − Th,o ) 4181 J / kg ⋅ K ( 300 − 292 )

& h = 1994 kg / s.
m

COMMENTS: (1) The required heat exchanger size is enormous due to the small
temperature differences involved,

(2) The concept was considered during the energy crisis of the mid 1970s but has not since
been implemented.