HEAT EXCHANGERS

Heat Exchangers
A heat exchanger is used to exchange heat between two fluids of different temperatures, which are separated by a solid wall. Heat exchangers are ubiquitous to energy conversion and utilization. They encompass a wide range of flow configurations. Applications in heating and air conditioning, power production, waste heat recovery, chemical processing, food processing, sterilization in bio-processes. Heat exchangers are classified according to flow arrangement and type of construction.

Heat Exchangers: Heat Transfer Process

DIRECT CONTACT TYPE in this type, two immiscible fluids at different temperatures come in direct contact. i.e. jet condensers, desuperheaters, open feed-water heaters, scrubbers and cooling towers. TRANSFER TYPE/RECUPERATORS - in this type, the cold and hot fluids flow simultaneously through the device, and the heat is transferred through the wall separating them. This type is commonly used in most fields of engineering. REGENERATORS/ STORAGE TYPE in this type, hot and cold fluids flow alternately on the same surface. This type is used as preheaters for steam power plants, blast furnaces, and oxygen producers.
3

Heat Exchangers: Construction Features

TUBULAR HEAT EXCHANGERS also known as tube in tube, concentric tube or double-pipe heat exchangers. SHELL AND TUBE HEAT EXCHANGERS also known as surface condensers and are most commonly used for heating, cooling, condensation, or evaporation applications. FINNED TUBE TYPE HEAT EXCHANGERS when a high operating pressure or an enhanced heat transfer rate is required, extended surfaces are used on one side of the heat exchangers. This type are used for liquid to gas heat exchange. i.e. gas turbines, automobiles, airplanes, heat pumps, refrigeration, electronics, cryogenics, air conditioning, humidification. COMPACT HEAT EXCHANGERS used for high area density heat transfer
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Finned Exchangers

Heat Exchanger Applications

Concentric Tube Construction

Parallel Flow
:

Counterflow
7

Heat Exchangers: Flow Arrangement

PARALLEL FLOW - also known as concurrent heat exchangers, hot and cold fluids enter through the same point and leaves at the other end. COUNTERCURRENT FLOW with this type, hot and cold fluids enter at opposite ends of the heat exchanger. CROSS FLOW here, two fluids flow at a right angle to each other. For this type, it can further be classified as unmixed flow or mixed flow.

Parallel Flow

Counter Current Flow

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Heat Exchanger Analysis

Expression for convection heat transfer for flow of a fluid inside a tube:

qconv mc p (Tm,o Tm,i )

For case 3 involving constant surrounding fluid temperature:

q U As Tlm
Tlm To Ti ln(To / Ti )

11

Heat Exchanger Analysis

In a two-fluid heat exchanger, consider the hot and cold fluids separately:

qh mh c p,h (Th ,i Th ,o ) qc mc c p ,c (Tc,o Tc,i )

q UA Tlm
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Tlm: 1. Parallel-Flow Heat Exchangers

T1 T2

q UA Tlm
Tlm
where

Parallel Flow

T T1 ln(T2 / T1 )
2 Counterflow

T1 Th,i Tc ,i T2 Th,o Tc ,o

13

Tlm: 2. Counter-Flow Heat Exchangers

T1 T2

q UA Tlm
Tlm T2 T1 ln(T2 / T1 )

Counterflow

where

T1 Th,i Tc ,o T2 Th,o Tc ,i
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Overall Heat Transfer Coefficient

For tubular heat Flow Parallel exchangers we must take into account the conduction Counterflow resistance in the wall and convection resistances of the fluids at the inner and outer tube surfaces.

1 1 1 Rcond UA hi Ai ho Ao Rcond ln( Do / Di ) 2kL

1 1 1 UA U i Ai U o Ao

where inner tube surface

Ai Di L Ao Do L
15

outer tube surface

Shell-and-Tube Heat Exchangers

One Shell Pass and One Tube Pass

Baffles are used to establish a cross-flow and to induce turbulent mixing of the shell-side fluid, both of which enhance convection. The number of tube and shell passes may be varied
16

Shell-and-Tube Heat Exchangers

One Shell Pass, Two Tube Passes

Two Shell Passes, Four Tube Passes

17

Multipass and Cross-Flow Heat Exchangers

To account for complex flow conditions in multipass, shell and tube and cross-flow heat exchangers, the log-mean temperature difference can be modified:

Tlm FTlm,CF
where F = correction factor

18

Correction Factor

where t is the tube-side fluid temperature

19

Fouling
Heat exchanger surfaces are subject to fouling by fluid impurities, rust formation, or other reactions between the fluid and the wall material. The subsequent deposition of a film or scale on the surface can greatly increase the resistance to heat transfer between the fluids. An additional thermal resistance, can be introduced: The Fouling factor, Rf.
Depends on operating temperature, fluid velocity and length of service of heat exchanger. It is variable during heat exchanger operation.

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Overall Heat Transfer Coefficient

The overall heat transfer coefficient can be written:

Rf",i Rf",o 1 1 1 1 1 Rcond UA Ui Ai Uo Ao hi Ai Ai Ao ho Ao

Uo

1 Ao R Ao 1 " Ao Rcond Rf ,o hi Ai Ai ho
" f ,i

Need to determine hi and ho

21

Determination of ho
Approach 1: Using correlations Approach 2: Using chart by Kern

Typical values of baffle cuts 20-25% for liquids and 40-45% for vapor
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Determination of tube side film coefficient, hi

Approach 1: Using correlations Approach 2: Sieder and Tate

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Determination of Conduction Resistance

Recall that

ln( Do / Di ) Rcond 2kL Do Ao Rcond ln( Do / Di ) 2k

or

rw Ao Rcond

Do ln( Do / Di ) 2k w

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Example
In a heat exchanger, hot fluid enters at 60OC and leaves at 48OC, where as the cold fluid enters at 35OC and leaves at 44OC. Calculate the mean temperature difference for a) parallel flow, b) counter flow, c) single pass cross flow (both fluids unmixed) d) single pass cross flow (hot side fluid mixed, cold side fluid unmixed)

25

Parallel Flow
Thi = Tha = 60OC Tci = Tca = 35OC Tho = Thb = 48OC Tco = Tcb = 44OC

T1 Th,i Tc ,i T2 Th,o Tc ,o

Tlm

T2 T1 ln(T2 / T1 )

T1 48 44 4 T2 60 35 25

25 4 Tlm ln( 25 / 4)

Tlm 11 .5 C
26

Countercurrent Flow
Thi = Tha = 60OC Tci = Tca = 35OC Tho = Thb = 48OC Tco = Tcb = 44OC

T1 Th,i Tc ,o T2 Th,o Tc ,i
T1 48 35 13 T2 60 44 16

Tlm

T2 T1 ln(T2 / T1 )

16 13 Tlm ln(16 / 13)

O

Tlm 14 .45 C
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Cross Flow
Thi = Tha = 60OC Tci = Tca = 35OC Tho = Thb = 48OC Tco = Tcb = 44OC

Single pass cross flow; both fluids unmixed Z = Thi Tho = Tcb Tci H = Tco Tci Thi Tci = 60 48 44 35 44 35 60 35 = 1.33 = 0.36

From Figure 15.7 (b), F = 0.94 LMTD = (0.94)(14.45OC) = 13.583OC

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Cross Flow
Thi = Tha = 60OC Tci = Tca = 35OC Tho = Thb = 48OC Tco = Tcb = 44OC

Single pass cross flow; hot fluid mixed, cold fluid unmixed Z = Thi Tho = Tcb Tci H = Tco Tci Thi Tci = 60 48 44 35 44 35 60 35 = 1.33 = 0.36

From Figure 15.7 (a), F = 0.98 LMTD = (0.98)(14.45OC) = 14.16OC

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Example
A 1-2 heat exchanger containing one shell pass and two tube passes heats 2.52 kg/s of water from 21.1 to 54.4OC by using hot water under pressure entering at 115.6 and leaving at 48.9OC. The outside surface area of the tubes in the exchanger is Ao = 9.30 m2. a) Calculate the mean temperature difference LMTD in the exchanger and the overall heat transfer coefficient Uo. b) For the same temperature but using a 2-4 exchanger, what would be the LMTD? Thi = Tha = 115.6OC Tci = Tca = 21.1OC Tho = Thb = 48.9OC Tco = Tcb = 54.4OC

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Example
q = mCp,c (Tco Tci) = 2.52 kg/s (4184 J/kg.K)(54.4 21.1OC) q = 351104.54 W LMTD for crossflow; LMTD = (Tha Tcb ) (Thb Tca) ln (Tha Tcb ) (Thb Tca) LMTD = (115.6 54.4) (48.9 21.1) ln (115.6 54.4) (48.9 21.1) = 42.3261OC

For multipass and crossflow heat exchangers

Tlm FTlm,CF
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Example
a) Single pass, shell fluid mixed, other fluids unmixed, use Figure 15.7 a ( 1 2 Heat Exchangers) Z = Thi Tho = 115.6 48.9 = 2.00 Tcb Tci 54.4 21.1

H = Tco Tci = 54.4 21.1 Thi Tci 115.6 21.1

= 0.352

From Figure 15.7 (a), F = 0.74 LMTD = (0.74)( 42.3261) = 31.3213OC Uo = q = 351104.54 W = 1205.351 W/m2.K Ao (LMTD) (9.30 m2)(31.3213OC)
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Example
b) Single pass, both fluids unmixed, use Figure 15.7 b ( 2 4 Heat Exchangers) Z = Thi Tho = 115.6 48.9 = 2.00 Tcb Tci 54.4 21.1

H = Tco Tci = 54.4 21.1 Thi Tci 115.6 21.1

= 0.352

From Figure 15.7 (b), F = 0.94 LMTD = (0.94)( 42.3261) = 33.60693OC Uo = q = 351104.54 W = 1123.375 W/m2.K Ao (LMTD) (9.30 m2)(33.60693OC)
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Example
A stainless steel tube (k = 45 W/m.K) of inner and outer diameters of 22 mm and 27 mm respectively, is used in a cross flow heat exchanger. The fouling factors for the inner and outer surfaces are estimated to be 0.0004 and 0.0002 (m2.K)/W respectively. Determine the overall heat transfer coefficient based on the outside surface area of the tube. Water at 75OC & 0.5 m/s

Di = 22 mm

Do = 27 mm

Air at 15OC & 20 m/s

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Properties of water at 75OC k = 0.6715 W/m.K = 0.39 x 10-6 m2/s Pr = 2.38 Re = u D = 0.5 m/s (0.022 m) = 28205.13 (turbulent) 0.39 x 10-6 m2/s Nu = hiDi = 0.023 Re0.8 Pr0.4 k = 0.023 (28205.13)0.8 (2.38)0.4 = 118.2 hi = 118.2 (0.6715) = 3608 W/m2.K 0.022
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Properties of air at 15OC k = 0.0255 W/m.K = 14.16 x 10-6 m2/s Pr = 0.704 Re = u D = 20 m/s (0.027 m) = 38135.59 14.16 x 10-6 m2/s Nu = hoDo = [0.04 Re0.5 + 0.06 Re0.67] Pr0.4 (/w)0.25 k = [0.04(38135.59)0.5 + 0.06(38135.59)0.67 ](0.704)0.4(1)0.25 = 139.3021 ho = 139.3021 (0.0255) = 131.5631 W/m2.K 0.027
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Rf",i Rf",o 1 1 1 1 1 Rcond UA Ui Ai Uo Ao hi Ai Ai Ao ho Ao

Uo

1 Ao R Ao hi Ai Ai
" f ,i

Ao Rcond R

" f ,o

1 ho

37

Ro =

1 = 1 = 0.0896 hoAo (131.5631 W/m2.K)()(0.027) (1) = 0.00401

Ri = 1 = 1 hiAi (3608 W/m2.K)()(0.022) (1)

Rfi =

Fi Ai

=
=

0.0004 ()(0.022) (1)

0.0002 ()(0.027) (1)

= 5.787 x 10 -3
= 2.358 x 10 -3 = 7.24 x 10 -3
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Rfo = Fo Ao

Rcond = ln Do/Di 2kL

= ln (0.027/0.022) 2 (45) (1)

1 1 1 Rcond U o Ao hi Ai Ai Ao ho Ao
1 0.00401 5.787 x 10 U o Ao
-3

R "f ,i

R "f ,o

7.24 x 10 -3 2.358 x 10

-3

0.0896

1 0.102489 U o Ao

1 Uo 0.102489 Ao
2

U o 115.0296 W/m .K
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A shell and tube heat exchanger with one shell pass and two tube passes is used to heat water (flowing in the tubes) at a rate of 10 kg/s from 30OC to 45OC with steam condensing over the tubes at 160OC. If the overall heat transfer coefficient (based on the outside area) has a value of 2000 W/m2.K, determine the area required. If 20 tubes of 25 mm OD are used. Determine the length of tube required.
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Example
A counterflow, concentric tube heat exchanger is used to cool the lubricating oil for a large industrial gas turbine engine. The flow rate of cooling water through the inner tube (Di=25 mm) is 0.2 kg/s, while the flow rate of oil through the outer annulus (Do=45 mm) is 0.1 kg/s. The oil and water enter at temperatures of 100 and 30C respectively. How long must the tube be made if the outlet temperature of the oil is to be 60C?

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Example
A shell-and-tube heat exchanger must be designed to heat 2.5 kg/s of water from 15 to 85C. The heating is to be accomplished by passing hot engine oil, which is available at 160C, through the shell side of the exchanger. The oil is known to provide an average convection coefficient of ho=400 W/m2.K on the outside of the tubes. Ten tubes pass the water through the shell. Each tube is thin walled, of diameter D=25 mm, and makes eight passes through the shell. If the oil leaves the exchanger at 100C, what is the flow rate? How long must the tubes be to accomplish the desired heating?

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Heat Exchanger Effectiveness

Defined as the ratio of actual rate of heat transfer in a given exchanger to the maximum possible amount of heat transfer if an infinite heat transfer area were available.

qh mh c p,h (Th ,i Th ,o ) qc mc c p ,c (Tc,o Tc,i )

mh c p , h C h mc c p , c C c then; C h C c

The cold fluid undergoes a greater temperature change, hence CC will be Cmin as minimum heat capacity and if there is an infinite area available then Tco = Thi.
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Heat Exchanger Effectiveness

e C h (Th,i Th,o ) Cc (Th,i Tc ,i ) e C max(Th,i Th,o ) C min(Th,i Tc ,i )

q eC min( Th ,i Tc ,i )
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Actual heat transfer

Heat Exchanger Effectiveness

In the case of a single pass, counter current flow

e Ch(Th,i Th,o ) C min(Th,i Tc ,i )

e Cc(Tc ,o Tc ,i ) C min(Th,i Tc ,i )

q Cc(Tc ,o Tc ,i ) UA(Th,o Tc ,i ) (Th,i Tc ,o ) ln[(Th,o Tc,i ) /(Th,i Tc ,o )]

45

e=

1 exp UA Cmin

1 Cmin Cmax

1 Cmin exp Cmax

UA Cmin

1 Cmin Cmax

Where: Number of Transfer Units is NTU = UA Cmin

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For parallel flow

1 exp UA 1 + Cmin Cmin Cmax 1 + Cmin Cmax

e=

47

Example
Water flowing at a rate of 0.667 kg/s enters a counter current heat exchanger at 308 K and is heated by an oil stream entering at 383 K at a rate of 2.85 kg/s (Cp = 1.89 kJ/kg.K). The overall U = 300 W/m2.K and the area A = 15.0 m2. Calculate the heat transfer rate and the exit water temperature.

Assuming

Tco = 370 K; Tf = (308 + 370 K) = 339 K Cp,C = 4.192 kJ/kg.K

Cp,h = Ch = 2.85 kg/s ( 1.89 x 103 J/kg.K) = 5386.5 W/K Cp,c = Cc = 0.667 kg/s ( 4.192 x 103 J/kg.K) = 2796.06 W/K
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Cmin Cmax
NTU

2796.06 = 5386.5
UA Cmin

0.5191

= 300 (15.0) = 2796.06

1.6094

For counter current flow exchanger, using Figure 15.9 (a) e = 0.71
q q = e Cmin (Thi Tci) = 0.71(2796.06)(383 308) = 148890.4 W = 148890.4 W = 2796.06 (Tco 308) Tco = 361.25 K
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Example
A double pipe, parallel flow heat exchanger uses oil (Cp=1.88 kJ/kgOC) at an initial temperature of 205OC to heat water, flowing at 225 kg/h, from 16OC to 44OC. The oil flow rate is 270 kg/h a) what heat exchanger area is required fro an overall heat transfer coefficient of 340 W/m2.K b) determine the number of transfer units c) calculate the effectiveness of HE (225 kg/h)(4.18 x 103 kJ/kg.OC)(44 16) OC = (270 kg/h)(1.88 x103 kJ/kg.OC) (205 Tho) OC Tho = 153.12OC LMTD for crossflow; LMTD = (Tha Tcb ) (Thb Tca) ln (Tha Tcb ) (Thb Tca)
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LMTD for crossflow; LMTD = (205 44 ) (153.12 16) = 148. 7406OC ln (205 44 ) (153.12 16) A = 225 (4.18 x 103) (44 16) (1/3600) = 0.1446 m2 340 (148.7406OC) Cmin = (mCp)H = 270 (1.88 x 103) = 507,600 J/h.OC Cmax = (mCp)C = 225 (4.18 x 103) = 940,500 J/h.OC NTU = UA = 340 (0.1446) = Cmin 507,600 (1/3600) 0.3487

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e=

1 exp

UA Cmin

1 + Cmin Cmax

1 + Cmin Cmax e= 1 exp 0.3487 1 + 507,600 940,500 1 + 507,600 940,500

e = 0.2698 = 26.98 %
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In an open heart surgery, under hypothermic conditions, the patients blood is cooled before the surgery and rewarmed afterward. It is proposed that a concentric tube counterflow heat exchanger of 0.5 m length be used for this purpose with a thin-walled inner tube that has a diameter of 55 mm. If the water at 60OC and 0.10 kg/s is used to heat the blood entering the exchanger at 18OC and 0.05 kg/s, what is the temperature of the blood leaving the exchanger? The overall heat exchanger coefficient is 500 W/m2.K and the specific heat of the blood is 3500 J/kg.K.
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A steam condenser condensing at 70OC has to have a capacity of 100 kW. Water at 20OC is used and the outlet water temperature is limited to 45OC. If the overall heat transfer coefficient has a value of 3100 W/m2.K, determine the area required.

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Heat Transfer Coefficients

The heat transfer coefficient hi for the tube side fluid in a shell and tube exchanger can be calculated using equations in chapter 12. the coefficient for the shell side ho cannot be calculated because the direction of flow is partly parallel to the tubes and partly across them. An approximate but general useful equation for predicting shell side coefficients is the Donohue equation. hoDo k = 0.2 DoGe
0.6

Cp k

0.33

0.14

Ge = Gb Gc

Gb = / Sb
Mass velocity parallel with tubes

Gc = / Sc
Mass velocity for crossflow
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Sb = b Ds2 Nb Do2 4 4
Total area of baffle window Total area occupied by the tubes

b = fraction of cross-sectional area of shell occupied by baffle window Ds = inside daimeter of shell Nb = number of tubes in baffle window Do = outside diameter of tubes Sc = P Ds ( 1 Do/) P = center to center distance between tubes = baffle pitch
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Heat Transfer Coefficients

ho Cp CpGe k
2/3

0.14

= jH = 0.2 DoGe

-0.4

j - factor form
Crossflow Exchangers hoDo k = 0.287 DoG
0.61

Cp k

0.33

Fa

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Example
A tubular exchanger with 35-in (889-mm) ID contains eight hundred and twenty eight -in (19-mm) OD tubes 12 ft (3.66-mm) long on a 1-in (25-mm) square pitch. Standard 25 percent baffles are spaced 12-in (305 mm) apart. Liquid benzene at an average bulk temperature of 60OF (15.6OC) is bing heated in the shell side of the exchanger at the rate of 100,000 lb/h (45,360 kg/h). If the outside surfaces of the tubes are at 140OF (60OC), estimate the individual heat transfer coefficient of the benzene. Do = 0.75 / 12 = 0.0625 ft Ds = 35 / 12 = 2.9167 ft P = 1 ft

= 1/ 12 = 0.0833 ft

Sc = P Ds ( 1 Do/) Sc = 1 x 2.9167 1 0.0625 0.0833

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Nb = 0.1955 x 828 = 161.8 161 tubes Sb = b Ds2 Nb Do2 4 4 Sb = 0.1955 (2.9167)2 161 (0.0625)2 4 4 Sb = 0.8123 ft2 Ge = Gb Gc

Gb = / Sb

Gc = / Sc

Gc = 100,000 = 137,137 lb/ft2.h 0.7292

Gb = 100,000 = 123,107 lb/ft2.h 0.8123

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Ge = (137,137)(123,107) = 129,933 lb/ft2.h Properties: @ 60OF = 0.70 cP Cp = 0.41 Btu/lb.OF hoDo k = 0.2 DoGe

@ 140OF =m0.38 cP k = 0.092 Btu/h.ft.OF

0.6

Cp k

0.33

0.14

ho = 0.2 0.0625(129,933) 0.6 (0.41)(0.70)(2.42) 0.33 0.70 0.70 (2.42) 0.092 0.38
ho = 101 Btu/h.ft2.OF (573 W/m2.OC)

0.14

0.092 0.0625

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HEAT TRANSFER IN AGITATED VESSELS

Heat transfer surfaces, which may be in the form of heating or cooling jackets or coils of pipe immersed in the liquid, are often used in the agitated vessels.
With helical coil and turbine impeller

hcDc = 0.17 Da2n k

0.67

Cp k

0.37

Da Dt

0.1

Dc Dt

0.5

0.24

To or from the jacket of a baffled tank

hjDi = k 0.76 Da2
2/3

Cp k

1/3

0.24

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Anchored agitators for viscous liquid

hjDt = k

Da2

Cp k

1/3

0.18

K = 1.0 a =

for 10 < Re < 300

K = 0.36 a = 2/3

for 300 < Re < 40,000

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Example
A turbine agitated vessel 3 m in diameter contains 6600 kg of a dilute aqueous solution. the agitator is 0.75 m in diameter and turns at 150 rev/min. the vessel is jacketed with steam condensing at 38 psig; the heat transfer area is 16 m2. the steel walls of the vessel are 10-mm thick. If the heat transfer coefficient of the steam is 12 kW/m2.OC, what is the rate of heat transfer between the steam and liquid and the time to heat the vessel contents from 30OC to 90OC? P = 52.7 psia Ts = 284.216OF = 140.12OC = 150 rev/min A = 16 m2 Ta = 30OC = 10 mm hc = 12 kW/m2.OC Tb = 90OC

63

hjDi = k

0.76

Da2

2/3

Cp k

1/3

0.24

Properties at Tf = 30 + 90 = 60OC = 140 OF 2 k = 0.378 Btu/ft.h.OF = 0.470 cP = 0.47 x 10-3 kg/m.s = 61.38 lb/ft3 w = 0.196 cP
hj (3) = 0.76 0.7522.5(983.65) 0.6542 4.7 x 10-3
2/3

4184(4.7x10-3) 1/3 0.47 0.6542 0.196

0.24

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hj = 6061.436 W/m2.OC Ui = 1 + 6061.436 1 1 12000 3 3.02 + 10/1000 45 3 3.01

Ui = 2131.093 W/m2.OC tT = 6600 (4184) ln (140.12 30)/(140.12 90) 2131.093 (16)

tT = 637.487 sec = 10.63 min

q = 2131.093 W/m2.OC (16 m2) ( 140.12 60)OC

65