ABSTRACT

Heat exchanger is a device used for transfer of thermal energy

between two or more fluids that are at different temperatures. Heat
exchangers work because heat naturally flows from high temperature to
lower temperature. Therefore if a hot fluid and a cold fluid are separated
by heat conducting surface heat can be transferred from the hot fluid to
cold fluid.
Heat exchangers may be classified according to transfer process,
construction, flow arrangement, surface compactness, number of fluids
and heat transfer mechanisms or according to process functions.
Heat exchangers are useful in many engineering processes like
those in refrigerating and air- conditioning systems, power systems,
food processing systems, chemical reactors and space or aeronautical
applications.
Double pipe heat exchanger is a simplest form of a heat
exchanger, for particular advantages for small thermal loads and high
pressure applications. It consists of a tube or pipe fixed concentrically
inside a larger pipe or tube. They are used when the flow rates of the
fluids and the heat duty are small (less than 500 kW).These are simple
to construction, but may require a lot of physical space to achieve the
desired heat transfer area.

LIST OF FIGURES
Figure

Title

Page No.

1.

Classification of heat

2.

Exchangers
Parallel-flow heat

3.

exchanger
Counter-flow heat

4.

exchangers.
Cross-flow heat

5.

exchangers
shell-and-tube heat

6.

exchanger
Double pipe heat

7.

exchanger
Straight Tube Double pipe

10

8.

heat exchanger
Hairpin or U-Tube Double

10

9.

pipe heat exchanger

Double pipe heat

11

exchanger- Two Hairpins

10.

in series
Double pipe heat

11

exchanger with
11.

longitudinal fins
Double pipe heat

12

exchanger with
longitudinal fins- Actual
12.

Image
Flow sheet of Parameters

14

LIST OF TABLES

Table

Title

Page No.

1.

Table For Piping

15

2.

Configurations
Effectiveness relations of

17

Heat Exchangers

INDEX
Sr. No.
1.

Content
Introduction:

Page No.
1

Heat Exchanger
2.

Classification of Heat

3.
4.

Exchanger
Shell and Tube Exchangers
Double Pipe Heat

8
9

5.

Exchanger
Types of Double Pipe Heat

10

6.

Exchangers
Advantages of Double

12

7.

Pipe Heat Exchangers

Components of Double

13

8.
9.
10.
11.

Pipe Heat Exchangers

Design constraints
Flow sheet of parameters
Design Procedure
Pressure Drop

13
14
18
19

12.
13.

Calculations
Conclusion
References

21
22

HEAT EXCHANGERS
Introduction Heat Exchanger is any device used for effecting the process of
heat exchange between two or more fluids that are at different
temperatures. The fluids may be single compounds or mixtures. In most
heat exchangers, the fluids are separated by a heat transfer surface, and
ideally they do not mix. Such exchangers are referred to as the direct
transfer type, Or simply recuperators. In contrast, exchangers in which
there is an intermittent heat exchange between the hot and cold fluids
via thermal energy storage and rejection through the exchanger surface
or matrixare referred to as the
Indirect transfer type or Storage type, or simply regenerators.
Such exchangers usually have leakage and fluid carryover from one
stream to the other.
Double pipe Heat Exchanger consists of a tube or pipe fixed
concentrically inside a larger pipe or tube. They are used when the flow
rates of the fluids and the heat duty are small (less than 500 kW).These
are simple to construction, but may require a lot of physical space to
achieve the desired heat transfer area.

CLASSIFICATION-

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1. Types of HX w.r.t Flow -: There are two primary classifications

of heat exchangers according to their flow arrangement.

Parallel-flow heat exchangers: If two fluids enter the

exchanger at the same side and moves in the same direction.

Counter-flow heat exchangers: The fluids enter the exchanger

from opposite ends, moves in parallel but in opposite direction.
The counter design is most efficient, in that it can transfer the
most heat from the heat (transfer) medium.

Cross-flow heat exchangers: In cross-flow heat exchanger, the

fluids travel at right angle to each other through the heat
exchanger.

2. Classification according to transfer process -:

1. Direct contact type heat exchangers -: In direct contact type, heat
is

transferred through direct contact between the hot and

cold immiscible fluids. Direct contact heat exchange takes place

between two process streams. The streams can include combinations
such as gas-solid, gas-liquid, liquid-liquid, liquid-solid, or solid-solid
streams. For obvious reasons, gas-gas systems cannot be achieved
directly. Direct contact heat exchangers include heat transfer between
hot and cold streams of two phases in the absence of a separating wall.
Hence such exchangers can be categorized as gas liquid, immiscible
liquid and solid liquid or solid gas.
(a) Immiscible fluid exchanger - In this type, two immiscible fluid
streams are

brought into direct contact. These fluids may be single-phase fluids, or

they may involve condensation or vaporization.
Condensation of organic vapors and oil vapors with water or air are
typical examples.
(b) Gas-liquid exchanger - In this type, one fluid is a gas (more
commonly, air)
and the other a low-pressure liquid (more commonly, water) and are
readily separable
after the energy exchange. In these exchangers, more than 90% of the
energy transfer is by virtue of mass transfer (due to the evaporation of
the liquid), and convective heat transfer is a minor mechanism.
Cooling tower with forced- or natural-draft airflow is the most
common application. Other applications are the air-conditioning spray
chamber, spray
drier, spray tower, and spray pond.
(c) Liquid-vapor exchanger - In this type, typically steam is partially
or fully
condensed using cooling water or water is heated with waste steam
through direct
contact in the exchanger. Non condensable and residual steam and hot
water are the
outlet streams.
Common examples are desuperheaters and open feedwater heaters in
power plants.
2. Indirect contact type heat exchangers -: In this type of heat
exchangers, the fluid streams remain separate, and the heat transfer
takes place continuously through a separating wall. There is no direct
mixing of the fluids because each fluid flows in separate fluid passages.

This type of heat exchanger also referred to as a surface heat exchanger,

can be further classified into (a) Direct-transfer type, (b) Storage type
(a) Direct-transfer type - In this type, heat transfers continuously from
the hot fluid to the cold fluid through a dividing wall. There is no direct
mixing of the two (or more) fluids because each fluid flows in separate
fluid passages. Some examples of direct transfer type heat exchangers
are tubular, plate-type, and extended surface exchangers.
(b) Storage type - In a storage type exchanger, both fluids flow
alternatively
through the same flow passages, and hence heat transfer is intermittent.
The
heat transfer surface (or flow passages) is generally cellular in structure
and is referred to as a matrix. When hot gas flows over the heat transfer
surface (through flow passages), the thermal energy from the hot gas is
stored in the matrix wall, and thus the hot gas is being cooled during the
matrix heating period. As cold gas flows through the same passages later
(i.e., during the matrix cooling period), the matrix wall gives up thermal
energy, which is absorbed by the cold fluid. Thus, heat is not transferred
continuously through the wall. This storage type heat exchanger is also
referred to as a regenerator.
3. Classification according to pass arrangements -: These are either
single pass or
multipass. In single pass, fluid flows through a section of heat exchanger
through its full length once. In multipass arrangement, a fluid is
reversed and flows through the flow length two or more times.
4. Classification according to phase of fluids -:

(a) Gas-Liquid -: Gas-Liquid heat exchangers are mostly tube-fin type

compact heat exchangers with the liquid on the tube side. The radiator is
best example of gas-liquid
heat exchanger. some other examples are air coolers for aircraft,
intercoolers and aftercoolers in compressors, and condensers and
evaporators of room air-conditioners.
(b) Liquid-Liquid -: Most of the liquid-liquid heat exchangers are shell
and tube, PHE to a lesser extent. Both fluids are pumped through the
exchanger, so the principal mode of heat transfer is forced convection.
The relatively high density of liquids result in very high heat transfer
rate.
(c) Gas-Gas -: These type of exchanger found in rotary generators,
intercoolers. Compare to liquid-liquid exchanger, size of gas-gas much
larger.

5. Classification according to construction -: According to

constructional details, heat exchangers are classified as :
(a) Tubular Heat Exchangers -: Shell-and-Tube Exchangers, Double
Pipe, Coiled Tube
(b) Plate-Type Heat Exchangers -: Gasketed Plate Heat Exchangers,
Welded, Spiral Plate Heat Exchangers, Lamella Heat Exchangers.
(c) Extended Surface Heat Exchangers -: Plate-Fin Heat Exchangers,
Tube-Fin Heat Exchangers.
(d) Regenerators -: Rotary Regenerators, Fixed-Matrix Regenerator

1. Shell-and-Tube Exchangers -: Shell-and-tube heat exchangers are

fabricated with round tubes mounted in cylindrical shells with their axes
coaxial with the shell axis. The differences between them any variations
of this basic type of heat exchanger lie mainly in their construction
features and the provisions made for handling differential thermal
expansion between tubes and shell
There are various design considerations to be taken into account such as
routing of fluids (shell or tube), pressure drop especially in the case of
increasing number of baffles and tube diameter and adjusting the area
with the suitability of the exchanger to conduct the heat required to heat
or cool a fluid with another one.

Applications -: They are extensively used as process heat exchangers

in the petroleum-refining and chemical industries; as steam generators,
condensers, boiler feed water heaters and oil coolers in power plants; as
condensers and evaporators in some air-conditioning and refrigeration
applications; in waste heat recovery applications with heat recovery
from liquids and condensing fluids; and in environmental control.

2. Double Pipe Heat Exchanger -: A typical double-pipe heat

exchanger is shown in Figure below. Essentially, it consists of one pipe
placed concentrically inside another one of larger diameter, with
appropriate end fittings on each pipe to guide the fluids from one section
to the next. The inner pipe may have external longitudinal fins welded to
it either internally or externally to increase the heat transfer area for the
fluid with the lower heat transfer coefficient. The double-pipe sections
can be connected in various series or parallel arrangements for either
fluid to meet pressure-drop limitations and LMTD requirements.

Fig- Double pipe heat exchanger (hair-pin)

Applications -: The major use of double-pipe exchangers is for sensible
heating or cooling of the process fluid where small heat transfer areas
(typically up to 50 m.) are required. They may also be used for small
amounts of boiling or condensation on the process fluid side. The
advantages of the double-pipe exchanger are largely in the flexibility of
application and piping arrangement, plus the fact that they can be
erected quickly from standard components by maintenance crews.

Types of Double Pipe Heat Exchanger1) Straight tube heat exchangers- It consists of two coaxial
pipes,is simple to fabricate and relatively easy to clean, maintain or
modify.However, it takes up a lot of space and single units have limited
thermal capacity.Heat exchangers of this types are sometimes made in
house for specific small scale applications,but most double pipe heat
exchangers are purchased from specialist manufacturers who provide a
wide range of designs, including straight tubes,U-tubes and multiple
units.

2) Hairpin or U-tube heat exchangers: Units of this types are

designed so that the U-tube can be withdrawn from the shells for
cleaning and maintainance. There is a removable shell cover at the Ubend and a bolted flange.The tube is held by a split ring, that can be
extracted after unbolting the flange to allow the tube to slide through the
shell in the direction of the U-bend or tail end.The sealing ring between
the tube and the shell is normally made from a compressible
metal,however other metals are used when corrosive fluids are involved.
(Guy,1983)

3) Multitube Units- In this,the tubes pass through and are sealed

into a perforated plate,called a tube sheet, at the head end.For low
pressure applications the tube sheet is sealed by a single compressible
ring that prevents leakage of the tube- amd shell-side fluids, in an
arrangement called a unihead.For high pressures,separated heads are
employed.(Guy 1983) When the pressure drop available for driving the
cold fluid is limited then parallel/series arrangement may be
adopted.The conventional log mean temperature difference used to
calculate the performance of one double pipe heat exchanger is not
applicable to the parallel/series arrangement.

4) Double pipe heat exchangers with longitudinal fins-Fins are

formed from a strip metal, fabricated in the shape of a U and usually
attached to the tube by spot welding.Commonly used fin materials are
carbon steel,stainless steel and alloys. Fins made from brass or similar
materials are usually soldered to copper,nickel or aluminium tubes.They
have limited temperature range and are not normally used used above
250c.

 Advantages of Double Pipe Heat Exchangers1) Simplicity of construction- In applications that requires only a
relatively small heat rating(<1000kW) and where heat transfer
enhancement is not necessary,a double pipe heat exchanger with plain
tubes may be advantageous because of simplicity of construction.
2) Ease of Access for maintenance- The sealing of double-pipe heat
exchangers is achieved by means of flanged joints and sealing rings.
This allows the inner pipes to be disconnected from the shells and
withdrawn for cleaning, an advantages that applies both to plain and
finned tubes.
3) Countercurrent Flow It permits pure countercurrent heat exchange
in which the cold fluid can be heated to a temperature above that of the
hot fluid at exit.This eliminates the restriction of temperature
approach or temperature crossthat applies to concurrent ,or multipass
systems.
4) Feasibility of finned tubes- The double pipe heat exchanger is
particularly suitable for the application of extended surface heat transfer
enhancement in the form of fins.Fins are used when the shell side heat
transfer coefficient is poor.This may occur when the fluid on the shellside is a gas or a high-viscosity liquid.
5) High pressure applications- For a given duty, a series of double pipe
heat exchangers will require much smaller shell diameters(50-200mm)
than the equivalent shell and tube exchanger.Because of this ,the shell
wal thickness is much smaller,and for high pressure applications this
may be a significant factor in determining the cost and even feasibility.

 Components of double pipe heat exchanger

1) Packing & glandThe packing and gland provides sealing to the annulus and support the
inner pipe.
2) Return bendThe opposite ends are joined by a U-bend through welded joints.
3) Support lugsSupport lugs may be fitted at these ends to hold the inner pipe
position.
4) FlangeThe outer pipes are joined by flanges at the return ends in order that
the assembly may be opened or dismantled for cleaning and
maintenance.
5) Union jointFor joining the inner tube with U-bend.
Design Constraints-

1. Cost to have an exchanger that costs the least.

2. Efficiency to have an exchanger that operates most efficiently,
with minimum loss of energy in the transfer, and minimum drop
in pressure of the fluids.
3. Space to have an exchanger that is small.
4. Materials an exchanger built from materials that are
compatible with the process streams and dont cost a lot.
5. Maintenance an exchanger that can be easily cleaned.
6. Ease of Construction

 Flow sheet of parameters-

Step 1: Basics
Available Methods: Logarithm Mean Temperature
Difference Method or NTU Method
1)LMTD

Inlet and Exit Temperatures

Calculate Tln

Calculate Fouling factor if necessary

Calculate Heat transfer coefficient

Q= UA Tln
NTU method

Inlet Temperatures are needed

Calculate Cmax & Cmin

Qmax = (Tmax Tmin)Cmin

Calculate Effectiveness using appropriate expression

Q= *Qmax

Step 2: Piping Configuration

-Division of HE in six different zones (graphix add)
-Calculation of total no. of pipes in each region
- Tube Dimensions
- Optimally transverse pitch (St) to outer diameter (OD) ratio is
1.25 1.5 (1.5 for 1st Iteration)
- Linear Configuration or Staggered.
- 60o for maximum density.
Total no. of pipes can now be calculated

Table- Piping configuration

Step 3: Calculation of Reynolds No.
Reynolds No. = Critical Length * V (max.) / Kinematic
Viscosity
For Inside the tubes:
a) Q is known and total no. of tubes is known
b) Inner cross-section area through BWG
c) V (max) is calculated
d) Critical length is inner diameter

For outside the tubes:

a) Q=A x V
b) Area is approx. to be consist of 1/6th of total length of Heat
Exchanger i.e. 0.4m (Region 1). So total area is 0.4m * 2.25m
c) Q can be obtained from fan calculations
Step 4: Nusselt No
Laminar or Turbulent (Different for Inside and outside
flow)
Flow inside the tube
- Laminar Flow (Re < 10,000)
Nu = constant= 3.66 or 4.36
- Turbulent Flow (Re >= 10,000)
Gnielinski equation,

F is Darcys friction factor given as,

Step 5: Calculate Total Resistance and hence total no. of transfer

units (NTU)
Total resistance (R x Total no. of Tubes in region)

Step 6: Evaluate Effectiveness, Q(maximum), Q(actual) and Outlet

Temperature
Qmax= Cmin(Thin - Tcin)
Q = Qmax x
= Chot(Thin - Thout)
= Ccold (Tcout - Tcin

Step 7: Fin Selection

Fin Analyzed: Circular

=(Fin height+0.5*Fin Thickness)*Sqrt(Convection Heat

Transfer Coeff./Fin Materials thermal conductivity*Fin
Thickness)

Total heat capacity=(Efficiency*Fin Surface Area*No. of fins in

that region+ Ext. surface area-Area no fin*No. of fins in that
region)*Temp. Diff. in that region*Convection heat transfer
Coeff. *Pipes in Cross Flow

The Design Procedure1) Calculate the log mean driving force, LMTD.
2) Select the diameters of the inner and outer pipes.If the
allowable pressure drops for the individual streams are
given,they may provide a basis for selection of the pipe
diameters.
3) Calculate the inner fluid Reynolds number; estimate the heat
transfer coefficient hi from the Dittus-Boelter equation.

Nu = hidi/k = 0.023(Re)0.8(Pr)0.3
4) Calculate the Reynolds number of the outer fluid flowing
through the annulus.Use the equivalent diameter of the
annulus.Estimate the outside heat transfer coefficient ho using
the equation or the chart mentioned above.
5) Calculate the clean overall heat transfer coefficient; calculate
the design overall coefficient Ud using a suitable value of the
dirt factor.
6) Calculate the heat transfer area A(for a counter flow doublepipe exchanger LMTD correction factor, F=1 Determine the
length of the pipe that will provide the required heat transfer
area.If the length is large use a number of hairpins in series.
7) Calculate the pressure drop of the fluids.Use the Reynolds
number calculated above to determine the friction factor.

Pressure drop calculations1)Tube-side pressure drop-

fGt2 Ln
Pt
2 g t d i t
where,
f = friction factor
Gt = mass velocity of the fluid
L = length of the tube, m
g =9.8m/s2
pt = density of tube fluid
di= inside diameter of tube
n =the number of tube passes
t = dimensionless viscosity ratio
Pt =pressure drop
t=(viscosity at bulk temperature/viscosity at wall
temperature)^m
where m=0.14 for Re > 2100

and m= 0.25 for Re < 2100

In a multi-pass exchanger, in addition to frictional loss the head

loss known as return loss has to be taken into account.
V2
t
Pr 4n
2 g The pressure drop owing to the return loss is
given by-

Where,
n=the number of tube passes
V=linear velocity of the tube fluid
The total tube-side pressure drop is

PT = Pt +
Pr
2)Shell-side pressure dropFor an unbaffled shell the following equation may be used

Ps

Where,

fGs2 LN
2 g t d i s

L=shell length, m
N=number of the shell passes
ps=shell fluid velocity, m/s
Gs=shell-side mass velocity, kg/m2 s
DH=hydraulic diameter of the shell, m
s=viscosity correction factor for the shell-side fluid

CONCLUSION

A double pipe heat exchanger is one of the simplest form of Heat

Exchangers.

The wall of the inner pipe is the heat transfer surface.

The major use of these Heat Exchanger is sensible cooling or

heating applications.

But Very long, even for moderate capacities.

Unviable to accommodate in an industrial space.

To make a Unit Isotropically Compact, the arrangement is made

in Multiple Times and Continuous Series and Parallel flow.
General design considerations are routing of fluids and the

suitability of the calculated area of heat transfer and other important

parameters like baffles arrangement to meet with the maximum pressure
loss requirement in shell-an-tube heat exchanger.

REFERENCES

1. Double pipe heat exchanger;G.F.Hewitt, G.L.Shires, T.R.Bott;

Process Heat Transfer ;2000
2. http://en.wikipedia.org/wiki/Heat_exchanger
3.http://www.sciencedirect.com/science?
_ob=ArticleListURL&_method=list&_ArticleListID=373745940&_so
rt=r&_st=13&view=c&_acct=C000228598&_version=1&_urlVersion
=0&_userid=10&md5=7bc37ed668db15f46c705bc7a40bcd26&searcht
ype=a
4.Standards of Tubular Exchanger Manufacturers,TEMA,New York;6th
edition;A.R.Guy(1978)
5.Holman, J.P. 2002. Heat transfer. 9th ed., McGraw Hill, New York, NY,
USA, pp. 553-565.
6. Timothy J. Rennie and Vijaya G.S. Raghavan, 2005, Experimental
studies of a double-pipe heat exchanger, Experimental Thermal
and Fluid Science, vol. 29, 919924.
.