A heat exchanger

is
a device used for
transferring heat
from a hot fluid
to
a cold fluid.

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There are literally hundreds of

possibilities for Heat Exchangers
being used in Industrial, Process
and Manufacturing applications
HOT or COLD

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Production of electricity

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Building s central heating, swimming pool

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Ice Making

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Beverage & Beer Cooling

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Hydraulic, Engine Oil Coolers

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THREE TYPES:
1. DOUBLE-PIPE
2. SHELL-AND-TUBE
3. CROSS-FLOW

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1. DOUBLE-PIPE HEAT EXCHANGERS

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1. DOUBLE-PIPE HEAT EXCHANGERS

Two TYPES in this group:
1a. counter-flow
1b. parallel-flow

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1. DOUBLE-PIPE HEAT EXCHANGERS

1a. parallel-flow:
fluids flow in the same direction

1b. counter-flow:
fluids flow in opposite directions

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2. SHELL-AND-TUBE HEAT EXCHANGERS

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3. CROSS-FLOW HEAT EXCHANGERS

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3. CROSS-FLOW HEAT EXCHANGERS

the two fluids flow at right angles to each other. Cross flow heat exchangers
may be further subdivided:
(a) Unmixed flow arrangement

(b) Mixed flow arrangement

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1
Ui =
1 ri ro
ri
+ ln +
h i k ri ro h o
Ai = 2 ri L

Uo =

1
ro 1 ro ro 1
+ ln +
ri h i k ri h o

Ao = 2 ro L

IMPORTANT NOTE
since Ui Ai = Uo Ao
Then Q is the same irrespective of which U.

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U
W/m 2 K

Application
Steam Condenser
Feedwater heater
Water-to-water heat exchanger
Finned-tube heat exchanger, water in tubes,
air across tubes
Water-to-oil heat exchanger
Steam to light fuel oil
Steam to heavy fuel oil
Steam to kerosene or gasoline
Finned-tube heat exchanger, steam in tubes,
air over tubes
Ammonia condenser, water in tubes
Alcohol condenser, water in tubes
Gas-to-gas heat exchanger
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1000 5600
1000 8500
850 1700
25 55
100 350
170 340
56 170
280 1140
28 280
850 1400
255 680
10 40
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Sources of fouling
a build-up of deposits due to harsh working
environment and impurities in the working
fluid/s,
these will add a thermal insulating layer on
either side of the heat exchanger surface, Rfi
and Rfo respectively, and as such the overall
heat transfer coefficient will be Lowered.
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1
Ui =
ri ro ri
ri
1
+ R fi + ln + R fo +
hi
k ri ro
ro h o
Uo =

1
ro
ro
ro ro
1
+ R fi + ln + R fo +
ri h i ri
k ri
ho
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Type of fluid

Fouling factor, Rf
m2 K/W

Seawater, below 50oC

Above 50oC
Treated boiler feedwater above 50oC
Fuel oil
Lubrication oil
Alcohol vapours
Steam, non-oil-bearing
Industrial air
Refrigerating liquid

0.0001
0.0020
0.0002
0.0009
0.0007
0.0001
0.0001
0.0004
0.0002

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Three Methods in use to appraise heat

exchangers:
a. LMTD method for double-pipe heat
exchangers

b. Corrected LMTD method for other

types of heat exchangers
c. Effectiveness NTU method

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The heat transfer process in a heat exchanger can be described as follows.

heat transfer between fluids across solid boundary
= Heat lost by hot fluid
= heat gained by cold fluid

Q = U A Tm

= mh .Cph. (Thi Tho)

= mc . Cpc .(Tco Tci)
with subscripts h, c representing the hot and cold fluids,
and

i, o for inlet and outlet respectively.

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The heat exchange for a small segment is dQ = U dA T

d( T) dT A dTB
=
T
Q / U .dA

To To Ti
ln
=
Ti
Q / U .A

To Ti
Q = U .A.

T
o
Ln

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This method for evaluating the performance of

heat exchangers has the advantage that it does
not require the calculation of the logarithmic
mean temperature difference.
Its main advantage is by using correction factors
for heat exchangers which are NOT the
standard parallel or counterflow.

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This method for evaluating the performance of heat

exchangers has the advantage that it does not require
the calculation of the logarithmic mean temperature
difference. The method depends on the evaluation of
three dimensionless parameters:
NTU
EFFECTIVENESS
& CAPACITY RATIO

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SOLVED EXAMPLE 8.2

It is desired to cool 0.6 kg/s of oil, from 125 oC to
65 oC.
Water is available with a flow rate of 0.5 kg/s at a
temperature of 10 oC. The overall coefficient of
heat transfer is 85 W/m2 K. Determine the length
of 3-cm I.D. tubing required for counterflow and
for parallel-flow heat exchange.
Data given:
Cpoil
Cpwater

= 2.10 kJ/kgK
= 4.18 kJ/kgK
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SOLUTION EXAMPLE 8.2

Equating heat contents of water and oil:

[m.Cp.T ]oil (0.60)(2.10)(60)

Tw =
=
= 36.17
[m.Cp ]w
(0.50)(4.18)
hence

Two = 36.17 + 10 = 46.17C

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SOLUTION EXAMPLE 8.2

for counter-flow:
and

To = 65 10 = 55
Ti = 125 46.17 = 78.8

Ti To
78.8 55
LMTD =
=
= 66.19
ln(Ti /To ) ln(78.8 / 55)

Q= [m.Cp.T]oil = (0.60).(2.10).(60) = 75.6 kW

A=

Q
75600
=
= 13.43 m 2
UxLMTD 85 x66.19
L=

A
13.43
=
= 142 m
.D (0.03)
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SOLUTION EXAMPLE 8.2

For parallel flow:
and
LMTD =

Ti = 125 10 = 115
To = 65 46.17 = 18.83

Ti To
115 18.83
=
= 53.14
ln(Ti /To ) ln(115 / 18.83)

75 600
Q
A=
=
= 16.7 m 2
UxLMTD (85) x(53.14)

A
(16.7)
L=
=
= 177m
d ( )(0.03)
The parallel-flow configuration requires larger area
to achieve the same heat transfer.
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SOLUTION EXAMPLE 8.2

for counter-flow:
and

To = 65 10 = 55
Ti = 125 46.17 = 78.8

Ti To
78.8 55
LMTD =
=
= 66.19
ln(Ti /To ) ln(78.8 / 55)

Q= [m. Cp .T ]oil = (0.60).(2.10).(60) = 75.6 kW

A=

Q
75600
=
= 13.43 m 2
UxLMTD 85 x66.19
L=

A
13.43
=
= 142 m
.D (0.03)
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How to get
the most out of
your heating

Since Q = A. U. dT
dT as it comes
U is almost constant for a given situation
A if increased, Q will be increased

The use of
fins in heat
exchangers

Fins IMPROVE heat transfer

by increasing the heat
exchanger area

Unfiined

Finned

(a) Integral with the base, ie rolled on, or

extruded
(b) Welded/soldered/brazed or even glued
to the surface
(c) Mechanically attached; either:(i) embedded in groove, or
(ii)tension wound

Typical fins are

Annular, or Flat;
for either 3
profiles:
Rectangular
Triangular, and
Parabolic

fin efficiency

where

hPx
m=
kAx
Px = 2w + 2t
Ax = w x t

tanh (mL)
F =
mL

t
w
L

Total heat due to fins and bare surfaces:Qt

= Qfin + Qbase
= h Af f T + h Ab T

Where
h convection heat transfer coefficient
T temperature difference between the
base surface and the fluid bulk
Ab unfinned base surface area.
Af finned surface area

t
b
L

Could have fins, on the

inner and outer surface/s

Q
T
=
1 Ai x
1 Ai
Ai
+
+
i hi A f
k o ho A f

SOLVED EXAMPLE 8.7

Investigate the effect of weight on heat transfer for
three materials : Copper, Aluminium and Stainless
steel in an environment where the convection heat
transfer coefficient h = 25 W/m2 K.
It is to investigate the suitability of iron fins of
dimensions 100mm long, 20mm thick and 1m
width.

SOLUTION EXAMPLE 8.7

P = 2w + 2t = 2 ( 1.00 + 0.02 ) = 2.04m
A = w x t = 1 x 20x10-3 = 0.020 m2
Lc = L + t/2 = 100 + 20/2 = 0.11m

w
t
L

hPx
2.04 h
h
m=
=
= 10.1
kAx
0.02 k
k

SOLUTION EXAMPLE 8.7

Material

Copper

385

Aluminium

170

Stainless
Steel

17

970
280
855

Weight
ratio
3.464
1
3.053

0.974

0.943 f
0.648

Q/W

1.033

0.290

0.687

0.225

Notes
Al lighter than both, weight ratio nearly 1/3
Although Al has a lower fin efficiency than Cu, its Q/W is 4
times better than both.

SOLVED EXAMPLE 8.9

The cylinder barrel of a motorcycle is constructed of 2024-T6
aluminium alloy and is of height H = 0.15 m and outside diameter
D = 50 mm. Under typical operating conditions the outer surface
of the cylinder is at a temperature of 500 K and is exposed to
ambient air at 300 K, with a convection coefficient of 50 W/m2
K. Annular fins of rectangular profile are typically added to
increase heat transfer to the surroundings. Assume that five such
fins ( k = 150 W/mK ), which are of thickness t = 6 mm, length L
= 20 mm and equally spaced, are added. What is the increase in
heat transfer due to addition of the fins?

SOLUTION EXAMPLE 8.9

(a) Without the fins, the heat transfer rate is
Awo

= H. 2r.L
H

Qwo

= h.AO .(Tb - T)

Qwo

= 50 (0.15 x 2 x 0.025) (500 - 300 )

= 236 W

r1
L
r2

SOLUTION EXAMPLE 8.9

(b)

P = (2x45/1000+ 6/ 1000) x 2 = 0.577 m

A = (2x45/1000+ 6/ 1000) = 1.69 x 10-3 m2
m=

50 x0.577
hP
=
= 10.652
kA
150 x1.69 x10 3

f =

tanh(ml ) tanh(10.652 x0.02)

=
= 0.985
ml
10.652 x0.02

Ab = Lb x 2 Af r1 = ( 0.15 - 5x0.06)x2x25/1000 = 0.01885x10-2 m2

Af = 5 [ 2 x x ( r22 - r12) ]= 0.044 m2
Qb

= h Ab Tb = 50 x 0.01885 x (500 - 300) = 188 W

Qf

= h Af F Tb = 50 x 0.985 x 0.044 x ( 500 - 300 ) = 433 W

Qt

= Qf + Qb

= 188 + 433 = 621 W