1

HUMID AIR HEAT EXCHANGERS

Markku J. Lampinen 1986. Translated from Finnish by Voitto W. Kotiaho.

1 PROPERTIES OF HUMID AIR

1.1 Thermodynamic properties

Humid air is a mixture of dry air (nitrogen, oxygen, carbon dioxide and noble gases) and
water vapor. The molar mass of dry air is Mi = 0,0290 kg/mol and of water vapor (water)
Mh = 0,0180 kg/mol.

According to the ideal gas equation, the partial density of dry air is

pi Mi
i  (1)
RT

where pi is the partial pressure of the dry air and the gas constant R = 8,314 J/mol K.

Correspondingly, the partial pressure of the water vapor is

ph Mh
h  (2)
RT

where ph is the partial pressure of the water vapor.

The density of the humid air is the sum of the densities of the dry air and water vapor

 = i + h (3)

and the total pressure is the sum of the pressures of the dry air and water vapor

p = p i + ph . (4)

The humidity of air, that is, ratio of water vapor and dry air, is defined as

h
x , (5)
i

which, by using equations (1), (2) and (3) can be expressed as

Mh ph p p
x  0,6220 h  0,6220 h . (6)
Mi pi pi p  ph

By solving ph we obtain

x
ph  p. (7)
0,6220  x

The enthalpy of the humid air is the sum of the enthalpies of the dry air and the water vapor

h = i hi + h hh (8)
 2

and, correspondingly, the specific heat

cp = i cpi + h cph . (9)

As the humid air flows through a device, e. g. heat exchanger, the flow of the dry air remains
constant but the humidity of air may change, for example, because of condensation. Because
of this, quantity hk, which is the enthalpy of the humid air per mass of dry air, has been taken
into usage. It is defined as

h
hk  , (10)
i

which, by using equations (8) and (5) can be expressed as

hk = hi + x hh . (11)

 i x with the dry airflow m

In a humid airflow, there is a flow of water vapor m i.
Correspondingly, the enthalpy flow of the humid air is m  ihk .

As liquid water at 0oC is chosen to be the reference point of the enthalpy, the enthalpies of the
dry air and the water vapor can be expressed approximately as

hi = cpi t  1006 t, J/kg

hh =  0 + cph t  2,50 106 + 1850 t , J/kg

and it follows that

hk = 1006 t + x (2,50 106 + 1850 t) , J/kgdry air. (12)

where t is the temperature of the humid air in Celsius (oC) degrees.

Each temperature T, which is lower than the boiling point at total pressure p, is corresponded
by some partial pressure of the water vapor, so called saturation pressure ph. The partial
pressure of the water vapor in an air-water vapor mixture cannot be bigger than ph at
temperature T. In case that the partial pressure of the water vapor is equal to the saturation
pressure, condensation of water takes place. The saturation pressure depends, with very high
accuracy, only on the temperature and very little on the total pressure, hence p'h = p'h(T).

The saturation pressure can be taken most accurately from the steam tables or can be
calculated approximately from the following formula:

 T  372,79 
p h (T)  p 0 exp11,78   , (13)
 T  43,15 

where p0 = 105 Pa and temperature T is in Kelvin (K) degrees.

 3

1.2 Kinetic properties

Heat- and mass transfer depend on the thermal conductivity  and the Kinematic viscosity 
of the humid air, and on the Diffusion coefficient D between the water vapor and the dry air.
These properties depend on temperature T, pressure p and humidity x in the following way (D
does not depend on the humidity):
 = (T, p, x) (14)
 = (T, p, x) (15)
D = D(T, p). (16)

There are empirical formulas for (14) and (15) in the literature (e. g. Tekniikan käsikirja, part
1, pages 367-369 and Tekniikan käsikirja, part 2, pages 746-758).

The Diffusion coefficient D can be obtained approximately from the following formula

T1,75
Da , (17)
p

where a = 1,190  10-4 m2/s, p is the total pressure in Pa and T is the temperature in K.

Instead of formulas, also tables can be used. On the following pages there are thermodynamic
properties of saturated air at different temperatures (Table 1). In practical calculations
properties of saturated air at saturation temperature are used as properties of the humid air.

Example 1 Air humidity x = 0,120. The pressure of the corresponding water vapor is
obtained from equation (7)
0,120
ph  105  1,617  104 Pa
0,6220  0,120

The saturation temperature of the air is 55,6oC and the nearest value in the
table is 56oC. Properties of the saturated air corresponding to this
temperature from table 1:

 = 0,02526 W/mK
 = 18,59  10-6 m2/s
D = 32.4  10-6 m2/s.

Partial densities for the saturated air at 56o can be taken from the same table

i = 0,900 kg/m3
h = 0,109 kg/m3.
 4

Table 1. Thermodynamic properties of saturated air at a total pressure of 100 kPa.

Tempera- Humidity Partial Partial density Partial density Specific enthalpy Specific heat
ture pressure of of of dry air of the mixture of the mixture
C kgH2O / kgdry air water vapor water vapor
kPa kgH2O / m3 kgdry air/m3 kJ/kgdry air J/kgK
0 0.003821 0.6108 0.004846 1.285 9.55 1010.8
2 0.004418 0.7054 0.005557 1.275 13.06 1012.0
4 0.005100 0.8129 0.006358 1.264 16.39 1013.4
6 0.005868 0.9346 0.007257 1.254 20.77 1014.9
8 0.006749 1.0721 0.008267 1.243 25.00 1016.7
10 0.007733 1.2271 0.009396 1.232 29.52 1018.6
12 0.008849 1.4015 0.01066 1.221 34.37 1020.8
14 0.010105 1.5974 0.01206 1.211 39.57 1023.3
16 0.011513 1.8168 0.01363 1.199 45.18 1026.0
18 0.013108 2.062 0.01536 1.188 51.29 1029.1
20 0.014895 2.337 0.01729 1.177 57.86 1032.5
22 0.016892 2.642 0.01942 1.165 65.02 1036.4
24 0.019131 2.982 0.02177 1.154 72.60 1040.7
26 0.021635 3.360 0.02437 1.141 81.22 1045.5
28 0.024435 3.778 0.02723 1.129 90.48 1050.9
30 0.027558 4.241 0.03036 1.116 100.57 1056.9
32 0.031050 4.753 0.03380 1.103 111.58 1063.5
34 0.034950 5.318 0.03758 1.090 123.72 1071.0
36 0.039289 5.940 0.04171 1.076 136.99 1079.3
38 0.044136 6.624 0.04622 1.061 151.60 1088.5
40 0.049532 7.375 0.05114 1.046 167.64 1098.9
42 0.055560 8.198 0.05650 1.030 185.40 1110.3
44 0.062278 9.010 0.06233 1.014 204.94 1123.2
46 0.069778 10.085 0.06867 0.997 226.55 1137.5
48 0.078146 11.161 0.07553 0.9791 250.45 1153.4
50 0.087516 12.335 0.08298 0.9606 277.04 1171.3
52 0.098018 13.613 0.09103 0.9411 306.64 1191.3
54 0.10976 15.002 0.09974 0.9207 339.51 1213.7
56 0.12297 16.509 0.1091 0.8999 373.31 1238.9
58 0.13790 18.146 0.1193 0.8768 417.72 1267.3
60 0.15472 19.92 0.1302 0.8532 464.11 1299.4
62 0.17380 21.84 0.1419 0.8283 516.57 1335.7
64 0.19541 23.91 0.1545 0.8021 575.77 1377.0
66 0.22021 26.14 0.1680 0.7746 643.51 1424.1
68 0.24866 28.55 0.1826 0.7456 721.01 1478.2
70 0.28154 31.16 0.1981 0.715 810.36 1541.8
72 0.31966 33.96 0.2146 0.6829 915.57 1613.2
74 0.36468 36.96 0.2324 0.6489 1035.6 1698.6
76 0.41790 40.19 0.2514 0.6132 1179.42 1799.4
78 0.48048 43.65 0.2717 0.5755 1348.40 1919.9
80 0.55931 47.36 0.2933 0.5358 1560.80 2066.4
82 0.65573 51.33 0.3162 0.4939 1820.46 2247.7
84 0.77781 55.57 0.3406 0.4497 2148.92 2476.7
86 0.93768 60.5 0.3666 0.4031 2578.73 2773.9
88 1.15244 64.95 0.3942 0.3542 3155.67 3170.8
90 1.45873 70.11 0.4235 0.3026 3978.42 3730.4
92 1.92718 75.61 0.4545 0.2482 5236.61 4574
94 2.73170 81.46 0.4873 0.1909 7395.49 5987
96 4.42670 87.69 0.5221 0.1305 11944.39 8820
98 10.30306 94.3 0.5588 0.06694 27711.34 17338
100  101.325 0.5977 0.000  
 5

Table 1 (cont.). Prandtl number (Pr) and Schmidt number (Sc) calculated from the values in
this table.

Tempera- Heat of Kinematic Diffusion Thermal Pr Sc

ture evaporation for viscosity coefficient conductivity
water air-water
C 10-6 m2/s W/mK
kJ/kg 10-6 m2/s
0 2500.8 13.25 22.2 0.02380 0.726 0.597
2 2495.9 13.43 22.4 0.02413 0.721 0.600
4 2491.3 13.61 22.6 0.02427 0.722 0.602
6 2486.6 13.79 22.8 0.02440 0.723 0.605
8 2481.9 13.97 23.1 0.02454 0.724 0.605
10 2477.2 14.15 23.3 0.02466 0.726 0.607
12 2472.5 14.34 23.6 0.02478 0.728 0.608
14 2467.8 14.52 23.9 0.02490 0.730 0.608
16 2463.1 14.71 24.2 0.02500 0.732 0.608
18 2458.4 14.89 24.5 0.02511 0.734 0.608
20 2453.1 15.08 24.8 0.02520 0.738 0.608
22 2449.0 15.27 25.2 0.02529 0.741 0.606
24 2442.0 15.46 25.5 0.02537 0.746 0.606
26 2439.5 15.65 25.9 0.02544 0.750 0.604
28 2434.8 15.84 26.3 0.02548 0.755 0.602
30 2430.0 16.03 26.6 0.02556 0.760 0.603
32 2425.3 16.22 27.0 0.02561 0.766 0.601
34 2420.5 16.41 27.4 0.02565 0.773 0.599
36 2415.8 16.61 27.8 0.02567 0.781 0.597
38 2411.0 16.80 28.3 0.02569 0.788 0.594
40 2406.2 17.00 28.7 0.02569 0.798 0.592
42 2401.4 17.20 29.1 0.02568 0.808 0.591
44 2396.6 17.39 29.6 0.02566 0.819 0.588
46 2391.8 17.59 30.0 0.02563 0.832 0.586
48 2387.0 17.79 30.5 0.02558 0.846 0.583
50 2382.1 17.99 30.9 0.02552 0.862 0.582
52 2377.3 18.19 31.4 0.02545 0.879 0.579
54 2372.4 18.39 31.9 0.02536 0.898 0.576
56 2367.6 18.59 32.4 0.02526 0.920 0.574
58 2362.7 18.79 32.9 0.02514 0.944 0.571
60 2357.9 18.99 33.4 0.02501 0.970 0.569
62 2353.0 19.19 34.0 0.02487 1.000 0.564
64 2348.1 19.38 34.5 0.02471 1.033 0.562
66 2343.1 19.57 35.1 0.02455 1.070 0.558
68 2338.2 19.76 35.7 0.02437 1.113 0.554
70 2333.3 19.94 36.3 0.02418 1.161 0.549
72 2328.3 20.10 36.9 0.02399 1.213 0.545
74 2323.3 20.28 37.6 0.02379 1.276 0.539
76 2318.3 20.44 38.3 0.02360 1.347 0.534
78 2313.3 20.58 39.0 0.02341 1.430 0.528
80 2308.3 20.71 39.8 0.02323 1.527 0.520
82 2303.2 20.81 40.7 0.02307 1.642 0.511
84 2298.1 20.90 41.5 0.02294 1.783 0.504
86 2293.0 20.96 42.5 0.02285 1.958 0.493
88 2287.9 20.99 43.6 0.02281 2.184 0.481
90 2282.8 20.99 44.7 0.02283 2.490 0.470
92 2277.6 20.94 46.0 0.02295 2.933 0.455
94 2272.4 20.84 47.4 0.02318 3.650 0.440
96 2267.1 20.69 49.0 0.02355 5.057 0.422
98 2261.9 20.47 50.8 0.02409 9.219 0.403
100 2256.7 20.08 52.8 0.02486  0.380
 6

2 PRINCIPLES OF HEAT EXCHANGER DESIGN

2.1 Analogy between heat transfer- and mass transfer coefficients

By studying the differential equations of the laminar flow, the following correspondence
between the heat transfer- and mass transfer coefficients can be derived:

Nu = G(Re, Pr) (18)

Sh = G(Re, Sc), (19)

where the dimensionless numbers have been defined as follows:

vL
Re  , Reynolds number

 cp
Pr  , Prandtl number


Sc  , Schmidt number
D
L
Nu  , Nusselt number

kL
Sh  , Sherwood number
D

The heat transfer coefficient has been denoted by , and corresponding mass transfer
coefficient by k. The analogy between these quantities means that the function
G( . , . ) is the same in equations (18) and (19). If there is a model for the heat transfer
coefficient, of the form (18), a model for mass transfer coefficient, based on that model, can
be derived, by replacing Prandtl number by Schmidt number and Nusselt number by
Sherwood number.

The analogy between equations (18) and (19) requires (on the boundary value) that there is no
convective flow on the surface. This requirement is not, however, fulfilled as water vapor
condensation takes place on the surface. In that case there is a convective flow perpendicular
to the surface, called Stefan-flow. Let us have a closer look at this flow and the reasons for it.

Let us denote the velocity component of the humid air normal to the surface by u. With the
velocities of the water vapor and dry air, u can be expressed as

u = huh + iui . (20)

Velocity u is the velocity of the center of gravity and it is a macroscopic quantity which
indicates the convective flow. u is the velocity which can be measured for example by the
Pitot-tube and which is called as Stefan-flow in this context.

The magnitude of term huh on the surface indicates the density of the water vapor-flow
condensing on the surface (kg/m2s) and it is not zero. How about the term iui? The
movement of the dry air is away from the surface and its magnitude corresponds the air
displaced in the condensation phenomenon where the water vapor becomes liquid, hence

h u h
ui   , (21)
v
 7

where  is the density of the liquid water. The minus mark in equation (21) is because the
direction of ui is opposite to uh.

Example 2 Water vapor condensation density huh = 1,9  10-3 kg/m2s. Temperature 56oC. On
the basis of example 1 we get h = 0,109 kg/m3 and i = 0,900 kg/m3.

1,9  103 kg/m 2 s

uh  3
 1,743 102 m/s
0,109 kg/m
 1,9  103 kg/m 2 s
ui  3
 1,9  106 m/s
1000kg/m
 = 0,109 kg/m3 + 0,900 kg/m3 = 1,009 kg/m3

0,109  1,743 102  0,900  1,9  106

u m/s  1,885  103 m/s
1,009

As can be seen in this example, it holds that ui  0, which means that the surface is a so called
semi-transparent surface. This means that the Diffusion coefficient of the water vapor is not
directly proportional to the pressure difference but the dependence is more complicated. One
study gives the following formula:

p p  p h (Ts )
h u h  M h k  ln (22)
RT p  ph

where ph (Ts ) is the pressure on the surface of the condensate. The derivation of formula (22)
has been shown in the Mass Transfer course as well as proof for formulas (18) and (19).

Example 3 A heat transfer model is Nu = A Rem Prn, that is, function G( . , .) has been
given as G(Re, Pr) = A Rem Prn. On the basis of formula (19) it is in this case
so that

Sh = A Rem Scn.

This can be developed forward:

n n
 Sc   Sc 
Sh  A Re m Pr n    Nu  , and it follows that
 
Pr  Pr 
n
k L  L   / D 
 , and this can be reduced to
D   c p  /  

k Le1n , (23)
 cp
D  cp Pr
where Le   is so called Lewis number.
 Sc
 8

2.2 Calculating surface temperature

Let us consider a certain spot in the exchanger, where the humid airflow is at temperature T
and at humidity x and the liquid or gas on the other side of the heat transfer wall is at
temperature Tv. Let us denote the surface temperature of the condensate at this particular spot
by Ts.

The heat flux through the inner surface As and the corresponding outer surface Au can be
expressed as follows, as the heat resistance of the condensate layer is neglected

As
 h A u (Ts ) 
   u A u (T  Ts )  m (Ts  Tv ) , (24)
s 1

s s

where m  h ( = huh) is the density of water vapor flow condensing on the outer surface, (Ts )
is the heat of evaporation for water at Ts, s is wall thickness, s is the heat conductivity, u is
the outer (humid air side) heat transfer coefficient and s is the inner heat transfer coefficient.

By using notation
As 1
G    (25)
Au s 1

s s

the equation (24) can be expressed as

 h (Ts )  G (Ts  Tv ) .

 u (T  Ts )  m (26)

In equation (24) we have obviously assumed that so called fin efficiency is unity. If there
were no condensation, the fin efficiency could be easily taken into account by using, as
effective outer surface, the actual outer surface multiplied by the fin efficiency. This kind of
concept, the fin efficiency, could of course be introduced in the case of condensation too, but
the problem is that the expression for the fin efficiency is a lot more complicated and there are
no complete formulas for it in the literature.

Hence we can continue the consideration by assuming that the fin efficiency is unity or by
assuming that Au denotes the effective outer surface, which has been obtained by multiplying
the actual outer surface by the fin efficiency.

By substituting equation (22) into equation (26) we get

p p  p h (Ts )
 u (T  Ts )  (Ts ) M h k  ln  G (Ts  Tv )  0 , (27)
R Tk p  ph

where Tk is the average boundary layer temperature at which the air properties are taken. In
example 1 this corresponded to the saturation temperature.

The surface temperature Ts can be solved from equation (27). If the condensation term weren't
there, Ts could be solved directly

 u T  G Tv
Ts  . (28)
 u  G 
 9

But because of the condensation, the value of Ts is bigger than that. This can be seen in
equation (24). Temperature difference Ts - Tv grows as  grows.

Let us denote the left side of eq (27) by F(Ts). Hence the task is to find solution for equation

F(Ts) = 0. (29)

One useful method for solving this is so called split-half method.

Fig. 1 Solving equation (29) by split-half method. The zero point is in the range Tv  Ts  T.

Always the range that gives F different signs in the endpoints, is split in half. Each step gives
a range, diminished to half, where the zero point is located. The split-half points generated
(Ts1, Ts2, Ts3,...) approach the zero point, lim Tsi  Ts .
i

Example 4 x = 0,12 , T = 353 K, Tv = 323 K, u = 80 W/m2K and G'' = 3500 W/m2K.

Air properties at mean temperature (Tk  329 K).
 cp = i cpi + h cph = 0,900  1006 + 0,109  1850 = 1107 J/m3K,
Le = D  cp /  = 32,4  10-6  1107 / 0,02526 = 1,420.
80
From equation (23): k   1,42210,33  0,0913m/s .
1107
(Ts )  (Tk )  2370 103 J/kg (in more accurate calculations the heat of
evaporation as a function of Ts can be represented as a formula).
0,12
ph  105 Pa  1,617  104 Pa
0,12  0,6220
By substituting the values into equation (27) we get

105  0,0913 105  p h (Ts )

80(353  Ts )  2,37  106  0,0180 ln 5  3500(Ts  323)  0 ,
8,314  329 10  1,617  104
where ph (Ts ) can be calculated from equation (13):
 T  372,79 
p h (T)  p 0 exp11,78  .
 T  43,15 
The solution is obtained by using the split-half method: Ts = 324,9 K.

 324,9  372,79 
p h (324,9 K)  105 exp11,78    1,350  104 Pa . The same
 324,9  43,15 
saturation pressure can be also read from Table 1 (324,9 K = 324,9 - 273,15 =
51,75oC).

The result can be correct only physically, as the following condition is satisfied:
ph (Ts )  p h . In this case it is (1,350 104Pa < 1,617 104Pa).
 10

In case that the result is ph (Ts )  p h , the calculation has to be repeated by
neglecting the term m h , that is, the surface temperature is obtained from
equation (28). In this case the heat transfer is dry and no condensation takes
place.

Once we have solved the surface temperature Ts, we can calculate the heat fluxes.
In case of example 4 these are:

- dry heat flux

u(T - Ts) = 80 (353 - 324,9) W/m2

- humid heat flux

p p  p h (Ts ) 105  0,0913 105  1,350  104 kg

 h  M h
m k  ln  0,0180 ln
R Tk p  ph 8,314  329 105  1,617  104 m 2 s
 1,889  103 kg/m 2 s

 h (Ts ) = 1,889 10-32370106 W/m2 = 4450 W/m2

m

- total heat flux

q = (2250 + 4450) W/m2 = 6700 W/m2

The total heat flux can be obtained also from the formula

G'' (Ts - Tv) = 3500 (324,9 - 323) = 6650 W/m2.

The little difference between the results is due to calculation inaccuracies and due
to that the value for the surface temperature, Ts = 324,9 K , is not quite the
accurate value.

2.3 Calculating state change of air flow

As humid airflow meets a surface, which is at a temperature lower than the air saturation
point, the condensation of the water vapor takes place. The air gets dryer and colder. The total
energy flux leaving the air is the same as the change in the enthalpy flow

  m
 i h k , (30)

where hk = hk(B) - hk(A), hk(B) is the enthalpy of the humid air after the heat transfer
element and hk(A) is the enthalpy before the element.

Correspondingly, the change of the humidity is obtained from equation

 h A u  m
m  i x , (31)

where x = x(B) - x(A) , x(B) is the humidity after the heat transfer element and x(A) is the
humidity before the element.

By dividing the equations (30) and (31) side by side and by notating q = /Au, we get
 11

h k q
 . (32)
x  h
m

The equation characterizes the state change of humid air at a certain spot of the exchanger. It
has to be emphazised, however, that ratio hk/x is usually different at different spots of the
exchanger, because the condensation ( m  h ) depends strongly on the state of the air. It has to
be noticed, too, that the temperature of the liquid or gas receiving the heat is different at
different spots of the exchanger, and also this temperature affects the heating power and
condensation.

Compared to the design of dry exchangers, the biggest difference is that there are no ready
formulas for the total conductance but the surface temperature has to be calculated at many
spots so that the amount of spots is adequate. This is the way the total heat flux can be
calculated and the exchanger can be designed.

Example 5 Water, flowing at the rate of m v = 160 kg/s, leaves a heat exchanger at 323 K.
The total outer surface of the exchanger is 1400 m2 and it is thought to be divided
into four elements for calculations. Calculate the state of air and water
 i = 87,5 kgdry air/s.
temperature after the first element as the dry airflow is m
Temperature and other values for the air entering the exchanger are the same as in
example 4.

In example 4, we obtained that surface temperature is Ts = 324,9 K , total heat

flux is q = 6700 W/m2 and condensation rate is m  h = 1,889 10-3 kg/m2s. The
enthalpy of the air entering the exchanger is obtained from equation (12):
hk(A) = 1006 (353 - 273,15) + 0,12 (2,50 106 + 1850 (353 - 273,15))
= 3,98 106 J/kgdry air.

1400 2
 m  6700W/m 2  2,35  106 W
4

The enthalpy change from equation (30)

 2,35  106 W
h k     2,69  104 J / kg dry air
mi 87,5 kg dry air / s
and enthalpy after the first element is thus
hk(B) = hk(A) + hk = (39,8 104 - 2,69 104) J/kgdry air = 3,71 104 J/kgdry air.
Change in humidity from equation (31)
1,889  103 (1450/ 4)
x    0,00756
87,5
and humidity after the first element is thus
x(B) = x(A) + x = 0,1200 - 0,00756 = 0,11244.

Air temperature from equation (12):

h  x  2,50  106 3,71 105  0,11244 2,50  106
t k C  C  74,05C .
1006  x  1850 1006  0,11244 1850
Therefore the air temperature in state B is T = (74,05 + 273,15) K = 347,2 K.
The air has thus cooled down (353 - 347,2) K = 5,8 K in the first element.

Correspondingly, the water has been heated up in the first element

 12

 2,35  106
Tv   K  3,51K
 v c pv 160  4186
m
and so the water temperature in spot B is Tv(B) = (323 - 3,51) K = 319,49 K.

The calculation of the example 5 can be continued in the same way from spot B to spot C. At
first, new surface temperature Ts is calculated by using the values of spot B, and after that the
condensation and total heat flux can be calculated. After that, the changes in humidity, air
temperature and water temperature can be calculated. By continuing this way, the
performance of the whole exchanger can be calculated.

The smaller elements the exchanger is divided into, the more accurate is the result of the
calculation.

The previous example can be understood from the point of view of design so that the
calculation procedure is continued, that is, elements are added, as long as desired entering
water temperature, or heating power, is achieved. The numerical values in the example are
from a case considering heat recovery from exhaust air of a paper machine.

2.4 Air cooler design example

A factory produces a tube-and-fin heat exchanger. The tubes are made of Cu and fins of Al.
The fin thickness is 0,2 mm, fin distribution 2,5 mm and the ratio of the outer surface (fin
surface) and inner surface (inner surface of the tubes) is Au/As = 27. The distribution of the
tubes (15/13) in the direction of the airflow is 30 mm and perpendicular to the airflow 60
mm. The outer heat transfer area of one row is 22,2 m2 per one square meter of the face area.

An airflow, m i = 2,4 kgdry air/s, is to be cooled from state (25oC, = 50%) down to state
(8oC, = 90%). The liquid in the tubes is water-glycol mixture and it flows at the rate of
4,0 kg/s and enters the exchanger at -5oC. Design the heat exchanger.

The first task is to find out the surface temperature of the condensate in the intake (Ts1) and in
the exit (Ts2). After the surface temperatures have been calculated, the outer area is obtained
from the formula

Au  (33)
G  ln
where
(T  Tv1 )  (Ts 2  Tv 2 )
 ln  s1 . (34)
Ts1  Tv1
ln
Ts 2  Tv 2
Temperature Tv1 is the temperature of the water glycol mixture at the first tube row and Tv2 is
its temperature at the last tube row (Tv2 = 268,15 K = -5oC).

The calculations step by step:

1) The properties of the air

ph1 = 0,5  3,17  103Pa = 1,585  103 Pa
1,585  103
x 1  0,6220 5  0,01002
10  1,585  103
hk1 = 1006  25 + 0,01002 (2,50  106 + 1850  25) = 50660 J/kgdry air
ph2 = 0,9  1072 Pa = 965 Pa
 13

965
x 2  0,6220  6,06  103
10  965
5

hk2 = 1006  8 + 0,00606 (2,50  106 + 1850  8) = 23290 J/kgdry air

2) Heating power of the exchanger

m  i (h k1  h k 2 )  2,4  (50660 23290)W  65,7 kW .

3) The outlet temperature of the water glycol mixture, Tv1

Let the mass fraction of the glycol be 30% in the mixture in which case the freezing
temperature of the mixture is -15oC and specific heat cpg = 3,65 kJ/kgK.

 g c pg (Tv1  Tv2 )   , hence

m

65,7
Tv1  Tv 2  K  4,5 K
4,0  3,65
and thus Tv1 = 268,15 + 4,5 = 272,65 K.

4) The heat transfer coefficient of the water glycol mixture

For a 30% mixture, the Kinematic viscosity is g = 4,0  10-6 m2/s, thermal conductivity
g = 0,465 W/mK and density g = 1045 kg/m3.
 g  g c pg 1045 4,0  106  3650
Pr    32,8
g 0,465
Let the arrangement of the tubes be such that the velocity of the mixture in the tubes is
1,35 m/s. In that case

v d 1,35  0,013
Re    4390 .
g 4,0  106
Nu = 0,037(Re0,75-180)Pr0,42 = 0,037(43900,75-180)32,80,42 = 57,6
g 0,465
and thus  s  Nu   57,6  2060 W/m 2 K .
d 0,013
Let it be noted that for pure water in the same conditions, the heat transfer coefficient
would have been approximately 3900 W/m2K, which is a lot better than for water glycol
mixture.

5) Outer heat transfer coefficient

The outer heat transfer coefficient for this particular exchanger calculated approximately
from the following formula  u  25,0  v W/m 2 K , where v is the face velocity in m/s.
Let us choose that the face velocity is v = 2,0 m/s. Hence
 u  25,0  2,0  35,4 W/m 2 K .

6) The face area

The mean temperature of the air is (25 + 8)/2 = 16,5oC = 289,65 K and the mean humidity
x = (0,01002 + 0,00606)/2 = 0,00804.
0,00804
ph   105 Pa  1276Pa
0,6220  0,00804
pi = (105 - 1276) Pa = 98720 Pa
pM 98720 0,0290
i  i i   1,189 kg/m 3 .
RT 8,314  289,65
The volume flow of the humid air
 14

V m i / i  2,40 / 1,189  2,02 m 3 /s

and the face area
A V  / v  2,02 m 3 /s / 2,0 m/s  1,01m 2 .
op

7) The mass transfer coefficient

The saturation temperature at the mean conditions of the airflow (part 6 above) is
approximately 10oC (Tk = 283,25 K). Let us take the properties according to saturated air
at this temperature.
i = 1,232 kg/m3 h = 0,0094 kg/m3
cp = 1,2321006 + 0,00941850 = 1257 J/m3K.
Le = Dcp/ = 23,310-61257/0,02466 = 1,188
35,4
From equation (23) k  1,18810,33  0,0316m/s .
1257

8) Conductance G''
1 1
From equation (25) G     75,9 W/m 2 K .
27 0,001 1

388 2060

9) Surface temperatures
Heat of evaporation (Ts )  (Tk )  2,48  106 J/kg.
The surface temperatures are ruled by equation (27). Surface temperature Ts1 is obtained
from equation
105  0,0316 105  p h (Ts1 )
35,4(298,15  Ts1 )  2,48  106  0,0180 ln
8,314  289,65 105  1585
 75,9 (Ts1  272,65)  0
which gives Ts1 = 282,9 K.
Surface temperature Ts2 is obtained from equation
105  0,0316 105  p h (Ts 2 )
35,4(281,15  Ts 2 )  2,48  106  0,0180 ln
8,314  289,65 105  965
 75,9 (Ts 2  268,15)  0
which gives Ts2 = 273,8 K.

10) Outer heat transfer area

The logarithmic mean temperature difference ln from equation (34)
(282,9  272,65)  (273,8  268,15)
 ln   7,72 K .
282,9  272,65
ln
273,8  268,15
The outer heat transfer area from equation (33)
65,7  103
Au   112 m 2 .
75,9  7,72

11) The number of the rows and the length of the exchanger in flow direction
For the face area, 1,01 m2 was chosen (part 6). Thus there is outer heat transfer area per
one row as much as 1,01  22,2 = 22,4 m2.
The number of tube rows in the direction of the airflow
z  112 m2/22,4 m2 = 5,0.
Hence z = 5.