CME 341

Heat Transfer
Lecture 10_2
Heat Exchanger

Dr. Hameed Muhamad

Chemical Engineering Department

College of Engineering

Abu Dhabi University

Heat exchanger
Objectives

• Recognize numerous types of heat exchangers, and classify them

• Develop an awareness of fouling on surfaces, and determine the overall heat
transfer coefficient for a heat exchanger
• Perform a general energy analysis on heat exchangers
• Obtain a relation for the logarithmic mean temperature difference for use in the
LMTD method, and modify it for different types of heat exchangers using the
correction factor
• Develop relations for effectiveness, and analyze heat exchangers when outlet
temperatures are not known using the effectiveness-NTU method
• Know the primary considerations in the selection of heat exchangers.

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Design of double pipe and
Design shell and tube heat exchanger
Objective:
Application of the principles of heat transfer to the design of equipment

 Engineers should select the best heat-exchanger equipment based on cost

 Cost equation normally contains weight and size of the heat exchanger,
i.e. weight and cost are considered economic variables

Aims of this chapter are to determine:

1. Methods of predicting heat exchanger performance.
2. Methods used to estimate the heat exchanger size.

3. Types of heat exchanger necessary to accomplish a particular task

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Types of Heat Exchanger

• Double Pipe (Concentric Tube)

• Shell and Tube (S&T)
• Cross Flow
• Plat Heat Exchanger
• Compact

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Double Pipe Heat Exchanger

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Compact Heat Exchanger
Characterized by large surface area ( >400m2/m3 for liquids and >700m2/m3
for gases , which is obtained by attaching closely separated thin plate or
corrugated fins to the walls separating the two fluids. It is used when space is
limited.

Commonly used in gas-to-gas and gas to

liquid heat applications

Example: car radiator, where fins are attached to the

air side of the tube surface, it is also used in aircrafts.

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 Cross-Flow Heat Exchanger

The two fluid move perpendicular to each other, i.e cross-flow, we may have finned or unfinned tubular HX.
Depending on the type of fluid motion they are categorized as:

(a) Unmixed flow: fins forces the

flow through a particular spacing (b) Mixed flow: fluid is free to
and prevent it from moving in the move in the traverse direction.
traverse direction

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Shell-and-tube Heat Exchanger
 Mostly used in chemical industries.
 One fluid passes in the tubes side while the other fluid is forced to
flow across the outside of the tubes (shell side)

 Baffles, are placed in the shell to induce turbulence and

ensure that the fluid flows across the tube, i.e. h for cross
flow is greater than that for parallel flow.

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Advantages and Disadvantages of TEMA Shell Types
 Baffle
Baffle selection is important to control shell-side flow distribution
and pressure drop. Single segmental baffles have the highest
pressure drop and heat transfer since they maximize the number of
tubes in cross flow. The typical baffle cut2 for single segmental
baffles varies from 20 to 35%, with 25% being the most common.
Double segmental baffles lower the pressure drop (and hence the
heat transfer) compared to single segmental baffles, as indicated in
Figure 3.7.
In recent years, non-TEMA baffles have become more popular. These alternative baffles provide for improved flow
distribution, which can also reduce pressure drop (for the same heat-transfer capacity). They are particularly advantageous
for tube-bundle replacements where flow rate and duty are increased.
Depending upon the header arrangement at the two ends of the heat exchanger, one or more passes
can be achieved

For a two-tube passes, the inlet header is split so that fluid

flowing into the tube passes through one-half of the tubes in
one direction, and then turns around and returns through the
other half of the tube where it started

inlet header

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Plate Heat Exchangers
1. Gasketed Plate-Frame Heat Exchangers
2. Shell-and-Plate Heat Exchangers
3. Plate-fin Heat Exchangers
Plate-and-frame heat exchanger (liquid-to-liquid
exchanger)
Hot and cold fluids flow in alternative passages, i.e. each
cold fluid stream is surrounded by two hot fluid streams
(effective heat transfer)

Miniature coiled tube-in-tube exchanger

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 The Overall Heat Transfer Coefficient
Consider the section of a double-pipe exchanger shown in Figure
3.13, in which the hot fluid is arbitrarily assumed to flow through
the inner pipe.

Heat is transferred by convection from the hot fluid to the wall of the inner pipe, by
conduction through the pipe wall, and then by convection from the pipe wall to the cold fluid.

The driving force for the heat transfer is the difference in temperature between the hot and
the cold streams. To describe this overall process, an overall heat-transfer coefficient, U, is
defined by:
(3.1)

(3.2)

(3.3)

Now, according to Equation (3.1), the thermal resistance is:

(3.4)
The Overall Heat Transfer Coefficient
But this resistance is made up of three resistances in series, namely, the convective resistance between the hot fluid
and the pipe wall, the conductive resistance of the pipe wall, and the convective resistance between the pipe wall and
the cold fluid. Hence,
(3.5)

where hi and ho are the heat-transfer coefficients for flow in the inner and outer pipes, respectively, and Ai is the surface
area of the inner pipe based on the inside diameter, i.e.,
(3.6)
Multiplying Equation (3.5) by Ao and inverting yields:

(3.7)
Equation (3.7) is correct when the heat exchanger is new and the heat-transfer surfaces are clean. With most fluids,
however, a film of dirt or scale will build up on the heat-transfer surfaces over a period of time.

This process is called fouling and results in decreased performance of the heat exchanger due to the added thermal
resistances of the dirt films.

Fouling is taken into account by means of empirically determined fouling factors, RDi and RDo, which represent the
thermal resistances of the dirt films on the inside and outside of the inner pipe multiplied by the respective surface
areas. Thus, for the inner dirt film:
(3.8)
 Adding these two additional resistances to Equation (3.5) and proceeding as before yields:

(3.9)

where UD is the overall coefficient after fouling has occurred.

Design calculations are generally made on the basis of UD since it is necessary that the exchanger be operable after
fouling has occurred. More precisely, the fouling factors should be chosen so that the exchanger will have a reasonable
operating period before requiring cleaning.

It should be noted that the effect of the fouling factors in Equation (3.9) is to decrease the value of the overall heat-transfer
coefficient, which increases the heat-transfer area calculated from Equation (3.1).
Fouling can occur by a number of mechanisms operating either alone or in combination. These include:

•Corrosion
•Crystallization
•Decomposition
•Polymerization
•Sedimentation

TABLE 3.3 Typical Values of Fouling Factors (h . Ft2 . F/Btu)

Example 3.1
A double-pipe heat exchanger will be used to cool a hot stream from 350 F to 250 F by heating a cold stream from
80 F to 120 F. The hot stream will flow in the inner pipe, which is 2-in. schedule 40 carbon steel with a thermal
conductivity of 26 Btu/h . ft2 . F. Fouling factors of 0.001 h . ft2 . F/Btu should be provided for each stream. The heat-
transfer coefficients are estimated to be hi = 200 and ho = 350 Btu/h . ft2 . F, and the heat load is 3.5 x 106 Btu/h.

(a) For counter-current operation, what surface area is required?

(b) For co-current operation, what surface area is required?

Solution
(a) Counter-current operation
From Equation (3.1) we have,

Clearly, we must compute values of UD and ΔTln in order to solve the problem. Counter flow can be represented
schematically as follows:
In order to compute UD from Equation (3.9), we first find Do and Di for 2-in. schedule 40 pipe. From Table B.2,
Di = 2.067 in. and Do =2.375 in. Then,

Therefore,

(b) Co-current operation

For parallel flow, the value of ΔTln will be different.
 The LMTD Correction Factor
In multi-pass shell-and-tube exchangers, the flow pattern is a mixture of co-current and counter-current flow, as
the two streams flow through the exchanger in the same direction on some passes and in the opposite direction
on others. For this reason, the mean temperature difference is not equal to the logarithmic mean. However, it is
convenient to retain the LMTD by introducing a correction factor, F, which is appropriately termed the LMTD
correction factor:
(3.10)

Note that in this relationship, the LMTD is computed as if the flow were counter current. The LMTD correction factor can
be computed analytically for any number of shell-side passes and any even number of tube-side passes as follows:
Let
N = number of shell-side passes (3.11)

(3.12)

Configurations for which the calculated value of F is less than

about 0.8 should not be used in practice for several reasons.
 For R ≠ 1, compute: (3.13)

(3.14)

(3.15)

For R = 1, compute:

(3.16)

(3.17)
Example 3.2
A fluid is to be heated from 100F to 160F by heat exchange with a
hot fluid that will be cooled from 230F to 150F. The heat-transfer
rate will be 540,000 Btu/h and the hot fluid will flow in the tubes.
Will a 1-2 exchanger (i.e., an exchanger with one shell pass and a
multiple of two tube passes) be suitable for this service? Find the
mean temperature difference in the exchanger.

Solution