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THERMAL ENGINEERING
CHAPTER 04
HEAT EXCHANGER
1
EDITED BY:
DR. YUSLI YAAKOB
FACULTY OF MECHANICAL ENGINEERING
UiTM PULAU PINANG
OBJECTIVES:
When finish studying this chapter, student should be able to:
2
OBJECTIVES:
When finish studying this chapter, student should be able to:
4.3 Log-mean-
4.4 Effectiveness of temperature difference
NTU (-NTU) method (LMTD) method &
correction
4
4.0 INTRODUCTION
5
4.0 INTRODUCTION
6
4.0 INTRODUCTION
Heat Exchanger
7
4.0 INTRODUCTION
8
4.0 INTRODUCTION
APPLICATIONS
Heat exchangers are often given specific names to reflect
the specific application for which they are used:
Condenser
A heat exchanger in which one of the fluids is cooled and
condenses as it flows through the heat exchanger.
Boiler
A heat exchanger in which one of the fluids absorbs heat and
vaporizes.
Space radiator
A heat exchanger that transfers heat from the hot fluid to the
surrounding space by radiation.
9
4.0 INTRODUCTION
APPLICATIONS
Car Radiator
coolcarreview.tk 10
http://www.iradiators.com/
4.0 INTRODUCTION
APPLICATIONS
Refrigerators Systems
http://www.e-refrigeration.com
Condenser
11
http://www.e-refrigeration.com
4.0 INTRODUCTION
APPLICATIONS
Air-conditioning Systems
http://www.thefullwiki.org/Surface_condenser
Surface Condenser
12
http://www.diytrade.com
Condenser
4.0 INTRODUCTION
APPLICATIONS
Power Plants
13
4.0 INTRODUCTION
APPLICATIONS
Steam Engine
http://science.howstuffworks.com/transport/engines-
equipment/steam2.htm
http://science.howstuffworks.com/transport/engines- 14
equipment/steam2.htm
4.1 TYPES OF HEAT EXCHANGERS
16
4.1 TYPES OF HEAT EXCHANGERS
17
4.1 TYPES OF HEAT EXCHANGERS
PARALLEL FLOW
In the parallel-flow arrangement
18
4.1 TYPES OF HEAT EXCHANGERS
COUNTER FLOW
In the counter-flow arrangement
the fluids enter at opposite
ends, in opposite directions,
and leave at opposite ends.
Temperature profile
out 19
4.1 TYPES OF HEAT EXCHANGERS
CROSS FLOW (COMPACT HE)
The fluids
may move in
cross-flow (perpendicular) to one
another.
21
4.1 TYPES OF HEAT EXCHANGERS
SHELL-AND-TUBE
22
4.1 TYPES OF HEAT EXCHANGERS
SHELL-AND-TUBE
These designs contain a large number of tubes (packed in a
shell) and heat transfer takes place as one fluid flows inside the
tubes while the other fluid flows outside the tubes through the
shell.
23
4.1 TYPES OF HEAT EXCHANGERS
SHELL-AND-TUBE
Baffles are commonly placed in the shell to force the shell-
side fluid to flow across the shell to enhance heat transfer
and to maintain a uniform spacing between the
tubes.
24
4.1 TYPES OF HEAT EXCHANGERS
SHELL-AND-TUBE MULTI PASS DESIGNS
25
4.1 TYPES OF HEAT EXCHANGERS
SHELL-AND-TUBE
26
4.1 TYPES OF HEAT EXCHANGERS
PLATE AND FRAME
This is an innovative design
which consists of a series of
plates with corrugated flat
flow passages.
27
4.2 THE OVERALL HEAT TRANSFER COEFFICIENT
(DOUBLE PIPE HEAT EXCHANGER)
28
4.2 THE OVERALL HEAT TRANSFER COEFFICIENT
DOUBLE PIPE HEAT EXCHANGER
The thermal resistance of the network is
thus:
1 ln Do Di
1
Rtot
hi Ai 2 kL ho Ao
So the thermal resistance in the path of heat flow from hot to cold
fluid in a heat exchanger includes:
i. Skin resistance associated with the flow
ii. Scale resistance from wall fouling (to be discussed later)
iii. Thermal resistance of wall material 29
4.2 THE OVERALL HEAT TRANSFER COEFFICIENT
DOUBLE PIPE HEAT EXCHANGER
T
Q UAT U i Ai T U o Ao T
R
Where U = overall heat transfer coefficient
Note: U i Ai U o Ao
Ui Uo unless Ai Ao
30
4.2 THE OVERALL HEAT TRANSFER COEFFICIENT
1 1 1
Rtot
U As U i Ai U o Ao
31
4.2 THE OVERALL HEAT TRANSFER COEFFICIENT
Ao Ai
Am
ln AAoi 32
4.2 THE OVERALL HEAT TRANSFER COEFFICIENT
Since:
1 1 1
Uo 1
Ao R Ao Ai hi k tAm Ao ho
1
1
1 Ao t Ao 1
hi Ai k Am ho
33
4.2 THE OVERALL HEAT TRANSFER COEFFICIENT
And since: Ao 2 Do L
Am 2 LDo Di
2 Do L
ln
2 Di L
Do Do
ln
Do Di Di
Do Do
ln
t Di
34
4.2 THE OVERALL HEAT TRANSFER COEFFICIENT
35
4.2 THE OVERALL HEAT TRANSFER COEFFICIENT
Do Do
t 0; 1 so ln 0
Di Di
1
1 1
Ui Uo
hi ho
36
4.2 THE OVERALL HEAT TRANSFER COEFFICIENT
When the tubes are finned on one side to enhance the heat transfer,
the total heat transfer surface area on the finned side becomes:
37
4.2 THE OVERALL HEAT TRANSFER COEFFICIENT
EXAMPLE 4.1
Hot oil is to be cooled in a double-tube counter-flow heat exchanger.
The copper inner tubes have a diameter of 2 cm and negligible
thickness. The inner diameter of the outer tube (shell) is 3 cm. Water
flows through the tube at 0.5 kg/s and oil flows through the shell at
0.8 kg/s. Taking the average temperatures of the water and the oil to
be 45C and 80C, respectively, determine the overall heat transfer
coefficient of this heat exchanger.
39
Assumptions:
water 990 m kg
3 Prwater 3.91
k water 0.637 W
mC water 0.602 106 m2
s
1 1 1
U hi ho
The hydraulic diameter for a circular tube is the diameter of the tube itself,
Dh, water = D = 0.02 m
Vm Dh , water
Re water
water
1.61 ms 0.02 m
53,490
water 0.602 10 6 m 2
s
Since Re > 4,000, which is the Recrit for a pipe, the flow of water is turbulent.
The Nusselt number is thus:
h Dh
Nuwater 0.023 Re 0water
.8
Prwater
0.4
k water
0.023 53,490 3.91 240.6
0.8 0.4
43
OVERALL HEAT TRANSFER COEFFICIENT
(EXAMPLE 4.1)
Then:
k water
hwater Nuwater
Dh , water
0.637 mWC
240.6 7,663 m 2WC
0.02 m
44
OVERALL HEAT TRANSFER COEFFICIENT
(EXAMPLE 4.1)
Dh,oil Do Di
0.03 0.02 0.01 m
45
OVERALL HEAT TRANSFER COEFFICIENT
(EXAMPLE 4.1)
Re oil
Vm,oil Dh,oil
2.39 ms 0.01 m
637
oil 37.5 10 6 m 2
s
The Nusselt number can be found from Table 13-3 (in text) for Dt/Ds= 0.667
as:
Nuoil 5.45
46
OVERALL HEAT TRANSFER COEFFICIENT
(EXAMPLE 4.1)
Therefore:
0.138 mWC
5.45 75.2 m2WC
koil
hoil Nuoil
Dh,oil 0.01 m
since 1 1 1
U hi ho
Then the overall heat transfer coefficient (U) for this heat exchanger
becomes: 1 1
U 74.5 m 2 C
W
1 1 1 1
47
hi ho 7,663 m 2 C 75.2 m 2WC
W
FOULING FACTOR
The fouling factor represents the theoretical
resistance to heat flow due to a build up of a layer
of dirt or other fouling substance on the tube
surfaces of the heat exchanger
48
4.2 THE OVERALL HEAT TRANSFER COEFFICIENT
DOUBLE PIPE HEAT EXCHANGER
EFFECT OF FOULING
The performance of heat exchangers usually deteriorates with time
as a result of the accumulation of deposits on heat transfer
surfaces.
49
4.2 THE OVERALL HEAT TRANSFER COEFFICIENT
DOUBLE PIPE HEAT EXCHANGER
EFFECT OF FOULING
If we define the fouling factors on the inside and the outside surface
to be Rfi and Rfo, respectively. Then the total thermal resistance (R)
with fouling and the overall heat transfer coefficient becomes:
1 R fi t R fo 1
R
Ai hi Ai k Am Ao Ao h0
1
1 Do Do Do Do 1
Uo R fi ln R fo
hi Di Di 2k Di ho
Generally, Uo is low for a fluid with low k-values (for example gases
and oils). 50
4.2 THE OVERALL HEAT TRANSFER COEFFICIENT
DOUBLE PIPE HEAT EXCHANGER
EXAMPLE 4.2
A double-pipe (shell and tube) heat
exchanger is constructed of a stainless
steel inner tube with inner diameter
(Di) of 1.5 cm and outer diameter (Do)
of 1.9 cm. and an outer shell of inner
diameter 3.2 cm.
51
Ai Di L 0.015 m 1 m 0.0471 m 2
Ao Do L 0.019 m 1 m 0.0597 m2
1 1 1
R
U As U i Ai U o Ao
1
R f ,i
ln R
Do
Di
1
f ,o
hi Ai Ai 2 kL Ao ho Ao 52
EFFECT OF FOULING
(EXAMPLE 4.2)
Therefore:
R
1
D
R f ,i ln Doi
R f ,o
1
hi Ai Ai 2 kL Ao ho Ao
0.0004 m WC
2
1
800 W
m C
2
0.0471 m 2
0.0471 m 2
0.019 m
ln m 2 C
0.015 m 0. 0001
1
W
2 15.1 mC 1 m 0.0597 m
W 2
1200 W
m C
2 0.0597 m 2
54
4.3 LOG MEAN TEMPERATURE DIFFERENCE (LMTD) METHOD & CORRECTION
ANALYSIS OF HEAT EXCHANGER
In heat exchanger analysis it is convenient to combine
the product of the mass flow and the specific heat of a
fluid into a single quantity called the heat capacity rate.
Cc m c c pc
C h m h c ph
Q Cc Tc ,out Tc ,in
Q C T T
h h ,in h ,out 55
4.3 LOG MEAN TEMPERATURE DIFFERENCE (LMTD) METHOD & CORRECTION
ANALYSIS OF HEAT EXCHANGER
Consider an incremental area of the heat exchanger surface (as shown for
either a counter-flow or parallel flow heat exchanger).
56
4.3 LOG MEAN TEMPERATURE DIFFERENCE (LMTD) METHOD & CORRECTION
ANALYSIS OF HEAT EXCHANGER
The heat transfer over the area (dA) can be expressed in three ways:
dQ U dA T
2) The heat gain by the cold fluid:
dQ Cc dTc
3) The heat given up by the hot fluid:
dQ Ch dTh 57
4.3LOG MEAN TEMPERATURE DIFFERENCE (LMTD)
METHOD
Q A U Tm
58
4.3 LMTD METHOD
Q Ch dTh
Q Cc dTc
59
4.3 LMTD METHOD
60
4.3 LMTD METHOD
The rate of heat transfer in the differential section can be
expressed as:
Q U Th Tc dA
Substituting this into the previous equations gives:
d Th Tc 1 1
U dA
Th Tc Ch Cc
61
4.3 LMTD METHOD
Integrating from the inlet to the heat exchanger to its outlet, we
get:
d Th Tc 1 1
L L
0 Th Tc U Ch Cc 0 dA
+ For parallel-flow
- For counter-flow
62
4.3 LMTD METHOD
Solving the integral for parallel flow
(where T1=Th,in-Tc,in and T2=Th,out-Tc,out) we get:
T2
Th ,out Tc ,out 1 1
ln U A
Th ,in Tc ,in C h Cc
T1
T2 C h Cc Cc 1 C h 1
ln U A U A
T1 C h Cc C h Cc Cc C h
63
4.3 LMTD METHOD
Since:
Then:
T2 T1
Q U A U A Tm
T2
ln
T1
Tm
Mean temperature
66
This is the log mean temperature difference
4.3 LMTD METHOD
The log mean temperature difference method (LMTD) can be used for both
parallel and counter-flow heat exchangers, if the following terms are used for
T:
CORRECTION FACTORS
Tm F TLMTD,
counter flow
CORRECTION FACTORS
Correction factor (F) is depends on the geometry of the HE
and the inlet and outlet temperatures of the hot and cold
fluid stream.
Available from standard charts for several common
configurations.
The correction factor, F for common shell and tube and cross-
flow heat exchangers versus two temperature ratios P and R:
CORRECTION FACTORS
EXAMPLE 4.3
71
LMTD METHOD
(EXAMPLE 4.3)
Th,in= 140C
Tc,out= 80C
Tc,in= 20C
Th,out= 90C
72
LMTD METHOD
(EXAMPLE 4.3)
T1 T2
Tlmtd
T1
ln
T2
90C 20C 140C 80C
64.9C
90C 20C
ln
140C 80C
73
LMTD METHOD
(EXAMPLE 4.3)
74
LMTD METHOD
(EXAMPLE 4.3)
0.97
75
LMTD METHOD
(EXAMPLE 4.3)
Therefore the surface area (As) is:
m c C pc Tc ,out Tc ,in
As
U F Tm
2 4.187
kg
s 80C 20C
kJ
kg K
26.6 m 2
76
4.4 THE EFFECTIVENESS -NTU METHOD
This method is useful when the LMTD method cannot be determined.
The required data may instead be determined from the -NTU
method charts of several common configurations
Definitions:
The heat capacity of the cold stream is given by:
Cc m c c pc
The heat capacity of the hot stream is given by:
Ch m h c ph
77
4.4 THE EFFECTIVENESS -NTU METHOD
Cc
C ; if Ch Cc
Ch
Ch
C ; if Ch Cc
Cc
78
4.4 THE EFFECTIVENESS -NTU METHOD
The -NTU Method is based upon a dimensionless paramater, Heat
Transfer Efectiveness, :
Where and
Cc m c c pc Ch m h c ph
79
4.4 THE EFFECTIVENESS -NTU METHOD
The heat transfer in the heat exchanger will reach its maximum
value when:
1) The cold fluid is heated to the inlet temperature of the hot fluid.
2) The hot fluid is cooled to the inlet temperature of the cold fluid.
80
4.4 THE EFFECTIVENESS -NTU METHOD
However, these two things cannot happen simultaneously unless:
Cc=Ch
81
4.4 THE EFFECTIVENESS -NTU METHOD
Therefore, the maximum possible heat transfer rate in
heat exchanger is:
82
4.4 THE EFFECTIVENESS -NTU METHOD
Q Actual heat transfer rate
Qmax Maximum possible heat transfer rate
Cc Tc ,out Tc ,in
Cmin Th,in Tc ,in
Ch Th ,in Th,out
Cmin Th,in Tc ,in
83
4.4 THE EFFECTIVENESS -NTU METHOD
As U U As
NTU
Cmin m C p min
84
4.4 THE EFFECTIVENESS -NTU METHOD
(STEP-BY-STEP PROCEDURE)
The -NTU Method Procedure
Cmin
c
Cmax
85
4.4 THE EFFECTIVENESS -NTU METHOD
(STEP-BY-STEP PROCEDURE)
2) Determine:
U As
NTU
Cmin
86
4.4 THE EFFECTIVENESS -NTU METHOD
(STEP-BY-STEP PROCEDURE)
3) Charts
87
4.4 THE EFFECTIVENESS -NTU METHOD
(STEP-BY-STEP PROCEDURE)
4) Compute the heat transfer rate:
88
4.4 THE EFFECTIVENESS -NTU METHOD
(STEP-BY-STEP PROCEDURE)
5) Calculate the outlet temperature:
Q
Th ,out Th ,in
Ch
Q
Tc ,out Tc ,in
Cc
89
4.3 LMTD METHOD
EXAMPLE 4.4
Alcohol is to be cooled at a rate of 0.2 kg/s from 75C to 35C
in a counter-flow heat exchanger. Cooling water enters the
heat exchanger at 12C at a rate of 0.16 kg/s. The convective
coefficient between alcohol and the tube wall and water is
0.34 kW/(m2K) and between the tube wall and water is 0.225
kW/(m2K). The tube may be assumed to be thin. The specific
heat for the alcohol is 2.52 KJ/(kgK) and water is 4.187
KJ/(kgK).
Calculate the capacity ratio (C), effectiveness (), and heat
exchanger surface area (As).
90
4.4 THE EFFECTIVENESS -NTU METHOD
EXAMPLE 4.5
A single, pass counter-flow shell-and-tube heat exchanger is
used to cool hot mercury (Cph=1.37 kJ/(kgK)) from 110C to
70C flowing at a rate of 1 kg/s with water (Cpc=4.187 kJ/(kgK))
entering at 30C and flowing at a rate of 0.2 kg/s. Calculate the
heat transfer surface area required and the exit temperature of
the water if the overall heat transfer coefficient (U) is 250
kW/(m2K).
91
TUTORIAL
1) 11.53
2)11.54
3) 11.55
4) 11.60
5) 11.63
6) 11.86
7) 11.88
8) 11.103
9) 11.107
10) Past Final Exam Questions
92
4.5 HEAT EXCHANGER DESIGN & CONSIDERATIONS
Some design considerations are:
Cost
Budgetary limitations always play an important role. Operating and
maintenance costs are also a factor.
Pumping Power
The fluids are normally forced by pumps or fans which require a pump with
associate electrical costs.
93
4.5 HEAT EXCHANGER DESIGN & CONSIDERATIONS
Size and weight
Normally the smaller and lighter, the better. This is especially true for
automotive and aerospace industries.
Type
The type of heat exchanger depends on the requirements, fluids
involved, size and weight limitations etc.
Materials
The materials in the heat exchanger construction may be an important
consideration, especially if thermal stresses are an issue.
94
REFERENCES
3. Incropera et.al., Heat and Mass Transfer, John Wiley, 6th Edition,
2007.
95