Chapter 6

6.
1 INTRODUCTION
• A heat exchanger can be defined as any device
that transfers heat from one fluid to another
that are at different temperatures.
• Some of the specific applications of heat
exchangers are
– in space heating and air-conditioning,
– power production,
– waste heat recovery, and
– chemical processing.
2
6.2 HEAT EXCHANGER TYPES
Heat exchangers may be classified according to:
 Flow arrangement,
Parallel flow,
Counter flow,
Cross flow.
 Construction type
Tubular,
Plate,
Extended,
Regenerative.
3
6.2 HEAT EXCHANGER TYPES…
 Number of fluid passes,
Two pass,
Three pass, …
Compactness
Gas to liquid,
Liquid to liquid,
Phase change.
Transfer processes
Direct,
Indirect.
4
• Double pipe, cross-flow and shell-and-tube
heat exchangers are the common types of
tubular heat exchangers.
a) b)
Fig. 6.1 Double pipe heat exchangers a) Parallel flow
b) Counter flow 5
Fig. 6.2 Cross flow heat exchangers a) Both fluids unmixed

b) One fluid mixed and the other unmixed 6
Fig. 6.3 Shell and Tube heat exchanger with one shell pass
and one tube pass
7
Fig. 6.4 Shell and tube heat exchangers with more

fluid passes 8
Fig. 6.5 Compact heat exchangers 9

6.3 HEAT EXCHANGER ANALYSIS
There are different types of heat exchanger analysis

techniques, the most common ones being:
The log mean temperature difference (LMTD) and
The effectiveness-number of transfer units (ε-NTU)
methods.
The LMTD method is appropriate when we need to
select a heat exchanger where the temperature
changes and the mass flow rate are known.
The ε-NTU method is used when we want to predict
the outlet temperatures of both fluids.
10
6.4 LOG MEAN TEMPERATURE DIFFERENCE
METHOD
Parallel flow heat exchangers
In heat exchanger analysis, the energy balance is
used along with the following assumptions:
The heat exchanger is insulated from its surroundings,
and the heat exchange is only between the hot and
cold fluids,
Axial conduction along the tubes is negligible,
Potential and kinetic energy changes are negligible,
The fluid specific heats are constant, and
The overall heat transfer coefficient is constant.
11
6.4 LOG MEAN TEMPERATURE
DIFFERENCE METHOD…
Fig. 6.6 Temperature distribution in parallel flow arrangement

12
According to the above assumptions, heat lost by
hot fluid is the same as heat gained by cold fluid.
Heat lost by hot fluid
Q   mh ch Th,o  Th,i   Ch Th,o  Th,i 
. .
(6.1)
Heat gained by cold fluid
Q  mc cc Tc,o  Tc,i   Cc Tc,o  Tc,i 
. .
(6.2)
We can also express the heat transfer rate across
area dA as,
.
d Q  UTdA (6.3)
13
• T=Th-Tc is the local temperature difference
between the hot and cold fluids.
• To integrate equation (6.3), let’s make use of
the following relation
d T   dT  dT
h c
. .
dQ dQ .  1 1 
d T     d Q  
Ch Cc  C h Cc 
 1 
d T   UTdA
1
 
 C h Cc 
d T   1 1 
 U   dA
T  C h Cc 
14
Integration of this equation gives
d T   1 1 
2 2
1 T  U  Ch  Cc 1 dA
 T2   1 1   T  T  T  T   UA
ln    UA    UA  h,o . h ,i  c ,o . c ,i   . Th ,o  Tc ,o   Th ,i  Tc ,i 
 
 T1   C h Cc   Q Q  Q

UA
.
T2  T1 
Q
 
  (6.4)
.  T  T1 
Q  UA 2 
 T 
 ln  2  
  T  
  1  15
 
 
.
 Th ,o  Tc ,o   Th ,i  Tc ,i 
Q  UA 
 Th ,o  Tc ,o 
 ln   
 T  T  
 h ,i c ,i 
 UATlm (6.5)
Tlm is the logmean temperature difference
16
Counter flow heat exchangers
Fig. 6.7 Temperature distribution in counter flow arrangement

17
• Equations (6.1) through (6.5) apply for counter
flow heat exchanger.
• However, for the counter flow exchanger the
endpoint temperature differences must now
be defined as
T1=Th,i-Tc,o (6.6)
T2=Th,o-Tc,I (6.7)
18
• And the log mean temperature difference will
be,    
   
 T2  T1   Th,o  Tc ,i   Th,i  Tc ,o 
Tlm   
  T    T  T 
 ln  2    ln  h,o c ,i
  (6.8)
  T1    T  T  
 h , i c , o  
• Then
. the heat transfer rate is
Q  UATlm
(6.9)
19
Multi-pass and cross flow heat exchangers
The log mean temperature difference method
developed earlier is limited to parallel and counter flow
heat exchangers.
Similar relations can also be developed for cross flow
and multi-pass shell-and-tube heat exchangers but the
resulting relations are so complicated because of the
complex flow conditions.
The easiest way is to relate the log mean temperature
difference of such heat exchangers with that of counter
flow heat exchanger using some correction factor F.
20
Tlm=FTlm,CF (6.10)
Where Tlm,CF is given by
   
   
 T2  T1   Th,o  Tc ,i   Th,i  Tc ,o  (6.11)
Tlm,CF   
  T    T  T 
 ln  2    ln  h,o c ,i  
  T1     Th,i  Tc ,o  
The correction factor F for some arrangements

can be obtained from figures.
21
t2  t1
P
T1  t1
T1  T2
R
t2  t1
a) One-shell pass and multiple of two (2, 4, 6, etc) tube passes

22
b) Two-shell pass and multiple of four (4, 8, 12, etc) tube passes
23
c) Single-pass cross-flow with one fluid mixed and the other unmixed
24
d) Single-pass cross-flow with both fluids unmixed
Fig. 6.8 correction factor F for common shell and tube and
25
cross flow heat exchangers
Example 6.1
A counter flow, concentric tube heat exchanger is used to
cool the lubricating oil for a large industrial gas turbine
engine. The flow rate of cooling water through the
inner tube (Di=25mm) is 0.2kg/s, while the flow rate of
oil through the annulus (Do=45mm) is 0.1kg.s. The oil
and water enter at temperatures of 100 and 300C,
respectively. If the outlet temperature of the oil is to be
600C and the heat exchanger is 60m long, determine
the outlet temperature of the water, the LMTD and the
overall heat transfer coefficient.
26
Solution
27
• Properties of the fluids from tables: Unused
engine oil (Th = 800C = 353 K): cp=2131J/kgK,
=3.25x10-2Ns/m2, k=0.138W/mK. Water
(Tc=350C): cp=4178 J/kgK, =725x10-6Ns/m2,
k=0.625W/mK, Pr = 4.85.
• The required heat transfer rate may be
obtained from the overall energy balance for
Q  mh ch Th,i  Th,o   0.1 2131(100  60)  8524W
. .
the hot fluid
28
• The water outlet temperature is
.
Q 8524
Tc ,o  Tc ,i   30   40.2 0 C
.
m c cc 0.2  4178
• The LMTD for counter flow arrangement is

   
   
 T2  T1   Th ,o  Tc ,i   Th,i  Tc ,o  60  30  100  40.2
Tlm     43.2
  T     Th,o  Tc ,i    60  30 
 ln  2
   ln    ln  
  T1        
 Th,i  Tc ,o 
100 40.2
29
• The overall heat transfer coefficient can be
obtained as,
. .
Q Q 8524
U    41.87W / m 2 K
ATlm Di LTlm   0.025  60  43.2
30
6.5 THE EFFECTIVENESS-NUMBER OF TRANSFER
UNITS (e-NTU) METHOD
• The parameter P in the LMTD correction factor
method requires three temperatures for its
computation.
• The inlet temperature of both the hot and cold
streams is usually a given, but when the cold-side
outlet temperature is not known, a trial-and-error
method is required to evaluate P.
• The trial-and-error procedure may be avoided in the
ε-NTU method, and because of its suitability for
computer-aided design, the ε-NTU method is gaining
more popularity.
31
UNITS (e-NTU) METHOD…
Kays and London (1984) have shown that the heat
exchanger transfer equations may be written in
dimensionless form, which results in three
dimensionless groups:
• Capacity rate ratio:
(6.14)
C* 
Cmin
0  C*  1
Cmax
• Exchanger heat transfer effectiveness:
.
(6.15)
e .
Q
0  e  1
Q max
32
This is the ratio of the actual heat transferred to
the maximum heat that could be transferred if
the exchanger were a counter-flow exchanger.
• Number of transfer units:
UA
NTU  (6.16)
C
min
• The number of transfer units is a measure of

the size of the exchanger.
• Observe that if Ch>Cc then (T1-T2)<(t2-t1) and if
Cc>Ch then (T1-T2)>(t2-t1)
33
• The fluid that “might” experience the
maximum temperature change,T1-t1, is the
fluid that has the minimum capacity rate.
Thus, the maximum possible heat transfer can
Q max  Cc T1  t1  Cc  Ch 
.
be expressed as
(6.17a)
Q max  Ch T1  t1  Ch  Cc 
.
Or
(6.17b)
34
• And either of these can be obtained with the
counter-flow exchanger. Therefore, the exchanger
effectiveness can be written as
C T  T  C t  t 
.
e
Q
 h 1 2  c 2 1 (6.18)
.
Q max Cmin T1  t1  Cmin T1  t1 
• Observe that the value of ε will range between

zero and unity and that for a given ε and Q , the .
max
actual heat transfer in the exchanger will be
Q  eC T  t 
.
(6.19)
min 1 1
35
36
Example 6.2
Hot oil (Cp=2200J/kgK) is to be cooled by water (Cp=4180J/kgK) in
a 1-shell-pass and 6-tube-pass heat exchanger. The tubes are
thin walled and are made of copper with an internal diameter
of 1.8cm. The length of each tube pass in the heat exchanger
is 3m, and the overall heat transfer coefficient is 340W/m2K.
Water flows through the tubes at a rate of 0.1kg/s, and the oil
through shell at a rate of 0.2kg/s. The water and oil enter at
temperatures 180C and 1600C, respectively. Determine the
rate of heat transfer and the outlet temperatures of the water
and the oil.
37
Solution
• The heat capacity rate of
oil is:
 . 
Ch   m c   0.2  2200  440W / K
 oil
• And the heat capacity
rate of water is:
 
Cc • The
.
m c  minimum heat
 0.1  4180  418W / K
capacity
 water rate is:
Cmin  Cc  418W / K 38
• The maximum heat transfer rate is:
Q max  Cmin T1  t1   418160  18  59356W
.
• The actual heat transfer rate is:

Q  eCmin T1  t1 
.
• Where the effectiveness ε is obtained from

table 6.1e as 1  exp  NTU 1  C *  
1

 
2
 2 1 C *  1 C *
 1  C * 
2


 1  C * exp  NTU 2
• The capacity rate ratio is

Cmin 418
C*    0.95
Cmax 440
39
• The number of transfer unit is
UA U 6dL  340  6    0.018  3
NTU     0.83
Cmin Cmin 418
• The effectiveness ε will be


   
1  exp  0.83 1  0.952 

1
e  21  0.95  1  0.95

 
  0.44
2

 
1  0.95 exp  0.83 1  0.952 

• Then
. the
. actual heat transfer rate is:
Q  e Q max  0.44  59356  26053.91W
40
• The outlet temperature of the water, t2, can
be. obtained from the relation
Q  Cc Tc,o  Tc,i   Cc t2  t1 
.
Q 26053.91
 t 2  t1   18   80.330 C
Cc 418
• The outlet temperature of the oil, T2, can be

obtained from the relation
Q  C T  T   C T  T 
.
h h ,i h ,o h 1 2
.
Q 26053.91
 T2  T1   160   100.80 C
Ch 440
41
Example 6.3
In a textile manufacturing plant, the waste dyeing
water (Cp=4925J/kgK) at 750C is to be used to
preheat fresh water (Cp=4180J/kgK) at 150C at the
same flow rate in a double-pipe counter-flow heat
exchanger. The heat transfer surface area of the heat
exchanger is 1.65m2and the overall heat transfer
coefficient is 625W/m2K. If the rate of heat transfer
in the heat exchanger is 35kW, determine the outlet
temperature and the mass flow rate of each fluid
stream.
42
Fresh
water
15C
Dyeing
water
75C
Th,out
Tc,out
43
Solution
• The temperature differences at the two ends
of the heat exchanger are
T1  Th,in  Tc,out  75  Tc,out
T2  Th,out  Tc,in  Th,out  15
and T1  T2 75  Tc , out   Th, out  15

Tlm  
 T1   75  Tc , out 
ln   ln  

 2
T  Th, out  15 
44
• Then the rate of heat transfer can be expressed
as .
Q  UA T S lm
75  T   T  15 (1)

35000  0.625  1.65  c , out h , out
 75  Tc , out 
ln  
T
 h , out  15 
• The rate of heat transfer can also be expressed as
 
Q  m C T  T   m 4180T  15  35000
. . .
p c , out c , in
(2) c , out
 
(3)
fresh water
 
Q  m C T  T   m 429575  T   35000
. . .
p h , in h , out h , out
  dyeing water
Tc,out=41.40C, Th,out=49.30C,
m  0.317 kg/s
45
Example 6.4
A cross-flow air-to-water heat exchanger with an
effectiveness of 0.65 is used to heat water
(Cp=4180J/kgK) with hot air (Cp=1010J/kgK).
Water enters the heat exchanger at 200C at a rate
of 4kg/s, while air enters at 1000C at a rate of
9kg/s. If the overall heat transfer coefficient
based on the water side is 260W/m2K, determine
the heat transfer surface area of the heat
exchanger on the water side. Assume both fluids
are unmixed.
46
Water
20C, 4 kg/s
Hot Air
100C
9 kg/s
47
Solution
• The heat capacity rates of the hot and cold
fluids are
Ch  m
 h C ph  (4 kg / s)(4.18 kJ / kg.  C) = 16.72 kW/ C
Cc  m
 c C pc  (9 kg / s)(1.01 kJ / kg.  C) = 9.09 kW/ C
Cmin  Cc  9.09 kW/ C

Therefore,
C 9.09
C  min   0.544
and Cmax 16.72
48
• Then the NTU of this heat exchanger
corresponding to C = 0.544 and = 0.65 is
determined to be
NTU = 1.5
• Then the surface area of this heat exchanger
UAs NTU C min (1.5)(9.09 kW/ C)
becomes
NTU  
 As    52.4 m 2
C min U 0.260 kW/m .C
2
49
6.6 FOULING FACTOR
• After a period of operation the heat transfer
surfaces for a heat exchanger may
– become coated with various deposits present in the
flow systems, or
– the surfaces may become corroded as a result of the
interaction between the fluids and the material used
for construction of the heat exchanger.
• In either event, this coating represents an
additional resistance to the heat flow, and thus
results in decreased performance.
50
6.6 FOULING FACTOR…
• The overall effect is usually represented by a fouling
factor, or fouling resistance, Rf, which must be included
along with the other thermal resistances making up the
overall heat transfer coefficient.
• Fouling factors must be obtained experimentally by
determining the values of U for both clean and dirty
conditions in the heat exchanger. The fouling factor is
thus defined as
(6.19)
• Fouling
Rf 
1factors

1 for some fluids are given in table 6.2.
U dirty U clean
51
Table 6.2 Fouling factors of some fluids
52
Table 6.2 Fouling factors of some fluids…
53
Example 6.5
Water at an average temperature of 107°C and an average
velocity of 3.5m/s flows through a 5m long stainless steel tube
(k=14.2W/mK) in a boiler. The inner and outer diameters of
the tube are Di=1.0cm and Do=1.4cm, respectively.
a) If the convection heat transfer coefficient at the outer
surface of the tube where boiling is taking place is
ho=8400W/m2K, determine the overall heat transfer
coefficient Ui of this boiler based on the inner surface area
of the tube.
b) Repeat the solution assuming a fouling factor Rf,i =
0.0005m2K/W on the inner surface of the tube
54
Solution
a) The properties water
6
at 107C  110C are
   /   0.268  10
2
m /s
k  0.682 W/m2 .K
Pr  1.58
• The Reynolds number is
Vm Dh (3.5 m/s)(0.01 m)
Re    130 ,600
 0.268  10 6 2
m /s
• which is greater than 10,000. Therefore, the
flow is turbulent.
55
• Assuming fully developed flow,
hDh
Nu   0.023 Re 0.8 Pr 0.4  0.023 (130 ,600 ) 0.8 (1.58) 0.4  342
k
k 0.682 W/m.C
and h
Dh
Nu 
0.01 m
(342) = 23,324 W/m2 .C
• The total resistance of this heat exchanger is

then determined from
56
1 ln( Do / Di ) 1
R  Rtotal  Ri  R wall  Ro   
hi Ai 2kL ho Ao
1 ln(1.4 / 1)
 
( 23,324 W/m .C)[  (0.01 m)(5 m) ] [2 (14 .2 W/m.C)(5 m)]
2
1

(8400 W/m2 .C)[  (0.014 m)(5 m) ]
= 0.00157 C/W
and
1 1 1
R 
U i    4055 W/m2 .C
U i Ai RAi (0.00157 C/W)[ (0.01 m)(5 m) ]
57
b) The thermal resistance of heat exchanger
with a fouling factor of Rf,i=0.0005m2.0C/W is
determined from
1 R f ,i ln( Do / Di ) 1
R   
hi Ai Ai 2kL ho Ao
1 0.0005 m 2 .C/W
R 
(23,324 W/m .C)[ (0.01 m)(5 m)] [ (0.01 m)(5 m)]
2
ln(1.4 / 1) 1
 
2 (14 .2 W/m.C)(5 m) (8400 W/m2 .C)[ (0.014 m)(5 m)]
 0.00476 C/W
58
Then,
1 1 1
R 
U i    1337 W/m2 .C
U i Ai RAi (0.00476 C/W)[ (0.01 m)(5 m) ]
59

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6.

Fig. 6.2 Cross flow heat exchangers a) Both fluids unmixed

Fig. 6.4 Shell and tube heat exchangers with more

Fig. 6.5 Compact heat exchangers 9

There are different types of heat exchanger analysis

Fig. 6.6 Temperature distribution in parallel flow arrangement

Fig. 6.7 Temperature distribution in counter flow arrangement

The correction factor F for some arrangements

a) One-shell pass and multiple of two (2, 4, 6, etc) tube passes

d) Single-pass cross-flow with both fluids unmixed

the hot fluid

• The LMTD for counter flow arrangement is

• The number of transfer units is a measure of

• Observe that the value of ε will range between

• The actual heat transfer rate is:

• Where the effectiveness ε is obtained from

• The capacity rate ratio is

• The effectiveness ε will be

e  21  0.95  1  0.95

• The outlet temperature of the oil, T2, can be

and T1  T2 75  Tc , out   Th, out  15

75  T   T  15 (1)

Cmin  Cc  9.09 kW/ C

• The total resistance of this heat exchanger is

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