ABSTRACT

Heat exchanger is a device used for transfer of thermal energy between two or
more fluids that are at different temperatures. Heat exchangers work because heat
naturally flows from high temperature to lower temperature. Therefore if a hot fluid
and a cold fluid are separated by heat conducting surface heat can be transferred from
the hot fluid to cold fluid.
Heat exchangers may be classified according to transfer process, construction,
flow arrangement, surface compactness, number of fluids and heat transfer
mechanisms or according to process functions.
Heat exchangers are useful in many engineering processes like those in
refrigerating and air- conditioning systems, power systems, food processing systems,
chemical reactors and space or aeronautical applications.
Double pipe heat exchanger is a simplest form of a heat exchanger, for
particular advantages for small thermal loads and high pressure applications. It
consists of a tube or pipe fixed concentrically inside a larger pipe or tube. They are
used when the flow rates of the fluids and the heat duty are small (less than 500
kW).These are simple to construction, but may require a lot of physical space to
achieve the desired heat transfer area.
 LIST OF FIGURES

Figure Title Page No.

1. Classification of heat 3
Exchangers
2. Parallel-flow heat 3
exchanger
3. Counter-flow heat 4
exchangers.
4. Cross-flow heat 5
exchangers
5. shell-and-tube heat 8
exchanger
6. Double pipe heat 9
exchanger
7. Straight Tube Double pipe 10
heat exchanger
8. Hairpin or U-Tube Double 10
pipe heat exchanger
9. Double pipe heat 11
exchanger- Two Hairpins
in series
10. Double pipe heat 11
exchanger with
longitudinal fins
11. Double pipe heat 12
exchanger with
longitudinal fins- Actual
Image
12. Flow sheet of Parameters 14
 LIST OF TABLES

Table Title Page No.

1. Table For Piping 15
Configurations
2. Effectiveness relations of 17
Heat Exchangers
 INDEX

Sr. No. Content Page No.

1. Introduction: 1
Heat Exchanger

2. Classification of Heat 2
Exchanger
3. Shell and Tube 8
Exchangers
4. Double Pipe Heat 9
Exchanger
5. Types of Double Pipe Heat 10
Exchangers
6. Advantages of Double 12
Pipe Heat Exchangers
7. Components of Double 13
Pipe Heat Exchangers
8. Design constraints 13
9. Flow sheet of parameters 14
10. Design Procedure 18
11. Pressure Drop 19
Calculations
12. Conclusion 21
13. References 22
 HEAT EXCHANGERS
Introduction -

Heat Exchanger is any device used for effecting the process of heat exchange
between two or more fluids that are at different temperatures. The fluids may be
single compounds or mixtures. In most heat exchangers, the fluids are separated by a
heat transfer surface, and ideally they do not mix. Such exchangers are referred to as
the direct transfer type, Or simply recuperators. In contrast, exchangers in which there
is an intermittent heat exchange between the hot and cold fluids via thermal energy
storage and rejection through the exchanger surface or matrix—are referred to as the
Indirect transfer type or Storage type, or simply regenerators.
Such exchangers usually have leakage and fluid carryover from one stream to the
other.
Double pipe Heat Exchanger consists of a tube or pipe fixed concentrically
inside a larger pipe or tube. They are used when the flow rates of the fluids and the
heat duty are small (less than 500 kW).These are simple to construction, but may
require a lot of physical space to achieve the desired heat transfer area.
CLASSIFICATION-

Contacting
technique

Flow
Basis of Construct
arrangem
ent
classification ion

Surface
compactne
ss

1. Types of HX w.r.t Flow -: There are two primary classifications of heat

exchangers according to their flow arrangement.

 Parallel-flow heat exchangers: If two fluids enter the exchanger at the same
side and moves in the same direction.
  Counter-flow heat exchangers: The fluids enter the exchanger from opposite
ends, moves in parallel but in opposite direction. The counter design is most
efficient, in that it can transfer the most heat from the heat (transfer) medium.

 Cross-flow heat exchangers: In cross-flow heat exchanger, the fluids travel

at right angle to each other through the heat exchanger.

2. Classification according to transfer process -:

1. Direct contact type heat exchangers -: In direct contact type, heat is

transferred through direct contact between the hot and cold immiscible fluids. Direct
contact heat exchange takes place between two process streams. The streams can
include combinations such as gas-solid, gas-liquid, liquid-liquid, liquid-solid, or solid-
solid streams. For obvious reasons, gas-gas systems cannot be achieved directly.
Direct contact heat exchangers include heat transfer between hot and cold streams of
two phases in the absence of a separating wall. Hence such exchangers can be
categorized as gas liquid, immiscible liquid and solid liquid or solid gas.

(a) Immiscible fluid exchanger - In this type, two immiscible fluid streams are
brought into direct contact. These fluids may be single-phase fluids, or they may
involve condensation or vaporization.
Condensation of organic vapors and oil vapors with water or air are typical
examples.
(b) Gas-liquid exchanger - In this type, one fluid is a gas (more commonly, air)
and the other a low-pressure liquid (more commonly, water) and are readily separable
after the energy exchange. In these exchangers, more than 90% of the energy transfer
is by virtue of mass transfer (due to the evaporation of the liquid), and convective heat
transfer is a minor mechanism.
Cooling tower with forced- or natural-draft airflow is the most
common application. Other applications are the air-conditioning spray chamber, spray
drier, spray tower, and spray pond.
(c) Liquid-vapor exchanger - In this type, typically steam is partially or fully
condensed using cooling water or water is heated with waste steam through direct
contact in the exchanger. Non condensable and residual steam and hot water are the
outlet streams.
Common examples are desuperheaters and open feedwater heaters in power plants.

2. Indirect contact type heat exchangers -: In this type of heat exchangers, the fluid
streams remain separate, and the heat transfer takes place continuously through a
separating wall. There is no direct mixing of the fluids because each fluid flows in
separate fluid passages. This type of heat exchanger also referred to as a surface heat
exchanger, can be further classified into (a) Direct-transfer type, (b) Storage type
(a) Direct-transfer type - In this type, heat transfers continuously from the hot fluid
to the cold fluid through a dividing wall. There is no direct mixing of the two (or
more) fluids because each fluid flows in separate fluid passages. Some examples of
direct transfer type heat exchangers are tubular, plate-type, and extended surface
exchangers.
(b) Storage type - In a storage type exchanger, both fluids flow alternatively
through the same flow passages, and hence heat transfer is intermittent. The
heat transfer surface (or flow passages) is generally cellular in structure and is
referred to as a matrix. When hot gas flows over the heat transfer surface (through
flow passages), the thermal energy from the hot gas is stored in the matrix wall, and
thus the hot gas is being cooled during the matrix heating period. As cold gas flows
through the same passages later (i.e., during the matrix cooling period), the matrix
wall gives up thermal energy, which is absorbed by the cold fluid. Thus, heat is not
transferred continuously through the wall. This storage type heat exchanger is also
referred to as a regenerator.

3. Classification according to pass arrangements -: These are either single pass or

multipass. In single pass, fluid flows through a section of heat exchanger through it’s
full length once. In multipass arrangement, a fluid is reversed and flows through the
flow length two or more times.

4. Classification according to phase of fluids -:

(a) Gas-Liquid -: Gas-Liquid heat exchangers are mostly tube-fin type compact heat
exchangers with the liquid on the tube side. The radiator is best example of gas-liquid
heat exchanger. some other examples are air coolers for aircraft, intercoolers and
aftercoolers in compressors, and condensers and evaporators of room air-conditioners.
(b) Liquid-Liquid -: Most of the liquid-liquid heat exchangers are shell and tube,
PHE to a lesser extent. Both fluids are pumped through the exchanger, so the principal
mode of heat transfer is forced convection. The relatively high density of liquids
result in very high heat transfer rate.
(c) Gas-Gas -: These type of exchanger found in rotary generators, intercoolers.
Compare to liquid-liquid exchanger, size of gas-gas much larger.
 5. Classification according to construction -: According to constructional details,
heat exchangers are classified as :
(a) Tubular Heat Exchangers -: Shell-and-Tube Exchangers, Double Pipe, Coiled
Tube
(b) Plate-Type Heat Exchangers -: Gasketed Plate Heat Exchangers, Welded, Spiral
Plate Heat Exchangers, Lamella Heat Exchangers.
(c) Extended Surface Heat Exchangers -: Plate-Fin Heat Exchangers, Tube-Fin
Heat Exchangers.
(d) Regenerators -: Rotary Regenerators, Fixed-Matrix Regenerator
1. Shell-and-Tube Exchangers -: Shell-and-tube heat exchangers are fabricated with
round tubes mounted in cylindrical shells with their axes coaxial with the shell axis.
The differences between them any variations of this basic type of heat exchanger lie
mainly in their construction features and the provisions made for handling differential
thermal expansion between tubes and shell
There are various design considerations to be taken into account such as routing of
fluids (shell or tube), pressure drop especially in the case of increasing number of
baffles and tube diameter and adjusting the area with the suitability of the exchanger
to conduct the heat required to heat or cool a fluid with another one.

Applications -: They are extensively used as process heat exchangers in the

petroleum-refining and chemical industries; as steam generators, condensers, boiler
feed water heaters and oil coolers in power plants; as condensers and evaporators in
some air-conditioning and refrigeration applications; in waste heat recovery
applications with heat recovery from liquids and condensing fluids; and in
environmental control.
2. Double Pipe Heat Exchanger -: A typical double-pipe heat exchanger is shown in
Figure below. Essentially, it consists of one pipe placed concentrically inside another
one of larger diameter, with appropriate end fittings on each pipe to guide the fluids
from one section to the next. The inner pipe may have external longitudinal fins
welded to it either internally or externally to increase the heat transfer area for the
fluid with the lower heat transfer coefficient. The double-pipe sections can be
connected in various series or parallel arrangements for either fluid to meet pressure-
drop limitations and LMTD requirements.

Fig- Double pipe heat exchanger (hair-pin)

Applications -: The major use of double-pipe exchangers is for sensible heating or
cooling of the process fluid where small heat transfer areas (typically up to 50 m.) are
required. They may also be used for small amounts of boiling or condensation on the
process fluid side. The advantages of the double-pipe exchanger are largely in the
flexibility of application and piping arrangement, plus the fact that they can be erected
quickly from standard components by maintenance crews.
Types of Double Pipe Heat Exchanger-
1) Straight tube heat exchangers- It consists of two coaxial pipes,is simple
to fabricate and relatively easy to clean, maintain or modify.However, it takes up a lot
of space and single units have limited thermal capacity.Heat exchangers of this types
are sometimes made “in house” for specific small scale applications,but most double
pipe heat exchangers are purchased from specialist manufacturers who provide a wide
range of designs, including straight tubes,U-tubes and multiple units.

2) Hairpin or U-tube heat exchangers: Units of this types are designed so

that the U-tube can be withdrawn from the shells for cleaning and maintainance.
There is a removable shell cover at the U-bend and a bolted flange.The tube is held by
a split ring, that can be extracted after unbolting the flange to allow the tube to slide
through the shell in the direction of the U-bend or tail end.The sealing ring between
the tube and the shell is normally made from a compressible metal,however other
metals are used when corrosive fluids are involved.(Guy,1983)
 3) Multitube Units- In this,the tubes pass through and are sealed into a
perforated plate,called a tube sheet, at the head end.For low pressure applications the
tube sheet is sealed by a single compressible ring that prevents leakage of the tube-
amd shell-side fluids, in an arrangement called a unihead.For high pressures,separated
heads are employed.(Guy 1983) When the pressure drop available for driving the
cold fluid is limited then parallel/series arrangement may be adopted.The
conventional log mean temperature difference used to calculate the performance of
one double pipe heat exchanger is not applicable to the parallel/series arrangement.

4) Double pipe heat exchangers with longitudinal fins-Fins are formed from a strip
metal, fabricated in the shape of a U and usually attached to the tube by spot
welding.Commonly used fin materials are carbon steel,stainless steel and alloys. Fins
made from brass or similar materials are usually soldered to copper,nickel or
aluminium tubes.They have limited temperature range and are not normally used used
above 250°c.
  Advantages of Double Pipe Heat Exchangers-
1) Simplicity of construction- In applications that requires only a relatively small
heat rating(<1000kW) and where heat transfer enhancement is not necessary,a double
pipe heat exchanger with plain tubes may be advantageous because of simplicity of
construction.
2) Ease of Access for maintenance- The sealing of double-pipe heat exchangers is
achieved by means of flanged joints and sealing rings. This allows the inner pipes to
be disconnected from the shells and withdrawn for cleaning, an advantages that
applies both to plain and finned tubes.
3) Countercurrent Flow – It permits pure countercurrent heat exchange in which the
cold fluid can be heated to a temperature above that of the hot fluid at exit.This
eliminates the restriction of “temperature approach” or “temperature cross”that
applies to concurrent ,or multipass systems.
4) Feasibility of finned tubes- The double pipe heat exchanger is particularly suitable
for the application of extended surface heat transfer enhancement in the form of
fins.Fins are used when the shell side heat transfer coefficient is poor.This may occur
when the fluid on the shell-side is a gas or a high-viscosity liquid.
5) High pressure applications- For a given duty, a series of double pipe heat
exchangers will require much smaller shell diameters(50-200mm) than the equivalent
shell and tube exchanger.Because of this ,the shell wal thickness is much smaller,and
for high pressure applications this may be a significant factor in determining the cost
and even feasibility.
  Components of double pipe heat exchanger
1) Packing & gland-
The packing and gland provides sealing to the annulus and support the inner pipe.
2) Return bend-
The opposite ends are joined by a U-bend through welded joints.
3) Support lugs-
Support lugs may be fitted at these ends to hold the inner pipe position.
4) Flange-
The outer pipes are joined by flanges at the return ends in order that the assembly
may be opened or dismantled for cleaning and maintenance.
5) Union joint-
For joining the inner tube with U-bend.

 Design Constraints-

1. Cost – to have an exchanger that costs the least.

2. Efficiency – to have an exchanger that operates most efficiently, with
minimum loss of energy in the transfer, and minimum drop in pressure of the
fluids.
3. Space –to have an exchanger that is small.
4. Materials –an exchanger built from materials that are compatible with the
process streams and don’t cost a lot.
5. Maintenance – an exchanger that can be easily cleaned.
6. Ease of Construction
  Flow sheet of parameters-

Step 1: Basics
Available Methods: Logarithm Mean Temperature Difference Method or
NTU Method

1)LMTD
• Inlet and Exit Temperatures
• Calculate ΔTln
• Calculate Fouling factor if necessary
• Calculate Heat transfer coefficient
• Q= UA ΔTln

NTU method
• Inlet Temperatures are needed
• Calculate Cmax & Cmin
• Qmax = (Tmax – Tmin)Cmin
• Calculate Effectiveness using appropriate expression
• Q= ε*Qmax
 Step 2: Piping Configuration
-Division of HE in six different zones (graphix add)
-Calculation of total no. of pipes in each region
- Tube Dimensions
- Optimally transverse pitch (St) to outer diameter (OD) ratio is 1.25 – 1.5 (1.5
for 1st Iteration)
- Linear Configuration or Staggered.
- 60o for maximum density.
Total no. of pipes can now be calculated

Table- Piping configuration

Step 3: Calculation of Reynolds No.

Reynolds No. = Critical Length * V (max.) / Kinematic Viscosity
For Inside the tubes:
a) Q is known and total no. of tubes is known
b) Inner cross-section area through BWG
c) V (max) is calculated
d) Critical length is inner diameter
For outside the tubes:
a) Q=A x V
b) Area is approx. to be consist of 1/6th of total length of Heat Exchanger i.e. 0.4m
(Region 1). So total area is 0.4m * 2.25m
c) Q can be obtained from fan calculations

Step 4: Nusselt No
Laminar or Turbulent (Different for Inside and outside flow)
Flow inside the tube
- Laminar Flow (Re < 10,000)
Nu = constant= 3.66 or 4.36
- Turbulent Flow (Re >= 10,000)
Gnielinski equation,

F is Darcy’s friction factor given as,

Step 5: Calculate Total Resistance and hence total no. of transfer units (NTU)
Total resistance (R x Total no. of Tubes in region)

Step 6: Evaluate Effectiveness, Q(maximum), Q(actual) and Outlet Temperature

Qmax= Cmin(Thin - Tcin)
Q = Qmax x ε
= Chot(Thin - Thout)
= Ccold (Tcout - Tcin
Step 7: Fin Selection-
• Fin Analyzed: Circular
• €=(Fin height+0.5*Fin Thickness)*Sqrt(Convection Heat Transfer Coeff./Fin
Material’s thermal conductivity*Fin Thickness)
• Total heat capacity=(Efficiency*Fin Surface Area*No. of fins in that region+
Ext. surface area-Area no fin*No. of fins in that region)*Temp. Diff. in that
region*Convection heat transfer Coeff. *Pipes in Cross Flow
The Design Procedure-
1) Calculate the log mean driving force, LMTD.
2) Select the diameters of the inner and outer pipes.If the allowable pressure
drops for the individual streams are given,they may provide a basis for
selection of the pipe diameters.
3) Calculate the inner fluid Reynolds number; estimate the heat transfer
coefficient hi from the Dittus-Boelter equation.
Nu = hidi/k = 0.023(Re)0.8(Pr)0.3
4) Calculate the Reynolds number of the outer fluid flowing through the
annulus.Use the equivalent diameter of the annulus.Estimate the outside heat
transfer coefficient ho using the equation or the chart mentioned above.
5) Calculate the clean overall heat transfer coefficient; calculate the design
overall coefficient Ud using a suitable value of the dirt factor.
6) Calculate the heat transfer area A(for a counter flow double-pipe exchanger
LMTD correction factor, F=1 Determine the length of the pipe that will
provide the required heat transfer area.If the length is large use a number of
hairpins in series.
7) Calculate the pressure drop of the fluids.Use the Reynolds number
calculated above to determine the friction factor.
Pressure drop calculations-

1)Tube-side pressure drop-

fGt2 Ln
Pt 
2 g t d i  t
where,

f = friction factor

Gt = mass velocity of the fluid

L = length of the tube, m

g =9.8m/s2

pt = density of tube fluid

di= inside diameter of tube

n =the number of tube passes

Φt = dimensionless viscosity ratio

∆Pt =pressure drop

Φt=(viscosity at bulk temperature/viscosity at wall temperature)^m

where m=0.14 for Re > 2100 and m= 0.25 for Re < 2100
 In a multi-pass exchanger, in addition to frictional loss the head loss known as
return loss has to be taken into account.

The pressure drop owing to the return loss is given by-

V 2 
Pr  4n   t
 2g 

Where,

n=the number of tube passes

V=linear velocity of the tube fluid

The total tube-side pressure drop is

2)Shell-side pressure drop-

For an unbaffled shell the following equation may be used

fGs2 LN
Ps 
2 g t d i  s
Where,

L=shell length, m

N=number of the shell passes

ps=shell fluid velocity, m/s

Gs=shell-side mass velocity, kg/m2 s

DH=hydraulic diameter of the shell, m

Φs=viscosity correction factor for the shell-side fluid

 CONCLUSION

• A double pipe heat exchanger is one of the simplest form of Heat Exchangers.
• The wall of the inner pipe is the heat transfer surface.
• The major use of these Heat Exchanger is sensible cooling or heating
applications.
• But Very long, even for moderate capacities.
• Unviable to accommodate in an industrial space.
• To make a Unit Isotropically Compact, the arrangement is made in Multiple
Times and Continuous Series and Parallel flow.
General design considerations are routing of fluids and the suitability of the
calculated area of heat transfer and other important parameters like baffles
arrangement to meet with the maximum pressure loss requirement in shell-an-tube
heat exchanger.
REFERENCES

1. “Double pipe heat exchanger”;G.F.Hewitt, G.L.Shires, T.R.Bott; “Process Heat

Transfer” ;2000
2. http://en.wikipedia.org/wiki/Heat_exchanger
3.http://www.sciencedirect.com/science?_ob=ArticleListURL&_method=list&_Arti
cleListID=373745940&_sort=r&_st=13&view=c&_acct=C000228598&_version=1
&_urlVersion=0&_userid=10&md5=7bc37ed668db15f46c705bc7a40bcd26&search
type=a
4.Standards of Tubular Exchanger Manufacturers,TEMA,New York;6th
edition;A.R.Guy(1978)
5.Holman, J.P. 2002. Heat transfer. 9th ed., McGraw Hill, New York, NY, USA, pp. 553-
565.
6. Timothy J. Rennie and Vijaya G.S. Raghavan, 2005, “Experimental
studies of a double-pipe heat exchanger,” Experimental Thermal
and Fluid Science, vol. 29, 919–924.
.