AME 365 Heat Transfer & Combustion (UNIT 5)

UNIT 6: HEAT EXCHANGERS
LEARNING OBJECTIVES
After studying this unit you should be able to:
 Classify the different types of heat exchangers
Understand the importance of the overall heat transfer coefficient in
heat transfer rate analysis.
Analyse heat exchanger problems using the logarithmic mean
temperature difference (LMTD) and the effectiveness- NTU methods.
Analyse the performance of heat exchangers under designed and off-
design conditions.
UNIT CONTENT
SESSION 1-6: Introduction to Heat Exchangers
Analysis of Heat Exchangers
SESSION 2-6: Logarithmic Mean Temperature Difference (LMTD)
Effectiveness-Number of Transfer Units (NTU)
Methods
PROF. F.K. FORSON; ME 366 LECTURE 8
SESSION 1-6: INTRODUCTION TO HEAT EXCHANGERS
Definition of Heat Exchangers

 Heat exchangers are devices that allow the exchange of heat between two
fluids that are at different temperatures without allowing them to mix with
each other.
 Heat transfer in a heat exchanger usually involves convection in each fluid
and conduction through the wall separating the two fluids.
 In the analysis of heat exchangers, it is convenient to work with an overall
heat transfer coefficient U that accounts for the contribution of all these
effects on heat transfer and the logarithmic mean temperature difference
LMTD, which is an equivalent mean temperature difference between the
two fluids for the entire heat exchanger.
Note:
 It must be stated that the LMTD method is best suited for determining the
size of a heat exchanger when the inlet and the outlet temperatures are
known.
 The effectiveness-NTU method is also used in heat exchanger analysis to
predict the outlet temperatures of the hot and cold fluid streams in a
specified heat exchanger.
SESSION 1-6.1: TYPES OF HEAT EXCHANGERS
 Different innovative heat exchanger designs have emerged in an attempt to match
heat transfer hardware to the heat transfer requirements.
 The simplest type of heat exchanger consists of two concentric pipes of different
diameters, as shown in Figure 77, called the double-pipe heat exchanger.
Figure 77: Different flow regimes andPROF.

associated temperature
F.K. FORSON; profiles
ME 366 in a double-pipe
LECTURE 8 heat exchanger
 One fluid in a double-pipe heat exchanger flows through the smaller pipe
while the other flows through the annular space between the two pipes.
 Two types of flow arrangement are possible in a double-pipe heat
exchanger:
 In parallel flow, both the hot and cold fluids enter the heat exchanger at
the same end and move in the same direction.
 In counter flow, on the other hand, the hot and cold fluids enter the heat
exchanger at opposite ends and flow in opposite directions.
Compact Heat Exchanger
This type is specifically to realise a large heat transfer surface area per unit
volume, of the heat exchanger.
 The ratio of the heat transfer surface area of a heat exchanger to its
volume is called the area density, β.
 A heat exchanger with β > 700m2/m3. is classified as being compact.
 Examples are the car radiator (β = 1000m2/m3) and the human lung (β =
2000m2/m3)

SESSION 1-6.1: TYPES OF HEAT EXCHANGER
Compact Heat Exchangers
 These heat exchangers enable us to achieve high heat transfer rates
between two fluids in a small volume, and are used in applications with
strict limitations on the weight and volume of heat exchangers.
 The large surface in compact heat exchangers is obtained by attaching fins
to the walls separating the two fluids.
 They are normally used in gas-to-gas and gas-to-fluid heat exchangers to
counteract the low heat transfer coefficient associated with gas flow with
increased surface area.
 In compact heat exchangers, the two fluids usually move perpendicular
to each other, and such flow configuration is called cross-flow (see Figure
78), which is further classified as mixed or unmixed flow.
 In the unmixed cases the plate fins force the fluid to flow through a
particular inter-fin spacing and prevent it from moving in the transverse
direction (e.g. car radiator).

Figure 78: Examples of different flow configurations in cross-flow heat

exchangers
 In the mixed case, fluid is free to move in the transverse direction (e.g.
flow of fluid through tubes with a second fluid flowing freely around the
tubes, see Figure 78).

Shell-and-tube Heat Exchanger
Figure 79: The schematic of a shell-and-tube heat exchanger (one-shell pass and
one-tube pass)
 The Shell-and-tube heat exchangers contain a large number of tubes packed in
a shell with their axes parallel to that of the shell.

 Heat transfer takes place as one fluid flows inside the tubes while the other
fluid flows outside the tubes through the shell.
 Baffles are commonly placed in the shell to force the shell-side fluid to flow
across the shell to enhance heat transfer and to ensure uniform spacing
between tubes.
 Such heat exchangers have headers (large flow areas at the ends where the
tube-side fluid accumulates before entering the tubes and after leaving them)
at both ends of the shell.
Note:
 Shell-and-tube heat exchangers are not suitable for use in automobile,
aircraft, and marine applications because of their relatively large size and
weight.
 Shell-and-tube heat exchangers are further classified according to the
number of shell and tube passes involved.


 Heat exchangers in which all the tubes make one U-turn in the shell, for example, are
called one-shell pass and two-tube passes heat exchangers (see Figure 80(a)).
Likewise, a heat exchanger that involves two passes in the shell and four passes in the
tubes is called a two-shell pass and four-tube pass heat exchanger (see Figure 80(b)).

Regenerative Heat Exchanger
 It involves the alternate passage of the hot and cold fluid streams through the same
flow area.
 The static-type regenerative heat exchanger is basically a porous mass that has a heat
storage capacity, such as a ceramic wire mesh. Hot and cold fluids flow through this
porous mass alternatively. Heat is transferred from the hot fluid to the matrix of the
regenerator during the flow of the hot fluid, and from the matrix to the cold fluid during
the flow of the cold fluid. Thus, the matrix serves as a temporary heat storage medium.
 The dynamic-type regenerator involves a rotating drum and continuous flow of the hot
fluid and cold fluid through different portions of the drum so that any portion of the
drum passes periodically through the hot stream, storing heat, and then through the
cold stream, rejecting this stored heat. Again the drum serves as the medium to
transport the heat from the hot to the cold fluid stream.
Note:
 Heat exchangers are often given specific names to reflect the specific application for
which they are used. For example, a condenser is a heat exchanger in which one of the
fluids gives up heat and condenses as it flows through the heat exchanger. A boiler is
another heat exchanger in which one of the fluids absorbs heat and vaporises. A
space radiator is a heat exchanger that transfers heat from the hot fluid to the
surrounding space by radiation.
SESSION 1-6.2: OVERALL HEAT TRANSFER COEFFICIENT
 A heat exchanger typically involves two flowing fluids separated by a solid wall. Any radiation
effects may usually be included in the convection transfer coefficients.
 The thermal resistance network associated with this heat transfer process involves two convection
and one conduction resistances, as shown in Figure 79.

 The total thermal resistance of the heat exchanger becomes;
1 In ro / ri  1 (6.2)
R   
hi Ai 2L h0 Ao
Where λ is the thermal conductivity of the wall material and L is the length of
the tube. Ai is the area of the inner surface of the wall that separates the
two fluids, and Ao is the area of the outer surface of the wall
 In the analysis of heat exchangers, it is convenient to combine all the thermal
resistances in the path of heat flow from the hot fluid to the cold fluid into a
single resistance R, and to express the rate of the heat transfer between the
two fluids as: Q  T  UAT  U A T  U A T (6.3)
i i o o
R
where U is the overall heat transfer coefficient, whose units is W/m 2 K.
 Cancelling ΔT , Equation 6.3 reduces to:
1 1 1 1 Inro / ri  1
  R   (6.4)
UA U i Ai U o Ao hi Ai 2L ho Ao

Note:
 UiAi = UoAo but Ui ≠ Uo unless Ai = Ao. Therefore, the overall heat transfer
coefficient U is meaningless unless the area on which it is based is specified.
This is especially the case when one side of the tube wall is finned and the
other side is not, since the surface area of the finned side is several times
that of the unfinned side.
 When the wall thickness of the tube is small and the thermal conductivity of
1 1 1
the tube material is high, the
 thermal
 resistance of the tube is negligible
(Rwall= 0) and Ui ≈ Uo and U hi ho
 When the tube is finned on one side to enhance heat transfer, the total heat
A  surface
transfer Atotal area
A finontheAfinned
unfinned
side becomes,
 (for Isothermal fins)
A   fin A fin  Aunfinned
 (for Non-Isothermal fins)

SESSION 1-6.2.1: FOULING FACTOR
 The performance of heat exchangers usually deteriorates with time as a result
of accumulation of deposits on heat transfer surfaces.
 The layer of deposits represents additional resistance to heat transfer and
causes the rate of heat transfer in a heat exchanger to decrease.

SESSION 1-6.2.1: FOULING FACTOR
The net effect of these accumulations on heat transfer is represented by a fouling
factor, Rf, which is a measure of the thermal resistance introduced by the fouling.
One type of fouling is the precipitation of solid deposits in a fluid on the heat
transfer surfaces. Hard water is the cause of this. The scales of such deposit come
off by scratching, and the surfaces can be cleaned of such deposits by chemical
treatment.
Another form of fouling, which is common in the chemical industry, is corrosion
and other chemical fouling.
The fouling factor depends on the operating temperature and the velocity of
the fluids, as well as the length of service. Fouling increases with increasing
temperature and decreasing velocity. To account for the effects of fouling, the
fouling resistance concept is introduced.
 In Equation 6.2, introducing the fouling factors at the inner at outer surfaces we
have:
1 R f ,i Inro / ri  R f ,o 1
R     (6.5)
hi Ai Ai 2L Ao ho Ao

SESSION 1-6.3: ANALYSIS OF HEAT EXCHANGERS
Assumptions:
 Heat exchangers operate for long periods of time with no change in their
operating conditions. Therefore, they are modelled as steady-flow devices, As
such, the mass flow rate of each fluid remains constant, and the fluid
properties such as temperature and velocity at any inlet or outlet remain the
same.
 The fluid streams experience little or no change in their velocities and
elevations, and thus the kinetic and potential energy changes are negligible.
 The specific heat of the fluid changes with temperature but, in a general
temperature range, it can be treated as a constant at some value with very
little loss of accuracy.
 Axial heat conduction along the tube is usually insignificant and can be
neglected.
Hence; the first law of thermodynamics requires that the rate of heat transfer
from the hot fluid be equal to the rate of heat transfer to the cold one, as;
Q  m c C pc Tc ,out  Tc ,in   m h C ph Th ,in  Th ,out  (6.6)

 In Heat exchanger analysis, it is convenient to combine the product of the
mass flow rate and the specific heat of a fluid into a single quantity. This
quantity is called the heat capacity rate and is defined as; C  m  Cp
 The heat capacity rate of a fluid stream represents the rate of heat transfer
needed to change the temperature of the fluid stream by 1o C as it flows
through the heat exchanger.
 The fluid with a large heat capacity rate will experience a small temperature
change, and the fluid with a small heat capacity rate will experience a large
temperature change.
Note:
 One of the fluids in a condenser or a boiler undergoes a phase-change
process, and the rate of heat transfer is expressed as;
Q  m h fg (6.7)
where ṁ is the rate of evaporation or condensation of the fluid and hfg is the
enthalpy of evaporation of the fluid at the specified temperature or
pressure. The heat capacity rate of a fluid during a phase-change process
must approach infinity since the temperature change is practically zero (see
Figure 80).
 In heat exchanger analysis, a condensing or boiling fluid is modelled as a fluid
whose heat capacity rate is infinity.
 That is, C = ṁCp→∞ when ΔT→0 , so that the heat transfer rate is a finite
quantity.
Figure 82: Variation of fluid temperatures in a heat exchanger when one all' the
fluid condenses or boils PROF. F.K. FORSON; ME 366 LECTURE 8
The rate of heat transfer in a heat exchanger can also be expressed in an
analogous manner to Newton's law of cooling as;
Q  UATm (6.8)
where U is the overall heat transfer coefficient, A is the heat transfer area, and
ΔTm is an appropriate average temperature difference between the two
fluids assumed constant along the entire length of the exchanger.
 The appropriate form of the mean temperature difference between the fluids
is logarithmic in nature, and its determination is presented in the next section.

SESSION 2-6.1: LOGARITHMIC MEAN TEMPERATURE DIFFERENCE (LMTD)
Parallel-flow heat exchanger

In order to develop a relation for the equivalent average temperature difference
between the fluids, consider the parallel-flow double-pipe heat exchanger, as
shown in Figure 83 below.


 The temperature difference between the hot and the cold fluids is large at inlet
of the heat exchanger but decreases exponentially toward the outlet. The
temperature of the hot fluid decrease, and that of the cold fluid increases along
the heat exchanger, but the temperature of the cold fluid can never exceed that of
the hot fluid no matter how long the heat exchanger is.
An energy balance on each fluid in a differential section of the heat exchanger
can be expressed as:
(6.9)
Solving the equation (6.9) above for dTh and dTc and taking their difference we get
 1 1 
dTh  dTc  d Th  Tc   Q   
m 
  h C ph m c C pc  (6.10)
The rate of heat transfer in the differential section of the heat exchanger can also
be expressed as:
Q  U T  T dAh c
(6.11)


Substituting Equation 6.11 this into Equation 6.10 and rearranging gives:
d Th  Tc   1 1 
 UdA   (6.12)
Th  Tc  m
  h C ph m c C pc 

Integrating from the inlet of the heat exchanger to its outlet, we obtain:
Th ,out  Tc ,out  1 1 
In  UA   (6.13)
Th ,in  Tc ,in  m C 
 h ph m c C pc 
Finally, solving Equation 6.6 for ṁcCpc and ṁhCph and substituting into Equation
6.13 gives, after some rearrangement,
 (6.14)
Q  UATlm
T1  T2
Tlm 
InT1 / T2  (6.15)


Where ΔTlm is the logarithmic mean temperature difference, which is the suitable
form of the average temperature difference for use in the analysis of heat
exchangers.
Here, ΔT1 and ΔT2 represent the temperature difference between the two fluids
at the two ends (inlet and outlet) of the heat exchanger and are defined as shown
in Figure 84(a) It makes no difference which end is designated as the inlet or the
outlet.

Counter-flow heat exchanger

The variation of fluid temperatures in a counter-flow double-pipe heat exchanger is
presented in Figure 85.

Counter -flow heat exchanger

 Note that the hot and cold fluids enter the heat exchanger from opposite ends,
and outlet temperature of the cold fluid in this case may exceed the outlet
temperature of the hot fluid. In the limiting case, the cold fluid will be heated to
the inlet temperature of the hot fluid. However, the outlet temperature of the cold
fluid never exceeds the inlet temperature of the hot fluid.
. An energy balance on each fluid in a differential section of the heat exchanger
can be expressed as:
(6.16)
Solving the equation (6.16) above for dTh and dTc and taking their difference we get
 
 1  1
dTh  dTc  d Th  Tc   Q 
m 
  h C ph m
 c C pc  (6.17)
The rate of heat transfer in the differential section of the heat exchanger can also
be expressed as:
Q  U T  T dA
h c
(6.18)


Substituting Equation 6.18 this into Equation 6.17 and rearranging gives:
d Th  Tc   1 1 
  UdA   (6.19)
Th  Tc  m
  h C ph m c C pc 

Integrating from the inlet of the heat exchanger to its outlet, we obtain:
Th ,out  Tc ,out  1 1 
In   UA   (6.20)
Th ,in  Tc ,in m  c C pc 
  h C ph m
Finally, solving Equation 6.6 for ṁcCpc and ṁhCph and substituting into Equation
6.13 gives, after some rearrangement,
 (6.21)
Q  UATlm
T1  T2
Tlm 
In T1 / T2  (6.22)


Where ΔTlm is the logarithmic mean temperature difference, which is the suitable
form of the average temperature difference for use in the analysis of heat
exchangers.
Here, ΔT1 and ΔT2 represent the temperature difference between the two fluids
at the two ends (inlet and outlet) of the heat exchanger and are defined as shown
in Figure 84(b) It makes no difference which end is designated as the inlet or the
outlet.

Note:
For specified inlet and outlet temperatures, the log mean temperature difference
for a counter-flow heat exchanger is always greater than that for a parallel-flow
heat exchanger. Thus, a smaller surface area (and thus a smaller heat exchanger) is
needed to achieve a specified heat transfer rate in the counter-flow heat
exchanger.
In counter-flow heat exchanger, the temperature difference between the hot and
the cold fluids will remain constant along the heat exchanger when the heat
capacity rates of the two fluids are equal (that is, ΔT = constant when Ch = Cc).
Then, we have ΔT1 = ΔT2 and the log mean temperature difference relation
above gives ΔTlm=0/0 , which is indeterminate. In this case, we have ΔTlm =ΔT1
=ΔT2
A condenser or boiler can be considered to be either a parallel- or counter-flow

heat exchanger since both approaches give the same result.
MULTI PASS AND CROSS FLOW HEAT EXCHANGERS
(The Use of a Correction Factor, F)
In such cases, it is convenient to relate the equivalent temperature difference to
the log mean temperature difference relation for the counter-flow case as:
Tlm  FTlm ,CF (6.23)
where F is the correction factor, which depends on the geometry of the heat exchanger
and the inlet and outlet temperatures of the hot and cold fluid streams.

MULTI PASS AND CROSS FLOW HEAT EXCHANGERS
(The Use of a Correction Factor, F)
The correction factor is less than unity for a cross-flow and multi-pass shell-and-
tube heat exchanger. Thus, the correction factor is a measure of deviation of the
log mean temperature from the corresponding values of the counter-flow case.
The correction factor F for common cross-flow and shell-and-tube heat exchanger
configurations is given in Figure 87 versus two temperature ratios defined as:
t t T1  T2 m C p tube side

P 2 1 and R   (6.24)
T1  t1 t 2  t1 m C p shell side
where the subscripts 1 and 2 represent the inlet and outlet, respectively.
Note that for the shell-and-tube heat exchanger, T and t represent the shell- and
tube-side temperatures, respectively, as shown in the correction factor charts. The
determination of the correction factor F requires the availability of the inlet and
outlet temperatures for both the cold and hot fluids.
Note that the value of P ranges from 0 to 1. The value of R ranges from 0 (for
phase change condition on shell side) to infinity (phase change on the tube side).
The correction factor for a condenser or boiler is unity regardless of the
configuration of the heat exchanger.
Correction Factor, F Charts for common shell-and tube and
cross flow heat exchangers

Correction Factor, F Charts for common shell-and tube and
cross flow heat exchangers

Worked Example 6.1: Heating Water in a Counter-
Flow Heat Exchanger
Question
A counter-flow double-pipe heat exchanger is to heat water from 20 oC to 80 oC at
a rate of 1.2 kg/s. The heating is to be accomplished by geothermal available at
160oC at a mass flow rate of 2 kg/s. The inner tube is thin-walled and has a
diameter of 1.5 cm. If the overall heat transfer coefficient of the heat exchanger is
640 W/m2.oC, determine the length of the heat exchanger required to achieve the
desired heating.
Solution: Water is heated in a counter-flow double-pipe heat exchanger by

geothermal water. The required length of the heat exchanger is to be determined.
Flow Heat Exchanger
Assumptions:
(1) Steady operating conditions exist.
(2) The heat exchanger is well insulated so that heat loss to the surroundings is
negligible and thus heat transfer from the hot fluid is equal to heat transfer to the
cold fluid.
(3) Changes in the kinetic and potential energies of the fluid streams are negligible.
(4) There is no fouling.
(5) Fluid properties are constant.
Properties:
Specific heats of water and geothermal fluid are 4.18 and 4.31 kJ/kg.oC,
respectively.
Analysis:
The rate of heat transfer in the heat exchanger can be determined from:
 
Q  m C p (T0ut  Tin ) water  (1.2 kg/s)(4.18 kJ/kg o C)(80  20) o C  301.0 kW

Flow Heat Exchanger
Analysis:
Noting that all of this heat is supplied by the geothermal water, the outlet
temperature of the geothermal water is determined to be:
Q

Q  m C p (Tin  Tout ) 
geothermal
 Tout  Tin 
m C p
301.0 kW
 160 o C   125.10 C
(2 kg/s)(4.31 kJ/kg C)
o
Knowing the inlet and outlet temperatures of both fluids, the logarithmic mean
temperature difference for this counter-flow heat exchanger becomes:
T1  Th ,in  Tc ,out  (160  80) o C  80 o C
T1  T2 (80  105.1) o C
Tlm    92 o C
T2  Th ,out  Tc ,in  (125.1  20) o C  105.1o C In (T1 / T2 ) In (80/105.1)
Then, the surface area of the heat exchanger is determined to be:
Q 301,000 W 5.11m 2
Q  UATlm  A    5.11 m 2 A  DL  L
A
  108.4 m
UTlm (640 W/m  C)(92 C)
2 o o
D π(0.015m)
Discussion: The inner tube of this counter-flow heat exchanger (and thus the heat
exchanger itself) needs to be over 100 m long to achieve the desired heat transfer,
which is impractical. PROF. F.K. FORSON; ME 366 LECTURE 8
Worked Example 6.2: Heating of Glycerin in a Multi-pass
Heat Exchanger
Question
A 2-shell passes and 4-tube passes heat exchanger is used to heat glycerin from 20
o
C to 50oC by hot water, which enters the thin-walled 2-cm-diameter tubes at 80 oC
and leaves at 40 oC .The total length of the tubes in the heat exchanger is 60 m. The
convection heat transfer coefficient is 25 W/m2.oC on the glycerin (shell) side and
160 W/m2.oC on the water (tube) side. Determine the rate of heat transfer in the
heat exchanger (a) before any fouling occurs and (b) after fouling with a fouling
factor or 0.0006 m2.oC/W occurs on the outer surfaces of the tubes.
Solution: Glycerin is heated in a 2-shell passes and 4-tube passes heat exchanger by hot
water. The rate of heat transfer for the cases of fouling and no fouling is determined.
Worked Example 6.2: Heating of Glycerin in a Multi-pass
Heat Exchanger
Assumptions:
cold fluid.
(4) Heat transfer coefficients and fouling factors are constant and uniform.
(5) The thermal resistance of the inner tube is negligible since the tube is thin-
walled and highly conductive.
Analysis:
The tubes are said to be thin-walled, and thus it is reasonable to assume the inner
surface area of the tubes to be equal to the outer surface area. Then the heat
transfer surface area of this heat exchanger becomes:
A  DL  π(0.02 m)(60 m)  3.77 m 2
The rate of heat transfer in this heat exchanger can be determined from:
Q  UAFTlm,CF
Worked Example 6.2: Heating of Glycerin in a Multi-pass Heat
Exchanger
Analysis:
These quantities are determined from:
T1  Th ,in  Tc ,out  (80  50) o C  30 o C
T1  T2 (30  20) o C
T2  Th ,out  Tc ,in  (40  20) o C  20 o C Tlm,CF    24.7 o C
In (T1 / T2 ) In (30/20)
t 2  t 1 40  80 
P   0.67 
T1  t 1 20  80 
F  0.90 (Figure 87b)
T1  T2 20  50
R   0.75
t 2  t1 40  80 

(a) In the case of no fouling, the overall heat transfer coefficient U is determined
from:
1 1
U    21.6 W/m 2  o C
1 1 1 1
 
hi ho 160 W/m 2  o C 25 W/m 2  o C
Then the rate of heat transfer becomes:
Q  UAFTlm,CF  (21.6 W/m 2 o C)(3.77 m 2 )(0.90)(24.7 o C)  1810 W

Worked Example 6.2: Heating of Glycerin in a Multi-pass Heat
Exchanger
Analysis:
 When there is fouling on one of the surfaces, the overall heat transfer
coefficient U is determined from:
1 1
U   21.3 W/m 2 o C
1 1 1 1
  Rf   0.0006 m 2 o C/W
hi ho 160 W/m  C 25 W/m  C
2 o 2 o
Then the rate of heat transfer becomes:

  UAFT
Q  (21.3W/m 
2 o
C)(3.77 m 2
)(0.90)(24.7 o
C)  1785 W
lm ,CF
Discussion: Note that the rate of heat transfer decreases as a result of fouling, as
expected. The decrease is not dramatic, however, because of the relatively
low convection heat transfer coefficients involved.

SESSION 2-6.2: THE EFFECTIVENESS – NTU METHOD
Recap of LMTD
 The log mean temperature difference (LMTD) is easy to use in heat
exchanger analysis when the inlet and the outlet temperatures of the hot
and cold fluids are known or can be determined from an energy balance.
 With the LMTD method, the task is to select a heat exchanger that will
meet the prescribed heat transfer requirements. The procedure to follow
in the selection process is as follows:
a. Select the type of heat exchanger suitable for the application.
b. Determine any unknown inlet and outlet temperature and the heat
transfer rates using an energy balance.
c. Calculate the log mean temperature difference and the correction factor, if
necessary.
d. Obtain (select or calculate) the value of the overall heat transfer coefficient
U.
e. Calculate the heat transfer surface area A.
The task is completed by selecting a heat exchanger that has a heat transfer
surface area equal to or larger than A.
 A second kind of problem encountered in heat exchanger analysis is the

determination of heat transfer rate and the unknown outlet
temperatures of both the hot and cold fluids for prescribed fluid mass flow
rates and inlet temperatures when the type and size of the heat exchanger
are specified. The effectiveness-NTU method is employed conveniently in
this case.
 This new method is based on a dimensionless parameter called the heat
transfer effectiveness ε , defined as:
Q Actual heat transfer rate

   (6.25)
Qmax Maximum possible heat transfer rate
 The actual heat transfer rate in a heat exchanger can be determined from
an energy balance on the hot or cold fluid streams and can be expressed
as,    
Q  C c Tc ,out  Tc ,in  C h Th ,in  Th ,out
(6.26)

ALTERNATIVE DEFINITION of Heat Transfer Effectiveness Ε
 The maximum temperature difference in a heat exchanger is the
difference between the inlet temperatures of the hot and cold fluids.
Determine Cmin and Cmax

i.e. Cmin = min of and and Cmax = max of and
The fluid with Cmin Is called minimum fluid and find ()
The fluid with Cmax is called maximum fluid and find ()
You can determine the effectiveness of the heat exchanger in

Problem 8 using this approach
Note:
 It must be noted that the heat transfer in a heat exchanger will reach its
maximum value when (1) the cold fluid is heated to the inlet temperature
of the hot fluid or (2) the hot fluid is cooled to the inlet temperature of the
cold fluid.
 These limiting conditions will not be attained unless the heat capacity rates of the
two fluids are identical (i.e. Cc = Ch). When Cc ≠ Ch, the fluid with the smaller heat
capacity rate will experience the maximum temperature, at which heat transfer
will come to a halt.
Figure 90: Counter flow heat exchanger

 Therefore, the maximum possible heat transfer rate in a heat exchanger is

(see Figure 90 above);
Q  C T T
max min  h ,in c ,in 
(6.27)
 Thus, once the effectiveness is known, the actual heat transfer rate can be
evaluated from the relation:
Q  Q max  C min Th ,in  Tc,in 

(6.28)
 In this way, the heat transfer can be determined without knowing the
outlet temperatures of the fluids. The effectiveness depends on the
geometry of the heat exchanger as well as the flow arrangement.

Parallel flow in double-pipe heat exchanger

 Rearranging equation (6.13), developed for a parallel-flow heat exchanger,
we obtain;
 Th ,out  Tc ,out   C  (6.29)
In    UA 1  c 
T  T  C  C 
 h ,in c ,in  c  h 
 Also, solving Equation 6.6 for Th,out gives:

Cc
Th ,out  Th ,in  Tc ,out  Tc ,in  (6.30)
Ch
Substituting this into equation (6.29), after adding and subtracting Tc,in gives:
Cc
Th,in  Tc ,in  Tc ,in  Tc ,out  Tc,out  Tc,in 
Ch UA  C c  (6.31)
In   1  
Th,in  Tc ,in Cc  Ch 
which simplifies to:
  Cc  Tc ,out  Tc ,in  UA  C c 
In 1  1      1  
(6.32)
  C h  Th ,in  Tc ,in  Cc  Ch 

 But, Q C T T T T     C
 
c c ,out c ,in

c ,out c ,in

min
Q max C min Th,in  Tc ,in  T

h ,in  Tc ,in  C c
(6.33)
Substituting this result into Equation 6.32, and solving for gives the following
relation for the effectiveness of a parallel-flow heat exchanger:
 UA  C 
1  exp  1  c 
 Cc  Ch  (6.34)
 parallel  flow 
 C C
1  c  min
 C h  Cc
Taking either Cc or Ch to be Cmin (both approaches the same result), the
relation can be expressed more conveniently as:
 UA  C min 
1  exp  1  
 C min  C max  1  exp NTU 1  C  (6.35)
 parallel  flow  
 C min  1 C
1  
 C max 

 Effectiveness relations involve the dimensionless group, UA / C min
 This quantity is called the number of transfer units (NTU) and is expressed
as: UA UA
NTU  
Cmin mC 
p min
(6.36)
 Note that the NTU is proportional to A. For specified values of U and Cmin,
the NTU is a measure of the heat transfer surface area A. Thus, the larger
the NTU, the larger the heat exchanger. The effectiveness is a function of
the number of transfer units (NTU) and the capacity ratio C (i.e. Cmin /
Cmax).
 The effectiveness of some common types of heat exchangers are plotted in

Figure 91. Effectiveness relations have also been developed for a large
number of heat exchangers, and the results are given in Table 14. Table 15
gives NTU directly when the effectiveness is known.
Table 14: Effectiveness Relations for heat exchangers

Table 14: Effectiveness Relations for heat exchangers
Applicable to Condensers, Boilers, and Evaporators

Table 15: NTU Relations for heat exchangers
Applicable to Condensers, Boilers,

and Evaporators

Figure 91: Effectiveness of some common types of heat exchangers



Worked Example 6.3: Cooling Hot Oil by Water in a Multi-pass Heat Exchanger
Question:
 Hot oil is to be cooled by water in a 1-shell-pass and 8-tube-passes heat
exchanger. The tubes are thin-walled and are made of copper with an
internal diameter of 1.4 cm.
 The length of each tube pass in the heat exchanger is 5 m, and the overall
heat transfer coefficient is 310 W/m2.oC. Water flows through the tubes at
a rate of 0.2 kg/s, and the oil through the shell at a rate of 0.3 kg/s. The
water and the oil enter at temperatures of 20 oC and 150 oC, respectively.
 Specific heats of water and oil are to be assumed as 4.18 and 2.13 kJ/kg. oC,
respectively. Determine the rate of heat transfer in the heat exchanger and
the outlet temperatures of the water and the oil.
Solution:
Hot oil is to be cooled by water in a heat exchanger. The mass flow rates and
the inlet temperatures are given. The rate of heat transfer and the outlet
temperatures are to be determined.

Figure 92 schematic for worked example 6.3
Assumptions:
cold fluid.
(4) The thickness of the tube is negligible since it is thin-walled.
(5) The overall heat transfer coefficient is constant and uniform.
Analysis:
 The outlet temperatures are not specified, and they cannot be determined
from an energy balance. The use of the LMTD method in this case will
involve tedious iterations, and thus the ε-NTU method is indicated. The
first step in the ε-NTU method is to determine the heat capacity rates of
the hot and cold fluids and identify the smaller one:
C h  m h C ph  (0.3kg/s)(2.13kJ/kgo C)  0.639 kW/ o C
C c  m c C pc  (0.2kg/s)(4.18kJ/kgo C)  0.836 kW/ o C
Therefore, C min  C h  0.639kW/ o C C min 0.639

C   0.764
C max 0.836
Then the maximum heat transfer rate is determined to be:
Qmax C (T  T )
min h ,in c ,in
 (0.639 kW/ o C)(150  20) o C  83.1 kW
A  n(DL)  8 (0.014m)(5m)  1.76m 2

Then the NTU of this heat exchanger becomes:

UA (310 W/m 2  o C)(1.76 m 2 )
NTU   0
 0.854
C min 639 W/ C
The effectiveness of this heat exchanger corresponding to C = 0.764

and NTU = 0.854 is determined from Figure 91 (c) to be: ε = 0.49
Alternatively, the effectiveness could be determined more accurately

from the third relation in Table 14 but with more labour.
Then, the actual rate of heat transfer becomes:
  Q

Q max  (0.49)(83.1 kW )  40.7 kW

 Finally, the outlet temperatures of the cold and the hot fluid streams are
determined to be:
Q
Q  C c (Tc ,out  Tc ,in )  Tc ,out  Tc ,in 
Cc
40.7 kW
 20 o C  o
 68.7 0
C
0.836 kW/ C
Q
Q  C h (Th ,in  Th ,out )  Th ,out  Th ,in 
Ch
40.7 kW
 150 o C  o
 86.3 0 C
0.639 kW/ C
Therefore, the temperature of the cooling water will rise from 20 oC to 68.7 oC
as it cools the hot oil from 150 oC to 86.3 oC in this heat exchanger.

Worked Example 6.4: Use of a 2-pass shell-and- tube heat exchanger to
condense a chemical
Question:
A two-pass shell-and-tube heat exchanger is used to condense a chemical on
the shell side at a rate of 50 kg/s at a saturation temperature of 80 oC. The
chemical enters as a dry saturated vapour and is not under-cooled during the
process. Water at 10 oC and a mass flow rate of 100 kg/s is available as coolant;
the velocity of the water is to be approximately 1.5 m/s. Using the data below
and taking a nominal tube diameter of 25 mm, neglecting tube wall thickness,
calculate:
The number of tubes required; The tube length; The number of transfer
units;
The effectiveness of the heat exchanger.
Data: Specific enthalpy of vaporisation of chemical, 417.8 kJ/kg; heat transfer
coefficient for shell side, 10 W/m2K; fouling factor for shell side, 0.1 m2K/kW;
fouling factor for tube side, 0.2 m 2
K/kW.
Nu  0.023(Re) (Pr) 0.4
0.8
For turbulent flow in a pipe, take
with all properties at the mean bulk temperature.

condense a chemical
Solution:
Water flows in the tubes and the chemical flow in the shell. Water is the cold
fluid while the chemical is the hot fluid.
Assumptions:
(2) The heat exchanger is well insulated so that heat loss to the surroundings
is negligible and thus heat transfer from the hot fluid is equal to heat
transfer to the cold fluid.
(3) Changes in the kinetic and potential energies of the fluid streams are
negligible.
Analysis:
Heat transferred is calculated as:
 m
Q  chem h fg , chem  (50kg/s)(417.8kJ/kg)  20,890 kW

condense a chemical
Assuming the specific heat capacity of water as 4.2 kJ/kg K, the exit temperature
of water in the tube can be determined from:
Q
Q  m w C pw (Tc ,out  Tc ,in )  Tc ,out  Tc ,in 
m w C pw
20,890 kW
 10 o C 
(100kg/s  4.2 kJ/kg  K)
 60 o C
Mean bulk temperature of water in the tube can then be obtained as:
Tc ,out  Tc ,in
10 o C  60 o C
Tb    35 o C
2 2
From page 10 of the steam tables, properties of liquid water at 35oC can be read
as:
vf = 0.001006m3/kg, μf = 718 x 10-6 kg/ms, λf = 625 x 10-6 kW/mK,
Prf = 4.80

condense a chemical
Mass flow rate of water = (number of tubes) x (mass flow rate per tube)
n p d 2V n p d 2V w
4v f m
m w  n p  AV   np 
4 4v f d 2V
From the relation above,
w
4v f m 4(0.001006m 3 /kg)(100kg/s)
np    136.6  137
d V
2 2
π(0.025m) (1.5m/s)
For the two tube passes in the shell [see Figure 88(a)], total number of tubes = 2
x 137 = 274 tubes.
From Equation 6.37, n is inversely proportional to V. Hence, for 137 tubes, the
actual velocity of water can be obtained as:
136.6
Actual water velocity  1.5m/s   1.496m/s
137

condense a chemical
Then,
Vd Vd (1.496m/s)(0.025m)
Re     51,778.5
 v f  (0.001006m /kg)(718  10 kg/ms)
3 6
The value of the Re exceeds the critical value of 2300 for flow through a tube;
hence, the flow is turbulent.
The Nusselt number can then be obtained by:
Nu  0.023(Re) 0.8 (Pr) 0.4
 0.023(51778.5) 0.8 (4.8) 0.4
 254.4
The heat transfer coefficient within the tube ht can be determined as:
ht d  625  10 6 kW/mK
Nu   ht  Nu   254.4  6.36 kW/m 2 K
 d 0.025m

condense a chemical
Then,
For Ai≈Ao , the overall heat transfer coefficient will be:
1 1 1
   R f , s  R f ,t
U hs ht
1 1
 2
 2
 0.1 m 2 K/W  0.2 m 2 K/W
10 kW/m K 6.36 kW/m K
 0.5572 m 2 K/W
U  1.7947 W/ m 2 K
The rate of heat transfer in this heat exchanger can also be expressed as:
Q  UAFTlm,CF
T1  Th ,in  Tc ,out  (80  60) o C  20 o C T1  T2 (20  70)

Tlm,CF    39.91 K
T2  Th ,out  Tc ,in  (80  10) o C  70 o C In (T1 / T2 ) In (20/70)

condense a chemical
The correction factor for a condenser or boiler is unity regardless of the

configuration of the heat exchanger; hence, F = 1.
Area required can then be computed as:
Q 20890 kW
A   291.65 m 2
UFTlm,CF 2
(1.7947 W/m K)(1)(39.91 K)
Tube length to provide the required area:

A
A  pn p  dL  L where p is the number of tube passes
pn p d
and n p is the number of tubes per pass
291.65 m 2

2  137    0.025 m
 13.55 m
The chemical will have an infinite heat capacity since it is undergoing a phase
change. Hence, Cmin will simply be the product of the mass flow rate of water and
the specific heat capacity of water.
condense a chemical
Number of Transfer Units:

AU 291.65 m 2  1.7947 W/m 2 K
NTU    1.246
C min (100 kg/s  4.2 kJ/kgK)
Effectiveness (ε) of the heat exchanger:

Q Q 
   
Qmax C min (Th ,in  Tc ,in )
20890 kW
  0.711
100 kg/s  4.2 kJ/kgK  (80 - 10) K
 71.1%

Worked Example 6.5: Single-pass multiple tubes
counter-flow shell-and-tube heat exchanger
Question:
An oil cooler consists of a single-pass, counter-flow shell-and-tube heat
exchanger with 300 tubes of internal diameter 7.3 mm and length 8 m. The oil
flows in the tube side entering at a mass flow rate of 8 kg/s at a temperature of
70oC. Cooling water in the shell side enters at a mass flow rate of 12 kg/s at a
temperature of 15oC. Using the data below, calculate:
The number of transfer units; The effectiveness of the heat exchanger and
the outlet temperature of the oil.
Data: Shell side heat transfer coefficient, 1000 W/m2K; heat transfer coefficient
for the tube side given by Nu  0.023(Re) 0.8 (Pr) 0.4
with properties as follows: specific heat capacity of oil, 3.42 kJ/kgK; density of
oil, 900 kg/m3; dynamic viscosity of oil, 1.5 x 10-3 kg/ms; thermal
conductivity of oil, 0.15 W/mK.
Solution: Two fluids exchange heat. Water flows in the shell and oil flows in the
tubes of a counter-flow shell-and-tube heat exchanger.

Worked Example 6.5: Single-pass multiple tubes counter-flow shell-and-tube
heat exchanger
Assumptions:
(2) The heat exchanger is well insulated so that heat loss to the surroundings
is negligible and thus heat transfer from the hot fluid is equal to heat
transfer to the cold fluid.
(3) Changes in the kinetic and potential energies of the fluid streams are
negligible.
Analysis:
Considering a single tube, Re  Vd but m  AV  V d
2
 oil
4
Expressing V in terms of ṁoil , ρ and d, and substituting in the expression for Re:
 oil
4m ṁoil is the mass flow rate of oil per tube. (Note: there are
Re 
d 300 tubes)

heat exchanger
4  8 kg/s
 Re  3
 3100.7
300  π  0.0073m  (1.5  10 kg/ms)
which falls in the turbulent flow regime for flow through a tube.
To determine the Prandtl number:
C p ,oil  oil
Pr 
oil
(3420 J/kgK)(1.5  10 3 kg/ms)

0.15 W/mK
 34.2
The Nusselt number can be obtained using the relation:
Nu  0.023(Re) 0.8 (Pr) 0.4

 0.023(3100) 0.8 (34.2) 0.4
 58.67

heat exchanger
But :
ht d  0.15 W/mK
Nu   ht  Nu   58.67  1205.5 W/m 2 K
 d 0.0073m
Ignoring the thickness of the tube and fouling effects, the overall heat transfer
coefficient is computed by:
1 1 1
 
U hs ht
1 1
 
1000 W/m 2 K 1205.5 W/m 2 K
 0.0018295 m 2 K/W
 U  546.6 W/m 2 K
There is the need to determine the heat capacity rates of the hot and cold
fluids and identify the smaller one:
C h  m h C ph  (8kg/s)(3.42kJ/kg  K)  27.36 kW/K
C c  m c C pc  (12kg/s)(4.20kJ/kg  K)  50.4 kW/K

heat exchanger
Therefore, C min  C h  27.36 kW/K and C  C min  27.36  0.543

C max 50.4
Then, the maximum heat transfer rate is determined to be:

Q max  C min (Th ,in  Tc ,in )
 (27.36 kW/K )(70  15)K  1504.8 kW
The heat transfer surface area is:
A  n(DL)  300 (0.0073m)(8m)  55.04m 2

Then, the NTU of this heat exchanger becomes:
UA (546.6 W/m 2  K )(55.04 m 2 )

NTU    1.1
C min 27360 W/K
The effectiveness of this heat exchanger corresponding to C = 0.543 and NTU =

1.1 is determined from Figure 91 (b) to be: ε = 0.59 (59 %)

heat exchanger
Alternatively, the effectiveness could be determined more accurately from the

second relation in Table 14 as 0.588 (58.8 %).
Then the actual rate of heat transfer becomes:
Q  Q max  (0.588)(1504.8 kW )  884.82 kW
Finally, the outlet temperature of the oil which is the hot fluid stream is
determined to be:
Q
Q  C h (Th ,in  Th ,out )  Th ,out  Th ,in 
Ch
884.82 kW
 70 C  o
 37.7 0 C
27.36 kW/K

Lecture Ends
THANK YOU
LUKE 19:13

AME 365 Heat Transfer & Combustion (UNIT 5)

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UNIT 6: HEAT EXCHANGERS

Definition of Heat Exchangers

Figure 77: Different flow regimes andPROF.

PROF. F.K. FORSON; ME 366 LECTURE 8

PROF. F.K. FORSON; ME 366 LECTURE 8

Figure 78: Examples of different flow configurations in cross-flow heat

PROF. F.K. FORSON; ME 366 LECTURE 8

PROF. F.K. FORSON; ME 366 LECTURE 8

PROF. F.K. FORSON; ME 366 LECTURE 8

Shell-and-tube Heat Exchanger

PROF. F.K. FORSON; ME 366 LECTURE 8

PROF. F.K. FORSON; ME 366 LECTURE 8

PROF. F.K. FORSON; ME 366 LECTURE 8

PROF. F.K. FORSON; ME 366 LECTURE 8

PROF. F.K. FORSON; ME 366 LECTURE 8

PROF. F.K. FORSON; ME 366 LECTURE 8

Q  m c C pc Tc ,out  Tc ,in   m h C ph Th ,in  Th ,out  (6.6)

PROF. F.K. FORSON; ME 366 LECTURE 8

Parallel-flow heat exchanger

PROF. F.K. FORSON; ME 366 LECTURE 8

Parallel-flow heat exchanger

PROF. F.K. FORSON; ME 366 LECTURE 8

Parallel-flow heat exchanger

PROF. F.K. FORSON; ME 366 LECTURE 8

Parallel-flow heat exchanger

PROF. F.K. FORSON; ME 366 LECTURE 8

Counter-flow heat exchanger

PROF. F.K. FORSON; ME 366 LECTURE 8

Counter -flow heat exchanger

PROF. F.K. FORSON; ME 366 LECTURE 8

Counter-flow heat exchanger

PROF. F.K. FORSON; ME 366 LECTURE 8

Counter-flow heat exchanger

PROF. F.K. FORSON; ME 366 LECTURE 8

A condenser or boiler can be considered to be either a parallel- or counter-flow

PROF. F.K. FORSON; ME 366 LECTURE 8

t t T1  T2 m C p tube side

PROF. F.K. FORSON; ME 366 LECTURE 8

PROF. F.K. FORSON; ME 366 LECTURE 8

Solution: Water is heated in a counter-flow double-pipe heat exchanger by

PROF. F.K. FORSON; ME 366 LECTURE 8

Q  UAFTlm,CF  (21.6 W/m 2 o C)(3.77 m 2 )(0.90)(24.7 o C)  1810 W

PROF. F.K. FORSON; ME 366 LECTURE 8

Then the rate of heat transfer becomes:

PROF. F.K. FORSON; ME 366 LECTURE 8

 A second kind of problem encountered in heat exchanger analysis is the

Q Actual heat transfer rate

PROF. F.K. FORSON; ME 366 LECTURE 9

Determine Cmin and Cmax

You can determine the effectiveness of the heat exchanger in

Figure 90: Counter flow heat exchanger

PROF. F.K. FORSON; ME 366 LECTURE 9

 Therefore, the maximum possible heat transfer rate in a heat exchanger is

Q  Q max  C min Th ,in  Tc,in 

PROF. F.K. FORSON; ME 366 LECTURE 9

Parallel flow in double-pipe heat exchanger

 Also, solving Equation 6.6 for Th,out gives:

Parallel flow in double-pipe heat exchanger

Q max C min Th,in  Tc ,in  T

Parallel flow in double-pipe heat exchanger