Heat Transfer

MEC 3609 / MEC 2303

Semester II
2009/2010

Heat Exchangers

Lecture (25)

Heat Transfer (MEC 3609 / MEC 2303) 1

Dr. Raed Kafafy
Types of Heat Exchangers

Different heat transfer applications

require different types of hardware
and different configurations of heat
transfer equipment.

What should we choose?

Heat Transfer (MEC 3609 / MEC 2303)

Dr. Raed Kafafy
Double-Pipe Heat Exchangers

• The simplest type of heat exchanger is called

the double-pipe heat exchanger.
• One fluid flows through the smaller pipe while
the other fluid flows through the annular space
between the two
pipes.
• Two types of flow
arrangement
– parallel flow,
– counter flow.

Heat Transfer (MEC 3609 / MEC 2303)

Dr. Raed Kafafy
Compact Heat Exchanger

Large heat transfer surface area per unit volume.

Area density b ─ heat transfer surface of a heat
exchanger to volume ratio.
Compact heat exchanger b >700 m2/m3.
Examples:
car radiators (b ≈1000 m2/m3),
glass-ceramic gas turbine heat
exchangers (b ≈6000 m2/m3),
the regenerator of a Stirling
engine (b ≈15,000 m2/m3), and
the human lung (b ≈20,000 m2/m3).

Heat Transfer (MEC 3609 / MEC 2303)

Dr. Raed Kafafy
 Compact heat exchangers are commonly used in
gas-to-gas and
gas-to liquid (or liquid-to-gas) heat exchangers.
Typically cross-flow configuration ─ the two fluids move perpendicular
to each other.
The cross-flow is further classified as
unmixed flow
and
mixed flow.

Heat Transfer (MEC 3609 / MEC 2303)

Dr. Raed Kafafy
Shell-and-Tube Heat Exchanger
The most common type of heat exchanger in industrial applications.
Large number of tubes are packed in a shell with their axes parallel
to that of the shell.
The other fluid flows outside the tubes through the shell.
Baffles are commonly placed in the shell.
Shell-and-tube heat exchangers are relatively large size and weight.
Shell-and-tube heat
exchangers are further
classified according to
the number of shell and
tube passes involved.

Heat Transfer (MEC 3609 / MEC 2303)

Dr. Raed Kafafy
Plate and Frame Heat Exchanger

Consists of a series of plates with corrugated flat flow

passages.
The hot and cold fluids flow in alternate passages
Well suited for liquid-to-liquid heat exchange
applications, provided that
the hot and cold fluid
streams are at about the
same pressure.

Heat Transfer (MEC 3609 / MEC 2303)

Dr. Raed Kafafy
The Overall Heat Transfer Coefficient
A heat exchanger typically involves two flowing fluids
separated by a solid wall.
Heat is transferred
from the hot fluid to the wall by
convection,
through the wall by conduction, and
from the wall to the cold fluid by
convection.
The thermal resistance network
two convection and
one conduction resistances.

Heat Transfer (MEC 3609 / MEC 2303)

Dr. Raed Kafafy
 For a double-pipe heat exchanger, the thermal resistance
of the tube wall is
ln  D0 Di 
Rwall 
2 kL
The total thermal resistance

1 ln  D0 Di  1
Rtotal  Ri  Rwall  Ro   
hi Ai 2 kL ho Ao
When one fluid flows inside a circular
tube and the other outside of it, we have

Ai   Di L ; Ao   Do L

Heat Transfer (MEC 3609 / MEC 2303)

Dr. Raed Kafafy
 It is convenient to combine all the thermal resistances
in the path of heat flow from the hot fluid to the cold
one into a single resistance R
T
Q
  UAT  U i Ai T  U o Ao T
R
U is the overall heat transfer coefficient, whose unit is
W/m2ºC.
Canceling T, Eq. 11–3 reduces to
1 1 1 1 1
  R  Rwall 
UAs U i Ai U o Ao hi Ai ho Ao

Heat Transfer (MEC 3609 / MEC 2303)

Dr. Raed Kafafy
 When the wall thickness of the tube is small and the thermal
conductivity of the tube material is high (Rwall = 0) and the inner
and outer surfaces of the tube are almost identical (Ai ≈ Ao ≈ As),
we get
1 1 1
 
U hi ho

1 1
When hi>>ho 
U ho

When hi<<ho 1 1

U hi

Heat Transfer (MEC 3609 / MEC 2303)

Dr. Raed Kafafy
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.
The fouling factor Rf : The net effect of these
accumulations on heat transfer.
Two common type of fouling:
precipitation of solid deposits in a
fluid on the heat transfer surfaces.
corrosion and other chemical fouling.

Heat Transfer (MEC 3609 / MEC 2303)

Dr. Raed Kafafy
 The overall heat transfer coefficient needs to be
modified to account for the effects of fouling on both
the inner and the outer surfaces of the tube.
For an unfinned shell-and-tube heat exchanger, it can
be expressed as
1 R f ,i ln  D0 Di  R f ,o 1
R    
hi Ai Ai 2 kL Ao ho Ao

Rf,i and Rf,o are the fouling factors at those surfaces.

Heat Transfer (MEC 3609 / MEC 2303)

Dr. Raed Kafafy
The Heat Exchanger Problem
Two different design tasks:
1) Specified:
- the temperature change in a fluid stream, and
- the mass flow rate.
Required:
- the designer needs to select a heat exchanger.
Method:
- the log mean temperature difference (or LMTD)

2) Specified:
- the heat exchanger type and size,
- fluid mass flow rate,
- inlet temperatures.
Required:
- the designer needs to predict the outlet temperatures and heat
transfer rate.
Method:
- the effectiveness–NTU method

Heat Transfer (MEC 3609 / MEC 2303)

Dr. Raed Kafafy
Common Assumptions
The analysis of heat exchangers can be greatly simplify
by making the following assumptions, which are
closely approximated in practice:
steady-flow,
kinetic and potential energy changes are negligible,
the specific heat of a fluid is constant,
axial heat conduction along the tube is negligible,
the outer surface of the heat exchanger is perfectly insulated.
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.

Heat Transfer (MEC 3609 / MEC 2303)

Dr. Raed Kafafy
Rate of Heat Transfer
The transfer rate to the cold fluid:
Q  m c c pc  Tc ,out  Tc ,in   Cc  Tc ,out  Tc ,in  ; Cc  m cc pc

The transfer rate to the hot fluid:

Q  m h c ph  Th ,in  Th ,out   Ch  Th ,in  Th ,out  ; Ch  m hc ph

Heat Transfer (MEC 3609 / MEC 2303)

Dr. Raed Kafafy
The Log Mean Temperature Difference Method

The temperature difference between the hot and cold

fluids varies along the heat exchanger.
 it is convenient to have a mean temperature
difference Tm for use in the relation

Q  UAs Tm
Consider the parallel-flow, double-pipe heat exchanger.

Heat Transfer (MEC 3609 / MEC 2303)

Dr. Raed Kafafy
 Q  UAs Tlm
T1  T2
Tlm 
ln  T1 T2 
DTlm is the log mean temperature difference.
DT1 and DT2 are the temperature difference between the two fluids at
the two ends
(inlet and outlet).
It makes no difference which
end of the heat exchanger is
designated as the inlet or the
outlet.

Heat Transfer (MEC 3609 / MEC 2303)

Dr. Raed Kafafy
Counter-Flow Heat Exchangers
The relation already given for the log
mean temperature difference for
parallel-flow heat exchanger can be used
for a counter-flow heat exchanger.
DT1 and DT2 are expressed as
shown in the figure.
DTlm, CF > DTlm, PF
A smaller surface area (a smaller heat
exchanger) is needed to achieve a specified
heat transfer rate in a counter-flow heat
exchanger.

Heat Transfer (MEC 3609 / MEC 2303)

Dr. Raed Kafafy
Multipass and Cross-Flow Heat Exchangers: Use of a
Correction Factor
The log mean temperature difference relation developed
earlier is limited to parallel-flow and counter-flow heat
exchangers only.
To simplify the analysis of cross-flow and multipass shell-
and-tube heat exchangers, it is convenient to express the log
mean temperature difference relation as

F is the correction factor, and DTlm, CF is the log mean

temperature for counter-flow case.

Tlm  F Tlm,CF

Heat Transfer (MEC 3609 / MEC 2303)

Dr. Raed Kafafy
F Charts for Common Shell-and-Tube and Cross-Flow
Heat Exchangers.

Shell and Tube Heat Cross Flow Heat Exchanger

Exchanger

Heat Transfer (MEC 3609 / MEC 2303)

Dr. Raed Kafafy
Selection of Heat Exchangers

An engineer going through catalogs of heat exchanger

manufacturers will be overwhelmed by the type and
number of readily available off-the-shelf heat
exchangers.
The proper selection depends on several factors:
heat transfer rate
Cost: procurement, maintenance, and power.
pumping power,
size and weight,
Type,
Materials,
miscellaneous (leak-tight, safety and reliability, Quietness).

Heat Transfer (MEC 3609 / MEC 2303)

Dr. Raed Kafafy