Chapter (6)

Heat and Mass Transfer lectures at BUE

Dr. Ahmed Abdel-Azim Ahmed
By the end of today’s lecture, you should be able to:

Learn how to deal with heat exchangers.

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 Heat exchangers are units designed to transfer heat from a hot flowing fluid
to a cold flowing fluid.

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 Construction
Function

Heat
Exchangers Flow
Classifications
arrangements
Surface
compactness

Number of
fluids

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 Heat Exchanger Types

According to flow arrangement According to type of construction

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 Simplest configuration.

 Superior performance associated with counter flow.

Parallel Flow Counterflow

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 Baffles are used to establish a cross-flow and to induce turbulent
mixing of the shell-side fluid, both of which enhance convection and to
support the tubes .
 The number of tube and shell passes may be varied.
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(a) One-shell pass and one-tube passes

(a) One-shell pass and two-tube passes

(b) Two-shell passes and four-tube passes

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 Widely used to achieve large heat rates per unit volume, particularly when
one or both fluids is a gas.
 Characterized by
large heat transfer
surface areas per unit
volume, small flow
passages, and laminar
flow.
(a) Fin-tube (flat tubes,
continuous plate fins)
(b) Fin-tube (circular
tubes, continuous plate
fins)
(c) Fin-tube (circular
tubes, circular fins)
(d) Plate-fin (single pass)
(e) Plate-fin (multipass)
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 Both fluids are One fluid mixed,
considered unmixed one fluid unmixed

 For cross-flow over the tubes, fluid motion, and hence mixing, in the transverse
direction (y) is prevented for the finned tubes, but occurs for the unfinned condition.
 Heat exchanger performance is influenced by mixing.
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• Flexible design through a variety of plate sizes and pass arrangements
• HT area easily accessible → change configuration to suit different process requirements by changing number of
plates
• Efficient HT: High HT coefficients for both fluids due to turbulence and small hydraulic diameter 22
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 Parallel-flow heat exchangers Counter flow heat exchangers

Th ,i Th ,o Th ,i Th ,o
Tc ,i Tc ,o Tc ,i
Tc ,o

Axial temperature distribution in typical single pass heat transfer matrices 31

Axial temperature distribution in a one shell pass, two tube pass heat exchanger
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Temperature distribution in a cross flow heat exchanger, both fluids are unmixed
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• A form of Newton’s Law of Cooling may be applied to
heat exchangers by using a log-mean value of the
temperature difference between the two fluids:
q  UA Tm
The temperature difference at each end of the exchanger is
calculated and combined using the following equation to
give the log mean temperature difference:
T2  T1
Tlm 
T
ln 2
T1 34
Evaluation of depends on the heat exchanger type.

Parallel-flow heat exchangers Counter flow heat exchangers

Th ,i Th ,o Th ,i Th ,o
Tc ,i Tc ,o Tc ,i
Tc ,o

Th ,i
Th ,i

Th ,o
Tc ,o Tc ,o Th ,o
Tc ,i
Tc ,i
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 T2  T1
Tlm 
T
ln 2
T1
Parallel-flow:

(Th,o  Tc ,o )  (Th,i  Tc ,i )
Tlm  LMTD 
ln[(Th,o  Tc ,o ) /(Th,i  Tc ,i )]

Counter flow:
(Th,o  Tc ,i )  (Th,i  Tc ,o )
Tlm  LMTD 
ln[(Th,o  Tc ,i ) /(Th,i  Tc ,o )]

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Cross-flow & Multi-pass (shell & tube)

Tlm cross flow  F Tlm counter flow

(Th ,o  Tc ,i )  (Th ,i  Tc ,o )
Tlm  LMTD  F
ln[(Th ,o  Tc ,i ) /(Th ,i  Tc ,o )]

F = correction factor

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F = correction factor

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• When one or more temperature value for the streams at the inlet or
outlet of the heat exchanger are NOT known, a trial and error procedure
may be needed.
• Instead, the method of number of transfer units (NTU) based on HEX
effectiveness may be used.
•The ε-NTU method is based on the fact that the inlet or exit
temperature differences of a heat exchanger are a function of UA/Cc
and Cc/Ch.
• The HEX heat transfer equations may be written in dimensionless form
resulting in some dimensionless groups.

NTU stands for “Number of Transfer Units”

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• The HEX heat transfer equations may be written in dimensionless form
resulting in some dimensionless groups.

Dimensionless groups
1. Heat capacity rate ratio:
2. HEX heat transfer
effectiveness

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Heat Capacity Rate

The heat capacity rate of a fluid stream represents the rate of heat transfer
needed to change the temperature of the fluid stream by 1°C as it flows
through a heat exchanger

For calculations of heat exchangers, we often deal with the heat capacity rate
of a fluid:
For hot fluid : Ch  m hC p ,h
For cold fluid : Cc  m cC p ,c
The heat capacity ratio
Cmin
Cr 
Cmax 41
 Heat Exchanger Effectiveness, 
qact
 0   1
qmax

where the maximum possible heat transfer rate of a heat exchanger, qmax, occurs
when we consider the maximum temperature difference, Tmax . The heat
transfer rate is defined as:
qmax  Cmin (Th,i  Tc,i )
Where:
Cmin = Ch , if Ch < Cc
Cmin = Cc , if Ch > Cc
the actual heat transfer rate of an exchanger as:

qact   Cmin (Th,i  Tc,i )

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The “Number of Transfer Units” (NTU) is a dimensionless group defined as:

UA
NTU 
Cmin

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 Effectiveness can also be expressed as a function of (NTU) where:

(B) Effectiveness for heat exchangers as a function of (NTU) (Mathematical Correlations)

Example – Concentric tube (double piped)

Parallel Flow:

Counter Flow:

where, Cr is the heat capacity ratio

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(B) Effectiveness for heat exchangers as a function of (NTU) (graphically)

Effectiveness for a parallel flow Effectiveness for a parallel flow

heat exchanger heat exchanger 46
Rate of heat Rate of heat Rate of heat
transfer by = loss = gain by cold
exchanger by hot fluid fluid

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 q  m h c p ,h (Th,i  Th,o )
 m c c p ,c (Tc ,o  Tc ,i )

q  UA Tm
Where:
U: Overall Heat Transfer Coefficient

1 1 1 1
R    & U h Ah  U C AC
U i Ai U o Ao hi Ai ho Ao
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 There are two main requires

1. Design of Heat exchangers 2. Performance of heat exchangers

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 1. Heat Exchanger Design Problems
For this type of problems, it is the engineer who must chose the appropriate heat exchanger
type and determine its size (i.e. heat transfer surface area)
Known Parameters: (given or desired)

 h,m
Th,i , Th,o , Tc,o , Tc,i , m c
Energy balance:
q  m h c p ,h (Th,i  Th,o )
 m c c p ,c (Tc ,o  Tc ,i )

 The problem in this case can be solved by one of the two methods
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1. Heat Exchanger Design Problems
With the LMTD method, the task is to select a heat exchanger that will meet the
prescribed heat transfer requirements. The procedure to be followed by the selection
process is:

1. Select the type of heat exchanger suitable for the application.

2. Determine any unknown inlet or outlet temperature and the heat transfer rate using
an energy balance.
3. Calculate the log mean temperature difference Tlm and the correction
factor F, if necessary.
4. Obtain (select or calculate) the value of the overall heat transfer coefficient U.
5. Calculate the heat transfer surface area As .

The task is completed by selecting a heat exchanger that has a heat transfer surface
area equal to or larger than As
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2. Performance Calculation Problem
Here the heat exchanger size and type are known.
It is required to determine the heat transfer rate and/or the outlet temperatures of the
hot and cold.

Here the task is to determine the heat transfer performance of a specified heat
exchanger or to determine if a heat exchanger available in storage will do the job.

The LMTD method could still be used for this alternative problem, but it is not
practical.
In an attempt to eliminate the iterations from the solution of such problems, the
effectiveness–NTU method, can be used to simplify heat exchanger analysis.

 The problem in this case is solved by NTU method as an easy and direct solution
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