Zulamita Zapata

Chapter 4

Heat Transfer Equipment:

Heat Exchangers
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Introduction
Heat exchangers are devices used to heat exchange between two fluids at different
temperatures and separated by a solid wall. Specific applications may be found in space
heating and air-conditioning, power production, waste heat recovery, and chemical
processing.
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Heat exchanger types

Heat exchanger are typically classified according to flow arrangement and type of
construction.

• Concentric-Tube Heat Exchangers

Parallel flow Counterflow

➢ Simplest configuration.
➢ Superior performance associated with counter flow.
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Heat exchanger types

• Shell-and-Tube Heat Exchangers

➢ Baffles are used to establish a cross-flow and to induce turbulent mixing of the shell-side fluid,
both of which enhance convection.
➢ The number of tube and shell passes may be varied, e.g.:

One Shell Pass, Two Tube Passes

Two Shell Passes, Four Tube Passes
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Overall heat transfer coefficient

• An essential requirement for heat exchanger design or performance calculations.
• Contributing factors include convection and conduction associated with the two fluids and the
intermediate solid, as well as the potential effects of time-dependent surface fouling.
• With subscripts o and i used to designate the outer and inner surface, respectively, the expression
for the overall coefficient is given by:

1 = 1 = 1
UA (UA )o (UA )i

1 Rf ,o Rf ,i
= + + Rw + + 1
ho Ao Ao Ai hi Ai
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Overall heat transfer coefficient

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Overall heat transfer coefficient

The coefficient which includes the dirt resistance is called the design or fouled overall
coefficient Uf , and that one obtained without consider the dirt resistance is called the
clean overall coefficient Uc.

The value of A corresponding to Uf rather than Uc provides the basis on which equipment
is ultimately built.

1 1
= + Rf ,i + Rf ,o
U f Uc
Rf

Uc −U f
Rf =
U cU f

When 𝑅𝑓 (deposited) > 𝑅𝑓 (allowed), as after a period of service, the apparatus no longer
delivers a quantity of heat equal to the process requirements and must be cleaned.
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Heat exchanger analysis: LMTD method

It is useful, when considering parallel or counterflow single-pass heat exchangers, to
draw a simple sketch depicting the general temperature variation experienced by each
fluid stream.
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Heat exchanger analysis: LMTD method

• 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:

Evaluation of T1 and T2 depends on the heat

q = UA Tlm exchanger type.
 T1 −  T2
Tlm =
1n (  T1 /  T2 )

• Counter-Flow Heat Exchanger:

 T1 = Th ,out − Tc ,in
 T2 = Th ,in − Tc ,out

• Parallel-Flow Heat Exchanger:

 T1 = Th ,in − Tc ,in
 T2 = Th ,out − Tc ,out
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Example
Light lubricating oil (cp = 2090 J/kgK) is cooled by allowing it to exchange
energy with water in a small heat exchanger. The oil enters and leaves the heat
exchanger at 375 and 350 K, respectively, and flows at a rate of 0.5 kg/s. Water
at 280 K is available in sufficient quantity to allow 0.201 kg/s to be used for
cooling purposes. Determine the required heat-transfer area for (a) counterflow
and (b) parallel-flow operations. The overall heat-transfer coefficient may be
taken as 250 W/m2K.
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Heat exchanger analysis: LMTD method

• Shell-and-Tube and Cross-Flow Heat Exchangers:

q = UA ( F Tlm )
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Example
A shell-and-tube heat exchanger must be designed to heat 2.5 kg/s of water from 15 to
85°C. The heating is to be accomplished by passing hot engine oil, which is available at
160°C, through the shell side of the exchanger. The oil is known to provide an average
convection coefficient of ho = 400 W/m2K on the outside of the tubes. Ten tubes pass the
water through the shell. Each tube is thin walled, of diameter D = 25 mm, and makes
eight passes through the shell. If the oil leaves the exchanger at 100°C, what is its flow
rate? How long must the tubes be to accomplish the desired heating?
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Example
A shell and tube heat exchanger (2-4) is used to exchange energy between two pressurized water
streams. The operating conditions for the clean exchanger are given by:

1200 kg/h, 200°C

Uc = 300 W/m2K
2500 kg/h, 25°C 100°C

It is observed that after a long period of operation, the cold stream is heated to 85°C for the same
conditions of flow and inlet temperatures of both streams. Determine the fouling factor for these
new conditions.
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Solución
1200 kg/h, 200°C Agua caliente
Uc = 300 W/m2K
Agua fría 2500 kg/h, 25°C 100°C

?
Uc −U f Nota:
Rf = - Hallar Uf
U cU f - Identificar que método se puede utilizar (LMTD o -NTU)
0 0
Balance de energía de la corriente fría 𝐸−𝑆+𝐺 =𝐴

𝑚ሶ 𝐹 𝑐𝑃,𝐹 𝑇𝐹 𝑖
− 𝑚ሶ 𝐹 𝑐𝑃,𝐹 𝑇𝐹 𝑜
+𝑞 =0 𝑞 = 𝑚ሶ 𝐹 𝑐𝑃,𝐹 𝑇𝐹 − 𝑚ሶ 𝐹 𝑐𝑃,𝐹 𝑇𝐹
𝑜 𝑖

𝑘𝑔 𝑘𝐽 𝑘𝑔 𝑘𝐽
𝑞 = 2500 ∙ 4.18 ∙ 373 𝐾 − 2500 ∙ 4.18 ∙ 298 𝐾
ℎ 𝑘𝑔. 𝐾 𝑜
ℎ 𝑘𝑔. 𝐾 𝑖

𝑘𝐽
𝑞 = 217.7 Flujo de calor recibido por la corriente fría
𝑠
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Balance de energía de la corriente caliente
?
𝑚ሶ 𝐶 𝑐𝑃,𝐶 𝑇𝐶 𝑖 − 𝑚ሶ 𝐶 𝑐𝑃,𝐶 𝑇𝐶 𝑜 − 𝑞 = 0

𝑚ሶ 𝐶 𝑐𝑃,𝐶 𝑇𝐶 𝑖
−𝑞
𝑇𝐶,𝑜 =
𝑚ሶ 𝐶 𝑐𝑃,𝐶 𝑜

𝑘𝑔 𝑘𝐽 𝑘𝐽
1200 ∙ 4.18 ∙ 473 𝐾 − 783750
ℎ 𝑘𝑔 ∙ 𝐾 ℎ
𝑇𝐶,𝑜 =
𝑘𝑔 𝑘𝐽
1200 ∙ 4.18
ℎ 𝑘𝑔 ∙ 𝐾

Temperatura de salida del

𝑇𝐶,𝑜 = 316 𝐾 = 43.75 °𝐶
agua caliente

Se tienen las 4 temperaturas se puede utilizar el método LMTD

?
El área de transferencia de
𝑞 = 𝑈𝑐 𝐴∆𝑇𝑙𝑚 𝐹
calor no cambia
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∆𝑇1 − ∆𝑇2 43.75°C 200°C

∆𝑇𝑙𝑚 = Uc = 300 W/m2K
∆𝑇 25°C
𝑙𝑛 ∆𝑇1 100°C
2
1 2
∆𝑇1 ∆𝑇2
43.75 − 25 − 200 − 100
∆𝑇𝑙𝑚 = = 48.54 𝐾
43.75 − 25
𝑙𝑛 200 − 100

𝑇𝐻1 − 𝑇𝐻2 200 − 43.75

𝑧= = = 2.08
𝑇𝐶2 − 𝑇𝐶1 100 − 25

𝑇𝑡,𝑜 − 𝑇𝑡,𝑖 100 − 25

𝑌= = = 0.43
𝑇𝑠,𝑖 − 𝑇𝑡,𝑖𝑛 200 − 25

IC Coraza y tubos 2-4

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𝐹 = 0.87

𝑘𝐽 1000 𝐽
217
𝑞 𝑠 ∙ 1 𝑘𝐽
𝐴= =
𝑈𝑐 ∆𝑇𝑙𝑚 𝐹 300 𝑊 ∙ 48.54 𝐾 ∙ 0.87
𝑚2 ∙ 𝐾

𝐴 = 17 𝑚2
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?
𝑇𝐻,𝑜 200°C
Uc = 300 W/m2K
25°C 85°C

1 2
∆𝑇1 ∆𝑇2

Balance de energía de la corriente fría 𝑚ሶ 𝐹 𝑐𝑃,𝐹 𝑇𝐹 𝑖

− 𝑚ሶ 𝐹 𝑐𝑃,𝐹 𝑇𝐹 𝑜
+𝑞 =0

𝑞 = 𝑚ሶ 𝐹 𝑐𝑃,𝐹 𝑇𝐹 𝑜
− 𝑚ሶ 𝐹 𝑐𝑃,𝐹 𝑇𝐹 𝑖

𝑘𝑔 𝑘𝐽 𝑘𝑔 𝑘𝐽
𝑞 = 2500 ∙ 4.18 ∙ 358 𝐾 − 2500 ∙ 4.18 ∙ 298 𝐾
ℎ 𝑘𝑔. 𝐾 𝑜
ℎ 𝑘𝑔. 𝐾 𝑖

𝑘𝐽 Flujo de calor recibido

𝑞 = 174.2
𝑠 por la corriente fría
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Balance de energía de la corriente caliente
?
𝑚ሶ 𝐶 𝑐𝑃,𝐶 𝑇𝐶 𝑖 − 𝑚ሶ 𝐶 𝑐𝑃,𝐶 𝑇𝐶 𝑜 − 𝑞 = 0

𝑚ሶ 𝐶 𝑐𝑃,𝐶 𝑇𝐶 𝑖
−𝑞
𝑇𝐶,𝑜 =
𝑚ሶ 𝐶 𝑐𝑃,𝐶 𝑜

𝑘𝑔 𝑘𝐽 𝑘𝐽
1200 ∙ 4.18 ∙ 473 𝐾 − 627000
ℎ 𝑘𝑔 ∙ 𝐾 ℎ
𝑇𝐶,𝑜 =
𝑘𝑔 𝑘𝐽
1200 ∙ 4.18
ℎ 𝑘𝑔 ∙ 𝐾

Temperatura de salida del método LMTD

𝑇𝐶,𝑜 = 348 𝐾 = 75 °𝐶
agua caliente recalculada o -NTU

𝑞 𝑞𝐹
𝜀= =
𝑞𝑚𝑎𝑥 𝑚𝑐
ሶ 𝑃 𝑚𝑖𝑛 𝑇𝐶,𝑖 − 𝑇𝐹,𝑖

∆𝑇𝑚𝑎𝑥
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𝑘𝑔 𝑘𝐽 𝑘𝐽
𝐶𝐶 = 𝑚ሶ 𝐶 𝑐𝑃,𝐶 = 1200 ∙ 4.18 = 5016
ℎ 𝑘𝑔 ∙ 𝐾 ℎ∙𝐾
𝐶𝐹 > 𝐶𝐶 𝐶𝑚𝑖𝑛
𝑘𝑔 𝑘𝐽 𝑘𝐽
𝐶𝐹 = 𝑚ሶ 𝐹 𝑐𝑃,𝐹 = 2500 ∙ 4.18 = 10450
ℎ 𝑘𝑔 ∙ 𝐾 ℎ∙𝐾

𝑘𝐽
𝑞 627000
𝜀= = ℎ = 0.71
𝑞𝑚𝑎𝑥 𝑘𝐽
5016 200 − 25 °𝐶
ℎ∙𝐾
 𝐶𝑚𝑖𝑛
𝐶𝑟 = = 0.48 𝑈𝑓 𝐴
𝐶𝑚𝑎𝑥 𝑁𝑇𝑈 =
𝐶𝑚𝑖𝑛
1/2
𝜀𝐶𝑟 − 1
𝐹= = 1.5 𝑁𝑇𝑈𝐶𝑚𝑖𝑛
𝜀−1 𝑈𝑓 =
𝐴
𝐹−1 𝑘𝐽
𝜀1 = = 0.5 1.69 ∙ 1.39
𝑈𝑓 = 𝑠∙𝐾
𝐹 − 𝐶𝑟
17 𝑚2

2Τ𝜀1 − 1 + 𝐶𝑟 𝑊
𝐸= = 2.28 𝑈𝑓 = 137.3 2
1 + 𝐶𝑟2 1/2 𝑚 ∙𝐾
300 − 137.3
𝑅𝑓" =
2
1
−2 𝐸−1 300 × 137.3
𝑁𝑇𝑈 1 =− 1+ 𝐶𝑟 𝑙𝑛 = 0.85
𝐸+1
𝑚2 ∙ 𝐾
𝑁𝑇𝑈 = 𝑛 𝑁𝑇𝑈 = 1.69 𝑅𝑓" = 0.0039
1 𝑊
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Heat exchanger analysis: Effectiveness-NTU method

• Computational Features/Limitations of the LMTD Method:

➢ The LMTD method may be applied to design problems for which the fluid
flow rates and inlet temperatures, as well as a desired outlet temperature, are
prescribed. For a specified heat exchanger type, the required size (surface area),
as well as the other outlet temperature, are readily determined.

➢ If the LMTD method is used in performance calculations for which both

outlet temperatures must be determined from knowledge of the inlet
temperatures, the solution procedure is iterative.

➢ For both design and performance calculations, the effectiveness-NTU method

may be used without iteration.
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• Heat exchanger effectiveness,  :

Definitions
q
= 0   1
qmax

• Maximum possible heat rate:

Ch if Ch  Cc

qmax = Cmin (Th ,i − Tc ,i ) → Cmin = or
C if C  C
 c c h

➢ The fluid characterized by Cmin will experience the largest possible temperature change
in transit through the heat exchanger

• Number of Transfer Units, NTU

T min change in T
NTU  UA → NTU = =
Cmin Tlm driving force
➢ A dimensionless parameter whose magnitude influences heat exchanger performance:
q  with  NTU
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Effectiveness – NTU relations

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Effectiveness – NTU relations

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Effectiveness – NTU relations

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Example
The condenser of a large steam power plant is a heat exchanger in which steam is condensed to liquid water.
Assume the condenser to be a shell and tube heat exchanger consisting of a single shell and 30,000 tubes, each
executing two passes. The tubes are of thin wall construction with D = 25 mm, and steam condenses on their outer
surface with an associated convection coefficient of ho = 11,000 W/m2K. The heat transfer rate that must be effected
by the exchanger is q = 2109 W, and this is accomplished by passing cooling water through the tubes at a rate of
3104 kg/s. The water enters at 20°C, while the steam condenses at 50°C. What is the temperature of the cooling
water emerging from the condenser? What is the required tube length L per pass?