CHAPTER

HEAT TRANSFER
6
EQUIPMENTS
 Classification
Recuperative / Regenerative

Transport: Direct / Indirect

Geometry: Tube / Plate / Extended

Phase: Single / Phase change

Fluid arrangement: Parallel / Counter / Cross

Three main types of heat exchangers:
In recuperative heat exchangers, the heat is
transferred from one fluid to the other through
a dividing wall.
In regenerative heat exchangers, heat is
transferred via a moving solid part, (a rotating
wheel with a large number of narrow channels).
In evaporative heat exchangers, hot water is
cooled by partly evaporating the water.
 Classification
Pool

Spray & tray

Packed column
Condenser
Shell & tube

Extended surface

Plate
Process function
Boiler (fired) Thermosiphon
Evaporator
Evaporator (unfired) Forced circulation

Cooler Steam generation

Exchanger Heater

Chiller
 Classification
Counter flow

Parallel flow

Single pass Cross flow

Split flow

Divided flow
Flow arrangement
Cross counter flow

Extended surface Cross parallel flow

Plate Compound flow

Multiple pass
Parallel counter flow

Shell & Tube Split flow

Divided flow
 Classification
Spiral tube

Tubular Double pipe

Fixed
tubesheet
Shell & tube U–tube
Removable
bundle
Finned tube Floating head
Recuperative Indirect Extended
(fixed heat contact type surface
transfer Finned plate
surface, Direct contact
continuously) type
Gasketed plate

Heat
exchanger
Plate Spiral plate
(cross/parallel
/counter flow)

Disk type Lamella

Rotary
Regenerative
regenerator
(batched heat Drum type
transfer
Fixed matrix
surface)
regenerator
 Classification

Spray & tray condenser Cooling tower

Classification

Cooling tower
 Classification

Columns Evaporator
Classification

Fired boiler
Classification

Fired boiler
Classification

Fired boiler
 Classification

Spiral plate Spiral tube

 Classification

Finned tube (liquid–gas)

Extended surface Finned plate (lamella for gas–gas)

Classification

Plate heat exchange (gasket)

Classification

Double pipe
 Classification
1 tube pass
Baffles

Head for 2
tube pass
Mini, 1 shell pass & 1 tube pass

Shell and tube

 Classification

Jacket vessel
Internal coils
Rotary regenerator
Double pipe exchanger.

• In this type, the hot and cold fluid streams do not

come into direct contact with each other. They are
separated by a tube wall or flat plate.
 Overall heat transfer coefficient
Q = UA (Δ T)
Q is the heat flow rate in W,
A is the heat flow area
ΔT is the temperature difference between the fluids

The resistances are:

(i) Convection resistance on the inner surface of the tube for heat flow from
fluid to wall. (1/hiAi)
(ii) The resistance due to deposits that will form during operation on the inside
of the tube called inside fouling resistance-Rfi.
(iii) The resistance due to heat conduction through the solid wall separating the
fluids.
(iv) The resistance due to deposits that will form during operation on the
outside of the tube called outside fouling resistance-Rfo.
(v) Convection resistance on the outer surface for heat flow from wall to the
fluid (1/hoAo).
 Overall heat transfer coefficient
- In tube flow the inside area will be different from the
outside area. → two values are possible for the area and
consequently two values are possible for the overall heat
transfer coefficient.
These are:
Ui—overall heat transfer coefficient based on inside area
Uo—overall heat transfer coefficient based on outside area.
The relationship between these two is given by: UiAi = UoAo
Q = UiAiΔT = UoAoΔT. In the case of plane wall Ui = Uo
The total resistances is given by
Overall heat transfer coefficient
 1 1 R fi 1 R fi
   Rw  
UA (h0 A)i (0 A)i (h0 A)0 (0 A)o
ηo: overall surface efficiency (if finned)
Parallel Flow vs. Counterflow
Parallel Flow vs. Counterflow
Parallel Flow vs. Counterflow
 Parallel Flow vs. Counterflow

Q = U.A.ΔTLM
 Parallel Flow vs. Counterflow

(a) Condensing, (b) Evaporating, (c) Condensing and evaporating.

Cooling, condensing and under cooling

(a) Cooling, condensation and

undercooling
(b) Heating, evaporation and
superheating.
 Crossflow
A third basic type of flow is crossflow.
The temperatures of both fluids at the outlets are different from
one side to the other of the flow channel.
In most heat exchangers, the flow is neither purely parallel,
counterflow or crossflow, but rather a mixture of these types.
The logarithmic mean temperature difference may still be used, if
corrected by factor F.: q = U⋅A⋅F⋅(LMTD)
Heat Exchanger Design – LMTD method
Water flowing at a rate of 0.723 kg/s enters the inside of a countercurrent, double-pipe
heat exchanger at 300K and is heated by an oil stream that enters at 485K at a rate of
3.2kg/s. The heat capacity of the oil is 1.89 kJ/kg K, and the average heat capacity of
water over the temperature range of interest is 4.192 kJ/kg K. The overall heat-transfer
coefficient of the exchanger is 300 W/m2 K, and the area for heat transfer is 15.4 m2.
What is the total amount of heat transferred if the temperature of water come out is
380K

33
Heat Exchanger Design – LMTD method
An exhaust pipe, 75 mm outside diameter, is cooled by surrounding it by an
annular space containing water.
The hot gases enters the exhaust pipe at 350oC, gas flow rate being 200 kg/h,
mean specific heat capacity at constant pressure 1.13 kJ/kg K, and comes out at
100oC.
Water enters from the mains at 25oC, flow rate 1400 kg/h, mean specific heat
capacity 4.19 kJ/kg K.
The heat transfer coefficient for gases and water may be taken as 0.3 and 1.5
kW/m2 K and pipe thickness may be taken as negligible.
Calculate the required pipe length for (i) parallel flow, and for (ii) counter flow.

34
 Heat Exchanger Design – LMTD method
Solution:
. . .
Q = mc cc (Tc,out – Tc,in) = mh ch (Th,in – Th,out)

(1400 kg/hr) (4.19 kJ/kg K) (Tc,out – 25)oC

= (200 kg/hr) (1.13 kJ/kg K) (350 – 100)oC

The temperature of water at the outlet = Tc,out = 34.63oC.

35
 Heat Exchanger Design – LMTD method
Solution continued:

(i) Parallel flow:

ΔTa = 350 – 25 = 325oC

ΔTb = 100 – 34.63 = 65.37oC

ΔTa - ΔTb 325 – 65.37

ΔTLM = = = 162oC
ln(ΔTa / ΔTb) ln(325 / 65.37)

.
Q = U A ΔTLM = (UA) 162oC

What is UA?36
 Heat Exchanger Design – LMTD method
Solution continued:

1/U = 1/hwater + 1/hgases

= 1/1.5 + 1/0.3 = 4 (kW/m2 K)-1

Therefore, U = 0.25 kW/m2 K

A = π (outer diameter) (L) = π (0.075 m) (L m)

.
Q = (UA) 162oC = (0.25) π (0.075) L (162) kW

.
What is Q?
37
 Heat Exchanger Design – LMTD method

Solution continued:

. . .
Q = mc cc (Tc,out – Tc,in) = mh ch (Th,in – Th,out)
= (200 kg/h) (1.13 kJ/kg K) (350 – 100)oC = 15.69 kW

Substituting the above in

.Q = (UA) 162oC = (0.25) π (0.075) L (162) kW

we get
L = 1.64 m
38
 Heat Exchanger Design – LMTD method
Solution continued:
(ii) Counter flow:

ΔTa = 350 – 34.63 = 315.37oC

ΔTb = 100 – 25 = 75oC

ΔTa - ΔTb 315.37 – 75

ΔTLM = = = 167.35oC
ln(ΔTa / ΔTb) ln(315.37 / 75)

.
Q = U A ΔTLM = (UA) 167.35oC

.
Q = 15.69 kW; U = 0.25 kW/m2 K ; A = π (0.075) L m2

Therefore, L = 1.59 39m

 Pure double pipe
Assumptions:
• No phase change and negligible heat losses
• Pure double pipe: parallel flow / counter
flow
• Constant specific heats ,
• Constant overall heat transfer coefficient
The ∆ for counter flow is higher than that one for
parallel flow, hence the area is smaller for given heat load
Non double pipe

= ∆
is a correction factor
 Non double pipe
1 shell pass – 2 tube passes
1.0

0.9 −
factor

=
−

0.8

0.7

0.6
−
=
−
0.5
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
 Non double pipe
1 shell pass – 2 tube passes
1 shell pass – 2 tube passes (error 2%)

1−
ln +1
= 1−
for ≠1
2− +1− +1
− 1 ln
2− +1+ +1

2
= for =1
2− 2− 2
1− ln
2− 2+ 2
 Non double pipe
2(1 shell pass – 2 tube passes)
1.0
factor

0.9

0.8

0.7

−
=
−
0.6

−
=
−
0.5
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
 Non double pipe
(1 shell pass – 2 tube passes)
: number of shells

for ≠1 ⁄
1− 1−
ln 1 − +1 −1
= = 1− ⁄
2− +1− +1 1−
− 1 ln −
1−
2− +1+ +1

for =1
2
= =
2− 2− 2 − +
1− ln
2− 2+ 2
 Non double pipe
2 shell pass – 4 tube passes
−
=
−
1.0
factor

0.9

0.8
= 20

15

10

4.0
8.0

6.0

3.0

2.5

2.0

0.7

0.6

0.5
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0

−
=
−
 Non double pipe
Divided flow shell – 2 tube passes
−
=
−
1.0
factor

0.9
= 20

15
10

6.0
8.0

0.8

0.7

0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0

−
=
−
 Non double pipe
Split flow shell – 2 tube passes
−
=
−
1.0
factor

0.9

0.8

0.7
4.0
8.0

6.0

5.0
= 10

0.6

0.5
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
−
=
−
 Non double pipe
single pass cross flow exchangers and both fluids unmixed
1.0
factor

0.9

0.8

0.7

−
=
0.6 −
−
=
−
0.5
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
 Non double pipe
single pass cross flow exchangers and one fluid mixed, the other
unmixed
1.0
factor

0.9

0.8

0.7

−
=
0.6 −
−
=
−
0.5
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
 Non double pipe

For phase change (evaporation & condensation),

constant temperature, = 0 or = 0, so = 1
 Design equation

, and operation
cost are covariant

= ∆
and capital cost
are covariant
 Example 4
An exhaust pipe, 75 outside diameter, is cooled by surrounding it
by an annular space containing water. The hot gases enters the
exhaust pipe at 350℃, gas flow rate being 200 ⁄ℎ, mean specific
heat capacity at constant pressure 1.13 ⁄ , and comes out at
100℃. Water enters from the mains at 25℃, flow rate 1400 ⁄ℎ,
mean specific heat capacity 4.19 ⁄ . The heat coefficient for
gases and water may be taken as 0.3 and 1.5 ⁄ and pipe
thickness may be taken as negligible.
Calculate the required pipe length for parallel flow and for counter
flow.
 Example 4
ℎ = 0.3 ⁄ Energy balance:
ℎ = 1.5 ⁄
= − = −
= 200 ⁄ℎ
= 1400 ⁄ℎ = 15.7 = 34.63℃
, = 1.13 ⁄
, = 4.19 ⁄
= 350℃ Overall heat transfer coefficient:
= 100℃ 2
= 25℃ = = 0.0589 ⁄
1 1
= 75 +
ℎ ℎ
 Example 4
Parallel flow Counter flow

1 2 1 2

∆ −∆ ∆ −∆
∆ = = 161.9℃ ∆ = = 167.4℃
∆ ∆
ln ln
∆ ∆

= = 1.65 = = 1.59
∆ ∆
 Heat Exchanger Effectiveness
Effectiveness

ℎ
= =
ℎ

In a thermodynamic sense, higher effectiveness

correspond to reduced thermodynamic
irreversibility and smaller entropy generation
 Heat Exchanger Effectiveness
Consider a counter-current double-pipe heat
exchanger:
 Heat Exchanger Effectiveness
Temperature profile in a double-pipe
heat exchanger:

Note that the temperature curves

are only approximately linear
Heat Exchanger Effectiveness

We want to compare the

amount of heat
transferred in this case
to the amount of heat
transferred in a PERFECT
heat exchanger.
 Heat Exchanger Effectiveness
If the heat exchanger were perfect, Thi=T
 Heat Exchanger Effectiveness

U .A
No. of transfer units (size of H.E.) NTU 
(mC p ) min
Heat Exchanger Effectiveness
Heat Exchanger Effectiveness
Heat Exchanger Effectiveness
Heat Exchanger Effectiveness
Heat Exchanger Effectiveness
 Non double pipe

• 1 shell pass – 2 tube passes, small error

• For phase change (evaporation & condensation),

constant temperature, →0

ln 1 − =−
 Non double pipe
1 shell pass – 2 tube passes 2 shell passes – 4 tube passes
100 100
⁄ =0
%

%
0.25
Effectiveness

Effectiveness
80 80
0.50

0.75
60 60
1.00

40 40

20 20

0 0
1 2 3 4 5 1 2 3 4 5
 Non double pipe
cross flow exchanger with one fluid cross flow exchanger with fluids
mixed unmixed
100 100
0.25 0.25
%

%
4.0 0.50
0.50 0.75

Effectiveness
Effectiveness

80 2.0 80
1.00
0.75
1.33

1.00
60 60

unmixed unmixed
40 40

mixed unmixed
20 20

0 0
1 2 3 4 5 1 2 3 4 5
 Summary
Flow geometry
Double pipe
1− − 1+ − ln 1 − 1 +
Parallel flow = =
1+ 1+
1− −1 1 −1
Counter flow = = ln
1− −1 −1 −1

Counter flow =1 = =
+1 1−
Cross flow
,
− −1
Both fluids unmixed =1− ,

1
=
Both fluids mixed 1 1
+ −
1− − 1− −
1− − −1 ln 1 −
mixed, unmixed = = − ln 1 +

− −1 − ln 1 + ln 1 −
unmixed, mixed =1− =
 Summary
Flow geometry
Shell and tube

2 2
−1− + 1+
1 shell pass = ln 2
1+ 1+ − 1+ −1− − 1+
2,4,6 tube passes 1+ +
1− − 1+ =
1+
1−
shell passes −1
1−
2 , 4 , 6 tube passes =
: for 1 shell pass 1−
−
1−
shell passes
2 , 4 , 6 tube passes
=
: for 1 shell pass 1+ −1
=1
All heat exchanger with
=1− − = − ln 1 −
=0

= = =
Design equation

= ,

= =

=
, − ,
 Example 5
Water flowing at a rate of 0.723 ⁄ enters the inside of a
countercurrent, double pipe heat exchanger at 300 and is heated by
an oil stream that enters at 485 at a rate of 3.2 ⁄ . The heat
capacity of the oil is 1.89 ⁄ , and the average heat capacity of
water over the temperature range of interest is 4.192 ⁄ . The
overall heat transfer coefficient of the exchanger is 300 ⁄ , and
the area for heat transfer is 15.4 . What is the total amount of heat
transferred if the temperature of water come out is 380 .
 Design problems
• Fluid properties
• Flow rate Process
• Temperature

• Overall heat transfer

coefficient Design
• Area
• Specification design
 Off–Design problems
• Fluid properties
• Flow rate
Process
• Area, specification design

• Overall heat transfer coefficient

• Temperature Design
• Heat load
 CHAPTER
HEAT TRANSFER
6
EQUIPMENTS