Course Name: Heat Transfer

Course Code: UME 720

Topic : Heat Exchangers

by
Dr. Madhup Kumar Mittal
Associate Professor
Department of Mechanical Engineering
Thapar Institute of Engineering & Technology
Heat Exchangers

Heat exchanger is a device which is used for the effective exchange of heat between the two fluids that are
at different temperatures. The purpose may be either to add heat to a fluid or to remove heat from a fluid.

Few notable examples of heat exchanger are:

Steam Boiler Hot

out shell gases

Engine
Radiator
Furnace

Steam Boiler Radiator Outdoor unit of Air-conditioner

Heat Exchangers
Types of heat exchangers (H.E.)
Concentric tube heat exchanger Shell and tube heat exchanger
(Tubular H.E. or double pipe H.E.) Tube Shell Shell
outlet inlet Baffles inlet
Cold out

Hot in Hot out

Baffles
Shell Tube
outlet inlet
Cold in One-shell pass & one-tube pass H.E. Shell
Parallel flow H.E. (1− 1 heat exchanger) outlet
Shell inlet
Cold in Shell inlet Tube outlet
Tube outlet
Hot in Hot out
Tube inlet
Tube inlet
Shell outlet
Cold out Shell outlet
One-shell pass & two-tube passes H.E. Two-shell passes & four-tube passes H.E.
Counter flow H.E. (1− 2 heat exchanger) (2− 4 heat exchanger)
continued….
Heat Exchangers
• Cross flow heat exchanger

Cross flow heat

exchanger

Both fluids unmixed One fluid mixed, other fluid unmixed

Heat Exchangers
Analysis of concentric tube heat exchanger
❑ For designing and predicting the performance of heat exchanger, it is necessary that
the total heat transfer (Q) must be related with its governing parameters such as:
• Overall heat transfer coefficient (U) to account for
various modes of heat transfer
• Effective surface area of heat transfer (A)
• Appropriate mean value of temperature difference between hot and cold fluid
[Logarithmic mean temperature difference (θm), LMTD]
tc1 tc2
Ri Rwall Ro
Cold Cold
th1 Hot th2 th1 Hot th2
Cold Cold ❑ The governing energy balance equations in heat exchangers are:
th1 • Heat given up by the hot fluid: 𝑄ℎ = 𝑚ℎ 𝑐𝑝ℎ 𝑡ℎ1 − 𝑡ℎ2
th1 tc2 tc1
• Heat gained by the cold fluid: 𝑄𝑐 = 𝑚𝑐 𝑐𝑝𝑐 𝑡𝑐2 − 𝑡𝑐1
tc2
t th2
t
• Heat transfer from hot fluid to cold fluid through the walls
tc2 th2
tc1 tc1 of heat exchanger: 𝑄 = 𝑈𝐴𝜃𝑚 (𝑈𝑖 𝐴𝑖 𝜃𝑚 = 𝑈𝑜 𝐴𝑜 𝜃𝑚 )
Length of HE (L) Length of HE (L) • Analysis of heat exchanger is based on the assumption
Heat transfer from hot fluid to cold fluid through the that there is no heal loss to the surroundings, i.e.
cylindrical walls of heat exchanger: 𝑄 = 𝑈𝐴𝜃𝑚 𝑄ℎ = 𝑄𝑐 = 𝑄
Heat Exchangers
Overall heat transfer coefficient (U)
We know that heat transfer (Q) is given by: Heat transfer (Q) can also be expressed as:
𝑄 = 𝑈𝑖 𝐴𝑖 ∆𝑇 𝑄 = 𝑈𝑜 𝐴𝑜 ∆𝑇
∆𝑇 ∆𝑇 ∆𝑇 ∆𝑇
= = = =
ln 𝑟𝑜 Τ𝑟𝑖 ln 𝑟𝑜 Τ𝑟𝑖
𝑈𝑖 𝐴𝑖 + + + +
𝑖 𝐴𝑖 2𝜋𝑘𝐿 𝑜 𝐴𝑜 𝑈𝑜 𝐴𝑜 𝑖 𝐴𝑖 2𝜋𝑘𝐿 𝑜 𝐴𝑜

ln 𝑟𝑜 Τ𝑟𝑖 ln 𝑟𝑜 Τ𝑟𝑖
∴ = + + ∴ = + +
𝑈𝑖 𝐴𝑖 𝐴
𝑖 𝑖 2𝜋𝑘𝐿 𝑜 𝐴𝑜 𝑈𝑜 𝐴𝑜 𝐴
𝑖 𝑖 2𝜋𝑘𝐿 𝑜 𝐴𝑜

The tube wall thickness of inner tube is The tube wall thickness of inner tube is
generally very small for low thermal generally very small for low thermal
resistance (i.e., ri ≈ ro ⸫ Ai ≈ Ao). Thus resistance (i.e., ri ≈ ro ⸫ Ai ≈ Ao). Thus
above Eq. is reduced to: above Eq. is reduced to:
Rwall
𝑖 𝑜 𝑖 𝑜
= + → 𝑈𝑖 = = + → 𝑈𝑜 = 𝑖 𝐴𝑖 𝑜 𝐴𝑜
𝑈𝑖 𝑖 𝑜 𝑖 + 𝑜 𝑈𝑜 𝑖 𝑜 𝑖+ 𝑜

Thus for thin walled tubes, the overall heat transfer coefficient is given by: 𝐴𝑖 = 2𝜋𝑟𝑖 𝐿
𝑖 𝑜 𝐴𝑜 = 2𝜋𝑟𝑜 𝐿
= = = + or, 𝑈𝑖 = 𝑈𝑜 = 𝑈 =
𝑈𝑖 𝑈𝑜 𝑈 𝑖 𝑜 𝑖 + 𝑜
Heat Exchangers
Logarithmic mean temperature difference (LMTD, θm) for parallel flow tc1
heat exchanger
Cold
Let us consider an element of length dx at a distance x from left hand side th1 Hot th2
Cold
of heat exchanger. The element has an elementary heat transfer area ‘dA’.
The heat flow rate through the elemental length of H.E. is given by: th1 tc2
dQ
𝑑𝑄 = 𝑈 𝑑𝐴 𝑡ℎ − 𝑡𝑐 = 𝑈 𝑑𝐴 𝜃 ....(1)
θ1 th
dth
As a result of heat transfer ‘dQ’ through the area ‘dA’, the temperature (=th1− tc1) th2
θ θ2 (=th2− tc2)
of cold fluid increases by dtc and the temperature of hot fluid decreases dtc tc2
by dth along the +ve direction of x. tc
tc1 x dx
1 2
x=0 Length of HE (L) x=L

....(2) ....(3) • Subscript ‘1’ refer to inlet fluid

temperatures. Subscript ‘1’ also refers
to H.E. section at x = 0.

• Subscript ‘2’ refer to outlet fluid

temperatures. Subscript ‘2’ also refers
..(4) to H.E. section at x = L.
Heat Exchangers
th1
Logarithmic mean temperature difference (LMTD, θm) for parallel flow
heat exchanger
θ1 th
....(4) (=th1− tc1) θ dQ th2
θ2 (=th2− tc2)
tc2
tc
tc1 x dx
Since, 𝑑𝑄 = 𝑈 𝑑𝐴 𝑡ℎ − 𝑡𝑐 = 𝑈 𝑑𝐴 𝜃 , above Eq. 1 2
can be written as: x=0 Length of HE (L) x=L

The total heat transfer between the two fluids is also given by:

Substituting above values in Eq. (5), we get:

Integrating above equation between section ‘1’ &
‘2’ of H.E. (i.e., from A = 0 to A = A), we get:

The above Eq. may be written as:

....(5)
Heat Exchangers
tc2
Logarithmic mean temperature difference (LMTD, θm) for counter flow
heat exchanger Cold
th1 Hot th2
Let us consider an element of length dx at a distance x from left hand side of
Cold
heat exchanger. The element has an elementary heat transfer area ‘dA’.
th1 tc1
The heat flow rate through the elemental length of H.E. is given by:
θ1 dQ
𝑑𝑄 = 𝑈 𝑑𝐴 𝑡ℎ − 𝑡𝑐 = 𝑈 𝑑𝐴 𝜃 ....(1) (=th1− tc2)
tc2 th
As a result of heat transfer ‘dQ’ through the area ‘dA’, the temperature of hot dth
fluid is cooled down by dth whereas the cold fluid is heated by dtc. However, θ th2
dtc θ2 (=th2− tc1)
the temperature of both the fluids decreases along the +ve direction of x. tc tc1
Hence for counter flow system: x dx
1 2
x=0 Length of HE (L) x=L

....(2) ....(3) • Subscript ‘1’ refer to inlet fluid

temperatures. Subscript ‘1’ also refers
to H.E. section at x = 0.

• Subscript ‘2’ refer to outlet fluid

temperatures. Subscript ‘2’ also refers
...(4) to H.E. section at x = L.
Heat Exchangers
th1
Logarithmic mean temperature difference (LMTD, θm) for counter flow θ1
heat exchanger (=th1− tc2)
tc2 th
....(4) θ dQ th2
θ2 (=th2− tc1)
tc tc1
Since, 𝑑𝑄 = 𝑈 𝑑𝐴 𝑡ℎ − 𝑡𝑐 = 𝑈 𝑑𝐴 𝜃 , above x dx
1 2
Eq. (4) can be written as: x=0 Length of HE (L) x=L

The total heat transfer between the two fluids is also given by:

Integrating above equation between section ‘1’ & Substituting above values in Eq. (5), we get:
‘2’ of H.E. (i.e., from A = 0 to A = A), we get:

....(5) The above Eq. may

be written as:
Heat Exchangers
Summary of LMTD ( θm) for parallel and counter flow heat exchanger

Parallel flow arrangement Counter flow arrangement

tc1 tc2

Cold Cold
th1 th1 Hot th2
Hot th2
Cold Cold

tc2 th1 tc1

th1
θ1
(= th1− tc2)
θ1 tc2
(= th1− tc1) th2 th2
θ (= th2− tc2) θ2 (= th2− tc1)
tc2 2
tc1
tc1
1 2 1 2
x=0 Length of HE (L) x=L x=0 Length of HE (L) x=L
Subscript ‘1’ refer to Subscript ‘2’ refer to The total heat transfer (Q) between the two fluids is also given by:
inlet fluid temperatures. outlet fluid temperatures.
Subscript ‘1’ also refers Subscript ‘2’ also refers
to H.E. section at x = 0. to H.E. section at x = L.
Heat Exchangers
Special case of practical interest th1=180 C
𝜃1 − 𝜃2 θ1
LMTD for heat exchanger is given by: 𝜃𝑚 = ....(1) tc2= 80 C
ln 𝜃1 Τ𝜃2 th2=130 C
θ2
A special case arises when θ1 = θ2 = θ in case of counter-flow heat exchanger. In tc1= 30 C
such a case, we have: 𝜃−𝜃 0
𝜃𝑚 = = ,which is indeterminate 𝜃1 = 𝜃2 = 𝜃
ln 𝜃 Τ𝜃 0
𝑓(𝑥) 𝑓′(𝑥)
The value of θm for such a case can be found by applying L’ Hospital’s rule which states that: lim = lim
𝑥 → 𝑎 𝑔(𝑥) 𝑥 → 𝑎 𝑔′(𝑥)

𝜃
𝜃2 𝜃1 −
2
Eq.(1) can be written as: 𝜃𝑚 =
ln (𝜃1 Τ𝜃2 )
𝜃1 𝜃2 𝑥 − 𝜃2 𝑥 − 𝜃2
let =𝑥 ∴ 𝜃𝑚 = = ....(2)
𝜃2 ln(𝑥) ln(𝑥)
as θ1 → θ2 ⸫x→1
Thus by using L’ Hospital’s rule in Eq.(2), θm can be calculated as:
𝑑
𝜃2 𝑥 − 𝜃2 𝜃2 𝑥 − 𝜃2 𝜃2
𝜃𝑚 = lim = lim 𝑑𝑥 = lim = 𝜃2 ∴ 𝜃𝑚 = 𝜃2 = 𝜃1 = 𝜃
𝑥 → 1 ln(𝑥) 𝑥→1 𝑑 𝑥 → 1 Τ𝑥
ln(𝑥)
𝑑𝑥
Question
Water (cp = 4.187 kJ/kg C) flowing (a) Parallel flow arrangement (b) Counter flow arrangement
through a double pipe heat exchanger th1=180 C th1=180 C
at the rate of 10500 kg/h is heated θ1
from 40 C to 80 C by using tc2= 80 C
θ1 th2=130 C th2=130 C
superheated steam which enters the θ2
tc2= 80 C tc1= 40 C
heat exchanger at 180 C and leaves
tc1= 40 C θ2
at 130 C. If overall heat transfer
coefficient from steam to water is
814 W/m2 C, what heat exchanger
area is required to handle the load for 80 − 40 − 30 − 80 80 − 80 − 30 − 40
= =
(a) parallel flow arrangement, and ln 80 − 40 Τ 30 − 80 ln 80 − 80 Τ 30 − 40
(b) counter flow arrangement? 00 − 90
40 − 50 = = 95.24°𝐶
Solution = = 87.4 °𝐶 ln 00Τ90
ln 40Τ50
Question
The flow rates of hot and cold water streams (cp = 4.187 kJ/kg C) running through a parallel flow heat exchanger are 0.2 kg/s and
0.5 kg/s respectively. The inlet temperatures on the hot and cold sides are 75 C and 20 C respectively. The exit temperature of hot
water is 45 C. If the heat transfer coefficients on both sides of inner tube are 650 W/m2 C, calculate the area of heat exchanger.

Solution

cph = cpc = 4.187 kJ/kg C

th1=75 C

θ1 th2=45 C
tc2= 32 C
tc1= 20 C θ2
Question
Dry saturated steam at 10 bar enters a counter-flow heat exchanger and leaves at 350 C. The mass flow rate of steam is 800 kg/min.
The hot flue gases enters the heat exchanger at 650 C with mass flow rate of 1350 kg/min. If the tubes are 30 mm mean diameter and
3 m long, determine the number of tubes required. Use the following data:
For steam: tsat = 180 C (at 10 bar); cps = 2.71 kJ/kg C; hs (heat transfer coeff.) = 600 W/m2 C
For gas: cpg = 1 kJ/kg C; hg = 250 W/m2 C
Solution

cps = cpc = 2.71 kJ/kg C;

cpg = cph = 1 kJ/kg C

th1=650 C
θ1
tc2=350 C
th2=377 C
θ2
tc1= 180 C
Heat Exchangers
Condenser
• This is a special type of heat exchanger in which one of the fluid condenses (i.e. undergoes a phase-change process) as it
flows through the heat exchanger.
Steam in (hot fluid) Condensate out
th1 th2 (= th1)
Warm water out Warm water out
water in water in t
t tc2 (cold fluid) c1 tc2
(cold fluid) c1

th2 (= th1) th1

Condensate out Steam in (hot fluid)
th1 = th2 th1 = th2
th1 th2 (= th1) th2 (= th1) th1
θ2 θ2
tc2 tc2
θ1 θ1

tc1 θ2= th2−tc2 tc1 θ2= th1−tc2

θ1= th1−tc1 θ1= th2−tc1
L L = th2−tc2
= th1−tc1
p=c p=c
th2 𝑄 = 𝑈𝐴𝜃𝑚 th2
th1 th1
where,
𝜃1 − 𝜃2
𝜃𝑚 =
ln 𝜃1 Τ𝜃2
Parallel flow Counter flow
Heat Exchangers
Evaporators (Boilers)
• This is also a special type of heat exchanger in which one of the fluid evaporates (i.e. undergoes a phase-change process)
as it flows through the heat exchanger.
Hot flue gas in (hot fluid) Hot flue gas in (hot fluid)
th1 th1
Saturated water in Steam out Saturated water in
(cold fluid) tc1 Steam out
tc2 (= tc1) tc2 (= tc1) tc1(cold fluid)

th2 th2
th1 Flue gas out th1 Flue gas out

θ1 θ1
t t
tc1 θ2 h2 θ2 h2
tc2 (= tc1) tc2 (= tc1) tc1
tc1 = tc2 tc1 = tc2
θ1= th1−tc1 L θ1= th1−tc2
θ2= th2−tc2 L θ2= th2−tc1 = th2−tc2
= th1−tc1
p=c p=c
tc1 𝑄 = 𝑈𝐴𝜃𝑚 tc1
tc2 where, tc2
𝜃1 − 𝜃2
𝜃𝑚 =
ln 𝜃1 Τ𝜃2
Parallel flow Counter flow
Question
The velocity of water flowing through the tube of concentric tube heat exchanger is 2 m/s. The mean diameter of inner
tube is 22 mm. Steam condensing at 150 C on the outside surface of the tube heats the water from 15 C to 60 C over
the length of the tube. If the overall heat transfer coefficient from steam to water side is 6771.7 W/m2 C, calculate the
length of the tube. Take the density of water at mean temperature as 990 kg/m3.
Solution

d = 22 mm
steam
water
steam
th1 = th2 = 150 C
th1 th2
hot fluid (steam) θ2
tc2
θ1

tc1
L
Heat Exchangers
Log Mean Temperature Difference (θm) for multi-pass heat exchangers
• The log mean temperature difference (θm) relation developed earlier is valid only for single-pass heat exchangers. Similar
relations had also been developed for multi-pass shell and tube heat exchangers, but the resulting expressions are lengthy
and complicated due to complex configurations of multi-pass heat exchangers and complex flow conditions in them.
• However, the log mean temperature difference (θm) for multi-pass heat th1 (Hot fluid)
exchangers can be conveniently expressed as: tc1 (cold fluid in)
𝜽𝒎 𝒎𝒖𝒍𝒕𝒊−𝒑𝒂𝒔𝒔 𝑯.𝑬. = 𝑭. 𝜽𝒎 𝒔𝒊𝒏𝒈𝒍𝒆−𝒑𝒂𝒔𝒔 𝒄𝒐𝒖𝒏𝒕𝒆𝒓 𝒇𝒍𝒐𝒘 𝑯.𝑬. tc2
where, th2
▪ F is called correction factor which represents the ratio of θm for multi-pass H.E.
multi-pass heat exchanger to θm for single-pass counter flow heat (Hot fluid in)
exchanger with the same inlet and outlet temperatures. th1

▪ The correction factor ‘F’ is always less than unity as no configuration

can be more effective than the single-pass counter flow configuration. tc2 tc1
(cold fluid in)
▪ Correction factors ‘F’ for common multi-pass shell and tube heat
exchangers are available in the form of charts. th2
• Heat exchange in multi-pass shell and tube heat exchanger is calculated single-pass counter flow H.E.
as follows: 𝜃1 − 𝜃2
𝜃𝑚 𝑠𝑖𝑛𝑔𝑙𝑒−𝑝𝑎𝑠𝑠 𝑐𝑜𝑢𝑛𝑡𝑒𝑟 𝑓𝑙𝑜𝑤 𝐻.𝐸. =
𝑄 = 𝑈. 𝐴. 𝐹. 𝜃𝑚 where, θm is LMTD for single-pass counter flow heat ln 𝜃1 Τ𝜃2
exchanger with the same inlet and outlet temperatures 𝜃𝑚 𝑚𝑢𝑙𝑡𝑖−𝑝𝑎𝑠𝑠 𝐻.𝐸.
𝐹=
as for multi-pass shell and tube heat exchanger. 𝜃𝑚 𝑠𝑖𝑛𝑔𝑙𝑒−𝑝𝑎𝑠𝑠 𝑐𝑜𝑢𝑛𝑡𝑒𝑟 𝑓𝑙𝑜𝑤 𝐻.𝐸.
Heat Exchangers
Correction factor (F) charts for multi-pass heat exchangers
• Correction factor data is presented as a function of two non-dimensional variables namely ‘P’ and ‘R’ which are defined as:
▪ P: It is defined as the ratio of the rise in temperature of cold fluid to 𝑃 = 𝑡𝑐2 − 𝑡𝑐1
the difference in the inlet temperatures of the two fluids. 𝑡ℎ1 − 𝑡𝑐1
𝑚 𝑐 𝐶
▪ R: It is defined as the ratio of the heat capacity rate of cold fluid to that 𝑅 = 𝑐 𝑝𝑐 = 𝑐
of hot fluid, i.e., 𝑚ℎ 𝑐𝑝ℎ 𝐶ℎ
𝑚𝑐 𝑐𝑝𝑐 𝐶𝑐 𝑡ℎ1 − 𝑡ℎ2 𝑡𝑒𝑚𝑝. 𝑑𝑟𝑜𝑝 𝑜𝑓 𝑡 𝑒 𝑜𝑡 𝑓𝑙𝑢𝑖𝑑
𝑠𝑖𝑛𝑐𝑒, 𝑚𝑐 𝑐𝑝𝑐 𝑡𝑐2 − 𝑡𝑐1 = 𝑚ℎ 𝑐𝑝ℎ 𝑡ℎ1 − 𝑡ℎ2 ∴𝑅= = = =
𝑚ℎ 𝑐𝑝ℎ 𝐶ℎ 𝑡𝑐2 − 𝑡𝑐1 𝑡𝑒𝑚𝑝. 𝑟𝑖𝑠𝑒 𝑜𝑓 𝑡 𝑒 𝑐𝑜𝑙𝑑 𝑓𝑙𝑢𝑖𝑑

th1

tc2
tc1

th2
Correction factor chart for heat exchanger with one-shell
pass and 2, 4, 6, etc. (any multiple of 2) tube passes
Heat Exchangers
Correction factor (F) charts for multi-pass heat exchangers

th1

tc2

tc1

th2

Correction factor chart for heat exchanger with two-shell

passes and 4, 8, 12 etc. (any multiple of 4) tube passes
Heat Exchangers
Correction factor charts for cross-flow heat exchangers

Correction factor chart for cross-flow heat Correction factor chart for cross-flow
exchanger, one fluid mixed and other unmixed heat exchanger with both fluids unmixed
Question
A heat exchanger is required to cool 0.889 kg/s of benzene (cp = 1.74 kJ/kg C) from 72 C to 42 C by using cooling water (cp = 4.18
kJ/kg C) which enters the heat exchanger at 15 C and leaves at 33.2 C. Calculate the area of heat exchanger for the following two
configurations of heat exchanger.
(i) 1− 4 heat exchanger (one-shell pass & four-tube passes heat exchanger); (ii) Cross flow with water mixed and benzene unmixed
The overall heat transfer coefficient (U) in both the cases may be taken as 0.28 W/m2 C.
Solution

U = 0.28 W/m2 C

th1=72 C (i) 1− 4 heat exchanger

θ1
tc2
=33.2 C th2=42 C
θ2 (ii) Cross flow heat exchanger
tc1= 15 C
Heat Exchangers
Limitation of LMTD method
• The LMTD method is easy to use only when the inlet and outlet temperatures of both the hot and cold fluids
are known or can be easily determined from the energy balance expressions. However, if only the inlet
temperatures are known, use of the LMTD method requires a tedious iterative procedure.

• Value of LMTD (θm) is given by:

th1

θ1 th
(=th1− tc1) θ dQ th2
θ2 (=th2− tc2) • Heat given up by the hot fluid = Heat gained by the cold fluid
tc2
tc
tc1 i.e., 𝑄 = 𝑚ℎ 𝑐𝑝ℎ 𝑡ℎ1 − 𝑡ℎ2 = 𝑚𝑐 𝑐𝑝𝑐 𝑡𝑐2 − 𝑡𝑐1
x dx
1 2 𝑄
x=0 Length of HE (L) x=L • Area of heat exchanger calculated 𝐴𝑐𝑎𝑙𝑐𝑢𝑙𝑎𝑡𝑒𝑑 =
𝑈𝜃𝑚
by using above two Eqs.:
• Actual area of heat exchanger: 𝐴𝑎𝑐𝑡𝑢𝑎𝑙 = 𝜋 × 𝑑 × 𝐿

• Kays and London proposed an alternative method in 1955, called the effectiveness-NTU
method, which eliminates the iterations from the analysis and solution of such problems.
Heat Exchangers
Effectiveness-NTU method
Important terms and their definitions used in effectiveness-NTU method
1.) Heat capacity rate: The product of mass flow rate and specific heat of a fluid is termed as heat capacity rate.
⸫ Heat capacity rate of hot fluid: Ch = mhch & Heat capacity rate of cold fluid: Cc = mccc
We know that:
Heat transfer rate in H.E. (Q) = Rate of heat gained by cold fluid = Rate of heat given up by hot fluid
i.e., Q = Cc.∆tc = Ch.∆th

∴ ∆t c = Q. ...(1) ∆t ℎ = Q. ...(2) From Eq. (1) and (2), it can be concluded that:
Cc Ch
th1 ∆t ∝ ...(3)
th1 C
Cc < Ch Ch < Cc
tc2 Above Eq.(3) says that the temperature
change of the cold and hot fluids is inversely
th2 tc2
related to their heat capacity rate, i.e., the
th2 fluid with a smaller value of heat capacity rate
tc1 tc1 will experience the larger change in
Length of HE (L) Length of HE (L) temperature or vice versa.

• In effectiveness-NTU method, the heat capacity rate of fluid having smaller heat capacity rate is represented as Cmin,
and the heat capacity rate of other fluid is represented as Cmax
Heat Exchangers (H.E.)
2.) Maximum possible heat transfer (Qmax)
• Maximum possible heat transfer in H.E. can be achieved in either of the following two cases: Conclusion:
Case-1: The cold fluid is heated up to the inlet Case-2: The hot fluid is cooled up to the Thus the maximum heat
temperature of hot fluid, i.e., tc2 = th1 inlet temperature of cold fluid, i.e., th2 = tc1 transfer (Qmax) in the
∴ 𝑄𝑚𝑎𝑥 = 𝐶𝑐 𝑡𝑐2 − 𝑡𝑐1 = 𝐶𝑐 𝑡ℎ1 − 𝑡𝑐1 ...(1) ∴ 𝑄𝑚𝑎𝑥 = 𝐶ℎ 𝑡ℎ1 − 𝑡ℎ2 = 𝐶ℎ 𝑡ℎ1 − 𝑡𝑐1 ...(2) heat exchanger will take
In this case cold fluid experiences larger change in In this case hot fluid experiences larger change place when one of the
temperature, hence Cc = Cmin. Thus Eq. (1) can be in temperature, hence Ch = Cmin. Thus Eq. (2) fluid of heat exchanger
written as: can be written as:
𝑄𝑚𝑎𝑥 = 𝐶𝑚𝑖𝑛 𝑡ℎ1 − 𝑡𝑐1 = 𝐶𝑚𝑖𝑛 . ∆𝑡𝑚𝑎𝑥 experiences maximum
∴ 𝑄𝑚𝑎𝑥 = 𝐶𝑚𝑖𝑛 𝑡ℎ1 − 𝑡𝑐1 = 𝐶𝑚𝑖𝑛 . ∆𝑡𝑚𝑎𝑥
tc2 where, ∆tmax is the temperature difference
tc2
maximum temperature (∆tmax) available in the
Cold
th1 Hot th2
difference available in Cold H.E. and the fluid that
th1 Hot th2
Cold the heat exchanger. experiences maximum
Cold
tc1 temperature difference
tc1
th1 Cc < Ch th1 will be the one which
Ch < Cc
tc2 or, Cc = Cmin or, Ch = Cmin has lower heat capacity
tc2
rate.
th2
th2
tc1 tc1
Heat Exchangers
3.) Heat exchanger effectiveness (ε)
𝑄𝑎𝑐𝑡 = 𝐶𝑐 𝑡𝑐2 − 𝑡𝑐1
It is defined as the ratio of the actual heat transfer (Qact) to maximum possible heat
transfer (Qmax), i.e.,
𝑄𝑎𝑐𝑡 ....(1)
𝜀=
𝑄𝑚𝑎𝑥
The actual heat transfer rate (Qact) is given by either of the following two equations:
𝑄𝑎𝑐𝑡 = 𝐶ℎ ∆𝑡ℎ 𝑎𝑐𝑡 = 𝐶ℎ 𝑡ℎ1 − 𝑡ℎ2 ....(2) 𝑄𝑎𝑐𝑡 = 𝐶𝑐 ∆𝑡𝑐 𝑎𝑐𝑡 = 𝐶𝑐 𝑡𝑐2 − 𝑡𝑐1 ....(3)

and, Qmax is given by: 𝑄𝑚𝑎𝑥 = 𝐶𝑚𝑖𝑛 . ∆𝑡𝑚𝑎𝑥 = 𝐶𝑚𝑖𝑛 𝑡ℎ1 − 𝑡𝑐1 ....(4)
𝐶ℎ 𝑡ℎ1 − 𝑡ℎ2 𝐶𝑐 𝑡𝑐2 − 𝑡𝑐1
....(5) or, 𝜀= ....(6)
Thus by using Eqs. (2), (3) & (4), Eq. (1) can be written as: 𝜀 = 𝐶𝑚𝑖𝑛 𝑡ℎ1 − 𝑡𝑐1
𝐶𝑚𝑖𝑛 𝑡ℎ1 − 𝑡𝑐1
Since either the hot or cold fluid may have the minimum value of heat capacity rate, therefore effectiveness (ε) can also
be expressed in simplified form as:
Cmin Cmax
𝐶ℎ 𝑡ℎ1 − 𝑡ℎ2 𝑡ℎ1 − 𝑡ℎ2
𝑖𝑓 𝐶ℎ < 𝐶𝑐 ; 𝑢𝑠𝑖𝑛𝑔 𝐸𝑞. 5 , 𝑤𝑒 𝑔𝑒𝑡: 𝜀 = = 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑐 𝑎𝑛𝑔𝑒 𝑜𝑓 𝑓𝑙𝑢𝑖𝑑 𝑎𝑣𝑖𝑛𝑔
𝐶𝑚𝑖𝑛 𝑡ℎ1 − 𝑡𝑐1 𝑡ℎ1 − 𝑡𝑐1 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑒𝑎𝑡 𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦 𝑟𝑎𝑡𝑒
Cmin Cmax 𝜀=
𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑎𝑣𝑎𝑖𝑙𝑎𝑏𝑙𝑒 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑑𝑖𝑓𝑓𝑒𝑟𝑒𝑛𝑐𝑒
𝐶𝑐 𝑡𝑐2 − 𝑡𝑐1 𝑡𝑐2 − 𝑡𝑐1
𝑖𝑓 𝐶𝑐 < 𝐶ℎ ; 𝑢𝑠𝑖𝑛𝑔 𝐸𝑞. 6 , 𝑤𝑒 𝑔𝑒𝑡: 𝜀 = =
𝐶𝑚𝑖𝑛 𝑡ℎ1 − 𝑡𝑐1 𝑡ℎ1 − 𝑡𝑐1
Heat Exchangers
4.) Heat capacity ratio (R)
It is defined as the ratio of the minimum to maximum heat capacity rate, i.e.,
𝐶𝑚𝑖𝑛
𝑅=
𝐶𝑚𝑎𝑥
𝐶𝑐
𝑖𝑓 𝐶𝑐 < 𝐶ℎ 𝑡 𝑒𝑛 𝐶𝑐 = 𝐶𝑚𝑖𝑛 & 𝐶ℎ = 𝐶𝑚𝑎𝑥 ; 𝑒𝑛𝑐𝑒, 𝑅= , 𝑖𝑓 𝐶𝑐 < 𝐶ℎ
𝐶ℎ
and,
𝐶ℎ
𝑖𝑓 𝐶ℎ < 𝐶𝑐 𝑡 𝑒𝑛 𝐶ℎ = 𝐶𝑚𝑖𝑛 & 𝐶𝑐 = 𝐶𝑚𝑎𝑥 ; 𝑒𝑛𝑐𝑒, 𝑅= , 𝑖𝑓 𝐶ℎ < 𝐶𝑐
𝐶𝑐

5.) Number of transfer units (NTU)

It is a dimensionless quantity, defined as:
𝑈𝐴
𝑁𝑇𝑈 =
𝐶𝑚𝑖𝑛
The value of NTU indicates the size of heat exchanger. For a specified value of U and Cmin, number of
transfer units (NTU) is proportional to area of heat exchanger (A). Thus, the larger the NTU, the larger
the size of heat exchanger.
Heat Exchangers
Expression of effectiveness (ε) for parallel flow heat exchanger in th1
terms of NTU (number of transfer units) & R (heat capacity ratio)
Let us consider an element of length dx at a distance x from left hand side of heat th
dth
exchanger. The element has an elementary heat transfer area ‘dA’. dQ th2
The heat flow rate through the elemental length of H.E. is given by: dtc tc2
tc
𝑑𝑄 = 𝑈 𝑑𝐴 𝑡ℎ − 𝑡𝑐 ....(1) tc1 x dx
As a result of heat transfer ‘dQ’ through the area ‘dA’, the temperature of cold fluid increases 1 2
x=0 Length of HE (L) x=L
by dtc and the temperature of hot fluid decreases by dth along the +ve direction of x.

From Eq. (1) & (4), we get 𝑡ℎ2 −𝑡𝑐2

ln 𝑡ℎ − 𝑡𝑐 𝑡ℎ1 −𝑡𝑐1 = −𝑈𝐴 +
𝐶ℎ 𝐶𝑐
..(2)
𝑡ℎ2 − 𝑡𝑐2
ln = −𝑈𝐴 + ..(5)
..(3) 𝑡ℎ1 − 𝑡𝑐1 𝐶ℎ 𝐶𝑐

Integrating above Eq. between section ‘1’ &

‘2’ of H.E. (i.e., from A = 0 to A = A), we get:
𝑡ℎ2 −𝑡𝑐2 𝐴
𝑑 𝑡ℎ − 𝑡𝑐
න = −𝑈 + න 𝑑𝐴
..(4) 𝑡ℎ − 𝑡𝑐 𝐶ℎ 𝐶𝑐
𝑡ℎ1 −𝑡𝑐1 0
Heat Exchangers
Expression of effectiveness (ε) for parallel flow heat exchanger
𝑡ℎ2 − 𝑡𝑐2 𝑡ℎ2 − 𝑡𝑐2
ln = −𝑈𝐴 + ....(5) ⇒ = − 𝜀 𝐶𝑚𝑖𝑛 + ...(10)
𝑡ℎ1 − 𝑡𝑐1 𝐶ℎ 𝐶𝑐 𝑡ℎ1 − 𝑡𝑐1 𝐶ℎ 𝐶𝑐

Now, from definition of effectiveness, we have: From Eq. (5) & (10), we get
𝐶ℎ 𝑡ℎ1 − 𝑡ℎ2 𝐶𝑐 𝑡𝑐2 − 𝑡𝑐1
...(6) and 𝜀= ...(7)
𝜀= 𝐶𝑚𝑖𝑛 𝑡ℎ1 − 𝑡𝑐1 ln − 𝜀 𝐶𝑚𝑖𝑛 + = −𝑈𝐴 +
𝐶𝑚𝑖𝑛 𝑡ℎ1 − 𝑡𝑐1 𝐶ℎ 𝐶𝑐 𝐶ℎ 𝐶𝑐

From Eqs. (6) & (7), the outlet temps. th2 & tc2 can be expressed as:
𝜀 𝐶𝑚𝑖𝑛 𝑡ℎ1 − 𝑡𝑐1 ⇒ − 𝜀 𝐶𝑚𝑖𝑛 + = 𝑒𝑥𝑝 −𝑈𝐴 +
𝑡ℎ2 = 𝑡ℎ1 − ....(8) 𝐶ℎ 𝐶𝑐 𝐶ℎ 𝐶𝑐
𝐶ℎ
𝜀 𝐶𝑚𝑖𝑛 𝑡ℎ1 − 𝑡𝑐1 − 𝑒𝑥𝑝 −𝑈𝐴 𝐶 + 𝐶
𝑡𝑐2 = 𝑡𝑐1 + ....(9)
𝐶𝑐 ℎ 𝑐
⇒ 𝜀=
𝐶𝑚𝑖𝑛 𝐶 + 𝐶
Now, Eq. (8) − Eq. (9) gives: ℎ 𝑐

𝑡ℎ2 − 𝑡𝑐2 = 𝑡ℎ1 − 𝑡𝑐1 − 𝜀 𝐶𝑚𝑖𝑛 𝑡ℎ1 − 𝑡𝑐1 + −𝑈𝐴 𝐶

𝐶ℎ 𝐶𝑐 − 𝑒𝑥𝑝 + 𝐶ℎ
𝐶ℎ 𝑐 ...(11)
⇒ 𝜀=
𝐶𝑚𝑖𝑛 +
⇒ 𝑡ℎ2 −𝑡𝑐2 = 𝑡ℎ1 − 𝑡𝑐1 − 𝜀 𝐶𝑚𝑖𝑛 + 𝐶ℎ 𝐶𝑐
𝐶ℎ 𝐶𝑐
Heat Exchangers
Expression of effectiveness (ε) for parallel flow heat exchanger
−𝑈𝐴 𝐶ℎ Case-2: Cc < Ch, i.e., Cc = Cmin & Ch = Cmax
− 𝑒𝑥𝑝 +
𝐶ℎ 𝐶𝑐 ...(11)
𝜀= In this case, Eq. (11) can be written as:
𝐶𝑚𝑖𝑛 𝐶 + 𝐶
ℎ 𝑐 −𝑈𝐴 𝐶
− 𝑒𝑥𝑝 𝐶 + 𝐶𝑚𝑎𝑥
𝑚𝑎𝑥 𝑚𝑖𝑛
Now, let us consider two cases here: 𝜀=
Case-1: Ch < Cc, i.e., Ch = Cmin & Cc = Cmax 𝐶𝑚𝑖𝑛 +
𝐶𝑚𝑎𝑥 𝐶𝑚𝑖𝑛
Case-2: Cc < Ch, i.e., Cc = Cmin & Ch = Cmax
−𝑈𝐴 𝐶𝑚𝑖𝑛 𝐶𝑚𝑎𝑥
− 𝑒𝑥𝑝 . +
𝐶𝑚𝑎𝑥 𝐶𝑚𝑖𝑛 𝐶𝑚𝑖𝑛
Case-1: Ch < Cc, i.e., Ch = Cmin & Cc = Cmax ⇒ 𝜀=
𝐶𝑚𝑖𝑛 +
In this case, Eq. (11) can be written as: 𝐶𝑚𝑎𝑥 𝐶𝑚𝑖𝑛

−𝑈𝐴 𝐶𝑚𝑖𝑛 −𝑈𝐴 𝐶𝑚𝑖𝑛

− 𝑒𝑥𝑝 + − 𝑒𝑥𝑝 𝐶 +
𝐶𝑚𝑖𝑛 𝐶𝑚𝑎𝑥 𝑚𝑖𝑛 𝐶𝑚𝑎𝑥
𝜀= ⇒ 𝜀=
𝐶𝑚𝑖𝑛 + 𝐶𝑚𝑖𝑛 +
𝐶𝑚𝑖𝑛 𝐶𝑚𝑎𝑥 𝐶𝑚𝑎𝑥 𝐶𝑚𝑖𝑛

− 𝑒𝑥𝑝 −𝑁𝑇𝑈 +𝑅 − 𝑒𝑥𝑝 −𝑁𝑇𝑈 +𝑅

⇒ 𝜀= ...(12) ⇒ 𝜀= ...(13)
+𝑅 +𝑅
Thus, irrespective of whether hot or cold fluid have minimum heat capacity rate, the
expression of effectiveness remains the same as given by Eqs. (12) or (13)
Heat Exchangers
Expression of effectiveness (ε) for counter flow heat exchanger
Following the same process as for parallel flow heat exchanger, the expression of effectiveness for counter flow
heat exchanger can be derived as:
− 𝑒𝑥𝑝 −𝑁𝑇𝑈 − 𝑅
𝜀=
− 𝑅 𝑒𝑥𝑝 −𝑁𝑇𝑈 − 𝑅

where, 𝑄𝑎𝑐𝑡 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑐 𝑎𝑛𝑔𝑒 𝑜𝑓 𝑓𝑙𝑢𝑖𝑑 𝑎𝑣𝑖𝑛𝑔 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑒𝑎𝑡 𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦 𝑟𝑎𝑡𝑒
𝜀= =
𝑄𝑚𝑎𝑥 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑎𝑣𝑎𝑖𝑙𝑎𝑏𝑙𝑒 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 𝑑𝑖𝑓𝑓𝑒𝑟𝑒𝑛𝑐𝑒

𝐶𝑚𝑖𝑛 𝑈𝐴
and, 𝑅= , 𝑁𝑇𝑈 =
𝐶𝑚𝑎𝑥 𝐶𝑚𝑖𝑛

Thus finally we have:

− 𝑒𝑥𝑝 −𝑁𝑇𝑈 +𝑅 − 𝑒𝑥𝑝 −𝑁𝑇𝑈 − 𝑅
𝜀= 𝜀=
+𝑅 − 𝑅 𝑒𝑥𝑝 −𝑁𝑇𝑈 − 𝑅

For parallel flow H.E. For counter flow H.E.

Heat Exchangers
Special case of practical interest
Effectiveness for H.E. For parallel flow H.E. For counter flow H.E.
is given by: − 𝑒𝑥𝑝 −𝑁𝑇𝑈 +𝑅 − 𝑒𝑥𝑝 −𝑁𝑇𝑈 − 𝑅
𝜀= ..(1) 𝜀= ..(2)
+𝑅 − 𝑅 𝑒𝑥𝑝 −𝑁𝑇𝑈 − 𝑅
Following are the two special cases of practical interest:
Case 1: when R = 0 Case 2: when R = 1

Case 1: when R = 0
Let us consider a case in which one of the fluid in Heat exchanger is being condensed or evaporated, i.e., one
of the fluid is undergoing a phase change process.
𝑑
We know that the specific heat of fluid during Specific heat at constant pressure is given by: 𝑐𝑝 =
𝑑𝑡
phase change process tends to be infinity. During phase change: dt = 0, ⸫ cp = ∞

Thus the capacity rate for the fluid undergoing phase change becomes: C = m.cp = ∞ = Cmax

Consequently in this case; capacity ratio = R = Cmin/Cmax = 0

Thus the expression of effectiveness in this case for both
parallel and counter flow configuration is reduced to: 𝜀= − exp(−𝑁𝑇𝑈)
Heat Exchangers
Case 2: when R = 1
Let us consider a case in which the mass flow rate and specific heat of hot and cold fluid are as given below:
For hot fluid: mh = 2 kg/s, ch = 1 kg/kg C; For cold fluid: mc = 4 kg/s, cc = 0.5 kg/kg C; Thus in this case R = 1
Effectiveness for H.E. For parallel flow H.E. For counter flow H.E.
is given by: − 𝑒𝑥𝑝 −𝑁𝑇𝑈 +𝑅 − 𝑒𝑥𝑝 −𝑁𝑇𝑈 − 𝑅 ..(2)
𝜀= ..(1) 𝜀=
+𝑅 − 𝑅 𝑒𝑥𝑝 −𝑁𝑇𝑈 − 𝑅
− 𝑒𝑥𝑝 −2. 𝑁𝑇𝑈
In case of parallel flow H.E., using R = 1 with Eq. (1), we get: 𝜀 =
2
− 𝑒𝑥𝑝 −𝑁𝑇𝑈 − 𝑅 0
In case of counter flow, H.E. using R = 1 with Eq. (2), we get: 𝜀 = = ,which is indeterminate
− 𝑅 𝑒𝑥𝑝 −𝑁𝑇𝑈 − 𝑅 0
𝑓(𝑥) 𝑓′(𝑥)
lim
The value of 𝜀 for such a case can be found by applying L’ Hospital’s rule which states that: 𝑥 → 𝑎 = lim
𝑔(𝑥) 𝑥 → 𝑎 𝑔′(𝑥)
− 𝑁𝑇𝑈 1−𝑅 𝑒 𝑁𝑇𝑈 1−𝑅 −
Eq.(2) [𝜀 for counter flow H.E.] can be rewritten as: 𝜀 = 𝑒 = 𝑁𝑇𝑈 1−𝑅
𝑅 𝑒 −𝑅
−
𝑒 𝑁𝑇𝑈 1−𝑅

Thus by using L’ Hospital’s rule, 𝜀 for this case can be calculated as:
𝑒 𝑁𝑇𝑈 1−𝑅 − 𝑒 𝑁𝑇𝑈 1−𝑅 . (−𝑁𝑇𝑈) −𝑁𝑇𝑈 𝑁𝑇𝑈
𝜀 = lim 𝑁𝑇𝑈 1−𝑅 = lim = =
𝑅→1 𝑒 − 𝑅 𝑅 → 1 [𝑒 𝑁𝑇𝑈 1−𝑅 . (−𝑁𝑇𝑈)] − −𝑁𝑇𝑈 − + 𝑁𝑇𝑈
Question
16.5 kg/s of the hot fluid (cp = 3.55 kJ/kg C) at 650 C, in a chemical plant, is to be used to heat 20.5 kg/s of the liquid
product (cp = 4.2 kJ/kg C) at 100 C in a concentric tube counter flow heat exchanger. If the overall heat transfer coefficient
is 0.95 W/m2 C and the effective heat transfer area is 44 m2, calculate outlet temperatures of both the fluids.
Solution
END