Lecture 3

THERMAL DESIGN
Conduction

Fourier’s law

∆𝑇
𝑞=
σ 𝑅𝑖
𝛿𝑖
𝑅𝑖 =
𝑘𝑖
Convection

Newton’s law

∆𝑇
𝑞=
𝑅
1
𝑅=
ℎ
ℎ = 𝑓 𝐺𝑟, 𝑅𝑒, 𝑃𝑟 …
 Radiation

Stefan–Boltzmann’s law

∆ 𝑇4 ∆𝑇
𝑞= =
… 𝑅
𝑔 𝜀𝑖 , 𝑓𝑖
𝑅=
𝜎 𝑇12 + 𝑇22 𝑇1 + 𝑇2
 General

𝑞 = 𝑈∆𝑇
൞ 1
𝑈=
σ 𝑅𝑐𝑜𝑛𝑑 + 𝑅𝑐𝑜𝑛𝑣 + 𝑅𝑟𝑎𝑑
 General

𝑇1 𝑇1 𝑇𝑤1 𝑇𝑤2 𝑇2

𝑇𝑤1
ℎ1
𝑄 𝑇1 − 𝑇2
𝑇𝑤2
𝑞= = = 𝑈∆𝑇
ℎ2
𝐴 1 𝛿 1
+ +
ℎ1 𝑘 ℎ2
𝑇2

0 𝛿 𝑥
𝑇1 − 𝑇 𝑥 𝑥 1
=𝑈 +
𝑇1 − 𝑇2 𝑘 ℎ1
 Example 1
One side of a plane wall is maintained at 100℃, while
the other side is exposed to a convection environment
having T = 10℃ and ℎ = 10 𝑊 Τ𝑚2 . The wall has 𝑘 =
1.6 𝑊 Τ𝑚℃ and is 40𝑐𝑚 thick. Calculate the heat
transfer rate through the wall.
 General

𝑞 𝑇2
𝑇1

𝑇1 𝑇𝑤1 𝑇𝑤2 𝑇2

𝑇1 − 𝑇2
𝑄=
1 1 𝑟2 1
+ ln +
2𝜋𝐿𝑟1 ℎ1 2𝜋𝑘𝐿 𝑟1 2𝜋𝐿𝑟2 ℎ2
 General

𝑞 𝑇2
𝑇1

𝑇1 𝑇𝑤1 𝑇𝑤2 𝑇2

𝑟2 − 𝑟1 𝑟 1
𝑇1 − 𝑇 𝑟 ln +
𝑘 𝑟1 ℎ1
=
𝑇1 − 𝑇2 1 𝑟2 − 𝑟1 𝑟2 1
+ ln +
ℎ1 𝑘 𝑟1 ℎ2
Overall heat transfer coefficients

Physical situation 𝑼 𝑾Τ𝒎𝟐 ℃

Brick exterior wall, plaster interior, uninsulated 2,55
Frame exterior wall, plaster interior, uninsulated 1,42
Frame exterior wall, plaster interior with rock–wool insulation 0,40
Plate–glass window 6,20
Double plate–glass window 2,30
Steam condenser 1100 – 5600
Feed water heater 1100 – 8500
Freon–12 condenser with water coolant 280 – 850
Water–to–water heat exchanger 850 – 1700
Overall heat transfer coefficients

Physical situation 𝑼 𝑾Τ𝒎𝟐 ℃

Water–to–oil heat exchanger 110 – 350
Steam to light fuel oil 170 – 340
Steam to heavy fuel oil 56 – 170
Steam to kerosene or gasoline 280 – 1140
Ammonia condenser, water in tubes 850 – 1400
Alcohol condenser, water in tubes 255 – 680
Gas–to–gas heat exchanger 10 – 40
Finned–tube heat exchanger, water in tubes, air across tubes 25 – 55
Finned–tube heat exchanger, steam in tubes, air over tubes 28 – 280
Critical thickness of insulation
𝑞
ℎ 𝑇∞
𝑇1
𝑟1 𝑇1 𝑇2 𝑇∞
𝑟2 𝑇2
𝑇1 − 𝑇2 𝑇2 − 𝑇∞
𝑄= =
1 𝑟2 1
ln 2𝜋𝑟2 𝐿ℎ
2𝜋𝑘𝐿 𝑟1
2𝜋𝐿 𝑇1 − 𝑇∞
Insulation 𝑄=
layer 1 𝑟2 1
ln +
𝑘 𝑟1 𝑟2 ℎ
Critical thickness of insulation
𝑑𝑄
=0
𝑑𝑟2

𝑘
𝑟𝑐 =
ℎ
 Critical thickness of insulation
𝑄 𝑄
𝑄𝑜

𝑄𝑜

𝑟2 𝑟𝑐 𝑟𝑖𝑛𝑠 𝑟𝑐 𝑟2 = 𝑟𝑖𝑛𝑠

• 𝑟2 < 𝑟𝑐 : insulation increases heat transfer

• 𝑟2 > 𝑟𝑐 : insulation decreases heat transfer
 Example 2
Calculate the critical radius of insulation for
asbestos 𝑘 = 0.17 𝑊 Τ𝑚℃ surrounding a pipe
and exposed to room air at 20℃ with ℎ =
3 𝑊 Τ𝑚2 ℃. Calculate the heat loss from a 200℃,
5𝑐𝑚 diameter pipe when covered with the critical
radius of insulation and without insulation
 Fouling factors

1 1
𝑅𝑓𝑜𝑢𝑙𝑖𝑛𝑔 = −
𝑈𝑑𝑖𝑟𝑡𝑦 𝑈𝑐𝑙𝑒𝑎𝑛
 Fouling factors

Type of fluid Fouling factor 𝒎𝟐 ℃Τ𝑾

Sea water, below 125oF 0,09 × 10−3
Sea water, above 125oF 2 × 10−3
Treated boiler feed water above 125oF 0,2 × 10−3
Fuel oil 0,9 × 10−3
Quenching oil 0,7 × 10−3
Alcohol vapors 0,09 × 10−3
Steam, non–oil–bearing 0,09 × 10−3
Industrial air 0,4 × 10−3
Refrigerating liquid 0,2 × 10−3
 Overall heat transfer coefficient
1 1
Negligible radiation 𝑈= =
𝑊 Τ𝑚2 ℃ σ 𝑅 𝑅𝑐𝑜𝑛𝑑 + 𝑅𝑐𝑜𝑛𝑣 + 𝑅𝑓𝑜𝑢𝑙𝑖𝑛𝑔

1 1
For plane wall 𝑈= =
σ𝑅 𝛿𝑖 1
𝑊 Τ𝑚2 ℃ σ + σ + σ 𝑅𝑓𝑜𝑢𝑙𝑖𝑛𝑔
𝑘𝑖 ℎ𝑖

1 2𝜋
For cylinder 𝑈𝐿 = =
𝑊 Τ𝑚℃ σ 𝑅 1 1 𝑟𝑖,𝑜𝑢𝑡 𝑅𝑓𝑜𝑢𝑙𝑖𝑛𝑔
σ + σ ln +σ
𝑟𝑖 ℎ𝑖 𝑘𝑖 𝑟𝑖,𝑖𝑛 𝑟𝑖
 Overall heat transfer coefficient
1 2𝜋
For cylinder 𝑈𝐿 = =
𝑊 Τ𝑚℃ σ𝑅 1 1 𝑟𝑖,𝑜𝑢𝑡 𝑅𝑓𝑜𝑢𝑙𝑖𝑛𝑔
σ + σ ln +σ
𝑟𝑖 ℎ𝑖 𝑘𝑖 𝑟𝑖,𝑖𝑛 𝑟𝑖
If based on outside area 𝐴𝑜 = 2𝜋𝑟𝑜𝑢𝑡
1
𝑈𝑜 =
1 𝑟𝑜𝑢𝑡 𝑟𝑜𝑢𝑡 𝑟𝑜𝑢𝑡 𝑟𝑜𝑢𝑡 𝑅𝑖𝑛,𝑓
2
𝑊 Τ𝑚 ℃ + + ln + 𝑅𝑜𝑢𝑡,𝑓 +
ℎ𝑜𝑢𝑡 𝑟𝑖𝑛 ℎ𝑖𝑛 𝑘 𝑟𝑖𝑛 𝑟𝑖𝑛
If based on inside area 𝐴𝑖 = 2𝜋𝑟𝑖𝑛
1
𝑈𝑖 =
1 𝑟𝑖𝑛 𝑟𝑖𝑛 𝑟𝑜𝑢𝑡 𝑟𝑖𝑛 𝑅𝑜𝑢𝑡,𝑓
2
𝑊 Τ𝑚 ℃ + + ln + 𝑅𝑖𝑛,𝑓 +
ℎ𝑖𝑛 𝑟𝑜𝑢𝑡 ℎ𝑜𝑢𝑡 𝑘 𝑟𝑖𝑛 𝑟𝑜𝑢𝑡
 Example 3
In a condenser steam flows outside the tubes of radius 59𝑚𝑚 and
54𝑚𝑚 and sea water flows inside the tubes. The thermal conductivity
of the tube material is 60 𝑊 Τ𝑚𝐾. The steam and water temperatures
are below 50℃. The convection coefficient on the steam side is
12000 𝑊 Τ𝑚2 𝐾 and the value on the water side is 650 𝑊 Τ𝑚2 𝐾.
a) Calculate the values of overall coefficient based on inside and
outside areas.
b) Determine the percentage error involved in neglecting conduction
resistance / fouling on the inside and outside and conduction /
considering only the water side resistance.
 Example 3
ℎ𝑖 = 650 𝑊 Τ𝑚2 𝐾 From tabulated values:
ℎ𝑜 = 12000 𝑊 Τ𝑚2 𝐾 𝑅𝑖 = 𝑅𝑠𝑒𝑎 𝑤𝑎𝑡𝑒𝑟 = 0.00009 𝑚2 𝐾Τ𝑊
𝑘 = 60 𝑊 Τ𝑚𝐾 ൝
𝑅𝑜 = 𝑅𝑠𝑡𝑒𝑎𝑚 = 0.00009 𝑚2 𝐾Τ𝑊
𝑟𝑖 = 54𝑚𝑚
𝑟𝑜 = 59𝑚𝑚
1
𝑈𝑜 = = 490 𝑊 Τ𝑚2 𝐾
1 𝑟𝑜 𝑟𝑜 𝑟𝑜 1
+ 𝑅𝑜,𝑓 + ln + + 𝑅𝑖,𝑓
ℎ𝑜 𝑘 𝑟𝑖 𝑟𝑖 ℎ𝑖

1
𝑈𝑖 = = 536 𝑊 Τ𝑚2 𝐾
𝑟𝑖 1 𝑟𝑖 𝑟𝑜 1
+ 𝑅𝑜,𝑓 + ln + + 𝑅𝑖,𝑓
𝑟𝑜 ℎ𝑜 𝑘 𝑟𝑖 ℎ𝑖
 Example 3
Neglecting conduction resistance:

1
𝑈𝑜 = = 512 𝑊 Τ𝑚2 𝐾
1 𝑟 1
+ 𝑅𝑜,𝑓 + 𝑜 + 𝑅𝑖,𝑓
ℎ𝑜 𝑟𝑖 ℎ𝑖

1
𝑈𝑖 = = 560 𝑊 Τ𝑚2 𝐾
𝑟𝑖 1 1
+ 𝑅𝑜,𝑓 + + 𝑅𝑖,𝑓
𝑟𝑜 ℎ𝑜 ℎ𝑖
 Example 3
Neglecting fouling on inside and outside and conduction resistance:

1
𝑈𝑜 = = 567 𝑊 Τ𝑚2 𝐾
1 𝑟𝑜 1
+
ℎ𝑜 𝑟𝑖 ℎ𝑖

1
𝑈𝑖 = = 619 𝑊 Τ𝑚2 𝐾
𝑟𝑖 1 1
+
𝑟𝑜 ℎ𝑜 ℎ𝑖
 Example 3
Considering only the water side resistance:

1
𝑈𝑜 = = 537 𝑊 Τ𝑚2 𝐾
1 𝑟𝑜 1
+ + 𝑅𝑖,𝑓
ℎ𝑜 𝑟𝑖 ℎ𝑖

1
𝑈𝑖 = = 587 𝑊 Τ𝑚2 𝐾
𝑟𝑖 1 1
+ + 𝑅𝑖,𝑓
𝑟𝑜 ℎ𝑜 ℎ𝑖
 The Log Mean
Temperature Difference ∆𝑇𝐿𝑀𝑇𝐷
 Pure double pipe

𝑇 𝑇

𝑇ℎ1

𝑇ℎ1
𝑇ℎ2
𝑇𝑐1
𝑇𝑐2 𝑇ℎ2

𝑇𝑐1
𝑇𝑐2

𝐴 𝐴
1 2 1 2
Parallel flow Counter flow
 Pure double pipe
𝑇 Parallel flow
𝑇ℎ1
“energy balance”
𝑑𝑞
𝑇ℎ 𝑑𝑞 = −𝑚ℎ 𝑐ℎ 𝑑𝑇ℎ 𝑑𝑇ℎ = −
“design equation” 𝑇ℎ2
𝑚ℎ 𝑐ℎ
𝑑𝑞 = 𝑈𝑑𝐴 𝑇ℎ − 𝑇𝑐
𝑇𝑐 𝑑𝑞 𝑇𝑐2
𝑑𝑞 “energy balance”
𝑇ℎ − 𝑇𝑐 = 𝑑𝐴 𝑑𝑞
𝑈𝑑𝐴 𝑇𝑐1 𝑑𝑞 = 𝑚𝑐 𝑐𝑐 𝑑𝑇𝑐 𝑑𝑇𝑐 =
𝑚𝑐 𝑐𝑐

𝐴
1 2

𝑑 𝑇ℎ − 𝑇𝑐 1 1
= −𝑈 + 𝑑𝐴
𝑇ℎ − 𝑇𝑐 𝑚ℎ 𝑐ℎ 𝑚𝑐 𝑐𝑐
 Pure double pipe
Integration from “section 1” to “section 2” 𝑄 = 𝑚ℎ 𝑐ℎ 𝑇ℎ1 − 𝑇ℎ2
𝑄 = 𝑚𝑐 𝑐𝑐 𝑇𝑐2 − 𝑇𝑐1
𝑇ℎ2 − 𝑇𝑐2 1 1
ln = −𝑈 + 𝐴
𝑇ℎ1 − 𝑇𝑐1 𝑚ℎ 𝑐ℎ 𝑚𝑐 𝑐𝑐
𝑇ℎ2 − 𝑇𝑐2 𝑇ℎ1 − 𝑇ℎ2 𝑇𝑐2 − 𝑇𝑐1
then, ln = −𝑈 + 𝐴
𝑇ℎ1 − 𝑇𝑐1 𝑄 𝑄
𝑇ℎ2 − 𝑇𝑐2 − 𝑇ℎ1 − 𝑇𝑐1
or, 𝑄 = 𝑈𝐴 = 𝑈𝐴∆𝑇𝐿𝑀𝑇𝐷
𝑇 − 𝑇𝑐2
ln ℎ2
𝑇ℎ1 − 𝑇𝑐1
∆𝑇𝑚𝑎𝑥 − ∆𝑇𝑚𝑖𝑛
where, ∆𝑇𝐿𝑀𝑇𝐷 =
∆𝑇𝑚𝑎𝑥
ln
∆𝑇𝑚𝑖𝑛
 Pure double pipe
Assumptions:
• No phase change and negligible heat losses
• Pure double pipe: parallel flow / counter flow
• Constant specific heats 𝑐ℎ , 𝑐𝑐
• Constant overall heat transfer coefficient 𝑈

The ∆𝑇𝐿𝑀𝑇𝐷 for counter flow is higher than that one for
parallel flow, hence the area is smaller for given heat load 𝑄
Non double pipe

𝑄 = 𝑓𝑈𝐴∆𝑇𝐿𝑀𝑇𝐷
𝑓 is a correction factor
 Non double pipe
1 shell pass – 2 tube passes
1.0
𝑇1
𝑡2

𝑡1
𝑇2
0.9 𝑇1 − 𝑇2
𝑓 factor

𝑅=
𝑡2 − 𝑡1

0.8

0.7

0.6
𝑡2 − 𝑡1
𝑃=
𝑇1 − 𝑡1
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 – 2𝑛 tube passes (error 2%)

1−𝑃
ln 1 − 𝑅𝑃 𝑅2 + 1
𝑓= for 𝑅 ≠ 1
2 − 𝑃 𝑅 + 1 − 𝑅2 + 1
𝑅 − 1 ln
2 − 𝑃 𝑅 + 1 + 𝑅2 + 1

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

0.9

𝑇1
𝑡2

0.8

𝑡1
𝑇2
0.7

𝑇1 − 𝑇2
𝑅=
𝑡2 − 𝑡1
0.6

𝑡2 − 𝑡1
𝑃=
𝑇1 − 𝑡1
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
𝑛(1 shell pass – 2 tube passes)
𝑛: number of shells

for 𝑅 ≠ 1 1Τ𝑛
1 − 𝑃′ 1 − 𝑅𝑃
−1
ln 𝑅2 + 1 1−𝑃
1 − 𝑅𝑃′
𝑓= 𝑃′ = 1Τ𝑛
2 − 𝑃′ 𝑅 + 1 − 𝑅2 + 1 1 − 𝑅𝑃
𝑅 − 1 ln −𝑅
1−𝑃
2 − 𝑃′ 𝑅 + 1 + 𝑅2 + 1

for 𝑅 = 1
2𝑃′ 𝑃
𝑓= 𝑃′ =
2 − 𝑃 ′ 2− 2 𝑃 − 𝑛𝑃 + 𝑛
1 − 𝑃′ ln
2 − 𝑃′ 2 + 2
 𝑇1

Non double pipe 𝑡2

2 shell pass – 4 tube passes 𝑡1

𝑇2
𝑇1 − 𝑇2
𝑅=
𝑡2 − 𝑡1
1.0
𝑓 factor

0.9

0.8
𝑅 = 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

𝑡2 − 𝑡1
𝑃=
𝑇1 − 𝑡1
 Non double pipe 𝑇1 𝑇1
𝑡2

𝑡1
Divided flow shell – 2 tube passes 𝑇2

𝑇1 − 𝑇2
𝑅=
𝑡2 − 𝑡1
1.0
𝑓 factor

0.9
𝑅 = 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

𝑡2 − 𝑡1
𝑃=
𝑇1 − 𝑡1
 Non double pipe 𝑇1
𝑡2

𝑡1
Split flow shell – 2 tube passes 𝑇2

𝑇1 − 𝑇2
𝑅=
𝑡2 − 𝑡1
1.0
𝑓 factor

0.9

0.8

0.7
𝑅 = 10

4.0
8.0

6.0

5.0

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
𝑡2 − 𝑡1
𝑃=
𝑇1 − 𝑡1
 Non double pipe
single pass cross flow exchangers and both fluids unmixed
1.0
𝑓 factor

0.9

𝑇1
0.8
𝑡1 𝑡2

𝑇2
0.7

𝑇1 − 𝑇2
𝑅=
0.6 𝑡2 − 𝑡1
𝑡2 − 𝑡1
𝑃=
𝑇1 − 𝑡1
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
𝑓 factor

0.9

𝑇1
0.8
𝑡1 𝑡2

𝑇2
0.7

𝑇1 − 𝑇2
𝑅=
0.6 𝑡2 − 𝑡1
𝑡2 − 𝑡1
𝑃=
𝑇1 − 𝑡1
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, 𝑃 = 0 or 𝑅 = 0, so 𝑓 = 1
 Design equation

𝑈, 𝑣 and operation
cost are covariant

𝑄 = 𝑓𝑈𝐴∆𝑇𝐿𝑀𝑇𝐷
𝐴 and capital cost
are covariant
 Example 4
An exhaust pipe, 75𝑚𝑚 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 𝑘𝑔Τℎ, mean specific heat
capacity at constant pressure 1.13 𝑘𝐽Τ𝑘𝑔𝐾, and comes out at 100℃.
Water enters from the mains at 25℃, flow rate 1400 𝑘𝑔Τℎ, mean
specific heat capacity 4.19 𝑘𝐽Τ𝑘𝑔𝐾. The heat coefficient for gases and
water may be taken as 0.3 and 1.5 𝑘𝑊 Τ𝑚2 𝐾 and pipe thickness may
be taken as negligible.
Calculate the required pipe length for parallel flow and for counter flow.
 Example 4
ℎ𝑖 = 0.3 𝑘𝑊 Τ𝑚2 𝐾 Energy balance:
ℎ𝑜 = 1.5 𝑘𝑊 Τ𝑚2 𝐾
𝑄 = 𝑚𝑖 𝑐𝑖 𝑇𝑖 − 𝑇𝑜 = 𝑚𝑜 𝑐𝑜 𝑡𝑜 − 𝑡𝑖
𝑚𝑖 = 200 𝑘𝑔Τℎ
𝑚𝑜 = 1400 𝑘𝑔Τℎ 𝑄 = 15.7𝑘𝑊 𝑡𝑜 = 34.63℃
𝑐𝑝,𝑖 = 1.13 𝑘𝐽Τ𝑘𝑔𝐾
𝑐𝑝,𝑜 = 4.19 𝑘𝐽Τ𝑘𝑔𝐾
Overall heat transfer coefficient:
𝑇𝑖 = 350℃
𝑇𝑜 = 100℃ 2𝜋
𝑡𝑖 = 25℃ 𝑈𝐿 = = 0.0589 𝑘𝑊 Τ𝑚𝐾
1 1
+
𝑑 = 75𝑚𝑚 𝑟ℎ𝑖 𝑟ℎ𝑜
 Example 4
𝑇 𝑇
Parallel flow Counter flow
𝑇1

𝑇1
𝑇2
𝑡1
𝑡2 𝑇2

𝑡1
𝑡2

𝐴 𝐴
1 2 1 2

∆𝑇𝑚𝑎𝑥 − ∆𝑇𝑚𝑖𝑛 ∆𝑇𝑚𝑎𝑥 − ∆𝑇𝑚𝑖𝑛

∆𝑇𝐿𝑀𝑇𝐷 = = 161.9℃ ∆𝑇𝐿𝑀𝑇𝐷 = = 167.4℃
∆𝑇𝑚𝑎𝑥 ∆𝑇𝑚𝑎𝑥
ln ln
∆𝑇𝑚𝑖𝑛 ∆𝑇𝑚𝑖𝑛
𝑄 𝑄
𝐿= = 1.65𝑚 𝐿= = 1.59𝑚
𝑈𝐿 ∆𝑇𝐿𝑀𝑇𝐷 𝑈𝐿 ∆𝑇𝐿𝑀𝑇𝐷
 Effectiveness 𝜀 and
Number of Transfer Units 𝑁𝑇𝑈
 Effectiveness

𝑎𝑐𝑡𝑢𝑎𝑙 ℎ𝑒𝑎𝑡 𝑡𝑟𝑎𝑛𝑠𝑓𝑒𝑟 𝑄𝑎𝑐𝑡

𝜀= =
𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑝𝑜𝑠𝑠𝑖𝑏𝑙𝑒 ℎ𝑒𝑎𝑡 𝑡𝑟𝑎𝑛𝑠𝑓𝑒𝑟 𝑄𝑚𝑎𝑥

𝑄𝑎𝑐𝑡 = 𝜀𝑄𝑚𝑎𝑥

In a thermodynamic sense, higher effectiveness

correspond to reduced thermodynamic irreversibility
and smaller entropy generation
 Pure double pipe
Parallel flow Counter flow
𝑇 𝑇

𝑇ℎ1

𝑇ℎ1
𝑇ℎ2
𝑇𝑐1
𝑇𝑐2 𝑇ℎ2

𝑇𝑐1
𝑇𝑐2

𝐴 𝐴
1 2 1 2

𝑄𝑎𝑐𝑡 = 𝑚𝑐 ℎ 𝑇ℎ1 − 𝑇ℎ2 𝑄𝑎𝑐𝑡 = 𝑚𝑐 ℎ 𝑇ℎ1 − 𝑇ℎ2

= 𝑚𝑐 𝑐 𝑇𝑐2 − 𝑇𝑐1 = 𝑚𝑐 𝑐 𝑇𝑐1 − 𝑇𝑐2
 Pure double pipe
Counter flow

𝑇ℎ,𝑖𝑛 𝑇ℎ,𝑖𝑛
𝑇𝑐,𝑜𝑢𝑡
𝑇ℎ,𝑜𝑢𝑡 𝑇𝑐,𝑜𝑢𝑡
𝑇ℎ,𝑜𝑢𝑡
𝑇𝑐,𝑖𝑛 𝑇𝑐,𝑖𝑛
𝑄𝑚𝑎𝑥 𝑄𝑚𝑎𝑥

1 2 1 2
𝑄𝑚𝑎𝑥 = 𝑚𝑐 𝑐 𝑇ℎ,𝑖𝑛 − 𝑇𝑐,𝑖𝑛 𝑄𝑚𝑎𝑥 = 𝑚𝑐 ℎ 𝑇ℎ,𝑖𝑛 − 𝑇𝑐,𝑖𝑛

𝑄𝑚𝑎𝑥 = 𝑚𝑐 𝑚𝑖𝑛 𝑇ℎ,𝑖𝑛 − 𝑇𝑐,𝑖𝑛

 Pure double pipe
Counter flow

For energy balance 𝑄𝑎𝑐𝑡 = 𝑚𝑐 ℎ 𝑇ℎ1 − 𝑇ℎ2 = 𝑚𝑐 𝑐 𝑇𝑐1 − 𝑇𝑐2

𝑚𝑐 𝑐 𝑇𝑐1 − 𝑇𝑐2 𝑇𝑐1 − 𝑇𝑐2

If 𝑚𝑐 𝑐 < 𝑚𝑐 ℎ 𝜀𝑐 = =
𝑚𝑐 𝑐 𝑇ℎ1 − 𝑇𝑐2 𝑇ℎ1 − 𝑇𝑐2

𝑚𝑐 ℎ 𝑇ℎ1 − 𝑇ℎ2 𝑇ℎ1 − 𝑇ℎ2

If 𝑚𝑐 ℎ < 𝑚𝑐 𝑐 𝜀ℎ = =
𝑚𝑐 ℎ 𝑇ℎ1 − 𝑇𝑐2 𝑇ℎ1 − 𝑇𝑐2

∆𝑇𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑚𝑐 𝑓𝑙𝑢𝑖𝑑
𝜀=
∆𝑇𝑚𝑎𝑥,𝑒𝑥𝑐ℎ𝑎𝑛𝑔𝑒𝑟
 Pure double pipe
Parallel flow
𝑄𝑚𝑎𝑥
𝑇ℎ,𝑖𝑛 𝑇𝑐,𝑜𝑢𝑡

𝑇ℎ,𝑜𝑢𝑡

𝑇𝑐,𝑖𝑛

1 2
𝑄𝑚𝑎𝑥 = 𝑚𝑐 𝑐 𝑇ℎ,𝑖𝑛 − 𝑇𝑐,𝑖𝑛
 Pure double pipe
Parallel flow
𝑇ℎ,𝑖𝑛

𝑇𝑐,𝑜𝑢𝑡

𝑇𝑐,𝑖𝑛 𝑇ℎ,𝑜𝑢𝑡
𝑄𝑚𝑎𝑥
1 2
𝑄𝑚𝑎𝑥 = 𝑚𝑐 ℎ 𝑇ℎ,𝑖𝑛 − 𝑇𝑐,𝑖𝑛

𝑄𝑚𝑎𝑥 = 𝑚𝑐 𝑚𝑖𝑛 𝑇ℎ,𝑖𝑛 − 𝑇𝑐,𝑖𝑛

 Pure double pipe
Parallel flow

For energy balance 𝑄𝑎𝑐𝑡 = 𝑚𝑐 ℎ 𝑇ℎ1 − 𝑇ℎ2 = 𝑚𝑐 𝑐 𝑇𝑐2 − 𝑇𝑐1

𝑚𝑐 𝑐 𝑇𝑐2 − 𝑇𝑐1 𝑇𝑐2 − 𝑇𝑐1

If 𝑚𝑐 𝑐 < 𝑚𝑐 ℎ 𝜀𝑐 = =
𝑚𝑐 𝑐 𝑇ℎ1 − 𝑇𝑐1 𝑇ℎ1 − 𝑇𝑐1

𝑚𝑐 ℎ 𝑇ℎ1 − 𝑇ℎ2 𝑇ℎ1 − 𝑇ℎ2

If 𝑚𝑐 ℎ < 𝑚𝑐 𝑐 𝜀ℎ = =
𝑚𝑐 ℎ 𝑇ℎ1 − 𝑇𝑐1 𝑇ℎ1 − 𝑇𝑐1

∆𝑇𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑚𝑐 𝑓𝑙𝑢𝑖𝑑
𝜀=
∆𝑇𝑚𝑎𝑥,𝑒𝑥𝑐ℎ𝑎𝑛𝑔𝑒𝑟
 Pure double pipe
Parallel flow

For energy balance 𝑚𝑐 ℎ 𝑇ℎ1 − 𝑇ℎ2 = 𝑚𝑐 𝑐 𝑇𝑐2 − 𝑇𝑐1

𝑇𝑐2 − 𝑇𝑐1
If 𝑚𝑐 𝑐 < 𝑚𝑐 ℎ 𝜀=
𝑇ℎ1 − 𝑇𝑐1

𝑇ℎ2 − 𝑇𝑐2 1 1
Design equation ln = −𝑈 + 𝐴
𝑇ℎ1 − 𝑇𝑐1 𝑚𝑐 ℎ 𝑚𝑐 𝑐

Temperature elimination
 Pure double pipe
Parallel flow

For energy balance 𝑚𝑐 ℎ 𝑇ℎ1 − 𝑇ℎ2 = 𝑚𝑐 𝑐 𝑇𝑐2 − 𝑇𝑐1

𝑚𝑐 𝑐
𝑇ℎ2 = 𝑇ℎ1 + 𝑇𝑐1 − 𝑇𝑐2
𝑇𝑐2 − 𝑇𝑐1 𝑚𝑐 ℎ
If 𝑚𝑐 𝑐 < 𝑚𝑐 ℎ 𝜀=
𝑇ℎ1 − 𝑇𝑐1

𝑇ℎ2 − 𝑇𝑐2 𝑈𝐴 𝑚𝑐 𝑐
Design equation ln =− +1
𝑇ℎ1 − 𝑇𝑐1 𝑚𝑐 𝑐 𝑚𝑐 ℎ

𝑚𝑐 𝑐
𝑇ℎ1 + 𝑇 − 𝑇𝑐2 − 𝑇𝑐2
𝑚𝑐 ℎ 𝑐1 𝑇ℎ1 − 𝑇𝑐1 𝑚𝑐 𝑐𝑇𝑐1 − 𝑇𝑐2 𝑇𝑐1 − 𝑇𝑐2
ln = ln + +
𝑇ℎ1 − 𝑇𝑐1 𝑇ℎ1 − 𝑇𝑐1 𝑚𝑐 𝑇
ℎ ℎ1 − 𝑇𝑐1 𝑇ℎ1 − 𝑇𝑐1
 Pure double pipe
Parallel flow

𝑚𝑐 𝑐 𝑈𝐴 𝑚𝑐 𝑐
Therefore, ln 1 − 1 + 𝜀 =− 1+
𝑚𝑐 ℎ 𝑚𝑐 𝑐 𝑚𝑐 ℎ

𝑚𝑐 𝑚𝑖𝑛 𝑚𝑐 𝑚𝑖𝑛
ln 1 − 1 + 𝜀 = −𝑁𝑇𝑈 1 +
𝑚𝑐 𝑚𝑎𝑥 𝑚𝑐 𝑚𝑎𝑥

𝑈𝐴
Number of Transfer Units 𝑁𝑇𝑈 𝑁𝑇𝑈 =
indicates the size of heat exchanger 𝑚𝑐 𝑚𝑖𝑛
 Pure double pipe
Counter flow

1−𝜀 𝑚𝑐 𝑚𝑖𝑛
ln = −𝑁𝑇𝑈 1 −
𝑚𝑐 𝑚𝑖𝑛 𝑚𝑐 𝑚𝑎𝑥
1−𝜀
𝑚𝑐 𝑚𝑎𝑥

𝑈𝐴
where, 𝑁𝑇𝑈 =
𝑚𝑐 𝑚𝑖𝑛
 Pure double pipe
Parallel flow Counter flow
100 100
𝐶𝑚𝑖𝑛 Τ𝐶𝑚𝑎𝑥 = 0
Effectiveness 𝜀 %

Effectiveness 𝜀 %
0.25
80 80

0.50

60 0.75 60
1.00

40 40

20 20

𝑁𝑇𝑈 𝑁𝑇𝑈
0 0
1 2 3 4 5 1 2 3 4 5
 Non double pipe

• 1 shell pass – 2 tube passes, small error

• For phase change (evaporation & condensation),

𝑚𝑐 𝑚𝑖𝑛
constant temperature, →0
𝑚𝑐 𝑚𝑎𝑥

ln 1 − 𝜀 = −𝑁𝑇𝑈
 Non double pipe
1 shell pass – 2𝑛 tube passes 2 shell passes – 4𝑛 tube passes
100 100
𝐶𝑚𝑖𝑛 Τ𝐶𝑚𝑎𝑥 = 0
Effectiveness 𝜀 %

Effectiveness 𝜀 %
0.25
80 80
0.50

0.75
60 60
1.00

40 40

20 20

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

Effectiveness 𝜀 %
4.0 0.50
0.50 0.75
80 2.0 80
1.00
0.75
1.33

1.00
60 60

unmixed unmixed
40 40

mixed unmixed
20 20

𝑁𝑇𝑈 𝑁𝑇𝑈
0 0
1 2 3 4 5 1 2 3 4 5
 Summary
Flow geometry 𝜺 𝑵𝑻𝑼
Double pipe
1 − 𝑒𝑥𝑝 −𝑁 1 + 𝐶 − ln 1 − 1 + 𝐶 𝜀
Parallel flow 𝜀= 𝑁=
1+𝐶 1+𝐶
1 − 𝑒𝑥𝑝 𝑁 𝐶 − 1 1 𝜀−1
Counter flow 𝜀= 𝑁= ln
1 − 𝐶𝑒𝑥𝑝 𝑁 𝐶 − 1 𝐶−1 𝐶𝜀 − 1
𝑁 𝜀
Counter flow 𝐶 = 1 𝜀= 𝑁=
𝑁+1 1−𝜀
Cross flow
𝑒𝑥𝑝 −𝐶𝑁 0,78 − 1
Both fluids unmixed 𝜀 = 1 − 𝑒𝑥𝑝
𝐶𝑁 −0,22
1
𝜀=
Both fluids mixed 1 𝐶 1
+ −
1 − 𝑒𝑥𝑝 −𝑁 1 − 𝑒𝑥𝑝 −𝑁𝐶 𝑁
1 − 𝑒𝑥𝑝 𝐶 𝑒𝑥𝑝 −𝑁 − 1 ln 1 − 𝐶𝜀
𝐶𝑚𝑎𝑥 mixed, 𝐶𝑚𝑖𝑛 unmixed 𝜀= 𝑁 = − ln 1 +
𝐶 𝐶
𝑒𝑥𝑝 −𝑁𝐶 − 1 − ln 1 + 𝐶 ln 1 − 𝜀
𝐶𝑚𝑎𝑥 unmixed, 𝐶𝑚𝑖𝑛 mixed 𝜀 = 1 − 𝑒𝑥𝑝 𝑁=
𝐶 𝐶
 Summary
Flow geometry 𝜺 𝑵𝑻𝑼
Shell and tube

2 2
− 1 − 𝐶 + 1 + 𝐶2
1 shell pass 𝜀= 𝜀
ln 2
1 + 𝐶 2 1 + 𝑒𝑥𝑝 −𝑁 1 + 𝐶 2 − 1 − 𝐶 − 1 + 𝐶2
2,4,6 tube passes 1+𝐶+ 𝜀
1 − 𝑒𝑥𝑝 −𝑁 1 + 𝐶 2 𝑁=
1 + 𝐶2
𝑛
1 − 𝐶𝜀𝑝
𝑛 shell passes −1
1 − 𝜀𝑝
2𝑛, 4𝑛, 6𝑛 tube passes 𝜀= 𝑛
𝜀𝑝 : for 1 shell pass 1 − 𝐶𝜀𝑝
−𝐶
1 − 𝜀𝑝
𝑛 shell passes
2𝑛, 4𝑛, 6𝑛 tube passes 𝑛𝜀𝑝
𝜀=
𝜀𝑝 : for 1 shell pass 1 + 𝑛 − 1 𝜀𝑝
𝐶=1
All heat exchanger with
𝜀 = 1 − 𝑒𝑥𝑝 −𝑁 𝑁 = − ln 1 − 𝜀
𝐶=0
𝑈𝐴 𝑚𝑐 𝑚𝑖𝑛
𝑁 = 𝑁𝑇𝑈 = 𝐶=
𝑚𝑐 𝑚𝑖𝑛 𝑚𝑐 𝑚𝑎𝑥
 Design equation

𝜀 = 𝑓 𝑁𝑇𝑈, 𝐶
𝑈𝐴 𝑚𝑐 𝑚𝑖𝑛
𝑁𝑇𝑈 = 𝐶=
𝑚𝑐 𝑚𝑖𝑛 𝑚𝑐 𝑚𝑎𝑥

𝑄 = 𝜀𝑄𝑚𝑎𝑥
𝑚𝑐 𝑚𝑖𝑛 𝑇ℎ,𝑖𝑛 − 𝑇𝑐,𝑖𝑛
 Example 5
Water flowing at a rate of 0.723 𝑘𝑔Τ𝑠 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 3.2 𝑘𝑔Τ𝑠. The heat
capacity of the oil is 1.89 𝑘𝐽Τ𝑘𝑔𝐾, and the average heat capacity of
water over the temperature range of interest is 4.192 𝑘𝐽Τ𝑘𝑔𝐾. The
overall heat transfer coefficient of the exchanger is 300 𝑊 Τ𝑚2 𝐾, and
the area for heat transfer is 15.4𝑚2 . What is the total amount of heat
transferred.
 Design problems
• Fluid properties
• Flow rate Process
• Temperature

• Overall heat transfer coefficient

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

• Overall heat transfer coefficient

• Temperature Design
• Heat load
 Problem 1
Calculate the heat exchange surface area required in a heat
exchanger comprised of tubes with an external diameter of
25 mm in order to cool a solution of oil (mass flow rate:
2,000 kg/h, heat capacity: 4.0 kJ/kg K) from 100C to
40C using a water flow (mass flow rate: 4,594 kg/h, heat
capacity: 4.18 kJ/kg K) entering at 25C. The overall heat
transfer coefficient related to the outside tube surface is
566 W/m2 K. Consider the following cases:
a) Parallel flow in a double-pipe exchanger
b) Counter-flow in a double-pipe exchanger.