ME 312 – HEAT TRANSFER

1st Semester, Academic Year 2022-2023 Professor: Engr. NIÑO BLONES, ME

Module 4 – HEAT EXCHANGERS

Module Outcomes
At the end of the module, the learner should be able to:
1. analyze heat exchangers using LMTD method for single-pass parallel flow, counterflow, and cross flow
configurations.
2. analyze heat exchangers using LMTD method for multi-pass heat exchangers in parallel flow, counterflow,
and cross flow configurations

Heat exchangers are devices that enable the exchange of heat between two fluids that are at different
temperatures without mixing with each other. Heat exchangers are commonly used in practice in a wide range of
applications, such as heating and air-conditioning systems, chemical processing and power production. Some
examples of heat exchangers are boilers, condensers, car radiators, air conditioning evaporators, among others.

4.1 TYPES OF HEAT EXCHANGERS

Double-Pipe Heat Exchanger
The simplest type of heat exchanger consists of two concentric pipes of different diameters, as shown in
Figure 4.1, called the double-pipe heat exchanger. One fluid in a double-pipe heat exchanger flows through the
smaller pipe while the other fluid flows through the annular space between the two pipes. Two types of flow
arrangement are possible in a double-pipe heat exchanger, namely parallel flow and counterflow. In parallel
flow, both the hot and cold fluids enter the heat exchanger at the same end and move in the same direction. In
counterflow, on the other hand, the hot and cold fluids enter the heat exchanger at opposite ends and flow in
opposite directions.

Cold fluid in Cold fluid out

Hot fluid Hot fluid

Hot fluid Hot fluid
in out
in out

Cold fluid in
Cold fluid out
(a) parallel flow (b) counter flow

Figure 4.1 Flow arrangement in double-pipe heat exchanger: (a) parallel flow and (b) counter flow

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Shell-and-Tube Heat Exchanger

The shell-and-tube heat exchanger is the most widely used type in the chemical process industries and
power plants. One fluid flows on the inside of the tubes, while the other fluid flows through the shell and over the
outside of the tubes. Baffles are placed in the shell to ensure that the shell-side fluid will flow across the tubes and
induce higher heat transfer. The tubes open to some large flow areas called headers at both ends of the shell,
where the tube-side fluid accumulates before entering the tubes and after leaving them.
Tube Shell
outlet inlet
Baffles
Front end
header

Rear end Tubes Shell

header
Shell Tube
outlet inlet

Figure 4.2 Schematic diagram of a shell-and-tube heat exchanger (one-shell pass and one-tube pass)

One or more tube passes may be employed, depending on the header configuration. Heat exchangers in
which all the tubes make one U-turn in the shell, for example, are called one-shell-pass and two tube-passes heat
exchangers. Likewise, a heat exchanger that involves two passes in the shell and four passes in the tubes is called
a two-shell-passes and four-tube-passes heat exchanger (Figure 4.3).

Shell-side
Shell-side fluid in
fluid in
Tube-side
Tube-side fluid out
fluid out
Tube-side
Tube-side fluid in
fluid in

Shell-side Shell-side
fluid out fluid out
(a) one-shell pass and two-tube passes (b) two-shell passes and four-tube passes

Figure 4.3 Schematic of multipass flow arrangements in shell-and-tube heat exchangers

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Cross-flow Heat Exchangers

Cross-flow exchangers are commonly used in air or gas heating and cooling applications. In this kind of
heat exchanger, the two fluids usually move perpendicular to each other. The cross-flow is further classified as
unmixed and mixed flow, depending on the flow structure, as shown in Figure 4.4.

Cross flow Cross flow

(unmixed) (mixed)

Tube flow
(unmixed) Tube flow
(unmixed)
(a) Both fluids unmixed (b) One fluid mixed, one fluid unmixed

Figure 4.4 Different flow configurations in cross-flow heat exchangers

Plate and Frame Heat Exchanger

An innovative type of heat exchanger that has found widespread use is the plate and frame (or just plate)
heat exchanger, which consists of a series of plates with corrugated flat flow passages. The hot and cold fluids
flow in alternate passages and thus each cold fluid stream is surrounded by two hot fluid streams, resulting in very
effective heat transfer. They are well suited for heat exchange between two liquids, provided that the hot and cold
fluid streams are at about the same pressure.

Regenerative Heat Exchanger

Another type of heat exchanger that involves the alternate passage of the hot and cold fluid streams
through the same flow area is the regenerative heat exchanger or regenerator. The static-type regenerative heat
exchanger is basically a porous mass that has a large heat storage capacity, such as a ceramic wire mesh. Hot and
cold fluids flow through this porous mass alternatively. During the flow of the hot fluid, heat is transferred from it
into the matrix of the regenerator, and from the matrix to the cold fluid during the flow of the cold fluid. Thus, the
matrix serves as a temporary heat storage medium. In regenerative heat exchangers, the fluid on either side of the
heat exchanger is usually the same fluid. That’s why it is called regenerative.

4.2 OVERALL HEAT TRANSFER COEFFICIENT

In the analysis of heat exchangers, it is convenient to work with an overall heat transfer coefficient 𝑈 that
accounts for the contribution of all these effects on heat transfer. A typical heat exchanger involves two flowing
fluids separated by a solid wall. Heat is first transferred from the hot fluid to the wall by convection, through the

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wall by conduction, and from the wall to the cold fluid again by convection. Any radiation effects are usually
included in the convection heat transfer coefficients.
Recall that
Δ𝑇
𝑄=
𝑅𝑡ℎ
where: 𝑄 = rate of heat transfer
Δ𝑇 = temperature difference
𝑅𝑡ℎ = thermal resistance

In heat exchanger analysis, we combine all the coefficient of all modes of heat transfer taking place in the
heat exchanger and we call it the overall heat transfer coefficient 𝑈 defined as
𝟏 𝟏
𝑼= or =𝑼𝑨 (𝑬𝒒. 𝟒. 𝟏)
𝑹𝒕𝒉 𝑨 𝑹𝒕𝒉

Then the rate of heat transfer is

𝚫𝑻𝒎
𝑸= = 𝑼 𝑨 𝚫𝑻𝒎 (𝑬𝒒. 𝟒. 𝟐)
𝑹𝒕𝒉

where: Δ𝑇𝑚 is the suitable mean temperature difference between the two fluids involved in the heat exchanger, (it
can be AMTD or LMTD, details are discussed in section 4.3 below)
𝑈 is the overall heat transfer coefficient, and
𝐴 is the surface area which the overall heat transfer coefficient is based on.
𝑊 𝐵𝑡𝑢
Note: The unit of 𝑈 is identical to that of the convection heat transfer coefficient ℎ. That is, or
𝑚2 ∙𝐾 ℎ𝑟∙𝑓𝑡 2 ∙𝑅

As mentioned above, the overall heat transfer coefficient 𝑈 is normally specified in terms of the area on
which it is based. There are two (2) overall heat transfer coefficients, one for the inner surface area and another
for the outer surface area. When 𝑈 is based on the inner surface area, it must be paired with the inner surface
area. Similarly, when 𝑈 is based on the outer surface area, it has to multiplied by the outer surface area. For a
steady-state heat transfer, the products 𝑈𝐴 on both sides of the heat exchanger are equal. That is,
𝑼𝒊 𝑨𝒊 = 𝑼𝒐 𝑨𝒐 (𝑬𝒒. 𝟒. 𝟑)

and consequently
𝑸 = 𝑼𝒊 𝑨𝒊 𝚫𝑻 = 𝑼𝒐 𝑨𝒐 𝚫𝑻 (𝑬𝒒. 𝟒. 𝟒)

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where: 𝑈𝑖 and 𝑈𝑜 are the overall heat transfer coefficients on the inner and outer surfaces, respectively; and
𝐴𝑖 and 𝐴𝑜 are the inner and outer areas, respectively.

Fouling Factor
The performance of heat exchangers usually deteriorates with time as a result of accumulation of deposits
on heat transfer surfaces. This layer of deposits represents an additional resistance to the heat flow, and thus
results in decreased performance. The overall effect is usually represented by a fouling factor 𝑅𝑓 , which must be
included along with the other thermal resistances making up the overall heat-transfer coefficient. The fouling
factor is obviously zero for a new heat exchanger and increases with time as the solid deposits build up on the
heat exchanger surface. Tables of fouling factors are available in heat transfer books as well as in handbooks.
However, in the absence of specific data, we can assume the surfaces to be coated with 0.2 mm of limestone as a
starting point to account for the effects of fouling.
Pipe fouling, 𝑅𝑓𝑜
(outer surface)

Cold fluid
Pipe fouling, 𝑅𝑓𝑖
(inner surface)

𝑟1
𝑟2

Hot fluid
ℎ1

ℎ2

Outer pipe
Inner pipe

Figure 4.5 Double-pipe heat exchanger with inner and outer layer of fouling deposits

Figure 4.5 illustrates the fouling resistance on the inner and outer surface of a double-pipe heat exchanger. These
fouling factors in the path of heat flow give the total thermal resistance 𝑅𝑡ℎ as
𝑅𝑡ℎ = 𝑅𝑐𝑜𝑛𝜈1 + 𝑅𝑓𝑖 + 𝑅𝑐𝑜𝑛𝑑 + 𝑅𝑓𝑜 + 𝑅𝑐𝑜𝑛𝜈2
𝟏 𝐥𝐧(𝒓𝟐 /𝒓𝟏 ) 𝟏
𝑹𝒕𝒉 = + 𝑹𝒇𝒊 + + 𝑹𝒇𝒐 + (𝑬𝒒. 𝟒. 𝟓)
𝒉𝟏 𝑨𝒊 𝟐𝝅 𝒌 𝑳 𝒉𝟐 𝑨𝒊

where: 𝑅𝑐𝑜𝑛𝜈1 and 𝑅𝑐𝑜𝑛𝜈2 are the inner and outer thermal resistances due convection, respectively;
𝑅𝑐𝑜𝑛𝑑 is the thermal resistance due to conduction; and
𝑅𝑓𝑖 and 𝑅𝑓𝑜 are the inner and outer surface fouling resistances, respectively.

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4.3 HEAT EXCHANGER ANALYSIS: LMTD AND AMTD METHOD

Logarithmic Mean Temperature Difference (LMTD)
In the analysis of heat exchangers, it is convenient to work with the logarithmic mean temperature
difference 𝐿𝑀𝑇𝐷, which is an equivalent mean temperature difference between the two fluids for the entire heat
exchanger. The appropriate form of the mean temperature difference between the two fluids was derived and
found to be logarithmic in nature. This suitable form of the average temperature difference for use in the analysis
of heat exchangers is called the logarithmic mean temperature difference (𝐿𝑀𝑇𝐷) and is expressed as

𝚫𝑻𝟏 − 𝚫𝑻𝟐
𝑳𝑴𝑻𝑫 = (𝑬𝒒. 𝟒. 𝟔)
𝚫𝑻
𝐥𝐧 ( 𝟏 )
𝚫𝑻𝟐

where: Δ𝑇1 = temperature difference between the two fluids at one end of the heat exchanger
Δ𝑇2 = temperature difference between the two fluids at the other end of the heat exchanger

LMTD for Parallel Flow Heat Exchangers

Consider the parallel-flow, double-pipe heat exchanger shown in Figure 4.6. Note that the temperature
difference between the hot and cold fluids is large at the inlet of the heat exchanger but decreases exponentially
toward the outlet.
Cold fluid out
𝑇𝑐,𝑜𝑢𝑡

Hot fluid in Hot fluid out

𝑇ℎ,𝑖𝑛 𝑇ℎ,𝑜𝑢𝑡

Cold fluid in
𝑇𝑐,𝑖𝑛

𝑇
𝑇ℎ,𝑖𝑛

𝑇ℎ, 𝑜𝑢𝑡

Δ𝑇1 = 𝑇ℎ,𝑖𝑛 − 𝑇𝑐,𝑖𝑛 Δ𝑇2 = 𝑇ℎ,𝑜𝑢𝑡 − 𝑇𝑐, 𝑜𝑢𝑡

𝑇𝑐, 𝑜𝑢𝑡
𝑇𝑐, 𝑖𝑛

𝐴
Figure 4.6 Variation of the fluid temperatures in a parallel-flow double-pipe heat exchanger

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Important notes:

• Two fluids are involved; one is hot, the other is cold. [parang kayo ng jowa mo...]
• During the heat exchange, the hot fluid gets colder, while the cold fluid gets hotter. [once
again, parang kayo ng jowa mo... minsan ang init ay lumalamig, at ang lamig ay umiinit ]

• There are 4 temperatures involved; 2 for hot fluid (entering and leaving) , 2 for cold fluid (entering and
leaving).

[parang kayo ulit, dumating sa buhay ng isa’t-isa pero umalis din kalaunan.]

1. 𝑇ℎ, 𝑖𝑛 = temperature of hot fluid entering the heat exchanger [parang ikaw; nung una kayong
nagkakilala, nag-aalab ang iyong damdamin ]

2. 𝑇ℎ, 𝑜𝑢𝑡 = temperature of hot fluid leaving the heat exchanger [parang ikaw; nung nanlamig ka na, aba'y
iniwan mo na sya]

3. 𝑇𝑐, 𝑖𝑛 = temperature of cold fluid entering the heat exchanger [parang siya; nung una kayong nagkakilala,
malamig pa ang feelings nya para sa'yo ]

4. 𝑇𝑐, 𝑜𝑢𝑡 = temperature of cold fluid leaving the heat exchanger [parang siya; uminit din ang damdamin sa huli,
kaya lang maghiwalay na kayo ]

• Therefore, there will be two Δ𝑇; Δ𝑇1 and Δ𝑇2

Δ𝑇1 = temperature difference between the two fluids at one end of the heat exchanger
Δ𝑇2 = temperature difference between the two fluids at the other end of the heat exchanger

For parallel flow:

Δ𝑇1 = 𝑇ℎ,𝑖𝑛 − 𝑇𝑐,𝑖𝑛
Δ𝑇2 = 𝑇ℎ,𝑜𝑢𝑡 − 𝑇𝑐,𝑜𝑢𝑡

Once the LMTD, the mass flow rates, and the overall heat transfer coefficient are available, the heat
transfer surface area of the heat exchanger can be determined from
𝑸 = 𝑼 𝑨𝒔 𝑳𝑴𝑻𝑫 (𝑬𝒒. 𝟒. 𝟕)

The LMTD method is very suitable for determining the size of a heat exchanger to realize prescribed
outlet temperatures when the mass flow rates and the inlet and outlet temperatures of the hot and cold fluids are
specified.

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LMTD for Counterflow Heat Exchangers

The variation of temperatures of hot and cold fluids in a counterflow heat exchanger is given in Figure
4.7. Note that the hot and cold fluids enter the heat exchanger from opposite ends, and the outlet temperature of
the cold fluid in this case may exceed the outlet temperature of the hot fluid. The LMTD equation above for
parallel flow heat exchanger is also applicable to counterflow heat exchangers. Except that, this time, Δ𝑇1 and
Δ𝑇2 are obtained in a different way as shown in the figure.

Cold fluid out

𝑇𝑐,𝑜𝑢𝑡

Hot fluid in Hot fluid out

𝑇ℎ,𝑖𝑛 𝑇ℎ,𝑜𝑢𝑡

Cold fluid in
𝑇𝑐,𝑖𝑛
𝑇
𝑇ℎ,𝑖𝑛

𝑇ℎ,𝑖𝑛 − 𝑇𝑐,𝑜𝑢𝑡 = Δ𝑇1

𝑇𝑐,𝑜𝑢𝑡
𝑇ℎ, 𝑜𝑢𝑡

Δ𝑇2 = 𝑇ℎ,𝑜𝑢𝑡 − 𝑇𝑐, 𝑖𝑛

𝑇𝑐, 𝑖𝑛

Figure 4.7 Variation of the fluid temperatures in a counterflow double-pipe heat exchanger

In counterflow heat exchangers, observe that the two fluids are flowing in opposite directions. Therefore,
the partnership of temperatures in Δ𝑇 will be different from that of the parallel flow.
For counterflow:
Δ𝑇1 = 𝑇ℎ,𝑖𝑛 − 𝑇𝑐,𝑜𝑢𝑡
Δ𝑇2 = 𝑇ℎ,𝑜𝑢𝑡 − 𝑇𝑐,𝑖𝑛
where: Δ𝑇1 = temperature difference between the two fluids at one end of the heat exchanger
Δ𝑇2 = temperature difference between the two fluids at the other end of the heat exchanger

Caution!
The formula for Δ𝑇1 and Δ𝑇2 are different for parallel flow and counterflow heat exchangers.

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For the same inlet and outlet temperatures of the two fluids, the logarithmic mean temperature difference
for a counterflow heat exchanger is always greater than that for a parallel flow heat exchanger. So, a smaller
surface area (and thus a smaller heat exchanger) is needed to achieve a specified heat transfer rate in a
counterflow heat exchanger. And so, it is common practice to use counterflow arrangements in heat exchangers.
But in the case of a condenser or a boiler, either a parallel flow or counterflow heat exchanger is considered; both
approaches give the same result.

Arithmetic Mean Temperature Difference (AMTD)

The arithmetic mean temperature difference (𝐴𝑀𝑇𝐷) is sometimes employed in calculating the heat
transfer rate 𝑄 in the heat exchanger because it is much simpler to calculate.

𝚫𝑻𝟏 + 𝚫𝑻𝟐
𝑨𝑴𝑻𝑫 = (𝑬𝒒. 𝟒. 𝟖)
𝟐

However, the 𝐿𝑀𝑇𝐷 is obtained by tracing the actual temperature profile of the fluids along the heat exchanger
and truly reflects the average temperature difference between the hot and cold fluids. When the difference
between Δ𝑇1 and Δ𝑇2 is not more than 40 percent, the error in using the 𝐴𝑀𝑇𝐷 is less than 1 percent. But the
error increases to undesirable levels when Δ𝑇1 differs from Δ𝑇2 by greater amounts. Therefore, it is strongly
advised to always use the logarithmic mean temperature difference when determining the rate of heat transfer in a
heat exchanger.

4.4 MULTI-PASS AND CROSS FLOW HEAT EXCHANGERS

The logarithmic mean temperature difference (LMTD) method is limited to parallel-flow and counter-
flow heat exchangers only. It cannot be directly applied for cross flow and multi-pass shell-and-tube heat
exchangers, because of the complex flow conditions.
In such cases, the LMTD equation for the counterflow heat exchanger is being used together with a
certain correction factor 𝐹. That is,
Multi-pass or Cross flow 𝑳𝑴𝑻𝑫 = Counterflow 𝑳𝑴𝑻𝑫 × 𝑭 (𝑬𝒒. 𝟒. 𝟗)

where: 𝐹 is the correction factor, which depends on the geometry of the heat exchanger and the inlet and outlet
temperatures of the hot and cold fluid streams.
The rate of heat transfer is then calculated as
𝑸 = 𝑼 𝑨 (Counterflow 𝑳𝑴𝑻𝑫) × 𝑭

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Important!
For multi-pass and cross flow heat exchangers, use the LMTD equation for the counterflow heat exchanger,
NOT the parallel flow. And multiply it with the value of 𝐹 as explained below.

The counterflow LMTD is determined from equation 4.6. The value of the correction factor is less than
unity for a cross flow and multi-pass shell-and-tube heat exchanger. It is a measure of deviation of the multi-pass
or cross flow LMTD from the corresponding values for the counterflow LMTD.

How to Determine the Value of 𝑭?

The correction factor 𝐹 depends on two temperature ratios 𝑷 and 𝑹 and is shown in Figure 4.8 for
common cross flow and multi-pass shell-and-tube heat exchanger configurations. These two temperature ratios
are defined as

𝒕𝟐 − 𝒕𝟏
𝑷= (𝑬𝒒. 𝟒. 𝟏𝟎)
𝑻𝟏 − 𝒕𝟏
and

𝑻𝟏 − 𝑻𝟐 (𝒎 𝒄𝒑 )shell fluid
𝑹= = (𝑬𝒒. 𝟒. 𝟏𝟏)
𝒕𝟐 − 𝒕𝟏 (𝒎 𝒄𝒑 )
tube fluid

where: subscript 𝟏 represent the inlet location

subscript 𝟐 represent the outlet location
𝑻 represents the shell-side temperatures
𝒕 represents the tube-side temperatures
These symbols are also shown in the correction factor charts.

Note:
• It makes no difference whether the hot or the cold fluid flows through the shell or the tube.
• The value of 𝑃 ranges from 0 to 1.
• The value of 𝑅 ranges from 0 to infinity, with 𝑅 = 0 corresponding to the phase-change (condensation or
boiling) on the shell-side and 𝑅 → ∞ to phase-change on the tube side.
• The correction factor for a condenser or boiler is 𝐹 = 1, regardless of the configuration of the heat
exchanger.

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Figure 4.8 Correction factor 𝑭 charts for common shell-and-tube and cross flow heat exchangers (from Heat
Transfer: A Practical Approach 2nd Ed by Cengel, 2002)

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Sample Problem 4.1

Determine the length required for a heat exchanger constructed from a 2.54-cm-outside diameter tube to cool 6.0
kg/s of ethyl alcohol solution (𝑐𝑝 = 3810 𝐽/𝑘𝑔 ∙ 𝐾) from 65 °C to 39 °C, using 6.3 kg/s of water available at 10
°C. Assume that the overall coefficient of heat transfer based on the outside area is 568 W/m2·K and consider
each of the following arrangements:
(a) parallel flow, shell-and-tube
(b) counterflow, shell-and-tube
(c) counterflow exchanger with 2 shell passes and 72 tube passes, the alcohol flowing through the shell and the
water flowing through the tubes

Solution:
(a) parallel flow, shell-and-tube

𝑇ℎ,𝑖𝑛
ethyl alcohol
𝑇ℎ, 𝑜𝑢𝑡
Δ𝑇1 = 𝑇ℎ,𝑖𝑛 − 𝑇𝑐,𝑖𝑛 Δ𝑇2 = 𝑇ℎ,𝑜𝑢𝑡 − 𝑇𝑐, 𝑜𝑢𝑡
𝑇𝑐, 𝑜𝑢𝑡
water
𝑇𝑐, 𝑖𝑛

Given in the problem,

𝑘𝑔 𝐽
𝑚̇ℎ = 6.0 𝑐𝑝ℎ = 3810 𝑇ℎ,𝑖𝑛 = 65 °𝐶 𝑇ℎ,𝑜𝑢𝑡 = 39 °𝐶
𝑠 𝑘𝑔 ∙ 𝐾
𝑘𝑔
𝑚̇𝑐 = 6.3 𝑇𝑐,𝑖𝑛 = 10 °𝐶
𝑠
𝑊
𝐷𝑜 = 2.54 𝑐𝑚 𝑈𝑜 = 568
𝑚2∙𝐾

• Solving for 𝑄
𝑄ℎ = 𝑚ℎ 𝑐𝑝ℎ (𝑇ℎ,𝑖𝑛 − 𝑇ℎ,𝑜𝑢𝑡 )

𝑘𝑔 𝐽
𝑄ℎ = (6.0 ) (3810 ) (65 − 39) 𝐾
𝑠 𝑘𝑔 ∙ 𝐾

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𝑄ℎ = 594,360 𝑊

• Solving for 𝑇𝑐,𝑜𝑢𝑡

By energy balance, that is, heat rejected by ethyl alcohol (𝑄ℎ ) equals heat absorbed by water (𝑄𝑐 )
assuming that no heat loss to the surroundings.
𝑄ℎ = 𝑄𝑐

594,360 𝑊 = 𝑚̇𝑐 𝑐𝑝𝑐 (𝑇𝑐,𝑜𝑢𝑡 − 𝑇𝑐,𝑖𝑛 )

𝑘𝑔 𝐽
594,360 𝑊 = (6.3 ) (4187 ) (𝑇𝑐,𝑜𝑢𝑡 − 10)
𝑠 𝑘𝑔 ∙ °𝐶

𝑇𝑐,𝑜𝑢𝑡 = 32.5 °𝐶

• Solving for LMTD for parallel flow (please refer to the above figure to avoid confusion)
Remember: Δ𝑇1 is a temperature difference at one end of the heat exchanger
Δ𝑇2 is a temperature difference at the other end of the heat exchanger

Δ𝑇1 = 𝑇ℎ,𝑖𝑛 − 𝑇𝑐,𝑖𝑛 = 65 − 10 = 55 𝐾

Δ𝑇2 = 𝑇ℎ,𝑜𝑢𝑡 − 𝑇𝑐,𝑜𝑢𝑡 = 39 − 32.5 = 6.5 𝐾

Δ𝑇1 − Δ𝑇2 55 − 6.5

𝐿𝑀𝑇𝐷 = =
Δ𝑇 55
ln ( 1 ) ln ( )
Δ𝑇2 6.5

𝐿𝑀𝑇𝐷 = 22.7 𝐾

Note: Interchanging the Δ𝑇1 and Δ𝑇2 in the formula of LMTD, the answer remains the same.

• Solving for the length, based on outside area

𝑄 = 𝑈𝑜 𝐴𝑜 𝐿𝑀𝑇𝐷

𝑄 = 𝑈𝑜 (𝜋 𝐷𝑜 𝐿) 𝐿𝑀𝑇𝐷

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 INSTRUCTIONAL MATERIALS in HEAT TRANSFER by: Engr. Niño G. Blones

𝑊 1𝑚
594,360 𝑊 = (568 ) (𝜋)(2.54 𝑐𝑚)(𝐿)(22.7 𝐾 ) × [ ]
𝑚2 ∙𝐾 100 𝑐𝑚

𝑳 = 𝟓𝟕𝟖 𝒎 → (𝑨𝒏𝒔𝒘𝒆𝒓)

Remarks: That is a very long heat exchanger, isn’t it? More than half of a kilometer. To make it shorter, the
recommendations would be to use several tubes, or to design it as a counterflow type instead of
parallel flow, and to design it as multi-pass type of heat exchanger.

(b) counterflow, shell-and-tube

Note: Most of the values in parallel flow remains the same for counterflow. Only the values of Δ𝑇1 , Δ𝑇2 , 𝐿𝑀𝑇𝐷,
and length of tube will change.

𝑇
𝑇ℎ,𝑖𝑛

𝑇ℎ,𝑖𝑛 − 𝑇𝑐,𝑜𝑢𝑡 = Δ𝑇1

𝑇𝑐,𝑜𝑢𝑡
𝑇ℎ, 𝑜𝑢𝑡

Δ𝑇2 = 𝑇ℎ,𝑜𝑢𝑡 − 𝑇𝑐, 𝑖𝑛

𝑇𝑐, 𝑖𝑛

• Solving for LMTD for counterflow (please refer to the above figure to avoid confusion)
Remember: Δ𝑇1 is a temperature difference at one end of the heat exchanger
Δ𝑇2 is a temperature difference at the other end of the heat exchanger
Δ𝑇1 = 𝑇ℎ,𝑖𝑛 − 𝑇𝑐,𝑜𝑢𝑡 = 65 − 32.5 = 32.5 𝐾
Δ𝑇2 = 𝑇ℎ,𝑜𝑢𝑡 − 𝑇𝑐,𝑖𝑛 = 39 − 10 = 29 𝐾

Δ𝑇1 − Δ𝑇2 32.5 − 29

𝐿𝑀𝑇𝐷 = = = 30.7 𝐾
Δ𝑇 32.5
ln ( 1 ) ln ( )
Δ𝑇2 29

• Solving for the length, based on outside area

𝑄 = 𝑈𝑜 𝐴𝑜 𝐿𝑀𝑇𝐷

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 INSTRUCTIONAL MATERIALS in HEAT TRANSFER by: Engr. Niño G. Blones

𝑄 = 𝑈𝑜 (𝜋 𝐷𝑜 𝐿) 𝐿𝑀𝑇𝐷

𝑊 1𝑚
594,360 𝑊 = (568 ) (𝜋)(2.54 𝑐𝑚)(𝐿)(30.7 𝐾 ) × [ ]
𝑚2 ∙𝐾 100 𝑐𝑚

𝑳 = 𝟒𝟐𝟕 𝒎 → (𝑨𝒏𝒔𝒘𝒆𝒓)

Remarks: That is still a very long heat exchanger, isn’t it? But at least, not so much as compared to that of the
parallel flow type. To shorten it further, the recommendations would be to use several tubes, and to
design it as multi-pass type of heat exchanger.

(c) counterflow exchanger with 2 shell passes and 72 tube passes, the alcohol flowing through the shell and the
water flowing through the tubes
For the 2-shell-pass counterflow arrangement, we will determine the LMTD by applying the correction factor
found in graph (b) in Figure 4. 8 (above) to the LMTD of counterflow. (The said graph b is also shown below
in cropped and highlighted view.)

Let’s focus our attention first to the encircled part of the diagram. The problem stated that “alcohol flowing
through the shell and the water flowing through the tubes”. Therefore,
𝑇1 = 𝑇ℎ,𝑖𝑛 = 65 °𝐶
𝑇2 = 𝑇ℎ,𝑜𝑢𝑡 = 39 °𝐶
𝑡1 = 𝑇𝑐,𝑖𝑛 = 10 °𝐶
𝑡2 = 𝑇𝑐,𝑜𝑢𝑡 = 32.5 °𝐶

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 INSTRUCTIONAL MATERIALS in HEAT TRANSFER by: Engr. Niño G. Blones

Important!
The uppercase letters 𝑇 refer to temperatures of the fluid in the shell; subscript 1 = in, subscript 2 = out
The lowercase letters 𝑡 refer to temperatures of the fluid in the tube; subscript 1 = in, subscript 2 = out

Now let us solve for 𝑃 and 𝑅 (both formulas are also shown in the figure)
𝑡2 − 𝑡1 32.5 − 10
𝑃= = = 0.41
𝑇1 − 𝑡1 65 − 10

𝑇1 − 𝑇2 65 − 39
𝑅= = = 1.16
𝑡2 − 𝑡1 32.5 − 10

At this point, we have to draw the 𝑹 curve (the pink curve) and the 𝑷 line (the vertical line). Then, read or
estimate the value of 𝑭 at their point of intersection.

Note:
In the figure below, I used a blue color for 𝑷 = 𝟎. 𝟒𝟏 and a green color for 𝑹 = 𝟏. 𝟏𝟔 to emphasize their location
and make it more distinct.

It is then approximated that 𝐹 = 0.97

Solving for the length, based on outside area and the number of tube passes 𝑁𝑡
𝑄 = 𝑈𝑜 𝐴𝑜 (Counterflow 𝐿𝑀𝑇𝐷) × 𝐹
𝑄 = 𝑈𝑜 (𝜋 𝐷𝑜 𝐿 𝑁𝑡 ) (Counterflow 𝐿𝑀𝑇𝐷 ) × 𝐹

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 INSTRUCTIONAL MATERIALS in HEAT TRANSFER by: Engr. Niño G. Blones

𝑊 1𝑚
594,360 𝑊 = (568 ) (𝜋)(2.54 𝑐𝑚)(𝐿)(72)(30.7 𝐾 ) × 0.97 × [ ]
𝑚2 ∙𝐾 100 𝑐𝑚

𝑳 = 𝟔. 𝟏𝟐 𝒎 → (𝑨𝒏𝒔𝒘𝒆𝒓)

PRACTICE PROBLEMS 4
Heat Exchangers

1. In a parallel-flow double pipe heat exchanger, the hot fluid enters the heat exchanger at 90 °C and leaves it at
50 °C, while the cold fluid enters the heat exchanger at 20 °C and leaves it at 40 °C. Calculate the LMTD.
[ Answer: 30.8 °C ]

2. In a counter-flow double pipe heat exchanger, the hot fluid enters at 200 °C and leaves at 100 °C, while the
cold fluid enters the heat exchanger at 20 °C and leaves at 80 °C. Calculate the LMTD.
[ Answer: 98.7 °C ]

3. Oil is cooled by water in a counterflow heat exchanger. The oil flow rate is 2000 kg/h, entering at 107°C and
leaving at 30°C. Its mean 𝑐𝑝 is 2.51 kJ/kg·K. Water enters at 15 °C and its exit temperature is not to exceed
80 °C. The overall heat transfer coefficient is expected to be 1.5 kW/m2 K. Determine the water flow rate, and
the surface area required. [ Answer:1425 kg/h, 3.5 m2 ]

4. Engine oil (𝑐𝑝 =2100 J/kg · °C) is to be heated from 20 °C to 60°C at a rate of 0.3 kg/s in a 2-cm-diameter
thin-walled copper tube by condensing steam outside at a temperature of 130 °C (ℎ𝑓𝑔 = 2174 kJ/kg). For an
overall heat transfer coefficient of 650 W/m2 ·°C, determine the rate of heat transfer and the length of the tube
required to achieve it. [Hint: Recall that condensing procecss occurs at constant temperature and the heat
released during the process is the latent heat of vaporization (ℎ𝑓𝑔 ).] [ Answer: 25.2 kW, 7.0 m ]

5. A shell-and-tube heat exchanger with 2-shell passes and 8-tube passes is used to heat ethyl alcohol (𝑐𝑝 =
2670 J/kg·°C) in the tubes from 25 °C to 70 °C at a rate of 2.1 kg/s. The heating is to be done by water (𝑐𝑝 =
4190 J/kg·°C) that enters the shell side at 95 °C and leaves at 45 °C. If the overall heat transfer coefficient is
950 W/m2·°C, determine the heat transfer surface area of the heat exchanger. [ Answer: 15.4 m2 ]

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