Problem 1

Shell-and-tube heat exchangers with hundreds of tubes housed in a shell are commonly used in
practice for heat transfer between two fluids. Such a heat exchanger used in an active solar hot-
water system transfers heat from a water-antifreeze solution flowing through the shell and the
solar collector to fresh water flowing through the tubes at an average temperature of 60 °C at a
rate of 15 L/s. The heat exchanger contains 80 brass tubes 1 cm in inner diameter and 1.5 m in
length. The roughness of brass tubing is ꜫ= 1.5 x 10 -6 m. Determine the pressure drop across a
single tube.

Solution
For A=Water at 60 °C:
µs = 0.473 x 10-3
Solving Reynold’s Number:
V Dp
ℜ=
µs
Solving Velocity
2
πD V
Q=
4
V =191 m/ s
Substituting
ℜ=4.089634 x 10
Interpolating from Moody Chart
At ℜ=4.089634 Million relative roughness at 1.5 x 10-6
f =0.01345
Pressure drops:
For Pipes:
From Head Loss Formula for head losses in pipes with darcy friction factor:
2
fL V
HL =
2 gD
Expressing equation in terms of pressure Head loss, we get:
 2
γ V Lf
ΔP = ; ΔP= 3.67 kPa
2d
Problem 2
The overall heat transfer coefficient for a shell and tube heat exchange for clean surfaces is
W
U o =400 2 . The fouling factor after one year of operation is found to be 100m2K/200W. The
m K
overall heat transfer coefficient at this time is _____.
Solution
Given:
2
W 1 m K
U o =400 2 , F=
m K 2000 W
1 1 1
= +
U with fouling 400 200

1 W
= 333
U with fouling 2
m K
Problem 3
Saturated steam at 100°C is condensing on shell side of a shell and tube heat exchanger.
The cooling water enters the tube at 30°C and leaves at 70°C. Calculate arithmetic mean
temperature difference in counter flow arrangement.

Temp Tn1 Tn2

Tc2 Tc1
Give:

T h 1=¿ T h 2=¿ 100° C ,T c 1=¿ 30 ° C ,T ¿ ¿

¿
c 2=¿70 ° C ¿

θ1=¿T h1=¿T c 2 θ 2=¿ T ¿

¿ ¿
h2−¿ T ¿
c1

θ1=¿100−70=30° C , θ 2=¿100−30=70¿ ¿

50 ° C
 θ1+¿ θ 70+30
AMTD= 2
= =¿¿
2 2

Problem 4

Saturated vapor at 200 °C condenses to saturated liquid at the rate of 150 kg/s on the shell side of
a heat exchanger (enthalpy of condensation h ig = 2400 kJ/kg). A fluid with C p = 4 kJ-kg-1K-1.
Enters at 100 °C on the tube side. If the effectiveness of the heat exchanger is 0.9, then the mass
flow rate of the fluid in the tube side is ______kg/s (in integer).
Concept:
In the heat exchanger, the rate of enthalpy decrease of hot fluid is equal to the rate of enthalpy
increase of cold fluid.
T ce−¿T
Effectiveness ε = ¿= ci

T he −T ci
Solution
Given:
mass flow rate of condensing, mc =150kg/s
kJ
h fg =2400 ,C 4 kJ-kg-1K-1
kg p=¿¿
T hi =T he=200 °C, T ci=100 ° C=T ce =?

Mass flow rate of fluid ṁ=?

Thi= 200°C The= 200°C

Tce=?
Tci= 200°C
effectiveness, ε =0.9

T ce−¿T
ε= =0.9 ¿
ci

T he −T ci

T ce−¿ 100
=0.9¿
200−100
T ce=¿0.9 x100+100=190¿°C

150ṁ=1000
x 2400=ṁ x 4 x (190−100)
kg /s
Problem 5
Hot oil at 100°C is used to heat air in a shell-and-tube heat exchanger. The oil makes six tube
passes and the air makes one shell pass; 2.0 kg/s of air are to be heated from 20 to 80°C. The
specific heat of the oil is 2100 J/kg. °C, and its flow rate is 3.0 kg/s. Calculate the area required
for the heat exchanger for U = 200W/m ⋅ °C.
Solution
The basic energy balance is
ṁo c o ∆ T o=ṁa c a ∆ T a or

(3.0) (2100) (100-T oe) = (2.0) (1009) (80-20)

T oe= 80.78°C

We have
ṁh c h=(3.0)(2100)=6300W /¿°C

ṁh c c =(2.0)(1009)=2018 W /¿°C

So, the air is the minimum fluid and

c min 2018
c= = =0.3203
c max 6300
∆Tc 80−20
The effectiveness is ϵ= = =0.75
∆T max 100−20
2
N=−¿0.32032)1/2 In [ −1−0.3203−¿ ¿]= 1.99
0.75
Now, with U =200 we ca ; calculate the area as
Cmin (1.99)(2018) 2
A=NTU = =20.09m
U 200
Problem 6
A shell and tube heat exchanger is used for cooling 0.5 kg/s of a process steam flowing through
the tubes from 160 °C to 100 °C. The tube has an inside diameter of 2.5 cm and negligible wall
thickness. The average properties of the process stream are p=950 kg/mº; k=0.5 W/m ⋅K, p=3.5
kJ/kg⋅K, u=0.002 kg/m⋅s and Pr=14 The coolant stream is water (cp=4.18 kJ/kg ⋅K) at a flow rate
of 0.7 kg/s and an inlet temperature of 10 °C, which yields an average tube side overall heat
transfer coefficient of 40 W/m K. Water 10°C 0.7 kg/s Process steam 160°C 0.5kg/s -100°
Determine the rate of heat transfer for this heat exchanger, in W.
Given
Hot Fluid (steam)
ṁh=0.5kg/s

T h 1=160°C, T h 2=100°C

Tube diameter, D = 2.5cm = 0.025m

C ph=3.5 kj/kg ⋅ k

Cold fluid (cold water)

kg
ṁ c =0.7
s
T c1 =10° C=10+273 k =283 k

kj
C ph=4.18 ⋅k
kg
Overall heat transfer coefficient (U) = 40 w/m2k
Rate of heat transfer (Q )
Q=ṁc C ph ¿ T h 2 ¿

T h 1=160+273=433 k

T h 2=100+273=373 k
3
Q=0.5 x 3.25 x 10 ̇

Q=105,000 W =105 KW

Problem 7
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/m 2. °C. Determine the heat
transfer surface area of the heat exchanger.
Solution
kg J
ṁc =2.1 , C p c =2670 ℃ , t 1=25 ℃ , t 2=70 ℃
sec kg
J
ṁr , C ph=4190 ℃, T 2=45 ℃
kg
W
U =950 2
℃ , 2 shell∧8−tube passes, A=?
m
∆ T 1−∆ T 2 (25−20)℃
∆ T LMTD= =22.41℃
∆T1 = 25
ln ⁡( ) ln ⁡( )
∆T2 20

T 1−T 2 (95−45)℃
R= =¿ =1.11
t 1−t 2 (70−25)℃
t 2−t 1 (70−25)℃
P= =¿ =0.643
T 1−t 1 (95−25)℃

At calculated value of R & P (from correction factor graph, F= 0.8 Approx.)

Q=UAF ∆T LMTD =ṁc x C pc x ( t 2 −t 1 )

W
950 2
℃ x A x 0.8 x 22.41=2.1 kg /sec x 2671 j/kg ℃ x(70−25)℃
m

2
A=14.815 m

Problem 8
A well-insulated Shell and Tube heat exchanger is to heat water (Cp= 4.18 kJ/kg ⋅°C) from
25°C to 60°C at a rate of 0.4 kg/s as shown in Figure. The heating is to be accomplished by
geothermal water (Cp = 4.3 1 kjkg ⋅°C) available at 140°C at a mass flow rate of 0.3 kgs.
The inner tube is thin-walled and has a diameter of 0.6cm. Determine the rate of heat
transfer.
Solution
Cold water
T cl=25 ℃

T c2 =60℃
 kg
ṁ c =0.4 , C pc=4.18 kJ /kg ℃
s
Q̇=ṁc C p x (T c2−T c 2)

Q̇=0.4 x 4.18 x (60−25)

Q̇=58.52 KW

Problem 9
Estimate the heat exchanger area needed to cool 55,000 lb/hr of a light oil (specific heat = 0.74
Btu/lb ⋅°F) from 190°F to 140°F using cooling water that is available at 50°F. The cooling water
can be allowed to heat to 90°F. An initial estimate of the Overall Heat Transfer Coefficient is 120
Btu/hr ⋅ft².°F. Also estimate the required mass flow rate of cooling water.

Solution
Imperial Units: Q = m.Cp. (T2 – T1) = 55,000 lb/hr x 0.74 Btu/lb°F (190 – 140) °F = 2,035,000 Btu/hr.

T1 = Inlet tube side fluid temperature (light oil hot side = 190 °F);

t2 = Outlet shell side fluid temperature (water cold side = 90 °F);

T2 = Outlet tube side fluid temperature (light oil cold side = 140 °F);

t1 = Inlet shell side fluid temperature (water cold side = 50 °F).

(190 – 90) – (140 – 50)

ΔTm= =° F
(190 – 90)
¿
(140 – 50)
(100) – (90)
ΔTm= =° F
(100)
¿
(90)
 10
ΔTm= =94.9 ° F
0.10536
The preliminary area estimate of the heat exchanger can now be calculated as:
Q
A= =¿
(U x ΔTm)
2 , 035 , 000 Btu /hr
A= =178.7 ft ²
(120 Btu /h . ft ².° F).(94.9 ° F )
The required mass flow rate of water can be calculated from Q = mCp ΔTm:
Q
m= =¿
Cp x ΔTm

m=
( 2,035,000
hr )
Btu
=28,978
lb

( 0.74 Btulb .° F ) ( 94.9 ° F ) hr

Problem 10

Taking the shell and tube heat exchanger described in Example 9, how many tubes of 3-inch
diameter and 10 ft length should be used?

Solution
3
The surface area per tube will be: Sa = πDL = π ( ) (10) ft² = 7.854 ft² - (D – tube diameter in ft).
12
 178.7 ft ²
n= =¿ 22.7 tubes(23∨24 tubes).
7.854 ft ²