Design of Heat Transfer Equipment - 19CHE213

Mr. Hareesh Padayath

Department of Chemical Engineering and Materials Science

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 Design of Heat Transfer Equipment - 19CHE213
• L-T-P-C (2-0-0-2): Lecture(2) – Tutorial(0) – Practical(0) – Credit(2)

• Class Timings:
• Wed: Slot 3 (10:30 AM - 11:20 AM)
• Fri: Slot 1 (8:40 AM - 9:30 AM)
• Note: Shift From Slot-5 on Tuesday to Slot 1 on Friday
• Wed: Slot 6 (2:10 PM - 3:00 PM) - Discussion Hour

• Evaluation:

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 Syllabus
• Three kinds of Heat Transfer Equipment (HTE):
• Heat Exchangers
• Evaporators
• Condensers

• For Each HTE:

• Types
• Working Principle
• Role in Industrial Processes
• Performance Analysis
• Design: Thermal and Mechanical
• ASPEN (Advanced System for Process Engineering) design

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 Syllabus
• Pre-Requisites:
• Energy Balance and Thermodynamics: 19CHE201
• Fluid Mechanics: 19CHE202
• Principles of Heat Transfer: 19CHE204

• Text:
• McCabe, Smith, and Harriot, Unit Operations in Chemical Engineering, 6th Edition, McGraw
Hill, International Edition, 2001
• J. R. Welty et al., Fundamentals of Momentum, Heat and Mass Transfer, 4th Edition, Wiley,
2000
• J. M Coulson and J. F. Richardson, Chemical Engineering Vol. I, 4th Edition, Asian Books Pvt.
Ltd., India, 1998

Note: For content outside these texts, source(s) would be mentioned

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 Heat Exchanger
• Definition:
• A device whose primary purpose is the transfer of energy between two fluids

• Classification:
• Regenerator:
• Hot and cold fluid streams flow alternately through the same space

• Open-Type:
• Hot and cold fluid streams enter, mix and leave as a single stream

• Closed-Type:
• Hot and cold fluid streams are separated by a surface
•

Hot Fluid Surface Cold Fluid

Convection Convection
Conduction 5
 Closed Type Heat Exchanger
• Classification:
• Single Pass:
• Hot and cold fluid flow (pass) once through the exchanger

• Multiple Pass
• Hot and cold fluid may flow (pass) multiple times through the exchanger

OR

• Classification:
• Co-current (Parallel) Flow: Hot and cold fluid flow in the same direction

• Counter-current (counter) Flow: Hot and cold fluid flow in the opposite direction

• Cross Flow: Hot and cold fluid flow perpendicular to each other
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 Double Pipe Heat Exchanger1:

1Cengel, Y. A., & Ghajar, A. J. (2015). Heat and Mass Transfer: Fundamentals & Applications (p. 650). Penn Plaza, NY:McGraw-Hill Education. 7
Double Pipe Heat Exchanger1:

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Double Pipe Heat Exchanger: Temperature Profile

• Parallel flow:
• Hot and cold fluid approach the same value Profile Crossover?
• Possibility of higher initial ∆T
• Possibility of higher initial heat transfer Thermal Equilibrium

• Counter flow:
• Possibility of TH out < TC out
• Possibility of higher net heat transfer
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Double Pipe Heat Exchanger: Temperature Profile

Temperature Change during Phase Change?

None

• Evaporator: Evaporation of cold fluid

• Temperature profile independent of cold fluid flow direction

• Condenser: Condensation of hot fluid

• Temperature profile independent of hot fluid flow direction
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Double Pipe Heat Exchanger: Temperature Profile

• Condenser + Counterflow Exchanger

• Hot Fluid: Complete Phase Change(vapor to liquid) + Cooling(reducing temperature)
Draw an example?
• Evaporator + Counterflow Exchanger
• Cold Fluid: Complete Phase Change(liquid to vapor) + Heating(increasing temperature)
Illustration for Composite Parallel Flow?

Note: Direction of flow is important

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Double Pipe Heat Exchanger: Analysis

Infinitesimal
element

dTH

dq dA
∆T

dTc

Counter Flow

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Double Pipe Heat Exchanger: Analysis

Infinitesimal
element

dTH

dq dA
∆T

dTc

Counter Flow

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 Overall Heat Transfer Coefficient
• Co-flow and Counter Flow Heat Exchanger:
• Q = U A ∆TLMTD
• ∆TLMTD = (∆T1 - ∆T2)/(ln(∆T1/ ∆T2))
• Arithmetic Mean > Logarithmic Mean
• When ∆T1 = ∆T2, ∆TLMTD = ∆T1 = ∆T2

• Fundamental Mechanism in a Heat Exchanger:

Hot Fluid Surface Cold Fluid

Convection Convection
Conduction

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 Overall Heat Transfer Coefficient

Diameter and not

Radius?

1Cengel, Y. A., & Ghajar, A. J. (2015). Heat and Mass Transfer: Fundamentals & Applications (p. 650). Penn Plaza, NY:McGraw-Hill Education. 15
 Overall Heat Transfer Coefficient

• R = Ri + Rwall + Ro

• q = U A ∆T = (∆T/ (1/UA) )

• R = (1/UA) =(1/UiAi) = (1/UoAo)

• Rwall = (ln(Do/Di) / 2∏kL)

• Ri = (1/hiAi)

• Ro = (1/hoAo) 16
 Overall Heat Transfer Coefficient
• Rwall → 0
• Wall thickness - Small: Do → Di
• Thermal Conductivity – High: High k

• R = Ri + Rwall + Ro
• Rwall → 0 - Ao ≈ Ai ≈ A
• R = (1/UA) = (1/UiAi) = (1/UoAo)
• (1/U) = (1/hi) + (1/ho)

• Fouling Factor (Rf):

• Fouling: Accumulation of deposits on heat transfer surfaces
• Fouling Factor (Rf): Measure of thermal resistance
introduced by fouling
• Precipitation: Hard Water
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• Chemical fouling: Products of Undesirable Chemical Reaction (Corrosion)
 Overall Heat Transfer Coefficient
• Fouling Factor (Rf):
• Dependent on Temperature and Velocity of fluids
• General Trend: Fouling increases with increasing temperature
and decreasing Velocity

• R = Ri + RFi + Rwall + RFo + Ro

(1/UA) = (1/UiAi) = (1/UoAo) = R

R = (1/hiAi) + Rfi/Ai + (ln(Do/Di)/2∏kL) + Rfo/Ao + (1/hoAo)

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Overall Heat Transfer Coefficient

Source: Cengel
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 Exercise
• Steam in the condenser of a power plant is to be condensed at a temperature
of 300C with cooling water from a nearby lake, which enters the tubes of the
condenser at 140C and leaves at 220C. The surface area of the tubes is 45 m2,
and the overall heat transfer coefficient is 2100 W/m2K. Determine the mass
flow rate of the cooling water needed and the rate of condensation of the
steam in the condenser. (Cengel)

• A counter-flow double-pipe heat exchanger is to heat water from 200C to 800C

at a rate of 1.2 kg/s. The heating is to be accomplished by geothermal water
available at 1600C at a mass flow rate of 2 kg/s. The inner tube is thin-walled
and has a diameter of 1.5 cm. If the overall heat transfer coefficient of the
heat exchanger is 640 W/m2K, determine the length of the heat exchanger
required to achieve the desired heating. (Cengel)
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 Exercise
• Light lubricating oil (Cp = 2090 J/kg K) is cooled by allowing it to exchange
energy with water in a small heat exchanger. The oil enters and leaves the
heat exchanger at 375 and 350 K, respectively, and flows at a rate of 0.5 kg/s.
Water at 280 K is available in sufficient quantity to allow 0.201 kg/s to be used
for cooling purposes. Determine the required heat-transfer area for
(a) counterflow and
(b) parallel-flow operations.
The overall heat-transfer coefficient may be taken as 250 W/m2 K.

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 Double Pipe Heat Exchanger
1. Temperature Profile

2. Analysis

3. Overall Heat Transfer Coefficient

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