HEAT EXCHANGER

ME 333 Module No. 4

HEAT TRANSFER CIT-UNIVERSITY

 INTENDED LEARNING OUTCOMES
At the end of the lesson, the student should be able to:
Topic 6: Heat Exchanger
• ILO1. Identify classification of heat exchanger
• ILO2. Describe the effect of varying temperature profile of hotter
and colder fluid.
• ILO3. Analyze heat exchangers using LMTD and NTU method.
• ILO4. Describe the effect of fouling and tube & shell passes to the
overall heat transfer coefficient.
• ILO5. Identify the heat exchanger design specifications.

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  Heat exchangers are use to transfer of thermal
energy between
 two or more fluids

 between a solid surface and a fluid

 between solid particulates and a fluid

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 Types:
Double-pipe exchanger Spiral heat exchangers.

Shell and tube exchangers Air cooled heat

exchangers
Plate and frame
exchangers Agitated vessels.

Plate-fin exchangers. Fired heaters.

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 Based on transfer process
Indirect Contact – Shell & Tube Heat Exchangers

Direct Contact – Cooling Towers

Based on phase of fluids

Gas-Liquid exchangers

Liquid-Liquid exchangers

Gas-Gas heat exchangers

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 Based on construction
Tubular
 Double pipe heat exchanger
 Shell and tube heat exchangers
 Spiral heat exchangers
Plate-type
 Plate and frame heat exchangers
 Spiral plate heat exchangers
Extended Surface
 Plate-fin exchanger
 Tube-fin exchanger

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 Based on flow arrangements
Parallel flow / Co-current flow

Counter flow

Cross flow

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 Shell Tube Heat Exchanger
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 Components of a Shell Tube Heat Exchanger
Shell Floating-Head Cover
Shell cover Nozzles
Tubes Tie-Rods & Spacers
Channel Pass Partition Plates
Channel Cover Impingement Plates
Tubesheet Sealing Strips & Sealing Rods
Baffles

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 Classification by Construction
Fixed-tubesheet heat exchanger
Has straight tubes secured at both ends to tubesheets welded to the

shell

Low cost, simplest construction.

Bundle is "fixed" to the shell so outside of the tubes cannot be

cleaned mechanically.
Application is limited to clean services on the shell side
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 Fixed-tubesheet heat exchanger

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 U-tube heat exchanger
Tubes are bent in the shape of a U

Only one tubesheet

Bending of tubes adds to the cost

Tube bundle is removable, outside of tubes can be cleaned.

Because of the U-bend, inside of the tubes can’t be cleaned

mechanically
Can’t be used for dirty fluids inside tubes.

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 U-tube heat exchanger

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 Floating head exchanger
 Most versatile and costliest.

 One tubesheet is fixed relative to the shell, and the other is free to “float”

within the shell.

 Cleaning of both the insides and outsides of the tubes

 Can be used for services where both the shell-side and the tube-side fluids

are dirty
 Widely used in Petroleum Industry

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 Floating head exchanger

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 Baffle/ Nozzle orientation
 The orientation of the baffle cut is important for heat exchanger
installed horizontally.
 When the shell side heat transfer is sensible heating or cooling with no phase
change, the baffle cut should be horizontal.
 For shell side condensation, the baffle cut for segmental baffles is
vertical.
 For shell side boiling, the baffle cut may be either vertical or horizontal
depending on the service.
 Positioning of inlet/ outlet nozzle is also important for the proper
functioning of exchangers.
 In cooling water services, the inlet nozzle should be at the bottom and outlet nozzle
should be at the top.
 For condensing services exit should be from the bottom nozzle.

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 Shellside Flow In

Tubeside Flow
Out
Shell

Tube Bundle

Shellside Flow
Out

Tubeside Flow
In

SINGLE SEGMENTAL BAFFLES - HORIZONTAL

 Shell Outlet

Channel Inlet

Channel
Outlet

Shell Outlet

44 SINGLE SEGMENTAL BAFFLES – VERTICAL

 Shell Inlet

Shell Outlet

DOUBLE SEGMENTAL TRANSVERSE BAFFLES

DOUGHNUT AND DISC TYPE BAFFLES
 Air cooled heat exchanger

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 Plate and Frame heat exchanger

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 Spiral heat exchanger

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 THE OVERALL HEAT TRANSFER COEFFICIENT
For a double-pipe heat exchanger,

 The rate of heat transfer between

the two fluids as

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 THE OVERALL HEAT TRANSFER COEFFICIENT
U is the overall heat transfer
coefficient, whose unit is W/m2 · °C,

When the wall thickness of the

tube is small and the thermal
conductivity of the tube material is
high,

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 FOULING
The deposition of any undesired material on heat
transfer surfaces is called fouling.
It significantly impact the thermal and mechanical
performance of heat exchangers.
Fouling increases the overall thermal resistance
 Lowers the overall heat transfer coefficient of heat
exchangers.
It impedes fluid flow, accelerates corrosion and
increases pressure drop across heat exchangers.
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 FOULING
The overall heat transfer coefficient to account for the
effects of fouling on both the inner and the outer
surfaces of the tube. For an unfinned shell-and-tube
heat exchanger, it can be expressed as

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Scaling/Crystallization Fouling
Particulate/Sedimentation Fouling
 Chemical Fouling

Corrosion Fouling
Freezing Fouling Biological Fouling
 Sample Problem No.1

SOLUTION

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 Sample Problem No.1

SOLUTION

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 Sample Problem No.1

SOLUTION

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 Sample Problem No.1

SOLUTION

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 Sample Problem No.1

SOLUTION

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 Sample Problem No.1

SOLUTION

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 Sample Problem No.1

SOLUTION

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 Sample Problem No.2

SOLUTION

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 Sample Problem No.2

SOLUTION

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 Sample Problem No.2

SOLUTION

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 Sample Problem No.2

SOLUTION

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 ANALYSIS
The first law of thermodynamics requires that the rate
of heat transfer from the hot fluid be equal to the
rate of heat transfer to the cold one. That is,

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 ANALYSIS
It is often convenient to combine the product of the
mass flow rate and the specific heat of a fluid into
a single quantity. This quantity is called the heat
capacity rate,

the only time the temperature rise of a cold fluid is equal to the temperature drop of the hot fluid is when
the heat capacity rates of the two fluids are equal to each other

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 ANALYSIS
 Two special types of heat exchangers commonly used in
practice are condensers and boilers. One of the fluids
in a condenser or a boiler undergoes a phase-change
process, and the rate of heat transfer is expressed as

hfg is the enthalpy of vaporization of the fluid at the specified temperature or pressure.

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Variation of fluid temperatures in a heat exchanger
when one of the fluids condenses or boils.
 LMTD METHOD
 Suitable form of the average temperature difference
for use in the analysis of heat exchangers.

 For parallel-flow and counter-flow heat

exchangers,

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 The ∆T1 and ∆T2 expressions in
parallel-flow and counter-flow heat exchangers.

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 LMTD METHOD
For cross-flow and multipass shell-and-tube heat
exchangers,

 Where F is the correction factor given in versus two

temperature ratios P and R defined as

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Correction
factor F charts
Correction
factor F charts
 Sample Problem No.3

SOLUTION
STEP 1: Establish assumptions
1 Steady operating conditions exist. 2 The heat exchanger is well insulated so that
heat loss to the surroundings is negligible and thus heat transfer from the hot
fluid is equal to the heat transfer to the cold fluid. 3 Changes in the kinetic and
potential energies of fluid streams are negligible. 4 There is no fouling. 5 Fluid
properties are constant.
STEP 2: Find properties
The heat of vaporization of water at 30°C is hfg = 2431 kJ/kg and the specific heat
of cold water at the average temperature of 18°C is Cp = 4184 J/kg · °C (Table
A–9).

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 Sample Problem No.3

SOLUTION

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 Sample Problem No.3

SOLUTION

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 Sample Problem No.3

SOLUTION

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 Sample Problem No.4

SOLUTION
STEP 1: Establish assumptions
1 Steady operating conditions exist. 2 The heat exchanger is well insulated so that
heat loss to the surroundings is negligible and thus heat transfer from the hot
fluid is equal to the heat transfer to the cold fluid. 3 Changes in the kinetic and
potential energies of fluid streams are negligible. 4 There is no fouling. 5 Fluid
properties are constant.
STEP 2: Find properties
We take the specific heats of water at the mean water temperature (20+80)/2 =
50 °C, cp = 4.181 kJ/kg · °C and geothermal fluid at 160 °C, cp = 4.34 kJ/kg · °C

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 Sample Problem No.4

SOLUTION

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 Sample Problem No.4

SOLUTION

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 Sample Problem No.4

SOLUTION

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 Sample Problem No.5

SOLUTION

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 Sample Problem No.5

SOLUTION

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 Sample Problem No.5

SOLUTION

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Correction
factor F charts
 Sample Problem No.5

SOLUTION

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 Sample Problem No.5

SOLUTION

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 THE EFFECTIVENESS–NTU METHOD
This method is used to calculate the rate of heat transfer in heat
exchangers (especially counter current exchangers) when there
is insufficient information to calculate the Log-Mean
Temperature Difference (LMTD).
 In heat exchanger analysis, if the fluid inlet and outlet
temperatures are specified or can be determined by simple
energy balance, the LMTD method can be used; but when
these temperatures are not available The NTU or The
Effectiveness method is used.

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 THE EFFECTIVENESS–NTU METHOD
This method is based on a dimensionless parameter called the
heat transfer effectiveness defined as

 maximum temperature difference and maximum

possible heat transfer rate Q max

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 THE EFFECTIVENESS–NTU METHOD

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 THE EFFECTIVENESS–NTU METHOD
Effectiveness relations of the heat exchangers typically involve
the dimensionless group called the number of transfer units
NTU and is expressed as

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 THE EFFECTIVENESS–NTU METHOD
In heat exchanger analysis, it is also convenient to define
another dimensionless quantity called the capacity ratio c as

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Effectiveness
for heat exchangers
Effectiveness
for heat exchangers
 Sample Problem No.6

SOLUTION

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 Sample Problem No.6

SOLUTION

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 Sample Problem No.6

SOLUTION

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 Sample Problem No.6

SOLUTION

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 Sample Problem No.7

SOLUTION
STEP 1: Establish assumptions
1 Steady operating conditions exist. 2 The heat exchanger is well insulated so that
heat loss to the surroundings is negligible and thus heat transfer from the hot
fluid is equal to the heat transfer to the cold fluid. 3 Changes in the kinetic and
potential energies of fluid streams are negligible. 4 There is no fouling. 5 Fluid
properties are constant.
STEP 2: Find properties
We take the specific heats of water at the mean water temperature (20+80)/2 =
50 °C, cp = 4.181 kJ/kg · °C and geothermal fluid at 160 °C, cp = 4.34 kJ/kg · °C

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 Sample Problem No.7

SOLUTION

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 Sample Problem No.7

SOLUTION

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 Sample Problem No.7

SOLUTION

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