25-03-2024

MODULE-IV
(HEAT EXCHANGERS)

Energy balance (HE)

Heat exchanger
𝑚̇ & 𝑚̇ : mass flow rates of the cold & hot fluids.
𝐻 &𝐻 ∶ enthalpies per unit mass of the cold fluid entering & leaving HE
𝐻 & 𝐻 ∶ enthalpies per unit mass of the hot fluid entering & leaving HE
𝑄 & 𝑄 : rate of heat addition to the cold fluid & hot fluid

@ SS, Q given out (hot fluid) = Q gained (cold fluid)- [Assumption : no heat loss from HE]

(1)
𝑄 = −𝑄
(2)
𝑚̇ 𝐻 − 𝐻 = −𝑚̇ 𝐻 −𝐻 =𝑄

𝑚̇ 𝐻 − 𝐻 = 𝑚̇ 𝐻 −𝐻 =𝑄 (3)

If only sensible HT takes place b/w hot & cold fluids [Assume : heat capacities (constant)]
(3)=>
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𝑚̇ 𝐶 𝑇 −𝑇 = 𝑚̇ 𝐶 𝑇 −𝑇 =𝑄 (4)

𝐶 &𝐶 − heat capacities of the cold & hot fluids

𝑇 &𝑇 ;𝑇 &𝑇 : have their usual meaning

Energy balance

For the latent heat transfer (i.e., condensation of vapours) from the condensing vapours to a coolant,

𝑚̇ λ = 𝑚̇ 𝐶 𝑇 −𝑇 =𝑄 (5)

𝑚̇ - rate of condensation of vapour

λ - latent heat of condensation of vapour

(5) => applicable to a condenser where the vapour entering is saturated & no subcooling of the condensed liquid takes
place

Overall Heat Transfer Coefficient & Fouling Factor

 When heat is transferred across a plane wall (Overall heat transfer coefficient),

1 1 𝑥 1
= + + (clean surfaces)
𝑈 ℎ 𝑘 ℎ

 When heat is transferred across a tubular surface, overall heat transfer coefficient (based on the inner area)
1 1 𝑟 𝑟 𝑟 1 (clean surfaces)
= + ln +
𝑈 ℎ 𝑘 𝑟 𝑟 ℎ
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 Overall heat transfer coefficient across a plane wall,

1 1 𝑥 1 𝐹 : fouling factor on the side (heat transfer coefficient is ℎ )

= +𝐹 + +𝐹 + 𝐹 : fouling factor on the side (heat transfer coefficient is ℎ )
𝑈 ℎ 𝑘 ℎ

 Overall coefficient (based on the inner area) across the surface of a tube

1 1 𝑟 𝑟 𝑟 𝑟 1
= + 𝐹 + ln + 𝐹 +
𝑈 ℎ 𝑘 𝑟 𝑟 𝑟 ℎ

Mean temp difference (𝜟𝑻𝒎 )

𝑞 = 𝑈𝐴𝛥𝑇
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Expression for 𝜟𝑻𝒎 : parallel-flow HE

 Consider an elementary area dA( = B dx ).
o Rate of heat transfer across it ,

𝑑𝑞 = 𝑈 𝑇 − 𝑇 𝐵𝑑𝑥 (1)

 Since there are no losses to the surroundings,

(heat transfer rate = rate of change of enthalpy) on either side
⸫ 𝑑𝑞 = −𝑚̇ 𝐶 𝑑𝑇 (2)

= 𝑚̇ 𝐶 𝑑𝑇 (3)

𝛥𝑇 = 𝑇 − 𝑇
(4)
𝑑 𝛥𝑇 = 𝑑𝑇 − 𝑑𝑇

𝑑 𝛥𝑇 1 1
=− + 𝑈𝐵𝑑𝑥
𝛥𝑇 𝑚̇ 𝐶 𝑚̇ 𝐶

𝑑 𝛥𝑇 1 1
=− + 𝑈𝐵 𝑑𝑥
𝛥𝑇 𝑚̇ 𝐶 𝑚̇ 𝐶

𝛥𝑇 1 1
ln =− + 𝑈𝐴 (5)
𝛥𝑇 𝑚̇ 𝐶 𝑚̇ 𝐶

if q = total rate of heat transfer in the HE,

𝑞 = 𝑚̇ 𝐶 (𝑇 −𝑇 (6)

= 𝑚̇ 𝐶 (𝑇 − 𝑇 ) (7)

𝛥𝑇 − 𝛥𝑇
𝛥𝑇 =
ln = − (𝑇 − 𝑇 ) + (𝑇 −𝑇 𝑈𝐴 𝛥𝑇
𝑙𝑛(
𝛥𝑇

(𝛥𝑇 − 𝛥𝑇
𝑞 = 𝑈𝐴 (performance equation for a parallel-flow HE)
𝛥𝑇
ln
𝛥𝑇
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Expression for 𝜟𝑻𝒎 : Counter flow

 Derivation : 𝜟𝑻𝒎 proceeds along similar lines to that for parallel flow.

 Use same nomenclature

𝑑𝑞 = 𝑈 𝑇 − 𝑇 𝐵𝑑𝑥

𝑑𝑞 = −𝑚̇ 𝐶 d𝑇

𝑑𝑞 = −𝑚̇ 𝐶 d𝑇

𝛥𝑇 − 𝛥𝑇
𝑞 = 𝑈𝐴
𝛥𝑇 𝛥𝑇 − 𝛥𝑇
ln 𝛥𝑇 =
𝛥𝑇 𝛥𝑇
ln
𝛥𝑇

Special case: Counter flow 𝑞 = 𝑚̇ 𝐶 (𝑇 −𝑇

Capacity rates on the two sides are equal

𝑚̇ 𝐶 = 𝑚̇ 𝐶
𝛥𝑇 − 𝛥𝑇
𝑇 −𝑇 = 𝑇 −𝑇 𝛥𝑇 =
𝛥𝑇
ln
𝛥𝑇

𝑜𝑟 𝛥𝑇 = 𝛥𝑇

𝛥𝑇 𝑃 − 1
𝛥𝑇 = 𝑝 → 1
ln 𝑝

𝛥𝑇 = 𝑝 → 1 = 𝛥𝑇 = 𝛥𝑇
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Cross flow
Case (i) : Single pass cross flow : both fluids are unmixed

 Area A (breadth B & length L) across which 𝑄̇ takes place

 Two fluids flowing on either side, [ one in the x-direction & other in the y-direction].

 Both Th & Tc = f (x &y) & exit temp profiles are not uniform.

 An elementary area dA = ( dx dy ).

 Rate of heat transfer across this area,

𝑑𝑞 = 𝑈 𝑇 − 𝑇 𝑑𝐴 = 𝑈 𝑇 − 𝑇 𝑑𝑥𝑑𝑦

 If U is constant, total heat transfer rate in the HE,

𝑞=𝑈 𝑇 − 𝑇 𝑑𝑥𝑑𝑦

where 𝑇 and 𝑇 are functions of x & y.

 Compare with performance eqn 𝑞 = 𝑈𝐴𝛥𝑇

1
∆𝑇 = 𝑇 − 𝑇 𝑑𝑥𝑑𝑦
𝐵𝐿

Determination of the ∆𝑻𝒎 involves a double integration & complicated.

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Case (ii). Mixing occurs on one side or on both sides.

Ex: one fluid (cold fluid) is mixed & other (hot fluid) is unmixed.

o Tc = f(x) and Th = f(x, y)

Case (iii). Mixing occurs on one side or on both sides.

𝑇 = 𝑓 𝑥 𝑎𝑛𝑑 𝑇 = 𝑓 𝑥
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Computations for 𝜟𝑻𝒎 : Cross flow (3 cases)

 Use methodology proposed by Bowman, Mueller and Nagle (1940) to evaluate integration numerically for 3
cases of cross flow
𝛥𝑇 − 𝛥𝑇
 Results are presented in the form of a correction factor F 𝛥𝑇 =
𝛥𝑇
𝜟𝑻𝒎 (𝑐𝑟𝑜𝑠𝑠 𝑓𝑙𝑜𝑤) ln
𝛥𝑇
𝐹=
𝜟𝑻𝒎 𝑖𝑓 𝑡ℎ𝑒 𝑎𝑟𝑟𝑎𝑛𝑔𝑒𝑚𝑒𝑡 𝑤𝑎𝑠 𝑐𝑜𝑢𝑛𝑡𝑒𝑟 𝑓𝑙𝑜𝑤

 If the bulk exit temp on the hot & cold sides : 𝑇 &𝑇
𝑇 −𝑇 − 𝑇 −𝑇
∆𝑇 =
ln 𝑇 − 𝑇 ⁄ 𝑇 − 𝑇

 For given values of the inlet & outlet temp on the hot & cold sides,
 𝜟𝑻𝒎 : highest for counter flow (for all flow arrangements)
 Correction factor (F) for any cross flow situation : 0 ≤ F ≤ 1.
𝛥𝑇 = 𝑇 −𝑇
 Heat transfer rate , 𝑞 = 𝑈𝐴 ∆𝑇
𝑞 = 𝑈𝐴F ∆𝑇 𝛥𝑇 = 𝑇 − 𝑇

F = function of two parameters, R and S (dimensionless quantity)

𝑇 −𝑇
𝑅= (𝑹 ≥ 𝟎)
𝑇 −𝑇
(ratio of the change in temp of the two fluids (or) ratio of the capacity rates on the two sides)

𝑇 −𝑇
𝑆= (𝟎 ≤ 𝑺 ≤ 𝟏)
𝑇 −𝑇
(ratio of the change in temp of one of the fluids to the difference of inlet temp of the two fluids.

NOTE
o Subscripts 1 & 2 correspond to the two fluids.
For the cases (i) both fluids unmixed (iii) both fluids mixed ,
 it is immaterial which subscript corresponds to the hot side & which to the cold side.

For case (ii) : fluid (1) - mixed, fluid(2) – unmixed only,

o care must be exercised in taking the mixed fluid (whether it be on the hot side or cold side) with subscript 1.
 i.e 1= h , 2 = c (or) 1 = c, 2 = h
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F-charts : cross-flow HEs

(Variation of F with S for a given value of R)

 Value of F starts with max value of unity when S = 0.

 It decreases as S increases, 1st rather slowly & then
rapidly.

Fluid (I) - mixed, Fluid(2) - unmixed

Special cases
 Product of the flow rate & specific heat 𝑚̇𝐶 : ∞ (either on the hot or on the cold side)

 Temp on the side having the infinite 𝑚̇𝐶 does not change

 𝜟𝑻𝒎 is the same whether the flow arrangement be parallel, counter or cross.
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The Effectiveness- NTU Method

Two types of HE problems
1) Determination of the size of a HE for a specified performance
For two fluids : given
o For specified flow rates, inlet & exit temp
o Calculate heat transfer area (A) req

2) Calculation of the performance of a specific HE

For a given HE exchanger & two given fluids,
o Only inlet temp & flow rates are specified
o Calculate exit temp of the two fluids

Case (i) : determination of the size of a HE

 𝑞, 𝑈 , ∆𝑇 : known .

𝑞 = 𝑚̇ 𝐶 𝑇 −𝑇 = 𝑚̇ 𝐶 𝑇 −𝑇

∆𝑇 = f (𝑇 , 𝑇 , 𝑇 , 𝑇 )
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Case (ii) : performance of HE

 Exit temp : not known (neither q nor 𝜟𝑻𝒎 can be calculated)

 Trial-and-error approach (LMTD) → soln of the problem (not practical)

1) Assume : exit temp,
2) Calculate q and 𝜟𝑻𝒎 (check performance eqn is satisfied).
3) If it is not, assume some other value for the exit temp
4) Repeat the process is repeated until performance eqn is satisfied

 This method is tedious & avoided : effectiveness-NTU method (alternative)

𝑅𝑎𝑡𝑒 𝑜𝑓 ℎ𝑒𝑎𝑡 𝑡𝑟𝑎𝑛𝑠𝑓𝑒𝑟 𝑖𝑛 𝑡ℎ𝑒 𝐻𝐸

𝐸𝑓𝑓𝑒𝑐𝑡𝑖𝑣𝑒𝑛𝑒𝑠𝑠 =
𝑀𝑎𝑥. 𝑝𝑜𝑠𝑠𝑖𝑏𝑙𝑒 ℎ𝑒𝑎𝑡 𝑡𝑟𝑎𝑛𝑠𝑓𝑒𝑟 𝑟𝑎𝑡𝑒

𝑅𝑎𝑡𝑒 𝑜𝑓 ℎ𝑒𝑎𝑡 𝑡𝑟𝑎𝑛𝑠𝑓𝑒𝑟 𝑖𝑛 𝑡ℎ𝑒 𝐻𝐸

EFFECTIVENESS 𝐸𝑓𝑓𝑒𝑐𝑡𝑖𝑣𝑒𝑛𝑒𝑠𝑠 =
𝑀𝑎𝑥. 𝑝𝑜𝑠𝑠𝑖𝑏𝑙𝑒 ℎ𝑒𝑎𝑡 𝑡𝑟𝑎𝑛𝑠𝑓𝑒𝑟 𝑟𝑎𝑡𝑒

 Actual 𝑄̇ in the HE ( q) = (capacity rate) * (change of temp of the fluid)

 Max. possible 𝑄̇ (qmax ) = [smaller of the two capacity rates, 𝑚̇𝐶 ] * [max possible rise (or) fall of temp,
𝑇 −𝑇 ]

Note
 Use smaller capacity rate for qmax
 If larger capacity rate 𝑚̇𝐶 is used, ∈ : dimensionless measure of the temp rise (or) fall (HE)
(0 ≤ ∈ ≤ 1).
o 𝑇 > 𝑇 (or) 𝑇 < 𝑇

𝑞 𝑚̇ 𝐶 𝑇 −𝑇 𝑚̇ 𝐶 𝑇 −𝑇
∈= = =
𝑞 𝑚̇𝐶 𝑇 −𝑇 𝑚̇𝐶 𝑇 −𝑇

𝑇 −𝑇
 If 𝑚̇ 𝐶 < 𝑚̇ 𝐶 ⇒ 𝑚̇ 𝐶 = 𝑚̇𝐶 𝑎𝑛𝑑 ∈ =
𝑇 −𝑇
̇ when 𝑚 𝐶
(Equilavent = 𝑚̇ 𝐶 )
𝑇 −𝑇
𝑚̇ 𝐶 > 𝑚̇ 𝐶 𝑡 ⇒ 𝑚̇ 𝐶 = 𝑚̇𝐶 𝑎𝑛𝑑 ∈ =
𝑇 −𝑇
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Effectiveness : Parallel-flow HE
̇ ̇
𝜖 = 1 − exp − 1 + ̇ ̇
/ 1+ ̇

Instead of 𝑚̇ 𝐶 = 𝑚̇𝐶 , that 𝑚̇ 𝐶 = 𝑚̇𝐶 ,

̇ ̇
𝜖 = 1 − exp − 1 + ̇ ̇
/ 1+ ̇

The two expressions for 𝜖 can be combined by ,

𝑚̇𝐶 𝑈𝐴 𝑚̇𝐶
𝜖 = 1 − exp − 1 + 1+
𝑚̇𝐶 𝑚̇𝐶 𝑚̇𝐶

Subscript b : larger of the two capacity rates

Capacity rate ratio & Number of transfer units 𝜖 = 1 − exp − 1 +

𝑚̇𝐶 𝑈𝐴
1+
𝑚̇𝐶
𝑚̇𝐶 𝑚̇𝐶 𝑚̇𝐶

𝑚̇𝐶
𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦 𝑟𝑎𝑡𝑒 𝑟𝑎𝑡𝑖𝑜, 𝐶 =
𝑚̇𝐶

𝑈𝐴
𝑁𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑡𝑟𝑎𝑛𝑠𝑓𝑒𝑟 𝑢𝑛𝑖𝑡𝑠, 𝑁𝑇𝑈 =
𝑚̇𝐶

Parallel-flow HE,

1 − exp[− 1 + 𝐶 𝑁𝑇𝑈]
𝜖=
1+𝐶

NOTE
 Performance (HE) = f(𝜖, C, NTU)- 3 parameters

 0 ≤ C ≤ 1 & NTU ≥ 0.

 NTU ∝ (heat transfer area : measure of the size of a HE).

 ∈ (vs) NTU [ C as a parameter]

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Expression for the effectiveness : Counter flow HE

Adopt same procedure for parallel flow

1 − 𝑒𝑥𝑝 − 1 − 𝐶 𝑁𝑇𝑈
∈=
1 − 𝐶 𝑒𝑥𝑝 − 1 − 𝐶 𝑁𝑇𝑈

∈ (vs) NTU [ C : parameter]

(Similar trend with the ∈ approaching the value of unity for all C)

Expression for the effectiveness : Cross flow HE

Kays & London [1964] and Mason [1954]

(i) Both fluids unmixed

𝑒𝑥𝑝 −𝑁𝑇𝑈 . 𝐶 − 1
∈= 1 − 𝑒𝑥𝑝
𝐶 𝑁𝑇𝑈 .
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(ii) 𝑚̇𝐶 mixed, 𝑚̇𝐶 unmixed,

1
∈= 1 − 𝑒𝑥𝑝 −𝐶 1 − 𝑒
𝐶

𝑚̇𝐶 unmixed, 𝑚̇𝐶 mixed,

1
∈= 1 − 𝑒𝑥𝑝 − 1 − exp −𝑁𝑇𝑈. 𝐶
𝐶

Expression for the effectiveness : Cross flow HE

Kays & London [1964] and Mason [1954]

(iii) Both fluids mixed

1 𝐶 1
∈= + .
−
1−𝑒 1−𝑒 𝑁𝑇𝑈

Note
 Given values of C & NTU & for specified flow arrangement
o Read off values, of ∈

 Use eqn (more precision),

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𝑚̇𝐶
Special cases 𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦 𝑟𝑎𝑡𝑒 𝑟𝑎𝑡𝑖𝑜, 𝐶 =
𝑚̇𝐶
Capacity rate (𝑚̇𝐶 ) : ∞ (either hot or cold)
 C = 0 (effectiveness-NTU method)

In this case, equations reduce to the simple form (all the flow arrangements )

∈= 1 − 𝑒 1 − exp[− 1 + 𝐶 𝑁𝑇𝑈]
𝜖=
1+𝐶

Parallel flow ,
−𝑙𝑛 1 − 1 + 𝐶 ∈
𝑁𝑇𝑈 =
1+𝐶

Counter flow ,

1 ∈ −1
𝑁𝑇𝑈 = 𝑙𝑛
𝐶−1 𝐶 ∈ −1

Cross flow,
1
𝑚̇𝐶 mixed, 𝑚̇𝐶 unmixed, 𝑁𝑇𝑈 = −𝑙𝑛 1 + 𝑙𝑛 1 − 𝐶 ∈
𝐶

1
𝑚̇𝐶 unmixed, 𝑚̇𝐶 mixed, 𝑁𝑇𝑈 = − 𝑙𝑛 1 + 𝐶𝑙𝑛 1 −∈
𝐶

Explicit relations : NTU = f(∈ , C) are not available for the other two cases of cross flow, viz., both fluids
unmixed and both fluids mixed.
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Effectiveness relations : common types of HE

Effectiveness relations for HE : NTU = UAs/Cmin and C= Cmin/Cmax = (mCp)min/(mCp)max
(Kays and London, 1964)
Heat Exchanger Type Effectiveness relation
Double pipe: 𝜖=
[ ]
Parallel-flow
[ ]
Counter Flow 𝜖=
[ ]
Shell and Tube: [
One shell pass (2,4……. Tube Passes) 𝜖 =2 1+𝑐+ 1+𝑐
[

Cross- flow (Single pass) .

.
𝜖 = 1 − 𝑒𝑥𝑝 𝑒𝑥𝑝 −𝑐𝑁𝑇𝑈 −1
Both fluids unmixed
𝜖= 1 − 𝑒𝑥𝑝1 − 𝑐 1 − 𝑒𝑥𝑝 −𝑁𝑇𝑈
Cmax mixed, Cmin unmixed
𝜖 = 1 − 𝑒𝑥𝑝{− 1 − 𝑒𝑥𝑝 −𝑐𝑁𝑇𝑈 }
Cmin mixed, Cmax unmixed
All heat exchangers with c = 0 𝜖 = 1 − 𝑒𝑥𝑝 −𝑁𝑇𝑈

(Relations (Table) → Effectiveness directly when NTU is known)

Effectiveness relations for HE : NTU = UAs/Cmin and C= Cmin/Cmax = (mCp)min/(mCp)max

(Kays and London, 1964)
Heat Exchanger Type NTU relation
Double pipe: NTU = −
Parallel-flow
Counter Flow NTU = ln( )

Shell and Tube: /

NTU = − ln( )
/
One shell pass 2,4……. tube
passes

Cross- Flow (Single pass) NTU = −ln 1 +

Cmax mixed, Cmin unmixed
NTU = −
Cmin mixed, Cmax unmixed

All heat exchangers with c = 0 NTU = −ln 1 − ϵ

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HEAT EXCHANGER DESIGN

(i) Double Pipe HE design

Calculation procedure :
1) Compute ho (outside) & hi (inside) to obtain overall clean “U”: UC
2) Account fouling resistance to obtain dirty overall “U” : UD
3) Calculate surface area using, 𝑄 = 𝑈 𝐴∆𝑇
 In the calculation procedure ,
 hot & cold fluid temp : upper & lower case letters
 Fluid properties : lower case letters

Process conditions req :

 Hot fluid: 𝑇 , 𝑇 , 𝑚̇ , 𝐶 , 𝜇, 𝑘, ∆𝑃, inside &outside dirt factor : 𝑅 & 𝑅
 Cold fluid: 𝑡 , 𝑡 , 𝑚̇ , 𝐶 , 𝜇, 𝑘, ∆𝑃, inside &outside dirt factor : 𝑅 & 𝑅
 Diameter of each pipe : given (or) assume
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Calculation procedure
(i) Check the heat balance, Q from T1, T2, t1, t2 using CP @ Tmean (Tm) & tmean (tm)

𝑄 = 𝑚̇ 𝐶 𝑇 −𝑇 = 𝑚̇ 𝐶 𝑡 −𝑡

𝑇 >𝑇 & 𝑡 >𝑡

𝑇 +𝑇 𝑡 +𝑡
𝑇 = ,𝑡 =
2 2

(ii) Calculate LMTD

∆ ∆ ∆𝑇 = 𝑇 − 𝑡 𝑇 ⟶𝑇
∆𝑇 (LMTD) = ∆ K
∆ ∆𝑇 = 𝑇 − 𝑡 𝑡 ⟶𝑡

(iii) Calculate physical properties : hot & cold fluid @ arithmetic mean of (T1 & T2) & (t1 & t2)
.
For non-viscous fluids, ≈1
Inner Pipe:

(iv) Flow area (Ai) = 𝐷

𝐷 𝑢𝜌 𝐷 𝐺
𝑁 = =
𝜇 𝜇
𝑚̇
𝐺=
𝐴
(v) Obtain CP, μ, k @ Tm (or) tm

𝐶 𝜇
𝑁 =
𝑘
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(vi) Obtain hi using Seider-Tate (or) Dittus-Boelter equation

.
Take =1

ℎ𝐷 .
= 0.023 𝑁 𝑁 a = 0.4 (heating), a = 0.3 (cooling)
𝑘

(vii) Convert hi to hio

𝐷
ℎ =ℎ ×
𝐷

For Annulus,
(viii) Flow area = 𝐴 = 𝐷 − 𝐷 ,𝑚
D1 = OD of inner pipe
D2 = ID of outer pipe

Equivalent dia : annulus,

𝜋
4 × 𝐹𝑙𝑜𝑤 𝑎𝑟𝑒𝑎 4× 𝐷 −𝐷
𝐷 = = 4
𝑤𝑒𝑡𝑡𝑒𝑑 𝑝𝑒𝑟𝑖𝑚𝑒𝑡𝑒𝑟 𝜋𝐷

𝐷 −𝐷
= (𝑚)
𝐷

(ix) Calculate mean velocity,

𝑚̇
𝐺 =
𝐴

(x) Obtain μ @ Tm (or) tm

𝐷 𝐺
𝑁 , =
𝜇
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(xi) Obtain CP, μ, k @ Tm (or) tm

𝐶 𝜇
𝑁 =
𝑘
.
(xii) Obtain ho either by Dittus-Boelter (or) Sieder-Tate equation [take ≈ 1]

ℎ 𝐷 .
𝐶 𝜇
= 0.023 𝑁
𝑘 𝑘
a = 0.4 (heating) & a = 0.3 (cooling)
(xiii) Compute UC [Overall clean coefficient]

1 1 1
= +
𝑈 ℎ ℎ

ℎ ℎ
𝑈 =
ℎ +ℎ

(xiv) Compute UD (Dirty overall heat transfer coefficient)

1 1
= +𝑅
𝑈 𝑈 Rd = dirt factor, (m2.K)/W

𝑅 =𝑅 +𝑅
𝑅 = Inside dirt factor
𝑅 = Outside dirt factor
(xv) Compute heat transfer area,

𝑄 = 𝑈 𝐴∆𝑇
Length of pipe (L) using, 𝐴 = 𝜋𝐷 𝐿

If metal wall resistance is to be considered , use following relation for Uc,

1 1 1 𝑥 𝐷 Dw (log mean diameter) = ⁄
= + + 𝑥 = wall thickness m
𝑈 ℎ ℎ 𝑘 𝐷 kw = thermal conductivity of metal wall
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(ii) Shell & tube HE design 𝐷 = Shell equivalent diameter

𝐺 = Shell side mass velocity
(i) Shell side coefficient
. / .
ℎ 𝐷 𝐺𝐷 𝐶 𝜇 𝜇
= 0.36 2000 > NRe > 1000000.
𝑘 𝜇 𝑘 𝜇

 Evaluate all properties of shell side fluid @ avg bulk temp (avg of inlet & outlet temp of the shell side fluid )

(ii) Shell side mass velocity

Side side (or) bundle cross area (as),

𝐼. 𝐷𝑋 𝐶 ’ 𝑋𝐵 𝑆ℎ𝑒𝑙𝑙 𝐼𝐷 𝑋 𝑐𝑙𝑒𝑎𝑟𝑎𝑛𝑐𝑒 𝑋 𝑏𝑎𝑓𝑓𝑙𝑒 𝑠𝑝𝑎𝑐𝑖𝑛𝑔 (𝑚2)

𝑎 = =
𝑃 𝑃𝑖𝑡𝑐ℎ
̇
mass velocity, 𝐺 = (𝑘𝑔/𝑚2𝑠)

(iii) Shell side equivalent diameter (𝑫𝒆 )

𝑓𝑙𝑜𝑤 𝑎𝑟𝑒𝑎
𝐷 = 4𝑋
𝑤𝑒𝑡𝑡𝑒𝑑 𝑝𝑒𝑟𝑖𝑚𝑒𝑡𝑒𝑟

For square pitch,

𝑑
𝑃 −𝜋
4
𝐷 =4
𝜋𝑑

For triangular pitch,

𝑑
(0.5 ∗ 0.86)𝑃 −𝜋
8
𝐷 =4
(1/2)𝜋𝑑

𝑑 = 𝑂𝐷 𝑜𝑓 𝑡ℎ𝑒 𝑡𝑢𝑏𝑒
𝑃 = 𝑃𝑖𝑡𝑐ℎ 𝑜𝑓 𝑡ℎ𝑒 𝑡𝑢𝑏𝑒
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(iv) Tube side coefficient

Use Sieder-Tate (or) Dittus-Boelter eqn

(v) Remaining part

Procedure as outlined for double pipe HE can be used

Area of heat transfer (𝐴 ) = 𝑛 ⨯ 𝑎 ⨯ 𝐿

n=number of tubes
L=length of tube
a=outside area (external surface)

𝐴 = 𝑛𝜋𝑑 𝐿

𝑛 = 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑡𝑢𝑏𝑒𝑠
𝑑 = 𝑑𝑖𝑎𝑚𝑒𝑡𝑒𝑟 𝑜𝑓 𝑡ℎ𝑒 𝑡𝑢𝑏𝑒

(vi) Check for suitability of HE

𝑈 −𝑈
𝑅 = (𝑚 𝐾)/𝑊
𝑈 .𝑈

If 𝑅 calculated from the above eqn ≥ 𝑅 (req/provided in problem statement)

 HE specifications (ID of Shell. OD of tube, Length, No of tubes) is suitable
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SELECTION OF HEAT EXCHANGERS (Self Study)