Other Heat Exchange Equipment &

Networks - Extended Surface Heat

Exchangers

I. Review

Last time, we discussed shell-and-tube heat exchangers. We began with an
introduction to shell-and-tube heat exchange designs available.
We readily learned about AT
TM
, which is used in the overall heat transfer equation,

q = U
o
A
o
AT
TM
.

AT
TM
for concentric pipe heat exchangers and single pass (1-1) shell-and-tube
heat exchangers is equal to AT
LM
. This equality does not hold for multiple pass
shell-and-tube designs. For the multiple pass variety of heat exchange equipment,
we require the introduction of the F
G
correction factor, such that AT
TM
= F
G
AT
LM
.
The F
G
, correction factor is easily determined from correlation charts of

Z = AT
h
/AT
c
and q
h
= AT
c
/AT
c,max
.

With shell & tube heat exchangers, we have encountered the Donohue equation,
an approximate correlation used to estimate the outside heat transfer coefficient,
h
o .
The inside heat transfer coefficient, h
i
, is found using the classic
Sieder-Tate relation. Note that h
i
and h
o
are the film coefficients
inside and outside the tubes, respectively.

We have also briefly reviewed technologies for increasing boiling and condensing
heat transfer coefficients both inside and outside tubes. This includes use of porous
coatings, grooves, low-fins, and fluting on tubes. For very low coefficients,
such as air and other gases, traditional large fins on the outsides of tubes
are often used.

Such fins allow air to be used as a cooling medium with banks of tubes and fans.
The main disadvantage of such air cooling is fouling and larger P on the process
side.



L fin G fin
Spiral
fin
Extended surface
tube bundle
Radial Fin Types
Let's consider our overall heat transfer coefficient for a typical
clean heat exchange system:


1
U
o
A
o
=
1
h
i
A
i
+
Ax
kA
LM
|
\

|
.
|
pipe
+
1
h
o
A
o


How can we modify the above equation to account for fins?







where A
b
=
A
f
=
q
f
=
( )
F F b o
pipe
LM i i o o
A A h kA
x
A h A U q +
+
|
|
.
|

\
| A
+ =
1 1 1
Area of bare tube (not occupied by fins)
Surface area of fins
Fin efficiency
To compute q
f
, we can use empirical relationships plus Figure 15.12 or
other provided graphs of fin efficiency



Longitudinal Fin Geometry:


k
S L h
a
p o
F
/
=






where h
o
= coefficient outside tube from Figure 15.13
k = thermal conductivity of metal in fin
L
p
= perimeter of fin
S = cross-sectional area of fin




x
F
A Fin-Fan Air Cooled Heat Exchanger
Induced Draft vs. Forced Draft Fan Coolers
& Condensers
Air Cooler Design
Air ambient temperature is based on the dry bulb temperature that is not
exceeded 5% of the time during summer
Highest temperature would lead to uneconomic design
Sometimes add a few degrees to allow for recirculation
Minimum approach of about 15F at cold end
F factor is typically 0.9 for air coolers
Face velocity (based on standard air) is typically about 500 ft/min (2.5m/s) based
on bundle area. Bundle area 2 x tube horizontal cross section area
Air side pressure drop is usually very low (0.6 water)
Fan power is calculated from air flow and p:
( )
|
|
.
|

\
|
=
6837
p ACFM
hp power Fan
Where:
ACFM = air flow in actual cubic ft/min
p = air side pressure drop in inches of water
= fan efficiency (typically 70%)
variation of U with Tubeside Coefficient
Tubeside h [Btu/(hr.ft2.F]
U

o
v
e
r
a
l
l
[
B
t
u
/
(
h
r
.
f
t
2
.

F
)
]
2.5
3.0
3.5
4.0
4.5
100 150 200 250 300 350 400
Typical
Example 15-6 in MSH
Steam (250 F)
Air (130 F)
0.035 in
0.50 in
1.5 in Sch 40
3 in. Sch 40
One of 28
longitudinal
fins
Process
heating
Condensate return
LP Main
MP Main
HP Main
Boiler &
Superheat
BFW
preheat
Process
heating
Process
heating
Process
heating
Make-up
Vent
Degassing
Typical Steam Distribution System
Make-up and
additives
Process Heat Load Typ. S&T Exchangers
Losses
Blowdown
Cooling tower sized
To flow, wet bulb approach,
and return water temp
Circulation pumps
Evaporation losses
Typical Cooling Water Distribution System
The Pinch point minimizes costly utilities
Gas Grille Building Codes, Conduction, Convection,
Radiation, and Fire Hazard