INTERCAMBIADO

R DE CALOR
 HEAT EXCHANGER
A heat exchanger is a device that is used to transfer thermal energy (enthalpy) between two
or more fluids, between a solid surface and a fluid, or between solid particulates and a fluid,
at different temperatures and in thermal contact. In heat exchangers, there are usually no
external heat and work interactions. Typical applications involve heating or cooling of a
fluid stream of concern and evaporation or condensation of single- or multicomponent fluid
streams. In other applications, the objective may be to recover or reject heat, or sterilize,
pasteurize, fractionate, distill, concentrate, crystallize, or control a process fluid.
Common examples of heat exchangers are shell and tube exchangers, automobile radiators,
condensers, evaporators, air preheaters, and cooling towers. If no phase change occurs in
any of the fluids in the exchanger, it is sometimes referred to as a sensible heat exchanger.
 CLASSIFICATION

Heat Exchangers may be classified according to the following criteria.

 Recuperators/ regenerators
 Transfer process: direct and indirect contact
 Geometry of construction; tubes, plates, and extended surfaces.
 Heat transfer mechanism: single phase and two phase
 Flow arrangement: Parallel, counter, cross flow.
CLASSIFICATION
CLASSIFICATION
 CLASSIFICATION

■ Tubular heat exchangers—double pipe, shell and tube.

■ Plate heat exchangers (PHEs)—gasketed, brazed, welded, spiral,
■ Extended surface heat exchangers—tube-fin, plate-fin
■ Regenerators—fixed matrix, rotary matrix
 Tubular heat exchangers
Double pipe
A double-pipe heat exchanger has two concentric pipes, usually in the form
of a U-bend design. Double pipe heat changers with U-bend design are
known as hairpin heat exchangers. The flow arrangement is pure
countercurrent. A number of double-pipe heat exchangers can be connected
in series or parallel as necessary. Their usual application is for small duties
requiring, typically, less than 300 ft2 and they are suitable for high pressures
and temperatures and thermally long duties.
Double pipe
Application. When the process calls for a temperature cross (when the hot fluid outlet
temperature is below the cold fluid outlet temperature), a hairpin heat exchanger is the most
efficient design and will result in fewer sections and less surface area. Also, they are
commonly used for high-fouling services such as slurries and for smaller heat duties.
Multitube heat exchangers are used for larger heat duties. A hairpin heat exchanger should
be considered when one or more of the following conditions exist:
■ The process results in a temperature cross
■ High pressure on tube side application
■ A low allowable pressure drop is required on one side
■ When an augmentation device to enhance the heat transfer coefficient is desired
■ When the exchanger is subject to thermal shocks
■ When flow-induced vibration may be a problem
■ When solid particulates or slurries are present in the process stream
Hairpin heat
exchanger
 Tubular heat exchangers
Shell and Tube
In process industries, shell and tube heat exchangers are used in great
numbers, far more than any other type of exchanger. More than 90% of heat
exchangers used in industry are of the shell and tube type. STHEs are the
“workhorses” of industrial process heat transfer. They are the first choice
because of well-established procedures for design and manufacture from a
wide variety of materials, many years of satisfactory service, and availability
of codes and standards for design and fabrication. They are produced in the
widest variety of sizes and styles. There is virtually no limit on the operating
temperature and pressure
Shell and
tube
 Plate Heat Exchangers
PHEs are less widely used than tubular heat exchangers but offer certain
important advantages. PHEs can be classified into two principal groups:
1. Plate and frame or gasketed PHEs used as an alternative to tube and shell
exchangers for low- and medium-pressure liquid–liquid heat transfer
applications
2. Spiral heat exchanger used as an alternative to shell and tube exchangers
where low maintenance is required, particularly with fluids tending to sludge
or containing slurries or solids in suspension
Plate Heat
Exchangers
RECUPERATION/REGENERATION HE

Conventional heat exchangers with heat transfer between

2 fluids. The heat transfer occurs thro a separating wall or
an interface.
In regenerators or storage type heat exchangers, the same
flow passage alternately occupied by one of the two
fluids. Here thermal energy is not transferred thro’ a wall
as in direct transfer type but thro’ the cyclic passage of 2
fluid thro the same matrix.
Example is the ones used for pre heating air in large coal
fired power plant or steel mill ovens.
 Classification According to Flow
Arrangement
The basic flow arrangements of the fluids in a heat exchanger are as follows:
■ Parallelflow
■ Counterflow
■ Crossflow
The choice of a particular flow arrangement is dependent upon the required exchanger
effectiveness, fluid flow paths, packaging envelope, allowable thermal stresses, temperature
levels, and other design criteria.
These basic flow arrangements are discussed next.
 Parallelflow Exchanger
In this type, both the fluid streams enter at the same end, flow parallel to each other in the
same direction, and leave at the other end. This arrangement has the lowest exchanger
effectiveness among the single-pass exchangers for the same flow rates, capacity rate (mass
× specific heat) ratio, and surface area. Moreover, the existence of large temperature
differences at the inlet end may induce high thermal stresses in the exchanger wall at inlet.
Parallelflows are advantageous. (a) In heating very viscous fluids, parallelflow provides for
rapid heating.
Although this flow arrangement is not used widely, it is preferred for the following reasons:
1. When there is a possibility that the temperature of the warmer fluid may reach its
freezing point.
2. It provides early initiation of nucleate boiling for boiling applications.
 Counterflow Exchanger

In this type the two fluids flow parallel to each other but in opposite directions, and its
temperature distribution may be idealized. Ideally, this is the most efficient of all flow
arrangements for single-pass arrangements under the same parameters. Since the
temperature difference across the exchanger wall at a given cross section is the lowest, it
produces minimum thermal stresses in the wall for equivalent performance compared to
other flow arrangements.
Counterflow
Exchanger
 Crossflow Exchanger

In this type the two fluids flow normal

to each other. Important types of flow
arrangement combinations for a single-
pass crossflow exchanger include the
following:
• Both fluids unmixed
• Both fluids mixed
 SELECTION OF HEAT
EXCHANGERS
Selection is the process in which the designer selects a particular type of
heat exchanger for a given application from a variety of heat exchangers.
There are a number of alternatives for selecting heat transfer equipment, but
only one among them is the best for a given set of conditions. The heat
exchanger selection criteria are discussed next.
Selection criteria are many, but primary criteria are type of fluids to be
handled, operating pressures and temperatures, heat duty, and cost. The
fluids involved in heat transfer can be characterized by temperature,
pressure, phase, physical properties, toxicity, corrosivity, and fouling
tendency. Operating conditions for heat exchangers vary over a very wide
range, and a broad spectrum of demands is imposed for their design and
performance. All of these must be considered when assessing the type of
unit to be used.
Materials of construction
Operating pressure and temperature, temperature program, and temperature driving force
Flow rates
Flow arrangements
Performance parameters—thermal effectiveness and pressure drops
Fouling tendencies
Types and phases of fluids
Maintenance, inspection, cleaning, extension, and repair possibilities
Overall economy
Fabrication techniques
Mounting arrangements: horizontal or vertical
Intended applications
REQUIREMENTS OF HEAT
EXCHANGERS
Heat exchangers have to fulfill the following requirements:
■ High thermal effectiveness
■ Pressure drop as low as possible
■ Reliability and life expectancy
■ High-quality product and safe operation
■ Material compatibility with process fluids
■ Convenient size, easy for installation, reliable in use
■ Easy for maintenance and servicing
■ Light in weight but strong in construction to withstand the operational pressures and vibrations
■ especially heat exchangers for military applications
■ Simplicity of manufacture
■ Low cost
■ Possibility of effecting repair to maintenance problems
 Design of heat
exchangers
A heat exchanger typically involves two flowing fluids
separated by a solid wall. Heat is first transferred from
the hot fluid to the wall by convection, through the
wall by conduction, and from the wall to the cold fluid
again by convection. Any radiation effects are usually
included in the convection heat transfer coefficients.
We discuss the two methods used in the analysis of
heat exchangers. Of these, the log mean temperature
difference (or LMTD) method is best suited for the first
task and the effectiveness–NTU (the number of transfer
units) method for the second task. But first we present
some general considerations.
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:
where the subscripts c and h stand for cold and hot fluids,
respectively, and
, mass flow rates
, specific heats
, outlet temperatures
, inlet temperatures
In heat exchanger 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 and is defined for the hot and cold fluid streams
as:
The heat capacity rate of a fluid stream represents the rate of
heat transfer needed to change the temperature of the
fluid stream by 1 C as it flows through a heat exchanger.
Note that in a heat exchanger, the fluid with a large heat
capacity rate experiences a small temperature change, and the
fluid with a small heat capacity rate experiences a large
temperature change. Therefore, doubling the mass flow rate of
a fluid while leaving everything else unchanged will halve the
temperature change of that fluid.
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
rate of evaporation or condensation of the
fluid
enthalpy of vaporization of the fluid at the
specified temperature or pressure.
The rate of heat transfer in a heat exchanger can
also be expressed in an analogous manner to
Newton’s law of cooling as
U overall heat transfer coefficient,
heat transfer surface area.
appropriate mean temperature difference
between the two fluids.
 THE LOG MEAN
TEMPERATURE
DIFFERENCE METHOD

,
represent the temperature difference between
the two fluids at the two ends (inlet and outlet)
of the heat exchanger
 Temperature distributions
for a parallel-flow heat exchanger
 Temperature distributions
for a counterflow heat exchanger
Examples
■ Hot oil with a specific heat of 0.5 Btu/lbm°F flows through a heat exchanger of flow
found at a rate of 50000lbm/h with a input temperature of 380°F and an exit
temperature of 150°F. Cold oil with a specific heat of 0.4 Btu/lbm°F flows inside at a
rate of 80000 lbm/h and comes out at a temperature of 300°F. Determine the area of the
heat exchanger necessary to maintain the load if the total heat transfer coefficient based
on the interior area is 135 Btu/h·ft2·°F
An essential, and often the most uncertain, part of any
heat exchanger analysis is determination of the overall
heat transfer coefficient. Recall that this coefficient is
defined in terms of the total thermal resistance to heat
transfer between two fluids. The coefficient was
determined by accounting for conduction and convection
resistances between fluids separated by composite plane
and cylindrical walls, respectively. For a wall separating
two fluid streams, the overall heat transfer coefficient
may be expressed.
Note that calculation of the UA product does not require
designation of the hot or cold side
(UcAc =UhAh). However, calculation of an overall
coefficient depends on whether it is based on the cold or
hot side surface area, since Uc Uh if Ac Ah.
During normal heat exchanger operation, surfaces
are often subject to fouling by fluid impurities,
rust formation, or other reactions between the
fluid and the wall material. The subsequent
deposition of a film or scale on the surface can
greatly increase the resistance to heat transfer
between the fluids. This effect can be treated by
introducing an additional thermal resistance in
termed the fouling factor, Rf. Its value depends on
the operating temperature, fluid velocity, and
length of service of the heat exchanger.
Where subscripts i and o refer to inner and outer
tube surfaces
 When the wall thickness of the tube is small and
the thermal conductivity of the tube material is
1
𝑈= high, as is usually the case, the thermal resistance
1 𝐿 1
+ + of the tube is negligible (Rwall0) and the inner and
h𝑖 𝑘 h0
outer surfaces of the tube are almost identical
(AiAo As).
Examples
A type-302 stainless steel tube of inner and
outer diameters Di 22 mm and Do 27 mm,
respectively, is used in a cross-flow heat
exchanger. The fouling factors, Rƒ, for the
inner and outer surfaces are estimated to be
0.0004 and 0.0002 m2 K/W, respectively.
Determine the overall heat transfer coefficient
based on the outside area of the tube, Uo.

A concentric tube heat exchanger of length L =2m is used to thermally process a pharmaceutical
product flowing at a mean velocity of um,c =0.1 m/s with an inlet temperature of Tc,i =20°C. The
inner tube of diameter Di =10 mm is thin walled, and the exterior of the outer tube (Do =20 mm)
is well insulated. Water flows in the annular region between the tubes at a mean velocity of
um,h =0.2 m/s with an inlet temperature of Th,i =60 C. Properties of the pharmaceutical product
are: viscosidad=10x-6 m^2/s, k =0.25 W/m K, densidad=1100 kg/m^3, and cp 2460 J/kg K.
Evaluate water properties at Th =50°C.
Examples
■ A long thin-walled double-pipe heat exchanger with tube and shell diameters of 1.0 cm
and 2.5 cm, respectively, is used to condense refrigerant-134a by water at 20 C. The
refrigerant flows through the tube, with a convection heat transfer coefficient of hi=
4100 W/m2K. Water flows through the shell at a rate of 0.3 kg/s. Determine the overall
heat transfer coefficient of this heat exchanger.
■ Repeat problem by assuming a 2-mm-thick layer of copper forms on the outer surface
of the inner tube.
■ A counterflow, concentric tube heat exchanger is used to cool the lubricating oil for a
large industrial gas turbine engine. The flow rate of cooling water through the inner tube
(Di 25 mm) is 0.2 kg/s, while the flow rate of oil through the outer annulus (Do 45
mm) is 0.1 kg/s. The oil and water enter at temperatures of 100 and 30 °C, respectively.
How long must the tube be made if the outlet temperature of the oil is to be 60 °C?
Multipass and Cross-Flow Heat Exchangers:
Use of a Correction Factor
The log mean temperature difference DTLM relation
developed earlier is limited to parallel-flow and counter-
flow heat exchangers only. Similar relations are also
developed for cross-flow and multipass shell-and-tube
heat exchangers, but the resulting expressions are too
complicated because of the complex flow conditions.
The correction factor F for common cross-flow
and shell-and-tube heat exchanger
configurations is given versus two temperature
ratios P and R defined.
Where the subscripts 1 and 2 represent the inlet
and outlet, respectively. Note that for a shell-
and-tube heat exchanger, T and t represent the
shell- and tube side temperatures, respectively.
The correction factor for a condenser or boiler
is F=1
A counter-flow double-pipe heat exchanger is to heat water from 20°C to 80°C at a rate of
1.2 kg/s. The heating is to be accomplished by geothermal water available at 160°C 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/m2·K, determine the length
of the heat exchanger required to achieve the desired heating.
A 2-shell passes and 4-tube passes heat exchanger is used to heat glycerin from 20°C to
50°C by hot water, which enters the thin-walled 2-cm-diameter tubes at 80°C and leaves at
40°C. The total length of the tubes in the heat exchanger is 60 m. The convection heat
transfer coefficient is 25 W/m2K on the glycerin (shell) side and 160 W/m2K on the water
(tube) side. Determine the rate of heat transfer in the heat exchanger (a) before any fouling
and (b) after fouling with a fouling factor of 0.0006 m2K/W occurs on the outer surfaces of
the tubes.
 Heat Exchanger Analysis: The
Effectiveness–NTU Method
It is a simple matter to use the log mean temperature difference (LMTD) method of heat
exchanger analysis when the fluid inlet temperatures are known and the outlet temperatures
are specified or readily determined from the energy balance expressions.
However, if only the inlet temperatures are known, use of the LMTD method requires a
cumbersome iterative procedure. It is therefore preferable to employ an alternative approach
termed the effectiveness–NTU (or NTU) method.
To define the effectiveness of a heat exchanger, we must first determine the maximum
possible heat transfer rate, qmax, for the exchanger. This heat transfer rate could, in
principle, be achieved in a counterflow heat exchanger of infinite length.
The determination of requires the availability
of the inlet temperature of the hot and cold
fluids and their mass flow rates, which are
usually specified. Then, once the effectiveness
of the heat exchanger is known, the actual heat
transfer rate can be determined from.
Effectiveness relations of the heat
exchangers typically involve the
dimensionless group UAs/Cmin. This
quantity is called the number of
transfer units NTU and is expressed
as:
In heat exchanger analysis, it is also
convenient to define another
dimensionless quantity called the
capacity ratio c as:
The value of the capacity ratio c ranges
between 0 and 1. For a given NTU, the
effectiveness becomes a maximum for c=0
and a minimum for c=1. The case
c=Cmin/Cmax 0 corresponds to
Cmax which is realized during a phase-
change process in a condenser or boiler. All
effectiveness relations in this case reduce to:
A shell-and-tube exchanger (two shells, four tube passes) is used to heat 10,000 kg/h of
pressurized water from 35 to 120C with 5000 kg/h pressurized water entering the exchanger
at 300C. If the overall heat transfer coefficient is 1500 W/m2 K, determine the required
heat exchanger area.