Heat Exchanger

Design Project Work

Introduction:
Types of Heat Exchangers
Shell and tube
Plate-type exchangers
Extended surface exchangers
Scraped surface exchangers

McCabe et.al. pp432-456.
Cross-Section
Side View
Resistances to Heat Flow
Hot Film
o
S
R
T T
q
) (
=
o o
o
h A
R
1
=
Driving force
Resistance
(Newtons Law of Cooling)
Which Law
is this?
Inner Pipe Wall
w
S S
R
t T
q
) (
=
( )
Lk
r
R
R
w
t 2
ln
=
(Fouriers Law integrated
over a cylinder r -> R)
Which Law
did we use
here?
Cold Film
i
s
R
t t
q
) (
=
i i
i
h A
R
1
=
(Newtons Law of Cooling)
Resistances to Heat Flow
(in Series)
1
/
(
h
o
A
o
)

1
/
(
h
i
A
i
)

( )
+ + :
i i o 0
A h
1
A h
1
Lk
r
R
t 2
ln
RL t 2 h
1
T T
q
o
S

=
( )
Lk
r
R
t
S
t 2
ln

=
S
T
q
rL 2 h
1
t
q
i
S
t
t
=
( )
rL 2 h
1
RL 2 h
1
T
q
i o
t t t
+ +

=
Lk
r
R
t
2
ln
( )
Lk
r
R
t 2
ln
Factors Affecting Film
Coefficients
Effect of Turbulence on h?
High turbulence -> high h
Thermal conductivity and heat
capacity also affect h
Evaluation of Film Coefficients
cooled being is fluid if 3 . 0
heated being is fluid if 4 . 0
023 . 0
8 . 0
=
=
|
|
.
|

\
|
|
|
.
|

\
|
|
.
|

\
|
=
n
n
k
c
ud
d
k
h
n
p

(Dittus-Boelter equation)
Note:
Properties are
determined at T and
t for h
o
and h
i

respectively.
Use hydraulic
diameter (D
i
-d
o
) for
h
o
in annulus.
Inlet/Outlet Temperatures

Generally temperatures are set.
Utilities (Cooling water) some flexibility for exit
temperature (t
2
).

Guidelines:
t
2
as high as possible
(T
2
- t
2
): Minimum of 5K.

(T
2
- t
2
)=5K satisfies both guidelines


Physical properties
vary with
temperature. This
needs to be taken into
account e.g. when
calculating the heat
transfer coefficients
for convection.
Bulk Temperature Profiles
T-t T
1
-t
1
T
2
-t
2
( )
i i o o
A h
1
A h
1
T
q
+ +

=
Lk
r
R
t
t 2
ln
|
|
.
|

\
|

= A
2 2
1 1
2 2 1 1
ln
) ( ) (
t T
t T
t T t T
T
lm
Where T
lm
= log mean temperature difference
T
1
= inlet hot fluid temperature
T
2
= outlet hot fluid temperature
t
1
= inlet cold fluid temperature
t
2
= outlet cold fluid temperature
As T-t varies across heat exchanger, so we use an average
of the inlet and outlet differences.
For co-current:
Bulk Temperature Profiles
T-t T
1
-t
2
T
2
-t
1
( )
i i o o
A h
1
A h
1
T
q
+ +

=
Lk
r
R
t
t 2
ln
|
|
.
|

\
|

= A
1 2
2 1
1 2 2 1
ln
) ( ) (
t T
t T
t T t T
T
lm
Where T
lm
= log mean temperature
difference
T
1
= inlet hot fluid temperature
T
2
= outlet hot fluid temperature
t
1
= inlet cold fluid temperature
t
2
= outlet cold fluid temperature
As T-t varies across heat exchanger, so we use an average
of the inlet and outlet differences.
For counter-current:
Determining Average Bulk Temperatures
T
b
and t
b
for hot and cold respectively.
These Temperatures are used to get the physical
properties to calculate h.

Calculation of the correct heat exchanger length
depends on accurate h
o
, k and h
i
values.
Method:
Which is smaller: T
1
-T
2
or t
2
-t
1
?
Use arithmetic average on smallest difference.
Use T
b
t
b
= T
LM
to calculate the other average.

e.g. Find
specific
heat for
water at
200
o
F
Side View
Calculation of Velocities
2
1 3
m
s m
A
dt
dV
u

=
Volumetric flow-rate / cross sectional
area

m
V
V
m
= =

=
A
dt
dm
u

4
2
i
i
d
A
t
=

4 4
2 2
o i
o
d D
A
t t
=

1 2
. . 26 . 0
1 1
1 1
2
ln
1 1

= =
=
=
+ +
|
.
|

\
|
+ +
A
=
kW K m
h h
L d A
L d A
A h A h Lk
d
d
A h A h
T
q
di do
i i
o o
i i i di
i
o
o do o o
LM
t
And now, finally:
Simplification (do not use this in
your assignment!)
pipe inside of Thickness
1 1 1 1
1
then If
= A
+ +
A
+ +
=
A =
= ~
x
h h k
x
h h
U
T UA q
A A A
i di do o
LM
i o
Example
A heat exchanger is required to cool
30kg/s of process water from 365K to
350K by means of 35kg/s cooling water
entering at 300K. If the overall coefficient
of heat transfer is constant at 2kW/m
2
K,
calculate the surface area required in a
counter- as well as co-current heat
exchanger. The average C
p
value for
water is 4,18kJ/(kgK).

( ) ( )
( ) ( )
2
1 2
2 1
1 2
2 1 1 2
2 1
1 2
2 1 1 2
84 . 1
0 . 51 2
188
0 . 51
ln
ln
: current - Counter
m
K K kWm
kJ
A
K
t T
t T
t T t T
t T
t T
t T t T
T
T U
q
A T UA q
LM
LM
LM
=

=
=
|
.
|

\
|

=
|
.
|

\
|

= A
A
= A =

( )
( )
( )
K
K
K kJkg kgs
kJ
t
c m
q
t
t t c m q
kJ
K K kJkg kgs
T T c m q
p
p
p
313
300
18 . 4 35
1881
Water Cooling
1881
365 350 18 . 4 30
Water Process
1 1 1
1
.
2
1 2
.
1 1 1
1 2
.
=
+

=
+ =
=
=
=
=


( ) ( )
( ) ( )
2
1 2
2 1
1 2
2 1 1 2
2 2
1 1
2 2 1 1
89 . 1
7 . 49 2
188
7 . 49
ln
ln
: current - Co
m
K K kWm
kJ
A
K
t T
t T
t T t T
t T
t T
t T t T
T
T U
q
A T UA q
LM
LM
LM
=

=
=
|
.
|

\
|

=
|
.
|

\
|

= A
A
= A =

IN GENERAL, COUNTER
CURRENT FLOW IS BETTER TO
USE AS IT LEADS TO A
SMALLER HEAT TRANSFER
AREA (AND HEAT EXCHANGER)