Heat Exchanger

Engr. Rolie Castro

Heat Exchanger
A heat exchanger is used to exchange

heat between two fluids of different

temperatures, heating one and cooling
the other, which are separated by a
solid wall.
Heat exchanger is an equipment made
to transfer heat between hot and cold
streams
through a combined
conduction-convection mechanism.

Heat Exchanger

Two
fluids,
of
different
starting
temperatures, flow through the heat
exchanger. One flows through the tubes
(the tube side fluid) and the other flows
outside the tubes but inside the shell (the
shell side fluid).

Heat Exchanger

The temperature of
the two fluids will
tend to equalize. The
heat
are
simply
exchanged from one
fluid to the other and
vice versa. The fluids
can be either liquids
or gases on either
the shell or the tube
side.

Heat Exchanger
Heat exchangers with only one phase on
each side can be called one-phase or
single-phase heat exchangers.
Two-phase heat exchangers can be used
to heat a liquid to boil it into a gas
(vapor), sometimes called boilers, or
cool a vapor to condense it into a liquid,
called condensers, with the phase
change usually occurring on the shell
side.

Heat Exchanger
Classification
Parallel Flow
known as concurrent heat exchangers,
hot and cold fluids enter through the
same point and leaves at the other end.

Heat Exchanger
Classification
Countercurrent Flow
With this type, hot and cold fluids enter
at opposite ends of the heat exchanger.

Heat Exchanger
Classification
Cross-Flow
Two fluids flow at perpendicular to each
other.

Design Calculations
Pipe Sizing
Overall HTC
Area of heat transfer
Length of heat exchanger
No. of tubes
No. of tube passes
No. of shell passes
Tube velocity
Heat exchanger duty

Double-Pipe Heat
Exchanger
Hairpin Heat exchanger
Two concentric pipes with one fluid

flowing through the center pipe

while the other fluid moves
cocurrently or countercurrently in
the annular space.

Design Equation
Gen. Equation:

Q=U A TLM

LMTD Method
Countercurrent
Parallel

Design Equation
If U is not constant but varies

linearly with temperature.

Countercurrent
Parallel

Design Equation
Heat given up by the hot fluid

Qhot= mh Cph Th
Heat given up by the cold fluid

Qcold= mc Cpc Tc
Note: Cp must be evaluated at mean temp.

Steam is condensing

Q s= m s s
Then: Q= Qhot = Qcold = Qs

Example

A counter-flow double-pipe heat exchanger is to

heat water from 20oC to 80oC at a rate of 1.2 kg/s.
The heating is to be accomplished by geothermal
water available at 160oC at a mass flow rate of 2
kg/s. The inner tube is thin-walled and has a
diameter of 1.5 cm. The overall heat transfer
coefficient of the heat exchanger is 640 W/m2.oC.
a) What is the surface area of the heat exchanger?
b) The length of the tube that must be design is?

NTU-Effectiveness
Method
Appropriate if only the inlet temperatures
of the fluid is known provided a mass flow
of both fluid is given.
Gen. Equation:
Q = Cmin (Th1 Tc1)
Cmin value:
Cc = mcCpc and
Ch = mhCph
If Cc >>> Ch then, Cmin = Ch
If Ch >>> Cc then, Cmin = Cc

Effectiveness Value,

, f (NTU vs. Rc)

Parallel

Counterflow

Effectiveness Value,

Example

Water flowing at a rate of 0.667 kg/s (Cp = 4.192

kJ/kg.K) enters a countercurrent heat exchanger at
308K and is heated by an oil stream entering at
383K at a rate of 2.85 kg/s (Cp = 1.89 kJ/kg.K).
The overall HTC is 300 W/m2.K and the area A =
15.0 m2. Calculate the heat transfer rate and the
exit water temperature.

Shell and Tube Heat

Exchanger
most common type of heat exchanger
One fluid runs through the tubes, and
another fluid flows over the tubes
(through the shell) to transfer heat
between the two fluids.

Allocation of Streams
Factor

Tube-side

Shell-side

Corrosion

More corrosive fluid

Less corrosive fluids

Fouling

Fluids with high fouling Low fouling and scaling

and scaling

Fluid temperature

High temperature

Low temperature

Operating pressure

High pressure

Low pressure

Viscosity

Less viscous fluid

More viscous fluid

Stream flow rate

High flow rate

Low flow rate

Phase Change

No phase change

With phase change

Kinds of Heat Exchanger

Double-Pipe
Shell and Tube
Air-finned Heat Exchanger
Plate and Frame Heat Exchanger
Phase-change Heat Exchanger

Boilers
Condensers

Shell and Tube

Classification

Shell and Tube HE Parts

Tubes
Provide heat transfer surface
May be seamless or welded
Commonly made of copper and

steel alloys.

Tube Sizing :
Birmingham Wire Gage (BWG)

Shell and Tube HE Parts

Tubes Sheets
Shell
Tube and Shell Nozzle
Channel Cover
Baffles
Pass Divider

Design Equation
Gen. Equation:

Q=U A (TLM x FT)

FT, (LMTD correction factor)

a.k.a. Fudge Factor or Geometric
Factor
Caused by variation in flow pattern
Varies as the number of tube and
shell passes

LMTD Correction Factor

F
T

function of (R and S)

Where;
- Shell side inlet
- Tube side inlet

- Shell side outlet

- tube side outlet

Note: For Condensing steam, FT =1

LMTD Correction Factor

LMTD Correction Factor

LMTD Correction Factor

LMTD Correction Factor

Design Equation
Heat given up by the hot fluid

Qhot= mh Cph Th
Heat given up by the cold fluid

Qcold= mc Cpc Tc
Note: Cp must be evaluated at mean temp.

Steam is condensing

Q s= m s s
Then: Q= Qhot = Qcold = Qs

No. of Tubes and Passes

Number of tubes per pass

mt vT ST T N T
Number of Passes

At DT LT N T N Pass

Example
A 2-shell passes and 4-tube passes heat exchanger is used

to heat glycerine (Cp = 2.324 kJ/kg-K) from 20 oC to 50oC

by hot water, which enters the thin-walled 2-cm diameter
tubes at 80oC and leaves at 40oC. The total length of the
tubes in the heat exchanger is 60m. The convection heat
transfer coefficient is 25 W/m2.oC on the glycerine (shell)
side and 160 W/m2.oC on the water (tube) side.
a) Calculate the overall HTC in W/m 2.oC.
b) Determine the rate of heat transfer.
c) What is the percentage increase in the consumption of
water if the outer surface of the tube is fouled with
coefficient of 0.006 m2.oC/W given that glycerine is to be
processed at same flow rate and temperature?

NTU-Effectiveness
Method
Gen. Equation:
Q = Cmin (Th1 Tc1)
Cmin value:
Cc = mcCpc and
Ch = mhCph
If Cc >>> Ch then, Cmin = Ch
If Ch >>> Cc then, Cmin = Cc

Effectiveness Value,

Example
Hot oil is to be cooled by water in a 1-4 Shell and Tube

heat exchanger. The tubes are thin walled and are made of
copper with an internal diameter of 1.4 cm. The length of
each tube per pass is 5m which consists of 30 tubes per
pass, and the tube overall HTC is 310 W/m 2.oC. Water
flows through the tubes at rate of 0.2 kg/s (Cp=4.18
kJ/kg.oC). , and the oil through the shell at a rate of 0.3
kg/s (Cp=2.13 kJ/kg.oC). The water and the oil enter at
temperature of 20oC and 150oC, respectively. Determine
the rate of heat transfer in the heat exchanger and the
outlet temperatures of the water and the oil.

End of Lecture