Thermal/Fluid System Design

Requirements

• Pre-requisites
– MMB 412
– MMB 417

• If you have not cleared any of the above course you are
advised to deregister
 Accreditation Status

• What is accreditation status of BEng Mechanical?

• What are requirements for accreditation?
• How does it affect the delivery of the programme/module/course?
• How am I affected?
• What are benefits for aligning course delivery (MMB 527) with
accreditation requirement.
 Exit Level Outcome (Outcome Based Learning)
Engineering Programmes (Global)
– Problem solving
– Application of scientific and engineering knowledge
– Engineering Design
– Investigations, experiments and data analysis
– Engineering methods, skills and tools, including Information Technology
– Professional and technical communication
– Impact of Engineering Activity
– Individual, Team and Multidisciplinary Working
– Independent Learning Ability
– Engineering Professionalism
– Engineering Management
 Design Analysis for Double Pipe Heat
Exchanger

Where have you seen this type of heat exchange and how does it work?
 Typical Industrial Application of Double Pipe
Heat Exchanger
• Application include
– Power generation sector
– Chemical processing sector
– Oil and gas industry
• Power generation sector
– To optimise the effectiveness of power generation plants in a variety of
important niche
• Energy recovery
• Energy storage
• Solar thermal energy

• Oil and gas sector

– Optimise performance whilst minimising costs
• Chemical processing
– Optimisation of reactor design to meet the customer’s exact requirements
 Design Analysis for Double Pipe Heat
Exchanger

• The main objective for heat exchanger is to transfer as much heat

energy as possible, while minimising the cost as highlighted in

the previous lesson.

• How do we achieve that?

• To achieve this goal, it is necessary to keep the system as small as

possible?
 Design Conditions

• Consider heat exchanger used to cool oil from an engine at a given

mass flow rate and temperatures. Water acts as the cooling fluid and

is available at a given temperature.

• In this case counter-flow arrangement will be assumed. WHY?

• Counter-flow will be assumed because it is more effective, as

compared to parallel (unidirectional) flow. Why is it more effective?

 Temperature Profile

• Temperature profiles for both parallel and counter-flow explains

why counter-flow arrangement is the preference.

• The temperature profile make it apparent as to why counter-flow

is a more logical choice when analysing the system
 Temperature Profile

• Counter-flow could potential allow the output of the hot fluid to be

cooler than the outlet for the cold fluid. This is not the case in parallel

flow as the outlet of the cold will never be above the outlet of the hot
 Optimisation of the Heat Transfer System

• To be able to optimise this system, our options are:

– pipe size,

– associated heat exchanger length

– placement of the fluids and

– Mass flow rate of water

• Based on all the above, it is therefore appropriate to look at the

mathematical model used to solve design problem for heat transfer
systems.
 Design Analysis

• Like most thermal fluid applications the problem can be analysed in two

sections:

– With respect to heat transfer

– With respect to fluid mechanics

• To begin the analysis it is necessary to determine the thermo-physical

properties of saturated fluids under review at their average temperatures.

This is done for the engine oil (unused) over a range of 273 K to 430 K (as

the oil outlet could vary.

 Design Analysis Con
• Next it is appropriate to choose pipe sizes for a given flow rate. Figure
below demonstrated the associated diameters of the heat exchanger

• While choosing the pipe sizes may seem random, it is necessary to

ultimately look at the length and pressure drop each pipe
combination offers for the system
 Design Analysis Con

• In developing mathematical model, it is important to start with

equation 1
𝜋𝐼𝐷𝑝2
𝐴𝑝 = equation 1
4
Here 𝐴𝑝 is the area of the pipe and 𝐼𝐷𝑝 is the inner diameter of the
pipe.

The annulus area 𝐴𝑎 to be calculated using the outer diameter, 𝑂𝐷𝑝

as demonstrated by equation 2
𝜋 𝐼𝐷𝑝2 −𝑂𝐷𝑝2
𝐴𝑎 = equation 2
4
Having the areas associated with the pipe and annulus, the fluid
velocities can then be computed as shown on the next slide
 Design Analysis Con
• Equations (3) and (4) demonstrated how fluids velocities are
calculated
𝑚ሶ
𝑢𝑝 = equation (3)
𝜌𝐴𝑝

𝑚ሶ
𝑢𝑎 = equation (4)
𝜌𝐴𝑎

Here 𝑢𝑝 is pipe velocity in (m/s), 𝑢𝑎 is the annulus velocity (m/s) and 𝑚ሶ

is the mass flow rate of the specified fluid in (kg/s)
 Design Analysis Con

• Using the tubing sizes, it is appropriate to calculate the hydraulic and

equivalent diameters of the annulus. Equation (5) allows the hydraulic
diameter to be computed, while equation (6) allows the equivalent
diameter to be computed.
𝐷ℎ = 𝐼𝐷𝑎 − 𝑂𝐷𝑝 equation (5)

𝐼𝐷𝑎2 −𝑂𝐷𝑝2
𝐷𝑒 = equation (6)
𝑂𝐷𝑝

With the associated diameters, it is feasible to compute the Reynolds

Numbers for the pipe and annulus as demonstrated in the next slide.
 Design Analysis Con
• The Reynolds numbers for the pipe and annulus are calculated as
follows:
𝑢𝑝 𝐼𝐷𝑝
𝑅𝑒𝑝 = equation 7
𝜈

𝑉𝑎 𝐼𝐷𝑎
𝑅𝑒𝑎 = equation 8
𝜈
Note that (𝜈) is the kinematic velocity, is a fluid property and is in
(m2/s)

Having the Reynolds Numbers allows the Nusselt Numbers for the pipe
and the annulus to be calculated as demonstrated in the next slide.
 Design Analysis Con
• Equation (9) is applied if the flow is laminar 𝑅𝑒 < 2200 , while
equation (10) is applied for turbulent flow 𝑅𝑒 > 10000 .
• For the combined entry length, a suitable correlation, due to Sieder
and Tabe

𝐷𝑅𝑒𝑃𝑟 1/3
𝑁𝑢 = 1.86 equation (9)
𝐿

𝑁𝑢 = 0.023 𝑅𝑒 4/5 𝑃𝑟 𝑛 equation (10)

Here (L) is the length of the heat exchanger in (m), Pr is the Prandtl
number (listed as a fluid property), and “n”is 3 for a fluid being cooled,
or “4”for a fluid being heated.
Note that (L) is going to require an iterative approach as it is an
unknown. Coupling equation (9) with equation (20), the length must be
iterated until the results converge.
 Design Analysis Con
• Using the Nusselt numbers, the convection coefficients for the pipe
and annulus can be computed. The following equations (11), (12), and
(13) are used.
𝑁𝑢𝑝 𝑘𝑓
ℎ𝑖 = equation (11)
𝐼𝐷𝑝

ℎ𝑖 𝐼𝐷𝑝
ℎ𝑝 = equation (12)
𝑂𝐷𝑝

𝑁𝑢𝑎 𝑘𝑓
ℎ𝑎 = equation (13)
𝐷𝑒

Here ℎ𝑖 is the heat transfer coefficient of the inner pipe, ℎ𝑝 being the
coefficient of the enter pipe, including the pipe wall, ℎ𝑎 being the
coefficient of the annulus, and 𝑘𝑓 is the fluid’s thermal conductivity, a
property of the fluid. Note that the convection coefficient are in
( 𝑊 Τ𝑚2 𝐾) . Having these coefficients it is possible to compute
exchanger coefficient , (𝑈𝑜 ) applying the equation 14 next slide.
 Design Analysis Con
• The exchanger coefficient is given by equation (14) below:

1
𝑈0 = 1 1 equation (14)
−
ℎ𝑝 ℎ𝑎

• Knowing all of the temperatures, it is possible to compute the log mean

temperature difference as depicted in equation (15).

𝑇1 −𝑇2 − 𝑇2 −𝑡1
𝐿𝑀𝑇𝐷 = equation (15)
ln 𝑇1 −𝑡2 Τ 𝑇2 −𝑡1

Note the equation (15) is applicable only for counter-flow

• Also by setting up a heat balance across the system, it is appropriate to

ultimately compute the mass flow rate of water, as demonstrated by
equations (16) and (17)
 Design Analysis Con
• Heat balance across the system is simple given as follows:

𝑞𝑤 = 𝑚ሶ 𝑤 𝐶𝑤𝑝 𝑇1 − 𝑇2 equation (16)

Here 𝐶𝑤𝑝 is the specific heat of the warm fluid kJ/kg. K

Using a heat balance, equation (17) is now appropriate

𝑞𝑤
𝑚ሶ 𝑐 = 𝑡2 − 𝑡1 equation (17)
𝐶𝑝𝑐

Here 𝐶𝑝𝑐 being the specific heat of the cool fluid.

Recognising the (𝑈𝑜 ) is an ideal exchanger coefficient, it is necessary to

look at the fouling factors the fluids have on the system. Equation (18)
therefore calculates the design coefficient (U), also in (𝑊 Τ𝑚2 𝐾)
 Design Analysis Con
• The design coefficient U is calculated as below
1
𝑈= 1 equation (18)
+ 𝑅𝑑𝑖 +𝑅𝑑0
𝑈𝑜

Here 𝑅𝑑𝑖 and 𝑅𝑑𝑜 are the fouling factors of the two fluids on the inner
and outer pipe respectively. Having the actual exchanger coefficient, it is
appropriate to calculate the area of the heat exchanger as demonstrated
below.
𝑞
𝐴𝑜 = equation (19)
𝑈(𝐿𝑀𝑇𝐷)

Equation (20) in the next slide allows the length of the system “L” to be
computed.
 Design Analysis Con
𝐴𝑜
𝐿= equation (20)
𝜋 𝑂𝐷𝑝

Note as previously state, the fact that both equation s (9) and (20) have
length in them, Microsoft Excel allows the length to be iterated until
convergence is achieve.

With the length “L” in m, while Reynolds Numbers were computed in

equation (7) and (8), it is now necessary to look at the Reynolds
Numbers to be able to o be able to obtain friction factors as demonstrated
in the next two slides.
 Design Analysis Con
𝑢𝑝 𝐼𝐷𝑝
𝑅𝑒𝑝 = equation (21)
𝜈

𝑢𝑝 𝐷ℎ
𝑅𝑒𝑝 = equation (22)
𝜈

Please note that .equation (22) requires the hydraulic diameter.

Furthermore, coupling these equations with the of roughness factor
the piping, it is possible to obtain the friction factor from the moody
chart (if the flow is turbulent) or using 64/𝑅𝑒 (if the flow is
laminar). The friction factors allows the pressure drop to be
computed for both the pipe and the annulus as demonstrated by the
next slide
 Design Analysis Con

• Equations (23) and (24) allows the pressure drops to be computed:

2
𝘧𝑝 𝐿𝜌𝑝 𝑢𝑝
∆𝑃𝑝 = 𝜋𝑟 2 equation (23)
𝐼𝐷𝑝 2𝑔𝑐

𝘧𝑎 𝐿 2
𝜌𝑎 𝑢𝑎
∆𝑃𝑎 = +1 equation (24)
𝐷ℎ 2𝑔𝑐

With equations (1) – (24), the mathematical analysis is complete.