Chapter 9

Heating and Cooling Inside Tubes

9_001.

A single-pass tubular heat exchanger is to be designed to heat water by condensing steam. The water is to
pass through the horizontal tubes in turbulent flow, and the steam is to be condensed dropwise in the shell.
The water flow rate, the initial and final water temperatures, the condensing temperature of the steam, and
the available tube-side pressure drop (neglecting entrance and exit losses) are all specified. In order to
determine the optimum exchanger design, it is desired to know how the total required area of the exchanger
varies with the tube diameter selected. Assuming that the water flow remains turbulent and that the thermal
resistance of the tube wall and the steam-condensate film is negligible, determine the effect of tube diameter
on the total area required in the exchanger.
Solution:
W = water flow rate
t1 and t2 = initial and final temperature.
tc = condensing temperature
p1 - p2 = available tube side pressure drop.

f=

0.046

(NRe )0.2

NRe =

DG

p1 p 2 =

G=

fG 2 L 4fG 2L
=
2gc rh 2c D

4w
ND 2

Equation 9-14:
2

3
hL c p w

c p G k b b

NRe

f=

0.14

( )

0.023 1 + D

L
=
0.2
DG

0.7

4w
D

4w
ND 2
=
=

ND

0.046
4w

ND

0.2

ND
= 0.04383

0.2

0.2

ND 4w
4(0.04383)

L
w ND2

p1 p 2 =
2c D

L 0.2 w 1.8

p1 p 2 = 0.14211
N 0.8D 3.8
g
D
c

L 7.0368. c (p1 p 2 )N 0.8D 3. 8

=
D
0.2 w 1.8
D
0.142110.2 w 1.8
=
L gc (p1 p 2 )N 0.8D 3.8

Page 1 of 25

Chapter 9
Heating and Cooling Inside Tubes
2

3
hL c p w

c p G k b b

0.14

( )

0.023 1 + D

L
=
0.2
DG

0.7

hL
ND 2hL
=
4c p w
4w
cp
2
ND
4w
D

DG
4w
ND 2

=
=
b
b
ND
hL
=
c pG

c p 3 w

b b

ND 2hL
4c p w
2

c p 3 w

hL

k b b
2

0.14

0.14

0.142110.2 w 1.8
0.0231 +
0.8 3.8
gc (p1 p 2 )N D
=
0.2
4w

ND

4c p w ND 0.2
0.25520.14 w 1.26

= 0.023
1 + 0.7 0.7

0.7
0.56
2.66
ND2 4w gc (p1 p 2 ) N D

0.14

c p w 0.8 0.2
= 0.0279 0.8 1.8
N D

Ac
Bc
hL = 0.8 1.8 + 1.36 4.46
N D
N D
q = hLAwtL

c p 3 w

hL

k b b

0.25520.14 w 1.26
1 +

0.7 g 0.7 (p p )0.7 N0.56D 2.66

c
1
2

Aw = NDL
0.8 3.8

L = CcN D
1.8 4.8
Aw = CcN D
Bc
Ac

q = 0.8 1.8 + 1.36 4.46 CcN1.8D 4.8 t L

N D
N D

q = Cc AcND 3 + BcN 0.44D 0.34 t L

Aw
N=

4.8
CcD

1
1.8

1
0.44
A
1.8 3
A w 1.8 0.34
w
q = Cc Ac
D
+
Bc
D t L

CcD 4.8

CcD 4.8

B ' A w 0.2444
q = Cc A 'c A w 0.5556D 0.3333 + c 2.3267
t L
D

Set dAw/dD = 0.
A 'c (0.3333)A w 0.5556
D 0.6667
A 'c (0.3333)A w 0.5556
D 0.6667

Page 2 of 25

B 'c (2.3267)A w 0.2444

D 3.3267
B 'c (2.3267)A w 0.2444
D 3.3267

=0

Chapter 9
Heating and Cooling Inside Tubes
A w 2.27332 =
B 'c =
A 'c =

6.9808B 'c
A 'c D 2.66

Bc

(Cc )0.2444
Ac

(Cc )0.2444

A w 2.27332 =

6.9808Bc
Ac (Cc )0.3112 D 2.66
4.8887Bc

A w 2.27332 =

AcCc 0.3112D 2.66

0.25520.14 w 1.26

Bc
=
Ac 0.7 gc 0.7 (p1 p 2 )0.7
Cc =

7.0368. c (p1 p 2 )
0.2 w 1.8

Bc
AcCc 0.3112
Bc
AcCc 0.3112
A w 2.27332 =

0.25520.14 w 1.26

0.2 w 1.8
= 0.7 0.7

gc (p1 p 2 ) 7.0368. c (p1 p 2 )

=

0.3112

0.139050.20 w 1.82
1.011gc 1.011 (p1 p 2 )1.011

(4.8887)(0.13905)0.20 w1.82
1.011gc 1.011 (p1 - p 2 )1.011D 2.66

Answer

Aw =

0.84384 0.088 w 0.80

[gc (p1 - p 2 )]0.445 D1.17

Heat Transfer area Aw increases as the diameter increases for optimum exchanger design.
9_002.

A tubular air heater has been accurately designed to heat a given stream of air to 170 F. The air passes
through 120 tubes, arranged in parallel, with steam condensing on the outside. From Eq. (9-17), it is
calculated that the tubes should be 16 ft long.
Because of the deviation of some of the data from Eq. (9-17), it is now decided to build the apparatus with a
20 per cent factor of safety. One engineer proposes to obtain this factor of safety by using 20 per cent more
16-ft tubes of the same diameter. Another argues that the 20 per cent factor of safety should be obtained by
making the tube diameters 20 per cent greater, while keeping the same number of tubes and the same tube
length.
Discuss the advantages and disadvantages of the foregoing methods. How would you build the heater to
have a 20 per cent factor of safety?
Solution:
Equation 9-17:

( )

L
t 2 t 1 (0.0576) D
=
t L
(DG )0.2
Equation 9-15:

Page 3 of 25

Chapter 9
Heating and Cooling Inside Tubes
0.0144c p G 0.8

hL =

D 0.2

Equation 9-16:
q = hLDLtL
Then N = number of tubes; tL= CONSTANT
q = hLDLtL
0.8
(DNL )(t )
q = 0.0144c p G

L
D 0.2

q = (0.0144 )c p G 0.8D 0.8NLLL

G=

4w
ND 2
0.8

4w
0.8
q = (0.0144 )c p
D NLLL
ND 2

0.8
N 0.2L
q = 0.054883c p w

L
D 0.8

0.2

q = 0.054883c pLL w 0.8 N

D 0.8

0.2

q = (CONSTANT ) N

D 0.8

Proposal (a), 20 Per Cent factor of safety using 20 per cent more 16 ft tubes:
0.2

0.2

Over all heat transfer factor = (N2 - N1 ) / N1

0.2

0.2

= ( 1.20 - 1 ) / 1
= 0.03714 or 3.714 Percent
Proposal (b), 20 Per Cent factor of safety using 20 per cent greater tube diameter:
Over all heat transfer factor = [(1/D2

)0.8

- (1/D1

)0.8

] / (1/D1

)0.8

0.8

= [(1/1.2) - 1] / 1
= -0.13572 or -13.572 Percent
Therefore:
1. Increasing number of tubes by 20 per cent will increase heat transfer rate by 3.714 per cent.
2. Increasing tube diameter by 20 per cent more will decrease heat transfer rate by 13.572 per cent.
Then use proposal number one, increasing number of tubes by 20 per cent is the desirable factor of safety.
9_003.

A liquid metal is flowing in well-developed turbulent motion in along smooth circular pipe with an i.d. of 1.95
-4
inches. The Prandtl number of the liquid metal is 10 , the kinematic viscosity / is 0.0388 sq ft /hr, and the
average velocity of the flow is 3.33 ft/sec.
a.

Page 4 of 25

The following equation defines a special heat-transfer coefficient h :

Chapter 9
Heating and Cooling Inside Tubes
qw

h' =

A w (t w t axis )
where the subscript w refers to the inside surface of the pipe wall. Estimate the numerical
magnitude of the special Nusselt number hD/k by employing the generalized velocity distribution of
Eqs. (9-4), (9-4a), and (9-4b) and by making the assumption that EH and EM are equal.
b.

What value is predicted by the Martinelli analogy for the Nusselt number based on the standard
heat-transfer coefficient h, defined as:
qw

h=

A w (t w t m )

where tm is the mixing-box mean temperature?

Solution:
a.

qw

h' =

A w (t w t axis )
Page 210 to 212.
tw - taxis = tw - t3
where tw - t3 is from Equation 9-5, 9-5b, and 9-5e.
Equation 9-5.
q w = kA w (t w t 1 )/y 1
y 1+ = 5
y 1+ =

f y1
2 rw

1 DV
2

DV

D = 1.95 in = 0.1625 ft
rw = 0.08125 ft
V = 3.33 ft/sec = 11,988 ft/hr
/ = 0.0388 sq ft / hr
(0.1625)(11988) = 50208
NRe =
(0.0388)
0.046
f=
= 0.00528
(NRe )0.2
NRe =

1
(50208) 0.00528 y 1 = 5
2
2 0.08125
15875y1 = 5
y 1+ =

-4

y1 = 3.15 x 10 ft

Page 5 of 25

Chapter 9
Heating and Cooling Inside Tubes
t w t 1=

q
y 1q w
= 3.15 10 4 w
kA w
kA w

Equation 9-5b

y 2+

5q w

= t 1 t 2
ln

1
+
N

1
Pr
5

A w c p u

p
NPr = 10 4 =
k
y 2 + = 30
/ = 0.0388 sq ft / hr
u = V f
2
u = (11988)

0.00528
= 616
2

5q w
30
ln1 + 10 4 1 = t 1 t 2
A w c p (616)
5

t 1 t 2 = 4.06 10 6 w
A w c p

q k

t 1 t 2 = 4.06 10 6 w

kA w c p
q 1
t 1 t 2 = 4.06 10 6 w - 4 (0.0388)
kA w 10
q
t 1 t 2 = 1.5753 10 3 w
kA w
Equation 9-5e.

y
1
r
qw
w

t 2 t 3 = 1.25
ln

A w c p u
y
y
5 + 2 1 2
rw rw

5 +

1.25
+

2y 2y 2
+ z
1 z 1
rw
A w c pu
rw

ln
z
2y 2y 2
z
1 + z 1
rw
rw
qw

where:
2
=

DGc p

f
c p
DV
k
c p

=
k

NPr = 10 4 =

k
/ = 0.0388 sq ft / hr
V = 11988 ft / hr

Page 6 of 25

y
rw

Chapter 9
Heating and Cooling Inside Tubes
c p
c
= DV p
DV

k
k

c p
= (0.1625)(119880) 10 4
DV

c p
= 5.021
DV

1
( ) 0.0388

2
0.00528
= 3.8762
5.021

z = 1 + 20
z = 1 + 20(3.8762)
z = 8.8614
y 2 + = 30
y 2 + = 15875y 2 = 30
-3

y2 = 1.890 x 10 ft
rw = 0.08125 ft
-3

y2 / rw = 1.890 x 10 / 0.08125 = 0.02326

at the axis (center),
y / rw = 1.0
Then:
2y 2y 2
+ z
1 z 1
rw
rw
[(1 2) 8.8614][(1 2(0.02326)) + 8.8614]

ln
= ln
[(1 2) + 8.8614][(1 2(0.02326)) 8.8614]
2y 2y 2
z
1 + z 1
rw
rw

= ln

[ 9.8614][9.81488] = 0.4427
[7.8614][ 7.90792]

y
1
5(3.8762) + (1)(1 1)
rw = ln
ln
5(3.8762) + (0.02326)(1 0.02326)
y y
5 + 2 1 2
rw rw
5 +

y
rw

19.381
= 1.18603 10 3
19.404
Substitute in Equation 9-5e, becomes:
= ln

1.25
t 2 t 3 = 1.25

qw
A w c p u*

Page 7 of 25

( 1.18603 10 )+
3

qw
A w c p u*
z

(0.4427)

Chapter 9
Heating and Cooling Inside Tubes

1.18603 10 3

+ 1.25 q w (0.4427)

(
)(
)
616
A
c
616
8.8614

w p

qw
t 2 t 3 = 9.897 10 - 5
A w c p

t 2 t 3 = 1.25

qw
A w c p

p
q 1
t 2 t 3 = 9.897 10 - 5 w - 4 (0.0388)
kA w 10

q
t 2 t 3 = 9.897 10 - 5 w
kA w

q
t 2 t 3 = 0.0384 w
kA w
t w t 3 = t w t1 + t1 t 2 + t 2 t 3
q
t w t 3 = 3.15 10 4 + 1.5753 10 3 + 0.0384
kA w

q
t w t 3 = t w t axis = 0.04029 w
kA w
kA (t t )
q w = h' A w (t w t axis ) = w w axis
0.04029
h'
= 24.82
k
h'D
= (24.82 )(0.1625)
k
Answer:

h'D
= 4.03325
k
b.
qw

h=

A w (t w t m )
tw - tm = tw - tb
Equation 9-6.

f
h
2
=
c pG t w t b
(5)NPr + ln 1 + 5NPr + 0.5NDR ln NRe
t w t c
60

-4

NPr = 10

NRe = 50,208 = 5 x 10
NPc = NRe x NPr = 5
Use Equation 9-5f.

Page 8 of 25

-4

Chapter 9
Heating and Cooling Inside Tubes
NDR (2)ln

NRe
60

f
= ln
2

1
y2 y2
1
1+
5rw rw

2y
z + 1 2

rw
1 z + 1

+ ln

z z - 1
2y

z 1 2
rw

2y
z + 1 2

rw
z + 1

ln

z - 1
2y

z 1 2
rw

ln

1
y2 y2
1
1+
5rw rw

= ln 8.8614 + 1 8.8614 + (1 2(0.02326))

8.8614 1 8.8614 (1 2(0.02326))

= ln[(1.25441)(1.24115)] = 0.442704

1
= 1.17154 10 3
= ln
0.02326
1+
(1 0.02326)
5(3.8762)

Substitute in Equation 9-5f.

NDR (2)ln

NDR ln

NRe
60

NRe
60

f
0.442704
= -1.17154 10 - 3 +
2
8.8614
f
= 0.024394
2
-4

Tablle 9-3, NPr = 10 , NRe = 50208 = 5 x 10

tw tb
= 0.562394
tw tc

Substitute in Equattion 9-6.

0.00528
h
2
=
= 1.427867
c p G (0.562394 )(5) 10 4 + ln 1 + 5 10 - 4 + 0.5(0.024394)

( ( ))

h
h
=
= 1.427867
c p V c p G
h
h k
= 1.427867
=
c p V kV c p
h
1

(0.0388) = 1.427867
k(11988) 10 - 4

Page 9 of 25

Chapter 9
Heating and Cooling Inside Tubes
h
= 44.1167
k
hD
= (44.1167)(0.1625)
k
Answer:
hD
= 7.1690
k
9_004.

It is planned to construct a horizontal single-pass multitubular preheater to warm 6000 pounds/hr of viscous
fuel oil from 80 to 100 F, while flowing in streamline motion inside horizontal tubes jacketed by exhaust
steam condensing at 220 F in the shell. For tubes having i.d. of 0.67 inch and lengths of 8, 12, 16, or 20 ft.
complete heaters (both shell and tubes) can be obtained at a first cost of $1.80 per foot of each tube. The
fixed charges on the heater in dollars per year per foot of length of each tube are $0.36. Mechanical energy,
delivered to the fluid, will cost $0.005/million ft-lb.
Show which tube length should be selected.
Data and Notes. The oil density is 56 lb/cu ft. The specific heat cp is constant at 0.48 gm-cal/(gm)(deg C),
and k may be assumed constant at 0.08 Btu/(hr)(sq ft)(deg F per ft). Viscosity varies with temperature as
shown below:

Deg F
Centipoises

80
400

90
270

100
185

110
140

120
110

130
82

It may be assumed that the pressure drop through the heater is due only to friction in the tubes. Assume
tubes clean on both sides and the Ui = hi.
Solution:
Ui = hi
1 cp = 2.42 lb/hr-ft
D = 0.67 inch = 0.05584 ft
Then at 100 F. = 2.42 * 185 = 447.7 lb/hr-sq ft
DG/ = 4w/D = 4(6000) / [()(0.0584)(447.7)]
DG/ = 306 < 2100 ( 1 tube minimum)
a.
For Length L = 8 ft.
Solve for number of tubes by trial and error.
For one (1) tube

4wc (4 )(6000)(0.48)
=
= 5,730
kL (0.8)(8 )
Equation 9-28a:

ha =

1.86k

D s

t a = (t s t) a
ts = 215 F

Page 10 of 25

0.14

= 1.25

0.14

4wc

kL

Chapter 9
Heating and Cooling Inside Tubes
t = (1/2)(80 F + 100 F) = 90 F
(1.86)(0.08) (1.25)(5730) 13 = 59.61
ha =
0.05584
ta = 215 F - 90 F = 125 F
Aw = NTDL
NT = Number of tubes
t 2 t1 =

ha A w t a
wc p

(100 80) = (59.61)(NT )( )(0.05584)(8)(125)

(6000)(0.48)
NT = 5.5 or 6 tubes
Try 6 tubes.
w = (6,000 lb/hr) / 6 = 1000 lb/hr
4wc (4 )(1000)(0.48)
=
= 955
kL (0.8)(8 )
ha =

(1.86)(0.08) (1.25)(955)

0.05584
h A t
t 2 t1 = a w a
wc p

= 32.81

(100 80) = (32.81)(NT )( )(0.05584)(8)(125)

(6000)(0.48)
NT = 10 tubes
Try 10 tubes.
w = (6,000 lb/hr) /10 = 600 lb/hr
4wc (4)(600)(0.48)
=
= 573
kL (0.8)(8)
ha =

(1.86)(0.08) (1.25)(573)

0.05584
h A t
t 2 t1 = a w a
wc p

= 27.67

(100 80) = (27.67)(NT )( )(0.05584)(8)(125)

(6000)(0.48)
NT = 12 tubes
Try 13 tubes.
w = (6,000 lb/hr) /13 = 461.54 lb/hr
4wc (4 )(461.54 )(0.48 )
=
= 441
kL
(0.8)(8 )

ha =

(1.86)(0.08) (1.25)(441)

0.05584
h A t
t 2 t1 = a w a
wc p

Page 11 of 25

= 25.354

Chapter 9
Heating and Cooling Inside Tubes

(100 80) = (25.354)(NT )( )(0.05584)(8)(125)

(6000)(0.48)
NT = 13 tubes
Then use 13 tubes for 8 ft length.
p i =

fG 2 vL
2gc rh

f = 16/NRe
rh = D/4 = (0.05584) / 4 = 0.01396 ft
2

G = w/Ai = 4w/D2= 4 (461.54)/[(0.05584) ]=188464

v = 1/ = 1/56
NRe = DG/ = 4w/D = (4)(461.54)/[(0.05584)(653.4)]
NRe = 16.11
f = 16/NRe = 16/16.11 = 0.9932
8

gc = 4.17x10 (lb of fluid)(ft)/(hr)(hr)(lb of fluid)

p i =

(0.9932)(188464)2 (8)
2(4.17 10 8 )(0.01396)(56 )

pi = 433 lb/sq ft
First Cost = $1.80 x 8 x 13 = $ 187.20
Fixed Charges = $ 0.36 x8 x13 = $ 37.44 per year.
Mechanical Energy:
$ 0.005 / million ft-lb
pi = 433 lb/sq ft
1 year = 8640 hours
Mechanical Energy = (6000 lb/hr)(433 lb/sq ft)(8640 hrs/yr)/(56 lb/cu ft)
= 400.84 Million Ft-lb / yr.
Mechanical Energy = ($ 0.005)(400.84) = $ 2.01 per year.
b.
For Length L = 12 ft.
Try 9 tubes.
w = (6,000 lb/hr) /9 = 666.67 lb/hr
4wc (4 )(666.67)(0.48 )
=
= 424.4
kL (0.8)(12)

ha =

(1.86)(0.08) (1.25)(424.4)

0.05584
h A t
t 2 t1 = a w a
wc p

= 25.032

(100 80) = (25.032)(NT )( )(0.05584)(12)(125)

(6000)(0.48)
NT = 8.75 tubes or 9 tubes.

Page 12 of 25

Chapter 9
Heating and Cooling Inside Tubes
Then use 9 tubes for 12 ft length.
NRe = DG/ = 4w/D = (4)(666.67)/[(0.05584)(653.4)]
NRe = 23.265
f = 16/NRe = 16/23.265 = 0.6877
8

gc = 4.17x10 (lb of fluid)(ft)/(hr)(hr)(lb of fluid)

2

G = w/Ai = 4w/D2= 4 (666.67)/[(0.05584) ]=272226

p i =

(0.6877)(272226)2 (12)
2(4.17 10 8 )(0.01396)(56 )

pi = 938 lb/sq ft
First Cost = $1.80 x 12 x 9 = $ 194.40
Fixed Charges = $ 0.36 x12 x 9 = $ 38.88 per year.
Mechanical Energy:
$ 0.005 / million ft-lb
pi = 938 lb/sq ft
1 year = 8640 hours
Mechanical Energy = (6000 lb/hr)(938 lb/sq ft)(8640 hrs/yr)/(56 lb/cu ft)
= 868.32Million Ft-lb / yr.
Mechanical Energy = ($ 0.005)(868.32) = $ 4.34 per year.
c.
For Length L = 16 ft.
Try 7 tubes.
w = (6,000 lb/hr) /7 = 857.14 lb/hr
4wc (4 )(857.14 )(0.48)
=
= 409.25
kL (0.8 )(16)

ha =

(1.86)(0.08) (1.25)(409.25)

0.05584
h A t
t 2 t1 = a w a
wc p

= 24.73

(100 80) = (24.73)(NT )( )(0.05584)(16)(125)

(6000)(0.48)
NT = 6.64 tubes or 7 tubes.
Then use 7 tubes for 16 ft length.
NRe = DG/ = 4w/D = (4)(857.14)/[(0.05584)(653.4)]
NRe = 29.91
f = 16/NRe = 16/29.91= 0.5349
8

gc = 4.17x10 (lb of fluid)(ft)/(hr)(hr)(lb of fluid)

2

G = w/Ai = 4w/D2= 4 (857.14)/[(0.05584) ]=350002

p i =

(0.5349)(350002)2 (16)
2(4.17 10 8 )(0.01396)(56 )

pi = 1608 lb/sq ft
First Cost = $1.80 x 16 x 7 = $ 201.60
Fixed Charges = $ 0.36 x16 x 7 = $40.32 per year.

Page 13 of 25

Chapter 9
Heating and Cooling Inside Tubes
Mechanical Energy:
$ 0.005 / million ft-lb
pi = 1608 lb/sq ft
1 year = 8640 hours
Mechanical Energy = (6000 lb/hr)(1608 lb/sq ft)(8640 hrs/yr)/(56 lb/cu ft)
= 1488.55 Million Ft-lb / yr.
Mechanical Energy = ($ 0.005)(1488.55) = $ 7.44 per year.
d.
For Length L = 20 ft.
Try 6 tubes.
w = (6,000 lb/hr) /6 = 1000 lb/hr
4wc (4 )(1000)(0.48)
=
= 382
kL (0.8 )(20)

ha =

(1.86)(0.08) (1.25)(382)

0.05584
h A t
t 2 t1 = a w a
wc p

= 24.17

(100 80) = (24.17)(NT )( )(0.05584)(20)(125)

(6000)(0.48)
NT = 5.43 tubes or 5 or 6 tubes.
Try 5 tubes.
w = (6,000 lb/hr) /5 = 1200 lb/hr
4wc (4 )(1200)(0.48 )
=
= 458.4
kL (0.8 )(20)
ha =

(1.86)(0.08) (1.25)(458.4)

0.05584
h A t
t 2 t1 = a w a
wc p

= 25.684

(100 80) = (25.684 )(NT )( )(0.05584)(20)(125)

(6000)(0.48)
NT = 5.11 tubes or 5
Then use 5 tubes for 20 ft length.
NRe = DG/ = 4w/D = (4)(1200)/[(0.05584)(653.4)]
NRe = 41.876
f = 16/NRe = 16/41.876= 0.382
8

gc = 4.17x10 (lb of fluid)(ft)/(hr)(hr)(lb of fluid)

2

G = w/Ai = 4w/D2= 4 (1200)/[(0.05584) ]=490004

p i =

(0.382)(490004)2 (20)
2(4.17 10 8 )(0.01396)(56 )

pi = 2814 lb/sq ft
First Cost = $1.80 x 20 x 5 = $ 180.00

Page 14 of 25

Chapter 9
Heating and Cooling Inside Tubes
Fixed Charges = $ 0.36 x 20 x 5 = $ 36.00 per year.
Mechanical Energy:
$ 0.005 / million ft-lb
pi = 2814 lb/sq ft
1 year = 8640 hours
Mechanical Energy = (6000 lb/hr)(2814 lb/sq ft)(8640 hrs/yr)/(56 lb/cu ft)
= 2605 Million Ft-lb / yr.
Mechanical Energy = ($ 0.005)(2605) = $ 13.03 per year.

Length
8 ft
12 ft
16 ft
20 ft

First Cost Fixed Charges

$187.20
$37.44
$194.40
$38.88
$201.60
$40.32
$180.00
$36.00

SUMMARY FOR ONE YEAR

Mech'l Energy Total Amount
$2.01
$226.65
$4.34
$237.62
$7.44
$249.36
$13.03
$229.03

Therefore Select 8 ft length of tube as the most economical. -- Ans.

9_005.

An experimental heat exchanger consists of a vertical copper tube with an i.d. of 1 inch, heated by a steam
jacket for a length of 10 ft. The steam condenses at a pressure of 1 atm, and the thermal resistance of the
copper tube and steam-condensate film is negligible. A cold oil, entering at 50 F, flows upward through the
copper tube.
Plot the exit temperature t of the oil vs. the oil flow rate w for the flow-rate range of 1 to 100,000 pounds/hr. In
order to simplify the calculation, the physical properties of the oil will be assumed to be independent of
temperature:
cp = 0.5
k = 0.1
= 10 centipoises

Solution:
Flow rate range = 1 to 100,000 lb/hr.
t1 = 50 F
Equations:
NRe < 2100, L/D > 60, Equation formed as discussed on page 240 and 241, reference.

DG c p D
haD

= 1.86F1

k
b k L

2100 < NRe < 10,000. Equation of Hausen, Page 241.

hm c p 3 s

c pb G k b

j =
D 2 3
1 +
L

Page 15 of 25

0.14

N 3 125
= 0.116 Re
NRe

Chapter 9
Heating and Cooling Inside Tubes

10,000 < NRe < 120,000, Equation 9-10c.

2

hL c p

c pb G k b

0.14

0.023
DG

0.2

at NRe = 2100, D = 1 in = 0.08333 in

NRe = DG/b = 4w/D = 2100
4w / [(0.08333)(24.2)] = 2100
w = 3,326 lb/hr
at NRe = 10,000, D = 1 in = 0.08333 in
NRe = DG/b = 4w/D = 10,000
4w / [(0.08333)(24.2)] = 10,000
w = 15,838 lb/hr
at NRe = 120000, D = 1 in = 0.08333 in
NRe = DG/b = 4w/D = 120,000
4w / [(0.08333)(24.2)] = 120,000
w = 190,059 lb/hr
Interval: 1000, 2000, 3000, 4000, 6000, 8000, 10000, 15000, 20000, 40000, 60000, 80000, 100000 lb/hr
t 2 t1 =

ha A w t a
wc p

t 2 = t1 +

ha A w t a
wc p

@ 1 atm = 212 F, then wall is at 207 F.

Aw = DL = p(0.08333)(10) = 2.6179 sq ft
ta = 207 F - (1/2)(t2 + t1)
ta = 207 F - (1/2)(t2 + 50) = 182 - 0.5t2
NRe < 2100, w = 1000, 2000, 3000 lb/hr:
Z=

t 2 t1
t 50
= 2
t a
180 0.5t 2

F1 =

Z
ln(2 + Z )

(2 Z )

DG c p D
haD

= 1.86F1

k
b k L

cp/k = (0.5)(24.2)/(0.1) = 121

D/L = 0.08333 ft / 10 ft = 0.008333
[w = 1000 lb/hr]

Page 16 of 25

Chapter 9
Heating and Cooling Inside Tubes
NRe = DG/b = 4w/D = 4(1000)/[()(0.08333)(24.2)] = 631.4
1
ha (0.08333)
= 1.86F1 [(631.4 )(121)(0.008333)] 3
(0.1)
ha = 19.2F1

t 2 = t1 +

ha A w t a
wc p

t 2 = t1 +

19.2F1 (2.6179)(182 0.5t 2 )

(1000)(0.5)

Solving trial and error:

t2
100 F
70 F
65 F

Z
0.3788
0.1361
0.1004

ln[(2+Z)/(2-Z)]
0.3834
0.1363
0.1005

F1
0.988
0.9985
0.999

F2
63.11
64.76
65

At w = 1000 lb/hr , t2 = 65 F

[w = 2000 lb/hr]
NRe = DG/b = 4w/D = 4(2000)/[()(0.08333)(24.2)] = 1262.8
1
ha (0.08333)
= 1.86F1 [(1262.8)(121)(0.008333)] 3
(0.1)
ha = 24.2F1

t 2 = t1 +

ha A w t a
wc p

t 2 = t1 +

24.2F1 (2.6179)(182 0.5t 2 )

(2000)(0.5)

Solving trial and error:

t2
65 F
60 F
59.65 F

Z
0.1004
0.0658
0.0634

ln[(2+Z)/(2-Z)]
0.1005
0.0658
0.634

F1
0.999
1
1

At w = 2000 lb/hr , t2 = 59.64 F

[w = 3000 lb/hr]
NRe = DG/b = 4w/D = 4(3000)/[()(0.08333)(24.2)] = 1894.15
1
ha (0.08333)
= 1.86F1 [(1894.15)(121)(0.008333)] 3
(0.1)
ha = 27.7F1

Page 17 of 25

F2
59.62
59.63
59.64

Chapter 9
Heating and Cooling Inside Tubes
t 2 = t1 +

ha A w t a
wc p

t 2 = t1 +

27.7F1 (2.6179)(182 0.5t 2 )

(3000)(0.5)

Solving trial and error:

t2
Z
ln[(2+Z)/(2-Z)]
59 F
0.05902
0.05904
57.4 F
0.04827
0.04828

F1
1
1

At w = 3000 lb/hr , t2 = 57.4 F

[w = 4000 lb/hr]
2

hm c p 3 s

0.14
2
c pb G k b
NRe 3 125

j =
=
0.116
NRe
D 2 3
1 +
L
cp/k = (0.5)(24.2)/(0.1) = 121
s

0.14

= 1.25
2

D 3
0.08333 3
1+ = 1+
= 1.0411
L
10
4w
G=
D 2
NRe = 4w/D = 4(4000)/[()(0.08333)(24.2)] = 2526
2

NRe 3 125
= 0.02435
NRe
G=

4w
D

4(4000)
(0.08333)2

= 733443

(121)2 3 (1.25)
hm
= (0.116)(0.02435)

(0.5)(733443) 1.0411
hm = 35.266

t 2 50
157

ln
207 t 2
35.266F1 (2.6179)
t 2 50
t 2 = t1 +

(4000)(0.5)
157
ln
207 t 2
t2 = 57.082 F
t m =

Page 18 of 25

F2
57.37
57.4

Chapter 9
Heating and Cooling Inside Tubes

[w = 4000 lb/hr]
NRe = 4w/D = 4(4000)/[()(0.08333)(24.2)] = 3788
2

NRe 3 125
= 0.03115
NRe
G=

4w
D

4(6000)
(0.08333)2

= 1100165

(121)2 3 (1.25 )
hm
= (0.116)(0.03115)

(0.5)(1100165) 1.0411
hm = 67.67

t 2 50
157

ln
207 t 2
67.67F1 (2.6179)
t 2 50
t 2 = t1 +

(6000)(0.5)
157
ln
207 t 2
t2 = 59.002 F
t m =

[w = 8000 lb/hr]
2

NRe = 4w/D = 4(8000)/[()(0.08333)(24.2)] = 5051

G=

4w
D

4(8000)
(0.08333)2

= 1466886

(121)2 3 (1.25 )
hm
= (0.116)(0.03354 )

(0.5)(1466886) 1.0411
hm = 97.15

t m =

t 2 50

157

ln
207 t 2
97.15F1 (2.6179)
t 2 50
t 2 = t1 +

(8000)(0.5)
157
ln
207 t 2
t2 = 59.671F

[w =10000 lb/hr]
NRe = 4w/D = 4(10000)/[()(0.08333)(24.2)] = 6316

Page 19 of 25

NRe 3 125
= 0.03354
NRe

Chapter 9
Heating and Cooling Inside Tubes
2

NRe 3 125
= 0.03431
NRe
G=

4w
D

4(10000)
(0.08333)2

= 1833608

(121) 2 3 (1.25 )
hm
= (0.116 )(0.03431)

(0.5)(1833608) 1.0411
hm = 124.23

t m =

t 2 50

157

ln
207 t 2
124.23F1 (2.6179)
t 2 50
t 2 = t1 +

(10000)(0.5)
157
ln
207 t 2

t2 = 59.888 F
[w = 15000 lb/hr]
NRe = 4w/D = 4(15000)/[()(0.08333)(24.2)] = 9471
2

NRe 3 125
= 0.03407
NRe
G=

4w
D 2

4(15000)
(0.08333)2

= 2750411

(121)2 3 (1.25)
hm
= (0.116)(0.03407)

(0.5)(2750411) 1.0411
hm = 185.04

t m =

t 2 50

157

ln
207 t 2
185.04F1 (2.6179)
t 2 50
t 2 = t1 +

(15000)(0.5)
157
ln
207 t 2
t2 = 59.820 F
[w = 20000 lb/hr]
2

hL c p

c pb G k b
cpb = 0.5

Page 20 of 25

0.14

0.23

DG

0.2

Chapter 9
Heating and Cooling Inside Tubes

cp/k = 121
2/3

(cp/k ) = 24.46378
0.14

s

= 1.25

b
NRe = 4w/D = 4(20000)/[()(0.08333)(24.2)] = 12628
G=

4w
D

4(20000)
(0.08333)2

hL

(0.5)(3667215)

= 3667215

(24.46378)(1.25) =

0.023

(12628)0.2

hL = 208.6
t 2 50

t L =

157

ln
207 t 2
208.6F1 (2.6179)
t 2 50
t 2 = t1 +

(20000)(0.5) 157
ln
207 t 2
t2 = 58.340 F

[w = 40000 lb/hr]
NRe = 4w/D = 4(40000)/[()(0.08333)(24.2)] = 25264
G=

4w
D

4(40000)
(0.08333)2

hL

(0.5)(7334430)

= 7334430

(24.46378)(1.25) =

0.023

(25264)0.2

hL = 363.19
t 2 50

t L =

157

ln
207 t 2
363.19F1 (2.6179)
t 2 50
t 2 = t1 +

(40000)(0.5)
157
ln
207 t 2

t2 = 57.29 F
[w = 60000 lb/hr]
NRe = 4w/D = 4(60000)/[()(0.08333)(24.2)] = 37883
G=

4w
D

4(60000)
(0.08333)2

= 11001644

hL
(24.46378)(1.25) = 0.0230.2
(0.5)(11001644)
(37883)
hL = 502.38

Page 21 of 25

Chapter 9
Heating and Cooling Inside Tubes
t 2 50

t L =

157

ln
207 t 2
502.38F1 (2.6179)
t 2 50
t 2 = t1 +

(60000)(0.5)
157
ln
207 t 2

t2 = 56.735 F
[w = 80000 lb/hr]
NRe = 4w/D = 4(80000)/[()(0.08333)(24.2)] = 50511
G=

4w
D

4(80000)
(0.08333)2

hL

(0.5)(14668859)

= 14668859

(24.46378)(1.25) =

0.023

(50511)0.2

hL = 632.39
t 2 50

t L =

157

ln
207 t 2
632.39F1 (2.6179)
t 2 50
t 2 = t1 +

(80000)(0.5)
157
ln
207 t 2

t2 = 56.366 F
[w = 100000 lb/hr]
NRe = 4w/D = 4(100000)/[()(0.08333)(24.2)] = 63138
G=

4w
D

4(100000)
(0.08333)2

= 18336074

hL
(24.46378)(1.25) = 0.0230.2
(0.5)(18336074)
(63138)
hL = 756
t L =

t 2 50

157

ln
207 t 2
756F1 (2.6179)
t 2 50
t 2 = t1 +

(100000)(0.5) 157
ln
207 t 2
t2 = 56.096 F
SUMMARY:
W, LB/HR

Page 22 of 25

t2, F

Chapter 9
Heating and Cooling Inside Tubes
1000
2000
3000
4000
6000
8000
10000
15000
20000
40000
60000
80000
100000

65
59.64
57.4
57.082
59.002
59.671
59.888
59.82
58.34
57.29
56.735
56.366
56.096

Plot of temperature and flow rate:

Page 23 of 25

Chapter 9
Heating and Cooling Inside Tubes

9_006

A single-pass heat exchanger is being used to preheat the oil fed to a distillation column. Heat is supplied by
saturated steam condensing on the outside of the tubes while the liquid flows inside the tubes. A promoter
is added to the steam, which causes dropwise condensation. The tube pass consists of 100 tubes, each 20 ft
long with an i.d. of 1 inch.
It is proposed to install an emergency stand-by heat exchanger in parallel with the existing exchanger
described above. Because of space limitations, the stand-by exchanger will employ tubes only 10 ft in length.
The tubes will have an i.d. of 1/2 inch, and a single tube pass will be used.
How many tubes are required in the stand-by exchanger for it to preheat the feed stock to the same
temperature as the original exchanger?
Note: It is known that the flow in the original exchanger is in the turbulent range and that the thermal
resistance of the tube and the steam-condensate film is negligible.
Solution:
Single pass heat exchanger data (old):
100 tubesm 29 ft long, ID = 1 inch = 0.08333 ft
New standby heat exchanger L
10 ft, Single pass, ID = 1/2 inch =0.0417 ft
Turbulent type.
wcp(t2 - t1) = hLAwDtL
wcp(t2 - t1) = hLAwDtL
hLAw = hLAw
Existing (old): hL, Aw
Stand By (new); hL, Aw
Aw = (100)()(0.0833)(20) = 523.58 sq ft
Aw = (NT)()(0.0417)(10) = 1.31NT
where NT = number of tubes required.
Equation 9-10a.

DG
hL D

= 0.023

kb
b

0.8

0.4

c p DG
4w

k ; = D
b
b

0.8

hLD = (Constant) / D
1.8

Constant = hLD
1.8

hL(D) = h:(D)
1.8

1.8

hL(0.5 in) = hL (1.0 in)

Page 24 of 25

1.8

Chapter 9
Heating and Cooling Inside Tubes
hL / hL = 3.4822
Then:
hLAw = hLAw
hL (523.58) = 3.4822hL(1.31NT)
NT = No. of tubes = 115 tubes. . . Ans.

- end -

Page 25 of 25