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HEAT EXCHANGERS
7.1 What are heat exchangers?
7.3 Fouling
Material deposits on the surfaces of the heat exchanger tube may add
further resistances to heat transfer in addition to those listed above. Such
deposits are termed fouling and may significantly affect heat exchanger
performance. The heat exchanger coefficient, Uc, determined above may be
modified to include the fouling factor Rf.
1 1
= + R"
Ud Uc
Most of the actual data on fouling factors is tightly held be a few specialty
consulting companies. The data which is commonly available is sparse. An
example is given below:
Fluid R”,
2
m K/Watt
Seawater and treated boiler feedwater (below 50oC) 0.0001
Seawater and treated boiler feedwater (above 50oC) 0.0002
River water (below 50oC) 0.0002-0.001
Fuel Oil 0.0009
Regrigerating liquids 0.0002
Steam (non-oil bearing) 0.0001
Table: Representative Fouling Factors
r
1 1 ln( o r ) 1
= + i
+ + R"
Ud ⎛⎜ ri ⎞⎟ k ho
hi ⋅ ⎝ r ⎠
o
T1 T2 T1 T2
Parallel Flow Counter Flow
T1 T1
Temperature
Temperature
T2 T2
t1 t2 t2 t1
Position Position
T2 T2
1
t2 t1
2
2
t1 t2
Position Position
Temperature Differences Between Hot and Cold Process Streams
Working from the three heat exchanger equations shown above, after
some development it if found that the integrated average temperature difference
for either parallel or counter flow may be written as:
θ1 − θ 2
Δθ = LMTD =
⎛θ ⎞
ln⎜ 1 ⎟
⎝θ2 ⎠
The correction factors, FT, can be found theoretically and presented in analytical
form. The equation given below has been shown to be accurate for any
arrangement having 2, 4, 6, .....,2n tube passes per shell pass to within 2%.
⎡ 1− P ⎤
R 2 + 1 ln ⎢
FT = ⎣1 − R ⋅ P ⎥⎦
(
⎡2 − P R + 1− R2 + 1 ⎤
( R − 1) ln ⎢⎢ ⎥ )
⎣⎢ (
2 − P R +1+ R +1 ⎥ 2 ⎥
⎦ )
where the capacity ratio, R, is defined as:
T1 − T2
R=
t 2 − t1
The effectiveness may be given by the equation:
1 − X 1/ N shell
P=
R − X 1/ N shell
provided that R≠1. In the case that R=1, the effectiveness is given by:
Po
P=
N shell − Po ⋅ ( N shell − 1)
where
t2 − t1
Po =
T1 − t1
and
Po ⋅ R − 1
X =
Po − 1
As an alternative to using the formulas for the correction factors, which can
become tedious for non-computerized calculations, charts are available. Several
are included in standard texts. Experience has shown that, due to variability in
reading charts, considerable error can be introduced into the calculations and the
equations are recommended. When charts are used, they should be reproduced
at a sufficiently large scale, and considerable care should be used in making
interpolations.
Effectiveness, ε
Consider two counter-flow heat exchangers, one in which the cold
fluid has the larger ΔT (smaller m⋅cp) and a second in which the cold
fluid has the smaller ΔT (larger m⋅cp):
Δt > ΔT ΔT > Δt T1
T1
M⋅Cp > m⋅cp m⋅cp > M⋅Cp
T2 t2
T2 t2
t1
t1
We may see in the first case that, because the cold fluid heat capacity
is small, its temperature changes rapidly. If we seek efficient energy
recovery, we see that in the limit a HX could be designed in which the
cold fluid exit temperature would reach that of the hot fluid inlet. In
the second case, the hot fluid temperature changes more rapidly, so
that in the limit the hot fluid exit temperature would reach that of the
cold fluid inlet.
The effectiveness is the ratio of the energy recovered in a HX to that
recoverable in an ideal HX.
m& ⋅ c p ⋅ (t 2 − t1 ) & ⋅ C ⋅ (T − T )
M
ε= ε=
p 1 2
ε=
(t − t )
2 1
ε=
(T − T )
1 2
(T − t )
1 1
Δt > ΔT
(T − t )
1 1
ΔT > Δt
We see that the numerator, in the two cases, is the temperature change
for the stream having the larger temperature change. The
denominator is the same in either case:
In the LMTD-Ft method an
Δ Tmax effectiveness was defined:
ε= t 2 − t1
(T − t )
1 1
P=
T1 − t1
Note that the use of the upper case T in the numerator, in contrast to
our normal terminology, does not indicate that the hot fluid
temperature change is used here. The max subscript over-rides the
normal terminology and indicates that this refers to the side having
the larger temperature change.
Q = U⋅A⋅Δθeff HX equation
Q = -M⋅Cp⋅ΔT 1st Law Equation
Q = m⋅cp⋅Δt 1st Law Equation
Again the use of the upper case letters is over-ridden by the use of the
subscripts.
U⋅A⋅Δθeff = (M⋅Cp)min⋅ΔTmax
U⋅A Δ Tmax
NTU ≡ =
( )
& ⋅ Cp
M
min
Δ θ eff
Capacity Ratio, CR
The final non-dimensional ratio needed here is the capacity ratio,
defined as follows:
In the LMTD-Ft method a
( M ⋅ Cp ) min Δ Tmin capacity ratio was defined:
CR ≡ = T1 − T2
( M ⋅ Cp ) max Δ Tmax R=
t 2 − t1
ε-NTU Relationships
In the LMTD-Ft method, we found a general equation which
described Ft for all 1-2N, 2-4N, 3-6N, etc. heat exchangers. Another
relationship, not given here, is required for cross flow arrangements.
In a similar fashion, we may develop a number of functional
relationships showing
ε = ε (NTU, CR)
or, alternatively:
NTU = NTU(ε,CR)
These relationships are shown in tables in standard text books. For
example, we find that the relationship for a parallel flow exchanger is:
Note: These correlations are
1− e − NTU ⋅ ( 1− C R )
not general. Specific
ε= correlations will be given for
1 − CR ⋅ e − NTU ⋅(1− CR ) different kind of HX.
The ε-NTU method offers a number of advantages to the designer
over the traditional LMTD-Ft method. One type of calculation where
the ε-NTU method may be used to clear advantage would be cases in
which neither fluid outlet temperature is known.