Table of content:

Abstract

Introduction

Concurrent (parallel-flow)

Countercurrent Flow

Approach to Heat-Exchanger Design

Types of heat exchanger:

Shell-and-tube exchanger
Cross-flow exchanger
Double-pipe heat exchanger
Theory of Double-pipe heat exchanger

References:

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Abstract:
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The goal of the heat exchanger is the maximum utilization of hot lines before storage process by
transfer of heat between two fluids. Types of heat exchanger based on the direction the liquids
flow which could be cocurrent (parallel flow), countercurrent flow or cross-flow. The types were
discussed in the report are double-pipe heat exchanger, shell-tube exchanger and cross-flow
exchanger also there are general overview about calculation of heat exchanger.

Introduction:
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 In process industries the transfer of heat between two fluids is generally done in heat
exchanger. The most common type in one in which the hot and the cold fluid do not come into
direct contact with each other but are separated by a tube wall or a flat or curved surface. The
transfer of heat is accomplished from the hot fluid to the wall or tube surface by convection,
through the tube wall or plate by conduction, and then by convection to the cold fluid. We will
discuss some of the types of equipment used and overall thermal analyses of exchangers [1].
Types of heat exchanger based on the direction the liquids flow. In such application, the heat
exchanger can be cocurrent (parallel-flow), cross-flow (perpendicular to each other), or
countercurrent.

Shell-and-tube-heat-exchanger

Concurrent (parallel-flow)
In parallel flow heat exchangers, the two mediums enter the exchanger at the same end, and
travel in parallel to one another to the other side [2]. (Fig 1)

(Fig1)[2]

Countercurrent Flow
In countercurrent flow heat exchangers the fluids enter the exchanger from opposite ends. The
counter flow design is most efficient, in that it can transfer the most heat from the heat transfer
medium[2]. (fig.2)

(Fig.2)[2]

Approach to Heat-Exchanger Design

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The proper use of basic heat-transfer knowledge in the design of practical heat-transfer
equipment is an art. Designers must be constantly aware of the differences between the idealized
conditions for and under which the basic knowledge was obtained and the real conditions of the
mechanical expression of their design and its environment. The result must satisfy process and
operational requirements (such as availability, flexibility, and maintainability) and do so
economically. An important part of any design process is to consider and offset the consequences
of error in the basic knowledge, in its subsequent incorporation into a design method, in the
translation of design into equipment, or in the operation of the equipment and the process. Heatexchanger design is not a highly accurate art under the best of conditions.

Types of heat exchanger:

Shell-and-tube exchanger
If larger flows involved a Shell-and-tube exchanger is used which is the most important type of
exchanger in use in process industries. In these exchangers the flow are continuous. Many tubes
in parallel are used, where on fluid flows inside these tubes. The tubes, arranged in a bundle, are
enclosed in a single shell and the others fluids flows outside the tubes in the shell side. The
simplest shell-and-tube exchanger is shown in (figure 4) for one shell pass and one tube pass (1-1
exchanger ), or counterflow exchanger. The cold fluid enters and flows inside through all the
tubes in parallel in one pass the hot fluid enters at the other end flows counterflow across the
outside of tube.[1]

fig.4 (1-1 exchanger)[1]

The liquid on the tube side flows in two passes as shown below (1-2 exchanger) and shell-side
liquid flows in one passes. In the first pass of the tube side the cold fluid is flowing counterflow
to the hot shell-side fluid, and in the second pass of the tube side the cold fluid flows in parallel
(concurrent) with the hot fluid. Another tube of exchanger has 2 shell-side passes and 4 tube
passes.[1]
see(Fig.5 -b)[3]

 Cross-flow exchanger
When a gas has such as air is being heated or cooled, a common device used is the cross-flow
heat exchanger as shown below. One of the fluids, which is a liquid, flows inside through the
tubes and the exterior gas flows across the tube bundle by forced or sometimes natural
convection. The fluid inside the tubes is considered to be unmixed since it is confined and cannot
mix with any other stream. The gas flow outside the tubes is mixed since it can move about
freely between the tubes and there will be a tendency for the gas temperature to equalize in the
direction normal to the flow.
For the unmixed fluid inside the tubes there will be a temperature gradient both parallel and
normal to the direction of flow. Fig.6

Fig.6[3]

A second type of cross-flow heat exchanger shown below is used typically in air-conditioning
and space-heating application. In this type the gas flows across a finned-tube bundle and is
unmixed since is confined in separate flow channels between the fins as it passes on the tubes.
The fluid in the tubes is unmixed.[1] (Fig.7)

(fig.7) Second type of cross-flow heat exchanger[3]

Double-pipe heat exchanger

The simplest exchanger is the double-pipe or concentric-pipe exchanger. Where on fluid flows
inside one pipe and the other fluid flows in the annular space between the two pipes .the fluids
can be in concurrent or countercurrent flow. The exchanger can be made from a pair of single
lengths of pipe with fittings at the ends or from a number of pairs interconnected in series. This
type of exchanger is useful mainly for small flow rate.[1] (Fig.3)

Fig.
3

Theory
q = U A Tlm
That is in double-pipe on other hand in shell-tube exchanger there is factor must be multiplied by
Tlm:
q = U A Tm

For a double-pipe heat exchanger the overall heat transfer coefficient, U, can be expressed as

In a heat exchanger the log-mean temperature difference is the appropriate average temperature
difference to use in heat transfer calculations. The equation for the log-mean temperature
difference is

Fluid properties such as density, viscosity and heat capacity are evaluated at the average
temperatures. The average is found by using the inlet and outlet values

Thermal conductivity, k, can be evaluated at the average of the average temperatures. In a

double-pipe heat exchanger the inner pipe is made of a conductive metal and is thin.
The problem can be further simplified if the equipment is assumed to be clean, which means that
no scaling exists. This is a poor simplification with the double-pipe heat exchanger in the
laboratory, because it is many years old. The fouling factors Rfo and Rfi can be looked up from
various sources, including Standards of the Tubular Exchange Manufacturers Association, or
lumped together and determined experimentally. The only part of the overall heat-transfer
coefficient that needs to be determined is the convective heat-transfer coefficients. Correlations
are used to relate the Reynolds number to the heat-transfer coefficient. The Reynolds number is a
dimensionless ratio of the inertial and viscous forces in flow.

In the inner pipe if the Reynolds is less than 2000 this is considered to be laminar flow and the
Nusselt number is equal to 4.36. If the Reynolds number is greater than 10,000, the Nusselt
number is given by

This gives a Nusselt number that can then be use to find hi

With the transient data taken experimentally an overall heat-transfer coefficient can be
determined at each time step. This can be solved numerically.

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Table (1.1) Typical Values of overall heat-transfer coefficients in shell-and-tube

We can get the approximate typical overall U values from different resource such as [1]

Fouling Factors
in actual practice, heat-transfer surface do not remain clean. Dirt, soot, scale, and other posits
from on oneTable
or both sides of the tube of an exchanger and on other heat-transfer surface.
See table (1.2)[1]

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References:

1. Geankoplis, C.J. Transport processes and separation process principles",4th edition,

prentice hall (2003), U.S.A .
2. https://iit.edu/arc/workshops/pdfs/Heat_Exchangers.pdf
3. Incropera, F. P. and D. P. DeWitt, Fundamentals of Heat and Mass Transfer, 4th edition,
John Wiley and Sons Inc., New York, 1996.
4. http://en.wikipedia.org/wiki/Main_Page

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