Heat Transfer Equipments

Objectives
Recognize what is heat exchanger
Differentiate numerous types of heat

exchanger, their classification and their

applications
Know the heat transfer equipment

terminologies
Know the primary consideration in the

selection of heat exchangers

What is a heat transfer equipment?

An equipment that permits efficient transfer

of heat from a hot fluid to a cold fluid without

any or with direct contact of fluids
Such an equipment is called

Heat Exchanger

What is a Heat Exchanger?

Technically speaking
A heat exchanger is a device that is used to
transfer thermal energy (enthalpy) between
two or more fluids, between a solid surface and
a fluid,
or between solid particulates and a fluid,
at different temperatures
and in thermal contact.

Heat Exchanger
Heat exchangers, can be seen in daily life,

like ??
as well as in industries, like??

What are these?

Aim and Application of HE

Typical applications involve heating or cooling of a

fluid stream of concern and evaporation or

condensation of single- or multicomponent fluid
streams.
In other applications, the objective may be to
recover or reject heat, or sterilize, pasteurize,
fractionate, distill, concentrate, crystallize, or control
a process fluid.
Common examples of heat exchangers are shell-and
tube exchangers, automobile radiators, condensers,
evaporators, air preheaters, and cooling towers.

Aim and Application of

There could be internal
HE thermal energy

sources in the exchangers, such as in

electric heaters and nuclear fuel elements.
Combustion and chemical reaction may
take place within the exchanger, such as in
boilers, fired heaters, and fluidized-bed
exchangers.
Mechanical devices may be used in some
exchangers such as in scraped surface
exchangers, agitated vessels, and stirred
tank reactors.

Aim and Application of

HE
Heat exchanger found applications in almost all
Chemical and petrochemical plants
Air Conditioning Systems
Power production
Waste Heat recovery
Automobile Radiator
Central Heating System
Electronic Parts

Different Terminologies of Heat

Transfer Equipment
Heat exchanger: both sides single-phase and process

streams
Cooler: one stream a process fluid and the other
cooling water or air.
Heater: one stream a process fluid and the other a hot
utility, such as steam or hot oil.
Condenser: one stream a condensing vapor and the
other cooling water or air.
Chiller: one stream a process fluid being condensed at
sub-atmospheric temperatures and the other a boiling
refrigerant or process stream.
Reboiler: one stream a bottoms stream from a
distillation column and the other a hot utility (steam or

Different Terminologies of Heat

Transfer Equipment

Discuss and elaborate the

examples in daily life and/or
industrial process of each of the
above mentioned equipments

Heat Exchanger
Classification

Heat exchangers are classified according to

Transfer process
Number of fluids
Degree of surface compactness
Construction
Flow arrangements
Heat transfer mechanisms

Shah, 1981

Heat Exchanger
Classification

Heat exchangers are classified according to

Transfer
process

Classification by Transfer
Processes

Classification by Transfer
Processes
1. Indirect contact type
The fluid streams remain separate and
the heat transfers continuously through
a dividing wall into and out of the wall
in a transient manner.

Classification by Transfer Processes

1. Indirect contact type
a) Direct transfer type heat exchanger
b) Storage type heat exchanger
c) Fluidized bed heat exchanger

Classification by Transfer Processes

a) Direct Transfer Type Heat Exchanger
In this, type heat transfers continuously from the hot

fluid to the cold fluid through a dividing wall.

There is no direct mixing of the fluids because each
fluid flows in separate fluid passages.
It is also known as recuperator. Examples, tubular
exchangers, plate and frame heat exchangers and
extended surface exchangers.

Tubular Exchanger

Plate and Frame

Classification by Transfer Processes

b) Storage Type Heat Exchanger (Regenerative Heat

Exchanger)
In a storage type exchanger, both fluids flow alternatively through the

same flow passages, and hence heat transfer is intermittent.

The heat transfer surface (or flow passages) is generally cellular in
structure and is referred to as a matrix, or it is a permeable (porous)
solid material, referred to as a packed bed.
When hot gas flows over the heat transfer surface (through flow
passages), the thermal energy from the hot gas is stored in the matrix
wall, and thus the hot gas is being cooled during the matrix heating
period.
As cold gas flows through the same passages later (i.e., during the
matrix cooling period), the matrix wall gives up thermal energy, which
is absorbed by the cold fluid.
Thus, heat is not transferred continuously through the wall as in a
direct-transfer type exchanger (recuperator), but the corresponding
thermal energy is alternately stored and released by the matrix wall.

Classification by Transfer Processes

b) Storage Type Heat Exchanger

(Regenerative Heat Exchanger)

Fixed Bed Regenerator

Continuous-passage matrices for a rotary

regenerator: (a) notched plate; (b) triangular
passage.

Classification by Transfer Processes

b) Storage Type Heat Exchanger

(Regenerative Heat Exchanger)

Regenerative heating was one of the most

important technologies developed during the

Industrial Revolution when it was used in the
hot blast process on blast furnaces.
It was later used in glass and steel making, to
increase the efficiency of open hearth furnaces,
and in high pressure boilers and chemical and
other applications, where it continues to be
important today.

Classification by Transfer Processes

c) Fluidized bed heat

exchanger
)In a fluidized-bed heat
exchanger, one side of a twofluid exchanger is immersed
in a bed of finely divided solid
material, such as a tube
bundle immersed in a bed of
sand or coal particles.
)The common applications of
the fluidized-bed heat
exchanger are drying, mixing,
adsorption, reactor
engineering, coal combustion,
and waste heat recovery

Classification by Transfer Processes

2. Direct-Contact Heat

Exchanger
In a direct-contact exchanger, two fluid

streams come into direct contact, exchange

heat, and are then separated.
Common applications of a direct-contact
exchanger involve mass transfer in addition to
heat transfer, such as in evaporative cooling
and rectification.
However, the applications are limited to those
cases where a direct contact of two fluid
streams is permissible.

Classification by Transfer Processes

2. Direct-Contact Heat Exchanger
a) Immiscible Fluid Exchangers
b) GasLiquid Exchangers
c) LiquidVapor Exchangers

Classification by Transfer Processes

a) Immiscible Fluid Exchangers
In this type, two immiscible fluid streams are
brought into direct contact.
These fluids may be single-phase fluids, or they may
involve condensation or vaporization.
Condensation of organic vapors and oil vapors with
water or air are typical examples.

Classification by Transfer Processes

b)GasLiquid Exchangers
)In this type, one fluid is a gas (more commonly, air) and the

other a low-pressure liquid (more commonly, water) and are

readily separable after the energy exchange.
)In either cooling of liquid (water) or humidification of gas
(air) applications, liquid partially evaporates and the vapor is
carried away with the gas.
)In these exchangers, more than 90% of the energy transfer
is by virtue of mass transfer (due to the evaporation of the
liquid), and convective heat transfer is a minor mechanism.
)A wet (water) cooling tower with forced- or natural-draft
airflow is the most common application.
)Other applications are the air-conditioning spray chamber,
spray drier, spray tower, and spray pond.

Classification by Transfer Processes

c) LiquidVapor Exchangers
In this type, typically steam is partially or fully

condensed using cooling water, or water is

heated with waste steam through direct contact
in the exchanger.
Noncondensables and residual steam and hot
water are the outlet streams.
Common examples are desuperheaters and
open feedwater heaters (also known as
deaerators) in power plants.

Classification by Transfer Processes

2. Direct-Contact Heat Exchanger
Compared to indirect contact recuperators and
regenerators, in direct-contact heat exchangers,
(1) very high heat transfer rates are
achievable,
(2) the exchanger construction is relatively
inexpensive, and
(3) the fouling problem is generally
nonexistent, due to the absence of a
heat transfer surface (wall) between the
two fluids.

Heat Exchanger
Classification

Heat exchangers are classified according to

Number of fluids

Classification by Number of
Fluidcooling, heat recovery,
Most processes of heating,
and heat rejection involve transfer of heat
between two fluids.
Hence, two-fluid heat exchangers are the most
common.
Three fluid heat exchangers are widely used in
cryogenics and some chemical processes (e.g., air
separation systems, a heliumair separation unit,
purification and liquefaction of hydrogen,
ammonia gas synthesis).
Heat exchangers with as many as 12 fluid streams
have been used in some chemical process
applications.

Heat Exchanger
Classification

Heat exchangers are classified according to

Degree of surface
compactness

Classification by Surface
Compactness
Heat exchangers are characterized by a large

heat transfer surface area per unit volume of

the exchanger, resulting in
reduced space,
reduce weight,
reduce support structure and footprint,
energy requirements and cost,
as well as improved process design
and plant layout and processing conditions,

together with low fluid inventory.

Classification by Surface
Compactness

The ratio of the heat transfer surface

area of a heat exchanger to its volume is
called the area density or surface
compactness .
A heat exchanger with = 700 m2/m3 (or
200 ft2/ft3) is classified as being
compact. Examples of compact heat
exchangers are car radiators ( 1000
m2/m3) and the human lung ( 20,000

Heat Exchanger
Classification

Heat exchangers are classified according to

Heat Transfer
Mechanisms

Classification by Heat Transfer

Mechanisms
The basic heat transfer mechanisms employed for transfer

of thermal energy from the fluid on one side of the

exchanger to the wall (separating the fluid on the other
side) are
single-phase convection (forced or free),
two-phase convection (condensation or evaporation, by

forced or free convection),

and combined convection and radiation heat transfer.

Any of these mechanisms individually or in combination

could be active on each fluid side of the exchanger.

Some examples of each classification type are automotive
radiators, passenger space heaters, regenerators,
intercoolers, economizers and so on.

Heat Exchanger
Classification

Heat exchangers are classified according to

Flow
arrangements

Classification by Flow Arrangement

Classification by Flow Arrangement

The choice of a particular flow arrangement is

dependent on the required exchanger

effectiveness,
available pressure drops,
minimum and maximum velocities allowed,
fluid flow paths,
packaging envelope,
allowable thermal stresses,
temperature levels,
piping and plumbing considerations,
and other design criteria.

Classification by Flow
Single Pass flow
Arrangement
arrangement

A fluid is considered to have made one

pass if it flows through a section of the
heat
exchanger through
its full length.
a) Counterflow
exchanger

In a counterflow or countercurrent exchanger, the two

fluids flow parallel to each other but in opposite directions
within the core.
The counterflow arrangement is thermodynamically
superior to any other flow arrangement.
It is the most efficient flow arrangement, producing the
highest temperature change in each fluid compared to any
other two-fluid flow arrangements for a given overall
thermal conductance (UA), fluid flow rates and fluid inlet
temperatures.
The maximum temperature difference across the

Classification by Flow
Arrangement
Single Pass flow
arrangement
b) Parallelflow exchanger
In a parallelflow (also referred to as
cocurrent or cocurrent parallel stream)
exchanger, the fluid streams enter
together at one end, flow parallel to each
other in the same direction, and leave
together at the other end.
This arrangement has the lowest
exchanger effectiveness among singlepass exchangers for given overall
thermal conductance and fluid flow rates
and fluid inlet temperatures.
In a parallelflow exchanger, a large
temperature difference between inlet
temperatures of hot and cold fluids exists
at the inlet side, which may induce high

Classification by Flow
Arrangement
Single Pass flow
arrangement
c) Crossflow Exchanger
In this type of exchanger, the two fluids
flow in directions normal to each other.
Thermodynamically, the effectiveness for
the crossflow exchanger falls in between
that for the counterflow and parallel flow
arrangements.
The largest structural temperature
difference exists at the corner of the
entering hot and cold fluids.
This is one of the most common flow
arrangements used for extended surface
heat exchangers, because it greatly
simplifies the header design at the
entrance and exit of each fluid.

Classification by Flow
Arrangement
Single Pass flow
arrangement
c) Splitflow Exchanger
In this exchanger, the shell fluid stream enters at the center of
the exchanger and divides into two streams.
These streams flow in longitudinal directions along the
exchanger length over a longitudinal baffle, make a 180 turn
at each end, flow longitudinally to the center of the exchanger
under the longitudinal baffle, unite at the center, and leave
from the central nozzle.
The other fluid stream flows straight in the tubes.

Classification by Flow Arrangement

Multipass flow arrangement
After flowing through one full length, if the

flow direction is reversed and fluid flows

through an equal- or different-sized section,
it is considered to have made a second pass
(or multipass) of equal or different size.

Take Home Assignment

What are the types, examples and

applications of the Multipass Flow
Exchangers?

Heat Exchanger
Classification

Heat exchangers are classified according to

Construction

Classification by construction
Tubular
Double pipe
Shell and

tube
Spiral tube
Pipe coils

Plate type
Plate and

frame
Spiral

Extended

surface
Plate-fin
Tube-fin
Regenerative
Rotary
Fixed-matrix
Rotating

hoods

Shell and Tube HE

Double Pipe HE

Plate and Frame HE

Plate-Fin HE

Could you guess which type

of heat exchanger is this?

Types of Heat Exchangers

We will study industrially
important heat exchanger in
more detail in upcoming
lectures

Approach to Heat-Exchanger
Design

The proper use of basic heat-transfer

knowledge in the design of practical heattransfer 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.

Approach to Heat-Exchanger
Design

The H.E design 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 of heat transfer,
in its subsequent integration into a design method,
in the translation of design into equipment,
in the operation of the equipment and the process.

Heat-exchanger design is not a highly accurate art

under the best of conditions.

1.
2.
3.
4.
5.

Selection criterion for heat

Material of construction
exchangers

Operating temperatures and pressures conditions

Flow rates
Flow arrangements
Performance
parameters
such
as
thermal
effectiveness and pressure drops
6. Fouling tendencies
7. Types and phases of fluid
8. Maintenance, inspection, cleaning ,extension and
repair possibilities
9. Overall economy
10. Fabrication techniques

1. Material of construction
For reliable and continuous use,
the material of construction of heat
exchangers should have well defined
corrosion rate in service environment.
the material should exhibit strength to with
stand with operating and temperature and
pressure

2. Operating temperature and pressure

conditions
Pressure
The design pressure is important to determine the thickness of

pressure retaining components. The higher the pressure, the

greater will be the required thickness of pressure retaining
equipment.

Temperature
Design

temperature: This parameter is important as it

indicate whether a material at design temperature can
withstand the operating pressure and various load imposed on
component.

Shell and tube heat exchanger units can be designed for almost
all condition of temperature and pressure. In extreme cases, high
pressure may impose a limitation by fabrication problems associate
with material thickness.
Compact Heat exchanger: Compact Heat exchanger are
constructed from thinner material by mechanical bonding like
welding. Therefore they are limited in operating pressure and
temperature

3. Flow rate
Flow rate determine the flow area: the

higher the flow rate the higher will be cross

flow area

4. Flow arrangement
The choice of typical flow arrangement

(cocurrent or countercurrent) is dependent

of required exchanger effectiveness,
exchanger construction types.

5. Performance
Thermal effectiveness
Parameter

Heat exchanger effectiveness is defined as the ratio

of the actual amount of heat transferred to the
maximum possible amount of heat that could be
transferred with an infinite area.

Pressure drop
Pressure drop is an important parameter in heat
exchanger design. The heat exchanger should
be design in such a way that unproductive
pressure drop should be avoided to maximum
extent in area like inlet and outlet bends

6. Fouling Tendencies
Fouling is defined as formation on heat exchanger
surface of undesirable deposit that decrease the
heat transfer and increase the resistance to fluid
flow, resulting in high pressure drop. The growth of
those deposit decrease the performance of
exchanger with time.

7. Type and Phases of fluid

The phase of fluid within the unit is an

important consideration in selection of heat

exchanger type.
Various combination of fluid dealt in
exchanger are Liquid-Liquid, Liquid-Gas and
Gas-Gas

8. Maintenance, inspection,
cleaning, extension and repair
The suitabilitypossibilities
of various heat exchanger

depend upon it maintenance cleaning and

repairing maintenance
Repairing and maintenance of shell and tube
exchanger is relatively easy but repairing of
expansion joint is somehow difficult.
Repairing and maintenance of compact heat
exchanger of tube/plate fin type heat
exchanger is very difficult except by plugging
of tube.

9. Overall Economy
There are two major cost to consider in designing of

heat exchanger,
the manufacturing cost and
operating cost, including maintenance cost

In general the less heat transfer area the less is the

complexity of design, the lower in manufacturing

cost.
The operating cost is pumping cost due to pumping
device such as pumps, fans and blowers.
The maintenance cost include cost of spares that
require frequent renewal due to fouling and corrosion

10. Fabrication technique

Fabrication technique is also determining

factor for heat exchanger design.

For example shell and tube exchanger
mostly fabricated by welding, plate fin
heat exchanger and automobile aluminum
radiator by brazing.
Most of circular tube fin exchanger
fabricate by mechanical assembling.

Study Reference
Materials

Fundamentals of Heat Exchanger Design.

Ramesh K. Shah and Duan P. Sekulic, John

Wiley & Sons, Inc.
Heat Exchanger Design Handbook. Kuppan
Thulukkanam, CRC Press.