CH-312

Heat Transfer Equipment Design

 Course Instructor: Prof. Dr. Javaid Rabbani Khan
Office: G-01
email: drjrabbani@giki.edu.pk
Office Hours: 8:00 am to 5: 00 pm Course Crdt.hr: 2

 Office # G-38 FMCE, GIK Institute, Ext: 2661

 Email: arooj@giki.edu.pk
 Office Hours: 8am~5pm
Sr. No Course Learning Outcomes

classify, design and operate heat transfer equipment as a process engineer to fulfill the
CLO_1
needs of industry in accordance with the national and international standards;

enhance efficiency and optimize the thermal performance as a professional engineer to

CLO_2
economize the production cost of the manufactured products.

practice and implement ethics and social responsibility to the community in terms of
CLO_3 quality, environmental aspects and diagnose / resolve industrial bottlenecks in the field of
heat transfer.
Announced & unannounced Quizzes 15%
Assignments & assignment sessions 5%
*PBL- Task 10%
Midterm Exam 30%
Final Exam 40%

(*problem based learning - task)

 Physical and ATTENTATIVE Presences without
any ill will .
The fallowing you must have during lectures:

 Note Book
 Scientific Calculator
 Course Text Book
Chemical engineer should be capable to select, design and operate a plant for economical and quality
manufacturing of desirable products by physical or chemical transformation of materials, along with the
technical skills to minimize environmental disturbance,
The activities include :
 Standardization of Specifications of the material to be transformed,
 Selection of necessities of a manufacturing process i.e. TECHNOLGY .
 Management and transfer of technology/ies involved,

 Equipment categorization and PFDs

 Abreast with the design and operational tools i.e. flow-sheeting, process control, simulation
software and scale models.
 Process simulation is a model-based representation of chemical, physical, biological, and

other technical processes and unit operations in a software to optimize the process problem
which has to be solved in an iterative process.
How Important is the H.T. Equipment Design
for Production?? Any Idea..!!
 Heat Transfer Equipments and Their function
A device whose primary purpose is the transfer of energy between two or more fluids.
 Heaters: are used primarily to heat process streams directly or indirectly,
Coolers : are employed to cool down streams, Water is a common cooling medium.
Equipment Function

Chiller Cools a fluid to a temperature below that obtainable if

water only were used as a coolant. It uses a refrigerant such as
ammonia or Freon.

Condenser Condenses a vapour or mixture of vapours, either

alone or in the presence of a non condensable gas.
Partial condenser
•Condenses vapours partially
•This saves heat and eliminates the need for providing a
separate preheater (using flame or steam).

Final condenser
• Condenses entire vapours to a final storage temperature
• It uses water cooling, which means that the transferred
heat is lost to the process.
Exchanger Performs a double function:

(1) Heats up a cold fluid by

(2) Cools down a hot fluid. None of the transferred heat is lost.
Heater Imparts sensible heat to a liquid or a gas by means of condensing
steam.

Reboiler
• Connected to the bottom of a distillation tower, to re-boil heat necessary
for distillation.
• The heating medium may be either steam or a hot-process fluid.

•Thermo-siphon reboiler Natural circulation of the boiling medium is obtained by

maintaining sufficient liquid head to provide for circulation.
•Forced-circulation reboiler A pump is used to force liquid through the re-boiler.
 The main types of heat exchangers used in chemical
process & allied industries,
1. Double-pipe exchanger: the simplest in configuration and
commonly used for low to medium cooling and heating.
2. Shell and tube exchangers: used for heavy heat duties.
3. Plate and frame exchangers (plate heat exchangers):
4. Plate-fin exchangers.
5. Spiral heat exchangers.
6. Air cooled: coolers and condensers.
7. Direct contact: cooling and quenching.
8. Agitated vessels.
9. Fired heaters.
SHELL AND TUBE EXCHANGERS: CONSTRUCTION DETAILS

The shell & tube exchanger is one the most commonly used type of heat-
transfer equipment used in the chemical and allied industries.

The advantages of this type are:

1. The configuration provides- a large surface area in a small volume.

2. Good mechanical layout - a good shape for pressure operation.
3. Well-established fabrication techniques are available.
4. Can be constructed from a wide range of materials.
5. Easily cleaned.
6. Well-established design procedures
Heat Exchanger Temperature Profiles

Axial temperature profiles for a single pass heat exchanger

Axial temperature profiles for a

double pass heat exchanger
 Wide uses of H.T. Equipment
Classified Types of H.T. Equipment For space heating, refrigeration, air-
conditioning, power-generation,
 Plate exchangers/Gasketed PHEs/ Spiral Plate are chemical plants, petrochemical
compact, economical alternative to shell & tube plants, petroleum refineries, natural-
designs, Utilities and thermal fluids gas processing & sewage treatment
 Other heat transfer systems use natural gas, electricity etc
or direct steam injection for heating purposes
 Finned-tube exchangers and scraped-surface
crystallizers are used for clean operation and quick
response,
 Agitated and rotating surface exchangers are
innovative and effective H.T. equipment.
 space heating, refrigeration, air-conditioning, power
generation, chemical plants, petrochemical
plants, petroleum refineries, natural-gas processing
& sewage treatment

Basic concept of HT
Steam generator Generates steam for use elsewhere in the plant by
using the available high heat elsewhere in the plant

Super heater Heats a vapour above the saturation temperature.

Vaporizer A heater which vaporizes part of the liquid beside water.

Waste-heat boiler
• Produces steam; similar to steam generator using heat wasted at any
location of the plant , e.g. hot gas or liquid produced in an exothermic
chemical reaction.
 Heaters (sensible heat changes)
 Coolers (sensible heat changes)

 Condensers (also change of state, V to L)

 Evaporators (also change of state, L to V)

Paul Ashall, 2008

 Chemical reactors (jackets, internal heat exchangers/calandria )
 Preheating feeds
 Distillation column re-boilers
 Distillation column condensers
 Air heaters for driers
 Double cone driers
 Evaporators
 Crystallisers
 Dissolving solids/solution
 Production support services – HVAC, etc.
 Heat transfer fluids
 Driers, crystallizers etc.

Paul Ashall, 2008

Heat exchangers are classified and developed to
meet the wide applications of industries,
 Operating principle ( nature of heat exchanger process),
 Process and Mechanical design and
constructional features,
 Relative direction of fluid flow and Physical state
of fluid etc.
 According to heat exchange process

Non Direct contact type of Direct contact type of heat

heat exchanger exchanger

Recuperator Regeneration Examples:

Examples: examples: 1.cooling tower
1.Radiator 1.Open hearth furnace 2.condensor etc.
2.Oil heaters etc. 2.Glass melting furnace etc.
 Direct contact type heat exchanger:
 In direct contact H. Exs heat transfer
occurs between hot & cold fluids by
direct contact,
 Simultaneous transfer of heat & mass
 The rate of heat transfer is maximum
 However, in direct contact heat exchanger the
both fluids are immiscible or if a single fluid
that undergoes through a phase change.
 Direct contact heat exchangers have limited
applications (where either mixing of both fluids is
desirable or harmless)
Non – contact or Indirect type of heat exchangers:
• No direct contact between two fluids e.g. heat exchanger, regenerators &
recuperates.
• Indirect type H . Exs. But H.T. occurs directly from hot stream to cold stream.
• Storage type or fluidized bed heat exchangers;
 B)According to the direction of flow

Parallel flow or
unidirectional flow Cross flow
or concurrent flow Counter flow or Examples:
Examples: counter current flow 1.Cooling units of
1.Oil coolers Examples: refrigeration system
2. Oil heaters 1. Used almost in all 2.Automobile radiator
engineering application
3.Water heaters
B1)Parallel flow/unidirectional flow:
 In case of parallel floe heat exchanger,
both the fluids are flowing in the same
directions.
 Fig.4 represented the variations in
temperature along the length of heat
exchanger.
 Since this type of heat exchanger needs a
large area of heat transfer, therefore , it is
rarely used in practice.
 As the two fluids are separated by a wall,
this type of heat exchanger may be called
parallel flow recuperator.
B2) Counter flow/ Counter current heat exchanger:
 In case of counter flow heat
exchanger , both the fluids are
flowing in the opposite
directions.
 The arrangement and
temperatures variations along
the length of heat exchange for
such heat exchangers are shown
in fig.
B3)Cross flow heat exchanger:
 Fig. shows schematic diagrams
of common arrangements of
cross flow heat exchangers,
both fluids are directed at right
angles to each others.
 Fig.(a) represents the case in
which there is no mixing of
fluids streams which is
flowing over the tube(i.e.
example: automobile radiator).
 Double pipe heat exchangers
• Simple & cheep in design & fabrication.
• Excellent capacity for thermal expansion;
• Easy to install, operate and maintain ,
• A good choice for small industries but suitable
• for low heat duties having limited efficiency,
• Modular design makes it easy to enhance
H.T. area by adding new assemblies;
• Occupies high space for large scale duties,
• Not cost effective and needs special gaskets

Hairpin: D/P exchangers are especially suitable

for extreme temperature crossing, high
pressure, high temp. & low to moderate
HT area requirements.
(d) NRe in the tube and annulus section
 Fig. represents concentric tube type of heat

exchanger.

These are also called tubular heat exchangers or

tube in tube type of heat exchangers or double

pipe heat exchanger.

DESIGN STEPS OF A DOUBLE PIPE HEAT EXCHANGER
 DESIGN STEPS OF A DOUBLE PIPE HEAT EXCHANGER

PROCESS CONDITIONS REQUIRED

Hot fluid: T1, T2, W, c, s, or ρ, µ, k, ∆P, Rdi, Rdo

Cold fluid: t1, t2, w, c, s, or ρ, µ, k, ∆P, Rdi, Rdo

 Film coefficients for fluids in annulus:

Fouling/ Scale formation or deposition on a heat

transfer surface is called fouling or dirt.
Types of fouling:
Precipitation fouling ( due to dissolved salts of Ca & Mg )
Particulate fouling( due to suspended particles )
Corrosion fouling (Chemical reactions may occur on contact of
the process fluid with heat transfer surfaces. The metallic surface acts as
a catalyst)
Chemical reaction fouling (due to deposits formed by
chemical reactions)
Bio fouling ( due to the attachment of bio chemical
species )
Solidification fouling ( due to sub cooling of fluids
Scale or Dirt is expressed in
terms of Fouling factors:
Fouling factors:
CALCULATION OF PRESSURE DROP
Equivalent diameter for heat transfer calculations:

Equivalent diameter for Pressure drop calculations:

 Construction of double pipe
 Hair pin: union of two legs of D/P H.Ex.is preferred because it requires less space,
 Packing & gland: The packing and gland provides sealing to the annulus and support
the inner pipe.
 Return bend: The opposite ends are joined by a U-bend through welded joints.

 Support lugs: Support lugs may

be fitted at these ends to hold the
inner pipe position.
 Flange: The outer pipes are joined
by flanges at the return ends in
order that the assembly may be
opened or dismantled for cleaning
and maintenance.
 Union joint: For joining the inner
tube with U-bend.
 DOUBLE PIPE EXCHANGERS IN SERIES- PARALLEL ARRANGEMENT

• D/P H. Exs. can be used for high temperature,

high pressure, and highly viscous services.
• Allowable pressure drop of the liquids
flowing through a heat exchanger is 10 psi.
• If the calculated Pressure drop is higher and
exceed from the available head,
• An ideal solution is to divide the flow to
reduce the mass velocity in parallel
arrangement,
• D/P H. Exs. in series are employed to achieve
high temperature in steps,
• Specific heat for liquids
• Viscosity for liquids
jH heat transfer factor
 Summary
Double Pipe Heat Exchanger Design

• Determination of the heat transfer surface area needed to

satisfy the required Heat duty/ Load, basic heat exchanger
equation: Q = UA ΔTlm, where:
• Q is the rate of heat transfer between the two fluids in the heat
exchanger in Btu/hr.
• Uc and UD is the overall H.T. coefficient in BTU/hr-ft2– oF,
• Find ho, hi, hio, RD ( either by calculations, or from literature)
• A : heat transfer surface area in ft2, and
• ΔTlm is the log mean temperature difference in oF, calculated from
the inlet and outlet temp. of both fluids
i. After determination of the required H.T. surface area, the diameter
and length of the inner pipe and outer pipe the diameter
ii. Finally, the length of the straight sections and the number of
bends can be selected.
iii. Find pressure drops for pipe and annulus sides separately.
Find the Length of double pipe Heat Exchanger
Continued ……

Customize the estimated Length

 Heat Transfer over a Flat Plate

VL

Nusselt number is a ratio of convective H.T. to conductive H.T.

 Determine Heat Transfer Coefficient over a Flat Plate

Find the length of a double pipe heat Exchanger for the same operating
conditions ( Diameters of Inner & outer Pipe 2” & 3” IPS Schedule 40)
 The Number of Transfer Units (ε-NTU) method
To calculate the rate of heat transfer in heat exchangers (especially counter current exchangers)
when there is an insufficient data to calculate (LMTD).

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.
The effectiveness ( ε ) - The ratio between the actual H.T. rate to the maximum possible H.T. rate.
ε=Q actual /Q theoretical or maximum

Effectiveness of a heat exchanger is based on the maximum possible heat transfer

(hypothetically) achieved in a counter flow needs an infinite length of the exchanger.
2 common methods to calculate the effectiveness, Empirical method and graphical methods,
 Temperature Effectiveness ( P )

• It is ratio of the temperature change to the maximum temperature difference

across the heat exchanger.

P= dTachieved/dTmax or dtachieved/dTmax

• dTmax = T hot (in) -t cold (in)

• dTachieved = T1 – T2 or t2 – t1
 Major projects will be assigned as a means to guide students through the primary
topics covered during undergraduate heat transfer courses

i. To achieve such a goal and found that a project -based learning (PBL). PBL is a very
promising dynamics and Heat Transfer.
ii. During this semester- A group of 4 to 5 students will data, design & fabricate the
experimental set up, collect & analyze experimental data and conclude the
findings, etc.

iii. Outcomes will improve confidence and life long learning of the student and
exercise will also be focused on engineering knowledge and skills.

iv. Proposal might be submitted till 18th Feb. 2019

 CH312 Heat Transfer Projects Based Learning

1- Design, fabricate an experimental set up to investigate Fourier law for linear conduction along a
circular bars of different materials, using conduction heat transfer.

Objectives,
i. Prove using the experimental data that the thermal conductivity k varies between different materials
and can be a function of temperature,
ii. Experimentally investigate that Fourier's Law by finding the conduction heat transfer resistance of the
used specimen and comparing this value to actual values available in literature.
iii. Plot the temperature profile along the length of the core and obtain the slope dT/dx
 Design, fabricate an experimental set up to investigate the effect of change in cross-sectional area on
temperature profile along a thermal conductor on conduction heat transfer unit.

OBJECTIVE:
i. The purpose of this experiment is to study the effects of surface contact on thermal
conduction between adjacent slabs of the same material.
ii. When two structures are connected, the total contact between the surfaces is not exactly
equal to100 percent; and therefore, heat will not be transferred as effectively. Because of
this very reason we define a new resistance called contact resistance:
 CH312 Heat Transfer Projects Based Learning

• Design, fabricate an experimental set up to demonstrate the working principle of a

concentric tube heat exchanger operating under counter flow conditions,
i. To compare the effectiveness of Co and counter flow,
ii. To compare the theoretically calculated and actual length of the exchanger
iii. Draw Temperature Profiles for the experimental data,
iv. Find out over all H.T. coefficient.

• Design, fabricate an experimental set up to investigate the influence of surface contact on

thermal conduction between adjacent slabs of metal.

3- Design, fabricate an experimental set up to investigate the influence of thermal insulation upon
conduction of heat between adjacent metals.
4- Design, fabricate an experimental set up To investigate the relation between power input and surface
temperature in forced convection.
• Design, fabricate an experimental set up to investigate Fourier law for linear conduction along a circular
bars of different materials, using conduction heat transfer. To achieve the fallowing objectives,

i. Prove using the experimental data that the thermal conductivity k varies between different materials
and can be a function of temperature,
ii. Experimentally investigate that Fourier's Law by finding the conduction heat transfer resistance of
the used specimen and comparing this value to actual values available in literature.
iii. Plot the temperature profile along the length of the core and obtain the slope dT/dx

OBJECTIVE:
The objective in this experiment is to investigate Fourier's Law for the linear conduction of heat along a
simple bar.
INTRODUCTION:

THEORY:
Design, fabricate an experimental set up to demonstrate the working
principle of a concentric tube heat exchanger operating under counter flow
conditions,
i. To compare the effectiveness of Co and counter flow,
ii. To compare the theoretically calculated and actual length of the exchanger
iii. Draw Temperature Profiles for the experimental data,
iv. Find out over all H.T. coefficient.

• Design, fabricate an experimental set up to study the temperature profile and calculate
the heat transfer rate resulting from radial stainless steel conduction through a
cylindrical wall.
• Design, fabricate an experimental unit to study conduction of heat
along a composite bar and evaluate the overall heat transfer co-efficient
using conduction heat transfer unit.

i. When two structures are connected, the total contact between the surfaces is
not going to be 100 percent;
ii. Therefore, heat will not be transferred as effectively as in individual structure.
Because of this reason, a new resistance called contact resistance is introduced
and calculated,
• Design, fabricate an experimental set up to demonstrate the working principle of a
concentric tube heat exchanger operating under parallel flow conditions.
• Design, fabricate an experimental set up to demonstrate the effect of flow rate variation
on the performance characteristics of a concentric tube heat exchanger operating under
counter flow conditions.
• Design, fabricate an experimental set up to demonstrate the working principle of a
concentric tube heat exchanger operating under counter flow conditions at different inlet
temperature.
 Shell and tube type heat exchangers:

In shell and tube type heat exchangers, one fluid with flow through shell and other will flow through
tube.
There is no direct contact between two fluids and the heat will transfer,
Shell and tube type heat exchangers may be used as a simple heat exchanger, condenser, evaporator,
Re-boiler, Boiler, etc.
A typical exchanger is shown in fig.

 Multiple shell and tube passes are used for enhancing the overall heat

transfer area.

Multiple type pass heat exchangers are those which re route the fluid

through tubes in opposite direction.

Examples are surface condensor in thermal power plants