Faculty Development Programme on Recent Trends

in Thermo-Fluids Engineering (RTTFE 2018)

organized by

Department Of Mechanical Engineering, NIT Arunachal Pradesh

HEAT EXCHANGER: TYPES, DESIGN AND ANALYSIS

by

BIJAN KUMAR MANDAL

Department Mechanical Engineering
Indian Institute of Engineering Science and Technology, Shibpur

1
 INTRODUCTION

• Heat exchangers are devices those facilitate heat

transfer between two or more fluids at different
temperatures.
• Heat exchangers are extensively used in steam
power plants, chemical industry, building heating
and air-conditioning, refrigerators, car radiators etc.
• In common types (shell and tube heat exchangers)
heat transfer is primarily by conduction and
convection from a hot to a cold fluid, which are
separated by a metal wall

2
 CLASSIFICATION

• According to heat transfer processes

 Direct contact type
 Recuperators
 Regenerators or storage type heat exchanger

• According to constructional features

 Tubular or tube in tube or double pipe heat exchanger

 Shell and tube heat exchanger
 Finned tube type
 Compact heat exchanger

3
 CLASSIFICATION (Cond.)

• According to flow arrangement

 Parallel flow heat exchanger

 Counter flow heat exchanger
 Cross flow heat exchanger

4
Direct contact type heat exchanger

5
Storage type heat exchanger (Regenerators)

6
Tubular heat exchanger

7
Shell and tube heat exchanger

8
 Multi pass flow arrangement in shell
and tube type heat exchanger

One shell pass and two tube pass Two shell pass and four tube pass

9
Arrangement for Different Types of
Compact Heat Exchangers

10
Parallel Flow and Counter Flow Heat
Exchangers

Parallel flow Counter flow

11
Different Flow Configurations In
Cross-flow Heat Exchangers

Both fluid unmixed One fluid mixed and one

fluid unmixed

12
 Temperature Profile

Parallel Flow Heat Counter Flow Heat

Exchanger Exchanger

13
Temperature Profile

Evaporator Condenser

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 Temperature Profile

Heat Exchanger with Uniform

Temperature Difference

One Shell Pass and Two Tube

Pass Heat Exchanger
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 Summary of Temperature Profile

 The temperature difference between the hot fluid and

the cold fluid remains almost the same throughout
the length in case of counter flow heat exchanger.

 In other cases, the temperature difference decreases

as the fluids move from inlet to the outlet section.

 In case of evaporator and condenser, the temperature

of one fluid remains the same throughout the length.
Concept of parallel and counter flow has no effect.

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 Overall Heat Transfer Coefficient
A heat exchanger involves two flowing
fluids separated by a solid wall.

The heat transfer rate is dependent on

• Heat transfer coefficients of the

fluids on both sides of the wall

• The thermal conductivity of the

wall

• Geometrical dimensions

The total thermal resistance is

1 ln d 0 d i  1
Rth   
hi Ai 2LK h0 A0
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 Overall Heat Transfer Coefficient
• The heat transfer rate

T
Q  UAT  U i Ai T  U 0 A0 T
Rth

• Overall heat transfer coefficient

1 1 1
Rth   
UA U i Ai U 0 A0

• Overall heat transfer coefficient based

on outside tube surface
1 1
U0  
A0 A0 d0 d
ln d 0 d i    0 ln d 0 d i  
1 1

Ai hi 2LK h0 d i hi 2 K h0

• Overall heat transfer coefficient based

on inside tube surface

1 1
Ui  
Ai A 1 di d
ln d 0 d i   i ln d 0 d i   i
1
 
hi 2LK A0 h0 hi 2 K d 0 h0 18
 Physical Situation U (W/m2.K)
Brick exterior wall, plaster interior, uninsulated 2.55
Frame exterior wall, plaster interior uninsulated 1.42
With rock wool insulation 0.4
Plate glass window 6.2
Steam condenser 1100-5600
Feedwater heater 1100-8500
Water to water heat exchanger 850-1700
Finned tube heat exchanger, water in tubes, air across tubes 25-55
Water to oil heat exchanger 110-350
Steam to heavy fuel oil 56-170
Steam to kerosene or gasoline 280-1140
Finned-tube heat exchanger, steam in tubes, air over tubes 28-280
Alcohol condenser, water in tubes 255-680
Gas to gas to heat exchanger 10-40 19
 FOULING FACTOR
An additional resistance to the heat transfer between the fluids is
considered to take into account the deposition of impurities on heat
exchanger surfaces. The fouling factor (Rf ) can be calculated as

1 1
Rf  
Udirty Uclean
Considering fouling on both fluid sides, the total thermal resistance is

ln  0 
d
  i   f ,o 
1 R f ,i d R 1
 R th  
Ai h i Ai 2Lk Ao Ao h o

The overall heat transfer co-efficient for a tubular heat exchanger as

1
Ui 
1 d d  d d 1
 R f ,i  i ln  o   i R f ,o  i
hi 2k  di  d o do h o
20
 Values of fouling factor in
some common cases
Type of fluid Fouling factor
m2. K/W
Seawater, below 500C 0.00009
Above 50ºC 0.002
Treated boiler feedwater above 500C 0.0002
Fuel oil 0.0009
Quenching oil 0.0007
Alcohol vapors 0.00009
Steam, non-oil-bearing 0.00009
Industrial air 0.0004
Refrigerating liquid 0.0002

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Heat Exchanger Analysis by LMTD Method

22
LMTD METHOD FOR PARALLEL FLOW HEAT EXCHANGER

Total heat transfer rate Q through the heat exchanger

Q
T0  TL A t U m  At Um
T0  TL 
 T   T 
ln  0  ln  0 
 TL   TL 

or , Q  At U m Tlm

Where logarithmic mean temperature difference (LMTD) is given by

Tlm 
T0  TL 
 T0 
ln  
 TL 
Special Cases:
0
 If T0  TL , then  Tlm  form, but in the limit applying L’Hospital’s
0
rule,  Tlm  T0  TL

 If T0 is not more than 50% greater than TL , the LMTD can be
approximated by arithmetic mean within about 1.4 percent error. 23
Application of LMTD method for Multi pass
and cross flow heat exchanger

The flow conditions and temperature distributions for the fluids are
complicated for multipass and cross flow heat exchanger.

Approximate LMTD value can be obtained by introducing a

correction factor F.

LMTD : Tlm  FTlm, counter flow

Tlm, counter flow : LMTD value for a counter flow arrangement with same
hot and cold fluid temperatures

The correction factor F depends on:

Geometry of the heat exchanger.

The inlet and outlet temperatures of the hot and the cold fluids.24
 Correction factor for one shell pass and
two tube pass or multiple of two tube pass

P : Thermal effectiveness of the tube side fluid

R : Heat capacity ratio 25

 Correction factor for two shell pass and
four tube pass or multiple of four tube pass

P : Thermal effectiveness of the tube side fluid

R : Heat capacity ratio 26

Correction factor for cross flow, both fluid
unmixed

P : Thermal effectiveness of the tube side fluid

R : Heat capacity ratio

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 EFFECTIVENESS- NTU METHOD

 The rating problem is concerned with the determination of the

heat transfer rate, the fluid outlet temperatures, and the

pressure drops.

 If the inlet or outlet temperatures of the hot and the cold fluid

are not specified, the LMTD can not be determined.

 In that case, the analysis is done by using   NTU or the

effectiveness method.

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 EFFECTIVENESS- NTU METHOD

Effectiveness of heat exchanger:

actual heat trans fer from one fluid to another
ε
maximum possible heat trans fer from one fluid to another
Q
 
Qmax

The maximum possible heat transfer rate:

Qmax  mc p min Th,in  Tc,in 

the actual heat transfer rate:

Q   mc p min Th,in  Tc,in 

29
 Determination of 
Effectiveness of heat exchanger:

Q

mc p min Th,in  Tc,in 
Actual heat transfer rate :
Q  mh c ph Th ,in  Th ,out   mc c pc Tc ,out  Tc ,in 

mh c ph Th,in  Th,out  Ch Th,in  Th,out 

 
So,
mc  T
p min h ,in  Tc,in  Cmin Th,in  Tc,in 

C C Tc ,out  Tc ,in 

This can also written as,  
C min Th ,in  Tc ,in 

where, C h  mh c ph , C c  mc c pc and Cmin is the smaller of Ch and Cc .

30
 Determination of  (Cond.)
Number of transfer unit (NTU) is a dimensionless parameter, can
be defined as:
AU m
NTU 
C min

1  exp  NTU C min Cc  Cmin Ch 

So, 
Cmin Cc  C min C h

1  exp NTU 1  C 
or ,  
1 C

C min
where, C
C max

31
Expressions for effectiveness
for various flow geometry
Flow Geometry Relation for effectiveness
1. Double pipe heat exchanger
1  exp  NTU 1  c 

(a)Parallel flow 1 c
(b)Counter flow 1  exp   NTU 1  c  

1  C exp   NTU 1  c  
1
2.Shell and tube heat exchanger:  1  exp   NTU 1  c 2  
One shell pass and 2,4, ……..tube passes   
  1  c  1  c 2

 1  exp   NTU 1  c 2  
  
3. Cross flow
 NTU0.22 
(a) Both fluid unmixed   1  exp  
exp 1  cNTU0.78  1 
  
 c 
(b) Cmax mix and Cmin unmixed 1
 
  1  exp c 1  exp   NTU  
c

(c) Cmax mix and Cmin unmixed  1 
  1  exp  1  exp  cNTU   
 c 
4. Boilers and condensers
  1  exp  NTU 
c min
c 0
c max 32
 Effectiveness charts for
various geometries

Effectiveness for parallel Effectiveness for counter

flow heat exchanger flow heat exchanger 33
 Effectiveness charts for
various geometries

Effectiveness for cross flow heat Effectiveness for cross flow heat
exchanger both fluid unmixed exchangerwith one fluid mixed 34
 Effectiveness charts for
various geometries

Effectiveness for single shell pass Effectiveness for two shell pass
with two, four etc. tube passes with four, eight etc. tube passes
35
.
SUMMARY OF NTU-EFFECTIVENESS METHOD

• The effectiveness of all heat exchangers varies from 0 to 1.

• Effectiveness increases rapidly with NTU upto 1.5.
• NTU value larger than 3 will not be economically justified.
• For a specified value of NTU and C, the counter flow heat exchanger
has the highest effectiveness and the parallel flow lowest. The
effectiveness of cross flow heat exchanger is in between.
• The effectiveness for all heat exchangers is more close for NTU values
less than 0.3 and it is independent of capacity ratio.
• For a given NTU, the effectiveness is maximum for C= 0 and minimum
for C = 1.
• For C = 0 ( condenser and evaporator), all heat exchangers will give
the same effectiveness and is given by    max  1  exp  NTU  .
36
.
Effectiveness vs. NTU

Comparison of effectiveness for Effectiveness for condensers and

different flow arrangements for C = 1 evaporators for C = 1.

37
 Physical Significance of NTU
The dimensionless parameters NTU is defined as

AU m heat capacity of exchanger, W/ 0 C

NTU  
C min heat capacity of flow, W/ 0 C

• For a specified value of Um/Cmin, the NTU is a measure of the

actual heat area A, or the physical size of the exchanger.

• The larger the value of NTU, the closer the heat exchanger
approaches its thermodynamic limit.

• A counterflow heat exchanger has the highest effectiveness

() for a specified values of NTU and C compared that with
other for other flow arrangements.
38
 Use of -NTU Relation
Rating:
Steps to be followed to determine the total heat flow rate Q and
the outlet temperatures Th,out and Tc,out.

C min
1. Find C and NTU  U m A from the given data.
C max Cmin
2. Knowing NTU and C determine  from the chart or equation

for the specified geometry and flow arrangement.

3. Calculate heat transfer rate as Q  C min Th ,in  Tc ,in 

4. Calculate outlet temperatures as

Q Q
Tc ,out  Tc ,in 
Th,out  Th,in 
m c p h m c p c
39
 Use of -NTU Relation
To find heat transfer area or length of the heat exchanger using
LMTD method:

1. Calculate heat transfer rate as Q  m c c p ,c Tc ,out  Tc ,in   m h c p ,h Th ,in  Th,out 

2. Calculate LMTD, Tlm

3. Apply Q  U 0 A0 Tlm Sizing

4. Caculate length as L 
Q
U 0 d 0 Tlm
problem
Alternative method using -NTU method:

1. Calculate heat capacity ratio

2. Calculate with known temperature

3. Obtain NTU value from charts or relations

U 0 A0
4. Calculate area using the relation NTU 
C min 40
R. K. Shah and D. P. Sekulic, Fundamental of Heat Exchanger Design,
John Wiley and Sons, 2003.
Sadik K. and Hongtan L., Heat Exchangers: Selection, Rating and
Thermal Design, 2nd Edition, CRC Press, Washington DC, 2002.
Yunus A. Cengel, Heat Transfer A Practical Approach, 2nd Edition, Tata
McGraw- Hill Education, New Delhi, 2004.
J. P. Holman, Heat Transfer, 9th Edition, Tata McGraw- Hill Education,
New Delhi, 2008.
Frank P Incropera and David P. DeWitt, Fundamentals of Heat and
Mass Transfer, 5th Edition, Wiley India, New Delhi, 2007.
R. K. Rajput, Heat and Mass Transfer, 2nd Edition, S. Chand and Co.
Ltd., New Delhi, 2003.
D. S. Kumar, Heat and Mass Transfer, 7th Edition, S . K. Kataria and
Sons, New Delhi, 2010.
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Dr. Bijan Kumar Mandal
Professor
Department of Mechanical Engineering
Indian Institute of Engineering Science and Technology,
Shibpur
P.O. Botanic Garden
Howrah 711 103
India
Mobile No: 9830017592
E-mail: bkm375@yahoo.co.in, bijan@mech.iiests.ac.in

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