ChE 301

Heat Transfer Equipment

Instructor:
Dr. Md. Easir Arafat Khan
Assistant Professor
Department of Chemical Engineering, BUET,
Dhaka-1000

January, 2021

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 Classification of Heat Exchanger

▪ Direct transfer type

✓ Cold and hot fluid flow simultaneously through the device
and heat is transferred through a wall separating the fluids

▪ Storage type
✓ Hot and cold fluids flow alternatively through a porous solid
matrix where hot fluid storing heat in it and cold fluid
extracting heat from it

▪ Direct contact type

✓ Where two fluids are not separated. If heat is transferred
between a gas and a liquid, the gas is either bubbled
through the liquid or the liquid is sprayed in the form of
droplets into the gas.

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 Heat Transfer Equipment
Classification of Heat Exchanger:
Direct contact
1) Type of contact
Indirect contact

Tubular (double pipe, shell & tube)

Plate
2) Type of Construction Extended surface
Regenerative

Single pass
3) Type of flow arrangement
Multi-pass

Non compact (area< 700 m2/m3)

4) Type of surface compactness
Compact (area> 700 m2/m3)

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 Heat Transfer Equipment
Direct contact heat exchanger
• No barrier between two fluids
• Cooling tower (Utility is cooled by contacting with upflowing air
• Vapor from an evaporator sometimes condensed by cold water
• Hot oils are sometimes directly cooled with cold water
• Distilled fatty acids are cooled with cold water
• In packed bed and fluidized bed, heat exchange between solid and fluid

Advantage:
It can avoid extra resistance of the barrier between the fluids
Disadvantage:

• Mixing between two fluids

• Two phases need to be separable
• Useful only when fluid are easily separable

Indirect contact heat exchangers are mostly used in the industry

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 Heat Transfer Equipment
Double pipe heat exchanger
• Fluid flows through tube/pipe
• Outer one acts like a Jacket of the inner one
• Hairpin construction mostly important to make
practical one where one hairpin is connected with
other one.
• Opposite ends are joint by U-bends
• Bending tube thickness is comparatively larger
• For low heat duty application

Double pipe HE

Double pipe HE schematic 5

Heat Transfer Equipment

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Heat Transfer Equipment

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 Heat Transfer Equipment
Condenser and Boiler

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 Heat Transfer Equipment
Comparison between parallel flow and counter flow, which one would be better
to use?

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 Heat Transfer Equipment
Shell and tube heat exchanger

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 Heat Transfer Equipment
Shell and tube heat exchanger

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 Heat Transfer Equipment
Various component of shell and tube heat exchanger
Shell
• Enclosure of tube bundle and allow the passage shell side fluid
• For big size shell metal plate is rolled and welded in axial direction
• If the diameter is less than 60 cm, a pipe with suitable thickness can be used
• Material of construction: carbon-steel is very common which mainly depends
on operating conditions, i.e. temperature, pressure and type of fluid

Tube

• Tube wall separate the two fluids and acts as surface for heat transfer
• Fluid following through the tube is called as tube side fluid
• Material of construction: carbon-steel, copper, brass or stainless steel which
mainly depends on operating conditions, i.e. temperature, pressure and type
of fluid
Tube size: ¾”, 1”, 1¼” and 1½”
• Narrower tube are used for smaller heat exchanger and working with clean
fluid

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 Heat Transfer Equipment
Various component of shell and tube heat exchanger
Tube Thickness
BWG –Bermingham wire gauge
It depends on i) operating pressure, ii) corrosiveness of fluid to be handled
and iii) thinning of tube wall during bending

Tube Length: 8’, 16’, 20’ and 24’

Tube arrangement:
1. Square pitch C = Clearance
2. Triangular pitch P = Pitch
C

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 Heat Transfer Equipment
Square pitch Triangular pitch

1. Easy cleaning 1. Preferred

2. Less pressure drop 2. More heat transfer for a fixed cell in
comparison to square pitch
3. Pressure drop is larger due to more
turbulence
4. Higher heat transfer coefficient can be
Equivalent diameter: achieved.

Flow area
De = 4rH = 4 Wetted perimeter

 2 d 02 
For square pitch: 4 PT − 
De =  4 
d 0
What is the equivalent diameter for triangular pitch arrangement?

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 Heat Transfer Equipment
Pass partition plate:

1. Tube side plate

2. Shell side plate

No of passes indicates the no of times the shell or tube side fluid traverses
the length of the heat exchanger.
M:N SHE; where M=no of shell side pass
and N= no of tube side pass
1:2 1:4 2:4 2:6

Increase of the number of passes reduce the flow area for the fluid and
increase
1. Turbulence
2. Flow rate
3. Heat transfer coefficient
4. Pressure drop

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 Shell
side

Tube
side

Heat transfer area available per unit volume: 100 - 500 m2/m3

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 Heat Transfer Equipment
Baffles

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 Heat Transfer Equipment
Segmental Baffles

Disc and doughnut Baffles

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 Heat Transfer Equipment
Orifice Baffles Baffle spacer

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 Heat Transfer Equipment
Various type of shell and tube heat exchanger

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Heat Transfer Equipment

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 Heat Transfer Equipment

Heat transfer area available per unit volume: 100 - 200 m2/m3 23
Heat Transfer Equipment

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 Heat Transfer Equipment
Compact Heat Exchanger

Heat transfer area available per unit volume:

is greater than 700 m2/m3 25
Compact Heat Exchanger (Fin Type)

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Heat Transfer Equipment

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Heat Transfer Equipment

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 Heat Transfer Equipment
Overall heat transfer coefficient
The total thermal resistance,

The overall heat transfer coefficient,

When tube wall thickness is small and

thermal conductivity is high, the resistance
becomes negligible, then

Where, inner and outer surface are almost

identical and Ui ≈ Uo 29
Heat Transfer Equipment

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Overall Heat Transfer Coefficient of a Heat Exchanger

Home work:
Hot oil is to be cooled in a double-tube counter-flow heat exchanger. The
copper inner tubes have a diameter of 2 cm and negligible thickness. The
inner diameter of the outer tube (the shell) is 3 cm. Water flows through the
tube at a rate of 0.5 kg/s, and the oil through the shell at a rate of 0.8 kg/s.
Taking the average temperatures of the water and the oil to be 45°C and
80°C, respectively, determine the overall heat transfer coefficient of this heat
exchanger.

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 Heat Transfer Equipment
Fouling Factor

Overall heat transfer coefficient

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Heat Exchanger Analysis
Log mean temperature difference (LMTD)
method
.
Want a relation Q = UATm

Where Tmis some mean T between hot and cold fluid

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 Energy balance (counter-flow) on element shown

dQ = −m h ch dTh = −m c cc dTc (1)

m = mass flow rate of fluid
c = specific heat
Rate Equation
dQ = UdA(T − T )
h c ( 2)
Counterflow
− dQ − dQ Note Th ,out can be  Tc ,out
Now from (1) dTh = dTc =
m h ch m c cc

 1 1 
 d (Th − Tc ) = dQ 
 − 
 m c cc m h ch 
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Subtract dQ from (2),
d (Th − Tc )  1 1 

=U − dA
Th − Tc  m c cc m h ch 

Integrate 1 → 2
 Th 2 − Tc 2   1 1 
ln  = UA − 
 Th1 − Tc1   m c cc m h ch 

Total heat transfer rate

Q = m h ch (Th1 − Th 2 ) and Q = m c cc (Tc1 − Tc 2 )

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  c and put
Substitute for m
T1 = Th1 − Tc1 END 1
T2 = Th 2 − Tc 2 END 2
 T2 − T1 
Q = UA 
 ln (T2 / T )
1 

Q = UA(LMTD )
LMTD is Log Mean Temperature Difference

▪ Remember – 1 and 2 are ends, not fluids

▪ Same formula for parallel flow (but T’s are different)
▪ Counterflow has highest LMTD, for given T’s therefore smallest
area for Q.

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LMTD Correction Factors:

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 Effectiveness-NTU Method
How will existing H. Ex. perform for given
inlet conditions ?
Define effectiveness :
Rate of heat transfer in heat exchanger
=
Maximum possible heat transfer rate
Q actual
= 
Qmax

where Q max is for an infinitely long H.Ex.

One fluid T → Tmax = Th ,in − Tc ,in
and since Q = (m cc )Tc = (m ch )Th
= Cc Tc = Ch Th
then only the fluid with lesser of C c , C h
heat capacity rate can have Tmax
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 Q
i.e. Q max = Cmin Tmax and  =
Cmin (Th.in − Tc.in )
If C c  C h then, C h = C min ,
Th.in − Th.out
=
Th.in − Tc.in
If C c  C h then, C c = C min ,
Tc.in − Tc.out
=
Th.in − Tc.in

For parallel flow exchanger,

Th.in − Th.out
we assume, C min = C h , then  =
Th.in − Tc.in
Th.in − Th.out  Ch   Ch 
 = 1 +  1 + 
Th.in − Tc.in  Cc   Cc  39
There,
 Th.in − Th.out Tc.in − Tc.out   Ch 
  =  +  1 + 
 Th.in − Tc.in Th.in − Tc.in   Cc 
 Th.out − Tc.out   Ch 
= 1 −  1 + 
 Th.in − Tc.in   Cc 
Th.out − Tc.out   1 1   − UA  Ch 
Now, = exp − UA +  = exp  1 + 
Th.in − Tc.in   C h Cc    C h  Cc  
Finally, C h = C min and NTU = UA/Cmin
 − UA  Cmin    Cmin 
1 - exp  1 +  1 - exp − NTU 1 + 
 Cmin  Cmax    Cmax 
= =
 Cmin   Cmin 
1 +  1 + 
 Cmax   Cmax 

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Procedure:
Determine Cmax, Cmin/Cmax
Get UA/Cmin, →  from chart

Q =  C min (Th.in − Tc.in )

UA NTU max C min

NTU max =  A=
C min U

▪ NTUmax can be obtained from figures in textbooks/handbooks

First, however, we must determine which fluid has Cmin

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 Heat Transfer Equipment
Heat Exchanger Design

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 Heat Transfer Equipment
Thermal Design of HE

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Calculation involved

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Calculation involved

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Calculation involved

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Calculation involved

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Calculation involved

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