MEC551

THERMAL ENGINEERING

CHAPTER 04
HEAT EXCHANGER

1
EDITED BY:
DR. YUSLI YAAKOB
FACULTY OF MECHANICAL ENGINEERING
UiTM PULAU PINANG
OBJECTIVES:

When finish studying this chapter, student should be

able to:

2
OBJECTIVES:

When finish studying this chapter, student should be

able to:

3
CONTENTS:

4
4.0INTRODUCTION

5
4.0INTRODUCTION

6
4.0INTRODUCTION

a device heat is transferred from

in which
one fluid to another through separating walls

differ from mixing chambers

7
4.0INTRODUCTION

convection in each
Heat transferred involves
fluid and conduction through the wall
separating the two fluids.

two fluids are kept

Process : The
separate by a solid wall at
different temperatures and they do
not mix as they flow through it separated by a
solid wall
8
 4.0 INTRODUCTION

APPLICATIONS
specific names to
Heat exchangers are often given
reflect the specific application for which they are
used:
Condenser
 A heat exchanger in which one of the fluids is cooled and
condenses as it flows through the heat exchanger.
Boiler
 A heat exchanger in which one of the fluids absorbs heat
and vaporizes.
Space radiator
 A heat exchanger that transfers heat from the hot fluid
to the surrounding space by radiation. 9
 4.0 INTRODUCTION

APPLICATIONS
Car Radiator

coolcarreview.tk 10
http://www.iradiators.com/
4.0 INTRODUCTION

APPLICATIONS
Refrigerators Systems

http://www.e-refrigeration.com

Condenser

11

http://www.e-refrigeration.com
4.0 INTRODUCTION

APPLICATIONS
Air-conditioning Systems

http://www.thefullwiki.org/Surface_condenser

Surface
Condenser

12
http://www.diytrade.com

Condenser
4.0 INTRODUCTION

APPLICATIONS
Power Plants

13
4.0 INTRODUCTION

APPLICATIONS
Steam Engine

http://science.howstuffworks.com/transport/engines-equipment/
steam2.htm

http://science.howstuffworks.com/transport/engines-equipment/ 14
steam2.htm
4.1 TYPES OF HEAT EXCHANGERS
Heat exchangers are typically can be classified
according to:
i) flow arrangement
ii) type of construction.

The simplest heat exchanger is

two concentric pipes of

- Consists of
different diameters (double pipe HE)
- one fluid in a double-pipe HE flow through the
smaller pipe
- the other fluid flows through annular space
between the two pipes. 15
4.1 TYPES OF HEAT EXCHANGERS
‘The simplest HE is one for which the hot and
cold fluids move in the same direction (parallel
flow) or opposite directions (counter flow) in a
concentric tube (or double pipe construction)’

16
4.1 TYPES OF HEAT EXCHANGERS

There are three basic flow arrangements in

Heat Exchanger:
i) Parallel flow,
ii) Counter-Flow, and
iii) Cross Flow

17
 4.1 TYPES OF HEAT EXCHANGERS
PARALLEL FLOW
In the parallel-flow arrangement

• the hot and cold fluids enter

the same end, flow in the same
direction, and leave at the same
end.
Temperature profile

18
4.1 TYPES OF HEAT EXCHANGERS
COUNTER FLOW
In the counter-flow arrangement
 the fluids enter at opposite
ends, in opposite
directions, and leave at
opposite ends.
Temperature profile

out 19
4.1 TYPES OF HEAT EXCHANGERS
CROSS FLOW (COMPACT HE)

Thefluids may move in
cross-flow (perpendicular) to
one another.
 Fluid motion over them may be
mixed or unmixed.

 The fluid is unmixed, because

fins inhibit motion in a direction that
is transverse to the main flow
direction(x)
Ex: in a car radiator
20
o The fluid is mixed since the fluid is
now free to move in the transverse
4.1 TYPES OF HEAT EXCHANGERS
CROSS FLOW (COMPACT HE)

21
4.1 TYPES OF HEAT EXCHANGERS
SHELL-AND-TUBE
 The most common type of heat exchanger in industrial
applications is the shell and tube heat exchanger.

22
4.1 TYPES OF HEAT EXCHANGERS
SHELL-AND-TUBE
 These designs contain a large number of tubes
(packed in a shell) and heat transfer takes place as one
fluid flows inside the tubes while the other fluid flows
outside the tubes through the shell.

23
4.1 TYPES OF HEAT EXCHANGERS
SHELL-AND-TUBE
 Baffles are commonly placed in the shell to force the
shell-side fluid to flow across the shell to enhance
heat transfer and to maintain a uniform
spacing between the tubes.

24
4.1 TYPES OF HEAT EXCHANGERS
SHELL-AND-TUBE MULTI PASS
DESIGNS
 Shell and tube heat
exchangers are further
classified by how many shell
and tube passes are involved.
 One-shell pass and two-tube passes
devices
 Heat exchangers in which all the
tubes make 1 U-turn in the shell
 Two-shell passes and four-tube
passes devices

25
4.1 TYPES OF HEAT EXCHANGERS
SHELL-AND-TUBE

26
4.1 TYPES OF HEAT EXCHANGERS
PLATE AND FRAME
 This is an innovative design
which consists of a series
of plates with corrugated
flat flow passages.
 Hot and cold fluids flow in
alternative passages, thus
the cold stream is
surrounded by two hot
streams.

27
4.2 THE OVERALL HEAT TRANSFER
COEFFICIENT
(DOUBLE PIPE HEAT EXCHANGER)
 A heat exchanger typically
involves two flowing
fluids separated by a
solid wall.
 Heat is transferred
1. from the hot fluid to the wall by
convection,
2. through the wall by conduction,
3. from the wall to the cold fluid
again by convection.
28
 4.2 THE OVERALL HEAT TRANSFER COEFFICIENT
DOUBLE PIPE HEAT EXCHANGER
 The thermal resistance of the
network is thus:

1 ln Do Di 
1
Rtot   
hi Ai 2 kL ho Ao

• So the thermal resistance in the path of heat flow from hot to

cold fluid in a heat exchanger includes:
i. Skin resistance associated with the flow
ii. Scale resistance from wall fouling (to be discussed later)
iii. Thermal resistance of wall material 29
4.2 THE OVERALL HEAT TRANSFER COEFFICIENT
DOUBLE PIPE HEAT EXCHANGER
 The heat transfer is therefore:

 T
Q UAT U i Ai T U o Ao T
R
 Where U = overall heat transfer coefficient

 Note:
U i Ai U o Ao
U i U o unless Ai  Ao
30
4.2 THE OVERALL HEAT TRANSFER COEFFICIENT

DOUBLE PIPE HEAT EXCHANGER

 In this equation, U is called the overall heat transfer coefficient.

1 1 1
  Rtot
U As U i Ai U o Ao

31
4.2 THE OVERALL HEAT TRANSFER COEFFICIENT

DOUBLE PIPE HEAT EXCHANGER

 Since:
thickness
  , t
Rwall 
ln    ln  
Do
Di
Ro
Ri Ro  Ri ln  
2Ro L
2Ri L

2 kL 2 kL Ro  Ri 2 kL
t 1 t 1 t
 2L Ro  Ri   Ao  Ai  
k  2R L  k ln Ao  k Am
o 
ln  
Ai
 2Ri L 

 where Am is called the logarithmic mean area

Ao  Ai
Am 
ln AAoi   32
4.2 THE OVERALL HEAT TRANSFER COEFFICIENT

DOUBLE PIPE HEAT EXCHANGER

 Since:

1 1  1 
Uo    
Ao R Ao  1
Ai hi  k tAm  Ao ho 
1

1
1  Ao  t  Ao  1 
       
 hi  Ai  k  Am  ho 

33
4.2 THE OVERALL HEAT TRANSFER COEFFICIENT

DOUBLE PIPE HEAT EXCHANGER

 And since: Ao 2 Do L

Am 2 LDo  Di 
 2 Do L 
ln 
 2 Di L 
Do  Do 
 ln 
Do  Di  Di 
Do  Do 
 ln 
t  Di 
34
4.2 THE OVERALL HEAT TRANSFER COEFFICIENT

DOUBLE PIPE HEAT EXCHANGER

 Therefore substituting this in gives:
1
1  Do  Do  Do  1 
U o     ln   
 hi  Di  2k  Di  ho 
1
1  1 Di  Do  1  D0  
Ui    ln     
Ai R  hi 2k  Di  ho  Di  

35
4.2 THE OVERALL HEAT TRANSFER COEFFICIENT

DOUBLE PIPE HEAT EXCHANGER

 For a thin tube:

Do  Do 
t  0; 1 so ln  0
Di  Di 

1
1 1
 U i U o    
 hi ho 

36
 4.2 THE OVERALL HEAT TRANSFER COEFFICIENT

DOUBLE PIPE HEAT EXCHANGER

 When the tubes are finned on one side to enhance the heat
transfer, the total heat transfer surface area on the finned
side becomes:

As  Atotal  A fin  Aunfinned

Surface Area of fins Surface Area of

Unfinned portion

37
 4.2 THE OVERALL HEAT TRANSFER COEFFICIENT

DOUBLE PIPE HEAT EXCHANGER

 Forshort fins of high thermal conductivity, we can use
this total area in the convection resistance relation:
1 1
Rconv  
h As h A fin  Aunfinned 
 Since in this case the fins will be isothermal.
 Otherwise we should determine the effective surface

area from:
As  Aunfinned  fin A fin
38
4.2 THE OVERALL HEAT TRANSFER COEFFICIENT
DOUBLE PIPE HEAT EXCHANGER
EXAMPLE 4.1
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
(shell) is 3 cm. Water flows through the tube at 0.5 kg/s and oil
flows through the shell at 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.

39

See Example 11-1 from text book

OVERALL HEAT TRANSFER
COEFFICIENT
(EXAMPLE 4.1)

Assumptions:

1) Thermal resistance of the inner tube is negligible

since the tube is highly conductive and its
thickness is negligible.
2) Both oil and water flow are fully developed.
3) Properties of oil and water are constant.
40
OVERALL HEAT TRANSFER
COEFFICIENT
(EXAMPLE 4.1)

Properties of water at 45C (Table A-9):

 water 990 mkg 3 Prwater 3.91


k water 0.637 W
m C  water  0.602 10  6 m2
s

Properties of oil at 80C (Table A-16):

 oil 852 mkg 3 Proil 490

 6 m2
koil 0.138 W
m C  oil 37.5 10 s 41
OVERALL HEAT TRANSFER
COEFFICIENT
(EXAMPLE 4.1)

 Since the thickness is small:

1 1 1
 
U hi ho
 The hydraulic diameter for a circular tube is the diameter of the tube itself,
Dh, water = D = 0.02 m

 Therefore the mean velocity (Vm) for water is:

m water m water
Vm  
water 
 water Ac  water 14  Dh2, water 
0.5 kgs
 1. 61 m

990  
kg
m3
 4  0.02 m 
1 2
 s 42
OVERALL HEAT TRANSFER
COEFFICIENT
(EXAMPLE 4.1)

 The Reynolds number for the water is:

Vm Dh , water
Re water 
water


1.61 ms 0.02 m 
53,490
 water 0.602 10 s 6 m2

 Since Re > 4,000, which is the Recrit for a pipe, the flow of water is turbulent.
The Nusselt number is thus:
h Dh
Nu water  0.023 Re 0water
.8 0.4
Prwater
k water
0.023 53,490  3.91 240.6
0. 8 0.4
43
OVERALL HEAT TRANSFER
COEFFICIENT
(EXAMPLE 4.1)

 Then:
k water
hwater  Nu water
Dh , water
0.637 mW C
 240.6  7,663 m 2W C
0.02 m

44
OVERALL HEAT TRANSFER
COEFFICIENT
(EXAMPLE 4.1)
 Now we repeat the analysis for oil.

Dh ,oil Do  Di
0.03  0.02 0.01 m

 The mean velocity of the oil is:

m oil m oil
Vm ,oil  
 
 oil Ac  oil 14  Do2  Di2 
0.8 kgs
 2.39 m
852  
kg
m3
1
 2 2
 
 4   0.03  0.02 m 2 s

45
OVERALL HEAT TRANSFER
COEFFICIENT
(EXAMPLE 4.1)

 So the Reynolds number for oil is:

Vm ,oil Dh ,oil 2.39 ms 0.01 m 

Re oil    6 m2
637
 oil 37.5 10 s

 Recrit for oil in a pipe is higher, so the flow of oil is laminar.

 The Nusselt number can be found from Table 13-3 (in text) for D t/Ds= 0.667
as:

Nuoil 5.45
46
OVERALL HEAT TRANSFER
COEFFICIENT
(EXAMPLE 4.1)
 Therefore:
koil  0.138 mW C 
hoil  Nuoil   5.45 75.2 W
2
m  C
Dh ,oil  0.01 m 

since 1 1 1
 
U hi ho

 Then the overall heat transfer coefficient (U) for this heat
exchanger becomes:1 1
U  74.5 m 2  C
W
1 1 1 1
  47
hi ho 7,663 m 2  C 75.2 m 2W C
W
FOULING FACTOR
 The fouling factor represents the
theoretical resistance to heat flow due to a
build up of a layer of dirt or
other fouling substance on the tube
surfaces of the heat exchanger

48
 4.2 THE OVERALL HEAT TRANSFER COEFFICIENT
DOUBLE PIPE HEAT EXCHANGER

EFFECT OF FOULING
 The performance of heat exchangers usually deteriorates
with time as a result of the accumulation of deposits on heat
transfer surfaces.
 The layer of deposits represents additional resistance to heat
transfer and causes Q to decrease.
 The net effect is represented by the fouling factor (Rf) which
is a measure of the thermal resistance introduced by fouling.

49
 4.2 THE OVERALL HEAT TRANSFER COEFFICIENT
DOUBLE PIPE HEAT EXCHANGER

EFFECT OF FOULING
 If we define the fouling factors on the inside and the outside
surface to be Rfi and Rfo, respectively. Then the total thermal
resistance (R) with fouling and the overall heat transfer
coefficient becomes:
R R
1 fi t fo 1
R    
Ai hi Ai k Am Ao Ao h0
1
1  Do   Do  Do  Do  1
U o     R fi    ln   R fo  
 hi  Di   Di  2k  Di  ho 

 Generally, Uo is low for a fluid with low k-values (for example50

gases and oils).
4.2 THE OVERALL HEAT TRANSFER COEFFICIENT
DOUBLE PIPE HEAT EXCHANGER
EXAMPLE 4.2
 A double-pipe (shell and tube) heat
exchanger is constructed of a stainless
steel inner tube with inner diameter
(Di) of 1.5 cm and outer diameter (Do)
of 1.9 cm. and an outer shell of inner
diameter 3.2 cm.

 For the convection values and fouling

factors given, determine the thermal
resistance of the heat exchanger and
heat transfer coefficients Ui and Uo.

51

See Example 11-2 from text book

EFFECT OF FOULING
(EXAMPLE 4.2)

 The areas are:

Ai  Di L  0.015 m 1 m  0.0471 m 2

Ao  Do L  0.019 m 1 m  0.0597 m 2

 The thermal resistance is:

1 1 1
R   
U As U i Ai U o Ao


1

R f ,i

ln   R
Do
Di

1
f ,o

hi Ai Ai 2 kL Ao ho Ao
52
EFFECT OF FOULING
(EXAMPLE 4.2)
 Therefore:

R 
1
 
D
R f ,i ln Doi

 
R f ,o

1
hi Ai Ai 2 kL Ao ho Ao
2
1 0.0004 m W C
  
800 W
2
m  C

 0.0471 m 2
 0.0471 m 2

 0.019 m 
ln  m 2  C
 0 . 015 m   0 .0001 1
 W

2 15.1 m C 1 m  0.0597 m
W 2
1200  W
2
m  C

 0.0597 m 2 

0.02654  0.00849  0.0025  0.00168  0.001396WC

0.0532 WC
53
4.3 LOG MEAN TEMPERATURE DIFFERENCE (LMTD) METHOD
& CORRECTION
ANALYSIS OF HEAT EXCHANGER

 The first law of

thermodynamics requires
that the heat transfer to the
cold fluid must be equal to the
heat transfer from the hot
Q m c C pc Tc ,out  Tc ,in 
fluid.


Q m h C ph Th ,in  Th ,out 

 Where the subscripts c and h

stand for cold and hot.
54
4.3 LOG MEAN TEMPERATURE DIFFERENCE (LMTD) METHOD
& CORRECTION
ANALYSIS OF HEAT EXCHANGER
 In heat exchanger analysis it is convenient to combine
the product of the mass flow and the specific heat of a
fluid into a single quantity called the heat capacity rate.

Cc m c c pc
C h m h c ph

Q Cc Tc ,out  Tc ,in 

Q C T  T 
h h ,in h ,out 55
 4.3 LOG MEAN TEMPERATURE DIFFERENCE (LMTD) METHOD
& CORRECTION
ANALYSIS OF HEAT EXCHANGER
 Consider an incremental area of the heat exchanger surface (as shown for
either a counter-flow or parallel flow heat exchanger).

Th,in dA Th,in Hot dA

Hot Th,out ΔTo Th,out

ΔTo Cold
Cold ΔTL
Tc,out ΔTL
Tc,out
Tc,in Tc,in

Parallel Flow Counter-flow

56
4.3 LOG MEAN TEMPERATURE DIFFERENCE (LMTD) METHOD
& CORRECTION
ANALYSIS OF HEAT EXCHANGER
 The heat transfer over the area (dA) can be expressed in three ways:

1) The heat flow between hot fluids:

dQ U dA T

2) The heat gain by the cold fluid:

dQ Cc dTc

3) The heat given up by the hot fluid:

dQ  Ch dTh 57
4.3 LOG MEAN TEMPERATURE
DIFFERENCE (LMTD) METHOD

 However, since the temperature difference (ΔT) between the

hot and cold fluids varies with distance along the heat
exchanger. It is convenient to use a mean temperature
difference (ΔTm) between the hot and cold fluids, so that:

Q  A U Tm

58
4.3 LMTD METHOD

 Consider a parallel double-pipe

heat exchanger. The heat
transfer on each fluid in the
differential section can be
expressed as:
Q  Ch dTh
Q  Cc dTc

59
4.3 LMTD METHOD

 Solving these equations gives:

Q Q
dTh  dTc 
Ch Cc
 Taking their difference gives:
 1 1 
dTh  dTc d Th  Tc   Q 
  
 C h Cc 

60
4.3 LMTD METHOD
 The rate of heat transfer in the differential section can be
expressed as:
Q U Th  Tc dA
 Substituting this into the previous equations gives:

d Th  Tc   1 1 
 U dA   
Th  Tc  C h Cc 

61
4.3 LMTD METHOD
 Integrating from the inlet to the heat exchanger to its outlet, we
get:

d Th  Tc 
L L
 1 1

0
Th  Tc
 U    dA
 C h Cc  0

+ For parallel-flow
- For counter-flow

62
 4.3 LMTD METHOD
 Solving the integral for parallel flow
(where ΔT1=Th,in-Tc,in and ΔT2=Th,out-Tc,out) we get:

   T2   
 
 Th ,out  Tc ,out   1 1 
ln  U A   
 Th ,in  Tc ,in   C h Cc 
     
 T1 
 T2   C h  Cc   Cc 1 C h 1 
ln   U A    U A     
 T1   Ch Cc   C h Cc Cc C h 
63
4.3 LMTD METHOD

• Since:

Cc  Th ,out  Th ,in  Ch Tc ,out  Tc ,in

 and 
Ch Tc ,out  Tc ,in Cc  Th ,out  Th ,in 

• Then:

 T2     Th ,out  Th ,in  1 Tc ,out  Tc ,in 1 

ln   U A      
  Tc ,out  Tc ,in  Cc  Th ,out  Th ,in  Ch 
 
 T1 
64
4.3 LMTD METHOD
 Solving:

 T2    Th ,out  Th ,in Tc ,out  Tc ,in 

ln   U A 
   
T
 1  Q Q 
  Th ,out  Tc ,out  Th ,in  Tc ,in 
 U A   
 Q 
 T2  T1 
U A   
 Q 
65
4.3 LMTD METHOD
 Therefore:

 
 
  T2  T1 
Q U A  U A Tm
  T2  
 ln  
  T1  
    
Tm
Mean temperature

66
 This is the log mean temperature difference
4.3 LMTD METHOD
 The log mean temperature difference method (LMTD) can be used for both
parallel and counter-flow heat exchangers, if the following terms are used for
ΔT:

Parallel Heat Exchangers Counter-flow/ Cross Flow

Heat Exchangers
67
4.3 LMTD METHOD
CORRECTION FACTORS

The LMTD method is strictly limited to single pass, parallel and
counter-flow heat exchangers only.
 However, similar relations are also developed for cross-flow and
multi-pass shell and tube heat exchangers, but these are very
complicated expressions.

 In these cases it is more convenient to relate the equivalent temperature

difference relation for the counter-flow case as:

Tm F TLMTD ,
counter  flow

Correction factor Log Mean Temperature Difference68

for counter-flow heat exchanger
 4.3 LMTD METHOD
CORRECTION FACTORS
 Correction factor (F) is depends on the geometry of the HE and
the inlet and outlet temperatures of the hot and cold fluid stream.
 Available from standard charts for several common configurations.

 The correction factor, F for common shell and tube and cross-flow
heat exchangers versus two temperature ratios P and R:

For condenser and boiler , F =1

t 2  t1
P
T1  t1
T1  T2 m c p tube side
R  Subscript 1 and 2 = inlet and outlet
t 2  t1 m c p shell side
69

T and t = shell and tube side temperature

4.3 LMTD METHOD
CORRECTION FACTORS

See Figure 11-19 from Text Book 70

4.3 LMTD METHOD
EXAMPLE 4.3

Cooling water (Cpc=4.187 kJ/(kgK)) flows

through a two-shell passes, four-tube passes
heat exchanger at the rate of 2 kg/s and
temperatures at entry of 20C and exit at 80C.
Hot oil enters through the shell side of the heat
exchanger at 140C and leaves at 90C.
Calculate the heat exchanger surface area if
the overall heat transfer coefficient (U) is 300
W/(m2C).

71
 LMTD METHOD
(EXAMPLE 4.3)

Th,in= 140C

Tc,out= 80C

Tc,in= 20C

Th,out= 90C

72
 LMTD METHOD
(EXAMPLE 4.3)

 The LMTD is:

T1  T2
Tlmtd 
 T1 
ln 
 T2 

90 C  20 C  140 C  80 C 
64.9 C
 90 C  20 C 
ln 
 140 C  80 C 

73
 LMTD METHOD
(EXAMPLE 4.3)

 Parameters to use the LMTD correction chart:

Tc ,out  Tc ,in 80 C  20 C

P  0.5
Th ,in  Tc ,in 140 C  20 C

Th ,out  Th ,in 140 C  90 C

R  0.833
Tc ,out  Tc ,in 80 C  20 C

74
 LMTD METHOD
(EXAMPLE 4.3)

0.97

 From chart (Figure 11-19 in text) the value F= 0.97

75
 LMTD METHOD
(EXAMPLE 4.3)
 Therefore the surface area (A ) is:
s

m c C pc Tc ,out  Tc ,in 

As 
U F Tm


2 4.187
kg
s 80 C  20 C 
kJ
kg K

300 10 0.9764.9 C 

3 kW
m 2  C
2
26.6 m
(See Example 11-3 to 11-5 in text book)

76
4.4 THE EFFECTIVENESS ε-NTU
METHOD
 This method is useful when the LMTD method cannot be
determined. The required data may instead be determined
from the ε-NTU method charts of several common
configurations

 Definitions:
 The heat capacity of the cold stream is given by:

Cc m c c pc

 The heat capacity of the hot stream is given by:

Ch m h c ph
77
4.4 THE EFFECTIVENESS ε-NTU
METHOD

 The capacity ratio is defined as:

Cc
C ; if Ch  Cc
Ch
Ch
C ; if Ch  Cc
Cc

78
4.4 THE EFFECTIVENESS ε-NTU
METHOD
 The ε-NTU Method is based upon a dimensionless paramater, Heat
Transfer Efectiveness, ε :

Q Actual heat transfer rate

 
Qmax Maximum possible heat transfer rate
 For counter-flow heat exchangers, the actual heat transfer rate may be
written either from the cold stream or from the hot stream as:

Q Cc Tc ,out  Tc ,in  Ch Th ,in  Th ,out 

Where and
Cc m c c pc Ch m h c ph
79
4.4 THE EFFECTIVENESS ε-NTU
METHOD

 The maximum temperature difference possible in a heat

exchanger is:
Tmax Th ,in  Tc ,in
 The heat transfer in the heat exchanger will reach its maximum
value when:
1) The cold fluid is heated to the inlet temperature of the hot fluid.

2) The hot fluid is cooled to the inlet temperature of the cold fluid.

80
 4.4 THE EFFECTIVENESS ε-NTU
METHOD
 However, these two things cannot happen simultaneously unless:
Cc=Ch

 But if Cc ≠ Ch as is normally the case, the fluid with the smaller

heat capacity will experience the larger temperature change and
thus will be the first to experience maximum temperature, at
which point heat transfer will come to a halt.

81
4.4 THE EFFECTIVENESS ε-NTU
METHOD
 Therefore, the maximum possible heat transfer rate
in heat exchanger is:

Q max Cmin Th ,in  Tc ,in 

where : Cmin is the smaller of Cc or Ch

82
4.4 THE EFFECTIVENESS ε-NTU
METHOD
Q Actual heat transfer rate
 
Qmax Maximum possible heat transfer rate

 Therefore the heat exchanger effectiveness for a counter-

flow heat exchanger is:

Cc Tc ,out  Tc ,in 


Cmin Th ,in  Tc ,in 

Ch Th ,in  Th ,out 


Cmin Th ,in  Tc ,in 
83
4.4 THE EFFECTIVENESS ε-NTU
METHOD

NTU – Number of Heat Transfer Unit

 The NTU is a measure of physical size of the heat exchanger; the
larger the NTU, the larger heat exchanger size. It is defined as
the ratio of the heat capacity of the heat exchanger to the
minimum heat capacity of the flow.

As U U As
NTU  
Cmin m C p min
84
4.4 THE EFFECTIVENESS ε-NTU
METHOD
(STEP-BY-STEP PROCEDURE)
The ε-NTU Method Procedure

1) Determine Cmin and Cmax from m c of the streams and
p
calculate the capacity ratio C.

Cmin
c
Cmax

85
4.4 THE EFFECTIVENESS ε-NTU
METHOD
(STEP-BY-STEP PROCEDURE)
2) Determine:

U As
NTU 
Cmin

Cc Tc ,out  Tc ,in  Ch Th ,in  Th ,out 

 
Cmin Th ,in  Tc ,in  Cmin Th ,in  Tc ,in 

86
4.4 THE EFFECTIVENESS ε-NTU
METHOD
(STEP-BY-STEP PROCEDURE)
3) Charts

Knowing ε, NTU, and C use the

chart (Figure 11-27 in the text)
to determine U and As in
question.

OR from standard derivation Tables

11-4 & 11-5

87
4.4 THE EFFECTIVENESS ε-NTU
METHOD
(STEP-BY-STEP PROCEDURE)
4) Compute the heat transfer rate:

Q  Cmin Th ,in  Tc ,in 

88
4.4 THE EFFECTIVENESS ε-NTU
METHOD
(STEP-BY-STEP PROCEDURE)
5) Calculate the outlet temperature:

Q
Th ,out Th ,in 
Ch
Q
Tc ,out Tc ,in 
Cc

89
4.3 LMTD METHOD
EXAMPLE 4.4
 Alcohol is to be cooled at a rate of 0.2 kg/s from 75C to 35C
in a counter-flow heat exchanger. Cooling water enters the
heat exchanger at 12C at a rate of 0.16 kg/s. The convective
coefficient between alcohol and the tube wall and water is
0.34 kW/(m2K) and between the tube wall and water is 0.225
kW/(m2K). The tube may be assumed to be thin. The specific
heat for the alcohol is 2.52 KJ/(kgK) and water is 4.187
KJ/(kgK).
 Calculate the capacity ratio (C), effectiveness (ε), and heat
exchanger surface area (As).
90
4.4 THE EFFECTIVENESS ε-NTU METHOD
EXAMPLE 4.5
A single, pass counter-flow shell-and-tube heat exchanger is
used to cool hot mercury (Cph=1.37 kJ/(kgK)) from 110C to
70C flowing at a rate of 1 kg/s with water (Cpc=4.187 kJ/(kgK))
entering at 30C and flowing at a rate of 0.2 kg/s. Calculate the
heat transfer surface area required and the exit temperature of
the water if the overall heat transfer coefficient (U) is 250
kW/(m2K).

91
TUTORIAL

1) 11.53
2)11.54
3) 11.55
4) 11.60
5) 11.63
6) 11.86
7) 11.88
8) 11.103
9) 11.107
10) Past Final Exam Questions

92
 4.5 HEAT EXCHANGER DESIGN &
CONSIDERATIONS
 Some design considerations are:
 Heat transfer rate
 This is the most important quantity. A heat exchanger must be capable of
transferring heat at a specified rate in order to achieve the desired
temperature change of the fluid at a specified mass flow rate.

 Cost
 Budgetary limitations always play an important role. Operating and
maintenance costs are also a factor.

 Pumping Power
 The fluids are normally forced by pumps or fans which require a pump with
associate electrical costs.

93
4.5 HEAT EXCHANGER DESIGN &
CONSIDERATIONS
 Size and weight
 Normally the smaller and lighter, the better. This is especially true for
automotive and aerospace industries.

 Type
 The type of heat exchanger depends on the requirements, fluids
involved, size and weight limitations etc.

 Materials
 The materials in the heat exchanger construction may be an important
consideration, especially if thermal stresses are an issue.

94
 REFERENCES

1. Yunus A. Cengel, Heat and Mass Transfer A Practical

Approach, McGraw Hill, 3rd Edition, 2007

2. Yunus A. Cengel, Introduction to Thermodynamics and Heat

Transfer, McGraw-Hill, 2008.

3. Incropera et.al., Heat and Mass Transfer, John Wiley, 6th

Edition, 2007.

4. J.P.Holman, Heat Transfer, McGraw-Hill, 10th Edition,2010.

5. P.K.Nag, Heat Transfer, Tata McGraw-Hill, 2003.

95