Heat Transfer/Heat Exchanger

How is the heat transfer?

Mechanism of Convection
Applications .
Mean fluid Velocity and Boundary layer and their effect on the rate of
heat transfer.
Fundamental equation of heat transfer
Logarithmic-mean temperature difference.
Heat transfer Coefficients.
Heat flux and Nusselt correlation
Simulation program for Heat Exchanger

How is the heat transfer?

Heat can transfer through materials and the surrounding
medium whenever temperature gradient exists until
thermal equilibrium is reached.
Heat transfer by:
Radiation
Conduction is the transfer of heat through materials by the
direct contact of matter
Convection is the transfer of heat by the motion of the fluid
(liquids and gases).
Natural convection
Forced Convection

Natural and forced Convection

Natural convection occurs whenever heat flows

between a solid and fluid, or between fluid
layers.
As a result of heat exchange
Change in density of effective fluid layers taken
place, which causes upward flow of heated
fluid.
If this motion is associated with heat transfer mechanism
only, then it is called Natural Convection

Forced Convection
If this motion is associated by mechanical means such as
pumps, gravity or fans, the movement of the fluid is
enforced.
And in this case, we then speak of Forced convection.

Heat Exchanger
A device whose primary purpose is the transfer of energy between two fluids

Applications of Heat Exchangers

Heat Exchangers
prevent car engine
overheating and
increase efficiency

Heat
exchangers are
used in AC and
furnaces

Heat exchangers are

used in Industry for
heat transfer

Basic Principles
Types
Open, Closed,

Double pipe heat exchanger

Concurrent

Countercurrent

Principle of Heat Exchanger

First Law of Thermodynamic: Energy is conserved.

0

0
0
0
dE

q
.h
.h
w
s e
generated
m
m

in
out
dt
out
in

Qh A.m h .C ph .Th
Qc A.m c .C pc .Tc

Control Volume

m .h m .h
in

out

COLD

HOT

Cross Section Area

Thermal Boundary Layer

THERMAL

Region III: Solid

Cold Liquid
Convection

BOUNDARY LAYER

Energy moves from hot fluid

to a surface (B-C) by
convection, through the wall
(C-D) by conduction, and
then by convection from the
surface to the cold fluid (D-E).

Ti,wall
A

dqx = hc (Tow -Tc ) dA

NEWTONS LAW OF
CCOLING

dqx = hh (Th -Tiw ) dA

To,wall
C

Tc

D
warm fluid

warm thermal BL

Temperature

Th

Region I : Hot LiquidSolid Convection

NEWTONS LAW
OF CCOLING

cold fluid

Region II : Conduction
Across Copper Wall

FOURIERS LAW

dT
dqx = -k
dr

 Velocity distribution and boundary layer

When fluid flow through a circular tube of uniform crosssuction and fully developed,
The velocity distribution depend on the type of the flow.
In laminar flow the volumetric flowrate is a function of the
radius.
r D/2

u2rdr

r 0

V = volumetric flowrate
u = average mean velocity

 In turbulent flow, there is no such distribution.

The molecule of the flowing fluid which adjacent to the
surface have zero velocity because of mass-attractive
forces. Other fluid particles in the vicinity of this layer,
when attempting to slid over it, are slow down by viscous
forces.
Boundary
layer

 Accordingly the temperature gradient is larger at the wall

and through the viscous sub-layer, and small in the
turbulent core.
Tube wall

qx hAT

heating

qx hA(Tw T)

Warm fluid

Metal
wall

Twh
cold fluid

Twc

qx

cooling
Tc

A(Tw T)

The reason for this is

1) Heat must transfer through the boundary layer by
conduction.
conductivity (k)
2) Most of the fluid have a low thermal
3) While in the turbulent core there are a rapid moving
eddies, which they are equalizing the temperature.

U = The Overall Heat Transfer Coefficient [W/m.K]

Region I : Hot Liquid
Solid Convection
Region II : Conduction

Across Copper Wall

Region III : Solid
Cold Liquid Convection

qx =

qx hhot .Th Tiw .A

qx

Th - Tc
R1 + R2 + R3

1
A.R

qx hc To,wall Tc Ao

qx U.A.Th Tc

kcopper.2L
r
ln o
ri

Th Tiw

qx
hh .Ai

ro
qx .ln
ri
To,wall Ti,wall
kcopper.2L

qx
To,wall Tc
hc .Ao

ro
ln

r
1
1
i

Th Tc qx

hh .Ai k copper.2L hc .Ao

ro
ro . ln

r
r
1

U o
hhot.ri
kcopper.ri
hcold

Calculating U using Log Mean Temperature

Hot Stream :

dqh m h .C ph .dTh

Cold Stream:

c .C .dTc
dqc m

d (T ) dTh dTc

T Th Tc

c
p

dq dqhot dqcold

1
1

d (T ) U .T .dA.

m .C h m .C c
c
p
h p

dq U .T .dA

T2

T1

T2

T1

dqh
dqc

d (T )

m .C h m .C c
c
p
h p

Th Tc A2
d (T )
. dA
U .

T
qc A1
qh

1
d (T )
1
U .

m .C h m .C c
T
c
p
h p

A2
. dA
A1

T
U . A.
Th Tc U . A Thin Thout Tcin Tcout
ln 2
q
q
T1

q U .A
Log Mean Temperature

T2 T1
T2
ln
T

Log Mean Temperature evaluation

m h .C ph .T3 T6 m c .C pc .T7 T10
T2 T1
TLn
U

T
A.TLn
A.TLn
ln 2
T1
COUNTER CURRENT FLOW

1 CON CURRENT FLOW

2
T3

T4

T6

T1

T1
T2

T6

Wall

T7

T2

T8
T9

T10

T10
T1

T4

T5

T2

T10
T1

T6

T3

T4

T2

T5

T3

T6

T9

T8
T7
Parallel Flow

T1 T T
in
h

in
c

T3 T7

T2 Thout Tcout T6 T10

T8

T7

T9

Counter - Current Flow

T1 T Tcout T3 T7
in
h

T2 Thout Tcin T6 T10

q hh Ai Tlm

2
T3

T4

T1

T6

T6

Wall
T2

T7

T8
T9
T10

DIMENSIONLESS ANALYSIS TO CHARACTERIZE A HEAT EXCHANGER

Nu = f (Re,Pr, L / D, mb / mo )
h.D
k

v.D. r

C p .

Further Simplification:

Nu = a.Re .Pr
b

Nu =

Can Be Obtained from 2 set of experiments

One set, run for constant Pr
And second set, run for constant Re

q=

A(Tw - T)

Empirical Correlation
For laminar flow
Nu = 1.62 (Re*Pr*L/D)

For turbulent flow

Nu Ln = 0.026. Re . Pr
0.8

1/ 3

mb
.
mo

Good To Predict within 20%

Conditions:
L/D > 10
0.6 < Pr < 16,700
Re > 20,000

0.14

Experimental
Apparatus
Switch for concurrent
and countercurrent
flow

Temperature
Indicator

Hot Flow
Rotameters

Cold Flow
rotameter

Heat
Temperature
Controller Controller

Two copper concentric pipes

Inner pipe (ID = 7.9 mm, OD = 9.5 mm, L = 1.05 m)
Outer pipe (ID = 11.1 mm, OD = 12.7 mm)

Thermocouples placed at 10 locations along exchanger, T1 through T10

Theoretical trend
y = 0.8002x 3.0841

Examples of Exp. Results

Theoretical trend
y = 0.026x

Experimental trend
y = 0.0175x 4.049

ln (Nu)

5.5
5
4 .5
4
3 .5

Experimental trend
y = 0.7966x 3.5415

3
2 .5
2
9 .8

10

10 .2

10 .4

10 .6

10 .8

250

11

200

Nus

ln (Re)

150
100

Theoretical trend
y = 0.3317x + 4.2533

50
0
150

ln (Nu)

4.8

2150

4150

6150

8150

10150

12150

Pr^X Re^Y

4.6
4.4

Experimental Nu = 0.0175Re0.7966Pr0.4622

4.2

Theoretical

4
0.6

0.8

ln (Pr)

1.2

1.4

Experimental trend
y = 0.4622x 3.8097

Nu = 0.026Re0.8Pr0.33

Effect of core tube velocity on the local and

over all Heat Transfer coefficients
Heat Transfer Coefficient Wm-2K-

35000
30000
25000
hi (W/m2K)
ho (W/m2K)
U (W/m2K)

20000
15000
10000
5000
0
0

4
-1

Velocity in the core tube (ms )