REPORT IN HEAT

EXCHANGERS
IN
ME 4103
(HEAT TRANSFER)
1st Semester 2016-2017
Central Philippine University
Submitted to:
Engr. Alejandro R. Manderico
Adviser
Submitted by:
Lonie Marie A.
Reyes
BSME-4

Heat Exchanger
The general function of a heat exchanger is to transfer heat from one fluid to
another. The basic component of a heat exchanger can be viewed as a tube with
one fluid running through it and another fluid flowing by on the outside. There are
thus three heat transfer operations that need to be described:
1. Convective heat transfer from fluid to the inner wall of the tube,
2. Conductive heat transfer through the tube wall, and
3. Convective heat transfer from the outer tube wall to the outside fluid.
Heat exchangers are typically classified according to flow arrangement and type of
construction. The simplest heat exchanger is one for which the hot and cold fluids
move in the same or opposite directions in a concentric tube (or double-pipe)
construction. In the parallel-flow arrangement of Figure 18.8(a), the hot and cold
fluids enter at the same end, flow in the same direction, and leave at the same end.
In the counterflow arrangement of Figure 18.8(b), the fluids enter at opposite ends,
flow in opposite directions, and leave at opposite ends.

Alternatively, the fluids may be in cross flow (perpendicular to each other), as

shown by the finned and unfinned tubular heat exchangers of Figure 18.9. The two
configurations differ according to whether the fluid moving over the tubes is
unmixed or mixed. In Figure 18.9(a), the fluid is said to be unmixed because the fins
prevent motion in a direction ( ) that is transverse to the main flow direction ( ).
In this case the fluid temperature varies with
and
. In contrast, for the
unfinned tube bundle of Figure 18.9(b), fluid motion, hence mixing, in the
transverse direction is possible, and temperature variations are primarily in the
main flow direction. Since the tube flow is unmixed, both fluids are unmixed in the
finned exchanger, while one fluid is mixed and the other unmixed in the unfinned
exchanger.

 Formulas for Heat Exchangers

1. Overall heat transfer coefficient,

2. Total

3.

, is

Heat transfer

is the logarithmic mean temperature difference

4. Final expression for the total heat transfer for a counterflow heat exchanger:

5. Efficiency of a Counterflow Heat Exchanger

 Types of Heat Exchanger

1. Double pipe heat exchanger - its simplest form is just one pipe inside
another larger pipe. One fluid flows through the inside pipe and the other
flows through the annulus between the two pipes. The wall of the inner
pipe is the heat transfer surface. The pipes are usually doubled back
multiple times as shown in the diagram at the left, in order to make the
overall unit more compact.

2. Shell and Tube heat exchangers it consist of a large number of small

tubes which are located within a cylindrical shell. The tubes are positioned
into the cylinder using a tube bundle or "tube stack" which can either
have fixed tube plates (permanently fixed to the body) or, in the case of
Thermex Heat Exchangers a floating tube stack which allows the tube
bundle to expand and contract with varying heat conditions as well as
allowing the tube bundle to be easily removed for servicing and
maintenance. Shell and tube heat exchangers are comprised of multiple
tubes through which liquid flows. The tubes are divided into two sets: the
first set contains the liquid to be heated or cooled. The second set
contains the liquid responsible for triggering the heat exchange, and
either removes heat from the first set of tubes by absorbing and
transmitting heat awayin essence, cooling the liquidor warms the set
by transmitting its own heat to the liquid inside. When designing this type
of exchanger, care must be taken in determining the correct tube wall
thickness as well as tube diameter, to allow optimum heat exchange. In
terms of flow, shell and tube heat exchangers can assume any of three
flow path patterns.

3. Plate Type Heat Exchanger it operates in very much the same way as a
shell and tube heat exchanger, using a series of stacked plates rather
than tubes. Plate heat exchangers are usually brazed or gasketed
depending on the application and fluids being used. Their compact
stainless steel construction makes them an ideal choice for use with
refrigerants or in food and beverage processing. Plate heat exchangers
consist of thin plates joined together, with a small amount of space
between each plate, typically maintained by a small rubber gasket. The
surface area is large, and the corners of each rectangular plate feature an
opening through which fluid can flow between plates, extracting heat from
the plates as it flows. The fluid channels themselves alternate hot and cold
fluids, meaning that heat exchangers can effectively cool as well as heat
fluidthey are often used in refrigeration applications. Because plate heat
exchangers have such a large surface area, they are often more effective
than shell and tube heat exchangers.

4. Regenerative Heat Exchanger - the same fluid is passed along both sides
of the exchanger, which can be either a plate heat exchanger or a shell
and tube heat exchanger. Because the fluid can get very hot, the exiting
fluid is used to warm the incoming fluid, maintaining a near constant
temperature. A large amount of energy is saved in a regenerative heat

exchanger because the process is cyclical, with almost all relative heat
being transferred from the exiting fluid to the incoming fluid. To maintain a
constant temperature, only a little extra energy is need to raise and lower
the overall fluid temperature.

5. Adiabatic Wheel Heat Exchanger - an intermediate fluid is used to store

heat, which is then transferred to the opposite side of the exchanger unit.
An adiabatic wheel consists of a large wheel with threads that rotate
through the fluidsboth hot and coldto extract or transfer heat.

6. Pillow Plate Heat Exchangers - it is commonly used in the dairy industry

for cooling milk in large direct-expansion stainless steel bulk tanks. The
pillow plate allows for cooling across nearly the entire surface area of the
tank, without gaps that would occur between pipes welded to the exterior
of the tank.

7. Spiral heat exchanger (SHE) it is a high-efficiency heat exchanger

suitable for steam-steam, steam-liquid and liquid-liquid heat transfer. It
adapts for chemical, petroleum, pharmacy, food, light-industry, textile,
metallurgy, steel rolling and coking industry etc.

8. Plate-fin heat exchanger it is a type of heat exchanger design that uses

plates and finned chambers to transfer heat between fluids. It is often
categorized as a compact heat exchanger to emphasise its relatively
high heat transfer surface area to volume ratio. The plate-fin heat
exchanger is widely used in many industries, including the aerospace
industry for its compact size and lightweight properties, as well as
in cryogenics where its ability to facilitate heat transfer with small
temperature differences is utilized.[1]

 Passes in Heat Exchanger

1. Heat Exchanger Pass refers to the movement of a fluid from one end of
the heat exchanger to the other.

Single Pass Fluid enters one end of the heat exchanger, and exits
at the other end.

Double Pass Fluid enters and exits the heat exchanger at the
same end.

Triple Pass Fluid travels the length of the heat exchanger body
three times before exiting.

A greater number of passes increases the amount of heat transfer available, but
can also lead to high pressure loss and high velocity.
The number of passes on the primary circuit can also be adjusted to optimise
thermal performance and efficiency by changing the baffle quantity and pitch.

Making the Heat Exchanger more efficient

Heat exchanger efficiency can be defined in many ways, in terms of
thermal performance there are several key factors to consider;
1. Temperature differential - the difference between the hot fluid and
coolant is very important when designing a heat exchanger. The
coolant always needs to be at a lower temperature than the hot fluid.
Lower coolant temperatures will take more heat out of the hot fluid
than warmer coolant temperatures. If you had a glass of drinking water
at room temperature for example, it is much more effective to cool it
down using ice rather than just cool water, the same principle applies
to heat exchangers.
2. Flow rate - Another important factor is the flows of the fluids in both
the primary and the secondary side of the heat exchanger. A greater
flow rate will increase the capability of the exchanger to transfer the
heat, but a greater flow rate also means greater mass, which can make
it more difficult for the energy to be removed as well as increasing
velocity and pressure loss.
3. Installation - The heat exchanger should always be installed based on a
manufacturer's guidelines. Generally speaking the most efficient way
to install a heat exchanger is with the fluids flowing in a countercurrent arrangement (so if the coolant is travelling left to right, the hot
fluid travels right to left) and for shell and tube heat exchangers the
coolant should enter at the lowest inlet position (as shown in the
diagrams above) to ensure that the heat exchanger is always full of
water. For air cooled heat exchangers it is important to consider the air

flow when installing a cooler, any part of the core which is blocked will
compromise cooling capacity.

Optimization
of
1.
2.
3.

There are three goals that are normally considered in the optimal design
heat exchangers:
Minimizing the pressure drop (pumping power)
Maximizing the thermal performance
Minimizing the entropy generation (thermodynamic)

Criteria in selecting an appropriate Heat Exchanger

1. High/low pressure limits
2. Thermal performance
3. Temperature ranges
4. Product mix (liquid/liquid, particulates or high-solids liquid)
5. Pressure drops across the exchanger
6. Fluid flow capacity
7. Cleanability, maintenance and repair
8. Materials required for construction
9. Ability and ease of future expansion
10.Material selection, such as copper, aluminum, carbon steel, stainless
steel, nickel alloys, ceramic, polymer, and titanium.

Fouling
Fouling occurs when impurities deposit on the heat exchange surface.
Deposition of these impurities can decrease heat transfer effectiveness
significantly over time and are caused by:
1.
2.
3.
4.
5.

Low wall shear stress

Low fluid velocities
High fluid velocities
Reaction product solid precipitation
Precipitation of dissolved impurities due to elevated wall
temperatures

The rate of heat exchanger fouling is determined by the rate of particle

deposition less re-entrainment/suppression. This model was originally
proposed in 1959 by Kern and Seaton.

Maintenance
Plate and frame heat exchangers can be disassembled and cleaned
periodically. Tubular heat exchangers can be cleaned by such methods as
acid cleaning, sandblasting, high-pressure water jet, bullet cleaning, or drill
rods.

In large-scale cooling water systems for heat exchangers, water

treatment such as purification, addition of chemicals, and testing, is used to
minimize fouling of the heat exchange equipment. Other water treatment is
also used in steam systems for power plants, etc. to minimize fouling and
corrosion of the heat exchange and other equipment.
A variety of companies have started using water borne oscillations
technology to prevent bio fouling. Without the use of chemicals, this type of
technology has helped in providing a low-pressure drop in heat exchangers.

Heat Exchangers Summary

Heat exchangers remove heat from a high-temperature fluid by

convection and conduction.

Counter-flow heat exchangers typically remove more heat than

parallel flow heat exchangers.

Parallel flow heat exchangers have a large temperature difference

at the inlet and a small temperature difference at the outlet.

Counter-flow heat exchangers have an even temperature difference

across the heat transfer length.

Regenerative heat exchangers improve system efficiency by

returning energy to the system.

A non-regenerative heat exchanger rejects heat to the

surroundings.

The heat transfer rate for a heat exchanger can be calculated using
the equation below.

Q=U o A o D T lm