CHAPTER 6

Overall Heat Transfer Coefcient and

Temperature Prole
Contents
6.1 Calculation of the Overall Heat Transfer Coefcient 79
6.2 Calculation of the Temperature Gradient in a Heat Exchanger 84
6.3 Viscosity Correction 86
Calculation procedure 86
6.4 Calculation of the Heat Transfer Coefcient from the Overall Heat Transfer Coefcient 88
Nomenclature 89
References 89

6.1 CALCULATION OF THE OVERALL HEAT TRANSFER

COEFFICIENT [1e10]
The equation for the heat transfer is as follows:

Q
Q U " A " LMTD A
U " LMTD

Normally the required heat exchanger surface area A is calculated for a given problem
denition. The amount of heat Q to be transferred will result from the problem
denition.
Likewise, the logarithmic mean temperature difference, LMTD, or for nonideal
countercurrent ow the corrected mean effective temperature difference (CMTD).
The main problem lies in establishing the heat transfer coefcients on the tube and
shell side of the heat exchanger.
If the heat transfer coefcients are known, the overall heat transfer coefcient can be
established.
Without considering the different areas on the inside and outside of the heat
exchanger tubes and the fouling and the conduction through the tube wall the following
Ua-value follows from the two heat transfer coefcients:
1 ai " ao
Ua 1 1
ai ao ai ao

Heat Exchanger Design Guide 2016 Elsevier Inc.

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80 Heat Exchanger Design Guide

Example 1: Calculation of Ua from the heat transfer coefcients

Data: ai 620 W/m2 K ao 699 W/m2 K
620 " 699 !
Ua 328 W m2 K
620 699
Alternatively the overall heat transfer coefcient Ua can be determined from the diagram in Figure 6.1.

Figure 6.1 Diagram for the determination of Ua from the a-values.

Example 2:
Data: ai 4000 W/m2 K ao 1500 W/m2 K
4000 " 1500 !
Ua 1091 W m2 K
4000 1500
The good heat transfer coefcient in the tube does not help much. The overall heat transfer coefcient
is always determined by the worse heat transfer coefcient.
The inner heat transfer coefcient ai must be converted to aio because with plain tubes the heat
exchanger surface area generally refers to the outer area of the tube.
di Ai " ! 2 #
aio ai " ai " W m K
do Ao

Example 3: Conversion of ai to the outside area

Data: ai 620 W/m2 K di 16 mm da 20 mm
16 ! 2
aio 620 " 496 W m K
20
The heat transfer coefcient aio is the tube side heat transfer coefcient based on the outside area of
the tubes.
 Overall Heat Transfer Coefcient and Temperature Prole 81

Next the heat conduction through the tube wall is to be considered especially with tube materials hav-
ing bad heat conductivity l, for instance, stainless steel.
1 " ! 2 #
Uclean 1 W m K
aio a1o ls

Example 4: Calculation of Uclean

Data: aio 496 W/m2 K ao 699 W/m2 K s 2 mm l 56 W/m K
1 !
Uclean 1 1 0:002
287 W m2 K
496 699 56

If chromiumenickelesteel is used with a heat conductivity of 16 W/m K, this deteriorates the overall
heat transfer coefcient.
1 !
Uclean 1 1 0:002
280 W m2 K
496 699 16

Finally, the fouling fi on the tube inside and fa on the tube outside have to be considered.
1 1 " ! 2 #
Udirty 1 W m K
aio a1o ls fi fa 1
Uclean fi f a

The fouling is dependent on the products, the operation period, the ow velocity, and the performed
cleanings. The values for the fouling fi on the tube inside and fa on the shell side lie in the range of 0.0001
e0.001 m2 K/W depending on the problem denition.
<1 m/s >1 m/s
Material <50 $C >50 $C <50 $C >50 $ C

Drinking water 0.0002 0.0004 0.0002 0.0004

Distilled water 0.0001 0.0001 0.0001 0.0001
River water 0.0006 0.0008 0.0004 0.0006
Cooling water 0.0002 0.0004 0.0002 0.0004
Brackish water 0.0004 0.0006 0.0002 0.0004
Sea water 0.0001 0.0002 0.0001 0.0002
Vessel-desalted water 0.0004 0.0004 0.0004 0.0004
Material f (m2 K/W)
Fuel oil 0.001
Lubricating oil 0.0002
Thermal oil 0.0002
Vegetable oil 0.0006
Organic liquids 0.0002
Organic vapors 0.0001
Diesel-exhaust gas 0.002
Oil-free vapor 0.0001
Oil-rich vapor 0.0002
Air 0.0004
82 Heat Exchanger Design Guide

The values are valid for an operation period of 1 year.

If the tubes will be coated for corrosion reasons, the heat conductivity resistance of the coating must
be additionally considered.

Example 5: Calculation of Udirty

Data: aio 496 W/m2 K ao 699 W/m2 K s 2 mm l 56 W/m K
fi 0.0002 m2 K/W fa 0.0002 m2 K/W Uclean 287 W/m2 K
1 !
Udirty 1 1 0:002
257 W m2 K
496 699 56 0:0002 0:0002
1 !
Udirty 1 257 W m2 K
287 0:0002 0:0002

It might be interesting to establish the fouling reserve of a new heat exchanger.

Thereby, the determined Uclean-value from the two heat transfer coefcients and the heat conduction
through the tubes is compared with that Ureq-value required for the problem denition.
X Uclean % Ueq
f
Uclean " Ureq

Example 6: Calculation of the existing fouling reserve Sf

Data: aio 496 W/m2 K ao 699 W/m2 K Uclean 287 W/m2 K
s 2 mm l 56 W/m K Ureq 230 W/m2 K
X Uclean % Ueq 287 % 230 m2 K
f 0:0009
Uclean " Ureq 287 " 230 W
In this case, for both fouling values fi fa 0.0004 m2 K/W is used so that an additional fouling reserve
of 0.0009 % 0.0004 0.0005 m2 K / W is available.

Inf luences of fouling

In Figure 6.2 it is shown that a good overall heat transfer coefcient Uclean is more highly reduced through
fouling than a bad overall heat transfer coefcient Uclean.
Through the fouling the U-values are leveled.
The calculations so far are based on the assumption of plain walls.
If the tube form in shell and tube heat exchangers is considered, then the following exact equation for
the overall heat transfer coefcient Uex in tubes results:
1
Uex $ %
fi " a1i " ddoi 2"l
do
" ln ddoi a1o fa
 Overall Heat Transfer Coefcient and Temperature Prole 83

Figure 6.2 The fall of the overall heat transfer coefcient with increasing fouling.

Example 7: Calculation of Uex for the data of Example 5

1 !
Uex & ' 254 W m2 K
1
0:0002 " 620 " 20 0:02 20 1
16 2"56 " ln 16 699 0:0002

The overall heat transfer coefcient Uex for tubes is a little bit lower, but the difference between Uex and
Udirty is small, so that a simple equation for plain walls can be used for the calculation.

Recommended calculation procedure

1. Calculation of the heat transfer coefcients ai in the tube and ao on the shell side
2. Correction of ai to aio: aio ai " ddoi W=m2 K
1 2
3. Calculation of Uclean: Uclean 1 1 s W=m K
aio ao l
1
4. Calculation of Udirty Udirty 1 W=m2 K
Uclean fi fa
P U % Ueq
5. Calculation of the fouling reserve of the new heat exchanger: f clean
Uclean " Ureq

Example 8: Calculation of the overall heat transfer coefcient and the fouling
reserve
Data: ai 620 W/m2 K ao 699 W/m2 K s 2 mm l 56 W/m K
di 16 mm do 20 mm fi fa 0.0002 m2 K / W Ureq 230 W/m2 K
16 !
aio 620 " 496 W m2 K
20
1 !
Uclean 1 1 0:002
287 W m2 K
496 699 56
84 Heat Exchanger Design Guide

1 !
Udirty 1 257 W m2 K
287 0:0002 0:0002
X Uclean % Ueq 287 % 230 m2 K
f 0:0009
Uclean " Ureq 287 " 230 W
A clear fouling reserve of 0.0005 m2 K / W is available.
Often it can be worthwhile for the selection or the design of a heat exchanger to calculate the overall
heat transfer coefcient per meter of the heat exchanger and consequently determine the required total
length. The corresponding equation for the calculation of the overall heat transfer coefcient UL per meter
tube is as follows:
p
UL 1 1 " ln do 1 fi fa
W=m K
ai "di 2"l di ao "do di do

From UL the required total length Lreq is calculated for a certain heat load Q as follows:
Q
Q UL " Lreq " CMTD W Lreq m
UL " CMTD

Example 9: Calculation of the overall heat transfer coefcient per meter heat
exchanger length
Data: ai 620 W/m2 Kao 699 W/m2 K s 2 mm l 56 W/m K
di 16 mm do 20 mm fI fa 0.0002 m2 K / W
Q 180,000 W LMTD 51 K
p
UL 15:96 W=m K
1 1 20 1 0:0002 0:0002
" ln
620 " 0:016 2 " 56 16 699 " 0:02 0:016 0:02
180; 000
Lreq 221 m
15:96 " 51

6.2 CALCULATION OF THE TEMPERATURE GRADIENT IN A HEAT

EXCHANGER
The temperature fall in the individual overall heat transfer resistances can be calculated
using the heat ux density q (W/m2):
l 1
q Udirty " Dttot ao " Dto aio " Dti " Dtwall " Dtfi
s fi
1 " ! #
" Dtfa W m2
fa
q q s
Dto Dti Dtwall q " Dtfi q " fi Dfa q " fa
ao aio l
1 1

Udirty ao
 Overall Heat Transfer Coefcient and Temperature Prole 85

Example 10: Calculation of the temperature gradient in the overall heat transfer
resistances
Data: ao 699 W/m2 K ai 620 W/m2 K l 56 W/m K
fa 0.0002 fi 0.0002 s 2 mm
Dttot 20 $ C LMTD di 20 mm do 25 mm
20 !
aio 620 " 496 W m2 K
25
1 1 1 0:002 !
0:0002 0:0002 0:0039 Udirty 257:6 W m2 K
Udirty 699 496 56
!
q U " Dttot 257:6 " 20 5151 W m2
q 5151 q 5151
Dto 7:4 $ C Dti 10:4 $ C
ao 699 aio 496
s 0:002
Dtwall q " 5151 " 0:2 $ C
l 56
Dtfi q " fi 5151 " 0:0002 1 $ C Dtfa q " fa 5151 " 0:0002 1 $ C
Check : Dttot 7:4 10:4 1 1 0:2 20 $ C
The calculated temperature fall is shown in Figure 6.3.
Outside fouling

tube
Inside fouling

wall

to = 7,4 C

tfa = 1,0 C

tWall = 0,2 C

tfi = 1,0 C

ti = 10,4 C

Figure 6.3 Calculation of the temperature gradient in the heat exchanger.

86 Heat Exchanger Design Guide

6.3 VISCOSITY CORRECTION

The viscosity has a predominant inuence on the thickness of the laminar border lm on
the wall and this border layer determines the heat transfer coefcient. The higher the vis-
cosity on the wall, thicker is the border lm and worse the heat transfer coefcient.
The correction of the calculated heat transfer coefcient am for the average product
temperature tm follows from the viscosity ratio of the product at average uid tempera-
ture and at wall temperature tW.
akorr F " am
& '0:14
hm hm
Cooling : <1 F
hW hW
& '0:14
hm hW
Heating : >1 F
hW hm
akorr corrected heat transfer coefcient (W/m2 K)
am calculated a-value at tm (W/m2 K)
F correction factor
hm viscosity at tm (mPas)
hW viscosity at wall temperature tW (mPas)
The wall temperature is smaller for cooling than the average product temperature and
the viscosity increases. This deteriorates the heat transfer coefcient.
It is the opposite for heating. The lower viscosity on the wall improves the heat trans-
fer coefcient.

Calculation procedure
1. Calculation of the heat transfer coefcient at average product temperature tm
tin tout
tm
2
tin inlet temperature ($ C)
tout outlet temperature ($ C)
2. Determination of the wall temperature tw
Cooling : tw tm % Dt $ C
Heating : tw tm Dt $ C
Calculation of the temperature difference Dt between tm and tW (see Chapter 6.2)
q $
Dt C
am
 Overall Heat Transfer Coefcient and Temperature Prole 87

q heat f lux density (W/m2)

3. Derivation of the viscosity at the calculated wall temperature
4. Calculation of the viscosity correction F

Example 11: Calculation of the viscosity correction at thin media

Data: aio 336 W/m2 K ao 700 W/m2 K U 202.11 W/m2 K
LMTD 16.83 $ C q 3401.92 W/m2
Shell side: Water 25 $ C 30 $ C tm 27.5 $ C
3401:92
Dto 4:9 $ C
700
tw 27:5 4:9 32:4 $ C
The wall temperature is higher at the shell side than the average product temperature and the viscosity
is smaller.

Tube side: Isopropanol 70 $ C 30 $ C tm 50 $ C

3401:92
Dti 10:1 $ C
336
tw 50 % 10:1 39:9 $ C
The wall temperature is smaller than the average product temperature and the viscosity on the wall is
higher.
From Figure 6.4 the viscosities of water on the shell side and isopropanol in the tubes at different tem-
peratures are taken.

Figure 6.4 Dynamic viscosity of some liquids as function of the temperature.

Water: At 27.5 $ C hm 0.89 mPas At 32.4 $ C hW 0.8 mPas

& '0:14 & '0:14
hm 0:89
1:01
hW 0:8
88 Heat Exchanger Design Guide

!
akorr 1:01 " 336 339 W m2 K

The lower viscosity at the wall improves the heat transfer coefcient.

Isopropanol: At 50 $ C hm 1.08 mPas At 39.9 $ C hW 1.37 mPas

& '0:14 & '0:14
hm 1:08
0:97
hW 1:37
!
akorr 0:97 " 700 679 W m2 K

The higher viscosity on the wall worsens the heat transfer coefcient.

Example 12: Calculation of the viscosity correction for a high viscous oil
aio 50 W/m2 K ao 1500 W/m2 K U 47.15 W/m2 K tm 70 $ C
LMTD 15 $ C q 707.229 W/m2
707:229
Dt 14:1 $ C tw 70 % 14:1 55:9 $ C
50
hm 110 mPas at 70 $ C hW 192 mPas at 55:9 $ C
& '0:14 & '0:14
hm 110 !
0:925 akorr 0:925 " 50 46:2 W m2 K
hW 192
!
U 43:8 W m2 K

Due to the high viscosity of the oil on the wall, the heat transfer coefcients and the overall heat trans-
fer coefcients become worse.

6.4 CALCULATION OF THE HEAT TRANSFER COEFFICIENT FROM THE

OVERALL HEAT TRANSFER COEFFICIENT
The following equation is valid for the overall heat transfer coefcient.
1 1 1 s
fi fa
Udirty ai ao l
After a simple conversion, the heat transfer coefcients can be determined.
1 1 1 s 1 1 1 s
% % % fi fa % % % fi fa
ai Udirty ao l ao Udirty ai l
 Overall Heat Transfer Coefcient and Temperature Prole 89

Example 13: Determination of the a-values from the overall heat transfer
coefcient U
Data: U 300 W/m2 K aa 1000 W/m2 K fi fa 0.0004 s/l 0.00014
1 1 1 ! 2
% % 0:00014 % 0:0004 ai 557:6 W m K
ai 300 1000
1 1 1 !
% % 0:00014 % 0:0004 ao 1000 W m2 K
ao 300 557:6

Kontrolle
1 1 1 s 1 1 !
fi fa 0:00014 0:0004 U 300 W m2 K
Udirty ai ao l 557:6 1000

NOMENCLATURE
A area of the exchanger (m2)
ai tube-side heat transfer coefcient (W/m2 K)
aio ai based on the outer area (W/m2 K)
ao shell-side heat transfer coefcient (W/m2 K)
di tube inner diameter (m)
do tube outer diameter (m)
fi inner fouling resistance (m2 K/W)
fa outer fouling resistance (m2 K/W)
U general overall heat transfer coefcient (W/m2 K)
Ua overall heat transfer coefcient calculated from both a-values (W/m2 K)
Uclean overall heat transfer coefcient without fouling (W/m2 K)
Udirty overall heat transfer coefcient with fouling (W/m2 K)
Ureq required overall heat transfer coefcient (W/m2 K)
Uex overall heat transfer coefcient considering fouling tube form (W/m2 K)
UL overall heat transfer coefcient per meter tube (W/m2 K)
L heat conductivity of the tube material (W/m K)
L length of the heat exchanger tubes (m)
Lreq required total length of the tubes (m)
CMTD corrected effective mean temperature difference (K)
Q heat load (W)
s tube wall thickness (m)

REFERENCES
[1] D.Q. Kern, Process Heat Transfer, McGraw-Hill, NY, 1950.
[2] W.H. McAdams, Heat Transmission, McGraw-Hill, NY, 1954.
[3] Perrys Chemical Engineers Handbook, McGraw-Hill, 1984.
[4] G.F. Hewitt, G.L. Shires, T.R. Bott, Process Heat Transfer, CRC Press, Boca Raton, 1994.
[5] Lord, Minton, Slusser, Design of heat exchangers, Chem. Eng. 26 ( Jan. 1970).
90 Heat Exchanger Design Guide

[6] N.P. Chopey, Heat transfer, in: Handbook of Chemical Engineering Calculations, McGraw-Hill,
New York, 1993.
[7] V.D.I. Warmeatlas, 5. Aufkage, VDI-Verlag, Dusseldorf, 1988.
[8] F. Hell, Grundlagen der Warme ubertragung, VDI-Verlag, D usseldorf, 1982.
[9] W.M. Rohsenow, J.P. Hartnett, Handbook of Heat Transfer, McGraw-Hill, NY, 1973.
[10] E.R.G. Eckert, R.M. Drake, Heat and Mass Transfer, McGraw Hill, NY, 1959.