HEAT TRANSFER

Heat Exchanger Design

Instructor: MSc. Trinh Ngoc Thao Ngan

Department of Food Engineering
Faculty of Food Science and Technology
 Heat Exchangers
• Various types and designs used by the food
industry
• Common Feature: transfer of heat from a hot
phase to a cold phase with the two phases
being separated by a solid (metal of high k)
boundary.

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 Double-pipe Heat Exchanger

• Noncontact-type heat exchanger, consisting of a pipe located

concentrically inside another pipe
• Two fluids flow in the annular space and in the inner pipe,
respectively.
• The streams may flow in the same direction (parallel flow =
concurrent flow) or in the opposite direction (countercurrent flow)
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 Shell and Tube Heat Exchanger

One of the fluid streams flows inside the tube while the other fluid
stream is pumped over the tubes through the shell.
By maintaining the fluid stream in the shell side to flow over the
tubes, rather than parallel to the tubes  higher rates of heat transfer.
Baffles located in the shell side allow the cross-flow pattern 4
 Plate-type Heat Exchanger

This heat exchanger consists of a series of parallel, closely spaced

stainless-steel plates pressed in a frame  turbulence flow
Gaskets (natural or synthetic rubber) seal the plate edges and ports
to prevent intermixing of liquids
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Double-pipe Heat Exchanger

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 DETAILS
Assumptions:
1. U is constant
2. Steady state flow (counter or concurrent)
3. Cp of both fluids is independent of temperature
4. Heat exchanger with the ambient is negligible

** Because the heat transfer occurs only between fluids H and C, the
decrease in the heat energy of fluid H must equal the increase in the
energy of fluid C  Energy balance:

𝒒̇ = 𝒎̇𝑯 𝒄𝒑𝒑 𝑻𝑯,𝒊𝒊𝒊𝒊𝒊 − 𝑻𝑯,𝒆𝒆𝒆𝒆 = 𝒎̇𝑪 𝒄𝒑𝒑 𝑻𝑪,𝒆𝒆𝒆𝒆 − 𝑻𝑪,𝒊𝒊𝒊𝒊𝒊

ṁ is mass flow rate of fluid (kg/s)

𝐶𝑝 is specific heat of a fluid (kJ/kgoC)
T is temperature (oC)
subscripts H and C indicated for heat and cold, respectively
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 DETAILS
𝑞̇ = 𝑈𝑈∆𝑇𝑙𝑙
where ΔTlm is the log mean temperature difference
ΔT1 and ΔT2 depends on the flows of fluid counter-current or parallel-flow

∆𝑇2 − ∆𝑇1
∆𝑇𝐿𝐿 =
∆𝑇2
𝑙𝑙
∆𝑇1 8
 Remember!!
• 𝑞̇ = 𝑈𝑈∆𝑇𝐿𝐿

• ∆𝑇𝑙𝑙 depends on the flow pattern, ∆𝑇𝑎𝑎𝑎𝑎𝑎𝑎𝑎 does not

• (∆𝑇𝑙𝑙 ) 𝑐𝑐𝑐𝑐𝑐𝑐𝑐 − 𝑐𝑐𝑐𝑐𝑐𝑐𝑐 > (∆𝑇𝑙𝑙 ) 𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐
(A) counter-current < A (concurrent)
• If ∆𝑇1 = ∆𝑇2  ∆𝑇𝑙𝑙 = ∆𝑇1 = ∆𝑇2
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Examples
A liquid food (𝐶𝑝 = 0.93 Btu/lbºF) at 120ºF is flowing at a rate of 3000
lb/hr through a tube of 1 inch i.d. placed in a stirred bath of constant 50ºF
where it is cooled down to 65ºF. If the overall heat transfer coefficient
from the bath to the food is assumed to be 160 Btu/hr-ft2-ºF, what length
of pipe would be required ?
Solution
𝑙𝑙 𝐵𝐵𝐵
𝑞𝑓̇ = 𝑚𝑓̇ 𝐶𝑝 f 𝑇𝑓,𝑖𝑖 − 𝑇𝑓,𝑜𝑜𝑜 = 3000 × 0.93 × 120𝑜𝐹 − 65𝑜𝐹
ℎ𝑟 𝑙𝑙𝑜𝐹
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𝐵𝐵𝐵
= 1.53 × 10
ℎ𝑟
𝑞𝑓̇ = 𝑞̇ = 𝑈𝑈∆𝑇𝐿𝐿
120𝑜𝐹 − 50𝑜𝐹 − (65𝑜𝐹 − 50𝑜𝐹)
∆𝑇𝐿𝐿 = = 36(𝑜𝐹)
120 𝐹 − 50 𝐹
𝑜 𝑜
𝑙𝑙
65𝑜𝐹 − 50𝑜𝐹
5 𝐵𝐵𝐵 𝐵𝐵𝐵
We have: 1.53 × 10 = 160 × 𝐴 𝑚2 × 36 ( oF)
ℎ𝑟 ℎ𝑟𝑟𝑟2𝑜𝑜
1.53 ×105 26.5
A= = 26.5 (𝑓𝑓 2 ) = 𝜋𝜋𝜋 → 𝐿 = 1 = 102 (𝑓𝑓)
160 ×36 𝜋× 10
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Exercise
68 kg/min of water are heated from 45° to 65° C utilizing oil (𝐶𝑝 =1.9
kJ/kg°C) as a heating medium through a countercurrent double-pipe
heat exchanger. The oil enters the system at 100°C and leaves at
80°C. The global heat transfer coefficient is 320 W/m2°C. Calculate
the area required for the heat exchanger. Repeat the previous problem,
this time considering that the heat exchange is done through parallel
flow.

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Shell and Tube Heat Exchanger

∆𝑻𝒍𝒍 = F*∆𝑻𝒍𝒍,𝒄𝒄𝒄𝒄𝒄𝒄𝒄−𝒄𝒄𝒄𝒄𝒄𝒄𝒄

Where F(≤1) is determined using 2 temperature ratios

𝑡2 −𝑡1 𝑇1 − 𝑇2
𝑃= 𝑅=
𝑇1 −𝑡1 𝑡2 −𝑡1

where t1, t2: temperature in tube

T1, T2: temperature in shell

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Correction factor F charts for shell and tube heat exchanger

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ID = 0.05m Example
L=8m 𝑡2 − 𝑡1 80 − 20
U = 320w/m2oC 𝑃= = = 0.75
𝑇1 − 𝑡1 100 − 20
𝑇1 − 𝑇2 100 − 90 1
𝑅= = =
𝑡2 − 𝑡1 80 − 20 6

From the chart  F = 0.93

90 − 20 − (100 − 80)
∆𝑇𝐿𝐿 =𝐹× = 37.11𝑜𝐶
90 − 20
𝑙𝑙
100 − 80

𝑞̇ = 𝑈𝑈∆𝑇𝐿𝐿 = 320 × 𝜋 × 0.05 × 8 × 37.11

𝑞̇ = 14 922.8 (𝑊)
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 THE EFFECTIVENESS – NTU METHOD
To calculate exit temperatures of hot and cold fluids when the size of the
heat exchanger, and inlet temperatures of the product and heating/cooling
streams are given

• Heat capacity rate (C) = Mass flow rate * Specific heat capacity
CH = 𝒎̇𝑯 𝑪𝒑𝒑
CC = 𝒎̇𝑪 𝑪𝒑𝑪
• The heat capacity ratio (C*), is defined as:
𝑪𝒎𝒎𝒎
𝑪∗ =
𝑪𝒎𝒎𝒎
(between CH and CC, the smaller value is Cmin and the other is Cmax)
• The number of heat transfer unit (NTU)
𝑼𝑼
𝑵𝑵𝑵 =
𝑪𝒎𝒎𝒎
Where A is the heat transfer area (m2 ), U is the overall heat transfer coefficient (W/m2oC) based on
the selected area and Cmin is the minimum heat capacity rate (W/oC)

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Heat Exchanger Effectiveness (𝜺𝑬 )
𝒒̇ 𝒂𝒂𝒂𝒂𝒂𝒂 𝒂𝒂𝒂𝒂𝒂𝒂 𝒓𝒓𝒓𝒓 𝒐𝒐 𝒉𝒉𝒉𝒉 𝒕𝒕𝒕𝒕𝒕𝒕𝒕𝒕
𝜺𝑬 = =
𝒒̇ 𝒎𝒎𝒎 𝒎𝒎𝒎. 𝒂𝒂𝒂𝒂𝒂𝒂𝒂𝒂𝒂𝒂 𝒓𝒓𝒓𝒓 𝒐𝒐 𝒉𝒉𝒉𝒉 𝒕𝒕𝒕𝒕𝒕𝒕𝒕𝒕
The actual rate of heat transfer:
𝒒̇ 𝒂𝒂𝒂𝒂𝒂𝒂 = 𝒎̇𝑯 𝒄𝒑𝒑 𝑻𝑯,𝒊𝒊𝒊𝒊𝒊 − 𝑻𝑯,𝒆𝒆𝒆𝒆 = 𝒎̇𝑪 𝒄𝒑𝒑 𝑻𝑪,𝒆𝒆𝒆𝒆 − 𝑻𝑪,𝒊𝒊𝒊𝒊𝒊

The maximum rate of attainable heat transfer

𝒒̇ 𝒎𝒎𝒎 = 𝑪𝒎𝒎𝒎 𝑻𝑯,𝒊𝒊𝒊𝒊𝒊 − 𝑻𝑪,𝒊𝒊𝒊𝒊𝒊

Thus:
𝒒̇ 𝒂𝒂𝒂𝒂𝒂𝒂 = 𝜺𝑬 𝒒̇ 𝒎𝒎𝒎 = 𝜺𝑬 𝑪𝒎𝒎𝒎 (𝑻𝑯,𝒊𝒊𝒊𝒊𝒊 − 𝑻𝑪,𝒊𝒊𝒊𝒊𝒊 )
 If εE could be found 𝑞̇ 𝑎𝑎𝑎𝑎𝑎𝑎 can be calculated without exit fluids
temperatures
 Once 𝑞̇ 𝑎𝑎𝑎𝑎𝑎𝑎 is determined  exit fluids temperatures can be calculated
using energy balance equations
εE : determined using plots or formula 16
NTU-Effectiveness Relations for Heat Exchangers

Table 4.4 The exchanger effectiveness is given in terms of NTU 17

 Effectiveness - NTU Relations for Heat Exchangers

Table 4.5 The NTU values are given as a function of the exchanger effectiveness
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Exercise
A liquid food (specific heat 4.0 kJ/[kg oC]) flows in the inner pipe
of a double-pipe heat exchanger. The liquid food enters the heat
exchanger at 20oC. The flow rate of the liquid food is 0.5 kg/s. In
the annular section, hot water at 90oC enters the heat exchanger
and flows in counter – current direction at a flow rate of 1 kg/s.
The average specific heat of water is 4.18 kJ/(kg oC). The average
overall heat transfer coefficient based on the inside area is 2000
W/(m2oC), and the diameter of the inner pipe is 5 cm and
length is 6.45 m. Assume steady state conditions. Calculate the exit
temperature of liquid food and water.

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Solution
Water:
Inlet temperature: 90oC
Specific heat: 4.18 kJ/(kgoC)
Flow rate: 1.0 kg/s
Liquid food:
Inlet temperature: 20oC
Specific heat: 4.0 kJ/(kgoC)
Flow rate: 0.5 kg/s

Heat exchanger:
Diameter of inner pipe : 5 cm = 0.05 m
Length of inner pipe : 6.45 m
Overall heat transfer coefficient 2000 W/m2oC
Flow = counter-current

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Solution
The heat capacity rates for the hot water (W) and liquid food (L) are
kg kJ kW
CW = ṁ W CpW = 1.0 × 4.18 o = 4.18 o
s kg C C
kg kJ kW W
CL = ṁ L CpL = 0.5 × 4.0 o = 2.0 o = 2000 o
s kg C C C
Because CW > CL
kW
Cmin = CL = 2.0 o
C
kW
Cmax = CW = 4.18 o
C
Cmin 2.0
C∗= = = 0.4785
Cmax 4.18
W
UA 2000 2𝑜 × π × 0.05m × 6.45m
NTU = = 𝑚 𝐶 = 1.0132
Cmin W
2000 o
C 21
From table 4.4
1 − e(−1.0132 1−0.4785 )
εE = (−1.0132 1−0.4785 )
= 0.5717
1 − 0.4785 × e

kW
q̇ max = Cmin TW,inlet − TF,inlet = 2.0 o × 90oC − 20oC = 140 kW
C
q̇ actual = εE q̇ max = 0.5717 × 140kW = 80.038 kW

For hot water stream:

kg kJ
q̇ actual = ṁ W CpW TW,inlet − TW,outlet = 1 × 4.18 × (90oC − TW,outlet )
s kgoC
TW,outlet = 90 − 19.5 = 70.85oC

For liquid food stream:

kg kJ
q̇ actual = ṁ L CpL TL,outlet − TL,inlet = 0.5 × 4 × (TL,outlet − 20oC)
s kgoC
TL,outlet = 40.019 + 20 = 60.019 oC

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