EKC 216

PROCESS HEAT
TRANSFER
Syamsul Rizal Abd Shukor
PhD, AMIChemE
 CHAPTER 10
HEAT EXCHANGERS
An equipment that is used to transfer heat energy
from one fluid to another, where the fluids are
separated by a solid medium to prevent mixing.
 CHAPTER 10
HEAT EXCHANGERS
To vaporize (boil)
fluid
To condense fluid
To increase or
decrease the
temperature of
flowing fluid (process
fluid)
 TYPES OF
HEAT EXCHANGER
1. Plate and Frame HEx
2. Shell and Tube
3. Double Pipe HEx
4. Coil HEx
5. Air-Cooled HEx
 HEAT EXCHANGER
In designing a heat exchanger, economics
of scale plays a key role
weight and size
materials of construction
types of heating or cooling fluid
 HEAT EXCHANGER
What are the important parameters involved
in designing a heat exchanger?
i. Overall heat transfer coefficient, U
ii. Area of heat transfer, A
iii. Temperature difference, ∆T

Recall;
q = UA∆Toverall
 OVERALL HEAT
TRANSFER COEFFICIENT
q = UA∆Toverall
In Chapter 2, you have seen that heat
transfer through the plane wall is given as
 OVERALL HEAT
TRANSFER COEFFICIENT
Similarly, in a double-pipe HEx (a more
applicable consideration)
 OVERALL HEAT
TRANSFER COEFFICIENT

Hence; The U may be

based either
the inside or
outside area
of the tube
 OVERALL HEAT
TRANSFER COEFFICIENT
Although values of
U can be
calculated
accurately based
on the
mathematical
expression, it is
helpful to have a
tabulation of
values of the U for
various condition
encountered in
practice
 OVERALL HEAT
TRANSFER COEFFICIENT
Example 1.0
Air at 2 bar and 200°C flows inside a 25 mm
schedule 80 steel pipe (1% carbon) with h =
65 W/m2 K. A hot gas with h = 180 W/m2.K
flows across the outside of the 1 m length
pipe at 400°C. Calculate the overall heat-
transfer coefficient inside and outside of
the tube.
 OVERALL HEAT
TRANSFER COEFFICIENT
Example 1.0: Solution

From Appendix A (Table A11) From Table A2

ID = 2.42 cm = 0.0242 m k = 42 W/mK
OD = 3.34 cm = 0.0334 m
 OVERALL HEAT
TRANSFER COEFFICIENT
 OVERALL HEAT
TRANSFER COEFFICIENT
Example 1.0: Solution
 OVERALL HEAT
TRANSFER COEFFICIENT
Example 1.0: Solution
LOG MEAN TEMPERATURE
DIFFERENCE (LMTD)
What is the importance of LMTD?
It is the driving force for the heat exchange
between 2 fluids
LMTD increase, amounts of heat transfer
between the 2 fluids also increases
LOG MEAN TEMPERATURE
DIFFERENCE (LMTD)

The application of LMTD (logarithmic average) in

calculating the heat transfer in heat exchange
equipment is based on the assumption that Cp does
not change with temperature and hconv is constant
throughout the length of the tube inside the
equipment.
LOG MEAN TEMPERATURE
DIFFERENCE (LMTD)
Temperature profiles for (a) parallel flow and (b)
Counter flow

(a) (b)
LOG MEAN TEMPERATURE
DIFFERENCE (LMTD)
Example 2.0
Water at the rate of 68 kg/min is heated
from 35 to 75 °C by oil having a specific
heat of 1.9 kJ/kg.°C, flowing in a counter-
flow double-pipe exchanger. The oil enters
the exchanger at 110°C and leaves at 75°C.
U is 320 W/m2.°C. Calculate the heat-
exchanger area.
LOG MEAN TEMPERATURE
DIFFERENCE (LMTD)
Example 2.0: Solution

How to start? What is given in the question?

mass flow rate, ∆T, specific heat
Hence, we can find ………….
LOG MEAN TEMPERATURE
DIFFERENCE (LMTD)
Example 2.0: Solution
The total heat transfer is determined from
the energy absorbed by the water;

LMTD;
LOG MEAN TEMPERATURE
DIFFERENCE (LMTD)
Example 2.0: Solution
Then, since q = UA∆Tm. Then
LOG MEAN TEMPERATURE
DIFFERENCE (LMTD)
Remember that, all the examples given
earlier are based on double-pipe HEx.
IF a different type of HEx is used, a
correction factor, F is applied to the LMTD
Hence, q = UAF∆Tm.
F is found from Table 10-8 to 10-11 in
your textbook.
CORRECTION FACTOR PLOT
MULTI-PASS CROSSFLOW HEx
CORRECTION FACTOR PLOT
MULTI-PASS CROSSFLOW HEx
CORRECTION FACTOR PLOT
MULTI-PASS CROSSFLOW HEx
MULTI-PASS CROSSFLOW
HEAT EXCHANGER
For multi tube passes;

Where
Tho = Temp of heating fluid
at the outlet
Thi = Temp of heating fluid
at the inlet
Tco = Temp of cooling fluid
at the outlet
Tci = Temp of cooling fluid
at the inlet
MULTI-PASS CROSSFLOW
HEAT EXCHANGER
Example 3.0
Water at the rate of 68 kg/min is heated
from 35 to 75 °C by oil having a specific
heat of 1.9 kJ/kg.°C. A shell-and-tube
exchanger was used with the water making
one-shell pass and the oil making two tube
passes. The oil enters the exchanger at 110°C
and leaves at 75°C. U is 320 W/m2.°C.
Calculate the heat-exchanger area.
MULTI-PASS CROSSFLOW
HEAT EXCHANGER
Example 3.0: Solution
First, find F from Figure 10-8
T1 = 35°C; T2 = 75°C; t1 = 110°C; t2 = 75°C
P = (t2-t1)/(T1-t1) = (75-110)/(35-110) = 0.467
R = (T1-T2)/(t2-t1) = (35-75)/(75-110) = 1.143
So the correction factor is F = 0.81

Given that q = UAF∆Tm,

So that
MULTI-PASS CROSSFLOW
HEAT EXCHANGER
MULTI-PASS CROSSFLOW
HEAT EXCHANGER
Example 4.0
Water at the rate of 4 kg/s is heated from 35 to 55°C
in a shell-and-tube heat exchanger. On the shell side
one pass is used with water as the heating fluid 2 kg/
s, entering the exchanger at 95°C. The overall heat-
transfer coefficient is 1420 W/m2 K, and the average
water velocity in the 20 mm diameter tubes is 0.4 m/
s, considering constant heat capacity for water.
Because of space limitations the tube length must not
be longer than 2.5m. Calculate the number of tube
passes, the number of tubes per pass, and the length
of the tubes, consistent with this restriction.
MULTI-PASS CROSSFLOW
HEAT EXCHANGER
Example 4.0: Solution

Firstly, assume one tube pass and check to see if it

satisfies the conditions of this problem. The exit
temperature of the hot water is calculated from
MULTI-PASS CROSSFLOW
HEAT EXCHANGER
Example 4.0: Solution

From the equation we can find ∆Th

Hence, we can find Tho;

Tho = Thi - ∆Th = 95-50 = 45°C

So now you can find LMTD

MULTI-PASS CROSSFLOW
HEAT EXCHANGER
Example 4.0: Solution

Next is to find the total required heat

transfer,
MULTI-PASS CROSSFLOW
HEAT EXCHANGER
Example 4.0: Solution
From that, we can now find the total heat
transfer area required, A

On the tube sides, we now calculate the total

required flow area;

Area of
tube walls
MULTI-PASS CROSSFLOW
HEAT EXCHANGER
Example 4.0: Solution
This total required flow area is the product
of the number of tubes and the flow area
per tube, hence

n = 32 number of tubes
MULTI-PASS CROSSFLOW
HEAT EXCHANGER
Example 4.0: Solution
Given that earlier we have found the total
surface area required for a one-tube-pass is
8.168 m2
Hence, the total length of the 20mm
diameter one-tube-pass is
L = 8.168/[𝝅(0.02)] = 130 m
Given that there is 32 number of tubes; the
new L is 130 m/32 tubes = 4.063 m
MULTI-PASS CROSSFLOW
HEAT EXCHANGER
Example 4.0: Solution
Length of tube, Lnew = 4.063 m is greater
than the allowable 2.5 m limit, so we must
use more than one tube pass.

So we try 2-passes, from Fig 10-8, F = 0.88

Thus,
MULTI-PASS CROSSFLOW
HEAT EXCHANGER
Example 4.0: Solution
The number of tubes per pass is still 32
because of the velocity requirement. For the
2-tube-pas HEx the total surface area is now
related to the length by A2-pass = 2n𝝅dL.
Hence,

Well below the requirement

of 2.5m tube length length
MULTI-PASS CROSSFLOW
HEAT EXCHANGER
Example 4.0: Solution
So the final design selection is

Number of tubes per pass = 32

Number of passes = 2
Length of tube per pass = 2.309 m
MULTI-PASS CROSSFLOW
HEAT EXCHANGER
In-class Example 4.0

In this particular example, only 2 temperatures are given; i.e. Thi

and Tci with the value of mass flow for both the cold stream
and hot streams. Hence, the LMTD method is not appropriate to be
used for this particular example. Thus, the effectiveness method
or the NTU method is more appropriate to be used to solve such
problem.

Submit your answer individually via eLearning by 11:59 pm, Thursday 18 May 2017
 EFFECTIVENESS
METHOD
The LMTD approach to HEx analysis is useful
when Ti and To are known or easily
determined.
If Ti and To are to be evaluated, then
Effectiveness Method offers more advantage.
 EFFECTIVENESS
METHOD
How to determine actual heat transfer and
maximum possible heat transfer????
1. Actual HT may be computed by
calculating either energy lost by the hot
fluid or the energy gained by the cold
fluid.
2. Maximum possible HT can be determined
by recognizing that this maximum value
could be attained if one of the fluids
were to undergo a temp change equal to
the maximum ∆T present in the HEx
 EFFECTIVENESS
METHOD
1. Actual HT
Co-current

Counter current

2. Maximum possible HT

The minimum among the 2 fluids

(either the hot fluid or the cold fluid)
NUMBER OF TRANSFER UNIT

(NTU)
NTU is indicative of the size of the HEx.
It is being used with 𝝐 as an alternative
method to design a HEx
Can be used when heat capacities of the
flowing fluid is made known beforehand.
The derivation of how NTU is being derived
can be referred to page 541-542 of your
textbook (Read and understand them as it
might come out in your quiz or test :D)
NUMBER OF TRANSFER UNIT

(NTU)
The procedures in using NTU method is
described as below

Step 1: Find cmin and cmax;

NUMBER OF TRANSFER UNIT

(NTU)
The procedures in using NTU method is
described as below

Step 1: Find cmin and cmax;

mass flowrate mass flowrate

of fluid a of fluid a
heat capacity heat capacity
of fluid a of fluid a
NUMBER OF TRANSFER UNIT

(NTU)
Step 2: Find c; where

Step 3: Find 𝝐 using

or

where;

Once 𝝐 is found, use Figure 10-12 to 10-17 to find NTU.

A more accurate value of NTU can be obtained using
equations from Table 10.4
NUMBER OF TRANSFER UNIT

(NTU)
Step 4: Using this relationship

Area, A can be calculated from

Note that the use of effectiveness-NTU

approach to design HEx obviates the need to
apply e correction factor as normally
practiced in LMTD
NUMBER OF TRANSFER UNIT

(NTU)
Do not misinterpret effectiveness, 𝝐 with the
physical meaning of HEx effectiveness!!
HEx with high 𝝐 at a certain flow condition
doesn not mean that it will have a higher
heat-transfer rate than at some low 𝝐
condition.
High values of 𝝐 corresponds to small ∆T
between the hot and cold fluid, while
higher heat transfer rates result from
larger ∆T (i.e. greater driving force)