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etermination of the heat transfer surface area needed for a double pipe heat exchanger
design can be done using the basic heat exchanger equation:
Q = UJ ǻTlm,
where:
Q is the rate of heat transfer between the two fluids in the heat exchanger in Btu/hr,
ǻTlm is the log mean temperature difference in o½, calculated from the inlet and outlet
temperatures of both fluids.
These parameters in the basic heat exchanger equation are discussed in '½undamentals of
Heat Exchanger esign', and they are used in an example in 'Preliminary Heat Exchanger
esign Example'. Jfter determination of the required heat transfer surface area, the diameter
and length of the inner pipe can be selected and then the diameter of the outer pipe. ½inally,
the length of the straight sections and the number of bends can be selected.
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Heat exchanger design is a multi-step, iterative process made up of the following steps:
1. Calculate the heat transfer rate, Q, in Btu/hr, based on specified information about
fluid flow rates and temperatures.
2. etermine an estimated value for the overall heat transfer coefficient, U, based on the
fluids involved.
3. Calculate the log mean temperature difference, ǻTlm, using the inlet and outlet
temperatures of the two fluids.
4. Make an initial estimate of the heat transfer area required, using: J = Q/(U ǻTlm).
5. Choose a preliminary configuration for the heat exchanger and make necessary
calculations (e.g. number and size of tubes in a shell and tube heat exchanger or pipe
diameters and length for a double pipe heat exchanger).
6. Estimate the pressure drop across the heat exchanger. af it is too high or too low,
revise the configuration of the heat exchanger until the pressure drop is acceptable.
7. Make a more detailed estimate of the overall heat transfer coefficient, U, based on the
current configuration of the heat exchanger.
8. af the latest estimate of U is significantly different than the previous estimate, repeat
steps 4 through 7 as many times as necessary until the two estimates are the same to
the desired degree of accuracy.
The most widely used equation for frictional head loss or frictional pressure drop in pipe flow
(and the equation used in the Excel formulas in this article's spreadsheet templates) is the
arcy eisbach equation:
hL = f(L/)(V2/2g)
where
L = pipe length, ft
= pipe diameter, ft
More details about the arcy eisbach equation, the parameters used in it, a table of pipe
roughness (İ) values for typical pipe materials, typical values for friction factor, f, and
equations and graphs for friction factor f as a function of Re and İ/ are available in the
article, "Pipe ½low Calculations 3: The ½riction ½actor & ½rictional Head Loss."
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Each of the three types of heat exchangers (Parallel, Cross and Counter ½low) has
advantages and disadvantages. But of the three, the counter flow heat exchanger design is the
most efficient when comparing heat transfer rate per unit surface area. The efficiency of a
counter flow heat exchanger is due to the fact that the average T (difference in temperature)
between the two fluids over the length of the heat exchanger is maximized, as shown in
½igure 4 Counter ½low. Therefore the log mean temperature for a counter flow heat
exchanger is larger than the log mean temperature for a similar parallel or cross flow heat
exchanger. The higher log mean temperature of the counter flow heat exchanger results in a
larger heat transfer rate.
Counter flow, as illustrated in ½igure 4, exists when the two fluids flow in opposite
directions. Each of the fluids enters the heat exchanger at opposite ends. Because the cooler
fluid exits the counter flow heat exchanger at the end where the hot fluid enters the heat
exchanger, the cooler fluid will approach the inlet temperature of the hot fluid. Counter flow
heat exchangers are the most efficient of the three types. an contrast to the parallel flow heat
exchanger, the counter flow heat exchanger can have the hottest cold fluid temperature
greater than the coldest hot-fluid temperature.