Heat Exchanger Design Analysis

1
MEC551
THERMAL ENGINEERING
4.0 Heat Exchangers
2
4.0 HEAT EXCHANGER
4.1 Types of Heat Exchanger: Shell and
Tube, Plate - Parallel Flow, Counter
Flow, Cross Flow.
4.2 Overall Heat Transfer Coefficient.
4.3 Log-mean-temperature difference (LMTD)
method & correction
4.4 Effectiveness of NTU (cNTU) method
4.5 Heat Exchanger Design and
Consideration

3
4.1 Heat Exchangers
The process of heat
exchange between two fluids
that are at different
temperatures and separated
by a solid wall occurs in
many engineering
applications.

The device used to make this
exchange is called a heat
exchanger.
4
Heat Exchangers
Heat exchangers are typically classified according to
flow arrangement and type of construction.

The simplest heat exchanger is one in which the hot
and cold fluids move in the same direction (parallel
flow) or opposite directions (counter flow) in a
concentric tube (or double pipe construction).

5
Heat Exchangers
(Parallel-flow)
In the parallel-flow
arrangement, the hot
and cold fluids enter
the same end, flow in
the same direction, and
leave at the same end.
6
Heat Exchangers
(Counter-flow)
In the counter-flow
arrangement, the fluids
enter at opposite ends,
in opposite directions,
and leave at opposite
ends.
out
in
cold fluid in
warmed
fluid out
7
Heat Exchangers
(Cross-Flow)
Alternatively, the fluids
may move in cross-flow
(perpendicular) to one
another.

Fluid motion over them
may be mixed or
unmixed. The fluid is
unmixed, because fins
inhibit motion in a
direction that is
transverse to the main
flow direction (x)
8
Heat Exchangers
(Shell and Tube Design)
The most common type of heat exchanger in
industrial applications is the shell and tube heat
exchanger.
9
Heat Exchangers
These designs contain a large number of tubes
(packed in a shell) and heat transfer takes place as
one fluid flows inside the tubes while the other fluid
flows outside the tubes through the shell.

10
Heat Exchangers
Baffles are commonly placed in the shell to force the
shell-side fluid to flow across the shell to enhance
heat transfer and to maintain a uniform spacing
between the tubes.

11
12
Heat Exchangers
(Shell and Tube Multi-pass designs)
Shell and tube heat
exchangers are further
classified by how many shell
and tube passes are involved.

One-shell pass and two-tube
passes devices
Heat exchangers in which all the
tubes make 1 U-turn in the shell
are called

Two-shell passes and four-
tube passes devices
13
Heat Exchangers
(Plate and Frame)
This is an
innovative design
which consists of
a series of plates
with corrugated
flat flow passages.

Hot and cold fluids
flow in alternative
passages, thus the
cold stream is
surrounded by two
hot streams.
14
Heat Exchangers
(Terminology)
Heat exchangers are often given specific names to
reflect the specific application for which they are
used:
Condenser
A heat exchanger in which one of the fluids is cooled
and condenses as it flows through the heat exchanger.
Boiler
A heat exchanger in which one of the fluids absorbs heat
and vaporizes.
Space radiator
A heat exchanger that transfers heat from the hot fluid to
the surrounding space by radiation.
15
4.2 Overall Heat Transfer
Coefficient U, W/m
2
.
o
C
16
Double-pipe Heat Exchanger
A heat exchanger typically
involves two flowing fluids
separated by a solid wall.

Heat is transferred
1. from the hot fluid to the wall
by convection,
2. through the wall by
conduction,
3. from the wall to the cold fluid
again by convection.
17
Inner tube (dimensions)
D
i
D
o
L

t

A
o
= D
o
L
A
i
= D
i
L
t = (D
o
- D
i
)/2 = R
o
- R
i
Outer surface area
inner surface area
Wall thickness
18
Thermal resistances of

the tube wall
R
wall
= ln (D
o
/D
i
)
2 kL
inner surface
R
i
= 1/h
i
A
i
,

outer surface
R
o
= 1/h
o
A
o

19
Double-pipe Heat Exchanger
The thermal resistance of the
network is thus:
( )
o o
D
D
i i
tot
A h kL A h
R
i
o
+ +
=
1
2
ln
1
t
So the thermal resistance in the path of heat flow from hot to
cold fluid in a heat exchanger includes:

i. Skin resistance associated with the flow
ii. Scale resistance from wall fouling (to be discussed later)
iii. Thermal resistance of wall material
20
Overall Heat Transfer Coefficient
The heat transfer is therefore:

Where U = heat transfer coefficient

Note:
T A U T A U T UA
R
T
Q
o o i i
A = A = A =
A
=
`
o i o i
o o i i
A A unless U U
A U A U
= =
=
21
In this equation, U is called the overall heat transfer
coefficient.
tot
o o i i s
R
A U A U A U
=
1 1 1
22
Since:

where A
m
is called the logarithmic mean area
( ) ( ) ( ) ( )
( )
( ) ( )
( )
m
A A
L R
L R
R R L
i o
L R
L R
t thickness
i o R
R
D
D
wall
A k
t
k
t
k
t
kL R R
R R
kL kL
R
i
A
o
A
i o
i
o
i o
i
o
i
o
i
o
= = =

= = =
|
|
.
|
\
|

ln
2
2
ln
2
2
2
,
1 1
2
ln
2
ln
2
ln
t
t
t
t
t
t t t

( )
i
o
A
A
i o
m
A A
A
ln
=
23
Since:

1
1 1
1 1
1 1 1
+
|
|
.
|
\
|
+
|
|
.
|
\
|
=
(
(
+ +
=
=
o m
o
i
o
i
h A A k
t
h A o o
o
h A
A
k
t
A
A
h
A R A
U
o o m i i
24
And since:
( )
|
|
.
|
\
|
=
|
|
.
|
\
|
=
|
|
.
|
\
|

=
i
o o
i
o
i o
o
i
o
i o
o
m
o
D
D
t
D
D
D
D D
D
L D
L D
D D L
L D
A
A
ln
ln
2
2
ln
2
2
t
t
t
t
25
Therefore substituting this in gives:
1
0
1
1
ln
2
1 1
1
ln
2
1
|
|
.
|
\
|
+
|
|
.
|
\
|
+ =
=
(
+
|
|
.
|
\
|
+
|
|
.
|
\
|
=
i o i
o i
i i
i
o i
o o
i
o
i
o
D
D
h D
D
k
D
h R A
U
h D
D
k
D
D
D
h
U
26
For a thin tube:
1
1 1
0 ln 1 ; 0
+ = =
=
|
|
.
|
\
|
~
o i
o i
i
o
i
o
h h
U U
D
D
so
D
D
t
27
When the tubes are finned on one side to enhance the
heat transfer, the total heat transfer surface area on
the finned side becomes:
unfinned fin total s
A A A A + = =
Surface
Area of fins
Surface
Area of Unfinned portion
28
For short fins of high thermal conductivity, we can use
this total area in the convection resistance relation:

Since in this case the fins will be isothermal.
Otherwise we should determine the effective surface
area from:
( )
unfinned fin s
conv
A A h A h
R
+
=
=
1 1
fin fin unfinned s
A A A + = q
29
Effect of Fouling
The performance of heat exchangers
usually deteriorates with time as a result
of the accumulation of deposits on heat
transfer surfaces.

The layer of deposits represents
additional resistance to heat transfer
and causes Q to decrease.
The net effect is represented by the
fouling factor (R
f
) which is a measure of
the thermal resistance introduced by
fouling.
30
Effect of Fouling
If we define the fouling factors on the inside and the
outside surface to be R
fi
and R
fo
, respectively. Then the
total thermal resistance (R) with fouling and the overall
heat transfer coefficient becomes:

Generally, U
o
is low for a fluid with low k-values (for example
gases and oils).
1
0
1
ln
2
1
1 1
+ +
|
|
.
|
\
|
+
|
|
.
|
\
|
+
|
|
.
|
\
|
=
+ +
+ +
=
o
fo
i
o o
i
o
fi
i
o
i
o
o o
fo
m i
fi
i i
h
R
D
D
k
D
D
D
R
D
D
h
U
h A A
R
A k
t
A
R
h A
R
31
(Example 11-1 p617)
Example 11-1 Hot oil is to be
cooled in a double-tube counter-
flow heat exchanger. The copper
inner tubes have a diameter of 2 cm
and negligible thickness. The inner
diameter of the outer tube (shell) is
3 cm. Water flows through the tube
at 0.5 kg/s and oil flows through the
shell at 0.8 kg/s. Taking the average
temperatures of the water and the
oil to be 45C and 80C,
respectively, determine the overall
heat transfer coefficient of this heat
exchanger.
Assumptions
1) Thermal resistance of the
inner tube is negligible since
the tube is highly conductive
and its thickness is negligible.
2) Both oil and water flow are
fully developed.
3) Properties of oil and water are
constant.
32
(Example 11.1)
Properties of water at 45C (Table A-9):

Properties of oil at 80C (Table A-16):
s
m
water C m
W
water
water
m
kg
water
k
2
3
6
10 602 . 0 637 . 0
91 . 3 Pr 990

= = =
= =
s
m
oil C m
W
oil
oil
m
kg
oil
k
2
3
6
10 5 . 37 138 . 0
490 Pr 852

= =
= =
v
33
(Example 11.1)
Since the thickness is small:

The hydraulic diameter for a circular tube is the diameter of the
tube itself, D
h, water
= D = 0.02 m

Therefore the mean velocity (V
m
) for water is:
o i
h h U
1 1 1
+ ~
( )
( ) ( ) | |
s
m
m
kg
s
kg
water h water
water
c water
water
water
m
m
D
m
A
m
V
61 . 1
02 . 0 990
5 . 0
2
4
1
2
, 4
1
3
=

=
=
=
t
t
` `
34
(Example 11.1)
The Reynolds number for the water is:

Since Re > 4,000, which is the Re
crit
for a pipe, the flow of water is
turbulent. The Nusselt number is thus:
( ) ( )
490 , 53
10 602 . 0
02 . 0 61 . 1
Re
2
6
,
=
=

s
m
s
m
water
water h
water
m
water
m
D V
v
( ) ( ) 6 . 240 91 . 3 490 , 53 023 . 0
Pr Re 023 . 0
4 . 0 8 . 0
4 . 0 8 . 0
= =
=
=
water water
water
h
water
k
D h
Nu
35
(Example 11.1)
Then:

( )
C m
W C m
W
water
water h
water
water
m
Nu
D
k
h

= =
=
2
663 , 7 6 . 240
02 . 0
637 . 0
,
36
(Example 11.1)
Now we repeat the analysis for oil.

The mean velocity of the oil is:
m
D D D
i o oil h
01 . 0 02 . 0 03 . 0
,
= =
=
( ) ( )
( ) ( ) | |
s
m
m
kg
s
kg
i o oil
oil
c oil
oil
oil m
m
D D
m
A
m
V
39 . 2
02 . 0 03 . 0 852
8 . 0
2 2 2
4
1
2 2
4
1
,
3
=

=
=
t
t
` `
37
(Example 11.1)
So the Reynolds number for oil is:

Re
crit
for oil in a pipe is higher, so the flow of oil is laminar.

The Nusselt number can be found from Table 13-3 (in text) for
D
t
/D
s
= 0.667 as:

( ) ( )
637
10 5 . 37
01 . 0 39 . 2
Re
2
6
, ,
=
=

s
m
s
m
oil
oil h oil m
oil
m
D V
v
45 . 5 =
oil
Nu
38
(Example 11.1)
Therefore:

since

Then the overall heat transfer coefficient (U) for this heat
exchanger becomes:
( )
C m
W C m
W
oil
oil h
oil
oil
m
Nu
D
k
h

=
|
|
.
|
\
|
= =
2
2 . 75 45 . 5
01 . 0
138 . 0
,
C m
W
C m
W
C m
W
o i
h h
U

=
+
=
+
=
2
2 2
5 . 74
2 . 75
1
663 , 7
1
1
1 1
1
o i
h h U
1 1 1
+ ~
39
Effect of Fouling
(Example 11.2)
Example 11.2 A double-pipe
(shell and tube) heat exchanger
is constructed of a stainless
steel inner tube with inner
diameter (D
i
) of 1.5 cm and
outer diameter (D
o
) of 1.9 cm.
and an outer shell of inner
diameter 3.2 cm.

For the convection values and
fouling factors given, determine
the thermal resistance of the
heat exchanger and heat
transfer coefficients U
i
and U
o
.
40
Effect of Fouling
(Example 11.2)
The areas are:

The thermal resistance is:
( )
o o o
o f D
D
i
i f
i i
o o i i s
A h A
R
kL A
R
A h
A U A U A U
R
i
o
+ + + +
=
1
2
ln
1
1 1 1
, ,
t
( ) ( )
( ) ( )
2
2
0597 . 0 1 019 . 0
0471 . 0 1 015 . 0
m m m L D A
m m m L D A
o o
i i
= = =
= = =
t t
t t
41
Effect of Fouling
(Example 11.2)
Therefore:
( )
( ) ( )
( ) ( ) ( ) ( )
( )
W
C
W
C
C m
W
W
C m
C m
W
W
C m
C m
W
o o o
o f D
D
i
i f
i i
m m m
m
m
m m
A h A
R
kL A
R
A h
R
i
o

=
+ + + + =
+ +
|
|
.
|
\
|
+
+ +
+ + + +
=
0532 . 0
001396 . 0 00168 . 0 0025 . 0 00849 . 0 02654 . 0
0597 . 0 1200
1
0597 . 0
0001 . 0
1 1 . 15 2
015 . 0
019 . 0
ln
0471 . 0
0004 . 0
0471 . 0 800
1
1
2
ln
1
2 2
2 2
, ,
2
2
2
2
t
t
.
.
42
Effect of Fouling
(Example 11.2)
Note that 19% of the total resistance in this case is due to fouling
and about 5% of it is due to the steel tube separating the two
fluids. The rest of the 76% is due to convective resistances on
the two sides of the inner tube.

Now know the thermal resistances, the overall heat transfer
coefficients can be found:
( ) ( )
( ) ( )
C m
W
W
C
o
o
C m
W
W
C
i
i
m A R
U
m A R
U

=
=
=
=
2
2
315
0597 . 0 0532 . 0
1 1
399
0471 . 0 0532 . 0
1 1
2
2
43
4.3 Log Mean Temperature
Difference Method
44
Analysis of Heat Exchangers
The first law of
thermodynamics requires
that the heat transfer to
the cold fluid must be
equal to the heat transfer
from the hot fluid.

Where the subscripts c and h
stand for cold and hot.
( )
( )
out h in h ph h
in c out c pc c
T T C m Q
T T C m Q
, ,
, ,
=
= +
`
`
`
`
45
In heat exchanger analysis it is convenient to combine
the product of the mass flow and the specific heat of a
fluid into a single quantity called the heat capacity
rate.
( )
( )
out h in h h
in c out c c
T T C Q
T T C Q
, ,
, ,
=
= +
`
`
ph h h
c m C
`
=
pc c c
c m C
`
=
46
Consider an incremental area of the heat exchanger surface (as
shown for either a counter-flow or parallel flow heat exchanger).
Parallel Flow Counter-flow
T
o
dA
Hot
Cold
T
h,in
T
c,in
T
c,out
T
L
T
o
T
h,in
T
c,out
T
h,out
T
L
T
h,out
T
c,in
Hot
Cold
dA
47
The heat transfer over the area (dA) can be expressed in three
ways:

1) The heat flow between hot fluids:

2) The heat gain by the cold fluid:

3) The heat given up by the hot fluid:
T dA U Q d A =
`
c c
dT C Q d =
`
h h
dT C Q d =
`
48
Log Mean Temperature
Difference Method
However, since the temperature difference (T)
between the hot and cold fluids varies with distance
along the heat exchanger. It is convenient to use a
mean temperature difference (T
m
) between the hot
and cold fluids, so that:
m
T U A Q A =
`
49
LMTD Method
Consider a parallel double-
pipe heat exchanger. The
heat transfer on each fluid in
the differential section can
be expressed as:
c c
h h
dT C Q
dT C Q
=
=
`
`
o
o
50
LMTD Method
Solving these equations gives:

Taking their difference gives:
c
c
h
h
C
Q
dT
C
Q
dT
` `
o o
= =
( )
|
|
.
|
\
|
+ = =
c h
c h c h
C C
Q T T d dT dT
1 1
`
o
51
LMTD Method
The rate of heat transfer in the differential section can
be expressed as:

Substituting this into the previous equations gives:
( ) dA T T U Q
c h
=
`
o
( )
|
|
.
|
\
|
=
c h c h
c h
C C
dA U
T T
T T d 1 1
52
LMTD Method
Integrating from the inlet to the heat exchanger to its
outlet, we get:
( )
} }
(
L
c h
L
c h
c h
dA
C C
U
T T
T T d
0 0
1 1
+ For parallel-flow
- For counter-flow
53
LMTD Method
Solving the integral for parallel flow
(where T
1
=T
h,in
-T
c,in
and T
2
=T
h,out
-T
c,out
) we get:
|
|
.
|
\
|
+ =
|
|
.
|
\
|
+
=
|
|
.
|
\
|
A
A
|
|
.
|
\
|
+ =
|
|
|
|
.
|
\
|
A
A
h c
h
c h
c
c h
c h
c h
T
in c in h
T
out c out h
C C
C
C C
C
A U
C C
C C
A U
T
T
C C
A U
T T
T T
1 1
ln
1 1
ln
1
2
, ,
, ,
1
2
_

54
LMTD Method
( )
(
(

+
|
|
.
|
\
|
+
=
|
|
.
|
\
|
A
A
h in h out h
in c out c
c in c out c
in h out h
C T T
T T
C T T
T T
A U
T
T 1 1
ln
, ,
, ,
, ,
, ,
1
2
Since:

Then:
( )
( )
in h out h
in c out c
c
h
in c out c
in h out h
h
c
T T
T T
C
C
and
T T
T T
C
C
, ,
, ,
, ,
, ,

=

=
55
LMTD Method
Solving:
( ) ( )
(
A A
+ =
(
+
=
(

+
+
=
|
|
.
|
\
|
A
A
Q
T T
A U
Q
T T T T
A U
Q
T T
Q
T T
A U
T
T
in c in h out c out h
in c out c in h out h
`
`
` `
1 2
, , , ,
, , , ,
1
2
ln
56
LMTD Method
Therefore:

This is the log mean temperature difference
m
e temperatur Mean
T
T A U
T
T
T T
A U Q
m
A =
(
(
(
(
(
|
|
.
|
\
|
A
A
A A
=
A
_
`
1
2
1 2
ln
57
LMTD Method
The log mean temperature difference method (LMTD) can be used
for both parallel and counter-flow heat exchangers, if the
following terms are used for T:
Parallel Heat Exchangers Counter-flow Heat Exchangers
58
Correction factors
for LMTD Method
The LMTD method is strictly limited to single pass parallel and
counter-flow heat exchangers only.

However, similar relations are also developed for cross-flow
and multi-pass shell and tube heat exchangers, but these are
very complicated expressions.

In these cases it is more convenient to relate the equivalent
temperature difference relation for the counter-flow case as:
flow counter
LMTD m
T F T
A = A
,
Log Mean Temperature Difference
for counter-flow heat exchanger
Correction factor
59
Correction factors
for LMTD Method
Correction factors (F) for several common
configurations are available from standard charts.

Figure 11-18 (in text) shown on the next slide, lists
some for common shell and tube cross-flow heat
exchangers. The correction factor used for this is:
( )
( )
side shell
p
side tube
p
c m
c m
t t
T T
R
t T
t t
P
=
`
`
1 2
2 1
1 1
1 2
60
Correction factors
for LMTD Method
61
LMTD Method
(Example 6.3)
Example 6.3 Alcohol is to be cooled at a rate of 0.2
kg/s from 75C to 35C in a counter-flow heat
exchanger. Cooling water enters the heat exchanger
at 12C at a rate of 0.16 kg/s. The convective
coefficient between alcohol and the tube wall and
water is 0.34 kW/(m
2
K) and between the tube wall
and water is 0.225 kW/(m
2
K). The tube may be
assumed to be thin. The specific heat for the alcohol
is 2.52 KJ/(kgK) and water is 4.187 KJ/(kgK).

Calculate the capacity ratio (C), effectiveness (),
and heat exchanger surface area (A
s
).
62
LMTD Method
(Example 6.3)
T
h,in
= 75C
T
c,out
= ?
T
c,in
= 12C
T
h,out
= 35C
T
T
h,in
T
c,out
T
h,out
T
c,in
T
1
T
2
K m
kW
o
K m
kW
i
h
h
=
=
2
2
225 . 0
340 . 0
63
LMTD Method
(Example 6.3)
The heat capacity ratio
(C) is:
since: C
c
> C
h
( ) ( )
( ) ( )
752 . 0
670 . 0
504 . 0
670 . 0 187 . 4 16 . 0
504 . 0 52 . 2 20 . 0
max
min
min max
= = = =
= =
= = =
= = =

c
h
h c
s K
kJ
K kg
kJ
s
kg
pc c c
s K
kJ
K kg
kJ
s
kg
ph h h
C
C
C
C
C
C C C C
c m C
c m C
`
`
64
LMTD Method
(Example 6.3)
Energy balance:
( ) ( ) ( )
( ) ( ) ( )
C C T
C C
C T
T c m T c m
Q Q
out c
K kg
kJ
s
kg
out c K kg
kJ
s
kg
alcohol ph h water pc c
loss gain
= + =
=

A = A
=
1 . 42
67 . 0
16 . 20
12
35 75 52 . 2 2 . 0
12 187 . 4 16 . 0
,
,
` `
` `
65
LMTD Method
(Example 6.3)
The effectiveness is thus:

C
min
is used for Q
max
because the fluid with the smaller
heat capacity rate will experience the largest
temperature change and thus be the first to
experience the maximum temperature, at which point
heat transfer stops.
( )
( )
( )
( )
635 . 0
12 75
35 75
, , min
, ,
max
=

=

= =
C C
C C
T T C
T T C
Q
Q
in c in h
out h in h h
`
`
c
66
LMTD Method
(Example 6.3)
The temperature differences are:

Therefore the LMTD is:
C C C T T T
C C C T T T
out c in h
in c out h
= = = A
= = = A
9 . 32 1 . 42 75
23 12 35
, , 1
, , 2
( ) ( )
C
C C T T
T
C
C
T
T
m
=

=
A A
= A
A
A
7 . 27
ln
9 . 32 23
ln
9 . 32
23
1 2
1
2
67
LMTD Method
(Example 6.3)
For a thin tube (as given) then r
o
~ r
i
, the overall heat
transfer coefficient is:

Finally, the surface area is:
K m
kW
o i
i
h h
U

=
(
+ =
(
+ =
2
1354 . 0
225 . 0
1
34 . 0
1 1 1
1
1
( ) ( )
2
495 . 0
273 7 . 27 1354 . 0
16 . 20
2
m
K
kW
T U
Q
A
K m
kW
m
s
=
+
=
A
=
`
68
LMTD Correction
(Example 6.4)
Example 6.4 Cooling water (C
pc
=4.187 kJ/(kgK))
flows through a two-shell pass, four-tube pass heat
exchanger at the rate of 2 kg/s and temperatures at
entry of 20 and exit at 80C. Hot oil enters through
the shell side of the heat exchanger at 140C and
leaves at 90C. Calculate the heat exchanger surface
area if the overall heat transfer coefficient (U) is 300
W/(m
2
C).
69
LMTD Correction
(Example 6.4)
T
h,in
= 140C
T
h,out
= 90C
T
c,out
= 80C
T
c,in
= 20C
70
LMTD Correction
(Example 6.4)
The LMTD is:
( ) ( )
C
C C
C C
C C C C
T
T
T T
T
m
=
|
.
|
\
|

=
|
|
.
|
\
|
A
A
A A
= A
9 . 64
80 140
20 90
ln
80 140 20 90
ln
2
1
2 1
71
LMTD Correction
(Example 6.4)
Parameters to use the LMTD correction chart:
833 . 0
20 80
90 140
5 . 0
20 140
20 80
, ,
, ,
, ,
, ,
=

=
=
=

=
=
C C
C C
T T
T T
R
C C
C C
T T
T T
P
in c out c
in h out h
in c in h
in c out c
72
LMTD Correction
(Example 6.4)
From chart (Figure 13-18 in text) the value F= 0.97
0.97
73
LMTD Correction
(Example 6.4)
Therefore the surface area (A
s
) is:
( )
( ) ( ) ( )
( ) ( ) ( )
2
3
, ,
6 . 26
9 . 64 97 . 0 10 300
20 80 187 . 4 2
2
m
C
C C
T F U
T T C m
A
C m
kW
K kg
kJ
s
kg
m
in c out c pc c
s
=

=
A

=

`
74
Two different design tasks:
1) Specified:
- the temperature change in a fluid stream, and
- the mass flow rate.
Required:
- the designer needs to select a heat exchanger.
2) Specified:
- the heat exchanger type and size,
- fluid mass flow rate,
- inlet temperatures.
Required:
- the designer needs to predict the outlet temperatures and heat transfer
rate.
Two methods used in the analysis of heat exchangers:
the log mean temperature difference (or LMTD)
best suited for the #1,
the effectivenessNTU method
best suited for task #2.
75
LMTD
( )
1 2
1 2
ln
s lm
lm
Q UA T
T T
T
T T
= A
A A
A =
A A
76
77
Correction factors
for LMTD Method
The LMTD method is strictly limited to single pass parallel and
counter-flow heat exchangers only.

However, similar relations are also developed for cross-flow
and multi-pass shell and tube heat exchangers, but these are
very complicated expressions.

In these cases it is more convenient to relate the equivalent
temperature difference relation for the counter-flow case as:
flow counter
LMTD m
T F T
A = A
,
Log Mean Temperature Difference
for counter-flow heat exchanger
Correction factor
78
4.4 The Effectiveness
NTU Method
79
The -NTU Method
This method is useful when the LMTD method cannot
be determined. The required data may instead be
determined from the -NTU method charts of several
common configurations

Definitions:
The heat capacity of the cold stream is given by:

The heat capacity of the hot stream is given by:
pc c c
c m C =
`
ph h h
c m C =
`
80
The -NTU Method
The capacity ratio is defined as:
c h
c
h
c h
h
c
C C if
C
C
C
C C if
C
C
C
< =
> =
;
;
81
The -NTU Method
The -NTU Method is based upon a dimensionless
paramater, Heat Transfer Efectiveness, :

For counter-flow heat exchangers, the actual heat transfer rate
may be written either from the cold stream or from the hot
stream as:

Where and

rate transfer heat possible Maximum
rate transfer heat Actual
Q
Q
=
max
`
`
c
( ) ( )
out h in h h in c out c c
T T C T T C Q
, , , ,
= =
`
pc c c
c m C =
`
ph h h
c m C =
`
82
The -NTU Method
The maximum temperature difference possible in a
heat exchanger is:

The heat transfer in the heat exchanger will reach its
maximum value when:

1) The cold fluid is heated to the inlet temperature of the hot
fluid.
2) The hot fluid is cooled to the inlet temperature of the cold
fluid.
in c in h
T T T
, , max
= A
83
The -NTU Method
However, these two things cannot happen
simultaneously unless: C
c
=C
h

But if C
c
C
h
as is normally the case, the fluid with
the smaller heat capacity will experience the larger
temperature change and thus will be the first to
experience maximum temperature, at which point
heat transfer will come to a halt.

84
The -NTU Method
Therefore, the maximum possible heat transfer rate in
heat exchanger is:

( )
in c in h
T T C Q
, , min max
=
`
h c
C or C of smaller the is C where
min
:
85
The -NTU Method

Therefore the heat exchanger effectiveness for a
counter-flow heat exchanger is:
( )
( )
( )
( )
in c in h
out h in h h
in c in h
in c out c c
T T C
T T C
T T C
T T C
, , min
, ,
, , min
, ,
=
c
c
rate transfer heat possible Maximum
rate transfer heat Actual
Q
Q
=
max
`
`
c
86
The -NTU Method
NTU Number of Heat Transfer Unit

The NTU is a measure of physical size of the heat
exchanger; the larger NTU, the larger heat exchanger
size. It is defined as the ratio of the heat capacity of
the heat exchanger to the minimum heat capacity of
the flow.

( )
min
min p
s s
C m
A U
C
U A
NTU
=
`
87
The -NTU Method
(Step-by-step Procedure)
The -NTU Method Procedure

1) Determine C
min
and C
max
from of the streams
and calculate the capacity ratio C.

max
min
C
C
c =
( )
p
c m
`
88
The -NTU Method
2) Determine:
( )
( )
( )
( )
in c in h
out h in h h
in c in h
in c out c c
s
T T C
T T C
T T C
T T C
C
A U
NTU
, , min
, ,
, , min
, ,
min

=

=
=
c
89
The -NTU Method
3) Charts

Knowing , NTU, and C use
the chart (Figure 11-26 in the
text) to determine U and A
s

in question.

OR from standard derivation
Tables 11-4 & 11-5
90
The -NTU Method
4) Compute the heat transfer rate:

( )
in c in h
T T C Q
, , min
=c
`
91
The -NTU Method
5) Calculate the outlet temperature:

c
in c out c
h
in h out h
C
Q
T T
C
Q
T T
`
`
=
=
, ,
, ,
92
The -NTU Method
(Example 6.5)
Example 6.5 A single, pass counter-flow shell-and-
tube heat exchanger is used to cool hot mercury
(C
ph
=1.37 kJ/(kgK)) from 110C to 70C flowing at a
rate of 1 kg/s with water (C
pc
=4.187 kJ/(kgK)) entering
at 30C and flowing at a rate of 0.2 kg/s. Calculate
the heat transfer surface area required and the exit
temperature of the water if the overall heat transfer
coefficient (U) is 250 kW/(m
2
K).
93
30C
70C 110C
The -NTU Method
(Example 6.5)
94
The -NTU Method
(Example 6.5)
The temperature difference (T
2
) is:

The heat capacities are:
C C C
T T T
in c out h
= =
= A
40 30 70
, , 2
( ) ( )
( ) ( )
s K
kJ
K kg
kJ
s
kg
pc c c
s K
kJ
K kg
kJ
s
kg
ph h h
C m C
C m C

= = =
= = =
836 . 0 187 . 4 2 . 0
37 . 1 37 . 1 1
`
`
95
The -NTU Method
(Example 6.5)
Since C
h
> C
c
, therefore:
61 . 0
37 . 1
836 . 0
836 . 0
370 . 1
max
min
min
max
= = =
= =
= =
C
C
C
C C
C C
s K
kJ
c
s K
kJ
h
96
The -NTU Method
(Example 6.5)
The total heat transfer (Q) is:

The maximum heat transfer is:
( )
( ) ( ) ( ) | |
kW
K
T T C Q
K kg
kJ
out h in h h
8 . 54
273 70 273 110 37 . 1
, ,
=
+ + =
=
`
( )
( ) ( ) ( ) | |
kW
K
T T C Q
s K
kJ
in c in h
9 . 66
273 30 273 110 836 . 0
, , min max
=
+ + =
=
`
97
The -NTU Method
(Example 6.5)
The heat exchanger effectiveness is:

Now consult the -NTU chart (Figure 11-26 in text)
82 . 0
9 . 66
8 . 54
max
= = =
kW
kW
Q
Q
`
`
c
98
The -NTU Method
(Example 6.5)
0.82
2.7
From the chart:

NTU = 2.7
99
The -NTU Method
(Example 6.5)
Therefore the surface area (A
s
) is:

The exit temperature of the water is thus:
( )
2
min
03 . 9
250
836 . 0 7 . 2
2
m
U
C NTU
A
K m
kW
s K
kJ
s
=
( )
( ) C or K K
kW
T
C
Q
T
T T C Q
s K
kJ
in c
c
out c
in c out c c
= + + =
+ =
=
6 . 95 6 . 368 273 30
836 . 0
8 . 54
, ,
, ,
`
`
100
4.5 Heat Exchanger Design
Considerations
101
Design Considerations
Some design considerations are:

Heat transfer rate
This is the most important quantity. A heat exchanger
must be capable of transferring heat at a specified rate in
order to achieve the desired temperature change of the
fluid at a specified mass flow rate.

Cost
Budgetary limitations always play an important role.
Operating and maintenance costs are also a factor.

Pumping Power
The fluids are normally forced by pumps or fans which
require a pump with associate electrical costs.
102
Design Considerations
Size and weight
Normally the smaller and lighter, the better. This is
especially true for automotive and aerospace industries.
Type
The type of heat exchanger depends on the
requirements, fluids involved, size and weight limitations
etc.
Materials
The materials in the heat exchanger construction may be
an important consideration, especially if thermal
stresses are an issue.

103
End Of Heat Exchanger Section C
C
104
End Of Lectures C
C
Study hard for your finals
I hope you all do well

Heat Exchanger Design Analysis

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