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'
.
!
out in
h m h m
.
h
h
p h h
T C m A Q A ! . . .
c
c
p c c
T C m A Q A ! . . .
0
0 0 0
Control Volume
Cross Section Area
HOT
COLD
Thermal Boundary Layer
27
Region I : Hot Liquid
Solid Convection
T
h
T
iw
!
q
x
h
h
.A
i
q
x
! h
hot
. T
h
T
iw
)
.A
Region II : Conduction
Across Copper Wall
q
x
!
k
copper
.2xL
ln
r
o
r
i
T
o,wall
T
i,wall
!
q
x
.ln
r
o
r
i
'
+
'
k
copper
.2xL
Region III : Solid Cold
Liquid Convection
T
o,wall
T
c
!
q
x
h
c
.A
o
q
x
! h
c
T
o,wall
T
c
)
A
o
+
T
h
T
c
! q
x
1
h
h
.A
i
+
ln
r
o
r
i
'
+
'
k
copper
.2xL
+
1
h
c
.A
o
|
q
x
!U.A. T
h
T
c
)
1
1
.
ln .
.
'
+
'
+ !
cold i copper
i
o
o
i hot
o
h r k
r
r
r
r h
r
U
U = The Overall Heat Transfer Coefficient [W/m
2
.K]
] 3 2 1 [ R R R qx T T
c h
+ + !
U !
1
A.LR
r
o
r
i
28
Q Q Q ! !
give get
m
Q KA
t
! A
m
Q
q K
t
A
! ! A
heat transfer Eq.
Basic Eq. of heat transfer
thermodynamics
where Q heat transfer rateW
A transport aream
2
t
m
mean temperature difference between
hot and cold fluids, K
K heat transfer coefficientW/m
2
.K
heat balance
or
29
Heat Exchangers - Types
Double-Pipe: A heat exchanger built from concentric tubes.
These are simple to construct, but may require a lot of physical space to
achieve the desired heat transfer area. Can be used for gases and
liquids.
30
31
Simplified Process Flow Diagram
T
hi
T
ho
T
ci
T
co
Q
out, TS
Q
in, TS
Q
in, SS
Q
out, SS
32
7.2.1 task of heat transfer
1 no phase transformation W
1
C
p1
(T
1
- T
2
) = W
2
C
p2
(t
2
- t
1
)
single pass exchanger
Q
release
=Q
absorb
W
2,
C
p2,
t
2
W
2,
C
p2,
t
1
W
1,
C
p1,
T
1 W
1,
C
p1,
T
2
2 hot fluid condense, cold fluid heating W
1
1
= W
2
C
p2
(t
2
- t
1
)
3 cold fluid evaporation, hot fluid cooling W
1
C
p1
(T
1
- T
2
)= W
2
2
4 two fluids phase transformation W
1
1
= W
2
2
W
2,
C
p2,
t
2
W
2,
C
p2,
t
1
W
1,
r
1,
T
W
1,
r
1,
T W
1,
C
p1,
T
1 W
1,
C
p1,
T
2
W
2,
r
2,
t
W
2,
r
2,
t
W
1,
r
1,
T
W
1,
r
1,
T
W
2,
r
2,
t
W
2,
r
2,
t
33
Shell&Tube Heat Exchangers
Shell and Tube: Most common in chemical process industries. This
type provides a large heat transfer surface in a small space, can operate
at high pressures, are easy to clean and can be made of a wide variety
of materials.
1-1 Counter Current Exchanger (1-shell, 1 tube pass)
34
35
36
Heat Exchangers - Types
1-2 Heat Exchanger: 1 shell pass, 2 tube passes.
37
Heat Exchangers - Types
2-4 Heat Exchanger: 2 shell passes, 4 tube passes.
38
cold fluid
t
1
cold fluid
t
2
hot fluid T
1
hot fluid T
2
Hot and cold fluids do not contact
directly. Heat is exchanged through
solid wall conduction .
Heat exchanger
space inside tubetube pass
space outside tubeshell pass
fluid flows mtimes in tubes
mtube pass
fluid flows mtimes in shell
mshell pass
Q
Q
tubular exchanger
singel pass shell-tube exchanger
double pass shell-tube exchanger
39
Heat Exchangers - Temperatures
40
Shell and Tube Heat Exchanger Shell and Tube Heat Exchanger
41
Parts of S&T Exchangers
Tubes & Tube sheet
Shell
Inlet& outlet nozzles
Baffles
Guide rods
Longitudinal baffles
Head
Stuffing box
42
Important things related to S&T Exchanger
Tube pitch (triangular or square)
Cleaning
Shell side pressure drop
Heat transfer area
Tube length (BWG 8,12,16,20)
Shell diameter (up to 23)
Baffle spacing (should not be less than one fifth of
shell dia or more than the inside diameter of the
shell)
Clearance (center to center distance between
tubes)
43
44
Shellside Shellside Flow Flow
Out Out
Tubeside Tubeside Flow Flow
In In
Tubeside Tubeside Flow Flow
Out Out
Shell Shell
Tube Bundle Tube Bundle
Shellside Shellside Flow Flow
In In
Shell and Tube Heat Exchanger Shell and Tube Heat Exchanger
Details Details
45
Shell inlet Shell inlet
Channel Inlet Channel Inlet
Channel Channel
Outlet Outlet
Shell Outlet Shell Outlet
SINGLE SEGMENTAL TRANVERSE BAFFLES SINGLE SEGMENTAL TRANVERSE BAFFLES
Shell and Tube Heat Exchanger Shell and Tube Heat Exchanger
46
Shell and Tube Heat Exchanger Shell and Tube Heat Exchanger
47
Doughnut and Disc Type Baffles
Shell and Tube Heat Exchanger Shell and Tube Heat Exchanger
48
Heat Exchangers Problems with Calculations
Temperature of fluid changes (possibly on shell and tube side).
Baffles and leakage around baffles.
Easy part is tube side use existing correlations to determine heat transfer
coefficient.
Difficult side is shell side as fluid flows across the tubes.
49
Fouling
Fouling is when a fluid goes through the heat exchanger and the
impurities precipitate onto the surface of the tubes. Precipitation
of these impurities are cause by not cleaning the heat exchanger
on a regular basis, using the heat exchanger often, reducing the
velocity of the fluids that are moving through the heat exchanger,
over sizing the heat exchanger. The effects of fouling are more
obvious in the cold tubes than the hot tubes because the impurities
are not likely to be dissolved in cold fluid. This is because the
solubility increases as the temperature increases. Fouling has the
effect of reducing the cross sectional area for the heat to be
transferred and causes an increase in the resistance to heat transfer
across the heat exchanger. This leads to less efficiency in the heat
exchanger which causes an increase in pumping and maintenance
costs.
50
Tube Bending Shell and Tube Heat Exchanger Tube Bending Shell and Tube Heat Exchanger
51
Tube Failure Shell and Tube Heat Exchanger Tube Failure Shell and Tube Heat Exchanger
52
FACTORS FOR U
THE BOUNDARY LAYER
SCALE/CHEMICAL DEPOSITS
SOOT/DIRT BUILDUP
53
Fouling in Shell and Tube Heat Exchanger Fouling in Shell and Tube Heat Exchanger
54
common heating agents and their applied temperature
heating agent hot water
saturated
steam
mineral oil
biphenyl
mixture
*
melt salts
*
flue gas
T / 40 100 100 180
180
250
255 380 142 530
500
1000
*melt saltsKNO
3
53%NaNO
2
40% NaNO
3
7%
common cooling agents and their applied temperature
cooling
agent
water & air
aqueous salt
solution*
liquid
ammonia
liquid ethane liquid ethene
T / 20 30 -4-20 -33.4 -88.6 -103.7
*salt of NaCl and CaCl
3
, etc.
55
Heat Exchangers - Types
Spiral: Constructed from sheets of metal wound in a circular fashion.
The fluids flow in adjacent chambers between the sheets of metal.
This design is based
on the ease of
fabrication.
56
57
Plate Heat Exchangers
consist of a number of very thin corrugated stainless steel heat
transfer plates clamped together in a frame. Every second
channel is open to the same fluid. Between each pair of plates
there is a rubber gasket, which prevents the fluids from mixing
and from leaking to the surroundings. Heat is thus transferred
from the warm fluid to the colder fluid via the thin stainless
steel plate. The corrugations support the plates against
differential pressure and create a turbulent flow in the
channels. In turn, the turbulent flow provides high heat transfer
efficiency, making the plate heat exchanger very compact
compared with the traditional shell-and-tube heat exchanger. In
most cases the plate type heat exchanger is the most efficient
heat exchanger.
58
Plate flow offers superior heat transfer
coefficients compared to shell and tube
heat exchangers.
Plate flow offers true countercurrent
flow. This maximizes the mean
temperature difference between the
fluids.
Disadvantages
of plate heat exchangers are their initial
expense, they don't work well under
high pressure rates and they are not well
suited for processing pulpy products or
product with particulates.
The main weakness of the plate and
frame heat exchanger is the necessity for
the long gaskets which holds the plates
together
59
60
The plates are clamped together, separated by spacing
gaskets, and the heating and cooling fluids are arranged so that they flow between
alternate plates.
Suitable gaskets and channels control the flow and allow parallel or counter current flow
in any desired number of passes.
A substantial advantage of this type of heat exchanger is that it offers a large transfer
surface that is readily accessible for cleaning. The banks of plates are arranged so that they
may be taken apart easily. Overall heat transfer coefficients are of the order of 2400-6000 J
m
-2
s
-1
C
-1
.
61
Plate Type Heat Exchanger
A popular heat exchanger for fluids of low viscosity, such as milk, is the plate heat
exchanger, where heating and cooling fluids flow through alternate tortuous
passages between vertical plates as illustrated in Figure
62
10
9
5
8
4
3
2
6
1 7
1
Plate and Frame Heat Exchanger Plate and Frame Heat Exchanger
63
Heat Exchangers - Types
Finned: contain fins on one heat exchange surface to increase the heat
exchange surface.
64
Heat Exchangers - Types
Compact heat exchangers: constructed from round or square channels.
Car radiator is an example of this type.
65
Serrated
Fins
Solid Fins
Studs
Extended Surface Area Extended Surface Area
66
67
PLAIN
A sheet of metal with corrugated fins at
right angles to the plates
PERFORATED
A plain fin constructed from perforated
material
HERRINGBONE
Made by displacing the fins sideways at
regular intervals to produce a zig-zag
effect.
SERRATED
Made by simultaneously folding and cutting
alternative sections of fins. These fins are
also known as the lanced or multi-entry
pattern.
Fin Types in Plate-Fin Exchangers
68
69
Finned Tubes
70
Scraped Surface Heat Exchanger
One type of heat exchanger, that finds considerable use in the
food processing industry particularly for products of higher
viscosity.
consists of a jacketed cylinder with an internal cylinder
concentric to the first and fitted with scraper blades, as
illustrated in Figure.
The blades rotate, causing the fluid to flow through the annular
space between the cylinders with the outer heat transfer
surface constantly scraped.
Coefficients of heat transfer vary with speeds of rotation but
they are of the order of 900-4000 J m
-2
s
-1
C
-1
.
These machines are used in the freezing of ice cream and in
the cooling of fats during margarine manufacture.
71
Scraped Surface Heat Exchanger
72
Jacketed Pan
In a jacketed pan, the liquid to be heated is contained in
a vessel, which may also be provided with an agitator to keep the
liquid on the move across the heat-transfer surface.
The source of heat is commonly steam condensing in the vessel
jacket. Practical considerations of importance are:
1. There is the minimum of air with the steam in the jacket.
2. The steam is not superheated .
3. Steam trapping to remove condensate and air is adequate.
The action of the agitator and its ability to keep the fluid moved
across the heat transfer surface are important. Some overall heat
transfer coefficients are shown in Table .
73
74
Condensing
fluid
Heated fluid Pan material
Heat transfer
coefficients
J m
-2
s
-1
C
-1
Steam Thin liquid Cast-iron 1800
Steam Thick liquid Cast-iron 900
Steam Paste Stainless steel 300
Steam Water, boiling Copper 1600
75
Heating Coils Immersed in Liquids
76
Problem:
Water flows at 50C
0
inside a 2.5cm inside diameter
tube such that hi= 3500/C
0
m
2
.the tube has a wall
thickness of 0.8mm with a thermal conductivity of 16
W/mC
0
.the outside of the tube looses heat by free
convection with h0=7.6/m
2
C
0
.calculate the overall
heat transfer coefficient and heat loss per unit length
to surrounding air at 20C
0
.
77