14

Thermal Design of Cooling

and Dehumidifying Coils
M. Khamis Mansour and M. Hassab
Mechanical Engineering Department, Faculty of Engineering,
Beirut Arab University,
Lebanon

1. Introduction
The cooling and dehumidifying coil is a critical component of air conditioning. Its
performance has a strong bearing on the ultimate indoor environmental conditions, which
in turn, has a significant impact on the indoor air quality. Decisions made to select a cooling
coil influence the initial investment as well as the costs of installing, providing, and
maintaining thermal comfort. The efficient thermal design of the cooling coil leads to a
crucial reduction in the coil surface heat transfer area and of course, its capital cost and its
weight. On the other hand, the enhancement in the coil thermal performance will usually be
established at expense of the hydraulic performance of the cooling coil and in turn, its
running cost. Because the cooling coil is an integral part of the air distribution system, its
geometry — size, number of rows, fin spacing, and fin profile — contributes to the airside
pressure drop and affects the sound power level of the fans. (Fan power needed to circulate
air through the duct system may warrant extra sound attenuation at the air handler.)
Cooling coils are an integral part of the chilled water system or the refrigeration unit, too.
The extent to which coils raise the chilled water temperature or the evaporation temperature
dramatically affects both capital investment in the cooling coil or the pumping power. Coil
performance can even influence the efficiency of the chiller or Dx-unit. The focus of this
chapter is on the description of the methodology should be used in thermal design of the
cooling coil either chilled water coil or Dx-coil.
Methods to design the cooling and dehumidifying coil either chilled water coil or Dx
evaporator coil are usually based on log mean enthalpy or log equivalent dry-bulb
temperature difference [1]. In both methods, the cooling coil is treated as a single
zone/region and hence the required surface area is determined [2]. This manner of the
cooling coil design could lead to an imprecise design particularly when the cooling coil is
partially wet. In this chapter, the numerical calculation using a discrete technique "row-by-
row method" will be presented to calculate the detailed design of the cooling coil in order to
enhance the calculation accuracy and trace the air and coil surface temperature locally.

2. Types of cooling coils

Cooling coils are classified to direct-expansion (DX) coils and chilled water coils as shown in
Figure 1. Some coil manufacturers fabricate coils from 5/8 inch OD copper tubes, others

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368 Heat Exchangers – Basics Design Applications

from 1/2 inch copper tube and still others use 3/8 inch tubes. Selection of the tube size is a
matter of manufacturer's choice and market demand. Price, as always, plays a major part in
the tube size selection.

a) b)
Fig. 1. Description of the cooling coil for a)- Dx-cooling; b)- Chilled water coil (Aerofin heat
transfer products).

3. Coil construction and geometry

In a coil, copper tubes are arranged parallel to one another, either in staggered pattern or
non-staggered pattern, along the length L of the coil. A staggered pattern is more commonly
used. For 5/8 inch tubes, the triangular pitch is 1.75 inch or 1.5 inch. For 1/2 inch tubes it is
1.25 inch. Plate or ripple fins are used to enhance the heat transfer area. Thus the primary
surface area (outside area of bare copper tubes) is enhanced greatly by adding a secondary
area of fins. The total area including fins is called outside surface area. The cross-section (L ×
H) which the air flows is called the face area or the finned area. Thus L is finned length and
H is fin height (see Figure 2). Fins are arranged perpendicular to the tubes. Where, the fin
spacing varies between 8 and 16 fins per inch of tube.

Fig. 2. Geometry configuration of the cooling coil (Aerofin heat transfer products).

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Thermal Design of Cooling and Dehumidifying Coils 369

ST

SL

Fig. 3. A 4-row coil with a 4-tube face.

The average air velocity across the face area is called the coil face/frontal velocity and it is
calculated as follows [3]:

/
⁄ =

The number of rows of tubes in the direction of air flow is termed as depth of coil (rows
deep, D). Coils with 3, 4, 6 or 8 rows are commonly used. Refrigerant or chilled water enters
the first row and leaves the coil from the last row. A coil in which chilled water or
refrigerant is supplied to all the tubes in the first row (also referred to as tubes high or tubes
in face) is called a maximum or full circuit coil (see Figure 3). Thus a typical coil of 17.5 inch
(0.44 m) height which has 10 tubes in face (based on 1.75 inch (0.044 m) pitch) will have a
maximum of 10 circuits. If the supply is given to alternate tubes in face, we get a half-circuit
coil with 5 circuits as against 10 circuits. The U-bends at the end of the tubes can be
arranged, at the time of manufacturing, to obtain the number of circuits desired. See Figure
4 for full and half circuit coils with 4 tube face.

Face velocity is restricted to 500 fpm (2.5 m/s) to avoid carryover of condensate from the
coil. The value of 500 fpm (2.5 m/s) is very commonly used for coil sizing and it works very
well for cfm/ton in the range of 500 to 600 (2.5 to 3 m3/s per ton). If cfm/ton ratio falls
below 500 (2.5 m3/s per ton), this generally happens when room sensible heat factor goes
below 0.8 due to high room latent load, a 4-row coil at 500 fpm (2.5 m/s) becomes
inadequate. A 5-row coil is not very common. Hence by lowering face velocity, a 4-row deep
coil can be selected at 400 fpm (2 m/s), when cfm/ton is about 400 (2 m3/s per ton).. As
cfm/ton ratio reduces further, 6-row or 8-row coils have to be selected. This situation is
encountered when the occupancy and/or fresh air components are high.

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370 Heat Exchangers – Basics Design Applications

Fig. 4. Full circuit and half circuit four row coils with 4-tube face.

3.1 Fin patterns

There are three standard plate fin patterns that are usually used in the cooling coil: flat-
plate, wavy-plate, and star-plate fin patterns, as shown in Figure 5. They are made of
Aluminum, copper, and stainless steel or carbon steel. The fins are permanently attached to
the tubes by expansion of each tube. Full fin collars allow for both precise fin spacing and
maximum fin-to-tube contact. The flat-plate fin type has no corrugation, which results in the
lowest possible air friction drop and lowest fan horsepower demands while the wavy-plate
fin corrugation across the fin provides the maximum heat transfer for a given surface area,
and is the standard fin configuration used. The star-plate fin pattern corrugation around the
tubes provides lower air friction. This pattern is used when lower air friction is desired
without a large decrease in heat transfer capacity.

(a) (b) (c)

Fig. 5. (a) Wavy-plate fin; (b) Star-plate fin; (c) Flat-plate fin (Aerofin heat transfer products).

4. Simultaneous heat and mass transfer in cooling and dehumidifying coils

In the cooling coil, the coolant fluid “chilled water or refrigerant” flows inside the tubes and
the air passes across the tube bundle. Since the coolant fluid temperature is less than the
dew point temperature to ensure the dehumidification process there is possibility of heat

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Thermal Design of Cooling and Dehumidifying Coils 371

and moisture transfer between them. The directions of heat and moisture transfer depend
upon the temperature and vapor pressure differences between air and wetted surface. As a
result, the direction of the total heat transfer rate, which is a sum of sensible heat transfer
and latent heat transfers. The concept of enthalpy potential [4] is very useful in quantifying
the total heat transfer in these processes and its direction.
The sensible (QS) and latent (QL) heat transfer rates are given by:

QS = ho AS (ti – ta)

QL = hmass AS (Wi – Wa) hfg

the total heat transfer QT is given by:

QT = QS +QL = ho AS (ti – ta) + hmass As (Wi – Wa) hfg

Where:
t a = dry-bulb temperature of air, oC
t i= temperature of water/wetted surface, oC
Wa = humidity ratio of air, kg/kg
Wi= humidity ratio of saturated air at ti, kg/kg
ho = convective heat transfer coefficient, W/m2.oC
hmass = convective mass transfer coefficient, kg/m2
hfg = latent heat of vaporization, J/kg
Since the transport mechanism that controls the convective heat transfer between air and
water also controls the moisture transfer between air and water, there exists a relation
between heat and mass transfer coefficients, hC and hD as discussed in an earlier chapter. It
has been shown that for air-water vapor mixtures,

Hmass≈ho/cpm or ho/hmass.cpm = Lewis number ≈ 1.0

Where cpm is the humid air specific heat ≈ 1.0216 kJ/kg.K. Hence the total heat transfer is
given by:

QT = QS +QL = ho AS (ti – ta) + hmass AS (Wi – Wa) hfg = (ho AS/Cpm )[(ti – ta) +(Wi – Wa) hfg]
by manipulating the term in the parenthesis of RHS, it can be shown that:

QT = QS +QL = (ho AS/cpm )[ (hi – ha)]

The air heat transfer coefficient, ho has been computed from the experimental correlations
derived in [3]. The heat transfer parameter is written as Stanton number, St times Prandtl
number, Pr to the 2/3 power. It is given as a function of Reynolds number, Re where the
function was established through curve-fitting of a set of the experimental data as follow:
/ .
× = . ×
Where these three dimensionless parameters are defined as:

A x h μ ×c m ×d
St = , Pr = , and Re =
m ×c k A x μ

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372 Heat Exchangers – Basics Design Applications

Where,
A = minimum free-flow air area, (m2)
m = mass flow rate of air through the cooling coil, (kg/s)
μ =dynamic viscosity of air (kg/m.s)
k =thermal conductivity of air (W/m. °C)
d =outside diameter, (m)

5. Governing equations and methodology

The sizing of cooling coil requires solving the two energy equations of the air-side and
coolant sides coupling with the heat and mass transfer equations. The design is
accomplished through discretizing the cooling coil into N segments according to the number
of the coil rows. The three governing equations are applied to each segment. By knowing the
process data, coil geometry, and the design cooling load imposed on the coil the required
surface area can be computed. The coil sizing is expressed by the face area and number of
rows of a finned-tube coil for satisfying the design coil cooling load.
Process data:
- Room dB temperature/Return air dB temperature (°C)
- Fresh air dB temperature (°C)
- Dehumidified air flow (cfm or m3/s)
- Fresh air quantity (cfm or m3/s)
- Grand sensible heat factor (GSHF)
- Coil cooling load (kW)
- Apparatus dew point ADP (°C) (This denotes the average outside surface temperature
of the coil.)
Coil geometry :
- Outside tube diameter, do (mm)
- Inside tube diameter, di (mm)
- Longitudinal tube spacing, SL (mm) (see Figure 3)
- Transverse tube spacing, ST (mm) (see Figure 3)
- No. of fins/m, Nf
- Aluminum fin thickness, tf (mm)
- Exchanger compactness, surface area over exchanger volume, β (m2/m3)
Air-Side

∆Q = m ha − ha (1)

∆Q = h ΔA ha − hs (2)

Water-Side

∆Q = m Cp Tw − Tw (3)

ΔQ = h ΔA Ts − Tw (4)

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Thermal Design of Cooling and Dehumidifying Coils 373

Here,

ha = , ha = ha − ha (5)

Tw = , Tw = Tw − Tw (6)

Eliminate hai+1 and Twi+1 from Equation (1) & (3) respectively, the energy equations can be
formulated;

∆Q = m ha − ha (7)

∆Q = m Cp Tw − Tw (8)
Eliminate ha between equations (2) & (7), it is yielded:
/
∆Q = /
∗ ha − hs (9)

Similarly, eliminate Tw between equations (4) and (8):

∆Q = ∗ Ts − Tw (10)
/

Now, by dividing equation (9) over equation (10):

=R (11)

Where,

∆
R= ∗ (12)
∆

ΔNTU = , ΔNTU =

Relation between hs and Ts:

a. Dry-Surface (Ts  Tdew point)

hs = ha + c (Ts -Ta) (13)

b. Wet-Surface ( Ts  Tdew point)

When the coil is wet the enthalpy of saturated air hs is a function of the temperature of the
wetted surface Ts , by curve fitting for psychometric chart [2] of the saturated air enthalpy
at different air temperatures of a range 3 to 11oC. The quadric equation is expressed as :

hs = . + . Ts + . Ts (14)
Solution for Ts :

Substituting for hs from equations (14) into equation (11), we obtain a solution for Ts as
follows:

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374 Heat Exchangers – Basics Design Applications

Wet Surface:

ha − hs = R Ts − Tw

ha − . + . ∗ Ts + . ∗ Ts = R Ts − Tw ,

. Ts + R+ . ∗ Ts − ha + R ∗ Tw − . =
The above equation can write as:

aTs + bTs −c=

This quadratic equation can now be solved for Tsm as

±√
Ts = (15)

Where,

a = o. o , b=R+ . and c = ha + R ∗ Tw − .
Solution of ∆Q , ha , Tw
∆ ∆
∆Q = ∗ Ts − Tw , ha = ha − , Tw = Tw −
/

Calculation of air dry-bulb temperature, Tai+1

The sensible heat transferred to the dry coil surface is written as:

∆Q = m c Ta − Ta (16)

∆Q = η h ΔA Ta − Ts (17)
or,

Q = η h ΔA − Ts (18)

Eliminate ∆Q between equations (15) & (16) and Solving for Tai+1

Ta = × Ta + × Ts (19)

Calculation of Wai+1:

×
Wa = . ×
(20)

Summary of final solution:

The final solutions for the coil capacity per row and for the states of air and water at the exit
of any row within a chilled-water coil are given, in terms of the mean outer surface
temperature of this row, as:
. . . × × .
Ts = (21)
.

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Thermal Design of Cooling and Dehumidifying Coils 375

∆Q = /
∗ Ts − Tw

∆
Tw = Tw − (22)

∆
ha = ha − (23)

Ta = × Ta + × Ts (24)

×
Wa = (25)
. ×

Where,

∆
R= ∗ (26)
∆

ΔNTU = , ΔNTU = , and the total coil cooling load Q is: Q = ∑ ∆Q

Calculation of the Number of Coil Rows, Nr:

The calculations of (Twi+1 , hai+1 , Tai+1 ,and ∆Q ) are started from the first row until reaching
the row number Nr at which its outlet water temperature is nearly equal to the given inlet
water temperature to the coil, i.e. TwNr+1Twin.

Procedure of cooling coil design at a given cooling load Q :

1. The condition of the air leaving a chilled-water coil is nearly saturated, therefore, the
relative humidity of the outlet air, ϕout from the coil can be assumed as 95 %.
2. Knowing [inlet air state, CSHF= QS /Q ,and ϕout , the enthalpy of the outlet air haout
from the coil can then be determined from the Psychometric Chart.
3. Knowing [Q , hain, and haout], then the air flow rate can be determined as:

m = kg/s

4. Knowing [Q , Twin, and Twout], the water flow rate can be determined as:

m = kg/s

5. Knowing [ma, Vface, ρ , , β, and SL], the outer surface area per row ∆Ao can be determined
as:

× ×
ΔA = m2
×

6. Starting the calculations of the unknowns [Tsmi , ∆Q , hai+1, Twi+1, Tai+1 , Wai+1] using in
order equations (14, 10, 3, 1, 17, and 18), from the first row, i=1 to the row i=Nr at which
TwNr+1  Twin. The calculations are then completed and as a final check, calculate the
CSHF and compare it with the given one.

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376 Heat Exchangers – Basics Design Applications

6. Worked example of chilled-Water coils

Cross-counter flow chilled water cooling coil using corrugated plate-fins, has the flowing
construction and operating design parameters:
Coil construction parameters:
Outside tube diameter, do =13.41 mm
Inside tube diameter, di =12.09 mm
Longitudinal tube spacing, SL =26.16 mm
Transverse tube spacing, ST =31.75 mm
No. of fins/m, Nf =554
Aluminum fin thickness, tf =0.15 mm
Exchanger compactness, β = 1060 m2/m3

Aflow/Aface on the air-side, 

Outside area/inside area, (Ao/Ai) =23
=0.529
Finned-surface weighted efficiency, = 0.85
Number of tube-passes per water loop, Np =6
Design operating Data:
Moist air
Total cooling load at full load, Qc =60 kW
Latent Load at full load, QL =20 kW
Inlet air conditions = t =Dry and wet bulb temperatures
are: 26 oC, and 19 oC
Air face velocity , V =2.8 m/s
Air heat transfer coefficient, hc =60 W/ (m2 oC)
Air mean specific heat, cpm =1.001 kJ/(kg. K)
Chilled water
Inlet water temperature, Twin =6 oC
Water mass flow rate, mw =2.9 kg/s
Water inlet velocity, Vw =1.25 m/s
Heat transfer coefficient on water side, hi =4000 W/ (m2 oC)
Number of tube-passes per water loop, Ntp =6
Exit water temperature, Twout =11 oC
Water specific heat, CPw =4.14 kJ/(kg. K)
Under the above design full load conditions, calculate:
a. The coil dimensions (tube length, finned width and coil depth).
b. The number of coil rows and the total number of tubes.
c. The exit air temperature.
Calculation Procedures
From psychometric chart at inlet air conditions the inlet air properties are obtained
represented by hain=54 kJ/kg, Wain=0.011 kgv/kga. and dew point temperature, dpt =
15.5oC. By knowing QC=60 kW, CSHF=0.75 (=1- QL/Qc), and ϕ = % using information
from inlet point, the exit conditions can be determined as haout=33 kJ/kg, Tao=10.5 oC, Wao =
0.008936 kgv /kga

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Thermal Design of Cooling and Dehumidifying Coils 377

- = = = 2.857 kg/s
- = = = 2.90 kg/s
. ∗

Calculations of the coil design parameters:

× × ∗ . ∗ .
Δ = = = . m2
× . ∗ .

. ∗ ∗ .
Δ = = = 0.435
. ∗

.
Δ = ×Δ = = . m2

∗ .
ΔNTU = = = 0.355
. ∗

∆
R= ∗ = 3.525 KJ/kg.K
∆

Row i=1:

. . . ∗ ∗ .
= .
= 14.65 oC

h ΔA
∆ = × Ts − Tw = .
+ ΔNTU /
Where, hi =4000 W/m2.C
∆ .
= − = − . ∗ .
= . oC

∆
ℎ =ℎ − = . kJ/kg

Ta = × Ta + × Ts = . oC

. .
Wa = = = . kgv/kga
. ∗ . .

Row i=2

. . . ∗ ∗ .
= = 13.28 oC
.

h ΔA
∆ = × − = .
+ ΔNTU /
∆ .
= − = . − = . oC
. ∗ .

∆
ℎ =ℎ − = . kJ/kg

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378 Heat Exchangers – Basics Design Applications

= × + × = . oC

. .
Wa = . ∗
= = . kgv/kga
. .

Row i=3

. . . ∗ ∗ .
= = . oC
.

h ΔA
∆ = × − = .
+ ΔNTU /
∆ .
= − = . − = . oC
. ∗ .

∆
ℎ =ℎ − = . kJ/kg

= × + × = . oC

. .
Wa = . ∗
= = . kgv/kga
. .

Row i=4

. . . ∗ ∗ .
= = . oC
.

h ΔA
∆ = × − = .
+ ΔNTU /
∆ .
= − = . − = . oC
. ∗ .

∆
ℎ =ℎ − = . kJ/kg

= × + × = . oC

∗ . .
Wa = = = . kgv/kga
. ∗ . .

Row i=5

. . . ∗ ∗ .
= = . oC
.

h ΔA
∆ = × − = .
+ ΔNTU /
∆ .
= − = . − = . oC
. ∗ .

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Thermal Design of Cooling and Dehumidifying Coils 379

∆
ℎ =ℎ − = . kJ/kg

= × +{ × = . oC

. .
Wa = . ∗
= = . kgv/kga
. .

Row i=6

. . . ∗ ∗ .
=
.
= . oC

h ΔA
∆ = × − = .
+ ΔNTU /
∆ .
= − = . − = . oC
. ∗ .

∆
ℎ =ℎ − = . kJ/kg

= × +{ × = . oC

. .
Wa = = = . kgv/ kga
. ∗ . .

= ∆ = . + . + . + . + . + .

The total calculated cooling load for 6-rows coil is: Q =64.31 kW

And coil sensible heat factor, = = = .

.

The calculated unknowns are listed row-by-row in the next Table; and the psychometric
process for the cooling and dehumidification process is represented by Figure 6.

Row number Surface condition Tsmi oC ∆QCi kW Twi+1 oC hai+1 kJ/kg Tai+1 oC Wai+1 gv/kga
Coil inlet wet 0 11 54 26 11
1 wet 14.65 13.15 9.9 49.4 21.87 10.83
2 Wet 13.28 12.17 8.89 45.14 18.74 10.4
3 Wet 12 11.2 7.96 41.22 16.27 9.86
4 Wet 10.8 10.22 7.11 37.64 14.27 9.25
5 Wet 9.68 9.25 6.34 34.40 12.59 8.64
6 Wet 8.65 8.3 5.65 31.5 11.14 8.1

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380 Heat Exchangers – Basics Design Applications

12

11

10

9
Moisture content (g w / kg a)

1
Psychrometric process

0
10 12 14 16 18 20 22 24 26
Dry Bulb Temp. (°C)
Fig. 6. Presentation of Cooling and dehumidifying process.

a. Calculation of Coil number of tubes, Nt

Nr = Number of coil rows= 6

= = 120 tubes

b. Calculation of Coil dimension (D, H, L)

= ∗

= =

Height of the coil, H=St*Nc=0.635 m

=∑ Δ = ∗Δ = ∗24.39 = 146.34 m2

Given: =

Ai = 6.363 m2 =

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Thermal Design of Cooling and Dehumidifying Coils 381

= ℎ ℎ = = .

= ℎ= ∗ = .
c. Exit air temperature

Taout=11.14 oC
Design of the cooling coil as single Region
In calculating the surface area of the cooling coil, the heat and mass transfer equations are
applied on the entire coil surface. This approximation will greatly simplify the analysis. The
obtained results ( Ao, Taout) for one-section coil will be compared with the corresponding
results obtained for Nr-sections coil.
Air-side

= ℎ −ℎ (1)

= ℎ ℎ −ℎ (2)

Water-side

= − (3)

=ℎ − (4)
Applying the heat transfer equations for the air and water at the inlet and exit sections of the
coil, this leads to the following equation for Ts at these sections:

R= = (5)

For an entire wet-surface, the saturated air temperature at the inlet and exit of the coil
surfaces Ts1 and Ts2 are obtained, in a similar manner as done before for N-sections coil, as:

. . . ∗ ∗ .
= (6)
.

. . . ∗ ∗ .
= .
(7)

Where,
Tw1 = inlet water temperature
Tw2 = exit water temperature

= (8)

Knowing (Ts1 & Tw1) and (Ts2 & Tw2), the mean temperature difference between the chilled
water and the coil surface can be assumed equal to the logarithmic mean temperature
difference. ∆ can be determined from:

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382 Heat Exchangers – Basics Design Applications

]
∆ = − = (9)

The area of the coil can now be determined from equation (4) as:

= (10)
∗∆

The outer coil surface area Ao is determined from

= (11)

The volume of the cooling coil is given as:

Volume = DHL

DHL = (12)
Number of Coil Tubes Nt:

= (13)

The Length of the Tube (Coil), L:

= (14)

The Coil Face Area, Aface:

= = (15)

From Equations (14) and (15) H can be determined as:

= ∗ (16)

Number of Rows, Nr:

= (17)

Depth of the Coil D:

= ∗ (18)
Calculation of exit air Temperature:
The temperature difference between the air stream and the coil surface is approximated as
arithmetic mean temperature difference as shown from the heat transfer equation for the
dry air.

= − (19)

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Thermal Design of Cooling and Dehumidifying Coils 383

= ℎ − (20)

= × + ×
(21)
Worked Example

We will solve the previous worked problem using principal of treating the coil as single
zone/section instead of multi-sections and compare the two results.
Calculation Procedures:
1. Knowing: [hain=54 kJ/kg, Wain=0.011 kgv/kga, QC=60 kW, CSHF=0.75, ϕ = %],
from the Psychometric-chart we obtain:

Air Exit Condition: [haout=33 kJ/kg, Tao=10.5 oC, Wao=0.86*10-3kgv/kga]

2. = = = 2.857 kg/s
3. = = . ∗
= 2.90 kg/s

=

= 3.41 KJ/kg.K
− + . + + . + . ∗ ℎ + ∗ − .
=
.
= . < . = [Coil surface is wet]

− + . + + . + . ∗ ℎ + ∗ − .
=
.
= . oC
Calculation of ∆
]
∆ = − =

∆ = . oC

Calculation of Ai & Ao

= = . m2
∗∆

= = . m2

Number of Coil Tubes Nt

= =

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384 Heat Exchangers – Basics Design Applications

The Length of the Tube (Coil), L:

= = . m

Height of the Coil, H:

= ∗ = . ∗ . = . m

Number of Rows, Nr
∗
= = = 5.65 ≈

Depth of the Coil, D:

= ∗ = . m
Calculation of Exit air condition

= × + × = . °C

= = . kgv/ kga
. ∗

Calculation of Latent load and CSHF

= − . ∗ − . =

−
= = .

Table-1 illustrates a comparison of the dimensions and exit air conditions for 60 kW cooling
coil analyzed as only single-section and cooling coil divided to Nr-sections (Nr=6).

Physical quantity Single-section coil 6-sections coil

Air exit temperature, oC 10.95 11.14
Number of tubes 120 120
Number of rows 6 6
Coil width ,m 0.674 0.635
Coil depth, m 0.157 0.157
Coil length, m 1.3 1.4
Coil SHF 0.717 0.67
Design cooling load, kW 60 60
Actual cooling load, kW 60 64.3
Table 1.

The results presented in Table-1 indicate that cooling coil analyzed as only one-section gives
results with good agreement with those obtained with the coil analyzed as 6-sections. The
maximum error is 7%.

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Thermal Design of Cooling and Dehumidifying Coils 385

7. Worked example of partially dry chilled-water coils

Cross-counter flow chilled water cooling coil using corrugated plate-fins, has the flowing
construction and operating design parameters:
Coil construction parameters:
Outside tube diameter, do =12.7 mm
Inside tube diameter, di =12.0 mm
Longitudinal tube spacing, SL =26.16 mm
Transverse tube spacing, ST =31.75 mm
No. of fins/m, Nf =554
Aluminum fin thickness, tf =0.38 mm
Exchanger compactness, β = 1060 m2/m3

Aflow/Aface on the air-side, 

Outside area/inside area, (Ao/Ai) =23
=0.529
Finned-surface weighted efficiency, = 0.85
Number of tube-passes per water loop, Np =6
Design operating Data:
Moist air
Total cooling load at full load, Qc =60 kW
Latent Load at full load, QL =20 kW
Inlet air conditions = t =Dry and wet bulb temperatures are:
27 oC, and 17 oC
Air face velocity , V =2.8 m/s
Air heat transfer coefficient, hc =60 W/ (m2 oC)
Air mean specific heat, cpm =1.001 kJ/(kg. K)
Chilled water
Inlet water temperature, Twin =6 oC
Water mass flow rate, mw =2.9 kg/s
Water inlet velocity, Vw =1.25 m/s
Heat transfer coefficient on water side, hi =4000 W/ (m2 oC)
Number of tube-passes per water loop, Ntp =6
Exit water temperature, Twout =11 oC
Water specific heat, CPw =4.14 kJ/(kg. K)
Under the above design full load conditions, calculate:
a. The coil dimensions (tube length, finned width and coil depth).
b. The number of coil rows and the total number of tubes.
c. The exit air temperature.
Calculation Procedures
From psychometric chart at inlet air conditions the inlet air properties are obtained represented
by hain=48 kJ/kg, Wain=0.0081 kgv/kga, dew point temperature, dpt = 10oC. By knowing QC=60
kW, CSHF=0.75 (=1- QL/Qc), and ϕ = % using information from inlet point, the exit
conditions can be determined as haout=30.6 kJ/kg, Tao=10.5 oC, Wao = 0.0078 kgv /kga

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386 Heat Exchangers – Basics Design Applications

- = = = 3.53 kg/s
.
- = = = 2.90 kg/s
. ∗

Calculations of the coil design parameters:

× × ∗ . ∗ .
Δ = = = . m2
× . ∗ .

. ∗ ∗ .
Δ = = = 0.432
. ∗

.
Δ = ×Δ = = . m2

∗ .
ΔNTU = = = 0.435
. ∗

∆
R= ∗ = 5.3 KJ/kg.K
∆

Row i=1:

. . . ∗ ∗ .
= = 13.5 oC
.

Since the mean coil surface temperature at the 1st row is 13.5 and it is larger than the inlet
dew point temperature of the entering air, dpt = 10oC the coil will be partially dry until the
coil surface temperature reaches at least the dew point temperature. Therefore, the dry coil
equations will be used here.
∗
= = 13.6 oC

h ΔA
∆ = × Ts − Tw = .
ΔNTU
−

Where, hi =4000 W/m2.C

∆ .
= − = − = . oC
. ∗ .

∆
Ta = Ta − = 2.2 oC

Wa = Wa = . 81 kgv/kga
Row i=2
∗
= = 11.81 oC

h ΔA
∆ = × − = .
ΔNTU
−

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Thermal Design of Cooling and Dehumidifying Coils 387

∆ .
= − = . − = . oC
. ∗ .

∆
Ta = Ta − = . oC

Wa = Wa = . 81 kgv/kga
Row i=3
∗
= = 10.42 oC

h ΔA
∆ = × − = .
ΔNTU
−

∆ .
= − = . − = . oC
. ∗ .

∆
Ta = Ta − = . oC

Wa = Wa = . 81 kgv/kga
Row i=4
∗
= = 9.34 oC

h ΔA
∆ = × − =
ΔNTU
−

∆ .
= − = . − . ∗ .
= . oC

∆
Ta = Ta − = . oC

Wa = Wa = . 81 kgv/kga
Row i=5

Tsm < dpt therefore, the coil will act as a wet coil

ℎ = 1.001xTa5+Wa5*(2501+1.8*Ta5) = 33.76 kJ/kg

. . . ∗ ∗ .
= = oC
.

h ΔA
∆ = × − = .
ΔNTU
−

∆ .
= − = . − = oC
. ∗ .

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388 Heat Exchangers – Basics Design Applications

∆
ℎ =ℎ − = . kJ/kg

= × +{ × = . oC

. .
Wa = . ∗
= = . 77 kgv/kga
. .

Row i=6

. . . ∗ ∗ .
= =8.1 oC
.

h ΔA
∆ = × − = .
ΔNTU
−

∆ .
= − = − = . oC
. ∗ .

∆
ℎ =ℎ − = kJ/kg

= × +{ × = . oC

.
Wa = . ∗
= = . 76 kgv/kga
. .

The total calculated cooling load for 6-rows coil is: Q = ∑ Q = 65.8 kW

And coil sensible heat factor,

−
= = = .
.
The calculated unknowns are listed row-by-row in the next Table; and the psychometric
process for the cooling and dehumidification process is represented by Figure 7.

Row number Surface condition Tsmi oC ∆QCi kW Twi+1 oC Tai+1 oC Wai+1 gv/kga
Coil inlet Dry 0 11 27 8.1
1 Dry 13.6 17.3 9.8 22.2 8.1
2 Dry 11.8 13.3 8.86 18.5 8.1
3 Dry 10.4 10.36 8.13 15.6 8.1
4 Dry 9.3 8 7.57 13.3 8.1
5 Wet 9.0 9.5 7 11.7 7.7
6 Wet 8.1 7.3 6.4 10.3 7.6
a. Calculation of Coil number of tubes, Nt

Nr = Number of coil rows= 6

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Thermal Design of Cooling and Dehumidifying Coils 389

8.2

Mositure content (gw/kga)

8.1
8
7.9
7.8
7.7
7.6
7.5
10 15 20 25 30
Dry bulb temperature (o C)

Fig. 7. Presentation of Cooling and dehumidifying process.

= = 120 tubes

b. Calculation of Coil dimension (D, H, L)

= ∗

= =

Height of the coil, H=St*Nc=0.635 m

=∑ Δ = ∗Δ = ∗29.95 = 179.7 m2

Given: =

Ai = 7.81 m2 =
= ℎ ℎ = = .
= ℎ= ∗ = .
c. Exit air temperature

Taout=10.3 oC
Treating the cooling coil as a single zone "Worked Example"
We will solve the previous worked problem using principal treating the coil as single
zone/section instead of multi-sections and compare the two results.
Calculation Procedures:
1. From psychometric chart at inlet air conditions the inlet air properties are obtained
represented by hain=48 kJ/kg, Wain=0.0081 kgv/kga, dew point temperature, dpt = 10oC.

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390 Heat Exchangers – Basics Design Applications

By knowing QC=60 kW, CSHF=0.75 (=1- QL/Qc), and ϕ = % using information

from inlet point, the exit conditions can be determined as haout=30.6 kJ/kg, Tao=10.5 oC,
Wao = 0.0078 kgv /kga

2. = = .
= 3.53 kg/s
3. = = = 2.90 kg/s
. ∗

= = 3.41 KJ/kg.K

− + . + + . + . ∗ ℎ + ∗ − .
=
.
= . > . = [Coil surface is dry]

∗
= = 14.62o C

∗
= = 7.02

Calculation of ∆
]
∆ = − =

∆ = .05 oC
Calculation of Ai & Ao

= = . m2
∗∆

= = . m2

Number of Coil Tubes Nt

= =

The Length of the Tube (Coil), L:

= = . m

Height of the Coil, H:

= ∗ = 0.683 m

Number of Rows, Nr
∗
= = = 5.5 ≈

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Thermal Design of Cooling and Dehumidifying Coils 391

Depth of the Coil, D:

= ∗ = . m

= = 2.43

Calculation of Exit air condition

= × + × = 9.2 °C

= = . kgv/ kga
. ∗

Calculation of Latent load and CSHF

= ma (Wa2- Wa1) x2501 =0.88 kW

.
= = .98

Table-2 illustrates a comparison of the dimensions and exit air conditions for 60 kW cooling
coil analyzed as only single-section and cooling coil divided to Nr-sections (Nr=6).

Physical quantity Single-section coil 6-sections coil

Air exit temperature, oC 9.2 10.3
Number of tubes 120 120
Number of rows 6 6
Coil width ,m 0.683 0.635
Coil depth, m 0.157 0.157
Coil length, m 1.62 1.71
Coil SHF 0.98 0.71
Design cooling load, kW 60 60
Actual cooling load, kW 60 65.8
Table 2.

The results presented in Table-2 indicate that cooling coil analyzed as only one-section gives
results with good agreement with those obtained with the coil analyzed as 6-sections. The
maximum error is 12%.

8. Worked problem on the thermal design of Dx-coils

Cross-counter flow Dx- evaporator coil using corrugated plate-fins, has the flowing
construction and operating design parameters:
Coil construction parameters:
Outside tube diameter, do =13.41 mm
Inside tube diameter, di =12.09 mm
Longitudinal tube spacing, SL =26.16 mm
Transverse tube spacing, ST =31.75 mm

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392 Heat Exchangers – Basics Design Applications

No. of fins/m, Nf =554

Aluminum fin thickness, tf =0.15 mm
Exchanger compactness, β = 1060 m2/m3

Aflow/Aface on the air-side, 

Outside area/inside area, (Ao/Ai) =23
=0.529
Finned-surface weighted efficiency, = 0.85
Number of tube-passes per water loop, Np =6
Design operating Data:
Moist air
Total cooling load at full load, Qc =60 kW
Latent Load at full load, QL =20 kW
Inlet air conditions = t = Dry and wet bulb temperatures are:
26 oC, and 19 oC
Air face velocity , V =2.8 m/s
Air heat transfer coefficient, hc =60 W/ (m2 oC)
Air mean specific heat, cpm =1.001 kJ/(kg. K)
R-134a
Evaporating temperature, Tev =7 oC
Heat transfer coefficient on refrigerant side, hi =2000 W/ (m2 oC)
Number of tube-passes per water loop, Ntp =6

Under the above design full load conditions, calculate:

a. The coil dimensions (tube length, finned width and coil depth).
b. The number of coil rows and the total number of tubes.
c. The exit air temperature.
Calculation Procedures
1. Knowing: [hain=54 kJ/kg, Wain=0.011 kgv/kga, QC=60 kW, CSHF=0.75, ϕ = %],
from the Psychometric-chart we obtain:

Air Exit Condition: [haout=33 kJ/kg, Tao=10.5 oC, Wao=0.86*10-3 kgv/kga]

2. m = = = 2.857 kg/s

3. R= = 1.7 KJ/kg.K

− R+ . + R+ . + . ∗ ha + R ∗ − .
Ts =
.
Ts = . <T . = [Coil surface is wet]

− R+ . + R+ . + . ∗ ha + R ∗ − .
Ts =
.
Ts = . oC

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Thermal Design of Cooling and Dehumidifying Coils 393

Calculation of ∆Tev
]
∆Tev = Ts − Tev =

∆ = . oC

Where, ∆Tev = mean temperature difference on the refrigerant-side.

Calculation of Ai & Ao

A = ∗∆
= . m2

A = A = . m2

Calculation of Exit air condition

= × + × = . °C

∆NTU = = .

Air is saturate at this temperature with ha2= 31.5 kJ/kg

∗
Wa = = . Kgv / kga
. ∗

Calculation of Latent load and CSHF

Q = m ha − ha = 64.28 kW

Q =Q −Q = . − . ∗ − . = . kW

. − .
CSHF = = .
.
Calculation of Dx-Coil Size
Number of Coil Tubes Nt

For DX-coil the number of tubes is determined by applying the continuity equation for the
refrigerant at the exit of the coil where the velocity attains its maximum value at this exit
section. Assuming the refrigerant as saturated vapor, and the maximum velocity of
vapor V ≈ 10 m/s, Nt is given as:

m = ∗
= . kg/s [Assume inlet dryness fraction, x = 0.9]

N = ≈ tube

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394 Heat Exchangers – Basics Design Applications

The Length of the Tube (Coil), L

L= = . m

Height of the Coil, H

Air face area, A = = . m2

A = L

= = . m2

Number of Rows, Nr
∗
N = = = 5.35 ≈ rows

Depth of the Coil, D:

= ∗ = . m

9. Conclusion
In this chapter, simulation of the cooling coil using a discrete technique "row-by-row
method" has been presented. The main advantage of this method is to trace the air and coil
surface temperature locally. In addition, this method gives more accurate results for the
cooling coil design or simulation compared with those given by ordinary method such as
log mean enthalpy method. Step-by-step procedure has been introduced and worked
examples are presented. The deviation between the two methods "numerical discrete
method and treating the coil as a single zone" is around of 12%.

10. Nomenclature
A = surface area, m2
Cp = specific heat, kJ/kg. C
h = heat transfer coefficient, W/m2. C
hmass = mass transfer coefficient, kg/m2.S
NTU = number of transfer unit
Q = heat transfer, W
T = temperature , oC
W = humidity ratio, kgv/kga

11. References
[1] ASHRAE Systems and Equipment Handbook (SI), 2000, Chapter 21
[2] Wibert Stoecker, and Jerold Jones. "Refrigeration & air-conditioning",2nd, Ed., 1982,
McGraw-Hill
[3] ASHRAE Fundamental Handbook (SI), 2001, Chapter 6
[4] Kays, W.M., and London A.L. Compact Heat Exchangers, 3rd edition, McGraw-Hill, New
York.1984
[5] Threlkeld, J.L. Thermal Environment Engineering, Prentice-Hall Inc., New Work, NY.
1970.

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 Heat Exchangers - Basics Design Applications
Edited by Dr. Jovan Mitrovic

ISBN 978-953-51-0278-6
Hard cover, 586 pages
Publisher InTech
Published online 09, March, 2012
Published in print edition March, 2012

Selecting and bringing together matter provided by specialists, this project offers comprehensive information
on particular cases of heat exchangers. The selection was guided by actual and future demands of applied
research and industry, mainly focusing on the efficient use and conversion energy in changing environment.
Beside the questions of thermodynamic basics, the book addresses several important issues, such as
conceptions, design, operations, fouling and cleaning of heat exchangers. It includes also storage of thermal
energy and geothermal energy use, directly or by application of heat pumps. The contributions are
thematically grouped in sections and the content of each section is introduced by summarising the main
objectives of the encompassed chapters. The book is not necessarily intended to be an elementary source of
the knowledge in the area it covers, but rather a mentor while pursuing detailed solutions of specific technical
problems which face engineers and technicians engaged in research and development in the fields of heat
transfer and heat exchangers.

How to reference
In order to correctly reference this scholarly work, feel free to copy and paste the following:

M. Khamis Mansour and M. Hassab (2012). Thermal Design of Cooling and Dehumidifying Coils, Heat
Exchangers - Basics Design Applications, Dr. Jovan Mitrovic (Ed.), ISBN: 978-953-51-0278-6, InTech,
Available from: http://www.intechopen.com/books/heat-exchangers-basics-design-applications/thermal-design-
of-cooling-and-dehumidifying-coils

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