Introduction To Heat Exchangers (HXS) : DR Rashid Ali

INTRODUCTION TO HEAT
EXCHANGERS (HXs)
DR RASHID ALI
PRESENTATION OUTLINE
• Introduction to HXs
• Applications of HXs
• Classification of HXs
• Types of HXs
• Research Areas in the field of HXs

Objectives and Outcomes
• Objectives:
• To familiarize the learners with HXs
• To learn fields of Application of HXs
• To be able to classify HXs
• To know basics of main types of HXs
• Outcomes:
• After this lecture the students shall be able to:
• Classify HXs w.r.t flow, design, process, fluid type
• Explain the basic construction and flow configuration of
main types of HXs
HEAT EXCHANGER
• A heat exchanger is a device used to transfer heat:
Between a solid object and a fluid,
OR
Between two or more fluids
OR
Between solid particulates and a fluid,
• The fluids may be separated by a solid wall to

prevent mixing or they may be in direct contact.
APPLICATIONS
• HXs are widely used in:
• Power Plants,
• Space heating, Refrigeration, Air Conditioning,
• Chemical Plants,
• Petrochemical plants,
• Petroleum refineries,
• Natural-gas processing,
• and sewage treatment
APPLICATIONS
• The classic example of a heat exchanger is

found in an internal combustion engine in
which a circulating fluid known as engine
coolant flows through radiator coils and air
flows past the coils, which cools the coolant
and heats the incoming air.
APPLICATIONS
• Another example is the heat sink, which is a

passive heat exchanger that transfers the heat
generated by an electronic or a mechanical
device to a fluid medium, often air or a liquid
coolant
CLASSIFICATION
• HXs can be classified into several different
ways such as [1]according to heat transfer
mechanisms,[2] according to process function,
[3]according to flow arrangement are a few to
mention.
• We will see different classifications in coming

slides
Home Work
• Please study different modes of heat transfer

i.e. Conduction, Convection, Radiation
• Any heat transfer book can be used such as
Fundamentals of heat and Mass Transfer b

By: Frank P Incropera
CLASSIFICATION
CLASSIFICATION
CLASSIFICATION
CLASSIFICATION
CLASSIFICATION
CLASSIFICATION
CLASSIFICATION
CLASSIFICATION
The three primary classifications of heat exchangers according to their
flow arrangement.
In parallel-flow heat exchangers, the two fluids enter the exchanger at

the same end, and travel in parallel to one another to the other side.
In counter-flow heat exchangers the fluids enter the exchanger from

opposite ends. The counter current design is the most efficient, in that
it can transfer the most heat from the heat (transfer) medium per unit
mass due to the fact that the average temperature difference along
any unit length is higher.
In a cross-flow heat exchanger, the fluids travel roughly perpendicular

to one another through the exchanger.
CLASSIFICATION
• For efficiency, heat exchangers are designed to

maximize the surface area of the wall between
the two fluids, while minimizing resistance to
fluid flow through the exchanger.
• The exchanger’s performance can also be
affected by the addition of fins or corrugations
in one or both directions, which increase
surface area and may induce turbulence
DOUBLE PIPE HEAT EXCHANGERS
• Double pipe heat exchangers are the simplest exchangers used
in industries.
• These HXs are cheap for both design and maintenance, making
them a good choice for small industries.
BUT
• These HXs have low efficiency coupled with the high space
occupied in large scales,
• Therefore, modern industries use more efficient heat
exchangers like shell and tube or plate type.
• However, since double pipe heat exchangers are simple, they

are used to teach heat exchanger design basics to students as
the fundamental rules for all heat exchangers are the same.
SHELL AND TUBE HXs
• Shell and tube HXs are the by far most extensively
used type of HX in the industry
• Shell and tube heat exchangers consist of series of
tubes. One set of these tubes contains the fluid that
must be either heated or cooled. The second fluid
runs over the tubes that are being heated or cooled
so that it can either provide the heat or absorb the
heat required.
• A set of tubes is called the tube bundle and can be
made up of several types of tubes: plain,
longitudinally finned, etc.
SHELL AND TUBE HXs
• Shell and tube heat exchangers are typically

used for high-pressure applications (with
pressures greater than 30 bar and
temperatures greater than 260 °C). This is
because the shell and tube heat exchangers
are robust due to their shape.
SHELL AND TUBE HXs
• Several thermal design features must be considered
when designing the tubes in the shell and tube heat
exchangers:
• There can be many variations on the shell and tube
design. Typically, the ends of each tube are
connected to plenums (sometimes called water
boxes) through holes in tube sheets. The tubes may
be straight or bent in the shape of a U, called U-
tubes.
SHELL AND TUBE HXs
SHELL AND TUBE HXs
PLATE TYPE HXs (PHEs)
• These exchangers are composed of many thin,
slightly separated plates that have very large surface
areas and small fluid flow passages for heat transfer.
• Advances in gasket and brazing technology have
made the plate-type heat exchanger increasingly
practical.
• In HVAC applications, large heat exchangers of

this type are called plate-and-frame; when
used in open loops, these heat exchangers are
normally of the gasket type to allow periodic
disassembly, cleaning, and inspection.
• There are many types of permanently bonded plate

heat exchangers, such as dip-brazed, vacuum-
brazed, and welded plate varieties, and they are
often specified for closed-loop applications such as
refrigeration.
• Plate heat exchangers also differ in the types
of plates that are used, and in the
configurations of those plates. Some plates
may be stamped with “chevron”, dimpled, or
other patterns, where others may have
machined fins and/or grooves.
PHASE CHANGE HXs
• In addition to heating up or cooling down fluids in
just a single phase, heat exchangers can be used
either to heat a liquid to evaporate (or boil) it or
used as condensers to cool a vapor and condense it
to a liquid.
• In chemical plants and refineries, reboilers used to
heat incoming feed for distillation towers are often
heat exchangers. Distillation set-ups typically use
condensers to condense distillate vapors back into
liquid.
PHASE CHANGE HXs
PHASE CHANGE HXs
• In the nuclear power plants called pressurized water
reactors, special large heat exchangers pass heat
from the primary (reactor plant) system to the
secondary (steam plant) system, producing steam
from water in the process. These are called STEAM
GENERATORS.
• All fossil-fueled and nuclear power plants using
steam-driven turbines have surface condensers to
convert the exhaust steam from the turbines into
condensate (water) for re-use.
MICROCHANNEL HXs (MCHs)
• MCHs are compact HXs and offer enhanced heat
transfer rates
• Micro heat exchangers, Micro-scale heat
exchangers, or microstructured heat exchangers are
heat exchangers in which (at least one) fluid flows in
lateral confinements with typical dimensions below
1 mm.
• The most typical such confinement are
microchannels, which are channels with a hydraulic
diameter below 1 mm.
MICROCHANNEL HXs (MCHs)
• Microchannel heat exchangers can be made from
metal, ceramic, and even low-cost plastic.
Microchannel heat exchangers can be used for
many applications including:
• High-performance aircraft gas turbine engines
• Heat pumps
• Air conditioning
• Heat recovery ventilators
Open Areas for Research in HXs
• How to achieve more compact heat exchangers

• High thermal efficiency
• Balance between enhanced heat transfer and
accompanied pressure drop
• Material issues especially for high temperature
applications
• Manufacturing methodology
• Fouling
• Non-steady operation
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INTRODUCTION TO HEAT

• Research Areas in the field of HXs

• The fluids may be separated by a solid wall to

• The classic example of a heat exchanger is

• Another example is the heat sink, which is a

• We will see different classifications in coming

• Please study different modes of heat transfer

• Any heat transfer book can be used such as

Fundamentals of heat and Mass Transfer b

In parallel-flow heat exchangers, the two fluids enter the exchanger at

In counter-flow heat exchangers the fluids enter the exchanger from

In a cross-flow heat exchanger, the fluids travel roughly perpendicular

• For efficiency, heat exchangers are designed to

• However, since double pipe heat exchangers are simple, they

• Shell and tube heat exchangers are typically

• In HVAC applications, large heat exchangers of

• There are many types of permanently bonded plate

• How to achieve more compact heat exchangers

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