CHE 311E: HEAT AND MASS TRANSFER

HEAT
EXCHANGERS
 HEAT
EXCHANGE
RS are devices that facilitate the
Heat exchangers
exchange of heat between two fluids that
are at different temperatures while keeping
them from mixing with each other.
 HEAT
EXCHANGE
Heat transferRS
in a heat exchanger usually involves convection in
each fluid and conduction through the wall separating
the two fluids. In the analysis of heat exchangers, it is convenient to
work with an overall heat transfer coefficient U that accounts for the
contribution of all these effects on heat transfer. The rate of heat
transfer between the two fluids at a location in a heat exchanger
depends on the magnitude of the temperature difference at that location,
which varies along the heat exchanger.
 HEAT
EXCHANGE
RS
The most common type is one in which the hot and the cold
fluid do not come into direct contact with each other but are
separated by a tube wall or a flat or curved surface. The
transfer of heat is accomplished from the hot fluid to the wall
or tube surface by convection, through the tube wall or plate
by conduction, and then by convection to the cold fluid.
DOUBLE-PIPE HEAT
EXCHANGER
The simplest exchanger is the double-pipe or concentric-pipe
exchanger. One fluid flows inside one pipe and the
other fluid in the annular space between the two
pipes. The fluids can be in co-current or countercurrent
flow. The exchanger can be made from a pair of single
lengths of pipe with fittings at the ends or from a number of
pairs interconnected in series. This type of exchanger is
useful mainly for small flow rates.
 SHELL-AND-TUBE
HEAT EXCHANGER
If larger flows are involved, a shell and tube exchanger
is used, which is the most important type of exchanger in use
in the process industries. In these exchangers the
flows are continuous. Many tubes in parallel are used
where one fluid flows inside these tubes. The tubes, arranged
in a bundle, are enclosed in a single shell and the other fluid
flows outside the tubes in the shell side.
 SHELL-AND-TUBE
HEAT EXCHANGER
The simplest shell and tube exchanger is for 1 shell pass and
1 tube pass, or a 1-1 counter-flow exchanger. The cold fluid
enters and flows inside through all the tubes in parallel in one
pass. The hot fluid enters at the other end and flows counter-
flow across the outside of the tubes. Cross baffles are used so
that the fluid is forced to flow perpendicular across the tube
bank rather than parallel with it. This added turbulence
generated by this cross flow increases the shell-side heat-
transfer coefficient.
SHELL-AND-TUBE
HEAT EXCHANGER
 SHELL-AND-TUBE
HEAT EXCHANGER
In a 1-2 parallel counter-flow exchanger, the liquid on the
tube side flows in two passes as shown and the shell-side
liquid flows in one pass. In the first pass of the tube side the
cold fluid is flowing counter-flow to the hot shell-side fluid,
and in the second pass of the tube side the cold fluid flows in
parallel (co-current) with the hot fluid.
SHELL-AND-TUBE
HEAT EXCHANGER
 SHELL-AND-TUBE
HEAT EXCHANGER
Another type of exchanger has 2 shell-side passes and
4 tube passes. Other combinations of number of
passes are also used sometimes, with the 1-2 and 2-4
types being the most common.
 CROSS-FLOW
EXCHANGER
When a gas such as air is being heated or cooled, a common device
used is the cross-flow heat exchanger. One of the fluids, which is a
liquid, flows inside through the tubes and the exterior gas flows across
the tube bundle by forced or sometimes natural convection. The fluid
inside the tubes is considered to be unmixed since it is confined and
cannot mix with any other stream. The gas flow outside the tubes is
mixed since it can move about freely between the tubes and there will
be a tendency for the gas temperature to equalize in the direction
normal to the flow. For the unmixed fluid inside the tubes there will be
a temperature gradient both parallel and normal to the direction of flow.
CROSS-FLOW
EXCHANGER
 CROSS-FLOW
EXCHANGER
A second type of cross-flow heat exchanger
shown in is used typically in air-conditioning
and space-heating applications. In this type the
gas flows across a finned-tube bundle and is
unmixed since it is confined in separate flow
channels between the fins as it passes over the
tubes. The fluid in the tubes is unmixed.
 LOG MEAN
TEMPERATURE
DIFFERENCE
When the hot and cold fluids in a heat exchanger are
in true countercurrent flow or co-current (parallel)
flow, the log mean temperature difference should be
used.
COUNTER-CURRENT
This holds for a double-pipe heat exchanger and a FLOW

1-1 exchanger with 1 shell pass and 1 tube pass in

parallel or counterflow.

CO-CURRENT FLOW
 LOG MEAN
TEMPERATURE
DIFFERENCE
In the cases where a multiple-pass heat exchanger is involved, it is
necessary to obtain a different expression for the mean temperature
difference to use, depending on the arrangement of the shell and tube
passes. Considering first the one-shell-pass, two-tube-pass exchanger, the
cold fluid in the first tube pass is in counter-flow with the hot fluid. In the
second tube pass the cold fluid is in parallel flow with the hot fluid.
Hence, the log mean temperature difference, which applies to either
parallel or counter-flow but not to a mixture of both types, as in a 1-2
exchanger, cannot be used to calculate the true mean temperature drop
without a correction.
 LOG MEAN
TEMPERATURE
DIFFERENCE
Figure 11-4 of the Perry’s ChE
Handbook (8 ed) shows the LMTD
th

correction for heat exchangers:

where is the inlet temperature of the

hot fluid, is the outlet of hot fluid, is
the inlet of the cold fluid, and is the
outlet of the cold fluid.
 LOG MEAN
TEMPERATURE
DIFFERENCE
In general, it is not recommended to use a heat exchanger
for conditions under which . Another shell and tube
arrangement should be used.
Using the correction , the equation for an exchanger
becomes:

where .
EXA
MPLE
A 1-2 heat exchanger containing one shell pass and two tube passes
heats 2.52 kg/s of water from 21.1 to 54.4°C by using hot water under
pressure entering at 115.6 and leaving at 48.9°C. The outside surface
area of the tubes in the exchanger is 9.30 m2.
a. Calculate the mean temperature difference in the exchanger and the
overall heat-transfer coefficient .
b. For the same temperatures but using a 2-4 exchanger, what would be
the ?
EXA
MPLE
A counter-flow double-pipe heat exchanger is to heat water from 20°C
to 80°C at a rate of 1.2 kg/s. The heating is to be accomplished by
geothermal water available at 160°C at a mass flow rate of 2 kg/s. The
inner tube is thin-walled and has a diameter of 1.5 cm. If the overall
heat transfer coefficient of the heat exchanger is 640 W/m 2-K, determine
the length of the heat exchanger required to achieve the desired heating.
EXA
MPLE
A 2-4 shell-and-tube heat exchanger is designed to cool oil with cp of
2.0 kJ/kg-K. Oil is to be cooled down to 328 K from 398 K. Water is
used to cool the oil which enters the shell side at 298 K and leaves 319
K. If the overall heat transfer coefficient is 900 W/m2-K. Approximate
the number of tubes required for the heat exchanger if the oil flow rate
is 10 kg/s and each tube has a diameter of 2.070” and length of 6 m.
 FOULING
FACTOR
In actual practice, heat-transfer surfaces do not remain clean. Dirt, soot,
scale, and other deposits form on one or both sides of the tubes of an
exchanger and on other heat transfer surfaces. These deposits form
additional resistances to the flow of heat and reduce the overall
heat-transfer coefficient . In petroleum processes coke and other
substances can deposit. Silting and deposits of mud and other materials
can occur. Corrosion products may form on the surfaces which could form
a serious resistance to heat transfer. Biological growth such as algae can
occur with cooling water and in the biological industries.
 FOULING
FACTOR
The effect of such deposits and fouling is usually taken care
of in design by adding a term for the resistance of the
fouling on the inside and the outside of the tube:

where is the fouling factor for the inside, is the fouling

factor for the outside.
EXA
MPLE
A double-pipe (shell-and-tube) heat exchanger is constructed of a
stainless steel (k = 15.1 W/m-K) inner tube of inner diameter 1.5 cm
and outer diameter 1.9 cm and an outer shell of inner diameter 3.2 cm.
The convection heat transfer coefficient is given to be 800 W/m 2-K on
the inner surface of the tube and 1200 W/m2-K on the outer surface. For
a fouling factor of 0.0004 m2-K/W on the tube side and 0.0001 m2-K/W
on the shell side, determine (a) the thermal resistance of the heat
exchanger per unit length and (b) the overall heat transfer coefficients,
and based on the inner and outer surface areas of the tube, respectively .
EXA
MPLE
A 2-shell passes and 4-tube passes heat exchanger is used to heat
glycerin from 20°C to 50°C by hot water, which enters the thin-walled
2-cm-diameter tubes at 80°C and leaves at 40°C. The total length of the
tubes in the heat exchanger is 60 m. The convection heat transfer
coefficient is 25 W/m2-K on the glycerin (shell) side and 160 W/m2-K
on the water (tube) side. Determine the rate of heat transfer in the heat
exchanger (a) before any fouling and (b) after fouling with a fouling
factor of 0.0006 m2-K/W occurs on the outer surfaces of the tubes.