HEAT

EXCHANGERS
What is Heat Exchanger?

Heat exchangers are exchange of heat between two fluids

that are at different temperatures while keeping them from
mixing with each other.

 From hot water to cold water

 From hot steam to cold water

 From hot gas to cold water

 From hot water or unsaturated steam to cool air.

What is Heat Exchanger?
 A heat exchanger is a component that allows the transfer of
heat from one fluid (liquid or gas) to another fluid.

Reasons for heat transfer include the following:

1. To heat a cooler fluid by means of a hotter fluid

2. To reduce the temperature of a hot fluid by means of a
cooler fluid
3. To boil a liquid by means of a hotter fluid
4. To condense a gaseous fluid by means of a cooler fluid
5. To boil a liquid while condensing a hotter gaseous fluid
Examples of Heat Exchanger?

 Steam Boilers  Evaporators

 Steam Condensers  Economizer
 Water Heaters  Fluid Heaters and Coolers
 Oil Heaters  Tube Tanks

 The simplest type of heat exchanger consists of two concentric

pipes of different diameters called the double-pipe heat
exchanger.

 One fluid in a double-pipe heat exchanger flows through the

smaller pipe while the other fluid flows through the annular space
between the two pipes.
Examples of Heat Exchangers

 Two types of flow arrangement are possible in a double-pipe

heat exchanger:
(a). Parallel Flow
(b). Cross Flow

 In parallel flow, both the hot and cold fluids enter the heat
exchanger at the same end and move in the same direction.

 In counter flow, on the other hand, the hot and cold fluids
enter the heat exchanger at opposite ends and flow in opposite
directions.
Examples of Heat Exchanger s
 Examples of Heat Exchanger s

 Another type of heat exchanger, which is specifically

designed to realize a large heat transfer surface area per unit
volume, is the compact heat exchanger.

 In compact heat exchangers, the two fluids usually move

perpendicular to each other, and such flow configuration is
called cross-flow.
Although heat exchangers come in every shape and size
imaginable, the construction of most heat exchangers fall into one
of two categories:

(a). Tube and shell

(b). Plate regenerative
(c). Recuperators.
Cross Flow

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

to one another 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 channel fluid flow or induce turbulence.
Tube and Shell

 The most basic and the most common type of heat

exchanger construction is the tube and shell, as shown in
Figure.

 This type of heat exchanger consists of a set of tubes in a

container called a SHELL. The fluid flowing inside
the tubes is called the tube side fluid and the fluid flowing on
the outside of the tubes is the shell side fluid.

 At the ends of the tubes, the tube side fluid is separated from
the shell side fluid by the tube sheet(s). The tubes are rolled
and press-fitted or welded into the tube sheet to provide a
leak tight seal.
Tube and Shell
Tube and Shell
Plate Heat Exchanger
 A plate type heat exchanger, as illustrated in Figure 2,
consists of plates instead of tubes to separate the hot and cold
fluids.

 The hot and cold fluids alternate between each of the plates.
Baffles direct the flow of fluid between plates.

 Because each of the plate has a very large surface area, the
plates provide each of the fluids with an extremely large heat
transfer area.

 Therefore a plate type heat exchanger, as compared to a

similar ly sized tube and shell heat exchanger, is capable
of transferring much more heat.

 This is due to larger area the plates provide over tubes.

Plate Heat Exchanger
Plate Type Heat Exchanger
 Recuperators

• A fourth type of heat exchanger uses an intermediate fluid or solid store to

hold heat, which is then moved to the other side of the heat exchanger to be
released.

• Two examples of this are adiabatic wheels, which consist of a large wheel
with fine threads rotating through the hot and cold fluids, and fluid heat
exchangers.

• This type is used when it is acceptable for a small amount of mixing to

occur between the two streams.
Recuperators
How to Build a Heat Exchanger
 Analysis of Heat Exchangers

 Heat exchangers usually operate for long periods of time with

no change in their operating conditions.

 They can be modeled as steady-flow devices.

 The mass flow rate of each fluid remains constant, and the
fluid properties such as temperature and velocity at any inlet or
outlet remain the same.

 kinetic and potential energy changes are negligible.

 Analysis of Heat Exchangers

 The only time the temperature rise of a cold fluid is equal to

the temperature drop of the hot fluid is when the heat capacity
rates of the two fluids are equal to each other.
Analysis of Heat Exchangers

Where:
Analysis of Heat Exchangers
 Analysis of Heat Exchangers

 Two special types of heat exchangers commonly used in

practice are condensers and boilers. One of the fluids in a
condenser or a boiler undergoes a phase-change process.
 Analysis of Heat Exchangers

 In heat exchanger analysis, a condensing or boiling fluid is

conveniently modeled as a fluid whose heat capacity rate is
infinity.
Log Mean Temperature Difference
 The log mean temperature difference (LMTD) is used
to determine the temperature driving force for heat
transfer in flow systems (most notably in heat
exchangers).

 The LMTD is a logarithmic average of the

temperature difference between the hot and cold streams
at each end of the exchanger.
LOG MEAN TEMPERATURE
DIFFERENCE (LMTD)

.
Heat Exchangers
Sample Problems:

1. A liquid to liquid counter flow heat exchanger

is used to heat a cold fluid from 120⁰F to 310⁰F.
Assuming that the hot fluid enters at 500⁰F and
leaves at 400⁰F, Calculate the log mean
temperature difference for the heat exchanger.

Ans: 232⁰F
Heat Exchangers
Sample Problems:

Ans: 16.37⁰C
Heat Exchangers
Sample Problems:

3. Exhaust Steam at 7 Kpa at the rate of 75 kg/s enters a single pass

condenser containing 5780 pcs copper tubes with a total surface
area of 2950 m2. The steam has a moisture content of 10% and the
condensate leaves saturated liquid at a steam temperature. The
cooling water flow rate is 4,413 liters per second entering at 20C.
Find the over-all heat transfer coefficient.
hf = 163.4 kJ/kg, hfg = 2409.1, Tsat @ 7 kPa = 39⁰C

Ans: 3,896 W/m2-K

Heat Exchangers
Sample Problems:

4. An oil heater heats 100 kg per minute of oil from 35C to 100C in
a counter-flow heat exchanger. The average specific heat of the oil
is 2.5 kJ/kg-C. Exhaust gases used for heating enter the heater with
an average specific heat of 1 kJ/kg-C, a mass flow rate of 250
kg/min and an initial temperature of 200C. The over-all heat
transfer coefficient is 75 W/m2-C. Determine the heating surface
area. (ME board Exam)

Ans: 36.11 m2