Heat Exchanger Design

Lecture
Basic Design Methods
Task
Heat Exchanger Sizing
Thermal and pressure drop
considerations, maintenance scheduling
with fouling consideration.
Heat Exchanger Rating
Checking the existing design for
compatibility with the user requirements
(outlet temperature, heat load etc.)
Energy Balance
For each side


Energy balance between hot and cold
sides
2 1
( ) Q mdi Q m i i o = =
1 2 2 1
( ) ( )
h h h c c c
Q m i i m i i = =
1 2 2 1
( ) ( ) ( ) ( )
p h h h p c c c
Q mc T T mc T T = =
Overall Heat Transfer Coefficient


The overall heat transfer coefficient for a single
smooth and clean plain wall can be written as
m
Q UA T = A
1 1
1 1
t
i i o o
UA
t
R
h A kA h A
= =
+ +
Tubular geometry
For the unfinned and clean tubular heat
exchanger, the overall heat transfer
coefficient is given by

1 1
ln( / ) 1 1
2
o o i i
t
o i
i i o o
U A U A
R
r r
h A kL h A t
= = =
(
+ +
(

Fouling
For the heat exchanger of which the wall is
fouled by deposit formation on both the
inside and outside surfaces, the total
thermal resistance can be expressed as


1 1 1 1 1
fi fo
t w
o o i i i i i o o o
R R
R R
UA U A U A h A A A h A
= = = = + + + +
Wall resistance
The wall resistance is obtained from the
following equations:

o i
(for a plane wall)
ln( r r )
(for a tube wall)
2
w
t
kA
R
kL t

U based on outside surface area

U is usually based on the outer area. U
based on the outside surface area of the
wall for an unfinned, tubular exchanger is
given by
1
ln( ) 1 1
o
o o o o i
fi fo
i i i o
U
r r r r r
R R
r h r k h
=
(
+ + + +
(

Log Mean Temperature Difference
(LMTD)
Differential energy balance





where C
h
and C
c
are the hot and cold fluid
heat capacity rates

( ) ( )
p h h p c c
Q mc dT mc dT o = =
h h c c
Q C dT C dT o = =
Also in terms of overall heat transfer
coeff. and temperature differences


From both energy balances


Using oQ


( )
h c
Q U T T dA o =
1 1
( )
h c h c
c h
d T T dT dT Q
C C
o
| |
= =
|
\ .
( ) 1 1
( )
h c
h c c h
d T T
U dA
T T C C
| |

=
|

\ .
Integrating the previous equation


or



Note that temperature distribution along
the heat exchanger is exponential.
2 1
1 2
1 1
ln
h c
h c c h
T T
UA
T T C C
| |

=
|

\ .
2 1 1 2
1 1
( ) exp
h c h c
c h
T T T T UA
C C
(
| |
=
( |
\ .

After obtaining C
h
and C
c
and solving for Q



or



where AT
1
is the temperature difference
between the two fluids at one end of the heat
exchanger and AT
2
is the one at the other end
of the heat exchanger.
1 2 2 1
1 2
2 1
( ) ( )
ln
h c h c
h c
h c
T T T T
Q UA
T T
T T

=
| |

\ .
1 2
1 2
ln( )
T T
Q UA
T T
A A
=
A A

Counter Flow heat exchanger
Defining LMTD as


The total heat transfer rate for all single-pass
flow arrangements


In case of CF HX with C
h
=C
c
, AT
lm
is
indeterminate


Therefore from LHospital: AT
lm
= AT
1
= AT
2


1 2
1 2
ln( )
lm
T T
T
T T
A A
A =
A A
lm
Q AU T = A
1 2 2 1 1 2
( ) ( ) and
h h c c
T T T T T T = A = A
In case of PF heat exchanger definition of
LMTD is valid. But obviously


LMTD represents the maximum
temperature potential for heat transfer that
can only be obtained in a counter flow heat
exchanger. Therefore, the surface area
required to obtain a prescribed heat transfer
rate Q is smaller for a counter flow
arrangement than that for a parallel flow
arrangement, assuming that U is the same
for both cases.
Also note that T
c2
can exceed T
h2
for counter
flow but not for parallel flow.
) ( T and ) (
2 2 2 1 1 1 c h c h
T T T T T = A = A
Multipass and Crossflow HX
LMTD defined for single pass (PF or CF)
HX is not valid for multipass and crossflow
HX. This time by defining a mean
temperature difference AT
m



We can determine AT
m
in terms of LMTD
of CF HX and two quantities P and R.
m
Q AU T = A
| |
2 1 1 2
,
2 1 1 2
( ) ( )
ln ( ) ( )
h c h c
lm cf
h c h c
T T T T
T
T T T T

A =

2 1
1 1 max
c c c
h c
T T T
P
T T T
A
= =
A
1 2
2 1
c h h
h c c
C T T
R
C T T

= =

Meanings of P and R
AT
lm.cf
is the log-mean temperature difference
for a counter flow arrangement with the same
fluid inlet and outlet temperatures.
P is a measure of the ratio of the heat actually
transferred to the cold fluid to the heat which
would be transferred if the same fluid were to be
raised to the hot fluid inlet temperature;
therefore is the temperature effectiveness of the
heat exchanger on the cold fluid side.
R is the ratio of the mc
p
value of the cold fluid to
that of the hot fluid and it is called the heat
capacity rate ratio.
Correction factor F
With the definition of the correction factor
F heat transfer rate for a multipass or
crossflow heat exchanger can be given as


F is a nondimensional term which depends
on the temperature effectiveness P, the
heat capacity rate ratio R, and the flow
arrangement.

, lm cf
Q UAF T = A
F for a two-pass shell-and-tube HX
F can also be expressed analytically for
the two-pass shell-and-tube heat
exchanger as:



or
( )
( ) ( )
( ) ( )
( ) ( )
2 2
1 2 2 1 1 2 2 1
2 2
1 2 1 2 1 2 2 1
1 2 2 1
2 2
1 2 1 2 1 2 2 1
( ) ( ) ln ( )
ln
h h c c h c h c
h h c c h h c c
h c h c
h h c c h h c c
T T T T T T T T
F
T T T T T T T T
T T T T
T T T T T T T T
+ (

=
(

+ + +

(
(
`

(
+ +
(
)

( ) ( )
( )
( ) ( )
( )
{ } ( )
2
2 2
1ln 1 1
1 ln 2 1 1 / 2 1 1
R P PR
F
R P R R P R R
+ (

=
(
+ + + + +
(

Charts for correction factors
Depending on the flow arrangement there
are series of charts to obtain F using
calculated values of P and R.







LMTD correction factor F for a shell-and-tube
heat exchanger one shell pass and two or
multiple of two tube passes


Effectiveness-Number of Transfer Units (c-NTU)
The c - NTU method is based on the fact
that the inlet or exit temperature
differences of a heat exchanger are a
function of UA/C
c
and C
c
/C
h
.
The heat exchanger heat transfer
equations may be written in dimensionless
form resulting in some dimensionless
groups.
Dimensionless groups
Heat capacity rate ratio:

Heat exchanger heat transfer effectiveness



c is the ratio of the actual heat transfer rate in a heat
exchanger to the thermodynamically limited
maximum possible heat transfer rate if an infinite
heat transfer area were available in a counter flow
heat exchanger.
min
max
C
C
C
-
=
max
Q
Q
c =
The actual heat transfer is obtained either
by the energy given off by the hot fluid or
the energy received by the cold fluid


If C
h
> C
c
, then (T
h1
-T
h2
) < (T
c2
-T
c1
)
If C
h
< C
c
, then (T
h1
-T
h2
) > (T
c2
-T
c1
)
The above equations are valid for CF and
PF. The fluid that might undergo the
maximum temperature difference is the fluid
having the minimum heat capacity rate C
min
.

1 2 2 1
( ) ( ) ( ) ( )
p h h h p c c c
Q mc T T mc T T = =
Maximum heat transfer:

or

Therefore, heat exchanger effectiveness can be
written as



The above equation is valid for all heat
exchanger flow arrangements. The value of c
ranges between 0 and 1.

max 1 1
( ) ( ) if
p c h c c h
Q mc T T C C = <
max 1 1
( ) ( ) if
p h h c h c
Q mc T T C C = <
1 2 2 1
min 1 1 min 1 1
( ) ( )
( ) ( )
h h h c c c
h c h c
C T T C T T
C T T C T T
c

= =

Number of Transfer Units
The third dimensionless number NTU
shows the dimensionless heat transfer size
of the heat exchanger
min min
1
NTU
A
AU
UdA
C C
= =
}
Example: Single pass heat exchanger C
c
>C
h

C
h
=C
min
and C
c
=C
max

We had obtained


By using definition of NTU



where the + is for counter flow and the is
for parallel flow

2 1 1 2
1 1
( ) exp
h c h c
c h
T T T T UA
C C
(
| |
=
( |
\ .

min
2 1 1 2
max
( ) exp NTU 1-
h c h c
C
T T T T
C
(
| |
=
( |
\ .

Using

and


T
h2
and T
c2
can be eliminated to obtain

1 2 2 1
( ) ( ) ( ) ( )
p h h h p c c c
Q mc T T mc T T = =
1 2 2 1
min 1 1 min 1 1
( ) ( )
( ) ( )
h h h c c c
h c h c
C T T C T T
C T T C T T
c

= =

| |
| |
min max
min max min max
1 exp NTU(1-
1 ( ) exp NTU(1-
C C
C C C C )
c

=

For C
min
/C
max
=1, this result is
indeterminate, but by applying
LHospitals rule, the following result is
obtained for counter flow



and for parallel flow
NTU
1 NTU
c =
+
2NTU
1
(1 )
2
e c

=
For C
min
/C
max
=0, both CF and PF HXs



Similar expressions for all flow
arrangements including multi pass
and cross flow can be obtained
following the same approach. Some of
those results are presented as tables
like the following. Also there are
charts like Fig 2.15 of the text book

NTU
1 e c

=
c-NTU Expressions
Type c(NTU,C*) NTU(c,C*)
Counter Flow
Parallel
Cross flow, C
min

mixed
Cross flow, C
max

mixed
1-2 shell-and-
tube heat
exchanger
( ) | |
( ) | | NTU 1 exp 1
NTU 1 exp 1
-

-

-

=
C C
C
c
|
|
.
|

\
|

=
c
c
1
1
ln
1
1
NTU
C
C
( ) | | | | NTU 1 exp 1
1
1
-
+
-
+
= C
C
c
( )
(

-
-

=
C
C NTU exp 1
exp 1 c
( ) | | { } | | NTU exp 1 exp 1
1

-

-
= C
C
c
( )
)
`

)
`

|
|
.
|

\
|
-
+
|
|
.
|

\
|
-
+ +
-
+ +
-
+
=
2 / 1
2
1 NTU exp 1
2 / 1
2
1 NTU exp 1
2 / 1
2
1 1
2
C
C
C C
c
( ) | |
-
+ +
-
+
= C
C
1 1 ln
1
1
NTU c
( ) | | c
-
+
-
= 1 ln 1 ln
1
NTU C
C
( )
(

-
+ = C
C
c 1 ln
1
1 -ln NTU
( )
)
`

)
`

|
|
.
|

\
|
-
+ +
-
+
|
|
.
|

\
|
-
+
-
+
-
+
=
2 / 1
2
1 1 2
2 / 1
2
1 1 2
ln
2 / 1
2
1
1
NTU
C C
C C
C
c
c


LMTD and c-NTU relations
LMTD c-NTU
F = | (P, R, flow arrangement) c = | (NTU, C*, flow arrangement)
cf lm
T UAF Q
,
A =
)
1 1
(
min c
T
h
T C Q = c
( )
2 1
ln
2 1
,
T T
T T
cf lm
T LMTD
A A
A A
= A =
( )
( )
( )
( )
1 1 min
1 2
1 1 min
2 1
c
T
h
T C
c
T
c
T
c
C
c
T
h
T C
h
T
h
T
h
C

= c
1 2 2
,
2 1 1 c
T
h
T T
c
T
h
T T = A = A
1 2
2 1
,
1 1
1 2
c
T
c
T
h
T
h
T
R
c
T
h
T
c
T
c
T
P

=
( )
( )
max
min
max
min
p
c m
p
c m
C
C
C

= =
-
}
= =
A
UdA
C C
UA
min
1
min
NTU
Heat Exchanger Sizing
If inlet temperatures, one of the outlet
temperatures and mass flow rates are
known, we can use LMTD method for
sizing problem:
1.Calculate Q and the unknown temperature
2. Calculate LMTD and F if necessary
3. Calculate U
4. Determine A from A=Q/(UFAT
lm,cf
)
Heat Exchanger Rating
For an available heat exchanger (size,
mass flow rates, inlet temperatures and
materials are known) using c-NTU method
we can rate the heat exchanger:
1. Calculate C*=C
min
/C
max
and NTU=UA/C
min
2. Determine c from appropriate charts or c-
NTU equations
3. Calculate Q=c C
min
(T
h1
-T
c1
)
4. Calculate outlet temperatures

Sizing Using c-NTU method
1. Calculate e using C
min
, C
max
and
temperatures
2. Calculate C*=C
min
/C
max

3. Calculate U
4. Determine NTU from charts or equations
5. When NTU is known calculate heat
transfer area from A=(C
min
NTU)/U
Rating using LMTD
LMTD method can also be used for rating
but for the unknown temperature trial and
error approach is required.
In general LMTD is more appropriate for
sizing and c-NTU is more appropriate for
rating problems.
Variable U may complicate the
calculations, next figure shows some
cases where U is variable.

Numerical analysis of variable U case
Divide heat exchanger length to regionsm
conveniently (index i is for regions). Select
a convenient AA
i

Calculate inner and outer heat transfer
coeffs and U for the initial AA increment
Calculate AQ
i
for this increment
Calculate the values of T
h
and T
c
for the
next increment.
Continue until the entire area handled.
Need for pressure drop calculations
Fluid friction effects cause pressure drop
Pressure drop calculation determines the
pump power requirement
Increasing pressure drop (pump power)
Increases initial cost (capital cost), larger
pumps are more expensive
Also increases operational costs due to higher
pumping costs.
Therefore pressure drop calculations are
as important as heat transfer calculations.
Tube-side pressure drop
Functional relationship for frictional
pressure drop (laminar or turbulent):


From Buckingham-pi theorem:


Fanning friction factor:

Therefore:
( , , , , )
m i
p
u d e
L
|
A
=
2
,
4( / )( / 2)
m
m i
i i
u d p e
L d u d

|

| |
A
=
|
\ .
2
4( / )( / 2)
m
i
p
f
L d u
A
=
(Re, / )
i
f e d | =
Moody diagram and correlations for f
In laminar region:

In turbulent region use Moddy diagram
(Figure 4.1) or for smooth pipes:
16
Re
f =
0.2 4 6
0.046Re for 3 10 Re 10 f

= < <
0.25 3 5
0.079Re for 4 10 Re 10 f

= < <

Relation to wall shear stress t
w

2
( )
4
i w i
p d d L
t
t t A =
2
/ 2
w
m
f
u
t

=

Non-circular cross sectional ducts
Hydraulic diameter:


D
h
in turbulent flow gives f within +- 8% of
measured values.
For annulus:


Use Table 4.1 with D
h
for turbulent flow
4(net free flow area)
4
wetted perimeter
c
h
A
D
P
= =
2 2
4( / 4)( )
( )
i o
h i o
i o
D d
D D d
D d
t
t

= =
+


For laminar flows no universal correlations
For a rectangular duct (axb):




Depending on
b/a ratio |
16
Re
f
|
=
4
where
2( )
h
ab
D
a b
=
+
For laminar flow in ducts of triangular or
trapezoidal cross section f is approx. by
16/Re with D
h
.
Frictional peressure drop for flow through
a duct of length L:




where G is mass velocity.
2 2
4 or 4
2 2
m
h h
u L L G
p f p f
D D

A = A =
Pressure drop for all the tubes in a shell-
and-tube heat exchanger (single phase in
tubes):


where N
p
is number of tubes and D
h
=d
i
.
The fluid will experience additional
pressure drop due expansions and
contractions during the return. The return
pressure drop:
2
4
2
p
t
h
LN
G
p f
D
A =
2
4
2
m
r p
u
p N

A =
Pump power
For an incompressible stream with a mass
flow rate m, power required by an
adiabatic pump is:


where is density, q
p
is isentropic
efficiency of the pump.
1
p
p
m
W p
q
= A
Pressure Drop in Tube Bundles in
Crossflow
For n tube rows counted in flow direction,
taking velocity as u
o
Euler number per
tube row is defined as: Eu=2Ap/(u
o
2
.n).
Using Figures together with the following
equation pressure drop for a crossflow (for
n>9):

2
Eu 1
2
o
p u n _
_
| |
A =
|
\ .


In figures 4.4 and 4.5, as in thermal
considerations, we need to find bulk mean
velocity in the bundle from pitch and
geometry.
The equation and figures also apply to non
isothermal flows if the fluid physical
properties are evaluated at the bulk mean
temperature and corrected for vp:

b
Eu Eu
p
w
b

| |
=
|
\ .
0.0018Re 0.28 for liquid heating p = +
0.0026Re 0.43 for liquid cooling p = +
Helical Coils: Laminar flow
De is Dean Number. De=Re (a/R)
1/2
.
Srinivasan et al. (7 < R/a < 104):



Manlapaz and Churchill:


Correction for vp:
0.275
0.5
1 for 30
0.419 for 30 300
0.1125 for 300
c
s
De
f
De De
f
De De
<

= < <

>

( )
0.5
2
0.5
2
0.18 /
1.0 1.0
3 88.33
1 35/
m
c
s
f a R De
f
De
(
| |
(
| | | | |
= + + +
(
| |
|
\ . \ .
(
( | +

\ .
(

0.25
0.91
c w
cp b
f
f

| |
=
|
\ .
Spiral coils, laminar flow:


Helical coils, turbulent flow:





Spiral coils, turbulent flow:
( )
0.7 0.7
2 1
0.6 0.3
0.63
for 500 Re( / ) 20000 and 7.3 / 15.5
Re ( / )
c
n n
f b a b a
b a

= < < < <

0.25
0.5 2 2
0.00725 0.076 Re for 0.034 Re 300
c
R R R
f
a a a

(
| | | | | |
= + < <
(
| | |
\ . \ . \ .
(

0.2
0.5 2 2
0.0084 Re for Re 700 and 7 10
c
R R R R
f
a a a a

(
| | | | | |
= < < <
(
| | |
\ . \ . \ .
(

0.33
Pr
Pr
c m
cp w
f
f

| |
=
|
\ .
( )
1.5
0.9 0.9
2 1
0.2
0.5
0.0074
Re( / )
c
n n
f
b a

=
(