3.

Heat exchanger design

3.2 Evaluation of the mean temperature difference in a heat exchanger

Extended use of the LMTD

Limitations on the use of LMTD

Restricted to the single-pass parallel and counter-flow configurations
For other configuration LMTD need to be adjusted

3. Heat exchanger design

3.2 Evaluation of the mean temperature difference in a heat exchangercont.)

Hot gas side

U is constant (more serious)

U(T, Configuration) Regionally Uniform? More severe in lager exchanger Less serious in compact exchanger

Water side

A typical case of a heat exchanger in which U varies dramatically.

JHH

College of Energy and Power Engineering

JHH

College of Energy and Power Engineering

3. Heat exchanger design

3.2 Evaluation of the mean temperature difference in a heat exchanger

3. Heat exchanger design

3.2 Evaluation of the mean temperature difference in a heat exchanger

Extended use of the LMTD

Extended use of the LMTD

Limitations
U variation

PFT-type boiler

The heat exchange surface for a steam generator

This PFT-type integral-furnace boiler,with a surface area of 4560 m2, is not particularly large. About 88% of the area is in the furnace tubing and 12% is in the boiler.
Side view of PFT boiler
College of Energy and Power Engineering JHH 3 College of Energy and Power Engineering JHH 4

3. Heat exchanger design

3.2 Evaluation of the mean temperature difference in a heat exchanger

3. Heat exchanger design

3.2 Evaluation of the mean temperature difference in a heat exchanger

Extended use of the LMTD

Extended use of the LMTD

LMTD should always calculated for the equivalent counterflow single-pass exchanger with the same hot and cold temperature The basis of the LMTD in a multipass exchanger

LMTD correction factor, F

For common range of heat exchanger[Bowman 1940]

F is an LMTD correction factor Tt temperature of tube flow, Ts temperature of shell flow P is the relative influence of overall temperature difference ( Ts Tt on tube flow temperature, P < 1
in in

T T T T tout tin sin sout Q = UA( LMTD) F , Tsin Ttin Ttout Ttin P R

R = Ct / Cs If one flow remain constant T, then either P or R equal 0, F=1

College of Energy and Power Engineering JHH 5 College of Energy and Power Engineering JHH 6

3. Heat exchanger design

3.2 Evaluation of the mean temperature difference in a heat exchanger

3. Heat exchanger design

3.2 Evaluation of the mean temperature difference in a heat exchanger

Extended use of the LMTD

Extended use of the LMTD

F for a one-shell-pass, four, six, tube-pass exchanger

F for a two-shell-pass, four or more tube-pass exchanger

R=

Tsin Tsout Ttout Ttin

R=

Tsin Tsout Ttout Ttin

For R > 1,

Shamsundar noted

F ( P, R) = F ( PR, 1 / R)
JHH 7

For R > 1,

Shamsundar noted

F ( P, R) = F ( PR, 1 / R)
JHH 8

College of Energy and Power Engineering

College of Energy and Power Engineering

3. Heat exchanger design

3.2 Evaluation of the mean temperature difference in a heat exchanger

3. Heat exchanger design

3.2 Evaluation of the mean temperature difference in a heat exchanger

Extended use of the LMTD

Extended use of the LMTD

F for a cross-flow exchanger with both passes unmixed

F for a cross-flow exchanger with one passes mixed

R=

Tsin Tsout Ttout Ttin

R=

Tsin Tsout Ttout Ttin

For R > 1,

Shamsundar noted

F ( P, R) = F ( PR, 1 / R)
JHH 9

For R > 1,

Shamsundar noted

F ( P, R) = F ( PR, 1 / R)
JHH 10

College of Energy and Power Engineering

College of Energy and Power Engineering

3. Heat exchanger design

3.2 Evaluation of the mean temperature difference in a heat exchanger

3. Heat exchanger design

3.2 Evaluation of the mean temperature difference in a heat exchanger

Example 3.4
5.795kg/s Oil 181oC Oil Cooler 49oC

Example 3.4

Known :Cpoil and U. To find: A=?

LMTD = (Thin Tcout ) (Thout Tcin ) T T ln( hin cout ) Thout Tcin (181 49) (38 32) = 40.76 K 181 49 ln 38 32

As R > 1 F ( P, R) = F ( PR, 1 / R)
PR = 0.959, 1 / R = 0.119

F = 0.92

Q = UAF ( LMTD)
A= = Q UF ( LMTD) c p (Tsin Tsout ) m UF ( LMTD)

Water 32oC

38oC

R=

Tsin Tsout Ttout Ttin

= 8.412 P =

Ttout Ttin Tsin Ttin

= 0.114

As R > 1

F ( P, R) = F ( PR, 1 / R) 1 / R = 0.119
JHH 11 College of Energy and Power Engineering JHH

= 121.2m 2

PR = 0.959,
College of Energy and Power Engineering

12

3. Heat exchanger design

3.3 Heat exchanger effectiveness

3. Heat exchanger design

3.3 Heat exchanger effectiveness

A design problem

Gessing an exit temperature

Effectiveness-NTU method
Developed by Kays and London in 1955
Compact heat exchanger in which U is likely fairly uniform
Heat exchanger effectiveness

Qh = Qc = Ch Th = Cc Tc

Calculate Q

Q = UAF ( LMTD)
To define

actual heat transfered maximum heat that could possibly be transfered from one stream to the other

Qh Check Q against Qh

Ch (Thin Thout ) Cmin (Thin Tcin )

Cc (Tcout Tcin ) Cmin (Thin Tcin )

Where Cmin is the smaller of Cc and Ch A design problem in which the LMTD cannot be calculated a priori
Qh Q not equal Qh?

so
13

Q = C min (Thin Tcin )

College of Energy and Power Engineering JHH 14

College of Energy and Power Engineering

JHH

3. Heat exchanger design

3.3 Heat exchanger effectiveness

3. Heat exchanger design

3.3 Heat exchanger effectiveness

Effectiveness-NTU method

Effectiveness of parallel & counterflow exchangers

Number of Transfer Units (NTU) defined by Nusselt

NTU = UA C min = heat capacity of the heat exchanger heat capacity of the flow

For counterflow single-pass case (Homework)

=
1 exp[(1 + Cmin / Cmax ) NTU] 1 + Cmin / Cmax exp[(1 + Cmin / Cmax ) NTU]

For parallel single-pass heat exchanger

(1 + Cc / Ch ) (Tcin Tcout ) + Tb 1 1 ln = UA + T C C b c h Cc Cmin Cmin Cmin + 1 = ln 1 + C + C NTU h c C h Cc

1 exp[(1 + Cmin / Cmax )NTU] C = fn( min , NTU) 1 + Cmin / Cmax Cmax
College of Energy and Power Engineering JHH 15 College of Energy and Power Engineering JHH 16

3. Heat exchanger design

3.3 Heat exchanger effectiveness

3. Heat exchanger design

3.3 Heat exchanger effectiveness

The effectiveness of cross-flow heat exchangers

Effectiveness of shell-and-tube heat exchangers

College of Energy and Power Engineering

JHH

17

College of Energy and Power Engineering

JHH

18

3. Heat exchanger design

3.3 Heat exchanger effectiveness

3. Heat exchanger design

3.3 Heat exchanger effectiveness

Example 3.5

Example 3.6
=49oC,

Known: parallel-flow heat exchanger, Tcin Cc=20000W/K, Thin=150oC, Ch=10000W/K, A=30 m2 , U=500W/m2K To find: Q=?, Tcout=?, Thout=?
Cannot find LMTD

Same kind of heat exchanger as Example 3.5. Thout=90oC To find A=?

Ch (Thin Thout ) Cmin (Thin Tcin )

= 0.5455

UA NTU = = 1.5 Cmin Cmin = 0.5 = 0.596 Cmax

Q = Cmin (Thin Tcin ) = 655.6kW

NTU=1.15=UA/Cmin . A=23.0m2 . Or Tcout = Tcin

Ch (Thout Thin ) Cc = 70o C

Thout Tcout

Q = Thin = 84.44o C Ch Q = Tcin = 72.78o C Cc

College of Energy and Power Engineering JHH
NTU

LMTD=52.79K Q=UA(LMTD) A=22.730m2 .

19 College of Energy and Power Engineering JHH

NTU

20

3. Heat exchanger design

3.4 Heat exchanger design

3. Heat exchanger design

3.4 Heat exchanger design

Heat exchanger design

Heat exchanger design

Small exchanger, typically the kind of compact crossflow exchanger

The method described before

Lager exchanger design process

Decide which fluid should flow in the shell side which tube side
Pumping power, corrosion behavior, fouling, cleaning

Larger exchanger pose difficulty in relation to U

The variation of U through the exchanger Hard to predict convective heat transfer coefficient h

Assess the cost of calculation

The converging accuracy of computation The investment in the exchanger The cost of miscalculation

Minimization of pumping power

Minimization of fixed costs
College of Energy and Power Engineering JHH 21

Pumping power =

p m

(W )

Rough estimate of the size of the exchanger by using U and experience Evaluate the Q, p, and the cost of various exchanger configurations that appear reasonable for the application Might involve 200 successive redesign

College of Energy and Power Engineering

JHH

22

3. Heat exchanger design

3.4 Heat exchanger design

Homework
3.20 3.28 300140 44124 1 2 3

2.25kg/s2000J/(kg*K) 80 560W/(m2K), 8m2 12 40

College of Energy and Power Engineering JHH 23