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Cross Flow Heat Exchangers PDF
Cross Flow Heat Exchangers PDF
of Chemical
Engineering
ISSN 0104-6632
Printed in Brazil
www.abeq.org.br/bjche
Vol. 24, No. 04, pp. 509 - 521, October - December, 2007
Abstract - Due to the wide range of design possibilities, simple manufactured, low maintenance and low cost,
cross-flow heat exchangers are extensively used in the petroleum, petrochemical, air conditioning, food
storage, and others industries. In this paper a mathematical model for cross-flow heat exchangers with
complex flow arrangements for determining -NTU relations is presented. The model is based on the tube
element approach, according to which the heat exchanger outlet temperatures are obtained by discretizing the
coil along the tube fluid path. In each cross section of the element, tube-side fluid temperature is assumed to
be constant because the heat capacity rate ratio C*=Cmin/Cmax tends toward zero in the element. Thus
temperature is controlled by effectiveness of a local element corresponding to an evaporator or a condensertype element. The model is validated through comparison with theoretical algebraic relations for single-pass
cross-flow arrangements with one or more rows. Very small relative errors are obtained showing the accuracy
of the present model. -NTU curves for several complex circuit arrangements are presented. The model
developed represents a useful research tool for theoretical and experimental studies on heat exchangers
performance.
Keywords: Effectiveness; NTU; Heat exchangers; Mathematical model.
INTRODUCTION
For calculation of heat exchanger performance, if
only the inlet temperatures are known, it is
preferable to use the effectiveness-number of transfer
units (-NTU) method, which simplifies the algebra
involved in predicting the performance of complex
flow arrangements. -NTU relations in algebraic
form are useful in computational calculations for
design and experimental studies. For compact heat
exchangers the mechanism of heat transfer and
pressure drop is fairly complex, and as a result,
analytical derivation of -NTU relations is a difficult
*To whom correspondence should be addressed
510
q
q max
Ch (Th,i Th,o )
C min (Th,i Tc,i )
Cc (Tc,o Tc,i )
(1)
(2)
UA
C min
(3a)
C min
Cmax
(3b)
Effectiveness-NTU Computation
cold fluid
Th,i
511
Th,o
Tcoi
hot fluid
Th
Tc,i
L
Tc,o
Tc,i
Tc
dx
L
(a)
(b)
Figure 1: (a) Variations in air and fluid temperature in the longitudinal direction with respect to the fluid flow;
(b) Variation in cross-flow air temperature in a differential volume element of the heat exchanger.
Figure 1(a) illustrates the variations in hot and
cold temperature along a tube of length L, whereas
Fig. 1(b) shows both temperature variations along
the length cold fluid flow in the differential length
(dx). In this infinitesimal section, the cold mass flow
rate is low and therefore the hot fluid temperature is
constant. The energy balance for the differential
length, dx, for the hot and cold fluids can be written
as
q = C h dTh
(4a)
q = dCc Tc
(4b)
dC* =
dCc
0
Ch
(5)
Tc
=
= 1 e dCc
(Th Tc, i )
Brazilian Journal of Chemical Engineering Vol. 24, No. 04, pp. 509 - 521, October - December, 2007
(6)
512
(7a)
dCc Cc
=
dA
A
(7b)
UA
Cc
= const
(8)
(9)
Th,i
Tc,i
Tc,o
Th,o
Figure 2: Element (i, j, k) with one fluid mixed and the other unmixed.
Brazilian Journal of Chemical Engineering
Effectiveness-NTU Computation
(10)
(11)
Cc
e Afr dAfr = Tc Cc
e
(12)
e =
Tce
(The
e
Tc,i
)
=1 e
(UA)e
Cec
(13)
513
Brazilian Journal of Chemical Engineering Vol. 24, No. 04, pp. 509 - 521, October - December, 2007
514
If Cmin = Ch
UA
UA
and Ce =
Cec =
h
*
NTU N c
NTU C N e N t
1.7 Compute temperature distribution iteratively
Compute e using Eq. (13)
Compute initial temperature distribution
Do
Compute the sum S =
Te
c,o
i, j,N r
c,o
i, j,N r
While
Snew S
< Tolerance
S
1.8 Compute effectiveness of heat exchanger
1
e
Tc,o =
Tc,o
N t N e i, j,N
Th,o
q=
1
=
Nc
e
Th,o
q e or q = C
i, j,k
h (Th,o
Effectiveness-NTU Computation
515
Table 2: Equations for the thermal effectiveness of the heat exchanger, , for single-pass
cross-flow heat exchanger configurations with one or more rows
(Eqs. 14-18, see ESDU, 1991; Eq. 19, see Stevens, 1957).
Nr
1
Side of Cmin
Relation
Equation
NTU )
1
[1 e C*(1e
]
=
C*
Air
Tube fluid
Air
(14a)
NTU C*
) / C*
= 1 e (1 e
1
=
[1 e 2KC* (1 + C * K 2 )]
C*
(14b)
(15a)
K = 1 e NTU / 2
2
Tube fluid
K2
= 1 e2K / C* 1 +
C *
(15b)
NTU C*/ 2
K =1 e
2
3 ( C *) K 4
1
=
1 e 3KC* 1 + C * K 2 ( 3 K ) +
C*
2
Air
3
Tube fluid
K = 1 e NTU / 3
K2 (3 K )
3K 4
= 1 e 3K / C* 1 +
+
2
C*
2 ( C *)
(16a)
(16b)
K = 1 e NTU C*/ 3
3
8 ( C *) K 6
1
2
=
1 e 4KC* 1 + C * K 2 6 4K + K 2 + 4 ( C *) K 4 ( 2 K ) +
C*
3
Air
4
Tube fluid
K = 1 e NTU / 4
K 2 6 4K + K 2
4K 4 ( 2 K )
8K 6
= 1 e 4K / C* 1 +
+
+
2
3
C*
3 ( C *)
( C *)
(17a)
(17b)
K = 1 e NTU C*/ 4
=1
=
0.22 C*NTU0.78
1 / C*
NTU
e
(18)
n
( NTU )m C*NTU n ( C * NTU )m
1
NTU
1
e
1 e
C * NTU n =0
m!
m!
m =0
m =0
Brazilian Journal of Chemical Engineering Vol. 24, No. 04, pp. 509 - 521, October - December, 2007
(19)
516
Table 3: Maximum relative error as a function of the number of tube rows between simulation results and
theoretical relations for geometries t1, t2, t3, and t4.
Nr
1
2
3
4
Geometry
t1-Eq.(14)
t2-Eq.(15)
t3-Eq.(16)
t4-Eq.(17)
*Relative error = s t
100
t
Table 4: Comparison between model prediction and approximate infinite series solution.
Nr
Geometry
5
6
7
8
9
10
20
50
t5-Eq.(19)
t6-Eq.(19)
t7-Eq.(19)
t8-Eq.(19)
t9-Eq.(19)
t10 - Eq.(19)
t20 - Eq.(19)
t50-Eq.(19)
100
Effectiveness-NTU Computation
(b)
(c)
517
Figure 3: Scheme of the circuit arrangement for the cross-flow heat exchangers considered in the present study:
(a) Z-shaped arrangement; (b) staggered two-row and two-circuit arrangement; (c) staggered three-row and twocircuit arrangement; (d) staggered six-row and five-circuit arrangement.
The effectiveness of the heat exchangers shown
in Fig. 3 (a-d) is illustrated in Figs. 4-7. The heat
capacity ratio varies from 0 to 1 with 0.25
increments. For C*=0, the equation = 1exp(NTU)
is used. These graphs were obtained with the
computational program (see straight lines in Figs. 47). Observing Figs. 4 and 5, some differences due to
the effect of the flow arrangement can be observed
for the two-row heat exchangers. The two-row heat
exchanger, geometry 2 flow arrangement, seems to
Brazilian Journal of Chemical Engineering Vol. 24, No. 04, pp. 509 - 521, October - December, 2007
518
(a)
(b)
Figure 4: Effectiveness of the theoretical relation (dashed line) and the model prediction (straight line)
of a Z-shaped cross-flow heat exchanger (geometry 1): (a) Cmax (mixed), Cmin (unmixed);
(b) Cmin (mixed), Cmax (unmixed).
(b)
(a)
Figure 5: Effectiveness of the theoretical relation (dashed line) and the model prediction (straight line)
of a staggered two-row and two-circuit cross-flow heat exchanger (geometry 2):
(a) Cmax (mixed), Cmin (unmixed); (b) Cmin (mixed), Cmax (unmixed).
(b)
(a)
Figure 6: Effectiveness of the theoretical relation (dashed line) and the model prediction (straight line)
of a staggered three-row and two-circuit cross-flow heat exchanger (geometry 3):
(a) Cmax (mixed), Cmin (unmixed); (b) Cmin (mixed), Cmax (unmixed).
Brazilian Journal of Chemical Engineering
Effectiveness-NTU Computation
519
(b)
(a)
Figure 7: Effectiveness of the theoretical relation (dashed line) and the model (straight line)
of a staggered six-row and five-circuit cross-flow heat exchanger (geometry 4):
(a) Cmax (mixed), Cmin (unmixed); (b) Cmin (mixed), Cmax (unmixed).
When there is no available relation for the
effectiveness of a heat exchanger with a complex
flow arrangement, an approximation using a
theoretical relation for the same number of rows is
used. In these cases, significant differences between
real and computed values of theoretical effectiveness
can occur. Figs 4 to 6 show a comparison between
effectiveness values obtained from both theoretical
relations (Eqs. 14-16) and computational results for
geometries 1-3 (Fig 3a-c). Table 5 shows maximum
and total errors obtained for each case. In Fig. 4 it
can be seen that a theoretical relation always
overestimates effectiveness values for geometry 1 up
to a maximum error of about 12 % (see Table 5), for
4.04, 8.72
3.29, 8.31
3.67, 7.81
3.45, 8.40
3.86, 7.81
Brazilian Journal of Chemical Engineering Vol. 24, No. 04, pp. 509 - 521, October - December, 2007
520
NTU
Q
T
U
[W] [K]
[W/(m2-K)]
CONCLUSIONS
Greek Symbol
The present paper is an extension of Navarro and
Cabezas-Gmezs (2005) previous work. Two new
aspects were introduced, the first a more detailed
explanation of the computational methodology and
the second a presentation of new results for complex
heat exchanger geometries for which -NTU
relations are not available.
A
simulation
element-by-element
model
discretizes the whole heat exchanger into smaller
ones along the tube fluid path based on a local
effectiveness concept. Computing the temperature
distribution of both fluids, the overall effectiveness
of the heat exchanger is calculated. The model was
validated through comparison with theoretical
relations found in the literature, obtaining very small
relative errors in all cases. The comparisons reveal
that the model is accurate and suitable for predicting
the theoretical performance of coils.
Effectiveness values were estimated for crossflow heat exchangers with complex flow
arrangements. For the cases analyzed, a maximum
difference of about 10 % was noted between
effectiveness model prediction and those based on
theoretical formulae. This should be considered in
experimental work. The results shown in Table 5 for
more than four rows indicate that the use of Eq. (18)
produces imprecise experimental values, which can
results in an erroneous conclusion about the effect of
the flow arrangement on a specific geometry.
Finally, it must be said, that due to its prediction
capability, the model developed is a useful research
tool for theoretical and experimental studies on heat
exchanger performance.
NOMENCLATURE
A
Afr
C
C*
L
Nc
Ne
Nr
Nt
[m2]
[m2
[W/K]
[-]
[m]
(-)
(-)
(-)
(-)
denotes difference
denotes difference
effectiveness of heat
exchanger
dimensionless parameter
defined by Eqs. (6) and (8).
(-)
(-)
(-)
(-)
Subscripts
C
H
I
max
min
O
(-)
(-)
(-)
(-)
(-)
(-)
Superscripts
e
element
(-)
REFERENCES
Effectiveness-NTU Computation
521
Temperature Difference in One, Two and Threepass Crossflow Heat Exchangers, Transactions
ASME, 79, 287 (1957).
Vardhan, A. and Dhar, P.L., A New Procedure for
Performance Prediction of Air Conditioning
Coils, International Journal of Refrigeration, 21,
No. 1, 77 (1998).
Wang, C.-C., Lee, C.-J., Chang, C.-T., and Lin, S.P., Heat Transfer and Friction Correlation for
Compact
Louvered
Fin-and-tube
Heat
Exchangers, International Journal of Heat and
Mass Transfer, 42, 1945 (1999a).
Wang, C.-C., Tao, W.-H., and Chang, C.-J., An
Investigation of the Airside Performance of the
Slit Fin-and-tube Heat Exchangers, International
Journal of Refrigeration, 22, 595 (1999b).
Wang, C.-C., Webb, R.L., and Chi, K.-Y., Data
Reduction for Air-side Performance of Fin-andtube Heat Exchangers, Experimental Thermal and
Fluid Science, 21, 218 (2000).
Brazilian Journal of Chemical Engineering Vol. 24, No. 04, pp. 509 - 521, October - December, 2007