Chapter 4

Heat Exchangers
Cross Flow heat exchangers –
Problems

1
Shell & tube heat exchanger – Diagram

2
Shell & tube heat exchanger – Diagram

3
Cross flow heat exchanger – Formulae
1) Rate of heat transfer, Q = F U A (∆T)lm

where
F – Correction factor (Obtained from databook)
U – Overall heat transfer co-efficient, W/m2K
A – Area, m2
(∆T)lm – Logarithmic mean temperature difference pertaining to counter flow

For a Counter flow:

where
[(T − t ) − (T2 − t1 )]
(∆T )lm = 1 2 T1 – Entry temperature of hot fluid
⎡ (T − t ) ⎤ T2 – Exit temperature of hot fluid
ln ⎢ 1 2 ⎥
⎣ (T2 − t1 ) ⎦ t1 – Entry temperature of cold fluid
t2 – Exit temperature of cold fluid

2) Heat lost by hot fluid = Heat gained by cold fluid

where
Qh = Qc mh – Mass flow rate of hot fluid
Q = mhCph(T1 – T2) = mcCpc(t2 – t1) mc – Mass flow rate of cold fluid
Cph – Specific heat of hot fluid
4
Cpc – Specific heat of cold fluid
 Cross flow heat exchanger – Problems
1. In a cross flow heat exchanger, both fluids unmixed, hot fluid with a
specific heat of 2300 J/kg K enters at 380 oC and leaves at 300 oC. Cold
fluids enters at 25 oC and leaves at 210 oC. Calculate the required surface
area off heat
h t exchanger.
h T k overall
Take ll heat
h t transfer
t f co-efficient
ffi i t is
i 750 W/m
W/ 2
K. Mass flow rate of hot fluid is 1 kg/s.
Given:
S
Specific
ifi heat
h t off hot
h t fluid,
fl id Cph = 2300 J/k
J/kg K
Entry temperature of hot fluid, T1 = 380o C
Exit temperature of hot fluid, T2 = 300o C
Mass flow rate of hot fluid,, mh = 1 kg/s.
g

Entry temperature of cold fluid, t1 = 25o C

Exit temperature of cold fluid, t2 = 210o C

Overall heat transfer co-efficient, U = 750 W/m2K

To find: Heat exchanger area (A)

Solution:
This is cross flow, both fluids unmixed type heat exchanger. 5
Cross flow heat exchanger – Problems
For cross flow heat exchanger, [HMT data book, Pg no:152]
Q = F U A (∆T)lm[counter flow] Æ (1)
where
F – Correction factor
(∆T)lm – Logarithmic mean temperature difference for counter flow.

For Counter flow

flow,
(∆T)lm = [(T1 - t2) - (T2 – t1)] / ln[(T1 - t2)/(T2 – t1)] = 218.3o C

Heat transfer, Q = mh Cph (T1 – T2) = 184 x 103 W

To find correction factor F, refer HMT data book page no 162

[Single pass cross flow heat exchanger – Both fluids unmixed]

From graph,
Xaxis value P = (t2 – t1) / (T1 – t1) = 0.52
Curve value R = (T1 – T2) / (t2 – t1) = 0.432
0 432
Xaxis value is 0.52, curve value is 0.432, corresponding Yaxis value is 0.97
i.e., F = 0.97 6
Cross flow heat exchanger – Problems

Substitute Q, F, (∆T)lm and U value in Equation (1)

(1) Î Q = F U A (∆T)lm
⇒ A = Q / F U (∆T)lm
⇒ =11.15
15 m2
Surface area, A = 1.15 m2
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 Cross flow heat exchanger – Problems
2. In a refrigerating plant, water is cooled from 20 oC to 7 oC by brine
solution entering at -2 oC and leaving at 3 oC. The design heat load is
5500 W and the overall heat transfer co-efficient is 800 W/m2 K. What area
is required when using a shell and tube heat exchanger with the water
making one shell pass and the brine making two tube passes.
Given:
Hot fluid – Water Cold fluid – brine solution
(T1 , T2) (t1 , t2)

Entry temperature of water, T1 = 20o C

E it temperature
Exit t t off water,
t T2 = 7o C
Entry temperature of brine solution, t1 = - 2o C
Exit temperature of brine solution, t2 = 3o C
Heat load, Q = 5500 W
Overall heat transfer co-efficient, U = 800 W/m2K
To find: Area required (A)

Solution:
Shell and tube heat exchanger – One shell pass and two tube passes 8
Cross flow heat exchanger – Problems
For shell and tube heat exchanger (or) cross flow heat exchanger,
[HMT data book, Pg no:152]
Q = F U A (∆T)lm[counter flow] Æ (1)
where
h
F – Correction factor
(∆T)lm – Logarithmic mean temperature difference for counter flow.
For Counter flow
flow,
(∆T)lm = [(T1 - t2) - (T2 – t1)] / ln[(T1 - t2)/(T2 – t1)] = 12.57o C

To find correction factor F

F, refer HMT data book page no 159
[one shell pass and two tube passes]

From graph,
Xaxis value P = (t2 – t1) / (T1 – t1) = 0.22
Curve value R = (T1 – T2) / (t2 – t1) = 2.6
Xaxis value is 0.22, curve value is 2.6, corresponding Yaxis value is 0.94
i
i.e., F = 0.94
0 94
9
Cross flow heat exchanger – Problems

Substitute Q,
Q F,
F (∆T)lm and U value in Equation (1)

(1) Î Q = F U A (∆T)lm
⇒ A = Q / F U (∆T)lm
⇒ = 0.58 m2
Surface area, A = 0.58 m2 10
 Cross flow heat exchanger – Problems
3. Saturated steam at 120o C is condensing in shell and tube heat
exchanger. The cooling water enters the tube at 25 oC and leaves at 80 oC.
Calculate the logarithmic mean temperature difference if the arrangement
i
is ( ) counter
(a) t flow
fl (b) parallel
ll l flow
fl ( ) cross flow
(c) fl
(one fluid mixed; other unmixed)
Given:
Hot fluid – steam Cold fluid – water
(T1 , T2) (t1 , t2)

Saturated steam temperature, T1 = T2 = 120o C

Entry temperature of water, t1 = 25o C

Exit temperature of water, t2 = 80o C
To find: (∆T)lm for parallel flow, counter flow and cross flow.

Solution:
Case (i)
For Parallel flow
flow, [HMT data book
book, Pg no:152]
(∆T)lm = [(T1 – t1) - (T2 – t2)] / ln[(T1 – t1)/(T2 – t2)] = 63.5o C
(∆T)lm for parallel flow = 63.5o C Æ (1) 11
 Cross flow heat exchanger – Problems
Case (ii)
For Counter flow,
(∆T)lm = [(T1 – t2) - (T2 – t1)] / ln[(T1 – t2)/(T2 – t1)] = 63.5o C

(∆T)lm for counter flow = 63.5o C Æ (2)

Case (iii)
For cross flow
flow,
(∆T)lm = F x (∆T)lm for counter flow

(∆T)lm = F x 63.5o C Æ (3)

where
F – Correction factor for a single pass cross flow heat exchanger

Correction factor for single pass cross flow heat exchanger

(One fluid mixed, other unmixed) [HMT data book page no 160]

Xaxis value P = (t2 – t1) / (T1 – t1) = 0.578

C
Curve value
l R = (T1 – T2) / (t2 – t1) = 0
Xaxis value is 0.578, curve value is 0, so corresponding Yaxis value is 1
i.e., F=1 12
Cross flow heat exchanger – Problems
(3) => (∆T)lm = F x 63.5o C = 1 x 63.5
(∆T)lm for cross flow = 63.5o C Æ (4)

Inference:
From (1), (2) and (4) we came to know when one of the fluids in a
heat exchanger changes phase, the logarithmic mean temperature difference
and rate of heat transfer will remain same for parallel flow, counter flow and
cross flow.

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