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Heat exchangers
Executive summary
Heat exchangers are easily one of the most important and widely used pieces of
process equipment found in industrial sites. Regardless of the particular industry in
question, it willy likely require some type of temperature regulation , and for that
exchanger and likely come into play . Heat exchangers may be used for either heating
or cooling , however , in the industrial sector , particularly with in plant refineries , they
are overwhelmingly used for cooling.
They are many type of heat exchangers, each with their own advantages and
drawbacks, yet tailored to best suit different purposes and industries. Heat exchangers
have very broad range of industrial applications .they used as components air
conditioning and cooling systems or of heating systems. many industrial purposes call
for a certain degree of heat function ; however, typically great care must be taken to
keep these processes from getting too hot . Within industrial plants and factories heat
exchangers are required to keep machinery, chemicals, water, and other substances
within a safe operating temperature

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Table of Content
Symbol Description Unit
A Area for heat transfer m2

Ai,i Surface area of the inside of the inner pipe m2

Ai,o Surface area of the outside of the inner pipe m2

ai Cross sectional area of inner pipe m2

Cpi Heat capacity of the fluid in the inner pipe kJ/kg.K

Cpo Heat capacity of the fluid in the outer pipe kJ/kg.K

Di,,i Inner diameter of inner pipe m

do,i Inner diameter of outer pipe m

di,,o Outer diameter of inner pipe m

do,,o Outer diameter of Outer pipe m

hi Convective heat-transfer coefficient of fluid in inner pipe W/m2K

ho Convective heat-transfer coefficient of fluid in outer pipe W/m2K

k Thermal conductivity of inner pipe material W/m.K

l Total pipe length m

mi Mass of fluid in inner pipe kg

mo Mass of fluid in outer pipe kg

Nui Nusselt number of fluid in inner pipe dimensionless

Nui Nusselt number of fluid in outer pipe dimensionless

Pri Prandtl number of fluid in inner pipe dimensionless

Pro Prandtl number of fluid in outer pipe dimensionless

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Symbol Description unit
Rei Reynolds number of fluid in inner pipe dimensionless

Reo Reynolds number of fluid in outer pipe dimensionless

o
Ti,i Inlet temperature of fluid in inner pipe C

o
To,i Inlet temperature of fluid in outer pipe C

o
Ti,o Outlet temperature of fluid in inner pipe C

o
To,o Outlet temperature of fluid in outer pipe C

o
LMTD Log-mean temperature difference C

o
Ti,a Average temperature of fluid in inner pipe C

o
To,a Average temperature of fluid in inner pipe C

Rfi Fouling factor inside the inner pipe W/m2K

Rfo Fouling factor outside the inner pipe W/m2K

ui Velocity of the fluid in the inner pipe m/s

uo Velocity of the fluid in the outer pipe m/s

qi Volumetric flow rate of the fluid in the inner pipe m3/s

qo Volumetric flow rate of the fluid in the inner pipe m3/s

Q Heat transfer rate kW

U Overall heat-transfer coefficient W/m2K

Greek symbols

ρi Density of the fluid in the inner pipe kg/m3

ρo Density of the fluid in the outer pipe kg/m3

µi Viscosity of the fluid in the inner pipe Pa.s

µo Viscosity of the fluid in the inner pipe Pa.s

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Background and introduction.
Heat exchangers are devices that facilitate the exchange of heat between two fluids that
are at different temperatures while keeping them from mixing with each other. Heat
exchangers are commonly used in practice in a wide range of applications, from heating
and air-conditioning systems in a household, to chemical processing and power
production in large plants.
They are many type of heat exchangers, each with their own advantages and
drawbacks, yet tailored to best suit different purposes and industries. Heat exchangers
have very broad range of industrial applications .they used as components air
conditioning and cooling systems or of heating systems. Many industrial purposes call
for a certain degree of heat function; however, typically great care must be taken to
keep these processes from getting too hot . Within industrial plants and factories heat
exchangers are required to keep machinery, chemicals, water, and other substances
within a safe operating temperature.
They are many type of heat exchangers, each with their own advantages and
drawbacks, yet tailored to best suit different purposes and industries. Heat exchangers
have very broad range of industrial applications.
Heat exchangers differ from mixing chambers in that they do not allow the two fluids
involved to mix. In a car radiator, for example, heat is transferred from the hot water
flowing through the radiator tubes to the air flowing through the closely spaced thin
plates outside attached to the tubes.
Heat exchangers are used everywhere around the human and its surrounding.
Heat exchangers are used in many industries, some of which include:
 Waste water management
 Refrigeration system
 Wine-Brewery industry
 Petroleum industry
 In aircraft industry to make the aircraft cool during the flights
This assignment includes all the steps that have been for the design of the heat
exchanger (shell and tube and to make the necessary calculations for heat exchanger.

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Literature Review
Classification of Heat Exchanger.
There are three primary classifications of heat exchangers according to their flow. In a
parallel-flow heat exchanger, the two fluids enter the exchanger at the same end and
travel in parallel to one another to the other end. In a counter-flow, the fluids enter the
heat exchanger from opposite ends. The counter current design is the most efficient
design because it can transfer the most heat due to the fact that the average
temperature difference along any unit is higher (Sundén, 2014).

Figure 1 shows the classification of heat exchangers

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Types of heat exchangers
Different types of heat exchangers are used for different applications, but all important
one’s want is to ensure that they’re making the appropriate selection for their needs.
Examples of heat exchangers include the likes of Shell and tube, plate heat exchangers
and fluid heat exchangers to name a few.

Shell and Tube heat exchanger.

A shell and tube heat exchangers are one of the most popular types of exchanger due
to flexibility the designer has to allow for a wide range of pressure and temperature. A
shell and tube exchanger consists of a number of tubes mounted inside a cylindrical
shell. Figure 1 illustrates a typical unit that may be found in a petrochemical chemical
plant. Two fluids can exchange heat, one fluid flows over the outside of the tubes while
the second fluid flows through the tubes. The fluids can be single or two phase and can
flow in a parallel or cross/counter flow arrangement.

The shell and tube exchanger consists of four major parts

 Front header – this is where the fluid enters the tubes ide of the exchanger. It is
sometimes referred to as the stationary header
 Rear header – this is where the tube side fluid leaves the exchanger or where it
is retuned to the front header in exchanger with multiple tubes ide passes
 Tube bundle – this comprises of the tubes, tube sheets, baffles and tie rods etc.
to hold the bundle together.
 Shell – this contains the tube bundle

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Plate type heat exchanger
Plate-Type Heat Exchangers: Plate-type heat exchangers are usually built of thin plates
(all prime surface). The plates are either smooth or have some form of corrugation and
they are either flat or wound in an exchangers. Generally these exchangers cannot
accommodate very high pressures temperatures, or pressure and temperature
differences. Plate heat exchangers (PHEs) can be classified as gasketed, welded (one
or both fluid passages), or brazed, depending on the leak tightness required. Other
plate-type exchangers are spiral plate, lamella, and plate coil exchangers.

Figure 1.2 shows a plate type heat exchanger

Classification according to flow arrangements:

Single-Pass Exchangers:

 Counter flow Exchanger.

 Parallel flow Exchanger.

 Cross flow Exchanger.

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Figure 1.3 : Cross-flow heat exchangers (a) Finned with fluids unmixed (b) Un-finned
Selection of Heat Exchanger
Selection is the process whereby the engineer selects a specific heat exchanger for a given
application from a variety of heat exchangers.The heat exchanger is required to meet the
requirements of the process it is intended for. It should also be maintainable thus it should have
a configuration have a setup that takes into consideration replacement or cleaning of any of the
components that could be damaged due to corrosion, erosion or wear and tear
(Saunders,1988).

The selection criteria are many, but the primary criteria to be focused on are the operating
pressures and temperatures, heat duties and costs. Operating conditions for heat exchangers
varies over a very wide range; a spectrum is imposed for their design and performance. All of
these must be assessed when considering the type of unit to be used. When selecting a heat
exchanger for a given duty the following topics must be considered (Saunders,1988 ):

 Flow arrangements
 Flow rates

 Fouling tendencies

 Performance parameters (thermal effectiveness and pressure drops)

 Types and phases of fluids

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Heat exchanger design methodology
Design is an activity aimed at providing complete descriptions of an
engineering system, part of a system, or just of a single system component These
descriptions represent an unambiguous specification of the system/component
structure, size, and performance, as well as other characteristics important for
subsequent manufacturing and utilization. This can be accomplished using a well
defined design methodology.

From the formulation of the scope of this activity, it must be clear that the
design methodology has a very complex structure. Moreover, a design methodology
for a heat exchanger as a component must be consistent with the life-cycle design
of a system. Lifecycle design assumes considerations organized in the following
stages.

Problem formulation (including interaction with a consumer):

Concept development (selection of workable designs preliminary design).
Detailed exchanger design (design calculations and other pertinent considerations).
Manufacturing. utilization considerations (operation, phase out disposal).

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