See discussions, stats, and author profiles for this publication at: https://www.researchgate.

net/publication/348548029

Design of a Heat Exchanger

Technical Report · January 2021

DOI: 10.13140/RG.2.2.32973.46561

CITATION READS

1 667

1 author:

Alvy Ahmed
Islamic University of Technology
15 PUBLICATIONS   1 CITATION   

SEE PROFILE

Some of the authors of this publication are also working on these related projects:

A project on Brake Design for a Shaft View project

Solar Tracking System View project

All content following this page was uploaded by Alvy Ahmed on 16 January 2021.

The user has requested enhancement of the downloaded file.

Islamic University of Technology
OIC, Gazipur.

Design of a Heat Exchanger

By:
Tamzeed Ahmed Alvy
170011063
MPE
Contents:

• Part A:
1. Introduction.
2. Basic Design Methods of Heat Exchangers.
3. Selection of Heat Exchangers and Their Components.
4. Design of an Automobile radiator.

• Part B:

Calculation

• Part C:

1. Limitations
2. Conclusions
Summary:
The aim is to design a basic heat exchanger for automobile applications. Through this, the
reader will get an overview of heat exchanger design in the simplest possible way. Heat
exchanger have an extensive application and therefore an understanding is important. This
paper is aimed for general understanding and thus written in a simplified manner.
 Part A

Introduction:
A heat exchanger is a device that is used to transfer thermal energy between two or more fluids,
between a solid surface and a fluid, or between solid particulates and a fluid, at different
temperatures and in thermal contact. In heat exchangers, there are usually no external heat and
work interactions. Heat exchangers are used in a wide variety of applications, such as:

1. power production,
2. chemical and food industries,
3. environmental engineering,
4. waste heat recovery,
5. manufacturing industry and
6. air-conditioning and refrigeration.

Typical applications involve heating or cooling of a fluid stream of concern and evaporation or
condensation of single- or multicomponent fluid streams. In other applications, the objective
may be to recover or reject heat, or sterilize, pasteurize, fractionate, distill, concentrate,
crystallize, or control a process fluid.

In a few heat exchangers, the fluids exchanging heat are in direct contact. In most heat
exchangers, heat transfer between fluids takes place through a separating wall or into and out
of a wall in a transient manner. In many heat exchangers, the fluids are separated by a heat
transfer surface, and ideally, they do not mix or leak.

Heat exchangers may be classified according to the following main criteria. These are:

1. Recuperators/regenerators.
2. Transfer processes: direct contact and indirect contact.
3. Geometry of construction: tubes, plates, and extended surfaces.
4. Heat transfer mechanisms: single phase and two phases.
5. Flow arrangements: parallel flows, counter flows, and cross flows.
Fig1: Criteria used in the classification of heat exchangers
Fig2: Indirect-contact-type heat exchangers: (a) double-pipe heat exchanger; (b) shell-and
tube-type heat exchanger.

Fig3: Rotary regenerators: (a) disk-type; (b) drum-type.

Fig4: Rotary storage-type heat exchanger.

Fig5: Direct-contact-type heat exchangers: (a) tray condenser; (b) spray condenser.

Fig6: Classification of heat exchangers.

Basic Design Methods of Heat Exchangers:
The most common tasks in heat exchanger design are rating and sizing. The rating problem is
concerned with the determination of the heat transfer rate and the fluid outlet temperatures for
prescribed fluid flow rates, inlet temperatures, and allowable pressure drop for an existing heat
exchanger; hence, the heat transfer surface area and the flow passage dimensions are available.
The sizing problem, on the other hand, involves determination of the dimensions of the heat
exchanger, that is, selecting an appropriate heat exchanger type and determining the size to
meet the requirements of specified hot- and cold-fluid inlet and outlet temperatures, flow rates,
and pressure drops.
• Heat Exchanger Design Methodology:
Based on the problem specifications, the exchanger construction type, flow
arrangement, surface or core geometry, and materials must be selected. In the selection
of the type of heat exchanger, the operating pressure and temperature levels,
maintenance requirements, reliability, safety, availability and manufacturability of
surfaces, and cost must be considered.

Heat exchanger design methodology

• Arrangement of Flow Paths in Heat Exchangers:
Heat exchangers may have the following patterns of flow:

1. Parallel flow, with two fluids flowing in the same direction.

2. Counterflow, with two fluids flowing parallel to one another but in opposite
directions.
3. Crossflow, with two fluids crossing each other.
4. Mixed flow where both fluids are simultaneously in parallel flow, in
counterflow.

Heat exchanger classification according to flow arrangements.

Multi-pass and multi-pass crossflow arrangements.
• Basic Equations in Design:
Basic heat transfer equations will be outlined for the thermal analysis (sizing and rating
calculations) of such heat exchangers. Although complete design of a heat exchanger
requires structural and economical considerations in addition to these basic equations,
the purpose of the thermal analysis given here will be to determine the heat transfer
surface area of the heat exchanger (sizing problem). Performance calculations of a heat
exchanger (rating problem) is carried out when the heat exchanger is available but it is
necessary to determine the amount of heat transferred, pressure losses, and outlet
temperatures of both fluids.

Fluid temperature variation in parallel-flow, counterflow, evaporator, and condenser

heat exchangers: (a) counterflow; (b) parallel flow; (c) cold fluid evaporating at
constant temperature; (d) hot fluid condensing at constant temperature.

Overall energy balance for the hot and cold fluids of a two-fluid heat exchanger.
• Overall Heat Transfer Coefficient:
Most heat exchanger surfaces tend to acquire an additional heat transfer resistance that
increases with time. This may either be a very thin layer of oxidation, or, at the other
extreme, it may be a thick crust deposit, such as that which results from a salt-water
coolant in steam condensers. This fouling effect can be taken into consideration by
introducing an additional thermal resistance, termed the fouling resistance Rs. Its value
depends on the type of fluid, fluid velocity, type of surface, and length of service of the
heat exchanger.

The order of magnitude and range of h for various conditions

• LMTD Method for Heat Exchanger Analysis:

In the heat transfer analysis of heat exchangers, the total heat transfer rate Q through
the heat exchanger is the quantity of primary interest. Let us consider a simple
counterflow or parallel-flow heat exchanger. The form of ΔTm in Equation 2.7 may be
determined by applying an energy balance to a differential area element dA in the hot
and cold fluids. The temperature of the hot fluid will drop by dTh. The temperature of
the cold fluid will also drop by dTc over the element dA for counterflow, but it will
increase by dTc for parallel flow if the hot-fluid direction is taken as positive. \

For parallel flow heat exchanger.

 Temperature variation for a counterflow heat exchanger

Some correction factors are given below:

• The ε-NTU Method for Heat Exchanger Analysis:
When the inlet or outlet temperatures of the fluid streams are not known, a trial-and-
error procedure could be applied for using the LMTD method in the thermal analysis
of heat exchangers. The converged value of the LMTD will satisfy the requirement that
the heat transferred in the heat exchanger must be equal to the heat convected to the
fluid. In these cases, to avoid a trial-and-error procedure, the method of the number of
transfer units (NTU) based on the concept of heat exchanger effectiveness may be used.
This method is based on the fact that the inlet or exit temperature differences of a heat
exchanger are a function of UA/Cc and Cc /Ch.
Selection of Heat Exchangers and Their Components:
SELECTION CRITERIA BASED ON OPERATING PARAMETERS:
• Operating Pressures and Temperatures:
The exchanger in operation must withstand the stresses produced by the operating
pressure and the temperature differences between two fluids. These stresses depend on
the inlet pressures and temperatures of the two fluids. The most versatile exchangers
for a broad range of operating pressures and temperatures are shell-and-tube exchangers
for medium- to high-heat duties and double-pipe exchangers for lower heat duties. They
can handle from high vacuum to ultrahigh fluid pressures [generally limited to 30MPa
(4350 psi) on the shell or annulus side and 140 MPa (20,000psi) on the tube side].
Coupled with high pressures, shell-and-tube exchangers can withstand high
temperatures, limited only by the materials used; however, the inlet temperature
difference is limited to 508C (1208F) from the thermal expansion point of view when
the exchanger design allows only limited thermal expansion, such as in the E-shell
design. These exchangers are used for gas, liquid, and phase-change applications.
• Cost:
Cost is a very important factor in the selection of the heat exchanger construction
type. The cost per unit of heat transfer surface area is higher for a gasketed plate
exchanger than for a shell-and-tube exchanger. However, from the total cost (capital,
installation, operation, maintenance, etc.) point of view, PHEs are less expensive than
shell-and-tube exchangers when stainless steel, titanium, and other higher quality alloys
are used. Since tubes are more expensive than extended surfaces or a regenerator
matrix, shell-and-tube (or broadly, tubular) exchangers are in general more expensive
 per unit of heat transfer surface area. In addition, the heat transfer surface area density
of a tubular core is generally much lower than that of an extended surface or
regenerative exchanger. Rotary regenerators made of paper or plastic is in general the
least expensive per unit of heat transfer surface area.
• Fouling and Cleanability:
Fouling and cleanability are among the most important design considerations for liquid-
to-liquid or phase-change exchangers and for some gas-to-fluid exchangers. Fouling
should be evaluated for both design and off-design points. Periodic cleaning and/or
replacement of some exchanger components depend on the fouling propensity of the
fluids employed.
• Fluid Leakage and Contamination:
Whereas in some applications, fluid leakage from one fluid side to the other fluid side
is permissible within limits, in other applications fluid leakage is absolutely not
allowed. Even in a good leak tight design, carryover and bypass leakages from the hot
fluid to the cold fluid (or vice versa) occur in regenerators. Where these leakages and
subsequent fluid contamination is not permissible, regenerators are not used. The
choices left are either a tubular, extended surface, or some plate type heat exchangers.
Gasketed plate exchangers have more probability of flow leakage than do shell-and-
tube exchangers. Plate-fin and tube-fin exchangers have potential leakage problems at
the joint between the corrugated fin passage and the header or at the tube-to-header
joint.
• Fluids and Material Compatibility:
Materials selection and compatibility between construction materials and working
fluids are important issues, in particular with regard to corrosion. While a shell-and-
tube heat exchanger may be designed using a variety of materials, compact heat
exchangers often require preferred metals or ceramics. For example, a requirement for
low cost, light weight, high conductivity, and good joining characteristics for compact
heat exchangers often leads to the selection of aluminum for the heat transfer surface.
On the other side, plate exchangers require materials that are either used for food fluids
or require corrosion resistance.
• Fluid Type:
A gas-to-gas heat exchanger requires a significantly greater amount of surface area than
that for a liquid-to-liquid heat exchanger for a given heat transfer rate. This is because
the heat transfer coefficient for the gas is 110 to 1100 that of a liquid. The increase in
surface area is achieved by employing surfaces that have a high heat transfer surface
area density. For example, fins are employed in an extended surface heat exchanger, or
a small hydraulic diameter surface is employed in a regenerator, or small-diameter tubes
are used in a tubular heat exchanger. Plate heat exchangers (of the type described in
Section 1.5.2) are generally not used in a gas-to-gas exchanger application because they
produce excessively high pressure drops. All prime surface heat exchangers with plain
(uncorrugated) plates are used in some waste heat recovery applications. The fluid
pumping power is generally significant and a controlling factor in designing gas-to-gas
exchangers.
Design of an Automobile radiator:
The radiator is a part of an automobile which is used mainly to cool down the heated coolant
of an engine. Its basic working is based on the heat exchanger principal except here one of
the working fluids is air.

Below, a design of a car radiator is given with simple calculations.

 Part C

Limitations:
• Bending of tubes in circular shape.
• Inserting of fins in the tubes.
• Dies are to be manufactured for circular radiators which are exorbitantly costly.

Conclusions:
• Low velocity zones and high temperature regions (low heat transfer regions) are
identified in corners we observe that velocity increases with the increase in rpm of
radiator fan.
• For optimum efficiency eliminate corners and develop radiator of Circular shape.
• Design is compact
• Less material requirement
• Less power consumption for fan.
• More efficient.
• Since material saving is about 24%, cost saving on mass scale production will be
about 20% , once the dies are manufactured.

View publication stats