Heat Exchanger

Before proceeding to design of heat exchangers (Double Pipe heat exchanger, Shell and Tube

heat exchanger) we need to know some basic concept.

Equivalent diameter:

Hydraulic and heated equivalent diameters are approximations to account for different flow

geometries in thermal-hydraulic analyses. For heat transfer calculations, as a general rule, the

heated equivalent diameter must be used for bundle geometries and the hydraulic equivalent

diameter for annulus geometries.

D1

D2

When fluid is flown through annulus of a pipe containing two fluids having different

temperatures, there will be heat transfer between fluids. For calculation of heat transfer

coefficients and other parameters, we need to calculate Reynolds number (and may be other

dimensionless groups also). For calculation of pressure drop (friction factor) we also need to

know the Reynolds No. For inner pipe, the diameter (D1) will be the perfect one, but for

annulus, neither D1 nor D2 is the value of exact diameter. For the purpose we need to know

some diameter to be considered equivalent to the same flow of fluid if passed through a

circular tube. If the flow channel is rectangular then also we need to know equivalent

diameter for getting the value of Reynolds No.

The equivalent diameter is defined as:

D (or Deq) = 4 × rH; where rH is called „hydraulic radius‟.

Again, hydraulic radius is defined as,

This should be noted that for (i) fluid flow (pressure drop calculation) and for (ii) heat

transfer through the annulus, equivalent diameter will be different.

Consider the annular pipe shown above for equivalent diameter calculation:

For fluid flow:

; here, inside wall of outer pipe and outside wall of inner

pipe both are wetted.

Therefore, D = (D2 – D1)

For heat transfer:

Consider fluid in outer pipe is hotter.

; here, heat transfer is taking place to the inner fluid only

from outside wall of inner pipe.

Therefore,

If inner pipe is made of metal with considerable wall thickness, then all calculations of

diameter should be with thickness.

Make an exercise for calculation of equivalent diameter of an annular rectangular pipe.

Fouling Factors in Heat Exchangers:

The fouling factor represents the theoretical resistance to heat flow due to build-up of a layer

of dirt or other fouling substance on the tube surfaces of the heat exchanger. The deposition

of any undesired material on heat transfer surfaces increases the overall thermal

resistance and lowers the overall heat transfer coefficient of heat exchangers. Fouling also

impedes fluid flow, accelerates corrosion and increases pressure drop across heat exchangers.

Fouling may be of Chemical fouling - when chemical changes within the

fluid cause a fouling layer to be deposited onto the tube surface; it may be of

Biological fouling - this is caused by the growth of organisms within the fluid which deposit

out onto the surfaces of the heat exchanger.

As during operation with liquids and gases a dirt film may build up on the heat exchanger

surfaces which after years in operation might be so high that required heat transfer would not

be possible by the heat exchanger. Therefore, when any heat exchanger is designed, this

phenomenon must be taken into account. We know that during surface area calculation of

heat transfer equipment we consider overall heat transfer coefficient (U) calculated based on

individual heat transfer coefficients, thermal conductivity of metal, surface area of inner and

outer pipes etc. Therefore, this overall coefficient (U) is based on the assumption that there is

no deposition on the surface of the pipes/tubes. The heat transfer co-efficient thus calculated

may be termed as „Clean Overall Heat Transfer Coefficient (UC)‟.

For actual operations of heat transfer equipment, dirt will deposit. So during design, a design

value of overall heat transfer coefficient should be considered taking into account of dirt

factor. This heat transfer coefficient is termed as “Design Overall Heat Transfer Coefficient

(UD)‟.

These two coefficients are related as:

1/UD = 1/UC + Rd
Rd = 1/UD - 1/UC

Where,

Rd = fouling factor - or unit thermal resistance of deposit (m2K/W)

UD = Design Overall Heat Transfer Coefficient of heat exchanger [after fouling], (W/m2K)

UC = Clean Overall Heat Transfer Coefficient of heat exchanger when remains clean,

(W/m2K).

We can also write as:

UD = 1/ [Rd + 1/UC]

SI Unit of Rd is m2K / W

Fouling factors are included in calculations to account for film build up. The resistance built

up on the outside is designated Ro, and the resistance built up on the inside is designated Ri.

They are presented in the literature for various materials and conditions. Overall resistance

due to fouling (Rd) is the summation of Ro and Ri.

Because scale or dirt resistance increases with time in service, some time basis must be

chosen for numerical values of fouling factors.

Temperature correction factor Or LMTD correction factor:

It is a measure of the heat exchanger's departure from the ideal behavior of a counter flow or

parallel flow heat exchanger having the same terminal temperatures. During LMTD

calculation we have considered that either the flow is co-current (Parallel) of the flow is

counter current wise. But in actual situation, heat transfer equipments are designed in such a

way that neither total fluid flow is parallel nor it is counter current wise. In almost all cases

flow patterns are cross flow type. Therefore, the concept and consideration of LMTD is

differed from actual temperature gradient. To overcome the problem, a temperature

correction factor is being introduced. This factor is represented by the symbol „F‟ (sometimes

it is represented as „FT‟).

So we can say the corrected actual temperature gradient for heat transfer will be LMTD

multiplied by temperature correction factor, i.e., ∆Tcm = F× ∆Tm; [∆Tm = LMTD]

To get the value of F, Log Mean Temperature Difference Correction Factor „F‟ is considered

to be dependent on temperature effectiveness „P’ and heat capacity rate ratio „R’ for a given

flow arrangement. Where,

F correction factor depends on the geometry of the heat exchanger and the inlet and outlet

temperatures of the hot and cold fluid streams. F for common cross-flow and shell-and-tube

heat exchanger configurations is given in the figure versus two temperature ratios P and R.
Utilization of jH Factor (Colburn factor):

In fluid flow we have seen the plot of Reynolds Number versus Friction factor (or drag

coefficient). Likewise there are plots of Reynolds Number versus Colburn jH Factor. It is used

to get the value of individual film heat transfer coefficient. In our earlier note, we have

noticed that Colburn jH factor is defined as:

 ; the term Nu (Nusselt No.) contains individual film heat transfer

coefficient. Therefore, if we know Reynolds No., from chart we can get the value of jH. From

jH, we must have the value of “h”.

In the plot there are a number of lines drawn for a particular Reynolds No. The varying

parameter is the ratio of (L/D), where L is the length and D is the diameter of flow pipe,

respectively.

For the design of Shell and Tube heat exchangers, where flow patter is disturbed (by using

baffles) to create cross flow and to support tube bundles, above diagram is modified to

another form.