DESIGN CALCULATION

Double Pipe Heat Exchanger Rating

HX-001

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Revision :0
Year : 2023
Prepared by : NFL
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Title :

Double Pipe Heat Exchanger Rating

Equipment :

HX-001

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 REVISION HISTORY PAGE

Change history

Revs Date Prepared by Changes

0 9/8/2023 NFL Created as first edition
- Add pressure drop calculation both inner and
1 9/12/2023 NFL outer pipe side
- Add summary section of the calculation

Remarks

1.
2.
3.
Project No. : Date : 8-Sep-23
Doc No. : Prepared by : NFL
Equipment tag : HX-001 Checked by : Vegapunk
Project Name :

Tittle : Double Pipe Heat Exchanger Rating Revision No. 1

1. Input Data

A. Inner Fluid Properties

Inner fluid Hot Fluid
Fluid media Methanol
Flow rate F_i = 4500 kg/h
Inlet temperature T_i in = 60 degC
Density ρ_i = 755 kg/m3
Viscosity μ_i = 0.000432 Pa.s
Specific heat Cp_i = 3118.26 J/(kg degC)
Thermal conductivity k_i = 0.196 W/(m degC)

B. Outer Fluid Properties

Outer fluid Cold Fluid
Fluid media Water
Flow rate F_o = 2500 kg/h
Inlet temperature T_o in = 25 degC
Density ρ_o = 996.327 kg/m3
Viscosity μ_o = 0.0089 Pa.s
Specific heat Cp_o = 3850.26 J/(kg degC)
Thermal conductivity k_o = 0.61 W/(m degC)

C. Heat Exchanger Properties

Overall length L =6 m

Inner pipe nominal size NPS_i = 1"

Outside diameter OD_i = 33.4 mm
Thickness thc_i = 2.77 mm
Inside diameter ID_i = 27.86 mm
Cross sectional area Ac_i = 0.00061 m2
Inner pipe material Stainless steel
Thermal conductivity k_i pipe = 14.9 W/(m degC)
Density ρ_i pipe = 7930 kg/m3

Outer pipe nominal size NPS_o = 2.5"

Outside diameter OD_o = 73 mm
Thickness thc_o = 3.05 mm
Inside diameter ID_o = 66.9 mm
Effective diameter ID_e = 39.04 mm
Effective cross sectional area Ac_e = 0.001197 m2
Outer pipe material Stainless steel
Thermal conductivity k_o pipe = 14.9 W/(m degC)
Density ρ_i pipe = 7930 kg/m3

Insulation material Rockwool

Insulation thickness thc_is = 20 mm
Insulation thermal conductivity k_is = 0.034 W/(m degC)

Page 4 of 9
Project No. : Date : 8-Sep-23
Doc No. : Prepared by : NFL
Equipment tag : HX-001 Checked by : Vegapunk
Project Name :

Tittle : Double Pipe Heat Exchanger Rating Revision No. 1

Insulation cladding material Stainless steel

Cladding thickness thc_clad =1 mm
Cladding conductivity k_clad = 14.9 W/(m degC)

D. Environmental Condition
External air temperature T_air = 30 degC
Wind speed U =2 m/s
Gravity g = 9.8 m/s2

2. Calculation

A. Inner fluid side heat ressistant, R1

Inner fluid side flow rate F_1 = 4500 kg/h
Inner fluid side volumetric flow rate Q_1 = 6.0 m3/h
Inner fluid side velocity v_1 = 2.7 m/s

Inner fluid side Reynold number NRe_1 = 132238

Inner fluid side Reynold number criteria = Turbulence
Inner fluid side Prandtl number NPr_1 = 6.9
For inner fluid side, Nusselt number are calculated using following equation by
Gneliensky (1976) :
𝑓
𝑅𝑒 − 1000 𝑃𝑟
8
𝑁𝑢 = 0.5
𝑓 2
1 + 12.7 (𝑃𝑟 3 − 1)
8

and f is friction factor :

1 2ε 2.51
= -2log +
𝑓 𝐼𝐷 𝑁𝑅𝑒 𝑓

Inner fluid side Nusselt number NNu_1 = 1993

Then, heat transfer coefficient calculated using :

𝑁𝑢 𝑘𝑖
ℎ=
𝐼𝐷𝑖
Inner fluid side heat transfer coefficient h_1 = 14024 W/m2 degC
Thus we get inner fluid side heat ressistance by convection :
1
R = ℎπ𝐷𝐿

Inner fluid side heat ressisstant R_1 = 0.000136 degC/W

B. Inner pipe wall conduction heat ressistant, R2

Inner pipe thermal conductivity k_i pipe = 14.9 W/(m degC)

Page 5 of 9
Project No. : Date : 8-Sep-23
Doc No. : Prepared by : NFL
Equipment tag : HX-001 Checked by : Vegapunk
Project Name :

Tittle : Double Pipe Heat Exchanger Rating Revision No. 1

For conduction ressistance in pipe wall side :

𝐷
ln( 𝑜𝑢𝑡ൗ𝐷 )
𝑖𝑛
R= 2π𝐿𝑘

Inner pipe wall conduction ressistant R_2 = 0.0003 degC/W

C. Outer fluid side heat ressistant, R3

Outer fluid side flow rate F_3 = 2500 kg/h
Outer fluid side volumetric flow rate Q_3 = 2.5 m3/h
Outer fluid side velocity v_3 = 0.6 m/s

Outer fluid side Reynold number NRe_3 = 4360.8

Outer fluid side Reynold number criteria = Turbulence
Outer fluid side Prandtl number NPr_3 = 56.2
Outer fluid side Nusselt number NNu_3 = 99

Outer fluid side heat transfer coefficient h_3 = 1545 W/m2 degC
Outer fluid side heat ressisstant R_3 = 0.000323 degC/W

D. Outer pipe wall conduction heat ressistant, R4

Outer pipe thermal conductivity k_o pipe = 14.9 W/(m degC)
Outer pipe wall conduction ressistant R_4 = 0.0002 degC/W

E. Insulation conduction heat ressistant, R5

Insulation thermal conductivity k_is = 0.034 W/(m degC)
Insulation conduction ressistant R_5 = 0.3409 degC/W

F. Insulation cladding conduction heat ressistant, R6

Insulation cladding thermal conductivity k_clad = 14.9 W/(m degC)
Insulation cladding conduction ressistant R_6 = 0.00003 degC/W

G. Environment side heat ressistant, R7

Environment air velocity U = 2.0 m/s

Environment side Reynold number NRe_7 = 14318.2

Environment side Reynold number criteria = Turbulence
Environment side Prandtl number NPr_7 = 0.7
Environment side Rayleigh number NRa_7 = 3603619

Environment side are directly exposed to ambient air, and Nusslet number are
calculated by combining both forced and free convection. For forced convection,
Nusselt number are (Churchill & Bernstein correlation) :

5/8 4/5
0.62𝑅𝑒1/2 𝑃𝑟1/3 𝑅𝑒
𝑁𝑢𝑓𝑜𝑟𝑐𝑒𝑑 = 0.3 + 1/4
+ 1+
0.42/3 282000
1+ 𝑃𝑟

Page 6 of 9
Project No. : Date : 8-Sep-23
Doc No. : Prepared by : NFL
Equipment tag : HX-001 Checked by : Vegapunk
Project Name :

Tittle : Double Pipe Heat Exchanger Rating Revision No. 1

and for free convection (Churchill & Chu correlation) :

1ൗ 2
0.387𝑁𝑅𝑎 6
𝑁𝑁𝑢 = 0.6 + 8ൗ
9ൗ 27
0.559 16
1 + 𝑁𝑃𝑟

Forced convection Nusselt number NNu_f = 66

Free convection Nusselt number NNu_n = 21
Combined Nusselt number NNu_7 = 66

Environment side heat transfer coefficient h_7 = 15 W/m2 degC

Environment side heat ressisstant R_7 = 0.030870 degC/W

H. Heat exchanger overall heat transfer coefficient

Now, the heat ressistant above are sum up to get overall heat transfer
coefficient. For exchanger region, heat are flowed from inner side pipe to outer side
pipe or vice versa. Thus , R1 through R3 are sum up, then overall heat transfer
coefficient are calculated :

𝑅𝑒𝑥𝑐ℎ𝑎𝑛𝑔𝑒𝑟 = ෍ 𝑅1 + 𝑅2 + 𝑅3

1
𝑈𝐴𝑒𝑥𝑐ℎ𝑎𝑛𝑔𝑒𝑟 = 𝑅
exchanger

Total heat exchanger ressistant R_tot = 0.000782 degC/W

Heat exchanger overall heat transfer coefficient UA_1 = 1279.0 W/degC

I. External overall heat transfer coefficient

For external region, heat are flowed from outer side pipe to environment or vice
versa. Thus , R4 through R7 are sum up, then overall heat transfer coefficient are
calculated :

Total heat exchanger ressistant Re_tot = 0.371935 degC/W

Heat exchanger overall heat transfer coefficient UA_2 = 2.7 W/degC

J. Final temperature
The calculation are start by applying basic energy balance and derive the equation
that occurs in both inner pipe and outer pipe. Since this is the time dependent
calculation which is temperature always change by the time until reached steady state,
the accumulation will not zero. For inner pipe side :

𝑑𝑄
𝑑𝑡
= 𝐹𝑖𝑛𝑙𝑒𝑡 𝐶𝑝𝑖𝑛𝑙𝑒𝑡 𝑇𝑖𝑛𝑙𝑒𝑡 − 𝐹𝑜𝑢𝑡𝑙𝑒𝑡 𝐶𝑝𝑜𝑢𝑡𝑙𝑒𝑡 𝑇𝑜𝑢𝑡𝑙𝑒𝑡 ± (𝑈𝐴1 Δ𝑇𝐿𝑀𝑇𝐷 )

Page 7 of 9
Project No. : Date : 8-Sep-23
Doc No. : Prepared by : NFL
Equipment tag : HX-001 Checked by : Vegapunk
Project Name :

Tittle : Double Pipe Heat Exchanger Rating Revision No. 1

and for outer pipe :

𝑑𝑄
𝑑𝑡
= 𝐹𝑖𝑛𝑙𝑒𝑡 𝐶𝑝𝑖𝑛𝑙𝑒𝑡 𝑇𝑖𝑛𝑙𝑒𝑡 − 𝐹𝑜𝑢𝑡𝑙𝑒𝑡 𝐶𝑝𝑜𝑢𝑡𝑙𝑒𝑡 𝑇𝑜𝑢𝑡𝑙𝑒𝑡 ± (𝑈𝐴1 Δ𝑇𝐿𝑀𝑇𝐷1 ) ± (𝑈𝐴2 Δ𝑇𝐿𝑀𝑇𝐷2 )

with LMTD are average logaritmic temperature different :

Δ𝑇1 − Δ𝑇2
Δ𝑇𝐿𝑀𝑇𝐷 =
𝑙𝑛Δ𝑇1 −𝑙𝑛Δ𝑇2
The equation above resulting simple ordinary differential equation and shall to
solve simultaneously. The second order Runge-Kutta method are selected in order to
solve both equation.

Final inner fluid outlet temperature T_if = 53.0 degC

Final outer fluid outlet temperature T_of = 35.1 degC
Final exchanger cladding surface temperature T_sf = 30.4 degC

Final inner fluid temperature different ΔT1 = 7.0 degC

Final outer fluid temperature different ΔT2 = 10.1 degC

Exchanger logaritmic average temperature different ΔT LMTD = 21.2 degC

K. Pressure drop
Pressure drop both for inner and outer pipe are calculated as follows (Kern) :

4 𝑓 𝐺 2𝐿
Δ𝑃 =
2ρ𝐷

Inner fluid mass flux Gi = 2050.5 kg/m2 s

Outer fluid mass flux Go = 580.1 kg/m2 s

Inner fluid pressure drop ΔPi = 1.8 bar

Outer fluid pressure drop ΔPo = 0.1 bar

3. Results

A. Heat exchanger construction

Inner pipe Outer pipe
Material Stainless steel Stainless steel
Pipe nominal size 1" 2.5"
Outside diameter (mm) 33.4 73
Thickness (mm) 2.77 3.05
Inside diameter (mm) 27.86 66.9
Length (m) 6 6
Effective cross sectional area (m) 0.00061 0.00120
Volume (L) 3.66 7.18
Empty weight (kg) 11.54 30.50
Filled with water weight (kg) 3.7 7.18

Page 8 of 9
Project No. : Date : 8-Sep-23
Doc No. : Prepared by : NFL
Equipment tag : HX-001 Checked by : Vegapunk
Project Name :

Tittle : Double Pipe Heat Exchanger Rating Revision No. 1

B. Heat exchanger duty

Inner pipe Outer pipe
Fluid service Methanol Water
Flowrate (kg/h) 4500 2500
Inlet temperature (degC) 60 25
Calculated outlet temperature (degC) 53.0 35.1
Calculated pressure drop (bar) 1.8 0.1
Fluid velocity (m/s) 2.7 0.6
Reynold Number 132237.7 4360.8
Heat transfer coefficient (W/m2 degC) 14024.2 1544.8
Overall heat transfer coefficient (W/m2 degC) 2031.6
Heat ressisstant (W/degC) 0.000782
Heat duty (kW) 27.1
Surface area (m2) 0.63
ΔT LMTD (degC) 21.2

TEMPERATURE OF FLUID VS TIME

60.00
55.00
TEMPERATURE (DEGC)

50.00
45.00
40.00
35.00
30.00
25.00
20.00
0.00 0.50 1.00 1.50 2.00 2.50 3.00 3.50 4.00 4.50 5.00
TIME (MIN)
Inner pipe Outer pipe

PRESSURE DROP VS LENGTH

2.00
PRESSURE DROP (BAR)

1.50

1.00

0.50

0.00
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 6.5
EXCHANGER LENGTH (M)

Inner pipe Outer pipe

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