ENRG406 - L4 - Thermal Design Recuperators

7/28/2022 Prepared by : Dr.
Muhammad Umar Siddiqui 1
HEAT EXCHANGER DESIGN (ENRG 406)

ENERGY ENGINEERING DEPARTMENT
COLLEGE OF ENGINEERING
IMAM ABDULRAHMAN BIN FAISAL UNIVERSITY
Lecture No. 4
Thermal Design Theory for Recuperators
Instructor: Dr. Farooq Saeed
Updated: July 2022

7/28/2022 Prepared by : Dr. Muhammad Umar Siddiqui 2
Topics Coverage
Thermal Circuit and UA Approach
Effectiveness – NTU Approach
P – NTU Approach
F – LMTD Approach
Lesson Objectives
By the end of this lesson, students will be able to
 Perform thermal design of heat exchangers using UA Approach
 Perform thermal design of heat exchangers using Effectiveness-NTU

Approach
 Perform thermal design of heat exchangers using P-NTU Approach
 Perform thermal design of heat exchangers using F-LMTD Approach
 Analyze Series and Parallel Coupling of Heat exchangers
 Thermally evaluate the complex system of multiple heat exchangers

Thermal Circuit and UA Approach

Note: Flue gases are the hot waste gases from exhaust
of any combustion process such as a gas turbine engine
Effectiveness – NTU Approach

Thermodynamic asymptotic value:

curve becomes almost flat
Use this when C* = 1

To get max. possible effectiveness of heat exchanger
when infinite amount of heat exchanger area is available
Recall that for evaporator or condenser C* = 0, i.e.,

Cmin is finite and Cmax is approaching infinity
I – temperatures at the
left end of exchanger
II – temperatures at the
right end of exchanger
I – temperatures at the left end of exchanger

II – temperatures at the right end of exchanger
< 120°C 
P-NTU Approach
𝑇, 𝑇,
𝑃
∆𝑇
Recall that in the -NTU approach:

q = Cmin Tmax = Cmin (Th,i – Tc,i) = qmax
qmax = Cmin (Th,i – Tc,i) = Cmin Tmax

Why P-NTU Approach?
qmax = Cmin (Th,i – Tc,i) = Cmin Tmax

Why P-NTU Approach?

P, NTU & R - Definitions
𝑇, 𝑇,
𝑃
∆𝑇
Cold: Hot:
q=𝑚 𝐶 , 𝑇, 𝑇 , =𝑚 𝐶 , 𝑇 , 𝑇 ,
P-NTU Relationships (Shell & Tube Hx)
n & j unknown
Use this instead.
Note: Stream symmetric implies you can use formulas for both fluid 1
& 2 or you can interchange fluids. See footnote to this table on slide 50
P-NTU Relationships
Note: In case of unmixed/mixed combination you

cannot use formulas for both fluid 1 & 2. The
given formulas are only to be used for fluid 1
P-NTU Relationships
Note: In this case, the formulas are given only for tube side fluid 1
Note: sinh 𝑥 , cosh 𝑥 , tanh 𝑥 , coth 𝑥 ?

P-NTU Relationships
P-NTU Relationships
P-NTU Relationships
P-NTU Relationships
P-NTU Relationships
Series product
P-NTU Relationships
P-NTU Relationships (Plate Hx)
𝑥 → 𝑁𝑇𝑈
𝑦→𝐶
P-NTU Relationships
P-NTU Relationships
P-NTU Relationships
P-NTU Relationships
P-NTU Relationships
Important note
Note: The origin of the P‐NTU method is related to shell‐and‐tube exchangers, and the
most useful NTU design range is from about 0.2 to 3.0 for shell‐and‐tube exchangers.
P-NTU Relationships
P-NTU Relationships
P-NTU Relationships
P-NTU Relationships
Multipass Exchangers: Series Coupling

A multi‐pass exchanger is a single exchanger having multi‐passing of one or both fluids
in the exchanger
A & B combined
𝑇, 𝑇,
𝑃
∆𝑇
If we refer to exchangers A and B of Fig. 3.19 (last slide) as A1 and A2, the generalized
expression for the combined temperature effectiveness of n exchangers (or passes) Ai in
series in overall counterflow can be written as
(formulas on slide 44)

FIGURE 3.20 Hypothetical exchanger array made up of counterflow (cf),

1–2 TEMA E, parallel flow (pf ), and crossflow exchangers
P1 – overall temperature effectiveness

R1 – overall heat capacity ratio
Multipass Exchangers: Series Coupling
𝑇, 𝑇,
The temperature effectiveness P1,Ai of individual exchangers is: 𝑃
∆𝑇
The overall temperature effectiveness P1 of n exchangers (or passes) in series is

given as follows
When individual passes of the multipass overall parallel flow exchanger are crossflow
exchangers, the resultant arrangement is referred to as the multipass cross‐parallelflow.
There are many possible combinations of this flow arrangement.
The simplified relationship of Eq. (3.142) is adequate for the design and analysis of most
two and three‐pass industrial exchangers
𝑇, 𝑇,
𝑃
∆𝑇
PC
𝑇, 𝑇,
𝑃
∆𝑇
Multipass Exchangers: Parallel Coupling
The results presented here are equally valid if the two exchangers are considered as
two passes of a multipass crossflow exchanger with fluids mixed between passes
The temperature effectiveness P1,Ai of individual exchangers is:
It can be shown that the temperature effectiveness P1,Ai of individual exchangers is

related by:
or
For this parallel coupling, the fluid 2 is the one that is divided into 2 steams and
the equations are given accordingly. Thus, the heat capacity rate of fluid 2 is then:
a) Series coupling and overall b) Series coupling and overall

counter flow parallel flow
(fluid 1) (fluid 1)
(fluid 2)
(fluid 2)
Symmetric streams : can interchange fluid 1 & 2

Choose: Shell fluid (water) as fluid 1 and tube fluid (oil) as fluid 2
𝑇, 𝑇,
𝑃
∆𝑇
P-NTU Relationships (slides 43-44)

c) Parallel coupling with shell fluid in series: Oil (fluid 2 in tube) flow rate is split into 2
(fluid 1)
d) Parallel coupling with tube fluid in series: Water (fluid 2 in shell) flow rate is split into 2
(fluid 1)
Other Considerations in Design

• From the heat transfer point of view, whenever the fluid velocity is reduced in the
exchanger, the corresponding heat transfer coefficient will be lower in turbulent and
transition flow regimes than that for the nominal fluid velocity. This, in turn, may reduce
the overall heat transfer coefficient and the heat transfer rate in the exchanger.
• However, the lower velocity will also reduce the pressure drop on that side. Now compare
the parallel coupling vs. series coupling. The fluid, which splits into two streams [oil for
case (c) and water for case (d)], will have lower heat transfer coefficient and will result in
lower overall U and higher required exchanger surface area than those calculated in the
example above.
• However, if the pressure drop specified is severely constrained, parallel coupling may be a
choice for the fluid with the limited pressure drop, to split it into two streams in the
parallel coupling. Of course, this solution will result in a twofold penalty in surface area
requirement for the same heat transfer: (1) an increase in the surface area for parallel
coupling vs. that for series coupling with overall counterflow as in the example above, and
(2) a reduction in the heat transfer coefficient and U for parallel coupling resulting in
increased surface area.
• Example 7.6 also provides some insight into performance of single-pass vs. two-pass
series or parallel coupled exchanges.
• In addition, there are other considerations, such as fouling, laminar vs. turbulent flow on
the shell side, pressure containment, and thermal stresses, that should be considered before
the specific choice is made for series vs. parallel coupling for a given application
Mean Temperature Difference Approach

LMTD Correction Factor - F

What does F physically represent?

Where is this approach used?

Correction
Factor F
correlations for
various Flow
Arrangements
Heat Exchanger Arrays and Multipassing

Heat Exchanger Arrays and Multipassing

Homework No. 3
• Solve Example 3.2 for 1-2 TEMA E Shell and Tube Heat
Exchanger.
• Solve Example 3.3 for Parallel Flow Heat Exchanger
• Solve Example 3.5 using mixed-mixed crossflow heat
exchanger for part a & b only.

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7/28/2022 Prepared by : Dr.

Muhammad Umar Siddiqui 1

HEAT EXCHANGER DESIGN (ENRG 406)

Instructor: Dr. Farooq Saeed

Updated: July 2022

Effectiveness – NTU Approach

 Perform thermal design of heat exchangers using UA Approach

 Perform thermal design of heat exchangers using Effectiveness-NTU

 Perform thermal design of heat exchangers using P-NTU Approach

 Perform thermal design of heat exchangers using F-LMTD Approach

 Analyze Series and Parallel Coupling of Heat exchangers

 Thermally evaluate the complex system of multiple heat exchangers

Thermal Circuit and UA Approach

Effectiveness – NTU Approach

Thermodynamic asymptotic value:

Use this when C* = 1

Recall that for evaporator or condenser C* = 0, i.e.,

I – temperatures at the left end of exchanger

Recall that in the -NTU approach:

qmax = Cmin (Th,i – Tc,i) = Cmin Tmax

Why P-NTU Approach?

qmax = Cmin (Th,i – Tc,i) = Cmin Tmax

Why P-NTU Approach?

P, NTU & R - Definitions

P-NTU Relationships (Shell & Tube Hx)

Note: In case of unmixed/mixed combination you

Note: sinh 𝑥 , cosh 𝑥 , tanh 𝑥 , coth 𝑥 ?

P-NTU Relationships (Plate Hx)

Multipass Exchangers: Series Coupling

(formulas on slide 44)

FIGURE 3.20 Hypothetical exchanger array made up of counterflow (cf),

P1 – overall temperature effectiveness

Multipass Exchangers: Series Coupling

The overall temperature effectiveness P1 of n exchangers (or passes) in series is

Multipass Exchangers: Parallel Coupling

It can be shown that the temperature effectiveness P1,Ai of individual exchangers is

a) Series coupling and overall b) Series coupling and overall

Symmetric streams : can interchange fluid 1 & 2

P-NTU Relationships (slides 43-44)

Other Considerations in Design

Mean Temperature Difference Approach

LMTD Correction Factor - F

What does F physically represent?

Where is this approach used?

Heat Exchanger Arrays and Multipassing

Heat Exchanger Arrays and Multipassing

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