1

SIT Internal

ASE2101 Heat Transfer &

Thermodynamics

Topic 4
Heat Exchanger Analysis

By: Patrick Chua

Email: Patrick.Chua@singaporetech.edu.sg
 SIT Internal

Content

O What is heat exchanger

O Types of heat exchanger

O Overall heat transfer coefficient

O Heat exchanger analysis using LMTD

O Heat exchanger analysis using 𝜀 − 𝑁𝑇𝑈

O Heat exchanger design

2
 SIT Internal

What is heat exchanger

• A heat exchanger (HX) is a device which enables the
continuous transfer of heat between two fluid streams
separated by a solid wall.

• Heat exchangers are used in numerous engineering systems

such as power generation, air conditioning, chemical
industries, food industries, aeroplanes, cars, etc. They are
usually classified according to flow arrangement and type of
construction.

3
 SIT Internal

Types of heat exchanger

Concentric tube or Double-pipe heat exchanger

Parallel flow Counter flow

4
 SIT Internal

Types of heat exchanger

Plate and frame heat exchanger

5
 SIT Internal

Types of heat exchanger

Plate and fin heat exchanger or compact heat exchanger
Plate fin
Helps to increase surface area
Usually crossed flow, two fluid
streams are perpendicular to each
other.

Can be mixed or unmixed

6
 SIT Internal

Fin and tube heat exchanger
Tube Fin Heat Exchangers, also called
finned coil heat exchangers, consist of
tubes that pass through a dense fin stack
that is mechanically supported by a
mounting frame. Fluid passes through the
tube coils, conducts heat to the fins and
dissipates heat to air forced through the
heat exchanger.

7
 SIT Internal

Types of heat exchanger

Shell-and-tube heat exchanger

Shell inlet
Tube inlet

Tube outlet
Shell outlet

Large size and weight, not

suitable for aircraft or
automotive applications

8
 SIT Internal

Types of heat exchanger

Shell-and-tube heat exchanger

Shell inlet
Tube inlet

Tube outlet
Shell outlet

Classified by number of passes

9
 SIT Internal

Types of heat exchanger

Look at the shell-and-tube heat exchanger in the picture. How many shell passes and tube
passes does this heat exchanger make?
A. 2 shell passes and 4 tube passes
B. 1 shell pass and 2 tube passes
C. 2 shell passes and 2 tube passes
D. 2 shell passes and 1 tube pass
10
 SIT Internal

Type of heat exchanger

• How many shell passes does this heat

exchanger make?
A. 1
B. 2
C. 3
D. 4

11
 SIT Internal

Type of heat exchanger

Which type of flow

arrangement is this?
A. Parallel flow
B. Counter flow
C. Shell and tube
D. Compact

12
 SIT Internal

Type of heat exchanger

• Which of these heat exchangers are not suitable for use on aircraft or
automobiles where weight is a significant issue?

A.
C.

B. D.

13
 SIT Internal

Overall heat transfer coefficient

Qn – What is 𝑅𝑤𝑎𝑙𝑙 ?
• Consider double pipe heat exchanger

Draw the thermal circuit

14
 SIT Internal

Overall heat transfer coefficient

• Total thermal resistance 𝑅
𝑟
ln 𝑟0
1 1
▪ 𝑅= + 𝑖
+
ℎ𝑖 𝐴𝑖 2𝜋𝑘𝐿 ℎ0 𝐴0
• Rate of heat transfer 𝑄ሶ
∆𝑇
▪ 𝑄ሶ =
𝑅
• Define overall heat transfer coefficient 𝑈
∆𝑇
▪ 𝑄ሶ = 𝑈𝐴∆𝑇 =
𝑅
1
▪ 𝑈𝐴 =
𝑅
• Similar to how we define k and h
▪ But which A to take?
• If 𝐴0 , then 𝑈 = 𝑈0
• If 𝐴𝑖 , then 𝑈 = 𝑈𝑖
1
▪ 𝑈𝐴 = = 𝑈𝑜 𝐴𝑜 = 𝑈𝑖 𝐴𝑖
𝑅

15
 SIT Internal

Overall heat transfer coefficient

• Total thermal resistance 𝑅
𝑟
ln 𝑟0
1 1
▪ 𝑅= + 𝑖
+
ℎ𝑖 𝐴𝑖 2𝜋𝑘𝐿 ℎ0 𝐴0
• Rate of heat transfer 𝑄ሶ
∆𝑇
▪ 𝑄ሶ =
𝑅
• Define overall heat transfer coefficient 𝑈
∆𝑇
▪ 𝑄ሶ = 𝑈𝐴∆𝑇 =
𝑅
1
▪ 𝑈𝐴 =
𝑅
• Similar to how we define k and h
▪ But which A to take?
• If 𝐴0 , then 𝑈 = 𝑈0
• If 𝐴𝑖 , then 𝑈 = 𝑈𝑖
1
▪ 𝑈𝐴 = = 𝑈𝑜 𝐴𝑜 = 𝑈𝑖 𝐴𝑖
𝑅

16
 SIT Internal

Overall heat transfer coefficient

• When wall thickness 𝐷0 − 𝐷𝑖 is small, 𝑘 is high → 𝑅𝑤𝑎𝑙𝑙 ≈ 0
𝑟0
• When 𝐴𝑖 ≈ 𝐴𝑜 = 𝐴 ln
𝑟𝑖
𝑅𝑤 =
1 2𝜋𝑘𝐿
𝑅= We want the transfer coefficient to be
𝑈𝐴
1
1 1 1
high for efficient heat transfer → 𝑈 small
= + is desired
𝑈𝐴 ℎ𝑖 𝐴 ℎ𝑜 𝐴

1 1 1 ℎ𝑖 and ℎ𝑜 should desirably be large

= +
𝑈 ℎ𝑖 ℎ𝑜
In a gas and fluid heat exchanger, ℎ𝑔𝑎𝑠
usually low

To increase heat transfer, we then

increase 𝐴𝑔𝑎𝑠 , say using fin
17
 SIT Internal

Overall heat transfer coefficient

When a heat exchanger uses one of its fluid as gas, fins are typically used. Why?
A. Because h of gas is naturally big, so to decrease U, we increase the surface
area in contact with the gas by using fins
B. To create more circulation to increase efficiency of heat transfer.
C. To increase the distance traveled by the gas.
D. Because h of gas is naturally small, so to increase U, we increase the surface
area in contact with the gas by using fins.

18
 SIT Internal

Fouling
• Remember our double pipe heat
exchanger in the coffee machine?
▪ Fouling can be seen – precipitation
along the pipe
▪ Types of fouling
• Precipitation of solid deposits (scaling)
• Corrosion or other chemical fouling
• Growth of algae
▪ Have to add an additional thermal
resistance term due to fouling 𝑅𝑓
𝑟0
1 𝑅𝑓,𝑖 ln 𝑟𝑖 𝑅𝑓,𝑜 1
𝑅= + + + +
ℎ𝑖 𝐴𝑖 𝐴𝑖 2𝜋𝑘𝐿 𝐴𝑜 ℎ0 𝐴0
19
 SIT Internal

Analysis of heat exchangers

• When we want to
▪ (a) choose a heat exchanger that can achieve the required temperature change
▪ (b) we want to predict outlet temperature of a specified heat exchanger
• Assumption
▪ Steady-flow
▪ Kinetic and potential energy changes negligible
▪ Constant specific heat – take an average in the temp range we know the fluid
will go through
▪ Neglect axial heat conduction
• 1D steady state heat conduction in radial direction
▪ Outer surface assumed to be perfectly insulated
• Heat transfer occurs between the two fluids only
20
 SIT Internal

Analysis of heat exchangers

• Heat gained by cold fluid = heat lost by hot fluid
𝑚ሶ = mass flow rate
▪ Heat gained by cold fluid 𝑐𝑝 = specific heat capacity
• 𝑄ሶ = 𝑚ሶ 𝑐 𝑐𝑝,𝑐 𝑇𝑐,𝑜𝑢𝑡 − 𝑇𝑐,𝑖𝑛 = 𝐶𝑐 ൫𝑇𝑐,𝑜𝑢𝑡 − 𝐶 = heat capacity rate
𝑇𝑐,𝑖𝑛 ൯ ℎ𝑓𝑔 = enthalpy of vaporization of fluid at
▪ Heat lost by hot fluid specified T/P 𝑇𝑐,𝑖𝑛

• 𝑄ሶ = 𝑚ሶ ℎ 𝑐𝑝,ℎ 𝑇ℎ,𝑖𝑛 − 𝑇ℎ,𝑜𝑢𝑡 = 𝐶ℎ ൫𝑇ℎ,𝑖𝑛 − 𝑚ሶ ℎ 𝑐𝑝,ℎ = 𝐶ℎ

𝑇ℎ,𝑜𝑢𝑡 ൯
𝑇ℎ,𝑖𝑛
• If there is phase change involved
▪ 𝑄ሶ = 𝑚ℎ ሶ 𝑓𝑔
• From heat flow between exchangers
𝑇ℎ,𝑜𝑢𝑡
▪ 𝑄ሶ = 𝑈𝐴𝑠 ∆𝑇𝑚
• Where ∆𝑇𝑚 is an average temperature
difference between the two fluids 𝑇𝑐,𝑜𝑢𝑡
• 𝑈 will also vary depending on actual ∆𝑇𝑚 𝑚ሶ 𝑐 𝑐𝑝,𝑐 = Cc
21
 SIT Internal

Analysis of heat exchangers

• (a) choose a heat exchanger that can achieve the required temperature
change
• Log Mean Temperature Difference Method (LMTD)
Th Th Note the difference
T
h
' Tc' Th'
in definition of ∆𝑇1
T' and ∆𝑇2 for parallel
c
and counter flow
Tc Tc

Parallel Flow Counter Flow

Δ𝑇2 − Δ𝑇1
𝑄ሶ = 𝑈𝐴Δ𝑇𝑚 Δ𝑇𝑚 =
ln Δ𝑇2 /Δ𝑇1
22
 SIT Internal

Analysis of heat exchangers

• What about cross-flow and multipass shell and tube heat exchangers?
▪ ∆𝑇𝑚 = 𝐹∆𝑇𝑚,𝐶𝐹
• F is the correction factor (depends on geometry and inlet/outlet temp of the hot and
cold fluid)
• ∆𝑇𝑚,𝐶𝐹 is the LMTD for counter-flow heat exchanger with same inlet and outlet
temperatures

𝐹 ≤ 1, 𝐹 = 1 if it’s a counter flow

heat exchanger

23
SIT Internal

R varies from 0 to ∞. R=0 correspond to

phase change on shell side. R=∞
correspond to phase change on tube
side. For both extreme cases, 𝐹 = 1

24
 SIT Internal

Analysis of heat exchangers

• Procedure using LMTD to select/design heat exchanger
▪ Select the type of heat exchanger (counter flow/shell and tube etc)
▪ Calculate heat transfer rate 𝑄ሶ using energy balance
▪ Calculate ∆𝑇𝑚 and determine F
▪ Obtain (select or calculate) 𝑈
▪ Calculate heat transfer surface area 𝐴𝑠
▪ Select the heat exchanger with a surface area ≥ 𝐴𝑠

25
 SIT Internal

Example 1 - LMTD
Cooling water: 1 kg/s, inlet temperature 10 C.
Hot water: 2 kg/s, inlet temperature 90 C, outlet 60 C.
U- value on the inner pipe (hot water side) about 3,660 W/m²K,specific
heat capacity cp = 4,200 J/kgK.
Solve for Heat exchanger surface area A using LMTD.

26
 SIT Internal

Example 1 - LMTD
• Want to find heat exchanger surface area A
𝑇𝑖𝑛,ℎ = 𝑇𝑜𝑢𝑡,ℎ =
Δ𝑇2 − Δ𝑇1
𝑄ሶ = 𝑈𝐴Δ𝑇𝑚 Δ𝑇𝑚 =
ln Δ𝑇2 /Δ𝑇1

• To Find ∆𝑇𝑚 , need to find all temperatures.

▪ What do we already know? 𝑇𝑜𝑢𝑡,𝑐 =
▪ What do we need to find?
• Employ energy balance for hot water 𝑇𝑖𝑛,𝑐 =
▪ 𝑄ሶ = 𝑚ሶ ℎ 𝑐𝑝,ℎ ∆𝑇ℎ • Employ energy balance for cold water
• 𝑚ሶ ℎ = ▪ 𝑄ሶ = 𝑚ሶ 𝑐 𝑐𝑝,𝑐 ∆𝑇𝑐
• 𝑚ሶ 𝑐 = ∆𝑇1 =
• 𝑐𝑝,ℎ =
• 𝑐𝑝,𝑐 = ∆𝑇2 =
▪ ∆𝑇ℎ = ∆𝑇𝑚 =
• 𝑇𝑜𝑢𝑡,𝑐 − 𝑇𝑖𝑛,𝑐 =
▪ 𝑄ሶ = 𝐴=
𝑄ሶ
=
𝑈∆𝑇𝑚
▪ ∆𝑇𝑐 =
▪ 𝑇𝑜𝑢𝑡,𝑐 =
27
 SIT Internal

Example 2 – LMTD with phase change

• Steam in the condenser of a powerplant is to be condensed at a temperature of 30℃ with cooling water
from a nearby lake, which enters the tubes of the condenser at 14℃ and leaves at 22℃. The surface
area of the tubes is 45𝑚2 , and the overall heat transfer coefficient 𝑈 = 2100 𝑊/𝑚2 ∙ ℃. Determine
the mass flow rate of the cooling water needed and the rate of condensation of the steam in the
condenser. Assume counterflow configuration. Heat of vaporization of water at 30℃ is assumed to be
𝑘𝐽
ℎ𝑓𝑔 = 2431 . 𝑐𝑝 of cold water at average temp of 18℃ is 4184 J/(kg ℃).
𝑘𝑔

How does the temperature graph look like for this case?

28
 SIT Internal

Example 2 – LMTD with phase change

• All the temperatures are known
▪ ∆𝑇1 =
▪ ∆𝑇2 =
Δ𝑇2 −Δ𝑇1 𝑇ℎ =30℃
▪ Δ𝑇𝑚,𝐶𝐹 = = 𝑇𝑜𝑢𝑡,𝑐 =22℃
ln Δ𝑇2 /Δ𝑇1
▪ Δ𝑇𝑚 = 𝐹Δ𝑇𝑚,𝐶𝐹 , what is F? 𝑇𝑖𝑛,𝑐 =14℃
• 𝑄ሶ = 𝑈𝐴Δ𝑇𝑚 =
• For water
▪ 𝑄ሶ = 𝑚ሶ 𝑐 𝑐𝑝,𝑐 ∆𝑇𝑐
▪ 𝑚ሶ 𝑐 =

29
 SIT Internal

Analysis of heat exchangers

• (b) we want to predict outlet temperature of a specified heat exchanger
• Effectiveness-NTU (𝜀 − 𝑁𝑇𝑈 method)
The effectiveness ε is defined as:
Qሶ Actual heat transfer rate
𝜺= =
Qሶ max Maximum possible heat transfer rate
Not
known
Heat transfer stops 𝑄ሶ = 𝐶𝑐 𝑇𝑐,𝑜𝑢𝑡 − 𝑇𝑐,𝑖𝑛 = 𝐶ℎ 𝑇ℎ,𝑜𝑢𝑡 − 𝑇ℎ,𝑖𝑛
when cold fluid
heated to 𝑇ℎ,𝑖𝑛 or hot All known
𝑄ሶ 𝑚𝑎𝑥 = 𝐶𝑚𝑖𝑛 𝑇ℎ,𝑖𝑛 − 𝑇𝑐,𝑖𝑛
fluid heated to 𝑇𝑐,𝑖𝑛
Smaller 𝐶, larger 𝑄ሶ = 𝜀 𝑄ሶ 𝑚𝑎𝑥
change in T, limiting
heat transfer Max possible temperature difference

30
 SIT Internal

Analysis of heat exchangers

Both dimensionless
• Can be shown that 𝜀 = 𝑓(𝑁𝑇𝑈, 𝑐) parameters
▪ 𝑐 = Capacity Rate Ratio
𝐶𝑚𝑖𝑛
𝑐=
𝐶𝑚𝑎𝑥
▪ NTU = Number of Transfer Units (a Non-dimensional parameter)
𝑈𝐴
𝑁𝑇𝑈 =
𝐶𝑚𝑖𝑛

Note for the same fluid property and also

U, NTU is proportional to A. The larger the
surface area of the heat exchanger, the
larger is NTU

31
 SIT Internal

Analysis of heat exchangers

Large value
of NTU
→slow
increase in 𝜀

• Note, Case 4 when c→ 0 occurs when

𝐶𝑚𝑎𝑥 = ∞, when phase change is involved

• Note: during phase change 𝐶 = ∞ since

∆𝑇 = 0 but 𝑄ሶ is finite
32
 SIT Internal

Analysis of heat exchangers

• Using 𝜀 − 𝑁𝑇𝑈 method to determine 𝑄ሶ
and 𝑇ℎ,𝑜𝑢𝑡 and 𝑇𝑐,𝑜𝑢𝑡
▪ Find 𝑄ሶ 𝑚𝑎𝑥
▪ From design of heat exchanger, find 𝜀
▪ Calculate 𝑄,ሶ 𝑇ℎ,𝑜𝑢𝑡 and 𝑇𝑐,𝑜𝑢𝑡
• Can also use to design heat exchanger if
outlet temperatures are known
▪ Calculate 𝑄ሶ
▪ Calculate 𝑄ሶ 𝑚𝑎𝑥
▪ Calculate 𝜀
▪ Determine NTU -> A can be found

33
 SIT Internal

Example 3 - 𝜀 − 𝑁𝑇𝑈
Cooling water: 1kg/s, inlet temperature 10 C.
Hot water: 2kg/s, inlet temperature 90 C, outlet 60 C.
U- value on the inner pipe (hot water side) about 3660 W/m²K,specific
heat capacity cp = 4200 J/kgK.

• What is the required heat exchanger surface area A?

34
 SIT Internal

Example 3 - 𝜀 − 𝑁𝑇𝑈

• Calculate 𝑄ሶ
▪ Hot water inlet outlet temperature is known
▪ 𝑄ሶ = 𝑚ሶ ℎ 𝑐𝑝,ℎ ∆𝑇ℎ =
• Calculate 𝑄ሶ 𝑚𝑎𝑥
▪ 𝑄ሶ 𝑚𝑎𝑥 = 𝐶𝑚𝑖𝑛 𝑇ℎ,𝑖𝑛 − 𝑇𝑐,𝑖𝑛 =
• Calculate 𝜀
Qሶ
▪ 𝜺 = Qሶ
max
• Determine NTU -> A can be found
▪ Which NTU equation should we use?
• 𝑁𝑇𝑈 =
𝐶𝑚𝑖𝑛 𝑁𝑇𝑈
• A= 𝑈
=

35
SIT Internal

36
 SIT Internal

37