Heat Exchangers: Fundamentals and Design Analysis

Heat Exchanger Network Analysis by Pinch Technique

Prof. P. K. Das.
Mechanical Engineering
IIT KHARAGPUR

Reference: The Pinch Design Method For Heat Exchanger Networks by B. Linnhoff and E. Hindmarsh
Chemical Engineering Science Vol.38, No.5, pp.745-763, 1983

1
 Heat Exchanger Network
Process Plant:
 Many streams need heating or cooling.
 Utilities like hot air , hot oil, steam for heating.
 Utilities like air, water, chilled water, refrigerant for cooling.
 Efforts to be made for reducing the use of utilities.
 This can be done by “ Heat Integration” .
 “ Heat Integration” implies heat exchange between the hot and cold streams.
 This reduces the use of utilities.
 However, this increases the number of heat exchangers.
 Heat exchanger synthesis means designing a network so that using minimum
number of heat exchangers, the use of utilities can also be minimized

2
Synthesis of Heat Exchanger Network (HEN)

 There are different techniques of synthesis of HEN.

 The pinch technique is very widely used.

3
 Schematic representation of Heat Exchanger Network

C1 C2 C3
H1 RULE:
Minimum number of Heat
H2 Exchangers (𝑈𝑚𝑖𝑛 ) = 𝑁-1
𝑁=No. of process streams ( N1 ) + No.
H3
of utilities(N2)

4
 Pinch Technique
Basic assumptions for present discussion:
 Logic Based- based on first and second law of thermodynamics.
 There is one hot utility and one cold utility of infinite capacity.
 Steady state operation.
 There is no restriction for matching the streams.
 All heat exchangers are without any phase change and without any heat generation or
reaction.
 Heat exchangers are assumed to be indirect contact and counter flow.

5
 Table 1. Stream data for test case
STREAM NUMBER & HEAT CAPACITY FLOW RATE 𝑪𝒑 TS(℃) TT(℃)
TYPE kW/℃

(1) HOT 2 150 60

(2) HOT 8 90 60

(3) COLD 2.5 20 125

(4) COLD 3.0 25 100

𝜟𝑻𝒎𝒊𝒏 = 𝟐𝟎° 𝑪

6
 4
3

2
1

20 ℃ 25 ℃ 60 ℃ 90 ℃ 100 ℃ 125 ℃ 150 ℃

Temperature
Goals of HEN synthesis
1) Minimum utility.
2) Stream matching.
3) No. of heat exchangers needed.
4) End temp of the heat exchangers.

7
T

Cold Hot
Utility Utility

8
Thank You!!

10
Heat Exchangers: Fundamentals and Design Analysis
Heat Exchanger Network Analysis by Pinch Technique
Prof. P. K. Das.
Mechanical Engineering
IIT KHARAGPUR

Reference: The Pinch Design Method For Heat Exchanger Networks by B. Linnhoff and E. Hindmarsh
Chemical Engineering Science Vol.38, No.5, pp.745-763, 1983

1
 Table 2. The problem table for Test case
SUBNET STREAMS AND TEMPERATURE DEFICIT ACCUMULATED HEAT FLOWS
WORK

COLD T(℃) HOT INPUT OUTPUT INPUT OUTPUT

STREA STREAMS
MS

150
SN1 3 -10 0 10 107.5/HU 117.5
125 145
SN2 120 +12.5 10 -2.5 117.5 105
4 100

SN3 +105 -2.5 -107.5 105 0

70 90
SN4 40 60 -135 -107.5 27.5 0 135

SN5 25 1 2 +82.5 27.5 -55 135 52.5

SN6 20 +12.5 -55 -67.5 52.5 40/CU

9
 Table 1. Stream data for test case
STREAM NUMBER & HEAT CAPACITY FLOW RATE 𝑪𝒑 TS(℃) TT(℃)
TYPE kW/℃

(1) HOT 2 150 60

(2) HOT 8 90 60

(3) COLD 2.5 20 125

(4) COLD 3.0 25 100

𝜟𝑻𝒎𝒊𝒏 = 𝟐𝟎° 𝑪

12
 4
3

2
1

20 ℃ 25 ℃ 60 ℃ 90 ℃ 100 ℃ 125 ℃ 150 ℃

Temperature
Goals of HEN synthesis
1) Minimum utility.
2) Stream matching.
3) No. of heat exchangers needed.
4) End temp of the heat exchangers.

13
T

Cold Q
Hot
Utility Utility

14
 Table 2. The problem table for Test case
SUBNET STREAMS AND TEMPERATURE DEFICIT ACCUMULATED HEAT FLOWS
WORK

COLD T(℃) HOT INPUT OUTPUT INPUT OUTPUT

STREA STREAMS
MS

150
SN1 125 -10 0 10 107.5/HU 117.5
3 145
SN2 100 +12.5 10 -2.5 117.5 105
4 120
SN3 70 +105 -2.5 -107.5 105 0
90
SN4 40 -135 -107.5 27.5 0 135
60
1 2
SN5 25 +82.5 27.5 -55 135 52.5
SN6 20 +12.5 -55 -67.5 52.5 40/CU

15
 𝑄𝐻𝑀𝐼𝑁 =107.5 kW
𝑄𝐻𝑀𝐼𝑁 =107.5 kW
SN1
117.5 1
SN2 Hot end 3
105 problem 4
SN3

0
SN4
135 Cold end
SN5 problem 3 4
1 2
52.5
SN6
𝑄𝐶𝑀𝐼𝑁 =40 kW 𝑄𝐶𝑀𝐼𝑁 =40 kW
(a) (b)
Fig. 1. (a) Subnetwork heat flow diagram for TC3. (b)Subnetworks combined into hot and cold region
 Rules for PINCH ANALYSIS

 Pinch point divides the HEN into two independent problems to be solved
separately.

 No heat flow is allowed across pinch point.

 No cold utility to be used in the hot end.

 No hot utility to be used in the cold end.

 Violation of (2) – (4) gives double penalty

 Design of each end should start at the pinch point.

17
Thank You!!

26
Heat Exchangers: Fundamentals and Design Analysis
Heat Exchanger Network Analysis by Pinch Technique
Prof. P. K. Das.
Mechanical Engineering
IIT KHARAGPUR

Reference: The Pinch Design Method For Heat Exchanger Networks by B. Linnhoff and E. Hindmarsh
Chemical Engineering Science Vol.38, No.5, pp.745-763, 1983

1
Rules for Pinch End Matching
1.For hot end 𝑁𝐻 ≤ 𝑁𝐶 𝑁𝐻 - No of Hot stream

For cold end 𝑁𝐶 ≤ 𝑁𝐻 𝑁𝐶 - No. of cold stream

Note: In the hot end, there is some amount of hot utility & hot stream which can only
exchange heat with cold stream.

2. For individual match

Hot end, 𝐶𝐻 ≤ 𝐶𝑐

Cold end,𝐶𝑐 ≤ 𝐶𝐻

3.For hot end

𝑁𝑐 𝑁𝐻 𝑁𝑜.𝑜𝑓 𝑀𝑎𝑡𝑐ℎ𝑒𝑠
( 1 𝐶𝑐 - 1 𝐶𝐻 )≥ 1 (𝐶𝑐 − 𝐶𝐻 )

18
 Some Examples

C Difference in C Difference in C
C
Composite “C” Composite “C”
1 1 4 difference
4 difference
8-6=2 9-6=3
2 Summation of match Summation of match”
2
2 “C” 2 Diff=(5-4)+(3-2)=2
Diff=(5-4)+(3-2)=2 Solution is possible.
Solution is possible.

3 5 3 5

4 3 4 3

1
5

19
 Hot End Design

Stream Data at Pinch

No
𝑁𝐻 ≤ 𝑁𝐶 Split cold stream

Yes

No Stream Splitting
𝐶𝐻 ≤ 𝐶𝐶 for each match and
cumulative stream
Yes

Solutio
n

20
 Stream Matching for Hot End
150 ℃ 90 ℃
𝑁𝐻 ≤ 𝑁𝐶 1 2

𝐶𝐻 ≤ 𝐶𝐶 70 ℃
3 H 2.5
125 ℃ 118 ℃ 120
(𝐶𝐻 )1= 2 4 70 ℃
H 3
100 ℃
(𝐶𝐶 )3= 2.5

(𝐶𝐶 )4 = 3
150 ℃ 90 ℃
All above conditions are satisfied i.e. number of hot 1 2
streams ≤ number of cold streams 70 ℃
3 H 2.5
125 ℃ 82℃ 30
4 70 ℃
3
100 ℃ 90

21
 Stream Matching for Cold End

𝑵𝑪 ≤ 𝑵𝑯
Cumulative , 𝐶𝐶 ≤ 𝐶𝐻 8 3
8 3
2 2.5 2 2.5

8 3

2 2.5

So, we have to split hot stream

22
 Splitting of Hot Streams
7.5 3
7.5 3
8 8
0.5 0.5
0.5
2 2.5 2.5
2 2.0

3
8 3
5

2 2.5
90℃ 80℃
C 60℃ 2

90℃ 3.5 60℃

8

4.5

70℃ 20℃
3 2.5
105 20

70℃ 25℃
4 3

135

So, the restrictions i.e. 𝐶𝐻 ≥ 𝐶𝐶 just next to pinch point

24
 150℃ 60℃
1 2

90℃ 60℃
2 8

125℃ 20℃
3 2.5
120℃ 105 20

100℃ 25℃ 3
4

25
Thank You!!

26
Heat Exchangers: Fundamentals and Design Analysis
Heat Exchanger Testing

Indranil Ghosh
Cryogenic Engineering Centre
IIT Kharagpur

1
Purpose of Experiments
o Characterisation of Heat Transfer Surfaces
o Performance Evaluation of Exchangers / Regenerators

Indranil Ghosh
Cryogenic Engineering Centre 2
Surface Characterisation ( j & f factors )
( )
•
q = h A Tw − Tf h = Heat Transfer Coefficient

h
(Pr )3 =
2
j= Colburn j- Factor
GC p
4 f L G2
∆P = f = Friction Factor
2D h ρ
j, f = F (Re, Fluid Properties (µ, Cp, k ), Fin Geometry)

Indranil Ghosh
Cryogenic Engineering Centre 3
j and f data
 j and f are critical parameters for design and simulation
 j and f as functions of Re for each fin geometry
 In principle, prediction is possible by CFD analysis
 Experiment gives most authentic data
 Careful design of experiments

Indranil Ghosh
Cryogenic Engineering Centre 4
Experimental Techniques
 Transient Technique (Single Blow)
 Steady State Technique

Indranil Ghosh
Cryogenic Engineering Centre 5
Single Blow Experimental Technique: Theory
Hot Stream Cold Stream
For Solid:

x=0 x x+dx x=L

For Fluid:

Ackermann R.A. 1997 Cryogenic Regenerative Heat Exchangers Barron R.F. & Nellis G. F. 2015 Cryogenic Heat Transfer 2nd Ed.

Indranil Ghosh
Cryogenic Engineering Centre 6
Single Blow Experimental Technique

Flow
To Blower and
Flow meter
Tf,i τ = Tf,o τ =

Tf,i τ = 0 Tf,o τ = 0

Indranil Ghosh
Cryogenic Engineering Centre 7
Single Blow Experimental Technique

Flow
To Blower and
Flow meter
Tf,i τ = 0 Tf,o τ = 0

Tf,i τ = Tf,o τ

Indranil Ghosh
Cryogenic Engineering Centre 8
Steady State Technique
Saturated
Steam ∆T, ∆P

mair

Air Out Air In (Room

(Heated) Temperature)

Steam

mc Condensate

Indranil Ghosh
Cryogenic Engineering Centre 9
Steady State Technique
Assumptions:
o Steam Temperature is constant
o High Heat Transfer Coefficient on Condensing Steam Side

Overall Heat Transfer

1 1 1
= + + R wall
UA (η 0 hA) unknown (η 0 hA) known
tanh (mh f ) 2h
Small η0 = 1 −
Af
(1 − η )
f
ηf =
mh f
m=
kct f
A
Indranil Ghosh
Cryogenic Engineering Centre 10
Steady State Technique Ts

 1   Ts − Tinlet 

Temperature
Ntu = ln  ≈ ln   Texit
1− ε   Ts − Toutlet 
Tin

Distance along flow length of exchanger

Friction factor:
G 2  2 Lf  G2 G 2  2 4 f d Ld 
∆P = 

2 ρ  Dh
 + [ (
Kc − 1 + σ +
2 G2
)] [
Ke + 1 + σ +
2
σ
 ( )] 
 2 ρ1 2ρ2 2ρ2  Dd 
Core Loss Entry Loss Exit Loss Duct Loss

Indranil Ghosh
Cryogenic Engineering Centre 11
Steady State Test Set up
Pressure Reducing Pressure Reducing Fuel
Data Acquisition System Station 2 Station 1

Separator Mixer

Bolier

Water Separator
Outlet T
Water
Pitot Tube ∆P Inlet T Core ∆P Blower

Motor

Flow Straightners Heat Exchanger

Separator
Air Flow
Blow Steam
Control Valve
Condensate

Ghosh, I. (2004) Experimental and Computational Studies on Plate Fin Heat Exchangers, Ph. D. Thesis

Indranil Ghosh
Cryogenic Engineering Centre 12
Air Flow System Blower:
• Capacity: 9500 m3/hr at 1.06 meter WG
• Impeller: Radial, directly mounted on motor
• Motor: 2900 rpm, 75 HP
7.35 m

Air Duct:
• Cross Section: 220 mm x 200 mm
• Total Length: ~ 6.1 m
Ghosh, I. (2004) Experimental and Computational Studies on Plate Fin Heat Exchangers, Ph. D. Thesis

Indranil Ghosh
Cryogenic Engineering Centre 13
Steam System Pressure Reducing Stations:
• Station 1: Inlet Pr. : 10 bar, Outlet Pr.: 3.5 bar
• Station 2: Inlet Pr. : 3.5 bar, Outlet Pr.: 1.5 bar
Fuel
Pressure Reducing Pressure Reducing
Station 1 Station 2
Separator Mixer Separator
Non IBR Heat
Bolier Exchanger
10 bar 3.5 bar 3.5 bar 1.5 bar
Water

Water Air
Boiler:
• Type: Non IBR, Diesel Fired Separator
• Dry Steam Output: 480 kg/hr Blow Steam

• Pressure: 15 kg/cm2 (max) Condensate

Cooling Subcooler
Water
Ghosh, I. (2004) Experimental and Computational Studies on Plate Fin Heat Exchangers, Ph. D. Thesis

Indranil Ghosh
Cryogenic Engineering Centre 14
Heat Exchanger Design

Steam In
Ntu: 1 and 3
Air Out "Blow steam" to "condensate" ratio: 3 and 6
Blower capacity is 5000 m3/hr
Pressure head: 1 m of water column
Air In
0.7 m (∆Pa) available to overcome core
La
pressure loss
Steam capacity: 480 kg/hr (dry steam)
Steam Out

Ghosh, I. (2004) Experimental and Computational Studies on Plate Fin Heat Exchangers, Ph. D. Thesis

Indranil Ghosh
Cryogenic Engineering Centre 15
Heat Exchanger Design
 T −T  Calculate Tex from (3.8)
e Ntu =  s inlet  Ntu ? Calculate Mean Temperature
Airside fin configuration : Fin

 Ts − Toutlet
Height, Thichness, Frequency, etc.
 Calculate µ,ρ,Cp,k at Mean Temperature

UA  A  j  4 La  Calculate no. of layers of layers of air fin

Ntu = = St  =   Blower Pr.Head
A  (Pr )2 / 3  D Calculate Dh
C min  ff   h  P?
Calculate free flow area, Aff
Calculate G, L using j & f correlation
h fg mc = ma C p (Toutlet − Tinlet ) Calculate Re, ma, mc, ms/mc

Check Check
2 Air flow rate < 5000 3 < (ms/mc) < 6 ? Print L, Re, G, (ms/mc)
4 fLa G
∆P = ?
2 ρ Dh

Ghosh, I. (2004) Experimental and Computational Studies on Plate Fin Heat Exchangers, Ph. D. Thesis

Indranil Ghosh
Cryogenic Engineering Centre 16
Steady State Test Set up

1 2 3 4
Temperature Nodal Point

8 7 6 5

End Point Connector

9 10 11 12

16 15 14 13

Section of Duct wiht Flange

Ghosh, I. (2004) Experimental and Computational Studies on Plate Fin Heat Exchangers, Ph. D. Thesis

Indranil Ghosh
Cryogenic Engineering Centre 17
Calibration of Test Set up
0.08
10.2 W 18 .152 (Al)
0.07

0.06
f (Kays & London)
0.05
f - factor

0.04

0.03

0.02
0.5 0.6 0.7 0.80.9 1 2 3 4 5 6 7 8
Re x 10-3

Ghosh, I. (2004) Experimental and Computational Studies on Plate Fin Heat Exchangers, Ph. D. Thesis

Indranil Ghosh
Cryogenic Engineering Centre 18
Calibration of Test Set up
0.1
10.2 W 18 0.152
f - factor

j - factor (Hot Test)

f - factor (Hot Test)
j - factor (Kays & London)
f - factor (Kays & London)
j - factor

f - factor (Cold Test)

0.01

0.5 0.6 0.7 0.80.9 1 2 3 4 5 6 7 8 9

-3
Re x 10

Ghosh, I. (2004) Experimental and Computational Studies on Plate Fin Heat Exchangers, Ph. D. Thesis

Indranil Ghosh
Cryogenic Engineering Centre 19
Error Estimation
R=R(x1, x2 x3 …xn)

∂R ∂R ∂R
δR = δx1 + δx2 + ..... + δxn
∂x1 ∂x2 ∂xn
0.5
 ∂R 
2
 ∂R 
2
 ∂R 
2

δR =  δx1  +  δx2  + ..... +  δxn  
∂
 1x  ∂
 2x   ∂xn  
0.5
 n  ∂R  
2

= ∑  δxi  
 i =1  ∂xi  

Ghosh, I. (2004) Experimental and Computational Studies on Plate Fin Heat Exchangers, Ph. D. Thesis

Indranil Ghosh
Cryogenic Engineering Centre 20
Mini-channel Heat Transfer

Dixit, T. and Ghosh, I. (2013) Experimental Thermal and Fluid Science 51 pp. 227–238

Indranil Ghosh
Cryogenic Engineering Centre 21
Foam Heat Transfer

Dixit, T. and Ghosh, I. (2016) Experimental Thermal and Fluid Science 77 pp.28–37

Indranil Ghosh
Cryogenic Engineering Centre 22
Foam Heat Transfer

Indranil Ghosh
Cryogenic Engineering Centre 23
Heat Exchanger Testing

Indranil Ghosh
Cryogenic Engineering Centre 24
Test Set up

Indranil Ghosh
Cryogenic Engineering Centre 25
 Faculty Name
Department Name 26