CH-312

Heat Transfer Equipment Design

 CH-312 : Heat Transfer Equipment Design
 Course Instructor: Prof. Dr. Javaid Rabbani Khan
Office: G-01
email: drjrabbani@giki.edu.pk
Office Hours: 8:00 am to 5: 00 pm
Course Crdt.hr: 2

 Office # G-38 FMCE, GIK Institute, Ext: 2661

 Email: arooj@giki.edu.pk
 Office Hours: 8am~5pm
Sr. No Course Learning Outcomes

classify, design and operate heat transfer equipment as a process engineer to fulfill the
CLO_1
needs of industry in accordance with the national and international standards;

enhance efficiency and optimize the thermal performance as a professional engineer to

CLO_2
economize the production cost of the manufactured products.

practice and implement ethics and social responsibility to the community in terms of
CLO_3 quality, environmental aspects and diagnose / resolve industrial bottlenecks in the field of
heat transfer.
Assessment Tools

Announced & unannounced Quizzes 15%

Assignments & assignment sessions 5%
*PBL- Task 10%
Midterm Exam 30%
Final Exam 40%

(*problem based learning - task)

General Instructions

Physical and ATTENTATIVE Presences without any ill

will .
The fallowing you must have during lectures:

 Note Book
 Scientific Calculator
 Course Text Book
What is a Process Design????
Chemical engineer should be capable to select, design and operate a plant for economical and quality
manufacturing of desirable products by physical or chemical transformation of materials, along with the
technical skills to minimize environmental disturbance,
The activities include :
 Standardization of Specifications of the material to be transformed,
 Selection of necessities of a manufacturing process i.e. TECHNOLGY .
 Management and transfer of technology/ies involved,
 Equipment categorization and PFDs
 Abreast with the design and operational tools i.e. flow-sheeting, process control, simulation software
and scale models.
 Process simulation is a model-based representation of chemical, physical, biological, and
other technical processes and unit operations in a software to optimize the process problem
which has to be solved in an iterative process.
How Important is the H.T. Equipment Design
for Production?? Any Idea..!!
 Heat Transfer Equipments and Their function
A device whose primary purpose is the transfer of energy between two or more fluids.
 Heaters: are used primarily to heat process streams directly or indirectly,
Coolers : are employed to cool down streams, Water is a common cooling medium.
Equipment Function

Chiller Cools a fluid to a temperature below that obtainable if

water only were used as a coolant. It uses a refrigerant such as
ammonia or Freon.

Condenser Condenses a vapour or mixture of vapours, either

alone or in the presence of a non condensable gas.
Partial condenser
•Condenses vapours partially
•This saves heat and eliminates the need for providing a
separate preheater (using flame or steam).

Final condenser
• Condenses entire vapours to a final storage temperature
• It uses water cooling, which means that the transferred heat
is lost to the process.
Exchanger Performs a double function:

(1) Heats up a cold fluid by

(2) Cools down a hot fluid. None of the transferred heat is lost.
Heater Imparts sensible heat to a liquid or a gas by means of condensing
steam.

Reboiler
• Connected to the bottom of a distillation tower, to re-boil heat necessary
for distillation.
• The heating medium may be either steam or a hot-process fluid.

•Thermo-siphon reboiler Natural circulation of the boiling medium is obtained by

maintaining sufficient liquid head to provide for circulation.
•Forced-circulation reboiler A pump is used to force liquid through the re-boiler.
 The main types of heat exchangers used in chemical
process & allied industries,
1. Double-pipe exchanger: the simplest in configuration and
commonly used for low to medium cooling and heating.
2. Shell and tube exchangers: used for heavy heat duties.
3. Plate and frame exchangers (plate heat exchangers):
4. Plate-fin exchangers.
5. Spiral heat exchangers.
6. Air cooled: coolers and condensers.
7. Direct contact: cooling and quenching.
8. Agitated vessels.
9. Fired heaters.
SHELL AND TUBE EXCHANGERS: CONSTRUCTION DETAILS

The shell & tube exchanger is one the most commonly used type of heat-
transfer equipment used in the chemical and allied industries.

The advantages of this type are:

1. The configuration provides- a large surface area in a small volume.

2. Good mechanical layout - a good shape for pressure operation.
3. Well-established fabrication techniques are available.
4. Can be constructed from a wide range of materials.
5. Easily cleaned.
6. Well-established design procedures
Heat Exchanger Temperature Profiles

Axial temperature profiles for a single pass heat exchanger

Axial temperature profiles for a

double pass heat exchanger
 Heat Transfer Equipment's: ” Used to fulfill a specific function of a process”
1) H.T. is an essential process in all chemical process industries (CPI)
2) A varieties of H. Exs. are designed and operated, however double pipe, shell & tube are the most
traditional and common.
Wide uses of H.T. Equipment
Classified Types of H.T. Equipment For space heating, refrigeration, air-
conditioning, power-generation, 
 Plate exchangers/Gasketed PHEs/ Spiral Plate are compact, chemical plants, petrochemical
economical alternative to shell & tube designs, Utilities and plants, petroleum refineries, natural-
thermal fluids gas processing & sewage treatment
etc
 Other heat transfer systems use natural gas, electricity or
direct steam injection for heating purposes
 Finned-tube exchangers and scraped-surface
crystallizers are used for clean operation and quick
response,
 Agitated and rotating surface exchangers are innovative
and effective H.T. equipment.
   space heating, refrigeration, air-conditioning, power
generation, chemical plants, petrochemical
plants, petroleum refineries, natural-gas processing
& sewage treatment

Basic concept of HT
Steam generator Generates steam for use elsewhere in the plant by
using the available high heat elsewhere in the plant

Super heater Heats a vapour above the saturation temperature.

Vaporizer A heater which vaporizes part of the liquid beside water.

Waste-heat boiler
• Produces steam; similar to steam generator using heat wasted at any
location of the plant , e.g. hot gas or liquid produced in an exothermic
chemical reaction.
Heat Exchangers
 Heaters (sensible heat changes)
 Coolers (sensible heat changes)

 Condensers (also change of state, V to L)

 Evaporators (also change of state, L to V)

Paul Ashall, 2008

Uses in chemical processes
 Chemical reactors (jackets, internal heat exchangers/calandria )
 Preheating feeds
 Distillation column re-boilers
 Distillation column condensers
 Air heaters for driers
 Double cone driers
 Evaporators
 Crystallisers
 Dissolving solids/solution
 Production support services – HVAC, etc.
 Heat transfer fluids
 Driers, crystallizers etc.

Paul Ashall, 2008

Classification of Heat Exchangers:
Heat exchangers are classified and developed to
meet the wide applications of industries,
 Operating principle ( nature of heat exchanger process),
 Process and Mechanical design and

constructional features,
 Relative direction of fluid flow and Physical state

of fluid etc.
 A) According to heat transfer process:

According to heat exchange process

Non Direct contact type Direct contact type of heat

of heat exchanger exchanger

Recuperator Regeneration Examples:

Examples: examples: 1.cooling tower
1.Radiator 1.Open hearth furnace 2.condensor etc.
2.Oil heaters etc. 2.Glass melting furnace etc.
 Direct contact type heat exchanger:
 In direct contact H. Exs heat transfer
occurs between hot & cold fluids by
direct contact,
 Simultaneous transfer of heat & mass
 The rate of heat transfer is maximum
 However, in direct contact heat exchanger the
both fluids are immiscible or if a single fluid
that undergoes through a phase change.
 Direct contact heat exchangers have limited
applications (where either mixing of both fluids is
desirable or harmless)
Non – contact or Indirect type of heat exchangers:
• No direct contact between two fluids e.g. heat exchanger, regenerators &
recuperates.
• Indirect type H . Exs. But H.T. occurs directly from hot stream to cold stream.
• Storage type or fluidized bed heat exchangers;
 B)According to the direction of flow

Parallel flow or
unidirectional flow Cross flow
or concurrent flow Counter flow or Examples:
Examples: counter current flow 1.Cooling units of
1.Oil coolers Examples: refrigeration system
2. Oil heaters 1. Used almost in all 2.Automobile radiator
engineering application
3.Water heaters
B1)Parallel flow/unidirectional flow:
 In case of parallel floe heat exchanger,
both the fluids are flowing in the same
directions.
 Fig.4 represented the variations in
temperature along the length of heat
exchanger.
 Since this type of heat exchanger needs a
large area of heat transfer, therefore , it is
rarely used in practice.
 As the two fluids are separated by a wall,
this type of heat exchanger may be called
parallel flow recuperator.
B2) Counter flow/ Counter current heat exchanger:
 In case of counter flow heat
exchanger , both the fluids are
flowing in the opposite
directions.
 The arrangement and
temperatures variations along
the length of heat exchange for
such heat exchangers are shown
in fig.
B3)Cross flow heat exchanger:
 Fig. shows schematic diagrams
of common arrangements of
cross flow heat exchangers,
both fluids are directed at right
angles to each others.
 Fig.(a) represents the case in
which there is no
mixing of fluids streams
which is flowing over the
tube(i.e. example: automobile
 Double pipe heat exchangers
• Simple & cheep in design & fabrication.
• Excellent capacity for thermal expansion;
• Easy to install, operate and maintain ,
• A good choice for small industries but suitable
• for low heat duties having limited efficiency,
• Modular design makes it easy to enhance
H.T. area by adding new assemblies;
• Occupies high space for large scale duties,
• Not cost effective and needs special gaskets

Hairpin: D/P exchangers are especially

suitable for extreme temperature
crossing, high pressure, high temp. &
low to moderate HT area requirements.
(d) NRe in the tube and annulus section
 Heat Transfer Equipment's (cont.…)
Maximum rate of HT, with minimum investment and operational cost.
 1) Concentric tube type heat exchangers:

 Fig. represents concentric tube type of heat

exchanger.

These are also called tubular heat exchangers or

tube in tube type of heat exchangers or double

pipe heat exchanger.

DESIGN STEPS OF A DOUBLE PIPE HEAT EXCHANGER
 DESIGN STEPS OF A DOUBLE PIPE HEAT EXCHANGER

PROCESS CONDITIONS REQUIRED

Hot fluid: T1, T2, W, c, s, or ρ, µ, k, ∆P, Rdi, Rdo

Cold fluid: t1, t2, w, c, s, or ρ, µ, k, ∆P, Rdi, Rdo

Heat Balance
 Cold Balance q  mc C p ,c ΔTc

 Hot Balance q  mH C p , H ΔTH

 In case of steam q= ms ʎ
s
Heat Balance
 Overall Heat Transfer
 Q = UA (LMTD)

ΔT2  ΔT1
q  UA
ΔT2
ln
ΔT1

q  UAΔTlm
Experimental Plan
 Hot water in center, opposite of lecture schematic
 Cold water in annular region
 Set hot water for parallel or countercurrent flow
◦ Read temperatures and flow rates
◦ Three readings per rate
◦ Five flows for each configuration
Data Analysis
 Calculate qc and qh. Compare.
 Calculate U.
 Calculate Error in U.
 Plot U vs. Re
Questions to Address:
 Which configuration was more efficient?
 How do these results compare with literature?
 Compare thermometer readings to thermocouple readings,

and their effect on the error in U.

C2) Shell and tube type heat exchangers:

These are also called surface condensor.

In shell and tube type heat exchangers, one fluid with flow through shell and other
will flow through tube.
There is no direct contact between two fluids and the heat will transfer.
A typical exchanger is shown in fig.

 Multiple shell and tube passes are used for enhancing the overall heat

transfer area.

Multiple type pass heat exchangers are those which re route the fluid

through tubes in opposite direction.

Examples are surface condensor in thermal power plants

C3) Compact heat exchangers
 These are special type of heat exchangers in which heat transfer surface area

per unit volume is very large.

 They are generally employed when convective heat transfer associated with

one of the fluids is much smaller than that of associated with the other fluids.

 These are usually cross floe heat exchangers.

.
C4) FINNED TUBE TYPE HEAT EXCHANGERS:

When very high rate of heat transfer is required, fins are placed on the

one side of heat exchanger which is called finned tube type of heat

exchangers.

The use of fins enhance heat transfer area and thereby heat exchanges.

These heat exchangers are in IC engine cylinder, Gas turbines,

refrigerators, electronics equipments, air conditioning systems etc.,

radiator of an automobiles is a example of said heat exchanger.

 D) Physical state of fluids

: Condensors Evaporators
D1) Condensors:
In condensors, the temperature of hot fluid
remains same for the entire length of the heat
exchanger but the temperature of cold fluid
increases gradually along the length of heat
exchanger.
Refer fig.
The hot fluid reject latent heat which is
absorbed by the cold fluid.
In case of condensor of thermal power plant,
the hot fluid is steam and the cold fluid is
cooling water which is gaining the heat and Fig. Temperature distribution for condensor
rejecting the heat in cooling towers.
D2)Evaporators:
In evaporators, the temperature of cold

fluid remains same and the hot fluid

temperature drops.

The cold fluids receives latent heat from

the hot fluid.

In case of thermal power plants, the flue

gases(hot fluids) reject the heat and the Fig. Temperature distribution for evaporator

heat and the same is gain by the cold fluid

 A N K
T H YOU