CHE 433: Transport Phenomena II

Heat Exchangers

DR. (MRS) T.E OLADIMEJI

 Heat Exchangers

• They are designed to transfer heat between two or more

fluids- liquids, vapors, or gases—of different
temperatures.
• Depending on the type of heat exchanger employed, the
heat transferring process can be gas-to-gas, liquid-to-gas,
or liquid-to-liquid and occur through a solid separator,
which prevents mixing of the fluids, or direct fluid
contact.
 Principles of Heat Exchangers
• Heat exchangers operate under the same fundamental
principles—namely the Zeroth, First, and Second Laws of
Thermodynamics
• The Zeroth Law of Thermodynamics states that
thermodynamic systems that are in thermal equilibrium
have the same temperature.
• The First Law of Thermodynamics (Law of
Conversation of Energy): builds upon the Zeroth Law &
est. the internal energy. It states that energy cannot be
created or destroyed, only transferred to another
thermodynamic system or converted to another form
(e.g., heat or work).
 Principles of Heat Exchangers
• The Second Law of Thermodynamics establishes entropy (S):
describes the natural and invariable tendency of the universe, and
any other closed thermodynamic system, to increase in entropy
over time.

• where ΔS represents the change in entropy, ΔQ represents the

change in the heat added to the system, and T represents the
absolute temperature:
 Heat Exchanger Design Characteristics

• H.E can be classified based on their design characteristics as;

-  Flow configuration
- Construction method
- Heat transfer mechanism
 Flow configuration: refers to the direction of movement of
the fluids within the heat exchanger in relation to each
other. Types of flow configurations include; Cocurrent flow,
Countercurrent flow, Crossflow, Hybrid flow
• Cocurrent flow H.E (parallel flow H.E): fluids move parallel
to and in the same direction to each other. t also allows for the
greatest thermal uniformity across the walls of the heat
exchanger. But lower efficiencies compared to counter flow.
 Heat Exchanger Design Characteristics
• Countercurrent flow /counter flow H.E: fluids moves
parallel but in opposite directions to each other within
the heat exchanger. highest efficiencies due to high
rate of heat transference between fluids
• Crossflow H.E: fluids flow perpendicularly to one
another.
• Hybrid flow  H.E: It employs both counter flow and
crossflow arrangements within a single heat
exchanger
 Heat Exchanger Design Characteristics
 Construction Method: The construction
characteristics include; Recuperative vs. regenerative,
Direct vs. indirect, Static vs. dynamic, Types of
components and materials employed.
• Recuperative vs. regenerative:
- Recuperative H.E: each fluid simultaneously flows
through its own channel within the heat exchanger.
Commonly used.
- Regenerative H.E: warm and cool fluids flow through
the same channel.
 Heat Exchanger Design Characteristics
• Direct contact or indirect contact transfer processes
- Direct: fluids are not separated within the device e.g
 cooling towers and steam injectors
- Indirect: in separated from one another by thermally
conductive components, e.g tubular or plate heat
exchangers.
• Static vs. Dynamic
- Static H.E: heat exchanger material and components
remains stationary as fluids flow through the device
- Dynamic H.E: the material and components move
throughout the heat transfer process. 
Heat Exchanger Classification by Construction
 Heat Exchanger Design Characteristics
 Heat transfer mechanism: there 2 types; Single-
phase or two-phase heat transfer.
- Single-phase H.E: the fluids do not undergo any
phase change throughout the heat transfer process, i.e
fluids remain in the same state of matter
- Two-phase H.E: fluids experience a phase change
during the heat transfer process. i.e from liquid to gas
or vice-versa
 Types of heat exchangers

• Types of heat exchangers include

- Double- Pipe heat exchanger

- Shell and tube heat exchanger
- Cross- flow heat exchanger
 Double- Pipe heat exchanger
• It employs the simplest heat exchanger design and configuration
which consists of two or more concentric, cylindrical pipes or
tubes (one larger tube and one or more smaller tubes
• The fluids is mostly countercurrent flow moving in opp.
Direction
• They can also be used in parallel flow where both fluids move
in the same direction
• It is mainly for small flow rates
• It can handle high pressures and high temperatures because they
are able to freely expand
• They can be paired in series or in parallel to increase the heat
transfer rate through a system without complication.
• In selection of suitable DPHE, consider some factors including;
working fluids, heat transfer , outlet temperatures
 Double- Pipe heat exchanger
How do double pipe heat exchangers work?

Flow in double-pipe H.E

• The hot fluid pass thru d inner tube while the outer shell contains the cold
flow
• The inner pipe acts as the conductive barrier, where one fluid flows through
this inner pipe and another flows around it through the outer pipe, 
• The outside or “shellside” flow passes over the inside, or “tubeside” flow,
which will cause heat exchange through the inner wall of the tube.
 Double- Pipe heat exchanger
Advantages of double-pipe heat exchangers
• It has a simple design hence one of the easiest designs to
fabricate
• They can handle both high pressures and high temperatures
well
• Their parts have been standardized due to their popularity,
allowing for easy part sourcing and repair
• They are one of the most flexible designs, allowing for easy
addition/removal of parts
• They have a small footprint that requires little to no
maintenance space while still having good heat transfer
 Double- Pipe heat exchanger
Disadvantages of double-pipe heat exchangers
• They are limited to lower heat duties than other, larger
designs
• Even though they are able to be used in parallel flow, they
are more often only used in counterflow regimes, which
restricts some applications
• Leaking can occur, especially when paired with more
units
• The tubes are easily fouled and difficult to clean without
disassembling the whole heat exchanger
 Shell and tube heat exchanger
• The most common type of heat exchangers in process
industries
• It involves large flows.
• consists of a shell (a large vessel) with a bundle of tubes inside
• It provide typically the surface area density ranging from 50 to
500 m2 /m3 and are easily cleaned.
• The tubes, arranged in a bundle are enclosed in a single shell
and the other fluid flows outside the tubes in the shell sides
• It can have multiple passes, such as 1-1, 1-2, 1-4, 1-6, and 1-8
exchangers but the most common ones are 1-1, 1-2
• -1-1 counterflow exchanger: it is the simplest where the cold
fluid enters thru the tubes in parallel in 1 pass while d hot fluid
enters d other end flowing counter- flow across the outside of
the tubes.
 Shell and tube heat exchanger
-1-2 counterflow exchanger: the fluid in the tube flows
in 2 passes while the shell-side liquid flows in 1 pass.
- 1st pass: cold fluid flows in the tube flows
countercurrent to the hot shell-side fluid
- 2nd pass: the cold fluid flows thru the tube in parallel
(co-current) with the hot fluid
some of the applications include preheating, oil cooling,
and steam generation.
(a) 1 shell and 1 tube S&T H.E
(a) 1 shell and 2 tubes S&T H.E
 Shell and tube heat exchanger
Theory and application
• Assume 2 fluids of different temp. one flows thru d tubes and
d other flows outside d tubes but inside d shell and heat
transfer occur
• In order to transfer heat efficiently, a large heat transfer area
should be used, hence more tubes are required to avoid heat
loss and conserve energy
• It is used for cooling of hydraulic fluid and oil in engines,
transmissions and hydraulic power packs. 
• It is easy to service and maintain
• used to cool or heat other mediums, such as swimming pool
water or charge air.
 Shell and tube heat exchanger
Selection Criteria
For efficient use of this exchanger certain factors can be
considered
 Selection of tube material :
• To be able to transfer heat well, the tube material should have
good thermal conductivity. Because heat is transferred from a
hot to a cold side through the tubes and also tube material
can expand leading to thermal stresses
• The tube material also should be compatible with both the
shell and tube side fluids for long periods under the operating
conditions to minimize deterioration such as corrosion
• Poor choice of tube material could result in a leak through a
tube causing fluid cross-contamination and possibly loss of
pressure.
 Shell and tube heat exchanger
Selection Criteria
 Fluid allocation: When deciding which side to allocate the hot
and cold fluids should be considered
1. Consider any and every safety and reliability aspect and
allocate fluids accordingly..
2. Ensure that the allocation of fluids complies with established
engineering practices.
3. Allocate the fluid likely to cause the most severe mechanical
cleaning problems (if any) to the tubeside.
4. If neither of the above are applicable, the allocation of the
fluids should be decided only after running two alternative
designs and selecting the
 Shell and tube heat exchanger
Selection Criteria
 Selection of Exchanger Geometry:
• Tube outside diameter,
• Tube wall thickness (recognized pressure vessel code)
• Tube length: the longer the tube length the cheaper the
exchanger
• Tube pitch: The smallest allowable pitch of 1.25 times the
tube outside diameter is normally used
• Number of tube passes: This is usually one or an even
number (not normally greater than 16). Increasing the number
of passes increases the heat transfer coefficient
• Shell diameter: Standard pipe is normally used for shell
diameters up to 610 mm (24"). Above this the shell is made
from rolled plate. Typically shell diameters range from 152
mm to 3000 mm (6" to 120").
 Shell and tube heat exchanger
Selection Criteria
 Selection of Exchanger Geometry:
• Materials of Construction: shell and tube exchangers are
made of metal, but for specialist applications (e.g., involving
strong acids or pharmaceuticals), other materials such as
graphite, plastic and glass may be used.
• Thermal Design: The thermal design of a shell and tube
exchanger is an iterative process which is normally carried out
using computer programs from organizations such as the Heat
transfer and Fluid Flow Service (HTFS) or Heat Transfer
Research Incorporated (HTRI).
 Shell and tube heat exchanger design procedure
• Define process requirements for the new exchanger
• Select a suitable type of shell and tube exchanger 
• Define design parameters such as - number of tube passes, tube size,
shell ID etc.
• Perform H.E cal. and modeling to get the output - outlet hot/cold fluid
temperature, heat transfer rate, pressure drop on shell/tube sides etc.
• Check of the output is in accordance with the process requirements
– If the output is as per process requirements and cost is within
budget then finalize the process design and prepare a heat
exchanger specification sheet
– If the design does not match with either the process requirement or
if it is over budget then go back to step 3, change the design
parameters and repeat this process again.
 Cross- flow heat exchanger
• When a gas is heated or cooled, a common device
used is the cross-flow H.E
• When the fluid (liquid) flows thru the tubes, the
exterior gas flows across the tube bundle by forced
or natural convection.
• The fluid in the tubes is unmixed while the gas
outside the tube is mixed since it can move freely
btw d tubes
• For unmixed fluid there will be a temp. gradient both
parallel and normal to the direction of flow
 Cross- flow heat exchanger
• It  exists when one fluid flows perpendicular to the
second fluid
• usually found in applications where one of the fluids
changes state (2-phase flow)
• An example is a steam system's condenser, in which
the steam exiting the turbine enters the condenser shell
side, and the cool water flowing in the tubes absorbs
the heat from the steam, condensing it into water. 
• Large volumes of vapor may be condensed using this
type of heat exchanger flow.
 Cross- flow heat exchanger
• A car radiator and an air conditioner evaporator coil
are examples of crossflow heat exchangers.
• In both cases heat transfer is taking place between a
liquid flowing inside a tube or tubes and air flowing
past the tubes.
• With a car radiator, the hot water in the tubes is being
cooled by air flowing through the radiator between
the tubes. 
• With an air conditioner evaporator coil, air flowing
past the evaporator coils is cooled by the cold
refrigerant flowing inside the tube(s) of the coil.
Log Mean Temperature difference correction Factor
• Log
  mean temperature difference is used
when hot and cold fluid in a heat exchanger
are in either countercurrent or cocurrent flow
but not combined
= (1)
Where is the temperature difference at one end of d
exchanger
• is the temperature difference at other end
• hold for double pipe H.E and 1-1 S&T H.E
• The
  eqn. is not applicable For multiple pass heat
exchanger but a different expression is obtained
depending on the arrangement of the shell and tube
passes
• Mathematical expression for multiple pass require a
correction factor (FT )
• FT X = (2)
• FT has been calculated for multiple passes using
graphs.
FT to correlation factor for 1-2 exchangers
 
 F to correlation factor for 2-4 exchangers
T
• From the gaphs 2 dimensionless ratio was obtained-

(3)

(4)

Where
Thi = inlet temp of hot fluid Tho =outlet temp of hot fluid
Tci = inlet temp of cold fluid Tco = outlet temp of cold
fluid
• Therefore,
  from eqn 3 &4 the for multiple pas
can be written as-

(5)

• Equation for heat exchanger can be written as;

(6)
Where (7)
Example
 Heat Exchanger Effectiveness
• The
  log mean T.D. is easy to calculate when inlet and
outlet temperatures of the fluids are known or can be
det. thru. Heat balance
• However, if the inlet or outlet temp. are unknown a
trial & error method will be used, and this method is
known has heat exchanger effectiveness ()
• H-EE is defined as the ratio of the actual rate of heat
transfer in a given exchanger to the max. possible
amt. of heat transfer if an infinite heat transfer area
were available
Temperature profile for countercurrent H.E
•• The
  heat balance for the cold (c) and the hot (H) fluids is
given in eqn (1) below;

Therefore, ( (2)
and the cold fluid undergoes a greater temperature change
than the hot fluid. Hence, we designate CC as Cmin or
minimum heat capacity.
• Then, if there is an infinite area available for heat
transfer ,
•Hence,
  Effectiveness, is

(2)

(3)
• In both eqn. the denominators are the same
and the numerator gives the actual heat
transfer
(4)
• Note eqn. 3 &4 req. only inlet temp. which is
an adv. If inlet temps. are known and outlet
temp can then be predicted
• For a single pass, counterflow exchanger,
combine eqn. 2 & 3
(5)

(6)
• combining eqn (1) & LHS eqn.(5), we have;

(7)

------------ (8)
Substitute CC = Cmin and CH = Cmax
 (9)

• Rearranging, we have;
(10)

Substituting eqn. (7) into eqn. (10)

(11)
• Substitute
  eqn 8 & 11 into eqn 6, rearrange,
take the antilog of both side and solve for