WEEK 5 – HEAT EXCHANGERS

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Textbook of the course: Geankoplis Christie, J. "Transport Processes and Unit Operations." (1993).
 Course Outline
Week Subjects Related Preparation
1 Introduction of process technology
Fundamental Laws: Conservation of Mass and energy, Ideal gas equation etc. and
2 Review the notes
Tables
3 Transfer of momentum and applications Review the notes
4 Heat transfer and applications Review the notes
5 Heat exchangers Review the notes
6 Evaporation Review the notes
7 Mass transfer and applications Review the notes
8 Midterm 1
9 Gas-vapor mixtures, conditioning, humidifying, de-humidifying and water cooling
10 Drying Review the notes
11 Distillation Review the notes
12 Extraction, adsorption, crystallization Review the notes

13 Thermal-Chemical Processes: Example Applications Review the notes

14 Thermal-Chemical Processes: Example Applications Review the notes

15 Final

10/5/2020 MKT3871 - Fall 2020-2021 2

 Quiz 3 - Homework 4 - Information
• We have small pop quiz at the end of the lesson.

• Quiz duration is 10 minutes.

• After this lesson, Homework will be available on UZEM

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 Outline

• Heat Exchanger Types

• Log Mean Temperature Correction Factor, FT

• Heat exchanger effectiveness – NTU Method

• Fouling

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 Types of Heat Exchangers
• In process indusries heat
transfer between two fluids is
usually done in heat
exchangers
• Transfer of heat accomplished
– from hot fluid to the wall (or
tube surface) by convection
– through the wall by conduction
– from the wall surface to cold
fluid by convection
• Three types considered are:
– Double pipe heat exchanger
– Shell-and-tube heat exchanger
– Cross-flow heat exchanger
– …
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 Double pipe heat exchanger (Concentric heat exchanger)

• Simplest type of heat

exchanger
• Consist of two
concentric pipes of
different diameters
• Two types of flow
arrangement are
possible
– Countercurrent flow
– Cocurrent (Parallel) flow
• Useful for small flow
rates
• Maybe arranged in
series, if necessary

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 Industrial examples for double-pipe heat exchanger

https://www.wksgroup.de/en/2016/05/25/dop
pelrohr-waermetauscher/

https://www.pipingengineer.org/double-pipe-heat-
exchangers-equipment-and-piping-layout/

https://www.researchgate.net/figure/4-Double-pipe-hair-
11/2/2021 pin-heat-exchanger_fig1_282654284 7
 Shell-and-tube heat exchanger
• Useful for large flow rate chemical processes
• Most important type in chemical industry
• Many tubes/pipes are arranged to build tube bundle
• Tube bundle is eclosed in a single shell
• One process fluid flows through the tubes and the other
flows through the shell
• There are many arrangements
– 1 shell pass, 1 tube pass (1-1 exchanger)
– 1 shell pass, 2 tube pass (1-2 exchanger)
– 2 shell pass, 4 tube pass (2-4 heat exchanger)
– etc.
• Cross baffles are used in the shell side so that the shell
side fluid forced to flow perpendicular across the tube
bundle.
• Baffles increases the shell side film heat transfer
coefficient
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https://www.sacome.com/en/tema-type-heat-exchangers/

The Tubular Exchanger Manufacturers

Association (TEMA) is an association of
manufacturers of shell and tube heat
exchangers.

TEMA has established a set of construction

standards for Shell and Tube Heat
Exchangers.

Most shell and tube exchangers ordered by

the process industries and for other high-
severity applications throughout the world
are built to TEMA standards.
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https://www.researchgate.net/figure/4-Fluid-flow-simulation-for-a-shell-and-tube-exchanger_fig3_319528508
 Cross-flow heat exchanger

• If air is heated or cooled this type is preferred

• Heating or cooling fluid in pipes
• Outside the pipes air is in forced state or in natural convection
• Fluid in pipes is in unmixed configuration
• Air may be in unmixed or mixed configuration
• Unmixed type usually used in air-conditioning or space heating
applications

11/2/2021 https://www.pwslaundry.com/i-7553214-ipso-
11
70231301p-dryer-coil-steam-4-row-pkg.html
 Log mean temperature difference correction factors

 Double pipe heat exchanger

valid for
 1-1 exchanger (shell-and-tube)

What if we have 1-2 or 2-4 exchanger ? We need to correct with a

correction factor as

 Mathematical derivation of is
quite complex
 Hence graphical correlation
method is available
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 Steps for calculating heat
transfer rate for given overall
heat transfer coefficient
1. For a given inlet and outlet
temperatures calculate
dimensionless numbers Y
and Z
2. Find graphically the
correction factor for given
exchanger type
3. Evaluate log mean
temperature difference

4. Calculate heat transfer using

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 Heat exchanger effectiveness-NTU method
• Log mean temperature method (LMTD) can be used
when all inlet outlet temperatures are known or can
be evaluated from heat balance
• When exit temperatures are not known, but mass
flow rates and inlet temperatures are known we have
two option
– Trial and error procedure
– Heat exchanger effectiveness method (effectiveness-NTU
method)
• Dimensionless number : heat transfer effectiveness

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 Actual heat transfer rate:

The cold fluid is heated to hot fluid inlet temperature

Maximum heat transfer rate

The hot fluid is cooled to the inlet temperature of the

cold fluid

Low (mCp) fluid undergoes bigger temperature change, in our case cold fluid undergoes
larger temperature change. We designate it as minimum heat capacity

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 Effectiveness factor depends on the geometry
of the heat exchanger
 Following equations are valid for double pipe
heat exchanger

 countercurrent  parallel

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 Ref: Yunus
11/2/2021 A. Cengel, Heat Transfer: A Practical Approach, McGraw-Hill. 19
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 Fouling in heat exchangers
• In actual practice, heat transfer surfaces do
not remain clean because of the operating
temperatures, type of the process fluids,
process disturbances etc.
• Dirt, soot, scale and other deposits form
one or both sides of the heat exchanger
• These phenomena is called as fouling
• Fouling causes additional resistances to heat
transfer
• If we have want to include fouling in the
design of heat exchanger, two resistances
should be added to overall heat transfer
coefficient, U, similar to the film coefficient
• i.e, for inside area based U

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https://chempds.blogspot.com/2018/12/types-of-fouling-in-heat-exchangers_18.html
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 Typical overall U values for shell and tube heat exchanger

Use these values for only initial estimation of the size of the shell-and-tube heat exchanger

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https://www.titanmf.com/products/chemical-heat-exchangers/ 24