Heat and Mass Transfer: Fundamentals & Applications

5th Edition in SI Units

Yunus A. Çengel, Afshin J. Ghajar
McGraw-Hill, 2015

Chapter 11
HEAT EXCHANGERS
 Objectives
• Recognize numerous types of heat exchangers, and
classify them
• Develop an awareness of fouling on surfaces, and
determine the overall heat transfer coefficient for a heat
exchanger
• Perform a general energy analysis on heat exchangers
• Obtain a relation for the logarithmic mean temperature
difference for use in the LMTD method, and modify it
for different types of heat exchangers using the
correction factor
• Develop relations for effectiveness, and analyze heat
exchangers when outlet temperatures are not known
using the effectiveness-NTU method

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TYPES OF HEAT EXCHANGERS

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 Compact heat exchanger: It has a large heat
transfer surface area per unit volume (e.g., car
radiator, human lung). A heat exchanger with the
area density  > 700 m2/m3 is classified as being
compact.

Cross-flow: In compact heat exchangers, the two fluids

usually move perpendicular to each other. The cross-
flow is further classified as unmixed and mixed flow.

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Shell-and-tube heat exchanger: The most common type of heat
exchanger in industrial applications.
They contain a large number of tubes (sometimes several hundred)
packed in a shell with their axes parallel to that of the shell. Heat
transfer takes place as one fluid flows inside the tubes while the other
fluid flows outside the tubes through the shell.
Shell-and-tube heat exchangers are further classified according to the
number of shell and tube passes involved.

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Regenerative heat exchanger:
Involves the alternate passage of the
hot and cold fluid streams through the
same flow area.
Dynamic-type regenerator: Involves a
rotating drum and continuous flow of
the hot and cold fluid through different
portions of the drum so that any
portion of the drum passes
periodically through the hot stream,
storing heat, and then through the
cold stream, rejecting this stored heat.
Condenser: One of the fluids is cooled
and condenses as it flows through the
heat exchanger.
Boiler: One of the fluids absorbs heat
and vaporizes.
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 Plate and frame (or just plate) heat exchanger: Consists of a series of plates
with corrugated flat flow passages. The hot and cold fluids flow in alternate
passages, and thus each cold fluid stream is surrounded by two hot fluid streams,
resulting in very effective heat transfer. Well suited for liquid-to-liquid applications.

A plate-and-frame
liquid-to-liquid heat
exchanger.

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Plate and Frame Heat Exchanger

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 THE OVERALL HEAT TRANSFER COEFFICIENT
• A heat exchanger typically involves two
flowing fluids separated by a solid wall.
• Heat is first transferred from the hot fluid to
the wall by convection, through the wall by
conduction, and from the wall to the cold
fluid again by convection.
• Any radiation effects are usually included
in the convection heat transfer coefficients.

Thermal resistance network

associated with heat transfer in
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a double-pipe heat exchanger.
 U the overall heat transfer
coefficient, W/m2C

When

The overall heat transfer coefficient U is dominated by the smaller convection

coefficient. When one of the convection coefficients is much smaller than the other
(say, hi << ho), we have 1/hi >> 1/ho, and thus U  hi. This situation arises frequently
when one of the fluids is a gas and the other is a liquid. In such cases, fins are
commonly used on the gas side to enhance the product UA and thus the heat
transfer on that side. 10
The overall heat transfer coefficient ranges from about 10 W/m2C for gas-to-gas heat
exchangers to about 10,000 W/m2C for heat exchangers that involve phase changes.

11
 Fouling Factor

The performance of
heat exchangers
usually deteriorates
with time as a result
of accumulation of
deposits on heat
transfer surfaces.
The layer of deposits
represents additional
resistance to heat
transfer. This is
represented by a
fouling factor Rf.

The fouling factor increases with the operating

temperature and the length of service and decreases
with the velocity of the fluids.
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 EXAMPLE 11–1
Overall Heat Transfer Coefficient of a
Heat Exchanger
Hot oil is to be cooled in a double-
tube counter-flow heat exchanger.
The copper inner tubes have a
diameter of 2 cm and negligible
thickness. The inner diameter of the
outer tube (the shell) is 3 cm. Water
flows through the tube at a rate of 0.5
kg/s, and the oil through the shell at a
rate of 0.8 kg/s. Taking the average
temperatures of the water and the oil
to be 45 oC and 80 oC, respectively,
determine the overall heat transfer
coefficient of this heat exchanger. 13
 ANALYSIS OF HEAT
AnEXCHANGERS
engineer often finds himself or herself in a position
1. to select a heat exchanger that will achieve a specified temperature
change in a fluid stream of known mass flow rate - the log mean
temperature difference (or LMTD) method.
2. to predict the outlet temperatures of the hot and cold fluid streams in
a specified heat exchanger - the effectiveness–NTU method.
The rate of heat transfer in heat
exchanger (HE is insulated): Two fluid
streams that
have the same
capacity rates
experience the
same
temperature
change in a well-
insulated heat
exchanger.

heat capacity rate

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 is the rate of evaporation or condensation of the fluid
hfg is the enthalpy of vaporization of the fluid at the specified temperature or pressure.
The heat capacity rate of a fluid during a phase-change process must approach
infinity since the temperature change is practically zero.

Variation of
fluid
temperatures
in a heat
exchanger
when one of
the fluids
condenses or
boils.

Tm an appropriate mean (average)

temperature difference between the two fluids
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THE LOG MEAN TEMPERATURE
DIFFERENCE METHOD

log mean
temperature
difference

Variation of the fluid

temperatures in a
parallel-flow double-
pipe heat exchanger. 16
17
Counter-Flow Heat Exchangers
In the limiting case, the cold fluid will be
heated to the inlet temperature of the
hot fluid.
However, the outlet temperature of the
cold fluid can never exceed the inlet
temperature of the hot fluid.
For specified inlet and outlet
temperatures, Tlm a counter-flow heat
exchanger is always greater than that
for a parallel-flow heat exchanger.
That is, Tlm, CF > Tlm, PF, and thus a
smaller surface area (and thus a smaller
heat exchanger) is needed to achieve a
specified heat transfer rate in a counter-
flow heat exchanger.

When the heat capacity rates

of the two fluids are equal

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Multipass and Cross-Flow Heat Exchangers:
Use of a Correction Factor

F correction factor depends on the

geometry of the heat exchanger and
the inlet and outlet temperatures of the
hot and cold fluid streams.
F for common cross-flow and shell-
and-tube heat exchanger
configurations is given in the figure
versus two temperature ratios P and R
defined as

1 and 2 inlet and outlet

T and t shell- and tube-side temperatures

F = 1 for a condenser or boiler

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Correction factor
F charts for
common shell-
and-tube heat
exchangers.

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Correction
factor F charts
for common
cross-flow heat
exchangers.

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The LMTD method is very suitable for determining the size of a
heat exchanger to realize prescribed outlet temperatures when
the mass flow rates and the inlet and outlet temperatures of the
hot and cold fluids are specified.
With the LMTD method, the task is to select a heat exchanger
that will meet the prescribed heat transfer requirements. The
procedure to be followed by the selection process is:
1. Select the type of heat exchanger suitable for the application.
2. Determine any unknown inlet or outlet temperature and the
heat transfer rate using an energy balance.
3. Calculate the log mean temperature difference Tlm and the
correction factor F, if necessary.
4. Obtain (select or calculate) the value of the overall heat
transfer coefficient U.
5. Calculate the heat transfer surface area As.
The task is completed by selecting a heat exchanger that has a
heat transfer surface area equal to or larger than As.
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EXAMPLE 11–3
The Condensation of Steam in a
Condenser
Steam in the condenser of a power
plant is to be condensed at a
temperature of 30oC with cooling
water from a nearby lake, which
enters the tubes of the condenser
at 14oC and leaves at 22oC. The
surface area of the tubes is 45 m2,
and the overall heat transfer
coefficient is 2100 W/m2 oC.
Determine the mass flow rate of
the cooling water needed and the
rate of condensation of the steam
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in the condenser.
 EXAMPLE 11–6
Cooling of Water in an Automotive
Radiator
A test is conducted to determine the
overall heat transfer coefficient in an
automotive radiator that is a compact
cross-flow water-to-air heat exchanger
with both fluids (air and water) unmixed.
The radiator has 40 tubes of internal
diameter 0.5 cm and length 65 cm in a
closely spaced plate-finned matrix. Hot
water enters the tubes at 90oC at a rate
of 0.6 kg/s and leaves at 65oC. Air flows
across the radiator through the interfin
spaces and is heated from 20oC to 40oC.
Determine the overall heat transfer
coefficient Ui of this radiator based on
the inner surface area of the tubes.
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 THE EFFECTIVENESS–NTU METHOD
A second kind of problem encountered in heat exchanger analysis is the
determination of the heat transfer rate and the outlet temperatures of the hot and
cold fluids for prescribed fluid mass flow rates and inlet temperatures when the
type and size of the heat exchanger are specified.

Heat transfer effectiveness

the maximum possible heat transfer rate

Cmin is the smaller of Ch and Cc
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Actual heat transfer rate

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The effectiveness of a
heat exchanger depends
on the geometry of the
heat exchanger as well
as the flow arrangement.
Therefore, different types
of heat exchangers have
different effectiveness
relations.
We illustrate the
development of the
effectiveness relation for
the double-pipe parallel-
flow heat exchanger.

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Effectiveness relations of the heat exchangers typically involve the
dimensionless group UAs /Cmin.
This quantity is called the number of transfer units NTU.

For specified values of U and Cmin,

the value of NTU is a measure of the
surface area As. Thus, the larger the
NTU, the larger the heat exchanger.
capacity
ratio

The effectiveness of a heat exchanger is a function of the

number of transfer units NTU and the capacity ratio c.

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29
Effectiveness
for heat
exchangers.

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31
When all the inlet and
outlet temperatures are
specified, the size of the
heat exchanger can
easily be determined
using the LMTD method.
Alternatively, it can be
determined from the
effectiveness–NTU
method by first evaluating
the effectiveness from its
definition and then the
NTU from the appropriate
NTU relation.

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(e.g., boiler, condenser)

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 EXAMPLE 11–8
The effectiveness-NTU method
A counter-flow double-pipe heat
exchanger is to heat water from 20oC
to 80oC at a rate of 1.2 kg/s. The
heating is to be accomplished by
geothermal water available at 160oC
at a mass flow rate of 2 kg/s. The
inner tube is thin-walled and has a
diameter of 1.5 cm. If the overall heat
transfer coefficient of the heat specific heats of water and
exchanger is 640 W/m2.oC, geothermal fluid are 4.18 and
4.31 kJ/kg oC, respectively.
determine the length of the heat
exchanger required to achieve the
desired heating. 34
 Summary
• Types of Heat Exchangers
• The Overall Heat Transfer Coefficient
 Fouling factor
• Analysis of Heat Exchangers
• The Log Mean Temperature Difference
Method
 Counter-Flow Heat Exchangers
 Multipass and Cross-Flow Heat Exchangers:
Use of a Correction Factor
• The Effectiveness–NTU Method

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Tutorial

Complete the following problems at the end of

chapter 11:
• 11.43
• 11.56
• 11.70
• 11.94
• 11.105

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