UNIT-IV

HEAT EXCHANGER
1. In a counter flow double pipe heat exchanger, oil is cooled from 85˚C to 55˚C by water
entering at 25˚C. The mass flow rate of oil is 9,800 kg/h and specific heat f oil is 2000 J/kg K.
The mass flow rate of water is 8,000 kg/h and specific heat of water is 4180 J/kg K. Determine
the heat exchanger area and heat transfer rate for an overall heat transfer co-efficient of 280
W/m2 K.

Given:

Hot fluid – oil, Cold fluid - water --------------------------

(T1, T2) (t1, t2) Water

--------------------------

Entry temperature of oil, T1 = 85˚C Oil

--------------------------

Exit temperature of oil T2 = 55˚C Water

--------------------------

Mass flow rate of oil (Hot fluid), mh = 9,800 kg/h

9 , 800
= kg/ s
3600

mh = 2.72 kg/s

Specific heat of oil, Cph = 2000 J/kg K

Mass flow rate of water (cold fluid), mc = 8,000 kg/h

8 , 000
= kg/ s
3600

mc = 2.22 kg/s

Specific heat of water, Cpc = 4180 J/kg K

Overall heat transfer co-efficient, U = 280 W/ m2K

To find:

1. Heat exchanger area, (A)

2. Heat transfer rate, (Q)

Solution:

We know that,

Heat lost by oil (Hot fluid) = Heat gained by water (cold fluid)

Qh = Qc

==> mh C ph ( T 1−T 2 ) =mc C pc ( t 2−t 1 )

==> 2. 72×2000 [ 85−55 ] =2 .22×4180×[ t 2−t 1 ]
==> 163 .2×10 =9279 .6 t 2 −( 231 .9×10 )
3 3

∘
==> t 2 =42. 5 C

Exit temperature of water,

t 2=42. 5∘ C

Heat transfer,

Q=mc C pc ( t 2 −t 1 ) ( or ) mh C ph ( T 1 −T 2 )
==> Q=2 . 22×4180×( 42 . 5−25 )
Q=162×103 W
We know that,

Heat transfer,Q=UA ( ΔT )m …….. (1)

Where

( ΔT )m - Logarithmic Mean Temperature Difference. (LMTD)

For Counter flow,

( T 1−t 2 ) −( T 2 −t 1 )
( ΔT )m=
In
[ ] T 1−t 2
T 2−t 1
( 85−42 .5 ) −( 55−25 )
( ΔT )m=
In [
85−42 .5
55−25 ]
( ΔT )m = 35. 8˚C

Substitute ( ΔT )m U and Q values in Equn (1)

(1)==> Q=UA ( ΔT )m
==>162×103 =280× A×35 . 8

==> A = 16.16 m2

Result:

1. Heat exchanger area, A = 16.16 m2

2. Heat transfer, Q = 162 ¿ 103 W

2. Water flows at the rate of 65 kg/min through a double pipe, counter flow heat exchanger.
Water is heated from 50˚C to 75˚C by oil flowing through the tube. The specific heat of the oil
is 1.780 kJ/kg K. The oil enters at 115˚C and leaves at 70˚C. The overall heat transfer co-
efficient is 340 W/m2K. Calculate the following

1. Heat exchanger area

2. Rate of heat transfer
Given:

Hot fluid – oil, Cold fluid - water

(T1, T2) (t1, t2)

Mass flow rate of oil (cold fluid), mc = 65 kg/min

65
= kg/ s
60

mc = 1.08 kg/s

Entry temperature of water, t1 = 50˚C

Exit temperature of water, t2 = 75˚C

Specific heat of oil (Hot fluid) Cph = 1.780 kJ/kg K

= 1.780¿ 103 J/m2K

Entry temperature of oil, T1 = 115˚C

Exit temperature of oil, T2 = 70˚C

Overall heat transfer co-efficient, U = 340 W/m2K

To find:

1. Heat exchanger area, (A)

2. Heat transfer rate, (Q)

Solution:

We know that,

Q=mc C pc ( t 2 −t 1 ) ( or ) mh C ph ( T 1 −T 2 )
Heat transfer,

==>Q=mh C pc ( T 2−T 1 )
==> Q=1 . 08×4186 ( 75−50 )

∵ Specific heat of water, Cpc = 4186 J/kgK

We know that,

Heat transfer, Q=U × A ( ΔT ) m …….(1)

Where

( ΔT )m - Logarithmic Mean Temperature Difference. (LMTD)

For Counter flow,

( T 1−t 2 ) −( T 2 −t 1 )
( ΔT )m=
In
[ ]
T 1−t 2
T 2−t 1
(115−75 )−( 70−50 )
==> ( ΔT )m=
In [
115−75
70−50 ]
( ΔT )m = 28. 8˚C

Substitute ( ΔT )m U and Q and U values in Equn (1)

(1)==> Q=UA ( ΔT )m
113×10 3 =340× A×28 .8

==> A = 11.54 m2

Result:

1. Heat exchanger area, A = 11.54 m2

2. Heat transfer, Q = 113 ¿ 103 W

3. In a counter flow single pass heat exchanger is used to cool the engine oil from 150˚C to
55˚C with water, available at 23˚C as the cooling medium. The specific heat of oil is 2125 J/kg
K. The flow rate of cooling water through the inner tube of 0.4 m diameter is 2.2 kg/s. The
flow rate of oil through the outer tube of 0.75 m diameter is 2.4 kg/s. If the value of the overall
heat transfer co-efficient is 240 W/m2 K, how long must the heat exchanger be to meet its
cooling requirement?
Given:

Hot fluid – oil, Cold fluid - water

(T1, T2) (t1, t2)

Entry temperature of oil, T1 = 150˚C

Exit temperature of oil, T2 = 55˚C

Entry temperature of water, T1 = 23˚C

Specific heat of oil (Hot fluid) Cph = 2125 kJ/kg K

Inner diameter, D1 = 0.4 m

Flow rate of water (cooling fluid), mc = 2.2 kg/s

Outer diameter, D2= 0.75 m

Flow rate of oil (Hot fluid), mh = 2.4 kg/s

Overall heat transfer co-efficient, U = 240 W/m2K

To find:

Length of the heat exchanger, L

Solution:

We know that,

Heat lost by oil (Hot fluid) = Heat gained by water (cold fluid)

==>Q h=Q c
==> m h C ph ( T 1 −T 2 )=mc C pc ( t 2 −t 1 )
==> 2. 4×2125 ( 150−55 )=2 . 2×4186×( t 2 −23 )

[∵ Specific heat of water, Cpc = 4186 J/kgK]

 ==> 484 . 5×103 =9209. 2 t 2 −( 211×103 )

Q=mc C pc ( t 2 −t 1 ) ( or ) mh C ph ( T 1 −T 2 )
Heat transfer,

==>Q=2. 2×4186×( 75. 6−23 )

Q=484 . 4×103 W

We know that,

Heat transfer Q=UA ( ΔT )m …… (1)

Where

( ΔT )m - Logarithmic Mean Temperature Difference. (LMTD)

For Counter flow,

( T 1−t 2 ) −( T 2 −t 1 )
( ΔT )m=
In
[ ]
T 1−t 2
T 2−t 1
(150−75 . 6 )−( 55−23 )
==> ( ΔT )m=
In [
150−75 . 6
55−23 ]
( ΔT )m = 50.2˚C

Substitute( ΔT )m , U and Q values in Equn (1)

(1)==> Q=UA ( ΔT )m
484 . 4×103 =10 3=240× A×50. 2

==> A = 40.20 m2
We know that,

Area, A = π×D 1 ×L

40.20 = π ¿ 0.4 ¿ L
 ==> L = 31.9 m

Result:

Length of the heat exchanger, L = 31.9 m.

4. In an oil cooler for a lubrication system, oil is cooled from 70˚C to 40˚C by using a cooling
water flow at 25˚C. The mass flow rate of oil is 900 kg/h and the mass flow rate of water is 700
kg/h. Give your choice for a parallel flow or counter flow heat exchanger, with reasons. If the
overall heat transfers co-efficient is 20 W/m 2K, find the area of the heat exchanger. Take
specific heat of oil is 2 kJ/ kg˚C.

Given:

Hot fluid – oil, (T1, T2) Cold fluid - water (t1, t2)

Entry temperature of oil, T1 = 70˚C

Exit temperature of oil, T2 = 40˚C

Entry temperature of water, T1 = 25˚C

The mass flow rate of oil,

m h =900 kg /h

900
= kg/ s
3600
=0. 25 kg/s

The mass flow rate of water,

m c =700 kg/h

700
= kg/ s
3600
=0. 197 kg /s
Overall heat transfer co-efficient, U = 20 W/m2K

Specific heat of oil, Cph = 2 kJ/kg˚C

= 2 ¿ 103 J/kg˚C

To find:
 1. Choice of heat exchanger (Whether parallel flow or counter flow)
2. Area of heat exchanger.

Solution:

We know that,

Heat lost by oil (Hot fluid) = Heat gained by water (Cold fluid)

==>Q h=Q c
==> m h C ph ( T 1 −T 2 )=mc C pc ( t 2 −t 1 )
==> 0 .25×2×10 3 ( 70−40 )=0 . 194×4186×( t 2 −25 )

[∵ Specific heat of water, Cpc = 4186 J/kg K]

==>15 , 000=812 .08 t 2 −20 ,302 .10

==> t2 = 43.47˚C

Exit temperature of water, t2 = 43.47˚C > T2

Since t2 > T2, counter flow arrangement should be used.

We know that,

Heat transfer Q=UA ( ΔT )m …… (1)

For Counter flow,

( T 1−t 2 ) −( T 2 −t 1 )
( ΔT )m=
In
[ ]
T 1−t 2
T 2−t 1
(70−43 . 47 )−( 40−25 )
==> ( ΔT )m=
In [
70−43. 47
40−25 ]
11. 53
¿
0 . 569
 ( ΔT )m = 20.26˚C
…….. (2)

We know that,

Heat transfer,

Q=mh C ph ( T 1−T 2 ) ormc C pc ( t 2−t 1 )

==> Q=mh C ph ( T 1 −T 2 )
¿ 0 . 25×2×103 ×( 70−40 )

Q = 15,000 J/s …….. (3)

Substitute, Q, U, and ( ΔT )m values in equation (1)

==>Q=UA ( ΔT )m
==> 15 , 000=20×A× ( 20. 26 )

==> A = 37.02 m2

Result:

1. Choice of heat exchanger – counter flow arrangement

2. Surface area, A = 37.02 m2.

5. In a refrigerating plant water is cooled from 20˚C to 7˚C by brine solution entering at - 2˚C
and leaving at 3˚C. The design heat load is 5500 W and the overall heat transfer co-efficient is
800 W/m2 K. What area required when using a shell and tube heat exchanger with the water
making one shell pass and the brine making two tube passes.

Given:

Hot fluid – water, Cold fluid – water

(T1, T2) (t1, t2)

Entry temperature of water, T1 = 20˚C

 Exit temperature of water, T2 = 7˚C

Entry temperature of water, T1 = - 2˚C

Exit temperature of brine solution, t2 = 3˚C

Heat load, Q = 5500 W

Overall heat transfer co-efficient, U = 800 W/m2K

To find:

Area required (A)

Solution:

Shell and tube heat exchanger – One shell pass and two tube passes

For shell and tube heat exchanger (or) cross flow heat exchanger.

Q=FUA ×( ΔT )m …….. (1)

[Counter flow]

Where

F – Correction factor

( ΔT )m - Logarithmic mean temperature difference for counter flow.

For Counter flow,

( T 1−t 2 ) −( T 2 −t 1 )
( ΔT )m=
In
[ T 1−t 2
T 2−t 1 ]
( 20−3 )−( 7+ 2 )
¿
In[ 20−3
7+ 2 ]
( ΔT )m = 12.57˚C

From graph,

t 2 −t 1 3+2 5
X axis value , P= = =
T 1 −t 1 20+2 22
 P = 0.22

T 1−T 2 20−7 13
P= = =
Curve value, t 2−t 1 3+ 2 5

R 2.6,
Xaxis value is 0.22, curve value is = 2.6and corresponding Y axis value is 0.94.

Substitute ( ΔT )m Q , U and F value in Equn (1)

(1)==> Q=FUA ( ΔT )m
==>5500=0 . 94×800× A×12 .57

==> A = 0.58 m2

Result:

Area of heat exchanger, A = 0.58 m2

6. A parallel flow heat exchanger is used to cool 4.2 kg/min of hot liquid of specific heat 3.5
kJ/kg K at 130˚C. A cooling water of specific heat 4.18 kJ/kg K is used for cooling purpose at
a temperature of 15˚C. The mass flow rate of cooling water is 17 kg/min. calculate the flowing.

1. Outlet temperature of liquid

2. Outlet temperature of water
3. Effectiveness of heat exchanger

Take

Overall heat transfer co-efficient is 1100 W/m2K.

Heat exchanger area is 0.30 m2

Given:

Mass flow rate of hot liquid, mh = 4.2 kg/min

mh = 0.07 kg/s

Specific heat of hot liquid, Cph = 3.5 kJ/kg K

C ph=3 .5×103 J /kgK

 Inlet temperature of hot liquid, T1 = 130˚C

Specific heat of water, Cpc = 4.18 kJ/kg K

C pc =4 . 18×10 3 J /kgK
Inlet temperature of cooling water, t1 = 15˚C

Mass flow rate of cooling water, mc = 17 kg/min

mc = 0.28 kg/s
Overall heat transfer co-efficient, U = 1100 W/m2K

Area, A = 0.30 m2

To find:

1. Outlet temperature of liquid, (T2)

2. Outlet temperature of water, (t2)
3. Effectiveness of heat exchanger, ( ε )

Solution:

Capacity rate of hot liquid,

C=mh ×C ph

=0. 07×3 .5×103

……….. (1)
C = 245 W/K

Capacity rate of water,

C=mc ×C ph

=0. 28×4 . 18×10 3

………… (2)
C = 1170.4 W/K
From (1) and (2),

Cmin = 245 W/K

Cmax = 1170.4 W/K

C min 245
==> = =0 . 209
C max 1170. 4
 C min
C max = 0.209 ……………. (3)

UA
C
Number of transfer units, NTU = min

1100×0. 03
==> NTU =
245

NTU = 1.34 …….. (4)

From graph,

Xaxis  NYU = 1.34

C min
=0 . 209
Curve  C max

Corresponding Yaxis value is 64%

i.e.,
ε =0 . 64

Maximum possible heat transfer

Qmax = Cmin (T1 – t1)

 = 245 (130 – 15)

Qmax = 28,175 W

Actual heat transfer rate

Q=ε×Q max
¿ 0 . 64×28 ,175

Q = 18,032 W
We know that,

Q=mc C pc ( t 2 −t 1 )
Heat transfer,

==>18 , 032=0 .28×4 . 18×103 ( t 2 −t 5 )

==> 18 , 0323=1170. 4 t 2 −17556
==> t 2 =30 . 40∘ C

Outlet temperature of cold water,

t 2=30 . 40∘ C

We know that,

Q=mh C pc ( T 1 −T 2 )
Heat transfer,

==>18 , 032=0 .07×3 .5×103 ( 130−T 2 )

==> 18 , 0323=31850−245 T 2
==> t 2 =56 . 4 ∘ C

Outlet temperature of hot liquid,

T 2=56 . 4 ∘ C

Result:

1. T2 = 56.4˚C
2. t2 = 30.40˚C
3. ε = 0.64
7. In a counter flow heat exchanger, water at 20˚C flowing at the rate of 1200 kg/h. it is heated
by oil of specific heat 2100 J/kg K flowing at the rate of 520 kg/h at inlet temperature of 95˚C.
Determine the following

1. Total heat transfer

2. Outlet temperature of water
3. Outlet temperature of oil

Take Overall heat transfer co-efficient is 100 W/m2 K.

Heat exchangers are is 1 m2.

Given:

Capacity rate of hot oil, C =

mh ×C ph

0 . 144×2100

C = 302.4 W/K ………… (1)

Capacity rate of water, C =

mh ×C ph

0 . 33×4186

C=1381 .3 W /K ………… (2)

Inlet temperature of hot liquid, T1 = 130˚C

Specific heat of water, Cpc = 4.18 kJ/kg K

C pc =4 . 18×10 3 J /kgK

From Equn (1) and (2),

Cmin = 302.4 W/K

Cmax = 1381.3 W/K

C min 302. 4
==> = =0 .218
C max 1381. 3
 C min
C max = 0.218 ……………. (3)

UA
C
Number of transfer units, NTU = min

1100×1
==> NTU =
302 . 4

NTU = 3.3 …….. (4)

From graph,

Xaxis  NYU = 3.3

C min
=0 . 218
Curve  C max

Corresponding Yaxis value is 0.95

i.e.,
ε =0 . 95
C min
=0 . 218
C max

Maximum possible heat transfer

 Qmax = Cmin (T1 – t1)

= 302.4 (95 – 20)

Qmax = 22,680 W

Actual heat transfer rate

Q=ε×Q max
¿ 0 . 95×22 , 680

Q = 21,546 W
We know that,

Q=mc C pc ( t 2 −t 1 )
Heat transfer,

21 , 546=0 . 33×4186 ( t 2−20∘ )

[ ∵ C pc=4186 J /kgK ]
==>21 , 546=1381. 38 t 2 −27 , 627 . 6

==>
t2 = 35.5˚C

Outlet temperature of water,

t 2=35 . 5∘ C

We know that,

Q=mh C pc ( T 1 −T 2 )
Heat transfer,

21 , 546=0 . 144×2100 ( 95−T 2 )

==> 21 ,546=28 , 728−302 . 4 T 2

==> T2 = 23.75˚C

Outlet temperature of oil,

T 2=23 . 75∘ C

Result:

1. T2 = 21,546W
 2. T2 = 23.75˚C
3. t2 = 35.5˚C

8. In a counter flow heat exchanger, water is heated from 20˚C to 80˚C by an oil with a
specific heat of 2.5 kJ/kg – K and mass flow rate of 0.5 kg/s. The oil is cooled from 110˚C to
40˚C. If the overall heats transfer co-efficient is 1400 W/m2K, find the following by using
NTU method

1. Mass flow rate of water

2. Effectiveness of heat exchanger
3. Surface area

Given:

Hot fluid – oil, Cold fluid - water

(T1, T2) (t1, t2)

Inlet temperature of water, t1 = 20˚C

Outlet temperature of water, t2 = 80˚C

Specific heat of oil, Cph = 2.5 kJ/kg - K

= 2.5 ¿ 103 J/kg - K

The mass flow rate of oil,

m h =0 .5 kg/ s

Inlet temperature of oil, T1 = 110˚C

Outlet temperature of oil, T2 = 40˚C

Overall heat transfer co-efficient, U = 1400 W/m2 K

To find:

1. Mass flow rate of water, mc

2. Effectiveness of heat exchanger, ε
3. Surface area, A

Solution:

We know that,
 Heat lost by oil = Heat gained by water

==>Q h=Q c
==> m h C ph ( T 1 −T 2 )=mc C pc ( t 2 −t 1 )
==> 0 .5×2 .5×103 ( 110−40 )=m c ×4186×( 80−20 )

[∵ Specific heat of water, Cpc = 4186 J/kg K]

==> mc = 0.348 kg/s

Mass flow rate of oil (Hot fluid), C = mhCph

0 . 5×2 .5×103

……… (1)
C = 1250 W/K

Capacity rate of water (Cold fluid), C = mcCpc

0 . 348×4186

C = 1456.73 W/K
………… (2)

From Equn (1) and (2),

Cmin = 1250 W/K

Cmax = 1456.73 W/K

C min 1250
==> = =0 . 858
C max 1456 .73

C min
C max = 0.858 ………… (3)

We know that,
 T 1 −T 2
ε=
Effectiveness, T 1 −T 1

110−40
=
110−20
ε =0 .77

From graph,

Xaxis  ε =0 .77

C min
=0 . 858
Curve  C max

Corresponding Xaxis value is 3.4, i.e., NTU = 3.4

We know that,

UA
NTU = C min

UA
NTU =
C min

==> A = 3.03 m2

Result:
1. mc = 0.348 kg/s
2. ε = 0.77
3. A = 3.03 m2