Heat Transfer Equipment

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 Heat Exchangers
o A heat exchanger is an equipment or device for transfer of heat
from a hot phase to a cold phase with the two phases being
separated by a solid boundary.
o A device for transferring thermal energy (heat) from one fluid
(liquid or gas) to another, when the two fluids are physically
separated.
o The heat transferred may be latent heat accompanying phase
changes such as condensation or vaporization, or it may be sensible
heat coming from increasing or decreasing the temperature of a
fluid without phase change. In heat exchangers heat is transferred
by conduction and convection. 3
 Heat Exchangers
Basic principle of a heat exchange
The essential principle of a heat exchanger is that it transfers the heat
without transferring the fluid that carries the heat.
Function of heat exchanger
The function of a heat exchanger is to increase the temperature of a cooler fluid
and decrease that of a hotter fluid. Heat exchangers are used to transfer heat from
one medium to another.

Types of heat exchangers:

1. Double pipe heat exchanger
2. Shell and tube exchanger
3. Plate-type exchanger
The double pipe heat exchanger has the following two major types:
 Counter flow/counter-current heat exchanger
 Parallel flow/co-current heat exchanger
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 1. Double pipe heat exchanger
• A double-pipe heat exchanger consists of two metal pipes, one inside the other as shown
in the Fig 1. One fluid flows through the inner tube while the other fluid flows in the
annular space between the pipe walls.
• When one of the fluids is hotter than the other, heat flows from it through the wall of the
inner tube into the other fluid. As a result, the hot fluid becomes cooler and the cold fluid
becomes warmer.
• Double pipe heat exchangers can be operated with counter-current or co-current flow of
fluid.
• If, the two fluids enter at opposite ends of the device and pass in opposite directions
through the pipes, the flow is counter-current.
• Cold fluid entering the device meets the hot fluid just as it is leaving, i.e., cold fluid at its
lowest temperature is placed in thermal contact with hot fluid also at its lowest
temperature.

Fig 1. Double pipe

heat exchanger

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• Changes in temperature of the two fluids as they flow counter-currently through the
length of the pipe are shown in the figure.

• The four terminal temperatures are as follows: Thi is the inlet temperature of the hot

fluid, Tho is the outlet temperature of the hot fluid, Tci is the inlet temperature of the

cold fluid, and Tco is the outlet temperature of the cold fluid leaving the system. A sign

of efficient operation is Tco close to Thi or Tho close to Tci.

• The alternative to countercurrent flow is cocurrent or parallel flow. In this mode of

operation, both fluids enter their respective tubes at the same end of the exchanger
and flow in the same direction to the other end. The temperature curves for cocurrent
flow are given in the figure. Cocurrent operation is not as effective as countercurrent;
it is not possible using cocurrent flow to bring the exit temperature of one fluid close
to the entrance temperature of the other.
• Instead, the exit temperatures of both streams lies between the two entrance
temperatures. Less heat can be transferred in parallel flow than in countercurrent
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• Double-pipe heat exchangers can be extended to several passes arranged in a
vertical stack, as illustrated in the figure. However, when large surface areas are
needed to achieve the desired rate of heat transfer.
• The weight of the outer pipe becomes so great that an alternative design, the
shell-and-tube heat exchanger, is a better and more economical choice.

Hairpin heat exchangers

(often also referred to
as double pipes) are
characterized by a
construction form which
imparts a U-shaped
appearance to the heat
exchanger.

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 Construction of double pipe heat exchangers

 Hair pin: union of two legs hairpin construction is preferred because it requires
less space
 Packing & gland: The packing and gland provides sealing to the annulus and
support the inner pipe.
 Return bend: The opposite ends are joined by a U-bend through welded joints.
 Support lugs: Support lugs may be fitted at these ends to hold the inner pipe
position.
 Flange: The outer pipes are joined by flanges at the return ends in order that the
assembly may be opened or dismantled for cleaning and maintenance.
 Union joint: For joining the inner tube with U-bend.
 Nozzles: Small sections of pipes welded to the shell or to the channel which acts
as the inlet or outlet of the fluids are called nozzles.
 Gaskets: Gaskets are placed between the two flanges to make the joint leak-free.

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 Fig. Double pipe heat exchanger

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Co-current counter current
 Q. Where is double pipe heat
exchanger used?
Ans: Double pipe heat
exchangers are used in many
industries because of their
low design and maintenance
costs, flexibility, and low
installation costs. They are
mainly used for sensible
heating or cooling of process
fluids in applications of small
heat transfer areas of up to 50
m2.

Fig. Double pipe heat exchanger

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Fig. Counter-current heat exchanger Fig. Co-current heat exchanger11
 2. Shell and Tube Exchanger
Shell and Tube heat exchangers are used for heating and cooling all types of fluid.
They have the advantage of containing very large surface areas in a relatively small
volume. The simplest form, called a single-pass shell and Tube heat exchanger, is
shown in the Fig 2.

Consider the device of the figure for exchange of sensible heat from one fluid to
another. The heat transfer system is divided into two sections: A tube bundle
containing pipes through which one fluid flows and a shell or cavity where the other
fluid flows.

Standard lengths of tubes for heat-exchanger construction are 8, 12, 16 & 20 ft.
Tubes are arranged on triangular or square pitch [The spacing between tubes
(centre to centre) is referred to as the tube pitch]. Hot or cold fluid may be put into
either the tubes or the shell. In a single-pass exchanger, the shell and tube fluids
pass down the length of the equipment only once. The fluid which is to travel in
tubes enters at the inlet header. The header is divided from the rest of the
apparatus by a tube sheet.

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Fig 2. Shell and Tube heat exchangers

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Open tubes are fitted into the tube sheet; Fluid in the header cannot enter the main cavity of
the exchanger but must pass into the tubes. The tube side fluid leaves the exchanger through
another header at the outlet. Shell-side fluid enters the internal cavity of the exchanger and
flows around the outsides of the tubes in a direction which is largely countercurrent to the
tube fluid. Heat is exchanged across the tube walls from hot fluid to cold fluid.
Baffles are often installed in the shell to decrease the cross-sectional area for flow and divert
the shell fluid. So it flows mainly across rather than parallel to the tubes (direct the shell side
fluid back and forth across the tube bundle to provide effective velocity and heat transfer rate).
Both these effects promote turbulence in the shell fluid which improves the rate of heat
transfer. Baffles run perpendicularly to the shell and are perforated to receive the tubes,
preventing the tubes from sagging over a long length. Baffles do not extend edge to edge, but
have a cut that allows shell side fluid to flow to next baffled chamber. For most liquid
applications, cuts areas represent 20-25% of the shell diameter. To minimize leakage, the
clearances between baffles and shell and tubes should be small. Baffles are supported by one
or more guide rods, which are fastened between the tube sheets by setscrews.
The length of tubes in a single-pass heat exchanger determines the surface area available for
heat transfer, and therefore the rate at which heat can be exchanged. However, there are
practical and economic limits to the maximum length of single-pass tubes; if greater heat-
transfer capacity is required multi-pass heat exchangers are employed. Heat exchangers
containing more that one tube pass are used routinely.
Shell and tube heat exchanges are described based on the number of passes the shell-side and
tube-side fluids must undergo. Exchangers are listed as 1-1, 1-2, 2-4, etc., in which the first
number signifies the number of passes for the shell-side fluid and the second number refers to
the tube-side fluid. 14
Fig. The schematic of a shell-and-tube heat exchanger (one-shell pass and one-tube pass).

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 Fig. Shell and tube heat exchanger
(1 shell pass and 1 tube passes (1-1 exchanger))

• The cold fluid enters and flow inside through all the tubes in
parallel in one pass.
• The hot fluid enters at the other end and flow counter-current
flow across the outside the tubes in the shell side.
• Cross-baffles increase the shell side heat transfer coefficient.
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 Fig. Shell and tube heat exchanger
(1 shell pass and 2 tube passes (1-2 exchanger))

• The liquid on the tube side flows in two passes

• The shell-side liquid flows in one pass
• In the first pass of the tube side, the cold fluid is flowing
counter-current flow to the hot shell-side fluid
• In the second pass of the tube side, the cold fluid flows in
parallel (co-current)
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 Fig . Shell and tube heat exchanger
(2 shell pass and 4 tube passes (2-4 exchanger))

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Fig. Shell and tube heat exchanger

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 Plate Heat Exchanger
A plate heat exchanger is a type of heat exchanger that uses metal
plates to transfer heat between two fluids.

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 Analysis of Heat Exchangers
The rate of heat transfer from the hot fluid be equal to the rate of heat transfer to the
cold one. That is,

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Fig. 23–12
Two fluids that have the
same mass flow rate and
the same specific heat
experience the same
temperature change in a
well-insulated heat
exchanger.

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 Mean Temperature Difference

Where there are two heat transfer fluids separated by a wall, the heat
transfer for the combined situation can be defined in terms of an overall heat
transfer coefficient, U based on the assumption that the fluid temperatures
remain constant.

This is not valid for a heat exchanger where there is heat transfer from one
fluid to another and the temperature difference between the hot and cold
fluids varies along the heat exchanger, and it is convenient to have a mean
temperature difference, ΔTm for use in the relation:

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 Mean Temperature Difference

Fig. 23–15 The ΔT1 and ΔT2 expressions in parallel-flow and counter-flow heat exchangers.

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 Log Mean Temperature Difference Method
The temperature difference between the hot and
cold fluids varies along the heat exchanger, and it is
convenient to have a mean temperature difference
ΔTm for use in the relation Q = UAs ΔTm.

In order to develop a relation for the equivalent

average temperature difference between the two
fluids, consider the parallel-flow double-pipe heat
exchanger shown in Fig. 23–14.

The temperature difference ΔT between the hot

and cold fluids is large at the inlet of the heat
exchanger but decreases exponentially toward the
outlet. The temperature of the hot fluid decreases
and the temperature of the cold fluid increases
along the heat exchanger, but the temperature of
the cold fluid can never exceed that of the hot fluid Fig. 23–14 Variation of the
no matter how long the heat exchanger is. fluid temperatures in a
parallel-flow double pipe
heat exchanger. 28
 Log Mean Temperature Difference Method
Assuming the outer surface of the heat exchanger to be well insulated so that any
heat transfer occurs between the two fluids, and disregarding any changes in kinetic
and potential energy, an energy balance on each fluid in a differential section of the
heat exchanger can be expressed as

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Log Mean Temperature Difference (counter-flow heat exchangers)

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Fig. 23–15 The ΔT1 and ΔT2 expressions in parallel-flow and counter-flow heat exchangers.

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Fig. 23–15 The ΔT1 and ΔT2 expressions in parallel-flow and counter-
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flow heat exchangers.
Note that ΔTlm is always less than ΔTam. Therefore, using ΔTam in calculations

instead of ΔTlm will overestimate the rate of heat transfer in a heat exchanger

between the two fluids. When ΔT1 differs from ΔT2 by no more than 40 percent,
the error in using the arithmetic mean temperature difference is less than 1
percent. But the error increases to undesirable levels when ΔT1 differs from ΔT2 by
greater amounts. Therefore, we should always use the logarithmic mean
temperature difference when determining the rate of heat transfer in a heat
exchanger.

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 Problem 1:

Solution:

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Problem 2: Steam in the condenser of a power plant is to be condensed at a temperature of 30
0
C with cooling water from a nearby lake, which enters the tubes of the condenser at 14 0C and
leaves at 22 0C. The surface area of the tubes is 45 m 2, and the overall heat transfer coefficient
is 2100 W/m2.0C. Determine the mass flow rate of the cooling water needed and the rate of
condensation of the steam in the condenser.

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Problem 5: A 2-shell passes and 4-tube passes heat exchanger is used to heat glycerin from 20
0
C to 50 0C by hot water, which enters the thin-walled 2-cm-diameter tubes at 80 0C and leaves
at 40 0C (Fig. 23–21). The total length of the tubes in the heat exchanger is 60 m. The
convection heat transfer coefficient is 25 W/m2.0C on the glycerin (shell) side and 160 W/m2.0C
on the water (tube) side. Determine the rate of heat transfer in the heat exchanger (a) before
any fouling occurs and (b) after fouling with a fouling factor of 0.0006 m 2.0C/W occurs on the
outer surfaces of the tubes.

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 Selection of Heat Exchangers
The proper selection depends on several factors.

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