Heat Exchanger

an equipment designed for efficient transfer of heat from one medium to

the other.






Principle: transfer of heat from body at a higher temp. to the one at a
lower temp.

Mechanism of heat transfer:

Heat can transfer between the surface of a solid conductor
and the surrounding medium whenever temperature
gradient exists.
1) Conduction
2) Convection
Natural convection
Forced Convection
3) Radiation
RADIATION
The process that moves heat from a heat source to an
object by means of heat rays without the medium
becoming hot.
Works on the principle that heat moves from a hot surface
to a surface with less heat.
Does not require air movement or anything in between the
source and component. (Like rays of the sun)
CONDUCTION
Heat is transferred through a solid and gets the solid hot.
(molecules get hot than they in turn give motion to nearby
molecules and they get hot too)
Different solids conduct different amounts of heat in a
specific time. (copper vs. glass)
Fouriers Law:
Q=-kA dT
dy
k is thermal conductivity of material
A is the cross-sectional surface area
dT is the temperature difference between the ends
dy is the distance between the ends.


CONVECTION
Occurs only in liquids, gases or vapors
The transfer of heat by the circulation of a liquid or a vapor
(like cooling system)
Heat flows from a hot surface to a surface containing less
heat.
Heat rises. (Like on a stove)
Natural and forced Convection
Natural convection occurs whenever heat flows
between a solid and fluid, or between fluid
layers.
As a result of heat exchange
Change in density of effective fluid layers take
place, which causes upward flow of heated
fluid.
If this motion is associated with heat transfer mechanism
only, then it is called Natural Convection
If this motion is associated by mechanical means such as
pumps, gravity or fans, the movement of the fluid is
enforced.
And in this case, we then speak of Forced convection.
Classification:
1) Parallel Flow: 2) Counter Flow: 3) Cross Flow:


Applications of Heat Exchangers
Heat Exchangers
prevent car engine
overheating and
increase efficiency
Heat exchangers are
used in Industry for
heat transfer
Heat
exchangers are
used in AC and
furnaces
Heat-transfer configurations for bioreactors: (a) jacketed
vessel; (b) external coil; (c) internal helical coil;
(d) internal baffle-type coil; (e) external heat exchanger
Types of Heat Exchangers:
1) Double pipe exchanger:


In this type, the hot and cold fluid streams do not come into
direct contact with each other. They are separated by a
tube wall or flat plate.

Parallel Flow Counterflow
Shell and Tube:






Baffles are used to establish a cross-flow and to induce
turbulent mixing of the shell-side fluid, both of which enhance
convection.
The number of tube and shell passes may be varied, e.g
One Shell Pass and One Tube Pass
One Shell Pass,
Two Tube Passes
Compact Heat Exchangers:
Widely used to achieve large heat rates per unit volume,
particularly when one or both fluids is a gas.
Characterized by large heat transfer surface areas per unit
volume, small flow passages, and laminar flow.
(a) Fin-tube (flat tubes, continuous plate fins)
(b) Fin-tube (circular tubes, continuous plate fins)
(c) Fin-tube (circular tubes, circular fins)
(d) Plate-fin (single pass)
(e) Plate-fin (multipass)
Q hot Q cold
T
h
T
i,wall

T
o,wall

T
c

Region I : Hot Liquid-
Solid Convection
NEWTONS LAW OF
COOLING
( ) A T T h Q
iw h h x
. . =
Region II : Conduction
Across Wall
FOURIERS LAW
T
B
kA
Q
x
A = .
Region III: Solid
Cold Liquid
Convection
NEWTONS LAW OF
CCOLING
( ) A T T h Q
c ow c x
. . =
THERMAL
BOUNDARY LAYER
Energy moves from hot fluid
to a surface by convection,
through the wall by
conduction, and then by
convection from the surface to
the cold fluid.
The temperature gradient is larger at the wall and through
the viscous sub-layer, and small in the turbulent core.





The reason for this is
1) Heat must transfer through the boundary layer by
conduction.
2) Most of the fluid have a low thermal conductivity (k)
3) While in the turbulent core there are a rapid moving
eddies, which are equalizing the temperature.
heating
cooling
Tube
wall

q
x
= hAAT
q
x
= hA(T
w
T)
) ( T T A
B
k
q
w x
=
h
Region I : Hot Liquid
Solid Convection

T
h
T
iw
=
q
x
h
h
.A
i

q
x
= h
hot
. T
h
T
iw
( )
.A
Region II : Conduction
Across Wall
i
o
x
r
r
L k
q
ln
2 . t
=
L k
r
r
q
T T
i
o
x
wall i wall o
t 2 .
ln .
, ,
|
|
.
|

\
|
=
Region III : Solid
Cold Liquid Convection

T
o,wall
T
c
=
q
x
h
c
.A
o
( )
o c wall o c x
A T T h q =
,
+
(
(
(
(
(

+
|
|
.
|

\
|
+ =
o c
i
o
i h
x c h
A h L k
r
r
A h
q T T
.
1
2 .
ln
.
1
t

q
x
=U.A. T
h
T
c
( )
1
1
.
ln .
.

(
(
(
(
(

+
|
|
.
|

\
|
+ =
cold i copper
i
o
o
i hot
o
h r k
r
r
r
r h
r
U
U = The Overall Heat Transfer Coefficient [W/m.K]
3 2 1
R R R
q
T T
x
c h
+ +
=

U =
1
A.ER

r
o
r
i
Design Equation of Heat Exchanger
Energy Balance:
s
in out
out in
w q h m h m
dt
dE
+ |
.
|

\
|
=


.

.
q h m h m
out in
=


.

.
0
0
Control Volume
Cross Section Area
HOT
COLD
Thermal Boundary Layer
Velocity distribution and boundary layer
When fluid flow through a circular tube of uniform cross-
section and fully developed,
The velocity distribution depend on the type of the flow.
In laminar flow the volumetric flowrate is a function of the
radius.
V = u2trdr
r =0
r = D/ 2
}
V = volumetric flowrate
u = average mean velocity
In turbulent flow, there is no such distribution.

The molecule of the flowing fluid which adjacent to the
surface have zero velocity because of mass-attractive
forces. Other fluid particles in the vicinity of this layer,
when attempting to slid over it, are slow down by viscous
forces.

r
Boundary
layer
Calculating U using Log Mean Temperature
cold hot
dq dq dq = =
c h
T T T = A
c h
dT dT T d = A ) (
h
h
p h h
dT C m dq . .

=
c
c
p c c
dT C m dq . .

=
Hot Stream :
Cold Stream:
|
|
.
|

\
|
= A
c
p c
c
h
p h
h
C m
dq
C m
dq
T d
. .
) (
dA T U dq . .A =
|
|
.
|

\
|
+ A = A
c
p c
h
p h
C m C m
dA T U T d
.
1
.
1
. . . ) (
} }
|
|
.
|

\
|
+ =
A
A
A
A
2
1
2
1
.
.
1
.
1
.
) (
A
A
c
p c
h
p h
T
T
dA
C m C m
U
T
T d
( ) ( ) ( ) | |
out
c
in
c
out
h
in
h c h
T T T T
q
A U
T T
q
A U
T
T
= A + A =
|
|
.
|

\
|
A
A . . .
ln
1
2
} } |
|
.
|

\
|
A
+
A
=
A
A
A
A
2
1
2
1
. .
) (
A
A
c
c
h
h
T
T
dA
q
T
q
T
U
T
T d
|
|
.
|

\
|
A
A
A A
=
1
2
1 2
ln
.
T
T
T T
A U q
Log Mean Temperature
CON CURRENT FLOW
|
|
.
|

\
|
A
A
A A
= A
1
2
1 2
ln
T
T
T T
T
Ln
7 3 1
T T T T T
in
c
in
h
= = A
10 6 2
T T T T T
out
c
out
h
= = A
COUNTER CURRENT FLOW


10 6 2
T T T T T
in
c
out
h
= = A
7 3 1
T T T T T
out
c
in
h
= = A
( ) ( )
Ln
c
p c
Ln
h
p h
T A
T T C m
T A
T T C m
U
A

=
A

=
.
. .
.
. .
10 7 6 3

T 1
T 2
T 4 T 5
T 3
T 7 T 8 T 9
T 10
T 6
Co un t e r - C u r re n t F l ow
T 1
T 2
T 4 T 5
T 6
T 3
T 7
T 8 T 9
T 10
P ara ll e l Fl ow
Log Mean Temperature evaluation
T
1

A
1 2
T
2

T
3

T
6

T
4

T
6

T
7

T
8

T
9

T
10

Wall
T 1
T 2
A
A
1 2
T
1

A
1 2
T
2

T
3

T
6

T
4

T
6

T
7
T
8

T
9

T
10

Wall

q = h
h
A
i
AT
lm

AT
lm
=
(T
3
T
1
) (T
6
T
2
)
ln
(T
3
T
1
)
(T
6
T
2
)

q = h
c
A
o
AT
lm

AT
lm
=
(T
1
T
7
) (T
2
T
10
)
ln
(T
1
T
7
)
(T
2
T
10
)