Heat transfer equipments:

i) Heat exchangers
ii) Evaporators
iii) Dryers
iv) Agitated vessel
Topic Outline
• Types of heat exchangers
• Log Mean Temperature Different (LMTD)
• Correction Factor of LMTD
• Heat Exchanger Effectiveness
• Fouling Factors
• Design of heat exchanger
HEAT EXCHANGERS
• Types of heat exchangers:
1. Double pipe heat exchanger
2. Shell and tube exchanger
3. Plate-type exchanger
4. Crossflow exchanger

• The function of a heat exchanger is to increase the temperature

of a cooler fluid and decrease that of a hotter fluid.
1. Double pipe heat exchanger
• The simplest configuration (Fig 1.1)
• One fluid flow through the inside pipe, and the second fluid
flows through the annular space between the outside and the
inside pipe.
• The fluid can be in co-current or countercurrent flow.
• Useful for small flow rates and when not more than 100 – 150
ft2 of surface is required.
Fig. 1.1 Double pipe heat exchanger
2. Shell and Tube Exchanger
• The most important type of exchanger in use in oil
refineries and larger chemical processes and is suited for
higher-pressure applications.

• Useful for larger flow rates as compared to double pipe heat

exchanger.

• The simplest configuration: 1-1 counterflow exchanger (one

shell pass and one tube pass) – refer to Figure 1.2.

• consists of a shell (a large pressure vessel) with a bundle of

tubes inside it.

• One fluid runs through the tubes, and another fluid flows
over the tubes (through the shell) to transfer heat between
the two fluids.
Fig 1.2 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 counterflow across
the outside the tubes in the shell side.
• Cross-baffles – increase the shell side heat transfer coefficient
Fig 1.3 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
counterflow to the hot shell-side fluid
• In the second pass of the tube side, the cold fluid flows in parallel
(co-current)
Fig 1.4 Shell and tube heat exchanger
(2 shell pass and 4 tube passes (2-4 exchanger))
Fig. 1.5 Shell and tube heat exchanger
Fig. 1.6 Hellical baffle
3. Plate heat exchanger
• Use metal plates to transfer heat between two fluids
• Consist of many corrugated stainless steel sheets separated by
polymer gaskets and clamped in a steel frame.
• The corrugation induce turbulence for improve heat transfer
• The space between plates is equal to the depth of the corrugations
(2 - 5 mm)
• The plates are compressed in a rigid frame to create an
arrangement of parallel flow channels with alternating hot and
cold fluids.
• Major advantage over a conventional heat exchanger in that the
fluids are exposed to a much larger surface area because the fluids
spread out over the plates.
Fig. 1.6 Plate heat exchanger
4. Cross-flow exchanger

Fig. 1.7 Cross-flow heat exchangers: (a) one fluid mixed (gas)
and one fluid unmixed; (b) both fluids unmixed.
• A common device used to heat or cool a gas such as air
• One of the fluids, which is a liquid, flows inside through the tubes,
and the exterior gas flows across the tube bundle by forced or
sometimes natural convection.
• The fluid inside the tubes is considered to be unmixed, since it is
confined and cannot mix with any other stream.
• The gas flow outside the tubes is mixed, since it can move about
freely between the tubes, and there will be a tendency for the gas
temperature to equalize in the direction normal to the flow.
• For the unmixed fluid inside the tubes, there will be a
temperature gradient both parallel and normal to the direction of
flow.

• A second type of cross-flow heat exchanger shown in Fig. 1.7(b)

is typically used in air- conditioning and space-heating
applications.
•In this type the gas flows across a finned-tube bundle and is
unmixed, since it is confined in separate flow channels between
the fins as it passes over the tubes. The fluid in the tubes is
unmixed.
Log Mean Temperature Difference (LMTD)
Correlation Factors
•For counter-current flow, LMTD for 1-1 exchanger with one shell pass and
one tube pass is given by:
ΔT1 ΔT2
T1  T2
Tlm  T1
 T1  ----------------- Eq. (1) T2
ln  t1
 T2 
t2
Where:
ΔTlm = log mean temperature difference
ΔT1 = T1 - t1 Temperature cross

ΔT2 = T2 – t2
T1 = inlet shell-side fluid temperature
T2 = outlet shell-side fluid temperature
t1 = outlet tube-side temperature
t2 = inlet tube-side temperature
•For co-current flow, LMTD for 1-1 exchanger with one shell pass and one tube
pass is given by:

T1  T2 ΔT1 ΔT2

Tlm 
 T1  ----------------- Eq. (2) T1
ln 
 T2 
T2
Where:
ΔTlm = log mean temperature difference t2
t1
ΔT1 = T1 - t1
ΔT2 = T2 - t2 Temperature cross
T1 = inlet shell-side fluid temperature
T2 = outlet shell-side fluid temperature
t1 = inlet tube-side temperature
t2 = outlet tube-side temperature
Exercise 1

A reaction mixture having a cpm = 2.85 kJ/kg.K is flowing

at a rate of 7260 kg/h and is to be cooled from 377.6 K to
344.3 K. Cooling water at 288.8 K is available and the
flow rate is 4536 kg/h. The overall Uo is 653 W/m2.K.
a) For counterflow, calculate the outlet water temperature
and the area Ao of the exchanger.
b) Repeat for cocurrent flow
Correction of LMTD in Multipass
Exchanger
• Multipass exchangers have more tube passes than shell passes.
• The LMTD as given in Eq (1 & 2) does not apply in this case
and it is customary to define a correction factor, FT.
• The relationship between LMTD and FT is define as below:
Tm  FT Tlm ---------------- Eq. (3)

Tm
Where is define as the correct mean temperature drop.
• The general equation for heat transfer across surface of an
exchanger is:
q  U i Ai Tm  U o Ao Tm ----------------- Eq. (4)
• Figure 4.9-4 (Geankoplis, 4th ed.) shows the correction factor to
LMTD for:
a) 1-2 and 1-4 exchangers
b) 2-4 exchangers
• Two dimensionless ratios are used as follows:

Thi  Tho Tco  Tci

Z Y ----------------- Eq. (5 & 6)
Tco  Tci Thi  Tci
• Using the nomenclature of Eqs. (5 & 6), the of Eq. (1) can be
written as:

Tlm 
Thi  Tco   Tho  Tci  ---------------- Eq. (7)
 Thi  Tco 
ln 
 Tho  Tci 
Figure 4.9-4(a) Correction factor to LMTD for 1-2 and 1-4
exchangers (Geankoplis, 4th ed.)
Figure 4.9-4(b) Correction factor to LMTD for 2-4
exchangers (Geankoplis, 4th ed.)
Example 1 Temperature Correction Factor for a Heat
Exchanger
A 1-2 heat exchanger containing one shell pass and two tube passes
heats 2.52 kg/s of water from 21.1 to 54.4 0C by using hot water
under pressure entering at 115.6 and leaving at 48.9 0C. The outside
surface area of the tubes in the exchanger is Ao = 9.30 m2.

a) Calculate the mean temperature different ΔTm in the exchanger

and the overall heat transfer coefficient Uo.
b) For the same temperatures but using a 2-4 exchanger, what would
be the ΔTm?

Solution:
The temperatures are as follows:
Thi = 115.6 0C Tho = 48.9 0C Tci = 21.2 0C
Tco = 54.4 0C
Heat balance on the cold water, assume Cpm of water of 4187 J/kg.K
and Tco – Tci = (54.4 – 21.1) 0C = 33.3 0C = 33.3 K

q = mCpm(Tco – Tci) = (2.52)(4187)(54.4 – 21.1) = 348 200 W

The log mean temperature difference using Eq. (1) is

Tlm 
115.6  54.4  48.9  21.1  42.3C  42.3K
 115.6  54.4 
ln 
 48.9  21.1 
Calculate the Z and Y values using Eq (5 & 6)
Thi  Tho 115.6  48.9
Z   2.00
Tco  Tci 54.4  21.1
Tco  Tci 54.4  21.1
Y   0.352
Thi  Tci 115 .6  21.1
From Figure 4.9-4(a), FT = 0.74
Using Eq. (3),

Tm  FT Tm  0.74(42.3)  31.3C  31.3K

Rearranging Eq. (4) to solve for Uo and substituting the known values,
we have
q 348200
Uo    1196 W/m 2 .K (211 bu/h.ft 2 .o F)
Ao Tm (9.30)(31.3)
b) for 2-4 exchanger, refer to Fig. 4.9-4(b), FT = 0.94, Then,

Tm  FT Tlm  0.94(42.3)  39.8C  39.8 K

Hence, in this case the 2-4 exchanger utilizes more of the available
temperature driving force.
Heat Exchanger Effectiveness – NTU Method
•The LMTD is used in equation q  UATlm if the inlet and outlet
temperatures of the two fluids are known and can be determined
by a heat balance.
•The surface area can be determined if U is known.
•However, when the temperature of the fluids leaving the
exchanger are not known, the tedious trial-and-error procedure is
necessary.
•To solve these cases, a method called the heat exchanger
effectiveness is used which does not involve any of the outlet
temperatures.
•The Effectiveness – NTU (Number of Transfer Unit) method is a
procedure for evaluating the performance of heat exchangers if
heat transfer area, A and construction details are known .
•Heat balance for the cold (C ) and hot (H ) fluids is:
q  (mC p ) H (THi  THo )  (mC p ) C (TCi  TCo ) ----------- Eq. (8)

•Calling (mC p ) H  C H
(mC p ) C  CC
, then CH > CC

•Designate CC as Cmin or minimum heat capacity.

•If there is an infinite area available for heat transfer, TCo = THi , the
effectiveness ε is
CH (THi  THo ) Cmax (THi  THo )
  ----------- Eq. (9)
CC (THi  TCi ) Cmin (THi  TCi )

•If the hot fluid

C (is T
T the minimum
Ci ) C fluid,
(T T  T =)T , and
  C Co  max Co HoCi Ci ----------- Eq. (10)
CH (THi  TCi ) Cmin (THi  TCi )
• In both equations the denominators are the same and the
numerator gives the actual heat transfer:
q   Cmin (THi  TCi ) ----------- Eq. (11)

• Note that Eq. (11) uses only inlet temperatures.

• For the case of a single-pass, counterflow exchanger, combining
Eqs (9 & 10):
CH (THi  THo ) C (T  T )
  C Co Ci ----------- Eq. (12)
Cmin (THi  TCi ) Cmin (THi  TCi )

• We consider first the case when the cold fluid is the minimum
fluid. Using the present nomenclature,

q  CC TCo  TCi   UA
THo  TCi   THi  TCo 
----------- Eq. (13)
 THo  TCi 
ln  
T 
 Hi Co T 
 •Combining Eq. (8) with the left side of Eq. (12) and solving for
THi. 1
THi  TCi  (TCo  TCi ) ----------- Eq. (14)

•Subtracting TCo from both sides,
1 1 
THi  TCo  TCi  TCo  (TCo  TCi )    1(TCo  TCi ) ----------- Eq. (15)
  

•From Eq. (8) for Cmin = CC and Cmax = CH , ----------- Eq. (16)
Cmin
THo  THi  (TCo  TCi )
Cmax

•This can be rearranged to give the following:

Cmin ----------- Eq. (17)
THo  TCi  THi  TCi  (TCo  TCi )
Cmax
•Substituting Eq. (14) into Eq. (17),
1 Cmin
THo  TCi  TCo  TCi   (TCo  TCi ) ----------- Eq. (18)
 Cmax
•Finally, substituting Eq. (15) and Eq. (18) into Eq. (13), rearranging,
taking the antilog of both sides, and solving for ε,

 UA  Cmin 
1  exp  1  
 Cmin  Cmax  ----------- Eq. (19)

Cmin  UA  Cmin 
1 exp  1  
Cmax  Cmin  Cmax 

•We define NTU as the number of transfer unit as follows:

UA ----------- Eq. (20)

NTU 
Cmin
•The same results would have been obtained if CH = Cmin
•For parallel flow we obtain:

 UA  Cmin 
1  exp  1  
 Cmin  Cmax  ----------- Eq. (21)

C
1  min
Cmax

•Figure 4.9-7 (Geankoplis, 4th ed.) shows the heat exchanger

effectiveness, ε for
a)counterflow exchanger – using Eq. (19)
b)parallel flow exchanger – using Eq. (21)
Figure 4.9-7 Heat exchanger effectiveness, ε:
a)counterflow exchanger; b)parallel flow
exchanger (Geankoplis, 4th ed.)
Example 2 Effectiveness of heat exchanger

Water flowing at a rate of 0.667 kg/s enters a countercurrent

heat exchanger at 308 K and is heated by an oil stream entering
at 383 K at a rate of 2.85 kg/s (cp = 1.89 kJ/kg.K). The overall
U = 300 W/m2.K and the area A = 15.0 m2. Calculate the heat
transfer rate and the exit water temperature.

Solution
Assuming that the exit water temperature is about 370 K,
the cp for water at an average temperature of (308 + 370)/2 =
339 K is 4.192 kJ/kg.K (Appendix A.2).

Then (mcp)H = CH = 2.85(1.89 x 103) = 5387 W/K and

(mcp)C = CC = 0.667(4.192 x 103) = 2796 W/K = Cmin.

Since CC is the minimum, Cmin /Cmax = 2796 / 5387 = 0.519.

Using Eq. (20), NTU = UA/Cmin = 300 (15.0)/2796 = 1.607

Using Fig. 4.9-7(a) for a counterflow exchanger, ε = 0.71.

Substituting into Eq. (11)

q = ε Cmin (THi – TCi) = 0.71 (2796)(383 – 308) = 148 900 W

Using Eq. (8), q = 128 900 = 2796 (TCo – 308)

Solving TCo = 361.3 K
Fouling Factors and Typical Overall U Values
• After a period of operation, the heat transfer surface for a heat
exchanger may become coated with various deposits present in the
flow system, dirt, soot or the surface may become corroded as a
result of the interaction between the fluids and the material used
for construction of the heat exchanger.
• Biological growth such as algae can occur with cooling water in
the biological industries.
• These deposits offer additional resistance to the flow of heat and
reduce the overall heat transfer coefficient U.
• To avoid or lessen these fouling problems, chemical inhibitors are
often added to minimize corrosion, salt deposition and algae
growth.
• It is necessary to oversize an exchanger to allow for the reduction
in performance during operation.
•The effect of fouling is allowed for in design by including the
resistance of the fouling on the inside and outside of the tube in Eq.
(22).
1
Ui 
1 1 ro  ri Ai Ai Ai ----------- Eq. (22)
   
hi hdi k A AA lm Ao ho Ao hdo
Where:
hdi = fouling coefficient for inside of the tube (W/m2.K)
hdo = fouling coefficient for outside of the tube (W/m2.K)

•Fouling coefficients or fouling factors must be obtained

experimentally by determining the value of U for both clean and
dirty conditions in the heat exchanger. The fouling factor, Rf is
define as:
1 1
Rf   ----------- Eq. (23)
U dirty U clean
•Typical Fouling Coefficients is shown in Table 1 and the typical
values of overall heat transfer coefficients are given in Table 2.

Table 1 Typical Fouling Coefficients

hd hd
(W/m2.K) (btu/h.ft2.0F)

Distilled and seawater 11350 2000

City water 5680 1000
Muddy water 1990-2840 350-500
Gases 2840 500
Vaporizing liquids 2840 500
Vegetable and gas oils 1990 350
Table 2 Typical Values of Overall Heat Transfer
Coefficient in Shell and Tube Exchanger
U U
(W/m2.K) (btu/h.ft2.0F)

Water to water 1140 – 1700 200 – 300

Water to brine 570 – 1140 100 – 200
Water to organic liquids 570 – 1140 100 – 200
Water to condensing steam 1420 – 2270 250 – 400
Water to gasoline 340 – 570 60 – 100
Water to gas oil 140 – 340 25 – 60
Water to vegetable oil 110 – 285 20 – 50
Gas oil to gas oil 110 – 285 20 – 50
Steam to boiling water 1420 – 2270 250 – 400
Water to air (finned tube) 110 – 230 20 – 40
Light organics to light organics 230 – 425 40 – 75
Heavy organics to heavy organics 55 - 230 10 – 40
Design of a Shell and Tube Exchangers
Example 3

Design an exchanger to sub-cool condensate from a

methanol condenser from 950C to 400C. Flow rate of
methanol 100,000 kg/h. Brackish water will be used as the coolant
with a temperature rise from 250C to 400C. The U for Brackish
water is 600 W/m2.0C

Solution
Heat capacity of methanol, cp = 2.84 kJ/kg0C
100,000
Heat load   2.8495  40   4340 kW
3600

Heat water capacity, cp = 4.2 kJ/kg0C

 4340
Cooling water flow   68.9 kg/s
4.2(40  25)

Tlm 
95  40  40  25  31C
 95  40 
ln 
 40  25 
Use one shell pass and two tube passes,
Thi  Tho 95  40
Z   3.67
Tco  Tci 40  25

Tco  Tci 40  25
Y   0.21
Thi  Tci 95  25

From Figure 4.9-4(a), FT = 0.85

Tm  FT Tm  0.85(31)  26C
Given, U = 600 W/m2.0C
Provisional area, A  q 4340  103
  278 m 2
UTm (600)(26)
Choose 20 mm o.d., 16 mm i.d., 4.83 m long tubes (3/4 inch x 16
ft), cupro-nickel.

Area of one tube  2jL  DL   (20  10 m)(4.83 m)  0.303 m

3 2

provisional area 278 m 2

Number of tubes, Nt   2
 918
area of one tube 0.303 m

As the shell-side fluid is relatively clean, use 1.25 triangular pitch.

(The constants, K1 = 0.249 and n1 = 2.207)
 1 / n1 1 / 2.207
 Nt   918 
Bundle diameter, Db  d o    20    826 mm
 K1   0.249 

Use a split-ring floating head type.

The bundle diametrical clearance = 68 mm
Hence, shell diameter, Ds = 826 + 68 = 894 mm.