Date: 06-08-2024

Thermal Equipment Design

ME G536

Module: 2
Classification of Heat Exchangers
Shall &Tube Heat Exchangers
 Classification of Heat Exchangers:
• Classification according to Transfer Process
• Indirect contact type
• Direct transfer type
• Single phase
• Multiphase
• Storage type
• Fluidized Bed
• Direct contact type
Fluidized bed dryer
• Immiscible fluids
• Gas – liquid
• Liquid – vapour
• Classification according to Number of Fluids
• Two – fluids
• Three – fluids
• N – fluids (N > 3)
• Classification according to Surface
Compactness
• Gas –to- fluid
• Compact (β ≥ 700 m2/m3)
• Non compact (β < 700 m2/m3)
• Liquid –to- liquid and phase change
• Compact (β ≥ 400 m2/m3)
• Non compact (β < 400 m2/m3)
 Contd. Figure 4 – Heat Transfer in a Double Pipe Heat Exchanger
•
• Classification according to Construction
• Tubular
• Double-pipe
• Shell-and-tube
• Cross flow to tubes
• Parallel flow to tubes
• Spiral Tube
• Pipe coils
• Plate Type
• PHE (Plate Heat Exchanger)
• Gasket
• Welded
• Brazed
• Spiral
• Plate coil
• Printed Circuit
• Extended Surface
• Plate – fin
• Tube – fin
• Ordinary separating wall
• Heat – pipe wall
• Regenerative
• Rotary
• Fixed – matrix
• Rotary hoods
Contd.
• Classification according to Flow Arrangements
• Single – pass
• Counter flow
• Parallel flow
• Cross flow
• Split-flow
• Divided-flow
• Multi pass
• Extended surface
• Cross- counter flow
• Cross- parallel flow
• Compound flow
• Shell-and-tube
• Parallel counter flow
• m- shell passes
• n- tube passes
• Split- flow
• Divided- flow
• Plate
• Fluid 1 m passes
• Fluid 2 n passes
Contd.

• f) Classification according to Heat Transfer Mechanisms

• Single- phase convection on both sides
• Single- phase convection on one side, two- phase convection on
other side
• Two- phase convection on both sides
• Combined convection and radiative heat transfer
1. PROCESS DESIGN OF SHELL AND TUBE EXCHANGER FOR SINGLE PHASE HEAT
TRANSFER
References: 1. Donald Q.Kern/Allan D. Kraus, Extended Surface Heat
Transfer, McGraw Book Company, 1972.
2. Ho Sung Lee, Thermal Design, John Wiley and Sons, 2010
Heat Exchanger Analysis
• In this analysis basic types of heat exchanger analysis is provided
based on references of Shah and Sekulic [7].
 Contd.
• The heat exchanger effectiveness, ε is defined as
Ch Th −Thout Cc Tcout −Tcin
• ε = Cmin
in
=C (2.1)
Th −Tcin min Th −Tcin
in in
• where Cmin is the smaller of Cc and Ch.
• To define the effectiveness of a heat exchanger, we must first determine the
maximum possible heat transfer rate, qmax , for the exchanger. This heat transfer
rate could, in principle, be achieved in a counterflow heat exchanger (Figure 2.9)
of infinite length. In such an exchanger, one of the fluids would experience the
maximum possible temperature difference, Th,i − Tc,i . To illustrate this point,
consider a situation for which Cc > Ch , in which case, from above Equation,
dTc > dTh . The cold fluid would then experience the larger temperature
change, and since L → ∞, it would be heated to the inlet temperature of the hot
fluid (Tc,o = Th,i ). Accordingly, from Equation 2.1,
• Cc > Ch : qmax = Cc (Th,i − Tc,i ) (2.2)
 Contd.
• Similarly, if 𝑪𝒉 > 𝑪𝒄 , the hot fluid would experience the larger temperature
change and would be cooled to the inlet temperature of the cold fluid (𝑻𝐡,𝒐 =
𝑻𝐜,𝒊 ). From Eqn 2.1, we then obtain
𝑪𝒉 > 𝑪𝒄 : 𝒒𝒎𝒂𝒙 = 𝑪𝒉 (𝑻𝐡,𝒊 − 𝑻𝐜,𝒊 ) (2.3)
• From the foregoing results we are then prompted to write the general
expression
𝒒𝒎𝒂𝒙 = 𝑪𝐦𝐢𝐧 (𝑻𝐡,𝒊 − 𝑻𝐜,𝒊 ) (2.4)
• where 𝑪𝐦𝐢𝐧 is equal to 𝑪𝒄 𝐨𝐫 𝑪𝒉 , whichever is smaller. For prescribed hot and
cold fluid inlet temperatures, Eqn. 2.4 provides the maximum heat transfer
rate that could possibly be delivered by the exchanger. A quick mental exercise
should convince the reader that the maximum possible heat transfer rate is not
equal to 𝑪𝐦𝐚𝐱 (𝑻𝐡,𝒊 − 𝑻𝐜,𝒊 ). If the fluid having the larger heat capacity rate
were to experience the maximum possible temperature change, conservation
of energy in the form as
𝑪𝒄 (𝑻𝐜,𝒐 − 𝑻𝐜,𝒊 ) = 𝑪𝒉 (𝑻𝐡,𝒊 − 𝑻𝐡,𝒐 ) (2.5)
 Contd.
• it would require that the other fluid experience yet a larger temperature
change. For example, if 𝑪𝒎𝒂𝒙 = 𝑪𝒄 and one argues that it is possible for 𝑻𝐜,𝒐
to be equal to 𝑻𝐡,𝒊 , it follows that as
𝑻𝐡,𝒊 − 𝑻𝐡,𝒐 = (𝑪𝒄 /𝑪𝒉 )(𝑻𝐡,𝒊 − 𝑻𝐜,𝒊 ) (2.6)
in which case 𝑻𝐡,𝒊 − 𝑻𝐡,𝒐 > 𝑻𝐡,𝒊 − 𝑻𝐜,𝒊 . Such a condition is clearly
impossible.
• It is now logical to define the effectiveness, ɛ, as the ratio of the actual
heat transfer rate for a heat exchanger to the maximum possible heat transfer
rate:
𝒒
ɛ≡ 𝒒 (2.7)
𝒎𝒂𝒙
• From Eqns. 2.1 and 2.4, it follows that
𝑪𝒉 (𝑻𝐡,𝒊 − 𝑻𝐡,𝒐 )
ɛ = 𝑪 (𝑻 − 𝑻 ) (2.8)
𝐦𝐢𝐧 𝐡,𝒊 𝐜,𝒊
or
𝑪𝒄 (𝑻𝐜,𝒐 = 𝑻𝐜,𝒊 )
ɛ= 𝑪𝐦𝐢𝐧 (𝑻𝐡,𝒊 − 𝑻𝐜,𝒊 )
(2.9)
 Contd.
• By definition the effectiveness, which is dimensionless, must be in the
range 𝟎 ≤ ɛ ≤ 𝟏. It is useful because, if ɛ, 𝑻𝐡,𝒊 , and 𝑻𝐜,𝒊 are known, the
actual heat transfer rate may readily be determined from the expression
𝐪 = ɛ𝑪𝒎𝒊𝒏 (𝑻𝐡,𝒊 − 𝑻𝐜,𝒊 ) (2.10)
• For any heat exchanger it can be shown that Kays and London [5]
𝑪𝒎𝒊𝒏
ɛ=𝐟 𝐍𝐓𝐔, (2.11)
𝑪𝒎𝒂𝒙
• where 𝑪𝒎𝒊𝒏 /𝑪𝒎𝒂𝒙 is equal to 𝑪𝒄 /𝑪𝒉 or 𝑪𝒉 /𝑪𝒄 , depending on the relative
magnitudes of the hot and cold fluid heat capacity rates. The number of
transfer units (NTU) is a dimensionless parameter that is widely used for
heat exchanger analysis and is defined as
𝑼𝑨
𝐍𝐓𝐔 ≡ 𝑪𝒎𝒊𝒏
(2.12)
Use of the Log Mean Temperature Difference

To design or to predict the performance of a heat exchanger, it is essential to relate

the total heat transfer rate to quantities such as the inlet and outlet fluid temperatures, the
overall heat transfer coefficient, and the total surface area for heat transfer. Two such
relations may readily be obtained by applying overall energy balances to the hot and cold
fluids, as shown in Figure 2.10. In particular, if q is the total rate of heat transfer between
the hot and cold fluids and there is negligible heat transfer between the exchanger and its
surroundings, as well as negligible potential and kinetic energy changes, application of
the steady flow energy equation gives
q = mh (ih,i − ih,o ) (2.13a)
and
q = mc (ic,o − ic,i ) (2.13b)

Fig 2.10 :Overall energy balances for the hot and cold fluids of a two-fluid heat
exchanger.
 Contd.
• where i is the fluid enthalpy. The subscripts h and c refer to the hot
and cold fluids, whereas i and o designate the fluid inlet and outlet
conditions. If the fluids are not undergoing a phase change and
constant specific heats are assumed, these expressions reduce to
•
• 𝐪 = 𝒎𝒉 𝒄𝐩,𝒉 (𝑻𝐡,𝒊 − 𝑻𝐡,𝒐 ) (2.14a)
• and
• 𝐪 = 𝒎𝒄 𝒄𝐩,𝒄 (𝑻𝐜,𝒐 − 𝑻𝐜,𝒊 ) (2.14b)
• where the temperatures appearing in the expressions refer to the
mean fluid temperatures at the designated locations. Note that Eqns.
2.13 and 2.14 are independent of the flow arrangement and heat
exchanger type.
 Contd.
• Another useful expression may be obtained by relating the total heat
transfer rate q to the temperature difference ∆𝐓 between the hot and
cold fluids, where
•
• ∆𝐓 ≡ 𝑻𝒉 − 𝑻𝒄 (2.15)
• Such an expression would be an extension of Newton’s law of cooling,
with the overall heat transfer coefficient U used in place of the single
convection coefficient h. However, since ∆𝐓 varies with position in the
heat exchanger, it is necessary to work with a rate equation of the form
•
• 𝐪 = 𝐔𝐀∆𝑻𝒎 (2.16)
• where ∆𝑻𝒎 is an appropriate mean temperature difference. Eqn 2.16 may
be used with Eqns 2.13 and 2.14 to perform a heat exchanger analysis.
Before this can be done, however, the specific form of ∆𝑻𝒎 must be
established.
Contd.
The Parallel-Flow Heat Exchanger:

• The hot and cold fluid temperature distributions associated with a

parallel-flow heat exchanger are shown in Figure 2.11. The temperature
difference ∆𝐓 is initially large but decays with increasing x, approaching
zero asymptotically. It is important to note that, for such an exchanger,
the outlet temperature of the cold fluid never exceeds that of the hot
fluid. In Figure 2.11 the subscripts 1 and 2 designated opposite ends of
the heat exchanger.
• This convection is used for all types of heat exchangers considered.
• For parallel flow, it follows that
𝑻𝐡,𝒊 = 𝑻𝐡,𝟏 , 𝑻𝐡,𝒐 = 𝑻𝐡,𝟐 , 𝑻𝐜,𝐢 = 𝑻𝐜,𝟏 , 𝑻𝐜,𝒐 = 𝑻𝐜,𝟐 .
• The form of ∆𝑻𝒎 may be determined by applying an energy balance to
differential elements in the hot and cold fluids. Each elements id of
length dx and heat transfer surface area dA, as shown in Figure 2.11.
Contd.

Fig 2.11: Temperature Distribution for a Parallel-flow Heat Exchanger

 Contd.
The energy balances and the subsequent analysis are subject to the following
assumptions.
• The heat exchanger is insulated from its surroundings, in which case the
only heat exchange is between the hot and cold fluids.
• Axial conduction along the tubes is negligible.
• Potential and Kinetic energy changes are negligible.
• The fluid specific heats are constant.
• The overall heat transfer coefficient is constant.
• Uniform Flows and Uniform Temperatures across the Heat Exchanger core.

• The specific heats may of course changes as a result of temperature

variations, and the overall heat transfer coefficient may change because of
variations in fluid properties and flow conditions. However, in many
applications such variations are not significant, and it is reasonable to work
with average values of 𝑪𝐩,𝒄 , 𝑪𝐩,𝒉 , and U for the heat exchanger.
 Contd.
• Applying an energy balance to each of the differential elements of Figure 2.11, it follows that

𝐝𝐪 = −𝒎𝒉 𝑪𝐩,𝒉 𝐝𝑻𝒉 ≡ −𝑪𝒉 𝐝𝑻𝒉 (2.17)

and
𝐝𝐪 = 𝒎𝒄 𝑪𝐩,𝒄 𝐝𝑻𝒄 ≡ 𝑪𝒄 𝐝𝑻𝒄 (2.18)
• Where 𝑪𝒉 and 𝑪𝒄 are the hot and cold fluid heat capacity rates, respectively. These
expressions may be integrated across the heat exchanger to obtain the overall energy
balances given by Eqns 2.13b and 2.14b. The heat transfer across the surface area dA may
also be expressed as
𝐝𝐪 = 𝐔 ∆𝐓 𝐝𝐀 (2.19)
• Where ∆𝐓 = 𝑻𝒉 − 𝑻𝒄 is the local temperature difference between the hot and cold fluids.

• To determine the integrated form of Eqn. 2.19, we begin by substituting Eqns. 2.17 and
2.18 into the differential form of Eqn. 2.15
𝐝 ∆𝑻 = 𝐝𝑻𝒉 − 𝒅𝑻𝒄 (2.20)
to obtain
𝟏 𝟏
• 𝐝 ∆𝑻 = −𝐝𝐪 𝑪 + 𝑪 (2.21)
𝒉 𝒄
Contd.
• Substituting for dq from Eqn. 2.19 and integrating across the heat exchanger, we obtain
𝟐 𝒅(∆𝑻) 𝟏 𝟏 𝟐
‫𝟏׬‬ = −𝑼 + ‫𝑨𝒅 𝟏׬‬ (2.22)
∆𝑻 𝑪𝒉 𝑪𝒄
∆𝑻𝟐 𝟏 𝟏
or In = −𝑼𝑨 + (2.23)
∆𝑻𝟏 𝑪𝒉 𝑪𝒄

• Substituting for 𝑪𝒉 and 𝑪𝒄 from Eqns 2.13b and 2.14b, respectively, it follows that
∆𝑻𝟐 𝑻𝒉,𝒊 −𝑻𝒉,𝒐 𝑻𝒄,𝒐 −𝑻𝒄,𝒊
In = −𝑼𝑨 +
∆𝑻𝟏 𝒒 𝒒
𝑼𝑨
=− [ 𝑻𝒉,𝒊 − 𝑻𝒄,𝒊 − 𝑻𝒉,𝒐 − 𝑻𝒄,𝒐 ] (2.24)
𝒒

• Recognizing that, for the parallel-flow heat exchanger of Figure 2.11,

∆𝑻𝟏 = 𝑻𝒉,𝒊 − 𝑻𝒄,𝒊 and ∆𝑻𝟐 = 𝑻𝒉,𝒐 − 𝑻𝒄,𝒐 ,
∆𝑻𝟐 −∆𝑻𝟏
we then obtain 𝒒 = 𝑼𝑨 (2.25)
𝑰𝒏 (∆𝑻𝟐 /∆𝑻𝟏 )

• Comparing the above expression with Eqn. 2.16, we conclude that the appropriate average
temperature difference is a log mean temperature difference, ∆𝑻𝒍𝒎 . Accordingly, we may write
𝒒 = 𝑼𝑨∆𝑻𝒍𝒎 (2.26)
∆𝑻𝟐 −∆𝑻𝟏 ∆𝑻𝟏 −∆𝑻𝟐
where ∆𝑻𝒍𝒎 = = (2.27)
𝑰𝒏 (∆𝑻𝟐 /∆𝑻𝟏 ) 𝑰𝒏 (∆𝑻𝟏 /∆𝑻𝟐 )

• Remember that, for the parallel-flow exchanger,

∆𝑻𝟏 ≡ 𝑻𝒉,𝟏 − 𝑻𝒄,𝟏 = 𝑻𝒉,𝒊 − 𝑻𝒄,𝒊
(2.28)
∆𝑻𝟐 ≡ 𝑻𝒉,𝟐 − 𝑻𝒄,𝟐 = 𝑻𝒉,𝒐 − 𝑻𝒄,𝒐
Contd.
• The Counter Flow Heat Exchanger:
• The hot and cold fluid temperature distributions associated with a counter flow heat
exchanger are shown in Figure 2.9. In contrast to the parallel-flow exchanger, this
configuration provides for heat transfer between the hotter portions of the two fluids
at one end, as well as between the colder portions at the other. For this reason, the
change in the temperature difference, ∆T = Th − Tc , with respect to x is nowhere as
large as it is for the inlet region of the parallel-flow exchanger. Note that the outlet
temperature of the cold fluid may now exceed the outlet temperature of the hot
fluid.
• Eqns. 2.13b and 2.14b apply to any heat exchanger and hence may be used for
the counter flow arrangement. Moreover, from an analysis like that performed in
Section 2.6.1.1, it may be shown that Eqns. 2.25 and 2.26 also apply. However, for the
counter flow exchanger the endpoint temperature differences must now be defined
as
∆T1 ≡ Th,1 − Tc,1 = Th,i − Tc,o
(2.29)
∆T2 ≡ Th,2 − Tc,2 = Th,o − Tc,i
• Note that, for the same inlet and outlet temperatures, the log mean temperature
difference for counter flow exceeds that for parallel flow, ∆Tlm,CF > ∆Tlm,PF . Hence
the surface area required to effect a prescribed heat transfer rate q is smaller for the
counterflow than for the parallel-flow arrangement, assuming the same value of U.
Also note that Tc,o can exceed Th,o for counterflow but not parallel flow.
The Counter Flow Heat Exchanger:
….Contd.
The Effectiveness-NTU Method
• For heat exchanger design problems, the NTU method may be used
by first calculating 𝜀 and (𝐶𝑚𝑖𝑛 /𝐶𝑚𝑎𝑥 ). The appropriate equation (or
chart) may then be used to obtain the NTU value, which in turn may
be used to determine A. For a performance calculation, the NTU and
(𝐶𝑚𝑖𝑛 /𝐶𝑚𝑎𝑥 ) values may be computed and 𝜀 may then be
determined from the appropriate equation (or chart) for a particular
exchanger type. Since 𝑞𝑚𝑎𝑥 may also be computed from Eqn 2.4, it
is a simple matter to determine the actual heat transfer rate from the
requirement that q = ɛ 𝑞𝑚𝑎𝑥 . Both fluid outlet temperatures may then
be determined from Eqns. 2.13b and 2.14b.
• To determine the exit temperatures of the two fluids for a given
exchanger, the LMTD method requires solving two simultaneous
equations for the case of pure parallel flow and counter flow
arrangements and an iterative solution for all other flow
arrangements. This iterative procedure can be avoided by using
effectiveness-NTU method. The limitations of the LMTD method are
illustrated in Example 2.3.
 EXAMPLE
In an oil to water heat exchanger, the oil [Cp = 2000 J/(kg. K)] enters J
the exchanger
at 100℃ with a heat capacity rate of 3700 W/K. Water (Cp = 4190 kg . K) enters the
exchanger at 15℃ with a mass flow rate of 0.6 kg/s. Determine the exit temperatures
of the two fluids for (i) parallel flow arrangement, (ii) counter flow arrangement, and
(iii) one2shell pass arrangement. Assume the total surface area2 of the heat exchanger
is 10 m and the overall heat transfer coefficient is 500 W/(m . K).
• SOLUTION
• Known: Fluid flow rates, inlet temperatures, overall heat transfer coefficients, and
heat transfer area, mass flow rates and specific heats of the two fluids
• Find: Exit temperatures of the two fluids
• Schematic: Shown in each case separately
• Assumptions:
• Negligible heat loss to the surroundings
• Negligible kinetic and potential energy changes
• Constant fluid properties
• Fully developed conditions for both fluids
 Analysis:
• Case (i) Solution for Parallel Flow Arrangement: From Eqn. (2.23) we have
•
1 1
• ∆T2 = ∆T1 exp −UA +
Ch Cc
•
1 1
• or Tho − Tco = Thi − Tci exp −UA − (a)
Ch Cc
•
• From heat balance equation we have
Ch Ch
• Tho + Tco = Thi + Tci (b)
Cc Cc
•
• The RHS of both Equations a and b can be determined from the given information
and hence these two equations can be solved simultaneously for Th,o and Tc,o.
Contd.
• Case (ii) Solution for Counter Flow Arrangement: For this arrangement Eqn. 2.23
reduces to
1 1
• Tho − Tci = Thi − Tco exp −UA − (c)
Ch Cc
•
1 1 1 1
• Tho + exp −UA −C Tco = exp −UA − Thi +Tci (d)
Ch c Ch Cc
•
• Eqn b holds good for counter flow arrangement also. Hence Eqns. b and d can be
solved simultaneously to get Th,o and Tc,o.
• Case (iii) Solution for Cross-flow and Multi pass Arrangements: Unfortunately the
solution for these type of heat exchangers are not as straight forward as the
above two types as the mean temperature difference involves the correction
factor F which requires the knowledge of the exit temperatures. Hence the
problem has to be solved by trial and error method as shown below.
 Contd.
Calculate R. Assume a value for F and read the value of P from the LMTD correction
factor chart for the particular arrangement. Knowing P, calculate Th,o, Tc,o, and Q. Then
calculate ΔTm for counter flow arrangement and check for the assumed value of F by
calculating F from the equation

Q
F = UA (ΔT (d)
m )counter flow

The procedure is repeated until the solution converges. This method for case (iii) is
illustrated by Shah and Sekulic [7] with an example and is reproduced here.

Given: Hot fluid is oil with: Th,i = 100C; Ch = 3700 W/K

Cold fluid is water with: Tc,i = 15C; mc = 0.6 kg/s; Cp,c = 4190 J/(kg K)
U = 500 W/(m2 K); A = 10 m2
 Contd.
• (a)Solution for Parallel flow arrangement: Cc = mc Cp c = 0.6 × 4190 = 2514
W/K
• From Equation a we have
1 1
• Tho − Tco = 100 − 15 exp −500x10 3700
+ 2514
• Or Tho − Tco = 3.01C (i)
• From Equation 2.18b we have
3700 3700
• Tho + Tco = x100 + 15
2514 2514

• or 1.47Tho + Tco = 162.20 (ii)

• Solving for Th,o and Tc,o from Equations i and ii we get
• Th,o = 66.89C, Tc,o = 63.88C, and Q = 3700 × (100 ─ 66.89) = 122,507 W
 Contd.
• (b) Solution for Counter flow arrangement: From Equation d we have
1 1 1 1
• Tho + exp −500x10x − Tco = exp −500x10x − x100 + 15
3700 2514 3700 2514
• or
• Tho + 1.982Tco = 204.20 C (iii)
• Solving for Th,o and Tc,o from Equations ii and iii we get
• Th,o = 57.6C
• Tc,o = 77.47C
• and
• Q = 2514 × (77.47 ─ 15) = 157,050 W
• (c)Solution for one shell pass two tube pass arrangement:
• Trial 1: Assume F = 0.8 (this generally is a minimum value for good design)
T1 − T2 Tco − Tci Ch 3771
• R= = = = = 1.50
t2 − t1 Thi − Tho Cc 2514
• From chart, corresponding to F = 0.8 and R = 1.50, P = 0.40. Hence
t2 −t1
• = 0.40
T1 −t1
Contd.
 Contd.
• t 2 = t1 + 0.40 T1 − t1 = 100 + 0.40 × (15 – 100)
• or
• t2 = 66.0C = Th,o
• Q = 3771 × (100 – 66.0) = 128,214 W
• Hence
Q 128214
• Tco = Tc1 + C = 15 + 2514
= 66.00C
c
100 −66 − (66 −15)
• (ΔTm)counterflow = 100 −66 = 41.93C
ln
(66 −15)
• Hence
Q 128214
• F = UA(ΔT = = 0.612
m )counterflow 500 × 10 × 41.93
• The calculated value of F is about 31% lower than the assumed value. Hence further
iterations have to be carried out. Table 2.1 shows the difference between the
assumed value of F and calculated value in % for first 4 iterations.
Contd.
Table 2.1 Iterative Solution for 1-2 Heat Exchanger of (Incropera et al.[9])

Trial F P Th,o Tc,o F (Calculated) ΔF in %

(Assumed)
1 0.80 0.4052 65.56 65.6 0.6080 +31.58
9
2 0.6080 0.4513 61.64 71.4 0.7701 ─21.05
6
3 0.7701 0.4163 64.61 67.0 0.6435 +19.67
9
4 0.6435 0.4456 62.13 70.7 0.7477 ─13.94
5

It can be seen from the above table that the convergence of the iterations is slow and F
continues to fluctuate, but it will converge. This rating problem can be guaranteed
convergent using the Newton–Raphson method (i.e., the solution of f(x) = 0 where
function f is nonlinear in the present case).
The above example illustrates the limitations of the mean temperature
difference method for solving the rating problem of a given heat exchanger. Though the
method is straight forward for parallel flow and counter flow arrangement, but it requires
solving two simultaneous equations to find T h,o and Tc,o. For cross-flow and multi pass
type heat exchangers, the method involves a trial and error solution wherein the solution
converges very slowly iterating on F. This problem can be solved relatively easily by
effectiveness–NTU method.
 Effectiveness-NTU Relations
• To determine a specific form of the effectiveness-NTU relation, Eqn. 2.24,
consider a parallel-flow heat exchanger for which Cmin = Ch . From Eqn 2.21
we then obtain
Th,i − Th,o
• ɛ= Th,i − Tc,i
(2.30)
• and from Eqns 2.13b and 2.14b it follows that
Cmin mh cp,h Tc,o − Tc,i
• Cmax
= mc cp,c
=T (2.31)
h,i − Th,o
• Now consider Eqn 2.24, which may be expressed as
Th,o − Tc,o UA Cmin
• In Th,i − Tc,i
= −C 1+ Cmax
(2.32)
min
• Or from Eqn. 2.25
Th,o − Tc,o Cmin
• = exp −NTU 1 + (2.33)
Th,i − Tc,i Cmax
 Contd.
• Rearranging the left-hand side of this expression as
Th,o − Tc,o Th,o − Th,i + Th,i − Tc,o
• = (2.34)
T −T h,i c,i T −T h,i c,i
• and substituting for Tc,o from Eqn 2.31, it follows that
Th,o − Tc,o Th,o − Th,i + Th,i − Tc,i − Cmin /Cmax Th,i − Th,o
• = (2.35)
Th,i − Tc,i Th,i − Tc,i
• or from Equation 2.30
Th,o − Tc,o Cmin Cmin
• = −ɛ + 1 − ɛ=1− ɛ 1+
T −T
h,i c,i Cmax Cmax
(2.36)
• Substituting the above expression into Eqn. 2.33 and solving for ɛ, we obtain for the
parallel-flow heat exchanger

1−exp{−NTU[1+(Cmin /Cmax )]}

• ɛ= (2.37)
1+(Cmin /Cmax )
 Contd.
• since precisely the same result may be obtained for Cmin = Cc , Equation
2.37 applies for any parallel-flow heat exchanger, irrespective of whether the
minimum heat capacity rate is associated with the hot or cold fluid.
• Similar expressions have been developed for a variety of heat exchangers,
Kays and London [5], and representative results are summarized in Table 2.2,
where Cr is the capacity ratio Cr ≡ Cmin /Cmax . In deriving eqn 2.41 for a
shell-and-tube heat exchanger with multiple shell passes, it is assumed that
the total NTU is equally distributed between shell passes of the same
arrangement, NTU = n(NTU) 1 . In order to determine ɛ, (NTU) 1 would first
be calculated using the heat transfer area for one shell, ɛ1 would then be
calculated from Eqn. 2.36, and ɛ would finally be calculated from Equation
2.41. Note that for Cr = 0, as in a boiler or condenser, ɛ is given by Eqn. 2.45
for all flow arrangements. Hence, for this special case, it follows that heat
exchanger behaviour is independent of flow arrangement. For the cross-flow
heat exchanger with both fluids unmixed, Eqn. 2.42 is exact only for Cr = 1.
However, it may be used to a good approximation for all 0<Cr ≤1. For Cr =
0, Eqn 2.45 must be used.
 Contd.
Explicit relations as a function of ɛ and Cr are provided in Table 2.3 for NTU.
Note that Eqn. 2.42 may not be manipulated to yield a direct relationship for
NTU as a function of ɛ and Cr , Note also that to determine the NTU for a shell-
and-tube heat exchanger with multiple shell passes, ɛ would first be calculated
for the entire heat exchanger. The variables F and ɛ1 would then be calculated
using Eqns 2.53c and 2.53b, respectively. The parameter E would subsequently
be determined from Equation 2.52 and substituted into Eqn. 2.51 to fond
(NTU)1 . Finally, this result would be multiplied by n to obtain the NTU for the
entire exchanger, as indicated in Eqn 2.53d.
Note that for Cr = 0, all heat exchangers have the same effectiveness, which
may be computed from Eqn 2.56. Moreover, if NTU ≲ 0.25, all heat exchangers
have approximately the same effectiveness, regardless of the value of Cr , and ɛ
may again be computed from Eqn 2.56. More generally, for Cr > 0 and NTU ≳
0.25, the counter flow exchanger is the most effective. For any exchanger,
maximum and minimum values of the effectiveness are associated with Cr = 0
and Cr = 1, respectively.
Contd.
Contd.
Contd.
As noted previously, in the context of cross-flow heat exchangers, the terms mixed and unmixed are
idealizations representing limiting cases of actual flow conditions. That is, most flows are neither completely
mixed nor unmixed, but exhibit partial degrees of mixing. This issue has been addressed by DiGiovanni and
Webb [11], and algebraic expressions have been developed to determine the ε-NTU relationship for arbitrary
values of partial mixing.

We also note that both the LMTD and ε-NTU methods approach heat exchanger analysis from a
global perspective and provide no information concerning conditions within the exchanger. Although flow and
temperature variations within a heat exchanger may be determined using commercial CFD (computational
fluid dynamic) computer codes, simpler numerical procedures may be adopted. Such procedures have been
applied to determine temperature variations in concentric tube and shell-and-tube heat exchangers by Lienhard
[13].
Try these Eq. conversions:
Cross Flow:

1
2. Both fluids mixed, 𝜀 = 𝑁𝑇𝑈 𝑁𝑇𝑈 𝐶∗
+ −1
1−exp(−𝑁𝑇𝑈) 1−exp(−𝑁𝑇𝑈 𝐶∗)

Where Cr or C* = Cmin/Cmax
Shall and Tube Heat Exchangers
Contd.
Contd
Contd.
Contd.
Contd.
Contd.
Contd.
Contd.
Contd.
Shall & Tube HE Process Design
Contd.
Contd.
Tube Layout:
Contd.
Contd.
Contd.
Design Problem:
Contd.
Contd.
Contd.
Contd.
Contd.
Contd.
Contd.
Contd .
Contd.
Contd.
Contd.
Contd.
Contd.
Contd.
Contd.
Contd.
Contd.

Note: This portion completes only Thermal Design, but needs to be carried
out Mechanical Design separately and if required another iteration of
Thermal may be required based on Mechanical Design.
Mechanical Design
Contd.
Contd.
Contd.
Contd.
Contd.
Contd.
Contd.
Contd.
Contd.

2.5
Contd.
Contd.
Contd.
Contd.

Design Components
Contd.
Contd.
Contd.
Contd.
Contd.
Contd.
Contd.
There is a need to calculate volumes of each part and then calculate total weight of Heat Exchanger
 Assignment Problem:
Design a Shall-and-Tube heat exchanger with a fixed tube sheet and one shall and two
tube passes, which has the total tube bundle length as 4+(Last 2 digits of ID x 0.02) m. The oil has
a mass flow rate of 36.3 kg/sec and shall be cooled from 66 oC to 60 oC or lower. The inlet
temperature and mass flow rate of seawater are 32 oC and 18.1 kg/sec respectively. The area
reserve factor is minimum of 20%. The maximum allowable pressure drop on Shall-side is 0.6 bar
with Inlet pressure of 2 bars g and maximum allowable pressure drop on Tube-side is 0.18 bar
with 4 bars g.
The recommended fouling resistances can be used for this design. After the thermal and
pressure drop calculations, subject the heat exchanger for mechanical design and size all
components and estimate the total weight.
Add dirt resistance
values
End