CH2035 FOOD ENGINEERING 2 SEMESTER 1, 2024/2025

TUTORIAL 6 - Design of Shell Tube Heat Exchanger

Q1: A long steel pipe with a 5-cm ID and 3.2-mm wall thickness (emissivity ε = 0.8) passes through a large
chamber maintained at 30◦C and atmospheric pressure; 0.6 kg/s of hot water enters one end of the pipe
at 82◦C. If the pipe is 15 m long, the convective heat transfer coefficient, h is 7.27 W/m2.oC.
Calculate the exit water temperature, considering both free convection and radiation heat loss from the
outside of the pipe.

Q2: Hot water at 90◦C flows on the inside of a 2.5-cm-ID steel tube [k = 36 W/m.oC] with 0.8-mm wall thickness
at a velocity of 4 m/s. Palm oil at 20◦C is forced across the tube at a velocity of 7 m/s.
The convective heat transfer coefficient of the fluid in the inner and outer of the pipe is respectively 20 000
W/m2.oC and 1167 W/m2.oC.
Calculate the overall heat-transfer coefficient for this arrangement.

Q3: Air at 2 atm and 200◦C flows inside a 1 inch schedule 80 steel pipe (do = 0.0334 m, di = 0.0243 m) [k = 43
W/m.oC] with h = 65 W/m2 ·◦C. A hot gas with h =180 W/m2 ·◦C flows across the outside of the pipe at 400◦C.
Calculate the overall heat-transfer coefficient.

Q4: A double-pipe heat exchanger is constructed of a copper (k = 380 W/moC)

inner tube of internal diameter Di = 1.2 cm and external diameter Do = 1.6 cm
and an outer tube of diameter 3.0 cm. The convection heat transfer
coefficient is reported to be hi = 700 W/m2.oC on the inner surface of the tube
and ho = 1400 W/m2.oC on its outer surface. For a fouling factor Rf, i = 0.0005
m2.oC/W on the tube side and Rf,o = 0.0002 m2.oC/W on the shell side.
Determine (a) the thermal resistance of the heat exchanger per unit length
and (b) the overall heat transfer coefficients Ui and Uo based on the inner and
outer surface areas of the tube, respectively.

Q5: Water at an average temperature of 110oC and an average velocity of 3.5 m/s flows through a 5-m-long
stainless steel tube (k = 14.2 W/m.oC) in a boiler. The inner and outer diameters of the tube are Di = 1.0 cm
and Do = 1.4 cm, respectively. If the convection heat transfer coefficient at the outer surface of the tube where
boiling is taking place is ho = 8400 W/m2.oC.
It is given that the properties of water at 110°C: v = 0.268 x 10-6 m2/s, k = 0.682 W/m2.K, Pr = 1.58.
Recognize it is a forced fluid flow inside of a pipe for heating, the suitable Nusselt number equation:
Nu = 0.023 Re0.8 Pr0.4
(a) Determine the overall heat transfer coefficient Ui of this boiler based on the inner surface area of the tube.
(b) Assuming a fouling factor, Rf ,i=0.0005m2.oC/W, determine the overall heat transfer coefficient Ui of this
boiler.

Q6: A long thin-walled double-pipe heat exchanger with tube and shell diameters
of 1.0 cm and 2.5 cm, respectively, is used to condense refrigerant-134a by
water at 20oC. The refrigerant flows through the tube, with a convection heat
transfer coefficient of hi = 5000 W/m2.oC. Water flows through the shell at a
rate of 0.3 kg/s.
It is given that the properties of water at 20°C: v = 1.004 x 10-6 m2/s, k = 0.598
W/m2.K, Pr = 7.01.
Recognize it is a forced fluid flow inside of a pipe for heating, the suitable
Nusselt number equation: Nu = 0.023 Re0.8 Pr0.4
Determine the overall heat transfer coefficient of this heat exchanger.

Q7: Hot water at 80°C enters the tube of two shell pass, eight tubes pass heat exchanger at the rate 0.375 kg/s
heating a gas mixture from 20°C. The overall heat transfer coefficient is 155 W/m2.K and the exchanger area
is 10m2. If the water exits at 44°C, determine the exit temperature of the gas mixture and its mass flow rate.
Given that the heat capacity of water and gas mixture (cp) is 4.185 and 5.2 kJ/kg.K, respectively.
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CH2035 FOOD ENGINEERING 2 SEMESTER 1, 2024/2025

Q8: A shell-and-tube heat exchanger with 2-shell passes and 12-tube passes is
used to heat water (cp = 4180 J/kg.oC) in the tubes from 20oC to 70oC at a
rate of 4.5 kg/s. Heat is supplied by hot oil (cp = 2300 J/kg.oC) that enters
the shell side at 170oC at a rate of 10 kg/s. For a tube-side overall heat
transfer coefficient of 350 W/m2.oC, determine the heat transfer surface
area on the tube side.

Q9: During an experiment, a shell-and-tube heat exchanger that is used to transfer heat from a hot-water stream
to a cold-water stream is tested, and the following measurements are taken:
Inlet Outlet Volume flow Mass flow Specific Heat
o o
temperature, C temperature, C rate, L/min rate, kg/s capacity, kJ/kg.oC
Hot-water stream 71.5 58.2 1.05 0.0172 4187
Cold-water stream 19.7 27.8 1.55 0.0258 4180

The heat transfer area is calculated to be 0.0200 m2.

(a) Calculate the rate of heat transfer to the cold water.
(b) Calculate the overall heat transfer coefficient.
(c) Determine if the heat exchanger is truly adiabatic. If not, determine the
fraction of heat loss and calculate the heat transfer efficiency.
(d) Determine the effectiveness and the NTU values of the heat exchanger.

Q10: A thin-walled double-pipe parallel-flow heat exchanger is used to

heat rice bran oil whose specific heat is 1800 J/kg.oC with hot water
(cp = 4180 J/kg. oC). The chemical enters at 20oC at a rate of 3 kg/s,
while the water enters at 110oC at a rate of 2 kg/s. The heat transfer
surface area of the heat exchanger is 7 m2 and the overall heat
transfer coefficient is 1200 W/m2.oC.
Determine the outlet temperatures of the rice bran oil and the water.

Q11: Water (cp = 4180 J/kg.oC) enters the 2.5-cm internal-diameter tube of a
double-pipe counter-flow heat exchanger at 17oC at a rate of 1.8 kg/s.
Water is heated by steam condensing at 120oC (hfg = 2203 kJ/kg) in the
shell. If the overall heat transfer coefficient of the heat exchanger is 700
W/m2.oC, determine the length of the tube required in order to heat the
water to 80oC using (a) the LMTD method and (b) the ε–NTU method.

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CH2035 FOOD ENGINEERING 2 SEMESTER 1, 2024/2025

SUGGESTED SOLUTION:
Q1: Pipe nearly constant temperature:

qconv=hA∆T = h(2∏rL) ∆T,

qrad = σA ε(Ts4- Tsurr4)

qtotal = qconv + qrad = 1005 W + 898 W = 1903 W

qtotal = 1903 = (0.6)(4175)∆Tw
∆Tw = 0.76oC
∆Tw (exit)= 82-0.76 = 81.2oC

Q2: For unit length of the pipe, the thermal resistances:

RTotal = 2.74 x 10-4 + 16.36 x 10-4 + 0.0103 = 0.01221oC/W.m

From UA=1/RTotal,
𝑈𝐴 1
= = 81.9
𝑚 𝑙𝑒𝑛𝑔𝑡ℎ 0.01221

Since Routside is the largest, the overall heat transfer coefficient is based on the outer area:
The outer surface area:

Uo = 81.9/0.0836 = 979.7 W/(m2.oC)

Q3: For 1 m length:

Rcond = ln (ro/ri) / 2∏kL = ln (0.0334 m / 0.0243 m) / [2 (3.142)(43)] = 1.177 x 10-3 oC/W

Q4: The heat transfer coefficients and the fouling factors are constant and uniform.
(a) The total thermal resistance of the heat exchanger per unit length:

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(b) The overall heat transfer coefficient based on the inner and the outer surface areas of the tube per length:

Q5: (a) The Reynolds number:

Re > 10,000. Therefore, the flow is turbulent.

The Nusselt number:

The convective heat transfer coefficient:

The total resistance of this heat exchanger is then determined from:

(b) The thermal resistance of heat exchanger with a fouling factor of Rf ,i = 0.0005m2 . oC/W is determined from:

Q6: The hydraulic diameter for annular space:

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CH2035 FOOD ENGINEERING 2 SEMESTER 1, 2024/2025

The average velocity of water in the tube and the Reynolds number:

The Reynolds number:

Re > 10,000. Therefore, the flow is turbulent.

The Nusselt number:

The convective heat transfer coefficient:

The overall heat transfer coefficient is determined to be:

Q7: The heat capacity rates for water: mcp = 0.375 × 4185 = 1570 W/K
NTU = UA/Cmin = 155 × 10 / 1570 = 0.99

The effectiveness can be obtained:

From Figure 14(d), Cmin/Cmax = 0.25, which validates the initial assumption of the water as minimum fluid

Cmin/Cmax = 0.25, so Cmax = Cair = 6280 W/K

The heat capacity of gas mixture, Cp = 5.2 kJ/kg.K,

Then, the mass flow rate of gas mixture, mg = 6280/5200 = 1.21 kg/s

From (mcp∆T)water = (mcp∆T)gas mixture

0.375 × 4185 x (80 – 44) = 1.21 x 5200 x (Tout - 20)
Tout = 28.98oC

Q8: Assumptions: (i) Steady operating conditions exist. (ii) The heat exchanger is well-insulated so that heat loss
to the surroundings is negligible and thus heat transfer from the hot fluid is equal to the heat transfer to
the cold fluid. (iii) Changes in the kinetic and potential energies of fluid streams are negligible. (iv) There is
no fouling. (v) Fluid properties are constant.

The rate of heat transfer in this heat exchanger is:

The outlet temperature of the oil is determined from:

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The logarithmic mean temperature difference for counterflow arrangement and the correction factor F are:

Then the heat transfer surface area on the tube side becomes:

Q9: Assumptions: (i) Steady operating conditions exist. (ii) Changes in the kinetic and potential energies of fluid
streams are negligible. (iii) Fluid properties are constant.

(a) The rates of heat transfer from the hot water and to the cold water are:

(b) The number of shell and tubes are not specified in the problem. Therefore, the correction factor is
taken to be unity in the following calculations. The logarithmic mean temperature difference and the
overall heat transfer coefficient are:

(Note that the average of two heat transfer rates was used in calculation.)

(c) The fraction of heat loss and the heat transfer efficiency are:

Therefore,

which is the smaller of the two heat capacity rates.

Then the maximum heat transfer rate becomes:

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CH2035 FOOD ENGINEERING 2 SEMESTER 1, 2024/2025

The effectiveness of the heat exchanger is:

The average heat transfer rate was used.

The smaller or greater heat transfer rates was used in calculations.

The NTU of the heat exchanger is determined from:

Q10: Assumptions: (i) Steady operating conditions exist. (ii) The heat exchanger is well-insulated so that heat loss
to the surroundings is negligible and thus heat transfer from the hot fluid is equal to the heat transfer to the
cold fluid. (iii) Changes in the kinetic and potential energies of fluid streams are negligible. (iv) The thickness
of the tube is negligible since tube is thin-walled. (v) The overall heat transfer coefficient is constant and
uniform.

The heat capacity rates of the hot and cold fluids are:

Therefore:

The c = cmin/cmax = 5.40/8.36 = 0.646

Then the maximum heat transfer rate becomes:

The NTU of this heat exchanger is:

Then the effectiveness of this parallel-flow heat exchanger corresponding to c = 0.646 and NTU=1.556 is
determined from:

Then the actual rate of heat transfer rate becomes:

Finally, the outlet temperatures of the cold and hot fluid streams are determined to be:

Q11: Assumptions: (i) Steady operating conditions exist. (ii) The heat exchanger is well-insulated so that heat loss
to the surroundings is negligible and thus heat transfer from the hot fluid is equal to the heat transfer to the

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cold fluid. (iii) Changes in the kinetic and potential energies of fluid streams are negligible. (iv) The overall
heat transfer coefficient is constant and uniform.

(a) The temperature differences between the steam and the water at the two ends of the condenser are:

The logarithmic mean temperature difference is:

The rate of heat transfer is determined from:

The surface area of heat transfer is:

The length of tube required then becomes:

(b) The maximum rate of heat transfer rate is:

Then the effectiveness of this heat exchanger becomes:

The NTU of this heat exchanger is determined using the relation in Table 1 (in lecture notes) to be:

The surface area is:

Finally, the length of tube required is: