UNIT III

HEAT-EXCHANGE EQUIPMENT
Course material Adapted from:
1. Warren. L, McCabe, Julian ,C. Smith and Peter Harriott, “Unit Operations of
Chemical Engineering”, 7th Edn., McGraw Hill International Edition, NewYork
2005.
2. Holman. J.P., “Heat Transfer” , 9th Edn., Tata McGraw Hill Book Co., New
Delhi, 2008.
3. R.C.Sachdeva, “Fundamentals of Engineering Heat and Mass Transfer”, 4th Edition, New
Age International Publishers,2010
4. http://www.slideshare.net/vatsalpateln/new-shell-tube-heat-exchanger
5. http://www.slideshare.net/rijumoniboro/heat-exchangers-12606868

CONTENTS
Typical heat exchange equipment, counter current and parallel-current flows, enthalpy
balances in: heat exchanges, total condensers. Double pipe exchanger, single-pass 1-1
exchanger, 1-2 parallel-counterflow exchanger, 2-4 exchanger, heat-transfer coefficients in
shell-and-tube exchanger, coefficients for crossflow, correction of LMTD for crossflow.
Condensers: shell-and-tube condensers, kettle-type boilers,
Introduction
In industrial processes heat energy is transferred by a variety of methods, including
conduction in electric resistance heaters; conduction –convection in exchangers, boilers and
condensers; radiation in furnaces and radiant heat dryers; and by special methods such as
dielectric heating
3.1. Types of heat exchangers
(i) Double pipe heat exchanger
(ii) Shell and tube heat exchanger
Single pass : 1-1 heat exchanger
multi pass: 1-2 exchanger, 2-4 exchanger
(iii) Plate type heat exchanger
(iv) Extended surface heat exchanger
(v) Compact heat exchanger

The design and testing of practical heat exchange equipment are based on the general
principles. From the material and energy balances, the required heat transfer rate is

1
calculated. Tubular exchangers are in general designed in accordance with various standards
and codes, such as the standards of the Tubular Exchanger Manufacturers Association
(TEMA) and the American Society of Mechanical Engineers, ASME – API Unfired Pressure
Vessel Code. Standards devised and accepted by TEMA are available covering in detail the
materials, methods of construction, technique of design, and dimensions for exchangers. In
designing an exchanger many decisions must be made to specify the materials of
construction, tube diameter, tube length, baffle spacing, number of passes, and so forth.

Fig.1. Flow pattern

3.2. DOUBLE PIPE HEAT EXCHANGER
It is the simplest type has one tube inside another. The inner tube may have longitudinal fins
on the outside. The simple double pipe exchanger is inadequate for flow rates that cannot
readily be handled in a few tubes.

(a) (b)

Fig.2. Double Pipe Heat Exchanger

2
3.3. SHELL AND TUBE HEAT EXCHANGERS
Tubular heat exchangers are so important and so widely used in the process industries that
their design has been highly developed. Tubular exchangers are in general designed in
accordance with various standards and codes, such as the standards of the Tubular Exchanger
Manufacturers Association (TEMA) and the American Society of Mechanical Engineers,
ASME – API Unfired Pressure Vessel Code. Standards devised and accepted by TEMA are
available covering in detail the materials, methods of construction, technique of design, and
dimensions for exchangers.
Single pass 1-1 exchanger:
The exchanger with one shell side pass and one tube side pass is a 1-1 exchanger. In an
exchanger the shell side and tube side heat transfer coefficients are of comparable
importance. The velocity and turbulence of the shell side liquid are as important as those of
the tube side fluid. To promote crossflow and raise the average velocity of the shell side fluid,
baffles are installed in the shell. Common practice is to cut away a segment having a height
equal to one fourth the inside diameter of the shell. The baffles are perforated to receive the
tubes.
Tubes and tube sheets
Tubes are arranged in a triangular or square layout known as triangular pitch or square pitch.
Pitch is the distance between the centers of adjacent tubes. It should not be less than one-fifth
the diameter of the shell.
Square pitch gives a lower shell side pressure drop than triangular pitch. In triangular pitch
more heat transfer area can be packed into a shell of given diameter than in square pitch.
Tubes in triangular pitch cannot be cleaned by running a brush between the rows. But Square
pitch allows cleaning of the outside of the tubes.
Shell and Baffles
Shell diameters are standardized. The diameter is fixed in accordance with American Society
for Testing and Materials (ASTM) pipe standards. The distance between the baffles is the
baffle pitch or baffle spacing. It should not be less than one fifth the diameter of the shell or
more than the inside diameter of the shell

3
 Fig.3. 1-1 Shell and tube Heat Exchanger

Fig.4. Main Parts of Shell and Tube Heat Exchanger

Fig.5. Tube Layout

4
Multipass Heat Exchangers
The 1-1 exchanger has limitations, because when the tube side flow is divided evenly among
all the tubes, the velocity may be quite low, giving a low heat transfer coefficient. Using
multi pass construction with two, four or more tube passes permits the use of standard length,
while ensuring a high velocity and high tube side coefficient. The disadvantages are that (1)
the construction of the exchanger is slightly more complicated (2) some sections in the
exchanger have parallel flow, which limits the temperature approach and (3) the friction loss
is greatly increased. For example, the average velocity in the tubes of a four pass exchanger is
four times that in a single pass exchanger having the same number and size of tubes and
operated at the same liquid flow rate. An even number of tube side passes are used in
multipass exchangers. The shell side may be either single pass or multi pass.
1-2 Shell and Tube Heat Exchanger
A common construction is the 1-2 shell and tube heat exchanger in which the shell side liquid
flows in single pass and the tube side liquid in two passes. The tube side liquid enters and
leaves through the same head, which is divided by a baffle to separate the entering and
leaving tube side streams. The 1-2 exchanger is arranged so that the cold fluid and the hot
fluid enter at the same end of the exchanger, giving parallel flow in the first tube pass and
counter flow in the second. This permits the closer approach at the exit end of the exchanger
than if the second pass were parallel

Fig.6. 1-2 Shell and Tube Heat Exchanger

5
2-4 Shell and Tube Heat Exchanger
The 1-2 exchanger has an important limitation. Because of the parallel flow pass, the
exchanger is unable to bring the exit temperature of one fluid very near to the entrance
temperature of the other. More common is 2-4 exchanger which has two shell side pass and
four tube side passes. This type of exchanger also gives higher velocities and a larger overall
heat transfer coefficient than 1-2 exchanger having two tube side passes and operating with
the same flow rates.

Fig.7. 2-4 Shell and Tube Heat Exchanger

Temperature patterns in heat exchanger:

(i) Single pass Heat exchanger

(a) (b)
Fig.8. (a) Countercurrent flow (b) Parallel flow

6
(ii) Multipass Heat exchanger

(a) (b)
Fig.9. (a) 1-2 Shell and tube Heat exchanger (b)2-4 shell and tube heat exchanger

Tha, Thb – inlet and outlet temperatures of hot fluid respectively

Tca,Tcb – inlet and outlet temperatures of cold fluid respectively.
Range and approach in heat exchangers:
Range: The change in temperature of the fluid,Tcb-Tca, Thb-Tha, in the heat exchangers is
called the temperature range.
Approach: The point temperature differences, Tha – Tca, Thb – Tcb (or) Thb – Tca, Tha – Tcb are
called the approaches.

LMTD:(Logarithmic mean temperature difference)

The local heat flux is related to the local value of T by the equation
dQ/dA =U T (1)
where, U = overall heat transfer coefficient
To apply this equation to the entire area of a heart exchanger the equation must be integrated.
This can be done formally where certain simplifying assumptions are accepted. The
assumptions are that (i)overall heat transfer coefficient U is constant(ii) the specific heat of
hot and cold fluid are constant (iii) heat exchange with the ambient is negligible (iv) the
flow is steady and either parallel or counter current.
Assumptions (ii) and (iv) imply that if Tc and Th are plotted against Q,as shown in figure.10,
straight lines are obtained. Since Tc and Th vary linearly with Q, T does likewise and
d(T)/dQ, the slope of the graph of T versus Q is constant. Therefore
d (T ) T2  T1
 (2)
dQ Q

7
 Fig.10. Temperature versus heat flow rate in counter current flow
Where T1 and T2 = approaches
Q = rate of heat transfer in entire exchanger
Elimination of dQ from equns (1) and (2) gives
d (T ) T  T1
 2 (3)
U dA T Q

The variables T and A can be separated, and if U is constant, the equation can be integrated
over the limits 0 and A for A and T1 and T2 .

d (T ) U T2  T1 

T2 A

 T
T1

Q 0 dA (4)

T2 UAT2  T1 

ln 
T1 Q

UAT2  T1 
Q  UATL (5)
T2
ln
T1

T2  T1 
Where, T L  (6)
T
ln 2
T1
Equation (6) defines the logarithmic mean temperature difference(LMTD).