What is Heat Exchanger

A heat exchanger is a device used to

transfer heat between two fluids. Heat
exchangers are used in both cooling and
heating processes.

Double pipe Heat Exchanger 1

Double pipe Heat Exchanger 2
 Classifications of Heat Exchangers

There are two classes of heat exchangers

1) Indirect contact Heat Exchangers:
The Heat exchanger in which two fluids are
separated by solid wall are called indirect
contact heat exchangers. In these heat
exchangers two fluids do not mixed with
each others. No contact with each others.
e.g. Double pipe heat exchangers etc.

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 Classifications of Heat Exchangers

There are two classes of heat exchangers

2) Direct contact Heat Exchangers:
The Heat exchanger in which two fluids are
not separated by solid wall are called direct
heat exchangers. In these heat exchangers
two fluids are mixed with each others. There
is direct contact b/t two fluids. E.g. Cooling
Towers.

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Types of indirect contact Heat Exchangers
(H.E.) bases on shape
1) Double pipe/pipe within pipe/Tubular
heat exchanger
2) Shell and tube heat exchangers
a) Fixed tube plate- shell and tube heat
exchangers
b) U-tube -shell and tube heat exchangers
c) Floating heat- Shell and Tube heat
exchangers

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Types of indirect contact Heat Exchangers
(H.E.) bases on shap

3) Scraped surface heat exchangers

4) Gasketed and welded plate heat
exchangers
5) Spiral plate heat exchangers
6) Compact heat exchangers

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Types of indirect contact Heat Exchangers
(H.E.) bases on fluids

 Gas to gas heat exchangers

 Air cooled heat exchangers
 Condensers
 Evaporators

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 Range with respect to hot fluid= ∆T= (Hot fluid in-Hot fluid out)=Th,in-Th,out

For example if hot fluid in is 50oC and hot fluid out is 40oC then
Range w.r.t hot fluid is= ∆T= 50-40=10oC
Range with respect to cold fluid = ∆T= (Cold fluid out –cold fluid in) = T c,out.-Tc,in
For example if cold fluid in is 15oC and cold fluid out is 23oC then
Range w.r.t. cold fluid is = ∆T= 23-15=7oC

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Approach at one end of H.E.= ∆T1= (Hot fluid in-cold fluid out)=Th,in-Tc,out

Approach at other end of H.E. = ∆T2= Hot fluid out –cold fluid in) = Th,out.-Tc,in

For example if cold fluid in is 15oC and cold fluid out is 23oC , similarly hot fluid in is 50oC
And hot fluid out is 40oC then what are the approaches at both ends.
Th,in=50oC, Th,out=40oC Tc,in=15oC, Tc,out=23oC

∆T1= 50-23=27oC
∆T2 = 40-15=25oC

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Approaches are used to find the ∆T for simple average or log mean Temperature
Difference (LMTD)
If (∆T1/ ∆T2 ) ≤2 OR (∆T2 / ∆T1 )≤2 (Note: Large /small)
Then we take simple average of ∆T1 and ∆T2
Temperature difference b/t hot and cold fluids=∆T= (∆T1 + ∆T2)/2
This ∆T will be used in Newton’s law of cooling for heat exchanger design.
e.g. if ∆T1= 50-23=27oC , ∆T2 = 40-15=25oC then we check
(∆T1/ ∆T2 )=27/25=1.08 ≤2
Now we take simple average =∆T= (∆T1 + ∆T2)/2=(27+25)/2= 26oC

If( ∆T1/ ∆T2 )>2 OR (∆T2 / ∆T1 )>2 (Note: Large /small)
Then we calculate LMTD
LMTD= ∆T= [∆T1- ∆T2 ]/ln(∆T1/ ∆T2)
e.g. if ∆T1=28oC , ∆T2 =12oC then we check
(∆T1/ ∆T2 )=28/12=2.333 >2
Now we calculate LMTD
LMTD= ∆T= [∆T1- ∆T2 ]/ln(∆T1/ ∆T2)=[28-12]/ln(28/12)=16/ln(2.33)
LMTD= ∆T=16/ln2.33= 16/.845=18.93 oC 15
Flow passes in Shell and tube heat exchanger

There are two main parts of shell and tube

heat exchanger
1. Shell side
2. Tube side
Therefore both (hot and cold) fluids are flow
in shell side or tube side

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 Flow passes in Shell and tube heat
exchanger
a) 1-1 pass shell and tube heat
exchanger
b) 1-2 pass shell and tube heat
exchanger
c) 2-4 pass shell and tube heat
exchanger

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 Flow passes in Shell and tube heat
exchanger
In flow passes description first digit is
showing shell side flow and second digit is
showing tube side flow. e.g.
1 -1 pass heat exchanger mean one shell
pass and one tube pass similarly
1- 2 pass mean one shell pass and two tube
pass and
2-4 pass mean two shell pass and four tube
pass.
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1-4 pass shell and tube heat exchanger

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 Flow area in heat exchangers
Flow area in heat exchanger mean cross-sectional area
for flow of fluids.
e.g. In double pipe heat exchanger flow area of inner is
cross-sectional area (Ac)of inner pipe.
Formula : Ac= πr2 = (πD2)/4 Note: r=D/2 OR D=2r
r= Radius , D= Diameter
Cross-sectional area of annular space= Cross-sectional
area of outer pipe- Cross-sectional area of inner pipe .

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Flow areas/Cross-sectional (Ac) in
shell and tube heat exchanger
Tube side Flow area/Cross-sectional area
Ac = [Cross-sectional area of one tube]*[Number
of total tubes(n)]
Ac= (πr2 )*(n)=[(πD2/4) )*(n)
Cross-sectional area of shell side= (Cross-
sectional area of shell)-(Cross-sectional area of
all tubes)

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 Heat Transfer area in heat exchangers
Heat Transfer area in heat exchanger mean surface area.
e.g. In double pipe heat exchanger, heat transfer area
mean surface area of inner tube (A s).
Formula : As= (Circumference of inner pipe)*Length of
inner pipe(L)
As= (2πr )*L= (πD)*L Note: r=D/2 OR D=2r
r= Radius of inner pipe , D= Diameter of inner pipe

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 Heat Transfer area in heat exchangers
Heat Transfer area in heat exchanger mean surface area.
e.g. in shell and tube heat exchanger, heat transfer area
mean surface area of all tubes(As).
Formula : As= (Circumference of one tube)*[Length of one
tube(L)]*[Number of tubes(n)]
As= (2πr )*L*n= (πD)*L*n
Note: r=D/2 OR D=2r
r= Radius of one tube , D= Diameter of one tube

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 Problem statement
It is desired to heat 9820lb/hr of cold benzene from
80oC to 120oC using hot toluene which is cooled
from 160oC to 130oC. The diameter of inner pipe is
0.02 m and outer pipe is 0.03 m. The length of both
pipes are 4m. Calculate
a) Rage
b) Approach
c) LMTD
d) Flow area
e) Heat transfer area
 Problem statement
A hot fluid enters a shell and tube heat
exchanger at a temperature 300 oF and is to be
cold to 200oF by a cold fluid entering at 100oF
and heated to 150oF. Consider co-current and
counter current flow configuration. There are 3
tubes with 0.01 m diameter and length of each
tube 4.44m. Calculate
a) Range, b) Approaches c) LMTD
d) Flow area e) heat transfer area
For co-current Flow
 Solution
Given data
Th,in = 300 oF Th,out= 200 oF
Tc,in= 100 oF Tc,out= 150 oF
a) Range with respect to hot fluid
∆T= Hot fluid in –hot fluid out
∆T= 300-200=100 oF
Range with respect to cold fluid
∆T= cold fluid out – clod fluid in
∆T= 150-100 = 50 oF
 Solution

b) Approaches
Approach at one end
∆T1= hot fluid in –cold fluid in
∆T1= 300-100 =200 oF
Approach at other end
∆T2= Hot fluid out-cold fluid out
∆T2= 200-150=50 oF
 Solution

Before calculating LMTD first of all we check the

ratio ∆T1/ ∆T2.
∆T1/ ∆T2 =200/50= 4>2
Now, we calculate LMTD
LMTD= ∆T= (∆T1- ∆T2 )/ln(∆T1/ ∆T2 )
LMTD= ∆T= (200-50)/ln(200/50)=150/ln(4)
LMTD= ∆T=150/1.38=108 oF
For counter current Flow
 Solution
Given data
Th,in = 300 oF Th,out= 200 oF
Tc,in= 100 oF Tc,out= 150 oF
a) Range with respect to hot fluid
∆T= Hot fluid in –hot fluid out
∆T= 300-200=100 oF
Range with respect to cold fluid
∆T= cold fluid out – clod fluid in
∆T= 150-100 = 50 oF
 Solution

b) Approaches
Approach at one end
∆T1= hot fluid in –cold fluid out
∆T1= 300-150 =150 oF
Approach at other end
∆T2= Hot fluid out-cold fluid in
∆T2= 200-100=100 oF
 Solution

Before calculating LMTD first all we check the

ratio ∆T1/ ∆T2.
∆T1/ ∆T2 =150/100= 1.5<2
So, no need for calculating LMTD, Only take
simple average of ∆T1 and ∆T2 .
∆T= (∆T1+ ∆T2 )/2 = (150+100)/2= 250/2= 125 oF
∆T= 125 oF
 Solution

Flow area, and heat transfer area are not

depend on flow configuration. They only
depend on tube diameter, length and number
of tubs.
Tube diameter =D= 0.01 m
Tube radius =r= D/2= 0.01/2= 0.005 m
 Flow area for tube side

Flow area for tube side= Ac= (πr2)*n

Flow area for tube side= Ac = [3.14*(.005)*3
Flow area for tube side= Ac= 0.0002355 m2
 Heat transfer area

Heat transfer area = As= (2πr)*(L)*(n)

As= (2*3.14*.005)*4.44*3
Heat transfer area = As= 0.4182 m2

L= Length of each tube

Note:

n= Number of tubes in shell and tube heat

exchanger
 Assignment#1

Q#1.
while a hot fluid is cooled from 300 oF to 200
o
F in counter flow double pipe heat
exchanger, a cold fluid is heated from 100 oF
to 275 oF.
Calculate LMTD if required other vise take
simple average.
 Assignment#1

Q#2. A cold fluid is heated from 100 oF to 275 oF in

shell and tube heat exchanger by using saturated
steam at 300oF. Calculate LMTD for Co-current
flow and counter current flow.
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