Course
Packet
LM03-MEFC
01 0702
Learning Module 03
Heat Exchangers
Course Packet 01
Analysis of Heat
Exchangers
Knowledge Area Code : BSME
Course Code : MEFC0702
Learning Module Code : LM03- MEFC0702
Course Packet Code : LM03- MEFC0702-01
Learning Module: Heat Transfer 1
Course
Packet LM02-MEFC
02 0702
Course Packet 01
Course Packet 01
Analysis of Heat Exchangers
Introduction
This course packet introduces the general types of heat exchangers and their analysis
particularly through the log mean temperature method and the use of the overall heat transfer
coefficient for heat exchangers.
Objectives
Solve heat transfer problems in heat exchangers through the log mean temperature method.
Learning Management System
BSME-3A: [Link]
BSME-3B: [Link]
BSME-3C: [Link]
Duration
• Topic 01: Types of Heat Exchangers = 2 hours
• Topic 02: Analysis of Heat Exchangers = 2 hours
Delivery Mode
This course packet should be delivered in synchronous mode.
Assessment with Rubrics
Requirement with Rubrics
An answered activity sheet is required for submission after finishing this course packet.
Criteria Description %
Able to translate the thought of the problem into a
Understanding circuit diagram or any visual drawing that signifies 15%
a student’s understanding of the problem.
Able to establish what is asked in the problem and
Interpretation 25%
apply appropriate mathematical equations/formula.
Able to solve the problem through solutions with
Execution mathematical strategies and have arrived at the 60%
correct answer.
TOTAL 100%
Learning Module: Heat Transfer 2
Course
Packet LM02-MEFC
02 0702
TYPES OF HEAT EXCHANGERS
The simplest type of heat exchanger consists of two concentric pipes of different diameters
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called the double-pipe heat exchanger. One fluid in a double-pipe heat exchanger flows
through the smaller pipe while the other fluid flows through the annular space between the
two pipes.
Two types of flow arrangement are possible in a double-pipe heat exchanger. In parallel flow,
both the hot and cold fluids enter the heat exchanger at the same end and move in the same
direction. In counter flow, the hot and cold fluids enter the heat exchanger at opposite ends
and flow in opposite directions.
Figure 1.1: Two types of double-pipe heat exchangers
Hot fluid in Hot fluid out
Cold fluid in Cold fluid out
Parallel Flow
Hot fluid in Hot fluid out
Cold fluid out Cold fluid in
Counter Flow
Figure 1.2: Two types of double-pipe heat exchanger in terms of temperature change
Temperature Temperature
Hot fluid
Hot fluid
Cold fluid Cold fluid
Parallel Flow Counter Flow
Learning Module: Heat Transfer 3
Course
Packet LM02-MEFC
02 0702
Another type of heat exchanger is the compact heat exchanger where the two fluids usually
move perpendicular to each other called cross-flow. The cross-flow is further classified as
unmixed and mixed flow depending on the flow configuration. The cross-flow is said to be
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unmixed when the plate fins force the fluid to flow through a particular interfin spacing and
prevent it from moving in the transverse direction. The cross-flow is said to be mixed when the
fluid is free to move in the transverse direction.
Figure 1.3: Mixed and unmixed cross-flow heat exchanger
OVERALL HEAT TRANSFER COEFFICIENT
A heat exchanger typically involves two flowing fluids separated by a solid wall. Heat is first
transferred from the hot fluid to the wall by convection, through the wall by conduction, and
from the wall to the cold fluid again by convection. Any radiation effects are usually included
in the convection heat transfer coefficients. The thermal resistance network associated with this
heat transfer process involves two convection and one conduction resistances.
Table 1.1: Total thermal resistance network associated with heat exchangers
total thermal resistance of the heat
R total = R i + R wall + R o R total
exchanger
1 1
1 ln ro ⁄ri 1 , thermal resistance against convection
R total = + + hi Ai ho Ao
hi Ai 2πkl ho Ao
ln ro ⁄ri
thermal resistance against conduction
2πkl
In the analysis of heat exchangers, it is convenient to combine all the thermal resistances in the
path of heat flow from the hot fluid to the cold one into a single resistance, and to express the
rate of heat transfer between the two fluids as a single quantity.
Table 1.2: Rate of heat transfer in heat exchangers in terms of overall heat transfer coefficient
∆T Q̇ rate of heat conduction (W)
Q̇ =
R
∆T temperature difference between the two fluids (°C)
Q̇ = UA∆T R total thermal resistance of the heat exchanger (°C/W)
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A surface area of the heat exchanger (m2)
U overall heat transfer (W/m2-°C)
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The overall heat transfer coefficient ranges from about 10 W/m2·°C for gas-to-gas heat
exchangers to about 10,000 W/m2·°C for heat exchangers that involve phase changes. The
reason is gases having a very low thermal conductivities and phase-change processes involving
very high heat transfer coefficients.
Table 1.3: Representative values of the overall heat transfer coefficients in heat exchangers
Type of heat exchanger U (W/m2·°C)
Water-to-water 850–1700
Water-to-oil 100–350
Water-to-gasoline or kerosene 300-1000
Feedwater heaters 1000-8500
Steam-to-light fuel oil 200-400
Steam-to-heavy fuel oil 50-200
Steam condenser 1000-6000
Freon condenser (water cooled) 300-1000
Ammonia condenser (water cooled) 800-1400
Alcohol condensers (water cooled) 250-700
Gas-to-gas 10-40
Water-to-air in finned tubes (water in tubes) 30-60/400-850
Steam-to-air in finned tubes (steam in tubes) 30-300/400-4000
ANALYSIS OF HEAT EXCHANGERS
Two methods are used in the analysis of heat exchangers. The log mean temperature difference
(or LMTD) method is the method that is best suited to select a heat exchanger that will achieve
a specified temperature change in a fluid stream of known mass flow rate. The effectiveness–
NTU method is for predicting the outlet temperatures of the hot and cold fluid streams in a
specified heat exchanger.
The general considerations for the analysis of heat exchangers are:
1. They operate for long periods of time with no change in their operating conditions or steady-
flow devices.
2. The mass flow rates of each fluid remains constant, and the fluid properties at any inlet or
outlet remain the same.
3. The fluid streams experience little or no change in their velocities and elevations, and the
kinetic and potential energy changes are negligible.
4. The specific heat of a fluid changes with temperature but can be treated as a constant at some
average value.
Learning Module: Heat Transfer 5
Course
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5. Axial heat conduction along the tube is usually insignificant and can be considered
negligible.
6. The outer surface of the heat exchanger is assumed to be perfectly insulated, so that there is
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no heat loss to the surrounding medium, and any heat transfer occurs between the two fluids
only.
The idealizations stated are closely approximated in practice and simplify the analysis of a heat
exchanger with little sacrifice of accuracy. Under these assumptions, the first law of
thermodynamics requires that the rate of heat transfer from the hot fluid be equal to the rate of
heat transfer to the cold one.
Table 1.4: Rate of heat transfer to the cold fluid stream
Q̇ rate of heat transfer to the cold fluid stream (kW)
ṁc mass flow rate of the cold fluid stream (kg/s)
Q̇ = ṁc cpc (Tc,out − Tc,in ) cpc constant specific heat of the cold fluid stream (kJ/kg-°C)
Tc,out temperature at the outlet of the cold fluid stream (°C)
Tc,in temperature at the inlet of the cold fluid stream (°C)
Table 1.5: Rate of heat transfer from the hot fluid stream
Q̇ rate of heat transfer to the hot fluid stream (kW)
ṁc mass flow rate of the hot fluid stream (kg/s)
Q̇ = ṁh cph (Th,in − Th,out ) cpc constant specific heat of the hot fluid stream (kJ/kg-°C)
Tc,out temperature at the outlet of the hot fluid stream (°C)
Tc,in temperature at the inlet of the hot fluid stream (°C)
Two special types of heat exchangers commonly used are condensers and boilers. One of the
fluids in a condenser or a boiler undergoes a phase-change process, and the rate of heat transfer
is expressed as:
Table 1.6: Rate of heat transfer from phase-change processes
Q̇ rate of heat transfer (W)
ṁ rate of evaporation or condensation of the fluid (kg/s)
Q̇ = ṁhfg
enthalpy of vaporization of the fluid at the specified
hfg
temperature or pressure (kJ/kg)
Learning Module: Heat Transfer 6
Course
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02 0702
LOG MEAN TEMPERATURE METHOD
The temperature difference between the hot and cold fluids varies along the heat exchanger,
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and it is convenient to have a mean temperature difference ∆T for use in the relation Q ̇=UA∆T.
The temperature difference which is the suitable form of the average temperature difference
for use in the analysis of heat exchangers can be calculated using the relation:
Table 1.7: Rate of heat transfer from the hot fluid stream
∆Tlm log mean temperature (°C)
∆T1 − ∆T2
∆Tlm = ∆T1 temperature difference between the two fluids at one end (°C)
ln ∆T1 ⁄∆T2
∆T2 temperature difference between the two fluids at the other end (°C)
ΔT1 and ΔT2 represent the temperature difference between the two fluids at the two ends of
the heat exchanger. It makes no difference which end of the heat exchanger is designated as the
inlet or the outlet.
Figure 1.2: Two types of double-pipe heat exchanger in terms of temperature change
Temperature Temperature
Hot fluid
Hot fluid ΔT1
ΔT1
ΔT2
ΔT2
Cold fluid Cold fluid
Parallel Flow Counter Flow
The log mean temperature difference relation is limited to parallel-flow and counter-flow heat
exchangers only. Similar relations are also developed for cross-flow and multipass shell-and-
tube heat exchangers, but the resulting expressions are too complicated because of the complex
flow conditions.
In such cases, it is convenient to relate the equivalent temperature difference to the log mean
temperature difference relation for the counter-flow case. A correction factor which depends
on the geometry of the heat exchanger and the inlet and outlet temperatures of the hot and cold
fluid streams is used in the relation.
Learning Module: Heat Transfer 7
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Table 1.7: Rate of heat transfer from the hot fluid stream
∆Tlm log mean temperature (°C)
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∆Tlm = F∆Tlm,cf F correction factor
∆Tlm,cf log mean temperature for a counter flow case (°C)
Learning Module: Heat Transfer 8
Course
Packet LM02-MEFC
02 0702
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Learning Module: Heat Transfer 9