Overall Heat Transfer Coefficient

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2 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. 2

3 For tubular heat exchangers we must take into account the conduction resistance in the wall and convection resistances of the fluids at the inner and outer tube surfaces. 1 UA Overall Heat Transfer Coefficient 1 h A i i ln( Do / Di ) 2 kl 1 h A o o The A i is the area of the inner surface of the wall that separates the two fluids, and A o is the area of the outer surface of the wall. In other words, A i and A o are surface areas of the separating wall wetted by the inner and the outer fluids, respectively. When one fluid flows inside a circular tube and the other outside of it, we have: Note that: 1 UA 1 U A i i o A A 1 U A i o o D L i D o L where inner tube surface where outer tube surface 3

4 Overall Heat Transfer Coefficient Then Eq. for the overall heat transfer coefficient simplifies to where U U i U o. hi and ho are the individual convection heat transfer coefficients inside and outside the tube,

5 Overall Heat Transfer Coefficient 5

6 Fouling

7 Fouling The performance of heat exchangers usually deteriorates with time as a result of accumulation of deposits on heat transfer surfaces. The layer of deposits represents additional resistance to heat transfer and causes the rate of heat transfer in a heat exchanger to decrease. The net effect of these accumulations on heat transfer is represented by a Fouling factor, R f. The overall heat transfer coefficient can be written: 1 UA h i 1 A i R " " f i R, ln( Do / Di ) f, o i 2 kl A o A h o 1 A o 7

8 Fouling Some values of fouling factors are given here. More comprehensive tables of fouling factors are available in handbooks. As you would expect, considerable uncertainty exists in these values, and they should be used as a guide in the selection and evaluation of heat exchangers to account for the effects of anticipated fouling on heat transfer. 8

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14 Use of a Correction Factor Multipass and Cross-Flow Heat Exchangers The log mean temperature difference ΔT lm relation developed earlier is limited to parallel-flow and counter-flow heat exchangers only. In such cases, it is convenient to relate the equivalent temperature difference to the log mean temperature difference relation for the counter-flow case as: where F is the correction factor, which depends on the geometry of the heat exchanger and the inlet and outlet temperatures of the hot and cold fluid streams. The ΔT lm,cf is the log mean temperature difference for the case of a counterflow heat exchanger with the same inlet and outlet temperatures and is determined from the above equation, and by taking: ΔT 1 = T h,in T c,out and ΔT 2 = T h,out T c,in as shown in the figure.

15 Multipass and Cross-Flow Heat Exchangers where the subscripts 1 and 2 represent the inlet and outlet, respectively. Note that for a shell-and-tube heat exchanger, T and t represent the shell- and tube-side temperatures, respectively, as shown in the correction factor charts.

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17 Example (3) : Cross Flow Heat exchangers Cross flow heat exchanger Heat Exchangers 17

18 Heat Exchangers 18

19 Example (4) Investigate the heat-transfer performance of the HEX in example 3 if the oil flow rate is reduced in half while the steam flow remains same. Assume U remains constant at 275 W/m 2. C 19

20 Q= mcp (t2 15) = m Cp (130 T1) (a) Q = U A T LMTD F (b) This why there was a need for another easier method Effective-Ntu method 20

21 Multipass and Cross-Flow Heat Exchangers

22 Multipass and Cross-Flow Heat Exchangers FIGURE Correction factor F charts for common shell-and-tube and cross-flow heat exchangers

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33 THE EFFECTIVENESS NTU METHOD Once ΔT lm, the mass flow rates, and the overall heat transfer coefficient (U) are available, the heat transfer surface area of the heat exchanger can be determined from Therefore, the LMTD method is very suitable for determining the size of a heat exchanger to realize prescribed outlet temperatures when the mass flow rates and the inlet and outlet temperatures of the hot and cold fluids are specified. With the LMTD method, the task is to select a heat exchanger that will meet the prescribed heat transfer requirements. The procedure to be followed by the selection process is: 1. Select the type of heat exchanger suitable for the application. 2. Determine any unknown inlet or outlet temperature and the heat transfer rate using an energy balance. 3. Calculate the log mean temperature difference ΔT lm and the correction factor F, if necessary. 4. Obtain (select or calculate) the value of the overall heat transfer coefficient U. 5. Calculate the heat transfer surface area A s.

34 THE EFFECTIVENESS NTU METHOD NTU Number of Transfer Units This method is based on a dimensionless parameter called the heat transfer effectiveness ε, defined as: The actual heat transfer rate in a heat exchanger can be determined from an energy balance on the hot or cold fluids and can be expressed as: To determine the maximum possible heat transfer rate in a heat exchanger, we first recognize that the maximum temperature difference: the maximum possible heat transfer rate in a heat exchanger is: where C min is the smaller of C h =ṁ h C Ph and C C = m C C pc

35 (ε) NTU Number of Transfer Units Consider two counter-flow heat exchangers, one in which the cold fluid has the larger ΔT (smaller m cp) and a second in which the cold fluid has the smaller ΔT (larger m cp): The effectiveness is the ratio of the energy recovered in a HX to that recoverable in an ideal HX. Note that the use of the upper case T in the numerator, in contrast to our normal terminology, does not indicate that the hot fluid temperature change is used here.

36 Example: Double pipe heat exchanger Water at the rate of 68 kg/min is heated from 35 to 75 C by an oil having a specific heat of 1.9 kj/kg. C. The fluids are used in counterflow double pipe heat exchanger, and the oil enters the exchanger at 110 C and leaves at 75 C. The overall heat-transfer coefficient is 320 W/m 2. C. Calculate the heat exchanger area. Solution: The total heat transfer is determined from the energy absorbed by the water. Since all the fluid temperatures are known, the LMTD can be calculated by using the temperature scheme. T lm To Ti ln( T / T ) o i From the expression: 36

37 Continue Example (1) : (1:2) Shell & Tube heat exchanger, knowing that water is in the shell side and oil is in the tube side, recalculate the needed area..?? = (75-110)/(35-110) = = (35-75)/(75-110) = Heat Exchangers 37

38 Example A thin-walled concentric tube heat exchanger of 0.19-m length is to be used to heat deionized water from 40 to 60 C at a flow rate of 5 kg/s. the deionized water flows through the inner tube of 30-mm diameter while hot process water at 95 C flows in the annulus formed with the outer tube of 60- mm diameter. The thermo physical properties of the fluids are: Find: (1) minimum flow rate required for the hot process water, (b) required overall heat transfer coefficient and whether it is possible to accomplish this heating, and (c) for CF arrangements minimum process water flow required and the effectiveness?

39 Assumptions: (1) Negligible heat loss to surroundings. (2) Negligible kinetic and potential energy changes.

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41 Example An automobile radiator may be viewed as a cross-flow heat exchanger with both fluids unmixed. Water, which has flow rate of 0.05kg/s, enters the radiator at 400K and is to leave at 330 K. The water is cooled by air which enters at 0.75kg/s and 300K. If the overall heat transfer coefficient is 200W/m 2.K, what is the required heat transfer surface area? Known: flow rate and inlet temperature for automobile radiator. Overall heat transfer coefficient. Find: Area required to achieve a prescribed outlet temperature. Schematic Assumptions: (1) Negligible heat loss to surroundings and kinetic and potential energy changes, (2) Constant properties.

42 Analysis: The required heat transfer rate is Using the ε-ntu method,

43 Example Water at 225 kg/h is to be heated from 35 to 95 C by means of a concentric tube heat exchanger. Oil at 225kg/h and 210 C, with a specific heat of 2095 J/kg.K, is to be used as the hot fluid, If the overall heat transfer coefficient based on the outer diameter of the inner tube if 550W/m 2.K, determine the length of the exchanger if the outer diameters is 100mm. Known: Concentric tube heat exchanger. Find: Length of the exchanger Schematic Assumptions: (1) Negligible heat loss to surroundings, (2) Negligible kinetic and potential energy changes, (3) Constant properties. The heat rate, q, can be evaluated from an energy balance on the cold fluid:

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45 Example Consider a very long, concentric tube heat exchanger having hot and cold water inlet temperatures of 85 and 15 C. The flow rate of the hot water is twice that of the cold water. Assuming equivalent hot and cold water specifies heats; determine the hot water outlet temperature for the following modes of operation (a) Counter flow, (b) Parallel flow. Known: A very long, concentric tube heat exchanger having hot and cold water inlet temperatures of 85 and 15 C, respectively: flow rate of the hot water is twice that of the cold water. Find: outlet temperatures for counter flow and parallel flow operations. Schematic Assumptions: (1) equivalent hot and cold water specific heats, (2) Negligible Kinetic and potential energy changes, (3) No heat loss to surroundings.

46 Operating in the counter flow mode is: Substituting numerical values:

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51 The determination of requires the availability of the inlet temperature of the hot and cold fluids and their mass flow rates, which are usually specified. Then, once the effectiveness of the heat exchanger is known, the actual heat transfer rate can be determined from: The below Equ developed before in previous lecture for a parallel-flow heat exchanger: can be rearranged as: Also, solving the following Eq. for T h,out Gives:

52 Then: which simplifies to: Eq We now manipulate the definition of effectiveness to obtain: Substituting this result into Eq and solving for e gives the following relation for the effectiveness of a parallel-flow heat exchanger: Taking either C c or C h to be C min (both approaches give the same result), the relation above can be expressed more conveniently as:

53 Effectiveness relations of the heat exchangers typically involve the dimensionless group U As /C min. This quantity is called the number of transfer units NTU and is expressed as: where U is the overall heat transfer coefficient and A s is the heat transfer surface area of the heat exchanger. NTU is a measure of the heat transfer surface area A s. Thus, the larger the NTU, the larger the heat exchanger. In heat exchanger analysis, it is also convenient to define another dimensionless quantity called the capacity ratio c as:

54 Effectiveness relations have been developed for a large number of heat exchangers, and the results are given in the Table below. The effectivenesses of some common types of heat exchangers are also plotted in the becoming figures

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58 Some observations from the effectiveness relations and charts already given: 1. The value of the effectiveness ranges from 0 to 1. It increases rapidly with NTU for small values (up to about NTU 1.5) but rather slowly for larger values. Therefore, the use of a heat exchanger with a large NTU (usually larger than 3) and thus a large size cannot be justified economically, since a large increase in NTU in this case corresponds to a small increase in effectiveness. Thus, a heat exchanger with a very high effectiveness may be highly desirable from a heat transfer point of view but rather undesirable from an economical point of view. 2. For a given NTU and capacity ratio c = C min /C max, the counter-flow heat exchanger has the highest effectiveness, followed closely by the cross-flow heat exchangers with both fluids unmixed. As you might expect, the lowest effectiveness values are encountered in parallel-flow heat exchangers (Fig ).

59 3. The effectiveness of a heat exchanger is independent of the capacity ratio c for NTU values of less than about The value of the capacity ratio c ranges between 0 and 1. For a given NTU, the effectiveness becomes a maximum for c = 0 and a minimum for c =1. The case c = C min /C max 0 corresponds to C max, which is realized during a phase-change process in a condenser or boiler. condenser or boiler. All effectiveness relations in this case reduce to:

60 it can also be determined from the effectiveness NTU method by first evaluating the effectiveness ε from its definition and then the NTU from the appropriate NTU relation mentioned in the following Table.

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66 Number of Transfer Units (NTU) Recall that the energy flow in any HX is described by three equations: Δθ eff The effective temperature difference We may generalize the latter two expressions, using ε-ntu terminology as follows: If we eliminate Q between the HX equation and one of the 1st Law equations This expression may be made non-dimensional by taking the temperatures to one side and the other terms to the other side:

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72 Capacity Ratio, C R The final non-dimensional ratio needed here is the capacity ratio, defined as follows:

73 SELECTION OF HEAT EXCHANGERS Heat exchangers are complicated devices, and the results obtained with the simplified approaches presented above should be used with care. The proper selection depends on several factors: 1. Heat Transfer Rate: A heat exchanger should be capable of transferring heat at the specified rate in order to achieve the desired temperature change of the fluid at the specified mass flow rate. 2. Cost: Budgetary limitations usually play an important role in the selection of heat exchangers, except for some specialized cases where money is no object. 3. Pumping Power: In a heat exchanger, both fluids are usually forced to flow by pumps or fans that consume electrical power. The annual cost of electricity associated with the operation of the pumps and fans can be determined from:

74 4. Size and Weight: SELECTION OF HEAT EXCHANGERS Normally, the smaller and the lighter the heat exchanger, the better it is. 5. Type: The type of heat exchanger to be selected depends primarily on the type of fluids involved, the size and weight limitations, and the presence of any phase change processes. 6. Materials: The materials used in the construction of the heat exchanger may be an important consideration in the selection of heat exchangers. For example, the thermal and structural stress effects need not be considered at pressures below 15 atm or temperatures below 150 C.

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