Thermal Unit Operation

(ChEg3115)
Lecture 2- Heat exchanger

Instructor: Mr. Tesfa Nega (M.Sc.)

By- Tesfa Nega (M.Sc.)

• Heat Exchanger (HXs)

• Classification of Heat exchanger

• Selection of Heat Exchanger

• Selected type of heat exchanger

• Types of flow

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 Review

𝑑𝑇
𝑄𝑥 = −𝑘𝐴 𝑄 = ℎ𝑐𝐴(𝑇𝑤 − 𝑇∞)
𝑑𝑥

Conduction, convection, and radiation heat transfer modes

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 Terminology
 Heater are primarily to heat process fluids, and steam is employed for this purpose,
although in oil refinery hot recirculated oil serves the same purpose.

 Coolers are employed to cool process fluids, water being the main cooling medium.

 Condensers are coolers whose primary purpose is the removal of latent heat instead of
sensible heat.

 Re-boiler supplies the heat requirements of a distillation process as latent heat.

 Evaporators are employed for the concentration of a solution by the evaporation of water.

 If any fluid is vaporized besides water, the unit is a vaporizer.

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 Heat Exchanger
What is heat exchanger?
 A heat exchanger is a device that is used to transfer thermal energy (enthalpy)
 between two or more fluids,
 between a solid surface and a fluid, or
 between solid particulates and a fluid, at different temperatures and in thermal
contact.
 In heat exchangers, there are usually no external heat and work interactions.
 A typical heat exchanger involves both conduction and convection heat transfers.

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 Heat Exchanger
 In most of the cases the heat exchangers operate in a steady state, hence the concept of
thermal resistance and overall heat transfer coefficient can be used very conveniently.

 Heat exchangers (HX) facilitate the exchange of heat transfer (Q).

 There are three requirements for HX:

 There should be two streams: stream 1 (S1) and stream 2 (S2)

 There should be temperature difference between the two streams: T1 and T2

 There should be no mixing

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 Heat Exchanger
Heat exchanger can be classified according to
A. Construction
 Tubular heat exchangers—double pipe, shell and tube, coiled tube
 Plate heat exchangers (PHEs)—gasketed, brazed, welded, spiral, panel coil, lamella
 Extended surface heat exchangers—tube-fin, plate-fin
 Regenerators—fixed matrix, rotary matrix

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 Heat Exchanger
B. Classification according to transfer Process
 Indirect contact type
 direct transfer type, storage type, fluidized bed
 Direct contact type—cooling tower and scrubbers
 the two fluids are not separated by a wall and come into direct contact, exchange heat,
and are then separated.
 the process of heat transfer is also accompanied by mass transfer.
 (a) immiscible fluid exchanger, (b) gas–liquid exchanger,
 and (c) liquid–vapor exchanger.

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 Heat Exchanger
C. Classification according to surface Compactness
 Compact heat exchangers are important when there are restrictions on the size and weight
of exchangers.
 The area density, β, is the ratio of heat transfer area A to its volume V (>700m2/m3).
 A compact heat exchanger employs a compact surface on one or more sides of a two-fluid
or a multifluid heat exchanger.
 higher thermal effectiveness than shell and tube exchangers (95% vs. the 60%–80%
typical for STHEs)
 More applicable in energy-intensive industries

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 Heat Exchanger
D. Classification according to flow arrangement
 Parallel flow
 Counter flow
 Cross flow
 The choice of a particular flow arrangement is dependent upon
 the required exchanger effectiveness, fluid flow paths,
 packaging envelope, allowable thermal stresses,
 temperature levels, and other design criteria.

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 Heat Exchanger
Parallel flow Exchanger
 This arrangement has the lowest exchanger effectiveness among the single-pass exchangers
for the same flow rates, capacity rate (mass × specific heat) ratio, and surface area.
 In heating very viscous fluids, parallel flow provides for rapid heating. (b) where the more
moderate mean metal temperatures of the tube walls are required, and (c) where the
improvements in heat transfer rates compensate for the lower LMTD.

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 Heat Exchanger
Counter flow Exchanger
 the two fluids flow parallel to each other but in opposite directions,

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 Heat Exchanger
Counter flow Exchanger
 the two fluids flow normal to each other.
 Important types of flow arrangement combinations for a single-pass crossflow
exchanger include the following:
 Both fluids unmixed
 One fluid unmixed and the other fluid mixed
 Both fluids mixed

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 Heat Exchanger
E. Classification according to Pass arrangements
 These are either single pass or multi-pass.
 A fluid is considered to have made one pass if it flows through a section of the heat
exchanger through its full length once.
 In a multi-pass arrangement, a fluid is reversed and flows through the flow length two or
more times.
 As the number of passes increases, the overall direction of the two fluids approaches that of
a pure counter flow exchanger.
 The multi-pass arrangements are possible with compact, shell and tube, and plate
exchangers.
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 Heat Exchanger
F. Classification according to Phase of fluids
 Gas–Liquid: The heat transfer coefficient on the air side will be lower than that on the liquid
side.
Fins will be generally used on the outside of the tubes to enhance the heat transfer rate.
 Liquid–Liquid
 Gas–Gas
 The size of the gas–gas exchanger will be much larger, because the convective heat transfer
coefficient on the gas side is low compared to the liquid side

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 Heat Exchanger
G. Classification according to heat transfer mechanisms
 The basic heat transfer mechanisms employed for heat transfer from one fluid to the other are
 single-phase convection, forced or free,
 two-phase convection (condensation or evaporation) by forced or free convection, and
 combined convection and radiation.
 Based on the phase change mechanisms, the heat exchangers are classified as (1) condensers
and (2) evaporators.

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 Heat Exchanger
SELECTION OF HEAT EXCHANGERS
 Selection is the process in which the designer selects a particular type of heat exchanger for
a given application from a variety of heat exchangers.
 Selection criteria are many, but primary criteria are type of fluids to be handled, operating
pressures and temperatures, heat duty, and cost.
 The fluids involved in heat transfer can be characterized by temperature, pressure, phase,
physical properties, toxicity, corrosivity, and fouling tendency.

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 Heat Exchanger
 When selecting a heat exchanger for a given duty, the following points must be considered:
 Materials of construction
 Operating pressure and temperature, temperature program, and temperature driving force
 Flow rates
 Flow arrangements
 Performance parameters—thermal effectiveness and pressure drops

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 Heat Exchanger
 Fouling tendencies
 Types and phases of fluids
 Maintenance, inspection, cleaning, extension, and repair possibilities
 Overall economy
 Fabrication techniques
 Mounting arrangements: horizontal or vertical
 Intended applications

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 Heat Exchanger
REQUIREMENTS OF HEAT EXCHANGERS
 Heat exchangers have to fulfill the following requirements:
 High thermal effectiveness
 Pressure drop as low as possible
 Reliability and life expectancy
 High-quality product and safe operation
 Material compatibility with process fluids
 Convenient size, easy for installation, reliable in use

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 Heat Exchanger
REQUIREMENTS OF HEAT EXCHANGERS
 Easy for maintenance and servicing
 Light in weight but strong in construction to withstand the operational pressures and
vibrations especially heat exchangers for military applications
 Simplicity of manufacture
 Low cost
 Possibility of effecting repair to maintenance problems

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 Types of Heat Exchangers
 Different heat transfer applications require different types of hardware and different
configurations of heat transfer equipment.

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 Types of Heat Exchangers
 Double-Pipe Heat Exchangers

 The simplest type of heat exchanger is called the double-pipe heat exchanger.

 One fluid flows through the smaller pipe while the other fluid flows through the annular
space between the two pipes.

 Double Pipe Hxs are long, even for moderate capacities.

 Unviable to accommodate in an industrial space.

 Two types of flow arrangement

 parallel flow,

 counter flow
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 Types of Heat Exchangers
Compact Heat Exchanger
 Large heat transfer surface area per unit volume.
 Area density b ─ heat transfer surface of a heat exchanger to volume ratio.
 Compact heat exchanger b >700 m2/m3.
 Examples:
– car radiators (b ≈1000 m2/m3),
– glass-ceramic gas turbine heat
exchangers (b ≈6000 m2/m3),
– the regenerator of a Stirling
engine (b ≈15,000 m2/m3), and
– the human lung (b ≈20,000 m2/m3).

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 Types of Heat Exchangers
 Compact heat exchangers are commonly used in
 gas-to-gas and
 gas-to liquid (or liquid-to-gas) heat exchangers.
 Typically cross-flow configuration ─ the two fluids move perpendicular to each other.
 The cross-flow is further classified as
 unmixed flow and
 mixed flow.

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 Types of Heat Exchangers
 Shell-and-Tube Heat Exchanger

 The most common type of heat exchanger in industrial applications.

 The shell and tube exchanger can be reasonably easily cleaned, and those components most
subject to failure - gaskets and tubes – can be easily replaced.

 Large number of tubes are packed in a shell with their axes parallel to that of the shell.

 The other fluid flows outside the tubes through the shell.

 More than 90% of heat exchangers used in industry are of the shell and tube type

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 Types of Heat Exchangers
 They are the first choice because of

 well-established procedures for design and manufacture from a wide variety of

 many years of satisfactory service, and

 availability of codes and standards for design and fabrication.

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Types of Heat Exchangers

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 Types of Heat Exchangers
 Baffles are commonly placed in the shell.

 Divert (direct) the flow across the bundle to obtain a higher heat transfer coefficient.

 Support the tubes for structural rigidity, preventing tube vibration and sagging

 Shell-and-tube heat exchangers are relatively large size and weight.

 Shell-and-tube heat exchangers are further classified according to the number of

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 Types of Heat Exchangers
 Plate and Frame Heat Exchanger
 Consists of a series of plates with corrugated flat flow passages.
 The hot and cold fluids flow in alternate passages
 Well suited for liquid-to-liquid heat exchange applications, provided that the hot
and cold fluid streams are at about the same pressure.

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 Types of Heat Exchangers
 Advantages
 Flexibility: Simple disassembly enables the adaptation of PHEs to new process
requirements by simply adding or removing plates, or rearranging the number of passes.
 Efficient heat transfer: The corrugations of the plates and the small hydraulic diameter
enhance the formation of turbulent flow.
 Low manufacturing cost.
 Ease of inspection and cleaning:
 Disadvantage
 Temperature and pressure limitations:
 High pressure drop: Because of the corrugated plates and the small flow space between
them, the pressure drop due to friction is high, which increases pumping costs.

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