3.

HEAT EXCHANGER DESIGN

3.1 Can you have a cross-flow exchanger in which both flows are mixed? Discuss.

Answer:

Yes, as long as there is a mixing portion in the line of flow like a cross flow cooling tower
illustration below

Crossflow is a design in which the airflow is directed perpendicular to the water flow. Air enters
through one or more vertical faces of the cooling tower to meet the fill material. Water flows
(perpendicular to the air) through the fill by gravity. The air continues through the fill and thus
past the water flow into an open plenum volume. Lastly, a fan forces the moisture-laden air o ut
into the atmosphere.

3.2 Find the appropriate mean radius, r , that will make Q  kAr T ro  ri  , valid for the one
dimensional heat conduction through a thick spherical shell, where Ar   4 r 2 (cf. Example
3.1)
Solution:
1  2 rT 
0
r r 2
 2 rT 
0
r 2
rT 
 C1
r
rT  C1r  C2

1
 3. HEAT EXCHANGER DESIGN

C2
T  C1 
r
At r = ro, T = To
At r = ri, T = Ti

Then,
C2
To  C 1 
ro
C2
Ti  C 1 
ri
Ti  To
1 1
Ti  To  T  C 2   
 ri ro 
T  To ri ro 
C2  i
ro  ri 
C T  To ri To ro  To ri  Ti ri  To ri
C 1  To  2  To  i 
ro ro  ri  ro  ri
T r  Ti ri
C1  o o
ro  ri
T r  T r T  To ri ro 
T oo i i  i
ro  ri ro  ri r
dT T  To ri ro 
 i
dr ro  ri r 2
Q  kA
dT
dr

 k 4 r 2  Tr T rrr r 
i o i o
2
 o i 
k 4 ri ro Ti  To 
Q
ro  ri
k 4 ri ro T
Q
ro  ri
Equating:

kAr T k 4 ri ro T
Q 
ro  ri ro  ri
k 4 r 2 T k 4 ri ro T

ro  ri ro  ri
r  ri ro  Answer.

3.3 Rework Problem 2.14, using the methods of Chapter 3.

Solution:
m a = 0.5 kg/s

2
 3. HEAT EXCHANGER DESIGN

 air At 20 C = 1.205 kg/m3

c pa At 20 C = 1006 J/kg.K
C min  m
 a c pa  (0.5 kg/s)(1006 J/kg.K) = 503 W/K
U = 300 W/m2.K

Equation 3.22:
lim   1  e NTU
Cmax 
UA
NTU 
C min
Q
Tcout  Tcin 
Cc
C c  Cmin = 503 W/K
Tcin = 20 C

Q   Cmin Thin  Tcin 
Thin = 120 C

 
(a) q  U Thin  Tcin = (300 W/m2.K)(120 C – 20 C) = 30,000 W/m2

(b) at x: A = (1 m)(x) = x m2
V = (1 m)(1 m)(x) = x m3

At the entrance:
ma c pa
dT
dt

 UA Thin  Tcin 
dT
Vcpa  qA
dt
dT
 xc pa  qx
dt
dT q 30000
  = 24.75 C/s
dt  c pa 1.205 1006 

(c) x = 2 m


Q   Cmin Thin  Tcin 
UA 300 2
NTU   =1.19284
C min 503
  1  e 1.19284 = 0.69664
Q  0.69664503120  20 = 35,041 W
Q 35041
Tcout  Tcin   20  = 89.7 C
Cc 503

3
 3. HEAT EXCHANGER DESIGN

3.4 2.4 kg/s of a fluid have a specific heat of 0.81 kJ/kg.K enters a counterflow heat exchanger at 0 C
and are heated to 400 C by 2 kg/s of a fluid having a specific heat of 0.96 kJ/kg.K entering the
unit at 700 C. Show that to heat the cooled fluid to 500 C, all other conditions remaining
unchanged, would require the surface area for a heat transfer to be increased by 87.5 %.

Solution:
Tcin = 0 C
Tcout = 400 C
C c = (2.4 kg/s)(0.81 kJ/kg.K) = 1.944 kW/K
Thin = 700 C
C h = (2 kg/s)(0.96 kJ/kg.K) = 1.92 kW/K
 
Q  C c Tcout  Tcin = (1.944 kW/K)(400 – 0 K) = 777.6 kW
Q 777.6
Thout  Thin   700  = 295 C
Ch 1.92
For counterflow heat exchanger

Ta  Thin  Tcout = 700 C – 400 C = 300 C

Tb  Thout  Tcin = 295 C – 0 C = 295 C
Ta  Tb 300  295
LMTD   = 297.5 C
 Ta   300 
ln  ln 
 Tb   295 
Q
A
ULMTD
Assume U is constant or unchanged at any new conditions.

Q 777.6
AU   = 2.6138 kW/K
LMTD 297.5

if Tcout = 500 C

 
Q  C c Tcout  Tcin = (1.944 kW/K)(500 – 0 K) = 972 kW
Q 992
Thout  Thin   700  = 193.75 C
Ch 1.92
Ta  Thin  Tcout = 700 C – 500 C = 200 C
4
 3. HEAT EXCHANGER DESIGN

Tb  Thout  Tcin = 193.75 C – 0 C = 193.75 C

Ta  Tb 200  193.75
LMTD   = 196.86 C
 Ta   200 
ln  ln 
 Tb   193.75 
Q 972
AU   = 4.9375 kW/K
LMTD 196.86

4.9375 2.6138
Percentage Increase = 100% = 88.9 %
2.6138

3.5 A cross-flow heat exchanger with both fluids unmixed is used to heat water (cp = 4.18 kJ/kg.K)
from 40 C to 80 C, flowing at the rate of 1.0 kg/s. What is the overall heat transfer coefficient if
the hot engine oil (cp = 1.9 kJ/kg.K), flowing at the rate of 2.6 kg/s, enters at 100 C? The heat
transfer area is 20 m2. (Note that you can use either an effectiveness or an LMTD method. It
would be wise to use both as check.)

Solution:

Cross-flow heat exchanger: A = 20 m2.

Water: C c  m
 w cw = (1.0 kg/s)(4.18 kJ/kg.K) = 4.18 kW/K
Tcin = 40 C
Tcout = 80 C
Hot Engine Oil: C h  m
 o co = (2.6 kg/s)(1.9 kJ/kg.K) = 4.94 kW/K
Thin = 100 C
Heat Balance:
  
Q  C c Tcout  Tcin  C h Thin  Thout 
4.1880  40  4.94100 Th out

Thout = 66.15 C

Use Effectiveness Method:

Eq. (3.16a)



C c Tcout  Tcin 
4.18 80  40 

C min Thin  Tcin 4.18 100  40 
= 0.667

For cross-flow heat exchanger, both unmixed flow.

Fig. 3.17,  = 0.667
C min C c 4.18
  = 0.85
C max C h 4.94
UA
NTU  = 2.3
C min

5
 3. HEAT EXCHANGER DESIGN

U20
 2.3
4.18
U = 0.48 W/m2.K

Use LMTD Method:

Ta  Tb
LMTD 
 T 
ln a 
 T b 
Ta = 66.15 C – 40 C = 26.15 C
Tb = 100 C – 80 C = 20 C
26.15  20 = 22.94 C
LMTD 
 26.15 
ln 
 20 
Q  UAFLMTD

Fig. 3.14 x, cross-flow heat exchanger, both passes unmixed.

Ttout T tin
P
Tsin  Ttin
Tsin T sout
R
Ttout  Ttin
use,

Tsin =100 C
T sout = 66.15 C
Ttout = 80 C
Ttin = 40 C
100  66.15
R = 0.85
80  40
80  40
P = 0.667
100 40
Then F = 0.81
 
Q  C c Tcout  Tcin  UAFLMTD
4.1880  40  U200.8122.94
U = 0.45 W/m2.K

3.6 Saturated non-oil-bearing steam at 1 atm enters the shell pass of a two-tube-pass shell
condenser with thirty 20 ft tubes in each tube pass. They are made of schedule 160, ¾ in. steel
pipe (nominal diameter). A volume flow rate of 0.01 ft3/s of water entering at 60 F enters each
tube. The condensing heat transfer coefficient is 2000 Btu/h.ft2.F, and we calculate h = 1380
Btu/h.ft2.F for the water in the tubes. Estimate the exit temperature of the water and the mass
rate of condensate.

6
 3. HEAT EXCHANGER DESIGN

Solution:
Properties of water at 60 F (15.56 C).
w = 999 kg/m3 = 62.37 lbm/ft3.
c pw = 4.1887 kJ/kg.K = 1.000 Btu/lbm.F
For 30 tubes,
m w = (0.01 ft3/s)(62.37 lbm/ft3)(30) = 18.711 lbm/s = 67,360 lbm/hr
Tcin = 60 F

Properties of steam at 1 atm (14.696 psia), from steam table of other references.
hfg = 1150.4 Btu/lbm – 180.2 Btu/lbm = 970.2 Btu/lbm
Thin  Thout = 212 F

Properties of Sch. 160 Steel Pipe, ¾ in Nom. Diameter, from other references.

 1 Btu / h. ft.F 
k s = 43 W/m.K   = 24.85 Btu/h.ft.F
 1.7307 W / m.K 
ri = (1/2)(0.612 in) = 0.306 in = 0.0255 ft
ro = (1/2)(1.050 in) = 0.525 in = 0.04375 ft

Table 2.3, non-oil bearing steam

 5.68 W m2K 

R f  0.0001 m2K W   1 Btu hr  ft 2
 F
  0.000568 hr  ft 2  F Btu

 
Based on outside area:
r 
ro ln o 
1 r
 o   ri   1  R
f
Uo ri hi ks ho
hi = 1380 Btu/h.ft.F, ho = 2000 Btu/h.ft.F

 0.04375 
0.04375 ln 
1

0.04375
  0.0255   1  0.000568
Uo 0.02551380  24.85 2000
Uo = 306.6 Btu/h.ft2.F
U A
NTU  o o
C min
Ao  2 roL
L = 30 (20 ft)(2) = 1200 ft
Ao  2 0.043751200 = 330 ft2.
C min  m
 w c pw = (67,360 lbm/h)(1.000 Btu/lbm.F) = 67,360 Btu/h.F
Uo Ao 306.6 330 
NTU   = 1.502
C min 67,360

7
 3. HEAT EXCHANGER DESIGN

  lim   1  e NTU  1  e 1.502 = 0.777

Cmax 

 
Q   Cmin Thin  Tcin = (0.777)(67,360)(212 – 60) = 7,955,486 Btu/h

Exit Temperature of Water

 
Q  C c Tcout  Tcin  m 
 w c pw Tcout  Tcin 

7,955,486  67,360 Tcout  60 
Tcout = 178.1 F

Average water temperature = 0.5(60 + 178.1) = 119 F

Properties of water at 119 F (48.3 C).
w = 988.7 kg/m3 = 61.7 lbm/ft3.
c pw = 4.1815 kJ/kg.K = 0.9986 Btu/lbm.F
For 30 tubes,
m w = (0.01 ft3/s)(61.7 lbm/ft3)(30) = 18.51 lbm/s = 66,636 lbm/hr
Tcin = 60 F

C min  m
 w c pw = (66,636 lbm/h)(0.9986 Btu/lbm.F) = 66,543 Btu/h.F
Uo Ao 306.6 330 
NTU   = 1.520
C min 66 ,543
  lim   1  e NTU  1  e 1.520 = 0.7813
Cmax 

 
Q   Cmin Thin  Tcin = (0.7813)(66,543)(212 – 60) = 7,902,486 Btu/h

Exit Temperature of Water

 
Q  C c Tcout  Tcin  m 
 w c pw Tcout  Tcin 

7,902,486  66,543 Tcout  60 
Tcout = 178.8 F (answer)

Mass flow rate of condensate:

Qm  c h fg
7,902,486  m  c 970.3
m c = 8,145 lbm/h (answer)

3.7 Consider a counterflow heat exchanger that must cool 3000 kg/h of mercury from 150 F to 128
F. The coolant is 100 kg/h of water, supplied at 70 F. If U is 300 W/m2.K, complete the design by
determining reasonable value for the area and the exit-water temperature.

Solution:
Mercury
Thin = 150 F = 65.56 C
Thout = 128 F = 53.33 C
8
 3. HEAT EXCHANGER DESIGN

m m = 3000 kg/h = 0.833333 kg/s

Th (average) = 0.5(65.56 + 53.33) = 59.45 C
c pm @ 60 C, Table A.3, pg.707 = 138.26 J/kg.K

Water
Tcin = 70 F = 21.11 C
m w = 100 kg/h = 0.027778 kg/s
c pw @ 21.11 = 4187.3 J/kg.K

U = 300 W/m2.K

C c  mw c pw = (0.027778)(4183.7) = 116.2 W/K

C h  mm c pm = (0.833333)(138.26) = 115.2 W/K

Tcout  Tcin 
Q
 Tcin 

C h Thin  Thout 
Cc Cc
115.265.56  53.33
Tcout  21.11  = 33.24 C = 91.83 F
116.2
Tc (average) = 0.5(21.11 + 91.83) = 56.47 C
c pw @ 56.47 = 4184.8 J/kg.K
C c  mw c pw = (0.027778)(4184.8) = 116.2 W/K

Effectiveness Method

For counterflow heat exchanger:

  C  
1  exp   1  min NTU 
  C max  

C   C  
1  min exp   1  min NTU 
C max   C max  
C min = 115.2 W/K
C max = 116.2 W/K

Solve for  .
  
Q   Cmin Thin  Tcin  C h Thin  Thout 


C h Thin  Thout 

C min Thin  Tcin 

115.265.56  53.33 = 0.275
115.265.56  21.11

9
 3. HEAT EXCHANGER DESIGN

Then:
  115.2  
1  exp   1  NTU 
  0.275    116.2  
115.2   115.2  
1 exp   1  NTU 
116.2   116.2  
 
0.275 1  0.9914e 0.008606NTU  1  e 0.008606NTU
0.008606NTU
e = 0.996749
NTU = 0.37843

UA 300 A
NTU   = 0.37843
C min 115.2
A = 0.1453 m2. (answer)

Tcout  Tcin 
Q
 Tcin 
 
C h Thin  Thout
Cc Cc
115.265.56  53.33
Tcout  21.11  = 33.24 C = 91.83 F (answer)
116.2

3.8 An automobile air-conditioner gives up 18 kW at 65 km/h if the outside temperature is 35 C. The

refrigerant temperature is constant at 65 C under these conditions, and the air rises 6 C in
temperature as it flows across the heat exchanger tubes. The heat exchanger is of the finned-
tube type shown in Fig. 3.6b, with U  200 W/m2.K. If U ~ (air velocity)0.7 and the mass flow rate
increases directly with the velocity, plot the percentage reduction of heat transfer in the
condenser as a function of air velocity between 15 and 65 km/h.

Solution:
Let C1 and C2 are constant, V = air velocity, km/h.

 a  C 1V
m
U  C2V 0.7
Solving for C2.
U  200  C 2 650.7
C2 = 10.76442

Solving for LMTD.

T  Tb
LMTD  a
 T 
ln a 
 T b 
Ta  Tr  Tcin = 65 C – 35 C = 30 C
Tb  Tr  Tcout
Tcout  Tcin = 6 C

10
 3. HEAT EXCHANGER DESIGN

Tcout = 35 C + 6 C = 41 C
Tb  Tr  Tcout = 65 C – 41 C = 24 C
Ta  Tb 30  24
LMTD   = 26.89 C
 Ta   30 
ln  ln 
 T b   24 
Solving for A.
Q  UALMTD
18,000  200A26.89
A = 3.347 m2.

Solving for ma

Tave = 0.5(35 + 41) = 38 C
c pa = 1007.1 J/kg.K
Qm 
 a c pa Tcout  Tcin 
18,000  m  a 1007.16
m a = 2.979 kg/s
Solving foe C1.
m a  C 1V
2.979  C1 65
C1 = 0.04583

Then at any air velocity:

m a  0.04583V
U  10.76442V 0.7

Solving for NTU.

UA
NTU 
C min
 a c pa  0.04583V 1007   46.15V
C min  m

NTU 
10.76442V 3.347  0.7807
0.7

46.15V V 0.3

Solving for  :
  C max
lim   1  e  NTU


 0.7807 
  1  exp  
 V 0.3 
 
Q   Cmin Thin  Tcin
  0.7807 
Q  1  exp  0.3 
46.15V 65  35
  V 

11
 3. HEAT EXCHANGER DESIGN

  0.7807 
Q  1384.5V 1  exp  0.3 
  V 
Percentage reduction, x, %.
Q  Q   
x 100%  1  1384.5V 1  exp  0.7807
0.3  
100 
Q  18000   V  
   0.7807  
x  100 1  0.07692V 1  exp  0.3  
   V  

Tabulation:

V , km/h x, %
15 66.2
20 58.1
25 50.6
30 43.4
35 36.6
40 30.0
45 23.7
50 17.5
55 11.5
60 5.7
65 0.0

Plot:

3.9 Derive eqn. (3.21).

12
 3. HEAT EXCHANGER DESIGN

Solution:

Eq. (3.21), Counter-flow:

  C  
1  exp   1  min NTU 
  C max  

C   C  
1  min exp   1  min NTU 
C max   C max  

Derivation:

Equation (3.17)
  
Q   Cmin Thin  Tcin = Cc Tcout  Tcin 
Equation (3.18)
UA
NTU 
C min
Equation (3.9)
Ta  1 1 
ln  UA  
 C 
 
  1  c  Tcin  Tcout  Ta
Ch 
 Cc Ch 


 
C
  1  c  
 Tcin  Tcout  Ta
 1
Ch 1 
ln    UA  
Ta  Cc Ch 
Ta  Thin  Tcout from Eq. 3.8 , counterflow.
Then

Ta  Thin  Tcin  Tcout  Tcin 
Q Q
Ta  
 C min C c
Let C c  Cmin , C h  Cmax
Q1   
Ta 
 C min
 C min  Q  
   1     
ln 
C max  C min   1  UA  1  C min 

 Q1     C  C
min  
  max

  C min 
 C      C min 
ln 1  min    1   1  NTU
 C max  1      C max 

13
 3. HEAT EXCHANGER DESIGN

 C min  
  1    1   
ln 
C max     1  C min NTU
 1   C max 
  
 
 C min 
  1
ln
C max    1  C min NTU
 1   C max 
  
 
 
 
ln 1    1  C min NTU
 C min   
   1   C max 
 C max 
1   C  
 exp   1  min NTU 
C min   C max  
  1
C max
C min   C     C  
1     exp   1  min NTU   exp   1  min NTU 
C max   C max     C max  
  C  
1  exp   1  min NTU 
  C max  

C   C  
1  min exp   1  min NTU 
C max   C max  

3.10 Derive the infinite NTU limit of the effectiveness of parallel and counterflow heat exchangers at
several values of Cmin/Cmax. Use common sense and the First Law of Thermodynamics, and refer
to eqn. (3.20) and eqn. (3.21) only to check your results.

Solution:
Eq. (3.20) – Parallel
  C  
1  exp   1  min NTU 
  C max  

C
1  min
C max
Eq. (3.21) – Counterflow

  C  
1  exp   1  min NTU 
  C max  

C   C  
1  min exp   1  min NTU 
C max   C max  
14
 3. HEAT EXCHANGER DESIGN

By energy balance, First Law of Thermodynamics.

Q
Thout  Thin 
Ch
Q
Tcout  Tcin 
Cc

For Parallel Flow:

Thout  Tcout
Then
Q
Tcout  Thin 
Ch
Q
Tcout  Tcin 
Cc
 1 1  Q  C 
Thin  Tcin  Q     1  min 
 Cc Ch  C min  C max 
 C 

Thin  Tcin   Thin  Tcin  1  min 
C max 

1

C
1  min
Cmax
  C  
Check with Eq. (3.20) with 1  exp   1  min NTU  = 0
  C max  
  C  
1  exp   1  min NTU 
  C max   10
 
C C
1  min 1  min
C max C max
1

C
1  min
C max

For Counterflow
Thin  Tcout
  
Q   Cmin Thin  Tcin  C c Tcout  Tcin 
Q   Cmin Thin  Tcin   C T
min hin  Tcin 
 =1

  C  
Check with Eq. (3.21) with 1  exp   1  min NTU  = 0
  C max  

15
 3. HEAT EXCHANGER DESIGN

  C  
1  exp   1  min NTU 
  C max   10
 
C   C   10
1  min exp   1  min NTU 
C max   C max  
 =1

3.11 Derive the equation   NTU, Cmin Cmax  for the heat exchanger depicted in Fig. 3.9.

Solution:
  NTU, Cmin Cmax 

Eq. (3.22), Cmax  

  lim   1  e NTU
C max 
Derivation for Parallel Flow
  C  
1  exp   1  min NTU 
  C max  

C min
1
C max
1  exp 1  0NTU

10
  lim   1  e NTU
C max 
Derivation for Counterflow
  C  
1  exp   1  min NTU 
  C max  

C   C  
1  min exp   1  min NTU 
C max   C max  
1  exp 1  0NTU

1  0exp 1  0NTU
  lim   1  e NTU
C max 

3.12 A single-pass heat exchanger condenses steam at 1 atm on the shell side and heats water from
10 C to 30 C on the tube side with U = 2500 W/m2.K The tubing is thin-walled, 5 cm in diameter,
and 2 m in length. (a) Your boss asks whether the exchanger should be counterflow or parallel
 H2O ; (d)  .
flow. How do you advise her? Evaluate: (b) the LMTD; (c) the m

Solution:

(a) I will advise here that counterflow or parallel flow configuration is irrelevant. The
temperature on the hot side is constant.
(b) For steam, Th = 100 C
16
 3. HEAT EXCHANGER DESIGN

For water, Tcin = 10 C, Tcout = 30 C,

Tc (average) = 0.5(10 + 30) = 20 C
Table A.3. c p = 4184.6 J/kg.K
For tubing, D = 5 cm = 0.05 m, L = 2 m, A = DL
T  Tb
LMTD  a
 T 
ln a 
 T b 
Ta =100 C – 10 C = 90 C
Tb = 100 C – 30 C = 70 C
90  70
LMTD  = 79.58 C
 90 
ln 
 70 

(c) Q  UALMTD  m 
 H2O c p Tcout  Tcin 
2500 0.05279.58  m H O 4184.630  10
2

 H2O = 0.7468 kg/s

m

(d)   lim   1  e NTU

C max 

UA UA 2500  0.052

NTU    = 0.2513
C min m H2O c p 0.7468 4184.6 

  1  e 0.2513 = 0.2222

3.13 Air at 2 kg/s and 27 C and a stream of water at 1.5 kg/s and 60 C each enter a heat exchanger.
Evaluate the exit temperatures if A = 12 m2, U = 185 W/m2.K, and:
a. The exchanger is parallel flow;
b. The exchanger is counterflow;
c. The exchanger is cross-flow, one stream mixed;
d. The exchanger is cross-flow. Neither stream mixed.

Solution:
m a = 2 kg/s
m w = 1.5 kg/s
Tcin = 27 C
Thin = 60 C
A = 12 m2
U = 185 W/m2.K

Specific heat of air at 27 C = cpa = 1007 J/kg.K

17
 3. HEAT EXCHANGER DESIGN

Specific heat of water at 60 C = cpw = 4186.2 J/kg.K

 a cpa = (2 kg/s)(1007 J/kg.K) = 2014 W/K = Cmin

Cc = m
 w cpw = (1.5 kg/s)(4186.2 J/kg.K) = 6279.3 W/K = Cmax
Ch = m

(a) Eq. 3.20 for parallel flow

  C  
1  exp   1  min NTU 
  C max  

C min
1
C max
UA 185 12 
NTU   = 1.1023
C min 2014 
  2014  
1  exp   1  1.1023 
   6279.3   = 0.5806
2014
1
6279.3
 
Q   Cmin Thin  Tcin
Q  0.5806201460  27 = 38,587.8 W

Q 38,587.8
Thout  Thin   60  = 53.86 C
Ch 6279.3
Q 38 ,587.8
Tcout  Tcin   27  = 46.16 C
Cc 2014
Tc (average) = 0.5(27 + 46.16) = 36.58 C
Th (average) = 0.5(60 + 53.86) = 56.93 C

Specific heat of air at 36.58 C = cpa = 1007 J/kg.K

Specific heat of water at 56.93 C = cpw = 4185 J/kg.K

 a cpa = (2 kg/s)(1007 J/kg.K) = 2014 W/K = Cmin

Cc = m
 w cpw = (1.5 kg/s)(4185 J/kg.K) = 6277.5 W/K = Cmax
Ch = m

  C  
1  exp   1  min NTU 
  C max  

C min
1
C max
UA 18512 
NTU   = 1.1023
C min 2014 

18
 3. HEAT EXCHANGER DESIGN

  2014  
1  exp   1  1.1023 
   6277 .5   = 0.5806
2014
1
6277.5

Q   Cmin Thin  Tcin 
Q  0.5806201460  27 = 38,587.8 W

Q 38 ,587.8
Thout  Thin   60  = 53.85 C (answer)
Ch 6277.5
Q 38 ,587.8
Tcout  Tcin   27  = 46.16 C (answer)
Cc 2014

(b) Eq. 3.21 for counterflow

  C  
1  exp   1  min NTU 
  C max  

C   C  
1  min exp   1  min NTU 
C max   C max  
  2014  
1  exp   1  1.1023 
   6279.3   = 0.6213
 2014    2014  
1  exp   1  1.1023 
 6279.3    6279.3  

Q   Cmin Thin  Tcin 
Q  0.6213201460  27 = 41,292.8 W

Q 41,292.8
Thout  Thin   60  = 53.42 C
Ch 6279.3
Q 41,292.8
Tcout  Tcin   27  = 47.50 C
Cc 2014
Tc (average) = 0.5(27 + 47.50) = 37.25 C
Th (average) = 0.5(60 + 53.42) = 56.71 C

Specific heat of air at 37.25 C = cpa = 1007.4 J/kg.K

Specific heat of water at 56.71 C = cpw = 4184.9 J/kg.K

 a cpa = (2 kg/s)(1007.4 J/kg.K) = 2014.8 W/K = Cmin

Cc = m
 w cpw = (1.5 kg/s)(4184.9 J/kg.K) = 6277.4 W/K = Cmax
Ch = m

19
 3. HEAT EXCHANGER DESIGN

  C  
1  exp   1  min NTU 
  C max  

C   C  
1  min exp   1  min NTU 
C max   C max  
UA 18512 
NTU   = 1.1019
C min 2014.8 
  2014.8  
1  exp   1  1.1019 
   6277.4   = 0.6211
 2014.8    2014.8  
1  exp   1  1.1019 
 6277.4    6277.4  

Q   Cmin Thin  Tcin 
Q  0.62112014.860  27 = 41,296.0 W

Q 41,296
Thout  Thin   60  = 53.42 C (answer)
Ch 6277.4
Q 41,296
Tcout  Tcin   27  = 47.50 C (answer)
Cc 2014.8

(c) For cross-flow, one stream mixed, Figure 3.17b

NTU = 1.1023
C mixed C 2014.8
 min  = 0.32
C unmixed C max 6277.4
Then,  = 0.60

Q   Cmin Thin  Tcin 
Q  0.602014.860  27 = 39,893 W

Q 39 ,893
Thout  Thin   60  = 53.65 C (answer)
Ch 6277.4
Q 39 ,893
Tcout  Tcin 
 27  = 46.80 C (answer)
Cc 2014.8
Average temperatures already considered.

(d) For cross-flow, neither stream mixed, Figure 3.17a

NTU = 1.1023
C mixed C 2014.8
 min  = 0.32
C unmixed C max 6277.4
Then,  = 0.60

Q   Cmin Thin  Tcin 
Q  0.602014.860  27 = 39,893 W

20
 3. HEAT EXCHANGER DESIGN

Q 39 ,893
Thout  Thin   60  = 53.65 C (answer)
Ch 6277.4
Q 39 ,893
Tcout  Tcin 
 27  = 46.80 C (answer)
Cc 2014.8
Average temperatures already considered.

3.14 Air at 0.25 kg/s and 0 C enters a cross-flow heat exchanger. It is to be warmed to 20 C by 0.14
kg/s of air at 50 C. The streams are unmixed. As a first step in the design process, plot U against
A and identify the approximate range of area for the heat exchanger.

Solution:

m a1 = 0.25 kg/s
Tcin = 0 C
Tcout = 20 C
m a2 = 0.14 kg/s
Thin = 50 C

Specific heat of air at 10 C (average of 0 C and 20 C) = c pa1 = 1006 J/kg.K

Specific heat of air at 50 C = c pa2 = 1008 J/kg.K

Cc  m
 a1 c pa1 = (0.25 kg/s)(1006 J/kg.K) = 251.5 W/K = Cmax
Ch  m
 a2 c pa2 = (0.14 kg/s)(1008 J/kg.K) = 141.12 W/K = Cmin

    
Q   Cmin Thin  Tcin  C c Tcout  Tcin  C h Thin  Thout 
  
C c Tcout  Tcin  C h Thin  Thout 
251.520  0  141.1250  Th out

Thout = 14.36 C
Th (average) = 0.5(14.36 + 50) = 32.18 C
Specific heat of air at 32.18 C = c pa2 = 1007 J/kg.K
Ch  m
 a2 c pa2 = (0.14 kg/s)(1007 J/kg.K) = 140.98 W/K = Cmin

 CminThin  Tcin   C c Tcout  Tcin 

 140.9850  0  251.520  0
 = 0.7136

Fig. 3.17a, cross-flow unmixed,

C min 140.98
 = 0.56
C max 251.5

21
 3. HEAT EXCHANGER DESIGN

 = 0.7136

Then,

UA
NTU  =2
C min
UA = 2(140.98) = 281.96 W/K

Table 2.2, Typical range of magnitudes of U for Air-to-Air is U = 60 – 550 W/m2.K

Plot:

281.96
At 60 W/m2.K, A = = 4.7 m2
60
281 .96
At 550 W/m2.K, A = = 0.513 m2
550
Range of area = 0.513 m2 to 4.70 m2.

3.15 A particular two shell-pass, four tube-pass heat exchanger uses 20 kg/s of river water at 10 C on
the shell side to cool 8 kg/s of processed water from 80 C to 25 C on the tube side. At what
temperature will the coolant be returned to the river? If U is 800 W/m2.K, how large must the
exchanger be?

Solution:
Shell side:
m r = river water = 20 kg/s
Tsin  Tcin = 10 C
Tube side:
m p = processed water = 8 kg/s

22
 3. HEAT EXCHANGER DESIGN

Ttin  Thin = 80 C
Ttout  Thout = 25 C
Specific heat of water at 52.5 C (average of 80 C and 25 C), c pp = 4183.2 J/kg.K
Specific heat of water at 10 C , c pr = 4196.2 J/kg.K
Cc  m
 r c pr = (20 kg/s)(4196.2 J/kg.K) = 83,924 W/K
Ch  m
 p c pp = (8 kg/s)(4183.2 J/kg.K) = 33,465.6 W/K
Using LMTD Method:

LMTD  in

Th  Tcout  Thout    Tcin 
 Th  Tcout 
ln in 
 Th  Tc 
 out in 
Solving for Tcout ;
  
Q  C h Thin  Thout  C c Tcout  Tcin 
33,465.680  25  83,924Tc out
 10 
Tcout = 31.93 C = Tsout
Tc (average) = 0.5(10 + 31.93) = 21.96 C
Specific heat of water at 21.96 C , c pr = 4183 J/kg.K
Cc  m
 r c pr = (20 kg/s)(4183 J/kg.K) = 83,660 W/K
Using LMTD Method:

LMTD  in

Th  Tcout  Thout    Tcin 
 Th  Tcout 
ln in 
 Th  Tc 
 out in 
Solving for Tcout ;
  
Q  C h Thin  Thout  C c Tcout  Tcin 
33,465.680  25  83,660Tc out

 10
Tcout = 32.0 C = Tsout (answer)

LMTD 
T hin  
 Tcout  Thout  Tcin 
 Th  Tcout 
ln in 
 Th  Tc 
 out in 

80  32  25  10 

LMTD  = 28.4 C
 80  32 
ln 
 25  10 
U = 800 W/m2.K
Tt  Ttin 25  80
P  out  = 0.786
Tsin  Ttin 10  80

23
 3. HEAT EXCHANGER DESIGN

Tsin  Tsout 10  32
R  = 0.40
Ttout  Ttin 25  80

For two shell-pass, four tube-pass heat exchanger, Fig. 3.14b

With P = 0.786, R = 0.4, then F = 0.936


Q  UAFLMTD  C h Thin  Thout 
800A0.93628.4  33,465.680  25
A = 86.552 m2.

3.16 A particular cross-flow process heat exchanger operates with the fluid mixed on one side only.
When it is new, U = 2000 W/m2.K, Tcin = 25 C, Tcout = 80 C, Thin = 160 C and Thout = 70 C. After 6
months of operation, the plant manager reports that the hot fluid is only being cooled to 90 C
and that he is suffering a 30% reduction in total heat transfer. What is the fouling resistance
after 6 months of use? (Assume no reduction of cold-side flow rate by fouling.)
Solution:
U = 2000 W/m2.K
Tcin = 25 C
Tcout = 80 C
Thin = 160 C
Thout = 70 C
Use LMTD Method:

LMTD1  in
  
Th  Tcout  Thout  Tcin


160  80   70  25 = 60.83 C
 Th  Tcout   160  80 
ln in  ln 
 Th  Tc   70  25 
 out in 

Q  UAFLMTD
Q1  U1 AF1 LMTD1 
Tt  Ttin 70  160
P  out  = 0.67
Tsin  Ttin 25  160
Tsin  Tsout 25  80
R  = 0.61
Ttout  Ttin 70  160
Fig. 3.14d, cross-flow, fluid mixed on one side only, F1 = 0.75
Q1  U1 A0.7560.83  45.62U1 A
with Q2  1  0.30Q1  0.70Q1
Thout = 90 C
T 
cout   
 Tcin  0.7 Tcout  Tcin
T 
cout  25  0.780  25
Tcout  63.5 C

24
 3. HEAT EXCHANGER DESIGN

LMTD1 
T hin  
 Tcout  Thout  Tcin   160  63.5  90  25 = 79.72 C
 Th  Tcout   160  63.5 
ln in  ln 
 Th  Tc   90  25 
 out in 

Tt  Ttin 90  160
P  out  = 0.52
Tsin  Ttin 25  160
Tsin  Tsout 25  63.5
R  = 0.55
Ttout  Ttin 90  160
Fig. 3.14d, cross-flow, fluid mixed on one side only, F2 = 0.95
Q2  U2 AF2 LMTD2 
Q2  U2 A0.9579.72  75.73U2 A
Q2  0.70Q1
75.73U2 A  0.7045.62U1 A
U2  0.4217U1
1 1  1  1  1.3714
Rf     1   
U2 U1  0.4217  U1  U1
1.3714
Rf  = 0.0006857 m2.K/W
2000

3.17 Water at 15 C is supplied to a one shell-pass, two tube-passes heat exchanger to cool 10 kg/s of
liquid ammonia from 120 C to 40 C. You anticipate a U on the order of 1500 W/m2.K when the
water flows in the tubes. If A is to be 90 m2, choose the correct flow rate of water.

Solution:

m a = 10 kg/s
Tsin  Thin = 120 C
Tsout  Thout = 40 C
Ttin  Tcin = 15 C
U = 1500 W/m2.K
A = 90 m2.

Specific heat of water at 15 C, c pw = 4189.4 J/kg.K

Specific heat of liquid ammonia at 80 C (average of 120 C and 40 C).
c pa = 5456.2 J/kg.K

Ch  m
 a c pa = (10)(5456.2) = 54,562 W/K
Try Cmin  C h = 54,562 W/K
Use Fig. 3.17c (one shell-pass, two tube-passes)
UA 1500 90 
NTU   = 2.474
C min 54 ,562

25
 3. HEAT EXCHANGER DESIGN

  
Q   Cmin Thin  Tcin  Ch Thin  Thout 
 Cmin120 15  Cmin120 40
 = 0.762
From Fig. 3.17c,
C min
 0.375
C max
Cmin 54 ,562
Cmax    145,499 W K
0.375 0.375
Cmax  C c  m
 w cpw
  
Q   Cmin Thin  Tcin  C c Tcout  Tcin 
0.76254,562120 15  145,499Tc out
 15 
Tcout  45 C
Tc (average) = 0.5(15 + 45) = 30 C
Specific heat of water at 30 C, c pw = 4180.4 J/kg.K
145,499  m  w 4180.4
m w  34.81 kg s (answer)

3.18 Suppose that the heat exchanger in Example 3.5 had been a two shell-pass, four tube-pass
exchanger with the hot fluid moving in the tubes. (a) What would be the exit temperature in this
case? (b) What would be the area if we wanted the hot fluid to leave at the same temperature
that it does in the example?

Solution:
From Example 3.5
Tcin = 40 C
C c = 20,000 W/K
Thin = 150 C
C h = 10,000 W/K
A = 30 m2
U = 500 W/m2.K

Answer from Ex. 3.5, Thout = 84.44 C

(a) Fig. 3.17d, two shell-pass, four tube-pass heat exchanger

Cmin  C h = 10,000 W/K
C max  C c = 20,000 W/K
UA 500 30 
NTU   = 1.5
C min 10 ,000
C min 10 ,000
 = 0.5
C max 20 ,000
 = 0.673

26
 3. HEAT EXCHANGER DESIGN

 
Q   Cmin Thin  Tcin = (0.673)(10,000)(150 – 40) = 740,300 W
Q 740 ,300
Thout  Thin   150  = 75.97 C
Ch 10,000

(b) Thout = 84.44 C

  
Q   Cmin Thin  Tcin  Cmin Thin  Thout 
Thin  Thout 150  84.44
  = 0.596
Thin  Tcin 150  40
C min
= 0.5
C max
Fig. 3.17d, two shell-pass, four tube-pass heat exchanger,

UA
NTU   1.14
C min
500A  1.1410,000

A = 22.8 m2.

3.19 Plot the maximum tolerable fouling resistance as a function of Unew for a counterflow exchanger,
with given inlet temperature, if a 30 % reduction in U is the maximum that can be tolerated.

Solution:
1 1
 Rf 
Uold Unew
if Uold  1  0.30Unew  0.70Unew
Then:
1 1 1
  Rf 
Uold 0.70Unew Unew
 1  1
  1  Rf
 0.70  U new
3
Rf 
7Unew

27
 3. HEAT EXCHANGER DESIGN

3.20 Water at 0.8 kg/s enters the tubes of a two-shell-pass, four-tube-pass heat exchanger at 17 C
and leaves at 37 C. It cools 0.5 kg/s of air entering the shell at 250 C with U = 432 W/m2.K.
Determine: (a) the exit air temperature; (b) the area of heat exchanger; and (c) the exit
temperature if, after some time, the tubes become fouled with Rf = 0.0005 m2K/W.

Solution:

m w = 0.8 kg/s
Tcin = 17 C
Tcout = 37 C
m a = 0.5 kg/s
Thin = 250 C
U = 432 W/m2.K
c pw at 27 C = 4181 J/kg.K [0.5(17 + 37) = 27 C]
c pa at 250 C = 1035 J/kg.K
C c  mw c pw = (0.8)(4181) = 3344.8 W/K
C h  ma c pa = (0.5)(1035) = 517.5 W/K

(a) Solve for exit air temperature.

   
C c Tcout  Tcin  C h Thin  Thout
3344.837  17  517.5250 Th out

Thout = 120.74 C
Th (average) = 0.5(250 + 120.74) = 185.37 C
c pa at 185.37 C = 1022.5 J/kg.K
C h  ma c pa = (0.5)(1022.5) = 511.25 W/K
3344.837  17  511.25250 Th out

Thout = 119.15 C (answer)
(b) Solving for the area of the heat exchanger.

28
 3. HEAT EXCHANGER DESIGN

Q  UAFLMTD

LMTD  in
  
Th  Tcout  Thout  Tcin


250  37  119.15  17 = 150.85 C
 Th  Tcout   250  37 
ln in  ln 
 Th  Tc   119.15  17 
 out in 

For two-shell-pass, four-tube-pass heat exchanger, use Fig. 3.14b

Ttout = 37 C
Ttin = 17 C
Tsin = 250 C
Tsout = 119.15 C
Ttout  Ttin 37  17
P  = 0.086
Tsin  Ttin 250  17
Tsin  Tsout 250  119.15
R  = 6.543 > 1
Ttout  Ttin 37  17
Since R > 1, use reciprocal rule.
P = PR = (0.086)(6.543) = 0.56
R = 1/R = 1/(6.543) = 0.153
Fig. 3.14b, F ~ 1.0
Then,
 
Q  C c Tcout  Tcin  3344.837  17 = 66,896 W
2
U = 432 W/m .K
Q  UAFLMTD
66,896 = (432)(A)(1.0)(150.85)
A = 1.03 m2. (answer)

(c) Exit temperature if Rf = 0.0005 m2K/W

1 1
 Rf 
U  U
1 1
 0.0005
U 432
U = 355.3 W/m2.K
Cmin  C h = 511.25 W/K
C max  C c = 3344.8 W/K
UA 355.31.03
NTU   = 0.7158
C min 511.25

Fig. 3.17b, two-shell-pass, four-tube-pass heat exchanger.

C min 511.25
 = 0.153
C max 3344.8
NTU = 0.7158
Then,  = 0.49
 
Q   Cmin Thin  Tcin  0.49511.25250 17 = 58,370 W

29
 3. HEAT EXCHANGER DESIGN

Q 58 ,370
Tcout  Tc in   17  = 34.45 C
Cc 3,344.8
Q 58 ,370
Thout  Thin   250  = 135.83 C
Ch 511.25
Tc (average) = 0.5(17 + 34.45) = 25.73 C
Th (average) = 0.5(250 + 135.83) = 192.92 C
c pw at 25.73 C = 4181.5 J/kg.K
c pa at 192.92 C = 1023.9 J/kg.K
C c  mw c pw = (0.8)(4181.5) = 3345.2 W/K
C h  ma c pa = (0.5)(1023.9) = 511.95 W/K
Cmin  C h = 511.95 W/K
C max  C c = 3345.2 W/K

UA 355.31.03
NTU   = 0.7148
C min 511.95

Fig. 3.17b, two-shell-pass, four-tube-pass heat exchanger.

C min 511.95
 = 0.153
C max 3345.2
NTU = 0.7148
Then,  = 0.49
 
Q   Cmin Thin  Tcin  0.49511.95250 17 = 58,449 W
Q 58 ,449
Tcout  Tc in   17  = 34.47 C (answer)
Cc 3,345.2
Q 58 ,449
Thout  Thin   250  = 135.83 C (answer)
Ch 511.95

3.21 You must cool 78 kg/min of a 60%-by-pass mixture of glycerin in water from 108 C to 50 C using
cooling water available at 7 C. Design a one-shell-pass, two-tube-pass heat exchanger if U = 637
W/m2.K. Explain any design decision you make and report the area, TH2Oout , and any other
relevant features.
Solution:
m g = 78 kg/min
Thin = 108 C
Thout = 50 C
Tcin = 7 C
Th (average) = 0.5(108 +50) = 79 C
c pg at 79 C of 60 % glycerin in water = 3474 J/kg.K
c pw at 7 C = 4201 J/kg.K
Ch  m
 g c pg = (78)(3474)/60 = 4516.2 W/K

30
 3. HEAT EXCHANGER DESIGN

 
Q  C h Thin  Thout  4516.2108  50 = 261,940 W

Q   Cmin Thin  Tcin 
say Cmin  C h = 4516.2 W/K
Q   4516.2108  7 = 261,940
 = 0.5743

Assume NTU = 1.5

One-shell-pass, two-tube-pass heat exchanger. Fig. 3.17c
C min
= 0.875
C max
C 4516.2
Cmax  min  = 5161.4
0.875 0.875

 
Q  Cmax Tcout  Tcin
261,940  5161.4T cout 
7
Tcout  57.75 C (answer)
Tc (average) = 0.5(7 + 57.75) = 32.38 C
c pw at 32.38 C = 4180 J/kg.K
5161.4
w 
m  60  74.1 kg min (answer)
4180

3.22 A mixture of 40%-by-weight glycerin, 60%-water, enters a smooth 0.113 m I.D. tube at 30 C. The
tube is kept at 50 C, and m mixture= 8 kg/s. The heat transfer coefficient inside the pipe is 1600
2
W/m .K. Plot the liquid temperature as a function of position in the pipe.

Solution:
 g = 8 kg/s
Tcin = 30 C, m
hi = 1600 W/m2.K
Thin  Thout = 50 C

c pg at 30 C, 40%-glycerin = 3480 J/kg.K, neglect variation of specific heat.

Cmin  C c  m
 g c pg = (8)(3480) = 27,840 W/K
C min
Cmax   ,  0 , lim   1  e NTU
C max Cmax 

  
Q   Cmin Thin  Tcin  C c Tcout  Tcin 
 CminThin  Tcin   CminTcout  Tcin 
 
Tcout   Thin  Tcin  Tcin
UA hi A
NTU  
C min C min
A   Dx

31
 3. HEAT EXCHANGER DESIGN

where x – position in pipe from Tcin .

  
Tcout  1  e NTU Thin  Tcin  Tcin
hi A hi Dx 
NTU  
C min C min

NTU 
1600 0.113x  0.0204x
27840

 
Tcout  1  e 0.0204x 50  30  30
Tcout  50  20e 0.0204x
Tabulation:
x, m Tcout  50  20e 0.0204x , C
0 30
1 30.4
2 30.8
3 31.2
4 31.6
5 31.9
6 32.3
7 32.7
8 33.0
9 33.4
10 33.7
20 36.7
30 39.2
40 41.2
50 42.8
 50.0
Plot:

32
 3. HEAT EXCHANGER DESIGN

3.23 Explain in physical terms why all effectiveness curves Fig. 3.16 and Fig. 3.17 have the same slope
as NTU  0. Obtain this slope from eqns. (3.20) and (3.21).

Solution:

For parallel flow, Eq. (3.20)

  C  
1  exp   1  min NTU 
  Cmax  

Cmin
1
Cmax
For counterflow, Eq. (3.21)

  C  
1  exp   1  min NTU 
  Cmax  

C   C  
1  min exp   1  min NTU 
Cmax   Cmax  

Slope for parallel flow:

  C  
1  exp   1  min NTU 

  Cmax  

C
1  min
Cmax

 C    C  
 1  min  exp   1  min NTU 
   
d  C max    C max  

dNTU C
1  min
C max

d   C  
 exp   1  min NTU 

dNTU   C max  

if NTU = 0

d C
 1 , independent of min , therefore, the same for all.
dNTU C max

33
 3. HEAT EXCHANGER DESIGN

Slope for counterflow:

  C  
1  exp   1  min NTU 
  Cmax  

C   C  
1  min exp   1  min NTU 
Cmax   Cmax  
 C min                 C      
NTU   1  min NTU   1  exp   1  min NTU   min
C C C C C C
1  exp   1  min  
 exp   1  min
     
 1  min

 exp   1  min
 
NTU 

d  C max   C max    C max    C max      C max    C max  C max    C max  
 2
dNTU     
NTU  
C min C
1  exp   1  min 
 C max   C max   
Substitute, NTU = 0.
 C  C  C  C 
 1  min  1  min   1  1 min  1  min 
d  
Cmax  
Cmax  C  Cmax 
 2
 max  
dNTU  C 
 1  min 
 Cmax 

 C  C  C  C 
 1  min  1  min   1  1 min  1  min 
d  
Cmax  
Cmax  C  Cmax 
 2
 max  
dNTU  C 
 1  min 
 Cmax 

d C
 1 , also independent of min , therefore, the same for all.
dNTU C max

3.24 You want to cool air from 150 C to 60 C but you cannot afford a custom-built heat exchanger.
You find a used cross-flow exchanger (both fluids unmixed) in storage. It was previously used to
cool 136 kg/min of NH3 vapor from 200 C to 100 C using 320 kg/min of water at 7 C; U was
previously 480 W/m2. K. How much air can you cool with this exchanger, using the same water
supply, if U is approximately unchanged? (Actually, you would have to modify U using the
methods of Chapters 6 and 7 once you had the new air flow rate, but that is beyond our present
scope.)
Solution:
m NH3 = 136 kg/min
Thin = 200 C
Thout = 100 C
m w = 320 kg/min
Tcin = 7 C
U = 480 W/m2.K.
Th (average) = 0.5(200 + 100) = 150 C
cpNH3 at 150 C = 2326 J/kg.K, Table A-6.
c pw at 7 C = 4201 J/kg.K

C max  m
 w c pw = (320)(4201)/(60) = 22,405 W/K

34
 3. HEAT EXCHANGER DESIGN

Cmin  m
 NH3 cpNH3 = (136)(2326)/(60) = 5272 W/K
  
Cmin Thin  Thout  Cmax Tcout  Tcin 
5272200 100  22,405 Tcout  7  
Tcout = 30.53 C
Tc (average) = 0.5(7 + 30.53) = 18.77 C
c pw at 18.77 C = 4185.6 J/kg.K
C max  m
 w c pw = (320)(4185.6)/(60) = 22,323 W/K

C min 5,272
 = 0.24
C max 22,323

  
Q   Cmin Thin  Tcin  C h Thin  Thout 
C h  Cmin = 5272 J/kg.K
Q   5272200 7  5272200 100
 = 0.52

From Fig. 3.17a, Cross-flow

C
 = 0.52, min = 0.24
C max
then, NTU = 0.80
UA
NTU 
C min
480 A
0.80 
5272
A = 8.79 m2.

For the new conditions:

c pa at 105 C (average of 150 C and 60 C) = 1012 J/kg.K

Using the same water temperature used as 7 C
Thin = 150 C
Thout = 60 C
Tcin = 7 C

Cmin  C h  m
 a c pa  1012m
 a W/K
UA 480 8.79  4.17
NTU   
C min a
1012m a
m

  
Q   Cmin Thin  Tcin  Cmin Thin  Thout 
 Thin  Tcin   Thin  Thout 

35
 3. HEAT EXCHANGER DESIGN

 150  7  150  60

 = 0.63

C max  m
 w c pw = 22,405 W/K
Cmin  1012ma
C min 1012m a
  0.04517 m
a
C max 22,405

Fig. 3.17a, cross-flow

C min
 0.04517 ma
C max
4.17
NTU 
a
m
 = 0.63

Tabulation of trial and error method:

a
m C min NTU NTU (graph)
C max
4 0.18 1.04 1.07
3 0.14 1.39 1.05

By interpolation:
x  1.04 x  1.07

1.39  1.04 1.05  1.07
x  1.04  17.5x  1.07
x = 1.068
Then:

1.068  1.07 
 a  
m 3  4   4 = 3.9 kg/s
 1.05  1.07 
  
Cmin Thin  Thout  Cmax Tcout  Tcin
C min
 0.045173.9   0.176
C max
0.176150 60  Tcout  7
Tcout = 22.84 C
Tc (average) = 0.5(7 + 22.84) = 14.92 C
c pw at 14.92 C = 4189.5 J/kg.K
C max  m
 w c pw = (320)(4189.5)/(60) = 22,344 W/K
C min 1012ma
  0.04529 m
a
C max 22,344

36
 3. HEAT EXCHANGER DESIGN

Fig. 3.17a, cross-flow

C min
 0.04517 ma
C max
4.17
NTU 
ma
 = 0.63

Tabulation of trial and error method:

a
m C min NTU NTU (graph)
C max
4 0.18 1.04 1.07
3 0.14 1.39 1.05

By interpolation:
x  1.04 x  1.07

1.39  1.04 1.05  1.07
x  1.04  17.5x  1.07
x = 1.068
Then:

1.068  1.07 
 a  
m 3  4   4 = 3.9 kg/s (answer)
 1.05  1.07 

3.25 A one tube-pass, one shell-pass, parallel-flow, process heat exchanger cools 5 kg/s of gaseous
ammonia entering the shell side at 250 C and boils 4.8 kg/s of water in the tubes. The water
enters subcooled at 27 C and boils when it reaches 100 C. U = 480 W/m2.K before boiling begins
and 964 W/m2.K there-after. The area of the exchanger is 45 m2, and hfg for water is 2.257 x 106
J/kg. Determine the quality of the water at the exit.

Solution: Parallel Flow:

m a = 5 kg/s
Thin = 250 C
m w = 4.8 kg/s
Tcin = 27 C
From Appendix A.
Specific heat of gaseous ammonia at 250 C, use 200 C, c pa = 2425 J/kg.K
Tc (average) = 0.5(27 + 100) = 63.5 C
Specific heat of water at 63.5 C, c pw = 4187.6 J/kg.K

Boiling water to 100 C, U1 = 480 W/m2.K

37
 3. HEAT EXCHANGER DESIGN

Tcout = 100 C
Q1  m 
 w c pw Tcout  Tcin 
Q1 = (4.8)(4187.6)(100 – 27)
Q1 = 1,467,335 W
Q1  U1 A 1 LMTD1 
  
Th  Tcin  Thout  Tcout 
LMTD1  in
 Th  Tcin 
ln in 
 Th  Tc 
 
 
out out

Q1  m a c pa Thin  hhout
1,467,335  52425250 T  hout

Thout = 128.98 C
Th (average) = 0.5(250 + 128.98) = 189.49 C
Specific heat of gaseous ammonia at 189.49 C, c pa = 2404.5 J/kg.K
Q1  m 
 a c pa Thin  hhout 
1,467,335 52404.5 250 Thout 
Thout = 127.95 C

250  27  127.95  100  = 93.92 C

LMTD1 
 250  27 
ln 
 127.95  100 
Q1  U1 A 1 LMTD1 
1,467,335  480A 193.92
A 1 = 32.55 m2.

Total Area, A = 45 m2.

Remaining area for evaporation at 100 C.

A 2 A  A 1
A 2  45  32.55 = 12.45 m2.

At evaporation, U2 = 964 W/m2.K.

Thin =127.95 C

Specific heat of gaseous ammonia at 127.95 C

c pa = 2287.5 J/kg.K, from Appendix A

   w h fg x 
Q2   Cmin Thin  Tcin  m
C min  m
 a c pa =(5)(2287.5) = 11,437.5 W/K

38
 3. HEAT EXCHANGER DESIGN

Tcin = 100 C
hfg = 2.257 x 106 J/kg
  lim   1  e NTU
Cmax 

U2 A2 964 12.45
NTU   = 1.049
C min 11437 .5
  1  e 1.049= 0.65
Q2   CminThin  Tcin  CminThin  Thout 

0.65127.95  100  127.95  Thout 
Thout =109.78 C
Th (average) = 0.5(127.95 + 109.78) = 118.86 C
Specific heat of gaseous ammonia at 118.86 C
c pa = 2271.5 J/kg.K, from Appendix A
C min  m
 a c pa =(5)(2271.5) = 11,357.5 W/K

  w h fg x 
Q2   Cmin Thin  Tcin  m

Q2  0.6511,357.5127.95  100  4.8 2.257 106 x  
x = 0.019 or 1.9 % vapor (answer)

3.26 0.72 kg/s of superheated steam enters a cross-flow heat exchanger at 240 C and leaves at 120 C.
It heats 0.6 kg/s of water entering at 17 C. U = 612 W/m2.K. By what percentage will the area
differ if a both-fluids-unmixed exchanger is used instead of a one-fluid-unmixed exchanger?

Solution:
m s = 0.72 kg/s
Thin = 240 C
Thout = 120 C
m w = 0.60 kg/s
Tcin = 17 C
Specific heat of superheated steam at 180 C average temperature, cps = 1976 J/kg.K, Table A.6
Specific heat of water at 17 C, cpw = 4187 J/kg.K.
Solving for Tcout .
Qm  
 s cps Thin  Thout  m  
 w cpw Tcout  Tcin
0.721976240  120  0.604187T cout  17 
Tcout = 85 C
Tc (average) = 0.5(17 + 85) = 51 C
Specific heat of water at 51 C, cpw = 4182.6 J/kg.K.
0.721976240 120  0.604182.6Tc out
 17 
39
 3. HEAT EXCHANGER DESIGN

Tcout = 85
T hin  
 Tcout  Thout  Tcin  240  85  120  17
LMTD   = 127.23 C
 Th  Tcout   240  85 
ln in  ln 
 Th  Tc   120  17 
 out in 
Tt out  Tt in
P
Tsin  Tt in
Tsin  Tsout
R
Ttout  Ttin
Tt out = 120 C
Tt in = 250 C
Tsin = 17 C
Tsout = 85 C
120  85
P = 0.54
120  240
17  85
R = 0.57
120  240
Qm  
 scps Thin  Thout  0.721976240  120 = 170,727 W
For cross-flow, both fluid unmixed, Fig. 3.14c.
F1 = 0.95
Q  UA 1 F1 LMTD
170,727  612A 10.95127.23
A 1 = 2.308 m2.
For cross-flow, one fluid unmixed, Fig. 3.14d
F2 = 0.933
Q  UA 2 F2 LMTD
170,727  612A 20.933127.23
A 2 = 2.350 m2.
A  A1
% area  2 100%   2.308  2.350 100%  = - 1.8 %
A2 2.350

3.27 Compare values of F from Fig. 3.14c and Fig. 3.14d for the same conditions of inlet and outlet
temperatures. Is the one with higher F automatically the more desirable exchanger? Discuss.

Discussion:

At given the same conditions of inlet and outlet temperatures, value of F from Fig. 3.14c is
higher than values from Fig. 3.14d. Higher values of F automatically will be the more desirable
heat exchanger because it will give lesser heat transfer area, A.

40
 3. HEAT EXCHANGER DESIGN

C min
3.28 Compare values of  for the same NTU and in parallel and counterflow heat exchangers.
C max
Is the one with higher  automatically the more desirable exchanger? Discuss.

Discussion:
Reference to Fig. 3.16,  -value for counterflow gives higher values than parallel-flow for the
C
same NTU and min . Higher values of  will automatically be the more desirable heat
C max

exchanger because it will give higher heating capacity, Q   C min Thin  Tcin . 
3.29 The irreversibility rate of a process is equal to the rate of entropy production times the lowest
absolute sink temperature accessible to the process. Calculate the irreversibility (or lost work)
for the heat exchanger in Example 3.4. What kind of configuration would reduce the
irreversibility given the same end temperatures?

Solution:
From Ex. 3.4, two-shell pass, four-tube passes oil cooler.
Oil: m o = 5.795 kg/s
Thin = 181 C
Thout = 38 C
Water:
Tcin = 32 C
Tc out = 49 C
c poil = 2282 J/kg.K
U = 416 W/m2.K
Using P = 0.959, R = 0.119, F = 0.92
A = 121.2 m2.

Solving for irreversibility:

T  T 
 ocpo ln hout   m
Sun  m  w cpw ln cout 
 Th   Tc 
 in   in 
Specific heat of water at 40 C, c pw = 4180 J/kg.K
Qm  
 o c po Thin  Thout  m 
 w c pw Tcout  Tcin 
5.7952282181 38  m w 418049  32
 w = 26.612 kg/s
m
 38  273   49  273 
S un  5.795 2282 ln   26.612 4180 ln  = 1031 W/K
 181  273   32  273 
Irreversibility = Tsink S un = (32 + 273)(1031) = 314,455 W

Any configuration will give the same irreversibility for the given the same end temperatures.

41
 3. HEAT EXCHANGER DESIGN

3.30 Plot Toil and TH2O as a function of position in a very long counterflow heat exchanger where
water enters at 0 C, with C H2O = 460 W/K, and oil enters at 90 C, with Coil = 920 W/K, U = 742
W/m2.K, and A = 10 m2. Criticize the design.

Solution:
For counterflow case:
  C  
1  exp   1  min NTU 
  Cmax  

C   C  
1  min exp   1  min NTU 
Cmax   Cmax  
UA
NTU 
Cmin
C min = C H2O = 460 W/K
C max = C oil = 920 W/K
Thin = 90 C
Tcin = 0 C
UA 742 A
NTU    1.613 A
C min 460
C min 460
 = 0.5
C max 920
1  exp 1  0.51.613 A

1  0.5exp 1  0.51.613 A
1  exp 0.8065 A

1  0.5 exp 0.8065 A
  
Q   Cmin Thin  Tcin  CH2O Tcout  Tcin 
Tc 
 Cmin T hin  TcinT
cin
C H2O

Tc   Thin  Tcin  Tcin
Tc  TH2O   90  0  0  90
 1  exp 0.8065 A  
TH2O  90  
 1  0.5 exp 0.8065 A  
Equation 3.5b
 C  C
Th  Tc  Thin   1  c Tc  c Tcout
 Ch  Ch
Tcout  90  90
 1  exp 0.8065  10  
Tcout  90    89.986 C
 1  0.5 exp 0.8065  10  

42
 3. HEAT EXCHANGER DESIGN

 C  C
Th  Thin  Tc   1  c Tc  c Tcout
 Ch  Ch
 460  460
Th  90  90   1  90   89.986 
 920  920
Th  45.007 45
 1  exp 0.8065 A  
Th  Toil  45.007  45 
 1  0.5 exp 0.8065 A  

Plot:

The design is twice as need. No added performance above 5 sq m.

3.31 Liquid ammonia at 2 kg/s is cooled from 100 C to 30 C in the shell side of a two shell-pass, four
tube-pass heat exchanger by 3 kg/s of water at 10 C. When the exchanger is new, U = 750
W/m2.K. Plot the exit ammonia temperature as a function of the increasing tube fouling factor.

Solution:
Unew = 750 W/m2.K
m a = 2 kg/s
Thin = 100 C
Thout = 30 C
 w = 3 kg/s
m
43
 3. HEAT EXCHANGER DESIGN

Tcin = 10 C
Specific heat of liquid ammonia at 65 C average temperature, c pa = 5348 J/kg.K
Specific heat of water at 10 C, c pw = 4196 J/kg.K
Cmin  Ch  m
 acpa = (2)(5348) = 10,696 W/K
Cmax  C c  m
 w cpw = (3)(4196) = 12,588 W/K
1 1
Rf  
Uold Unew
For new unit: two-shell-pass, four-tube-pass
  
Q  Ch Thin  Thout  Cc Tcout  Tcin 
10,696100 30  12,588Tc out
 10 
Tcout = 69.48 C

Tc (average) = 0.5(10 + 69.48) = 39.74 C

Specific heat of water at 39.74 C, c pw = 4179.6 J/kg.K
Cmax  C c  m
 w cpw = (3)(4179.6) = 12,538.8 W/K
10,696100 30  12,538.8Tc out
 10 
Tcout = 69.71 C

LMTD 
T hin  
 Tcout  Thout  Tcin   100  69.71  30  10 = 24.79 C
 Th  Tcout   100  69.71 
ln in  ln 
 Th  Tc   30  10 
 out in 
Tsin = 100 C
Tsout = 30 C
Tt in = 10 C
Ttout = 69.71 C

Tt out  Tt in
P
Ts in  Tt in
Tsin  Tsout
R
Ttout  Ttin
69.71  10
P = 0.66
100  10
100  30
R = 1.18 > 1
69.71  10

Use Reciprocal Rule:

P = PR = (0.66)(1.18) = 0.78
R = 1/R = 1/1.18 = 0.85
From Fig. 3.14b, F = 0.60
44
 3. HEAT EXCHANGER DESIGN

 
Q  Ch Thin  Thout  UAFLMTD
10,696100 30  750A0.6024.79
A = 67.12 m2.

For old unit:

1 1
Rf  
Uold Unew
Unew = 750 W/m2.K
1 1 1
 Rf   Rf 
Uold Unew 750
750
Uold 
750R f  1
 750 
 67.12
Uold A  750R f  1 
NTU  
Cmin 10 ,696
4.7064
NTU 
750R f  1
C min 10 ,696
  0.85
C max 12,538.8

Cmin
Fig. 3.17d, Tabulation for  0.85
Cmax

NTU 
5 0.778
4 0.760
3 0.720
2 0.66

By curve fitting:
  0.4761 0.1129NTU  0.0105NTU2 , for 5 > NTU > 2
Then,
  
Q   C min Thin  Tcin C h Thin  Thout 
Cmin  Ch

Thout  Thin   Thin  Tcin 
Thout  100  100 10  100 90

Thout  100 90 0.4761 0.1129NTU  0.0105NTU2 
Thout  57.151 10.161NTU  0.945NTU 2

45
 3. HEAT EXCHANGER DESIGN

2
 4.7064   
Thout  57.151  10.161   0.945 4.7064 
 750R  1   750R  1 
 f   f 
47.82 20.932
 57.151  
750R f  1 750R f  12
Thout

Tabulation of Values:
R f , m2.K/W Thout , C
0 30.3
0.0005 33.5
0.0010 36.7
0.0015 39.3

Plot:

3.32 A one shell-pass, two tube-pass heat exchanger cools 0.403 kg/s of methanol from 47 C to 7 C
on the shell side. The coolant is 2.2 kg/s of Freon 12, entering the tubes at –33 C with U = 538
W/m2.K. A colleague suggests that this arrangement wastes Freon. She thinks you could do
almost as well if you cut the Freon flow rate all the way down to 0.8 kg/s. Calculate the new
methanol outlet temperature that would result from this flow rate, and evaluate her suggestion.

Solution:
First condition,
m m = 0.403 kg/s
Thin = 47 C = Tsin
Thout = 7 C = Tsout
 f = 2.2 kg/s
m
Tcin = -33 C = Ttin
U = 538 W/m2.K

Specific heat of Methanol at 27 C, c pm = 2534 J/kg.K

46
 3. HEAT EXCHANGER DESIGN

Specific heat of Freon 12 at –33 C, c pf = 882 J/kg.K

  
Q  mm c pm Thin  Thout  m f c pf Tcout  Tcin 
0.403253447  7  2.2882Tc out
  33 
Tcout = -11.95 C = Ttout
Tc (average) = 0.5(-11.95 – 33) = -22.48 C
Specific heat of Freon at –22.48 C, c pf = 897.78 J/kg.K
0.403253447  7  2.2897.78Tc out
  33
Tcout = -12.32 C = Ttout

Q  0.403253447  7 = 40,848 W
Q  UAFLMTD

LMTD  in
   
Th  Tcout  Thout  Tcin 47   12.32   7   33
 = 49.03 C
 Thin  Tcout   47   12.32  
ln  ln 
 Th  Tc 
 out in 
 7   33 
Tt  Ttin  12.32   33
P  out  = 0.26
Tsin  Ttin 47   33
Tsin  Tsout 47  7
R  = 1.94 > 1
Ttout  Ttin  12.32   33
Use Reciprocal Rule:
P = PR = (0.26)(1.94) = 0.50
R = 1/R = 1/(1.94) = 0.52
From Fig. 3.14a, F = 0.935
Q  UAFLMTD
40,848  538A0.93549.03
A = 1.66 m2.

Second Condition: U = 538 W/m2.K, A = 1.66 m2.

m m = 0.403 kg/s
c pm = 2534 J/kg.K
 f = 0.8 kg/s
m
c pf = 897.78 J/kg.K
Thin = 47 C
Tcin = -33 C
Ch  m
 m c pm = (0.403)(2534) = 1021.2 W/K
Cc  m
 f c pf = (0.80)(897.78) = 718.22 W/K
Cmin  C c
47
 3. HEAT EXCHANGER DESIGN

Cmax  C h
C min 718.22
 = 0.70
C max 1021.2
UA 538 1.66 
NTU   = 1.243
C min 718.22
Fig. 3.17c, one shell-pass, two-tube pass heat exchanger,
 = 0.56
 
Q   Cmin Thin  Tcin  0.56718.2247   33 = 32,176 W

Q 32,176
Thout  Thin   47  = 15.5 C
Ch 1021.2
Th (average) = 0.5(47 +15.5) = 31.25 C

Check for Tcout :

Q 32,176
Tcout  Tcin   33  = 11.8 C
Cc 718.22
Tc (average) = 0.5(-33 + 11.8) = -10.6 C

Specific heat of Methanol at 31.25 C, c pm = 2563.3 J/kg.K

Specific heat of Freon 12 at –10.6 C, c pf = 916.3 J/kg.K
Ch  m
 m c pm = (0.403)(2563.3) = 1033.0 W/K
Cc  m
 f c pf = (0.80)(916.3) = 733.0 W/K
Cmin  C c
Cmax  C h
Use  = 0.56
 
Q   Cmin Thin  Tcin  0.56733.047   33 = 32,839 W
Q 32,839
Thout  Thin   47  = 15.2 C
Ch 1033.0
Q 32,839
Tcout  Tcin   33  = 11.8 C
Cc 733.0

New Methanol outlet temperature, Thout = 15.5 C > 7 C, which is warmer. Therefore, her
suggestion will not attain 7 C methanol temperature. Consider the effect of temperatures and
flow rates on the U-value.

3.33 The factors dictating the heat transfer coefficients in a certain two shell-pass, four tube-pass
heat exchanger are such that U increase as m  shell  . The exchanger cools 2 kg/s of air from 200
0.6

C to 40 C using 4.4 kg/s of water at 7 C, and U = 312 W/m2.K under these circumstances. If we
double the airflow, what will its temperature be leaving the exchanger?

48
 3. HEAT EXCHANGER DESIGN

Solution:
m a= m  shell = 2 kg/s
Thin = 200 C = Tsin
Thout = 40 C = Tsout
 w = 4.4 kg/s
m
Tcin = 7 C = Ttin
U = 312 W/m2.K
U  m shell 0.6
U  km
 shell 0.6
312  k2.00.6
k = 205.84
U  205.84m shell 0.6  205.84m
 a 0.6
Specific heat of air at 120 C (average of 40 C and 200 C), c pa = 1013 J/kg.K
Specific heat of water at 7 C, c pw = 4201 J/kg.K

First condition:
Qm 
 a c pa Th  Th   m

w c pw T cout  Tcin
21013200 40  4.44201T  7
in out

cout

Tcout = 24.55 C = Ttout

Tc (average) = 0.5(7 + 24.55) = 15.78 C
Specific heat of water at 15.78 C, c pw = 4188.5 J/kg.K

21013200 40  4.44188.5Tc out


7
Tcout = 24.59 C = Ttout

Q  21013200  40 = 324,160 W

Q  UAFLMTD

LMTD  in
  
Th  Tcout  Thout  Tcin


200  24.59   40  7
= 85.25 C
 Thin  Tcout   200  24.59 
ln  ln 
 Th  Tc   40  7 
 out in 

Ttout  Ttin 24.59  7

P  = 0.091
Tsin  Ttin 200  7
Tsin  Tsout 200  40
R  =9.10 > 1
Ttout  Ttin 24.59  7
Use Reciprocal Rule:
P = PR = (0.091)(9.10) = 0.83
R = 1/R = 1/(9.10) = 0.11
From Fig. 3.14, two shell-pass, four tube-pass heat exchanger
F = 0.975
49
 3. HEAT EXCHANGER DESIGN

Q  UAFLMTD
324,160 = (312)(A)(0.975)(85.25)
A = 12.5 m2.

Second Condition: neglect now the variation in specific heat.

m a= m  shell = 2(2 kg/s) = 4 kg/s
Thin = 200 C
m w = 4.4 kg/s
Tcin = 7 C
U  205.84m
 shell 0.6  205.84m
 a 0.6
U  205.844.00.6 = 472.9 W/m2.K
A = 12.5 m2.
Ch  m a c pa = (4)(1013) = 4052 W/K
Cc  m
 w c pw = (4.4)(4188.5) = 18,430 W/K
Cmin  C h = 4052 W/K
C max  C c = 18,430 W/K
C min 4052
 = 0.22
C max 18430
UA 472.9 12.5
NTU   = 1.46
C min 4052
Fig. 3.17d, two shell-pass, four tube-pass heat exchanger
 = 0.72


Q   Cmin Thin  Tcin 
Q  0.724052200 7 = 563,066 W

Q 563,066
Thout  Thin   200  = 61.0 C (answer)
Ch 4052

3.34 A flow rate of 1.4 kg/s of water enters the tubes of a two-shell-pass, four-tube-pass heat
exchanger at 7 C. A flow rate of 0.6 kg/s of liquid ammonia at 100 C is to be cooled to 30 C on
the shell side; U = 573 W/m2.K. (a) How large must the heat exchanger be? (b) How large must it
be if, after some months a fouling factor of 0.0015 will build up in the tubes, and we still want to
deliver ammonia at 30 C? (c) If we make it large enough to accommodate fouling, to what
temperature will it cool the ammonia when it is new? (d) At what temperature does water leave
the new, enlarged exchanger?

Solution:
(a) Two-shell-pass, four-tube-pass
m w = 1.4 kg/s
Tcin  Ttin = 7 C
 a = 0.6 kg/s
m
50
 3. HEAT EXCHANGER DESIGN

Thin  Tsin = 100 C

Thout  Tsout = 30 C
U = 573 W/m2.K

Specific heat of liquid ammonia at 65 C, c pa = 5348 J/kg.K

Specific heat of water at 7 C, c pw = 4201 J/kg.K

C h  C min  m
 a c pa = (0.6)(5348) = 3208.8 W/K
C c  C max  m
 w c pw = (1.4)(4201) = 5881.4 W/K
 
Q  C h Thin  Thout = (3208.8)(100 – 30) = 224,616 W
Q  UAFLMTD

Th  Tcout  Thout
LMTD  in
   Tcin 
 Th  Tcout 
ln in 
 Th  Tc 
 out in 


Q  C c Tcout  Tcin 
224.616  5881.4  Tcout  7 
Tcout = 45.2 C = Ttout
Tc (average temperature) = 0.5.(7 + 45.2) = 26.1 C
Specific heat of water at 26.1 C, c pw = 4181.4 J/kg.K
C c  C max  m
 w c pw = (1.4)(4181.4) = 5854 W/K
 
Q  C c Tcout  Tcin
224.616  5854T cout 
7
Tcout = 45.4 C = Ttout

100  45.4   30  7 = 36.55 C

LMTD 
 100  45.4 
ln 
 30  7 
Tt  Ttin 45.4  7
P  out  = 0.41
Tsin  Ttin 100  7
Tsin  Tsout 100  30
R  = 1.82 > 1
Ttout  Ttin 45.4  7
Use Reciprocal Rule:
P = PR = (0.41)(1.82) = 0.75
R = 1/R = 1/(1.82) = 0.55
From Fig. 3.14, two shell-pass, four tube-pass heat exchanger
F = 0.915
Q  UAFLMTD
224,616 = (573)(A)(0.915)(36.55)
51
 3. HEAT EXCHANGER DESIGN

A = 11.7 m2.

(b) if R f = 0.0015

1 1
 Rf 
Uold Unew
1 1
 0.0015
U 573
U = 308.15 W/m2.K
Q  UAFLMTD
224,616 = (308.15)(A)(0.915)(36.55)
A = 21.80 m2.

(c) if A = 21.80 m2, U = 573 w/m2.K

C min = 3208.8 W/K, make it constant

C max = 5854 W/K, make it constant
Thin = 100 C
Tcin = 7 C
C min 3208.8
 = 0.55
C max 5854
UA 57321.75
NTU   = 3.9
C min 3208.8
Fig. 3.17d, two shell-pass, four tube-pass heat exchanger
 = 0.85


Q   Cmin Thin  Tcin 
Q  0.853208.8100 7 = 253,656 W

Q 253,656
Thout  Thin   100  = 21 C
Ch 3208.8

Q 253,656
(d) Tcout  Tcin   7 = 50.3 C
Cc 5854

3.35 Both C’s in a parallel-flow heat exchanger are equal to 156 W/K, U = 327 W/m2.K and A = 2 m2.
The hot fluid enters at 140 C and leaves at 90 C. The cold fluid enters at 40 C. If both C’s are
halved, what will be the exit temperature of the hot fluid?

Solution: Cmin  Cmax

For parallel flow, Eq. 3.20

52
 3. HEAT EXCHANGER DESIGN

  C  
1  exp   1  min NTU 
  Cmax  

Cmin
1
Cmax
C min
=1
C max
if Cmin  Cmax = (1/2)(156 W/K) = 78 W/K
UA 327 2
NTU   = 8.385
Cmin 78
1  exp 1  18.385
 = 0.5
11
 
Q   Cmin Thin  Tcin = (0.5)(78)(140 – 40) = 3900 W
Q 3900
Thout T hin   140 = 90 C
C 78
This is still the same since NTU >5,  remain the same.
3.36 A 1.68 ft2 cross-flow heat exchanger with one fluid mixed condenses steam at atmospheric
pressure ( h = 2000 Btu/h.ft2.F) and boils methanol ( Tsat = 170 F and h = 1500 Btu/h.ft2.F) on the
other side. Evaluate U (neglecting resistance of the metal), LMTD, F, NTU,  , and Q.

Solution:
Steam at atmosphere, Th = 212 F
Methanol, Tc = 170 F
Solving for U,
1 1 1
 
U 2000 1500
U = 857 Btu/h.ft2.F
Solving for LMTD.
F = 1.0 for isothermal fluid.
LMTD = Th - Tc = 212 – 170 = 42 F
Solving for NTU,
UA
NTU 
C min
but Cmin  
NTU  0
Solving for 
  C max
lim   1  e  NTU


but NTU = 0
  1.0
Solving for Q,
Q = U x A x LMTD
Q = 857 x 1.68 x 42 = 60,470 Btu/hr

53
 3. HEAT EXCHANGER DESIGN

Cmin
3.37 Eqn. (3.21) is troublesome when  1.0 . Develop a working equation for  in this case.
Cmax
Compare it with Fig. 3.16.

Solution:
Eq. (3.21)
  C  
1  exp   1  min NTU 
  C max  

C    C  
1   min  exp   1  min NTU 
 C max    C max  
Cmin
if  1.0
Cmax
0

0
L’Hospital rule.
  C  
1  exp   1  min NTU 
  Cmax  
Lim   Lim
Cmin
0
Cmin
0 C    C  
Cmax Cmax 1   min  exp   1  min NTU 
 Cmax    Cmax  
    Cmin   
1  exp   1  NTU  
C     Cmax    Cmin 1
 min 
Cmax
  Cmax 
   C    C   
1  
min 
 exp   1  min NTU  
C    Cmax    Cmax    Cmin 1
 min 
Cmax
 Cmax 
   C   
  NTU  1exp   1  min NTU  
   Cmax    Cmin 1

Cmax

C    C      C  
  NTU  min  1exp   1  min NTU    exp   1  min NTU 
 Cmax    Cmax      Cmax   Cmin 1
Cmax

  C  
 NTU exp   1  min NTU 
  Cmax   Cmin 1

Cmax

  Cmin     C  
 NTU    1 exp   1  min NTU 
  Cmax     Cmax   Cmin 1
Cmax

54
 3. HEAT EXCHANGER DESIGN

NTU

  Cmin  
NTU    1
  Cmax   Cmin 1
Cmax

NTU

NTU  1

Comparison Table:
NTU NTU Fig. 3.16, 

NTU  1
5 0.83 0.83
4 0.8 0.8
3 0.75 0.75
2 0.67 0.67

3.38 The effectiveness of a cross-flow exchanger with neither fluid mixed can be calculated from the

 
following approximate formula:   1  exp  exp  NTU 0.78 r  1  
NTU 0.22 
r
 where r 
C min
C
. How
  max

does this compare with correct values?

Solution:
Fig. 3.17a

Comparison
C
r  min = 1.0
C max
NTU  (approximate)  (Fig. 3.17a)
5 0.749 0.75
4 0.723 0.72
3 0.684 0.68
2 0.615 0.62
1 0.469 0.47

C min
r = 0.75
C max
NTU  (approximate)  (Fig. 3.17a)
5 0.828 0.83
4 0.800 0.800
3 0.755 0.75
2 0.675 0.67
1 0.505 0.51

Therefore, it gives very near values to two digits.

55
 3. HEAT EXCHANGER DESIGN

C min
If r  =0
C max
The term

exp NTU r   1NTUr

0.22
0
0.78

0
Use L’Hospital rule:

exp NTU 0.78

 
r  1 NTU 0.22

   
exp  NTU 0.78 r  1 NTU 0.22 
r 0
Lim = r
r 0 r 
r 
r r 0

=

 NTU 0.78 exp  NTU 0.78 r r 0
=  NTU0.78
1 r 0
Then

  1  exp  NTU 0.78 
Comparison r 
Cmin
Cmax
=0,   1  exp  NTU 0.78  

NTU  (approximate)  (Fig. 3.17a)

5 0.970 0.99
4 0.948 0.98
3 0.905 0.95
2 0.820 0.87
1 0.632 0.64

C min C
At lower values of r  or r  min  0 , this will not give correct values accurately.
C max C max

3.39 Calculate the area required in a two-tube pass, one-shell pass condenser that is to condense 106
kg/h of steam at 40 C using water at 17 C. Assume that U = 4700 W/m2.K, the maximum
allowable temperature rise of the water is 10 C and hfg = 2406 kJ/kg.

Solution:
  1  e NTU
UA
NTU 
Cmin
Th = 40 C
Tcin = 17 C
Tcout = 27 C
 s = 106 kg/h
m

56
 3. HEAT EXCHANGER DESIGN

U = 4700 W/m2.K
hfg = 2406 kJ/kg

 
Q  Cmin Tcout  Tcin  m
 s hfg

 
Cmin 27  17  10 6 
 1 
2406 
 3600 
Cmin = 66,833 W/K
 
Q   Cmin Thin  Tcin  m
 s hfg

 66,83340  17  10 6 

 1 
2406 
 3600 
 = 0.4348
  1  e NTU
0.4348 1  e NTU
NTU = 0.5706
UA
NTU 
Cmin

0.5706
4700A
66,833
A = 8.114 m2.

3.40 An engineer wants to divert 1 gal/min of water at 180 F from his car radiator through a small
cross-flow heat exchanger with neither flow mixed, to heat 40 F water to 140 F for shaving when
he goes camping. If he produces a pint per minute of hot water, what will be the area of the
exchanger and the temperature of the returning radiator coolant if U = 720 W/m2.K?

Solution:
Thin = 180 F
Tcin = 40 F
Tcout = 140 F

Specific heat of water at 180 F, c ph = 1.003 Btu/lb-F

Specific heat of water at 90 F (average of 40 F and 140 F), c pc = 0.998 Btu/lb-F
Density of water at 180 F,  h = 60.56 lb/ft3. As diverted.
Density of water at 140 F,  c = 61.37 lb/ft3. As produced.

720
U = 720 W/m2.K = Btu/hr-ft2-F
5.6786
U = 126.8 Btu/hr-ft2-F

h
Solving for m

 h   hVh
m
57
 3. HEAT EXCHANGER DESIGN

Vh = (1 gal/min)(231 in3/gal)(1 ft3 / 1728 in3)( 60 min/hr)

Vh = 8.0208 ft3/hr
m h = (60.56)(8.0208) lb/sec = 485.74 lb/sec

c
Solving for m

m c   cVc
Vc = (1 pint/min)(0.125 gal/min)(231 in3/gal)(1 ft3 / 1728 in3)( 60 min/hr)
Vc = 1.0026 ft3/hr
m c = (61.37)(1.0026) lb/sec = 61.53 lb/sec

Qm 
 c c pc Tcout  Tcin 
Q = (61.53)(0.998)(140 – 40) = 6141 Btu/hr

Qm 
 h c ph Thin  Thout 
6141 = (485.74)(1.003)(180 - Thout )
Thout = 167.4 F
Th (average) = 0.5(180 + 167.4) = 173.7 F
Specific heat of water at 167.4 F, c ph = 1.0023 Btu/lb-F
Qm 
 h c ph Thin  Thout 
6141 = (485.74)(1.0023)(180 - Thout )
Thout = 167.4 F

LMTD 
Thin  
 Tcout  Thout  Tcin 
 Th  Tcout 
ln in 
 Th  Tc 
 out in 

180  140   167.4  40 

LMTD  = 75.45 F
 180  140 
ln 
 167.4  40 
Tt  Ttin 140  40
P  out  = 0.71
Tsin  Ttin 180  40
Tsin  Tsout 180  167.4
R  = 0.126
Ttout  Ttin 140  40

Fig. 3.14c, Cross-flow exchanger, neither mixed, F = 0.965.

Q  UAFLMTD
6141 = (126.8)(A)(0.965)(75.45)
A = 0.665 ft2
58
 3. HEAT EXCHANGER DESIGN

and Thout = 167.4 F

3.41 In a process for forming lead shot, molten droplets of lead are showered into the top of a tall
tower. The droplets fall through air and solidify before they reach the bottom of the tower. The
solid shot is collected at the bottom. To maintain a steady state, cool air is introduced at the
bottom of the tower and warm air is withdrawn at the top. For a particular tower, the droplets
are 1 mm in diameter and at their melting temperature of 600 K when they are released. The
latent heat of solidification is 850 kJ/kg. They fall with a mass flow rate of 200 kg/hr. There are
2430 droplets per cubic meter of air inside the tower. Air enters the bottom at 20 C with a mass
flow rate of 1100 kg/hr. The tower has an internal diameter of 1 m with adiabatic walls.

a. Sketch, qualitatively, the temperature distribution of the shot and the air along the height of
the tower.
b. If it is desired to remove the shot at a temperature of 60 C, what will be the temperature of
the air leaving the top of the tower?
c. Determine the air temperature at the point where the lead had just finishing solidifying.
d. Determine the height that the tower must have in order to function as desired. The heat
transfer coefficient between the air and the droplets is h = 318 W/m2.K

Solution:

(a)

(b) Specific heat of lead shot = c pl = 130 J/kg.K

Specific heat of air = c pa = 1008 J/kg.K
m l = 200 kg/hr
h = 850 kJ/kg = 850,000 J/kg
True value for lead, h = 23.1 kJ/kg = 23,100 J/kg
Qm   
 l h  c pl Thin  Thout
Thin = 600 K = 327 C
Thout = 60 C

59
 3. HEAT EXCHANGER DESIGN

 1 
Q  200  23,100  130327  60  = 3212 W
 3600 
 a = 1100 kg/hr
m
Tcin = 20 C
Qm 
 a c pa Tcout  Tcin 
3212  1100 
 1 
1008  Tcout  20  
 3600 
Tcout = 30.43 C
Tc (average) = 0.5(20 + 30.43) = 25.22 C
Specific heat of air = c pa = 1007 J/kg.K

3212  1100 
 1 
1007  Tcout  20  
 3600 
Tcout = 30.44 C (answer)

(c) Cooling required after solidification

Q2  m 
 l c pl Thin  Thout 
 1 
Q2  200  130 327  60  = 1928.33 W
 3600 
Q2  m 
 a c pa Tcout2  Tcin 
1928.33  1100 
 1 
1008  Tcout 2  20  
 3600 
Tcout 2 = 26.26 C
Tc (average) = 0.5(20 + 26.26) = 23.13 C
Specific heat of air = c pa = 1006.6 J/kg.K

1928.33  1100 
 1 
1006.6  Tcout  20  
 3600 
Tcout 2 = 26.27 C (answer)

(d) h = 318 W/m2.K

Q  UALMTD
U = h = 318 W/m2.K
Solidification: Q1 = 3212 – 1928.33 = 1283.67 W

LMTD1 
T hin  
 Tcout 2  Thin  Tcout1 
 Th  Tcout 2 
ln in 
 Th  Tc 
 in out 1 

60
 3. HEAT EXCHANGER DESIGN

327  26.27  327  30.44  = 298.64 C

LMTD1 
 327  26.27 
ln 
 327  30.44 
Q1  UA 1LMTD1 
1283.67  318A 1 298.67
A 1 = 0.0135 m2.

Cooling, Q2 = 1928.33 W

LMTD2  in
   
Th  Tcout 2  Thout  Tcin
 Th  Tcout 2 
ln in 
 Th  Tc 
 out in 

327  26.27  60  20  = 129.24 C

LMTD2 
 327  26.27 
ln 
 60  20 
Q2  UA 2 LMTD2 
1928.33  318A 2 129.24
A 2 = 0.0469 m2.

A T  A 1  A 2 = 0.0135 m2 + 0.0469 m2 = 0.0604 m2.

AT 0.0604
No. of droplets =  = 19,226
 d  0.001 2
2

19 ,226 droplets
VT = Volume of Tower = 3
= 7.9 m3.
2430 droplets / m
4VT 47.9 
H = Height of Tower =  = 10.06 meters (answer)
 D 2  12

- End -

61