1

Thermal Power Plant

Part of
Heat Exchangers
Lecture 4
Dr. Tareq Al-hababi
Mechanical Engineering Department,
Sana'a University
Undergraduate Students 2023-2024
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Outlines
2.1 Introduction

2.2 Arrangement of Flow Paths in Heat Exchangers

2.3 Basic Equations in Design

2.4 Overall Heat Transfer Coefficient

2.5 Analysis of Heat Exchangers

2.5.1 LMTD Method for Heat Exchanger Analysis

2.5.2 Multipass and Crossflow Heat exchangers (Use of a correction factor, F)

2.5.3 The ε-NTU Method for Heat Exchanger Analysis

2.6 Summary of Heat Exchanger Design Calculation

4
2.5.3 The ε-NTU Method for HEX Analysis
A second kind of problem encountered in HEXs analysis is the
determination of the heat transfer rate and the outlet temperatures of the hot
and cold fluids for prescribed fluid mass flow rates and inlet temperatures
when the type and size of the HEX are specified. The heat transfer surface
area A of the heat exchanger in this case is known, but the outlet
temperatures are not. Here the task is to determine the heat transfer
performance of a specified heat exchanger or to determine if a heat
exchanger available in storage will do the job.
𝑄 =?? & 𝑇ℎ,𝑜 = ? ? & 𝑇𝑐,𝑜 = ? ?

√ Type and size of the HEX are specified & √ A

➢ Heat transfer performance?
➢ Will the HEX available in the storage do the job? ?
5
2.5.3 The ε-NTU Method for HEX Analysis

• The LMTD method could still be used for this alternative

problem, but the procedure would require tedious
iterations, and thus it is not practical.

• In an attempt to eliminate the iteration from the solution of

such problems, Kays and London came up with a method
in 1955 called the effectiveness-NTU method, which
greatly simplified heat exchanger analysis.
6
2.5.3 The ε-NTU Method for HEX Analysis
This method is based on three dimensionless parameters (𝑪, 𝜺, and
NTU) as:
1. Capacity rate ratio:
𝑪𝒎𝒊𝒏
𝑪=
𝑪𝒎𝒂𝒙
where
𝐶𝑚𝑖𝑛 and 𝐶𝑚𝑎𝑥 are the smaller and larger of the two magnitudes of 𝐶ℎ
and 𝐶𝑐 , respectively, and (𝐶 ≤ 1).

When 𝐶 = 0 corresponds to a finite 𝐶𝑚𝑖𝑛 and 𝐶𝑚𝑎𝑥 approaching ∞ (a

condensing or evaporating fluid).
7
2.5.3 The ε-NTU Method for HEX Analysis

2. Heat Exchanger effectiveness:

𝑸 Actual heat transfer rate

𝜺= = & 0≤𝜀≤1
𝑸𝒎𝒂𝒙 Maximum possible heat transfer rate

The actual heat transfer is obtained by either the energy given

off by the hot fluid or the energy received by the cold fluid, from
Equations
𝑄 = 𝒎𝑪 ሶ 𝒑 𝑻𝒉𝟏 − 𝑻𝒉𝟐 = 𝒎𝑪 ሶ 𝒑 𝑻𝒄𝟐 − 𝑻𝒄𝟏
𝒉 𝒄
𝐼𝐹 𝐶ℎ > 𝐶𝑐 , then 𝑇ℎ1 − 𝑇ℎ2 < 𝑇𝑐2 − 𝑇𝑐1
𝐼𝐹 𝐶ℎ < 𝐶𝑐 , then 𝑇ℎ1 − 𝑇ℎ2 > 𝑇𝑐2 − 𝑇𝑐1
8

𝐼𝐹 𝐶ℎ > 𝐶𝑐 , then 𝑇ℎ1 − 𝑇ℎ2 < 𝑇𝑐2 − 𝑇𝑐1

𝐼𝐹 𝐶ℎ < 𝐶𝑐 , then 𝑇ℎ1 − 𝑇ℎ2 > 𝑇𝑐2 − 𝑇𝑐1

The fluid that might undergo the maximum temperature difference is the
fluid with the minimum heat capacity rate 𝐶𝑚𝑖𝑛 . Therefore, the maximum
possible heat transfer is generally expressed as

𝑸𝒎𝒂𝒙 = 𝑪𝒎𝒊𝒏 𝑻𝒉𝒊 − 𝑻𝒄𝒊

𝑄𝑚𝑎𝑥 = 𝑚𝐶
ሶ 𝑝 𝑐
𝑇ℎ1 − 𝑇𝑐1 𝑖𝑓 𝐶𝑐 < 𝐶ℎ

or
𝑄𝑚𝑎𝑥 = 𝑚𝐶
ሶ 𝑝 ℎ
𝑇ℎ1 − 𝑇𝑐1 𝑖𝑓 𝐶ℎ < 𝐶𝑐
9

Heat exchanger effectiveness, ε, is therefore written as

𝑪𝒉 𝑻𝒉𝟏 − 𝑻𝒉𝟐 𝑪𝒄 𝑻𝒄𝟐 − 𝑻𝒄𝟏

𝜺= =
𝑪𝒎𝒊𝒏 𝑻𝒉𝟏 − 𝑻𝒄𝟏 𝑪𝒎𝒊𝒏 𝑻𝒉𝟏 − 𝑻𝒄𝟏

The first definition is for 𝐶ℎ = 𝐶𝑚𝑖𝑛 , and the second is

for 𝐶𝑐 = 𝐶𝑚𝑖𝑛 .
* Notice that the previous equation is valid for all
heat exchanger flow arrangements.
10
2.5.3 The ε-NTU Method for HEX Analysis

3. Number of transfer unit (NTU):

we can obtain this value either from Figures or from relations

Effectiveness NTU
Relations Relations
11

Effectiveness
Relations
12

NTU
Relations
13
14

C = Cmim/Cmax

𝜺
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20 Upper Limit for Heat Transfer in a Heat Exchanger
Example 13-7
Cold water enters a counter-flow heat exchanger at 10 ℃ at a rate
of 8 𝑘𝑔/𝑠, where it is heated by a hot water stream that enters the
heat exchanger at 70 ℃ at a rate of 2 𝑘𝑔/𝑠. Assuming the specific
heat of water to remain constant at 𝐶𝑝 = 4.18 𝑘𝐽Τ𝑘𝑔. ℃ and the
heat exchanger effectiveness is 1, determine the maximum heat
transfer rate and the outlet temperatures of the cold and the hot
water streams for this limiting cases.
Solution
21
Solution
The heat capacity rates (Ch, Cc) of the hot and cold fluids are
determined from

𝐶ℎ = 𝑚ሶ ℎ 𝐶𝑝ℎ = 2 × 4.18 = 8.36 𝑘𝑊 Τ℃

𝐶𝑐 = 𝑚ሶ 𝑐 𝐶𝑝𝑐 = 8 × 4.18 = 33.4 𝑘𝑊 Τ℃
𝐶𝑐 > 𝐶ℎ

Therefore
𝐶𝑚𝑖𝑛 = 𝐶ℎ = 8.36 𝑘𝑊 Τ℃
22
The maximum heat transfer rate is
𝑄𝑚𝑎𝑥 = 𝐶𝑚𝑖𝑛 𝑇ℎ𝑖 − 𝑇𝑐𝑖 = 8.36 × 70 − 10 = 𝟓𝟎𝟐 𝒌𝑾
𝜀 = 𝑄Τ𝑄𝑚𝑎𝑥 → 𝑄 = 𝑄𝑚𝑎𝑥 × 𝜀 = 502 × 1 = 502 𝑘𝑊
The outlet temperatures of the cold and hot streams in this limiting case are
determined to be
𝑄 502
𝑄 = 𝐶𝑐 𝑇𝑐,𝑜 − 𝑇𝑐,𝑖 → 𝑇𝑐,𝑜 = 𝑇𝑐,𝑖 + = 10 + = 𝟐𝟓 ℃
𝐶𝑐 33.4
𝑄 502
𝑄 = 𝐶ℎ 𝑇ℎ,𝑖 − 𝑇ℎ,𝑜 → 𝑇ℎ,𝑜 = 𝑇ℎ,𝑖 − = 70 − = 𝟏𝟎 ℃
𝐶ℎ 8.38

10 ℃

25 ℃
*****
23
Special case
The temperature rise of the cold fluid in a heat exchanger will be equal to
the temperature drop of the hot fluid when the mass flow rates and the
specific heats of the hot and cold fluids are identical.

𝑄 = 𝑚ℎ 𝐶𝑝ℎ ∆𝑇ℎ = (𝑚𝑐 𝐶𝑝𝑐 )∆𝑇𝑐

If
𝑚ℎ 𝐶𝑝ℎ = 𝑚𝑐 𝐶𝑝𝑐

𝐶ℎ = 𝐶𝑐
Then
∆𝑇ℎ = ∆𝑇𝑐
*****
24
Heating Water in a Counter-flow heat exchanger
Example 13-8
A counter-flow double-pipe heat exchanger is to
heat water from 20 ℃ to 80 ℃ at a rate of
1.2 𝑘𝑔Τ𝑠. The heating is to be accomplished by
geothermal water available at 160 ℃ at a mass
flow rate of 2 𝑘𝑔Τ𝑠. The inner tube is thin-walled
and has a diameter of 1.5 cm. Take the specific
heats of water and geothermal fluid to be
( 4.18 𝑘𝐽Τ𝑘𝑔. ℃ ) and ( 4.31 𝑘𝐽Τ𝑘𝑔. ℃ )
respectively. If the overall heat transfer coefficient
of the heat exchanger is 640 𝑊 Τ𝑚2 . ℃ ,
determine the length of the heat exchanger
required to achieve the desired heating by using
the effectiveness-NTU method.
25
Given data:
Counter-flow double-pipe heat exchanger, 𝑖𝑛𝑛𝑒𝑟 𝑡𝑢𝑏𝑒 𝑤𝑎𝑙𝑙 𝐼𝐷 = 1.5 𝑐𝑚
Cold fluid:
(increasing temp. from 20 ℃ to 80 ℃), 𝑚ሶ = 1.2 𝑘𝑔Τ𝑠, 𝐶𝑝 = 4.18 𝑘𝐽Τ𝑘𝑔. ℃
Hot fluid:
(decreasing temp. from 160 ℃), 𝑚ሶ = 2 𝑘𝑔Τ𝑠, 𝐶𝑝 = 4.31 𝑘𝐽Τ𝑘𝑔. ℃
Overall heat transfer coefficient of the heat exchanger is 640 𝑊 Τ𝑚2 . ℃

Length (L) = ?
26 Solution (Example 13-8)
In the effectiveness-NTU method, we first determine the heat
capacity rates (Ch, Cc) of the hot and cold fluids and identify the
smaller one:
𝐶ℎ = 𝑚ሶ ℎ 𝐶𝑝ℎ = 2 × 4.31 = 8. 62 𝑘𝑊 Τ℃
𝐶𝑐 = 𝑚ሶ 𝑐 𝐶𝑝𝑐 = 1.2 × 4.18 = 5.02 𝑘𝑊 Τ℃
𝐶ℎ > 𝐶𝑐
Therefore
𝐶𝑚𝑖𝑛 = 𝐶𝑐 = 5.02 𝑘𝑊 Τ℃
And
𝑪𝒎𝒊𝒏 𝟓. 𝟎𝟐
𝑪= = = 𝟎. 𝟓𝟖𝟑
𝑪𝒎𝒂𝒙 𝟖. 𝟔𝟐
27 Solution (Example 13-8)

The maximum heat transfer rate is

𝑄𝑚𝑎𝑥 = 𝐶𝑚𝑖𝑛 𝑇ℎ𝑖 − 𝑇𝑐𝑖 = 5.02 × 160 − 20 = 702.8 𝑘𝑊

The actual heat transfer rate in this heat exchanger is

𝑄 = 𝑚ሶ 𝐶𝑝 (𝑇𝑜𝑢𝑡 − 𝑇𝑖𝑛 ) = 1.2 × 4.18 × 80 − 20 = 301 𝑘𝑊

𝑊𝑎𝑡𝑒𝑟

𝑸 𝟑𝟎𝟏
𝜺= = = 𝟎. 𝟒𝟐𝟖
𝑸𝒎𝒂𝒙 𝟕𝟎𝟐. 𝟖
The (NTU) of this counter-
flow can be determined from:
1- Figure 13-26b

𝑪𝒎𝒊𝒏 𝟓. 𝟎𝟐
𝑪= = = 𝟎. 𝟓𝟖𝟑
𝑪𝒎𝒂𝒙 𝟖. 𝟔𝟐
⟹ 𝑁𝑇𝑈
𝑸 𝟑𝟎𝟏
𝜺= = = 𝟎. 𝟒𝟐𝟖
𝑸𝒎𝒂𝒙 𝟕𝟎𝟐. 𝟖

𝑁𝑇𝑈 = 0.651 0.651

 NTU Relations
2- Relation from Table 13-5
(it will be chosen for more
accuracy)

1 𝜀−1
𝑁𝑇𝑈 = ln
𝑐−1 𝜀𝑐 − 1

1 0.428 − 1
= ln
0.583 − 1 0.428 × 0.583 − 1

= 0.651

𝑁𝑇𝑈 = 0.651
30 Solution (Example 13-8)

Then the heat transfer surface area becomes

𝑈𝐴 𝑁𝑇𝑈 𝐶𝑚𝑖𝑛 0.651 × 5020

𝑁𝑇𝑈 = → 𝐴= = = 5.11 𝑚2
𝐶𝑚𝑖𝑛 𝑈 640

𝐴 5.11
𝐴 = 𝜋𝐷𝐿 → 𝐿= = = 𝟏𝟎𝟖 𝒎
𝜋𝐷 𝜋 × 0.015

Note that we obtained the same result as in the example (13-4, in the last
lecture) with the effectiveness-NTU method in a systematic and
straightforward manner.

*****
31 Cooling hot oil by water in a multipass heat exchanger
Example 13-9
Hot oil is to be cooled by water in a 1-shell-pass and 8-
tube-passes heat exchanger. The tubes are thin-walled
and are made of copper with an internal diameter of 1.4
cm. The length of each tube pass in the heat exchanger
is 5 m, and the overall heat transfer coefficient is
310 𝑊 Τ𝑚2 . ℃. Water flows though the tubes at a rate
of 0.2 𝑘𝑔/𝑠, and the oil through the shell at a rate of
0.3 𝑘𝑔/𝑠. The water and the oil enter at temperatures of
20 ℃ 𝑎𝑛𝑑 150 ℃, respectively. Take the specific heats
of water and oil fluid to be 4.18 𝑘𝐽Τ𝑘𝑔. ℃ and
2.13 𝑘𝐽Τ𝑘𝑔. ℃ respectively. Determine the rate of heat
transfer in the heat exchanger and the outlet
temperatures of the water and the oil.
32
Given data

A 1-shell-pass and 8-tube-passes heat exchanger

𝑖𝑛𝑛𝑒𝑟 𝑡𝑢𝑏𝑒 𝑤𝑎𝑙𝑙 𝐼𝐷 = 1.4 𝑐𝑚,
The length of each tube pass 𝐿 = 5 𝑚
𝑈 = 310 𝑊 Τ𝑚2 . ℃
Tubes- Cold fluid-Water (𝑇𝑖𝑛 = 20 ℃),
𝑚ሶ = 0.2 𝑘𝑔Τ𝑠, 𝐶𝑝𝑐 = 4.18 𝑘𝐽Τ𝑘𝑔. ℃
Shell- Hot fluid-Oil (𝑇𝑖𝑛 = 150 ℃),
𝑚ሶ = 0.3 𝑘𝑔Τ𝑠, 𝐶𝑝ℎ = 2.13 𝑘𝐽Τ𝑘𝑔. ℃

𝑸 =? & 𝑻𝒐𝒖𝒕,𝑶𝒊𝒍 =? & 𝑻𝒐𝒖𝒕,𝑾𝒂𝒕𝒆𝒓 =?

33 Solution (Example 13-9)

The use of the LMTD method in this case will involve tedious
iterations, and thus the 𝜺-NTU method is suitable.
𝐶ℎ = 𝑚ሶ ℎ 𝐶𝑝ℎ = 0.3 × 2.13 = 0. 639 𝑘𝑊 Τ℃

𝐶𝑐 = 𝑚ሶ 𝑐 𝐶𝑝𝑐 = 0.2 × 4.18 = 0.836 𝑘𝑊 Τ℃

𝐶ℎ < 𝐶𝑐

Therefore
𝐶𝑚𝑖𝑛 = 𝐶ℎ = 0. 639 𝑘𝑊 Τ℃
34

And

𝐶𝑚𝑖𝑛 0. 639
𝐶= = = 0.764
𝐶𝑚𝑎𝑥 0.836

The maximum heat transfer rate is

𝑄𝑚𝑎𝑥 = 𝐶𝑚𝑖𝑛 𝑇ℎ,𝑖 − 𝑇𝑐,𝑖 = 0.639 × 150 − 20 = 83.2 𝑘𝑊

The heat transfer surface area is

𝐴 = 𝒏 𝜋𝐷𝐿 = 8𝜋 × 0.014 × 5 = 1.76 𝑚2
35
Then the NTU of this heat exchanger becomes

𝑈𝐴 310 × 1.76
𝑁𝑇𝑈 = = = 0.853
𝐶𝑚𝑖𝑛 639

The effectiveness ( 𝜺) of this heat exchanger corresponding to

𝐶 = 0.764 & 𝑁𝑇𝑈 = 0.853 is determined from Figure 13-26c to be

𝜺 = 𝟎. 𝟒𝟕

The actual heat transfer rate (Q ) in this heat exchanger is

𝑸
𝜺= → 𝑄 = 𝜺 𝑸𝒎𝒂𝒙 = 0.47 × 83.1 = 𝟑𝟗. 𝟏 𝒌𝑾
𝑸𝒎𝒂𝒙
36 Solution (Example 13-9)

The outlet temperatures of the cold and the hot fluid streams are
determined to be
𝑄 39.1
𝑄 = 𝐶𝑐 𝑇𝑐,𝑜 − 𝑇𝑐,𝑖 → 𝑇𝑐,𝑜 = 𝑇𝑐,𝑖 + = 20 + = 𝟔𝟔. 𝟖 ℃
𝐶𝑐 0.836
𝑄 39.1
𝑄 = 𝐶ℎ 𝑇ℎ,𝑖 − 𝑇ℎ,𝑜 → 𝑇ℎ,𝑜 = 𝑇ℎ,𝑖 − = 150 − = 𝟖𝟖. 𝟖 ℃
𝐶ℎ 0.639

Therefore, the temperature of the cooling water will rise from

20 ℃ to 66.8 ℃ as it cools the hot oil from 150 ℃ to 88.8 ℃ in
this heat exchanger.
*****
37
Using the LMTD method & Using the ε-NTU method

Example 2 .9
A shell-and-tube heat exchanger with two tube passes and
baffled single shell pass is used as oil cooler. Cooling water at
20°C flows through the tubes at a flow rate of 4.082 kg /s.
Engine oil enters the shell side at a flow rate of 10 kg/s. The
inlet and outlet temperatures of oil are 90°C and 60°C,
respectively. Determine the surface area of the heat exchanger
by both the LMTD and ε-NTU methods if the overall heat
transfer coefficient based on the outside tube area is
262 WΤm2 . K. The specific heats of water and oil are 4179 J/kg
⋅ K and 2118 J/kg ⋅ K, respectively.
38
Using the LMTD method & Using the ε-NTU method

Solution
A shell-and-tube heat exchanger 2-tube passes 1-shell
Tubes- Cold fluid- Water (𝑇𝑖𝑛 = 20 ℃),
𝑚ሶ = 4.082 𝑘𝑔Τ𝑠, 𝐶𝑝𝑐 = 4179 𝐽Τ𝑘𝑔. 𝐾
Shell- Hot fluid- Oil (𝑇𝑖𝑛 = 90 ℃ 𝑎𝑛𝑑 𝑇𝑜𝑢𝑡 = 60 ℃),
𝑚ሶ = 10 𝑘𝑔Τ𝑠, 𝐶𝑝ℎ = 2118 𝐽Τ𝑘𝑔. 𝐾
𝑈 = 262 𝑊 Τ𝑚2 . 𝐾 (based on the outside tube area)

𝑨 =?
39 Using the LMTD method
First, using the LMTD method, we shall calculate the heat transfer rate Q and the LMTD for counterflow.
Subsequently, P, R, and the correction factor F will be determined. Then, applying the heat transfer rate Equation,
the heat transfer surface area A will be determined.
The heat capacity rates for the shell fluid (oil) and the tube fluid (water) are

𝐶ℎ = 𝑚ሶ ℎ 𝐶𝑝ℎ = 10 × 2118 = 21180 𝑊 Τ𝐾

𝐶𝑐 = 𝑚ሶ 𝑐 𝐶𝑝𝑐 = 4.082 × 4179 = 17058.7 𝑊 Τ𝐾

The heat transfer rate from the temperature drop of the oil is
𝑄 = 𝐶ℎ 𝑇ℎ,𝑖 − 𝑇ℎ,𝑜 = 21180 × 90 − 60 = 635400 𝑊
The water outlet temperature from the energy balance is
𝑄 635400
𝑄 = 𝐶𝑐 𝑇𝑐,𝑜 − 𝑇𝑐,𝑖 = 635400 𝑊 → 𝑇𝑐,𝑜 = 𝑇𝑐,𝑖 + = 20 + = 𝟓𝟕. 𝟐𝟓 ℃
𝐶𝑐 17058.7
For a counterflow arrangement
∆𝑇1 − ∆𝑇2 32.75 − 40
∆𝑇𝑙𝑚 = = = 36.4 ℃
ln ∆𝑇1 Τ∆𝑇2 ln 32.75Τ40
𝑡2 − 𝑡1 57.25 − 20 𝑇1 − 𝑇2 𝐶𝑐 17058.7
𝑃= = = 0.532 𝑎𝑛𝑑 𝑅 = = = = 0.805
𝑇1 − 𝑡1 90 − 20 𝑡2 − 𝑡1 𝐶ℎ 21180
From the Fig. 13-18a we get the value of (𝐹 = 0.85)
𝑄 635400
𝑄 = 𝑈 𝐴 𝐹 ∆𝑇𝑙𝑚,𝑐𝑜𝑢𝑛𝑡𝑒𝑟−𝑓𝑙𝑜𝑤 → 𝐴 = = = 𝟕𝟖. 𝟔 𝒎𝟐
𝑈𝐹∆𝑇𝑙𝑚,𝑐𝑜𝑢𝑛𝑡𝑒𝑟−𝑓𝑙𝑜𝑤 262 × 0.85 × 36.4 ⋕
40 Using the ε-NTU method
Using the ε-NTU method, we will first determine ε and C and, subsequently, NTU and then A. In this problem, 𝐶ℎ > 𝐶𝑐
and, hence, 𝐶𝑐 = 𝐶𝑚𝑖𝑛

𝐶ℎ = 𝑚ሶ ℎ 𝐶𝑝ℎ = 10 × 2118 = 21180 𝑊 Τ𝐾

→ 𝐶𝑐 = 𝐶𝑚𝑖𝑛 = 17058.7 𝑊 Τ𝐾
𝐶𝑐 = 𝑚ሶ 𝑐 𝐶𝑝𝑐 = 4.082 × 4179 = 17058.7 𝑊 Τ𝐾
𝐶𝑚𝑖𝑛 17058.7
𝑐= = = 0.805
𝐶𝑚𝑎𝑥 21180
From the given temperature, for 𝐶𝑐 = 𝐶𝑚𝑖𝑛
𝐶𝑐 𝑇𝑐2 − 𝑇𝑐1 57.25 − 20
𝜀= = = 0.532
𝐶𝑚𝑖𝑛 𝑇ℎ1 − 𝑇𝑐1 90 − 20

Now calculate NTU either from the formula of Table 13-5 or from Figure 13-26c with a proper interpretation for ε, NTU,
and C. From Table 13-5 for a 1 to 2 shell-and-tube heat exchanger, we have
1 2Τ𝜀 − 1 − 𝑐 − 1 + 𝑐 2 1 2Τ0.532 − 1 − 0.805 − 1 + 0.8052
𝑁𝑇𝑈 = − ln =− ln = 1.226
1 + 𝑐2 2Τ𝜀 − 1 − 𝑐 + 1 + 𝑐 2 1 + 0.8052 2Τ0.532 − 1 − 0.805 + 1 + 0.8052

Hence,
𝑈𝐴 𝐶𝑚𝑖𝑛 17058.7
𝑁𝑇𝑈 = → 𝐴= 𝑁𝑇𝑈 = × 1.226 = 𝟕𝟗. 𝟖 𝒎𝟐
𝐶𝑚𝑖𝑛 𝑈 262
The same surface area of heat transfer we obtained from LMDT method ***** ⋕
41

Summary
of
Heat Exchanger Design Calculation
42
2.6 Summary of Heat Exchanger Design Calculation
Thus far, two methods for performing a heat exchanger thermal analysis have been discussed. The
rating and sizing of heat exchangers are two important problems encountered in the thermal analysis
of heat exchangers.
For example, if inlet temperatures, one of the fluid outlet temperatures, and mass flow rates are known,
then the unknown outlet temperature can be calculated from heat balances and the LMTD method can be
used to solve this sizing problem with the following steps:
1. Calculate Q and the unknown outlet temperature.
2. Calculate ∆𝑇𝑙𝑚 and obtain the correction factor F, if necessary.
3. Calculate the overall heat transfer coefficient U.
4. Determine A.
The LMTD method may also be used for rating problems (performance analysis) for an available heat
exchanger, but computation would be tedious, requiring iteration since the outlet temperatures are not known.
In such situations, the analysis can be simplified by using the ε-NTU method.
The rating analysis with the ε-NTU method is as follows:
1. Calculate the capacity rate ratio 𝑐 = 𝐶𝑚𝑖𝑛 Τ𝐶𝑚𝑎𝑥 and 𝑁𝑇𝑈 = 𝑈𝐴Τ𝐶𝑚𝑖𝑛 from the input data.
2. Determine the effectiveness ε from the appropriate charts or ε-NTU equations for the given heat
exchanger and specified flow arrangement.
3. Knowing ε, calculate the total heat transfer rate.
4. Calculate the outlet temperatures.
43
2.6 Summary of Heat Exchanger Design Calculation

The ε-NTU method may also be used for the sizing problem, and the procedure is as follows:
1. Knowing the outlet and inlet temperatures, calculate ε.
2. Calculate the capacity rate ratio 𝒄 = 𝑪𝒎𝒊𝒏 Τ𝑪𝒎𝒂𝒙 .
3. Calculate the overall heat transfer coefficient U.
4. Knowing ε, C, and the flow arrangement, determine NTU from charts or from ε-NTU relations.
5. Knowing NTU, calculate the heat transfer surface area A.
The use of the ε-NTU method is generally preferred in the design of compact heat exchangers for
automotive, aircraft, air-conditioning, and other industrial applications where the inlet temperatures of
the hot and cold fluids are specified and the heat transfer rates are to be determined. The LMTD method
is traditionally used in the process, power, and petrochemical industries.
44
45

Summary of Equations
𝜋𝑑 2
𝑄, 𝑈, 𝐴 𝐿, 𝐷 , ∆𝑇𝑙𝑚 , T, 𝐶𝑝 , 𝑚, 𝑅𝑓 , 𝐹 𝑃, 𝑅 , 𝐶 𝐶𝑚𝑖𝑛 , 𝐶𝑚𝑎𝑥 , 𝜀, 𝑄𝑚𝑎𝑥 , 𝑁𝑇𝑈 𝐴= = 𝜋𝑑𝐿
4
Parallel and counter flow
∆𝑇2 −∆𝑇1 ∆𝑇1 −∆𝑇2
𝑄 = 𝑈 𝐴 ∆𝑇𝑙𝑚 = 𝑚𝐶
ሶ 𝑝 𝑇ℎ1 − 𝑇ℎ2 = 𝑚𝐶
ሶ 𝑝 𝑇𝑐2 − 𝑇𝑐1 & ∆𝑇𝑙𝑚 = =
ℎ 𝑐 ln ∆𝑇2 Τ∆𝑇1 ln ∆𝑇1 Τ∆𝑇2

Cross and Multipass flows

𝑄 = 𝑈 𝐴 𝐹 ∆𝑇𝑙𝑚,𝑐𝑜𝑢𝑛𝑡𝑒𝑟−𝑓𝑙𝑜𝑤 & ∆𝑇𝑙𝑚(𝑐𝑟𝑜𝑠𝑠 𝑎𝑛𝑑 𝑚𝑢𝑙𝑡𝑖𝑝𝑎𝑠𝑠 𝑓𝑙𝑜𝑤) = 𝐹 ∆𝑇𝑙𝑚,𝑐𝑜𝑢𝑛𝑡𝑒𝑟−𝑓𝑙𝑜𝑤

𝑡2 − 𝑡1 𝑇1 − 𝑇2
𝑃= 𝑎𝑛𝑑 𝑅 =
𝑇1 − 𝑡1 𝑡2 − 𝑡1
𝑄 𝐶ℎ 𝑇ℎ1 − 𝑇ℎ2 𝐶𝑐 𝑇𝑐2 − 𝑇𝑐1
𝑄𝑚𝑎𝑥 = 𝐶𝑚𝑖𝑛 𝑇ℎ𝑖 − 𝑇𝑐𝑖 𝜀= = =
𝑄𝑚𝑎𝑥 𝐶𝑚𝑖𝑛 𝑇ℎ1 − 𝑇𝑐1 𝐶𝑚𝑖𝑛 𝑇ℎ1 − 𝑇𝑐1

𝑈𝐴 𝐶𝑚𝑖𝑛
𝑁𝑇𝑈 = & 𝑐=
𝐶𝑚𝑖𝑛 𝐶𝑚𝑎𝑥
46

Homework (3)
(Due date: Wednesday, August 23, 2023)

1. What is the effectiveness of a heat exchanger? What is its range of possible

values?

2. Hot exhaust gases, which enter a finned-tube, cross-flow heat exchanger at

300 ℃ and leave at 100 ℃, are used to heat pressurized water at a flow rate of 1
kg/s from 35 ℃ to 125 ℃. The specific heat of water at the average water
temperature is 4197 J/kg. K. The overall heat transfer coefficient based on the
gas-side surface area is 𝑈ℎ = 100 𝑊 Τ𝑚2 . 𝐾. Determine the required gas-side
surface area 𝐴ℎ using the 𝜺 −NTU method.