Elementary Chemistry and Thermodynamics

The School of Workforce Development, Continuing Education & Online

Learning

Instructor: Pakeeza Hafeez

• 3
Recap/
There are _________modes
MCQ
of heat transfer between the two bodies.
conduction is the process of heat being transferred between objects through direct
• __________
contact.

• Conduction rate equation is described by the Fourier Law: True / False

q = kA dT/dx

• Convection: The mode of energy transfer between a solid surface and the adjacent
motion
liquid or gas that is in __________, and

Fluid motion
• it involves the combined effects of conduction and ___________.

electromagnetic
• Radiation is the transmission of energy through _______________waves.
 AGENDA
Week 10

• Heat exchangers
• Classification of heat exchangers
• Applications of heat exchangers
• Methods of calculations:
• Summary
Learning outcome
 Learning check
• How can we transfer heat between two surfaces?

• Are we using heat exchangers in home ?

• If yes then where ?

 Heat Exchangers
• Heat exchangers are devices that facilitate the exchange of
heat between two fluids that are at different temperatures
while keeping them from mixing with each other.

Plate, shell and tube and Fin heat exchangers

 Heat Exchangers
Applications
Heat exchangers are commonly used in practice in a wide
range of applications , from heating and air-conditioning
systems in a household, to chemical processing and power
production in large plants

Examples:
Intercoolers and preheaters
Condensers and boilers in steam plant
Evaporators and condensers refrigeration units
 Think Pair Share
• What are the two modes of heat transfer involved in heat
exchangers?
 Classification of Heat
Exchangers
Heat Excahngers can be classified in many different ways
based on their design characteristics

The main characteristics by which heat exchangers can be

categorized include:

• Heat transfer mechanism

• Construction method
• Flow configuration
Classification of Heat Exchangers
Based on Heat Transfer Mechanism

Single Phase Heat Exchangers

• the fluids do not undergo any phase change
• both the warmer and cooler fluids remain in the same state
of matter at which they entered the heat exchanger
• Example: water-to-water heat transfer applications

Two Phase Heat Exchangers

• fluids do experience a phase change during the heat transfer
process
• Example: boilers, condensers, and evaporators.
Classification of Heat Exchangers
Based on Construction

Tubular
• Shell and tube ,Spiral Double pipe, Pipe coils, etc

Plate Type
• Spiral , plate and coil, etc

Extended Surface
• Plate fin, tube fin, regenerative, rotary, etc
 Classification of Heat Exchangers
Shell and Tube Heat
Exchangers
• It is the most common type
used in industry

• Heat transfer by conduction

and convection

• Operating pressure range

from vacuum to 40 Mpa

• Temperature range from –

250o C to 800o C
 Classification of Heat Exchangers
Shell and Tube Heat
Exchangers

Components found in Shell and tube

heat exchangers are
• Heads
• Tube sheets
• Baffles
• Pass partition plates
• Expansion joints ( when required
ASME BPV Code Section VIII governs
the design and construction of heat
exchangers
 Classification of Heat Exchangers
U- Tube Heat Exchangers
 Classification of Heat Exchangers
Function of Baffles

a)They direct the fluid through multiple passes as the fluid flows from inlet
to outlet through the shell. In doing so, the fluid in the shell contacts the
entire tube bundle, maximizing contact for heat transfer to occur.

b) They slow the rate of fluid flow. This maximizes the amount of time for
heat transfer to occur.

c) They support the tube bundle, so that the tubes do not carry excessive
stress at the tube sheet attachment.

d) They prevent the tubes from contacting each other or the shell, so the
tubes are always properly spaced, permitting fluid flow.
 Classification of Heat Exchangers
• The head partition is an important feature of shell-and-tube type.

• This solid piece directs the tube-side heat exchange fluid through the
tubes.

• It also keeps fluid from bypassing the tube bundle and entering the
outlet directly.

• U-tube heat exchanger shells are usually designed with dished heads.

• This design withstands internal pressure more efficiently than flat

heads.

• A disadvantage of U-tube heat exchangers is that the internal tube

surfaces are difficult to clean mechanically, because of the numerous
bends.
 Classification of Heat Exchangers
Straight Tube Heat Exchangers
 Classification of Heat Exchangers
• The straight tube heat exchanger is quite similar to the U-tube heat
exchanger

• It too has multiple fluid passes, baffles, and head partitions. However,
the straight tube heat exchanger has two tube sheets (one for each end
of the tubes)

• Straight tube heat exchangers are much easier to clean than U-tube
designs, because mechanical cleaning devices can easily pass the
entire length of the tube
 Classification of Heat Exchangers
• Depending on the length of the heat exchanger, straight tube heat
exchanger shells may require expansion joints to accommodate
differential thermal expansion / reduce tube sheet stress

• In general straight tube shell and tube heat exchanger are more
complex; they have more joints, gaskets, and fasteners than U tube
designs, due to which they have more potential leak pathways
 Classification of Heat Exchangers
Shell and Coil Heat Exchangers (used as boiler water sample cooler)
 Classification of Heat Exchangers
• The shell-and-coil heat exchanger has a horizontal or vertical steel shell
that contains a coiled tube

• These heat exchangers are extremely compact, and make efficient use
of space

• They can handle fluids that are subject to sudden and large
temperature variations, such as those in steam and refrigeration
systems

• These compact heat exchangers have very high heat transfer rates,
especially if connected counter flow

• One disadvantage of shell-and-coil heat exchangers is that they are

impossible to clean mechanically
 Classification of Heat Exchangers
Plate Type Heat Exchangers
• Made of thin corrugated metal plates

• It’s aligned on a carrying bar

• Gaskets acts as barricades for heat transfer fluids

• It’s secured leak-tight by end plates

• Compact and cost effective

• Not usually used with steam as

• The condensate does not easily drain

• Thin plates do not tolerate water hammer

 Classification of Heat Exchangers
Spiral Plate Heat Exchangers

• True counter flow design

• Very efficient in heat transfer

• Self cleaning ability

• Reduced maintenance cost

 Learning check
• What is the role of fins in heat exchanger geometry?
Classification of Heat Exchangers
Based on Flow Configuration
Parallel Flow Heat Exchangers
• In a parallel flow exchanger, the
fluid streams enter together at
one end, flow parallel to each
other in the same direction, and
leave together at the other end.

• A large temperature difference

between inlet temperatures of hot
and cold fluids exists at the inlet
side, which may induce high
thermal stresses in the exchanger
wall at the inlet.
Classification of Heat Exchangers
Counter Flow Heat Exchangers

• In counter flow, heat exchanger

the hot and cold fluids enter the
heat exchanger at opposite ends
and flow in opposite directions.
 Classification of Heat Exchangers
Cross Flow Heat Exchangers

• In crossflow heat exchangers, fluids

flow perpendicularly to one another.

• a) the cross-flow is said to be unmixed

since the plate fins force the fluid to
flow through a particular interfin spacing
and prevent it from moving in the
transverse direction (i.e., parallel to the
tubes).

• The cross-flow in (b) is said to be mixed

since the fluid now is free to move in
the transverse direction.
• Both fluids are unmixed in a car
radiator.
 Learning Check
Which type of heat exchanger is presented in the figure?

a) Parallel

b) Counter

c) Cross

d) none
 Fouling
Common Concern When Operating Heat Excahngers

If there is a gradual decline in heat transfer fouling may be occurring which

can sometimes plug the tubes. Fouling is caused by:

• Mineral deposits (scaling)

• Decomposition of heat exchange fluids
• Ice formation
• Soot
• Ash
• Algae
• Entrained sediments
 Fouling
Common Concern When Operating Heat Excahngers

Zebra Muscles

• When heat exchanger is cooled with lake water biological organisms

grow on heat exchanger surfaces. Problems arise from algae and other
microbes such as zebra mussels.

Debris

• Such as rocks , trash may get into heat exchanger cause fouling.
Strainers can be used to prevent it.
 Learning Check (poll)

(a) Fouling increases the overall thermal resistance True / False

(b) Fouling lowers the overall heat transfer coefficient of heat exchangers

True / False
 Fouling
Cleaning Methods for Fouling

Four popular methods of removing fouling include:

• Mechanical cleaning using brushes and scraping.

• Chemical cleaning using solvent or chemicals.

• High velocity cleaning using water jets.

• Electronic water treatment.

 Cleaning Brush
Cleaning of shell and tube heat exchangers
 Fouling
Shell and Tube (to reduce Fouling)

• Keep velocities sufficiently high to avoid deposits

• Avoid stagnant regions where dirt can collect
• Avoid hot spot where scaling may occur
• Avoid cold spots where freezing may occur
 Fouling
Build up of 0.6mm thick layer of fouling and scaling
 Fouling
Fouling increases with increasing temperature and reducing
velocity
Fouling
Fouling
Fouling
 Summary
• We talked about heat exchanger and their classification based on three
criteria: heat transfer method, construction and flow arrangement

• Shell and tube , U tube and straight tube , shell and coil spiral plate heat
exchangers are discussed

• Reasons for fouling and method to reduce fouling are discussed

 Next Lecture Heads up
Common concerns in heat
exchanger and their inspection
No question is a silly
question

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