SOLUTIONS Out: 09/24/2024

Due: 10/01/2024

HOME ASSIGNMENT # 2
MECH 5191 & 6091, Heat Exchanger Design & Engineering
Fall 2024

1. Assume that in a vapor condenser, the liquid condensate leaves the heat exchanger at
saturation temperature Th (i.e., there is no subcooling of the condensed liquid). Show that
variation of the coolant temperature along the condenser is given by the following (where Tc1
is the cooling water inlet temperature):

Tc − Tc1  UA 
= 1 − exp  − 
Th − Tc1  Cc 

From energy balance and the heat exchanger rate equation it follows that

dq = Cc dTc = U (Th − Tc ) dA

Hence, integrating along the heat exchange surface area (and up to a given location) yields

x
dTc
x
U  T −T  UA
1 Th − Tc = 1 Cc dA or ln  h c  = −
 Th − Tc1  Cc

This expression can be algebraically rearranged as

Th − Tc1 + Tc1 − Tc  UA  T −T  UA 
= exp  −   c c1 = 1 − exp  
Th − Tc1  Cc  Th − Tc1  Cc 
Note that flow arrangement has no influence in this case (saturated condensation or phase
change in one fluid stream).

2. Heat Exchanger Sizing Problem: Water (cp = 4182 J/kgK) at a flow rate of 5000 kg/hr is
heated from 10C to 35C in an oil cooler by hot engine oil (cp = 2072 J/kgK) that has an
inlet temperature of 65C and a flow rate of 6000 kg/hr. If the overall heat transfer
coefficient in this heat exchanger is 3500 W/m2K, determine the required surface area when
the flow arrangement is (a) parallel flow, and (b) counter flow, respectively, and comment on
your finding.

Known: U = 3500 W/m2K

Water: Tc,i = 10C, Tc,o = 35C, cp,c = 4182 J/kgK, mc = 5000 kg/hr
Oil: Th,i = 65C, cp,h = 2072 kJ/kgK, mh = 6000 kg/hr

Total heat transfer from hot oil flow to cooling water flow is given by,

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SOLUTIONS Out: 09/24/2024
Due: 10/01/2024

qh = qc = ( mc p ) (Tc,o − Tc,i ) = 145.21 kW

c

(
Also, qh = mc p ) (T
h h ,i − Th,o )  Th,o = 23°C

(a) For Parallel flow:

The outlet temperature of water (cooling fluid) is higher than outlet temperature of oil
(hot fluid). This is thermodynamically not possible in any parallel flow heat exchanger,
and hence, this arrangement cannot be used for the given conditions.

(b) For Counter flow:

The average mean temperature difference is given by,

T1 − T2
Tln = ; T1 = ( 65 − 35 ) = 30 C; T2 = ( 23 − 10 ) = 13 C  Tln = 20.33 C
ln ( T1 T2 )

The required heat transfer surface area is thus,

q = (UA ) Tm ;  A = 2.04 m2

3. Heat Exchanger Rating Problem: It is proposed to recover waste heat from flue gases in a
gas-fired furnace in a foundry to heat water in a double-pipe, counter-flow heat exchanger.
Water enters the inner tube (4-cm inner diameter and 2-mm wall thickness) at 40C with a
velocity of 0.5 m/s, and has an average heat transfer coefficient of 2649 W/m2K. The
combustion products (flue gases) enter the annulus of the heat exchanger at 200C with a
mass flow rate of 1.2 kg/s, and have an average heat transfer coefficient of 705 W/m2K.
Because the gas-side heat transfer coefficient is much less than that on the waterside, 16
longitudinal (axial) fins, made of Cu with a rectangular cross section, are brazed to the outer
surface of the inner pipe. Each fin is 6-cm high (radial length L) and 1 mm thick, as shown
in the figure below, and have a small gap between the tips and inner surface of the outer tube.
If the length of the heat exchanger is 5 m, and assuming that the properties of flue gases are
the same as those of air, find the total heat transfer rate q (kW), and the exit temperatures of
the gas and water streams.

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SOLUTIONS Out: 09/24/2024
Due: 10/01/2024

Given: Double-pipe heat exchanger, length LH = 5 m, di = 0.04 m, do = (0.04 + 0.004) = 0.044 m

Fin material: copper, k = 401 W/mK (@300K)
Number of fins, N = 16; Lf = 0.06 m, and t = 1 mm = 0.001 m

Tube-side: Water, Tc,i = 40C, hc = 2649 W/m2K, Vc = 0.5m/s  mc =  AV = 0.6214kg / s

Shell-side: Gas, Th,i = 200C, hh = 705 W/m2K, mh = 1.2 kg/s

Assume: Th,o = 45C , and Tc,o = 50C (alternatively, evaluate initial fluid properties at their
respective inlet temperatures).

Tlm =
(T − T ) − (T
h ,i c ,o h ,o − Tc ,i )
= 42.6C
ln (T − T ) (T
h ,i c ,o h ,o − Tc ,i )

Fluid Properties
Air Water
Tm = (200 – 42.6) = 157.4C (say ~ 400K) Tm = (40+50)/2 = 45C (say ~ 320K)
 = 0.8711 Kg/m3  = 989 Kg/m3
cp = 1014 J/kgK cp = 4180 J/kgK
k = 0.0338 W/mK k = 0.64 W/mK

Ch = ( mc p ) = (1.2 1014)h = 1216.8 W/K; Cc = ( mc p ) = ( 0.6214  4180)c = 2597.5 W/K

h c

C* = (Cmin/Cmax) = (Ch/Cc) = 0.468

The overall resistance summation for the heat exchanger yields

ln(ro / ri ) ln(0.044 / 0.04)

UA =  hi Ai  + Rw +  hoo Ao  , where Rw =
−1 −1 −1
= = 7.566 10−6 K/W
2 kL 2  401 5

The fin effectiveness for the outer surface (shellside) fins can be determined as

tanh ( mLc )
(1 − ) ; 
Af
o = 1 − = ;
Ao
f f
( mLc )

Lc =  L f + ( t 2 )  = 0.06 + ( 0.001 2 )  = 0.0605 m;

m = 2ho kt = ( 2  705) ( 401 0.001) = 59.3 m −1    f = 0.278

Af = ( 2 L f + t ) NLH = 9.68 m 2 ; Ao = A f + ( d o − Nt ) LH = 10.29 m 2   o = 0.321

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SOLUTIONS Out: 09/24/2024
Due: 10/01/2024

The overall thermal resistance can thus be obtained as,

−1
 1 1 
UA =  + 7.566 10−6 + = 1017.4 W/K
 2649    0.04  5 705  0.32110.29 

 NTU = (UA Cmin ) = (1017.4 1216.8 ) = 0.836

Now for a pure counter-flow heat exchanger,

1 − exp  − NTU (1 − C *) 
= = 0.513
1 − C *exp  − NTU (1 − C *) 

Total heat transfer rate:

q =  qmax =  Cmin  o =  Ch (Th ,i − Tc ,i ) = 0.513 1216.8 ( 200 − 40 ) = 99,848 W

Fluid outlet temperatures:

Th ,o = Th ,i − ( q Ch )  =  200 − ( 99848 1216.8 )  = 117.9 C

Tc ,o = Tc ,i + ( q Cc )  =  40 + ( 99848 2597.5)  = 78.4 C

Tlm =
(T − T ) − (T
h ,i c ,o h ,o − Tc ,i )
= 98.1C
ln (T − T ) (T
h ,i c ,o h ,o − Tc ,i ) 


Fluid Properties
Air Water
Tm = (200 – 98.1)  100C (say ~ 375K) Tm = (40+78.4)/2 = 59.2C ( ~ 332K)
 = 0.933 Kg/m 3
 = 987 Kg/m3
cp = 1011.5 J/kgK cp = 4185 J/kgK
k = 0.0319 W/mK k = 0.653 W/mK

Ch = ( mc p ) = 1213.8 W/K; Cc = ( mc p ) = 2600.6 W/K

h c

C* = (Cmin/Cmax) = (Ch/Cc) = 0.467

The overall resistance will be same, and hence, UA = 1017.4 W/K

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SOLUTIONS Out: 09/24/2024
Due: 10/01/2024

 NTU = (UA Cmin ) = (1017.4 1213.8 ) = 0.838

Now for a pure counter-flow heat exchanger,

1 − exp  − NTU (1 − C *) 
= = 0.514
1 − C *exp  − NTU (1 − C *) 

(a) Total heat transfer rate:

q =  qmax =  Cmin  o =  Ch (Th ,i − Tc ,i ) = 0.514 1213.8 ( 200 − 40 ) = 99, 788 W

(b) Fluid outlet temperatures:

Th ,o = Th ,i − ( q Ch )  =  200 − ( 99788 1213.8 )  = 117.8 C

Tc ,o = Tc ,i + ( q Cc )  =  40 + ( 99788 2600.6 )  = 78.4 C

Note: The new or revised outlet temperature values are virtually the same as those in the first
iteration, and thus further iterations are not necessary.

4. Heat Exchanger Sizing Problem: In a supercomputer, signal propagation delays are reduced
by resorting to high-density circuits, which are cooled by immersing them in a special dielectric
liquid. This liquid is pumped in a closed loop through the computer and an adjoining shell-
and-tube heat exchanger, which has one shell and two tube passes as schematically shown
below.

During normal operation, heat generated within the computer is transferred to the dielectric
liquid passing through it at a flow rate of m f = 4.81 kg/s. In turn, this liquid passes through

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SOLUTIONS Out: 09/24/2024
Due: 10/01/2024

the tubes of the exchanger and the heat is then transferred to cooling water flowing in the shell
side. The dielectric liquid may be assumed to have constant properties of cp,f = 1.04 kJ/kgK,
f = 7.6510-4 kg/sm, kf = 0.058 W/mK, and Prf = 14. The chilled water flow rate is mw =
2.5 kg/s with an inlet temperature of Tw,i = 5C, specific heat of cp,w = 4.2 kJ/kg.K, and an
average convective heat transfer coefficient of hw = 10,000 W/m2K on the outer surface of the
tubes.
(a) If the heat exchanger consists of 72 thin-walled tubes, each of 10-mm diameter, then what
is the convective heat transfer coefficient for the dielectric liquid flow through the tubes?
(b) If the dielectric liquid enters the heat exchanger at Tf,i = 25C and is to exit at Tf,o = 15C,
then what is the required tube length per pass for the tube bundle?
(c) The site specialist engineer for the computer facilities is concerned about changes in the
performance of the water chiller that supplies the cooling water ( mw and Tw,i) and their
effect on the outlet temperature Tf,o of the dielectric liquid. With all other conditions
remaining the same, determine the effect of a 10% change in the cold water flow rate on
Tf,o.

Given: Properties and flow rate of computer coolant (dielectric fluid). The diameter and number
of heat exchanger tubes. Heat exchanger transfer rate and inlet temperature of computer coolant.
Flow rate, fluid properties, respective inlet temperatures, and the average convection coefficient
of water.

Tube-side: “Hot” coolant flow  T f ,i = 25C, T f ,o = 15C, m f = 4.18 kg/s, c p , f = 1,040 J/kgK,
 f = 7.65 × 10-4, k f = 0.058 W/mK, and Pr = 14; di = 10 mm = 0.01 m; Nt = 72
Shell-side: Cold water flow  Tw,i = 5C, mw = 2.5 kg/s, c p , w = 4,200 J/kgK, and hw = 10,000
W/m2K

(a) Heat transfer coefficient of flow through tubes:

Consider the flow to be evenly distributed in the Nt = 72 thin-walled ( di d o ) tubes.

The Reynolds number through each tube is then

 Udi   m f di   4  4.81 
Re =   =   =   = 11,119 (turbulent flow regime)
    Nt Ac ,i    72    0.01 0.000765 

Thus, for turbulent flow inside a tube, the Fanning friction factor is given by,
−2
f = 1.58ln ( Re ) − 3.28 = 7.64 × 10-3

( f 2 ) Re Pr
and the Nusselt Number is given by, Nu = = 122.75
1.07 + 12.7 ( f 2) ( Pr 2/3 − 1)

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SOLUTIONS Out: 09/24/2024
Due: 10/01/2024

h d 
and, Nu =  f i   h f = 712 W/m2K ( = hi )
 k 

(b) Length of tube:

Overall heat transfer coefficient is given by,

−1
 1 1 
(UA) =  + Rw + 
 hi Ai ho Ao 

However, because of “thin walled” tubes with negligible wall thickness, Ai  Ao and Rw  0
−1 −1
U =  hi−1 + ho−1  = (1 712 ) + (1 10, 000 )  = 664.65 W/m2K

Now from the overall energy balance:

q = ( mc p ) (Th,i − Th,o ) = ( mc p ) (Tc,o − Tc,i )
h c

q = ( 4.811040 )h ( 25 − 15) = ( 2.5  4200 )c (Tc ,o − 5)  Tc,o = 9.8 C

C   5002.4 
(
Now, Ch = mc p ) = 5002.4 W/K; Cc = ( mc p ) = 10500 W/K; C* =  min =  = 0.476
 Cmx   10500 
h c

And, the effectiveness of the heat exchanger is given by,

 = Ch (Th,i − Th,o ) Cmin (Th,i − Tc ,i ) = 0.5

Thus, for the shell-and-tube heat exchanger with one shell pass with two tube passes, the NTU is
given by

NTU = −
1  E −1 
ln  ; where E =
( 2  ) − (1 + C *)

(1 + C *2 )  E + 1  (1 + C *2 )
E = 2.278; and NTU = 0.85

 UA   NTU  Cmin   0.85  5002.4 

 NTU =    A= =  = 6.4 m
2

 Cmin   U   664.65 

Noting that di  do = d , for two tube passes: A =  d ( 2 L ) Nt 

 L = ( A 2 dN t ) = 1.415 m ~ 1. 5 m

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SOLUTIONS Out: 09/24/2024
Due: 10/01/2024

(c) Effect of mass flow rate:

(
From the overall energy balance: q = mc p ) (T
h h ,i − Th,o ) = ( mc p ) (Tc,o − Tc,i )
c

It is clear that 10% change in the cold-water flow rate is directly proportional to the  10%
change in the coolant inlet and outlet temperature difference. In other words, if all conditions are
remaining same, the 10 % change in the cold-water flow rate will reduce or increase the coolant
outlet temperature by 10 %.

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