72
Prof. P. K. Das Energy Conservation and Waste Heat Recovery Heat Exchangers mech14.weebly.com

Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

  • Upload
    others

  • View
    2

  • Download
    0

Embed Size (px)

Citation preview

Page 1: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

Heat Exchangers

mech14.weebly.com

Page 2: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

Classification of Heat Exchanger

Indirect contact type Direct contact type

1. Transfer Process

Storage type

Fluidized bed

Single Phase

Multiphase Immiscible fluid

Gas-Liquid

Liquid-VaporDirect transfer type

2.Number of Fluids

Two-fluid Three-fluidN-fluid

mech14.weebly.com

Page 3: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

3. Surface Compactness

Gas-to-Fluid Liquid-to-Fluid and Phase change

Noncompact(𝛽 Τ𝑚 𝑚Compact(𝛽 Τ𝑚 𝑚Compact(𝛽 Τ𝑚 𝑚Noncompact(𝛽 Τ𝑚 𝑚

4. Construction

Extended surface Regenerative Plate type Tubular Double-pipe

Shell-and-tube

Spiral

Pipe coils

PHE

Spiral

Plate coil

Printed circuit

Plate-fin

Tube-fin

Rotatory

Fixed-matrix

Rotating Hoods

mech14.weebly.com

Page 4: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

Combined convection and

radiation heat transfer

5.Heat Transfer Mechanism

Single-phase

Convection on

both-sides

Two-phase convection

on both side Single-phase convection on one

side , two-phase convection on

other side

6. Flow Arrangement

Single-phase Multi-phase

Counter Parallel Split- flow Divided-flowCounter flow

Extended Surface

Shell-and-tube

Plate

mech14.weebly.com

Page 5: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

5

Double pipe heat exchanger

https://qph.ec.quoracdn.net/main-qimg-

c9e98e0940812c1a290c7e382e81ad7e

https://qph.ec.quoracdn.net/main-qimg-

41639803193702862731666502e01718

mech14.weebly.com

Page 6: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

6

Shell and tube heat exchanger

Sigle pass

http://classes.engineering.wustl.edu/mase-thermal-lab/htlab-10.jpg

http://www.southwestthermal.com/images/products_

shelltube_drawing_LG.jpg

Multi pass

https://upload.wikimedia.org/wikipedia/commons/5/

59/Straight-tube_heat_exchanger_2-pass.PNG

Exploded view

mech14.weebly.com

Page 7: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

7

http://fchart.com/ees/heat_transfer_library/compact_hx/typehx

_diagram.gif

Finned tube and plate-fin (cross flow) heat exchanger

mech14.weebly.com

Page 8: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

8

Plate & frame and spiral heat exchanger

https://qph.ec.quoracdn.net/main-qimg-

7cd9a2c31a4fd878142fbac59f1c7194-c

https://4.imimg.com/data4/XV/LF/MY-

13558103/spiral-heat-exchanger-250x250.jpg

http://www.enggcyclopedia.com/wp-content/uploads/2010/12/spiral-

type-heat-exchager-schematic.jpg

mech14.weebly.com

Page 9: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

9

Plate & frame heat exchanger

https://www.youtube.com/watch?v=Jv5p7o-7Pms

mech14.weebly.com

Page 10: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

Methods of analysis of Heat Exchangers

To analyze heat exchange problem, a set of some assumptions are introduced so that resulting models are

simple to analyze. The assumptions are:

Heat exchanger operates under steady state condition.

Heat losses to and from surrounding are assumed to be negligible.

There are no thermal energy sources or sinks in the exchanger walls or fluids, such as electric

heating,chemical reaction, or nuclear processes.

Temperature of each fluid is assumed to be uniform in a cross-section.

Wall thermal resistance is distributed uniformly.

mech14.weebly.com

Page 11: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

Basic Definitions

The definitions of mean overall heat transfer coefficient and mean temperature difference are introduced

first by reaarging basic equation= − ) 𝒂 𝑨 = 𝜟 𝑨Above equation presented in integral form, ∆ = 𝑨 𝑨Now the definition of mean temperature difference and mean overall heat transfer coefficient as follows:

∆ = ∆=𝑨 𝑨= ∗ 𝑨 ∗ ∆

Here, is mean overall heat transfer coefficient, and ∆ is true mean temperature difference(MTD),

also referred to as mean temperature driving potential or force for heat transfer.

mech14.weebly.com

Page 12: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

Temperature distribution in counter flow exchanger of single phase fluids

(Shah,1981).

mech14.weebly.com

Page 13: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

Temperature distribution in parallel heat exchanger (Shah,1981).

mech14.weebly.com

Page 14: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

Temperature distribution at inlet and outlets of an unmixed cross flow

heat exchanger (Shah,1981)

mech14.weebly.com

Page 15: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

15

Heat Exchanger Analysis

Let ሶ𝑚 =Mass flow rate, Τ𝑔𝐶 = Specific heat of fluid at constant pressure, Τ 𝑔℃,

T= Temperature of fluid, ℃ , and ∆ =Temperature drop or rise of a fluid across the heat exchanger

ℎ,𝑖 ℎ,,𝑖,

mech14.weebly.com

Page 16: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

1. F-LMTD

F-LMTD In the analysis of heat exchangers total heat transfer rate is of primary interest. The log-

mean temperature difference (LMTD or ∆ for counter and parallel flow is defined as

LMTD = 𝜵 = ∆ −𝜵Τ𝜵 𝜵

Total heat transfer between hot and cold fluids in a counter flow arrangement= 𝐀 ∆Where 𝛻 = ℎ,𝑖 − , 𝛻 = ℎ, − ,𝑖 ( Counter Flow)𝛻 = ℎ,𝑖 − ,𝑖 𝛻 = ℎ, − , ( Parallel Flow)

LMTD represent maximum temperature potential for heat transfer that can be obtained in counter flow

exchanger.

Special Case: In case of counterflow with ( ሶ𝑚 ℎ= ( ሶ𝑚 , the quantity ∆ is indeterminate. In this

case, by applying L’ Hospital’s rule = 𝐴 ℎ − with ℎ − = ∆ =∆ .

mech14.weebly.com

Page 17: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

17

1. F-LMTD for Multipass and Crossflow Heat Exchangers

The LMTD shown in previous slide is not applicable for heat transfer analysis of crossflow and multipass

flow heat exchangers.

∆ , = , − , − , − ,[ ൗ, − , , − , ]= , − ,, − , = ∆∆ 𝒂𝒙 ( Heat actually transferred to the heat which would be transferred if the same cold fluid

temperature was raised to the hot-fluid inlet temperature. Hence it is temperature effectiveness of heat

exchanger.)= 𝑪𝑪 = , − ,, − , ( Ratio of ሶ𝑚 of cold fluid to that of hot fluid and is called the heat capacity rate ratio.)

Where ∆ , is the LMTD for counter flow arrangement with the same fluid inlet and outlet temperature.

Hence , in crossflow heat is calculated by introducing a non-dimensional number called F.= A F ∆ ,mech14.weebly.com

Page 18: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

18

F is nondimensional number ; it depends on the temperature effectiveness , the heat capacity rate

ratio , and the flow arrangement. 𝑭 = 𝝓 , , flow arrangement)

mech14.weebly.com

Page 19: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

∈ −𝑁 Method

Applicable when inlet or outlet temperatures of the fluid streams are not known.

Method is based on fact inlet or exit temperature difference are function of 𝑈𝐴𝐶𝑐 and Τ𝐶 𝐶ℎ.

Dimensionless Form

Capacity rate ratio: 𝐶∗=𝐶 𝑖𝐶 𝑎 , where 𝑖 and 𝑎 are the smaller and larger of the two magnitudes of

ℎand , respectively , and ∗ . Exchanger heat transfer effectiveness: It is the ratio of actual heat transfer rate in heat exchanger to the

thermodynamically limited maximum possible heat transfer.

mech14.weebly.com

Page 20: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

Actual heat transfer is obtained by using energy given off by hot fluid or energy received by cold fluid,= ሶ ( , − , ) =( ሶ ( , − , )If ℎ > , then ( ℎ,𝑖 − ℎ, ) < ( , − ,𝑖If ℎ < ,then ( ℎ,𝑖 − ℎ, ) > ( , − ,𝑖The fluid that might undergo maximum temperature difference is the fluid with minimum heat capacity

rate 𝑖 . Therefore, the maximum possible heat transfer is expressed as

𝒂𝒙=( ሶ ( , − , if < or 𝒂𝒙=( ሶ ( , − ,

mech14.weebly.com

Page 21: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

21

Heat exchanger effectiveness, 𝜖, is therefor written as𝝐 = , − ,𝑪 , − , = , − ,𝑪 , − ,The above equation is valid for all heat exchanger flow arrangements. The value of 𝜖 ranges between

zero and 1.

If the effectiveness is known, Equation provides expression for determination of

= 𝝐 ∗ ሶ *( , − ,

mech14.weebly.com

Page 22: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

Number of transfer unit: It depicts the nondimensional heat transfer size of the heat exchanger.

NTU = 𝑨

= 𝑨For counter flow following expression is obtained :

𝝐 = − 𝐞𝐱𝐩[−𝑵 − Τ𝑪 𝐚𝐱 ]− Τ 𝒂𝒙 𝐞𝐱𝐩[−𝑵 − Τ 𝒂𝒙 ]If < ℎ = 𝑖 , ℎ = 𝑎 , the result will be the same.

In case of parallel flow, a similar analysis may be applied to obtain following expression:

𝝐 = − 𝐞𝐱𝐩[−𝑵 + Τ 𝒂𝒙 ]+ Τ 𝒂𝒙

mech14.weebly.com

Page 23: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

23

SPECIAL CASE:

Τ𝐶 𝑖 𝐶 𝑎 equal to 1

𝝐 = 𝑵𝑵 + ( Counter Flow) , 𝜺 = ( − − 𝑵 ( Parallel Flow).

Τ𝐶 𝑖 𝐶 𝑎 equal to 0 as in boiler and condensers for parallel flow and counter flow ,

equation becomes

𝝐 = − 𝐞𝐱𝐩 −𝑵 𝝐 = 𝝓 𝑵 , ∗, flow arrangement)

mech14.weebly.com

Page 24: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

24

Effectiveness- NTU chart: an example

http://userscontent2.emaze.com/images/3f54344d-c988-440d-b903-

539c0c6c9279/Slide21_Pic2_635933982388373132.png

mech14.weebly.com

Page 25: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

25

Exchanger NTU Effectiveness

Automobile Radiator 0.5 40%

Steam Plant Condenser 1 63%

Regenerator for Industrial

Gas Turbine

10 90%

Regenerator for Stirling

Engine

50 98%

Regenerator for LNG

Plant

200 99%

Approximate Values of NTU & Effectivenes for typical

Heat Exchangers

mech14.weebly.com

Page 26: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

26

In a 1-2 TEMA E shell-and-tube exchanger, water enters the shell at 21 ºC at a

rate of 1.4 kg/s. Engine oil flows through the tubes at a rate of 1.0 kg/s. The inlet

and outlet temperatures of the oil are 150 ºC and 90 ºC, respectively. Determine

the surface area of the exchanger by both the MTD and ε–NTU methods if U =

225 W/m2 . K. The specific heats of water and oil are 4.19 and 1.67 J/g . K

respectively.

Fundamentals of heat exchanger design, by R. K.

Shah & D. P. Sekulic, 2003, John Wiley & Sons

Shell & tube heat exchanger: an example with LMTD and ε–NTU

methods

mech14.weebly.com

Page 27: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

27

,𝑖=21 ℃, ሶ𝑚 = 1.4 kg/s

, =90℃

,𝑖=15 ℃, =1.67 J/g . K

Water

Oil, =4.19 J/g . K

U = 225 W/m2. K

Schematic representation of a 1-2 TEMA E shell-and-tube exchanger

mech14.weebly.com

Page 28: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

28

3

3

1.4 / 4.19 10 / . 5866 /

1.0 / 1.67 10 / . 1670 /

s P

s

t P

t

C mc kg s J kg K W K

C mc kg s J kg K W K

The heat capacity rates for the shell fluid (water) and the tube fluid (oil) are:

3

, , 1670 / 150 90 100.2 10t t i t o

q C T T W K C W

The heat transfer rate from the oil is:

Using the energy balance equation, we could find the water outlet temperature: 3

, ,

100.2 1021 38.1

5866 / Ks o s i

s

q WT T C C

C W

mech14.weebly.com

Page 29: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

29

150 38.1 111.9

90 21 69

I

II

T C C C

T C C C

15 ℃38.1℃

9 ℃21℃

x/L0 1

Oil

Water

I II

oil waterC C

oil waterC C

, ,o

1

, s,

s,o s,i

1

, t,o

150 90

150 21

0.4651

1670 /

5866 /

0.2847

t i t

t i i

t

t i s

T T CP

T T C

T T C W KR

T T C W K

mech14.weebly.com

Page 30: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

30

LMTD correction factor F as a function of P1

and R1

for a 1-2 TEMA E shell-and-

tube exchanger with the shell fluid unmixed

mech14.weebly.com

Page 31: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

31

32

2

100.2 105.133

225 / 0.9776 88.74lm

q WA m

UF T W m K K

The heat transfer area from the rate equation is:

The ε–NTU method:

In this problem, t s

C C

1670 /0.2847

5866 /

t

s

C W KC

C W K

Hence,

Using the definition of the effectiveness for the tube side (Cmin side), we get

,

, ,o

, s,

150 900.4651

150 21

t i t

t i i

T T C

T T C

From the figure, F = 0.9776

mech14.weebly.com

Page 32: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

32mech14.weebly.com

Page 33: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

33mech14.weebly.com

Page 34: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

34

2min

2

1670 /0.6916 5.133

225 /

C W KA NTU m

U W m K

Either from the figure or the formula, NTU = 0.6916

mech14.weebly.com

Page 35: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

35

Heat Exchangers Specially Suited for Energy

Conservation & Waste Heat Recovery

Regenerators

Special Recuperators

Heat Pipes

Run Around Coils

mech14.weebly.com

Page 36: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

36

Fixed Twin Bed Regenerator

Hot Gas

Cold Gas

mech14.weebly.com

Page 37: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

37

Rotary Regenerator

https://upload.wikimedia.org/wikipedia/commons/thu

mb/a/a8/Rotary-heat-exchanger.svg/2000px-Rotary-

heat-exchanger.svg.png

http://us.klingenburg.de/fileadmin/_processed_/csm_Rotor-

Schema_HT-US_c759652afb.jpg

mech14.weebly.com

Page 38: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

38

Rotary Regenerator

https://www.youtube.com/watch?v=roImOiIxrjo

mech14.weebly.com

Page 39: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

39

Regenerator with a Rotary Hood

Fundamentals of heat exchanger design, by R. K.

Shah & D. P. Sekulic, 2003, John Wiley & Sons

mech14.weebly.com

Page 40: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

40

Estimation of heat transfer from Regenerator/Heat Wheel

Based on a simple analysis,

Rate of heat transfer in a cycle

1 1 1 1

6

gh gc

h c

h h c c h c

A t tQ

b

h h k

τ - time, the wheel is in contact with a particular gas stream

- temperature of a particular gas stream, h - hot, c - cold

b - length parameter

k - thermal conductivity

mech14.weebly.com

Page 41: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

41

Special types of Recuperators

http://enconi.com/images/recuprater.jpg

Heat recovery for Canadian food and beverage

industries, Agriculture Canada, 1984

Waste Heat Boiler

mech14.weebly.com

Page 42: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

42

http://www.immak.eu/Admin/photos/markabuyuk/63356211

7303593750.jpg

Run around coil

mech14.weebly.com

Page 43: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

43

Run around coil- schematic representation

Hot gas

Th1Th2

Tc2Tc1

Cold gas

Ts2Ts1

1 high temperature

2 low temperaturepump

mech14.weebly.com

Page 44: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

44

Assume

1 2 1 2 1 2h h c c s s

h C s

Q mC T T mC T T mC T T

h C s

mC mC mC

1 2 1 2 1 2

1 1 2 2 1 1 2 2,

h h c c s s

h s h s s c s c

T T T T T T

T T T T T T T T

Three temperature lines are therefore straight

lines and parallel

lm i eT T T

1 1 1 1

h c

h s s c

Q QU A U A

T T T T

Ts1

Th1

Th2

Ts2

Tc1

Tc2

mech14.weebly.com

Page 45: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

45

The temperature line for the secondary fluid must be midway between the temperature

lines for the hot and cold fluids.

1 11

2 22

2

2

h cs

h cs

T TT

T TT

The total heat recovery is

1 1

2

h c

h

T TQ U A

And since1 2c c

c

QT T

mC

1 2

2

h ch

h

c

U A T TQ

U A

mC

mech14.weebly.com

Page 46: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

46

In a shell-and-tube feed water heater, cold water at ℃ flowing at the rate of 180 Kg/h is

preheated to 90℃ by flue gases from 150℃ flowing at the rate of 900 Kg/h. The water flows

inside the copper tubes( 𝑖=25mm, =32mm) having thermal conductivity 𝑘 =381W / m .

K . The heat transfer coefficients on gas and water sides are 120 and 1200 W/m2K,

respectively. The fouling factor on the water side is 0.002 m2.K/W. Determine the flue gas

outlet temperature, the overall heat transfer coefficient based on the outside tube

diameter, and the true mean temperature difference for heat transfer. Consider specific

heats for flue gases and water as 1.05 and 4.19 J/ g .K respectively, and total tube

outside area as 5m2 . There are no fins inside or outside the tubes, and there is no fouling

on the gas side.

Shell & tube heat exchanger: an example with LMTD

Fundamental of heat exchanger design, by R. K.

Shah & D. P. Seculic, 2003, John Wiley & Sons

mech14.weebly.com

Page 47: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

47

SOLUTION

Problem Data and Schematic: Fluid flow rates, inlet temperature , and cold fluid outlet temperature are

provided for a shell-and-tube exchanger of prescribed tube inner and outer diameter. Also, the thermal

conductivity of tube and thermal resistance on the cold fluid side are given. There are no fins on either

side of tubes.

Determine: Hot fluid temperature ℎ, , overall heat transfer coefficient , and true mean temperature

difference ∆ .

Assumptions: Hot-fluids-side fouling is negligible.

mech14.weebly.com

Page 48: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

48

ℎ,𝑖=150 ℃, ሶ𝑚ℎ=900Kg/h, ,ℎ=1.05 J/g.K

, =90 ℃

,𝑖=15 ℃ሶ𝑚 =180 Kg/h, , =4.19J/g.K

ℎ,

𝑖=25mm

=32mm𝑘 =381W/m . K

ℎ 𝑎 =ℎℎ=120 W/m2Kℎ 𝑎 =ℎ =1200 W/m2K, =0.002 m2.K/W𝐴 =5m2

mech14.weebly.com

Page 49: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

49

Analysis: The required heat transfer may be obtained from overall energy balance for the cold

fluid.

𝑞 = 𝐶 , − ,𝑖=(

/ℎ/ℎ )(4.19 Τ𝑔. (1000 Τ𝑔 𝑔 ℃− ℃ = ,Apply the equation on the hot fluid side to find the outlet temperature for flue gas:

ℎ, = ℎ,𝑖 − 𝑝 ሶ ℎSince ሶ𝑚ℎ= /ℎ𝑆/ℎ=0.25 Τ𝑔

mech14.weebly.com

Page 50: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

50

We get

ℎ, = ℃− , 𝑊. Τ ∗ Τ ℃ = . ℃Since U is based on A = 𝐴ℎ= 𝜋 𝑁 ,R = 𝑈ℎ =ℎℎ + ℎℎ,𝑓 + 0ln Τ0 𝑖 + 0ℎ𝑐,𝑓 𝑖 + 0ℎ𝑐 𝑖

= (0.00833+0.00001+0.00256+0.00107) = 0.01197 m2.K/W

Hence, ℎ=85.4W/m2 . K

∆ = 𝑈ℎ𝐴ℎ = 37.6℃mech14.weebly.com

Page 51: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

51

Fundamental of heat exchanger design, by R. K.

Shah & D. P. Seculic, 2003, John Wiley & Sons

One important design for a radiator design is to cool the engine at 50 km/h on a 7%

grade road. Your responsibility as a design engineer is to make sure that the coolant

(50% water – 50% glycol) at the radiator inlet (top tank) does not exceed 120 ºC

temperature at 100 kPa gauge radiator cap pressure. Determine the radiator top tank

temperature for the following conditions: engine heat rejection rate q = 35 kW, air

flow rate 0.75 kg/s, air inlet temperature 53 ºC, and water-glycol flow rate 1.4 kg/s.

For this radiator, UA =1180 W/K. The specific heats for the air and the water-glycol

mixture are 1009 3664 J/kg.K respectively. What will be the outlet temperature of the

water-glycol mixture? Consider the radiator with both fluids unmixed.

An example

mech14.weebly.com

Page 52: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

52

Water/glycol mixture

Tci

air

Tco

Thi

Tho

mech14.weebly.com

Page 53: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

53

min

min

0.75 / 1009 / . 756.75 /

1.4 / 3664 / . 5129.6 /

756.75 /0.148

5129.6 /

1180 /1.559

756.75 /

air C P

air

liquid h P

liquid

air

liquid

C C mC kg s J kg K W K C

C C mC kg s J kg K W K

C W KC

C W K

UA W KNTU

C W K

From Table for an unmixed-unmixed crossflow exchanger 0.769

min

35 1000 /53 113.1

0.769 756.75 /

35 1000 /113.1 106.3

5129.6 / K

hi ci

ho hi

h

q kW W kWT T C C

C W kW

q kW W kWT T C C

C W

mech14.weebly.com

Page 54: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

54

Heat Exchanger Network Analysis by Pinch Technique

Reference

The Pinch Design Method For Heat Exchanger Networks by B. Linnhoff and E. Hindmarsh

Chemical Engineering Science Vol.38, No.5, pp.745-763, 1983

mech14.weebly.com

Page 55: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

55

Heat Exchanger Network

Process Plant:

Many streams need heating or cooling.

Utilities like hot air , hot oil, steam for heating.

Utilities like air, water, chilled water, refrigerant for cooling.

Efforts to be made for reducing the use of utilities.

This can be done by “ Heat Integration” . “ Heat Integration” implies heat exchange between the hot and cold streams.

This reduces the use of utilities.

However, this increases the number of heat exchangers.

Heat exchanger synthesis means designing a network so that using minimum number of

heat exchangers, the use of utilities can also be minimized

mech14.weebly.com

Page 56: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

56

Synthesis of Heat Exchanger Network (HEN)

There are different techniques of synthesis of HEN.

The pinch technique is very widely used.

mech14.weebly.com

Page 57: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

57

C1 C2 C3

H1

H2

H3

Schematic representation of Heat Exchanger Network

RULE:

Minimum number of Heat

Exchangers ( 𝑖 = 𝑁-1𝑁 =No. of process streams

( N1 ) + No. of utilities(N2)

mech14.weebly.com

Page 58: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

58

Pinch Technique

Logic Based- based on first and second law of thermodynamics.

There is one hot utility and one cold utility of infinite capacity.

Steady state operation.

There is no restriction for matching the streams.

All heat exchangers are without any phase change and without any heat

generation or reaction.

Heat exchangers are assumed to be indirect contact and counter flow.

mech14.weebly.com

Page 59: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

59

STREAM NUMBER &

TYPE

HEAT CAPACITY FLOW RATE 𝑪kW/℃ TS(℃) TT(℃)

(1) HOT 2 150 60

(2) HOT 8 90 60

(3) COLD 2.5 20 125

(4) COLD 3.0 25 100

Table 1. Stream data for test case

𝜟 = ° 𝑪mech14.weebly.com

Page 60: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

60

℃ ℃ ℃ ℃ ℃ ℃ ℃Temperature

1

2

3

4

Goals of HEN synthesis

1) Minimum utility.

2) Stream matching.

3) No. of heat exchangers needed.

4) End temp of the heat exchangers.

mech14.weebly.com

Page 61: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

61

Hot UtilityCold Utility

T

Q

mech14.weebly.com

Page 62: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

62

SUBN

ETW

ORK

STREAMS AND TEMPERATURE DEFICIT ACCUMULATED HEAT FLOWS

COLD

STREAM

S

T(℃ HOT

STREAMS

INPUT OUTPUT INPUT OUTPUT

150

SN1

145

-10 0 10 107.5/HU 117.5

SN2

120

+12.5 10 -2.5 117.5 105

SN3

70 90

+105 -2.5 -107.5 105 0

SN4 40 60 -135 -107.5 27.5 0 135

SN5 25 +82.5 27.5 -55 135 52.5

SN6 20 +12.5 -55 -67.5 52.5 40/CU

Table 2. The problem table for Test case

3

4

1 2

125

100

mech14.weebly.com

Page 63: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

63

SN1

SN2

SN3

SN4

SN5

SN6

𝐻 =107.5 kW

.

.𝐶 =40 kW

34

3 4

𝐻 =107.5 kW

𝐶 =40 kWFig. 1. (a) Subnetwork heat flow diagram for TC3. (b)Subnetworks combined into hot and cold region

(a) (b)

1

1 2

Cold end

problem

Hot end

problem

mech14.weebly.com

Page 64: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

64

Pinch point divides the HEN into two independent problems to be

solved separately.

No heat flow is allowed across pinch point.

No cold utility to be used in the hot end.

No hot utility to be used in the cold end.

Violation of (2) – (4) gives double penalty

Design of each end should start at the pinch point.

Rules for PINCH ANALYSIS

mech14.weebly.com

Page 65: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

65

1.For hot end 𝑁𝐻 𝑁𝐶 𝑁𝐻- No of Hot stream

For cold end 𝑁𝐶 𝑁𝐻 𝑁𝐶- No. of cold stream

Note: In the hot end, there is some amount of hot utility & hot stream which can only

exchange heat with cold stream.

2. For individual match

Hot end, 𝐶𝐻 𝐶Cold end,𝐶 𝐶𝐻

3.For hot end

(σ 𝑐 𝐶 -σ 𝐶𝐻) σ . 𝑎 ℎ 𝐶 − 𝐶𝐻)

Rules for Pinch End Matching

mech14.weebly.com

Page 66: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

66

Some Examples

4

3

2

1

3

5

2

4

C Difference in C

Composite “C” difference

8-6=2

Summation of match

“C” Diff=(5-4)+(3-2)=2

Solution is possible.

4

3

2

1

C

5

4

5

2

3

1

Difference in C

Composite “C” difference

9-6=3

Summation of match” Diff=(5-4)+(3-2)=2

Solution is possible.

mech14.weebly.com

Page 67: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

67

Hot End Design

Stream Data at Pinch

𝑁𝐻 𝑁𝐶 NoSplit cold stream

Yes

𝐶𝐻 𝐶𝐶 for each match and

cumulative stream

Stream SplittingNo

Yes

Solution

mech14.weebly.com

Page 68: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

68

Stream Matching for Hot End

1150 ℃

125 ℃ 70 ℃100 ℃ 70 ℃

90 ℃118 ℃ .3

4

1150 ℃

125 ℃ 70 ℃100 ℃ 90

.3

4

3082℃

120H

H

H

𝑁𝐻 𝑁𝐶𝐶𝐻 𝐶𝐶(𝐶𝐻)1= 2

(𝐶𝐶)3= 2.5

(𝐶𝐶)4 = 3

All above conditions are satisfied i.e. number of hot

streams number of cold streams

90 ℃70 ℃

mech14.weebly.com

Page 69: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

69

Stream Matching for Cold End

𝑵𝑪 𝑵𝑯Cumulative , 𝐶𝐶 𝐶𝐻

8 3

2 2.5

8 3

2 2.5

8 3

2 2.5

So, we have to split hot stream

mech14.weebly.com

Page 70: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

70

Splitting of Hot Streams

3

2 2.5

87.5

0.5

3

2 2.5

83

5

3

2

0.5

2.5

2.0

87.5

0.5

mech14.weebly.com

Page 71: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

71

So, the restrictions i.e. 𝐶𝐻 𝐶𝐶 just next to pinch point

℃℃ ℃

℃℃ ℃

..

.C

mech14.weebly.com

Page 72: Heat Exchangers - ME14mech14.weebly.com/.../me_ecwhr_18_heat_exchangers.pdf · To analyze heat exchange problem, a set of some assumptions are introduced sothat resulting models are

Prof. P. K. Das Energy Conservation and Waste Heat Recovery

72

℃℃ ℃

℃℃ ℃

.℃

mech14.weebly.com