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Prof. P. K. Das Energy Conservation and Waste Heat Recovery
Heat Exchangers
mech14.weebly.com
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
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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
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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
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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
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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
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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
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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
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Prof. P. K. Das Energy Conservation and Waste Heat Recovery
9
Plate & frame heat exchanger
https://www.youtube.com/watch?v=Jv5p7o-7Pms
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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.
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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.
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Prof. P. K. Das Energy Conservation and Waste Heat Recovery
Temperature distribution in counter flow exchanger of single phase fluids
(Shah,1981).
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Prof. P. K. Das Energy Conservation and Waste Heat Recovery
Temperature distribution in parallel heat exchanger (Shah,1981).
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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)
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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,
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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 − = ∆ =∆ .
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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
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)
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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.
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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 ( , − ,
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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 *( , − ,
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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
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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)
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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
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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
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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
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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
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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
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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
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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
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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
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Prof. P. K. Das Energy Conservation and Waste Heat Recovery
32mech14.weebly.com
Prof. P. K. Das Energy Conservation and Waste Heat Recovery
33mech14.weebly.com
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
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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
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Prof. P. K. Das Energy Conservation and Waste Heat Recovery
36
Fixed Twin Bed Regenerator
Hot Gas
Cold Gas
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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
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Prof. P. K. Das Energy Conservation and Waste Heat Recovery
38
Rotary Regenerator
https://www.youtube.com/watch?v=roImOiIxrjo
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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
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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
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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
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Prof. P. K. Das Energy Conservation and Waste Heat Recovery
42
http://www.immak.eu/Admin/photos/markabuyuk/63356211
7303593750.jpg
Run around coil
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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
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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
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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
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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
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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.
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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
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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
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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
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
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Prof. P. K. Das Energy Conservation and Waste Heat Recovery
52
Water/glycol mixture
Tci
air
Tco
Thi
Tho
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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
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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
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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
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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.
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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)
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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.
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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
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Prof. P. K. Das Energy Conservation and Waste Heat Recovery
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℃ ℃ ℃ ℃ ℃ ℃ ℃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.
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Hot UtilityCold Utility
T
Q
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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
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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
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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
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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
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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.
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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
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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 ℃
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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
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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
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So, the restrictions i.e. 𝐶𝐻 𝐶𝐶 just next to pinch point
℃
℃℃ ℃
℃
℃℃ ℃
..
.C
℃
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℃
℃℃ ℃
℃
℃℃ ℃
.℃
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