Content

1. Introduction 1
1.1 Types of Heat Exchanger 2
1.1.1. Parallel Flow Heat Exchanger 2
1.1.2. Counter Flow Heat Exchanger 3
1.1.3. Split Flow Heat Exchanger 3
1.1.4. Divided Flow Heat Exchanger 4
1.1.5. Cross Flow Heat Exchanger 4
1.1.6. Multi-pass Exchangers 5
1.2 Heat Transfer Enhancement 5
1.2.1. Active Method 6
1.2.2. Passive Method 6
2. Literature Review 7
3. Methods of Heat Exchanger Analysis 11
3.1.1. Wilson Plot Method 11
3.1.2. LMTD Method 13
3.1.3. NTU Method 15
4. Heat Exchanger Characteristics 16
4.1.1 Friction Factor 16
4.1.2 Nusselt Number 17
5. Applications of Double Pipe Heat Exchanger 17
6. Conclusion 17
References
 1. Introduction

A heat exchanger is a device that is used to transfer thermal energy between two or more
fluids, between a solid surface and a fluid or between solid particulates and a fluid at different
temperatures and in thermal contact. In heat exchangers, there are usually no external heat and
work interactions. Typical applications involve heating or cooling of a fluid stream of concern
and evaporation or condensation of single- or multicomponent fluid streams. In other
applications, the objective may be to recover or reject heat, or sterilize, pasteurize, fractionate,
distill, concentrate, crystallize, or control a process fluid.
In a few heat exchangers, the fluids exchanging heat are in direct contact. In most heat
exchangers, heat transfer between fluids takes place through a separating wall or into and out of
a wall in a transient manner. In many heat exchangers, the fluids are separated by a heat transfer
surface, and ideally they do not mix or leak. Such exchangers are referred to as direct transfer
type, or simply recuperators. In contrast, exchangers in which there is intermittent heat exchange
between the hot and cold fluidsvia thermal energy storage and release through the exchanger
surface or matrix are referred to as indirect transfer type, or simply regenerators. Such
exchangers usually have fluid leakage from one fluid stream to the other, due to pressure
differences and matrix rotation/valve switching. Common examples of heat exchangers are shell-
and tube exchangers, automobile radiators, condensers, evaporators, air preheaters, and cooling
towers. If no phase change occurs in any of the fluids in the exchanger, it is sometimes referred
to as a sensible heat exchanger. There could be internal thermal energy sources in the
exchangers, such as in electric heaters and nuclear fuel elements. Combustion and chemical
reaction may take place within the exchanger, such as in boilers, fired heaters, and fluidized-bed
exchangers. Mechanical devices may be used in some exchangers such as in scraped surface
exchangers, agitated vessels, and stirred tank reactors.

ii
 1.1. Types of Heat Exchanger

1.1.1. Parallel Flow Heat Exchanger

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. Fluid temperature variations
can be idealized as one-dimensional. This arrangement has the lowest exchanger effectiveness
among single-pass exchangers for given overall thermal conductance (UA) and fluid flow rates
and fluid inlet temperatures; however, some multi-pass exchangers may have an even lower
effectiveness. However, for low-effectiveness exchangers, the difference in parallel flow and
counter flow exchanger effectiveness is small. In a parallel flow exchanger, 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.

iii
 1.1.2. Counter Flow Heat Exchanger

In a counter flow or countercurrent exchanger, the two fluids flow parallel to each other
but in opposite directions within the core. The temperature variation of the two fluids in such an
exchanger may be idealized as one-dimensional. The counter flow arrangement is
thermodynamically superior to any other flow arrangement. It is the most efficient flow
arrangement, producing the highest temperature change in each fluid compared to any other two-
fluid flow arrangements for a given overall thermal conductance (UA), fluid flow rates (actually,
fluid heat capacity rates), and fluid inlet temperatures. Moreover, the maximum temperature
difference across the exchanger wall thickness (between the wall surfaces exposed on the hot and
cold fluid sides) either at the hot- or cold-fluid end is the lowest, and produce minimum thermal
stresses in the wall for an equivalent performance compared to any other flow arrangements.

Fig.1. Temperature profiles for (a) parallel flow and (b) counter flow in double-pipe heat
exchanger [1]

1.1.3. Split Flow Heat Exchanger

In this exchanger, the shell fluid stream enters at the center of the exchanger and divides
into two streams. These streams flow in longitudinal directions along the exchanger length over a
longitudinal baffle, make a 180 degree turn at each end, flow longitudinally to the center of the
exchanger under the longitudinal baffle, unite at the center, and leave from the central nozzle.
The other fluid stream flows straight in the tubes.

iv
 Fig.2. Single pass split flow exchanger [2]

1.1.4. Divided Flow Heat Exchanger

In this exchanger, the shell fluid stream enters at the center of the exchanger and divides
into two streams. These streams flow ideally in longitudinal directions along the exchanger
length and exit from two nozzles, one at each end of the exchanger. The other fluid stream flows
straight in the tubes.

1.1.5. Cross Flow Heat Exchanger

In this type of exchanger, the two fluids flow in directions normal to each other. Typical
fluid temperature variations are idealized as two dimensional. Thermodynamically, the
effectiveness for the cross flow exchanger falls in between that for the counter flow and parallel
flow arrangements. The largest structural temperature difference exists at the corner of the
entering hot and cold fluids. This is one of the most common flow arrangements used for
extended surface heat exchangers, because it greatly simplifies the header design at the entrance
and exit of each fluid. If the desired heat exchanger effectiveness is high (such as greater than
80%), the size penalty for the cross flow exchanger may become excessive. In such a case, a
counter flow unit is preferred.
In a cross flow arrangement, mixing of either fluid stream may or may not occur,
depending on the design. A fluid stream is considered unmixed when it passes through individual
flow channels or tubes with no fluid mixing between adjacent flow channels. In this case within
the exchanger, temperature gradients in the fluid exist in at least one direction (in the transverse
plane) normal to the main fluid flow direction. A fluid stream is considered completely mixed
when no temperature gradient exists in the transverse plane, either within one tube or within the
transverse tube row within the exchanger. Ideally, the fluid thermal conductivity transverse to the
flow is treated as zero for the unmixed-fluid case and infinity for the mixed-fluid case.
v
 Fig.3. (a) Plate-fin unmixedunmixed cross flow heat exchanger; (b) serpentine (one tube
row) tube-fin unmixedmixed cross flow heat exchanger [3].

1.1.6. Multi-pass Exchangers

When the design of a heat exchanger results in either an extreme length significantly low
fluid velocities or a low effectiveness, a multi-pass heat exchanger or several single-pass
exchangers in series, or a combination of both, is employed. Heat exchangers in any of the five
basic flow arrangements can be put into series to make a multi-pass unit. In addition, there exist
other multi-pass flow arrangements that have no single-pass counterpart. One of the major
advantages of proper multi passing is to increase the exchanger overall effectiveness over the
individual pass effectiveness, but with increased pressure drop on the multi-pass side.

1.2. Heat Transfer Enhancement

Heat transfer enhancement is the process of increasing the effectiveness of heat

exchangers. This can be achieved when the heat transfer power of a given device is increased or
when the pressure losses generated by the device are reduced. A variety of techniques can be
applied to this effect, including generating strong secondary flows or increasing boundary layer
turbulence.
Generally, heat transfer augmentation techniques are classified in three broad categories:
(a) Active method,
(b) Passive method,

vi
(c) Compound method.
The active and passive methods are described with examples in the following
subsections. A compound method is a hybrid method in which both active and passive methods
are used in combination. The compound method involves complex design and hence has limited
applications.

1.2.1. Active method

This method involves some external power input for the enhancement of heat transfer and
has not shown much potential owing to complexity in design. Furthermore, external power is not
easy to provide in several applications. Some examples of active methods are induced pulsation
by cams and reciprocating plungers, the use of a magnetic field to disturb the seeded light
particles in a flowing stream, etc.

1.2.2. Passive method

This method does not need any external power input and the additional power needed to
enhance the heat transfer is taken from the available power in the system, which ultimately leads
to a fluid pressure drop. The heat exchanger industry has been striving for improved thermal
contact (enhanced heat transfer coefficient) and reduced pumping power in order to improve the
thermo hydraulic efficiency of heat exchangers. A good heat exchanger design should have an
efficient thermodynamic performance, i.e. minimum generation of entropy or minimum
destruction of available work (exergy) in a system incorporating a heat exchanger. It is almost
impossible to stop exergy loss completely, but it can be minimized through an efficient design.
Some of common methods for heat transfer enhancement by passive techniques are
achieved by using -
(i) Treated surfaces: In these methods fine scale alteration is made to surface finish or
coating which may be continuous or discontinuous. These methods are used in
boiling and condensation applications.
(ii) Rough surfaces: These are the surface modifications done to promote turbulence in
the flow field near the wall region. These methods are used for single phase fluids,
mostly in turbulent flow regime. Heat transfer area remains unaffected even after
surface modification.

vii
 (iii) Extended surfaces: Extended surface include small surfaces of various shapes, or
perforations of on primary heat transfer surface. They are used in heat transfer
enhancement of single phase flow, condensation and boiling.
(iv) Coiled tubes: It produces secondary flows and vortices which promote higher heat
transfer coefficients in single phase flows as well as in most regions of boiling.
(v) Swirl flow devices: They generate and superimpose swirl flow (secondary flow) on
axial flow in a channel. These devices include twisted tape, twisted duct and screw
inserts. They find application for single phase and two phase fluid.

2. Methods of Heat Exchanger Analysis

3.1.1. Wilson Plot Method

The Wilson plot method constitutes a suitable technique to estimate the convection
coefficients in a variety of convective heat transfer processes. The Wilson plot method avoids the
direct measurement of the surface temperature and consequently the disturbance of the fluid flow
and heat transfer introduced while attempting to measure those temperatures.
This Wilson plot method was developed by Wilson [30] in 1915 to evaluate the convection
coefficients in shell and tube condensers for the case of a vapour condensing outside by means of
a cool liquid flow inside. It is based on the separation of the overall thermal resistance into the
inside convective thermal resistance and the remaining thermal resistances participating in the
heat transfer process.

The overall thermal resistance of the condensation process in a shell-and-tube condenser can be
expressed as the sum of three thermal resistances corresponding to the internal convection (Ri),
the tube wall (Rs) and the external convection (Ro) as

Rov = Ri + Rs + Ro (1)

For the sake of simplicity, the thermal resistances of the fluid fouling are neglected. Wilson
theorized that if the mass flow of the cooling liquid was modified, then the change in the overall
thermal resistance would be mainly due to the variation of the coolant HTC, while the remaining
thermal resistances remained nearly constant. The HTC varies with the fluid mass flow for many

viii
cases of the convection heat transfer process excluding the phase changes. It is valid also for
complex heat exchanger geometries.
Therefore, the thermal resistances on the condensation side and the tube wall could be
considered constant. In the case of a condenser where steam condenses inside the tubes is
considered

+ = 1 (2)

Where C1 is a constant. For the thermal resistance on the cooling water side Ro is considered

1
= (3)

Where A is the heat surface area and the HTC on the cooling water side h is proportional to the
power of the fluid velocity v.

= 2 . (4)

where C2 is a constant and n is the velocity exponent.

Upon combining Eq. (1), Eq. (2), Eq. (3) and Eq. (4), the overall thermal resistance turns out to
be a linear function of vn.

1 1
= .
+ 1 (5)
2 .

Fig 5.Original Wilson plot.[30]

ix
From here, the straight line equation that fits the experimental data can be deduced by applying
simple linear regression. The overall thermal resistance may be expressed as a function of the
overall heat transfer coefficient U and surface area A.
1
= . (6)

3.1.2. LMTD Method

The logarithmic mean temperature difference (also known as log mean temperature
difference or simply by its initials LMTD) is used to determine the temperature driving force for
heat transfer in flow systems, most notably in heat exchangers. The LMTD is a logarithmic
average of the temperature difference between the hot and cold feeds at each end of the double
pipe exchanger. The larger the LMTD, the more heat is transferred. The use of the LMTD arises
straightforwardly from the analysis of a heat exchanger with constant flow rate and fluid thermal
properties.
The heat duty supplied by hot fluid can be expressed as:
= (, , ) (7)

Where Qh, mh, Cph represents the heat supplied by the hot fluid, mass and specific heat of hot
fluid, respectively. While, Th,in and Th,out denotes the inlet and outlet temperatures of hot fluid,
respectively.
The heat duty absorbed by Cold fluid can be expressed as:
= (, , ) (8)
Where Qc, mc, Cpc represents the heat absorbed by the cold fluid, mass and specific heat
of cold fluid, respectively. While, Tc,in and Tc,out denotes the inlet and outlet temperatures of cold
fluid, respectively.
The average heat duty of system is calculated using eq. (9):
+
= (9)
2

For the counter flow double Pipe heat exchanger the heat transfer coefficient is calculated
using eq. (10)
= (10)

x
Where, U, As and TLMTD denotes the overall heat transfer coefficient, Heat transfer area and
logarithmic mean temperature difference respectively. Here, TLMTD can be calculated as below:

(, , )(, , )
= , , (11)

, ,

The overall heat transfer coefficient can be written in term of individual heat transfer coefficients
as given below:
1 1 1
= + + (12)
( ) ( )

Where, U, As, h and Rw denotes the overall heat transfer coefficient, surface area of heat
transfer, heat transfer coefficient and wall resistance respectively. The fouling resistance is
neglected for the analysis. In such case one can evaluate the wall resistance Rw as below:

= (13)

Thickness of inner tube is very small and thermal conductivity is very high. Therefore,
the wall resistance of the tube material can be neglected for the analysis. Neglecting the wall
resistance (Rw), eq. 12 can be written as:
1 1 1
= + (14)
( ) ( )

Initially, Dittus-Boelter equation is used to estimate the heat transfer coefficient for both
water side and air side for the lowest flow rate of the air. Subsequently, the thermal resistance
were calculated for both water and air sides. The maximum water side resistance is found to be
1.003% of the air side resistance.
1 1
(15)
( ) ( )

Therefore, the water side resistance can be neglected and eq. 12 can be written as:
1 1
= (16)
( )

In such case, the overall heat transfer coefficient can be written as:
= (17)
Nusselt Number can be calculated by using following equation

xi

=
(18)

Where, hc, D, K denotes air side convective heat transfer coefficient of cold fluid side,
hydraulic mean diameter of annulus and thermal conductivity of air, respectively.
In this study pressure drop is measured along the length of test section in the annulus.
The average friction factor is calculated as below:

= (19)
2 2

Assumptions and Limitations

It has been assumed that the rate of change for the temperature of both fluids is
proportional to the temperature difference; this assumption is valid for fluids with a
constant specific heat, which is a good description of fluids changing temperature over a
relatively small range. However, if the specific heat changes, the LMTD approach will no
longer be accurate.
Particular cases for the LMTD are condensers and reboilers, where the latent heat
associated to phase change is a special case of the hypothesis. For a condenser, the hot
fluid inlet temperature is then equivalent to the hot fluid exit temperature.
It has also been assumed that the heat transfer coefficient (U) is constant, and not a
function of temperature. If this is not the case, the LMTD approach will again be less
valid.
The LMTD is a steady-state concept, and cannot be used in dynamic analyses. In
particular, if the LMTD were to be applied on a transient in which for a brief time, the
temperature differential had different signs on the two sides of the exchanger, the
argument to the logarithm function would be negative, which is not allowable.
3.1.3. NTU Method
The Number of Transfer Units (NTU) Method is used to calculate the rate of heat transfer in
heat exchangers (especially counter current exchangers) when there is insufficient information to
calculate the Log-Mean Temperature Difference (LMTD).
To define the effectiveness of a heat exchanger we need to find the maximum possible heat
transfer that can be hypothetically achieved in a counter-flow heat exchanger of infinite length.
Therefore one fluid will experience the maximum possible temperature difference, which is the
difference of Th,i Tc,i (The temperature difference between the inlet temperature of the hot

xii
stream and the inlet temperature of the cold stream). The method proceeds by calculating the
heat capacity rates Ch and Cc for the hot and cold fluids respectively, and denoting the smaller
one as Cmin.
= (, , ) (20)

where is the maximum heat that could be transferred between the fluids per unit time. Cmin
must be used as it is the fluid with the lowest heat capacity rate that would, in this hypothetical
infinite length exchanger, actually undergo the maximum possible temperature change. The other
fluid would change temperature more quickly along the heat exchanger length. The method, at
this point, is concerned only with the fluid undergoing the maximum temperature change.

The effectiveness (), is the ratio between the actual heat transfer rate and the maximum possible
heat transfer rate:

= (21)

For any heat exchanger it can be shown that:

= (, ) (22)

and the number of transfer units,

.
= (23)

3. Heat Exchanger Characteristics

4.1.1 Friction Factor
The pressure drop across the annulus was measured using differential pressure
transducers. The annulus friction factors were calculated directly from the measured pressure
drop with
2
= (24)
2

where p is the measured pressure drop of the fluid along length Ldp of the annulus, and V is the
annulus fluid velocity.

4.1.2 Nusselt Number

xiii
 The Nusselt number is equal to the dimensionless temperature gradient at the surface and
it essentially provides a measure of the convective heat transfer. The Nusselt number may be
viewed as the ratio of the conduction resistance of a material to the convection resistance of the
same material.
.
= (25)

4. Applications of Double Pipe Heat Exchanger

Heat exchangers have a very broad range of industrial applications. They are used as
components of air conditioning and cooling systems or of heating systems. Many industrial
processes call for a certain degree of heat to function; however, typically great care must be
taken to keep these processes from getting too hot. Within industrial plants and factories heat
exchangers are required to keep machinery, chemicals, water, gas, and other substances within a
safe operating temperature. Heat exchangers may also be used to capture and transfer steam or
heat exhaust that is released as a byproduct of a process or operation so that the steam or heat can
be put to better use elsewhere, thereby increasing efficiency and saving the power plant money.
Other applications include-
Specific heat exchanger application such as radiator in space vehicles and other space
applications.
Process industries.
Cooling and heating in evaporators.
Thermal power plants.
Air-conditioning equipment.
Refrigerator, automobiles.

5. Conclusion
The passive techniques are valuable compared with the active techniques because the
swirl inserts manufacturing process is simple and can be easily employed in an existing heat
exchanger. Also passive techniques do not require an external power source and have only a one
time manufacturing cost. Insertion of swirl flow devices enhance the convective heat transfer by

xiv
making swirl into the bulk flow and disrupting the boundary layer at the tube surface due to
repeated changes in the surface geometry. That is to say such devices induce turbulence and
superimposed vortex motion (swirl flow) which induces a thinner boundary layer and
consequently results in a better heat transfer coefficient and higher Nusselt number due to the
changes in the twisted tape geometry. However, the pressure drop inside the tube will be
increased by introducing the swirl inserts, therefore a balance between the two is needed to
enhance the thermal performance.

xv