Heat Ex Changers Formulas

Energy Technology Heat Exchangers Formulas, Tables and Figures
1
LESSON 1. HEAT EXCHANGERS
FORMULAS
Thermal resistance for conduction in a plane wall:
kA
L
R
cond t

,
.
Thermal resistance for convection:
hA
R
conv t
1
,
.
Overall heat transfer coefficient, U:
UA
R R
t tot
1
.
Thermal resistance for conduction in a cylindrical wall:
Lk
r r
R
cond t
2
) / ln(
1 2
,
.
Thermal resistance for convection in a cylindrical wall:
rLh Ah
R
conv t
2
1 1
,
.
The overall heat transfer coefficient in a cylindrical wall depends on the surface area it is
expressed: ( )
1
3 3 2 2 1 1
...

t i i
R A U A U A U A U .
Heat exchanger overall heat transfer coefficient:
h o h o
h f
w
c o
c f
c o h h c c
hA A
R
R
A
R
hA A U A U UA ) (
1
) ( ) ( ) (
1 1 1 1
, ,

+

+ +

+ , where subscripts c and h
refers to the cold and hot fluid, respectively, and R
w
is the thermal resistance for conduction.
The terms 1/(
o
hA) are the thermal resistances of the fin arrays of each fluid and
o
the
overall efficiency of the surface with the fin array. This is the quotient between the heat
dissipated by the system with the fin array and the heat that would be dissipated it the entire
surface were at the base temperature:
) (

T T hA
q
b t
o
, where A
t
is the total area of heat
transfer (surface of the exposed portion of the base and the fins).
The overall efficiency can be expressed as a function of a single fin efficiency:
) 1 ( 1
f
t
f
o
A
A
, where A
f
is the surface area of all the fins.
For a rectangular straight fin of length L and the and the tip treated as adiabatic the expresin
of the efficiency is:
mL
mL
f
) tanh(
, where m = (2h/kt)
1/2
and t is the thickness of the fin.

2
The Reynolds number for internal flow is based on the internal diameter of the tube and the
mean fluid velocity over the tube cross section:

int m int m
D
D u D u
Re . As
c m
A u m & , for
a circular tube the Reynolds number can be expressed as:

int
D
D
m
Re
& 4
.
The Reynolds number for external cross flow over a cylinder is based on the external diameter
of the tube and the free flow velocity, u
or V:

ext ext
D
VD D u
Re

.
Nusselt number:
fluid
D
k
hD
Nu .
Prandtl number:
Pr .
Thermal diffusivity:
p
c k / .
Zhukauskas correlation for flow across a bank of tubes:
4 / 1
36 . 0
,
_
s
m
D,max D
Pr
Pr
Pr CRe Nu . With
1
1
1
]
1
< <
< <
500 7 . 0
10 2 1000
20
6
Pr
Re
N
D,max
L
. The constants C and m are listed in Table 1. The fluid properties
are evaluated at 2 / ) (
sal ent
T T T + , except Pr
s
at T
s
. For N
L
< 20 a correction factor is applied
such that
20
2
20 <

L L
N
D
N
D
Nu C Nu , where C
2
is listed in Table 2.
S
T
is the transverse pitch and S
L
the longitudinal pitch (measured between tubes centres).
Re
D,max
is based on the maximum velocity of the fluid within the tube bank.
For the aligned arrangement V
max
occurs at the transversal plane and its values is
V
D S
S
V
T
T
max
.
For the staggered configuration, the same expression is used it the maximum velocity occurs
in the transverse plane. But if it occurs at the diagonal plane the expression is
V
D S
S
V
D
T
max
) ( 2
. The maximum velocity occurs at the diagonal plane is the following
condition is fulfilled:
2 2
) ( ) ( 2
2 / 1
2
2
D S S
S S D S D S
T T
L D T D
+
<
1
1
]
1
,
_
+ < .

3
Dittus-Boelter correlation for internal turbulent fully developed flow:
n
D D
Pr Re Nu
5 / 4
023 . 0 .
Where n = 0.4 for heating (T
s
> T ), n = 0.3 for cooling (T
s
< T ), fluid properties evaluated at
2 / ) (
sal ent
T T T + , and
1
1
1
]
1

10 ) / (
000 , 10
160 7 . 0
D L
Re
Pr
D
.
Sieder and Tate correlation for internal turbulent fully developed flow with great variation of
the properties:
14 , 0
3 / 1 5 / 4
027 . 0
,
_
s
D D
Pr Re Nu
. Properties evaluated at 2 / ) (
sal ent
T T T + ,
except
s
at T
s
, and
1
1
1
]
1

10 ) / (
000 , 10
700 , 16 7 . 0
D L
Re
Pr
D
.
For concentric tubes, the hydraulic diameter is used for the flow between the tubes. The
hydraulic diameter is the quotient between four times the cross-sectional area and the wetted
perimeter:
wet
c
h
P
A
D
4
. For circular tubes:
int ext
int ext
int ext
h
D D
D D
D D
D
+
) (
4 / ) ( 4
2 2
.
Heat transfer between the hot and cold fluids inside a heat exchanger based on the variation of
their specific enthalpies, i: ) ( ) (
, , , , in c out c c out h in h h
i i m i i m q & & . If the fluids are not
undergoing a phase change and contact specific heats are assumed:
) ( ) (
, , , , , , in c out c c p c out h in h h p h
T T c m T T c m q & & . These equations are independent of the flow
arrangement and heat exchanger type.
Fluid heat capacity rate (capacidad trmica de flujo):
p
c m C & .
Log mean temperature difference:
( ) ( )
2 1
2 1
1 2
1 2
ln ln T T
T T
T T
T T
T
ml

. The subscripts 1 and 2
relates to the opposite sides of the heat exchanger in a general way for all the types.
Total heat transfer in parallel flow or counter-flow heat exchanger obtained with the Newtons
law of cooling with the overall heat transfer coefficient and the log mean temperature
difference:
ml
T UA q .
For the same inlet and outlet temperatures of the fluids, it occurs that
FP ml CF ml
T T
, ,
> .
If the heat capacity rate of one of the fluids is much larger than that of the other fluid or if one
of the fluids experiences a phase change, C , the temperature of that fluid remains
approximately constant throughout the heat exchanger.

4
For the case when the heat capacity rates of both fluids are equals, C
h
C
c
, the temperature
difference is a constant throughout the heat exchanger, T
1
= T
2
= T
lm
.
Total heat transfer in a shell-and-tube or in a cross-flow heat exchanger:
CF ml
T UAF q
,
,
where F is the correction factor represented graphically in Figures 2 to 5, based on the factors
P and R where t lowercase is assigned to the temperature of the tube-side fluid, not matter
whether it is the hot or the cold.

in in
in out
t T
t t
P
;
in out
out in
t t
T T
R
. t lowercase is assigned to the temperature of the tube-side fluid,

not matter whether it is the hot or the cold.
If the temperature change of one fluid is negligible (phase change), P or R is zero and F is 1,
hence, heat exchanger behaviour is independent of the specific configuration.
The maximum heat transfer of a heat exchanger is the product of the smaller heat capacity
rate multiplied by the maximum possible temperature difference: ) (
, , in c in h min max
T T C q .
The effectiveness of a heat exchanger, , is the ratio of the actual heat transfer rate of a heat
exchanger to the maximum possible heat transfer rate (0 1):
) (
) (
) (
) (
, ,
, ,
, ,
, ,
in c in h min
in c out c c
in c in h min
out h in h h
max
actual
T T C
T T C
T T C
T T C
q
q
.
The number of transfer units of a heat exchanger is a dimensionless parameter defined as:
min
C
UA
NTU .
The heat capacity rate ratio is: C
r
= C
min
/C
max
.
The relationships ( )
r
C f , NTU for the different types of heat exchangers are represented
analytically in Tables 11.3 y 11.4 from Incropera and are graphically represented in Figures
6 to 11.
Particular cases:
For shell-and-tube heat exchangers with multiple pass through the shell, it is assumed
that the total NTU is equally distributed between each pass, NTU = n (NTU)
1
. Hence,
when using the
1
expression for this case, NTU is replaced by NTU/n.
For the boilers and condensers (C
r
= 0) the expression is unique for all flow
arrangements.

5
For the cross-flow heat exchangers with both fluids unmixed, the corresponding
equation is only valid for C
r
= 1, however it may be used to a good approximation for
all values of C
r
.
The explicit relation for NTU for the case of shell-andtube heat exchangers provides the
NTU per shell pass, so this result is multiplied by the number o passes, n, to obtaien the
NTU for the entire exchanger.
For NTU 0.25 all heat exchangers have approximately the same effectiveness.
More generally, for C
r
> 0 and NTU 0.25, the counter-flow heat exchanger is the most
effective.
For any exchanger, maximum and minimum values of the effectiveness are associated
with C
r
= 0 y C
r
= 1, respectively.
For compact heat exchangers, heat transfer and flow characteristics are typically presented in
the format of figures (Figures 12 and 13).
Heat transfer results are correlated in terms of the Colburn j factor,
3 / 2
H
StPr j and the
Reynolds number, where both the Stanton (
p
Gc h St / ) and Reynolds ( /
h
GD Re )
numbers are based on the maximum mass velocity (it is a mass flow, mass velocity per area
unit),
1
]
1

s m
kg

2
fr ff ff
fr
A
m
A
m
A
VA
V G
max
& &
, where is the ratio of the minimum freeflow
area of the finned passages (cross-sectional area perpendicular to flow direction), A
ff
, and the
frontal area of the exchanger, A
fr
.
For each configuration different geometric parameters are listed in the figures: the hydraulic
diameter of the flow passage, D
h
, the ratio of heat transfer surface area to total heat exchanger
volume, , and the ratio of fin to total heat transfer area, A
f
/A.
The pressure drop associated with flow across finned-tube banks mya be computed from the
expression:
1
]
1
,
_
+
in
m
in
out in
A
A
f
G
p
v
v
1
v
v
) 1 (
2
v
ff
2
2
, where v
in
and v
out
are the fluid inlet
and outlet specific volumes and v
m
=(v
in
+ v
out
)/2.

6
TABLES AND FIGURES
Figure 1. Tube arrangements in a bank: a) aligned; b) Staggered.

Table 1. Coefficients of Zhukauskas correlation for the tube bank in cross flow.
Configuration Re
D,max
C m
Aligned 10 - 10
2
0.80 0.40
Staggered 10 - 10
2
0.90 0.40
Aligned 10
2
- 10
3
Approximated as a single cylinder
Staggered 10
2
- 10
3
Approximated as a single cylinder
Aligned (S
T
/ S
L
> 0,7) 10
3
- 210
5
0.27 0.63
Staggered (S
T
/ S
L
< 2) 10
3
- 210
5
0.35(S
T
/ S
L
)
1/5
0.60
Staggered (S
T
/ S
L
> 2) 10
3
- 210
5
0.40 0.60
Aligned 210
5
- 210
6
0.021 0.84
Staggered 210
5
- 210
6
0.022 0.84
For S
T
/ S
L
< 0.7, heat transfer is inefficient and aligned tubes should not be used.
Table 2. Correction factor C
2
of Zhukauskas correlation for the tube bank in cross flow for
N
L
< 20 and Re
D
> 10
3
.
N
L
1 2 3 4 5 7 10 13 16
Aligned 0.70 0.80 0.86 0.90 0.92 0.95 0.97 0.98 0.99
Staggered 0.64 0.76 0.84 0.89 0.92 0.95 0.97 0.98 0.99

7

Table 3. Thermophysical properties of motor oil at atmospheric pressure.
T
(K)

(kg/m
3
)
c
p

(J/kgK)
10
2

(Ns/m
2
)
10
6
(m
2
/s)
k10
3

(W/mK)
10
7

(m
2
/s)
Pr 10
3

(K
-1
)
273 899.1 1796 385 4.28 147 0.910 47,000 0.70
280 895.3 1827 217 2.43 144 0.880 27,500 0.70
290 890.0 1868 99.9 1.12 145 0.872 12,900 0.70
300 884.1 1909 48.6 550 145 0.859 6400 0.70
310 877.9 1951 25.3 288 145 0.847 3400 0.70
320 871.8 1993 14.1 161 143 0.823 1965 0.70
330 865.8 2035 8.36 96.6 141 0.800 1205 0.70
340 859.9 2076 5.31 61.7 139 0.779 793 0.70
350 853.9 2118 3.56 41.7 138 0.763 546 0.70
360 847.8 2161 2.52 29.7 138 0.753 395 0.70
370 841.8 2206 1.86 22.0 137 0.738 300 0.70
380 836.0 2250 1.41 16.9 136 0.723 233 0.70
390 830.6 2294 1.10 13.3 135 0.709 187 0.70
400 825.1 2337 0.874 10.6 134 0.695 152 0.70
410 818.9 2381 0.698 8.52 133 0.682 125 0.70
420 812.1 2427 0.564 6.94 133 0.675 103 0.70
430 806.5 2471 0.470 5.83 132 0.662 88 0.70

8

Table 4. Thermophysical properties of air at atmospheric pressure.
T
(K)

(kg/m
3
)
c
p

(J/kgK)
10
7

(Ns/m
2
)
10
6
(m
2
/s)
k10
3

(W/mK)
10
6

(m
2
/s)
Pr
100 3.5562 1032 71.1 2.00 9.34 2.54 0.786
150 2.3364 1012 103.4 4.43 13.8 5.84 0.758
200 1.7548 1007 132.5 7.59 18.1 10.3 0.737
250 1.3947 1006 159.6 11.44 22.3 15.9 0.720
300 1.1614 1007 184.6 15.89 26.3 22.5 0.707
350 0.9950 1009 208.2 20.92 30.0 29.9 0.700
400 0.8711 1014 230.1 26.41 33.8 38.3 0.690
450 0.7740 1021 250.7 32.39 37.3 47.2 0.686
500 0.6964 1030 270.1 38.79 40.7 56.7 0.684
550 0.6329 1040 288.4 45.57 43.9 66.7 0.683
600 0.5804 1051 305.8 52.69 46.9 76.9 0.685
650 0.5356 1063 322.5 60.21 49.7 87.3 0.690
700 0.4975 1075 338.8 68.10 52.4 98.0 0.695
750 0.4643 1087 354.6 76.37 54.9 109 0.702
800 0.4354 1099 369.8 84.93 57.3 120 0.709
850 0.4097 1110 384.3 93.80 59.6 131 0.716
900 0.3868 1121 398.1 102.9 62.0 143 0.720
950 0.3666 1131 411.3 112.2 64.3 155 0.723
1000 0.3482 1141 424.4 121.9 66.7 168 0.726
1100 0.3166 1159 449.0 141.8 71.5 195 0.728
1200 0.2902 1175 473.0 162.9 76.3 224 0.728
1300 0.2679 1189 496.0 185.1 82 238 0.719
1400 0.2488 1207 530 213 91 303 0.703
1500 0.2322 1230 557 240 100 350 0.685

9

Table 5. Thermophysical properties of saturated water.
T
(K)
P
(bar)

(kg/m
3
)
h
fg

(kJ/kg)
c
p

(J/kgK)
10
6

(Ns/m
2
)
k10
3

(W/mK)
Pr 10
6

(K
-1
)
273.15 0.00611 1000 2502 4217 1750 569 12.99 -68.05
275 0.00697 1000 2497 4211 1652 574 12.22 -32.74
280 0.00990 1000 2485 4198 1422 582 10.26 46.04
285 0.01387 1000 2473 4189 1225 590 8.81 114.1
290 0.01917 999.0 2461 4184 1080 598 7.56 174.0
295 0.02617 998.0 2449 4181 959 606 6.62 227.5
300 0.03531 997.0 2438 4179 855 613 5.83 276.1
305 0.04712 995.0 2426 4178 769 620 5.20 320.6
310 0.06221 993.0 2414 4178 695 628 4.62 361.9
315 0.08132 991.1 2402 4179 631 634 4.16 400.4
320 0.1053 989.1 2390 4180 577 640 3.77 436.7
325 0.1351 987.2 2378 4182 528 645 3.42 471.2
330 0.1719 984.3 2366 4184 489 650 3.15 504.0
335 0.2167 982.3 2354 4186 453 656 2.88 535.5
340 0.2713 979.4 2342 4188 420 660 2.66 566.0
345 0.3372 976.6 2329 4191 389 668 2.45 595.4
350 0.4163 973.7 2317 4195 365 668 2.29 624.2
355 0.5100 970.9 2304 4199 343 671 2.14 652.3
360 0.6209 967.1 2291 4203 324 674 2.02 697.9
365 0.7514 963.4 2278 4209 306 677 1.91 707.1
370 0.9040 960.6 2265 4214 289 679 1.80 728.7
373.15 1.0133 957.9 2257 4217 279 680 1.76 750.1
375 1.0815 956.9 2252 4220 274 681 1.70 761
380 1.2869 953.3 2239 4226 260 683 1.61 788
385 1.5233 949.7 2225 4232 248 685 1.53 814
390 1.794 945.2 2212 4239 237 686 1.47 841
400 2.455 937.2 2183 4256 217 688 1.34 896
410 3.302 928.5 2153 4278 200 688 1.24 852
420 4.370 919.1 2123 4302 185 688 1.16 1010
430 5.699 909.9 2091 4331 173 685 1.09
440 7.333 900.9 2059 4360 162 682 1.04
450 9.319 890.5 2024 4400 152 678 0.99
460 11.71 879.5 1989 4440 143 673 0.95
470 14.55 868.1 1951 4480 136 667 0.92
480 17.90 856.9 1912 4530 129 660 0.89
490 21.83 844.6 1870 4590 124 651 0.87
500 26.40 831.3 1825 4660 118 642 0.86

10
Figure 2. Correction factor for a shell-and-tube heat exchanger with one
shell and any multiple of two tube passes (2, 4, 6,).
0.50
0.60
0.70
0.80
0.90
1.00
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
P
F
R=0.1
R=0.2
R=0.4
R=0.6
R=0.8
R=1
R=1.2
R=1.5
R=2
R=3
R=4
R=6
R=10

11
Figure 3. Correction factor for a shell-and-tube heat exchanger with two shell
passes and any multiple of four tube passes (4, 8,).
0.50
0.60
0.70
0.80
0.90
1.00
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
P
F
R=0.2
R=0.4
R=0.6
R=0.8
R=0.9
R=1.2
R=1.5
R=2
R=3
R=4
R=6
R=10

12
Figure 4. Correction factor for a single-pass, cross-flow heat exchanger with
both fluids unmixed.
0.50
0.60
0.70
0.80
0.90
1.00
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
P
F
R=0.2
R=0.4
R=0.6
R=0.8
R=1.2
R=1.5
R=2
R=3
R=4

13
Figure 5. Correction factor for a single-pass, cross-flow heat exchanger with
one fluid mixed and the other unmixed.
0.50
0.60
0.70
0.80
0.90
1.00
0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
P
F
R=0.1
R=0.2
R=0.4
R=0.6
R=0.8
R=1.2
R=1.5
R=2
R=3
R=4
R=6
R=8

14
Figure 6. Effectiveness of a parallel flow heat exchanger.
0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
0.90
1.00
0 1 2 3 4 5 6
NTU
E
Cr = 0
Cr = 0.2
Cr = 0.4
Cr = 0.6
Cr = 0.8
Cr = 1

15
Figure 7. Effectiveness of a counter-flow heat exchanger.
0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
0.90
1.00
0 1 2 3 4 5 6
NTU
E
Cr = 0
Cr = 0.2
Cr = 0.4
Cr = 0.6
Cr = 0.8
Cr = 1

16
Figure 8. Effectiveness of a shell-and-tube heat exchanger with one shell
and any multiple of tow tube passes (2, 4, 6,).
0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
0.90
1.00
0 1 2 3 4 5 6
NTU
E
Cr = 0
Cr = 0.2
Cr = 0.4
Cr = 0.6
Cr = 0.8
Cr = 1

17
Figure 9. Effectiveness of a shell-and-tube heat exchanger with two shell
passes and any multiple of four tube passes (4, 8,).
0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
0.90
1.00
0 1 2 3 4 5 6
NTU
E
Cr = 0
Cr = 0,2
Cr = 0,4
Cr = 0,6
Cr = 0,8
Cr = 1

18
Figure 10. Effectiveness of a single-pass, cross-flow heat exchanger with
both fluids unmixed.
0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
0.90
1.00
0 1 2 3 4 5 6
NTU
E
Cr = 0
Cr = 0.2
Cr = 0.4
Cr = 0.6
Cr = 0.8
Cr = 1

19
Figure 11 A. Effectiveness of a single-pass, cross-flow heat exchanger with
one fluid mixed (Cmin) and the other unmixed (Cmax).
0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
0.90
1.00
0 1 2 3 4 5 6
NTU
E
Cmix/Cunmix = 0
Cmix/Cunmix = 0.2
Cmix/Cunmix = 0.4
Cmix/Cunmix = 0.6
Cmix/Cunmix = 0.8
Cmix/Cunmix = 1

20
Figure 11 B. Effectiveness of a single-pass, cross-flow heat exchanger with
one fluid mixed (Cmax) and the other unmixed (Cmin).
0.00
0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
0.90
1.00
0 1 2 3 4 5 6
NTU
E
Cmix/Cunmix = 100
Cmix/Cunmix = 8
Cmix/Cunmix = 4
Cmix/Cunmix = 2
Cmix/Cunmix = 1.5
Cmix/Cunmix = 1

21
Figure 12. Heat transfer and friction factor for a circular tube- circular fins heat exchanger,
surface CF-7.0-5/8J from Kays and London.

22
Figure 13. Heat transfer and friction factor for a circular tube-continuous fin heat
exchanger, surface 8.0-3/8T from Kays and London.

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. t lowercase is assigned to the temperature of the tube-side fluid,

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