❤️‍🔥Heat and Mass Transfer Unit 5 – Heat Exchangers

Basics of Heat Exchangers

• Heat exchangers transfer thermal energy between two or more fluids at different temperatures
• Consist of a surface separating the fluids, allowing heat transfer without direct mixing
• Classified based on flow arrangement (parallel flow, counter flow, cross flow)
• Can be further categorized by construction type (shell and tube, plate, fin)
• Heat transfer occurs through conduction, convection, and radiation
  • Conduction: heat transfer through direct contact of materials
  • Convection: heat transfer through fluid motion
  • Radiation: heat transfer through electromagnetic waves
• Commonly used in various applications (HVAC systems, power plants, chemical processing)
• Essential for energy conservation and process efficiency in many industries

Types of Heat Exchangers

• Shell and tube heat exchangers
  • Consist of a bundle of tubes enclosed within a cylindrical shell
  • One fluid flows through the tubes while the other flows through the shell
  • Widely used in industrial applications due to their robustness and versatility
• Plate heat exchangers
  • Composed of a series of corrugated plates stacked together
  • Fluids flow through alternate channels formed by the plates
  • Compact design and high heat transfer efficiency
  • Commonly used in food processing and pharmaceutical industries
• Fin heat exchangers
  • Utilize extended surfaces (fins) to increase the heat transfer area
  • Fins can be attached to tubes or plates
  • Suitable for gas-to-liquid or gas-to-gas heat exchange
  • Often used in air conditioning and refrigeration systems
• Double pipe heat exchangers
  • Simplest type, consisting of one pipe inside another
  • Fluids flow in a counter-current arrangement
  • Limited heat transfer area, primarily used for small-scale applications
• Regenerative heat exchangers
  • Store thermal energy in a matrix (usually a solid material)
  • Hot and cold fluids alternately flow through the matrix
  • Examples include rotary regenerators and fixed matrix regenerators

Heat Transfer Mechanisms

• Conduction
  • Heat transfer through direct contact between materials
  • Occurs due to the kinetic energy transfer between particles
  • Governed by Fourier's law: $q = -kA\frac{dT}{dx}$
    • $q$: heat transfer rate (W)
    • $k$: thermal conductivity (W/m·K)
    • $A$: cross-sectional area (m²)
    • $\frac{dT}{dx}$: temperature gradient (K/m)
• Convection
  • Heat transfer through fluid motion
  • Involves the combined effects of conduction and fluid motion
  • Two types: natural convection (buoyancy-driven) and forced convection (externally-induced flow)
  • Described by Newton's law of cooling: $q = hA(T_s - T_∞)$
    • $h$: convective heat transfer coefficient (W/m²·K)
    • $A$: surface area (m²)
    • $T_s$: surface temperature (K)
    • $T_∞$: fluid temperature (K)
• Radiation
  • Heat transfer through electromagnetic waves
  • Occurs between surfaces at different temperatures without a medium
  • Governed by the Stefan-Boltzmann law: $q = \varepsilon\sigma A(T_1^4 - T_2^4)$
    • $\varepsilon$: emissivity (0 ≤ ε ≤ 1)
    • $\sigma$: Stefan-Boltzmann constant (5.67 × 10⁻⁸ W/m²·K⁴)
    • $A$: surface area (m²)
    • $T_1, T_2$: surface temperatures (K)

Design Principles

• Maximize heat transfer while minimizing pressure drop and fouling
• Select appropriate materials based on fluid properties, operating conditions, and cost
  • Materials should have high thermal conductivity, corrosion resistance, and mechanical strength
• Determine the optimal flow arrangement (parallel, counter, or cross flow) based on the application
• Consider the heat transfer surface area and geometry
  • Increase surface area using fins, corrugations, or multiple passes
  • Optimize geometry to promote turbulence and enhance heat transfer
• Ensure proper fluid distribution and minimize dead zones
  • Use baffles, headers, or distributors to achieve uniform flow
• Account for thermal expansion and mechanical stresses
  • Provide adequate clearances and use expansion joints if necessary
• Incorporate features for easy maintenance and cleaning
  • Include access ports, removable covers, or cleaning-in-place (CIP) systems
• Comply with relevant codes, standards, and regulations (ASME, TEMA, API)

Performance Analysis

• Evaluate heat exchanger performance using key parameters
  • Heat transfer rate ($Q$)
  • Overall heat transfer coefficient ($U$)
  • Log mean temperature difference (LMTD)
  • Effectiveness ($\varepsilon$)
  • Number of transfer units (NTU)
• Heat transfer rate: $Q = UA\Delta T_{LMTD}$
  • $U$: overall heat transfer coefficient (W/m²·K)
  • $A$: heat transfer surface area (m²)
  • $\Delta T_{LMTD}$: log mean temperature difference (K)
• Overall heat transfer coefficient: $\frac{1}{U} = \frac{1}{h_1} + \frac{t}{k} + \frac{1}{h_2}$
  • $h_1, h_2$: convective heat transfer coefficients (W/m²·K)
  • $t$: wall thickness (m)
  • $k$: thermal conductivity of the wall material (W/m·K)
• LMTD: $\Delta T_{LMTD} = \frac{\Delta T_1 - \Delta T_2}{\ln(\Delta T_1 / \Delta T_2)}$
  • $\Delta T_1, \Delta T_2$: temperature differences at the ends of the heat exchanger (K)
• Effectiveness: $\varepsilon = \frac{Q}{Q_{max}}$
  • $Q$: actual heat transfer rate (W)
  • $Q_{max}$: maximum possible heat transfer rate (W)
• NTU method: $NTU = \frac{UA}{C_{min}}$
  • $C_{min}$: minimum heat capacity rate (W/K)

Efficiency and Effectiveness

• Efficiency: ratio of the actual heat transfer rate to the maximum possible heat transfer rate
  • Affected by factors such as flow arrangement, surface area, and fluid properties
  • Can be improved by optimizing design parameters and minimizing losses
• Effectiveness: measure of how close the heat exchanger performance is to an ideal counterflow heat exchanger
  • Depends on the flow arrangement, heat capacity rates, and NTU
  • Higher effectiveness indicates better performance
• Relationship between effectiveness and NTU
  • Effectiveness increases with increasing NTU
  • The relationship is non-linear and depends on the flow arrangement
• Factors affecting efficiency and effectiveness
  • Fluid properties (viscosity, thermal conductivity, specific heat)
  • Flow rates and heat capacity rates
  • Fouling and scaling on heat transfer surfaces
  • Leakage and bypass flows
• Strategies to improve efficiency and effectiveness
  • Periodic cleaning and maintenance to minimize fouling
  • Optimize flow distribution and minimize dead zones
  • Use enhanced heat transfer surfaces (fins, turbulators)
  • Implement heat recovery systems to utilize waste heat

Applications in Industry

• HVAC systems
  • Used for heating, cooling, and dehumidification in buildings
  • Examples include air-to-air heat exchangers, water-to-air heat exchangers, and refrigerant-to-air heat exchangers
• Power generation
  • Used in steam power plants for condensers, feedwater heaters, and air preheaters
  • Enhance overall plant efficiency by recovering waste heat
• Chemical processing
  • Used for heating, cooling, and condensing process fluids
  • Examples include shell and tube heat exchangers, plate heat exchangers, and fin heat exchangers
• Refrigeration and air conditioning
  • Used in condensers, evaporators, and subcoolers
  • Essential for heat rejection and absorption in refrigeration cycles
• Automotive industry
  • Used in radiators, oil coolers, and air conditioning systems
  • Ensure proper cooling of engine components and passenger comfort
• Food processing
  • Used for pasteurization, sterilization, and cooling of food products
  • Plate heat exchangers are commonly used due to their ease of cleaning and maintenance
• Waste heat recovery
  • Utilize waste heat from industrial processes to generate steam, preheat combustion air, or drive absorption chillers
  • Improve overall energy efficiency and reduce environmental impact

Troubleshooting and Maintenance

• Common issues in heat exchangers
  • Fouling and scaling: accumulation of deposits on heat transfer surfaces
  • Leakage: unintended mixing of fluids due to seal or gasket failure
  • Corrosion: degradation of materials due to chemical reactions with fluids
  • Vibration: caused by improper support, flow-induced vibration, or mechanical issues
• Troubleshooting techniques
  • Monitor inlet and outlet temperatures and pressures
  • Perform visual inspections for leaks, corrosion, or damage
  • Use non-destructive testing methods (ultrasonic, radiographic) to detect internal flaws
  • Analyze fluid samples for contamination or degradation
• Maintenance practices
  • Establish a regular cleaning schedule based on the application and fluid properties
  • Use chemical cleaning, mechanical cleaning, or high-pressure water jetting to remove fouling
  • Replace gaskets, seals, and other wear components as needed
  • Perform periodic inspections and tests to identify potential issues early
• Preventive measures
  • Select materials compatible with the fluids and operating conditions
  • Use filtration systems to reduce particulate fouling
  • Implement water treatment programs to minimize scaling and corrosion
  • Install vibration monitoring and control systems
  • Provide proper support and anchoring to minimize mechanical stress
• Maintenance planning and documentation
  • Develop a comprehensive maintenance plan with scheduled tasks and inspections
  • Document all maintenance activities, repairs, and replacements
  • Keep records of operating conditions, performance data, and fluid analysis results
  • Regularly review and update the maintenance plan based on the equipment's performance and condition