Module – 5

HEAT EXCHANGERS
5.1 INTRODUCTION
Heat Exchanger is a process equipment designed for the effective transfer of heat energy between
two fluids, i.e., a hot fluid and a coolant. To use heat exchanger in a thermal system, temperature
drop is required to transfer the heat, The temperature drop can be decreased by utilizing a larger
heat exchanger. But economic considerations are important in a complete engineering design
of heat exchanger equipments. The role of heat exchangers has taken on increasing importance
recently and engineers have become energy conscious and want to optimize design and energy
payback of a system.
Examples of Heat Exchangers
Boilers, Superheaters, condensers, automobile radiators, evaporators of an ice plant and milk
chiller, water and air heaters.
5.2 CLASSIFICATION OF HEAT EXCHANGERS
Heat exchangers are classified as follows
I. According to the nature of heat exchanging process
a) Direct contact heat exchangers
b) Regenerators
c) Recuperates
II. According to direction of flow of fluids
a) Parallel flow heat exchangers
b) Counter flow heat exchangers
c) Cross flow heat exchangers
III. According to design and construction
a) Concentric tube heat exchangers
b) Shell and tube exchangers
c) Compact heat exchangers
IV. According to the physical state of fluids
a) Condenser
b) Evaporator
Direct Contact Heat Exchangers
In this type of heat exchangers, heat transfer between the hot and cold fluids is achieved by
their complete physical mixing in one another.
Ex: Cooling towers, Jet Condensers.
Regenerators:
In a regenerator type heat exchanger, the hot and cold fluids pass alternatively through a space
containing solid particles called matrix. The heat stored in the matrix is transferred to the cold
fluid by allowing it to pass over the heated matrix. Thus, fluids flow through the same space but
alternatively and do not get mixed.
Ex: Pre heaters for steam power plant, Blast furnaces.
514 Heat Transfer

Recuperator:
In this the hot and cold fluids flow simultaneously on either side of a separating wall. The
heat is transferred by a combination of convection to and from the wall and conduction through
the wall. The wall can include extended surface such as fins or other heat transfer enhancement
devices.
Ex: Automobile radiators, oil coolers, boilers, surface condensers.
Parallel Flow Heat Exchangers:
In parallel flow, both the fluids flow in the same direction.
Cold Fluid

Hot Fluid

Counter Flow Heat Exchangers:

In counter flow the two fluids flow in opposite direction.

Hot Fluid

Cold Fluid
Cross Flow Heat Exchangers:
In cross flow heat exchangers the heat and cold fluids flow at right angles to each other.

Cold
Fluid

Hot Fluid
Concentric tube Heat exchangers:
In this, two concentric tubes are used. Each caries one of the fluids. The direction of flow may
be parallel or counter flow.
 Heat Exchangers 515

Shell and Tube Heat Exchangers:

In this, one of the fluids flow through a bundle of tubes enclosed by a shell and the another
fluid is forced through the shell and made to flow over the tubes.
Compact Heat Exchangers:
They have a very large heat transfer area per unit volume of the heat exchanger. Applications
in which compact heat exchangers are required include (i) an automobile heater core in which
engine coolant is circulated through tubes and the passenger compartment air is blown over the
finned exterior surface of the tubes. (ii) Refrigerator condensers.
Condenser:
In this, condensing fluid remains at constant temperature through out the heat exchanger. The
temperature of the colder fluid gradually increases from inlet to outlet.
Evaporator:
In this cold fluid remains at constant temperature, while temperature of hot fluid gradually
decreases from inlet to outlet.
5.3 OVERALL HEAT TRANSFER COEFFICIENT
The thermal design of heat exchanger involves the calculation of the necessary surface area
required to transfer heat at a given rate for given flow rates and fluid temperatures. It makes use
of concept of the overall heat transfer coefficient.
In a heat exchanger, the energy is transferred from one fluid to another across a good conducting
wall.
∆T
W. K. T Q
= = R t thermal resistance
ΣR t
and=
Q UA ∆T
For Plane Wall :
∆T
= UA ∆T
ΣR t
∆T
= UA ∆T hi
1 L 1
+ + Ti T1
h i A KA h o A ho
1
= UA
1 L 1 ∆T ∆T ∆T
+ + W. K.=
=
= TW.QK. T=W. T QT2 =
Q K. = R t thermal
R t thermal
resistance
R t resistanc
thermal
h i A KA h o A ΣR t ΣR t ΣR T
t o

1 and=
Q and
UA
= Q∆TUA
and= Q
∆T UA ∆T
U=
1 L 1 For Plane
For Wall
Plane
For
: Wall
Plane
: Wall :
+ +
hi K ho ∆T ∆T ∆T
= UA =∆TUA
L=∆T UA ∆T
1 1 L 1 ΣR t ΣR t ΣR t
= + +
U hi K ho ∆T ∆T ∆T
= UA =∆TUA= ∆T UA ∆T
For Cylindrical Wall : 1 L1 1L 1 1 L 1
+ ++ ++ +
∆T h i A KA
h i A hKA
oAh i A h oKA
A hoA
UA ∆T =
ΣR t 1 1 1
= UA = UA = UA
1 1 L1 1L 1 1 L 1
UA = + ++ ++ +
ΣR t h i A KA
h i A hKA
oAh i A h oKA
A hoA
Based on outside area 1 1 1
U= U= U=
1 1 L 1 1 L 11 L 1
+ ++ + + +
Uo Ao = h K h h K hh K h
 ∆T
UA ∆T =
ΣR t
516 1 Heat Transfer
UA =
ΣR t
Based on outside area
1
Uo Ao =
r
log e o
1 ri 1
+ +
hA i 2πKL h o A o ri
Ai =
2π ri L Ao =
2π ro L
hi ro
1
Uo =
ro
A o log e
Ao ri 1
+ +
h i Ai 2πKL ho ho
1
=
ro
2πro L log e
2π ro L ri 1
+ +
h i 2π ri L 2π KL ho
1
=
1 ro ro r 1
+ log e o +
h i ri K ri h o
1 1 r r r 1
or =o + o log e o +
U o h i ri K ri h o
Similarly based on inside area
1 1 ri r r 1
= + log e o + i
Ui h i K ri ro h o

1) The overall heat transfer coefficient depends on the flow rate and properties of the fluid.
2) For the fluids like tars, oils [low thermal conductivities] the overall heat transfer coefficient
will decrease.
3) For an efficient and effective design, there should be no high thermal resistances in the heat
flow path, all resistance in the heat exchanger must be low.
5.4 FOULING
The phenomenon of rust formation and deposition of fluid impurities on the tube surface of
heat exchanger is called fouling.
The surface deposits increase thermal resistance with a corresponding drop in the performance
of heat exchanger. The effect of scale on heat flow is considered by specifying an equivalent scale
heat transfer coefficient.
Thermal resistance due to fouling
1 
=R fi → inside the pipe 
A i h fi  h fi = h si

1 h = h so
=R fo → ouside the tube  fo
A o h fo 
h fi and h fo are the heat transfer coefficients between scale and fluid at inside and outside of the tube.
Now the overall heat transfer coefficient becomes
1 1 1 r r r 1 r 1
= + + i log e o + i + i
U h h K r r h r h
 1 h = h so
=R fo → ouside the tube  fo
A o h fo 
h fi and
Heat h fo are the heat transfer coefficients between scale and fluid at inside and outside of the517
Exchangers tube.
Now the overall heat transfer coefficient becomes
1 1 1 r r r 1 r 1
= + + i log e o + i + i
U i h i h fi K ri ro h fo ro h o
1 1 1 ro r r 1 ro 1
and = + + log e o + i +
U o h o h fo K ri ro h fi ri h i
5.4.1 Fouling Factor
The reciprocal of scale heat transfer coefficient is called as fouling factor.
1
i.e., Fouling factor R f =
hf
1 1
i.e., R fo
= = and R fi for outer and inner sides of the pipe
h fo hf1
Fouling factors are determined experimentally by testing the heat exchanges in both the clean
and dirty conditions.
1 1
i.e.,=
Rf −
U dirty U clean

5.5 ANALYSIS OF HEAT EXCHANGER

Analysis of heat exchanger mainly include rating and sizing. Two methods are applied for
analyzing heat exchangers. They are
i) Logarithmic Mean Temperature Difference Method
ii) Effectiveness – NTU method
5.5.1. Logarithmic Mean Temperature Difference (LMTD) Method
The thermal analysis of heat exchangers depend on variables like inlet and outlet fluid
temperature, overall heat transfer coefficient, total surface area of heat exchanger and the heat
transfer rate.
The temperature difference between hot and cold fluids is ΔT =Th – Tc. Since ΔT is varying
with position along the length of the heat exchanger, the heat transfer becomes
Q = UAs ΔTm
Where, ΔTm = Mean Temperature difference across the heat exchanger.
For heat exchangers this mean temperature difference will be in the form of a logarithmic
relation. Hence it is referred as Logarithmic Mean Temperature Difference (LMTD).
Assumptions:
For the analysis of heat exchanger under LMTD, the following assumptions are considered.
a) The overall heat transfer coefficient is uniform through out the heat exchanger.
b) The specific heats and mass flow rates of both the fluids are constant.
c) The potential and kinetic energy changes are negligible.
d) The heat exchange takes place only between the two fluids
e) The temperature of both the fluids are constant over a given cross-section.
 518 Heat Transfer

5.5.2 Analysis of parallel flow heat exchanger using LMTD

Cold Fluid Thi
dTh Tho
θ1 θ θ2
Hot Tco
Fluid dTc
Tci

dx
Length of Heat exchangers
Consider a parallel flow heat exchanger as shown in fig.
Let Thi = Inlet temperature of hot fluid
Tho = Outlet temperature of hot fluid
Tci = Inlet temperature of cold fluid
Tco = Outlet temperature of cold fluid
Cph & Cpc are specific heats of hot and cold fluids
m h & m c are mass flow rate of hot and cold fluids
A s = Surface area of heat exchanger
Also Let q1= Thi − Tci
q 2= Tho − Tco
Total heat transfer between the two fluids
=Q m h Cph ( Thi −=
Tho ) m c Cpc ( Tco − Tci )
or Q= Ch ( Thi − Tho =
) Cc ( Tco − Tci )
Where Ch m=
= h C ph and C c m c Cpc are called heat capacity rates of hot and cold fluids.
Consider a small element of thickness 'dx' as shown in fig.
For hot fluid
dTh is − ve along the length of the heat exchanger 
dQ =
− m h Cph dTh =
− Ch dTh as the temperature decreases along + x axis 
 
− dQ
or dTh =
Ch
For cold fluid
= dQ m= h C pc dTc Cc dTc
dQ
or dTc =
Cc
But for the element
q= Th − Tc
or d=
q dTh − dTc
 as the temperature decreases along + x axis 
− dQ
or dTh =
Heat Exchangers C h 519
For cold fluid
= dQ m= h C pc dTc Cc dTc
dQ
or dTc =
Cc
But for the element
q= Th − Tc
or d=
q dTh − dTc
−dQ dQ
= −
Ch Cc
 1 1 
dq = − dQ  + 
 C h Cc 
 1 1 
dq = − UdAq  +  [ dQ = UdA . q]
 C h Cc 
dq  1 1 
= − UdA  + 
q  C h Cc 
Integrating along the heat exchanger length between inlet and outlet of heat exchanger.
2 A
dq  1 1  s
i.e., ∫1 q =
− U  +  ∫ dA
 C h Cc  0
q2  1 1 
log e
= − UA s  + 
q1  C h Cc  But
 1 1  Q
Ch =
 Q Q  Thi − Tho
− UA s 
= + 
 Thi − Tho Tco − Tci  Q
Cc =
  Tco − Tci
− UA s
=
Q
[ Thi − Tho + Tco − Tci ]
− UA s
= ( Thi − Tci ) − ( Tho − Tco ) 
Q 
q 2 − UA s
log
= e
q1 Q
[q1 − q2 ]
q 2 UA s
− log=
e
q1 Q
[q1 − q2 ]
−1
 q2  UA s
log e  = 
 q1  Q
[q1 − q2 ]
q1 UA s
log=
e
q2 Q
[q1 − q2 ]

Q = UA s
(q1 − q2 )
  q2  UA s
log e  = 
 q1  Q
[q1 − q2 ]
q1 UA s
520
log=
e
q2 Q
[q1 − q2 ] Heat Transfer

Q = UA s
(q1 − q2 )
q1
log e
q2
Q UA s q m
=
q − q2
Where q m = 1 is called Logorithemic Mean Temperature Difference [ LMTD ]
q
log e 1
q2
5.5.3 Analysis of Counter Flow Heat Exchanger Using LMTD
Thi

θ1
dTh
Tco Tho
Hot
dTc
Fluid θ2

Tci

Cold Fluid
x dx
Length of Heat exchanger
Consider a counter flow heat exchanger as shown in fig
Let Thi & Tho are temperature of hot fluid at inlet & outlet
Tci & Tco are temperature of cold fluid at inlet & outlet
m h & m c are mass flow rates of hot and cold fluids
Cph & Cpc are specific heats of hot and cold fluids
A s = Surface area of heat exchanger
Let heat transfer between two fluids as
=Q m h Cph ( Thi −=
Tho ) m c Cpc ( Tco − Tci )
) Cc [ Tco − Tci ]
Q= Ch ( Thi − Tho =
Also q1= Thi − Tco
q 2= Tho − Tci
For a small elemental area dA, heat transfer is
dTh and dTc are − ve along the length of heat exchanger 
dQ = − m h Cph dTh =
−Ch dTh as temperature decreases along + x axis 
 
and dQ = − m c Cpc dTc =
−Cc dTc
−dQ −dQ
or
= dTh = & dTc
Ch Cc
 dTh and dTc are − ve along the length of heat exchanger 
dQ =
− m h Cph dTh =
−Ch dTh as temperature decreases along + x axis 
 
Heat Exchangers 521
and dQ =
− m c Cpc dTc =
−Cc dTc
−dQ −dQ
or
= dTh = & dTc
Ch Cc
From the diagram at a distance of x
q= Th − Tc
or d=
q dTh − dTc
−dQ  dQ   1 1 
= −− =− dQ  − 
Ch  Cc   C h Cc 
 1 1 
dq = − UdA q  − 
 C h Cc 
dq  1 1 
= − U  −  dA
q  C h Cc 
Integrating between inlet and outlet conditions
2 A
dq  1 1  s
∫1 q = − U  −  ∫ dA
 C h Cc  0
q  1 1 
log e 2 = − UA s  − 
q1  C h Cc 
 
 1 1 
− UA s 
= − 
 Q Q 
 Thi − Tho Tco − Tci 
− UA s − UA s
= ( Thi − Tho ) − ( Tco −=
 Tci )  ( Thi − Tco ) − ( Tho − Tci ) 
Q Q 
q 2 − UA s  q1= Thi − Tco
log
= e
q1 Q
[q1 − q2 ]  q = T − T
 2 ho ci

q1 UA s
log=
e
q2 Q
[q1 − q2 ]

Q UA s
=
[q1 − q2 ]
= UA s q m
q
log e 1
q2
q − q2
Where, qm = 1 is the Lagaritemic Mean Temperature Difference [ LMTD ]
q
log e 1
q2
 522 Heat Transfer

5.6 CAPACITY RATES

Capacity rate is the product of mass flow rate and specific heat of fluid at constant pressure.
For cold fluid, capacity rate Cc = mc Cpc
hot fluid, capacity rate Ch = mh Cph
5.6.1 Capacity Ratio
It is defined as the ratio of minimum to maximum capacity rates
Capacity rate of hot fluid = Ch = mh Cph
Capacity rate of cold fluid = Cc = mc Cpc
Cc
\ Capacity ratio C = if Cc < Ch
Ch
Ch
or Capacity
= ratio C if C h < Cc
Cc
5.6.2 Effectiveness of Heat Exchanger
It is defined as the ratio of the energy actually transferred to the maximum theoretical energy
transferred.
Q
i.e., Effectiveness ∈= act
Q max
Tho ) m c Cpc [ Tco − Tci ]
Qact m h Cph ( Thi − =
=
Maximum available temperature difference
= Thi − Tci
Maximum possible heat transfer occurs when the fluid of a small heat capacity rate undergoes the
maximum temperature difference.
= Cmin ( Thi − Tci )
\ Q max
m h Cph ( Thi − Tho ) Ch [ Thi − Tho ]
\∈ =
Cmin ( Thi − Tci ) Cmin [ Thi − Tci ]
m c Cpc [ Tco − Tci ] Cc [ Tco − Tci ]
=or ∈ =
Cmin [ Thi − Tci ] Cmin [ Thi − To ]
Ch [ Thi − Tho ] Thi − Tho
If Ch < Cc then ∈= =
Ch [ Thi − Tci ] Thi − Tci
Cc [ Tco − Tci ] Tco − Tci
If Cc < Ch then ∈= =
Cc [ Thi − Tci ] Thi − Tci

5.6.3 Number of Transfer Units [NTU]

It is a measure of the size of heat exchanger. It is a dimensionless parameter.
It is given by
UA s
NTU =
Cmin

 Heat Exchangers 523

5.6.4 Importance of NTU Effectiveness method

The analysis of heat exchanger mainly involves rating & sizing. The rating problem mainly
deals with the determination of heat transfer rate, the fluid outlet temperatures for the already
sized heat exchanger.
The sizing problem deals with the determination of matrix dimensions to meet the specified
heat transfer requirements. If the inlet and outlet temperatures of the hot and cold fluid and overall
heat transfer coefficient are known, then LMTD method is used to solve both rating and sizing.
However, if heat transfer coefficient is unknown, then determination of rating and sizing by
LMTD is very difficult. It is overcome by using ε - NTU method.
5.7 ANALYSIS OF HEAT EXCHANGERS BY NTU - EFFECTIVENESS METHOD
Parallel flow Heat Exchanger
We Know That
 1 1  Thi
dq = − dQ  + 
 C h Cc  dTh Tho
 1 1 
=− UdAq  +  θ1 θ θ2
C
 h C c 
Tco
dq  1 1  dTc
= − U  +  dA
q  C h Cc  Tci
Integrating between inlet and outlet conditions, we get
q2  1 1  0 x
log e − UA s  + 
= dx
q1  C h Cc 
 1 1 
q2 − UAs  + 
 C h Cc 
=e
q1
 1 1 
Tho − Tco − UAs  + 
= e  C h Cc 
− − − (1)
Thi − Tci
Ch ( Thi − Tho ) Cmin
But Effectiness ∈
=
Cmin ( Thi − Tci )
or Tho= Thi − ∈
Ch
[ Thi − Tci ] − − − ( 2)
Cc [ Tco − Tci ] Cmin
Also ∈
=
C min [ Thi − Tci ]
or Tco= Tci + ∈
Cc
( Thi − Tci ) − − − ( 3)

Equation ( 2 ) − ( 3) gives
Cmin  C 
Tho − Tco= Thi − ∈ [Thi − Tci ] − Tci − ∈ min ( Thi − Tci )
Ch  C c 
 1 1 
= ( Thi − Tci ) − ∈ Cmin  +  [ Thi − Tci ]
 C h Cc 
  1 1 
= ( Thi − Tci ) 1− ∈ Cmin  + 
  C h Cc  
Tho − Tco  1 1 
= 1− ∈ C min  +  − − − ( 4)
Thi − Tci  C h Cc 
Equating (1) & ( 4 )
 =
= +  [ Thi − Tci ]
(Thi − Tci ) − ∈ Cmin  C
 Ch C c 
  1 1  
= ( Thi − Tci ) 1− ∈ Cmin 
=
524 +   Heat Transfer
  Ch Cc  
Tho − Tco  1 1 
∈C min
= 1− ∈ min  +  − − − ( 4)
Thi − Tci  C hh Ccc 
Equating (1) & ((44))
 1 1 
 1 UAs 1 ++1  
1 −−UA
C C
1− ∈ Cmin  +  = e  C h h Cc c 
C
 hh C 
cc 
 1
UAs 1 ++1  
1 
 1 1 −−UA
C Ch h CC
c c 
∈ C min
min  +  1
= − e
C
 hh C cc 
  11 11 
− UA
− UAs  ++  
C C
1− e  Ch h Cc c 
∈=
∈=
 11 11 
Cmin
C min  ++ 
CChh CCcc 
C 
− UAs Cc c++11 
− UA
Ch 
1− e C
 h 
∈=
∈=
Cmin
C  Ccc 
min  C
++11
Ccc C
C  Chh 
CCminmin UAUA
Assume
== Ccc Cmin
min=and Chh C=
= = , CC
max & ,=
=NTU
& NTU
s
max
CCmaxmax Cmin
C min
UAsCCmimin
−−UA n +1
 +1
Cmin
min CCmax
1− e C max 

\∈
∈==
Cmin
min  C min 

min
+ 1
min  C max
Cmin max 
− NTU ( C +1)
11−− ee− NTU( C +!)
∈=
\ ∈=
CC++11
NOTE :
Cmin Cmin
(1) If Cmax tends to infinity then the ratio
= C = = 0
Cmax ∞
\ Effectiveness of parallel flow heat exchanger ∈= 1 − e − NTU
( 2) When C = 1
\ Effectiveness of parallel flow heat exchanger
1 − e − NTU( C +1) 1 − e − NTU(1+1)
=∈ =
C +1 1+1
1 − e −2 NTU
∈=
2
 Heat Exchangers 525

5.7.1 Counter flow Heat Exchanger

Thi
We
We know
know that
that
 11 11  θ1
ddq = − dQ 
q = − dQ  C − C  −  dTh
 Chh Ccc  Tco Tho
 11 11  θ
= dQ
= dQ  C − −  dTc
 Ccc C Chh  θ2
 11 11 
=
= ddqq UdA
UdAq q  C − − C  Tci
 Ccc Chh 
= q U  11 − 11  dA
ddq
= q U  C − C  dA
q  Ccc Chh  x
Integrating dx
Integrating between
between inlet inlet and
and outlet
outlet conditions
conditions

log= q 22 U  11 − 11  A
q
log= e
e q U  C − C  A ss
q11  Ccc Chh 
 1 1 
q UA  1 − 1 
q 22 = e UAss  CCcc − CCnn 
q1 = e
q 1
 1 1 
T
Tho − Tci UAs  1 − 1 
ho − Tci = e
UAs  Cc − Ch 
 Cc C h 
T − T = e
Thi − Tco
hi co
 1 1 
T −T
Thihi − Tco
− UAs  1 − 1 

− ((11))
− UAs  Cc − Ch 
=
= co e
e  Cc C h  −
−−−−
T − T
Tho − Tci ho ci

But Ch (( T
C −T
Thi − Tho ))
But Effectiness
Effectiness ∈= ∈= C h Thi − Tho or
( hi ci )
min ( Thi − Tci )
Cmin
CminC
orho= ThoT=hi −T∈hi −C∈ [ T
T min − T ]
hi [ T ci− T ]
hi ci
h C
h

Also Cc [[ T
C Tco −−TTci ]] or T T
C
Cmin
min ( T − T )
Also =
∈
∈ C c Tco − Tci
= or =
Tco
= Tci +
+ ∈
∈ ( Thihi − Tcici )
Cmin [[ Thi − Tci ]] C
co ci
min hi ci Ccc
Substituting Tho & Tco relation in equation (1)
Cmin
Thi − Tci − ∈
Cc
( Thi − Tci )  1
− UAs  − 
1 
 Cc C h 
=e
Cmin
Thi − ∈
Ch hi
( T − Tci ) − Tci
Cmin
( Thi − Tci ) − ∈ Cc
( Thi − Tci ) − UAs  1 − 1 
 Cc C h 
=e
C
( Thi − Tci ) − ∈ Cmin ( Thi − Tci )
h

Cmin
1− ∈  1 1 
Cc − UAs  − 
 Cc C h 
 CminC
( TThihi −− TTcici ) −− ∈
∈ min ( T
C
C
−T
Thihi − Tcici ) −
 1
UAs  1 −
− UA
s C
1 
− 1 

 Ccc C
= ee
cc
= Chh 
Cmin
526 ∈ Cmin
( TThihi −− TTcici ) −− ∈ ( TThihi −− TTcici ) Heat Transfer
C
Chh
Cmin
11− −∈ ∈ Cmin  1
− UA  1 − 1 
1 
C
Ccc = e − UAss  CCcc − CChh 
Cmin =e
11− ∈ C
−∈ min
C
Chh
 1
 1 1 
1 
Cmin
∈ Cmin 1− ∈ C Cmin
min 
 −− UA
UAss  C − − C 
11−
−∈ ==  1− ∈ e
e  Ccc Chh 
Ccc
C Chh 
C
 1 1   1 1 
UAs  1 − − 1  UAs  1 − − 1 
C
Cmin
− UA
− s C
 Ccc C  Cmin −− UA
Chh  − ∈ C min
s C
 Ccc C 
11=
−
=
−∈∈ min e
e −∈ e
e
Chh 
C
Ccc C
Chh
 C − UA
−
 11
UAss  C −
1
1 
C  −− UA  11
UAss  C −
11 
C − C 
C − C 
∈×  min ee
∈×  c = h −
− min  ee h  −1
min  C C  min  C C h
−1
c h c
=  c
 CC C
C c  
 
h
h c

 11 11 
− UA
− UAss  C − − C 

∈= ee  Ccc Chh  − 11
−
∈=  1 1 
UAs  1 − − 1 
Cmin
C min e
− UA
− s C Ch  C
Cmin
e
 Ccc C h −
− min
C
Chh C
Ccc
− UA
− UAss 1− C
Cc 
1− c 
C
Ccc  C
ee − 11
Chh 
= −
= UAs  C
− UA Cc 
− s 1− c 
Cmin
C min e
Cmin
C Cc 1− C
Ch 
e −
− min
C c h

C
Chh C
Ccc
UA
UA ss and C CCmin
But
But NTU
=
= NTU == and C min & Assume
=
& Assume
= C
Ccc C
Cmax
C
Cmin
min
C
C max
max
max

NTU ((11−
ee −− NTU −CC)) − 1
\∈= −1
\∈= Cmin
− NTU (1 −
C ee − NTU(1− C) −
C
C )
− Cmin
Cmin
C min
NTU ((11−
ee −− NTU −C C)) − 1
∈= −1
∈= − NTU ((11−− CC))
C ee
C − NTU − 11
−
1− NTU ((11−
− ee −− NTU −CC))
or ∈=
∈= 1
or − NTU (1− C)
11 −
−CC ee − NTU(1− C)
NOTE :
Cmin Cmin
(1) If Cmax tends to infinity then the ratio
= C = = 0
Cmax ∞
\ Effictiveness of counter flow heat exchanger ∈= 1 − e − NTU
( 2 ) When C = 1
When C = 1, Effictiveness of counter flow heat exchanger becomes indeterminite
\ NTU (1 − C ) << 1 and e − NTU (1− C ) =
1 − NTU (1 − C )
1 − 1 − NTU (1 − C ) 
∈=
1 − C 1 − NTU 1 − C 
 \ Effictiveness of counter flow heat exchanger ∈= 1 − e − NTU
( 2 ) When C = 1
Heat Exchangers 527
When C = 1, Effictiveness of counter flow heat exchanger becomes indeterminite
\ NTU (1 − C ) << 1 and e − NTU(1− C ) =
1 − NTU (1 − C )
1 − 1 − NTU (1 − C ) 
∈=
1 − C 1 − NTU (1 − C ) 
NTU (1 − C )
=
1 − C +  NTU (1 − C ) C 
NTU (1 − C )
=
(1 − C ) + NTU (1 − C ) C
NTU (1 − C )
=
(1 − C ) (1 + NTU . C )
NTU NTU
== =
∈ [ C =
1]
1 + NTU × C 1 + NTU
5.8 HEAT PIPE
It is a device which transfer a large quantity of heat over a large distance at a constant
temperature without any power input.
Construction of heat pipe
Insulation Wick Copper tube
Liquid flow

Heat In Vapour flow Heat Out

Adiabatic section
Evaporation section Condenser section
Heat pipe is basically a sealed circular tube containing an annular layer of wicking material on
the side surface of the tube. The core of the system is hollow in the centre to permit working fluid
to pass freely form one end to other. The wick transports the working medium in liquid form from
one end to other end by capillary action.
Heat pipe consist of three sections.
(i) An evaporator section where fluid absorbs heat of evaporation and turns into vapour.
(ii) A condenser section where vapour is condensed and rejects its latent heat.
(iii) The adiabatic section between evaporator and condenser section. Here, vapour and liquid
phrases flow in opposite directions through core and wick respectively to complete the
cycle without any heat transfer between fluid and its surroundings.
Wick is made by mesh screen, stainless steel fibres, cintered fibers and powders.
Working : Initially the wick of heat pipe is soaked with saturated liquid and core section is filled
with saturated vapour. When the evaporator section of heat pipe is placed in hot environment, the
heat is transferred to saturate liquid, the starts vapourising and causing vapour pressure to rise.
Thus resulting pressure difference drives the vapour through the core from evaporator section to
condenser section. The condenser section of the heat pipe is located in the cooling medium, thus
528 Heat Transfer

its surface is slightly at a lower temperature. The vapour comes in contact of this cooler surface,
condenses releasing its latent heat which is rejected to cooling medium. The condensed liquid
then return to the evaporator end through the wick as a result of capillary action. Thus completes
the cycle. Thus, the heat is absorbed at one end of the heat pipe and is rejected at the other with
the fluid inside serving as transport medium for heat.
5.8.1 Applications of heat pipe
1. Heat pipes are extensively used for waste gas heat recovery.
2. Use of heat pipe in electrical and electronics system can reduce the size of magnetic
components by 30%.
3. In air conditioning system exhaust air leaving room can precool or preheat the incoming air
with the use of heat pipe.
4. VAPIPE heat pipe is used in a car engine to vaporize gasoline by exhaust gases before it
enters the engine.
5. In gas turbine plant, the heat pipes are used to preheat the compressed air before it enters
the combustion chamber. It increases thermal efficiency of plant.
6. Heat pipes can be used in extrusion of plastic materials to maintain the temperature gradient.
7. Heat pipes are used in solar applications such as space heating, snow melting, kitchen
cooking, spray drying, pollution control laundries, biscuit and bread ovens.

Problems on Heat Exchangers

NOTE: Heat and Mass transfer data book by C. P. Kothandaraman is used for solving problems.
1. A copper pipe (K = 350W/mK) of 1.75cm inner dia and 2cm outside dia conveys water
and the oil flow through the annular passage between this pipe and a steel pipe. On the
water side the film coefficient is 4600W/m2K and the fouling factor is 0.00034m2K/W.
The corresponding values for the oil side are 1200W/m2K and 0.00086m2K/W. Workout
the overall heat transfer coefficient between the water and oil.
Data: K copper =
350W / mK, d o =2cm = 2 × 10−2 m, d i =
1.75cm =
1.75 ,×U10
o
−2
= m, 4600W / m 2 K
? hi =
2 2
R fi 0.00034m
= K / W, R fo 0.00086m
= K / W, h o 1200W / m 2 K
Overall heat transfer coefficient
Oil based on outer surface of the inner pipe
1 1 r ro ro r 1
= + R fo + o logWater + R fi + o
1.75cm

e
Uo h o K copper ri ri ri h i 2 cm
Copper pipe
1 1 × 10−2 1000 × 10−2 1 × 10−2 1 × 10−2 2 1
K copper = =
350W + 0.00086 + log −2 + × 0.00034
−2 +
1200/ mK, d o = 2cm350= 2 × 10e 0.875
m, d×i 10
1.75cm
== −2
0.8751.75
× 10×−210 m, h i = 4600W
0.875 /m
× 10 −2 K
4600
2 2 2
R fi 0.00034m
U= K / W,
= 435.16W /m R
2
Kfo 0.00086m
=
Steel pipe K / W, h o 1200W / m K
o
Overall heat transfer coefficient based on outer surface of the inner pipe
1 1 r r r r 1
= + R fo + o log e o + o R fi + o
Uo h o K copper ri ri ri h i
1 1 × 10−2  1 × 10−2  1 × 10−2 1 × 10−2 1
=+ 0.00086 + log e  −2 
+ −2
× 0.00034 + −2
×
1200 350  0.875 × 10  0.875 × 10 0.875 × 10 4600
U o = 435.16W / m 2 K
Heat Exchangers 529

2. A stainless steel tube (K = 45W/mK) of inner and outer diameters of 22mm and 27mm
respectively, is used in a cross flow heat exchanger. The fouling factors for the inner and
outer surfaces are estimated to be 0.0004 and 0.0002m2K/W respectively. Determine the
overall heat transfer coefficient based on the outside surface area of the tube.
(Refer the fig)
2
ho, Rfo = 0.0002m K/W

hi, Rfi
vω = 0.5m/sec
H2O di do
Tωi = 75oC

Air, T∞ = 15oC, vair = 20m/sec

To find ho
Properties of water at 75o C ( From HMT Data Book )
K
= i ni 0.39 × 10−6 m 2 / s, P=
0.6715W / mK, = ri 2.38
vi d i 0.5 × 22 × 10−3
R ei
= = = 28205
ni 0.39 × 10−6
Since R ei > 2300, flow is turbulent
h i di  From HMT data book Forced 
= 0.023 ( R ei ) ( Pr )
0.8 0.4
\ N ui = Convection through tubes 
Ki  
N ui 0.023( 28205) × ( 2.38) 118.2
0.8 0.4
= =
118.2 × 0.6715
=hi = 3608W / m 2 K
0.022
To find ho
Properties of air at 15o C
K
= o no 14.61 × 10−6 m 2 / s, =
0.0255W / mK, = Pr 0.704
vo d o 20 × 0.027
R eo
= = = 36961
Ko 14.61 × 10−6
From HMT data book flow across tubes
0.25
h odo m 
N uo =
= 0.4 R eo
0.5 0.6667
+ 0.06R eo  Pr0.4  ∞ 
Ko  mω 
m∞
For gases =1
mω
\ N uo = 0.4 × ( 36961) + 0.06 ( 36961)  × 0.7040.4
0.5 0.6667
 
= 130.4
h odo
N uo =
= 130.4
Ko
130.4 × 0.0255
=ho = ⇒ h o 123W / m 2 K
0.027
Overall heat transfer coefficient based on outer surface area
  
= 130.4
h odo
N uo =
530
= 130.4 Heat Transfer
Ko
130.4 × 0.0255
=ho = ⇒ h o 123W / m 2 K
0.027
Overall heat transfer coefficient based on outer surface area
1 1 r r r r 1
= + R fo + o log e o + o R fi + o
Uo h o K steel ri ri ri h i
1 13.5 × 10 −3 27 27 27 1
= + 0.0002 + × log e + × 0.0004 + ×
123 45 22 22 22 3608
U o = 110W / m 2 K
3. Water at 25oC and a velocity of 1.5m/s enters a brass condenser tube 6m long, 1.34cm ID,
1.58cm OD and K = 110W/mK. Steam is condensing on the outer surface of the tube with
a heat transfer coefficient of 12000W/m2K. The fouling factors for the inner and outer
surface are both equal to 0.00018m2K/W. Calculate the overall heat transfer coefficient
based on inside surface area and outside surface area.
Data:
ho = 12000W/m2K
Rfo = 0.00018m2K/W
Steam

hi = ?
φ 1.34cm

φ 1.58cm
Water Rfi = 0.00018m2K/W

6m
o
K brass 110W /=
= mK, Twi 25
= C, v wi 1.5m / sec
To find h i
Properties of water at 25o C
K=
w 0.6805W / mK, n=
w 0.945 × 10−6 m 2 / s, =
Pr 6.22
v w d i 1.5 × 0.0134
R eω
= = = 21270 > 2300
nw 0.945 × 10−6
\ Flow is turbulent
0.8 0.4
Now N ui = 0.023 R ew Pr
= 0.023 × ( 21270) ( 6.22) 0.4 = 138.5
0.8

h i di h i × 0.0134
=N ui = , 138.5
Kw 0.6805
h i = 6289.5W / m 2 K
( i) Overall heat transfer coefficient based on inner surface area
1 1 r r r r 1
= + R fi + i log e o + i R fo + i
Ui h i K brass ri ro ro h o
 ( ) ( )
h i di h i × 0.0134
=N ui = , 138.5
Kw 0.6805
Heat Exchangers 531
h i = 6289.5W / m 2 K T=
hi 80 C, Tho o
= 30 C, T=ci Tco
= 20 o

( i) Overall heat transfer coefficient based on inner surface

= area
v h 50cm
= / s 0.5m=
/ s, U ?
1 1 r r r r 1 Mass flow rate of hot fluid
= + R fi + i log e o + i R fo + i
Ui h i K brass ri ro ro h o π
mh = rh A v h =0.8 × 1000 ×
1 0.0134  0.0158  0.0134 0.0134 1 4
= + 0.00018 + log e   + × 0.00018 + ×
6289.5 2 × 110  0.0134  0.0158 0.0158 12000 = 0.1256kg / s
U = 1747W / m 2 K Total energy transferred by the oil
i
Q= m h Cph ( Thi − Tho =
) 0.125
( ii) Overall heat transfer coefficient based on outer surface area
= 15.7kW
Ui Ai = Uo Ao
Assume parallel flow / counter flow ar
U i × πd i L= U o πd o L
d (Since T= ci T=
co 20o C both parallelan
U= Ui × i
o
do For Parallel flow HE
0.0134 q1= Thi − Tci = 80 − 20= 60o C
1747 ×
= =1481.6W / m 2 K
0.0158 q 2 = Tho − Tco = 30 − 20= 10o
4. A tubular heat exchanger is to be designed for cooling oil from a temperature q1 −ofq80
o
C60to− 10
=
30 C by large stagnant water which may be assumed to remain constant mat a temperature
o q = 2
= 27.9
q1 60
of 20oC.The heat transfer surface consists of 30m long straight tube of 20mm log e
log ediameter.
q2 10
The oil (Cp = 2.5 kJ/kgK, Sp.gr = 0.8) flows through the cylindrical tube with an average
velocity of 50cm/s. Calculate the overall heat transfer coefficient for the A oil dL = π × 0.02 × 30 = 1.8
= πcooler.
Data: Thi= 80o C, Tho= 30o C, T= ci T =
co 20 o
C, l
= 30m, d
= 20mm
= 20 × 10
=
−3
m,
Q UA s q m
= v h 50cm
= / s 0.5m= / s, U ? 15.7 =× U 1.884 × 27.90
Stagnant
Mass flow water
rate of 20 C
hot fluido T hi U = 0.2987kW / m 2 K
π Tho
mh = rh A v h = 0.8 × 1000 × × ( 20 × 10 )
θ1−7 2 × 0.5 Counter
Oil 30oC 4 θ2
q1= Thi − Tco
80 C
o
= 0.1256kg / s Tci T
= 80 − 20 = 60co
Total energy transferred by the oil
q 2= Tho − Tci
Q= m h Cph ( Thi − Tho )= 0.1256 × 2.5 ( 80 − 30 ) L = 30 − 20 = 10
T=hi
o
=
80 C, Tho15.7kW o
= 30 C, T= ci Tco o
= 20 C, = l 30m, = d 20mm = 20 ×q10−−q3 m, 60 − 10
= qm 1
= 2
= 27.9o C
= vAssume
50cm
= parallel flow
/ s 0.5m = //s,
counter
U ? flow arrangement q1 60
h
log e log e
(Sinceflow
Mass T=ci rate
co of 20
T= hotCfluid
o
both paralleland counter flow arrangements givesame q 2 LMTD10 )
π rh
For Parallel flow
rh AHE ( )
2
mh = vh = 0.8 × 1000 × × 20 × 10−3 × 0.5 Sp.gr =
rω
q1= Thi − Tci = 80 − 20= 60o 4C
= 0.1256kg / s rh Sp.gr × rw
=
q2 = Tho − Tco = 30 − 20 = 10o C
Total energy transferred by the oil = 0.8 × 1000
q − q2 60 − 10
ph ( Thi − Tho =
)60 0.1256
=Qq=m m h1C= = 27.9o×C2.5 ( 80 − 30)
q1
log e
= 15.7kW log e
q2 10
Assume parallel
A = πdLflow= π ×/ counter
0.02 × 30flow arrangement
= 1.884m 2

(Since T== UAq20 C both paralleland counter flow arrangements givesame LMTD)
Q T=
ci co m
o

For Parallel
15.7flow
=U HE
× 1.884 × 27.90
 =
qm 1
= 2
= 27.9o C
Total energy transferred by the oil q1 60
log e log e
Q= m h Cph ( Thi − Tho = ) 0.1256 × 2.5 (80 − 30) q2 10
532 Heat Transfer
= 15.7kW A = πdL = π × 0.02 × 30 = 1.884m 2
Assume parallel flow / counter flow arrangement =Q UA s q m
15.7 =× U 1.884 × 27.90
(Since T= ci T=co 20o C both paralleland counter flow arrangements givesame LMTD )
U = 0.2987kW / m 2 K
For Parallel flow HE
Counter Flow
q1= Thi − Tci = 80 − 20= 60o C
q1= Thi − Tco
q 2 = Tho − Tco = 30 − 20= 10o C
= 80 − 20 = 60
q1 − q 2 60 − 10
= qm = = 27.9o C q 2= Tho − Tci
q1 60
log e log e = 30 − 20 = 10
q2 10
q1 − q 2 60 − 10
A = πdL = π × 0.02 × 30 = 1.884m 2 = qm = = 27.9o C
q1 60
= Q UA s q m log e log e
q2 10
15.7 =× U 1.884 × 27.90 r
2 Sp.gr = h
U = 0.2987kW / m K rω
Counter
5. A simple heat exchanger consisting of two concentric = rh Sp.gr flow × rpassages is used for heating
w
1110kg/h
q1= Thiof− T oil
co
(Cp = 2.1kJ/kgK) from a temperature = 0.8 ×of 100027 C to 49oC. The oil flows
o

through = 80the
− 20inner
= 60pipe made of copper (K = 350W/mK) with 2.54cm ID and 2.86cm
OD. The surface heat transfer coefficient on the oil side is 635W/m2K. The oil is heated
q 2= Thosupplied
by water − Tci at a rate of 390kg/hr and at an inlet temperature of 93oC. The water
= 30transfer
side heat − 20 = 10coefficient is 1270W/m2K, the fouling factors at the water side and oil
side are 0.0001
q1 − q 2 and 600.0004m
− 10
2
k/W o
respectively. What is the length of the heat exchanger
= qm
required =
for (i) Parallel= 27.9
flow, (ii) C
Counter flow arrangement. Jan - 2006
q1 60
Data log
: m c 1110kg log o o
= = q 2 / h 0.3083kg =/ s, Cpc 21000J / kgK,
= Tci 27= C, Tco 49 = C, K 350W / mK
e e
10
r 2 2 390
=h i 635W
Sp.gr = h / m K, R fi 0.0001m
= = K / W, m h 0.1083kg
= / s, Cph 4200kJ / kgK,
r 3600
ω
93o C, h o =
Thi = 1270W / m 2 K, R fo =
0.0004m 2 K / W,d i =2.54 × 10 −2 m,d o =
2.86 × 10 −2 m
rh Sp.gr × rw
=
Overall heat transfer coefficient based on outside area of the inner tube
= 0.8 × 1000
1 r 1 ro r r 1
= o + R fi + o log e o + R fo +
U o ri h i ri K ri ho
0.0286 1 0.0286 0.0286 0.0286 1
= × + × 0.0001 + log e + 0.0004 +
0.0254 635 0.0254 350 0.0254 1270
2
U o = 325W / m K
Now Q m c Cpc [ Tco − Tci ] =0.3083 × 2100 ( 49 − 27 )
=
= 14243.5W
=Q m h Cpc [ Thi − Tho ]
14243.5 =0.1083 × 4200 [ 93 − Tho ]
Tho = 61.7 o C
( i ) Parallel flow arrangement
q1= Thi − Tci
= 93 − 27 = 66o C
q= T −T
 =Q m h Cpc [ Thi − Tho ]
14243.5 =0.1083 × 4200 [ 93 − Tho ]
Heat Exchangers 533
Tho = 61.7 o C
( i) Parallel flow arrangement
q1= Thi − Tci Thi Water Tho
= 93 − 27 = 66o C Tco
Tci Oil
q 2= Tho − Tco
= 61.7 − 49= 12.7 o C
q − q2
qm = 1 L
q Thi
log e 1
q2 Tho
66 − 12.7 θ1 θ2
= = 32.34o C
66 Tco
log e
12.7
Tci
=Q Uo Asqm
14248=
.5 325 × π × 0.0286 × L × 32.34 L

L = 15.1m Tho Thi

Water
( ii) Counter Flow Arrangement Tco
q1= Thi − Tco Tci Oil

= 93 − 49 = 44o C
q 2= Tho − Tci
L
= 61.7 − 27 = 34.7 o C
q1 − q 2 Thi
=
qm = 39.2o C θ1
q Tho
log e 1
q2 Tco θ2
Q Uo Asqm ,
= Tci
14243.5
= 325 × π × 0.0286 × L × 39.2
L = 12.5m L
6. Exhaust gases (Cp = 1.12kJ/kgK) flowing through a tubular heat exchanger at the rate
of 1200kg/h is cooled from 400oC to 120oC. The cooling is affected by water (Cp = 4.2kJ/
kgK) that enters the system at 10oC at the rate of 1500kg/hr. If the overall heat transfer
coefficient is 500kJ/m2hroC, what heat exchange area is required to handle the load for
parallel flow and counter flow arrangement.
Data: Cph 1.12kJ /=
= kgK, m h 1200kg= / hr, Thi 400
= o
C, Tho 120
= o
C, Cpc 4.2kJ / kgK,
o
=Tci 10
= C, m c 1500kg
= / hr, U 500kJ / m 2 hr
= o
C, A s ?
Q = m h Cph ( Thi − Tho ) = 1200 × 1.12 ( 400 − 120)
= 376320kJ / hr
=Q m c Cpc ( Tco − Tci )
1500 × 4.2 ( Tco − 10)
376320 =
Tco = 70o C
i Parallel Flow Arrangement
 Q = m h Cph ( Thi − Tho ) = 1200 × 1.12 ( 400 − 120)
= 376320kJ / hr
534 Heat Transfer
=Q m c Cpc ( Tco − Tci )
1500 × 4.2 ( Tco − 10)
376320 =
Tco = 70o C
( i ) Parallel Flow Arrangement Thi
o
q1= Thi − Tci= 400 − 10= 390 C Tho
θ1
o
q 2= Tho − Tco= 120 − 70= 50 C θ2
q1 − q 2 390 − 50 Tci Tco
=
qm = = 165.35o C
q1 390
log e log e
q2 50
L
Now, =
Q UA s q m
376320 = 500 × A s × 165.35
A s = 4.547m 2
( ii) Counter Flow Arrangement
Thi
q1= Thi − Tco= 400 − 70= 330o C
θ1 Tho
110o C
q 2= Tho − Tci= 120 − 10 =
Tco θ2
q1 − q 2 330 − 110
=
qm = = 200.25o C Tci
q1 330
log e log e
q2 110
Now, =
Q UA s q m L
376320 = 500 × A s × 200.25
A s = 3.758m 2
7. An existing heat exchanger of 20m2 surface area is to be used to condense low pressure
steam. The cooling medium will be feed water available at 40oC, its flow rate being
0.9kg/s. The overall heat transfer coefficient is 120W/m2K. Calculate the quantity of
steam condensed and exit temperature of the feed water. Take ts = 100oC, hfg = 2257kJ/kg
for steam,
Data:= A s 20m 2=
, Tci 40o C,= s, U 120W / m o C,=
m c 0.9kg / = m h ?,= Tco ?,
T=
ho T=
hi 100o C, h=
fg 2257kJ / kg
Assume parallel flow heat exchanger
(Since, Thi = Tho , both parallel & counter flow arrangement gives same LMTD)
q1= Thi − Tci= 100 − 40= 60o C Steam
q 2= Thi − T=
co 100 − Tco
q − q2 Water
qm = 1
q
log e 1
q2
Steam
60 − 100 + Tco
=
60
log e
100 − Tco
 q 2= Thi − T=
co 100 − Tco
q − q2
qm = 1
q
Heat Exchangers log e 1 535
q2
60 − 100 + Tco
=
60
log e
100 − Tco Thi Tho
Now Q = m c Cpc ( Tco − Tci ) = UA s q m θ2
θ1
Tco
= 0.9 × 4.2 × 10 ( Tco − 40)
3

Tco − 40 Tci
= 120 × 20 ×
 60 
log e  L
 100 − Tco 
Tco = 68.29o C
Mass of steam condenssed
m h h fg m c Cpc ( Tco − Tci )
=
m h × 2257 =0.9 × 4.2 ( 68.29 − 40)
m h = 0.0471kg / s
8. A counter flow concentric tube heat exchanger (CFHE) is used to cool the lubricating oil
of a large industrial gas turbine engine. The oil flows through the tube at 0.19kg/s (Cp =
2.18kJ/kgK) and the coolant water flows in a annular in the opposite direction at a rate
of 0.15kg/s (Cp = 4.2kJ/kgK). The oil enters the cooler at 425K and leaves at 345K while
the coolant enters at 285K. How long must the tube is made to perform this duty if the
heat transfer coefficient from oil to tube surface temperature is 2250W/m2K and from
tube surface to water is 5650W/m2K. The tube has a mean diameter of 12.5mm and its
wall presents negligible resistance to heat transfer.
Data:
= CFHE, m h 0.19kg
= / s, Cph 2.18kJ
= / kgK, m c 0.15kg
= / s, Cpc 4.2kJ / kgK,
2
=Thi 425K,T
= ho 345K,
= Tci 285K,
= , h i 2250W / m
= K, h o 5650W / m 2 K,
=d m 12.5mm
= 0.0125m
m h C ph ( Thi − Tho )
Q =×
= 0.19 × 2.18 ( 425 − 345 ) =33.13kW
Again,
= = 0.15 × 4.2 ( Tco − 285 )
Q m c C pc ( Tco − Tci ) ⇒ 33.13
Tco = 337.85K Thi
q = T − T = 425 − 337.85= 87.15K θ1 Tho
1 hi co

q2= Tho − Tci= 345 − 285= 60K Tco θ2

q1 − q2 87.15 − 60 Tci
=
qm = = 72.79K
q 87.15
log e 1 log e
q2 60
L
1 1 1 Thermal resistance due to conductance 
= +  
U ho hi  is neglected, also ri = ro 
1 1
= +
5650 2250
U = 1609.18W / m 2 K
 q1 87.15 Now = +
log e log e
q2 60 U ho hi
1 1 1 Thermal resistance Todue
find
tohconductance
i 
536
= +  Heat Transfer
U ho hi  is neglected, also ri = ro rvd r × m d m×d
=Re = =
1 1 m r × a m π d2 × m
= +
5650 2250 4
U = 1609.18W / m K 2 4 × 3000
=
=Q UA s qm π × 0.02 × 855 × 10−6
3
= 74496 > 2300
33.13 × 10
= 1609.18 × A s × 72.79
\ Flow is turbulent
A s = 0.2829m 2 = π d m L
N u = 0.23R e0.8 Pr0.4
0.2829 = π × 0.0125 × L
0.023 × ( 74496 ) × ( 5.83)
0.8 0.4
=
L = 7.29m
= 367.6
9. A one shell, two tube pass heat exchanger having 3000 thin wall brass tubes of 20mm dia
hid
has been installed in a steam power plant with a load of 2.3 × 108W. The =steam
367.6condenses
at 50oC and the cooling water enters the tubes at 20oC at the rate of K 3000kg/s. Calculate
the overall heat transfer coefficient, the tube length per pas and the hrate i × 20 10−3
of×condensation
= 367.6
of steam. Take the heat transfer coefficient for condensation on the outer0.613 surface of tubes
as 15500W/m2K, hfg = 2380kJ/kg. h i = 11260W / m 2 K
Assume for water
Cp = 4180J/kgK, μ = 855 × 10-6Ns/m2, K = 0.163W/mK, Pr = 1 1 1
\5.83.
= +
Data: One shell, two tube pass HE U 15500 11260
−3
N= 3000, d = 20mm = 20 × 10 m, Q = 2.3 × 10 W, Thi =
8
Tho = 50o C,
U =T6525W
ci = 20o C,
/ m2 K
m c 3000kg / s, =
= h o 15500W / m 2 K,= U ?,= L ?, =ms ?= Q m c Cpc ( Tco − Tci )
For thin walled tubes, thermal resistance due to conduction is neglected
2.3 × 108 = 3000 × 4180 ( Tco − 20
1 1 1
Now = + Tco = 38.34o C
U ho hi
To find h i m = r × discharge
= r× a × v
rvd r × m d m×d 4m
=Re = = = m
m r × a m π d 2 × m πdm v=
ra
4
4 ×1 3000
= −3 −6
=m c = 1kg / s / tube
π × 20 × 10 × 855 × 10 3000
= 74496 > 2300 Steam
\ Flow is turbulent
N u = 0.023R 0.8
e Pr
0.4

Water
0.023 × ( 74496 ) × ( 5.83)
0.8 0.4
=
= 367.6
Water
hid
= 367.6
K
h i × 20 × 10−3 Steam
= 367.6
0.613 One shell, Two tube
h i = 11260W / m 2 K
1 1 1
 hid
= 367.6
K
−3
Heat Exchangers h i × 20 × 10 = 367.6 537
0.613
h i = 11260W / m 2 K
1 1 1
\= +
U 15500 11260
U = 6524W / m 2 K
=Q m c Cpc ( Tco − Tci )
2.3 × 108 = 3000 × 4180 ( Tco − 20 )( for 3000 tubes )
Tco = 38.34o C
Since Thi Tho , both parallel flow & counter flow arrangements give same value of qm
\ Correction factor is not needed. \ For parallel flow
o
q1= Thi − Tci = 50 − 20= 30 C
q2 = Tho − Tco = 50 − 38.34= 11.66o C
Thi Tho
q1 − q2 30 − 11.66
=
qm = = 19.40o C θ2
q 30 θ1
log e 1 log e Tco
q2 11.66
Q UA s qm
= Tci
8
2.3 × 10 = 6524 × A s × 19.4
L
A s = 1817m 2
For two pass heat exchanger with 3000 tubes
A s =2πdL × N
1817 = 2π × 20 × 10−3 × L × 3000
L = 4.82m
Mass flow rate of condensation
ms h fg = Q
ms × 2380 × 103 = 2.3 × 108
ms = 96.64kg / s
10. A heat exchanger is to be designed to condense 8kg/s of an organic liquid (ts = 80oC, hfg =
600kJ/kg) with cooling water available at 15oC and at a flow rate of 60kg/s. The overall
heat transfer coefficient is 480W/m2K. Calculate (i) no. of tubes required, the tubes are to
be of 25mm OD, 2mm thick and 4.85 length, (ii) no. of tube passes. The velocity of cooling
water is not to exceed 2m/s.
Data: m= h 8kg / s, T=
hi T=
ho 80o C, h=
fg 600kJ / kg, T=
ci 15o C, m
= c 60kg / s, =
N ?
480W / m 2 K, d o =
U= 21 × 10−3 m, l =
0.025m, d i = 4.85m, tube passes =
?, v =
2m / s
Q=
m h h fg =×
8 600 =
4800kW
Also,
= Q m c Cpc ( Tco − Tci )
4800 × 103 =60 × 4200 ( Tco − 15)
o
 m=
h 8kg / s, T=
hi T=
ho 80o C, h=
fg 600kJ / kg, T=
ci 15o C, m
= c 60kg / s, =
N ?
480W / m 2 K, d =
U= 21 × 10−3 m, l =
0.025m, d i = 4.85m, tube passes =
?, v =
2m / s
538 o Heat Transfer
Q= m h h fg =×
8 600 = 4800kW
Also,
= Q m c Cpc ( Tco − Tci )
4800 × 103 =60 × 4200 ( Tco − 15)
Tco = 34.11o C
Assume parallel flow arrangement (Thi = Tho , Both parallel / counter flow arrangement
give same q m )
q1= Thi − Tci = 80 − 15= 65o C Thi Tho
q 2 = Tho − Tco = 80 − 34.11= 54.91o C θ2
θ1
Tco
q1 − q 2 65 − 54.91
=
qm = = 59.81o C
q1  65  Tci
log e log e 
q2  54.91
Q= UA s q m × N L
3
= 480 × π × 0.025 × 4.85 × 59.81 × N
4800 × 10
N = 439 tubes
Mass of cold water passing through each pass
 π 2 
mc =  r d1 v × no. of tubes / pass
4
π
= 1000 × × 0.0212 × 2 × n
60
4
n = 86.06
Total no of tubes N 439
\ no. of passes = = = ≈5
No. of tubes / passes n 86.06
11. A steam condenser employed in a steam power plant is to handle 3000kg/hr of dry
saturated steam at 50oC. The outer and inner diameter of the tubes are 25mm and
22.5mm. The cooling water enters the tubes at 15oC, flows with an average velocity of
2m/s and leaves at 25oC. If the heat transfer coefficient on the steam side is 5000W/m2K,
make calculations for the following.
i) Mass flow rate of water and no. of tubes required for water flow
ii) Overall heat transfer coefficient and heat transfer area
iii) No. of tube passes, if the length of each tube is not to exceed 2.5m
Ignore thermal resistance of wall material. Take hfg = 2375kJ/kg for steam.
Data: m= h 36000kg / hr
= 10kg / s, T= ho T=hi 50o C, d=o 0.025m, d= i 0.0225m, T=
ci 15o C,
= h o 5000W / m 2 K, =
v c 2m / s,= m c ?,=
N ?,=
U ?,=
A s ?, no. of passes
= ?,
=L 2.5m,
= / kg,Tco 25o C
h fg 2375kJ=
Q =m h × h fg =10 × 2375 =23750kW
Also,
= Q m c Cpc ( Tco − Tci )
= m c × 4.2 ( 25 − 15)
23750
=m c 567.36kg
= / s Total mass flow rate of water
25 + 15 o
=L 2.5m,
= / kg,Tco 25o C
h fg 2375kJ=
Q =m h × h fg =10 × 2375 =23750kW
Heat Exchangers 539
Also,
= Q m c Cpc ( Tco − Tci )
= m c × 4.2 ( 25 − 15)
23750
=m c 567.36kg
= / s Total mass flow rate of water
25 + 15
Properties of water
= at Tb = 20o C
2
r = 998.8kg / m , Cp = 4.2kJ / kgK, n = 1 × 10−6 m 2 / s, K = 0.6W / mK, Pr = 6.97
3

Mass flow rate of water in each tube

π
m=rav =998.3 × × 0.02252 × 2
4
= 0.7938kg / s
\ No. of tubes
m c 567.36
=N = = 715
m 0.7938
To Calculate h i
rvd i 4 m 4m
Re
= = =
m πd i m πd irn
4 × 0.7938
= = 44997 > 2300
π × 0.0225 × 998.8 × 1 × 10−6
\ Flow is turbulent
Now, N u = 0.023 R e0.8 Pr0.4
= 0.023( 44997) ( 6.97) 0.4
0.8

N u = 263.96
h i di
= 263.96
K
h i × 0.0225
= 263.96
0.6
h i = 7039W / m 2 K
Overall heat transfer coefficient based on outer surface area of tube
1 1 do 1 1 0.025 1
= × + = × +
U h i d i h o 7039 0.0225 5000
U = 2795W / m 2 K
Since Thi = Tho , correction factor becomes 1
\ Both parallel flow and counter flow arrangement gives same value of q m .
Assume counter flow arrangement
q1= Tho − Tci = 50 − 15= 35o C
q 2 = Thi − Tco = 50 − 25= 25o C
q1 − q 2 35 − 25
=
qm = = 29.72o C
q1 35
log e log e
q2 25
 Assume counter flow arrangement
q1= Tho − Tci = 50 − 15= 35o C
540 Heat Transfer
q 2 = Thi − Tco = 50 − 25= 25o C
q1 − q 2 35 − 25
=
qm = = 29.72o C
q1 35
log e log e
q2 25
Q UA s q m
= Thi Tho
θ2
28750 × 103= 2795 × A s × 29.72 θ1
Tco
A s = 285.95m 2
Tci
πd o l × N =
285.95
π × 0.025 × l × 715 = 285.95
L
l = 5.095m
But length of the tube is limited to 2.5m / pass
5.092
\ no of passes = = 2
2.5
12. A one shell, two tube pass, heat exchanger is to be designed to heat 0.5kg/s of water
entering the shell side at 10oC. The hot fluid oil enters the tube at 80oC with a mass flow
rate of 0.3kg/s and leaves the exchanger at 30oC. The overall heat transfer coefficient is
250W/m2K. Assuming the specific heat of oil to be 2kJ/kgK, calculate the surface area of
the heat exchanger required.
o o o
=
Data: m c 0.5kg= / s, Tci 10= C, Thi 80= C, m h 0.3kg=/ s, Tho 30
= C, A s ?
=U 250W
= / m 2 K, Cph 2kJ / kgK
Q = m h Cph ( Thi − Tho ) = 0.3 × 2000 ( 80 − 30) = 3000W
Now
= Q m c Cpc ( Tco − Tci )
3000 = 0.5 × 4.2 × 1000 ( Tco − 10)  For water Cpc = 4.2 × 103 J / kg / K 
Tco = 24.3o C
Since Thi ≠ Tho , q m will be different for both parallel and counter flow arrangement.
\ It is required to calculate correction factor
Assume counter flow arrangement
q1= Thi − Tco = 80 − 24.3= 55.7 o C
Water
q 2 = Tho − Tci = 30 − 10= 20o C
q1 − q 2 55.7 − 20 Oil
=
qm = = 34.35o C
q1 55.7
log e log e
q2 20
Oil
Calculation of correction factor
For single shell, two tube pass HE Water
t1 T=
= ci 10o C, T
=1 T=
hi 80o C
t 2 T=
= co 24.3o C, T
=2 T=
ho 30o C
From HMT data book ( HE with one shell two, four or multiple tube passes)
T1 − T2 80 − 30
=R = = 3.5
 For single shell, two tube pass HE
t1 T=
= ci 10o C, T
=1 T=
hi 80o C
Heat Exchangers 541
t 2 T=
= co 24.3o C, T
=2 T=
ho 30o C
From HMT data book ( HE with one shell two, four or multiple tube passes)
T1 − T2 80 − 30
=R = = 3.5
t 2 − t1 24.3 − 10 = m c 3kg = / s, Cpc 4200J / =
kgK, Tci 30= o
C, Tco 80o C,
t 2 − t1 24.3 − 10
= P = = 0.204 = Tho 100= o
C, U 200W /= m 2 K, A s ?
T1 − t1 80 − 10
at the obtained P and R, the correction factor F = 0.875 c pc ( co
Q= m C T − Tci ) =× 3 4200 ( 80 − 30) =63000
Assume counter flow HE
\q
= m = 30.5o C
0.875 × 34.35
=Q UA q q1= Thi − Tco= 225 − 80= 145o C
s m

3000 = 250 × A s × 30.5 q 2= Tho − Tci= 100 − 30= 70o C

q1 − q 2 145 − 70
A s = 3.93m 2 qm = = = 54.62o C
q1 145
log e log e
13. A single pass cross flow heat exchanger uses hot gases (mixed) q2 to heat water (unmixed)
70
from 30 C to 80 C at a rate of 3kg/s. The exhaust
o o
gases having
Correction factor thermophysical properties
similar to air enter and leave the exchanger at 225 and 100oC respectively. If the overall
heat transfer coefficient is 200W/m2K, determine the t 2 − t1 area
80of
− 30
= P surface
= = heat exchanger.
0.256
o T −t
=
Data: m c 3kg= / s, Cpc 4200J / = kgK, Tci 30 = o
C, Tco 80= C,1 Cph1 1005J 30
225 − kgK, Thi 225o C
/=
o T1 − T2 225 − 10
= Tho 100
= C, U 200W /= m 2 K, A s ? = R = = 2.5
t 2 − t1 80 − 30
Q= m c Cpc ( Tco − Tci ) =×
3 4200 ( 80 − 30) = 630000W
From HMT data book for singleTci pass, cross flow mixed &
Assume counter flow HE
= at P 0.256,
= R 2.5
q1= Thi − Tco= 225 − 80= 145o C We get, F = 0.93
( )
Correction factor
q 2= Tho − Tci= 100 − 30= 70o C o
\q
= m 0.93 × 54.62
= 50.8 C
q1 − q 2 145 − 70
qm = = = 54.62o C = Q UA s q m
q 145 Thi= 200 × A × 50.8 Tho
log e 1 log e 630000
q2 70 s
2
Correction factor A s = 32.89m
t 2 − t1 80 − 30 T1 = Thi
=P = = 0.256 T2 = Tho
T1 − t1 225 − 30
T1 − T2 225 − 100
10 t1 = Tci
=R = = 2.5 Tco
t 2 − t1 80 − 30 t 2 = Tco
From HMT data book for single pass, cross flow mixed & unmixed heat exchanger,
at P 0.256,
= = R 2.5
We get, F = 0.93 ( Correction factor )
\q
= m = 50.8o C
0.93 × 54.62
Q UA s q m
=
630000 = 200 × A s × 50.8
A s = 32.89m 2
T1 = Thi
T2 = Tho
542 Heat Transfer

14. A two shell pass, four tube pass heat exchanger is used to heat water with oil. Water
enters the tubes at a flow rate of 2kg/s and at 20oC and leaves at 80oC. Oil enters the shell
side at 140oC and leaves at 90oC. If the overall heat transfer coefficient is 300W/m2K,
calculate the heat transfer area required.
o o o
Data:
= m c 2kg= / s, Tci 20= C, Cpc 4200J / kgK,
= Tco 80
= C, Thi 140= C, Tho 90o C,
U = 300W / m 2 K
=Q m c Cpc ( Tco − Tci ) Oil

2 4200 ( 80 − 20) =
=× 50400W Water

Correction Factor
t1 T=
= ci 20o C, T=
1 T=
hi 140o C
t 2 T=
= co 80o C, T
=2 T=
ho 90o C
t 2 − t1 80 − 20
=P = = 0.5 Water
T1 − t 2 140 − 20
Oil
T1 − T2 140 − 90
R == = 0.83
t 2 − t1 80 − 20
From chart F = 0.97 ( two shell pass, four tube pass)
Now q1= Thi − Tco= 140 − 80= 60o C ( Counter flow arrangement )
q 2 = Tho − Tci = 90 − 20= 70o C
 
 q1 − q 2  0.97 × ( 60 − 70)
qm = F ×  = = 60.9o C
q
 log e 1  60
 log e
q 2  70
Q UA s q m
=
504000 = 300 × A s × 60.9
A s = 26.7m 2
15. Hot water having Cp = 4200J/kgK flows through a heat exchanger at the rate of 4kg/
min with an inlet temperature of 100oC. A cold fluid having Cp = 2400J/kgK flows at a
rate of 8kg/min and with an inlet temperature of 20oC. Make calculation for maximum
effectiveness if the fluid flow confirms to (i) parallel flow arrangement, (ii) counter flow
arrangement.
Data: Cph 4200J =
= / kgK, m h 4kg= / min, Thi 100= o
C, Cpc 2400J= / kgK, m c 8kg / min
T
=ci 20o C, ∈=
max ?
Thermal capacity rates
4
Ch =m h Cph = × 4200 = 280W / K → Cmin
60
8
Cc =m c Cpc = × 2400 = 320W / K → Cmax
60
C min 280
Capacity ratio= C= = = 0.875
 T
=ci 20 C, ∈=
max ?
Thermal capacity rates
Heat ExchangersC h =
4 543
m h Cph = × 4200 =280W / K → Cmin
60
8
Cc =m c Cpc = × 2400 = 320W / K → Cmax
60
Cmin 280
Capacity ratio= C= = = 0.875
C max 320
Effectiveness
( i) Parallel flow arrangement
1 − e − NTU(1+ C)
Effectivenss ∈=
(1 + C)
For max possible effectiveness NTU = ∞
1 − e −∞ 1− 0
=
\∈ = = 0.533
1 + C 1 + 0.875
( ii) Counter flow heat exchanger
1 − e − NTU(1− C)
∈=
1 − C e − NTU(1− C)
1 − e −∞ 1− 0
= = = 1
1− C e −∞
1− 0
16. A counter flow heat exchanger is used to cool 2000kg/h of oil (Cp = 2.5kJ/kgK) from
105 to 30oC by the use of water entering at 15oC. If the overall heat transfer coefficient
is expected to be 1.5kW/m2K, make calculation for the water flow rate, the surface area
required and effectiveness of heat exchanger. Use NTU - effectiveness approach. Assume
that exit temperature of the water is not to exceed 80oC.
o o
=
Data: m h 2000kg = / hr, Cph 2.5kJ / kgK,
= Thi 105= C, Tho 30
= C, Tci 15o C,
Tco =80o C, U =1.5 × 1000 × W / m 2 K
Heat lost by the oil = Heat gained by the water
m h Cph ( Thi −=
Tho ) m c Cpc ( Tco − Tci )
2000 × 2.5 (105 − 30) = m c × 4.2 ( 80 − 15)
m c = 1380.2kg / hr
Thermal capacity rates
C=
c m c Cpc= 1380.2 × 4.2
= 5769.24kJ / hr K → Cmax
Ch = m h Cph = 2000 × 2.5= 5000kJ / hr K → Cmin
Cmix 5000
=C = = 0.867
Cmax 5769.24
Thi − Tho 105 − 30
=∈ = = 0.833
Thi − Tci 105 − 15
1 − e − NTU(1− C)
Also, ∈= ( Counter flow heat exchanger )
1 − C e − NTU(1− C)
1 − e − NTU(1− 0.867)
0.833 =
1 − 0.867 × e − NTU(1− 0.867)
 Cmix 5000
=C = = 0.867
Cmax 5769.24
Thi − Tho 105 − 30
544 Heat Transfer
=∈ = = 0.833
Thi − Tci 105 − 15
1 − e − NTU(1− C)
Also, ∈= ( Counter flow heat exchanger )
1 − C e − NTU(1− C)
1 − e − NTU(1− 0.867)
0.833 =
1 − 0.867 × e − NTU(1− 0.867)
NTU = 3.84
NTU can also be obtained from the graph of C vs ∈
i.e., From HMT data book
at C 0.867
= = & ∈ 0.833, we get = NTU 3.84
UA s 1.5 × 1000 × A s
=Now NTU = , 3.84
Cmin 5000
A s = 3.55m 2
17. A parallel flow heat exchanger uses 1500kg/hr of cold water entering at 25oC to cool
600kg/hr of hot water entering at 70oC. The exit temperature on the hot side is required
to be 50oC, Neglecting the effects of fouling, make calculations for the area of heat
exchanger. It may be assumed that the individual heat transfer coefficient on both sides
are 1600W/m2K. Use LMTD and NTU approaches.
Data:
= m c 1500kg= / hr, Tci 25
= o
C, m h 600kg=/ hr, Thi 70
= o
C, Tho 50o C,
h=
i h=
o 1600W / m 2 K, PFHE ( Parallel Flow Heat Exchanger )
m c Cpc ( Tco −=
Tci ) m h Cph ( Thi − Tho )
mh
Tco =
Tci + ( Thi − Thi )
mc
600
( 70 − 50) =33o C
=25 +
1500
=Q m h Cph ( Thi − Tho )
600
= × 4180 ( 70 − 50)= 13933W
3600
( i) LMTD approach
q1= Thi − Tci = 70 − 25= 45o C
q 2 = Tho − Tco = 50 − 33= 17 o C
q1 − q 2 45 − 17
=
qm = = 28.77 o C
q1 45
log e log e
q2 17
1 1 1 1 1
= + = +
U h o h i 1600 1600
U = 800W / m 2 K
Q UA s q m
=
13933 = 800 × A s × 28.77
2
 2

1 1 1 1 1
= + = +
U h o h i 1600 1600
Heat Exchangers 545
U = 800W / m 2 K
Q UA s q m
=
13933 = 800 × A s × 28.77
A s = 0.605m 2
( ii ) NTU approach
600
Ch = m h Cph = × 4180 = 696.67W / K → Cmin
3600
1500
Cc = m c Cpc = × 4180 = 1741.67W / K → Cmax
3600
Cmin 696.67
=C = = 0.4
Cmax 1741.67
Thi − Tho 70 − 50
=∈ = = 0.444 ( Based on
= Cmin Chn )
Thi − Tci 70 − 25
From the chart
= at C 0.4=
& ∈ 0.444
We get NTU = 0.695
UA s
NTU =
C min
800 × A s
0.695 =
696.97
A s = 0.605m 2
18. Calculate the exit temperature of the hot fluid and inlet temperature of the cold fluid for
a counter flow heat exchanger having the following specifications.
Mass flow rate of hot fluid = 3kg/s
Mass flow rate of cold fluid = 0.75kg/s
Cp for hot fluid = 1.05kJ/kgK
Cp for cold fluid = 4.2kJ/kgK
Inlet temperature of hot fluid = 500oC
Exit temperature of cold fluid = 85oC
Overall heat transfer coefficient = 450W/m2K
Total surface area = 1m2
Ans: Ch = m h Cph =3 × 1050 =3150W / K
Cc =m c Cpc =0.75 × 4200 =3150W / K
3150
=C = 1
3150
Now Ch ( Thi − Tho =
) Cc ( Tco − Tci )
\ Thi − Tho
= Tco − Tci − − − (1)
UA s 450 × 1
\ NTU = = = 0.1428
Cmin 3150
For counter flow heat exchanger
1 − e − NTU(1− C)
∈= − NTU (1− C)
 h hi ho c co ci

\ Thi − Tho
= Tco − Tci − − − (1)
UA s 450 × 1
546
\ NTU = = = 0.1428 Heat Transfer
Cmin 3150
For counter flow heat exchanger
1 − e − NTU(1− C)
∈=
1 − C e − NTU(1− C)
When C = 1
NTU 0.1428
= ∈ = = 0.1250
1 + NTU 1 + 0.1428
T − Tho 85 − Tci
But
= ∈ hi ⇒= 0.1250
Thi − Tci 500 − Tci
62.5 − 0.125Tci =
85 − Tci
Tci = 25.7 o C
Substituting Tci in (1)
500 − Tho =85 − 25.7
Tho = 440.7 o C
19. A tubular heat exchanger consists of 200 tubes each 20mm OD and 5m length. Hot
fluid flows inside the tube and cold over it and in opposite direction to the hot fluid. The
overall heat transfer coefficient based on outside diameter is 320W/m2K. Determine the
outlet temperature of both fluids and the total heat transfer from the following data.
Inlet temperature of hot fluid = 120oC
Inlet temperature of cold fluid = 20oC
Rate of flow of hot fluid is 20kg/s
Rate of flow of cold fluid is 5kg/s
Specific heat of hot fluid = 2000J/kgK
Specific heat of cold fluid = 4000J/kgK VTU Jan - 2006 (06)
Data: No. of =tubes 200,= d o 20mm
= 0.02m, = L 5m,= U 320W / m K, 2
= Thi 120o C,
=Tci 20
= C, m h 20kg
= / s, m c 5kg
= / s, Cph 2000J / kgK,
= Cpc 4000J / kgK,
Tho ?, =
= Tco ?,=
Q ?
Counter flow heat exchangeer
Ch = m h Cph =20 × 2000 =40000W / K → Cmax
Cc =
m c Cpc = 20000W / K
5 × 4000 = → Cmin
2 0000
= =
min
0.5
max 4 0000
UA But A = π × d × L × no. of tubes
NTU
min = π × 0.02 × 5 × 200
320 × 62.83
= 62.83m
20000
1.0053
For counter flow heat exchanges
1 − e − NTU(1− C) 1 − e −1.0053(1− 0.5)
=∈ =
1 − C e − NTU(1− C) 1 − 0.5 e −1.0053(1− 0.5)
 Cmin = π × 0.02 × 5 × 200
320 × 62.83
= 62.83m 2
Heat Exchangers 20000 547
= 1.0053
For counter flow heat exchanges
1 − e − NTU(1− C) 1 − e −1.0053(1− 0.5)
=∈ =
1 − C e − NTU(1− C) 1 − 0.5 e −1.0053(1− 0.5)
∈= 0.5663
Q Q
Now =∈ =
Q max Cmin ( Thi − Tci )
Q = ∈× Cmin ( Thi − Tci )= 0.566. × 20000 × (120 − 20)
Q = 1132559.14Watts
Now
= Q m h Cph ( Thi − Tho )
= 40000 (120 − Tho )
1132559.14
Tho = 91.69o C
Again,
= Q m c Cpc ( Tco − Tci )
= 20000 ( Tco − 20)
1132559.14
Tco = 76.63o C
20. An oil cooler for a large diesel engine is to cool engine oil from 60 to 45oC using sea water
at an inlet temperature of 20oC with a temperature rise of 15oC. The design heat load is
140kW and mean overall heat transfer coefficient based on the outer surface area of the
tubes is 700W/m2 oC. Calculate the heat transfer surface area for single pass counter flow
and parallel flow arrangement. Jan - 2008
Data: Thi = 60 C, Tho = 45 C, Tci = 20 C, Tco = 20 + 15 = 35 C, Q = 140 × 10 W,
o o o o 3

=U 70W
= / m 2 o C, A s ?
( i) Counter flow heat exchanger
qi= Thi − Tci= 60 − 35= 25o C
q 2 = Tho − Tci = 45 − 20= 25o C
Since, q1 =q 2 ,
q1 + q 2 25 + 25
LMTD
= AMTD
= = = 25o C
2 2
3
Q = UA s q m ⇒ 140 × 10 = 70 × A s × 25
A s = 80m 2
( ii) Parallel flow Heat exchanger
q1= Thi − Tci = 60 − 20= 40o C
q 2 = Tho − Tio = 45 − 35= 10o C
q1 − q 2 40 − 10
=
qm = = 21.64o C
q1 40
log e log e
q2 10
Q UA s q m
=
3
 q 2 = Tho − Tio = 45 − 35= 10 C
q1 − q 2 40 − 10
= =
qm = 21.64o C
q1 40
548
log e log e Heat Transfer
q2 10
Q UA s q m
=
140 × 103 = 70 × A s × 21.64
A s = 92.42m 2
21. Engine oil is to be cooled from 80oC to 50oC by using a single pass counter flow, concentric
heat exchanger with cooling water available at 20oC. Water flows inside dia of 25mm at
rate of 0.08kg/s and oil flows through the annular at the rate of 0.16kg/s. The heat transfer
coefficient for the water side and oil side are 1000W/m2K and 80W/m2K respectively.
The fouling factors are 0.00018m2K/W on both water side and oil side. Neglecting
tube wall resistance, calculate the tube length required. Take Cpw = 4180J/kgK and
Cpoil = 2090J/kgK. VTU June - 2008
Data:
= Thi 80o C, = Tho 50o C,
= Tco 20o =
C, d i 25mm
= 0.025mm, = m c 0.08kg = / s, L ?,
m=
h h i 1000W / m 2 K, h=
0.16kg / s, = o 80W / m 2 K, R=
fo R=
fi 0.00018m 2 K / W,
=Cpc 4180J
= / kgK, Cph 2090J / kgK
Q = m h Cph ( Thi − Tho ) = 0.16 × 2090 ( 80 − 50 ) = 10032W
=Q m c Cpc ( Tco − Tci )
10032 = 0.08 × 4180 ( Tco − 20 )
Tco = 50o C
1 1 r 1 r r
= + i + R fi + R fo + i log e o
U i h i ro h o K ri
ri r 
log e  o =0 [ tube wall resistance is neglected ]
K  ri 
1 1 ri 1
\ = + + R fi + R fo [ ro =
ri ]
U i h i ro h o
1 1
= + + 0.00018 + 0.00018
1000 80
= 0.01386
U=
i U= 72.15W / m 2 K
For Counter flow arrangement
qi = Thi − Tco = 80 − 50= 30o C
q2 = Tco − Tci = 50 − 20 = 30o C
Q UA s qm
=
Since, q1 =02
30 + 30
LMTD
= AMTD
=
2
\qm = 30o C
Q UA s qm
=
1003
= 72.15 × π × d × L × 30
 Since, q1 =02
30 + 30
LMTD
= AMTD
=
Heat Exchangers 2 549
\qm = 30o C
Q UA s qm
=
1003
= 72.15 × π × d × L × 30
= 72.15 × π × 0.025 × L × 30
L = 59.01m
22. A counter flow heat exchanger is employed to cool 0.55kg/s (Cp = 2.45kJ/kgK) of oil from
115oC to 40oC by the use of water. The inlet and outlet temperature of cooling water are
15oC and 75oC respectively. The overall heat transfer coefficient is expected to be 1450W/
m2 oC. Using NTU method calculate (i) Mass flow rate of water, (ii) Effectiveness of heat
exchanger, (iii) Surface area required. VTU Feb - 2003
Data: m h =0.55kg / s, Cph =×2.45 103 J / kgK, Thi =
115o C, Tho = 40o C, Tci =15o C, Tco =75o C
U= 1450W / m 2 o C, m=
c ?, ∈
= ?, A=
s ?,
=Q m h Cph ( Thi − Tho ) ⇒ 0.55 × 2.45 × 103 (115 −=
40 ) 101062.5W
Also, Q = m c Cpc ( Tco − Tci ) ⇒ 101062.5 = m c × 4.2 × 103 ( 75 − 15 )
m c = 0.40kg / s
Capacity ratio
Cc = m c Cpc = 0.40 × 4.178 × 103 = 1671.2W / K → Cmax
3
Ch = m h Cph = 0.55 × 2.45 × 10 = 1347.5W / K → Cmin
Cmin 1347.5
=C = = 0.80
Cmax 1671.2
Ch ( Thi − Tho ) Cc ( Tco − Tci )
Effectiveness
= ∈ =
Cmin ( Thi − Tci ) Cmin ( Thi − Tci )
1347.5  115 − 40  1671.2 ( 75 − 15 )
= =  
1347.5  115 − 15  1347.5 (115 − 15 )
= 0.75
For counter flow heat exchanger
1 − e − NTU (1− C )
∈=
1 − C e − NTU (1− C )
1 − e − NTU (1− 0.80)
0.75 =
1 − 0.80 e − NTU (1− 0.80)
0.75 − 0.6047 e −0.194 NTU =
1 − e −0.194 NTU
0.3953 e −0.194 NTU = 0.25
e −0.194 NTU = 0.6324
− 0.194NTU = log e 0.6324
NTU = 2.36
U As 1450 × A s
Now
= NTU = , 2.36
Cmin 1347.5
2
 e −0.194 NTU = 0.6324
− 0.194NTU = log e 0.6324
550 Heat Transfer
NTU = 2.36
U As 1450 × A s
Now
= NTU = , 2.36
Cmin 1347.5
A s = 2.195m 2
23. Water enters a counter flow heat exchanger at 15oC flowing at a rate of 1300kg/h. It is
heated by oil (Cp = 2000J/kgK) flowing at the rate of 550kg/h from an outlet temperature
of 94oC for an area 1m2 and overall heat transfer coefficient of 1075W/m2K. Determine
the total heat transfer and outlet temperature of water and oil. VTU Feb - 2008
o o
Data:
= Tci 15= C, m c 1300kg =/ hr, Cph 2000J / kgK,
= m h 550kg= / h, Thi 94
= C, A s 1m 2
U = 1075W / m 2 K
1300
Cc = m c Cpc = × 4200 = 1511.6W / K = Cmax
3600
550
Ch = m h Cph = × 2000 = 305.55W / K = Cmin
3600
Cmin 305.55
=C = = 0.202
Cmax 1511.6
UA s 1075 × 1
NTU
= = = 3.518
Cmin 305.55
For counter flow Heat Exchanger
1 − e − NTU(1− C) 1 − e − NTU(1− 0.202)
=∈ = = 0.95
1 − C e − NTU(1− C) 1 − 0.202 e −3.518(1− 0.202)
Ch ( Thi − Tho ) 305.55  94 − Tho 
But
= ∈ = = 0.95
C min ( Thi − Tci ) 305.55  94 − 15 
Tho = 18.95o C
Cc ( Tco − Tci ) 1511.6  Tco − 15 
Again ∈
= = = 0.95
C min ( Thi − Tci ) 305.55  90 − 15 
Tco = 30.17 o C
Q= m c Cpc ( Tco − Tci )= 1511.6 ( 30.17 − 15)= 22.93 × 103 W
24. In a parallel flow heat exchanger, engine oil enters at 150oC and leaves at 80oC. The
cooling water enters at 30oC and leaves at 65oC. If the fluid rates and inlet conditions are
unchanged, find (i) exit temperature of each stream in counter flow heat exchanger, (ii)
lowest temperature at which the oil may be cooled in (a) parallel flow, (b) counter flow
by increasing the length of the exchanger.
Data:
= Thi 150=o
C, Tho 80
= o
C, Tci 30=o
C, Tco 65o C,
Ch ( Thi − Tho =
) Cc ( Tco − Tci )
Ch  Tco − Tci  65 − 30 0.5 Cmin
= = = =
Cc  Thi − Tho  150 − 80 1 Cmax
Ch ( Thi − Tho ) 150 − 80
=∈ = = 0.58
Cmin ( Thi − Tci ) 150 − 30
 Ch ( Thi − Tho =
) Cc ( Tco − Tci )
Ch  Tco − Tci  65 − 30 0.5 Cmin
= 
Heat Exchangers = = = 551
Cc  Thi − Tho  150 − 80 1 Cmax
Ch ( Thi − Tho ) 150 − 80
=∈ = = 0.58
Cmin ( Thi − Tci ) 150 − 30
From the graph for parallel flow HE,=
at C 0.5=
& ∈ 0.58
We get NTU = 1.6
UA s
NTU
= = 1.6
Cmin
( i) Since the temperature remains the same, for counter flow HE
NTU 1.6,
= = C 0.5
From the graph for counter flow HE, at=
NTU 1.6
= & C 0.5
We get ∈= 0.68
Thi − Tho 150 − Tho
= ∈ = = 0.68, = Tho 68.4o C
Thi − Tci 150 − 30
Cc ( Tco − Tci ) 1  Tco − 30 
Again ∈= = ⇒ 0.68 = ⇒ Tco 70.6o C
Ch ( Ti − Tci ) 0.5  150 − 30 
( ii) When the oil is cooled to a lowest temperature
Cc ( Tco − Tci=
) Ch ( Thi − Tho ) For lowest oil temperature
Ch
( Tco − 30
= ) Cc
(150 − Tco ) Tho = Tco

Tco = 70.0o C
25. Saturated steam at 120oC is condensing on the outer surface of the single pass heat
exchanger. The overall heat transfer coefficient is 1600W/m2K. Determine the surface
area of the heat exchanger required to heat 2000kg/h of water from 20oC to 90oC. Also
determine the rate of condensation of steam in kg/h. Assume the latent heat of steam to
be 2195kJ/kg. VTU Jan - 2009 (02)
Data: T=hi T=
ho
o
120 C, = 2
U 1600W / m K, A =s ?, m
= c 2000kg /=
h 0.556kg / s, T=ci 20o C
Tco 90o C,=
= m h ?,=
h fg 2195kJ / kg
Since Thi = Tho , the problem is solved with either parallel flow or counter flow heat
exchanger,
Considering parallel flow heat exchanger
q1= Thi − Tci= 120 − 20= 100o C
q 2= Tho − Tco= 120 − 90= 30o C
Logerithmic temperature difference
q − q 2 100 − 30
LMTD =q m = 1 = =61.43o C
q1 100
log e log e
q2 30
Now, Q= m c Cpc ( Tco − Tci )= 0.556 × 4.2 × 103 ( 90 − 20)
= 16.3 × 104 J / s or W
 Logerithmic temperature difference
q − q 2 100 − 30
LMTD =q m = 1 = =61.43o C
q1 100
552 log e log e Heat Transfer
q2 30
Now, Q= m c Cpc ( Tco − Tci )= 0.556 × 4.2 × 103 ( 90 − 20)
= 16.3 × 104 J / s or W
Now, =
Q UA s q m
16.3 × 104 =
1600 × A s × 61.43
A s = 1.663m 2
Q = m h h fg
16.34 × 104 = m h × 2195 × 103
m h 7.44 × 10−2 kg / s
=
26. A cross flow heat exchanger in which both fluids are unmixed is used to heat water
with an engine oil. Water enters at 30oC and leaves at 25oC at a rate of 1.5kg/s while the
engine oil with Cp = 2.3kJ/kgK enters at 120oC with a mass flow rate of 3.5kg/s. The heat
transfer surface area is 30m2. Calculate the overall heat transfer coefficient using LMTD
method. VTU June - 2009 (06)
Data: Cross flow heat exchanger, T=ci
o
30 C, T=co
o
85 C, m= c 1.5kg / s, C=
ph 2.3 × 103 J / kgK
o 2
=Thi 120= C, m h 3.5kg
= / s, A s 30m
= , U ?
We know that
=Q m c Cpc ( Tco −=
Tci ) m h Cph ( Thi − Thi )
1.5 × 4.2 × 103 ( 85 − 30 ) = 3.5 × 2.3 × 103 (120 − Tho )
Tho = 76.96o C
Assume counter flow arrangement
q1= Thi − Tco= 120 − 85= 35o C
q2= Tho − Tci= 76.96 − 30= 46.96o C
Determination of correction factor
t 2 − t1 Tco − Tci 85 − 30
= P = = = 0.61
T1 − t1 Thi − Tci 120 − 30
T1 − T2 Thi − Tho 120 − 76.96
=R = = = 0.783
t 2 − t1 Tco − Tci 85 − 30
From HMT data book, for cross flow heat exchanger, both fluids unmixed
=at P 0.61
= and R 0.783, we get
Correction factor CF = 0.9
q − q2
LMTD, qm = CF × 1
q
log e 1
q2

= 0.9 ×
( 35 − 46.96 )
35
log e
46.96
= 36.62o C
 Correction factor CF = 0.9
q − q2
LMTD, qm = CF × 1
q
Heat Exchangers log e 1 553
q2

= 0.9 ×
( 35 − 46.96 )
35
log e
46.96
= 36.62o C
Heat transfer
= rate Q m c Cpc ( Tco − Tci )
= 1.5 × 4.2 × 103 ( 85 − 30 )
= 34.65 × 104 W
Overall heat transfer coefficient
= Q U o A s qm
34.65 × 104 = U o × 30 × 36.62
U o = 315.4W / m 2 K
27. A heat exchanger has 17.5m2 is available for heat transfer. It is used for cooling oil at
200oC by using water available at 20oC. The mass flow rate and specific heat of oil are
10000kg/h amd 1.9kJ/kgK. If the overall heat transfer coefficient is 300W/m2 oC, estimate
the outlet temperature of oil and water for parallel flow and counter flow arrangement
using LMTD method. VTU Jan - 2010 (02)
Data: A s =17.5m 2 , Thi ==
200o C, Tci 20o C, m h =10000kg / h, Cph = 1.9 × 103 J / kgK, Tho =
?
mc = 4.137 × 103 J / kgK, U =
3000kg / h, Cpc = 300W / m 2 o C, Tco =
?
Case ( i ) : For parallel flow heat exchanger
m h Cph ( Thi −=
Tho ) m c Cpc ( Tco − Tci )
10000 3000
× 1.9 × 103 ( 200 − Tho ) = × 4.137 × 103 ( Tco − 20)
3600 3600
200=− Tho 0.6532 ( Tco − 20) Thi
200=
− Tho 0.6532 Tco − 13.06 Tho
θ1 θ2
0.6532 Tco =200 + 13.06 − Tho
Tco
0.6532
= Tco 213.06 − Tho
Tci
Tco 326.18 − 1.53 Tho
= − − − (1)
q1= Thi − Tci= 200 − 20= 180o C L
q 2= Tho − Tco= Tho − 326.18 + 1.53 Tho = 2.53 Tho − 326.18
q1 − q 2 180 − 2.53 Tho + 326.18
LMTD =
= qm =
q 180
log e 1 log e
q2 2.53 Tho − 326.18
Q= U A s q m ⇒ m h Cph ( Thi − Tho=
) UAsqm
10000
× 1.9 × 103 ( 200 − Tho ) = 300 × 17.5 ×
(180 − 2.53 Tho + 326.18)
3600  180 
log e 
 2.53 Tho − 326.18 
(506.18 − 2.53 Tho )
 LMTD =
= qm 1
= 2 ho
q1 180
log e log e
q2 2.53 Tho − 326.18
554 Heat Transfer
Q= U A s q m ⇒ m h Cph ( Thi − Tho=
) UAsqm
10000
× 1.9 × 103 ( 200 − Tho ) = 300 × 17.5 ×
(180 − 2.53 Tho + 326.18)
3600  180 
log e 
 2.53 Tho − 326.18 

200 − Tho =
0.995
(506.18 − 2.53 Tho )
 180 
log e 
 2.53 Tho − 326.18 
Using Trial and error method, we get
Tho = 134o C
Exit Temperature of cold fluid
From equation (1)
Tco= 326.18 − 1.53 × 134
Tco = 121.16o C
Case ( ii ) : For counter flow heat exchanger
q1 = Thi − Tco = 200 − Tco = 200 − ( 326.18 + 1.53Tho )
=q1 1.53 Tho − 126.18
q 2= Tho − Tci= Tho − 20
q − q2 Thi
LMTD =q m = 1 θ1
q Tho
log e 1
q2 Tco θ2
1.53Tho − 126.18 − Tho + 20 Tci
=
 1.53Tho − 126.18 
log e  
 Tho − 20 L
0.53Tho − 106.18
=
 1.53Tho − 126.18 
log e  
 Tho − 20
Heat transfer rate
= Q U As qm
10000
× 1.9 × 103 ( 200 − Tho ) = 300 × 17.5 ×
( 0.53Tho − 106.18)
3600  1.53Tho − 126.18 
log e  
 Tho − 20

200 − Tho =
0.995
( 0.53Tho − 106.18)
 1.53Tho − 126.18 
log e  
 Tho − 20
Using Trail and error method, we get
Tho = 122.56o C
Exit temperature of cold fluid ( From equation (1) )
Tco= 326.18 − 1.53 × 122.56
 log e  ho

 Tho − 20
Using Trail and error method, we get
Heat Exchangers 555
Tho = 122.56o C
Exit temperature of cold fluid ( From equation (1) )
Tco= 326.18 − 1.53 × 122.56
= 138.66o C
28. The flow rate of hot and cold fluids running through a parallel flow heat exchanger are
0.2 and 0.5kg/s respectively. The inlet temperature on the hot and cold sides are 75oC
and 20oC respectively. The exit temperature of hot water is 45oC. If the individual heat
transfer coefficient on both sides are 650W/m2K, calculate the area of heat transfer.
VTU Jan - 2010 (06)
Data:
= m h 0.2kg= / s, m c 0.5kg
= / s, Thi 75
= o o
C, Tci 20= o
C, Tho 45 C,
h=
i h=
o 650W / m 2 K, A=
s ?
Parallel flow heat exchanger
Overall heat transfer coefficient Thi
1 1 1 Tho
= +
U hi ho θ1 θ2
1 1 Tco
= +
650 650 Tci
U = 325W / m 2 K
L
m h Cph ( Thi − Tho ) =
m c Cpc ( Tco − Tci )

( For hot & cold water C p = 4.2kJ / kg K )

) 0.5 ( Tco − 20)
0.2 ( 75 − 45=
Tco = 32o C
q1= Thi − Tci = 75 − 20= 55o C
q 2 = Tho − Tci = 45 − 32= 13o C
q1 − q 2 55 − 13
=
qm = = 29.12o C
q1 55
log e log e
q2 13
Surface area of heat exchanger
Q = m h Cph ( Thi − Tho ) = 0.2 × 4.2 × 103 ( 75 − 45)
= 25200W
Q= U A s q m ⇒ 25200= 325 × A s × 29.12
A s = 2.663m 2
29. The velocity of water flowing through a tube of 2.2cm diameter is 2m/s. Steam condensing
at 150oC on the outside surface of tube heats the water from 15oC to 60oC over the length
of the tube. Find the heat transfer coefficient and the length of the tube neglecting the
steam and tube side resistance. VTU June - 2012 (06)
556 Heat Transfer

Data: d =
2.2 × 10−2 m, v =
2m / s, Thi = 150o C, Tci =
Tho = 15o C, Tco =
60o C, L =
?
( i) The heat transfer coefficient
The mean temperature of water
Tci + Tco 15 + 60
= Tm = = 37.5o C
2 2
From HMT data book, at Tm = 37.5o C, properties of water
r 990kg / m3 , C=
= p 4.2 × 103 J / kg o C, =
K 0.5418W / m o C, =
m 700 × 10−6 kg / ms
rvd 990 × 2 × 0.022
Re
= = = 62228 > 2300, Flow is turbulent
m 700 × 10−6
mCp 700 × 10−6 × 4.2 × 103
=Pr = = 5.426
K 0.5418
Now N u = 0.023 R e0.8 Pr0.333
0.023 × ( 62228) × ( 5.426)
0.8 0.333
=
= 274.97
hd
N=u = 274.97
K
h × 0.022
= 274.97
0.5418
h = 6771.7W / m 2 o C
( ii) Length of the tube
π π
mc =rav =r× × 0.0222 × 2 =990 × × 0.0222 × 2
4 4
= 0.753kg / s
Q= m c Cpc ( Tco − Tci )= 0.753 × 4.2 × 103 ( 60 − 15)
= 142317W
q1= Thi − Tci= 150 − 15= 135o C
q 2= Tho − Tco= 150 − 60= 90o C
q1 − q 2 135 − 90
=
qm = = 111o C
q1 135
log e log e
q2 90
Now =Q U As qm
142317
= 6771.7 × A s × 111
A s = 0.189m 2 = π dL
0.189 = π × 0.022 × L
L = 2.74m
Heat Exchangers 557

30. An oil cooler consists of straight tube of 2cm OD and 1.5cm ID enclosed with in a pipe
and co-centric with it. The external pipe is well insulated. The oil flows through the tube
at 0.05kg/s (Cp = 2kJ/kgoC) and cooling fluid flows in the annulus in the opposite direction
at the rate of 0.1kg/s (Cp = 4kJ/kgoC). The oil enters the cooler at 180oC and leaves at 80oC
while cooling liquid enter the cooler at 30oC. Calculate the length of the pipe required if
heat transfer coefficient from oil to the surface is 1720W/m2 oC and from metal surface to
coolant is 3450W/m2 oC. Neglect the resistance of the tube wall. VTU Dec - 2011 (06)
−−22 −−22 3 3 o o
Data: d oo =2 × 10 m, d ii =1.5 × 10 m, m hh =0.5kg
0.05kg/ s,/ s,Cph 2 ×210
Cph=
= × 10J /Jkg
/ kgC,C,m cm= 0.1kg
c =
/ s,/ s,
0.1kg
4 × 1033 J // kgK,
Cpcpc =
= kgK, TThihi =
180
=
o
180oC,C, TThoho =
80
=
o
80oC,C, TTcici =
30 o
30oC,
= C, LL=
?,?, hhoo =
= 1720W 2o
1720W//mm 2 oC,
= C,
2o
h ii = 3450W // m
m 2 oCC
Counter flow heat exchanger
Overall heat transfer coefficient
1 1 1 1 1
= += +
U h ii h oo 3450 1720
2
U = 1147.78W // m m 2K
K
m hhCph
ph
( Thihi −=
Tho
ho
) mccCpcpc ( Tcoco − Tcici )
0.05 × 2 × 1033 (180 − 80 ) = 0.1 × 4.2 × 1033 ( Tcoco − 30 )
Tcoco = 53.81oo C
q11= Thihi − Tcoco= 180 − 53.81= 126.19oo C Thi
q22 = Tho − Tcici = 80 − 30 = 50 C oo θ1 Tho
ho
q11 − q22 126.19 − 50 Tco θ2
=
qmm = = 82.29oo C
q 126.19 Tci
log ee 11 log ee
q22 50
Q U A ssqmm
=
L
B
=ut,
But, Q m ccCph
ph
( Thihi − Thoho )
= 0.05 × 2 × 1033 (150 − 80 )
= 10000W
10000
= 1147.78 × A ss × 82.29
A ss = 0.1059m 22 = πd ooL
0.1059 = π × 2 × 10−−22 × L
L = 1.685m
31. A heat exchanger has an effectiveness of 0.5 when the flow is counter and the thermal
capacity of one fluid is twice that of the other fluid. Calculate the effectiveness of the heat
exchanger if the direction of one of the fluid is reversed with the same mass flow rates as
before. VTU June - 2011 (06)
558 Heat Transfer

C min 1
Data: ∈counter =0.5, C = min = =0.5, ∈parallel =?
counter
C min
min
2 parallel

Effectiveness of counter flow heat exchanger

NTU((11−−C
C))
1 − e −−NTU
∈counter =
NTU((11−−CC))
counter
1 − C e −−NTU
NTU((11−−0.5
0.5))
1 − e −−NTU
0.5 =
NTU((11−−0.5
0.5))
1 − 0.5 e −−NTU
NTU((0.5
0.5)) NTU((0.5
0.5))
0.5 − 0.25 e −−NTU 1 − e −−NTU
=
NTU((0.5
0.5)) NTU((0.5
0.5))
0.5 e −−NTU
1 −= − 0.25 e −−NTU
NTU((0.5
0.5))
0.5 = 0.75 e −−NTU
Taking log ee on both sides
log ee 0.666 =
− NTU × 0.5log ee e
NTU = 0.811
Effectiveness of parallel flow heat exchanger
NTU((11++C C))
1 − e −−NTU
∈parallel =
parallel
1+ C
0.811((11++0.5
0.5))
1 − e −−0.811
= = 0.222
1 + 0.5
32. Oil at 100 C (Cp = 3.6kJ/kgoC) flows at the rate of 30000kg/h and enters into a parallel flow
o

heat exchanger. Cooling water enters the heat exchanger at 10oC at the rate of 50000kg/h.
The heat transfer area is 10m2 and overall heat transfer coefficient is 1000W/m2 oC.
Calculate (i) outlet temperature of oil and water, (ii) maximum possible outlet temperature
of water. VTU Dec - 2011 (02)
30000 50000
Data: m h = = 8.33kg / s, Cph = 3.6 × 103 J / kg o C, Thi =
100o C, m c = 13.89kg / s
=
3600 3600
Cpc = 4.2 × 103 J / kg o C, Tci = 10o C, U = 1000W / m 2 o C, A = 10m 2
Parallel flow heat exchanger,
= Tho ?,=
Tco ?, T=
co max ?
Ch =m h Cph =8.33 × 3.6 × 103 =30 × 103 W / K =Cmin
Cc= m c Cpc= 13.89 × 4.2 × 103= 58.34 × 103 W / K= Cmax
Cmin 30 × 103 Thi
=C = = 0.514
Cmax 58.34 × 103 Tho
( i) The outlet temperature of oil and water Tco
Tci
U A s 1000 × 10
NTU
= = = 0.33
C min 30 × 103
1 − e − NTU(1+ C) 1 − e −0.33(1+ 0.514)
=∈ =
1+ C 1 + 0.514
= 0.32
 max

( i) The outlet temperature of oil and water

Heat ExchangersNTU
U A s 1000 × 10 559
= = = 0.33
C min 30 × 103
1 − e − NTU(1+ C) 1 − e −0.33(1+ 0.514)
=∈ =
1+ C 1 + 0.514
= 0.32
Ch ( Thi − Tho )
Now ∈=
Cmin ( Thi − Tci )
30 × 103 (100 − Tho )
0.32 =
30 × 103 (100 − 10)
Tho = 71.2o C
Cc ( Tco − Tci ) 58.34 × 103 ( Tco − 10)
Again ∈
= = ⇒ 0.32
Cmin ( Thi − Tci ) 30 × 103 (100 − 10)
Tco = 24.8o C
( ii) Maximum possible outlet temperature of water
For maximum possible outlet temperature of water, Thi
we have Tco = Tho Tho = Tco
Tci
m h Cph ( Thi −=
Tho ) m c Cpc ( Tco − Tci )
30 × 103 (100 − Tco ) = 58.34 × 103 ( Tco − 10)
Tco max = 40.5o C
33. In a parallel flow double pipe heat exchanger, water flows through the inner pipe and is
heated from 20oC to 70oC. Oil flowing through the annulus is cooled from 200oC to 100oC.
It is desired to cool and oil to a lower temperature by increasing the length of the heat
exchanger. Determine the minimum temperature to which the oil may be cooled. Also
determine the exit temperature of each fluid if heat exchanger was switched to counter
flow. VTU June - 2011 (02)
Data:
= Tci 20 =o
C, Tco 70=o
C, Thi 200 =o
C, Tho 100o C,
Ch ( Thi − Tho =
) Cc ( Tco − Tci )
Ch Tco − Tci 70 − 20 0.5 Cmin
= = = =
Cc Thi − Tho 200 − 100 1 Cmax
Ch ( Thi − Tho ) 200 − 100
=∈ = = 0.56
Cmin ( Thi − Tci ) 200 − 20
Now for parallel flow heat exchanger
1 − e − NTU (1+ C ) 1 − e − NTU (1− 0.5)
=∈ = , 0.56
1+ C 1 + 0.5
NTU = 1.3
( i ) Minimum temperature to which the oil may be cooled in parallel flow heat exchnager
If heat exchanger is too long, then both fluids attain a common exit i.e., Tho = Tco
Now Ch ( Thi − Tho =
) Cc ( Tco − Tci )
Ch
 1+ C 1 + 0.5
NTU = 1.3
( i ) Minimum temperature to which the oil may be cooled in parallel flow heatHeat
560 exchnager
Transfer
If heat exchanger is too long, then both fluids attain a common exit i.e., Tho = Tco
Now Ch ( Thi − Tho =
) Cc ( Tco − Tci )
Ch
or ( Thi − Tho ) =Tho − Tci
Cc
0.5 ( 200 − Tho ) =Tho − 20
100 − 0.5 Tho =
Tho − 20
Tho = 80o C
Exit temperature of fluids if heat exchanger is swithched to counter flow
Since the size of the heat exchanger is not changed, the NTU of both parallel flow and
counter flow HE remains the same
1 − e − NTU (1− C ) 1 − e −1.3(1− 0.5)
=
∈counter = = 0.6468
1 − C e − NTU (1− C ) 1 − 0.5 e −1.3(1− 0.5)
 T − Tho  Ch 0.5  200 − Tho 
= ∈counter  hi = , 0.6468  =  , Tho 83.58o C
 Thi − Tci  Cmin 0.5  200 − 20 
Cc  Tco − Tci  1  Tco − 20 
Again,
= ∈counter  =⇒ 0.6468   , Tco = 78.21o C
Cmin  Thi − Tci  0.5  200 − 20 
34. Water to water heat exchanger of a counter flow arrangement has heating surface area
of 2m2. Mass flow rate of hot and cold fluids are 2000kg/h and 1500kg/h respectively.
Temperature of hot and cold fluids at inlet are 85 and 25oC respectively. Determine the
amount of heat transferred from hot to cold water and their temperature at exit if the
over all heat transfer coefficient is 1400W/m2K.
Data: Counter flow=HE, m h 2000kg
= / h 0.556kg
= / s, m c 1500kg
= / h 0.417kg
= / s, A s 2m 2
Tci 25o C,=
= Thi 85o C,=
Q ?, =
Tho ?, = U 1400W / m 2 K
Tco ?,=
Ch = Cph × m h = 4.2 × 103 × 0.556 = 2.335 × 103 W / K = Cmax
Cc = Cpc × m c = 4.2 × 103 × 0.417 = 1.751 × 103 W / K = Cmin
Cmin 1.751 × 103
C = Capacity ratio
= = = 0.75
Cmax 2.335 × 103
No. of Transfer Units
U A s 1400 × 2
NTU
= = = 1.6
Cmin 1.75 × 103
Effectiveness of counter flow HE
1 − e − NTU(1− C) 1 − e −1.6(1− 0.75)
=∈ = = 0.663
1 − C e − NTU(1− C) 1 − 0.75 e −1.6(1− 0.75)
( i) Exit temperature of hot and cold water
Ch ( Thi − Tho ) 2.335 × 103  85 − Tho 
= ∈ = ⇒ 0.663
Cmin ( Thi − Tci ) 1.751 × 103  85 − 25 
Tho = 55.19o C
 1 − e − NTU(1− C) 1 − e −1.6(1− 0.75)
=∈ = = 0.663
1 − C e − NTU(1− C) 1 − 0.75 e −1.6(1− 0.75)
Heat Exchangers 561
( i) Exit temperature of hot and cold water
Ch ( Thi − Tho ) 2.335 × 103  85 − Tho 
= ∈ = ⇒ 0.663
Cmin ( Thi − Tci ) 1.751 × 103  85 − 25 
Tho = 55.19o C
Cc ( Tco − Tci ) Tco − 25
Again ∈= ⇒ 0.663 =
Cmin ( Thi − Tci ) 85 − 25
Tco = 64.78o C
( ii) Heat transfer from hot to cold water
Q = Ch ( Thi − Tho ) = 2.335 × 103 ( 85 − 55.19)
=Q 69.61 × 103 W
35. A concentric tube heat exchanger uses water which is available at 15oC to cool ethylene
glycol from 100oC to 60oC. The water and glycol flow rates are each 0.5kg/s. What are the
maximum possible heat transfer rate and effectiveness of the heat exchanger? Which is
preferred, a parallel flow or counter flow mode operation? Take Cp for glycol = 2637J/kgK.
Data: T=ci
ci 15oo C, T=
hi
hi 100oo C, T=
ho
ho 60oo C, m
= cc m=
hh 0.5kg / s, Q max
= ?
max

Heat capacity rate are

C hh =m ccC ph
ph =0.5 × 2637 =
1318.5W / K =C mix
mix

Ccc = m ccC pcpc = 0.5 × 4.2 × 1033 = 2090W / K = C max

max

Maximum possible heat transfer

Q max
= max min ( Thi
C min ci )
hi − Tci

= 1318.5 (100=
− 15 ) 112.07kW
Outlet temperature for cold fluid
Chh ( Thihi − Tho ) Ccc ( Tcoco − Tcici )
ho =

1318.5 (100 − 60 ) = 2090 × ( Tcoco − 15 )

Tcoco = 40.23oo C
Cold fluid outlet temperature is less than the hot fluid outlet temperature. Hence heat
exchanger may be operated in parallel flow mode.
Effectiveness of heat exchanger
Qactual Chh ( Thihi − Tho
ho )
=∈ =actual
Q max
max Q max
max

1318.5 (100 − 60 )
= = 0.470
112.07 × 1033
36. In a double pipe heat exchanger hot fluid capacity rate is half of the capacity rate of
cold fluid. Deduce an expression interms of temperature for the ratio of area of counter
flow heat exchanger to that of parallel flow heat exchanger which will give same hot fluid
562 Heat Transfer

outlet temperature. Find the ratio if hot fluid inlet and outlet temperature are 150 &
90oC and cold fluid inlet temperature is 30oC.
Data:
= o
Thi 150= C, Tho 90 =o
C, Tci 30
= o
C, Ch 0.5 Cc ,=Tho parallel Tho counter

Cmin Ch 0.5 Cc
Capacity ratio =
C = = = 0.5
Cmax Cc Cc
Effectiveness of heat exchanger
Ch ( Thi − Tho ) Cc ( Tco − Tci )
∈= =
Cmin ( Thi − Tci ) Cmin ( Thi − Tci )
Thi − Tho 1  Tco − Tci 
=
Thi − Tci 0.5  Thi − Tci 
Tco= Tci + 0.5 ( Thi − Tho ) − − − (1)
Since the outlet temperature of hot fluid in both heat exchangers is same, the heat lost in
both cases remains the same i.e.,
= Q U A s PF q= m parallel U A s CF q m counter
A s CF q m parallel
or
= − − − ( 2)
A s PF q m counter
For parallel flow arrangement
q1= Thi − Tci
q 2= Tho − Tco= Tho − Tci − 0.5 ( Thi − Tho ) (Substituting (1) )
= 1.5Tho − 0.5Thi − Tci
q1 − q 2
q m parallel =
q
log e 1
q2
Thi − Tci − 1.5Tho + 0.5Thi + Tci
=
 Thi − Tci 
log e 
 1.5Tho − 0.5Thi − Tci 
1.5 ( Thi − Tho )
− − − ( 3)
 Thi − Tci 
log e 
 1.5Tho − 0.5Thi − Tci 
For counter flow arrangment
q1= Thi − Tco= Thi − Tci − 0.5 ( Ti − Tho ) (Substitutin ( 2) )
= 0.5Thi + 0.5Tho − Tci
q 2= Tho − Tci
q1 − q 2
q m counter =
q
log e 1
q2
 q1= Thi − Tco= Thi − Tci − 0.5 ( Ti − Tho ) (Substitutin ( 2) )
= 0.5Thi + 0.5Tho − Tci
Heat Exchangers 563
q 2= Tho − Tci
q1 − q 2
q m counter =
q
log e 1
q2
0.5Thi + 0.5Tho − Tci − Tho + Tci
=
 0.5 ( Thi + Tho ) + Tci 
log e  
 Tho − Tci 
0.5 ( Thi − Tho )
= − − − ( 4)
 0.5 ( Thi − Tho ) − Tci 
log e  
 Tho − Tci 
Substituiting equation ( 3) & ( 4) in ( 2)
 0.5 ( Thi − Tho ) − Tci 
log e  
A s CF 1.5 ( Thi − Tho )  Tho − Tci 
= ×
A s PF  Thi − Tci  0.5 ( Thi − Tho )
log e  
1.5 Tho − 0.5 Thi − Tci 
  0.5 ( Thi + Tho ) − Tci  
 log e   
  Tho − Tci  
= 3
 Thi − Tci 
 log e  
 1.5 Tho − 0.5 Thi − Tci  
o o
at Thi 150
= = C, Tci 30
= C, Tho 90o C
  0.5 (150 + 90) − 30  
 log e   
A s CF   90 − 30  
=3
A s PF   150 − 30 
 log e  
 1.5 × 90 − 0.5 × 150 − 30  
= 0.877
37. In a tube type parallel flow heat exchanger the hot water at 80oC is cooled to 65oC by cold
water entering the heat exchanger at 20oC and leaving at 35oC. What would be the exit
temperature if the flow rates of water are doubled?
Data: Parallel flow=HE, Thi 80= o
C, Tho 65
=o
C, Tci 20=o
C, Tco 35o C
From the data, Thi − Tho = 80 − 65 = 15o C
Tco − Tci = 35 − 20 = 15o C
Since both fluids have equal temperature difference, we get
m h Cph = m c Cpc
\ C=
1
80 − 65
Effectiveness
= ∈ = 0.25
80 − 20
1 − e − NTU(1+ C)
Again, ∈=
1+ C
 co ci

Since both fluids have equal temperature difference, we get

m h Cph = m c Cpc
564 Heat Transfer
\ C=
1
80 − 65
Effectiveness
= ∈ = 0.25
80 − 20
1 − e − NTU(1+ C)
Again, ∈=
1+ C
1 − e − NTU(1+1)
0.25
= ⇒ NTU
= 0.3466
1+1
When flow rates are doubled, still the heat capacity ratio will remain unchanged i.e., C = 1
(
But, m Cp ) New
(
= 2 mCp ) old

UA s NTU
\ NTU1 = =
Cmin 2
0.3460
= = 0.1733
2
New effectiveness
1 − e − NTU1 (1+ C) 1 − e −0.1733(1+1)
∈= =
1+ C 1+1
= 0.1464
Exit temperature
Tho= Thi − ∈( Thi − Tci =
) 80 − 0.1464 (80 − 20)
= 72.21o C
Tco= Tci − ∈( Thi − Tci =
) 20 + 0.1464 (80 − 20)
= 28.75o C
38. Oil is cooled to 100oC in a concurrent heat exchanger by transferring its heat to cooling
water, that leaves the exchanger at 30oC. However, it is now required that the oil must be
cooled down to 75oC by increasing the length of heat exchanger, while oil and water flow
rates, their inlet temperature and other dimensions of the exchanger keeping constant.
The inlet temperature of water and oil being 15oC and 150oC respectively. If the original
cooler was 1m long calculate (i) outlet temperature of water in new cooler, (ii) length of
new cooler.
Data: Concurrent ( Parallel ) Flow HE
Case ( i )
oo oo oo
Tho
=ho11 100= C, Thihi 150= C, L11 1m,
= Tcoco11 30= C, Tcici 15oo C
Case ( ii )
Thihi 150oo C, =
= Tho
ho22 75oo C,=
Tcici 15oo C, =
Tcoco22 ?,=
L 22 ?
For original cooler
m hhCph (
ph Thi
hi − T
=ho11
ho ) (
m ccCpcpc Tcoco11 − Tcici )
Chh (150 − 100 )= Ccc ( 30 − 15 )
C min C hh 30 − 15
= =
min
= 0.3
= C
Cmax
max Ccc 150 − 10
Heat Exchangers 565

Thi
Tho
1
Tho
2

Tco
Tco 2
1

Concurrent ( Parallel)TFlow HE
ci
Case ( i )
o o o
= Tho1 100= C, Thi 150= C, L1 1m,
= Tco1 30= C, Tci 15o C
Case ( ii ) L1 ΔL
= Thi 150o C, =
Tho2 75o C,=
L2 o C, =
Tci 15 Tco2 ?,= L2 ?
For original cooler
(
m h Cph Thi − T
=ho1 ) (
m c Cpc Tco1 − Tci )
Ch (150 − 100) = Cc ( 30 − 15)
Cmin Ch 30 − 15
= = = 0.3
= C
Cmax Cc 150 − 100
Effectiveness of heat exchanger
Ch ( Thi − Tho ) 150 − 100
=∈1 = = 0.37
Cmin ( Thi − Tci ) 150 − 15
1 − e − NTU(1+ C) 1 − e − NTU1 (1+ 0.3)
Again, ∈1
= =
1+ C 1 + 0.3
NTU1 = 0.50
U A s1
= 0.50
C min
U πdL1  U πd 
=  L1 0.5
×=
C min  Cmin 
U πd 0.5 0.5
or = = = 0.5 − − − (1)
C min L1 1
For New Cooler

=∈2
(
Ch Thi − Tho2
= = 0.55
)
150 − 75
Cmin ( Thi − Tci ) 150 − 15
1 − e − NTU2 (1+ C)
Again, ∈2 =
1+ C
1 − e − NTU2 (1+ 0.3)
0.55 =
1 + 0.3
U A s2 U πdL 2
NTU
= 2 0.965
= = − − − ( 2)
Cmin Cmin
Substituting equation (1) in ( 2)
 1 − e − NTU2 (1+ C)
Again, ∈2 =
1+ C
566 1 − e − NTU2 (1+ 0.3) Heat Transfer
0.55 =
1 + 0.3
U A s2 U πdL 2
NTU
= 2 0.965
= = − − − ( 2)
Cmin Cmin
Substituting equation (1) in ( 2)
0.965
= 0.5 × L 2
L 2 = 1.93m
The outlet temperature of water in new cooler

=∈2
(
Cc Tco2 − Tci
=
)
⇒ 0.55
1 Tco2 − 15 ( )
Cmin ( Thi − Tci ) 0.3 (150 − 15)
Tco2 = 37.27 o C

39. Simple counter flow heat exchanger operates under the following conditions.
Fluid-A inlet and outlet temperature 80oC and 40oC
Fluid-B inlet and outlet temperature 20oC and 40oC.
The exchanger is cleaned, causing an increase in overall heat transfer coefficient by
10% and inlet temperature of fluid B is changed to 30oC. What will be the new outlet
temperature of fluid A and fluid B? Assume the heat transfer coefficient and capacity
rates are unchanged by temperature changes.
=
Data: Thihi 80oo C,=
Tho
ho11
40oo C,
= Tcici1 20 o
20oC,=
C,
= TTcoco1 40 o
40oC,=
C,
= TTcici2 30 o
30oC, TThoho2 ?,
C,=
= TTcoco2 ?,?,
?,=
=
1 1 2 2 2

U 22 = 1.1U11 Counter flow HE

For orignal heat exchanger
m chC (
Cphph Thihi − T
=ho
ho11
)
m ccCpcpc Tco
co11
− Tcici1
1
( )
m hhCph Tcoco1 − Tcici1 40
40 −− 20
20 C
Cmin
= = == 0.5
=
ph
= 1
= 1
0.5
= min
m ccCpcpc Thihi − Thoho1 80 − 40
80 − 40 C
Cmax
max
1

∈
NTU11((11−−CC))
11−− ee−−NTU C (
Chh T
Thihi −− T
Tho )
∈11= ∈
∈11=
ho11
= =
11−− C − NTU1 (1− C )
C ee − NTU1 (1− C) C
Cmin
min
( TT
hi
hi T )
−− T
ci
ci11

11−− ee NTU11((11−−C
−−NTU C))
 80
80 −− 40
40  0.667
0.667
=
0.667 = =
= 1 ((1 ))= =
 80  0.667
80 −− 20
−−NTU −−0.5
11−− 0.5
0.5 ee NTU 1 1 0.5
20 
NTU
NTU11 == 1.386
1.386
For
For Cleaned Heat Exchanger
Cleaned Heat Exchanger
U
U 22A
Ass 1.1 U U11A Ass 1.1 NTU
NTU
=
NTU
= 22 =
= 1.1 = = 1.1 NTU11
C
Cmin CCmin
min min
=
= 1.1
1.1××1.386
1.386= =1.52
1.52
−−NTU 2 ((11− CC)) 1.52((11−−0.5
0.5))
11−− ee NTU 2 − 11−− ee−−1.52
Now
Now ∈ ∈22 =
= − NTU 2 (1− C )
⇒
⇒ −1.52(1− 0.5 )
11−− CC ee − NTU2 (1− C) 11−− 0.5
0.5 ee −1.52(1− 0.5)
∈ =0.695
∈22 = 0.695
Outlet
Outlet temperature of
temperature of fluid
fluid A A and
and fluid
fluid B B
C
Chh T ( −T
Thihi − Tho ) 80 −T
80 − Tho
=∈ = ⇒ 0.695
⇒
ho22 ho22
=∈22 = 0.695
 min min

1.1 × 1.386 =
= 1.52
− NTU 2 (1− C )
Heat Exchangers 1− e 1 − e −1.52(1− 0.5) 567
Now ∈2 = ⇒
1 − C e − NTU2 (1− C ) 1 − 0.5 e −1.52(1− 0.5)
∈2 =0.695
Outlet temperature of fluid A and fluid B

=∈2
(
Ch Thi − Tho2
= ⇒ 0.695
)80 − Tho2
(
Cmin Thi − Tci2 )80 − 30

Tho2 = 45.2o C

Again, ∈2
(
Cc Tco2 − Tci2 )
1.0  Tco2 − 30 
= = =   0.695
(
Cmin Thi − Tci2 )
0.5  80 − 30 

Tco2 = 47.4o C
40. 8000kg/h of air at 100oC is cooled by passing it through a single pass cross flow heat
exchanger. To what temperature is the air cooled if water entering at 15oC flows through
the tubes unmixed at the rate of 7500kg/h. Take U = 500kJ/hm2 oC, surface area = 20m2,
Cpair = 1kJ/kgoC. Treat both fluids are unmixed.
8000 7500
Data: m h = 2.22kg / s, Cph =
= 1 × 103 J / kg o C, Thi =
100o C, m c = = 2.08kg / s,
3600 3000
500 × 103
Cpc = 4.2 × 103 J / kg o C, U == 138.9W / m 2 o C, A s ==
20m 2 , Tco ?
3600
C=h = 2.22 × 1 × 10= 2.22 × 103 W / o=
m h Cph 3
C Cmin
Cc = m c Cpc = 2.08 × 4.2 × 103 = 8.736 × 103 W / o C = Cmax
Cmin 2.2 × 103
=C = = 0.254
Cmax 8.736 × 103
U A s 138.9 × 20
NTU
= = = 1.25
Cmin 2.22 × 103
From the graph ( ∈ v / s NTU for cross flow HE )
at NTU 1.25
= = & C 0.254, we
= get ∈ 0.63
Ch ( Thi − Tho )  100 − Tho 
=∈ = ⇒ 0.63  = ⇒ Tho 46.45o C
Cmin ( Thi − Tci )  100 − 15 
Cc ( Tco − Tci ) 8.736 × 103  Tco − 15 
Again, ∈= ⇒ 0.63 =
Cmin ( Thi − Tci ) 2.22 × 103  100 − 15 
Tco = 28.6o C
Air is cooled to a minimum temperature of 46.45o C
41 A heat exchanger is used for cooling oil at 1800 C using water available at 250 C. The mass
flow rates of oil and water are 2.5 kg/s and 1.2 kg/s respectively. If the heat exchanger
has 16 m2 area available for heat transfer. Calculate the outlet temperatures of oil and
water for, 16 m2 area available for heat transfer. Calculate the outlet temperatures of oil
and water for,
568 Heat Transfer

i. Parallel flow and

ii. Counter flow arrangement.
Take CP(oil) = 1900 J/kg - K Cp(water) = 4184 J/kg - K, U = 285 W/m2 - K.
VTU Dec/Jan 2015
Data: Thi = 180 C, Tci = 25 C, mh = 2.5 kg/s, mc = 1.2 kg/s, As = 16m , Tho=?, Tco=?, Cph=1900 J/kg K,
0 0 2

Cpc=4184 J/kg-K, U = 285 w/m2 K

Ch = m h × Cph = 2.5 × 1900 = 4750 → Cmin
Cc =m c Cpc =
1.2 × 4184 =5020.8 → Cmax
Cmiin 4750
=C = = 0.95
Cmax 5020
( i) Parallel flow arrangement
UA s 285 × 1.6
NTU
= = = 0.96
Cmin 4750
1 − e − NTU(1+ C) 1 − e −0.96(1+ 0.95)
=ε = = 0.434
1+ C (1 + 0.95)
Now ε =
Ch ( Thi − Th1 ) (180 − T )
⇒ 0.434 = h 0
Cmin ( Thi − Ti ) (180 − 25)
Th 0 = 112.730 C
Again
Cc ( Tco − Tci ) 5020.8 ( Tco − 25)
=ε =
Cmin ( Thi − Tci ) 4750 (180 − 25)
5020.8  Tco − 25 
0.434 =  
4750  180 − 25 
Tc0 = 88.640 C
( ii ) Counter flow arrangement
1 − e − NTU(1− C) 1 − e −0.96(1− 0.96) 0.0367
=ε = − NTU (1− C)
= = 0.4946
−0.96(1− 0.96)
1 − Ce 1 − 0.96 × e 0.07616
Ch ( Thi − Tho ) 180 − Tho
Now ε
= = ⇒ 0.4646
Cmin ( Thi − Tci ) 180 − 25
Tn 0 = 103.340 C
Cc ( Tco − Tci )
Again ε =
Cmin ( Thi − Tci )
5620.8 ( Tco − 25)
0.4946 =
4750 (180 − 25)
Tc0 = 97.530 C
Heat Exchangers 569

42. 8000 kg/hr of air at 105°C is cooled by passing it through a counter flow heat exchanger.
Find the exit temperature of air if water enters at 15°C and flows at a rate of 7500 kg/
hr. The heat exchanger has heat transfer area equal to 20 m and the overall heat transfer
co-efficient corresponding to this area is 145 W/m2- K. Take Cp of air = 1 kJ/kg - K and
that of water (Cpw) = 4.18kJ/kg-K. VTU June/July 2015
Ans. mh =8000 kg/h=2.22 kg/s
7500
= Thi 105o C,T
= ci 15o C,
= m c = 2.083kg /= 2
s, A 20 m= , U 145 W / m 2 K,
3600
Cph = 1 × 103 J / kg K,Cpc = 4.18 × 103 J / kg K
Thi
q1
Tho
Tco q2
Tci
L
3 3
C=
h m h C=
ph 2.22 × 1 × 10= 2.22 × 10 → Cmin
Cc = m c Cpc = 2.083 × 4.18 × 10 = 8.71 × 103 → Cmax
Cmin 2.22 × 103 UAss 145 × 20
=C
= = 3
0.26 and
= NTU
= = 1.306
Cmax 8.71 × 10 Cmin 2.22 × 103
From NTU v / s Cchart for counter flow heat exchanger
exchanges
at NTU 1.306&C
= = 0.26
we get ∈= 0.69
Ch ( Thi − Tho )
∈=
C min ( Thi − Tci )
105 − Tho
0.69 =
105 − 15
Tho = 42.9o C
43. 8000 kg/hr of air at 100°C is cooled by passing it through a single pass cross flow heat
exchanger. To what temperature is the air cooled, if water entering a 15°C flows through
the tubes unmixed at the rate of 7500 kg/hr. Take,U = 500kJ/hr – m2 °C , A = 20m2, Cp of
air = 1kJ/kg °C , Cp of water = 4.2 kJ/kg °C. [Fig] VTU Dec 2015 / Jan 2016
th1 = 100oC

tc1 = 15oC tc2 = ?

th2 = ?
Ans. Data : mh = 8000 kg/h = 2.22 kg/s
Thi = 100oC, Tci = 15oC, mc = 7500 kg/h = 2.08 kg/s
U = 500 × 103 J/h m2 oC = 138.88 W/m2 oC
570 Heat Transfer

A = 20m2 Cph = 1 × 103 J/kg oC

Cpc = 4.2 × 103 J/kg oC Tho = ? Tco =
Ch = mh × Cph = 2.22 × 1 × 103 = 2220 W/K → Cmin
CC = mc × Cpc = 2.08 × 4.2 × 103 = 87.36 W/K → Cmax
Cmin 2220
=C = = 0.254
Cmax 8736
UAS 138.88 × 20
NTU
= = = 1.25
Cmin 2220
For cross flow heat exchanger one fluid mixed and another unmixed
At C = 0.254 and NTU = 1.25
We get (Effectiveness v/s NTU graph)
∈ = 0.67
C ( T − Tho )
Now ∈= h hi
Cmin ( Thi − Tci )
2220 (100 − Th 0 )
0.68 =
2220 (100 − 15)
Th 0 = 42.2 o C
CC ( Tco − Tci )
Again ∈=
Cmin ( Thi − Tci )
8736 ( Tco − 15)
0.68 =
2220 (100 − 15)
Tco = 29.69 o C
44. Hot engine oil is to be cooled in a double pipe counter flow heat exchanger. The copper
tube has a diameter of 2cm with negligible thickness. The inner diameter of outer tube is
3cm. The water flow through the inner tube at a rate of 0.5 kg/s and oil flows through the
annular space at a rate of 0.8 kg/s. Taking the average temperature of water and oil as 47
and 80oC, Assume fully developed flow. Calculate the overall heat transfer coefficient of
the heat exchanger. VTU Jan 2018
Data : di = 0.02m, d0 = 0.03m, nC = 0.5 kg/s, mh = 0.8 kg/s, TC = 47 C, Th = 80 C, U = ?
o o

Cold water di d0

Hot oil
Properties of water at 47 C(HMT data book)
o

r = 989 kg/m3, K = 0.637 W/mK, n = 0.59 × 10–6 m2/s, Pr = 3.79

Properties of unused engine oil at 80oC (HMT data book)
Heat Exchangers 571

r = 852 kg/m3, K = 0.138 W/mK, n = 37.5 × 10–6 m2/s, Pr = 490

Determination of hi
v di mc di 0.5 0.02
For water R e = = × = × = 54576 > 2300
n rA i n 989 × π × 0.022 0.59 × 10−6
4
Flow is turbulent
Now N u = 0.023 R e0.8 Pr0.4 ( From HMT data book for internal flows )
h i di 0.8 0.4 h i × 0.02
Nu = 0.023 × ( 54576 ) ( 3.79 ) =
=
K 0.637
2
h i = 7690 W / m K
Determination of h 0
Engine oil flow through annular space
4A
Hydraulic diameter D h =
Wetted perimeter
π
4 × d 02 − d i2 
= 4 = d 0 − d i = 0.03 − 0.02 = 0.01m
π [di + d 0 ]
vD h m h D h mh D
Re = = × = × h
n rA n π  n
r  ( d 02 − d12 ) 
4 
0.8 0.01
= × = 637.6 < 2300 Flow is laminar
π −6
852 × [ 0.032 − 0.022 ] 37.5 × 10
4
N u = 5.45 [ From HMT data book, for internal flow ]
h 0 Dh
= 5.45
K
h 0 × 0.01
= 5.45 ⇒ h 0 = 75.2 W / m 2 K
0.138
 Thermal resistance due to conduction is neglected. 
Overall heat transfer coefficient  
 Also for inner tube, thickness is neglected 
1 1 1 1
U= + = + = 75 W / m 2 K
h i h 0 7690 75.2
Thermal resistance due to conduction is neglected. Also for inner tube, thickness is neglected.
45. Calculate the overall heat transfer coefficient based on outer surface of a steel pipe. K =
54 W/mK with inner and outer diameter as 25mm and 35mm respectively. The inside and
outside heat transfer coefficients are 1200 W/m2K and 2000 W/m2K respectively.
 (VTU Jan 2018)
Data : K = 54 W/mK, di = 0.025m, d0 = 0.035m, hi = 1200 W/m K, h0 = 2000 W/m2K, U0 = ?
2

Overall heat transfer coefficient without fouling factors

 572 Heat Transfer

1 1 r0 r0 r 1 1 0.035 0.035 0.035 1

= + log e 0 + = × + log e +
U 0 h i ri K ri h 0 1200 0.025 2 × 54 0.025 2000
U 0 = 563.16 W / m 2 K
46. A counter flow, concentric tube heat exchanger used to cool the lubricating oil for a large
industrial gas turbine engine. The flow rate of cooling water through the inner tube.
(di = 20 mm) is 0.18 kg/sec. While the flow rate of engine oil through the outer annulus
(d0 = 40 mm) is 0.12 kg/sec. The inlet and outlet temperature of oil are 95°C and 65°C
respectively. The water enters at 30°C to the exchanger. Neglecting tube wall thermal
resistance, fouling factors and heat loss to the surroundings, calculate the length of the
tube. (VTU June/July 2016)
Data : Counter flow heat exchanger mc = 0.18 kg/s, mh = 0.12 kg/s, di = 20 ×10–3m, d0 = 40 ×10–3m.
Thi = 95oC, Th0 = 65oC, Tci = 30oC, L = ?
Thi
q1
Th0
Th0
d0 di Water q2
Thi

For Oil
Thi + Tho 95 + 65
=Tb = = 80o C
2 2
From HMT data book,for engine oil
at Tb = 80o C, we get
=Cp 2131J
= NS/ m 2 , K 0.138 W / mK.
/ kgK, m 0.0325=
Determination of h0
rvd h m do m ( do − di ) 4m h
Re = = r× = × =
m r A m π d 2 − d 2 m π ( do + di ) m
4
( o 1)
4 × 0.12
= = 78.35
π ( 0.04 + 0.02 ) × 0.0325
mCP 0.0325 × 2131
Pr
= = = 506.49
K 0.138
N u = 0.023R e 0.8 Pr 0.3
= 0.023 × ( 78.35 ) ( 506.49 )
0.8 0.3

= 4.879
h o ( do − di )
Nu =
K
h o × ( 0.04 − 0.02 )
4.879 =
0.138
h o = 33.66 W / m 2 K
 N u = 0.023R e 0.8 Pr 0.3
= 0.023 × ( 78.35 ) ( 506.49 )
0.8 0.3
Heat Exchangers 573
= 4.879
h o ( do − di )
Nu =
K
h o × ( 0.04 − 0.02 )
4.879 =
0.138
h o = 33.66 W / m 2 K
Determination of h1
From HMT data book, properties of water at 30oC
CP = 4174 J/kgK, m = 725 × 10–6 NS/m2
K = 0.625 W/mK, Pr = 4.85
rvd i 4m c 4 × 0.18
Re =
= = = 15805.73
m πd i m π × 0.02 × 725 × 10−6
N u = 0.023R e 0.8 Pr 0.3
= 0.023 × (15805.73) ( 4.85)
0.8 0.3

= 84.43
hd h × 0.02
N u = i i ⇒ 84.43 = i
K 0.625
h i = 2638.47 W / m 2 K
1 1 1 d 1 1 0.02
= + × i = + ×
U i h i h 0 d 0 2638.47 33.66 0.04
U i = 65.64 W / m 2 K
Now m C CPC ( TC0 −=
TCi ) m h CPh ( Thi − Th 0 )
0.18 × 4.178 ( TC0 − 30 ) = 0.12 × 2.131( 95 − 65 )
TC0 = 40.2o C

=qm
q1 − q2
=
( 95 − 40.2 ) − ( 65= − 30 )
44.16o C
q
log e 1 log e
( 95 − 40.2 )
q2
( 65 − 30 )
Q = m C Cpc ( TCo − TCi ) = 0.18 × 4.178 ( 40.2 − 30 )
= 7.67 × 10−3 kW
Q= U i ASqm= U i πd i Lqm ⇒ 7.67 × 103= 64.65 × π × 0.02 × L × 44.16
L = 42.11m
47. Saturated steam at 140°C is condensing on the outer surface of a single pass heat
exchanger. The overall heat transfer coefficient is 1500 W/m2 K. Determine the surface
area of the heat exchanger required to heat 2000 kg/h of water from 20°C to 45°C. Also
determine the rate of condensation of steam in kg/h. Assume the latent heat of steam to
be 2145 kJ/kg. [VTU Dec 2016 /Jan 2017]
Data : U = 1500 W/m2K, AS = ?, mC = 2000 kg/h = 0.556 kg/s, TCi = 20oC, TC0 = 45oC, mS = ?,
574 Heat Transfer

hfg = 2145 kJ/kg, Thi = Th0 = 140oC

Since Thi = Th0 , both parallel flow and counter flow arrangements give same value of LMTD.
\ Correction factor is not required
For parallel flow arrangement
q1 = Thi – TCi = 140 – 20 = 120oC
q2 = Th0 – TC0 = 140 – 45 = 95oC
q − q2
LMTD qm = 1
q
log e 1
q2
120 − 95
= = 107.01o C
120
log e
95
Now Q m C CPC ( TC0 − TCi )
=
= 0.556 × 4.2 × 103 ( 45 − 20 )
= 58.38 × 103 W
Also
= Q U AS qm
58.38 × 103 = 1500 × AS × 107.01
AS = 0.364 m 2
Rate of condensation of steam
Q = mS hfg
58.38 × 103 = mS × 2145 × 103
mS = 0.0272 kg/s
 Heat Exchangers 575

Review Questions and Practice Problems

1.
What is heat exchanger? What are its application?
2.
With a neat sketch, classify and explain heat exchangers.
3.
Define fouling and fouling factor.
4.
Define LMTD, obtain an expression for LMTD of parallel flow and counter flow heat
exchanger.
5. Define, (i) capacity rate, (ii) capacity ratio, (iii) effectiveness.
6. Obtain an expression for effectiveness of parallel flow and counter flow heat exchanger.
7. What are the advantages of NTU-ε method over LMTD method.
8. Show that for parallel flow heat exchanger
1 − e −2 NTU
∈ = when C 1
2
9. Show that for parallel flow heat exchanger
NTU
= ∈ = for C 1
1 + NTU
10. Write a note on compact heat exchanger.
11. The following data relate to a parallel flow heat exchanger in which air is heated by hot
exhaust gases. Heat transferred per second = 46.52kJ. Inside heat transfer coefficient = 166W/
m2 oC. Outside heat transfer coefficient = 186W/m2 oC. Inlet and outlet temperature of hot
fluid = 400oC & 150oC. Inlet and outlet temperature of cold fluid 50oC and 100oC. Inside and
outside diameter of tube = 50mm and 60mm. Calculate the length of the tube required, Neglect
tube resistance.
[Ans: 25.2m]
12. Water is heated while flowing through a 15mm × 35mm rectangular cross-section tube at a
velocity of 1.2m/s. The water enters at 40oC and tube wall in maintained at 85oC. Determine
the length of the tube required to rise the temperature of water by 30oC.
[Ans: L = 4.78m]
13. An oil cooler of concentric tube type is used for cooling oil at 65.5 C to 54.4oC with water at
o

26.7oC with a temperature rise of 11.1oC. Assuming overall heat transfer coefficient of 738W/
m2K based on the outside area of tube, determine the heat transfer surface area required for a
design load of 190.5kW for a single pass (i) parallel flow, (ii) counter flow modes.
[Ans: 9.85m2, 9.3m2]
14. It is desired to condense 4000kg/h of dry and saturated steam at a pressure of 0.05 bar
(saturation temperature = 32.76oC) in a single pass steam condenser. The cooling water enters
the tube at 20oC and leaves at 26oC. The tubes are 25mm ID and 27.5mm OD and the thermal
conductivity of tube material is 110W/mK. The film transfer coefficients of water and steam
sides are 7090 and 5930W/m2K. If the length of tube is 3m, calculate the following (i) surface
area of the tubes (ii) heat transfer rate, (iii) number of tubes.
[Ans: 927.23m2, 26933.3kW, 3578]
15. The following data relate to a single pass surface condenser.
576 Heat Transfer

Quantity of steam to be handled = 5100kg/h (dry and saturated steam at 50oC) outer and inner
diameters of tube = 20mm & 17mm, length of the tube = 3m. Inlet and outlet temperature of
water = 20oC and 30oC. Heat transfer coefficient of steam side =1700W/m2 oC. Fouling factor
of water side = 0.0002m2 oC/W. Thermal conductivity to tube material = 93W/moC fouling
factor of steam side = 0.0009m2 oC/W. Calculate the number of tubes.
[Ans: 1031]
16. A shell and tube exchanger (two-shell, four passes) is used to heat 10000kg/h of pressurised
water from 35oC to 120oC with 5000kg/h water entering the exchanger at 300oC. If the overall
heat transfer coefficient is 1500W/m2K, determine the heat exchanger area.
[Ans: 4.95m2]
17. A counter flow tubular oil cooler is to be designed to cool 1500kg/h of oil from temperature
90oC to 30oC by means of water entering the cooler at 20oC and leaving the cooler at 50oC.
Calculate the amount of water flow rate required and heat transfer area. Take Cp of oil as 3kJ/
kgK and overall heat transfer coefficient equal to 1200W/m2K.
[Ans: mc = 0.598kg/s, A = 288m2]
18. Steam condenses at atmospheric pressure on the external surface of the tubes of steam
condenser. The tubes are 12 in number and each is 30mm in diameter and 10m long. The
cooling water temperature flowing inside the tubes is 25oC and 60oC. If the flowing rate is
1.1kg/s calculate the following
i) The rate of condensation of steam
ii) The overall heat transfer coefficient
iii) No. of transfer units
iv) Effectiveness of the condenser.
[Ans: 257kg/h, 255.9W/m2 oC, 0.628, 0.47]
19. Water enters a counter flow double pipe heat exchanger at 38oC flowing at 0.076kg/s. It is
heated by oil (Cp = 1800J/kgK) flowing at the rate of 0.152kg/s from an inlet temperature of
116oC. For an area of 1m2 and U = 340W/m2K, determine the total heat transfer rate.
[Ans: 13.26kW]
20. In a cross flow heat exchanger, oil of specific heat of 3.6kJ/kgoC flows in at the rate of
15000kg/h at 100oC and is cooled by water which enters at 10oC and flows at the rate of
25000kg/h. The effective heat transfer area is 10m2 and the overall heat transfer coefficient is
500W/m2K. Calculate the temperature of oil water. Consider both fluids are unmixed.
[Ans: 70.3oC, 25.3oC]
21. A particular two shell pass, four tube pass heat exchanger uses 20kg/s of river water at 10oC
on the shell side to cool 8kg/s of processed water from 80oC to 25oC on the tube side. At what
temperature will the coolant be returned to the river? If U is 800W/m2K how large must the
exchanger be?
[Ans: 32oC, 88.2m2]
22. A counter flow heat exchanger is used to heat water from 20 C to 80 C at a rate of 1.2kg/s. The
o o

heating is obtained by using geothermal water available at 160oC at a mass flow rate of 2kg/s.
The inner tube is thin walled and has a diameter of 1.5cm. If U is 640W/m2K, calculate the
length of heat exchanger required to achieve the desired heating by using ε-NTU method. Take
specific heat for geothermal water as 4.31kJ/kgK and that of ground water as 4.18kJ/kgK.
[Ans: L = 108.6m]
Heat Exchangers 577

23. Two fluids pass through a heat exchanger the cold fluid is heated from 40oC to 90oC while the
hot fluid is cooled from 200 to 100oC. (a) What percentage saving in surface area is made by
using a counter flow exchanger instead of a parallel flow, (b) What are the temperature of the
two fluids at the middle of the exchanger for parallel flow arrangement.
[Ans: 34.5%, 60oC, 141.5oC]
24. Water enters a counter flow double pipe heat exchanger at 12 C and flow rate of 0.16kg/s.
o

The water is to cool alcohol (Cp = 2520 J/kgK) from 75oC to 35oC. The convection coefficient
between alcohol and the tube wall is 340W/m2K and that between the tube wall and water is
225W/m2K. Presuming tube to be thin, make calculation for the capacity ratio, ε, and heat
transfer area.
[Ans: 0.75, 0.635, 5.31m2]
25. In a tubular counter current heat exchanger 0.3kg/s of water is heated from 40oC to 80oC by
hot flue gasses (Cp = 1.01kJ\kgK) which enter at 200oC and leave at 100oC. The U is 0,2kW/
m2K. Workout the surface area both by LMTD approach and ε-NTU method.
[Ans: 2.88m2]
 HEAT TRANSFER WITH PHASE CHANGE
5.9 INTRODUCTION
Condensation refers to a change from the vapour to a liquid phase and boiling involves change
from liquid to vapour phase of a fluid system.
Condensation and boiling processes are common in power plants (Boilers and condensers),
refrigeration systems (Evaporators and condensers), melting of metals in furnaces, heat exchangers
used in refineries and solar mills.
5.10 CONDENSATION
It is a process in which fluid in a gaseous or vapour phase changes to a liquid state with the
liberation of heat from the vapour.
Condensation occurs when the vapour is in contact with the surface whose temperature is less
than the saturation temperature of vapour. The condensation of vapour libesates latent heat and
there is heat flow to the surface.
5.11 Types of Condensation
Two types of condensation are
1) Film condensation
2) Drop wise condensation.
1) Film Condensation :-
In this type, the condensate wets the solid surface, spreads out and forms a continuous film
over the entire surface. The liquid flows down the cooling surface under the action of gravity.
The layer continuously grows in thickness because of newly condensing vapors. This film offers
thermal resistance and restrict further transfer of heat between the vapour and the surface.
Film condensation occurs when a vapour relatively free from impurities and is allowed to
condense on a clean surface.
2) Drop wise Condensation :
In this type the condensate collects in droplets and does not wet the solid cooling surface.
The droplets develop in cracks and pits on the surface, grow in size, break away from the surface
and eventually run off the surface without forming a film. Thus higher heat transfer rates are
experienced.
Drop wise condensation is observed on surfaces contaminated with impurities like fatty acids
and organic compounds. Drop wise condensation is provoked artificially by surface coatings
called promoters that inhibit wetting.
5.12 NUSSELT THEORY OF LAMINAR FILM CONDENSATION ON A
VERTICAL PLATE
Nusselt theory estimates the heat transfer coefficient for the liquid film by setting up expressions
for the velocity distribution, mass flow rate and heat flux through the layer for film condensation
on vertical plate.
Assumptions
1) Temperature at the inside of the film is taken equal to the surface temperature. Temperature
at the outer surface of the film is taken equal to saturation temperature at the given pressure.
Heat Transfer with Phase Change 579

2) The condensate film is so thin that a linear temperature variation exists between the plate
surface and the vapour conditions.
3) The physical parameters (K, μ, ρ) of the condensate film are independent of temperature.
4) Vapour density is small compared to that of the condensate.
5) The vapour delivers only the latent heat and the heat flow across the plate is by conduction.
6) An element of fluid mass with in the film is influenced by the viscous shear and gravitational
force.
7) There is velocity gradient at the liquid - vapour interface.
8) The condensing vapour is entirely clean and free from gases, air and non condensing
impurities.
9) Drainage of condensate film along the vertical surface is by the action of gravity and is
through a laminar motion.
10) Radiation between the vapour and the liquid film, horizontal component of velocity at any
point in the liquid film and the curvature of the film are considered negligibly small.
5.12.1 Nusselt Theory Analysis
b

dy
O
y  dv   dv d2 v 
µ dy  b dx A dx  µ + µ dy  b dx
x  dy dy 2 
δ  
A Tv vapour
Ts y ρg b dx dy
L Velocity variation
v (y) (ii) Force balance
Temperature m
variation T(y)
dQ=KAΔT dQ=hfgdm
Flat vertical plate dQ=hAΔT
(i) Condensate layer on A
dm
flat plate

m + dm
(iii) Mass and Heat balance
Consider the process of film condensation on a vertical plate surface as shown in figure (i).
Let O → Origin at the upper end of the plate
L → height of vertical plate
b → Width of film at a distance x from the origin
δ → Thickness of film at a distance x from the origin
Ts → Surface temperature
Tv → Vapour temperature or film surface temperature
Assume thickness of film is zero at the upper end of the plate.
1) Velocity distribution
Consider an elementary volume b dx dy of the liquid film as shown in figure (ii).
Gravitational force on the element = ρ g b dx dy
580 Heat Transfer

dv
Viscousshearing stress on the element face at y = µ
dy
d  dv 
Changein shearing stressin distance =
dy µ dy
dy  dy 
d2 v
=µ dy
dy 2
dv d2 v
Shearing stress at a distance of y + dy = µ +µ 2
dy dy
Equating forces, we get
 dv d2 v  dv
rg b dx dy + µ + µ 2 dy  bdx = µ bdx
 dy dy  dy
Simplifying we get
d2 v
rg = −µ
dy 2
d2 v rg
= −
dy 2 µ
Integrating twice, we get
dv rg
= − y + c1
dy µ
−rg y 2
=n + c1 y + c 2
µ 2
Applying boundary conditions
i) at y= 0, n= 0
∴0 = 0 + 0 + c 2 ∴ c2 = 0
dv
ii) at y = δ, =0
dy
dv −rg
i.e.,
= y + c1
dy µ
−rg
= 0 δ + c1
µ
−rg
∴ c1 = δ
µ
−rg y 2 rg
=
∴n + δy
µ 2 µ
rg  y2 
=
n δ y −
µ  2 
 −rg
∴ c1 = δ
µ
2
Heat Transfer −rg y rg 581
= ∴n with Phase+Change
δy
µ 2 µ
rg  y2 
=
n  δy − 
µ  2
The mean film velocity vm of the liquid film at a distance x from the top edge is given by
δ
1
δ ∫0
v=
m n.dy

δ
1 rg  y2 
δ ∫0 µ 
= δ y − dy
2 
rgδ 2
vm =
3µ

Mass flow rate

The downward flow of the liquid at any elevation x.
m = mean flow velocity × flow area × density
rg 2
m= δ × bδ × r
3µ
gbr2 δ3
m=
3µ
An increase in mass flow rate of condensation during downward flow of condensate
from x to x + dx
d  gbr2 δ3 
dm =  
dδ  3µ 
gbr2 δ2
dm =
µ

Heat flux and film thickness

Heat flow rate into the film
dQ = Latent heat release during condensation
dQ = dm × hfg
gbr2 δ2
dQ
= × h fg − − − (1)
µ
Nusselt assumed that the heat released during condensation flows only by conduction
through the film.
dT
∴ dQ =
KA
dx
K.bdx
=dQ ( Tv − Ts ) − − − ( 2)
δ
From (1) and (2) we get
gbr2 δ2 bdx
× h fg K
= ( Tv − Ts )
µ δ
3 Kµ
 dT
∴ dQ =
KA
dx
582 K.bdx Heat Transfer
= dQ
δ
( Tv − Ts ) − − − ( 2)

From (1) and (2) we get

gbr2δ 2 bdx
µ
× h fg K
=
δ
( Tv − Ts )
Kµ
=δ3 2
r gh fg
( Tv − Ts ) dx
Integrating
δ4 Kµ
= 2
4 r gh fg
( Tv − Ts ) x + c − − − ( 3)

Applying boundary condition for equation ( 3)

i.e.,at x= 0, δ= 0
∴ 0 = 0 + c or c = 0
δ4 Kµ
∴ Equation ( 3) becomes
= 2
4 r g h fg
( Tv − Ts ) x
1
 4Kµ ( Tv − Ts ) x  4

Or δ = 
 r2 g h fg 

Film heat transfer coefficient

It is assumed that heat flow from the vapour to the surface is by conduction through the liquid
film.
K b dx
= i.e.,dQ ( Tv − Ts ) − − − ( 4)
δ
Heat flow can also be expressed as
=dQ h x b dx ( Tv − Ts ) − − − ( 5)
h x = local heat transfer coefficient
From ( 4 ) and ( 5 ) we get
K
hx =
δ
0.25
 4kµ ( Tv − Ts ) 
But δ = 
 r g h fg
2

0.25
 K 3r2 g h fg 
∴hx =  
 4µx ( Tv − Ts ) 
Average heat transfer coefficient
L
1
h = ∫ h x .dx
L0
0.25
1  K r g h fg 
L 3 2

h = ∫  dx
L 0  4µx ( Tv − Ts ) 
0.25
  
Average heat transfer coefficient
L
1
L ∫0
Heath Transfer
= h xwith
.dx Phase Change 583

0.25
1  K r g h fg 
L 3 2

h = ∫  dx
L 0  4µx ( Tv − Ts ) 
0.25
 K 3r2 g h fg  1
L
h   × ∫ x −0.25 dx
 4µx ( Tv − Ts )  L0
0.25 L
 K 3r2 g h fg   x -0.75 
h   × 
 4µx ( Tv − Ts )   0.75  0
0.25
4  K r g h fg 
3 2

h=  
3  4µx ( Tv − Ts ) 
4
h = hx
3
0.25
 K 3r2 g h fg 
or h = 0.943  
 µx ( Tv − Ts ) 

5.13 REYNOLDS NUMBER FOR A CONDENSATE FLOW

b

Laminar film

Undulating

Turbulent film

The character of condensate film can range from laminar to highly turbulent.
The liquid flows in laminar film at the upper end of the plate, then becomes undulating in the
middle section and flows in a turbulent state.
The parameter indicating the commencement of turbulent flow is the Reynolds number and it
is given by
rvd eq
Re =
µ
4A
d eq Equivalent
= diameter
p
A = Flow area = bδ
P = Wetted perimeter of thesolid int erface,simply the width of the plate b.
4bδ
∴ d eq = =δ 4
b
 4A
d eq Equivalent
= diameter
p
A = Flow area = bδ
584 Heat Transfer
P = Wetted perimeter of thesolid int erface,simply the width of the plate b.
4bδ
∴ d eq = =δ 4
b
rv × 4δ r ( bδ ) v × 4
∴=Re =
µ µ×b
4m
Re = | m =rAv =rbδv
µb
Mass flow ratein terms of heat transfer
Q hA s ( Tv − Ts )
m= =
h fg h fg
hA s ( Tv − Ts ) 4hbL ( Tv − Ts )
∴ R e =4 × =
µbh fg h fg µb
4hL ( T − Ts )
∴Re = v
µh fg
The transition from laminar to turbulent flow occurs at a critical Reynolds number of 1800.
Note: (1) Kirk bridge equation for the average heat transfer coefficient
y3
 K 3r 2 g 
0.4
h = 0.0077R  2 e
 µ 
Which is valid for R e > 1800.
(2) Heat transfer coefficient relation derived from Nusselt theory is 20% lower than the measured
values. Mc Adam proposed to consider 20% more in calculating heat transfer coefficient i.e., with
Mc Adam's factor. h = 1.2hwithout
5.14 EFFECT OF NON-CONDENSIBLE GASES IN CONDENSATION PROCESS
The presence of appreciable quantities of a non-condensible gas will in general reduce the
heat transfer. If high rates of heat transfer are desired, it is considered good practice to vent the
non-condensible gas, which otherwise will blanket the cooling surface and add considerably to
the thermal resistance. Non-condensible gases also inhibit mass transfer by offering diffusional
resistance.
5.14.1 CORRELATIONS FOR CONDENSATION
i) Inclined plates
 K 3r2 h fg g sin θ 
h = 0.943  
 µL ( Τv − Ts ) 
θ =inclination angle with the horizontal
or h= h vertical × ( sin θ )
0.25

ii) Horizontal tubes

Heat Transfer with Phase Change 585

0.25
 K 3r2 gh fg 
h = 0.725  

ce
 µL ( Τv − Ts ) 

rfa
su
D = Outer diameter of the tube g sinθ

n
tio
sa
iii) Vertical tube L

en
nd
0.25
 K 3r2 g h fg 

Co
h = 0.943  
 µL ( Τv − Ts ) 
iv) Bank of Horizontal tubes
The average film coefficient
0.25 θ
 K 3r2 g h fg 
h = 0.725  
 µDe ( Τv − Ts ) 

De = Equivalent tube diameter of the tube bank

For n tubes in a vertical column of tube pattern
De = nD
D = Diameter of a single tube in the bank.
For tubes in a vertical column of the tube bank pattern n = 3
∴ De = 3D
586 Heat Transfer

BOILING
5.15 INTRODUCTION
Boiling constitutes the convective heat transfer process that involves a phase change from
liquid to vapour state. Boiling occurs when the surface temperature is more than that of saturation
temperature of vapour.
The boiling process has the following applications.
1) In production of steam in nuclear and steam power plants.
2) Absorption of heat in refrigeration and air conditioning systems.
3) Concentration, dehydration and drying of foods and materials.
4) Distillation and refining of fluids.
5.16 DIFFERENT FORMS OF BOILING
1) Pool Boiling : In this form, the heat surface is submerged beneath a free surface of liquid.
The liquid above the hot surface is essentially stagnant. The only motion near the surface is
because of free convection and mixing induced by bubble growth and detachment.
Pool boiling occurs in boilers employing natural convection.
2) Forced convection boiling : In this form, the fluid motion is induced by external means.
The liquid is pumped and forced across the surface in a controlled manner.
3) Subcooled or local boiling : In this the temperature of the liquid is below the saturation
temperature and boiling takes place only in the vicinity of the heated surface. The vapour
bubbles travel a short path and then vanish apparently they condense in the bulk of the
liquid which is at temperature less than the boiling point.
4) Saturated boiling : The temperature of the liquid exceeds the saturation temperature.
The vapour bubbles generated at the solid surface are transported through the liquid by
buoyancy effects and eventually escape from the surface. The actual evaporation process
then sets in.
5.17 REGIMES OF POOL BOILING
Interface Nucleate Film
evaporation Boiling Boiling
I
Bubbles rise to surface
Bubbles condensed in

Radiation coming
super heated liquid

Free
Unstable film

into play
Stable film

convection
VI
IV

V
III
II

106
A
Surface Heat flux

B
qs - W/m2

105

104

103
1.0 5.0 10 30 120 1000
Excess temperature (Tw – Tsat) or (Ts – Tv)
Heat Transfer with Phase Change 587

The six regimes of pool boiling are discussed below

1) In region I, called the free convection zone, the excess temperature is very small (≈5oC). Here
the liquid near the surface is super heated slightly. The convection currents circulate the liquid and
evaporation takes place at the liquid surface.
2) Nucleate boiling: It exists in regions II & III. As the excess temperature is increased, bubbles
begin to form on the surface at certain located spots. The bubbles condense in the liquid without
reaching the liquid surface. Region II is the beginning of the nucleate boiling. As the excess
temperature is further increased bubbles are formed more rapidly and rise to the surface of the
liquid resulting in rapid evaporation. This is indicated in region III. The maximum heat flux
known as critical heat flux occurs at point A.
3) Film Boiling: The increase of heat flux with increase in excess temperature observed upto
region III and reversed in region IV. This is due to that bubbles formed so rapidly blanket the
heating surface with a vapor film preventing the inflow of fresh liquid from taking their place.
Now, the heat is transferred through this liquid film by conduction to the liquid and affect the
further boiling. Since the thermal conductivity of vapor film is less than that of the liquid, the
value of surface heat flux qs decreases with increase of excess temperature.
In region IV, the vapor film is not stable and collapses and reforms rapidly. With further
increase in excess temperature the vapor film is stabilised and the heating surface is completely
covered by a vapor blanket and the heat flux is the lowest in region V.
The surface temperature required to maintain a stable film is high and under these conditions
a sizeable amount of heat is lost by the surface due to radiation as indicated in region VI.
5.18 CORRELATIONS FOR POOL BOILING
1) Free convection boiling:
N u = f1 ( G r ) f 2 ( Pr )
Function f1 and f 2 depend upon the geometry of the heating sufrace.
The heat flux relation
Q K
q = C ( G r Pr ) ∆T
m
=
A L
C & m are constants
∆T = excess temperature
1
m = for laminar flow
4
= 1/ 3 for turbulent flow
With water as the boiling liquid
N u = 0.028 ( R e ) ( Pr )
0.8 0.4

2) Nucleate Boiling:
It is correlated by
N u = f1 ( R e ) f 2 ( Pr )
Reynold's number is replaced by a modulus of the agitation ( mixing and turbulent motion ) of
the fulid particles.
Db G b
i.e., R e b =
µf
 It is correlated by
N u = f1 ( R e ) f 2 ( Pr )
588 Heat Transfer
Reynold's number is replaced by a modulus of the agitation ( mixing and turbulent motion ) of
the fulid particles.
Db G b
i.e., R e b =
µf
D b = average bulb temperature
G b = mass velocity of the bubble / unit area
µ f =fluid viscosity
2σ
D= Cd β
g ( rf − rg )
b

Q
A ×  rf 
Gr = h fg =
latent heat of evaporation
h fg  rg 
Cd = Constant ( 0.0148 for Hydrogen and water bubbles )
σ =Surface tenssion of the liquid
β =Bubble contact angle measured through liquid in deg rees.
( i ) Based on experimental data the following expression is used for nucleate pool boiling
 g ( rf − rg )   C pf ∆T
0.5 3
Q 
= µf h f g    
A  σ   Csf h fg Prf 
Where, µ f =liquid viscosity, Ns / m 2
rg =Density of dry saturated vapour, kg / m3
rf =Density of saturated fluid, kg / m3
σ =surface tension, N / m
Cpf = Specific heat of saturated fluid, J / kgK
Prf = Prandtle number of saturated fluid
Csf = Surface fluid constant
∆T = Tw − Tsat = excess temperature
Q
= heat flux per unit area, W / m 2
A
( ii ) Jacob relation for low heat fluxes boiling on a flat plate at atmospheric pressure
0.33
 K 2r2β g ∆T Cp 
( G r Pr ) and h 0.16 
0.33
= N u 0.16
= 
 r2 
( iii ) Nucleate boiling on a vertical flat plate
N u = 0.61[ G r Pr ]
0.25

0.25
 K 3r2β g ∆T Cp 
h = 0.61  
 Lµ 
( iv ) Under the constant heat flux conditons
( iii ) Nucleate boiling on a vertical flat plate
Heat Transfer with Phase Change 589
N u = 0.61[ G r Pr ]
0.25

0.25
 K 3r2β g ∆T Cp 
h = 0.61  
 Lµ 
( iv ) Under the perat heat flux conditons
 σ ( rf − rg ) g 
0.25 0.5
Q  rf 
  = 0.18 r g h fg    
 A  max rg 2  rg + rf 
 
0.6
Q  rf − rg

and =  0.00374 rg h fg  
 A  max  r
 g 
applicable for water and variety of organic fluid
The minium heat flux during film boiling
 g ( rf − rg ) 
0.5 0.25
Q  σ 
 = 0.09 rg h fg    
 A  min  rf + rg   g ( rf + rg ) 
590 Heat Transfer

Solved Problems on Condensation

NOTE: Heat and Mass transfer data book by C. P. Kothandaraman is used for solving problems.
1. A vertical cooling fin approximately a flat plate 40cm in height is exposed to steam at
atmospheric pressure. If surface of the fin is heated at 80oC, make calculations for the
following parameter.
i) Film thickness at the bottom edge of the film
ii) Over all heat transfer coefficient
iii) Heat transfer rate and condensate mass flow rate.
Assume unit width of the fin and check the flow Reynold's number for the assumption of
laminar flow conditions.
Data:= L 40cm = 0.4m, = Ts 80o C,= δ ?,=
h ?, = Q ?, m= s ?,=b 1
At atmospheric pressure, saturation temperature of water is 100o C = Tv
From steam table at p = 1.0103bar, we get
h fg 2257 × 103 J / kgK
=
Tv + Ts 100 + 80
Mean film temperature,
= Tf = = 90o C
2 2
o
at Tf = 90 C properties of water are
=r 965.3kg / m3 =
, K 67.99 × 10−2 W / mK,
= µ 3.153 × 10−4 Ns / m 2
( i ) The film thickness at a distance x from the edge
0.25
 4µKx ( Tv − Ts ) 
δ   − − − Eq (1)
 g h fg r2 
0.25
 4 × 3.153 × 10−4 × 67.99 × 10−2 × 0.4 (100 − 80 ) 
= 
9.81 × 2257 × 103 × ( 965.3)
2
 
4
=δ 1.135 × 10−= m 0.1135mm
( ii ) Overall heat transfer coefficient
4K 4 67.99 × 10−2
h= = ×
3δ 3 1.135 × 10−4
h = 7987.07W / m 2 K
( iii ) Heat transfer rate
= hA ( Tv − Ts=
Q ) 7987.07 × ( 0.4 × 1)(100 − 80 )
= 63896.62W
Now, Q ms × h fg
=
63896.62 =ms × 2257 × 103
ms = 0.0283kg / s
Checking the film Reynold's No.
4m 4 × 0.0283
R
= e = = 360 < 1800
µb 3.153 × 10−4 × 1
 Now, Q ms × h fg
=
63896.62 =m × 2257 × 103
Heat Transfer with Phase Change
s 591
ms = 0.0283kg / s
Checking the film Reynold's No.
4m 4 × 0.0283
R
= e = = 360 < 1800
µb 3.153 × 10−4 × 1
Thus the assumption of laminar flow has been correct.
2. Saturated steam at 2 bar condenses on a cylindrical vertical drum having an outside
diameter of 25cm and a temperature of 90.4oC. Calculate how long must the drum be to
condense 50kg of steam per hour. Also estimate the thickness of condensate layer.
Data: P= 2 bar, d= 25cm= 0.25m, Ts= 90.4o C, ms= 50kg / h, L= ?, δ= ?
For saturated steam at p = 2 bar, from stream table, we get
=Tv 119.6o C,
= h fg 2201.6 × 103 J / kg,
Tv + Ts 119.6 + 90.4
=Tf = = 105o C
2 2
Properties of water at 105o C
=r 954.7kg
= / m3 , K 0.683W / mK, = µ 0.253 × 10−6 × 954.7
= 2.415 × 10−4 Ns / m 2
50
Q= m h fg = × 2201.6 × 103 = 30.58 × 103 W
3600
= Q h A s ( Tv − Ts )
30.58 × 103 = h × πd × L (119.6 − 90.4 ) = h × π × 0.25 × L (119.6 − 90.4 )
30.58 × 103
h=
π × 0.25 × L (119.6 − 90.4 )
1.33 × 103
h= ..... (1)
L
0.25 0.25
 4Kµ ( Tv − Ts ) L   4 × 0.683 × 2.415 × 10−4 (119.6 − 90.4 ) × L 
Now δ =  = 
( 954.7 ) × 9.81× 2201.6 × 103
2
 r2 g h fg   
=δ 1.77 × 10−4 × L0.25
4K 4 0.683 3858.75
h= = × −4 0.25
= .... ( 2 )
3 δ 3 1.77 × 10 L L0.25
Equating (1) & ( 2 )
1.33 × 103 3858.75
=
L L0.25
L = 0.243m
=δ 1.777 × 10−4 × 0.243=
0.25
1.24 × 10−4 m =
0.133mm
3. A condenser is to be designed to condense 225kg of steam per hr, at a pressure of 0.15
bar. A square array of 400 tubes, each of 6mm in dia, is available for the task. If the tube
surface temperature is to be maintained at 26oC, make calculations for the length of each
tube.
592 Heat Transfer

225
Data:
= m 225kg
= /h
= 0.0625kg / = s, P 0.15bar, No. of tubes
= 400,
3600
=d 6mm
= 0.006m,=Ts 26o C,
= L ?
From steam table at P = 0.15bar,
Tv 53.96o C,=
we get,= h fg 2373 × 103 J / kg
Tv + Ts 53.96 + 26
=Tf = = 40o C
2 2
o
at Tf = 40 C properties of water are
r = 922.2kg / m3 , =
K 13.34 × 10 −2 W / mk,=
µ 6.54 × 10 −6 kg / s − m
No. of tubes in vertical,
= n = 400 20
De = nD = 20 × 0.006 = 0.12m
0.25
 K 3r2 g h fg 
h = 0.728   for N tubes
 De µ ( Tv − Ts ) 
0.25
( )
 13.34 × 10 −2 3 × ( 992.2) 2 × 9.81 × 2373 × 103 
= 0.728  
 0.12 × 6.54 × 10 −6 ( 53.96 − 26) 
 
2
= 5205.34W / m K
Total surface area of 400 tubes
A
= s 400 × π × 0.006 ×= L 7.536L
∴
= Q hA s ( Tv −=
Ts ) m h fg
= 5205.34 × 7.536L ( 53.96 − 26=
) 0.0625 × 2373 × 103
L = 1.353m
4. Dry saturated steam at a pressure of 2.45 bar condenses on the surface of vertical tube
of height 1m. The tube surface is kept at 117oC. Estimate the thickness of the condensate
film and heat transfer coefficient at a distance of 0.2m from the upper end of the tube.
Assume the condensate film to be laminar. VTU Feb - 2002
o
Data:= p 2.45bar,= L 1m, = Ts 117 C,= δ ?,= h ?,= x 0.2m
From steam table at p = 2.45bar, we get
Tv 128.0o C,=
= h fg 2195 × 103 J / kg,
128.0 + 117
=Tf = 122.5o C
2
At Tf = 122.5o C, the properties of water are
r 945kg / m3 , =
= K 6.85 × 10−3 W / mK,=
µ 2.33 × 10−4 Ns / m 2
0.25
 K 3r2 g h fg 
hx =  
 4µx ( Tv − Ts ) 
0.25
(
 6.85 × 10−3 ) × 9452 × 9.81 × 2195 × 103 
3

= 
 v fg

128.0 + 117
=Tf = 122.5o C
2
Heat Transfer with Phase Change 593
At Tf = 122.5o C, the properties of water are
r 945kg / m3 , =
= K 6.85 × 10−3 W / mK,=
µ 2.33 × 10−4 Ns / m 2
0.25
 K 3r2 g h fg 
hx =  
 4µx ( Tv − Ts ) 
0.25
 ( 6.85 × 10−3 )3 × 9452 × 9.81 × 2195 × 103 
= 
 4 × 2.33 × 10−4 × 0.2 (128 − 117 ) 
 
2
h x = 4953.6W / m K
K 6.85 × 10−3
δ x= = = 0.000137m= 0.137mm
hx 4953.6
5. A vertical square plate 30cm × 30cm is exposed to steam at atmospheric pressure. The
plate temperature is 98oC. Calculate the heat transfer and the mass of steam condensed
per hour. VTU Feb - 2003
o
Data: b= L= 0.3m, p= 1.013bar, Ts= 98 C, Q= ?, m= ?
From steam table at p = 1.013bar, we get
Tv 100o C, =
= h fg 2257 × 103 J / kg
100 + 98
=Tf = 99o C
2
at Tf = 99o C, water properties are
r 961kg / m3=
= , µ 0.293 × 10−6 × 961
= 2.85 × 10−4 Ns / m 2 , =
K 0.6804W / mK
0.25
 K 3r2 g h fg 
h = 0.943  
 µL ( Tv − Ts ) 
0.25
 0.68043 × 9612 × 9.81 × 2257 × 103 
= 0.943  
 2.85 × 10−4 × 0.3 (100 − 98 ) 
= 14464.61W / m 2 K
Q =h × A s × ( Tv − Ts )
= 14464.61 × 0.3 × 0.3 (100 − 98 )
= 2603.63Watts
Q = m h fg
m 2257 × 103
2603.63 =×
m 1.147 × 10−3 kg / s
=
m = 4.15kg / h
6. Saturated steam at 80oC condenses as a film on vertical plate at a temperature of 70oC.
Calculate the average heat transfer coefficient and the rate of condensation. Assume that
the latent heat of evaporation at 80oC as 2309kJ/kg and length is 1m. VTUAug - 2004
594 Heat Transfer

Data:=
Tv 80o C,=
Ts 70o C,
= h ?,= h fg 2309 × 103 J / kg
m ?, =
80 + 70
=Tf − 75o C
2
Properties of water at 75o C are
r 970kg / m3 , =
= µ 0.385 × 10−6 × 970
K 0.6612W / mK,= = 8.73 × 10−4 Ns / m 2
0.25
 K 3r2 g h fg 
h = 0.943  
 µL ( Tv − Ts ) 
0.25
 0.66123 × 9702 × 9.81 × 2309 × 103 
= 0.943  
 3.73 × 10−4 × 1( 80 − 70) 
2
h = 6375.019W / m K
=Q hA s ( Tv =
− Ts ) 6375.019 × 1 × 1( 80 − 70) [ Assume
= b 1m ]
= 63750.19W
Q= m × h fg
63750.19 =×m 2309 × 103
m = 0.0276kg / s
7. Saturated steam at 120oC condenses on a 2cm outer diameter tube which is 20cm long.
The tube wall is maintained at a temperature of 119oC. Calculate the average heat tranfer
coefficient and the thickness of the condensate film at base of the tube. Assume Nusselt's
solution is valid.
Given, psat = 1.985bar, ρw = 943kg/m3, hfg = 2202.2kJ/kg, K = 0.686W/mK,
μ = 237.3 × 10–6Ns/m2. Assume vertical condition. VTU Aug - 2003
Data: Tv= 120 C, d= 0.02m, L= 0.2m, Ts= 119 C, h= ?, δ= ?
o o

0.25
 4Kµ ( Tv − Ts ) L 
δ = 
 r2 gh fg 
0.25
 4 × 0.686 × 2373 × 10 −6 (120 − 119) × 0.2  −5
=  2 3 = 5.10 × 10 m
 943 × 9.81 × 2202.2 × 10 
4K 4 × 0.686
h
= =
3δ 3 × 5.10 × 10 −5
= 17925.7W / m 2 K
8. Steam at 0.065 bar condenses on a vertical square plate of length 0.6m. If the surface
temperature of plate is maintained at 15oC, estimate the rate of condensation. Saturation
temperature of steam = 37.7oC, Latent heat of steam at 0.065 bar = 2412 × 103J/kg.
VTU May - 2007
o o 3
Data: p =0.065bar, L = 0.6m = b, Ts =15 C, Tv = 37.7 C, h fg =2412 × 10 J / kg, m =
?
15 + 37.7
=Tf = 26.35o C
2
Properties of water at Tf = 26.35o C are
 p=
0.065bar, L =
0.6m = 15o C, Tv =
b, Ts = 37.7 o C, h fg =
2412 × 103 J / kg, m =
?
Heat Transfer with 15 +Change
37.7 595
= T Phase
f = 26.35o C
2
Properties of water at Tf = 26.35o C are
r 998kg / m3 ,=
= µ 0.931 × 10−6 × 998
= 9.39 × 10−4 Ns / m 2 , =
K 0.613W / mK
0.25
 K 3r2 g h fg 
h = 0.943  
 µL ( Tv − Ts ) 
0.25
 0.6133 × 9982 × 9.81 × 2412 × 103 
= 0.943  
 9.29 × 10 × 0.6 × ( 37.7 − 15 ) 
−4

h = 4291.76W / m 2 K
Q hA s ( Tv − T
= =s) 4291.76 × 0.6 × 0.6 ( 37.7 − 15 )
= 35072.28W
Q = m h fg
35072.28 = m × 24.12 × 103
Rate of condensation m = 0.01454kg / s
9. Air free saturated steam at a temperature of 65oC and pressure of 25.03kPa condenses on
a vertical outer surface of 0.3m long vertical tube maintained at a uniform temperature
of 35oC, Assuming film condensation, calculate the average heat transfer coefficient over
the entire length of the surface. Calculate the average heat transfer coefficient and rate
of condensate flow for horizontal tube of 2.5cm outer diameter. VTU June - 09(06)
Data:
= Tv 65= o
C, p 25.03kPa,
= L 3m,
= o
Ts 35 C, h for vertical
= tube ?
h for horizontal tube
= ?,= m ?,= D 0.025m
Mean film temperature
Tv + Ts 65 + 35
= Tf = = 50o C
2 2
o
At Tf = 50 C, the properties of water are
r 990kg / m3 , =
= µ 5.62 × 10−4 Ns / m 2
K 0.6397W / mK,=
From steam table
= at p 25.03kPa , we get
= h fg 2348.7 × 103 J / kg
Heat transfer coefficient for vertical tube
0.25
 K 3r2 g h fg 
h = 0.943   [ From HMT databook ]
 µL ( Tv − Ts ) 
0.25
 0.63973 × 9902 × 9.81 × 2348.7 × 103 
= 0.943  
 5.62 × 10−4 × 3( 65 − 35) 
h = 3100.65W / m 2 K
Heat transfer coefficient for horizontal tube
0.25
 K 3r2 g h fg 
h = 0.728   [ From HMT databook ]
 µD ( Tv − Ts ) 
0.25
 0.63973 × 9902 × 9.81 × 2348.7 × 103 
= 0.728  
 Heat transfer coefficient for horizontal tube
0.25
 K 3r2 g h fg 
596
h = 0.728   [ From HMT databook ] Heat Transfer
 µD ( Tv − Ts ) 
0.25
 0.63973 × 9902 × 9.81 × 2348.7 × 103 
= 0.728  
 5.62 × 10−4 × 0.025 ( 65 − 35) 
h = 7922.39W / m 2 K
rate Q hA s ( Tv − Ts )
Heat transfer=
= 7922.39 × π × 0.025 × 3( 65 − 35)
= 56000.04W
Rate of condensate flow
We have Q = m h fg
m × 2348.7 × 103
56000.04 =
m = 0.0238kg / s
10. A vertical tube of 60mm outside diameter and 1.2m long is exposed to steam at atmospheric
pressure. The outer surface of tube is maintained at a temperature of 30oC by circulating
cold water through the tube. Calculate the following, i) The rate of heat transfer rate to
the coolant, ii) The rate of condensation of steam. VTU Dec - 2011 (06)
Vertical tube,
= D 0.06m, = L 1.2m,
= p 1.0132bar,= Ts 30o C,= Q ?,= m ?
at atmospheric pressure
= Tv 100o C and
= h fg 2256.9 × 103 J / kg
Tv + Tf 100 + 30
Mean film temperature
= Tf = = 65o C
2 2
From HMTdata book, properties of water at Tf = 65o C are
r =980kg / m3 , =K 0.6599W / mK,= µ 4.44 × 10−4 Ns / m 2
Heat transfer coefficient for vertical tube
0.25
 K 3r2 g h fg 
h = 0.943  
 µL ( Tv − Ts ) 
0.25
 0.65993 × 9802 × 9.81 × 2256.9 × 103 
Data: = 0.943  
 4.44 × 10−4 × 1.2 × (100 − 30) 
h = 3373.75W / m 2 K
( i) Heat transfer rate to the coolant
Q= hA s ( Tv − Ts )= h × πDL ( Tv − Ts )
= 3373.75 × π × 0.06 × 1.2 (100 − 30)
Q = 53418.72W
( ii) Rate of steam condensation
Q = m h fg
m × 2256.9 × 103
53418.72 =
m = 0.0237kg / s
 Q = 53418.72W
( ii ) Rate of steam condensation
Heat Transfer with Phase Change 597
Q = m h fg
m × 2256.9 × 103
53418.72 =
m = 0.0237kg / s
11. A vertical cooling fin approximates a flat plate of 40cm height and exposed to saturation
steam at 100oC (hfg = 2257kJ/kg). The fin is maintained at a temperature of 90oC. Calculate
i) Thickness of the film at bottom of fin.
ii) Average heat transfer coefficient
iii) Heat transfer rate after incorporating Mc Adam's correction. VTU June - 2011 (06)
o 3 o
Data:= =L
L 0.4m,
0.4m, = T
Tvv 100
= 100o C,C, hh=
=
fg 2257
2257 ×× 10
103 JJ // kg,
kg, =T
=Tss 90
90o C,C,=
= δδ ?,
?,=
=hh ?,
?,=Q
Q ??
=
fg
Mean
Mean film
film tempertature,
tempertature,
T
Tvv ++ T
Tss 100
100 ++ 90
90 95oo C
=
= T
Tff = = =
= 95 C
22 22
o
From
From HMT
HMT databook
databook ,, porperties
porperties ofof water
water at at T
Tf == 95
95o CC are
are
f
3 −4 2
rr 965kg
=
= 965kg // m
m3,,=
K
=K 0.6804W
0.6804W // mK,
mK,= = µ 3.02
µ 3.02 ×× 10
10−4 Ns
Ns // m
m2
((ii)) The
The film
film thickness
thickness at
at bbottom
ottom of fin (( xx == L
of fin L))
0.25
 44µ KL((T Tss )) 
0.25

δδ = µKL Tvv −− T
= gg hhfgrr22

 fg

0.25
 4 × 3.02 × 10−−44 × 0.6804 × 0.4 (100 −− 90
90)) 
0.25
==  4 × 3.02 × 10 × 0.68043× 0.4 (100 
 9.81 2
 9.81 ×× 2257
2257 ×× 10
103 ×× 965
9652 
−4
=
=δδ 1.124
1.124 ×× 10
10=−4 m
= m 0.1124mm
0.1124mm
((iiii)) Average
Average heat
heat transfer
transfer coefficient
coefficient
4K 44 ×× 0.6804
hh 4K
=
= =
=
0.6804
−4
33δδ 33 ×× 1.124
1.124 ×× 10
10−4
2
hh == 8073.17W
8073.17W // m m 2KK
((iii
iii)) Hea
Heatt transfer
transfer rate
rate after
after incorporating
incorporating Mc
Mc Adam
Adam 's
's correction
correction is
is
2
hh =
=1.2
1.2 ×× 8073.17
8073.17 =
= 9687.80W
9687.80W // m
m 2KK
Heat
Heat transfer
transfer=rate
rate Q
= hAs ((T
Q hA Ts ))
Tv −− T s v s

= 9687.8
= 0.4((100
9687.8 ×× 11 ×× 0.4 90))
100 −− 90
== 38751.21W
38751.21W
12. A square array of 400 tubes, 15mm outer diameter is used to condense steam at atmospheric
pressure. The tube walls are maintained at 88oC by a coolant flowing through the tubes.
Calculate the amount of steam condensed per hour per unit length of the tubes.
VTU Dec - 2010 (06)
598 Heat Transfer

Data: No. of=

tubes 400,
= D 0.015m,
= o
Ts 88= C, p 1.0132bar,
= m ?
From steam table at p = 1.0132 bar, we get
Tv 100o C,=
= h fg 2257 × 103 J / kg
Tv + Ts 100 + 88
Mean film temperature=
Tf = ⇒= Tf 94o C
2 2
From HMT data book, at Tf = 94o C, properties of water are
r =965kg / m3 , = µ 3.02 × 10−4 Ns / m 2
K 0.6804W / mK,=
No. of tubes in vertical
= n = 400 20
Equivalent diamter D= e nD
= 20 × 0.015
= 0.3m
Heat transfer coefficient of Bank of N tubes
0.25
 K 3r2 g h fg 
h = 0.728  
 µ De ( Tv − Ts ) 
0.25
 0.68043 × 9652 × 9.81 × 2257 × 103 
= 0.728  
 3.02 × 10−4 × 0.3(100 − 88) 
h = 928.97W / m 2 K
Total surface area of 400 tubes
A
= s 1 18.85m 2
400 × π × 0.015 ×=
rate Q hA s ( Tv − Ts )
Heat transfer=
928.97 × 18.85 (100 − 88)
=
= 210128.06W
Amount of steam condensed
Q= m × h fg
m 2257 × 103
210128.06 =×
m = 0.0931kg / s
13. A tube of 15 mm outside diameter and 1.5 m long is used for condensing steam at 40 kPa.
Calculate the average heat transfer coefficient when the tube is : i) horizontal
ii) vertical and its surface temperature is mentioned at 50°C. VTU June/July 2015
Ans. d = 15 x 10-3 m , L=1.5 m,p =40 kPa, Ts = 50oC, h = ?
From steam table at p=40 kPa
Heat Transfer with Phase Change 599

we get Tv = 76o C
50 + 76
=Tf = 63o C
2
Properties of water at Tf = 63o C
rl 950 kg / m3=
= ,K
, µ l 0.432 × 10 −3 Ns / m 2=k1l 0.66 W / mk,
K= h fg 2320 kJ / kg
( i) Horizontal tube
0.25
 K 3r2 g h fg 
h = 0.728  
 µD ( Tv − Ts ) 
0.25
 0.663 × 9502 × 9.81 × 2320 × 103 
= 0.728  
 0.432 × 10 × 15 × 10 ( 76 − 50) 
−3 −3

= 10000 W / m 2 K
( ii) Vertical tube
0.25
 K 3r2 gh fg 
h = 0.943  
 µL ( Tv − Ts ) 
0.25
 0.663 × 9502 × 9.81 × 2320 × 103 
= 0.943  
 0.432 × 10 × 1.5 ( 76 − 50) 
−3

2
= 4080.22 W / m K
14. Saturated steam at 90oC and 70 kPa is condensed on outer surface of a 1.5m long
2.5m diameter tube maintained at uniform temperature of 70oC. Assuming film wise
condensation, calculate the heat transfer rate on the tube surface. [VTU Jan 2018]
Data : p = 70 kPa, TV = 90oC, L = 1.5m, d = 2.5m, TS = 70oC, Q = ?
TV + TS 90 + 70
From HMT databook, =at Tf = = 80o C
2 2
3
For water= r 974 kg / m = , K 0.668 W / mK,
= µ 0.355 × 10−3 NS/ m 2
From steam
= table at p 70= kPa, h fg 2309 kJ / kg
Heat transfer coefficient for vertical tube
0.25
 K 3r2 g h fg 
h = 0.943   ( From HMT databook − Condensation )
 µL ( TV − TS ) 
0.25
 0.6683 × 9742 × 9.81 × 2309 × 103 
0.943
=   4669.91 W / m 2 K
−3
(
 0.355 × 10 × 1.5 90 − 70 ) 
Heat transfer =rate Q hA s ( TV=− TS ) 4669.91 × π × 2.5 × 1.5 ( 90=
− 70 ) 1099.8kW
600 Heat Transfer

15. Air free saturated steam at 85°C and pressure of 57.8 kPa condenses on the outer
surface of 225 horizontal tubes of 1.27 cm outside diameter arranged in 15×15 array.
Tube surfaces are maintained at a uniform temperature of 75°C. Calculate the total
condensation rate/m length of the tube bundle. [VTU June/July 2016]
Data : TV = 85 C, p = 57.8 kPa, n = 225, d = 1.27 × 10 m, TS = 75 C, m = ?
o –2 o

TV + TS 85 + 75
= Tf = = 80o C
2 2
From HMT data book, properties of water at Tf = 80oC
r = 974 kg/m3, n = 0.364 × 10-4 Ns/m2
From steam table at p = 57.5 kPa,
We get hfg = 2296.1 × 103 J/kg
Heat transfer coefficient
 K 3r2 g h fg 
h = 0.728  
 Nd ( TV − TS ) µ 
0.25
 0.6687 −3 × 9742 × 9.81 × 2296.1 × 103 
h = 0.728  −4 
15 × 1.27 × 10 × ( 85 − 75 ) × 3.54 × 10 
−2

= 9847.23W / m 2 K
Q hAS ( TV − TS ) × number of tubes
=
= 9847.23 × π × 1.27 × 10−2 × 1( 85 − 75 ) × 225
= 8.84 × 105 W
Q= m × h fg
8.84 × 105 =
m × 2296.1 × 103
m = 0.385kg / s
 Heat Transfer with Phase Change 601

Solved Problems on Boiling

1. Water at atmospheric pressure is to be boiled in polished copper pan. The diameter of the
pan is 350mm and is kept at 115oC. Assume Csf = 0.013 for polished copper pan and for
ΔTL =15oC. Calculate
i) Power of the burner Q
ii) Rate of evaporation of water, m
iii) Critical heat flux for these conditions. VTU Aug - 2002
Data: d = 350mm = 0.35m, Ts = 115o C, Csf = 0.013, ∆T = Ts − Tv = 15o C, Q = ?, m = ?,
d = 350mm = 0.35m, Ts = o 115o C, Csf = 0.013, ∆T = Ts − Tv = 15o C, Q = ?, m = ?,
q = ?, Tv = 115 − 15 = 100 C
q = ?, Tv = 115 − 15 = 100o C
(
Since Ts − Tv is in the range of 5 to 30o C, this problem comes under Nucleate boiling )
(
Since Ts − Tv is in the range of 5 to 30o C, this problem comes under Nucleate boiling
Physical properties of water at 100o C
)
Physical properties of water at 100o C3
= Cp1 4216J= / kgK, rL 960.6kg / m = , Pr1 1.74,= µ 0.282 × 10−3 Ns / m 2
3
= Cp1 4216J= / kgK, r 960.6kg / m = , Pr1 1.74,
= µ 0.282 × 10 −3 Ns / m 2
For steam at 100o C L
o
rFor steam
= 0.598kg
v
at 100
/ m 3C
, h= 2257 × 103 J / kg, C= 0.013 water copper combination
fg sf ( )
rv 0.598kg / m3 , h=
= 2257 × 103 J / kg, C= 0.013( water copper combination )
=n 1 for= water, σ 0.0588N
fg
/ m [ From HMTsf data book,for boiling ]
=ni Power
1 for=
water, σ 0.0588N / m [ From HMT data book,for boiling ]
() of burner
( i) Power of burner 3.0
 g (r − r )   Cpl ∆T 
0.5
Q
= µ1 h fg  g rL − rv  0.5  C ∆Tn  3.0
A = µ h  ( Lσ v )  Csf hpl fg Pr 
Q
1 fg    n 
A  σ   Csf h fg Pr 
3  9.81( 960.6 − 0.598)  0.5
0.5 3.0
−3 4216 × 15 
= 0.282 × 10 × 2257 × 10 
 9.81( 960.6 − 0.598) 0.013 × 2257
3.0
0.0588 153 × 1.74 
4216××10
= 0.282 × 10 −3 × 2257 × 103  
 3 
Q  0.0588   0.013 × 2257 × 10 × 1.74 
2
= 484134.11W / m
Q
A
= 484134.11W / m 2
A π
Q =× 0.352 × 484134.11 = 43579.16W
4π
Q =× 0.352 × 484134.11 = 46579.16W
( ii) Rate of evaporation
4
( ii ) Rate Qof
= evaporation
m×h fg
Q= mQ× h fg43579.16
= m = × 3600 = 74.29kg / h
hQfg 2257
46579.16
× 103
= m = × 3600 = 74.29kg / h
( iii) Critical heat 2257 × 103
h fg flux
( iii) Critical heat flux
 σg ( rL − r v ) 
0.25
 Q
= 0.18 h fg rv   0.25
A Q  max  σg ( rrLv − rv )
2
=
  0.18 h fg r v  
A  r2v  0.0588 × 9.81( 960.6 − 0.598)  0.25
 Q  max 3
  = 0.18 × 2257 × 10 × 0.598  0.0588 × 9.81 960.6 − 0.598)
( 2 0.25
AQ  max 3  0.598
  = 0.18 × 2257 × 10 × 0.598  
 QA  max 6 2  0.5982 
 = 1.52 × 10 W / m
AQ  max 6 2
 = 1.52 × 10 W / m
A max
602 Heat Transfer

2. Water is to be boiled at atmospheric pressure in a polished copper pan by means of an

electrical heater. The bottom of the copper pan is 0.4m diameter and is kept at 120oC.
Calculate, i) Power required to boil water in the pan, (ii) The rate at which water will
evaporate from the pan due to boiling process.
Data:
=
= PP 1atm,
1atm, copper
copper pan
pan
=
= dd 0.4m,
0.4m,=
= 120ooC,
TTss 120 C,
=
= Q ?,?,
Q == m ??
m
At atm
At atm pr,
pr, T 100oo C
Tvv == 100 C
Properties of
Properties of water
water at 100oo C
at 100 C
C=
C=ppll
4216J //kgK,
4216J kgK, =
= 960.6kg/ /mm3 3, , =
rl l 960.6kg
r Prl rl 174,
P= 174,=
µ=
µl l 0.282 −3−3 Ns / m
0.282××1010 Ns / m 2
2

For steam
For steam at 100oo C
at 100 C
=
rrvv 0.60kg
= m33,, h=
0.60kg //m h=
fgfg 2257 103 3JJ/ /kg,
2257××10 kg,=
= 58.8× 10
σσ 58.8 −3 −3 N / m, C
× 10 N / m, C= = 0.013, n = 1
sf sf 0.013, n = 1

(( ii ) Power
Power required
required
3
 gg ((r rv ))  0.5  C
0.5 3
Q
Q rl − −r Cppll ∆∆T T 
=
µ h ×
µllh fgfg =
= 
l v
  4 
A
A σ
σ   CCsfsf hhfgfg pprr4 

 9.81( 960.6 − 0.60)) 
0.5
0.5 3

10  9.81( 960.6 − 0.600

−−33 33
4216××20
4216 20 
3
0.282××10
== 0.282 10 ××2257
2257××10  
58.8 × 10 −3
0.588  0.13
0.13××1.74 103 3
2257××10
174 ××2257

=
= 11.476 11.476××10 1035W
W//mm2 2

Q= =ππ × 0.422 × 11.476 × 105 5

Q × 0.4 × 11.476 × 10
44
QQ == 144.21kW
144.21kW
(( iiii )) RRate
ate of
of evaporation
evaporation
Q 144.21
Q 1033
144.21××10
m
=
m h= 2257 × 1033 ××3600
= = 3600
h fgfg 2257 × 10
m == 230kg
m 230kg //hh
3. Water flows normal to a polished 15mm diameter copper tube at the rate of 3.5m/s. The
tube is maintained at 116oC and film boiling occurs. Workout the boiling heat transfer
coefficient.
Data:
= d 15mm= 0.015m, = n 3.5m / s,
= T 116 C,
= h ?
Ts Tv 116 100
=T = = 108 C
2 2
at T 108 C, for steam
K=
v 2.49 × 10 2 W / mK, r=
v 0.586kg / m3 , h=
fg 2.25 × 106 J / kg, C pu
= 2058J / kgK
σr 5.67 × 10−8 W / m 2 K 4 ,=
= µ v 11.96 × 10−6 Ns / m 2 , =
ε 0.22, = r 960.6kg / m3
For film boiling
Heat transfer coefficient due to convection
 K v r v ( r − r v ) g ( h fg + 0.68 Cpu ∆T ) 
0.25

h 0.62   ( From HMT data book )

 µ D∆T 
0.25
 2.49 × 10 2
× 0.586 960.6 − 0.586 9.81 2250 × 103 + 0.68 × 2058 × 1 
 K=
v 2.49 × 10 W / mK, r=
v 0.586kg / m , h=
fg 2.25 × 10 J / kg, C pu
= 2058J / kgK
σr 5.67 × 10−8 W / m 2 K 4 ,=
= µ v 11.96 × 10−6 Ns / m 2 , =
ε 0.22, = rl 960.6kg / m3
For film
Heat Transfer boiling
with Phase Change 603
Heat transfer coefficient due to convection
 K 3v r v ( rl − r v ) g ( h fg + 0.68 Cpu ∆T ) 
0.25

h c = 0.62   ( From HMT data book )

 µ v D∆T 
0.25
 ( 2.49 × 10−2 )3 × 0.586 ( 960.6 − 0.586 ) 9.81( 2250 × 103 + 0.68 × 2058 × 16 ) 
= 0.62  
 11.96 × 10−6 × 0.015 × 16 
 
2
= 1868.24W / m K
Heat transfer coefficient due to radiation
 T 4 − Tv4 
h r =σ r ε  s  ( From HMT data book )
 Ts − Tv 
−8
 (116 + 273)4 − (100 + 273)4 
= 5.67 × 10 × 0.22  
 116 − 100 
= 2.76W / m 2 K
Total heat transfer coefficient
h h c + 0.75h r
= ( From HMT data book )
= 1868.24 + 0.75 × 2.76
h = 1868.447W / m 2 K
4. A metal clad heating element of 6mm diameter and emissivity equal to unity is horizontally
immersed in a water bath. The surface temperature of the metal is 225oC under steady
state boiling conditions. If the water is at atmospheric pressure estimate the power
dissipation per unit length of the heater.
Data:
= d 6mm Ts 225o C,=
= 0.006m,= Tv 100o C,
= Q ?
∆T= 225 − 100= 155o C > 120o C Film boiling conditions will prevail
Heat transfer coefficient

( ) 
0.25
 K 3v rv ( rl − rv ) g h fg + 0.68Cpv ∆T
h c = 0.62  ( From HMT databook )
 µ v D∆T 
Properties of water at 100o C are
rl 957.9kg / m3 , h=
= fg 2257 × 103 J / kg, Pr operties of steam at100o C
K
= v µ v 14.85 × 10 −6 Ns / m 2
0.0331W / mK, =
rV =4.808kg / m3
C
= PV 2.56 × 103 J / Kg K

( ) 
0.25
 0.03313 × 4.808 ( 957.9 − 4.808) × 9.81 2257 × 103 + 0.68 × 2.56 × 103 × 155
h c = 0.62 
 14.85 × 10 −6 × 0.006 × 155 
= 460.W / m 2 K
 Ts4 − Tv4  −8
 ( 225 + 273) 4 − (100 + 273) 4 
h r = σr ε ×   = 5.67 × 10 ×  
 Ts − Tv   225 − 100 
= 21.3W / m3 K
 ( )
0.25
 0.03313 × 4.808 ( 957.9 − 4.808) × 9.81 2257 × 103 + 0.68 × 2.56 × 103 × 155 
h c = 0.62  
 14.85 × 10 −6 × 0.006 × 155 
604 Heat Transfer
= 460.W / m 2 K
 Ts4 − Tv4  −8
 ( 225 + 273) 4 − (100 + 273) 4 
h r = σr ε ×   = 5.67 × 10 ×  
 Ts − Tv   225 − 100 
= 21.3W / m3 K
Now, = h h c + 0.75h r
= 460 + 0.75 × 21.3 = 476W / m 2 K
Q hA s ∆=
= T 476 × π × 0.006 × 155
Q 1.36 × 103 W / m
=
5. Saturated water at Tsat = 100oC is boiled inside a copper pan having a heating surface area
5 × 10–2 m2 which is maintained at uniform surface temperature Ts = 120oC. Calculate, i)
The surface heat flux (q), ii) The rate of evaporation (m). VTU Jan - 2010 (06)
Data: Tv = o
100 C, A s = −2 2
5 × 10 m , Ts = 100 oo
120 C, qq== ?,?, mm==
??
From HMT data book, properties of water at Tv = 100o C are
= rl 960.6kg / m3 ,=
Cpl 4216J / kgK,= Prl 1.74,
= µ 0.282 × 10−3 Ns / m 2
For steam at 100o C
r=
v 0.60kg / m3 , h=
fg 2257 × 103 J / kg
Surface tension σ =58.8 × 10−3 N / m ( HMT data book ) , Csf =
0.013, n =
−1
( i ) Surface heat flux
0.5 3
Q  g ( rl − r v )   Cpl ∆T 
= q = µ l h fg    n 
A  σ   Csf h fg Pr 
0.5
 9.81( 960.6 − 0.60 ) 
3
−3 3  4216 × 20 
= 0.282 × 10 × 2257 × 10    0.013 × 2257 × 103 × 1.741 
 58.8 × 10−3   
=q 11.476 × 105 W / m 2
( ii ) Rate of evaporation
Q = q × A s = 11.476 × 105 × 5 × 10−2 = 57380W
Q = m h fg
m 2257 × 103
97380 =×
m = 0.0254kg / s