Heat transfer

Heat exchanger

Department: Mechanical Power Engineering

Date of Submission: 2025\5\17

Student Name: Ahmed Mohamed ahmed Mohamed Ibrahim
Student ID: 703006
Student Name: Ahmed Khaled Abdelfattah Mohamed
Student ID: 703002
Student Name: Mohamed Fawzy Mohamed Mohamed
Student ID: 703030
Student Name: Yousef Mohamed Salah Khalil
Student ID: 703035
Student Name Yousef Mohamed Abdelaziz Ibrahim
Student ID: 703036
Introduction to the Heat Exchanger Report
The heat exchanger is a fundamental component in many engineering and industrial
systems, used to transfer thermal energy between two fluids without direct contact.
Its importance lies in its ability to enhance energy efficiency and regulate
temperatures in various industrial processes, making it indispensable in fields such
as refrigeration, air conditioning, power generation, and the chemical and
petrochemical industries.

This report provides a comprehensive overview of heat exchangers, covering the main
types‫د‬. It also explores their practical applications across different industries,
highlighting the differences in efficiency and usage.

In addition, the report includes key thermal equations used in the design and
performance analysis of heat exchangers. These include the heat transfer rate
equation, the calculation of the effective temperature difference, and the overall heat
transfer coefficient.

The goal of this study is to shed light on the role of heat exchangers in improving
thermal system efficiency and to provide a solid knowledge base for both theoretical
understanding and practical application.

In this section, we will explore the most common types of heat exchangers.

1. Shell and Tube Heat Exchanger

2. U-tube heat exchanger
3. Concentric tube heat exchanger
4. Plate and Frame Heat Exchanger
5. Compact Heat Exchanger
1. Shell and tube heat exchanger
Two fluids, of different starting temperatures, flow through the heat exchanger. One flows
through the tubes (the tube side) and the other flows
outside the tubes but inside the shell (the shell side). Heat is
transferred from one fluid to the other through the tube
walls, either from tube side to shell side or vice versa. The
fluids can be either liquids or gases on either the shell or the
tube side. In order to transfer heat efficiently, a large heat
transfer area should be used, leading to the use of many
tubes. In this way, waste heat can be put to use. This is an
efficient way to conserve energy.

Heat exchangers with only one phase (liquid or gas) on each

side can be called one-phase or single-phase heat
exchangers. Two-phase heat exchangers can be used to
heat a liquid to boil it into a gas (vapor), sometimes called boilers, or cool a vapor to
condense it into a liquid (called condensers), with the phase change usually occurring on
the shell side. Boilers in steam engine locomotives are typically large, usually cylindrically-
shaped shell-and-tube heat exchangers. In large power plants with steam-driven turbines,
shell-and-tube surface condensers are used to condense the exhaust steam exiting the
turbine into condensate water which is recycled back to be turned into steam in the steam
generator.

2. U-tube heat exchanger

In nuclear power plants called pressurized water reactors, large heat exchangers called
steam generators are two-phase, shell-and-tube heat exchangers which typically have U-
tubes. They are used to boil water recycled from a surface condenser into steam to drive a
turbine to produce power. Most
shell-and-tube heat exchangers are
1, 2, or 4 pass designs on the tube
side. This refers to the number of
times the fluid in the tubes passes
through the fluid in the shell. In a
single pass heat exchanger, the fluid
goes in one end of each tube and out
the other.
tube heat exchanger (one pass tube side )

Surface condensers in power plants are often 1-pass straight-tube heat exchangers. Two
and four pass designs are common because the fluid can enter and exit on the same side.

tube heat exchanger (two pass tube side)

There are often baffles directing flow through the shell side so the fluid does not take a
short cut through the shell side leaving ineffective low flow volumes. These are generally
attached to the tube bundle rather than the shell in order that the bundle is still removable
for maintenance.
3. Concentric tube heat exchanger
The concentric tube heat exchanger consists of two tubes that are concentrically arranged.
One of the fluid (either hot or cold fluid) flows through the tube and the other through the
annulus. For a CTHX, two types of flow arrangements are possible - co-current and
counter-current flow. In the parallel or co-current arrangement, the flow direction of the hot
fluid will be the same as that of the cold fluid. In the counter-current arrangement, the flow
directions of the hot and the cold fluids are opposite to each other.

4. Plate and Frame Heat Exchanger

These exchangers are usually built of thin plates (all prime surfaces). The plates are

either smooth or have some form of corrugations, and they are either flat or wound in an

exchanger. Generally, these exchangers cannot accommodate very high pressures,

temperatures, and pressure and temperature differentials. These exchangers may be

further classified as plate, spiral plate, lamella, and plate coil exchangers,
5. Compact Heat Exchangers
One variation of the fundamental compact exchanger element, the core,

The core consists of a pair of parallel plates with connecting metal members that

are bonded to the plates. The arrangement of plates and bonded members provides both a

fluid-flow channel and prime and extended surface. It is observed that if a plane were

drawn midway between the two plates, each half of the connecting metal members could

be considered as longitudinal fins [1].

Compact heat exchangers may be classified by the kinds of compact elements that

they employ. The compact elements usually fall into five classes:

a. Circular and flattened circular tubes.

b. Tubular surfaces.

c. Surfaces with flow normal to banks of

smooth tubes.

d. Plate fin surfaces.

e. Finned-tube surfaces.
Applications of Heat Exchangers
Introduction

Heat exchangers are devices used to transfer thermal energy between two or more
fluids at different temperatures without mixing them. They are essential in many
industrial and commercial processes where heating or cooling is required. Due to
their ability to efficiently manage energy flow, they contribute significantly to energy
conservation, operational safety, and process optimization.

1. Power Generation

In power plants, heat exchangers play a central role in transforming thermal energy into
mechanical energy, which is then converted into electricity.

• In thermal power plants, steam generators use heat exchangers to convert water
into steam using heat from burning fuel or nuclear reactions.

• Condensers are used to cool and condense exhaust steam from turbines,
completing the thermodynamic cycle.

• In combined cycle plants, heat recovery steam generators (HRSGs) use the exhaust
heat from gas turbines to produce additional electricity from steam turbines,
increasing overall efficiency.

2. HVAC (Heating, Ventilation, and Air Conditioning)

In HVAC systems, heat exchangers ensure thermal comfort in buildings by transferring heat
between indoor and outdoor environments.

• In air conditioning systems, they cool indoor air by transferring heat to a refrigerant.

• In heating systems, they use hot water or steam to warm air or water in radiators and
coils.

• Heat recovery ventilation systems use exchangers to reclaim heat from exhaust air
and use it to preheat incoming fresh air, improving energy efficiency.
3. Food and Beverage Industry

Heat exchangers are critical in ensuring product safety, quality, and shelf life in food and
beverage processing.

• Pasteurization uses heat exchangers to raise the temperature of dairy, juice, and
other products to kill pathogens.

• Sterilization processes require precise temperature control, which heat exchangers

provide.

• Cooling systems reduce the temperature of products quickly to preserve freshness

after processing.

• Heat recovery is also common, where outgoing hot product helps heat incoming
cold product, saving energy.

4. Chemical and Petrochemical Industries

Heat exchangers are extensively used in chemical processing for controlling reaction
conditions and improving efficiency.

• They are used for heating or cooling reactants, condensation of vapors, evaporation
of solvents, and heat recovery from waste streams.

• In refineries, exchangers are employed in distillation columns, catalytic crackers,

and reformers.

• Due to the aggressive nature of fluids involved, exchangers in this field must often
be corrosion-resistant and built to withstand high pressures and temperatures.

5. Automotive Industry

Modern vehicles rely on various heat exchangers to manage temperatures of key

components.

• Radiators cool the engine coolant to prevent overheating.

• Oil coolers maintain optimal temperature in transmission and engine oils.

• Intercoolers reduce the temperature of compressed air in turbocharged engines,

increasing performance and fuel efficiency.

• In electric vehicles, thermal management systems use compact heat exchangers to

cool battery packs, inverters, and electric motors.
Key Equations in Heat Exchanger Analysis

1. Heat Transfer Rate

Q=m˙⋅cp⋅(Tin−Tout)Q = \dot{m} \cdot c_p \cdot (T_{\text{in}} - T_{\text{out}})Q=m˙⋅cp

⋅(Tin−Tout)

Used to calculate the amount of heat transferred by a fluid.

2. LMTD Method (Log Mean Temperature Difference)

Q=U⋅A⋅ΔTlmwhereΔTlm=ΔT1−ΔT2ln⁡(ΔT1/ΔT2)Q = U \cdot A \cdot \Delta T_{\text{lm}}

\quad \text{where} \quad \Delta T_{\text{lm}} = \frac{\Delta T_1 - \Delta T_2}{\ln(\Delta
T_1 / \Delta T_2)}Q=U⋅A⋅ΔTlmwhereΔTlm=ln(ΔT1/ΔT2)ΔT1−ΔT2

Used when all inlet and outlet temperatures are known.

3. Effectiveness – NTU Method

ε=QactualQmax,NTU=UACmin⁡,Qmax=Cmin⁡(Th,in−Tc,in)\varepsilon =
\frac{Q_{\text{actual}}}{Q_{\text{max}}}, \quad \text{NTU} = \frac{UA}{C_{\min}}, \quad
Q_{\text{max}} = C_{\min} (T_{h,\text{in}} - T_{c,\text{in}})ε=QmaxQactual,NTU=Cmin
UA,Qmax=Cmin(Th,in−Tc,in)

Used when outlet temperatures are unknown.

4. Overall Heat Transfer Coefficient

1U=1hi+twkw+1ho\frac{1}{U} = \frac{1}{h_i} + \frac{t_w}{k_w} + \frac{1}{h_o}U1=hi1+kw

tw+ho1

Accounts for convection and conduction resistances.

5. Heat Capacity Rate

C=m˙⋅cpC = \dot{m} \cdot c_pC=m˙⋅cp

Used to find Cmin⁡C_{\min}Cmin and Cmax⁡C_{\max}Cmax in NTU method