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Heat Exchanger 1

This report provides a comprehensive overview of heat exchangers, detailing their types, applications, and key thermal equations essential for design and performance analysis. Heat exchangers are crucial in various industries such as power generation, HVAC, food processing, and automotive for efficient thermal energy transfer. The document emphasizes the importance of heat exchangers in enhancing energy efficiency and optimizing industrial processes.

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10 views

Heat Exchanger 1

This report provides a comprehensive overview of heat exchangers, detailing their types, applications, and key thermal equations essential for design and performance analysis. Heat exchangers are crucial in various industries such as power generation, HVAC, food processing, and automotive for efficient thermal energy transfer. The document emphasizes the importance of heat exchangers in enhancing energy efficiency and optimizing industrial processes.

Uploaded by

ahmedkahttouni
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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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.

Heat Exchanger Equations

1. Parallel Flow Heat Exchanger


Both hot and cold fluids enter the exchanger from the same side and flow in
the same direction.

Q = ṁₕ · cₚ,ₕ · (Tₕ,in - Tₕ,out) = ṁ𝚌 · cₚ, 𝚌 · (T 𝚌,out - T 𝚌,in)

ΔTlm = [(Tₕ,in - T𝚌,in) - (Tₕ,out - T𝚌,out)] / ln[(Tₕ,in - T 𝚌,in) / (Tₕ,out - T 𝚌,out)]

Q = U · A · ΔTlm
ε = [1 - exp(-NTU(1 + Cr))] / (1 + Cr)

2. Counter Flow Heat Exchanger


Hot and cold fluids enter from opposite ends and flow in opposite directions.

ΔTlm = [(Tₕ,in - T𝚌,out) - (Tₕ,out - T𝚌,in)] / ln[(Tₕ,in - T 𝚌,out) / (Tₕ,out - T 𝚌,in)]

Q = U · A · ΔTlm

ε = [1 - exp(-NTU(1 - Cr))] / [1 - Cr · exp(-NTU(1 - Cr))]

Cr = Cmin / Cmax, NTU = U · A / Cmin

3. Cross Flow Heat Exchanger


Fluids flow perpendicular to each other (used in air coolers, radiators, etc.).

Q = U · A · F · ΔTlm

LMTD: Use parallel or counter flow formula, then multiply by correction factor
F.

Effectiveness depends on whether flows are mixed or unmixed.

4. Shell and Tube Heat Exchanger


One fluid flows through tubes, another in the shell around the tubes.

Q = U · A · F · ΔTlm

LMTD and effectiveness are adjusted using correction charts based on shell
configuration.

5. Plate Heat Exchanger


Multiple thin plates create flow channels, similar to multiple counter-flow
heat exchangers.

Q = U · A · ΔTlm

LMTD: Same as counter-flow.

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