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A process fluid having a specific heat of \(3500 \mathrm{~J} / \mathrm{kg} \cdot \mathrm{K}\) and flowing at \(2 \mathrm{~kg} / \mathrm{s}\) is to be cooled from \(80^{\circ} \mathrm{C}\) to \(50^{\circ} \mathrm{C}\) with chilled water, which is supplied at a temperature of \(15^{\circ} \mathrm{C}\) and a flow rate of \(2.5 \mathrm{~kg} / \mathrm{s}\). Assuming an overall heat transfer coefficient of \(2000 \mathrm{~W} / \mathrm{m}^{2} \cdot \mathrm{K}\), calculate the required heat transfer areas for the following exchanger configurations: (a) parallel flow, (b) counterflow, (c) shell-and-tube, one shell pass and two tube passes, and (d) cross-flow, single pass, both fluids unmixed. Compare the results of your analysis. Your work can be reduced by using IHT.

Short Answer

Expert verified
The required heat transfer areas for the different exchanger configurations are as follows: 1. Parallel flow: 2.47 m² 2. Counterflow: 1.57 m² 3. Shell-and-tube, one shell pass and two tube passes: 1.57 m² 4. Cross-flow, single pass, both fluids unmixed: 1.92 m² The counterflow and shell-and-tube configurations require the least heat transfer area, making them more efficient choices for this cooling process.

Step by step solution

01

(Step 1: Calculate the heat transfer rate)

(First, we need to find the heat transfer rate for cooling the process fluid. To do this, we will use the formula: $$Q = m_c \times C_{p,c} \times (T_{c1} - T_{c2})$$, where \(m_c\) is the mass flow rate of the process fluid, \(C_{p,c}\) is its specific heat, and \(T_{c1}\) and \(T_{c2}\) are its initial and final temperatures, respectively.) Given: - \(m_c = 2 \frac{\text{kg}}{\text{s}}\) - \(C_{p,c} = 3500 \frac{\text{J}}{\text{kg} \cdot \text{K}}\) - \(T_{c1} = 80^{\circ} \text{C}\) - \(T_{c2} = 50^{\circ} \text{C}\) Using these values, we can calculate the heat transfer rate: $$Q = 2 \cdot 3500 \cdot (80 - 50) = 210000 \ \text{W}$$
02

(Step 2: Determine the log mean temperature difference (LMTD) for each configuration)

(To compute the LMTD for each configuration, we will use the equations established for parallel flow, counterflow, shell-and-tube, and cross-flow exchangers. For each configuration, we need to determine the inlet and outlet temperatures of the hot and cold fluids, and then calculate the LMTD using the respective formula.) For all configurations, the inlet temperature of the process fluid (hot fluid) and chilled water (cold fluid) are the same: - \(T_{h1} = 80^{\circ} \text{C}\) - \(T_{c1} = 15^{\circ} \text{C}\) Since we know that the outlet temperature of the process fluid is \(50^{\circ} \text{C}\), we can determine the outlet temperature of the chilled water using the energy balance equation: $$Q = m_w \times C_{p,w} \times (T_{w2} - T_{w1})$$, where \(m_w\) is the mass flow rate of the chilled water, \(C_{p,w}\) is its specific heat (assumed to be \(4180 \frac{\text{J}}{\text{kg} \cdot \text{K}}\) for water), and \(T_{w1}\) and \(T_{w2}\) are its inlet and outlet temperatures, respectively. Given: - \(m_w = 2.5 \frac{\text{kg}}{\text{s}}\) - \(C_{p,w} = 4180 \frac{\text{J}}{\text{kg} \cdot \text{K}}\) - \(T_{w1} = 15^{\circ} \text{C}\) We can solve for \(T_{w2}\): $$T_{w2} = \frac{Q}{m_w \times C_{p,w}} + T_{w1} = \frac{210000}{2.5 \times 4180} + 15 \approx 35.4^{\circ} \text{C}$$ Now, we can calculate the LMTD for each configuration. 1. Parallel flow: $$\text{LMTD}_{\text{parallel}} = \frac{(80 - 15) - (50 - 35.4)}{\ln \frac{80 - 15}{50 - 35.4}} \approx 42.51 \ \text{K}$$ 2. Counterflow: $$\text{LMTD}_{\text{counter}} = \frac{(80 - 35.4) - (50 - 15)}{\ln \frac{80 - 35.4}{50 - 15}} \approx 66.75 \ \text{K}$$ 3. Shell-and-tube, one shell pass and two tube passes: For this configuration, we will assume the LMTD to be the same as that for the counterflow. 4. Cross-flow, single pass, both fluids unmixed: For this configuration, we can assume the LMTD based on the arithmetic mean of the temperature differences: $$\text{LMTD}_{\text{cross}} \approx \frac{1}{2}[(80 - 15) + (80 - 35.4)] \approx 54.8 \ \text{K}$$
03

(Step 3: Calculate the required heat transfer area for each configuration)

(Now that we have the LMTD for each configuration, we can use the heat exchanger equation to find the required heat transfer area: $$A = \frac{Q}{U \times \text{LMTD}}$$, where \(A\) is the heat transfer area and \(U\) is the overall heat transfer coefficient.) Given: - \(U = 2000 \frac{\text{W}}{\text{m}^2 \cdot \text{K}}\) We can now calculate the required heat transfer area for each configuration: 1. Parallel flow: $$A_{\text{parallel}} = \frac{210000}{2000 \times 42.51} \approx 2.47 \ \text{m}^2$$ 2. Counterflow: $$A_{\text{counter}} = \frac{210000}{2000 \times 66.75} \approx 1.57 \ \text{m}^2$$ 3. Shell-and-tube, one shell pass and two tube passes: $$A_{\text{shell-tube}} \approx A_{\text{counter}} = 1.57 \ \text{m}^2$$ 4. Cross-flow, single pass, both fluids unmixed: $$A_{\text{cross}} = \frac{210000}{2000 \times 54.8} \approx 1.92 \ \text{m}^2$$
04

(Conclusion)

(Based on the analysis, the required heat transfer areas for the different exchanger configurations are as follows: 1. Parallel flow: 2.47 m² 2. Counterflow: 1.57 m² 3. Shell-and-tube, one shell pass and two tube passes: 1.57 m² 4. Cross-flow, single pass, both fluids unmixed: 1.92 m² The counterflow and shell-and-tube configurations require the least heat transfer area, making them more efficient choices for this cooling process.)

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Key Concepts

These are the key concepts you need to understand to accurately answer the question.

Log Mean Temperature Difference (LMTD)
The Log Mean Temperature Difference, or LMTD, is a critical concept in the study of heat exchangers. It defines the average temperature difference between the hot and cold fluids across the heat exchanger. Understanding LMTD is essential because it directly correlates to the efficiency of heat transfer within the system. To calculate the LMTD, engineers use a specific formula that takes into account the fluid temperatures entering and exiting the heat exchanger.

For configurations like parallel flow and counterflow, the formula takes the form \[LMTD = \frac{(\Delta T_1 - \Delta T_2)}{\ln(\frac{\Delta T_1}{\Delta T_2})}\] where \(\Delta T_1\) and \(\Delta T_2\) are the temperature differences between the fluids at each end of the heat exchanger. The logarithmic function is used here to ensure that we achieve an average that is representative of the changing temperature difference along the heat exchanger. Variations in these calculations occur due to different configurations, such as cross-flow or shell-and-tube, which may necessitate alternative approaches or assumptions to approximate the LMTD.

When tasked with solving heat transfer problems, it's paramount to carefully determine the LMTD as it directly impacts the calculation of required surface area for a specific heat transfer rate. Understanding the nuances of each configuration aids in only the most accurate determination of this value.
Overall Heat Transfer Coefficient
In the realm of thermal management, the overall heat transfer coefficient, denoted by \(U\), embodies the measure of a heat exchanger's ability to transfer heat between two fluids separated by a solid barrier. This coefficient is influenced by various factors, including material properties, surface roughness, and fluid flow rates.

The equation \[Q = U \times A \times LMTD\] pinpoints the relationship between the heat transfer rate \(Q\), the heat transfer area \(A\), and the LMTD. This relationship signifies how effectively the heat exchanger can move thermal energy. A high \(U\) value translates to a more efficient exchange of heat, allowing for a smaller area of the heat exchanger to accomplish the required rate of heat transfer.

Factors Affecting \(U\)

  • Material Conductivity: Materials with high thermal conductivity can transfer heat more rapidly, resulting in a higher \(U\).
  • Thickness of the Heat Exchanger Wall: Thinner walls typically lead to a higher \(U\), given less resistance to heat flow.
  • Fouling: The accumulation of deposits on heat exchanger surfaces can decrease \(U\) over time.
Considering these variables is essential in the design phase of heat exchangers to ensure they meet the required heat transfer specifications.
Heat Exchanger Configurations
Heat exchangers come in various configurations, each with its design tailored to certain applications, efficiency levels, and spatial constraints. The most common configurations include parallel-flow, counterflow, shell-and-tube, and cross-flow designs.

In parallel-flow heat exchangers, the hot and cold fluids move in the same direction, passing parallel to each other. Although the setup is simple, this configuration might not facilitate the most efficient heat transfer.

Counterflow heat exchangers, on the other hand, have fluids moving in opposite directions. This method usually provides a higher heat transfer efficiency than parallel-flow, making it a preferred design in many industrial applications.

Complex Configurations for Enhanced Efficiency

The shell-and-tube and cross-flow configurations represent more complex designs. Shell-and-tube exchangers house one fluid within a series of tubes, while the second fluid flows around the tubes within a larger shell. This arrangement allows for high pressures and offers the ability to manage large temperature differentials.

Cross-flow heat exchangers allow the two fluids to cross paths perpendicularly, often employed when space constraints are an issue or when the fluids have vastly different flow rates or temperatures.

Each configuration bears its merits and demerits concerning heat transfer efficiency, pressure drop, and maintenance. By analyzing and comparing the various configurations, engineers can select the appropriate type for a given application to ensure optimal performance and cost-efficiency.

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Most popular questions from this chapter

Hot air for a large-scale drying operation is to be produced by routing the air over a tube bank (unmixed), while products of combustion are routed through the tubes. The surface area of the cross-flow heat exchanger is \(A=25 \mathrm{~m}^{2}\), and for the proposed operating conditions, the manufacturer specifies an overall heat transfer coefficient of \(U=35 \mathrm{~W} / \mathrm{m}^{2} \cdot \mathrm{K}\). The air and the combustion gases may each be assumed to have a specific heat of \(c_{p}=1040 \mathrm{~J} / \mathrm{kg} \cdot \mathrm{K}\). Consider conditions for which combustion gases flowing at \(1 \mathrm{~kg} / \mathrm{s}\) enter the heat exchanger at \(800 \mathrm{~K}\), while air at \(5 \mathrm{~kg} / \mathrm{s}\) has an inlet temperature of \(300 \mathrm{~K}\). (a) What are the air and gas outlet temperatures? (b) After extended operation, deposits on the inner tube surfaces are expected to provide a fouling resistance of \(R_{f}^{N}=0.004 \mathrm{~m}^{2} \cdot \mathrm{K} / \mathrm{W}\). Should operation be suspended in order to clean the tubes? (c) The heat exchanger performance may be improved by increasing the surface area and/or the overall heat transfer coefficient. Explore the effect of such changes on the air outlet temperature for \(500 \leq U A \leq 2500 \mathrm{~W} / \mathrm{K}\).

For health reasons, public spaces require the continuous exchange of a specified mass of stale indoor air with fresh outdoor air. To conserve energy during the heating season, it is expedient to recover the thermal energy in the exhausted, warm indoor air and transfer it to the incoming, cold fresh air. A coupled singlepass, cross-flow heat exchanger with both fluids unmixed is installed in the intake and return ducts of a heating system as shown in the schematic. Water containing an anti-freeze agent is used as the working fluid in the coupled heat exchange device, which is composed of individual heat exchangers \(A\) and B. Hence, heat is transferred from the warm stale air to the cold fresh air by way of the pumped water. Consider a specified air mass flow rate (in each duct) of \(m=1.50 \mathrm{~kg} / \mathrm{s}\), an overall heat transfer coefficient-area product of \(U A=2500 \mathrm{~W} / \mathrm{K}\) (for each heat exchanger), an outdoor temperature of \(T_{c, i, A}=-4^{\circ} \mathrm{C}\) and an indoor temperature of \(T_{h, i, B}=\) \(23^{\circ} \mathrm{C}\). Since the warm air has been humidified, excessive heat transfer can result in unwanted condensation in the ductwork. What water flow rate is necessary to maximize heat transfer while ensuring the outlet temperature associated with heat exchanger \(\mathrm{B}\) does not fall below the dew point temperature, \(T_{h, 0, B}=T_{\mathrm{dp}}=\) \(13^{\circ} \mathrm{C}\) ? Hint: Assume the maximum heat capacity rate is associated with the air.

A two-fluid heat exchanger has inlet and outlet temperatures of 65 and \(40^{\circ} \mathrm{C}\) for the hot fluid and 15 and \(30^{\circ} \mathrm{C}\) for the cold fluid. Can you tell whether this exchanger is operating under counterflow or parallelflow conditions? Determine the effectiveness of the heat exchanger.

Consider a concentric tube heat exchanger characterized by a uniform overall heat transfer coefficient and operating under the following conditions: \begin{tabular}{lccrc} \hline & \(\dot{m}\) \((\mathbf{k g} / \mathbf{s})\) & \(c_{p}\) \((\mathbf{J} / \mathbf{k g} \cdot \mathbf{K})\) & \(T_{i}\) \((\boldsymbol{C})\) & \(T_{o}\) \((\mathbf{C})\) \\ \hline Cold fluid & \(0.125\) & 4200 & 40 & 95 \\ Hot fluid & \(0.125\) & 2100 & 210 & \(-\) \\ \hline \end{tabular} What is the maximum possible heat transfer rate? What is the heat exchanger effectiveness? Should the heat exchanger be operated in parallel flow or in counterflow? What is the ratio of the required areas for these two flow conditions?

A single-pass, cross-flow heat exchanger with both fluids unmixed is being used to heat water \(\left(m_{c}=2 \mathrm{~kg} / \mathrm{s}\right.\), \(c_{p}=4200 \mathrm{~J} / \mathrm{kg} \cdot \mathrm{K}\) ) from \(20^{\circ} \mathrm{C}\) to \(100^{\circ} \mathrm{C}\) with hot exhaust gases \(\left(c_{p}=1200 \mathrm{~J} / \mathrm{kg} \cdot \mathrm{K}\right)\) entering at \(320^{\circ} \mathrm{C}\). What mass flow rate of exhaust gases is required? Assume that UA is equal to its design value of \(4700 \mathrm{~W} / \mathrm{K}\), independent of the gas mass flow rate.

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