King Abdulaziz University

Mechanical Engineering Department

MEP 460 Heat Exchanger design

Ch. 10 Compact Heat Exchangers

March 2019
 Ch. 10 Compact Heat Exchangers

1-Introduction
2-Tube-fin heat exchangers
3-Plate-fin heat exchangers
4-Examples
1- Introduction
Compact heat exchangers
Surface heat transfer area over volume 𝛼
Tube fin compact heat exchangers
Tube fin compact heat exchangers
Non-circular tubes
 2- Tube fin heat exchangers

continuous fins on Continuous fins Circular fins on

flat tubes on circular tube circular tubes
Heat transfer and pressure drop for tube
fin heat exchangers
1 1 𝑅𝑓𝑖 𝑅𝑓𝑜 1
= + + 𝑅𝑤 + +
𝑈𝑜 𝐴𝑜 ℎ𝑖 𝜂𝑖 𝐴𝑖 𝜂𝑖 𝐴𝑖 𝜂𝑜 𝐴𝑜 ℎ𝑜 𝜂𝑜 𝐴𝑜

Overall surface efficiency 𝜂𝑜

𝐴𝑓
𝜂𝑜 = 1 − (1 − 𝜂𝑓 )
𝐴
𝜂𝑓 is the fin efficiency

For ho outside (gas) heat transfer coefficient use Kays &

London book in compact heat exchangers
 Definitions
Frontal area Afr
Free Flow area Amin= Aff
𝐹𝑟𝑒𝑒 𝑓𝑙𝑜𝑤 𝑎𝑟𝑒𝑎 𝐴𝑓𝑓
𝜎= =
𝐹𝑟𝑜𝑛𝑡𝑎𝑙 𝑎𝑟𝑒𝑎 𝐴𝑓𝑟

Fin area/total area=Af/Ao

𝛼 = Surface area/Volume

Hydraulic diameter Dh

Mass velocity G=umax

 Definitions

Colburn jH factor 𝑗𝐻 = 𝑆𝑡𝑃𝑟 2Τ3 𝑅𝑒 = 𝐺𝐷ℎ /𝜇

𝑁𝑢 ℎ ℎ
Stanton Number 𝑆𝑡 = = =
𝑅𝑒 𝑃𝑟 𝜌𝐶𝑝 𝑉𝑚𝑎𝑥 𝐶𝑝 𝐺

𝜌𝑉𝐴𝑓𝑟 𝑚ሶ 𝑚ሶ
Mass velocity [kg/(m2.s) 𝐺 = 𝜌𝑉𝑚𝑎𝑥 =
𝐴𝑓𝑓
= =
𝐴𝑓𝑓 𝜎𝐴𝑓𝑟

Major Pressure drop

𝐿 𝑉2
Friction coefficient f Δ𝑃 = 𝑓 𝜌
𝐷 2
 Pressure drop gas side

A: heat transfer area 𝑣𝑖 + 𝑣𝑜

𝑣𝑚 =
Afr Frontal area 2
Aff Free flow area 𝐴 𝛼𝑉
=
𝐴𝑓𝑓 𝜎𝐴𝑓𝑟
𝑣𝑖 specifc volume at inlet
𝑣𝑜 specific volume at outlet
𝑣𝑖 +𝑣𝑜 𝐹𝑖𝑛 𝑎𝑟𝑒𝑎 𝐴𝑓
𝑣𝑚 mean specific volume = 𝜎= =
2 𝑇𝑜𝑡𝑎𝑙 𝑎𝑟𝑒𝑎 𝐴
The above equation for pressure drop can be also written in 𝐴
terms of densities instead of specific volume 𝛼=
𝑉
From Incropera
6th edition
Surface information(CF-7.0-5/8J)

Circular fin on circular tubes

Typical data for tube fin heat exchangers (8.0-3/8T)

Continuous fin on circular tubes

Surface information

Hydraulic
diameter Dh

𝐹𝑟𝑒𝑒 𝑓𝑙𝑜𝑤 𝑎𝑟𝑒𝑎 𝐴𝑓𝑓

𝜎= =
𝐹𝑟𝑜𝑛𝑡𝑎𝑙 𝑎𝑟𝑒𝑎 𝐴𝑓𝑟
𝐴
Surface density 𝛼=𝛽=
𝑉

𝐹𝑖𝑛 𝑎𝑟𝑒𝑎 𝐴𝑓
=
𝑇𝑜𝑡𝑎𝑙 𝑎𝑟𝑒𝑎 𝐴
Surface information
Evaluating overall heat transfer coefficient

1 1 𝑅𝑓𝑖 𝑅𝑓𝑜 1
= + + 𝑅𝑤 + +
𝑈𝑜 𝐴𝑜 ℎ𝑖 𝜂𝑖 𝐴𝑖 𝜂𝑖 𝐴𝑖 𝜂𝑜 𝐴𝑜 ℎ𝑜 𝜂𝑜 𝐴𝑜
ln(𝑟𝑜 Τ𝑟𝑖 )
𝑅𝑤 =
2𝜋𝑘𝐿
Neglecting fouling resistances

1 1 𝐴𝑜 𝑙𝑛(𝑟𝑜 Τ𝑟𝑖 ) 1
= + +
Τ
𝑈𝑜 ℎ𝑖 (𝐴𝑖 𝐴𝑜 ) 2𝜋𝑘𝐿 ℎ𝑜 𝜂𝑜
1 1 𝐷𝑖 𝑙𝑛(𝑟𝑜 Τ𝑟𝑖 ) 1
= + +
𝑈𝑜 ℎ𝑖 (𝐴𝑖 Τ𝐴𝑜 ) 2𝑘 (𝐴𝑖 Τ𝐴𝑜 ) ℎ𝑜 𝜂𝑜

Need to know the heat transfer area ratio Ai/Ao

 Ratio of inside to outside heat transfer area
𝐴𝑖 = 𝜋𝐷𝑖 𝐿 Inside heat transfer area

𝐴𝑜,𝑝 = 𝜋𝐷𝑜 𝐿 Outside heat transfer area

without fins
𝐴𝑖 𝐷𝑖
=
𝐴𝑜,𝑝 𝐷𝑜
𝐷𝑖 Di Do
𝐴𝑖 = 𝐴𝑜,𝑝
𝐷𝑜

𝐴𝑜 = 𝐴𝑢𝑓 + 𝐴𝑓 = 𝐴𝑜,𝑝 + 𝐴𝑓

Neglecting the area occupied by Fins

fins. i.e. Auf=Aop
𝐴𝑖 𝐷𝑖 𝐴𝑓
𝐴𝑜,𝑝 = 𝐴𝑜 − 𝐴𝑓 = ∗ 1−
𝐴𝑜 𝐷𝑜 𝐴𝑜
 Example 11.6
 hi is given
 From frontal area Afr,  and mass flow rate get G and
ReDh
 Get j from Kays & London graphs and ho
 Get fin efficiency for circular fins on circular pipe
 Get Uo value
 Knowing q and qmax get the effectiveness 
 Knowing Cr and the effectiveness  get NTU
 From NTU=UA/Cmin calculate the heat transfer area Ao
 Calculate the volume of the heat exchanger using𝛼 =
𝐴𝑜
𝛽=
𝑉
 Get the depth of the heat exchanger L form V=AfrL
 Calculate the number of rows of tubes
Surface: 8.0-3/8 T

Continuous fins
on circular tubes
Surface CF-8.72(c)

Circular fins on
circular tubes
 CF-8.7-5/8J

Circular fin on
circular tubes
Heat transfer
factor j and friction
coefficient f for
some tube-fin and
plate- fin surface

Ref.: Kays & London

Continuous fin
with flat tube
Some of the data for plate-fin and tube fin
compact heat exchangers
 Pressure drop (Gas side)
𝐺2 𝐿 𝜌𝑖 𝜌𝑖
Δ𝑝 = 4𝑓 + 1 + 𝜎2 −1
2𝜌𝑖 𝐷ℎ 𝜌 𝜌𝑜

𝐴 4𝐿 ℎ𝑒𝑎𝑡 𝑡𝑟𝑎𝑛𝑠𝑓𝑒𝑟 𝑎𝑟𝑒𝑎

= =
𝐴𝑚 𝐷ℎ 𝑚𝑖𝑛. 𝑓𝑙𝑜𝑤 𝑎𝑟𝑒𝑎

𝐺2 𝐴 𝜌𝑖 𝜌𝑖
Δ𝑝 = 𝑓 + 1 + 𝜎2 −1
2𝜌𝑖 𝐴𝑚𝑖𝑛 𝜌 𝜌𝑜

4𝐴𝑚𝑖𝑛 𝐿 𝐴𝑚𝑖𝑛 𝐿 𝐴 4𝐿
𝐷ℎ = =4 =
𝑃 𝐿 𝐴 𝐴𝑚𝑖𝑛 𝐷ℎ

L
A=heat transfer area=P*L
A =heat transfer
area
Dh= 4Amin/P
P=perimeter

Amin min. flow area

3- Plat fin compact heat exchangers
Kays & London heat transfer and pressure drop
data for plate-fin and tube-fin heat exchangers
Ch. 9
 Plain fins

Ch. 9 Kays & London

 Strip fins

Ch. 9 Kays & London

 Louvered fins

Ch. 9 Kays & London

Ch. 9 Kays & London
Circular tubes, continuous fins

Flat tubes continuous fins

Ch. 9 Kays & London

Circular tubes- circular fins

Ch. 9 Kays & London

Flow inside circular and flattened tubes

Ch. 9 Kays & London

 Pressure drop for plat-fin heat
exchanger

𝐺2 𝜌𝑖 𝐴 𝜌𝑖 𝜌𝑖
Δ𝑝 = 𝑘𝑐 + 1 − 𝜎 + 2 −1 +𝑓 − 1 − 𝑘𝑒 − 𝜎 2
2𝜌𝑖 𝜌𝑜 𝐴𝑚𝑖𝑛 𝜌 𝜌𝑜

Friction
Entrance Exit
Acceleration Major loss

Average density can be found using

1 1 1 1
= +
𝜌 2 𝜌𝑖 𝜌𝑜
Typical data for plate-fin compact heat exchanger
Surface tabulated data for plate-fin compact heat
exchangers
 Plate-fin compact heat exchanger (Gas-to-Gas HX)
Calculate
1-Number of passes Np L2
2-Calculate volume between plates for L1
side 1 and side 2
3-Calculate heat transfer area A1, and A2
4-Calculate Amin1, Amin2 Afr2
5-Calculate G1, and G2 L3
6-Get j1,j2, f1, f2 Afr1 Air
7-Calculate h1 and h2 Gas
8-Calculate ηf1, ηf2, η01,η02
9-Calculate U value
10-Calculate Cr and NTU,
then get  Surface 2
Surface 1
11-Calculate outlet temperatures Hydaulic diameter Dh2
12-Calculate pressure drops Hydaulic diameter Dh1 Plate spacing b2
for both sides Plate spacing b1
Fin thickness 𝛿𝑓2
Fin thickness 𝛿𝑓1
Area/ volume between plate, 𝛽2
Area/ volume between plate, 𝛽1
Fin area/heat transfer area, 𝜔2
Fin area/heat transfer area, 𝜔1
Length of the fin, 𝑙𝑓2
Length of the fin, 𝑙𝑓1
1=A1/V
2 =A2/V
 Calculating the heat transfer areas for side (1)
and side (2)

Assuming the number of passes in one side is Np and Np+1 on the other side,
then the common edge length can be written in terms the pate spacing's b1,
b2 and the plate thickness a as follows

𝐿𝑐 = 𝑁𝑝 𝑏1 + 𝑁𝑝 + 1 𝑏2 + 2 𝑁𝑝 + 1 𝑎

𝐿𝑐 − 𝑏2 − 2𝑎
𝑁𝑝 =
𝑏1 + 𝑏2 + 2𝑎

Volume between the plates for side (1) and side (2)

𝑉𝑝1 = 𝐿1 ∗ 𝐿2 ∗ 𝑁𝑝 ∗ 𝑏1 𝑉𝑝2 = 𝐿1 ∗ 𝐿2 ∗ 𝑁𝑝 ∗ 𝑏2
Utilizing the relation between  and the volume between the plates

𝐴1 𝐴2
𝛽1 = 𝛽2 =
𝑉𝑝1 𝑉𝑝2
 If 1 and 2 are calculated based on b1, b2 a,
and  , then one can easily find the heat
transfer areas A1 and A2

𝐴1 𝐴2
𝛼1 = 𝛼2 =
𝑉 𝑉

Where V is the total volume of the heat exchanger

 Deducing the relation for 1 and 2
𝑚𝑖𝑛. 𝑓𝑙𝑜𝑤 𝑎𝑟𝑒𝑎 𝑉 = 𝑉𝑜𝑙𝑢𝑚𝑒 𝑜𝑓 𝑡ℎ𝑒 ℎ𝑒𝑎𝑡 𝑒𝑥𝑐ℎ𝑎𝑛𝑔𝑒𝑟
𝜎1 =
𝑓𝑟𝑜𝑛𝑡𝑎𝑙 𝑎𝑟𝑒𝑎
𝐴𝑚𝑖𝑛,1 𝐴𝑚𝑖𝑛,1 𝐿𝑝1 𝐴1 𝐷ℎ,1 Τ4 𝑉1 𝛽1 𝐷ℎ,1 Τ4 4𝐴𝑚𝑖𝑛 𝐿 𝐴𝑚𝑖𝑛 𝐿
𝜎1 = = = = 𝐷ℎ = =4
𝐴𝑓𝑟,1 𝐴𝑓𝑟,1 𝐿𝑝,1 𝑉 𝑉 𝑃 𝐿 𝐴

ℎ𝑒𝑎𝑡 𝑡𝑟𝑎𝑛𝑠𝑓𝑒𝑟 𝑎𝑟𝑒𝑎

𝛽= 𝐿𝑝1 𝑓𝑙𝑜𝑤 𝑝𝑎𝑠𝑠𝑎𝑔𝑒 𝑙𝑒𝑛𝑔𝑡ℎ 𝑓𝑜𝑟 𝑠𝑖𝑑𝑒 (1)
𝑉𝑜𝑙𝑢𝑚𝑒 𝑏𝑒𝑡𝑤𝑒𝑒𝑛 𝑡ℎ𝑒 𝑝𝑙𝑎𝑡𝑒𝑠

𝑉 = 𝐿1 ∗ 𝐿2 [𝑏1 𝑁𝑝 + 𝑏2 (𝑁𝑝 +1) + 2𝑎 ∗ (𝑁𝑝 + 1)]

𝑉1 𝛽1 𝐷ℎ,1 Τ4 𝐿1 ∗ 𝐿2 ∗ 𝑏1 ∗ 𝑁𝑝 ∗ 𝛽1 𝐷ℎ,1 Τ4
𝜎1 = =
𝐿1 ∗ 𝐿2 [𝑏1 𝑁𝑝 + 𝑏2 (𝑁𝑝 +1) + 2𝑎 ∗ (𝑁𝑝 + 1)] 𝐿1 ∗ 𝐿2 [𝑏1 𝑁𝑝 + 𝑏2 (𝑁𝑝 +1) + 2𝑎 ∗ (𝑁𝑝 + 1)]

𝑏1 𝛽1 𝐷ℎ,1 Τ4
𝜎1 = 𝑏1 𝑏2 𝑎𝑟𝑒 𝑡ℎ𝑒 𝑝𝑙𝑎𝑡𝑒 𝑠𝑝𝑎𝑐𝑖𝑛𝑔
𝑏1 + 𝑏2 + 2𝑎
𝑓𝑜𝑟 𝑠𝑖𝑑𝑒 1 𝑎𝑛𝑑 𝑠𝑖𝑑𝑒 2

𝐴1 𝐴1 𝐴1 Τ𝐿1 4 𝐴𝑚𝑖𝑛,1 Τ𝐷ℎ,1 4𝜎1 𝑏1 𝛽1

𝛼1 = = = = = =
𝑉 𝐴𝑓𝑟,1 𝐿1 𝐴𝑓𝑟,1 𝐴𝑓𝑟,1 𝐷ℎ,1 𝑏1 + 𝑏2 + 2𝑎

𝑁𝑝 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑝𝑎𝑠𝑠𝑒𝑠
 For side 2

𝑏2 𝛽2 𝐷ℎ,2 Τ4
𝜎2 =
𝑏1 + 𝑏2 + 2𝑎

𝐴2 𝐴2 𝐴2 Τ𝐿2 4 𝐴𝑚𝑖𝑛,2 Τ𝐷ℎ,2 4𝜎2 𝑏2 𝛽2

𝛼2 = = = = = =
𝑉 𝐴𝑓𝑟,2 𝐿2 𝐴𝑓𝑟,2 𝐴𝑓𝑟,2 𝐷ℎ,2 𝑏1 + 𝑏2 + 2𝑎

𝑏1 𝑏2 𝑎𝑟𝑒 𝑡ℎ𝑒 𝑝𝑙𝑎𝑡𝑒 𝑠𝑝𝑎𝑐𝑖𝑛𝑔

𝑓𝑜𝑟 𝑠𝑖𝑑𝑒 1 𝑎𝑛𝑑 𝑠𝑖𝑑𝑒 2

𝑁𝑝 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑝𝑎𝑠𝑠𝑒𝑠
Overall heat transfer for plate-fin heat exchanger
1 1 1
= + 𝑅𝑤 +
𝑈1 𝐴1 ℎ1 𝐴1 𝜂01 ℎ2 𝐴2 𝜂02

𝑎
𝐴𝑤 = 𝐿1 𝐿2 ∗ 2(𝑁𝑝 + 1) 𝑅𝑤 = Conduction resistance
𝑘𝑤 𝐴𝑤

𝐴𝑓1
𝜂01 = 1 − (1 − 𝜂𝑓1 )
𝐴1
𝐴𝑓2
𝜂02 = 1 − (1 − 𝜂𝑓2 )
𝐴2

tanh(𝑀𝑙𝑓 ) 2ℎ 𝑙𝑓 is the length of the fin

𝜂𝑓 = 𝑀=
𝑀𝑙𝑓 𝑘𝑓 𝛿𝑓 𝛿𝑓 is the fin thickness
 Some types of plate fin Compact HX

a) Plain triangular fin c) Wavy fin

b) Plain rectangular fin
d) Offset strip fin e) multi-louver fin f) Perforated fin
Fin types for plate fin compact heat exchanger
4-Examples
 Air at p=1 atm
T=400 K
U=10 m/s

Find h and Dp
Example 10.1
Example 10.1
 Air at p=2 atm
T=500 K
U=20 m/s

Find h and Dp
Example 10.2
Example 10.2
 To=100 C

Air at p=1 atm

T=30 C
m=1500 kg/s
Afr=0.25 m2

Find h and Dp
Example 10.3
Example 10.3