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Fundamentals of Heat Transfer Theory

Three basic natural laws of physics:
1. Heat will always be transferred from a hot medium to a cold medium, until equilibrium is reached.

2. There must be a temperature difference between the two media for heat transfer to take place.

3. The heat lost by the hot medium is equal to the amount of heat gained by the cold medium, except for losses to the surroundings.

Q1 = Q2
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Modes of Heat Transfer

Three modes:
Radiation = Electromagnetic waves

Conduction = Molecular or atomic vibrations

Convection = Transport of small mass elements

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Modes of Heat Transfer

A sunny but windy day on the beach!

Radiation Convection

Conduction
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Which heat transfer mode is important in heat exchangers?

Radiation?
- Insignificant

Conduction? - Interesting! Convection? - The most effective way of heat transfer!

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Two heat exchanger types

Direct
Principle: Product and service medium are in direct contact Example: Water and air in a cooling tower

Indirect
Principle: Product and service medium are separated by a wall Example: Hot water and product in a plate heat exchanger
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Flow Principles: Laminar

Flow profile
Parabolic velocity profile:

Velocity profile

friction close to wall -> lower velocity centre of tube -> higher velocity

Low velocity and low Reynolds number -> low pressure drop Distinct parallel fluid layers -> no mixing between layers Only conduction -> poor heat transfer efficiency

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Flow principles
Two types of flow
Turbulent
Convection Flow profile
No orderly flow Random eddy motion mixes the fluid Always a laminar film closest to the wall Ex., water at higher velocity

Conduction

Velocity profile

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Heat Transfer Equations

T2out

Q = m * Cp * (Tin - Tout) Qhot = Qcold

m2, T2in, Cp2 T1out
Q = rate of heat transfer or heat load, W m = mass flow rate, kg / s Cp = specific heat (amount of heat required to heat 1 kg of the media 1C), J / kg / C Tin = inlet temperature, C Tout = outlet temperature, C

m1, T1in, Cp1

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Calculation Example
What is the cold fluid outlet temperature?
T2 out= XXC ?

m2= 120 kg/s T2in= 20 C Cp2= 4.2 kJ/(kg C) T1out= 40 C

m1 = 100 kg/s T1in= 80 C Cp1= 4.0 kJ/(kg C)

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Heat Transfer Equations

Q = A * k * LMTD
k = overall heat transfer coefficient, W / m2,C A = heat transfer surface area, m2 LMTD = Log Mean Temperature Difference, C

Temperature difference is driving force for heat transfer!

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Q = k * A * LMTD

Heat Transfer Area

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Q = k * A * LMTD
LMTD = Logarithmic mean temperature difference
Depend on counter-current or co-current flow
Counter-Current Flow T1 in
(1 T2 out

Co-Current Flow T1 in
(1

T1 out (2 T2 in Area

T2 in Area

T1 out (2 T2 out

LMTD!

(1 (2 (1 ln (2
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Q = k * A * LMTD - calculation
What is the LMTD for the two cases below?
Counter-Current Flow 90C
(1 40 C

Co-Current Flow 90 C
(1

45C (2 20 C Area

20 C Area

45C (2 40 C

LMTD = (50-25) / ln(50/25) = 25 / ln 2 = 36.1C

(1 (2 LMTD! (1 ln (2

LMTD = (70-5) / ln(70/5) = 65 / ln 14 = 24.6C

Counter-current flow gives a higher LMTD

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Q = k * A * LMTD
The k-value consists of 3 different heat transfer resistances
Wall T1, Bulk temperature on hot side Called E1-value Film heat transfer coefficient on hot side T3 Hot side Flow direction T4 Flow direction Cold side Wall conductivity, P Wall thickness, H Resistance from the wall Film heat transfer coefficient on cold side Called E2-value

T2, Bulk temperature on cold side Heat transfer (Q) driven by temperature difference

1 1 1 H !   E1 E2 k P
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Thermal length
Describes how difficult a duty is thermally
Two names for the same thing:
Number of Transfer Units (NTU) Theta, 5 (mainly used in Alfa Laval)

We use the Theta concept in several ways:

Thermal duty (high / low theta duties) Unit (high / low theta PHE models) Plates (high / low theta plates) Channels (high / medium / low theta channels)

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Thermal length Theta

Theta is calculated for the hot and cold side
NTU 1 ! U 1 = T1in  T1out LMTD NTU 2 ! U 2 ! T2in  T2 out LMTD

How many times the LMTD that the fluid is cooled/heated

T1 in
(1 T2 out

Lower 5 T1 out (2 T2 in Area

(1 (2 LMTD! (1 ln (2

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Thermal length Theta

What factors decide Theta of a plate? 1. Channel Length 2. Pressing Depth 3. Chevron Angle

Theta Length Pressing depth

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Low theta Short 4.0 mm

Medium Medium 2.5 & 4.0 mm

High Long 2.5 mm

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Thermal length Theta

Also possible to make multi-pass design
For very high theta duties If there is no plate that fits in single pass Choose best available unit and make it multi-pass

Example, 2 pass hot side / 2 pass cold side

Cold out Hot in

Cold in Hot out

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Thermal length - plates & channels

We have two plate corrugations (L and H) These form three different channels (L, M and H)

L: Low theta

H: High theta

L + L = L channels

L + H = M channels

H + H = H channels

We choose between L, M and H channels Tailor-make it for the specific duty

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Thermal length - plates & channels

Low turbulence & pressure drop Medium turbulence & pressure drop High turbulence & pressure drop

L + L = L channels
Advantages

L + H = M channels
Benefits

H + H = H channels

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Efficient heat transfer High wall shear stress Variable thermal length Strong construction

Increased heat recovery Low fouling Optimal design Insensitive to vibration

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