Republic of the Philippines

Bicol University

College of Engineering

MECHANICAL ENGINEERING DEPARTMENT

Legazpi City

HEAT LOSS CALCULATION THROUGH BARE

AND LAGGED PIPES AND TEST OF PARALLEL
AND COUNTERFLOW HEAT EXCHANGERS

Submitted by:

May-Ann B. Bonto

Submitted to:

Engr. Mary Joy R. Mandane

Course Professor
VISION

A world-class university producing leaders and change agents for social transformation and
development.

Mission

The aforecited vision is rooted in Bicol University’s mandate as provided in RA 5521 which is ‘’to
give professional and technical training and provide advanced and specialized instruction in
literature, philosophy, the sciences and arts, besides providing promotion of scientific and
technological reaserches, (Sec. 3).”

QUALITY POLICY

Bicol University commits to continually strive for excellence in instruction, research, and
extension by meeting the highest level of clientele satisfaction and adhering to quality standards.

INSTITUTIONAL MISSION

"To give professional and technical training and provide advanced and specialized instruction in
literature, philosophy, the sciences and arts, besides providing for the promotion of scientific and
technological researches (RA 5521 Sec. 3).”

GOALS AND OBJECTIVES

Goals of the College of Engineering

"To primarily give professional and technical training and provide advanced and specialized
instruction in Engineering and provide for the promotion of scientific and technological
researches.”

Instruction

 To produce professionals in architecture and engineering, with managerial capability

through improved instruction and relevant experiences.
 To embark on relevant new programs.
 To intensify the development of moral, spiritual, social, intellectual and physical well
being of the students.
 To improve the competency of teaching Engineering and Architecture in the Region
through utilization of innovative methods and the development and production of
instructional materials.

Research and Extension

 To conduct studies in industry and energy, culture and heritage, utilities and
infrastructure, environmental protection and control, housing, and instructional concerns
through the use of different research methods for various end-users.
 To conduct extension activities within the service area of the college through non formal
education, and strengthen linkages with other schools and agencies along areas in
 industry, disaster preparedness, heritage conservation, energy utilization, safety in
buildings, environmental protection and control, and social sciences.

Production

 To increase the financial capability of the college through institutionalized income-

generating projects.

Infrastructure Development Maintenance

 To realize the infrastructure development in the University and modernize classrooms

and other instructional facilities and make them a work of art in engineering and
architecture.
 To properly maintain the existing facilities and make them a work of art in engineering
and architecture.
 To enhance the output of the college through the acquisition of sufficient facilities and
equipment.

Human Resources

 To enhance the quality of services through the development of knowledge, skills, and
values of human resources.
Table of Contents
Topic 1
HEAT LOSS CALCULATION THROUGH BARE & LAGGED PIPES

1. Heat loss from lagged pipes

Heat loss/gain takes place from a pipe carrying hotter/colder fluid than ambient
temperature. Insulation reduces the heat loss to surroundings. Heat loss depends upon
number of factors like insulation thickness, ambient temperature, wind speed etc.

Overall heat transfer coefficient of an insulated pipe is defined as following.

1
U
D  D 
D3 ln 2  D3 ln 3 
D3
  D1    D2   1
D1hin 2kpipe 2kinulation hair

where, kpipe , kinsulation are thermal conductivities of pipe and insulation, hin is heat transfer
coefficient for fluid flowing in pipe and h is heat transfer coefficient due to air flowing outside
the pipe. The first two terms of denominator in above equation are generally smaller
compared to remaining terms and can be neglected. For this example first term due to pipe
fluid is ignored.

Air Side Heat Transfer Coefficient, hair

Air side heat transfer is due to combined effect of convection and radiation. Assume a
temperature at cladding surface tsurface and steel pipe surface tinterface. Calculate average air film
temperature as following.
t surface  t ambient
t average 
2
Estimate thermodynamic properties of air like thermal conductivity (k), viscosity (μ),
expansion coefficient (β = 1/t_average), air density (ρ), kinematic viscosity (ν), specific heat
(cp) and thermal diffusivity (α) at average air film temperature. These properties are available
in literature in form of tables.

hradiation

Heat transfer coefficient due to radiation is calculated using following relation.

 Tsurface
4
 Tambient
4

hradiation 
Tsurface  Tambient
 Where σ= 0.1713 x 10-8 Btu/hr-ft2-R4 = 5.67 x 10-8 W/m2.K4 is Stefan Boltzmann
coefficient and ε is emissivity for cladded surface.

hconvection

Convective heat transfer coefficient comprises of forced and free convection. Forced
convection can be modeled based on correlation by one of the equations given by McAdams.
0.6
hDo  D V 
 0.24 o 
kf   
 f 
The value of (DoVρ)/ μf should be between 1000 and 50,000; Do is the outside diameter;
and kf and f are evaluated at the film temperature.

Free convection is calculated for a hot surface in atmospheric air,

Vertical plates over 1 ft high:

hc  0.27t 0.25 Btu ft 2  hr  F
Horizontal pipes and vertical pipes over 1 ft high:
0.25
 t 
hc  0.27  Btu ft 2  hr  F
 Do 
where the subscript c is used as a reminder that only convected heat is involved and that
the radiant heat should also be considered; Dois the outside diameter in feet; t is the
temperature difference between the air and the surface.

Air side heat transfer coefficient is calculated as following.

hair  hradiation  hconvection

Overall Heat Transfer Coefficient, U

Thermal conductivity for insulation material and pipe is available in literature and
depends upon temperature.

Heat transfer resistance due to pipe and insulation is calculated using following relation,
D 
D3 ln 2 
Rpipe   D1 
2k pipe
D 
D3 ln 3 
Rinsulation   D2 
2k insulation
Overall heat transfer coefficient is calculated as,
1
Roverall  R pipe  Rinsulation 
hair
1
U
Roverall
Heat flowing through insulation is estimated.
 t operating  t ambient
Q
Roverall

A revised estimate for interface and surface temperature is made.

t interface  t operating  QRpipe
t surface  t interface  QRinsulation
Above steps are repeated with these new estimates till there is negligible difference in
temperature.

Heat loss per unit length of pipe is estimated as following.

Heat Loss = D3Q

2. Heat loss from bare pipes

For heat loss from bare pipe all above steps are repeated with resistance due to insulation
not considered.
D 
D2 ln 2 
Rpipe   D1 
2k pipe
1
Roverall  R pipe 
hair

Example no. 1

A 3" steel pipe (sch. 40) is carrying hot oil at 180°C and insulated with 50 mm thick
magnesia insulation. Insulation is cladded with a sheet with surface emissivity of 0.9. Ambient
temperature is 28°C and wind velocity is 3.5 m/s. Calculate surface temperature and heat loss
per unit length from insulated and bare pipe.

Given:
3 in steel schedule 40.
Hot oil at 180 C
Insulation = 50 mm magnesia insulation
e = 0.90
Ambient temperature = 28 C
Wind velocity = V = 3.5 m/s

Required:
Surface temperature and heat loss from insulated and bare pipe.
Solution:
For carbon steel pipe, 3 in Sch. 40
D1 = ID = 3.068 in = 78 mm = 0.078 m
D2= OD = 3.5 in =89 mm = 0.089 m
D3 = OD + 2(50 mm) = 89 + 2(50) = 189 mm = 0.189 m

From Thermodynamics by Faires.

Thermal conductivity of pipe, steel, kpipe = 45 W/m-K
Thermal conductivity of insulation, magnesite insulation, kinsulation= 0.062 W/m-K
For air

A. For Insulated Pipe (Lagged)

D 
D3 ln 2 
Rpipe   D1 
2k pipe

0.189ln 0.089 
R pipe   0.078 
245
R pipe  0.000277
D 
D3 ln 3 
Rinsulation   D2 
2k insulation

0.189ln 0.189 
Rinsulation   0.089 
20.062
Rinsulation  1.147886

For hair:
0.6
hDo  D V 
 0.24 o 
kf   
 f 

V  3.5 m s
t operating  t ambient
As first trial, assume t f 
2
180  28
tf   104 C
2
At 104 C: From Thermodynamic by Faires (104 C = 219 F), tf = 1.45 x 10-
5lbm/ft.sec

 lbm  1 kg  3.281 ft 
 f   1.45  10 5   
 ft  sec  2.205 lbm  1 m 
 f  2.156  10 5 kg m  s
kf of air at 104 C or 219 F
k f  0.218 Btu  in. ft 2  hr  F
k f  0.2180.14419  0.03143 W m2  K

Tsat 104 C, pressure = 101.325 kPa

p 101.325
 
RT 0.287104  273
  0.9365 kg m 3

Do  D3  0.189 mm

h0.189  0.1893.50.9365 
0.6

 0.24  
0.03143  2.156  10 5
hconvection  18.886 W m 2  K

 Tsurface
4
 Tambient
4

hradiation 
Tsurface  Tambient

hradiation 
5.67  10 0.9180  273  28  273 
8 4 4

180  28

hradiation  11.382 W m 2  K

hair  hconvection  hradiation  18.886  11.382  30.268 W m 2  K

1
Roverall  R pipe  Rinsulation 
hair
1
Roverall  0.000277  1.147886 
30.268
Roverall  1.1812
t operating t ambient 180  28
Q 
Roverall 1.1812
Q  128.683 W m 2

t interface  t operating  QRpipe

t interface  180  128.6830.000277  179.964 C
t surface  t interface  QRinsulation
t surface  179.964  128.6831.147886  32.3 C
t surface  t ambient
t average 
2
32.3  28
t average   30.2 C  104 C
2
Use tf = 30.2 C = 86 F
At 30.2C: From Thermodynamic by Faires (30.2C =86 F), f = 1.25 x 10
-5lbm/ft.sec

 lbm  1 kg  3.281 ft 
 f   1.25  10 5   
 ft  sec  2.205 lbm  1 m 
 f  1.86  10 kg m  s
5

kf of air at 30.2 C or 86 F
k f  0.1824 Btu  in. ft 2  hr  F
k f  0.1824 0.14419   0.0263 W m2  K

at30.2 C, pressure = 101.325 kPa

p 101.325
 
RT 0.28730.2  273
  1.1644 kg m 3

Do  D3  0.189 mm

h0.189   0.189 3.51.1644  

0.6

 0.24  
0.0263  1.86  10 5
hconduction  19.6778 W m2  K
 Tsurface
4
 Tambient
4

hradiation 
Tsurface  Tambient

hradiation 
5.67  10 0.932.3  273  28  273 
8 4 4

32.3  28

hradiation  5.687 W m 2  K

hair  hconvection  hradiation  19.6778  5.687  25.3648 W m2  K

1
Roverall  R pipe  Rinsulation 
hair
1
Roverall  0.000277  1.147886 
25.3648
Roverall  1.1876
t t 180  28
Q  operating ambient 
Roverall 1.1876
Q  127.989 W m2

t interface  t operating  QRpipe

tinterface  180  127.9890.000277   179.965 C
t surface  t interface  QRinsulation
t surface  179.965  127.9891.147886   33.0 C
 t surface  t ambient
t average 
2
33.0  28
taverage   30.5 C  30.2
2
Therefore, t surface  33.0 C (answer)
Heat loss per unit length of pipe is estimated as following.

Heat Loss = D3Q

Heat Loss = (0.189)(127.989) = 76 Watts per meter. (answer)

B. Bare Pipe

For hair:
0.6
hDo  D V 
 0.24 o 
kf   
 f 

V  3.5 m s

t operating  t ambient
As first trial, assume t f 
2
180  28
tf   104 C
2
hair  hconvection  hradiation  30.268 W m 2  K

1
Roverall  R pipe 
hair
1
Roverall  0.000277 
30.268
Roverall  0.033315
t operating t ambient 180  28
Q 
Roverall 0.033315
Q  4562.5 W m 2

t surface  t operating  QRpipe

t surface  180  4562.50.000277  178.74 C
t surface  t ambient
t average 
2
178.74  28
t average   103.4 C  104 C
2

Therefore, t surface  103.4 C (answer)

Heat loss per unit length of pipe is estimated as following.
 Heat Loss = D2Q
Heat Loss = (0.089)(4562.5) = 1275.9 Watts per meter. (answer)

3. Heat Loss from Piping Chart For Piping Intended to Be Installed Outdoors

Insulation Type Insulation Heat Loss per Inch Thickness

Factor Based on K Factor @ 50 F Mean Temp.
(Btu/h-F-Ft2)

Glass fiber (ASTM C547) 1.00 0.25

Calcium silicate (ASTM C533) 1.50 0.375

Cellular glass (ASTM C552) 1.60 0.40

Rigid cellular urethane 0.66 0.165

(ASTM C591)
Foamed elastomer (ASTM 1.16 0.29
C534)
Mineral fiber blanker (ASTM 1.20 0.30
C553)
Expanded perlite (ASTM 1.50 0.375
C610)

Insulati T IPS
on ,F
Thickne ½ ¾ 1 1 1 2 2 3 4 6 8 10 12
ss (in.) ¼ ½ ½

Tubing Size (in.)

¾ 1 1 1
¼ ½

10 0.5 0.6 0.7 0.8 0.9 1.1 1.3 1.5 1.8 2.6 3.3 4.1 4.8
0.5 50 2.5 2.9 3.5 4.1 4.8 5.5 6.5 7.7 9.6 13. 17.2 21.1 24.8
5
 10 5.2 6.1 7.2 8.6 9.9 11. 13. 15. 19. 28. 35.8 43.8 51.6
0 5 5 9 9 1

15 8.1 9.5 11. 13. 15. 17. 21. 24. 31. 43. 55.7 68.2 80.2
0 2 4 5 9 0 8 9 8

20 11. 13. 15. 18. 21. 24. 29. 34. 42. 60. 76.9 94.1 110.
0 2 1 5 5 4 7 0 3 7 4 7

25 14. 17. 20. 24. 27. 32. 37. 44. 55. 78. 100. 122. 144.
0 6 1 2 1 9 2 8 7 7 8 3 6 2

10 0.3 0.4 0.4 0.5 0.6 0.6 0.7 0.8 1.0 1.4 1.8 2.2 2.6

50 1.6 1.9 2.2 2.5 2.9 3.2 3.7 4.4 5.4 7.4 9.4 11.4 13.4

10 3.4 3.9 4.5 5.2 5.9 6.8 7.8 9.1 11. 15. 19.5 23.8 27.8
0 2 5

1.0 15 5.3 6.1 7.0 8.2 9.3 10. 12. 14. 17. 24. 30.4 37.0 43.3
0 5 2 2 4 1

20 7.4 8.4 9.7 11. 12. 14. 16. 19. 24. 33. 42.0 51.2 59.9
0 3 8 6 8 6 0 4

25 9.6 11. 12. 14. 16. 19. 22. 25. 31. 43. 54.9 66.9 78.2
0 0 6 8 7 0 0 6 4 6

10 0.3 0.3 0.3 0.4 0.4 0.5 0.5 0.6 0.8 1.0 1.3 1.4 1.8

50 1.3 1.5 1.7 1.9 2.2 2.4 2.8 3.2 3.9 5.3 6.6 8.0 9.3

10 2.7 3.1 3.5 4.0 4.5 5.1 5.8 6.7 8.1 11. 13.8 16.7 19.5
0 1

1.5 15 4.3 4.8 5.5 6.3 7.1 7.9 9.1 10. 12. 17. 21.5 26.0 30.3
0 4 6 2

20 5.9 6.7 7.6 8.7 9.8 11. 12. 14. 17. 23. 29.7 36.0 41.9
0 0 5 5 5 8

25 7.8 8.7 9.9 11. 12. 14. 16. 18. 22. 31. 38.9 47.1 54.8
0 4 8 4 4 9 8 1

10 0.2 0.2 0.3 0.3 0.4 0.4 0.4 0.5 0.6 0.8 1.0 1.2 1.4

50 1.1 1.3 1.4 1.6 1.8 2.0 2.3 2.6 3.1 4.2 5.2 6.3 7.3
2.0
10 2.4 2.7 3.0 3.4 3.8 4.2 4.8 5.5 6.5 8.8 10.9 13.1 15.2
0
 15 3.7 4.2 4.7 5.3 5.9 6.6 7.5 8.5 10. 13. 17.0 20.4 23.6
0 2 7

20 5.2 5.8 6.5 7.4 8.2 9.1 10. 11. 14. 19. 23.5 28.2 32.7
0 3 8 1 0

25 6.8 7.5 8.5 9.6 10. 11. 13. 15. 18. 24. 30.7 36.9 42.7
0 7 9 5 4 5 8

10 0.2 0.2 0.2 0.3 0.3 0.3 0.4 0.4 0.5 0.7 0.8 1.0 1.2

50 1.0 1.1 1.3 1.4 1.6 1.8 2.0 2.3 2.7 3.6 4.4 5.2 6.0

10 2.2 2.4 2.7 3.0 3.3 3.7 4.1 4.7 5.6 7.4 9.1 10.9 12.6
0

2.5 15 3.4 3.7 4.2 4.7 5.2 5.8 6.5 7.3 8.7 11. 14.2 17.0 19.6
0 5

20 4.7 5.2 5.8 6.5 7.2 8.0 9.0 10. 12. 16. 19.6 23.5 27.1
0 2 1 0

25 6.1 6.8 7.5 8.5 9.4 10. 11. 13. 15. 20. 25.7 30.7 35.4
0 4 7 3 8 9

10 0.2 0.2 0.2 0.3 0.3 0.3 0.3 0.4 0.5 0.6 0.7 0.9 1.0

50 1.0 1.1 1.2 1.3 1.4 1.6 1.8 2.0 2.4 3.1 3.8 4.5 5.2

10 2.0 2.2 2.4 2.7 3.0 3.3 3.7 4.2 4.9 6.5 7.9 9.4 10.8
0

3.0 15 3.1 3.4 3.8 4.3 4.7 5.2 5.8 6.6 7.7 10. 12.3 14.7 16.8
0 1

20 4.3 4.8 5.3 5.9 6.5 7.2 8.0 9.0 10. 14. 17.0 20.3 23.3
0 7 0

25 5.7 6.2 6.9 7.7 8.5 9.4 10. 11. 13. 18. 22.3 26.5 30.5
0 5 8 9 3

Example problem no. 2

In Appendix A, dimensions of standard steel pipe are given. Suppose a 3-in schedule 80
pipe is covered with 1 in of an insulation having k = 60 m W/m · ◦C and the outside of the
insulation is exposed to an environment having h = 10 W/m2 · ◦C and T∞ = 20◦C. The temperature
of the inside of the pipe is 250◦C. For unit length of the pipe calculate (a) overall thermal
resistance and (b) heat loss.

Solution:

Di = 2.90

Do = 3.50 in

𝑊
K = 43 𝑚 .°𝐶

ln(3.50 𝑖𝑛 ÷ 2.90 𝑖𝑛)

𝑅𝑠𝑡𝑒𝑒𝑙 = 𝑤 = 6.96 x 10 − 4
(2𝜋) (43 ) (1)
𝑚 .° 𝐶

ln(5.5 𝑖𝑛 ÷ 3.50 𝑖𝑛)

𝑅𝑖𝑛𝑠 = = 1.1999
(2𝜋)(0.06)(1)

1 1
𝑅𝑐𝑜𝑛𝑣 = = 𝑤 = 0.2278
ℎ𝐴𝑜 (10 ) (5.5)(0.0254)
𝑚 2

𝑅𝑡𝑜𝑡 = 1.427

∆𝑇 250°C – 20°C
𝑞= = = 161.1 W/m
𝑅 1.427

Example problem no. 3

A steel pipe with 5-cm OD is covered with a 6.4-mm asbestos insulation [k = 0.096 Btu/h
· ft · ◦F] followed by a 2.5-cm layer of fiberglass insulation [k = 0.028 Btu/h · ft · ◦F]. The pipe-wall
temperature is 315◦C, and the outside insulation temperature is 38◦C. Calculate the interface
temperature between the asbestos and fiberglass.

Solution:

kA = 0.166 W/m∙°C

kf = 0.0485 W/ m∙°C

315 − 𝑇𝑖 𝑇𝑖 − 38
=
ln(31.4/25) ln(56.4/31.4)
0.166 0.0485

𝑇𝑖 = 286.7℃

Example problem no. 4

 A hot steam pipe having an inside surface temperature of 250◦C has an inside diameter of
8 cm and a wall thickness of 5.5 mm. It is covered with a 9-cm layer of insulation having k = 0.5
W/m · ◦C, followed by a 4-cm layer of insulation having k = 0.25 W/m · ◦C. The outside
temperature of the insulation is 20◦C. Calculate the heat lost per meter of length. Assume k = 47
W/m · ◦C for the pipe.

Solution:

For 1 m length,

ln(9.1/8)
𝑅𝑝𝑖𝑝𝑒 = = 0.463 × 10−4
2𝜋(47)

ln(27.1/9.1)
𝑅𝑖𝑛𝑠1 = = 0.3474
2𝜋(0.5)

ln(35.1/27.1)
𝑅𝑖𝑛𝑠2 = = 0.8246
2𝜋(0.25)

𝑅𝑡𝑜𝑡 = 1.172

∆𝑇 250 − 20 𝑊
𝑞= = = 196.2
𝑅 1.172 𝑚

Example problem no. 5

A hollow tube having an inside diameter of 2.5 cm and a wall thickness of 0.4 mm is
exposed to an environment at h = 100 W/m2 · ◦C and T∞ = 40◦C. What heat generation rate in the
tube will produce a maximum tube temperature of 250◦C for k = 24 W/m · ◦C?

Solution:

𝑟𝑖 = 0.0125 𝑚

𝑟𝑖 = 0.0129 𝑚

Assume inner surface is insulated,

𝑑𝑇 𝑞̇ 𝑟 𝑐1
= = =0 𝑎𝑡 𝑟 = 𝑟𝑖
𝑑𝑟 2𝑘 𝑟

𝑞̇ 𝑟12
𝑐1 =
2𝑘

−𝑞̇ 𝑟 2
𝑇= + 𝑐1 ln 𝑟 + 𝑐2
4𝑘
 −𝑞̇ 𝑟𝑖2
𝑇𝑖 = 𝑐 ln 𝑟𝑖 + 𝑐2
4𝑘 1

−𝑞̇ 𝑟𝑜2
𝑇𝑜 = 𝑐 ln 𝑟𝑜 + 𝑐2
4𝑘 1

𝑞 2 2 𝑟𝑖
𝑇𝑖 − 𝑇𝑜 = (𝑟𝑜 −𝑟𝑖 ) + 𝑐1 ln ( )
4𝑘 𝑟𝑜

We take,

𝑊 𝑊
𝑇𝑖 = 250℃, ℎ = 100 , 𝑇∞ = 40℃, 𝑘 = 24
𝑚2 ∙℃ 𝑚∙℃

Inserting the numerical values in the previous 2 equations and solving gives,

𝑀𝑊
ℎ = 53.26
𝑚3

𝑇𝑜 = 249.76℃

Example problem no. 6

Water flows on the inside of a steel pipe with an ID of 2.5 cm. The wall thickness is 2 mm,
and the convection coefficient on the inside is 500 W/m2 · ◦C. The convection coefficient on the
outside is 12 W/m2 · ◦C. Calculate the overall heat-transfer coefficient. What is the main
determining factor for U?

Solution:

𝑤
𝑘 = 43
𝑚∙ ℃

1 0.025 1 1
𝑈𝑖 = + ( )=
1 2𝑥10 + 4.31𝑥10−5 + 71.84𝑥10−3
−3
+ ln(1.25) 𝜋(0.025)/(2𝜋)(43) 0.029 12
500

𝑊
𝑈𝑖 = 13.54
𝑚2 ∙℃

Example problem no. 7

The pipe in Problem 2-56 is covered with a layer of asbestos [k = 0.18 W/m · ◦C] while
still surrounded by a convection environment with h = 12 W/m2 · ◦C. Calculate the critical
insulation radius. Will the heat transfer be increased or decreased by adding an insulation
thickness of (a) 0.5 mm, (b) 10 mm?
Solution:

𝑘 0.18
𝑟𝑜 = = = 0.015 𝑚 = 1.5 𝑐𝑚
ℎ 12

𝑎) 𝑟𝑜 = 1.25 + 0.05 = 1.3 𝑐𝑚 𝑖𝑛𝑐𝑟𝑒𝑎𝑠𝑒𝑑

𝑏) 𝑟𝑜 = 1.25 + 1.0 = 2.25 𝑐𝑚 𝑑𝑒𝑐𝑟𝑒𝑎𝑠𝑒𝑑

Example problem no. 8

Air flows at 120◦C in a thin-wall stainless-steel tube with h = 65 W/m2 · ◦C. The inside
diameter of the tube is 2.5 cm and the wall thickness is 0.4 mm. k = 18 W/m · ◦C for the steel. The
tube is exposed to an environment with h = 6.5 W/m2 · ◦C and T∞ = 15◦C. Calculate the overall
heat-transfer coefficient and the heat loss per meter of length. What thickness of an insulation
having k = 40 mW/m · ◦C should be added to reduce the heat loss by 90 percent?

Solution:

𝑓𝑜𝑟 𝐿 = 1 𝑚

1 1
= = 0.1959
ℎ𝑖 𝐴𝑖 (65)𝜋(0.025)

𝑟
ln ( 0 ) ln (2.58)
𝑟𝑖 2.5 = 2.79𝑥10−4
=
2𝜋𝑘 2𝜋(18)

1 1
= = 1.898
ℎ𝑜 𝐴𝑜 (6.5)𝜋(0.0258)

𝑈𝐴 = 1/ ∑ 𝑅 = 2.094

𝑞 𝑊
= (2.094)(120 − 15) = 219.9
𝐿 𝑚

Example problem no. 9

A 2.5-cm-diameter tube has circumferential fins of rectangular profile spaced at 9.5-mm

increments along its length. The fins are constructed of aluminum and are 0.8 mm thick and 12.5
mm long. The tube wall temperature is maintained at 200◦C, and the environment temperature
is 93◦C. The heat-transfer coefficient is 110 W/m2 · ◦C. Calculate the heat loss from the tube per
meter of length.

Solution:
To= 200°C

T∞=93°C

L= 12.5 mm

t=0.8 mm

r1=1.25 cm

k=204

Lc=12.9 mm

h=110

r2c=2.54

r2c=2.54

r2c/r1= 2.03

𝐴𝑚 = 1.03 𝑥 10−5 𝑚2

1
3
ℎ 2
𝐿2𝑐 ( ) = 0.335
𝑘𝐴𝑚

𝜂𝑓 = 0.87

1.0
𝑁𝑜. 𝑜𝑓 𝑓𝑖𝑛𝑠 = = 105.3
0.0095

𝑇𝑢𝑏𝑒 𝑠𝑢𝑟𝑓𝑎𝑐𝑒 𝑎𝑟𝑒𝑎 = (105.3)𝜋(0.025)(9.5 − 0.8)(10−3 ) = 0.0719 𝑚2

𝑇𝑢𝑏𝑒 ℎ𝑒𝑎𝑡 𝑡𝑟𝑎𝑛𝑠𝑓𝑒𝑟 = (110)(0.0719)(200 − 93) = 846.6 𝑊

𝑞
= (0.87)(2)𝜋(110)(0.02542 − 0.01252 )(200 − 93) = 31.46 𝑊
𝑓𝑖𝑛

𝑇𝑜𝑡𝑎𝑙 𝑓𝑖𝑛 ℎ𝑒𝑎𝑡 𝑡𝑟𝑎𝑛𝑠𝑓𝑒𝑟 = (31.46)(105.3) = 3312 𝑊

𝑇𝑜𝑡𝑎𝑙 ℎ𝑒𝑎𝑡 𝑡𝑟𝑎𝑛𝑠𝑓𝑒𝑟 = 846.6 + 3312 = 4159 𝑊

Topic 2
TEST OF PARALLEL & COUNTERFLOW HEAT EXCHANGERS

1. Log Mean Temperature Difference

To design or to predict the performance of a heat exchanger, it is essential to relate the

total heat transfer rate to quantities such as the inlet and outlet fluid temperatures, the overall
heat transfer coefficient, and the total surface area for heat transfer. Two such relations may
readily be obtained by applying overall energy balances to the hot and cold fluids, as shown
in Figure 1.

In particular, if q is the total rate of heat transfer between the hot and cold fluids and there
is negligible heat transfer between the exchanger and its surroundings, as well as negligible
potential and kinetic energy changes, application of the steady flow energy equation, gives
qm  h hh,i  hh,o  (1a)
and qm  c hc ,o  hc ,i  (2a)
where h is the fluid enthalpy. The subscript h and c refer to the hot and cold fluids,
whereas i and o designate the fluid inlet and outlet conditions. If the fluids are not undergoing
a phase change and constant specific heats are assumed, these expressions reduces to
qm  h c p ,h Th ,i  Th ,o  (1b)
and  c c p ,c Tc ,o  Tc ,i 
qm (2b)

where the temperatures appearing in the expressions refer to the mean fluid
temperatures at the designated locations. Note that Equations 1 and 2 are independent of the
flow arrangement and heat exchanger type.
Another useful expression may be obtained by relating the total heat transfer rate q to the
temperature difference T between the hot and cold fluids, where
T  Th  Tc (3)

Such an expression would be an extension of Newton’s law of cooling, with the overall
heat transfer coefficient U used in place of the single convection coefficient h. However, since
DT varies with position in the heat exchanger, it is necessary to work with a rate equation of
the form
q  UATm (4)
where ΔTm is an appropriate mean temperature difference. Equation 4 may be used with
Equations 1 and 2 to perform a heat exchanger analysis. Before this can be done, however,
the specific form of ΔTm must be established.
2. The Parallel-Flow Heat Exchanger

The hot and cold fluid temperature distribution associated with a parallel-flow heat
exchanger are shown in Figure 2.

The temperature difference T is initially large but decays with increasing x, approaching
zero asymptotically. It is important to note that, for such an exchanger, the outlet temperature
of the cold fluid never exceeds that of the hot fluid. In Figure 2 the subscripts 1 and 2 designate
opposite ends of the heat exchanger. This convention is used for all types of heat exchangers
considered. For parallel flow, it follows that Th,i = Th,1, Th,o = Th,2, Tc,i = Tc,1, and Tc,o = Tc,2.
The form of Tm may be determined by applying an energy balance to differential
elements in the hot and cold fluids. Each element is of length dx and heat transfer surface area
dA, as shown in Figure 2. The energy balances and the subsequent analysis are subject to the
following assumptions.
1. The heat exchanger is insulated from its surroundings, in which case the only heat
exchange is between the hot and cold fluids.
2. Axial conduction along the tubes is negligible.
3. Potential and kinetic energy changes are negligible.
4. The fluid specific heats are constant.
5. The overall heat transfer coefficient is constant.

The specific heats may of course change as a result of temperature variations, and the
overall heat transfer coefficient may change because of variations in fluid properties and
flow conditions. However, in many applications such variations are not significant, and it
is reasonable to work with average values of cp,c, cp,h, and U for the heat exchanger.
 The appropriate average temperature difference is a log mean temperature
difference, Tlm. Accordingly, we may write
q  UATlm (5)
T2  T1 T1  T2
where Tlm   (6)
lnT2 T1  lnT1 T2 

Remember that, for the parallel-flow exchanger,

 T1  Th ,1  Tc ,1  Th ,i  Tc ,i 
T  T  T  T  T  (7)
 2 h , 2 c , 2 h ,o c , o 

3. The Counter-Flow Heat Exchanger

The hot and cold fluid temperature distributions associated with a counterflow heat
exchanger are shown in Figure 3.

In contrast to the parallel-flow exchanger, this configuration provides for heat transfer
between the hotter portions of the two fluids at one end, as well as between the colder
portions at the other. For this reason, the change in the temperature difference, T = Th – Tc,
with respect to x is nowhere as large as it is for the inlet region of the parallel-flow exchanger.
Note that the outlet temperature of the cold fluid may now exceed the outlet temperature of
the hot fluid.
Equations 1b and 2 b apply to any heat exchanger and hence may be used for the
counterflow arrangement. However, for the counterflow exchanger the endpoint
temperature differences must now be defined as
  T1  Th ,1  Tc ,1  Th ,i  Tc ,o 
T  T  T  T  T  (8)
 2 h ,2 c ,2 h ,o c ,i 
Note that, for the same inlet and outlet temperatures, the log mean temperature
difference for counterflow exceeds that for parallel flow, Tlm,CF> Tlm,PF. Hence the surface
area required to effect a prescribed heat transfer rate q is smaller for the counterflow than
for the parallel-flow arrangement assuming the same value of U. Also note that Tc,o can exceed
Th,o for counterflow but not for parallel flow.
.
4. Special Operating Conditions

It is useful to note certain special conditions under which heat exchangers may be operated.
Figure 4a shows temperature distributions for a heat exchanger in which the hot fluid has a
heat capacity rate, Ch mhcp,h. which is much larger than that of the cold fluid,Cc = mccp,c . For
this case the temperature of the hot fluid remains approximately constant throughout the
heat exchanger, while the temperature of the cold fluid increases.

The same condition is achieved if the hot fluid is a condensing vapor. Condensation occurs at
constant temperature, and, for all practical purposes, Ch→∞. Conversely, in an evaporator or
boiler (Figure 4b), it is the cold fluid that experiences a change in phase and remains at a
nearly uniform temperature (Cc→∞). The same effect is achieved without phase change if
Ch«Cc. Note that, with condensation or evaporation, the heat rate is given by Equation 1a or
2a. The third special case (Figure 4c) involves a counterflow heat exchanger for which the
heat capacity rates are equal (Ch = Cc). The temperature difference T must then be a constant
throughout the exchanger, in which case T1 = T2 = Tlm.

Example problem no. 1

A counterflow, concentric tube heat exchanger is used to cool the lubricating oil for a large
industrial gas turbine engine. The flow rate of cooling water through the inner tube (Di = 25
mm) is 0.2 kg/s, while the flow rate of oil through the outer annulus (Do = 45 mm) is 0.1 kg/s.
The oil and water enter at temperatures of 100 and 30 C, respectively. How long must the
tube be made if the outlet temperature of the oil is to be 60 C?

Given:
Lubricating oil
m h  0.1 kg s
Th,i  100 C
Th,o  60 C
Water
 c  0.2 kg s
m

Di  25 mm  0.025 m
Do  45 mm  0.045 m

Required:
Length of tube

Solution:Reference : Fundamentals of Heat and Mass Transfer – Incropera, et. Al.

1
Unused engine oil at T h  100  60  80 C  353 K
2
c p  2131 J kg  K
  3.25  10 2 N  s m 2
k  0.138 N m.K
Water at Tc = 35 C trial.
c p  4178 J kg  K
  725  10 6 N  s m 2
k  0.625 N m.K
Pr  4.85

Required heat transfer

 h c p ,h Th ,i  Th ,o 
qm
q  0.12131100  60  8524 W
Also,
 c c p ,c Tc ,o  Tc ,i 
qm
q
Tc ,o   Tc ,i
m c c p ,c
8524
Tc ,o   30  40.2 C
0.24178
Accordingly, use of Tc = 35 C to evaluate the water properties was a good choice.
For heat exchanger length:
q  UATlm
A  Di L

T  Tc ,o   Th ,o  Tc ,i 
Tlm  h ,i

T T 
ln h ,i c ,o 
 Th ,o  Tc ,i 
100  40.2  60  30
Tlm 
 100  40.2 
ln 
 60  30 
 59.8   30 
Tlm   43.2 C
 59.8 
ln 
 30 
Then
1
U
1 1

hi ho

Water flow through the tube

4mc 40.2
Re D    14 ,050
Di   0.025725  10 6 
NuD  0.023ReD4 5 Pr 0.4
NuD  0.02314,0504 5 4.850.4  90

k 900.625
hi  NuD   2250 W m  K
Di 0.025

Flow of oil through the annulus:

Dh D o Di  0.045  0.025  0.02 m

um Dh
ReD 

 Do  Di  4mh
ReD  
  Do  Di2 
2

4mh
Re D 
 Do  Di 
40.1
ReD   56
 0.045  0.0253.25  10 2 
The annulus flow is therefore laminar. Table 8.2 of reference with Di/Do = 25/45 = 0.56,
ho Dh
Nu i   5.63
k
Nui k
ho 
Dh
5.630.138
ho   38.847 W m 2  K
0.025
The overall convection coefficient is
1
U
1 1

hi ho
1
U  38.188 W m 2  K
1 1

2250 38.847

Length of tube
q  Di LUTlm
 q 8524
L 
Di UTlm  0.02538.188 43.2
L = 65.8 m (answer)

Example problem no. 2

A counter flow double-pipe heat exchanger is to be used to heat 0.7 kg/s of water from
35 to 90◦C with an oil flow of 0.95 kg/s. The oil has a specific heat of 2.1 kJ/kg · ◦C
and enters the heat exchanger at a temperature of 175◦C. The overall heat-transfer
coefficient is 425 W/m2 · ◦C. Calculate the area of the heat exchanger and the
effectiveness.

Solution:
𝑘𝑔 𝑘𝑔
𝑞 = (0.7) (4175)(90℃ − 35℃) = (0.95 ) (2100)(175℃ − 𝑇𝑒 ) = 160,470 𝑊
𝑠 𝑠
𝑇𝑒𝑜 = 94.4℃
85 − 59.4
∆𝑇𝑚 = = 71.44
85
ln ( )
59.4
𝑊
𝐴 = 160,740 = 5.294 𝑚2
𝑊
425 2 (71.44)
𝑚
175℃ − 94.4℃
𝑜𝑖𝑙 𝑖𝑠 𝑚𝑖𝑛. 𝑓𝑙𝑢𝑖𝑑: 𝜀 = = 0.575
175℃ − 35℃
Example problem no. 3

High-pressure hot water at 120◦C is used to heat an oil from 30 to 40◦C. The water
leaves the counterflow heat exchanger at a temperature of 90◦C. If the total area
of the heat exchanger is 5 m2, calculate the effectiveness of the exchanger. What
would be the effectiveness if a parallel-flow exchanger were used with the same
area?

Solution:

120℃ − 90℃
𝜀= = 0.333
120℃ − 30℃
Same for parallel and counterflow

Example problem no. 4

Calculate the number of transfer units for each of the exchangers in Problem 10-41.
Solution:
𝐶𝑚𝑖𝑛 10
= = 0.333
𝐶𝑚𝑎𝑥 30
𝜀 = 0.333
𝑝𝑎𝑟𝑎𝑙𝑙𝑒𝑙 𝑓𝑙𝑜𝑤: 𝑁𝑇𝑈 ≈ 0.45
𝑐𝑜𝑢𝑛𝑡𝑒𝑟𝑓𝑙𝑜𝑤: 𝑁𝑇𝑈 ≈ 0.47
Example problem no. 5
Water at 75◦C enters a counterflow heat exchanger. It leaves at 30◦C. The water is
used to heat an oil from 25 to 48◦C. What is the effectiveness of the heat exchanger?

Solution:
∆𝑇𝑤 = 75℃ − 30℃ = 45℃
∆𝑇𝑜 = 48℃ − 25℃ = 23℃
∆𝑇𝑤 45℃
𝑊𝑎𝑡𝑒𝑟 𝑖𝑠 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑓𝑙𝑢𝑖𝑑: 𝜀 = = = 0.9
∆𝑇𝑚𝑎𝑥 75℃ − 25℃

Example problem no.6

Water at 90◦C enters a double-pipe heat exchanger and leaves at 55◦C. It is used to
heat a certain oil from 25 to 50◦C. Calculate the effectiveness of the heat exchanger

Solution:
𝐶𝑤 (90 − 55) = 𝐶𝑜 (50 − 25)
𝐶𝑤 25
=
𝐶𝑜 35
𝐶𝑤 = 𝐶𝑚𝑖𝑛
90 − 55
𝜀= = 53.8%
90 − 25
Example problem no. 7

A counterflow double-pipe heat exchanger is employed to heat 25 kg/s of water

from 20 to 40◦C with a hot oil at 200◦C. The overall heat-transfer coefficient is
275 W/m2 · ◦C. Determine effectiveness and NTU for exit oil temperatures of 190,
180, 140, and 80◦C.

Solution:
𝑘𝑔
𝑚𝑤 = 30 𝐶𝑤 = (30)(4174) = 125,220 𝑇𝑤1 = 20℃
𝑠
𝑇𝑤2 = 40℃ 𝑇𝑜𝑖 = 200℃ 𝑈 = 275
𝑞 = (125,220)(40 − 24) = 2.504 × 106 𝑊

1 𝜀−1
𝑁= ln ( )
𝑐−1 𝑐𝜀 − 1

𝑇𝑏𝑒 ∆𝑇𝑜 𝐶𝑜 𝐶 𝜀 𝑁𝑇𝑈

190 10 250,440 0.5 0.1111 0.1212

180 20 125,220 1.0 0.1111 0.125

140 60 41,740 0.333 0.333 0.432

80 120 20,870 0.167 0.667 1.177