Fundamentals of Heat Exchanger Design E-Book

Dusan P. Sekulic

• Herausgeber: John Wiley & Sons
• Kategorie: Fachliteratur
• Sprache: Englisch

Seitenzahl: 1499

Veröffentlichungsjahr: 2023

Beschreibung

Fundamentals of Heat Exchanger Design A cutting-edge update to the most essential single-volume resource on the market Heat exchangers are thermal devices which transfer heat between two or more fluids. They are integral to energy, automotive, aerospace, and myriad other technologies. The design and implementation of heat exchangers is an essential skill for engineers looking to contribute to a huge range of applications. Fundamentals of Heat Exchanger Design, Second Edition provides a comprehensive insight into the design and performance of heat exchangers. After introducing the basic heat transfer concepts and parameters, an overview of design methodologies is discussed. Subsequently, details of design theory of various types of exchangers are presented. The first edition established itself as the standard single-volume text on the subject. The second edition preserves an established in-depth approach but reflects some new technological developments related to design for manufacturing compact heat exchangers, including novel 3-D printing approaches to heat exchanger design. Readers of the second edition of Fundamentals of Heat Exchanger Design will also find: * A new section on the design for manufacturing of compact heat exchangers * A new section on design for additive manufacturing compact heat exchangers * Detailed discussions of the design of recuperators and regenerators, pressure drop analysis, geometric parameters, heat transfer correlations, and more Fundamentals of Heat Exchanger Design is ideal for practicing engineers, as well as for advanced undergraduate and graduate students in mechanical and aerospace engineering, energy engineering, and related subjects.

Leseprobe

Fundamentals of Heat Exchanger Design

Second Edition

Dušan P. Sekulić

University of Kentucky, Lexington, Kentucky

Ramesh K. Shah

Rochester Institute of Technology, Rochester, New York

Senior Staff Research Scientist at Delphi Harrison Thermal Systems, Lockport, New York

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Library of Congress Cataloging-in-Publication DataNames: Sekulić, Dušan P., author. | Shah, R. K. (Ramesh K.), author.Title: Fundamentals of Heat Exchanger Design / Dušan P. Sekulić, Ramesh K. Shah.Description: Hoboken, New Jersey : Wiley, [2024] | Includes index.Identifiers: LCCN 2023014050 (print) | LCCN 2023014051 (ebook) | ISBN 9781119883265 (hardback) | ISBN 9781119883272 (adobe pdf) | ISBN 9781119883289 (epub)Subjects: LCSH: Heat exchangers--Design and construction.Classification: LCC TJ263 .S4158 2024 (print) | LCC TJ263 (ebook) | DDC 621.402/5--dc23/eng/20230331

LC record available at https://lccn.loc.gov/2023014050LC ebook record available at https://lccn.loc.gov/2023014051

Cover Design: WileyCover Image: © korkeng/Shutterstock

About the Authors

Dušan P. Sekulić, Dr.Sc.Eng, J.G. Morris Aluminum Secat Professor in the Mechanical and Aerospace Department in the College of Engineering, University of Kentucky. He is a Fellow of the American Society of Mechanical Engineering, and a Fellow of the American Welding Society. Professor Sekulic has also lectured in a capacity of a visiting Professor at a number of Universities and research establishments in US, Europe and Asia. He has authored/edited a number of books and numerous publications involving thermodynamics, heat transfer and materials science, funded by NSF, DOE, NASA and others.

Ramesh K. Shah, is Research Professor at the Rochester Institute of Technology and Senior Staff Research Scientist at Delphi Harrison Thermal System and General Motors. He has contributed widely to research publications on heat exchanger design and related subjects.

Preface to the Second Edition

After the first English edition, followed by the first Mandarin edition, the “Fundamentals of Heat Exchanger Design,” has become the leading comprehensive single‐volume source of information on theory and performance of heat exchangers. It has been used by both engineering professionals and academia. The use by engineers has been motivated by an in‐depth presentation of details of design procedures and an attention to the rigor of the interpretation of included topics. The students have considered this book as a source of relevant information on implementation of the introduced concepts while solving the real‐world application problems. However, over time, two issues became evident. The book appears to be too voluminous as a primary source of information for senior undergraduate and even graduate students. On the other hand, the book offers a heavy phenomenological background for pragmatic engineering professionals. So, when the publisher suggested preparation of the second edition, I followed an attempt to reduce the diversity of its content by eliminating redundant narrative and streamlining the content exposition, without impacting the rigor of the text.

Chapter 1 has been thoroughly modified. The verbose narrative on classification of heat exchangers is now shifted to Appendix A. At the same time, the fundamentals of modeling and thermodynamics analysis of a heat exchanger are shifted from the former Chapter 11 to the opening chapter. Chapter 2 was expanded by including two new subsections involving compact heat exchangers. The issues involving manufacturing of compact heat exchangers, assembled by using controlled atmosphere brazing, are discussed in a newly included subsection. Yet another new subsection on the 3D printing for heat exchanger design provides several examples of an implementation of the state‐of‐the‐art additive manufacturing for design of compact heat exchangers. The content involving various design issues presented in Chapter 3 was edited, including the repositioning the large tables on effectiveness‐NTU equations into Appendix B. Main advances in design methods procedures, since publishing the first edition, have not significantly changed the calculation algorithms. In practice, all that material has changed little, thus the original literature sources have been left unchanged. What has changed significantly in practical applications is the wide‐spread use of numerical calculation routines often involving heat transfer and fluid flow details of heat exchangers’ flow passages. The inherent lack of transparency of design procedures executed by computer software though offers little to the understanding of the underlined physics concepts. So, the content of Chapters 5–10 has not changed except for further polishing the narrative. However, numerous editorial changes, and a smaller number of typographical errors have been implemented/corrected. Chapter 4, devoted to relaxation of design assumptions, has been complemented by an inclusion of the material related to an impact of maldistribution of fluid flow on the heat exchanger performance, but excluding the consideration of the header and manifold design. Correspondingly, the remaining auxiliary material on header/manifold design in Chapter 12, was not included. Finally, the chapter on fouling and corrosion is not included to accommodate a need for a more focused exposition of heat exchanger core design. The book includes 60 solved examples. All additional, unsolved problem formulations, a total of 105, as well as 253 review questions, are collected in the instructor companion web site (www.wiley.com/NN).

The second edition of the book keeps the same depth of the content exposition as the one Dr. Ramesh Shah and I have envisioned when assembled the first edition. I hope that the second edition will continue to be used widely by engineers and students in both English version and Mandarin translation.

Dušan P. Sekulić

University of KentuckyLexington, Kentucky

September 2023

Preface to the First Edition

Over the past quarter century, the importance of heat exchangers has increased immensely from the viewpoint of energy conservation, conversion, recovery, and successful implementation of new energy sources. Its importance is also increasing from the standpoint of environmental concerns such as thermal pollution, air pollution, water pollution, and waste disposal. Heat exchangers are used in the process, power, transportation, air‐conditioning and refrigeration, cryogenic, heat recovery, alternate fuels, and manufacturing industries, as well as being key components of many industrial products available in the marketplace. From an educational point of view, heat exchangers illustrate in one way or another most of the fundamental principles of the thermal sciences, thus serving as an excellent vehicle for review and application, meeting the guidelines for university studies in the United States and overseas. Significant advances have taken place in the development of heat exchanger manufacturing technology as well as design theory. Many books have been published on the subject, as summarized in the General References at the end of the book. However, our assessment is that none of the books available seems to provide an in‐depth coverage of the intricacies of heat exchanger design and theory so as to fully support both a student and a practicing engineer in the quest for creative mastering of both theory and design. Our book was motivated by this consideration. Coverage includes the theory and design of exchangers for many industries (not restricted to, say, the process industry) for a broader, in‐depth foundation.

The objective of this book is to provide in‐depth thermal and hydraulic design theory of two‐fluid single‐phase heat exchangers for steady‐state operation. Three important goals were borne in mind during the preparation of this book:

To introduce and apply concepts learned in first courses in heat transfer, fluid mechanics, thermodynamics, and calculus, to develop heat exchanger design theory. Thus, the book will serve as a link between fundamental subjects mentioned and thermal engineering design practice in industry.

To introduce and apply basic heat exchanger design concepts to the solution of industrial heat exchanger problems. Primary emphasis is placed on fundamental concepts and applications. Also, more emphasis is placed on analysis and less on empiricism.

The book is also intended for practicing engineers in addition to students. Hence, at a number of places in the text, some redundancy is added to make the concepts clearer, early theory is developed using constant and mean overall heat transfer coefficients, and more data are added in the text and tables for industrial use.

To provide comprehensive information for heat exchanger design and analysis in a book of reasonable length, we have opted not to include detailed theoretical derivations of many results, as they can be found in advanced convection heat transfer textbooks. Instead, we have presented some basic derivations and then presented comprehensive information through text and concise tables.

An industrial heat exchanger design problem consists of coupling component and system design considerations to ensure proper functioning. Accordingly, a good design engineer must be familiar with both system and component design aspects. Based on industrial experience of over three decades in designing compact heat exchangers for automobiles and other industrial applications and more than 20 years of teaching, we have endeavored to demonstrate interrelationships between the component and system design aspects, as well as between the needs of industrial and learning environments. Some of the details of component design presented are also based on our own system design experience.

Considering the fact that heat exchangers constitute a multibillion‐dollar industry in the United States alone, and there are over 300 companies engaged in the manufacture of a wide array of heat exchangers, it is difficult to select appropriate material for an introductory course. We have included more material than is necessary for a one semester course, placing equal emphasis on four basic heat exchanger types: shell‐and‐tube, plate, extended surface, and regenerator. The choice of the teaching material to cover in one semester is up to the instructor, depending on his or her desire to focus on specific exchanger types and specific topics in each chapter. The prerequisites for this course are first undergraduate courses in fluid mechanics, thermodynamics, and heat transfer. It is expected that the student is familiar with the basics of forced convection and the basic concepts of the heat transfer coefficient, heat exchanger effectiveness, and mean temperature difference.

Starting with a detailed classification of a variety of heat exchangers in Chapter 1, an overview of heat exchanger design methodology is provided in Chapter 2. The basic thermal design theory for recuperators is presented in Chapter 3, advanced design theory for recuperators in Chapter 4, and thermal design theory for regenerators in Chapter 5. Pressure drop analysis is presented in Chapter 6. The methods and sources for obtaining heat transfer and flow friction characteristics of exchanger surfaces are presented in Chapter 7. Surface geometrical properties needed for heat exchanger design are covered in Chapter 8. The thermal and hydraulic designs of extended‐surface (compact and noncompact plate‐fin and tube‐fin), plate, and shell‐and‐tube exchangers are outlined in Chapter 9. Guidelines for selecting the exchanger core construction and surface geometry are presented in Chapter 10. Chapter 11 is devoted to thermodynamic analysis for heat exchanger design and includes basic studies of temperature distributions in heat exchangers, a heuristic approach to an assessment of heat exchanger effectiveness, and advanced topics important for modeling, analysis, and optimization of heat exchangers as components. All topics covered up to this point are related to thermal–hydraulic design of heat exchangers in steady‐state or periodic‐flow operation. Operational problems for compact and other heat exchangers are covered in Chapters 12 and 13. They include the problems caused by flow maldistribution and by fouling and corrosion. Solved examples from industrial experience and classroom practice are presented throughout the book to illustrate important concepts and applications. Numerous review questions and problems are also provided at the end of each chapter. If students can answer the review questions and solve the problems correctly, they can be sure of their grasp of the basic concepts and material presented in the text. It is hoped that readers will develop good understanding of the intricacies of heat exchanger design after going through this material and prior to embarking on specialized work in their areas of greatest interest.

For the thermal design of a heat exchanger for an application, considerable intellectual effort is needed in selecting heat exchanger type and determining the appropriate value of the heat transfer coefficients and friction factors; a relatively small effort is needed for executing sizing and optimizing the exchanger because of the computer based calculations. Thus, Chapters 7, 9, and 10 are very important, in addition to Chapter 3, for basic understanding of theory, design, analysis, and selection of heat exchangers.

Material presented in Chapters 11 through 13 is significantly more interdisciplinary than the rest of the book and is presented here in a modified methodological approach. In Chapter 11 in particular, analytical modeling is used extensively. Readers will participate actively through a set of examples and problems that extend the breadth and depth of the material given in the main body of the text. A number of examples and problems in Chapter 11 require analytical derivations and more elaborate analysis, instead of illustrating the topics with examples that favor only utilization of the formulas and computing numerical values for a problem. The complexity of topics requires a more diverse approach to terminology, less routine treatment of established conventions, and a more creative approach to some unresolved dilemmas.

Because of the breadth of the subject, the coverage includes various design aspects and problems for indirect‐contact two‐fluid heat exchangers with primarily single‐phase fluids on each side. Heat exchangers with condensing and evaporating fluids on one side can also be analyzed using the design methods presented as long as the thermal resistance on the condensing or evaporating side is small or the heat transfer coefficient on that side can be treated as a constant. Design theory for the following exchangers is not covered in this book, due to their complexity and space limitations: two‐phase and multiphase heat exchangers (such as condensers and vaporizers), direct‐contact heat exchangers (such as humidifiers, dehumidifiers, cooling towers), and multifluid and multistream heat exchangers. Coverage of mechanical design, exchanger fabrication methods, and manufacturing techniques is also deemed beyond the scope of the book.

Books by M. Jakob, D. Q. Kern, and W. M. Kays and A. L. London were considered to be the best and most comprehensive texts on heat exchanger design and analysis following World War II. In the last thirty or so years, a significant number of books have been published on heat exchangers. These are summarized in the General References at the end of the book.

University by Dr. Peter Jones, Southern Methodist University by Dr. Donald Price, University of Tennessee by Professor Edward Keshock, and Gonzaga University by Professor A. Aziz. In addition, these course notes have been used occasionally at a number of other U.S. and foreign institutions. The notes of the second author have also been used for a number of undergraduate and graduate courses at Marquette University and the University of Kentucky.

The first author would like to express his sincere appreciation to the management of Harrison Thermal Systems, Delphi Corporation (formerly General Motors Corporation), for their varied support activities over an extended period of time. The second author acknowledges with appreciation many years of support by his colleagues and friends on the faculty of the School of Engineering, University of Novi Sad, and more recently at Marquette University and the University of Kentucky. We are also thankful for the support provided by the College of Engineering, University of Kentucky, for preparation of the first five and final three chapters of the book. A special word of appreciation is in order for the diligence and care exercised by Messrs. Dale Hall and Mack Mosley in preparing the manuscript and drawings through Chapter 5.

The first author is grateful to Professor A. L. London of Stanford University for teaching him the ABCs of heat exchangers and for providing constant inspiration and encouragement throughout his professional career and particularly during the course of preparation of this book. The first author would also like to thank Professors Sadik Kakaç of the University of Miami and Ralph Webb of the Pennsylvania State University for their support, encouragement, and involvement in many professional activities related to heat exchangers. The second author is grateful to his colleague and friend Professor B.S. Bačlić University of Novi Sad, for many years of joint work and teaching in the fields of heat exchanger design theory. Numerous discussions the second author have had with Dr. R. Gregory of the University of Kentucky regarding not only what one has to say about a technical topic, but in particular how to formulate it for a reader, were of a great help in resolving some dilemmas. Also, the continuous support and encouragement of Dr. Frederick Edeskuty of Los Alamos National Laboratory, and Professor Richard Gaggioli of Marquette University were immensely important to the second author in an effort to exercise his academic experience on both sides of the Atlantic Ocean. We appreciate Professor P. V. Kadaba of the Georgia Institute of Technology and James Seebald of ABB Alstom Air Preheater for reviewing the complete manuscript and providing constructive suggestions, and Dr. M. S. Bhatti of Delphi Harrison Thermal Systems for reviewing Chapters 1 through 6 and Dr. T. Skiepko of Bialystok Technical University for reviewing Chapter 5