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HEAT\nEXCHANGERS\nSELECTION, RATING,\nand THERMAL DESIGN\nSecond Edition HEAT\nEXCHANGERS\nSELECTION, RATING,\nand THERMAL DESIGN\nSecond Edition\nSadik Kakac\nHongtan Liu\nDepartment of Mechanical Engineering\nUniversity of Miami\nCoral Gables, Florida\nCRC PRESS\nBoca Raton London New York Washington, D.C. METU LIBRARY 255002010410671893 Preface This second edition of Heat Exchangers: Selection Rating and Thermal Design has retained the basic objectives and level of the first edition to present a systematic treatment of the selection, thermal-hydraulic design, and rating of the various types of heat exchanging equipment. All the popular features of the first edition are retained, while new ones are added. In this edition, modifications have been made throughout the book in response to users' suggestions and input from students who heard lectures based on the first edition of this book. Because of the importance of heat transfer enhancement, introductory material on the subject has been added to Chapter 10. Chapter 8 has been modified; as an application of the Bell-Delaware method, a new solved example has been added and the others revised. Chapter 9, dealing with the gasketed-plate heat exchanger, has been revised and new correlations to calculate heat transfer and friction coefficients for chosen Type plates have been provided; solved examples in Chapter 9 and throughout the book have been modified. Included are 37 solved examples to demonstrate thermal-hydraulic design and the rating of heat exchangers; those examples have been extensively revised. A complete solutions manual is now also available, which provides guidance for approaching the thermal design problems of heat exchangers and for the design project topics suggested at the end of each chapter. Heat exchangers are vital in power producing plants, processes and chemical industries, and in heating, ventilating, air-conditioning, refrigeration systems, and cooling of electronic systems. A large number of industries are engaged in designing various types of heat exchanging equipment. Courses are offered at many colleges and universities on thermal design under various titles. There is extensive literature on this subject; however, the information has been widely scattered. This book provides a systematic approach and should be used as an up-to-date textbook based on scattered literature for senior undergraduate and first year graduate students in mechanical, nuclear, aerospace, and chemical engineering programs who have taken introductory courses in thermodynamics, heat transfer, and fluid mechanics. This systematic approach is also essential for beginners who are interested in industrial applications of thermodynamics, heat transfer, and fluid mechanics, and for the designers and the operations of the heat exchanging equipment. This book focuses on the selection, thermo-hydraulic design, design processes, rating, and operational problems of various types of heat exchangers. The new criterion provided by the Accreditation Board on Engineering and Technology (ABET) requires engineering design across engineering curricula. Therefore, one of the main objectives of this textbook is to introduce thermal design by describing various types of single-phase and two-phase flow heat exchangers, detailing their specific fields of application, selection, and thermo-hydraulic design and rating, and showing thermal design and rating processes with worked examples and end-of-chapter problems including student design projects. Much of this text is devoted to double-pipe, shell-and-tube, compact, gasketed-plate heat exchanger types, condensers, and evaporators. Their design processes are described and thermal-hydraulic design examples are presented. Some other types, mainly specialized ones, are briefly described without design examples. Thermal design factors and their connection, however, to all heat exchangers, regardless of their function. This book begins in Chapter 1 with the classification of heat exchangers according to different criteria. Chapter 2 provides the basic design methods for sizing and rating heat exchangers. Chapter 3 is a review of single-phase forced convection correlations in ducts. A large number of experimental and analytical correlations are available for the heat transfer coefficient and flow friction factor for laminar and turbulent flow through ducts. Thus, it is often a difficult and confusing task for a student, and even a designer, to choose appropriate correlations. In Chapter 3, recommended correlations are given with worked examples. Chapter 4 discusses pressure drop and pumping power for header and other piping circuit analysis. One of the major unresolved problems in heat exchanger equipment is fouling; the design of heat exchangers subject to fouling is presented in Chapter 5. The thermal design methods and applications for double-pipe, shell-and-tube, compact and gasketed-plate heat exchangers are presented in Chapters 6, 8, 9, and 10 for single-phase tubes, respectively. The important design correlations for the design of two-phase flow heat exchangers are given in Chapter 7. With this arrangement, both advanced students and beginners will achieve a better understanding of thermal design and will be better prepared to specifically understand the thermal design of condensers and evaporators that is introduced in Chapter 11. The appendix provides the thermophysical properties of various fluids, including the new refrigerants. In every chapter, examples illustrating the relevant thermal design methods and procedures are given. Although the use of computer programs is essential for the thermal design and rating of these exchangers, for all advanced students as well as beginners, manual thermal design analysis is essential during the initial learning period. Fundamental design knowledge is needed before one can correctly use computer design software and develop new reliable and sophisticated computer software for rating to obtain an optimum solution. Therefore, one of the primary goals of this book is to encourage students and practicing engineers to develop a systematic approach to the thermal-hydraulic design and rating of heat exchangers. This is demonstrated with 37 solved examples in the text and with more than 125 end-of-chapter problems. The end-of-chapter problems, including student design projects, are selected to enhance the design applications. A solution manual accompanies the text. Additional problems are added to the solution manual which may be helpful to instructors. Design of heat exchange equipment requires explicit consideration of mechanical design, economics, optimization techniques, and environmental considerations. Information on these topics is available in various standard references and handbooks and from manufacturers. Several individuals have made very valuable contributions to this book. E.M. Sparrow and A. Bejari reviewed the manuscript and provided helpful suggestions. We gratefully appreciate their support. Sadık Kakac has edited several books on the fundamentals and design of heat exchangers and is very thankful to them. The authors are especially indebted to the following individuals whose contributions to the field of heat exchange made this book possible: Kenneth J. Bell, David Butterworth, John Collier, Paul J. Mastro, Mike B. Pate, Ramesh K. Shah, and J. Taborek. The authors express their sincere appreciation to their students, who contributed to the improvement of the manuscript by their critical questions. The authors wish to thank Dr. Likin You, Dr. Claudia C. Gavioles, and Dr. Liging Cao for their valuable assistance during the classroom teaching and various stages of this project. Special thanks to Dr. Tianhong Zhou for his assistance in the preparation of the manuscript and to Dr. Likin You and Ms. Lin Wang for their assistance in the preparation of the second edition and the solution manual. Thanks are also due to Cindy Renee Carelli, Engineering Publications Editor, and Helene Redhawk, Supervisor, EPD, and other individuals at CRC Press LLC, who have initiated the first edition and contributed their talents and energy to this edition. Finally, we wish to acknowledge the encouragement and support of our lovely wives and children who made many sacrifices during the preparation of this text. Sadık Kakac Hongtan Liu Authors Sadık Kakac is a Professor of Mechanical Engineering at the University of Miami in Coral Gables, Florida. He served as chairman of the department from 1990 to 1998. In 1955, he received the Dipl.-Ing. in Mechanical Engineering from the Technical University of Istanbul and then received his M.S. in Mechanical Engineering in 1959 and his M.S. in Nuclear Engineering in 1960, both from the Massachusetts Institute of Technology. In 1965, he received his Ph.D. in the field of heat transfer from the Victoria University of Manchester, UK. He was elected as a member of the Turkish Scientific and Technical Research Council in 1972 and became General Secretary of the Turkish Atomic Energy Commission in 1978, representing Turkey in a number of scientific endeavors abroad. He was the recipient of the Alexander von Humboldt Senior Distinguished U.S. Scientist Award in 1989, the Science Award of the Association of Turkish-American Scientists in 1994, the ASME Heat Transfer Memorial Award in 1997, the ICHMT Fellowship Award in 1997, and the Distinguished Service Award from the Turkish Scientific and Technical Research Council (TÜBİTAK) in 2000. He is a fellow of the ASME, the Turkish Academy of Sciences, and the Academy of the Sciences of the Russian Federation. He is an honorary professor at the Shanghai Institute of Electrical Power in China, a consulting professor of Xi’an Jiaotong University in China, and an honorary professor of the College of Engineering at the Gandhi Institute of Technology and Management in India. He received the Doctor Honoris Causa from the University Ovidius, Romania in 1998 and the Doctor Honoris from the University of Reims, France in 1999. Dr. Kakac was formerly a Professor of Mechanical Engineering of the Middle East Technical University in Ankara, Turkey. Dr. Kakac has focused his research efforts on steady-state and transient forced convection in single-phase and two-phase flow instabilities in flow boiling. He is the author or co-author of six heat transfer text books and more than 140 research papers, as well as fourteen edited volumes in the field of thermal sciences and heat exchanger fundamentals and design, including the Handbook of Single-Phase Convective Heat Transfer. Hongtan Liu is an Associate Professor of Mechanical Engineering at the University of Miami in Coral Gables, Florida. He received his B.S. in Mechanical Engineering from Shenyang Civil and Architectural Engineering Institute in 1982 and both his M.S. (1988) and Ph.D. (1993) in Mechanical Engineering from University of Miami. From 1990 to 1991, he was a research fellow at the Institute of Thermodynamics of the Technical University of Munich in Germany, where he concluded research on boiling two-phase flows. From 1996 to 1997, Dr. Liu was a Senior Research Engineer at Energy Partners, Inc., where he was in charge of the research in fluid flow, heat, and mass transfer in PEM fuel cells. He was the recipient of Fluid/Light Luxury Excellence in Research awards in both 1998 and 1999. Dr. Liu has focused his research efforts on fuel cell technology, two-phase flow instability and heat transfer, solar energy applications, and hydrogen energy systems. He is the author or co-author of one textbook, two book chapters, and more than 60 research papers. He was invited to deliver two keynote papers at international conferences and give more than 15 invited lectures at international conferences, universities, and industrial corporations. Dr. Liu is also an Editorial Board Member for the International Journal of Hydrogen Energy.