Performance of A Double-Pipe Heat Exchanger: Unit Operations Laboratory

Experiments in Chemical Engineering Double- Pipe Heat
Exchanger

Unit Operations Laboratory Page 1
PERFORMANCE OF A DOUBLE-PIPE HEAT EXCHANGER

INTRODUCTION

Modern manufacturing industries employ processes that require heating and cooling.
From the preparation of the raw materials, to their processing, to the conditioning of the
final products into sellable items and even down to the treatment of process effluents,
heat transfer mechanisms are always applied. Most of the time, heating and cooling
are done using heat exchangers and a double-pipe heat exchanger is one of the
commonly used type. Being such a vital industrial tool, it is of great importance that
chemical engineering students learn the basic concepts and theories especially the
operation of a double-pipe heat exchanger. The fundamental concepts applied will
enable the students to analyze and design other types of heat exchanger.

OBJECTIVES

1. To familiarize the students with the characteristics, parameters and problems
involved in the operation of a double-pipe heat exchanger when operated using
countercurrent or co-current flow.
2. To determine and compare measured and calculated mean temperature
difference between hot and cold water in both countercurrent and co-current
flow.
3. To compare experimental overall heat transfer coefficient obtained using data
from direct measurements with the theoretical overall heat transfer coefficients
calculated using available empirical equations.

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THEORY

Although there are several ways of transferring heat between fluids, the most common is
the use of a heat-exchanger wherein the hot fluid and cold fluid are separated by a
solid boundary. Different types of heat exchangers have been developed. The simplest
type is a double-pipe heat exchanger. This consists essentially of two concentric pipes
with one fluid flowing through the inside of the inner pipe while the other fluid moves co-
currently in the annular space. This type of heat exchanger, however, is not
recommended for processes that require very large heating surfaces.

The heat transfer analysis of a double-pipe heat exchanger deals with the application
of several equations that relate the different parameters involved. Consider the heat
exchanger,

Where: mh = Mass flow rate of hot fluid, lbm/hr
mc = mass flow rate of cold fluid, lbm/hr
Tc = temperature of cold fluid, F
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Th = temperature of hot fluid, F
**subscript 1 refers to entrance conditions, 2 refers to exit conditions

To determine the rate of heat loss by the hot fluid or the heat gained by the cold fluid,
we apply a steady overall energy balance between the two ends of the heat
exchanger. On the basis of 1 lbm/sec of fluid flowing, we have,

W + JQ = Z(
) +
+ J (1)
Where: W = shaft work
Z(
) = mechanical potential energy

= mechanical kinetic energy

= kinetic energy velocity correction factor
( = 1.0 for turbulent flow; 0.5 for laminar flow)

Since no shaft work W, is involved, Z(
) and
, are small compared with the

thermal energy transfer. Then for one fluid, the equation reduces to,

Q = H = (H2 H1) (2)

If no change in phase involved,

H = CpT (3)

Therefore, the rates of heat transfer for the cold and hot fluids are respectively,

qc = mcCpc(Tc2 Tc1) (4)
qh = mhCph(Th1 Th2) (5)

If heat losses to the surroundings are neglected,
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qc = qh or (6)
mcCpc(Tc2 Tc1)= mhCph(Th1 Th2) (7)
To relate the heat transfer rate with the size of the heat exchanger, we apply the
transfer around the differential element of length, dL. Thus,

dq = U1(Th Tc)dA = Uo(Th Tc)dAo (8)

Where: U = Overall heat transfer coefficient, Btu/hr-ft
2
F
A = heat transfer area, ft
2

T = temperature driving force, F = (Th Tc)
**subscript 1 refers to the inside of the heating surface and
subscript o refers to the outside of the heating surface

For double-pipe heat exchangers, the overall heat transfer coefficient is almost
constant along the length of the heat exchanger and the driving potential may be
considered almost linear with q so that Equation (7) can be integrated to give,

q = UiAiTln = UoAoTln (9)

where: Tln = Logarithmic mean temperature difference
logarithmic mean temperature difference is defined by the
equation,

Tln =

(10)

Where: T1 = Temperature approach in one end
T2 = Temperature approach in the other end

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The Tln is fairly accurate if the T is linear with q or L. however, in most situations, this
relationship is not always true. Let us compare therefore the log mean temperature
difference as defined by equation (9) and the arithmetic mean temperature difference,
To defined by,

To =

(11)

With the true mean temperature difference, Tm which is obtained directly from
equation (7) by expressing T in terms of L,

q = 2UD
= 2UDL(T)tm (12)
therefore,

(T)tm =

(13)

Equation (11) is evaluated using graphical or numerical integration by plotting values of
T against exchanger length and getting the area under the curve. These are then
divided by the total length of the exchanger.

It is given that the experimental overall heat transfer coefficient may be calculated
based on equation (8) by determining the rate of heat transfer by direct measurements.
To determine theoretical overall heat transfer coefficient, express Ui or Uo in terms of the
individual transfer coefficients by considering resistances involved when heat travels
from the hot to the cold fluid. Such a relationship, assuming relatively clean surface, is
given by:

(14)

Where: xm =Thickness of the tube wall
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km = Thermal conductivity of the metal
A = Average heat transfer area

If Uo is desired, equation (12) simplifies to

(15)

If Ui is desired, we get

(16)

Since the values of the xm, Do, and km can easily be obtained from available data, the
problem now boils down to the evaluation of the individual heat transfer coefficients.
This involves the choice of a particular empirical equation based on several factors such
as mechanism of heat transfer, character of flow, geometry of the system type of fluid
involved, etc.

Since most of the conditions in this experiment can be set, the equations for h may be
limited to only several choices. Based on mechanism, we can limit it to forced
convection by using flow rates that yield turbulent flow. This will eliminate the effects of
natural convection. Based on geometry, we are limited to horizontal tubes with fluids
flowing inside the conduits, circular and annular. Based on the type of fluid, we are
limited to usng hot and cold water.

In general, for forced convection in turbulent flow, (NRE > 10,000), k may be calculated
considering the effect of tube length by

(
) (
=
(
(17)

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Where the properties Cp, , k are evaluated based on the arithmetic mean bulk
temperature of the fluid defined by,

Tave =
(18)

The viscosity, based on the wall temperature, w will have to be determined by
estimating Tw by iterative calculation using individual resistances evaluated by first
neglecting the effect of w.

If the effect of the tube length can be ignored, (L/D > 60) and the (w/)
0.14
is
approximately equal to 1, the simpler Dittus-Boelter Equation (Foust 13-77), given by

NNu = 0.023(NRe)
0.8
(NPr)
n
(19)

May be applied, where n= 0.4 where the fluid is heated and 0.3 when it is being cooled.
Here, the dimensionless numbers are defined as

NNu =
Nusseltss Number
NRe =
Reynolds Number
NPr =
Prandtl Number

Another equation which is limited to water based temperature range of 40F to 220F,
turbulent flow, may be used. This is given by

h = 150 (1 + .011 T)
()

(20)
where: T = Arithmetic temperature of fluid, F
D = Tube diameter, inches

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Equations (15), (16) and (17) are used to determine both hi and ho. to get hi, the
corresponding inside diameter of the tube is used for D. to get ho, the D is replaced by
the equivalent diameter, De, which is four times the hydraulic radius RH, defined to be
the ratio of the cross-sectional area of the annular space to the wetted perimeter. For
an annular space,

RH =
(
)
()
=
( ) (21)

Where: Dij = inside diameter of jacket (outer tube)
Dot = outside diameter of inner tube

It is possible that flow with Reynolds number less than 10,000 will be encountered. In this
case, Equations (15),(16) and (17) are no longer valid. For NRe = 2100 and for fluids of
moderate velocity.

Gr
1/3
= 1.75 (
(22)

For NRe between 2100 and 10,000, Figure 9-22 (MC) will have to be used. Also, if the flow
is laminar, the effect of natural convection should not be discounted. This effect can be
accounted for by multiplying hia (computed from equation (19) or figure 9-22) by the
factor

n =
(
(23)

NGr =

(24)

Where: De = equivalent diameter
= coefficient of thermal expansion, F
-1

f = subscript indicating that fluid properties should be based on
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Tf =

EQUIPMENT

Figure 1. Side view of Double-pipe Heat Exchanger

Equipment Description

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The double-pipe heat exchanger set-up as shown in the previous figure consists
essentially of concentric pipes welded in series. The inner is made of brass with an inside
diameter of 0.625 inch and an outside diameter of 0.815 inch. The outer tube made of
standard 1 steel pipe. The unit is composed of 12 sections in series. Each section is
approximately 50 inches long. Hot water, which comes from the nearby tubular heat
exchanger, is passed through the inner pipe and the cold water, coming from the
supply main is passed through the annular space between the tubes.

Valves are provided for reversing the direction of the cold stream to obtain either
countercurrent or co-current flow. Valves on both lines are also provided to control the
flow rates of the streams. Each section is provided with thermometer wells, which
contain small amount of oil, to measure the temperature of the streams at appropriate
points along the heat exchanger. At the exit ends of the pipes, weighing tanks with
calibrated levels are provided for measurement of flow rates.

PROCEDURE

It is important that this experiment should be performed with proper coordination with
Experiment B2, Performance of a Tubular Heat Exchanger, since the hot water used in
this experiment is the hot water discharged from the tubular exchanger. Any valve
movement in Experiment B2 will affect the temperature and flow rate of the hot water.
Therefore, each run for both experiments should start and end simultaneously.

1. Familiarizing yourself with the parts and operation of the equipment, especially
the use of the valves provided in the lines. Place the thermometers at the
appropriate wells provided.
2. Open the supply valve for cold water, check whether water is flowing out the
measuring tanks, if not, checks exit valves. Pressure gauge provided should
indicate a constant reading. Adjust this valve to have a feel of the range of flow
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rates to be used. Approximately determine the setting so as to get six different
flow rates later for each run. The exit valves in the measuring tanks should be
open to drain the liquid to avoid overflowing when flow is not being measured.
3. Adjust the four valves in the cold water line to get either co-current or
countercurrent flow. This is done by fully opening or closing two opposite valves.
Trace the direction of flow from inlet to exit to determine this.
4. If hot water is already available, allow this to flow through the lines by fully
opening the exit valves.
Note: you should not move any valve along the hot water line without the
consent of the people operating the tubular exchanger nor they should move
anything without you knowing it. The flow rate of the hot water is usually at their
control, so regular consultation is advised.
5. If flow rates have been established, prepare to continue the run by regularly
checking the temperature indicated by the thermometers at regular intervals of
time to determine whether steady conditions have already been established and
by measuring the flow rates of the two streams. The flow rate is measured by
closing the first exit valve for the water level to pass between pre-selected points
in the level gauge. The more time you spend in the measurement, the better. The
volumetric flow rate is obtained by dividing the volume of water collected by the
time interval.
6. If reasonable steady state conditions have been established, record all
temperature readings and flow rates i.e., no significant changes are observed,
and the run is completed.
7. Proceed with another run by adjusting the flow rate of the cold fluid and/or the
flow rate of the hot fluid. Each run should last approximately 20 minutes.
8. Perform a total of six runs; three countercurrent and three co-current flows.
9. Tabulate all data collected, measure the length of each section accurately,
check diameter of tubes, etc.

DATA SHEET
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A. CO-Current Flow Operation
Trial 1
Well Number 1
st
Reading 2
nd
Reading 3
rd
Reading
TH (C) TC (C) TH (C) TC (C) TH (C) TC (C)
1 37 37 37 37 37 37
2 39.8 37 40 37 40 37
3 40.5 36 40.9 36.5 41 36.75
4 41.5 35.5 42 36 42 36
5 43 34 44 34.25 44 34.25
6 45.5 32 46 32.5 46 32.75
7 49 30 49.5 50 50 30
Flow Rate (kg/s) 0.266667 0.33333 0.3 0.366667 0.3 0.366667

Trial 2
Well Number 1
st
Reading 2
nd
Reading 3
rd
Reading
1 33 33 32.5 32.5 33 33
2 43 33 45.5 32.5 45 33.5
3 46.5 32 46 32 46 32
4 49 35 48.5 34.5 50.25 34.5
5 53 37 53 37 54 32.5
6 53.5 36.5 53.5 36 54.5 32
7 54 36 54 35.5 55.5 31
Flow Rate (kg/s) 0.25 0.366667 0.258333 0.375 0.25 0.366667

B. Countercurrent Flow Operation

Trial 1
Well Number 1
st
Reading 2
nd
Reading 3
rd
Reading
1 38.5 39.5 38.5 38.5 38.5 39
2 38 29 38 29 38.5 29
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3 41 31 40 30.5 40.5 31
4 43 33 42 32.5 42.5 32.5
5 46 34 45 34 45.5 34
6 48 36 47 36.5 47.5 36
7 50.5 38 49.5 37.5 50.5 38
Flow Rate (kg/s) 0.272222 0.355556 0.283333 0.366667 0.283333 0.366667

Trial 2
Well Number 1
st
Reading 2
nd
Reading 3
rd
Reading
1 42 42 42 42.5 42 42
2 45 42.5 45 42.5 46 42.5
3 46 40.5 46 40.5 46.5 40.5
4 48 39.5 48 39.5 47 39
5 50 38 49 38 49 38
6 50.5 37.5 49.5 37 49.5 37.5
50.5 51 37 50 36.5 51 37
Flow Rate (kg/s) 0.25 0.366667 0.258333 0.375 0.25 0.366667

ANALYSES AND CALCULATIONS

1. Plot for each run the temperature of the hot and cold fluid versus the length of
the heat exchanger indicating whether it is countercurrent flow or co-current
flow. Also, in the same graph, plot T versus length. Present these figures (1) to (6).
Did you get linear behavior? Explain.
2. Using the terminal temperatures for each run, calculate the logarithmic mean
and arithmetic mean temperature differences. Based on the plot of T versus L as
given in Figures (1) to (6), calculate the true mean temperature difference by
graphical integration. Calculate also the percentage deviation of Ta from Ttm.
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Tabulate the results and present as Table 1. Explain the results you got as to the
validity of the various temperature differences you obtained.
3. Calculate the heat gained by the cold fluid, qc, and the heat lost, qh. Compare
the two by solving for the difference. Tabulate the results and present this as
Table 2.
4. Using qh as the basis, calculate for the experimental Ui, by calculating first A, and
using Tln in Equation (2). Tabulate the results and present this as Table 3.
5. Calculate the theoretical Ui by first solving hi and ho using appropriate empirical
formulas. Summarize the results by preparing a table indicating the run number,
average bulk temperature, Reynolds number, Prandtl number, h and theoretical
U. also compare h obtained using Equations (14) and (15). Present this as Table 4.
6. Calculate the percentage difference between the experimental and the
theoretical Ui. Present this as Table 5.
7. Using only the date from one run each for co-current and countercurrent flow,
calculate h using equations (13), (14), and (15). Compare by tabulating the
results. Present this as Table 6.
GUIDE QUESTIONS

1. Based on your findings, discuss the applicability of the arithmetic mean and
logarithmic temperature difference in double pipe heat exchanger calculations.
What affects accuracy?

In computation for the temperature difference, a little variation has been
observed. The logarithmic mean temperature difference records a value of
several decimal places, which can be considered as more accurate than of the
arithmetic mean temperature difference. In a double pipe heat exchanger,
logarithmic mean difference should be used instead of arithmetic mean
difference, although a small deviations exist considering an accuracy of the
value, the former hold true. Accuracy of the measurement might due to parallax
error relative to the reader of the of the thermometer in each well on the double
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pipe heat exchanger. The condition of the atmosphere or the surroundings might
intervene as well.

The behavior of a heat exchanger in variable regime can be described by a two
parameter model with a time lag and a time constant. In many studies, the
analytical calculation based on the energy balance permitted to express the
time constant in various configurations of the device operating. However, the
time lag is only experimentally determined. An empirical method for the
prediction of this parameter when a double pipe heat exchanger is submitted to
a flow rate step at the entrance.

2. Give your comments as to the validity of the theoretical and experimental overall
heat transfer coefficients you obtained.

Certain possibilities can be considered as to how the heat gained by the cold
fluid differs from the heat lost by the hot fluid, the wall resistance of the tube, the
length the fluid travels in the heat exchanger and the type of the materials used
for the pipe system.

The overall heat transfer coefficient can also be calculated by the view of
thermal resistance. The wall is split in areas of thermal resistance where
- the heat transfer between the fluid and the wall is one resistance
- the wall itself is one resistance
- the transfer between the wall and the second fluid is a thermal resistance

3. What are the problems you encountered in the operation of the double-pipe
heat exchanger? How did you overcome these problems and what
recommendations can you give to streamline or improve the use of such
experiment?

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The distance between the sheets in the spiral channels are maintained by using
spacer studs that were welded prior to rolling. Once the main spiral pack has
been rolled, alternate top and bottom edges are welded and each end closed
by a gasketed flat or conical cover bolted to the body. This ensures no mixing of
the two fluids will occur. If a leakage happens, it will be from the periphery cover
to the atmosphere, or to a passage containing the same fluid.

4. Give the physical significance of NRe, NNu and NPr in relation to heat transfer
characteristics.

Reynolds Number, Nusselt, and Prandtl Numbers are significant in the calculations
and widely applicable in the heat exchange principle. NRe determines the type
of flow regime in the heat exchanger equipment as well as in the pipeline. The
flow of the fluid or the velocity affects the temperature in somewhat
considerable amount. The laminar or turbulence behavior of the fluid also
accounts to the film resistance of the fluid and thus needed to be determined.
NNu or the Nusselt number is a dimensionless quantity, which is define as the ratio
of the tube diameter to the equivalent thickness of the laminar layer. Further,
Nusselt number is the resulting correlation on the ratio of the total heat transfer by
molecular and turbulent transport to heat transfer by molecular transport alone.
The physical significance of the Prandtl number appears that it is the ratio of the
velocity to the thermal diffusivity, it is therefore a measure of the magnitude of
the momentum, diffusivity relative to that of the thermal diffusivity. Its numerical
value depends on the temperature and pressure of the fluid, and therefore it is a
true property.

Low-Reynolds Number turbulent flow, and laminar non-Newtonian flow. Heat
exchaner configurations and materials were examined, as were compact and
noncompact versions and heat transfer and fouling.

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The Prandtl number effects on heat transfer are categorized into two
perspectives: fin perspective and array perspective. The fin perspective Prandtl
number effects explain the dependence of the periodic fully developed Nusselt
number on Prandtl number. The array perspective is analogous to the thermal
entry length perspective in duct flow. Array perspective Prandtl number effects
yield higher Nusselt numbers in the entrance region of the offset fin array.

Nusselt numbers are measured in three counterflow tube-in-shell heat exchangers
with flow rates and temperatures representative of thermosyphon operation in
solar water heating systems. Mixed convection heat transfer correlations for these
tube-in-shell heat exchangers were previously developed in Dahl and Davidson
(1998) from data obtained in carefully controlled experiments with uniform heat
flux at the tube walls. The data presented in this paper confirm that the uniform
heat flux correlations apply under more realistic conditions. Water flows in the
shell and 50 percent ethylene glycol circulates in the tubes. Actual Nusselt
numbers are within 15 percent of the values predicted for a constant heat flux
boundary condition. The data reconfirm the importance of mixed convection in
determining heat transfer rates. Under most operating conditions, natural
convection heat transfer accounts for more than half of the total heat transfer
rate.

5. Discuss briefly the relative merits of countercurrent and co-current flow of fluids
for the transfer of heat?

Countercurrent exchange along with Concurrent exchange comprise the
mechanisms used to transfer some property of a fluid from one flowing current of
fluid to another across a semipermeable membrane or thermally-conductive
material between them. The property transferred could
be heat, concentration of a chemical substance, or others. Countercurrent
exchange is a key concept in chemical engineeringthermodynamics and
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manufacturing processes, for example in extracting sucrose from sugar
beet roots.

Concurrent Flow In this exchange system, the two fluids flow in the same
direction. As the diagram shows, a concurrent exchange system has a
variable gradient over the length of the exchanger. With equal flows in the
two tubes, this method of exchange is only capable of moving half of the
property from one flow to the other, no matter how long the exchanger is. If
each stream changes its property to be 50% closer to that of the opposite
stream's inlet condition, exchange will stop because at that point equilibrium
is reached, and the gradient has declined to zero. In the case of unequal
flows, the equilibrium condition will occur somewhat closer to the conditions
of the stream with the higher flow.
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Countercurrent Flow - By contrast, when the two flows move in opposite
directions, the system can maintain a nearly constant gradient between the
two flows over their entire length. With a sufficiently long length and a
sufficiently low flow rate this can result in almost all of the property being
transferred. However, note that nearly complete transfer is only possible if the
two flows are, in some sense, "equal". If we are talking about mass transfer,
then this means equal flowrates of solvent or solution, depending on how the
concentrations are expressed. For heat transfer, then the product of the
average specific heat capacity (on a mass basis, averaged over the
temperature range involved) and the mass flow rate must be the same for
each stream. If the two flows are not equal (for example if heat is being
transferred from water to air or vice-versa), then conservation of mass or
energy requires that the streams leave with concentrations or temperatures
that differ from those indicated in the diagram.

6. Give a summary of your findings and conclusions and give recommendations, if
any.

The experiment presents the results of an experimental study of shell-side heat
transfer and flow resistance performance of multi-tube type of double-tube heat
exchanger units, which is a double-pipe heat exchanger with smooth or roughen
tubes and a segmental baffled one with smooth tubes, using water and crude oil
(a mixture of oil and water) as working fluids. The experimental results indicate
that the double-tube heat exchanger with a spiral groove tube bundle provides
superior shell-side heat transfer and pressure drop characteristics. Double-tube
heat exchanger is installed for heating crude oil in a solar energy system.

1. Plot of Temperature vs Length of Pipe

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2. Computing for the Logarithmic Mean Temperature Difference

1 2
1
2
T -T
LMTD =
T
ln
T

Where: T1 = Tleaving temperature , hot fluid Tentering temperature, cold fluid
T2 = Tentering temperature, hot fluid Tleaving temperature, cold fluid
| |
|
\ .
(39-32.6)-(40.5-33.5)
LMTD=
39-32.6
ln
40.5-33.5

LMTD = 6.6955
0
C

3. Computing for the Arithmetic Mean Temperature Difference
1 2
2
T T A + A
AMTD =
( ) ( )
0
2
. . . 39 32 6 + 4 5 33 5
AMTD =
Length of the heat exchanger pipe
Temperature,
o
C
Plot of Temperature vs Length of pipe
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AMTD = 6.70
0
C

4. Comparison of LMTD and AMTD for Counter-current Flow
LMTD AMTD
Flow 1 6.6955 6.70
Flow 2 6.4499 6.450
Flow 3 6.1434 6.150
Flow 4 5.8994 5.90
Flow 5 6.2467 6.25
Flow 6 6.2467 6.25

5. Plot of Temperature vs Length of Pipe

6. Computing for the Logarithmic Mean Temperature Difference

1 2
1
2
T -T
LMTD =
T
ln
T

Length of the heat exchanger pipe
Temperature, C
Plot of Temperature vs Length of pipe
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Where: T1 = Tleaving temperature , hot fluid Tentering temperature, cold fluid
T2 = Tentering temperature, hot fluid Tleaving temperature, cold fluid

40 27 5
38 29 5
.
.
| |
|
\ .
(40-27.5)-(38-29.5)
LMTD=
ln

LMTD = 10.3718
0
C

Computing for the Arithmetic Mean Temperature Difference

1 2
2
T T A + A
AMTD =

AMTD = 10.50
0

7. Comparison of LMTD and AMTD for Counter-current Flow
LMTD AMTD
Flow 1 10.3718 10.50
Flow 2 8.6084 7.5
Flow 3 5.4389 5.5
Flow 4 3.6995 3.75
Flow 5 2.4663 2.5
Flow 6 2.0

( ) ( )
40 27 5 38 29 5
2
. . +
AMTD =

Performance of A Double-Pipe Heat Exchanger: Unit Operations Laboratory

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Experiments in Chemical Engineering Double- Pipe Heat

) = mechanical potential energy

= mechanical kinetic energy

, are small compared with the

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