Heat Exchanger

1. Abstract
The objective of this experiment is to study the function and the working of shell and
tube heat exchanger. Calculations on the heat transfer and heat loss were carried out
for energy balance study. LT! and heat transfer coefficient also calculated for this
experiment. "rom the data collected# we found out that configuration of $hell and
Tube heat exchanger in counter current flow has a higher effectiveness than the co%
current flow.
2. Introduction
& heat exchanger is an e'uipment in which heat exchange takes place between (
fluids that enter and exit at different temperatures. The main function of heat
exchanger is to either remove heat from a hot fluid or to add heat to the cold fluid.
The direction of fluid motion inside the heat exchanger can normally categorised as
parallel flow# counter flow and cross flow. )n this experiment# we study only the
parallel flow and counter flow. "or parallel flow# also known as co%current flow# both
the hot and cold fluids flow in the same direction. *oth the fluids enter and exit the
heat exchanger on the same ends. "or counter flow# both the hot and cold fluids flow
in the opposite direction. *oth the fluids enter and exit the heat exchanger on the
opposite ends. )n this experiment# we focused on the shell and tube heat exchanger.
3. Experiment Methods and Materials
The apparatus used in this experiment include a $hell and Tube heat exchanger# a cold
water circuit consists of a +,L tank and centrifugal pump# a hot water circuit consists
of a +,L tank and centrifugal pump# temperature and flow rate indicators.
The experiment procedures include-
.eneral $tart%up /rocedure
& 'uick inspection was done to make sure the e'uipment is in a proper working
condition. &ll the valves are made sure to be initially closed except 0( and 01(. The
hot water tank was filled up via a water supply hose connected to 0(2. The valve was
closed once the tank is full. The cold water tank was filled up by opening valve 0(3
and the valve was left opened for continues water supply. & drain hose was connected
to the cold water drain point. Then# the main power and the heater for the hot water
were switched on. The temperature controller was also set pointed to +,
o
C. The water
temperature in the hot water tank was allowed to reach the set point. &fter that# the
e'uipment is ready to be run.
.eneral $tart%down /rocedure
The heater was switched off and the hot water temperature was waited until it drops
below +,
o
C . Then# pump /1 and /( were switch off. &fter that# the main power was
switched off and all water in the process lines were drained off. The water in the hot
and cold water tanks was retained. "inally# all the valves were closed.
Counter%current
& first# general start%up procedure was performed before the experiment begins. The
arrangement of the valve of $hell and Tube heat exchanger was switch to counter%
current as the experiment begins. /ump /1 and /( were also switched on. Then#
valves 04 and 015 were opened and adjusted to obtain the desired flow rates for hot
water and cold water stream respectively. The system was allowed to reach steady
state for 1, minutes. !ata for "T1# "T(# TT1# TT(# TT4# and TT5 were recorded.
These steps were repeated for different combinations of flow rate "T1 and "T( as
recorded under the tables below. /ump /1 and /( were switch off when the
experiment complete. &ll the results are tabulated under the tables below. &fter that#
we proceed to the following experiment.
Co%current
& first# general start%up procedure was performed before the experiment begins. The
arrangement of the valve of $hell and Tube heat exchanger was switch to co%current
as the experiment begins. /ump /1 and /( were also switched on. Then# valves 04
and 015 were opened and adjusted to obtain the desired flow rates for hot water and
cold water stream respectively. The system was allowed to reach steady state for 1,
minutes. !ata for "T1# "T(# TT1# TT(# TT4# and TT5 were recorded. These steps
were repeated for different combinations of flow rate "T1 and "T( as recorded under
the tables below. /ump /1 and /( were switch off when the experiment complete. &ll
the results are tabulated under the tables below. "inally# the e'uipment was shut
down.

4. Data Analysis
The specific results for this experiment allow us to determine the heat transfers# heat
losses# heat transfer coefficient and LT! values.
$hell 6 Tube Heat Exchanger
Tube 7.!. 8d
o
9 - :.+4 mm
Tube ).!. 8d
i
9 - 2.2+ mm
Tube Length 8L9 - +,, mm
Tube Count 8N
t
9 - 1, 8single pass9
Tube /itch 8p
t
9 - 13 mm
Tube arrangement - Triangle
$hell 7.!. - 1,, mm
$hell ).!. 8D
s
9 - 3+ mm
*affle Count - 3
*affle Cut 8B
c
9 - (, ;
*affle !istance 8l
B
9 - +, mm
aterial of Construction - 41<L $tainless $teel=*orosilicate .lass
Counter%current
FT1
!"min#
FT2
!"min#
TT1

o
$#
TT2

o
$#
TT3

o
$#
TT4

o
$#
%eat
Trans&er
'(#
%eat
!osses
'(#
1, ( +,., 52.< 51.2 4(.: 1.((,< ,.+,5:
1, 5 5:.3 5<.3 4:.( 4(.: 1.253, ,.4(4,
1, < +,., 5<.+ 42.3 4(.3 (.,31( ,.44+1
1, 3 +,.4 5<.4 4<.3 4(.3 (.(2+2 ,.53+2
1, 1, 5:.2 5<.+ 4<., 4(.< (.4+:1 ,.52(4
FT1
!"min#
FT2
!"min#
TT1

o
$#
TT2

o
$#
TT3

o
$#
TT4

o
$#
%eat
Trans&er
'(#
%eat
!osses
'(#
( 1, 5:.< 5,., 44.: 4(.< ,.:,(1 ,.5(+4
5 1, 5:.3 55.( 45.4 4(.< 1.12:2 ,.4<25
< 1, +,., 55.3 4+.1 4(.< 1.2452 ,.51:2
3 1, +,., 5+.4 4+.< 4(.< (.,31< ,.+1+(
1, 1, 5:.4 5+.< 4+.: 4(.+ (.(3:2 ,.(<+4
) '(# !MTD A
o
A
i
*
o
*
i
1.4(2+ 1,.5( ,.1( ,.,:< 1.,<1< 1.4,+4
1.+521 11.2+ ,.1( ,.,:< 1.,:24 1.45:1
(.1+55 1(.+: ,.1( ,.,:< 1.5(<, 1.2+44
(.+:<3 14.,+ ,.1( ,.,:< 1.<+3( (.,433
(.+++, 1(.31 ,.1( ,.,:< 1.<<(1 (.,54<
Co%current
FT1
!"min#
FT2
!"min#
TT1

o
$#
TT2

o
$#
TT3

o
$#
TT4

o
$#
%eat
Trans&er
'(#
%eat
!osses
'(#
1, ( 5:.2 52.4 4(.2 51.1 1.1+14 ,.+,+<
1, 5 5:.: 5<.< 4(.2 43.3 1.<:(< ,.+3+:
1, < 5:.2 5<.1 4(.2 42.5 1.:+<5 ,.+(:,
1, 3 +,.1 5<.1 4(.+ 4<.5 (.1<52 ,.<<+2
1, 1, +,.4 5+.2 4(.4 4+.2 (.4+:( ,.252+
FT1
!"min#
FT2
!"min#
TT1

o
$#
TT2

o
$#
TT3

o
$#
TT4

o
$#
%eat
Trans&er
'(#
%eat
!osses
'(#
( 1, 5:.2 5,.2 4(.4 44.< ,.:,(( ,.4(34
5 1, 5:.< 55., 4(.4 45.1 1.12:2 ,.4<+2
< 1, +,.1 5+., 4(.4 45.3 1.2453 ,.51:<
3 1, 5:.3 5+.( 4(.4 4+.4 (.,312 ,.5+:4
1, 1, 5:.< 5+.< 4(.4 4+.2 (.4+:( ,.5,(3
) '(# !MTD A
o
A
i
*
o
*
i
1.(4,+ 11.2: ,.1( ,.,:< ,.3<:2 1.,<:4
1.+524 14.+< ,.1( ,.,:< ,.:+,: 1.1<:1
(.1+55 14.:1 ,.1( ,.,:< 1.(:,2 1.+3<:
(.+51, 14.23 ,.1( ,.,:< 1.+4<2 1.33:4
(.2<(, 14.<, ,.1( ,.,:< 1.<:(5 (.,3,3
+. Discussion
"ormulas for Calculation
Co%current "low heat balance-
m
t
C
pt
(t
2
- t
1
) = m
s
C
ps
(T
1
- T
2
) = q
Counter%current "low heat balance-
m
t
C
pt
(t
2
- t
1
) = m
s
C
ps
(T
1
- T
2
) = q
where#
m
t
> mass flowrate of cold fluid in the tube 8kgs
%1
9
m
s
> mass flowrate of hot fluid in the shell 8kgs
%1
9
C
pt
> specific heat of cold fluid in the tube 8k?kg
%1
@C
%1
9
C
ps
> specific heat of hot fluid in the shell 8k?kg
%1
@C
%1
9
t
1
, t
2
> temperature of cold fluid entering=leaving the tube 8@C9
T
1
, T
2
> temperature of hot fluid entering=leaving the shell 8@C9
q > heat exchange rate between fluid 8kA9
The general e'uation for heat transfer across the tube surface in a shell and tube heat
exchanger-
q = U
o
A
o
T
m
= U
i
A
i
T
m
849
where#
A
o
> outside area of the tube 8m
(
9
A
i
> inside area of the tube 8m
(
9
T
m
> mean temperature difference 8@C9
U
o
> overall heat transfer coefficient based on
the outside area of the tube 8kAm
%(
@C
%1
9
U
i
> overall heat transfer coefficient based on
the inside area of the tube 8kAm
%(
@C
%1
9
The coefficients U
o
and U
i
-
and#
where#
h
o
> outside fluid film coefficient 8kAm
%(
@C
%1
9
h
i
> inside fluid film coefficient 8kAm
%(
@C
%1
9
h
od
> outside dirt coefficient 8fouling factor9 8kAm
%(
@C
%1
9
h
id
> inside dirt coefficient 8kAm
%(
@C
%1
9
k
w
> thermal conductivity of the tube wall material 8kAm
%1
@C
%1
9
d
o
> tube outside diameter 8m9
d
i
> tube inside diameter 8m9
LT! 8log-me! tempe"t#"e di$$e"e!ce9-

"rom the data collected# the counter%current and co%current heat exchangerBs exit
temperature of the hot fluid is higher than the exit temperature of the cold fluid. This
shows that heat may not spontaneously transfer from a colder body to a hotter body.
The increase in flow rate of one of the stream will results in an increase in the rate of
heat transfer. Theoretically# the amount of heat loss form the hot water should be
e'ual to the heat gain by the cold water. However# this cannot be done practically.
This may because of the heat loss to the surrounding# the heat loss in counter current
flow is approximately (<; and the heat loss in counter current flow is approximately
4,; which is slightly higher. *ased on the calculation done# we found out that the
values of LT! for co%current flow is higher than the counter%current flow. *ut# the
overall heat transfer coefficient for counter%current flow is higher than the co%current
flow. This mean that counter current flow heat exchanger has a higher effectiveness.
,. $onclusion
This experiment shows that the shell and tube heat exchanger follows the basic law of
thermodynamics. )n parallel 8co%current9 flow configuration# the exit temperature of
the hot fluid is always higher than the exit temperature of the cold fluid. )n counter%
current flow configuration# the exit temperature of the hot fluid is also higher than the
exit temperature of the cold fluid. However# in counter current flow configuration# the
exit temperature of the cold fluid is higher than the exit temperature of the cold fluid
in co%current configuration. Hence# it is clear that for heat exchanger# counter current
flow configuration has a higher effectiveness than the co%current flow configuration.
The experiment shows that when the flow rate of one of the stream increases# the rate
of heat transfer will also increases. The amount of heat loss form the hot water is not
e'ual to the heat gain by the cold water due to the heat loss to the surrounding. "rom
the calculations done# the LT! 8log mean temperature difference9 for co%current
flow is higher than the counter%current flow. However# the overall heat transfer
coefficient for counter%current flow is higher than the co%current flow. &s a
conclusion# counter current flow configuration of heat exchanger is more preferred for
practical application. 7ne of the application of heat exchanger is oil cooler.