1.

0 ABSTRACT
The aim of this experiment was to demonstrate the heat transfer process using shell
and tube heat transfer, to evaluate and study the heat load and head balance, LMTD and
overall heat transfer coefficient, to calculate the Reynolds numbers at the shell and tubes sides
and lastly to measure and determine the shell and tube sides pressure drop. The experiment
was begun with general startup of the apparatus which had been done by the lab assistance.
Student only need to manipulated the data by change the water flow rate for hot water and
cold water. Firstly, student only set the hot water flow rate at 10 LPM and the cold water flow
rate at 2 LPM. After 10 minutes, students recorded all temperature and the pressure drop at
the monitor. The cold water flow rate were change by increasing 2LPM until it become same
flow rate as hot water. The experiment was repeated by fixed the cold water flow rate at 10
LPM and varies the hot water flow rate. At the end of the experiment, it is found that, the head
loss of cold water and hot water changed when the water flow rate adjusted. The LMTD also
depends on the flow rate either hot water of cold water. When the flow rate increase, the
LMTD also increase. The Reynold Number also has been calculated and it was found that the
flow in the apparatus was laminar flow. Overall of the experiment was succeeded.

1.0

2.0 INTRODUCTION
A heat exchanger can be defined as any device that transfers heat from one fluid to another or
from or to a fluid and the environment. There are several types of shell and tube heat
exchanger: A heat exchanger can be defined as any device that transfers
heat from one fluid to another or from or to a fluid and the environment.
There are several types of shell and tube heat exchanger:

Figure 1: Heat exchanger with fixed tube plates (four tubes, one shell-pass)

Figure 2: Heat exchanger with floating head (two tube-pass, one shell pass)

Figure 3: Heat exchanger with hairpin tubes

Basic Considerations in Choosing a Mechanical Arrangement of Heat Exchanger. There are

four basic considerations in choosing a mechanical arrangement that provides for efficient
heat transfer between the two fluids or vapors, while taking care of such practical matters as
preventing leakage from one into the other. They are:

Consideration for differential thermal expansion of tube and shell

Means of directing fluid through the tubes
Methods of controlling fluid flow through the shell
Consideration for ease of maintenance and servicing

Advantages of Heat Exchanger The main advantages of shell-and-tube heat exchangers are:

Condensation or boiling heat transfer can be accommodated in either the tubes or the
shell, and the orientation can be horizontal or vertical.
The pressures and pressure drops can be varied over a wide range.
Thermal stresses can be accommodated inexpensively.
There is substantial flexibility regarding materials of construction to accommodate
corrosion and other concerns. The shell and the tubes can be made of different
materials.
Extended heat transfer surfaces (fins) can be used to enhance heat transfer.
Cleaning and repair are relatively straightforward, because the equipment can be
dismantled for this purpose.

Applications of Heat Exchanger Shell and tube heat exchangers represent the most widely
used vehicle for the transfer of heat in industrial process applications. They are frequently
selected for such duties as:

Process liquid or gas cooling Process or refrigerant vapor or steam condensing

Process liquid, steam or refrigerant evaporation
Process heat removal and preheating of feed water Thermal energy conservation
efforts, heat recovery
Compressor, turbine and engine cooling, oil and jacket water
Hydraulic and lube oil cooling
Many other industrial applications Shell and tube heat exchangers have the ability to
transfer large amounts of heat in relatively low cost, serviceable designs.
They can provide large amounts of effective tube surface while minimizing the
requirements of floor space, liquid volume and weight

3.0 OBJECTIVES
i.
To demonstrate the heat transfer process using shell and tube heat transfer.
4

ii.

To evaluate and study the heat load and head balance, LMTD and overall heat
transfer coefficient
To calculate the Reynolds numbers at the shell and tubes sides.
To measure and determine the shell and tube sides pressure drop.

iii.
iv.

4.0 THEORY
This part of calculation is to use the data in Table 1 to check the heat load Q H and QC and to
select the set of values where Qc is the closet to QH
Hot water flow rate (HH)
QH =mHCpH(THi-THo)
Cold water flow rate
Qc=mCCpC(TCo-TCi)

Where:QH =Heat load for hot water flow rate

QC =Heat load for cold water flow rate
mH =Hot water mass flow rate
mC =Cold water mass flow rate
THi =Hot water inlet temperature
THo =Hot water outlet temperature
TCo =Cold water outlet temperature
TCi =Cold water inlet temperature

LOG MEAN TEMPERATURE DIFERENT (LMTD)

5

T
T
( HiT Co )
ln
(T HoT Ci)
( HiT Co )(T HoT Ci )

LMTD=
Where all variables are same with the above section:

Overall Heat Transfer Coefficient, U

Overall heat transfer coefficient ,U can be calculated by using equation by using equation
below. In this experiment, the total heat transfer area, A has been given and equal to 2.93 m2.
Q=U . A . LMTD

U=

Q
A x LMTD

Where :
U= Overall heat transfer coefficient
Q = Heat rate with respect to the average head load

Reynolds Number Calculation

Re

DV

Where
= density of liquid (kg/m3)
D =Diameter (m)
V=Volumetric flow rate (m3/s)
=Viscosity of fluid (kg.s/m)
Area of Shell,As= 0.029 ft2
Area of tubes ,At= 0.02139 ft2
Pressure drop
6

This part would determine the following:

HW :

The measured tube-inside pressure drop DP (tube) which will be corrected and is
expected to be more than calculated tube-side pressure drop.

CW :

The measured shell-inside pressure drop DP (shell) which will be corrected and is
expected to be more than calculated tube-side pressure drop.

Notice that, both calculated pressure and also measured pressure are considered in unit
mmH2O. In this case, since calculated pressure drop in both of shell and tube side have been
obtained during the experiment, so its only required conversion factor to change the value
into unit of mmH2O.
Conversion factor: .

x.bar

1 105 Pa 1mmH2O

1bar
(9.81) Pa

Where x is the calculated pressure value in unit bar.

5.0 APPARATUS

SHELL AND TUBE HEAT EXCHANGER

6.0 PROCEDURE
Step i)
1. All the pump suction valves (for PH, PC1, and PC2) are checked so
that they are fully opened all the time.
2. BVC2 is opened fully but CV2 is closed fully so that PC2 shall operate
as a back-mixing pump for tank T2 in the next experiment. Both CV1
and BVC1 are opened fully. Only PC1 shall be used here to pump CW
into the Heat Exchanger in the next experiment. Do not switch on
any CW pumps (PC1, PC2) yet.
3. HV is closed fully but BVH is opened fully.
4. Pump PH for HW is started to circulate around tank T1 via only BVH.
5. The heaters are started and TlC5 is noted. When the HW in tank T1 is
almost 70 C/158 F
(see TlC5), HV is opened fully. The HW flowrate is
quickly adjusted to about 25 USGPM by regulating its by-pass valve
BVH.
6. Both the CW pumps, PC1 and PC2 are switched on. The CW flowrate
is quickly adjusted to about 10 USGPM by regulating the by-pass
valve BVC1.
7. The DP Selector Switch is switched to the DP (Shell) position.
Step ii)
a) The first set of temperature and flowrate readings are taken.
CW: Temperature - inlet/outlet, T13*(T1), T14*(T2):
Flowrate FC at FI(C*)
HW: Temperature - inlet/outlet, TI1*(T1), T12*(T2):
Flowrate FH at FI(H*)
Note that the CW inlet temperature (T1) is increasing gradually. The CW
outlet temperature (T2) varies together with the HW inlet/outlet
temperatures t1/t2. It is important that all the temperature and flowrate
readings be taken almost simultaneously.
These readings are recorded appropriately in Table 1.
Also the respective inlet pressure and inlet pressure drop of the CW
and HW flow streams are recorded. For the pressure drop readings,
9

DP (shell), DP (tube) at the panel amount DPI*, use the DP signal

Selector Switch appropriately as explained below:
CW: PG-C; DPI* for DP (shell) with the DP Selector Switch at the DP
(shell) position.
HW: PG-H; DPI* for DP (tube) with the DP Selector Switch at the DP
(tube) position.
To take the DP readings at DPI*, they are waited till they are fairly
steady.
The DP reading is then taken at its highest reading (i.e. peak reading)
just when it starts to decrease.
b) The second and third sets of the above readings for RUN 1 are
continued and taken consecutively. The last set of temperature
readings should be taken when all the temperatures are fairly
steady.
Step iii)
1. RUN 1 is completed, with three sets of the above readings.
2. All the CW pumps PC1 and PC2 are stopped.
3. The heaters are kept on for the next RUN.
4. With the HW pump PH still running, the discharge valve HV is closed
fully but the by-pass valve BVH is opened fully.
5. The DP Selector Switch is switched to the equalizing (vertical or 0)
position.

Step iv)
1. RUN 2, 3, 4 and 5 are repeated at different recommended nominal
flowrate of CW (i.e. FC) and HW (i.e. FH) using the following
procedures check-list.
To continue with the next run
10

The HW pump PH is checked so that it is running with BVH fully

opened and HV fully closed.
With the heaters ON, the HW in tank T1is heated till it almost
70
C/150 F
(see TlC5).
HV is fully opened. The HW flowrate is adjusted until FH at Fl
(H*) is almost at the recommended nominal flowrate for the
RUN. This is done by regulating the by-pass valve BVH with HV
fully opened. (However, if the flowrate is still too high even
when its by-pass valve is fully open, its discharge valve, HV is
gradually closed to get the required HW flowrate).
The CW pumps PC1 and PC2 are started with CV1/BVC1/BVC2
are fully opened but CV2 is fully closed. FC at Fl(C*) is noted.
FC is adjusted to the recommended nominal flowrate for the
RUN by regulating the by-pass valve BVC1 with CV1 fully
opened. (However if the CW flowrate (FC) from PC1 is still
inadequate even when its by-pass valve BVC1 is fully closed,
use the second CW pump (PC2) by gradually opening CV2 and
simultaneously closing BVC2 to get the required CW flowrate).
The DP Selector Switch is switched to the DP (shell) position.
The various readings for the RUN are taken.

To end a RUN after getting 3 sets of readings

All the CW pumps, PC1 and PC2 are stopped.
The DP Selector Switch is switched to the equalizing (vertical or
0) position.
With the HW pump PH and the heaters stillON, HV is closed
fully nut BVH is opened fully.

11

PLANT SHUT-DOWN
1. The heaters are switched OFF.
2. All the pumps (PH, PC1 and PC2) are checked so that they are
switched OFF.
3. The DP Selector Switch is switched to the equalizing (vertical or 0)
position.
4. The main power supply to the plant at the front of the panel/cubical
is switched OFF. All the pumps suction valves, discharge valves (HV,
CV1 and CV2) and by-pass valves (BVH, BVC1 and BVC2) are
opened.

12

7.0 RESULT
FT1
FT2
(LPM)
(LPM)

TT1
(C)

TT2
(C)

TT3
(C)

TT4
(C)

DPT1
(mm H2O)

DPT2
(mm H2O

10

43.2

30.8

47.8

50.1

104

12

10

38.0

29.8

46.8

49.0

105

19

10

35.8

29.3

45.6

48.6

104

66

10

34.2

29.3

44.5

48.5

105

136

10

10

34.0

29.6

45.3

49.7

104

180

FT1
(LPM)

FT2
(LPM)

QH
(KJ/s)

QC
(KJ/s)

Q
(kJ/s)

10

8.65

0.32

4.49

11.20

0.1368

10

5.73

0.62

3.175

13.78

0.0786

10

4.54

1.26

2.9

14.48

0.0683

10

3.42

2.23

2.83

14.75

0.0655

10

10

3.08

3.07

3.07

TABLE 1

13

LMTD

TABLE2
FT1
(LPM)
2

FT2
(LPM)
10

TT1
(C)
31.5

TT2
(C)
29.5

TT3
(C)
40.0

TT4
(C)
48.8

DPT1
(mm H2O)
5

DPT2
(mm H2O
180

10

31.9

29.5

43.0

48.9

176

10

32.6

29.6

44.3

49.8

22

177

10

33.4

29.5

44.2

48.6

51

177

10

10

34.8

29.5

44.5

48.3

108

176

FT1
(LPM)

FT2
(LPM)

QH
(KJ/s)

QC
(KJ/s)

Q
(kJ/s)

LMTD

10

0.279

6.138

3.209

13.618

0.08

10

0.670

4.115

2.393

15.183

0.054

10

1.256

3.836

2.546

15.917

0.055

10

2.176

3.069

2.622

14.949

0.06

10

10

3.697

2.881

3.289

14.237

0.079

8.0 CALCULATION
14

For the first reading

FT1
(LPM)
2

FT2
(LPM)
10

TT1
(C)
31.5

TT2
(C)
29.5

Head load:
QH

=mHCpH(THi-THo)
= (0.033kg/s)(4.185KJ/Kg.K)(31.5-29.5)
= 0.2762 KJ/s

Qc

=mCCpC(TCo-TCi)
=(0.167kg/s)(4.185kJ/kg.K)(48.8-40.0)
=6.138 kJ/s

Log mean temperature different

T
T
( HiT Co )
ln
(T HoT Ci)
( HiT Co )(T HoT Ci )

LMTD=
LMTD=

(29.540)(31.548.8)
(31.548.8)
ln
(29.540)

=13.62C

Overall heat tranfer coefficient

U=

Q
A x LMTD

U=

3.2071
2.93 x 13.62

15

TT3
(C)
40.0

TT4
(C)
48.8

DPT1
(mm H2O)
5

DPT2
(mm H2O
180

=0.08

Reynold Number
Re

DV

For shell :
Re

(1000)( 0.06)( 0.03)

4(0.8007)

=0.98
For Tube :
Re

(1000)(0.08)(0.167)
4(0.5494)

=6.97

16

9.0 DISCUSSION
In this experiment, the objectives are to evaluate and study the heat load and head balance,
LMTD and overall heat transfer coefficient, to calculate the Reynolds numbers at the shell
and tubes sides and to measure and determine the shell and tube sides pressure drop. At the
end of the experiments, all objectives are met although maybe there are some errors.
The reason the head loss of this experiment was being calculated were because student can
observe the energy loss when the heat being transferred from one medium to another medium.
Form the table 1, when the flow rate of the cool water being increase, the head loss for cold
increase but for head loss for the hot water decrease. This show that at low flowrate of cold
water, more energy being absorb by the cold water but less energy loss for hot water. Same
goes to table 2, when flow rate of hot water decrease, it need more energy to transfer the heat
to reach the required temperature at the output.
The pressure drop also depends on the water flow rate. In the table 1, when the cold water was
at low flow rate, the pressure drop also low, but it increase when the cold water flow rate
increase. It was also happened in the table 2 when the hot water flow rate increase, the
pressure drop increase. This is because, at low flow rate, the shear stress of
The logarithmic mean temperature difference (LMTD) is used to determine the temperature
driving force for heat transfer in flow systems, most notably in heat exchangers. The LMTD is
a logarithmic average of the temperature difference between the hot and cold feeds at each
end of the double pipe exchanger. The larger the LMTD, the more heat is transferred. From
both table, LMTD increasing when the flow rate increasing. But at table 2, the LMTD
decrease suddenly which might cause from the error or miscalculation.
The overall heat transfer coefficients are also calculated in this experiment to determine the
total thermal resistance to heat transfer between two fluids. The resistance can be reduced by
increasing the surface area, which will lead to a more efficient heat exchanger. The overall
heat transfer were depends on the value of LMTD. If the LMTD increase, the overall heat
transfer coefficient will be decrease. It mean that, when the rate of heat transfer is higher, the
resistance for the water to absorb heat is low .
The calculated Reynolds Number is to determine whether the flow of water in shell and tube
heat exchanger is turbulent flow or laminar flow. Form the experiment, it was found that the
flow is laminar flow. But according to theory, the flow show be in turbulent flow as the water
17

flow rate increase. All the calculation were based on the data result. So if there are some
errors when handling the experiment, the calculation also will have an error.

10.0 CONCLUSION
From the experiment, all the objectives had been achieved. Student have ,demonstrate the heat
transfer process using shell and tube heat transfer, evaluated and studied the heat load and
head balance, LMTD and overall heat transfer coefficient, calculated the Reynolds numbers at
the shell and tubes sides and lastly measured and determined the shell and tube sides pressure
drop. Although the Reynold Number was not accurate, but overall of the experiment was
succeeded.

18

11.0 RECOMMENDATION
From the experiment, there are few recommendation that can be make so ensure the
experiment can have better result. First, the cold water which was used as the cooling agent
can be replaced with oil which has highest heat capacity than water. Oil also has high
viscosity which allowed the mass flow much slower to avoid much waste.
Second recommendation is, the spiral heat exchanger can be replaced with other types
such as plate heat exchanger so that student can varies the different between heat exchanger.
Student may learnt on which heat exchanger is better to use in industry or for large scale.
Last recommendation is, the time or period to take the data can be reduce to less than
10 minutes. This is to ensure the students didnt waste much time on looking at the apparatus.
Student may do other experiment during the 10 minutes times so that they can learn how other
apparatus in the lab operating.

12.0 RFERENCES
I.
II.

Coulson and Richardson; Chemical Engineering; Volume 1, 6th edition.

Max S. Peter & Klaus D. Timmerhaus; Plant Design and Economic for Chemical

III.

Engineering; 4th edition; Page 576.

Rase, Howard F; Chemical Reactor Design and for Process and plants; Volume 1; 1st

IV.

edition.
G.C DRYDEN; The Efficient Use of Energy; 1st edition.

19

13.0 APPENDICES

20