February3,2014

UniversityofCalifornia,SanDiego

DepartmentofNanoEngineering

LaJolla,CA92093

ToWhomItMayConcern:

Asrequested,thisPlateHeatExchangerreportincludestheoverallheattransfercoefficientby
varyinghotandcoldwaterflowratesinsteadystateandbatchoperations.

Wehopethisreportwillsatisfythedesiredexpectations.Ifyouhaveanyquestionsorconcerns,
pleasecontactus.

Sincerely,

GroupB4

BrandonSanchez JanetMok
bobbyjoedik@gmail.com janet.mok14@gmail.com

LilianaBusanez SamanHadavand
lilianabusanez@gmail.com hada4gold@gmail.com

DepartmentofNanoEngineering,
ChemicalEngineering

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PlateHeatExchangers

Lab1Report

Presentedtothe
UniversityofCalifornia,SanDiego
DepartmentofNanoengineering
CENG176A
3February2015

Preparedby:
GroupB4

LeadAuthor Section

JanetMok LetterofTransmittal,Abstract,Intro,
Conclusion

LilianaBusanez TheoryandBackground

BrandonSanchez ResultsandDiscussion

SamanHadavand TechMemoandPresentation

2
Abstract

Thegoaloftheexperimentwastounderstandthecharacteristicsanddesignofaplate

heatexchanger,aswellastoevaluatetheeffectsofvaryingflowratesontheoverallheattransfer

coefficient.Thesteadystateoperationinvolvedmovingcoldwaterfromasourcetanktoa

receivingtankwherethehotwaterstreamexchangesheatwiththecoldwaterstreaminthe

sourcetank.Inthebatchoperation,thecoldwaterwaspumpedintothesametank,withconstant

stirring,afterexchangingheatwiththehotwaterstream.Thedataandresultsshowedthatinthe

steadystateoperation,theoverallheattransfercoefficientincreasedasthemassflowrates

increased.However,itwasseenthatinthebatchoperation,theoverallheattransfercoefficient

decreasedasthetemperaturedifferencedecreased.

3
TableofContents
Introduction pp.5

Theory Figure1,CocurrentFlow pp.6

Figure2.CountercurrentFlow

Methods pp.9

Results pp.11
Figure3.MeasuredFlowRate
Figure4.LMTDvs.time

Discussion pp.13

Conclusion pp.16

References pp.17

Appendices TableA1.Batchdata pp.18

TableA2.Steadystatedata
TableA3.CalibrationBatch
TableA4.CalibrationSteadystate

4
Introduction

ThePlateHeatExchanger(PHE)Experimentusescommonequipmentfoundinheat

exchangeprocessesusedinindustriessuchas:power,airconditioning,andbiomedical

industries.TheearliestdevelopmentofPHEswasinresponsetoincreasinglystrictrequirements

fromfoods,particularlydairyproductsinthelatenineteenthcentury.Theveryfirstpatentfora

PHEwasgrantedtothegermanAlbrechtDracke,whoproposedin1878thecoolingofone

liquidbyanother,witheachflowinginalayeronoppositesidesofaseriesofplates.The

growingdemandforenergyconservation,whileusingsustainabletechnologyandpreservingthe

environment,hasleadtohighperformance,compactheatexchangerswithincreasedenergy

efficiency.ThePHEdesignisdecentralizedinnature,andbenefitsincludeflexiblesizingof

variousplatestomeetbatchprocessingheatloaddemandsforsustaininghygienicconditions

commoninfood,andpharmaceuticalproductprocessing.

ThePHEconsistsofapackofgasketedcorrugatedmetalplates,pressedtogetherina

frame,whichallowsfluidtoflowthroughaseriesofparallelflowchannelsandexchangeheat

throughthethinmetalplates.Plateheatexchangersareusedfortransferringheatforany

combinationofgas,liquid,andtwophasestreams.Thegasketspreventleakagetotheoutside

anddirectsthefluidsasdesired.Heatisthentransferredfromthewarmfluidviathedividing

walltothecolderfluidinapurecounterflowarrangement,whichsupplementsthehigh

effectivenessofthePHEs.

Theimportanceoftheplateheatexchangercanbeseenthroughthevariousstructural

advantagesthatithastooffer.Theplatesurfacecorrugationspromotesenhancedheattransferby

meansofpromotingswirlorvortexflowsandincreasedeffectiveheattransferarea.Theheat

5
transfercoefficientsobtainedaresignificantlyhigherthanotherheatexchangersforcomparable

fluidconditions,whichleadstoamuchsmallerthermalsize.Becauseoftheirhighheattransfer

coefficientsandtruecounterflowarrangement,PHEsareabletooperateunderveryclose

approachtemperatureconditionswhichresultsinupto90%heatrecovery.Anotheradvantage

ofPHEsisduetothethinchannelscreatedbetweenthetwoadjacentplates,wherethevolumeof

fluidcontainedintheheatexchangerissmall.Therefore,itreactstotheprocesscondition

changesinarathershorttimetransientandiseasiertocontrol.Becauseplateswithdifferent

surfacepatternscanbecombinedinasinglePHE,differentmultipassarrangementscanbe

configuredwhichenablesbetteroptimizationofoperatingconditions.

Inthisexperiment,inordertoevaluatetheoverallheattransfercoefficient,weanalyzed

differenttransientheatoperatingconditionsforplateheatexchangersatvaryinghotandcold

flowrates.Theheatexchangertransfercoefficientfrombatchheatoperations,andunder

continuousoperationswasusedtoevaluateresultsthatcanbeappliedtoscaleupcalculationsas

inindustrytotransferthermalenergyinbetweenmediums.TheDataloggingVIwasusedtorun

theexperiment,andtheflowratesandapproachtemperaturedifferencewereadjustedtoset

operatingconditions.

Background&Theory

PlateHeatExchangers(PHE)promotewellmixedflowsalongtheplatewithhigh

convectiveheattransfercoefficientsthatresultfromtheintercorrugationflowpath.Theplates

themselvesconfinefluidstreamwithintheinterplateflowchannels.Thisenhancesheattransfer

6
andtheresultantheattransfercoefficientissignificantlyhigherforPHEthanthetraditional

shellandtubeheatexchangers.

TheplatepackingasketedPHEsiseasilydisassembledandreassembled.Thethin

rectangularsheetmetalsplatesareinbetweengaskets,assembledinapack,andboltedina

frame.Heatistransferredfromthehotfluidviatheplatewalltothecolderfluidincounterflow

arrangement.TheadvantageofPHEcomparedtootherhighlycompactexchangersinclude

thermalflexiblesizingofplates,easycleaningnecessaryforthefoodindustryasmentioned,and

closeapproachtemperaturepurecountercurrentflowoperations(~ 1 C )thatleadtohigh

effectivenessofPHEs.

ForPHE,therearethreeprimarydesignflowarrangementsforhotandcoldfluid

arrangementsthatofparallelflow,counterflow,andmultipassarrangement.Mostcommon,is

cocurrentandcountercurrentconfigurations:

Figure1:
Cocurrent Figure2:
Countercurrent

Energymovesfromhotfluidtoasurfacebyconvection,throughthewallbythermal

conduction,andthenbyconvectionfromthesurfacetothecoldfluid.Heatconvectionisforced

withinaheatexchangeranditistheconvectivetransferthatgovernsitsperformances.The

7
overallheattransfer(orrate)equationinheatexchangersisgivenbytheenergybalanceacross

theseparatingwall:
out
Q = m c C c (T h T in
c ) = m h C h (T
in
h T out
c ) = U AT LM T D (1)

where, Q=Rateofheattransfer(duty),U=OverallheattransferCoefficient,A=crosssectional

Areaforheattransfer, T LM T D =LogMeanTemperatureDifference

TheLogMeanTemperatureDifference(LMTD)isusedtodeterminethetemperature

drivingforcefor
heattransfer
inflowsystems.LMTDisconstantalongthelength,andused

mostnotablywithheatexchangers.

(2)

out
where, T 1 = (T h T in
c ) , T 2 = (T in
h T out
c ) arethebulktemperatures,orthe

temperaturedifferenceforcountercurrentasdemonstratedinFigure2.

Theoverallheattransfercoefficientisdeterminedforsteadystateandbatchoperations.

Heatlossesorgainsofawholeexchangerwiththeenvironmentcanbeneglected.Thesteady

stateoperationequationtoanalyzetheperformanceoftheheatexchangeris

mC c dT /dx = U AT LM T D (3)

OverallHeatTransferCoefficientcanbeestimatedfordifferentfluidsaswellasthetype

ofheatexchangersysteminvolved(PHE).Wheretheheattransfercoefficient,U,forwaterto

waterheatexchangers,canbeatypicaltransfercoefficientofabout2000 [W /m 2 K] .

8
 FortheBatchHeatingbalanceequations,theheatbalanceinawellmixedtankcanbe

basedonthecoldsidetransfer,hotsidetransfer,heatedbyanexternalheatexchangersothetank
in
temperatureisthecoldsideinlet, T c .Theprocessconditionsandheatloadarevarying

throughoutthebatch.

Inbatchheating,therequireddutyisafunctionofthechangingbatchtemperature

T LM T D asafunctionoftime.where T 1 and T 2 areresultofhotandcoldmassflow

in
rates,anddifferentiationof T c ,inconsiderationtothebatchheatbalance.Substitutinginbatch

heating, T LM T D ,toEq.(1),thetemperaturetimederivativecancelsout.Theequationforbatch

asafunctionoftimeisgivenby:

T in T in (t) (K 1)
ln| T inh T inc (0) | = [ m(K cch) ]t (4)
h c h

Theconstant,K,isgraphedinasemilogplot,wherefromtheslopeKcanbedeterminedto

obtaintheoverallheattransfercoefficientusingthefollowingtodetermineU:

K = exp( UCpA ( mc
1

1
mh
)) (5)

Methods

ThisexperimentinvolvedusingaplateheatexchangerandthePHE99_MAIN.viforboth

steadystateandbatchoperations.Threewatertankswereusedtotesttheplateheatexchangerin

ordertodeterminetheoverallheattransfercoefficient.Twocoldwatertankswerefilledwithtap

waterataboutnearroomtemperature.Thelengthsandwidthsweremeasuredforboththecold

watertanksaswellastheinitialwaterlevel.Bothoperationsinvolvedcyclinghotandcoldwater

throughoutthesystemuntilastabletemperaturehasbeenreached.TheLabviewprogram

9
PHE99_MAIN.viwasusedtoautomaticallyturnonthepumpsandrecordtheHotin,Coldin,

Hotout,andColdouttemperaturesmeasuredbythethermocouplespositionedinthepipes.

Whiletheproceduretoexecutetheexperimentforeachoperationwassimilar,thereweresome

differencesinmethodsanduseofequipment.

Forthesteadystateoperation,twotrialswereperformedbykeepingthehotwaterflow

rateconstantwhilevaryingthecoldwaterflowrates.Thecoldwaterfromonetankwasmoved

totheotherinordertoproduceasteadygroupofdataduringacertaintimeinterval,inwhich

therewereminimaltemperaturefluctuationsfromasetthermocoupletemperaturereading.A

FromtankandaTotankwerefirstdeterminedfromthetwocoldwatertanks.Thevalves

fromtheColdoutstreamandColdinstreamwereopenedandclosedrespectivelydependingon

thelabeledtank.Lastly,thehotandcoldflowratevalveswerebothadjustedtothedesiredlevel.

TheVIwasthenrunandbothhotwaterandcoldwaterpumpswereturnedonandthe

temperaturedatawasrecorded.Oncetheplateheatexchangerhasreachedsteadystate,theVI

wasstoppedafter60secondsofstabledata.Betweeneachtrial,thewaterheaterhadtowarmthe

tankuptonearlyfullyhot.

Similarprocedureswereusedforthebatchoperation,butthisoperationinsteadwouldbe

circulatingthecoldwaterbackintothesametankitwaspumpedfrom.Onlyonecoldwatertank

wouldbeusedwhoselevelofwaterwasnottoohighortoolow.Thedepthofthewatertank

wouldberecordedandtheColdoutandColdinstreamvalveswereadjustedaccordingly.The

restoftheprocedurewasthesameasthesteadystateoperationexcepttherehadtobea

motorizedconsistentstirringinthecoldwatertanktoallowthewatertemperaturetoachieve

10
equilibriumbeforepassingthroughtheheatexchanger.Theflowratesforbothhotandcold

watershouldnotbeadjustedsothatthereisaslittlehumaninputaspossible.

Lastlytheinlineflowmeterwascalibratedtoresultinagoodcalibrationcurve.Error

couldincreasewithincreasingtemperaturesresultinginaninaccuratereading.Atemperature

wasestablishedtorunthecalibration,andtheFromtankwassettothisparticulartemperature.

Thetemperaturesofbothtankswererecordedaswellastheinitialwaterlevelinthechosen

Totank.Thecoldwaterpumpwasswitchedonforoneminuteatacertainflowrate,andthen

thetimeelapsedandnewwaterlevelwasthenrecorded.

Aftertheexperimentwasfinished,thewaterheaterwasturneddowntothelowsetting

andthelabviewprogramwasclosedandshutdown,accordingly.Thedatafromthesteadystate

andbatchoperationswerethenusedtodeterminetheoverallheattransfercoefficientforthis

particularplateheatexchanger.

Results

Thecoldstreamflowratewasmeasuredandvariedoverdifferenttimeintervals.A

calibrationgraphwasdevelopedasshowninFigure3.Thehotstreamwasnotusedfor

calibrationasitwasassumedthatinformationononeoftheflowstreamswouldprovide

identicalinformationontheother.Aslopeof1onthecalibrationcurvewouldindicateanideal

flowmeter.Aslopeof1.0792indicatesanerrorinthecalculatedflowrateofbeing

approximately8%higherthantheflowratedisplayedbytheflowmeter.

11


Figure3
:Coldstreamcalibrationforcalculatedflowratevs.measuredflowrate

Temperaturedatafromthebatchoperationswereusedtosolveforthelogmean
In
temperaturedifferencesaccordingtoEqn.2.T
Hvalueswereaveragedoverthedurationofthe

trialsduetominorfluctuationsinboilertemperature.ThenegativevaluesoftheLMTDsforthe

trialswereplottedagainsttimeasshowninFigure4.Theslopesofthecurvesforeachtrialwere

extractedandusedtosolveforthevalueofKaccordingtoEqn.3.TheseKvalueswerethen

usedtosolvefortheoverallheattransfercoefficientaccordingtoEqn.4.Theseresultsalong

withtheparametersusedineachequationaredisplayedinTableA1.Theareaoftheheat
2
exchangerplateusedis.0321m.Thisvalueismultipliedby7toaccountforthe7platesinthe

heatexchanger.Notethattheflowstreamswereadjustedby7.92%duetocalibration.

12


Figure4:
PlotsofLMTDvs.timeforbatchtrials

Temperaturedatafromthesteadystateoperationwasaveragedduringthedurationofthe

trialsduetominorfluctuationsintemperaturereadings.Theoverallheattransfercoefficientwas

determinedbyEqn1.BecauseEqn.Uwascalculatedusingbothhotandcoldstream

information,whichgives2valuesofUforeachtrial.Thisdataalongwithtemperaturedatais

displayedinTableA2.

Discussion

Datafortheoverallheattransfercoefficientwasproducedusingflowratesthathadnot

beencalibrated.Uponadjustingtheflowrates,itwasfoundthattheoverallheattransfer

coefficientincreasedforsteadystateresultsanddecreasedforbatchresults.Thesevaluesalong

withpercentdifferencesaredisplayedinTableA3andA4,respectively.Notingthattheflow

ratecalibrationisonlycorrectingerrorintheflowmeterreadingsofourdata,itwasfoundthat

calibratingthemassflowratewillincreasethevalueofU.ThiscanbeseenbyanalyzingEq.1.

13
Thearea,temperaturedifferencesandheatcapacitiesarethesamevaluesasbefore,thereforean

increaseintheflowratecanonlyincreaseU.Hence,theoverallheattransfercoefficientandthe

massflowratearedirectlyproportionalforthissystem.

ThebatchresultsrequiremoreanalysisduetothesolutiontechniqueforcalculatingU.

WhenutilizingEqn.4,thevaluesoftheLHSarethesame.TheRHShasincreasedflowrates,

thereforethevalueofKdecreasesaftercalibration.WhenusingEqn.5,thecalculatedUvalueis

smaller.Thismaybelessintuitivethanthesteadystateresultsbecauseamisleadingassumption

mayleadonetoconcludethatincreasingflowratesincreasestheheattransferrate.The

temperaturedynamicsofthebatchsystemmayaccountfortheresultsforincreasedhotandcold

inletflowrates.Ahigherhotstreaminletflowratewouldincreasethecoldstreamoutlet

temperatureatafasterrate.Thiswouldalsoincreasethecoldstreaminlettemperatureatafaster

rate,whichisalsoflowingfasterintotheheatexchanger.Becauseallstreamsareapproaching

steadystatetemperaturesatafasterrate,theoverallheattransfercoefficientdecreasesasthe

temperaturedifferencesbetweenthehotandcoldstreamsdecreases.

Theprocedurefortheflowratecalibrationmayhaveintroducederrorwhendeveloping

thecalibration.Thecontainerusedtofillthewaterfromthecoldstreamhosehadapproximate

volumemeasurementsandwerenotcompletelyaccurate.Althoughthevolumeswere

approximateonthecontainer,ourgroupagreedthatmeasurementoftheoriginalwatertub

intendedfortheprocedurewouldintroducemoreerror.Thiswasconcludedbecausethetubis

roundedandwarpedanddoesntaccuratelyrepresentarectangularprism.Thus,thedimensions

ofthetubswouldintroducesignificanterrorinvolumecalculations.Calibrationofthehotstream

mayintroduceerrorifthehotstreamequipmentcontainsmorefoulingduetohightemperature

14
streams.Thethermalenergyfromthehotstreamsmayloosenanddistributemoreparticles

throughthepipesthanthecoldstreams,howeveritwasassumedthatthecoldandhotstream

equipmentwasidentical.

TheresultsforUforthebatchandsteadystateoperationswerenotpreciseandranged
2
fromabout300to1900W/mK.ThelargestsourceoferrormaybefromassumingthatUisa

constantandnotafunctionoftemperature.Thismaybedetrimentalincalculationsbecause

dependingonthetemperatureoftheheatexchangerplates,Umaybeahigherorlowervalue.

ThevaluesofUandU
c forthesteadystateoperationshouldtheoreticallybeequal
H

valuesinaclosedsystem.Sourcesoferrorarelimitedduetothesimplicityofthesystem.

Temperaturesreadfromthethermocouplesmayhaveintroducedsignificanterrorbecausethe

thermocoupleswerenotcalibratedwithmanualthermometerreadingsofthewatertanks.Bynot

calibratingthethermocouples,temperaturedifferencesmayactuallybehigherorlower,andwill

definitelyaffectthevaluesofU.Thesmallamountofdataanalyzedforthesteadystatesystem

maynotbeenoughtoaccuratelyrepresenttheheatexchangerdynamics,andmoretrialswould

needtobeconductedtogetmoreaccurateresults.

ThebatchoperationresultsproducedinconsistentUvaluesof1507,298,470and755
2
W/mK.AftertakingalookatTableA1andnotingthedifferencesinHOmassforeachtrial,it
2

maybeconcludedthatthemassofHOthatwentthroughthesystemhadthegreatesteffecton
2

calculatingU.ThiscanbeseenbyEqn.4,asmassofwaterinthedenominatorwillaffectthe

valueofK,whichwillinturnaffectthecalculationofUinEqn.5.Moretrialswouldneedtobe

conductedwithmorevarianceinflowratestoextractconsistentKvalues,andhencecalculatea

bettervalueofU.

15
Conclusion

Inconclusion,plateheatexchangersareusedthroughoutawiderangeofindustries,such

asdairyandotherhygienicindustries,aswellasinsustainableenergyconservationand

biomedicalindustries.Thepurposeofthisexperimentwastodeterminetheoverallheattransfer

coefficientunderboththesteadystateandbatchoperationswhilevaryinghotandcoldwater

flowrates.Itwasfoundthatforthesteadystateoperation,theoverallheattransfercoefficient

increasedwithincreasingflowrates,whichshowsthattheoverallheattransfercoefficientand

themassflowratesaredirectlyproportional.Howeverforthebatchoperation,sinceallthe

streamswereapproachingsteadystatetemperaturesatafasterrate,theoverallheattransfer

coefficientdecreasesasthetemperaturedifferencesbetweenthehotandcoldstreamsdecreases.

Furthermore,theflowratecalibrationoftheplateheatexchangerindicatedan8%discrepancy

betweenthemeasuredflowrateandthecalculatedflowrate.Thisindicatesanerrorinthe

calibrationoftheflowmeter.

16
References

[1]Wang,LBengt,SManglik,R.M.,PlateHeatExchangers:Design,Applicationsand
Performance:Southampton:WIT,2002.

[2]
Perry,R.H.,Green,D.W.(Eds.):Perry'sChemicalEngineers'Handbook,7thedition,
McGrawHill,1997,Section11.

[3]Pinto,M.J.Gut,J.A.WAScreeningMethodFortheOptimalSelectionOfPlateHeat
ExchangerConfigurations BrazilianJournalofChemicalEngineering 27May2002:433439.
Print.

[4]Kakac,Sadik,andHongtanLiu.HeatExchangersSelection,Rating,andThermalDesign .
BocaRaton:CRCPress,2002.Print.

[5]Martinez,IHeatExchangers.
Webserver.dmt [Online]
19952015
,pp116
http://webserver.dmt.upm.es/~isidoro/bk3/c12/Heat%20exchangers.pdf (accesssedJanuary28,
2015).

17
Appendices

In In
Trial T
H(K) T
C(K) C(J/kg
p W c Wh Mass K U
2
K) (kg/s) (kg/s) H O
2 (W/m
(kg) K)

1 339.5 301.4 4184 .2045 .2052 27.63 1.0013 1507

2 334.8 293.41 4184 .2454 .0954 15.90 .9027 297.7

3 334.5 302.4 4184 .2045 .2052 8.327 1.0004 470.2

4 332.7 300.3 4184 .1363 .2045 14.76 1.104 755.2

TableA1:
Batchdatafordeterminingoverallheattransfercoefficient

In In Out Out
Trial T
H T
C TH T
C W c Wh UH UC U
(K) (K) (K) (K) (kg/s) (kg/s) (W/m2
K) (W/m2
K) %Diff.

1 327.7 292. 317.7 307.3 .1023 .2045 1557 1159 29.3

4

2 335.9 291. 323.0 310.0 .1363 .2045 1568 1761 11.6

7

TableA2:
Steadystatedatafordeterminingoverallheattransfercoefficient

2
OverallHeatTransferCoefficient(W/mK)

U
C U
H

Trial Uncalibrated Calibrated Uncalibrated Calibrated

1 1159 1251 1557 1680

2 1761 1900 1568 1692

TableA3:
Calibratedsteadystatevaluesofoverallheattransfercoefficient

18
 2
OverallHeatTransferCoefficient(W/mK)

Trial Uncalibrated Calibrated %Difference

1 1556 1507 3.2

2 300.5 297.7 .936

3 474.9 470.3 .973

4 1008 755.2 28.68

Calibratedbatchvaluesofoverallheattransfercoefficient
TableA4:

19
TO:NanoEngineeringDepartmentFaculty
FROM:BrandonSanchez,SamanHadavand,JanetMok,LilianaBusanez
DATE:January30,2015
SUBJECT:CVD
WeproposetodesignaChemicalVaporDeposition(CVD)reactorusingthe

COMSOLsimulation.CVDisachemicalprocessessentialtomicroelectronicdevice

manufacturing.InthisexperimentwewillconductasimulationofaCVDreactortounderstand

thekineticsofsilanedeposition.Todothis,multiplevariableswillbeadjustedincluding:

temperature,waferpackingdensity,pressure,inletvelocity,andmolefractionofhydrogen

presentintheinlet.Weexpecttoseeanincreaseintherateofsilanedepositionastemperature

increases.Furthermore,webelievethatanincreaseinhydrogenmolefractionandinletvelocity

willincreasetherateofsilaneproductionandthusitsdepositioninthereactor.Ifyouhaveany

concerns,pleasecontactSamanHadavandat(760)8849484.

20