ABSTRACT

What is a Heat Exchangers? Heat Exchangers are devices that facilitate the exchange
of heat between two fluids that are at different temperatures while keeping them from mixing
with each other. There are several heat exchangers, for this experiment, we are conducting
Shell and Tube Heat Exchanger. This experiment was conducted to evaluated and study the
heat balance and heat loss, LMTD, and overall heat transfer coefficient. This experiment is
also conducted to measure and determine the shell and tube side pressure drop. There are two
experiments that has been conducted, first experiment is the flow rate of Hot Water are set
constant at 10LPM, the only flow rate manipulated is the Cold Water flow rate change from
2,4,6,8,10 LPM. Then, for the second experiments the flow rate of Cold Water are set
constant at 10LPM and the flow rate of Hot Water are changing from 2,4,6,8,10 LPM. Then
the result of calculation of heat loss, LMTD and overall heat transfer coefficient are
successfully calculated and the value of pressure drop is 234.87 Pa.
INTRODUCTION

What is Shell and Tube Heat Exchanger? Shell and Tube Heat Exchangers are one of the
most popular types of exchanger. It is due to the flexibility the designer has to allow for a
wide range of pressures and temperatures (Brogan. R, 2011)

What is TEMA? TEMA is the Tubular Exchangers Manufacturers Association which

publishes standards defining how shell and tube heat exchangers should be built using the
correct diameter, flow rates and else. Tubes are arranged in a bundle and held in place by a
tube sheet. They are normally specified using BWG and typically are employed in 8, 12, 15,
and 20 foot lengths. Mechanical cleaning is limited to tubes 20 ft and shorter, although
standard exchangers can be built with tubes up to 40 ft.

Shells are also typically purchased in standard sizes to control costs. Inside the shell,
baffles (dividers) are installed to direct the flow around the tubes, increase velocity, and
promote cross flow. They also help support the tubes. The baffle cut is the ratio of the baffle
window height to the shell diameter. Typically, baffle cut is about 20 percent. It effects both
heat transfer and pressure drop. Designers also need to specify the baffle spacing; maximum
spacing depends on how much support the tubes need.

A pass is when liquid flows all the way across from one end to the other of the
exchanger. We will count shell passes and tube passes. An exchanger with one shell pass and
two tube passes is a 1-2 exchanger (shown in the figure). Almost always, the tube passes will
be in multiples of two (1-2, 1-4, 2-4, etc.), since odd numbers of tube passes have more
complicated mechanical stresses, etc. An exception: 1-1 exchangers are sometimes used for
vaporizers and condensers.
OBJECTIVES/AIM

1-To evaluate and study the heat transfer and heat loss for energy balance study.

2-To calculate the LMTD and heat transfer coefficient.

3-To measure and determine the shell and tubes side pressure drop and compare with the
experimental result.
THEORY

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 categorized as parallel flow, counter flow and cross flow. In this experiment, we
study only counter-current flow. For counter-current flow, both the hot and cold fluids flow
in the opposite direction. Both the fluids enter and exit the heat exchanger on the opposite
ends. In this experiment, we focused on the shell and tube heat exchanger.

Heat load and heat balance

This part of the calculation is to calculate the heat load QH and QC

Hot water flow rate ( H W )

QH = FH  CpH  (t1  t 2 )

Hot water flow rate ( CW )

QC = FC  CpC  (T2  T1 )

Where:

QH = Heat load for hot water flow rate

QC = Heat load for cold water flow rate

FH  Hot water mass flow rate

FC  Cold water mass flow rate

t1  Hot water inlet temperature

t 2  Hot water outlet temperature

T1  Cold water inlet temperature

T2  Cold water outlet temperature

LMTD

Calculations of log mean temperature difference (LMTD).

(t1 T 2)  (t 2  T1 )
LMTD 
(t  T2 )
ln 1
(t 2  T1 )

Overall heat transfer coefficient, U

Overall heat transfer coefficient at which equivalent to U D can be calculated by using

equation below.

Q
U
A  LMTD

Where:

Q=Heat rate with respect to the average head load

A=Area of the tube

LMTD=Log Mean Temperature Difference

Pressure Drop

𝑁𝑙𝑓𝑥𝜌(𝑉𝑚𝑎𝑥)2
∆𝑃 =
2
Where:

f=Friction Factor

x=Correction Factor

P=Density

V max=Maximum Velocity

D=Diameter of the tube

N=Tube count

(Cengel, 2015)
APPARATUS

Summary List of Instrumentation

Field-Mount

FT (H) : Flow Transmitter for HW. Vortex flow meter, 0-30 USGPM

FT (C) : Flow Transmitter for CW. Magnetic flow meter, 0-30 USGPM.

DPT : Differential Pressure Transmitter for Shell/Tube side Pressure

drop, 0-5000 mm H2O.

TE1 to TE5 : Temperature Element Resistance Temperature Detector

(RTD), for t1, t2, T1, T2 TIC5 respectively, 0-1000C.

PG-H, PG-C : Pressure gauges, 0-60 psig.

TG2 : Temperature gauge, 0-1000C.

TSV3A,TSV3B: Temperature Solenoid Valve.

Panel-Mount

FI (H), FI (C) : Flow Indicator for HW, CW. Digital display, 0-30 USPGM

TI1, TI2, TI4 : Temperature Indicator for TE1, TE2, TE4, displaying t1, t2 and
T2 respectively. Digital display, 0-1000C

TI3 (T1)/TIC3 : Temperature Indicator with ON/OFF control for TE3 i.e. T1.
Digital display, 0-1000C

TIC5 : Temperature Indicator with ON/OFF control for TE5.

Digital display, 0-1000C

DPI : Differential Pressure Indicator for DP (Shell) and DP (Tube) of

Heat Exchanger. Digital display, 0-5000 mm H2O
RESULTS

General start-up procedures

1. A quick inspection is performed to make sure that the equipment is in a proper

working condition.

2. All valve are initially closed, except V1 and V12.

3. Hot water tank is filled up via a water supply hose connected to valve V27. The valve
is closed after the tank is full.

4. The cold water tank is filled up by opening valve V28 and leaves the valve opened for
continuous water supply.

5. A drain hose is connected to the cold water drain point.

6. Main power is switched on and heater for the hot water also switched on and set the
temperature controller to 50°C.

7. The water temperature in the hot water tank is allowed to reach the set point.

8. The equilibrium is already set up.

General Shut-down

1. The heater is switched off. The hot water temperature drops is wait until below 40°.

2. The pump P1 and P2 is switched off.

3. Main power is switched.

4. All the water in process lines is drain off. All valves is closed.
Experiment 1 Counter-Current Shell & Tube Heat Exchanger

1. All the general start-up procedures had been done.

2. The valves was switch to counter-current Shell & Tube Heat Exchanger arrangement.

3. Pumps P1 and P2 was switched on.

4. Valves V3 and V14 was open and adjusted to obtain the desired flow rates for hot
water and cold water streams respectively.

5. The system was allowed to reach steady state for 10 minutes.

6. FT1, FT2, TT1, TT3 and TT4 was recorded.

7. Pressure drop measurements was recorded for shell-side and tube-side for pressure
drop studies.

8. Steps 4 to 7 was repeated for different combinations of flow rates FT1 and FT2.

9. Pumps P1 and P2 was switched off after the completion of experiment.

10. General shut-down procedures had been made.

RESULTS

Table 1: Counter-current Shell and Tube Heat Exchanger at constant FT1

FT1 FT2 TT1 TT2 TT3 TT4 DPT1 DPT2

(LPM) (LPM) (ºC) (ºC) (ºC) (ºC) (mmH20) (mmH20)
10 2 44.7 30.5 46.9 48.2 110.00 -5.00
10 4 38.6 29.6 46.6 49.1 109.00 -1.00
10 6 35.6 29.6 44.9 48.7 106.00 44
10 8 34.7 30.1 45.9 50.0 108.00 145
10 10 34.7 30.9 45.3 49.1 117.00 206

Table 2: Counter-current and Tube Heat Exchanger at constant FT2

FT1 FT2 TT1 TT2 TT3 TT4 DPT1 DPT2

(LPM) (LPM) (ºC) (ºC) (ºC) (ºC) (mmH20) (mmH20)
2 10 32.3 30.8 38.6 49.1 -5 207
4 10 33.0 31.0 43.1 48.3 8 208
6 10 34.1 31.1 45.2 50.2 34 205
8 10 34.6 31.2 44.7 49.3 83 206
10 10 34.8 31.2 44.1 47.6 115 204
CALCULATION

Density of hot water= 988.927 kg/m³

Density of cold water= 994.965 kg/m³

Specific heat capacity for hot water= 4180.95 J/Kg.K

Specific heat capacity for cold water= 4178 J/Kg.K

1. Calculation of heat loss for hot water constant

For the first value,

𝑄ℎ𝑜𝑡 (𝑊) = 𝑚ℎ 𝐶𝑝 ∆𝑇
𝐿 1𝑚3 1 𝑚𝑖𝑛 𝑘𝑔 𝐽
= 10.0 × × × 988.18 3 × 4180.95
𝑚𝑖𝑛 1000𝐿 60 𝑠 𝑚 𝑘𝑔 ∙ ℃
× (48.2 − 46.9)℃ = 895.165𝑊

𝑄𝑐𝑜𝑙𝑑 (𝑊) = 𝑚ℎ 𝐶𝑝 ∆𝑇
𝐿 1𝑚3 1 𝑚𝑖𝑛 𝑘𝑔 𝐽
= 2.0 × × × 994.965 3 × 4178
𝑚𝑖𝑛 1000𝐿 60 𝑠 𝑚 𝑘𝑔 ∙ ℃
× (44.7 − 30.5)℃ = 1967.63𝑊

𝐻𝑒𝑎𝑡 𝐿𝑜𝑠𝑡 𝑅𝑎𝑡𝑒 = 𝑄ℎ𝑜𝑡 − 𝑄𝑐𝑜𝑙𝑑 = (895.165 − 1967.63)𝑊 = −1072.465𝑊

𝑄 895.165
𝜀= = × 100% = 45.49%
𝑄𝑚𝑎𝑥 1967.63

Q hot(W) Q cold(W) Heat loss (W) ɛ (%)

1 895.165 1967.63 -1072.465 45.49
2 1721.471 1247.08 474.391 138.04
3 2616.636 831.39 1785.246 314.73
4 2823.213 637.40 2185.813 442.93
5 2616.636 526.55 2090.086 496.94
2. Calculation of LMTD

[(𝑇ℎ,𝑖𝑛 − 𝑇𝑐,𝑜𝑢𝑡 ) − (𝑇ℎ,𝑜𝑢𝑡 − 𝑇𝑐,𝑖𝑛 )]

∆𝑇𝑙𝑚 =
(𝑇ℎ,𝑖𝑛 − 𝑇𝑐,𝑜𝑢𝑡 )
ln[ ]
(𝑇ℎ,𝑜𝑢𝑡 − 𝑇𝑐,𝑖𝑛 )

For the first value,

[(48.2 − 44.7) − (46.9 − 30.5)]

∆𝑇𝑙𝑚 = = 8.35℃
(48.2 − 44.7)
ln[ ]
(46.9 − 44.7)

LMTD (º C)
1 8.35
2 13.49
3 14.17
4 15.55
5 Math error
3. Calculation of the overall heat transfer coefficient, U

𝑄 = 𝑈𝐴𝑠∆𝑇𝑙𝑚

For the first value,

𝑄 = 𝑄 𝑙𝑜𝑠𝑠 = 1072.465𝑊

𝐴𝑟𝑒𝑎 = 𝜋𝐷𝐿 = (𝜋)(9.53 𝑋 10−3 𝑚)(500 𝑋 10−3 𝑚) = 0.015𝑚2

𝑄 1072.465 𝑊 𝑊
𝑈= = = 8562.60 ℃
𝐴∆𝑇𝑙𝑚 (0.015𝑚2 )(8.35℃) 𝑚2

Heat Transfer Coefficient, U (W/m².C)

1 8562.60
2 2344.41
3 8399.18
4 9371.12
5 Math error!
4. Temperature profile of Overall Heat Transfer Coefficient Versus Hot Flow rates

Graph Heat Transfer Coefficient,U Vs Hot

Water Flow rate
10000

8000

6000

4000

2000

0
1 2 3 4 5

Overall Heat Transfer Coefficient, U Flow rate of Hot water

5. Calculation of the Pressure Drop

𝐿 1𝑚3 ̇
1𝑚𝑖𝑛 𝑚3
𝑉̇ = 10 × × = 1.67 × 10−4
𝑚𝑖𝑛 1000𝐿 60𝑠 𝑠

𝐴𝑟𝑒𝑎 = 𝜋𝐷𝐿 = (𝜋)(7.75 𝑋 10−3 𝑚)(500 𝑋 10−3 𝑚) = 0.012𝑚2

𝑉̇ 1.67 × 10−4 𝑚
𝑣= = = 0.014
𝐴 0.012 𝑠
𝑚
𝑆𝑇 (18 𝑋 10−3 ) (0.014 ) 𝑚
𝑉𝑚𝑎𝑥 = 𝑉= 𝑠 = 0.025
𝑆𝑇 − 𝐷 −3 −3
(18 𝑋 10 ) − (7.75 𝑋 10 ) 𝑠

𝑘𝑔 𝑚 −3
𝜌𝑉𝑚𝑎𝑥𝐷 988.927 𝑚3 × 0.025 𝑠 × 7.75 𝑋 10 𝑚
𝑅𝑒 = = = 348.75 (𝑡𝑢𝑟𝑏𝑢𝑙𝑒𝑛𝑡 𝑓𝑙𝑜𝑤)
𝜇 0.0005494𝑃𝑎 ∙ 𝑠

𝑓𝑟𝑖𝑐𝑡𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑜𝑟, 𝑓 𝑔𝑒𝑡 𝑓𝑟𝑜𝑚 𝑔𝑟𝑎𝑝ℎ =1.9

𝑐𝑜𝑟𝑟𝑒𝑐𝑡𝑖𝑜𝑛 𝑓𝑎𝑐𝑡𝑜𝑟, 𝑥 𝑔𝑒𝑡 𝑓𝑟𝑜𝑚 𝑔𝑟𝑎𝑝ℎ = 1.0

𝑘𝑔 𝑚 2
𝑁𝑙𝑓𝑥𝜌(𝑉𝑚𝑎𝑥) 2 (10)(1.9)(1.0) (988.927 3 ) (0.025 𝑠 )
𝑚
∆𝑃 = = = 234.87 𝑃𝑎
2 2
DISCUSSIONS

This experiment is to evaluate and study the performance of the Shell and Tube Heat
Exchanger at various operations conditions. This Shell and Tube Heat Exchanger experiment
is conducted using SOLTEQ Heat Exchanger Training apparatus which is used as cooling
devices. The purposes of this experiment are to study the working principle of counter flow
heat exchanger and to evaluate and study the overall heat transfer coefficient, LMTD and heat
transfer and heat loss for energy balance. This heat exchanger is operated with heated water as
the heating medium at the tube side and ambient or warm water at cold water at the Shell side.
The temperature inlet for cold water are lower than temperature outlet and temperature inlet
for heat water are much higher than temperature outlet.

In this shell and heat pump exchanger, cold water flows through the outer pipe which
is the shell while hot water will flows through the inner pipe which is in the tube. Heat will be
transfer from high temperature (hot water stream) to low temperature (cold water stream). This
mechanisms causes hot water to decrease in temperature while cold water to increase in
temperature until both hot and cold water streams have the same temperature. This proven that
there are heat exchanger process happened during the experiment.

In the experiment, volumetric flow rates of hot water is constant which is 10 LPM while
volumetric flow rates of cold water is change every 10 minutes from 2 LPM to 10 LPM. Heat
transfer of hot water, QH is higher than heat transfer of cold water, QC. Therefore, heat transfer
occur efficiently at almost equal volumetric flow rates of hot and cold water.

The graph shown at the end went into zero value is because when calculating the LMTD,
we get the value of 0. This is because when getting the value at the control panel, we did not
wait until the temperature is constant. At the end of the experiments, all objectives are met
although maybe there are some errors. Presence of air bubbles in the tube also is one of the
factors that cause inaccurate results.
CONCLUSIONS

Based on the experiment, the main objective is to evaluate and study the overall heat
transfer coefficient, LMTD, heat transfer and heat loss for energy balance as well as to evaluate
and study the performance of shell and tube heat exchanger at various operating condition. . In
this shell and tube heat exchanger, the fluids flow in counter-current flow which results in faster
heat exchange. The experiment shows that the flow rate of one of the stream is directly
proportional to the rate of heat transfer since the rate of heat transfer is increases as the flow
rate of fluid increases. The basic theory in this experiment is QH=QC, which the amount of
heat release by hot water is equal to the amount of heat absorb by cold water. However, the
results is different than the basic theory where the amount of heat release by hot water is not
equal to the amount of heat absorb by cold water, QH ≠ QC. This is due to some errors during
conducting this experiment which are the presence of bubbles in tube where the hot water flows.
The presence of these bubbles can cause corrosion and disturb the process of heat transfer.
Although the results are not following the basic theory, this experiment can be said as
successful because objectives of this experiment were already achieved.
RECOMMENDATIONS

There are a few recommendations and precautions that need to be taken during
conducting this experiment in order to get an accurate value and success results. Firstly, make
sure that the equipment is in a good condition so that the flow of the experiment does not
disturb by the in constant data. Secondly, to ensure the data obtained is accurate, make sure
there is no air bubbles in the tube during experiment. Thirdly, the readings of FT1, FT2, DPT1,
and DPT2 must be taken when the system is stabilized and reach its steady state to get good
results in calculations. Fourthly, the eye must be perpendicular to the reading scale of
volumetric flow rates of hot and cold water to avoid parallax error during changing this flow
rates. Besides that, the heat exchanger must be well insulated in order to reduce the heat loss
to the surroundings. The last set of temperature readings should be taken when all the
temperatures are fairly steady. While recording the data, make sure that the pressure and
temperature is at constant value because this can affect the calculation made.
REFERENCES

(2003, May 2). Retrieved from Shell and Tube Heat Exchangers: Introduction:
http://facstaff.cbu.edu/rprice/lectures/shelltube.html

Brogan. R, J. (2011, February 2). Shell and Tube Heat Exchangers. Retrieved from Thermopedia:
http://www.thermopedia.com/content/1121/

Cengel, Y. A. (2015). External Heat Convection (Chapter 7). In Y. A. J.Ghajar, Heat and Masss Transfer
(p. 444). New York: Mc Graw Hill Education.

Sakshat Virtual Labs. (2013, April 7). Retrieved from Shell and Tube Heat Exchanger:
http://iitkgp.vlab.co.in/?sub=35&brch=107&sim=1174&cnt=1

Shell & Tube Heat Exchanger. (n.d.). Retrieved from SOLTEQ Equipment for Engineering Education &
Research:
http://www.labequip.co.za/docs/Shell%20%20Tube%20Heat%20Exchanger%20%20HE668.p
df
APPENDIX

Control Panel Pressure Transmitter

TT1 TT2
 TT3 TT4

Cold Water Flow rate Hot Water Flow rate