Question 2:

Plot and discuss on the temperature profiles of co-current and counter-current flow.
The plot of “flow temperature” Vs “length of the tube” is known as temperature profile in Heat
exchanger.

Co-current flow (Parallel flow)

Hot Side Cold Side

Temperature in, Temperature out, Temperature in, Temperature out,
Thot, in (°C) Thot, out (°C) Tcold, in (°C) Tcold, out (°C)
Trial 1 49.7 49.1 31.0 35.4
Trial 2 49.7 49.0 30.9 33.8
Trial 3 49.8 49.0 31.0 33.3
Trial 4 49.8 49.0 31.0 33.1
Trial 5 49.8 48.7 31.0 32.9
Average 49.76 48.96 30.98 33.70

∆T1 = Thot, in - Tcold, in

∆T2 = Thot, out - Tcold, out

Temperature Difference (°C)

∆T1 18.78
∆T2 15.26

∆T1−∆T2
Log Mean Temperature Difference, LMTD = ∆T1
ln( )
∆T2

LMTD, (°C) 16.96

 Temperature Profile for Co-current Flow
60
49.76 48.96
Flow Temperature, (°C) 50

40 33.7
30.98
30

20

10

0
Length of the Tube
Inlet Outlet

Counter-current flow (Cross flow)

Hot Side Cold Side

Temperature in, Temperature out, Temperature in, Temperature out,
Thot, in (°C) Thot, out (°C) Tcold, in (°C) Tcold, out (°C)
Trial 1 50.0 49.3 31.0 35.9
Trial 2 49.9 49.2 31.2 34.0
Trial 3 49.8 49.0 31.2 33.6
Trial 4 49.7 48.9 31.1 33.3
Trial 5 49.7 48.6 31.1 33.0
Average 49.82 49.00 31.12 33.96

∆T1 = Thot, in - Tcold, out

∆T2 = Thot, out - Tcold, in

Temperature Difference (°C)

∆T1 15.86
∆T2 17.88

∆T1−∆T2
Log Mean Temperature Difference, LMTD = ∆T1
ln( )
∆T2

LMTD, (°C) 16.85

 Temperature Profile for Counter-current Flow
60

Flow Temperature, (°C)

49.82 49
50

4033.96
31.12
30

20

10

0
Inlet Length of the Tube Outlet
Discussion:

From the above two temperature profiles, we can conclude that counter-current flow is more
efficient than co-current flow. This is because the counter-current flow had achieved greater heat
recovery. The co-current flow graph shown that the uniform temperature difference, ∆T2 between
hot and cold fluids was lesser compare to counter-current flow.

In the co-current graph, the temperature of the cold stream outlet, Tcold, out is always
lesser than that of the hot stream outlet, Thot, out. Therefore, the heat transfer is restricted by the cold
stream's outlet temperature, Tcold,out. On the other hand, in the counter-current graph, the restriction is
relaxed and Tcold,out can exceed Thot, out. Hence in this design, the heat transfer is restricted by the cold
stream's inlet temperature, Tcold, in.

Now we use LMTD method. The LMTD value in co-current flow is 16.96°C, while in
counter-current flow is 16.85°C. The log mean temperature difference is the maximum mean
temperature difference. Theoretically, the LMTD value for co-current flow is lesser than the counter-
current flow. However, in this experiment, the LMTD value shows otherwise, the LMTD value in
co-current flow is about 0.11°C higher than the counter-current flow. This difference can be
considered as an experimental error.
Question 4：
Based on Fourier law, discuss on how to improve the rate of heat transfer in a heat exchanger.
Fourier’s Law states that “the time rate of heat transfer through a material is proportional to the
negative gradient in the temperature to the area.”

𝑑𝑇
Q = −kA( )
𝑑𝑥

According to the formula, there are 3 ways to improve the rate of heat transfer in a heat exchanger:-

(i) Increasing the k value

The k value is the thermal conductivity. In this experiment, the tube has the thermal conductivity of
stainless steel which is approximately 12-45W/m K.[1] Materials that are higher than 45W/m K can
increase the heat exchange. For example, copper metal, aluminium metal or platinum. The highest
thermal conductivity will be diamond.

(ii) Increasing the area

By increasing the surface area of the tube, the heat transfer will be more efficient. In this experiment,
a cylinder shape of tube is being used. My recommendation will be using longer cylinder tube or
installing a bundle of round tubes just like the tube and shell heat exchanger.

(iii) Increase the temperature difference

This is the most convenience way to increase the heat transfer rate. In this experiment, the
temperature difference is approximately 15-20°C. We can increase the range by 50°C in order to
have an obvious result in heat transfer rate of a pipe.
Question 5:
Discuss on the application of shell & tube, spiral, concentric tube and plate heat exchanger in the
industries.
Shell and Tube Heat Exchanger

Shell and Tube heat exchange is built of a bundle of round tubes mounted in a large cylindrical shell
with tube axis parallel to the shell to transfer the heat between the two fluids. Cold water flow
through the shell while hot water flow through the tubes. Baffle is mounted inside the tube to
increase the efficiency of the heat transfer of the fluid flow.

Usually in chemical industry and process application, it is used as oil-coolers, power condensers,
preheaters in power plants and also steam generators in nuclear power plants. The most common
types of shell-and-tube heat exchanger are fixed tubesheet design, U-tube design and floating-head
type. Cleaning this heat exchanger is easy. Instead of easily cleaning, it is also low in cost.
Generally, counter-current fluid flow is widely used due to its greater heat recovery. However, in
some cases, co-current heat exchanger is used.

The first case is the fact that counter-current flow may cause the temperature exchange
completely. It means that the cold fluid is in the tube while the hot fluid in the shell. To avoid this,
co-current is to be considered here since the temperature of the cold fluid never exceeds a particular
temperature.

The second case is the isothermal heat transfer. There is no obvious advantage either in co-
current and counter current flow. For example, water when is undergoing phase exchange from
steam to liquid.

Spiral-Tube Heat Exchanger

It has the same built of shell and tube heat exchanger but helical or coiled tube. This is found mostly
in refrigeration systems as co-axial condensers and co-axial evaporators. This is due to the fact that
the heat transfer coefficient is higher compared to a straight tube. Therefore, the cooling effect can
be done in a short while. Due to its shape, the cleaning is impossible, so the fluid flowing should be
very clean to extend its lifetime. In another words, solid particle is not allowed inside this exchanger.

Another advantage of the spiral-tube heat exchanger is the efficient use of space. A compact
spiral heat exchanger can lower costs, while an oversized one can have less pressure drop, higher
thermal efficiency, less pumping energy, and lower energy costs. Using physics concept, the inertia
force and the gravitational force acted on the fluid in spiral manner help in maintaining the velocity
of the flow. Hence, less pressure drop and less pumping energy.

Concentric Tube Heat Exchanger (Double Pipe)

Concentric tube heat exchange is the simplest version of the tube and shell heat exchanger. It
consists of only two pipe, one is the smaller pipe and the other one is the big pipe. On the other
hand, tube and shell heat exchanger consists of one big pipe and many small pipe.

Concentric tube heat exchanger has lesser capacity and less transfer rate compare to tube and
shell heat exchanger. It is mainly used in lab experiment due to its small capacity for experimental
purposes and it is very easy to clean.

Plate Heat Exchanger

Plate heat exchanger has many thin plates that are slightly apart and have very large surface areas
and fluid flow passages that are good for heat transfer. In current technology, it is much more
effective heat exchanger compare to tube and shell heat exchanger. There are 3 types of plate heat
exchanger.

(i) Gasketed Plate Heat Exchanger

A gasketed plate heat exchanger consists of a series of thin plates that have wavy surface which
function as separating the hot and cold fluids. The plates come with corner parts arranged so that
the two media between which heat is to be exchanged flow through interchange exclaim spaces.

Since the flow passages are quite small, strong eddying gives high heat transfer coefficients, high
pressure drops, and high local shear which minimizes fouling. These exchangers provide a
relatively compact and lightweight heat transfer surface. Gasketed plate are typically used for
heat exchange between two liquid streams. This type can be found in food processing industries
because of the compatibility to be cleaned easily and sterilized as it completely disassembled.

(ii) Spiral Plate Heat Exchanger

In spiral plate heat exchanger, two plate is being bent into spiral shape and attached together. This is
different with spiral tube heat exchange with only one tube is being spiralled. Spiral plate heat
exchange is quite compact and are relatively expensive due to the specialized fabrication. Hence, it
is used mainly in large industries with specific purpose.

For example, a steam vaporizer. It is mainly used in

chemical processing which it is ideal for handling
fouling fluids, viscous media, slurries, sewage sludge,
and other dirty process fluids and effluents with
suspended solids or fibers. This is because it has self-
cleaning passage, by inducing high shear rates which
will then scrub away deposits as they form.
The high thermal efficiency is what makes it the best. Single and long curving flow passages ensure
the superior flow distribution with higher surface area. The curving creates intense turbulence of the
flow which may increase the heat transfer coefficients by 50-100% compare to shell and tubes heat
exchanger.
Appendix
Reference

[1] Thermal Conductivity of Metals. (n.d.). Retrieved from

https://www.engineeringtoolbox.com/thermal-conductivity-metals-d_858.html