Abstract

This experiment investigates the heat transfer process at steady state. It studies the effect of

liquid flow rate on the overall heat transfer coefficient and heat exchanger effectiveness. It

also studies the effect of flow arrangement on overall heat transfer coefficient and the

exchanger effectiveness. This experiment is separated to two parts, the effect of the flow rate

of hot water stream and the effect of the flow rate of cold water stream on the heat exchanger.

The general procedure for the experiment is to check the counter current flow of heat

exchanger by adjusting the valves. The cold water stream was set at constant flow rate which

is 8LPM. Hot water stream was manipulated with flow rate of 5,10, 15 and 20LPM. The

temperatures for inlets and outlets for both streams were recorded. This experiment is

repeated by setting the hot water flow rate constant at 8LPM, alternating the cold water

stream with the same sets of flow rates. From the results comparison, counter current heat

exchanger will have higher heat transfer rate from start of experiment until end of the

experiment. The effectiveness of the heat exchanger was greatly depending on the cold water

stream than hot water stream. Highest value of effectiveness of exchanger for hot water

stream is when the flow rate is 5LPM while for cold water stream is 20LPM. For a better

result, the experiment should be run 5 times or more. Other than that, the flow rate must be

measured correctly because it will affect the result obtained. If there is error in the flow rate,

the result would be worthless. By insulating the heat exchanger, the heat loss to the

surrounding can be reduced and thus the result would have less error.

1
 Methodology

General start up procedure:

At least 3/4 of
All valves are
water was filled in The power supply
ensured to be
the hot and cold was switched on.
initially closed.
water tank.

Experiment A: Co-current shell and tube heat exchanger. For Experiment B, the steps are all
the same but before ran the experiment, the valves were set to counter current process.
To study the
The valves The heater was When the temp effect of hot
were set to co- switched on and becomes constant, the water
current process temperature pumps(P1&P2)and air sream,HV5
was set to 50℃ cooler were switched valve was
on. The air trapped was adjusted to
released by opening the obtain the
HV14 valve. desired
flowrate for hot
water.

The steps were

repeated for 4
All the The system At the same time,
different setting
data was was allowed the flowrate for
of hot water flow
recorded. to reach cold water stream
rate.
steady state. was fixed using
HV15.
To study the
effect of cold At the same
water stream, The system The data were
time,the flow Pumps (P1
HV15 valve was was allowed recorded and steps
rate for hot & P2 were
adjusted to to reach were repeated for
water was switched
obtain desired steady state. 4 diff setting of
fixed using off.
flowrate for the cold water
HV5 valve.
cold water. flowrate.

2
RESULT:
Table 1: Effect of Hot Water Stream in co-current flow
Cold water flow rate (FT2 or FI2): 8 LPM

Flow Rate Hot Water Outlet Hot Water Inlet Cold Water Outlet Cold Water Inlet
(FT1 or FI1) (TT2 or TI2) (TT1 or TI1) (TT4 or TI4) (TT3 or TI3)
LPM (oC) (oC) (oC) (oC)

5 43.7 49.1 34.9 27.8

10 46.7 49.0 36.4 28.1
15 48.6 49.6 37.3 28.3
20 49.8 50.3 38.0 28.4

Table 2: Effect of Cold Water Stream in co-current flow

Hot water flow rate (FT1 or FI1): 8 LPM

Flow Rate Hot Water Outlet Hot Water Inlet Cold Water Outlet Cold Water Inlet
(FT2 or FI2) (TT2 or TI2) (TT1 or TI1) (TT4 or TI4) (TT3 or TI3)
LPM (oC) (oC) (oC) (oC)

5 46.7 49.1 37.9 28.5

10 45.9 49.2 36.0 28.6
15 45.0 49.0 33.9 28.8
20 44.2 49.2 33.0 29.0

Table 3: Effect of Hot Water Stream in counter-current flow

Cold water flow rate (FT2 or FI2): 8 LPM

Flow Rate Hot Water Outlet Hot Water Inlet Cold Water Outlet Cold Water Inlet
(FT1 or FI1) (TT2 or TI2) (TT1 or TI1) (TT4 or TI4) (TT3 or TI3)
LPM (oC) (oC) (oC) (oC)

5 43.8 48.9 36.1 29.1

10 46.7 49.0 36.9 29.2
15 48.9 49.6 37.5 29.2
20 49.6 50.3 38.4 29.3

Table 4: Effect of Cold Water Stream in counter current flow

Hot water flow rate (FT1 or FI1): 8 LPM

Flow Rate Hot Water Outlet Hot Water Inlet Cold Water Outlet Cold Water Inlet
(FT2 or FI2) (TT2 or TI2) (TT1 or TI1) (TT4 or TI4) (TT3 or TI3)
LPM (oC) (oC) (oC) (oC
5 47.2 49.4 38.2 29.5
10 46.5 49.2 37.6 29.5
15 43.8 49.0 35.0 29.7
20 44.0 49.0 34.0 29.8

3
Discussion

To calculate and analyse the heat transfer process at steady state

To ease our calculation, we change the unit of flow rate from LPM to kg/s at first. Take the
density of water as 1000 kg/m3.

Unit conversion:

Liter Minutes 1000kg 1m3 kg

× × 3
× =
Minutes 60 Seconds m 1000 Liters s

Flow rate (LPM) Flow rate (kg/s)

5 0.0833
10 0.1667
15 0.2500
20 0.3333
8 0.1333

To calculate the heat transfer rate, q including heat load and heat loss.

q = mass flow rate × cpm × ∆T

Calculation of heat loss and heat absorb from Table 1.1 to Table 4.1 are using the above
equation, assuming cpm of water is 4.181 kJ/kg.K and ∆T as Thi − Tho or Tco − Tci . The
value of Tho , Thi , Tco 𝑎𝑛𝑑 Tci was referred to from Table 1 to Table 4.

Table 1.1: Heat Transfer Rate for Hot and Cold Water in Co-Current Shell and Tube Heat
Exchanger Data Analysis with Hot Water Stream Effect
Flow 𝐓𝐡𝐢 − 𝐓𝐡𝐨 Heat Flow 𝐓𝐜𝐨 − 𝐓𝐜𝐢 Heat Average Heat
Rate 1 Rate 2
loss absorb Transfer Rate,
(kg/s) (kg/s)
(kJ/s) (kJ/s) q,( kJ/s)

0.0833 5.4 1.881 0.1333 7.1 3.957 2.919

0.1667 2.3 1.603 0.1333 8.3 4.626 3.115

0.2500 1.0 1.045 0.1333 9.0 5.016 3.030

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0.3333 0.5 0.696 0,1333 9.6 5.350 3.023

Table 2.1: Heat Transfer Rate for Hot and Cold Water in Co-Current Shell and Tube Heat
Exchanger Data Analysis with Cold Water Stream Effect
Flow 𝐓𝐡𝐢 − 𝐓𝐡𝐨 Heat Flow 𝐓𝐜𝐨 − 𝐓𝐜𝐢 Heat Average Heat
Rate 1 Rate 2
loss absorb Transfer Rate,
(kg/s) (kg/s)
(kJ/s) (kJ/s) q,( kJ/s)

0.1333 2.4 1.338 0.0833 9.3 3.239 2.289

0.1333 3.3 1.839 0.1667 7.4 5.158 3.499

0.1333 4.0 2.230 0.2500 5.1 5.331 3.781

0.1333 5.0 2.787 0.3333 4.0 5.574 4.181

Table 3.1: Heat Transfer Rate for Hot and Cold Water in Counter-Current Shell and Tube
Heat Exchanger Data Analysis with Hot Water Stream Effect
Flow 𝐓𝐡𝐢 − 𝐓𝐡𝐨 Heat Flow 𝐓𝐜𝐨 − 𝐓𝐜𝐢 Heat Average Heat
Rate 1 Rate 2
loss absorb Transfer Rate,
(kg/s) (kg/s)
(kJ/s) (kJ/s) q,( kJ/s)

0.0833 5.1 1.776 0.1333 7.0 3.901 2,839

0.1667 2.3 1.603 0.1333 7.7 4.291 2.947

0.2500 0.7 0.732 0.1333 8.3 4.626 2.679

0.3333 0.7 0.975 0.1333 9.1 5.072 3.024

Table 4.1: Heat Transfer Rate for Hot and Cold Water in Counter-Current Shell and Tube
Heat Exchanger Data Analysis with Cold Water Stream Effect
Flow 𝐓𝐡𝐢 − 𝐓𝐡𝐨 Heat Flow 𝐓𝐜𝐨 − 𝐓𝐜𝐢 Heat Average Heat
Rate 1 Rate 2
loss absorb Transfer Rate,
(kg/s) (kg/s)
(kJ/s) (kJ/s) q,( kJ/s)

0.1333 2.2 1.226 0.0833 8.7 3.030 2.128

0.1333 2.7 1.505 0.1667 8.1 5.645 3.575

0.1333 5.2 2.898 0.2500 5.3 5.540 4.219

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0.1333 5.0 2.787 0.3333 4.2 5.853 4.320

To determine the effect of liquid flow on heat transfer coefficient, we need to use the
heat transfer rate calculated in objective 1 to proceed by using the formula:

𝑞𝐴𝑉𝐺
𝑈𝑜 =
A ∆Tlm
Where; 𝑈𝑜 = overall heat transfer coefficient
A = heat exchanger area = Number of Tube × Tube surface area=
= 37 × 0.0491m2
==
1.8167m2
𝑞𝐴𝑉𝐺 = Average heat transfer rate
And;
(Thi − Tco )– (Tho − Tci )
∆Tlm =
T −T
ln (Thi − Tco )
ho ci

𝑞𝐴𝑉𝐺 , kJ/s ∆Tlm , K 𝑈𝑜 , kW/m2.K

2.919 15.03 0.107
3.115 15.41 0.111
3.030 15.97 0.104
3.023 16.43 0.101
Table 1.1.1: Average heat transfer rate, log mean temperature and overall heat transfer
coefficient for co-current heat exchanger with hot water stream effect.

𝑞𝐴𝑉𝐺 , kJ/s ∆Tlm , K 𝑈𝑜 , kW/m2.K

2.289 14.42 0.087

3.449 15.16 0.125
3.781 15.64 0.133
4.181 15.69 0.147
Table 2.1.1: Average heat transfer rate, log mean temperature and overall heat transfer
coefficient for co-current heat exchanger with cold water stream effect.

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𝑞𝐴𝑉𝐺 , kJ/s ∆Tlm , K 𝑈𝑜 , kW/m2.K

2.839 13.73 0.114

2.947 14.63 0.111
2.679 15.59 0.095
3.024 15.73 0.106
Table 3.1.1: Average heat transfer rate, log mean temperature and overall heat transfer
coefficient for counter-current heat exchanger with hot water stream effect

𝑞𝐴𝑉𝐺 , kJ/s ∆Tlm , K 𝑈𝑜 , kW/m2.K

2.128 14.20 0.082
3.575 14.13 0.139
4.219 14.05 0.165
4.320 14.60 0.163
Table 4.1.1: Average heat transfer rate, log mean temperature and overall heat transfer
coefficient for counter-current heat exchanger with cold water stream effect.

Heat exchanger efficiency

Ch = (ṁ x Cp) hot
Cc = (ṁ x Cp) cold

Assume Cp, water = Cp, hot = Cp, cold =4.181 kJ/kg.K

When Cmin =Cc

𝐶ℎ (𝑇ℎ𝑖 −𝑇ℎ𝑜 )
Efficiency, ε =
𝐶𝑐 (𝑇ℎ𝑖 −𝑇𝑐𝑖 )

When Cmin =Ch

𝐶𝑐 (𝑇𝑐𝑜 −𝑇𝑐𝑖)
Efficiency, ε =
𝐶ℎ (𝑇ℎ𝑖 −𝑇𝑐𝑖 )

Table 1.1.1.1: The value of Ch, Cc, and Efficiency for co-current heat exchanger with hot
water stream effect: (Constant cold water flow rate = 0.1333 kg/s)

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Ch , kW/K Cc , kW/K Cmin Efficiency, ε
0.3483 0.5573 Ch 0.533
0.6970 0.5573 Cc 0.138
1.0453 0.5573 Cc 0.088
1.3935 0.5573 Cc 0.057

Table 2.1.1.1: The value of Ch, Cc, and Efficiency for co-current heat exchanger with cold
water stream effect: (Constant hot water flow rate = 0.1333 kg/s)

Ch Cc Cmin Efficiency, ε
0.5573 0.3483 Cc 0.186
0.5573 0.6970 Ch 0.449
0.5573 1.0453 Ch 0.474
0.5573 1.3935 Ch 0.495

Table 3.1.1.1: The value of Ch, Cc, and Efficiency for counter-current heat exchanger with hot
water stream effect: (Constant cold water flow rate = 0.1333 kg/s)

Ch Cc Cmin Efficiency, ε
0.3483 0.5573 Ch 0.566
0.6970 0.5573 Cc 0.145
1.0453 0.5573 Cc 0.064
1.3935 0.5573 Cc 0.083

Table 4.1.1.1: The value of Ch, Cc, and Efficiency for counter-current heat exchanger with
cold water stream effect: (Constant hot water flow rate = 0.1333 kg/s)

Ch Cc Cmin Efficiency, ε
0.5573 0.3483 Cc 0.177
0.5573 0.6970 Ch 0.513
0.5573 1.0453 Ch 0.515
0.5573 1.3935 Ch 0.547

8
 Heat Transfer Coefficient, U against Water
Flow Rate
0.18
Ooverall Heat Transfer Coefficient

y=2.498x-0.314
0.16
R square= 0.8065 y=3.964x-0.279
0.14 R square= 0.895

0.12 y=2.22-19.02x
(W/m2.K)

R square= 0.5705
0.1 Hot stream(co-current)
y=1.058-7.974x
0.08 cold stream(co-current)
R square= 0.3832
0.06 Hot stream(counter current)
Cold stream(Counter current)
0.04

0.02

0
0 0.1 0.2 0.3 0.4
Water Flow Rate (kg/s)

Figure 3. Overall heat transfer coefficient against water flow rate (hot and cold streams, co-
current and counter current flows)

From figure 3, the heat-transfer rate (q) of a given exchanger depends on its design
and the properties of the two fluid streams. A heat exchanger’s performance is predicted by
calculating the overall heat transfer coefficient U and the area A. According to the theory, the
heat transfer is directly proportional to the heat transfer coefficient. Based on the graph in
Figure 3, increasing the flow rate will increase the heat transfer coefficient for cold stream by
co-current and counter current flow. However, the hot stream by co-current and counter
current flow are increasing the flow rate will decrease the heat transfer coefficient. The
overall heat transfer coefficient for cold water stream of counter current had the highest value
when the volumetric flow rate is 20 LPM. The possible reason why this phenomena happened
is the heat transfer process happened the best in this flow rate. According to [Geankoplis
(2003)], even without the high flow rate, by using counter current heat exchanger, the most
heat can be transferred due to the greater average temperature difference along any unit
length. By comparing the initial and final values of overall heat coefficient, we can see that
the hot water stream for counter current heat exchanger has higher values at the beginning
and the cold water stream for counter current heat exchanger has higher values at the end.

9
Thus, we can say that counter current heat exchanger will have higher heat transfer rate from
the starting of the experiment until end of the experiment.

Efficiency against Water Flow Rate

0.6 y=0.506x-0.013
R square= 0.6755
0.5
y=0.633x-0.045
0.4 R square= 0.7230
Efficiency

Hot Stream(Co-current)
0.3
Cold Stream(Co-current)
0.2 Hot Stream(Counter Current)
y=0.293-0.417x
R square= 0.7399 Cold Stream(Counter Current)
0.1
y=0.2895-0.3788x
0 R square= 0.6956
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35
Water Flow Rate (kg/s)

Figure 4. Effectiveness against water flow rate (hot and cold streams, co-current and counter
current flows)

From the result, we can see the flow trend of hot water stream effect and cold water
stream effect co-current and counter-current heat exchanger. The average effectiveness of the
cold water stream in co-current and counter current heat exchanger is higher compared to the
hot water stream in co-current and counter current heat exchanger effect by 0.401, 0.438,
0.204 and 0.2145 respectively. Thus, the cold water stream effect is more effective compared
to the hot water stream. From Figure 3 and 4, it was obviously demonstrated that the
effectiveness of heat exchanger was greatly depend on the cold water stream rather than hot
water stream. However, when the volumetric flow rate of hot water stream was manipulated
in the counter current heat exchanger, the effectiveness had shown the highest value when the
flow rate is 5 LPM. When the volumetric flow rate of cold water stream was manipulated in
the co-current heat exchanger, the effectiveness had shown the highest value when the flow
rate is 20 LPM. Again, the possible reason is because the flow rate is at the optimum level
where the heat transfer takes place in the best performance.

10
 In the experiment A, we need to find out what is the effect of hot water and cold
stream in the co-current shell & tube heat exchanger. From the Table 1.1.1 and 2.1.1, we can
know that the heat transfer of hot water is not stable but cool water was increased when
increasing the hot and cold water flow rate. From the Figure 3, increasing the cold water flow
rate can let the overall heat transfer coefficient increase.On the other hand, increasing the hot
water flow rate, the overall heat transfer coefficient not stable. The mean temperature
differences also increase when the hot and cold water flow rate was increased. This show that
higher the flow rate can create greater the temperature difference, then had the better heat
transfer and overall performance. A higher flow rate of fluid was improve the heat transfer
and let the entering and the leaving fluid temperature frequently. This gives a better approach
to the saturation temperature. Figure 4 show that the efficiency of heat transfer decrease when
the hot water flow rate increase while the efficiency of heat transfer was increased when the
cold water flow rate increased .

In experiment B, we need to find out what is the effect of hot water and cold stream in
the counter shell & tube heat exchanger. The Table 3.1.1 and 4.1.1 show that the heat transfer
of hot water is not stable but cool water was increased when increasing the hot and cold water
flow rate. From Figure 3, we can know that the overall heat transfer coefficient was increased
when the cool water flow rate was increased while the overall heat transfer coefficient is not
stable when the hot water flow rate increased .Same situation with experiment A, the higher
flow rate of fluid can improve the heat transfer and bring entering fluid temperature and the
leaving fluid temperature on the other side more frequently, thus, it can get the better
approach to the saturation temperature. From the figure 4, the efficiency of heat transfer was
decrease when the hot water flow rate was increased while the efficiency of heat transfer
increased when the cold water flow rate increased.

11
CONCLUSION

There are three objectives in this experiments. The first objectives is to calculate and

analyze the heat transfer process at steady state. The unit of flow rate must be changed from

LPM to kg/s to ease our calculation. The heat transfer rate, q from each tables has been

calculated and get the average to determine the overall heat transfer coefficient. Heat

exchanger efficiency also has been calculated for each of the experiments. The second

objective is to study the effect of liquid flow rate on the overall heat transfer coefficient and

the heat exchanger effectiveness. Next is to study the effect of flow arrangements either its

counter-current flow or co-current flow on overall heat transfer coefficient and heat

exchanger effectiveness. For the first experiment (co-current flow), the cold water stream was

set at constant flow rate that is 8LPM. The hot water stream has been set to 5LPM, 10LPM,

15LPM, and 20LPM. The temperatures from the inlets and outlets has been recorded. This

experiment was repeated for the hot water stream at constant flow rate that is 8LPM and

alternating the cold water with the same set of flow rates. The same steps are used to do for

the counter-current flow. From figure 3, we can see that the hot water stream for counter

current heat exchanger has higher values at the beginning and the cold water stream for

counter current heat exchanger has higher values at the end. So we can conclude that that

counter current heat exchanger will have higher heat transfer rate from starting until the end

of the experiment. For the effectiveness of the heat exchanger against the water flow rate

based on the graph on figure 4, the average effectiveness of the cold water stream in co-

current and counter current heat exchanger is higher compared to the hot water stream in co-

current and counter current heat exchanger. We can conclude that the cold water stream

effect is more effective compared to hot water stream.

12
RECOMMENDATION

In order to improve the experiment, there are number of things that could be

done. To increase the accuracy of the result, instead of 4, we could run the experiment 5 or

more times. This step is important to verify the result obtained. Besides that, heat loss from

the heat exchanger might affect the result. By using insulated heat exchanger, the heat loss to

the surrounding can be minimized (Vaughn & Ware, 2000). Flow rates are one of the

important things in heat exchanger experiment. The flow rates used can vary the result

obtained and might cause error in the experiment. During the experiment, ensured that the

flow rate is measured correctly because it took some time for the heat exchanger to detect the

value of the flow rates (Vaughn & Ware, 2000). Furthermore, before the experiment is

conducted, it is important to ensure that all the valves is fully closed or opened. This step is

important to prevent build ups and leeks (J.Constantinou,2004).

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