[Chemical Engineering Laboratory III]

SEGi University

EXPERIMENT 2: HEAT EXCHANGER

Candidate’s Name: TAN YEN BING

Student ID: SCM-030472
Group Number: 3
Group Member’s Name:
1. KOW JING YANG
2. NG LIANG AIK
3. FONG KAH WEI
4. MOHSEN

Lecturer/Supervisor: IR KUA & DR AIDA

Date of Experiment: 9/3/2016
Date of Submission: 16/3/2016
ABSTRACT

The objective of this experiment is to investigate the function and the working
principles of shell and tube heat exchangers. Counter-current and Co-current shells
were used with tube heat exchangers to perform two familiar experiments. Flow rates
of hot and cold waters were adjusted throughout the experiments to study the difference
in outcomes. Temperatures of waters were recorded to calculate heat transfer and heat
loss for energy balance study. Logarithmic mean temperature difference (LMTD) and
heat transfer coefficient were also calculated. From the data obtained, it was found that
the configuration of counter-current shell and tube heat exchanger has a higher
efficiency than co-current shell.

OBJECTIVES

i. To allow students to get familiarized with shell and tube heat exchangers

ii. To collect data and calculate the heat losses, heat transfer coefficient and LMTD
values.
INTRODUCTION

A heat exchanger is an equipment in which heat exchange occurs between 2

fluids that enter and leave at different temperatures. The main function of a heat
exchanger is to remove heat from a hot fluid or to add heat to a cold fluid. The direction
of fluid motion inside the heat exchanger can be categorized into parallel flow (co-
current flow), counter flow and cross flow. However, in this experiment only co-current
flow and counter current flow were investigated. For co-current flow, both hot and cold
water flow in the same direction and leave the heat exchanger on the same ends. While
for counter current flow, both hot and cold water flow in opposite direction so they exit
the heat exchanger on the opposite ends too.

Figure 1: Temperature profile for a parallel-flow heat exchanger

 Figure 2: Temperature profile for a counter-flow heat exchanger

For a parallel-flow shell and tube heat exchanger with one tube pass and one shell
pass shown in Figure 2a, the heat balance is given as:

mtCpt (t2 - t1) = msCps(T1 - T2) = q (1)

Similarly, for the counterflow shell and tube heat exchanger with one tube pass and
one shell pass shown in Figure 2b, the heat balance is given as:

mtCpt (t2 - t1) = msCps(T1 - T2) = q (2)

The general equation for heat transfer across the tube surface in a shell and tube heat
exchanger is given by:

q =UoAoTm = UiAiTm (3)

The coefficients Uo and Ui are given by:

1 1 1 d o ln(d o d i ) d o d
     o (4)
Uo ho hod 2k w d i hid d i hi
and,

1 1 1 d i ln(d o d i ) d d
    i  i (5)
U i hi hid 2k w d o hod d o ho

The mean temperature difference for both parallel and counter-flow shell and tube
heat exchanger with single shell pass and single tube pass is normally expressed in
terms of log-mean temperature difference,

T1  T2
Tlm  (6)
T
ln 1 

 T2

APPARATUS

i. Shell & Tube Heat Exchanger

Tube O.D. (do) : 9.53 mm
Tube I.D. (di) : 7.75 mm
Tube Length (L) : 500 mm
Tube Count (Nt) : 10 (single pass)
Tube Pitch (pt) : 18 mm
Tube arrangement : Triangle
Shell O.D. : 100 mm
Shell I.D. (Ds) : 85 mm
Baffle Count : 8
Baffle Cut (Bc) : 20 %
Baffle Distance (lB) : 50 mm
Material of Construction : 316L Stainless Steel/Borosilicate Glass
ii. Cold Water Circuit
Tank : 50 liter
Material : Stainless Steel
Circulation Pump : Centrifugal type
Operating Flow rate : 10 LPM (dry-run protected by level switch)

iii. Hot Water Circuit

Tank : 50 liter
Material : Stainless Steel
Circulation Pump : Centrifugal type
Operating Flow rate : 20 LPM (dry-run protected by level switch)
Heating System : 11.5 kW immersion type heater protected by
temperature controller and level switch

iv. Instrumentations
- Measurements of inlet and outlet temperatures for hot water and cold water
streams
- Measurements of flow rates for the hot water and cold water circuits

v. Control Panel
- To mount all the necessary digital indicators, temperature controller and all
switches
- To house electrical components and wirings
- To house all the necessary data acquisition modules and signal conditioning
unit
 SHELL & TUBE HEAT EXCHANGER V20

V4 V5

V19 SPIRAL HEAT EXCHANGER V22

V6 V7

CONCENTRIC HEAT EXCHANGER V24

T2 V21

V8 V9

V23 PLATE HEAT EXCHANGER

V25
V26

V11
V10

T1
T3

FI1
V27 T4 V17 V15
Water
FI2 Water
Inlet
Inlet
FT1 V28
Hot Water FT2
Tank Cold Water
V3 Tank
V14
HEATER
V2 V13
LEVEL SWITCH
LEVEL SWITCH V18 V16

V12 V30
V29 V1 To Drain Pump 2 To Drain
Pump 1
To Drain

Figure 2 Schematic Diagram for Heat Exchanger Training Apparatus

(Model: HE 158C)
PROCEDURES

A) General Start-up Procedures

1. A quick inspection was performed to make sure that the equipment was in a
proper working condition.
2. All valves were ensured to be initially closed, except V2 and V12.
3. Hot water tank was filled up via a water supply hose connected to valve V27.
Once the tank was full, the valve was closed.
4. The cold water tank was filled up by opening valve V 28 and the valve was left
opened for continual water supply.
5. A drain hose was connected to the cold water drain point.
6. Main power was switched on. The heater for the hot water tank was switched
on and the temperature controller was set point to 50 C.
(Note: Recommended maximum temperature controller set point was 70 C)

7. The water temperature in the hot water tank was allowed to reach the set-point.
8. The equipment was now ready to be run.

B) General Shut-down Procedures

1. Heater was switched off. The hot water temperature was waited to drop below
50°C.
2. Pump P1 and pump P2 were switched off.
3. Main power was switched off.
4. All water in the process lines was drained off. Water in the hot and cold water
tanks were retained for next laboratory session.
5. All valves were closed.
Note: If the equipment was not to be run for a long period, all liquids were
drained completely.
C) Process Instruments

It is important that the user read and fully understand all the instructions and precautions
stated in the manufacturer's manuals supplied with the unit prior to operating. The
following procedures serve as a quick reference for operating the unit.

1. Temperature Controller
i. The first line displays the liquid temperature in the tank while the second
line displays the set value. Adjust the set value as follows:
ii. Press the ENT button, and then press UP or DOWN arrow key continuously
until almost near the desired set value.
iii. Press UP or DOWN arrow key one by one until desired set value is reached.
Notice that the least digit point is flashing.
iv. Press ENT to register the data. Notice that the least digit point goes off.

2. Valve Arrangements

Table 1: Valves Arrangement for Flow Selection

OPEN CLOSE LEAVE ALONE
V15, V18, V2, V3, V4 - V11,
Counter- V1, V12, V16,
V27, V29, V13, V14, V19 -
Current V17, V28
V30 V26
V16, V17, V2, V3, V4 – V11,
Co- V1, V12, V15,
V27, V29, V13, V14, V19 –
Current V18, V28
V30 V26

Table 2: Valves Arrangement for Heat Exchanger Selection

OPEN CLOSE
Shell & Tube
V4, V5, V19, V20 V6 - V11, V21 - V26
Heat Exchanger
Spiral Heat V4, V5, V8 - V11, V19,
V6, V7, V21, V22
Exchanger V20, V23 - V26
Concentric Heat V4 - V7, V10, V11, V19
V8, V9, V23, V24
Exchanger - V22, V25, V26
Plate Heat V10, V11, V25,
V4 - V9, V19 - V24
Exchanger V26
 Valve V3: to vary hot water flow rate
Valve V14: to vary cold water flow rate
Valve V2 and V13: Flow bypass for water pump. These valves should be
partially opened all the time. If the water flow rates are not stable, reduce the
bypass.

3. Flow Measurements
FT1: Hot water flowrate
FT2: Cold water flowrate

4. Temperature Measurements
i. Counter-Current
TT1: Hot water inlet temperature
TT2: Hot water outlet temperature
TT3: Cold water inlet temperature
TT4: Cold water outlet temperature

ii. Co-Current
TT1: Hot water inlet temperature
TT2: Hot water outlet temperature
TT3: Cold water outlet temperature
TT4: Cold water inlet temperature

5. Operating Limits
Temperature : max. 70 ºC
D) Experiment 1: Counter-Current Shell & Tube Heat Exchanger

In this experiment, cold water enters the shell at room temperature while hot water
enters the tubes in the opposite direction. Students shall vary the hot water and cold
water flow rates and record the inlet and outlet temperatures of both the hot water and
cold water streams at steady state.

Procedure:

1. General start-up procedures in Section A were performed.

2. The valves were switched to Counter-Current Shell & Tube Heat Exchanger
arrangement (Please refer to Section C).
3. Pumps P1 and P2 were switched on.
4. Valves V3 and V14 were opened 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, TT2, TT3 and TT4 were recorded.
7. Pressure drop measurements for shell-side and tube-side were recorded for pressure
drop studies.
8. Steps 4 to 7 were repeated for different combinations of flow rate FT1 and FT2 as
in the results sheet.
9. Pumps P1 and P2 were switched off after the completion of experiment.
10. Relevant data was recorded in table.
E) Experiment 2: Co-Current Shell & Tube Heat Exchanger

In this experiment, cold water enters the shell at room temperature while hot water
enters the tubes in the same direction. Students shall vary the hot water and cold water
flow rates and record the inlet and outlet temperatures of both the hot water and cold
water streams at steady state.

Procedure:

1. General start-up procedures in Section A were performed.

2. The valves were switched to Co-Current Shell & Tube Heat Exchanger arrangement
(Please refer to Section C).
3. Pumps P1 and P2 were switched on.
4. If there is air trap in the shell-side, the valves were switched to counter-current and
the air was bleed with high water flow rate. Then the valves were switched back to
co-current position.
5. Valves V3 and V14 were opened and adjusted to obtain the desired flow rates for
hot water and cold water streams, respectively.
6. The system was allowed to reach steady state for 10 minutes.
7. FT1, FT2, TT1, TT2, TT3 and TT4 were recorded.
8. Pressure drop measurements for shell-side and tube-side were recorded for pressure
drop studies.
9. Steps 5 to 8 were repeated for different combinations of flow rate FT1 and FT2 as
in the results sheet.
10. Pumps P1 and P2 were switched off after the completion of experiment.
11. Relevant data was recorded in table.
 RESULTS

FT 1 FT 2 TT 1 TT 2 TT 3 TT 4 Q̇Hot Q̇Cold ∆Tlmtd U

(L/min) (L/min) (°C) (°C) (°C) (°C) (W) (W) (°C)
(W/m2 oC)

10 2 50.0 48.5 34.4 31.9 1043.96 347.99 16.02 4353.11

10 6 49.9 48.4 33.3 32.0 1043.96 542.86 16.46 4236.74
10 10 50.0 48.2 32.9 32.1 1252.75 556.78 16.57 5050.33

Table 1: Counter-Current Concentric Shell & Tube Heat Exchanger

FT 1 FT 2 TT 1 TT 2 TT 3 TT 4 Q̇Hot Q̇Cold ∆Tlmtd U

(L/min) (L/min) (°C) (°C) (°C) (°C) (W) (W) (°C)
(W/m2 oC)

2 10 49.7 46.4 32.6 32.1 459.34 347.99 15.62 1964.41

6 10 49.8 47.8 32.8 32.1 835.16 487.18 16.31 3420.53
10 10 49.9 48.2 33.0 32.1 1183.15 626.37 16.47 4798.71

Table 2: Counter-Current Concentric Shell & Tube Heat Exchanger

FT 1 FT 2 TT 1 TT 2 TT 3 TT 4 Q̇Hot Q̇Cold ∆Tlmtd U

(L/min) (L/min) (°C) (°C) (°C) (°C) (W) (W) (°C)
(W/m2 oC)

10 2 49.8 48.5 33.7 32.1 904.76 222.71 16.21 3728.45

10 6 49.8 48.1 33.0 31.4 1183.15 668.13 16.70 4732.62
10 10 49.8 48.0 32.7 31.5 1252.75 835.16 16.76 4993.08

Table 3: Co-Current Concentric Shell & Tube Heat Exchanger

76

FT 1 F··8T 2 TT 1 TT 2 TT 3 TT 4 Q̇Hot Q̇Cold ∆Tlmtd U

(L/min) (L/min) (°C) (°C) (°C) (°C) (W) (W) (°C)
(W/m2 oC)

2 10 49.8 48.0 32.4 31.6 250.55 556.78 16.87 992.10

6 10 49.8 47.6 32.5 31.6 918.68 375.82 16.60 3969.87
10 10 49.7 46.5 32.4 31.8 2227.10 417.58 15.92 9344.90

Table 4: Co-Current Concentric Shell & Tube Heat Exchanger

SAMPLE CALCULATION

1. To calculate 𝑚̇ in kg/s:

2𝐿 1𝑚𝑖𝑛 1𝑚3 999𝑘𝑔

× × × = 0.0333𝑘𝑔/𝑠
𝑚𝑖𝑛 60𝑠 1000𝐿 𝑚3

2. To calculate Q̇Hot in W:

𝑄̇𝐻𝑜𝑡 = 𝑚̇𝐶𝑝 (𝑇𝑇1 − 𝑇𝑇2)

= 0.0333 x 4180 x (49.7 - 46.4)

= 459.34W

3. To calculate Q̇Cold in W:

𝑄̇𝐶𝑜𝑙𝑑 = 𝑚̇𝐶𝑝 (𝑇𝑇3 − 𝑇𝑇4)

= 0.1665 x 4180 x (32.6 - 32.1)

= 347.99W

4. To calculate Q̇loss in W:

Q̇loss = Q̇Hot - Q̇Cold

= 459.34 – 347.99
= 111.35
5. To calculate logarithmic mean temperature difference, ∆Tlmtd in oC:

(∆𝑇1 − ∆𝑇2 )
∆𝑇𝑙𝑚𝑡𝑑 =
∆𝑇
ln⁡( 1⁄∆𝑇 )
2

(49.7⁡–⁡32.1)−(46.4−32.6)
=
ln⁡[(49.7−32.1)/(46.4−32.6)]

= 15.62oC

6. To calculate overall heat transfer coefficient, U in W/m2 oC:

𝑄̇𝐻𝑜𝑡
U⁡ =
𝐴∆𝑇𝑙𝑚𝑡𝑑

459.34
= (0.015×15.62)

= 1960.48W/m2oC
DISCUSSION

From the data obtained, it was found that when the volumetric flow rate of the
fluid increases, both Qhot and Qcold increase too. The overall heat transfer coefficient, U
also increases. When the flow rate of hot fluid was kept constant while increasing the
flow rate of cold fluid, both the Q and U values increased but the difference was not
that big. However, when the flow rate of cold fluid was kept constant while increasing
the flow rate of hot fluid, both the Q and U value increased dramatically. While the
∆Tlmtd did not change much even when adjusting the flow rate of hot fluid or cold fluid.
The amount of heat loss form the hot water is not equal to the heat gain by the cold
water due to the heat loss to the surrounding.

In co-current flow configuration, the exit temperature of the hot fluid is always
higher than the exit temperature of the cold fluid. In counter-current flow configuration,
the exit temperature of the hot fluid is also higher than the exit temperature of the cold
fluid. However, in counter-current flow configuration, the exit temperature of the cold
fluid is higher than the exit temperature of the cold fluid in co-current configuration.
Hence, it is clear that for heat exchanger, counter-current flow configuration has a
higher effectiveness than the co-current flow configuration.

This experiment was conducted successfully and important information was

obtained to calculate the heat transfer, heat loss, LMTD and overall heat transfer
coefficient. However, there might be some random errors when the experiment was
conducted which caused the results to be not so accurate. For example, the temperature
reading displayed was keep changing and time was needed to wait for the reading to be
consistent. Thus, to improve the results, random error could be prevented by recording
the temperature at the correct timing. Besides, the heat exchanger apparatus used was
too old and might cause rapid overheating when experiment is still in progress.
CONCLUSION

This experiment shows that the shell and tube heat exchanger follows the basic
law of thermodynamics. For heat exchanger, counter-current flow configuration has a
higher effectiveness than the co-current flow configuration. The overall heat
transfer coefficient for counter-current flow is higher than the co-current flow. As a
conclusion, counter current flow configuration of heat exchanger is more preferred
for practical application.

REFERENCES

1. Incropera, F. P., De Witt, D.P., Fundamentals of Heat and Mass Transfer, John
Wiley & Sons, Singapore, 1990.

2. Heat and Mass Transfer (A Practical Approach) – 3rd EditionYunus A.

CengelMcGraw Hill (2006).