Shell and Tube

ABSTRACT
The experiment was conducted to determine the function of the shell and tube heat exchanger.
The experiment was also to evaluate the heat transfer and heat loss for energy balance, LMTD,
heat transfer coefficient, overall heat transfer coefficient (U) and the pressure drop of the shell
and tube heat exchanger. The experiment is conducted using different flow rates for the cold
water and hot water. The flow rates of the cold water will remain constant while the flow rates of
the hot water will be varies between 2 to 10 LPM in the first experiment. For the second
experiment, the flow rates of the hot water will remain constant and the flow rates for the cold
water will be varies. Then, the temperature will be taken for cold water and hot water and the
calculation will be done. From the results obtained, the pressure drop of the shell is lower than
the counter current for both systems. The experiment was completed and the carried out
adequately. The data is being recorded for temperature and pressure for each flow rates within
3 minutes interval.
INTRODUCTION
The process of heat exchange between the fluids at certain temperature with a separation of
solid and liquid occurred in many applications in engineering process. Heat exchanger is a
device used to implement the exchange process. The heat exchanger is where the heat
exchange taken places between two fluids that enter and exit the system with different
temperature. The transfer of thermal energy for the heat exchanger is between two or more
fluids, between a solid surface and liquid or between solid particles and liquid at the different
temperature and in thermal contact.
There are many types of heat exchanger uses in the industry. The most common heat
exchanger being used is shell and tube heat exchanger. For shell and tube heat exchanger, the
fluids are being separated based on the temperature of the fluids. The fluid will flow through the
tubes sides and through the shell side around the tube. This type of heat exchanger consists of
series of tubes and it must be filled with hot or cold fluid.(Cengel, 2013)
The heat exchanger is being classified to three flow arrangement. The flow arrangements are
counter-flow, parallel-flow and cross flow. For the parallel flow heat exchanger, the fluid will
enter the system at the same side and the flow travel parallel to each other. The counter-flow
heat exchanger allows the fluid to enter the system at the opposite direction. This type of heat
exchanger is the most efficient because it can transfer more heat from the heat medium due to
higher average temperature difference. For cross-flow heat exchanger, the fluid will travel
perpendicular to one another through the exchanger.
The heat exchanger is made of structural steel. The participating fluids are water flowing
through the tube side and air flowing through the shell side. The baffles introduce some crossflow to the air and such increasing the area of heat exchange. Another advantage is that the
baffles helps to reduce the vibration due to the fluid motion.(Comsol,2013).
OBJECTIVES
1. To determine the function of the shell and tube heat exchanger
2. To calculate the value of heat transfer and heat loss, LMTD, heat transfer coefficient,
overall heat transfer coefficient and the pressure drop
3. To perform the temperature profile of shell and tube heat exchanger
THEORY
Most chemical transfer involves heat transfer to or from the process fluid. Heat exchanger is
equipment built to help in transferring the heat. There are many type of heat exchanger but the
most common used heat exchanger in industry is shell and tube heat exchanger. Tube and shell
heat exchanger consist of series of tube and these tubes consist of cooled or heated fluid.
There are parallel-flow heat exchanger and counter-flow heat exchanger. The parallel-flow heat
exchanger is where the two fluids enter at the same end and the fluid travel parallel to each
other. The counter-current heat exchanger is where the fluid enters the exchanger from different
ends.
Heat balance
For a parallel-flow shell and tube heat exchanger with one tube pass and one shell pass, the
heat
balance is given by:
mt C pt ( t 2t 1 )=m t C ps ( T 1T 2 ) =q
The heat balance for counter-flow shell and tube heat exchanger with one tube pass and one
shell pass is:
mt C pt ( t 2t 1 )=m t C ps ( T 1T 2 ) =q
where,
mt
= mass flow rate of cold fluid in the tube (kgs-1)
ms
= mass flow rate of hot fluid in the shell (kgs-1)
C pt
= specific heat of cold fluid in the tube (kJkg-1oC-1)
C ps
= specific heat of hot fluid in the shell (kJkg-1oC-1)
t 1 , t 2 = temperature of cold fluid entering/leaving the tube (oC)

T 1 , T 2 = temperature of hot fluid entering/leaving the shell (oC)
q
= heat exchange rate between fluid (kW)
Heat transfer
The general heat equation for heat transfer across the tube surface in shell and tube heat
exchanger is :
q=U o A o T m=U i Ai T m
where,
Ao
= outside area of the tube (m2)
Ai
= inside area of the tube (m2)
T m = mean temperature difference (oC)

Uo
= overall heat transfer based on the outside area of the tube (kWm-2oC-1)
Ui
= overall heat transfer based on the inside area of the tube (kWm-2oC-1)
The coefficient
U o and U i are given by:
d
1
1 1 d o ln ( d o /d i ) d o
= + +
+
+ o
U o ho hod
2kw
di hid d i hi
And,
d
d
1 1 1 d i ln ( d o /d i )
= + +
+ i + i
U i hi hid
2k w
d o h id d o hi
Where,
ho
= outside fluid film coefficient (kWm-2oC-1)
hi
= inside fluid film coefficient (kWm-2oC-1)
hod = outside dirt coefficient (fouling factor) (kWm-2oC-1)

hid = inside dirt coefficient (fouling factor) (kWm-2oC-1)
kw
= thermal conductivity of the tube wall material (kWm-1oC-1)
do
= tube outside diameter (m)
di
= tube inside diameter (m)
Overall heat transfer coefficient, U

The equation to calculate the overall heat transfer coefficient is:
U=
Q
A LMTD
Where,
Q
A
QC
QH
= Heat rate with respect to the flow rate of water
= Area of the tube
Log mean temperature difference (LMTD)
or
The mean temperature difference for both parallel and counter flow shell and tube heat
exchanger with single shell pass and single pass tube is expressed as log-mean temperature
difference,
T lm=
T T out
ln
T
T out
LMTD is effective for both types of flow conditions. The assumption made during calculating the
LMTD is:
1. The fluid specific heat capacity do not vary with temperature
2. The convection heat transfer coefficient are constant throughout the exchanger
The second assumption is influenced by the entrance effects fluids viscosity and thermal
conductivity changes. The heat loss from the hot fluid flowing in the inner tube is determined
from this equation:
QH =mH C PH ( t 1t 2)
Where
mH =hot water mass flow rate

C PH =specific heat capacity of hot water
t 1 =inlet hot fluid temperature
t 2 =outlet hot fluid temperature
Besides that, the heat gained by the cold fluid flowing in the space between the inner and outer
pipes can be calculated using:
qC =m C C PC ( T 1T 2 )
Where
mC =cold water mass flow rate

C PC =specific heat capacity of cold water
T 1 =inlet cold fluid temperature
T 2 =outlet cold fluid temperature
Supposedly,
qC
is less than
qH
because some heat is lost through the insulated material
to the surrounding air, abiding the outer surface of the concentric tube is insulated. Hence, the
efficiency can be obtained from:
qC
qH
The effectiveness of a heat exchanger is defined as:
actual heat transfer

maximum possible heat transfer
By calculating the energy lost by the hot fluid from equation or the energy gained by the cold
fluid from equation, the value of the actual heat transfer can be obtained.
Tube-side heat transfer coefficient, hi

For turbulent flow, Sieder-Tate equation can be used:
Nu=C 0.8 Pr 0.33 ( f / w )0.14

Where,
= Reynolds number
f ut d e / f
Nu = Nusselt number hi d e /k f
Pr
de
= Prandtl number
C p f /k f
= equivalent diameter (m)

= 4 (cross sectional area of flow) / wetted perimeter
= fluid viscosity of bulk fluid temperature (Nsm-2)
= fluid viscosity at the wall (Nsm-2)
= fluid velocity in the tube (ms-1)
= fluid density (kgm-3)
Cp
= fluid specific heat, heat capacity (J/kg0C)
= 0.023 for non-viscous liquid

0.027 for viscous liquid
kf
= fluid thermal conductivity (W/m0C)
For laminar flow (Re < 2000),
Nu=1.86 ( . Pr ) 0.33 ( d e / L )0.33 ( f / w )0.14

Where,
= tube length (m)
Tube-side Pressure Drop, Pt
f u2t
Pt =N p [ 8 j f ( L /di ) ( / w ) +2.5 ]
2
m
Where,
Pt
= tube-side pressure drop (N/m2)
Np
= number of side tube passes
jf
= tube dimensionless friction factor
= length of the tube (m)
ut
= tube-side velocity (m/s)
= 0.25 for laminar

= 0.14 for turbulent
APPARATUS AND MATERIAL
PROCEDURE
General Start-up
1. The valve was initially closed except for V1 and V2.
2. The hot water tank was filled up via water supply hose connected to valve V27 and when
the tank is full, the valve was closed.
3. The cold water tank was filled up via water supply hose connected to valve V28 and the
4.
5.
6.
7.
valve is open for continuous water supply.

The drain hose was connected to the cold water drain point.
The main power and the heater were switched on until the hot water reached 500C.
The water temperature in the hot water tank was allowed to reach the set-point.
The equipment was ready to be run.
The Counter-current Shell and Tube Heat Exchanger

1. The valves were switched on to counter-current Shell & Tube Heat Exchanger
arrangement.
2. The pump P1 and P2 was switched on.
3. The valves V3 and V14 were opened and being adjusted to obtain the desired flowrates
for hot and cold water streams respectively.
4. The system was allowed to reach the steady state for 3 minutes.
5. The FT1, FT2, TT1, TT2, TT3 and TT4 were recorded.
6. The pressure drop measurement was recorded for shell-side and tube-side for pressure
drop studies.
7. The steps 3 to 6 were repeated for different combinations of FT1 and FT2.
8. The pumps P1 and P2 were switched off after the experiment was done.
Co-current Shell and Tube Heat Exchanger

1. The valves were switched to co-current Shell & Tube Heat Exchanger arrangement.
2. The pumps P1 and P2 were switched on.
3. The valves were switched to the counter-current arrangement when there is air bubble
trap in the shell-side and flow the water with high water flowrates.
4. The valves were switched to the co-current arrangement back when there is no air
bubble.
5. The valves V3 and V14 were opened and being adjusted to obtain the desired flow rates
for hot and cold water streams respectively.
6. The system was allowed to reach the steady state for 3 minutes.
7. The FT1, FT2, TT1, TT2, TT3 and TT4 were recorded.
8. The pressure drop measurement was recorded for shell-side and tube-side.
9. The steps 5 to 8 were repeated for different combinations of FT1 and FT2.
10. The pumps P1 and P2 were switched off after the experiment was completed.
General Shut-down Procedures

1.
2.
3.
4.
5.
The heater was switched off.

The pumps P1 and P2 was switched off
The main power was switched off.
All water in the process lines was drained.
All valves were closed.
RESULTS
Counter-current Shell and Tube Heat Exchanger
FT1
(LPM)
2
4
6
8
10
FT2
(LPM)
10
10
10
10
10
TT1
0
( C)
30.8
31.5
32.2
33.3
34.0
TT2
0
( C)
29.2
29.2
29.3
29.7
29.8
TT3
0
TT4
0
DPT1
DPT2
( C)
38.1
43.1
44.0
44.8
45.1
( C)
49.3
48.8
49.2
49.5
48.7
(mmH2O)
193
195
191
192
191
(mmH2O)
-5
-5
-5
-5
-5
TT3
TT4
DPT1
DPT2

FT1
(LPM)
10
10
10
10
10
FT2
(LPM)
2
4
6
8
10
TT1
0
( C)
41.4
37.9
35.4
34.0
33.2
TT2
0
( C)
29.9
30.2
29.2
28.9
28.9
( C)
47.5
46.6
45.6
44.9
44.6
( C)
49.1
49.1
49.0
48.9
48.9
(mmH2O)
6
69
126
214
377
(mmH2O)
-5
-5
-5
-5
-5
TT3
TT4
DPT1
DPT2
Counter-current Shell and Tube Heat Exchanger

FT1
(LPM)
2
4
6
8
10
FT2
(LPM)
10
10
10
10
10
TT1
0
( C)
29.9
29.9
30.0
30.1
30.2
TT2
0
( C)
31.4
31.8
32.7
33.7
34.0
( C)
38.6
43.2
44.3
45.4
45.4
( C)
49.5
48.8
49.2
50.0
49.4
(mmH2O)
679
678
675
678
676
(mmH2O)
604
601
583
530
527

FT1
FT2
TT1
TT2
TT3
TT4
DPT1
DPT2
(LPM)
10
10
10
(LPM)
2
4
6
(0C)
30.3
30.4
30.3
(0C)
38.1
36.0
34.4
(0C)
47.2
46.6
46.0
(0C)
48.7
48.9
48.9
(mmH2O)
23
7
653
(mmH2O)
526
524
524
10
10
8
10
30.1
30.0
34.0
33.7
45.6
45.2
48.7
49.0
670
712
523
530
COSTANT FLOW RATE OF HOT WATER

Cold water counter-current flow
TEST
VOLUMETRIC FLOWRATE (LPM)
2.00
4.00
6.00
8.00
10
MASS FLOWRATE (kg/s)
0.0333
0.0667
0.1000
0.1333
0.1667
HEAT TRANSFER RATE (J/s)
223.09
694.15
994.04
2221.27
2984.84
TEST
10
10
10
10
10
0.1667
0.1667
0.1667
0.1667
0.1667
8002.08
5294.59
4263.17
3506.80
2956.72
Hot water counter current flow
TEST
-11.98
-13.64
-14.96
-15.44
Undefined
HEAT LOSS(W)
7778.99
4600.44
3269.16
1285.53
-28.12
EFFICIENCY (%)
2.79
13.11
23.32
63.34
100.95
LOG
MEAN,
T lm
OVERALL HEAT TRANSFER COEFFICIENT

TEST
Total exchange area(
Overall
heat
m2
transfer
coefficient(
0.15
0.15
0.15
0.15
0.15
4453.02
2344.21
1899.81
1514.16
Undefine
W /m2 . K
TUBE SIDE
TEST
4.7210-5
4.7210-5
4.7210-5
4.7210-5
4.7210-5
4.7210-4
4.7210-4
4.7210-4
4.7210-4
4.7210-4
348.94
348.94
348.94
348.94
348.94
LINEAR VELOCITY (m/s)
0.3531
0.3531
0.3531
0.3531
0.3531
REYNOLDS NUMBER
4922.25
4922.25
4922.25
4922.25
4922.25
PRANDTL NUMBER
3.56
3.56
3.56
3.56
3.56
TYPE OF FLOW
Turbulent
Turbulent
Turbulent
Turbulent
Turbulent
0.0039
0.0039
0.0039
0.0039
0.0039
2423.94
2423.94
2423.94
2423.94
2423.94
CROSS
SECTION
AREA
m
TOTAL CROSS FLOW AREA, (
2
m
MASS
VELOCITY
(kg /m2 . s)
HEAT
TRANSFER
FACTOR,
jh
TUBE
COEFFICIENT,
ht (
W /m . K
SHELL SIDE
TEST
CROSS FLOW AREA (
MASS VELOCITY
m2
(kg /m2 . s)
0.002
0.002
0.002
0.002
0.002
16.6
33.35
50.00
66.67
83.50
0.0166
0.033
0.050
0.067
0.167
EQUIVALENT DIAMETER (m)
0.0278
0.0278
0.0278
0.0278
0.0278
REYNOLDS NUMBER
576.35
1157.90
1735.98
2314.78
2899.09
PRANDTL NUMBER
5.44
5.44
5.44
5.44
5.44
TYPE OF FLOW
Laminar
Laminar
Laminar
Turbulent
Turbulent
0.023
0.050
0.043
0.039
0.034
513.26
2344.21
2890.31
3495.80
3816.44
282.14
282.14
282.14
282.14
282.14
0.77
6.63
13.09
21.32
115.47
HEAT TRANSFER FACTOR,

SHELL
jh
COEFFICIENT,
hS
(W /m . K )
TEST
PRESSURE DROP(
Pa - tube
PRESSURE DROP( Pa -shell
Cold water counter-current

TEST
10.00
10.00
10.00
10.00
10.00
0.1667
0.1667
0.1667
0.1667
0.1667
7774.46
3956.64
3609.57
3262.50
2498.93
TEST
2.00
4.00
6.00
8.00
10.00
0.0333
0.0667
0.1000
0.1333
0.1667
220.03
632.60
1196.44
1980.31
2887.96
Hot water counter-current
TEST
-13.12
-15.54
-15.82
-15.64
-15.00
HEAT LOSS (W)
-7554.43
-3324.04
-2413.13
-1282.20
389.03
EFFICIENCY (%)
3533.36
625.46
301.69
164.75
86.53
LOG
T lm
MEAN,

TEST
m2
Total exchange area (

Overall
heat
transfer
0.15
0.15
0.15
0.15
0.15
111.80
271.39
504.19
844.12
1283.54
coefficient
(W /m2 . K )
TUBE SIDE
TEST
4.7210-5
4.7210-5
4.7210-5
4.7210-5
4.7210-5
4.7210-4
4.7210-4
4.7210-4
4.7210-4
4.7210-4
70.62
141.24
234.19
282.49
353.11
0.0714
0.1429
0.2370
0.2859
0.3573
REYNOLDS NUMBER
996.19
1991.81
3303.55
3984.89
4981.07
CROSS
SECTION
AREA
m2
TOTAL CROSS FLOW AREA, (
m2
MASS
VELOCITY
(kg /m2 . s)
PRANDTL NUMBER
3.56
3.56
3.56
3.56
3.56
TYPE OF FLOW
Laminar
Laminar
Turbulent
Turbulent
Turbulent
0.0048
0.0030
0.0036
0.0040
0.0040
603.66
754.58
1501.88
2012.71
2515.76
HEAT
TRANSFER
FACTOR,
jh
TUBECOEFFICIENT,
ht (W /m2 . K )
SHELL SIDE
TEST
0.002
0.002
0.002
0.002
0.002
83.33
83.33
83.33
83.33
83.33
0.0837
0.0837
0.0837
0.0837
0.0837
0.0278
0.0278
0.0278
0.0278
0.0278
REYNOLDS NUMBER
2893.19
2893.19
2893.19
2893.19
2893.19
PRANDTL NUMBER
5.44
5.44
5.44
5.44
5.44
TYPE OF FLOW
Turbulent
Turbulent
Turbulent
Turbulent
Turbulent
0.010
0.010
0.010
0.010
0.010
1120.16
1120.16
1120.16
1120.16
1120.16
CROSS FLOW AREA (

MASS VELOCITY
m2
(kg /m2 . s)

SHELL
jh
COEFFICIENT,
hS
(W /m 2 . K )
TEST
PRESSURE DROP(
Pa - tube
PRESSURE DROP( Pa -shell
12.75
41.37
122.67
187.12
292.26
8.53
8.53
8.53
8.53
8.53
Cold water co-current flow

TEST
2.00
4.00
6.00
8.00
10.00
0.0333
0.0667
0.1000
0.1333
0.1667
-208.24
-888.61
-1207.82
-1721.49
-2637.76
Hot water
TEST
10
10
10
10
10
0.1667
0.1667
0.1667
0.1667
0.1667
-5363.35
-3850.61
-2819.20
-2681.67
-2544.15
TEST
-13.21
-14.19
-14.40
-14.83
-14.94
HEAT LOSS (W)
-5155.11
-2962.10
-1611.38
-960.18
93.61
EFFICIENCY (%)
3.88
23.07
42.84
64.19
103.68
LOG
MEAN,
T lm

TEST
m2
0.15
0.15
0.15
0.15
0.15
Overall
heat
transfer
coefficient
4038.40
(W /m 2 . K )
1809.07
1305.19
1205.51
1135.27
TUBE SIDE
TEST
4.7210-5
4.7210-5
4.7210-5
4.7210-5
4.7210-5
4.7210-4
4.7210-4
4.7210-4
4.7210-4
4.7210-4
348.94
348.94
348.94
348.94
348.94
0.3531
0.3531
0.3531
0.3531
0.3531
REYNOLDS NUMBER
4922.25
4922.25
4922.25
4922.25
4922.25
PRANDTL NUMBER
3.56
3.56
3.56
3.56
3.56
TYPE OF FLOW
Turbulent
Turbulent
Turbulent
Turbulent
Turbulent
0.0039
0.0039
0.0039
0.0039
0.0039
2423.94
2423.94
2423.94
2423.94
2423.94
CROSS
SECTION
AREA
m2
TOTAL CROSS FLOW AREA,
m2
MASS
VELOCITY
(kg /m2 . s)
HEAT
TRANSFER
FACTOR,
jh
TUBE COEFFICIENT,
ht
(W /m . K )
SHELL SIDE
TEST
CROSS FLOW AREA(
m2
0.002
0.002
0.002
0.002
0.002
MASS VELOCITY
(kg /m2 . s)
16.6
33.35
50.00
66.67
83.33
0.0166
0.033
0.050
0.067
0.084
0.0278
0.0278
0.0278
0.0278
0.0278
REYNOLDS NUMBER
576.35
1157.90
1753.98
2314.76
2893.19
PRANDTL NUMBER
5.44
5.44
5.44
5.44
5.44
TYPE OF FLOW
Laminar
Laminar
Laminar
Turbulent
Turbulent
0.023
0.048
0.044
0.038
0.032
513.26
2152.19
2988.22
3406.16
3584.51
TEST
PRESSURE DROP( Pa - tube
282.14
282.14
282.14
282.14
282.14
0.77
6.37
13.39
20.77
27.50

SHELL
jh
COEFFICIENT,
hS
(W /m . K )
PRESSURE DROP(
Pa -shell
Cold water co-current flow

TEST
10.00
10.00
10.00
10.00
10.00
0.1667
0.1667
0.1667
0.1667
0.1667
-7566.21
-3887.23
-3401.32
-3193.08
-2776.59
Hot water co-current flow

TEST
2.00
4.00
6.00
8.00
10.00
0.0333
0.0667
0.1000
0.1333
0.1667
-206.28
-522.58
-1113.93
-1980.31
-2612.91
TEST
-12.38
-14.84
-15.08
-15.44
-14.96
HEAT LOSS (W)
7359.93
3364.65
2287.39
1212.77
163.68
EFFICIENCY (%)
3667.93
743.85
305.34
161.24
106.26
LOG
T lm
MEAN,

TEST
Overall
heat
m2
transfer
0.15
0.15
0.15
0.15
0.15
111.08
234.76
492.45
855.06
1164.39
coefficient
(W /m2 . K )
TUBE SIDE
TEST
CROSS
SECTION
AREA
4.7210-5
4.7210-5
4.7210-5
4.7210-5
4.7210-5
4.7210-4
4.7210-4
4.7210-4
4.7210-4
4.7210-4
m2
TOTAL CROSS FLOW AREA,
m2
MASS
VELOCITY
70.62
141.24
211.86
282.49
353.11
0.0715
0.1429
0.2144
0.2859
0.3573
REYNOLDS NUMBER
996.19
1992.37
2988.56
3984.89
4981.07
PRANDTL NUMBER
3.56
3.56
3.56
3.56
3.56
TYPE OF FLOW
Laminar
Laminar
Turbulent
Turbulent
Turbulent
0.0050
0.0030
0.0036
0.0039
0.0040
628.81
754.58
1358.69
1962.39
2515.76
(kg /m2 . s)
HEAT
TRANSFER
FACTOR,
jh
TUBE COEFFICIENT,
ht
(W /m . K )
SHELL SIDE
TEST
0.002
0.002
0.002
0.002
0.002
83.33
83.33
83.33
83.33
83.33
0.0837
0.0837
0.0837
0.0837
0.0837
0.0278
0.0278
0.0278
0.0278
0.0278
REYNOLDS NUMBER
2893.19
2893.19
2893.19
2893.19
2893.19
PRANDTL NUMBER
5.44
5.44
5.44
5.44
5.44
TYPE OF FLOW
Turbulent
Turbulent
Turbulent
Turbulent
Turbulent
0.01
0.01
0.01
0.01
0.01
CROSS FLOW AREA (

MASS VELOCITY
m2
(kg /m2 . s)
jh
SHELL
COEFFICIENT,
1120.16
h S (W /m . K )
1120.16
1120.16
1120.16
1120.16
TEST
PRESSURE DROP( Pa - tube
13.05
41.37
100.39
184.97
292.26
8.53
8.53
8.53
8.53
8.53
PRESSURE DROP(
Pa -shell
Temperature profile and heat transfer coefficient for co-current and counter-current flow
1. Temperature profile for counter-current flow with fixed flow rates of cold water
60
50
40
30
20
10
cold water
hot water
1400
1200
1000
800
600
400
200
0
1
10
11
10
11
3000
2500
2000
1500
tube side
shell side
1000
500
0
1
2. Temperature profile for counter-current flow with fixed flow rates of hot water
60
50
40
30
20
10
hot water
cold water
12
10
0
1
10
10
11
4500
4000
3500
3000
2500
shell side
2000
tube side
1500
1000
500
0
1
3. Temperature profile for co-current flow with fixed flow rates of cold water
60
50
40
30
hot water
cold water
20
10
1400
1200
1000
800
600
400
200
0
1
10
11
3000
2500
2000
tube side
1500
shell side
1000
500
0
1
10
11
4. Temperature profile for co-current flow with fixed flow rates of hot water
60
50
40
30
hot water
cold water
20
10
4500
4000
3500
3000
2500
2000
1500
1000
500
0
0
10
12
4000
3500
3000
2500
shell side
2000
tube side
1500
1000
500
0
1
10
11
CALCULATIONS
Rate of heat transfer and heat lost for counter-current shell and tube heat exchanger
1. F1 = 10 LPM , F2 = 2 LPM
Heat transfer for hot water
L
1 m3
1 min
kg
J
10
988.18 3 4175
( 41.429.9 )
min 1000 L 60 s
kg .
m
8002.08 W
Heat transfer for cold water
QC =mC C PC ( T 2T 1 )
L
1 m3
1 min
kg
J
2
995.67 3 4183
( 49.147.5 )
min 1000 L 60 s
kg .
m
223.09W
Heat lost rate
QH QC
8002.08223.09
7778.99W
Efficiency
QC
100
QH
223.09
100
8002.08
2.79
Calculation of Log Mean Temperature Difference
T lm=
T T out
ln
T
T out
( 41.449.1 ) (29.947.5 )
( 41.449.1 )
ln
( 41.449.1 )
11.98
Calculation of the tube and shell heat transfer coefficient by Kerns method
For 1-shell pass and I tube pass

Heat transfer coefficient at tube side
Cross flow area , A=
0.00775
4
d 2i
4
4.72 105 m2
Total cross flow area , A t= A number of tubes
4.72 105 10
4.72 104 m2
Mass velocity , G t =
mt
At
0.1647
4
4.72 10
348.94
kg
2
m .s
Linear velocity ,ut =
Gt
348.94
988.18
0.3531
m
s
Reynoldsnumber , =
Gt d e
348.94 0.00775
5.494 104
4922.25(turbulent flow)
Prandt number , Pr=
Cp
k
5.494 104 4175

0.6436
3.56
Tube side heat transfer factor, jh =0.0039
j h Pr 0.33 k
tube side coefficient , hi =
di
0.0039 4922.25 3.56

0.00775
2423.94
0.33
0.6436
W
2
m K
Heat transfer coefficient at shell side
Cross flow area , A s=
( tube pitcht ube OD ) shell diameter Baffle distance

tube pitch
( 0.0180.00953 ) 0.085 0.05

0.018
0.002 m2
Mass velocity , G s=
ms
As
0.0332
0.002
16.6
kg
2
m .s
Linear velocity ,u s=
Gs
16.6
995.67
0.0166
m
s
Equivalent diameter , d e =
1.1 2
2
( p 0.917 d o )
do t
1.1
(0.018 20.917 ( 0.00953 )2 )
0.00953
0.0278 m
Reynolds number , =
G s d e
16.6 0.0278
8.007 104
576.35(laminar flow)
Prandt number , Pr=
Cp
k
8.007 104 4183

0.6155
5.44
Shell side heat transfer factor, jh =0.023
j h Pr 0.33 k
shell side coefficient ,h i=
de
0.023 576.35 5.440.33 0.6155
0.0278
513.26
W
m2 K
Overall heat transfer coefficient,U
Total e xcahnge area , A=Number of tube tubeOD lenghof tube

10 0.00953 0.5
0.15 m
U=
QH
A T lm
8002.08
0.15 11.98
4453.02
Calculation of pressure drop across tube and shell
de
d s /
Ps =8 j f
0.0278
0.085 /
8(0.023)
0.77 Pa
2
u
Pt =N p [ 8 j f ( L /di ) ( / w ) +2.5 ] f t
2
m
(988.18)(0.3531)2
0.5
0.14
( 8 0.0039 )
( 1.0 ) + 2.5
0.0075
2
282.14 Pa
Rate of heat transfer and heat lost for co-current shell and tube heat exchanger
2. F1 = 10 LPM , F2 = 2 LPM
10
L
1 m3
1 min
kg
J
988.18 3 4175
( 30.338.1 )
min 1000 L 60 s
kg
.
m
5363.35 W
L
1 m3
1 min
kg
J
995.67 3 4183
( 47.248.7 )
min 1000 L 60 s
kg
.
m
208.24 W
Heat lost rate
QH QC
5363.35(208.24)
5155.11 W
Efficiency
QC
100
QH
208.24
100
5363.35
3.88
T lm=
T T out
ln
( TT )
out
( 30.348.7 )( 38.147.2 )
(30.348.7 )
ln
( 38.147.2 )
13.21

d 2i
4
0.007752
4
4.72 105 m2
5
4.72 10 10
4.72 104 m2
mt
At
0.1647
4
4.72 10
348.94
kg
2
m .s
Gt
348.94
988.18
0.3531
m
s
Reynoldsnumber , =
Gt d e
348.94 0.00775
5.494 104
Prandt number , Pr=
Cp
k
5.494 104 4175

0.6436
3.56
j h Pr 0.33 k
di
0.0039 4922.25 3.560.33 0.6436

0.00775
2423.94
W
m2 K
( tube pitchtubeOD ) shell diameter Baffle distance

tube pitch
( 0.0180.00953 ) 0.085 0.05

0.018
0.002 m2
ms
As
0.0332
0.002
16.6
kg
m2 . s
16.6
995.67
0.0166
m
s
Gs
1.1 2
( pt 0.917 d 2o)
do
1.1
2
2
(0.018 0.917 ( 0.00953 ) )
0.00953
0.0278 m
Reynolds number , =
G s d e
16.6 0.0278
8.007 104
Prandt number , Pr=
Cp
k
8.007 10 4183
0.6155
5.44
j Pr
shell side coefficient ,h i= h
de
0.023 576.35 5.44
0.0278
513.26
0.33
0.33
0.6155
W
2
m K
Total exchange area , A=Number of tube tubeOD lenghof tube

10 0.00953 0.5
0.15 m
U=
QH
A T lm
8002.08
0.15 13.21
4038.40
W
m2 K
de
d s /
Ps =8 j f
0.0278
0.085 /
8(0.023)
0.77 Pa
Pt =N p [ 8 j f ( L /di ) ( / w )m +2.5 ]
( 8 0.0039 )
282.14 Pa
f u2t
2
(988.18)(0.3531)2
0.5
( 1.0 )0.14 + 2.5
0.0075
2
DISCUSSION
This experiment is done to determine the function of the shell and tube heat exchanger in
various conditions. This also been done to demonstrate the working principle of the shell and
tube heat exchanger under counter-current and co-current flow conditions and the effect of flow
rates to the performance of the shell and tube heat exchanger. Besides, the experiment is also
to determine the efficiency of the heat exchanger in co-current and counter-current flow
condition. Then, the heat transfer of the system, LMTD and also the pressure drop of the
system are being calculated.
The experiment is being done with different flow rates of the hot water and the cold water. When
the hot water flow rates kept constant, the flow rates of the cold water will be varies between 2
to 10 LPM and vice versa. The temperature of the system will be taken every 3 minutes for each
of the flow rates. Based on the theory, the counter-current flow condition should be more
efficient than the parallel flow condition. This is because the larger difference of the temperature
at the end of the system will lead to the higher thermal stresses that will lead to the material
failure.
Based on the experiment being conducted, the efficiency of the counter-current flow is lower
than the co-current flow which contradicts to the theory. There is error occur during the
experiment that lead to the error in result. The efficiency calculated for co-current flow is beyond
hundred percent and it is impossible for the system to has more than 100 percent efficiency.
The pressure drop is dependence on the value of the flow rates. When the flow rates are varies,
the pressure drop also varies.
When the flow rates being fixed, there is no difference in
pressure drop. This is due to the condition of the flow that is in steady state condition. During
steady state condition, the pressure drop is constant. The difference in pressure drop when the
flow rates vary is because the flow does not achieved the steady state yet.
There are errors occur during the experiments that affect the result of the experiments. The
errors include the equipment error occur during the experiment. The data taken is beyond the
range of the equipment can calculate so the data taken is considered not exact. There is air
bubbles are being trapped in the pipeline that gives effect the amount of pressure in the system.
Then, the system in not in steady state condition when the data is taken. The temperature and
pressure of the system is changing during the data taken shows the system required longer time
to achieve the steady state condition.
CONCLUSION
From the experiment, we can conclude that the most efficient flow conditions for shell and tube
heat exchanger is for counter-current flow conditions. The pressure drop of the shell and tube
heat exchanger is low thus increases the efficiency of the heat exchanger. The pressure drop for
the shell is lower than the tube for both flow conditions. Besides, the LMTD calculated is in
negative sign shows that the system is cooling. The experiment is completed and the objectives
have achieved.
RECOMMENDATIONS
1.
2.
3.
4.
5.
6.
All the procedures must be follows and understood before doing the experiment.
All the equipment must be checked and rectify any leaks.
Always make sure the heater is fully immersed in the water.
Do not touch the hot components of the unit.
Extremely careful when handling liquid at high temperature.
Always switch off the heater and allow the liquid to cool down before draining.
REFERENCES
1. Thermodynamics An Engineering Approach Sixth Edition (SI Units) by Yunus A.

Cengel And Michael A. Boles. (Mc Graw Hill)
2. Chopey, N.P. Handbook of Chemical Engineering Calculations (2nd Edition),
McGraw-Hill, 1994.
3. Heat and Mass Transfer Fundamentals & Application (Fifth Edition in SI Units),
by Yunus A. Cengel and Afshin J. Ghajar
4. https://www.scribd.com/doc/109549338/Lab-Heat-Exchanger retrieved on 19
March 2015
5. http://en.wikipedia.org/wiki/Heat_exchanger retrieved on 18 March 2015
APPENDICES
3. F1 = 10 LPM , F2 = 4 LPM
10
L
1 m3
1 min
kg
J
988.18 3 4175
( 37.930.2 )
min 1000 L 60 s
kg .
m
5294.59W
L
1 m3
1 min
kg
J
995.67 3 4183
( 49.146.6 )
min 1000 L 60 s
kg .
m
694.15W
Heat lost rate

QH QC
5294.59694.15
4600.44 W
Efficiency
QC
100
QH
694.15
100
5294.59
13.11
T lm=
T T out
ln
( TT )
out
( 37.949.1 ) ( 30.246.6 )
( 37.949.1 )
ln
(30.246.6 )
13.64

d 2i
4
0.007752
4
4.72 105 m2
4.72 105 10
4
4.72 10 m
mt
At
0.1647
4
4.72 10
348.94
kg
2
m .s
Gt
348.94
988.18
0.3531
m
s
Reynoldsnumber , =
Gt d e
348.94 0.00775
0.0005494
Prandt number , Pr=
Cp
k
0.0005494 4175
0.6434
3.56
j h Pr 0.33 k
di
0.0039 4922 3.560.33 0.6436

0.00775
2423.94
W
m2 K


tube pitch
( 0.0180.00953 ) 0.085 0.05

0.018
0.002 m2
ms
As
0.0667
0.002
33.35
kg
m2 . s
33.35
995.67
0.033
m
s
Gs
1.1 2
( pt 0.917 d 2o )
do
1.1
2
2
(0.018 0.917 ( 0.00953 ) )
0.00953
0.0278 m
Reynolds number , =
G s d e
33.35 0.0278
0.0008007
1157.90(laminar flow )
Prandt number , Pr=
Cp
k
0.0008007 4183
0.6155
5.44
j h Pr 0.33 k
de
0.05 1158 5.44 0.33 0.6436

0.0278
2344.21
W
m2 K
Total excahnge area , A=Number of tube tubeOD lenghof tube

10 0.00953 0.5
0.15 m
U=
QH
A T lm
5294.59
0.15 13.64
2344.21
W
m2 . K

de
d s /
Ps =8 j f
0.0278
0.085 /
8(0.05)
6.63 Pa
f u2t
Pt =N p [ 8 j f ( L /di ) ( / w ) +2.5 ]
2
m
( 8 0.0039 )
282.14 Pa
(988.18)(0.3531)
0.5
( 1.0 )0.14 + 2.5
0.0075
2
4. F1 = 10 LPM , F2 = 4 LPM
10
L
1 m3
1 min
kg
J
988.18 3 4175
( 30.436.0 )
min 1000 L 60 s
kg
.
m
3850.61W
L
1 m3
1 min
kg
J
995.67 3 4183
( 46.648.9 )
min 1000 L 60 s
kg .
m
888.61W
Heat lost rate

QH QC
3850.61(888.51)
2962.1W
Efficiency
QC
100
QH
888.51
100
3850.61
23.07
T lm=
T T out
ln
( TT )
out
( 30.448.9 )( 36.046.6 )
( 30.448.9 )
ln
( 36.046.6 )
14.19

d 2i
4
0.00775
4
4.72 105 m2
4.72 105 10
4
4.72 10 m
0.1647
4
4.72 10
mt
At
348.94
kg
2
m .s
Gt
348.94
988.18
0.3531
m
s
Reynoldsnumber , =
Gt d e
348.94 0.00775
0.0005494
Prandt number , Pr=
Cp
k
0.0005494 4175
0.6436
3.56
Tube side heat transfer factor, jh = 0.0039

j h Pr 0.33 k
di
0.0039 4922 3.560.33 0.4636

0.00775
2423.94
W
2
m K


tube pitch
( 0.0180.00953 ) 0.085 0.05

0.018
2
0.002 m
ms
As
0.0667
0.002
33.35
kg
m2 . s
Gs
33.35
995.67
0.033
m
s
1.1 2
( pt 0.917 d 2o )
do
1.1
(0.018 20.917 ( 0.00953 )2 )
0.00953
0.0278 m
Reynolds number , =
G s d e
33.35 0.0278
0.0008007
1157.90(laminar flow )
Prandt number , Pr=
Cp
k
0.0008007 4183
0.6155
5.44
Shell side heat transfer factor, jh = 0.048
j h Pr 0.33 k
de
0.048 1158 5.44

0.0278
2152.19
0.33
0.6155
W
2
m K

10 0.00953 0.5
0.15 m
U=
QH
A T lm
3850.61
0.15 14.19
1809.07
W
m2 K

de
ds/
Ps =8 j f
0.0278
0.085 /
8(0.048)
6.37 Pa
f u2t
Pt =N p [ 8 j f ( L /di ) ( / w ) +2.5 ]
2
m
( 8 0.0039 )
282.14 Pa
(988.18)(0.3531)2
0.5
( 1.0 )0.14 + 2.5
0.0075
2
5. F1 = 2 LPM , F2 = 10 LPM
L
1 m3
1 min
kg
J
988.18 3 4175
( 30.829.2 )
min 1000 L 60 s
kg
.
m
220.03W
10
L
1 m3
1 min
kg
J
995.67 3 4183
( 49.338.1 )
min 1000 L 60 s
kg .
m
7774.46W
Heat lost rate

QH QC
220.037774.46
7554.43 W
Efficiency
QC
100
QH
7774.46
100
220.03
3533.36
T lm=
T T out
ln
( TT )
out
( 30.849.3 )( 29.238.1 )
( 30.849.3 )
ln
( 29.238.1 )
13.12

2
d
Cross flow area , A= i
4
0.007752
4
4.72 105 m2
5
4.72 10 10
4
4.72 10 m
mt
At
0.0333
4.72 104
70.62
kg
m2 . s
Gt
70.62
988.18
0.0714
m
s
Reynoldsnumber , =
Gt d e
70.62 0.00775
0.0005494
Prandt number , Pr=
0.0005494 4175
0.6434
3.56
Cp
k

j h Pr 0.33 k
di
0.0048 996 3.560.33 0.6436

0.00775
603.66
W
m2 K


tube pitch
( 0.0180.00953 ) 0.085 0.05

0.018
0.002 m2
ms
As
0.1667
0.002
83.33
kg
m2 . s
Gs
83.33
995.67
0.0837
m
s
1.1 2
( pt 0.917 d 2o )
do
1.1
2
2
(0.018 0.917 ( 0.00953 ) )
0.00953
0.0278 m
Reynolds number , =
G s d e
83.33 0.0278
0.0008007
2893.19(turbulent flow )
Prandt number , Pr=
Cp
k
0.0008007 4183
0.6155
5.44
j h Pr 0.33 k
de
0.01 2893 5.440.33 0.6436

0.0278
1120.16
W
m2 K
Total excahnge area , A=Number of tube tube OD lenghof tube
10 0.00953 0.5
0.15 m2
U=
QH
A T lm
220.03
0.15 13.12
3533.36
W
2
m .K

de
ds/
Ps =8 j f
0.0278
0.085 /
8(0.01)
8.53 Pa
Pt =N p [ 8 j f ( L /di ) ( / w ) +2.5 ]
m
( 8 0.0048 )
f u2t
2
(988.18)(0.0714)2
0.5
( 1.0 )0.14+ 2.5
0.0075
2
12.75 Pa
6. F1 = 2 LPM , F2 = 10 LPM
L
1 m3
1 min
kg
J
988.18 3 4175
( 29.931.4 )
min 1000 L 60 s
kg .
m
206.28W
10
L
1 m3
1 min
kg
J
995.67 3 4183
( 38.649.5 )
min 1000 L 60 s
kg
.
m
7566.21 W
Heat lost rate
QH QC
206.28(7566.21)
7359.93W
Efficiency
QC
100
QH
7566.21
100
206.28
3667.93
T lm=
T T out
ln
T
T out
( 29.949.5 ) ( 31.438.6 )
( 29.949.5 )
ln
( 31.438.6 )
12.38

d 2i
4
0.00775
4
5
4.72 10 m

5
4.72 10 10
4.72 104 m2
mt
At
0.0333
4.72 104
70.62
kg
m2 . s
Gt
70.62
988.18
0.0714
m
s
Reynoldsnumber , =
Gt d e
70.62 0.00775
0.0005494
Prandt number , Pr=
Cp
k
0.0005494 4175
0.6436
3.56
Tube side heat transfer factor, jh = 0.0050
j h Pr 0.33 k
di
0.0050 996 3.560.33 0.4636

0.00775
628.81
W
m2 K


tube pitch
( 0.0180.00953 ) 0.085 0.05

0.018
2
0.002 m
0.1667
0.002
ms
As
83.33
kg
2
m .s
Gs
83.33
995.67
0.0837
m
s
1.1 2
( pt 0.917 d 2o )
do
1.1
(0.018 20.917 ( 0.00953 )2 )
0.00953
0.0278 m
Reynolds number , =
G s d e
83.33 0.0278
0.0008007
2893.19(turbulent flow )
Prandt number , Pr=
0.0008007 4183
0.6155
Cp
k
5.44
Shell side heat transfer factor, jh = 0.01
j h Pr 0.33 k
de
0.01 2893 5.440.33 0.6155
0.0278
1120.16
W
m2 K

10 0.00953 0.5
0.15 m2
U=
QH
A T lm
206.26
0.15 12.38
111.08
W
m2 K

de
ds/
Ps =8 j f
0.0278
0.085 /
8(0.01)
8.53 Pa
Pt =N p [ 8 j f ( L /di ) ( / w ) +2.5 ]
m
( 8 0.0050 )
628.81 Pa
f u2t
2
(988.18)(0.0715)2
0.5
( 1.0 )0.14+ 2.5
0.0075
2

Shell and Tube

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Shell and Tube

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ABSTRACT

= mass flow rate of cold fluid in the tube (kgs-1)

= mass flow rate of hot fluid in the shell (kgs-1)

= specific heat of cold fluid in the tube (kJkg-1oC-1)

= specific heat of hot fluid in the shell (kJkg-1oC-1)

t 1 , t 2 = temperature of cold fluid entering/leaving the tube (oC)

= heat exchange rate between fluid (kW)

= outside area of the tube (m2)

= inside area of the tube (m2)

T m = mean temperature difference (oC)

U o and U i are given by:

= outside fluid film coefficient (kWm-2oC-1)

= inside fluid film coefficient (kWm-2oC-1)

hod = outside dirt coefficient (fouling factor) (kWm-2oC-1)

= thermal conductivity of the tube wall material (kWm-1oC-1)

= tube outside diameter (m)

= tube inside diameter (m)

Overall heat transfer coefficient, U

Log mean temperature difference (LMTD)

mH =hot water mass flow rate

mC =cold water mass flow rate

because some heat is lost through the insulated material

The effectiveness of a heat exchanger is defined as:

actual heat transfer

Tube-side heat transfer coefficient, hi

Nu=C 0.8 Pr 0.33 ( f / w )0.14

= equivalent diameter (m)

= fluid viscosity of bulk fluid temperature (Nsm-2)

= fluid viscosity at the wall (Nsm-2)

= fluid velocity in the tube (ms-1)

= fluid density (kgm-3)

= fluid specific heat, heat capacity (J/kg0C)

= 0.023 for non-viscous liquid

= fluid thermal conductivity (W/m0C)

For laminar flow (Re < 2000),

Nu=1.86 ( . Pr ) 0.33 ( d e / L )0.33 ( f / w )0.14

= tube length (m)

Tube-side Pressure Drop, Pt

= tube-side pressure drop (N/m2)

= number of side tube passes

= tube dimensionless friction factor

= length of the tube (m)

= tube-side velocity (m/s)

= 0.25 for laminar

APPARATUS AND MATERIAL

valve is open for continuous water supply.

The Counter-current Shell and Tube Heat Exchanger

Co-current Shell and Tube Heat Exchanger

General Shut-down Procedures

The heater was switched off.

Co-current Shell and Tube Heat Exchanger

Counter-current Shell and Tube Heat Exchanger

Co-current Shell and Tube Heat Exchanger

COSTANT FLOW RATE OF HOT WATER

VOLUMETRIC FLOWRATE (LPM)

MASS FLOWRATE (kg/s)

HEAT TRANSFER RATE (J/s)

VOLUMETRIC FLOWRATE (LPM)

MASS FLOWRATE (kg/s)

HEAT TRANSFER RATE (J/s)

Hot water counter current flow

OVERALL HEAT TRANSFER COEFFICIENT

LINEAR VELOCITY (m/s)

LINEAR VELOCITY (m/s)