ABSTRACT

Heat exchangers are devices that allow the exchange of heat between two fluids without allowing
them to mix with each other. We were conducting the heat exchanger experiment by using
SOLTEQ Heat exchanger Training Apparatus (Model: HE 158C) to evaluate and study the heat
transfer, heat loss, heat transfer effectiveness, log mean temperature difference, overall heat
transfer coefficient and compare the pressure drop value. Most of the value were increasing
when the volume flow rates were increased except for the heat transfer effectiveness which were
decreased. The pressure drop calculated were quite far from the measured value. The
performance of heat exchanger may deteriorates because of fouling factor.

INTRODUCTION

Heat exchanger is an equipment that facilitates the exchange of heat between two fluids that are
at different between temperatures while keeping them from mixing each other. The application
of heat exchanger is commonly used in heating and air conditioning system in a household and
chemical processing and power production in large plant.

The mode of heat transfer in heat exchanger involves convection in each fluid and conduction
through the wall separating the two fluids. In the analysis of heat exchanger, an overall heat
transfer coefficient, U, is contribute all the effects on heat transfer. The magnitude of the
temperature difference at a location which can be varied along the heat exchanger, influence the
rate of heat transfer between the two fluids at that location in a heat exchanger (Yunus A.
Cengel, Afshin J. Ghajar, 2015).

There are variety of types of heat exchanger in industrial applications such as double-pipe
exchanger, printed circuit heat exchanger, shell-and-tube heat exchanger, plate and frame heat
exchanger and regenerative heat exchanger. In this experiment, we were using shell-and-tube
heat exchanger.

1
AIMS

To evaluate and study the heat transfer, heat loss, heat transfer effectiveness, log mean
temperature difference, overall heat transfer coefficient, heat transfer effectiveness and compare
the pressure drop value.

THEORY

Shell-and-tube heat exchanger is the common type of heat exchanger in industrial application. It
is classified according to the number of shell and tube passes involved. If all the tubes make one
U-turn in the shell, it is called one-shell-pass and two-tube-passes heat exchanger. Likewise, a
heat exchanger that involves two passes in the shell and four passes in the tubes is called a two-
shell-passes and four-tube-passes heat exchanger.

Figure 1: the schematic diagram of a shell-and-tube heat exchanger (one-shell pass and one-tube
pass)

It is contain a large number of tubes packed in a shell with it axes parallel to that of the shell. As
one fluid flows inside the tubes and the other fluid flows outside the tubes through the shell, the
heat transfer process takes place. Baffles which located in the shell help to enhance heat transfer

2
rate by force the shell side fluid to flow across the shell. Headers are large flow area where the
tube slide fluid accumulates before entering tubes and after leaving them. The analysis of heat
exchanger is conduct to analyze it operating condition by using few methods.

The heat transfer rate associated with heat exchanger depends on how the control volume is
selected. When the entire heat exchanger is selected as the control volume, Q̇ become zero, since
no boundary for this case lies just beneath the insulation and little or no heat crosses the
boundary. If, however, only one of the fluids is selected as the control volume, then heat will
cross this boundary as it flows from on liquid to the other and Q̇ will be not zero. In fact, Q̇ in
this case will be the rate of heat transfer between the two fluids (Yunus A. Cengel, 2011).

The rate of heat transfer in high temperature medium is called as Q̇h while in low temperature
medium defined as Q̇c the heat transfer rate can be expressed as

Q̇ = CΔT = ṁcpΔT

Where;

C = heat capacity (J/s.°C)

ṁ = mass flow rates (kg/s)

cp = specific heat of fluid (J/kg.°C)

ΔT= temperature difference (°C)

The rate of heat losses can be defined as;

Q̇loss = Q̇hot - Q̇cold

The heat Heat transfer effectiveness:

𝑄̇ actual heat ransfer rate

ε = 𝑄̇ = 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑝𝑜𝑠𝑠𝑖𝑏𝑙𝑒 ℎ𝑒𝑎𝑡 𝑡𝑟𝑎𝑛𝑠𝑓𝑒𝑟 𝑟𝑎𝑡𝑒
𝑚𝑎𝑥

Where;

Q̇ = actual heat transfer rate (W)

3
 Q̇max = maximum possible heat transfer rate (W)

Q̇max = Cmin (Th,in – Tc,in)

Cmin is the smaller of Ch and Cc

The temperature difference between the hot and cold fluids varies along the heat exchanger and
it is convenient to have a Mean Temperature Difference ΔTlm. This method is best suited for
determining the size of a heat exchanger when all the inlet and outlet temperatures are known.

𝛥𝑇1 −𝛥𝑇2
ΔTlm = 𝛥𝑇1
ln( )
𝛥𝑇2

𝛥𝑇1 = Th,in – Tc,out

𝛥𝑇2 = Th,out – Tc,in

Heat transfer in heat exchanger usually involves convection in each fluid and conduction through
the wall separating two fluids. In the analysis of heat exchangers, it is convenient to work with an
overall Heat Transfer Coefficient, U which can be determined from:

𝑄̇
Heat Transfer Coefficient, U = 𝐴
𝑠 𝛥𝑇𝑙𝑚

Where;

As = the surface area (m2)

Reynolds number, Re is a dimensionless quantity which can be used to determine the fluid
motion either it is laminar or turbulent. The smooth and orderly flow of fluid is called laminar
while turbulent is rather chaotic.

ρv𝑑𝑖
Reynolds number, Re =
𝜇

Where;

ρ = density of fluid (kg/𝑚3 )

v = velocity of fluid (m/s)

di = tube initial diameter

4
 𝑘𝑔
𝜇 = 𝑣𝑖𝑐𝑜𝑠𝑖𝑡𝑦 𝑜𝑓 𝑓𝑙𝑢𝑖𝑑 ( . 𝑠)
𝑚

Re < 2300 is laminar flow

Re > 2300 is turbulent flow

Pressure drop, ΔP, is the irreversible pressure loss between the inlet and the exit of the tube.

𝑓.𝐿 1
Tube; ΔP = 4 ( 𝑑 𝑡 + 1) 𝑁𝑃 2 𝜌. 𝑣 2
𝑖

In Shell;

𝐷 1
ΔP = 𝑓 𝐷𝑠 (𝑁𝑏 + 1) 2 𝜌. 𝑣 2
𝑒

Where;

Lt = tube length

f = friction factor

Nb = number of baffle

De = equivalent diameter

5
 APPARATUS & MATERIALS

Figure 2 : SOLTEQ Heat Exchanger Training Apparatus (HE 158C)

1. Spiral heat exchanger 12. TT1 (cold water outlet reading)

13. TT2 (cold water inlet reading)
2. Concentric heat exchanger
14. TT3 (hot water outlet reading)
3. Shell and tube heat exchanger

4. Valve 17 15. TT4 (hot water inlet reading)

5. Valve 15 16. TT5

6. Valve 16
17. ΔPT1 reading
7. Valve 18
18. ΔPT2 reading
8. Hot water centrifugal pump
Cold water centrifugal pump 19. Heater switch
9.
10. Flowrate meter 1 (Hot water) 20. Hot water pump switch

11. Flowrate meter 2 (Cold water)

21. Cold water pump switch

6
PROCEDURES

GENERAL START-UP PROCEDURES.

1. A quick inspection was performed to make sure that the equipment was in proper working
condition.
2. All valves were initially closed, except V1 and V1.
3. Hot water tank was filled up via a water supply hose connected to valve V27. The valve
was closed after the tank was full.
4. The cold water tank was filled up by opening valve V28 and leaves the valve opened for
continuous water supply.
5. A drain hose was connected to the cold water drain point.
6. Main power was switched on and heater for the hot water also switched on and set the
temperature controller to 50℃.
7. The water temperature in the hot water tank was allowed to reach the set point.
8. The equilibrium was already set up.

GENERAL SHUT-DOWN PROCEDURES.

1. The heater was switched off. The hot water temperature drops was been waited until below
40℃.
2. The pump P1 and P2 was switched off.
3. Main power was switched off.
4. All the water in process line was drain off. All valves was closed.

COUNTER-CURRENT SHELL & TUBE HEAT EXCHANGER PROCEDURES.

1. General start-up procedures were performed.
2. The valves were switched to counter-current Shell & Tube Heat Exchanger arrangement.
3. Pumps P1 and P2 was switched on.
4. Valves V3 and V14 were opened and adjusted to obtain the desired flowrate for hot water
and cold water stream. The hot water flow rate (FT1) was set to fixed which is 10LPM and
cold water flow rate (FT2) was varied.
5. The system was allowed to reach steady state for 10 minutes.

7
 6. FT1, FT2, TT1, TT2, TT3 and TT4 were recorded.
7. The pressure drop measurement for shell side and tube side were also recorded for pressure
drop studies.
8. The steps 4 to 7 was repeated for different combination of flowrates FT1 and FT2 as in the
result sheet.
9. The pumps P1 and P2 were switched off after the experiment was completed.

RESULTS

Experiment 1: counter-current Shell and Tube Heat Exchanger at constant FT1

FT1 FT2 TT1 (°C) TT2 (°C) TT3 (°C) TT4 (°C) DP1 (mm DP2 (mm
(LPM) (LPM) Cold out cold in hot out hot in H2O) H2O)
hot cold
10 2 43.1 32.8 47.2 48.7 76 5
10 4 39.7 31.7 47.3 49.0 76 7
10 6 39.1 31.5 46.9 49.1 75 4
10 8 39.4 31.5 45.8 47.5 74 3
10 10 39.3 31.6 45.7 47.6 75 4

Experiment 2: counter-current Shell and Tube Heat Exchanger at constant FT2

FT1 FT2 TT1 (°C) TT2 (°C) TT3 (°C) TT4 (°C) DP1 (mm DP2 (mm
(LPM) (LPM) H2O) H2O)
2 10 32.8 31.0 41.0 49.0 5 180
4 10 33.2 31.1 43.9 49.0 5 178
6 10 33.9 31.0 43.6 48.0 3 177
8 10 34.5 30.9 43.8 47.2 24 176
10 10 35.6 30.9 45.7 48.7 74 179

8
 CALCULATION

Hot water Cold water

Density (kg/m3) 988.18 995.67
Heat capacity (J/kg.K) 4175.00 4183.00
Viscosity (Pa.s) 0.0005494 0.0008007

Experiment 1: counter-current Shell and Tube Heat Exchanger at constant FT1

Q̇ = CΔT = ṁcpΔT
Hot water flow rate is constant = 10 LPM
Flow rate cold Q
water (LPM)
𝐿 3
1𝑚 1 𝑚𝑖𝑛 𝑘𝑔 𝐽
2 Q̇hot = 10 𝑚𝑖𝑛 × 1000𝐿 × 60 𝑠 × 988.18 𝑚3 × 4175 𝑘𝑔.°𝐶 × (48.7 − 47.2)° 𝐶

𝐽
= 1031.41 = 1031.41 𝑊
𝑠

𝐿 3
1𝑚 1 𝑚𝑖𝑛 𝑘𝑔 𝐽
Q̇cold = 2 𝑚𝑖𝑛 × 1000𝐿 × 60 𝑠 × 995.67 𝑚3 × 4183 𝑘𝑔.°𝐶 × (43.1 − 32.8)° 𝐶

= 1429.94 𝑊

Heat loss rate, Q̇loss = Qhot - Qcold

Flow rate cold water (LPM)

2 Q̇loss = 1031.41- 1429.94 = -398.53 W

9
 𝑄̇ actual heat ransfer rate
Heat transfer effectiveness, ε = 𝑄̇ = 𝑚𝑎𝑥𝑖𝑚𝑢𝑚 𝑝𝑜𝑠𝑠𝑖𝑏𝑙𝑒 ℎ𝑒𝑎𝑡 𝑡𝑟𝑎𝑛𝑠𝑓𝑒𝑟 𝑟𝑎𝑡𝑒
𝑚𝑎𝑥

Q̇max = Cmin (Th,in – Tc,in)

Cmin is the smaller of Ch and Cc
𝐿 1 𝑚3 1 𝑚𝑖𝑛 𝑘𝑔 𝐽 𝑊
Ch = 10 𝑚𝑖𝑛 × 1000𝐿 × × 988.18 𝑚3 × 4175 𝑘𝑔.°𝐶 = 687.61
60 𝑠 °𝐶

(𝑄 +𝑄 ) ̇ ̇
Q̇ = Q̇avg = ℎ2 𝑐

Flow rate cold

water (LPM)
(1031.41+ 1429.94 )
2 Q̇avg = = 1230.68 𝑊
2
𝐿 1 𝑚3 1 𝑚𝑖𝑛 𝑘𝑔 𝐽 𝑊
Cc = 2 𝑚𝑖𝑛 × 1000𝐿 × × 995.67 𝑚3 × 4183 𝑘𝑔.°𝐶 = 138.83
60 𝑠 °𝐶

Cmin = Cc
𝑊
Q̇max = 138.83 × (48.7 − 32.8)°𝐶 = 2207.40 W
°𝐶
1230.68
ε = 2207.40 × 100% = 55.75%

𝛥𝑇1 −𝛥𝑇2
Log Mean Temperature Difference, LMTD = 𝛥𝑇1
ln( )
𝛥𝑇2

𝛥𝑇1 = Th,in – Tc,out

𝛥𝑇2 = Th,out – Tc,in
Flow rate cold water (LPM)

𝛥𝑇1 = (48.7 – 43.1)°𝐶 = 5.6°𝐶

𝛥𝑇2 = (47.2 – 32.8)°𝐶 = 14.4°𝐶
2
(5.6−14.4)
LMTD = 5.6 = 9.32°𝐶
ln( )
14.4

10
 𝑄̇
Heat Transfer Coefficient, U = 𝐴
𝑠 𝛥𝑇𝑙𝑚

Heat Transfer Surface Area, As

Tube O.D = 0.00953m
Tube length = 0.5m
As = π × tube O.D × length
= π × 0.00953 × 0.5 = 0.015 m2

Flow rate cold water (LPM)

1230.68 𝑊 𝑊
U = 0.015 𝑚2 × 9.32°𝐶 = 8803.15 𝑚2 .°𝐶
2

ρv𝑑𝑖
Reynolds number, Re = 𝜇
𝑉̇
ρ = density of fluid (kg/𝑚3 ) v=𝐴
𝑡

v = velocity of fluid (m/s) 𝑉̇ = volume flow rate (m3/s)

di = tube initial diameter A= area (m2)
𝑘𝑔
𝜇 = 𝑣𝑖𝑐𝑜𝑠𝑖𝑡𝑦 𝑜𝑓 𝑓𝑙𝑢𝑖𝑑 ( . 𝑠)
𝑚

𝜋𝑑𝑖 2 𝑁𝑡
Area of tube, At = 4 𝑁𝑝
Tube
Nt = number of tube
NP = number of passes

11
Shell
𝐷𝑠 𝐶𝑡 𝐵
Area of shell, As = 𝑃𝑡

Ds = diameter inside of shell (m)

Ct = tube clearance (m) = Pt – do
Do = tube O.D
B = baffle distance (m)
Pt = tube pitch (m)

Example calculation
Tube 10 LPM:
𝜋 × 0.007752 10
At = = 4.717 × 10−4 𝑚2
4 1

1.67×10−4 𝑚
v = 4.717 × 10−4 = 0.354 𝑠

988.18 ×0.354 ×0.00775

Re = = 4934.60
0.0005494

Shell 2 LPM:
0.085 ×(0.018−0.00953)𝑚 ×0.05𝑚
As = = 2 × 10−3 𝑚2
0.018𝑚

𝑚3
3.33𝑥10−5 𝑚
𝑠
v= = 0.01665
2×10−3 𝑚2 𝑠

𝑘𝑔 𝑚
995.67 × 0.01665×0.085𝑚
𝑚3 𝑠
Re = 𝑘𝑔 = 1759.86
0.0008007
𝑚.𝑠

12
 𝑓.𝐿 1
ΔP = 4 ( 𝑑 𝑡 + 1) 𝑁𝑃 2 𝜌. 𝑣 2
𝑖

Lt = tube length
f = friction factor
ReD <2300 = laminar
Tube ReD >2300=turbulent
Laminar:
16
𝑓=
𝑅𝑒𝐷
Turbulent:

Pressure drop, ΔP f = [1.58 ln(ReD) – 3.28)]-2

𝐷 1
ΔP = 𝑓 𝐷𝑠 (𝑁𝑏 + 1) 2 𝜌. 𝑣 2
𝑒

Nb = number of baffle
f = exp[0.576 - 0.19 ln(ReS)]

Shell
2 𝜋𝑑𝑜 2
√3 𝑃𝑡
−
4 8
De = equivalent diameter = 4 ( 𝜋𝑑𝑜 )
2

Example calculation

10 LPM:
16
𝑓= = 0.016
989.71
(0.016 × 0.5𝑚) 1 988.18𝑘𝑔
∆𝑃 = 4 [ + 1] (1) × ×
0.00775𝑚 2 𝑚3
Tube
𝑚 2 1𝑁 𝑁
× (0.071 ) × = 20.25 2 = 20.25𝑃𝑎
𝑠 𝑘𝑔 𝑚
1 2
𝑚

13
 2 LPM:
𝑓 = exp[0.0576 − 0.19 ln(1759.86)] = 0.430
√3 (0.018)2 𝜋(0.00953)2
−
4 8
De = 4 ( 𝜋(0.00953) ) = 0.028𝑚
2

Shell
0.085𝑚 1 𝑚3 𝑚
ΔP = 0.43 × 0.028𝑚 (8 + 1) × 2 × 995.67 𝑘𝑔 × (0.01665 𝑠 )2 ×
1𝑁
𝑘𝑔 = 1.612𝑃𝑎
1 2
𝑚

*calculations were repeated for 4, 6, 8, 10 LPM and also Experiment 2: counter-current Shell and
Tube Heat Exchanger at constant FT2*

14
 Experiment 1: counter-current Shell and Tube Heat Exchanger at constant FT1

Flow rate Rate of Heat Heat

LMT Pressure drop
of cold heat transfer Transfer Reynolds number
Qh (W) Qc (W) D (Pa)
water loss effectivenes Coefficient,
(°𝐶) 𝑊
(LPM) (W) s, ε (%) U (𝑚2 .°𝐶 )
Tube Shell Tube Shell

2 1031.41 1429.94 -398.53 55.75 9.32 8803.15 402.5

4934.60 1759.86 1.621
7
-
4 1168.93 2221.27 35.29 12.18 9278.05 402.5
4934.60 3525.01 5.703
1052.34 7

6 1512.74 3165.31 -1652.5 31.91 12.51 12464.85 402.5

4934.60 5284.87 11.876
7
-
8 1168.93 4387.01 31.27 10.91 16975.07 402.5
4934.60 7028.88 19.909
3218.08 7
- Pressure drop (Pa)
10 1306.46 5344.94 30.23 10.95 20247.79 402.5
4934.60 8825.74 30.062
4038.48 1 mmH2O = 9.80665 Pa 7
Experimental
Calculated Experimental value (B) Calculated
value (A)
Tube Shell Tube Shell Tube Shell Tube Shell
745.31 5 402.57 1.621 49.03 1765.20 20.25 30.062
745.31 7 402.57 5.703 49.03 1745.58 59.93 30.062
735.50 4 402.57 11.876 29.42 1735.78 742.12 30.062
725.69 3 402.57 19.909 235.36 1725.97 258.57 30.062
735.50 4 402.57 30.062 725.69 1755.39 402.57 30.062

Experiment 2: counter-current Shell and Tube Heat Exchanger at constant FT2

15
Flow rate Rate of Heat Heat
LMT Pressure drop
of cold heat transfer Transfer Reynolds number
Qh (W) Qc (W) D (Pa)
water loss effectivenes Coefficient,
(°𝐶) 𝑊
(LPM) (W) s, ε (%) U (𝑚2 .°𝐶 )
Tube Shell Tube Shell
2 1100.17 1249.47 -149.3 47.46 6.2 12632.47 989.71 8825.74 20.25 30.062
4 1402.72 1457.71 -54.99 29.05 14.25 6691.06 1965.48 8825.74 59.93 30.062
742.1
6 1815.29 2013.03 -197.74 27.29 13.34 9566.02 2955.19 8825.74 30.062
2
258.5
8 1870.30 2498.93 -628.63 24.36 12.80 11378.20 3930.96 8825.74 30.062
7
- 402.5
10 2062.83 3262.50 21.75 13.93 12743.07 4934.60 8825.74 30.062
1199.67 7

16
DISCUSSION
From the results and calculation, both the experiment A and B show as increased the volume of
flow rate of fluid, the heat transfer, heat loss, log mean temperature difference, overall heat
transfer coefficient and compare the pressure drop value were also increased except for the heat
transfer effectiveness were decreased. The pressure drop calculated were far from measured
value.

Theoretically, the Q̇hot and Q̇cold would have the same value since the heat release by high
temperature fluid will be absorbed by lower temperature fluid and the tank and also the pipes of
hot fluid were insulated to reduce heat loss to surrounding. But there were still heat loss with
time so Q̇hot ≠ Q̇cold. The higher the percentage of effectiveness of heat exchanger, the ideal it will
be.

Heat transfer enhancement in heat exchanger is usually accompanied by increase pressure drop.
Usually the more viscous fluid is more suitable for the shell side causes larger passage area and
thus lower pressure drop. The highly disordered fluid motion that typically occurs at high
velocity cannot prevent the random and rapid fluctuations of the fluid. At small or moderate
Reynolds number, however, the fluctuations and be suppressed and the fluid and be keep in line.

17
Fluids are usually forced to flow by pumps or fans that consume electrical power. Minimizing
the pressure drop and the mass flow rate of the fluids will minimize the operating cost of the heat
exchanger but it will maximize the size of the heat exchanger and thus initial cost. As a rule of
thumb, doubling the mass flow rate will reduce initial cost by half but will increase the pumping
power requirements by a factor roughly eight. Low velocities are helpful in avoiding erosion,
tube vibrations and noise as well pressure drop.

Fouling factor causes the effectiveness of heat exchanger lessen with time. The most common
type of fouling are precipitation of solid deposit on the heat transfer surfaces and corrosion. The
fouling factor depends on the operating temperature and the velocity of the fluids as well as the
length of service. Fouling increases with increasing temperature and decreasing velocity (Fouling
Factors in Heat Exchangers, 2016).

CONCLUSION

As the volume flow rate increased, the heat transfer, heat loss, heat transfer effectiveness, log
mean temperature difference, overall heat transfer coefficient and the pressure drop were also
increased except for heat transfer effectiveness decreased. We success achieve all the objectives
as analysis of heat exchanger is very important especially in industry for example in order to
select a heat exchanger that will achieve a specified temperature change in a fluid stream of
known mass flow rate, we must do the proper selection.

RECOMMENDATIONS

Few recommendations are firstly, a proper cleaning of heat exchanger to avoid accumulation of
deposits on heat transfer surfaces. Second, the metal pipes can be coated with glass or using
plastic pipe instead of metal one to avoid chemical fouling. Third, layer the tank or pipes with
good insulation material to reduce heat loss.

18
REFERENCE

 Geankoplis, C. J. (2014). Drying of Process Materials. In C. J. Geankoplis, Transport

Processes & Separation Process Principles (p. 576). England: Pearson Education Limited.
 Fouling Factors in Heat Exchangers. (2016, August 17). Retrieved from hrs-
heatexchangers: https://www.hrs-heatexchangers.com/resource/fouling-factors-heat-
exchangers/
 Yunus A. Cengel, Afshin J. Ghajar. (2015). Heat Exchangers. In A. J. Yunus A. Cengel,
Heat and Mass Transfer: Fundamentals and Applications (p. 647). New York: McGraw-
Hill Education.
 Raza, A. (n.d.). Specifying Shell-and-Tube Heat Exchangers. Retrieved from
http://stoppingclimatechange.com/Shell-and-Tube%20Heat%20Exchangers.pdf
 Yunus A. Cengel, M. A. (2011). Heat Exchangers. In M. A. Yunus A. Cengel,
Thermodynamics an Engineering Approach (pp. 236-237). New York: McGraw-Hill
Education.

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