ABSTRACT

In this experiment, the objective to be achieved is to determine the heat load,

heat balance, LMTD, overall heat transfer coefficient, Reynolds number and also
pressure drop operating at various conditions. All the result has been calculated
using the specific formula and calculations. Heat exchanger is briefly state how the
two fluid with two different temperature flow in different direction (counter-current
flow). When it passes each other, the temperature of fluid flow will become
difference. In this experiment we assume internal, potential and kinetic energy are
negligible, therefor QH is equal to Qc. One fluid will flow in the tube side and other
fluid in the shell tubes. To have efficient heat transfer, a large transfer area should be
used. In this way, waste heat can be put to use to conserve energy.
We used the counter-current shell and tube heat exchanger.

INTRODUCTION
Shell and tube heat exchanger are one of common types of exchanger. Heat
exchanger is equipment that usually found in all plant. It is used to build efficient heat
transfer from one medium to another medium. It usually separated by solid wall to
prevent the mixing between hot water and cold water and prevent from into contact.
The main purpose is simple that, it wants to cool down hot water using cold water
and heat up cold water using hot water by circulating the fluid also by using different
flow rates. For an example is air conditioner, it will take in the hot or sir surrounding
and then circulate it becoming cold air out. In transferring heat, fluid can be various
liquid such as water, oil or moving air. It not limited for heating applications, but can
also be used for cooling application.
In this experiment, we use the counter current flow. Hot water and cold water
will enter the exchanger at the different direction and flow in opposite direction. Each
fluid arrangement leads to different heat rates and the calculations are different
accordingly [1].

Shell-Side Outlet

Shell-Side Inlet

Tube-Side Inlet

Tube-Side Outlet

Figure 1 Schematic of a Single-Pass Shell- and-Tube Heat Exchanger with ParallelFlow Configuration

Shell and tube heat exchanger contains bundle of tubes in parallel axes. Tube
bundle in the shell, will confines the fluid that flow over outside the tube. The tube
side fluid will take a single or multiple passes through the exchanger. At the end, it
will make a reversed flow through the baffles and sent the fluid back in different
tubes. Tubes is divided in baffles. The shell side fluid will also make one or more
passes across the tube bundle, depend configuration of baffles. Therefore, the heat
transfer coefficient will be found by solving differential energy balance equations for
hot and cold water.

Construction of shell and heat exchanger

According to Birmingham wire gauge system, the selection of thickness tube
depends on maximum pressure and corrosion effect.
Tube pitch- when placing the tube, it cannot be close to each other because at the
end of the exchanger, it will have more amount of metal between drilled
tubes hole. But, if the space too far, it will have less surface area
between drilled tube holes. Therefore, an appropriate distance should
be maintained. The distance is called tube pitch, it is between 1.25
times diameter of tube.
Shell

- shell is the outer casing of heat exchanger. One fluid will flow inside the
tube and another liquid is between the wall of shell and tube. Carbon
steel is a common material used to made shell. It can prevent from
corrosion, pressure and temperature,

Baffles

- baffles is used to redirecting the fluid flow I shell side exchanger. It

situated at the wall of shell to force the liquid flow at right angle at the

tube. It also will increase the strength of tube to prevent their vibration
during the great heat transfer.
Advantages by using shell and tube heat exchanger is it can be used in a system
with higher temperatures, pressures and have less pressure drop across a tube
cooler. The disadvantages for this type are heat transfer efficiency is less compared
to plate type cooler and also difficult to maintain it cleaners [2].

AIMS/ OBJECTIVES

To study the working principle of counter current flow heat exchanger

To evaluate and study the heat transfer coefficient, LMTD, heat transfer and

heat loss for energy balance

To measure and determine the shell and tube sides pressure drop
To study the effect of fluid flow rated on heat exchanger performance

THEORIES

The temperature between hot water and cold water are different along the
length of heat exchanger. It is because that the hot water will decrease in
temperature when it is transfer to cold water. Vice versa with the cold water, it will
increase in temperature when it is transfer to hot water. As the result, the heat
coefficients also become different. Therefore, overall heat transfer rate can be
expressed in terms of overall heat transfer coefficient and mean temperature:
Q = Uov Aov Tm
The mean temperature is also being calculated using Log Mean Temperature
Difference.
With the constant heat capacity:

dQ
dt

= UAT

dQ/dt = Rate of heat transfer between two fluids

U

= Overall heat transfer coefficient

= Area of the tube

= Logarithmic mean temperature difference

To calculate heat load :

HW

Hot water flow rate (

QH = mH x CpH x (t1-t2)
CW

Cold water flow rate (

QC = mC x CpC x (T2-T1)
Where:

QH

= Heat load for hot water flow rate

QC

= Heat load for cold water flow rate

mH

Hot water mass flow rate

mC

Cold water mass flow rate

t1

Hot water inlet temperature

t2
T1
T2

Hot water outlet temperature

Cold water inlet temperature

Cold water outlet temperature

To calculate heat balance, LMTD :

LMTD

(t1 T 2 ) (t 2 T1 )
(t T2 )
ln 1
(t 2 T1 )

Heat loss rate

QH - QC

Dirt factor, Q

0.5 (QH + QC )

To calculate heat transfer coefficient, U :

Where:

Q
A LMTD

Q
Heat rate with respect to the flow rate of water

QH

QC

or

In this experiment, value of total heat transfer area A has been given. A = 0.0375 m 2

APPARATUS

Counter-current heat exchanger

Tube side flow in
Tube side flow out
Shell side flow in
Shell side flow out
Baffles
Tube bundle
Water
Temperature detector

METHODOLOGY/PROCEDURE
1. Tank T1 and T2 are filled with water to their maximum level. By-pass valve
(BPH), discharged valves (HV), and suction valve (PH) is fully open. Their
overflow drains is pipe D. Water in tank T1 is heated until temperature
reached 70C.
2. Valves are switch to counter-current shell and tube heat exchanger
arrangement.
3. Flow rate, FT1 for hot water is set at 10 LPM while FT2 is set at 2 LPM.
System is allowed to steady for 10 minutes before reading for TT1, TT2, TT3,
TT4, DPT1 and DPT2 is taken.
4. Record pressure drop measurement for shell-side and tube-side for pressure
drop studies.
5. Steps 3 and 4 is repeated with different combination of flow rate FT1 and FT2.

FT1

FT2

(LPM)
10
10
10
10
10

(LPM)
2
4
6
8
10

FT1

FT2

(LPM)
2
4
6
8
10

(LPM)
10
10
10
10
10

6. Pump P1 and P2 are switched off after the completion of experiment.

RESULTS

Table 1: Counter-current Shell and Tube Heat Exchanger at constant FT1

FT1

FT2

TT1

TT2

TT3

TT4

DPT1

DPT2

(LPM)
10
10
10
10
10

(LPM)
2
4
6
8
10

(C)
43.8
39.1
36.5
35.4
34.4

(C)
30.6
30.1
29.6
29.5
29.9

(C)
47.2
46.4
45.5
45.4
44.8

(C)
48.6
48.8
49.0
48.8
48.7

(mmH2O)
103
102
100
101
104

(mmH2O)
-5
15
50
98
184

Table 2: Counter-current and Tube Heat Exchanger at constant FT2

FT1

FT2

TT1

TT2

TT3

TT4

(LPM)
2
4
6
8
10

(LPM)
10
10
10
10
10

(C)
32.0
32.4
33.2
34.0
35.0

(C)
29.9
30.0
30.1
30.3
30.3

(C)
40.1
42.8
43.8
44.1
45.7

(C)
48.8
48.5
49.0
48.8
49.5

CALCULATIONS
Experiment 1: at constant FT 1
(i)

At FT1=10 LPM, FT2=2 LPM

DPT1

DPT2

(mmH2O) (mmH2O)
5
185
-1
183
19
184
50
180
97
182

Heat transfer for hot water, QH = mHCpT

L
1 min
1 m3
QH
= 10.0 min x 1000 L x 60 s

kg
x 988.18 m3

x 4175

J
kg .C

x 4183

J
kg .C

(43.8 30.6) 0C
= 9076.43 W

Qc

Heat transfer rate for cold water,

QC

L
min x

= 2.0

1 m3
1000 L

= mc Cp T

1 min
60 s

kg
x 995.67 m3

(48.6 47.2) 0C
= 194.36 W

Heat loss Rate = QH - QC

QH - QC

= 9076.43 W 194.36 W
= 8882.07 W
T1 - t2)

LMTD, TLM =

(T2 - t1)

ln
(T1 - t2) - (T2 - t1)

47.2 - 30.6)

(48.6 - 43.8)

ln
(47.2 - 30.6) - (48.6 - 43.8)

= 9.51

Dirt Factor, Q= 0.5 (QH+QC)

= 0.5 (9076.43 + 194.36)

= 4635.40 W

Overall heat transfer coefficient, U

=
=

Q
A LMTD
4635.40
0.0375 9.51

= 12997.97 kg/s2

Efficiency

QC
x 100
QH

= (194.36/9076.43) x 100%
= 2.14%

(ii)
At FT1=10 LPM, FT2=4 LPM
Heat transfer for hot water, QH = mHCpT
L
1 min
1 m3
QH
= 10.0 min x 1000 L x 60 s

kg
x 988.18 m3

x 4175

J
kg .C

x 4183

J
kg .C

(39.1 30.1) 0C
= 6188.48 W

Qc

Heat transfer rate for cold water,

QC

= 4.0

L
min x

1 m3
1000 L

= mc Cp T

1 min
60 s

(48.8 46.4) 0C
= 666.38 W

Heat loss Rate = QH - QC

QH - QC

= 6188.48 W 666.38 W
= 5522.10 W
T1 - t2)

LMTD, TLM =

(T2 - t1)

ln
(T1 - t2) - (T2 - t1)

kg
x 995.67 m3

46.430.1 )

(48.8 - 39.1)

ln
(46.4 - 30.1) - (48.8 - 39.1)

= 12.72

Dirt Factor, Q= 0.5 (QH+QC)

= 0.5 (6188.48 +666.38)
= 3427.43 W

Overall heat transfer coefficient, U

=
=

Q
A LMTD
3427.43
0.0375 12.72

= 7185.39 kg/s2

Efficiency

QC
x 100
QH

= (666.38/6188.48) x 100%
= 10.77%

(iii)
At FT1=10 LPM, FT2=6 LPM
Heat transfer for hot water, QH = mHCpT
3
L
1 min
1m
QH
= 10.0 min x 1000 L x 60 s

kg
x 988.18 m3

x 4175

J
kg .C

x 4183

J
kg .C

(36.5 29.6) 0C
= 4744.50 W

Qc

Heat transfer rate for cold water,

QC

= 6.0

(49.0 45.5) 0C

L
min x

1m
1000 L

= mc Cp T

1 min
60 s

kg
x 995.67 m3

= 1457.71 W

Heat loss Rate = QH - QC

QH - QC

= 4744.50 W 1457.71 W
= 3286.79 W
T1 - t2)

LMTD, TLM =

(T2 - t1)

ln
(T1 - t2) - (T2 - t1)

45.5 - 29.6)

(49.0 - 36.5)

ln
(45.5 - 29.6) - (49.0 - 36.5)

= 14.13

Dirt Factor, Q= 0.5 (QH+QC)

= 0.5 (4744.50 + 1457.71)
= 3101.11 W

Overall heat transfer coefficient, U

=
=

Q
A LMTD
3101.11
0.0375 14.13

= 5852.53 kg/s2

Efficiency

QC
x 100
QH

= (1457.71/4744.50) x 100%
= 30.72%

(iv)

At FT1=10 LPM, FT2=8 LPM

Heat transfer for hot water, QH = mHCpT

L
1 min
1 m3
QH
= 10.0 min x 1000 L x 60 s

kg
x 988.18 m3

x 4175

J
kg .C

x 4183

J
kg .C

(35.4 29.5) 0C
= 4057.89 W

Qc

Heat transfer rate for cold water,

QC

L
min x

= 8.0

1 m3
1000 L

= mc Cp T

1 min
60 s

kg
x 995.67 m3

(48.8 45.4) 0C
= 1867.77W

Heat loss Rate = QH - QC

QH - QC

= 4057.89 W 1867.77 W
= 2190.12 W
T1 - t2)

LMTD, TLM =

(T2 - t1)

ln
(T1 - t2) - (T2 - t1)

45.4 - 29.5)

(48.8 - 35.4)

ln
(45.4 - 29.5) - (48.8 - 35.4)

= 14.61

Dirt Factor, Q= 0.5 (QH+QC)

= 0.5 (4057.89 + 1867.77)
= 2962.83 W

Overall heat transfer coefficient, U

=
=

Q
A LMTD
2962.83
0.0375 14.61

= 5407.86 kg/s2

Efficiency

QC
x 100
QH

= (1867.77/4057.89) x 100%
= 46.03%

(v)
At FT1=10 LPM, FT2=10 LPM
Heat transfer for hot water, QH = mHCpT
L
1 min
1 m3
QH
= 10.0 min x 1000 L x 60 s

kg
x 988.18 m3

x 4175

J
kg .C

x 4183

J
kg .C

(34.4 29.9) 0C
= 3094.24 W

Qc

Heat transfer rate for cold water,

QC

L
min x

= 10.0

1m
1000 L

= mc Cp T
1 min
60 s

(48.7 44.8) 0C
= 2707.18 W

Heat loss Rate = QH - QC

QH - QC

= 3094.24 W 2707.18 W
= 387.06 W
T1 - t2)

LMTD, TLM =

(T2 - t1)

ln
(T1 - t2) - (T2 - t1)

kg
x 995.67 m3

44.8 - 29.9)

(48.7 - 34.4)

ln
(44.8 - 29.9) - (48.7 - 34.4)

= 14.60

Dirt Factor, Q= 0.5 (QH+QC)

= 0.5 (3094.24 + 2707.18)
= 2900.71 W

Overall heat transfer coefficient, U

=
=

Q
A LMTD
2900.71
0.0375 14.60

= 5298.10kg/s2

Efficiency

QC
x 100
QH

= (2707.18/3094.24) x 100%
= 87.81%

Experiment 2: at constant FT 2
(i)
At FT1=2 LPM, FT2=10 LPM
Heat transfer for hot water, QH = mHCpT
L
1 min
1 m3
QH
= 2.0 min x 1000 L x 60 s

kg
x 988.18 m3

x 4175

J
kg .C

x 4183

J
kg .C

(32.0 29.9) 0C
= 288.80 W

Heat transfer rate for cold water,

QC

= 10.0

(48.8 40.1) 0C

L
min x

1 m3
1000 L

Qc

= mc Cp T
1 min
60 s

kg
x 995.67 m3

= 6039.09 W

Heat loss Rate = QH - QC

QH - QC

= 288.80 W 6039.09 W
= -5750.29 W
T1 - t2)

LMTD, TLM =

(T2 - t1)

ln
(T1 - t2) - (T2 - t1)

40.1 - 29.9)

(48.8- 32.0)

ln
(40.1 - 29.9) - (48.8 - 32.0)

= 13.23

Dirt Factor, Q= 0.5 (QH+QC)

= 0.5 (288.80 + 6039.09)
= 3163.95 W

Overall heat transfer coefficient, U

=
=

Q
A LMTD
3163.95
0.0375 13.23

= 6377.32 kg/s2

Efficiency

QC
x 100
QH

= (6039.09/288.80) x 100%
= 2091.10%

(ii)
At FT1=4 LPM, FT2=10 LPM
Heat transfer for hot water, QH = mHCpT

QH

L
min x

= 4.0

1m
1000 L

1 min
60 s

kg
x 988.18 m3

x 4175

J
kg .C

x 4183

J
kg .C

(32.4 30.0) 0C
= 660.10 W

Qc

Heat transfer rate for cold water,

QC

L
min x

= 10.0

1 m3
1000 L

= mc Cp T
1 min
60 s

kg
x 995.67 m3

(48.5 42.8) 0C
= 3956.64 W

Heat loss Rate = QH - QC

QH - QC

= 660.10 W 3956.64 W
= -3296.54 W
T1 - t2)

LMTD, TLM =

(T2 - t1)

ln
(T1 - t2) - (T2 - t1)

42.8 - 30.0)

(48.5 - 32.4)

ln
(42.8 - 30.0) - (48.5 - 32.4)

= 14.39

Dirt Factor, Q= 0.5 (QH+QC)

= 0.5 (660.10 + 3956.64)
= 2308.37 W

Overall heat transfer coefficient, U

=
=

Q
A LMTD
2308.37
0.0375 14.39

= 4277.73 kg/s2

Efficiency

QC
x 100
QH

= (3956.64/660.10) x 100%
= 599.40%

(iii)
At FT1=6 LPM, FT2=10 LPM
Heat transfer for hot water, QH = mHCpT
L
1 min
1 m3
QH
= 6.0 min x 1000 L x 60 s

kg
x 988.18 m3

x 4175

J
kg .C

x 4183

J
kg .C

(33.2 30.1) 0C
= 1278.95W

Qc

Heat transfer rate for cold water,

QC

L
min x

= 10.0

1m
1000 L

= mc Cp T
1 min
60 s

(49.0 43.8) 0C
= 3609.57 W

Heat loss Rate = QH - QC

QH - QC

= 1278.95 W 3609.57 W
= -2330.62 W
T1 - t2)

LMTD, TLM =

(T2 - t1)

ln
(T1 - t2) - (T2 - t1)

kg
x 995.67 m3

43.8 - 30.1)

(49.0 - 33.2)

ln
(43.8 - 30.1) - (49.0 - 33.2)

= 14.73

Dirt Factor, Q= 0.5 (QH+QC)

= 0.5 (1278.95 + 3609.57)
= 2444.26 W

Overall heat transfer coefficient, U

=
=

Q
A LMTD
2444.26
0.0375 14.73

= 4425.00 kg/s2

Efficiency

QC
x 100
QH

= (3609.57/1278.95) x 100%
= 282.23%

(iv)
At FT1=8 LPM, FT2=10 LPM
Heat transfer for hot water, QH = mHCpT
L
1 min
1 m3
QH
= 8.0 min x 1000 L x 60 s

kg
x 988.18 m3

x 4175

J
kg .C

x 4183

J
kg .C

(34.0 30.3) 0C
= 2035.32 W

Qc

Heat transfer rate for cold water,

QC

L
min x

= 10.0

1 m3
1000 L

= mc Cp T
1 min
60 s

kg
x 995.67 m3

(48.8 44.1) 0C
= 3262.50 W

Heat loss Rate = QH - QC

QH - QC

= 2035.32 W 3262.50 W
= -1227.18 W
T1 - t2)

LMTD, TLM =

(T2 - t1)

ln
(T1 - t2) - (T2 - t1)

44.1 - 30.3)

(48.8 - 34.0)

ln
(44.1 - 30.3) - (48.8 - 34.0)

= 14.29

Dirt Factor, Q= 0.5 (QH+QC)

= 0.5 (2035.32 + 3262.50)
= 2648.91 W

Overall heat transfer coefficient, U

=
=

Q
A LMTD
2648.91
0.0375 14.29

= 4943.15 kg/s2

Efficiency

QC
x 100
QH

= (3262.50/2035.32) x 100%
= 160.29%

(v)
At FT1=10 LPM, FT2=10 LPM
Heat transfer for hot water, QH = mHCpT
L
1 min
1 m3
QH
= 10.0 min x 1000 L x 60 s

kg
x 988.18 m3

x 4175

J
kg .C

x 4183

J
kg .C

(35.0 30.3) 0C
= 3231.76 W

Qc

Heat transfer rate for cold water,

QC

L
min x

= 10.0

1 m3
1000 L

= mc Cp T
1 min
60 s

kg
x 995.67 m3

(49.5 45.7) 0C
= 2637.76 W

Heat loss Rate = QH - QC

QH - QC

= 3231.76 W 2637.76 W
= 594.00 W
T1 - t2)

LMTD, TLM =

(T2 - t1)

ln
(T1 - t2) - (T2 - t1)

45.7 - 30.3)

(49.5 - 35.0)

ln
(45.7 - 30.3) - (49.5 - 35.0)

= 14.95

Dirt Factor, Q= 0.5 (QH+QC)

= 0.5 (3231.76 + 2637.76)
= 2934.76 W

Overall heat transfer coefficient, U

=
=

Q
A LMTD
2934.76
0.0375 14.95

= 5234.80 kg/s2

Efficiency

QC
x 100
QH

= (2637.76/3231.76) x 100%
= 50.68%

DISCUSSION

The exchanger are basically made up from a bundle of parallel tubes

so that the fluid can flow and enclosed in shell where the other fluid is placed.
Shell side should have high number of baffles to provide high velocities and more
efficient cross flow from outside the tubes. Other than that, baffles are used to
increase the coefficient of shell-side by increasing the velocity and make it
turbulent. Baffles pitch usually 0.2-1.0 times the diameter of the shell tube. Heat
transfer coefficient and pressure drop depends on the baffles pitch. The good
selection in needed to optimize the heat exchanger. Fluid that entered the
streams may have suspended materials. When it continues within long time of
period, the flow of liquid inside the stream will eventually become slower. The
surface becomes corroded and resulting products may also deposit on the
surface. The deposition at heat exchanger is called fouling while, the heat
transfer resistance caused by the corrosion is called fouling factor or dirt factor.
Dirt factor can be determined by experimental calculations.
In this experiment, we also able to calculate the heat load, log mean
temperature difference (LMTD), and overall heat transfer coefficient value. From
data that we obtain, it shows that there are some deviations values. This is
because the value of Qh and Qc have a very large difference. Qc/Qh unity means
that it both have value that close to each other. The experiment is also to
examine the Reynolds number, so that we can know types of liquid flow. Based

on calculation, the tube side has the laminar flow while the shell side have the
turbulent flow.
In experiment 1, volumetric flowrates of hot water is constant at 10
LPM while volumetric flowrates of cold water is change from 2 LPM to 10 LPM
for every 10 minutes. Heat transfer of hot water,QH is higher than heat transfer of
cold water,QC. Heat transfer occur efficiently at equal value of volumetric
flowrates. The highest efficiency in experiment 1 is 87.81% at FT1=10LPM and
FT2=10LPM where its QH=3094.24 W, QC=2707.18 W, heat loss rate is 387.06
W, LMTD=14.60, dirt factor,Q=2900.71 W and heat transfer
coefficient,U=5298.10 kg/s2.
In experiment 2, volumetric flowrates of cold water is constant at 10 LPM
while volumetric flowrates of hot water change from 2 LPM to 10 LPM for every 10
minutes. The highest efficiency in experiment 2 is 2091.10% at FT1=2LPM and
FT2=10LPM where its QH=288.80 W, QC=6039.09 W, heat loss rate is -5750.29 W,
LMTD=13.23, dirt factor,Q=3163.95 W and heat transfer coefficient,U=6377.32
kg/s2.
Based on theoretically, as we assume negligibility of internal, kinetic and
potential energy, supposed QH=QC. Heat released by hot water must equal to energy
absorbed by cold water. Unfortunately, in this experiment Q H QC, maybe due to
some error during experiment is conducted.

CONCLUSION
In this experiment, we had achieve all objective in calculate the heat
transfer coefficient, LMTD, heat transfer and heat loss for energy balance. Basic
theory of the experiment is QC=Qh, amount of heat transfer is equal with the heat
absorbed. But, in this experiment, we could not have 100% theory, therefore QH
QC. It only can be achieve if there is no error occur while conducting experiment

RECOMMENDATION
When taking the measurement, it is recommended to take the reading when
the machine is totally stabilized. If measurement is taking when not stable, it will
affect the calculation result. Other than that, eye must be perpendicular with the
tank when adjusting the value of FT1 and FT2 (LPM). Besides that, the water in
the tank must be removed every time that the experiment is not in used. If the
water remains in the tank, it will cause the corrosion. Presence of bubble can also
cause corrosion and can decrease heat transfer efficiency.

REFERENCES

https://www.scribd.com/doc/204565808/Heat-Exchanger-Lab-Report-

Shell- and-Tube
Retrieved on 23.10.2015
http://www.ejbowman.co.uk/products/ShellandTubeHeatExchangers.html
Retrieved on 23.10.2015
Incropera, DeWitt, Bergman, Lavine. (2007) Introduction to Heat Transfer

5th Edition John Wiley, New York

Retrieved on 23.10.2105
http://www.cems.ou.edu/ulab/CHE3432/2_heatexchanger/exp2_objective.
html
Retrieved on 22.10.2015