2.

0 INTRODUCTION
A heat exchanger is a device that allows heat from a fluid a liquid or a gas to pass to a
second fluid which is another liquid or gas without the two fluids having to mix together or come
into direct contact. In this model, two separated fluids at different temperatures flow through the
heat exchanger: one through the tubes tube side and the other through the shell around the tubes
shell side. The two fluids can flow in the same direction (known as parallel flow), in opposite
directions which are counter flow or counter-current, or at right angles cross flow. (Chris,2016)
Parallel flow or co-current flow is the flow where the hot and the cold fluid is flow in the same
direction. The most effective flow in the heat exchanger is a countercurrent flow where the fluid
paths flow in opposite directions, with exiting and the other enters. This results in faster heat
exchange. For this experiment, counter-current heat exchanger is used. In counter flow heat
exchangers, the two fluids flow against each other, maintaining a maximum temperature
difference between the hot and cold streams which allows for maximum heat transfer.

Figure 1 Shell and Tube Heat Exchanger

Figure 2 Shell and Tube Heat Exchanger in counter current flow

There are advantages and disadvantages in shell and tube heat exchanger. The advantages
are extended heat transfer surfaces can be used to enhance heat transfer and cleaning and repair
are relatively straightforward because the equipment can be dismantled for this purpose. The
disadvantage is heat transfer efficiency is less compared to plate type cooler. (Shankar, n.d)

OBJECTIVE
The objectives of this experiment are to evaluate and study the overall heat transfer
coefficient, LMTD, heat transfer and heat loss for energy balance. Second objectives are to study
the effect of fluid temperature on counter flow heat exchanger performance. It is also to
investigate the effect of fluid flow rated on heat exchanger performance.

THEORY
The main function of heat exchanger is to either remove heat from a hot fluid or to add
heat to the cold fluid. The direction of fluid motion inside the heat exchanger can normally
categorized as parallel flow, counter flow and cross flow. In this experiment, heat exchanger used
is only counter-current flow. For counter-current flow, both the hot and cold fluids flow in the
opposite direction. Both the fluids enter and exit the heat exchanger on the opposite ends. This
experiment focused on the shell and tube heat exchanger.
Heat load and heat balance
Hot water flow rate (Hw )
QH = mH x CpH x (t1-t2)

Hot water flow rate (Cw )

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=Hot water outlet temperature
T1=Cold water inlet temperature
T2=Cold water outlet temperature

LMTD
Calculations of log mean temperature difference (LMTD)

Heat loss rate =

QH - QC

Dirt factor, Q =

0.5 (QH + QC )

Overall heat transfer coefficient,

Overall heat transfer coefficient at which equivalent to

can be calculated by using equation

below. In this case, the value of total heat transfer area

has been given and equal to 0.05 m2.

Where:
Heat rate with respect to the average head load

Reynolds Number Calculation

=

v ( d sd o )

At which
do Tube outside diameter, m

ds = Shell diameter, m
Viscosity, taken at average fluid temperature in the shell, Pa.s
As Exchange area, m2

APPARATUS
1) Shell and Tube Heat Exchanger
PROCEDURE
General Start-up Procedure :
1. A quick inspection was performed to make sure that the equipment is in proper working
condition.
2. All valves were initially closed except V1 and V12.
3. Hot tank was filled via a water supply hose connected to valve V27. Once the tank is full, the
valve was closed.
4. The cold water tank was filled up by opening valve V28 and the valve was left opened for
continuous 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 to 50oC.
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.

Counter-current Shell & Tube Heat Exchanger Procedures :

1. General start-up procedures was performed.
2. The valves to counter-current Shell & Tube Heat Exchanger arrangement was switched.
3. Pumps P1 and P2 were switched on.
4. Valves V3 and V14 were adjusted and opened to obtain the desired flowrates 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 flowrate FT1 and FT2.
9. Pumps P1 and P2 were switched off after the completion of experiment.

General Shutdown Procedure :

1. The heater was switched off. The hot water temperature was waited until it dropped below
40oC.
2. Pump P1 and pump P2 were switched off.
3. The main power was switched off.
4. All water in the process line was drained off. The water in the hot and cold water tanks were
retained for next laboratory sessions.
5. All valves were closed.

DISCUSSION
In this experiment of shell and tube heat exchanger particular apparatus, water is used as
both the hot and cold fluid. The purpose of this heat exchanger is to cool a hot stream. Cooling
water flows through the outer pipe (the shell), and hot water flows through the inner pipe on the
inside. Heat transfer occurs in both directions; the hot water is cooled, and the cooling water is
heated. This arrangement is called a shell-and-tube heat exchanger. There are many other
forms of heat exchangers; most notably, the double-pipe heat exchanger.
For this experiment, counter-current heat exchanger is used. In counter flow heat
exchangers, the two fluids flow against each other, maintaining a maximum temperature
difference between the hot and cold streams which allows for maximum heat transfer.
In experiment 1, volumetric flowrates of hot water is constant which is 10 LPM while
volumetric flowrates of cold water is change every 10 minutes from 2 LPM to 10 LPM. Heat
transfer of hot water,QH is higher than heat transfer of cold water,QC. However, QH keep
decreasing while QC keeps increasing as volumetric flowrate of cold water increases. The
highest efficiency in experiment 1 is 533.63% at FT1=10LPM and FT2=10LPM where its
QH=481.32 W, QC=2568.45 W, heat loss rate is -2087.45 W, LMTD=14.75, dirt factor,Q=1524.89
W and heat transfer coefficient,U=652.64

W
2
m . K . It means that heat transfer occur efficiently

at equal volumetric flowrates of hot and cold water.

In experiment 2, volumetric flowrates of cold water is constant at 10 LPM while
volumetric flowrates of hot water is difference every 10 minutes from 2 LPM to 10 LPM. Heat
transfer of hot water,QH is lower than heat transfer of cold water,QC. However, QH keep
increasing while QC keep decreasing as volumetric flowrates of hot water increases. The highest
efficiency in experiment 2 is 110.63% at FT1=2LPM and FT2=10LPM where its QH=1003.91 W,
QC=1110.64 W, heat loss rate is -106.73 W, LMTD=11.31, dirt factor,Q=11.31 W and heat
transfer coefficient,U=1775.26

W
2
m .K

Theoretically, heat released by hot water must be equal to heat absorb by cold water,
QH=QC assuming the negligibility of internal, kinetic and potential energy. However, in this
experiment, QH QC due to some errors that occur during conducted this experiment. For
example, suspended matters or dissolves solid that may contain in the fluid streams. Deposition
of the tube surfaces and shell surfaces occurs when such a fluid flows through a heat exchanger
over a long period of time. The surfaces may also be corroded by fluid slowly and the resulting
corrosion products also get deposited on the surfaces. This formation of the deposit on a heat
transfer surface is called fouling and the heat transfer resistance offered by the deposit is called

the fouling factor or dirt. Presence of air bubbles in the tube also is one of the factors that cause
an inaccurate result.
According to Kevin M. (2006) there are many ways to increase the efficiency of heat
exchanger which are determined that the exchanger is operating correctly as designed.
Correcting flaws in construction and piping that may have effect on heat transfer and pressure
drop may be the solution, estimate how much pressure drop is available. For single phase heat
transfer coefficients, higher fluid velocity increases heat transfer coefficients and pressure drop,
estimate fouling factors that are not overstated. The layer of deposits represents additional
resistance to heat transfer and causes the rate of heat transfer to decrease.(Yunus A.C,2007)
Excessive fouling factors at the design state result in oversized exchangers with low velocities.
These low velocities may exacerbate the fouling problem. More liberal fouling factors and
periodic cleaning may increase the heat exchangers performance. It also must consider using a
basic shell-and-tube exchanger with enhancement or intensification such as finning, tube inserts,
modified tubes, or modified baffles.

CONCLUSION
The main objectives of this experiment is to evaluate and study the overall heat transfer
coefficient, LMTD, heat transfer and heat loss for energy balance as well as to evaluate and
study the performance of shell and tube heat exchanger at various operating condition. In this
shell and tube heat exchanger, the fluids flow in counter-current flow which results in faster heat
exchange. The basic theory in this air experiment is QH=QC, which the amount of heat release by
hot water is equal to the amount of heat absorb by cold water. However, the results is different
than the basic theory where the amount of heat release by hot water is not equal to the amount of
heat absorb by cold water, QH QC. This is due to some errors during conducting this experiment
which are the presence of bubbles in tube where the hot water flows. The presence of these
bubbles can cause corrosion and disturb the process of heat transfer. Although the results are not
followed the basic theory, this experiment can be said as successful as the objectives of this
experiment is already achieve.

Result
Experiment A : Counter-current Shell & Tube Heat Exchanger (constant FI 1).
FI 1

FI 2

TT 1

TT 2

TT 3

TT 4

TT 5

DPT 1

DPT 2

(LPM)
(LPM)
(0C)
(0C)
(0C)
(0C)
(0C)
(mmH2O) (mmH2O)
10
2
44.1
32.2
47.2
48.3
50.2
87
4
10
4
39.5
32.1
46.1
48.9
50.2
84
9
10
6
37.8
31.4
46.5
49.7
51.2
86
44
10
8
35.9
31.8
44.6
47.8
49.6
85
108
10
10
35.7
32.0
48.3
49.0
50.8
85
202
Table 1 : Counter-current Shell & Tube Heat Exchanger with constant FI 1

Experiment B : Counter-current Shell & Tube Heat Exchanger (constant FI 2).

FI 1

FI 2

TT 1

TT 2

TT 3

TT 4

TT 5

DPT 1

DPT 2

(LPM)
(LPM)
(0C)
(0C)
(0C)
(0C)
(0C)
(mmH2O) (mmH2O)
2
10
33.5
31.9
40.6
47.9
51.6
5
205
4
10
33.9
32.0
43.7
48.6
50.4
3
201
6
10
34.6
32.0
43.9
48.5
51.9
23
187
8
10
35.2
32.1
44.3
48.3
60.1
53
196
10
10
36.0
32.2
45.6
49.2
50.8
89
198
Table 2 : Counter-current Shell & Tube Heat Exchanger with constant FI 2

Sample Calculation
Experiment A: Counter-Current Flow
Hot Water
Density:

988.18 kg/m3

Heat Capacity:

4175.00 J/kg.K

Thermal cond:

0.6436 W/m.K

Viscosity:

0.0005494 Pa.s

Cold Water
Density:

995.67 kg/m3

Heat Capacity:

4183.00 J/kg.K

Thermal cond:

0.6155 W/m.K

Viscosity:

0.0008007 Pa.s

EXPERIMENT 1 :
1. Calculation On Heat Transfer and heat load (constant FT1) and Calculation of Log Mean
Temperature Difference (LMTD) :

Heat transfer rate for hot water,

Qh

L
1 m3
= 10.0 min x 1000 L

Qh

= mh Cp T

1 min
x 60 s

kg
x 988.18 m 3

47.2) C
= 756.37 W

Heat transfer rate for cold water,

Qc

= mc Cp T

J
x 4175 kg.C

x (48.3-

Qc

= 2.0

L
min x

1m
1000 L

1 min
60 s

kg
x 995.67 m3

x 4183

J
kg .C

32.2) C
= 1652.07 W

Heat loss Rate =

QhQc

QhQc

= 756.37-1652.07

= -895.70 W
=

Q 895.70
=
100 =54.21
Qmax 1652.07

Efficiency

Qc
x 100
Qh

1652.07
x 100
756.37

= 21.82 %

LMTD, TLM = [( Th,in Tc,out) (Th,out Tc,in)] / ln[( Th,in Tc,out)

/(Th,out- Tc,in)]

( 48.344.1 )(47.232.2)
(48.344.1)

( 47.232.2)

= 8.48C

Dirt Factor, Q = 0.5 (Qh+Qc)

= 0.5 (756.37+165.07)
= 1204.22

EXPERIMENT 2 :

x (44.1-

1. Calculation On Heat Transfer and heat lost (constant FT2) and Calculation of Log Mean
Temperature Difference (LMTD) :

Qh

Heat transfer rate for hot water,

= 2.0

1 m3
1000 L

L
min x

1 min
60 s

= mh Cp T
kg
x 988.18 m3

x 4175

J
kg .C

x (47.9-40.6) C

= 1003.91 W

Heat transfer rate for cold water,

= 10.0

L
min x

1m
1000 L

Qc

1 min
60 s

= mc Cp T
kg
x 995.67 m3

x 4183

J
kg .C

x (33.5-31.9)

C
= 1110.64 W

Heat loss Rate =

QhQc

= 1003.91-1110.64
= -106.73 W
=

Q 106.73
=
100 =9.61
Qmax 1110.64

Efficiency

1110.64
x 100
1003.91

Qc
x 100
Qh

= 110.63 %

LMTD, TLM = [( Th,in Tc,out) (Th,out Tc,in)] / ln[( Th,in Tc,out) /( Th,out - Tc,in)]

( 33.547.9 )(31.940.6)
(33.547.9)

(31.940.6)

= 11.31C

Dirt Factor, Q = 0.5 (Qh+Qc)

= 0.5 (1003.91+1110.64)
= 1057.28

EXPERIMENT 1 :
Calculation On Heat Transfer and heat load (constant FT1) and Calculation of Log Mean
Temperature Difference (LMTD) :
FI 1

FI 2

(LPM)

(LPM)

10
10
10
10
10

2
4
6
8
10

Heat
transfer rate
for hot
water,
Qh
(W)
756.37
1925.30
2200.35
2200.35
481.32

Heat transfer
rate for cold
Qc
water,

Heat loss
Rate
(W)

Efficiency
(%)

LMTD,
TLM
()

Dirt
Factor, Q

-895.70
-129.38
-465.18
-76.48
-2087.45

21.82
106.72
121.14
103.47
533.63

8.48
11.55
13.48
12.34
14.75

1204.22
1989.99
2432.94
2238.58
1524.89

(%)

(W)

1652.07
2054.68
2665.30
2276.81
2568.45

-54.18
-6.30
-17.45
-3.36
-81.27

EXPERIMENT 2 :
Calculation On Heat Transfer and heat lost (constant FT2) and Calculation of Log Mean
Temperature Difference (LMTD)

FI 1

FI 2

(LPM)

(LPM)

2
4
6
8
10

10
10
10
10
10

Heat
transfer rate
for hot
water,
Qh
(W)
1003.91
1347.71
1897.80
2200.35
2500.44

Heat transfer
rate for cold
Qc
water,

Heat loss
Rate
(W)

Efficiency
(%)

LMTD,
TLM
(

Dirt
Factor, Q

-106.73
28.83
93.02
48.49
-137.32

110.63
97.86
95.10
97.80
105.49

11.31
12.07
12.87
12.64
13.30

1057.28
1333.30
1851.29
2176.11
2569.10

(%)

(W)

1110.64
1318.88
1804.78
2151.86
2637.76

-9.61
2.14
4.90
2.20
-5.21

Sample Calculation of the shell and tube heat transfer coefficient

EXPERIMENT 1
0.8
0.33
At tube side (hot water-cooling process): Nu=0.023 Pr
3
L
1 m3 1 min
4 m
V =10

=1.67 10
min 1000 L 60 s
s

d 2 (0.02664)
2
A=
=
=0.000557 m
4
4

V 1.67 104
m
v= =
=0.299
A 0.000557
s

vd
=

988.18

Cp
Pr=
=
k

kg
m
0.299 0.02664 m
3
s
m
=14327 ( turbulent flow )
0.0005494 Pa s

( 0.0005494 Pa s ) ( 4175
0.6436

J
)
kg K

W
mK

=3.564

Nu=0.023 0.8 Pr0.33 =0.023 143270.8 3.564 0.33=73.55

Nuk
h=
=
d

W
m K
W
=1776.91 2
0.02664 m
m K

73.55 0.6436

At shell side (cold water-heating process):

0.8

Nu=0.023 Pr

0.4

EXPERIMENT 2
For (2 LPM)
1 min
L
1m
m
V =2

=3.33 105
min 1000 L 60 s
s
3

0.085

( 2( 0.0334 )2)

(d 2sd 2o)
A=
=
4

5
V 3.33 10
m
v= =
=0.0069
A
0.0048
s

v ( d sd o )
=

955.67

kg
m
0.0069 ( 0.0850.0334 m)
3
s
m
0.0008007 Pa s

425 ( laminar flow )

Cp
Pr=
=
k

( 0.0008007 Pa s ) (4183
W
0.6155
m K

J
)
kg K

=5.49

Nu=0.023 0.8 Pr0.4 =0.023 4250.8 5.490.4 =5.76

W
Nuk
m K
W
h=
=
=68.68 2
d
(0.085 m0.0334 m)
m K
5.76 0.6155

FT2
(LPM)

A
2
( m

m
( s

Pr

Nu

( s

h
(

W
m2 K

3.33 10 0.0048
5

0.0069

425

5.49

5.76

)
68.68

5.49

10.80

120.26

5.49

13.91

166.03

5.49

17.55

209.38

5.49

20.96

250.02

( laminar flow )
4

6.67 105 0.0048

0.0139

856

( laminar flow )
6

1 10

0.0048

0.0208

1281

( laminar flow )
8

0.0048
1.333 104

0.0278

1712

( laminar flow )
10

1.667 10 0.0048
4

0.0347

2137

( laminar flow )

Sample Calculation for Overall heat transfer coefficient:

Total exchange area , A= tube od length= 0.02664 m 0.5 m=0.05 m2

U=

Qhot
756.37 W
W
=
=1783.89 2
A T lm 0.05 m 2 8.48
m K

FT1 (HOT) Constant=10 LPM

FT1

FT2

(LPM)

(LPM)

10
10
10
10
10

2
4
6
8
10

Qhot
(W)

A
2

( m

LMTD

( m2 K

756.37
1925.30
2200.35
2200.35
481.32

0.05
0.05
0.05
0.05
0.05

8.48
11.55
13.48
12.34
14.75

1783.89
3333.85
3264.61
3566.21
652.64

Qhot

LMTD

FT2 (COLD) Constant=10 LPM

FT1

FT2

(LPM)

(LPM)

2
4
6
8
10

10
10
10
10
10

(W)
1003.91
1347.71
1897.80
2200.35
2500.44

2
( m

0.05
0.05
0.05
0.05
0.05

( m2 K

11.31
12.07
12.87
12.64
13.30

1775.26
2233.16
2949.18
3481.57
3760.06

RECOMMENDATION
For this experiment of shell and tube heat exchanger, it is recommended that the heat
exchanger be well insulated in order to reduce the heat loss to the surroundings. Presently, the
heat exchanger has no insulation and the ambient room temperature has a large effect on the
results obtained in this experiment.
Apart from that, the flowrate measure during this experiment must be taken accurately.
The eyes must be perpendicular to the scale of the flow meter so that the readings will be more
accurate.During the experiment, it is recommended that the readings such as FT1, FT2, DPT1,
DPT2 and temperature must be taken when the system is stabilized and reach its steady state. If
the readings were taken when the system are not in stabilized condition, error might be occur.
Then this will affect the readings and also the calculations.
Lastly, the water to the tube side should be the first and last flow rate to be turned on.
The steam should be turned on only after the water is flowing through the tube side and the water
should be turned on only after the steam has been turned on so that the tube and shell heat
exchanger can operates more effectively.

REFERENCE
1) Chris.W (2016). Heat Exchanger. Retrieved from http://www.explainthatstuff.com/howheat-exchangers-work.html
2) Shankar.S (n.d). Shell and Tube Heat Exchanger.
3) Yunus A.Cengel (2007). Heat and Mass Transfer Fundamentals and Application.

APPENDIX

Figure 1. SOLTEQ Heat Exchanger Study Unit Model: HE158C

ABSTRACT
Heat exchanger is a device that allows heat from a fluid (a liquid or a gas) to pass to a second
fluid (another liquid or gas) without the two fluids having to mix together or come into direct
contact. Thus, a device named Heat Exchanger Training Apparatus (Model; HE 158C) was used
to conduct Shell and Tube Heat Exchanger experiment. The objectives of this experiment are to
evaluate and study the heat load and head balance, LMTD and overall heat transfer coefficient, to
calculate the Reynolds numbers at the shell and tubes sides and to measure and determine the
shell and tube sides pressure drop. To do that, we 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. The flow of hot and cold water is counter-current flow.