EXPERIMENT

Double-Pipe Heat-Exchanger Characteristics

Objective
To evaluate the performance characteristics of a double-pipe heat exchanger under parallel and
counter-flow arrangements.

Background
The technology of heating and cooling of systems is one of the most basic areas of mechanical
engineering. Wherever steam is used, or wherever hot or cold fluids are required we will find a
heat exchanger. They are used to heat and cool homes, offices, markets, shopping malls, cars,
trucks, trailers, aeroplanes, and other transportation systems. They are used to process foods,
paper, petroleum, and in many other industrial processes. They are found in superconductors,
fusion power labs, spacecrafts, and advanced computer systems. The list of applications, in both
low and high tech industries, is practically endless.
Heat exchangers are typically classified according to flow arrangement and type of
construction. In this introductory treatment, we will consider three types that are representative
of a wide variety of exchangers used in industrial practice. The simplest heat exchanger is one
for which the hot and cold fluids flow in the same or opposite directions in a concentric-tube (or
double-pipe) construction. In the parallel-flow arrangement of Fig. 1a, the hot and cold fluids
enter at the same end, flow in the same direction, and leave at the same end. In the counter flow
arrangement, Fig. 1b, the fluids enter at opposite ends, flow in opposite directions, and leave at
opposite ends. A common configuration for power plant and large industrial applications is the
shell-and-tube heat exchanger, shown in Fig. 1c. This exchanger has one shell with multiple
tubes, but the flow makes one pass through the shell. Baffles are usually installed to increase the
convection coefficient of the shell side by inducing turbulence and a cross-flow velocity
component. The cross-flow heat exchanger, Fig. 1d, is constructed with a stack of thin plates
bonded to a series of parallel tubes. The plates function as fins to enhance convection heat
transfer and to ensure cross-flow over the tubes. Usually it is a gas that flows over the fin
surfaces and the tubes, while a liquid flows in the tube. Such exchangers are used for air-
conditioner and refrigeration heat rejection applications.
Figure 1: Types of Heat Exchangers concentric tube (a) Parallel flow, and (b) counter-flow; (c) Shell-and-
tube: one shell pass and one tube pass; (d) Cross-flow.

Heat Exchanger Analysis

The concept of overall heat transfer resistance or coefficient that you were introduced earlier in
your heat transfer course, if we apply this concept to a, for example, double-pipe heat exchanger,
the total resistance is the sum of the individual components; i.e., resistance of the inside flow, the
conduction resistance in the tube material, and the outside convective resistance, given by

1 1 1
R total (Eq. 1)
Ai hi Aln k Ao ho

where subscripts i and o refer to inner and outer heat-transfer surface areas, respectively, t is the
wall thickness, and is the logarithmic mean heat transfer area, defined as

Ao Ai
Aln (Eq. 2)
ln o
A
Ai

The total heat transfer resistance can be defined in terms of overall heat transfer coefficient based
on either outer or inner areas, as long as the basis is clearly spelled out. For example, based on
outer area, we have
 1 A tA 1
Ao Rtotal o o (Eq. 3)
Uo Ai hi Aln k ho

which after simplifying yields the overall heat transfer coefficient based on inner and outer areas,
respectively as [1]

1
Ui (Eq. 4)
1 Di ln Do Di Di

hi 2k Do ho

1
Uo (Eq. 5)
Do D ln Do Di 1
o
Di hi 2k ho

where the inner and outer heat-transfer areas, as well as the wall thickness, and the logarithmic
mean heat transfer area, in terms of tube inner and out diameters and length L, are given,
respectively, as

Ai Di L (Eq. 6a)

Ao Do L (Eq. 6b)

Do Di
t (Eq. 6c)
2

Do Di L
Aln (Eq. 6d)
D
ln o
Di

We note from the above equations that if the wall thickness is negligible, for example, in thin
tube heat exchangers or the thermal conductivity of the tube material is very high, the conduction
resistance through the tube may be neglected in Equations (4.4) and (4.5) to give

1 1 1 1
(Eq. 7)
U i U o hi ho
The convection coefficients for the inlet and outlet side of the heat exchanger tube can be
estimated using empirical correlations appropriate for the flow geometry and conditions. For the
double pipe heat exchanger in MEL PIEAS such a correlation is given as

f Re 1000 Pr
Nu 8 h
(Eq. 8)
1

1 12.7 f Pr 3 1
2 2

Where

f 0.76 ln Re w 1.64
2
(Eq. 9)

Prandtl number is given as

Cp
Pr (Eq. 10)
k

Here Re represents Reynolds number given as

m HD
Re (Eq. 11)
A

There are two types of Reynolds number, one based on wetted perimeter called wetted Reynolds
number Rew and other based on heated perimeter called heated Reynolds number Reh. These
perimeters appear in definition of Hydraulic Diameter HD.

4A
HD (Eq. 12)
P

Heat Transfer
The general heat exchanger equation is written in terms of the mean-temperature difference
between the hot and cold fluid, Tm as

q UATm (Eq. 13)

This equation, combined with the First Law equations, defines the energy flows for a heat
exchanger. It can be expressed in terms of the temperature change of the hot and cold fluids, as
 q m
C p h Th C h Th C c Tc (Eq. 14)

where C h and C o are the hot and cold fluid capacitance rates, respectively.

Log Mean Temperature Difference (LMTD)

Heat flows between the hot and cold streams due to the temperature difference across the tube
acting as a driving force. As seen in Fig. 2, the difference will vary with axial location so that
one must speak in terms of the effective or integrated average temperature differences.
The form of the average temperature difference, Tm, may be determined by applying an
energy balance to differential control volumes (elements) in the hot and cold fluids. As shown in
Fig. 2, for the case of parallel flow arrangement, each element is of length dx and the heat
transfer surface area is dA. It follows for the hot and cold fluid as [1-3]

dq C h dTh C c dTc (Eq. 15)

The heat transfer across the surface area dA may be expressed by the convection rate equation in
the differential form as

dq UdAdT (Eq. 16)

where dT = T - T is the local temperature difference between the hot and cold fluids.
h c

Figure 2: Temperature differences between hot and cold process streams

To determine the integrated form of Equation 16, we begin by substituting Equation 15 into the
differential form for the temperature difference,
 d T d Th Tc (Eq.1 7)

to obtain

d T 1 1
2 A

1 T U C h C c 0 dA
(Eq. 18)

T 1 1
ln 2 UA
(Eq. 19)

1
T h
C C c

Substituting C h and C c from the fluid energy balances, Equations 15 and integrating, we get after
some manipulation,

T2 T1
Q UA (Eq. 20)
T
ln 2
T1

Comparing the above expression with Equation 13, we conclude that the appropriate mean
temperature difference is the log mean temperature difference, Tlmtd. Accordingly, we have

T2 T1 T1 T2
Tm Tlmtd (Eq. 21)
T T
ln 2 ln 1
T1 T2
Where

T1 Th,i Tc,i (Eq. 22)

T2 Th,o Tc,o (Eq. 23)

A similar derivation can be shown for counter-flow heat exchangers; however, the temperature
difference as shown in Figure 2, will be
 T1 Th,i Tc,o (Eq. 24)

T2 Th,o Tc,i (Eq. 25)

As discussed above, the effective mean temperature difference calculated from this equation is
known as the log mean temperature difference, frequently abbreviated as LMTD, based on the
type of mathematical average, which it describes. While the equation applies to either parallel or
counter flow, it can be shown that T will always be greater in the counter flow arrangement.
m

Experimental Apparatus and Procedure

The objectives of the heat exchanger experiments are achieved through the use of a bench
mounted double-pipe heat-exchanger unit installed in MEL PIEAS. The schematic of the
experimental facility is shown in Fig. 3. The unit consists of two passes which will be used
during the experiment. The hot fluid flows in the inner tube, while the cold in outer tube. The
cold fluid is provided from overhead water tank while hot fluid is provided by means of a water
bath. It is important that water at constant temperature is provided to both fluid circuits. Two
temperature gauges are available for both the hot and cold fluid temperature measurements. The
flow rates of hot and cold fluids are measured using rotameters, connected to the inner and outer
tubes. Notice that the measurements would be taken for temperatures and flow rates for both (a)
parallel and (b) counter-flow arrangements. It is very important that the water flow through the
tubes reaches stable and steady state conditions before recording the following parameter for
both parallel and counter flow conditions:

1. Set the flow rate at the lowest (stable) reading and then monitor the difference between the
inlet and outlet temperatures for both hot and cold water until a steady state is
established.

2. Measure the temperature difference for both hot and cold flows.

3. Change the cold water flow, each time repeating (1) and (2) above.

4. Repeat the above sequence by raising the hot-side water flow rate.
 Figure 3: Schematic diagram of the experimental facility.

Data Analysis

Organize your lab data and calculated values in a neat spreadsheet array. Use only the SI
system of units;

Plot the heat transfer to the cold fluid versus the log-mean-temperature difference.

Calculate the heat loss by the hot fluid and heat gain by the cold fluid;

From the experiments performed, determine the average overall heat transfer coefficient, U
and the length of the heat exchanger.

Suggestions for Discussion

(i) What effect does the heat loss have on the performance of heat exchangers?
(ii) Is it important to consider heat losses from the counter- or parallel-flow arrangement?
(iii) What errors may be introduced in calculating heat exchanger effectiveness from the
experimental measurements?
(iv) What would you recommend to improve the reliability of this experiment?
References:
[1] Incropera, F. P. and D. P. DeWitt, Fundamentals of Heat and Mass Transfer, 4th edition,
John Wiley and Sons Inc., New York, 1996.
[2] engel, Yunus A., Heat Transfer: A Practical Approach, 2nd edition, McGraw-Hill, New
York, 2003.
[3] Thomas, L.C., Heat Transfer Professional Version, 2nd edition, Capstone Publishing Corp,
1999
 LAB DATA SHEET
Double-pipe heat exchanger characteristics
Name: ________________________________ Group #:_______ Date:__________

Make sure that the process has reached steady state conditions before recording any readings.
Fluid Temperature and Properties Dimension of Heat Exchanger:
Temp (C) Density Sp. Heat Di = ______________ mm
3
(kg/m ) (J/kg.K)
Do = ______________ mm

Experimental and calculated values of temperatures, flow rates and heat transfer rates.
Parameter Parallel-flow Counter-flow
Hot fluid Cold Fluid Hot fluid Cold Fluid
Inlet temperature (in C)
Outlet temperature (in C)
Average temperature (in C)
Density at avg. temp (in kg/m3)
Sp. heat at avg. temp (in kJ/kg.K)
Volume flow rate (in m3/sec)
Mass flow rate (in kg/sec)
Thermal Capacitance rate, mCp (in W/K)
Heat transfer rate (in kW)
Average heat transfer rate (in kW)
Nusslet number using Eq
Heat transfer coefficient (in kJ/m2. K)
Overall heat transfer coefficient (in kJ/m2. K)

T1 (in C)

T2 (in C)
LMTD
Length of the heat exchanger (in m)