EXPERIMENT: HEAT EXCHANGER

BKF2423 | HEAT TRANSFR

Supervisor: Dr Nor Hanimah Hamidi

SECTION: 03G

1. RUSHDI GAAFAR AHMED BA RAGAA – KA14169

2. MUHAMAD FAEZ BIN LUKMAN – KE13026
3. NURUL NURSHAQIRA BINTI MOHD RAZMAN - KC15166
4. MOHAMMED AHMED OMAR BAHAMT - KA15217
5. RAMZI HASAN ALI SAGHIR QASEM – KA14166
1.0 ABSTRACT

The objectives of the experiment are to calculate and analyse the heat transfer process
at steady state, to study the effect of liquid flow rate on the overall heat transfer coefficient
and heat exchanger effectiveness. Besides, the objective of this experiment is to study the
effect of flow arrangement (co-current and counter current) on overall heat transfer
coefficient and heat exchanger effectiveness. The experiment started by manipulate the effect
of hot water flow rate. The hot and cold water tanks must be filled at least three over four of
water in the tank. The heater was switched on and temperature was set to 50℃. The pumps
and air cooler were switched on when temperature remain constant at 50℃. The air trap in
shell side was released by opening HV14 valve. The cold water flow rate was fixed at 20
LPM and the hot water flow rates were adjusted from 5 LPM, 10 LPM, 15 LPM and 20 LPM.
The system was allowed to reach the steady state. The related data was recorded. The above
steps were repeated by manipulate the cold water flow rate and fixed the hot water flow rate.
This experiment started with the co-current flow and then repeated counter current flow with
same steps. The result showed the higher the flow rate, the higher the overall heat transfer
coefficient except for hot water at counter current flow. Besides, the result from Figure 1.2
show that he higher the flow rate the lower the effectiveness. The overall heat transfer
coefficient for co-current flow was higher compared to counter current flow based on Figure
1.1 In term of flow arrangement, the counter current flow showed have higher effectiveness
compared to co-current flow. In conclusion, the overall heat transfer coefficient increased
when the flow rate increased. While, the highest effectiveness of the heat exchanger can be
obtained by setting the higher flow rate on the shell side and on the tube side the flow rate
must be set to slow.

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 2.0 METHODOLOGY

Experiments: Co-current (Exp1) / Counter current (Exp2) Shell & Tube Heat
Exchanger

The valves were set to co-

¾ of water were filled in
The power supply at the current (Exp1) or counter
the hot and cold water
electrical header and current (Exp2) process as
tank by opening the HV2
equipment panel were in Table 1, and the heater
and/or HV5 valve(s),
switched ON. was switched ON and the
respectively.
temperature was set to
50̊C.

*The effect of hot water stream was studied*

The air trap in shell side

A) HV5 valve was adjusted to obtain
were released by The pumps (P1 and
the desired flowrate for hot water
opening the HV14 valve P2) and the air cooler
(range: 5-20LPM), and the flowrate for
and valve was closed were switched ON
the cold water stream was fixed using
back after the air trap when the temperature
HV15 valve at the same time (one
released. becomes constant at
value of flowrate was set).
50̊C.

B) The system was allowed to reach Steps (A) and (B) were
steady state condition and the related repeated for FOUR
data were recorded. different setting of the
*The effect of cold
hot water flowrate
water stream was
(range: 5-20 LPM).
studied*

A) HV15 valve was

adjusted to obtain the
desired flowrate for cold
Steps (A) and (B) were water (range: 5-20LPM),
B) The system was allowed to
repeated for FOUR different and the flowrate for the
reach steady state condition and
setting of the hot water hot water stream was
the related data were recorded.
flowrate (range: 5-20 LPM). fixed using HV5 valve at
the same time (one value
of flowrate was set).

Pumps (P1 and P2) were switched OFF.

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3.0 RESULT & DISCUSSION

Table 3.1: Effect of Hot Water Stream in co-current flow

Cold water flow rate: 20 LPM
Hot Cold
Flow
Water Water
Rate Hot Water Outlet (oC) Cold Water Outlet (oC)
Inlet Inlet
(LPM)
(oC) (oC)
5 50 39 39 39 39 39 30 34 34 34 34 34
10 50 42 42 42 42 42 30 35 35 35 35 35
15 50 44 44 44 44 44 30 36 36 36 36 36
20 50 46 46 46 46 46 30 37 37 37 37 37

Table 3.2: Effect of Cold Water Stream in co-current flow

Hot water flow rate: 20 LPM
Hot Cold
Flow
Water Water
Rate Hot Water Outlet (oC) Cold Water Outlet (oC)
Inlet Inlet
(LPM) o
( C) (oC)
5 50 47 47 47 47 47 30 40 41 41 41 41
10 50 46 47 47 47 47 30 38 38 38 38 38
15 50 46 46 46 46 46 30 37 37 37 37 37
20 50 46 45 46 46 46 30 36 36 36 36 36

Table 3.3: Effect of Hot Water Stream in counter-current flow

Cold water flow rate: 20 LPM
Hot Cold
Flow
Water Water
Rate Hot Water Outlet (oC) Cold Water Outlet (oC)
Inlet Inlet
(LPM)
(oC) (oC)
5 50 38 38 38 38 38 31 34 34 34 34 34
10 50 42 42 42 42 42 32 34 34 34 34 34
15 50 42 42 43 43 43 32 34 34 34 34 34
20 50 45 45 45 45 45 32 35 35 35 35 35

Table 3.4: Effect of Hot Water Stream in counter-current flow

Hot water flow rate: 20 LPM
Hot Cold
Flow
Water Water
Rate Hot Water Outlet (oC) Cold Water Outlet (oC)
Inlet Inlet
(LPM)
(oC) (oC)
5 50 46 46 46 46 46 32 38 38 38 38 38
10 50 46 46 46 46 46 32 37 37 37 37 37
15 50 46 46 46 46 46 32 36 36 36 36 36
20 50 45 45 45 45 45 32 35 35 35 35 35

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Heat Balance and Efficiency on Hot Water Stream
Heat Load, q h = ṁ h cp (Thi − Tho ) = 0.083 kg/s × 4.179 kJ/kg.K× (323.15K – 312.15K)
=3830.8 W [3]
Heat Absorb, q c = ṁ c cp (Tco − Tci )[3] = 0.083kg/s × 4.178 kJ/kg.K × (307.15K – 303.15K)
=5566.4 W
Heat loss, q = q h − q c = 3830.3 W – 5566.4W = -1735.7 W [4]
Tco−Tci 307.15K−303.15 K)
Heat transfer efficiency of cold water, η = × 100%= x100%
Thi−Tho (323.15 K −312.15K)

= 36.36 % [4]
By assuming that C𝑝,ℎ𝑜𝑡 of water is 4.179 kJ/kg.K and C𝑝,𝑐𝑜𝑙𝑑 of water is 4.178 kJ/kg.K.
Then, we can calculate heat loss and heat absorb by using the above equation. The value of
𝑇ℎ𝑜 , 𝑇ℎ𝑖 , 𝑇𝑐𝑜 and 𝑇𝑐𝑖 was referred from Table 4.2(a) until Table 4.2(d). After that, to
determine the effect of liquid flow rate on overall heat transfer coefficient, we need to use the
heat absorb to proceed by using the formula:
(πODL)–(πIDL) (π(0.014)×1.42−(π(0.011)×1.42
Log mean area= ∆Alm = OD = 0.014 [1]
ln ( ) ln
𝐼𝐷 0.011

=0.05549m²
Total area = ∆Alm x Number of Tube[1]
= 0.05546m2 x 37 = 2.0533 m²
Then calculate log mean temperature difference
(Thi − Tco )– (Tho − Tci )
∆Tlm = [3]
T −T
ln (Thi − Tco )
ho ci
(323.15K−307.15K)−(312.15K−303.15K)
= =12.166 K
ln ((323.15K−307.15K)/( 312.15K−303.15K)

qabsorb
Uo = = 5566.4 W/ 2.0533 m2 x 12.166 K[3]
A ∆Tlm

Where; 𝑈𝑜 = overall heat transfer coefficient

Heat exchanger effectiveness, ε

Ch = (ṁ x Cp) hot = 0.0833kg/s x is 4.1797 kJ/kg.K = 0.3482 kW.K [3]

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 Cc = (ṁ x Cp) cold = 0.3333kg/s x 4.1783 kJ/kg.K = 1.3926 kW.K [3]
Ch (Thi −Tho )
When Cmin =Cc, Effectiveness, ε = [3]
Cc (Thi −Tci )

C (T −T )
When Cmin =Ch , Effectiveness, ε = Cc (Tco−Tci) [3]
h hi ci

Cc (Tco −Tci )
Effectiveness, ε = [3]
Ch (Thi −Tci )

= 1.3926 kW.K (307.15K-303.15K) / 0.3482kW.K (323.15K-303.15K)

= 0.799

Table 4.2(a) Heat load, Heat Absorb, Heat Loss, Effectiveness, Efficiency, Overall heat
transfer coefficients, log mean temperature difference for the Effect of Hot water
stream in Co-Current Flow
Heat Heat Heat Effective 𝑈𝑜 ,
ṁh ṁ c Efficienc
Load, Absorbed, Loss, ness W/m2.K ∆Tlm , K
(kg/s) (kg/s) y, η (%)
qh (J/s) qc (J/s) q (J/s)
0.0833 0.3333 3830.8 5566.4 -1735.7 0.799 36.36 222.8460 12.17

0.1667 0.3333 5572.0 6958.0 -1386.0 0.499 63.50 252.0770 13.44

0.2500 0.3333 6790.9 8349.6 -1558.8 0.399 92.31 295.7989 13.75

0.3333 0.3333 5572.0 9741.2 -4169.2 0.200 57.14 328.3875 14.45

Table 4.2(b) Heat load, Heat Absorb, Heat Loss, Effectiveness, Efficiency, Overall heat
transfer coefficients, log mean temperature difference for the Effect of Cold water
stream in Co-Current Flow
Heat Heat Heat Effective 𝑈𝑜 ,
ṁh ṁ c Efficienc
Load, Absorbed, Loss, ness kW/m2.K ∆Tlm , K
(kg/s) (kg/s) y, η (%)
qh (kJ/s) qc (kJ/s) q (kJ/s)
0.3333 0.0833 4179.7 3743.1 436.6 0.600 27.907 143.1638 12.734

0.3333 0.1667 4528.0 5571.1 -1043.3 0.325 40.625 190.5080 14.243

0.3333 0.2500 5572.9 7312.0 -1739.1 0.267 57.143 246.4959 14.448

0.3333 0.3333 5921.2 8356.6 -2435.4 0.213 70.833 273.9415 14.858

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 Table 4.2(c) Heat load, Heat Absorb, Heat Loss, Effectiveness, Efficiency, Overall heat
transfer coefficients, log mean temperature difference for the Effect of Hot water
stream in Counter-Current Flow
Heat Heat Heat Effective 𝑈𝑜 ,
ṁh ṁ c Efficienc
Load, Absorbed, Loss, ness kW/m2.K ∆Tlm , K
(kg/s) (kg/s) y, η (%)
qh (kJ/s) qc (kJ/s) q (kJ/s)
0.0833 0.3333 4179.7 4178.3 1.4 0.6307 25.0 186.9293 10.887

0.1667 0.3333 5572.9 4178.3 1394.6 0.3154 37.5 152.5068 13.344

0.2500 0.3333 7314.5 4178.3 3136.2 0.2102 42.9 146.3646 13.904

0.3333 0.3333 6966.2 4178.3 2787.9 0.2781 60.0 145.6114 13.976

Table 4.2(d) Heat load, Heat Absorb, Heat Loss, Effectiveness, Efficiency, Overall heat
transfer coefficients, log mean temperature difference for the Effect of Cold water
stream in Counter-Current Flow
Heat Heat Heat Effective 𝑈𝑜 ,
ṁh ṁ c Efficienc
Load, Absorbed, Loss, ness kW/m2.K ∆Tlm , K
(kg/s) (kg/s) y, η (%)
qh (kJ/s) qc (kJ/s) q (kJ/s)
0.3333 0.0833 5572.9 2089.2 3483.8 0.8892 66.67 186.9293 12.97
0.3333 0.1667 5572.9 3481.9 2091.0 0.4446 80.00 152.5068 13.49
0.3333 0.2500 5572.9 4439.4 1133.5 0.2923 94.12 146.3646 14.12
0.3333 0.3333 6966.2 4178.3 2787.9 0.2779 60.00 145.6114 13.98

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4.0 DISCUSSION

The overall heat transfer coefficient depends on the resistance in system. The overall
heat transfer coefficient was higher when the resistance in the system was higher. The
resistance such as fouling factor of fluids, pressure drop, conduction of tubes, conversion of
medium and heat transfer of shell and tubes can affect the overall heat transfer
coefficient.[1]This experiment only consider the heat transfer with conversion between tubes
and shell because the flow rate of water as domino effect to heat transfer between cold and
hot water. The liquid flow rate will affect the overall heat transfer coefficient. This is because
the higher the velocity inside the tubes the higher the overall heat transfer. This is due to the
breaking-down of the inside film coefficient caused by both the turbulence and the sweeping
action. The sweeping action will retard the deposition of contaminants on the inside walls,
usually referred to as fouling.[5] But it will increase the pressure drop and then increased of
pump energy.[1] Next, the effectiveness of a heat exchanger is refer to the maximum heat
transfer rate with the maximum temperature difference. (The temperature difference between
the inlet temperature of the hot stream and the inlet temperature of the cold stream).[4]

The theory dictate that when the flow rate increased, the overall heat transfer
coefficient also increased similar with the results from Figure 1.1. Figure 1.1 showed that the
overall heat transfer coefficients increased when the flow rate increased except for overall
heat transfer coefficient for hot water flow rate at counter current flow. This is because of the
system did not reach steady state yet before the data was recorded. This can occur during the
changing of flow configuration. The cold water inlet for counter current flow was slightly
increased because of the piping of previous cold water outlet was still hot. The hot pipe could
heated up the cold water inlet that cause the anomaly on the overall heat transfer coefficient
for the hot water counter current flow. For the flow arrangement, the overall heat transfer
coefficient for co-current flow was higher compared to counter current flow based on Figure
1.1. Based on theory from reference book, the heat flux is proportional to the driving force
which is ∆T(Th – Tc) [3]. Based on our result, the ∆T for the co-current flow was higher than
compared to counter current flow which caused the overall heat transfer coefficient for co-
current higher than counter current.[2]

Furthermore, the highest effectiveness of the heat exchanger can be obtained by

setting higher flow rate on the shell side and on the tube side the flow rate must be set to slow
flow rate.[1] Similarly, Figure 1.2 showed that the highest effectiveness was obtain at the

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flow rate 5 LPM while the other flow rate was set to constant at 20 LPM. But as the flow rate
is increased the effectiveness of the heat exchanger was dropped drastically. This is because
the flow rate of the operating liquid is almost the same with the heating or cooling fluid
which cause the effectiveness and performance of the heat exchanger decreased. In term of
flow arrangement, counter current flow should have higher effectiveness compared to co-
current. [2]This was showed in Figure 1.2. The effectiveness of cold water stream in counter
current flow arrangement obtain the highest value at 0.89 at 5 LPM, while the lowest value of
effectiveness at 5 LPM was cold water stream in co-current flow was at 0.60. Based on the
result also proved that when maintain the hot water flow rate at 20 LPM and set the cold
water flow rate at 5 LPM, the highest effectiveness was obtained than fixed the flow rate of
cold water.

Overall Heat Transfer Coefficients vs Flowrate and flow arrangement

400.000
Uo, W/m2 .K

300.000
Uhot,co-current
200.000
Ucold,Co-current
100.000
Uhot,Counter
0.000
0 5 10 15 20 25 Ucold,Counter
Flowrate, LPM

Figure 1.1 (Overall Heat Transfer Coefficient versus Flow rate at Atmospheric Pressure)

Effectiveness vs Flowrate and Flow Arrangement

1.000
Effectiveness, ℇ

0.800
0.600 effectiveness,hot-co
0.400 effectiveness,cold-co
0.200 effect,hot-counter
0.000 effect,cold-counter
0 5 10 15 20 25
Flowrate ,LPM

Figure 1.2 (Effectiveness versus Flow rate and Flow Arrangement at Atmospheric Pressure)

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5.0 CONCLUSION

The overall heat transfer coefficient will increase when the flow rate was increased.
This is because higher flow rate will remove inside film coefficient by the turbulence and
sweeping action caused by fast flow rate and also can retard the fouling action inside the tube
and the shell. Based on the Figure 1.1, the higher the flow rate of water the higher the overall
heat transfer coefficient except for the overall heat transfer coefficient for hot water at
counter current flow arrangement. This is because the delta T of the water was deviated from
the standard. These possibly occur during the changes of the flow configuration from co-
current to counter current. The cold water inlet entering the hot piping instrument that
previously run outlet for cold water that ended heated up the inlet cold water that caused the
delta T to deviate from the standard. Figure 1.1 also showed that the co-current flow had
higher overall heat transfer coefficient than counter current. Furthermore, the effectiveness of
the heat exchanger will decrease as the flow rate increase. Based on Figure 1.2 showed that at
flow rate 20 LPM the effectiveness of the heat exchanger was dropped rapidly till the lowest
level for all type of fluid flow and type of flow arrangement. Besides that, Figure 1.2 also
showed that the effectiveness of cold water stream in counter flow arrangement obtain the
highest value at 0.89 when the flow rate at 5 LPM, while the lowest value of effectiveness at
5 LPM was cold water stream in co-current flow was at 0.6. This showed that the counter
current have higher effectiveness than co-current flow similar with the theoretical review.

In order to improve the result of this experiment, the procedure of changing the flow
configuration needs to be changed or wait for the piping system to cold down before
proceeding with the experiments. Because when changing the flow trend some of the water
piping is still hot when it need to run cold water inlet. This can cause anomaly in the data
recorded. Besides that, make sure to wait the instrument to reach steady state before taking
the data. Lastly make sure when taking the temperature compare the temperature reading
from the control panel and the thermometer reading on the piping system.

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6.0 REFERENCE

1. Coulson & Richardson's, Chemical Engineering Vol.6 Chemical Engineering Design

4th Edition, Chapter 8 (Design Information and Data) & Chapter 12(Heat Transfer
Equipment). Oxford: Elsevier Butterworth-Heinemann.

2. Comparison Heat Transfer Types, Engineers Edge.Retrieved from

http://www.engineersedge.com/heat_exchanger/Comparison_heat_exchanger_types.h
tm

3. Christie John Geankoplis, Transport Processes & Separation Process Principles 4th
Edition, Chapter 4 (Principles of Steady State Heat Tranfer). England: Pearson
Education Limited.

4. Practical Thermal Design of Shell-And-Tube Heat Exchangers, FLUID PHYSICS &

ENGINEERING, Series in Thermal & Fluid Physics & Engineering, by Rajiv
Mukherjee, published by Begell House, year of 2004.

5. Engineering Thermo fluids: Thermodynamics, Fluid Mechanics, and Heat Transfer,

by Mahmoud Massoud, illustrated edition, published by Springer, year of 2005.

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