University of Santo Tomas CHE 514L:

Faculty of Engineering Chemical Engineering Laboratory

Department of Chemical 2
Engineering Formal Laboratory Report
Date Performed: 02 Dec 2019
Name: Alli, Daniel Louis G.
Date Submitted: 16 Dec 2019
Section: 5ChE-A Group No: 1 Instructor: Engr. R. M. Pacia, MSc

Experiment B3:
Heat Transfer Analysis in a Shell-and-Tube Heat Exchanger

I. INTRODUCTION
Heat exchangers are heat transfer equipment widely used in the chemical process industries to
allow heat transfer between two fluids without direct contact, hence, no mixing between the two fluids
occurs. Heat exchangers are commonly used in heating or cooling buildings, engines, machines such
as refrigerators, air conditioners, etc. to optimize their functions. [1] Heat is transferred from the hot
stream to the cold stream. There are two (2) common fluid flow arrangements through the heat
exchanger used in designing a heat exchanger for simplification: co-current (or parallel flow) and
countercurrent flow. Both the hot and cold fluid enters the heat exchanger parallel to each other, while
in the countercurrent flow, the fluid enters the heat exchanger on opposite sides.[2] A corresponding
temperature profile is used to represent the temperature change in the system for both arrangements.

Fig. 1 Co-current Flow Arrangement Fig. 2. Countercurrent Flow Arrangement

The objectives of this experiment are to demonstrate the differences between countercurrent
flow and co-current flow and the effect on heat transferred and temperature difference, and to
determine the overall heat transfer coefficient for a tubular heat exchanger using log mean temperature
difference to perform the calculations for co-current and countercurrent flows.

II. METHODOLOGY
Before starting with the experiment, preliminary checking is required. The main switch should
be turned off. The emergency stop button on the front panel should be set in the stop position. Next,
the HT30XC should be connected to the electricity supply and check if the RCDs on the back panel
are switch on with the levers in the up position. The equipment is then connected to the PC through
Experiment B#: Title

the USB port and enable the USB virtual serial COM port in the PC. After connecting all necessary
connections, the main switch should now be turned on and the “enabled” light should illuminate
indicating that the unit is powered on. The emergency stop button should be released. Run the Armfield
HT30XC software and choose the counter-current operation option from the start-up screen then go
to the diagram screen where a message that should say “IFD: OK” at the bottom right corner of the
screen. When the computer was connected to the HT30XC, the red and green USB status LEDs on
the front panel should both be illuminated. On the computer screen click the “power on” switch. The
green “run” light on the front of the HT10XC should illuminate. The pressure regulator is set to minimum
by turning the knob anticlockwise. The flowrate of the cold water was controlled using the software
and was set to 100%. The flowrate of the cold water was then gradually increased by turning the knob
clockwise to 3 L/min. When the flowrate is correct, the grey knob should be pushed to lock the setting
then the flowrate was set to 0%.

For the start-up, the lid of the hot water vessel was removed then filled with clean water up to a
level approximately 20 mm from the top. The low-level indication in the software should not be
activated and the in-line isolating valves were both fully open. The hot water flow “flow” button on the
PID controller was turned on. The pump speed was set to 50% in the software and let run until all air
bubbles were displaced from the flexible tubing into the hot water vessel.

For the both the co-current and countercurrent experimental procedure, using the temperature
controller, the temperature was set to 60oC and using the hot water circulator when using the HT30X.
The flowrate of the cold water was set to 1 L/min using the cold water valve or the Vhot setting of the
hot water flow was set to 2 L/min. Once the temperatures were stable, the values of T1, T2, T3, T4,
Fhot, and Fcold were noted.

Fig. 3. Set-up of the experiment

For the shutdown procedure, the COM session was stopped, and the USB connection was
disconnected. Both the PC and the equipment were turned off as well as the main circuit breaker at
the back of the equipment. The water from the tank was drained. Lastly, the equipment was unplugged
from the outlet.

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Experiment B#: Title

III. RESULTS AND DISCUSSION

Table 1. Co-current Flow Data

Number T1 (°C) T2 (°C) T3 (°C) T4 (°C) Fhot (L/min) Fcold (L/min)

196 60.30 54.60 27.70 34.80 2.01 1.11
197 60.50 54.70 27.70 34.80 2.00 1.11
198 60.60 54.80 27.70 34.90 2.00 1.11
199 60.70 54.90 27.70 34.90 2.00 1.11

Temperature Profile - Co-current Flow

70.0
60.0 60.70
Temperature (°C)

54.90
50.0
40.0
34.90
30.0 27.70 Thot
20.0
Tcold
10.0
0.0
0 0.2 0.4 0.6 0.8 1
Time

Fig. 4. Temperature Profile of Co-current Flow Arrangement

Table 2. Countercurrent Flow Data

Number T1 (°C) T2 (°C) T3 (°C) T4 (°C) Fhot (L/min) Fcold (L/min)

54 56.60 59.00 27.60 34.90 2.00 1.07
55 56.30 58.80 27.50 34.90 2.00 1.07
56 56.50 59.20 27.50 34.90 2.00 1.07
57 56.60 59.00 27.60 34.90 2.00 1.07

Temperature Profile - Countercurrent Flow

70.0
60.0 59.00
Temperature (°C)

56.60
50.0
40.0
34.90
30.0 27.60 Thot
20.0 Tcold
10.0
0.0
0 0.2 0.4 0.6 0.8 1
Time

Fig. 5. Temperature Profile of Countercurrent Flow Arrangement

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Experiment B#: Title

Table 3. Data Summary of Samples

Co-current Countercurrent
Thot, oC -5.80 -2.40
Tcold, oC 7.20 7.30
TLM, oC 25.96 26.47
h 17.58% 7.64%
c 21.82% 25.17%
m 19.70% 16.41%
U, kW/m2-K -1.8076 -0.7261

To demonstrate the differences between countercurrent flow and co-current flow and the effect
on heat transferred and temperature difference, Table 1 and Table 2 shows the sample data obtained
from the experiment for co-current flow and countercurrent flow respectively. The final value where the
data is constant was used in the calculations the overall heat transfer coefficient for a tubular heat
exchanger using log mean temperature difference. The log mean temperature difference can be
calculated using the given temperature profile in the figures above. A countercurrent flow arrangement
will be more favorable in this experiment as it shows a lower change in temperature compared to a co-
current flow arrangement as a co-current flow arrangement induces thermal shock on the fluid since
the temperature difference between the entering fluids are too high. The temperature difference is also
a factor that could affect the heat transfer rate. From the summary of data (see Appendix for
calculations), it can be determined that using a countercurrent flow arrangement will be more favorable
as it has a lower heat transfer rate (negative sign indicates a loss of heat). However, the value of the
mean temperature efficiency of a countercurrent flow arrangement is less than the co-current flow
arrangement.

IV. ANSWERS TO QUESTIONS

1. What is the essence of determining the temperature difference (i.e. LMTD) and their
efficiencies?
- The log mean temperature difference is used to determine the driving force in any heat transfer
calculations involving two (2) fluids.[3] It is the logarithmic average of the temperature difference
between the fluids. It is also a determining factor for the overall heat transfer. The larger the LMTD,
the larger the heat transfer rate. It is used for the calculation of OHTC.
- The temperature efficiency is the ratio between the actual and the ideal heat transferred in a
system. It is used in selecting a heat exchanger. It determines which is the best design for a certain
type of a heat exchanger.[3]

2. Based on the results of the experiment, discuss the factors that affect the OHTC.
- The overall heat transfer coefficient refers to how effective a material is as an insulator. It is
the rate of heat transfer through a material divided by the log mean temperature difference of the heat
exchanger.[4] The more effective the material used as an insulator, the lower the OHTC. Some factors

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Experiment B#: Title

that affect the OHTC based on the experiment are the flow arrangement, the log mean temperature
difference, and the temperature of the inlet hot stream.

3. What is the essence of calculating the OHTC?

- The OHTC plays a big role in designing a heat transfer equipment. The OHTC estimates the
heat surface area required from heat transfer, the material to be used, the cost of the whole equipment,
and in determining the performance of the equipment.[5]

V. CONCLUSION
In this experiment, a shell-and-tube heat exchanger was used to determine the difference
between countercurrent flow and co-current flow arrangement and their effect on the heat transferred
and temperature difference. Based on the results shown in the temperature profile, co-current flow had
a lower temperature difference compared to countercurrent flow. This temperature difference was then
used to calculate for the overall heat transfer coefficient for both arrangements. The mean temperature
efficiency was also calculated. Comparing the experimental data from accepted literature, it can be
determined that the results are unreliable as literature says that a countercurrent flow arrangement
should have a greater efficiency compared to a co-current flow arrangement hence should give a better
overall heat transfer rate. This error may be due to the flowrate supplied to the heat exchanger. Ideally,
the flowrate supplied should be constant, however, for this experiment, it is not since the water source
was from a tap which has a single line connected over the whole laboratory which other students were
using, hence, reducing or increasing the water supply to the heat exchanger. To possibly reduce errors,
it is recommended to have a water source that is specifically for the use of this experiment alone.

VI. REFERENCES

1. How heat exchangers work? (2018, December 8). Retrieved December 15 2019, from
https://www.explainthatstuff.com/how-heat-exchangers-work.html
2. Thermal Analysis of a Steady State Heat Exchanger, Subramanian, R. S. (n.d.). Retrieved
December 15, 2019, from https://web2.clarkson.edu/projects/subramanian/ch330/notes/Thermal%
20Analysis%20of%20a%20Steady%20State%20Heat%20Exchanger.pdf
3. What is LMTD? (2010). Retrieved December 15, 2019, from https://www.industrialheating.com/
blogs/14-industrial-heating-experts-speak-blog/post/89862-what-is-lmtd
4. What is a U-value? (2015, February 1). Retrieved December 15, 2019, from https://www.thenbs.com
/knowledge/what-is-a-u-value-heat-loss-thermal-mass-and-online-calculators-explained
5. Why do we want to find the heat transfer coefficient? (2018, June 25), Retrieved December 15,
2019, from http://quora.com/why-do-we-want-to-find-the-heat-transfer-coefficient

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APPENDIX

Fig. 6. Raw data for Co-current Flow Arrangement

Fig. 7. Raw data for Countercurrent Flow Arrangement

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Fig. 8. Nomenclature and Equations used for Countercurrent Flow Arrangement

Fig. 9. Treatment of Raw Data for Countercurrent Flow Arrangement

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Fig. 11. Nomenclature and Equations used for Co-current Flow Arrangement

Fig. 12. Treatment of Raw Data for Co-current Flow Arrangement

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