HEAT TRANSFER

(BKF 2423)
REPORT:
HEAT TRANSFER STUDY ON SHELL AND
TUBE HEAT EXCHANGER

GROUP MEMBERS:

NO. NAME ID NO.

1. NURUL SUHANA BINTI JAMALUDDIN KA16034
2. DURAR AMANI BINTI ZULKARNAL KA16050
3. RHAKESH A/L GANDHI KA15133
4. TANG GAO HAN KA16078
5. NADZIRAH ASMIDAH BINTI ROSLAN KA16161
6. NUR SYAHIRAH BINTI JUHARI KA16066

DATE OF SUBMISSION

2 MAY 2018

1
 ABSTRACT

This experiment is to calculate and analyse the heat transfer process at steady state in a shell
and tube heat exchanger. This experiment is also to study the effect of liquid flow rate on the
overall heat transfer coefficient and heat exchanger effectiveness and to study the effect of
flow arrangement in co-current and counter current on overall heat transfer coefficient and
heat exchanger effectiveness. This experiment consists of two parts which are co-current flow
and counter current flow. Generally, all steps for both parts of the experiment are the same
except for certain valves that are need to be opened or closed based on Table 1 given in the
manual to differentiate co-current or counter current flow. To study the effect of hot water
stream, the flowrate for cold water stream need to be fixed then four different flow rates of
hot water is set to allow the system to reach steady state and vice versa for both parts of
experiment. Finally, all data were recorded. For co-current flow, the highest overall heat
transfer, U (165.1590 W/m2.℃) is when the mass flow rate of hot water at
0.2667 kg/s and the flow rate of cold water is constant at 0.4000 kg/s
however the highest U (223.8900 W/m 2.℃) obtained is when the mass
flow rate of cold water is 0.5333 kg/s and the flow rate of hot water is
remain at 0.4000 kg/s. For counter current flow, the highest U (169.4702
W/m2.℃) is when the cold water flow rate is constant at 0.4000 kg/s and
the flow rate of hot water is 0.4000 kg/s however the highest U (189.1475
W/m2.℃) obtained at 0.5333 kg/s flow rate of cold water and the flow rate
of hot water is remain constant at 0.4000 kg/s. In conclusion, the effect of
hot water of 0.1333 kg/s flow rate on counter current flow and the flow
rate of cold water is constant at 0.4000 kg/s is the most effective since it
is recorded has the highest effectiveness of 0.4468 .

2
 METHODOLOGY

Table 1: Valve arrangements for Shell & Tube Heat Exchanger

FLOW QUARTERLY LEAVE

OPEN CLOSE
ARRANGEMENT OPEN ALONE
HV1, HV3, HV6, HV2, HV7,
Co- Current HV4, HV9 HV5, HV15
HV11, HV13 HV10, HV12
HV1, HV3, HV6, HV2, HV7,
Counter Current HV4, HV9 HV5, HV15
HV8, HV10, HV12 HV11, HV13

3
 RESULT AND DISCUSSION

Heat Exchanger Layout:

Type : 1-1 Number of tubes : 37

Length of tube : 1.42 m Shell diameter : 0.150 m
Tube ID : 0.011 m Baffle length : 0.284 m
Tube OD : 0.014 m Density of water : 1000 kg/m3
Tube surface area : 0.0491 m2 Heat capacity of water cold, Cp : 4183
J/kg.℃
Heat Capacity of water hot, Cp ; 4185
J/kg.℃

Calculation:

i) Area=NπDL=(37)(π )(0.014 m)(1.42 m)=2.311m2

1 m3
ii) Mass flow rate , ṁ= 8 ( L
min )( kg
1000 3
m )( 1000 L )( 160mins )=0.1333 kgs
iii) Heat load ,q h=( ṁC p )h ( T hi−T ho )

kg J
(
¿ 0.1333
s )(
4185
kg . ℃ )
( 48.60℃−40.72℃ )=4397.0400 W

iv) Heat absorb , q c =( ṁC p ) c ( T co−T ci )

kg J
(
¿ 0.1333
s
4183)(
kg . ℃ )
( 32.66 ℃−29.00℃ )=2041.3040 W

v) Heat loss=heat load −heat absorb=2355.7360 W

T hi −T ho ( 48.60 ℃−40.72℃)
vi) Efficiency= ×100 = × 100 =40.2041
T hi −T ci ( 48.60 ℃−29.00 ℃)

vii) log meantemperature for co−current , ∆ T lm ,

( T hi−T ci ) −(T ho−T co ) ( 48.60−29.00 )−(40.72−32.66)

¿ = =12.9865 ℃
(T −T ci ) (48.60−29.00)
ln hi ln
(T ho−T co ) (40.72−32.66)

viii) log mean temperature for counter current , ∆ T lm ,

4
 ( T hi−T co ) −(T ho−T ci ) (50.30−34.28 )−(41.60−30.40)
¿ = =13.4665℃
(T −T co ) (50.30−34.28)
ln hi ln
(T ho−T ci ) (41.60−30.40)

ix) Overall heat transfer coefficient ,U

qload 4397.0400 W W
¿ = 2
=146.5105 2
A ∆T lm (2.311 m )(12.9865 ℃) m .℃

x) Heat exchanger effectiveness , ε for co−current

([ −UA
C ) ( C )]
C min
1−exp ∙ 1+
min max

[( )]
W

)(
−(146.5105 )×2.311 m2 J
2 557.8605
m ∙℃ s ∙℃
¿ 1−exp ∙ 1+ =0.4161
J J
557.8605 1673.2
s ∙℃ s∙℃

xi) Heat exchanger effectiveness , ε for counter current

1−exp
[( ) ( ) ]
−UA
C min
C
∙ 1+ min
C max

1−
C min
C max
∙exp
[( ) ( )]
−UA
Cmin
C
∙ 1+ min
C max

[( )]
W

)(
−(155.9903 )∙ 2.311 m2 J
2 557.8605
m ∙℃ s ∙℃
1−exp ∙ 1+
J J
557.8605 1673.2
s∙℃ s ∙℃
¿

[( )]
J W J

)(
557.8605 −(146.5105 2 )× 2.311 m2 557.8605
s∙℃ m ∙℃ s∙℃
1− ∙ exp ∙ 1+
J J J
1673.2 557.8605 1673.2
s∙℃ s∙℃ s ∙℃

¿ 0.4468

5
 (A) Co-current Flow

Table 2: Effect of Hot Water Stream in co-current flow

Cold water flowrate : 24 LPM

Flow Rate Hot Water Hot Water Cold Water Cold Water
(LPM) Inlet (℃) Outlet (℃) Inlet (℃) Outlet (℃)
8 48.6 40.72 29 32.66
16 49.4 44.24 29.2 33.32
24 48.9 46.22 29.4 34.02
32 49.5 47.4 29.7 35.26

Mass Overall
Flow Heat Efficien Heat Effectiven
Rate Heat Load Absorb Heat Loss cy ∆Tlm Transfer ess
(kg/s) (W) (W) (W) (%) (℃) (W/m2.℃)
4397.040 2041.30 2355.736
0.1333 0 40 0 40.2041 12.9865 146.5105 0.4161
5758.560 4595.72 1162.837
0.2667 0 27 3 25.5446 15.0873 165.1590 0.2606
-
4486.320 7730.18 3243.864
0.4000 0 40 0 13.7436 15.5658 124.7155 0.1457
-
4687.200 12403.9 7716.789
0.5333 0 893 3 10.6061 15.6590 129.5239 0.1536

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 Table 3: Effect of Cold Water Stream in co-current flow

Hot water flowrate : 24 LPM

Flow
Rate Hot Water Hot Water Cold Water Inlet Cold Water
(LPM) Inlet (℃) Outlet (℃) (℃) Outlet (℃)
8 49.4 47.68 29.7 39.02
16 49.9 47.22 29.9 36.58
24 49.2 46.66 30.1 35
32 50.4 46.72 30.4 34.36

Mass Overall
Flow Heat Heat Efficienc Heat Effectiven
Rate Load Absorb Heat Loss y ∆Tlm Transfer ess
(kg/s) (W) (W) (W) (%) (℃) (W/m2.℃)
-
5198.074 4238.314
0.1333 959.7600 7 7 8.7310 13.4322 30.9182 0.1178
-
2990.880 7451.317 4460.437
0.2667 0 3 3 13.4000 14.8310 87.2629 0.1561
-
4251.960 8198.680 3946.720
0.4000 0 0 0 13.2984 15.0753 122.0463 0.1431
8213.760 8834.496 -
0.5333 0 0 620.7360 18.4000 15.8748 223.8900 0.2387

(B) Counter-current Flow

Table 4: Effect of Hot Water Stream in counter-current flow

Cold water flowrate : 24 LPM

Flow Hot Water

Rate Hot Water Outlet Cold Water Cold Water Outlet
(LPM) Inlet (℃) (℃) Inlet (℃) (℃)
8 50.3 41.6 30.4 34.28
16 50.5 45.52 30.5 35.02
24 50.3 46.72 30.8 35.6
32 50 47.66 31 36.44

Mass Heat Heat Absorb Heat Loss Efficien ∆Tlm Overall Effectivene
Flow Load (W) (W) cy (℃) Heat ss

7
 Rate Transfer
(kg/s) (W) (%) (W/m2.℃)
0.1333 4854.6000 2164.0053 2690.5947 43.7186 13.4665 155.9903 0.4468
0.2667 5557.6800 5041.9093 515.7707 24.9000 15.2488 157.7091 0.2565
0.4000 5992.9200 8031.3600 -2038.4400 18.3590 15.3019 169.4702 0.1810
0.5333 5222.8800 12136.2773 -6913.3973 12.3158 15.0569 150.0984 0.1755

8
 Table 5: Effect of Cold Water Stream in counter current flow

Hot water flowrate : 24 LPM

Flow Rate Hot Water Hot Water Cold Water Inlet Cold Water
(LPM) Inlet (℃) Outlet (℃) (℃) Outlet (℃)
8 49.7 47.96 31 39.28
16 50.4 47.32 31.1 37.38
24 50.1 46.92 31.3 36.2
32 49.5 46.64 31.5 35.42

Mass Overall
Flow Heat Efficienc Heat Effectiven
Rate Load Heat Absorb Heat Loss y ∆Tlm Transfer ess
(kg/s) (W) (W) (W) (%) (℃) (W/m2.℃)
-
970.920 3647.112
0.1333 0 4618.0320 0 9.3048 13.4256 31.2933 0.1193
-
3437.28 3567.850
0.2667 00 7005.1307 7 15.9585 14.5614 102.1434 0.1798
-
5323.32 2875.360
0.4000 00 8198.6800 0 16.9149 14.7433 156.2386 0.1775
-
6383.52 2361.738
0.5333 00 8745.2587 7 15.8889 14.6036 189.1475 0.2125

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Overall heat transfer coefficient vs mass flow rate of water Effectiveness vs Water Flowrate
250 0.5
0.45
200 0.4
0.35

Effectiveness
150 0.3
2.℃)

0.25
cient, U(W/m

100 0.2
0.15
Overall heattransfercoef

50 0.1
0.05
0 0
0.13 0.27 0.4 0.53 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5 0.55 0.6

Mass flow rate (kg/s) Water Flowrate(kg/s)

Hot stream, co-current Hot Stream, Co-Current

Cold stream, co-current Col d Stream, Co-Current
Hot stream, counter current Hot Stream, Counter Current
Cold stream, counter current Col d Current, Counter Current

Graph A Graph B

Based on the Graph A, the overall heat transfer coefficient decreased when cold water
flowrate is constant and hot water flowrate is increasing. However, the overall heat transfer
coefficient constantly increases when hot water flowrate is constant and cold water flowrate
is increasing. This is because the water flow through the tubes is staying laminar therefore
making the overall heat transfer coefficient more constant.[ CITATION Dav00 \l 17417 ] But
when cold water flowrate is constant, the overall heat transfer coefficient increase with hot
water flowrate is increasing but decrease after 0.4 kg/s. The reason for this is believed to be
caused from the baffles within the shell in the heat exchanger, when the flow increases so
much the baffles start to make the flow turn more turbulent then laminar, so the overall heat
transfer coefficient changes.[ CITATION Dav00 \l 17417 ] However, the overall heat transfer
coefficient constantly increases when hot water flowrate is constant and cold water flowrate
is increasing. This is because the water flow through the tubes is staying laminar therefore
making the overall heat transfer coefficient more constant.[ CITATION Dav00 \l 17417 ]
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11
Based on the Graph B, the effectiveness of the hot water constant flowrate had similar lines.
There is no significant effect on manipulating any of the co current flowrate because of the
log mean temperature differences were nearly same. While, the effectiveness of the hot water
constant flowrate had similar lines but both are decreasing.

When the hot water flow is constant, the effectiveness increases along with cold water
flowrate. Although the value of effectiveness fluctuates, the straight line plotted still goes
with the theory. Based on the theory, since the capacity coefficient of hot or cold water
increases with its flow rate, this will then increase the effectiveness.[ CITATION Chr03 \l
17417 ]

However, the effectiveness decreases with the increase of hot water flowrate for both co-
current and counter-current flows. This is because when the hoy water flow rate is higher
than that of cold water, this gives a minimum capacity coefficient of hot water compared to
the cold water with the maximum capacity coefficient. Hence, the increase of hot water flow
rate leads to the increase in the Cmin which is in the denominator resulting in lower
effectiveness. [ CITATION Kis16 \l 17417 ]

Based on all graph above, the overall heat coefficient and the effectiveness of heat transfer
obtained are higher in the counter-current configuration than that in the co-current
configuration. This is because the counter-current flow had higher temperature difference
which produce more uniform rate of heat transfer. In contrast, for the co-current flow, the
temperature is not generally constant but varies with length of tube. [ CITATION Par \l 17417
]

REFERENCES

1. Geankoplis, C. J. (2003). Transport Processes and Separation Process Principles (Includes Unit
Operations) Fourth Edition. Prentice Hall.

2. Kishk, M. A. (2016). Characteristics and performance of heat and mass flowrate in LPG.
International Journal of Advanced Scientific and Technical Research.

3. Parallet and Counter FLow Design. (n.d.). Retrieved from Engineers Edge:
https://www.engineersedge.com/heat_transfer/parallel_counter_flow_designs.htm

4. Vaughn, D., & Ware, T. (2000). Heat Exchanger Analysis.

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13
 CONCLUSION

The objectives of this experiment are to calculate and analyze 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 and to study the effect of flow arrangement (co-
current and counter current) on overall heat transfer coefficient and heat exchanger
effectiveness are achieved. Based on the experiment, the highest overall heat transfer
coefficienr achieved on cold water stream in co-current flow which is 223.89000 W/m 2.°C
and its effectiveness value is 0.2387. However, the highest effectiveness is achieved in hot
water stream in counter current flow is 0.4468 when the overall heat transfer coefficient is
155.9903 W/m2.°C. Therefore, counter-current flow is more effective than co-current flow
based on this experiment. The effectiveness becomes higher when the temperature change is
also higher.

There are some recommendations that can be taken in order to improve the
experiment. Firstly, we need to ensure that there is no air bubbles in the tube during the
experiment to get an accurate data, so the air bubbles need to be released before start doing
the experiment by opening the air trap valve, as it can reduce the surface area for heat
transfer. Besides, it is recommended that the shell and tube heat exchanger have alert sign or
alarm that can give a sign to take the readings at the correct time. It is also recommended that
the shell and tube heat exchangers be well insulated to prevent heat loss to the surrounding.

REFERENCES

Geankoplis C.J. (2003); Textbook Transport Processes & Separation Process Principles: Heat
Exchanger, 4TH Edition.

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