1.

0OBJECTIVES
• To evaluate and study the performance of the shell and tube heat exchanger at various
operating conditions.

• To determine the heat load, log mean temperature difference (LMTD), overall heat transfer
coefficient U.
2.0SUMMARY
This experiment was conducted to evaluate and study the performance of the shell and tube heat
exchanger heat load and heat balance, LMTD, overall heat transfer coefficient, Reynolds shell
side and tube side, heat transfer coefficient and pressure drop at shell side and tube side. Every
run will be using different flow rate. From the result, the pressure drop depends on the flow rate
not the temperature. Heat exchanger is a device that are design to transfer or exchange heat from
one matter to another in efficiently. There are several types of heat exchanger and one of it that
are mostly use in industrial applications is a shell and tube heat exchanger. Fluids that flow in
this device are in counter-current flow where two fluids flow against each other, maintaining a
maximum temperature difference between the hot and cold streams which allows for maximum
heat transfer. We assumed that internal, potential and kinetic energy was negligible in this
process, so QH must be equal to QC. In experiment 1, FT1 was constant at 10LPM. The highest
efficiency of heat transfer was 99.58% at FT1=10 and FT2=6. It means that heat transfer occur
efficiently at equal volumetric flowrates of hot and cold water. the results was different than the
basic theory where the amount of heat release by hot water was not equal to the amount of heat
absorb by cold water, QH ≠ QC due to some errors and the recommendation and precautions were
made to improve this experiment.
3.0INTRODUCTION
Shell-and-tube heat exchangers are commonly used in oil refineries and other large-scale
chemical processes. Heat exchanger is a device that are design to transfer or exchange heat from
one matter to another in efficiently. It means that matter that release heat will decrease in
temperature while the other matters that gain heat will increase in temperature. A heat exchanger
is a device that is used to transfer thermal energy between two or more fluids, between a solid
surface and a fluid a fluid, or between solid particulates and a fluid at different temperatures and
in thermal 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).

Heat exchangers can be in cross-flow, parallel-flow or countercurrent. Cross flow is the

flow where the cold and the hot fluid flow axis is at an angle to each other. Hence, the fluids will
cross each other in this arrangement. Mostly, this type of flow has the angle between axes as 90
degree. 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.

Heat exchangers are classified according to transfer process, number of fluids, degree of
surface contact, design features, flow arrangements and heat transfer mechanism. Several design
parameters and operating conditions influence the optimal performance of a shell-and-tube heat
exchanger. The main purpose of this model is to show the basic principles for setting up a heat
exchanger model. It can also serve as a starting point for more sophisticated applications, such as
parameter studies or adding additional effects like corrosion, thermal stress, and vibration. .
There are several types of heat exchanger and one of it that are mostly use in industrial
applications is a shell and tube heat exchanger.
 Figure 1: Shell and tube heat exchanger

It contain a large number of tubes (sometimes several hundred) packed in a shell with their axes
parallel to that of the shell. Heat transfer takes place as one fluid flows inside the tubes while the
other fluid flows outside the tubes through the shell. Shell-and-tube heat exchangers are further
classified according to the number of shell and tube passes involved.
4.0PROCEDURES

Preparation procedures are run before conductiong the machine. Tank T1 and T2 are filled
to their max level and the main power supply to Model HE12 are switched ON. Discharge valve
(HV) are fully shut and by-pass valve (BVH) are fully opened at tank T1. HW pump PH are
started for the water to recirculate around tank T1 and the suction valve of pump PH are remain
opened all the time. Heater are switched ON and the water in tank T1 are left to be heated until
70oC(see TIC5). While waiting for the water to be heated, the preparation procedures for CW
system are run. All CW pumps (PC1,PC2), by-pass valve (BVC1,BVC2) and discharge valves
(CV1,CV2) are checked to make sure it is all opened. The external water supply to tank T2 are
checked also and CW pumps PC1 and PC2 need to make sure is OFF. BVC1, BVC2, the manual
by-pass valves of the CW pumps are fully opened and CW pump whose suction is from tank T2
is switched ON. The manual discharge valve CV1 are fully opened and BVC1 is fully shut for
maximum the CW flowrate FC to the HEX.

After running the preparation procedures, we move onto the experiment. For the first run,
you need to start-up the HW system. The hot water tank T1 is filled with water until up to its
overflow drain pipe level. HW discharge valve are shut and manual by-pass valve (BVH) are
opened and the pumps are started for the water to circulate. The heater started and note the high
rise in temperatureat tank T1. While the BVH fully shut, HW flowrate are adjusted to 10
USGPM at manual discharge valve HV. Next, the CW start up procedure is the CW pumps PC1
and PC2 are switched on and BVC1 and CV is fully shutted. Then, the CW flowrate are adjusted
to 6 USGPM. After that, results are recorded.

After run 1 is finished, all CW pumps PC1 and PC2 are to be stopped but the heater
needs to stay ON for the next run. The DP Selector Switch are switched to Equalizing. After that,
run 2,3 and 4 are conducted and the results are to be recorded.
5.0RESULT/DISCUSSION

RUN1 HW, FH: 10 USGPM CW, FC: 6 USGPM

RUN2 HW, FH: 10 USGPM CW, FC: 10 USGPM

RUN3 HW, FH: 15 USGPM CW, FC: 10 USGPM

RUN4 HW, FH: 20 USGPM CW, FC: 10 USGPM

 RUN 1 RUN 2 RUN 3 RUN 4
cw hw cw hw cw hw cw hw

Norminal 𝑚3 𝑚3 : : : : : :
FC: 1.36 ℎ𝑟 FC: 2.27 ℎ𝑟
𝑚3 𝑚3 𝑚3 𝑚3 𝑚3 𝑚3 𝑚3
flow: ℎ𝑟 : 6 USGPM : 10 USGPM 2.27 ℎ𝑟 2.27 ℎ𝑟 2.27 ℎ𝑟 3.41 ℎ𝑟 2.27 ℎ𝑟 4.54 ℎ𝑟
: USGPM :10 :10 :10 :15 :10 : 20
Actual flow: USGP USGP USGP USGP USGP USGP
𝑚3 M M M M M M
ℎ𝑟
: USGPM

Temp, ℃/F, T13: T1: 21 T11: t1: 66.6 T1: 29 t1: 64.7 T1: 32 t1: 66.5 T1:35 t1:
inlet T14: T2: 50.7 T12: t2: 50.0 T2: t2: 46.9 T2: 50 t2: 52.2 T2: 66.8
Temp, ℃/F, 45.1 54.5 t2:
outlet 56.1

Pressure, psig, PG-C: 7 PG-H: 2 : 11 :2 : 12 :8 : 12 : 16

inlet
Pressure drop, DP (shell): DP(Shell): : 1054 : 1276 :1251 : 2302 : 1264 : 4110
mm 𝐻2 𝑂 417 1016
Calculate:
Temp T2-T1: 23.7 t1-t2: 16.6 : 16.1 : 17.8 : 18 : 14.3 : 19.5 : 10.7
change,℃/F
Average temp, 𝑇2+𝑇1 𝑡1−𝑡2 : 37.05 : 55.8 : 41 : 59.35 : 44.75 : 61.45
: 38.85 : 58.3
2 2
℃/f

Q, head load, QC: QH: QC: QH: QC: QH:

QC: 127.7 QH: 149.29
BTU/hr 144.8 160.1 161.9 193.2 175.4 192.5

Compute ratio: 𝑄𝐶 𝑄𝐶 𝑄𝐶 𝑄𝐶
: 0.86 : 0.9 : 0.84 : 0.91
𝑄𝐶 𝑄𝐻 𝑄𝐻 𝑄𝐻 𝑄𝐻
𝑄𝐻

Select set 1 or Set 1 is selected/ not selected Set 2 is selected/ Set 3 is selected/ Set 4 is selected/
set2 or set3 not selected not selected not selected
on the best
convergence
of QC and
QH i.e QC is
nearest to 1
For selected Not selected Not selected Not selected selected
set, compute
0.5 (QC+QH),
BTU/HR
The purpose of the experiment was to evaluate and to learn the performance of the shell and tube
heat exchanger at various operating conditions and determine the head load, log mean
temperature difference (LMTD), overall heat transfer coefficient U. As established, the heat
exchanger function is to add or remove heat to the cold fluid and either parallel or counterflow is
the direction of the fluid in the heat exchanger. Fluids moving in the same direction are known as
parallel flow, whereas liquids moving in the reverse direction are known as counter flows.

The experiment was began with run 1 before that there are 4 run and each run have
different nominal flow. Run 1 began with 6 USGPM and 10 USGPM for cold and hot water. For
run 2 10 USGPM was set for hot and cold water, then run 3 the cold water were maintained 10
USGPM and for hot water 15 USGPM also run 4 the cold was still the same 10 USGPM and the
hot water was 20 USGPM. The result for each run was named as set 1, set 2, set 3, set 4. The
temperature for each run were set to 70℃, It is also crucial to equalize in between changing the
DP. Other than that the temperature inlet and outlet for hot and cold water were taken. Moreover
outlet and inlet temperature set 1 cold water, were 27℃ and 50.7℃. for hot water were 66.6℃
and 50.0 ℃. For set 2 cold were 29℃ and 45.1℃ also hot water were 64.7℃ and 46.9℃. also
for set 3 were 32℃ and 50.0℃ and hot water were 66.5℃ and 52.2℃. lastly for run 4 cold 35℃
and 54.5℃ and hot water 66.8 and 56.1.

Based on the result, it can concluded that run 4 (0.91 KJ/HR) is the selected run because
the result were calculated and have the nearest number to 1. This is based on the QC and QH that
have been calculated. Followed by run 2 than run 1 the last is run 3. Theoretically, warm water
heat must be equivalent to cold water heat absorbing. That is QH= QC, assuming that inner,
kinetic and potential power is insignificant. (Wikiversity,2014). In this experiment, however,
QHQQC may be due to some of the blunders that occurred during this experiment. The surfaces,
for example, can also be gradually eroded by fluid and the subsequent erosion products stored on
the surfaces.

In the sense of time management and better outcome, there are several ways to improve the
quality of the experiment. First, make sure that the equalize is also chosen when altering the DP
range. This is because setting the DP reading to 0 is the equalizing feature. Secondly, ensure that
the purge airlock button is pressed during the experiment and that the reading is continuous when
the button is released. This is to ensure accurate reading within the exchanger. As known air
within the machine can affect the experiment's inaccurate reading, releasing the air is the right
thing to do. Finally, when setting the machine's nominal flow reading, be sure to set it correctly
as it may also defect your entire result in the experiment and take more than one reading if
possible so that the result is more specific and accurate.

CALCULATIONS
1. Changing volumetric flow rate to mass flow rate using formula 𝑚̇= ρ𝑄̇

With ρ = 998kg/m3

Volumetric flowrate, 𝑄̇ , m3/hr Mass flow rate, kg/hr

1.36 1357.28
2.27 2265.46
3.41 3403.18
4.54 4530.92

2. Changing temperature from °C to K using formula : K= °C + 273.15

∆T = Temperature Change, T2-T1

℃ K
27 300.15
50.7 323.85
66.6 339.75
50 323.15
64.7 337.85
46.9 320.05
66.5 339.65
35 308.15
3. Calculating QC and QH
SET 1 SET 2
𝐾𝐺 𝐵𝑇𝑈 𝑘𝑔 𝐵𝑇𝑈
QC: 1.36 ℎ𝑟 × 3.9619 𝑘𝑔/℃ × 23.7℃ QC: 2.27 ℎ𝑟 × 3.9619 × 16.1℃
𝑘𝑔/℃
𝐵𝑇𝑈 𝐵𝑇𝑈
= 127.7 = 149.3
ℎ𝑟 ℎ𝑟
𝑘𝑔 𝐵𝑇𝑈 𝑘𝑔 𝐵𝑇𝑈
QH: 2.27 ℎ𝑟 × 3.9619 𝑘𝑔/℃ × 16.6℃ QH = 2.27 ℎ𝑟 × 3.9619 × 17.8℃
𝑘𝑔/℃
𝐵𝑇𝑈 𝐵𝑇𝑈
= 149.3 𝐻𝑅 = 2692687.243 ℎ𝑟

SET 3 SET 4
𝑘𝑔 𝐵𝑇𝑈 𝑘𝑔 𝐵𝑇𝑈
QC = 2.27ℎ𝑟 × 3.9619 × 18℃ QC = 2.27 ℎ𝑟 × 3.9619 × 19.5℃
𝑘𝑔/℃ 𝑘𝑔/𝐾
𝐵𝑇𝑈 𝐵𝑇𝑈
= 161.9 ℎ𝑟 = 175.4 ℎ𝑟
𝑘𝑔 𝐵𝑇𝑈 𝑘𝑔 𝐵𝑇𝑈
QH = 3.41 ℎ𝑟 × 3.9619 × 14.3℃ QH = 4.54 ℎ𝑟 × 3.9619 × 10.7℃
𝑘𝑔/℃ 𝑘𝑔/℃
𝐵𝑇𝑈 𝐵𝑇𝑈
= 193.2 ℎ𝑟 = 192.5 ℎ𝑟

4. Determining which ratio of Head Load is closest to 1

The formula QC÷QH

𝑘𝐽
SET 1 = 0.86 ℎ𝑟

𝑘𝐽
SET 2 = 0.9 ℎ𝑟

𝑘𝐽
SET 3 = 0.84 ℎ𝑟

𝑘𝐽
SET 4 = 0.91 ℎ𝑟
6.0CONCLUSION

In conclusion, the objectives of the experiment were archieved. Based on results obtained, it
can deduce that the U calculated for the hot stream was only slightly different then the U
calculated for the cold stream. This indicates that there is heat lost to the surrounding areas. The
heat exchanger was most effective when the hot water was directed into the tubes and the flow
was counter-current. Also for the flow rates examined the heat transfer rate increases as the flow
rate increases. While, baffle spacing and cutting space reduced the heat transfer coefficient when
increases. The fouling factor on shell side can affect the heat transfer heat more than that for tube
side, therefore it is important to reduce fouling rate on shell side. The parameters selection has
direct effect on both overall heat transfer coefficient and pressure drop. It is believed that the
baffles cause the flow to become turbulent.

7.0RECOMMENDATION

There were few possible errors that maybe can occur during the experiment. In an effort to
reduce the heat loss to the surroundings, it is recommended that the heat exchanger be well
insulated. Presently the heat exchanger has no insulation and the ambient room temperature has a
large effect on the results. It is also recommended that during the process of data collection that
the user adjusts the flow rate of only one stream per setup. If this is not done the graphs of the
data becomes very difficult to read and understand. Another recommendation is to ensure that
the flow rates obtained are measured accurately. There are two ways that this may be done. One
way is to purchase new flow meters, and the other is to manually measure each flow rate with
great care. This is extremely important because without accurate flow rates the temperature data
is worthless.
8.0 REFERENCE

1. Heat Exchanger. [Online]. [Accessed 27 September, 2019]. Available from World Wide Web:
https://www.scribd.com/doc/51634873/Heat-Exchanger-Lab-Report

2. Shell and Tube Heat Exchanger. [Online]. [Accessed 27 September, 2019]. Available from
World Wide Web:
http://www.chem.mtu.edu/chem_eng/current/new_courses/CM4120/2009/Sample_Oral_Presenta
tion.pdf

3. Schematic diagram of overall heat exchange apparatus. Analysis of Enhanced Concentric

Tube and Shell and Tube Heat Exchanger. [Online]. [Accessed 27 September, 2019]. Available
from World Wide Web: https://docplayer.net/21603711-Me-315-heat-transfer-laboratory-
experiment-no-7-analysis-of-enhanced-concentric-tube-and-shell-and-tube-heat-exchangers.html