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Title
Abstract/Summary
Introduction
Aims
Theory
Apparatus
Methodology/Procedure
Results
Calculations
Discussion
Conclusion
Recommendations
Reference
Appendix
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ABSTRACT
In this experiment, the objective is to determine the efficiency of enhanced concentric
shell-tube heat exchanger using water as the heat exchange medium for counter-current flow heat
exchanger. The experiment was also to evaluate the heat transfer and heat loss for energy balance,
LMTD, heat transfer coefficient, overall heat transfer coefficient (U) and the pressure drop of the
shell and tube heat exchanger. The instrument was combined with thermometer , thus the TT1(hot
in) , TT2(hot out) , TT3(cold in) , TT4( cold out) can be measured. At first, the hot water water
flow rate (FT1) was set to fixed which is 10LPM and cold water flow rate (FT2) was varied.The
experiment then repeated by varied the hot water water flow rate (FT1) and fixing the cold water
flow rate (FT2) to 10LPM . The data is being recorded for temperature and pressure for each flow
rates within 10 minutes interval. From the results, it can be concluded that the pressure drop is
depends on flow rate not the temperature. Furthermore, for shell and tube heat transfer coefficient
is depends on flow rate, which is for tube coefficient is constant because the flow rate is constant
but for shell coefficient, the shell coefficient is increase as the flow rate is increase
INTRODUCTION
Heat exchanger is a device which is used for transferring energy in the form of heat from
one fluid to another. In some cases, a solid wall may separate the fluids and prevent them from
mixing. In other designs, the fluids may be in direct contact with each other. In the most efficient
heat exchangers, the surface area of the wall between the fluids is maximized while simultaneously
minimizing the fluid flow resistance. Fins or corrugations are sometimes used with the wall in
order to increase the surface area and to induce turbulence. Heat exchangers are widely used in the
process industries so their design has been highly developed. Most exchangers are liquid-to-liquid,
but gas and no condensing vapours can also be treated in them.
Shell and tube heat exchanger is most common type of heat exchanger been used in
industrial applications. Shell and tube heat exchanger placed a large number of tubes, about
several hundred packed in a shell with their axes parallel to that of their shell. Heat transfer take
place as one fluid flows inside the tube, while the other tube flows throughout the shell. Baffles
installed inside the shell functions to force shell-side fluid to flow across the shell and to
increase residence time so that enhance heat transfer between the fluids. Besides, baffles
also placed in the shell to maintain uniform spacing between the tubes. Note that the tubes in
shell tube heat exchanger are connected to large flow area called header at both ends of the shell,
parts where fluid accumulates before entering the tubes and after leaving them. In the counterflow heat exchanger, the fluids enter the exchanger from opposite sides. This is the most efficient
design because it transfers the greatest amount of heat. Next, counter current heat exchangers
allow the highest log mean temperature difference between the hot and cold streams. Many
companies however do not use single pass heat exchangers because they can break easily in
addition to being more expensive to build. Often multiple heat exchangers can be used to
simulate the counter current flow of a single large exchanger.
exchanger, the fluids come in from the same end and move parallel to each other as they flow to
the other side. The coss-flow heat exchanger moves the fluids in a perpendicular fashion.
Figure 2 : the schematic of a shell-and-tube heat exchanger (one shell pass one tube pass)
OBJECTIVES
1. To determine the function of the shell and tube heat exchanger
2. To evaluate the value of heat transfer and heat loss, LMTD, heat transfer coefficient, overall
heat transfer coefficient and the pressure drop
THEORY
The Heat Exchanger Design Equation
Heat exchanger theory leads to the basic heat exchanger design equation:
Q = U A Tlm , where
Q is the rate of heat transfer between the two fluids in the heat exchanger in W,
U is the overall heat transfer coefficient in W/m2.k,
A is the heat transfer surface area in m2,
and Tlm is the log mean temperature difference in K, calculated from the inlet and outlet
temperatures of both fluids.
The basic heat exchanger design equation can be used to calculate the overall heat transfer
coefficient for known or estimated values of the other three parameters, Q, A, and T lm. Each of
those parameters will now be discussed briefly.
Heat Transfer Rate, Q
Heat transfer rate, Q can be calculated from the known flow rate of one of the fluids, its heat
capacity, and the required temperature change. Following is the equation to be used:
Qhot = mt Cpt (THin - THout) = Ws Cps (TCout - TCin) , where
mt = mass flow rate of hot fluid, kg/s,
Cpt = heat capacity of the hot fluid, J/s,
Ws = mass flow rate of cold fluid, kg/s,
Cps = heat capacity of the cold fluid, J/s,
The required heat transfer rate can be determined from known flow rate, heat capacity and
temperature change for either the hot fluid or the cold fluid. Then either the flow rate of the other
fluid for a specified temperature change, or the outlet temperature for known flow rate and inlet
temperature can be calculated.
Log Mean Temperature Difference
The driving force for any heat transfer process is a temperature difference. For heat exchangers,
there are two fluids involved, with the temperatures of both changing as they pass through the heat
exchanger, so some type of average temperature difference is needed. Log mean temperature is
defined in terms of the temperature differences as shown in the equation at below. Th,inand Th,out are
the inlet and outlet temperatures of the hot fluid and T c,in and Tc,out are the inlet and outlet
temperatures of the cold fluid.
T hot, in = Inlet temperature of hot fluid (oC ) , T hot, out = Outlet temperature of hot fluid (oC )
T cold, in = Inlet temperature of cold fluid (oC), T cold, out = Outlet temperature of cold fluid (oC
For the counter flow direction as in Figure 3, the fluids enter at opposite ends, flow in opposite
directions, and leave at opposite ends. Once value of TLM and area, A is obtained, the overall
heat transfer coefficient can be determined. Heat transfer rate, Q also can be calculated using
this formula
Q = m x Cp x T
For constant specific heats with no change of phase, the heat balance for both co-current and
counter current flow is Q = (mc Cpc)cold (Tc2 Tc1) = (mh Cph)hot (Th1 Th2)
, Ccold= mc cp cold
The temperature profiles in the heat exchanger can be study by looking at the
characteristics of the heat exchangers which are the flow arrangement ( either the hot and cold
fluids move in the same or opposite directions) and type of construction. The temperature
profile obtained from chart of temperature difference between the hot fluid and cold fluid at inlet
and outlet. It may vary along the length of the heat exchanger. This is due to the fact that the hot
fluid temperature decreases as it transfers heat to the cold fluid, while the cold fluid temperature
increases. As shown in the figure 3.1 below, for co-current flow arrangement, the temperature
difference is maximum at the inlet and decreases slowly towards the outlet. For countercurrent flow arrangement, the difference between the temperature of the hot and cold fluid
almost uniform, means that the heat transfer rate at any location is usually maximum at any
location throughout the tube. The temperature difference decreases less dramatically compared
to parallel flow arrangement as we move towards hot fluid exit. For either flow arrangement, it
can be observed that the T is not constant and changes along the length of a heat exchanger.
12
4. Valve 17
5. Valve 15
6. Valve 16
7. Valve 18
8. Hot water centrifugal pump
EXPERIMENTAL PROCEDURES
13
flowrate was adjusted to about 25 USGPM by regulating the by-pass valve BVH.
6. The CW pumps PC1 and PC2 were switched on simultaneously. Then, the CW flowrate
was adjusted to 10 LPM by regulating the by-pass valve BVC1.
7. The DP Selector Switch was switched to the DP (Shell) position.
14
Experiment 1 : Counter- Current Flow Direction inside Shell and Tube Heat
Exchanger
1. General start-up procedures was performed.
2. The valves were switched to the counter-current Shell & Tube Heat Exchanger
arrangement. V15 and V18 were opened while V16 and V17 were closed.
3. Heater switch, Pump P1 and P2 was switched on. TT5 is ensured to be at 50
4. The valves V3 and V14 were adjusted to desired flow rates for hot water and cold water
stream .
5. The system is left ,run for 10 minutes until steady state operating condition is reached.
6. FT1, FT2, TT1, TT2, TT3 and TT4 readings were recorded after next 3 minutes to
after the process has stable.
7. Pressure drop measurement for shell-side and tube-side was taken at DPT1 and DPT2
readings
8. Steps 4 till 7 was repeated for different combination of flow rates FT1 and FT2.
9. V15 and V18 is tightly closed.
General Shut-down Procedures
1. Heater is switched off and waits until hot water temperature drops below 40 .
2. Pump P1 and P2 was switched off.
3. All water was drained off in the process lines. Water retained in the hot and cold water
tanks for next laboratory session.
4. All valves are closed.
RESULT
FT1(LPM)
TT1( C)
TT2( C)
TT3( C)
TT4( C)
DT1(mmH2O)
DDT2(mmH2O)
10
FT2(LPM)
2
49.2
47.8
31.5
44.8
91
10
49.0
46.7
31.4
39.6
92
17
10
49.3
46.0
30.5
36.7
93
67
10
48.9
45.4
30.2
35.2
93
126
10
10
48.9
45.1
30.9
34.5
93
243
FT1(LPM)
TT1( C)
TT2( C)
TT3( C)
TT4( C)
DT1(mmH2O)
DDT2(mmH2O)
FT2(LPM)
10
48.7
39.9
30.8
32.4
-5
243
10
49.2
43.5
30.9
32.8
238
10
49.4
44.1
30.6
33.4
22
242
10
49.5
45.0
30.5
34.3
50
240
10
10
49.4
45.4
30.5
34.5
87
245
TEST 2
TEST 3
TEST 4
TEST 5
L/min
Kg/s
0
C
0
C
J/s
mmH20
10.0
0.1647
49.2
47.8
962.65
91
10.0
0.1647
49.0
46.7
1581.50
92
10.0
0.1647
49.3
46.0
2269.11
93
10.0
0.1647
48.9
45.4
2406.63
93
10.0
0.1647
48.9
45.1
2612.91
93
L/min
Kg/s
0
C
0
C
J/s
mmH20
2.0
0.0332
31.5
44.8
1846.43
3
4.0
0.0664
31.4
39.6
2276.81
17
6.0
0.1000
30.5
36.7
2582.23
67
8.0
0.1328
30.2
35.2
2776.59
126
10.0
0.1659
30.9
34.5
2498.93
243
C
C
0
C
0
C
0
C
W
%
49.2
47.8
31.5
44.8
9.09
-883.78
191.81
49.0
46.7
31.4
39.6
12.11
-695.31
143.97
49.3
46.0
30.5
36.7
14.00
-313.12
113.80
48.9
45.4
30.2
35.2
14.44
-369.96
215.37
48.9
45.1
30.9
34.5
14.30
113.98
95.64
m2
W/m2.K
0.15
706.01
0.15
870.63
0.15
1080.53
0.15
1111.09
0.15
1218.14
mm
mm
1
1
0.5
7.75
9.53
18
0.0150
10
85
50
1
1
0.5
7.75
9.53
18
0.0150
10
85
50
1
1
0.5
7.75
9.53
18
0.0150
10
85
50
1
1
0.5
7.75
9.53
18
0.0150
10
85
50
1
1
0.5
7.75
9.53
18
0.0150
10
85
50
m2
0.000047
0.000047
2
0.000047
2
0.0000472
0.0000472
10
0.000472
10
0.000472
10
0.000472
10
0.000472
0
0
m
mm
mm
mm
m2
2
10
0.000472
Kg/m2.s
m/s
349.13
0.3533
4924.98
3.56
turbulent
64.52
0.0039
349.13
0.3533
4924.98
3.56
turbulent
64.52
0.0039
349.13
0.3533
4924.98
3.56
turbulent
64.52
0.0039
345.64
0.3498
4875.73
3.56
turbulent
64.52
0.0039
342.15
0.3462
4826.48
3.56
Turbulent
64.52
0.0039
W/m2.K
2426.16
2426.16
2426.16
2401.90
2377.64
m2
Kg/m2.s
m/s
mm
0.002
16.60
0.0167
27.78
575.88
5.44
laminar
20
0.023
513.18
0.002
31.53
0.0317
27.78
1094.17
5.44
laminar
20
0.018
763.08
0.002
46.47
0.0467
27.78
1612.46
5.44
laminar
20
0.016
999.59
0.002
60.57
0.0608
27.78
2101.96
5.44
laminar
20
0.014
1140.16
0.002
75.51
0.0758
27.78
2620.25
5.44
laminar
20
0.012
1218.25
heat exchanger
Tube-side friction
0.0058
0.0058
0.0058
0.0058
0.0058
factor, Jf
Shell-side friction
0.098
0.086
0.075
0.072
0.070
factor, Jf
Tube-side pressure drop,
338.8
338.8
338.8
332.1
325.4
DPtube (Pa)
Tube-side pressure drop,
33.4
33.4
33.4
32.8
32.1
DPtube (mmH20)
Shell-side pressure
0.3
10.5
19.9
32.5
49.1
0.3
1.0
2.0
3.2
4.8
Mass velocity
Linear velocity
Reynolds number
Prandtl number
Type of flow
L/ID
Heat transfer factor,
Jh
Tube coefficient,
Hi
Shell side
Cross flow area
Mass velocity
Linear velocity
Equivalent diameter
Reynolds number
Prandtl number
Type of flow
Baffle cut
Heat transfer factor,jh
Shell coeffient,hs
Pressure drop across
drop, DPshell
(mmH2O)
%
W/m2.K
TEST 2
TEST 3
TEST 4
TEST 5
L/min
Kg/s
0
C
0
C
J/s
2.0
0.0329
48.7
39.9
1210.19
4.0
0.0659
49.2
43.5
1567.75
6.0
0.0988
49.4
44.1
2186.60
8.0
0.1318
49.5
45.0
2475.39
10.0
0.1647
49.4
45.4
2750.43
L/min
Kg/s
0
C
0
C
J/s
10.0
0.1659
30.8
32.4
1110.64
10.0
0.1659
30.9
32.8
1318.88
10.0
0.1659
30.6
33.4
1943.61
10.0
0.1659
30.5
34.3
2637.76
10.0
0.1659
30.5
34.6
2776.59
C
C
0
C
0
C
0
C
W
%
48.7
39.9
30.8
32.4
12.35
99.55
91.77
49.2
43.5
30.9
32.8
14.42
248.87
84.13
49.4
44.1
30.6
33.4
14.71
242.99
88.89
49.5
45.0
30.5
34.3
14.85
-162.37
106.56
49.4
45.4
30.5
34.6
14.85
-26.16
100.95
m2
W/m2.K
0.15
653.27
0.15
724.80
0.15
990.98
0.15
1111.29
0.15
1234.76
mm
mm
1
1
0.5
7.75
9.53
18
0.0150
10
85
50
1
1
0.5
7.75
9.53
18
0.0150
10
85
50
1
1
0.5
7.75
9.53
18
0.0150
10
85
50
1
1
0.5
7.75
9.53
18
0.0150
10
85
50
1
1
0.5
7.75
9.53
18
0.0150
10
85
50
m2
0.000047
0.000047
0.000047
0.0000472
0.0000472
m2
Kg/m2.s
m/s
2
10
0.000472
69.79
0.0706
2
10
0.000472
139.57
0.1412
2
10
0.000472
209.36
0.2119
10
0.000472
279.15
0.2825
10
0.000472
348.93
0.3531
0
0
m
mm
mm
mm
m2
Reynolds
Prandtl number
Type of flow
L/ID
Heat transfer factor, Jh
Tube coefficient, hi
Shell side
Cross flow area
Mass velocity
Linear velocity
Equivalent diameter
Reynolds number
Prandtl number
Type of flow
Baffle cut
Heat transfer factor, Jh
Shell coefficient, hs
Pressure drop across
W/m2.K
m2
Kg/m2.s
m/s
mm
%
W/m2.K
984.48
3.56
Laminar
64.52
0.0050
621.54
1968.82
3.56
Laminar
64.52
0.0030
745.80
2953.29
3.56
turbulent
64.52
0.0036
1342.46
3937.77
3.56
turbulent
64.52
0.0039
1939.13
4922.11
3.56
Turbulent
64.52
0.0040
2486.02
0.002
82.97
0.0833
27.78
2880.69
5.44
laminar
20
0.01
1510.37
0.002
82.97
0.0833
27.78
2880.69
5.44
laminar
20
0.01
1510.37
0.002
82.97
0.0833
27.78
2880.69
5.44
laminar
20
0.01
1510.37
0.002
82.97
0.0833
27.78
2880.96
5.44
laminar
20
0.01
1510.37
0.002
82.97
0.0833
27.78
2880.69
5.44
Laminar
20
0.01
1510.37
heat exchanger
Tube-side friction
0.0058
factor, Jf
Shell-side friction
0.098
0.086
0.075
0.072
0.070
factor,Jf
Tube-side pressure
13.05
41.37
100.39
184.97
292.26
drop,DPtube (Pa)
Shell-side pressure
8.53
8.53
8.53
8.53
8.53
0.0058
0.0058
drop,DPshell (Pa)
0.0058
0.0058
Temperature Profile
60
50
47.8
44.8
40
Hot water
Cold water
Temperature
30
20
10
0
1
600
400
200
0
10
Figure 6 : Graph of overall heat transfer coefficient against cold water flow rate
tube side
2000
shell side
1500
1000
500
0
2 4 6 8 10
Figure 7 : Graph of relationship between heat transfer coefficient and cold water flow rate
CALCULATIONS
COLD WATER
995.67
4183.00
0.6155
0.0008007
Outlet temperature( )
47.8 (TT2)
44.8 (TT4)
L
1 m3
1 min 988.18 kg 4175 J (
49.247.8 )
min 1000 L 60 s
kg .
m3
962.65 W
L
1 m3
1 min 995.67 kg 4183 J (
44.831.5 )
min 1000 L 60 s
kg .
m3
1846.43W
Efficiency =
QC
1846.43 W
100 =
100 =191.81
QH
962.65 W
2. Calculation of LMTD
h ,T c ,out =49.244.8=4.4
T 1=T
c ,=47.831.5=16.3
T 2=T h ,out T
T lm=
T 1 T 2 4.416.3
=
=9.09
T1
4.4
)
ln (
) ln (
16.3
T2
3. Calculation of the tube and shell heat transfer coefficients by Kerns method :
For 1-shell pass; 1-tube pass,
T m=T lm
Mass velocity , G t =
mt
0.1647
kg
=
=349.13 2 . s
At 0.000472
m
349.13 kg
G
m2 . s
Linear velocity ,ut = t =
=0.3533 m/s
988.18 kg /m3
349.13 kg
7.75 m
Gt de
m2 . s
1
Renolds n umber , =
=
=4924.9(turbulent flow )
0.0005494 Pa. s
1000
Prandtl , Pr=
Cp H
=
k
0.0005494 Pa . s 4175
0.6436
J
kg . K
W
m. K
=3.56
1.1 2
1.1
t 0.917 d 20 ) =
( 1820.917 ( 9.53 )2 ) mm=27.78 mm
(
d0
9.53
16.60 kg
27.78 mm
2
G s de
m .s
1
Reynolds number , =
=
=575.93(laminar flow )
0.0008007 Pa . s
1000
CpC
=
k
J
kg . K
W
m.K
=5.44
0.33
0.33
0.6155
=490.95
W
2
m .K
QH
962.65W
W
=
=706.01 2
2
A T lm 0.15 m 9.09
m .
8 0.0057
Pt =N p
2
t
0.5m
0.0005494 Pa. s
0.00775m
0.0005494 Pa. s
)(
u
L
8 jf
2
di
( )( )
w
0.14
+2.5 =338.8 Pa
+ 2.5 =1
m 2
)
s
Ds
Ps =8 j f
de
2
L u s
IB 2
0.0167 m/s
2
995.67 kg
(
)
m3
0.14 (
0.085 m
= 8 0.092 )
w
0.02778 m
( )( ) ( )
DISCUSSION
0.5m
)( 0.05m
)
test 4 and 292.26Pa for test 5. But for measure value of pressure drop, the value is 243
mmH2O for test 238 mmH2O for test 2, 242 mmH 2O for test 3, 240 mmH2O for test 4 and
245mmH2Ofor test 5. Maybe some error had been done while handling the equipment.
The graph plotted in Figure 5 shows inlet temperature of hot fluid is higher than the
outlet and as for cold fluid the inlet temperature is lower than the outlet temperature as it
increases throughout the process.
From result above, the pressure drop is depends on the flow rate not the temperature. The
pressure drop is increase as the cold flow rate increase and constant at tube side because the
flow rate is constant at 10 LPM. Same goes to heat transfer coefficient for tube side and shell
side. For tube side, the value of tube coefficient is constant as the hot water flow rate is
constant at 10 LPM but for shell coefficient, the value is increasing as the cold water flow
rate increase. The pressure drop is depend on the flow rates as the flow rates is changed the
pressure drop also change. This is due to the flow does not achieved the steady state yet.
CONCLUSION
RECOMMENDATION
As recommendation, firstly make sure the system is fully drain after each use of water
on tube side and steam condensate on shell side in order to avoid corrosion build-up during
down-times. Next, the eye position should be perpendicular to the meniscus and the scale to
prevent from parallax error. Beside that, the water to the tube side should be the first and last
flow rate to be turned on. The steam should be turned on only after the water is flowing
through the tube side. Avoid any leakage of the instrument, the instrument should be working
properly and lastly make sure that the time taken to collect the data is punctually followed.
REFFERENCES