SCHOOL OF ENGINEERING

OFFICIAL RECORD OF STUDENT WORK

ACADEMIC YEAR 2014/2015

THINK SAFETY AT ALL TIMES

Students are reminded of their obligation to behave and work in a safety conscious manner at all time, but
particularly when in workshops or laboratories. Failure to comply with this requirement will result in
expulsion from the lab (or college in the case of serious breaches) and ZERO entered as a CA mark.
DEPARTMENT OF MECHANICAL ENGINEERING
Lab title -

Thermodynamics 2 - Double Pipe Heat Exchanger Laboratory

Lecturer -

Chris Keogh

Student name

Conor Moore

(X00004502)

Class group-

Declaration
I hereby declare that this is my original work produced without the help of any third party.
Signed:

Conor Moore

Date:

28-Nov-2014

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1. Introduction

1. Introduction

Temperature can be defined as the amount of energy that a substance has. Heat exchangers are used to
transfer that energy from one substance to another. In process units it is necessary to control the
temperature of incoming and outgoing streams.
A heat exchanger is a piece of equipment built for efficient heat transfer from one medium to another.
In a heat exchanger forced convection allows for the transfer of heat of one moving stream to another
moving stream. With convection as heat is transferred through the pipe wall it is mixed into the stream and
the flow of the stream removes the transferred heat. This maintains a temperature gradient between the
two fluids. The double-pipe heat exchanger is one of the simplest types of heat exchangers. It is called a
double-pipe exchanger because one fluid flows inside a pipe and the other fluid flows between that pipe
and another pipe that surrounds the first. This is a concentric tube construction.
Flow in a double-pipe heat exchanger can be co-current or counter-current. There are two flow
configurations: co-current is when the flow of the two streams is in the same direction, counter current is
when the flow of the streams is in opposite directions.
In a heat exchanger forced convection allows for the transfer of heat of one moving stream to another
moving stream. With convection as heat is transferred through the pipe wall it is mixed into the stream and
the flow of the stream removes the transferred heat. This maintains a temperature gradient between the
two fluids.
The double-pipe heat exchanger is one of the simplest types of heat exchangers. It is called a double-pipe
exchanger because one fluid flows inside a pipe and the other fluid flows between that pipe and another
pipe that surrounds the first. This is a concentric tube construction.
Flow in a double-pipe heat exchanger can be co-current or counter-current. There are two flow
configurations: co-current is when the flow of the two streams is in the same direction, counter current is
when the flow of the streams is in opposite directions.
In this double-pipe heat exchanger a hot process fluid flowing through the inner pipe transfers its heat to
cooling water flowing in the outer pipe. The system is in steady state until conditions change, such as flow
rate or inlet temperature. These changes in conditions cause the temperature distribution to change with
time until a new steady state is reached. The new steady state will be observed once the inlet and outlet
temperatures for the process and coolant fluid become stable. In reality, the temperatures will never be
completely stable, but with large enough changes in inlet temperatures or flow rates a relative steady state
can be experimentally observed.
A heat exchanger is a piece of process equipment in which heat exchange takes place between two fluids
that enter and exit at different temperatures. The primary design objective of the equipment may be either
to remove heat from a hot fluid or to add heat to a cold fluid. Depending upon the relative direction of fluid
motion, shell-and-tube heat exchangers are classified as parallel flow, counter flow, cross flow. In parallel
flow, the hot and cold fluids flow in the same direction and therefore enter the exchanger on the same end
and exit the exchanger on the same end. In counter flow, the two fluids flow in opposite directions and thus
enter the exchanger and exit the exchanger from opposite ends. Cross flow heat exchangers will not be
analysed as a part of this laboratory experiment
A heat exchanger is equipment in which heat exchange takes place between 2fluids that enter and exit at
different temperatures. The main function of heat exchanger is to either remove heat from a hot fluid or to
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add heat to the cold fluid. The direction of fluid motion inside the heat exchanger can normally categorised
as parallel flow, counter flow and cross flow. In this experiment, we study only the parallel flow and counter
flow. For parallel flow, also known as co-current flow, both the hot and cold fluids flow in the same
direction. Both the fluids enter and exit the heat exchanger on the same ends. For counter flow, both the
hot and cold fluids flow in the opposite direction. Both the fluids enter and exit the heat exchanger on the
opposite ends. In this experiment, we focused on the shell and tube heat exchanger.

2. Objective

2. Objective
In this experiment the performance of a double pipe heat exchanger was evaluated in both parallel and
counter-flow configurations.

3. Experimental procedure
3.1 Equipment used
Heat exchanger rig (setup in both parallel and counterflow configurations).

3.2 Results

Reading

Set1

Set2

Cold stream inlet temperature

4.11

9.41

Cold stream outlet temperature

7.13

12.01

40

40

Hot stream inlet temperature

52.5

48.22

Hot stream outlet temperature

50.2

46.23

40

40

Cold stream flow rate

Hot stream flow rate

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NOTE: The temperature change over the length of a heat exchanger is not linear as depicted by the above
graphs this is due to the limitations of Microsoft excel and only having two points for each liquid flow.
The average temperature change is calculated by the log mean temperature difference.

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Parallel flow configuration:

Parallel flow configuration calculations:

( ) ( )
(52.5 4.11) (50.2 7.13) (48.39 43.07)
=
=
= 45.68
52.5 4.11
( )
ln
1.13
(
)
(
)
50.2 7.13
( )

= .
= 40 l/min, made up of 32 l/min of water and 8 l/min of polypropylene glycol.
= 0.53
The density of polypropylene glycol = 1.01 kg/l, therefore the =
0.135 /
= . /
Cp of water = 4.183 kj/kg
Cp of polypropylene glycol = 2.5 kj/kg
By mass, the mixture contains 79.7% water and 20.3% polypropylene glycol,
so the Cp of the mixture = (4.183)(0.797) + (2.5)(0.203) = 3.84 kj/kg.
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(8)(1.01)
60

Cp of the mixture = 3.84 kj/kg

=
= (0.665)(3.84)(7.13-4.11)
= 7.71 kW

Heat exchanger internal diameter = 39.6mm

Heat exchanger external diameter = 42mm
Heat Exchanger curved surface area = = = (3.14)(0.042)(6) = 0.792 2

7.71
= 0.21
(0.792)(45.68)

U = 0.21

Counter flow configuration

Counter flow configuration calculations:

( ) ( )
(48.22 12.01) (46.23 9.41) (36.21 36.82)
=
=
48.22 12.01
( )
ln 0.98
( 46.23 9.41 )
(
)
( )
= 30.5
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 = .
= . /
Cp of the mixture = 3.84 kj/kg

=
= (0.665)(3.84)(12.01-9.41)
= 6.64 kW

6.64
= 0.28
(0.792)(30.5)

U = 0.28

The counter flow configuration is more efficient as it can transfer the most heat from heat transfer medium
(0.28 kW(m^2 K) versus 0.21kW(m^2 K)).
The log mean temperature difference (LMTD) is higher for a counter flow configuration than a parallel flow
configuration. However in our case the LMTD was higher for the parallel flow configuration (45.68 oC versus
30.5oC). The reason for this is that the inlet temperatures were different for each configuration (see table of
results).

From the data in Table 1, the general characteristics of parallel flow and counter flow heat exchangers can
be observed. In the parallel flow configuration, the exit temperature of the hot fluid must be higher than
the exit temperature of the cold fluid. This is supported by the data taken. In the counter flow
configuration, the exit temperature of the hot fluid must be higher than the entrance temperature of the
cold fluid, but it does not necessarily need to be higher than the exit temperature of the cold fluid. This is
also supported by the data, even though in this case the exit temperature of the hot fluid is still hotter than
the exit temperature of the cold fluid. From the calculations resulting in overall effectiveness, it is shown
that the counter flow heat exchanger is more effective than the parallel flow heat exchanger. This supports
generally held knowledge and experimental data concerning the two types of heat exchanger, governed by
the Clausius Statement.
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Some inefficiency can exist with the shell and tube heat exchanger.
One of the main sources of efficiency loss over time is the presence of fouling.
Fouling can occur from many sources:

Scaling/Crystallization Fouling (e.g. limescale).

Particulate/Sedimentation Fouling (sedimentation occurs when particles (e.g. dirt, sand or rust) in
the solution settle and deposit on the heat transfer surface.

Corrosion Fouling (results from a chemical reaction which involves the heat exchanger surface
material).

Chemical Fouling (occurs from chemical reactions in the fluid stream which result in the deposition
of material on the heat exchanger surface).

Freezing Fouling (occurs when a portion of the hot stream is cooled to near the freezing point of
one of its components).

Biological Fouling (occurs when biological organisms grow on heat transfer surfaces).

There are also a number of ways to increasing the performance of a shell and tube heat exchanger:

Finning
Tubes can be finned on both the interior and exterior. This is probably the oldest form of heat transfer
enhancement. Finning is usually desirable when the fluid has a relatively low heat transfer film coefficient
as does a gas. The fin not only increases the film coefficient with added turbulence but also increases the
heat transfer surface area.
Tube Inserts
Inserts are inserted into the tube to promote turbulence. These devices are most effective with high
viscosity fluids in a laminar Many vendors have developed proprietary surface configures by deforming the
tubes. The resulting deformation appears corrugated, twisted, or spirally fluted. The surface condenses
steam on the outside and heats water on the inside.
flow regime. Increases in the heat transfer film coefficients can be as high as five times. Inserts are used
most often with liquid heat transfer and to promote boiling. Inserts are not usually effective for condensing
in the tube and almost always increase pressure drop. However, through the modification of the number of
passes, a resulting heat transfer coefficient gain can be achieved at lower pressure drop in some situations.
Tube Deformation
Baffles
Baffles are designed to direct the shell side fluid across the tube bundle as efficiently as possible. Forcing
the fluid across the tube bundle ultimately results in a pressure loss. The most common type of baffle is the
Page 8 of 10

single segmental baffle which changes the direction of the shell side fluid to achieve cross flow. Deficiencies
of the segmented baffle include the potential for dead spots in the exchanger and excessive tube vibration.
Baffle enhancements have attempted to alleviate the problems associated with leakage and dead areas in
the conventional segmental baffles.

Conclusion:
The heat exchanger apparatus follows the basic laws of thermodynamics and this can be shown
experimentally. From all of the parallel flow configurations, the exit temperature of the hot fluid is always
hotter than the exit temperature of the cold fluid. This supports the Clausius Statement in which heat may
not spontaneously transfer from a colder body to a hotter body. From the other experiments that hold
flow rates constant or vary the flow rates, it is clear that the First Law of Thermodynamics and
conservation of energy applies to the heat exchanger apparatus. In practical application, the counter flow
configuration is preferred for its higher effectiveness. This experiment did show that this configuration
does in fact have a higher effectiveness than the parallel flow configuration. Additionally, the counter flow
configuration is also capable of have a cold fluid exit temperature that is higher than the hot fluid exit
temperature. This was not shown experimentally, however from the data collected it is clear that the flow
rates were too high to achieve this desired result. If the experiment were repeated with lower flow rates, it
would be possible to demonstrate a situation where the exit temperature of the cold fluid is hotter than
the exit temperature of the hot fluid.
This experiment shows that the shell and tube heat exchanger follows the basic law of thermodynamics. In
parallel (co-current) flow configuration, the exit temperature of the hot fluid is always higher than the exit
temperature of the cold fluid. In counter-current flow configuration, the exit temperature of the hot fluid is
also higher than the exit temperature of the cold fluid. However, in counter current flow configuration, the
exit temperature of the cold fluid is higher than the exit temperature of the cold fluid in co-current
configuration. Hence, it is clear that for heat exchanger, counter current flow configuration has a higher
effectiveness than the co-current flow configuration. The experiment shows that when the flow rate of one
of the stream increases, the rate of heat transfer will also increases. The amount of heat loss form the hot
water is not equal to the heat gain by the cold water due to the heat loss to the surroundings. From the
calculations done, the LMTD (log mean temperature difference) for parallel flow is higher than the counter
flow. However, the overall heat transfer coefficient for counter flow is higher than the parallel flow. As a
conclusion, counter flow configuration of heat exchanger is more preferred for practical application.

References:
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(1) Bryan Research and Engineering, Inc. - Technical Papers

(2) http://www.hcheattransfer.com/fouling1.html

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