Abstract/Summary

The objectives of this experiment are to evaluate and study the heat
load and head balance, LMTD and overall heat transfer coefficient, to
calculate the Reynolds numbers at the shell and tubes sides and to measure
and determine the shell and tube sides pressure drop. This experiment
consists of five runs. For each of the run, three sets of data are obtained. A
set of data from each of the run is selected based on the best convergence
of QC and QH (the ratio of QC/QH is nearest to 1.0). From the selected set,
the heat load and head balance, LMTD and overall heat transfer coefficient,
Reynolds numbers and pressure drop are determined. From the results
obtained, an ideal set to choose based on the ratio is majorly from set 3.

Introduction
A heat exchanger can be defined as any device that transfers heat from one
fluid to another or from or to a fluid and the environment. There are several
types of shell and tube heat exchanger:

Figure 1: Heat exchanger with fixed tube plates (four tubes, one shell-pass)

Figure 2: Heat exchanger with floating head (two tube-pass, one shell pass)

Figure 3: Heat exchanger with hairpin tubes

Basic Considerations in Choosing a Mechanical Arrangement of Heat

Exchanger
There are four basic considerations in choosing a mechanical arrangement
that provides for efficient heat transfer between the two fluids or vapors,
while taking care of such practical matters as preventing leakage from one
into the other. They are:

Consideration for differential thermal expansion of tube and shell

Means of directing fluid through the tubes

Methods of controlling fluid flow through the shell

Consideration for ease of maintenance and servicing

Advantages of Heat Exchanger

The main advantages of shell-and-tube heat exchangers are:

Condensation or boiling heat transfer can be accommodated in either

the tubes or the shell, and the orientation can be horizontal or vertical.

The pressures and pressure drops can be varied over a wide range.

Thermal stresses can be accommodated inexpensively.

There is substantial flexibility regarding materials of construction to

accommodate corrosion and other concerns. The shell and the tubes
can be made of different materials.

Extended heat transfer surfaces (fins) can be used to enhance heat

transfer.

Cleaning and repair are relatively straightforward, because the

equipment can be dismantled for this purpose.

Applications of Heat Exchanger

Shell and tube heat exchangers represent the most widely used vehicle for
the transfer of heat in industrial process applications. They are frequently
selected for such duties as:

Process liquid or gas cooling

Process or refrigerant vapor or steam condensing
Process liquid, steam or refrigerant evaporation
Process heat removal and preheating of feed water
Thermal energy conservation efforts, heat recovery
Compressor, turbine and engine cooling, oil and jacket water
Hydraulic and lube oil cooling
Many other industrial applications

Shell and tube heat exchangers have the ability to transfer large amounts of
heat in relatively low cost, serviceable designs. They can provide large
amounts of effective tube surface while minimizing the requirements of floor
space, liquid volume and weight.

Aims/Objectives

To evaluate and study the heat load and head balance, LMTD and

overall heat transfer coefficient.

To calculate the Reynolds numbers at the shell and tubes sides.
To measure and determine the shell and tube sides pressure drop.

Theory
Heat load and heat balance
This part of the calculation is to use the data in Table 1 to check the heat
QC
QC
QH
QH
load
and
and to select the set of values where
is closest to .

HW

Hot water flow rate (

)
QH

FH Cp H (t1 t 2 )

CW

Hot water flow rate (

)
FC CpC (T2 T1 )

QC

Where:

QH

= Heat load for hot water flow rate

QC

= Heat load for cold water flow rate

FH

Hot water mass flow rate

FC

Cold water mass flow rate

t1

Hot water inlet temperature

t2
T1
T2

Hot water outlet temperature

Cold water inlet temperature
Cold water outlet temperature

LMTD
Calculations of log mean temperature difference (LMTD).

LMTD

(t1 T 2) (t 2 T1 )
(t T2 )
ln 1
(t 2 T1 )

Where, all variables are same with the above section:

(t1 T2 )
(t2 t1 )

(t2 t1 )
(T1 t1 )

Both equations would determine the value of correction factor

FT

value obtained from the graph with respect to

and

FT

. Practically,

value. In this case,

the correction factor would apply to enhance the LMTD value. So, equation
below show the corrected LMTD can be determined.
LMTD FT LMTD

Overall heat transfer coefficient,

Overall heat transfer coefficient at which equivalent to

UD

can be calculated

by using equation below. In this case, the value of total heat transfer area
has been given and equal to 31.0 ft2

Q
A LMTD FT

Where:

Q
Heat rate with respect to the average head load
FT

Correction factor

Reynolds Number Calculation

Re(s)

Shell-side

CW

for

Re( s)

De.Gs

Where:

De

de
12
2

do
4(1 / 2 PT 0.86 PT 1 / 2 .
)
4
de
1 / 2 .do

At which:
PT
do

Pitch = 0.81inch

Tube outside diameter, inch

Viscosity, taken at average fluid temperature in the shell, lbmft-1hr-1

Gs
Ws
As

Ws
As

(lbmft-2hr-1)

Flow rate in (lbmhr-1)

0.029 ft2

Re(t )

Tube-side

HW

for

Re( t )

D.Gt

Where:
D

Tube ID = 0.04125 ft

Viscosity, taken at average fluid temperature in the tube, lbmft-1hr-1

Gt
Wt
At

Wt
At

(lbmft-2hr-1)

Flow rate in lbmhr-1

0.02139 ft2

Pressure drop
This part would determine the following:
HW

The measured tube-inside pressure drop DP (tube) which will be

corrected and is expected to be more than calculated tube-side pressure

drop.
CW

The measured shell-inside pressure drop DP (shell) which will be

corrected and is expected to be more than calculated tube-side pressure

drop.
Notice that, both calculated pressure and also measured pressure are
considered in unit mmH2O. In this case, since calculated pressure drop in
both of shell and tube side have been obtained during the experiment, so its
only required conversion factor to change the value into unit of mmH2O.

x.bar

1 105 Pa 1mmH2O

1bar
(9.81) Pa

Conversion factor:
Where

is the calculated pressure value in unit bar.

6) PROCEDURE

General start-up procedures

1. A quick inspection is performed to make sure that the equipment is in a proper working
condition.
2. All valve are initially closed, except V1 and V12.
3. Hot water tank is filled up via a water supply hose connected to valve V27. The valve is
closed after the tank is full.
4. The cold water tank is filled up by opening valve V28 and leave the valve opened for
continuous water supply.
5. A drain hose is connected to the cold water drain point.
6. Main power is switched on and heater for the hot water also switched on and set the
temperature controller to 50C.
7. The water temperature in the hot water tank is allowed to reach the set point.
8. The equilibrium is already set up.
General Shut-down
1. The heater is switched off. The hot water temperature drops is wait until below 40.
2. The pump P1 and P2 is switched off.
3. Main power is switched.
4. All the water in process lines is drain off. All valves is closed.

Experiment 1: Counter-current Concentric Heat Exchanger

1. The general start-up procedure is performed.
2. The valve is switched to counter-current Concentric Heat Exchanger arrangement.
3. The pumps P1 and P2 is switched on.
4. The valve V3 and V14 is opened and adjusted to obtain the desired flowrates for hot
water and cold water stream.
5. The system is allowed to reach steady state for 10 minutes.
6. FT1, FT2, TT1, TT2, TT3 and TT4 is recorded.
7. The pressure drop measurement for shell-side and tube side also recorded for pressure
drop studies.
8. The steps 4 to 7 is repeated for different combination of flowrates FT1 and FT2 as in the
result sheet.
9. The pumps P1 and P2 is switched off after the experiment is completed.
10. The next experiment is proceed.

Experiment 2: Co-Current Concentric Heat Exchanger

1. The valves is switched to Co-Current Concentric Heat Exchanger arrangement.
2. The pumps P1 and P2 is switched on.
3. The valves V3 and V14 is opened and adjusted to obtain the desired flowrates for hot
water and cold water streams.
4. The system is allowed to reach steady state for 10 minutes.
5. FT1, FT2,TT1, TT2, TT3 and TT4 is recorded.
6. The pressure drop measurement for shell-side and tube side is recorded for pressure drop
studies.
7. Steps 4 to 7 is repeated for different combinations of flowrate FT1 and FT2 as in result
sheet.

8. Pumps P1 and P2 is switched off after the experiment is completed.

9. The equipment is shut-down.

7) RESULT

FT 1 Hot Water Flow rate

FT 2 Cold Water Flow rate
TT 1 Cold water Outlet temperature
TT 2 Cold water Inlet temperature
TT 3 Hot water Outlet temperature
TT4 - Hot water Inlet temperature

Experiment 1: Counter current

FT 1
(LPM)

FT 2
(LPM)

TT 1
(C)

TT 2
(C)

TT 3
(C)

TT 4
(C)

10.0

2.0

33.5

29.4

48.4

49.1

DPT 1
(mmH2
O)
33

DPT 1
(mmH2
O)
81

10.0
10.0
10.0
10.0

4.0
6.0
8.0
10.0

31.9
31.9
32.2
32.6

29.9
30.7
31.2
31.7

48.3
48.8
48.7
48.5

49.0
49.7
49.4
49.2

40
77
130
140

82
81
87
96

FT 1
(LPM)

FT 2
(LPM)

TT 1
(C)

TT 2
(C)

TT 3
(C)

TT 4
(C)

2.0
4.0
6.0
8.0
10.0

10.0
10.0
10.0
10.0
10.0

32.4
32.4
32.6
32.6
32.8

31.8
31.8
31.9
31.9
31.7

47.5
47.6
48.2
48.4
48.5

50.1
49.3
49.3
49.3
49.3

DPT 1
(mmH2
O)
140
140
140
140
140

DPT 1
(mmH2
O)
10
18
36
54
60

Experiment 2 : Co-Current Concentric Heat Exchanger

FT 1
(LPM)

FT 2
(LPM)

TT 1
(C)

TT 2
(C)

TT 3
(C)

TT 4
(C)

DPT 1
(mmH2O
)

DPT 1
(mmH2O
)

10.0

2.0

32.4

34.9

48.7

49.2

-5

81

10.0

4.0

32.4

34.1

48.9

49.8

-5

81

10.0

6.0

32.1

33.5

48.0

48.8

-5

83

10.0

8.0

31.8

33.0

48.7

49.5

90

82

10.0

10.0

31.7

32.7

48.4

49.2

113

FT 1
(LPM)

FT 2
(LPM)

TT 1
(C)

TT 2
(C)

TT 3
(C)

TT 4
(C)

DPT 1
(mmH2O
)

DPT 1
(mmH2O
)

2.0

10.0

31.7

32.3

46.4

49.2

137

10

4.0

10.0

31.8

32.4

48.1

50.1

133

18

6.0

10.0

31.8

32.6

47.7

49.2

137

35

8.0

10.0

31.8

32.7

47.9

49.0

136

54

10.0

10.0

31.8

32.6

47.7

48.8

136

83

Notes
FT 1 Hot Water Flow rate
temperature

TT 1 Cold water Outlet

FT 2 Cold Water Flow rate

temperature

TT 2 Cold water Inlet

TT 3 Hot water Outlet temperature

TT4 - Hot water Inlet temperature

8) Calculation

Exp 1: Counter-Current Flow

83

Hot Water
Density:
Heat Capacity:
Thermal cond:
Viscosity:
Cold Water
Density:
Heat Capacity:
Thermal cond:
Viscosity:

988.18 kg/m3
4175.00 J/kg.K
0.6436 W/m.K
0.0005494 Pa.s
995.67 kg/m3
4183.00 J/kg.K
0.6155 W/m.K
0.0008007 Pa.s

1. Calculation of heat transfer and heat lost

Hot Water Flowrate = 10.0 LPM

LPM

Cold water flowrate = 2,4,6,8,10

1)
L
1m 3
1min
kg
J
(
)
Q hot W =mh C p T =10.0

988.18 3 4175
( 49.148.4 ) =481.33 W
min 1000 L 60 s
kg
m

Qcold ( W )=mh C p T =2.0

L
1 m3
1 min
kg
J

995.67 3 4183
( 33.529.4 ) =563.84 W
min 1000 L 60 s
kg
m

Heat Lost Rate=Qhot Qcold =( 481.33563.84 ) W =82.51W

=

Q
481.33
=
100 =85.37
Qmax 563.84

2)
L
1 m3
1 min
kg
J
(
)
Q hot W =mh C p =10.0

988.18 3 4175
( 49.048.3 ) =481.33W
min 1000 L 60 s
kg
m

Qcold ( W )=mh C p T =4.0

L
1m
1 min
kg
J

995.67 3 4183
(31.929.9 ) =555.32 W
min 1000 L 60 s
kg

Heat Los t Rate=Qhot Qcold =( 481.33555.32 ) W =73.99W

=

Q
481.33
=
100 =86.68
Qmax 555.32

3)
Q hot (W )=mh C p =10.0

L
1 m3
1 min
kg
J

988.18 3 4175
( 49.748.8 ) =618.85W
min 1000 L 60 s
kg
m

Qcold ( W )=mh C p =6.0

L
1m
1min
kg
J

995.67 3 4183
( 31.930.7 ) =499.79 W
min 1000 L 60 s
kg

Heat Lost Rate=Qhot Qcold =( 618.85499.79 ) W =119.06 W

=

Q
499.79
=
100 =80.76
Qmax 618.85

4)
Q hot (W )=mh C p =10.0

L
1 m3
1 min
kg
J

988.18 3 4175
( 49.448.7 ) =481.33 W
min 1000 L 60 s
kg
m
3

Qcold ( W )=mh C p T =8.0

L
1m
1 min
kg
J

995.67 3 4183
( 32.231.2 ) =555.32W
min 1000 L 60 s
kg

Heat Lost Rate=Qhot Qcold =( 481.33555.32 ) W =73.99W

=

Q
481.33
=
100 =86.68
Qmax 555.32

5)
Q hot (W )=mh C p =10.0

L
1 m3
1 min
kg
J

988.18 3 4175
( 49.248.4 ) =481.33 W
min 1000 L 60 s
kg
m
3

Qcold ( W )=mh C p T =10.0

L
1m
1 min
kg
J

995.67 3 4183
( 32.631.7 ) =624.73 W
min 1000 L 60 s
kg

Heat L ost Rate=Qhot Qcold =( 481.33624.73 ) W =143.40 W

=

Q
481.33
=
100 =77.05
Qmax 624.73

2. Calculation of Log Mean Temperature Difference (LMTD)

T lm=

[ ( Th ,Tc ,out ) ( Th ,out Tc , ) ]

ln [

( Th, Tc ,out )
]
( Th, out Tc , )

1)
T lm=

[ ( 49.133.5 )( 48.429.4 ) ]
=17.24
( 49.133.5 )
ln [
]
( 48.429.4 )

2)
T lm=

[ ( 49.031.9 )( 48.329.9 ) ]
=17.74
( 49.031.9 )
ln [
]
( 48.329.9 )

3)
T lm=

[ ( 49.731.9 )( 48.830.7 )]
=18.1
( 49.731.9 )
ln [
]
( 48.830.7 )

4)
T lm=

[ ( 49.432.2 )( 48.731.2 ) ]
=17.35
( 49.432.2 )
ln [
]
( 48.731.2 )

5)
T lm=

[ ( 49.232.6 )( 48.531.7 ) ]
=16.70
( 49.232.6 )
ln [
]
( 48.531.7 )

3. Calculate of the tube and shell heat transfer coefficient

0.8
0.33
At tube side (hot water-cooling process): Nu=0.023 Pr

L
1 m3 1 min
m3
V =10

=1.67 104
min 1000 L 60 s
s
2

d 2 (0.02664)
A=
=
=0.000557 m2
4
4
4
V 1.67 10
m
v= =
=0.299
A 0.000557
s

vd
=

988.18

Cp
Pr=
=
k

kg
m
0.299 0.02664 m
3
s
m
=14327 ( turbulent flow )
0.0005494 Pa s

( 0.0005494 P a s ) ( 4175
W
0.6436
mK
0.8

Nu=0.023 Pr

h=

Nuk
=
d

J
)
kg K

0.33

=3.564

0.8

=0.023 14327 3.564

0.33

=73.55

W
m K
W
=1776.91 2
0.02664 m
m K

73.55 0.6436

At shell side (cold water-heating process):

For (2 LPM)

L
1m3 1 min
m3
V =2

=3.33 105
min 1000 L 60 s
s
0.085

( 2( 0.0334 )2)

(d 2sd 2o)
A=
=
4
V 3.33 105
m
v= =
=0.0069
A
0.0048
s

Nu=0.023 0.8 Pr0.4

v ( d sd o )
=

955.67

kg
m
0.0069 ( 0.0850.0334 m)
3
s
m
0.0008007 Pa s

425 ( laminar flow )

Cp
Pr=
=
k

( 0.0008007 Pa s ) (4183
0.6155

0.8

J
)
kg K

W
m K

0.4

=5.49

0.8

0.4

Nu=0.023 Pr =0.023 425 5.49 =5.76

W
5.76 0.6155
Nuk
m K
W
h=
=
=68.68 2
d
(0.085 m0.0334 m)
m K

At shell side : ( 4 LPM)

3
L
1m 3 1 min
5 m

V =4

=6.67 10
min 1000 L 60 s
s

0.085

( 2( 0.0334 )2)

(d 2sd 2o)
A=
=
4
V 6.67 105
m
v= =
=0.0139
A
0.0048
s

v ( d sd o )
=

955.67

kg
m
0.0139 ( 0.0850.0334 m)
3
s
m
0.0008007 Pa s

856 ( laminar flow )

Cp
Pr=
=
k

( 0.0008007 Pa s ) (4183
0.6155

0.8

0.4

J
)
kg K

W
m K
0.8

=5.49

0.4

Nu=0.023 Pr =0.023 856 5.49 =10.80

W
10.80 0.6155
Nuk
m K
W
h=
=
=120.26 2
d
(0.085 m0.0334 m)
m K

At shell side : ( 6 LPM)

V =6

L
3
1m
1 min
4 m
m

=1 10
1000 L 60 s
s

0.085

( 2( 0.0334 )2)

(d 2sd 2o)
A=
=
4

4
V 1 10
m
v= =
=0.0208
A 0.0048
s

v ( d sd o )
=

955.67

kg
m
0.0208 ( 0.0850.0334 )
3
s
m
0.0008007 Pa s

1281 ( laminar flow )

Cp
Pr=
=
k

( 0.0008007 Pa s ) (4183
0.6155

0.8

0.4

J
)
kg K

W
m K

=5.49

0.8

0.4

Nu=0.023 Pr =0.023 1281 5.49 =13.91

W
12.35 0.6155
Nuk
m K
W
h=
=
=166.03 2
d
(0.085 m0.0334 m)
m K

At shell side : ( 8 LPM)

3
L
1 m3
1 min
4 m

V =8

=1.333 10
min 1000 L 60 s
s

0.085

( 2( 0.0334 )2)

(d 2sd 2o)
A=
=
4

4
V 1.333 10
m
v= =
=0.0278
A
0.0048
s

v ( d sd o )
=

955.67

kg
m
0.0278 ( 0.0850.0334 )
3
s
m
0.0008007 Pa s

1712 ( laminar flow )

Cp
Pr=
=
k

( 0.0008007 Pa s ) (4183
0.6155

0.8

0.4

J
)
kg K

W
m K

=5.49

0.8

0.4

Nu=0.023 Pr =0.023 1712 5.49 =17.55

W
17.55 0.6155
Nuk
m K
W
h=
=
=209.38 2
d
(0.085 m0.0334 m)
m K

At shell side : ( 10 LPM)

3
1 min
L
1 m3
4 m

V =10

=1.667 10
min 1000 L 60 s
s

0.085

( 2( 0.0334 )2)

(d 2sd 2o)
A=
=
4

4
V 1.667 10
m
v= =
=0.0347
A
0.0048
s

v ( d sd o )
=

955.67

kg
m
0.0347 ( 0.0850.0334 )
3
s
m
0.0008007 Pa s

2137 ( laminar flow )

Cp
Pr=
=
k

( 0.0008007 Pa s ) (4183
0.6155

0.8

0.4

J
)
kg K

W
m K

=5.49

0.8

0.4

Nu=0.023 Pr =0.023 2137 5.49 =20.96

W
20.96 0.6155
Nuk
m K
W
h=
=
=250.02 2
d
(0.085 m0.0334 m)
m K

Overall heat transfer coefficient:

Total exchange a rea , A= tube od length= 0.02664 m 0.5 m=0.05 m

1.
U=

Qhot
481.33 W
W
=
=558.39 2
2
A T lm 0.05 m 17.24
m K

2.

U=

Qhot
481.33 W
W
=
=542.65 2
2
A T lm 0.05 m 17.74
m K

3.

U=

Qhot
681.85W
W
=
=753.43 2
A T lm 0.05 m 2 18.1
m K

4.
U=

Qhot
481.33 W
W
=
=554.84 2
2
A T lm 0.05 m 17.35
m K

5.

U=

Qhot
481.33 W
W
=
=576.44 2
2
A T lm 0.05 m 16.70
m K

Discussion
In this experiment, the objectives are to evaluate and study the heat
load and head balance, LMTD and overall heat transfer coefficient, to
calculate the Reynolds numbers at the shell and tubes sides and to measure
and determine the shell and tube sides pressure drop. At the end of the
experiments, all objectives are met although maybe there are some errors.
It is found that the calculated values of QH and QC are not really
satisfied the theory since supposedly, the ratio of QC/QH is unity means the
ideal condition is the value of QC should be closed to the value of QH. But in
the calculated results, it is found that there are some deviations in the value
but it is normal because it is impossible to have an ideal system in real life.
The most irrelevant data for QC/QH is in run 1, set 3 where the ratio is 2.11.
The margin is big when compare to the ideal condition where QC/QH = 1.0.
The irrelevant value of this ratio is maybe caused by the unstable conditions
of shell and tube heat exchanger where this phenomenon occurs at the
beginning of the experiment.
For LMTD, the calculations consist of the use of graph which called as
correction factor graph. This graph is used to obtain a more accurate LMTD
as the calculated LMTD values may deviated from the actual one. The
correction factor, FT is obtained from the graph by finding the values of R
and S.
The overall heat transfer coefficients are also calculated in this
experiment to determine the total thermal resistance to heat transfer

between two fluids. The resistance can be reduced by increasing the surface
area, which will lead to a more efficient heat exchanger
The calculated Reynolds Number is to determine whether the flow of
water in shell and tube heat exchanger is turbulent flow or laminar flow. After
the Reynolds Number are obtained, we can determine whether the flow is
turbulent or laminar as for Re<2100, the flow is laminar flow and for
Re>4200, the flow is turbulent flow. For this experiment, based on the
calculated results, the water flow is turbulent at the tube sides of heat
exchanger as Reynolds Number that we obtained all exceeded 4200.
.

Conclusion
In conclusion, every objectives of this experiment had been achieved.
Although there might be errors, students still can achieve the objectives of
this experiment. At the end of the experiment, students are able to evaluate
and study the heat load and head balance, LMTD and overall heat transfer
coefficient, as well as to calculate the Reynolds numbers at the shell and
tubes sides and also to measure and determine the shell and tube sides
pressure drop. Students also are able to learn the fundamentals of shell and
tube heat exchanger, as well as the applications and advantages of it. All the
calculated data for this experiment can be referred to the table in calculation
section.

Recommendations

Follow safety regulations such as wearing a goggle, appropriate

clothes, and gloves to avoid any over-exposure to the substances
which can be harmful.

All the temperature and flowrate readings are taken simultaneously as

CW

inlet

temperature

is

increasing

gradually

and

CW

outlet

temperature varies together with the HW inlet/outlet temperature.

The last set of temperature readings should be taken when all the

temperatures are fairly steady.

Whenever the annunciator TAH3 is activated during the course of the

experiment, press the red acknowledge button to silence the buzzer.

The first set of data must be taken right away after the process is
started.

References
1. Coulson and Richardson; Chemical Engineering; Volume 1, 6th edition.
2. Max S. Peter & Klaus D. Timmerhaus; Plant Design and Economic for
Chemical Engineering; 4th edition; Page 576.
3. Rase, Howard F; Chemical Reactor Design and for Process and plants;
Volume 1; 1st edition.
4. G.C DRYDEN; The Efficient Use of Energy; 1st edition.

5. Frank P. Incropera, David P. DeWitt, 2002, Fundamental of Heat and

Mass Transfer, United State of America, 5 th Edition, John Wiley & Sons,
Inc.