Manipal University Jaipur

Department of Chemical Engineering

CE 1631- TRANSPORT PHENOMENA LABORATORY-II

III YEAR, 6TH SEMESTER, 2018

EXPERIMENT #8

CROSS FLOW HEAT EXCHANGER

INSTRUCTOR:

Dr. ANAND GUPTA CHAKINALA

GROUP #4

AKRITI AGARWAL

Experiment carried on: March 7, 2018

Report submitted on: March 12, 2018

PRELAB (10) ______

EXECUTIVE SUMMARY (10) ______

INTRODUCTION/OBJECTIVES/SCOPE/PROCEDURE (30) ______

RESULTS & DISCUSSION (30) ______

CONCLUSIONS (5) ______

REFERENCES (5) ______

APPENDIX

a) Original data, sample calculations, other information (5) ______

GENERAL COMPLETENESS

a) Conciseness and neatness (5) ______

TOTAL (100) ______

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Table of Contents
EXEXCUTIVE SUMMARY ................................................................................................................................ 5
INTRODUCTION ........................................................................................................................................ 6
OBJECTIVE ................................................................................................................................................. 9
EXPERIMENTAL SET UP .......................................................................................................................... 9
PROCEDURE ............................................................................................................................................. 10
Start up .................................................................................................................................................... 10
Operation ................................................................................................................................................ 10
Shut down ............................................................................................................................................... 11
RESULTS AND DISCUSSION ................................................................................................................. 11
CONCLUSION AND RECOMMENDATION .......................................................................................... 12
REFERENCES ........................................................................................................................................... 12
APPENDIX A1 ........................................................................................................................................... 13
Other Information ................................................................................................................................... 13
Original data obtained ............................................................................................................................. 13
Detailed calculation ................................................................................................................................ 14
A) Physical Properties Obtained .................................................................................................. 14
B) Calculations............................................................................................................................. 14
C) Graphs used ............................................................................................................................. 15

List of figures
Figure 1: Flow pattern in a cross flow HEX when one fluid is mixed (gas) and one fluid is unmixed ........ 6
Figure 2: Flow pattern in cross flow HEX when both fluids are unmixed ................................................... 7
Figure 3: Experimental set-up for cross flow heat exchanger....................................................................... 9
Figure 4: Correction factor Ft to LMTD for both fluids unmixed in a cross flow HEX ............................. 15

List of Tables
Table 1: Results obtained for constant cold water flow rate of 190 LPH ................................................... 11
Table 2: Results obtained for constant hot water flow rate of 100LPH ...................................................... 11
Table 3: Original data obtained for constant cold water flow rate .............................................................. 13
Table 4: Original data obtained for constant hot water flow rate ............................................................... 14
Table 5: Physical property data for constant cold water flow-rate ............................................................. 14

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Table 6: Physical property data for constant hot water flow rate................................................................ 14
Table 7: Calculation performed for constant cold water flow rate ............................................................. 14
Table 8: Calculations for constant hot water flow rate ............................................................................... 15

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EXEXCUTIVE SUMMARY
The objective of the experiment was to determine the heat transfer co-efficient for a cross flow
heat exchanger. The cross flow heat exchanger had an inside diameter 0.016m, outside diameter
0.02m, 22 tubes of length 0.25m. For a constant cold water flow rate of 190 LPH and varying hot
water flow rate (100, 145, 180, 220 LPH) the overall heat transfer co-efficient was found to vary
from 110 to 180 W/m2-K. For a constant hot water flow rate of 100 LPH and varying cold water
flow rates (50, 80, 150, 225) the overall heat transfer co-efficient varied from 100-127 W/m2-K.

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INTRODUCTION
In the process industries the transfer of heat between two fluids is generally done in heat
exchangers1. The most common type is one in which the hot and cold fluids do not come into
direct contact with each other but are separated by a tube wall or a flat or curved surface1. The
transfer of heat from hot fluid to the wall or tube surface is accomplished by convection, through
the tube wall or plate by conduction, and then by convection to the cold fluid.There are mainly 5
types of heat exchangers.
 Shell & tube heat exchangers.
 Plate heat exchangers.
 Plate & frame heat exchangers.
 Double pipe heat exchangers.
 Cross flow heat exchangers.
This experiment uses a cross flow heat exchanger whose overall heat transfer co-efficient is to be
calculated. When a gas such as air is being heated or cooled a common device used is the cross
flow heat exchanger as shown in Fig. 1

Figure 1: Flow pattern in a cross flow HEX when one fluid is mixed (gas) and one fluid is unmixed

One of the fluids, which is a liquid, flows inside through the tubes and the exterior gas flows
across the tube bundle by forced or sometimes natural convection1. The fluid inside the tubes is
considered to be unmixed, since it is confined and cannot mix with any other stream. The gas
flow outside the tubes is mixed, since it can move about freely between the tubes, and there will
be a tendency for the gas temperature to equalize in the direction normal to the flow. For the
unmixed fluid inside the tubes, there will be a temperature gradient both parallel and normal to

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the direction of flow. A second type crossflow heat exchanger is typically used in air-
conditioning and space heating applications and is shown in Fig 2.

Figure 2: Flow pattern in cross flow HEX when both fluids are unmixed

In this type, the gas flows across a finned-type bundle and is unmixed, since it is confined in
separate flow channels between the fins as it passes over the tubes. The fluid in the tube is
unmixed. The heat transferred to the cold air flow, is the actual heat throughput of the heat
exchanger.

The equations used are given below.

∆𝑇ℎ = 𝑇2 − 𝑇1………………………………………. (1)

∆𝑇1 = 𝑇1 − 𝑇3 ………………………………………… (2)

∆𝑇2 = 𝑇2 − 𝑇4 …………………………………………. (3)

∆T1 − ∆T2
∆TLMTD = ∆T1 …………………………….(4)
ln
∆T2

𝐶. 𝐿𝑀𝑇𝐷 = 𝐹𝑡 × 𝑇𝐿𝑀𝑇𝐷 ……………………… (5)

Fh ×ρh
Mh = ………………………………….. (6)
3600×1000

𝑄ℎ = 𝑀ℎ × 𝐶𝑝ℎ × (𝑇1 − 𝑇2 ) ……………………….. (7)

Mh ×Di
Reh = Ai ×μh
………………………………………… (8)

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 Cph ×μh
Prh = ………………………………………… (9)
kh

𝐷𝑖 2 𝑁𝑡
𝐴𝑡 = 𝑝𝑖 × × …………………………………… (10)
4 2

𝑅𝑒×𝑃𝑟×𝐷𝑖 0.33
𝑁𝑢ℎ = 1.86 × ( ) ……………………….. (11)
𝐿

𝑁𝑢×𝑘
ℎ𝑖 = ……………………………………………. (12)
𝐷𝑖

ℎ𝑖×𝐷𝑖
ℎ𝑖𝑜 = …………………………………………….. (13)
𝐷𝑜

ℎ ×ℎ
𝑈𝑐 = ℎ𝑖𝑜+ℎ𝑖 …………………………………………….. (14)
𝑖𝑜 𝑖

Where,

ℎ𝑖 = inside heat transfer coefficient (W/ m2 K)

ℎ𝑖𝑜 = outside heat transfer coefficient (W/ m2 K)
𝐷𝑖 = inside diameter of the tube (m)
𝐷𝑜 = outside diameter of the tube (m)
𝑀ℎ = Mass flowrate of hot water (kg/s)
𝑘ℎ = thermal conductivity of hot water at the mean temperature (W/m K)
𝜌ℎ = density of hot water at the mean hot water temperature (kg/m3)
𝐶𝑝ℎ = Specific heat capacity of hot water at mean hot water temperature (J/kg K)
𝜇ℎ = Viscosity of hot water at mean hot water temperature (kg/ m s)
𝑃𝑟ℎ = Prandtl number of hot water
𝑅𝑒ℎ = Reynolds number of hot water
𝑃𝑟ℎ = Prandtl number of hot water
L = length of the tubes (m)
Nt = number of tubes
Qh = heat transfer by hot water (J/s)
𝑈𝑐 = overall heat transfer coefficient calculated (W/ m2 K)
𝑈𝑑 = overall heat transfer coefficient measured (W/ m2 K)
𝐴𝑡 = area of tube side(m2)
𝐴𝑜 = outside heat transfer area (m2)
𝑇1 = Temperature of hot water inlet (°C)
𝑇2 = Temperature of hot water outlet (°C)
𝑇3 = Temperature of cold water inlet (°C)
𝑇4 = Temperature of cold water outlet (°C)
∆𝑇𝐿𝑀𝑇𝐷 = log mean temperature difference (°C)

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In the preceding section the log mean temperature difference was used. When the temperature of
the fluids leaving the exchanger are not known and a given exchanger is to be used a method
called the heat exchanger effectiveness is used. The heat exchanger effectiveness is defined as
the ratio of actual amount of heat transfer in a given exchanger to the maximum amount of heat
transfer if an infinite heat transfer area were available.
−𝑈𝐴 𝐶
1 − exp [ 𝐶 (1 − 𝐶𝑚𝑖𝑛 )]
𝑚𝑖𝑛 𝑚𝑎𝑥
ɛ= … … … … … . (15)
𝐶𝑚𝑖𝑛 −𝑈𝐴 𝐶
1 − 𝐶𝑚𝑎𝑥 exp [ 𝐶 (1 − 𝐶𝑚𝑖𝑛 )]
𝑚𝑖𝑛 𝑚𝑎𝑥

Equation 15 is valid if Cmax = CH = (mcp)H

−𝑈𝐴 𝐶
1 − exp [ 𝐶 (1 + 𝐶𝑚𝑖𝑛 )]
𝑚𝑖𝑛 𝑚𝑎𝑥
ɛ= … … … . (16)
𝐶𝑚𝑖𝑛
1 + 𝐶𝑚𝑎𝑥

Equation 16 is valid if CH = Cmin

OBJECTIVE
To study the heat transfer rate, to determine the overall heat transfer coefficient and understand
the significance of LMTD at different flow rates.

EXPERIMENTAL SET UP

Figure 3: Experimental set-up for cross flow heat exchanger

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Figure 3 shows the set-up for cross flow heat exchanger. It consists of a cross flow heat
exchanger with inside diameter 0.016m, outside diameter 0.02m, 22 tubes of length 0.25m.
Heat is transferred from hot to cold fluid inside the heat exchanger. R1 and R2 are rotameters that
tells us the flow rate of hot and cold water in the heat exchanger respectively. The pump is used
to transport hot water from the hot water tank to the heat exchanger. The hot water tank has two
heaters which maintain the temperature of the hot fluid by continuously heating it. The
temperature of the heater can be maintained by a digital temperature controller in the control
panel. The control panel is used to start the set-up and the temperature readings are obtained
here. V stands for valves that control the flow rate of fluids flowing. V1 controls the flow rate of
cold water, V2 controls the flow rate of hot water, V3 is the by-pass valve for the pump
transporting hot water, V4, V5 and V6 are drain valves for shell side, tube side and hot water tank
respectively. T1, T2, T3 and T4 are thermosets that measures the temperature of inlet and outlet
temperature of cold and hot water flowing through the heat exchanger.

PROCEDURE
Start up
1. Ensure that all the valves of the apparatus are closed and the main electricity supply is
switched off.
2. Fill in water inside the storage tank such that both the heaters are completely immersed in
water and the tank is filled up to 75% of its height to initiate better heat exchange.
3. Switch on the heater and set the temperature of the heater to 85°C.

Operation
1. Wait till the hot water temperature reaches 85°C
2. Open the cold water inlet valve and allow it to flow.
3. Adjust the flowrate (LPH) of the cold water using the cold water inlet valve and set the
flowrate.
4. Switch on the pump and allow the hot water to flow through the heat exchanger.
5. Adjust the flowrate (LPH) of the hot water using the control valve and set the flowrate to
a desired value.
6. Allow the temperature of all thermo-sets to become constant and then note down the
temperatures of the inlet and outlet water temperatures.
7. Change the hot water flowrate and again note down the readings of the thermosets.
8. Take at least 4 set of readings of temperatures of the inlet and outlet water in the shell
side and tube side for constant cold water flowrate and varying hot water flowrate.
9. Now keep the hot water flowrate constant and vary the cold water flowrate.
10. Take at least 4 set of readings of temperatures of the inlet and outlet water for constant
hot water flowrate and varying cold water flowrate.
11. Repeat steps 6-10 for two more sets of flowrate of hot and cold water.

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Shut down
1. Switch of the heater and the pump.
2. Close the cold water inlet valve.
3. Empty the shell side and tube side of the heat exchanger.
4. Allow the water in the storage tank to cool down to the room temperature.
5. Open the outlet valve of the storage tank to drain out the water in it.
6. Switch off the main electricity supply.
7. Ensure that all the valves are closed.

RESULTS AND DISCUSSION

For a cross flow heat exchanger with inside diameter 0.016m, outside diameter 0.02m, 22
tubes of length 0.25m , the results obtained are shown in Table 1 and 2. The detailed calculation
can be seen in Appendix A1. The results were obtained using equations 1-14.

Table 1: Results obtained for constant cold water flow rate of 190 LPH

Hot water flow rate Cold water flow rate hi hio Uc C.LMTD Qh Ud
(LPH) (LPH) (W/m2-K) (W/m2-K) (W/m2-K) (K) J/s (W/m2-K)
100 190 163.0635 130.4508 72.47267 27.90237 2152.892 111.6371
145 190 184.2278 147.3823 81.87904 27.47066 3105.177 163.5478
180 190 197.7454 158.1964 87.88686 27.83176 3280.564 170.5436
220 190 211.3029 169.0423 93.91241 28.44558 3558.501 181.0005

Table-1 shows the inside and outside heat transfer coefficient for constant cold water flowrate
(190 LPH) and varying hot water flowrate (100, 145, 180, 220 LPH) in the range of 130 to 211
W/m2-K, overall heat transfer coefficient (Ud) in the range of 111 to 181 W/m2-K. For constant
cold water flowrate (190 LPH) and increasing hot water flowrate, there is increase in the outside
heat transfer coefficient as well as in the overall heat transfer coefficient. This shows that with
increase in hot water flowrate, the heat transfer rate also increases which proves the
proportionality of flowrate with the heat transfer rate.

Table 2: Results obtained for constant hot water flow rate of 100LPH

Hot water flow rate Cold water flow rate hi hio Uc C.LMTTD Qh Ud
(LPH) (LPH) (W/m2-K) (W/m2-K) (W/m2-K) J/s (W/m2-K)
100 50 163.0998 130.4798 72.4888 23.18631 2050.374 127.9466
100 80 163.1143 130.4914 72.49524 27.50173 2141.501 112.6641
100 150 163.1681 130.5345 72.51914 29.49617 2039.107 100.0235
100 225 163.1681 130.5345 72.51914 26.32581 1970.757 108.3126

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Table-2 shows the inside and outside heat transfer coefficient for constant hot water flowrate
(100 LPH) and varying cold water flowrate (50, 180, 150, 225 LPH) in the range of 130 to 163
W/m2-K and the overall heat transfer coefficient (Ud) in the range of 100 to 127 W/m2-K. Heat
transfer co-efficient decreases with increase in cold water flow rate.

From the above tables, the general characteristics of cross flow heat exchangers can be observed.
In the cross flow configuration, the exit temperature of the hot fluid is lower than that of the
entrance temperature while the exit temperature of the cold fluid is higher than that of the
entrance temperature. At constant flow rates the ratio between temperature differences of the hot
fluid and the cold fluid changes with respect to the flow rates. The energy removed from the hot
fluid is added to the cold fluid. When cold water flow rate is constant and hot water flow rate is
increased the overall heat transfer coefficient increases. If hot water flow rate is kept constant
and cold water flow rate increases the heat transfer coefficient decreases as the contact time
decreases.

CONCLUSION AND RECOMMENDATION

The objective of the experiment was to determine the heat transfer co-efficient for a cross flow
heat exchanger with inside diameter 0.016m, outside diameter 0.02m, 22 tubes of length 0.25m.
For a constant cold water flow rate of 190 LPH and varying hot water flow rate (100, 145, 180,
220 LPH) the overall heat transfer co-efficient was found to vary from 110 to 180 W/m2-K. With
increase in hot water flow rate overall heat transfer co-efficient increases. For a constant hot
water flow rate of 100 LPH and varying cold water flow rates (50, 80, 150, 225) the overall heat
transfer co-efficient varied from 100-127 W/m2-K. With increase in cold water flow rate the
overall heat transfer co-efficient decreases.

REFERENCES
1. Geankoplis, C. J. Transport Processes and Separation Process Principles: Includes Unit
Operations. (Prentice Hall Professional Technical Reference, 2003).
2. Green, D. W. & Perry, R. H. Perry’s Chemical Engineers’ Handbook, Eighth Edition.
(McGraw-Hill Education, 2007).

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APPENDIX A1
Other Information
𝐶2
1. µ = exp(𝐶1 + 𝑇
+ 𝐶3 𝑙𝑛𝑇 + 𝐶4 𝑇 𝑐5) 2
Where,
C1=-52.843
C2=3703.6
C3=5.866
C4 = -5879E-29
C5= 10

2. 𝑘 = 𝐶1 + 𝐶2 𝑇 + 𝐶3 𝑇 2 + 𝐶4 𝑇 3 2
Where,
C1 = -0.432
C2= 0.0057255
C3 = -.000008078
C4= 1.861E-09

(𝑇1 −𝑇2 )
3. 𝑅 =
(𝑇4 −𝑇3)
𝑇4 −𝑇3
𝑆=
𝑇1 −𝑇3

4. Number of tubes = 22
Outer diameter of the tube = 0.02m
Inner diameter of the tube = 0.016m
Length of the tube = 0.25m
Cross sectional area = 0.1727m2

Original data obtained

Table 3: Original data obtained for constant cold water flow rate

Hot water flow rate Cold water flow rate T1 T2 T3 T4

(LPH) (LPH) (°C) (°C) (°C) (°C)
100 190 77 58.1 29.3 41.2
145 190 76.3 57.5 29.3 41.3
180 190 74.3 58.3 29.3 41.4
220 190 73.5 59.3 29.3 41.5

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 Table 4: Original data obtained for constant hot water flow rate

Hot water flow rate Cold water flow rate T1 T2 T3 T4

(LPH) (LPH) (°C) (°C) (°C) (°C)
100 50 76.8 58.8 29.1 48.2
100 80 77.3 58.5 29.3 43.9
100 150 77.2 59.3 29.4 41
100 225 76.9 59.6 29.3 46

Detailed calculation
A) Physical Properties Obtained

Table 5: Physical property data for constant cold water flow-rate

Hot water flow rate Cold water flow rate Th Cph kh µh ρh

(LPH) (LPH) (K) (W/m-K) Pa-s kg/m3
100 190 340.55 4180 0.654479 0.000482 981.04
145 190 339.9 4180 0.65391 0.000486 981.04
180 190 339.3 4180 0.65338 0.000491 981.03
220 190 339.4 4180 0.653469 0.00049 981.03

Table 6: Physical property data for constant hot water flow rate

Hot water flow rate Cold water flow rate Th Cph kh µh ρh

(LPH) (LPH) (K) (W/m-K) Pa-s kg/m3
100 50 340.8 4180 0.654696 0.00048 981.04
100 80 340.9 4180 0.654783 0.000479 981.04
100 150 341.25 4180 0.655086 0.000477 981.1
100 225 341.25 4180 0.655086 0.000477 981.1

B) Calculations
Table 7: Calculation performed for constant cold water flow rate

Hot water rate Cold water rate Mass flow Area

rate of hot
Nre Pr Nu LMTD Z Y Ft
(LPH) (LPH) Mh(kg/s) m2
100 190 0.027251 0.01769 51.186 3.07544 3.9864 29.68338 1.5882 0.249 0.94
145 190 0.039514 0.01769 73.513 3.10771 4.50772 28.91649 1.5667 0.255 0.95
180 190 0.049052 0.01769 90.449 3.138 4.8424 28.69253 1.3223 0.269 0.97
220 190 0.059952 0.01769 110.71 3.13292 5.17369 29.0261 1.1639 0.276 0.98

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 Table 8: Calculations for constant hot water flow rate

Hot water rate Cold water rate Mass flow Area Nre Pr Nu LMTD Z Y Ft
(LPH) (LPH) Mh(kg/s) m2
100 50 0.02725111 0.01769 51.374 3.0632 3.986 24.666 0.942408 0.400419 0.94
100 80 0.02725111 0.01769 51.449 3.0583 3.9858 28.063 1.287671 0.304167 0.98
100 150 0.02725278 0.01769 51.716 3.0413 3.9853 30.725 1.543103 0.242678 0.96
100 225 0.02725278 0.01769 51.716 3.0413 3.9853 27.14 1.035928 0.35084 0.97

C) Graphs used

Figure 4: Correction factor Ft to LMTD for both fluids unmixed in a cross flow HEX

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