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= 0.5 inch
BWG
= 16
Length
= 96 inch
Table 01: Observed data for Study of shell and tube heat exchanger
No
of
Obs
Steam
Pressure
(psig)
Flow
meter
reading
(L)
Water
Temperature
(C)
Inlet
(T1)
Outlet
(T2)
Weight of
condensat
e
+
bucket
(kg)
Manometer
Reading
Time
Water
(sec)
Condensate
(min)
Left
(inch)
Right
(inch)
10
24.5
32
2.45
11.1
33
36
10
24.5
31
2.7
8.79
32
36.7
10
24.5
30.5
6.91
30.6
37.5
10
24.5
29.5
3.2
5.54
27.5
38.8
10
27
34.5
3.1
10.09
32.6
36.4
10
27
33.5
3.65
8.6
31.5
37
10
27
32.5
3.75
30.1
37.5
10
27
31
3.9
5.72
27.4
38.8
2.5
CALCULATED DATA
Table 02: Calculated data for Mean, Saturation, Film and Wall temperature and Heat of
condensation and manometer reading in meter
No
Saturation
Mean
Film
Wall
Heat of
of Temperature, Temperature, Temperature, Temperature, Condensation
Obs
Ts (C)
Tm (C)
Tf (C)
Tw (C)
hfg (kJ/kg)
Manometer
Reading
Left
(m)
Right
(m)
104.44
28.25
75.86875
66.345
2244.6
0.8382
0.9144
104.44
27.75
75.68125
66.095
2244.6
0.8128
0.93218
104.44
27.5
75.5875
65.97
2244.6
0.77724
0.9525
104.44
27
75.4
65.72
2244.6
0.6985
0.98552
108.39
30.75
79.275
69.57
2234
0.82804 0.92456
108.39
30.25
79.0875
69.32
2234
0.8001
0.9398
108.39
29.75
78.9
69.07
2234
0.76454
0.9525
108.39
29
78.61875
68.695
2234
0.69596 0.98552
Table 03: Calculated data for properties of water at mean temperature and properties of
condensate at film temperature
Density
(kg/m3)
Viscosity
(kg/m.s)
Cp
(kJ/kg.C)
Thermal
conductivity
(W/m.C)
Density
(kg/m3)
Viscosity
(kg/m.s)
Thermal
conductivity
(W/m.C)
995.96
0.00083865 4.18056775
0.6165596
974.27875 0.00037466
0.6684263
996.12
0.00084655 4.18063425
0.6157496
974.39125 0.00037559
0.6682913
996.2
0.0008505
4.1806675
0.6153446
974.4475
0.00037606
0.6682238
996.36
0.0008584
4.180734
0.6145346
974.56
0.000377
0.6680888
995.16
0.00079915 4.18023525
0.6206096
972.235
0.00035763
0.6708788
995.32
0.00080705 4.18030175
0.6197996
972.3475
0.00035856
0.6707438
995.48
0.00081495 4.18036825
0.6189896
972.46
0.0003595
0.6706088
995.72
0.0008268
0.6177746
972.62875 0.00036091
0.6704063
4.180468
Table 04: Calculated data for water and condensate flow rate, Heat rate of water and steam
and mean heat rate
Water
No of
Flow
Obs Rate, mw
(kg/s)
Condens
ate Flow
rate, mc
(kg/s)
Heat
absorbed
by water
Qw (kW)
Heat
released by
steam, Qc
(kW)
Heat loss
(kW)
Percent
heat loss
Mean Heat
Flow, Qm
(kW)
0.89726
0.00791
28.1329612
17.76975
-10.363
-58.31
22.9513556
1.13324
0.01
30.7948658
22.446
-8.3488
-37.19
26.6204329
1.44167
0.0125
36.1630764
28.0575
-8.1055
-28.88
32.1102882
1.79848
0.01416
37.5949109
31.7985
-5.7964
-18.22
34.6967055
0.98628
0.0133
30.9217263 29.7866667
-1.1350
-3.81
30.3541965
1.15734
0.01791
31.4474379 40.0258333
8.57839
21.43
35.7366356
1.42211
0.01875
32.6972877
41.8875
9.19021
21.94
37.2923939
1.7407
0.02
29.1089203
44.68
15.57
34.85
36.8944601
Table 05: Calculated data for tube and shell side heat transfer co-efficient
No
of
Obs
Tube side
Reynolds'
No
Tube Side
prandtl no.
Viscosity
of water at
wall
temperature
(kg/m.s)
Tube side
Nusselt No
67.57398
jH value
Tube side
heat
transfer
coefficient,
hi
(W/m2.C)
Shell side
heat transfer
coefficient,
ho
(W/m2.C)
34.4410319 4433.21835
4730.50156
4719.37987
4713.85036
4702.85325
4765.7861
43.5368188 5556.47796
4754.58813
4743.47295
84.252684
59.194071
7615.08844
4726.953
Table 06: Calculated data for experimental and theoretical overall heat transfer coefficient
Overall
Experimental
heat transfer
coefficient,
UoE
(W/m2.C)
Overall
Theoretical
heat transfer
coefficient,
UoT
(W/m2.C)
No of Obs
Mass velocity
of water
(kg/m2.s)
LMTD (C)
Outside
surface area
of 19 tubes
(m2)
680.277018
76.1284364
1.84847321
163.0978635
1937.165799
859.190895
76.6440681
1.84847321
187.8985402
2146.361712
1093.03828
76.9009928
1.84847321
225.891088
2368.989501
1363.55732
77.41309
1.84847321
242.4714874
2568.412839
747.771014
77.5795876
1.84847321
211.6694175
2062.035309
877.467745
78.0949212
1.84847321
247.5584263
2204.945136
1078.2051
78.6079342
1.84847321
256.6496755
2392.27619
1319.79988
79.3732024
1.84847321
251.4630026
2570.629003
Table 07: Calculated data for tube side experimental and theoretical pressure drop
No
of
Obs
Experiment
al Pressure
Drop from
manometer
reading,
(Pa)
Friction
Specific
factor
gravity,
(sq ft/sq
s
inch)
10161.8141
0.0003
23372.1724 0.00025
Pressure
drop due to
velocity
head (Pa)
Total
Theoretical
Pressure
drop PT
(Pa)
1.09923283
2362.721233 937.945183
3300.66642
1.100118
3388.780082 1495.46379
4884.24387
0.9962
1.10055656
5075.783231 2419.70643
7495.48967
1.10142577
7260.296222 3763.82565
11024.1219
1.09919479
2666.729295
1136.0307
3802.75999
1.10012354
3406.298481 1563.52805
4969.82653
25065.808
0.00024 0.99548
1.10104053
4742.740664 2359.59079
7102.33145
1.10239447
6800.188707 3532.93806
10333.1268
0.99596
t
(/w)^0.14
Pressure
drop through
tubes Pt
(Pa)
GRAPHS
1) jH factor vs Reynolds No
jH Factor
100
y = 0.8001x +log0.00395
10
1000
10000
100000
Reynolds' No
10
jH Factor
100
y = 0.8001x +log0.00395
10
1000
10000
100000
Reynolds' No
11
35000
30000
25000
20000
Experimental
Theoretical
15000
10000
5000
0
0.6
0.7
0.8
0.9
1.1
1.2
1.3
1.4
Figure 04: Pressure Drop vs Velocity of Water for 2.5 psig Steam Pressure
12
35000
30000
25000
20000
Experimental
Theoretical
15000
10000
5000
0
0.7
0.8
0.9
1.1
1.2
1.3
1.4
Figure 05: Pressure Drop vs Velocity of Water for 5 psig Steam Pressure
13
SAMPLE CALCULATION
For observation no. 2 (2.5 psig steam pressure):
Water inlet temperature, T1
= 24.5oC
= 31oC
T1 T2
=
2
24.5 31
2
= 27.75oC
= 996.12 kg/m3
Viscosity,
= 0.00084655 kg/m.sec
= 4.18063425 kJ/kg. C
[From J. P. Holman, Heat Transfer, McGraw - Hill, 10th Ed, 1997, Page-605, Table A-5]
Saturation temperature at 2.5 psig steam pressure, Ts = 104.44oC
Heat of Condensation at 2.5 psig steam pressure, hfg
= 2244.6 kJ/kg
= 1.5 kg
Weight of condensate
= (2.7-1.5) kg
= 1.2 kg
1.2 kg
2 60 sec
= 0.01 kg/sec
Heat released by condensation, Qc = mchfg
= (0.012244.6) kW
= 22.446 kW
14
10 10 3 m 3 996.12kg / m 3
=
8.79 sec
= 1.133242321 kg/sec
Heat absorbed by water, Qw
= mwCp(T2-T1)
= 1.1332423214.18063425(31-24.5)
= 30.79486579 kW
= (Qc Qw)
Heat loss
= (22.446 - 30.79486579) kW
= -8.3489 kW
Percent heat loss
(QC QW )
100%
QC
= -37.195 %
Average heat transfer, Qavg
Q w Qc
2
30.79486579 22.446
2
= 26.6204 kW
Logarithmic Mean Temperature Difference,
LMTD
(Ts T1 ) (Ts T2 )
T T1
ln s
Ts T2
104.44 31
= 76.6441 C
15
= 190.596 inch2
= 2865.14 inch2
= 1.84847 m2
Experimental overall heat transfer co-efficient,
UOE
Q avg
A 0 LMTD
26.6204 1000
1.84847 76.6441
= 187.8985 W/m2. C
Flow area of tube, Ai
19 0.1076
inch2
1
= 2.0444 inch2
= 0.001318965 m2
Velocity of water
=
=
1.133242321
0.001318965 996.12
= 0.86254 m/sec
Mass velocity of water,
=
=
1.133242321
= 859.191 kg/m2sec
0.001318965
16
Reynolds number, Re
Di v w
= 9538.333
Wall temperature
Tw
Prandtl Number, Pr
= 5.74765
-1/3
jH = Nu .Pr
.
w
0.14
= 41.2042
k
Di
= 81.1978
0.6157496
0.009398
= 5320.0201 W/m2. C
17
= Ts 0.75 (Ts-Tw)
Film temperature, Tf
= 75.68125 oC
Properties of condensate at film temperature (75.68125oC),
Density, f
= 60.859 kg/m3
Viscosity, f
= 0.907023 kg/m.sec
f ( f v )gh fg k f 3
= 0.725
f nd(Tg Tw )
f 2 gh fg k f 3
= 0.725
f D o (Tg Tw )
0.25
0.25
= 4719.3798 W/m2. C
Theoretical overall heat transfer co-efficient,
UOT
1
D
o
=
h 0 Di h i
-1
= 2146.362 W/m2. C
Pressure Drop Calculation:
For Reynolds no = 9538.333
The value of friction factor, f = 0.00027 sq ft/sq inch
[From Donald Q. Kern, Process Heat Transfer, McGraw - Hill, International Ed, 1997,
Page-836, Figure 26]
Mass velocity of water Gt = 633513.753 lb/hr.ft2
Length of the tube, L = 8 ft
No of tube passes, n = 1
18
f Gt 2 L n
5.22 1010 D s ( / w ) 0.14
= 0.491500997 psi
= 3388.780082 Pa
Velocity of water, v = 2.82985 ft/s
Acceleration of gravity, g = 32.174 ft/s2
Velocity head,
v2
= 0.1244489 ft
2g'
4 n v 2 62.5
s
2 g ' 144
= 0.21689868 psi
= 1495.464 Pa
Total pressure drop, PT = Pt+ Pr
= 4884.24387 Pa
Difference in manometer height, h = (0.93218- 0.8128) m Hg
= 0.11848 m Hg
Density of mercury, Hg = 13594 kg/m3
Experimental pressure drop = hHgg
= 0.11848 13594 9.81
= 15920.175 Pa
19
--------
10161.8 to 38614.9 Pa
3300.7 to 11024.12 Pa
Some of the heat loss found in this experiment were a negative value. But that was not
expected. The condensate was collected through a steam trap, in which the flow was not
continuous. As a result condensate flow rate was not steady for this experiment, hence
negative heat loss encountered in the experiment. The steam pressure was considered
constant during the experiment but it was not constant. Heat lost during the experiment due to
convection and conduction was not also considered.
Two types of graphs were drawn in the experiment. From the 1st type of graph, jH factor vs
reynolds no the slope was found 0.8001 both for 2.5 and 5 psig steam pressure, which proves
the validity of Sieder-Tate equation.
From the 2nd type of graph, pressure drop vs velocity of water the experimental pressure drop
was found somewhat greater than the theoretical pressure drop both for 2.5 and 5 psig steam
pressure. The theoretical values found in this experiment were not absolutely theoretical.
These values are found based on some parameters that are determined experimentally in one
way or another. Hence, they cannot be said to be purely theoretical. However, these
theoretical values can be of great importance when reasonable approximation and comparison
are required in real life consequence. One of the important things in shell and tube exchanger
operation is the pressure limitation that must be abided both in shell and tube sides. Beyond
this pressure limits the system can become unstable and materials of construction is affected
mainly due to corrosion and erosion.
Excess fouling might encounter in tube side which decrease the overall heat transfer coefficient.
20
After two consecutive reading we have to pause our experiment meanwhile heat exchanger
lost its current status & become cool .Thereby temperature exchange not happen linearly
which is great obstacle to perform this experiment.
21