ABSTRACT

The experiment was about the study of the effect of flow rate in effectiveness of shell-
and-tube heat exchanger. Heat exchanger is used to transfer heat from one fluid to another.
The common heat exchanger used is shell-and-tube heat exchanger.

The objectives of this experiment were to calculate and analyse heat transfer at steady
state, to determine effect of liquid flow rate on heat transfer coefficient and compare
effectiveness heat transfer base on flow Stream.

This experiment started by performing general procedure as instructed in Work

Instruction of the equipment and module. Next, the hot tank temperature was set at 50◦C then
the pump (P1, P2) and air cooler were switched on. The air trap in shell side was released by
opening valve HV14. The valve HV5 was adjusted to obtain the desire flow rate for hot water
and at the same time the flow rate for cold water was fixed by using valve HV15. Then, the
system was allowed to reach the steady state. The data of different hot water flow rate was
recorded. The experiment was repeated for cold water stream where the flow rate for hot
water was fixed by using valve HV15 while flow rate for cold water was adjusted to obtain
desired flow rate by using valve HV5. The data of different cold water flow rate was
recorded.

The result that obtained for hot water stream was the temperature of hot water and
cold water increases. For cold water stream, the temperature of hot water decreases. The
temperature of cold water outlet increase while the temperature of cold water inlet decreases.

To conclude, the study of this experiment shows that shell-and-tube heat exchanger
follows thermodynamics rules.

1
METHODOLOGY

Experiment A: Effect of Hot Water System

The hot tank was set at Adjusted valves

The general start-up
procedure was 50oC. When the
temperature was constant
perform (refer to
work instruction on at 50oC, the pumps (P1
and P2) and air cooler
equipment)
was switch on. The air
trap was released in shell
side by opening valve
HV14
HV5 to obtain the
desired flow rate for
hot water and at
same time fix the
flow rate for cold
water stream using
valve HV15 (please
set one value of flow
rate)

Step 3 and 4 was repeated for next 4 The system was allowed
different flow rate (Hot Water Flow to reach steady state and
rate Range: 2 – 20 LPM) and the all the data was
equipment was shut down recorded

Experiment B: Effect of Cold Water System

Adjusted valves HV5

The general start-
up procedure was
perform (refer to
work instruction
on equipment)
The hot tank was set at
50oC. When the
temperature was
constant at 50oC, the
pumps (P1 and P2) and
air cooler was switch
on. The air trap was
released in shell side by
opening valve HV14
to obtain the desired
flow rate for hot
water and at same
time fix the flow rate
for cold water stream
using valve HV15
(please set one value
of flow rate)

Step 3 and 4 was repeated for next 4 The system was

different flow rate (Hot Water Flow allowed to reach
rate Range: 2 – 20 LPM) and the steady state and all the
equipment was shut down data was recorded

2
RESULTS

Flow Rate 1 (FT2 or FI2):

Flow Rate 2 Hot Water Hot Water Cold Water Inlet Cold Water
Inlet Outlet Outlet
(FT1 or FI1) (TT3 or TI3)
(TT1 or TI1) (TT2 or TI2) (TT4 or TI4)
LPM (oC)
(oC) (oC) (oC)

5 49.3 36.6 30.7 34.4

10 49.0 42.0 31.5 36.2

15 49.4 43.6 32.0 37.0

20 48.9 44.7 32.4 37.6

Table 1: Effect of Hot Water Stream Data Analysis

Flow Rate 1 (FT1 or FI1):

Flow Rate 2 Hot Water Hot Water Cold Water Cold Water Inlet
(FT2 or FI2) Inlet Outlet Outlet (TT4 or TI4)
LPM (TT1 or TI1) (TT2 or TI2) (TT3 or TI3) (oC)
(oC) (oC) (oC)
5 49.3 45.2 32.6 39.3

10 49.0 44.5 32.7 38.6

15 49.2 44.3 32.9 38.1

20 4 9.3 44.0 33.0 37.3

Table 2: Effect of Cold Water Data Analysis

3
DISSCUSION

This experiment was conducted by using SOLTEQ Shell & Tube Heat Exchanger (Model: HE
667).

Heat load when the temperature water is maintained around 50°C

𝑄 = 𝑚𝐶∅
Q = Heat Energy
m = Mean hot water flow rate (kg/s)
Cp = Specific heat capacity of the hot water at 50oC = 4183J/kgoC
∅ = Temperature change of the hot water (Tf – Ti)

Based on appendix 2.3 Transport Process, the density of water when is at 50°C is 0.98897 kg/L
FT1 TT1 TT2 CHANGES TT3 TT4 CHANGES
(LPM) (°C) (°C) (TT1-TT2) (°C) (°C) (TT4-TT3)
5 49.3 36.6 12.7 30.7 34.4 3.7
10 49.0 42.0 7.0 31.5 36.2 4.7
15 49.4 43.6 5.8 32.0 37.0 5.0
20 48.9 44.7 4.2 32.4 37.6 5.2

Convert LPM to kg/s, then calculate the heat load

Heat Load

FT1 m (kg/s) Heat load, Qhot = mC[TT1-TT2]

(LPM)
5 0.0823 (0.0823)(4183)(12.7) = 4.37 kW
10 0.1647 (0.1647)(4183)(7.0) = 4.82kW
15 0.2469 (0.2469)(4183)(5.8) = 5.98 kW
20 0.3292 (0.3292)(4183)(4.2) = 5.78kW

Heat Absorb

FT2 m (kg/s) Heat absorb, Qcold = mC[TT4-TT3]

(LPM)
5 0.0823 (0.0823)(4183)(3.7) = 1.27kW
10 0.1647 (0.1647)(4183)(4.7) = 3.24kW
15 0.2469 (0.2469)(4183)(5.0) = 5.16kW
20 0.3292 (0.3292)(4183)(5.2) = 7.16kW

4
Heat Loss

Heat Loss ((Qhot - Qcold)

4.37 kW - 1.27kW = 3.1kW
4.82 kW - 3.24kW = 1.58kW
5.98 kW - 5.16kW = 0.82kW
5.78 kW - 7.16kW = -1.38kW

Efficiency

FT1/FT2 𝑻 −𝑻 𝑻𝒄𝒐𝒍𝒅⁡𝒐𝒖𝒕 −𝑻𝒄𝒐𝒍𝒅⁡𝒊𝒏

ƞ𝒉𝒐𝒕 = 𝑻 𝒉𝒐𝒕⁡𝒊𝒏−𝑻 𝒉𝒐𝒕⁡𝒐𝒖𝒕 x100% ƞ𝒄𝒐𝒍𝒅 = x100%
𝑻𝒉𝒐𝒕⁡𝒊𝒏⁡ −𝑻𝒄𝒐𝒍𝒅⁡𝒐𝒖𝒕
(LPM) 𝒉𝒐𝒕⁡𝒊𝒏⁡ 𝒄𝒐𝒍𝒅⁡𝒐𝒖𝒕

5 78.36% 35.07%
10 58.68% 44.63%
15 42.86% 49.58%
20 35.09% 53.51%
Log-Mean-Temperature, Tlm
𝑑𝑇 −𝑑𝑇
2 1
Tlm = ln⁡(𝑑𝑇
2 /𝑑𝑇 2)
For counter flow -

dT1 = Temperature of the hot fluid entering - Temperature of the cold fluid exiting
dT2 = Temperature of the hot fluid exit - Temperature of the cold fluid entering

Hot water stream in oC

Flow rate 1(FT1) ∆T1 ∆T2 ∆Τm

5.00 13.40 7.60 10.2274
10.00 12.10 10.40 11.2286
15.00 11.90 12.70 12.2957
20.00 11.40 13.50 12.4204

Cold water stream in OC

Flow rate 2(FT2) ∆T1 ∆T2 ∆Τm

6.00 17.70 5.40 10.3608
10.00 17.50 5.40 10.2908
14.00 17.10 5.90 10.5251
18.00 17.10 6.40 10.8875

5
Reynolds number

Flow rate = (5L/min) (1min/60s) (1ft3/28.317L) = 2.9429x10-3 ft3/s

Velocity in pipe = flow rate/ area of = (2.9429x10-3ft3/s) x (1/1.0229x10-3ft2) = 2.8770ft/s
Pipe diameter (ID) = (11mm) x (3.2808ft/m) = 0.0361ft
Cross- sectional area of pipe = πD2//4 = π(0.0361)2/4 = 1.0229x10-3ft2
Density, p = 61.6822lbm/ft3
Viscosity, µ = (0.5494cp) (6.7197x10-4lbm/ft.s.cp) = 3.6918x10-4 lbm/ft.s
𝐷𝑣𝑝 (1.0229𝑥10−3 𝑓𝑡 2 )(2.8770𝑓𝑡/𝑠)(61.6822𝑙𝑏𝑚/𝑓𝑡 3 )
Nre for 5LPM = = = 491.69
µ (3.6918𝑥10−4
Are for 10LPM = 491.69 x 2 = 983.38
Are for 15LPM = 491.69 x 3 = 1475.07
New for 20LPM = 491.69 x 4 = 1966.76

Heat Transfer Coefficient

𝒒𝑨𝑽𝑮
𝑼=
𝑨∆𝑻𝒍𝒎

𝑈 = 𝐻𝑒𝑎𝑡⁡𝑡𝑟𝑎𝑛𝑠𝑓𝑒𝑟⁡𝑐𝑜𝑒𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡⁡(𝑘𝑊 ⁄𝑚2 𝐾)
𝑞𝐴𝑉𝐺 ⁡ = ⁡𝐴𝑣𝑒𝑟𝑎𝑔𝑒⁡ℎ𝑒𝑎𝑡⁡𝑡𝑟𝑎𝑛𝑠𝑓𝑒𝑟⁡𝑟𝑎𝑡𝑒⁡(𝑘𝑊)
𝐴 = 𝐴𝑟𝑒𝑎⁡𝑜𝑓⁡ℎ𝑒𝑎𝑡⁡𝑒𝑥𝑐ℎ𝑎𝑛𝑔𝑒𝑟 (m2)
∆𝑇𝑙𝑚 = 𝐿𝑜𝑔 − ⁡𝑚𝑒𝑎𝑛 − ⁡𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒 (K)

𝐻𝑒𝑎𝑡⁡𝐿𝑜𝑎𝑑 + 𝐻𝑒𝑎𝑡⁡𝐴𝑏𝑠𝑜𝑟𝑏
𝑞𝐴𝑉𝐺⁡ =
2
𝐴 = Tube⁡surface⁡area⁡ × Number⁡of⁡tubes
𝑑𝑇2 −𝑑𝑇1
𝑇𝑙𝑚 = ln⁡(𝑑𝑇
2/𝑑𝑇2)

Hot water stream

Average heat transfer Average of heat Log-Mean- Heat transfer

rate (kW) exchanger (m2) Temperature (K) coefficient (kW/m2K)
3.83035 1.8167 10.2274 0.2062
4.77050 1.8167 11.2286 0.2338
5.17420 1.8167 12.2957 0.2316
6.95410 1.8167 12.4204 0.3081

Cold water stream

Average heat Average of heat Log-Mean- Heat transfer

transfer rate (kW) exchanger (m2) Temperature (K) coefficient
(kW/m2K)
3.8785 1.8167 10.3608 0.2061
5.1405 1.8167 10.2908 0.2750
5.8343 1.8167 10.5251 0.3051
7.2958 1.8167 10.8875 0.3689
6
 Heat Transfer Coefficient vs Water Flow Rate

0.8

0.7
Heat Transfer Coefficient (kW/m2K)

0.6

0.5

0.4 Cold stream

Hot stream
0.3

0.2

0.1

Water Flow Rate (LPM)

0
5 10 15 20
Cold stream 0.2061 0.275 0.3051 0.3689
Hot stream 0.2062 0.2338 0.2316 0.3081

Efficiency vs Flow Rate

120.00%
35.07%
44.63%
100.00%
49.58%
53.51%
80.00%
Efficiency (%)

78.36%
Cold stream
60.00%
Hot stream
58.68%
40.00%
42.86%
35.09%
20.00%

0.00%
5 10 15 20
Flow Rate (LPM)

7
 As the flow rate of both cold and hot stream increases, the value for heat load for hot stream
varies around 0.5-1 kW. The value of heat absorb for cold stream also varies with slightly larger
value around 2 kW. It does not make sense because the hot side heat load supposedly to be a little
more skewed because that is the flow rate that was varied in these trials. Meanwhile, heat loss
decreases to -1.38 Kw as the flow rate increases. The heat lost during the heat transfer process
depends on hot fluid inlet temperature. Based on the graph, heat transfer coefficient of cold stream
and hot stream differs around 0.1-0.2 kW/m2K. The percentage efficiency for both hot and cold
stream decreases.

When looking at the results from that data taken it is seen that the heat exchanger does
perform as it should. When the cold water is left at a constant flow rate and the hot water flow is
increased, the average U value increases. The response of the average U value with a variance of
flow rate is different for the hot water in the tubes and the hot water in the shell. When the hot water
is in the shell, the U increase until 0.3081 kW/m2K .The reason for this is believed to be caused
from the baffles within the shell in the heat exchanger, when the flow increases so much the baffles
start to make the flow turn more turbulent then laminar, so the U value changes. When the hot water
flow is in the tubes and is increased, the average U value increases constantly with flow increase.
This is because the water flows through the tubes is staying laminar therefore making the U value
more constant. When the hot water was left constant and the cold water varied while flowing
through the shell, the results seemed to be completely similar. However, that is not quite right as the
average U value should decrease with increasing flow rates.

The difference of the result from the theory probably because of some possible errors like
the temperature was not constant at 50oC all the times as it sometimes dropped to 49 oC and 48 oC.
Besides, it is probably because the of the flow rate too as it also was not constant at the desired flow
rate

8
CONCLUSION

In conclusion, this experiment shows that the shell-and-tube heat exchanger follows the
basic law of thermodynamics. The efficiency calculated for the hot water stream differs from the
efficiency for the cold-water stream at different flow rate. This indicates that there was heat lost to
the surrounding areas. 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.

The experiment shows that when the flow rate of one of the stream increases, the rate of heat
transfer will also increase. The amount of heat loss from the hot water is not equal to the heat gain
by the cold water due to the heat loss to the surrounding. This will logically follow the concept
where more cold water delivered to carry away heat as time increases. Additionally, increased flow
rate results in more turbulent flow also increases the heat transfer rate. According to the heat
exchanger theory, there was no noticeable difference in the heat transfer rate between parallel flow
and counter current flow. The counter current flow should show improvement on the heat transfer
ability by applying oil cooler.

There are few recommendations in order to improve this experiment. Firstly, the shell and
tube heat exchanger should be operated at approximation of 75% for sufficient heat transfer and
economic efficiency. Next, a large heat transfer area should be used so that many tubes could be
used and hence waste heat can be put to use. This can lead to an efficient way to conserve energy.
Besides, the set temperature should be made constant as it did dropped and rose slightly in order to
get an accurate reading of the temperature at the TT1, TT2, TT3 and TT4. Lastly, pressure gauge
(PG-07) at low steam rate should be monitored in order to prevent vacuum.

9
REFERENCES

1. Geankoplis, Christie J. Transport Processes and Unit Operations, 3rd ed. Englewood
Cliffs, NJ. Prentice-Hall Publishing, Inc. 1993.

2. Heald, C. C. Cameron Hydraulic Data. Liberty Corner, NJ. Ingersoll-Dresser Pump

Co. 1998.

3. http://www.pitt.edu/~ljb59/shellandtube.pdf

4. https://en.wikipedia.org/wiki/Shell_and_tube_heat_exchanger

5. Lienhard, J. H., & Lienhard, J. H. (2013). A Heat Transfer Textbook. Newburyport:

Dover Publications

6. Thomas, L. C. (1991). Heat transfer. Englewood Cliffs, NJ: Prentice-Hall.

10
APPENDIX

The elements at SOLTEQ shell and

tube exchanger

The temperature was recorded by

adjusting the digital temperature

11