Advanced Program

Hanoi University of Mining and Geology, HUMG

ECH 155B, 2020
Chemical Engineering Laboratory

Shell and Tube Heat Exchangers

Goals of the Experiment

In this experiment we will study the efficiency of shell and tube heat exchanges. The objectives
of this experiment are:
 To perform an energy balance of a shell and tube heat exchanger
 To investigate the difference between cocurrent and countercurrent flows
 To determine the overall heat transfer coefficient for a shell and tube heat exchanger
 To investigate the effect flow rates on heat exchanger efficiency and overall heat transfer
coefficient

Background
The shell and tube heat exchanger is commonly used in chemical process industries. This type
of exchanger consists of a number of tubes in parallel enclosed in a cylindrical shell. Heat is
transferred between one fluid flowing through the tubes and another fluid flowing through the
cylindrical shell around the tubes.
In this laboratory experiment, you will be investigating the impact of the flow patterns and flow
rates on the energy exchange between a hot and cold water stream in a shell and tube heat
exchanger. Groups will study both cocurrent or countercurrent as illustrated in Figure 1.

Figure 1. Schematic of cocurrent and countercurrent flow in a shell and tube heat exchanger.
By measuring the changes in temperature of the two separate fluid streams in a shell and tube
heat exchanger, the heat energy transferred to/from each stream can be determined as well as
the overall efficiency of the heat exchanger.

Part 1: Overall Energy Balance:

The total energy transfer in a heat exchanger can be readily determined from the change in
temperatures of the hot and cold fluid streams – assuming only sensible heat is transferred (no
phase transitions). Here, we talk about the heat duty as we neglect losses in the system and
simply write:
̇ (1)
As the hot fluid typically is in the tubes with the cold fluid in the shell, is usually based on
the heat lost by the hot fluid to the cold fluid. This enables us to neglect heat losses or gains by
the fluid in the shell which is exposed to the external environment. The efficiency of the heat
exchanger can be found by comparing the heat duty for the cold and hot streams. For example:
̇ ̅ (2)
where ̇ is the flow rate of the cold fluid stream, ̅ is the mean heat capacity, and the
temperature gradient is based on the change between the outlet and inlet streams. In the first
ECH 155B Shell and Tube Heat Exchanger

part of your data analysis, determine the efficiency of the heat exchanger in cocurrent and
countercurrent flow patterns.
Next, from , the overall heat transfer coefficient, , can be found using the average
temperature gradient in the fluids, which depends on the flow pattern, and the area for heat
transfer in the heat exchanger.
In the case of cocurrent and countercurrent flow patterns, the temperature gradient along the
heat exchanger can be represented as shown in Figure 2.

Figure 2. Typical temperature profiles for the hot and cold fluid streams for countercurrent and
cocurrent flow patterns.
Because the temperature difference between the hot and cold fluid streams varies along the
length of the heat exchanger it is necessary use an average temperature difference (driving
force) from which heat transfer calculations can be performed. This average temperature
difference is called the Logarithmic Mean Temperature Difference, , and is given by:

(3)
( )

where
(4)
(5)
In this example the equation for LMTD is the same for both countercurrent and cocurrent
operation. However, in cocurrent flow T2 is the hot fluid outlet temperature and T1 is the hot
fluid inlet temperature.
The heat transmission area in the exchanger must be calculated using the arithmetic mean
diameter of the inner tubes, , where the outer diameter of a tube is
designated by od and the inner diameter by id. The total heat transfer length, , is given by
, where is the number of tubes in the heat exchanger and is the length of an
individual tube. Therefore, the total area for heat transfer is given by .
Finally, the overall heat transfer coefficient can be found using:

(6)

Analysis for Part 1:

Comparison of the total heat transfer of the hot and fluid streams, the efficiency of the heat
exchanger, and determination of the overall heat transfer coefficient. Which was more
efficient, cocurrent or countercurrent flow? Explain why the overall heat transfer coefficient is
different for the two flow configuations. Carry out appropriate error analysis in order to report
the error on the heat transfer to the hot and cold fluids and efficiency of the heat exchanger.

Part 2: Traditional Analysis of Conductive and Convective Heat Transfer:

Energy or Heat transfer in the shell and tube heat exchanger occurs by conductive heat transfer
through the tube walls and convective heat transfer by the moving fluids.
Fourier’s Law relates the heat transfer, , by conduction to the temperature gradient, the area
of contact, , the thermal conductivity of the wall, , and the wall thickness, , where

2
ECH 155B Shell and Tube Heat Exchanger

(7)

Analogously to electrical current resistence, the thermal resistance, ,can be found using
(8)

Combining equations 5 and 6 yields:

(9)
Newton’s Law of Cooling relates the heat transfer, , by convection to the temperature
gradient between a moving fluid, , and and a surface, , the area for heat transfer, , and
the fluid heat transfer coefficient, :
(10)
In applying the concepts of conductive and convective heat transfer in a shell and tube heat
exchanger, we can consider the thermal resistances which appear in each medium: hot fluid,
cold fluid, and walls. These three resistances arranged in series constitute the total resistance,
, which is the sum of each individual resistance. A schematic of the resistences is shown in
Figure 3.
Tube wall
Temperature
distribution

q Cold fluid

Hot fluid

Tavg,h 1/hhAh Ts,h x/K. Ts,c 1/hcAc Tavg,c

A
Figure 3. Schematic of heat transfer in a tube of a shell and tube heat exchanger.
Analyzing the heat transfer based on the three resistences shown in Figure 2 yields:

(11)

For a Shell and Tube exchanger of length , in which the hot fluid flows through the internal
tube and cold fluid flows through the space between the internal and external tubes, the area
for heat transfer is different for the hot and cold fluid where the cold fluid is in contact with the
outer diameter (od) of the tubes and the hot fluid is in contact with the inner diameter (id) of
the tubes. Due to the fact that the wall has a cylindrical shape, the conduction resistance is
expressed as:
( )
(12)

The most influential terms concerning the total thermal resistance, , are the convection
terms. Due to the fact that diameters are specified, it is critical to determine the various
convection heat transfer coefficients, , in order to predict heat exchange. Use appropriate
Nusselt Number relationships to determine the heat transfer coefficients and global heat
transfer coefficient, . Compare this value to your numerical analysis determination of .
Analysis for Part 2:

3
ECH 155B Shell and Tube Heat Exchanger

Compare your overall heat transfer coefficient from the analysis in Part 1 and Part 2. Were your
estimates for the heat transfer coefficients accurate? Carry out appropriate error analysis in
order to report the error on the overall heat transfer coefficient for parts 1 and 2. What was the
largest discrepancy or what do you believe is the largest source of error?

Part 3: Numerical Analysis of Differential Energy Balances:

The overall heat transfer in the system can be solved by setting up differential energy balances
around the hot and cold streams. To simplify the energy balance, we will assume steady-state
operation, plug flow, and constant, average, properties for all fluids and materials.
In the case of cocurrent flow, the energy balance on the hot and cold streams are:

Hot steam: ̇ ̅ (13)

with boundary conditions: and

Cold stream: ̇ ̅ (14)

with boundary conditions: and

In the equations above, the subscripts “c” and “h” refer to the cold and hot streams
respectively, ̇ is the mass flow rate, ̅ is the average specific heat capacity, is the local
temperature ( is the ambient temperature), is the variable position along the lenth of the
tubes, is the overall heat transfer coefficient across the tube wall, is the number of tubes,
is the tube perimeter, is the overall heat transfer eoefficient across the shell wall, and
is the shell perimeter.
In the case of countercurrent flow, the energy balance on the hot and cold streams are:

Hot stream: ̇ ̅ (15)

with boundary conditions: and

Cold stream: ̇ ̅ (16)

with boundary conditions: and

Note that there is a sign change for the cold stream due to the opposite flow direction relative
to the hot stream.
Once you have collected data on the dimensions of the heat exchanger, flow rates, and
temperatures at steady state, the system of differential equations must be solved
simultaneously over the length of the tubes. Using an appropriate method, numerically
integrate the equations to determine , , and the temperature profile along the heat
exchanger and as a function of position, . Note, you will need to numerically integrate
the equations while simultaneously finding the optimum values for and so that the
proper temperatures at the boundary conditions are obtained.
Analysis for Part 3:
Plot the temperature profiles for cocurrent and countercurrent flow for each of the hot water
flow rates. Are the trends as you expected? How well do they compare to your measured
temperature profiles for the various experimental conditions? What do you hypothesize as the
largest source of error in predicting the temperature profiles? Compare your numerical solution
for the overall heat transfer coefficient to those obtained in parts 1 and 2. Is the assumption of
average fluid properties sufficiently accurate? How might you improve your numerical

4
ECH 155B Shell and Tube Heat Exchanger

calculation? Does the heat transfer loss to the surroundings match the efficiency found in part
1?

Additional Analysis for Parts 1 and 2 for oral presentations:

Under what operating conditions is the heat exchanger operating at maximum efficiency and
why? Under which operating conditions do you believe your modeling and analysis of the data
is most accurate. What were the largest sources of error?

Lab Equipment:
The experimental apparatus is Shell and Tube Heat Exchanger EDIBON's TITC that is connected
to a computer containing SCADA Control software. Temperatures are measured at the following
locations and distance positions in the heat exchanger:
Hot water: ST1 in x = 0
ST2 in x = 0.5m

Cold water: ST3 in x= 0

ST4 in x = 0.125m
ST5 in x = 0.25m
ST6 in x = 0.375m
ST7 in x = 0.5m

Heat Exchanger Dimensions:

Outer dimension of the heat exchanger?

Lab Activities:
1) Each group will be responsible for operating the heat exchanger under cocurrent and
countercurrent flow at one flow rate of the hot fluid stream. The flowrates are: Group 1
̇ 3 ̇ , Groups 4 and 5 ̇ ,
Groups 6 and 7 ̇ , Groups 8 and 9 ̇ , Groups 10 and 11
̇ , Groups 12 and 13 ̇ .
2) The temperature of the hot fluid stream inlet will be 65°C. The flow rate of the cold fluid
stream will be determined by Engineer Tuan and kept constant for all measurements.
3) Data collection must be done carefully and submitted to Dr. Linh so that all the data can
be shared amongst the different groups for the oral presentations.

Experimental Procedure:
1) Check that the valves are opened and that we have countercurrent flow pattern.
2) Check that the heating tank is filled with water above the level switch.
3) Switch on pump and the resistor (equipment supply).
4) Set the tank temperature in 60°C (ST16).
5) Fix the hot water flow (SC1) to your group’s assigned flow rate. Mr.Tuan will adjust the
cold water flow rate (SC2).
6) Once steady state operating conditions have been obtained write down the
temperature and flow measurements on the experiment sheet for the countercurrent
flow pattern on the next page.
7) Set the valves appropriately in order to invert the cold water flow direction to produce a
cocurrent flow pattern.
8) Make sure that the cold water flow rate is not altered and that the hot water flow rate
and temperature is maintained at 60°C when you change to the cocurrent flow pattern.
9) Once steady state operating conditions have been obtained again write down the
temperature and flow measurements on the experiment sheet for the cocurrent flow
pattern below.

5
ECH 155B Shell and Tube Heat Exchanger

Experimental Data Sheet

Test 1 Test 2
Countercurent flow Parallel flow
ST 16 (oC) 60 60
ST1 (oC)
ST 2 (oC)
ST 3 (oC)
ST 4 (oC)
ST 5 (oC)
ST 6 (oC)
ST 7 (oC)
SC 1 (l/min)
SC 2 (l/min)