Plate Heat Exchanger

1.1 Objectives
• To determine the overall heat transfer coefficient of a plate heat exchanger operating under
parallel and counter flow conditions, and compare the results.
• To demonstrate the effect of flow rate variation on the performance characteristics of a Flat
plate heat exchanger.

1.2 Theory

1.2.1 Introduction to convection

Convection is the heat transfer mode between a surface and a fluid in motion at different temperatures.
It is a result of the superposition of two physical phenomena: energy transported by the random
movement of molecules (diffusion) and energy transported by the fluid macroscopic motion (a great
number of molecules moving as a whole).

Convection Heat transfer may be classified as Forced or Natural Convection. Forced convection occurs as
a result of external means (a fan, a pump or atmospheric wind) causing a flow or current. Natural
convection occurs when flow is induced by buoyancy forces which are as a result of density differences
caused by variations in temperature of a fluid.

A consequence of fluid-surface interaction is the formation of an area within the fluid through which
velocity varies from zero on the surface to a finite value associated to the fluid. This is the Hydrodynamic
Limit/boundary Layer. If temperature between the surface and the fluid varies as well, a thermal
boundary layer appears where temperature varies from the temperature on the surface to the
temperature on the outer part of the fluid. 99% of the heat transfer between the surface and the fluid
takes place in this thin layer.

The first step in the treatment of Convection Heat Transfer is determining whether the Hydrodynamic
Limit Layer is laminar or turbulent since Heat Transfer Rate depends strongly on this condition.

In laminar regime the motion of the fluid follows a pattern; it is possible to identify the flux lines along
which particles move. Laminar fluid is associated with low Reynolds numbers, that is, the ratio between
inertia forces and viscosity forces is low. This way, fluid perturbations (originating from superficial
rugosity or by the free flow itself) vanish quickly when the flow is arranged (laminar). If Reynolds
number is high, inertia forces will be strong enough to amplify perturbations produced in a laminar flow,
generating vortexes that indicate the appearance of a turbulent regime in the fluid. Turbulent regime is
characterized by irregular movement and random fluctuations of velocity.

Since diffusivity of vortices is much higher than molecular diffusivity; velocity and temperature profiles
at the core of the limit/boundary layer are more uniform in turbulent regime, therefore velocity and
temperature gradients are much higher. Thus heat transfer rate is much higher in turbulent than in
laminar flows. On the other hand, high velocity gradients cause big superficial currents so we may be
able to state that turbulent regime has an adverse effect as pressure drops in the direction of the flow.
This higher pressure drop will require stronger pumps or fans.

Regardless of whether the flow is in laminar or turbulent regime, convection heat transfer rate between
a surface and a fluid is given by Newton's law of cooling, whose expression is:

𝑄̇ = ℎ𝐴(𝑇𝑠 − 𝑇∞ ) (W) ……………………………………………… 5.1

Where
𝑄̇ = convection heat transfer rate, W
A = Heat transfer area, m2
Ts = Surface temperature, K
h= convection heat transfer coefficient, W/m2/K
𝑇∞ =Fluid temperature, K

1.2.2 Heat Exchangers

Heat exchangers are devices that transfer heat between fluids at different temperatures. Heat
exchangers are used in a wide range of industrial and commercial applications. Examples are found in
power, air-conditioning, refrigeration, cryogenics, heat recovery, process, aircraft, marine, and
manufacturing industries, as well as many products available in the marketplace.

1.2.3 Types of Heat Exchangers

The various types of heat exchangers that are commercially available may be categorized according to
the geometric configuration of the heat transfer surface and flow arrangement as well as certain other
considerations.

Different types of heat exchangers according to the geometric configuration are

• Double-pipe heat exchanger

• Shell-and-tube heat exchanger
• Plate heat exchanger etc.

On basis of flow arrangement the configuration of heat exchangers are classified as

• parallel flow
• counter flow
• cross flow heat exchangers
Since we, in this experiment are more concerned about the flow arrangement of heat exchangers, so
following is given a brief description of these heat exchangers.
 1.2.3.1 Parallel flow
In this type of arrangement the hot and cold fluid enter at the same end, flow in the same direction and
exit at the same end as shown in figure 6.1.

Figure 5.1 Parallel Flow Heat Exchanger

1.2.3.2 Counter flow

In counter-flow arrangement, the fluid enters at the opposite ends, flow in opposite directions and exit
at opposite ends as shown in figure 6.2.

Figure 5.2 Counter Flow Heat Exchanger

1.2.3.3 Cross flow

In this type, one fluid runs through tubes and other fluid passes over the tubes making a 90 angle with
respect to the fluid inside the tubes as shown in figure 6.3.

Figure 5.3 Cross-Flow Heat Exchanger

1.2.4 Formulae
Certain formulae to find out various quantities related to heat exchangers, specifically for this
experiment are given below.

∆𝑇ℎ = 𝑇ℎ,𝑖𝑛 − 𝑇ℎ,𝑜𝑢𝑡 (K) ……………………………………………… 5.2

 ∆𝑇𝑐 = 𝑇𝑐,𝑜𝑢𝑡 − 𝑇𝑐,𝑖𝑛 (K) ……………………………………………… 5.3

𝑄̇ℎ = 𝑚̇ℎ 𝑐𝑝,ℎ ∆𝑇ℎ (W) ……………………………………………… 5.4

𝑄̇𝑐 = 𝑚̇𝑐 𝑐𝑝,𝑐 ∆𝑇𝑐 (W) ……………………………………………… 5.5

Where
𝑇ℎ,𝑖𝑛 = 𝐻𝑜𝑡 𝑤𝑎𝑡𝑒𝑟 𝑖𝑛𝑙𝑒𝑡 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒
𝑇ℎ,𝑜𝑢𝑡 = 𝐻𝑜𝑡 𝑤𝑎𝑡𝑒𝑟 𝑒𝑥𝑖𝑡 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒
∆𝑇ℎ = 𝐷𝑒𝑐𝑟𝑒𝑎𝑠𝑒 𝑖𝑛 ℎ𝑜𝑡 𝑤𝑎𝑡𝑒𝑟 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒
𝑇𝑐,𝑖𝑛 = 𝐶𝑜𝑙𝑑 𝑤𝑎𝑡𝑒𝑟 𝑖𝑛𝑙𝑒𝑡 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒
𝑇𝑐,𝑜𝑢𝑡 = 𝐶𝑜𝑙𝑑 𝑤𝑎𝑡𝑒𝑟 𝑒𝑥𝑖𝑡 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒
∆𝑇ℎ = 𝐼𝑛𝑐𝑟𝑒𝑎𝑠𝑒 𝑖𝑛 𝑐𝑜𝑙𝑑 𝑤𝑎𝑡𝑒𝑟 𝑡𝑒𝑚𝑝𝑒𝑟𝑎𝑡𝑢𝑟𝑒
𝑄̇ℎ = heat rejected from hot water
𝑚̇ℎ = mass flow rate of hot water
𝑐𝑝,ℎ = specific heat of hot water
𝑄̇𝑐 = heat absorbed by cold water
𝑚̇𝑐 = mass flow rate of cold water
𝑐𝑝,𝑐 = specific heat of cold water

According to thermal energy balance:

𝐻𝑒𝑎𝑡 𝑙𝑜𝑠𝑡 = ℎ𝑒𝑎𝑡 𝑟𝑒𝑗𝑒𝑐𝑡𝑒𝑑 − ℎ𝑒𝑎𝑡 𝑎𝑏𝑠𝑜𝑟𝑏𝑒𝑑 (W) ………………………………………. 5.6

1.2.4.1 Global Heat Transfer Coefficient (U)

Global Heat Transfer Coefficient U is defined as a factor that, for a given geometric and hydrodynamic
configuration, provides the total amount of transferred heat rate when multiplying it by the heat
exchange area and by the temperature difference between hot and cold medium. The temperature
difference between hot and cold fluid varies along the length of exchanger. Thus, defining an average
value, ∆T𝑎𝑣𝑔 is required for the calculation of total heat rate exchanged:

𝑄̇ = 𝑈𝐴∆T𝑎𝑣𝑔 (W) ……………………………………………… 5.7

From the analysis developed in most of the text books dealing with heat transfer, we may find that the
appropriate average temperature difference is a logarithmic mean temperature difference, ∆T𝑙𝑚 i.e. Log
mean temperature difference given below:

∆𝑇1 − ∆𝑇2
∆𝑇𝑙𝑚 = (K) ……………………………………………… 5.8
ln (∆𝑇1 ⁄∆𝑇2 )
Where

∆𝑇1 = 𝑇ℎ,𝑖𝑛 − 𝑇𝑐,𝑖𝑛 (𝐹𝑜𝑟 𝑝𝑎𝑟𝑟𝑎𝑙𝑙𝑒𝑙 𝑓𝑙𝑜𝑤)

∆𝑇2 = 𝑇ℎ,𝑜𝑢𝑡 − 𝑇𝑐,𝑜𝑢𝑡 (𝐹𝑜𝑟 𝑝𝑎𝑟𝑟𝑎𝑙𝑙𝑒𝑙 𝑓𝑙𝑜𝑤)

∆𝑇1 = 𝑇ℎ,𝑖𝑛 − 𝑇𝑐,𝑜𝑢𝑡 (𝐹𝑜𝑟 𝑐𝑜𝑢𝑛𝑡𝑒𝑟 𝑓𝑙𝑜𝑤)

∆𝑇2 = 𝑇ℎ,𝑜𝑢𝑡 − 𝑇𝑐,𝑖𝑛 (𝐹𝑜𝑟 𝑐𝑜𝑢𝑛𝑡𝑒𝑟 𝑓𝑙𝑜𝑤)

We may see that for equal input and output temperatures ∆T𝑙𝑚 is greater for countercurrent than for
parallel flow. Thus the area required for a specific q heat transfer rate is smaller for countercurrent than
for parallel flow, assuming the same U value.

Overall/Global heat transfer coefficient,

𝐻𝑒𝑎𝑡 𝑅𝑒𝑗𝑒𝑐𝑡𝑒𝑑 𝑏𝑦 ℎ𝑜𝑡 𝑤𝑎𝑡𝑒𝑟

𝑈= (W/m2-K) ……………………………… 5.9
∆𝑇𝑙𝑚 ∗ 𝐻𝑒𝑎𝑡 𝑇𝑟𝑎𝑛𝑠𝑓𝑒𝑟 𝐴𝑟𝑒𝑎

1.2.4.2 Effectiveness of the Heat Exchanger

First we may define effectiveness as the coefficient between the actual heat exchanged and the
maximum that may be transferred in an infinite area exchanger in countercurrent flow.

𝑄̇𝑟𝑒𝑎𝑙
𝜀= (%) ……………………………………………… 5.10
𝑄̇𝑚𝑎𝑥
where

𝑄̇𝑟𝑒𝑎𝑙 = 𝐻𝑒𝑎𝑡 𝑒𝑥𝑐ℎ𝑎𝑛𝑔𝑒 𝑏𝑦 ℎ𝑜𝑡/𝑐𝑜𝑙𝑑 𝑤𝑎𝑡𝑒𝑟

𝑄̇𝑚𝑎𝑥 = 𝑇ℎ𝑒 𝑡𝑜𝑡𝑎𝑙 ℎ𝑒𝑎𝑡 𝑒𝑥𝑐ℎ𝑎𝑛𝑔𝑒𝑑 𝑖𝑓 𝑡ℎ𝑒 ℎ𝑒𝑎𝑡 𝑡𝑟𝑎𝑛𝑠𝑓𝑒𝑟 𝑎𝑟𝑒𝑎 𝑖𝑠 𝑖𝑛𝑓𝑖𝑛𝑖𝑡𝑒
To calculate 𝑄̇𝑚𝑎𝑥 we have two different cases:
1 If 𝑚̇ℎ 𝑐𝑝,ℎ < 𝑚̇𝑐 𝑐𝑝,𝑐 𝑄̇𝑟𝑒𝑎𝑙 = 𝑚̇ℎ 𝑐𝑝,ℎ (𝑇ℎ,𝑖𝑛 − 𝑇ℎ,𝑜𝑢𝑡 ), 𝑄̇𝑚𝑎𝑥 = 𝑚̇ℎ 𝑐𝑝,ℎ (𝑇ℎ,𝑖𝑛 − 𝑇𝑐,𝑖𝑛 )because the
hot fluid experience the highest change in temperature
2 If 𝑚̇𝑐 𝑐𝑝,𝑐 < 𝑚̇ℎ 𝑐𝑝,ℎ 𝑄̇𝑟𝑒𝑎𝑙 = 𝑚̇𝑐 𝑐𝑝,𝑐 (𝑇𝑐,𝑜𝑢𝑡 − 𝑇𝑐,𝑖𝑛 ), 𝑄̇𝑚𝑎𝑥 = 𝑚̇𝑐 𝑐𝑝,𝑐 (𝑇ℎ,𝑖𝑛 − 𝑇𝑐,𝑖𝑛 )because the
cold fluid that may experience one the highest temperature change, being (𝑇ℎ,𝑖𝑛 − 𝑇𝑐,𝑖𝑛 )the
highest possible difference in temperature

Therefore, effectiveness may be:

(𝑇ℎ,𝑖𝑛 −𝑇ℎ,𝑜𝑢𝑡 )
𝜀= if 𝑚̇ℎ 𝑐𝑝,ℎ < 𝑚̇𝑐 𝑐𝑝,𝑐
(𝑇ℎ,𝑖𝑛 −𝑇𝑐,𝑖𝑛 )

(𝑇𝑐,𝑜𝑢𝑡 −𝑇𝑐,𝑖𝑛 )
𝜀= if 𝑚̇𝑐 𝑐𝑝,𝑐 < 𝑚̇ℎ 𝑐𝑝,ℎ
(𝑇ℎ,𝑖𝑛 −𝑇𝑐,𝑖𝑛 )
1.3 Apparatus
EDIBON Plate Heat Exchanger allows for the study of heat transfer between hot and cold water flowing
through alternate canals formed between parallel plates.

The equipment consists of two parts: the base unit and heat exchanger. The base unit and the Plate
Exchanger are joined by flexible tubes allowing hot and cold water flow.

The interface and the SACED Control Software shows real-time measurements taken while performing a
test. It shows temperatures in the exchanger, water temperatures in the heating tank and water flow
rates.

1.3.1 Base Unit

The base unit performs the following tasks:

1. Water heating in the tank through variable resister (AR-1) controlled through the software
2. Control and measure hot and cold flow rates
3. Hot water Pump (AB-1) to vary the hot water flow rate
4. Changing the direction of cold water flows i.e. parallel or counter flow as shown in the table 5.1

Table 5.1 Arrangement of Valves for Parallel and counter flow

COUNTER CURRENT FLOW PARALLEL FLOW

AV-2 Valve CLOSED AV-2 Valve OPEN

AV-3 Valve OPEN AV-3 Valve CLOSED

AV-4 Valve OPEN AV-4 Valve CLOSED

AV-5 Valve CLOSED AV-5 Valve OPEN

 Figure 5.4 Base Unit

1.3.2 The heat exchanger unit

• Consists of 20 corrugated stainless steel plates
• 4 input and output ports or connections for hot and cold water
• Surface 0.64 m2
The Plate Heat Exchanger consists of a set of corrugated metal plates confined in a shell. Each metal
plate has 4 ports or holes. The plates and the ports are sealed by joints at their edge to allow hot
and cold fluids flowing through narrow alternate passages formed between the plates. Heat
transfers through the thin plates, offering relatively low thermal resistance. Flow on both sides of
the plates may be counter-current or parallel flow, although the former is more common:

1.3.3 Control system

The temperature of the water tank (ST-16) can be regulated through the PID in the software. Cold
water flow is regulated by the control valve (AVR-2) on the base unit. Hot water flow is regulated by
the pump’s speed, which is controlled in the software, and by the bypass valve (AVR-1).
1.4 Specifications
Table 5.2 Description of elements constituting the unit

Identification Description

ST-16 Water Tank Temperature Sensor

ST-3 Cold Water Temperature Sensor at the inlet/outlet of the exchanger

ST-1 Hot Water temperature Sensor at the inlet of the exchanger

ST-4 Cold Water Temperature Sensor at the inlet/outlet of the exchanger

ST-2 Hot Water Temperature Sensor at the outlet of the exchanger

SC-1 Hot Water Flow Sensor

SC-2 Cold Water Flow Sensor

AVR-1 Hot Water Flow Regulation Valve

AVR-2 Cold Water Flow Regulation Valve

AN-1 Water Tank Level switch

AR-1 Electric Resistance

AB-1 Hot Water Flow Centrifugal Pump with velocity adapter

AV-2,AV-3, AV-4 and AV-5 Cold Water Circuit Ball Valves to set parallel / countercurrent flow

AV-1, AV-6, AV-7 and AV-8 Ball Valves for draining the pipes

1.5 Procedure for Experiment:

1. Verify that the valves are opened and counter-current flow configuration is set
2. Verify that the heating tank is filled with water over the level switch
3. Turn on the software TICC and the SACED unit
4. Fix the tank temperature at 50ºC (ST-16) through the PID control
5. Set the cold water flow at 2 l/min (SC-2)
6. Vary the pump speed from 2 to 10 to change the hot water flow rate
7. At each value of the hot water flow rate note the readings of ST-1, ST-2, ST-3 and ST-4
8. In step 7 above, wait for 5 to 10 min before taking each reading
9. Calculate the value of heat transfer coefficient and effectiveness for each value of the flow rate
10. Repeat the above process for parallel flow configuration
11. Comment on how the exchanger characteristics change with flow rate and with the flow
configuration.
 Exercise
Constants:

Density of water = 987.1 kg/m3

𝑉𝑐̇ = 𝐶𝑜𝑙𝑑 𝑤𝑎𝑡𝑒𝑟 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒 = _______________ l/min (measured by SC-2)
𝐽
𝑐̇𝑝,ℎ = 4178
𝑘𝑔. 𝐾
𝐽
𝑐̇𝑝,𝑐 = 4178
𝑘𝑔. 𝐾
𝑇𝑜𝑡𝑎𝑙 ℎ𝑒𝑎𝑡 𝑡𝑟𝑎𝑛𝑠𝑓𝑒𝑟 𝑎𝑟𝑒𝑎, 𝐴𝑚 = 0.192 𝑚2
𝑉̇ℎ = ℎ𝑜𝑡 𝑤𝑎𝑡𝑒𝑟 𝑓𝑙𝑜𝑤 𝑟𝑎𝑡𝑒, (measured by SC-1)
U = overall heat transfer coefficient
𝑄̇ℎ = 𝐻𝑒𝑎𝑡 𝑟𝑒𝑗𝑒𝑐𝑡𝑒𝑑 𝑏𝑦 ℎ𝑜𝑡 𝑤𝑎𝑡𝑒𝑟
𝑄̇𝑐 = 𝐻𝑒𝑎𝑡 𝑎𝑏𝑠𝑜𝑟𝑏𝑒𝑑 𝑏𝑦 𝑐𝑜𝑙𝑑 𝑤𝑎𝑡𝑒𝑟

Table 5.1: Parallel Flow -Observations

Pump SC-1/𝑉̇ℎ ST-1/𝑇ℎ.𝑖𝑛 ST-2/𝑇ℎ.𝑜𝑢𝑡 ST-3/𝑇𝑐.𝑜𝑢𝑡 ST-4/𝑇𝑐.𝑖𝑛

Speed 𝑙/𝑚𝑖𝑛 °𝐶 °𝐶 °𝐶 °𝐶

10

Table 5.2: Parallel Flow-Calculations

Effectiveness
𝑚̇ℎ 𝑚̇ℎ 𝑐𝑝.ℎ 𝑚̇𝑐 𝑐𝑝.𝑐 𝑄̇ℎ 𝑄̇𝑐 ∆𝑇1 ∆𝑇2 ∆𝑇𝑙𝑚 𝑈
𝜀

𝑘𝑔/𝑠 𝑊/𝐾 𝑊/𝐾 𝑊 W K K K W/m2/K

 Table 5.3: Countercurrent Flow-Observations

SC-1/𝑉̇ℎ ST-1/𝑇ℎ.𝑖𝑛 ST-2/𝑇ℎ.𝑜𝑢𝑡 ST-3/𝑇𝑐.𝑖𝑛 ST-4/𝑇𝑐.𝑜𝑢𝑡

Pump Speed
𝑙/𝑚𝑖𝑛 °𝐶 °𝐶 °𝐶 °𝐶

10

Table 5.4: Countercurrent Flow-Calculations

Effectiveness
𝑚̇ℎ 𝑚̇ℎ 𝑐𝑝.ℎ 𝑚̇𝑐 𝑐𝑝.𝑐 𝑄̇ℎ 𝑄̇𝑐 ∆𝑇1 ∆𝑇2 ∆𝑇𝑙𝑚 𝑈
𝜀

𝑘𝑔/𝑠 𝑊/𝐾 𝑊/𝐾 𝑊 W K K K W/m2/K

Analysis:

• Plot the graph of U versus hot water flow rate 𝑉̇ℎ for parallel flow and counter-flow
configurations
• Plot the graph of effectiveness versus hot water flow rate 𝑉̇ℎ for parallel flow and counter-flow
configurations

Q 1. What is the effect of changing configuration of the flow (i.e. parallel or counter-flow) on the
effectiveness and the overall heat transfer coefficient?

Q2. Why is the heat absorbed by cold water _______ than the heat rejected by hot water?

Q3. Where are heat exchangers employed in refrigeration and heat pump cycles?

Q4. Why do we use log mean temperature difference while calculating the overall heat transfer
coefficient?

Q5. Write some applications of heat exchangers.