DEPARTMENT OF CHEMICAL ENGINEERING: BEng Tech

CHEMICAL ENGINEERING LABORATORY 1A

HEAT EXCHANGER INDIVIDUAL TECHNICAL REPORT

Surname, Initials Student Number/s Percentage contribution Student Signature

Sindelo L 22030293 100%

PRAC NAME Heat Exchanger

DATE OF PRAC 27/09/2022

LECTURER LUBISI T.P

Table of Contents
Summary...........................................................................................................................................3

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 Introduction.......................................................................................................................................4
Theory...............................................................................................................................................5
Experimental Method and Apparatus...............................................................................................8
Results and Discussions...................................................................................................................11
Conclusion and Recommendations.................................................................................................13
Nomenclature..................................................................................................................................13
References...........................................................................................................................................14
Appendix..........................................................................................................................................14

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Summary
A Heat exchanger is a pressure vessel that is used to transfer a huge amount of heat at low
energy consumptions (Coulson, J M; Richardson, J F; Backhurst, J R; Harker, J H;, 1954).
This practical was conducted to compare the efficiency of different types of heat exchangers,
to determine which Heat exchanger works best. These include the shell-and-tube, double
pipe, and plate-and-frame heat exchanger. For each Heat exchanger temperature repeatability
was to be determined. Also, the effect of cold fluid flow rate on the overall heat transfer
coefficient for all the heat exchangers.

To conduct this experiment, the hot water was fed at a constant temperature then the values
needed were recorded. Then the flow rate of cold water at the inlet was increased then again,
the values were recorded.

Both the shell-and-tube and double-pipe heat exchangers have a shell side and the tube side
which are separated by a tube sheet. One fluid flows in the shell side and the other in the tube
side then heat transfer takes place. However, before the fluids were introduced into the
system it was first determined which fluid was to go on the shell side or the tube side. To do
this, properties like viscosity, corrosiveness, temperature, and dirtiness of fluid are taken into
consideration to choose where each fluid goes. The Plate-and-frame has a similar
configuration except it uses plates that contain hot and cold fluids which are next to each
other to make heat transfer possible.

Variables that remained constant:

 Hot water inlet temperature.

 Hot water flow rate.

Variables that were varied:

 Cold water flowrate.

Variables that were recorded:

 Cold water inlet temperature.

 Hot water outlet temperature.
 Cold water outlet temperature.

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While conducting the experiment calculations of certain variables were made. This led to
depicting the obtained calculations of the different heat exchangers in graphical form. For the
shell and heat exchanger a uniformly increasing trend was obtained as it showed the flowrate
is directly proportional to the overall heat transfer coefficient for this type of heat exchanger.
The double pipe heat exchanger trend was obtained when graphing data of flow rate and
overall heat transfer coefficient, the trend was increasing at the start of the practical but as the
system was at high flow rates the trend started to decline. Lastly the plate-and-frame heat
exchanger the trend shown by the graph was overall an increasing trend but throughout the
trend, there was a decline but then it picked up at high flowrates as it started to increase
again.

It was determined that for this practical there could be improvements in increasing heat
transfer such as decreasing the velocity of the fluids or using high-heat conductive pipes.
Using fouling-resistant material for the design of heat exchangers could be another way to
increase heat transfer as it counters the decrease in heat transfer due to fouling (deposits of
fluid attaching to the pipes).

Introduction
As stated in the summary, a Heat exchanger is a pressure vessel that is used to transfer a huge
amount of heat at low energy consumptions. This report focuses on Heat exchangers which
are used to transfer heat between two fluids of interest. One at inlet will be hot and the other
at inlet will be cold. They both leave at different temperatures than the ones at inlet due to
heat transfer. This experiment is of relevance because it is used in the industry as it is very
effective with heat transfer process, and it provides low costly mechanical designs.

Objectives

 Determine the effect of the cold-fluid flow rate on the overall heat transfer coefficient,
for the shell-and-tube heat exchanger, double pipe heat exchanger and the plate-and-
frame heat exchanger.
 Determine which of the three heat exchangers is the most suitable and the optimum
cooling water flow rate to be used.
 Determine repeatability of temperature reading at varied cooling water flowrate, for
each heat exchanger.

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The report has the following layout, theory, experimental method and apparatus, results and
discussions, conclusion and recommendations, nomenclature, references, and appendices.

Theory
To begin with the heat exchanger experiment is widely governed by the second law of
thermodynamics. Which in shallow words states that heat will move from zones of high
temperature to low temperature (Perry, Robert H; Green, W Don;, 1984). This makes heat
transfer possible.

Figure 1:Shell-and-Tube Heat exchanger

In figure 1 one fluid flows in the shell side the other in the tube side.

Figure 2:Double pipe heat exchanger model

Figure 2 is a simple model of a double pipe heat exchanger depicting a shell side where one
fluid flows and a tube side where the other fluid flows.

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Figure 3:Plate-and-Frame Heat exchanger

In figure 3 The Plate-and-frame heat exchanger uses plates where the hot fluid flows in one
plate and the cold fluid in the other.

b) This Process is affected by several factors and those being viscosity of fluids involved,
temperature of fluids and fouling of fluids whether it is light or heavily fouling to name the
ones that have a great effect. With fluid allocation we look at many different factors. For both
shell-and-tube and double heat exchanger the focus is on flowrate, temperature, viscosity
corrosiveness and fouling of fluids.

For flowrate place fluids with low flowrate on shell side this is for economical design in
terms of reducing cost. For temperature place fluids with high temperatures on the tube side
as it is much cheaper to replace and clean the tube side than the shell side. When it comes to
viscosity, highly viscous fluids are placed in the shell side because pressure drops can be
easily minimized in the shell side than on the tube side. Corrosive fluids are allocated to the
tube side to reduce the cost of the Heat exchanger. Heavily fouling liquids are allocated to the
tube side as it is much easier to clean mechanically and chemically than the shell side.

c) One of the key parameters studied in this report is the overall heat transfer coefficient,
which is mandatory because it allows for easy determination of how effective a heat
exchanger is. The surface area needed in the heat exchanger is also another parameter to be
determined, as it shows how much space is needed and can help in cost cutting as the one
with a small area is chosen. Hence, reducing the materials needed.

d) Main Equations used:

1. Q=UA ∆T LM

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 Where:
 Q is heat transfer rate in (J/s)

 U is the overall heat transfer coefficient in ( m W. ℃ )

2

 A is area in (m 2 ¿
 ∆ T LM is logarithmic temperature in (℃ ¿

( ∆ T 2 )−( ∆ T 1 )
∆ T LM =
2.
ln
( )
∆T 2
∆T 1

Where:
 ∆ T LM is the logarithmic temperature in (℃ ¿

 ∆ T 1 , ∆T 2 is the temperature difference between the hot and cold fluid at each end
of the Heat exchanger in (℃ ¿

3.Q= ṁc p ( ∆ T )

Where:
 Q is the heat transfer rate in (J/s)
 ṁ is the flowrate in(kg/s)

 c p is the specific heat capacity in ( Kg.J℃ )

 ∆ T is the temperature difference between fluids in (℃ ¿

Shell-and-Tube Heat exchanger(equations)

 A=π Do ln
Where:
 Do is tube outer diameter(m)
 L is tube length(m)
 N is number of tubes

Plate-and-Frame Heat exchanger(equations)

 Effective no. of plates = total no. of plates - 2

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  Atotal = Aplate x eff. no. of plates
Where:
 Atotal is the total heat transfer area of the plate-and-frame exchanger (m¿¿ 2)¿
 Aplate is the surface area of each plate (one side)(m¿¿ 2)¿

Double Pipe Heat exchanger(equations)

 Adouble_pipe = Do π L
Where:
 L – total tube length of the inner pipe [m]
 Do – outside diameter of inner pipe [m]

Experimental Method and Apparatus

Figure 4:Actual equipment used in laboratory

Figure 4 shows the actual equipment that was used in the laboratory. This heat exchanger
bench has the plate-and-frame heat exchanger on the right mounted vertically. The double
pipe heat exchanger painted in blue on the near side. The shell-and-tube heat exchanger at the
back with the colour grey. The control panel in white where readings for each heat exchanger
were recorded from. Each of the heat exchangers were fed hot steam at 90℃ through the
silver pipe mounted vertically on the far back left.

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Figure 5:Block diagram of Heat Exchanger Apparatus

Apparatus:

1. Shell-and-Tube
 19 stainless tubes
 Shell chamber
 Baffles
 Tube sheet
2. Double pipe
 316 stainless steel tubes
 Baffles
 Tube sheet
3. Plate-and-Frame
 20 stainless steel plates

Operating procedure:

1. The flexible hoses were connected to the heat exchanger selected for experimentation.
The exchangers were to be connected in counter-current configuration.

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 2. The power switch was turned on to supply power to the temperature indicators and the
solenoid valve controlling steam flow to the brazed-plate exchanger.
3. The steam isolation valve was opened.
4. Open the water isolation valve was opened along with the needle valves on the
rotameters.
5. The steam switch was opened.
6. The steps were repeated until all required values were obtained for each heat
exchanger.

Variables that remained constant:

 Hot water inlet temperature. (90℃ )

 Hot water flow rate. (200℃ )

Variables that were varied:

 Cold water flow rate. (150-550 L/hr)

Variables that were recorded:

 Cold water inlet temperature.

 Hot water outlet temperature.
 Cold water outlet temperature.

=
‫ ر‬du
dy

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Results and Discussions
The whole idea of the Heat Exchanger is to reduce the temperature of the hot fluid coming in.
In the results to follow I have shown the relation between the flowrate and the hot water
outlet temperature.

Heat transfer rate(J/s) vs. Flowrate(l/hr)

7000
6000
5000
Heat transfer(J/s)

4000
3000
2000
1000
0
150 250 350 450 550
Flowrate(l/hr)

Graph 1:Shell-and-Tube heat transfer rate vs. flowrate

Graph 1 above it is shown that the heat transfer rate increases as the flow rate increases. This
is expected because heat is transferred from a hot surface to a cold surface. This is because
the surface (where the cold water is flowing) is getting colder therefore more heat is
transferred from the hot surface to the cold surface. So, an increase in flow rate (of cold
water) increases the heat transfer rate because they are directly proportional according to the
formula [Q̇= ṁc p ( ∆ T )].

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 Heat transfer rate(J/s) vs. Flowrate(l/hr)
9000
8000
7000
Heat transfer(J/s)

6000
5000
4000
3000
2000
1000
0
150 250 350 450 550

Flowrate(l/hr)

Graph 2:Double pipe heat transfer rate vs. flowrate

Graph 2 shows the heat transfer rate vs. flowrate. The data shows the heat transfer rate rises
then at a later stage starts to decline. This is not an ideal trend for a heat exchanger because
the heat transfer rate is supposed to increase with the flow rate. Therefore, for a double-pipe
heat exchanger the heat transfer rate decreases at high flow rates of cold water. This may be
due to the amount of contact time in the system, it may be too short so the liquid leaves while
hot.

Heat transfer rate(J/s) vs. Flowrate(l/hr)

12000

10000
Heat transfer(J/s)

8000

6000

4000

2000

0
150 250 350 450 550
Flowrate(l/hr)

Graph 3:Plate-and-Frame heat transfer rate vs. flowrate

Graph 3 shows an increasing trend for the heat transfer rate vs. flow rate data. This is an
expected outcome. However, the problem would be the decline in heat transfer rate at flow

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rates of (250-350 l/hr). Overall, the heat transfer rate recovers at a late stage as it increases at
flow rates of (350-550 l/hr). This would not be good because low heat transfer rates are
obtained when more work is added. This is not a good outcome for engineers as the aim is to
obtain higher outputs(energy) at lower inputs(work).

Conclusion and Recommendations

The report concludes that Heat exchangers continue to be an effective process for heat
transfer, this is from results showing very well that the heat transfer requirements are met.
The Shell-and-Tube heat exchanger achieved a steadily increasing trend when comparing the
heat transfer rate of all the heat exchangers it is continuously increasing compared to the
other heat exchangers meaning more efficiency. Therefore, it honoured the theory of heat
transfer constantly better than the other heat exchangers.

For better optimum results the equipment used should be cleaned periodically when the
practical is to be conducted. The heat exchangers should be maintained to prevent leakages
and fouling. Keep addressing little issues that may affect the heat exchangers like pressure
drop.

Nomenclature
2
A Area m
T Temperature ℃
 μ Viscosity Pa . s
kg
 ρ density m3
 P pressure Pa
 Q Heat transfer rate J/s

 U Overall heat transfer coefficient ( W

2
m .℃ )
 Do Outside diameter m

 N Number of tubes -
 c p Specific heat capacity ( Kg.J℃ )
L Length of tube m
(kg/s)

 ṁ Flowrate

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  ∆ T LM Logarithmic temperature ℃

References
Coulson, J M; Richardson, J F; Backhurst, J R; Harker, J H;. (1954). Chemical Engineering Volume 1
(6th ed.). Worbon: Pergamon Press.

Perry, Robert H; Green, W Don;. (1984). Perry's Chemical Engineers Handbook (8 ed.). New York:
McGraw-Hill.

Sinnot, R. (2005). Coulson & Richardson’s Chemical Engineering. Burlington.

Appendix
Raw Data Tables for the Heat Exchangers Experimented

Shell-and-tube
Hot water flow(l/hr) 200 200 200 200 200
Cold water flow/l/hr) 150 250 350 450 550
Hot water IN temperature(T1) 90 90 90 90 90
Cold water IN temperature(t1) 23,9 23,8 23,9 23,8 24
Hot water out temperature(T2) 68,4 67,5 66 64,6 64,1
Cold water out temperature(t2) 41,2 38,4 35,9 34,1 33
Table 1:Raw data for Shell and Tube heat exchanger

Double pipe
Hot water flow(l/hr) 200 200 200 200 200
Cold water flow/l/hr) 150 250 350 450 550
Hot water IN temperature(T1) 90 90 90 90 90
Cold water IN temperature(t1) 23,9 23,8 23,9 23,8 24
Hot water out temperature(T2) 48,6 50,8 51,2 51,2 50,6
Cold water out temperature(t2) 49,5 46,4 40 40 28,2
Table 2: for Double pipe heat exchanger

Plate-and-frame
Hot water flow(l/hr) 200 200 200 200 200
Cold water flow/l/hr) 150 250 350 450 550
Hot water IN temperature(T1) 90 90 90 90 90
Cold water IN temperature(t1) 24 24 24 24 23,8
Hot water out temperature(T2) 33,6 41 44,8 45 47,7
Cold water out temperature(t2) 68,8 62,1 47,9 43,6 41,4
Table 3: raw data for Plate and Frame heat exchanger

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Heat Exchanger Specifications(as of Practical manual)
Shell-and-tube heat exchanger
Number of tubes 19
Tube length 600 mm
Tube outer diameter 8 mm
Tube inner diameter 6.8 mm
Tube material ASI 316 stainless steel
Shell inner diameter 62.5 mm
surface area(m^2) calculated 0,286513
specific heat capacity of water(J/kg.Ԩ ) 4187
Heat transfer(J/s) 3018,129 4245,153 4884,833 5390,763 5757,125
overall heat transfer coefficient(W/m^2.Ԩ ) 608,9014 1014,836 1420,77 1826,704 2232,639
Table 4:Calculated values for shell and tube heat exchanger

Plate-and-frame heat exchanger

Plate material ASI 316 stainless steel
Fluid volume per side 5 litres
Surface area per plate (one side) 0.08 m2
specific heat capacity of water(J/kg.Ԩ ) 4187
Heat transfer(J/s) 7815,733 11078,1 9728,96 10258,15 11258,38
overall heat transfer coefficient(W/m^2.Ԩ ) 2180,729 3634,549 5088,368 6542,188 7996,007
Table 5:Calculated values for plate and frame heat exchanger

Double pipe heat exchanger

Inner Pipe
Outer diameter 21.3 mm
Inner diameter 17.1 mm
Material ASI 316 stainless steel
Outer Pipe
Outer diameter 33.4 mm
Inner diameter 27.9 mm
Material ASI 316 stainless steel
Overall Length 2.8 m
specific heat capacity of water(J/kg.Ԩ ) 4187
Heat transfer(J/s) 7815,733 11078,1 9728,96 10258,15 11258,38
overall heat transfer coefficient(W/m^2.Ԩ ) 2180,729 3634,549 5088,368 6542,188 7996,007

Table 6:Calculated values for double pipe heat exchanger

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