HEAT EXCHANGER ANALYSIS

Stage 2, Mechanical Engineering, UCD, MEEN 20050, Heat Exchanger Analysis

1st November 2023

Aaryan Sukhdeo, 22326595

Lab Partner: Ripley Gallagher
Contents
UCD School of Mechanical and Materials Engineering..............................................................2
ABSTRACT ...................................................................................................................................3
INTRODUCTION ..........................................................................................................................4
OBJECTIVES ................................................................................................................................6
THEORY ......................................................................................................................................7
Test 1 ......................................................................................................................................7
Test 2 ......................................................................................................................................7
Test 3 ......................................................................................................................................8
EXPERIMENTAL METHODS .........................................................................................................9
EXPERIMENTAL RESULTS ..........................................................................................................11
Test 1 ....................................................................................................................................11
Test 2 ....................................................................................................................................11
Test 3 ....................................................................................................................................11
DISCUSSION & CONCLUSIONS..................................................................................................13
Test 1 ....................................................................................................................................13
Test 2 ....................................................................................................................................13
Test 3 ....................................................................................................................................14
REFERENCES .............................................................................................................................15

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 UCD School of Mechanical and Materials Engineering

Laboratory Report Submission Form

MEEN 30040 Measurement & Instrumentation

This form should be completed and digitally signed. It should be incorporated into your submission and
should appear as a single page immediately after the title page.

Student Name: Aaryan Sukhdeo

Student Number: 22326595

Report Title: Heat Exchanger Analysis, Stage 2, Mechanical Engineering, UCD, MEEN 20050,
Heat Exchanger Analysis

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 ABSTRACT

This report deals with the analysis of a heat exchanger. There are three heat exchangers in the
lab, one of which will be examined in detail in this report. They consist of a shell and tube,
plate and crossflow heat exchangers. The experiment is divided into three sections, each part
deals with a different method of calculating the heat exchanger values. The first part relates
to the law of conservation of energy and deals with the energy balance across the heat
exchangers. The second part examines the log mean temperature difference(LMTD) approach
to determining the U – value for the heat exchanger. The final examination utilizes the NTU-
effectiveness approach to estimating the heat exchanger values.

Each of these three calculation methods can be used on all three of the heat exchangers. Each
of the three methods rely on different aspects of the apparatus and can each be used
depending on the available information and circumstances. For example, the LMTD approach
is useful when there is a desired U – value and the NTU approach is used when there is
limited data available.

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 INTRODUCTION

Heat exchangers are devices used to exchange thermal energy (enthalpy) from one medium to
another. They typically uses fluids and gases, the media is separated by a solid wall to
prevent mixing or direct contact. Heat exchangers are extensively used in many engineering
aspects, including power generation, refrigeration as well as chemical processing. The way
heat exchangers are differentiated depends on the design and flow arrangement. Heat
exchangers vary greatly and are often designed and manufactured for a specific purpose.
There are three main types, all of which can be examined in the lab, (fig.1) shell and tube
heat exchanger, (fig.2) plate heat exchanger and a (fig.3) cross flow heat exchanger. The shell
and tube heat exchanger is the primary device discussed in this report. (Shah, R.K. and
Sekulic, D.P., 1998.) (Shah, R.K. and Sekulic, D.P., 2003.)

Fig. 1, Shell and tube heat exchanger

Fig. 2, Plate heat exchanger

Fig. 3, Cross flow heat exchanger

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A shell and tube heat exchanger consists of several inner tubes and one larger outer shell. In
the lab, the shell and tube heat exchanger examined has seven inner tubes. These inner tubes
can carry fluids or gases, in this case water. The inner tubes carry hot water while the outer
shell contains cold water. The flow can be in parallel or counter flow, this means the flow
moves in the same direction or in opposite directions. The shell and tube exchanger in the lab
was set up to perform a counter flow operation. The exchanger has two inlets and two outlets,
for hot and cold water and for the inner tubes and shell. A diagram showing the operation of
the shell and tube heat exchanger can be seen below in fig.4.

Fig. 4, Operation of the shell and tube heat exchanger

Heat exchanger can also contain gases which can be used as a media. An example of this in
the lab is the cross flow heat exchanger. These are usually used in ventilation and cooling
systems that require heat to be exchanged from on stream of air or fluid to another. (Zhan, C.,
Zhao, X., Smith, S. and Riffat, S.B., 2011.)

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 OBJECTIVES

In the experiment, three separate tests were conducted. For a set operating condition, with
known values, the heat transfer rate must be calculated for the hot and cold flow. The heat
transfer rate is the amount of heat transferred per unit time (J/s). In order to calculate this, the
two flow rates and four temperatures are taken from the apparatus as well as constants that
depend on certain factors. The heat transfer rate is helpful in calculating the K-value (thermal
conductivity) of the materials used as well as for the heat exchanger.( Rochelle Enrera,2021.)

The second objective is to use the log mean temperature difference(LMTD) approach to
estimate the UA-value of the heat exchanger. This is the logarithmic average of the difference
in temperature between the hot and cold water at the inlets and outlets of the heat exchanger.
The higher the LMTD the higher the heat transfer. This method is applicable with a constant
flow and thermal properties, it also works with both parallel and concurrent flow. The four
temperatures have to be known for the use of this method. The LMTD approach is commonly
used when there is a desired heat transfer rate (UA- value ). ( Dan Herring, THE HERRING
GROUP Inc. December 8, 2010.)

The final objective is to uses the NTU-effectiveness approach to estimate the heat transfer
rate and the hot and cold outlet temperatures. This method is valid for an exchanger with a
new, unknown operation condition. It requires the two inlet temperatures, mass flowrate and
specific heat capacity. The NTU method defines the rate of heat transfer for the two fluids in
terms of a new parameter, , effectiveness, which is between 0 and 1. NTU stands for the
number of transfer units and can easily be related to the U-value, R-value, Capacity ratio and
effectiveness. This allows us to compute the Heat transfer rate and outlet temperatures. The
approach is also valid for parallel and counter flow. This method relies on manufactures
specification for the heat exchanger as well as values depending on the inlet temperatures of
the water. (Iu, I., Weber, N.A., Bansal, P. and Fisher, D.E., 2007.)

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 THEORY
Test 1

The first observation was to determine the heat transfer rate for the hot and cold streams by
using the Steady State Steady Flow (SSSF) equation, fig. 5 . The useable* data that relates to
this experiment includes the two inlet and two outlet temperatures and the volumetric flow
rate. The density and specific heat capacity for each of the streams can be estimated from the
charts below in fig. 6, these values depend on the temperature of the water. To obtain a value
for the temperature, the average of the inlet and outlet temperatures are used. The densities
and specific heat capacities can be taken as follows. The rate at which heat energy is
transferred can be calculated from the SSSF equations below in fig 5 .

*useable refers to the data required for this specific test, not all the possible data obtainable.

Fig. 5, Steady State Steady Flow (SSSF) equation

Fig. 6, Estimations of the density and specific heat capacity for each of the streams

Test 2

The log mean temperature difference approach uses the logarithmic average of the inlet and
outlet temperatures of the hot and cold streams to estimate the U-value for a specific heat
exchanger. This method is commonly used when there is a desired U-value. The temperature
difference across the hot and cold streams must be calculated first, this can be seen in fig. 7.
below. From this the log mean temperature difference, Tlm , can be defined, fig. 8. The
dimensions of the heat exchanger can be used to calculate the approximate surface are of the
tubes within the apparatus. This allows us to use the heat transfer value from part 1 of the
experiment to calculate the UA-value for the heat exchanger and then the U-value. All of
which calculations can be seen below in fig. 9.

Fig. 7

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 Fig. 8

Fig. 9

Test 3

The NTU – effectiveness approach is an estimate of the outlet temperatures of the heat
exchanger. It involves consulting the manufactures handbook for the exchanger. It is often
used where there is little information available about the heat exchanger. The data required
consists of the two entry temperatures and mass flowrates as well as the manufactures U –
value. The heat capacity rate for each of the streams can be calculated by multiplying the
mass flowrate and specific heat capacity. This is then used to determine the capacity ratio, a
ratio of the minimum over the maximum capacity ratios. The UA – value for the heat
exchanger is required again, however this must be calculated again with the manufactures U
– value. The NTU can be calculated by dividing the UA – value by the minimum heat
capacity rate. The effectiveness of the shell and tube heat exchanger can be calculated from
the equation below in fig. 10. It can also be estimated from the graph seen in fig 13. The
effectiveness times the maximum heat transfer gives us an estimate for the heat transfer rate.
The maximum heat transfer can be calculated from the equation below in fig. 11. From the
SSSF equation used in part 1 of the experiment we can estimate the output temperatures by
using our estimated heat transfer rate. These equation can be seen blow in fig. 12.

Fig. 10

Fig. 11

Fig. 12

Fig. 13

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 EXPERIMENTAL METHODS

The shell and tube heat exchanger is a device used to transfer heat energy from to one
medium to another. In includes seven stainless steel inner tubes and as well as an outer shell
(fig. 14). The exchanger has two inlets and two outlets, for the hot and cold water. The
apparatus also consists of centrifugal pumps to supply a constant flow to the inlets. There is
also an interface where the temperatures and flow rates are displayed. These values are
obtained from sensors placed within the apparatus, which are connected to the side of the
interface which can be seen below (fig. 15). The exchanger was set to perform a counter flow
operation, this means the hot and cold water flow in different directions, this remained the
case over the course of the three observations.

Fig. 15, Sensors

Fig. 14, Seven tubes

The first observation involved calculating the heat transfer rate for the hot and cold streams.
We noted the four temperatures and volumetric flow rates, making sure to wait before each
value was taken. This allows the flows and temperatures to steady. The water density and
specific heat capacity for the hot and cold streams must be obtained next. These values are
approximated from the average water temperature between the inlet and outlet. A graph
displaying the data for the heat capacity and density can be seen above in fig. 6. The mass
flow rate is obtained from the volumetric flow rate and the density, multiplying these values
gives us the flow rate in kg/s. The rate of heat transfer for the hot and cold streams should
theoretically be same value, which is obtained from the 1st law Steady State Steady Flow
process. This equation requires the values calculated and recorded from the experiment and
outputs the rate of heat transfer.

The log mean temperature difference approach (LMTD) is applicable when a specific heat
transfer rate is desired. It is based on the inlet and outlet temperatures as well as the
mass flow rate for the hot and cold streams. Since the flow rates and temperatures remained
constants for the three observations, we are able to use to same mass flow rates computed in
the last test. Keeping these values constant also allows us to easily compare the different
approaches to examining a heat exchanger. The logarithmic average between the hot and cold
streams is calculated from the four temperatures and is defined as ∆ . The heat transfer

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value from part 1 is also required for the calculations, this value divided by ∆ gives us the
UA-value for the heat exchanger. The dimensions for each component of the heat exchanger
was given in the initial experiment brief. These values are used to calculate an estimate for
the total heat transfer surface area. This is then divided into the UA-value to give the U-value
for the heat exchanger. The manufacture also released a U-value graph, which depends on the
volumetric flow rate, this graph is used to obtain a value for the manufactures specified U-
value for our flow rate. This value is then compared to the calculated value found from
experimentation. This manufactures graph can be seen below in fig. 16 ( Zavala Río, A.,
Femat Flores, A.R. and Santiesteban Cos, R., 2005.)

Fig. 16

The NTU-effectiveness approach is used when there is limited data available about the heat
exchanger. It is an estimate of the output temperatures and heat transfer rate. The data
required includes the inlet temperatures, mass flow rates and specific heat capacity, all of
which can be taken from the two previous tests since the apparatus was not altered in any
way. We ensured that the values were constant for each of the experiments to be able to
accurately compare the tests and results. From these values we can compute the heat capacity
rate, which is the mass flow rate times the specific heat capacity, for the hot and cold streams.
The heat capacity rate is the amount of heat a certain flow of mass is able to release or absorb
per unit temperature change per unit time. From these two values we can also calculate the
capacity ratio, which ranges from zero tom one. It is the ratio of the minimum capacity rate to
the maximum capacity rate. The fluid with the lower capacity rate will experience a greater
change in temperature compared to the higher capacity rated fluid. The NTU value can be
calculated by dividing the UA-value by the minimum heat capacity rate, however this is not
the same UA-value from the previous experiment as this method is valid for when we don’t
have any measured values. Instead we use the manufactures U-value of 1050 W/ . The
NTU- value can be used to calculate the effectiveness of the heat exchanger. We used the
equation above in fig 10. to calculate the effectiveness, we also cross checked our value with
the NTU-effectiveness chart, fig. 13. The heat transfer rate can be estimated from the
effectiveness by multiplying it by the maximum possible heat transfer. The max heat transfer
is the minimum heat capacity rate times the greatest difference in temperature. Using the
SSSF equations the outlet temperatures can be calculated for the hot and cold streams.
(Indian council of agricultural research, iasri. 25 March 2014. ) (Navarro, H.A. and Cabezas-
Gómez, L.C., 2007.)

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 EXPERIMENTAL RESULTS
Test 1

The measured data includes the volumetric flowrates and the entry and exit temperatures for
the hot and cold streams. From this the flowing results can be obtained in fig. 17.

Fig. 17

Test 2

The data required for calculations consists of the entry and exit temperatures and mass flow
rates. Since the operating conditions remain the same for each of these tests we can take the
temperatures to be the same as part 1, as well as the mass flow rate from the graph in fig. 18.
The heat transfer value from part 1 is also assumed for this test. From this the log mean
temperature difference can be calculated and used to determine the U – value seen below.

Fig. 18

Test 3

The NTU – effectiveness approach is used when there is limited data available, in this case
we had the input temperatures, mass flow rates and specific heat capacities of the two
streams. These values can be taken from the previous tests as the apparatus remains

11
unchanged. From these figures we can estimate the exit temperatures for the two streams as
seen below in fig. 19.

Fig. 19

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 DISCUSSION & CONCLUSIONS

Test 1

Based on the data above we can see several expected outcomes, this includes the
temperatures and energy transferred. The hot inlet is greater than the hot outlet as expected
since the heat energy is being transferred to the cold water. This is confirmed as the cold
outlet temperature is greater than the cold inlet temperature, which verifies that heat is being
exchanged. In theory the energy from the hot water would be equal the energy transferred
unto the cold water, however in reality there is a number of experimental factors which must
be considered. This ranges from the apparatus to the quality of the water. The exchanger is
over 25 years old, with usually wear and tear. The heat from the hot water is dissipated not
only to the cold contra flow, but also to the surrounding materials and air. The water used has
slight impurities which can affected the experiment as well. However, this is the main reason
the energy balance for the cold water is less that for the hot water.

Test 2

As I said before the apparatus used is over 25 years old and cannot be expected to perform as
new. The manufactures U-value when new is 1050, however the calculated U- value from
experimental data is 725, a significant amount less. This relates to a number of factors,
mainly related to the age of the machine and quality of the parts and water used. The water
used is non-potable, which means it’s not safe for drinking and contains bacteria. This can be
seen from the colour (fig. 20) of the water and bacteria residue inside the heat exchanger. The
machine consists of seven stainless steel tubes which run inside the outer shell (fig. 22). The
ends of the tubes can be seen from the sides of the exchanger and clear signs of corrosion can
be seen (fig. 21). These factors as well as the uncontrollable wear and tear all contribute to
the difference in the U-values.

Fig. 20, Water colour Fig. 21, Corrosion Fig. 22, Seven tubes

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Test 3

From the results above, our estimated temperatures differ from the measured ones by a small
margin. The NTU- effectiveness approach works under perfect conditions with perfect
equipment and water. The heat capacities were calculated from the temperature of the water
at the inlet, however the water used is non-potable and therefore not considered a perfect
sample of water. The heat capacities are estimates and can differ from the calculations. From
the previous test, we concluded that the measured U-value was lower than the manufactures
U-value. In this test we used the value of 1050 W/m2K, which can cause an approximation in
our results. Below can be seen the same table of results but a value of 14.568 WK-1 was used
for UA (fig. 23). The estimated and measured temperatures are much closer, however the
NTU approach assumes that the apparatus is not within reach or there is no availably for an
experiment to obtain a U-value from.

Fig. 23, Table of results, value of 14.568 WK-1 used for UA

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 REFERENCES

1. Shah, R.K. and Sekulic, D.P., 1998. Heat exchangers. Handbook of heat transfer, 3.
2. Zhan, C., Zhao, X., Smith, S. and Riffat, S.B., 2011. Numerical study of a M-cycle cross-
flow heat exchanger for indirect evaporative cooling. Building and Environment, 46(3),
pp.657-668.
3. Shah, R.K. and Sekulic, D.P., 2003. Fundamentals of heat exchanger design. John Wiley &
Sons.
4. Rochelle Enrera,2021. Heat transfer rate through conduction.
5. Dan Herring, THE HERRING GROUP Inc. December 8, 2010. What is LMTD?
6. Iu, I., Weber, N.A., Bansal, P. and Fisher, D.E., 2007. Applying the effectiveness-NTU
method to elemental heat exchanger models. ASHRAE Transactions, 113(1), pp.504-513.
7. Zavala Río, A., Femat Flores, A.R. and Santiesteban Cos, R., 2005. An analytical study of
the logarithmic mean temperature difference.
8. Indian council of agricultural research, iasri. Tuesday, 25 March 2014, 9:52 AM. Heat
exchanger performance in terms of Capacity ratio, Effectiveness and Number of transfer
units, Effectiveness for parallel flow heat exchanger.
9. Navarro, H.A. and Cabezas-Gómez, L.C., 2007. Effectiveness-NTU computation with a
mathematical model for cross-flow heat exchangers. Brazilian Journal of Chemical
Engineering, 24, pp.509-521.
10. Fig 1, https://www.jdsplumbingservice.com/blog/ultimate-guide-to-hvac-maintenance-
and-repair
11. Fig. 2, https://www.heatflow.co.za/plate-heat-exchangers/
12. Fig. 3, https://armfield.co.uk/product/ht35x-cross-flow-heat-exchanger/
13. Fig. 4, https://chemcastic.in/straight-tube-configuration/

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