DEDAN KIMATHI UNIVERSITY OF TECHNOLOGY

SCHOOL OF ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

ENGINEERING THERMODYNAMICS I

EMG. 2206

LECTURER: DR. NGUGI

TECHNOLOGIST NAME: Mr GEFFREY

DATE: 11/11/2024

GROUP NUMBER: 2

GROUP MEMBERS:

NAME REG NO SIGNATURE

1 SERENA CHEPNGETICH E029-01-1426/2023

2 MERKES JACOB E029-01-1423/2023

3 MESHACK KIBET E029-01-1424/2023

4 SYLVESTER YEGON E029-01-2106/2023

5 BRIAN KIPCHUMBA E029-01-1408/2023

6 BRIAN KIPTOO E029-01-1418/2023

7 KIPTOO WESELY E029-01-1405/2023

8 COLLINS KIPLAGAT E029-01-1417/2023

9 JANETH KISINGU E029-01-1655/2121

ABSTRACT

The experiment explored the performance and efficiency of a counter current heat exchanger using
the HT30X Heat Exchanger System. By measuring temperature variations between two water streams
—hot and cold—flowing in opposite directions, calculate heat transfer rates, temperature
efficiencies, and examined the impact of varying flow rates on overall efficiency. Results showed that
increased flow rates improved heat absorption in the cold stream but also highlighted significant
energy losses due to thermal dissipation to the surroundings. These findings provided valuable
insights for optimizing heat exchanger designs to enhance thermal efficiency in industrial
applications.

INTRODUCTION

The HT30X is a versatile, computer-controlled heat exchanger service unit designed for educational
and research applications. It allows for the study of heat transfer through various heat exchanger
types, such as tubular, plate, and shell-and-tube exchangers. The system includes a hot water vessel
with an electric heater, a pump for water circulation, and a controlled cold-water flow, all managed
through a computer interface.

Key features include the ability to reverse the flow direction of the hot water for co-current and
counter-current studies, and it supports up to 10 temperature measurements and flow rate
monitoring. The unit is ideal for experiments involving heat transfer principles like energy balance,
heat transfer coefficients, and the effects of fluid flow configurations on performance. It also
supports remote operation and user-designed software.

Objective

To demonstrate indirect heating or cooling by transfer of heat from one fluid stream to another when
separated by a solid wall.

Experimental Setup

The experiment was conducted using a counter current heat exchanger. The primary variables
monitored included the temperature of the hot and cold fluids at ten points along the exchanger, the
flow rates of both fluids, and the thermal properties (specific heat and density) of the fluids. The hot
water pump setting and cold-water valve setting were adjusted during the experiment to observe
their effect on heat transfer efficiency.

Apparatus

HT30X Tabular Exchanger

Key parameters were as follows:

Hot fluid: Inlet temperature set around 62°C.

Cold fluid: Inlet temperature set around 27°C.

Flow orientation: Counter current.

 Theory

A heat exchanger is a device designed to facilitate thermal energy transfer between different fluids
without mixing them. It operates with two main types of flow arrangements: parallel flow and
counter-current flow. Temperature, which represents the thermal energy of a substance, can be
transferred effectively between fluids using a heat exchanger, ensuring optimal performance of both
inlet and outlet streams.

Heat transfer within the system occurs through three primary mechanisms:

Conduction: Heat moves through a solid barrier, such as the tube walls.

Convection: Heat is transferred within and between fluid layers as they flow.

Radiation: While present, it plays a minimal role in most heat exchanger applications.

A double pipe heat exchanger consists of two concentric pipes, where hot fluid passes through the
inner tube and cooler fluid flows through the space between the inner and outer tubes. A small
temperature difference across the metal wall facilitates the heat transfer between the fluid streams.
This configuration supports high operating pressures and allows significant pressure differences
between the fluids, making it suitable for specific industrial applications.

Flow rates: Hot fluid flow rate varied from 2.9 to 3.1 l/min, and cold fluid flow rate varied from 1.34
to 1.44 l/min.

Thermal properties: Specific heat of both fluids was considered constant (Hot fluid: 4.184 kJ/kg·K,
Cold fluid: 4.179 kJ/kg·K).

PROCEDURE

1. Set Temperature Controller: The temperature controller was set to approximately 45°C above the
cold-water inlet temperature (T4). For example, if T4 was 15°C, the controller was set to 60°C.

2. Activate Circulation: For the HT30X, the hot water circulator was switched on.
 3. Set Cold and Hot Water Flow Rates:

o The cold-water control valve was adjusted to achieve a flow rate of 1 litter per minute
(L/min).

o For the HT30X, the hot water control valve was set to reach a flow rate of 3 L/min. For
the HT30XC, the hot water flow was set to "Automatic" in the software, with a set point
of 3 L/min.

4. Monitor and Stabilize: The system was allowed to stabilize, with temperature readings monitored
through the software or control console.

5. Record Initial Data: Using the record icon in the software or manually, the readings for
temperatures T1–T6 and flow rates Fhot and Fcold were noted.

6. Adjust Cold Water Flow: The cold-water flow rate was then adjusted to 2 L/min, and once stable,
new readings were recorded on a fresh results sheet.

7. Experiment with Different Flow Rates: If time permitted, various combinations of hot and cold
flow rates were tested, with each set recorded on a new results sheet.

8. Save Data: The logged data was saved by selecting "Save" or "Save As" in the software, with files
named descriptively (e.g., "HT31A").

Hot Hot Cold

Sam Tem Tem Tem Tem Tem Tem Cold
Temp Temp Temp Temp Water Water Water
ple p p p p p p Water Flow
Pump Flowrat Valve
Num Flowrate Orientation
T7 T8 T9 T10 Settin e Settin
ber T1 T2 T3 T4 T5 T6 Fcold
[°C] [°C] [°C] [°C] g Fhot g
[°C] [°C] [°C] [°C] [°C] [°C] [l/min]
[%] [l/min] [%]

1 62.4 59.7 57.1 21.7 27.3 32.8 133.0 133.0 133.0 133.0 35 3.0 50 1.34 Countercurrent
2 62.3 59.7 57.1 21.7 27.3 32.9 133.0 133.0 133.0 133.0 33 3.0 50 1.38 Countercurrent
3 62.4 59.6 57.0 21.7 27.3 32.8 133.0 133.0 133.0 133.0 34 2.9 50 1.34 Countercurrent
4 62.2 59.6 57.0 21.8 27.3 32.9 133.0 133.0 133.0 133.0 34 3.1 50 1.38 Countercurrent
5 62.3 59.7 57.0 21.8 27.3 32.8 133.0 133.0 133.0 133.0 34 2.9 50 1.44 Countercurrent
6 62.2 59.6 57.0 21.8 27.3 32.9 133.0 133.0 133.0 133.0 35 3.0 50 1.40 Countercurrent
7 62.3 59.6 56.9 21.8 27.3 32.9 133.0 133.0 133.0 133.0 34 3.1 50 1.39 Countercurrent
8 62.1 59.5 56.9 21.8 27.4 32.9 133.0 133.0 133.0 133.0 34 3.1 50 1.33 Countercurrent
9 62.1 59.5 56.9 21.8 27.3 32.9 133.0 133.0 133.0 133.0 34 3.0 50 1.42 Countercurrent
10 62.1 59.5 56.8 21.8 27.3 32.9 133.0 133.0 133.0 133.0 34 2.9 50 1.40 Countercurrent
 Specific Hot Cold
Specific Density
Heat Hot fluid Density Cold Fluid Hot Fluid Cold Fluid Mass Mass
Heat Cold
Cold Fluid Average Hot Fluid Average Change Change Flow Flow
Hot Fluid Fluid
Temperature Temperature Thot Tcold Rate Rate
Cph
Cpc [°C] [kg/m³] [°C] [°C] [°C] qmh qmc
[kJ/kg K] [kg/m³]
[kJ/kg K] [kg/s] [kg/s]

4.184 4.179 59.7 983.3 27.3 996.4 5.3 11.1 0.050 0.022

4.184 4.179 59.7 983.4 27.3 996.4 5.2 11.2 0.049 0.023

4.184 4.179 59.7 983.4 27.3 996.4 5.4 11.1 0.048 0.022

4.184 4.179 59.6 983.4 27.3 996.4 5.2 11.2 0.050 0.023

4.184 4.179 59.7 983.4 27.3 996.4 5.3 11.0 0.048 0.024

4.184 4.179 59.6 983.4 27.3 996.4 5.2 11.1 0.049 0.023

4.184 4.179 59.6 983.4 27.3 996.4 5.4 11.1 0.050 0.023

4.184 4.179 59.5 983.4 27.3 996.4 5.2 11.1 0.050 0.022

4.184 4.179 59.5 983.5 27.3 996.4 5.2 11.1 0.050 0.024

4.184 4.179 59.5 983.5 27.3 996.4 5.3 11.0 0.048 0.023

Heat Heat Heat Temp Temp Overall

Overall Mean LMTD Questions
Power Power Power Efficiency Efficiency Heat
Efficiency Temp Score
emitted absorbed lost for hot for cold Transfer
Efficiency
Qe Qa Qf fluid fluid Coefficient
[%] [%] [%]
[W] [W] [W] [%] [%] U

Hidden Hidden Hidden Hidden Hidden Hidden Hidden

DISCUSSION

During the experiment, it was observed that the temperature change in the hot water stream
decreased as its flow rate increased. This behaviour is expected, as a higher flow rate of hot water
means the fluid spends less time in the heat exchanger, reducing the amount of heat it can transfer
to the cold fluid. Therefore, the temperature of the hot water decreases less significantly when the
flow rate is increased.

Chart Title
1400.0 133.0 133.0 133.0
133.0 133.0 133.0
1200.0 133.0 133.0 133.0
1000.0 133.0 133.0 133.0
133.0 133.0 133.0
800.0 133.0 133.0 133.0
62.1 59.5
62.1 59.5 56.8 133.0 133.0 133.0
600.0 62.1 59.5 56.9
62.3 59.6 56.9
62.2 59.6 56.9 133.0 133.0 133.0
62.3 59.7 57.0 32.9
32.9
400.0 62.2 57.0 27.3
27.3 32.9 133.0 133.0 133.0
59.6 57.0 21.8
21.8 27.4
27.3 32.9
32.9
62.4 59.6 57.0 21.8
21.8 27.3 32.8
200.0 62.3 59.7 57.1 21.8
21.8 27.3
27.3 32.9
32.8 133.0 133.0 133.0
62.4 59.7 57.1 21.8
21.7
21.7 27.3
27.3 32.9
21.7 27.3 32.8 2.9
3.0
3.1
2.9
3.0
0.0
Temp Temp Temp Temp Temp Temp Temp Temp Temp Hot Water
Flowrate
T1 T2 T3 T4 T5 T6 T7 T8 T10 Fhot
[°C] [°C] [°C] [°C] [°C] [°C] [°C] [°C] [°C] [l/min]

Series1 Series2 Series3 Series4 Series5

Series6 Series7 Series8 Series9 Series10

Conversely, the temperature change in the cold water increased with a higher flow rate. This seems
counterintuitive, but it can be explained by the fact that, as the cold-water flow rate increases, the
fluid absorbs more heat, leading to a greater rise in its temperature. Even though the cold water
flows faster, it still gains more heat, as the overall heat transfer from the hot fluid remains significant,
given the setup.

As for the heat transfer values, it was observed that the heat power lost by the hot fluid (Qe) was not
exactly the same as the heat power gained by the cold fluid (Qa), although the difference was small.
In theory, the heat lost by the hot fluid should equal the heat gained by the cold fluid (i.e., Qe = Qa).
However, slight discrepancies between Qe and Qa are common due to several factors, such as:

Measurement errors: Small inaccuracies in temperature readings due to sensor calibration or slight
placement errors.

Environmental influences: Heat loss to the surroundings or imperfect insulation around the heat
exchanger.

Idealized assumptions: Theoretical calculations often assume perfect conditions, which may not
entirely match the real-world experimental setup.

Despite these small differences, the values of Qe and Qa were very close, indicating that the heat
exchange process was largely efficient.
Conclusion

The experiment successfully demonstrated the principles of fluid-to-fluid heat transfer in a counter
current tubular heat exchanger. The results were in line with theoretical expectations, showing that:

As the flow rate of hot water increased, the temperature change in the hot water decreased, while
the temperature change in the cold water increased as its flow rate increased.

The heat power emitted (Qe) was nearly equal to the heat power absorbed (Qa), confirming the
effectiveness of the heat exchanger, with only minor discrepancies likely due to experimental
uncertainties.

Overall, the system performed efficiently, and the experiment validated the concept of counter
current flow for heat exchangers, showing minimal heat loss and demonstrating a high level of
efficiency. The observed small differences between the theoretical and experimental heat powers
can be attributed to human error, sensor inaccuracies, or environmental factors, but these were
minor and did not significantly impact the overall conclusion.

REFFERENCE

1. J.P. Holman, Heat Transfer: Tenth Edition, McGraw – Hill International

Edition, 2010

2. Foumeny, E. A., and P. J. Heggs, eds., 1991, Heat Exchange Engineering, Vol. 2; Compact Heat
Exchangers: Techniques for Size Reduction, Ellis Horwood, London.
3. Roetzel, W., and Y. Xuan, 1998, Dynamic Behaviour of Heat Exchangers, Vol. 3, Computational
Mechanics Publications, WIT Press, Southampton, UK.