HEAT EXCHANGER

COMPARISON REPORT
EGH 422

Sameer Prafulbhai Maiyad

N10104160
Isaac Baldry
N9194550
1 CONTENTS
1.1 Table of figures ..................................................................................................................... 1
1.2 Table of tables ....................................................................................................................... 2
2 Aim................................................................................................................................................ 3
3 Equipment & Data......................................................................................................................... 3
4 Procedure ..................................................................................................................................... 4
5 Practical data ................................................................................................................................ 5
5.1 All the data collected during the heaty exchanger practical session is in the following tables
5
6 Calculation: ................................................................................................................................... 6
6.1 LMTD Calculation .................................................................................................................. 9
6.2 Area calculations: ................................................................................................................ 12
6.3 Overall heat transfer coefficient: ........................................................................................ 13
6.4 Comparison Graphs ............................................................................................................. 16
7 Simulation of the model on Ansys Workbench ........................................................................... 17
7.1 results ................................................................................................................................. 18
7.2 Appendix ............................................................................................................................. 20
7.2.1 Aluminium Double Pipe Heat Exchange Parallel Flow ................................................. 20
7.2.2 Copper Double Pipe Heat Exchange Parallel Flow ....................................................... 23
7.2.3 Aluminium Double Pipe Heat Exchange Counter Flow ................................................ 25
7.2.4 Copper Double Pipe Heat Exchange Counter Flow ...................................................... 26
7.3 Velocity Graphs: .................................................................................................................. 29
7.3.1 Aluminium Counter Flow: ........................................................................................... 29
7.3.2 Copper counter flow ................................................................................................... 30
7.3.3 Copper Parallel Flow ................................................................................................... 32

1.1 TABLE OF FIGURES

Figure 1: Hampden Model H-6878 6-pass heat exchanger demonstrator with main components
highlighted ............................................................................................................................................ 3
Figure 2: Heat Transfer Coefficient vs flow rate .................................................................................. 16
Figure 3: Heat Transfer Coefficient comparison ................................................................................. 16
Figure 4: Heat transfer comparison .................................................................................................... 17
Figure 5: Counter flow aluminium temperature contour for half mass flow rate ............................... 18
Figure 6: Counter flow copper temperature contour for half mass flow rate ..................................... 18
Figure 7: Practical vs Simulation results comparison plot ................................................................... 19
Figure 8: Full flow rate (Hot and Cold) ................................................................................................ 20
Figure 9: ½ flow rate (hot and cold) .................................................................................................... 21

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Figure 10: ¾ flow rate (hot and cold) .................................................................................................. 21
Figure 11: ¼ flow rate (hot and cold) .................................................................................................. 22
Figure 12: Full flow rate ...................................................................................................................... 23
Figure 13: ½ Flow rate......................................................................................................................... 23
Figure 14: ¾ flow rate ......................................................................................................................... 24
Figure 15: ¼ flow rate ......................................................................................................................... 24
Figure 16: Full Flow rate...................................................................................................................... 25
Figure 17: ½ Flow rate......................................................................................................................... 25
Figure 18: ¾ Flow rate......................................................................................................................... 26
Figure 19: ¼ Flow rate ......................................................................................................................... 26
Figure 20: Full Flow rate...................................................................................................................... 27
Figure 21: ½ flow rate ......................................................................................................................... 27
Figure 22: ¾ flow rate ......................................................................................................................... 28
Figure 23: ¼ flow rate ......................................................................................................................... 28
Figure 24: Full Flow ............................................................................................................................. 29
Figure 25: ½ Flow ................................................................................................................................ 29
Figure 26: ¾ Flow rate (hot and cold) ................................................................................................. 30
Figure 27: ½ flow rate (hot and cold) .................................................................................................. 30
Figure 28: Full Flow ............................................................................................................................. 31
Figure 29: Full Flow ............................................................................................................................. 32
Figure 30: ¾ flow rate ......................................................................................................................... 32
Figure 31: ½ Flow ................................................................................................................................ 33
Figure 32: ¼ Flow ................................................................................................................................ 33
Figure 33: Simulation LMTD Results ................................................................................................... 34

1.2 TABLE OF TABLES

Table 1: Aluminium double pipe heat exchanger parallel flow ............................................................. 5
Table 2: Copper double pipe heat exchanger parallel flow ................................................................... 5
Table 3: Copper double pipe heat exchanger counter flow .................................................................. 5
Table 4: Aluminium double pipe heat exchanger counter flow ............................................................ 5
Table 5: Shell and tube heat exchanger ................................................................................................ 5
Table 6: Cross Flow Heat Exchanger ..................................................................................................... 5
Table 7: Aluminium double pipe heat exchanger parallel flow ............................................................. 7
Table 8:Copper double pipe heat exchanger parallel flow.................................................................... 8
Table 9:Copper double pipe heat exchanger counter flow ................................................................... 8
Table 10:Aluminium double pipe heat exchanger counter flow ........................................................... 8
Table 11:Shell and tube heat exchanger ............................................................................................... 8
Table 12: Cross Flow Heat Exchanger ................................................................................................... 8
Table 13: LMTD Calculations ............................................................................................................... 10
Table 14: Shell and tube heat exchanger LMTD values ....................................................................... 11
Table 15: Cross flow heat exchanger LMTD values ............................................................................. 11
Table 16: Heat exchanger Area data ................................................................................................... 12
Table 17: Overall heat transfer co-efficients ....................................................................................... 15
Table 18: Ansys simulation parameters .............................................................................................. 17

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2 AIM
• To calculate the heat exchange by the heat exchanger
• To calculate overall heat transfer coefficient
• To calculate the LMTD (average temperature difference between two fluids from
inlet and outlet temperature of the water with the use of correction factor ‘F’ if
required

3 EQUIPMENT & DATA

• Hot water and Cold water supply system
• Hot water and Cold water flow rate meters
• Inlet and outlet flow temperature measurement for both fluids
• Aluminium Double Pipe Heat Exchanger
(L=1220mm,Di=12.6mm,Do=15.9mm,k=154 W/mK)
• Copper Double Pipe Heat Exchanger
(L=1220mm,Di=13.8mm,Do=15.9mm,k=339W/mK)
• Shell and Tube Heat Exchanger
(28tubes,L=200mm,Di=5.52mm,Do=6.35mm,k=339W/mK)
• Cross-flow Heat Exchanger (60tubes,L=350mm,Di=5.6mm,Do=7.0mm,k=339W/mK)

Figure 1: Hampden Model H-6878 6-pass heat exchanger demonstrator with main components highlighted

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4 PROCEDURE
Because each set of measurements should be made with the heat exchanger
operating in a steady state, always allow a few minutes for temperatures to stop
changing before recording data.

1. Set up the flow control valves for parallel flow through the Aluminium
Double Pipe Heat Exchanger, with the hot water on the inner pipe ,and
both flow rates near their minimum values (approximately ¼ full flow)
2. Wait for the outlet water temperatures to stop changing :so that the heat
exchanger is operating under steady state conditions
3. Measure the flow rates and the inlet and outlet temperatures of each water
flow
4. Repeat the flow rate and temperature measurements for a total of 4
different flow rates ,set at approximately:
a. ¼ flow hot water with ¼ flow cold water
b. ½ flow hot water with ½ flow cold water
c. ¾ flow hot water with ¾ flow cold water
d. Full flow hot water with full flow cold water
5. Set up the flow control valves for Counter flow through the
Aluminium Double Pipe Heat Exchanger and repeat steps 1-3 for
full flow rates only
6. Repeat the above steps (1-3) for both parallel flow and counter flow
through the Copper Double Pipe Heat Exchanger
7. Repeat the above steps (1-3,4(b,d))for the Shell and Tube Heat Exchanger with
the hot
Water in the tubes and the cold water in the shell
8. Repeat the above steps (1-3,4(b,d)) for the Cross Flow Heat Exchanger
with the hot water in the tubes and the cold water flowing across the
tubes.

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 5 PRACTICAL DATA

5.1 ALL THE DATA COLLECTED DURING THE HEATY EXCHANGER PRACTICAL SESSION IS IN THE
FOLLOWING TABLES
Configuration Hot water Cold water Hot water Cold water Hot water Cold water
flow rate flow rate inlet temp. inlet temp outlet temp outlet temp

¼ hot / ¼ cold 3.6 2 57.4 16.6 49.5 27.7

½ hot / ½ cold 7.2 4 57.1 17.7 50.1 27.2
¾ hot / ¾ cold 10.8 6 59.1 19 52.9 27.8
full hot / full 14.5 8 57.2 18.4 52.2 26.7
cold
Table 1: Aluminium double pipe heat exchanger parallel flow

Configuration Hot water Cold water Hot water Cold water Hot water Cold water
flow rate flow rate inlet temp. inlet temp outlet temp outlet temp

full hot / full 14.5 8 59.1 17.9 54.2 26.6

cold
Table 2: Copper double pipe heat exchanger parallel flow

Configuration Hot water Cold water Hot water Cold water Hot water Cold water
flow rate flow rate inlet temp. inlet temp outlet temp outlet temp

full hot / full 14.5 8 56 19.3 51.6 27.0

cold
Table 3: Copper double pipe heat exchanger counter flow

Configuration Hot water Cold water Hot water Cold water Hot water Cold water
flow rate flow rate inlet temp. inlet temp outlet temp outlet temp

full hot / full 14.5 8 56.2 19.7 51.4 27.6

cold
Table 4: Aluminium double pipe heat exchanger counter flow

Configuration Hot water Cold water Hot water Cold water Hot water Cold water
flow rate flow rate inlet temp. inlet temp outlet temp outlet temp

½ hot / ½ cold 7.2 4 57.0 19.8 50.8 29.6

full hot / full cold 14.5 8 59.2 20.8 54.2 29.5
Table 5: Shell and tube heat exchanger

Configuration Hot water Cold water Hot water Cold water Hot water Cold water
flow rate flow rate inlet temp. inlet temp outlet temp outlet temp

½ hot / ½ cold 7.2 4 57.2 17.5 52.6 23.6

full hot / full cold 14.5 8 57.8 18.5 52.1 27.8
Table 6: Cross Flow Heat Exchanger

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6 CALCULATION:

Now For overall heat transfer:-

𝑸̇ = 𝑼⋅𝑨⋅ ∆𝑻lm

𝑸̇ = Amount of heat transfer (W)

U= Overall heat transfer coefficient (kW/m2K)

A = Area of inner surface of inner and outer surface heat exchanger

∆𝑻lm = LMTD Log mean temp.

Now heat transfer:

𝑸̇̊ (𝒈𝒂𝒊𝒏/𝒍𝒐𝒔𝒔) = 𝒎̇ ⋅𝑪𝒑⋅ ∆T

𝑸̇̊ (𝒈𝒂𝒊𝒏/𝒍𝒐𝒔𝒔) = heat transfer

𝒎̇ = Mass flow

Cp = Specific heat capacity

∆T = Change in temp

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CONFIGURATION HEAT TRANSFER (KW) HOT HEAT TRANSFER (KW) COLD

¼ Hot / ¼ Cold -1.98 1.54

½ Hot / ½ Cold -3.46 2.64

¾ Hot / ¾ Cold -4.6 3.67

Full hot and full cold -4.9 4.61

Table 7: Aluminium double pipe heat exchanger parallel flow

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Configuration Heat Transfer (kW) (Hot Heat Transfer (kW) (cold)

Full hot / Full cold -4.88 4.83

Table 8:Copper double pipe heat exchanger parallel flow

Configuration Heat Transfer (kW) (Hot Heat Transfer (kW) (cold)

Full hot / Full cold -4.38 4.28

Table 9:Copper double pipe heat exchanger counter flow

Configuration Heat Transfer (kW) (Hot Heat Transfer (kW) (cold)

Full hot / Full cold -4.83 4.39

Table 10:Aluminium double pipe heat exchanger counter flow

Configuration Heat Transfer (kW) (Hot Heat Transfer (kW) (cold)

½ Hot / ½ Cold -3.10 2.70

Full hot / Full cold -4.98 4.83

Table 11:Shell and tube heat exchanger

Configuration Heat Transfer (kW) (Hot Heat Transfer (kW) (cold)

½ Hot / ½ Cold -2.3 1.69

Full hot / Full cold -5.68 5.17

Table 12: Cross Flow Heat Exchanger

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6.1 LMTD CALCULATION

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By following the same procedure, the other values of LMTD were found which is shown in
the following table:

Aluminium Double Pipe Heat Exchanger LMTD (C°)

Parallel flow

¼ Hot / ¼ Cold 30.31

½ Hot / ½ Cold 30.41

¾ Hot / ¾ Cold 32.02

Full hot / Full cold 31.69

Copper Double Pipe Heat Exchanger

Parallel Flow

Full hot / Full cold 33.95

Copper Double Pipe Heat Exchanger

Counter Flow

Full hot / Full cold 30.25

Aluminium Double Pipe Heat Exchanger

Counter Flow

Full hot / Full cold 33.30

Table 13: LMTD Calculations

Now using the correction factor for the remaining configurations of shell and tube heat
exchanger:

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By using the correction factor graph these values were found and the results are shown in
the tables below:

Shell and Tube Heat Exchanger LMTD(C°)

½ Hot / ½ Cold 28.45

Full hot / Full cold 31.05

Table 14: Shell and tube heat exchanger LMTD values

Cross flow Heat Exchanger LMTD(C°)

½ Hot / ½ Cold 34.07

Full hot / Full cold 31.20

Table 15: Cross flow heat exchanger LMTD values

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6.2 AREA CALCULATIONS:

A = Π × DO/I × L

Now from calculating the areas by the formula mentioned above :

Heat Exchanger Area Inside m2 Area Outside

m2

Aluminium Double Pipe Heat Exchanger Parallel .048 .061

Copper Double Pipe Heat Exchanger Parallel .053 .061

Shell and Tube Heat Exchanger .097 .112

Cross flow heat Exchanger 0.369 0.462

Table 16: Heat exchanger Area data

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6.3 OVERALL HEAT TRANSFER COEFFICIENT:

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Similarly, all the overall co-efficients can be calculated:

ALUMINIUM PARALLEL FLOW

Flow UI (W/m2K) U0 (W/m2K) OVERALL U

(W/m2K)

¼ Hot 1335 835 514

½ Hot 2359 1425 888

¾ Hot 2973 1880 1152

Full hot 3252 2390 1378

Copper double pipe heat exchanger parallel

FLOW UI (W/m2K) U0 (W/m2K) OVERALL U

(W/m2K)

FULL 2719 2338 1257

Copper double pipe heat exchanger counter

FLOW UI (W/m2K) U0 (W/m2K) OVERALL U

(W/m2K)

FULL 2739 2322 1257

ALUMINIUM COUNTER FLOW

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Hot water UI (W/m2K) U0 (W/m2K) OVERALL U
(W/m2K)

FULL 3344 2219 1334

Shell and tube heat exchanger

Hot water UI (W/m2K) U0 (W/m2K) OVERALL U

(W/m2K)

1/2 1109 857 483

Full 1651 1394 756

Cross flow heat exchanger

COLD WATER UI (W/m2K) U0 (W/m2K) OVERALL U

(W/m2K)

1/2

181 108 67
Full
493 359 208
Table 17: Overall heat transfer co-efficients

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6.4 COMPARISON GRAPHS

HEAT TRANSFER COEFFICIENT (U) VS.

FLOW RATE
Overall Heat Transfer Coefficient

1600
1400
1200
U (W/M^2*K)

1000
800
600
400
200
0
1.00 2.00 3.00 4.00 5.00 6.00 7.00 8.00 9.00
FLOW RATE (L/MIN)

Figure 2: Aluminium double pipe Heat Transfer Coefficient vs flow rate

Heat Transfer Coefficient Comparison (U)

1600
1378 1334
1400 1257 1257
1200
U (W/m^2*K)

1000
756
800
600
400
208
200
0
1

Aluminium Parallel Aluminium Counter Copper Parallel

Copper Counter Shell and Tube Cross Flow

Figure 3: Heat Transfer Coefficient comparison

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 Heat Transfer Comparison (Q)
6000.00 5681.14
5377.63
4976.50 4881.94 4979.43
5000.00 4382.28
4000.00
Q (W)

3000.00

2000.00

1000.00

0.00
1

Aluminium Parallel Aluminium Counter Copper Parallel

Copper Counter Shell and Tube Cross Flow

Figure 4: Heat transfer comparison

7 SIMULATION OF THE MODEL ON ANSYS WORKBENCH

A Numerical Model of a simple heat exchanger was developed using the ANSYS software as
per the guidelines given into the handout with the help of the following parameters:

Table 18: Ansys simulation parameters

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7.1 RESULTS

Figure 5: Counter flow aluminium temperature contour for half mass flow rate

Figure 6: Counter flow copper temperature contour for half mass flow rate

The ANSYS simulation was run for all 16 different flow scenarios and the results plots for these are
located in the appendix of the report. Temperature contours were also produced for these
simulations and two examples are shown above in figures 5 and 6 comparing an aluminium and
copper contour for the same flow direction and rate. The LMTD was also calculated for these
simulations and the full results table for this is also located in the appendix. A plot was produced to
compare the LMTD of the practical and the ANSYS simulation for aluminium parallel flow at various
flow rates and this is shown below in figure 7.

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 Aluminium parrallel flow LMTD comparison
38
36
34
32
LMTD

30
28
26
24
0.25 0.5 0.75 1
Flow Rate

SIM Prac

Figure 7: Practical vs Simulation results comparison plot

8 DISCUSSION
The Practical experiment to test these heat exchangers was quite useful and produced some
interesting results. The first thing to discuss would be a factor that is common across all of the heat
exchanger types. This is of course the flow rate, Figure 2 clearly shows a correlation between the
increase in flow rate and the increase in the heat transfer coefficient. This graph was produced from
the results of the aluminium double pipe heat exchanger and would likely differ slightly from one
exchanger type to another according to their relative surface areas and designs. The results are to be
expected however as the increase in flow rate increases the conduction rate of heat from the fluid.
This is a phenomena utilised in daily life by someone blowing on their food to cool it quicker than it
otherwise would in still air. Figures 3 and 4 compare the different heat exchangers in terms of both
raw heat transfer (Q) and also in terms of the Coefficient (U). These results show that the aluminium
and copper double pipe exchangers exhibit less heat transfer than the cross flow and shell and tube
exchangers. However when viewing the transfer coefficients the latter perform very poorly. This is
due to the co-efficient taking into account their much larger surface area, showing that they exhibit
a lower heat transfer rate per square meter than the double pipe exchangers do. The data appears
to show very similar heat transfer coefficients when comparing the aluminium and copper
exchangers and also don’t exhibit much change when comparing the parallel and counter flow
directions. Its is possible that taking the measurements over a smaller pipe length could make these
results clearer as although they may conduct heat at different rates, they could both have reached
steady state by the end of the testing apparatus.

This theory is backed up by viewing the contour plots produced from the ANSYS Simulations shown
in figures 5 and 6. This compares aluminium and copper exchangers for the same flow rate and
direction. They appear to show that although the copper appears to do most of the heat transfer
very early on in the pipe the aluminium appears to bring the cooler water to a similar temperature
by the end of the pipe, despite taking longer to do so. It is therefore necessary to conduct a direct
comparison of the practical and simulated results to determine if the data can be trusted. To do this
the LMTD was calculated for the Ansys simulation of the aluminium parallel pipe flow exchanger at 4
flow rates and compared with the practical data from the same test. The graph showing this

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comparison can be seen above in figure 7. This shows somewhat of a correlation between the 2 data
sets with all of the data being within relatively close proximity to each other and displaying a
somewhat similar trend. Although the practical data shows a slight upwards trend in heat transfer as
the flow rate increases the simulated data seems to display a somewhat more linear trend. There
are many possibilities for differences in these results. These include mesh quality or incorrect model
setup and parameter in the ANSYS simulation or slight differences between the true temperatures
present within the practical experiment and those that were recorded. Despite this the data is clear
enough to show some correlation between the two test types although more in depth testing would
be required before producing dependable results.

9 APPENDIX
9.1.1 Aluminium Double Pipe Heat Exchange Parallel Flow

Figure 8: Full flow rate (Hot and Cold)

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Figure 9: ½ flow rate (hot and cold)

Figure 10: ¾ flow rate (hot and cold)

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Figure 11: ¼ flow rate (hot and cold)

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9.1.2 Copper Double Pipe Heat Exchange Parallel Flow

Figure 12: Full flow rate

Figure 13: ½ Flow rate

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Figure 14: ¾ flow rate

Figure 15: ¼ flow rate

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9.1.3 Aluminium Double Pipe Heat Exchange Counter Flow

Figure 16: Full Flow rate

Figure 17: ½ Flow rate

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 Figure 18: ¾ Flow rate

Figure 19: ¼ Flow rate

9.1.4 Copper Double Pipe Heat Exchange Counter Flow

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Figure 20: Full Flow rate

Figure 21: ½ flow rate

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Figure 22: ¾ flow rate

Figure 23: ¼ flow rate

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9.2 VELOCITY GRAPHS:
9.2.1 Aluminium Counter Flow:

Figure 24: Full Flow

Figure 25: ½ Flow

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9.2.2 Copper counter flow

Figure 26: ¾ Flow rate (hot and cold)

Figure 27: ½ flow rate (hot and cold)

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Figure 28: Full Flow

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9.2.3 Copper Parallel Flow

Figure 29: Full Flow

Figure 30: ¾ flow rate

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Figure 31: ½ Flow

Figure 32: ¼ Flow

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Figure 33: Simulation LMTD Results

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