NAME: AMARACHI CHUWA

MATRICULATION NUMBER:
LEVEL: 400LEVEL
DEPARTMENT: CHEMICAL ENGINEERING
GROUP: A4
SERIAL NUMBER: 034
COURSE CODE: CHE401
TITLE OF EXPERIMENT: SHELL AND TUBE HEAT EXCHANGER
EXPERIMENT NUMBER: 02
AIM OF EXPERIMENT:
I. To demonstrate indirect heating or cooling by transfer of heat
II. To perform an energy balance across a shell and tube heat exchanger and
calculate the overall efficiency at different fluid flow rate
III. To demonstrate the difference between parallel flow and countercurrent
flow and the effect on heat transferred and temperature efficiencies
IV. To determine the overall heat transfer coefficient for a tubular heat
exchanger using the Logarithmic Mean Temperature Difference to perform
calculations
V. To investigate the effect of changes in hot and cold fluid flow rate on the
temperature efficiencies and overall heat transfer coefficient
DATE OF EXPERIMENT: 08/02/2021
DATE OF SUBMISSION: 12/02/2021
INSTRUCTOR’S NAME: ENGR. EKENE EGHAREVBA ETINOSA

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 TABLE OF CONTENTS
List of figures 3
Abstract 4
Introduction 5
Theory 8
Description of Apparatus 18
Procedure 20
Results 22
Discussion 25
Conclusion 27
Recommendation 28
References 29
Appendix 34

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 LIST OF FIGURES AND TABLES
FIGURES / TABLES PAGES
FIGURE 1: Schematic of a shell and tube heat exchanger 14
FIGURE 2: Temperatures in counter current flow 15
FIGURE 4: Diagram of HT30X heat exchanger service unit 18
TABLE 1: Results from variation of flow rate 22
TABLE 2: Results from variation of temperature 23
TABLE 3: Conversion of flow rate 23
TABLE 4: Density of fluid (Water) at different temperatures 24

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 ABSTRACT
The experiment; the shell and tube Heat exchanger was performed with the aim
of calculating the mass flow rates of the hot and cold fluid, Heating efficiency of
the heat exchanger, Overall heat transfer coefficient, Temperature efficiency for
the hot and cold fluid, Logarithmic Mean Temperature Difference (LMTD) and the
Mean temperature efficiency. The experiment was done using the Armfield Heat
Exchanger.In the first experiment, the flow rate of hot fluid was kept constant at
3L/min, while the flow rate of the cold fluid was changed from 1 to 1.5L/min.
However, in the second experiment, the flow rate of both the hot and cold fluids
were kept constant at 2L/Min and 1L/Min respectively and the temperature of
the controller was varied by 10°C from 50°C to 80°C. The highest heating
efficiency was 30.25% at flow rate of hot and cold fluids as 2L/min and 1L/min
respectively and T of 80°C and overall heat transfer coefficient was 0.6212W/m 2k.
This shows how the flow rate affected the results gotten.

Care must be taken when handling the shell and tube heat exchanger. Corrosion
and pipe lagging must be looked out for. Also avoid touching hot surfaces of the
equipment.It was concluded that if flow rates are alternated, we could see the
effect of flow rate on the transfer of heat. In the first instance; when the flow
rates were set far apart at 3 and 1L/min, we saw a very low heat transfer which
quickly rose when the flow rates difference was reduce by a measly 0.5
difference.

At the end of the experiment recommendations were made to improve the

efficiency of the experiment.

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 INTRODUCTION
The heat exchanger works with the principle of heat transfer between fluids. This
can be achieved when there is significant difference in the fluid temperatures.
One has to be higher while the other will be lower.

Heat transfer is a discipline of thermal engineering that concerns the generation,

use conversion and exchange of thermal energy between physical systems. This
heat transfer if classified into various mechanisms such as thermal conduction,
thermal convection, thermal radiation and transfer of energy by phase changes.
The thermal convection is the main principle on which the heat exchangers works.

The convective heat transfer, simply known as convection is the transfer of heat
from one place to another by the movement of fluids. It is the most dominant
form of heat transfer in liquids and in gases.

A heat exchanger is a device used to transfer heat between two or more fluids.
The fluids can be single or two phase and, depending on the exchanger type, may
be separated or in direct contact. Devices involving energy sources such as
nuclear fuel pins or fired heaters are not normally regarded as heat exchangers
although many of the principles involved in their design are the same.
There are three primary classifications of heat exchangers according to
their flow configuration;

1. Parallel – flow
2. Cross – flow
3. Counter – current

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In parallel-flow heat exchangers, the two fluids enter the exchanger at the same
end, and travel in parallel to one another to the other side.

In counter-flow heat exchangers the fluids enter the exchanger from opposite

ends. The counter current design is the most efficient, in that it can transfer the
most heat from the heat (transfer) medium per unit mass due to the fact that the
average temperature difference along any unit length is higher.

In a cross-flow heat exchanger, the fluids travel roughly perpendicular to one

another through the exchanger.

TYPES OF HEAT EXCHANGER

There are various types of heat exchangers namely;

1. Double pipe heat exchangers

2. Shell and Tube heat exchanger

3. Plate heat exchanger

4. Plate and shell heat exchanger

5. Adiabatic wheel heat exchanger

6. Plate fin heat exchanger

7. Pillow Plate Heat exchanger

The detailed explanation on the various types of heat exchangers will be

discussed in details in the theory section.

Shell and tube heat exchanger is a device that consists of a shell and a bundle of
tubes mounted inside it. One fluid runs through the tubes, and another fluid flows

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over the tubes (through the shell) to transfer heat between the two fluids. These
two integral pathways are usually built out of thermally conductive metals that
allow easy heat transfer (steel, aluminum alloys, etc.). The tubes carry a fluid from
their inlet to their outlet (the “tube-side” flow), while the shell passes a separate
fluid over these tubes (the “shell-side” flow). The number of tubes, known as the
tube bundle will dictate how much surface area is exposed to the shell-side flow,
and therefore determines how much heat is transferred.Shell and tube heat
exchangers have a simple design, robust characteristics and relatively low
purchase and maintenance costs. They also have a very high heat transfer rate
although they require more space than a plate heat exchanger of similar thermal
exchange capacity. They are widely distributed in industry, being useful for
condensers, turbine coolers, evaporators, feed water preheating, and much more.
The shell and tube heat exchanger is made up of four major parts:
Front Header—this is where the fluid enters the tubeside of the exchanger. It is
sometimes referred to as the Stationary Header.
Rear Header—this is where the tubeside fluid leaves the exchanger or where it is
returned to the front header in exchangers with multiple tubeside passes.
Tube bundle—this comprises of the tubes, tube sheets, baffles and tie rods etc. to
hold the bundle together.
Shell—this contains the tube bundle. It is a pressure vessel designed to match the
fluid pressure that is flowing through it.

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 THEORY
As earlier defined, the heat exchanger is a device used to transfer heat between
two or more fluids.

Double pipe heat exchanger

Double pipe heat exchangers are the simplest exchangers used in industries. On
one hand, these heat exchangers are cheap for both design and maintenance,
making them a good choice for small industries. On the other hand, their low
efficiency coupled with the high space occupied in large scales, has led modern
industries to use more efficient heat exchangers like shell and tube or plate.
However, since double pipe heat exchangers are simple, they are used to teach
heat exchanger design basics to students as the fundamental rules for all heat
exchangers are the same.

Plate heat exchangers

Another type of heat exchanger is the plate heat exchanger. These exchangers are
composed of many thin, slightly separated plates that have very large surface
areas and small fluid flow passages for heat transfer. Advances
in gasket and brazing technology have made the plate-type heat exchanger
increasingly practical. In HVAC applications, large heat exchangers of this type are
called plate-and-frame; when used in open loops, these heat exchangers are
normally of the gasket type to allow periodic disassembly, cleaning, and
inspection. There are many types of permanently bonded plate heat exchangers,
such as dip-brazed, vacuum-brazed, and welded plate varieties, and they are
often specified for closed-loop applications such as refrigeration. Plate heat
exchangers also differ in the types of plates that are used, and in the
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configurations of those plates. Some plates may be stamped with "chevron",
dimpled, or other patterns, where others may have machined fins and/or
grooves. When compared to shell and tube exchangers, the stacked-plate
arrangement typically has lower volume and cost. Another difference between
the two is that plate exchangers typically serve low to medium pressure fluids,
compared to medium and high pressures of shell and tube. A third and important
difference is that plate exchangers employ more countercurrent flow rather than
cross current flow, which allows lower approach temperature differences, high
temperature changes, and increased efficiencies.

Plate and shell heat exchanger

A third type of heat exchanger is a plate and shell heat exchanger, which
combines plate heat exchanger with shell and tube heat exchanger technologies.
The heart of the heat exchanger contains a fully welded circular plate pack made
by pressing and cutting round plates and welding them together. Nozzles carry
flow in and out of the plate pack (the 'Plate side' flow path). The fully welded
plate pack is assembled into an outer shell that creates a second flow path (the
'Shell side'). Plate and shell technology offers high heat transfer, high pressure,
high operating temperature, uling and close approach temperature. In particular,
it does completely without gaskets, which provides security against leakage at
high pressures and temperatures.

Adiabatic wheel heat exchanger

A fourth type of heat exchanger uses an intermediate fluid or solid store to hold
heat, which is then moved to the other side of the heat exchanger to be released.

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Two examples of this are adiabatic wheels, which consist of a large wheel with
fine threads rotating through the hot and cold fluids, and fluid heat exchangers.

Plate fin heat exchanger

This type of heat exchanger uses "sandwiched" passages containing fins to

increase the effectiveness of the unit. The designs include cross flow and counter
flow coupled with various fin configurations such as straight fins, offset fins and
wavy fins.

Plate and fin heat exchangers are usually made of aluminum alloys, which provide
high heat transfer efficiency. The material enables the system to operate at a
lower temperature difference and reduce the weight of the equipment. Plate and
fin heat exchangers are mostly used for low temperature services such as natural
gas, helium and oxygen liquefaction plants, air separation plants and transport
industries such as motor and aircraft engines.

Advantages of plate and fin heat exchangers:

 High heat transfer efficiency especially in gas treatment

 Larger heat transfer area
 Approximately 5 times lighter in weight than that of shell and tube heat
exchanger.
 Able to withstand high pressure

Disadvantages of plate and fin heat exchangers:

 Might cause clogging as the pathways are very narrow

 Difficult to clean the pathways
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 Aluminum alloys are susceptible to Mercury Liquid Embrittlement Failure

Shell and tube heat exchanger

Shell and tube heat exchangers, which is our main focus; consist of a series of
tubes which contain fluid that must be either heated or cooled. A second fluid
runs over the tubes that are being heated or cooled so that it can either provide
the heat or absorb the heat required. A set of tubes is called the tube bundle and
can be made up of several types of tubes: plain, longitudinally finned, etc. Shell
and tube heat exchangers are typically used for high-pressure applications (with
pressures greater than 30 bar and temperatures greater than 260 °C).[4] This is
because the shell and tube heat exchangers are robust due to their shape.
Several thermal design features must be considered when designing the tubes in
the shell and tube heat exchangers: There can be many variations on the shell and
tube design. Typically, the ends of each tube are connected
to plenums (sometimes called water boxes) through holes in tube sheets. The
tubes may be straight or bent in the shape of a U, called U-tubes.

 Tube diameter: Using a small tube diameter makes the heat exchanger
both economical and compact. However, it is more likely for the heat
exchanger to
 foul up faster and the small size makes mechanical cleaning of the fouling
difficult. To prevail over the fouling and cleaning problems, larger tube
diameters can be used. Thus to determine the tube diameter, the available
space, cost and fouling nature of the fluids must be considered.

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 Tube thickness: The thickness of the wall of the tubes is usually determined
to ensure:
o There is enough room for corrosion
o That flow-induced vibration has resistance
o Axial strength
o Availability of spare parts
o Hoop strength (to withstand internal tube pressure)
o Buckling strength (to withstand overpressure in the shell)

 Tube length: heat exchangers are usually cheaper when they have a smaller
shell diameter and a long tube length. Thus, typically there is an aim to make
the heat exchanger as long as physically possible whilst not exceeding
production capabilities. However, there are many limitations for this, including
space available at the installation site and the need to ensure tubes are
available in lengths that are twice the required length (so they can be
withdrawn and replaced). Also, long, thin tubes are difficult to take out and
replace.
 Tube pitch: when designing the tubes, it is practical to ensure that the tube
pitch (i.e., the centre-centre distance of adjoining tubes) is not less than 1.25
times the tubes' outside diameter. A larger tube pitch leads to a larger overall
shell diameter, which leads to a more expensive heat exchanger.
 Tube corrugation: this type of tubes, mainly used for the inner tubes,
increases the turbulence of the fluids and the effect is very important in the
heat transfer giving a better performance.

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 Tube Layout: refers to how tubes are positioned within the shell. There are
four main types of tube layout, which are, triangular (30°), rotated triangular
(60°), square (90°) and rotated square (45°). The triangular patterns are
employed to give greater heat transfer as they force the fluid to flow in a more
turbulent fashion around the piping. Square patterns are employed where
high fouling is experienced and cleaning is more regular.
 Baffle Design: baffles are used in shell and tube heat exchangers to direct
fluid across the tube bundle. They run perpendicularly to the shell and hold
the bundle, preventing the tubes from sagging over a long length. They can
also prevent the tubes from vibrating. The most common type of baffle is the
segmental baffle. The semi-circular segmental baffles are oriented at 180
degrees to the adjacent baffles forcing the fluid to flow upward and
downwards between the tube bundles. Baffle spacing is of large
thermodynamic concern when designing shell and tube heat exchangers.
Baffles must be spaced with consideration for the conversion of pressure drop
and heat transfer. For thermos economic optimization it is suggested that the
baffles be spaced no closer than 20% of the shell's inner diameter. Having
baffles spaced too closely causes a greater pressure drop because of flow
redirection. Consequently, having the baffles spaced too far apart means that
there may be cooler spots in the corners between baffles. It is also important
to ensure the baffles are spaced close enough that the tubes do not sag. The
other main type of baffle is the disc and doughnut baffle, which consists of two
concentric baffles. An outer, wider baffle looks like a doughnut, whilst the
inner baffle is shaped like a disk. This type of baffle forces the fluid to pass

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 around each side of the disk then through the doughnut baffle generating a
different type of fluid flow.

Fixed tube liquid-cooled heat exchangers especially suitable for marine and harsh
applications can be assembled with brass shells, copper tubes, brass baffles, and
forged brass integral end hubs.

Parallel flow heat exchanger

In a parallel flow heat exchanger, the two fluid streams (hot and cold) flow
through the heat exchanger in the same direction. The two fluid streams enter at
one end of the heat exchanger and leave at the other end. it is clear that the
temperature difference between the fluid streams decreases from the inlet to the
outlet of the heat exchanger. Parallel flow heat exchangers are rarely employed
due to their requirement of large surface area for heat transfer.

Examples: Oil heaters, oil coolers, water heaters etc.

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Temperature difference (θ1) = th1 − tc1 … (1)

Temperature difference (θ2) = th2 − tc2 … (2)

Log mean temperature difference (LMTD) = (θ1 − θ2)/ln θ1 − θ2 … (3)

Counter flow heat exchanger

In a counter flow heat exchanger, the two fluid streams flow in relatively
opposite directions. The fluid streams enter at opposite ends. Counter flow heat
exchangers provide the maximum heat transfer rate for a given surface area.
Hence, they are the most widely used heat exchangers.

Fig.1 diagrammatic representation of a counter-flow heat exchanger

Temperature difference (θ1) = th1 − tc2 … (4)

Temperature difference (θ2) = th2 − tc1 … (5)

Log mean temperature difference (LMTD) = (θ1 − θ2)/ln (θ1 − θ2)… (6)

Heat load and heat balance

Hot water flow rate (Hw )

QH = mH x CpH x (t1-t2)
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Hot water flow rate (Cw )

QC = mC x CpC x (T2-T1)

Where:

QH = Heat load for hot water flow rate

QC = Heat load for cold water flow rate
mH = Hot water mass flow rate
mC = Cold water mass flow rate
t1 = Hot water inlet temperature
t2 = Hot water outlet temperature
T1 = Cold water inlet temperature
T2 = Cold water outlet temperature

LOGARITHMIC MEAN TEMPERATURE DIFFERENCE (LMTD)

The logarithmic mean temperature difference (LMTD) is used to determine the
temperature driving force for heat transfer in flow systems, most notably in heat
exchangers. The LMTD is a logarithmic average of the temperature difference
between the hot and cold feeds at each end of the double pipe exchanger. For a
given heat exchanger with constant area and heat transfer coefficient, the larger
the LMTD, the more heat transferred.

The use of the LMTD arises straightforwardly from the analysis of a heat
exchanger with constant flow rate and fluid thermal properties.

Calculations of log mean temperature difference (LMTD)

( t 1 −T 2 )−( t 2−T 1 )
LMTD=
( t 1 −T 2 )
ln
( t 2 −T 1 )

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Heat loss rate = QH - QC

Dirt factor (Q) = 0.5 (QH + QC)

OVERALL HEAT TRANSFER COEFFICIENT (U)

Overall heat transfer coefficient at which equivalent to U D can be calculated by

using equation below. In this case, the value of total heat transfer area A has
been given and equal to 0.05 m2.

Q
U=
A×LMTD

Where:

Q= Heat rate with respect to the average head load

Reynolds Number Calculation

ρv ( d s −d o )
ℜ=
μ

At which

do =T ube outside diameter, m

ds = Shell diameter, m
  Viscosity, taken at average fluid temperature in the shell, Pa.s

As = Exchange area, m2

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 DESCRIPTION OF APPARATUS

The Shell and Tube Heat Exchangers are one of the most popular types of
exchanger due to the flexibility the designer has to allow for a wide range of
pressures and temperatures.
A shell and tube exchanger consists of a number of tubes mounted inside a
cylindrical shell. Two fluids can exchange heat, one fluid flows over the outside of
the tubes while the second fluid flows through the tubes. The fluids can be single
or two phase and can flow in a parallel or a cross/counter flow arrangement.
The shell and tube exchanger consists of four major parts:
 Front Header; this is where the fluid enters the tube-side of the exchanger.
It is sometimes referred to as the Stationary Header.

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  Rear Header; this is where the tube-side fluid leaves the exchanger or
where it is returned to the front header in exchangers with multiple tube-
side passes.
 Tube bundle; this comprises of the tubes, tube sheets,  baffles and tie rods
etc. to hold the bundle together.
 Shell; this contains the tube bundle.
The cold water stream is generated from a mains water supply. The flow through
the heat exchanger is adjusted by a variable flow valve, again under software
control. A manually adjustable pressure regulator is used to minimize the effect of
mains pressure fluctuations.
Conditioning circuits for up to 10 K-type thermocouples are included, (the
thermocouples themselves are supplied with the heat exchangers). The
instrumentation also includes flow meters to measure the flow rates of the two
fluid streams.

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 PROCEDURES

General Procedure

 A quick inspection was performed to make sure that the equipment was in
perfect condition.
 All valves were initially closed except V1 and V2.
 Hot tank was filled through a water supply hose connected to valve V 2; with
valve closed as it got filled.
 The cold water tank was then filled up by opening valve V 1. The valve was
left opened for continuous water supply.
 A drain hose was connected to the cold water drain point.
 The equipment was now ready to be run

Experiment 1

 The main power was switched on. The heater for the hot water tank was
also switched on and the temperature controller set to 71oC.
 The water temperature in the hot water tank was allowed to reach the set
point.
 The flow rate of the hot and cold fluids were set at 3L/min and 1L/min
respectively
 Valves V3 and V4 were adjusted and opened to obtain the desired flowrates
for hot water and cold water streams, respectively.
 The system was allowed to reach steady state for a few minutes and values
for T1, T2, T3 and T4 were recorded.

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  The above processes were repeated, adjusting flow rates of 3L/min and
1.5L/min for the hot and cold respectively.

Experiment 2

 The system was then allowed to cool for some minutes to get it to the
required room temperature for optimum result
 The flow rate was set at a constant value of 2L/min and 1L/min for the hot
and cold respectively
 The temperature was then adjusted to a set temperature of 50 oC
 When the required temperature has been reached and normalized the
readings are then taken
 This is done repeatedly with a temperature increase of 10 oC until 80 oC is
achieved
 The values of T1, T2, T3, T4 are taken for all temperatures.

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 RESULTS
S/ Cold Hot Hot fluid Hot fluid Cold fluid Cold fluid
N fluid fluid inlet outlet inlet outlet
flow flow Temperatu Temperatu Temperatu Temperatu
rate Fc rate Hc re T1 (oC) re T2 (oC) re T3 (oC) re T4 (oC)
(L/min (L/min
) )
1 1.0 3.0 67.0 61.5 27.1 28.8

2 1.5 3.0 69.9 61.7 27.2 29.4

Table 1: Values recorded for experiment with varying flow rates at set
temperature 71oC

S/N F (L/min) Qv (m3/s)

1. 1 1.6667 x 10-5
2. 1.5 2.50005 x 10-5
3. 2 3.3334 x 10-5
4. 3 5.0001 x 10-5
Table 2: Conversion of flow rate

S/ Temperat Cold Hot Hot fluid Hot fluid Cold fluid Cold fluid
N ure in fluid fluid inlet outlet inlet outlet
controller flow flow Temperat Temperat Temperat Temperat
display T rate rate ure T1 (oC) ure T2 (oC) ure T3 (oC) ure T4 (oC)
(oC) Fc Hc
(L/mi (L/mi
n) n)
1 50 1.0 2.0 50.4 44.0 27.2 31.9

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 2 60 1.0 2.0 60.9 52.0 27.3 34.3

3 70 1.0 2.0 70.1 60.7 27.4 36.9

4 80 1.0 2.0 79.5 68.6 27.4 39.5

Table 3: Values recorded for experiment with varying temperatures at set

flowrates for hot and cold set to 2L/min and 1L/min respectively

Density of fluid
S/N T (°C) ρ
(Kg/m3)
1. 50 988.037
2. 60 983.200
5. 70 977.771
6. 80 971.799
Table 4: Density of fluid (water) at different temperature (From Perry’s
Handbook).
To ensure unit uniformity of the hot and cold flow rates, we have to convert
L/min to m3/s to ease our calculation when trying to compute the mass flow rates.

m3/s = L/min x 60mins/hr x m3/1000L

= 0.06m3/hr x hr/3600s
= 1.6667 x 10-5m3/s (This is the conversion factor)
Hence, we have to convert all L/min to m3/s
 At Fc = 1L/min;
Fc = 1 x 1.6667 x 10-5m3/s
= 1.6667 x 10-5m3/s
 At Fc = 1.5L/min;
Fc = 1.5 x 1.6667 x 10-5m3/s
= 2.50005 x 10-5m3/s

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  At Hc = 2L/min;
Hc = 2 x 1.6667 x 10-5m3/s
= 3.3334 x 10-5m3/s
 At Hc = 3L/min;
Hc = 3 x 1.6667 x 10-5m3/s
= 5.0001 x 10-5m3/s
More calculation are shown in the appendix section.

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 DISCUSSION

This experiment was conducted by using the HT30X Heat Exchanger Service Unit
apparatus which is used as cooling devices

The experiment; Shell and Tube Heat Exchanger was conducted with the aim of;

 Calculating the Heating efficiency of the heat exchanger,

 Flow rates of the hot and cold fluid,
 Overall heat transfer coefficient,
 Temperature efficiency for the hot and cold fluid,
 Logarithmic Mean Temperature Difference (LMTD),
 The Mean temperature efficiency.

The experiment was conducted using the Armfield Shell and tube heat exchanger
at flow rates of 1L/min, 1.5L/min, 3L/min and 2L/min for the hot and cold fluid.
The experiment was also conducted using varying temperatures and operating
conditions.

Upon successful inspection of our equipment, to ensure it was in a proper

working condition; the first experiment was carried out at fixed temperature of
71oC and flow rates of 3L/min and 1L/min for the hot and cold fluid respectively.
In this experiment the fluid used was water. With the results gotten, the flow rate
of the cold fluid was altered to 1.5L/min. This was done to measure and compare
the efficiency of the heat transfer in our heat exchanger. The efficiency of the
heat transfer was found to be 4.45% and 5.43%. Such results point to a very low
heat transfer efficiency. This could be as a result of the low flow rate of the fluid
inside the heat exchanger and its constant fluctuations.
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The second experiment was carried out with the flow rates of the fluid kept
constant at 2L/min and 1L/min for hot and cold fluid respectively. This was done
at a temperature of 50oC. The experiment was then repeated, with varying length
of time and at temperature intervals of 10oC up until 80oC. This was done to show
the effect of temperature on the efficiency in the transfer of heat. With values
gotten, the efficiency was then computed and found to be; 25.4%, 26.32%,
28.61%, and 30.25%. This shows a gradual increase in the heat transfer efficiency
between the liquids with an increase in temperature.

The Logarithmic Mean Temperature Difference value for the first set of runs
showed an increase of 1.1531oC for the Logarithmic Mean Temperature. The
difference, which seems to indicated a neigh negligible temperature increase.
While the second set of runs show a steady increase of the Logarithmic Mean
Temperature Difference.

In the use of a shell and tube heat exchanger, several precaution must be put in
place. They include;

 Beware of leakage caused by corrosion

 Always check for slurry flow, this may cause erosion inside the heat
exchanger and leaking may occur.
 Avoid over pressuring the heat exchanger.
 Keep out of hot surfaces that may cause skin burn.
 Monitor the tube plugging due to buildup of foulants.

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 CONCLUSION

The use of a heat exchanger help to tell a lot about heat transfer in fluids. The
Armfield Heat Exchanger was used for this experiment can be seen to be another
contributing factor to the results gotten from this experiment. Factors such as the
irregular flow rates and the slow leaking of water from the various hoses that we
could not properly clamp.

It was observed that even with a high heat transfer capacity of water, it did not
perform very well at low flow rates as well as temperature. This can be seen in
reverse with the experiment where the temperature was raised.

Operating conditions that affect the rate of heat transfer could be the flow rate,
temperature and pressure of the fluid.

The temperature can also be taken into consideration as we saw that the
temperature of the cold fluid rose to high levels when we set the temperature of
the hot fluid to a temperature of 80 degrees. This would explain why steam is
preferably used in plants and industries to achieve higher transfers like in oil and
fat industries.

In conclusion; when alternating flow rate we could see the effect of flow rate on
the transfer of heat. In the first instance when the flow rates were set far apart at
3 and 1L/min. we saw a very low heat transfer which quickly rose when the flow
rates difference was reduce by a measly 0.5 difference.

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 RECOMMENDATION

1. An experiment should have also been done on a heat exchanger using

parallel flow to determine the effect of flow in the transfer of heat
2. A better heat exchanger should be used to account for the loss of heat
through radiation and conduction while moving through the pipe
3. The stabilization of the flowrates of the machine would help to achieve
4. A different liquid could be used in the transfer of heat to also study how the
Heat capacity of different liquids
5. A double check of the results would ensure accurate results are gotten
from them
6. To ensure accurate data collected, no air bubbles should be found in the
tube during the experiment.
7. The heat exchanger should be well insulated to reduce the heat loss to the
surroundings
8. The last set of temperature readings should be taken when all
temperatures are fairly steady

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 REFERENCE
 McCabe .W. L. Smith .J. C. and Harriot P. (2001): Unit operations pf
chemical engineering 6th Edition, McGraw Hill Chemical Engineering Series,
New York.
 Armfield Engineering and Research Equipment Instruction manual.
 Coulson M. Richardson .J. F. with Backhurst .J.R. and Harker .J. H. (2004);
Chemical Engineering Volume 1: 6th Edition, Butterwort Heinennaun.
 Perry’s Chemical Engineering Handbook

 Kakaç, S., H. Liu, A. Pramuanjaroenkij, Heat Exchangers: Selection, Rating,

and Thermal Design, 3rd Edition, CRC Press, 2012.
 Incropera, F. P., D. P. DeWitt, T. L. Bergman, A. S. Lavine, Introduction to
Heat Transfer, 5th Edition, John Wiley & Sons, 2007.
 Kessler, D.P., Greenkorn, R.A. (1999). Momentum, Heat, and Mass Transfer
Fundamentals, New York: Marcel Dekker Inc., pp (768-828).
 Yunus A.Cengel, 2006, Heat and Mass Transfer: A Practical Approach.
McGraw Hill, 3rd Edition

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 APPENDIX

TECHNICAL DATA:
Inner tube inside diameter (di) = 0.00515 (m)
Inner tube outside diameter (do) = 0.00635 (m)
Heat transmission Length (L) = 1.008 (total) (m)
Hot fluid volume flow rate qvhot (m3/s)
Hot fluid inlet temperature T1 (°C)
Hot fluid outlet temperature T2 (°C)
Cold fluid volume flow rate qvcold (m3/s)
Cold fluid inlet temperature T3 (°C)
Cold fluid outlet temperature T4 (°C)
Hot fluid Hc (°C)
Cold fluid Fc (°C)

From Perry’s Handbook, the standard values of Specific heat capacity of water
(Hot and cold fluid);
Cp(c) = 4183.00J/Kg.K
Cp(h) = 4175.00J/Kg.K

CALCULATIONS:  
A. Calculations for mass flow rate:
Recall that;
Mass flow rate = Qv x ρ
Where;
Qv = Volumetric flow rates
Ρ = Density of fluid
For experiment 1:
Using the formula above;
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At Qv = 5.0001 x 10-5(m3/s) and ρ (67.0°C) = 979.459 (Kg/m3)
ṁh = (5.0001 x 10-5) x (979.459) = 0.049 Kg/s

At Qv = 5.0001 x 10-5(m3/s) and ρ (69.9°C) = 977.828 (Kg/m3)

ṁh = (5.0001 x 10-5) x (977.828) = 0.0489 Kg/s

For experiment 2:
Using the same formula above;
At ρ (50.0°C) = 988.037 (Kg/m3) and Qv (hot) = 3.3334 x 10-5(m3/s)
ṁh = (3.3334 x 10-5) x (988.037) = 0.0329 Kg/s

At ρ (60.0°C) = 983.200 (Kg/m3) and Qv (hot) = 3.3334 x 10-5(m3/s)

ṁh = (3.3334 x 10-5) x (983.200) = 0.0328 Kg/s

At ρ (70.0°C) = 977.771 (Kg/m3) and Qv (hot) = 3.3334 x 10-5(m3/s)

ṁh = (3.3334 x 10-5) x (977.771)= 0.0326 Kg/s

At ρ (80.0°C) = 971.799 (Kg/m3) and Qv (hot) = 3.3334 x 10-5(m3/s)

ṁh = (3.3334 x 10-5) x (971.799)= 0.0324 Kg/s
 
B. Calculations for heating efficiency of heat exchanger:
Where; Heat efficiency = Temperature efficiency of the heated fluid
Theoretically;
ξ= Qactual = ṁhCph (Tc2-Tc1) = (Tc2-Tc1)
Qfinal ṁhCph (Th1-Tc2) (Th1-Tc2)
ξ= (T4-T3)
(T1-T4)
For experiment 1:
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Using the formula above;
At Fc = 1.0 L/min and Fh = 3 L/min
ξ = (28.8 - 27.1)/(67.0 – 28.8) = 0.0445 = 4.45%

At Fc = 1.5 L/min and Fh = 3 L/min

ξ = (29.4 – 27.2)/(69.9 – 29.4) = 0.0543 = 5.43%
For experiment 2:
Using the same formula above;
At T = 50°C
ξ = (31.9 – 27.2)/(50.4 – 31.9) = 0.2541 = 25.41%
At T = 60°C
ξ = (34.3 – 27.3)/(60.9 – 34.3) = 0.2632 = 26.32%
At T = 70°C
ξ = (36.9 – 27.4)/(70.1 – 36.9) = 0.2861 = 28.61%
At T = 80°C
ξ = (39.5 – 27.4)/(79.5 – 39.5) = 0.3025 = 30.25%

C. Calculations for heat power emitted from hot fluid:

Qh = ṁhCp(hot) (th1 – th2)… Experiment 1

Qh = ṁhCp(hot) (T1 – T2)… Experiment 2
For experiment 1:
Using the formula above;
At Qh = 0.0490 x 4175.00 (67 – 61.5) = 1125.16W
At Qh = 0.0489 x 4175.00 (69.9 – 61.7) = 1674.09W
For experiment 2:
Using the same formula above;

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At Qh = 0.0329 x 4175 (50.4 – 44.0) = 879.09W
At Qh = 0.0328 x 4175 (60.9 – 52.0) = 1218.77W
At Qh = 0.0326 x 4175 (70.1 – 60.7) = 1279.39W
At Qh = 0.0324 x 4175 (79.5 – 68.6) = 1474.44W

D. Calculations for Logarithmic Mean Temperature Difference (LMTD):

θm = θ2 – θ1
In(θ2/ θ1)
When; θ1 = Th1-Tc2
θ2 = Th2-Tc1
Where;
Temperature of hot fluid inlet (th1) = T1
Temperature of hot fluid outlet (th2) = T2
Temperature of cold fluid inlet (tc1) = T3
Temperature of cold fluid outlet (tc2) = T4
Therefore, θm = (T2 – T3) – (T1 – T4)
In (T2– T3/ T1 – T4)
For experiment 1:
Using the formula above;
At T1 = 67.0°C, T2 = 61.5°C, T3 = 27.1°C and T4 = 28.8°C
θm = (61.5 – 27.1) – (67.0 – 28.8) = 36.2668°C
In[(61.5 – 27.1)/ (67.0 – 28.8)}]

At T1 = 69.9 °C, T2 = 61.7°C, T3 = 27.2°C, T4 = 29.4°C

θm = (61.7 – 27.2) – (69.9 – 29.4) = 37.4199°C
In[(61.7 – 27.2)/(69.9 – 29.4)]
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For experiment 2:
Using the same formula above;
At T1 = 50.4°C, T2 = 44.0°C, T3 = 27.2°C, T4 = 31.9°C
θm = (44.0 – 27.2) – (50.4 – 31.9) = 17.6363°C
In[(44.0 – 27.2)/( 50.4 – 31.9)]
At T1 = 60.9 °C, T2 = 52.0°C, T3 = 27.3°C, T4 = 34.3°C
θm = (52.0 – 27.3) – (60.9 – 34.3) = 25.6383°C
In[(52.0 – 27.3)/( 60.9 – 34.3)]
At T1 = 70.1 °C, T2 = 60.7°C, T3 = 27.4°C, T4 = 36.9°C
θm = (60.7 – 27.4) – (70.1 – 36.9) = 33.2500°C
In[(60.7 – 27.4)/(70.1 – 36.9)]
At T1 = 79.5 °C, T2 = 68.6°C, T3 = 27.4°C, T4 = 39.5°C
θm = (68.6 – 27.4) – (79.5 – 39.5) = 40.5970°C
In[(68.6 – 27.4)/(79.5 – 39.5)]

E. Calculations for overall heat transfer coefficient:

U = q/A˳θm
Where:
U = Overall heat transfer coefficient
A˳ = Area with respect to outer base diameter (A˳= 4πd˳L)
(A˳ = 4π x 0.00635 x 1.008 = 0.0804m2)
θm = Logarithmic mean temperature difference
q = Total heat transfer
For experiment 1:
Using the formula above;

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At Qh = 1125.16W, A˳= 0.0804 m2, θm = 36.2668°C
U = (1125.16)/(0.0804 x 36.2668) = 385.88W/m 2.oC
At Qh = 1674.09W, A˳= 0.0804 m2, θm = 37.4199°C
U = (1674.09)/(0.0804 x 37.4199) = 556.44W/m 2.oC

For experiment 2:
Using the same formula above
At Qh = 879.09W, A˳= 0.0804 m2, θm = 17.6363°C
U = (879.09)/(0.0804 x 17.6363)= 619.97W/m 2.oC
At Qh = 1218.77W, A˳= 0.0804 m2, θm = 25.6383°C
U = (1218.77)/(0.0804 x 25.6383)= 591.26W/m 2.oC
At Qh = 1279.39W, A˳= 0.0804 m2, θm = 33.2500°C
U = (1279.39)/(0.0804 x 33.2500)= 478.58W/m 2.oC
At Qh = 1474.44W, A˳= 0.0804 m2, θm = 40.5970°C
U = (1474.44)/(0.0804 x 40.5970)= 451.73W/m 2.oC

F. Calculations for temperature efficiency of hot fluid:

ηh = (th1 – th2)/( th1 – tc1) x 100
ηh = (T1 – T2)/( T1 – T3) x 100
Where:
Temperature of hot fluid inlet (th1) = T1
Temperature of hot fluid outlet (th2) = T2
Temperature of cold fluid inlet (tc1) = T3
For experiment 1: Using the formula above;
1. Where T1 = 67.0 T2 = 61.5 T3 = 27.4
ηh = (67.0 – 61.5)/(67.0 – 27.4) x 100 = 13.7845%

2. Where T1 = 69.9 T2 = 61.7 T3 = 27.2

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 ηh = (69.9 – 61.7)/(69.9 – 27.2) x 100 = 19.2037%

For experiment 2: Using the same formula above;

1. Where T1 = 50.4 T2 = 44.0 T3 = 27.2
ηh = (50.4 - 44.0)/ (50.4 – 27.2) x 100 = 27.5862%

2. Where T1 = 60.9 T2 = 52.0 T3 = 27.3

ηh = (60.9 – 52.0)/(60.9 – 27.3) x 100 = 26.4881%

3. Where T1 = 70.1 T2 = 60.7 T3 = 27.2

ηh = (70.1 – 60.7)/(70.1 – 27.4) x 100 = 22.0141%

4. Where T1 = 79.5 T2 = 68.6 T3 = 27.4

ηh = (79.5 – 68.6)/ (79.5 – 27.4) x 100 = 20.9213

G. Calculations for temperature efficiency of cold fluid:

ηh = (tc2 – tc1)/ ( th1 – tc1) x 100

ηh = (T4 – T3)/ (T1 – T3) x 100

Where;
Temperature of hot fluid inlet (th1) = T1
Temperature of cold fluid outlet (tc2) = T4
Temperature of cold fluid inlet (tc1) = T3
For experiment 1:
Using the formula above;
At T1 = 67.0°C, T3 = 27.1°C, T4 = 28.8°C
ηh = (28.8 – 27.1)/ (67.0 – 27.1) x 100 = 4.2607%
At T1 = 69.9°C, T3 = 27.2°C, T4 = 29.4°C
ηh = (29.4 – 27.2)/(69.9 – 27.2) x 100 = 5.1522%

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For experiment 2:
Using the same formula above;
At T1 = 50.4°C, T3 = 27.2°C, T4 = 31.9°C
ηh = (31.9 - 27.2)/(50.4 – 27.2) x 100 = 20.2586%
At T1 = 60.9°C, T3 = 27.3°C, T4 = 34.3°C
ηh = (34.3 – 27.3)/ (60.9 – 27.3) x 100 = 20.8333%
At T1 = 70.1°C, T3 = 27.4°C, T4 = 36.9°C
ηh = (36.9 – 27.4)/ (70.1 – 27.4) x 100 = 22.2482%
At T1 = 69.9°C, T3 = 27.4°C, T4 = 39.5°C
ηh = (39.5 – 27.4)/ (79.5 – 27.4) x 100 = 23.2246%

H. Calculations for mean temperature efficiency:

ηm = (ηhot + ηcold)
2
Where:
ηm = Mean temperature efficiency
ηhot = Temperature efficiency of hot fluid
ηcold = Temperature efficiency of hot fluid
For experiment 1:
Using the formula above;
At ηhot = 13.7845%, ηcold = 4.2607%
ηm = (13.7845 + 4.2607) =9.0226%
2
At ηhot = 19.2037%, ηcold = 5.1522%
ηm = (19.2037 + 5.1522) = 12.1780%
2
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For experiment 2:
Using the same formula above;
At ηhot = 27.5862%, ηcold = 20.2586%
ηm = (27.5862 + 20.2586) = 23.9224%
2
At ηhot = 26.4881%, ηcold = 20.8333%
ηm = (26.4881 + 20.8333) = 23.6607%
2
At ηhot = 22.0141%, ηcold = 22.2482%
ηm = (22.0141 + 22.2482) = 22.1312%
2
At ηhot = 20.9213%, ηcold = 23.2246%
ηm = (20.9213 + 23.2246) = 22.0730%
2

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