PRACTICAL GUIDE

Faculty Engineering and Technology

Chemical and Metallurgical

Department
Engineering
Chemical Engineering
Course
Laboratory 1 (EHCEL1A)

Title Heat Exchanger

Compiled by N. Nyembe -2019

Revised by S Muthubi- 2022

Year Semester 2 2022

NQF Level 6

Credits 12
 GRADUATE ATTRIBUTE (GA)
Graduate attributes form a set of individually assessable outcomes that are components indicative of
the graduate’s potential to acquire competence to practice at the appropriate level. The graduate
attributes are exemplars of the attributes expected of graduates from an accredited program.

Experimentation and practical investigations are essential in the development of a graduate in the
engineering field. As such, the learner will be assessed in their ability to conduct investigations of well-
defined problems through locating and searching relevant codes and catalogues, conduct standard tests,
experiments, and measurements. Therefore, the learner needs to follow the competency indicators to be
deemed competent in a GA. Competency indicators are standard criteria the learner must use to achieve
competency in a particular GA. This practical assesses GA 4. For GA 4, the competency indicators that
need to be realized are as follows:

• Scope of the investigation is defined

• Investigations are planned and conducted within an appropriate practical
• Available literature is searched, and material is evaluated for suitability to the
investigation
• Relevant equipment is selected and appropriately used for the investigation
• Data obtained is analyzed and interpreted
• Conclusions are drawn from an analysis of all available evidence
• Purpose, process and outcomes of the investigation are recorded in a technical report

Page 1 of 9
EHCEL1A-Heat Exchanger
 1. Main objective
The main objective of the practical is to apply the basic concepts of heat transfer on a Shell
and Tube Heat Exchange.

1.2. Specific objectives are:

1.2.1. To perform energy balance across a shell and tube heat exchanger.

1.2.2. Determine the type of flow (Laminar, turbulent or transitional) in convection heat
transfer inside pipes on both co-current & counter-current

1.2.3. Determine the convective coefficient hi for hot water on both co-current &
countercurrent

1.2.4. Determine the overall coefficient Ui based on the heat transfer flux q/Ai in W/m2 on
both co-current & counter-current

Theory
Heat conduction is that type of transfer concerning heat exchanges without macroscopic
movement of matter. This phenomenon absolutely occurs in solid bodies where there is no
relative movement of mass particles. Any temperature difference across the metal tube wall
will result in the transfer of heat between the two fluid streams. The hot water flowing through
the inner tube bundle will be heated.

For this demonstration the Heat Exchanger can be configured with the two streams flowing in
opposite directions (counter-current flow). The cold fluid flowing through the shell is forced
to flow over and under baffles in the shell which forces the fluid to flow across the tube bundle
to improve the heat exchange.

Page 2 of 9
EHCEL1A-Heat Exchanger
 Methodology
3.1. Description of equipment

• AISI 304 stainless steel framework, wheels mounted

• Shell and tube exchanger with shell in borosilicate glass and tubes in stainless steel
AISI 316, exchange surface 0.11 m2 , initials E1

• Boiler with AISI 304 stainless steel tank, initial D1, polyurethane insulation and 6 kW
heating resistance, initial J1
• Variable area flowmeter for cold water, glass and stainless-steel execution, range of
100/1000 l/h, initials FI1
• Variable area flowmeter for hot water, glass and stainless-steel execution, range of
100/1000 l/h, initials FI2
• Pressure safety valve for the cold-water line, initial SV1
• 5RTDs, Pt 100, initial TI1, TI2, TI3, TI4 and TW1
• Digital thermostat for hot water temperature control
• IP 55 electrical switchboard with plant synoptic and E.L.C.B

3.2. Consumables required

• Distilled water

3.3. Utilities required

• Power supply: three-phase, P=3.5 kW

• Tap water for cooling
3.4. Experimental procedure

3.4.1. Start Up

• Connect the plant to the electrical supply

Page 3 of 9
EHCEL1A-Heat Exchanger
 • Insert the E.L.C.B and push Green START button
• Close valve V5, V9, V10 and V11
• Fill the tank D1 with distilled water if possible (otherwise with tap water)
• The temperature of the hot water in the tank D1 is presented at 70 ̊ C using the
thermostat TW1
• Switch on the resistance J1
• Close valve V6
• Open valve V7 and V8
• Start the pump G1

• When the temperature of hot water is about 70 ̊C, set the hot water flow rate at desired
value using V6
• Connect and open the plant to tap water
• Wait 3 minutes for process to stabilize

To operate the heat exchanger E1 in co-current:

• Close valve V2 and V4
• Open valve V1 and V3
• Set the cold-water flow rate at the desired value using valve V3.
• Set the hot water flow rate at the desired value using valve V6.
• Wait for the process to be stable, approximately 5 minutes
• Vary the flow rate of the two fluids up to the desired values and take note of the
experimental data, 5 minutes intervals

Table 1: Co-current operation

Fhot Fcold hi U q
TI1 TI2 TI3 TI4
(L/h) (L/h) (W/m2K)(kW/m2.°C (W)
1000 600
800 600
600 600
400 600
200 600

Page 4 of 9
EHCEL1A-Heat Exchanger
 To operate the heat exchanger E1 in counter current:

• Close valve V1 and V3

• Open valve V2 and V4 (partially)
• Set the cold-water flow rate at the desired value using valve V2.
• Wait for the process to be stable, approximately 5 minutes
• Vary the flow rate of the two fluids up to the desired values and take note of the
experimental data, 5 minutes interval

Table 2: Counter current operation

Fhot Fcold hi U q
TI1 TI2 TI3 TI4
(L/h) (L/h) (W/m2K)(kW/m2.°C) (W)
1000 600
800 600
600 600
400 600
200 600

Where TI1 = Cold fluid inlet temperature

TI2 = Hot fluid inlet temperature
TI3= Cold fluid outlet temperature
TI4= Hot fluid outlet temperature

Emergency stop
• Press the red mushroom-head pushbutton.

3.4.2. Shut down

• Close the main valve of cold water

• Disconnect the E.L.C.B
• Switch off the plant from the power supply
• Close the water supply tap
Page 5 of 9
EHCEL1A-Heat Exchanger
 Calculations guidelines

Convection Heat Transfer inside Pipes Laminar flow:

Most convective heat transfer processes involve heating or cooling inside a closed circular
conduit or pipeline.

If the Reynolds number is less than 2100 (NRE < 2100), the flow is considered Laminar and
the convective film coefficient can be estimated as:

This equation is valid when:

The heat transfer rate is calculated using the inlet & outlet bulk temperatures.

Turbulent flow:
If the Reynolds number is greater than 6000 (NRE > 6000), the flow is considered Turbulent
and the convective coefficient can be estimated as:

This equation is valid when:

The heat transfer rate is calculated using the equation below:

Page 6 of 9
EHCEL1A-Heat Exchanger
 Transitional flow:
If the Reynolds number lies between 2100 and 6000 (2100 < NRE > 6000), the flow is
considered Transitional. To date, there are no empirical equations that can be used to clearly
define the convective coefficient in the transitional regime and this is due to the complexity of
the friction factor.

Equations

Log Logarithmic mean temperature (0C)

Arithmetic mean diameter(m)

Heat transmission area (m2) A=πdmLNt

Graphs to plot
Use the findings to graphically represent the following (for both counter/co-current
configurations in the same axis):

• Heat emitted versus hot fluid flow rate (L/h)

• Renolds number (NRe) versus hot fluid flow rate (L/h)
• Convective coefficient hi versus hot fluid flow rate (L/h)
• Overall heat transfer coefficient versus hot fluid flow rate (L/h)

Physical properties and Technical data

• Shell execution: borosilicate glass
• Inner shell diameter: 50 mm
• Tubes execution: AISI 316 stainless steel
• External tubes diameter: 10 mm
• Tubes thickness: 1 mm
• Tubes length: 900 mm

Page 7 of 9
EHCEL1A-Heat Exchanger
 • Tubes number: 5
• Baffles: 13, cut at 75% diameter
Below are empirical equations that must be used to determine the physical
properties required for the calculations.

Density equation:
Substance C1 C2 C3 C4
Water 5.459 0.30542 647.13 0.081

Heat capacity equation:

Substance C1 C2 C3 C4 C5
Water 2.7637×105 –2.0901×103 8.1250 –1.4116×10−2 9.3701×10−6

Thermal conductivity
T (oC) T(K) K(W/m.K)
0 273.2 0.5694
15.6 288.8 0.5884
26.7 299.9 0.6109
37.8 311 0.6283
65.6 338.8 0.6629
93.3 366.5 0.6802
121.1 394.30 0.6836
148.9 422.1 0.6836
204.4 477.6 0.6611
260 533.2 0.604
315.6 588.8 0.5071

Page 8 of 9
EHCEL1A-Heat Exchanger