CHG 3122

CHEMICAL ENGINEERING PRACTICE

Heat Exchangers
In this experiment steady state temperatures are measured at the inlets and outlets of two types of heat
exchangers; a shell and tube, and plate heat exchanger. The temperatures will be measured at various
operating conditions and the heat exchangers can be rated based on the measured performance.

OBJECTIVES

1. Determination of the overall heat transfer coefficient for both a shell and tube, and plate heat
exchanger using the LMTD, and ε-NTU method.
2. Evaluation of energy loss to surroundings to determine the validity of the ideal heat exchanger
assumption.
3. Determining the dependence of the overall heat transfer coefficient and exchanger effectiveness on
the cold fluid flowrate, and temperature gradient.

EQUIPMENT

The equipment provided in this experiment can perform steady state heat transfer experiments. For
accurate results ensure steady state is achieved before recording data.

The apparatus consists of a service module (TD360) and two interchangeable heat exchangers; plate heat
exchanger (TD360b), shell and tube exchanger (TD360c). The service module and heat exchangers are
manufactured by TecQuipment Ltd.

Service Module (TD 360)

The service module is connected to an electrical supply, data acquisition system, cold water line, and a
drain. It is the frame to which the heat exchangers are mounted to by thumb screws. The service module
contains a cold and hot circuit.

The cold circuit consists of the incoming cold water supply flowing through a hand adjusted flow control
valve, which is then passed through the heat exchanger, and out to the drain. The tubing connecting the
service module to the heat exchanger is blue for the cold circuit. Thermocouples are installed inline at the
junction to the heat exchanger; note the connectors for the hot and cold circuits are not interchangeable
thus the location (shell or tube side) of the hot and cold fluid cannot be altered.

The hot water circuit is a closed system – the water is recirculated unlike the cold circuit. There is a water
storage tank, the level of which is indicated by 3 LEDs. The tank is electrically heated, the temperature of
which is controlled by a PID controller located on the front of the service module. There is a pump which
circulates the hot fluid, the flow of which is controlled by a manually adjusted flow control valve. The
tubing connecting the service module to the heat exchanger is red for the hot circuit. Thermocouples are
installed inline at the junction to the heat exchanger.
Plate Heat Exchanger (TD360b)

The plate heat exchanger allows for heat transfer between two fluids in either parallel or countercurrent
flow configurations. The plate heat exchanger consists of 4 stainless steel plates with a total heat exchange
area of 0.02 m2. On top of the heat exchanger is an inlet and outlet for both the cold and hot circuit to
connect to.

Shell and Tube Heat Exchanger (TD360c)

The shell and tube heat exchanger allows for heat transfer between two fluids in either parallel or
countercurrent flow configurations. The shell consists of a large acrylic tube with an inner and outer
diameter of 50 mm and 60 mm respectively. The tube bundle consists of 6 stainless steel tubes with and
inner and outer diameter of 4 mm and 6 mm respectively. There are three baffles with a baffle spacing of
45 mm. The mean heat exchange area is 0.02 m2.

PROCEDURE

1. Open the cold water supply entering the service module. Power the service module and data
acquisition system by turning on the power switches located on the back and side of the service
module. Turn on the PC and launch “TecQuipment VDAS”. Ensure to click the arrow to allow for
communication between the data acquisition system and the PC. Ensure water tank is filled or fill
if necessary, and that the controller/heater is powered. Keep the pump powered off until a heat
exchanger is connected; ensure that the cold water flow control valve is closed and that the
pump is powered off before disconnecting any lines.
2. Familiarize yourself with the software, ensuring you know how to record a data entry, export to
excel and ensure communication with the data acquisition system.
3. Set the controller set point to 40ºC.
4. Select 3 (low, intermediate, high) values for the cold water flow rates (Fc). The bounds for the
flowrate are 0.5 L⸱min-1 and 3.0 L⸱min-1. Measure the length of the inner tubes of the shell and
tube heat exchanger (L).
5. Connect the shell and tube heat exchanger in parallel flow configuration. Switch the hot water
pump on and set the hot water flow rate (FH) to 3.0 L⸱min-1. Set FC to the lowest of the values
selected in step 3 (FC,min). Wait for steady state, and record the temperatures and flowrates using
the data acquisition software.
6. Turn off the hot water pump and close the flow control valve for the cold circuit. Reconnect the
shell and tube heat exchanger in a countercurrent flow configuration. Switch the hot water pump
on and set the FH to 3.0 L⸱min-1. Collect steady state data for all three of the flowrates selected for
FC in step 3.
7. Turn off the hot water pump and shut the flow control valve for the cold circuit. Switch the heat
exchanger to the plate heat exchanger. Repeat step 5, but this time using the plate heat
exchanger.
8. Repeat step 6 using the plate heat exchanger.
9. Raise the set point of the controller to 60ºC.
10. Collect Steady state data at FC = FC,min, FH = 3.0 L⸱min-1, for both heat exchangers in both parallel
and countercurrent flow configurations. This will require disconnecting both cold and hot lines
multiple times, ensure that the cold water flow control valve is closed and that the pump is
powered off before disconnecting any lines.
11. Save data to USB.

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 12. Turn off power for the pump and controller on the front of the service module. Shut the cold
water control valve and the main water supply. Turn off the power to the service module and data
acquisition system located on the side and back of the service module. Power the PC off.

THEORY

A. Energy Balance

An energy balance around an ideal two stream heat exchanger yields Equation 1.

𝑚̇ℎ 𝐶𝑝,ℎ (𝑇ℎ,𝑖𝑛 − 𝑇ℎ,𝑜𝑢𝑡 ) = 𝑚̇ 𝑐 𝐶𝑝,𝑐 (𝑇𝑐,𝑜𝑢𝑡 − 𝑇𝑐,𝑖𝑛 ) (1)

where mh, and mc are the mass flow rates of the hot and cold stream respectively. Th,in, Th,out, Tc,in and Tc,out
are the inlet and outlet temperatures of the hot and cold stream respectively. Cp,h, and Cp,c are the specific
heat capacity at constant pressure of the hot and cold fluids.

An energy balance coefficient (EB) can be derived by dividing the right hand side of Equation 1 by the left
hand side. The energy balance coefficient may be evaluated to check the validity of the ideal heat
exchanger assumption. If the value of EB exceeds unity, heat was absorbed into the cold fluid from the
surroundings, and if it is less than unity heat was lost to the surrounding environment.

𝑚̇ 𝑐 𝐶𝑝,𝑐 (𝑇𝑐,𝑜𝑢𝑡 − 𝑇𝑐,𝑖𝑛 )

𝐸𝐵 = (2)
𝑚̇ ℎ 𝐶𝑝,ℎ (𝑇ℎ,𝑖𝑛 − 𝑇ℎ,𝑜𝑢𝑡 )

B. ε-NTU Method

For any two stream heat exchanger and flow configuration the rate of heat transfer (q) can be calculated
using Equation 3.

𝑞 = 𝐶ℎ (𝑇ℎ,𝑖𝑛 − 𝑇ℎ,𝑜𝑢𝑡 ) = 𝐶𝑐 (𝑇𝑐,𝑜𝑢𝑡 − 𝑇𝑐,𝑖𝑛 ) (3)

where Cc, and Ch is heat capacity rate of the cold and hot stream.

The heat capacity rate of the hot (Ch) and cold stream (Cc) can be calculated using Equation 4 and 5
respectively.

𝐶ℎ = 𝑚̇ℎ 𝐶𝑝,ℎ (4)

𝐶𝑐 = 𝑚̇𝑐 𝐶𝑝,𝑐 (5)

The ε-NTU method analysis for heat exchangers was developed by London and Seban, using this method
the total rate of heat transfer (q) from the hot to the cold fluid can be calculated using Equation 6.

𝑞 = 𝜀𝐶𝑚𝑖𝑛 (𝑇ℎ,𝑖𝑛 − 𝑇𝑐,𝑖𝑛 ) (6)

where ε is the heat exchanger effectiveness.

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In a two stream heat exchanger typically one stream undergoes a greater temperature change than the
other; this stream has the lesser heat capacity rate. The minimum (Cmin) and maximum heat capacity rates
(Cmax) are calculated using Equation 7 and 8 below.

𝐶𝑚𝑖𝑛 = 𝑀𝐼𝑁𝐼𝑀𝑈𝑀(𝐶ℎ , 𝐶𝑐 ) (7)

𝐶𝑚𝑎𝑥 = 𝑀𝐴𝑋𝐼𝑀𝑈𝑀(𝐶ℎ , 𝐶𝑐 ) (8)

The heat capacity rate ratio (C*) is calculated as shown below in Equation 9 and by definition is always
less than 1.

𝐶𝑚𝑖𝑛
𝐶∗ = 𝐶𝑚𝑎𝑥
≤1 (9)

The number of transfer units (NTU) is the nondimensional thermal size of the heat exchanger and is
defined by Equation 10 below.

̅𝐴
𝑈 1
𝑁𝑇𝑈 = = ∫ 𝑈𝑙𝑜𝑐𝑎𝑙 𝑑𝐴 (10)
𝐶𝑚𝑖𝑛 𝐶𝑚𝑖𝑛 𝐴

where A is the area of the heat exchanger, and U is the overall heat transfer coefficient which is defined
as the inverse of the sum of all resistance to heat transfer within the exchanger, as shown in Equation 11.

1
𝑈= ∑ 𝑅𝑡,𝑗
(11)

where Rt,j is the resistance to either convective heat transfer, conductive heat transfer, or fouling.

For the scenario of convective heat transfer separated by a solid surface the product of UA can be
calculated using Equation 12.

′′ ′′
1 1 𝑅𝑓,𝑐 1 𝑅𝑓,ℎ
= + + 𝑅𝑤 + + (12)
𝑈𝐴 𝑛𝑜 ℎ 𝑐 𝐴 𝑛𝑜 𝐴 𝑛𝑜 ℎ ℎ 𝐴 𝑛𝑜 𝐴

where Rw is the resistance of the solid surface, R’’f,c and R’’f.h are the specific fouling resistance for the cold
and hot fluid side respectively, hc and hh are the convective heat transfer coefficient for the cold and hot
fluid. no is the overall surface efficiency, which can be assumed to be 1 for the case of a surface without
fins. A is the heat exchange area.

A tubular heat transfer surface, such as the kind found in shell and tube heat exchangers, do not have
identical heat transfer areas on both sides of the wall; thus U must be coupled with A or based on either
the inner or outer heat transfer area (Note: U1A1 = U2A2). Equation 13 allows for the calculation of Uo
based on the outer surface area of the tubular surface.

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𝑈𝑜 = 𝑑 (13)
𝑑𝑜 ln( 𝑜 ) 𝑅 𝑑𝑜
1 𝑑𝑖 𝑓,𝑖 𝑑
+ 𝑅𝑓,𝑜 + + + 𝑜
ℎ𝑜 2𝑘𝑤 𝑑𝑖 ℎ𝑖 𝑑 𝑖

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where the di, do, hi, ho, are the inner and outer diameters, and convective heat transfer coefficients
respectively. kw is the conductive heat transfer coefficient of the tube.

The maximum rate of heat transfers possible (qmax) between two streams may be calculated using
Equation 14.

𝑞𝑚𝑎𝑥 = 𝐶𝑚𝑖𝑛 (𝑇ℎ,𝑖𝑛 − 𝑇𝑐,𝑖𝑛 ) (14)

The heat exchanger effectiveness (ε) can be found graphically from figures such as Figure 6a and 7
attached at the end of the handout. Alternatively, ε can be calculated using Equation 15.

𝑞 𝐶ℎ (𝑇ℎ,𝑖𝑛 −𝑇ℎ,𝑜𝑢𝑡 ) 𝐶𝑐 (𝑇𝑐,𝑜𝑢𝑡 −𝑇𝑐,𝑖𝑛 )

𝜀= = = (15)
𝑞𝑚𝑎𝑥 𝐶𝑚𝑖𝑛 (𝑇ℎ,𝑖𝑛 −𝑇𝑐,𝑖𝑛 ) 𝐶𝑚𝑖𝑛 (𝑇ℎ,𝑖𝑛 −𝑇𝑐,𝑖𝑛 )

The thermal effectiveness of a shell and tube heat exchanger (P) can be calculated if both inlet and one
outlet temperatures are known with Equation 16.

𝑡𝑜𝑢𝑡 − 𝑡𝑖𝑛
𝑃= (16)
𝑇𝑖𝑛 − 𝑡𝑖𝑛

where tin, and tout refer to the tube side inlet and outlet temperatures respectively, and Tin is the shell side
inlet temperature.

Alternatively, P can be calculated from the heat exchanger effectiveness and the heat capacity rate ratio
C* using the applicable Equation below.

𝑃 = 𝜀 𝑓𝑜𝑟 𝐶𝑡 = 𝐶𝑚𝑖𝑛 (17)

𝑃 = 𝜀𝐶 ∗ 𝑓𝑜𝑟 𝐶𝑡 = 𝐶𝑚𝑎𝑥 (18)

where CT is the tube side heat capacity rate.

The heat capacity ratio R can be calculated by either Equations 19, 20, or 21.

𝐶𝑇 𝑇𝑖𝑛 − 𝑇𝑜𝑢𝑡
𝑅= = (19)
𝐶𝑠 𝑡𝑜𝑢𝑡 − 𝑡𝑖𝑛

where Cs is the shell side heat capacity rate. Note uppercase T designates shell side temperature and lower
case t designates tube side temperature.

𝑅 = 𝐶 ∗ 𝑓𝑜𝑟 𝐶𝑡 = 𝐶𝑚𝑖𝑛 (20)

𝑅 = 1/𝐶 ∗ 𝑓𝑜𝑟 𝐶𝑡 = 𝐶𝑚𝑎𝑥 (21)

Thus R is always greater than or equal to the heat capacity rate ratio C*.

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 C. LMTD Method

The rate of heat transfer (q) transferred from the hot fluid to the cold fluid can be calculated using
Equation 22.

𝑞 = 𝑈𝐴∆𝑇𝑡𝑚 (22)

where ΔTtm is the true mean temperature across the heat exchanger. Since heat exchangers rarely exhibit
pure parallel or concurrent flow the true mean temperature cannot be calculated and is approximated by
Equation 23.

∆𝑇𝑡𝑚 = 𝐹∆𝑇𝑙𝑚 (23)

where F is a correction factor defined as the ratio of the true mean temperature difference, and the log
mean temperature difference (ΔTlm). The log mean temperature difference (LMTD) is calculated using
Equation 24 and Equation 25 for parallel and countercurrent flow configurations, respectively.

(𝛥𝑇2 − 𝛥𝑇1 ) (𝑇ℎ,𝑜𝑢𝑡 − 𝑇𝑐,𝑜𝑢𝑡 )−(𝑇ℎ,𝑖𝑛 − 𝑇𝑐,𝑖𝑛 )

∆𝑇𝑙𝑚 = 𝛥𝑇 = (𝑇ℎ,𝑜𝑢𝑡 − 𝑇𝑐,𝑜𝑢𝑡 )
(24)
ln( 2⁄𝛥𝑇 ) ln( ⁄ )
1
(𝑇ℎ,𝑖𝑛 − 𝑇𝑐,𝑖𝑛 )

(𝛥𝑇2 − 𝛥𝑇1 ) (𝑇ℎ,𝑜𝑢𝑡 − 𝑇𝑐,𝑖𝑛 )−(𝑇ℎ,𝑖𝑛 − 𝑇𝑐,𝑜𝑢𝑡 )

∆𝑇𝑙𝑚 = 𝛥𝑇 = (𝑇ℎ,𝑜𝑢𝑡 − 𝑇𝑐,𝑖𝑛 )
(25)
ln( 2⁄𝛥𝑇 ) ln( ⁄ )
1
(𝑇ℎ,𝑖𝑛 − 𝑇𝑐,𝑜𝑢𝑡 )

F is unity for a true counterflow heat exchanger, for other flow configurations F is generally less than unity.
F factor charts are published in various literatures such as Perry’s Chemical Engineers’ Handbook and Heat
Exchanger Design Handbook for various shell and tube combinations. The most applicable F factor chart
for the shell and tube heat exchanger utilized during the laboratory is depicted by Figure 6b at the end of
this handout.

D. Tube Side Convective Heat Transfer Coefficient

The convective heat transfer coefficient (h) can be calculated for a fluid if the Nusselt number (Nu) is
known.

ℎ𝑑
𝑁𝑢 = (26)
𝑘𝑓

where d is the characteristic length (di for a tube), and kf is the thermal conductivity of the fluid.

Since direct calculation of the Nusselt number requires h, the parameter we are interested in determining,
an empirical equation must be used to predict the Nusselt number. For turbulent flow the Nusselt number
can be calculated with Equation 27, and by Equation 28 for laminar flow.

𝜇 0.14
𝑁𝑢 = 𝐶𝑅𝑒 0.8 𝑃𝑟 0.33 ( ) 𝑓𝑜𝑟 𝑅𝑒 > 10,000 (27)
𝜇 𝑤

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where Re is the Reynolds Number given by equation 29 and Pr is the Prandtl number is defined by
equation 30. C is a constant depending on the nature of the fluid. C equals 0.021, 0.023, and 0.027 for
gases, non-viscous liquids, and viscous liquids respectively.

𝑑 0.33 𝜇 0.14
𝑁𝑢 = 1.86(𝑅𝑒𝑃𝑟)0.33 ( 𝑖 ) (𝜇 ) 𝑓𝑜𝑟 𝑅𝑒 < 2100 (28)
𝐿 𝑤

where µ is the fluid viscosity at the bulk fluid temperature, and µw is the fluid viscosity at the wall
temperature.

If the calculated Nu is less than 3.5 by Equation 28, use the value of 3.5 instead. If they Reynolds number
is between 2100 and 10000 calculate the Nusselt number using both methods and take the lower of the
two values.

𝜌𝑣𝑡 𝑑
Re = (29)
µ
where vt is the fluid velocity within the tube.

𝐶𝑝 µ
Pr = (30)
𝑘𝑓

QUESTIONS FOR THE REPORTS

In your analysis, please calculate density, and heat capacity for each stream at the average circuit
temperature (arithmetic mean of the inlet and outlet temperature for the respective circuit).

Set 1:
1. For all values of Fc use the LMTD method (Assume F factor is 1) to calculate the overall heat
transfer coefficient (U), and heat exchanger effectiveness (ε), for both heat exchangers in
countercurrent configuration (use only the data collected with a set point of 40ºC). Tabulate and
discuss your observations; are your observations as expected/predicted by first principles?
2. Using the LMTD method (Assume F factor is 1), calculate the overall heat transfer coefficient (U)
for the plate heat exchanger in both parallel and countercurrent flow configurations at heater set
points of 40ºC, and 60ºC (FC = FC,min). Comment on the temperature dependence of U. Can you
explain your observations using first principals? Discuss the effect of flow configuration.
3. What are typical values of U for each type of heat exchanger? Do the values of U calculated in
Question 1 fall within the range reported in literature for a similar exchanger with water as both
working fluids?
4. What is meaning of F? Was F = 1 a good assumption for each exchanger? Comment on the validity
of the assumption.
5. For all applicable trials with similar operating conditions and flow configurations compare the
performance of the shell and tube and plate heat exchangers. What are the advantages and
disadvantages of each exchanger type?

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 6. Calculate the tube side Reynolds number for one trial (state which trial and provide all operating
conditions) collected during Step 6 of the procedure. For the same trial determine if the flow is
laminar or turbulent and predict the tube side convective heat transfer coefficient using the
definition of the Nusselt number and the appropriate empirical equation provided in the Theory
section. Using the overall heat transfer coefficient calculated in question 1 estimate the value of
the shell side convective heat transfer coefficient. State all assumptions.

Set 2:
1. For all values of Fc use the LMTD method (Assume F Factor is 1) to calculate the overall heat
transfer coefficient (U), and heat exchanger effectiveness (ε), for both heat exchangers in
countercurrent configuration (use only the data collected with a set point of 40ºC). Tabulate and
discuss your observations; are your observations as expected/predicted by first principles?
2. Using the LMTD method (Assume F factor is 1) calculate the overall heat transfer coefficient (U)
for the shell and tube heat exchanger in both parallel and countercurrent flow configurations with
heater set points of 40ºC, and 60ºC (FC = FC,min). Comment on the temperature dependence of U.
Can you explain your observations using first principals? Discuss the effect of flow configuration.
3. What is the TEMA shell type of the shell and tube exchanger used during the lab? How many tube
passes?
4. Calculate and tabulate the energy balance coefficient for all trials. What does an energy balance
coefficient greater or less than unity mean? Outline the condition for which you would expect an
energy balance coefficient greater than unity; was this condition met in any of your trials?
Comment on the validity of ideal heat exchanger assumption.
5. Calculate the overall heat transfer coefficient (U) using the ε-NTU method for the plate heat
exchanger for all trials performed in step 8 of the procedure with the aid of Figure 7 and relevant
theory provided. (Perform this for all values of FC for the plate heat exchanger in countercurrent
configuration and a set point of 40ºC). Can you observe any trends? Compare the values of U
calculated using the ε-NTU method to those calculated using the LMTD method in question 1 (for
comparable operating conditions, exchanger and flow configuration).
6. Calculate the tube side Reynolds number for one trial (state which trial and provide all operating
conditions) collected during Step 6 of the procedure. For the same trial determine if the flow is
laminar or turbulent and predict the tube side convective heat transfer coefficient using the
definition of the Nusselt number and the appropriate empirical equation provided in the Theory
section. Using the overall heat transfer coefficient calculated in question 1 estimate the value of
the shell side convective heat transfer coefficient. State all assumptions.

REFERENCES

Thulukkanam, Kuppan. Heat Exchanger Design Handbook. Hoboken: CRC Press, 2013.
Incropera, Frank P. Introduction to Heat Transfer. 5th ed. Hoboken NJ: Wiley, 2007.

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