University of Jordan

Faculty of Engineering & Technology

Department of Chemical Engineering
Chemical engineering Laboratory (2)
Experiment No. (1)
Shell and tube heat exchanger
Done by:
Abdullah Ali Al-kesbeh (2030214)

Partner name:
Mohammad soboh
hmad o!ebedat
Date o" per"orming Experiment: #uesday$ %&'11'%(()
Date o" Submitting *eport: #uesday$ 1+'1%'%(()
*eport #ype: ,ull *eport
Table of Contents
Abstract 2
Introduction 3
Theory 6
Experimental Apparatus 11
Procedure 15
Results 16
Discussion of Results 21
onclusions 22
Recommendations 23
!omenclature 2"
References 25
Appendices 26
Abstract
An experiment was performed to study the principles of shell and tube
heat exchanger with cooling water in the tubes and steam in the shell.
The overall heat transfer coefficient is evaluated with log mean
temperature difference method and the local heat transfer coefficient
and the dirty factor have been determined. Energy balance was
established to calculate heat losses from the heat exchanger to the
surrounding. The results showed the variation effect of steam flow rate
on the overall, local heat transfer coefficient and the dirty factor and the
results were compared with the representative results and showed high
degree of agreement.
Introduction
General background
Heat exchanger is a device to promote heat transfer between two
streams of fluids at different temperature and separated by a solid wall.
Heat exchanger applications include space heating, air conditioning,
power production, waste heat recovery, drying, and agricultural and
chemical processing.
Classification of heat exchanger:
flow arrangement :
Parallel !o"current flow#.
!ounter !ounter current flow#.
!ross flow mixed or unmixed fluid#.
Construction type :
$ouble pipe concentric tube# heat exchanger.
!ompact heat exchanger.
%hell and tube heat exchanger.
&inned or un"finned heat exchanger.
%ingle or multi pass heat exchanger.
%hell and tube heat exchangers are the most important class of heat
transfer e'uipment because they can be constructed with very large
surfaces in a relatively small volume, and can be used for heating and
condensing all (inds of fluids where its common industrial application for
li'uid) li'uid heat exchange and generally less efficient than double pipe
heat exchanger but are more compact and easier to build for a given duty.
These heat exchangers are employed when a process re'uires large
'uantities of fluid to be heated or cooled. $ue to their compact design,
these heat exchangers contain a large amount of heat transfer area and
also provide a high degree of heat transfer efficiency.
*ver the years, many different types of shell and tube heat exchangers
have been designed to meet various process re'uirements. +n order to
accomplish as much transfer of energy in as little space as possible, it is
desirable to utili,e multiple passes of one or both fluids. These heat
exchangers are denoted by a pair of numbers which indicates the number
of shell and tube side passes. &or example, in a -"2 heat exchanger, the
shell side fluid will traverse the heat exchanger once while the tube side
fluid will traverse the exchanger twice. Although variations on the number
of tube"and"shell passes are encountered in numerous applications, it is
not common practice to use more than two shell"side passes.
.ood mixing of the shell"side fluid is accomplished using baffles. /ithout
the use of baffles, the fluid becomes stagnant in certain parts of the shell.
Heat exchangers in industry are most often designed with the aid of
software programs. .iven the re'uired specifications for a heat
exchanger, these simulators perform the appropriate calculations.

Types of shell and tube heat exchanger:
&ixed head &ixed tube sheet#.
0" Tube 0" 1end#.
&loating head.
Utility of measurements
At different pressure of inlet steam, temperatures and pressures of
inlet and outlet cooling water and steam is measured and the flow rate of
condensate and its temperature is measured, to calculate the overall heat
transfer coefficient using the log mean temperature difference method
which re'uires the 2 temperatures to be (nown.
Approach taken
+n this experiment shell and tube heat exchanger used to heat the
cooling water which fed into a bundle of 34 tubes with inside and outside
diameters of -2,-2 mm respectively, by steam fed into the shell and
losses heat through 3 m
2
effective heat transfer area to the cooling water
so its temperature decreases from the saturation temperature then it
condensates and collected in a graduated cylinder. The flow pattern of
steam in the shell is a mixture of parallel, countercurrent and cross flow
with one shell pass. A series of single segmental 256 vertically cut baffle
installed inside the shell to direct the flow around the tubes. The cooling
water is fed into the exchanger via a 7ota meter to indicate the flow rate
and control valve to indicate the flow pressure of cooling water and
steam, thermometers are installed to measure temperatures of inlet and
outlet streams.
Obecti!es
The obecti!es of this experiment are:
-" To determine the overall heat transfer coefficient and
fouling factor using steam in the shell and cooling water in
the tube side by log mean temperature difference.
2" +nvestigate the effect of co"current flow on the heat transfer
coefficient.
3" Establishing energy balance in the heat exchanger for
calculation of heat losses from system to the surrounding.
Theory

The properties of water, is determined at T

average
, &or the cold fluid
cooling water#:
%
# #
#
o $ c i c$
c
+
.(1)
"here:#
c
#
= the average temperature 8#.
o $ c
#
9 the outlet cooling water temperature 8#.
i c$
#
= the inlet cooling water temperature 8#.
The log mean temperature difference : T
lm
# for co"current flow;
( ) ( )
( )
( )
1
1
]
1

i $ s i $ s
o $ - o $ s
i $ s i $ s o $ - o $ s
lm
# #
# #
ln
# # # #
#
..(2)
the mass flow rate of steam ;
s s
.

s
m
..(3)
"here:-
s
m
: <ass flow rate of steam (g)s#.
s
.

: =olumetric flow rate of steam >)s#

s

: $ensity of steam at T
sat
(g)m
3
#.

=olumetric flow rate of water;

&rom the water scale reading, the flow rate of water using the
calibration curve in >)sec.#
mass flow rate of water ;

- - -
. m

(4)
"here:
-
m
: <ass flow rate of water (g)s#
-
.

: =olumetric flow rate of water m3 )s#

-

: $ensity of water at
c
#
(g)m
3
#

To determine if the flow in the tubes is laminar or not by

finding 7e 7eynolds no.#
- i
-
D N
m /
*e

..(5)
"here:
Re : 7eynolds no. $imensionless#
-
m
: <ass flow rate of water (g)sec.#
D
i
: inside diameter of tube m#
N : number of tubes.
-

: =iscosity of water at
c
#

?.s)m
2
#
+f the flow is laminar
1/ . (
s
+
1
i +
1
+
1
0
D
1 Pr *e 23 . 1 Nu

,
_

,
_

..(6)
"here:
?u ; ?uselt number dimensionless#
Pr

; Prandlt number at c
#
dimensionless#
$
i
; the inside diameter of tube m#
> ; >ength of the tube m#

; =iscosity of water at c
#
?.s)m
2
#
s

; =iscosity of steam at T
sat
?.s)m
2
#

i
i
i i
D
4 Nu
h
4
D h
Nu

.(7)
"here:
h
i
9 heat transfer coefficient of inside fluid w)m
2
.8#
8 9 thermal conductivity at T
sat
w )m.8#
the heat given by the steam to water and the heat gained by
the water;

( )
s s $ p s s s
# 5 h m 6 +
(8)
"here:
@
s
; heat given by the steam watt#
s
m
; <ass flow rate of steam (g)s#
h
s
; heat of vapori,ation at T
sat
. (A )(g#
!
p,s
; specific heat of steam at T
sat
(A)(g.8#
:T
s
; difference between inlet and outlet steam temperature
(#.
@ gained by water;

- - $ p - -
# 5 m 6
.......................................... B#
Where:
Q
w
: heat gained ! water (watt)
s
m
: "a## $%&w rate &$ water ('g(#e))
- $ p
5
: #*e)i$i) heat at
c
#
('+ ('g.,)
%ometimes there will be some dirtCs inside the tube which acts an
isolated material, to calculate the dirt factor using;

5 d
d
7
1
7
1
*
888888888888 (1()
"here:
7
d
; dirt factor m
2
.()w#
0
d
; dirt overall heat transfer coefficient w)m
2
.(#
/hich is;

lm
s
d
#
6
7

. (11)
"here:
@
s
; heat given by the steam watt#
A; Area of heat transfer m
2
#
:T
lm
; >og mean temperature (#
-
)
: )%ean &.era%% heat tran#$er )&e$$i)ient (w("
2
.,)
Whi)h e/0a%:

( ) ( )

i i
4 . m 9 2)1( richardson and coulson "rom
5
h D
D
h
1
1
7
%

...(12)

"here:
h
o
; heat transfer coefficient for outside fluid w)m
2
.(#
$
o
; outside diameter m#
$
i
; inside diameter m#
h
i
; heat transfer coefficient for inside fluid w)m
2
.(#
%ome of heat for steam is given for water and some of it will go to the
outside atmosphere, to find @
>
losses of heat#;
Q
1
= Q
#
2 Q
w
(13)
Where:
@
s
; heat given by steam watt#
@
w
; heat given by water watt#

: 1((
6
6
6 :
s
0
0

.. (14)

$xperimental Apparatus:
A diagram of the apparatus to be used in this experiment is shown in
figure -# and 2#
The unit consists of 5D mm diameter shell and tube heat exchanger with
an effective heat transfer area of 3 m
2
.
+t is supplied complete with all necessary instruments and valves for
monitoring and controlling, pressure, temperature and flow rate within the
unit.
!ooling water is fed into the exchanger via a rotameter to indicate the
flow rate and control valve so that the flow pressures are indicated at the
end of the pass. The steam is introduced in the shell from the main
supply.
A series of baffles are fitted along the shell which increase the velocity of
flow, thus giving better heat transfer. These baffles are of the segmental
form with about 256cut as shown in figure 3#
#pecifications$

+nside tube diameter 9 -2 mm.

*utside tube diameter 9 -2mm.

Tube length 9 2D3Dmm.

?umber of tuber 9 34.

There are - tube passes

%hell internal diameter 9 D.-5 m

+nternal area of tubes 9 2.E3-F m

2

External area of tubes 9 3.3D35 m

2
,igure (%): shell and tube heat exchanger
figure 3#; segmental baffles vertically cut
,igure (/): shell and tube heat exchanger description
%rocedure:
-. &or all the experiments to be done; valves 2, 5 are (ept always
closed and valve -D is always opened.
2. =alve E is opened very slowly to introduce the cold water in the tube
side. the flow rate is regulated as re'uired;
&or co"current experiment;
=alves 2, 4 are opened and valves -, F are closed.
&or counter current experiment;
=alves -, F are opened and valves 2, 4 are closed.
3. =alve B is opened very slowly to introduce steam to the shell, and
adGust the pressure as re'uired. The steam goes through a trap to a
collector and then to drain.
2. %ufficient time is allowed to reach steady state condition.
At steady state, the following variable is recorded;
+nlet and outlet water temperature.
+nlet and outlet steam temperature.
+nlet and outlet water pressures.
+nlet and outlet steam pressures.
!ooling water scale reading.
The flow rate of the steam condensate.
At the end of the experiment, the pressure of steam is reduced
slowly. Then the heat exchanger is allowed to cool before reducing the
cold water supply.

&iscussion of 'esults:
Heat transfer is thermal energy transit due temperature difference
from high temperature region to low temperature region.
%hell and tube heat exchanger is a common configuration of the
heat exchanger.
+n this experiment co"current flow arrangement was used, while
there is another flow patterns more efficient which is counter current
flow. This configuration provides more heat transfer between the hot
and cold fluid because the change in temperature difference is
larger than that for the co"current flow.
%team is put in the shell and water in the tube side because the
pressure drop of steam in the shell is greater than of the pressure
drop of water in tubes shell is stronger than tubes# and to reduce
the losses of heat.
Heat lost by saturated steam will be gained by water and so
condensation occurs. %ome of the heat will be dissipated to the
atmosphere.
The data shows increase in cooled water tube fluid# temperature
and decrease in steam shell fluid# temperature then the data is
accurate and logic.
The main variable that affects the performance of the heat
exchanger is the steam flow. !hanging this variable cause the
system to be under transient state so we should wait about -D"-5#
minutes until the system return to steady state.
/hile increasing the flow rate of steam in the shell, the heat transfer
from steam to cold water will be greater so the condensate flow rate
will increase, since;
@
s
9 m
s
h
f.g
H !p :T
s
#
/hile increasing the steam flow rate in the shell, the inside heat
transfer coefficient hi# will be increase and then dirt and clear heat
transfer coefficient will be in crease as shown in Table A.3#, figure
5# and figure F#.
/hile increasing the system flow rate in the shell, the fouling
factor will be decrease as shown in figure 4#.
The dirtiness of the e'uipment affects the dirt factor.
Personal error may affect the results of the experiment negative
values of dirt factor# as well as fouling and scaling in the heat
exchanger.
Conclusion
%hell and tube heat exchanger, its a device used in the process of
heat exchanger between two fluids that are at different temperature.
1affles which are filled along the shell increase the velocity of flow
and thus giving better heat transfer and they have another Gob that
wor( as supports for the tube from bending with time.
!ounter !urrent flow is more efficient than the co"current one
because the amount of heat transferred from steam to li'uid will be
higher log mean temperature will be increase#.
+mportance of steam trap to get red of condensate in the steams
stream and to prevent builds up of pressure on the whole system.
The diameters of tubes are very small and large number to get large
effective area as possible perpendicular to the heat transfer.
/hile increasing the steam flow rate the heat gained by the water,
the overall heat transfer coefficient. The dirt and clean heat transfer
coefficient, the heat losses @
>
# and the log mean temperatures will
be greater while the fouling factor will be smaller.
$rrors and source of error
Personal errors in mainting the accurate valves of pressure, volume
of water, time of flow, Temperature.
%ome amount of heat of steam has been loss to the atmosphere so
we donCt have accurate valves of heat losses.
+nstrumental errors such as inaccurate meters, graduated cylinders,
etc.
'ecommendation
/aiting enough time between the trails to ma(e sure that we reach
steady state condition, the experiment results will be more accurate.
The tubes inside the device was very dirty, the dirtCs are
accumulated in the device because it is very old and affects the
ta(en reading, so maintenance should be done every six months at
least.
<ore sufficient valve should be used for the steam to prevent the
flow rate and pressure fluctuation.
This experiment should be done using counter current flow in order
to compare it with the co"current flow.
'eferences:
-. !oulson A.<. and 7ichardson A.&. , I!hemical EngineeringJ, =olume
-, 2
nd
Edition, Pergamon press.
2. 8ern $.@. , IProcess Heat TransferJ, <c.raw Hill.
3. Perry 7.H, !hilton !.H., I!hemical Engineering Handboo(J. 5
th

Edition, <c.raw Hill.
2. &ran( P.+ncropera and $avid P.$
E
/itt, fundamentals of heat and
mass transfer ,5
th
edition ,2DD2
5. http;))fetweb.Gu.edu.Go)staff)che)shawab(e
F. !hemical engineering lab sheet.
(omenclatures
%ymbol $escription 0nit
A Heat transfer Area m
2
$
i
inside diameter of tube m
$
o
outside diameter of tube m
> tube length m
N ?umber of tubes "
s

density of steam (g)m

3
-

density of water (g)m

3
s

viscosity of steam ?.s)m

2
-

viscosity of water ?.s)m

2
s
m
mass flow rate of steam (g)sec.
-
m
mass flow rate of water (g)sec.
s
.

volumetric flow rate of steam m

3
)sec.
-
.

volumetric flow rate of water m

3
)sec.
!
p
specific heat 8A)(g.8
h
f,g
heat of vapori,ation (A)(g
8 thermal conductivity w)m.8
Pr prandlt number "
?u ?usselt number "
:T
lm
log mean temperature difference 8
7e 7eynolds number "
h
i
heat transfer coefficient of inside fluid w)m
2
.(
h
o
heat transfer coefficient of outside fluid w)m
2
.8
0
d
dirt overall heat transfer coefficient w)m
2
.8
0
c
clean overall heat transfer coefficient w)m
2
.8
7
d
dirt factor m
2
.() w
@
s
heat given by steam watt
@
w
heat gained by water watt
@
>
losses in heat watt
Appendix B :Sample of calculations:
For second run :
( )
( )
( )
( )
( )
( )
( )
( )
( )
( )
( )
( )
( )
( )
laminar %1(( (33% . ;%) *e
1( ;2 . )2( (1% . ( +;
(1%3( . ( / /
*e
(1%3( . ( 12 . &/) 1( ++ . 1
1( ++ . 1
1( 3(
min
min
ml (( 2
1/3& . ( %3 . &2& 1( /2 . 1
1( /2 . 1
1((( 3(
min
min
0 & . 2
cm 1./ reading scale sheet lab in cur<e n calibratio "rom
. 1( %+;
%+& . /
12 . &/)
%%1%
: at inlet properties
4 /+ . +2&
absolute bar ;3+%) . 1 P at steam o" re temperatu
;&; . + Pr
. 1( )2 . 3+&
. 1( ;2 . )2(
1;&& . /
%3 . &2&
4 +12.3) at -ater cold o" properties physical table steam "rom
3) . +12 ) . /3
%
31 +%
3
)
s
+ )
3
+
/
-
+ /
+
% 3
.
+
s
$
in S$
+
% 3
.
+
-
<

w i
w
s s
s
w w
w
s
s P
g f
sat
sat
w
w
w P
C
D
m
s !g " m
s m
ml
m
s
"
s !g " m
s m
L
m
s
"
m s
!g !# C
m !g
!g !# h
T
T
sturation
$ m % $
m s
!g !# C
m !g
$ C T

( ) ( ) ( )
( ) ( ) ( )
( )
( ) ( )
( ) ( ) ( )

( )
( ) ( )

( )
( )
( )
( )
( )
: ;%; . +3 : 6
: 1((
3% . %21/+
%1 . 1(++3
: 6
: 1((
6
6
: 6
9 %1 . 1(++3 /1 . 1;2(; 3% . %21/+ 6 6 6 loss heat
9 /1 . 1;2(; +% 31 1;&& . / 1/3& . ( # 5 m 6
6 -ater cold by gained heat
9 m.4 ((1/+ . (
12(; . %+)
1
;);/ . +)/
1
7
1
7
1
*
4 . m 9 12(; . %+)
1;); . %2% (1% . (
(1/ . (
2)1(
1
1
h D
D
h
1
1
7
.4 m 9 ;);/ . +)/
(/ . %/ + . +
3% . %21/+
#
6
7
# 7 6
4 (/ . %/
+2
1/
ln
+2 1/
#
#
ln
# #
#
9 3% . %21/+ %+& . / ;( ;) %%1% 6 1( (1% . ( 6
5 # h m 6 steam by lost heat
4 . m 9 1;); . %2%
(1% . (
1( )2 . 3+& %&/+ . )
h
4
D h
Nu
%&/+ . ) %+; ;2 . )2( (+( . % (1% . ( ;&; . + (33 . ;%) 23 . 1 Nu
0 D Pr *e 23 . 1 Nu
0
0
S
0
0
9 S 0
9 9 $ P 9 9
9
5 d
d
%
i i
4 . m 9 2)1( richardson and coulson "rom
5
%
lm
S
S
lm d S
+2 +% ;( # # # 1/ 31 ;) # # #
1
%
1 %
lm
+
S
P S "g S S
%
+
i
-
i i
1/ . ( ++ . ( ++ . (
1/ . (
s -
++ . (
i
++ . (
%
i $ 9 i $ S 1 = $ 9 = $ S %

,
_

,
_

+
+