Lab Manual

FACULTY OF ENGINEERING & BUILT ENVIRONMENT

SUBJECT: EGE 3431 LABORATORY INVESTIGATIONS 4
EXPERIMENT 5: SHELL AND TUBE HEAT EXCHANGERS
1.0 OBJECTIVE
i.

To allow students to get familiarized with shell and tube heat exchangers

ii.

To collect data and calculate the heat losses, heat transfer coefficient and LMTD values.

2.0 THEORY/INTRODUCTION
2.1 Shell & Tube Heat Exchanger
Most chemical processes involve heat transfer to and from the process fluids. The most
commonly used heat-transfer equipment is the shell and tube heat exchanger. If the fluids both
flow in the same direction, as shown in Figure 1a, it is referred to as a parallel-flow type; if they
flow in the opposite directions, a counterflowtype.

Figure 1a: Temperature profile for a parallel-flow heat exchanger.

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Figure 1b: Temperature profile for a counterflow heat exchanger.

Figure 1c: Temperature profile for a 1:2 heat exchanger.

2.2 Heat Balance
For a parallel-flow shell and tube heat exchanger with one tube pass and one shell pass shown in
Figure 2a, the heat balance is given as:
mtCpt (t2 - t1) = msCps(T1 - T2) = q

(1)

Similarly, for the counterflow shell and tube heat exchanger with one tube pass and one shell
pass shown in Figure 2b, the heat balance is given as:
mtCpt (t2 - t1) = msCps(T1 - T2) = q

(2)

where,
mt

= mass flow rate of cold fluid in the tube (kgs-1)

ms

= mass flow rate of hot fluid in the shell (kgs-1)

Cpt

= specific heat of cold fluid in the tube (kJkg-1C-1)

Cps

= specific heat of hot fluid in the shell (kJkg-1C-1)

t1, t2

= temperature of cold fluid entering/leaving the tube (C)

T1, T2

= temperature of hot fluid entering/leaving the shell (C)

= heat exchange rate between fluid (kW)

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2.3 Heat Transfer

The general equation for heat transfer across the tube surface in a shell and tube heat exchanger
is given by:
q =UoAoTm = UiAiTm

(3)

where,
Ao

outside area of the tube (m2)

Ai

inside area of the tube (m2)

Tm =

mean temperature difference (C)

Uo

overall heat transfer coefficient based on the outside area of the tube (kWm-2C-1)

Ui

overall heat transfer coefficient based on the inside area of the tube (kWm-2C-1)

The coefficients Uo and Ui are given by:

1 1
1 d o ln( d o d i ) d o
d

o
Uo ho hod
2k w
d i hid d i hi

(4)

d
d
1 1 1 d i ln( d o d i )

i i
U i hi h id
2k w
d o hod d o ho

(5)

and,

where,
ho

= outside fluid film coefficient (kWm-2C-1)

hi

= inside fluid film coefficient (kWm-2C-1)

hod

= outside dirt coefficient (fouling factor) (kWm-2C-1)

hid

= inside dirt coefficient (kWm-2C-1)

kw

= thermal conductivity of the tube wall material (kWm-1C-1)

do

= tube outside diameter (m)

di

= tube inside diameter (m)

The mean temperature difference for both parallel and counterflow shell and tube heat
exchanger with single shell pass and single tube pass is normally expressed in terms of log-mean
temperature difference,

Tlm

T1 T2

ln T1
T2

(6)

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where, T1 and, T2are as shown in Fig. 1a and Fig. 1b.

For a more complex heat exchanger, such as 1:2 heat exchanger (Fig. 1c), an estimate of the
true temperature difference is given by,

Tm= FtTlm

(7)

whereFt is the temperature correction factor as a function of two dimensionless temperature

ratios R and S:
R

(T1 T2 )
(t t )
S 2 1
(t 2 t1 ) and,
(T1 t1 )

(8)

Having calculated R and S, then Ft is determined from the standard correction factor figures.
2.4 Tube-side Heat-transfer Coefficient, hi
For turbulent flow, Sieder-Tate equation can be used:

Nu C Re 0.8 Pr 0.33 ( f / w ) 0.14

where,
Re

= Reynolds Number = f u t d e / f Gt d e / f

Nu

= Nusselt Number = h i d e / k f

Pr

= Prandtl Number =

de

= equivalent (or hydraulic) diameter (m)

C p f / k f

= 4 x (cross-sectional area of flow) / wetted perimeter

= di for tubes
Gt

= mass velocity, mass flow per unit area (kg/ s.m2)

= fluid viscosity of bulk fluid temperature (Nsm-2)

= fluid viscosity at the wall (Nsm-2)

= fluid density (kgm-3)

ut

= fluid velocity in tube (ms-1)

Cp

= fluid specific heat, heat capacity (J/kgC)

=0.023 for non-viscous liquids

= 0.027 for viscous liquids

kf

= Fluid thermal conductivity (W/mC)

(9)

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For laminar flow (Re < 2000), the following correlation is used:

Nu 1.86(Re . Pr) 0.33 (d e / L) 0.33 f w

where, L =

0.14

(10)

the tube length (m)

2.5 Shell-side Heat-transfer Coefficient, hs (Kerns Method)

In order to determine the heat transfer coefficient for fluid film in shell, first calculate the crosssectional area of flow As for hypothetical row of tubes of the shell as follows:
As ( pt d o )D s l B / pt

(12)

where,
do

tube outside diameter (m)

pt

tube pitch (m)

Ds

shell inside diameter (m)

lB

distance between baffle (m)

Then, the shell-side mass velocity, Gs and linear velocity, us are calculated as follows::
Gs

W s /A s (13)

us

G s / f (14)

Ws

Fluid flowrate on the shell-side (kg/s)

shell-side fluid density (kg/m3)

where,

The shell equivalent diameter, de is given by:

de

4( pt2 d o2 / 4)
d o

1.27

pt2 0.785d o2
do

(15)

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(For square pitch arrangement)

1
p

4 t 0.87 p t d o2 / 4
2
2

de
d o / 2

1.10 2
pt 0.917d o2
do

(16)

(For equilateral triangular pitch arrangement)

Thus, Reynolds number in shell is given by:
Re

Gs de / f

us de f / f

(17)

Baffle cut, Bc, is used to specify the dimensions of a segmental baffle. It is the height of the
segment removed to form the baffle, expressed as a percentage of the baffle disc diameter.
Using this Reynolds number and given Bc value, the heat transfer factor, jh value is determined
from Figure C.4. Then, the heat transfer coefficient for fluid film in shell is calculated from:

Nu hs d e / k f j h Re Pr 0.33 f w

0.14

(18)

2.6 Shell-side Heat-transfer Coefficient, hs (Bells Method)

The shell-side heat transfer coefficient is given by:
hs hoc Fn Fw Fb FL

(20)

where,
hoc = heat transfer coefficient calculated for cross-flow over an ideal tube bank, no leakage or
by-passing,
Fn = correction factor to allow for the effect of the number of vertical tube rows,
Fw = window effect correction factor,
Fb = by-pass stream correction factor,
FL = leakage correction factor.
The ideal cross-flow heat transfer coefficient hoc is given by,

h oc d o
j h Re Pr 0.33 ( f w ) 0.14
kf

(21)

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where,
Re

Gs do/ f

us do f / f

Heat-transfer coefficient for an ideal cross-flow tube banks can be calculated using the heat
transfer factors, j h from Figure C.6 in Appendix C.
The correction factor Fn is determined as follows:
a)

For Re > 2000, turbulent, take Fn from Figure C.7

b)

For Re > 100 to 2000, transition region, take Fn = 1.0

c)

For Re < 100, laminar region,

Fn (N c ) 0.18

where N c = numbers of rows crossed in series from end to end of the shell.

The window correction factor Fw is plotted against Rw as shown in Figure C.8 where Rw is the
ratio of the numbers of tubes in the window zones to the total number in the bundle.
The by-pass correction factor Fb is,

A
13
Fb exp b 1 2N s / N cv
As

for N s N cv / 2
(22)

where,

1.5 for laminar flow, Re < 100,

1.35 for transitional and turbulent flow Re > 100

Ab

clearance area between the bundle and the shell

As

maximum area for cross-flow

Ns

number of sealing strips encountered by the by-pass stream

in the cross-flow zone

Ncv

the number of constrictions, tube rows, encountered in the cross-flow

section

If there is no sealing strip used, Fb is obtained from Figure C.9.

The leakage correction factor FL is,
FL 1 L Atb 2 Asb / AL

where

a factor obtained from Figure C.10.

Atb

tube-to-baffle clearance area, per baffle,

(23)

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Asb

shell-to-baffle clearance area, per baffle,

AL

total leakage area, Atb + Asb

3.0 APPARATUS
i.

Shell & Tube Heat Exchanger

Tube O.D. (do)

9.53 mm

Tube I.D. (di)

7.75 mm

Tube Length (L)

500 mm

Tube Count (Nt)

10 (single pass)

Tube Pitch (pt)

18 mm

Tube arrangement

Triangle

Shell O.D.

100 mm

Shell I.D. (Ds)

85 mm

Baffle Count

Baffle Cut (Bc)

20 %

Baffle Distance (lB)

50 mm

Material of Construction :
ii.

iii.

316L Stainless Steel/Borosilicate Glass

Cold Water Circuit

Tank

50 liter

Material

Stainless Steel

Circulation Pump

Centrifugal type

Operating Flow rate

10 LPM (dry-run protected by level switch)

Tank

50 liter

Material

Stainless Steel

Circulation Pump

Centrifugal type

Operating Flow rate

20 LPM (dry-run protected by level switch)

Heating System

11.5

Hot Water Circuit

kW

immersion

type

heater

protected

temperature controller and level switch

iv.

Instrumentations
Measurements of inlet and outlet temperatures for hot water and cold water streams
Measurements of flow rates for the hot water and cold water circuits

v.

Control Panel
To mount all the necessary digital indicators, temperature controller and all switches
To house electrical components and wirings

by

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To house all the necessary data acquisition modules and signal conditioning unit

Figure 2 Schematic Diagram for Heat Exchanger Training Apparatus (Model: HE 158 C)
4.0 PROCEDURES
4.1 General Start-up Procedures
1.

Perform a quick inspection to make sure that the equipment is in a proper working
condition.

2.

Be sure that all valves are initially closed, except V2 and V12.

3.

Fill up hot water tank via a water supply hose connected to valve V27. Once the tank
is full, close the valve.

4.

Fill up the cold-water tank by opening valve V 28 and leave the valve opened for
continues water supply.

5.

Connect a drain hose to the cold water drain point.

6.

Switch on main power. Switch on the heater for the hot water tank and set point the
temperature controller to 50 C.

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Note: Recommended maximum temperature controller set point is 70 C

7.

Allow the water temperature in the hot water tank to reach the set-point.

8.

The equipment is now ready to be run.

4.2 General Shut-down Procedures

1. Switch off heater. Wait until the hot water temperature drops below 50C.
2. Switch off pump P1 and pump P2.
3. Switch off main power.
4. Drain off all water in the process lines. Retain water in the hot and cold water tanks for
next laboratory session.
5. Close all valves.
Note: If the equipment is not to be run for a long period, drain all liquids completely.
4.3 Process Instruments
It is important that the user read and fully understand all the instructions and precautions stated
in the manufacturer's manuals supplied with the unit prior to operating. The following procedures
serve as a quick reference for operating the unit.
1. Temperature Controller
i.

The first line displays the liquid temperature in the tank while the second line
displays the set value. Adjust the set value as follows:

ii.

Press the ENT button, and then press UP or DOWN arrow key continuously until
almost near the desired set value.

iii.

Press UP or DOWN arrow key one by one until desired set value is reached. Notice
that the least digit point is flashing.

iv.

Press ENT to register the data. Notice that the least digit point goes off.

2. Valve Arrangements
Table 1: Valves Arrangement for Flow Selection
OPEN
Counter- V1, V12, V16,
Current V17, V28
CoCurrent

V1, V12, V15,

V18, V28

CLOSE
V15, V18,
V27, V29,
V30
V16, V17,
V27, V29,

LEAVE ALONE
V2, V3, V4 - V11,
V13, V14, V19 V26
V2, V3, V4 V11,
V13, V14, V19

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V30

V26

Table 2: Valves Arrangement for Heat Exchanger Selection

OPEN
Shell & Tube
Heat Exchanger
Spiral Heat
Exchanger
Concentric Heat
Exchanger
Plate Heat
Exchanger

V4, V5, V19, V20

V6, V7, V21, V22
V8, V9, V23, V24
V10, V11, V25,
V26

CLOSE
V6 - V11, V21 - V26
V4, V5, V8 - V11, V19,
V20, V23 - V26
V4 - V7, V10, V11, V19
- V22, V25, V26
V4 - V9, V19 - V24

Valve V3: to vary hot water flow rate

Valve V14: to vary cold water flow rate
Valve V2 and V13: Flow bypass for water pump. These valves should be partially opened
all the time. If the water flow rates are not stable, reduce the bypass.
3. Flow Measurements
FT1: Hot water flowrate
FT2: Cold water flowrate
4. Temperature Measurements
i.

Counter-Current
TT1: Hot water inlet temperature
TT2: Hot water outlet temperature
TT3: Cold water inlet temperature
TT4: Cold water outlet temperature

ii.

Co-Current
TT1: Hot water inlet temperature
TT2: Hot water outlet temperature
TT3: Cold water outlet temperature
TT4: Cold water inlet temperature

5. Operating Limits

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Temperature :

max. 70 C

4.4 Experiment A: Counter-Current Shell & Tube Heat Exchanger

In this experiment, cold water enters the shell at room temperature while hot water enters the
tubes in the opposite direction. Students shall vary the hot water and cold water flow rates and
record the inlet and outlet temperatures of both the hot water and cold water streams at steady
state.
Procedure:
1.

Perform general start-up procedures in Section 4.1.

2.

Switch the valves to counter-current Shell & Tube Heat Exchanger arrangement
(Please refer to Section 4.3).

3.

Switch on pumps P1 and P2.

4.

Open and adjust valves V3 and V14 to obtain the desired flow rates for hot water and
cold water streams, respectively.

5.

Allow the system to reach steady state for 10 minutes.

6.

Record FT1, FT2, TT1, TT2, TT3 and TT4.

7.

Record pressure drop measurements for shell-side and tube-side for pressure drop
studies.

8.

Repeat steps 4 to 7 for different combinations of flow rate FT1 and FT2 as in the
results sheet.

9.

Switch off pumps P1 and P2 after the completion of experiment.

10.

Proceed to the next experiment or shut-down the equipment.

11.

Record relevant data in Table A1 and A2

4.5 Experiment B: Co-Current Shell & Tube Heat Exchanger

In this experiment, cold water enters the shell at room temperature while hot water enters the
tubes in the same direction. Students shall vary the hot water and cold water flow rates and
record the inlet and outlet temperatures of both the hot water and cold water streams at steady
state.
Procedure:
1. Perform general start-up procedures in Section 4.1.

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2. Switch the valves to co-current Shell & Tube Heat Exchanger arrangement (Please refer to
Section 4.3).
3. Switch on pumps P1 and P2.
4. If there is air trap in the shell-side, switch the valves to counter-current and bleed the air with
high water flow rate. Then switch the valves position back to co-current position.
5. Open and adjust valves V3 and V14 to obtain the desired flow rates for hot water and cold
water streams, respectively.
6. Allow the system to reach steady state for 10 minutes.
7. Record FT1, FT2, TT1, TT2, TT3 and TT4.
8. Record pressure drop measurements for shell-side and tube-side for pressure drop studies.
9. Repeat steps 5 to 8 for different combinations of flow rate FT1 and FT2 as in the results
sheet.
10. Switch off pumps P1 and P2 after the completion of experiment.
11. Proceed to the next experiment or shut-down the equipment.
12. Record relevant data in Table B1 and B2
5.0 RESULTS
Table A1Counter-Current Shell & Tube Heat Exchanger
FT 1 (L/min)

FT 2 (L/min)

10
10
10
10
10

2
4
6
8
10

TT 1 (C)

TT 2 (C)

TT 3 (C)

TT 4 (C)

Table A2Counter-Current Shell & Tube Heat Exchanger

FT 1 (L/min)

FT 2 (L/min)

2
4
6
8
10

10
10
10
10
10

TT 1 (C)

TT 2 (C)

TT 3 (C)

TT 4 (C)

Table B1Co-Current Shell & Tube Heat Exchanger

FT 1 (L/min)

FT 2 (L/min)

10

TT 1 (C)

TT 2 (C)

TT 3 (C)

TT 4 (C)

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10
10
10
10

4
6
8
10
Table B2Co-Current Shell & Tube Heat Exchanger

FT 1 (L/min)

FT 2 (L/min)

2
4
6
8
10

10
10
10
10
10

TT 1 (C)

TT 2 (C)

TT 3 (C)

TT 4 (C)

6.0 DISCUSSION
i.

Calculate the heat transfer and heat loss for energy balance study for both experiments A
and B.

ii.

Calculate the LMTD for both experiments A and B.

iii.

Calculate heat transfer coefficients for both experiments A and B.

iv.

Comment on safety and maintenance of the experiment.

v.

Comment on the heat transfer coefficient of the shell and tube heat exchanger.

vi.

Comment on the accuracy of the experiment and ways of improving it.

7.0 REFERENCES
i.

Chopey, N.P. Handbook of Chemical Engineering Calculations (2nd Edition), McGrawHill, 1994.

ii.

Coulson, J.M. and Richardson, J.F. Chemical Engineering, Volume 1 (3 rd Edition),

Pergamon Press, 1977.

iii.

Coulson, J.M. and Richardson, J.F. Chemical Engineering, Volume 6 (Revised 3 rd

Edition), Butterworth-Heinemann, 1996.

iv.

Kern, D.Q. Process Heat Transfer (Intl Edition), McGraw-Hill, 1965.

v.

Perry, R.H., Green, D.W. and Maloney, J.O. Perrys Chemical Engineering Handbook
(6th Edition), McGraw-Hill, 1984.

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8.0 APPENDICES
Appendix A: Heat Transfer Properties of Liquid Water, SI Units

999.6
998.0
996.4
994.7
981.9
962.7
943.5
917.9
858.6

cp(kJ/kg.K
)
4.229
4.187
4.183
4.183
4.187
4.229
4.271
4.312
4.522

k
(W/m.K)
0.5694
0.5884
0.6109
0.6283
0.6629
0.6802
0.6836
0.6836
0.6611

13.3
8.07
5.89
4.51
2.72
1.91
1.49
1.22
0.950

x 103
(Pa.s)
1.786
1.131
0.860
0.682
0.432
0.3066
0.2381
0.1935
0.1384

784.9
679.2

4.982
6.322

0.6040
0.5071

0.859
1.07

0.1042
0.0862

T (C)

T (K)

(kg/m3)

0.0
15.6
26.7
37.8
65.6
93.3
121.1
148.9
204.4

273.2
288.8
299.9
311.0
338.8
366.5
394.3
422.1
477.6

260.0
315.6

533.2
588.8

Appendix B Tube side heat transfer factors

NPr

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Appendix C Shell side heat transfer factors, segmental baffles ample o the required material.

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Result Sample
Table A1 Counter-Current Shell & Tube Heat Exchanger
FT 1 (L/min)

FT 2 (L/min)

10
10
10
10
10

2
4
6
8
10

TT 1 (C)

TT 2 (C)

TT 3 (C)

TT 4 (C)

Table A2 Counter-Current Shell & Tube Heat Exchanger

FT 1 (L/min)

FT 2 (L/min)

2
4
6
8
10

10
10
10
10
10

TT 1 (C)

TT 2 (C)

TT 3 (C)

TT 4 (C)

Table B1 Co-Current Shell & Tube Heat Exchanger

FT 1 (L/min)

FT 2 (L/min)

10
10
10
10
10

2
4
6
8
10

TT 1 (C)

TT 2 (C)

TT 3 (C)

TT 4 (C)

Table B2 Co-Current Shell & Tube Heat Exchanger

FT 1 (L/min)

FT 2 (L/min)

2
4
6
8
10

10
10
10
10
10

TT 1 (C)

TT 2 (C)

TT 3 (C)

TT 4 (C)