EKC 291

CHEMICAL ENGINEERING LABORATORY I

SEMESTER II, 2010/2011

EXPERIMENT 2
SHELL AND TUBE HEAT EXCHANGER

GROUP NUMBER: 9

GROUP MEMBERS:1. CHAI BUI HON (104697)

2. NURSYUHAIDA BINTI MOHAMAD SOBRI (104752)
3. EMILY OOI SHI YUN (104702)

DATE OF EXPERIMENT : 8TH MARCH 2011

DATE OF SUBMISSION : 18TH MARCH 2011

SUPERVISOR : DR. SUZYLAWATI ISMAIL

GA : MUSLINA ABD MAJID
TECHNICIAN : EN. MOHD ISMAIL

TABLE OF CONTENT

No. Contents Page

Page 1 of 30
 1.0 Objective 3

2.0 Theory 3–6

3.0 Experimental Data and Result 7 – 16

4.0 Calculations 17 – 25

5.0 Discussions 25 – 31

6.0 Error Analysis 31

7.0 Conclusion 32

8.0 References 32

1.0 OBJECTIVE

 To calculate heat load and heat balance LMTD (log mean temperature
difference), and overall heat transfer coefficient U.
 To observe the performance of shell and tube heat exchanger for different
volumetric flow rate.
 To determine Reynolds Number for shell side and tube side (turbulent/laminar
flow).
 To determine heat transfer coefficient.

2.0 THEORY

A shell and tube heat exchanger is a class of heat exchanger designs.[1][2] It

is the most common type of heat exchanger in oil refineries and other large

Page 2 of 30
chemical processes, and is suited for higher-pressure applications. As its name
implies, this type of heat exchanger consists of a shell (a large pressure vessel)
with a bundle of tubes inside it. One fluid runs through the tubes, and another
fluid flows over the tubes (through the shell) to transfer heat between the two
fluids. The set of tubes is called a tube bundle, and may be composed by several
types of tubes: plain, longitudinally finned, etc.

Two fluids, of different starting temperatures, flow through the heat exchanger.
One flows through the tubes (the tube side) and the other flows outside the tubes
but inside the shell (the shell side). Heat is transferred from one fluid to the other
through the tube walls, either from tube side to shell side or vice versa. The fluids
can be either liquids or gases on either the shell or the tube side. In order to
transfer heat efficiently, a large heat transfer area should be used, leading to the
use of many tubes. In this way, waste heat can be put to use. This is an efficient
way to conserve energy.

The basic design calculation for any heat exchanger is the determination of
heat transfer area. Most generally, this is done using

although in practice it is more common to assume that fluid properties can be

treated as constant at the bulk average values, and approximate the design
equation with:

Page 3 of 30
 To use this equation, it is necessary to determine the heat transfer coefficient
and the temperature difference. We have seen that for a double pipe heat
exchanger the required average temperature difference is the log mean
temperature difference (LMTD). Unfortunately, the flow patterns in shell and
tube exchangers are such that the LMTD by itself is no longer adequate. It must
first be adjusted by means of a correction factor.

The second parameter that must be calculated for a typical process design is
the pressure drop in the fluids moving through the exchanger.

Correcting the LMTD

The LMTD was developed for a model restricted to parallel and

countercurrent flow patterns. In shell and tube exchangers, the flow pattern is a
mixture of cocurrent, countercurrent, and crossflow, so the LMTD does not
directly apply. Instead, a corrected LMTD must be used. Correction factors
(F correction factors) are tabulated and used to adjust:

The correction factor charts are available from many sources (Levenspiel Fig
13.5-10; Brodkey & Hershey Fig 11.16; MSH6 Fig 15.6). They are based on two
parameters:

These parameters are cross-referenced on the appropriate chart to find the F

factor. A different chart is needed for each exchanger layout (1- 2, 1-4, etc.).
Note that the charts provided in MSH are written using hot and cold subscripts

Page 4 of 30
and assume that the hot fluid is on the shell side of the exchanger. Be careful
and do what is right for your problem.

F factor curves drop off rapidly below 0.8. Consequently, if your design is
indicating an F less than 0.8, you probably need to redesign (add tube passes,
increase temperature differences, etc.) to get a better approximation of
countercurrent flow and thus higher F values.

Similar correction factors are available for exchanger types other than shell and
tube, including crossflow and compact exchangers

In areas of heat exchanger technology, the principles of heat transfer theory

should be applied correctly with the heat exchanger design and operation in
specific cases. It is essential to alter the amount of energy in the system in
rapid, controllable and reliable way. A practical heat exchanger has to fulfill a
number of requirements and the following factors have to be considered:

1. safety– the design and operation of heat exchanger must be safe in dealing
with both normal process condition and any reasonably foreseeable
overload. Some operation should be designed correctly to cope with the
problems of high pressure or temperature or to carry aggressive, corrosive
or explosive materials.
2. reliability– any practical heat exchanger must be reliable in plant and
process economy. Special care must be taken to deal potential corrosion
and fouling problems by eliminating them at the design stage rather than
having to incur extra expense by attempting to rectify them later.
3. capability – heat exchanger must be capable in working not only between
two temperatures i.e. that of the hot and cold stream, but also at specific
rate of heat transfer (removing or adding heat at the required rate).

Page 5 of 30
Page 6 of 30
3.0 EXPERIMENT DATA AND RESULTS

Table 1:
RUN I Set 1 Set 2 Set 3 Set 4
CW HW CW HW CW HW CW HW
Flow, 15 25 15 25 15 25 15 25
USGPM
88.7 143.6 91.4 156.2 95.0 149.0 96.8 150.8
T, IN
111.2 118.4 118.4 123.8 120.2 127.4 122.0 127.4
T, OUT
T 22.5 25.2 27.0 32.4 25.2 21.6 25.2 23.4
change,
˚F 167483.94 310724.97 200835.01 398479.35 187322.89 265788.46 187602.42 287864.08
Q, Head
Load
P, IN 3.8 6.5 3.8 6.4 3.8 6.4 3.8 6.3
P, OUT 1.6 1.3 1.6 1.2 1.6 1.2 1.6 1.2
P 2.2 5.2 2.2 5.2 2.2 5.2 2.2 5.1
Change,
psi

RUN II Set 1 Set 2 Set 3 Set 4

CW HW CW HW CW HW CW HW

Page 7 of 30
Flow, 10 20 10 20 10 20 10 20
USGPM
93.2 152.6 98.6 154.4 102.2 154.4 104.0 154.4
T, IN
122 127.4 127.4 131.0 131.0 132.8 131.0 132.8
T, OUT
T change, 28.8 25.2 28.8 23.4 28.8 21.6 27.0 21.6
˚F
142722.21 247942.72 142582.23 230070.06 142469.78 212322.34 133538.39 212322.34
Q, Head
Load
P, IN 1.2 4.3 1.2 4.3 1.2 4.3 1.2 4.4
P, OUT 0.2 0.5 0.2 0.4 0.2 0.5 0.2 0.3
P Change, 1.0 3.8 1.0 3.9 1.0 3.8 1.0 4.1
psi

RUN III Set 1 Set 2 Set 3 Set 4

CW HW CW HW CW HW CW HW
Flow, 10 15 10 15 10 15 10 15
USGPM
97.7 156.2 102.2 156.2 104.0 156.2 104.9 156.2
T, IN
127.4 129.2 127.4 129.2 129.2 131.0 129.2 131.0
T, OUT

Page 8 of 30
T change, ˚F 29.7 27.0 25.2 27.0 25.2 25.2 24.3 25.2
Q, Head 147050.57 199057.26 124710.26 199057.26 124661.06 185782.05 119712.12 185782.05
Load
P, IN 1.4 2.2 1.4 2.2 1.4 2.2 1.4 2.2
P, OUT 0.4 0.2 0.4 0.1 0.4 0.1 0.4 0.1
P Change, 1.0 2.0 1.0 2.1 1.0 2.1 1.0 2.1
psi

RUN IV Set 1 Set 2 Set 3 Set 4

CW HW CW HW CW HW CW HW
Flow, 10 10 10 10 10 10 10 10
USGPM
105.8 158.0 105.8 156.2 106.7 158.0 106.7 157.1
T, IN
129.2 129.2 127.4 127.4 127.4 127.4 127.4 127.4
T, OUT
T 23.4 28.8 21.6 28.8 20.7 30.6 20.7 29.7
change,
˚F 115733.28 141548.23 106852.34 141614.90 102389.80 150476.37 102389.80 146023.91
Q, Head
Page 9 of 30
Load
P, IN 1.2 0.8 1.2 0.8 1.2 0.9 1.2 0.8
P, OUT 0.2 0 0.2 0 0.2 0 0.2 0
P 1.0 0.8 1.0 0.8 1.0 0.9 1.0 0.8
Change,
psi

RUN V Set 1 Set 2 Set 3 Set 4

CW HW CW HW CW HW CW HW
Flow, 6 10 6 10 6 10 6 10
USGPM
95.9 157.1 107.6 156.2 112.1 158.0 113.0 158.0
T, IN
122.0 125.6 129.2 132.8 134.6 136.4 138.2 138.2
T, OUT
T 26.1 31.5 21.6 23.4 22.5 21.6 25.2 19.8
change,
˚F 77586.76 154908.75 64085.46 114981.99 66685.37 106066.41 74654.29 97200.72
Q, Head
Load
P, IN 0.1 0.8 0.1 0.7 0.1 0.7 0.1 0.7
P, OUT 0.1 0 0.1 0 0.1 0 0.1 0
P 0 0.8 0 0.7 0 0.7 0 0.7

Page 10 of 30
Change,
psi

Table 2: Calculation of Heat Load, LMTD and from PART 1

QH QC Qavg LMTD x FT U
RUN SET
(BTU/hr) (BTU/hr) (Btu/hr) (˚F) (BTU/hr.ft2 ˚F)
I. 4 287864.08 187602.42 237733.25 27.02 279.31
II. 3 212322.34 142469.78 177396.06 23.63 238.43
III. 2 199057.26 124710.26 161883.76 24.26 211.84
IV. 1 141548.23 115733.28 128640.76 22.63 180.46
V. 3 106066.41 66685.37 86375.89 21.70 126.34

Table 3:
Part II: Reynolds Numbers

RUN For CW
Ws Gs µ Re(s)
(lbm/hr) (lbm/hr.ft2) (lbm/ft.hr)
I 7456.17 257109.31 1.4539 7727.96
II 4953.16 170798.62 1.3541 5512.07
III 4955.36 170874.48 1.3780 5418.88
IV 4952.06 170760.69 1.3424 5558.88
V 2967.03 102311.38 1.2706 3518.82
Page 11 of 30
 RUN For HW
Ws Gs µ Re(t)
2
(lbm/hr) (lbm/hr.ft ) (lbm/ft.hr)
I 12307.55 575388.03 1.1066 21448.36
II 4915.51 229804.11 1.0663 8890.01
III 7375.51 344811.13 1.0741 13242.21
IV 4915.51 229804.11 1.0663 8890.01
V 4909.50 229523.14 1.0358 9140.60

Part III: Heat Transfer Coefficient

For Shell Side:

For Shell Side:

　 Tavg µ k µw 　 　 　 　
RUN (0F) (lbm/ft.hr) (BTU/ (lbm/ft.hr) Re(s) jH a h0

Page 12 of 30
　 　 　 hrft0F) 　 　 　 　 　

1 109.4 1.4539 0.36778 1.1066 7727.96 31 424.4326203 2574.183842

2 116.6 1.3541 0.37045 1.0663 5512.07 22 213.3449702 1293.937244

3 114.8 1.378 0.36979 1.0741 5418.88 21 282.5021065 1713.375276

4 116.6 1.3541 0.37045 1.0663 5558.88 20 266.4743088 1616.166683

5 123.35 1.2706 0.37282 1.0358 3518.82 15 194.8386613 1181.696481

For Tube Side:

　 Tavg µ k µw 　 　 　 　
RUN (0F) (lbm/ft.hr) (BTU/ (lbm/ft.hr) Re(t) jH b hio
　 　 　 hrft0F) 　 　 　 　 　

1 139.1 1.1066 0.37796 1.4539 21448.36 79 931.6153149 737.8393294

2 143.6 1.0663 0.37923 1.3541 8890.01 60 712.5299875 564.3237501

3 142.7 1.0741 0.37897 1.3780 13242.21 49 575.0603791 455.4478202

4 143.6 1.0663 0.37923 1.3541 8890.01 36 422.2639231 334.4330271

Page 13 of 30
5 147.2 1.0358 0.38027 1.2706 9140.60 35 412.2347662 326.4899349

Comparison of Uc, UD and RD

RUN Uc UD RD

(Btu/hr.ft2.ºF) (Btu/hr.ft2.ºF) (hr.ft2.ºF/Btu)

I 573.47 279.31 0.001836

II 392.95 238.43 0.001649
III 359.80 211.84 0.001941
IV 255.81 180.46 0.001632
V 252.70 126.34 0.004572

Page 14 of 30
4.0 CALCULATION

For all the calculations in Part I, Part II and Part III are based on Set 1 in the data
table for all 5 run.

PART I

(i) Heat Load and Heat Balance

For HW :

 BTU   Ibm   BTU 

QH   = FH   x specific heat   x (t2 – t1) 0F
 hr   hr   hr 

For CW :

 BTU   Ibm   BTU 

QC   = FC   x specific heat   x (T2 – T1) 0F
 hr   hr   hr 

Where,
T1 = inlet temperature of CW
T2 = outlet temperature if CW
t1 = inlet temperature of HW
t2 = outlet temperature of HW

For Cold Water:

From Fluid Preperties calculator, specific heat of water at 104.9

Specific heat of water, Cp =

Take RUN 1 SET4 (CW) as example:

From the fluid properties calculator, the density at 109.4 ,

density, ρ = 992.84 kg/m3

Page 15 of 30
Flow rate of cold water,

USgal min kg 1Ibm 0.001m 3

FC = 15 x 60 x 992.84 3 x 0.4536kg x
min hr m 0.2642USgal

= 7456.17 Ibm/h

QC = FC x Cp x T

= 7456.17 lbm/hr x 0.99844 Btu/lbmoF x 25.2 oF

= 187602.4 Btu/hr

For Hot Water:

From Fluid Properties calculator, specific heat of water at 140.0 ,

Specific heat of water, Cp =

Take RUN 1 SET4 (HW) as example:

From the fluid properties calculator, the density at 139.1 ,

density, ρ = 983.3kg/m3

Flow rate of hot water,

USgal min kg 1Ibm 0.001m 3

FH = 25 x 60 x 983.3 3 x 0.4536kg x
min hr m 0.2642USgal

= 12307.54 Ibm/hr

QH = FH x Cp x T

= 12307.54 lbm/hr x 0.99954 Btu/lbmoF x 23.4 oF

Page 16 of 30
 = 287864.08 Btu/ hr

(ii) LMTD

t1 = inlet temperature of hot water= 156.2 ºF

t2 = outlet temperature of hot water= 123.8 ºF
T1 = inlet temperature of cold water= 91.4 ºF
T2 = outlet temperature of hot water= 118.4 ºF

= [(150.8-122.0) - (127.4-96.8)] / [ln (150.8-122.0)/(127.4-96.8)]

= 29.69 oF

T1  T 2
R=
t 2  t1

= (96.8-122.0) / (127.4-150.8)

= 1.077

t 2  t1
S=
T 1  t1

= (127.4-150.8) / (96.8-150.8)

= 0.433

From Figure 10-8, page 534 of Heat Transfer by J.P. Holman.

So,FT = 0.91 Thus,

LMTD x FT ( corrected ) = 0.91 x 29.69oF

= 27.02 oF

Page 17 of 30
 (iii) Overall heat transfer Coefficient

Total heat transfer area, A = 31.50 ft 2

QH  QC
Qav=
2

= (287864.08 + 187602.42)/2

= 237733.25 Btu/hr

1 1
Overall heat transfer coefficient,U = Q x x
A LMTD * FT

1
= 237733.25 Btu/hr x 31.50 ft 2 x 1/27.02

= 279.31 (Btu/hr.ft2.oF)

Part II: Reynolds Number

(i) Shell-side Re(s) , for cold water, CW :

For example, data from RUN I SET 4 is used.

De  Gs
Re(s) = 

Given that,

PT = pitch = 0.81 ins

4[(1/2)PT x 0.86PT  (1/2)π (d o2 /4)]

de =
(1/2)π d o

4[(1/2) 0.81 x 0.86(0.81)  (1/2)π (0.625/4)]

=
(1/2)π x 0.625

= 0.5244 ins

de
De =
12

0.5244
= ins
12
Page 18 of 30
 = 0.0437 ins

Shell ID x Clearance x Baffle Space

As =
PT x 144

6.065 , x 0.1875 ,, x 3 ,,
=
0.81,, x 144

= 0.029 ft2

Ws = flow rate of cold water in Ibm/hr

= 7456.17Ibm/hr

From Fluid Properties Calculator,

µ= viscosity taken at the average fluid temperature in the shell( T avg =109.4ºF )

= 1.4539 lbm / fthr

De.Gs
Re(s) = μ

Ws
De.( )
= As
μ

7456.17
0.0437.( )
= 0.029
1.4539

= 7727.96

(ii) Tube-side Re(t) for hot water,HW:

De  Gt
Re (t) = 

Given that,

D = Tube Internal Diameter,ID

Page 19 of 30
 = 0.04125 ft

No. of tubes  flow area per tube

At = No of tube passes

32  0.1924 ft 2
=
2  144

= 0.02139 ft2

Wt= flow rate of hot water in Ibm/hr

= 12307.55Ibm/hr

From Fluid Properties Calculator

µ= viscosity taken at the average fluid temperature in the shell (T avg = 139.1
ºF)

= 1.1066 Ibm/ft.hr

D.Gt
Re(t) = μ

Wt
D.( )
= At
μ

12307.55
0.04125.( )
= 0.02139
1.1066

= 21448.36

Part III: Heat Transfer Coefficient

(i) For shell side

Water properties at Tavg = 109.4 ºF, from fluid properties calculator

µ = 1.4539 Ibm/ft.hr

Page 20 of 30
k = 0.36778 Btu/hr.ft.ºF

cp = 0.97115 Btu/Ibm.ºF

µw = viscosity at average wall temperature, Tw=139.1 ºF

= 1.1066 Ibm/ft.hr

From figure 24, pg. 25, [c], when Re(s)=7727.96 , jH = 31,

a.De ( c p . μ) -1/3 [ (  ) ] -0.14

jH = x x
k k -1/3 [ (μ w ) ]-0.14

a.0.0437 ( 0.97115 x 1.4539) -1/3

[ ( 1.4539) ] -0.14
31 = x x
0.36778 0.36778 -1/3 [ (1.1066) ] -0.14

a = 424.4326203

Therefore,

ho = a x ID

= 424.4326203x 6.065 Btu/hr.ft2.ºF

= 2574.18 Btu/hr.ft2.ºF

(ii) For tube side

Water properties at Tavg = 139.1 ºF, from fluid properties calculator

µ = 1.1066 Ibm/ft.hr

k = 0.37796Btu/hr.ft.ºF

cp = 0.97091 Btu/Ibm.ºF

µw = viscosity at average wall temperature, Tw = 109.4 ºF

= 1.4539 Ibm/ft.hr

From figure 24, pg. 25, [c], when Re(s)= 20309.74, jH = 79,
Page 21 of 30
 b.De ( c p . μ) -1/3 [ (  ) ] -0.14

jH = x x
k k -1/3 [ (μ w ) ]-0.14

b.0.0437 ( 0.97091 x 1.1066) -1/3

[ ( 1.1066 ) ] -0.14
79 = x x
0.37796 0.37796 -1/3 [ (1.4539) ] -0.14

b = 931.62

Ttherefore,

b x ID
hio =
OD

931.62 x 0.495
=
0.625

=737.84 Btu/hr.ft2.0F

h io x h o
For clean overall heat transfer coefficient, Uc =
h io  h o

737.84 x 2574.18
=
737.84  2574.18

= 573.47 Btu/hr.ft2.ºF

Uc  UD
Rd =
UC x UD

573.47  279.31
=
573.47 x 279.31

= 0.001836 hr.ft2.ºF/Btu

5.0 DISCUSSION

a. Discuss the performance of the Heat Exchanger to heat 15 USGPM of CW using 25 USGPM of
HW.
RUN SET QH QC Qavg
Page 22 of 30
 (BTU/hr) (BTU/hr) (Btu/hr)
I. 4 287864.08 187602.42 237733.25
II. 3 212322.34 142469.78 177396.06
III. 2 199057.26 124710.26 161883.76
IV. 1 141548.23 115733.28 128640.76
V. 3 106066.41 66685.37 86375.89

The performance of the heat exchanger to heat 15 USGPM of CW using 25

USGPM of HW is the first run which is RUN I. From the table, it can be
conclude that the heat transfer for the RUN I is the highest among the others
as highest flow rate is used if we compare with other RUN with lower flow rate.

Heat load, Q = Flow rate x Specific heat x Temperature difference

The heat energy contained in the water is the highest for RUN I. This explains
that for RUN 1, the performance of heat exchanger as well as heat transfer
rate is better and higher if compared to the others.

b. Similarly comment on the performance of the Heat Exchanger to heat

 About 10 USGPM of CW, using about to 10 to 20 USGPM of HW.
QH QC Qavg
RUN SET
(BTU/hr) (BTU/hr) (Btu/hr)
II. 3 212322.34 142469.78 177396.06
III. 2 199057.26 124710.26 161883.76
IV. 1 141548.23 115733.28 128640.76

For 10 USGPM of CW, using about to 10 to 20 USGPM of HW it is

RUN II,III and IV. From the table it can be said that RUN II have the highest
QH and QC and the lowest is RUN IV as the volumetric flow rate for the RUN
II is 20 USGPM and the flow rate for RUN III and RUN IV is 15 USGPM and
10 USGPM respectively. Heat transfer will be decreased as less amount of
hot water is being used to heat the same amount of cold water. When the
volumetric flow rate of hot water decreases from 20 to 10 USGPM, it is
observed that the temperature difference for the hot water is increasing, this

Page 23 of 30
 kind of situation can be explained that when the area of heat transfer for hot
water ( tube ) is constant, increasing volumetric flow rate will provide high
velocity to the hot water.

 About 6 USGPM of CW, using only about to 10USGPM of HW.

QH QC Qavg
RUN SET
(BTU/hr) (BTU/hr) (Btu/hr)
IV. 1 141548.23 115733.28 128640.76
V. 3 106066.41 66685.37 86375.89

The volumetric flow rate for both RUN are the same which is 10 USGPM
but the only difference is the volumetric flow rate for the cold water. The
flow rate for RUN IV is 10 USGPM and for RUN V is 6 USGPM. Heat
produced by RUN V is lower compared to RUN IV. The heat load for cold
water, Qc experience a sudden drop followed by decrease of volumetric
flow rate of cold water. This is because there is less cold water that needs
to be heated by the same amount of hot water. The performance is still low
due to its low flow rates.

c. Amount of heat transfer from one fluid stream to another is usually

accomplished by varying the flow rate of one of the stream. Thus to
maintain the outlet temperature of HW at a certain temperature despite
its flow rate or temperature variation, the flow rate of CW is varied
accordingly. Since the heat transfer area of the Heat Exchanger is fixed,
the heat transfer equation Q = U.A.LMTD, requires that Q be varied by
changing U and LMTD. This means that changing the flow rate of CW to
control cooling is actually an exercise to change “internally” U and
LMTD. Is U and LMTD in TABLE 2 expected to be constant then?

The values of overall heat transfer coefficient, U and log mean temperature
difference, LMTD are not expected to remain constant in the variation of
temperature and flow rate.

Overall heat transfer coefficient, U

Page 24 of 30
 Varying Reynolds number, Red caused by the changing flow rate directly
changes the value of U. Thus, the values of heat transfer coefficient, h will
also change, and the value of U which is dependent of h will vary directly.
Correlation between h and Red is shown below:

hd d 1/3 μ 0.14
Nud = = 1.86( RedPr )1/3 ( ) ( )
k L μw

Log Mean Temperature Difference, LMTD

Based on the equation of the log mean temperature difference, the value of
LMTD will be altered definitely as LMTD depends on the inlet and outlet
temperature of cold and hot water.

d.
 At what flow rate of HW is the flow in the tube laminar? What is the
effect laminar flow on its heat transfer coefficient, h i?

For laminar flow, when Reynolds number, Re is less than 2100. So, in hot
water

µ = 1.1066 lbm / fthr (From Run I, set 4)

Re (t) < 2100

Gt  d
μ
< 2100

Wt
( )d
At < 2100
μ

Wt  d
At  μ
< 2100

Page 25 of 30
 Wt  0.04125 ft
< 2100
0.02139 ft 2  1.1066 lbm/ft.hr

Wt < 1205.03 lbm/hr

Therefore, the volumetric flow rate of hot water should be less than
1205.03 lbm/hr to achieve the laminar flow. Heat transfer coefficient, h i will
decrease in the laminar flow. This is due to low flow rate of the laminar
flow will result in small value of Reynolds number, Re d and as a result, the
value of hi will also decrease.

 Comment similarly on the shell side.

For laminar flow, when Reynolds number, Re is less than 2100. Applying
the same formula so, in cold water

µ = 1.4539 lbm / fthr (From Run I, set 4)

Re(s)< 2100

Gs.De
μ
< 2100

Ws
( ).De
As < 2100
μ

Ws.De
As.μ
< 2100

Ws.0.0437 ft
< 2100
0.029 ft 2 x1.4539 lbm/ft.hr

Ws < 2026.14 lbm/hr

So, the volumetric flow rate of hot water should be less than 2026.14
lbm/hr to achieve the laminar flow. Similar to the condition of laminar flow
in tube, the heat transfer coefficient will also decrease in the laminar flow.

Page 26 of 30
e. Compare the Tube-side and Shell-side pressure drop calculated with the
pressure gauges reading. Discuss the discrepancies, taking note in
particular what the pressure gauges actually measures.
The pressure drop calculated is larger for tube-side comparing to shell-side
because pressure drop is proportional to temperature. The temperature
changes of inlet and outlet that have a larger range will result in high pressure
drop of hot water. From the table, water flow rate in RUN l is the highest, thus
the pressure drop is relatively larger than the other RUN partly due to higher
force in forward direction which creates the same resistance force against
fluid.

f. Compare the clean and dirty overall heat transfer coefficient, U C and UD
using their rations in the form of the Dirty Factor, R d. What should be
done if Rd does not exceed the recommended value of 0.003 for water.
RUN Uc UD RD

(Btu/hr.ft2.ºF) (Btu/hr.ft2.ºF) (hr.ft2.ºF/Btu)

I 573.47 279.31 0.001836

II 392.95 238.43 0.001649
III 359.80 211.84 0.001941
IV 255.81 180.46 0.001632
V 252.70 126.34 0.004572

From the table, it showed that Uc in all the 5 RUNs are larger than UD, and all
the values are under the recommended value of 0.003 hr.ft 2.ºF/Btu except
Run V. The range for RUN I until RUN IV is between 0.001632 to 0.001836
except for RUN V which is 0.004572. Usually, after long period of operation,
inner surface of heat exchanger maybe coated with various sediments in the
flow system resulting from the interaction between the fluid and the material
constructed. The heat transfer and the performance of that heat exchanger
maybe effected by the thermal resistance of the system which is relatively
high. If Rd does not exceed 0.003, its value can be raised by reducing the
value of UD. UD can be reduced by reducing the flow rates of CW and HW. So
flow rates should be reduced if Rd does not exceeds the recommended value
of 0.003 for water.

Page 27 of 30
 g. If 25 USGPM of HW at 55ºC can heat 15 USGPM of CW by 10ºC from 33ºC
to 43ºC, it does not necessarily mean that it can also heat 15 USGPM of
CW by 10ºC from 45ºC to 55ºC. Discuss and comment why not?
Change of temperature will alter properties of water such as density, ρ and
specific heat, cp. From Appendix A table A-9, Heat Transfer Tenth Edition by
J.P.Holman, at higher temperature (T= 55 ºC - 45 ºC), c p of water is higher than
that in lower temperature (T= 55ºC - 33 ºC).

[Heat load = flow rate  specific heat of water  temperature difference]

Hence, 25 USGPM of hot water at 55°C can heat 15 USGPM of cold water by
10°C from 33°C to 43°C. More heat is needed to heat the same amount of cold
water at higher temperature because cp is increase when the temperature is
increase. So, it does not mean that it can also heat 15 USGPM of cold water
by 10°C from 45°C to 55°C.

h. The recommended U values for water/water heat exchanger is 150

Btu/hr.ft2.ºF. Is this value conservative enough for design purpose.
For design purpose ,the recommended U values is not enough and
should be higher. When we conducting the experiment by operate the heat
exchanger, there might be a lot of uncertainty occurs and also error. For
example, the friction in the flow of hot water and cold water, the U values
should be higher as the increasing of the U values will increase the heat
transfer. It is because not all heat will fully transfer to the cold water.

6.0 ERROR ANALYSIS

From the results, the calculated value of QH and QC are not the same in all the
five RUNs. Thus, it can be concluded that some errors might have occurred
during the experiment. The errors are as following:

 Some readings of temperature and pressure might not be taken

simultaneously because of the timing’s problem and this caused some
inaccuracy in the data taken.

Page 28 of 30
  Parallax error happened when taking the readings of temperature and
pressure.

 The pressure and the temperature shown on the meter is not stable, suppose
the needle should stop at one reading, but it keeps moving up and down.

 Presence of water bubbles in the shell and tube heat exchanger affect the
efficiency as well.

7.0 Conclusion
From this experiment, we observe that the pressure drop vary with different flow
rates of both hot water and cold water and pressure drop increases with
increasing flow rate of water. Theoretically, the value of QC should be the same
as QH because heat loss from hot water should be fully absorbed by cold water.
However, the value are not the same because there are some heat lost from hot
water to the surroundings. Besides, from the experiment, the values of ‘clean’
overall heat transfer coefficient UC is generally bigger than the values of ‘dirty’
heat transfer coefficient UD. It shows that the efficiency of shell and tube heat
exchanger actually is not 100% due to various factors such as friction in the
water flow and the corroded contact surface inside the heat exchanger .Other
than that, heat load (Q), overall heat transfer coefficient (U) and log mean
temperature difference (LMTD) will not achieve constant value in each RUN
because the heat transfer is dependent on varies factors such as viscosity,
density, flow rate, temperature, heat transfer area, thermal conductivity and
specific heat.

8.0 REFERENCES

 J. P. Holman, “Heat Transfer”, Eighth Edition, McGraw-Hill, International

Edition 1997.

Page 29 of 30
 Lab Module EKC 291 Chemical Engineering Laboratory II, Semester II
Session 2010/2011.
 Website: http://www.cbu.edu/~rprice/lectures/stcalcs.html

 Website: http://www.mhtl.uwaterloo.ca/old/onlinetools/airprop/airprop.html
 Website: http://en.wikipedia.org/wiki/Shell_and_tube_heat_exchanger

Page 30 of 30