Mapúa University

School of Chemical, Biological, and Materials

Engineering and Sciences

Experiment 2
Shell-and-Tube Heat Exchanger

by
Badillo, Allyssa Sophia
(Note: Introduction and Methods are collectively written by G05)

Submitted in Partial Fulfillment of the Requirements for

Chemical Engineering Laboratory (CH142L)

Engr. Peter Matthew Paul Fowler

April 2022
Abstract
A shell and tube heat exchanger (STHE) is a heat exchanging equipment or device that is
customarily made up of a large cylindrical shell or enclosure that is composed of accurately spaced
tubing that are compacted in its interior. In an STHE sets two fluids in thermal contact through the
utilization of the tubes that are situated within the outer cylindrical cell. The tubes direct the fluid
from their inlet to their outlet while the shell simultaneously passes a separate fluid on the shell-
side flow. Moreover, there are three (3) STHE flow types namely the parallel flow, the
countercurrent flow, and the crosscurrent flow. In the experiment the parallel and crosscurrent
flow are employed. Specifically, it is the aim of the experiment to determine the effects of varying
inlet hot water temperatures, hot water and cold water flowrates for the countercurrent flow set-
up. Meanwhile, it is the objective to determine the effects of varying the inlet hot water temperature
in the parallel flow set-up. In terms of the methods, the WL 110 Heat Exchanger Supply Unit was
employed. Distinctively, the primary set-up of the experiment is comprised of a heater, heat
exchanger, and a software in which the flow rates of the hot and cool water can be adjusted, and
the temperature of the water can be determined. From the obtained data, it is found out in this
experiment that in the countercurrent flow, the outlet temperature of the cold water is able to
approach the highest temperature of the how water fluid’s inlet temperature. Also, this flow allows
a near uniform temperature difference between the two involved fluids which leads to lesser
thermal stress in the heat exchanger. Contrastingly, in the parallel set-up, there is a large
temperature difference at the ends which can lead to large thermal stresses. In addition, the
expansion and contraction that opposes each other due to the large difference in the fluid
temperature can lead to material or equipment failure. Also, it is surmised that in the countercurrent
set-up of the countercurrent set-up, there is a direct proportionality between the T1 and the LMTD
as well as the T1 and Mean Temperature Efficiency. The same linear and proportional relationship
can as well be deemed in the parallel set-up with the same parameters. On the other hand, F1 and
LMTD are inversely proportional to one another. However, in varying the cold water flow rate, it
is found out that F2 and LMTD are directly proportional. Lastly, with regards the mean
temperature efficiency, an inverse relationship was observed for F1 vs. Mean Temperature
Efficiency and F2 vs. Mean Temperature Efficiency.

Keywords: STHE, Shell-and-Tube, Heat Exchanger, Countercurrent Flow, Parallel Flow

1. Introduction
A shell and tube heat exchanger (STHE) is a heat exchanging equipment or device that is
customarily made up of a large cylindrical shell or enclosure that is composed of accurately spaced
tubing that are compacted in its interior [1]. Generally, an STHE sets two fluids in thermal contact
through the utilization of the tubes that are situated within the outer cylindrical cell. The tubes
direct the fluid from their inlet to their outlet while the shell simultaneously passes a separate fluid
on the shell-side flow [2]. Moreover, the number of tubes is referred to as the tube bundle; the
surface area exposed to the shell-side flow is dependent on this. At the same time, it is the
determinant of the amount of heat transferred [2].
STHEs are common in oil refineries or large chemical processes given its ability to sustain
higher-pressure applications. Additionally, STHEs are capable of removing the process heat and
feed water preheating, the cooling of lube and hydraulic oil, the cooling of engines, turbines, and
compressors, and the condensing and evaporating of process vapor or stream and liquid or stream,
respectively [3]. Given its various advantages, STHEs are widely applied by numerous industries
to ensure cost-effective yet efficient processes in a plant.
Distinctively, STHEs are composed of six (6) primary parts: the tubes, the tubesheet, the
shell and shell-side nozzles, the tube-side channel and nozzles, the baffles, and the tie rods [4].

Figure 1. STHE Schematic Diagram [4]

Figure 1 presents the schematic diagram for the basic components of an SHTE. The
elaboration regarding the parts of an STHE is accounted in the succeeding paragraphs:

Tubes. Tubes provides the heat transfer surface in between the fluid that flows inside the
tube and the other fluid that flows across the exterior of the tube. Tubes of an STHE can either be
welded or seamless and are conventionally made up of copper, nickel, or steel alloys.

Tubesheets. The tubesheets are where the tubes are held in place. Specifically, it prevents
the shell-side fluid from mixing with the other fluid on the “tube-side”. In figure 2, a double
tubesheet that stops the mixing of the fluids is exhibited.
 Figure 2. Double-type Tubesheet [4]

Shell and Shell-side Nozzles. The shell is the container for the fluid in the shell-side.
Furthermore, the shell-side nozzles are simply the inlet and outlet ports. The shell usually has a
circular cross-section and is made up by a rolled metal plate.

Tube-side Channel and Nozzles. The tube-side channels take control of the tube-side fluid
flow. It is regarded that tube-side fluid is more corrosive [4]. Henceforth, the channels and nozzles
in the tube-side are made up of alloy materials that are compatible with the tubes and the tubesheet.

Pass Dividers. A pass divider is necessary in one channel for an exchanger that has two
tube-side passes. In multi-pass exchangers, pass dividers are arbitrarily used to provide the
approximate number of tubes for every pass, to minimize the pressure difference, to minimize the
numbers of tubes lost from the count, and to set an adequate surface bearing for the gasket.

Baffles. Baffles support the tubes for them to be set in a proper position during the assembly
or the operation itself. The baffles intercept the tube vibration that are caused by eddies.
Additionally, they serve as a guide for the shell-side across the tube field given that it increases
the heat transfer coefficient and velocity. Moreover, they maintain proper tube spacing in the
STHE. Figure 4 shows segmental baffles (a segment is a baffle cut that allows the parallel flow of
fluid to the tube axis as it flows from one space of baffle to another).

Figure 3. Segmental Baffles

 Tie Rods. Tie roads are normally used to hold together the baffle assembly while
maintaining the chosen baffle spacing. The tie rods are fixed at one end to the lllast baffle and at
one end to the tube sheet (as presented in Figure 4).

Figure 4. Tie Rods

On the other hand, there are four (4) types of STHE as indicated by the Tubular Exchangers
Manfacturers Association (TEMA) and are divided into three (3) categories which are Class B,
Class C, and Class R. The aforesaid TEMA categories for an STHE are Class B Chemical
Processing, Class C General Commercial Applications, and Class R Petroleum and Large-Scale
Applications [5].

Aside from STHE types, there are also different types of flow for the involved fluid in an
STHE. There are three (3) STHE flow types namely the parallel flow, the countercurrent flow, and
the crosscurrent flow. These flows are described as follows [5]:

Parallel Flow. In a parallel flow, the shell and tube sides both enter the STHE at the same
end and consequently flow straightforwardly to the opposite end. In this flow type, the change in
temperature is the same for the involved fluids.

Figure 5. Parallel Flow

 Counter Flow. A counter flow is when the fluids enter the STHE at opposite ends and are
flowing in opposite directions. Given this, the discharge also take place at opposite ends. This is
considered as the most efficient type to use in an STHE.

Figure 6. Counter Flow

Cross Flow. In a cross flow, the fluids move perpendicularly (in a 90𝑜 angle) to each other.
In this flow type, one of the fluids changes its state and is absorbed by the fluid that is held in the
liquid state.

Figure 7. Cross Flow

In a theoretical aspect, STHEs generally revolve around the following equation:

𝑄 = 𝑈 × 𝐴𝑜𝑣𝑒𝑟𝑎𝑙𝑙 × 𝐿𝑀𝑇𝐷
Where Q is the overall heat transfer rate, U is the overall heat transfer coefficient, Aoverall
is the overall heat transfer surface area, and LMTD is the logarithmic mean temperature difference.
LMTD is the average quantified value of the temperature difference between the shell and tube
sides. It is calculated by the equation:
∆𝑇1 − ∆𝑇2
𝐿𝑀𝑇𝐷 =
∆𝑇
ln (∆𝑇1 )
2

Where ∆𝑇1 is the temperature difference at one end of the heat exchanger between hot and
cold fluids while ∆𝑇2 is the temperature difference at the other end. However, this equation is only
valid for 1,1-STHE. If the STHE have multiple shell and tube passes, a correction factor is used
which is represented by 𝐹𝑇 in the following equation:
∆𝑇1 − ∆𝑇2
𝐿𝑀𝑇𝐷 = × 𝐹𝑇
∆𝑇
ln (∆𝑇1 )
2
 Another important parameter in STHE is the heat transfer area required. This represents
the total number of tubes needed which can be seen in the equation:
𝐴𝑜𝑣𝑒𝑟𝑎𝑙𝑙
𝑁𝑇 =
𝜋 × 𝑂𝐷 × 𝐿
Where OD is the outside diameter of the chosen tube size and L is the total tube length.
Moreover, Reynolds number can be estimated using the tube side velocity. The tube side velocity,
𝑉𝑇 , is represented by the equation:
𝑁
4𝑚 (𝑁𝑃 )
𝑇
𝑉𝑇 =
𝜋 × 𝜌 × 𝐼𝐷2
Where M is the mass flow rate on the tube side, 𝑁𝑃 and 𝑁𝑇 is the number of tubes passes
and number of tubes respectively, 𝜌 is the tube side fluid density, and ID is the internal diameter
of the tube. Given the parameters mentioned above, the Reynold’s number for the tube side fluids
can be estimated as:
𝑁
4𝑚 (𝑁𝑃 )
𝑇
𝑅𝑒 =
𝜋 × 𝜇 × 𝐼𝐷
Where 𝜇 is the viscosity for the tube side fluid. Knowing the values for 𝐴𝑜𝑣𝑒𝑟𝑎𝑙𝑙 and LMTD,
the only missing value to calculate the overall heat transfer rate is the overall heat transfer
coefficient U. This can be computed by:
1 1 𝐴𝑜 𝑂𝐷 − 𝐼𝐷 𝐴𝑜 1 𝐴𝑜
= [ + 𝑅𝑑𝑜 + ( )+ ( )+ 𝑅 ]
𝑈 ℎ𝑜 𝐴𝑖 2𝑘𝑤 𝐴𝑖 ℎ𝑖 𝐴𝑖 𝑑𝑖
Where ℎ𝑜 , ℎ𝑖 , 𝑅𝑑𝑜 and 𝑅𝑑𝑖 represents the shell side and tube side heat transfer coefficient
respectively, OD is the outer diameter for the chosen tube size while ID is for the inner diameter.
Ao and Ai are the outer inner surface are values for the tubes and kw is the value of the tube wall’s
resistance.
With the background of an STHE laid out, the objectives sought after for this experiment are the
following:
For the counter flow set-up
1. Determine the effects of varying hot water temperature (inlet).
2. Determine the effects of varying hot water flow rate.
3. Determine the effects of varying cold water flow rates.
For the parallel flow set-up,
1. Determine the effects of varying hot water temperature (inlet).
 2. Methodology

This section tackles the set-up, methods, and controls utilized for the STHE experiment. The
methodology for this experiment is based on the video lectures for this experiment’s materials.

2.1. Operating the STHE

1. Starting the Heat Exchanger

Figure 8. Set-up of the experiment

Figure 9. Inside Parts of Heater

 Figure 10. STHE Software

As shown in Figure 8, a Shell and Tube Heat Exchanger was used in the experiment to
determine the effects of varying flow rates and inlet temperatures of fluids in parallel and
counterflow heat exchangers. The main set-up of the experiment consists of a heater, heat
exchanger, and software in which the flow rates of the hot and cool water can be adjusted, and the
temperature of the water can be determined. As shown in Figure 9, the Heater consists of a
temperature sensor, coil, liquid level sensor, and holes where hot water's heating process and
recirculation occur. Specifically, a large coil is used as a heating element up to the set point
temperature. A small tube is utilized as temperature sensor and a liquid level controller tells the
level of the liquid. A liquid level controller needs to float to tell whether the amount of liquid inside
the heater is enough, otherwise it will not function. Distilled water is commonly used fluid in the
Heater to avoid biofouling and scaling. To begin with, start the equipment by setting the
temperature of hot water in the control panel. Hot water is the tube inlet hot fluid, while the cooler
hot fluid goes back to the container for recirculation of water, and the cold fluid is the shell inlet
fluid, while the cooler fluid is discarded in the sink. After adjusting the desired temperature and
fluid flow rates, the cold fluid in the heat exchanger will reach its steady state, located in the control
panel.
2.2. Parallel Flow
2.2.1. Varying Hot Water Temperature (Inlet)
The simulation employed varied hot water temperatures to see how the input temperature
influences the operation of the STHE. To do this, the STHE must be appropriately assembled to
mimic variable temperatures, with the cold and hot input pipes connected to the same sides or in a
parallel arrangement. Change the input temperature via the Temperature Controller (TIC) by
pushing the upward and downward buttons, increasing and decreasing the temperature. By doing
so, the heating coil changes its temperature, heating the distilled water inside the tank. The new
inlet temperatures for this experiment were set at 40°C, 50°C, and 60°C, with a 10°C gap. After
setting the new temperature, wait for it to reach the setpoint before turning on the pump. After that,
examine the changes in the data and their implications.
2.3. Countercurrent Flow
2.3.1. Varying Hot Water Temperature (Inlet)
To simulate how varying hot water inlet temperature in a countercurrent flow arrangement
affects the operation of the STHE, assemble the STHE correctly. Place the cold inlet pipes and hot
outlet pipes on the same side. Change the input temperature via the Temperature Controller (TIC)
by pushing the upward and downward buttons and increasing and decreasing the temperature. By
doing so, the heating coil changes its temperature, heating the distilled water inside the tank. The
new inlet temperatures for this experiment were set at 40°C, 50°C, and 60°C, with a 10°C gap.
After setting the new temperature, wait for it to reach the setpoint before turning on the pump.
After that, examine the changes in the data and their implications.
2.3.2. Varying Hot Water Flow Rate
To determine how the varying hot water flow rate affects the operation of the shell and
tube heat exchanger through a countercurrent flow STHE must be set appropriately. To deliver
water from one source to another, a pump controller is present at the STHE set up. Flow rates of
hot and cold water can be modified using the pumps using the valves that serve as the flow rate
controller. By default, the hot water connected to the hot water source is fed inside STHE where
some of the energies are imparted to the cold fluid outside of the tubes in the STHE that causing
the loss of the sensible heat. Losing sensible heat makes the exiting water measure cooler
temperature as it goes back to the water tank to be heated again.
2.3.3. Varying Cold Water Flow Rate
For the varying cold water flow rate, likewise with the hot water, the former also requires
a source which for this experiment, is tap water. The cold water or the shell fluid from the tap
water will then go to the tank before entering the STHE. Once it enters the STHE, the flow of the
shell fluid will be countercurrent or opposite direction relative to the hot fluid. The shell fluid will
fill all the chambers before it exits the STHE and goes back to the system before it can be discarded.
This shell fluid will acquire the sensible heat given off by the hot fluid resulting in an increase in
temperature as it moves.
 3. Results and Discussion
This segment discusses the data, results, and findings that are gathered from the recorded
experiment. Particularly, this section involves the data when the hot water temperature (inlet), hot
water flow rate, and cold water flow rate were varied in the counter flow set-up. Also, the data
obtained after varying the hot water temperature (inlet) in the parallel flow set-up is encompassed.
Moreover, to denote the inlet and outlet temperatures and flowrates for the hot and cold
fluid, Table 1 presents the used notations in terms of the employed WL 110 Heat Exchanger Supply
Unit.
Table 1. Notations for Involved Parameters
Water Type Inlet Temperature, Outlet Flowrate, l/min
oC Temperature, oC
Hot Fluid T1 T3 F1
Cold Fluid T4 T6 F2

3.1. Counter Flow Set-up

3.1.1. Varying Hot Water Temperature (Inlet)

Table 2. Varying Hot Water Temperature (Inlet) Data

Temperature Hot Fluid Cold Fluid
Controller
T1, oC (TIC) T1, oC T3, oC F1, l/min T4, oC T6, oC F2, l/min
40 41.5 39.5 1.45 30.1 32.1 1.50
50 50.9 47.4 1.44 30.4 34.1 1.51
60 59.9 54.4 1.44 30.7 36.1 1.52

Table 2 is comprised of the data on varying the inlet hot water temperatures. The set T1 in
the controller are 40, 50, and 60𝑜 𝐶, respectively. Furthermore, the flow rate for the tube is set to
a constant 1.45 l/min.
It is anticipated that lower temperature values must appear on T3 in comparison to T1
values; this is reflected on Table 2 (from columns 2 to 3). The values for the outlet temperature for
the hot water is lower as T1 is varied. Contrastingly, it is anticipated for T6 to have a higher
temperature value than that of T4; this is exhibited in columns 5 and 6.
Also, it can be regarded that in accordance with Newton’s Law of Cooling, heat transfer is
related to the instantaneous temperature difference between the hot and cold fluid [6]. To show the
aforementioned difference between the hot and cold media, temperature profiles for the different
inlet temperatures for the hot water are determined.
Figure 11. Temperature Profile for Counter-current Heat Exchanger (𝑇1 = 40𝑜 𝐶)

Figure 12. Temperature Profile for Counter-current Heat Exchanger (𝑇1 = 50𝑜 𝐶)

Figure 13. Temperature Profile for Counter-current Heat Exchanger (𝑇1 = 60𝑜 𝐶)
 From the temperature profiles depicted in Figures 11, 12, and 13, it can be deemed that the
counter-current flow set-up us followed. The graphs show a near uniform temperature difference
between the two involved fluids. This then reduces the thermal stresses in the exchanger and
generates a more uninform rate of heat transfer [7]. Additionally, in accordance with the figures,
the outlet temperature of the cold water is able to approach the highest temperature of the how
water fluid’s inlet temperature.
Meanwhile, the LMTD values are obtained with respect the varying inlet temperature for
the hot water T1.

Figure 14. T1 vs. LMTD

It can be regarded in Figure 11 that there is a direct proportionality between the how water
temperature (inlet) and the LMTD. Aside from this, an r-squared 𝑅 2 value of 0.9999 or 99.99%
was attained. Therefore, the data from the experiment can be accounted as accurate and precise
given its near 100% r-squared value.
In terms of mean temperature efficiency, 17.54385965, 17.56097561, and 18.66438356 are
the percentages yielded with respect to 𝑇1 = 40𝑜 𝐶, 𝑇1 = 50𝑂 𝐶, and 𝑇 = 60𝑜 𝐶.
 Figure 15. T1 vs. Mean Temperature Efficiency

Figure 15 presents a direct relationship between the inlet temperature of the hot water and
the mean temperature efficiency or the thermal efficiency. Regardless of the small difference in
the value between the first two temperatures to (𝑇1 = 40𝑜 𝐶, 𝑇1 = 50𝑂 𝐶), it can still be deduced
that higher temperatures for the hot inlet water result to a higher efficiency value.

3.1.2. Varying Hot Water Flow Rate

Table 3. Varying Hot Water Flowrate Data at 𝑇 = 60𝑜 𝐶

Set Flow Hot Fluid Cold Fluid
Rate
F1 (set), T1, oC T3, oC F1 T4, oC T6, oC F2
l/min (equipment), (equipment),
l/min l/min
1.0 60.1 53.0 0.95 30.6 35.1 1.52
1.5 59.9 54.4 1.44 30.7 36.1 1.52
2.0 59.6 55.1 2.06 31.2 37.5 1.52

The hot water flow rate F1 is varied in this part as denoted in Table 2. The flow rates are
increased from 1.0 l/min to 1.5 l/min, and 2.0 l/min. From these changing F1 values, it can be taken
into account that the cold water flow rate F1 is maintained at a constant 1.52 l/min. Aside from
this, there are only a small decrease in T1, a slight increase in T3, T4, and T6 as the F1 value is
increased.
 Figure 16. F1 vs. LMTD

Figure 16 shows the relationship of the varying flow rate for the hot water F1 and the
calculated LMTD values. The trendline in the figure depicts an inverse proportionality between
F1 and LMTD. This is to imply that as the F1 increases, the LMTD decreases and vice-versa. Since
larger LMTD entails that more heat is transferred [8], it can be purported that increasing F1 leads
to a decrease in LMTD and consequently, of heat transfer rate. Although heat transfer and flow
rate are considered to be directly proportional [9], data showed otherwise yet is still linearly related
to one another. This points out that the direct proportionality of the said parameters is only to a
certain extent. Into the bargain, the r-squared value acquired for F1 vs. LMTD is 0.7321 or 73.21%;
the slight fluctuation in the data (as seen in the figure) accounts to the lower percentage for the r-
squared.
 Figure 17. F1 vs. Mean Temperature Efficiency
It is shown in Figure 17 that F1 is inversely related to the mean temperature efficiency or
thermal efficiency. Meaning to imply, as F1 increases, the thermal efficiency decreases.

3.1.3. Varying Cold Water Flow Rate

Table 4. Varying Cold Water Flowrate Data at 𝑇 = 60𝑜 𝐶
Set Flow Hot Fluid Cold Fluid
Rate
F1 (set), T1, oC T3, oC F1 T4, oC T6, oC F2
l/min (equipment), (equipment),
l/min l/min
1.0 60.2 55.5 1.49 31.5 38.5 1.01
1.5 59.9 54.4 1.44 30.7 36.1 1.52
2.0 59.7 53.9 1.49 30.6 35.0 2.03

Figure 18. F2 vs. LMTD

In contrast to the varying hot water flow rate F1, it can be denoted in Figure 18 that there
is linear and direct relationship between the cold water flow rate F2 and the LMTD. This trendline
agrees to the theory that an increased in flow rate results to an increase in heat transfer rate given
that the heat transfer rate and LMTD has a proportional relationship [8]. With this, it show that the
increase in F2 leads to more heat being transferred. Also, the r-squared value for the graph is
0.8987 or 89.87%; this high value shows good accuracy and precision with the obtain data. This
is as well higher than that of F1 vs. LMTD plot.
 Figure 19. F2 vs. Mean Temperature Efficiency

Just like in Figure 17, Figure 19 shows that the F2 is significantly inversely proportional
with the mean temperature efficiency although it has a linear relationship with it.

3.2. Parallel Flow Set-up

3.2.1. Varying Hot Water Temperature (Inlet)

Table 5. Varying Hot Water Temperature (Inlet) Data
Temperature Hot Fluid Cold Fluid
Controller
T1, oC (TIC) T1, oC T3, oC F1, l/min T4, oC T6, oC F2, l/min
40 41.5 39.6 1.50 29.8 32.0 1.50
50 50.8 47.3 1.50 30.2 33.8 1.49
60 60.0 54.7 1.52 30.6 36.1 1.49

Table 5 is composed of the data on varying the inlet hot water temperatures in the parallel
flow set-up. Just like the temperatures set in the countercurrent flow set-up, the used T1 in the
controller are 40, 50, and 60𝑜 𝐶, respectively. Although there are slight fluctuations with F1 and
F2, the values are still near 1.50 l/min.
In a parallel flow set-up, it is expected for the hot water outlet temperature to be lower than
that of the hot water inlet, and this can be observed from columns two and three. On the other
hand, for the cold fluid, it is anticipated for T6 to have aa higher value than T4 (this is reflected in
columns 5 and 6).
 As mentioned, in terms of Newton’s Law of Cooling, heat transfer is linked to the
instantaneous temperature difference between the hot and cold fluid [6]. Thus, to then again portray
the difference between the temperature difference for the hot and cold fluid, temperature profiles
for the different inlet temperatures for the hot water are determined using the parallel flow set-up
data.

Figure 20. Temperature Profile for a Parallel Heat Exchanger (𝑇1 = 40𝑜 𝐶)

Figure 21. Temperature Profile for a Parallel Heat Exchanger (𝑇1 = 50𝑜 𝐶)
 Figure 22. Temperature Profile for a Parallel Heat Exchanger (𝑇1 = 60𝑜 𝐶)

Figures 20, 21, and 22 show the temperature profiles for the different inlet how water
temperatures in a parallel set-up. With this laid out, it can be presumed that the parallel flow set-
up us followed. This set-up can be advantageous if the two involved fluids are to be brought to the
same temperature. However, as seen in the graph, in the parallel flow, there is a large temperature
difference at the ends. This large difference in temperature can result to large thermal stresses [10].
At the same time, the temperature of the cold outlet fluid does not exceed the hot fluid’s lowest
temperature. With this on regard, this set-up can be deduced to be disadvantageous if the purpose
of the equipment or the system is to raise the cold fluid’s temperature. Generally, the expansion
and contraction that opposes each other due to the large difference in the fluid temperature can
lead to material or equipment failure [10].
Moreover, the LMTD values are obtained with respect the varying inlet temperature for
the hot water T1 in the parallel flow set-up.
 Figure 23. T1 vs. LMTD

Just like the what the trendline portrayed in the counterflow set-up, same relationship for
the T1 and the LMTD is exhibited in Figure 23. It presents that there is a direct relationship
between T1 and the LMTD in the parallel flow set-up. Henceforth, the higher the hot onlet water
temperature, the higher the value is for the temperature driving force in the heat exchanger.
Furthermore, an r-squared value of 0.9998 or 99.98% was acquired. This high percentage means
a great accuracy and precision in data values; this is also clear with reference to the linearity of the
trendline.
 Figure 24. T1 vs. Mean Temperature Efficiency

With regards mean temperature efficiency, 17.52136752, 17.23300971, and 18.36734694

are the percentages obtained with respect to 𝑇1 = 40𝑜 𝐶, 𝑇1 = 50𝑂 𝐶, and 𝑇 = 60𝑜 𝐶. The
percentages are similar to that acquired in the countercurrent set-up.

Figure 25. T1 vs. Mean Temperature Efficiency

It can be seen in Figure 25 that T1 and the Mean Temperature Efficiency is directly
proportional to one another; the same relationship is exhibited in the countercurrent flow set-up.
Although there is again only a slight difference in the value between the first two temperatures to
(𝑇1 = 40𝑜 𝐶, 𝑇1 = 50𝑂 𝐶), it can still be observed that the mean temperature efficiency increases
with the hot water fluid inlet temperature.

Conclusions
It is the objective of this experiment to determine the effects of certain parameters in two
(2) heat exchanger flow set-ups namely the countercurrent flow and parallel flow set-up,
respectively. In the former, it is set to determine the effects of varying hot water temperature (inlet),
to determine the effects of varying hot water flow rate, and to determine the effects of varying cold
water flow rates. Meanwhile, for the latter, it is the aim to determine only the effects of varying
hot water temperature (inlet).
In an STHE, two fluids in thermal contact through the utilization of the tubes that are
situated within the outer cylindrical cell. The tubes direct the fluid from their inlet to their outlet
while the shell simultaneously passes a separate fluid on the shell-side flow. With that laid out, the
following are the conclusions drawn from the analysis of the data obtained:
Foremost, it is deduced from the temperature profile that in the countercurrent flow, lower
temperature values appear on T3 in comparison to T1 while T6 to have higher temperature values
than that of T4. Also, in terms of the temperature profiles in the countercurrent flow, it can be
denoted that there is a near uniform temperature difference between the two involved fluids which
leads to lesser thermal stress in the heat exchanger. Moreover, in the aforementioned flow, the
outlet temperature of the cold water is able to approach the highest temperature of the how water
fluid’s inlet temperature. In contrast, for the parallel flow set-up, the hot water outlet temperature
is lower than that of the hot water inlet while T6 (cold water outlet) has a higher value than T4
(cold water inlet). From the temperature profiles in the parallel flow, it can be conjectured that
there is a large temperature difference at the ends which can lead to large thermal stresses.
Additionally, the temperature of the cold outlet fluid does not exceed the hot fluid’s lowest
temperature. With this, the expansion and contraction that opposes each other due to the large
difference in the fluid temperature can lead to material or equipment failure. From the observations
in between the temperature profiles of the counterflow and parallel flow set-ups, it can be
distinguished that the latter is more advantageous if one needs to raise the cold fluid’s temperature.
Nonetheless, the parallel flow can be beneficial if the goal is to bring the two involved fluid to the
same temperature.
On the other hand, in terms of the countercurrent set-up, it is surmised that there is a direct
proportionality between the T1 and the LMTD as well as the T1 and Mean Temperature Efficiency.
The same linear and proportional relationship can as well be deemed in the parallel set-up with the
same parameters.
Furthermore, in varying the how water flow rate, it is regarded that F1 and LMTD are
inversely proportional to one another. However, in varying the cold water flow rate, it is found out
that F2 and LMTD are directly proportional; this coincides with the theory that as the flowrate
increases, then so does the heat transfer. In line with the mean temperature efficiency, an inverse
relationship was observed for both cases (F1 vs. Mean Temperature Efficiency and F2 vs. Mean
Temperature Efficiency. Henceforth, as the flowrate increases, the thermal efficiency decreases
and vice-versa.
As a whole, the experiment achieved the mentioned objectives, and it can be accounted
that STHEs are versatile and can be employed for various set-ups in numerous industries.
Appendices
Calculation for the Mean Temperature Efficiency and LMTD (Original Excel File: LMTD
AND MEAN TEMPERATURE EFFICIENCY.xlsx)
Table 2. Varying Hot Water Temperature (Inlet) Data
Temper
ature
Hot Fluid Cold Fluid
Controll
er
o
T1, C F1, F2, Efficiency Mean temperature
T1, o C T3, o C T4, o C T6, o C Efficiency (hot) lmtd
(TIC) l/min l/min (cold) efficiency
40 41 39.5 1.45 30.1 32.1 1.5 13.76146789 18.34862385 16.05504587 -0.5 -0.05466 9.147723
50 50.9 47.4 1.44 30.4 34.1 1.51 17.07317073 18.04878049 17.56097561 -0.2 -0.01183 16.8998
60 59.9 54.4 1.44 30.7 36.1 1.52 18.83561644 18.49315068 18.66438356 0.1 0.004211 23.74996

Table 2. Varying Hot Water Flowrate Data at

Set Flow
Hot Fluid Cold Fluid
Rate
F1 F2
F1 (set), (equipm (equipm Efficiency Mean temperature
T1, o C T3, o C T4, o C T6, o C Efficiency (hot) lmtd
l/min ent), ent), (cold) efficiency
l/min l/min
1 60.1 53 0.95 30.6 35.1 1.52 24.06779661 15.25423729 19.66101695 2.6 0.109815 23.67621
1.5 59.9 54.4 1.44 30.7 36.1 1.52 18.83561644 18.49315068 18.66438356 0.1 0.004211 23.74996
2 59.6 55.1 2.06 31.2 37.5 1.52 15.84507042 22.18309859 19.01408451 -1.8 -0.0783 22.98826

Table 3. Varying Cold Water Flowrate Data at

Set Flow
Hot Fluid Cold Fluid
Rate
F1 F2
F1 (set), (equipm (equipm Efficiency Mean temperature
T1, o C T3, C o o o
T4, C T6, C Efficiency (hot) lmtd
l/min ent), ent), (cold) efficiency
l/min l/min
1 60.2 55.5 1.49 31.5 38.5 1.01 16.37630662 24.3902439 20.38327526 -2.3 -0.10074 22.83069
1.5 59.9 54.4 1.44 30.7 36.1 1.52 18.83561644 18.49315068 18.66438356 0.1 0.004211 23.74996
2 59.7 53.9 1.49 30.6 35 2.03 19.93127148 15.12027491 17.5257732 1.4 0.05835 23.99319

Table 4. Varying Hot Water Temperature (Inlet) Data

Temper
ature
Hot Fluid Cold Fluid
Controll
er
T1, o C F1, F2, Efficiency Mean temperature
T1, o C T3, o C T4, o C T6, o C Efficiency (hot) lmtd
(TIC) l/min l/min (cold) efficiency
40 41.5 39.6 1.5 29.8 32 1.5 16.23931624 18.8034188 17.52136752 -0.3 -0.03109 9.649223
50 50.8 47.3 1.5 30.2 33.8 1.49 16.99029126 17.47572816 17.23300971 -0.1 -0.00587 17.04995
60 60 54.7 1.52 30.6 36.1 1.49 18.02721088 18.70748299 18.36734694 -0.2 -0.00833 23.99986
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