SyedaMalaikahBukhari371873 - Lab 6 - HVAC Lab - ME-13B - A

Heat Transfer and HVAC Lab
Lab Report 06
SHELL AND TUBE HEAT EXCHANGER (counter flow)
6TH SEMESTER
Submitted to: LE Zeeshan Ahsan

Session: 2021 Section: ME-13B Group: A
SUBMITTED BY
Name CMS Marks
Syeda Malaikah Bukhari 371873
School of Mechanical and Manufacturing Engineering

Objectives:
• To determine the effectiveness of shell and tube heat exchanger in case of counter flow
configuration.
Apparatus:
• Shell and Tube Heat Exchanger.
• Base Unit.
Figure 1: Shell & Tube Heat Exchanger
Introduction:
Shell And Tube Heat Exchanger
Shell and tube heat exchangers consist of a bundle of tubes enclosed in a cylindrical shell. Fluids
flow through either the tubes or shell to facilitate heat transfer between the two fluids. They are
widely used in chemical processes due to their ability to achieve a large heat transfer surface area
in a compact volume.
Counterflow:
Counter flow (also known as contra-flow) heat exchangers have two flowing mediums that are
flowing in a counter direction (180° apart) to each other. Each flowing medium enters the heat
exchanger at opposite ends and is discharged at opposite ends. Because the cooler medium exits
the counter flow heat exchanger at the end where the hot medium enters the heat exchanger, the
cooler fluid will approach the inlet temperature of the hot fluid; this makes the potential delta T
far greater than that of a parallel flow heat exchanger. Counter flow heat exchangers are the most
efficient type of heat exchanger.
fig.2 Figure explaining parallel and counter flow in heat exchanger
𝛥𝑇
𝑞 = −𝑘𝐴
𝛥𝑥
For conduction:
𝛥𝑥
𝑅𝑡 =
𝑘𝐴
For convection:
1
𝑅𝑡 =
ℎ𝐴
𝛥𝑇
𝑞= ; 𝛥𝑇 = 𝑇ℎ − 𝑇𝑐
𝑅𝑡𝑜𝑡𝑎𝑙
1 𝛥𝑥 1
𝑅 𝑡𝑂𝑡𝑎𝑙= + +
ℎℎ𝐴ℎ 𝑘𝐴 ℎ𝐶𝐴𝐶
𝑇ℎ − 𝑇𝑐
𝑞= 1 𝛥𝑥 1
( + + )
ℎ ℎ𝐴ℎ 𝑘𝐴 ℎ 𝐶 𝐴𝐶
𝑇ℎ −𝑇𝑐
𝑞= 1 𝛥𝑥 1 ; 𝑅ℎ𝑖 & 𝑅𝐶𝑖 are resistances due to impurities
(𝑅ℎ𝑖 + + + +𝑅𝐶𝑖)
ℎℎ𝐴 ℎ 𝑘𝐴 ℎ𝐶𝐴 𝐶
𝑞 = 𝑈𝐴𝛥𝑇 m
𝛥𝑇1 − 𝛥𝑇2
𝛥𝑇𝑚 =
𝛥𝑇
𝑙𝑛 ( 1 )
𝛥𝑇2
In counter balance flow:
𝛥𝑇1 = 𝑇ℎ𝑖 − 𝑇𝐶0 & 𝛥𝑇2 = 𝑇ℎ0 − 𝑇𝑐𝑖
𝑞ℎ = 𝑚 ℎ 𝐶𝑝ℎ (𝑇ℎ𝑖 − 𝑇ℎ0 ); 𝑞𝐶 = 𝑚 𝑐 𝐶𝑝𝑐(𝑇𝐶0 − 𝑇𝑐𝑖 )

𝑞
𝜀=
𝑞𝑚𝑎𝑥
𝑞𝑚𝑎𝑥 = 𝑚 ℎ 𝐶𝑝ℎ (𝑇ℎ𝑖 − 𝑇𝑐𝑖 ); 𝑚 𝐶 𝐶𝑃𝐶 < 𝑚 ℎ𝐶𝑃 ℎ
𝑞𝑟𝑒𝑎𝑙 = 𝑚 ℎ 𝐶𝑝ℎ (𝑇ℎ𝑖 − 𝑇ℎ0 ); 𝑚 𝐶 𝐶𝑃𝐶 < 𝑚 ℎ𝐶𝑃 ℎ

𝑇ℎ𝑖 − 𝑇ℎ0
𝜀=
𝑇ℎ𝑖 − 𝑇𝑐𝑖
Procedure:
• Arrange the valves in parallel flow configuration.
• Water in the heating tank should be above the level switch.
• Turn on the heating element and pump.
• Using the ST-16 temperature sensor display on the control unit, change the temperature
of the hot water tank.
• Select the desired temperature by clicking on 'MODE' and using the ∆ and 𝛻 buttons.
• Set the hot and cold-water flow rates accordingly.
• Allow suuficient time for the hot water at the intake to reach steady-state conditions, as
indicated by temperature (T1).
• Perform calculations and record the temperature and flow readings.
• For counter flow valves settings, perform the experiment again.
• Turn off the heater supply and pump before shutting off the main power switch.
Results:
Inner area: Ai = 21𝜋 × 8 𝑚𝑚 × 500 𝑚𝑚 =0.264 m2
Outer area: Ao = 21𝜋 × 10 𝑚𝑚 × 500 𝑚𝑚 =0.33 m 2
Volume flow rate of cold water = 1.2 l/min = 2 × 10 -5 m3 /s
Volume flow rate of hot water = 1.8 l/min = 3 × 10 -5 m3 /s
𝜌𝑐 = 996 𝑘𝑔/𝑚3
𝑚 𝑐 = 996(2 × 10 -5 ) = 0.019 kg/s
𝜌ℎ = 990 𝑘𝑔/𝑚3
𝑚 ℎ = 990(3.333 × 10 -5 ) = 0.029 kg/s
𝐶𝑃𝐶 = 𝐶𝑝ℎ = 4.186 J/g ˚C
Cmin = 𝐶𝐶= 𝑚𝑐. 𝐶𝑃𝐶= 4.186(0.019) = 0.079 kw/k

Cmax =𝐶ℎ= 𝑚ℎ .𝐶𝑃ℎ= 4.186(0.029) = 0.121 kw/k
(Counter flow):
Identifiers Temperature in Temperature
kelvin in kelvin
ST-16 308.15 313.15
Hot water inlet ST-1 305.15 308.15
Hot water outlet ST-2 302.15 305.15
Cold water inlet ST-7 297.15 298.15
Cold water outlet ST-3 302.15 302.15
Effectiveness 𝜀 0.574 0.612

Inner global heat 𝑈𝑖 382.17 184.52
transfer (W/m2K)
coefficient
Outer global heat 𝑈𝑜 280.97 226..09
transfer (W/m2K)
coefficient
Sample Calculation:
𝑞𝐶 = 𝐶𝑐(𝑇𝐶0 − 𝑇𝑐𝑖 ) = 0.079(302.15-297.15) = 395 W
q= 𝑞𝑟𝑒𝑎𝑙 = 𝑞ℎ = 𝐶ℎ (𝑇ℎ𝑖 − 𝑇ℎ0 )= 0.121(305.15-302.15) = 363 W
𝑞𝑚𝑎𝑥 = Cmin(𝑇ℎ𝑖 − 𝑇𝑐𝑖 ) = 0.079(305.15 – 297.15) = 632 W

𝑞 363
𝜀= = 632 = 0.574
𝑞 𝑚𝑎𝑥
𝛥𝑇1 = 𝑇ℎ𝑖 − 𝑇𝐶0 = 305.15 – 302.15 = 3 k
𝛥𝑇2 = 𝑇ℎ0 − 𝑇𝑐𝑖 = 302.15 – 297.15 =5 k

𝛥𝑇1 −𝛥𝑇2 3−5
𝛥𝑇𝑚 = 𝛥𝑇1 = 3 = 3.915 K
𝑙𝑛( ) 𝑙𝑛 ( )
𝛥𝑇2 5
𝑞 = 𝑈𝐴𝛥𝑇 m
>>Inner transfer coefficient

𝑞(𝑐𝑜𝑙𝑑) 0.395
𝑈𝑖 = = (0.264 )(3.915)= 382.17 W/m2 K
𝐴𝑖 𝛥𝑇m
>>Outer transfer coefficient

𝑞 (ℎ𝑜𝑡 ) 0.363
𝑈𝑜 = 𝐴 = (0.33)(3.915)= 280.97 W/m2 K
𝑜 𝛥𝑇m
Discussion:
The experiment aimed to assess the effectiveness of a shell and tube heat exchanger in a counter
flow configuration while varying the set temperatures of the water tank.
The results revealed a notable increase in effectiveness alongside a decrease in both inner and outer
global heat transfer coefficients. Our observations align with the expected behavior, indicating
improved efficiency of heat transfer within the system. The experiment also demonstrated that as
the set temperature of the water tank increased, the effectiveness of the heat exchanger also
increased..
However in contrast to expected trend, the global heat transfer coefficient decreased as the set
temperature of the water tank increased. Global heat transfer coefficient trends can vary due to
factors such as flow rate changes, fouling, and material degradation
Error in experimental results may be due to
• heat loss
• imperfect insulation
• inaccuracies in measurements
These factors can affect the overall heat transfer process and as a result impact the calculated
coefficients.
Conclusion:
In conclusion, while general trends suggest that increasing the set temperature of water tanks leads
to higher inner and outer global heat transfer coefficients and improved effectiveness, our
experimental results showed an opposite trend. While effectiveness increased, both global heat
transfer coefficients decreased. Several factors may have contributed which led us to have different
results fom expected trend,It may be due to
• conduction through the heat exchanger walls
• radiation from its surfaces
• convective losses
• inadequate insulation
• fluid leakage
• fouling or scaling
• potential design flaws.
These factors can compromise heat transfer efficiency and exacerbate heat loss.

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Heat Transfer and HVAC Lab

Submitted to: LE Zeeshan Ahsan

Syeda Malaikah Bukhari 371873

School of Mechanical and Manufacturing Engineering

Figure 1: Shell & Tube Heat Exchanger

𝑞ℎ = 𝑚 ℎ 𝐶𝑝ℎ (𝑇ℎ𝑖 − 𝑇ℎ0 ); 𝑞𝐶 = 𝑚 𝑐 𝐶𝑝𝑐(𝑇𝐶0 − 𝑇𝑐𝑖 )

𝑞𝑟𝑒𝑎𝑙 = 𝑚 ℎ 𝐶𝑝ℎ (𝑇ℎ𝑖 − 𝑇ℎ0 ); 𝑚 𝐶 𝐶𝑃𝐶 < 𝑚 ℎ𝐶𝑃 ℎ

Cmin = 𝐶𝐶= 𝑚𝑐. 𝐶𝑃𝐶= 4.186(0.019) = 0.079 kw/k

Effectiveness 𝜀 0.574 0.612

q= 𝑞𝑟𝑒𝑎𝑙 = 𝑞ℎ = 𝐶ℎ (𝑇ℎ𝑖 − 𝑇ℎ0 )= 0.121(305.15-302.15) = 363 W

𝑞𝑚𝑎𝑥 = Cmin(𝑇ℎ𝑖 − 𝑇𝑐𝑖 ) = 0.079(305.15 – 297.15) = 632 W

𝛥𝑇1 = 𝑇ℎ𝑖 − 𝑇𝐶0 = 305.15 – 302.15 = 3 k

𝛥𝑇2 = 𝑇ℎ0 − 𝑇𝑐𝑖 = 302.15 – 297.15 =5 k

>>Inner transfer coefficient

>>Outer transfer coefficient

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