MECHANICAL ENGINEERING SCIENCE 9

3RD YEAR LABORATORY EXPERIMENT

Heat Exchanger

Shane Menezes (H00304185)

Group 1
Abstract
This paper focuses on the effects of the fluid flow configuration in shell and tube heat exchangers. This was experimentally
investigated using varying flow rates of warm and cold fluid flows for both flow configurations, then comparing the effects of
these changes on the heat transfered. From the data collected, it was concluded that configuration of Shell and Tube heat
exchanger in parallel current flow has a higher effectiveness than the counter flow, which goes against literature and has been
explained by the myriads of technical and systematic errors experienced in the lab.

Contents
Abstract .................................................................................................................................................................................................. 1
Introduction ........................................................................................................................................................................................... 2
Objectives: ......................................................................................................................................................................................... 6
Theory .................................................................................................................................................................................................... 7
Sample Calculation ............................................................................................................................................................................ 7
Equipment .............................................................................................................................................................................................. 8
Procedure ........................................................................................................................................................................................ 10
Results & Discussion............................................................................................................................................................................. 11
Conclusion ............................................................................................................................................................................................ 12
Abstract ................................................................................................................................................................................................ 13
References ........................................................................................................................................................................................... 14
Bibliography ......................................................................................................................................................................................... 15
Introduction
What is a heat exchanger?
Heat exchangers are machines designed for the purpose of transferring heat, typically between two or more fluids at differing
temperatures, without the fluids having direct contact with each other. There are exceptions that use direct contact to facilitate
heat transfer but are less widespread that other conventional types. Depending on the purpose or the environmental conditions,
a heat exchanger can use working fluid combinations of gas-to-gas, liquid-to-gas, or in rarer conditions, liquid-to-gas. Since the
function of a heat exchanger is to transfer heat, it can function both as a heater (heat engine), or a cooler (reverse heat engine).
Heat exchangers are used in a variety of industries, primarily in industries that need strictly regulated temperature conditions,
such as in the oil, gas, petrochemical, and beverage industry, to keep fluids within a safe operating temperature. In most of these
large-scale cases, they are used within industrial plants or refineries, and primarily are used for refrigeration. For more sustainable
or eco-friendly oriented plants or processes, heat exchangers are used to capture heat, and reutilize it in other areas (such as
powering office space heaters for employees), thereby reducing running costs and even increasing overall production efficiency.

Figure 1: An intercooler, an example of a heat exchanger Source: Automotive Superstore

There are also smaller scale uses for heat exchangers, such as use within automobiles. Within a car engine, the regulation of oil
temperature and the engine fluid is essential for peak performance and the healthy lifespan of the engine and its parts. The
temperature of a fluid is linked to its viscosity and density, and any deviation out of a favorable range can cause issues in
performance. As such, an intercooler (which functions as a cross flow heat exchanger) is present in order to maintain thermal
equilibrium within the engine bay. Pictured above is an example of a downflow intercooler, which takes in the warm radiator
working fluid from the top, when then flows down the intercooler, cooling down as air flow across the front surface area of the
intercooler, after the heat is extracted from the working fluid, it returns back to the engine bay, and the cycle continues.
During the selection process of a heat exchanger, the parameters that would typically be taken into consideration would be the
construction material, expected pressure and heat characteristics of the surroundings and the working fluid, performance
parameters (temperature setup, flow, pressure gradient), frequency of maintenance, type of working fluids to be used and their
phases, the size of the heat exchanger and availability of resources. Based on these parameters, a specific type of heat exchanger
can be selected. The various types of heat exchangers are summarized below, based on their flow arrangement and physical
structure:
Parallel flow & Counter flow
The most rudimentary and common configuration of a heat exchanger is where the two fluids move in a concentric pipe layout.
Depending on the pipe inflow and outflow arrangements, the fluids either flow in the same direction (parallel flow), or flow in
opposite directions (counter flow).

Figure 2 & 3: Parallel flow, counter flow configurations Source: Engineer’s Edge

One disadvantage of parallel setups is due to the direction of fluid flow. There is a large buildup of temperature difference at the
ends of the system, which causes thermal stress due to the vastly opposing temperature gradients caused at one side of the
tubing. Due to thermodynamic principles of heat exchange, the maximum temperature attainable by the colder fluid will never be
greater that the lowest temperature of the warmer fluid. This is only a detriment if the desired outcome is to increase the
temperature of the cooler fluid.
Counterflow systems are preferred due to its many benefits over a parallel configuration. The temperature gradient between the
fluids over the entire pipe flow is more uniform, resulting in the thermal stresses experienced by the system are greatly reduced.
This uniform temperature difference also results in a more uniform rate of heat transfer from one fluid to another.
This type of heat exchanger uses conduction and convection in order to achieve its goal.
Cross flow

Figure 4 & 5: Finned & unfinned tubular heat exchangers, examples of flow configurations Source: Engineer’s Edge

A crossflow heat exchanger has two perpendicular flows of fluids and typically used with a gas-to- liquid working fluid
configuration. A common example of a crossflow heat exchangers is in steam condensers where the heat is delivered to the cooler
liquid, to convert it into a gas. Two subcategories of crossflow types exist, being finned tubular and unfinned tubular heat
exchangers.
Finned heat exchangers are typically used where air is used as the cooling fluid. The surface area available for heat transfer
determines the efficiency of the heat transfer process. Finned tubular exchangers are optimized for maximizing heat transfer
surface area, thereby being one of the most efficient heat exchangers available.
In a finned heat exchanger, the fluid is unmixed due to the fins preventing the fluids from traversing across them, acting as a
barrier. However, the unfinned configuration allows the air to mix. Both versions of the crossflow heat exchanger maintain an
unmixed flow in the tube.
This type of heat exchanger uses conduction and convection in order to achieve its goal.

Shell and Tube

This heat exchanger is comprised of an outer shell that contains a number of discrete tubes to contain the working fluid. The tubes
are collectively called a tube bundle, or tube nest. In addition, they contain two headers (or caps) at the ends of the shell, the front
header (where the fluid enters the exchanger), and the read header (where the fluid leaves the exchanger). Each individual part of
the shell and tube exchanger can be customized, to match the particular needs of the specific industry. Based on selecting
different configuration of these modules, an assortment of many heat exchangers can be produced. This flexibility and modularity
results in the Shell and Tube exchanger being the most widespread in the modern industry. An extent of its versatility can be
observed in the figure below.

Figure 6: Varieties of shell and tube configurations Source: EnggCyclopedia

Due to this enhanced flexibility and versatility, they are extensively used in the industry, and make up approximately 90% of the
total heat exchangers used, both commercially and industrially.
Figure 7: Components of a shell-and-tube heat exchanger Source: Çengel, Yunus A, and Afshin J. Ghajar. Heat and Mass Transfer:

Fundamentals & Applications. New York: McGraw-Hill, 2011

The main body comprises of two sets of inlets and outlets for each fluid, one flowing through the tubes and on through the shell
structure. The tube fluid enters from the tube inlet, passes through the tube bundle, and exits through the tube outlet. Similarly,
the shell fluid starts at the shell inlet, passes over the tubes, and exits at the shell outlet. The headers on either side of the tube
arrangement create spaces for the tube fluid to collect, either directly after entry or before departure from the system.
Each tube contains a turbulator, which triggers turbulent flow within the fluid. This disruption reduces the probability of dissolved
solids accumulating the walls of the tube and shell. In essence, turbulent flow has a self-cleaning effect on the tank. A similar
process is triggered within the tube flow section by barriers known as baffles, which maximizes the thermal mixing between the
shell-side fluid and the tube-side fluids by redirecting the water stream multiple times on its path through the heat exchanger.
The shape and structure of these baffles can be altered to produce differing results based on the fluids used and the amount of
heat transfer desired.

The myriads of configurations of Shell-and-Tube heat exchangers can be grouped into three main classifications:

• U-tube heat exchanger

Figure 8: U-tube heat exchanger Source: EnggCyclopedia

In this heat exchanger, the tube bundle is bent into a “U” shape and is held in place by a tubeplate. The bend allows for
thermal expansion to occur without having the need of using expansion joints. This particular class of heat exchanger is
used in the industry for high contrasting temperature gradients between the two working fluids. An apparent downside
due to the shape of the tubes is the fact that the inner walls are difficult to clean, making maintenance harder than the
other classes of shell-tube exchangers.
 • Fixed tube heat exchanger

Figure 9: Fixed tube heat exchanger Source: EnggCyclopedia

The fixed tube method uses simplicity in its ideology, to provide the most cost-effective configuration that is also easy to
manufacture. It, however, suffers with handling high temperature gradients between the two fluids due to the fact that
the tubes are fixed in place. This does not allow for significant expansion, as that would result in a risk of damage to the
structural integrity of the exchanger. Hence, the temperate difference between fluids is minimal.

• Floating head exchanger

Figure 10: Floating head heat exchanger Source: EnggCyclopedia

This variant aims to fix the disadvantages raised by the other two types, while also assimilating their advantages. The
left end of the tube bundle is fixed in place, but the other end is free to expand. This allows for fluids with high
temperature gradients like the U-tube exchanger. The layout of the pipe bundle also allows for easy cleaning, making
maintenance easier. This is the best variant with regards to efficiency and maintenance, albeit at a greater monetary
cost.

Objectives:

There are a few objectives the lab focuses on, which are raised in order to understand the relevance of fluid flow in the tube
system, and how varying it can affect real life scenarios. Finding a correlation between the direction of flow and the overall
effectiveness of the heat transfer helps in determining methods to maximize heat exchanger efficiency in the real world. The
objectives can be summarized as such:

1. To determine the effectiveness of the heat exchanger based on the flow arrangement
2. To study effect of fluid temperature on counter flow heat exchanger performance
3. To study effect of fluid temperature on parallel flow heat exchanger performance
Theory
One of the general values of each heat exchanger is the rate of heat transfer. It can be defined by the following formula:

The performance of the heat exchanger is best described by the amount of heat transferred in the system. This can be determined
by using the following equation:

𝑄̇ = 𝑚̇𝑐𝑝 (𝑇𝑖𝑛 − 𝑇𝑜𝑢𝑡 )

Equation 1

Where 𝑸̇ is the rate of heat transfer, 𝒎̇ is the mass flow rate , 𝒄𝒑 is the specific heat capacity of water, and 𝑻𝒊𝒏 is the inlet
temperature, and 𝑻𝒐𝒖𝒕 is the outlet temperature.
Equation 1 uses mass flow rate in order to calculate the heat transfer. However, during the experiment, values of volumetric flow
rate were measured. Therefore, the values have to be converted to match the equation, and is done via the following:

𝑚̇ = 𝜌 × 𝑄
Equation 2

Where 𝒎̇ is the mass flow rate, 𝝆 is the density of water and 𝑸 is volume flow rate of the fluid.

Sample Calculation

Heat transferred for fluid flows in parallel flow configuration, at 2.67 lpm:
Converting volumetric flow rate to mass flow rate:
For cold water:

𝑄𝑐𝑜𝑙𝑑 = 2.67 𝑙⁄𝑚𝑖𝑛

2.67 𝑘𝑔
𝑚̇ = ( ) ∗ 1000 = 0.0445 ⁄𝑠
60 ∗ 1000

For warm water:

𝑄𝑤𝑎𝑟𝑚 = 2.15 𝑙⁄𝑚𝑖𝑛

2.15 𝑘𝑔
𝑚̇ = ( ) ∗ 1000 = 0.0386 ⁄𝑠
60 ∗ 1000

Heat transferred for each fluid:

𝑘𝑔 𝐽
𝑄̇𝑐𝑜𝑙𝑑 = 0.0445 ⁄𝑠 × 4186 ⁄𝑘𝑔𝐾 × (306.85 𝐾 − 301.25 𝐾) = 1043.15 𝑊

𝑘𝑔 𝐽
𝑄̇𝑤𝑎𝑟𝑚 = 0.0386 ⁄𝑠 × 4186 ⁄𝑘𝑔𝐾 × (333.05 𝐾 − 327.05 𝐾) = 969.48 𝑊
Equipment
Experimental testing was conducted using a centrifugal GUNT W110 heat exchanger and a tube network. The pipe network
contained two pressure gauges, to measure upstream and downstream pressure heads. A variable frequency drive control panel
was used to control the impeller speeds, and a tachometer was used to measure the rotational speed of the impeller.
Complete list of equipment is as follows:
1. GUNT W110 heat exchanger
2. Tube network (one pair for warm fluid, one for cold fluid)
3. Temperature gauges (to measure inlet, outlet, and middle temperatures)
4. Temperature controls (to regulate the warm water inlet temperature)
5. Flowmeters (to measure flow rate at inlet and outlet)
6. Control panel (containing switches for power supply, and water delivery)
7. Valve-flow controls (to regulate flow rate of warm and cold sources)
8. Sink valve (used as the source of the cold water)
9. Exit pipe (for dispersing the cold water into the sink or the reservoir)
10. Water reservoir (to collect excess water dispersed form the cold water flow)

Figure 11: Laboratory Setup

Figure 11 displays the entire laboratory setup, including the pipe and tube network, pump and sink, pressure gauges and
rotameter. The tubes and fittings are also seen, mounted on the heat exchanger. The figure also shows the temperature control
panel, voltage response analyzer and WILO pump. A comprehensive list, accompanied with a label describing each figure is
present below:
Figure 12: Control panel, power & water supply switches Figure 13: Temperature controller

Figure 14: Valve-flow controls Figure 15: Temperature gauges

Figure 16: Heat exchanger Figure 17: Basic flow circuit

The flow of the warm water is driven by the pump, and is recirculated repeadatly, from a tank. This cycle continues for as long as
the system in turned on. The cold water is drawn from the water supply, and leaves the system through the sink. The main
variable that is controlled in this expiriment is the flow rate of the fluids, and the arrangemetn of pipes resulting in either counter
flow or parallel flow. An important factor to note, is that the flow rate for the hot water will be more accurate than the flow rate
for the cold water, due to there being a lot more fluctuation in the cold-water flow, as it is received from the mains, which is not a
reliable source of flow.

Procedure
There is a range of flow rates for both the working fluids to choose from. When a certain flow rate and warm water temperature
combination has been chosen, the laboratory procedure can begin:

1. The tubes connecting the two flows of water are arranged to produce the counter flow configuration (where the
direction of working fluids are in the opposite direction)
2. The heat exchanger is switched on, by turning the red knob on the control panel clockwise, providing power to
the system.
3. The sink valve is opened, to supply the cold water flow. A water reservoir has been set up, in order to collect
excess water, in addition to an exit pipe that leads into the sink.
4. Next, the predetermined warm water temperature range is selected by entering the desired value into the
temperature controller.
5. The pump supplying warm water is then switched on, via the black switch labelled “pump”, directly above the
power supply knob. This starts circulating warm water through the system.
6. The two fluids are left to flow for between 3 to 4 minutes, before any readings can be plotted. This is done in
order to ensure the system reaches steady state flow.
7. The first set of readings are plotted for the highest with the flow rate in the system being the maximum.
8. The flow rates for both fluids are set to 2 litres per minute. The procedure in step 7 is repeated.
9. The flow rate for the hot fluids is lowered to 1 litre per minute, while the cold flow remains at 2 litres per
minute. The procedure in step 7 is repeated.
10. The flow rates for both fluids are lowered to 1 litre per minute. The procedure in step 7 is repeated.
11. The flow of both fluids are temporarily halted, in order to change the layout of flow.
12. The tubes connecting the two flows of water are arranged to produce the parallel flow configuration (where the
direction of working fluids are in the same direction)
13. Steps 2 through 10 are repeated, to derive all necessary values for the parallel flow configuration.
14. The heater, pump, and sink valve are all turned off. Then, the main power can be turned off. All water in any
pipe or tubing are to be drained. All valves are closed, ending the experiment
15. A final check in conducted to ensure the entire setup has been switched off, and that there are no leaks or
malfunctions of any kind.

Safety & Precautions:

When conducting any lab experiment, it is imperative to have a safe working space. Individuals conducting the experiment must
behave in a manner that prevents inference with others around, and the experiment itself. Wearing safety shoes, and a lab coat
prevents the risk of damage in the event of spillage of chemicals, or heavy items that are present in the lab. This experiment
contains flowing water and a constant source of power in the pump. An inspection of every pipe and valve was performed to
ensure that there are no leaks present, and that the equipment is in a proper working condition. In the case of a spillage, clean the
surrounding area and avoid contact with the equipment until it is perfectly safe to do so. Turn off all equipment in the case that
any leaks have been detected. In the current situation of a global pandemic, the individual conducting the experiment must
beware of the health risks associated with not following the safety regulations which includes the wearing of a mask at all times
and maintaining social distancing of at least 2 metres.
Results & Discussion
Parallel flow
Table 1: Tabulated values for parallel flow

Hot Stream Cold Stream

𝑇𝑖𝑛 (℃) 𝑇𝑜𝑢𝑡 (℃) ∆𝑇ℎ𝑜𝑡 (℃) 𝑘𝑔
𝑚̇ℎ𝑜𝑡 ( ⁄𝑠) 𝑄̇ℎ𝑜𝑡 (𝑊) 𝑇𝑖𝑛 (℃) 𝑇𝑜𝑢𝑡 (℃) ∆𝑇𝑐𝑜𝑙𝑑 (℃) 𝑘𝑔
𝑚̇𝑐𝑜𝑙𝑑 ( ⁄𝑠) 𝑄̇𝑐𝑜𝑙𝑑 (𝑊)
Test 1 58.9 52.3 6.6 0.0383 993.3 22.2 28 5.8 0.0445 1084.02
Test 2 59.5 54.0 5.5 0.0333 770.0 27.9 34.4 6.5 0.0333 910.0
Test 3 58.9 52.2 6.7 0.0167 469.0 28.9 32.2 3.3 0.0333 462.0
Test 4 59.6 52.8 5.8 0.0167 406.0 29.3 36.1 6.8 0.0167 476.0

Counter flow
Table 2: Tabulated values for counter flow

Hot Stream Cold Stream

𝑇𝑖𝑛 (℃) 𝑇𝑜𝑢𝑡 (℃) ∆𝑇ℎ𝑜𝑡 (℃) 𝑘𝑔
𝑚̇ℎ𝑜𝑡 ( ⁄𝑠) 𝑄̇ℎ𝑜𝑡 (𝑊) 𝑇𝑖𝑛 (℃) 𝑇𝑜𝑢𝑡 (℃) ∆𝑇𝑐𝑜𝑙𝑑 (℃) 𝑘𝑔
𝑚̇𝑐𝑜𝑙𝑑 ( ⁄𝑠) 𝑄̇𝑐𝑜𝑙𝑑 (𝑊)
Test 1 59.6 54.0 5.6 0.0355 834.96 22.2 28 5 0.0480 1008.0
Test 2 60.4 55.2 5.2 0.0333 728.0 27.9 34.4 6.3 0.0333 822.0
Test 3 59.8 53.0 6.8 0.0167 476.0 28.9 32.2 4.4 0.0167 308.0
Test 4 59.8 53.9 5.9 0.0167 413.0 29.3 36.1 6.6 0.0167 462.0

Parallel Flow
Heat Transferred (Watts)

Cold Circuit Hot Circuit

1500
1000
500
0
0 0.01 0.02 0.03 0.04 0.05
Mass Flow Rate (kg/s)

Graph 1: Mass flow rate vs Heat transferred for Parallel Flow

Counter Flow
Cold Circuit Hot Circuit
Heat Transferred (Watts)

1200

700

200

-300 0 0.01 0.02 0.03 0.04 0.05

Mass Flow Rate (kg/s)

Graph 2: Mass flow rate vs Heat transferred for Counter Flow

The experiment mainly uses the heat transferred between the two fluids with respect to its mass flow rate as a measure of the
effectiveness of each configuration. To achieve this, the various values of both warm and cold circuits were tabulated, and a graph
of mass flow rate versus heat transferred was plotted for each flow configuration.
Comparing the maximum flow rates observed for each circuit, it was noted that the maximum flow rate achieved for parallel flow
was lesser than the value for counter flow (0.0358 kg/s versus 0.0445 kg/s respectively). Therefore, a direct comparison between
the peak values of heat transfer on each graph cannot be attained. An anomaly was observed in the cold-water circuit for both
configurations, where the value of heat transfer increased instead of decreasing when going from 0.0333 kg/s to 0.0167 kg/s. This
is caused, in part, due to the minimal temperature gradient between the two working fluids. Other possible reasons of error are
summarised at the end of the discussion. The trend observed from the parallel flow graph is that the heat transfer is directly
proportional to the increase of mass flow rate increases, corresponding to the expected relationship denoted in literature,
disregarding the anomaly discussed before. The counter flow configuration also yielded expected results (disregarding the
anomaly discussed before) matching with theory in literature yet again.
It was observed that every data point for counter flow yielded lower values of heat transfer than parallel flow, leading to the
conclusion that the parallel flow configuration is more effective than counter flow. As noted before, a direct comparison of values
is only possible for lower mass flow rates. An example would be the rate of heat transfer in between both configurations. In
parallel flow, the values of heat transferred yielded were 770W for the hot flow, and 910W for the cold flow at 0.0333 kg/s. For
counter flow, values yielded for heat transferred were 728W for the hot flow, and 882W for the cold flow at 0.0333 kg/s.
Therefore, the heat transfer efficiency of a shell and tube heat exchanger is deemed to be greater with a parallel flow
configuration than with a counter flow setup.
The temperature readings for the cold fluid flow vary greatly, due to the fact that the water was supplied from the mains and is
not a part of the heat exchanger assembly like the hot fluid flow. Therefore, the temperature at the cold feed inlet cannot be
controlled like the hot water inlet via the temperature controller. This irregularity led to the anomalies mentioned above. In order
to produce more accurate readings, either multiple repeat readings for each data plot should be taken and averaged to derive a
value of temperature that is more stable, as the fluctuations would eventually average out. Another approach would be to use a
tank to store the cold fluid, instead of using water from the mains supply.
Theoretically, the amount of heat loss from the warm fluid flow should be equivalent to the heat gained from the cold fluid flow.
However, this can never be achieved practically, due to the fact that some heat will always be lost to the surroundings. The
amount that is lost can be reduced however, by lagging the tubes and heat exchanger unit. Lagging refers to the practice of
covering any surface that is in contact with the outside (in this case, attention to detail is necessary, as the sections that transfer
heat from one fluid to another should obviously not be lagged). It was noted that the temperature readings of both the warm and
cold fluid flows shown by the measuring equipment were never fluctuating, meaning that there might have been a fault with the
equipment, or that a misunderstanding of which readings to note down was done on part of the experimenters. Another issue
would be the fact that the time spent waiting between the fluids reading steady state flow could be too little, and an additional 5
minutes could be allotted to waiting, between the initial change of temperature till the temperatures of both fluids reached a
stable value.

Conclusion
This experiment focused on the effectiveness of various fluid flow configurations of the overall effectiveness of the heat transfer
of a shell and tube exchanger. This was achieved through running a series of tests, where the flow of both warm and cold fluids
were changed, and the heat exchanged was measured. These values were tabulated, and graphs of the mass flow rate versus the
heat transferred for both warm and cold circuits were plotted, for parallel flow and counter flow. These graphs revealed the trend
that the heat transfer is directly proportional to the increase of mass flow rate increases, which corresponded to the expected
relationship denoted in literature. The values also confirmed that the heat exchanger follows the laws of thermodynamics, as the
exit temperature of the warm fluid flow in both parallel and counter flow would always be greater than the exit temperature of
the cold fluid flow. This was observed in both configurations.

It was concluded that parallel flow was more effective that counter flow. This, however, is untrue, based on literature. This
discrepancy can be held up to the unreliability of flow rate produced by the cold-water system, and the fact that only sole readings
of each data plot were noted.
Abstract
Mass Flow Rate Vs Heat Transfer of warm water flow
Parallel flow Counter flow
Mass Flow rate kg/s Heat Transfer W Mass Flow rate kg/s Heat Transfer W
0.0383 993.3 0.0355 834.96
0.0333 770.0 0.0333 728.0
0.0167 469.0 0.0167 476.0
0.0167 406.0 0.0167 413.0

Mass Flow Rate Vs Heat Transfer of cold water flow

Parallel flow Counter flow
Mass Flow rate kg/s Heat Transfer W Mass Flow rate kg/s Heat Transfer W
0.045 1092.54 0.0480 1008.0
0.033 897.89 0.0333 822.0
0.033 455.85 0.0167 308.0
0.017 483.90 0.0167 462.0
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