Table of Contents

Abstract....................................................................................................................................2

Introduction..............................................................................................................................3

Experimental setup...................................................................................................................6

Procedure.................................................................................................................................6

Raw Data..................................................................................................................................7

Sample Calculation.................................................................................................................10

Conclusion..............................................................................................................................19

References..............................................................................................................................20

1
Abstract

The purpose of this experiment is to illustrate the differences between counter-

current flow and co-current flow as well as their impact on the heat exchanger's
overall efficiency, temperature profiles, and mean temperature. Also, the heat
exchanger's overall heat transfer coefficient will be calculated. In heat transfer, overall
heat transfer coefficient refers to the total resistance between fluids. The experimental
value of the overall heat transfer coefficient is considered as the slope of graph
between heat flux and the logarithmic mean temperature difference (LMTD), and it is
W W
equal to (24.5 2 ) for counter-current flow and equal to (20.9 2 ) for co-
m .℃ m .℃
current flow. While the theoretical value of the overall heat transfer coefficient is
calculated for both counter-current and co-current flow (depending on inner surface
W W
area of inner pipe) and it is equal to (9410.74 2 ) and (5962.389 2 )
m .℃ m .℃
respectively. Comparing the theoretical and experimental data, the efficiency range
for counter-current flow data is approximately (8.9 %-20.38 %). The efficiency range
for co-current flow is approximately (13.95%-21.3%). Which indicates accuracy.

2
Introduction
A common system used to transfer heat between two or more fluids is a heat
exchanger device. The technology is employed in numerous utilities, including
the generation of electricity, space heating, and waste heat recovery, among
others. Different-temperature fluids enter the heat exchanger divided by a
wall; the fluid with the higher temperature will be chilled by gaining heat, and
vice versa. Additionally, heat will travel through the wall via conduction, but
it will do so differently for each fluid due to convection [1].Additionally, there
are two ways that fluids enter the heat exchanger: as a countercurrent, when
hot and cold fluids flow in the opposite directions and enter the system at
opposing ends (Fig 1). The second form, however, has both fluids entering the
device from the same end and flowing in the same direction (Fig. 2) [1].

Figure 1: Counter current flow heat exchanger

Figure 2: Co- current flow heat exchanger

The following equations will be used for the calculation:

q = U As Tl,m (1)

- q: Amount of heat transferred (W)

W
- U : Overall heat transfer coefficient ( 2 )
m .K

3
 - As: Surface area of exchange (m2)
- Tl,m : logarithmic mean temperature difference.

The log mean temperature difference for the Co-Current Flow:

Δ T 2−ΔT 1
Δ T l , m=
ln
( )
ΔT2
ΔT1
(2)

Δ T 1=(T ❑h1−T c1) (3)

Δ T 2=(T h2 −T c2 ) (4)

The log mean temperature difference for the counter current Flow:

ΔT 2−ΔT 1
Δ T l , m=
ln
( )
ΔT2
ΔT1
(5)

Δ T 1=(T ❑h1−T c2) (6)

Δ T 2=(T h2 −T c1 ) (7)

- T ❑h1 :Temperature of the hot fluid at the inertance of heat exchanger (K).
- T h2 :Temperature of the hot fluid at the exit of heat exchanger(K).
- T c1 : Temperature of the cold fluid at the inertance of heat exchanger(K).
- T c2 : Temperature of the cold fluid at the exit of heat exchanger(K).

r0
ln
1 1 1 Ai
= +
( )
U i h i ho A o
+ Ao(
ri
2 πkl
) (8)

- Ai Inside area of the inner tube (m2)

W
- hi heat transfer coefficient of the inside fluid ( ).
m2 . K

4
 Ao =π d o L (9)

Ai=π d i L (10)

- d o : Outer dimeter of the inner tube m

- d i : Inner dimeter of the inner tube m
- L: Length of the tube. m

d i Q i ρi
R e i=
π 2 (11)
μi (di )
4
- R e i: Reynolds number of the inner fluid
Kg
- ρi : Density of the inner fluid 3
m
3
- Qi: Flow rate of the inner fluid m
s
Kg
- μi: Viscosity of the inner fluid ( ).
m. s

R e o=¿ ¿ ¿ (12)

- R e o: Reynolds number of the outer fluid

Kg
- ρ o : Density of the outer fluid 3
m
3
m
- Q o : Flow rate of the outer fluid
s
- D i: Inner dimeter of the shell m

Kg
- μo : Viscosity of the outer fluid ( ).
m. s

d o =d i +2thikness (13)

For turbulent flow:

5
 0.8 0.33
Nu=0.027 R e Pr (14)

For laminar flow:

Nu=4.36 (15)

N ui k i
hi = (16)
di

N uo ko
h o= (17)
D i−d o

Experimental setup

The device that would be used in this experiment is theTubular Heat

Exchanger (Gunt, WL 110). the tubular heat exchanger is consisting of two
concentric tubes conveying hot and cold fluids. To minimize the total length
of the tubes and make it possible to measure the temperature at various
locations along both fluid streams, the tubes are separated into parts.

Figure 3. Experimental setup - Gunt, WL 110

Procedure
To start, the required temperature should be adjusted to 60°C. The data
Acquisition software has to be prepared to collect data. The fluid connections
were arranged in a co-current manner (flow in the same direction) when the
temperature reaches a steady sate. After data for this configuration is collected

6
 and the mass flow rate start to increase. The connection is then changed to be
in a counter-current manner (flow in opposite direction). Same steps were
being repeated for this configuration.

Raw Data
- Effective tube length = 360 mm

Table 1. Technical data for heat exchanger

Outer Tube Inner Tube

Material Transparent Poly (methyl Stainless steel
methacrylate
Thickness (mm) 2 1
Internal Diameter (mm) 16 10

 For co-current flow:

Table 2. Raw data for the hot fluid

Trail # Flowrate Flowrate Tin (°C) Tout(°C) Tmean(°C)

(L/min) (m 3 /s ¿
Trail 1 2.07 3.45 ×10−5 70.7 66 67.4
−5
Trail 2 2.08 3.47 ×10 70.1 64.1 66.1
Trail 3 2.10 3.50 ×10−5 70.1 64.2 66.2
−5
Trail 4 2.11 3.52 ×10 70.1 63.2 65.9

Table 3. Raw data for the cold fluid

Trail # Flowrate Flowrate Tin (°C) Tout(°C) Tmean(°C)

(L/min) (m 3 /s ¿
−6
Trail 1 0.49 8.17 ×10 37 54.2 47.6
−5
Trail 2 0.96 1.60 ×10 37.6 48.9 43.9
−5
Trail 3 1.26 2.10 ×10 38.1 47.1 43.2
−5
Trail 4 1.76 2.93 ×10 37.7 45.4 42

7
  For counter flow:

Table 8. Raw data for the hot fluid

Trail # Flowrate Flowrate Tin (°C) Tout(°C) Tmean(°C)

(L/min) (m 3 /s ¿
Trail 1 3.01 5.02 ×10−5 70.7 66.6 68.7
−5
Trail 2 2.99 4.98 × 10 70.3 65.1 67.8
Trail 3 2.90 4.83 × 10−5 70.4 65.7 68.2
−5
Trail 4 2.03 3.38 ×10 69.8 63.3 66.3

Table9. Raw data for the cold fluid

Trail # Flowrate Flowrate Tin (°C) Tout(°C) Tmean(°C)

(L/min) (m 3 /s ¿
−6
Trail 1 0.30 5.00 ×10 24.8 57.9 56.7
−6
Trail 2 0.54 9.00 ×10 25.3 52.8 43
−5
Trail 3 1.29 2.15 ×10 37.6 48.2 43.2
−5
Trail 4 1.61 2.68 ×10 37.9 46 42.1

Table 10: Obtained properties for co-current flow

∆T1 ∆T2 ∆Log mean T Tb Hot Tb Cold

33.7 11.8 20.86910173 68.35 45.6
32.5 15.2 22.76481549 67.1 43.25
32 17.1 23.77694585 67.15 42.6
32.4 17.8 24.37558575 66.65 41.55

Table 11: Obtained properties for the counter flow

∆T1 ∆T2 ∆Log mean T Tb Hot Tb Cold

12.8 41.8 24.50460211 68.65 41.35
17.5 39.8 27.13998042 67.7 39.05
22.2 28.1 25.03423246 68.05 42.9
23.8 25.4 24.59132547 66.55 41.95

Table 12: Calculated required data for co-current flow

8
 Q Hot (W) Q Cold (W) Q overall (W) Q/ A inner (W/m^2) U(exp) (W/m^2.℃)
190.2359094 2624.297858 1407.266884 124429.7115 5962.389429
242.8543524 1724.102662 983.4785074 86958.59215 3819.868085
238.8067798 1373.179112 805.9929457 71265.42301 2997.248825
279.2825052 1174.831018 727.0567615 64285.93194 2637.30819

Q Hot (W) Q Cold (W) Q overall (W) Q/ A inner (W/m^2) U(exp) (W/m^2.℃)
165.9504741 5050.247622 2608.099048 230606.5864 9410.746006
210.4737721 4195.825063 2203.149418 194801.1779 7177.646222
190.2359094 1617.299843 903.767876 79910.62493 3192.054122
263.0922151 1235.8612 749.4767078 66268.29043 2694.783188

Table 13: Calculated required data for counter flow

Sample Calculation
for first trial:

Co-current calculations:

I. Inner tube (hot fluid):

1) Volumetric flow rate:

3 3
L 1 min 1m −5 m
Q=2.07 × × =3.45× 10
min 60 sec 1000 L s

2) Bulk temperature:

T h 1 +T h 2 70.7+66
T b= = =67.4 ° C
2 2

3) Finding the change in temperatures:

∆ T 1=T h 1−T c1=70.7 C−37 ° C=33.7 ° C

∆ T 2=T h 2−T c2 =66 ° C−54.2 °C=11.8 ° C

4) Log mean temperature:

9
 ∆ T 2 −∆ T 1 33.7 °C−11.8 ° C
∆ T l ,m = = =16.4 ° C
ln
( )
∆ T2
∆ T1
ln( )
11.8
33.7

5) Finding the properties of the water were found from appendix A-9 using
interpolation:

Kg
ρ=985.05
m3

J
C p=4179
Kg° C

Kg
μ=5.016× 10−5
m.s

W
K=0.6504
m° C

Pr=3.221

6) Finding the mass flow rate:

3
m Kg Kg
m=Vρ=3.45 × 10−5 × 985.05 3 =3.39 ×10−2
s m s

7) Finding the heat transfer rate:

Kg J
q h=m C p ( T h 1−T h 2 ) =3.39× 10−2 × 4179 × ( 70.7 ° C−66 ° C ) =665.84 W
s Kg ° C

8) Finding the inner surface area and the cross-sectional area given that the
internal diameter is 10 mm and the length 360 mm:
2
Ai=π d i L=π × 0.01 m× 0.360m=0.0113 m

π 2 −5 2
Ac = × ( 0.010 m) =7.85× 10 m
4

9) Finding the heat flux:

q 665.84 W W
= =5.89 ×104 2
A i 0.0113 m 2
m

10) Finding the Reynolds number:

10
 Kg Kg
0.01 m× 3.45× 10−5
× 985.05 3
Di Vρ s m
R e i= = =86307
AC × μ −5 2 −5 Kg
7.85 ×10 m ×5.016 × 10
m.s

Re > 2000 therefore the flow is turbulent and hence the following Nusselt number formula is
used

11) Finding the Nusselt number:

Nu=0.023 × R e 0.8 × Pr 0.3=0.023× 863070.8 ×3.2210.3 =290.4

12) Finding the heat transfer convective coefficient:

W
290.4 ×0.6504
Nu × K m° C W
hi = = =18887
Di 0.01 m 2
m .°C

II. Outer tube (cold fluid):

1) Finding the volumetric flow rate:

3 3
L 1 min 1m −6 m
V =0.49 × × =8.17 ×10
min 60 s 1000 L s

2) Bulk temperature:
T c1 +T c2 37+54.2
T b= = =47.6 ° C
2 2

3) Finding the properties of the water were found from appendix A-9 using
interpolation:

Kg
ρ=992.54 3
m

J
C p=4174
Kg ° C

−5 Kg
μ=6.693× 10
m.s

W
K=0.6313
m .° C

11
 Pr=4.436

4) Finding the mass flow rate:

3
Kg −6 m Kg
m=ρV =992.54 3
×8.17 ×10 =8.109E-03
m s s

5) Finding the heat transfer rate:

Kg J
q c =mC p ( T c2−T c 1 )=8.109E-03 × 4174 × (54.2 ° C−37° C )=582.7 W
s Kg °C

6) Finding cross-sectional and surface areas given that the outer diameter 16 mm
with the internal tube thickness 2 mm and the length is 360 mm:

A s=π ( D i+ d o ) L=π × ( 0.016 m+ 0.012 m ) ×0.36 m=0.03167 m2

π π
Ac = (Di−d o )2= × ( 0.016−0.012 )2 m2 =8.796 ×10−5 m2
4 4

D h=D i−d o=0.016 m−0.012 m=0.004 m

7) Finding the flux:

q 582.7 W W
= =1.84 × 104 2
A 0.03167 m2 m

8) Finding Reynolds number:

3
m Kg
0.004 m×8.17 × 10−6
× 992.54 3
D Vρ s m
ℜ= h = =7351.7
AC × μ −5 2 −5 Kg
8.796 ×10 m × 5.016 ×10
m. s

Re > 2000 therefore the flow is turbulent and hence the following Nusselt number formula is
used

9) Finding the Nusselt number:

0.8 0.4 0.8 0.4
Nu=0.023 × R e × Pr =0.023 ×7351.7 × 4.436 =51.7

10) Finding the heat convective transfer coefficient:

W
51.7 ×0.6313
Nu × K m. °C W
h o= = =8159.5 2
Dh 0.004 m m °C

11) Finding the U (empirical):

12
 ro
ln ( )(
( ) ( )
1 1 Ai 1 ri 10.01131m2 1
= + + A )= +
U i h o A o hi 2 πKL i W 0.01357 m 2
W
8159.5 2 1096.2 2
m °C m °C

+ ln ( 0.006
0.005 )
× 0.013309
2 π (16.3)(0.36)

−5 m2 ° C
¿ 7.93 ×10
W

1 W
U i= 2
=12608
m °C m2 ° C
7.93 ×10−5
W

12) Finding U (experimental):

q 4 W
1.84 × 10 2
A m W
U exp = = =5962.39 2
∆ T lm 20.896 m °C

The experimental heat transfer coefficient was found graphically from figure 1:

W
U =slope=1215
m2 ° C

Counter-current calculations:

I. Inner tube (hot fluid):

1) Volumetric flow rate:

3 3
L 1 min 1m −5 m
V =3.01 × × =5.02× 10
min 60 s 1000 L s

2) Bulk temperature:

T h 1 +T h 2 ( 70.7+66.6 ) ° C
T b= = =68.7° C
2 2

13
 3) Finding the properties of the water were found from appendix A-9 using
interpolation:

Kg
ρ=985.05 3
m

J
C p=4179
Kg° C

−4 Kg
μ=5.016× 10
m. s

W
K=0.6504
m. ° C

Pr=3.221

4) Finding the mass flow rate:

3
Kg −5 m −4 Kg
m=ρV =985.05 3
× 5.02× 10 =4.94 × 10
m s s

5) Finding the heat transfer rate:

−4 Kg J
q h=m C p ( T h 1−T h 2 ) =4.94 × 10 × 4179 × ( 70.7−66.6 ) °C=8.46 W
s Kg° C

6) Finding the inner surface area and the cross-sectional area given that the internal
diameter is 10 mm and the length 360 mm:
2
Ai=π d i L=π × 0.01 m× 0.360m=0.0113 m

π 2 −5 2
Ac = × ( 0.010 m) =7.85× 10 m
4

7) Finding the heat flux:

q 8.46 W W
= =748.67 2
A 0.0113m2 m

8) Finding the Reynolds number:

m3 −5 Kg
0.01 m× 5.02× 10
× 985.05 3
Di Vρ s m
ℜ= = =12558.4
AC × μ −5 2 −4 Kg
7.85 ×10 m × 5.016× 10
m. s

14
Re > 2000 therefore the flow is turbulent and hence the following Nusselt number formula is
used

9) Finding the Nusselt number:

0.8 0.3 0.8 0.3
Nu=0.023 × R e × Pr =0.023× 12558.4 ×3.221 =62.12

10) Finding the heat transfer convective coefficient:

W
62.12× 0.6504
Nu × K m°C W
hi = = =4040.3
Di 0.010 m 2
m .° C

II. Outer tube (cold fluid):

1) Finding the volumetric flow rate:

3 3
L 1 min 1m −6 m
V =0.30 × × =5.00 ×10
min 60 s 1000 s s

2) Bulk temperature:

T c1 +T c2 ( 24.8+57.9 ) ° C
T b= = =56.7 ° C
2 2

3) Finding the properties of the water were found from appendix A-9 using
interpolation:

Kg
ρ=992.65 3
m

J
C p=4174
Kg ° C

−4 Kg
μ=6.72× 10
m. s

W
K=0.6310
m .° C

Pr=4.458

4) Finding the mass flow rate:

15
 3
Kg −6 m −3 Kg
m=ρV =992.65 3
× 5.00× 10 =4.96 ×10
m s s

5) Finding the heat transfer rate:

−3 Kg J
q c =mC p ( T c2−T c 1 )=4.96× 10 × 4174 × ( 57.9−24.8 ) ° C=685.3 W
s Kg ° C

6) Finding cross-sectional and surface areas given that the outer diameter 16 mm
with the internal tube thickness 2 mm and the length is 360 mm:
2
A s=π ( D i+ d o ) L=π × ( 0.016 m+ 0.012 m ) ×0.36 m=0.03167 m

π 2 π 2 2 −5 2
Ac = (Di−d o ) = × ( 0.016−0.012 ) m =8.796 ×10 m
4 4

D h=D i−d o=0.016 m−0.012 m=0.004 m

7) Finding the heat flux:

q 685.3 W W
= =21638.7 2
A 0.03167 m 2
m

8) Finding the Reynolds number:

3
m −5 Kg
0.004 m×5.00 ×10 ×992.65 3
Dh Vρ s m
ℜ= = =3358.8
AC × μ −5 2 −4 Kg
8.796 × 10 m ×6.72 ×10
m.s

Re > 2000 therefore the flow is turbulent and hence the following Nusselt number formula is
used.

9) Finding the Nusselt number:

Nu=0.023 × R e 0.8 × Pr 0.4 =0.023 ×3358.80.8 × 4.4580.4 =27.69

10) Finding the heat transfer coefficient:

Nu × K 27.69 ×0.63103 W
h0 = = =4368.3 2
Dh 0.004 m °C

11) Finding the U (empirical):

16
 ro
ln ( )(
( ) ( )
1 1 Ai 1 ri 1 00.01131m2 1
= + + A )= +
U i h o A o hi 2 πKL i W 0.01357 m2
W
4368.3 2 1036.31 2
m °C m °C

+ ln ( 0.006
0.005 )
× 0.013309
2 π (16.3)(0.36)

−5 m2 ° C
¿ 8.119 ×10
W

1 W
U i= 2
=12315
m °C m2 ° C
1.253 ×10−3
W

12) Finding the U(experimental):

q W
230606.57 2
A m W
U exp = = =9410.7 2
∆ T lm 24.5 ° C m °C

The experimental heat transfer coefficient was found graphically from figure 2:

W
U =slope=1629.4
m2 °C

Graphs for the CO-Current flow:

17
 Q vs Logmean T
1600
1400
f(x) = − 196.908853824327 x + 5499.33988283544
1200
1000
Q (W)

800
600
400
200
0
20.5 21 21.5 22 22.5 23 23.5 24 24.5 25
Logmean T(C)

U exp Vs Outlet T hot

7000

6000
f(x) = 1215.03656703132 x − 74363.7753702634
5000
U exp (W/m^2C)

4000

3000

2000

1000

0
63 63.5 64 64.5 65 65.5 66 66.5
T outlet hot (C)

Graphs for the counter flow:

18
 Q vs Logmean Tempreature
3000

2500

2000
f(x) = 238.483289326281 x − 4421.68578894412
Axis Title

1500

1000

500

0
24 24.5 25 25.5 26 26.5 27 27.5
Axis Title

U exp vs T2 hot
10000
9000
8000
f(x) = 1629.36070865369 x − 100574.776801999
7000
U exp (W/m^2C)

6000
5000
4000
3000
2000
1000
0
63 63.5 64 64.5 65 65.5 66 66.5 67
T outlet Hot (C)

Conclusion

19
 To conclude what was done in this experiment, it wanted to demonstrate the
differences between co-current flow and counter-current flow and their effects on the
mean temperature, temperature profiles, and overall efficiency of the heat exchanger.
The overall heat transfer coefficient of the heat exchanger will also be determined.
The entire resistance between fluids is referred to as the overall heat transfer
coefficient in heat transfer. The experimental value of the total heat transfer
coefficient, which is equal to (9410.74 W/(m2. °C)) for counter-current flow and
(5962.39 W/(m2.°C)) for co-current flow, is taken into account as the slope of the
graph between heat flux and the logarithmic mean temperature difference (LMTD).
While the theoretical value of the overall heat transfer coefficient is determined by the
inner surface area of the inner pipe. It is evident from a comparison of theoretical and
practical data that the efficiency range for counter-current flow data is roughly (8.9
%-20.38 %). For co-current flow, the efficiency is roughly (13.95%-21.3%).

20