HVAC Lab

Lab Report 04

Shell and Tube Heat Exchanger

6th SEMESTER

Submitted to: Engr. Zeeshan Ahsan

Section: C
SUBMITTED BY
Name CMS

Hafiz M Haris Ali 394480

School of Mechanical and Manufacturing Engineering

Objectives:

 To determine the effectiveness of shell and tube heat exchanger.

 To calculate the heat rejected by the hot water, heat absorbed by the cold water and heat loss
during the heat transfer process.
 Calculate the global heat transfer co-efficient ‘U’ for both inner and outer surface of the tubes.

Introduction:
A shell and tube heat exchanger (STHE) is a type of heat exchanging device constructed using a
large cylindrical enclosure, or shell, that has bundles of perfectly spaced tubing compacted in its
interior. Heat exchanging is the transfer of heat from one substance or medium to a similar
substance or medium. Shell and tube heat exchangers are the most common form of heat
exchange design. They are classified according to their properties, tubing type, and other
characteristics.
Theory and application: 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.

Apparatus:

Figure 1: Shell & Tube heat exchanger apparatus

Procedure:
1. Set the valves in parallel/counter flow configuration.
2. Check that the heating tank is full of water above the level switch.
3. Switch on the pump and the heating element.
 4. Set the temperature of hot water tank [ Look for ST-16 temperature sensor display on
control unit, Press ‘MODE’, set the required temperature by pressing ∆ and ∇] • Set the
flow rate of hot water and cold water.
5. Wait until the steady states conditions are reached. One indication that can be used is that
the temperature of hot water at the inlet of heat exchanger (T1) becomes constant.
6. Write down temperature and flow measurements on data recording sheet and perform
required calculations.
7. Repeat the process for other power inputs or temperature of the tank.

NOTE:
- Allow sufficient time for the system to reach steady state conditions after each adjustment.
- Always turn off the heater supply before shutting down the main power switch after completing
the experiment.

Observations & Calculations:

The specifications of the heat exchanger is as follows:

No. of stainless-steel tubes 21

Exchange length of external tube

500 mm
and other internal stainless tubes

Internal dia of each tube 8 mm

External dia of each tube 10 mm
Thickness of the tube 1 mm
Shell outer diameter 160 mm
Shell internal diameter 148 mm
Shell Thickness 6 mm
Electric heater power 3000 W

Parallel Flow
Volume flow rate of hot water = 1.85 Lpm
Hot Tank Set Temperature = ST-16 = 60 oC

Volume flow rate of cold water

- 1.2 1.4 1.6
(LPM)
Hot water inlet ST-1 41 41 41
Hot water outlet ST-2 36 38 36
Cold water inlet ST-3 27 28 29
Cold water outlet ST-7 38 35 35
 C.W. temperature in 1st
ST-4 32 32 31
section (parallel to flow)
C.W. temperature in 2nd
ST-5 35 33 32
section (parallel to flow)
C.W. temperature in 3rd
ST-6 37 34 33
section (parallel to flow)

Counter Flow
Volume flow rate of hot water = 1 Lpm
Hot Tank Set Temperature = ST-16 = 60 oC

Volume flow rate of cold water

- 1.2 1.4 1.6
(LPM)
Hot water inlet ST-1 39 39 39
Hot water outlet ST-2 36 33 36
Cold water inlet ST-3 27 21 27
Cold water outlet ST-7 35 32 35
C.W. temperature in 1st
ST-4 35 31 34
section (parallel to flow)
C.W. temperature in 2nd
ST-5 33 30 32
section (parallel to flow)
C.W. temperature in 3rd
ST-6 32 29 31
section (parallel to flow)

Graph:
Parallel flow
 Temp Variation Hot vs Cold
45
40
35
30
Temp (0C)

25
20
15
10
5
0
0 100 200 300 400 500 600
mm

COLD HOT
Counter flow

Temp Variation Hot vs Cold

45
40
35
30
Temp (0C)

25
20
15
10
5
0
0 100 200 300 400 500 600

mm

COLD HOT

Discussion:
The experiment's data suggests that parallel flow heat exchangers are relatively inefficient due to
heat transfer ceasing once both liquids reach equilibrium. This is attributed to their flow direction
being the same, resulting in minimal heat exchange. Additionally, it's evident that hot liquid loses
a considerable amount of heat compared to what cold water absorbs, mainly due to inadequate
insulation leading to significant heat dissipation into the surroundings.
Conversely, findings strongly indicate that counter flow heat exchangers outperform parallel flow
counterparts in terms of efficiency. There's a notable disparity in heat exchange, with counter flow
facilitating greater heat transfer from hot to cold fluids. The key advantage of counter flow lies in
its ability to maintain a consistent temperature difference along the exchanger's length, unlike
parallel flow where the temperature difference diminishes continuously, resulting in reduced heat
transfer efficiency towards the exit.

Conclusion:
In conclusion, counter flow heat exchangers prove notably more efficient than parallel flow
counterparts. This efficiency is evidenced by greater heat exchange rates and consistent
temperature differences along the exchanger's length. The closely matched inner and outer heat
transfer coefficients validate experimental accuracy. Overall, counter flow's continuous heat
transfer contrasts with the diminishing efficiency of parallel flow, particularly towards the
exchanger's exit.