Chemical Engineering Laboratory-1 

 
(CHE F312) 
 
Lab Report 
 
Heat Transfer Lab 
 
H-1 
 
HEAT EXCHANGERS

Group 14

Vedant Desai
Pratyush Srivastava
Hritik Vinayak Lal
Apoorv Kaushik
Objective:
1. Study of Shell and tube type heat exchanger
2. Study of Double pipe type heat exchanger

Aim:
1. To determine the log mean temperature difference (LMTD) and calculate the
heat transfer coefficient in Shell & Tube type heat exchanger
2. To determine the log mean temperature difference (LMTD) and calculate the
heat transfer coefficient in Double pipe type heat exchanger

Brief Theory:
Heat exchangers are devices that allow heat transfer between two fluids at different
temperatures. It does this when the fluids are separated by a wall or if the fluids are
immiscible in each other. Tube and plate are two major distinctions between heat
exchangers on the basis of structure. Heat exchangers have very broad applications.
They are usually used in refrigeration, heat generation, coolants and heaters,
automobiles, radiators and so on.

Types of heat exchangers:

In the following experiment we focus on the shell and tube heat exchanger and the
double pipe heat exchanger.
Shell and Tube​: It consists of a shell which encases numerous copper tubes of smaller
diameter and axis parallel to that of the shell. The hot fluid is passed through the tubes
while the cold fluid flows through the shell. A shell and tube heat exchanger usually
employs devices called baffles to provide support to its framework. They also induce
turbulence and cross flow velocity in the tubes which help to increase the convection
coefficient of the shell-side fluid.
Double pipe​: It consists of two concentric pipes of different diameters, one fluid flows
through the smaller pipe while the other flows through the space between two pipes.
Based on direction, we can say that this exchanger operates on two different
arrangements - the parallel flow and the counter flow. In parallel flow, both hot and cold
fluids enter from the same end and flow in the same direction whereas in counter flow,
their flow is in the opposite direction. We measure both inlet and outlet temperatures,
i.e. the temperature of fluids using sensors.

Experimental Setup:

1. ​Shell & Tube Heat exchanger

Exchanger: Experimental setup consists of an outer shell and 55 inner copper tubes.
Hot water from a geyser flows through the inner tubes via a rotameter to record the flow
rate. Coldwater is pumped through the shell.

Temperature Indicator: The inlet and outlet temperatures for the hot and cold water
tubes are measured with thermocouples and read from a digital temperature indicator
(range 0 to 400 C).

Geyser: Capacity of 3 liters, wattage 3 kW, trip at 80 o C

Rotameter: The attached rotameter measures the flow rate (60 to 600 LPH)

Pump: 1900 LPH for the given head, 0.25 HP.

2.​ Double-pipe heat exchanger

Exchanger: The Apparatus consists of two concentric cylinders through which hot and
cold water flow in opposite directions (counter flow) or in the same direction (parallel
flow). Hot water from a geyser flows through the inner cylindrical tube via a rotameter to
record the flow rate. Coldwater is pumped through the outer tube.

Temperature Indicator: The inlet and outlet temperatures for the hot and cold water
tubes are measured with thermocouples and read from a digital temperature indicator
(range 0 to 400 degrees C).

Geyser: Capacity of 3 liters, wattage 3 kW, trip at 80 O C

Rotameter: The attached rotameter measures the flow rate (60 to 600 LPH)

Pump: 1900 LPH for the given head, 0.25 HP.

S.No T1 C T2 C T3 C T4 C Cold Water Hot Water

Steady 55.8 52.2 27.6 32 310 340

1.T1=T​hi​ = 55.8℃
2. T2=T​ho​=52.2 ℃
3.T3 =T​ci​=27.6 ℃
4.T4=T​co​= 32 ℃
5.T​m,hot​= (55.8 + 52.2 )/2 = 54
Properties of water were calculated according to:
Shell and Tube Heat Exchanger:

SPECIFICATION/KNOWN DATA
Outer (shell) diameter of outer tube (D​i​) : 150 mm
Inner diameter of inner tube (d​i​) : 7 mm
Outer diameter of inner tube (d​o​) : 9.5 mm
Length of the tube (L) : 300 mm

S.No T1 T2 T3 T4 Cold Hot water

Steady 51 46.8 26.7 33.6 250 350

1.T1=T​hi​ = 51 ℃
2. T2=T​ho​= 46.8℃
3.T3 =T​ci​=26.7 ℃
4.T4=T​co​= 33.6 ℃
Precautions:
1. Use a stable AC Single phase supply only.

2. Never switch on the mains power supply before ensuring that all the ON/OFF
switches given on the panel are in the OFF position.

3. Regulate and change voltage supply to the heater in a slow manner.

Never run the apparatus if the supply voltage is less than 180 volts and above
than 240 volts.

4. Operate the selector switch of the temperature indicator gently.

5. Always keep the apparatus free from dust.

Exercise:

Q1. Compare and analyze the theoretical and experimental heat transfer
coefficients.

Theoretical values are greater than experimental values because we have made
assumptions for theoretical calculations such as no heat losses, no friction due to which
energy losses are not accounted for. Some other assumptions are that, during total heat
transfer the temperature gradient is constant. This does not happen practically, as the
body is continuously cooling. We consider properties at a particular temperature of the
body. However, since the body gets cooled over time. the calculated radiations will be
higher than the actual. Due to such reasons, there is always a difference between
theoretical and experimental values.

Q2. Write a brief note on application of any type of heat exchanger for a chemical
industry of your choice.

The simple design of a shell and tube heat exchanger makes it an ideal cooling solution
for a wide variety of applications. One of the most common applications is the cooling of
hydraulic fluid and oil in engines and petroleum industries. It is suited for
higher-pressure applications. As its name implies, this type of heat exchanger consists
of a shell with a bundle of tubes inside it. Shell and tube heat exchangers can be
single-phase, or two-phase. A single-phase exchanger keeps the fluid’s phase constant
throughout the process (e.g. liquid water enters, liquid water leaves) while a two-phase
exchanger will cause a phase change during heat transfer process (e.g. steam enters
and liquid water leaves).

DISCUSSION :
PRATYUSH:
● A heat exchanger is a device that allows heat from a fluid (a liquid or a gas) to
pass to a second fluid (another liquid or gas) without the two fluids having to mix
together or come into direct contact

● Double pipe heat exchanger:-one fluid flows inside a pipe and the other fluid
flows between that pipe and another pipe that surrounds the first. This is a
concentric tube construction. Flow in a double-pipe heat exchanger can be
co-current or counter-current. There are two flow configurations: co-current is
when the flow of the two streams is in the same direction, counter current is
when the flow of the streams is in opposite directions.

● Shell and tube heat exchanger :-this type of heat exchanger is most commonly
used , it consists of a shell and bundles of tubes inside it. Hot fluid flows inside
the tubes and colder one in the shell side.Again the operation can be co-current
or counter current .

● CoCurrent and Counter current : flow is said to be co-current if both hot and cold
fluid flow in the same direction whereas in counter current they flow in opposite
directions .
Counter current flow is better operation as the temperature difference between
hot and cold fluid remains uniform throughout which ultimately provides a more
uniform heat transfer.
● Baffles :- Baffles are usually installed to increase the convection coefficient of the
shell-side fluid by inducing turbulence and cross-flow velocity components. In
addition, the baffles physically support the tubes, reducing flow-induced tube
vibration
● Observation from the experiment : -
1.LMTD was less in shell and tube than in double pipe ,it may be due to the fact
that Area for heat transfer exchange was more in shell and tube for same amount
of heat supplied ,resulting in lesser LMTD
2.Overall heat transfer coefficient obtained theoretically was higher than the
experimental one , this may be due to various errors and assumptions which we
make during the experiment like in experiment there are heat losses to
surrounding which are not incorporated in theoretical calculations.

● Possible errors :
1.Calculation and round off errors
2.Inaccuracy of equipments
3.external factors like temperature
4.friction losses due to fluid motion .

● Application: ​They are widely used in space heating, refrigeration, air conditioning,
power stations, chemical plants, petrochemical plants, petroleum refineries,
natural-gas processing, and sewage treatment.
VEDANT :
A heat exchanger is a device that allows heat transfer between fluids without the two
fluids having to mix together or come into direct contact. In this experiment, we studied
heat transfer through shell & tube heat exchanger and double pipe heat exchanger. We
use ​Log mean temperature difference ​(LMTD) for our calculations rather than mean
temperature difference because the ​temperature variation along the heat exchanger
are non-linear and it is very difficult to calculate the arithmetic mean temperature
difference so we use LMTD which makes our calculations easier and we can easily
measure the temperature driving force.
(ΔTlmtd)counter-flow > (ΔTlmtd)parallel-flow because for parallel flow the
temperature difference between hot and cold streams is very high at the inlet but goes
on decreasing towards the outlet as we proceed in the same direction whereas for
counterflow both the streams move in opposite directions, so the temperature difference
between them as we move along a particular direction is always relatively higher. Also,
in counter-flow ​it is possible to get the outlet temperature of hot stream lower than
the outlet temperature of cold stream which is not possible for parallel flow as in
parallel flow the temperature of hot stream can never be lower than any temperature of
the cold stream.

We also see that the value of theoretical heat transfer coefficient is greater than the
experimental overall heat transfer coefficient ( Ui,theoretical> Ui,experimental) for
both the shell & tube and double pipe heat exchangers. This is because in experimental
conditions there are ​heat losses to the atmosphere by convection and due to radiation
and other factors which are not accounted for in theoretical calculations. Also, there
may not be a perfect steady state and ​we approximate for steady state conditions
for our experiment which also leads to the difference in the theoretical and experimental
values. There may also be other errors due to flaws and impurity of the exchanger
material as well as the fluids being used.
The lower ​LMTD ​in case of shell and tube may be due to the inner tubes collectively
providing more surface area than a single inner pipe in Double pipe, providing the same
heat transfer rate at relatively lower temperature gradient.
Many chemical industries use the heat exchangers for various purposes like:
● ONGC industry uses heat exchangers
● Industries like Mining, Pulp and Paper Production and Pharmaceutics
● Plate type heat exchangers are used in dairy and food processing. In a plate heat
exchanger plates transfer heat between two fluids

HRITIK :

● A heat exchanger is a system used to transfer heat between two or more fluids.
Heat exchangers are used in both cooling and heating processes. The fluids may
be separated by a solid wall to prevent mixing or they may be in direct contact.
● There are many different types of heat exchangers available. Here in this
experiment we studied 2 different types which are Double pipe heat exchanger
and shell tube heat exchanger. The most common arrangements for flow paths
within a heat exchanger are counterflow and parallel flow.
● In counter-flow heat exchanger the direction of the flow of one of the working
fluids is opposite to the direction of the flow of the other fluid.
● In a parallel flow exchanger, both fluids in the heat exchanger flow in the same
direction.
● The counter-flow heat exchanger has significant advantages over the parallel
flow design because the more uniform temperature difference between the two
fluids minimizes the thermal stresses throughout the exchanger and the more
uniform temperature difference produces a more uniform rate of heat transfer
throughout the heat exchanger also we can get higher outlet temperature of the
cold fluid in the case of counterflow heat exchanger than in the case of parallel
flow exchanger.
● Double pipe heat exchanger​: Double pipe heat exchanger consists of two
concentric pipes of different diameters. One fluid flows through the inside pipe
and the other flows through the annulus between the two pipes. The wall of the
inner pipe is the heat transfer surface.
 ● Shell tube heat exchanger​: In the Shell and Tube heat exchanger, a large
number of tubes are packed in a shell with their axes parallel to that of the shell.
This is where the heat transfer takes place as one fluid flows inside the tubes
while the other fluid flows outside the tubes through the shell. The fluids can flow
in parallel or counter flow arrangement.Comparing the theoretical and
experimental heat transfer coefficients we see that the theoretical is greater than
the experimental values for both shell and tube and double pipe heat
exchangers.
● Baffles are obstructing sheets/panels which can be used to direct the flow in
desired direction. They increase the velocity and turbulence of the shell side fluid
and thereby increase the heat transfer.
● Few observations:
● We used LMTD(Logarithmic mean temperature difference) instead of
Arithmetic mean temperature difference because The counter-current
temperature profile curve and the co-current configuration for heat transfer are
not straight lines, but curved/exponential.
●The lower temperature difference in case of shell and tube HE may be due to
the fact that the inner tubes collectively provide more surface area than a single
inner pipe in Double pipe and hence for the same heat amount of heat transfer, a
lower temperature difference is required in Shell and tube HE.
● Possible Sources of Error​:
● Rounding of errors in calculations
● Friction losses in in heat transfer due to movement of fluids
●Inaccuracy of equipment used. Eg: Geyser temperature sensor might not be
very accurate.
●External environmental conditions like extreme temperatures in some locations
might lead to some inaccurate results.
● Real life applications of Heat exchangers​:
1.Power plant generation.
2.petroleum oil and gas industry.
3.chemical processing plant.
4.Transportation,alternate fuels, cryogenic, air conditioning and refrigeration,
heat recovery systems etc.

APOORV:

● In this Experiment, we learnt about heat exchangers, which are the devices that
exchange the heat between two fluids of different temperatures that are
separated by a solid wall.
● In this device the temperature differential is the driving force.
● Two types of flow patterns exist: ​Counter Current ​and ​Co-current.
● All the substances flow in the opposite direction of each other in counter current,
while they flow in the same direction in co-current. The experiment was carried
out in two parts: We used a Double Pipe heat exchanger in one experiment,
while we used a Shell and Tube heat exchanger in the other one.
● Types of flow pattern:
 ○ Counter flow​: The hot and cold fluids enter the heat exchanger at opposite
ends and flows in opposite directions.
○ Parallel Flow​: Both the hot and cold fluids enter the heat exchanger from
the same end and move in the same direction.

● Counter current flow is more efficient than parallel flow as it creates a more
uniform temperature difference between the fluids over the entire length of fluid
path and so the log mean temperature difference is more there.
● Under​ turbulent flow​, the increase in heat transfer rate is more significantly than
that under laminar flow. This is due to an increase in Reynolds number of flowing
fluid in turbulent flow. Therefore, there is turbulence in shell side flow of Shell and
tube heat exchanger.
● Double Pipe heat exchanger: ​Two concentric tubes of varying diameters
consist of a double pipe heat exchanger.For cold liquids, one pipe is and another
is for cold fluid. Cold fluid flows from the outer pipe in this experiment, as well as
hot fluid from the inner pipe. The same flow direction can be used by all fluids,
i.e. parallel flow or the opposite flow direction,i.e. counter flow. It is counter-flow
in this experiment with this type of heat exchanger so there is a slight variation in
the temperature of the hot fluid going out to that of the cold fluid going in and
even in the cold fluid coming out.
● Shell and tube heat exchanger: ​It consists of a shell which contains a large
number of parallel tubes. One hot or cold flow of fluid in the shell, and another
hot or cold flow in the pipe. It can also have two flow forms i.e. counter or parallel
flow. In this experiment this type of heat exchanger is parallel flow since the
temperature of the hot fluid going out is approximately the same as that of the
cold fluid going out.
● When compared, the shell and tube heat exchanger seem to be more efficient
than double pipe heat exchanger as it has multiple passes for the fluid and hence
the fluid can stay longer in contact with the material that is being heated.
According to ​Nusselt's equation,​ the longer the contact time and the higher the
heat exchange surface, the greater the heat exchange.
● Apart from what given in theory ​baffles a ​ lso help in holding tubes in
position(prevents sagging) both in production and operation and it also prevents
the effects of steam starvation, which is increased with both fluid velocity and
length of exchanger.
● Plate exchanger​ i​ s more efficient due to turbulent flow on both sides
● A few ​examples​ of industries where heat exchangers are used are:
○ Air conditioning
○ power stations
○ sewage treatment
○ petrochemical plants
○ petroleum refineries

● Some of the factors that industry professionals should keep in mind when
designing​ and ​choosing​ a heat exchanger include:
○ The type of fluids, the fluid stream, and their properties
 ○ The desired thermal outputs
○ Size limitations
○ Costs

CONCLUSION​:
Double Pipe Heat Exchanger​:
1.The log-mean temperature difference (LMTD) :​24.197 K
2.The theoretical heat transfer coefficient: ​1135.255 W/m K2
3. The experimental overall heat transfer coefficient: ​962.956 W/mK

Shell and Tube Heat Exchanger​:

1.The log-mean temperature difference (LMTD) :​18.266​ ​K

In this experiment we analyzed the differences and similarities between the two given
heat exchangers and worked out heat transfer coefficients, both theoretical and
experimental. It is seen that the theoretical value of overall heat transfer was found to
be greater than experimental value due to heat losses in the experiment.

REFERENCES​:
● Heat Lab Manual
● Demonstration in the class