Heat Exchanger Analysis

10/22/2014
Heat Exchanger Analysis
By
David Vaughn
And
Tyler Ware
September 19, 2000

UTC Engr 435
DR.s Henry, Cunningham, Jones
Introduction
For this analysis a tube and shell heat exchanger was used in a variety of different ways to determine the
convection coefficient different parts of the exchanger. The convection coefficient was found for the tube
side of the exchanger for varying flow rates, and also for the shell side the exchanger for varying flow
rates. This was done by measuring the flow rates for each test and recording the temperatures for the inlet
and outlet of the hot and cold water flow.
Theory and Background
A tube and shell exchanger means that one fluid flows though a series of tubes while the other fluid flows
through a shell that surrounds the tubes. This exchanger had a total of 55 tubes, which amounted to a
total area of transfer of 2.93ft2. The total volume of the shell within this exchanger is 16.0 in3 and the
tubes with have a volume of 8.7in3. This exchanger in particular was set up so the hot water is capable of
flowing through the tubes or the shell, and also the hot and cold water can be set to flow co-current or
counter current. This means that the two streams are flowing the same direction or opposite directions
http://chem.engr.utc.edu/ENgr435/Heat-exchanger/Heat-Exchanger.htm
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respectively. In Figure 1 is a schematic of the heat exchanger and its system. A, B, C, and D are all 4way valves, meaning that they have two inputs and two exits. 1 and 4 are the tube entrances into the heat
exchanger, and 2 and 3 are the shell entrances. For example, if the hot water was set to flow in the tubes
and counter current with the cold water, then in A the hot water in would take the path to C and then to 1,
while the cold water in would flow from B to D and then to 3.
Figure 1 Heat Exchanger Diagram

On this exchanger the input function for the hot water is a motor percentage which pumps water through
a hot water heater and then into the exchanger, changing the motor input changes the output of hot water
flow rate. The temperature is considered a constant coming out of the water heater. For the cold water,
the input function is a proportional valve percentage that varies the amount of cold water aloud to flow
through the system from the faucet. The output of the cold water is also varying a flow rate, which
depends upon some valve percentage.
The way that a heat exchanger works is hot water and cold water enter the exchanger, where the process
of cold water gaining some heat and the hot water losing some takes place, before they both exit the
exchanger. What is actually happening is, the hot water is heating either the inside or the outside of the
tubes in the exchanger, depending on where it is flowing, by what is known as convection. Then the heat
is conducted through the tubes to the other side, either the outside or the inside, where it is then
convected back into the cold water raising its temperature. Convection is a mode of heat transfer that
involves motion of some fluid that either absorbs heat from a source or gives heat to some surrounding.
Conduction is a mode of heat transfer in which the heat is moving through a stationary object or fluid.
For a heat exchanger that flows parallel or counter current then the coefficient of heat transfer is called
the over all coefficient of heat transfer. It is calculated using the log mean temperature difference, which
is found two different ways, depending of whether the flow is parallel or counter.
Modeling
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There were two main equations used to analyze the heat exchanger. They were:
Q = Cp(DT)
Where Q is the heat exchanged, Cp is the heat capacity, and DT is the temperature difference between the
inlet and the outlet streams of the heat exchanger. This equation can be used for both the cold and hot
water streams. The other primary equation was as follows:
Q = U*A* DTlm
Where the Q is the heat exchanged, U is the overall heat transfer coefficient, A is the surface area for the
heat to be exchanged, and DTlm is a log mean temperature difference and is defined below.
DTlm = (DT2 - DT1 ) / ( ln (DT2 / DT1 ))
For parallel flow : DT1 = Thi Tci and DT2 = Tho - Tco
For counter flow : DT1 = Thi Tco and DT2 = Tho - Tci
Figure 2 Tube and Shell Co-Current Flow

Procedure
In conducting an analysis on the heat exchanger, the first thing to do is to understand the exchanger and
to then decide the procedure that will be used in order to take data that will be useful later for analysis.
For this experiment we decide to divide the actual procedure in to four different groups: first using the
hot water in the shell and the flows counter-current, second hot water in the shell and the flows are cocurrent, third we would leave the flow co-current and switch the flow of hot water from the shell to the
tubes, and for the last experiments we would leave the hot water in the tubes, but the flow would be
switched to counter current. Then for each of the partial procedures the flow rate should be varied for the
hot water and the cold water. With this procedure in mind we started the labview Temperature Manual
Remote program. After selecting the settings we were going to use first, the run button was pushed on the
interface, and the experiment was started. The temperatures were then recorded off the computer for the
hot water input and output and the cold water input and output. After the data was recorded we stopped
the program and left the computer as it was when we arrived.
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Results
The results from the spreadsheet were as follows:
HW Tube - Counter Current

HW flow CW flow D T1 *C D
4.4
4.5
13.8
4.0
4.5
14.4
3.6
4.5
15.2
3.3
4.5
15.9
2.7
4.5
16.5
2.2
4.5
17.2
1.8
4.5
18.0
1.4
4.5
18.9
0.6
4.5
19.6
4.4
4.0
13.2
4.4
3.8
12.8
4.4
3.6
11.6
4.4
3.1
8.6
4.8
3.9
11.1
4.8
4.3
12.0
HW shell Counter Current
4.50
3.80
10.50
3.40
3.80
11.00
1.70
3.80
12.00
HW Shell Co-Current
4.50
3.80
21.30
3.70
3.80
20.10
4.66
4.36
18.60
4.66
3.20
18.60
HW shell Counter Current
3.70
3.80
11.30
HW Tubes Co-Current
T2 *C DT Log Mean U (kW/m^2 K)

15.1
14.4
1.29
14.6
14.5
1.20
13.7
14.4
1.14
12.5
14.1
1.11
11.0
13.6
1.04
9.3
12.8
0.99
7.0
11.6
0.98
3.8
9.4
0.97
0.3
4.6
0.90
14.8
14.0
1.21
15.0
13.9
1.19
14.9
13.2
1.17
15.0
11.5
1.14
14.1
12.5
1.29
13.3
12.6
1.29
T2 *C
12.30
9.40
4.50
11.38
10.18
7.65
1.07
1.13
0.98
T2 *C
4.90
4.30
4.40
3.40
11.16
10.25
9.85
8.94
0.91
0.87
0.94
0.90
11.10
11.20
1.07
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4.77
4.77
4.57
3.20
22.90
17.50
4.70
2.90
11.49
8.12
1.15
1.00
Table 1 Collected Data
The data was plotted and the results follow:
Figure 2 HW Tube Counter Current
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Figure 3 HW Shell Counter Current
Figure 4 CW Tube Counter Current
The Reynolds number was calculated for the tubes of the heat exchanger and was found to be less than
1000 for all flow rates that were possible. Therefore the flow through the tube side of the heat exchanger
was assumed laminar.
Note! Insert Reynold # vs. U Here

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Discussion
When the cold water is left at a constant flow rate and the hot water flow is increased, the average U
value increases. The response of the average U value with a varying flow rate is different for the hot
water in the tubes and the hot water in the shell. When the hot water is in the shell, the U increase until
the flow rate is around 3.65 L/min, and which time the U value decreases with increased flow rates. The
reason for this is believed to be caused from the baffles within the shell in the heat exchanger, when the
flow increases so much the baffles start to make the flow turn more turbulent than laminar, so the U
value changes. When the hot water flow is in the tubes and is increased, the average U value increases
constantly with flow increase. This is because the water flow through the tubes is staying laminar
therefore making the U value more constant. When the hot water was left constant and the cold water
varied while flowing through the shell, the results seemed to be completely opposite. The average U
value decreased with increasing flow rates until the flow was about 3.7 L/min at which time the U value
started to increase with higher flow rates.
Conclusions
The heat exchanger performed as it was expected to perform. The U calculated for the hot stream was
only slightly different then the U calculated for the cold stream. This indicates that there is heat lost to
the surrounding areas. The heat exchanger was most effective when the hot water was directed into the
tubes and the flow was counter-current. Also for the flow rates examined the heat transfer rate increases
as the flow rate increases. It was seen that when the flow in the shell reached about 3.7 L/min the flow
began to be disturbed. It is believed that the baffles cause the flow to become turbulent.
Recommendations
In an effort to reduce the heat loss to the surroundings, it is recommended that the heat exchanger be well
insulated. Presently the heat exchanger has no insulation and the ambient room temperature has a large
effect on the results. It is also recommended that during the process of data collection that the user
adjusts the flow rate of only one stream per setup. If this is not done the graphs of the data becomes very
difficult to read and understand. Another recommendation is to ensure that the flow rates obtained are
measured accurately. There are two ways that this may be done. One way is to purchase new flow
meters, and the other is to manually measure each flow rate with great care. This is extremely important
because without accurate flow rates the temperature data is worthless.
David Vaughn
Wrote for report:
Modeling
Results
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Conclusions
Recommendations
Also:
Collected data for two days of lab
Tyler Ware
Wrote for the report:
Introduction
Theory and Background
Procedure
Discussion
Also:
Gave both oral presentations
Collected data for all three days of lab
Appendices
Physical properties for water:
Cp = 4.18 kJ / kg k
Equations:
Q = Cp(DT)
Q = U*A* DTlm
DTlm = (DT2 - DT1 ) / ( ln (DT2 / DT1 ))
For parallel flow : DT1 = Thi Tci and DT2 = Tho - Tco
For counter flow : DT1 = Thi Tco and DT2 = Tho - Tci
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Data curves and calculations:

*see the following sheets
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Discussion
When looking at the results from that data taken it is seen that the heat exchanger does perform as it
should. When the cold water is left at a constant flow rate and the hot water flow is increased, the
average U value increases. The response of the average U value with a varing flow rate is different for
the hot water in the tubes and the hot water in the shell. When the hot water is in the shell, the U increase
until the flow rate is around 3.65 L/min, and which time the U value decreases with increased flow rates.
The reason for this is believed to be caused from the baffles within the shell in the heat exchanger, when
the flow increases so much the baffles start to make the flow turn more turbulent then laminar, so the U
value changes. When the hot water flow is in the tubes and is increased, the average U value increases
constantly with flow increase. This is because the water flow through the tubes is staying laminar
therefore making the U value more constant. When the hot water was left constant and the cold water
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varied while flowing through the shell, the results seemed to be completely opposite. The average U
value decreased with increasing flow rates until the flow was about 3.7 L/min at which time the U value
started to increase with higher flow rates.
11/11

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10/22/2014