C19436526 Lab 5 MECH4008

Lab 5: Shell and Tube heat exchanger

Bachelor of Engineering (BE) in

Lab Report
Jason Samuel

Supervisor: Camila D’Bastiani

Mechanical Engineering
School of Mechanical Engineering
TU Dublin, City Campus, Bolton St

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C19436526 Lab 5 MECH4008

Nomenclature
𝑡 = thickness (mm)
𝐹𝑂𝑆 𝑜𝑟 𝑠 = Factor of Safety
𝑄 = Heat loss (J)
𝑄̇ = rate of heat loss (W)
𝑚̇ 𝑜𝑟 𝑆 = mass flow rate (Kg/s)
𝛥ℎ = change in enthalpy (kJ/Kg)
ℎ = enthalpy (kJ/Kg)
𝑐 = heat capacity (J/Kg.K)
𝑚 = mass (Kg)
𝑊
R = Thermal resistance (𝑚2 ⋅𝐾)

ρ = density (Kg/m3)
A = Cross sectional area (m2)
V = velocity (m/s)
P = pressure (Pa)
𝛥𝑥 = change in length (m)
𝑘 = Thermal conductivity (W/m.k)
h = thermal conductivity for pipes (W/m.k)
𝑉̅ = specific volume (m3/Kg)
D = diameter (m)
𝛥𝑇 = change in temperature (K)
U = Overall heat transfer coefficient ( W/m2K)
L = length (m)
Nu = Nusselts number
Ra = Raleigh Number
h = convection coefficient (W/m2K)
g = gravity (m/s2)
β = Volumetric thermal expansion coefficient ( K-1)
Pr = Prandtl Number
ν = kinematic viscosity (m2/s)

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C19436526 Lab 5 MECH4008

ε = emissivity
V and I = Volts and Amps ( V and I)

Subscripts used
i = inner
o = outer
p = specific
f = fluid
g = gas
c = cold
H = hot

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C19436526 Lab 5 MECH4008

Table of Contents
Nomenclature .............................................................................................................................. i

Subscripts used.......................................................................................................................ii

Aims ........................................................................................................................................... 2

Theoretical Background ............................................................................................................. 3

Procedure ................................................................................................................................... 4

Results ........................................................................................................................................ 5

Sample Calculations................................................................................................................... 9

Discussions .............................................................................................................................. 11

Conclusions .............................................................................................................................. 12

References ................................................................................................................................ 13

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C19436526 Lab 5 MECH4008

Table of Graphs
Graph 1 Table of data (Parallel) ................................................................................................. 5
Graph 2 Parallel flow ................................................................................................................. 6
Graph 4 Counterflow.................................................................................................................. 8
Graph 5 U Value......................................................................................................................... 8

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C19436526 Lab 5 MECH4008

Table of Tables
Table 1 Table of data (counterflow) ........................................................................................... 7
Table 2 Counterflow calculations pt1 ........................................................................................ 7
Table 3 Counterflow ctd............................................................................................................. 7

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C19436526 Lab 5 MECH4008

Introduction
One of the most popular and adaptable kinds of heat transfer equipment utilized in a variety
of industrial processes, HVAC systems, and thermal power plants are shell and tube heat
exchangers. These heat exchangers are made up of a series of tubes enclosed in a cylinder
shell that allow hot and cold fluids to flow in parallel or counter-current configurations,
allowing for the exchange of heat.

The main goals of this lab experiment are to find a shell and tube heat exchanger's overall
thermal heat coefficient (U-value) and to examine the temperature distribution.
Comprehending these variables is essential for evaluating heat exchanger efficacy and
performance, refining their architecture, and guaranteeing efficient heat transfer among fluid
streams.

Convective heat transfer, which transfers heat between hot and cold fluids through the tube
walls, is the basis for how the shell and tube heat exchanger works. Temperature gradients
that form when the fluids pass through the tubes and the shell cause heat exchange and
variations in the fluid's temperature.

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C19436526 Lab 5 MECH4008

Aims
To compute and compare the overall heat transfer coefficients for counterflow and parallel
flow in a shell and tube heat exchanger.

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C19436526 Lab 5 MECH4008

Theoretical Background
A bundle of tubes is housed inside a cylindrical shell in a shell and tube heat exchanger.
While one fluid (the shell side fluid) flows over the outside surface of the tubes inside the
shell, another fluid (the tube side fluid) flows through the tubes. The two fluids can transport
heat effectively thanks to this configuration.

There are three different flow configurations that shell and tube heat exchangers can function
in: crossflow, co-current, and counter current. The hot and cold fluids flow in opposing
directions during counter-current flow, which maximizes the temperature differential across
the exchanger and improves the efficiency of heat transfer. [1]

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C19436526 Lab 5 MECH4008

Procedure
1. Wait until steady state is reached for one preset flow rate of the warmer fluid and one
of the colder fluids. When the temperature changes by less than 1°C every minute,
proceed with the experiment.
2. Read the appropriate values for the hot and cold inlet and outlets.
3. Read the volume flow rates and ensure they are in the correct order.
4. Change the flow rates.
5. Once all the data is collected, switch the configuration to counterflow and repear the
process.

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C19436526 Lab 5 MECH4008

Results
Here is the data recorded for the parallel configuration:
Cold
Hot Fluid
Fluid

Set
of 𝑽̇̇ 𝒉 Th,i Th,o 𝑽̇̇ 𝒄 Tc,i Tc,o
Data

L/mi
L/min °C °C °C °C
n
1 2.5 60 50 4 20.9 25.8
2 2.5 60.2 50.8 3 20.8 26.8
3 3.5 60 51.6 4 20.8 26.3
4 3.5 59.8 52.1 3 20.8 27.7
Graph 1 Table of data (Parallel)

The calculations for the parallel flow are shown below:

Figure 1 Parallel calculations pt1

Here is the continued calculations for the parallel flow:

Figure 2Parallel calculations pt2

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C19436526 Lab 5 MECH4008

Here is the graph of parallel flow:

Parrallel Flow
70

60

50 Set 1 (Hot)
Set 2 (Hot)
Temp (°C)

40 Set 3 (Hot)
Set 4 (Hot)
30
Set 1 (Cold)
20 Set 2 (Cold)
Set 3 (cold)
10
Set 4 (Cold)
0
0 0.5 1 1.5 2 2.5
Phase

Graph 2 Parallel flow

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C19436526 Lab 5 MECH4008

Here is the data for the counterflow:

Set
of 𝑽̇̇ 𝒉 Th,i Th,o 𝑽̇̇ 𝒄 Tc,o Tc,i
Data

L/mi
L/min °C °C °C °C
n
1 2.5 59.2 49.3 4 25.7 21
2 2.5 59.5 50.1 3 27 21.1
3 3.5 59.6 51.3 4 26.5 21.2
4 3.5 59.4 51.7 3 27.9 21.1
Table 1 Table of data (counterflow)

The calculations for the counter flow are shown below:

Table 2 Counterflow calculations pt1

Table 3 Counterflow ctd

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C19436526 Lab 5 MECH4008

Here is the graph of counterflow:

Counterflow
70

60

50
Temperature

40 Set 1 (hot)

30 Set 2 (Hot)
Set 3 (cold)
20
Set 4 (cold)
10

0
0 0.5 1 1.5 2 2.5
Phase

Graph 3 Counterflow.

U value vs Flow
3000

2500
U Value (W/m2K)

2000

V= 4 parrallel
1500
V = 3 parrallel

1000 V = 3 counterflow
V = 4 counterflow
500

0
0 0.5 1 1.5 2 2.5 3 3.5 4
Phase

Graph 4 U Value

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C19436526 Lab 5 MECH4008

Sample Calculations
𝑇 𝑇 +𝑇ℎ,𝑜
𝑎𝑣𝑔= ℎ,𝑖
2
60 + 50
=
2
= 55°𝐶
Step 2: Find the specific volume from tables.
𝑣 = 0.001015 m3/kg
Step 3: Find the density of fluid.
1
𝜌=
𝑣
1
=
0.001015
𝑘𝑔
= 985.22 3
𝑚
Step 4: Find specific heat of water using tables.
Water = 4182 J/kg
Step 5:
𝑚 = 𝜌̇ × 𝑉̅
985.22 × 0.0000416
𝑘𝑔
= 0.041
𝑠
Step 6:
𝑄ℎ = 𝑚̇ℎ 𝑐𝑝 (𝑇ℎ,𝑖 − 𝑇ℎ,𝑜 )
= 0.0041 × 4182(60 − 50)
= 1716.4 𝑊
Step 7:
𝑄𝑐 = 𝑚̇𝑐 𝑐𝑝 (𝑇𝑐,𝑖 − 𝑇𝑐,𝑜 )
= 0.065 × 4182(20.9 − 25.8)
= 1345.93 𝑊
Step 8:
𝑄𝑐 + 𝑄ℎ
𝑄𝑎𝑣𝑔 =
2
1345.93 + 1716.4
=
2
= 1531.4𝑊

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C19436526 Lab 5 MECH4008

Step 9:
∆𝑇1 = 𝑇ℎ,𝑖 − 𝑇𝑐,𝑖
∆𝑇2 = 𝑇ℎ,𝑜 − 𝑇𝑐,𝑜
∆𝑇1 = 60 − 20.9
= 39.1 °𝐶
∆𝑇2 = 50 − 25.8
= 24.2°𝐶
Step 10:
∆𝑇2 − ∆𝑇1
∆𝑇𝑙𝑚,𝑝𝑎𝑟𝑎𝑙𝑙𝑒𝑙 =
∆𝑇2
ln (∆𝑇1)
24.2 − 39.1
=
24.2
𝑙𝑛 39.1

= 31.06
Step 11:
𝑄𝑎𝑣𝑔 = 𝑈𝐴∆𝑇𝑙𝑚
= 1531.4 ÷ (0.02 × 31.06)
= 2465.41𝑊/𝑚2 𝐾

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C19436526 Lab 5 MECH4008

Discussions
In theory the heat lost by the hot fluid should be gained by the cold fluid, this was not the
case as there were many losses in the system. First of which, was heat loss due to radiation.
Although it may be small, a small fraction of heat would be lost to that.
There were also bends in the heat exchanger, which result in a loss in kinetic energy which
therefore contribute to the loss in heat energy.
The U-value calculated were very similar in the parallel and counterflow configurations. The
slight variation could be caused by surface roughness, material properties and measurements
error. This can all amount to the error found between the two U values.
In this experiment, there was an assumption that it was steady state, as the volume flow rate
and the temperature were being recorded, there is possibilities that these values were not
recorded correctly.
In conclusion, there was no difference in running the heat exchanger in either parallel or
counter flow as they both produced similar U values.

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C19436526 Lab 5 MECH4008

Conclusions
To sum up, shell and tube heat exchangers are essential parts of many industrial processes
that effectively transfer heat between streams of fluid. Determining the U value, which stands
for the overall heat transfer coefficient, is essential to maximizing these heat exchangers'
efficiency and performance.

The U value was calculated and compared to know values. The reasons of the losses were
discussing and future improvements were also mentioned.

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C19436526 Lab 5 MECH4008

References

[1] A. J. G. Yunus Cengel, Heat and Mass transfer, SIngapore: McGraw Hill, 2020`.

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