MANIPAL UNIVERSITY

Jaipur

Department of Chemical Engineering

CE2130- TRANSPORT PHENOMENA
LABORATORY- 2 nd YEAR, 3rd SEMESTER,
2023

EXPERIMENT #1

SHELL & TUBE HEAT EXCHANGER

INSTRUCTOR-DR. HARSH PANDEY

PERFORMED BY- SHASWAT GOYAL (229101002) & MRAGANK

RASTOGI (229101003)
EXPERIMENT CARRIED ON: 2ND FEBRUARY 2024
REPORT SUBMITTED ON: 9 T H FEBRUARY 2024
PRELAB ___________ (10)
EXECUTIVE SUMMARY ___________ (10)
OBJECITIVES/INTRODUCTION/SCOPE/PROCEDURE ___________ (30)
RESULTS & DISCUSSION ___________ (30)
CONCLUSION ___________ (5)
REFERENCES ___________ (5)
APPENDIX
a) Original data, sample calculations, other information ____________ (5)

GENERAL COMPLETENESS
a) Conciseness and neatness ____________ (5)

TOTAL (100) ____________

 TABLE OF CONTENTS

1. EXECUTIVE SUMMARY...................................................................................
2. OBJECTIVE..........................................................................................................
3. INTRODUCTION................................................................................................
4. THEORY & EXPERIMENTAL SETUP…………………………………………...
5. EXPERIMENTAL PROCEDURE & RESULTS.................................................................
6. DISCUSSION.......................................................................................................
7. PRECAUTIONS...................................................................................................
8. CONCLUSION....................................................................................................
9. REFERENCES…………………………………………………………………
EXECUTIVE SUMMARY:
The objective of this experiment was to assess and analyse the performance of a shell and
tube heat exchanger by examining heat load, heat balance, LMTD (Log Mean Temperature
Difference), overall heat transfer, coefficient heat transfer coefficients. Each run was
conducted with varying flow rates of hot water. A shell and tube heat exchanger is designed
to efficiently transfer heat between two substances. In industrial applications, the counter-
current flow design is often employed, ensuring a maximal temperature difference between
hot and cold streams for optimal heat transfer. We assumed negligible contributions from
internal, potential, and kinetic energy in this process, implying that QH (heat released by hot
water) should be equal to Qc (heat absorbed by cold water). However, in Experiment 1 with a
constant FT1 (flow rate 1) of 150 LPH and varying flow rate of hot water we get different
heat transfer coefficients for each case but for each case the Qh and Qc were approximately
close . This suggests efficient heat transfer at equal volumetric flow rates of hot and cold
water, deviating from the basic theory where QH is not necessarily equal to Qc. Errors were
identified, and recommendations and precautions were proposed to enhance the accuracy of
future experiments.
OBJECTIVE:
Study heat transfer in shell and tube heat exchange & calculate the LMTD, heat transfer rate
and coefficient.

INTRODUCTION:
A heat exchanger is a crucial device facilitating efficient heat transfer between fluids in
various industrial applications. Examples include car radiators, domestic refrigerator
condensers, and thermal power plant steam boilers. These devices operate by ensuring
thermal energy exchange without direct fluid contact, preserving fluid integrity. Heat
exchangers contribute to energy efficiency and conservation across diverse sectors,
highlighting their adaptability and importance in modern industrial processes. From everyday
appliances to large-scale power generation, heat exchangers play a vital role in optimizing
thermal management and promoting sustainability.
Heat exchangers are classified in three categories:
1. Transfer Type.
2. Storage Type.
3. Direct Contact Type

THEORY & EXPERIMENTAL SETUP:

The primary purpose of a heat exchanger is to either extract heat from a hot fluid or introduce
heat to a cold fluid. Fluid motion within a heat exchanger is typically classified as parallel
flow, counterflow, or cross flow. For this experiment, our focus is solely on counter-current
flow. In counter-current flow, the hot and cold fluids move in opposite directions, entering
and exiting the heat exchanger at opposite ends. The experiment specifically centres on the
shell and tube heat exchanger configuration.
The transfer type exchanger can be classified into two categories:
1. Single pass: A single pass shell and tube heat exchanger allows fluids to flow
through the tubes and shell only once. This design is straightforward and cost-
effective, suitable for applications where simplicity is prioritized.
2. Multi pass: A multi-pass shell and tube heat exchanger allow fluids to circulate
through the tubes and shell multiple times before exiting. This design enhances heat
transfer efficiency by prolonging contact between the hot and cold fluids, making it
suitable for applications where maximizing heat exchange is essential.
 EXPERIMENTAL SETUP

The setup includes a manufactured shell containing tubes with baffles on the outer side. It is
configured as a 1-2 pass shell and tube heat exchanger. Hot water flows through the inner
tube, while cold water circulates through the shell side. Valves are incorporated for regulating
the flow rates of hot and cold water. Rotameters are employed for flow measurement,
positioned at the inlet of the cold water and the outlet of the hot water line. A magnetic drive
pump is utilized to circulate hot water from a recycled-type water tank, equipped with a
heater and digital temperature controller.

FORMUALE:
QH = MHCph(T1-T2) A0= π*D0*L*N
MC= (FC*ρc)/ (3600*1000) Ai=π*Di*L*N
Mh= (Fh*ρh)/ (3600*1000) Ui=Q/ (Ai ΔTm)
QC=MCCpc(T4-T3) U0=Q/ (A0 ΔTm)
Q= (QH+QC)/2
ΔT1=T1-T3
ΔT2=T2-T4
ΔTm= (ΔT1- ΔT2)/ ln (ΔT1/ ΔT2)
PROCEDURE:
1. Ensure valves V1-V6 are closed.
2. Open the lid of the hot water tank, fill it with water, and close the lid securely.
3. Verify that the switches on the panel are in the OFF position.
4. Connect the electric supply to the setup.
5. Set the desired water temperature using the Digital Temperature Controller (DTC) by
using the increment or decrement buttons.
6. Open the bypass valve V3 and turn on the pump.
7. Switch on the heater and wait until the desired temperature is reached.
8. Connect the cooling water supply to the setup.
9. Connect the outlet of cooling water from the heat exchanger to the drain.
10. Open valve V1 to allow the circulation of cold water and adjust the flow rate.
11. Allow hot water to flow through the heat exchanger and adjust the flow rate using
valves V2-V3.
12. Record the temperatures and flow rates of hot and cold water at steady state (constant
temperature).
13. Repeat the experiment for different flow rates of hot and cold water.

CLOSING PROCEDURE:
1. Turn OFF the heater at the conclusion of the experiment.
2. Switch OFF the pump.
3. Cease the cooling water supply by closing valve V1.
4. Drain the water from the hot water tank by opening valve V6.
5. Release the water from the shell side by opening valve V5.
6. Drain the water from the tube side by opening valve V4.

OBSERVATION TABLE:

CALCULATION TABLE:

Sr. No. QC (W) Qh (W) Q (W) ΔTm (C) Ui W/m2C U0 W/m2C

1 2.492 0.812 1.65 34.11 0.0988 0.0803
2 2.4883 1.0616 1.774 20.72 0.1747 0.1419
3 2.4 0.6625 1.5581 20.049 0.1586 0.1288
 Sr. No. Hot Water Side Cold Water Side
Fh (L/H) T1 (C) T2 (C) FC (L/H) T3 (C) T4 (C)
1 100 55.1 48 150 24.1 38.5
2 150 57.3 51.1 150 24.6 39
3 200 55.9 53 150 26.1 40.3

DISCUSSION:
The experiment utilizes the Heat Exchanger Training apparatus designed for cooling
applications. Objectives include equalizing the temperatures of hot and cold streams,
studying the working principle of a counter-flow heat exchanger, and evaluating parameters
such as overall heat transfer coefficient, Log Mean Temperature Difference (LMTD), and
heat transfer and loss for energy balance. In this shell and tube heat exchanger, cold water
circulates through the outer pipe (shell), while hot water flows through the inner pipe (tube).
Heat transfers from the high-temperature hot water stream to the low-temperature cold water
stream, resulting in both streams reaching the same temperature. The experiment comprises
three sets of data for analysis.
It is observed that the calculated values of QH and QC deviate from the theoretical
expectation, where the ideal condition is for QC/QH to approach unity. The discrepancies are
acknowledged as normal given the challenges of achieving an ideal system in real-world
applications.
In the experiment, the volumetric flow rate of cold water remains constant at 150 LPH, while
the volumetric flow rate of hot water changes every 10 minutes from 100 LPH to 200 LPH.
The heat transfer of hot water, QH, is consistently lower than the heat transfer of cold water,
QC. However, QC decreases while QH increases as the volumetric flow rate of hot water
increases. This suggests that heat transfer occurs efficiently at nearly equal volumetric flow
rates of hot and cold water.
Despite potential errors, all objectives are achieved by the end of the experiments. The
presence of air bubbles in the tube is identified as one of the factors contributing to
inaccuracies in the results.

PRECAUTIONS:
1. **Temperature Management: ** Implement careful regulation and continuous
monitoring of temperatures to mitigate the risk of burns or injuries. Ensure that the handling
of hot fluids adheres to established safe temperature limits.
2. **Pressure Oversight: ** Exercise vigilant monitoring and control over pressure levels to
prevent unforeseen incidents. Validate the integrity of connections and confirm the presence
of relief valves.
3. **Secure Fastenings: ** Routinely examine and reinforce all connections and fittings to
forestall potential leaks. Securely fasten pipes and tubes to prevent unintended disconections.
4. **Emergency Protocols: ** Acquaint yourself with emergency protocols, including the
identification of exits, locations of eyewash stations, and safety showers. Be proficient in
promptly shutting off equipment during emergency situations.
5. **Adherence to Operational Guidelines: ** Rigorously adhere to the guidelines
provided by the manufacturer and the laboratory procedures for operating the equipment.
Avoid circumventing safety features and ensure that personnel are adequately trained in
equipment usage.

REFERENCES:
1. https://www.studocu.com/row/document/institute-of-space-technology/heat-mass-
transfer/heat-exchanger-lab-report/15157749
2. https://www.scribd.com/document/344602220/CPE533-Shell-and-Tube-Heat-
Exchanger
3. https://www.thermopedia.com/content/1121/
4. https://en.wikipedia.org/wiki/Shell-and-tube_heat_exchanger