HMT & HVAC

Lab Report 1
6TH SEMESTER

Submitted to: Lab Engr. Muhammad Zeeshan

Submitted by
MALIK HASEEB ULLAH
CMS ID: 428302
Section: B

School of Mechanical and Manufacturing Engineering

Title:
Shell & Tube Heat Exchanger
Objectives:
• To Determine the effectiveness of a shell & tube heat exchanger.
• To Measure the Logarithmic Mean Temperature Difference (LMTD) to evaluate the
thermal performance.
• Calculating the overall heat transfer coefficient based on experimental data.
• To Analyze the effect of flow rate and temperature variation on heat transfer efficiency.
• To Compare parallel flow and counterflow configurations to determine which is more
effective.

Apparatus:
1. Shell & Tube Heat Exchanger Unit – The main experimental setup where heat transfer
occurs between two fluids.
2. Hot Fluid Source –Electric heater with a temperature control system.
3. Cold Fluid Source – A continuous water supply.
4. Flow Meters – To measure the flow rates of both hot and cold fluids.
5. Temperature Sensors – To measure the inlet and outlet temperatures of both fluids.
6. Control Valves – To regulate the flow of hot and cold fluids.
7. Piping and Fittings – To ensure proper fluid circulation within the system.
8. Data Acquisition System – For digital recording of temperature and flow data.

Figure 1 Shell & Tube Heat Exchanger

Theory:
A shell and tube heat exchanger is a widely used device in industries to transfer heat between
two fluids. It consists of a shell (outer casing) and multiple tubes (inner passages), where one
fluid flows through the tubes while the other flows around them inside the shell. The heat
exchange occurs through the walls of the tubes, and the system can be configured in parallel flow
or counterflow to optimize heat transfer efficiency.
1. Heat Transfer Mechanism
o Heat flows from the hot fluid to the cold fluid through conduction and convection.
o The rate of heat transfer is governed by Fourier’s Law of Heat Conduction and
Newton’s Law of Cooling.
2. Logarithmic Mean Temperature Difference (LMTD)
o The temperature difference between the hot and cold fluids varies along the length
of the exchanger.
o LMTD is used to represent the average temperature difference to simplify
calculations:

o This helps in determining the efficiency of the heat exchanger.

3. Overall Heat Transfer Coefficient (U-value)
o Represents the effectiveness of heat transfer across the tubes.
o Defined by: Q=UAΔT where:
Q = Heat transfer rate
U = Overall heat transfer coefficient
A = Heat transfer area
ΔT = Temperature difference
4. Effectiveness-NTU Method
o The Number of Transfer Units (NTU) method is used when inlet and outlet
temperatures are unknown.
o Effectiveness (ε) is defined as the ratio of actual heat transfer to the maximum
possible heat transfer
 o This approach is useful for evaluating performance without detailed temperature
data.
5. Parallel Flow vs. Counterflow
o Parallel Flow: Both fluids move in the same direction, leading to lower
efficiency.
o Counterflow: Fluids move in opposite directions, maximizing heat transfer.
This experiment helps in understanding real-world applications of heat exchangers in power
plants, refrigeration, and chemical processing industries.

Figure 2 Schematic Diagram

Procedure:
1. Ensure that the heat exchange unit is clean and properly assembled.
2. Check the inlet and outlet connections for both the hot and cold fluids.
3. Fill the required tanks with hot water.
4. Turn on the tap for cold water.
5. Switch on the heating system to raise the temperature of the hot fluid.
6. Adjust the flow rates of both fluids using control valves to achieve desired conditions.
7. Allow the system to run for a few minutes until steady-state conditions are reached.
 8. Record the inlet and outlet temperatures of the hot and cold fluids using temperature
sensors (thermocouples).
9. Measure the flow rates of both fluids using flow meters.
10. Set up 3 different flow rates for Cold water
11. Hot water remains at same flow rate for all readings
12. First make the connections for Parallel flow heat exchanger
13. Take 3 readings
14. Then make the connections for Counter flow heat exchanger
15. Take 3 Readings.
16. Turn off the heating system and close all valves.
17. Allow the heat exchanger to cool down before disconnecting.
18. Record observations and compare experimental results with theoretical values.
Graphs:
Data:
Number of tubes = 21
Ain = 0.0251m2
Aout = 0.0314 m2
Diameter = 8mm
For hot fluid:
mh = (1000×1.667×10−5) = 0.01667 kg/s
Parallel Flow Data:

Vc Vh ST1 ST2 ST3 ST4 ST5 ST6 ST7

(L/min) (L/min) (oC) (oC) (oC) (oC) (oC) (oC) (oC)

0.6 1 44 32 25 28 30 31 31

1.2 1 44 36 25 30 32 33 33

1.8 1 44 38 25 31 34 34 34
Table 1

Counter Flow Data:

Vc Vh ST1 ST2 ST3 ST4 ST5 ST6 ST7

(L/min) (L/min) (oC) (oC) (oC) (oC) (oC) (oC) (oC)

0.6 1 45 33 36 35 32 30 25

1.2 1 45 36 37 36 32 31 26

1.8 1 45 38 38 37 34 33 26

Table 2

Sample Calculations:
Let's calculate the mass flow rate and then use it to find Qh, Qc and Qloss in Watts.
Given Data:
• Density of water = 1000 kg/m³
• Specific heat capacity of water (C) = 4184 J/kg·K
• Volume flow rates:
 o Hot fluid: Vh = 1 L/min =1.667×10−5 m³/s
o Cold fluid: Vc = 0.6,1.2,1.8 L/min converted similarly.
Convert Volume Flow Rate to Mass Flow Rate
m = ρ⋅V
For hot fluid:
mh = 0.01667 kg/s
For cold fluid:

Vc mc
(L/min) (kg/s)

0.6 0.010

1.2 0.020

1.8 0.030

Calculate Qh and Qc
Qh = mh Ch (ST1 - ST2)
Qc = mc Cc (ST7 - ST3)
Qloss = Qh – Qc
For Parallel Flow:

Vc Qloss
(L/min) (W)

0.6 19.702

1.2 62.984

1.8 106.3968
For Counter Flow:

Vc Qloss
(L/min) (W)

0.6 39.426

1.2 82.686

1.8 231.598

The Reynolds number is given by:

𝝆𝒗𝑫
𝑹𝒆 =
𝛍
where:
• ρ = 1000 kg/m³ (density of water),
• D = 0.008 m (diameter of tube),
• μ = 0.001 Pa·s (dynamic viscosity of water),
• v = velocity of fluid inside the tube,
Velocity is given by:
𝑸
v=
𝑨
where:
• Q = volumetric flow rate (m³/s),
• A = cross-sectional area of one tube.
The total cross-sectional area for 21 tubes is:
21 × 𝜋(0.008)2
𝐴𝑡𝑜𝑡𝑎𝑙 =
4
Atotal = 0.001055 m2
𝑉𝑐
𝑄=
1000 × 60
For different values of Vc:

Vc Qc
(L/min) (m³/s)

0.6 1.00×10−5

1.2 2.00×10−5

1.8 3.00×10−5

Now, calculate velocity:

𝑄
𝑣=
𝐴𝑡𝑜𝑡𝑎𝑙

Vc Qc Velocity
(L/min) (m³/s) (m/s)

0.6 1.00×10−5 0.00948

1.2 2.00×10−5 0.01896

1.8 3.00×10−5 0.02844

Calculate Reynolds Number Re

1000 × 𝑣 × 0.008
𝑅𝑒 =
0.001
𝑅𝑒 = 8000 × 𝑣

Vc (L/min) Velocity (m/s) Re

0.6 0.00948 75.8

1.2 0.01896 151.7

1.8 0.02844 227.6

Graphs:

Parallel FLow
120

100

80
Qloss

60

40

20

0
0 50 100 150 200 250
Reynold Number

Counter Flow
250

200

150
Qloss

100

50

0
0 50 100 150 200 250
Reynold Number
Observations:
1. Temperature Differences:
o The temperature of the hot fluid decreases as it moves through the exchanger.
o The temperature of the cold fluid increases, demonstrating heat transfer.
o Counterflow configuration maintains a higher and more uniform temperature
difference compared to parallel flow.
2. Heat Transfer Efficiency:
o The overall heat transfer rate is higher in counterflow due to the greater Log Mean
Temperature Difference (LMTD).
o Effectiveness varies based on flow rate, inlet temperatures, and exchanger design.
3. Effect of Flow Rate:
o Increasing the flow rate of one fluid enhances heat transfer up to a certain point
but may reduce residence time.
o Decreasing flow rate can result in better heat absorption but lower overall heat
transfer.
4. Effect of Insulation:
o If the system is well insulated, external heat loss is minimized, improving
efficiency.
o Poor insulation results in lower heat transfer effectiveness and affects calculated
values.
5. Comparing Theoretical vs. Experimental Results:
o The experimental heat transfer coefficient may differ from theoretical values due
to heat losses and errors.

Errors:
1. Inaccurate or faulty thermocouples/sensors can lead to incorrect temperature readings.
2. Improper sensor placement may not capture the actual temperature difference.
3. Inconsistent flow rates of hot and cold fluids due to pump instability can affect heat
transfer.
4. Air bubbles or cavitation in the pipes can disturb the flow.
5. Poor insulation of the heat exchanger can lead to heat loss, reducing efficiency.
6. External environmental factors, such as room temperature variations, may impact
reading.
7. Improper sealing can result in pressure loss and reduced efficiency.
8. Uncalibrated sensors, flow meters, or pressure gauges may lead to incorrect readings.
Conclusion:
The experiment successfully analyzed the heat transfer characteristics of a shell and tube heat
exchanger. Results confirmed that counterflow configuration is more efficient than parallel flow
due to a higher and more uniform Log Mean Temperature Difference (LMTD). Factors like flow
rate, insulation, and sensor accuracy influence heat transfer effectiveness. Observed deviations
between theoretical and experimental values highlight the impact of heat losses and measurement
errors. Proper calibration and insulation can enhance accuracy, making the system more efficient
for practical applications.