Student Names: _______________________________________________________________

Heat Exchanger
Learning Outcome
When you complete this laboratory exercise you will be able to ….
Operate two different types of heat exchangers and learn the factors that affect the rate of heat
transfer.

Frequently in the chemical industry a process stream is required to be heated or cooled or a vapor
condensed or a liquid boiled. This operation is carried out in a heat exchanger in which the heat
is allowed to transfer from a warmer fluid to a cooler fluid. It is important for students and
operators to know the fundamental principles of heat transfer and the factors which effect the
rate of heat transfer between the fluids will be learned.

Learning Objectives
Here is what you will be able to do when you complete each objective.
1. Trace the flows and arrange the valving of the flow of hot and cold water through the
exchanger on which each experiment is to be performed.

2. Collect temperature and flow data for hot and cold water from the equipment for each
experiment.

3. Calculate the sensible heat loss by the hot water and gain by the cold water for each
exchanger.

4. Describe the effect of parallel and counter current flow patterns on the heat exchanged and
interpret results for which arrangement gives greater heat transfer.

5. Describe the effect of tube metallurgy on heat transfer. Interpret and compare results to
determine whether copper or stainless steel gives the greater heat transfer.

6. Describe the effect of shell side baffles on heat exchanged. Interpret results to determine
whether shell side baffles improve heat transfer.

7. Describe the effect of the number of passes on tube side of exchanger on heat exchanged.
Interpret results to determine whether more passes on tube side give more heat transfer.

8. Describe the effect of fluid flow rate on heat exchanged. Interpret the results whether greater
flow rate gives greater heat transfer.

9. Compare the performance of shell and tube exchanger with that of a plate and frame
exchanger. Interpret the results to determine which exchanger gives higher heat transfer.

10. Calculate the log mean temperature difference and heat transfer coefficients for each
experiment and interpret the results.

PEOP1009 Page 1 of 12
Student Names: _______________________________________________________________

Introductory Theory
HEAT EXCHANGER
A heat exchanger is a device that allows heat to be transferred from a warmer fluid to a cooler
fluid. A physical barrier between the fluids does not allow intermixing between the fluids.

A simple type of heat exchanger consists of one fluid flowing through the interior of a tube while
the other fluid surrounds and flows past the outer surface of the tube.

Exchange of heat is influenced by a number of conditions:

(a) Difference in temperature between the two fluids - the greater the temperature difference -
the greater the rate of heat flow.
(b) Surface area of the physical barrier between fluids - the greater the surface area - the greater
the amount of heat flow.
(c) Transfer of heat through the physical barrier (usually a metal) is limited by the thermal
conductivity of the barrier - the greater the thermal conductivity - the more rapid the heat
flow.
(d) Heat transfer rates between a fluid and the barrier are generally greater when the fluid has a
higher velocity, with more turbulence at the contact surface between fluid and barrier.
(e) Heat transfer rates between a liquid and the barrier are generally greater than heat transfer
rates between a vapor and the barrier.
(f) Segmental baffles on shell side cause turbulence and increase the rate of heat transfer.
(g) Parallel versus countercurrent flow, it is not possible with the parallel flow to bring the exit
temperature of one fluid nearly to the entrance temperature of other and the heat that can be
transferred is less than that possible in countercurrent flow.

If the purpose of a heat exchanger is to vaporize portions or all of a fluid stream, the exchanger is
usually called: boiler, reboiler or a vaporizer. Hot fluids such as combustion gases, steam or
other hot streams can be used as the heating medium.

If the purpose of a heat exchanger is to merely heat a process stream, the exchanger would be
called a heater.

If the purpose of a heat exchanger is to condense portions or all of a fluid stream, the exchanger
is called a condenser. Cool fluids such as cold water, atmospheric air or other cold streams can
be used as the cooling medium.

If the purpose of a heat exchanger is to merely cool a process stream, the exchanger would be
called a cooler.
In many cases a heat exchanger is used to cool a hot process stream and simultaneously warm a
cold stream. This type of application helps to improve cost efficiency in a plant by saving both
heating (fuel) and cooling costs.

Figures below show the main parts of a shell and tube exchanger and segmental baffles
arrangement.

PEOP1009 Page 2 of 12
Student Names: _______________________________________________________________

Figure 1
Single-pass 1-1 counterflow heat exchanger

Figure 2
1-2 parallel-counterflow exchanger

Figure 3
Segmental baffles
(Reference: Unit Operations of Chemical Engineering, 5 th Edition, McCabe, Smith, Harriott)

In a heat exchanger, if both the shell side fluid and the tube side fluid are flowing in the same
direction, the flow is said to be parallel. If they flow in opposite directions, the flow is
countercurrent. In a multiple-pass exchanger, both parallel and counter current flow can exist.
A single pass exchanger can be either parallel or counter current.

PEOP1009 Page 3 of 12
Student Names: _______________________________________________________________

Lab Heat Exchangers - Description

In this lab heat exchangers will be used to investigate parameters that affect heat transfer.

The heat exchangers are numbered from top to bottom with number one at the top. A brief
explanation of each exchanger follows:

Surface Area
Exchanger #401 Exchanger with a glass shell and a U-tube bundle 4.1 ft2
(Two tube passes). Segmental baffles have been
installed in accordance with good engineering
practice.
Exchanger #402 Exchanger is identical to number one except all of the 4.1 ft2
segmental baffles have been removed.
Exchanger #403 Exchanger is a 1-4 exchanger which means the 4.3 ft2
exchanger has four passes on the tube side and one
pass on the shell side. The tubes are brass.
Exchanger #404 Exchanger is a 1-1 exchanger which means the 4.3 ft2
exchanger has one tube side pass and one shell side
pass. The tubes in this exchanger are stainless steel.
Exchanger #405 Exchanger is also a 1-1 exchanger. It is identical to 4.3 ft2
exchanger #4 except the tubes are made of brass.
Exchanger #406 Exchanger is a plate and frame exchanger. The 4.48 ft2
plates are made of stainless steel.

NOTE
1. To facilitate ease of comparison, assume all of the exchangers have an equal heat exchange
area of 4.3 ft2. {1ft³= 0.0283m³}

2. A reading of 100% on both water flow meters corresponds to a flow of 10 USGPM. {1

USGPM = 0.000063 m3/s}. NB: To get mass flow rate use density of 1000 kg/m3 for
simplicity regardless of the temperature.

Experimental Procedures
HEAT EXCHANGER
START-UP PROCEDURE – HEAT EXCHANGER
A detailed explanation of how to operate the heat exchanger equipment follows. Read over this
procedure and become familiar with how flows are adjusted and temperatures are read. If in
doubt, obtain assistance before going on to do the experiments outlined below.

PEOP1009 Page 4 of 12
Student Names: _______________________________________________________________

To complete the assigned experiments, it will be necessary to follow the outlined operating
procedure.
1. Spend the first few minutes of the lab tracing the flow and becoming familiar with the
apparatus.

2. Open the block valves for the process and cold water supply to the equipment.

3. Open the block valves in the drain lines.

4. Open the block valve in the instrument air-line.

5. Turn on the electric power on the control panel.

6. Open the isolation valves for the specific exchanger to be used. Be sure that the isolation
valves for all other exchangers are closed.

7. Select the appropriate flow rates for both hot and cold water using the flow controllers.
The controllers should be in the automatic mode. All experiments are performed at 50%
of maximum flow rate of process and cold water except where the flow of process and
cold water is changed to 20%, 30%, and 40%.

8. After a brief period of stabilization, record the data indicated for the following 6
experiments.

DATA COLLECTION

Experiment #1 Effect of Baffles

Since the exchanger #401 and #402 are identical except for the presence or absence of baffles,
any difference in performance between these two exchangers must be due to the effect of baffles.
Operate exchanger #401 at a prescribed flow rate of 50% for both the process and cold water,
and then operate exchanger #402 at the exact same flow rate. For each exchanger record the
process and cold water flow rates and temperatures in and out of exchanger.

Experiment #2 Effect of Multiple Passes

Since exchanger #403 and exchanger #405 are identical except for the number of tube passes,
any difference in performance between these two exchangers must be due to the effect of
multiple passes. Operate exchanger #403 at a prescribed flow rate of 50% for both process and
cold flows and then operate exchanger #405 at the same flow rate. For each exchanger, record
process and cold water flow rates and temperatures in and out of exchanger.

Experiment #3 Effect of Tube Bundle Metallurgy

Since exchanger #404 and #405 differ only in the metallurgy of the tubes, any difference in
performance must be due to the fact that exchanger #4 has a stainless steel tube bundle and
exchanger #405 has a brass tube bundle. Operate exchanger #404 at the prescribed flow rate of

PEOP1009 Page 5 of 12
Student Names: _______________________________________________________________

50% for both process and cold flows and then operate #405 at the same flow rate. For each
exchanger, record process and cold water flow rates and temperatures in and out of exchanger.

Experiment #4 Effect of Flow Arrangement

To illustrate the effect of flow arrangement on heat exchanged, any of the single pass exchangers
can be used, but the plate and frame exchanger will show the effect most dramatically. Select
the plate and frame exchanger and operate it with counter current flow with both process and
cold flows at 50%. Then switch the flow to parallel by adjusting the four way valve. Make sure
that the flow rate does not change. For each case, record process and cold water flow rates and
temperatures in and out of exchanger.

Experiment #5 Effect of Flow Rate

Select the plate and frame exchanger and operate it at flow rates of 20%, 30% and 40% for both
process and cold flows. Since only one variable is being changed, any difference in exchanger
performance must be due to the effect of flow rate. For each case, record process and cold water
flow rates and temperatures in and out of exchanger.

Experiment #6 Comparison of Shell and Tube Exchanger to Plate and Frame

Exchanger.
The plate and frame exchanger #406 is a single pass exchanger and the plates are stainless steel.
It is therefore, most logical to compare it to exchanger #404. Operate both of these exchangers
at a flow rate of 50% for both process and cold flows. For each exchanger, record process and
cold water flow rates and temperatures in and out of exchanger.

SHUTDOWN PROCEDURE

1. Close the block valves in the supply and drain lines of hot and cold water.

2. Close the valve in the instrument air-line.

3. Turn off the power switch on the control panel.

Required Calculations
HEAT EXCHANGER
Sensible Heat Transfer

To interpret the data from each of these experiments, the following calculations must be made:

STEP 1 First calculate the mass flow in kg/s and then calculate the heat lost by the process
fluid using the formula:

Q = m x Cp x (T in – T out)

PEOP1009 Page 6 of 12
Student Names: _______________________________________________________________

STEP 2 Calculate the mass flow in kg/s and then calculate the heat gained by cold fluid
using:
Q = m x Cp x (T out – T in)
Q = Heat transferred in kW
m = mass flow rate in kg/s
Cp = specific heat of water, 4.184 kJ/kg ºC

STEP 3 Consider the actual heat transferred to be the average of the heat lost by the
process and the heat gained by the cold water. In theory, these two values should
be equal. If they are significantly different the accuracy of the data is
questionable.

STEP 4 Calculate the overall heat transfer coefficient, U. For single pass exchangers use
the formula:

Q = U x A x log mean temperature difference (LMTD)

U = Overall heat transfer coefficient, W/m2•ºC

A = Area of exchanger, m2

If the exchanger is a multiple-pass exchanger, the formula becomes:

Q = U x A x FG x log mean temperature difference (LMTD).

FG = Correction factor for multi-pass exchangers. Correction factor charts are provided after the calculations procedure. For simplicity use FG =1

COUNTERCURRENT AND PARALLEL – COCURRENT FLOWS

The two fluids enter at different ends of the exchanger shown in Figure 4(a) and pass in opposite
directions through the unit. This type of flow is that commonly used and is call counterflow or
countercurrent flow. The temperature-length curves for this case are shown in Figure 4(a). The
four terminal temperatures are denoted as follows:

Temperature of hot fluid inlet, Tha Temperature of cold fluid inlet, Tca
Temperature of hot fluid outlet, Thb Temperature of cold fluid outlet, Tcb

PEOP1009 Page 7 of 12
Student Names: _______________________________________________________________

If the two fluids enters at the same end of the exchanger and flow in the same direction to the
other end, the flow is called parallel or cocurrent flow. The temperature-length curves for
parallel flow are shown in figure 4(b).

Log Mean Temperature Difference (LMTD)

Parallel Flow
T1  T2
Δ T1 = Tha - Tca Δ T2 = Thb - Tcb LM TD 
T
log n 1
T2
Countercurrent Flow
T1  T2
ΔT1 = Thb - Tca Δ T2 = Tha - Tcb LM TD 
T
log n 1
T2

LMTD Correction factor for multipass exchangers.

Obtain values of correction factor for LMTD (FG) for multi-pass heat exchangers, from figure
provided below.

z
Tha - Thb  Tcb - Tca
H 
Tcb - Tca Tha - Tca

Figure 5
1 Shell, 2 or More Tube Passes

Report
This lab is to be completed as a formal lab report. Be sure you include all of the following:

PEOP1009 Page 8 of 12
Student Names: _______________________________________________________________

A table of raw data collected and the following analyses:

1. Interpret and compare the results of heat transferred using an exchanger with shell side
baffles and an exchanger with no baffles. Determine whether the shell side baffles gave
more heat transfer and why? Report the percentage difference based on the heat transferred
in the exchanger with no baffles.

2. Interpret and compare the results of heat transferred in a one tube pass and 4 tube pass
exchanger. Determine whether greater number of tube passes gave greater heat transfer and
why? Report the percentage difference based on heat transfer in one pass exchanger.

3. Interpret and compare results of heat transferred using copper and stainless steel tubes.
Determine which tube metallurgy gave higher heat transfer and why? Report the percentage
difference based on heat transfer with stainless steel tubes.

4. Calculate the heat transferred in parallel and counter current flow arrangement for the plate
exchanger. Compare the results and determine which flow arrangement gave higher heat
transfer. Report the percentage difference based on parallel flow arrangement.

5. Interpret and compare the results of heat transferred with flow of process and cold water at
20%, 30% and 40% of the maximum flow. Determine if the greater fluid flow rate gave
greater heat transfer and why? Report the percentage difference based on the heat transfer
with 20% flow through the exchanger.

6. Interpret and compare the results of heat transferred in a shell and tube and in a plate and
frame exchanger. Determine which exchanger gave higher heat transfer and why? Report
the percentage difference based on the heat transfer in the shell and tube exchanger.

7. Calculate the sensible heat loss by the process water and gain by the cold water for each heat
exchanger. Compare the heat gained and heat lost values. Report the percentage difference
based on heat lost and give possible reasons for the difference.

8. Interpret and compare the heat transfer coefficients, U calculated for each experiment and
give possible reasons for the difference.

9. Reference Text: Unit Operations of Chemical Engineering 5th Edition, McGraw Hill

Add pages as needed to your lab for sample calculations. Include discussion on the above and
conclusions.

Mass flow at 50%= ______________ Mass flow at 40%= _____________

Mass flow at 30%= ______________ Mass flow at 20%= ___________

PEOP1009 Page 9 of 12
 TABLE OF RAW DATA AND CALCULATIONS: Specific heat capacity of water: 4.184 kJ/KgoC
Label TUBE SIDE SHELL SIDE
Flow% Flow kg/s Inlet oC Outlet oC ∆T oC Heat J/s Flow% Flow kg/s Inlet oC Outlet oC ∆T oC Heat J/s ∆Q % U
E401 50%
U 40%
with 30%
Baffles 20%

E402
U
with NO
Baffles

E403
4-
Pass
Brass

E404
One
Pass
S.S.

E405
One
Pass

Brass.

E406
Counter
Plate &
Frame

E406
Parallel
Plate &
Frame
…..

PEOP1009 Page 10 of 12
The following is a diagram of the apparatus:

PEOP1009 Page 11 of 12
Label TUBE SIDE SHELL SIDE
o
Flow% Flow kg/s Inlet C Outlet Co
∆T C
o
Heat J/s Flow% Flow kg/s Inlet oC Outlet oC ∆T oC Heat J/s ∆Q % U
E401 50% 50%
U 40% 40%
with 30% 30%
Baffles 40% 20%
E402 50% 45 33 12 50% 10 14 4
U 40% 40%
with NO 40% 30%
Baffles 40% 20%
E403 50% 60 31 29 50% 15 40 25
4- 40% 40%
Pass 30% 30%
Brass 20% 20%
E404 50% 60 37 23 50% 15 35 20
One 40% 40%
Pass 30% 30%
S.S. 20% 20%
E405 50% 48 33 15 50% 5 13 8
One 40% 40%
Pass 30% 30%
Brass. 20% 20%
E406 50% 50 28 50% 12 28
Counter 40% 46 25 40% 8 22
Plate & 30% 54 28 30% 13 24
Frame 20% 45 29 20% 15 25
E406 50% 41 26 50% 17 24
Parallel 40% 37 25 40% 16 26
Plate & 30% 37 28 30% 10 18
Frame 20% 45 29 20% 6 16

PEOP1009 Page 12 of 12