Abdalrzag Emhemmed Alazgal ID:3115164

Experiment(4) :
Air-Water Heat Exchanger

1. Introduction

A heat exchanger is a device used to transfer heat between two or more fluids. A solid
wall to prevent mixing may separate the fluids or they may be in direct contact. They
are widely used in space heating, refrigeration, air conditioning, power stations,
chemical plants, petrochemical plants, petroleum refineries, natural gas processing,
and sewage treatment. The classic example of a heat exchanger is found in an internal
combustion engine in which a circulating fluid known as engine coolant flows
through radiator coils and air flows past the coils, which cools the coolant and heats
the incoming air. Another example is the heat sink, which is a passive heat exchanger
that transfers the heat generated by an electronic or a mechanical device to a fluid
medium, often air or a liquid coolant.

Air-Water Heat Exchanger is used to apply the heat transfer principles between two
fluids (Air & Water).Air is used to cool hot water (heated by boiler) flowing through
the cooling tunnel , it's one of the most effective heat exchanger with large surface
area (Radiator) which allow maximum exchange between two fluids ,but one of its
disadvantages is that, the difficulty in cleaning.

Plate-Fin Heat Exchanger (Water /Air):

Plate fin heat exchangers (PFHEs) are a form of compact heat exchanger consisting of
a stack of alternate flat plates called “parting sheets” and fin corrugations, brazed
together as a block. Different fins (such as the plain triangular, louver, perforated, or
wavy fin) can be used between plates for different applications.
Designed for low-pressure applications, with operating pressures limited to about
1000 kPa g (150 psig) and operating temperature from cryogenic to 150°C (all-
aluminum PFHE) and about 700°C–800°C (1300°F–1500°F) (made of heat-resistant
alloys).

The units cannot be mechanically cleaned, so their use is restricted to clean process
and service steams.

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Abdalrzag Emhemmed Alazgal ID:3115164

.Figure 1:Plate-fin exchanger

Advantages

1. Very high thermal effectiveness can be achieved; for cryogenic applications,

effectiveness of the order of 95% and above is common.
2. PFHE can achieve temperature approaches as low as 1°C between single-
phase streams and 3°C between multiphase streams.
3. With their high surface compactness, ability to handle multiple streams, and
with aluminum’s highly desirable low-temperature properties, brazed
aluminum plate fins are an obvious choice for cryogenic applications.
4. Large heat transfer surface area per unit volume (Typically 1000 m2/m3),
5. Low weight,
6. Multi-stream operation (Up to ten process streams can exchange heat in a
single heat exchanger.).
7. Able to withstand high pressure.
Disadvantages

1. Limited range of temperature and pressure.

2. Difficulty in cleaning of passages, which limits its application to clean and
relatively non-corrosive fluids.
3. Aluminum alloys are susceptible to Mercury Liquid Embrittlement Failure.
4. Narrow passages in plate-fin exchangers make them susceptible for fouling
and they cannot be cleaned by mechanical means. This limits their use to clean
applications like handling air, light hydrocarbons, and refrigerants.

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Abdalrzag Emhemmed Alazgal ID:3115164

2. Theory:
The quantity of heat exchanger during a certain time period t is given
by :
Qi=m∗C P . i∗∆ T i
Where :
m : is the mass flow rate , kg/s.
C P . i : is the specific heat, J/ kg . oC .
∆ T i : is the difference between initial and final temperature, oC.
The amount of heat lost from the water ( W )
Qw =mw∗C P . w∗∆ T 1
Where :
mw : is the rate of flow air, Kg/h.
mw =V ∗ρw
V :is volumetric flow rate, L /h.

ρwater = 1000 Kg/m3

C P . w : is the specific heat of water ,J/ kg . oC, Cp water = 4184 J/Kg.oC.

∆ T 1 : is the difference between initial and final temperature (T1- T2) , oC .

The amount of heat given from the air ( W )

Qa=ma∗C P . a∗∆ T 2
Where :
ma : is the rate of flow ,Kg /h .
C P . a : is the specific heat of air, J/ kg .oC, Cp air = 962 J/Kg.oC

∆ T 2 : is the difference between initial and final temperature (T4- T3) , oC.

Heat Lost From The Water = Heat Given From The Air
Qw =Q a

3. Objective of experiment

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Abdalrzag Emhemmed Alazgal ID:3115164

 Perform energy balance calculations on a water to air heat exchanger

 Measure the difference in the temperature of the water,∆T 1, between the inlet
and the outlet of the heat exchanger
 Measure the difference in the temperature of the air ,∆T 2, between the inlet
and the outlet of the heat exchanger

 Determine the quantities of heat, Q w and Qa , exchanged in either direction in

the unit time.

4. Composition and Description:

4.1. Composition : 77
22 77

66

11

4
5

33
33

Figure 2 :Overall view of the standard version.

1. Test tunnel with heat exchanger ,diaphragm and fan

2. Differential micromanometer
3. Water recirculation and feed tank
4. Three-speed electric pump
5. Electric boiler
6. Flow meter

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7. Electrical control panel.

4.2. Process Description

Figure 2 : General synoptic .

1. Test tunnel with radiator and calibrated diaphragm

2. Variable speed axial electric-fan
3. Differential micromanometer
4. Recovery and water circulation tank
5. Floating cock
6. Tank discharge valve
7. Motor-driven pump
8. Electric resistance
9. Flow meter
10. Flow rate regulation valve
11. Air valve
12. Electric board
13. T1 ,T2, T3, T4 Temperatures

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Abdalrzag Emhemmed Alazgal ID:3115164

4.3. Electrical control panel:

Figure 3 : Electrical control panel.

IA. Magneto thermic automatic switch.

ID. Differential switch.
LO. Power on telltale.
A. Pump selector.
B. Door lock switch.
C. Digital thermometer.
D. Heat resistor selector.
E. Fan speed trimmer.
F. Fan ON/OFF switch.
G. Fan ON telltale.
H. Electricity meter ( K=2) .
I. Electric boiler ON/OFF switch.
L. Boiler ON telltale.
M. Flow rate digital display (only for SAD/T157D version).
N. Differential pressure digital display (only for SAD/T157D version).

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Abdalrzag Emhemmed Alazgal ID:3115164

4.4. Differential Micromanometer:

The bench is fitted with a manomeric fluid differential manometer (see Fig.4 ) for
the measurement of the differential pressure of the air that reaches the heat
exchanger.

To work with this micro manometer it is necessary :

 To fill up the Plexiglas tank (1) with the manomeric fluid supplied as
standard (Density 0.8 kg /dm3) .
 To select the measuring scale (2) by arranging the mobile tube at an angle
corresponding to the desired scale :

15o 0-50 mmH2o

30o 40-100 mmH2o
45o 80-140 mmH2o
90o 0-200 mmH2o

 To reset the instrument by means of the adjustment screw (3) and have the
starting valve of the scale correspond to the level of the manomeric fluid.

With the aid of the micro manometer ,you can immediately work out, from the
value of pressure ∆ P , the air flow ,through the calibration diagram shown in
fig. and on the tunnel.

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Abdalrzag Emhemmed Alazgal ID:3115164

Figure 4 :Differential Micro Manometer.

Figure 5 :Calibration diagram .

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Abdalrzag Emhemmed Alazgal ID:3115164

5. Procedure

1. Connect the set to the water network and the power mains .
2. Fill up the differential micromanometer,3, with the monometric fluid supplied
as standard.
3. Wait for the tank,4,to fill up.
4. On the electric control board, 14,set the door lock control B on ''1'' and switch
IA on ''ON''.
5. Open the water flow control valve,12.
6. Start the electrical water circulation pump,7,by means of switch A.
7. Eliminate the air bubbles, if any, by means of the bleed valve,13; (all you have
to do is loosen by a few turns the knurled cap at the top of the valve ).
8. Turn on the electric boiler, 10,by means of switch I.
9. Adjust the water flow rate to the desired value (with reference to Flow meter
11 or the digital display, M, situated on the electrical control panel in the
version with the SAD/T157D data acquisition system ).
10. Set selector D on ''1'' and read the valve of the temperature on digital display C.
11. Wait until the desired temperature T1 become stable.
12. Start fan 2 by means of switch F and adjust the air flow to the desired value by
means of trimmer E. Read the corresponding pressure value on the differential
micromanometer 3 (or on the digital display, N, of the electrical control panel
in the version with the SAD/T157D data acquisition system ) and referring to
the flow-rate diagram, Q (located on the left side of the tunnel).
For instance ,with∆ P=2.5 mm c.a. we get an air flow of 100 kg/h.

13. Set the desired valve of water flow, V.

14. Set the desired valve of air flow ,Qm.
15. Wait for the testing conditions to stabilize .
16. Measure ( temperatures T1 ,T2 ,T3 ,T4, flow-rate, and electric energy values) by
means of instruments 11 (or M ), 3 (or N), C , H .
17. Enter the values of V ,Qm ,T1 ,T2 ,T3 ,T4 in the ad hoc table given in annex1.
18. Write down the values of the temperatures in a diagram similar to the one
given in the section concerning the test results.
19. Repeat the tests for different flow and temperature values.
20. Determine∆ T 1 , ∆ T 2 ,Q w , Qa .

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Abdalrzag Emhemmed Alazgal ID:3115164

6. Results, Calculation, & Discussion:

6.1. Results:

From the experiment are obtain the following results:

 At constant flow rate.

Table 1 :Results of the Experiment at Constant Flow Rate.

T4 T3 T2 T1 Pressure Drop Flow rate

(oC) (oC) (oC) (oC) ∆P (mm) (L/h)
32 23.6 31.2 44.8 15 46
33.7 23.5 35.8 40 3 46
32.1 22.8 35.1 41 5 46

 At constant pressure Drop.

Table 2 : Results of the Experiment at Constant Pressure Drop.

T4 T3 T2 T1 Pressure Drop Flow rate

(oC) (oC) (oC) (oC) ∆P (mm) (L/h)
32.3 23.2 36.9 41.5 9 120
31.6 23.4 35.3 39.2 9 135
31.8 23.5 34.8 40.1 9 95

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 Abdalrzag Emhemmed Alazgal ID:3115164

6.2. Calculation:
Qi=mi∗C p∗(T hot −T cold )

Cp water = 1000 Cal/ Kg.oC = 4184 J/Kg.oC

Cp air = 230 Cal/ Kg.oC = 962 J/Kg.oC

ρwater = 1000 Kg/m3

Table 4 :Calculation

mair
Qa Qw (T4 -T3) (T1 -T2) mair (fig.5) ∆P mw=Vw × ρw Vw Vw
(W) (W) o
C o
C (Kg/s) (Kg/h) (mm) (Kg/s) (m3/s) (L/h)
727.0
594.84 9 8.4 13.6 0.0736 265 15 0.01278 0.000013 46
224.5
291.65 4 10.2 4.2 0.0297 107 3 0.01278 0.000013 46
315.4
385.20 3 9.3 5.9 0.0431 155 5 0.01278 0.000013 46
641.5
522.82 5 9.1 4.6 0.0597 215 9 0.03333 0.000033 120
611.9
471.11 1 8.2 3.9 0.0597 215 9 0.03750 0.000038 135
585.1
476.86 8 8.3 5.3 0.0597 215 9 0.02639 0.000026 95

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7. Conclusion
In this experiment there are several mistakes that occur when do the
experiment , the amount of heat lost is not equal to the heat gained as
a result of the loss of heat to the surrounding for several reasons
 The heat is lost by convection outside through the walls of
apparatus not moving to cold fluid(air).
 Inaccurate readings (from sensors) of different temperatures
due to some mistakes in thermocouples.

In the second and third readings that the amount of heat gained(by
air) is greater than the heat loss(by water) and this results are not
logical, perhaps due to the obtained readings without giving the
process an opportunity for steady state. or as a result of incorrect
reading of the micromanometer to calculate air flow rate accurately.

To make the calculations more accurate, the experiment should be

repeated several times, and the process should be set to steady.

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8. References

 Coulson, J.M. and Richardson, J.F, ''Chemical Engineering Design'', Volume

6,R.KSinnott, (1993).
 Kuppan Thulukkanam ''Heat exchanger design handbook'', Second
edition,2013

 THERMODYNAMICS/ T157D - Air/Water Heat Exchangers Study Unit -

Code 950520.

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