Heat Mass Transfer

DOI 10.1007/s00231-015-1662-8

ORIGINAL

Overall heat transfer coefficient andpressure drop ina typical

tubular exchanger employing alumina nanofluid asthe tube side
hot fluid
A.E.Kabeel1 MohamedAbdelgaied1

Received: 9 December 2014 / Accepted: 8 August 2015

Springer-Verlag Berlin Heidelberg 2015

Abstract Nano-fluids are used to improve the heat

transfer rates in heat exchangers, especially; the shelland-tube heat exchanger that is considered one of the
most important types of heat exchangers. In the present study, an experimental loop is constructed to study
the thermal characteristics of the shell-and-tube heat
exchanger; at different concentrations of Al2O3 nonmetallic particles (0.0, 2, 4, and 6%). This material concentrations is by volume concentrations in pure water
as a base fluid. The effects of nano-fluid concentrations
on the performance of shell and tube heat exchanger
have been conducted based on the overall heat transfer
coefficient, the friction factor, the pressure drop in tube
side, and the entropy generation rate. The experimental
results show that; the highest heat transfer coefficient is
obtained at a nano-fluid concentration of 4% of the shell
side. In shell side the maximum percentage increase in
the overall heat transfer coefficient has reached 29.8%
for a nano-fluid concentration of 4%, relative to the case
of the base fluid (water) at the same tube side Reynolds
number. However; in the tube side the maximum relative
increase in pressure drop has recorded the values of 12,
28 and 48% for a nano-material concentration of 2, 4
and 6%, respectively, relative to the case without nanofluid, at an approximate value of 56,000 for Reynolds
number. The entropy generation reduces with increasing

* A. E. Kabeel
kabeel6@hotmail.com; kabeel6@feng.tanta.edu.eg
Mohamed Abdelgaied
mohamed_13480@yahoo.com
1

Mechanical Power Engineering Department, Faculty

ofEngineering, Tanta University, Tanta, Egypt

the nonmetallic particle volume fraction of the same

flow rates. For increase the nonmetallic particle volume
fraction from 0.0 to 6% the rate of entropy generation
decrease by 10%.
List of symbols
A Area of heat transfer (m2)
Cp Specific heat capacity [J/(kg C)]
d Tube diameter (m)
D Shell diameter (m)
f Friction factor
h Heat transfer coefficient [W/(m2C)]
k Thermal conductivity [W/(m2C)]
LMTD Logarithmic mean temperature difference (C)
m
Mass flow rate (kg/s)
Q Rate of heat transfer (W)
S gen Total entropy generation rate
T Temperature (C)
U Overall heat transfer coefficient [W/(m2C)]
Greek symbol
Dynamic viscosity (Ns/m2)
Density (kg/m3)
v Volume fraction
m Mass fraction
Subscript
bf Base fluid
c, in Inlet cooling water
c, out Outlet cooling water
h, out Outlet hot nano-fluid
h, in Inlet hot nano-fluid
i Inner
nf Nano-fluid
np Nano-particle

13

Heat Mass Transfer

o Outlet
sa Surface area
ss Shell side surface

1Introduction
Mechanisms of heat transfer are one of the most important
tools to save energy in different engineering application. Utilization of nonmetallic additives which have higher thermal
conductivity than cooling medium allows one to enhance the
heat transfer in different engineering applications.
Suspension of nonmetallic species in conventional fluids
is a new innovative category of fluids called as nano-fluids.
Nano-fluids are now of great interest to modify the performance of the heat transfer. The mass transfer rate of oxygen in the presence of nanometer size (organic droplets) has
been studied by [1]. The results show that, the diffusion and
the mass transfer rate into the nano-particles depend on the
particle size; the percentage improving in mass transfer rate
might be lower at larger particle sizes. The measured values can be much higher in the presence of very fine particles
2030nm. That effect can be caused by the increases of the
diffusion and the mass transfer rate. The effect of suspended
nano-particles on the mass transfer between a rotating disc
electrode and anode was investigated experimentally by [2].
The results show that, the suspended particles increased the
limiting diffusion current value between a rotating disc electrode and anode. Moreover, the addition of nano-particles,
improves the physical properties of fluids and mass transfer [38]. The most important physical property of nanofluids in many applications of heat transfer including heat
exchanger is thermal conductivity [9]. The thermal conductivity enhancement of nano-fluids can be attributed to several factors such as the volume fraction of nano-particle,
temperature, type of nano-particle, size and shape of nanoparticle. Numerous studies have been conducted to determine the effect of these parameters on the enhancement of
thermal conductivity of nano-fluids [10, 11]. It has been
seen that the thermal conductivity of nano-fluid increases
linearly with respect to the volume fraction of nano-particles [12, 13]. Therefore, the thermal conductivity of nanofluid is expected to enhance the performance of heat transfer compared to the conventional heat transfer of base fluid
(water) [6, 14, 15]. The highest heat transfer rate occurs to
the cylindrical shape of the nano-particles [16].
Vakili etal. [17] studies the effect of TiO2 nano-fluids
concentration on the convective heat transfer in a straight
vertical pipe under both the laminar and turbulent flow conditions. They found that, the enhancement of the convective
heat transfer coefficient for the mixture consisting of 60%
ethylene glycol and 40% pure water is more than the nanofluid of pure water.

13

12

6
3

Electrical heater
11

14

15

7
2

13
STHE
STHE

Nano-fluid
Nano-fluid
tank

Cooling
Cooling
tower

16

10
9

Paddle
Water inlet

8
Hot nano-fluid cycle
Cooling water cycle

Fig.1Experimental setup. 5, 6, 12, 13, thermocouples; 4, 11 differential. U-tube manometer; 3, 11 rotameter; 2, 9 pump; 1, 7, 8, 14, 15,
16 valve

Wang etal. [18] studies the effect of the new flower

baffles arrangement on the performance of the shell-andtube heat exchanger, and compared the results with the
original segmental baffle heat exchanger. The result show
that, the Nusselt number for using flower baffles arrangement is about 50% of that of original segmental baffle heat
exchanger, while the pressure drop of the former is about
30% of the latter.
Wang etal. [19] studies the effects of two-phase flow
on the heat transfer coefficient in the shell side of a horizontal TEMA-F heat exchanger. Two-phase flow has
been conducted using glycerin-water solution and air
mixture. The results show that, at the same flow pattern,
gas flux and liquid flux have effects on the heat transfer
coefficient.
In the present work, an experimental test rig used to
study the thermal characteristics of shell-and-tube heat
exchanger; at different concentrated of Al2O3 nonmetallic
particles (0.0, 2, 4, and 6%) volume fractions in pure liquid water as a base fluid.

2Experimental setup
The experimental setup for studying the performance of
shell and tube heat exchanger (STHE) is shown in Fig.1.
The experiment setup consists of two cycles: hot nano-fluid
cycle and cooling water cycle. The descriptions of the two
cycles are shown below.
1. Hot nano-fluid cycle: the nano-fluid is heated by an
electrical heater. The experiments are carried out at
different concentration of nonmetallic. At each run
the nonmetallic concentrations are 0.0, 2, 4, 6%

Heat Mass Transfer

Table1Main dimensions of experimental shell-and-tube heat
exchanger
Items

Dimensions

Shell inner diameter

Length of shell
Tubes inner diameter
Tubes outer diameter
Number of pass
Tube pitch ratio
Total number of baffles
Baffle spacing
Baffle cut

180mm
600mm
6.5mm
9.5mm
2
1.3
4
120mm
30%

Total number of tubes

86

Arrangement of tube

Staggered

volume fractions. The temperature of the nano-fluid

inlet to STHE is controlled by a temperature controlling device to obtain a constant inlet temperature at
(60C) at all nano-fluid volume flow rates. The hot
nano-fluid flows from a nano-fluid tank through rotameter (3) into the tube side of the STHE. After that,
the nano-fluid returns to the nano-fluid tank. The
temperature of the nano-fluid flow through STHE
at inlet and outlet are directly measured by thermocouples (5) and (6), respectively. The nano-fluid is
pumping through the cycle by a pump (2). The valves
(1) and (7) are used to control the flow rates through
the cycle.
2. Cooling water cycle: the cooling water flows from a
cooling tower through a Rota meter (10) into the shell
side of the STHE. After absorbing the heat from the
STHE, the water returns to the cooling tower. The temperature of the cooling water flow through STHE at the
inlet and outlet are directly measured by thermocouples
(12) and (13) respectively. The cooling water is pumping through the cycle by a pump (9). The valves (8) and
(14) are used to control the flow rate through the cycle.

the physical properties of alumina nano-fluid have been

well documented. The characteristics of nano-fluids used
in this work are governed by not only the type, shape and
size of the nano-particles, but also distribution of nano-particles in the base fluid. The shape and dimensions of the
nano-material similar to that shown in the photo presented
in Fig.2 [20] taken by transmission electron microscopy
(TEM), alumina nano-material have a spherical shape. The
size has a normal distribution in a range from 10 to 100nm
(47nm average diameter is given from the manufacturer)
as shown in Fig.3 [20]. The physical properties of the alumina used in this study are: bulk density=260kg/m3, true
density=3600kg/m3, specific heat=765J/kgK, melting
point=2046C. The nano-fluid concentrations used in this
study are 0, 2, 4, and 6% volume fraction. The nano-fluids
were treated by ultrasonication to keep the nano-fluid, stable, uniform, and continuous suspension.

Fig.2Characteristics of nano-fluid, TEM photographs of Al2O3

nano-particles [20]

Type of the shell-and-tube heat exchanger used in this

study is a TEMA-S horizontal heat exchanger. It consists of a
cylindrical steel shell and copper tubes. The main dimensions
of the shell-and-tube heat exchanger are given in Table1.

3Nanofluids properties
The non particles used in the current experimental work
is alumina (Al2O3). Alumina is widely used in that area
of research due to different requirements such as stability,
homogeneity, and continuous suspension without any outstanding chemical change of the base fluid and also that

Fig.3Size distribution of the nano-particles [20]

13

Heat Mass Transfer

4Experimental data reduction

hss =

In the present experimental study, the volume flow rate,

the temperature, and the pressure drop were all measured
directly by the rotameter, the thermocouples, and the differential U-tube manometer respectively. The energy balance
between both the tube side and the shell side is calculated
from the data recorded by the measuring devices.
The net rate of heat flow based on the fluid in tube side
was calculated from Eq.(1).


Q=m
nf cp,nf Th,in Th,out
(1)
The logarithmic mean temperature difference LMTD of the
shell and tube heat exchanger is calculated from Eq.(2).

 

Th,out Tc,in Th,in Tc,out


LMTD =
(2)
Th,out Tc,in
ln Th,in
Tc,out

For two-pass shell-and-tube heat exchangers, the flow

directions are combinations of countercurrent, reducing the
effective value of LMTD. The corrective factor FT of the
logarithmic mean temperature difference was determined
from Eq.(3) [21]

ln [(1 S)/(1 RS)] R2 + 1



FT =

2S R+1 R2 +1
(3)



(R 1) ln
2S R+1+

R2 +1

where:

R=

Th,in Th,out
,
Tc,out Tc,in

and

S=

Tc,out Tc,in
Th,in Tc,in

Q
(LMTD)FT Asa

(4)

The Nusselt numbers and the heat transfer coefficients

inside the tubes are deduced from Eqs.(5, 6) [22]:
1/3

Nui = 0.023 Re0.8

i Pri
hi =

(5)

ki Nui
di

(6)

The calculation of the Reynolds number and the Prandtl

number gives:

Rei =

i vi di
,
i

and Pri =

i Cp,i
ki

The heat transfer coefficient in shell side hss is deduced

from Eq.(7) [19].

13

1 do
hi di

do
2k

ln

 
do
di

(7)

The amount of nano-particles dispersed in the nano-fluid

was measured by volume concentration.
The volume concentration of nano-particles in nanofluids v was determined from Eq.(8) [16].

  

1
1
+1

=
1

/
np
(8)
bf
m

Density of nano-fluid nf was determined from Eq.(9) [16].



nf = bf v bf np
(9)

Specific heat capacity of nano-fluid Cp,nf was determined

from Eq.(10) [16].




 

Cp bf v Cp bf Cp np
(10)
Cp,nf =
nf
Viscosity of nano-fluid nf was determined from Eq.(11)
[16].


nf = (1 v )2.5 bf
(11)
Thermal conductivity of nano-fluid knf was determined
from Eq.(12) [16].



knp + 2kbf 2v kbf knp

 kf
knf =
(12)
knp + 2kbf + v kbf knp
4.1Entropy generation rate

The overall heat transfer coefficient U was determined

from Eq.(4) [21]

U=

1
1
U

The losses in the heat exchanger due to the irreversibility

are evaluated in terms of entropy generation. The entropy
generation rate caused by finite temperature difference,
S gen,T can be written as follows
out



 
mC
p dT
mC
p dT
+
T
T
in
c
h



Th,out
Tc,out 
= mC
p c ln
+ mC
p h ln
Tc,in
Th,in

S gen,T =



(13)

The entropy generation rate caused by the pressure drop,

S gen,p can be written as follows




Th,out
Tc,out
ln
ln
P
P
T
T
c
c,in
h,in
h

 +m

h
c
S gen,p = m
c Tc,out Tc,in
h Th,out Th,in

(14)

The total entropy generation rate in heat exchanger can be

written as:

Heat Mass Transfer

S gen = S gen,T + S gen,P




Th,out
Tc,out 
+ mC
p h ln
= mC
p c ln
Tc,in
Th,in




Th,out
Tc,out
ln
ln
Pc
Ph
Tc,in
Th,in



 +m
+m
c
h
c Tc,out Tc,in
h Th,out Th,in

(15)

Friction factor, f was calculated by using Eqs.(16) or (17)

[16]

f =

64
,
Rei

(16)

For laminar flow

f = (0.790 ln Rei 1.64)2 ,

For turbulent flow

(17)

Table2Summary of uncertainties
Parameter

Uncertainty

Density of nano-fluid
Specific heat capacity of nano-fluid
Thermal conductivity of nano-fluid
Viscosity of nano-fluid
Discharge of nano-fluid
Mass flow rate of nano-fluid
Temperature
Overall heat transfer coefficient
Heat transfer coefficient in shell side

4.6%
3%
4.5%
4.7%
3.2%
4.8%
0.1C
7.2%
7.6%

Rate of heat transfer

5%

Pressure drop

4.2%

5Uncertainty analysis
The uncertainty in the present study is calculated based on
the method presented by [23]. The uncertainty of the experimental results was determined from Eq.(16) [16].

2 
2 
2
r
r
r
Vy1 +
Vy2 +
Vy3 +
Vr =
y1
y2
y3

n (1/2)
r
+
Vyn
(18)
yn
where: r=f(y1, y2, y3,,yn), y1, y2, y3,, yn are variables
influencing the quantity r, Vy1, Vy2, Vy3,, Vyn are the
absolute uncertainties of y1, y2, y3,, yn:
The accuracy of measurements devices and the uncertainties of the derived values are summarized in Table2.

6Results anddiscussion
The experimental work has been carried out at four runs.
At the first run, no nano-material is added to the pure water,
while from the second run to the fourth run, the nano-material concentration was from 2 to 6vol%. At each experimental run, the Reynolds number is increased by using
both the needle valve and the flow meter. The inlet-exit fluids temperatures, the fluids flow rates and pressure drops
are measured at each measuring state. The effects of different concentrations of nano-material on the thermal performance of the shell and tube heat exchanger are presented
in the following subsections at the constant flow rate in the
cooling side.
6.1Overall heat transfer coefficients
Figure4 shows the variation of the overall heat transfer coefficient with the tube side the Reynolds number of different

Fig.4Effect of tube side Reynolds number on the overall heat transfer coefficient at different concentrated volume fractions of nanomaterial

concentrations of nano-fluid. The overall heat transfer coefficient increases with increasing both the tube side Reynolds
number and the nano-fluid concentration. For a constant value
of Reynolds number, the highest overall heat transfer was
attained at 4% nano-fluid volume fraction concentration as
shown in Fig.5. The maximum increase in overall heat transfer coefficient was recorded 29.8% at 4% nano-fluid concentration, while that increase recorded 14.4% at 6% concentration. The increase or decrease in the overall heat transfer
coefficient is references to the case without nano-fluid. After
adding the nano-material, the overall heat transfer coefficient
was increased above the case without nano-material due
to the enhancement in nano-fluid physical properties especially the nano-fluid thermal conductivity. The decrease in
the overall heat transfer coefficient value after increasing the

13

Heat Mass Transfer

Fig.5Effect of nano-fluid volume fraction on the overall heat transfer coefficient

nano-fluid concentration beyond 4%, could explained as the

nano particles tendency for agglomeration was increased with
increasing their concentration above a certain limit of concentration (4%). So, the overall heat transfer coefficient could
record less value after 4% nano-fluid concentrations. The
result shows that; the rate of entropy generation in nano-fluid
decreases with the increasing the nano-fluid concentration.
Table 3 shows the measurement data of the hot nanofluid temperature difference in different nano-fluid concentration. The results show that, the hot nano-fluid temperature difference decreases with increasing the tube side
Reynolds number at all nano-fluid concentration as shown
in Table3. For a constant value of the Reynolds number,
the highest hot nano-fluid temperature difference was
attained at 4% nano-fluid volume fraction concentration.
6.2Friction factor andpressure drop intube side
The friction losses are strongly dependant on the fluid viscosity. Adding nano material in the base fluid changes the
Table3Measurements, data on
the hot nano-fluid temperature
difference

13

Rei

Fig.6Effect of nano-fluid volume fraction on the friction factor

fluid viscosity. So; for increasing the nano-material concentrations increases the viscosity of the nano-fluid, hence
increases the fluid friction factor. Also the particle-to-wall
interactions, particularly if the agglomeration is occurring could participate in the increase in friction losses. The
effect of increasing the nano-fluid concentrations on the
fluid friction factor is illustrated in Fig.6
In addition to the geometry, the pressure drop in the tube
side of the shell and tube heat exchanger depends on fluid
density, fluid viscosity, and the flow rate. Applying the nanofluid, both the viscosity and the density were increased with
the increase in nano- materials concentration, so the pressure
drop increase with the increase in nano material concentrations. Figure7 shows the variation of the pressure drop in
the tube side with the tube side Reynolds number for the different concentrations of the nano-fluid. The pressure drop
in the tube side increases linearly with increasing the Reynolds number for all concentration of nano-fluid. Also, Fig.8
shows the effect of nano-fluid concentration on the pressure
drop in constant Reynolds number. The results show that, the
maximum relative increase in pressure drop has recorded 12,

Hot nano-fluid temperature difference (T5T6)C

Nano-fluid volume
fraction, 0.0%

Nano-fluid volume
fraction, 2%

Nano-fluid volume
fraction, 4%

Nano-fluid volume
fraction, 6%

9500
19,000
28,500
38,000
47,500

23.6
13.8
10
8.5
7.4

28.4
16.5
12
10.2
8.8

34.3
20
14.5
12.3
10.7

31
18
13.1
11.1
9.6

56,000

6.8

8.2

9.9

8.9

Heat Mass Transfer

28 and 48% for a nano-material concentration of 2, 4 and

6% respectively. All the increases in the pressure drops were
relative to the case without nano-fluid, at an approximate
value of 56,000 for Reynolds number. The measured pressure drop in the present study includes the entrance and the
exit losses.
Table4 shows the measurement data of the pressure drop
in the tube side at different nano-fluid concentration. The
results show that, the pressure drop increases with increasing both the tube side Reynolds number and the nano-fluid
concentration as shown in Table4.
6.3Entropy generation rate

Fig.7Effect of tube side Reynolds number on the pressure drop at

different concentrated volume fractions of nano-material

Figure 9 shows the changes of entropy generation rate

for nano-fluid flow rate 25L/min, cooling fluid flow rate
20L/min, and different nano-fluid volume fractions. As
seen, the entropy generation rate reduces with increasing the nano-particles, volume fraction of constant flow
rates. The entropy generation rate due to fluid friction
has been decreased by 10% by increasing of nano-fluid
concentration of 06% at constant flow rates.

7Conclusion
An experimental work was carried out to study the effects
of nano-fluid concentration on the heat transfer, friction
factor, pressure drop, and entropy generation in a clean
shell and tube heat exchanger (no fouling effect) using
Al2O3/water nano-fluid (0.0, 2, 4, and 6%) volume fractions and for constant flow rate in cooling side. The experimental results are summarized as follows:

Fig.8Effect of nano-fluid volume fraction on the pressure drop

Table4Measurement data of
the pressure drop in the tube
side

Rei

In the shell and tube heat exchanger, heat transfer rate

is enhanced by using Al2O3 nano particles in the range
from 2 to 6% volume fraction.
The maximum increase in the overall heat transfer coefficient recorded 29.8% for 4% nano particle concentration relative to the case without nano-fluid.

Pressure drop in the tube side (kPa)

Nano-fluid volume
fraction, 0.0%

Nano-fluid volume
fraction, 2%

Nano-fluid volume
fraction, 4%

Nano-fluid volume
fraction, 6%

9500
19,000
28,500
38,000
47,500

4.5
16.5
28.5
40.5
52.5

5.04
18.48
31.92
45.46
58.8

5.76
21.12
36.48
51.14
67.2

6.66
24.42
42.18
59.94
77.7

56,000

64.5

72.24

82.56

95.46

13

Fig.9Effect of nano-particles volume fraction on the entropy generation rate

The increase in the overall heat transfer coefficient is

reduced to 14.4% for 6% nano particle concentration
relative to the case without nano-fluid.
In the tube side the maximum relative increase in pressure drop has recorded the values of 12, 28 and 48%
for a nano-material concentration of 2, 4 and 6%,
respectively relative to the case without nano-fluid, at an
approximate value of 56,000 for Reynolds number.
With an increase in volume fraction of nano-particles,
entropy generation reduces
The current study with its conclusions is limited to that
type of heat exchanger the mentioned heat exchanger
geometry and specifications, the mentioned nano particles (Al2O3) and the used shell side fluid.
In spite of the agglomeration of nano-fluid could
affected the overall heat transfer coefficient, it has no
sensible effect on the pressure drop this could arisen
due to the less sensitivity of the used pressure drop
transducers. So, with the available data (experimental
data collected), no hard and fast conclusions are possible and a more elaborate study is required to explain the
phenomenon more convincingly.
Alumina nano-fluids are used in that research because
they are widely used in that area of research due to
requirements such as stability, homogeneity, and continuous suspension. Alumina nano-fluids should subject to
an extensive study that incorporate the chemical change
of the base fluid with time.

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