Submission Date:22.11.

2018

ChE-410

Shell & Tube Heat Exchanger

Experiment 4.2

Group Number: B11

Submitted by: Kenan AKGÜN
Celalettin KÖYLÜ
Kazım SOYDAN
Samet Özdilek
Submitted to: Dr. Görkem Külah

ChE-410
Chemical Engineering Laboratory
Middle East Technical University
 Abstract

In the experiment, the objective was to observe the effect of Reynolds number on individual
heat transfer coefficients, and then, the overall heat transfer coefficient and performance of the
shell and tube heat exchanger are compared for both counter and co-current flow arrangements.
To make the calculations in an easier manner, some crucial assumptions ought to be made.
Steady state conditions, one dimensional heat transfer and constant flow rates can be given as
main assumptions. At the beginning of the experiment the co-current arrangement is applied. Flow
rate of hot stream is kept constant at 300 L/h and the flow rate of the cold stream is change after
each steady condition beginning from 300 L/h to 400 L/h and then 500 L/h finally. For each flow
rate, the data is taken from the panel and noted into datasheet. After completing the co-current
data, the flow type is changed into counter current flow by opening valves 2 and 4.
Via using the experimental data, the average heat duty Qavg is estimated to find overall
heat transfer coefficient. The empirical way to calculate the overall heat transfer coefficient is Kern
method. The values obtained from experimental data and theoretical method are tabulated and
compared. As a result, the overall heat transfer coefficient is increases when the flow rate of cold
stream increases. The condition that the value of overall heat transfer coefficient is more in co-
current mode than the counter current mode is expected however because of an error, that is
inverse for the experiment. The Reynolds number of fluid is also taken into account and the effect
of Re number is observed by using Gnielinski and Donohue equations.
The temperature values at inlet and outlet streams are taken until the steady state
conditions are observed. The temperature distribution is also graphed, and it shows that the
temperature gradient is constant during the counter-current mode. It means uniform heat transfer
between hot and cold streams. However, in co-current flow arrangement, there is big heat transfer
rate at the beginning due to larger temperature difference.

1
 Table of Contents
Nomenclature................................................................................................................................................ 3
Introduction................................................................................................................................................... 4
Experimental Procedure .............................................................................................................................. 13
Results ......................................................................................................................................................... 14
Discussion .................................................................................................................................................... 18
Conclusion ................................................................................................................................................... 19
References ................................................................................................................................................... 20
Appendix...................................................................................................................................................... 21
MATLAB Codes for Co-Current Flow ....................................................................................................... 21
MATLAB Code for Counter-Current Flow ................................................................................................ 22

2
 Nomenclature
𝐴𝐴: 𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴(𝑚𝑚2 )
𝑇𝑇: 𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇(℃)
𝑅𝑅𝑅𝑅: 𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅 𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁
𝑃𝑃𝑃𝑃: 𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃 𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁
𝑁𝑁𝑁𝑁: 𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁 𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁
𝐷𝐷: 𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷(𝑚𝑚), 𝐿𝐿: 𝐿𝐿𝐿𝐿𝐿𝐿𝐿𝐿𝐿𝐿ℎ(𝑚𝑚)
𝑄𝑄: 𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻 𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷(𝑘𝑘𝑘𝑘)
𝑊𝑊
𝑘𝑘: 𝑇𝑇ℎ𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒𝑒 𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶 � �
𝑚𝑚𝑚𝑚
𝑊𝑊
ℎ: 𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻 𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡 𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶 � �
𝑚𝑚2 𝐾𝐾
𝑊𝑊
𝑈𝑈: 𝑂𝑂𝑂𝑂𝑂𝑂𝑂𝑂𝑂𝑂𝑂𝑂𝑂𝑂 𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻 𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡 𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶 � 2 �
𝑚𝑚 𝐾𝐾
∆𝑃𝑃: 𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃 𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷
𝐵𝐵: 𝐵𝐵𝐵𝐵𝐵𝐵𝐵𝐵𝐵𝐵𝐵𝐵 𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆
𝜇𝜇: 𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉(𝑃𝑃𝑃𝑃𝑃𝑃)
𝑘𝑘𝑘𝑘
𝜌𝜌: 𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷𝐷 � 3 �
𝑚𝑚
𝐽𝐽
𝐶𝐶𝑝𝑝 : 𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻 𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶 � �
𝑘𝑘𝑘𝑘𝑘𝑘
𝑃𝑃: 𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇 𝑃𝑃𝑃𝑃𝑃𝑃𝑃𝑃ℎ(𝑚𝑚)
𝐿𝐿𝐿𝐿𝐿𝐿𝐿𝐿: 𝐿𝐿𝐿𝐿𝐿𝐿 𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚 𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡(℃)
𝐹𝐹: 𝐿𝐿𝐿𝐿𝐿𝐿𝐿𝐿 𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐 𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓𝑓
𝑚𝑚
𝑉𝑉: 𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉𝑉 � �
𝑠𝑠
𝑁𝑁𝑡𝑡 : 𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁𝑁 𝑜𝑜𝑜𝑜 𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇
𝑓𝑓: 𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹 𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹
𝜀𝜀: 𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸 𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹𝐹
𝑠𝑠: 𝑆𝑆ℎ𝑒𝑒𝑒𝑒𝑒𝑒 𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆 𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝, 𝑡𝑡: 𝑇𝑇𝑇𝑇𝑇𝑇𝑇𝑇 𝑆𝑆𝑆𝑆𝑆𝑆𝑆𝑆 𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝𝑝

3
 Introduction

The objective through the experiment, as taking the data at different flow rate, is to
determine the effect of Reynold’s number on overall heat transfer coefficient and to determine the
difference of the heat transfer amount between co-current and counter-current heat exchangers.
In this experiment, the flow rate of the cold stream is changed, and temperatures are noted. In
figure 1, Shell and Tube heat exchanger is shown;

Figure 1-Shell and Tube Heat Exchanger

The heat exchangers provide the energy transfer between the two fluids and the driving
force for the transfer is temperature difference. Shell and Tube Heat Exchangers are the most
used type of the heat exchangers in petrochemical industry. According to flow direction, heat
exchanger can be divided into two part; they are co-current and counter- current. In co-current
both streams are flowing in the same directions, on the other hand, in counter-current, shell side
and tube side fluids are opposite directions. In figure 2 and 3, the representative flow direction can
be shown.

Figure 2-Co-current flow Figure 3-Temperature behavior of co-current flow

4
 Figure 4-Counter current flow Figure 5-Temperature behavior of counter current

Other advantage of shell and tube is that there are baffles in this type exchangers. Thanks
to them, the heat surface area is increased so that, amount of heat transfer goes up because
baffles improve the convection heat transfer coefficient of fluid.

Dimensionless Numbers and Correlations

Reynold’s Number: Ratio of inertial forces to viscous forces.

(1)

Nusselt Number:

(2)

Lch : Characteristic Length h: Heat Transfer Coefficient k: Thermal Conductivity

Prandtl Number:

(3)

μ: Viscosity Cp : Specific Heat Capacity α: Thermal Diffusivity

k: Thermal Conductivity ν: Kinematic Viscosity

5
 Kern Method:

(4)

(5)

(6)

(7)

(8)

(9)

(10)

mh : Hot Fluid Mass Flow Rate mc : Cold Fluid Mass Flow Rate

ch : Specific heat of the Hot Fluid cc : Specific heat of the Cold Fluid

Thi : Inlet Temperature of the Hot Fluid Tho : Outlet Temperature of the Hot Fluid

Tci : Inlet Temperature of the Cold Fluid Tco : Outlet Temperature of the Cold Fluid

U0 : Overall Heat Transfer Coefficient A0 : Heat Transfer Area

∆Tlm : Log Mean Temperature Difference F: Correction Factor ∆Tm : Mean Temperature Difference

Instead of using terminal temperature differences, mean temperature difference is used during
the process. Overall heat transfer coefficient can be calculated;

(11)

6
 One of the main problems for heat exchanger is fouling. It decreases the heat transfer between
hot and cold fluid streams. To account fouling, F(correction factor) is used. To determine F, R and S is used
and from temperature correction factor graph, the value of F is read.

(12)

Figure 6-Temperature Correction Factor Graph

Equations for Shell Side Calculations

1. Calculate Tavg−cold .
2. Calculate flow area per tube.

(13)

3. Calculate flow area per pass.

(14)

Nt : Total Number of Tubes nt : Number of Tubes Passes

7
 4. Calculate average velocity.

(15)

5. Calculate Reynold’s number.

(16)
6. Calculate Prandtl number.

(17)

μ: Viscosity Cp : Specific Heat Capacity k: Thermal Conductivity

7. Use Gnielinski equation

(18)

2300 < Ret < 104 → ReD = Ret − 1000

0.5 < Prt < 2000 ReD = �
104 < Ret < 5 ∙ 106 → ReD = Ret

(19)

ε is taken as 0.05 mm or the following equation, (20) is used.

8
8. Diameter correction.

Do : Outer Diameter Ds : Inner Shell Diameter

Equations used in Shell Side Calculations:

1. Calculate Tavg−hot .
2. For one shell pass, calculate area for cross flow.
0.2 Ds ≤ B ≤ Ds

(21)

P: Tube Pitch B: Baffle Spacing Do : Outer Diameter Ds : Inner Shell Diameter

Mass velocity for the cross flow to the tubes:

(22)

w: Mass Flowrate
3. For one shell pass, calculate area for baffle window

(23)

Mass velocity parallel to the tubes:

(24)
w: Mass Flowrate

Nt
fb : 0.1955 for 25% baffle cut Nb = Note: Nb should be an integer.
4

4. Calculate equivalent mass velocity.

9
 (25)

5. Calculate Reynold Number for the shell side

(26)

6. Calculate Prandtl number for the shell side.

(27)

7. Use Donohue Equation for the shell side.

(28)

8. Calculate temperature of the tube wall:

(29)

9.

(30)
10.

(31)

11. Calculate clean overall heat transfer coefficient:

(32)

10
12.
(33)

Lt = Length of a Tube in One Pass

13. Calculate Dirt Factor:

(34)

Pressure Drop Estimation

For the shell side:

1. Estimate f with following formula for the Re calculated by the equation,

(35)

2. Calculate the crosses number.

(36)

3.

(37)

4.

(38)

π ∙ D2o
⎧ (P 2 − )
⎪ 4 4 for square pitch
π ∙ Do
Dh = (39)
⎨ (P ∙ (0.86)P − 0.5π ∙ D2 /4)
o
⎪4 2 for triangular pitch
⎩ (0.5) ∙ π ∙ Do

For the tube side:

1. Calculate pressure difference for the tube.

11
 (40)

2. Calculate pressure difference for the returns at the tube side:

(41)

3. Calculate total pressure difference is found by the summation.

(42)

Relative error in overall heat transfer coefficients:

(43)

where U is overall heat transfer coefficient determined using experimental data and Uc is overall
heat transfer coefficient determined using Kern method.

Heat loss by free convection can be calculated according to:

(44)

Free convection coefficient for air can be calculated by Churchill and Chu correlation (Incropera,
2011) :

(45)

Heat loss by radiation can be calculated according to:

(46)

where σ is Stefan-Boltzmann constant and ε= 0.8 for borosilicate glass.

12
 Experimental Procedure
As the first step, the tank D1 which is filled with deionized water is raised to a temperature
of 70 C by the help of thermostat TW1. This water is then used as hot water stream for the heat
exchanger. Resistance is switched on in parallel with thermostat. The button G1 is pushed and
the pump which is connected to tank D1 is started to circulate the water inside the tank to get
desired temperature. The valve V6 is closed and the V7 and V8 are open for circulation.
To start the flow through the heat exchanger, the main valve cold stream water is opened.
When the water temperature in tank D1 is get 70 C, the valve V6 is opened and flow rate of inlet
hot stream for heat exchanger is fixed. To adjust the flow type through the exchanger, the valves
V1, V2, V3, V4 are used so that while the valves V1 and V3 are opened, the flow type is co-current
and while the valves V2 and V4 are used the flow regime is counter current. These both types are
used in the experiment.

Figure 1-Flow diagram of the experiment

In the experiment, the flow rate of hot stream is kept constant while the rate of cold stream
is adjusted at three different values. The inlet and outlet temperatures of both the hot and cold
streams are recorded through the experiment within each 1-minute time interval for each of the
three different flow rates until the panel shows the steady state condition by showing the non-
increasing or non-decreasing values. This procedure is repeated both for co-current and counter
current flow.
After completing the main procedure, the shutdown step is considered. Firstly, the
thermostat is stopped then the hot water stream valves are closed. The pump is also stopped.
The main valve of cold water stream is closed and then the valves V1 and V3 are closed.

13
Results
The steady state values of temperature are given in the following table for different flow
rate and counter & co-current flow;

Table 1 St-st Temperature Values

Flow Hot Flow Rate Cold Flow Rate

T1(ᵒC) T2(ᵒC) T3(ᵒC) T4(ᵒC)
Direction (L/h) (L/h)
14.8 68.5 33.9 55.6
Counter Co-Current

300
400 14.6 68.3 30 53.8
500 14.5 66.7 27.3 51.6
400

300 14.5 66.2 34.2 52.6

400 14.5 65.5 30.5 50.8
500 14.5 63.6 27.3 48.7

Following table shows thermophysical properties of waters;

Table 2 Thermophysical Data of Water at Average Temperature

Flow Cold Flow

Th,avg(⁰C) Cp,h(kJ/kg.K) ρh(kg/m3) µh(N.s/m2) kh(W/m.K)
Direction Rate(L/h)
Counter Co-Current

300 62.05 4.186 981.6 0.00045 0.656

400 61.05 4.185 982.1 0.00045 0.653
500 59.15 4.184 983.2 0.00046 0.651
300 59.4 4.184 983.2 0.00046 0.651
400 58.15 4.184 983.9 0.00048 0.650
500 56.15 4.183 986.0 0.00049 0.648
Flow Cold Flow
Tc,avg(⁰C) Cp,c(kJ/kg.K) ρc(kg/m3) µc(N.s/m2) kc(W/m.K)
Direction Rate(L/h)
Counter Co-Current

300 24.35 4.182 997.3 0.00091 0.612

400 22.3 4.181 997.4 0.00095 0.609
500 20.9 4.180 998.0 0.00097 0.606
300 24.35 4.182 997.3 0.00091 0.612
400 22.5 4.181 997.4 0.00093 0.609
500 20.9 4.180 998.0 0.00097 0.606

After determining the data, the parameters these are Re number (eqn. 16 & 26), log mean
temperature (eqn. 10), heat duty (eqn. 4, 5 & 6), loss (eqn. 46), experimental overall heat transfer
coefficient (eqn. 8) and empirical one (eqn. 32) are shown in Table.3. Since there is a difference
between hot fluid and cold fluid while calculating heat duty, average one has been shown. Also,
pressure drops that are calculated by eqn. 37 for shell and 40, 41 & 42 for tube side are given in
Pascal unit. Following table shows their values;

14
Table 3 Parameters for Both Counter and Co-Current Flow

Flow Cold Fluid

ΔTlm(⁰C) Q(kW) qloss(W) Uexp(W/m2K) U(W/m2K) Error% Side Reynolds ΔP(Pa)
Direction Flow rate(L/h)
Tube 7559 743.84
300 34.96 6.53 3.47 1391 1013 20
Shell 3115 20.54
Counter

Tube 7249 748.48

400 35.64 7.06 1.97 1476 1096 19
Shell 4064 34.66
Tube 7169 751.92
500 35.23 7.12 0.7 1504 1158 16
Shell 4874 52.3
Tube 7714 740.65
300 35.23 6.26 3.47 1320 1018 18
Shell 3115 20.54
Co-Current

Tube 7718 740.98

400 36.72 6.87 1.81 1393 1109 15
Shell 3978 34.81
Tube 7559 743.84
500 36.45 7.15 0.7 1460 1175 14
Shell 4874 52.3

After calculating parameters, overall heat transfer coefficients and temperature distribution
graphs are shown in the following figures;

1600

1400
Overall Heat Tr Coeff (W/m2K)

1200

1000
Experimental
800
U
600

400

200

0
250 300 350 400 450 500 550
Qc(L/h)

Figure 7 Comparison of Empirical and Experimental U for Counter-Current

15
 1600

1400

1200
Overall Heat Tr Coeff (W/m2K)

1000
Exp U
800 Emp U

600

400

200

0
250 300 350 400 450 500 550
Qc(L/h

Figure 8 Comparison of Empirical and Experimental U for Co-Current

7.2

7.1

6.9 Counter-Curr Heat Duty

Heat Duty (kW)

6.8 Co-Curr Heat Duty

6.7

6.6

6.5

6.4

6.3

6.2
250 300 350 400 450 500 550
Qc(L/h)

Figure 9 Heat Duty Comparison btw. Co & Counter Current

16
 60

55

50

45
Tc,o for Counter
T(⁰C)

40 Tc,o for Co
Th,o for Counter
35 Th,o for Co

30

25
250 300 350 400 450 500 550
Q(L/h)

Figure 10 Outlet temperature of Fluids for Different Flow Configuration

3.5

3
Counter FLow

2.5 Co FLow
Qloss(W)

1.5

0.5

0
250 300 350 400 450 500 550
Q(L/h)

Figure 11 Loss because of Radiation in HEX for Different Flow Configuration

17
Discussion
In this experiment, effects of flow rate on heat transfer, how much precise Kern method is
for shell & tube hex designer and effectiveness of Reynolds number on flow and heat transfer are
examined. Also, the experiment shows which flow configuration is good for heat transfer. To
investigate all of them, data by three different flow rate and different flow direction are gathered.
While the amount of flow rate is increased, transferred heat is increasing. However, that
increasing the pressure drop. So, as thinking about the thermal energy, mechanical energy should
not be ignored. If hex is before any distillation column to keep pressure constant some spending
are needed to be done. Because increasing pump power may cause lots of operational costs,
optimum flow rate ought to be selected as designing. In Figure 3, comparison between flow rate
& heat transfer can be seen.
As seen in the Table 3, experimental heat duty for counter-current flow is higher than the
co-current flow. In addition to this, when fluids enter the hex, temperature difference are needed
to be considered. Because, huge difference damage tubes highly, in the future it causes lots of
material costs. Otherwise, if huge temperature difference in little time, co-current flow is proper to
be used. Because in counter-current flow configuration there is no huge temperature gradient, it
is effective in long way. However, using empirical equations is increasing relative error (%) is
nearly 16. So that means, while designing a hex, only trusting one method should be avoided. So,
more than one methods should be used and as an engineer, standards by clarified by TEMA are
to be carried out.
While determining the heat transfer, loss factor was not forgotten, however, because there
is no high temperature like 500K and no bulk motion at outside of the shell, its value is too much
smaller than transferred one. Since Stefan-Boltzmann constant, which is too small, is in radiation
equation, loss due to radiation becomes %0.001 of the transferred heat. So, it can be negligible.
Free convection loss can be found by Ra and Nu number correlation whereas radiation is found
by Stefan-Boltzmann Law.
The other factors that influences data are external and correction factors. While writing
down the temperature data, because hot fluid was fluctuated, that situation increase the time for
the process to reach steady-state condition, so it leads to an unexpected situation occurs. That is,
log mean temperature difference for co-current flow become higher than the counter-current one.
Also, there was leak in the scaler that arrange hot fluid flow rate. All these instrumental errors
provide unwanted value for parameters. So, before starting to experiment, all external forces and
instruments should be examined and repair if there is any disorder. Also, as viscosity correction
factor is considering in the Nu number correlation, it is taken as one.

18
 Conclusion

Along the experiment, both the counter and co-current flow arrangements are applied. The
procedure is applied by changing the flow rate of the cold stream while the flow rate of hot stream
is kept constant. As the flow rate is changed, the inlet and outlet temperatures of the hot and cold
streams are recorded until the steady state is reached. To estimate the overall heat transfer
coefficient, firstly the average heat transfer Qavg is calculated from the experimental data. After that
step, the overall heat transfer coefficient U is calculated by using Kern method and the values
obtained from experimental data. The theoretical method is compared with the experimental and
tabulated. By using the Gnielinski and Donohue equations, the effect of Reynolds number on
individual heat transfer coefficients is observed.
The temperature gradient in the counter current flow is almost constant and this condition
makes it more advent. However, in co-current flow, there is big heat transfer initially, but it
decreases with time. Experiment also shows that, by increasing the flow rate heat transfer rate is
also increased. However, because of the instrumental error that leads to that empirical solution,
Kern method, is more trustable, unwanted values have been got. So, relative error we found is
also wrong since experimental values is totally wrong. As a result, counter current is good at
getting high temperature transfer and high flow rate is good for heat transfer however not for
pressure drop.

19
References
• Incropera, F. P., “Principles of Heat and Mass Transfer”, 7th ed., Wiley.
• Kern, D. Q., “Process Heat Transfer”, McGraw-Hill
• IAPWS. 2018, retrieved from wiki.anton-paar.com/en/water/
• Heat capacity of liquid water, retrieved from
www.vaxasoftware.com/doc_eduen/qui/caloresph2o.pdf

20
Appendix
MATLAB Codes for Co-Current Flow
%Do: outer Tube,Ds:shell; Di: inner Tube,
%B:baffle Space,P: pitch; Bc:baffle cut, F: Correction Factor
Do = 10/1000; Nt = 5; L = 900/1000; nt = 1;t = 1/1000;F = 0.95;
Di = Do-2*t;Ds = 50/1000; P = 20/1000; B = 48/1000;
fb = 0.1955; Nb = round(Nt/4);
qc = [300 400 500]; qh = [400 400 400];
Cph = [4.186 4.185 4.184]; Cpc = [4.182 4.181 4.180];%Heat Capacity kj/kgK
kc = [0.612 .609 0.606]; kh = [0.656 0.653 0.651];%COnductivity W/mK
dh = [981.6 982.1 983.2]; dc = [997.3 997.4 998]; %Density kg/m^3
visc = [0.00091 0.00095 0.00097]; vish = [0.00045 0.00045 0.00046];%Viscosity Pa.s
e = 0.05/1000;k = 14;%Rougness m ; conductivity for steel W/mK
Thi = [68.5 68.3 66.7]; Tho = [55.6 53.8 51.6]; %Celcius
Tci = [14.8 14.6 14.5];Tco = [33.9 30.0 27.3];%Celcius
dT1 = (Thi-Tci); dT2 = (Tho-Tco);
FMTD = ((dT2-dT1)./log(dT2./dT1)).*F;
LMTD = FMTD./F;
mh = qh.*dh./3600000; mc = qc.*dc./3600000;
A = pi.*Do.*L.*Nt;
Q = (mc.*Cpc.*(Tco-Tci)+mh.*Cph.*(Thi-Tho))/2;
U = Q./(A.*FMTD);
%Tube Side
at = pi.*Di.^2./4;
At = Nt.*at./nt;
Vt = (mh./(At.*dh));
Ret = dh.*Vt.*Di./vish; Prt = 1000.*Cph.*vish./kh;
A = (e./Di./2.5497).^1.1098+(7.149./Ret).^0.8981;
f = (-4.*log10(e./Di./3.7065-5.0452.*log10(A)./Ret)).^(-2);
Nut = (f./2).*(Ret-1000).*Prt./(1+12.7.*(f./2).^0.5.*(Prt.^0.66-1));
hi = Nut.*kh./Di; hio = hi.*Di./Do;
Ptube = 2.*f.*L./nt.*Vt.^2.*dh./Di;
Preturn= 4.*nt.*dh.*Vt.^2./2;
TotalPtube = Ptube+Preturn;
%Shell Side
Sc = (P-Do).*B.*Ds/P;
Sb = fb*(pi.*Ds.^2/4)-Nb*(pi.*Do.^2/4);
Gc = mc./Sc;Gb = mc./Sb;
Ge = sqrt(Gc.*Gb);
Res = Ge.*Do./visc;Prs = 1000.*Cpc.*visc./kc;
Nus = 0.2.*Res.^0.6.*Prs.^0.33;
hs = kc.*Nus./Do;
ho = hs;
Uc = (1./hio+1./ho+((Do./2).*log(Do./Di)/k)).^(-1);
Dh= 4.*(P.^2-pi.*Do.^2./4)./(pi.*Do);
Res = Dh.*Gc./visc;
fs = 1.7789*Res.^(-0.195868);
N = round(L./B)-1;
fi = 1;
Pshell = (fs.*Gc.^2.*Ds.*(N+1))./(2.*Dh.*fi.*dc);

error = ((Uc-(U.*1000))./(U.*1000)).*100;

21
ep = 0.8; k=5.67*10.^(-8);
Tamb = 20+273; Ts = (Tco+Tci)/2;
Ao = (Ds+2*0.00524)*pi*0.9;
Qrad = ep.*k.*Ao.*((Ts+273).^4-Tamb.^4);

MATLAB Code for Counter-Current Flow

%Do: outer Tube,Ds:shell; Di: inner Tube,
%B:baffle Space,P: pitch; Bc:baffle cut, F: Correction Factor
Do = 10/1000; Nt = 5; L = 900/1000; nt = 1;t = 1/1000;F = 0.95;
Di = Do-2*t;Ds = 50/1000; P = 20/1000; B = 48/1000;
fb = 0.1955; Nb = round(Nt/4);
qc = [300 400 500]; qh = [400 400 400];
Cph = [4.184 4.184 4.183]; Cpc = [4.182 4.181 4.180]; %Heat Capacity kj/kgK
kc = [0.612 .609 0.606]; kh = [0.651 0.650 0.648];%COnductivity W/mK
dh = [983.2 983.9 986.0]; dc = [997.3 997.4 998]; %Density kg/m^3
visc = [0.00091 0.00093 0.00097]; vish = [0.00046 0.00048 0.00049];%Viscosity Pa.s
e = 0.00005;k = 14;%Rougness m ; conductivity for steel W/mK
Thi = [66.2 65.5 63.6]; Tho = [52.6 50.8 48.7]; %Celcius
Tci = [14.5 14.5 14.5];Tco = [34.2 30.5 27.3];%Celcius
dT1 = (Thi-Tco); dT2 = (Tho-Tci);
FMTD = ((dT2-dT1)./log(dT2./dT1)).*F;
LMTD = FMTD./F;
mh = qh.*dh./3600000; mc = qc.*dc./3600000;
A = pi.*Do.*L.*Nt;
Q = (mc.*Cpc.*(Tco-Tci)+mh.*Cph.*(Thi-Tho))/2;
U = Q./(A.*FMTD);

%Tube Side
at = pi.*Di.^2./4;
At = Nt.*at./nt;
Vt = (mh./(At.*dh));
Ret = dh.*Vt.*Di./vish; Prt = 1000.*Cph.*vish./kh;
A = (7.149./Ret).^0.8981;
f = (-4.*log10(-5.0452.*log10(A)./Ret)).^(-2);
Nut = (f./2).*(Ret-1000).*Prt./(1+12.7.*(f./2).^0.5.*(Prt.^0.66-1));
hi = Nut.*kh./Di; hio = hi.*Di./Do;
Ptube = 2.*f.*L./nt.*Vt.^2.*dh./Di;
Preturn= 4.*nt.*dh.*Vt.^2./2;
TotalPtube = Ptube+Preturn;
%Shell Side
Sc = (P-Do).*B.*Ds/P;
Sb = fb*(pi.*Ds.^2/4)-Nb*(pi.*Do.^2/4);
Gc = mc./Sc;Gb = mc./Sb;
Ge = sqrt(Gc.*Gb);
Res = Ge.*Do./visc;Prs = 1000.*Cpc.*visc./kc;
Nus = 0.2.*Res.^0.6.*Prs.^0.33;
hs = kc.*Nus./Do;
ho = hs;
Uc = (1./hio+1./ho+((Do./2).*log(Do./Di)/k)).^(-1);
Dh= 4.*(P.^2-pi.*Do.^2./4)./(pi.*Do);

22
Res = Dh.*Gc./visc;
fs = 1.7789*Res.^(-0.195868);
N = round(L./B)-1;
fi = 1;
Pshell = (fs.*Gc.^2.*Ds.*(N+1))./(2.*Dh.*fi.*dc);

ep = 0.8; k=5.67*10.^(-8);
Tamb = 20+273; Ts = (Tco+Tci)/2;
Ao = (Ds+2*0.00524)*pi*0.9;
Qrad = ep.*k.*Ao.*((Ts+273).^4-Tamb.^4)

23