ChE 304

Chemical engineering laboratory - III

Experiment No. 3 Group No. 03 (A2)
Name of the experiment:


STUDY OF A SI NGLE PASS SHELL AND TUBE
HEAT EXCHANGER





Submitted by:

Md. Hasib Al Mahbub

Student Id: 0902045

Level: 3; Term: 2

Section: A2







Date of performance: 21/01/2014

Date of submission: 28/01/2014
Partners Student Id. 0902041

0902042

0902043

0902044








Department of Chemical Engineering.

Bangladesh University of engineering and technology, Dhaka.

1

Summary

The objective of this experiment was to study a single pass shell and tube heat exchanger which
included the comparison between theoretical and experimental results of both individual and
overall heat transfer coefficients and tube side pressure drops. In this experiment, cooling water
was used to recover heat form saturated steam. The cooling water was flown through the pipe
and the saturated steam was flown through the annulus. The experiment was performed at
different steam pressure. The values of overall heat transfer coefficient found experimentally
vary from 173.7199- 290.2413 J/sec.m
2
.K where the theoretical values range from 1651.821-
2593.331 J/sec.m
2
.K. The tube side pressure drop were in between 8092.587-39451.36 Pa
experimentally, where the theoretical pressure drop range from 1987.478- 12326.29 Pa.
Colburn JH factor (JH) vs. Reynoldss number (Re) and pressure drop (P) vs. velocity (v)
graphs are plotted both for 2.5 and 5 psig. The graphs show deviation from the theoretical graphs.
The possible discrepancies are described in discussion.




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Experimental Setup
2
3
























Figure 3: Temperature profile of the Shell and Tube Heat Exchanger

Figure 2: Schematic Diagram of a 1-1 Shell and Tube Heat Exchanger




T1 Water Ts Steam
T2
Steam
Condensed
Cold Water
Hot Water
4

Observed Data

Weight of Bucket = 1.5 Kg
Heat Exchanger
Shell: Nominal Size 6
Schedule No. 40
Passes: Shell side=1
Tube side=1
Tubes: OD= 0.5 inch
BWG=16
Length=96 inch
Number= 19
Pump
Centrifugal pump
1.5 kW; 240 V; 50 Hz; 2900 rpm
Hmax =38m; Qmax = 250 l/h



Table 1: Table of observed data for the study of a single pass shell and tube heat exchanger

No.
of
Obs
Steam
pressure
Flow
meter
reading
Water
temperature
Weight of
Bucket
+
Condensate
Collection time Manometer
reading
Inlet Outlet Water Condensat
e
Left Right
psig Litre
o
C
o
C Kg sec sec inch inch
1
2.5 10 23
30 2.35 14.75 60 33.5 36
2 29 2.4 10.57 60 32.6 36.5
3 28.5 2.5 8.47 60 31.5 37.3
4 27.5 2.55 6.75 60 30 38
5 27 2.6 5.25 60 27.6 39.3
6
5 10 23
31 2.1 11.47 60 33.4 35.8
7 30.75 2.3 9.54 60 32.3 36.5
8 30.5 2.5 8.56 60 31.5 37
9 29.5 2.6 7.09 60 30 37.7
10 28.75 2.65 5.41 60 27.5 39






5

Calculated Data


Table 2: Table of different water bulk temperatures and flow rates of water and condensate

No.
of
Obs
Steam
pressure
Water
bulk
temperature
(Tb)
Weight Flow rate
Water
(mw)
Condensat
e
(mc)
Water
(Ww)
Condensate
(Wc)
psia
o
C kg kg kg/sec kg/sec
1
17.2
26.5 9.96653 0.85 0.675697 0.014167
2 26 9.96787 0.9 0.943034 0.015
3 25.75 9.96853 1 1.176922 0.016667
4 25.25 9.96984 1.05 1.477013 0.0175
5 25 9.9705 1.1 1.899143 0.018333
6
19.7
27 9.96517 0.6 0.868803 0.01
7 26.875 9.9655 0.8 1.044602 0.013333
8 26.75 9.96585 1 1.164235 0.016667
9 26.25 9.9672 1.1 1.405811 0.018333
10 25.875 9.9682 1.15 1.842551 0.019167



Table 3: Properties of water at bulk temperature









No.
of
Obs
Water
bulk
temperature
(Tb)
Density

(w)
Viscosity
()
Heat Capacity
(c)
Thermal
Conductivity

(k)

o
C Kg/m
3
Pa-sec KJ/Kg-Kelvin Watt/m-Kelvin
1 26.5 996.653 0.00086 4.181 0.6097
2 26 996.787 0.00087 4.181 0.6089
3 25.75 996.853 0.00088 4.182 0.608
4 25.25 996.984 0.00089 4.182 0.608
5 25 997.05 0.00089 4.182 0.607
6 27 996.517 0.00085 4.181 0.611
7 26.875 996.55 0.00085 4.181 0.61
8 26.75 996.585 0.00086 4.181 0.61
9 26.25 996.72 0.00087 4.181 0.609
10 25.875 996.82 0.00087 4.181 0.609
6

Table 4: Properties of condensate at film temperature



















Table 5: Table of heat balances, LMTD and experimental overall heat transfer coefficient

No.
of
Obs
Heat absorbed
by water

(Qw)
Heat released
by steam

(Qc)
Average heat
transfer

(Qavg)
LMTD Overall heat
transfer co-
efficient
(Experimental)
(UOE)
KJ/sec KJ/sec KJ/sec
o
C J/sec.m
2
. K
1 19.77562261 31.25350833 25.51456547 77.64741898 177.7150635
2 23.6569524 33.09195 28.3744512 78.16162176 196.3346702
3 27.07038471 36.76883333 31.91960902 78.41785647 220.1434079
4 27.79591392 38.607275 33.20159446 78.92862108 227.5032022
5 31.76886171 40.44571667 36.10728919 79.18316212 246.6182049
6 29.05972155 22.355 25.70736077 80.03337223 173.7198577
7 33.84796699 29.80666667 31.82731683 80.1625715 214.7293829
8 36.50749315 37.25833333 36.88291324 80.29162756 248.4380115
9 38.20502268 40.98416667 39.59459467 80.8064335 265.0043796
10 44.29630391 42.84708333 43.57169362 81.19106797 290.2413437










No. of
Obs
Film
temperature

(Tf)
Viscosity

()

Density

(w)
Thermal
Conductivity

(k)

o
C Kg/m
3
Pa-sec Watt/m-Kelvin
1 75.0625 0.00037 974.82 0.667
2 74.875 0.00038 974.93 0.667
3 74.78125 0.00038 974.99 0.667
4 74.59375 0.00038 995.1 0.667
5 74.5 0.00038 975.15 0.666
6 77.0625 0.00037 973.61 0.668
7 77.015625 0.00036 973.64 0.668
8 76.96875 0.00037 973.67 0.668
9 76.78125 0.00037 973.78 0.668
10 76.640625 0.00037 973.87 0.668
7

Table 6: Table of nusselt number, prandtl number, shell and tube side heat transfer co-
efficients and theoretical overall heat transfer coefficient

No.
of
Obs
Nusselt
number


(Nu)
Prandtl
number


(Pr)
Heat transfer
co-efficient
(Tube side)
hi
Heat transfer
co-efficient
(Shell side)

ho
Overall heat
transfer co-
efficient
(Theoretical)
(UOT)
J/sec.m
2
. K J/sec.m
2
. K J/sec.m
2
. K
1 53.08764109 5.897424963 3443.354763 4694.305766 1651.820895
2 69.72368795 5.973838069 4516.463148 4655.903542 1945.816467
3 83.74419646 6.052894737 5416.645899 4652.332961 2153.43645
4 100.968729 6.121677632 6530.743325 4692.60798 2381.073628
5 123.1305926 6.131762768 7951.092521 4636.44016 2593.330737
6 64.72125544 5.816448445 4206.881604 4676.51856 1869.194017
7 75.04255252 5.825983607 4869.782664 4706.898753 2041.264854
8 82.29696073 5.89452459 5340.547451 4673.020676 2141.434843
9 96.27353274 5.972857143 6237.295898 4666.042579 2320.590061
10 119.5366115 5.972857143 7744.446425 4660.863049 2570.638783



Table 7: Table of Reynolds number, friction factor, jh, velocity, and mass velocity of water

No.
of
Obs
Reynolds
number

(Re)
Friction
factor

(f)
Velocity of water


(Vw)
Mass velocity


(Gt)
jH
ft
2
/in
2
m/sec Kg/sec.m
2

1 5536.655319 0.00033 0.514156 512.4351199 26.6662382
2 7727.213425 0.0003 0.717483538 715.1782638 34.81625786
3 9643.689957 0.00028 0.895372019 892.5542833 41.56792595
4 12102.63527 0.00027 1.123526074 1120.13752 49.8502936
5 15561.56116 0.00025 1.444533524 1440.27215 60.95457329
6 7118.96444 0.00031 0.661185789 658.882879 32.60597739
7 8559.457667 0.00029 0.794947694 792.2051245 37.78511626
8 9539.730612 0.00028 0.885958061 882.9325141 41.20905477
9 11519.20394 0.00027 1.069647532 1066.139088 47.91833705
10 15097.84657 0.00025 1.401811645 1397.353884 59.49709619












8

Table 8: Table of tube side experimental and theoretical pressure drops

No.
of
Obs
Diff. in manometer
reading
Pressure drop
(Experimental)
(p)
Pressure drop
(Theoretical)
(p)
Wall
temperature
(Tw)
Viscosity at
wall
temperature
()
m Pa Pa
o
C Kg/m
3

1 0.063500772 8429.778306 1987.477737 65.35 0.00043
2 0.099061205 13150.45416 3496.852602 65.1 0.00043
3 0.147321791 19557.08567 5133.144374 64.975 0.00043
4 0.203202471 26975.29058 7953.500684 64.725 0.00043
5 0.297183614 39451.36247 12326.28535 64.6 0.00044
6 0.060960741 8092.587174 3096.933688 67.05 0.00042
7 0.106681297 14162.02755 4227.592083 66.9875 0.00042
8 0.139701699 18545.51227 5109.137718 66.925 0.00042
9 0.195582378 25963.71718 7364.585232 66.675 0.00042
10 0.292103552 38776.98021 11789.0593 66.4875 0.00042





























9

Sample Calculation

Sample calculation for observation no. 6

Water inlet temperature, T1 = 23
o
C
Water outlet temperature, T2 = 31
o
C
Water Mean temperature, Tm =
2
T T
2 1
+
=
2
31 23 +
= 27
o
C
Properties of water at mean temperature (27
o
C),
Density, = 996.517 Kg/m
3

Heat capacity, Cp = 4.181 KJ/Kg-kelvin
Viscosity, =0 .00085 Pa-sec
Thermal conductivity, k = .611 Watt/m-kelvin

Weight of bucket and condensate = 2.1 kg
Weight of bucket = 1.5 kg
Weight of condensate = (2.1-1.5) kg
= 0.6 kg

Flow rate of condensate, mc =
sec 60
Kg 0.6

= 0.01 Kg/sec

Heat of condensation, c = 2235.5 KJ/Kg

Heat released by condensation, Qc = mc c
= (0.012235.5) KJ/sec
= 22.355 KJ/sec
Volume of water = 10 L
Weight of water = 10996.517/1000 = 9.96517 Kg

Flow rate of water, mw = (9.96517/11.47) Kg/sec
= 0.868802964 Kg/sec

10

Heat absorbed by water, Qw = mw Cp(T2-T1)
= 0.868802964 4.181(31-23)
= 29.05972155KJ/ sec

Average heat transfer, Qavg =
2
Q Q
c w
+

=
2
29.05972 355 . 2 2 +

= 25.70736077 KJ/sec


Saturation temperature at 5 psig (=19.7 psia), Ts = 107.1
o
C

Logarithmic Mean Temperature Difference,

LMTD =
|
|
.
|

\
|

2 s
1 s
2 s 1 s
T T
T T
ln
) T (T ) T (T

=
|
|
.
|

\
|

2 s
1 s
1 2
T T
T T
ln
T T

=
|
.
|

\
|

1 3 1 . 07 1
3 2 1 . 07 1
ln
3 2 1 3


= 80.03337223 K


The outside area of a 0.5 inch 16 BWG tube = 0.03991 m
2
/ lin m
Length of each tube = 96 inch = 2.438 m
Number of tubes = 19
Total outside area, A0 = 19 2.4384 0.03991
= 1.849 m
2

Experimental overall heat transfer co-efficient,
UOE =
LMTD A
Q
0
avg

= 3600
143.3259 849 . 1
35.23095

11

= 173.72 J/sec.m
2
. K


Prandtl Number, Pr =
k
C
p

= 5.81645

Flow area of tube, Ai = 0.0000694 m
2



Velocity of water, Vw =
i
w
A
m

=
19 0.0000694 996.517
0.868803



= 0.66119 m/sec

Reynolds number, Re =

v D
w i


= 7118.96





Tube wall temperature (steam side),
Tw =
2
)] T T ( 0.5 [Ts
2 1
+ +

=
2
)] 31 3 2 ( 0.5 [107.1 + +

= 67.07
o
C


12

Using Seider-Tate equation,

Nu =0.027 Re
0.8
Pr
1/3
(f/ w)
0.14

= 0.027 (7118.96)
0.8
(5.81645)
1/3
(0 .00085/0.00042)
0.14

= 32.606


Water side heat transfer co-efficient for turbulent flow,
hi = Nu
i
D
k

= 4206.88 J/ sec. m
2
. K

Film temperature, Tf = Ts 0.75 (Ts-Tw)
= 107.1 0.75 (107.1- 67.05)
= 77.0625
o
C

Properties of condensate at film temperature (77.0625
o
C),

Density, f = 973.61 Kg/m
3

Viscosity, f = 0.00037 Pa-sec
Thermal conductivity, kf = 0.668 Watt/ m-kelvin
Heat of condensation, hfg = c = 2235500 J/Kg
Density of steam, v ~ 0
Saturation temperature, Tg =Ts = 107.1
o
C = 380.1 K

Using Nusselt equation, steam side heat transfer co-efficient,
ho = 0.725
25 . 0
w g f
3
f fg v f f
) T nd(T
k gh ) (
(
(

= 0.725
25 . 0
w g o f
3
f fg
2
f
) T (T D
k gh
(
(

= 4676.52 J/ sec. m
2
.
o
C
13

Theoretical overall heat transfer co-efficient,
UOT =
-1
i i
o
0
h D
D
h
1
|
|
.
|

\
|
+
= 1869.19 J/ sec. m
2
.

K

jH factor calculation, jH = Nu .Pr
-1/3
.
14 . 0
w

|
|
.
|

\
|

= 32.606

Tube side Pressure Drop Calculation,
Specific gravity, s = 1
Internal diameter, D = 0.37 inch = 0.031 ft
Length of the tube, L = 8 ft
No. of pass in tube side, n = 1
The factor, |t =
14 . 0
w

|
|
.
|

\
|
=
14 . 0
0.00042
0.00085
|
.
|

\
|
= 1.10373
Mass velocity, Gt = 658.883 lb/hr.ft
2

For this mass velocity,
2g'
V
2
|
|
.
|

\
|
144
52.5
= 0.03 psi
For Reynolds number of 7118.96,
Friction factor, f = 0.00031ft
2
/in
2

Pressure drop, Api =
t
10
2
t
Ds 10 5.22
Ln G f

= 0.3288 psi

Pressure drop due to velocity head,
Ap r =
|
|
.
|

\
|
2g'
V
s
4n
2
|
|
.
|

\
|
144
52.5

= 0.12042 psi



14

Total theoretical pressure drop, Ap = Api + Apr
= (0.3288 + 0.12042)
= .4493psi
Again,
Manometer reading (left) = 33.4 in
Manometer reading (right) = 35.8 in
Difference = (35.8 33.4) in
= 2.4 in

Experimental pressure drop, Ap = 1.174 psi



15

Results and Discussions

The results are summarized bellows
Heat transfer co-efficient (Shell side), h0 4636.44016-4706.898753 J/sec.m
2
. K
Heat transfer co-efficient (Tube side), hi 3443.354763-7951.092521 J/sec.m
2
. K
Overall heat transfer co-efficient
(Theoretical), UOT
1651.821- 2593.331 J/sec.m
2
.K
Overall heat transfer co-efficient
(Experimental), UOE
173.7199- 290.2413 J/sec.m
2
.K

For the jH Factor vs. NRe plotted on log-log coordinate

1. The slope for 2.5 psig = 0.8 is shown at figure 4
2. The slope for 5 psig = 0.8 is shown at figure 5

All the graphs had shown their expected characteristics. The slope for steam pressure 2.5 psig
is 0.8 and for steam pressure 5.0 is 0.8 whereas the theoretical value is 0.8. Thus, the graphs
establish the validity of Sieder-Tate equation.

The theoretical and experimental results shows some discrepancies. The possible causes are
discussed here-

1. The theoretical values obtained in this experiment are not wholly theoretical. These
values are found based on some parameters that are determined experimentally in one
way or another. Hence, they cannot be said to be purely theoretical.
2. There might be some heat loss through the pipes and wall which was not accounted
during the calculation. This might have brought the discrepancy. The theoretical value
was not a pure literature value. It was calculated by manipulating some data or
parameters.
3. The apparatus was very old and proper maintenance is not taken for several years.
Excess fouling may encounter in tube side which decrease the overall heat transfer co-
efficient.
4. Heat absorbed by water was greater than the heat released by the steam which is
normally impossible. Uses of steam trapper caused this.
16

5. We assumed that the convection heat transfer co-efficient are constant through the heat
exchanger, but experimentally the heat transfer co-efficient were not constant while
operation.
6. The steam pressure was considered constant during operation, but, it was not constant
while operation.







17

NuPr
(-1/3)
(u/uw)
-.014
vs. Reynolds Number (2.5 psig)


Figure 4: Graph of NuPr
(-1/3)
(u/uw)
-.014
vs. Reynolds Number at 2.5 psig pressure








y = 0.027x
0.8
10
100
5000
N
u
P
r
^
(
-
1
/
3
)
(
u
/
u
w
)
^
-
.
0
1
4
Reynold's Number
18

NuPr
(-1/3)
(u/uw)
-.014
vs. Reynolds Number (5 psig)


Figure 5: Graph of NuPr
(-1/3)
(u/uw)
-.014
vs. Reynolds Number at 5 psig pressure





y = 0.027x
0.8
10
100
5000
N
u
P
r
^
(
-
1
/
3
)
(
u
/
u
w
)
^
-
.
0
1
4
Reynold's Number
19

Pressure drop vs. Water velocity (2.5 psig)


Figure 6: Graph of Pressure drop vs. water velocity at 2.5 psig pressure








0
5000
10000
15000
20000
25000
30000
35000
40000
45000
0.4 0.6 0.8 1 1.2 1.4 1.6
P
r
e
s
s
u
r
e

d
r
o
p
Water velocity
Theoretical
Experimental
20

Pressure drop vs. Water velocity (2.5 psig)



Figure 7: Graph of Pressure drop vs. water velocity at 2.5 psig pressure

0
5000
10000
15000
20000
25000
30000
35000
40000
45000
0.6 0.7 0.8 0.9 1 1.1 1.2 1.3 1.4 1.5
P
r
e
s
s
u
r
e

d
r
o
p
Water velocity
Theoretical
Experimental