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ABSTRACT

The objective of this experiment is to evaluate the performance of counter-current flow of heat
exchanger and to study the routine of the heat exchanger under various flow rates by using
concentric tube heat exchanger or simply double pipe heat exchanger. The experiment was
divided into two parts. The first part is where the hot water volume flowrate was set to be
constant at 10L/min while the cold water flowrates were varied at 2L/min, 4L/min, 6L/min,
8L/min and 10L/min. For the second part, the cold water volume flowrate was set to be constant
while the hot water volume flowrates were varied. TT1, TT2, TT3 and TT4 were recorded every
10 minutes. As the temperature of the hot water increases, the overall heat transfer coefficient is
also increasing. The increasing of the overall heat transfer coefficient will causes the rate of heat
transfer also increases. The higher the flow rate of the fluids flowing in the heat exchanger, the
higher the rate of heat transfer, thus the better the performance of the heat exchanger. This can be
shown in the Figure 1.5 and Figure 1.6. As the flow rate was increase from 2 L/min to 10L/min,
the overall heat transfer coefficient also increase from 595.4W/m2. to 761.9W/m2. for
constant hot flowrate, while 415.6W/m2. to 761.9W/m2. for constant cold water flowrate.
The increasing in heat transfer coefficient shows increasing in rate of heat transfer which reflects
in increasing of the performance of the heat exchanger.

1.1

INTRODUCTION
Heat exchangers are devices that facilitate the exchange of heat between two fluids that
are at different temperatures while keeping them from mixing with each other (Yunus A.
Cengel and Ghajar, 2011). Heat transfer in heat exchanger usually involves convection in
each fluid and conduction through the wall separating the two fluids. The rate of heat
transfer between the two fluids depends on the magnitude of the temperature difference
and the flow rate of the fluids. Heat exchangers are usually can be found in extensive
range of applications, from heating and air-conditioning systems in household, to
chemical processing and power production in large plants.
In this experiment, concentric tube heat exchanger is used or simply called double
pipe heat exchanger in used in order to get better understanding on how this device
works. It is called a double-pipe exchanger because one fluid flows inside a pipe and the
other fluid flows between that pipe and another pipe that surrounds the first, where one
fluid in a double pipe heat exchanger flows through the smaller pipe while the other fluid
flows through the annular space between the two pipes. Concentric tube heat exchanger is
the simplest type of heat exchanger which consists of two coaxial tubes of different
diameters, the outer diameter and the inner diameter.

Figure 1.1 : Counter current flow in double pipe heat exchanger


Typically, there are two types of flow arrangements are possible in this concentric
tube heat exchanger, parallel flow and counter-current flow. Counter-current flow
arrangement is used in the experiment, where the hot and cold fluids enter the heat
exchanger at opposite ends and flow in opposite direction. Based on Figure 1.1, heat from
the hot fluid diffuses through the tube wall and been transferred into cold fluid by
convection, then pass through the wall by conduction, and then from the wall through
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cold liquid by convection. The hot water, cold water circuits and hot water tanks all are
well insulated to minimize heat loss or heat gains between the tank and the heat
exchangers. are used for liquid-liquid, condensing and gas cooling applications. Usually
the counter current movement is used as the rate of heat transfer is more as compared to
co-current movement.
The SOLTEQ Heat Exchanger Training Apparatus (Model: HE 158C) has been
designed to allow students to get familiarized with different kinds of heat exchangers and
to collect the necessary experimental data for the calculation of heat losses, heat transfer
coefficient, log mean temperature difference and more. Besides, students will also be able
to study the effect of flow rate on the heat transfer rate. The unit used in the experiment
comes with four different types of heat exchangers and two stainless steel sump tanks for
hot and cold water source.
The hot tank is fitted with an 11.5 kW immersion type heater that is protected
against possible overheating. Each tank has a centrifugal pump capable of delivering the
required 10 LPM of water. As stated by P.A Hilton LTD (2004), the inner tube of the
double pipe heat exchanger is mostly made from stainless steel while the outer side is
from clear acrylic. The primary advantage of concentric heat exchanger or double pipe
heat exchanger compared to shell and tube, spiral and plate heat exchangers is the
simplicity in the design of it. Thus, it is very easy to construct and to operate. Due to
simple design, it is very easy to clean and maintain both of the surfaces of the heat
exchanger which can decrease the rate of fouling.

1.2

OBJECTIVES
The experiment is conducted to evaluate and study the performance of the concentric
tube heat exchanger at various operating conditions.

1.3

THEORY
Heat exchangers usually operate for a long time period with no change in their operating
conditions. Thus, they are labelled as steady-flow devices. Design of heat exchanger is to
relate the inlet and outlet temperatures, the overall heat transfer coefficient, and the
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geometry of the heat exchanger, to the rate of heat transfer between the two fluids. As
stated by Yunus A. Cengel, Afshin J. Ghajar (2004), the theory starts with the first law of
thermodynamics which required that the rate of heat transfer from the hot fluid be equal
to the rate of heat transfer to the cold one. That is:
Q=mCpc (Th ,Th, out)
Tc , outTc ,
Q=mCph
Where,
c and h stand for cold and hot fluids, respectively,
m = Mass flowrate (kg/s)
Cpc,Cph = specific heat capacity (KJ/Kg.)
Tc,out, Th,out = outlet temperature ()
Tc,in, Th,in = inlet temperature ()
Q = heat exchange rate between fluids (KJ/s or kW))
Note that the heat transfer rate, Q is taken to be a positive quantity, and its direction is
understood to be from the hot water to the cold water, obeys the second law of
thermodynamics. Cp at specific temperature of liquid water was obtained by
interpolation.
The overall heat transfer rate is expressed in terms of an overall heat transfer coefficient
and a mean temperature. This is based on the analogous manner to Newtons law of
cooling as:
Q=U As Tm

Since the total heat transfer coefficient, h for the whole system is approximately equal to
U, h is expressed in terms of overall heat transfer coefficient.
Power emitted , Qe
Overall Heat Transfer Coefficient ,U =
As Tm
The overall U value is calculated by an equation specific to the geometric configuration
of a heat exchanger. The overall U value is calculated over the total surface area A of the
heat exchanger, across which the fluids exchange heat. A is determined from the formula:

Total surface area , As= tubeouter diameter length of tube


Inner diameter of the tube is used for calculation, since the different between outer
diameter and inner diameter was too small, the tube wall is thin enough to facilitate heat
transfer process between hot fluid and cold fluid. Mean temperature is not taken simply
as the difference between the average bulk temperature of the hot fluid and the cold fluid
but it is calculated according to the formula of log mean temperature difference, Tm as
follow:
Tm ( )=

T 1 T 2
ln(T 1 T 2)

where for counter-current flow,


T 1 ( )=Th,Tc , out (Hot inlet temperatureCold outlet temperature )
T 2 ( ) =Th, out Tc , ( Hot outlet temperatureCold inlet temperature )

The temperature profile in the heat exchanger can be revised by looking at the
characteristics of the heat exchangers which are the flow arrangement either the hot and
cold fluids move in the same or opposite directions and the type of construction. The
temperature profile obtained from chart of temperature difference between the hot fluid
and cold fluid at inlet and outlet. It may vary along the length of the heat exchanger. This
is due to the fact that the hot fluid temperature decreases as it transfers heat to the cold
fluid, while the cold fluid temperature increases.
For counter-current flow arrangement, the difference between the temperature of
the hot and cold fluid almost uniform, means that the heat transfer rate at any location is
usually maximum at any location throughout the tube. The temperature difference
decease less dramatically compared to parallel flow arrangement as we move towards hot
fluid exit. For either flow arrangement, it can be observed that the Tm is not constant
and changes along the length of a heat exchanger.
1.4

APPARATUS AND MATERIALS

Description of diagram:
The SOLTEQ Heat Exchanger Training Apparatus (HE 158C) was used to study the heat
exchanger process between hot and cold fluid by varying the flow rates and flow
direction (counter current). The flowrate are being controlled by using F1 valve and F2
valve of FT1 for hot water and FT2 for cold water. V16 and V17 are open to perform
counter- current flow direction Temperature reading at each part is taken at TT1, TT2,
TT3, and TT4. The operating limit for this unit is 50.

Figure 1.2 : SOLTEQ Heat Exchanger Training Apparatus (HE 158C)


1. Spiral heat exchanger
3. Shell & tube heat exchanger
5. Valve 15
7. Valve 18
9. Cold water centrifugal pump
11. Flowrate meter 2 (cold water)
13. TT2 (hot water outlet reading)
15. TT4 (Cold water outlet reading)
17. PT1 reading
19. Power pump switch
21. Cold water pump switch

2. Concentric heat exchanger


4. Valve 17
6. Valve 16
8. Hot water centrifugal pump
10. Flowrate meter 1 (hot water)
12. TT1 (Hot water inlet reading)
14. TT3 (Cold water inlet reading)
16. TT5
18. PT2 reading
20. Hot water pump switch

1.5

PROCEDURE
General start-up procedure
1. A quick inspection was performed to make sure that the equipment is in a proper
working condition.
2. Make sure all valves are closed, except V1 and V12.
3. Hot water tank is filled via a water supply hose connected to V27. The valve is closed
when the tank is full.
4. Valve V28 is opened to fill up the cold- water tank and leave the valve opened for
continuous water supply.
5. Drain hose is connected to the cold water drain point.
6. The main power is switched on and heater is opened for hot water tank to set the
temperature controller to 50 .
7. The water temperature in the hot water tank is allowed to reach the set point.
Experiment: Counter Current Concentric Heat Exchanger
1. General start-up procedure is performed.
2. Pump P1 and P2 are switched on.
3. Valve V3 and V14 are opened to obtain the desired flowrates for hot water and cold
water streams, respectively.
4. The system reached steady state for 2 minutes.
5. FT1, FT2, TT1, TT2, TT3 and TT4 are recorded
6. Pressure drop measurements for shell-side and tube-side are recorded.
7. Steps 3 to 6 are repeated for different combinations of flowrate FT1 and FT2.
8. Pumps P1 and P2 are switched off after the completion of experiment.
9. General shut down is performed.
General shut - down procedure
1. The heater is switch off and wait until the hot water temperature drops below 40 .
2. Pump P1 and P2 are switched off.
3. Main power is switched off.
4. All water in the process line is drained off 5. All valves are closed.

1.6

RESULTS
Table 1.1 : Counter-current flow for constant hot water flow rate
FT 1
(LPM)

FT 1
(LPM)

10.0
10.0
10.0

2.0
4.0
6.0

TT 1
(TCout)
(oC)
36.7
33.5
33.1

Tmid
(oC)
34.55
32.75
32.25

TT 2
(TCin)
(oC)
32.4
32.0
31.4

TT 3
(THout)
(oC))
47.8
47.6
48.5

Tmid
(oC)
48.10
47.90
48.85

TT 4
(THin)
(oC)
48.4
48.2
49.2
7

10.0
10.0

8.0
10.0

33.2
34.1

32.80
33.55

32.4
33.0

47.8
48.1

48.15
48.45

48.5
48.8

Tmid
(oC)

TT 4
(THin)
(oC)
48.0
48.7
49.8
48.4
48.8

Table 1.2 : Counter-current flow for constant cold water flow rate
FT 1
(LPM)

FT 1
(LPM)

2.0
4.0
6.0
8.0
10.0

10.0
10.0
10.0
10.0
10.0

TT 1
(TCout)
(oC)
33.8
33.9
34.1
34.1
34.1

Tmid
(oC)
33.50
33.60
33.70
33.70
33.55

TT 2
(TCin)
(oC)
33.2
33.3
33.3
33.3
33.0

TT 3
(THout)
(oC))
46.0
47.4
48.3
47.5
48.1

47.00
48.05
49.05
47.95
48.45

Table 3: Calculation of power emitted, power absorbed and heat loss for the constant hot
volume flow rate
Cold WaterFlowrate
(L/min)
2
4
6
8
10

Power emitted, Qe
(W)

Power emitted, Qe
(W)

Heat loss (W)

413.4
413.4
482.2
482.3
482.2

595.4
415.7
706.8
443.4
761.9

-182
-2.3
-224.6
38.9
-279.7

Table 4: Calculation of power emitted, power absorbed and heat loss for the constant cold
volume flow rate
Hot Water Flowrate
(L/min)
2
4
6
8
10

Power emitted, Qe
(W)
275.7
358.3
619.9
496.1
482.3

Power emitted, Qe
(W)
415.6
415.5
554.0
554.0
761.9

Heat loss (kW)


-139.9
-57.2
65.86
-57.93
-279.65
8

Table 5: Log mean temperature and the overall heat transfer coefficient for the constant
hot volume flow rate
Cold

T1 (oC)

T2 (oC)

Tm (oC)

Overall heat

WaterFlowrate

transfer

(L/min)

coefficient, U,

2
4
6
8
10

(W/m2.C)
650.22
578.12
615.80
665.68
685.64

11/7
14.7
16.1
15.3
14.7

15.4
15.6
17.1
15.4
15.1

13.47
15.15
16.59
15.35
14.90

Table 6: Log mean temperature and the overall heat transfer coefficient for the constant
cold volume flow rate
Hot Water

T1 (oC)

T2 (oC)

Tm (oC)

Flowrate
(L/min)
2
4
6
8
10

Overall heat
transfer
coefficient, U,

14.2
14.8
15.7
14.3
14.7

12.8
14.1
15.0
14.2
15.1

13.49
14.45
15.35
14.25
14.90

(W/m2.C)
432.99
515.34
855.60
737.60
685.72

Temperature Profile for Counter-Current Flow for Constant Hot Flowrate

48.4

36.7

48.1

47.8
Hot Water

34.55

32.4

Cold Water

Figure 1.3 : Temperature Profile for Counter Current Flow for Constant Hot Water
Flowrate
Temperature Profile for Counter-Current Flow for Constant Cold Flowrate

48

47

46
Hot Water

33.8

33.5

32.4

Cold Water

Figure 1.4 : Temperature Profile for Counter Current Flow for Constant Cold Water
Flowrate

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Power vs Cold Water Flowrate


800
700
600
500
Power (W)

400

Power Absorbed

300

Power Emitted

200
100
0
2

10

Cold Water Flowrate


(L/min)

Figure 1.5 : Graph of Power vs Cold Water Flowrate

Power vs Hot Water Flowrate


800
700
600
500
Power (W)

400

Power Absorbed

300

Power Emitted

200
100
0
2

10

Hot Water Flowrate


(L/min)

Figure 1.6 : Graph of Power vs Hot Water Flowrate

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Overall Heat Transfer Coefficient vs Water Flowrate


900
800
700
600
500
Cold Water Flowrate

U (W/m2.oC) 400

Hot Water Flowrate

300
200
100
0
2

10

Water Flowrate
(L/min)

Figure 1.7 : Graph of Overal Heat Transfer vs Water Flowrate

1.7

CALCULATIONS
12

To find the properties of water for the constant hot volume flow rate
Tc , mid ( ) =

32.4 +36.7
=3 4.55
2

Water properties for cold water from Table A-9 in Appendix


From interpolation,
=0.99518 kg / L
Cp=4.1782

kJ
kg . K

Th ,mid ( )=

48.4+ 47.8
=48.10
2

Water properties for hot water from Table A-9 in Appendix


From interpolation,
=0.98886 kg/ L
Cp=4.18062

kJ
kg . K

To find the properties of water for the constant cold volume flow rate
Tc , mid ( ) =

33.8+33.2
=33.50
2

Water properties for cold water from Table A-9 in Appendix


From interpolation,
=0.994 6 kg /L
Cp=4.1782

kJ
kg . K

Th ,i mid ( )=

46.0+ 48.0
=47.00
2

Water properties for hot water from Table A-9 in Appendix


From interpolation,
=0.9893 kg / L

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Cp=4.1804

kJ
kg . K

Sample calculation of power emitted, power absorbed and heat loss during flow rate of
cold water at 2L/min
Power emitted ,Qe=Vh h Cph(Th ,Th , out)

Qe=

10 L 1min
kg
kJ
1 000W

0. 98 8 86 4.181 062
( 48.447.8 )=0.4134 kW
=413.4 W
min 60 s
L
kg .
1 kW

Tc , outTc ,
Power absorbed , Qa=Vc c Cpc

Qa=

2 L 1 min
kg
kJ

0.994 18 4.1782
(36.732.4)
min 60 s
L
kg .

0.595 4 k W

1000 W
=595.4 W
1kW

Heat Loss Rate=QeQa=413.4595.4=182 W

To find the log mean temperature difference for counter-current flow


Tm ( )=

T 1 T 2
ln(T 1 T 2)

T 1 ( )=Th,Tc , out
T 2 ( ) =Th, outTc ,
For cold water flow rate of 2L/min;
T 1 ( )=Th,Tc , out=48.436.7=11.7

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T 2 ( ) =Th, outTc , 47.832.4=15.4

Tm ( )=

11.715.4
=13.47
ln(11.7 15.4)

To find heat transfer coefficient


d0 = 0.0334 m
di = 0.02664 m
L = 0.5m
dm = (0.0334 + 0.02664) /2
= 0.03002 m
Total surface area , As= diameter length of tube
0.03002m 0.5 m=0.0 472m

Overall Heat Transfer Coefficient ,U =

413,4 W
(0.0472 m)(13.47 )
650.22

1.8

Power emitted , Qe
As Tm

W
m .
2

DISCUSSION
The experiment is aims to evaluate the performance of counter-current flow of heat
exchanger and to study the routine of the heat exchanger under various flow rates by
using concentric tube heat exchanger or simply double pipe heat exchanger. The
experiment was divided into two parts. The first part is where the hot water volume
flowrate was set to be constant at 10L/min while the cold water flowrates were varied at
2L/min, 4L/min, 6L/min, 8L/min and 10L/min. For the second part, the cold water
volume flowrate was set to be constant while the hot water volume flowrates were varied.
TT1, TT2, TT3 and TT4 were recorded every 10 minutes.

15

From data obtained, the exit temperature of the hot fluid is higher than the exit
temperature of the cold fluid. This shows that the heat transfer must occur from hot body
to the cold body. It is impossible for heat transfer to take place from a cold body to hot
body. As stated by Yunus A. Cengel, Afshin J. Ghajar (2015), the outlet temperature of
the cold fluid can never exceed the inlet temperature of the hot fluid, since this would be
a violation of the second law of thermodynamics. Thus, the results obtained are correct.
As the temperature of the hot water increases, the overall heat transfer coefficient
is also increasing. The increasing of the overall heat transfer coefficient will causes the
rate of heat transfer also increases. This is because the rate of heat transfer is affected by
both temperature and overall heat transfer coefficient as the following equation. The
increasing of the rate of heat transfer will causes the performance of heat exchanger to
increase. The overall heat transfer coefficient is generally weakly dependent on
temperature. As the temperature of the fluids change, the degree to which the overall heat
transfer coefficient will be affected depends on the sensitivity of the viscosity of the
fluids to temperature.

The higher the flow rate of the fluids flowing in the heat exchanger, the higher the
rate of heat transfer, thus the better the performance of the heat exchanger. This can be
shown in the Figure 1.5 and Figure 1.6. As the flow rate was increase from 2 L/min to
10L/min, the overall heat transfer coefficient also increase from 595.4W/m2. to
761.9W/m2.

for

constant

hot

flowrate,

while

415.6W/m2.

to

761.9W/m2. for constant cold water flowrate. The increasing in heat transfer
coefficient shows increasing in rate of heat transfer which reflects in increasing of the
performance of the heat exchanger.
However, the higher the flow rate, the greater the pressure loss then the bigger the
pump needed to circulate the water. Other than that, low flow rate means low in velocity
which is helpful in avoiding erosion, tube vibration and noises as well as pressure drop;
henceforth a standard velocity used in heat exchanger is established. Despite of that,
supposedly the efficiency of the heat exchanger increasing along with the increasing of
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the heat transfer coefficient, however the efficiency calculated is decreasing as the flow
rate is increasing. This decrement in efficiency might because of the temperature is taken
before it is stabilize.
Based on the results calculated, the experiment reached the main objectives;
howerver, there might be some error occurred while conducting the experiment. The
water flow rate may not not constant during the experiment and this led to inaccuracy of
taking the results for every 10 minutes. Lastly, the inaccuracy of calculations for the heat
exchangers heat loss may because of fouling occur in the pipe.
The most common heat exchanger problem for many chemical engineers is
fouling which can occur within the inside of a tube wall and decrease performance and
even damage the heat exchanger in the long run. Fouling is a term used to describe
material which builds up on the inside of a tube wall within heat exchangers and in turn
affects the performance of the heat exchanger. Material or fluids which might collect on
the side wall will build up over time and, if not taken care of, can reduce the heat transfer
within your heat exchanger and increase the pressure drop which can cause more
problems in the heat exchangers.
The performance of the heat exchanger can be increased in many ways. One of
them is by increasing the overall heat transfer coefficient, U. U can be increase by
increasing turbulence in the flowing fluids on tube, by reducing fouling rates through pretreatment of the fluids or increasing cleaning schedules and by eliminating stagnant areas
inside the exchanger by judicious designs.

1.9

CONCLUSION
Double pipe heat exchanger has two types of flow which are co-current low or
parallel , and counter-current flow. In this experiment, the flow used is counter-current.
Both the hot and cold fluids enter the heat exchanger at opposite ends and flow in
opposite directions in counter flow. Based on the data taken from the experiments, the
characteristics of the heat exchanger such as power lost, power absorbed, power emitted,
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log mean temperature tm, and overall heat transfer coefficient can be calculated. The
results show that at higher temperature gives higher efficiency of the heat exchanger. The
higher the flow rate of the fluids flowing in the heat exchanger, the higher the rate of heat
transfer, thus the better the performance of the heat exchanger. This can be shown in the
Figure 1.5 and Figure 1.6. As the flow rate was increase from 2 L/min to 10L/min, the
overall heat transfer coefficient also increase from 595.4W/m2. to 761.9W/m2. for
constant hot flowrate, while 415.6W/m2. to 761.9W/m2. for constant
cold water flowrate. The increasing in heat transfer coefficient shows increasing in
rate of heat transfer which reflects in increasing of the performance of the heat exchanger.

1.10

RECOMMENDATION
In order to recover the mistakes and perform a better experiment progress, a few
suggestions that can be made are:

1. It might be wisely to make a regular maintenance and cleaning of the pipes to avoid
fouling and error to the performance of the heat exchangers and to increase the efficiency
of heat transfer process.
2. It is much better to particularly check the dual between the pipes to minimize heat loss to
the surroundings.
3. It more wisely to install a new high sensitivity thermometer as to increase the accuracy
of the temperatures readings.
4. It is more easily to have an electronic flowmeter device as to reduce the inaccuracy of
changing the flow rates for the heat exchangers to work.

18

1.11

REFERENCES/APPENDICES
1.

http://www.solution.com.my Experimental Manual Heat Exchanger Training

Apparatus

Model

HE158C.

Retrieved

26th

April,

2016,

from

Solteq:

http://www.solution.com.my/pdf/TR14(A4).pdf
2.

Yunus A. Cengel, afshin J. Ghajar, (2015). Chapter 11: Heat Exchangers. Heat &

Mass Transfer, fundamentals & Applications, 5th Edition, 647-687.


3.

Double Pipe Heat Exchanger Design. Retrieved 25th April 2016, from

http://www.brighthubengineering.com/hvac/64548-double-pipe-heat-exchanger-design/
4.

P. A. Hilton LTD, (May 2004). Optional Concentric Tube Heat Exchanger

H101A. Concentric Manual: Experimental Operating & Maintenance procedures.

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