Experiment 6: Crossflow Heat Exchanger

GROUP MEMBERS:
1. AHMAD FIRDAUS BIN ZAINUSHAM (ME0107325)
2.DHARSSHAN A/L KARUPPIAH (ME0102867)
3.DARVINESH A/L GUNASEGARAN (ME01081209)
4.ISWARAN A/L CHANDRAN (ME01081443)
5.MUHAMMAD FARIZ IZZUDDIN BIN MOHD FOZI
(ME01081077)
SECTION: 01
GROUP : 5

INSTRUCTOR: Ir. Ts. Dr. Prem A/L Gunnasegaran

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TABLE OF CONTENTS

Content Page
Introduction 3
Objective 4
Theory 5-6
Apparatus 7-8
Procedure 9
Results 10
Calculations 11
Graph and analysis 12-13
Discussion 14-16
Conclusion 17

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INTRODUCTION
A crossflow heat exchanger is a device that is used to transfer heat between two fluids that
flow in opposite directions. This type of heat exchanger is commonly used in industries such
as power generation, petroleum, and chemical processing. The aim of the crossflow heat
exchanger laboratory report is to investigate the performance of a crossflow heat exchanger
and to identify any shortcomings in the design or operation that could be improved through
future modifications.

The crossflow heat exchanger laboratory report will begin with a brief introduction of the
concept of crossflow heat exchangers and their applications. This will be followed by a
description of the experiment that was conducted to investigate the performance of the
crossflow heat exchanger. The report will also include details about the materials and
equipment used in the experiment, the experimental procedure, and the data collection and
analysis techniques that were employed.

The results of the experiment will be presented and interpreted in the report. The performance
of the crossflow heat exchanger will be evaluated based on various parameters such as heat
transfer, pressure drop, and mass transfer. Any shortcomings in the design or operation of the
crossflow heat exchanger will be identified, and recommendations will be made for future
improvements.

The report will conclude with a summary of the findings and a listing of recommendations
for future experiments or modifications. The aim of the crossflow heat exchanger laboratory
report is to provide a comprehensive understanding of the performance of crossflow heat
exchangers and to identify areas for improvement.

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OBJECTIVE
1. To observe relationship between air velocity with surface temperature across two
different type of surface heater.
2. To investigate on the determination of cross flow heat transfer to air from different type of
surface heater.

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THEORY
In a crossflow heat exchanger, heat is transferred between flowing heat transfer streams in
opposite directions through a common wall or partition. This process occurs in a series of
stages, each separated by a stream-to-stream wall, which serves to protect the fluids from
mixing and intermixing.
The common wall separating the two streams helps prevent the mixing of the fluids, ensuring
that they only exchange heat within the exchanger. Additionally, each stage of the heat
transfer process is designed to achieve a specific transfer efficiency target for optimal
performance of the unit. To provide the necessary thermal mass, stages could include multiple
heat transfer tubes or pipe bundles as well as other heat transfer surface types.
To transfer energy from one moving fluid to another, the two fluids flow past each other in
opposite directions in a series of stages, typically separated by heat exchanger tubing. As the
two fluids collide with the walls of the heat exchanger tubes, they exchange heat due to
thermal gradients that exist between them. The rate at which the thermal energy is exchanged
depends on the temperature, mass flow rate, and heat transfer coefficient of each fluid. The
goal of the heat exchanger stages is to achieve a steady-state temperature profile in the inlet
and outlet streams with minimal differences in temperature for optimized performance.

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Figure 1: Graphical representation of heat transfer theory

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Apparatus

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 A Temperature Point 2 J Power Meter
B Temperature Point 1 K Fan Regulator
C Temperature Control P L Control Panel Box
D Air Velocity Transmitter M Mains 240AC
E Air blower N Emergency Stop Button
F Temperature Point 2 Display O Main frame
G Temperature Point 1 Display P Air duct
H Temperature Control Display Q Fin Plate Heater
I Air Velocity Meter R Blower On/Off

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PROCEDURE
1. At the beginning, the main power supply and the power switch on the control panel
was switched on.
2. The first specimen which was the tube bundle was placed accordingly on the heater
placement and tighten with the lock nut provided.
3. Then the power connection cable to the heater was connected.
4. Before the heater turn on the initial readings was recorded such as T1, T2 and Tc.
5. Followed by the heater switch was on and the power was regulated to 900W.
6. The heating point was set to 35oC and waited for the temperature to reached.
7. Once, the temperature, Tc reached 35oC the fan was turned on and regulated to 1m/s
and waited 2 minutes. After 2 minutes, the data was recorded in the table.
8. Then the steps were repeated with 2m/s and 3m/s and the data recorded.
9. Allowed 5 minutes for the heating specimen to be cooled down. Then, the heating
specimen was replaced by the flat plate heating specimen by removing the lock nuts
and placing the flat plate heating specimen in the heater placement accordingly by
tightening with the given lock nuts.
10. Same procedures repeated with the flat plate specimen. The initial readings for the
temperature such as T1, T2 and Tc was recorded. The heating point was set to 35oC
and waited for the temperature to reached.
11. Once, the temperature, Tc reached 35oC the fan was turned on and regulated to 1m/s
and waited 2 minutes. After 2 minutes, the data was recorded in the table.
12. Then the steps were repeated with 2m/s and 3m/s and the data recorded the
coefficient of convection heating and the overall heat transfer was calculated.

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RESULTS
Flat Plate Surfaces
Air Temperature, Temperature, Temperature Temperature Cross Heat transfer
velocity, T1 (℃) T2(℃) control, Tc difference, flow coefficient, h
v (m/s) (℃) ∆𝑇 (℃) heat (W/𝑚2 .K)
transfer
rate, Q
(W)
0.389 30 33 35.6 3 57.183 1357.621083
0.5 30 31.7 31 1.7 41.65 1745.014245
1 30 39.8 35.6 9.8 480.2 3490.02849
1.5 31 37.2 36.8 6.2 455.7 5235.042735
1.7 31 35.8 35.6 4.8 399.84 5933.048433

Tube Bundle
Air Temperature, Temperature, Temperature Temperature Cross flow Heat
velocity, T1 (℃) T2(℃) control, Tc difference, heat transfer transfer
v (m/s) (℃) ∆𝑇 (℃) rate, Q (W) coefficient, h
(W/𝑚2 .K)
0.389 25 42.5 36.1 17.5 1031.557494 676.7639782
0.5 26 44.1 28.1 18.1 1371.369125 869.8765786
1 27 44 29.2 17 2576.0525 1739.753157
1.5 27 44 29.7 17 3864.07875 2609.629736
1.7 28 43.9 29.9 15.9 4095.923475 297.580367

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CALCULATIONS

Cp=1000 J/kg.K
𝜌𝑎𝑖𝑟 = 1.225 𝑘𝑔/𝑚3

𝑚 = 𝜌𝑎𝑖𝑟 𝐴𝑉∆𝑇
=(1.225)(0.0133333)(0.389)(3)
= 0.019061

Cross flow Heat Transfer Rate, Q

= 𝑚Cp∆𝑇
=(0.019061)(1000)(3)
=57.183 W

Heat transfer Coefficient, Hc

𝑄
=
𝐴𝑠∆𝑇
57.183
0.1404(3)
=1357.621083 W/𝑚2 .K

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GRAPH AND ANALYSIS

Graph of cross flow heat transfer rate vs heat transfer coefficient for the flat plate surface

Graph of air velocity vs heat transfer coefficient for the flat plate surface

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Graph of cross flow heat transfer rate vs heat transfer coefficient for the tube bundle
surfaces.

Graph of air velocity vs heat transfer coefficient for the tube bundles surfaces

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DISUCSSIONS

Effect of Air Velocity on Heat Transfer Rate

The relationship between air velocity and heat transfer rate is complex and often non-
linear. As air velocity increases, the convective heat transfer rate typically increases due to
enhanced fluid flow and increased heat transfer coefficient. However, beyond a certain point,
further increases in velocity may lead to diminishing returns or even a decrease in heat transfer
rate. This phenomenon can be attributed to the formation of a turbulent boundary layer near
the surface, which disrupts the flow and reduces the effectiveness of heat transfer.
In the scenario provided, the maximum heat transfer rate of 480.2 W is achieved at an
air velocity of 1 m/s, and it decreases to 399.8 W at the maximum velocity of 1.7 m/s. This
decrease in heat transfer rate with increasing velocity suggests that turbulence effects become
significant at higher velocities, impeding the heat transfer process. Turbulence causes irregular
fluctuations in fluid motion, leading to inefficient heat transfer across the boundary layer.
Turbulence and Boundary Layer Disturbance: Turbulence occurs when the flow of a
fluid becomes chaotic and unpredictable, characterized by swirling eddies and rapid velocity
fluctuations. In the context of heat transfer, turbulence disrupts the formation of a smooth and
well-defined boundary layer, which is essential for efficient heat transfer between the surface
and the fluid. Instead of a laminar flow regime, where fluid particles move in parallel layers
with minimal mixing, turbulence introduces mixing and agitation, reducing the effectiveness
of heat transfer.
At lower velocities, the flow is more likely to remain laminar, allowing for efficient
heat transfer and higher heat transfer rates. However, as the velocity increases, the flow
becomes more prone to turbulence, leading to boundary layer thickening and reduced heat
transfer rates. This is evident in the decrease in heat transfer rate observed as air velocity
increases from 1 m/s to 1.7 m/s in the provided scenario.
Relationship between Heat Transfer Coefficient and Air Velocity: The heat transfer
coefficient (h) is a measure of the ability of a fluid to transfer heat to a solid surface per unit
area per unit temperature difference. It is directly proportional to the heat transfer rate and is
influenced by factors such as fluid properties, surface roughness, and flow conditions. In
convective heat transfer, the heat transfer coefficient typically increases with increasing flow
velocity, up to a certain point where turbulence effects become dominant.
In the scenario provided, the maximum heat transfer coefficient of 5933.05 W/m²·K is
achieved at an air velocity of 1.7 m/s. This corresponds to the point where turbulence effects
are most pronounced, leading to increased convective heat transfer coefficients. However,
despite the higher heat transfer coefficient at this velocity, the overall heat transfer rate is
reduced due to the disruptive effects of turbulence on the boundary layer.
Effect of Air Velocity on Heat Transfer Coefficient and Boundary Layer Thickness
The relationship between air velocity and heat transfer coefficient is fundamental to
understanding convective heat transfer processes. Generally, an increase in air velocity leads
to an increase in the heat transfer coefficient, as higher velocities enhance the fluid's ability to

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carry heat away from the surface. This relationship can be attributed to the increased fluid flow
and turbulence, which disrupts the boundary layer and promotes heat exchange between the
fluid and the surface.
When air flows over a solid surface, it forms a thin layer of fluid adjacent to the surface
known as the boundary layer. In laminar flow conditions, this boundary layer is relatively thick,
and heat transfer occurs primarily through conduction within this layer. However, as the
velocity of the air increases, the flow transitions from laminar to turbulent, leading to a
significant reduction in the thickness of the boundary layer.
Turbulence introduces mixing and agitation within the boundary layer, effectively
thinning it and enhancing heat transfer rates. The increased mixing disrupts the thermal
boundary layer, allowing for more efficient heat exchange between the surface and the fluid.
As a result, the heat transfer coefficient, which represents the rate of heat transfer per unit area
per unit temperature difference, increases with higher velocities.
In the scenario provided, the maximum heat transfer coefficient of 5933.05 W/m²·K is
achieved at an air velocity of 1.7 m/s. This corresponds to the point where turbulence effects
are most pronounced, leading to increased convective heat transfer coefficients. The thinner
boundary layer at higher velocities allows for more effective heat transfer, despite the decrease
in overall heat transfer rate due to turbulence-induced disruptions.
Furthermore, the enhancement of heat transfer coefficient with increasing air velocity
underscores the importance of flow control and optimization in various engineering
applications. By manipulating air flow conditions, such as using aerodynamic designs or flow
control devices, engineers can modulate the thickness of the boundary layer and maximize heat
transfer rates.
The Relationship Between Cross Flow Heat Transfer Rate and Heat Transfer Coefficient
The relationship between cross flow heat transfer rate and heat transfer coefficient
shares similarities with the behaviour observed in flat plate configurations. In both cases, the
heat transfer rate and heat transfer coefficient tend to exhibit similar trends in response to
changes in flow conditions, such as air velocity.
When considering cross flow heat transfer, which typically occurs when a fluid flows
perpendicular to a solid surface, similar principles apply as with flat plate configurations. As
air velocity increases, there is an associated increase in the heat transfer coefficient. This
increase is due to the enhanced fluid flow and turbulence, which disrupts the boundary layer
and promotes more efficient heat exchange between the fluid and the surface.
In the scenario provided, the maximum heat transfer coefficient of 2957.58 W/m²·K is
achieved at an air velocity of 1.7 m/s, coinciding with the maximum cross flow heat transfer
rate of 4095.9 W. This correspondence suggests that, similar to flat plate configurations, higher
velocities lead to increased convective heat transfer coefficients and higher heat transfer rates
in cross flow heat transfer configurations.
The Maximum h Value and Cross Flow Heat Transfer Rate at 1.7 m/s
At an air velocity of 1.7 m/s, both the maximum heat transfer coefficient (h) and the
maximum cross flow heat transfer rate are achieved. This convergence indicates a critical point

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where the flow conditions are optimal for heat transfer. The high heat transfer coefficient at
this velocity suggests that turbulence effects are significant, leading to increased mixing and
disruption of the boundary layer, thereby enhancing heat transfer rates.
The relationship between air velocity and heat transfer coefficient behaves similarly to
that observed in flat plate configurations. As air velocity increases, turbulence becomes more
pronounced, leading to thinner boundary layers and higher convective heat transfer
coefficients. This phenomenon results in increased heat transfer rates, as evidenced by the
maximum values achieved at 1.7 m/s in the provided scenario.
Understanding and Optimizing Cross Flow Heat Transfer
The principles governing cross flow heat transfer, including the relationship between
air velocity, heat transfer coefficient, and heat transfer rate, are crucial for optimizing heat
exchange systems in various engineering applications. By manipulating flow conditions and
geometry, engineers can maximize heat transfer rates while minimizing energy consumption
and operational costs.
Furthermore, insights from studies on flat plate heat transfer can be applied to cross
flow configurations, enabling engineers to leverage existing knowledge and techniques to
design efficient heat exchange systems. By carefully controlling flow conditions and surface
properties, engineers can enhance heat transfer rates and improve the overall performance of
cross flow heat exchangers in applications ranging from HVAC systems to industrial processes.

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CONCLUSIONS
The experiment aimed to understand how air velocity influences heat transfer on flat
plates and a tube bundle. Interestingly, we found that both surfaces reached their peak heat
transfer rates at an air velocity of 1.7 m/s. This aligns with our expectations, as higher air speeds
generally enhance heat transfer.
However, we observed a discrepancy with the tube bundle. Theoretical predictions
suggested it would have a higher heat transfer coefficient due to its design, but our experiment
did not support this. Possible errors in experimental setup or data collection might have
influenced this result, such as uneven airflow or measurement inaccuracies.
Nevertheless, the experiment affirmed the direct relationship between heat transfer
coefficient and heat transfer rate for both surfaces. This underscores the importance of
controlling airflow for efficient heat transfer. Moving forward, refining experimental
techniques and exploring alternative methods to boost heat transfer in tube bundles will be key
for advancing our understanding and practical applications in heat exchange systems.

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