Heat Exchanger Project

Fernando Enrique Castillo Vicencio

Written in 2019 by Fernando Enrique Castillo Vicencio.
 Heat Exchanger Project

Project
developed during my activities as a Research
Professor at the Polytechnic School at the
Autonomous University Center of Brasil (UniBrasil).

by

Fernando Enrique CAſTıLLO VıCENCıO

MSc. in Mechanical Engineering – Thermal Sciences (UTFPR‐Brazil),
BSc. in Fluid Mechanics Engineering (UNMSM‐Peru),
born in Lima, Peru.
Contents

1 Problem Definition 3
1.1 Introduction 3
1.2 Types of Heat Exchanger 3
1.3 Heat Exchanger Selection 4
1.4 CFD in Heat Exchangers 5
1.5 Objectives of this Project 5

Bibliography 7

Figures

1.1 A shell‐and‐tube heat exchanger (STHE), an example of tubular heat exchanger. 3

1.2 An example of plate heat exchanger (PHE). 3

iv
Preface
This is the Preface....
BlogDoCastillo 1 1: https://blogdocastillo.com

1
 Problem Definition 1
1.1 Introduction

Heat exchangers are used in different applications in the industry as air

conditioning, refrigeration, heat recovery, manufacturing industries, nu‐
clear generators, cooling towers, among many others. The main areas of
applications are national defence, households, electronics, transportation,
environment engineering, farm and fishery, energy, and industry [Kakaç
et al., 2012, p.25].
For many authors [Kakaç et al., 2012, Shah and Sekulić, 2002, Thu‐
lukkanam, 2013], heat exchanger may be classified according to:

• Construction: Tubular, plate‐type, extended surface, regenerators.

• Transfer process: Direct contact type (cooling towers) and indirect
contact type (fluidized beds).
• Flow arrangements: Parallel flows, counter flows, and cross flows.
• Pass arrangements: Single pass, multipass.
Figure 1.1: A shell‐and‐tube heat
• Phase of the process fluids: Gas‐liquid, liquid‐liquid, gas‐gas. exchanger (STHE)2 , an example of
tubular heat exchanger.
• Heat transfer mechanism: Single‐phase convection, two‐phase con‐ 2: https://www.indiamart.com/
vection, combined convection and radiation. proddetail/shell-and-tube-heat-
exchangers-16833604112.html

1.2 Types of Heat Exchanger

According to Kakaç et al. [2012, p.26], there are some criteria for heat ex‐
changer selection:
• It must satisfy the process requirements;
• It must abide the plant operating conditions;
• It must be able of maintenance;
Figure 1.2: An example of plate heat
• It must be cost effective; exchanger (PHE)3 .
3: https://www.indiamart.com/
• It must attend limitations on dimensions, configuration, installation, proddetail/plate-heat-exchanger-
among others. 15316428748.html

3
4 1 Problem Definition

Thulukkanam [2013, p.89] proposes a series of guidelines to select a type

of heat exchanger. Its criteria is based on viscosity of fluids, fouling, type
of fluids, and application. The types of heat exchanger described by Thu‐
lukkanam [2013, p.89] are:
• Double pipe heat exchanger (DPHE),
• Shell and tube heat exchanger (STHE),
• Coiled tube heat exchanger (CTHE),
• Finned‐tube heat exchanger,
• Air cooled heat exchanger (ACHE),
• Plate‐fin heat exchanger,
• Regenerators,
• Plate heat exchanger (PHE),
• Spiral plate heat exchanger (SPHE),
• Printed circuit heat exchangers (PHCE),
• Lamella heat exchanger (LHE),
• Heat pipe heat exchanger,
• Plate coil heat exchanger,
• Scrapped surface heat exchanger.

1.3 Heat Exchanger Selection

According to Thulukkanam [2013, p.89], double‐pipe heat exchangers

(DPHE) have some characteristics as:
• Usually, it has a U‐bend design, being known as harpin heat exchang‐
ers;
• The flow arrangement is countercurrent;
• Multiple DPHEs can be connected in series or parallel thermal cir‐
cuits;
2
• It is typical for small duties requirement, area less than 300 ft ;
• It is suitable for high‐pressures —up to 14000 psi— and temperatures
—up to 600∘ C—, and thermally long duties;
• Pressure and temperature design is similar to STHEs;
• The design is carried out by using the method of Kern [1965, p.102].
Aditionally, the method of Kakaç et al. [2012, p.273] can be used;
• It can be used when one or more conditions exists:
a. The process requires a temperature cross,
b. High pressure on the tubeside,
 1.4 CFD in Heat Exchangers 5

c. Low pressure is required on one side,

d. Increasing heat transfer coefficient is required,
e. The exchanger is subject to thermal shocks,
f. The flow‐induced vibration may be a problem,
g. Solid particles or slurries are present on the flow.
For this project, the above‐mentioned 𝑎, 𝑐 and 𝑑 items are required. There‐
fore, the use of a DPHE is applicable.

1.4 CFD in Heat Exchangers

Kanaris et al. [2006] argues that Computational Fluid Dynamics (CFD) code
is a reliable tool for heat exchanger analysis. This tool can help to esti‐
mate momentum and heat transfer rates and to evaluate its performance.
Pressure losses may be determined under different geometrical configura‐
tions. Authors indicate that CFD can help to optimize the energy economy
of a heat exchanger.
Bhutta et al. [2012] developed a review of many CFD investigations in heat
exchangers. Authors point that CFD is a cost effective alternative, providing
speedy solutions for heat exchanger design. Some commercial softwares
can be used for various types of heat exchangers. In fact, authors indicate
that CFD results are an integral part of all design process leading towards
eliminating prototyping.
At this point, it should be noted that CFD is an important tool for heat design
process. In this work, a CFD analysis of the heat exchanger will be carried
out to improve the design process.

1.5 Objectives of this Project

This work has been developed with the aim to exchange heat between cold
water (𝑇𝑐 = 10∘ C) and hot water (𝑇ℎ = 60∘ C) under different flow rates
between 1 − 15 LPM.
The goal of the heat exchanger to be designed is to chill the hot water up to
𝑇 = 15∘ C. Among the types of heat exchanger above‐mentioned, a double
pipe heat exchanger (DPHE) was selected due to its relative construction
easiness.
CFD tool will be performed to improve the design process of this heat ex‐
changer. Prediction of pressure drop and –inlet and outlet– temperatures
will be verified and compared with experimental results.
Both CFD and experimental procedures will be described in this work to
help in the thermal design as well as verification of CFD results. This work
can serve as reference for future works developed by the author or for any
scientists or engineers.
Bibliography

M. M. A. Bhutta, N. Hayat, M. H. Bashir, A. R. Khan, K. N. Ahmad, and S. Khan. CFD applications in various heat
exchangers design: A review. Applied Thermal Engineering, 32:1–12, 2012. doi: 10.1016/j.applthermaleng.2011.09.
001. URL https://www.sciencedirect.com/science/article/pii/S1359431111004807.
S. Kakaç, H. Liu, and A. Pramuanjaroenkij. Heat Exchangers: Selection, Rating, and Thermal Design. Taylor & Francis–
CRC Press, Boca Raton, 3rd edition, March 2012. ISBN 978‐1‐4398‐4991‐0.
A. G. Kanaris, A. A. Mouza, and S. V. Paras. Flow and heat transfer prediction in a corrugated plate heat exchanger
using a CFD code. Flow and Heat Transfer Prediction in a Corrugated Plate Heat Exchanger using a CFD Code, 29(8):923–
930, 2006. doi: 10.1002/ceat.200600093. URL https://onlinelibrary.wiley.com/doi/abs/10.1002/ceat.200600093.
D. Q. Kern. Process Heat Transfer (International Student Edition). McGraw‐Hill Book Company Japan, Tokyo, 1965. ISBN
0‐07‐085353‐3.
R. K. Shah and D. P. Sekulić. Fundamentals of Heat Exchanger Design. John Wiley & Sons, Inc., New Jersey, 1st edition,
June 2002. ISBN 0‐471‐32171‐0.
K. Thulukkanam. Heat Exchanger Design Handbook. Taylor & Francis–CRC Press, Boca Raton, 2nd edition, May 2013.
ISBN 978‐1‐4398‐4213‐3.