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MODELLING AND ANALYSIS OF DOUBLE PIPE HEAT EXCHANGER

CHAPTER 1
INTRODUCTION
HEAT TRANSFER
The transfer of heat is normally from a high temperature object to a lower temperature
object. Heat transfer mechanisms can be grouped into 3 broad categories:

Conduction
Regions with greater molecular kinetic energy will pass their thermal energy to regions
with less molecular energy through direct molecular collisions, a process known as conduction.
In metals, a significant portion of the transported thermal energy is also carried by conduction-
band electrons.

Convection
When heat conducts into a static fluid it leads to a local volumetric expansion. As a
result of gravity-induced pressure gradients, the expanded fluid parcel becomes buoyant and
displaces, thereby transporting heat by fluid motion (i.e. convection) in addition to conduction.
Such heat-induced fluid motion in initially static fluids is known as free convection.

Radiation
All materials radiate thermal energy in amounts determined by their temperature, where
the energy is carried by photons of light in the infrared and visible portions of the
electromagnetic spectrum. When temperatures are uniform, the irradiative flux between objects
is in equilibrium and no net thermal energy is exchanged. The balance is upset when
temperatures are not uniform, and thermal energy is transported from surfaces of higher to
surfaces of lower temperature.

HEAT EXCHANGERS

Heat exchanger is a device used for affecting the process of heat exchange between two
fluids that are at different temperatures. Heat exchangers are use full in many engineering
processes like those in refrigerating and air conditioning systems, power plants, food processing
industries, chemical reactors and space and aeronautical applications.
A Heat Exchanger in which two fluids exchange heat by coming in direct contact is
called a direct heat exchanger. Examples of this type are open feed water heaters and jet
condensers. Recuperators (closed type exchangers) are heat exchangers in which fluids are
separated by a wall. The wall me be a simple plane wall or a tube or a complex configuration
involving fins, baffles and multi-pass of tubes.
The temperature and pressure levels, as well as differences often impose several
problems. The corrosiveness, toxicity and scale forming tendency in addition to thermal
properties of substances must be considered. There are also economic considerations, which
include factor such as initial cost of the exchanger, necessary space, and required life of the unit
cases of maintenance.

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MODELLING AND ANALYSIS OF DOUBLE PIPE HEAT EXCHANGER

CLASSIFICATION OF HEAT EXCHANGERS:


The heat exchanger classification is based on the devices basic operation, transfer processes,
construction, number of fluids, heat transfer mechanisms and the type of flow and their
arrangements. The heat exchangers are classified as:
• Recuperators and Regenerators
• The direct contact transfer and indirect contact transfer processes.
• Based on geometry as tubes, plates and extended surfaces.
• The heat transfer mechanisms as single phase and two phase flows.
• Based on the flow arrangement as parallel flow, counter flow and cross flow.

CLASSIFICATION BASED ON FLOW ARRANGEMENTS

Parallel and counter flow provides alternative arrangements for certain specialized
applications. In parallel flow both the hot and cold streams enter the heat exchanger at the same
end and travel to the opposite end in parallel streams. Energy is transferred along the length
from the hot to the cold fluid so the outlet temperatures asymptotically approach each other. In
a counter flow arrangement, the two streams enter at opposite ends of the heat exchanger and
flow in parallel but opposite directions. Temperatures within the two streams tend to approach
one another in a nearly linearly fashion resulting in a much more uniform heating pattern.
Shown below the heat exchangers are representations of the axial temperature profiles for each.
Parallel flow results in rapid initial rates of heat exchange near the entrance, but heat transfer
rates rapidly decrease as the temperatures of the two streams approach one another. This leads
to higher exergy loss during heat exchange. Counter flow provides for relatively uniform
temperature differences and, consequently, lead toward relatively uniform heat rates throughout
the length of the unit.

Parallel flow and counter flow heat exchangers are the basic heat exchanger flow arrangements.

 Parallel flow heat exchanger:

Fig 1.1: Parallel flow heat exchanger

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MODELLING AND ANALYSIS OF DOUBLE PIPE HEAT EXCHANGER

In a double pipe heat exchanger a parallel flow can be maintained by having the fluids
entrance and exit on either side of the heat exchanger. Both the fluids will enter at different
temperatures but they will exit at same temperature. This heat exchanger requires large surface
area. In parallel flow heat exchanger the initial heating rate is very high and is used where the
tube walls are to be developed with their temperature.

 Counter flow heat exchanger:

Fig 1.2: counter flow heat exchanger

In this type of heat exchanger the hot fluid enters from one side and the cold fluid enters
from other side. A double pipe heat exchanger is used in type of heat exchanger. It is most
commonly used is liquid to liquid type. It is most efficient type of heat exchanger. Counter flow
heat exchangers have larger LMTD value and also greater potential recovery. This permits even
a smaller area of heat exchange.

 Cross flow:

These types of heat exchangers are found in car radiators and air conditioning systems
where most of application is found. The air passing through the evaporator coils is cooled by a
cold refrigerant present in it. Gas and liquid media heat transfer takes place mostly in this type
of heat exchangers.

Fig.1.3: Cross flow heat exchanger

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 Cross/Counter flow

In industrial heat exchangers, hybrids of the above flow types are often found.
Examples of these are combined crossflow/counter flow heat exchangers and multi pass
flow heat exchangers.

Fig 1.4: Cross/Counter flow

CLASSIFICATION ACCORDING TO TRANSFER PROCESSES

Heat exchangers are classified according to transfer processes into indirect- and direct
contact types.

Indirect-Contact Heat exchanger

In an indirect-contact heat exchanger, the fluid streams remain separate and the heat
transfers continuously through an impervious dividing wall or into and out of a wall in a
transient manner. Thus, ideally, there is no direct contact between thermally interacting fluids.
This type of heat exchanger also referred to as a surface heat exchanger, can be further classified
into direct-transfer type, storage type, and fluidized-bed exchangers.

Fig 1.5: Example of Indirect contact heat exchanger

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MODELLING AND ANALYSIS OF DOUBLE PIPE HEAT EXCHANGER

Direct-Contact Heat Exchangers

In a direct-contact exchanger, two fluid streams come into direct contact, exchange heat,
and are then separated. Common applications of a direct-contact exchanger involve mass
transfer in addition to heat transfer, such as in evaporative cooling and rectification; applications
involving only sensible heat transfer are rare. The enthalpy of phase change in such an
exchanger generally represents a significant portion of the total energy transfer. The phase
change generally enhances the heat transfer rate. Compared to indirect contact recuperators and
regenerators, in direct-contact heat exchangers, (1) very high heat transfer rates are achievable,
(2) the exchanger construction is relatively inexpensive, and (3) the fouling problem is generally
nonexistent, due to the absence of a heat surface (wall) between the two fluids. However, the
applications are limited to those cases where a direct contact of two fluid streams is permissible.
The design theory for these transfer exchangers is beyond the scope of this book and is not
covered. These exchangers may be further classified into Immiscible Fluid Exchangers, Gas–
Liquid Exchangers, and Liquid–Vapor Exchangers.

Fig 1.6: Direct contact type heat exchanger

RECUPERATORS

A recuperator is a special purpose counter-flow energy recovery heat exchanger


positioned within the supply and exhaust air streams of an air handling system, or in the exhaust
gases of an industrial process, in order to recover the waste heat.
Recuperators are often used in association with the burner portion of a heat engine, to
increase the overall efficiency. For example, in a gas turbine engine, air is compressed, mixed
with fuel, which is then burned and used to drive a turbine. The recuperator transfers some of
the waste heat in the exhaust to the compressed air, thus preheating it before entering the fuel
burner stage. Since the gases have been pre-heated, less fuel is needed to heat the gases up to

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MODELLING AND ANALYSIS OF DOUBLE PIPE HEAT EXCHANGER

the turbine inlet temperature. By recovering some of the energy usually lost as waste heat, the
recuperator can make a heat engine or gas turbine significantly more efficient.

Fig 1.7: Typical arrangement of recuperator

REGENERATOR
A regenerative heat exchanger, or more commonly a regenerator, is a type of heat
exchanger where heat from the hot fluid is intermittently stored in a thermal storage medium
before it is transferred to the cold fluid. To accomplish this the hot fluid is brought into contact
with the heat storage medium, then the fluid is displaced with the cold fluid, which absorbs the
heat. In regenerative heat exchangers, the fluid on either side of the heat exchanger can be the
same fluid. The fluid may go through an external processing step, and then it is flowed back
through the heat exchanger in the opposite direction for further processing. Usually the
application will use this process cyclically or repetitively.

Regenerative heating was one of the most important technologies developed during the
Industrial Revolution when it was used in the hot blast process on blast furnaces, It was later
used in glass and steel making, to increase the efficiency of open hearth furnaces, and in high
pressure boilers and chemical and other applications, where it continues to be important today.

Fig 1.8: Regenerative heat exchanger

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MODELLING AND ANALYSIS OF DOUBLE PIPE HEAT EXCHANGER

CLASSIFICATION ACCORDING TO NUMBER OF FLUIDS

Most processes of heating, cooling, heat recovery and heat rejection involve transfer of
heat between two fluids. Hence, two-fluid heat exchangers are the most common. Three fluid
heat exchangers are widely used in cryogenics and some chemical processes (e.g., air separation
systems, a helium–air separation unit, purification and liquefaction of hydrogen, ammonia gas
synthesis). Heat exchangers with as many as 12 fluid streams have been used in some chemical
process applications.

BASED ON GEOMETRY AS TUBES, PLATES AND EXTENDED


SURFACES

Shell and tube heat exchanger


Shell and tube heat exchangers consist of series of tubes. One set of these tubes contains
the fluid that must be either heated or cooled. The second fluid runs over the tubes that are being
heated or cooled so that it can either provide the heat or absorb the heat required. A set of tubes
is called the tube bundle and can be made up of several types of tubes: plain, longitudinally
finned, etc. Shell and tube heat exchangers are typically used for high-pressure applications
(with pressures greater than 30 bar and temperatures greater than 260 °C). This is because the
shell and tube heat exchangers are robust due to their shape. Several thermal design features
must be considered when designing the tubes in the shell and tube heat exchangers: There can
be many variations on the shell and tube design. Typically, the ends of each tube are connected
to plenums (sometimes called water boxes) through holes in tube sheets. The tubes may be
straight or bent in the shape of a U, called U-tubes.

Fig 1.9: Shell and tube Heat exchanger

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Plate heat exchangers

Another type of heat exchanger is the plate heat exchanger. These exchangers are
composed of many thin, slightly separated plates that have very large surface areas and small
fluid flow passages for heat transfer. Advances in gasket and brazing technology have made the
plate-type heat exchanger increasingly practical. In HVAC applications, large heat exchangers
of this type are called plate-and-frame; when used in open loops, these heat exchangers are
normally of the gasket type to allow periodic disassembly, cleaning, and inspection. There are
many types of permanently bonded plate heat exchangers, such as dip brazed, vacuum-brazed,
and welded plate varieties, and they are often specified for closed loop applications such as
refrigeration. Plate heat exchangers also differ in the types of plates that are used, and in the
configurations of those plates. Some plates may be stamped with "chevron", dimpled, or other
patterns, where others may have machined fins and/or grooves.

When compared to shell and tube exchangers, the stacked-plate arrangement typically
has lower volume and cost. Another difference between the two is that plate exchangers
typically serve low to medium pressure fluids, compared to medium and high pressures of shell
and tube. A third and important difference is that plate exchangers employ more counter current
flow rather than cross current flow, which allows lower approach temperature differences, high
temperature changes, and increased efficiencies.

Fig 1.10: Plate type Heat Exchanger

DOUBLE-PIPE HEAT EXCHANGER

In this project we are using u-bend double pipe heat exchanger. The double-pipe heat
exchanger is one of the simplest types of heat exchangers. 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. This is a concentric tube construction. Flow in a double-pipe heat
exchanger can be co-current or counter-current. There are two flow configurations: co-current
is when the flow of the two streams is in the same direction, counter current is when the flow
of the streams is in opposite directions As conditions in the pipes change: inlet temperatures,
flow rates, fluid properties, fluid composition, etc., the amount of heat transferred also changes.

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MODELLING AND ANALYSIS OF DOUBLE PIPE HEAT EXCHANGER

This transient behavior leads to change in process temperatures, which will lead to a point where
the temperature distribution becomes steady. When heat is beginning to be transferred, this
changes the temperature of the fluids. Until these temperatures reach a steady state their
behavior is dependent on time.

In this double-pipe heat exchanger a hot process fluid flowing through the inner pipe
transfers its heat to cooling water flowing in the outer pipe. The system is in steady state until
conditions change, such as flow rate or inlet temperature. These changes in conditions cause
the temperature distribution to change with time until a new steady state is reached. The new
steady state will be observed once the inlet and outlet temperatures for the process and coolant
fluid become stable. In reality, the temperatures will never be completely stable, but with large
enough changes in inlet temperatures or flow rates a relative steady state can be experimentally
observed.

Fig 1.11: Example of double pipe U-Bend heat exchanger

Advantages
 Double pipe heat exchangers can handle high pressures and temperatures well.
 When they are operating in true counter flow, they can operate with a temperature cross.
 The cold side outlet temperature is higher than the hot side outlet temperature.
 Very simple to construct
 Very easy of operation
 U-type or hairpin constructions handle differential thermal expansions.

Disadvantages
 The use of two single flow areas leads to relatively low flow rates and moderate
temperature differences.
 Can’t be used in handling dirty fluids. (Choking problem)(Used for only clean fluids)

Applications
 A primary advantage of a hairpin or double pipe heat exchanger is that it can be operated
in a true counter flow pattern, which is the most efficient flow pattern.
 It will give the highest overall heat transfer coefficient for the double pipe heat
exchanger design.

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MODELLING AND ANALYSIS OF DOUBLE PIPE HEAT EXCHANGER

SELECTION OF HEAT EXCHANGERS


Due to the many variables involved, selecting optimal heat exchangers is challenging.
Hand calculations are possible, but much iteration is typically needed. As such, heat exchangers
are most often selected via computer programs, either by system designers, who are typically
engineers, or by equipment vendors.

To select an appropriate heat exchanger, the system designers (or equipment vendors)
would firstly consider the design limitations for each heat exchanger type. Though cost is often
the primary criterion, several other selection criteria are important:

• High/low pressure limits


• Thermal performance
• Temperature ranges
• Product mix (liquid/liquid, particulates or high-solids liquid)
• Pressure drops across the exchanger
• Fluid flow capacity
• Clean ability, maintenance and repair
• Materials required for construction
• Ability and ease of future expansion
• Material selection, such as copper, aluminum, carbon steel, stainless steel, nickel alloys,
ceramic, polymer, and titanium.

Choosing the right heat exchanger requires some knowledge of the different heat
exchanger types, as well as the environment where the unit must operate. Typically in the
manufacturing industry, several differing types of heat exchangers are used for just one process
or system to derive the final product. For example, a kettle heat exchanger for preheating, a
double pipe heat exchanger for the ‘carrier’ fluid and a plate and frame heat exchanger for final
cooling. With sufficient knowledge of heat exchanger types and operating requirements, an
appropriate selection can be made to optimize the process.

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MODELLING AND ANALYSIS OF DOUBLE PIPE HEAT EXCHANGER

CHAPTER 2
HEAT TRANSFER ENHANCEMENT IN
HEAT EXCHANGERS WITH INSERTS
Introduction
The heat exchangers have an important role in the energy storage and recovery. Due to
the development of modern technology, the heat exchangers required in various industries for
high heat-flux cooling to the level of megawatt per meter square. At this level, cooling with
conventional fluids such as water and ethylene glycol and so forth, are challenging. Hence, it is
necessary to increase the heat transfer performance of working fluids in the heat transfer
devices. Heat transfer augmentation techniques (passive, active and compound) are commonly
used in areas such as process industries, heating and cooling in evaporators, thermal power
plants, air-conditioning equipment, refrigerators, radiators for space vehicles, automobiles, etc.
The rate of heat transfer can be increased passively by increasing the surface area, roughness,
and by changing the boundary conditions. The active method involves addition of nano sized,
high thermal conductivity, and metallic powder to the base fluid, to increase the heat transfer
rate. Such a fluid is termed as nano fluid. Passive techniques, where inserts are used in the flow
passage to augment the heat transfer rate, are best suited compared to active techniques.
Because the insert manufacturing process is simple and these techniques can be easily applied
in an existing application.
In many literature gap shows the experimentation on perforated twisted insert like in
experimental analysis of heat transfer characteristics using inserts in tubes. Heat transfer
enhancement techniques refer to different methods used to increase rate of heat transfer without
affecting much the overall performance of the system. Heat transfer augmentation techniques
refer to different methods used to increase these techniques and broadly divided in two groups,
passive and active. Active techniques involve some external power input for the enhancement
of heat transfer.
Passive heat transfer augmentation method does not use any external power input. One
of the ways to enhance heat transfer performance in passive method is to increase the effective
surface area and residence time of the heat transfer fluid. Use of this technique causes the swirl
in the bulk of the fluids and disturbs the actual boundary layer so as to increase surface area,
given time and similarly heat transfer coefficient in existing system. Inserts refer to the
additional arrangements made as an obstacle to fluid flow so as to augment heat transfer rate.

DIFFERENT METHODS OF HEAT TRANSFER ENHANCEMENT

Heat transfer enhancement or augmentation techniques refer to the improvement of


thermos hydraulic performance of heat exchangers. Existing enhancement techniques can be
broadly classified into three different categories:
1. Passive Techniques
2. Active Techniques
3. Compound Techniques

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MODELLING AND ANALYSIS OF DOUBLE PIPE HEAT EXCHANGER

PASSIVE TECHNIQUES

These techniques generally use surface or geometrical modifications to the flow channel
by incorporating inserts or additional devices. They promote higher heat transfer coefficients
by disturbing or altering the existing flow behavior (except for extended surfaces) which also
leads to increase in the pressure drop. In case of extended surfaces, effective heat transfer area
on the side of the extended surface is increased. Passive techniques hold the advantage over the
active techniques as they do not require any direct input of external power. Heat transfer
augmentation by these techniques can be achieved by using:

Treated Surfaces
This technique involves using pits, cavities or scratches like alteration in the surfaces of
the heat transfer area which may be continuous or discontinuous. They are primarily used for
boiling and condensing duties.

Rough surfaces
These surface modifications particularly create the disturbance in the viscous sublayer
region. These techniques are applicable primarily in single phase turbulent flows.

Extended surfaces
Plain fins are one of the earliest types of extended surfaces used extensively in many heat
exchangers. Finned surfaces have become very popular now a day’s owing to their ability to
disturb the flow field apart from increasing heat transfer area.

Displaced enhancement devices


These inserts are used primarily in confined forced convection. They improve heat transfer
indirectly at the heat exchange surface by displacing the fluid from the heated or cooled surface
of the duct with bulk fluid from the core flow.

Swirl flow devices


They produce swirl flow or secondary circulation on the axial flow in a channel. Helical twisted
tape, twisted ducts & various forms of altered (tangential to axial direction) are common
examples of swirl flow devices. They can be used for both single phase and twophase flows.

Coiled tubes:
In these devices secondary flows or vortices are generated due to curvature of the coils which
promotes higher heat transfer coefficient in single phase flows and in most regions of boiling.
This leads to relatively more compact heat exchangers.

ACTIVE TECHNIQUES

These techniques are more complex from the use and design point of view as the method
requires some external power input to cause the desired flow modification and improvement in
the rate of heat transfer. It finds limited application because of the need of external power in
many practical applications. In comparison to the passive techniques, these techniques have not
shown much potential as it is difficult to provide external power input in many cases. Various
active techniques are as follows:

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Mechanical Aids:
Examples of the mechanical aids include rotating tube exchangers and scrapped surface
heat and mass exchangers. These devices stir the fluid by mechanical means or by rotating the
surface.

Surface vibration:
They have been used primarily in single phase flows. A low or high frequency is applied to
facilitate the surface vibrations which results in higher convective heat transfer coefficients.

Fluid vibration:
Instead of applying vibrations to the surface, pulsations are created in the fluid itself.
This kind of vibration enhancement technique is employed for single phase flows.

Electrostatic fields:
Electrostatic field like electric or magnetic fields or a combination of the two from DC
or AC sources is applied in heat exchanger systems which induces greater bulk mixing, force
convection or electromagnetic pumping to enhance heat transfer. This technique is applicable
in heat transfer process involving dielectric fluids.

Injection:
In this technique, same or other fluid is injected into the main bulk fluid through a
porous heat transfer interface or upstream of the heat transfer section. This technique is used
for single phase heat transfer process.

Suction:
This technique is used for both two phase heat transfer and single phase heat transfer
process. Two phase nucleate boiling involves the vapour removal through a porous heated
surface whereas in single phase flows fluid is withdrawn through the porous heated surface.

Jet impingement:
This technique is applicable for both two phase and single phase heat transfer processes.
In this method, fluid is heated or cooled perpendicularly or obliquely to the heat transfer surface.

COMPOUND TECHNIQUES

When any two or more techniques i.e. passive and active may be employed
simultaneously to enhance the heat transfer of any device, which is greater than that of produced
by any of those techniques separately, the term known as Compound enhancement technique.

From the above techniques the passive techniques are simple because these techniques
generally use simple surface or geometrical modifications to the flow channel by incorporating
by inserts or additional devices. It does not need any external power input.

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INSERTS

The Passive heat transfer augmentation methods does not need any external power
input. In the convective heat transfer one of the ways to enhance heat transfer rate is to increase
the effective surface area and residence time of the heat transfer fluids. By Using this technique
causes the swirl in the bulk of the fluids and disturbs the actual boundary layers which increase
effective surface area, residence time and simultaneously heat transfer coefficient increases in
an existing system. Methods generally used are, extended surface, displaced enhancements
devices, rough surfaces surface tension devices, Inserts.
Inserts requires additional arrangements to make to fluid flow which enhance and
augment the heat transfer. The types of inserts are: twisted tape, wire coils, ribs, baffles, plates,
helical screw insert, mesh inserts, convergent – divergent conical rings, conical rings etc.

TYPES OF INSERTS

Inserts are so many types which are classified based on their shapes and functions.
Some important types of inserts are explained s follows

SWIRL FLOW DEVICES

Swirl flow devices causes swirl flow or secondary flow in the fluid .A variety of devices
can be employed to cause this effect which includes tube inserts, altered tube flow
arrangements, and duct geometry modifications. Dimples, ribs, helically twisted tubes are
examples of duct geometry modifications. Tube inserts include twisted-tape inserts, helical strip
or cored screw–type inserts and wire coils. Periodic tangential fluid injection is type of altered
tube flow arrangement. Among the swirl flow devices, twisted- tape inserts had been very
popular owing to their better thermal hydraulic performance in single phase, boiling and
condensation forced convection, as well as design and application issues.

Fig 2.1: Twisted tape inserts

Twisted tape inserts increases the heat transfer coefficients with relatively small
increase in the pressure drop. They are known to be one of the earliest swirl flow devices
employed in the single phase heat transfer processes. Because of the design and application
convenience they have been widely used over decades to generate the swirl flow in the fluid.
Size of the new heat exchanger can be reduced significantly by using twisted tapes in the new
heat exchanger for a specified heat load. Thus it provides an economic advantage over the fixed
cost of the equipment.
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Twisted tapes can be also used for retrofitting purpose. It can increase the heat duties of
the existing shell and tube heat exchangers. Twisted tapes with multi tube bundles are easy to
fit and remove, thus enables tube side cleaning in fouling situations. Inserts such as twisted
tape, wire coils, ribs and dimples mainly obstruct the flow and separate the primary flow from
the secondary flows. This causes the enhancement of the heat transfer in the tube flow. Inserts
reduce the effective flow area thereby increasing the flow velocity. This also leads to increase
in the pressure drop and in some cases causes’ significant secondary flow. Secondary flow
creates swirl and the mixing of the fluid elements and hence enhances the temperature gradient,
which ultimately leads to a high heat transfer coefficient.

COILED TUBES

A coiled or curved tube causes secondary flows due to continuous change in the bulk
velocity vector at the curve surface of the duct. Coiled tubes are used in domestic water heaters,
chemical process reactors, solar heating system, industrial & marine boilers, kidney dialysis
devices and blood oxygenators. Secondary flows are generated due the centrifugal force on the
fluid motion, induced because of the curvature of the coils. This curvature induced flow
characteristics of the coiled tubes depends on the geometrical attributes like radius of curvature,
helical number etc.

Fig 2.2: Coiled tubes

DISPLACED ENHANCEMENT DEVICES:

Displaced enhancement devices displace the fluid elements from the core of the channel
to heated or cooled surfaces and vice versa .Displaced enhancement devices include inserts like
static mixer elements (e.g. Kenics, Sulzer), metallic mesh, and discs, wire matrix inserts, rings
or balls. Different types of conical ring inserts used in circular tubes. These inserts do not alter
heat transfer surface and provide a lot of scope for inter-mixing of the fluid particles. Disks
promote higher heat transfer with moderate increase in friction factor whereas friction factor is
very high for rings and round balls. Burgles found that pressure drop in the turbulent flows are
extremely high. Most of the devices are suitable for laminar flow only. The main objective
behind the use of static mixers is to increase the fluid mixing, so its application is limited to
chemical processes with heat transfer only.

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Heatex wire matrix tube insert is one of the commercially available new displaced
enhancement devices as shown in Fig.2.4.Degree of the disturbance and mixing depends on the
coil matrix densities attached to core rod. Megrelian carried out the experiments with spiral
brush inserts for turbulent flows and found out that heat transfer coefficient can be improved as
much as 8.5 times that in a smooth tube, but pressure drop was very high.

Fig 2.3: Heatex wire matrix tube insert

TUBE INSERTS

 In a refinery furnace, heat exchanger is a vital component required for preheating the
throughput before it reaches the furnace, thus recovering a significant portion of energy
generated in the refinery. Without heat exchangers refining cost will be substantially
higher. The throughput is made to flow through a number of heat exchangers arranged
as cold pre heat train and hot pre heat train before entering the furnace.
 It is essential that all heat exchangers must function near optimally in order for the
throughput to achieve the desired CIT (coil inlet temperature) at furnace entry.
 Heat exchangers are prone to internal fouling (tube side) and it is more so when the
crude is (bitumen bearing) in nature. This problem will sometimes be so severe that a
shut down needs to be taken before the scheduled end of run.
 It is possible to achieve the above, by making the flow of throughput more turbulent
(less laminar). Thus, tube inserts are employed to simultaneously carry out two
functions:
 To enhance turbulence in the throughput flow (increase the Reynold’s Number)
 Through mechanical action, inhibit the rate of deposition as well as restrict it to a low
level
 Tube inserts are used to improve the heat transfer efficiency by cleaning up the existing
fouling and prevention of fouling to improve the heat transfer.

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VARIOUS TYPES OF TUBE INSERTS USED IN HEAT EXCHANGER

 SPIRELF
 TURBOTAL
 FIXOTAL

BENFITS OF TUBE INSERTS

 Sustenance of heat duty


 Reduction of fouling
 Based on the data of the problematic heat exchangers we can recommend which type of
insert would be the best suited and customize the most relevant solution.
 Reduction in fouling
 Heat transfer improvement
 Increase in run time
 Higher outlet temperature
 Fuel savings at the furnace
 Reduction in production losses and
 Savings in maintenance

Fig 2.4: SPIRELF Type inserts

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Fig 2.5: TURBOTAL Type inserts

2.6: FIXOTAL Type inserts

TYPE OF INSERTS USED

For experimentation, the inserts made from aluminum rods with 1m length,15 mm
pitch,2.5 mm depth were used.
1.Plain twisted tape
2.cut twisted tape

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Fig 2.7: Model of inserts in solid works

Fig 2.8: cut twisted tape

ALUMINIUM ROD

With copper and iron as the principle containments, achieve optimum mechanical
properties typical (tensile property) of 70-80Mpa.

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COMPOSITION OF ALUMINIUM (COMMERCIAL: CODE EC)


Table 2.1: Composition of aluminium

ALUMINIUM 99%

SILICON (0.2-0.3%)

COPPER (0.2%-.0.3%)

IRON (0.8%-0.7%)

2.6. 2 PHYSICAL PROPERTIES OF ALUMINIUM

Table 2.2: Typical physical properties for aluminium


Physical property Value
Density 2.91 kg/𝑐𝑚3

Melting point 650 °C


Thermal expansion 24 x10^-6 /K

Modulus of
Elasticity 71 GPa

Thermal
Conductivity 222 W/m.K

Electrical
Resistivity 0.0282 x10^-6 Ω .m

2.6.3 TYPICAL PROPERTIES OF ALUMINIUM


Some important properties of aluminum are explained below:

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Density of Aluminum

Aluminum has a density around one third that of steel or copper making it one of the
lightest commercially available metals. The resultant high strength to weight ratio makes it an
important structural material allowing increased payloads or fuel savings for transport
industries in particular.

Strength of Aluminum

Pure aluminum doesn’t have a high tensile strength. However, the addition of alloying
elements like manganese, silicon, copper and magnesium can increase the strength properties
of aluminum and produce an alloy with properties tailored to particular applications.

Aluminum is well suited to cold environments. It has the advantage over steel in that
its’ tensile strength increases with decreasing temperature while retaining its toughness. Steel
on the other hand becomes brittle at low temperatures.

Thermal conductivity of Aluminum


The thermal conductivity of aluminum is about three times greater than that of steel.
This makes aluminum an important material for both cooling and heating applications such as
heat-exchangers. Combined with it being non-toxic this property means aluminum is used
extensively in cooking utensils and kitchenware.

Table 2.3: Typical properties for aluminium.


Property Value
Atomic Number 13
Atomic Weight (g/mol) 26.98

Valency 3
Crystal Structure FCC
Melting Point (°C) 660.2

Boiling Point (°C) 2480


Mean Specific Heat (0-100°C) (cal/g.°C) 0.219
Thermal Conductivity (0-100°C) (cal/cms. °C) 0.57
Co-Efficient of Linear Expansion (0-100°C) (x10-6/°C) 23.5
Electrical Resistivity at 20°C (&#937.cm) 2.69

Density (g/cm3) 2.6898


Modulus of Elasticity (GPa) 68.3
Poissons Ratio 0.34

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CHAPTER-3
COMPUTATIONAL FLUID DYNAMICS
COMPUTATIONL FLUID DYNAMICS
Computational fluid dynamics (CFD) is the use of applied mathematics, physics and computational
software to visualize how a gas or liquid flows -- as well as how the gas or liquid affects objects as
it flows past. Computational fluid dynamics is based on the Navier-Stokes equations. These
equations describe how the velocity, pressure, temperature, and density of a moving fluid are related.

Computational fluid dynamics has been around since the early 20th century and many people are
familiar with it as a tool for analyzing air flow around cars and aircraft. As the cooling infrastructure
of server rooms has increased in complexity, CFD has also become a useful tool in the data center for
analyzing thermal properties and modeling air flow. CFD software requires information about the
size, content and layout of the data center. It uses this information to create a 3D mathematical model
on a grid that can be rotated and viewed from different angles. CFD modeling can help an
administrator identify hot spots and learn where cold air is being wasted or air is mixing.

Simply by changing variables, the administrator can visualize how cold air will flow through the
data center under a number of different circumstances. This knowledge can help the administrator
optimize the efficiency of an existing cooling infrastructure and predict the effectiveness of a
particular layout of IT equipment. For example, if an administrator wanted to take one rack of hard
drive storage and split the hard drives over two racks, a CFD program could simulate the change and
help the administrator understand what adjustments would be need to be made to deal with the
additional heat load before any time or money has been spent.

BACKGROUND AND HISTORY OF CFD


The fundamental basis of almost all CFD problems is the Navier–Stokes equations, which define
many single-phase (gas or liquid, but not both) fluid flows. These equations can be simplified by
removing terms describing viscous actions to yield the Euler equations. Further simplification, by
removing terms describing vorticity yields the full potential equations. Finally, for
small perturbations in subsonic and supersonic flows (not transonic or hypersonic) these equations
can be linearized to yield the linearized potential equations.
Historically, methods were first developed to solve the linearized potential equations. Two-
dimensional (2D) methods, using conformal transformations of the flow about a cylinder to the flow
about an airfoil were developed in the 1930s.
One of the earliest type of calculations resembling modern CFD are those by Lewis Fry Richardson,
in the sense that these calculations used finite differences and divided the physical space in cells.
Although they failed dramatically, these calculations, together with Richardson's book "Weather
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prediction by numerical process", set the basis for modern CFD and numerical meteorology. In fact,
early CFD calculations during the 1940s using ENIAC used methods close to those in Richardson's
1922 book.
The computer power available paced development of three-dimensional methods. Probably the first
work using computers to model fluid flow, as governed by the Navier-Stokes equations, was
performed at Los Alamos National Lab, in the T3 group. This group was led by Francis H. Harlow,
who is widely considered as one of the pioneers of CFD. From 1957 to late 1960s, this group
developed a variety of numerical methods to simulate transient two-dimensional fluid flows, such
as Particle-in-cell method (Harlow, 1957), Fluid-in-cell method (Gentry, Martin and Daly,
1966), Vorticity stream function method (Jake Fromm, 1963), and Marker-and-cell method (Harlow
and Welch, 1965). Fromm's vorticity-stream-function method for 2D, transient, incompressible flow
was the first treatment of strongly contorting incompressible flows in the world.
The next step was the Euler equations, which promised to provide more accurate solutions of
transonic flows. The methodology used by Jameson in his three-dimensional FLO57 code (1981)
was used by others to produce such programs as Lockheed's TEAM program and IAI/Analytical
Methods' MGAERO program. MGAERO is unique in being a structured Cartesian mesh code, while
most other such codes use structured body-fitted grids (with the exception of NASA's highly
successful CART3D code, Lockheed's SPLITFLOW code and Georgia Tech's NASCART-
GT). Antony Jameson also developed the three-dimensional AIRPLANE code which made use of
unstructured tetrahedral grids.
In the two-dimensional realm, Mark Drela and Michael Giles, then graduate students at MIT,
developed the ISES Euler program (actually a suite of programs) for airfoil design and analysis. This
code first became available in 1986 and has been further developed to design, analyze and optimize
single or multi-element airfoils, as the MSES program. MSES sees wide use throughout the world.
A derivative of MSES, for the design and analysis of airfoils in a cascade, is MISES, developed by
Harold "Guppy" Youngren while he was a graduate student at MIT.
The Navier–Stokes equations were the ultimate target of development. Two-dimensional codes, such
as NASA Ames' ARC2D code first emerged. A number of three-dimensional codes were developed
(ARC3D, OVERFLOW, CFL3D are three successful NASA contributions), leading to numerous
commercial packages

METHODOLOGY
In all of these approaches the same basic procedure is followed.

During preprocessing

 The geometry and physical bounds of the problem can be defined using computer
aided design (CAD). From there, data can be suitably processed (cleaned-up) and the
fluid volume (or fluid domain) is extracted.
 The volume occupied by the fluid is divided into discrete cells (the mesh). The mesh
may be uniform or non-uniform, structured or unstructured, consisting of a
combination of hexahedral, tetrahedral, prismatic, pyramidal or polyhedral elements.
 The physical modeling is defined – for example, the equations of fluid motion
+ enthalpy + radiation + species conservation

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 Boundary conditions are defined. This involves specifying the fluid behavior and properties
at all bounding surfaces of the fluid domain. For transient problems, the initial conditions are
also defined.
 The simulation is started and the equations are solved iteratively as a steady-state or
transient.
 Finally, a postprocessor is used for the analysis and visualization of the resulting solution.

Discretization methods

The stability of the selected discretization is generally established numerically rather than
analytically as with simple linear problems. Special care must also be taken to ensure that the
discretization handles discontinuous solutions gracefully. The Euler equations and Navier–Stokes
equations both admit shocks, and contact surfaces.
Some of the discretization methods being used are:

Finite volume method

The finite volume method (FVM) is a common approach used in CFD codes, as it has an advantage
in memory usage and solution speed, especially for large problems, high Reynolds number turbulent
flows, and source term dominated flows (like combustion).
In the finite volume method, the governing partial differential equations (typically the Navier-
Stokes equations, the mass and energy conservation equations, and the turbulence equations) are
recast in a conservative form, and then solved over discrete control volumes.
This discretization guarantees the conservation of fluxes through a particular control volume. The
finite volume equation yields governing equations in the form,

where Q is the vector of conserved variables, F is the vector of fluxes (see Euler
equations or Navier–Stokes equations), V is the volume of the control volume element,A and is
the surface area of the control volume element.

Finite element method

The finite element method (FEM) is used in structural analysis of solids, but is also applicable to
fluids. However, the FEM formulation requires special care to ensure a conservative solution. The
FEM formulation has been adapted for use with fluid dynamics governing equations. Although
FEM must be carefully formulated to be conservative, it is much more stable than the finite volume
approach. However, FEM can require more memory and has slower solution times than the FVM.
In this method, a weighted residual equation is formed:

where Ri is the equation residual at an element vertex I , Q is the conservation equation expressed
on an element basis, Wi is the weight factor, and Ve is the volume of the element.

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Finite difference method

The finite difference method (FDM) has historical importance and is simple to program. It is
currently only used in few specialized codes, which handle complex geometry with high accuracy
and efficiency by using embedded boundaries or overlapping grids (with the solution interpolated
across each grid)

where Q is the vector of conserved variables, and F,G , and H are the fluxes in the x ,y ,
and z directions respectively.

Turbulence models

In computational modeling of turbulent flows, one common objective is to obtain a model that can
predict quantities of interest, such as fluid velocity, for use in engineering designs of the system
being modeled. For turbulent flows, the range of length scales and complexity of phenomena
involved in turbulence make most modeling approaches prohibitively expensive; the resolution
required to resolve all scales involved in turbulence is beyond what is computationally possible.
The primary approach in such cases is to create numerical models to approximate unresolved
phenomena. This section lists some commonly used computational models for turbulent flows.
Turbulence models can be classified based on computational expense, which corresponds to the
range of scales that are modeled versus resolved (the more turbulent scales that are resolved, the
finer the resolution of the simulation, and therefore the higher the computational cost). If a majority
or all of the turbulent scales are not modeled, the computational cost is very low, but the tradeoff
comes in the form of decreased accuracy.
In addition to the wide range of length and time scales and the associated computational cost, the
governing equations of fluid dynamics contain a non-linear convection term and a non-linear and
non-local pressure gradient term. These nonlinear equations must be solved numerically with the
appropriate boundary and initial conditions.

Reynolds-averaged Navier–Stokes
Reynolds-averaged Navier-Stokes (RANS) equations are the oldest approach to turbulence
modeling. An ensemble version of the governing equations is solved, which introduces
new apparent stresses known as Reynolds stresses. This adds a second order tensor of unknowns
for which various models can provide different levels of closure. It is a common misconception that
the RANS equations do not apply to flows with a time-varying mean flow because these equations
are 'time-averaged'. In fact, statistically unsteady (or non-stationary) flows can equally be treated.
This is sometimes referred to as URANS. There is nothing inherent in Reynolds averaging to
preclude this, but the turbulence models used to close the equations are valid only as long as the
time over which these changes in the mean occur is large compared to the time scales of the
turbulent motion containing most of the energy.
RANS models can be divided into two broad approaches:

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(i) Boussinesq hypothesis

This method involves using an algebraic equation for the Reynolds stresses which include
determining the turbulent viscosity, and depending on the level of sophistication of the model,
solving transport equations for determining the turbulent kinetic energy and dissipation. Models
include k-ε (Launder and Spalding), Mixing Length Model (Prandtl), and Zero Equation Model
(Cebeci and Smith). The models available in this approach are often referred to by the number of
transport equations associated with the method. For example, the Mixing Length model is a "Zero
Equation" model because no transport equations are solved; the k-€ is a "Two Equation" model
because two transport equations (one for Ⱪ and one for €) are solved.

(ii) Reynolds stress model (RSM)

This approach attempts to actually solve transport equations for the Reynolds stresses. This means
introduction of several transport equations for all the Reynolds stresses and hence this approach is
much more costly in CPU effort

Large eddy simulation


Large eddy simulation (LES) is a technique in which the smallest scales of the flow are removed
through a filtering operation, and their effect modeled using subgrid scale models. This allows the
largest and most important scales of the turbulence to be resolved, while greatly reducing the
computational cost incurred by the smallest scales. This method requires greater computational
resources than RANS methods, but is far cheaper than DNS.
Detached eddy simulation
Detached eddy simulations (DES) is a modification of a RANS model in which the model switches
to a sub grid scale formulation in regions fine enough for LES calculations. Regions near solid
boundaries and where the turbulent length scale is less than the maximum grid dimension are
assigned the RANS mode of solution. As the turbulent length scale exceeds the grid dimension, the
regions are solved using the LES mode. Therefore, the grid resolution for DES is not as demanding
as pure LES, thereby considerably cutting down the cost of the computation. Though DES was
initially formulated for the Spalart-Allmaras model (Spalart et al., 1997), it can be implemented with
other RANS models (Strelets, 2001), by appropriately modifying the length scale which is explicitly
or implicitly involved in the RANS model. So, while Spalart-Allmaras model based DES acts as
LES with a wall model, DES based on other models (like two equation models) behave as a hybrid
RANS-LES model. Grid generation is more complicated than for a simple RANS or LES case due
to the RANS-LES switch. DES is a non-zonal approach and provides a single smooth velocity field
across the RANS and the LES regions of the solutions.
Direct numerical simulation
Direct numerical simulation (DNS) resolves the entire range of turbulent length scales. This
marginalizes the effect of models, but is extremely expensive. The computational cost is proportional
to Re3. DNS is intractable for flows with complex geometries or flow configurations.
Coherent vortex simulation
The coherent vortex simulation approach decomposes the turbulent flow field into a coherent part,
consisting of organized vertical motion, and the incoherent part, which is the random background
flow. This decomposition is done using wavelet filtering. The approach has much in common with
LES, since it uses decomposition and resolves only the filtered portion, but different in that it does

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not use a linear, low-pass filter. Instead, the filtering operation is based on wavelets, and the filter
can be adapted as the flow field evolves. Farge and Schneider tested the CVS method with two flow
configurations and showed that the coherent portion of the flow exhibited the -40/3 energy spectrum
exhibited by the total flow, and corresponded to coherent structures (vortex tubes), while the
incoherent parts of the flow composed homogeneous background noise, which exhibited no
organized structures. Goldstein and Vasilyev applied the FDV model to large eddy simulation, but
did not assume that the wavelet filter completely eliminated all coherent motions from the sub filter
scales. By employing both LES and CVS filtering, they showed that the SFS dissipation was
dominated by the SFS flow field's coherent portion.

PDF methods
Probability density function (PDF) methods for turbulence, first introduced by Lundgren, are based
on tracking the one-point PDF of the velocity, fv(v,x,t), which gives the probability of the velocity
at point x being between v and dv. This approach is analogous to the kinetic theory of gases, in
which the macroscopic properties of a gas are described by a large number of particles. PDF methods
are unique in that they can be applied in the framework of a number of different turbulence models;
the main differences occur in the form of the PDF transport equation. For example, in the context
of large eddy simulation, the PDF becomes the filtered PDF.PDF methods can also be used to
describe chemical reactions, and are particularly useful for simulating chemically reacting flows
because the chemical source term is closed and does not require a model. The PDF is commonly
tracked by using Lagrangian particle methods; when combined with large eddy simulation, this leads
to a Langerin equation for sub filter particle evolution

Vortex method
The vortex method is a grid-free technique for the simulation of turbulent flows. It uses vortices as
the computational elements, mimicking the physical structures in turbulence. Vortex methods were
developed as a grid-free methodology that would not be limited by the fundamental smoothing
effects associated with grid-based methods. To be practical, however, vortex methods require means
for rapidly computing velocities from the vortex elements – in other words they require the solution
to a particular form of the N-body problem (in which the motion of N objects is tied to their mutual
influences). A breakthrough came in the late 1980s with the development of the fast multipole
method (FMM), an algorithm by V. Rokhlin (Yale) and L. Greengard (Courant Institute). This
breakthrough paved the way to practical computation of the velocities from the vortex elements and
is the basis of successful algorithms. They are especially well-suited to simulating filamentary
motion, such as wisps of smoke, in real-time simulations such as video games, because of the fine
detail achieved using minimal computation.[52]
Software based on the vortex method offer a new means for solving tough fluid dynamics problems
with minimal user intervention.[citation needed] All that is required is specification of problem geometry
and setting of boundary and initial conditions. Among the significant advantages of this modern
technology;

 It is practically grid-free, thus eliminating numerous iterations associated with RANS and LES.
 All problems are treated identically. No modeling or calibration inputs are required.
 Time-series simulations, which are crucial for correct analysis of acoustics, are possible.
 The small scale and large scale are accurately simulated at the same time.

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Vorticity confinement method


The vorticity confinement (VC) method is an Eulerian technique used in the simulation of turbulent
wakes. It uses a solitary-wave like approach to produce a stable solution with no numerical
spreading. VC can capture the small-scale features to within as few as 2 grid cells. Within these
features, a nonlinear difference equation is solved as opposed to the finite difference equation. VC
is similar to shock capturing methods, where conservation laws are satisfied, so that the essential
integral quantities are accurately computed.
Linear eddy model
The Linear eddy model is a technique used to simulate the convective mixing that takes place in
turbulent flow. Specifically, it provides a mathematical way to describe the interactions of a scalar
variable within the vector flow field. It is primarily used in one-dimensional representations of
turbulent flow, since it can be applied across a wide range of length scales and Reynolds numbers.
This model is generally used as a building block for more complicated flow representations, as it
provides high resolution predictions that

psilon models
The K-epsilon model is one of the most common turbulence models, although it just doesn't perform
well in cases of large adverse pressure gradients (Reference 4). It is a two equation model, that
means, it includes two extra transport equations to represent the turbulent properties of the flow.
This allows a two-equation model to account for history effects like convection and diffusion of
turbulent energy.
The first transported variable is turbulent kinetic energy, . The second transported variable in this
case is the turbulent dissipation, . It is the variable that determines the scale of the turbulence,
whereas the first variable, , determines the energy in the turbulence.
There are two major formulations of K-epsilon models (see References 2 and 3). That of Launder
and Sharma is typically called the "Standard" K-epsilon Model. The original impetus for the K-
epsilon model was to improve the mixing-length model, as well as to find an alternative to
algebraically prescribing turbulent length scales in moderate to high complexity flows.
As described in Reference 1, the K-epsilon model has been shown to be useful for free-shear layer
flows with relatively small pressure gradients. Similarly, for wall-bounded and internal flows, the
model gives good results only in cases where mean pressure gradients are small; accuracy has been
shown experimentally to be reduced for flows containing large adverse pressure gradients. One
might infer then, that the K-epsilon model would be an inappropriate choice for problems such as
inlets and compressors.
To calculate boundary conditions for these models see turbulence free-stream boundary conditions.

Usual k-epsilon models are

1. Standard k-epsilon model


2. Realizable k-epsilon model
3. RNG k-epsilon model

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APPLICATIONS OF CFD

 Aerospace
 Architecture
 Automotive
 Civil engineering
 Movies and computer graphics
 Nuclear Thermal Hydraulics
 Process industry
 Semiconductor industry
 Steel industry
 Turbomachinery
 Glass industry
 Water and Wastewater

ADVANTAGES OF CFD

 A great time reduction and cost reduction in new designs


 There is a possibility to analyze different problem whose experiments are very difficult and
dangerous
 The CFD techniques offer the capacity of studying system under conditions over its limits.
 The level of detail is practically unlimited.
 The product gets added value. The possibility to generate different graph permits to understand
the features of the result. This encourages buying a new product.
 Accuracy in the result is doubted i.e. in certain situations we will not obtain successful result.
 It is necessary to simplify mathematically the phenomenon to facilitate calculus. If the
simplification has been good the result will be more accurate.
 There are several incomplete models to describe the turbulence, multiphase phenomenon, and
other difficult problems.
 Untrained user of CFD has the tendency to believe that the output of the pc is always true

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CHAPTER-4
MODELLING AND CFD ANALYSIS OF DOUBLE
PIPE HEAT EXCHANGER

MODELLING OF FLUID DOMAIN

A double pipe heat exchanger is modelled using solid works 2016 modelling software.
The procedure follows as: -

Step 1

Selecting top plane and using required dimensions a solid inner shell tube is designed using extrude
command as shown below.

Fig 4.1: Shell design

Step 2
Now for this inner tube a cavity is required for the insertion of smaller tubes, for this two cavities
are made using extrude cut command which is available in solid works as shown below.

Fig 4.2: Final shell design with cavity

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Step 3
Inner u-tubes of required diameters from which the cold fluid flows is generated using sweep
command

Fig 4.3: U-tube design

Step 4
Final fluid domain of double pipe heat exchanger is shown below

Fig 4.4: Final heat exchanger design

HEAT EXCHANGER WITH INSERTS

Fig 4.5: heat exchanger with inserts

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MODELLING OF INSERTS

Step 1
A rectangle of h/d ratio is created and it should be swept of required length as shown below

Fig 4.6: Rectangle before twist


Step 2
The above shown rectangle swept body is twisted with a calculated angle as shown

Fig 4.7: After twisting

Step 3
For cut twisted tape same procedure is followed with including a cut profile on the tape as shown
in below figure

Fig 4.8: Cut twist tape

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CFD ANALYSYS IN ANSYS WORKBENCH(FLUENT)

Step 1 - STARTING FLUENT

Ansys workbench is opened and under Analysis system tree FLUENT is selected and dragged to
right side of free space to open FLUENT modular as shown below.

Fig 4.9: Starting of fluent

Step 2 - IMPORTING GEOMETRY

On fluid flow(fluent) tree geometry should be imported by right clicking Geometry-import-browse


as shown below

Fig 4.10: Model importing process

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Step 3 - CHANGING DOMIAN STATE

After importing geometry, required changes (creating solid domains to fluid) to it have to be
performed in design module as shown below

Fig 4.11: Changing domain to fluid

Step 4 - NAMED SELECTIONS

After updating the geometry from design modular to meshing section, named selections should be
created to identify boundary conditions in fluent solver. This is shown below

Fig 4.12: Creating named selections

Fig 4.13: Named selection

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Step 5 – MESHING

The main part of CFD analysis is MESHING which is carried out after named selections. In this
project a unstructured tetrahedron mesh is performed. The procedure is shown below

Fig 4.14: Choosing meshing method

Fig 4.15: Tetrahedron mesh of heat exchanger

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Fig 4.16: Meshed model of plain twist tape

Fig 4.17 Meshed model of twisted tape

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Step 6 - BOUNDARY CONDITIONS AND SOLVING

After meshing the geometry, mesh file should be imported to setup module by double-clicking setup
under fluid flow tree. The solving type have to set as pressure based system in setup- general-
pressure based as shown below.

Fig 4.18: Starting of solver

Since the Reynolds number is greater than 2000 the model has to be set has turbulence model k-
epsilon-standard wall treatment. Since the problem is based on heat transfer energy equation should
be activated as shown below figure.

Fig 4.19: Choosing turbulence model

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Material selection has to be done from ansys fluent material data base. The fluid in this problem is
water where as solid materials are copper and steel for tubes and shell respectively. The below figure
gives the selection process.

Fig 4.20: Material selection

In cell-zone condition everything is set to be fluid because in tubes and shell water is the working
Fluid. By double clicking the desired part shown in cell zone we can change the fluid to water.

Fig 4.21: Cell zone condition

Fig 4.22: Changing fluid domain to water

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In boundary conditions, for cold inlets say 3lpm(0.05kg/s) mass flow rate is given and this flow rate
is varied for different cases say (5lpm ,7lpm, 9lpm, 11lpm, 13lpm, 15lpm,) with 300c c inlet
temperature and for hot inlet 6lpm (0.1 kg/s) constant mass flow rate is maintained with 600c inlet
temperature. Outlets of the tube and shell is selected as pressure-outlet. The interface between shell
and tube is changed to coupled wall for conduction and convection through walls. For walls of shell
and tube 0.003 and 0.002 thickness and their corresponding materials are selected. The boundary
condition window is shown below.

Fig 4.23: Massflow rate condition

Fig 4.24: Wall condition

Fig 4.25: Coupled condition

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The solution method is set to simple with pressure, momentum, turbulences energies with second
order. Which is shown in below figure.

Fig 4.26: Changing solution methods

To observe the temperature behavior while calculating solution a monitor plot is set as shown in
below figure.

Fig 4.27: Creating surface monitor

For calculating the solution ansys assumes some initial guesses which is done by solution
initialization. For convince and better solution convergence criteria we use hybrid initialization as
shown below.

Fig 4.28: Initialization of solution

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Final step of solution setup is to mention the number of iterations for solution convergence after this
step fluent will start to calculate at every iteration and checks is convergence criteria. This window
looks as shown below.

Fig 4.29: Giving number of iterations

When calculation starts this are the residuals equations which are moving for convergence.

Fig 4.30: Residual variations

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Step 7- POSTPROCESSING RESULTS AND CONTOURS

When solution converges, or reaches to constant residual criteria, the final step is to extract results,
visualize flow, plot contours and plotting graphs all these are carried out in ansys fluent
postprocessing also known as Results. To start postprocessing double click on the results under fluid
flow tree. The interface of postprocessing window is shown below

Fig 4.31: Postprocessing window

To visualize the total volume output of any variable, say temperature volume rendering is used. To
enable it double click on the option volume rendering on top of the window and select temperature
as variable and click ok. This is shown in below figure.

Fig 4.32: Volume rendering

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To visualize any variable intensity in between the models or at any section contours are most
advanced option. To activate contours one has to select an appropriate plane i.e. section where one
want to study the variable intensity. After selection of plane select contour option which is available
on top of the tool bar and select required variable and the plane is selected as location. Below figure
gives the clear idea.

Fig 4.33: Selection of plane

Fig 4.34: Selection of temperature contour

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CMRCET 43
MODELLING AND ANALYSIS OF DOUBLE PIPE HEAT EXCHANGER

To visualize the actual flow and its turbulence stream lines are used in postprocessing. To activate
this, click on stream line and select the inlets and outlets to give the flow direction and click apply.
This appears as shown below.

Fig 4.35: Streamlines

All the procedure is carried out in same way for the heat exchanger with twisted tape insert and cut
twist tape inserts.

Department of Mechanical Engineering


CMRCET 44
MODELLING AND ANALYSIS OF DOUBLE PIPE HEAT EXCHANGER

CHAPTER 5

EXPERIMENTAL CALCULATIONS AND PLOTS

EXPERIMENTAL SETUP

The experimental setup consists of a test section, flow meters, chiller, hot fluid tank, cold fluid tank,
pumps, bypass valve arrangement and u-tube manometer. The test section consists of a U-bend
double pipe heat exchanger; the inner tube copper and it has an inner diameter (ID) of 0.017m, and
the annulus tube is made of mild steel with an OD of 0.019 m. The total length of the inner tube is
1.5m and the bend is equidistant from both ends at a distance of 120mm; with radius of 60 mm. The
outside surface of the annulus tube is wounded with asbestos rope insulation to minimize the heat
loss from the test section to atmosphere. The inner tube is concentric to the annulus tube and fully
enclosed by it. The hot fluid is pumped through the annular region and the water/nanofluid flows
through the inner tube by using a pump, and are controlled with by-pass valves, the two flow meters
are used to measure the mass flow rate of cold fluid and hot fluid. Throughout the experiments the
mass flow rate of hot fluid through annulus is kept constant (6 LPM) and the working fluid mass
flow rate is 3LPM, 7LPM, 11LPM, 15LPM. The test section consists of inlet pipe, bend and outlet
pipe.

Fig 5.1: Experimental setup

Department of Mechanical Engineering


CMRCET 45
MODELLING AND ANALYSIS OF DOUBLE PIPE HEAT EXCHANGER

EXPERIMENTAL PROCEDURE

1. It is a counter flow double pipe heat exchanger. Ensure that lagging was provided on
the outer side of outer pipe to reduce the heat loss.
2. The tank contains fluid (water) which is heated with the help of attached heater with hot
water tank. The hot fluid from the hot water tank was going to the annulus side inlet
through pump. Pump was providing between hot water tank and flow meter. Outlet of
hot fluid is collected in hot water tank.
3. Another fluid (cold water) passing to inlet of inner pipe in counter direction through
flow meters. And outlet of cold water is collected in cold water tank.
4. Temperature of both pipes at the inlet as well as the outlet is measured with the Help of
thermocouple.
5. Flow meters at inlet of both pipe measure flow rates. Pressure of fluid in inner pipe can
be measured with the help of manometer.
6. Experiments were performed with various mass flow rates of cold water i.e. are 3LPM,
7LPM, 11LMP, 15LPM and at fixed flow rate i.e. 6LPM of hot water entering the test
section. The hot water flow rate is constant.
7. Before any data were recorded, the system was allowed to approach the steady state.
The flow rates of the water are controlled by adjusting the valve.
8. Once the hot fluid reaches steady state of 60C, readings of thermocouples of cold fluid
inlet were recorded.
9. After that start the both hot fluid pump and cold fluid pump for 5minutes and noted
down the outlet readings of cold fluid and hot fluid.
10. The uncertainties of measurements data and the relevant parameters obtained from the
data reduction process are calculated.
11. Readings are being taken for following types of inserts and noted in the observation
table with 1. Without any insert (plain tube) 2. With twisted tape insert 3. With cut
twisted tape insert.
12. The heat transfer coefficients, Nusselt numbers, Friction factors are calculated; the
surface area related to the bend region is relatively small compared to the surface areas
of the inner and outer pipes. Therefore, the heat transfer in the bend region can be
neglected with no significant loss of accuracy.

SPECIFICATIOS OF HEAT EXCHANGER


The experimental study is done in a double pipe heat exchanger having the
specifications as listed below: -
Inner pipe ID = 17mm
Outer pipe OD =19mm
Material of construction= Copper
Heat transfer length= 4*1.4 m
Water at room temperature was allowed to flow through the inner pipe while hot water (set
point 60°C) flowed through the annulus side in the counter current direction.

Department of Mechanical Engineering


CMRCET 46
MODELLING AND ANALYSIS OF DOUBLE PIPE HEAT EXCHANGER

FORMULAE USED

1. Heat transferred to the cold water in the test section,

QC=mccpc(Tco -Tci)
2. The heat transfer rate from the hot water in the annulus side

Qh=mhcph(Thi -Tho)

3. For fluid flows in a U-tube heat exchanger, the average heat transfer rate is calculated
from

𝑄𝑐+𝑄ℎ
Qavg =
2

4. Inner heat transfer coefficient is calculated from

Qavg =Aihi∆TLMTD

Where,
Ai= 𝜋dil
(𝑇ℎ𝑖−𝑇𝑐𝑜)−(𝑇ℎ𝑜−𝑇𝑐𝑖)
∆TLMTD = 𝑇 −𝑇𝑐𝑜
ln( ℎ𝑖 )
𝑇ℎ𝑜−𝑇𝑐𝑖

5. The average Nusselt number based on the inner diameter of the tube, was then evaluated
by

Nu=

6. The Reynolds number is based on the flow rate at the inlet of the tube

𝑣∗𝑑𝑖
Re =
𝜗

Where 𝜗 is the kinematic viscosity of the working fluid.

7. Friction factor, f can be calculated from

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CMRCET 47
MODELLING AND ANALYSIS OF DOUBLE PIPE HEAT EXCHANGER

∆𝑝
f= 𝑙 2
( )∗𝜌∗( 𝑣 )
𝑑𝑖 2

Where is, the pressure drop across the test section, is the density of working fluid, is the
inner diameter of tube, v is the velocity of working fluid, and l is the length of tube.

REYNOLDS NUMBER CALCULATIONS

For 3 lpm




V=0.2208 m/s

 The Reynolds number is based on the flow rate at the inlet of the tube

𝑣∗𝑑𝑖
Re =
𝜗
0.221∗0.017
Re =
0.740∗10−6

Re=5077.02
Similarly, Reynolds number can be calculated for 5lpm, 7lpm, 9lpm, 11lpm, 13lpm, 15lpm
are below.
Table 5.1: Reynolds number table

SNO Reynolds
number
1 5077.02
2 8133.33
3 11187.66
4 14285.17
5 17299.37
6 20297.87
7 23393.52

Department of Mechanical Engineering


CMRCET 48
MODELLING AND ANALYSIS OF DOUBLE PIPE HEAT EXCHANGER

PLAIN TUBE EXPERIMENTAL CALCULATIONS

Case1-3 lpm

Tic=30oc Toc=39oc Tmean=34.5 Thi=60oc Tho=55oc

1. Heat transferred to the cold water in the test section,

Qc=mccpc(Tco -Tci)
Qc=0.05*4178*(39-30)
Qc=1880.1 j/s

2. The heat transfer rate from the hot water in the annulus side

Qh=mhcph(Thi -Tho)

Qh=0.1*4178*(60-55)
Qh=2089 j/s

𝑄𝑐+𝑄ℎ
Qavg =
2
Qavg=1984.55 j/s

3. Inner heat transfer coefficient is calculated from

Qavg =Aihi∆TLMTD where


Ai= 𝜋dil
(𝑇ℎ𝑖−𝑇𝑐𝑜)−(𝑇ℎ𝑜−𝑇𝑐𝑖)
∆TLMTD = 𝑇 −𝑇
ln( ℎ𝑖 𝑐𝑜)
𝑇ℎ𝑜−𝑇𝑐𝑖
(60−39)−(55−30)
∆TLMTD= 60−39
ln( )
55−30
∆TLMTD=22.94

hi=1157.241 w/m2co

Nu=
Nu=31.75128

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CMRCET 49
MODELLING AND ANALYSIS OF DOUBLE PIPE HEAT EXCHANGER

4. Friction factor calculation

∆𝑝=49 pascal
∆𝑝
f= 𝑙 2
( )∗𝜌∗( 𝑣 )
𝑑𝑖 2
f= 0.024487

PLAIN TUBE WITH TWISTED TAPE INSERT CALCULATION

Tic=30oc Toc=42.5oc Tmean=36.25oc Thi=60oc Tho=54oc

1. Heat transferred to the cold water in the test section,

Qc=mccpc(Tco -Tci)
Qc=0.05*4178*(42.5-30)
Qc=2611.25 j/s

2. The heat transfer rate from the hot water in the annulus side

Qh=mhcph(Thi -Tho)

Qh=0.1*4178*(60-54)
Qh=2506.8 j/s

𝑄𝑐+𝑄ℎ
Qavg =
2
Qavg=2559.025 j/s

3. Inner heat transfer coefficient is calculated from

Qavg =Aihi∆TLMTD where


Ai= 𝜋dil
(𝑇ℎ𝑖−𝑇𝑐𝑜)−(𝑇ℎ𝑜−𝑇𝑐𝑖)
∆TLMTD = 𝑇 −𝑇
ln( ℎ𝑖 𝑐𝑜)
𝑇ℎ𝑜−𝑇𝑐𝑖
(60−42.5)−(54−30)
∆TLMTD= 60−42.5
ln( )
54−30
∆TLMTD=20.59

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CMRCET 50
MODELLING AND ANALYSIS OF DOUBLE PIPE HEAT EXCHANGER

hi=166.35 w/m2co

Nu=

Nu=45.43

4. Friction factor calculation

∆𝑝=101pascal
∆𝑝
f= 𝑙 2
( )∗𝜌∗( 𝑣 )
𝑑𝑖 2
f= 0.050474

PLAIN TUBE WITH CUT TWISTED TAPE INSERT

Tic=30oc Toc=43oc Tmean=36.5oc Thi=60oc Tho=53.5oc

1. Heat transferred to the cold water in the test section,

Qc=mccpc(Tco -Tci)
Qc=0.05*4178*(43-30)
Qc=2715.7 j/s

2. The heat transfer rate from the hot water in the annulus side

Qh=mhcph(Thi -Tho)

Qh=0.1*4178*(60-53.5)
Qh=2506.8 j/s
2715.7
𝑄𝑐+𝑄ℎ
Qavg =
2
Qavg=2715.7j/s

3. Inner heat transfer coefficient is calculated from

Qavg =Aihi∆TLMTD where

Department of Mechanical Engineering


CMRCET 51
MODELLING AND ANALYSIS OF DOUBLE PIPE HEAT EXCHANGER

Ai= 𝜋dil
(𝑇ℎ𝑖−𝑇𝑐𝑜)−(𝑇ℎ𝑜−𝑇𝑐𝑖)
∆TLMTD = 𝑇 −𝑇𝑐𝑜
ln( ℎ𝑖 )
𝑇ℎ𝑜−𝑇𝑐𝑖
(60−43)−(53.5−30)
∆TLMTD=
ln( 60−43 )
53.5−30
∆TLMTD=20.07

hi=1810.04 w/m2co

Nu=
Nu=49.41

4. Friction factor calculation

∆𝑝=106 pascal
∆𝑝
f= 𝑙 2
( )∗𝜌∗( 𝑣 )
𝑑𝑖 2
f= 0.052973

similarly, all other calculations can be done for plain tube, plain tube with twisted tape insert and
plain tube with cut twisted tape insert for 5lpm, 7lpm, 9lpm, 11lpm, 13lpm, 15lpm. The following
table gives the calculated values of nusselt number and heat transfer coefficient for all cases

NUSSELT NUMBER EXPERIMENTAL

Table 5.2: Nusselt number table for experiment

SNO PLAIN TUBE TWISTED TAPE INSERT CUT TWISTED TAPE INSERT
1 31.75 45.43 49.41
2 36.89 50.47 54.87
3 39.09 52.76 57.64
4 43.74 59.23 59.23
5 45.13 64.63 65.83
6 47.54 64.67 67.15
7 49.04 69.99 72.57

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MODELLING AND ANALYSIS OF DOUBLE PIPE HEAT EXCHANGER

HEAT TRANSFER COFFECIENT EXPERIMENTAL (W/m2k)

Table 5.3: Heat transfer coefficient table for experiment

SNO PLAIN TUBE TWISTED TAPE INSERT CUT TWISTED TAPE INSERT
1 1157.24 1663.35 1810.04
2 1340.73 1839.64 2001.50
3 1417.96 1918.63 2097.39
4 1585.78 2151.45 2151.45
5 1635.31 2345.92 2387.92
6 1721.23 2344.34 2434.01
7 1774.42 2535.89 2629.17

FRICTION FACTOR EXPERIMENTAL

Table 5.4: Friction factor table for experiment

SNO PLAIN TUBE TWISTED TAPE INSERT CUT TWISTED TAPE INSERT
1 0.0244 0.0504 0.0529
2 0.0191 0.0317 0.0329
3 0.0158 0.0242 0.0246
4 0.0161 0.0228 0.0230
5 0.0151 0.0210 0.0212
6 0.0142 0.0198 0.0200
7 0.0146 0.0198 0.0200

Department of Mechanical Engineering


CMRCET 53
MODELLING AND ANALYSIS OF DOUBLE PIPE HEAT EXCHANGER

COMPARISION PLOTS OF EXPERIMENTAL DATA (NU)


1. PLAIN TUBE VS TWISTED TAPE NUSSELT NUMBER COMPARISION

Graph 5.1: Experimental comparison of plain tube and twisted tape

From the above graph, we can say Nusselt number has consistently increased by inserting twisted
tape which clearly indicates the enhancement of heat transfer.

2. PLAIN TUBE VS CUT TWISTED TAPE NUSSELT NUMBER COMPARISION

Graph 5.2: Experimental comparison of plain tube and cut twisted tape

From the above graph, Nusselt number has increased after placing cut twisted tape in the hollow
pipe compared to plain tube.

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CMRCET 54
MODELLING AND ANALYSIS OF DOUBLE PIPE HEAT EXCHANGER

3. TWISTED TAPE VS CUT TWISTED TAPE COMPARISION

Graph 5.3: Experimental comparison of twisted tape and cut twisted tape

From the above graph, the Nusselt number has further increased after replacing plain twisted tape
with cut twisted tape comparatively.

4. COMPARISION BETWEEN ALL CASES

Graph 5.4: Experiment comparison of all cases

The above graph shows the comparison of all three cases by indicating Nusselt number and
Reynold’s number in which the enhancement of heat transfer can be observed clearly.

Department of Mechanical Engineering


CMRCET 55
MODELLING AND ANALYSIS OF DOUBLE PIPE HEAT EXCHANGER

COMPARISION PLOTS OF EXPERIMENTAL DATA (friction factor)


1. PLAIN TUBE VS TWISTED TAPE

Graph 5.5: Friction factor comparison of plain tube and twisted tape.

From the above graph, we can say Friction factor has consistently increased by inserting twisted
tape which clearly indicates the enhancement of heat transfer.

2. PLAIN TUBE VS CUT TWISTED TAPE

Graph 5.6: Friction factor comparison of plain tube and cut twisted tape.

From the above graph, Friction factor has increased after placing cut twisted tape in the hollow pipe
compared to plain tube.

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CMRCET 56
MODELLING AND ANALYSIS OF DOUBLE PIPE HEAT EXCHANGER

3. TWISTED TAPE VS CUT TWISTED TAPE

Graph 5.7: Friction factor comparison of twisted tape and cut twisted tape.

From the above graph, the Friction factor has further increased after replacing plain twisted tape
with cut twisted tape comparatively.

4. COMPARISON BETWEEN ALL CASES

Graph 5.8: Comparison of all three cases (friction factor).

The above graph shows the comparison of all three cases by indicating Friction factor and
Reynold’s number in which the enhancement of heat transfer can be observed clearly.

Department of Mechanical Engineering


CMRCET 57
MODELLING AND ANALYSIS OF DOUBLE PIPE HEAT EXCHANGER

HEAT TRANSFER COFFECIENT PLOTS (EXPERIMENTAL DATA)


1. PLAIN TUBE VS TWISTED TAPE

Graph 5.9: heat transfer coefficient comparison of plain tube and twisted tape.

From the above graph, we can say Heat Transfer Coefficient has consistently increased by inserting
twisted tape which clearly indicates the enhancement of heat transfer.

2. PLAIN TUBE VS CUT TWISTED TAPE

Graph 5.10: heat transfer coefficient comparison of plain tube and cut twisted tape.
From the above graph, Heat Transfer Coefficient has increased after placing cut twisted tape in the
hollow pipe compared to plain tube.

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CMRCET 58
MODELLING AND ANALYSIS OF DOUBLE PIPE HEAT EXCHANGER

3. TWISTED TAPE VS CUT TWISTED TAPE

Graph 5.11: heat transfer coefficient comparison of twisted tape and cut twisted tape.
From the above graph, the Heat Transfer coefficient has further increased after replacing plain
twisted tape with cut twisted tape comparatively.

4. COMPARISION OF ALL CASES

Graph 5.12: Comparison of all cases


The above graph shows the comparison of all three cases by indicating Heat Transfer Coefficient
and Mass flow rate in which the enhancement of heat transfer can be observed clearly.

Department of Mechanical Engineering


CMRCET 59
MODELLING AND ANALYSIS OF DOUBLE PIPE HEAT EXCHANGER

CHAPTER 6

CFD CALCULATIONS AND PLOTS

CFD CONTOURS AND CALCULATIONS FOR PLAIN TUBE


CASE1-3 lpm

TEMPERATURE CONTOUR

Fig 6.1: Temperature contour

From the above contour, cold fluid is gaining heat and hot fluid is losing heat by this we can say
that Heat Transfer is taking place.

PRESSURE CONTOUR

Fig 6.2: Pressure contour

The above figure indicates the pressure drop in both tube side and shell side.

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CMRCET 60
MODELLING AND ANALYSIS OF DOUBLE PIPE HEAT EXCHANGER

VELOCITY CONTOUR

Fig 6.3: Velocity contour

The velocity is constant throughout the system except at the bends.

TURBULANCE CONTOUR

Fig 6.4: Turbulence Contour

Since it is plain tube the above figure shows high turbulence at the beginning stage and at the bends,
but at the middle of the pipe the turbulence is negligible comparatively.

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CMRCET 61
MODELLING AND ANALYSIS OF DOUBLE PIPE HEAT EXCHANGER

CALCULATIONS FOR 3 lpm

Tic=30oc Toc=40.39oc Tmean=35.19oc Thi=60oc Tho=54.81oc

1. Heat transferred to the cold water in the test section,

Qc=mccpc(Tco -Tci)
Qc=0.05*4178*(40.39-30)
Qc=2170.47 j/s

2.The heat transfer rate from the hot water in the annulus side

Qh=mhcph(Thi -Tho)

Qh=0.1*4178*(60-54.81)
Qh=2168.38 j/s
𝑄𝑐+𝑄ℎ
Qavg =
2
Qavg=2169.42j/s

3.Inner heat transfer coefficient is calculated from

Qavg =Aihi∆TLMTD where


Ai= 𝜋dil
(𝑇ℎ𝑖−𝑇𝑐𝑜)−(𝑇ℎ𝑜−𝑇𝑐𝑖)
∆TLMTD = 𝑇 −𝑇
ln( ℎ𝑖 𝑐𝑜)
𝑇ℎ𝑜−𝑇𝑐𝑖
(60−40.39)−(54.81−30)
∆TLMTD= 60−40.39
ln( )
54.81−30

∆TLMTD=22.11

hi=1312.28 w/m2co

Nu=
Nu=35.94

Department of Mechanical Engineering


CMRCET 62
MODELLING AND ANALYSIS OF DOUBLE PIPE HEAT EXCHANGER

4.Friction factor calculation


∆𝑝=45.60 pascal
∆𝑝
f= 𝑙 2
( )∗𝜌∗( 𝑣 )
𝑑𝑖 2
f= 0.0227

CFD CONTOURS AND CALCULATIONS FOR TWISTED TAPE


INSERT-3 lpm
TEMPERATURE CONTOUR

Fig 6.5: Temperature contour

From the above contour, cold fluid is gaining heat and hot fluid is losing heat by this we can say
that Heat Transfer is taking place more than the plain tube.

PRESSURE CONTOUR

Fig 6.6: Pressure contour


The above figure indicates the high pressure drop in both tube side and shell side because of twisted
tape inserts.

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CMRCET 63
MODELLING AND ANALYSIS OF DOUBLE PIPE HEAT EXCHANGER

VELOCITY CONTOUR

Fig 6.7: Velocity contour

The velocity is fluctuating throughout the system.

TURBULANCE CONTOUR

Fig 6.8: Turbulence contour

From the above turbulence contour it is clear that turbulence created is high compared to plan tube
contour which is the indication of enhancement of Heat Transfer.

Department of Mechanical Engineering


CMRCET 64
MODELLING AND ANALYSIS OF DOUBLE PIPE HEAT EXCHANGER

CALCULATIONS FOR 3 lpm

Tic=30oc Toc=43.34oc Tmean=36.67oc Thi=60oc Tho=53.34oc

1. Heat transferred to the cold water in the test section,

Qc=mccpc(Tco -Tci)
Qc=0.05*4178*(43.34-30)
Qc=2786.72 j/s

2.The heat transfer rate from the hot water in the annulus side

Qh=mhcph(Thi -Tho)

Qh=0.1*4178*(60-53.34)
Qh=2784.54 j/s
𝑄𝑐+𝑄ℎ
Qavg =
2
Qavg=2784.63j/s

3.Inner heat transfer coefficient is calculated from

Qavg =Aihi∆TLMTD where


Ai= 𝜋dil
(𝑇ℎ𝑖−𝑇𝑐𝑜)−(𝑇ℎ𝑜−𝑇𝑐𝑖)
∆TLMTD = 𝑇 −𝑇
ln( ℎ𝑖 𝑐𝑜)
𝑇ℎ𝑜−𝑇𝑐𝑖
(60−43.34)−(53.34−30)
∆TLMTD= 60−43.34
ln( )
53.34−30

∆TLMTD=19.81

hi=1879.99w/m2co

Nu=
Nu=51.30

Department of Mechanical Engineering


CMRCET 65
MODELLING AND ANALYSIS OF DOUBLE PIPE HEAT EXCHANGER

4.Friction factor calculation


∆𝑝=91.42pascal
∆𝑝
f= 𝑙 2
( )∗𝜌∗( 𝑣 )
𝑑𝑖 2
f= 0.0456

CFD CONTOURS AND CALCULATIONS FOR CUT TWISTED TAPE


INSERT-3 lpm
TEMPERATURE CONTOUR

Fig 6.9: Temperature contour

From the above contour, cold fluid is gaining heat and hot fluid is losing heat by this we can say
that Heat Transfer is taking place more than the twisted tape insert.

PRESSURE CONTOUR

Fig 6.10: Pressure contour

The above figure indicates the comparatively more pressure drop in both tube side and shell side
because of cut twisted tape inserts.

Department of Mechanical Engineering


CMRCET 66
MODELLING AND ANALYSIS OF DOUBLE PIPE HEAT EXCHANGER

VELOCITY CONTOUR

Fig 6.11: Velocity contour

The velocity is fluctuating throughout the system and more at the cut section.

TURBULANCE CONTOUR

Fig 6.12: Exaggerated figure of turbulence

From the above figure we can observe the turbulence created at the cut sections, which is slightly
greater compared to twisted tape and largely greater when compared to plain tube. Above is the
proof for heat transfer enhancement with cut twisted tape inserts.

Department of Mechanical Engineering


CMRCET 67
MODELLING AND ANALYSIS OF DOUBLE PIPE HEAT EXCHANGER

CALCULATIONS FOR 3 lpm

Tic=30oc Toc=43.88oc Tmean=36.94oc Thi=60oc Tho=53.09oc

1. Heat transferred to the cold water in the test section,

Qc=mccpc(Tco -Tci)
Qc=0.05*4178*(43.88-30)
Qc=2899.53 j/s

2.The heat transfer rate from the hot water in the annulus side

Qh=mhcph(Thi -Tho)

Qh=0.1*4178*(60-53.09)
Qh=2886.99 j/s
𝑄𝑐+𝑄ℎ
Qavg =
2
Qavg=2893.26j/s

3.Inner heat transfer coefficient is calculated from

Qavg =Aihi∆TLMTD where


Ai= 𝜋dil
(𝑇ℎ𝑖−𝑇𝑐𝑜)−(𝑇ℎ𝑜−𝑇𝑐𝑖)
∆TLMTD = 𝑇 −𝑇
ln( ℎ𝑖 𝑐𝑜)
𝑇ℎ𝑜−𝑇𝑐𝑖
(60−43.88)−(53.09−30)
∆TLMTD= 60−43.88
ln( )
53.09−30

∆TLMTD=19.40

hi=1994.61w/m2co

Nu=
Nu=54.40

Department of Mechanical Engineering


CMRCET 68
MODELLING AND ANALYSIS OF DOUBLE PIPE HEAT EXCHANGER

4.Friction factor calculation


∆𝑝=94.61 pascal
∆𝑝
f= 𝑙 2
( )∗𝜌∗( 𝑣 )
𝑑𝑖 2
f= 0.04728

in the same way, all calculations can be done for plain tube, twisted tape insert and cut twisted tape
insert for 5lpm, 7lpm, 9lpm. 11lpm, 13lpm, 15lpm. The following table shows the calculated values
of all cases.

NUSSELT NUMBER

Table 6.1: Nusselt number of CFD

SL NO NU PLAIN TUBE NU PLAIN TWIST NU CUT TWIST


TAPE TAPE
1 35.94 51.30 54.40
2 40.84 56.73 59.48
3 44.92 61.50 64.52
4 46.37 63.37 66.28
5 48.45 66.45 69.25
6 50.30 67.07 71.99
7 50.86 70.42 74.02

HEAT TRANSFER w/m2k

Table 6.2: Heat Transfer Coefficient of CFD

SL NO HTC PLAIN TUBE HTC PLAIN HTC CUT TWIST


TWIST TAPE TAPE
w/m2k w/m2k w/m2k
1 1312.28 1839.99 1994.61
2 1486.31 2069.74 2170.96
3 1631.62 2238.43 2348.95
4 1681.93 2301.96 2408.07
5 1755.96 2411.48 2513.63
6 1821.92 2432.12 2610.73
7 1840.96 2551.92 2683.80

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CMRCET 69
MODELLING AND ANALYSIS OF DOUBLE PIPE HEAT EXCHANGER

FRICTION FACTOR

Table 6.3: Friction Factor of CFD

SNO Friction factor-plain Friction factor- Friction factor-cut


tube twisted twisted
1 0.0244 0.0504 0.0529
2 0.0191 0.0317 0.0329
3 0.0158 0.0242 0.0246
4 0.0161 0.0228 0.0230
5 0.0151 0.0210 0.0212
6 0.0142 0.0198 0.0200
7 0.0146 0.0198 0.0200

COMPARISION PLOTS OF CFD DATA (NUSSELT NUMBER)


1. PLAIN TUBE VS TWISTED TAPE

Graph 6.1: CFD comparison of plain tube and twisted tape.

From the above graph, we can say Nusselt number has consistently increased by inserting twisted
tape which clearly indicates the enhancement of heat transfer.

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MODELLING AND ANALYSIS OF DOUBLE PIPE HEAT EXCHANGER

2. PLAIN TUBE VS CUT TWISTED TAPE

Graph 6.2: CFD comparison of plain tube and cut twisted tape.

From the above graph, Nusselt number has increased after placing cut twisted tape in the hollow
pipe compared to plain tube.

3. TWISTED TAPE VS CUT TWISTED TAPE

Graph 6.3: CFD comparison of twisted tape and cut twisted tape.

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MODELLING AND ANALYSIS OF DOUBLE PIPE HEAT EXCHANGER

From the above graph, the Nusselt number has further increased after replacing plain twisted tape
with cut twisted tape comparatively.
4. COMPARISION OF ALL CASES

Graph 6.4: Comparison of all three cases

The above graph shows the comparison of all three cases by indicating Nusselt number and
Reynold’s number in which the enhancement of heat transfer can be observed clearly.

COMPARISION PLOTS OF CFD DATA (FRICTION FACTOR)


1. PLAIN TUBE VS TWISTED TAPE

Graph 6.5: CFD comparison of plain tube and twisted tape (friction factor)

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MODELLING AND ANALYSIS OF DOUBLE PIPE HEAT EXCHANGER

From the above graph, we can say Friction factor has consistently increased by inserting twisted
tape.
2. PLAIN TUBE VS CUT TWISTED TAPE

Graph 6.6: CFD comparison of plain tube and cut twisted tape (friction factor)

From the above graph, Friction factor has increased after placing cut twisted tape in the hollow pipe
compared to plain tube.

3. TWISTED TAPE VS CUT TWISTED TAPE

Graph 6.7: CFD comparison of twisted tape and cut twisted tape (friction factor)

From the above graph, the Friction factor has further increased after replacing plain twisted tape
with cut twisted tape comparatively.

Department of Mechanical Engineering


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MODELLING AND ANALYSIS OF DOUBLE PIPE HEAT EXCHANGER

4. COMPARISION OF ALL CASES

Graph 6.8: comparison of all three cases.

The above graph shows the comparison of all three cases by indicating Friction factor and
Reynold’s number in which the enhancement of heat transfer can be observed clearly.

HEAT TRANSFER COFFECIENT PLOTS (CFD)


1. PLAIN TUBE VS TWISTED TAPE

Graph 6.9: CFD comparison of plain tube and twisted tape (HTC)

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MODELLING AND ANALYSIS OF DOUBLE PIPE HEAT EXCHANGER

From the above graph, we can say Heat Transfer Coefficient has consistently increased by inserting
twisted tape which clearly indicates the enhancement of heat transfer.
2. PLAIN TUBE VS CUT TWISTED TAPE

Graph 6.10: CFD comparison of plain tube and cut twisted tape (HTC).
From the above graph, Heat Transfer Coefficient has increased after placing cut twisted tape in the
hollow pipe compared to plain tube.

3. TWISTED TAPE VS CUT TWISTED TAPE

Graph 6.11: CFD comparison of twisted tape and cut twisted tape (HTC)
From the above graph, the Heat Transfer coefficient has further increased after replacing plain
twisted tape with cut twisted tape comparatively.

Department of Mechanical Engineering


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MODELLING AND ANALYSIS OF DOUBLE PIPE HEAT EXCHANGER

4. COMPARISION OF ALL CASES

Graph 6.12: Comparison of all three cases.


The above graph shows the comparison of all three cases by indicating Heat Transfer Coefficient
and Mass flow rate in which the enhancement of heat transfer can be observed clearly.

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MODELLING AND ANALYSIS OF DOUBLE PIPE HEAT EXCHANGER

CHAPTER 7

RESULTS AND DESCUSSION

NUSSELT NUMBER COMPARISION OF CFD AND


EXPERIMENTAL DATA WITH % ERROR
1. PLAIN TUBE

Table 7.1: Nusselt number comparison of CFD and Experiment (Plain tube)

S NO MASS FLOW RATE(kg/s) NU CFD NU EXPERIMENTAL % ERROR


1 3 35.94 31.75 11.65
2 5 40.84 36.89 9.67
3 7 44.92 39.09 12.97
4 9 46.37 43.74 5.67
5 11 48.45 45.13 6.85
6 13 50.30 47.54 5.48
7 15 50.86 49.04 3.57

Table 7.1: Nusselt number comparison of CFD and Experiment (Plain tube)

From the above graph, we can say that better results are obtained by CFD of plain tube compared
to Experiment of plain tube with a %Error of 7.98 which is acceptable.

Department of Mechanical Engineering


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MODELLING AND ANALYSIS OF DOUBLE PIPE HEAT EXCHANGER

2. TWISTED TAPE

Table 7.2: Comparison table of twisted tape(NU)

S NO MASS FLOW RATE(kg/s) NU CFD NU EXPERIMENTAL % ERROR


1 3 51.30 45.43 11.44
2 5 56.73 50.47 11.03
3 7 61.50 52.76 14.21
4 9 63.37 59.23 6.53
5 11 66.45 64.63 2.73
6 13 67.07 64.67 3.57
7 15 70.42 69.99 0.61

Graph 7.2: Nusselt number comparison of CFD and Experiment (twisted tape)

From the above graph, we can say that better results are obtained by CFD of twisted tape compared
to Experiment of twisted tape with a %Error of 7.16 which is acceptable.

Department of Mechanical Engineering


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MODELLING AND ANALYSIS OF DOUBLE PIPE HEAT EXCHANGER

3. CUT TWISTED TAPE

Table 7.3: Comparison table of cut twisted tape(NU).

S NO MASS FLOW RATE(kg/s) NU CFD NU EXPERIMENTAL % ERROR


1 3 54.40 49.41 9.17
2 5 59.48 54.87 7.75
3 7 64.52 57.64 10.66
4 9 66.28 59.23 10.63
5 11 69.25 65.83 5.24
6 13 71.99 67.15 6.72
7 15 74.02 72.57 1.95

Graph 7.3: Nusselt number comparison of CFD and Experiment (cut twisted tape)

From the above graph, we can say that better results are obtained by CFD of cut twisted tape
compared to Experiment of cut twisted tape with a %Error of 7.44 which is acceptable.

Department of Mechanical Engineering


CMRCET 79
MODELLING AND ANALYSIS OF DOUBLE PIPE HEAT EXCHANGER

HEAT TRANSFER COFFECIENT(w/m2k) COMPARISION OF CFD


AND EXPERIMENTAL DATA WITH %ERROR
1. PLAIN TUBE

Table 7.4: Comparison table of plain tube(HTC)

S NO MASS FLOW RATE(kg/s) HTC CFD HTC EXPERIMENTAL % ERROR


1 3 1312.28 1157.24 11.81
2 5 1486.31 1340.73 9.791
3 7 1631.62 1417.96 13.09
4 9 1681.93 1585.78 5.71
5 11 1755.96 1635.31 6.87
6 13 1821.92 1721.23 5.52
7 15 1840.96 1774.42 3.61

Graph 7.4: Heat Transfer Coefficient comparison of CFD and Experiment (Plain tube)

From the above graph, we can say that better results are obtained by CFD of plain tube compared
to Experiment of plain tube with a %Error of 8.04 which is acceptable.

Department of Mechanical Engineering


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MODELLING AND ANALYSIS OF DOUBLE PIPE HEAT EXCHANGER

2. TWISTED TAPE

Table 7.5: Comparison table of twisted tape(HTC)

S NO MASS FLOW RATE(kg/s) HTC CFD HTC EXPERIMENTAL % ERROR


1 3 1839.99 1663.35 9.60
2 5 2069.74 1839.64 11.11
3 7 2238.43 1918.63 14.28
4 9 2301.96 2151.45 6.53
5 11 2411.48 2345.92 2.59
6 13 2432.12 2344.34 3.60
7 15 2551.92 2535.89 0.62

Graph 7.5: Heat Transfer Coefficient comparison of CFD and Experiment (twisted tape)

From the above graph, we can say that better results are obtained by CFD of twisted tape compared
to Experiment of twisted tape with a %Error of 6.90 which is acceptable.

Department of Mechanical Engineering


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MODELLING AND ANALYSIS OF DOUBLE PIPE HEAT EXCHANGER

3. CUT TWISTED TAPE

Table 7.6: Comparison table of cut twisted tape(HTC)

S NO MASS FLOW RATE(kg/s) HTC CFD HTC EXPERIMENTAL % ERROR


1 3 1994.61 1810.04 9.25
2 5 2170.96 2001.50 7.80
3 7 2348.95 2097.39 10.70
4 9 2408.07 2151.45 10.65
5 11 2513.63 2387.92 5.00
6 13 2610.73 2434.01 6.76
7 15 2683.80 2629.17 2.0

Graph 7.6: Heat Transfer Coefficient comparison of CFD and Experiment (cut twisted tape)

From the above graph, we can say that better results are obtained by CFD of cut twisted tape
compared to Experiment of cut twisted tape with a %Error of 7.42 which is acceptable.

Department of Mechanical Engineering


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MODELLING AND ANALYSIS OF DOUBLE PIPE HEAT EXCHANGER

FRICTION FACTOR COMPARISION OF CFD AND


EXPERIMENTAL DATA WITH %ERROR

1. PLAIN TUBE
Table 7.7: Comparison table of plain tube(FF)

S NO MASS FLOW RATE(kg/s) f (CFD) f (EXPERIMENTAL) % ERROR


1 3 0.0227 0.0244 6.96
2 5 0.0169 0.0191 11.51
3 7 0.0152 0.0158 3.79
4 9 0.0158 0.0161 1.86
5 11 0.0148 0.0151 1.98
6 13 0.0140 0.0142 1.40
7 15 0.0144 0.0146 1.36

Graph 7.7: Friction Factor comparison of CFD and Experiment (Plain tube)

From the above graph, we can say that better results are obtained by CFD of plain tube compared
to Experiment of plain tube with a %Error of 4.14 which is acceptable.

Department of Mechanical Engineering


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MODELLING AND ANALYSIS OF DOUBLE PIPE HEAT EXCHANGER

2. TWISTED TAPE

Table 7.8: Comparison table of twisted tape(FF)


S NO MASS FLOW RATE(kg/s) f (CFD) f (EXPERIMENTAL) % ERROR
1 3 0.0456 0.0504 9.52
2 5 0.0299 0.0317 5.67
3 7 0.0235 0.0242 2.89
4 9 0.0226 0.0228 0.87
5 11 0.0207 0.0210 1.42
6 13 0.0195 0.0198 1.51
7 15 0.0197 0.0198 0.50

Graph 7.8: Friction Factor comparison of CFD and Experiment (twisted tape)

From the above graph, we can say that better results are obtained by CFD of twisted tape compared
to Experiment of twisted tape with a %Error of 3.19 which is acceptable.

Department of Mechanical Engineering


CMRCET 84
MODELLING AND ANALYSIS OF DOUBLE PIPE HEAT EXCHANGER

3. CUT TWISTED TAPE

Table 7.9: Comparison table of cut twisted tape(FF)

S NO MASS FLOW RATE(kg/s) f (CFD) f (EXPERIMENTAL) % ERROR


1 3 0.0472 0.0529 10.77
2 5 0.0308 0.0329 6.38
3 7 0.0238 0.0246 3.25
4 9 0.0225 0.0230 2.17
5 11 0.0204 0.0212 3.77
6 13 0.0190 0.0200 5
7 15 0.0193 0.0200 3.5

Graph 7.9: Friction factor comparison of CFD and Experiment (cut twisted tape)

From the above graph, we can say that better results are obtained by CFD of cut twisted tape
compared to Experiment of cut twisted tape with a %Error of 4.97 which is acceptable.

Department of Mechanical Engineering


CMRCET 85
MODELLING AND ANALYSIS OF DOUBLE PIPE HEAT EXCHANGER

FUTURE SCOPE

The present work has been carried out with twisted tape and cut twisted tape with h/d
ratio of 3 and with a cut depth of 1mm. form the experiment and cfd analysis we have observed
that changing cut depth and changing h/d ratio of twisted tape there is a drastic change in heat
transfer rate. So, we like to carry this project in future with h/d ratios of 5, 7 and with depth of
2mm.

Department of Mechanical Engineering


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MODELLING AND ANALYSIS OF DOUBLE PIPE HEAT EXCHANGER

CONCLUSION
The project objective enhancement of heat transfer achieved. The heat transfer and
friction factor analysis have been evaluated and compared experimentally and using simulation
technique(CFD) performed with plain tube, with twisted tape insert and cut twisted tape insert
with h/d ratio of 3 and depth of cut is 1mm. The results show that the average Nusselt numbers
increase with an increase of Reynolds number. It also been proved heat transfer rate is increased
with twist tape insert and cut twist tape insert compared to plain tube.

The enhancement of heat transfer is achieved in the following manner:

I. EXPERIMENTAL

1. When the heat transfer coefficient compared with plain tube and tubes with plain twisted
inserts at 3LPM mass flow rate 30.42%, at 7LPM mass flow rate 26.09%, at 11LPM mass flow
rate 30.29% and at 15LPM mass flow rate 30.02% increases. And the average increase is
29.25%. The nusselt number also increases with the rise of Reynolds number.

2.. When the heat transfer coefficient compared with plain tube and tubes with cut twisted
inserts at 3LPM mass flow rate 36.06%, at 7LPM mass flow rate 32.39%, at 11LPM mass flow
rate 31.51% and at 15LPM mass flow rate 32.52% increases. And the average increase is
33.12% which is greater than the plain tube with twisted tape insert. The nusselt number also
increases with the rise of Reynolds number.

ii. SIMULATION (CFD)

1. When the heat transfer coefficient compared with plain tube and tubes with plain twisted
inserts at 3LPM mass flow rate 28.68%, at 7LPM mass flow rate 27.10%, at 11LPM mass flow
rate 27.18% and at 15LPM mass flow rate 27.85% increases. And the average increase is
27.70%. The nusselt number also increases with the rise of Reynolds number.

2.When the heat transfer coefficient compared with plain tube and tubes with cut twisted inserts
at 3LPM mass flow rate 34.20%, at 7LPM mass flow rate 30.53%, at 11LPM mass flow rate
30.14% and at 15LPM mass flow rate 31.40% increases. And the average increase is 31.53%
which is greater than the plain tube with twisted tape insert. The nusselt number also increases
with the rise of Reynolds number.

iii. COMPARISION

Finally, when experimental results of heat transfer is compared to CFD analysis for plain tube with
plain twisted tape insert results there is an %9.72 error and for plain tube with cut twisted tape is
%4.80 which is acceptable.

Department of Mechanical Engineering


CMRCET 87
MODELLING AND ANALYSIS OF DOUBLE PIPE HEAT EXCHANGER

REFERENCES

1. Heat and Mass Transfer Text Book- Er. R.K. Rajput


2. Investigation of Trapezoidal-Cut Twisted Tape Insert in A Double Pipe U-Tube Heat
Exchanger Using Al2o3/Water Nanofluid- P.V. Druga Prasad, A.V.S.S.K.S. Gupta And
K. Deepak.
3. Experimental Studies on Heat Transfer Augmentation Using Modified Reduced Width
Twisted Tapes (Rwtt) As inserts For Tube Side Flow of Liquids- Gaurav Johan
&Veranda Hasda.
4. Heat and Fluid Flow Analysis Over Different Tube Inserts in Concentric Tube Heat
Exchanger- Pankaj P. Kamaliya, Assistant Professor.
5. Heat Transfer Enhancement in Heat Exchangers with Inserts- N. C. Kanojiya, V. M.
Kriplani, And P. V. Walke, Professors, Department of Mechanical Engineering.
6. Experimental Investigation of Exergy & Energy Analysis of Double Pipe Heat
Exchanger Using Twisted Tape- B. V. Bhuva, Mr. Sukritindra Soni.
7. Experimental Study on Heat Transfer Characteristics of Shell and Tube Heat Exchanger
Using Hitran Wire Matrix Turbulators As Tube Inserts. - Manoj, A M Mulla, Umesh
Jangamashetti, Kiran K.
8. Performance Improvement of Double Pipe Heat Exchanger By
a. Using Tabulator- C. K. Pardhi, Dr. Prasant Baredar.
9. Double-Pipe Heat Exchanger- Jeffrey B. Williams.
10. Heat Transfer Enhancement in Circular Tube Using Twisted Tape Inserts of Different Width
Ratio Under Constant Wall Heat Flux Condition- Prashant Tike, Prof. A. M. Andheri
11. Thermal Analysis of Multi Tube Pass Shell and Tube Heat Exchanger- Chandra Sekhar,
D. Krishnaiah, F. Anand Raju

Department of Mechanical Engineering


CMRCET 88

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