CHAPTER 1

INTRODUCTION

Heat exchangers are one of the mostly used equipment in the

process industries. Heat exchangers are used to transfer heat between two process streams.
One can realize their usage that any process which involve cooling, heating, condensation,
boiling or evaporation will require a heat exchanger for these purpose. Process fluids,
usually are heated or cooled before the process or undergo a phase change. Different heat
exchangers are named according to their application. For example, heat exchangers being
used to condense are known as condensers, similarly heat exchanger for boiling purposes
are called boilers. Performance and efficiency of heat exchangers are measured through the
amount of heat transfer using least area of heat transfer and pressure drop. A more better
presentation of its efficiency is done by calculating over all heat transfer coefficient.
Pressure drop and area required for a certain amount of heat transfer, provides an
insight about the capital cost and power requirements (Running cost) of a heat
exchanger. Usually, there is lots of literature and theories to design a heat exchanger
according to the requirements. A variety of heat exchangers are used in industries, such as
shell-and-tube heat exchangers, plate-fin heat exchangers, fin and tube heat exchangers etc.
The shell-and-tube heat exchanger (STHX) has relatively simple manufacture and multi-
purpose application possibilities for gaseous and liquid media in a large temperature and
pressure range, so they are still widely used in chemical industry, power production, food
industry, environment engineering, waste heat recovery, air-conditioning, and refrigeration
and so on.

Due to the high consumption and the reducing availability of fossil fuel resource,
high thermal performance heat exchanger is subject to great interest over decades.
Typically, two fluids with different temperature circulate through the heat exchanger in
natural or forced convection manners and the thermal energy is exchanged via surfaces
during the process. There are two primary flow arrangements in the heat exchanger: a
parallel-flow and a counter-flow. Two fluids travel from the same end to another end in the

1
parallel-flow heat exchanger. For the counter-flow arrangement, the two fluids run in the
opposite direction from two ends of the heat exchanger. The arrangement for the flow
direction leads to the efficiency difference. The counter-flow path provide higher heat
transfer, benefiting from the more uniform temperature difference and relatively high flow
rate, compared to the parallel-flow path. To improve the efficiency of the heat exchanger,
maximizing the surface area of the wall between two fluids and minimizing resistance flow
passing across the exchanger are two most concerned focuses. Different approaches have
been made on these two directions. The increase of area is the most direct way to exchange
more thermal energy. However, the efficiency and the performance do not increase,
following the area increment, alongside the area increase results in a higher expense of
manufacturing. Additionally, the working space requirement is another limiting factor.
Another direction is the faster fluid transportation in heat exchanger to make the rate of
thermal exchange to be higher. Flow resistance can be reduced by a higher surface finish or
by adding nanoparticles and polymer additives. The increased cost of manufacturing and
the stability of additives and the erosion of the facilities due to added particles constrained
the development. Improving the efficiency and the performance of heat exchanger is an
important topic of research.
Heat exchangers are of two types:-
 Where both media between which heat is exchanged are in direct contact
with each other is Direct contact heat exchanger,
 Where both media are separated by a wall through which heat is transferred
so that they never mix, indirect contact heat exchanger.

A typical heat exchanger, usually for higher pressure applications up to 552 bars, is
the shell and tube heat exchanger. Shell and tube type heat exchanger is also known as
indirect contact type heat exchanger. It consists of a series of tubes, through which one of
the fluids runs. The shell is the container for the shell fluid. Generally, it is cylindrical in
shape with a rectangular or circular cross section, although shells of different shapes are
used in specific applications. A shell is the most commonly used due to its low cost and
simplicity, and has the highest log-mean temperature-difference (LMTD) correction factor.

2
Although the tubes may have single or multiple passes, there is one pass on the shell side,
while the other fluid flows within the shell over the tubes to be heated or cooled. The tube
side and shell side fluids are separated by a tube wall.

The project involves staggered type of heat exchanger and Double Cross Flow heat
exchanger which are types of shell and tube heat exchanger. In Staggered type heat
exchanger, there are two sets of tubes and both are arranged in horizontal direction to the
shell side flow and fluid flows in zigzag. In Double Cross Flow heat exchanger, one set of
tube is arranged in horizontal direction and the other set in vertical direction and the shell
side fluid passes through the tubes are in perpendicular.

The project involves fabrication of both staggered type heat exchanger And Double
Cross Flow type heat exchanger. It is necessary to perform experiments having similar
areas to analyze the performance of Double Cross Flow heat exchanger with Staggered type
of heat exchanger by comparing pressure drop, overall heat transfer coefficient, heat
transfer rate, heat transfer coefficient, effectiveness and Logarithmic Mean Temperature
Difference. This comparison helps to realize the benefits of modified arrangement of pipes
and could be used in industrial applications.

The complexity with experimental techniques involves quantitative description of

flow phenomena using measurements dealing with one quantity at a time for a limited
range of problem and operating conditions. Computational Fluid Dynamics is now an
established industrial design tool, offering obvious advantages. In this study, a full 360°
CFD model of shell and tube heat exchanger is considered. By modeling the geometry
as accurately as possible, the flow structure and the temperature distribution inside the
shell are obtained.

3
1.1 ADVANTAGES
Here are the main advantages of shell-and-tube heat exchangers.
1. Condensation or boiling heat transfer can be accommodated in either the
tubes or the shell, and the orientation can be horizontal or vertical. You may want to check
out the orientation of the heat exchanger in our laboratory. Of course, single phases can be
handled as well.
2. The pressures and pressure drops can be varied over a wide range.
3. Thermal stresses can be accommodated inexpensively.
4. There is substantial flexibility regarding materials of construction to
accommodate corrosion and other concerns. The shell and the tubes can be made of
different materials.
5. Extended heat transfer surfaces (fins) can be used to enhance heat transfer.
6. Cleaning and repair are relatively straightforward, because the equipment
can be dismantled for this purpose.

1.2 NEED OF WORK

Performance and efficiency of heat exchangers are measured through the amount of
heat transfer using area of heat transfer and pressure drop. A more better presentation of its
efficiency is done by calculating over all heat transfer coefficient. Pressure drop and area
required for a certain amount of heat transfer, provides an insight about the capital
cost and power requirements (Running cost) of a heat exchanger. Heat transfer rate
increases by increasing contact surface area. By using Stagerred type and double cross
flow type of arrangement of heat exchanger we can have more contact surface area of tubes
with shell side fluid so we will have more heat transfer rate.
1.3 OBJECTIVE
The main objective of this project work is
 To simulate the fluid flow and heat transfer in staggered type of heat
exchanger and double cross flow heat exchanger using CFD and to
investigate pressure drop, velocity distribution and temperature distribution.

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 To develop a correlation for Nusselt number for Double cross flow type heat
exchanger for shell side.

Existing Nusselt number correlation for outside tube

for staggered type arrangement

Outside heat transfer coefficient

Overall heat transfer coefficient
for tube

Inside heat transfer coefficient

Inside Nusselt number and Nusselt number

Correlation for inner side of tube for staggered type
arrangement

Inside heat transfer coefficient for double cross flow

type from the Nusselt number correlation of inner side
of Staggered type heat exchanger

Overall heat transfer Outside heat

coefficient for DCF transfer coefficient
for tube

Average Nusselt number and

Nusselt number correlation for
outside tube for DCF

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 CHAPTER 2

LITERATURE REVIEW

2.1 TYPES OF HEAT EXCHANGERS

In industries, there are lots of heat exchanger that can be seen. The types of heat
exchanger can be classified in three major constructions which are tubular type, plate type
and extended surface type.

2.1.1 Tubular Heat Exchanger

The tubular type consists of circular tubes. One fluid flows inside the tubes and the
other flows on the outside of the tubes. The parameters of the heat exchanger like the tube
diameter, the number of pitch, tube arrangement, number of tubes and length of the tube
can be manipulated. The common type of heat exchangers that lie under this category are
double-pipe type, shell-and-tube type and spiral tube type. The tubular heat exchangers can
be designed for high pressure relative to the environment and high pressure
difference between the fluids. These exchangers are used for liquid-to-liquid and liquid-to-
vapor heat exchanges. But when the operating temperature or pressure is very high or
fouling factor is a concern, it will be used for gas-to-liquid and gas-to- gas heat transfer
applications.

2.1.2 Double-Pipe Heat Exchanger

A double-pipe heat exchanger consists of smaller and larger diameter pipe where
the smaller pipe fitted concentrically into the larger one in purpose to give direction to the
flow from one section to another. One set of these tubes includes the fluid that has to be
cooled or heated. The second fluid runs over the tubes being cooled or heated in order to
provide heat or absorb the heat. A set of tubes is the tube bundle and it can be made up of
several types of tubes such as longitudinally plain, longitudinally finned, and more. If the

6
application requires an almost constant wall temperature, the fluids may flow in a parallel
direction. It's easy to clean and convenient to disassemble and assemble. The double-pipe
heat exchanger is one of the simplest. Usually, it is used for small capacity applications
because it is so expensive on a cost per unit area basis. Figure 2.1 presents the model of
double- pipe heat exchanger.

Figure: 2.1 Double Pipe Heat Exchanger

Reference:[http://www.platetypeheatexchangers.com/double_pipe_heat_exchanger.html]

2.1.3 Shell-and-Tube Heat Exchanger

This exchanger is built of a bundle of round tubes mounted in a large cylindrical
shell with the tube axis parallel to the shell to transfer the heat between the two fluids. The
fluid flows inside the tubes and other fluid flows across and along the tubes. But for baffled
shell-and-tube heat exchanger the shell side stream flows across between pairs of baffles
and then flows parallel to the tubes as it flows from one baffle compartment to the next.
This kind of exchanger consists of tubes, shells, front-end head, rear-end head, baffles and
tubesheets. The different type of shell-and-tube heat exchangers depends on different
application. Usually in chemical industry and process application, it is used as oil-coolers,
power condensers, preheaters in power plants and also steam generators in nuclear

7
power plants. The most common types of shell-and-tube heat exchanger are fixed tubesheet
design, U-tube design and floating-head type. Cleaning this heat exchanger is easy. Instead
of easily cleaning, it is also low in cost. But among all tube bundle types, the U-tube is the
least expensive because it only needs one tube sheet. Technically, because of its
construction in U shape, the cleaning ishardly done in the sharp bend. An even number of
tube passes only can be achieved. Shell and tube heat exchanger is shown in figure 2.2.

Figure: 2.2 Shell and Tube Heat exchanger

Reference:[http://www.extranheattransfer.com.au/products/shell-and-tube-heat-exchangers]

2.1.4 Spiral-Tube Heat Exchanger

A spiral heat exchanger is a helical or coiled tube configuration. It consists of
spirally wound coils placed in a shell or designed as co-axial condensers and co- axial
evaporators that are used in refrigeration systems. The heat transfer coefficient is higher in
a spiral tube than in a straight tube. Since the cleaning is impossible, the spiral tubes are
suitable for thermal expansion and clean fluids. A compact spiral heat exchanger can lower
costs, while an oversized one can have less pressure drop, higher thermal efficiency, less
pumping energy, and lower energy costs. Spiral heat exchangers are frequently used when
heating fluids that have solids and therefore often foul the inside of the heat exchanger.
Spiral heat exchangers have three types of flow arrangements. Firstly, the spiral flow and
cross flow has one fluid in each. A second type is the distributed vapour and spiral flow.
The coolant moves in a spiral and exits through the top. The hot gases that enter will leave
as condensate out of the bottom outlet. The third type is the counter-current flow where
8
both of the fluids will flow in opposite directions and are used for liquid-to-liquid
applications. It has shown in figure 2.3.

Figure: 2.3
Reference:[http://www.thermaltransfersystems.com/Spiral_Exchangers/spiral_exchangers.h
tml]

2.1.5 Plate Heat Exchanger

A second type of heat exchanger is a plate heat exchanger. It has many thin plates
that are slightly apart and have very large surface areas and fluid flow passages that are
good for heat transfer. This can be a more effective heat exchanger than the tube or shell
heat exchanger due to advances in brazing and gasket technology that have made this plate
exchanger more practical. Large heat exchangers are called plate and frame heat
exchangers and there allow for periodic disassembly, cleaning, and inspection. There
are several types of permanently bonded plate heat exchangers like dip brazed and vacuum
brazed plate varieties, and they are often used in refrigeration. These heat exchangers can
further be classified as gasketed plate, spiral plate and lamella.

9
2.1.6 Gasketed Plate Heat Exchanger
A gasketed plate heat exchanger consists of a series of thin plates that have wavy
surface which function as separating the fluids. The plates come with corner parts arranged
so that the two media between which heat is to be exchanged flow through interchange
exclaim spaces. Gaskets prevent leakage to the outside and direct the fluids in the plates as
desired. The flow pattern is generally chosen so that the media flow counter-current to each
other. Since the flow passages are quite small, strong eddying gives high heat transfer
coefficients, high pressure drops, and high local shear which minimizes fouling..
Gasketed plateare typically used for heat exchange between two liquid streams. This type
can be found in food processing industries because of the compatibility to be cleaned easily
and sterilized as it completely disassembled and it has been shown in the figure 2.4.

Figure: 2.4 Gasketed Plate Heat exchanger

Reference: [http://deltathx.com/contentpg.aspx?itemid=655]
2.1.7 Spiral Plate Heat Exchanger
Spiral heat exchangers are formed by rolling two long, parallel plates into a spiral
using a mandrel and welding the edges of adjacent plates to form channels. The distance
between the metal surfaces in both channels is maintained by means of distance pinswelded
to the metal sheet. The two spiral paths introduce a secondary flow, increasing the heat
transfer and reducing fouling deposits. These heat exchangers are quite compact but are

10
relatively expensive due to the specialized fabrication. The spiral heat exchanger is
particularly effective in handling sludges,viscous liquids, and liquids with solids in
suspension including slurries.The spiral heat exchanger is made in three main types which
differ in the connections and flow arrangements.
Type Ι has flat covers over the spiral channels. The media flow countercurrent
through the channels via the connections in the center and at the periphery. This type is
used to exchange heat between media without phase changes such as liquid- liquid, gas-
liquid, or gas-gas. One stream enters at the center of the unit and flows from inside
outward. The other stream enters at the periphery and flows towards the center. Thus the
counter-flow is achieved.
Type ΙΙ is designed for cross flow operation. One channel is completely seal-
welded, while the other is open along both sheet metal edges. The passage with the medium
in spiral flow is welded shut on each side, and the medium in crossflow passes through the
open spiral annulus. This type is mainly used as a surface condenser in evaporating plants.
It is also highly effective as a vaporizer. Two spiral bodies are often built into the same
jacket and are mounted below each other.

2.2SURVEY ON CROSS FLOW HEAT EXCHANGER

Cross-Flow, Staggered-Tube Heat Exchanger Analysis for High Enthalpy

Flows -Gary L. Hammock

Cross flow heat exchangers are a fairly common apparatus employed throughout
many industrial processes. For these types of systems, correlations have been
extensively developed. However, there have been no correlations done for very high
enthalpy flows as produced by Arnold Engineering Development Center’s (AEDC)
H2 facility. The H2 facility uses a direct current electric arc to heat air which is then
expanded through a converging-diverging nozzle to impart a supersonic velocity to
the air. This high enthalpy, high temperature air must be cooled downstream by the

11
use of a cross flow heat exchanger. It is of interest to evaluate the actual
performance of the air cooler to determine the effectiveness of possible facility
upgrades. In order to characterize cooler effectiveness, a numerical model is built to
calculate per-tube-row energy balances using real (temperature and pressure
dependent) air and water properties and cross-flow Nusselt number calculations.

2.3SURVEY ON GRID INDEPENDENCE TEST

Grid-independent Issue in Numerical Heat Transfer - Yao WeiWang Jian*, Liao

Guangxuan

Grid independent is associated with the accuracy or even rationality of numerical

results. This paper takes two-dimensional steady heat transfer for example to reveal
the effect of grid resolution on numerical results. The law of grid dependence is
obtained and a simple mathematical formula is presented. The production acquired
here can be used as the guidance in choosing grid density in numerical simulation
and get exact grid independent value without using infinite fine grid. Through
analyzing grid independent, we can find the minimum number of grid cells that is
needed to get grid independent results. Such strategy can save computational
resource while ensure a rational computational result.

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 CHAPTER 3

COMPUTATIONAL FLUID DYNAMICS (CFD)

CFD is a sophisticated computationally-based design and analysis

technique. CFD software gives you the power to simulate flows of gases and liquids,
heat and mass transfer, moving bodies, multiphase physics, chemical reaction, fluid-
structure interaction and acoustics through computer modelling. This software can
also build a virtual prototype of the system or device before can be apply to real-
world physics and chemistry to the model, and the software will provide with
images and data, which predict the performance of that design. Computational fluid
dynamics (CFD) is useful in a wide variety of applications and use in industry. CFD
is one of the branches of fluid mechanics that uses numerical methods and algorithm
can be used to solve and analyse problems that involve fluid flows and also simulate
the flow over a piping, vehicle or machinery. Computers are used to perform the
millions of calculations required to simulate the interaction of fluids and gases with
the complex surfaces used in engineering. More accurate codes that can accurately
and quickly simulate even complex scenarios such as supersonic and turbulent flows
are ongoing research. Onwards the aerospace industry has integrated CFD
techniques into the design, R & D and manufacture of aircraft and jet engines. More
recently the methods have been applied to the design of internal combustion engine,
combustion chambers of gas turbine and furnaces also fluid flows and heat transfer
in heat exchanger. Furthermore, motor vehicle manufactures now routinely predict
drag forces, under bonnet air flows and surrounding car environment with CFD.
Increasingly CFD is becoming a vital component in the design of industrial products
and processes.

13
3.1 CFD PROGRAMS

The availability of affordable high performance computing hardware and the

introduction of user-friendly interfaces have led to the development of commercial
CFD packages. Before these CFD packages came into the common use, one had to
write his own code to carry out a CFD analysis. The programs were usually different
for different problems, although a part of the code of one program could be used in
another. The programs were inadequately tested and reliability of the results was
often questioned. Today, well tested commercial CFD packages not only have made
CFD analysis a routine design tool in industry, but also have helped the research
engineer focus on the physical system more effectively. All formal CFD software
contain three elements

1. a pre-processor,
2. the main solver, and
3. a post-processor

3.1.1 The Pre-processor

Pre-processing is the first step of CFD analysis in which the user

a. defines the modeling goals,

b. identifies the computational domain, and
c. designs and creates the grid system

The process of CFD modelling starts with an understanding of the flow problem
and identification of the computational domain. This is followed by generations of
the grid structure, which is the most significant portion of the pre-processing
activity. It is said that over 50% of the time spent by a CFD analyst goes towards
grid generation. Both computation time and solution accuracy depend on the grid
structure. Optimal meshes are often non-uniform – finer in areas where large
variation of variables is expected and courser in regions with relatively little change.
14
In order to reduce the drudgery of engineers and maximize productivity, all the
major CFD programs include facilities for importing shape and geometry
information from CAD packages AutoCAD and I-DEAS, and for applying a
meshing procedure. Current research is underway to develop CFD codes with an
adaptive meshing capability.

3.1.2 The Main Solver

The solver is the heart of CFD software. It sets up the equation set according
to the options chosen by the user and meshes points generated by the pre-processor,
and solves them to compute the flow field. The process involves the following tasks:

 selecting appropriate physical model,

 defining material properties,
 prescribing boundary conditions,
 providing initial solutions,
 setting up solver controls,
 set up convergence criteria,
 solving equation set, and
 saving results

Once the model is completely set up, the solution starts and intermediate results can
be monitored in real time from iteration to iteration. The progress of the solution
process is displayed on the screen in terms of the residuals, a measure of the extent
to which the governing equations are not satisfied.

15
3.1.3 The Post-processor

The post-processor is the last part of a CFD software. It helps the user to
examine the results and extract useful data. The results may be displayed as vector
plots of velocities, contour plots of scalar variables such as pressure and
temperature, streamlines and animation in case of unsteady simulation. Global
parameters like drag coefficient, lift coefficient, Nusselt number and friction factor
etc. may be computed through appropriate formulas. These data from a CFD post-
processor can also be exported to visualization software for better display.

Several general-purpose CFD packages have been published in the past

decade. Prominent among them are: PHOENICS, FLUENT, STAR-CD, CFX, CFD-
ACE, ANSA, CFD++, FLOW-3D and COMPACT. Most of them are based on the
finite volume method. CFD packages have also been developed for special
applications; FLOTHERM and ICEPAK for electronics cooling, CFX-TASCFLOW
and FINE/TURBO for turbo machinery and ORCA for mixing process analysis are
some examples. Most CFD software packages contain their own grid generators and
post processors. Software such as ICEM CFD, Some popular visualization software
used with CFD packages are TECPLOT and FIELDVIEW.

3.2 OVERVIEW OF FLUENT PACKAGE

FLUENT is a state-of-the-art computer program for modeling fluid flow and

heat transfer in complex geometries. FLUENT provides complete mesh flexibility,
solving your flow problems with unstructured meshes that can be generated about
complex geometries with relative ease. Supported mesh types include 2D
triangular/quadrilateral, 3D FLUENT also allows user to refine or coarsen grid
based on the flow solution.

16
 FLUENT is written in the C computer language and makes full use of the
flexibility and power offered by the language. Consequently, true dynamic memory
allocation, efficient data structures, and flexible solver control are all made possible.
In addition, FLUENT uses a client/server architecture, which allows it to run as
separate simultaneous processes on client desktop workstations and powerful
compute servers, for efficient execution, interactive control, and complete flexibility
of machine or operating system type.

All functions required to compute a solution and display the results are
accessible in FLUENT through an interactive, menu-driven interface. The user
interface is written in a language called Scheme, a dialect of LISP. The advanced
user can customize and enhance the interface by writing menu macros and functions.

Program Structure

FLUENT package includes the following products:

 FLUENT, the solver.

 PrePDF, the preprocessor for modeling non-premixed combustion in
FLUENT.
 ANSA, the preprocessor for geometry modeling and mesh generation.
 TGrid, an additional preprocessor that can generate volume meshes from
existing boundary meshes.
 Filters (translators) for import of surface and volume meshes from CAD/CAE
packages such as ANSYS, CGNS, I-DEAS, NASTRAN, PATRAN, and
others.

17
 3.3 APPLICATION OF CFD:

CFD not just spans on chemical industry, but a wide range of industrial and
nonindustrial application areas which is in below:

 Aerodynamics of aircraft and vehicle.

 Combustion in IC engines and gas turbine in power plant.
 Loads on offshore structure in marine engineering.
 Blood flows through arteries and vein in biomedical engineering.
 Weather prediction in meteorology.
 Flow inside rotating passages and diffusers in turbo-machinery.
 External and internal environment of buildings like wind loading and
heating or ventilation system.
 Mixing and separation or polymer moldings in chemical process
engineering.
 Distribution of pollutants and effluent in environmental engineering.

18
 CHAPTER 4

COMPUTATIONAL MODEL FOR HEAT EXCHANGER

4.1 PROBLEM DESCRIPTION:

Design of Staggered and Double cross flow type shell and tube heat
exchanger using Solid works, meshing with ANSA, and analysis with ansys Fluent.
To study the temperature and pressure inside the tube with different mass flow rate.

4.1.1 Analyzing procedure

STEP 1 - GEOMETRY CREATION

STEP 2 - MESH GENERATION
STEP 3 - DEFINING THE BOUNDARY CONDITIONS
STEP 4 - SOLVING
STEP 5 - POST PROCESSING THE RESULTS

4.1.2 Model geometry:

Determining the model geometry was the first step towards solving
problem. While some specifications for the geometry were had to be made based on
assumptions related to the capabilities of Solidworks 2013. The computational
model of an experimental is shown in figure and the geometry parameters for both
staggered type heat exchanger and double cross flow heat exchanger are listed in
Table 4.1. The 3D model of staggered type heat exchanger is shown in figure and
the 3D model of double cross flow type heat exchanger is shown in below figure

19
 Table 4.1 Geometric specifications of Staggered type heat exchanger
and Double cross flow heat exchanger
Length of shell 500 mm
Width of shell 75 mm
Height of shell 75 mm
Outer diameter of tube 6 mm
Inner diameter of tube 4 mm
Longitudinal pitch, SL 50 mm
Transverse pitch, ST 7.5 mm

Fig:4.1 Staggered type heat exchanger

Fig:4.2 Double cross flow heat exchanger

20
 To simplify numerical simulation, some basic characteristics of the process
following assumption are made:
1. The shell side fluid is constant thermal properties.
2. The fluid flow and heat transfer processes are turbulent and in steady
state
3. The natural convection induced by the fluid density variation is
neglected
4. The tube wall temperature kept constant in the whole shell side.
5. The heat exchanger is well insulated hence the heat loss to the
environment is totally neglected.

4.1.3Mesh Generation:

The three-dimensional model is then discretized in ANSA. The domain is

extracted and the entire model is discretized using triangular mesh elements which
are accurate and involve less computation effort. Fine control on the triangular mesh
near the wall surface allows capturing the boundary layer gradient accurately. The
inlet and outlet walls are given in this ANSA. Here only surface meshing is done.
This surface mesh is imported into AnsysTgrid Software, here volume meshing is
done. For higher accuracy tetrahedral meshing is done. The entire geometry is
divided into three fluid domains Fluid shell, Tube3_fluid and Tube4_fluid. The heat
exchanger is discretized into solid and fluid domains in order to have better control
over the number of nodes. The fluid mesh is made finer than solid mesh for
simulating conjugate heat transfer phenomenon. The first cell height in the fluid
domain from the tube surface is maintained at 100 microns to capture the velocity
and thermal boundary layers. Once the meshes are checked for free of errors and
minimum required quality it is exported to ANSYS Fluent pre-processor.

21
4.2 GRID INDEPENDENCE TEST:

Grid independent is a very important issue in numerical simulation, but still

now little literatures has concerned with this matter. Grid-independent means
calculational results change so little along with a denser or looser grid that the
truncation error can be ignored in numerical simulation. Whether the grid is
independent directly influences the truncation error or even the rationality of
numerical results. The previous research reveals that the grid resolution and time
step have a very great effect on the results of unsteady numerical simulation in a
certain range. When considering grid-independent issue, in principle a very dense
grid can avoid this problem but the calculational resource may be wasted
unnecessarily. In practice, we usually increase the grid resolution according to a
certain ratio, for example 1/3, and then compare the results of two neighborhood
results. If the results tend towards identical, the grid can be considered as grid-
independent. Such strategy can utilize computational resource most efficiently as
well as obtain reasonable results. Grid independence test is conducted to test the
independence of results of numerical simulation on the size of mesh or grid i.e.,
there is no further variation of result by increasing the further mesh size.

4.2.1Mesh test For Staggered Type heat exchanger:

Initially a relatively coarser mesh is generated with 0.12 million cells of

surface mesh and 0.49 million cells of volume mesh. This mesh contains mixed cells
(Tetra and tetrahedral cells) having triangular faces at the boundaries. Care is taken
to use structured cells (Tetrahedral) as much as possible, for this reason the
geometry is divided into several parts for using automatic methods available in the
ANSYS meshing client. It is meant to reduce numerical diffusion as much as
possible by structuring the mesh in a well manner, particularly near the wall region.

22
Later on finer mesh size is regenerated until the solution doesnot vary on further size
of mesh size

Table 4.2: Grid independence test for Staggered type heat exchanger

S.no Mesh size(in lakhs) Heat transfer rate(Q)

Mesh Test 1 4.9 125.79
Mesh Test 2 9 133.86
Mesh Test 3 11.5 139.9
Mesh Test 4 13.8 140.9

Since by increasing 20% of volume mesh size there is only change 0.7%
change in heat transfer rate which is negligible so 11.5 lakhs of volume mesh can be
taken for simulation of Staggered type heat exchanger.

Figure:4.3 Surface mesh generation of Staggered Heat exchanger

23
4.2.2. Mesh test For Double cross flow Type heat exchanger:

Initially a relatively coarser mesh is generated with 2.2 lakhs cells of surface
mesh and 9.9 lakhs cells of volume mesh. This mesh contains mixed cells (Tetra and
tetrahedral cells) having triangular faces at the boundaries. Care is taken to use
structured cells (Tetrahedral) as much as possible, for this reason the geometry is
divided into several parts for using automatic methods available in the ANSYS
meshing client. It is meant to reduce numerical diffusion as much as possible by
structuring the mesh in a well manner, particularly near the wall region. Later on
finer mesh size is regenerated until the solution does not vary on further size of
mesh size

Table: 4.3 Grid independence test for Double cross flow heat exchanger

S.no Mesh size(in lakhs) Heat transfer rate(Q)

Mesh Test 1 9.9 136.95
Mesh Test 2 11.1 137.38
Mesh Test 3 13.9 141.22
Mesh Test 4 15.4 141.66
Since by increasing 11% of volume mesh size there is only 0.3% change in
heat transfer rate which is negligible so 13.9 lakhs of volume mesh can be taken for
simulation for double cross flow type heat exchanger.

24
 Fig 4.4: Surface mesh generation of Double cross flow type heat exchanger

4.3 Mathematical Model and Numerical Methods

The equations governing the incompressible fluid motion and the heat
transfer from tubes to the flow with fluid passing tubes are presented in this Chapter.
Boundary conditions imposed on the velocity field at the inlet, outlet, the tube
surfaces and the wall of channel are described. The thermal boundary conditions are
also described in this Chapter.

4.3.1 Boundary and initial conditions

In order to obtain a well-posed system of equations, reasonable boundary and
initial conditions for the computational domain have to be implemented.
Boundary conditions were applied, at inlet as velocity inlet, which is set as
uniform air velocity with temperature, outlet as pressure outlet, which is set as
1.013x105 Pa, pipe wall as wall, which is set as adiabatic with no-slip condition and
balls walls as interfaces in which the temperatures of the fluid and the balls were
determined by coupled energy equations and the boundary conditions are shown in
following table 4.4.

25
 Table:4.4 Boundary conditions for computational analysis

Boundary type Boundary condition

Shell inlet Mass flow inlet
Shell outlet Pressure outlet
Tube-3 inlet Mass flow inlet
Tube-3 outlet Pressure outlet
Tube-4 inlet Mass flow inlet
Tube-4 outlet Pressure outlet

4.4 Solution techniques

 In FLUENT, solver is set as segregated which solves the equations
individually. Steady state has been formulated as 1st order implicit condition
and cell based gradient option has been taken.
 The discretization scheme for momentum, laminar and all has been taken as
first order upwind.
 The interfaces of solid and liquid phases are made coupled.
 Addmaterials and edit properties assumed (Appendix-I).
 Then under relaxation factors have been taken for solution control in different
flow quantities as pressure = 0.3, density = 1, body forces = 1, momentum =
0.7, energy=1. For pressure-velocity coupling Phase Coupled SIMPLE
method has been chosen.
 Then solution has been initialized from all zones and set the initial condition
of solids phases. The convergence criteria are pre-set conditions for the
residuals that determine when an iterative solution is converged. For any set
of convergence criteria, the assumption is that the solution is no longer
changing with more iteration and when the condition is reached there is an
overall mass balance throughout the domain.

26
  Simulation was carried out under the various inlet mass flow rate conditions,
0.0005 to 0.0026kg/s for air and 0.001 to 0.006 kg/s for with inlet
temperature 438 K for air and 302 K for water.

4.5 Post-processing
The results were post processed using FLUENTand a detailed discussion of
the results is given in Chapter 6.

27
 CHAPTER 5

EXPERIMENTAL SETUP
5.1MODELLING PROCEDURE OF HEAT EXCHANGER

5.1.1MODEL OF DOUBLE CROSS FLOW SHELL AND TUBE HEAT

EXCHANGER

Based on the following procedure the preliminary model of the modified heat
exchanger was designed.

 Material selection
 Design features
 Tube diameter
 Shell cross section and its dimensions
 No. of sets of tubes
 Type of insulation provided
 Shell length
 Tube length

Fig:5.1 Profile of Bent tube

28
Tube dimensions:

 Bent radii – 50 mm
 Length – 250 mm

3D drawings were prepared using SOLIDWORKS 2013 software

Figure 5.2: STAGGERED FLOW TYPE HEAT EXCHANGER

Figure 5.3: DOUBLE CROSS FLOW TYPE HEAT EXCHANGER

5.2DIMENSIONS OF HEAT EXCHANGER:

FOR SHELL

1. Material - Mild steel

2. Length - 1000 mm
3. Height - 150 mm× 150 mm
4. Coating - Aluminum

29
FOR TUBE

 Material - Copper
 Diameter - 12 mm

5.3 SPECIFICATIONS OF OTHER EQUIPMENTS:

 THERMOCOUPLE
 Type - K type
 Diameter - 3 mm

 DATA LOGGER
 MODEL - AGILENT 34972A

5.4 FABRICATION PROCEDURE:

 After finalizing the materials for shell and tubes of the heat exchanger,
drawings were made with specified dimensions using CATIA software.
 Initially two plates of L-section are welded together for producing shell of the
heat exchanger.
 Holes were drilled at the required points on the shell surface for inserting the
tubes.
 Tubes were bent as per the drawing given in the fig 3.1 using a roller bending
machine for the ease in the fabrication of the heat exchanger
 Tubes were inserted through the holes on the shell and brazed at the points
indicated in the fig 5.1
 The Shell was coated with Aluminium paint to enhance corrosion resistance.
 All the above steps were followed for the fabrication of both the types of heat
exchangers.

The fabricated models of this project are as shown in figures 5.4 &5.5:

30
5.4.1.1 STAGGERED FLOW TYPE

Figure : 5.4 Fabricated model of Staggered type heat exchanger

5.4.1.2 DOUBLE CROSS FLOW TYPE:

Figure : 5.5 Fabricated model of Double cross flow type heat exchanger

31
5.5 EXPERIMENTATION ASSEMBLY OF HEAT EXCHANGER AND
OVER HEAD TANKS

The fabricated shell and tube heat exchanger was assembled with air
compressor to supply pressurized air for shell side and water pipes which supply
water for tube side to get heated.

The assembled experimental setup of the model consists of

 Heat exchanger
 Water reservoir
 Sink
 Air Compressor
 Connecting hoses
 Thermocouples
 Data logger
 Computer system (to record the data)

Thus the setup was made successfully and the readings were taken for different heat
inputs.

5.5.1 STAGGERED FLOW EXPERIMENTAL SETUP:

Figure 5.6: Experimental setup of Staggered type of heat exchanger

32
5.5.2 DOUBLE CROSS FLOW EXPERIMETAL SETUP:

Figure 5.7: Experimental setup of Double cross flow type heat exchanger

5.6 EXPERIMENTAL PROCEDURE:

 Hose connections were made for the supply of air and water through the shell
and tubes respectively.
 Air was supplied through the electrical heater to increase the temperature of
the air before entering into the shell.
 Mass flow rate of the air was measured using the water column readings of
the manometer.
 Water was pumped at room temperature through the tubes as a fluid to be
heated.
 Mass flow rate of the water was calculated by weighing the amount of water
outlet from tubes for 40 seconds.
 Heat input to the supply air was varied using a variable transformer.
 Temperatures were measured using K-type thermocouples and stored for
analysis using Data logger.
 Pressure drop value of the air inside the shell was measured by using a water
manometer.
 Standard correlations were used to find Nusselt number, from which the
individual and overall heat transfer coefficients are computed.

33
  Heat transfer rate from air to water was found out for different heat supply
and pressure of the air.
 Logarithmic Mean Temperature Difference was found out using overall heat
transfer coefficient.
 Correction factor for the heat exchange rate for both the heat exchangers was
found out by comparing the LMTD values.
 Since the configurations of the heat exchangers are not conventional,
correction factors were to be found out and included in all the calculations.
 Effectiveness values were found out for various cases.
 All the above steps were followed for both the types of heat exchangers and
the results were compared.

5.7 ASSUMPTIONS IN CALCULATIONS:

 Fully developed flow through the heat exchanger.

 Same correlations are suitable for both the setups.
 LMTD for parallel flow can be considered, though the setups are not
conventional.

5.7.1 OTHER EQUIPMENTS USED FOR EXPERIMENATION

 DATA LOGGER
The term data logger (also sometimes referred to as a data recorder) is
commonly used to describe a self contained, stand alone data acquisition
system or device. These products are comprised of a number of analog and
digital inputs that are monitored, and the results or conditions of these inputs
is then stored on some type of local memory (e.g. SD Card, Hard Drive).

34
 Figure 5.8: Data Logger

5.7.2 KEY FEATURES & SPECIFICATIONS

 3-slot LXI data acquisition unit with 6 ½-digit DMM (22-bit) and 8 plug-in
modules to choose from
 Measures 11 different input signals including temperature with
thermocouples, RTDs and thermistors; DC/AC volts or current; 2- or 4- wire
resistance; frequency and period
 Accepts all 34972A switch and control plug-in modules, and is backward
compatible with the 34972A SCPI command set
 1Gbit LAN and USB 2.0 for easy connectivity to the PC
 USB memory port for data storage or transfer Graphical Web interface for
easy set up and control
 Free BenchLink data logger software to create tests without programming

A. THERMOCOUPLE

A thermocouple circuit is formed when two dissimilar metals are joined at

both ends and there is a difference in temperature between the two ends. This
difference in temperature creates a small current and is called the Seebeck effect
after Thomas Seebeck who discovered this phenomenon in 1821.

When there is a difference in temperature between the two ends of this

circuit, a small voltage is formed within the circuit. This voltage or EMF (electro
motive force) is usually measured in the 1/1000th of a volt (millivolt). Most

35
people’s body produces more voltage than that! The higher the difference in
temperature, the higher the voltage. If the right pairs of materials are used, these
thermocouple circuits can be used to measure temperature

Figure 5.9: Thermocouple

The junction that is put into the process in which temperature is being
measured is called the HOT JUNCTION. The other junction which is at the last
point of thermocouple material and which is almost always at some kind of
measuring instrument, is called the COLD JUNCTION.

B. HEATER

A heating element converts electricity into heat through the process of Joule
heating. Electric current through the element encounters resistance, resulting in
heating of the element. Here, the heating element is made up of Ni-chrome 80/20
(80% nickel, 20% chromium) wire. Ni-chrome 80/20 is an ideal material, because it
has relatively high resistance and forms an adherent layer of chromium oxide when
it is heated for the first time. Material beneath this layer will not oxidize, preventing
the wire from breaking or burning out. The heating coil was wound over an insulator
in such a way that the inlet air attains a higher turbulence flow so as to have a better
heating of the air. Power of the heating coil is 1350 Watts, with a total resistance of
35 ohms. This heater preheats the inlet air up to 200oC.

36
 Figure 5.10: Heater

Figure:5.11 Circuit for Heater

37
 CHAPTER 6

RESULTS AND DISCUSSION

6.1. COMPUTATIONAL RESULTS:

6.1.1Temperature drop:

The following graph shows the variation of Temperature drop in outside tube fluid
for Double cross flow type heat exchanger and Staggered type heat exchanger. As the mass
flow rate increases temperature drop decreases in both Staggered type heat exchanger and
double cross flow type heat exchanger as shown in the graph.

120
∆T_drop in outside tube fluid, C

115
110
105
100
DCF
95
Stagerred
90
85
80
0.0005 0.001 0.0015 0.002 0.0025

m, kg/s

Figure:6.1 Staggered and double cross flow comparison – Variation of temperature

drop along the outside tube for various mass flow rates

6.1.2Temperature rise:

The following graph shows the variation of Temperature rise in tube side
fluid for Double cross flow type heat exchanger and Staggered type heat exchanger.
As the mass flow rate increases temperature rise decreases in both Staggered type
heat exchanger and double cross flow type heat exchanger as shown in the graph.

38
 15

∆T_rise in inside tube fulid, C

14

13

12

11 DCF

10 Stagerred

8
0.001 0.002 0.003 0.004 0.005 0.006
m, kg/s

Figure:6.2 Staggered and double cross flow comparison – Variation of temperature

rise along the inside tube for various mass flow rates

6.1.3 PRESSURE DROP:

The following graph shows the variation of Pressure drop in shell side fluid
for Double cross flow type heat exchanger and Staggered type heat exchanger. As
the mass flow rate increases pressure drop increases more in Staggered type heat
exchanger than double cross flow type heat exchanger as shown in the graph

39
 3000

∆P in outside tube fluid, Pa

2500

2000

1500
DCF
1000
Stagerred
500

0
0.0005 0.001 0.0015 0.002 0.0025
m, kg/s

Figure: 6.3 Staggered and double cross flow comparison – Variation of Pressure
drop along the outside tube for various mass flow rates

The following graph shows the variation of Pressure drop in tube-3 side fluid
for Double cross flow type heat exchanger and Staggered type heat exchanger. As
the mass flow rate increases pressure drop increases more in Staggered type heat
exchanger than double cross flow type heat exchanger as shown in the graph

1300

1100
∆P in 3-tubes, Pa

900

700
DCF
500
Stagerred
300

100
0.001 0.002 0.003 0.004 0.005 0.006

m, kg/s

Figure:6.4 Staggered and double cross flow comparison – Variation of Pressure drop
along the tube-3 side for various mass flow rates

40
 The following graph shows the variation of Pressure drop in tube-4 side fluid
for Double cross flow type heat exchanger and Staggered type heat exchanger. As
the mass flow rate increases pressure drop increases more in Staggered type heat
exchanger than double cross flow type heat exchanger as shown in the graph

950
850
750
∆P in 4-tubes, Pa

650
550
450 DCF
350
Stagerred
250
150
50
0.001 0.002 0.003 0.004 0.005 0.006
m, kg/s

Figure:6.5 Staggered and double cross flow comparison – Variation of Pressure drop
along the tube-4 side for various mass flow rates

6.1.4 VARIATION OF NUSSELT NUMBER WITH REYNOLDS NUMBER

The following graph shows the variation of Nusselt number with

Reynolds number for tube side fluid for Double cross flow type heat exchanger and
Staggered type heat exchanger. As the Reynolds number increases Nusselt number
increases more in Double cross flow type heat exchanger than Staggered type heat
exchanger as shown in the graph

41
 0.55
0.5
0.45

0.4
NU Staggered
0.35
DCF
0.3
0.25
300 800 1300 1800
Re

Figure: 6.6 Staggered and double cross flow comparison – Variation of Nusselt
Number with Reynolds number along inside tube fluid

The following graph shows the variation of Nusselt number with Reynolds
number for shell side fluid for Double cross flow type heat exchanger and Staggered
type heat exchanger. As the Reynolds number increases Nusselt numberincreases
more in Double cross flow type heat exchanger than in Staggered type heat
exchanger as shown in the graph

16

14

12
Nu

10
Staggered
8 DCF
6

4
20 40 60 80 100 120
Re

Figure:6.7 Staggered and double cross flow comparison – Variation of Nusselt

Number with Reynolds number along outside tube fluid

42
6.1.5VARIATION OF PRESSURE DROP PER UNIT MASS FLOW RATE

The following graph shows the variation of Pressure drop per unit
mass flow rate in shell side fluid for Double cross flow type heat exchanger and
Staggered type heat exchanger. As the Reynolds number increases pressure drop per
unit mass flow rate increases more in Staggered type heat exchanger than double
cross flow type heat exchanger as shown in the graph

13

11
∆P/Q, Pa/W

7
Staggered
5 DCF

1
24 44 64 84 104 124
Re

Figure: 6.8 Staggered and double cross flow comparison – Variation of ∆P/Q with
Reynolds number Along outside tube fluid

43
6.1.6 Pressure contour:

6.1.6.1 Pressure contours for ma = 0.5×10-3 kg/s and mw = 1×10-3 kg/s:

Figure 6.9: Double cross flow heat exchanger (ma = 0.5×10-3 kg/s and mw =1×10-3kg/s)

Figure 6.10: Staggered heat exchanger (ma = 0.5×10-3 kg/s and mw = 1×10-3 kg/s)

44
6.1.6.2 Pressure contours for ma = 1.445×10-3 kg/s and mw = 3.25×10-3 kg/s:

Figure 6.11: Double cross flow heat exchanger(ma = 1.445×10-3 kg/s and
mw =3.25×10-3 kg/s)

Figure 6.12: Staggered heat exchanger(ma = 1.445×10-3 kg/s and

mw =3.25×10-3 kg/s)

45
6.1.6.3 Pressure contours for ma = 2.495×10-3 kg/s and mw = 5.75×10-3 kg/s:

Figure 6.13: Double cross flow heat exchanger(ma = 2.495×10-3 kg/s and
mw = 5.75×10-3 kg/s)

Figure 6.14: Staggered heat exchanger(ma = 2.495×10-3 kg/s and

mw = 5.75×10-3 kg/s)

46
6.1.7 Temperature contour:

6.1.7.1 Temperature contours for ma = 0.5×10-3 kg/s and mw = 1×10-3 kg/s:

Figure 6.15: Double cross flow heat exchanger(ma = 0.5×10-3 kg/s and mw =1×10-3kg/s)

Figure 6.16: Staggered heat exchanger (ma = 0.5×10-3 kg/s and mw =1×10-3kg/s)

47
6.1.7.2 Temperature contours for ma = 1.445×10-3 kg/s and mw = 3.25×10-3 kg/s:

Figure 6.17: Double cross flow heat exchanger(ma = 1.445×10-3 kg/s and
mw =3.25×10-3 kg/s)

Figure 6.18: Staggered heat exchanger(ma = 1.445×10-3 kg/s and

mw =3.25×10-3 kg/s)

48
6.1.7.3 Temperature contours for ma = 2.495×10-3 kg/s and mw = 5.75×10-3 kg/s:

Figure 6.19: Double cross flow heat exchanger(ma = 2.495×10-3 kg/s and
mw = 5.75×10-3 kg/s)

Figure 6.20: Staggered heat exchanger(ma = 2.495×10-3 kg/s and

mw = 5.75×10-3 kg/s)

49
6.1.8 Velocity contour:

6.1.8.1 Velocity contours for ma = 0.5×10-3 kg/s and mw = 1×10-3 kg/s:

Figure 6.21: Double cross flow heat exchanger(ma = 0.5×10-3 kg/s and mw =1×10-3kg/s)

Figure 6.22: Staggered type heat exchanger (ma = 0.5×10-3 kg/s and mw =1×10-3kg/s)

50
6.1.8 Effect of mass flow rate

The temperature variation for different mass flow rate was investigated along shell
side and tube side for both staggered type heat exchanger and double cross flow type
heat exchanger

420

400
Temperature, K

380
Mass flow rate
360 m = 0.0005 kg/s
340 m = 0.001445 kg/s
m = 0.002495 kg/s
320

300
0 100 200 300 400 500 600
Axial length,mm

Figure 6.23 Variation of shell side temperature along axial length for staggered type
heat exchanger

420
400
Temperature, K

380
Mass flow rate
360 m = 0.0005 kg/s
340 m = 0.001445 kg/s
m = 0.002495 kg/s
320
300
0 100 200 300 400 500 600
Axial length,mm

Figure 6.24 Variation of shell side temperature along axial length for double cross
flow type heat exchanger

51
 308

307

306
Temperature, K

305
Mass flow rate

m = 0.0005 kg/s
304
m = 0.001445 kg/s
303 m = 0.002495 kg/s

302

301
0 100 200 300 400 500
Axial length,mm

Figure 6.25 Variation of tube3 side temperature along axial length for staggered type
heat exchanger

308

307
Temperature, K

306
Mass flow rate
305
m = 0.0005 kg/s
m = 0.001445 kg/s
304
m = 0.002495 kg/s

303

302
0 100 200 300 400 500
Axial length,mm

Figure 6.26 Variation of tube3 side temperature along axial length for double cross
flow type heat exchanger

52
 311

310
Temperature, K 309

308
Mass flow rate
307
m = 0.0005 kg/s
306
m = 0.001445 kg/s
305
m = 0.002495 kg/s
304

303

302
0 100 200 300 400 500
Axial length,mm

Figure 6.27 Variation of tube4 side temperature along axial length for staggered type
heat exchanger

311

310

309
Temperature, K

308
Mass flow rate
307
m = 0.0005 kg/s
306

305 m = 0.001445
kg/s
304

303

302
0 100 200 300 400 500
Axial length,mm

Figure 6.28 Variation of tube4 side temperature along axial length for double cross
flow type heat exchanger
53
6.2 EXPERIMENTAL RESULTS

 Shell fluid is hot air

 Tube fluid is cold air at room temperature

6.2.1 Experimental set-1

 Mass flow rate of water = 0.137 kg/s

 Mass flow rate of air = 0.0974kg/s

55
Percentage of Heat

50

45
Tranferred

40

35 DCF
30
SF
25

20
46 51 56 61
Inlet Temperature of Hot Fluid

Figure 6.29 Variation of % of heat transferred to cold fluid with respect to

inlet temperature of hot fluid

54
 12.5

11.5
LMTD(oC)

10.5
DCF
SF
9.5

8.5

7.5
46.5 57.43 61.97

Figure 6.30 Variation of LMTD with respect to inlet temperature of hot fluid

176.7

176.6

176.5
U(W/m2k)

176.4
DCF
176.3 SF

176.2

176.1

176
46.5 57.43 61.97

Figure 6.31 Variation of Overall heat transfer co-efficient with respect to inlet
temperature of hot fluid

55
6.2Experimental set-2
Mass flow rate of water = 0.141 kg/s

Mass flow rate of air = 0.0167 kg/s

70
Percentage of Heat Transferred

65

60

55

50
DCF
45
SF
40

35

30
33.85 42.49 48.265 52.4
Inlet temperature of hot fluid(oC)

Figure: 6.32Variation of % of Heat Transferred with respect to the hot fluid Inlet
Temperature

0.94
0.92
0.9
Effectiveness

0.88
0.86
0.84
DCF
0.82 SF
0.8
0.78
33.85 42.49 48.265 52.4

Inlet Temperature of Hot Fluid

Figure: 6.33Variation of Effectiveness with respect to the hot fluid inlet temperature

56
 0.94

0.92

0.9
Effectiveness

0.88

0.86

0.84

0.82

0.8

0.78
33.85 42.49 48.265 52.4

Inlet Temperature of Hot Fluid

Figure: 6.34 Variation of LMTD with respect to the inlet temperature of hot Fluid

190

185
U(W/m2K)

180

175

170

165

160
33.85 42.49 48.265

Hot water inlet temperature (oC)

DCF SF

Figure: 6.35 Variation of Overall Heat Transfer with respect to the inlet
temperature of hot fluid

57
6.2.3 Experimental Set-3
Mass flow rate of water = 0.134 kg/s

Mass flow rate of air = 0.0145 kg/s

190

185

180
U(W/m2K)

175

170

165

160
33.85 42.49 48.265

Hot water inlet temperature (oC)

Figure 6.35: Variation of % of heat transferred to cold fluid with respect to

inlet temperature of hot fluid

7
LMTD(K)

2
61.5 63 64.5 66 67.5 68.5

Hot air inlet temperature(oC)

DCF SF

Figure: 6.36 Variation of LMTD with respect to inlet temperature of hot fluid

58
 0.95

0.9
Effectiveness

0.85

0.8

0.75

0.7
61.5 63 64.5 66 67.5 68.5

Hot air inlet temperature(oC)

DCF SF

Figure: 6.37 Variation of Effectiveness with respect to inlet temperature of

hot fluid

174
173
172
171
U(W/m2K)

170
169
168
167
166
165
63 64.5 66 67.5 68.5

Hot water inlet temperature (oC)

DCF SF

Figure: 6.38 Variation of Overall Heat Transfer Co-efficient with respect to

inlet temperature of hot fluid

59
 CHAPTER-7
CONCLUSIONS
A Computational study and experimental validation of Staggered flow heat
exchanger and Double cross flow heat exchanger with the laminar fluid flow has been
presented. The modified model of shell and tube heat exchangers has been developed and
analyzed using Fluent to investigate the Overall heat transfer coefficient, heat transfer rate,
LMTD, Nusselt number and pressure drop. The pressure drop, temperature drop in shell
side fluid, temperature rise in tube side fluid has been studied by varying mass flow rate.
Heat transfer rate is higher in Double cross flow heat exchanger by 1.5 to 2% than
Staggered type heat exchanger.
By increasing mass flow rate of water ranging from 0.001 kg/s to 0.006kg/s and 0.0005
kg/s to 0.0026 kg/s the following conclusions were made.
 Heat transfer rate increases around 3.65times for both Staggered type heat
exchanger and Double cross flow heat exchanger
 Pressure drop along shell side increases around 26 times for both Staggered type
heat exchanger and Double cross flow type heat exchanger
 Pressure drop along tube-3 side increases around 7.6 times for Staggered type heat
exchanger and 7 times for Double cross flow type heat exchanger
 Pressure drop along tube-4 side increases around 14.33 times for Staggered type
heat exchanger and 7 times for Double cross flow type heat exchanger
 Temperature drop in shell side decreases around 30% for Staggered type heat
exchanger and Double cross flow type heat exchanger
 Temperature rise in tube side decreases around 30% for Staggered type heat
exchanger and 40% for Double cross flow type heat exchanger

The average Nusselt number correlations are developed

1. For tube side of Staggered type heat exchanger
𝑵𝒖 = 𝟓. 𝟖𝟕 × 𝟏𝟎−𝟒 𝑹𝒆𝟎.𝟓𝟐𝟒𝟒𝑷𝒓𝟐.𝟔𝟗𝟐𝟏
2. For outside of Double cross flow type heat exchanger
𝑵𝒖 = 𝟏𝟓. 𝟎𝟒𝑹𝒆𝟎.𝟓𝟐𝟒𝟒𝑷𝒓𝟔.𝟑𝟐𝟏𝟓

60
 The RMS value of average Nusselt number correlation of inside tube for Staggered
type heat exchanger is 0.0699 and average Nusselt number correlation of outside tube for
Staggered type heat exchanger is 0.4662
The obtained results from CFD simulation give a good estimation of performance
parameters of heat exchangers. The experimental and CFD results of the analyzed data have
been presented in the chapters 6. The results from both of the analysis show reasonable
agreement with each other, although the temperatures were found to be higher than those
from experiments. This could be attributed to imperfect adiabatic surfaces, different mass
flow rates and inlet conditions.
It can be concluded that presented work could provide a better guideline to
understand theNusselt number variation with Reynolds number and Prandtl number.
In present study only laminar flowin shell side and tube side fluid is considered for
future scope it can be extended to both turbulent flow, one laminar flow and one turbulent
flow.

61
 REFERENCES
1. Agilent – Model no. 34972 A [http://www.keysight.com/en/pd-1756491-pn-
34972A/lxi-data-acquisition-data-logger-switch-unit]: Description and Key
features.
2. Donald Q.Kern., 2005.Process Heat Transfer, McGraw Hill Education, New
York.
3. C.P.Gupta and RajendraPrakash., 2004. Engineering Heat and Mass Transfer,
NemChand and Brothers, Roorkee.
4. J.P.Holman., 2009. Heat Transfer, McGraw Hill Education, New York.
5. C.P.Kothandaraman and S.Subramanyan.,2014. Heat and Mass Transfer Data
Book, New Age, Mumbai.
6. K-type thermocouple: [http://www.thermocoupleinfo.com/] : Types of
thermocouples and temperature Ranges.
7. R.K.Rajput., 2008. Engineering Heat and Mass Transfer, S.Chand, New
Delhi.
8. R.C.Sachdeva., 2010. Engineering Heat and Mass Transfer, New Age
Science Ltd., New Delhi.
9. Types of Heat Exchangers:[http://www.thomasnet.com/articles/process-
equipment/heat-exchanger-types].

10. Anderson, J. D., 1995, “Computational Fluid Dynamics”, McGraw Hill, New
York.
11. ANSYS Heat transfer modeling, www.fluentusers.com 08, 2009
12. Fluent 6.2 User’s Guide Fluent Inc. Centerra Resource Park 10 Cavendish Court
Lebanon, NH 03766 January 2005.

62
 APPENDIX
EXPERIMENTAL SET 1:
Double cross flow type heat exchanger

Mass flow rate of water = 0.137 kg/s

Mass flow rate of air = 0.0974kg/s

OBSERVATION OF HEAT TRANSFER RATE FOR DCF:

T T T T Heat Lost Heat % Heat
1 2 3 4
by Hot Gained Transfer
(°C) (°C) (°C) (°C)
Fluid by Cold
(Watts) Fluid
(Watts)
46.9 33.43 29.17 31.08 794.60 268.29 33.77
57.83 34.59 29.20 31.36 901.49 462.89 51.35
61.67 34.61 29.56 32.16 1083.13 538.98 50.98

HEAT TRANSFER COEFFICIENT AND EFFECTIVENESS FOR DCF:

Convective Convective Overall Heat LMTD Effectiveness
Heat Transfer Heat Transfer Transfer Co-
Co-efficient of Co-efficient of efficient
2 2
Air W/m K Water W/m K
2
W/m K
30.68 182.45 176.39 7.60 0.76
30.52 182.60 176.51 11.64 0.81
30.21 182.81 176.65 11.52 0.84

63
Staggered type heat exchanger

Mass flow rate of Water = 0.141 kg/s

Mass flow rate of Air = 0.0975 kg/s

OBSERVATION AND HEAT TRANSFER RATE FOR STAGGERED:

T T T T Heat Lost by Heat Gained %
1 2 3 4
Hot by Cold Heat
(C) (C) (C) (C)
Fluid(Watts) Fluid Trans
(Watts) fer
47.6 30.55 29.11 32.86 1560.18 339.60 21.77
56.9 34.12 29.20 33.12 1630.55 453.73 27.83
62.4 36.86 29.25 33.56 1792.52 508.70 28.21

COMPARISONTABLE FOR DCF vs STAGGERED:

S.no LMTD(K) EFFCTIVENESS Qair(W) Qwater(W)
DCF SF DCF SF DCF SF DCF SF
1 7.60 7.77 0.76 0.69 794.60 1560.18 268.29 339.60
)
2 11.64 8.03 0.81 0.71 901.49 1630.55 462.89 453.73
3) 11.52 12.93 0.84 0.77 1083.13 1792.52 538.98 508.70
)

HEAT TRANSFER COEFFICIENT AND EFFECTIVENESS FOR

STAGGERED:
Convective Convective Overall Heat
Heat Heat Transfer Co- Effectiveness LMTD
Transfer Co- Transfer Co- efficient
2
efficient of efficient of W/m K
2
Air W/m K Water
2
W/m K
21.35 182.54 174.28 0.69 7.77
21.31 182.26 174.01 0.71 8.03
21.45 181.96 173.78 0.77 12.93

64
COMPARISONOFHEAT TRANSFERRATE
SF DCF % INCREASE IN
% OF HEAT % OF HEAT HEAT TRANSFR
TRANSFER TRANSFER RATE
21.77 33.77 35.53
27.83 51.35 44.66
28.21 50.98 45.80

2. Double cross flow type heat exchanger

Mass flow rate of water = 0.141 kg/s

Mass flow rate of air = 0.0167 kg/s

OBSERVATION AND HEAT TRANSFER RATE:

T T T3 T4 Heat Gained by Heat lost by
1 2
(°C) (°C) cold Fluid hot Fluid
(°C) (°C)
(water) (air)
(Watts) (Watts)
33.98 29.19 28.35 28.53 100.92 180.42
42.38 29.16 27.59 27.72 76.13 221.84
48.06 28.99 26.80 27.05 148.73 320.04
52.48 28.83 26.61 27.02 228.41 396.82

HEAT TRANSFER COEFFICIENT AND EFFECTIVENESS:

Convective Convective Overall Heat
Heat Transfer Heat Transfer Transfer Co-
Co-efficient of Co-efficient of efficient Effectiveness LMTD
2 2 2
Air W/m K Water W/m K W/m K
13.56 183.88 171.43 0.85 3.09
13.59 182.29 170.08 0.89 5.15
13.51 174.42 163.15 0.89 6.52
13.56 173.91 162.73 0.91 7.55

65
Staggered type heat exchanger

Mass flow rate of water = 0.141 kg/s

Mass flow rate of air = 0.0167 kg/s

OBSERVATION AND HEAT TRANSFER RATE:

T T T3 Heat GainedT4 Heat Lost by % Heat
1 2
(°C) (°C) by Cold Hot Fluid Gain
(°C) (°C)
Fluid (Air)
(Water) (Watts)
(Watts)
32.85 28.18 27.08 27.16 78.37 47.21 39.75
42.76 28.53 27.18 27.38 238.82 118.04 50.57
47.95 32.66 28.909 29.18 256.77 159.95 37.70
52.35 33.23 29.557 29.904 321.03 204.80 36.20
HEAT TRANSFER COEFFICIENT AND EFFECTIVENESS:
Convective Convective Overall Heat Effectiveness
Heat Transfer Heat Transfer Transfer Co-
Co-efficient of Co-efficient of efficient LMTD
2 2 2
Air W/m K Water W/m K W/m K
9.36 186.2 168.58 0.80 2.74
9.36 186.05 168.46 0.81 5.53
9.34 186.17 168.53 0.83 9.15
9.36 182.85 165.83 0.91 10.11
COMPARISONTABLE:
S.no LMTD(K) EFFCTIVENESS Qair(W) Qwater(W)
DCF SF DCF SF DCF SF DCF SF
3.092 2.74 0.85 0.80 180.42 78.37 100.92 47.21
1
5.15 5.53 0.89 0.81 221.84 238.82 76.13 118.04
2
6.52 9.15 0.89 0.83 320.0 256.77 148.73 159.95
3
7.55 10.11 0.91 0.91 396.83 321.03 228.41 204.80
4

66
COMPARISONOFHEAT TRANSFERRATE
SF DCF % INCREASE INHEAT
% OF HEAT % OF HEAT TRANSFRRATE
TRANSFER TRANSFER
39.75 44.06 10.19
50.57 65.67 23.02
37.70 42.52 12.82
36.20 53.43 32.35

Double cross flow type heat exchanger

Mass flow rate of water = 0.134 kg/s

Mass flow rate of air = 0.0167 kg/s

OBSERVATION AND HEAT TRANSFER RATE:

T1 T2 T3 T4 Heat Heat Lost % Heat

Gained by by Hot Transfer
(°C) (°C) (°C) (°C)
Cold Fluid Fluid

61.69 33.20 30.85 31.81 362.45 417.23 86.86

62.77 33.47 31.15 31.97 312.35 429.32 72.75

63.43 33.52 31.13 31.93 299.82 438.09 68.43

65.81 33.80 31.35 32.16 308.17 468.90 65.72

66.14 33.83 31.31 32.10 301.72 472.68 63.83

66.55 34.04 31.52 32.40 334.74 476.09 70.31

67
HEAT TRANSFER COEFFICIENT AND EFFECTIVENESS:

Convective Convective Overall Heat Effectiveness

Heat Transfer Heat Transfer Transfer Co-
Co-efficient of Co-efficient of efficient LMTD
2 2 2
Air W/m K Water W/m K W/m K
12.55 186.44 172.76 6.32
0.92
12.57 186.66 172.96 0.92 5.17

12.57 186.75 173.04 0.92 5.24

12.63 186.66 173.02 0.92 7.14

12.65 186.75 173.12 0.92 5.96

12.66 186.87 173.23 0.92 6.70

Staggered type heat exchanger:

Mass flow rate of water = 0.134 kg/s

Mass flow rate of air = 0.0145 kg/s

OBSERVATION AND HEAT TRANSFER RATE:

T1 T2 T3 T4 Heat Heat Lost % Heat

Gained by by Hot Transfer
(°C) (°C) (°C) (°C)
Cold Fluid Fluid

61.88 31.76 29.80 30.06 153.59 509.47 37.15

67.74 34.21 31.47 32.12 364.38 491.06 54.20
68.16 34.40 31.58 32.03 255.29 494.58 51.61
68.42 34.44 31.67 32.11 248.54 497.65 49.94
68.36 34.51 31.73 32.16 228.86 495.85 47.55
68.60 34.43 31.68 32.22 301.96 500.52 60.32

68
HEAT TRANSFER COEFFICIENT AND EFFECTIVENESS:

Convective Convective Overall Heat Effectiveness

Heat Transfer Heat Transfer Transfer Co-
Co-efficient of Co-efficient of efficient LMTD
2 2 2
Air W/m K Water W/m K W/m K
8.77 186.44 167.77 0.77 2.34

8.79 186.66 167.97 0.87 2.64

8.79 186.75 168.04 0.90 2.89

8.82 186.87 168.19 0.88 3.22

8.85 187.01 168.37 0.81 3.54

COMPARISONTABLE:
S.no LMTD(K) EFFCTIVENESS Qair(W) Qwater(W)

DCF SF DCF SF DCF SF DCF SF

1) 6.32 2.34 0.92 0.77 417.23 509.48 362.45 153.59

2) 5.17 2.64 0.92 0.87 429.35 491.09 312.37 364.38

3) 5.24 2.89 0.92 0.90 438.09 494.58 299.82 255.29

4) 6.42 3.22 0.93 0.88 449.30 497.65 215.57 248.54

5) 6.90 3.54 0.92 0.81 453.80 495.85 264.91 228.86

6) 7.26 4.10 0.93 0.91 459.60 498.67 321.46 225.33

69
COMPARISONOFHEAT TRANSFERRATE
SF DCF % INCREASE IN HEAT
% OF HEAT % OF HEAT TRANSFRRATE
TRANSFER TRANSFER
37.14 86.86 57.24

54.20 72.75 25.47

51.61 68.43 24.58

49.94 65.72 24.02

47.55 63.83 25.51

60.32 70.31 14.2

70