ANALYSIS OF HEAT TRANSFER IN CONICAL SHELL AND CIRCULAR TUBE

HEAT EXCHANGER

A synopsis
Submitted to
Gujarat Technological University

For the award of

Doctor of Philosophy

In
Mechanical Engineering

By
Chirag Amrutlal Maradiya
[139997119001]

Under the supervision of

Dr. Jeetendra A. Vadher

GUJARAT TECHNOLOGICAL UNIVERSITY

CHANDKHEDA, AHMEDABAD
 INDEX

Sr. No. Topic Page No.

1. Title Page 1

2. Index 2

3. Abstract 3

4. State of art of research 5

5. Problem definition 5

6. Objective of work 6

7. Scope of work 6

8. Original contribution by the thesis 6

9. Research Methodology 7

10. Achievement with respect to objectives 18

11. Conclusion 19

12. Future scope 20

13. Details of research paper published 21

14. References 22

2
ABSTRACT

Heat transfer equipments have been used for exchange and recovery of heat in many
industrial and domestic applications. Since last few decades, there has been continuous efforts to
develop a design of heat exchanger that can result in reduction in operating cost (energy
consumption) as well as material and other cost saving. Heat transfer enhancement techniques
generally reduce the thermal resistance either by increasing the effective heat transfer surface
area or by generating turbulence. Tube in tube heat exchanger is one of the widely used heat
exchanger due to its simple construction and operation. In tube-tube heat exchanger geometries
like twisted tapes, winglets, vertex generators, etc are normally placed inside inner tube of heat
exchanger to enhance heat transfer rate. In tube - tube heat exchanger both the pipes are
cylindrical. In this research, outer cylindrical tube of ordinary concentric tube heat exchanger has
been replaced by conical tube instead of any geometry placed inside inner tube. Ratio of inlet
diameter to outlet diameter of outer pipe represented as diameter ratio. Four outer tube of
diameter ratio 1 (straight), 0.882, 0.741 and 0.612 have been analyzed in this research.
Numerical analysis of cylindrical shell (straight) and conical shells (Continuous decreasing
annulus space) heat exchanger has been carried out to evaluate effect of conical shape on heat
transfer rate considering different Nusselt number correlations for annulus flow. In numerical
analysis, overall heat transfer coefficients have been calculated considering for various Nusselt
number correlations. Results of numerical analysis represent, the overall heat transfer coefficient
for conical shape heat exchanger is higher than cylindrical shape heat exchanger. For
experimental investigation, new conical tubes of above mentioned diameter ratios have been
constructed by epoxy resin and glass fiber. Experiments were carried out for conical tube heat
exchanger of length 1 meter. The flow rate of water for inner tube considered 1 LPM and for
outer conical tube 1 LPM to 7 LPM. During experiment temperature and flow rate have been
measured. From measured data, the overall heat transfer coefficient and heat transfer rate
calculated. The heat transfer results of conical tubes were analyzed and compared with the
results of cylindrical tubes. Results revealed that the rate of heat transfer was inversely
proportional to diameter ratio and proportional to flow rate. Results revealed a rise of heat
transfer rate up to 22%. A linear correlation for heat transfer rate was developed for water
flowing through outer conical tubes. This correlation shows relation of heat transfer rate with
diameter ratio and flow rate of water in outer shell. Results from derived correlations are in good

3
agreement with experimental results. Exergy analysis of tube - tube heat exchanger has been
carried out based on second law analysis. In exergy analysis total entropy generation, entropy
generation number and exergy destruction number have been calculated for all the configuration
of experiment. When NE <1, system is optimized. It was observed that exergy destruction
number was more than 1 and increases with taper of conical shape which represents non-
favorable condition.

4
STATE OF ART OF RESEARCH

Heat transfer equipments are widely used in industrial as well as domestic applications.
Heat transfer enhancement techniques have been used to improve effectiveness of heat
exchanging equipments. Heat transfer enhancement helps to enhance heat transfer rate, reduce
size of heat exchanger and save material cost. Heat transfer enhancement techniques either
produce secondary turbulence or improve effective heat transfer area.

Heat transfer enhancement techniques have been classified into two categories: Active
techniques and Passive techniques. Active techniques consumed extra energy for fluid suction or
injection, heat transfer surface vibration, pulsating flow, etc. Where as in passive techniques
external power is not required. Insert twisted tape, winglet type turbulator, generate artificial
surface, etc are some of the famous passive techniques used in heat exchanger.

Tube in tube heat exchanger is one of the most commonly used heat exchanger which
uses to exchange heat between two fluids. In tube in tube heat exchanger twisted tapes with
different configurations and arrangements have been used in inner pipe to enhance heat transfer
rate. Where as turbulators have been used in outer tube to enhance heat transfer rate. In tube in
tube heat exchanger outer tube is cylindrical. Focus have been made on analysis of heat transfer
rate in conical outer tube instead of cylindrical tube.

PROBLEM DEFINITION

Heat exchangers are used in various industries and one of the most using equipment in
the world. Tube in tube heat exchanger is one of the widely used heat exchanger due to its simple
construction and operation. In tube in tube heat exchanger enhancement of heat transfer rate is
one of the most important issue in current scenario. Enhancement of heat transfer rate in tube in
tube heat exchanger can be achieved by several active and passive techniques like pulsating
flow, vibration of heat exchanging surface, insert twisted tape, winglets, turbulators, nano
particles, corrugated tubes, etc. But effect of shape change of outer cylindrical shell required to
be analyzed. In present study, outer shell is considered conical and its effect on heat transfer rate
should be analyzed.

5
OBJECTIVE OF WORK:

 To study effect of passive heat transfer enhancement techniques used in tube-tube heat
exchanger
 To theoretically analyze effect of conical shape as an outer shell of tube-tube heat
exchanger
 Experimental analysis of conical shell and cylindrical tube heat exchanger
 To derive mathematical model of heat transfer rate on the basis of experimental data and
validate it
 Exergy analysis of heat exchanger from experimental results

SCOPE OF WORK:

Tube-tube heat exchanger is one of the most commonly used heat exchanger. This type of
heat exchanger mostly used to exchange heat between liquids. Outer shell of this type of heat
exchanger is normally cylindrical in shape. Conical outer shell of tube-tube heat exchanger
affects performance of heat exchanger.

ORIGINAL CONTRIBUTION BY THE THESIS:

Studied from the literature, it was concluded that passive heat transfer enhancement
techniques use inserts, baffles, twisted tapes, etc to improve heat transfer characteristics. Effect
of shape of outer shell in tube-tube heat exchanger has not been analyzed. So, main aim of the
research was to analyze effect of conical shape on heat transfer rate and derive mathematical
model of heat transfer rate in tube-tube heat exchanger.

The original contributions of the work are:

 Theoretical and experimental analysis of conical shell and cylindrical tube heat
exchanger
 Derive mathematical model of heat transfer rate in conical shell and cylindrical tube heat
exchanger
 Exergy analysis of conical shell and cylindrical tube heat exchanger

6
RESEARCH METHODOLOGY:

Research of this topic has been carried out in following sequence:

1) Literature Survey and identifying parameters affecting heat transfer characteristics

From the literature review, it can be concluded that the heat transfer enhancement occurs
in all cases due to reduction in the flow cross section area, an increase in turbulence intensity and
an increase in tangential flow established by various types of inserts. Geometrical parameters of
inserts like width, length, twist ratio, etc. affect the heat transfer enhancement considerably.
Exhaustive research has been done by many investigators on the use of twisted tape, artificial
roughness or vortex generators to enhance the heat transfer characteristics in tube heat
exchangers as discussed in this review; however the areas related to outer tube geometries like
conical, parabolic, frustum, etc have not yet been explored and could be the focus of new
research.

From literature it has been concluded that following parameters are involved in
convective heat transfer:

• Temperature difference
• Fluid properties density (ρ), viscosity (µ), specific heat(Cp), thermal conductivity (k)
• Convective heat transfer coefficient (h)
• Fluid velocity (V)
• Dimensions of heat exchanger (d/l)

All these parameters are combine and reduced to following dimensionless numbers
• Nu (Nusselt Number), Re (Reynolds Number) and Pr (Prandtl Number)
Relation between these numbers is as below:
Nu = f (Re, Pr)
So, if we consider Prandtl Number constant and changes in Reynolds Number will directly
affect Nusselt Number.
• Reynolds number represents combined effect of fluid property and velocity of fluid

7
 • As Reynolds number increases, turbulence in the flow increases which leads to rise in
heat transfer rate

2) Theoretical analysis of heat transfer improvement due to conical shape in tube-tube heat
exchanger

In conical shape heat exchanger, outer shell is conical and inner shell is cylindrical (as
usual).

Effect of conical shape on heat transfer coefficient has been studied considering Dittus–
Boelter correlation.

. .
𝑁𝑢 = 0.023 . 𝑅𝑒 . 𝑃𝑟

For annulus flow

( )
𝑁𝑢 = -------------------(1)

Now as per Dittus–Boelter equation

. .
𝑁𝑢 = 0.023 𝑅𝑒 𝑃𝑟 ---------------(2)

From equation (1) and (2)

0.023 𝑅𝑒 . 𝑃𝑟 .
ℎ= 𝑘
(𝑑 − 𝑑 )
( )
𝑅𝑒 = for annulus flow

0.023 𝑅𝑒 . 𝑃𝑟 .
ℎ= 𝑘
(𝑑 − 𝑑 )
.
𝜌𝑉(𝑑 − 𝑑 ) .
0.023 𝑃𝑟 𝑘
𝜇
ℎ=
(𝑑 − 𝑑 )

8
 .
4 𝜌𝑄(𝑑 − 𝑑 ) .
0.023 𝑃𝑟 𝑘
𝜋(𝑑 − 𝑑 )𝜇
ℎ=
(𝑑 − 𝑑 )
.
4 𝜌𝑄(𝑑 − 𝑑 ) .
1
ℎ = 0.023 𝑃𝑟 𝑘
𝜋 𝑑 −𝑑 𝜇 (𝑑 − 𝑑 )
.
4 𝜌𝑄(𝑑 − 𝑑 ) .
1
ℎ = 0.023 𝑃𝑟 𝑘
𝜋(𝑑 − 𝑑 )(𝑑 + 𝑑 )𝜇 (𝑑 − 𝑑 )
.
4 𝜌𝑄 .
1
ℎ = 0.023 𝑃𝑟 𝑘
𝜋(𝑑 + 𝑑 )𝜇 (𝑑 − 𝑑 )
.
4 𝜌𝑄 .
1 1
ℎ = 0.023 𝑃𝑟 𝑘 .
𝜋𝜇 (𝑑 + 𝑑 ) (𝑑 − 𝑑 )
.
4 𝜌𝑄 .
1 1
ℎ = 0.023 𝑃𝑟 𝑘 .
𝜋𝜇 (𝐷 − 𝑥. tan 𝜃 + 𝑑 ) (𝐷 − 𝑥. tan 𝜃 − 𝑑 )

From the equation it has been concluded that h will increase with decrease in outer diameter.
On the basis of this equation local heat transfer coefficient has been calculated for following
data:

• Fluid : Water
• Outer Pipe Outer Diameter: 85
• Outer Pipe Inner Diameter: 38
• Flow Rate: 10 LPM
No. Of Cases: 3 (85-85 (straight), 85-75(Conical), 85-65(Conical))

9
 It has been observed that local heat transfer coefficient increases as the diameter
decreases along the length.
For theoretical analysis average heat transfer coefficient calculated for annulus side from
local heat transfer coefficient. For constant heat transfer coefficient on inner side, overall heat
transfer has been calculated using following equation.
1 1 1
= +
𝑈 ℎ ℎ
To study behavior of overall heat transfer coefficient in conical shape heat exchanger
more correlations have been considered with some assumptions. Following are the correlations:
 Dittus–Boelter correlation:𝑁𝑢 = 0.023 𝑅𝑒 .
𝑃𝑟
.
 Mc Adams correlation:𝑁𝑢 = 0.023 𝑅𝑒 .
𝑃𝑟 /

.
 Davis correlation: Nu = 0.038 𝑎 . (𝑎 − 1) .
𝑅𝑒 .
𝑃𝑟 /

.
 McAdams correlation:𝑁𝑢 = 0.03105 𝑎 . (𝑎 − 1) .
𝑅𝑒 .
𝑃𝑟 /

.
 Foust & Christian correlation:𝑁𝑢 = ( ) .
𝑅𝑒 .
𝑃𝑟 .

 Monrad & Pelton correlation:𝑁𝑢 = 0.023 𝑅𝑒 .

𝑃𝑟
.
 Wiegand et al. correlation: 𝑁𝑢 = 0.023 𝑎 .
𝑅𝑒 .
𝑃𝑟
. .
 Potukhov & Roizen correlation:𝑁𝑢 = ( ) .
𝑅𝑒 .
𝜉
𝜉 = 1 𝑓𝑜𝑟 𝑎 ≤ 5
 Stain & Begell correlation:𝑁𝑢 = 0.02 𝑎 .
𝑅𝑒 .
𝑃𝑟 /

10
  Crookston et al. correlation:𝑁𝑢 = 0.023 𝑎 /
𝑅𝑒 /
𝑃𝑟 /

Assumptions:
 Inner flow is constant (water - 5 LPM)
 Fluid properties remain constant with temperature change
 Thermal resistance for inner pipe is neglected
 Heat transfer into atmosphere is neglected
Overall heat transfer coefficient for three cases have been calculated and represented as
shown in fig.

Figure 1 Overall heat transfer coefficient for 85-85 straight pipe

Figure 2 Overall heat transfer coefficient for 85-75 conical Figure 3 Overall heat transfer coefficient for 85-65 conical
shell shell

11
Figure 4 % rise in overall heat transfer coefficient in 85-75 Figure 5 % rise in overall heat transfer coefficient in 85-65
conical shell heat exchanger compared to straight pipe heat conical shell heat exchanger compared to straight pipe heat
exchanger exchanger

From theoretical study it has been observed that overall heat transfer coefficient increases
with flow rate. From the theoretical results, it was also concluded that overall heat transfer
coefficient increases with the taper of conical shell. But percentage rise in overall heat transfer
coefficient decreases with flow rate.
In conical shell heat exchanger, due to continuous reduction in outer diameter along the
length velocity increases. Increment in velocity raises Reynolds Number which leads to improve
annulus side heat transfer coefficient and ultimately overall heat transfer coefficient.
From figure (4 & 5), it was observed that percentage rise in overall heat transfer coefficient
compared to straight pipe heat exchanger is higher at low flow rate and decreases as flow rate
increases.

3) Experimental investigation of effect of conical shape on tube-tube heat exchanger

From theoretical study it has been observed that overall heat transfer coefficient increases
in conical shape heat exchanger compared to straight pipe heat exchanger. So, for experimental
investigation 4 tube-tube heat exchanger have been constructed (1 straight pipe and 3-conical
pipe). Hot water was supplied from inner pipe and cold water was supplied form annulus space.
The inner tube was cylindrical, made from copper. Copper is used as an inner tube material due
to its high thermal conductance. For better thermal resistance at the outer surface and to devise
an irregular shape at the outer shell epoxy resin and glass fiber was used. Inlets to outlet diameter
ratios for outer conical tubes are 0.88, 0.74 and 0.61.

12
 It has been also concluded that percentage rise in overall heat transfer coefficient is
higher at low flow rate and decreases with increase in flow rate. So, it has been decided to
conduct experiment for lower flow rate. The hot water was made to flow constant at 1 LPM
through an inner copper tube and cold water was set to flow varying from 1 LPM to 7 LPM
through the annulus.
Inlet and outlet temperatures of hot and cold water for different flow rates have been
measured. From experimental data heat transfer rate, logarithmic temperature difference and
overall heat transfer coefficient have been calculated by using following equations.

 Heat transfer from the hot fluid : Q = mCp(ΔTh) = mCp(Th,in - Th,out)
 Heat transfer to the cold fluid: Q = mCp(ΔTc) = mCp(Tc,out – Tc,in)

Logarithmic mean temperature difference

θ1 = Th1 - Tc2, θ2 = Th2 - Tc1

𝜃 − 𝜃
∆𝑇 = 𝐿𝑀𝑇𝐷 =
𝜃
ln
𝜃
The overall heat transfer coefficient of the system
𝑄
𝑈=
𝐴. ∆𝑇
The percentage error of heat loss from hot water and heat gain by cold water was found
out to be 1% to 7.8%, ensuring a minimum possible loss of heat to the atmosphere.

13
 Figure 6 Schematic diagram of experiment set-up

Figure 7 Heat transfer rate Figure 8 Overall heat transfer coefficient

The effects of the flow rate of fluid (water) and diameter ratio of the outer conical tube on
heat transfer characteristics were examined. Figure 7 shows the heat transfer rate for flow rate
ranging from 1 LPM to 7 LPM on outer annulus space. In this experiment, the analysis was done
for flow through outer tubes having diameter ratio 1, 0.882, 00.741
.741 and 0.612. The heat transfer
rate for cylindrical shell ( diameter ratio 1) heat exchanger varies from 33.91kJ/min at 1 LPM to
46.89 kJ/min at 7 LPM. Whereas the heat transfer rate in conical shell heat exchanger is: 35.17
kJ/min to 52.75 kJ/min for conical shape heat exchanger with diameter ratio 0.882, 36.42 kJ/min
to 52.76 kJ/min for HE with diameter ratio 0.741 and 36.
36.84
84 kJ/min to 55.68 kJ/min for heat
exchanger with diameter ratio 0.612. Figure 8 shows the overall heat transfer coefficient. The
overall
verall heat transfer coefficient for heat exchanger having diameter ratio 1 varies with flow rate (
1 LPM to 7 LPM ) from 171.5 W/m2K to 239.34 W/m2K. It is for heat exchanger having

14
diameter ratio 0.882, 0.741 and 0.612 was 183.9 W/m 2K to 271 W/m2K, 226.8 W/m2K to 293
W/m2K and 251 W/m2K to 340.3 W/m2K respectively. So, the overall heat transfer coefficient
rises up to 12 % in conical shape heat exchanger having diameter ratio of 0.882 compared to
cylindrical heat exchanger. Same as overall heat transfer coefficient rises up to 16 % and 22 % in
conical shape heat exchanger having diameter ratio 0.741 and 0.612 respectively. From the
experimental results, it has been observed that the heat transfer rate and the overall heat transfer
coefficient improves with the rise in flow rate. It has also been observed that the heat transfer
rate and the overall heat transfer coefficient increase with the decrease in diameter ratio.
Improvement in heat transfer characteristics in conical outer geometry is due to turbulence
generated when water passes through the taper section. It happens due to the continuous increase
in Re Number along the length. Increases of Re Number along the length ultimately improve the
heat transfer rate and performance of heat exchanger.

4) Mathematical modeling and validation

From experimental results mathematical model (linear model) of heat transfer rate have
been developed using Minitab and Excel. Equation of heat transfer rate has been modeled in
form of mass flow rate of fluid and diameter ratio. Comparison of mathematical model was
mentioned in following table.
Minitab Excel (ANNOVA)
R-sq 94.32 97.11
R-sq (ad) 94.04 94.31
Constant 48.2 48.2
Coefficients m 2.705 2.705
do/di 16.64 -16.64
Equation 48.20+2.705m-16.64do/di 48.20+2.705m-16.64do/di
+ 3.87 3.83
Error
- -10.55 -10.52

For both the equations R-squared value is more than 94% which shows very less
difference between observation and fitted value.

15
 Figure 9 Experiment vs Predicted values

To validate experimental data of cylindrical shell type heat exchanger have been
compared with previously published correlations. First Nusselt numbers for inner flow and
annulus flow have been calculated considering following 3 correlations to compare experimental
results.

For inner flow

. .
Dittus–Boelter correlation: 𝑁𝑢 = 0.023 𝑅𝑒 𝑃𝑟

For annulus flow

. ∗ .
Stephan’s equation: 𝑁𝑢 = 4.364 + . .
. ∗ ∗

/
VDI - Warmeatlas : 𝑁𝑢 = 𝑁𝑢 + 𝑁𝑢
.
𝑁𝑢 = 3.66 + 1.2 ∗ 𝐷

. /
𝑁𝑢 = 1.615(1 + 0.14 ∗ 𝐷 )𝐺

𝐺𝑧 = 𝑅𝑒. 𝑃𝑟.

𝐷 = , dT = diameter of tube, ds = diameter of shell

On the basis of Nu No. heat transfer coefficient have been calculated and then overall
heat transfer coefficient. From the value of overall heat transfer coefficient and temperature heat
transfer rate have been calculated and represented in following figure.

16
 From figure it has been observed that heat transfer rate of experimental results and
previous correlations have same pattern (increases with flow rate) but experimental results were
higher than results from previous correlations. It was due to the following reasons:

 Due to surface roughness

 Fluid enters in shell side from cross flow direction
 Turbulence generated due to RTD placed in flow region

5) Exergy analysis:

Exergy analysis of tube - tube heat exchanger has been carried out based on second law
analysis as below.

 Total entropy generation

𝑇 𝑇
𝑆 =𝑚 𝐶 ln + 𝑚 𝐶 ln
𝑇 𝑇
 Entropy generation number
𝑆
𝑁 =
𝐶
 Exergy destruction number
𝑁
𝑁 =
𝑁

Where, Nsa = Entropy generation number for augmented(conical) arrangement

Nss = Entropy generation number for straight arrangement

17
 Exergy destruction number of all flow rate and all conical cases have been represented in
figure. From the figure it has been observed that Exergy destruction number was approximate 1
or more than 1. An average exergy destruction number was more than one for all three cases.
When Ne < 1, system is optimized. In present study Ne > 1, which represents non-favorable
condition. It was also observed that exergy destruction number increases with taper of conical
shell.

ACHIEVEMENTS WITH RESPECT TO OBJECTIVES

Objectives Achievements
To study effect of passive heat transfer From previous work it was observed that
enhancement techniques used in tube-tube heat transfer characteristics influenced
heat exchanger considerably with passive heat transfer
enhancement techniques. It was occurs
either by increasing heat transfer exchange
surfaces or due to turbulence produced by
inserts.
To theoretically analyze effect of conical Theoretically analyzed effect of conical
shape as an outer shell of tube-tube heat shape on heat transfer characteristics
exchanger considering empirical correlations and
found heat transfer rate increases in conical
shape heat exchanger
Experimental analysis of conical shell and Experiments have been performed for 1
cylindrical tube heat exchanger straight pipe heat exchanger and 3 conical
shape heat exchangers. It was observed that

18
 heat transfer rate improves in conical shape
heat exchanger and also increases with taper
of conical shape.
To derive mathematical model of heat Linear mathematical model of heat transfer
transfer rate on the basis of experimental rate have been derived using Minitab and
data and validate it excel and found it was having higher R-sq
value. Results of straight pipe have been
compared with previously published
correlations to validate mathematical model.
Exergy analysis of heat exchanger from Exergy analysis of the system has been
experimental results carried out by second law analysis and
found exergy destruction number more than
1.

CONCLUSION:

Passive heat transfer enhancement techniques have been used to improve heat transfer
characteristics by inserting elements in flow passage or by generating artificial roughness. The
effects of shape of outer shell on heat transfer characteristics needed to be analyzed. So, the
impacts of conical shape as outer shell of tube in tube heat exchanger have been studied
theoretically and experimentally. 4 heat exchangers have been constructed for the analysis, 1
straight (cylindrical) and 3 conical with different taper. From theoretical and experimental study
it have been concluded that heat transfer rate increases with taper of conical shell. Heat transfer
rate improves upto 22 %. Exergy analysis revealed that exergy destruction number were more
than one and increases with taper of conical shell.

FUTURE SCOPE:

 In present study experiments were carried out on heat exchanger having length 1m and 4
different diameter ratios. In future, more length and diameter ratio will be consider to
analyze effect of taper angle.
 Experiments can be carried out with fluid other than water to understand combined effect
taper and fluid properties on heat transfer characteristics.

19
PAPER PUBLISHED:

1) Numerical Analysis of Conical Heat Exchanger,18-21, ICRISET-2017, IJTE

2) The heat transfer enhancement techniques and their thermal performance factor, Beni-
Suef University Journal of Basic and Applied Sciences 7(2018), 1-18. (Elsevier)
3) Performance analysis of conical shell cylindrical tube heat exchanger, Journal of
Emerging Technologies and Innovative Research, 5 (12), 272-279.
4) Experimental study of heat transfer in conical tube heat exchanger, International Journal
of Engineering Research and Technology. ISSN 0974-3154, Volume 12, Number 12
(2019), pp. 2587-2591. (Scopus Indexed)

20
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