Numerical Investigation of Heat Transfer Enhancement and Pressure Drop of a Double Tube Heat Exchanger with Rectangular Fins in the Annulus Side
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1 International Journal of Dynamics of Fluids. ISSN Volume 13, Number 2 (2017), pp Research India Publications Numerical Investigation of Heat Transfer Enhancement and Pressure Drop of a Double Tube Heat Exchanger with Rectangular Fins in the Annulus Side N Sreenivasalu Reddy * Rajarajeswari College of Engineering, Bengaluru, Karnataka, India. K Rajagopal Sri Krishnadevaraya University, Anantapuramu, Andhra Pradesh, India. P H Veena Smt.V.G.College for Women, Gulberga, Karnataka, India. Abstract In the present study the design and performance of double pipe heat exchanger with straight rectangular fins in the annulus side are analyzed numerically. Computational fluid dynamics (CFD) model using free open source code has been performed to study the fluid flow, heat transfer coefficient and pressure drop in the annulus side of double pipe heat exchanger for different configurations. A numerical investigation is carried out for different values of mass flow rate and varying the number of fins. The numerical results first validated with experimental results for a simple double pipe heat exchanger. Then the CFD model results have been validated with rectangular fins. The results of rectangular fins in the annulus side causes increased rate of heat transfer and pressured drop compared to plain double pipe heat exchanger. The numerical study is performed by varying mass flow rate of cold fluid in the annulus side and kept mass flow rate of hot fluid in the inner pipe is constant. The performance and increased pressure drop is a function of number of fins and mass flow rate.
2 296 N Sreenivasalu Reddy, K Rajagopal and P H Veena NOMENCLATURE A heat transfer surface area (m 2 ) Cp U Q T M LMTD K SIMPLE Specific heat, KJ/kg o C Overall heat transfer coefficient KW/m 2 o C Heat transfer rate, KW Temperature, o C Mass flow rate, kg/s Log mean temperature difference Thermal conductivity, KW/m o C Semi Implicit method for pressure linked equations INTRODUCTION Double pipe heat exchangers have an important role in various engineering process application. A double pipe heat exchanger consists inner pipe and outer pipe. Heat flows between two fluids, which are flowing in inner and outer pipes respectively. The fluids may flow in parallel or counter flow direction. Double pipe exchangers are used in applications involving low volume flow rate. Recently there are many studies have been done in improvements, enhance ment heat transfer rate, Yang et al. [1], Akpinar [2], Ma et al. [3], their results in low cost, raising thermal rating and life of the equipment. Pourahmad and Pesteei [4] studied on double pipe heat exchanger by providing curvy strip turbulators in the inside pipe, their findings are on improvements in enhancement of heat transfer characteristics. Ibrahim [5] investigated the increase of laminar flow and heat transfer plane tubes with helical tape inserts. Results of permeable baffles and flow pulsation on a concentric tube heat exchanger effectiveness was studied by Targui and Kahalerras [6], the authors proposed that addition of rotary machinery in the inner pipe increases the heat transfer. An analysis of using plain and perforated variable spacing with helical tabulators was studied by Sheikholeslami et al. [7], heat transfer and fluid flow analysis were carried out for different area ratios and pitch ratios. Results shows that effectiveness is an increasing function of open area ratio and decreasing function of pitch ratio. Recently the fast growth of various computational methods on double heat exchanger is done based on methods [8, 9]. These methods are complement to experiments and theory. Gorman et al. [10] presented a numerical method for the thermal design. A detailed review was carried out by Ahmed et al. [11], on star shaped finned tube heat exchangers. Further the heat transfer enhancement methods are studied in [12-20].
3 Numerical Investigation of Heat Transfer Enhancement and Pressure Drop 297 In the present paper a detailed numerical study of heat transfer for a water to water concentric tube exchanger with rectangular fins at the annulus side is carried out. In the literature baffles are almost used in shell and tube heat exchanger to increase heat transfer rate and to decrease pressure drop, and no publication studying on thermo hydraulic performance in the annulus side of the concentric tube heat exchanger could be found. The mass flow rate in the inner pipe is kept constant as in conventional concentric tube heat exchanger. The experiments were conducted for different cases of number of fins in the annulus side. The numerical results of simple plain tube are validated with experimental results. NUMERICAL METHOD Geometry Details The main objective of this research is to compare different configuration of rectangular fins in the annulus side of concentric tube heat exchanger. Addition of these fins changes the pressure and velocity distribution along the annulus side of the heat exchanger and thus changes in heat transfer and pressure drop. The configuration of rectangular finned heat exchanger is as shown in Figure 1. The number of rectangular fins varied from 6 to 8. In modified configurations the effect of geometric, flow and thermal variables are numerically studied. Though the geometry is simple, its numerical thermo fluid study is complex because of the flow regime in annulus side. Figure 1. Model of Inner Pipe of Double Pipe Heat Exhanger with 8 Fins and 6fins The hot water flows in the inner tube while the cold water flows in the annulus side of the double pipe heat exchanger. The material of the heat exchanger parts is copper and its thermal conductivity is 401 W/m-k. Water is taken as a Newtonian and incompressible fluid with constant thermo physical properties. In addition, the fluid is considered as laminar and steady state. The viscous heating and compression work
4 298 N Sreenivasalu Reddy, K Rajagopal and P H Veena terms are neglected in the energy equation. The heat exchanger is assumed newly fabricated and fouling resistance is not considered. In the present study the parts of the heat exchangers are modeled using Solid Edge software. The unstructured mesh is generated using ANSYS Fluent software. And it is solved in open source codes (OpenFoam). Domain Definitions, Mess Sensitivity and Boundary conditions In the present study there are three double pipe heat exchangers are modeled. One simple unfinned double pipe heat exchanger, second double pipe heat exchanger with 6 fins, and third double pipe heat exchanger is with 8 fins. For each of the three studied heat exchangers, three domains are defined. Two fluid domains (water in the inner tube and water in the annulus side) and one solid domain (copper wall with rectangular fins). The domains are meshed with a mix of unstructured tetrahedral and prism grid. To ensure the accuracy of the results, the mesh sensitivity test was conducted for 6 finned and 8 finned double pipe heat exchanger. The boundary condition of no slip is set for all the solid walls. Zero heat flux is set for annulus side wall, the walls of the inner tube and fins have the boundary condition of coupling heat transfer. These walls considered as solid fluid interfaces between two fluid domains and the solid domain. The inlet boundary conditions for the inner tube side and annulus are set as mass inlet, the out let boundary conditions are set as pressure out let is zero, so that inlet pressure is equal to pressure drop on both the inner tube side and annulus. The open source codes are used to calculate fluid flow and heat transfer in the computational domains. The governing equations are solved by finite volume formulation with conjugate heat transfer SIMPLE algorithm. The numerical solution is based on continuity, momentum and energy equations. DATA REDUCTION For the temperatures deviations, a log mean temperature difference (LMTD) LMTD = [(Tw,h,in Tw,c,in) (Tw,h,out Tw,c,out)] ln [ Tw,h,in Tw,c,in Tw,h,out Tw,c,out ] (1) LMTD = [(Tw,h,in Tw,c,out) (Tw,h,out Tw,c,in)] ln [ Tw,h,in Tw,c,out Tw,h,out Tw,c,in ] (2)
5 Numerical Investigation of Heat Transfer Enhancement and Pressure Drop 299 For parallel flow and for counter flow is used. Heat transferred to the cold water in the annulus, Qw,c, can be determined from Qw, c = mw, c Cp, w(tw, c, out Tw, c, in) = UOAOLMTD (3) where mw, c is the mass flow rate of cold water which passing through the annulus, Uo is heat transfer coefficient, Ao is the surface area of the outside diameter of the inner pipe, Cp, w is the specific heat of cold and hot water, Tw, c, in and Tw, c, out are the inlet and outlet temperatures of cold water.heat transferred from the hot water in the inner pipe, Qw,h, can be determined as Qw, h = mw, h Cp, w(tw, h, in Tw, h, out) = UiAiLMTD (4) where mw, h is the mass flow rate of hot water which passing through the inner tube of heat exchanger, Ui is heat transfer coefficient, Ai is the surface area of the inside diameter of the inner pipe, Cp, w is the specific heat of cold and hot water, Tw, h, in and Tw, h, out are the inlet and outlet temperatures of hot water. The average heat transfer rate, Qave, is determined from the hot water side and cold water side as Qave = Qw,c+Qw,h 2 Qavg = UoAo LMTD (6) The overall heat transfer coefficient Uo based on outer surface area of the inner pipe can be determined as per the energy balance equation t, with negligible heat losses to surroundings, from equations (1) and (2): (5) RESULTS AND DISCUSSION To validate the numerical results a comparison is made with experimental data to evaluate heat transfer for simple double pipe heat exchanger. Validation is done for a hot water inlet temperature of 55 o C and 65 o C by varying the mass flow rate, from 0.01 kg/s to 0.03 kg/s in the annulus side of the heat exchanger, keeping constant mass flow rate of 0.01 kg/s in the inner pipe. Validation of rate of heat transfer and heat transfer coefficient at inlet temperature of 65 o C for counter flow direction with plain tube as shown in figure 2 and Figure 3 respectively. The numerical results are good agreement with experiment results. Therefore it is concluded that present
6 300 N Sreenivasalu Reddy, K Rajagopal and P H Veena numerical model produce a good prediction for heat transfer characteristics and pressure drop. Rate of Heat transfer Q Watts Experimental plain tube Thi=65C Numerical Plain Tube Mass flow rate Kg/s Figure 2. Validation of rate of heat transfer at inlet temperature of 65 o C for counter flow direction with plain tube Heat transfer coefficient w/m 2 o C Experimental plain tube Thi=65C Numerical Plain tube Mass flow rate Kg/s Figure 3. Validation heat transfer coefficient at inlet temperature of 65 o C for counter flow direction with plain tube Figure 4 and 6 shows the variation of rate of heat transfer in the annulus and mass flow rate in the annulus side of different configuration of double tube heat exchanger for counter flow direction at inlet temperature of 55 o C and 65 o C respectively. It can be seen from the Figure 4 that maximum deviation for the heat transfer in the annulus side is 12 %. Heat transfer coefficient on the annulus side is determined by Newton s law of cooling from the temperature field. Figure 5 and 7 shows the variation of heat transfer coefficient using plain tube, 6 fins and 8 fins at inlet temperature of 55 o C and 65 o C respectively. It can be seen that there is an increment in heat transfer coefficient as the increasing mass flow rate.
7 Numerical Investigation of Heat Transfer Enhancement and Pressure Drop 301 Rate of Heat transfer Q Watts Numerical Plain Tube numerical 6 fins Numerical 8 fins Mass flow rate Kg/s Figure 4. The variation of rate of heat transfer at inlet temperature of 55 o C 700 Rate of Heat transfer Q Watts Numerical Plain Tube Numerical 6 fins Numerical 8 fins Mass flow rate Kg/s Figure 6. The variation of rate of heat transfer at inlet temperature of 65 o C
8 302 N Sreenivasalu Reddy, K Rajagopal and P H Veena Heat transfer coefficient w/m 2 o C Numerical Plain tube Numerical 6 fins Numerical 8 fins Mass flow rate Kg/s Figure 5. The variation of heat transfer coefficient at inlet temperature of 55 o C Heat transfer coefficient w/m 2 o C Numerical Plain tube Numerical 6 fins Numerical 8 fins Mass flow rate Kg/s Figure 7. The variation of rate of heat transfer coefficient at inlet temperature of 65 o C From the above discussion it is concluded that numerical model as a reasonable precision the same model is used for a similar double pipe heat exchanger with rectangular fins. As it is mention in the boundary conditions, both side out lets are zero pressure, therefore the pressure drop is equal to inlet pressures for both annulus and inner pipe side. Variation of pressure drop in the annulus side and mass flow rate of cold water as shown in Figure 8. The results obtained for 6 fins and 8 fins are same trend that of plain tube. It is very clear from Figure 8 that the rise in the pressure drop is a function of mass flow rate in annulus side. As it can be observed that there is an increment in pressure drop as the mass flow rate increases.
9 Numerical Investigation of Heat Transfer Enhancement and Pressure Drop 303 Pressure drop in Pa plain tube Thi=65C 6 fins counterl flow 8 fins Mass flow rate Kg/s Figure 8. The variation of pressure drop at inlet temperature of 55 o C Figure 9. The temperature distribution at inlet temperature of 65 o C using 6 fins Figure 9 and 13 shows the temperature distribution at the center plane of the heat exchanger, for a counter flow direction at a mass flow rate of 0.01 kg/s using 6 and 8 fins respectively. The velocity stream lines for 6 fins and 8 fins are as shown in Figure 14 and 17 respectively. It can be observed that the flow patterns are in the annulus side is irrotational. Figure 12 shows that flow patterns in the annulus side. Increasing the velocity of the fluid is the one of the most enhance heat transfer performance for the same mass flow rate. Out of three studied without fin, 6 fins and 8 fins the highest velocity in the annulus side is located at the near the inlet at the entrance region. This is because of the sudden decreasing flow area, velocity of the annulus have to increase
10 304 N Sreenivasalu Reddy, K Rajagopal and P H Veena to keep mass flow rate through annulus side constant. Figure 16 shows turbulent kinetic energy contours, the maximum values or identified near to the entrance region. The highest value of turbulence and velocity at the entrance region indicate that large local pressure drop could be generated. The distribution of pressure, using 6 fins and 8 fins at the mass flow rate of cold fluid is 0.01 kg/s in the annulus side for a inlet hot water temperature of 65 o C as shown in figure 10 and 15 respectively. Figure 10. The pressure variation at inlet temperature of 65 o C using 6 fins Figure 11. The velocity distribution at inlet temperature of 65 o C using 6 fins
11 Numerical Investigation of Heat Transfer Enhancement and Pressure Drop 305 Figure 12. The velocity vector at inlet temperature of 65 o C using 6 fins Figure 14. The streamlines at inlet temperature of 65 o C using 6 fins Figure 16. The variation turbulence kinetic energy distribution at inlet temperature of 65 o C using 6 fins
12 306 N Sreenivasalu Reddy, K Rajagopal and P H Veena Figure 13. The temperature distribution at inlet temperature of 65 o C using 8 fins Figure 15. The pressure variation at inlet temperature of 65 o C using 8 fins Figure 17. The streamlines at inlet temperature of 65 o C using 8 fins
13 Numerical Investigation of Heat Transfer Enhancement and Pressure Drop 307 CONCLUSIONS In this study CFD model is used to investigate and compare the performance of double pipe heat exchanger with rectangular fins in the annulus side. The effects of rectangular fins and mass flow rate are studied. The results shows that compared to plain annulus side, using rectangular fins in the annulus side enhance the heat transfer on average with increasing pressure drop equal on average to 2,5,11 time pressure drop for a plain annulus side for plain tube, 6 fins and 8 fins respectively. The increase in pressure drop because of entrance region effect. The heat transfer enhancement makes the double tube heat exchanger more compact without changing it size and weight. The highest thermo hydraulic performance is obtained when 8 fins are used in a laminar flow region. REFERENCES [1] Yang D, Guo Y, Zhang J, Evaluation of the thermal performance of an earth to air heat exchanger (EAHE) in a harmonic thermal environment. Energy Conversion and Management, Vol. 109, pp [2] Akpinar EK, Evaluation of heat transfer and exergy loss in a concentric double pipe exchanger equipped with helical wires, Energy Conversion and Management; Volume 47, Issues 18 19, pp [3] Ma T, Li L, Xu X-Y, Chen Y-T, Wang Q-W, Study on local thermal hydraulic performance and optimization of zigzag-type printed circuit heat exchanger at high temperature, Energy Conversion and Management, Volume 104, pp [4] Pourahmad S, Pesteei S M, Effectiveness-NTU analyses in a double tube heat exchanger equipped with wavy strip considering various angles, Energy Conversion and Management, Volume 123, pp [5] Ibrahim E Z, 2011, Augmentation of laminar flow and heat transfer in flat tubes by means of helical screw-tape inserts, Energy Conversion and Management, Volume 52, Issue 1, pp [6] Targui N, Kahalerras H, Analysis of a double pipe heat exchanger performance by use of porous baffles and pulsating flow, Energy Conversion and Management, Volume 76, pp [7] Sheikholeslami M, Gorji-Bandpy M, Ganji D D, Effect of discontinuous helical turbulators on heat transfer characteristics of double pipe water to air heat exchanger, Energy Conversion and Management, Volume 118, Pages [8] Du YP, Qu ZG, Zhao CY, Tao WQ, Numerical study of conjugated heat transfer in metal foam filled double-pipe, International Journal Heat and Mass Transfer, Volume 53, Issues 21 22, pp
14 308 N Sreenivasalu Reddy, K Rajagopal and P H Veena [9] Rennie T J, Raghavan V G S, Numerical analysis of the lethality and processing uniformity in a double-pipe helical heat exchanger. Chem Eng Process, volume 49 Issue7, pp [10] Gorman J M, Krautbauer K R, Sparrow E M, Thermal and fluid flow first principles numerical design of an enhanced double pipe heat exchanger, Applied Thermal Engineering, Volume 107, pp [11] Sayed Ahmed E, Mesalhy O M, Abdelatief M A, 2015, Flow and heat transfer enhancement in tube heat exchangers, Heat and Mass Transfer, Volume 51, Issue 11, pp [12] Ibrahim E, Moawed M, Forced convection and entropy generation from elliptic tubes with longitudinal fins Energy Conversion and Management, Volume 50, Issue 8, pp [13] Sayed Ahmed E, Ahmed Sayed, Mesalhy Osama M, Abdelatief Mohamed A, Effect of longitudinal-external-fins on fluid flow characteristics for wingshaped tubes bundle in crossflow, Journal Thermodynamics, 16. [14] Syed KS, Ishaq M, Iqbal Z, Hassan A, Numerical study of an innovative design of a finned double-pipe heat exchanger with variable fin-tip thickness, Energy Conversion and Management, Volume 98, pp [15] Zohir A E, Habib M A, Nemitallah M A, Heat transfer characteristics in a doublepipe heat exchanger equipped with coiled circular wires, Exp Heat Transfer, Pages [16] Eiamsa-ard S, Thianpong C, Promvonge P, Experimental investigation of heat transfer and flow friction in a circular tube fitted with regularly spaced twisted tape elements, Int Commun Heat Mass Transfer 2006;33: //2006. [17] Sheikholeslami M, Gorji-Bandpy M, Ganji D D, Experimental study of the influence of perforated circular-ring on pressure loss and heat transfer enhancement using sensitivity analysis, Appl Therm Eng, pp [18] Agrawal AK, Sengupta S, Laminar fluid flow and heat transfer in an annulus with an externally enhanced inner tube, Int J Heat Fluid Flow, vol. 4, pp [19] Jaisankar S, Radhakrishnan T K, Sheeba K N, Experimental studies on heat transfer and thermal performance characteristics of thermo siphon solar water. heating system with helical and Left-Right twisted tapes, Energy Conversion and Management, Volume 52, Issue 5, pp [20] Kahalerras H, Targui N, Numerical analysis of heat transfer enhancement in a double pipe heat exchanger with porous fins, International Journal of Numerical Methods for Heat & Fluid Flow, Vol. 18 Issue: 5, pp
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