CCB 3033

Advanced Transport Process

May 2015 Semester
CFD SIMULATION OF HEAT EXCHANGE
EQUIPMENT
GROUP 3
TEAM MEMBERS:
Name

ID

Muhamad Asyraf Bin Mohd Aris

17670

Hani Zarith Alia Binti Zaharudin

17516

Nor Nadiah Ahmad Hamidi

17154

Syed Amirul Alwi Bin Syed Mohd Zaki

17274

Due Date

: 18 August 2015

TABLE OF CONTENTS

No.

Title

Page

Introduction about Heat Exchanger

Governing Equations and Simulation Method

Flow Regime in Heat Exchanger

Heat Transfer Coefficient

10

Results

12

Discussion

26

Conclusions

27

References

27

Introduction About Heat Exchanger

A heat exchanger is a device used to transfer heat between one or more fluids. The fluids
may be separated by a solid wall to prevent mixing or they may be in direct contact. There are
three primary classifications of heat exchangers according to their flow arrangement. For
efficiency, heat exchangers are designed to maximize the surface area of the wall between the
two fluids, while minimizing resistance to fluid flow through the exchanger.
Heat exchanger consists of heat transfer elements such as a core or matrix containing the
heat transfer surface, and fluid distribution elements such as headers, manifolds, tanks, inlet and
outlet nozzles or pipes, or seals. Usually, there are no moving parts in a heat exchanger;
however, there are exceptions, such as a rotary regenerative exchanger (in which the matrix is
mechanically driven to rotate at some design speed) or a scraped surface heat exchanger.
In parallel-flow heat exchangers, the two fluids enter the exchanger at the same end, and
travel in parallel to one another to the other side. In counter-flow heat exchangers the fluids enter
the exchanger from opposite ends. The counter current design is the most efficient, in that it can
transfer the most heat from the heat (transfer) medium per unit mass due to the fact that the
average temperature difference along any unit length is higher. In a cross-flow heat exchanger,
the fluids travel roughly perpendicular to one another through the exchanger.
Types of heat exchangers:
1. Shell-and-Tube Exchanger
This exchanger, shown in Fig. 1.5, is generally built of a bundle of round tubes mounted
in a cylindrical shell with the tube axis parallel to that of the shell. One fluid flows inside
the tubes, the other flows across and along the tubes.

2. Plate Heat Exchanger

These exchangers are composed of many thin, slightly separated plates that have very
large surface areas and small fluid flow passages for heat transfer. Advances
in gasket and brazing technology have made the plate-type heat exchanger increasingly
practical.

3. Plate and Shell Heat Exchanger

It combines plate heat exchanger with shell and tube heat exchanger technologies. The
heart of the heat exchanger contains a fully welded circular plate pack made by pressing
and cutting round plates and welding them together. It does completely without gaskets,
which provides security against leakage at high pressures and temperatures.

4. Plate Fin Heat Exchanger

Plate and fin heat exchangers are usually made of aluminium alloys, which provide high
heat transfer efficiency. The material enables the system to operate at a lower temperature
difference and reduce the weight of the equipment. Plate and fin heat exchangers are
mostly used for low temperature services.

Governing Equations

1. Convective heat flux equation

q=h(Text-T)
2. Reynolds number
Re =

3. Continuity Equation

= distributed resistance

( + ) 2

=

2

i=u,v and w momentum equation

f= friction factor
d = hydraulic diameter
C= permeability

Note : K-factor term operates on a single momentum equation

S= rotating coordinates
=

= rotational speed
r= distance from axis of rotation

4. Energy equation

Simulation Method
1. Open COMSOL.
2. Add study Stationary.
3. Add Physics.
a) Non-isothermal
4. Add materials - water to all boundaries.
5. Draw the geometry according to individual values.
6. In Non-Isothermal flow:
a. Add inlet with To=298 K and v=1.11 m/min.
b. Add outlet at boundary.
c. Add heat flux at circles.
7. Compute study.
8. Add study group to build.
a. Temperature profile and velocity field streamline in 2D.
b. Temperature and Velocity profile in revolve-3D (225o).
c. Isosurface plot for temperature.
d. Temperature distribution at different z position.
9. Do a trial and error between heat transfer coefficient and exit temperature.
10. Plot graph.
a. Trial and error process to determine heat transfer coefficient.
b. Relationship between heat transfer coefficient and T2.

Flow Regime in Heat Exchanger

Flow regime can be determined from the Reynolds number.
Reynolds number = Inertia force/ Viscous force
(vL)/
Where = density of the fluid
v = velocity of the fluid
L = Length of the fluid inlet
= dynamic Viscosity of the fluid
[999.9(kg/m3)*0.11*105(m/s)*0.05(m)] / [0.896*103] Pa.s
6.26, which is in the limit of Laminar flow.
Hence, the flow regime can be considered as Laminar Flow.

17274

17154

17516

17670

Heat Transfer Coefficient

By using COMSOL, the heat transfer coefficient for the heat exchanger can be determined.
For the value of X = 0.11m, Y = 0.17m, at T2 = 111C and v1 = 0.11m/min, the heat transfer
coefficient, h = 104 W/m2K.

17274

For the value of X = 0.11m, Y = 0.156m, at T2 = 111C and v1 = 0.11m/min, the heat transfer
coefficient, h = 104.

17154

10

For the value of X = 0.16m, Y = 0.128m, at T2 = 111C and v1 = 0.11m/min, the heat transfer
coefficient, h = 71.75.

17516

For the value of X = 0.21m, Y = 0.128m, at T2 = 111C and v1 = 0.11m/min, the heat transfer
coefficient, h = 75

17670

11

Results
ID: 17154; X = 0.11m, Y = 0.156m, T2=111OC, v1=0.11m/min

Figure 1 : Temperature profile and velocity field streamline in 2D

Figure 2: Temperature and velocity profile in revolve-3D (225degrees)

12

Figure 3: Outlet temperature surface

Figure 4: Isosurface plot for temperature

13

Figure 5: Temperature distribution at different z position

Figure 6: Relationship between heat transfer coefficient and T2

14

Optimum Point

Figure 7: Trial and error process to determine heat transfer coefficient

ID: 17670; X = 0.21m, Y = 0.128m, T2=111OC, v1=0.11m/min

Figure 3 : Temperature profile and velocity field streamline in 2D

15

Figure 4: Temperature and velocity profile in revolve-3D (225degrees)

Figure 3: Outlet temperature surface

16

Figure 4: Isosurface plot for temperature

Figure 5: Temperature distribution at different z position

17

140

Averaged Outlet T2

120
100

80
60
40
20
0
0

20

40

60

80

100

120

Heat Transfer Coefficient

Figure 6: Relationship between heat transfer coefficient and T2

Optimum Chart
100
90

T Average Outlet T2

80
70
60
50
40

Optimum Point

30
20
10
0
0

20

40

60

80

Heat Transfer Coefficient

100

120

Figure 7: Trial and error process to determine heat transfer coefficient

ID: 17516; X = 0.16m, Y = 0.128m, T2=111OC, v1=0.11m/min

18

Figure 5 : Temperature profile and velocity field streamline in 2D

Figure 6: Temperature and velocity profile in revolve-3D (225degrees)

19

Figure 3: Outlet temperature surface

Figure 4: Isosurface plot for temperature

20

Figure 5: Temperature distribution at different z position

Averaged outlet T2 (degree celsius)

120
100
80
60
40
20
0
0

10

15

20

25

30

35

40

45

50

55

60

65

70

75

80

Heat transfer coefficient

Figure 6: Relationship between heat transfer coefficient and T2

21

100

Optimum Chart

90

T_avg_outlet-T2

80

70
60
50
40

Optimum Point

30

20
10
0
50

55

60

65

70

75

80

Heat transfer coefficient

Figure 7: Trial and error process to determine heat transfer coefficient

ID: 17274; X = 0.11m, Y = 0.17m, T2=111OC, v1=0.11m/min

Figure 7 : Temperature profile and velocity field streamline in 2D

22

Figure 8: Temperature and velocity profile in revolve-3D (225degrees)

Figure 3: Outlet temperature surface

23

Figure 4: Isosurface plot for temperature

Figure 5: Temperature distribution at different z position

24

Figure 6: Relationship between heat transfer coefficient and T2

Optimum Point

Figure 7: Trial and error process to determine heat transfer coefficient

25

Discussion
From the figure of temperature profile and velocity field streamline in 2D, we can observe that
the inlet temperature is approximately 300K and increases up to 500K when it passes through the
heating coil. Maximum temperature is obtained near the heat flux generation region which is the
heating coil. As a much finer mesh is generated in that region, temperature profile is accurately
predicted.

From the velocity profile in revolve 3D, we can observe that the velocity is zero when
approaching the wall due to the no slip condition principle. Maximum velocity is obtained at the
center of the inlet which is 2x10-3 m/s. Velocity is obtained near the inlet and it gradually
decreased due to the fluctuations in the geometry. After achieving a uniform flow, the velocity
raised and headed to a high velocity near the outlet.

From the figure of outlet surface temperature, it can be observed that the temperature is
maximum at the center of the outlet which is 430 K while lowest near the wall which is 370 K.
The same observation can be made from the isosurface plot for temperature.

From the graph of average outlet T2 vs Heat transfer coefficient, we can observe that the
temperature is gradually increasing with the increase of heat transfer coefficient. From the trial
and error process, we can conclude that the optimum heat transfer coefficient is 104 W/m2K.
From the calculations performed, the flow regime is said to be laminar flow. Hence, the velocity
throughout the domain is between 0 to 1 m/s. With respect to the flow, the velocity is zero near
the walls which follows the no slip condition.

26

Conclusion
When we compare the three different types of x (in meter) which is 0.11, 0.16, 0.21 given
to us to build the heat exchanger, we found that increase in the length of x (in meter) results in
decrease of overall temperature of the heat exchanger. This can be seen on the surface
temperature profile in results part. Moreover, decrease in x value, makes the velocity streamline
flows easily, shown on the Streamline Velocity field. In addition, the outlet temperature surface
shows higher temperature when x value (in meter) is greater.

Furthermore, when we look at the temperature distribution curve for all the three x
values, we can see that x = 0.11 gives a more consistent curve with less oscillations compare to
the other two values. This shows that the heat exchanger with x = 0.11 has a more stable
temperature distribution compared to the other two.

References

1. Heat Exchanger (n.d). Retrieved from https://en.wikipedia.org/wiki/Heat_exchanger

27