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Article history:
Received 12 January 2013
Received in revised form
10 July 2013
Accepted 1 August 2013
Available online 4 September 2013
Tube bundles are usually used for heat transfer in heat exchangers. The walls bounding the tube bundles
will inuence the ow and heat transfer in the tube bundles. This becomes critical for the once through
steam generators of gas cooled reactors due to it is very compact and sensitive. URANS simulation of the
cross ow and heat transfer in a wall bounded inline tube bundle is presented in this paper. The numerical method was veried with experimental measurements. The local and average ow and heat
transfer characteristics were analyzed. The ow has the intrinsic characteristics of unsteadiness as that in
a free tube bundle. Bounding walls modify the ow and heat transfer signicantly. Near wall ow
passages have lower ow resistances due to the walls suppress wakes after the tubes. The uid velocities
in the near wall passages are larger and the temperatures are higher. The wall effects depress turbulence
intensities of the ow in the near wall ow passages, so the heat transfer coefcients of the near wall
tubes are 10% lower than those of the tubes in the middle of the bundle.
2013 Elsevier Masson SAS. All rights reserved.
Keywords:
Tube bundle
Turbulent cross ow
Heat transfer
Wall effect
Steam generator
1. Introduction
High temperature gas-cooled reactor (HTGR) is especially
excellent in safety due to its inherent safety design [1]. The helical
tube once through steam generator is an important equipment in
HTGR. It should be compact and very reliable. The primary side
helium absorbs heat from the reactor core, and then transfers it to
the secondary side water through the helical tube bundles in the
once through steam generator. The shell or bounding walls over the
tube bundles will certainly inuence the ow and heat transfer in
the tube bundles. Understanding the cross ow and heat transfer
characteristics in wall bounded tube bundles is very important for
the design of the HTGR steam generator.
Turbulent cross ow heat transfer in tube bundles is a basic ow
pattern in tube and shell type heat exchangers. There are many
investigations on the turbulent cross ow and heat transfer over a
single tube or a free (big enough) tube bundle [2]. Experimental
correlations of heat transfer and pressure drop have been established [3,4]. Coutanceau and Defaye [5] did a detailed survey of the
ow visualization works of the cross ow over a single circular
cylinder. Niemann and Holscher [6] reviewed the experiments
about drag and Strouhal number of cross ow over tube bundles.
128
129
Fig. 4. Grid size inuence on local velocity distribution. (a) Overall. (b) Enlarged.
2. Numerical method
2.1. Geometry model and boundary conditions
The numerical model is shown in Fig. 1. It is a two dimensional
wall bounded tube bundle. The tubes are in inline arrangement.
There are 7 rows and 5 columns of tubes in the bundle. Column No.
1 and column No. 5 tubes are adjacent to the walls. The tube
diameter is 19 mm. The tube pitches in the ow direction are
S2 25 mm, the tube pitches in the transverse direction are
S1 30 mm. The distances between the wall and the centers of wall
adjacent column tubes are S1/2. The computational area is
175 mm 150 mm. Flow enters the tube bundles from the left. Grid
distribution is shown in Fig. 2. The grid is intensied near the wall
regions. The smallest element dimension is 0.01 mm to ensure that
y is well below 1. The total element number is 222,000. Constant
temperature and non-slip wall boundary conditions were set for
the tube walls. Adiabatic and non-slip wall boundary conditions
were used for the bounding walls. Periodically fully developed
boundary condition was assumed for the inlet and outlet. For more
detailed description of the periodic boundary condition and the
numerical methods please refer to Li et al. [32,33] and reference
[34]. The working uid was helium with constant properties. The
Table 1
Grid size inuence on Nusselt number and friction factor.
Element number
442, 632
221, 948
115, 163
61, 955
Nu
152.66
0.21785
150.24
0.21637
162.17
0.17922
186.05
0.15619
130
Fig. 6. Velocity distribution. (a) x 0, u. (b) x 0, v. (c) x 11, u. (d) x 11, v. (e) x 16.5, u. (f) x 16.5, v. (g) y 0, u. (h) y 0, v. (i) y 22.5, u. (j) y 22.5, v.
average velocity was 18,000. Uniform velocity was used for the
inlet. Fully developed condition was used for the outlet.
2.2. Governing equations and numerical scheme
The governing equations were the time-dependant threedimensional incompressible Reynolds averaged NaviereStokes
equations and the energy equation. The pressure variance in the
131
Fig. 6. (continued).
132
Fig. 7. Turbulence intensity distribution. (a) x 0, u. (b) x 11, u. (c) x 16.5, u. (d) y 0, u. (e) y 22.5, u.
Fig. 1. The boundary conditions were almost the same except that
the up and down bounding walls were changed to periodic conditions. The ow and heat transfer were simulated with Reynolds
numbers from 10,000 to 50,000. As shown in Fig. 9, the Nusslet
numbers and friction factors are compared with empirical correlations. The Nusselt number correlation is proposed by Zukauskas
and Ulinskas [4] as in Eq. (1). The friction factor correlation is
proposed by Idelchik [36] as shown in Eq. (2). It can be seen that the
differences between the numerical and empirical correlation for
133
Fig. 8. Strouhal number of the row 4 column 5 tube in the staggered tube bundle of
Simonin and Barcouda [8].
represents the lift coefcient. The drag and lift coefcients are
calculated using Eqs. (3) and (4).
both Nusselt numbers and friction factors are below 25%. The differences maybe induced by both the uncertainties of the correlations and the numerical simulations.
Cd
Fp;x Fv;x
0:5ru2N DH
(3)
Nu 0:27Re0:63 Pr 0:36
Cl
Fp;y Fv;y
0:5ru2N DH
(4)
x 0:38
W D
0:94
LD
(1)
0:59
0:5
WD 2
W
Re0:2 LD
1
D
(2)
Fig. 11. Strouhal number. (a) Row 4 column 3 tube. (b) Row 4 column 1 tube.
134
along the wall surfaces. D is the tube diameter, H is the tube height
in z direction, it is unit in this case.
From Fig. 10, the drag and lift coefcients vary periodically with
time. There are total 34 periods for the drag coefcient, while there
are 17 periods for the lift coefcient. The oscillation period of the lift
coefcient is 0.32/17 z 0.0188 s. Compared with the transient velocity eld, it can be found that one period represents a variation of
the wake direction. Fig. 10 also shows that the variation of the lift
coefcient is much larger than the drag coefcient. This coincides
with the experimental measurements by Zhan et al. [13]. The experiments of Buresti and Lanciotti [12] also showed that the lift
coefcient of a single cylinder will increase when a wall approximates, while the drag coefcient will decrease. The lift coefcient
can be higher than the drag coefcient when the gap between the
wall and the tube is very small.
Fig. 11(a) shows the FFT analysis of the drag coefcient of row 4
column 3 tube as shown in Fig. 10. Fig. 11(b) shows the FFT analysis
Fig. 12. Transient velocity eld. (a) t 0.475 s (b) t 0.4797 s (c) t 0.4844 s (d) t 0.4891 s (e) t 0.4938 s.
passes the tubes. This shows the intrinsic characteristics of unsteadiness of the cross ow over tube bundles. From Fig. 12(a), the
wakes of the middle three columns (column No. 2, 3 and 4) of tubes
in the rst row point to upper right, the wakes of the middle three
columns of tubes in the third and fourth rows point to lower right,
the wakes of the middle three columns of tubes in the sixth and
seventh rows point to upper right, while the wakes of the middle
three columns of tubes in the second and fth rows are in transition. In Fig. 12(b), it is the tubes in the third and seventh rows are in
transition. In Fig. 12(c), the directions of the wakes of the middle 3
columns of tubes are opposite to those in Fig. 12(a), and with the
second and fth rows in transition. In Fig. 12(d), the tubes of the
fourth and seventh rows are in transition. In Fig. 12(e), the directions of the wakes of the middle 3 columns of tubes return to the
states in Fig. 12(a). So the time period of one sway of the wakes is
about 0.0188 s. This coincides with the oscillation periods of the lift
coefcient shown in Fig. 10. From the pictures in Fig. 12, we can see
that the wakes of the tubes in the middle 3 columns can sway up
and down freely, but the wakes of the tubes in the side columns
(column No. 1 and 5) are conned by the walls. They can hardly
sway to the walls. This is the difference between the present wall
bounded tube bundle and a free tube bundle.
135
The time averaged velocity, temperature and turbulence intensity distributions in the ow passages in the tube bundle are
shown in Fig. 13. The horizontal coordinates are the ow passage
numbers, the vertical coordinates are the averaged velocity, temperature and turbulence intensity. The ow passage locations and
its numbering method are illustrated in the small picture at the top
of Fig. 13. The solid lines numbered 1 to 6 represent locations of the
ow passages, where the time and local average was carried out.
The velocity, temperature and turbulence intensity values shown in
Fig. 13(a), (b) and (c) are time and area averaged on the locations at
the solid lines numbered 1 to 6 in several ow periods. The ow
passages numbered 1 and 6 are the side passages which have the
bounding wall as one of its walls. The widths of passage No. 1 and
No. 6 are only half that of the passages numbered 2 to 5. The
averaged velocity, temperature and turbulence intensity in Fig. 13
show symmetric distribution.
From Fig. 13(a), the velocities in the middle passages (No. 2, 3, 4,
and 5) are lower than that in the two side passages (No. 1 and 6).
The side passages numbered 1 and 6 have the highest velocities.
This seems to be incorrect due to that the bounding walls compose
one of the walls of passage No. 1 and 6, which will make the viscous
forces of passage No. 1 and No. 6 larger than that of the passages in
the middle. This can be explained from the ow resistance coefcients shown in Fig. 14. The ow resistance of passage No. 1 is
calculated by the sum of the drag force on its adjacent wall and half
the drag force on tube No. 1, while the ow resistance of passage
No. 2 is calculated by the sum of half the drag forces on both tube
No. 1 and tube No. 2 (the tube number can be seen in the small
picture at the top of Fig. 15). The calculation of the ow resistance
coefcient of passage No. 6 is similar to passage No. 1, while that of
passage No. 3, 4, 5 are similar to passage No. 2. From Fig. 14, the ow
resistances of the six passages have a symmetric distribution. The
ow resistances of passage No. 1 and 6 are lower than that of
passage No. 2, 3, 4 and 5. The higher ow resistances in the middle
of the tube bundle cause the lower velocity.
Why the ow resistance of passage No. 1 and 6 are lower? This
should be explained from the time and area averaged viscous and
pressure force coefcients on the tubes and walls shown in Fig. 15.
From Fig. 15, the pressure forces on the tubes in x direction are
much larger than the viscous forces in the same direction. Also the
pressure forces in y direction on the tubes are much larger than the
viscous forces in the same direction. So the pressure forces dominate the drag and lift forces on the tubes. The rectangular symbols
in Fig. 15 clearly show that the pressure forces on the middle 3
tubes (tube No. 2, 3, 4) in x direction (the drag force) are higher than
Fig. 13. Velocity, temperature and turbulence intensity distributions in the ow passages in the tube bundle.
Fig. 15. Pressure and viscous force coefcients on tubes and walls.
136
that on the wall adjacent tubes (tube No. 1 and 5). So the ow resistances of the middle four passages (No. 2, 3, 4 and 5) are higher
than that of the two side passage (No. 1 and 6).
Then why the drag forces on the middle 3 tubes are higher than
that on the wall adjacent tubes? This can be explained from the
time and local area averaged pressure distributions on the tubes
shown in Fig. 16. As shown in Fig. 12, the ow in the tube bundle is
unsteady and the wake sways with time. The wakes of the tubes
adjacent to the walls cannot sway towards the walls. The wakes
determine the pressure distributions on the tubes, so the walls will
modify the pressure forces on the wall adjacent tubes. Fig. 16 shows
the pressure distributions on the tubes. Zero degree represents the
incoming ow direction, and the circumferential direction goes
clockwise (from the top view). From Fig. 16(a), we can see that
pressure distribution on tube No. 1 and No. 5 is not symmetric, the
side adjacent to the walls have relatively lower pressure. The
asymmetry of the pressure distributions on tubes numbered 2 and
4 is very small. The pressure distribution on tube No. 3 is totally
symmetric. So the pressure forces in the y direction of tube No. 1
and 5 are higher. The detailed comparison of Fig. 16(a), (b) and (c)
shows that the pressure in the region of 112.5e247.5 (where are
the wake regions) of tube No. 1 and 5 are higher than that of the
tube No. 2 and 4, while the pressure in the regions of 0.0e67.5 and
292.5e360 are almost the same. So the pressure resistances in x
direction on tube No. 1 and 5 are relatively lower. From the above
analysis we can see that it is the wall effect that results in the
different drag and lift forces on the tubes adjacent to the walls. This
nally results in the low ow resistance and higher uid velocity in
the two side ow passages (No. 1 and 6).
From Fig. 13(b), we can see that the temperatures of the uids
are higher in the two side passages, and the temperatures of the
uids in the middle passages are almost the same. The higher
temperatures in the two side passages are due to the higher velocities. The heat transfer coefcients on the tubes cannot vary
signicantly (we can see later in Fig. 19), so the uids in the two side
passages with larger ow rates will have higher temperatures. The
uniformity of the temperatures in passage No. 2, 3, 4 and 5 can be
explained from Fig. 17. Fig. 17 shows the time and local area averaged longitudinal and transverse velocities in the tube bundles
(absolute velocities are used during the average). The locations of
the ow passages are shown in the small picture at the top of Fig. 17.
Flow passage No. 1, 2, 3, 4, 5 and 6 are the same as in Figs. 13 and 14,
the average velocities in these passages are in the longitudinal direction. Flow passage No. 1.5, 2.5, 3.5, 4.5 and 5.5 are the transverse
passages, the average velocities in these passages are in the
transverse direction. From Fig. 17, we can see that the averaged
absolute transverse velocity in passage No. 3.5 can be more than
half the averaged velocity in the streamwise direction. The transverse velocities in passage No. 2.5 and 4.5 are slightly lower than
that in passage No. 3.5, while the transverse velocities in passage
No. 1.5 and 5.5 are only 30% of that in passage No. 3.5. This means
that the uids in passage No. 2, 3, 4 and 5 exchange greatly. So the
uid temperatures in passage No. 2, 3, 4 and 5 are almost the same.
While the two side passages numbered 1 and 6 have relatively less
exchange of uids with the middle passages, so their temperatures
can be more different from that in the middle.
Fig. 13(c) is the turbulence intensity distribution in the tube
bundle. The turbulence intensities in the two side passages
numbered 1 and 6 are relatively lower, while that in the middle
passages numbered 2, 3, 4 and 5 are almost uniform. This is due to
the large exchange of uids in the middle four ow passages
numbered 2, 3, 4 and 5. In the two side passages, due to the viscous
effect induced by the two bounding walls and the suppression of
the tube wakes, the turbulence is suppressed, and the turbulence
Fig. 16. Local pressure distribution on tubes. (a) Pressure on tube No. 1 and 5. (b) Pressure on tube No. 2 and 4. (c) Pressure on tube No. 3.
Fig. 17. Averaged absolute transverse and longitudinal velocities in the tube bundle.
intensity are smaller than that in the middle of the tube bundle.
This will certainly inuences the heat transfer characteristics.
4.3. Time averaged heat transfer characteristics
The time and area averaged local heat ux on the tubes are
shown in Fig. 18. As in Fig. 16, zero degree represents the incoming
ow direction, the circumferential direction goes clockwise (from
the top view). From Fig. 18(a), we can see that the local heat ux of
tube No. 1 and 5 have opposite distributions, and they both have
higher heat ux at the near wall side. This is due to the higher uid
137
q
h
Tup Tdown 2 Tw
(5)
where q is the local heat ux. Tup is the uid temperature just
before the tube, Tdown is the uid temperature just behind the tube,
the positions are shown by the solid or dashed lines before and
Fig. 18. Local heat ux distribution on tubes. (a) Heat ux on tube No. 1 and 5. (b) Heat ux on tube No. 2 and 4. (c) Heat ux on tube No. 3.
138
behind each tube in the small picture at the top of Fig. 19. Tw is the
tube wall temperature.
The local heat ux was calculated using Eq. (6). The near wall
turbulent thermal conductivity was zero.
vT
q l
vn wall
(6)
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139
Cl,v: viscous force coefcient in y direction, Cl;v Fv;y =0:5ru2N DH, dimensionless
D: tube diameter [m]
f: oscillation frequency of forces acting on the tube, [Hz]
Fp: pressure force, [N]
Fv: viscous force, [N]
h: convective heat transfer coefcient, [Wm2 C1]
H: tube length (it is unit in this paper) or the distance between the wall and
the tube, [m]
q
2 k=u , dimensionless
I: turbulence intensity, I
N
3
k: turbulence kinetic energy, k 12 u0i u0i , [m2 s2]
p: pressure [Pa]
Pr: Prandtl number, dimensionless
q: local heat ux, [W m2]
Re: Reynolds number, Re rumaxD/m, dimensionless
S1: transverse pitches, [m]
S2: longitudinal pitches, [m]
St: Strouhal number, St fD/umax, dimensionless
t: time [s]
T: temperature, [ C]
Tdown: uid temperature behind tubes, [ C]
Tup: uid temperature before tubes, [ C]
Tw: tube wall temperature, [ C]
uN: inlet velocity, [m s1]
umax: maximum average velocity in the tube bundle, [m s1]
y: dimensionless distance normal to the wall (yu*/y), dimensionless
Nomenclature
Greek symbols
2 3
3 : turbulence dissipation rate, [m s
]
l: molecular thermal conductivity, [W/m C]
m: dynamic viscosity [kg m1 s1]
x: friction factor, dimensionless
r: density, [kg m3]
Subscripts
p: pressure
v: viscous
w: wall
x: x direction
y: y direction