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Design of Shell and Tube Heat Exchanger Using Computational Fluid Dynamics
Tools
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2 authors, including:
Arjun Sunil
Indian Institute of Technology (ISM) Dhanbad
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Keywords: Shell and tube heat exchanger, computational fluid dynamics tools, helix Baffles, Heat Transfer Coefficient,
Pressure Decline.
Introduction Water Shell and Tube Heat Exchangers with various baffle
geometries of 5 continuous helical baffles and one segmental
Highest thermal performance is the key factor determining the baffle and test results were compared for performance with
efficiency of any Shell and Tube Heat Exchanger. Hence, in the respect to their heat transfer coefficient and pressure decline
design of Heat Exchanger, the foremost considerations should values at shell side by Kral et.al.3. When they have made
be given to the cost and effectiveness so as to improve its comprehensive comparison on the most important geometric
efficiency. The baffles of helical type instead of segmental type factor of helix angle, 400 helix angle outperformed the other
when used in conjunction with changes in its geometry by angles with respect to the heat transfer per unit shell side fluid
giving a full 3600 CFD model inclination, a higher decline in pumping power or unit shell side fluid pressure decline. The
pressure across the heat exchanger could be achieved using flow patterns in the shell side of the shell and tube heat
Ansys tools. The temperature distribution and flow structure are exchanger with continuous helical baffles were found always
favorably obtained upon fine modelling the geometry rotational and helical due to the peculiar geometry of the
accurately. The present study is taken up with the major continuous helical baffles which resulted in a significant
objective of obtaining pressure decline at shell side and increase in heat transfer coefficient per unit pressure decline in
consequent achievement of hike in heat transfer by design and the shell and tube heat exchanger.
simulation of angle of helical baffles.
The continuous helical baffles when designed well can prevent
Lutcha and Nemcansky1 upon investigation of the flow field the flow induced vibration and fouling in the shell side. Similar
patterns generated by various helix angles used in helical baffle results on fouling were reported by Murugesan and
geometry found that the flow patterns obtained in their study are Balasubramanian4. The experimental study of Shell and Tube
similar to plug flow condition which is expected to decline Heat Exchangers with the use of continuous helical baffles can
pressure at shell side and increase heat transfer process result approximately ten per cent hike in heat transfer
significantly. Stehlik et al.2 studied the effect of optimized coefficient in comparison with that of traditional segmental
segmental baffles and helical baffles in heat exchanger based on baffles for the same shell side pressure decline. Development of
Bell-Delaware method and demonstrated the heat transfer and non-dimensional correlations for heat transfer coefficient and
pressure decline correction factors for a heat exchanger. Oil- pressure decline based on the experimental data on proposed
meant to reduce numerical diffusion as much as possible Velocity 1.44085 m/s, Ration of specific heat 1.4 was
by structuring the mesh in a well manner, particularly near considered.
the wall region. Later on, for the mesh independent model, a
fine mesh is generated with 5.65 Million cells. For this fine SIMPLEC was set as Pressure Velocity coupling and Skewness
mesh, the edges and regions of high temperature and pressure correction was set at zero. In Spatial Discretization zone, Least
gradients are finely meshed. The details are provided in figure- square cell based Gradient and standard
st Pressure were used.
3 and 4. Momentum, Turbulent Kinetic Energy and Energy all were set
as First order upwind. In Solution control, Pressure was 0.7,
Density 1 , Body force 1, Momentum 0.2 , turbulent kinetic
and turbulent dissipation rate was set s at 1, energy and
turbulent Viscosity was 1. Solution initialization was standard
method and solution was initialized from inlet with 300K
temperature. Under the Above boundary condition and solution
initialize condition, simulation was set for 1000 iteration.
it For
convergence of solution; the continuity, X-velocity,
X Y velocity,
velocity, k, epsilion should be less than 10-4 and the energy
Z-velocity,
should be less than 10-7. The heat transfer rate is calculated
from the following formulae from which heat h transfer rate
is calculated across shell side. Q = m * Cp * ∆T Where m =
0.000 0.200 (m) mass flow rate, Cp = Speific Heat of Water, ∆T = Temperature
difference between tube side
0.100
Figure-3
Meshing diagram of shell and tube heat exchanger
Results and Discussion
Baffle inclination: For Zero degree baffle inclination
solution was converged at 160th iteration. Simulation of 100
Baffle inclination is converged at 133th iteration. Simulation of
200 baffle inclination is converged at 138th iteration. Similar
results were reported by Khairun et al.7.
Figure-4
Surface mesh with Helical Baffle and tube bundle of shell
and tube heat exchanger
selected. Water-liquid
liquid and copper, aluminum was selected as
materials for simulation. Boundary condition was selected for
inlet, outlet. In inlet and outlet 1Kg/s velocity and
temperature was set at 353K. Across each tube 0.05Kg/s Figure--5
velocity and 300K temperature was set. Mass flow was selected Temperature Distribution across the tube and shell
in each inlet. In reference Value Area set as 1m2, Density 998
Kg/m3, enthalpy 229485 J/Kg, length 1m, temperature 353K,
353.00
350.35
347.70
345.05
342.40
339.75
337.10
334.44
331.79
329.14
326.49
323.84
321.19
318.54
315.89
313.24
310.59
307.94
305.28
302.63
299.96
Figure-6
Temperature Distribution for 100 baffle inclination
Figure--8
Temperature Distribution across Tube outlet in 00 baffle
inclination
334.44
353.00
350.35
347.70
345.05
342.40
339.75
337.10
331.79
329.14
326.49
323.84
321.19
318.54
315.89
313.24
310.59
307.94
305.28
302.63
299.96
6.46
6.14
5.81
5.49
5.17
4.85
4.52
4.20
3.88
3.55
3.23
2.91
2.58
2.26
1.94
1.62
1.29
0.97
0.65
0.32
0.00
Figure-7
Temperature Distribution of 200 baffle inclination
Figure--9
Temperature of the hot water in shell and tube heat exchanger at Velocity profile across the shell at 00 baffle inclination
inlet was 353K and in outlet it became 347K. In case of cold
water, inlet temperature was 300K and the outlet became 313K.
Similar results were reported by Usman and Goteberg, 20118.
Tube outlet
let Temperature Distribution was given below in
exchanger (figure-8).
8). Similar enhanced heat transfers in heat
exchangers were reported by Murugesan and
Balasubramanian9,10.
-1.12e4
2.18e5
2.06e5
1.95e5
1.83e5
1.72e5
1.61e5
1.49e5
1.38e5
1.26e5
1.15e5
1.03e5
9.18e4
8.04e4
6.89e4
5.75e4
4.60e4
3.46e4
2.31e4
1.17e4
2.26e2
6.98
6.63
6.26
5.93
5.58
5.23
4.88
4.53
4.19
3.84
3.49
3.14
2.79
2.44
2.09
1.74
1.40
1.05
0.70
0.35
0.00
Figure-11 Figure-13
13
Velocity profile across the shell at 200 baffle inclination Pressure Distribution across the shell at 100 baffle
inclination
Variation of Pressure: Figure-12, 12, 13 and 14 shows the
pressure distribution across shell and tube heat exchanger at
different baffle inclinations. With every increase in baffle
inclination angle, the pressure decline inside the shell is
decreased and the pressure
ure was found varying widely from inlet
to outlet.
-1.12e4
2.18e5
2.06e5
1.95e5
1.83e5
1.72e5
1.60e5
1.49e5
1.38e5
1.26e5
1.15e5
1.03e5
9.18e4
8.03e4
6.89e4
5.75e4
4.60e4
3.46e4
2.31e4
1.17e4
2.17e2
14
Figure-14
Pressure Distribution across the shell at 200 baffle
inclination
-6.02e3
-1.76e4
Figure- 15.
Figure-12 ansfers are reported by Emerson12 and Li and
Similar heat transfers
Pressure Distribution across the shell at 00 baffles Kottek13
inclination.
Table-2
Change in Outlet Temperature with respect to baffle inclination angle
Baffle Inclination Angle Outlet Temperature of Shell side Outlet Temperature of Tube side
(Degree) (Kelvin) (Kelvin)
0 346 317
10 347.5 319
20 349 320
The shell-side
side pressure declines when the baffle inclination
360
angle is increased from 00 to 200. For shell and tube heat
350 exchanger a 100 baffle inclination angle results in pressure drop
of 4 per cent and 200 baffle inclination angle results in pressure
340 drop of 16 per cent when compared to the pressure drop at 00
Temperature
310 Table-33
Pressure Decline inside Shell with respect to baffle
300 inclination angle
0 10 20 Baffle Inclination Angle Pressure Decline Inside
Baffle Inclination Angle (degree) (Degree) Shell (kPA)
Figure-15 0 230.992
Plot of Baffle inclination angle vs Outlet Temperature of 10 229.015
shell and tube side 20 228.943
It has been found that the increasing baffle inclination angle Table-4
4
from 00 to 200 affect the outlet temperature of shell side Velocity inside Shell with respect to baffle inclination angle
significantly. Pressure Decline inside Shell with respect to Baffle Inclination Angle Velocity inside shell
baffle inclination angle is provided in table 3. (Degree) (m/sec)
0 4.2
Similar results were reported by Diaper and Hesler, 199014, 10 5.8
Sunil and Pancha15 and Zhang et al., 200816 using 20 6.2
Computational Fluid Dynamics software. Pressure Decline
inside Shell with respect to baffle inclination angle is provided Similar performance resulting from baffle inclinations in heat
in figure-16.
16. Velocity inside the shell with respect to baffle exchangers are reported by Thirumarimurugan et al., 200817.
inclination angle from 00 to 200 is detailed in table 4 and figure-
17.
231.5
231
Pressure decline (kPa)
230.5
230
229.5 Pressure…
229
228.5
228
227.5
0 10 20
Baffle angle
Figure-16
Plot of Baffle angle vs Pressure Decline
5
Velocity (m/s)
3 Velocity…
2
0
0 10 20
4300
4200
(W/m2)
4100
4000
3900
Heat Transfer rate
3800
3700
3600 Heat Transfer rate
3500
3400
3300
3200
0 10 20
Baffle Inclination Angle
Figure-18
Heat Transfer Rate along Tube side
Table-6
Overall Calculated value in Shell and Tube heat exchanger in simulation
Baffle inclination Shell Outlet Tube Outlet Pressure Heat Transfer Outlet
(in Degree) Temperature Temperature Drop Rate(Q) (in W/m2) Velocity(m/s)
(Kelvin) (Kelvin)
00 346 317 230.992 3554.7 4.2
100 347.5 319 229.015 3972.9 5.8
200 349 320 228.943 4182 6.2
14. Diaper A.D. and Hesler L.E., Cross flow Pressure Drop 16. Zhang J.F., He Y.L. and Tao W.Q., 3 D numerical
and Flow Distributions within a Tube Bundle Using simulation of shell and tube heat exchanger with middle-
Computational Fluid Dynamic, Proc. Heat Transfer Conf., overlapped helical baffle, Journal of School of energy and
Israel, 235-240 (1990) power engineering, 132, 1-8 (2008)
15. Sunil K.S. and Pancha M.H., Comparative thermal 17. Thirumarimurugan M., Kannadasan T. and Ramasamy E.,
performance of shell and tube heat Exchanger with Performance Analysis of Shell and Tube Heat
continuous helical baffle using different angles, Exchanger Using Miscible System, American Journal of
International Journal of Engineering Research and Applied Sciences, 5, 548-552 (2008)
Applications, 2(4), 2264-2271 (2012)