International Journal of Dynamics of Fluids.

ISSN 0973-1784 Volume 13, Number 2 (2017), pp. 345-362

© Research India Publications
http://www.ripublication.com

CFD Analysis of a Cross-flow Heat Exchanger with

Different fin thickness

K.Ravikumar1, Ch.Naga Raju2, Meera Saheb3

1
Assistant Professor, V.R.Siddhartha Engineering College,.
2
Professor, V.R.Siddhartha Engineering College.
3. Professor, JNTU Kakinada,

Abstract
Efficiency of heat exchanger and its dimensions are ones of the most
important parameters to consider in engineering design. The size of heat
exchanger can be more compact by introducing the fins to increase the heat
transfer rate between the heat exchanger surface and the surroundings.
Different engineering methods are used in heat exchanger design process. The
proper correlations or modeling and simulation tools are often applied to
receive the general recommendation at early stages of exchanger study. The
performance of the fin-tube heat exchanger for different fin thickness is
calculated. To give indications about the accuracy of numerical outcome, the
most popular correlations are evaluated and results obtained from Ansys CFX
program are verified. Analyzing the output, it seems that the implementation
of the CFD model offers particular benefits especially when minor
modification are applied to the fin surface for which the correlation equations
are not defined. The objective of the present work is to simulate the 3D
geometry for cross flow smooth and finned tube heat exchanger with using hot
water inside the tube and cooling air outside the tube by using computational
fluid dynamic (ANSYS-FLUENT 15). The enhancement of heat transfer has
been introduced in many fields of industrial and scientific applications. For
the simulation, purpose a symmetric view of the simplified geometry of the
heat exchanger is made using solid works software.
Keywords: Heat exchanger, Fin thickness, CFX, CFD,

1. Introduction
346 .Ravikumar, Ch.Naga Raju, Meera Saheb

Heat exchangers are devices used to transfer heat energy from one fluid to another.
Typical heat exchangers experienced by us in our daily lives include condensers and
evaporators used in air conditioning units and refrigerators. Boilers and condensers in
thermal power plants are examples of large industrial heat exchangers. There are heat
exchangers in our automobiles in the form of radiators and oil coolers. Heat
exchangers are also abundant in chemical and process industries. Different heat
exchangers are named according to their applications. For example, heat exchangers
being used to condense are known as condensers; similarly heat exchangers for
boiling purposes are called boilers. Performance and efficiency of heat exchangers are
measured through the amount of heat transferred using least area of heat transfer and
pressure drop. A better presentation of its efficiency is done by calculating over all
heat transfer coefficient. Pressure drop and area required for a certain amount of heat
transfer, provides an insight about the capital cost and power requirements (Running
cost) of a heat exchanger. Usually, there is lots of literature and theories to design a
heat exchanger according to the requirements. A good design is referred to a heat
exchanger with least possible area and pressure drop to fulfill the heat transfer
requirements. Cross flow heat exchangers may be finned or corrugated and may be
used in single-pass or multipass modes of operation. Flow passages associated with
compact heat exchangers are typically small, and the flow is usually laminar.

2. Fin-tube cross-flow heat exchanger geometry

The analysis of heat transfer from finned surfaces involves solving second-order
differential equations and is often a subject of researches including also the variable
heat transfer coefficient as a function of temperature or the fin geometrical
dimensions. In general, the study of the extended surface heat transfer compromises
the movement of the heat within the fin by conduction and the process of the heat
exchange between the fin and the surroundings by convection [18]. For the ideal case,
the optimized profile of the symmetrical radial fin of least material can be found from
the generalized differential equation [19]. It leads to the parabolic fin shape for which
the heat flux is less sensitive to the variation of the tip temperature than in the case of
rectangular and trapezoidal fin profiles. In practice, flow mal distribution is common
during the air flow and influences the performance of heat exchangers. The analysis
and design of heat exchangers consider problems in which the temperature of the fluid
changes as it flows through a passage as a result of heat transfer between the wall and
the fluid. For heat transfer analyses, at least the following heat transfer surface
geometrical properties are needed on each side of a two-fluid exchanger: minimum
free-flow area, core frontal area, heat transfer surface area which includes both
primary and fin area, hydraulic diameter, and flow length.
CFD Analysis of a Cross-flow Heat Exchanger with Different fin thickness 347

Figure 1: Fin-tube geometry, with minimum cross-sectional area

Surface area of one sector consists of fin and tube are defined as
1 
 
Surface area of fins: Af    D 2f  D 2    D f 
2 
Surface area of tube between fins: At   DS

AT   D  S   
Total surface area:
Reynolds number, maximum fluid velocity and Nusselt number is defined as
 max D
Re D 
 (1)

mf
 max 
Ao  (2)

hD
Nu 
kf
(3)
The heat exchanger characteristic dimensions are written for different fin thickness is
tabulated in Table 1:
348 .Ravikumar, Ch.Naga Raju, Meera Saheb

Table:1: Heat exchanger characteristic dimensions

Fin version Rf  Df / 2 R=D/2 mm  t
mm
Pf Pt mm  mm
mm mm
a 19.5 12.0 2.0 3.0 41 1.0
b 19.5 12.0 2.0 3.0 41 0.9
c 19.5 12.0 2.0 3.0 41 0.7

3.Correlation for external heat transfer in fin-tube cross flow heat exchanger
The value of heat transfer depends on local fluid velocity, fluid properties and details
of the tube bank geomentry. Correlations that allow calculating average heat transfer
coefficient h ' are derived from experimental data and take into account geometrical
features.
3.1. Recommended correlation to calculate the average Nusselt number for
staggered tube banks by Engineering Sciences Data Unit [21]

The correlation can be applied for Reynolds number range 2 103  Re  4 104 and
s X
0.13   0.57 1.15  t  1.72
l , Xl :
0.091
s  Xt 
0.297 1
Nu  0.242 Re 0.658
    .Pr 3 .F1.F2
l  Xl  (4)

Where
X t  Pt
-transverse tube pitch
X l  longitudinaltubepitch
,
F1-Factor for fluid property variation
F2-Factor for number of fin-tube rows (F2=0.71 is applied for all correlations)
0.98 For four or more rows
0.93 For three rows
0.81 For two rows
0.73 For one row
CFD Analysis of a Cross-flow Heat Exchanger with Different fin thickness 349

3.2 Correlation of Briggs and Young [19], [22], [23]

s s
1 0.200 0.1134

Nu  0.134 Re 0.681
Pr .  
3
 
l   (5)
The correlation is based on experimental data for eight row tube banks laid out on
equilateral triangular pitch and 1.103  Re  1.8 104
,11.02<D<40.32mm,1.38<l<16.43mm,0.33mm<δ<1.96mm,0.76mm<s<2.72mm,24.2
1mm<Xt<109.02mm,

3.3 Effective heat transfer coefficient

Effective heat transfer coefficient , for the air flowing outside and at right angles to
the axis of a bank of finned pipes ,can be represented approximately by the
dimensional equation[24]:
Af  At
h'  h
AT (6)

 IN 0.6  Xt 
h  5.29   0.6
D 0.4
 Xt  D  (7)

4. Mean temperature Coefficient and heat transfer in heat exchanger

Total heat transfer can be calculated taking into consideration fin efficiency:

Q  hT  f Af  At   h' TA

(8)
Where
f
-fin efficiency

h ' -effective heat transfer coefficient

To evaluate the heat transfer, it is necessary to find the effective mean temperature
difference, ∆T. since the fluid temperature changes in fluid flow through the tube
bank, the fluid temperature difference ∆TFluid can be calculated from energy
exchanged as:
Q  hT  f Af  At   m f c f TFluid
(9)
Where
350 .Ravikumar, Ch.Naga Raju, Meera Saheb

T 
T0  TOUT   T0  TIN 
T0  TOUT
ln
T0  TIN (10)
And for
TIN  TOUT

TFluid  TIN  TOUT (11)

After transformation
h  f Af  At 
TFluid  T
mf cf
(12)
h  f Af  At 
TOUT  TIN  T
mf cf
(13)

 h  f Af  At  
1  exp   
 mf cf 
T  TIN  T0 
h
mf cf
 f Af  At 
(14)
Having calculated effective mean temperature difference, ∆T, average heat transfer
coefficient, ℎ̅, and fin efficiency, ηf, the rate of heat transfer can be found from
Eq.(11)
The fin efficiency value ηf can be achieved from Equation [20]
 2h 
tanh  . 

  k f  
f 
2h
.
 k f  (15)

Where

D  Df  D 
   11  0.35ln f 
2 D  D 
(16)
CFD Analysis of a Cross-flow Heat Exchanger with Different fin thickness 351

4. Results of heat transfer calculations

Calculations are done for circular fin-tube heat exchanger. Three-dimensional models
are performed to find heat transfer characteristics between a finned tube and the air
for different fin shapes in order to find the heat transfer rate between the air and the
fin material during the air flow in the cross flow heat exchanger. The model allows
considering the heat transfer in three directions. The output is compared with the
results received from the correlation formula.
Using the described correlation, the heat transfer is determined based on defined the
mass flow rate (inlet velocity 4.0 m/s), inlet temperature of the fluid (300oC) and the
internal tube surface temperature (70oC). Values of Vmax, Nu for one row, effective
heat transfer coefficient and fluid outlet temperature, received from correlation
functions for each fin version, are written in Table 2.

Table2. Heat exchanger surface and flow parameters for fin version (a), (b) and (c).
Correlation Eq.(4) Correlation Eq.(5) Correlation Eq.(7)
(a) (b) (c) (a) (b) (c) (a) (b) (c)
V_max 12.30 11.25 10.68 12.30 11.25 10.68 12.30 11.25 10.68
̅̅̅̅(one row) 70.19 69.74 68.35 59.86 59.68 60.21 ----
𝑁𝑢 ---- ----
ℎ̅w/(m2K) 72.17 71.42 70.34 62.45 62.78 63.76 63.56 63.56 63.56
TOUT, ºC 251.2 247.6 248.4 258.9 258.9 258.9 258.6 259.2 259.2

Numerical analysis is also carried out to examine modified finned tube heat
exchangers and the influence of the fin thickness on the heat transfer. The numerical
outcome of heat transfer coefficient form 3D model is compared to the results
received from the correlations for the fin-tube heat exchanger of uniform fin
thickness. Correlations are used to check the numerical calculation of the heat transfer
and its accuracy in relation to fin shape modifications.

Results are presented in Table 3, where

T _ correlat  T _correlat
 .100%
T _ correlat (17)
352 .Ravikumar, Ch.Naga Raju, Meera Saheb

Table 3. Comparison between numerical calculations and correlations for fin version
(a),(b) and (c)
Correlation Eq. (4) Correlation Eq. (5) Correlation Eq. (7)
(a) (b) (c) (a) (b) (c) (a) (b) (c)
∆T_Correlatº 43.1 42.8 42.8 38.4 38.3 38.7 39.8 39.6 38.3
C
∆T_modelºC 43.6 42.1 41.3 44.2 42.5 40.7 44.3 42.6 40.8
∆ - 1.66 3.63 - - - - - -
1.1 % % 13.12 9.88 4.91 10.15 7.04 6.12
% % % % % % %

4.1 Mesh Generation

Mesh generation is very important step of pre-processing stage because it fits the
limits of computational domain. Many engineering applications need mesh generation
that is appropriate for the solving of 3D Navier-Stokes equations. In the present work,
tetrahedron element is used for 3D geometry mesh. Good mesh is recognized from its
generated cells number. For a complex geometry, increase the cells number will
increase the resolution and the accuracy, but also this increase will be opposed by
increase in computer memory, need for high processor and take more time to
complete the solution. At last there must be an optimization between the number of
cells generated and the time consumed for the solution process. For the present work,
the mesh generation is shown in Figure 2.

Figure 2: Mesh generation of the present work geometry

CFD Analysis of a Cross-flow Heat Exchanger with Different fin thickness 353

4.2 GOVERNING EQUATIONS

The fundamental basis of most of CFD problems are the solutions of (mass,
momentum and energy) equations, as well as the transport equation for turbulent
viscosity and its scale. These are in steady state and have been stated below in simple
form. For turbulent flow[4]:

5. THE BOUNDARY CONDITIONS

A. Inlet Boundary Conditions
The velocity of the inlet air is limited with a values of (1, 2, 3, and 4) m/s, while the
volume flow rate of tube side liquid is limited with a values of (2, 3, 4, 5 and 6) L/min
and the temperature of inlet air is the room temperature, while the temperature of tube
side liquid is limited with a values of (50, 60, 70 and 80) °C.
B. Outlet Boundary Conditions
The outlet for air side and tube side fluid is specified as pressure outlet and it’s
represented by the atmospheric pressure.

6 . RESULTS AND DISCUSIONS

The numerical simulation is done by ANSYS FLUENT 15. software to show both the
flow field and heat transfer of the present models. Many cases are studied. Three
cases are discussed in the following sections. Same boundary conditions are used in
the three cases, which are (air velocity of 1 m/s, water inlet temperature and flow rate
of (80 °C) and (2 L/min) respectively).
354 .Ravikumar, Ch.Naga Raju, Meera Saheb

A. Temperature Contours
Figure 3 shows a 3D simulation of temperature distribution in the test section, figures
4. and 5. reveal temperature contours of smooth tube with water and integral finned
tube with water. From these figures, it is noted that there is a gradient of temperature
distribution along with test tube and the temperature difference are clearly appear in
all cases. Also, it is clear from the figures that the temperature gradient of finned tube
is higher than that of smooth tube. This means that fining have a substantial effect on
increasing the temperature difference inside the test tube.

Figure 3(a): shows contours of Total Temperature (mixture) (K)

B. Velocity and Vectors Contours

Figure 4. “(a)” shows a longitudinal section of velocity contour, from figure, the
velocity of water inside the tube is constant due to stability of water flow rate. Figure
4. “(b)”demonstrate a cross section of velocity contour, this figure represent the
behavior of air through the test section, before the test tube the velocity of air are
constant, the air velocity are increased during it across through the passes of test tube,
ddies are formed behind the test tube and turbulence is increased.
CFD Analysis of a Cross-flow Heat Exchanger with Different fin thickness 355

Figure 4 (a) longitudinal section of velocity contour Figure 4 (b) cross section of
velocity contour
356 .Ravikumar, Ch.Naga Raju, Meera Saheb
CFD Analysis of a Cross-flow Heat Exchanger with Different fin thickness 357
358 .Ravikumar, Ch.Naga Raju, Meera Saheb
CFD Analysis of a Cross-flow Heat Exchanger with Different fin thickness 359
360 .Ravikumar, Ch.Naga Raju, Meera Saheb

7. CONCLUSIONS
The main objective of this research is to determine numerically the performance of
the heat transfer process in a single row fin-tube cross flow heat exchanger for
different fin configurations. The most popular correlations are applied for heat
transfer evaluation. For Briggs and Young correlation, the heat transfer decreases with
the fin thickness increase. The opposite results are seen for the other correlations. The
heat transfer is also analyzed by means of numerical computation. The results are
verified with the known correlations for circular fins of constant thickness. Analyzing
CFD Analysis of a Cross-flow Heat Exchanger with Different fin thickness 361

the output received from numerical calculations with those gathered from
correlations, it seems that the differences are within the standard deviation and
numerical techniques can predict heat transfer coefficients with acceptable accuracy.
The use of the CFD model offers particular benefits especially when minor
modification are applied to the fin surface for which the correlation equations are not
defined, for instance fin thickness modification. However, comparative analyses are
still required and the numerical model should be examined, verified with proper
correlations or experimental values.

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