Int. J. Mech. Eng. Res.
& Tech 2019
ISSN 2454 – 535X [Link]
Vol. 11, Issue. 2, June 2019
Gas Exhaust Heat Exchanger CFD Study of Heat Recovery in a
Gas-Fired Power Plant
A Hari Krishna1, S Vijay Kumar 2 B Srihari 3, J Suresh Babu4
ABSTRACT
The availability of affordable, reliable energy sources is crucial to a thriving economy. However, the current energy sources are
being used up at an alarming pace. Therefore, new methods of energy conservation must be implemented. This is an effort to market a
ceramic heat exchanger with novel cross [Link] mass distribution, thermal stresses due to inhomogeneous heating and cooling,
etc. are only some of the many process intensification challenges that early heat exchangers helped pave the way for. Ceramic materials have
been presented as a replacement for traditional materials as a means of overcoming the aforementioned challenges. Given that ceramic
materials are advantageous in many ways, including their resistance to corrosion and high temperature. Ceramic heat exchangers' specially
designed surfaces ensure that incoming fluxes are distributed uniformly.
Computational fluid dynamics (CFD) was used to model a variety of ceramic heat exchanger tube configurations for this [Link] physical
model of the complex, multi-shaped construction was brought into Fluent 18.2. To measure how efficient and effective heat transmission is,
engineers developed the ceramic monolith heat exchanger. The whole domain, including the fluid area on the exhaust gas side, the ceramic
core, and the fluid region on the air side, was computed numerically. Different duct cross sections (rectangular, elliptical, and cylindrical)
with air and exhaust flowing in opposite directions were used to calculate the total system. When the predicted heat transfer rate is compared
between theoretical calculation and numerical computing, the latter is shown to be 15% higher.
INTRODUCTION
These days, it takes more effort to save [Link] in large part to a lack of fossil fuels, which are used in the
production of energy, there is a restricted supply of such energy. There are a wide variety of energy resources
available, including oil, natural gas, and others. Today's vehicles are more energy-hungry than ever. Oil reserves
will be depleted shortly if production continues at its present pace. The finite supply of fossil fuels, however, will
become more problematic when production rates begin to drop.
The release of greenhouse gases is another, more pressing reason to create energy-efficient automobiles. Emissions
of carbon dioxide (CO2) from the burning of fossil fuels contribute to global warming because they absorb heat
reflected back from Earth's surface. The ability of the environment to store CO2 is diminished as a result of the
greenhouse effect's interference with natural marine and carbon cycles. Energy production from the combustion of
fossil fuels was the single greatest contributor to global CO2 emissions (45 percent). Since 1970, human-caused
carbon dioxide (CO2) emissions have grown by around 80 percent overall (and by more than 100 percent in the
transportation sector), raising average atmospheric temperatures by about 0.8 degrees Celsius. While this may not
seem like much on a grand scale, the global impact of this trend is expected to be catastrophic.
1,2,3,4
Asst. Professor,
Department of ME, K. S. R. M College of Engineering(A), Kadapa
Int. J. Mech. Eng. Res. & Tech 2019
ISSN 2454 – 535X [Link]
Vol. 11, Issue. 2, June 2019
correlation was adopted to the ξ-NTU method among
the several correlations.
There is a significant emphasis on environmental
sustainability in vehicle and engine development due Chandrakala[2](2015)- In their study the
to the need to cut emissions and decrease the use of performance of heat transfer and pressure drop is
fossil fuel reserves. Therefore, it is evident that the calibrated by numerical computation. The main aim
CO2emissions from renewable sources should be is to reduce the hot side temperature from 1100oc to
reduced by the use of electric cars. 600oc and later it passes through the metallic heat
exchanger temperature ranges less than 600oc. By
increasing the Reynolds number on the cold air side
this increase the velocity of the cold fluid Increase
There has been significant effort put towards the heat transfer rate also increase the velocity by
improving the efficiency of combustion engines by using nuzzling effect on cold air slot. The main
decreasing these losses. The losses caused by purpose using the ceramic is to withstand with high
mechanical friction can be decreased, the engine's temperature than metal.
combustion efficiency can be improved, and better
gas exchange pathways may be designed to [Link][3](2016);In their study they stated that
accomplish this goal. Ceramic heat exchanger has low material cost and
also it can withstand high temperatures compared to
metallic heat exchanger. Due to this reason it is
important to predict the performance of ceramic heat
1.1 OBJECTIVES OF PRESENT exchanger, before it gets fabricated .In this project
STUDY CFD analysis is performed on the ceramic heat
exchanger having rectangular and circular ducts
The present work include following where aluminum nitride is used to predict and
objectives optimize various parameters like heat transfer rate
Designing of Rectangular, circular and and effectiveness.
elliptical shapes using CREO-
PARAMETRIC 3.0 2. WORKING OF CFD CODE:
Simulating the designs with ANSYS
All the CFD codes contain three main elements. They
FLUENT 15.
are as follows,
To enhance heat transfer coefficient of
Rectangular, circular and elliptical tubes. Pre-processor.
Calculating the heat transfer rate.
Solver.
5. Calculation of heat transfer coefficient
Post processor.
for Rectangular, circular and elliptical shape
tubes 3.3.1 Pre Processor
Comparing heat transfer coefficient between
optimized shapes of tubes. It transfers the input of a flow problem to
CFD program by means of an operator friendly
interface and the subsequent transformation of this
input into a suitable format, which can be used by
1. LITERATURE REVIEW solver. The stage wise preprocessor activities include.
Determining the geometry of the region
Young Hawn Yoon[1](2009)In their study they of the interest i.e. the computational
found the performance of heat transfer and pressure domain.
drop by numerical computation and ξ-NTU method. Grid generation or mesh generation
By comparisons of both performances by the (subdivision of the computational
numerical computation and the ξ-NTU method, the domain into small segments, which are
effectiveness by ξ-NTU method was closest to the called as cells, control volumes)
result by the numerical computation within the Selection of the physical and chemical
relative of 2.14%when Stephan's Nusselt number phenomena that need to be modeled.
Definition of fluid properties.
Int. J. Mech. Eng. Res. & Tech 2019
ISSN 2454 – 535X [Link]
Vol. 11, Issue. 2, June 2019
Specification of appropriate boundary 4. Inlet velocity and temperature of the
conditions at cells, which coincide with rectangular and trapezoidal heat
or touch the domain boundary.
sinks isuniform.
The solution to a flow problem (pressure, 5. Uniform air velocity is assumed
velocity, temperature etc.) is defined at nodes,
corners of each cell. The number of the cells in the
along the length of the fin
grid governs the accuracy of a CFD solution. In 6. The wall resistance and fouling
general, the larger number of cells the better the factors are negligible.
solution accuracy, but increases the time required for 7. All the heat rejected from
solution. microelectronic processing system
assumed to be absorbed in heat
3.3.2 Solver
sinks.
There are three distinct of numerical solution
techniques: finite difference, finite element and finite 4.4NUMERICAL ANALYSIS OF HEAT
volume method. The outlines of the numerical EXCHANGER
method that form the basis of the solver perform the
following sequence steps: 4.4.1. Geometrical Model of rectangular tube heat
Approximation of the unknown flow exchanger;
variables by means of simple function.
Discretization by substitution of the
approximation into the governing equations The geometric model for the rectangular
and subsequent mathematical manipulation.
Solution of the algebraic equation through tube Heat Exchanger is as shown in the Fig.
an interactive process.
4.2.1
3.3.3 Post Processor
As in preprocessing, a huge amount of
development work has recently taken place in the
post-processing field. Owing to the increased
popularity of engineering workstations, many of
which have outstanding graphics capabilities, the
leading CFD package are now equipped with
versatile data visualization tools. These includes,
3. ANALYSIS OF HEAT EXCHANGER
Fig.4.4.1 Fig shows Geometric Model of rectangular tube heat
4.1 Assumptions exchanger.
4.4.2. Meshing module of rectangular tube heat
1. The governing equations are exchanger;
assumed to be in steady state and
taken for compressible fluid. The meshing module for the rectangular tube Heat
2. The fluid flowing through the heat Exchanger is as shown in the Fig. 5.4.2
sink channel exhibits Newtonian
behaviour.
3. The density of the air is taken at
constant pressure and at ambient
temperature
Int. J. Mech. Eng. Res. & Tech 2019
ISSN 2454 – 535X [Link]
Vol. 11, Issue. 2, June 2019
Fig.4.4.2 shows meshing module of rectangular tube heat
exchanger. Fig. 4.3.3. Shows Contours Of temperature for elliptical tube
heat exchanger at air side
4.4.3temperature,Pressureandvelocity
distributions of rectangular Structure:
Fig. 4.3.4 Shows Contours Of temperature for elliptical tube heat
Fig. 4.4.3 Shows Contours Of temperature for rectangular tube exchanger at exhaust side
heat exchanger at air side
4. Results &Discussion
GRAPHICAL REPRESENTATION:
Fig.5.1. mass flow rate vs. heat transfer rate
rectangular tube:
Fig. 4.4.4 Shows Contours Of velocity for rectangular tube heat
exchanger at exhaust side
TEMPERATURE, PRESSURE AND VELOCITY
DISTRIBUTIONS OF ELLIPTICAL FIG.5.1. mass flow rate VS heat transfer rate
STRUCTURE: The above Fig.5.1 shows the variation of
heat transfer rate with the mass flow rate. As the
mass flow rate is increases heat transfer rate is also
increases With respect to the mass flow rate. Mass
flow ratewill changes heat transfer rate either rise or
fall down and then maximum heat transfer rate will
be obtained at 0.003966kg/s.
Int. J. Mech. Eng. Res. & Tech 2019
ISSN 2454 – 535X [Link]
Vol. 11, Issue. 2, June 2019
Effectiveness between rectangle,elliptical and
FIG.5.2. mass flow rate VS heat transfer rate cylindrical shapes from numerical analysis
The above Fig.6.2 shows the variation of heat
transfer rate with the mass flow rate. As the mass
flow rate is increases heat transfer rate is also
increases With respect to the mass flow rate. Mass
flow rate will changes heat transfer rate either rise or
fall down and then maximum heat transfer rate will
be obtained at 0.003966kg/s of an elliptical tube
5. CONCLUSION
The present study contrasted theoretical and
numerical analyses of the performance of a ceramic
FIG.5.3. mass flow rate VS heat transfer rate monolith heat exchanger. Exhaust gas and ambient
air at temperatures between 600 and 1000 C have
The above Fig.6.3 shows the variation of
been the subject of theoretical studies. Theoretical
mass flow rate with heat transfer rate. As the mass
and numerical analyses assessed the overall heat
flow rate is increases the heat transfer rate is also
transfer rate and [Link] Nusselt number
[Link] above Fig.6.1 shows the variation of
correlations found in the literature have been used in
heat transfer rate with the mass flow rate. As the
the computations that have been carried out using the
mass flow rate is increases heat transfer rate is also
NTU approach.
increases With respect to the mass flow rate. Mass
flow rate will changes heat transfer rate either rise or (1) Numerical calculation improved heat transfer
fall down and then maximum heat transfer rate will performance by 15% compared to theoretical study.
be obtained at 0.003966kg/s. The total heat transfer by NTU technique with the
Stephen correlation is the most similar to the
5.6 RESULT TABULAR numerical approach of calculating the Nusselt
number.
Comparison between Reynolds Number &
Correlations (2) Rectangular tube heat exchangers have an
estimated Efficiency of 52%, elliptical tube heat
exchangers have an Efficiency of 55%, and
cylindrical tube heat exchangers have an Efficiency
of 62%.
6. FUTURE SCOPE:
Ni-Cr-Al, NiCrAl + MgZrO3, and MgZrO3
are the ceramic materials used for the whole of this
project. The same may be achieved by using state-
Comparison between Mass flow rate & Correlations
Int. J. Mech. Eng. Res. & Tech 2019
ISSN 2454 – 535X [Link]
Vol. 11, Issue. 2, June 2019
of-the-art ceramic materials that are naturally Engineering 31 (2011) 2141-2145, David J.
resistant to high temperatures. Kukulka a, Rick Smith b, Kevin G. Fuller b.
By keeping the right L/D ratio and without changing
the mass distribution, you may employ cross sections
other than the standard rectangular, elliptical, and
cylindrical ones. "Heat transfer enhancement in dimpled
tubes," Applied Thermal Engineering 21 (2001)
As an alternative to venting smoke stack exhaust 535-547, Juin Chen (a), Hans Muller-Steinhagen
outside, it may be used to preheat air in the pre (b), and Georey G. Ducy (a) [6].
heater, allowing it to function at a lower, more
energy-efficient temperature. This is possible so long
as the appropriate parameters for the application are
known.
[7]. C. Son, J.E. Kima, J.H. Dooa, M.Y.
Haa, H.S. Yoonb, and J.H. Dooa Numerical
investigation on flow and heat transfer
characteristics in a cooling channel with a
protrusion-in-dimple surface, International
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Int. J. Mech. Eng. Res. & Tech 2019
ISSN 2454 – 535X [Link]
Vol. 11, Issue. 2, June 2019
