EXPERIMENTAL AND CFD ANALYSIS OF DOUBLE

PIPE COUNTER FLOW HEAT EXCHANGER

A PROJECT REPORT

Submitted by

AZARUDEEN.A (513317114006)

SUBASH.K (513317114040)

TAMSIL AHMED.M.M (513317114044)

VISHNU.D (513317114049)

In Partial fulfilment for the award of the degree

of

BACHELOR OF ENGINEERING

in
MECHANICAL ENGINEERING

UNIVERSITY COLLEGE OF ENGINEERING ARNI

ANNA UNIVERSITY: CHENNAI 600025

APRIL 2021
 BONAFIDE CERTIFICATE

Certified that this project report “EXPERIMENTAL AND CFD

ANALYSIS OF DOUBLE PIPE COUNTER FLOW HEAT
EXCHANGER” is the bonafide work of
“AZARUDEEN.A(513317114006), SUBASH.K(513317114040),
TAMSIL AHMED.M.M(513317114044), VISHNU.D(513317114049)”
who carried out the project work under my supervision.

SIGNATURE SIGNATURE

GUIDE HEAD OF THE DEPARTMENT

Mr. K. MURALI Dr. P. SARAVANAN KUMAR, Ph.D.

Teaching fellow, Assistant professor
Department of Mechanical Engineering, Department of Mechanical Engineering,
University College of Engineering, Arni University College of Engineering, Arni

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 ACKNOWLEDGEMENT

At the outside we express our deep gratitude to the almighty lord for
bestowing his grace and blessing upon to complete the project.

We express our sincere thanks to DR. R. ARULARASAN, M.Tech.,

Ph.D. our beloved dean (i/c) who has given an opportunity to carry out the
project work and completing the same.

We honestly thank Dr. P. SARAVANAKUMAR, M.Tech., Ph.D.., Head

of the Department of Mechanical Engineering for his kind permission and
give the support to us.

We thank our project coordinator DR. A. MADHANAGOPAL, Ph.D.,

Asst. Professor department of Mechanical Engineering for his immense
support to our project with encouragement and wishes and blessing.

We thank our beloved parents for providing a huge financial assistance to

support our project encouragement and blessing. We also thank all our
teaching staff of our department who helped us directly or indirectly to
complete this project successfully.

We sincerely thanks to our project guide MR. K,. MURALI, M.E.,

Teaching fellow, Department of Mechanical Engineering we thank him for
his excellent guidance that inspired to the height of sincerity leading us all
the way to reach the goal.

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ABSTACT

The Heat exchanger is a device which used to transfer heat from one fluid to
another through a solid medium or interface. There is various type of heat
exchanger available. In this paper Counter flow heat exchanger is selected. Our
objective was to change different fluid in the inner pipe with fin and without fin
to improve the efficiency of the heat exchanger. Different fluid passes in the
inner pipe with fin and without fin is selected for the study. Experimental model
of the double pipe counter flow heat exchanger is done and 3D modeling is done
in Solidworks 2018. We use ANSYS FLUENT12.1 software and experimental
calculations to analyse the temperature drops as a function of both inlet velocity
and inlet temperature and how each varies with the others. Finite Element
Analysis software ANSYS Workbench 18.0 is used to perform CFD analysis
under a standard working condition to find performance parameter. We found
that the water provides more effective heat exchange due to with fin and without
fin.

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 TABLE OF CONTENTS

CHAPTER NO TITLE PAGE NO.

ABSTRACT vi

LIST OF FIGURES viii

LIST OF TABLES xi

1 INTRODUCTION 1
2 LIETERATURE SURVEY 3
3 HEAT EXCHANGER 6
3.1 Heat exchanger types 6
3.1.1 Plate type heat exchanger 7
3.1.2 Shell or Tube type heat exchanger 7
3.1.3 Double pipe heat exchanger 7
3.1.4 Types of double pipe heat exchanger 8
3.1.4.1 Counter flow heat exchanger 8
3.1.4.2 Parallel flow heat exchanger 9
3.1.4.3 Cross flow heat exchanger 9
3.2 Efficiency of heat exchanger 10
3.3 Advantages 10
3.4 Disadvantages 11
3.5 Application 12

4 FIN 13
4.1 Types of fin 13
4.2 Application of fin 14

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5 COMPUTATIONAL FLUID DYNAMICS
5.1 Discretization Methods 16
5.1.1 Finite Difference Method (FDM) 17
5.1.1 Finite Volume Method (FVM) 17
5.1.2 Finite Element Method (FEM) 18
5.2 CFD procedure 19
5.2.1 Pre-processing 19
5.2.2 Solver 20
5.2.3 Post-processing 24
5.3 Differential Equations used in CFD 25
5.3.1 Navier- Stokes Equations 25
5.3.2 Reynolds-averaged Navier-Stokes Equations 28
5.4 Advantages of CFD 29

6 CONSTITUENTS OF HEAT EXCHANGER 31

6.1 Copper pipe 31
6.2 Galvanized Iron pipe 32
6.3 Thermocouple wire 32
6.4 Digital temperature indicator 33

7 EXPERIMENTAL SETUP AND METHOD ANALYSIS 34

7.1 Setting up heat exchanger 34
7.2 Setting up different fluid in the heat exchanger 36
7.3 Heat transfer 37
7.4 Logarithmic Mean Temperature Difference 37
7.5 Effectiveness of fin 38
7.6 Mass flow rate 38
7.7 Experimental reading 39

8 ANALYSIS AND RESULT 41

8.1 Geometry of heat exchanger 41
8.2 Mesh Generation 44
8.3 Boundary condition 45
8.4 Results and discussion 46
8.5 Experimental calculations will be done to use as a
cross check 48
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 8.6 Graph of fluid heat transfer in temperature 53

9 CONCLUSION 56
10 REFERENCES 58

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 LIST OF FIGURES

CHAPTER NO FIGURES PAGE NO.

3. 1. Counter flow schematic diagram 8

2. Parallel flow schematic diagram 9
3. Cross flow schematic diagram 9

5. 4. Algorithm of numerical approach used by simulation

softwares 23
6. 5. Copper pipe is used as inner pipe 31
6. Galvanized pipe is used as outer pipe 32
7. Thermocouple (K-type wire) 33
8. Digital Temperature Indicator 33
7. 9. a) Copper pipe without fin 35
b) Copper pipe with fin 35
10. Experimental setup of heat exchanger 36

8. 11. Select XYPlane in Workbench Geometry 42

12. Geometry of heat exchanger without fin 43
13 Geometry of heat exchanger with fin 44
14. Meshing of double pipe heat exchanger 45
15. Left end is outlet of inner pipe of Water temperature in
volume rendering 47
16. Left end is inlet of inner pipe of Water temperature in
volume rendering 47
17. Hot fluid without fin in celsuis 53
18. Cold fluid without fin in celsuis 54
19. Hot fluid with fin in celsuis 54
20. Cold fluid with fin in celsuis 55

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 LIST OF TABLES

CHAPTER NO TABLE NAME PAGE NO.

7. 1. Experimental reading 40
8. 2. Fluent reading 46
3. LMTD and Effectiveness Values 53

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 Chapter 1

INTRODUCTION

A typical double pipe heat exchanger consists of one pipe placed

concentrically inside another larger diameter with appropriate fittings to
direct the flow from one section to next. Double pipe heat exchanger can be
arranged into various series and parallel arrangements to meet pressure drop
and mean temperature difference requirements. The major use of double
pipe heat exchanger is for sensible heating and cooling of process fluid
where small heat transfer areas is required (up to 50m2). This configuration
is also very suitable when one or both fluid are at high pressure. The major
disadvantage in the double pipe heat exchanger are bulky and expensive. If
the heat transfer coefficient is poor for annulus, axially finned inner tubes
can be used. Generally double pipe heat exchanger are built in modular
concept, i.e., in the form of hairpins. Study has been done on the type of the
flows in the circular straight pipes, and the effect of Prandtl and Reynolds
Number on the flow patterns and on Nusselt Numbers. The two basic
boundary conditions that are faced in the applications are constant
temperature and the constant heat flux of the wall.

Computational fluid dynamics (CFD) is a computer-based simulation

method for analysing fluid flow, heat transfer, and related phenomena such
as chemical reactions. In this project CFD is used for analysis of flow and

1
heat transfer (not for analysis of chemical reactions). Some examples of
application areas are: aerodynamic lift and drag (i.e. airplanes or windmill
wings), power plant combustion, chemical processes, heating/ventilation,
and even biomedical engineering (simulating blood flow through arteries
and veins). CFD analyses carried out in the various industries in R&D and
manufacture of aircraft, combustion engines, as well as many other
industrial products.

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 Chapter 2

LITERATURE SURVEY

Naphon (2006) studied, the theoretical and experimental results of the

second law analysis on the heat transfer and flow of a horizontal concentric
tube heat exchanger are presented. Hot water and cold water are used as
working fluids. The test runs are done at the hot and cold water mass flow
rates ranging between 0.02 and 0.80 kg/s and between 0.02 and 0.80 kg/s ,
respectively. The predicted results obtained from the model are validated
by comparing with the present measured data.

Foli et al. (2011) made two different approaches for the advancement of
micro heat exchanger. Considering the geometric parameter and flow
condition the two approaches would be like CFD analysis for the
optimization of different inlet parameters and other one would be
supposedly combination of genetic algorithm and CFD for development in
heat exchanger.

Kamyar et al. (2012) evaluated the thermal performance using Nano

fluids instead of using the water as likely to be passive method. They got a
better conductivity and heat transfer coefficient rather than the liquid water
which provides them the better simulation results for heat transfer however
for a two phase model it requires some modification.

Michael Crawford et. al. (2005) studied, engine oil was assumed to be
flowing through the inner pipe which was made of copper and cooled by the

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outer concentric pipe in which water was flowing. Material properties such
as Dynamic viscosity, Density, Prandtl Number, and Thermal Conductivity
were obtained.

Khannan et al. (2014) studied that the heat transfer through the double
pipe heat exchanger with annular fins. Three different configurations
annular ring, spiral rod and the rectangular projection were considered on
the outside surface of the outer tube. Experiments were done with varied
mass flow rates. It was observed that heat transfer rate was increased for a
finned tube. Fin with annular ring showed better performance than the other
methods.

Das et al. (2012) reviewed the multi stream plate fin heat exchanger. As
it is very compact and has a capability to handle different fluid streams well
enough than the regular used two-stream heat exchanger. As they stated
there is no such universally accepted thermal design for heat exchanger but
with the help of differential and numerical analysis & by some area
manipulation the heat exchanger effectiveness would be enhanced up to
certain extend.

Jibin Johnson et. al. (2015) reviewed that is a powerful tool for research
and development in heat transfer simulation and modeling of heat exchanger
in the multiphase flow systems. Ansys Fluent is feasible and famous
software that compute accurately the conjugate heat transfer. Herewith
realizable K-Epsilon, standard wall function mode can also be employed.
This simulation gives the values of pressure, temperature, heat transfer rate
and velocity at various sections of the annulus and pipe.

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 Nagarseth et al. (2017) gives a better conception of counter flow water
tube heat exchanger with CFD analysis. A discrete phase modeling at
different zones along the length has been done. MATLAB used to simulate
and CFD used for validation of the result with the experimental results.

Andrea de L. et. al. concerned that the required heat transfer area is
small (up to 50 m2 ), the double pipe heat exchanger plays major role. Here,
the flow arrangement is important when one or both of the process fluids are
operated at high pressure, because of the smaller diameter of the pipes.
While designing the heat-transfer equipment it is to be noted that the trade-
off between the two conflicting goals of low capital cost (high overall heat-
transfer coefficient with small heat-transfer area) and low operating cost
(small stream pressure drop). Already it is described by the use of different
numerical methods such as NTU and LMTD methods. However, in these
methods are computationally time consuming, obtaining numerical errors
during calculation and cannot be predicted all thermal and hydraulic
behaviours of fluids in the flow fields. To resolve these difficulties,
computational fluid dynamics (CFD) software can be used. CFD is the
science of predicting fluid flow pattern, heat and mass transfer, chemical
reactions, and related phenomena by solving the set of governing
mathematical equations such as conservation of mass, conservation of
momentum, conservation of energy, conservation of species, effects of body
forces, etc.

Mohanty et al. (2014) prepares a double pipe heat exchanger using CFD
and for checking the performance of heat exchanger ANSYS 19 used. This
techniques for performance evaluation and shows graphically that how the
performance enhances at the expense of pressure drop, velocity difference
and temperature gradients.

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 Chapter 3

HEAT EXCHANGER
3. 1. HEAT EXCHANGER

A heat exchanger is a system used to transfer heat between two or

more fluids. Heat exchangers are used in both cooling and heating
processes.[1] The fluids may be separated by a solid wall to prevent mixing or
they may be in direct contact.[2] They are widely used in space
heating, refrigeration, air conditioning, power stations, chemical
plants, petrochemical plants, petroleum refineries, natural-gas processing,
and sewage treatment. The classic example of a heat exchanger is found in
an internal combustion engine in which a circulating fluid known as engine
coolant flows through radiator coils and air flows past the coils, which cools
the coolant and heats the incoming air.

In a double pipe heat exchanger, into its simplest form is presently one pipe
within another larger pipe. One fluid flows through the inside pipe and the
further flows through the annulus between the two pipes. The wall of the inner
pipe is the heat transfer surface.

3.2 HEAT EXCHANGER TYPES:

1. Plate type
2. Shell or Tube type
3. Double type

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3.2.1 PLATE TYPE HEAT EXCHANGER:

A plate heat exchanger is a type of heat exchanger that uses metal plates
to transfer heat between two fluids. This has a major advantage over a
conventional heat exchanger in that the fluids are exposed to a much
larger surface area because the fluids are spread out over the plates. This
facilitates the transfer of heat, and greatly increases the speed of
the temperature change. Plate heat exchangers are now common and very
small brazed versions are used in the hot-water sections of millions
of combination boilers.

3.2.2 SHELL or TUBE TYPE HEAT EXCHANGER:

It is the most common type of heat exchanger in oil refineries and other
large chemical processes, and is suited for higher-pressure applications. As
its name implies, this type of heat exchanger consists of a shell (a
large pressure vessel) with a bundle of tubes inside it. One fluid runs through
the tubes, and another fluid flows over the tubes (through the shell) to
transfer heat between the two fluids. The set of tubes is called a tube bundle,
and may be composed of several types of tubes: plain, longitudinally finned,
etc.

3.2.3 DOUBLE PIPE HEAT EXCHANGER:

The double pipe heat exchanger is, in its simplest form, one pipe held
concentrically inside of a larger pipe (“Pipe in pipe’’). The inner pipe acts
as the conductive barrier, where one fluid flows through this inner pipe and
other flows around it through the outer pipe, forming an annulus shape. The
outside or “shell side” flow passes over the inside, or “tube side” flow, which

7
 will cause heat exchange through the inner tube’s walls. They are also often
referred to as hairpin, jacketed pipe, jacketed u-tube, and pipe-in-pipe
exchangers.

3.2.4 Types of Double Pipe Heat Exchangers:

1. Counter Flow Heat Exchanger

2. Parallel Flow Heat Exchanger
3. Cross Flow Heat Exchanger

3.2.4.1 Counter Flow Heat Exchanger

A counter-flow heat exchanger is one in which the direction of
the flow of one of the working fluids is opposite to the direction to
the flow of the other fluid. It is the most efficient flow arrangement,
producing the highest temperature change in each fluid compared to any
other two fluid flow arrangements.

Fig. 1. Counter flow schematic diagram

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3.2.4.2 Parallel Flow Heat Exchanger

In the parallel-flow arrangement, the hot and cold fluids enter at the same
end, flow in the same direction, and leave at the same end. The two fluids
enter the exchanger at the same end, and travel in parallel to one another to
the other side.

Fig. 2. Parallel flow schematic diagram

3.2.4.3 Cross Flow Heat Exchanger:

In a cross-flow heat exchanger, the fluids travel roughly perpendicular to

one another through the exchanger. This is typically utilized when one fluid
is a liquid and the other is a gas, as in a car radiator in which hot water
flowing left and right is cooled by air moving up or down.

Fig. 3. Cross flow schematic diagram

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3.3 EFFICIENCY OF HEAT EXCHANGER:

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. The exchanger's performance can also be affected by
the addition of fins in one or both directions, which increase surface area and
channel fluid flow or induce turbulence.

3.4 ADVANTAGES:
1. PLATE TYPE:
• More compact design.
• A lower cost option wherever stainless steel is required.
• Higher operating pressure capabilities.
• Higher temperature capabilities.
• Ideal for small district heating, beverage cooling, food and
pharmaceutical production and low duty oil cooling applications.

2. PLATE or SHELL TYPE:

• Less expensive as compared to Plate type coolers.

• Can be used in systems with higher operating temperatures and
pressures.
• Pressure drop across a tube cooler is less.
• Tube leaks are easily located and plugged since pressure test is
comparatively easy.

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 3. DOUBLE PIPE TYPE:
• Double pipe heat exchanger is that it can be operated in a true
counterflow pattern, which is the most efficient flow pattern
• It will give the highest overall heat transfer coefficient
• Double pipe heat exchangers can handle high pressures and
temperatures well
• It can operate with a temperature cross, that is, where the cold side outlet
temperature is higher than the hot side outlet temperature.

3.5 DISADVANTAGES:
1. PLATE TYPE:
• Bonding material between the plates limits the operating
temperature of the cooler.
• Over tightening of clamping bolts results in increased pressure
drop across the cooler.
• Initial cost of titanium is high
• Parts of the cooling system is susceptible to corrosion

2. SHELL or TUBE TYPE:

• Heat transfer efficiency is less compared to plate type cooler.

• Cleaning and maintenance is difficult since a tube cooler requires
enough clearance at one end to remove the tube nest.
• Capacity of tube cooler cannot be increased.
• Requires more space in comparison to plate coolers

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 3. DOUBLE PIPE :
• Leaking can occur, especially when paired with more units.
• The tubes are easily fouled and difficult to clean without
disassembling the whole heat exchanger
• Budget and space exist for a shell and tube exchanger, then
a double pipe design is often a less efficient method
of heat transfer.

3.6 APPLICATIONS:

Heat exchangers can be used in food Industry as a process of cooling

down various products in the industry. Heat exchangers are often used to
reduce or eliminate microbials, thereby making products safe for
consumption and extending their shelf life.

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 Chapter 4

FIN

A fin is a surface that extends from an object to increase the rate of heat
transfer to or from the environments by increase convection. Adding a fin to
an object increases the surface area and can sometimes be an economical
solution to heat transfer problems. Finned surfaces are commonly used in
practice to enhance heat transfer. In the analysis of the fins, we consider steady
operation with no heat generation in the fin. We also assume that the
convection heat transfer coefficient to be constant and uniform over the entire
surface of the fin.

The rate of heat transfer from a solid surface to atmosphere is given by 𝑄 =

ℎ𝐴∆𝑇 where, h and ∆𝑇 are not controllable.

So, to increase the value of Q, surface area should be increased. The

extended surface which increases the rate of heat transfer is known as fin.

4.1 Types of fin:

1. Straight fin with uniform cross sections

2. Straight fin with non-uniform cross sections
3. Annular fin
4. Pin fin with non-uniform cross section

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4.2 Application of fin

a) Cooling of electronic components.

b) Cooling of motor cycle engines.
c) Cooling of small capacity compressors
d) Cooling of transformers.
e) Cooling of radiators and refrigerators etc.

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 Chapter 5

COMPUTATIONAL FLUID DYNAMICS

Study of fluid flow has been around for millennium, dating back to
ancient Greece, but their understanding did not go beyond what they need to
know to run aqueducts and other water works. Da Vinci further pursued the
topic during the retainage observing waves and free jets. Even newton
studied fluids. Computational fluid dynamics is a term to describe a way of
modelling the fluids using algorithms and numerical methods. Currently they
are solved utilizing computers but early methods were completed manually
without the aid of the computers. Computational fluid dynamics are a
powerful tool to model fluids, but even with the most state of an art
supercomputers and technological advances they are only an approximation
of what would occur in reality.

Fluid Flow is classified as external and internal, depending on whether

the fluid is forced to flow over a surface or, in a conduit. Fluid flow in circular
and non-circular is commonly encountered in practise. The hot and cold
water that we use in our homes is pumped through pipes. Water in a city is
distributed by extensive piping network. Oil and natural gas are transported
hundreds of miles by large pipelines. Blood is carried through our bodies by
arteries and veins. The cooling water is an engine is transported by hoses to
the pipes in radiator where it is cooled as it flows. Thermal energy in a
hydronic space heating system is transferred to the circulating water in the
boiler and then it is transported to the desired location through the pipes.

15
 So, it can be seen that many of the industrial processes have to deal with
the flow through pipe. If analysis and simulation of flow through the pipe is
done well than many of the industrial problems can be understood and solved
using the results obtained. Hence, in this project incompressible flow through
the double pipe heat exchanger, is simulated using CFD code software
ANSYS FLUENT 19.1.

The physical aspects of any fluid flow are governed by three fundamental
principles:
1) Conservation of Mass (i.e. Continuity Equation)
2) Newton’s second law (force = rate of change of momentum)
3) Conservation of Energy (Energy equation)

These fundamental principles are expressed in terms of basic mathematical

equations, which generally are either integral equations or partial differential
equations. CFD is the art of replacing the integrals or the partial derivatives
in these equations with discretized algebraic forms, which in turn are solved
to obtain numerical values for the flow field at discrete points in time and/or
space.

5.1. Discretization Methods

There are three discretization methods in CFD:

1. Finite difference method (FDM)
2. Finite volume method (FVM)
3. Finite element method (FEM)

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5.1.1. Finite difference method (FDM)

A finite difference method (FDM) discretization is based upon the

differential form of the partial differential equation to be solved. Each
derivative is replaced with an approximate difference formula (that can
generally be derived from a Taylor series expansion). The computational
domain is usually divided into hexahedral cells (the grid), and the solution
will be obtained at each nodal point. The FDM is easiest to understand when
the physical grid is Cartesian, but through the use of curvilinear transforms
the method can be extended to domains that are not easily represented by
brick-shaped elements. The discretization results in a system of equation of
the variable at nodal points, and once a solution is found, then we have a
discrete representation of the solution.

5.1.2. Finite volume method (FVM)

A finite volume method (FVM) discretization is based upon an integral

form of the partial differential equation to be solved (e.g. conservation of
mass, momentum, or energy). The partial differential equation is written in a
form which can be solved for a given finite volume (or cell). The
computational domain is discretized into finite volumes and then for every
volume the 12 governing equations are solved. The resulting system of
equations usually involves fluxes of the conserved variable, and thus the
calculation of fluxes is very important in FVM. The basic advantage of this
method over FDM is, it does not require the use of structured grids, and the
effort to convert the given mesh in to structured numerical grid internally is
completely avoided. As with FDM, the resulting approximate solution is a
discrete, but the variables are typically placed at cell centers rather than at
nodal points. This is not always true, as there are also face- centered finite

17
 volume methods. In any case, the values of field variables at non storage
locations (e.g. vertices) are obtained using interpolation.

5.1.3. Finite element method (FEM)

A finite element method (FEM) discretization is based upon a piecewise

representation of the solution in terms of specified basis functions. The
computational domain is divided up into smaller domains (finite elements)
and the solution in each element is constructed from the basic functions. The
actual equations that are solved are typically obtained by restating the
conservation equation in weak form: the field variables are written in terms
of the basic functions, the equation is multiplied by appropriate test
functions, and then integrated over an element. Since the FEM solution is in
terms of specific basis functions, a great deal more is known about the
solution than for either FDM or FVM. This can be a double-edged sword, as
the choice of basic functions is very important and boundary conditions may
be more difficult to formulate. Again, a system of equations is obtained
(usually for nodal values) that must be solved to obtain a solution.

Comparison of the three methods is difficult, primarily due to the many

variations of all three methods. FVM and FDM provide discrete solutions,
while FEM provides a continuous (up to a point) solution. FVM and FDM
are generally considered easier to program than FEM, but opinions vary on
this point. FVM are generally expected to provide better conservation
properties, but opinions vary on this point also.

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5.2. CFD procedure

CFD codes are structured around the numerical algorithms that can be tackle
fluid problems. In order to provide easy access to their solving power all
commercial CFD packages include sophisticated user interfaces input
problem parameters and to examine the results.

Hence all codes contain three main elements:

1. Pre-processing.
2. Solver
3. Post-processing.

5.2.1. Pre-Processing

This is the first step in building and analyzing a flow model. Preprocessor
consist of input of a flow problem by means of an operator –friendly interface
and subsequent transformation of this input into form of suitable for the use
by the solver. The user activities at the Pre-processing stage involve:

• Definition of the geometry of the region: The computational domain.

• Grid generation the subdivision of the domain into a number of smaller,

non overlapping sub domains (or control volumes or elements Selection of
physical or chemical phenomena that need to be modeled).

• Definition of fluid properties

• Specification of appropriate boundary conditions at cells, which coincide

with or touch the boundary. The solution of a flow problem (velocity,
pressure, temperature etc.) is defined at nodes inside each cell. The accuracy
of CFD solutions is governed by number of cells in the grid. In general, the
larger numbers of cells better the solution accuracy. Both the accuracy of
the solution & its cost in terms of necessary computer hardware &

19
 calculation time are dependent on the fineness of the grid. Efforts are
underway to develop CFD codes with a (self) adaptive meshing capability.
Ultimately such programs will automatically refine the grid in areas of rapid
variation.

GAMBIT (CFD PREPROCESSOR)

GAMBIT is a state-of-the-art preprocessor for engineering analysis. With

advanced geometry and meshing tools in a powerful, flexible, tightly-
integrated, and easy-to use interface, GAMBIT can dramatically reduce
preprocessing times for many applications. Complex models can be built
directly within GAMBIT‘s solid geometry modeler, or imported from any
major CAD/CAE system. Using a virtual geometry overlay and advanced
cleanup tools, imported geometries are quickly converted into suitable flow
domains. A comprehensive set of highly-automated and size function driven
meshing tools ensures that the best mesh can be generated, whether
structured, multiblock, unstructured, or hybrid.

5.2.2. Solver

The CFD solver does the flow calculations and produces the results.
FLUENT, FloWizard, FIDAP, CFX and POLYFLOW are some of the types
of solvers. FLUENT is used in most industries. FloWizard is the first general-
purpose rapid flow modeling tool for design and process engineers built by
Fluent. POLYFLOW (and FIDAP) are also used in a wide range of fields,
with emphasis on the materials processing industries. FLUENT and CFX two
solvers were developed independently by ANSYS and have a number of
things in common, but they also have some significant differences. Both are
control-volume based for high accuracy and rely heavily on a pressure-based
solution technique for broad applicability. They differ mainly in the way they

20
integrate the fluid flow equations and in their equation solution strategies.
The CFX solver uses finite elements (cell vertex numerics), similar to those
used in mechanical analysis, to discretize the domain.

In contrast, the FLUENT solver uses finite volumes (cell centered

numerics). CFX software focuses on one approach to solve the governing
equations of motion (coupled algebraic multigrid), while the FLUENT
product offers several solution approaches (density-, segregated- and
coupled-pressure-based methods) The FLUENT CFD code has extensive
interactivity, so we can make changes to the analysis at any time during the
process. This saves time and enables to refine designs more efficiently.
Graphical user interface (GUI) is intuitive, which helps to shorten the
learning curve and make the modeling process faster.

In addition, FLUENT's adaptive and dynamic mesh capability is unique

and works with a wide range of physical models. This capability makes it
possible and simple to model complex moving objects in relation to flow.
This solver provides the broadest range of rigorous physical models that have
been validated against industrial scale applications, so we can accurately
simulate real-world conditions, including multiphase flows, reacting flows,
rotating equipment, moving and deforming objects, turbulence, radiation,
acoustics and dynamic meshing.

The FLUENT solver has repeatedly proven to be fast and reliable for a
wide range of CFD applications. The speed to solution is faster because suite
of software enables us to stay within one interface from geometry building
through the solution process, to post-processing and final output. The
numerical solution of Navier–Stokes equations in CFD codes usually implies
a discretization method: it means that derivatives in partial differential
equations are approximated by algebraic expressions which can be

21
alternatively obtained by means of the finite-difference or the finite-element
method.

Otherwise, in a way that is completely different from the previous one,

the discretization equations can be derived from the integral form of the
conservation equations: this approach, known as the finite volume method,
is implemented in FLUENT, because of its adaptability to a wide variety of
grid structures. The result is a set of algebraic equations through which mass,
momentum, and energy transport are predicted at discrete points in the
domain.

In the freeboard model that is being described, the segregated solver has
been chosen so the governing equations are solved sequentially. Because the
governing equations are non-linear and coupled, several iterations of the
solution loop must be performed before a converged solution is obtained and
each of the iteration is carried out as follows:

(1) Fluid properties are updated in relation to the current solution; if the
calculation is at the first iteration, the fluid properties are updated
consistent with the initialized solution.

(2) The three momentum equations are solved consecutively using the
current value for pressure so as to update the velocity field.

(3) Since the velocities obtained in the previous step may not satisfy the
continuity equation, one more equation for the pressure correction is
derived from the continuity equation and the linearized momentum
equations: once solved, it gives the correct pressure so that continuity is
satisfied. The pressure–velocity coupling is made by the SIMPLE
algorithm, as in FLUENT default options.

22
 (4) Other equations for scalar quantities such as turbulence, chemical
species and radiation are solved using the previously updated value of the
other variables; when inter-phase coupling is to be considered, the source
terms in the appropriate continuous phase equations have to be updated
with a discrete phase trajectory calculation.

(5) Finally, the convergence of the equations set is checked and all the
procedure is repeated until convergence criteria are met.

Fig. 4: Algorithm of numerical approach used by simulation softwares

The conservation equations are linearized according to the implicit

scheme with respect to the dependent variable: the result is a system of linear
equations (with one equation for each cell in the domain) that can be solved
simultaneously. Briefly, the segregated implicit method calculates every

23
 single variable field considering all the cells at the same time. The code stores
discrete values of each scalar quantity at the cell centre; the face values must
be interpolated from the cell centre values. For all the scalar quantities, the
interpolation is carried out by the second order upwind scheme with the
purpose of achieving high order accuracy. The only exception is represented
by pressure interpolation, for which the standard method has been chosen.

5.2.3 Post-Processing:

This is the final step in CFD analysis, and it involves the organization and
interpretation of the predicted flow data and the production of CFD images
and animations. Fluent's software includes full post processing capabilities.
FLUENT exports CFD's data to third-party post-processors and visualization
tools such as Ensight, Fieldview and TechPlot as well as to VRML formats.
In addition, FLUENT CFD solutions are easily coupled with structural codes
such as ABAQUS, MSC and ANSYS, as well as to other engineering process
simulation tools. Thus FLUENT is general-purpose computational fluid
dynamics (CFD) software ideally suited for incompressible and mildly
compressible flows.
Utilizing a pressure-based segregated finite-volume method solver,
FLUENT contains physical models for a wide range of applications
including turbulent flows, heat transfer, reacting flows, chemical mixing,
combustion, and multiphase flows. FLUENT provides physical models on
unstructured meshes, bringing you the benefits of easier problem setup and
greater accuracy using solution-adaptation of the mesh.
FLUENT is a computational fluid dynamics (CFD) software package to
simulate fluid flow problems. It uses the finite-volume method to solve the
governing equations for a fluid. It provides the capability to use different

24
 physical models such as incompressible or compressible, inviscid or viscous,
laminar or turbulent, etc.
Geometry and grid generation is done using GAMBIT which is the
preprocessor bundled with FLUENT. Owing to increased popularity of
engineering work stations, many of which has outstanding graphics
capabilities, the leading CFD are now equipped with versatile data
visualization tools. These include
• Domain geometry & Grid display.
• Vector plots.
• Line & shaded contour plots.
• 2D & 3D surface plots.
• Particle tracking.
• View manipulation (translation, rotation, scaling etc.)

5.3. Differential equation used in CFD

5.3.1 Navier-Stokes equations:

The ''Navier-Stokes equations'', named after Claude-Louis Navier and

George Gabriel Stokes, describe the motion of fluid substances. These
equations arise from applying Newton's second law to fluid motion, together
with the assumption that the fluid stress is the sum of a diffusing viscous
term (proportional to the gradient of velocity), plus a pressure term.

The fundamental of almost all CFD problems are the Navier–Stokes

equations, which define any single-phase fluid flow. These equations can be
simplified by removing terms describing viscosity to yield the Euler
equations.

25
 The Navier-Stokes equations dictate not position but rather velocity. A
solution of the Navier-Stokes equations is called a velocity field or flow
field, which is a description of the velocity of the fluid at a given point in
space and time. Once the velocity field is solved for, other quantities of
interest (such as flow rate or drag force) may be found.

The derivation of the Navier–Stokes equations begins with an

application of Newton's second law: conservation of momentum (often
alongside mass and energy conservation) being written for an arbitrary
portion of the fluid.

Navier- Stokes equations in conservation form :-

In x direction as

Similarly, we can write in y and z direction also.

Navier–Stokes equations (general form)

26
where v is the flow velocity,

ρ is the fluid density,

p is the pressure,

T is the stress tensor,

and f represents body forces (per unit volume) acting on the fluid and

∇ is the del operator.

The Navier–Stokes equations are nonlinear partial differential equations in

almost every real situation. In some cases, such as one-dimensional flow
and Stokes flow (or creeping flow), the equations can be simplified to linear
equations. The nonlinearity makes most problems difficult or impossible to
solve and is the main contributor to the turbulence that the equations model.

The nonlinearity is due to convective acceleration, which is an acceleration

associated with the change in velocity over position. Hence, any convective
flow, whether turbulent or not, will involve nonlinearity.

The numerical solution of the Navier-Stokes equations for turbulent flow

is extremely difficult, and due to the significantly different mixing-length
scales that are involved in turbulent flow, the stable solution of this requires
such a fine mesh resolution that the computational time becomes significantly
infeasible for calculation . Attempts to solve turbulent flow using a laminar
solver typically result in a time-unsteady solution, which fails to converge
appropriately. To counter this, time-averaged equations such as the Reynolds-
averaged Navier–Stokes equations (RANS), supplemented with turbulence
models, are used in practical computational fluid dynamics (CFD)
applications when modeling turbulent flows. Some models include
the Spalart-Allmaras, k-ω (k-omega), k-ε (k-epsilon), and SST models which
add a variety of additional equations to bring closure to the RANS equations.

27
5.3.2 Reynolds-averaged Navier-Stokes equations

The Reynolds-averaged Navier–Stokes equations (or RANS equations)

are time-averaged equations of motion for fluid flow. The idea behind the
equations is Reynolds decomposition, whereby an instantaneous quantity is
decomposed into its time-averaged and fluctuating quantities, an idea first
proposed by Osborne Reynolds. The RANS equations are primarily used to
describe turbulent flows. These equations can be used with approximations
based on knowledge of the properties of flow turbulence to give approximate
time-averaged solutions to the Navier–Stokes equations. For a stationary,
incompressible Newtonian fluid, these equations can be written in Einstein
notation as:

The left hand side of this equation represents the change in mean
momentum of fluid element owing to the unsteadiness in the mean flow and
the convection by the mean flow. This change is balanced by the mean body
force, the isotropic stress owing to the mean pressure field, the viscous

stresses, and apparent stress owing to the fluctuating velocity field,

generally referred to as the Reynolds stress. This nonlinear Reynolds stress
term requires additional modeling to close the RANS equation for solving,
and has led to the creation of many different turbulence models.

28
5.4. Advantages of CFD

Major advancements in the area of gas-solid multiphase flow modeling

offer substantial process improvements that have the potential to significantly
improve process plant operations. Prediction of gas solid flow fields, in
processes such as pneumatic transport lines, risers, fluidized bed reactors,
hoppers and precipitators are crucial to the operation of most process plants.

Up to now, the inability to accurately model these interactions has limited

the role that simulation could play in improving operations. In recent years,
computational fluid dynamics (CFD) software developers have focused on
this area to develop new modeling methods that can simulate gas-liquid-solid
flows to a much higher level of reliability.

As a result, process industry engineers are beginning to utilize these

methods to make major improvements by evaluating alternatives that would
be, if not impossible, too expensive or time-consuming to trial on the plant
floor. Over the past few decades, CFD has been used to improve process
design by allowing engineers to simulate the performance of alternative
configurations, eliminating guesswork that would normally be used to
establish equipment geometry and process conditions.

The use of CFD enables engineers to obtain solutions for problems with
complex geometry and boundary conditions. A CFD analysis yields values
for pressure, fluid velocity, temperature, and species or phase concentration
on a computational grid throughout the solution domain.

29
Advantages of CFD can be summarized as:

1. It provides the flexibility to change design parameters without the expense

of hardware changes. It therefore costs less than laboratory or field
experiments, allowing engineers to try more alternative designs than would
be feasible otherwise.

2. It has a faster turnaround time than experiments.

3. It guides the engineer to the root of problems, and is therefore well suited
for trouble-shooting.

4. It provides comprehensive information about a flow field, especially in

regions where measurements are either difficult or impossible to obtain.

30
 Chapter 6

CONSTITUENTS OF HEAT EXCHANGER

Heat exchanger is made of following materials:-

1. Copper pipe
2. Galvanized Iron pipe
3. Thermocouple wire
4. Digital temperature indicator

6.1 Copper pipe

Copper is a good conductor of heat. This means that if you heat one end
of a piece of copper, the other end will quickly reach the same temperature.
Copper has a 60% better thermal conductivity rating than aluminium and a
3,000% better rating than stainless steel.

1. Density = 8978 (Kg/m3)

2. Thermal conductivity = 387.6 (W/m-K)
3. Specific heat = 381 (J/Kg-K)

Fig. 5 Copper pipe is used as inner pipe

31
6.2 Galvanized Iron pipe

The galvanizing galvanized layer is thick, with uniform plating, strong

adhesion and long service life.

1. Density = 7047 (Kg/m3)

2. Thermal conductivity = 55 (W/m-K)
3. Specific heat = 456 (J/Kg-K)

Fig. 6 Galvanized Iron pipe is used as Outer pipe

6.3 Thermocouple wire

Type K (chromel–alumel) is the most common general-

purpose thermocouple with a sensitivity of approximately 41 µV/°C. It is
inexpensive, and a wide variety of probes are available in its −200 °C to
+1350 °C (−330 °F to +2460 °F) range.
The main limitation with thermocouples is precision; system errors of
less than one degree Celsius (°C) can be difficult to achieve.

32
 Fig. 7 Thermocouple (K-type wire)

6.4 Digital Temperature Indicator

Temperature indicators are installation instruments which can

process signals from temperature sensors and show them on the display.
Temperature indicators enable easy and economic valuation of resistance
sensors, such as Pt100 or different thermo element types.
We use the 12 Point Digital Temperature Indicator with
thermocouple wire to find the temperature.

Fig. 8 Digital Temperature Indicator

33
 Chapter 7

EXPERIMENTAL SETUP AND METHOD OF ANALYSIS

The Experimental setup includes the following steps and they are as
follow;

7.1.1 Setting up heat exchanger.

7.1.2 Setting up different fluid in the heat exchanger.

7.1 Setting up heat exchanger

The following are the materials used in the fabrication of the double
pipe heat exchanger and the experimental analysis:

Galvanized steel pipe, Thermocouples, Instant electric water heater, Control

Valves, Wood, Hose (pipes), switch cables, Copper pipe without fin (fig 9.a)
and Copper pipe with fin (fig 9.b).

The following are factors that were considered during the

selection of material to be used for the heat exchanger.

1. Compatibility of the materials with the process fluids.

2. Compatibility of the materials with the other component materials.
3. Ease of manufacture and fabrication by using standard methods like
machining, rolling, forging, forming, and metal joining methods such as
welding, brazing, and soldering.
4. Strength and ability to withstand operating temperature and pressure.
5. Cost.

34
6. Availability.
7. Type of fluid.
8. Fluid physical and chemical properties.
9. Thermal conductivity of the pipes.
10. Heat capacity of the pipes.
11. Sizes and weights of the pipes.

Fig 9.a Copper pipe without fin

Fig 9.b Copper pipe with fin

35
7.2 Setting up different fluid in the heat exchanger

Water was used as the base fluid flowing through tubing or piping. Its
material properties were derived from tables based on the temperature which
was being calculated in the model. The material was defined in FLUENT
using its material browser. For the different flow arrangement problem
model certain properties were defined by the user prior to computing the
model, these properties were: thermal conductivity, density, heat capacity at
constant pressure, ratio of specific heats, and dynamic viscosity.

Fig. 10 Experimental setup of heat exchanger

36
7.3. Heat transfer

In general, heat transfer describes the flow of heat (thermal energy) due
to temperature differences and the subsequent temperature distribution and
changes. The study of transport phenomena concerns the exchange of
momentum, energy, and mass in the form of conduction, convection, and
radiation.

Heat transfer, Q = m × Cp × Δ T

Where, Q = Watts

m = mass flow of fluid (Kg)

Cp = Specific capacity of fluid (J/Kg-K)

Δ T = Temperature difference

7.4 Logarithmic Mean Temperature Difference

The logarithmic mean temperature difference is used to determine the

temperature driving force for heat transfer in flow systems, most notably in
heat exchangers. The LMTD is a logarithmic average of the temperature
difference between the hot and cold feeds at each end of the double pipe
exchanger.

Where ΔT1 = TH1 - TC2

ΔT2 = TH2 - TC1

37
 TH1 – Hot fluid inlet temperature

TH2 – Hot fluid outlet temperature

TC1 – Cold fluid inlet temperature

TC2 – Cold fluid outlet temperature

7.5 Effectiveness of fin

The fin temperature effectiveness or fin efficiency is defined as the ratio

of the actual heat transfer rate through the fin base divided by the maximum
possible heat transfer rate through the fin base, which can be obtained if the
entire fin is at base temperature.

Effectiveness = (heat transfer without fin)

(heat transfer with fin)

Where,
Heat transfer without fin Q = m.Cp.∆𝑇
Heat transfer with fin 𝑄 𝑓𝑖𝑛 = √(ℎ𝜌𝑘𝐴)(Tb - T∝)tan ℎ(𝑚𝐿)

7.6 Mass flow rate:

The mass flow rate is the mass of a liquid substance passing per unit time.
In other words, the mass flow rate is defined as the rate of movement of liquid
pass through a unit area. The mass flow is directly dependent on the density,
velocity of the liquid, and area of cross-section. It is the movement of mass per
unit time.

38
 𝑚 = 𝜌. 𝑄
Where,

 𝜌 = Density of fluid (kg/m3)

 Q = Flow rate (m3/s)

= 1/(1000 x t ) where,
t = time taken of outlet fluid per litre in second

There is an elementary equation from basic thermodynamics that states

that the rate of heat transfer (Q) equals the mass flow rate (M) times a Constant
(the specific heat of water) times the Delta T (fluid temp out minus fluid temp
in): In other words, the rate of heat transfer is directly proportional to mass
flow rate.

7.7 Experimental reading:

We take the temperature reading of hot fluid and cold fluid of both cases
in the heat exchanger setup as shown in table.

39
 Table 1. Experimental reading

Without fin With fin

Name
of the Hot fluid in Cold fluid in Hot fluid in Cold fluid in
fluids Temperature Temperature Temperature Temperature
(˚C ) (˚C ) (˚C ) (˚C )
Inlet Outlet Inlet Outlet Inlet Outlet Inlet Outlet

Water 92 82 34 42 87 74 36 44
Engine
Oil 76 59 37 48 75 49 32 42
Refined
Oil 81 69 33 42 81 50 30 45

40
 Chapter 8

RESULT ANALYSIS

In this chapter, the output characteristics of each experiment and theoretical

study are presented and the obtained results are discussed in detail. Initially, the
results of the offline measurements like delamination at the entry, and different
fluids in a heat exchanger using with fins and without fins. The observations of
CFD simulation results are discussed below for the given boundary conditions.
To determine the best design for double pipe heat exchanger type.

i. Results will be analysed using ANSYS FLUENT.

ii. Experimental calculations will be done to use as a cross check
iii. ANSYS FLUENT is a useful tool for modelling laminar flow heat transfer.

8.1 Geometry of heat exchanger

By default, ANSYS Workbench will analyse the problem in 3D. In this

problem, we are modelling a plane stress scenario, which allows us to reduce the
analysis down to a 3D problem. Enter the Design Modeler application by double-
clicking on the Geometry module. Design Modeler is similar to a CAD program.
Here you can work with the model and create sketches by clicking on the tabs on
the left.

41
 Fig. 11 Select XYPlane in Workbench Geometry

The aim here is to draw a heat exchanger with fin and without fin a circle cut-
out on the XYPlane that will become a model of the plate with a hole. To take
advantage of the symmetry of the model, we can model just one-quarter of the
square and remove a quarter circle on one of the corners.

42
 Fig. 12 Geometry of heat exchanger without fin

The geometry made in ANSYS workbench. This geometry imported to ansys

fluent and repairs the geometry. The geometry consists of a length of 0.5m.
Concentric tube of inner tube inner diameter 0.012m and outer tube inner
diameter 0.020m. For this project, fully developed laminar and turbulent
incompressible fluid flow will be analyzed in three different fluid in without fin
(Fig. 11) and with fin (Fig.12) cases: water, engine oil and refined oil in a heat
exchanger. The resulting temperature difference will be compared and be
determined as a function of the inlet velocity and inlet temperatures. The overall
objective is to determine the max temperature difference in these cases. To
simplify the number of variables, water and two oils will be chosen as the fluids
to maintain viscosities and densities of the fluids constant. The type of heat
exchanger used will be of concentric tube design. Water will be the cooling
medium and water, engine oil and refined oil are the working fluid.

43
 Fig. 13 Geometry of heat exchanger with fin

8.2 MESH GENERATION

Initially a relatively coarser mesh is generated with 96833 cells. This mesh
contains mixed cells (Tetra and Hexahedral cells) having both triangular and
quadrilateral faces at the boundaries. Care is taken to use structured cells
(Hexahedral) as much as possible, so further we switched to the medium mesh
which generates 151962 cells with 139851 numbers of nodes. It is meant to
reduce numerical diffusion as much as possible by structuring the mesh in a
well manner, particularly near the wall region. Later on, for the mesh
independent model, a fine mesh is generated with 200950 cells. For this fine
mesh, the edges and regions of high temperature and pressure gradients are
finely meshed. But the fine mesh lies very close to the medium mesh and
considering the medium mesh the results for the temperature change comes
out very good. So that’s why we go with the medium mesh.

44
 Fig. 14 Meshing of double pipe heat exchanger

8.3 BOUNDARY CONDITION

In order to simulate the conditions observed in the experiments, the fully

developed parabolic velocity profile needs to be obtained before the fluid
enters the tube. The parabolic velocity profile in a laminar flow and the
empirical power-law equation in a turbulent flow in the channel with a circular
cross-section are obtained and verified [8]. To make the inlet velocity profile
to be similar as in the following literature [8], some dynamic boundary
conditions are applied. Aluminum is used as a material of construction and
water liquid for fluid phase. Using viscous k-ε RNG model turning the energy
equation on the iterations continued.

45
8.4 RESULTS AND DISCUSSION

The convergence of Simulation is required to get the parameters of the

counter flow heat exchanger in outlet. It also gives accurate value of
parameters for the requirement of heat transfer rate. Continuity, X-velocity,
Y-velocity, Z-velocity, energy, k epsilon are the part of scaled residual which
have to converge in a specific region. For the continuity, X-velocity, Y-
velocity, Z-velocity, k-epsilon should be less than 10-4 and the energy should
be less than 10-7. Values and boundary conditions mentioned above leads to
convergence criteria. As discussed earlier from the first principle, the open
loop temperature profile obtained by fixing the cold inlet temperature and hot
inlet temperature.

Fluent reading:

Table 2. Fluent reading

Without fin With fin

No. of
fluids Hot fluid in Cold fluid in Hot fluid in Cold fluid in
Temperature Temperature Temperature Temperature
(˚C ) (˚C ) (˚C ) (˚C )
Inlet Outlet Inlet Outlet Inlet Outlet Inlet Outlet

Water 92 80.72 34 61.19 87 73.5 36 46.95

Engine
76 52.56 37 50.7 46.36 32 45.46
Oil 75
Refined
81 69.63 33 44.92 48.08 30 47.16
Oil 81

46
Fig. 15 Left end is outlet of inner pipe of Water temperature in volume
rendering

Fig. 16 Left end is inlet of inner pipe of Engine Oil temperature in volume
rendering

47
8.5 Experimental calculations will be done to use as a cross check
To find the LMTD of heat exchanger without fins and with fins and
Effectiveness of fins.

Calculation:

1. Mass flow rate

Without fins:
a) Water
mH = 999.2 x 1/(1000 x 26)
= 0.03843077 Kg/s
mC = 999.2 x 1/(1000 x 21)
= 0.04758094 Kg/s

b) Engine Oil
mH = 880 x 1/(1000 x 363)
= 0.00242424 Kg/s
mC = 999.2 x 1/(1000 x 23)
= 0.04344348 Kg/s

c) Refined Oil
mH = 960 x 1/(1000 x 338)
= 0.002840231 Kg/s
mC = 999.2 x 1/(1000 x 14)
= 0.07137143 Kg/s

48
 With fins:

a) Water
mH = 999.2 x 1/(1000 x 23)
= 0.04344348 Kg/s
mC = 999.2 x 1/(1000 x 22)
= 0.04541 Kg/s

b) Engine Oil
mH = 880 x 1/(1000 x 366)
= 0.002841561 Kg/s
mC = 999.2 x 1/(1000 x 26)
= 0.03843077 Kg/s

c) Refined Oil
mH = 960 x 1/(1000 x 333)
= 0.002972136 Kg/s
mC = 999.2 x 1/(1000 x 18)
= 0.05551112 Kg/s

2. LMTD

Without fins:
a) Water
LMTD = (58 – 19)/ln(58/19)
= 48.4439 ˚C

49
b) Engine Oil
LMTD = (39 – 11)/ln(38/11)
= 22.1227 ˚C

c) Refined Oil
LMTD = (48 – 30)/ln(48/30)
= 38.297 ˚C

With fins:

a) Water
LMTD = (51 – 12)/ln(51/12)
= 39.9704 ˚C

b) Engine Oil
LMTD = (43 – 4)/ln(43/4)
= 16.4217 ˚C

c) Refined Oil
LMTD = (51 – 4)/ln(51/4)
= 18.46 ˚C

50
3. Effectiveness

Without fins:
a) Water
QH = 0.038731 x 4.182(92 – 82)
= 1.607 KJ/Kg – K
QC = 0.047581 x 4.182(42 – 34)
= 1.591 KJ/Kg - K
Q = (QH + QC)/2
= (1.607 + 1.591)/2
= 1.5995 KJ/Kg – K

b) Engine Oil
QH = 0.0024242 x 1.845(76 – 59)
= 0.07603 KJ/Kg – K
QC = 0.043443 x 4.182(48 – 37)
= 1.9985 KJ/Kg – K
Q = (QH + QC)/2
= (0.07603 + 1.9985)/2
= 1.03726 KJ/Kg – K

c) Refined Oil
QH = 0.00284 x 1.88(81 – 69)
= 0.04805 KJ/Kg – K
QC = 0.07137 x 4.182(42 – 33)
= 2.6863 KJ/Kg - K
Q = (QH + QC)/2
= (0.04805 + 2.6863)/2
= 1.3672 KJ/Kg – K

51
With fins:

a) Water
Q fin = √(39.494 x 0.0377 x 0.6 x 2.0734 x 10-4)(80.5 - 40).tan h(389.57
x 0.5)
= 1.95962 KJ/Kg-K

b) Engine Oil
Q fin = √(140 x 0.0377 x 0.145 x 2.0734 x 10 -4)(62 - 37).tan h(224.16
x 0.002)
= 1.41448 KJ/Kg-K

c) Refined Oil
Q fin = √(135 x 0.0377 x 0.12 x 2.0734 x 10-4)(65.5 – 37.5)tan h(230.5
x 0.003)
= 1.3914 KJ/Kg-K

Water, E = 1.95962
1.5995
= 1.225

Engine Oil, E = 1.41448

1.03726
= 1.017696

Refined Oil, E = 1.3914

1.3672
= 1.3637

52
Table 3. LMTD and Effectiveness Values

LMTD without
No. of fluids fin LMTD with fin Effectiveness of
(˚C ) (˚C ) fin

Water 48.99 40.448 1.22514437

Engine Oil 24.88 23.12 1.0176956

Refined Oil 37.48 27.22 1.36366633

8.6 Graph of Fluid heat transfer in temperature

Fluid without fins in temperature (Celusis):

Fig. 17 Hot fluid without fin in celsuis

53
 Fig. 18 Cold fluid without fin in celsuis

Fluid with fins in temperature (Celusis):

Fig. 19 Hot fluid with fins in Celsius

54
Fig. 20 Cold fluid with fins in Celsius

55
 Chapter 9

CONCLUSION

From the results and data obtained from CFD we have concluded that K-w
turbulence model provide better suitability to our simulation. Model with
hexagonal tube provides better effectiveness than other models. Heat transfer
rate in the heat exchanger with hexagonal tube also provides good heat transfer
rate. Increasing effectiveness of heat exchanger increases its performance in
its respective application.

The design and CFD analysis on double pipe heat exchanger has been done
and the results were compared with the effectiveness and the LMTD method.
We had observed a considerable amount of deviation from the actual value to
the value that is obtained in the simulation. The temperature of the hot water
at the tube outlet was used in comparison with effectiveness and LMTD
method for calculation of effectiveness of the double pipe counter flow heat
exchanger.

The performance, CFD analysis of different fluids were investigated on

counter flow in concentric tube heat exchanger.

 Physical characteristics and thermal performance of a real heat exchanger

were studied in this work.
 In cold fluid graph (Fig. 18 & 20), the cold fluid absorbs more heat from
hot fluid when we use the fins compared to the without fin flow.
 In hot fluid graph (Fig. 17 & 19), the hot fluid loss more heat when we use
the fins compared to the finless flow.

56
 From the graphs (Fig. 17, 18, 19 & 20) conclude that achieving the highest
values of heat transfer is water in all three fluids compared to other cases.
 From the graphs (Fig. 17, 18, 19 & 20), we conclude that the lowest values
of heat transfer is engine oil in all three fluids compared to other cases.
 Effectiveness of fin are calculated shown as table 3. In this table, three
fluids are more than 1. So, it is better efficiency than without fin.
 LMTD are calculated for both cases shown in table 3. In this table, without
fin values has more difference and with fin values has less difference to
compared to each other.

57
 Chapter 10

1. REFERENCES

[1] Naphon P, (2006), Second law analysis on the heat transfer of the
horizontal concentric tube heat exchanger, International Communications
in heat and mass transfer.

[2] Mohammed, H. A., et al. (2011), "Heat transfer and fluid flow
characteristics in microchannels heat exchanger using nanofluids: a
review." Renewable and Sustainable Energy Reviews 15.3: 1502-1512.

[3] Kays, William, Michael Crawford, and Bernhard Weigand (2005).

Convective Heat and Mass Transfer. 4th ed. New York: The McGraw-Hill
Companies, Inc.

[4] Kamyar, A., R. Saidur, and M. Hasanuzzaman. (2012) "Application of

computational fluid dynamics (CFD) for nanofluids." International Journal
of Heat and Mass Transfer 55.15-16: 4104-4115.

[5] Shiva Kumar, K. Vasudev Karanth, Krishna Murty (October 13,2014),

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