THERMAL ANALYSIS OF DOUBLE PIPE HEAT EXCHANGER USING CFD

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International Journal of Research and Innovation (IJRI)

THERMAL ANALYSIS OF DOUBLE PIPE HEAT EXCHANGER USING CFD

Lakamana Satyabhaskar1, K.koteswara Rao2,Y Dhana Shekar3

1 Research Scholar,Department Of Thermal Engineering, Kits, Peddapuram(M) Tirupathi Village, Divili 533-433,Eg Dt,AP, India.2 Associate Professor,Department Of Thermal Engineering, Kits, Peddapuram(M) Tirupathi Village, Divili 533-433,Eg Dt,AP, India.3 Assistant Professor , Department Of Thermal Engineering, Kits, Peddapuram(M) Tirupathi Village, Divili 533-433,Eg Dt,AP, India.

*Corresponding Author:

Lakamana SatyabhaskarResearch Scholar,Department Of Thermal Engineering, Kits, Peddapuram(M) Tirupathi Village, Divili 533-433,Eg Dt,Andhra Pradesh, India.

Published: January 02, 2015Review Type: peer reviewedVolume: II, Issue : I

Citation: Lakamana Satyabhaskar, Thermal Analysis Of Double Pipe Heat Exchanger Using CFD

INTRODUCTION

A heat exchanger is a device that is used to transfer thermal energy (enthalpy) between two or more flu-ids, between a solid surface and a fluid, or between solid particulates and a fluid, at different tempera-tures and in thermal contact. In heat exchangers, there are usually no external heat and work inter-actions.

Typical applications involve heating or cooling of a fluid stream and evaporation or condensation of single- or multicomponent fluid streams. In other applications, the objective may be to recover or re-ject heat, or sterilize, pasteurize, fractionate, distill, concentrate, crystallize, or control a process fluid. In a few heat exchangers, the fluids exchanging heat are in direct contact.

In most heat exchangers, heat transfer between flu-ids takes place through a separating wall or into and out of a wall in a transient manner. In many heat exchangers, the fluids are separated by a heat

transfer surface, and ideally they do not mix or leak. Such exchangers are referred to as direct transfer type, or simply recuperators. In contrast, exchang-ers in which there is intermittent heat exchange be-tween the hot and cold fluids—via thermal energy storage and release through the exchanger surface or matrix are referred to as indirect transfer type, or simply regenerators. Such exchangers usually have fluid leakage from one fluid stream to the other due to pressure differences and matrix rotation/valve switching.

Classifications of heat exchangers:

There are a number exchanger types based on the type of flow configuration, method of heat transfer and constructional features. The process designer has to select the best suitable type that meets the performance and operational requirements. Follow-ing is the list of heat transfer equipment.

Based on Principles of Operation (Transfer pro-cess):Recuperative Type (Direct Transfer):

Cold and hot fluids flow simultaneously. Heat is transferred through a wall separating the fluids. Eg: Steam boilers, Heaters, Condensers etc.

Regenerative type (Storage):

One and the same heating surface is alternatively exposed to the cold and hot fluids. Heat carried by the hot fluid is taken away and stored in the walls of the apparatus and then transferred to the cold fluid Eg: Open hearth and glass melting furnaces, Air heaters of blast furnaces.

Abstract

Heat transfer equipment is defined by the function it fulfills in a process. On the similar path, Heat exchangers are the equipment used in industrial processes to recover heat between two process fluids. They are widely used in space heating, refrigeration, air conditioning, power plants, chemical plants, petrochemical plants, petroleum refineries, and natural gas processing. The operating efficiency of these exchangers plays a very key role in the overall running cost of a plant. So the designers are on a trend of developing heat exchangers which are highly efficient, compact, and cost effective.

A common problem in industries is to extract maximum heat from a utility stream coming out of a particular process, and to heat a process stream. Therefore the objective of present work involves study of refinery process and applies phenomena of heat transfer to a double pipe heat exchanger.


1401-1402

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Fluidized Bed Type:

It is a direct transfer type used to transfer heat between a fluid and finally divided particles of a sold material Eg: used in chemical industry, Coal fired boilers for waste heat recovery.

Based on Fluid Flow Arrangement:Counter flow:Parallel flow:Cross Flow:Single Pass Shell and Tube:

The tube bundle, or stack, is inserted inside the shell. Tube sheets hold the tubes in place and form a barrier to prevent the tube-side fluid from mixing with the shell-side fluid. A series of baffles directs the flow of cooling fluid back and forth across the tube bundle.

Based on Method of Heat Transfer and Construc-tional FeaturesShell and Tube Heat Exchanger:

Fixed tube heat exchangerU- tube exchangerFloating head exchanger

Single Tube Heat Exchanger:

Double pipe exchangerTrombone coolerCoils in vessel

Parallel Plate Heat Exchanger:

Gasketed Plate exchangerSpiral plate exchangerLamella exchangerPlate evaporator.

External Heating Type:

Jacketed VesselSteam Tracing

Heat Transfer without Surfaces:

Flash evaporationDirect contact condensersCooling towersHeat transfer fluidsDirect heatingDirect use of steamSubmerged combustion

Extended Surfaces:

Air cooled exchangerPlate fin exchangerTank heating with finned tubesSolids heating with a bank of longitudinally finned tubes.Air heater

Based on application:

Condenser, Cooler, Chiller, Evaporator, Vaporizer, Recoiled heater, Waste heat boiler etc.

Special Types:

Scrubber condenserFroth- cooled heat exchangerPlastic tube exchangerCarbon block exchangerScrapped surface exchanger

Materials And Manufacturing Process

The selection of materials of construction is a very important aspect to be considered before undertak-ing the design of heat exchangers. In each individu-al case, the choice of proper material shall be made, bearing in mind the specific requirements which are normally as follows:

1. Mechanical resistance i.e. strength and sufficient toughness at operating temperatures.2. Chemical resistance under operating conditions with regard to corrosive media, concentration, tem-perature, foreign substances, flow behavior etc. the rate of corrosion must be negligible over a prolonged period of time and the material must be resistant against other corrosion phenomenon.3. No detrimental interference by the material on the process or on the products.4. Easy supply of material within time permitted and in the time required.5. Good workability.6. Lowest possible costs.

Descriptions of some of the material and their specifications:

SA20 : Specification for general requirements for steel plates for pressure vessels.SA480: Specification for general requirements for delivery of flat rolled stainless Steel, stainless and heat resisting steel plates, sheet and strip.SA530: Specification general requirements for spe-cialized carbon and alloy steel pipe.SA450: Specification for general requirements for carbon, feritic alloy and austenitic alloys steel tubes.SA203: Nickel alloy steel plated for pressure vessels.SA204: Molybdenum alloys steel plates for pressure vessels.SA240: Chromium and Chromium nickel, stainless steel plates, sheet and strip for fusion welded un-fired pressure vessels.SA264: Stainless, Chromium, Nickel steel, clad plate, sheet and strip.SA285: Low and intermediate tensile strength car-bon steel plates for pressure vessels.SA299: Carbon manganese, Silicon steel plates for pressure vessels.SA575: Carbon Steel plates for pressure vessels for intermediate and high temp ServiceSA577: High strength alloy steel plates, quenched

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and tempered for pressure VesselsSA537: Carbon magnesia, silicon steel plates, heat treated for pressure vessels.SA105: Forgings, carbon steel for piping compo-nents.SA181: Forgings carbon steel for general purpose piping.SA182: Forged or rolled alloy steel pipe flanges, forged fittings and valves.SA234: Pipe fitting of wrought carbon steel and al-loy to moderate and elevated temperature services.SA350: Forgings, Carbon and low alloy steel requir-ing notch toughness, testing for piping components.SA420: Pipe fittings of wrought carbon and alloy steels for low temperature serviceSA336: Alloy steel forgings for seamless drum heads and other pressure vesselsSA106: Seamless carbon steel pipe for high temper-ature service (343ºC to 427ºC)SA312: Seamless and welded austenitic stainless steel pipe.SA333: Seamless and welded steel pipe for low tem-perature eservice.

Problem description

The present work is based on industrial require-ment. In the petroleum refinery, after distillation, different grades of oil come out at different high temperature which comes in to a pump and sup-plied at required level. The aim is to design a double pipe heat exchanger for an already existing suction pool of pump in which hot hydrocarbons are pass-ing after distillation. The heat recovered from high temperature hydrocarbons is utilized to increase the temperature of crude oil up to required limit. The pool data, drawings, temperature of hydrocar-bon and required temperature rise of crude oil were given by industry.

Refinery Process Description Introduction:

Every refinery begins with the separation of crude oil into different fractions by distillation. The fractions are further treated to convert them into mixtures of more useful saleable products by vari-ous methods such as cracking, reforming, alkyla-tion, polymerization and isomerization. These mix-tures of new compounds are then separated using methods such as fractionation and solvent extrac-tion. Impurities are removed by various methods, e.G. Dehydration, desalting, sulphur removal and hydrotreating. Refinery processes have developed in response to changing market demands for certain products. With the advent of the internal combus-tion engine, the main task of refineries became the production of petrol. Distillation is the first step in the processing of crude oil and it takes place in a tall steel tower called a fractionation column. The inside of the column is divided at intervals by horizontal trays. The column is kept very hot at the bottom (the column is insu-lated) but as different hydrocarbons boil at different

temperatures, the temperature gradually reduces towards the top, so that each tray is a little cooler than the one below. The crude needs to be heated up before entering the fractionation column and this is done at first in a series of heat exchangers where heat is taken from other process streams which require cooling be-fore being sent to rundown. Heat is also exchanged against condensing streams from the main column. Typically, the crude will be heated up in this way up to a temperature of 200 - 280 0C, before entering a furnace. As the raw crude oil arriving contains quite a bit of water and salt, it is normally sent for salt removing first, in a piece of equipment called a de-salter. Upstream the desalter, the crude is mixed with a water stream, typically about 4 - 6% on feed. Intense mixing takes place over a mixing valve and (optionally) as static mixer. The desalter, a large liq-uid full vessel, uses an electric field to separate the crude from the water droplets.

Distillation (Fractionation):

Because crude oil is a mixture of hydrocarbons with different boiling temperatures, it can be separated by distillation into groups of hydrocarbons that boil between two specified boiling points. Two types of distillation are performed: atmospheric and vacu-um.

Design Aspects of Present Heat Exchanger

The thermal design is based upon a certain pro-cess parameters, the thermal and physical proper-ties of the process fluids and the basic governing equations. Conventionally design method of heat exchanger is largely based on the use of empiri-cal equations as well as experimental data which is available mostly in the form of graphs and chart.

Salient Features of Heat ExchangerThe heat exchanger considered for analysis here has the following parameters.

Shell side. Type of fluid: crude oil. Inlet temperature =313KOutlet temperature =553K.Mass flow rate=0.320kg/s.Diameter of shell=0.3m.

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Tube side Type of fluid: diesel oil. Inlet temperature =618KOutlet temperature =?.Mass flow rate=145.6kg/s.Specific gravity=0.874Tube inside diameter =0.2027m.Tube outside diameter=0.2191m

The properties of fluid are not available so with the help of the specific gravity mentioned for the hot fluid, obtained by API gravity equation 3.1. The petroleum refining is a major industry, petroleum products are an important fuel for power industry, and petroleum derivates are starting point for many syntheses in the chemical industry. Therefore given common names or denoting the refinery operations by which they were produced, and specific gravities are defined by a scale established by the American Petroleum Institute and termed either degrees API or oAPI. The oAPI is related to the specific gravity by

After obtaining API gravity from table hot fluid is identified as diesel. As cold fluid is crude oil.

Design of double pipe heat exchanger:Thermal design calculations

For this the following data are required

Hot side(tube side)

Inlet temperature Thi=618 KOutlet temperature Tho=?Mass flow rate Mh=145.6kg/s Specific heat Cph=3277.3J/kg KDensity =874kg/m3

Thermal conductivity k=0.1107 w/m K

Viscosity -3 2=4.5 10 Ns/m (or) pa-sµ ×

Thickness of fin t=0.002 m

Fin pitch s=0.142 mNumber of fins fN 34=

cold side(shell side)

Inlet temperature Tci=313 KOutlet temperature Tco=553 KMass flow rate Mc=0.320kg/s Specific heat Cpc=2491J/kg KDensity =698kg/m3Thermal conductivity k=0.130 w/m K

Viscosity -3 2=0.75 10 Ns/m (or) pa-sµ ×

For counter flow LMTD

Flow area of fin Consider as 10% fin cut so the area of cut is calcu-lated by the following

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Area of fin

Bare area (or) unfin area

Total fin area

Perimeter

Equivalent diameter

Velocity

Hence it is turbulent flow Friction factor

Colburn factor

Prenatal number

Pressure drop

Geometry

The designed geometry under consideration in this thesis is a double pipe heat exchanger type or concentric tube heat exchanger with a circular fins or baffles the domain is sub divided in to two sections with a shell and tube channels. Figures 3.2 show schematic two-dimensional views of the heat exchanger to be analyzed. This type of heat ex-changer has been designed to recovery of heat from hot source (hot fluid) which is flowing through the tube and the shell side fluid is cold the flow is coun-ter flow. The heat exchanger is one shell pass and one tube pass based on these conditions the heat exchanger is designed.

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CFD ANALYSIS OF PLAIN TUBE

Heat exchanger without mesh

Heat Exchanger with mesh

Temperature variation on plane along the heat ex-changer

Numerical Simulation Procedure

Results and Discussion

Over view

The present work involves the numerical analysis of the heat exchanger with different materials with varying fin thickness and by changing the mass flow rates for cold fluid. Initially the simulation is car-ried out with mass flow rate 0.320 Kg/s and shifted to 0.220 And 0.120 Kg/s. The analysis was carried out for steel, aluminum, and copper material for dif-ferent thickness range of 0.002M to 0.005M in the interval of 0.001M and the simulations and results are discussed. These simulations are done as an attempt for analysis of heat transfer and flow phe-nomena in the shell side and tube side. The steady state and unsteady simulations are done with inlet conditions using turbulence model. The domain in the present study is quite a complex 3-d geometry, so it is quite diligent to present the flow physics in the whole domain for discussion. The 2-d planes are taken in the geometry for the discussion. The plane and line along with the whole geometry and the co-ordinate axes are shown in fig 6.1. The plane and line are taken along the length of the heat exchang-er in the x-y planes of constant z-coordinate. Plane is taken in the centre of tubular section and a line is at 0.220M from an outlet of the section. The de-tails of fin materials along with different thickness for comparison are presented in table 6.1.

Material/fin thickness

Steel Aluminum Copper

t1 0.002 0.002 0.002

t2 0.003 0.003 0.003

t3 0.004 0.004 0.004

t4 0.005 0.005 0.005

Details of Comparative Study

The Plane and position of line in the flow domain.

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Material Steel

Temperature variation on plane along the heat ex-changer.

Temperature variation across Outlet for varying Fin thickness

Material Aluminum

Temperature variations on plane along the heat ex-changer

Temperature variation across Outlet for varying Fin thickness.

Material copper.

Temperature variations on plane along the heat ex-changer.

Temperature variation across Outlet for varying Fin thickness.

Comparison of materials

Temperature variation on fin along the heat ex-changer.

Variation of Heat Transfer with varying fin thick-ness.

The above graph shows the relation between the heat transfer and fin thickness with different ma-terials. As the fin thickness increases the value of heat transfer is increasing. For copper heat transfer is maximum value when compared to other materi-als and steel is having the least value of heat Transfer.

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(a) Varition of Friction factor with Reynolds number(b) Varition of Heat Transfer Coefficient with Reyn-olds number

Summary of resultsMass flow rates 0.320kg/s

Sr no

Thick-ness of fin (m)

Tem-perature (k)

Pres-sure (Pascal)

Velocity(m/s)

Heat trans-fer (W)

1 0.002 526.65 37.65 0.14 167265.66

2 0.003 528.38 38 0.14 168600.05

3 0.004 529.72 38 0.14 169622.3

4 0.005 530.72 38 0.14 170435.08

Sr no


Tem-perature (k)

Pres-sure (Pascal)

Velocity(m/s)

Heat trans-fer (W)

1 0.002 538.39 37.7 0.14 176473.69

2 0.003 539.76 38 0.14 177524.04

3 0.004 540.55 38 0.14 178145.21

4 0.005 541.07 38 0.14 178549.9

Sr no


Tem-perature (k)

Pres-sure (Pascal)

Velocity(m/s)

Heat trans-fer (W)

1 0.002 540.46 38 0.14 178074.16

2 0.003 541.39 37.8 0.14 178820.6

3 0.004 541.88 38 0.14 179189.36

4 0.005 542.21 37.8 0.14 179464.3

Variation of properties with different thickness(a) Steel (b) Aluminum (c) Copper

Mass flow rates 0.120kg/s

Sr no


Tem-perature (k)

Pres-sure (Pascal)

Velocity(m/s)

Heat trans-fer (W)

1 0.002 604.47 37.65 0.14 88704

2 0.003 605.12 38 0.14 88896

3 0.004 605.59 38 0.14 89088

4 0.005 605.96 38 0.14 89232

Sr no


Tem-perature (k)

Pres-sure (Pascal)

Velocity(m/s)

Heat trans-fer (W)

1 0.002 604.47 37.65 0.14 88704

2 0.003 605.12 38 0.14 88896

3 0.004 605.59 38 0.14 89088

4 0.005 605.96 38 0.14 89232

Sr no


Tem-perature (k)

Pres-sure (Pascal)

Velocity(m/s)

Heat trans-fer (W)

1 0.002 609.17 37.65 0.14 90208

2 0.003 609.47 38 0.14 90272

3 0.004 609.59 38 0.14 90304

4 0.005 609.69 38 0.14 90320

Variation of properties with different thickness (a) Steel (b) Aluminum (c) Copper

Mass flow rates 0.220kg/s

Sr no


Tem-perature (k)

Pres-sure (Pascal)

Velocity(m/s)

Heat trans-fer (W)

1 0.002 604.47 37.65 0.14 134432

2 0.003 605.12 38 0.14 135200

3 0.004 605.59 38 0.14 135744

4 0.005 605.96 38 0.14 136192

Sr no


Tem-perature (k)

Pres-sure (Pascal)

Velocity(m/s)

Heat trans-fer (W)

1 0.002 565.17 37.65 0.14 139648

2 0.003 575.88 38 0.14 140224

3 0.004 576.52 38 0.14 140560

4 0.005 576.93 38 0.14 140768

Sr no


Tem-perature (k)

Pres-sure (Pascal)

Velocity(m/s)

Heat trans-fer (W)

1 0.002 576.44 37.65 0.14 140512

2 0.003 577.18 38 0.14 140912

3 0.004 577.58 38 0.14 141136

4 0.005 577.83 38 0.14 141232

Variation of properties with different thickness(a) Steel (b) Aluminum (c) Copper

Conclusions

1. As we increase the fin thickness the temperature of the cold fluid at the outlet of the heat exchanger increases. 2. We get high temperature profile at outlet in case of Aluminum and copper compared to steel mate-rial.3. There is very minor changes occur in the pres-sure and velocity profile with increase of fin thick-ness as well as change of material that is pressure and velocity doesn’t get much affected by thickness of fin and material of fin.

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4. The simulated outlet temperature is 543k which is very near to design outlet temperature 553k. There is less than 3% variation occurs than design value.5. By decreasing the mass flow rate for there is in-creasing the value of temperature up to 609k and 577k.6. After 5min there is no variation in temperature with respect to time.

Future Scope

1. Optimization of fin thickness and material for a heat exchanger 2. Experimentation thermal analysis of double pipe heat exchanger.3. Numerical analysis of double pipe heat exchanger using augmentation devices.

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Authors

Lakamana SatyabhaskarResearch Scholar(mtech in Thermal Engineering)Kits, Peddapuram(M) Tirupathi Village, Divili 533-433, Eg Dt,Andhra Pradesh,India.

K.koteswara Rao.Assistant professorKits, Peddapuram(M) Tirupathi Village, Divili 533-433, Eg Dt,Andhra Pradesh,India.

Y Dhana Shekar,Assistant Professor ,Kits, Peddapuram(M) Tirupathi Village, Divili 533-433,Eg Dt,Andhra Pradesh, India

THERMAL ANALYSIS OF DOUBLE PIPE HEAT EXCHANGER USING CFD

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