Optimization and Analysis of Tube-In-tube Heat Exchanger With Fins-Libre

OPTIMIZATION AND ANALYSIS OF
TUBE-IN-TUBE HEAT EXCHANGER WITH FINS

PROJECT REPORT
Submitted in partial fulfillment of the requirements for the award
of the degree of Bachelor of Technology in Mechanical Engineering
to the University of Kerala.

by
ALPHIN C. TOM
ARJUN RAMANATHAN
ARUN KRISHNAN

Department of Mechanical Engineering
College of Engineering, Thiruvananthapuram-16
April 2007
OPTIMIZATION AND ANALYSIS OF
TUBE-IN-TUBE HEAT EXCHANGER WITH FINS

PROJECT REPORT
Submitted in partial fulfillment of the requirements for the award
of the degree of Bachelor of Technology in Mechanical Engineering
to the University of Kerala.

by
ALPHIN C. TOM
ARJUN RAMANATHAN
ARUN KRISHNAN

College of Engineering, Thiruvananthapuram-16
April 2007
DEPARTMENT OF MECHANICAL ENGINEERING
COLLEGE OF ENGINEERING, TRIVANDRUM-16.

CERTIFICATE
This to certify that the Project report entitled OPTIMIZATION AND ANALYSIS
OF TUBE-IN-TUBE HEAT EXCHANGER WITH FINS submitted by
ALPHIN C. TOM, ARJUN RAMANATHAN AND ARUN KRISHNAN to the University
of Kerala in partial fulfillment of the requirements for the award of the Degree of Bachelor of
Technology in Mechanical Engineering is a bonafide record of work carried out by them
under my/our guidance and supervision. The contents of this work in full or in parts, have not
been submitted to any other institute or University for the award of any degree or diploma.

DILIP D.
Lecturer
(Guide)

Head of Department
ACKNOWLEDGMENTS
For the past few months we were engaged in a fruitful exercise which we must admit leaves us
richer in knowledge and experience which is mainly due to the invaluable guidance,
encouragement and assistance acquired from many cognizant resources.
We take this opportunity to thank god Almighty for his blessing to help us finish this project. We
express our profound gratitude to our project guide Dilip D., Lecturer, Department of
Mechanical Engineering for his individual encouragement & guidance .We also thank Dr B.
Anil, Professor, Department of Mechanical Engineering and Prof SarathChandra Das M. R.,
HOD , for their guidance & support for completing this venture.
Alphin C. Tom
Arjun Ramanathan
Arun Krishnan

ABSTRACT

A heat exchanger is a device built for efficient heat transfer from one fluid to another. They are
widely used in refrigeration, air conditioning, space heating, electricity generation, and chemical
processing. Heat exchangers may be classified as parallel-flow, cross-flow and counter-flow heat
exchangers. The counter current design is most efficient, in that it can transfer the most heat.
Hence such heat exchangers are much preferred for heating and cooling of fluids. The counter-
flow heat exchangers can be classified according to their constructional features as Concentric
Tubes, Shell and Tube, Multiple Shell and Tube passes and Compact heat exchangers. In our
analysis we consider Concentric Tubes or Tube in Tube heat exchanger. In this type, two
concentric tubes are used, each carrying one of the fluids. For designing of a heat exchanger the
total heat transfer may be related with its governing parameters. In this Project we undertake the
complete thermal design and analysis of a Longitudinally Fined Double Pipe Heat Exchanger.
Our aim is to optimize the height of the fin so as to obtain maximum possible heat transfer
without any wastage of material at a given length and inlet conditions. For this we have to
perform the thermal analysis for all possible fin heights. This has to be carried out using a
computer program. Number of fins is fixed by the outer diameter specified from the thermal data
tables. The results obtained from the program will be analyzed to fix the optimum fin height.
And this fin height will be used in creating a finite element model of the heat exchanger using
ANSYS. With the help of ANSYS the temperature profile of the heat exchanger can be obtained.
Unfinned heat exchanger is also modeled and compared with the Finned one. Thus a
comprehensive performance evaluation of thermal aspect is carried out.

TABLE OF CONTENTS

CHAPTER 1: INTRODUCTION
1.1 OBJECTIVE 2
1.2 SCOPE 2
1.3 CLASSIFICATION OF HEAT EXCHANGERS 3
1.3.1.CLASSIFICATION ACCORDING TO CONSTRUCTION 3
1.3.2 CLASSIFICATION ACCORDING TO TRANSFER PROCESS 5
1.3.3 CLASSIFICATION ACCORDING TO SURFACE COMPACTNESS 7
1.3.4 CLASSIFICATION ACCORDING TO FLOW ARRANGEMENT 7
1.3.5 CLASSIFICATION ACCORDING TO PASS ARRANGEMENTS 8
1.3.6 CLASSIFICATION ACCORDING TO PHASE OF FLUIDS 8
1.3.7 CLASSIFICATION ACCORDING TO HEAT TRANSFER 9
MECHANISMS
1.4 SELECTION OF HEAT EXCHANGER 9
1.5 REQUIREMENTS OF A HEAT EXCHANGER 17
CHAPTER 2: LITERATURE REVIEW 19
2.1 EXPERIMENTAL HEAT EXCHANGER STUDIES 20
2.2 EXPERIMENTAL HEAT EXCHANGER CORELATIONS 23
2.3 APPLICATION TO THE PRESENT STUDY 31
CHAPTER 3: PROJECT DESCRIPTION 34
3.1 PROBLEM DEFINITION 35
3.2 COMPUTATIONAL SCHEME 36

CHAPTER 4: PROJECT THEORY 38
4.1 SOME IMPORTANT DEFINITIONS 39
4.2 HEAT EXCHANGER BASIC ANALYSIS METHODS 44
4.3 THE -NTU METHOD 45
4.4 FINS OR EXTENDED SURFACES 47
4.5 HEAT TRANSFER COEFFICIENT 53
4.6 DOUBLE PIPE HEAT EXCHANGER 58
4.7 FOULING IN HEAT EXCHANGERS 59
CHAPTER 5: THERMAL DESIGN PROCEDURE 60
5.1 ANALYSIS OF DOUBLE PIPE HEAT EXCHANGERS 60
5.2 DESIGN OF LONGITUDINALLY FINNED DOUBLE PIPE
HEAT EXCHANGERS 65
5.3 STEPS INVOLVED IN THE THERMAL DESIGN OF -
A LONGITUDINALLY FINNED DOUBLE PIPE HEAT EXCHANGER 70
CHAPTER 6: OPTIMIZATION USING COMPUTER PROGRAM 74
6.1 DATA INPUT 74
6.2 THERMAL DESIGN 77
6.3. RESULTS AND DISCUSSIONS 79
CHAPTER 7: THERMAL ANALYSIS USING ANSYS 82
7.1 FINITE ELEMENT METHOD 82
7.2. ANSYS 83
7.3. BUILDING THE MODEL 88
7.4. MESHING 90
7.5. APPLYING LOADS 91
7.6. SOLUTION 92
7.7. POSTPROCESSING 92
7.8. PROBLEM DESCRIPTION 93
7.9. DISCUSSION 113
7.10. COMPARISON OF RESULTS AND CONCLUSION 115
CHAPTER 8: CONCLUSION 117
APPENDIX A 118
C++ PROGRAM CODE FOR THE OPTIMIZATION OF FIN HEIGHT 118

LIST OF FIGURES

FIGURE NO. TITLE PAGE
FIGURE 1.1. DOUBLE PIPE HEAT EXCHANGER SINGLE PASS
WITH COUNTER FLOW
FIGURE 1.2. DOUBLE PIPE HEAT EXCHANGER MULTI PASS
WITH COUNTER FLOW
FIGURE 1.3. HEAT EXCHANGE CLASSIFICATION ACCORDING
TO CONSTRUCTION
FIGURE 1.4. CLASSIFICATION ACCORDING TO TRANSFER PROCESS
FIGURE 1.5. CLASSIFICATION ACCORDING TO SURFACE
COMPACTNESS
FIGURE 1.6. CLASSIFICATION ACCORDING TO FLOW
ARRANGEMENTS
FIGURE 6.1. DATA INPUT MODE SELECTION MENU
FIGURE 6.2. SAMPLE PROBLEM SCREEN 1
FIGURE 6.5. MANUAL DATA INPUT SCREEN 1
FIGURE 6.6. MANUAL DATA INPUT SCREEN 2
FIGURE 6.7. UNFINNED HEEX CALCULATED RESULTS
FIGURE 6.8. CALCULATION RESULTS AT FIN HEIGHT = 15MM
FIGURE 6.9. THE THERMAL DESIGN RESULTS AT
VARIOUS FIN HEIGHTS
FIGURE 6.10. THE FINAL RESULT OF THE PROGRAM
FIGURE 7.1. SOLID 90 ELEMENT
FIGURE 7.2. CROSS SECTION
FIGURE 7.3. EXTRUDED MODEL
FIGURE 7.4. MESHED MODEL
FIGURE 7.5. CONTOUR PLOT OF NODAL TEMPERATURE- END VIEW
FIGURE 7.6. CONTOUR PLOT OF NODAL TEMPERATURE
FIGURE 7.7. CONTOUR PLOT OF NODAL HEAT FLUX
FIGURE 7.8. VECTOR PLOT OF THERMAL FLUX
FIGURE 7.9. VECTOR PLOT OF THERMAL GRADIENT
FIGURE 7.10. FLUX VS RADIAL DISTANCE
FIGURE 7.11. HEAT FLOW VS RADIAL DISTANCE
FIGURE 7.14. CONTOUR PLOT OF THERMAL FLUX
FIGURE 7.16. TEMPERATURE VS RADIAL DISTANCE
FIGURE 7.17. HEATFLOW VS RADIAL DISTANCE
FIGURE 7.20. CONTOUR PLOT OF THERMAL FLUX
FIGURE 7.23. HEAT FLOW VS RADIAL DISTANCE
FIGURE 7.24. TEMPERATURE VS RADIAL DISTANCE

LIST OF TABLES

FIGURE NO. TITLE PAGE
TABLE 2.1. WANG (1998C): PARAMETRIC RANGE
TABLE 2.2. MCQUISTON (1979) PLAIN FIN
CORRELATIONS: PARAMETRIC RANGE
TABLE 2.3. WEBB (1986) PLAIN FIN CORRELATIONS:
PARAMETRIC RANGE
TABLE 2.4. WANG (1999) PLAIN FIN CORRELATIONS:
PARAMETRIC RANGE
TABLE 2.5. WEBB (1998) LOUVERED FIN CORRELATIONS:
PARAMETRIC RANGE
TABLE 2.6. WANG (1998B) LOUVERED FIN CORRELATIONS:
PARAMETRIC RANGE
TABLE 4.1. TEMPERATURE DISTRIBUTION AND HEAT TRANSFER
RATE FOR FINS OF UNIFORM CROSS SECTIONAL AREA
TABLE 5.1. THERMAL DESIGN DATA TABLE
TABLE 7.1. SOLID90 ELEMENT OUTPUT DEFINITIONS
TABLE 7.2. COMPARISON VARIOUS MODEL ANALYSIS RESULTS

ABBREVIATIONS

LMTD Log Mean Temperature Difference
NTU Number of Transfer Units
HVAC - Heating, Ventilating, And Air Conditioning
FEM Finite Element Method
Re Reynolds Number
Pr Prandtl Number
NFA Net Flow Area
PDE Partial Differential Equation
GUI Graphic User Interface

1

CHAPTER 1: INTRODUCTION

Heat Exchangers are the class of equipment used to transfer heat in industrial processes.
Most often the transfer of heat takes place between to fluid streams. However, in
certain cases heat may also e transferred to vacuum (as in the case of space radiators).
Truly speaking, the term Heat Exchangers is a misnomer. Heat is never exchanged
but transferred. The difference between these two terms is that exchange means to
transfer in lieu of something, whereas transfer indicates unconditional flow in one
direction. Hence, the equipment transferring heat should have been called Heat
Transmitter or Heat Transferor. However, engineers have decided to stay with the
traditional term Heat Exchanger often abbreviated as HX.
Heat exchangers are a family of equipment, which are often called by other names in
specific applications. For example, automobile radiators, power plant economizers, air
preheaters, super heaters, condensers, feed water heaters, cooling towers, space
radiators, oil coolers, stirred tanks with cooling jackets are all essentially heat
exchangers. The use of Heat exchangers is extensive in power, chemical processes,
nuclear, aerospace, food processing, petrochemical, metallurgical, refrigeration and
cryogenic industry. Even though the underlying principles, of the construction of heat
exchangers are essentially those of conduction, convection, and sometimes radiation,
the application of these principles is not very straightforward. The factors that make the
construction, design and operation of a heat exchanger complex are economic
considerations, space and weight considerations an above all thermal and hydraulic
performance. In some applications, some specific factor may gain a controlling

2

importance, for example weight and space requirements are of prime concern in the
aerospace industry which uses compact heat exchangers; regular cleaning is a
requirement of the brewing and dairy industry and hence that use plate heat exchangers
which can be readily disassembled and assembled, and so on.
1.1. OBJECTIVE
In this Project we undertake the complete thermal design and analysis of a
Longitudinally Fined Double Pipe Heat Exchanger. The thermal analysis was carried
out based on the given geometrical parameters. Our aim is to optimize the height of the
fin so as to obtain maximum possible heat transfer without any wastage of material at a
given length and inlet conditions. For this we have to perform the thermal analysis for
all possible fin heights. This has to be carried out using a computer program. Number
of fins is fixed by the outer diameter specified from the thermal data tables. The results
obtained from the program will be analyzed to fix the optimum fin height. And this fin
height will be used in creating a finite element model of the heat exchanger using
ANSYS. With the help of ANSYS the temperature profile of the heat exchanger can be
obtained. Unfinned heat exchanger can also be modeled and compared with the Finned
one.
1.2. SCOPE
From the Analysis carried out in the Project undertaken we will be able to determine
the optimum fin height for a given length, inlet conditions and other geometric
parameters. The presence of fins provides an increase in heat transfer due to the
increased surface area. Thus instead of providing larger diameter pipes, we can make

3

use of expensive durable materials for the construction of thinner pipe and provide fins
of a cheaper material to account for the same heat transfer or more. Moreover form the
optimization program we will be able to demonstrate that just increasing the fin height
does not necessarily result in an increase in heat transfer. There is an optimum height
beyond which increasing the fin height results in nothing more than loss of material. By
computing this value we can conserve material and construction costs.
Fluids with lower specific heats need extra surface area for a particular heat transfer
compared to the others. By providing fins into this surface we can provide an
alternative to increasing the diameter of Pipes used.
1.3. CLASSIFICATION OF HEAT EXCHANGERS

Heat Exchangers appear in a variety of sizes and constructions. It is interesting to note
that heat exchangers can be as huge as a power plant condenser transferring hundreds
of megawatts of heat on one hand and on the other; it can be as tiny as an electronic
chip cooler which transfers only few watts of thermal energy. Hence, a wide range of
design of heat exchangers is available for a variety of application. There is no unique
method of classifying the large family of heat exchangers. They can be classified on
different aspects of their construction and operation.
1.3.1. Classification According To Construction
According to constructional details, heat exchangers are classified as:
1. Tubular heat exchangers-double pipe, shell and tube, coiled tube
2. Plate heat exchangers-gasketed, spiral, plate coil, lamella

4

3. Extended surface heat exchangers-tube-fin, plate-fin
4. Regenerators-fixed matrix, rotary

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9

Gas-liquid heat exchangers are mostly tube-fin type compact heat exchangers with the
liquid on the tubeside. The radiator is by far the major type of liquid-gas heat
exchanger, typically cooling the engine jacket water by air.
1.3.6.2. Liquid-Liquid
Most of the liquid-liquid heat exchangers are shell and tube type, and plate heat
exchangers to a lesser extent. Both fluids are pumped through the exchanger, so the
principal mode of heat transfer is forced convection.
1.3.6.3. Gas-Gas
This type of exchanger is found in exhaust gas-air preheating recuperators, rotary
regenerators, intercoolers and/or aftercoolers to cool supercharged engine intake air of
some land-based diesel power packs and diesel locomotives, and cryogenic gas
liquefaction systems
1.3.7. Classification According to Heat-Transfer Mechanisms
The basic heat-transfer mechanisms employed for heat transfer from one fluid to the
other are single-phase convection, forced or free, two-phase convection (condensation
or evaporation) by forced or free convection, and combined convection and radiation.
Any of these mechanisms individually or in combination could be active on each side
of the exchanger.
1.4. SELECTION OF HEAT EXCHANGERS
Selection criteria are many, but primary criteria are type of fluids to be handled,
operating pressures and temperatures, heat duty, and cost. Fluids involved in heat

10

transfer can be characterized by temperature, pressure, phase, physical properties,
toxicity, corrosivity, and fouling tendency. Operating conditions for heat exchangers
vary over a very wide range, and a broad spectrum of demands is imposed for their
design and performance. All of these must be considered when assessing the type of
unit to be used [It%]. When selecting a heat exchanger for a given duty, the following
points must be considered:
1. Materials of construction
2. Operating pressure and temperature, temperature program, and temperature driving
force
3. Flow rates
4. Flow arrangements
5. Performance parameters-thermal effectiveness and pressure drops
6. Fouling tendencies
7. Types and phases of fluids
8. Maintenance, inspection, cleaning, extension, and repair possibilities
9. Overall economy
10. Fabrication techniques
1 1. Intended applications

11

1.4.1. Materials of Construction
For reliable and continuous use, the construction materials for pressure vessels and heat
exchangers should have a well-defined corrosion rate in the service environments.
Furthermore, the material should exhibit strength to withstand the operating
temperature and pressure. Shell and tube heat exchangers can be manufactured in
virtually any materials that may be required for corrosion resistance, for example, from
nonmetals like glass, Teflon, and graphite to exotic metals like titanium, zirconium,
tantalum, etc. Compact heat exchangers with extended surfaces are mostly
manufactured from any metal that has drawability, formability, and malleability. Heat
exchanger types like plate heat exchangers normally require a material that can be
pressed or welded.
1.4.2. Operating Pressure and Temperature
Pressure. The design pressure is important to determine the thickness of the pressure
retaining components. The higher the pressure, the greater will be the required
thickness of the pressure retaining membranes and the more advantage there is to
placing the high-pressure fluid on the tubeside. The pressure level of the fluids has a
significant effect on the type of unit selected.
1. At low pressures, the vapor-phase volumetric flow rate is high and the low
allowable pressure drops may require a design that maximizes the area available for
flow, such as crossflow or split flow with multiple nozzles.
2. At high pressures, the vapor-phase volumetric flow rates are lower and allowable
pressure drops are greater. These lead to more compact units.

12

3. In general, higher heat-transfer rates are obtained by placing the low-pressure gas on
the outside of tubular surfaces.
4. Operating pressures of the gasketed plate heat exchangers and spiral plate heat
exchangers are limited because of the difficulty in pressing the required plate thickness,
and by the gasket materials in the case of PHEs. The floating nature of floating-head
shell and tube heat exchangers and lamella heat exchangers limits the operating
pressure.
1.4.3. Temperature:
Design Temperature. This parameter is important as it indicates whether a material at
the design temperature can withstand the operating pressure and various loads imposed
on the component. For low-temperature and cryogenic applications toughness is a
prime requirement, and for high temperature applications the material has to exhibit
creep resistance.
Temperature Program. Temperature program in both a single pass and multipass
shell and tube heat exchanger decides the mean metal temperatures of various
components like shell, tube bundle, and tubesheet, and the possibility of temperature
cross. The mean metal temperatures affect the integrity and capability of heat
exchangers and thermal stresses induced in various components.
Temperature Driving Force. The effective temperature driving force is a measure of
the actual potential for heat transfer that exists at the design conditions. With a
counterflow arrangement, the effective temperature difference is defined by the log
mean temperature difference (LMTD). For flow arrangements other than counterflow

13

arrangement, the LMTD must be corrected by a correction factor, F. The F factor can
be determined analytically for each flow arrangement but is usually presented
graphically in terms of the thermal effectiveness P and the heat capacity ratio R for
each flow arrangement.
Flow Rate
Flow rate determines the flow area: the higher the flow rate, the higher will be the
crossflow area. Higher flow area is required to limit the flow velocity through the
conduits and flow passages, and the higher velocity is limited by pressure drop,
impingement, erosion, and, in the case of shell and tube exchanger, by shell-side flow-
induced vibration. Sometimes a minimum flow velocity is necessary to improve heat
transfer, to eliminate stagnant areas, and to minimize fouling.
Flow Arrangement
As defined earlier, the choice of a particular flow arrangement is dependent upon the
required exchanger effectiveness, exchanger construction type, upstream and
downstream ducting, packaging envelope, and other design criteria.
1.4.4. Performance Parameters-Thermal Effectiveness and Pressure Drops
Thermal Effectiveness.
For high-performance service requiring high thermal effectiveness, use brazed plate-fin
exchangers (e.g., cryogenic service) and regenerators (e.g., gas turbine applications),
use tube-fin exchangers for slightly less thermal effectiveness in applications, and use
shell and tube units for low thermal effectiveness service.

14

Pressure Drop.
Pressure drop is an important parameter in heat exchanger design. Limitations may be
imposed either by pumping cost or by process limitations or both. The heat exchanger
should be designed in such a way that unproductive pressure drop is avoided to the
maximum extent in areas like inlet and outlet bends, nozzles, and manifolds. At the
same time, any pressure drop limitation that are imposed must be utilized as nearly as
possible for an economic design.
Fouling Tendencies
Fouling is defined as the formation on heat exchanger surfaces of undesirable deposits
that impede the heat transfer and increase the resistance to fluid flow, resulting in
higher pressure drop. The growth of these deposits causes the thermohydraulic
performance of heat exchanger to decline with time. Fouling affects the energy
consumption of industrial processes, and it also decides the amount of extra material
required to provide extra heat-transfer surface to compensate for the effects of fouling.
Compact heat exchangers are generally preferred for nonfouling applications. In a shell
and tube unit the fluid with more fouling tendencies should be put on the tube side for
ease of cleaning. On the shellside with cross baffles, it is sometimes difficult to achieve
a good flow distribution if the baffle cut is either too high or too low.
Stagnation in any regions of low velocity behind the baffles is difficult to avoid if the
baffles are cut more than about 20-25%. Plate heat exchangers and spiral plate
exchangers are better chosen for fouling services. The flow pattern in plate heat
exchanger induces turbulence even at comparable low velocities; in the spiral units, the
scrubbing action of the fluids on the curved surfaces minimizes fouling.

13

Types and Phases of Fluids
The phase of the fluids within a unit is an important consideration in the selection of
the heat exchanger type. Various combinations of fluid phases dealt in heat exchangers
are liquid-liquid, liquid-gas, and gas-gas. Liquid phase fluids are generally the
simplest to deal with. The high density and the favorable values of many transport
properties allow high heat-transfer coefficients to be obtained at relatively low pressure
drops .
Maintenance, Inspection, Cleaning, Repair, and Extension Aspects
Consider the suitability of various heat exchangers as regards maintenance, inspection,
cleaning, repair, and extension. For example, the pharmaceutical, dairy, and food
industries require quick access to internal components for frequent cleaning. Since
some of the heat exchanger types offer great variations in design, this must be kept in
mind when designing for a certain application. For instance, consider inspection and
manual cleaning. Spiral plate exchangers can be made with both sides open at one edge,
or with one side open and one closed. They can be made with channels between 5 mm
and 25 mm wide, with or without studs. The shell and tube heat exchanger can be made
with fixed tubesheets or with a removable tube bundle, with small- or large-diameter
tubes, or small or wide pitch. A lamella heat exchanger bundle is removable and thus
fairly easy to clean on the shellside. Inside the lamella, however, cannot be drilled to
remove the hard fouling deposits. Gasketed plate heat exchangers (PHEs) are easy to
open, especially when all nozzles are located on the stationary end-plate side. The plate
arrangement can be changed for other duties within the frame and nozzle capacity.
Repair of some of the shell and tube exchanger components is possible, but the repair

16

of expansion joint is very difficult. Tubes can be renewed or plugged. Repair of
compact heat exchangers of tube-fin type is very difficult except by plugging of the
tube. Repair of the plate- fin exchanger is generally very difficult. For these two types
of heat exchangers, extension of units for higher thermal duties is generally not
possible. All these drawbacks are easily overcome in a PHE. It can be easily repaired,
and plates and other parts can be easily replaced. Due to modular construction, PHEs
possess the flexibility of enhancing or reducing the heat transfer surface area,
modifying the pass arrangement, and addition of more than one duty according to the
heat-transfer requirements at a future date.
Overall Economy
There are two major costs to consider in designing a heat exchanger: the manufacturing
cost and the operating costs, including maintenance costs. In general, the less the heat-
transfer surface area and less the complexity of the design, the lower is the
manufacturing cost. The operating cost is the pumping cost due to pumping devices
such as fans, blowers, pumps, etc. The maintenance costs include costs of spares that
require frequent renewal due to corrosion, and costs due to corrosion & fouling
prevention and control. Therefore, the heat exchanger design requires a proper balance
between thermal sizing and pressure drop.
Fabrication Techniques
Fabrication techniques are likely to be the determining factor in the selection of a heat-
transfer surface matrix or core. They are the major factors in the initial cost and to a
large extent influence the integrity, service life, and ease of maintenance of the finished
heat exchanger . For example, shell and tube units are mostly fabricated by welding,

17

plate-fin heat exchangers and automobile aluminum radiators by brazing, copper-brass
radiators by soldering, most of the circular tube-fin exchangers by mechanical
assembling, etc.
1.5. REQUIREMENTS OF HEAT EXCHANGERS
1. High thermal effectiveness
2. Pressure drop as low as possible
3. Reliability and life expectancy
4. High-quality product and safe operation
5. Material compatibility with the process fluids
6. Convenient size, easy for installation, reliable in use
7. Easy for maintenance and servicing
8. Light in weight but strong in construction to withstand the operational pressures
9. Simplicity of manufacture
10. Low cost
11. Possibility of effecting repair to maintenance problems
The heat exchanger must meet normal process requirements specified through problem
specification and service conditions for combinations of the clean and fouled
conditions, and uncorroded and corroded conditions. The exchanger must be
maintainable, which usually means choosing a configuration that permits cleaning as

18

required and replacement of tubes, gaskets, and any other components that are damaged
by corrosion, erosion, vibration, or aging. This requirement may also place limitations
on space for tube bundle pulling, to carry out maintenance around it, lifting
requirements for heat exchanger components, and adaptability for in-service inspection
and monitoring.

19

CHAPTER 2: LITERATURE REVIEW
Finned-tube heat exchangers are common devices; however, their performance
characteristics are complicated. As previously mentioned this study focuses on the air
side performance of fin tube heat exchangers. The working fluid was chosen to be
water to reduce the cost and time to change coils. The water side heat transfer and
pressure drop behavior inside the tubes is well established and fairly straight forward.
In contrast, the air side heat transfer and pressure drop behavior is the subject of
countless research studies and is quite complicated. Designers must rely on
experimental measurement of these characteristics. Often, air side performance is
proprietary. Finned-tube heat exchangers have been tested for at least the last 90 years
(Wilson 1915). During that time, advances in technology as well as the efforts of many
research engineers has increased the knowledge and availability of air side performance
data. The endeavors of D.G. Rich (1973, 1975), F.C. McQuiston (1978, 1981), R.L.
Webb (1986, 1998), and C.C. Wang (1998a, 1998b, 1998c, 1999, 2000a, 200b) serve as
milestones in the road of experimental performance measurement and correlation of
the air-side performance. This literature review will address a number of experimental
studies, experimental correlations, and data reduction publications which focused on
the airside performance of fin tube heat exchangers.
There is a wealth of heat transfer coefficient and friction factor data for finned tube heat
exchangers, which is often presented in correlation equation form. However, there are
also an infinite number of configurations for heat exchangers: e.g. transverse tube
spacing, longitudinal tube spacing, tube diameter, number of tube rows, fin spacing, fin
thickness, and fins type (plain, louvered, or other enhancement), to name a just few

20

defining parameters. To further confuse the matter, experimental techniques and
methods of data reduction vary from one experimenter to the next. For instance, the
equilibrium criteria or the appropriate -NTU relationship for the given geometry are not
standardized. Also, nomenclature is not standardized and definitions for some
parameters are not readily available.
2.1. EXPERIMENTAL HEAT EXCHANGER STUDIES
Wilson (1915) performed an experimental work in which he developed a graphical
method of calculating the water-side heat transfer coefficient as a function of water
velocity. This method was included in McAdams (1954); it was also incorporated in the
study by Rich (1973). A modified form of Wilsons graphical method was used in this
present study.
Rich published two experimental studies. The first (1973) study focused on the effect
of fin spacing on heat transfer and friction performance of four-row finned-tube heat
exchangers, is discussed in section B because it contains heat transfer coefficient and
friction factor correlations. The second (1975) study focused on the effect of the
number of tube rows on heat transfer performance of heat exchangers, was a
continuation of his previous experimental work. In it Rich tested six coils which were
geometrically identical to his previous research with two exceptions: the number of
tube rows was varied from 1 to 6 and all of the coils had a fin pitch of 14.5 fins/in. The
coils were labeled on the basis of the number of tube rows. The tube diameter was
0.525 in. after expansion. Rich also performed a separate test on the four row coil,
measuring the temperature of the inlet and outlet of each row. The circuiting for this

21

test was such that the tubes of each row were connected to form a separate circuit. This
allowed Rich to calculate the heat transfer coefficient for each row.
Rich concluded the following:
1. The average heat transfer coefficient for a deep coil can be higher or lower
than that of a shallow coil, depending on Reynolds number. Similarly the
heat transfer coefficients for a down stream row can be higher or lower than
for an upstream row depending on Reynolds number.
2. The addition of downstream rows has a negligible effect on heat transfer
from upstream rows.
3. At high Reynolds number, heat transfer coefficients of downstream rows are
higher than those of upstream rows; similarly average coefficients for deep
coils are higher than for shallow coils, at high Reynolds number.
4. At low Reynolds number, heat transfer coefficients for deep coils are
significantly lower than for shallow coils.

Wang et al. (1998c) performed a comparison study of eight finned-tube heat
exchangers. Table 1 shows the systematic variation of parameters that define the heat
exchangers studied. This study is similar to the variation of parameters in the present
study. The louver height and major louver pitch are not known. Wang et al. concluded
that the effect of fin pitch on heat transfer performance is negligible for four-row coils
having Re > 1,000 and that for Re < 1,000 heat transfer performance is highly Dc Dc
dependent on fin pitch. The upper Reynolds number range result is supported by
experimental data from Rich (1973), and from several studies performed by Wang et al.

22

Wang et al. also concluded that the heat transfer performance of two-row configuration
increases with decrease of fin pitch. This publication discusses the choice of minimum
equilibrium criterion used as well as the method of data reduction. The minimum
equilibrium criterion chosen by Wang states that the heat transfer rate as calculated
from the tube-side and from the air side should be within 3%, and that the tube-side
resistance (evaluated as
1
biAi
) was less than 15% of the overall thermal resistance in all
cases. The data reduction methods include: the use of the unmixed-unmixed cross-flow
- NTU relationship, the incorporation of the contact resistance (which was stated to be
less than 4%) into the air-side resistance, and the inclusion of entrance and exit pressure
losses in the calculation of friction factor.
1ab|e 2.1. Wang (1998c): arametr|c kange

No.

Fin
Pattern

Fin Pitch
mm(fins/in)

Nominal
Tube OD
mm (in)

P
1
mm
[in]

P
2
mm
[in]

Number
of
Rows
1 Plain 1.78(14.26) 7.0(0.273) 21[0.826] 12.7[0.5] 2
2 Plain 1.22(20.8) 7.0(0.273) 21[0.826] 12.7[0.5] 2
3 Plain 1.78(14.26) 7.0(0.273) 21[0.826] 12.7[0.5] 4
4 Plain 1.22(20.8) 7.0(0.273) 21[0.826] 12.7[0.5] 4
5 Louver 1.78(14.26) 7.0(0.273) 21[0.826] 12.7[0.5] 2
6 Louver 1.22(20.8) 7.0(0.273) 21[0.826] 12.7[0.5] 2
7 Louver 1.78(14.26) 7.0(0.273) 21[0.826] 12.7[0.5] 4
8 Louver 1.22(20.8) 7.0(0.273) 21[0.826] 12.7[0.5] 4

23

2.2. EXPERIMENTAL HEAT EXCHANGER CORRELATIONS
Rich (1973) performed experimental work to determine the effect of fin spacing on heat
transfer and friction performance of multi-row fin-and-tube heat exchangers. Except for
the fin spacing all of the physical dimensions of the nine coils tested were identical.
Each coil had 4 rows of staggered tubes in the air flow direction. The tube diameter was
0.525 in. after expansion. The fin spacing varied from 0 to 20.6 fins per inch. Rich
developed a correlation for both heat transfer coefficient and friction factor using row
spacing as a basis for the Reynolds number. It should be noted that Richs correlations
are only valid for his geometry: there is only one tube spacing configuration and one
tube diameter.
Rich concluded the following:
1. The heat transfer coefficient is essentially independent of fin spacing between
3-21 fins per inch at a given mass velocity.
2. The pressure drop can be broken into two additive components, one due to the
tubes, form drag, and one due to the fins, skin drag.
3. The friction factor for the fins is independent of fin spacing for 3-14 fins per
inch at a given mass velocity.
4. For fin spacing of less than 14 fins per inch the friction factor for the fins varies
similar to that of developing flow over a plate where the boundary layer is
retriggered at each tube row rather than flow in a channel with fully developed
flow over the length of the coil width.

24

Zukauskas and Ulinskas (1998) developed correlations for the pressure drop of a
staggered bank of bare tubes (no fins) in cross flow. These correlations give pressure
drop as a function of geometry over a range of Reynolds numbers. Geometric
parameters included in the analysis are: tube diameter, transverse tube spacing,
longitudinal tube spacing, and number of tube rows. Zukauskas and Ulinskas discuss
several possible variations that influence the pressure drop, including
1. Wall to bulk viscosity.
2. Property variations through the bank of tubes.
3. Acceleration pressure drop arising from temperature rise.
McQuiston (1979) developed correlations for both Colburn j and Fanning friction
factors based on several sources of data. McQuistons goal was to make correlations
for wet surface mass transport. In order to do this, he first correlated dry surface
sensible heat transfer and friction data, which are the correlations investigated in this
present study. The j factors were correlated within 10% while the f factors were
correlated within 35%. The parametric range of McQuistons correlation is shown in
Table 2. The application of this correlation to compare with the coils in the present
study stretches the limits of the correlation; the tube spacing in the present study is 0.77
in. in the flow direction, compared to the 1 - 1.5 in. parametric range. All other
parameters are within their respective ranges.
1ab|e 2.2. Mcu|ston (1979) |a|n I|n Corre|at|ons: arametr|c kange
Fin Pattern Plain
Number of Rows 1 4

23

Diameter OD (ft) [in] 0.031 0052 [0.375 0.625]
Fin Pitch (fins/ft) [fins/in] 96 168 [8 14]
Tube Spacing 0.083 0.125 [1 1.5]

Webb and Gray (1986) developed heat transfer coefficient and fin friction factor
correlations based on their own experimental data as well as other sources. Data from
16 heat exchanger configurations were used to develop the heat transfer coefficient
correlation; the resulting RMS error is 7.3%. Similarly, data from 18 heat exchanger
configurations were used to develop the fin friction factor correlation; the resulting
RMS error is 7.8%. A multiple regression technique was used with inputs being
geometric quantities: transverse tube spacing, longitudinal tube spacing, tube diameter,
number of tube rows, and fin spacing. Entrance and exit pressure drops were not
included in the fin friction factor. The parametric range of Webb and Greys correlation
is shown in Table 3. The application of this correlation to compare with the coils in the
present study stretches the limits of this correlation; the S
t
/D parameter is 2.63 in the
present study compared to the applicable 1.97 2.55 range. All other parameters are
within their respective ranges.
1ab|e 2.3. Webb (1986) |a|n I|n Corre|at|ons: arametr|c kange
Fin Pattern Plain
Number of Rows 1 8
S
t
/D 1.97 2.55
S
1
/D 1.7 2.58
s/D 0.08 0.64

26

Wang et al. (1999) performed a correlation for plain fin geometry based on several
sources of experimental data. Data from a total of 74 coil configurations were used to
develop the correlation. The heat transfer correlation can correlate 88.6% of the
database within 15%, and the friction correlation can correlate 85.1% of the database
within 15%. The parametric range of Wangs correlation is shown in Table 4. The
application of this correlation to compare with the coils in the present study is
appropriate; all of the parameters are within their respective ranges.
1ab|e 2.4. Wang (1999) |a|n I|n Corre|at|ons: arametr|c kange
Fin Pattern Plain
Number of Rows 1 6
Diameter OD mm(in) 0.635 12.7 (0.25 0.5)
Fin Pitch mm(fins/in) 1.19 8.7 (2.9 21.5)
P
1
mm(in) 17.7 31.75 (0.694 1.25)
P
2
mm(in) 12.4 27.5 (0.488 1.08)

Webb and Kang (1998) performed experimental work on eight enhanced fin shapes.
Nine different coil configurations were tested and used to develop the heat transfer
coefficient correlation. The heat transfer coefficient correlation can correlate 63% of
this database within 15%. The parametric range of Webb and Kangs correlation is
shown in Table 5. The application of this correlation to compare with the coils in the
present study stretches the limits of this correlation; the four-row coils in this study are
/D parameter is 2.053 which is outside of the 1.59 1.89 outside of the 1 2 row range,

27

P
1
/D parameter is 0.127 (for the 21 fpi coils in the present study) which is range, and
the P
f
/D outside the 0.134 - 0.252 range.
1ab|e 2.S. Webb (1998) Louvered I|n Corre|at|ons: arametr|c kange
Fin Pattern Louvered
Number of Rows 1 2
P
t
/D 2.32 2.80
P
1
/D 1.59 1.89
P
f
/D 0.134 0.252

Wang et al. (1998b) performed a correlation for louvered fins based on several sources
of experimental data. Data from a total of 49 coil configurations were used to develop
the correlation. The heat transfer correlation can correlate 95.5% of the database within
15%, and the friction correlation can correlate 90.8% of the database within 15%.
The parametric range of Wangs correlation is shown in Table 6. The application of this
correlation to compare with the coils in the present study stretches the parameter is 0.77
in. which is outside the 0.5 0.75 in. limits of this correlation: the P
1
range and the
major louver pitch is 0.064 in. in the present study which is outside the 0.067 0.147
in. range. All other parameters are within their respective ranges.
1ab|e 2.6. Wang (1998b) Louvered I|n Corre|at|ons: arametr|c kange
Fin Pattern Louvered
Number of Rows 1 6
Diameter OD mm(in) 6.93 10.42 (0.27 0.41)

28

Fin Pitch mm (fins/in) 1.21 2.49 (10.2 21.2)
P
t
mm(in) 17.7 25.4 (0.694 1)
P
1
mm(in) 12.7 22 (0.5 0.75)
Louver height mm(in) 0.9 1.4 (0.03 0.055)
Major Louver Pitch mm(in) 1.7 3.75 (0.067 0.147)

Fin efficiency calculation is of the greatest importance in refrigerant-to-air heat
exchanger engineering, for the evaluation of the finned surface performance or for the
determination of the air-side heat transfer coefficient from experimental data. High
efficiency heat exchangers use enhanced fin geometry (louvered and slit fins) for which
the fin efficiency could be overestimated by usual formulations and more precisely
equivalent circular fin and conventional 1-D sector methods. Because the slits (or
louvers) alter the conduction path through the fin, the assumption of radial heat flow
pattern is no more valid.
Fin-and-tube heat exchangers are widely used in several domains such as heating,
ventilating, refrigeration and air conditioning systems. In practical application of air-to-
refrigerant heat exchangers, the dominant resistance is on the air-side and improving
the accuracy of the analysis of the air-side heat transfer is required by the growing
demand of high performance heat transfer surfaces. The fin performance is commonly
expressed in terms of heat transfer coefficient and fin efficiency, which is defined as
the ratio of the actual fin heat transfer rate to the heat transfer rate that would exist if all
the fin surface was at the base temperature. This case is the one providing the
maximum heat transfer rate because this corresponds to the maximum driving potential

29

(temperature difference) for the convection heat transfer. Many experimental studies
available in the open literature have been performed in order to characterize the air-
side heat transfer performance of several type of fins used in finned tube heat
exchangers [1] [2] [3], and establish correlations which are used for design, rating and
modeling of heat exchangers. In order to obtain the heat transfer coefficient, it is
necessary to determine the fin efficiency [4]. What is observed in nearly all published
papers is that, whatever the fin type (plain, louvered, slit), the fin efficiency calculation
is always performed by analytical methods derived from circular fin analysis. When the
heat transfer coefficient h is considered separately from its corresponding fin
efficiency calculation q (used for h measurement), error could be generated. If h is
always associated to the fin efficiency calculation that served for h measurement, there
is no possible error. The analytical circular fin analysis involves a number of
assumptions which need to be addressed.
These assumptions, known as ideal fin assumptions (attributed to Gardner [5]), are:
1. 1-D radial conduction,
2. steady state conditions,
3. radiative heat transfer negligible,
4. constant fin conductivity,
5. constant heat transfer coefficient over the entire fin,
6. the fin base temperature is assumed to be constant,
7. the thermal contact resistance between the prime surface and the fin is negligible,

30

8. the surrounding fluid is assumed at constant temperature.
In the present study, the commonly used analytical methods for fin efficiency
calculation in finned tube heat exchangers are reviewed and compared. Among the
ideal fin assumptions, the first one should be carefully considered because the actual fin
geometry used in finned tube heat exchanger differs significantly from the plain
circular fin shape. In particular, for enhanced fin designs with louvers or slits, the fin
shape alters the conduction path within the fin. 2-D numerical models are used in order
to quantify the deviation generated by the 1-D assumption, depending on the fin
geometry and type
Fouling of heat exchangers used in heating, ventilating, and air conditioning (HVAC)
systems is important both because of their widespread use in commercial, residential
and industrial buildings and the energy and indoor air quality impacts that can result
from fouling. Fouling of indoor fin and tube heat exchangers, particularly air
conditioner evaporators, is especially important as space cooling in buildings is an
important contributor to overall energy use and peak electric demand. Furthermore, the
location of heat exchangers in HVAC systems means that if bioaerosols containing
bacteria, fungi, and viruses deposit on heat exchangers and remain viable, they can
quickly spread through an indoor space if they are re-entrained in the airflow.
Before discussing the details of particle deposition on air conditioner evaporators, it is
important to clearly describe the system being studied. The HVAC heat exchangers of
interest are designed to exchange energy between a refrigerant and an air stream that is
in turn used to condition an indoor space. Typical heat exchangers consist of horizontal
refrigerant tubes with attached thin vertical fins to increase heat transfer. A typical

31

residential heat exchanger has two staggered sets of 0.95 cm (3/8 inch) copper
refrigerant tubes that run horizontally through vertical aluminum fins. Commercial and
industrial systems can have much larger tubes. Fin spacings range from 2.4 to 7.9
fins/cm (6 - 20 Fins/inch or FPI), with typical systems having 4.7 fins/cm (12 FPI). The
fins are approximately 100 m thick and are often corrugated to increase surface area
for heat transfer. Heat exchanger depth can vary, but typical residential and small
industrial and commercial heat exchangers are about 5 cm (2 inch) thick and are often
grouped together for larger capacities. Air velocities range from 1 to 5 m/s (200 - 1000
ft/min) in these systems.
2.3. APPLICATION TO THE PRESENT STUDY
This experimental study will incorporate and discuss methods and evaluate correlations
presented in this literature review. The discussion of the application of the reviewed
literature will progress from heat transfer to friction factor and finally to an overview of
the parametric ranges of the presented correlations. The present study incorporates
several methods and practices from the literature reviewed to help calculate the heat
transfer characteristics of heat exchangers, as the following will detail. A modified
Wilson method was used to determine the water side thermal resistance. This method
was also used by Rich (1973). Wang (1998c) opted for Gnielinskis (1976) correlation
to determine the waterside heat transfer coefficient. The use of Gnielinskis correlation
would eliminate the need for the modified Wilson test and therefore reduce the time to
acquire a full data set for a coil. However, an experimental method was preferred to a
correlation, because it more accurately characterizes the water side heat transfer
behavior. Thermal contact conductance between the fins and the tubes is not

32

calculated, and is indirectly included in the air side heat transfer results. According to
Wang (1999) it is very difficult to accurately predict the contact resistance and hence,
most of the published works on the airside performance absorbed contact resistance
into the airside performance. Tubes in this study are mechanically expanded to an
interference fit of 0.004 in. to ensure minimal contact resistance. The present study uses
Schmidts (1949) approximation method to calculate the fin efficiency. This is
consistent with Wangs experimental methods.
Wang et al. (2000b) discuss the proper choice of -NTU correlation for a given
geometry. In the present study since the circuiting was serpentine each row was
analyzed independently and furthermore when NTU is less than 1.5 the effect of the
number of rows is insignificant and therefore all available c-NTU correlations are
essentially equivalent and the cross-flow unmixed-unmixed c-NTU correlation was
used.
The present study incorporates several methods and practices from the literature
reviewed to help calculate the friction characteristics of heat exchangers, as the
following will detail. The work of Rich (1973) was used as a guide to separate the
pressure drop into two additive superimposed components, one component due to the
tubes and one component due to the fins. All literature reviewed followed this
convention when calculating the fanning friction factor for the fins. Rich performed a
tube bundle pressure drop test. Wang opted to use a correlation from Kays and London
(1984) to approximate the pressure drop due to the bare tubes. Correlations from a
more recent study, Zukauskas and Ulinskas (1998), were used to approximate the
pressure drop due to the bare tubes in the present study. Webb also used Zukauskas
correlations to calculate the pressure drop due to the bare tubes. Kays and London

33

(1984) states that when the core pressure drop is calculated this takes into account the
tube row contraction and expansion (entrance, K
c
, and exit, K
e
) loss coefficients, thus
K
c
and K
e
will be zero. The flow acceleration due to the contraction ratio, o , and the
density change is included in the fin friction factor formula.

34

CHAPTER 3: PROJECT DESCRIPTION
A heat exchanger can be defined as any device that transfers heat from one fluid to
another or from or to a fluid and the environment. They may be direct contact type or
indirect contact type. Depending on the construction, heat exchangers can be classified
into Shell and tube Heat exchangers, Tube in tube heat exchangers, plate heat
exchangers etc. Another classification is based on the relative direction of flow of fluids
- Parallel Flow, Counter Flow and Cross Flow heat exchangers. In a heat exchanger,
there are two process streams; a hot stream and a cold stream. The heat transfer takes
place between these streams and is described by the enthalpy balance. The basic
equation on which the heat exchanger design is based is the general heat conduction
equation Q=U.A.(T
1
-T
2
) where U is the overall heat transfer coefficient, A is the
surface area for heat transfer and T
1
and T
2
are the temperature limits. For designing of
a heat exchanger the total heat transfer may be related with its governing parameters: U
(overall heat transfer coefficient), A (total surface area of heat transfer), and T
1
and T
2
(inlet and outlet fluid temperatures).
Under steady flow conditions and a constant temperature difference, the only
way of increasing heat transfer rates in a heat-exchanger is to increase the surface area.
One way of achieving this is through the use of extended or finned surfaces. Fins can
be either Longitudinal, Transverse or pin type. Usually in a double pipe heat exchanger,
longitudinal fins are used. This is because longitudinal fins provide passages for fluid
flow and has very little effect on the flow properties. Transverse fins, on the other hand
produce some amount of turbulence and a significant pressure loss thus altering the

33

flow . Fins can also be of different cross sections-rectangular, parabolic or triangular.
Pin shaped fins are also used in a variety of applications.
3.1. PROBLEM DEFINITION
The project is done based on a longitudinally finned double pipe heat exchanger. The
flow type is taken as counterflow. The hot fluid flows in the inner tube called the pipe
and the cold fluid flows in counterflow in the shell side or annulus. The pressure drop
in the pipe is neglected. Data required to perform the design and optimization of the
above heat exchanger are
1. Pipe Inner Diameter
2. Pipe Outer Diameter
3. Shell Inner Diameter
4. Thickness of Fin
5. No. of Fins
6. Length of Pipe
7. Inlet Temperatures of both the Fluids
8. Mass flow Rate of Hot and Cold Fluids
9. Fluid Properties of both the fluids at inlet temperature
10. Properties of the Material of Pipe and Fin
11. Fouling Resistances of both pipe and annulus

36

3.2. COMPUTATIONAL SCHEME
Based on the above data provided the design, optimization and analysis of the finned
heat exchanger can be performed in the following ways:
1. The thermal design is performed manually for unfinned construction and at a
particular fin height randomly chosen.
2. A computer program is written using Turbo C++ to perform the thermal design
and performance evaluation at all fin heights possible for the given shell
diameter.
3. From the tabulated results from the program as well as graphs obtained, the
optimum fin height is determined.
4. The results are checked with that obtained in the manual calculations to confirm
the accuracy of the program.
5. ANSYS is used to model the heat exchanger according to earlier said
specifications and the optimum fin height obtained from the program. An
unfinned model is also created. The FEM analysis is done on both of them and
the results are compared. The temperature profile of the heat exchangers can be
also obtained.
6. A heat exchanger with triangular fins is also modeled and the analysis and post-
processing is done. Then it is compared with the rectangular finned heat
exchanger.

37

Figure 3.1. Cross Section View of Heate Exchanger in Problem Modelled in Auto-Cad

38

CHAPTER 4: PROJECT THEORY
In this Project we encounter the Design, Optimization and Analysis of a Double Pipe
Heat Exchanger. A variety of methodologies are available for this purpose. Even
though all these methods are the same, but for the different forms of equations, by
virtue of the fat that they all rise from the energy balance equation for the two fluids,
different charts and tables are convenient from different application points of view.
Some methods are convenient for rating (performance evaluation) of heat exchangers
while some other methods are convenient are more convenient for sizing (design of
heat exchangers). Some methods are suited when the heat capacity rates of each fluid
are known apriori while some others are more suited when they are not known
accurately. Due to the presence of a large number of different types of heat exchangers,
no one method can be rated as the best. Another issue which is not accounted for
properly is Fouling. The complex and unpredictable nature of this phenomenon has
probably attracted less number of investigators in this area, but from an industys point
of view this is a critical issue.
The simulation of Heat Exchangers is a fairly complex. The complex 3-dimensional
simulation is too complex to be carried out for a design purpose. Thus in most cases,
we are happy with the overall performance evaluation of the heat exchangers. For this
purpose, some simplifications are made to reduce the mathematical complexities of
modeling.

39

The fluid streams are transversely mixed which gives a one-dimensional or
plug flow in all the types of heat exchangers except cross flow where a two
dimensional temperature field is assumed only if a stream is unmixed.
The heat transfer is primarily through the main surface, heat transfer through
baffle, tube sheet etc. is negligible.
Fluid leakage, bypass and flow misdistribution are neglected both in tubes and
shells.
The heat exchanger is assumed to be completely completely insulated from the
surroundings.
The fluid thermophysical properties and the heat transfer coefficient in the heat
exchanger are assumed to be constant over the entire length. However, at the
end of this chapter the effect of variable heat transfer coefficient and variable
(temperature dependent) heat capacity have been discussed.
4.1. SOME IMPORTANT DEFINITIONS
4.1.1. Overall Heat Transfer Coefficient:
In a heat exchanger, heat is transferred from one fluid to the other through the wall.
Hence between the two fluids, the thermal conductance comes from the heat transfer
coefficient of both the sides of the wall and the thermal conductance comes from the
heat transfer coefficient of both the sides of the wall and the thermal conductance of the
solid wall. For each fluid the thermal conductance is given by the product of the heat
transfer coefficient on that side and the corresponding heat transfer area. Thus for one
fluid inside and the the other outside of a tube the total heat transfer resistance can be
given by,

40

R =
1
tubc conductuncc
+
1
wuII conductuncc
+
1
outsdc ]Iow conductuncc

=
1
hA
+
1
kAmt
+
1
hoAo

where A
i
and A
o
are the inside and outside areas of the tube, h
i
and h
o
are the respective
heat transfer coefficients, t is the wall thickness of the tube and k is the thermal
conductivity of the tube material.
However, practically one more factor is added to the thermal resistance to heat flow
known as fouling. Fouling is the phenomenon of deposition of material on the surfaces
from the fluids in the form of scales, layered sediments or biological agents. This
increases the fluids in the form of scales, layered sediments or biological agents. This
increases the resistance to the heat transfer. Under such cases the overall heat transfer
coefficient can be written,

1
0oAo
=
1
0A
=
1
Ah
+
P
A
+
t
kAm
+
Po
Ao
+
1
Aoho

In tubular heat exchangers, it is customary to use the overall heat transfer
coefficient based on outside area of tubes Ao. Hence normally by U we mean Uo.
It should be mentioned here that if one or both sides of the heat exchanger are
finned the overall heat transfer coefficient is defined as

1
0oAo
=
1
qhA
+
P
qA
+
t
kAm
+
Po
qoAo
+
1
qoAoho

Where p is the fin efficiency of the particular side. If a side is unfinned then p = 1.

41

4.1.2. The Temperature Differences
From Newtons law of cooling a heat transfer engineer is tempted to express the heat
transferred in the form of the product of three quantities :
A term similar to heat transfer coefficient
An area which defines the transfer coefficient
A temperature difference term
Locally the heat transfer rate is given by
dQ = U (T
h
T
c
) dA
= U AT dA
Where U is the local overall heat transfer coefficient and T
h
and T
c
are the local bulk
temperatures of the fluids. Integrating this equation over the entire length of the heat
exchanger we get
]
d
A1
= ] uJA
A

The mean overall heat transfer coefficient is defined as
U
m
=
1
A
] uJA
A

Similarly we can define a mean temperatue difference (MTD) AT
m
as

1
ATm
=
1
]
d
A1

42

Where Q is the total heat transferred from one fluid to the other in the heat exchanger.
By eliminating ]
d
A1
we get,
Q = U
m
AAT
m
4.1.3. Capacity Ratio
Capacity Ratio is an important parameter in a heat exchanger. It is the ratio of heat
capacity of cold fluid to hot fluid or vice versa. Accordingly
R
1
=
mcCpc
mhCph
,
R
2
=
mhCph
mcCpc
,
R
1
= 1 / R
2

Where m is the mass flow rate and C
p
is the specific heat rate. Suffixes h and c indicate
hot or cold fluid respectively
4.1.4. Temperature Effectiveness (P)
Temperature effectiveness tells about the performance of a heat exchanger with respect
to temperature alone. It is the ratio of temperature difference that one fluid undergoes to
the maximum temperature prevailing across the heat exchanger. Accordingly,
P
1
= (T
c,out
T
c,in
) / (T
h,in
- T
c,in
)
P
1
= (T
h,in
- T
h,out
)/ (T
h,in
- T
c,in
)

43

4.1.5. Effectiveness of Heat Exchanger ()
The maximum amount of heat transfer (Q
max
) that can occur between two streams in a
countercurrent heat exchanger is that for which the outlet temperature of the stream
with the lowest mC
p
reaches the inlet temperature of the other stream. This case is
illustrated schematically in the diagram. If the cold stream has a value of mC
p
greater
than the hot stream then the maximum heat transfer occurs when the hot stream is
cooled to the inlet temperature of the cold stream. When mC
p
of the hot stream is
higher, the cold fluid will be heated to the inlet temperature of the hot stream. This is
because of the fact that heat balance should be maintained under such condition which
can be given by,
Q
max
= (mC
p
)
min
AT
max
where (mC
p
)
min
is the lower of the two for the respective streams and AT
max
is the
difference between the stream inlet temperature.
AT
max
= (T
h,in
T
c,in
)
To achieve maximum heat transfer, an infinite surface area for the heat exchanger will
be required because the temperature difference approaches zero at the end of the heat
exchanger at which the end temperatures become equal.Effectiveness of a heat
exchanger is defined as the raio of actual to maximum heat transfer rates.
c =
mux

Because Q= U
m
AAT
m
, we see that c is given by

44

c =
UmAATm
(mCpmIn )ATmax

It follows that
c =
mhCph(1h,n-1h,out)
(mCpmIn )(1h,n-1c,n)
=
mcCpc(1c,out-1c,n)

4.1.6. Number Of Transfer Units
It is often convenient to use the number of transfer units as the basis of design. The
NTU values for the respective streams are
NTU
h
=
A0
mhCph

NTU
c
=
A0
mcCpc

where A is the total heat exchanger area and U is the overall heat transfer
coefficient.We may also define NTU
min
as the NTU of the stream having minimum
mC
p
.
NTU
min
=
A0
(mCp)mn

4.2. HEAT EXCHANGER BASIC ANALYSIS METHODS
Depending on the nature of the problem and available data, a method of analysis of the
heat exchanger can be selected.

43

The following are some of the commonly used analysis methods:
The LMTD-F method
The c-NTU method
The P-NTU method
The 0-P method
F- 0-P-NTU method
P-R Combination method
As only the inlet temperatures of the streams and their specific heats are known ,the
analysis is carried out using Effectiveness NTU method.
4.3. THE -NTU METHOD
The LMTD approach to heat exchanger analysis is useful when the inlet and outlet
temperatures are known or easily deermined. The LMTD is then easily determined and
the heat flow can thus be obtained. When the inlet or exit temperatures are to be
evaluated, the analysis frequently involves an iterative procedure because of the
logarithmic function in LMTD. In these cases , the analysis is performed more easily
by utilizing a method based on the effectiveness of the heat exchanger.The
effectiveness method also offers many advantages for analyss of problems in which a
comparison between various types of heat exchangers is to be made.
The heat exchanger effectiveness is defined as
Effectiveness= c =
ActuuI hcut tuns]c
Muxmum possbIc hcut tuns]c

46

The maximum possible heat transfer rate could be achieved in a counter flw heat
exchanger of infinita length.In such an exchange , one of the fluids would experience
the maximum possible temperature difference, Ib, in -Ic, in
If m
c
C
pc
<m
h
C
ph
, thecold fluid would experience a larger temperature change and as the
heat exchanger length is infinite, it would be heated to the inlet temperature of the hot
fluid, ie, T
c,out
=T
h,in
Hence, q
max
=m
c
C
pc
(T
hi
-T
ci
)
Similaly if m
h
C
ph
< m
c
C
pc
, the hot fluid would experience the larger temperature
change and would be cooled to the inlet temperature of the cold fluid in which case we
have,
q
max
=m
h
C
ph
(T
hi
-T
ci
)
Therefore we can write,
c =
mhCph(1h,n-1h,out)
=
mcCpc(1c,out-1c,n)

The NTU values for the respective streams are
NTU
h
=
A0
mhCph

NTU
c
=
A0
mcCpc

We may also define NTU
min
as the NTU value corresponding to the stream having the
minimum mC
p.

47

NTU
min
=
A0
(mCp)mn

Now , c =
QmIn
=
A0ATm
(mCp)mnATmax
= NTU
min
ATm
ATmax

Usually, NTU
min
is defined as NTU.
For a Counter Flow Heat Exchanger, the effectiveness in terms of NTU is obtained as,
c =
j1-cxp _-N10]1-(
Cmin
Cmcx
)_[
j1-(
Cmin
Cmcx
)cxp_-N10]1-(
Cmin
Cmcx
)_[

The value of this expression becomes maximum when NTU is infinity for the given
values of C
min
and C
max
.
4.4. FINS OR EXTENDED SURFACES
In the study of heat transfer, a fin is a surface that extends from an object to increase
the rate of heat transfer to or from the environment by increasing convection. The
amount of conduction, convection, or radiation of an object determines the amount of
heat it transfers. Increasing the temperature difference between the object and the
environment, increasing the convection heat transfer coefficient, or increasing the
surface area of the object increases the heat transfer. Sometimes it is not economical or
it is not feasible to change the first two options. Adding a fin to an object, however,
increases the surface area and can sometimes be an economical solution to heat transfer
problems.

48

The knowledge of temperature distribution along the fin is necessary for the proper
design of fins. The mathematical analysis for finding out the temperature distribution
and heat flow is discussed below-
4.4.1. Simplified Case
To create a simplified equation for the heat transfer of a fin, many assumptions need to
be made.
Assume:
1. Steady state
2. Constant material properties (independent of temperature)
3. No heat transfer
4. No internal heat generation
5. One-dimensional conduction
6. Uniform cross-sectional area
7. Uniform convection across the surface area
The fin analysis can be carried out using the basic Fourier conduction equation.
Fouriers law states that
Q
x
= - kA
c
d1
dx

49

where A
c
is the cross-sectional area of the differential element. Therefore the
conduction rate at x+dx can be expressed as

Hence, it can also be expressed as
.
Since the equation for heat flux is

then dq
conv
is equal to

where A
s
is the surface area of the differential element.
By substitution it is found that

This is the general equation for convection from extended surfaces. Applying certain
boundary conditions will allow this equation to simplify.

The ab
where
convec

The so
0(x) =
where
and
The co
four c
The bo
length
above equatio

re P is the pe
vection from e
solution to the
= C
1
e
mx
+ C
2
e
re
constants C
1

cases have th
boundary con
th of the fin.
tion will simpl
perimeter of
extended surf
.
the simplified
e
mx

.
and C
2
can b
the boundary
ondition at x

plify because
f the cross-se
urfaces with co
.
d equation is
n be found by
ry condition T
= L, howeve
30
se the area is c
sectional area
constant cros

y applying th
T(x = 0) = T
ver, is differe
s constant and
rea. Thus, the
oss-sectional a
the proper bou
T
b
for the tem
rent for all of
nd
he general eq
l area simplifi
oundary cond
temperature a
of them, wher
equation for
ifies to
nditions. All
at the base.
here L is the

31

1ab|e 4.1. 1emperature D|str|but|on and neat 1ransfer kate for f|ns of Un|form Cross Sect|ona| Area

4.4.2. Fin Performance
Fin performance can be described in different ways.
Fin effectiveness-It is the ratio of the fin heat transfer rate to the heat transfer
rate of the object if it had no fin. c=
Hcut Iost wth ]n
Hcut Iost wthout ]n

c=
Kmhj1+][
mK
h
tanhmL[
][
mK
h
+tanhmL

where , m= PbKAc
2
= bKo
2
, (for rectangular fin)
L= Height of fin
2o= Thickness of fin

32

P=Fin perimeter
In this case, a non-dimensional number named as Biot Number is defined.
Biot number B
i
=
h6
K
=
IntcnuI csstuncc o] ]n mutcuI
LxtcnuI csstuncc o] ]Iud on ]n su]ucc

where the thermal conductivity K refers to the conducting body.
The value of Biot number directly affects the fin effectiveness.
1. If B
i
=1
Then, c =1. So there is no use of putting the fins.
2. If B
i
>1
Then, c <1. So there is an adverse effect on heat flow and the fin works as an
insulator.
3. If B
i
<1
Then, c >1. This is the most desirable case.This is possible by using the high
conductivity material like Cu or Al.

Fin Efficiency- This is the ratio of the fin heat transfer rate to the heat transfer
rate of the fin if the entire fin were at the base temperature.It should be noted
that because of the thermal resistance of the fin material, the temperature of the
fin surface away from the base decreases.Hence the lateral area of the fin near
the base is more effectively used than near its tip.If the fin is made of a material
of high thermal conductivity , the value of B
i
is very small and the whole fin
area is nearly at the base temperature and the fin s said to be fully effective.

33

q
f
=
Hcut Iost ]om thc ]n
Hcut Iost ]om ]n ] thc whoIc ]n su]ucc s ut thc oot tcmpcutuc

If the heat lost from the end surfaces and edges of the fin is neglected , then,
q
f
=
tanhmL
mL
, where L= Height of fin.
Fin Uses
Fins are most commonly used in heat exchanging devices such as radiators in
cars and heat exchangers in power plants. They are also used in newer
technology such as hydrogen fuel cells. Nature has also taken advantage of the
phenomena of fins. The ears of jackrabbits act as fins to release heat from the
blood that flows through them.
4.5. HEAT TRANSFER COEFFICIENT
The heat transfer coefficient is used in calculating the convection heat transfer
between a moving fluid and a solid in thermodynamics. The heat transfer coefficient is
often calculated from the Nusselt numberThere are different heat transfer relations for
different liquids, flow regimes, and thermodynamic conditions. A common example
pertinent to many of the necessary power plant efficiency and thermal hydraulic
calculations is the Dittus-Boelter heat transfer correlation, valid for water in a circular
pipe with Reynolds numbers between 10 000 and 120 000 (in the turbulent pipe flow
range) and Prandtl numbers between 0.7 and 120.

4.5.1.
The N
transfe
if just
transfe
directi
where

Nusselt Nu
Nusselt num
sfer from a su
st conduction
sfer when conv
ction
re
L = charac
Area of the
umber
mber is a dim
surface that oc
on occurred. T
onvection take
racteristic leng
the body (usef
imensionless n
occurs in a 're
. Typically it
kes place.
ngth, which i
eful for more
34
s number that
'real' situation
it is used to m
in
is simply Vo
re complex sha
at measures the
on, compared
o measure the
in perpendi
Volume of the
hapes)
the enhanceme
d to the heat t
he enhanceme
dicular to
the body divid
ment of heat
t transferred
ent of heat
the flow
vided by the

33

k
f
= thermal conductivity of the "fluid"
h = convection heat transfer coefficient
4.5.2. Prandtl Number
The Prandtl number is a dimensionless number approximating the ratio of momentum
diffusivity (viscosity) and thermal diffusivity. It is named after Ludwig Prandtl.
It is defined as:

where:
v is the kinematic viscosity, = / .
u is the thermal diffusivity, = k / ( c
p
).
Typical values for Pr are:
around 0.7 for air and many other gases,
around 7 for water
around 710
21
for Earth's mantle
between 100 and 40,000 for engine oil,
between 4 and 5 for R-12 refrigerant
around 0.015 for mercury

36

4.5.3. Reynolds Number
In fluid mechanics, the Reynolds number is the ratio of inertial forces (vsp) to viscous
forces (/L) and consequently it quantifies the relative importance of these two types of
forces for given flow conditions. Thus, it is used to identify different flow regimes,
such as laminar or turbulent flow.
It is one of the most important dimensionless numbers in fluid dynamics and is used,
usually along with other dimensionless numbers, to provide a criterion for determining
dynamic similitude. When two geometrically similar flow patterns, in perhaps different
fluids with possibly different flowrates, have the same values for the relevant
dimensionless numbers, they are said to be dynamically similar.
It is named after Osborne Reynolds (18421912), who proposed it in 1883. Typically it
is given as follows:

where:
* vs - mean fluid velocity,
* L - characteristic length,
* - (absolute) dynamic fluid viscosity,
* v - kinematic fluid viscosity: v = / p,
* p - fluid density.

37

For flow in pipes for instance, the characteristic length is the pipe diameter, if the cross
section is circular, or the hydraulic diameter, for a non-circular cross section.
Laminar flow occurs at low Reynolds numbers, where viscous forces are dominant, and
is characterized by smooth, constant fluid motion, while turbulent flow, on the other
hand, occurs at high Reynolds numbers and is dominated by inertial forces, producing
random eddies, vortices and other flow fluctuations.
The transition between laminar and turbulent flow is often indicated by a critical
Reynolds number (Recrit), which depends on the exact flow configuration and must be
determined experimentally. Within a certain range around this point there is a region of
gradual transition where the flow is neither fully laminar nor fully turbulent, and
predictions of fluid behaviour can be difficult. For example, within circular pipes the
critical Reynolds number is generally accepted to be 2300, where the Reynolds number
is based on the pipe diameter and the mean velocity vs within the pipe, but engineers
will avoid any pipe configuration that falls within the range of Reynolds numbers from
about 2000 to 3000 to ensure that the flow is either laminar or turbulent.
For flow over a flat plate, the characteristic length is the length of the plate and the
characteristic velocity is the free stream velocity. In a boundary layer over a flat plate
the local regime of the flow is determined by the Reynolds number based on the
distance measured from the leading edge of the plate. In this case, the transition to
turbulent flow occurs at a Reynolds number of the order of 105 or 106.

38

4.6. DOUBLE PIPE HEAT EXCHANGER
The double pipe heat exchanger is one of heat exchangers. This type of heat exchanger
is also called concentric tube/pipe, jacketed-tube or hair pin: heat exchanger. The
areas where double pipe heat exchangers are used in smaller duty, usually less than
5000kW where the heat transfer surface requirement is not so high as well the mass
flow rate of the shell fluid is low.
In a variety of applications the double pipe heat exchangers are found to be
advantageous. The advantages of double pipes heat exchangers are many folded such as
:
Counter current operation: The counter flow operation of double pipe heat
exchanger makes it most efficient heat exchanger for a given NTU and R.
Elimination of cocurency in multipass operation: it offers a unique design of No
of tube passes = No of shell passes.
Simplicity of construction and manufacturing: The double pipe heat exchanger
is one of the simplest constructions in heat exchanger family. Is manufacturing
is rather simple because it is simply joining together the standard available pats
such as tubes, flauges, valves.
Application to high temperature and pressure: when compared to the other
nearly counterflow heat exchangers it gives a very high pressure and
temperature range.
Ease of Maintenance: Due to simple construction and flanged joint it is easier to
access the heat exchangers and mechanical cleaning.

39

Enhancement : Heat transfer on the shell side can be enhanced by the finned
construction particularly for gas liquid application.
Cost and Flexibility: Due to simplicity it is cheaper and can be down or up sized
for different applications.
4.7. FOULING IN HEAT EXCHANGERS
Fouling is generally defined as the accumulation of unwanted materials on the surfaces
of processing equipment. It has been recognized as a nearly universal problem in design
and operation and affects the operation of equipment in two ways:
The fouling layer has a low thermal conductivity. This increases the resistance
to heat transfer and reduces the effectiveness of heat exchangers increasing
temperature
As deposition occurs, the cross-sectional area is reduced, which causes an
increase in pressure drop across the apparatus

60

CHAPTER 5: THERMAL DESIGN PROCEDURE
5.1. ANALYSIS OF DOUBLE PIPE HEAT EXCHANGERS
5.1.1. Simple Flow Configurations
The double pipe heat exchanger selected is a counterflow heat exchanger. Hence, the
correlations for LMTD and c for counterflow heat exchangers derived holds true. As
per the definition the mean temperature difference can be given by LMTD, thus
AT
m
= AT
lm
Therefore the heat transfer equation reduces to
Q = UA AT
LM

Where U is the overall heat transfer coefficient and A is the area on which heat transfer
coefficient is defined. In terms of the inlet and outlet temperatures the heat transfer Q can be
written as
Q = UA
{(Th-Tco)-(Tho-Tc)]
In
Thi-Tcc
Thc-Tci

Where suffixes h and c stand for hot and cold fluids and i and o indicate inlet and outlet
conditions respectively.
But in our problem the outlet conditions are unknown, so the above method cannot be
directly applied. So we use the c NTU method as described in the previous chapter.
In the c NTU method, the effectiveness of double pipe heat exchanger is given by

61

c =
1-cxp |-N10(1-R)]
1-Rcxp|-N10(1-R)]

In recent times the P-R method has become very popular because it does not require
specification of the fluid with minimum heat capacity a priori. But we decided to go
with the usual c NTU method.
5.1.2. Heat Transfer Characteristics
In the above section, the overall heat transfer coefficient U was used without any
specific reference to its evaluation. Now we take up this task. So as per the definition of
overall heat transfer coefficient we can write
1
0oAo
=
1
hoAo
+
Ro
Ao
+
Rw
A
+
R
A
+
1
hA

where,
A
o
= outside area of the (plain) inner tube
A
i
= inside area of the inner tube
h
o
,h
i
= the outside and inside film heat transfer coefficient of the inside tube
defined on the
basis of A
o
and A
i
respectively
R
o
,R
i
= outside and inside fouling resistance for inner tube
R
w
= tube wall resistance =
d In (do d / )
2kw

k
w
= tube wall thermal conductivity

62

The tube resistance term can be determined for the case of steady state conduction
through the walls of a symmetric cylinder. The overall heat transfer coefficient U
o
is
defined on the outside surface area of the (plain) pipe A
o
. For double pipe configuration
heat transfer area can be put as
A = nJI
where L is the length of the tube surface and d is the corresponding diameter (d
o
for
outer and d
i
for inner surface giving A
o
and A
i
respectively). This reduces the Eqn.
(5.5)
1
0o
=
1
ho
+ Ro +
d In (do d / )
2kw
[
do
d
+
Rdo
d
+
1
h
[
do
d

Thus, the task reduces to determination of film transfer coefficient h
i
and h
o
. For tube
side coefficient well known correlation such as Dittus-Boelter equation can be used
(Chapter 4). However, a more frequently used correlation is the Sieder-Tate equation.
But we used the former for simplicity in calculations. The important difficulty in using
these correlations is the determination of fluid property because the equations
mentioned above suggest to use the fluid properties at average film temperature which
is the mean between bulk mean temperature of the fluid and the wall temperature. In
our problem the fluid temperature vary from inlet to outlet and the wall temperature is
not known. Hence, two approaches are possible.
First, calculations are carried out with properties at the mean bulk temperature
on each side where
T
meanbulk
=
1buIk,n + 1buIk,out
2

63

On the basis of result obtained the wall temperature at each end can be
calculated by temperature drop from the hot stream and temperature rise in the
cold stream. At the hot fluid inlet wall temperature may be approximately
calculated as
1wuII-1c,out
RcoId
=
1h,n-1wuII
Rhot

And at the cold fluid inlet the wall temperature is calculated as
1wuII-1c,n
RcoId
=
1h,out-1wuII
Rhot

Here the wall resistance is divided into two (may be equal) parts and added to
film and fouling resistance of each side to get R
cold
and R
hot
. With these wall
temperatures on both the ends the mean wall temperature can be calculated and
then the properties can evaluated at the mean film temperature given by
T
f,mean
=
1mcunbuIk+1mcunwuII
2

This has to be iterated and within two to three iterations and a good converged
result can be obtained.
If iteration is to be avoided we can assume that both U and AT vary linearly
within the heat exchanger. This gives an average heat transfer coefficient U
m
as
U
m
=
A(02AT1-U1AT2)
In[
U2AT1
U1AT2

Here the suffixes 1 and 2 refer to the ends of the heat exchanger.

64

5.1.3. Heat Transfer Coefficient of the Annular Side
For shell side heat transfer coefficient the equation for heat transfer coefficient in
annulus has to be used. For turbulent flow the same correlation can be used for tube
flow only the diameter should be replaced by equivalent diameter, d
e
.
Here, one important distinction has to be made between thermal and hydraulic
performance. The fluid friction for the annular space takes place at both the inner wall
of the outer tube (shell) and outer wall of the inner tube, whereas, heat transfer takes
place at the outer surface of the inner tube. Thus, for evaluating the heat transfer
coefficient of the annular side, the equivalent diameter is calculated as
d
e
=
4 PIow Acu
Pcmctc o] Hcut 1uns]c
=
4
n
4
(ds
2
-do
2
)
do
=
(ds
2
-do
2
)
do

Where d
s
= the inside diameter of the shell
d
o
= the outside diameter of the tube
For fluid flow and the definition of the Reynolds Number, the hydraulic diameter
should be used which is given by
d
h
=
4 PIow Acu
cttcd Pcmctc
=
4
n
4
(ds
2
-do
2
)
(ds+do)
= d
s
d
o

or annular gap width.
Thus, it must be kept in mind that
Re =
dh

63

where V = fluid mean velocity =
m
NPA

= kinematic viscosity
but
Nu
o
=
ho dc
ko

where, o indicates outer surface of inner tube and k
o
is the thermal conductivity of the
fluid in the annulus.
However, the above quantities are for unfinned units only. For finned construction the
details are given in design section later.
5.2. DESIGN OF LONGITUDINALLY FINNED DOUBLE PIPE
HEAT EXCHANGERS
In the last section we saw the analysis of simple unfinned tube heat exchanger for
understanding the process of heat transfer and important issues such as evaluation of
properties and heat transfer in annulus. This section describes design approach used in
the case of a finned construction as shown in Fig. (3.1).
Now let us define the previously defined quantities in the light of finned construction.
Hydraulic Mean Diameter, d
h
=
4 NPA
p

Thermal Equivalent Diameter, d
e
=
4 NPA
p- ds

66

where, NFA is the Net Flow Area for fluid flow in the annulus and W
p
is the Wetted
Perimeter. These parameters are given by
NFA =
ds
2
4
j
do
2
4
o[
W
p
= ad
s
+ ad
o
+ 2 N
f
H
f
N
f
o
f
where, the new quantities are
N
f
= number of fins
H
f
= fin height
o
f
= fin thickness
A typical finned tube with the geometrical parameters is shown in Fig. ().
1ab|e S.1. 1herma| Des|gn Data 1ab|e
Tube Outside Diameter (d
o
) in mm No. of Fins
25.4 20
25.4 20
48.3 36
48.3 36
60.3 40

67

48.3 36
60.3 40
73.0 48

With the assumption of absence of contact resistance between the tube and the fins, a
constant heat transfer coefficient over the entire finned length and fin Biot Number
along thickness small enough to consider it one dimentional, the fin efficiency can be
calculated as
q
f
=
tanhmH]
mH]

Kern (1965) calculated the entire heat transfer coefficient based on inner tube area but
Guy (1983) used total outside finned area which is more popular. Here we use the latter
method. Thus, the total area A
tot
is given by
A
tot
= A
f
+ A
b
where, A
f
= total fin surface area = 2 N
f
L
f
H
f
A
b
= unfinned bare tube area = L
f
(ad
o
-N
f
o
f
)
The total fin efficiency of the finned surface neglecting heat transfer from the fin tip is
given by

68

q
f
=
A]q]+Ab
Atot
= q
f
[
A]
Atot
+
[1 -
A]
Atot

Since the total efficiency affects the fin surface as well as the fouling surface, the
fouled surface heat transfer coefficient can be given by
1
0]s
= R
o
+
1
ho

where, R
o
is the fouling resistance on the fins.
The fin perimeter P
f
can be approximated as 2L
f
since L
f
>>o
f
. This reduces the value of
m to
m =
2 0]s
kw 6]

where, m
2
=
hP]
k]A]c

h = heat transfer coefficient based on finned area
P
f
= fin perimeter = 2(o
f
+L
f
)
L
f
= length of pipe/fin
A
fc
= cross-sectional area of the fin = L
f
o
f

k
f
= thermal conductivity of fin matrial
Thus, the total finned surface efficiency acts as a correlation factor to U
fs
based on the
total area. Thus, the overall heat transfer coefficient can be calculated as

69

1
0o
=
1
0]s
+ R
w
[
Atot
Ao
+ [Ri
1
h
Atot
A

where,
U
o
= overall heat transfer coefficient
R
w
=
do In (do d / )
2kw
= wall thermal resistance
R
i
= tube side fouling factor
Now the design of a double pipe unit can be carried out based on the above equations
and basic heat exchanger analysis methods explained in the previous chapter. The only
difference between the finned and unfinned construction being, in case of unfinned A
tot
A
o
and q
f
1. Hence, the procedure we used in the design of the longitudinally
finned double pipe heat exchanger is listed in step by step format in the next section.
The design we did was only for the rating or performance evaluation.
For rating purpose the information available are
The pipe dimensions (tube and shell)
The fin geometry and numbers (Fin Height was varied from 0 mm to maximum
possible for the given shell size)
The material data for pipes and fins
The inlet temperatures and property data tables for both the fluids
All the thermal data were determined at unfinned condition as well as at all possible fin
heights in 1mm steps. In the next chapter the computer program, developed using C++,

70

to perform this design will be explained. The method used at a particular fin height is
given below.
5.3. STEPS INVOLVED IN THE THERMAL DESIGN OF A
LONGITUDINALLY FINNED DOUBLE PIPE HEAT
EXCHANGER
Step 1: Calculation of Fin Geometrical Parameters:
Calculation of Net Flow Area (NFA):
NFA =
ds
2
4
j
do
2
4
o[
Calculation of Wetted Perimeter (W
p
):
W
p
= ad
s
+ ad
o
+ 2 N
f
H
f
N
f
o
f

Total Fin Surface Area (A
f
):
A
f
= 2 x N
f
L
f
H
f

Unfinned Bare Tube Area (A
b
):
A
b
= L
f
(nd
o
N
f
x o
f
)
Total Area (A
tot
)
A
tot
= A
f
+ A
b
Step 2: Calculation of d
e
and d
h
from Fin Geometrical Parameters:
Thermal Equivalent Diameter (d
e
):
d
e
=
4 NPA
p- ds

71

Hydraulic Mean Diameter (d
h
):
d
h
=
4 NPA
p

Step 3: Calculation Of Reynolds Number And Nusselt Number:
In the computation of the non dimensional parameters we need the property
values of fluids. Due to the fact that we do not know the value of the mean temperature,
the fluid properties are found out at the inlet temperature.
Fluid Mean velocity (V
o
):
V
o
=
m c
c NPA

Reynolds Number (Re):
Re
o
=
o dh

Nusslet Number (Nu):
Nu
o
= 0.023 x (Re
o
)
0.8
x (Pr
o
)
0.4

Step 4 : Calculation Of Heat Transfer Coefficient In The Shell Side:
h
o
=
Nuo k
dc

Step 5 : Calculation Of Heat Transfer Coefficient In The Tube Side:
Repeat all the procedures from Step 1 to Step 4 to determine the heat transfer
coefficient in the tube side (h
i
).

72

Step 6: Calculation of Fin Efficiency:
Fouled Heat Transfer Coefficient (U
fs
):

1
0]s
= R
o
+
1
ho

m =
2 0]s
kw 6]

Fin Efficiency (q
f
)
q
f
=
tanhmH]
mH]

Step 7: Calculation Of Overall Heat Transfer Coefficient:
The total fin efficiency of the finned surface neglecting heat transfer from the
fin tip (q
f
):
q
f
=
A]q]+Ab
Atot
= q
f
[
A]
Atot
+
[1 -
A]
Atot

Overall Heat Transfer Coefficient (U
o
):
1
0o
=
1
0]s
+ R
w
[
Atot
Ao
+ [Ri
1
h
Atot
A

Step 8: Calculation of NTU and R:
Number of Transfer Units (NTU):
NTU =
0o Atot
(mC)mn

73

Capacity Ratio (R):
(mC)
min
/(mC)
max
Step 9 : Calculation Of Effecetiveness Of Double Pipe Heat Exchanger:
Effectiveness of double pipe heat exchanger (c):
c =
1-cxp |-N10(1-R)]
1-Rcxp|-N10(1-R)]

Step 10 : Calculation of Net Heat Transfer:
Net Heat Transfer (Q):
Q = Effectiveness x Maximum Possible Heat Transfer
Q
max
= (mC)
min
x AT
max

Q = c x (mC)
min
x (T
hi
T
ci
)

4. Step 11: Outlet Temperatures of Both Fluids:
These can be obtained from the Heat Balance Equation.
Q = m
h
C
ph
x (T
hin
T
ho)
=

m
c
C
pc
x (T
co
T
ci)
Cold Fluid Outlet Temperature:
T
co
= T
ci
+
mCp

Hot Fluid Outlet Temperature:
T
ho
= T
hi
-
mhCph

This completes the performance evaluation of thermal aspect.

74

CHAPTER 6: OPTIMIZATION USING COMPUTER
PROGRAM
In the previous chapter we have seen the complete design procedure of a longitudinally
finned double pipe heat exchanger. Based on this procedure a computer program is
written in Turbo C++. Program code is given in Appendix A. The program is able to
perform the performance evaluation of any longitudinally finned double pipe heat
exchanger if the required geometrical data and fluid properties at inlet are provided.

I|gure 6.1. Data Input Mode Se|ect|on MLNU
6.1. DATA INPUT
The first section of the program deals with data input. In this part all the required
variables are defined. The program first displays the assumptions used in the design
procedure. Then a MENU is displayed which will allow the user to select the mode of
data input. Option 1 will allow the user to skip the manual data entering procedure and
go with a sample problem. Option 2 will permit the user to input the geometrical data
of the heat exchanger and the fluid and material properties. This can be entered by
referring to a Heat Transfer Data Book. Option 3 will exit the program. When the

73

sample problem is selected the program displays all the property values and
geometrical data assumed. This completes the data input stage.

I|gure 6.2. Samp|e rob|em Screen 1


76


I|gure 6.S. Manua| Data Input Screen 1

I|gure 6.6. Manua| Data Input Screen 2

77

6.2. THERMAL DESIGN
After all the required data about the heat exchanger are obtained the program starts to
perform the performance evaluation to obtain the heat transfer, outlet temperatures,
effectiveness etc. This procedure is performed first in the case of a unfinned
construction. Now program performs design for finned construction with the fin height
varying from 1mm to the maximum possible ie the annular spacing in steps of 1mm.
All the performance data are displayed at each step. After the steps are all complete the
output results are displayed as a table. The design procedure at every fin height consists
of two parts:

I|gure 6.7. Unf|nned neLx Ca|cu|ated kesu|ts

78

6.2.1. Fluid Calculations
In this the NFA is calculated first and then the W
p
. Using this the hydraulic mean
diameter and thermal equivalent diameter are determined. The flow velocity is
determined using the mass flow rate, density and NFA. Then the Reynolds Number is
determined and Dittus-Boelter Eqn. is used to determine the Nusselt Number. From the
Nusselt Number the film heat transfer coefficient is determined. This method is used to
calculate the heat transfer coefficients of the outer and inner surfaces. This will be
repeated at all fin heights.
6.2.2. Thermal Calculations
After determining the heat transfer coefficient, the fin efficiency is calculated and total
finned surface efficiency is determined. The heat transfer coefficients are combined
with the fouling resistances to get the fouled heat transfer coefficient. The wall thermal
resistance is then calculated. Then from inner and outer fouled heat transfer coefficients
and the wall thermal resistance the overall heat transfer coefficient is determined. This
U
o
with the total surface area of the finned pipe gives the NTU. From NTU, the Heat
Exchanger effectiveness is determined by the formula for effectiveness-NTU method.
The obtained effectiveness when multiplied with the maximum possible heat transfer
gives the net heat transfer. From this heat transfer value, the outlet temperature of both
hot and cold fluid is determined. This will conclude the thermal design for the
particular fin height. The process is repeated for all fin heights.

79

I|gure 6.8. Ca|cu|at|on kesu|ts at I|n ne|ght = 1Smm
6.3. RESULTS AND DISCUSSIONS
The U
o
, Heat Transfer, NTU, effectiveness and outlet temperatures of hot and cold
fluids at unfinned stage, and at all possible fin heights are displayed as a table. From
the table we can see that the overall heat transfer coefficient is continuously decreasing
since the surface area is increasing even though there is an increase in the heat transfer
coefficient. But the effectiveness and heat transfer values are found increasing. This is
because the small drop in U
o
is compensated by a large increase in area, A
tot
. The
effectiveness will not stop increasing within our size limits. So to find an optimum fin
height, we cant just take the point of maximum effectiveness.

80

1ab|e 6.9. 1he 1herma| Des|gn kesu|ts at var|ous f|n he|ghts

To solve this problem a graph is plotted with the fin height on the x-axis and
effectiveness on the y-axis. The graph shows that beyond a particular point the graph
becomes horizontal, ie. Effectiveness becomes almost constant. So this point is
assumed to be the optimum fin height. To confirm this assumption another graph is
plotted with the percentage increase in volume of the fin and pipe material and
percentage increase in heat transfer at each step along the y-axis and fin height along
the x-axis. The graph shows that the percentage increase in volume is almost constant
at all fin heights. But the percentage increase in heat transfer falls to almost zero at a
particular fin height and the percentage increase in volume is much higher than zero. So
beyond this point increasing fin height results more in wastage of material and thus
more cost than in increase of heat transfer. Therefore this point fixed as the optimum
fin height.

81

The final results obtained are given below:

I|gure 6.10. 1he I|na| kesu|t of the program

82

CHAPTER 7: THERMAL ANALYSIS USING ANSYS
7.1. FINITE ELEMENT METHOD
The Finite element method (FEM) is used for finding approximate solution of partial
differential equations (PDE) as well as of integral equations such as the heat transport
equation. The solution approach is based either on eliminating the differential equation
completely (steady state problems), or rendering the PDE into an equivalent ordinary
differential equation, which is then solved using standard techniques such as finite
differences, etc.
In solving partial differential equations, the primary challenge is to create an equation
that approximates the equation to be studied, but is numerically stable, meaning that
errors in the input data and intermediate calculations do not accumulate and cause the
resulting output to be meaningless. There are many ways of doing this, all with
advantages and disadvantages. The Finite Element Method is a good choice for solving
partial differential equations over complex domains (like cars and oil pipelines), when
the domain changes (as during a solid state reaction with a moving boundary), or when
the desired precision varies over the entire domain. For instance, in simulating the
weather pattern on Earth, it is more important to have accurate predictions over land
than over the wide-open sea, a demand that is achievable using the finite element
method.

83

7.2. ANSYS
ANSYS is the original (and commonly used) name for ANSYS Mechanical or ANSYS
Multiphysics, general-purpose finite element analysis software. ANSYS, Inc. actually
develops a complete range of CAE products, but is perhaps best known for ANSYS
Mechanical & ANSYS Multiphysics.
ANSYS Mechanical and ANSYS Multiphysics are self contained analysis tools
incorporating pre-processing (geometry creation, meshing), solver and post processing
modules in a unified graphical user interface. ANSYS is a general purpose finite
element modeling package for numerically solving a wide variety of mechanical
problems. These problems include: static/dynamic structural analysis (both linear and
non-linear), heat transfer and fluid problems, as well as acoustic and electro-magnetic
problems.
The software is used to analyze a broad range of applications. ANSYS Mechanical
incorporates both structural and material non-linearities. ANSYS Multiphysics includes
solvers for thermal, structural, CFD, electromagnetics, acoustics and can couple these
separate physics together in order to address multi-disciplinary applications. ANSYS
software is also used in Civil Engineering, Electrical Engineering, Physics and
Chemistry.
7.2.3. Analyzing Thermal Phenomena in ANSYS
A thermal analysis calculates the temperature distribution and related thermal
quantities in a system or component. Typical thermal quantities of interest are:
The temperature distributions

84

The amount of heat lost or gained
Thermal gradients
Thermal fluxes.
The basis for thermal analysis in ANSYS is a heat balance equation obtained from the
principle of conservation of energy. The finite element solution you perform via
ANSYS calculates nodal temperatures, then uses the nodal temperatures to obtain other
thermal quantities.The ANSYS program handles all three primary modes of heat
transfer: conduction, convection, and radiation.
7.2.4. Convection
You specify convection as a surface load on conducting solid elements or shell
elements. You specify the convection film coefficient and the bulk fluid temperature at
a surface; ANSYS then calculates the appropriate heat transfer across that surface. If
the film coefficient depends upon temperature, you specify a table of temperatures
along with the corresponding values of film coefficient at each temperature.
7.2.5. Types of Thermal Analysis
ANSYS supports two types of thermal analysis:
1. A steady-state thermal analysis determines the temperature distribution and
other thermal quantities under steady-state loading conditions. A steady-state
loading condition is a situation where heat storage effects varying over a period
of time can be ignored.

83

2. A transient thermal analysis determines the temperature distribution and other
thermal quantities under conditions that vary over a period of time.
In the following analysis, we are performing a steady state thermal analysis.
The results obtained from the C++ program has been used for modeling the heat
exchanger in Ansys. The thermal solid element 20 node 90 has been used for all the
models.
7.2.6. SOLID90 Element Description
SOLID90 is a higher order version of the 3-D eight node thermal element (SOLID70).
The element has 20 nodes with a single degree of freedom, temperature, at each node.
The 20-node elements have compatible temperature shapes and are well suited to model
curved boundaries. The 20-node thermal element is applicable to a 3-D, steady-state or
transient thermal analysis. If the model containing this element is also to be analyzed
structurally, the element should be replaced by the equivalent structural element (such
as SOLID95). Convection or heat flux (but not both) and radiation may be input as
surface loads at the element faces as shown by the circled numbers on figure. Heat
generation rates may be input as element body loads at the nodes

I|gure 7.1. So||d 90 e|ement

86

7.2.7. SOLID90 Input Summary
Nodes
I, J, K, L, M, N, O, P, Q, R, S, T, U, V, W, X, Y, Z, A, B
Degrees of Freedom
TEMP
Real Constants
None
Material Properties
KXX, KYY, KZZ, DENS, C, ENTH
Surface Loads
Convection or Heat Flux (but not both) and Radiation (using Lab = RDSF) --
face 1 (J-I-L-K), face 2 (I-J-N-M), face 3 (J-K-O-N),
face 4 (K-L-P-O), face 5 (L-I-M-P), face 6 (M-N-O-P)
Body Loads
Heat Generations --
HG(I), HG(J), HG(K), HG(L), HG(M), HG(N), HG(O), HG(P), HG(Q), HG(R),
HG(S), HG(T), HG(U), HG(V), HG(W), HG(X), HG(Y), HG(Z), HG(A), G(B)

87

7.2.8. SOLID90 Output Data
Table 7.1. SOLID90 Element Output Definitions
Label Definition
EL Element Number
NODES Nodes - I, J, K, L, M, N, O, P
MAT Material number
VOLU: Volume
XC, YC, ZC Location where results are reported
HGEN Heat generations HG(I), HG(J), HG(K), HG(L), HG(M),
HG(N), HG(O), HG(P), HG(Q), ..., HG(Z), HG(A), HG(B)
TG:X, Y, Z,
SUM
Thermal gradient components and vector sum at centroid
TF:X, Y, Z,
SUM
Thermal flux (heat flow rate/cross-sectional area) components
and vector sum at centroid
FACE Face label
NODES Corner nodes on this face
AREA Face area
HFILM Film coefficient
TAVG Average face temperature
TBULK Fluid bulk temperature

88

Label Definition
HEAT RATE Heat flow rate across face by convection
HEAT
RATE/AREA
Heat flow rate per unit area across face by convection
HFLUX Heat flux at each node of face
HFAVG Average film coefficient of the face
TBAVG Average face bulk temperature
HFLXAVG Heat flow rate per unit area across face caused by input heat
flux

7.3. BUILDING THE MODEL
To build the model, you specify the jobname and a title for your analysis. Then, you
use the ANSYS preprocessor (PREP7) to define the element types, element real
constants, material properties, and the model geometry
1. To specify element types, you use the following:
GUI: Main Menu> Preprocessor> Element Type> Add/Edit/Delete
2. To define constant material properties, use either of the following:
GUI:
Main Menu> Preprocessor> Material Props> Material Models>
Thermal

89

7.3.1. Creating Model Geometry

I|gure 7.2. Cross sect|on

I|gure 7.3. Lxtruded mode|
The model is created either from primitives or can be directly modeled in Ansys or can
even be imported from other softwares. Here, the cross section is first modelled and
then extruded to get the required geomety.
7.3.2. Defining the Analysis Type
During this phase of the analysis, you must first define the analysis type:

90

In the GUI, choose menu path Main Menu Solution> Analysis Type> New Analysis>
Steady-state (static).
The geometry is then created using the preprocessor
7.4. MESHING
The model is then meshed using the mesh tool or using smart size option. A free mesh
will form an unstructured grid whereas a mapped mesh will form a structured grid.In
mapped meshing ,the element size is to be specified whereas in free mesh , ANSYS
automatically decides the mesh size.

I|gure 7.4. Meshed mode|

91

7.5. APPLYING LOADS
You can apply loads either on the solid model (keypoints, lines, and areas) or on the
finite element model (nodes and elements). You can specify loads using the
conventional method of applying a single load individually to the appropriate entity, or
you can apply complex boundary conditions as tabular boundary conditions
1. Convections (CONV)
Convections are surface loads applied on exterior surfaces of the model to account for
heat lost to (or gained from) a surrounding fluid medium. They are available only for
solids and shells. In line-element models, you can specify convections through the
convection link element
Main Menu> Solution> Define Loads> Apply> Thermal> Convection
2. neat I|uxes (nILUk)
Heat fluxes are also surface loads. Use them when the amount of heat transfer across a
surface (heat flow rate per area) is known, or is calculated through a FLOTRAN CFD
analysis. A positive value of heat flux indicates heat flowing into the element. Heat flux
is used only with solids and shells. An element face may have either CONV or HFLUX
(but not both) specified as a surface load. If you specify both on the same element face,
ANSYS uses what was specified last
Main Menu> Solution> Define Loads> Apply> Thermal> Heat Flux

92

7.6. SOLUTION
Once meshing is done and the loads are applied, the fem model can be solved using the
solve command.
To start the solution, use the following:
GUI: Main Menu> Solution> Solve> Current LS
7.7. POSTPROCESSING
After the finite element model is solved results are retrieved using the postprocessor of
Ansys.
To display your results, use the following menu paths.
For contour displays:
GUI:
Main Menu> General Postproc> Plot Results> Contour Plot> Element Solu
Main Menu> General Postproc> Plot Results> Contour Plot> Elem Table
Main Menu> General Postproc> Plot Results> Contour Plot> Nodal Solu
Contour plots show the variation of the selected parameter on the geometry itself .In
addition to contour plots, vector plots can also be obtained. Graphs can be plotted by
defining paths and mapping the required item onto the path.
The results can be listed using the following GUI path:
For table listings:

93

GUI:
Main Menu> General Postproc> List Results> Element Solution
Main Menu> General Postproc> List Results> Nodal Solution

7.7.1. Reviewing Analysis Results
ANSYS writes the results from a thermal analysis to the thermal results file,
Jobname.RTH. Results contain the following data:
Primary data
Nodal temperatures (TEMP, TBOT, TE2, TE3, . . . TTOP)
Derived data
Nodal and element thermal fluxes (TFX, TFY, TFZ, TFSUM)
Nodal and element thermal gradients (TGX, TGY, TGZ, TGSUM)
Element heat flow rates
Nodal reaction heat flow rates
7.8. PROBLEM DESCRIPTION
7.8.1. Pipe Without Fins
The inner tube of a tube-in-tube counter flow heat exchanger without fins is
analyzed.
Specifications
Pipe length 5cm
Inside diameter 6cm

94

Outside diameter 6.9cm
Fin type No fin
Loading
Convection on the inside surface with Film Coefficient=8334.7W/m
2
K
Fluid bulk temperature (inside) = 95
0
Celsius
Convection on the outside surface with Film Coefficient = 93.35 W/m
2
K
Fluid bulk temperature(outside) = 40
0
Celsius
Pipe is insulated at both ends, ie, Heat flux=0
7.8.2. Results

I|gure 7.S. Contour p|ot of noda| temperature- Lnd v|ew

93

I|gure 7.6. Contour p|ot of Noda| 1emperature

I|gure 7.7. Contour p|ot of Noda| heat f|ux

96

I|gure 7.8. Vector p|ot of 1herma| f|ux

I|gure 7.9. Vector p|ot of therma| grad|ent

97

PRINT ALONG PATH DEFINED BY LPATH COMMAND. DSYS= 0
***** PATH VARIABLE SUMMARY *****
S TEMP FLUX HEATFLOW
0.0000 94.306 5805.9 0.33825E-01
0.22500E-03 94.285 5766.2 0.22339E-01
0.45000E-03 94.263 5726.4 0.11674E-01
0.67500E-03 94.242 5686.6 0.18316E-02
0.90000E-03 94.221 5646.9 -0.71892E-02
0.11250E-02 94.200 5607.1 -0.15388E-01
0.13500E-02 94.179 5567.4 -0.22766E-01
0.15750E-02 94.158 5527.6 -0.29321E-01
0.18000E-02 94.137 5487.8 -0.35055E-01
0.20250E-02 94.117 5448.1 -0.39967E-01
0.22500E-02 94.096 5408.3 -0.44057E-01
0.24750E-02 94.076 5368.6 -0.47326E-01
0.27000E-02 94.056 5328.8 -0.49772E-01
0.29250E-02 94.036 5289.0 -0.51397E-01
0.31500E-02 94.017 5249.3 -0.52200E-01

98

0.33750E-02 93.997 5209.5 -0.52182E-01
0.36000E-02 93.978 5169.8 -0.51342E-01
0.38250E-02 93.958 5130.0 -0.49679E-01
0.40500E-02 93.939 5090.2 -0.47196E-01
0.42750E-02 93.920 5050.5 -0.43890E-01
0.45000E-02 93.901 5010.7 -0.39763E-01
The above values are plotted in the following graphs-

I|gure 7.10. I|ux vs kad|a| d|stance

99

I|gure 7.11. neat f|ow vs kad|a| d|stance
The following items are included in the element table:
Heat1-Heat flow rate across face1 of the element by convection
Heat2- Heat flow rate across face2 of the element by convection
Heat flow- Sum of heat flow by convection across all the faces
Volume- Volume of each element.

100

After defining the element table, sum of each item is calculated over all elements
and the results are listed below.
SUM ALL THE ACTIVE ENTRIES IN THE ELEMENT TABLE
TABLE LABEL TOTAL
HEAT1 23.2804
HEAT2 29.3213
HEAT3 34.9446
HEAT4 0.00000
HEAT5 21.5256
HEAT6 0.00000
HEATFLOW 109.072
VOLUME 0.455926E-04
All units are in SI system
7.8.3. Pipe with rectangular longitudinal fins
The inner tube of a tube-in tube counter flow heat exchanger with longitudinal fins of
rectangular cross section is analyzed.
Specifications
Pipe length 5cm

101

Inside diameter 6cm
Fin type Longitudinal fins, rectangular cross section
Number of fins-40
Fin height-15mm
Fin thickness-0.9mm
Loading
2
K
0
Celsius
Convection on the outside surface with Film Coefficient = 268.13
W/m
2
K
0
Celsius

102

7.8.4. Results

I|gure 7.12. contour p|ot of Noda| 1emperature

I|gure 7.13. Contour p|ot of Noda| 1emperature

103

I|gure 7.14. Contour p|ot of 1herma| f|ux

I|gure 7.1S. Vector p|ot of 1herma| f|ux

104

0.0000 88.232 56851. 0.53365E-01
0.97500E-03 87.316 55539. 0.43654E-01
0.19500E-02 86.405 54280. 0.22573E-01
0.29250E-02 85.509 68839. -0.18220E-02
0.39000E-02 84.178 0.13639E+06-0.12090E-02
0.48750E-02 81.616 0.18793E+06-0.26461E-02
0.58500E-02 78.166 0.20087E+06-0.52274E-02
0.68250E-02 75.059 0.18054E+06-0.62020E-02
0.78000E-02 72.284 0.16132E+06-0.65923E-02
0.87750E-02 69.811 0.14330E+06-0.54885E-02
0.97500E-02 67.620 0.12671E+06-0.20283E-02
0.10725E-01 65.688 0.11123E+06-0.34405E-02
0.11700E-01 63.998 96815. -0.46582E-02
0.12675E-01 62.534 83477. -0.19783E-02
0.13650E-01 61.283 70756. -0.19005E-02

103

0.14625E-01 60.232 58633. -0.30442E-02
0.15600E-01 59.372 47228. -0.27243E-02
0.16575E-01 58.695 36216. -0.12757E-02
0.17550E-01 58.194 25506. -0.29579E-02
0.18525E-01 57.864 15044. -0.20605E-02
0.19500E-01 57.704 4734.2 -0.96108E-03

I|gure 7.7. 1emperature vs rad|a| d|stance

106

I|gure 7.8. neatf|ow vs kad|a| d|stance


107

TABLE LABEL TOTAL
HEAT1 106.352
HEAT2 124.293
HEAT3 745.511
HEAT4 0.00000
HEAT5 86.2822
HEAT6 0.00000
HEATFLOW 1062.44
VOLUME 0.725942E-04
7.8.5. Pipe With Triangular Longitudinal Fins
The inner tube of a tube-in tube counter flow heat exchanger with longitudinal fins of
triangular cross section is analyzed.
Specifications
Pipe length 5cm
Inside diameter 6cm
Fin type Longitudinal fins, triangular cross section

108

Number of fins-40
Fin height-15mm
Fin thickness-0.9mm
Loading
2
K
0
Celsius
Convection on the outside surface with Film Coefficient = 268.13
W/m
2
K
0
Celsius
7.8.6. Results

I|gure 7.9. Contour p|ot of Noda| temperature

109

I|gure 7.10. Contour p|ot of 1herma| f|ux

I|gure 7.11. Vector p|ot of therma| f|ux

110

0.0000 88.717 52774. 0.88081E-01
0.97500E-03 87.866 51601. 0.54954E-01
0.19500E-02 87.022 50430. 0.24177E-01
0.29250E-02 86.189 61966. 0.47707E-04
0.39000E-02 84.998 0.12340E+06-0.24159E-02
0.48750E-02 82.626 0.17467E+06-0.35495E-02
0.58500E-02 79.331 0.17290E+06-0.11868E-01
0.68250E-02 76.213 0.17856E+06-0.20279E-01
0.78000E-02 73.295 0.17452E+06-0.19466E-01
0.87750E-02 70.524 0.16539E+06-0.29327E-01
0.97500E-02 67.905 0.15633E+06-0.37053E-01
0.10725E-01 65.436 0.14727E+06-0.37315E-01
0.11700E-01 63.117 0.13808E+06-0.46430E-01
0.12675E-01 60.941 0.13012E+06-0.47067E-01
0.13650E-01 58.890 0.12248E+06-0.42218E-01

111

0.14625E-01 56.964 0.11484E+06-0.33039E-01
0.15600E-01 55.162 0.10723E+06-0.24990E-01
0.16575E-01 53.484 99754. -0.16915E-01
0.17550E-01 51.912 93384. -0.10818E-01
0.18525E-01 50.445 87015. -0.80580E-02
0.19500E-01 49.081 80646. -0.86362E-02


112

I|gure 7.13. neat f|ow vs kad|a| d|stance

I|gure 7.14. 1emperature vs kad|a| d|stance

113

TABLE LABEL TOTAL
HEAT1 88.0925
HEAT2 102.742
HEAT3 696.007
HEAT4 0.00000
HEAT5 99.8752
HEAT6 0.00000
HEATFLOW 986.717
VOLUME 0.590911E-04
7.9. DISCUSSION
7.9.1. Pipe Without Fins
In the contour plot of nodal temperature , we find that as we proceed towads the
periphery of the pipe from the inside, there is a linear drop in temperature as is evident
from the temperature vs radial distance plot.The contour plot of Thermal flux as well as
Thermal gradient also show similar variation .The vector plot of thermal flux shows
that the thermal flux is directed radially outwards whereas thermal gradient vectors are
directed towards the inside.From the plot of Heatflow vs the radial distance , it is

114

found that heatflow is directed into the elements for the initial part of the radius, but as
we proceed outwards, the heat flow changes sign meaning that heat flow is directed
outwards.
7.9.2. Rectangular Finned Pipe
The contour plot of nodal temperature shows the variation of temperature in the finned
pipe.It is found that there is very little temperature drop in the pipe thickness and the
major drop is confined to the fins. Apart from that , the drop in temperature is
substantial as compared to an unfinned pipe of the same dimensions.The contour plot
of thermal flux is completely different from the temperature plot n this case. We find
that maximum thermal flux is found at the bottom parts of the fin . This can be
attributed to the sudden reduction in area of heat flow.The thermal gradient plot is
almost similar to the plot of flux.From the vecto plot of thermal flux, it is evident that
most of the flux lines are confined to the fins and very little heat flux is present in the
unfinned region between the fins.The thermal gradient vectors are directed towards the
inside as expected. The plot of temperature vs radial distance shows that the variation
in temperature is no longer linear but follows a curve. The plot of flux shows that the
maximum flux is present at the lower regions of the fins and it decreases as we move to
the top of the fin.Heat flow is found tobe positive initially and becomes negative as we
reach the fins because the heat starts to flow out of the elements and into the
surrounding fluid due of the presence of fins.
7.9.3. Pipe With Triangular Fins
The variation in temperature follows a curve similar to that of a rectangular finned case.
The flux is found to remain almost constant in the fins owing to the reduction in cross

113

sectional area towards the periphery. The vector plots in this case are similar to that of
the rectangular fins, but for the fact that they are closer together in the fins due to the
pointed shape.The heat flow is also identical to the rectangular case.
7.10. COMPARISON OF RESULTS
The sum of element table results for each case is given below-
1ab|e 7.2. Compar|son Var|ous Mode| Ana|ys|s kesu|ts
Rectangular fins Pipe (no fins) Triangular fins
TABLE LABEL TOTAL TOTAL TOTAL
HEAT1 106.352 23.2804 88.0925
HEAT2 124.293 29.3213 102.742
HEAT3 745.511 34.9446 696.007
HEAT4 0.00000 0.00000 0.00000
HEAT5 86.2822 21.5256 99.8752
HEAT6 0.00000 0.00000 0.00000
HEATFLOW 1062.44 109.072 986.717
VOLUME 0.725942E-04 0.455926E-04 0.590911E-04

We find that maximum heat flow for a given length of pipe and a given fin height is
obtained in case of rectangular cross section fins. Heat flow in the case of triangular
fins is comparable to that of rectangular fins. Compared to a bare pipe, the heatflow is

116

found to increase many times .This can be attributed to the increase in surface area of
heat transfer.
It is found that the use of triangular fins reduces the volume of material used by a
substantial amount without appreciable change in the heat transferred. As a result a
triangular fin provides the added advantage of reduced material as compared to
rectangular fins without much change in heat transfer. This is due to the fact that as we
move towards the top of a rectangular fin , the heat flux is found to decrease. This
means that the fin cross section towards the tip of the fin is not effectively utilized as
compared to the bottom part of the fin. To account for this, the cross sectional area is
reduced towards the periphery to obtain a triangular fin .A fin of parabolic profile can
also be used, but triangular profile is preferred owing to the ease of manufacture and
the cost involved.

117

CHAPTER 8: CONCLUSION
With the help of the Optimization Program and ANSYS software we have been able to
conclude that as the Fin height increases the rate of increase of Heat Transfer
Decreases. Moreover increasing the fin height does not necessarily result in an increase
in heat transfer. There is an optimum value of fin height above which further increase
in height does not aid the heat transfer process considerably. With the help of the C++
program we have been able to successfully determine this value of optimum fin height
for particular input conditions and fin thickness. We also obtained substantial increase
in the values of heat transfer coefficients and effectiveness of a heat exchanger when
fins were provided. This also demonstrates the fact that Fins provide a thermodynamic
advantage. Thereby designing a heat exchanger at the optimum fin height can lead to
reducing capital costs and increasing savings. Also providing cheap materials for the
fin and expensive durable materials for thinner pipes can increase Heat Exchanger Life
span and save capital costs as well. If outlet conditions are provided and fins are also
created then by virtue of the fins we can decrease the length of the heat exchanger thus
save material. Using triangular fins we can save more material and obtain heat transfer
close to that of rectangular fins.
Use of parabolic fins in heat exchangers can be analyzed in the future. In this analysis
we have considered fluid properties at bulk mean temperature, modeling in FLUENT
can assist in the design and analysis in transient conditions which will provide a
bonafide report on the advantages of fins and design of heat exchangers.

118

APPENDIX A: C++ PROGRAM CODE FOR THE
OPTIMIZATION OF FIN HEIGHT
// FINAL YEAR PROJECT DONE BY ALPHIN C. TOM, ARJUN RAMANATHAN & ARUN
KRISHNAN
//*****************************************************************************//
// DEPARTMENT OF MECHANICAL ENGINEERING
// COLLEGE OF ENGINEERING, TRIVANDRUM
//-----------------------------------------------------------------------------//
// OPTIMISATION AND ANALYSIS OF
// LONGITUDINALLY FINNED DOUBLE PIPE HEAT EXCHANGER
//-----------------------------------------------------------------------------//

#include <iostream.h>
#include <stdio.h>
#include <process.h>
#include <stdlib.h>
#include <conio.h>
#include <graphics.h>
#include <math.h>
#define pi 3.14

void main()
{
clrscr();
long double
inID,inOD,outID,length,fin_h,de,dh,Rei,Reo,Nui,Nuo,Uo[500],Ufs,m,fin_t,NFA,WetP,NFAi,kw,Af,Ab,
Atot[500],Ro,ho,hi,Ri,Rw;
int noffins;
char ch;
long double mh,mc,cpc,cph;
long double etaf,etaf1;

119

long double dens_o,dens_i,ko,ki,Pri,Pro,iflmeanvel,ikinvisco,oflmeanvel,okinvisco;
long double
Ao,Vol[500],NTU[500],eff[500],Heat[500],R,mC_min,mC_max,Thi,Tci,Tho[500],Tco[500];
textcolor(2);
clrscr();
gotoxy(32,5);cout<<"FINAL YEAR PROJECT";
gotoxy(24,18);cout<<"OPTIMISATION AND ANALYSIS OF";
gotoxy(15,20);cout<<"LONGITUDINALLY FINNED DOUBLE PIPE HEAT EXCHANGER";
gotoxy(13,16);cout<<"----------------------------------------------------";
gotoxy(13,22);cout<<"----------------------------------------------------";
cout<<"\n\n\n\n\t\t\t\t Done by";
cout<<"\n\n\n\t\t\t Alphin C. Tom S8M1 - 28106";
cout<<"\n\n\t\t\t Arjun Ramanathan S8M1 - 28110";
cout<<"\n\n\t\t\t Arun Krishnan S8M2 - 28210";
cout<<"\n\n\n\t\t\t\t Guided by";
cout<<"\n\n\t\t\t\t Dilip D.";
getch();
clrscr();
cout<<"\n\n\t\t\t\t ASSUMPTIONS";
cout<<"\n\t\t\t\t ---------------";
cout<<"\n\n\n\t\t1. Flow type is Counterflow";
cout<<"\n\n\t\t2. Hot fluid flows in the pipe (Inner Tube)";
cout<<"\n\n\t\t3. Cold fluid flows in the annulus (Outer Tube)";
cout<<"\n\n\t\t4. Heat transfer at the tip of fin is neglected";
getch();
MENU:
clrscr();
cout<<"\n\n\n\t Select the Mode of DATA Input";
cout<<"\n\t ---------------------------------";
cout<<"\n\n\n 1. Go with a SAMPLE PROBLEM";
cout<<"\n\n 2. Enter your own DATA";
cout<<"\n\n 3. Exit Program";

120

cout<<"\n\n\n Enter your choice : ";
cin>>ch;
switch(ch)
{
case '1': clrscr();
cout<<"\n\n\n\t SAMPLE PROBLEM DEFINITION : ";
cout<<"\n\t ---------------------------------";
cout<<"\n\n Hot Fluid is Water in the pipe";
cout<<"\n\n Cold Fluid is Ethylene Glycol in conterflow in the annulus";
cout<<"\n\n Geometric Values are : ";
cout<<"\n\n Pipe Inner Diameter = 6cm";inID=.06;
cout<<"\n\n Pipe Outer Diameter = 6.9cm";inOD=.069;
cout<<"\n\n Shell Inner Diameter = 11.7cm";outID=.117;
cout<<"\n\n Pipe Length = 114m";length=114.0;
cout<<"\n\n Fin Thickness = 0.9mm";fin_t=.0009;
cout<<"\n\n No. of Fins = 40";noffins=40;
cout<<"\n\n Massflow Rate of Water = 5kg/s";mh=5.0;
cout<<"\n\n Massflow Rate of Ethylene Glycol = 2kg/s";mc=2.0;
cout<<"\n\n Specific Heat of Water = 4205.5 J/kgK";cph=4205.5;
cout<<"\n\n Specific Heat of Ethylene Glycol = 2474 J/kgK";cpc=2474.0;
cout<<"\n\n\n\n Press any key to continue....";
getch();
clrscr();
Thi=95.0;
Tci=40.0;
cout<<"\n\n\n\t PROPERTIES OF WATER AT 95 degree celcius";
cout<<"\n\n Density = 967.5kg/m^3";dens_i=967.5;
cout<<"\n\n Kinematic Viscosity = .3285 x 10^-6 m^2/s";ikinvisco=.0000003285;
cout<<"\n\n Prandtl Number = 1.98";Pri=1.98;
cout<<"\n\n Thermal Conductivity = 0.675W/mK";ki=0.675;
cout<<"\n\n\n\t PROPERTIES OF ETHYLENE GLYCOL AT 40 degree celcius";

121

cout<<"\n\n Density = 1101kg/m^3";dens_o=1101.0;
cout<<"\n\n Kinematic Viscosity = 8.686 x 10^-6 m^2/s";okinvisco=.000008686;
cout<<"\n\n Prandtl Number = 93.00";Pro=93.00;
cout<<"\n\n Thermal Conductivity = .2559W/mK";ko=.2559;
break;
case '2': textcolor(7);
clrscr();
cout<<"\n\n\t\t\t THERMAL DESIGN DATA INPUT";
cout<<"\n\t\t\t ------------------------";
cout<<"\n\n\n Tube Inner Diameter (in m) = ";cin>>inID;
cout<<" \n Tube Outer Diameter (in m) = ";cin>>inOD;
cout<<" \n Shell Inner Diameter (in m) = ";cin>>outID;
cout<<" \n Total Length of the Pipe (in m) = ";cin>>length;
cout<<" \n Thickness of Fin (as per std) = 0.9 mm";fin_t=0.0009;
cout<<" \n\n No. of Fins (From Data Table) = ";
if (inOD>=.07)
noffins=48;
else
if (inOD>=0.06)
noffins=40;
else
if (inOD>=0.045)
noffins=36;
else
noffins=20;
cout<<noffins;
getch();
cout<<"\n\n\n Mass Flow Rate of the Hot Fluid (kg/s) = ";cin>>mh;
cout<<" \n Mass Flow Rate of th Cold Fluid (kg/s) = ";cin>>mc;
cout<<" \n\n Inlet Temp. of Hot Fluid (degree C) = ";cin>>Thi;
cout<<" \n Inlet Temp. of Cold Fluid (degree C) = ";cin>>Tci;

122

clrscr();
cout<<"\n\t\t\t FLUID PROPERTIES INPUT";
cout<<"\n\t\t\t --------------------------";
cout<<"\n\n Cold/Outer Fluid Properties at "<<Tci<<" degree celcius";
cout<<"\n---------------------------------------------------------------";
cout<<"\n\n Density (kg/m^3) : ";
cin>>dens_o;
cout<<"\n Kinematic Viscosity (m^2/s) : ";
cin>>okinvisco;
cout<<"\n Prandtl Number : ";
cin>>Pro;
cout<<"\n Thermal Conductivity (W/mK) : ";
cin>>ko;
cout<<"\n Specific Heat (J/kgK) : ";
cin>>cpc;
cout<<"\n\n Hot/Inner Fluid Properties at "<<Thi<<" degree celcius";
cout<<"\n ------------------------------------------------------------";
cout<<"\n\n Density (kg/m^3) : ";
cin>>dens_i;
cout<<"\n Kinematic Viscosity (m^2/s) : ";
cin>>ikinvisco;
cout<<"\n Prandtl Number : ";
cin>>Pri;
cout<<"\n Thermal Conductivity (W/mK) : ";
cin>>ki;
cout<<"\n Specific Heat (J/kgK) : ";
cin>>cph;
break;
case '3': exit(1);
default : goto MENU;
}

123

getch();
textcolor(7);
clrscr();
cout<<"\n\n\n\n The Outer Surface Fouling Resistance, Ro = 0.0001 m^2K/W";
Ro=0.0001;
cout<<"\n\n The Inner Surface Fouling Resistance, Ri = 0.0001 m^2K/W";
Ri=0.0001;
cout<<"\n\n Thermal Conductivity of Wall, kw = 60 W/mK";
cout<<"\n\n\n Wall material is assumed to be 1% Chrome Steel";
kw=60.0;
getch();
if (mh*cph<mc*cpc)
{
mC_min=mh*cph;
mC_max=mc*cpc;
}
else
{
mC_min=mc*cpc;
mC_max=mh*cph;
}
clrscr();
cout<<"\n\n NO FIN CALCULATIONS";
cout<<"\n-----------------------";
NFA=(pi*outID*outID/4.000)-(pi*inOD*inOD/4.00); //Net Flow Area
WetP=pi*outID+pi*inOD; //Wetted Perimeter
dh=4.000*NFA/WetP; //Hydraulic Mean Diameter
de=4.000*NFA/(WetP-pi*outID); //Heat Transfer Mean Diameter
NFAi=(pi*inID*inID)/4; // Net Flow Area for inner pipe
oflmeanvel=mc/(NFA*dens_o); //Mean Flow Velocity in the annulus
Reo=oflmeanvel*dh/okinvisco; //Reynolds Number in the annulus

124

Nuo=0.023*pow(Reo,0.8)*pow(Pro,0.4); //Nusselt Number in the annulus --- Dittus-Boelter equation
for heating
ho=Nuo*ko/de; //Outer Surface Convection Heat Tranfer Coefficient
iflmeanvel=mh/(NFAi*dens_i); //Mean Flow Velocity in the pipe
Rei=iflmeanvel*inID/ikinvisco; //Reynolds Number in the pipe
Nui=0.023*pow(Rei,0.8)*pow(Pri,0.3);//Nusselt Number in the pipe --- Dittus-Boelter equation for
cooling
hi=Nui*ki/inID; //Inner Surface Convection Heat Tranfer Coefficient
cout<<"\n\n Outer Surface Convection Heat Transfer Coefficient : ";
cout<<"\n\n\t ho = "<<ho<<" W/m^2K";
cout<<"\n\n Inner Surface Convection Heat Transfer Coefficient : ";
cout<<"\n\n\t hi = "<<hi<<" W/m^2K";
getch();
Ufs=1.000/(Ro+(1.000/ho)); //Outer surface convection with fouling
Atot[0]=Ao=pi*inOD*length; //Unfinned pipe outer surface area
Rw=(inOD*log(inOD/inID))/(2.000*kw); // Wall thermal resistance
Uo[0]=1.000/((1.000/Ufs)+Rw+(Ri+(1/hi))*(Ao/(pi*inID*length)));//Overall Heat Transfer Coefficient
NTU[0]=(Uo[0]*Ao)/mC_min; //Number of Transfer Units
Vol[0]=length*(pi*(inOD*inOD-inID*inID)/4); //Volume of the pipe material required
R=mC_min/mC_max; // ratio of specific heats
eff[0]=(1.000-exp(-NTU[0]*(1.000-R)))/(1.000-R*exp(-NTU[0]*(1.000-R)));//heat exchanger
effectiveness
Heat[0]=eff[0]*(mC_min*(Thi-Tci)); // Net Heat Transfer
Tho[0]=Thi-(Heat[0]/(mh*cph)); // Hot Fluid Outlet Temp.
Tco[0]=Tci+(Heat[0]/(mc*cpc)); // Cold Fluid Outlet Temp.
cout<<"\n\n\n\n NTU = "<<NTU[0]<<"\n\n Net Heat Transfer Area, Atot = "<<Atot[0]<<"
m^2"<<"\n\n Heat Exchanger Effectiveness = "<<eff[0]<<"\n\n Net Heat Transfer = "<<Heat[0]<<" W";
cout<<"\n\n Hot Inlet Temp = "<<Thi<<"\t Hot Outlet Temp = "<<Tho[0]<<"\n\n Cold Inlet Temp =
"<<Tci<<"\t Cold Outlet Temp = "<<Tco[0]<<"\n\n\n Overall Heat Transfer Coefficient, Uo =
"<<Uo[0];
getch();
fin_h=0.001;
clrscr();
for (int i=2;(2.000*fin_h+inOD)<=outID;i++)

123

{
clrscr();
cout<<"\n\n\n Step No. "<<i-1;
cout<<"\n\n Fin Height = "<<fin_h*1000<<" mm";
// FLUID FLOW CALCULATIONS
NFA=(pi*outID*outID/4.000)-((pi*inOD*inOD/4.00)+noffins*fin_h*fin_t); //Net Flow Area
WetP=pi*outID+pi*inOD+2.00*noffins*fin_h-noffins*fin_t; //Wetted Perimeter
dh=4.000*NFA/WetP; //Hydraulic Mean Diameter
de=4.000*NFA/(WetP-pi*outID); //Heat Transfer Mean Diameter
NFAi=(pi*inID*inID)/4; // Net Flow Area for inner pipe
oflmeanvel=mc/(NFA*dens_o); //Mean Flow Velocity in the annulus
Reo=oflmeanvel*dh/okinvisco; //Reynolds Number in the annulus
Nuo=0.023*pow(Reo,0.8)*pow(Pro,0.4); //Nusselt Number in the annulus --- Dittus-Boelter equation
for heating
ho=Nuo*ko/de; //Outer Surface Convection Heat Tranfer Coefficient
iflmeanvel=mh/(NFAi*dens_i); //Mean Flow Velocity in the pipe
Rei=iflmeanvel*inID/ikinvisco; //Reynolds Number in the pipe
Nui=0.023*pow(Rei,0.8)*pow(Pri,0.3);//Nusselt Number in the pipe --- Dittus-Boelter equation for
cooling
hi=Nui*ki/inID; //Inner Surface Convection Heat Tranfer Coefficient
cout<<"\n\n Outer Surface Convection Heat Transfer Coefficient : ";
cout<<"\n\n\t ho = "<<ho<<" W/m^2K";
cout<<"\n\n Inner Surface Convection Heat Transfer Coefficient : ";
cout<<"\n\n\t hi = "<<hi<<" W/m^2K";
// HEAT TRANSFER CALCULATIONS
Ufs=1.000/(Ro+(1.000/ho)); //Outer surface convection with fouling
m=sqrt((Ufs*2.000)/(fin_t*kw));
etaf=(tanh(m*fin_h))/(m*fin_h); //Fin eficiency
Af=2.000*noffins*length*fin_h; //Fin Surface Area
Ab=length*(pi*inOD-noffins*fin_t); //Base Area
Atot[i-1]=Af+Ab; //Net Outer Surface Area
etaf1=(Af*etaf+Ab)/Atot[i-1]; //Net fin efficiency of the outer surface

126

Ao=pi*inOD*length; //Unfinned pipe outer surface area
Rw=(inOD*log(inOD/inID))/(2.000*kw); // Wall thermal resistance
Uo[i-1]=1.000/((1.000/(Ufs*etaf1))+Rw*(Atot[i-1]/Ao)+(Ri+(1/hi))*(Atot[i-
1]/(pi*inID*length)));//Overall Heat Transfer Coefficient
NTU[i-1]=(Uo[i-1]*Atot[i-1])/mC_min; //Number of Transfer Units
Vol[i-1]=length*(pi*(inOD*inOD-inID*inID)/4+fin_h*fin_t*noffins); //Volume of the pipe material
required
R=mC_min/mC_max; // ratio of specific heats
eff[i-1]=(1.000-exp(-NTU[i-1]*(1.000-R)))/(1.000-R*exp(-NTU[i-1]*(1.000-R)));//heat exchanger
effectiveness
Heat[i-1]=eff[i-1]*(mC_min*(Thi-Tci)); // Net Heat Transfer
Tho[i-1]=Thi-(Heat[i-1]/(mh*cph)); // Hot Fluid Outlet Temp.
Tco[i-1]=Tci+(Heat[i-1]/(mc*cpc)); // Cold Fluid Outlet Temp.
// DISPLAY RESULTS
cout<<"\n\n\n\n NTU = "<<NTU[i-1]<<"\n\n Net Heat Transfer Area, Atot = "<<Atot[i-1]<<"
m^2"<<"\n\n Heat Exchanger Effectiveness = "<<eff[i-1]<<"\n\n Net Heat Transfer = "<<Heat[i-1]<<"
W";
cout<<"\n\n Hot Inlet Temp = "<<Thi<<"\t Hot Outlet Temp = "<<Tho[i-1]<<"\n\n Cold Inlet Temp =
"<<Tci<<"\t Cold Outlet Temp = "<<Tco[i-1]<<"\n\n\n Overall Heat Transfer Coefficient, Uo =
"<<Uo[i-1];
getch();
fin_h=fin_h+.001; // Fin Height Incrementation
} // END OF LOOP
clrscr();
// TABLE OF VALUES OBTAINED AT VARIOUS FIN HEIGHTS

gotoxy(1,1);cout<<"No";gotoxy(5,1);cout<<"FinHt";gotoxy(12,1);cout<<"Atot";gotoxy(21,1);cout<<"U
o";

gotoxy(32,1);cout<<"Eff..";gotoxy(42,1);cout<<"Heat";gotoxy(60,1);cout<<"Tho";gotoxy(70,1);cout<<"
Tco";

gotoxy(1,2);cout<<"********************************************************************
***********";
int yp;
for(int k=1;k<i;k++)
{

127

if (!(k%40))
{
getch();
clrscr();

gotoxy(1,1);cout<<"No";gotoxy(5,1);cout<<"FinHt";gotoxy(12,1);cout<<"Atot";gotoxy(21,1);cout<<"U
o";

gotoxy(32,1);cout<<"Eff..";gotoxy(42,1);cout<<"Heat";gotoxy(60,1);cout<<"Tho";gotoxy(70,1);cout<<"
Tco";

gotoxy(1,2);cout<<"********************************************************************
***********";
}
if(k>=40)
yp=k-37;
else
yp=k+2;
gotoxy(1,yp);cout<<k;gotoxy(5,yp);cout<<.001*(k-1);gotoxy(12,yp);cout<<Atot[k-
1];gotoxy(21,yp);cout<<Uo[k-1];
gotoxy(32,yp);cout<<eff[k-1];gotoxy(42,yp);cout<<Heat[k-1];gotoxy(60,yp);cout<<Tho[k-
1];gotoxy(70,yp);cout<<Tco[k-1];
}
getch();
// GRAPH PLOTTING
// Plot a graph of Fin Height in mm versus the Heat Exchanger Effectiveness
/* request auto detection */
int gdriver = DETECT, gmode, errorcode;
/* initialize graphics mode */
initgraph(&gdriver, &gmode, "..\\bgi");
/* read result of initialization */
errorcode = graphresult();
if (errorcode != grOk) /* an error occurred */
{
printf("Graphics error: %s\n", grapherrormsg(errorcode));

128

printf("Press any key to halt:");
getch();
exit(1); /* return with error code */
}
int ii,scale=500;
if(eff[i-2]*500>getmaxy()-30)
scale=300;
cleardevice();
setcolor(getmaxcolor()-1);
setfillstyle(SOLID_FILL, getmaxcolor()-4);
line(15, 15, 15, getmaxy()-15);
line(15,getmaxy()-15,getmaxx()-15,getmaxy()-15);
line(15,15,getmaxx()-15,15);
line(getmaxx()-15,15,getmaxx()-15,getmaxy()-15);
// X-AXIS PLOTTING
for (k=0;k<15;k++)
{
fillellipse(15+k*40, getmaxy()-15, 2,2);
}
// Y-AXIS PLOTTING
for (k=1;k<=10;k++)
{
fillellipse(15,getmaxy()-15-k*scale/10, 2,2);
}
settextstyle(0,0,1);
outtextxy(100,getmaxy()-10,"Fin Height in mm (5mm per Division) -->");
outtextxy(10,50,"Effectiveness % (10% per Division) -->");
int x1=15,y1=getmaxy()-15,x2,y2;
getch();
// Plotting the Points and the conneting lines

129

for (ii=0;ii<i-1;ii++)
{
setcolor(5);
fillellipse(x1, y1, 3,3);
x2=15+(ii)*8;
y2=(getmaxy()-15)-int(eff[ii]*scale);
line(x1,y1,x2,y2);
getch();
x1=x2;
y1=y2;
}
setcolor(9);
line(x2,y2,15,y2);
getch();
double perc;

// To find the optimum fin height
k=i-2;
for(ii=0;ii<i-1;ii++)
{
perc=(eff[ii+1]*100.0-eff[ii]*100.0)/(eff[ii]*100.0)*100.0;
if(perc<=0.3) // Percentage increase in Eff. less than 0.3%
{
k=ii;
break;
}
}
int opt=k;
setcolor(7);
// PLOT THE OPTIMUM POINT

130

line(15+k*8,y2,15+k*8,getmaxy()-15);
getch();
setcolor(10);
line(15+k*8,(getmaxy()-15)-int(eff[k]*scale),15,(getmaxy()-15)-int(eff[k]*scale));
getch();
//Percentage increase in volume and Percentage increase in Heat are plotted against fin height
cleardevice();
setcolor(getmaxcolor()-1);
line(15, 15, 15, getmaxy()-15); //Left Vertical
line(15,getmaxy()-15,getmaxx()-15,getmaxy()-15); //Bottom Horizontal
line(15,15,getmaxx()-15,15); //Top Horizontal
line(getmaxx()-15,15,getmaxx()-15,getmaxy()-15); //Right Vertical
// X-AXIS DIVISION PLOTTING
for (k=0;k<15;k++)
{
fillellipse(15+k*50, getmaxy()-15, 2,2);
}
// Y-AXIS DIVISION PLOTTING
for (k=1;k<=10;k++)
{
fillellipse(15,getmaxy()-15-k*80, 2,2);
}
outtextxy(100,getmaxy()-10,"Fin Height in mm (5mm per Division) -->");
outtextxy(10,10,"Percentage Increase in Vol & Heat % (10% per Division) -->");
long double percVol,percHeat;
int ya1,yb1,ya2,yb2;
x1=15,ya1=getmaxy()-15,yb1=getmaxy()-15;
for (k=1;k<(i-1);k++)

131

{
getch();
percVol=(Vol[k]-Vol[k-1])/Vol[k-1]*100;
percHeat=(Heat[k]-Heat[k-1])/Heat[k-1]*100;
setcolor(5);
fillellipse(x1, ya1, 3,3);
fillellipse(x1, yb1, 3,3);
x2=15+k*10;
ya2=(getmaxy()-15)-int(percVol*8.00);
yb2=(getmaxy()-15)-int(percHeat*8.00);
line(x1,ya1,x2,ya2);
setcolor(6);
line(x1,yb1,x2,yb2);
x1=x2;
ya1=ya2;
yb1=yb2;
}
getch();
cleardevice();
getch();
/* clean up */
closegraph();
clrscr();
// RESULTS AND CONCLUSIONS
cout<<"\n RESULTS AND CONCLUSIONS";
cout<<"\n---------------------------";
cout<<"\n Graph 1. The effectiveness is found to be increasing as the fin height increases. But beyond
a point it becomes almost constant.";
cout<<"\n Graph 2. ";
cout<<"\n\n The optimum value of the fin height obtained from the graphs is : "<<opt<<" mm";

132

cout<<"\n\n Corresponding Net Heat Transfer Rate is "<<Heat[opt]<<" W";
cout<<"\n\n Heat Exchanger Effectiveness is "<<eff[opt]*100<<" %";
cout<<"\n\n Percentage increase in Heat Transfer Rate from unfinned pipe is "<<(Heat[opt]-
Heat[0])/Heat[opt]*100<<" %";
cout<<"\n\n Percentage increase in Volume when fins are added = "<<(Vol[opt]-
Vol[0])/Vol[opt]*100<<" %";
getch();
clrscr();
goto MENU;
}

133

REFERENCES
1. Wang, C.C., Lee, W.S., Sheu, W.J., 2001, A comparative study of compact
enhanced fin-and-tube heat exchangers, International Journal of Heat and Mass
transfer, vol. 44: p.3565-3573.
2. Du, Y.J., Wang, C.C., 2000, An experimental study of the air-side performance of
the superslit fin-and-tube heat exchangers, International Journal of Heat and Mass
Transfer, vol. 43: p.4475-4482.
3. Kim, N.H., Youn, B., Webb, R.L., 1999, Air side heat transfer and friction
correlations for plain fin-and-tube heat exchangers with staggered tube arrangements,
ASME Transaction, vol.121, august 1999.
4. Wang, C.C., Webb, R.L., Chi, K.Y., 2000, Data reduction for air-side performance
of fin-and-tube heat exchangers, Experimental Thermal and Fluid Science, vol. 21:
p.218-226.
5. Creed Taylor, December 2004 ,Measurement Of Finned-Tube Heat Exchanger
Performance. P 9-23.
6. Jeffrey Siegel and Van P. Carey, September 2001, Fouling of HVAC Fin and Tube
Heat Exchangers,p 1-4.
7. Sarit.K.Das, Process Heat Transfer, Alpha Science Intl Ltd, p 89-230
8. Adrian Bejan , Allan D. Kraus Heat Transfer Handbook, Wiley, New York, 2003.
9. Stephen Schneider, December 2000, Water Heat exchanger Optimisation for Space
Flight Applications. University of Colorado.
10. Wolverine Tube Heat Transfer Data Book, www.wlv.com/products/databook/.
11. Latif.M.Jiji, 2006, Heat Convection. Springer; 1 edition, P293-343.
12.Hans.Dieter Baehr, Karls Stephan, Heat and Mass Transfer, 2
nd
Edition, Berlin:
Springer 2006.
13. T.Kuppan, Heat Exchanger Design Handbook, Marcel Dekker 2003. P 1-158.
14. http://en.wikipedia.org/wiki/Heat_exchanger.
15. http://en.wikipedia.org/wiki/Heat_transfer_coefficient.
16. google.com/heat exchangers :pdf

Optimization and Analysis of Tube-In-tube Heat Exchanger With Fins-Libre

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Optimization and Analysis of Tube-In-tube Heat Exchanger With Fins-Libre

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OPTIMIZATION AND ANALYSIS OF

TUBE-IN-TUBE HEAT EXCHANGER WITH FINS

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