THERMAL ANALYSIS OF DOUBLE PIPE HEAT EXCHANGER USING CFD

21
International Journal of Research and Innovation (IJRI)
THERMAL ANALYSIS OF DOUBLE PIPE HEAT EXCHANGER USING CFD
Lakamana Satyabhaskar1
, K.koteswara Rao2
,Y Dhana Shekar3
1 Research Scholar,Department Of Thermal Engineering, Kits, Peddapuram(M) Tirupathi Village, Divili 533-433,Eg Dt,AP, India.
2 Associate Professor,Department Of Thermal Engineering, Kits, Peddapuram(M) Tirupathi Village, Divili 533-433,Eg Dt,AP, India.
3 Assistant Professor , Department Of Thermal Engineering, Kits, Peddapuram(M) Tirupathi Village, Divili 533-433,Eg Dt,AP, India.
*Corresponding Author:
Lakamana Satyabhaskar
Research Scholar,Department Of Thermal Engineering, Kits,
Peddapuram(M) Tirupathi Village, Divili 533-433,Eg Dt,
Andhra Pradesh, India.
Published: January 02, 2015
Review Type: peer reviewed
Volume: II, Issue : I
Citation: Lakamana Satyabhaskar, Thermal Analysis Of
Double Pipe Heat Exchanger Using CFD
INTRODUCTION
A heat exchanger is a device that is used to transfer
thermal energy (enthalpy) between two or more flu-
ids, between a solid surface and a fluid, or between
solid particulates and a fluid, at different tempera-
tures and in thermal contact. In heat exchangers,
there are usually no external heat and work inter-
actions.
Typical applications involve heating or cooling of
a fluid stream and evaporation or condensation of
single- or multicomponent fluid streams. In other
applications, the objective may be to recover or re-
ject heat, or sterilize, pasteurize, fractionate, distill,
concentrate, crystallize, or control a process fluid.
In a few heat exchangers, the fluids exchanging
heat are in direct contact.
In most heat exchangers, heat transfer between flu-
ids takes place through a separating wall or into
and out of a wall in a transient manner. In many
heat exchangers, the fluids are separated by a heat
transfer surface, and ideally they do not mix or leak.
Such exchangers are referred to as direct transfer
type, or simply recuperators. In contrast, exchang-
ers in which there is intermittent heat exchange be-
tween the hot and cold fluids—via thermal energy
storage and release through the exchanger surface
or matrix are referred to as indirect transfer type, or
simply regenerators. Such exchangers usually have
fluid leakage from one fluid stream to the other due
to pressure differences and matrix rotation/valve
switching.
Classifications of heat exchangers:
There are a number exchanger types based on the
type of flow configuration, method of heat transfer
and constructional features. The process designer
has to select the best suitable type that meets the
performance and operational requirements. Follow-
ing is the list of heat transfer equipment.
Based on Principles of Operation (Transfer pro-
cess):
Recuperative Type (Direct Transfer):
Cold and hot fluids flow simultaneously. Heat is
transferred through a wall separating the fluids. Eg:
Steam boilers, Heaters, Condensers etc.
Regenerative type (Storage):
One and the same heating surface is alternatively
exposed to the cold and hot fluids. Heat carried by
the hot fluid is taken away and stored in the walls
of the apparatus and then transferred to the cold
fluid Eg: Open hearth and glass melting furnaces,
Air heaters of blast furnaces.
Abstract
Heat transfer equipment is defined by the function it fulfills in a process. On the similar path, Heat exchangers are
the equipment used in industrial processes to recover heat between two process fluids. They are widely used in space
heating, refrigeration, air conditioning, power plants, chemical plants, petrochemical plants, petroleum refineries, and
natural gas processing. The operating efficiency of these exchangers plays a very key role in the overall running cost
of a plant. So the designers are on a trend of developing heat exchangers which are highly efficient, compact, and cost
effective.
A common problem in industries is to extract maximum heat from a utility stream coming out of a particular process,
and to heat a process stream. Therefore the objective of present work involves study of refinery process and applies
phenomena of heat transfer to a double pipe heat exchanger.
1401-1402

22
Fluidized Bed Type:
It is a direct transfer type used to transfer heat
between a fluid and finally divided particles of a sold
material Eg: used in chemical industry, Coal fired
boilers for waste heat recovery.
Based on Fluid Flow Arrangement:
Counter flow:
Parallel flow:
Cross Flow:
Single Pass Shell and Tube:
The tube bundle, or stack, is inserted inside the
shell. Tube sheets hold the tubes in place and form
a barrier to prevent the tube-side fluid from mixing
with the shell-side fluid. A series of baffles directs
the flow of cooling fluid back and forth across the
tube bundle.
Based on Method of Heat Transfer and Construc-
tional Features
Shell and Tube Heat Exchanger:
Fixed tube heat exchanger
U- tube exchanger
Floating head exchanger
Single Tube Heat Exchanger:
Double pipe exchanger
Trombone cooler
Coils in vessel
Parallel Plate Heat Exchanger:
Gasketed Plate exchanger
Spiral plate exchanger
Lamella exchanger
Plate evaporator.
External Heating Type:
Jacketed Vessel
Steam Tracing
Heat Transfer without Surfaces:
Flash evaporation
Direct contact condensers
Cooling towers
Heat transfer fluids
Direct heating
Direct use of steam
Submerged combustion
Extended Surfaces:
Air cooled exchanger
Plate fin exchanger
Tank heating with finned tubes
Solids heating with a bank of longitudinally finned
tubes.
Air heater
Based on application:
Condenser, Cooler, Chiller, Evaporator, Vaporizer,
Recoiled heater, Waste heat boiler etc.
Special Types:
Scrubber condenser
Froth- cooled heat exchanger
Plastic tube exchanger
Carbon block exchanger
Scrapped surface exchanger
Materials And Manufacturing Process
The selection of materials of construction is a very
important aspect to be considered before undertak-
ing the design of heat exchangers. In each individu-
al case, the choice of proper material shall be made,
bearing in mind the specific requirements which are
normally as follows:
1. Mechanical resistance i.e. strength and sufficient
toughness at operating temperatures.
2. Chemical resistance under operating conditions
with regard to corrosive media, concentration, tem-
perature, foreign substances, flow behavior etc. the
rate of corrosion must be negligible over a prolonged
period of time and the material must be resistant
against other corrosion phenomenon.
3. No detrimental interference by the material on
the process or on the products.
4. Easy supply of material within time permitted
and in the time required.
5. Good workability.
6. Lowest possible costs.
Descriptions of some of the material and their
specifications:
SA20 : Specification for general requirements for
steel plates for pressure vessels.
SA480: Specification for general requirements for
delivery of flat rolled stainless Steel, stainless and
heat resisting steel plates, sheet and strip.
SA530: Specification general requirements for spe-
cialized carbon and alloy steel pipe.
SA450: Specification for general requirements for
carbon, feritic alloy and austenitic alloys steel tubes.
SA203: Nickel alloy steel plated for pressure vessels.
SA204: Molybdenum alloys steel plates for pressure
vessels.
SA240: Chromium and Chromium nickel, stainless
steel plates, sheet and strip for fusion welded un-
fired pressure vessels.
SA264: Stainless, Chromium, Nickel steel, clad
plate, sheet and strip.
SA285: Low and intermediate tensile strength car-
bon steel plates for pressure vessels.
SA299: Carbon manganese, Silicon steel plates for
pressure vessels.
SA575: Carbon Steel plates for pressure vessels for
intermediate and high temp Service
SA577: High strength alloy steel plates, quenched

23
and tempered for pressure Vessels
SA537: Carbon magnesia, silicon steel plates, heat
treated for pressure vessels.
SA105: Forgings, carbon steel for piping compo-
nents.
SA181: Forgings carbon steel for general purpose
piping.
SA182: Forged or rolled alloy steel pipe flanges,
forged fittings and valves.
SA234: Pipe fitting of wrought carbon steel and al-
loy to moderate and elevated temperature services.
SA350: Forgings, Carbon and low alloy steel requir-
ing notch toughness, testing for piping components.
SA420: Pipe fittings of wrought carbon and alloy
steels for low temperature service
SA336: Alloy steel forgings for seamless drum heads
and other pressure vessels
SA106: Seamless carbon steel pipe for high temper-
ature service (343ºC to 427ºC)
SA312: Seamless and welded austenitic stainless
steel pipe.
SA333: Seamless and welded steel pipe for low tem-
perature eservice.
Problem description
The present work is based on industrial require-
ment. In the petroleum refinery, after distillation,
different grades of oil come out at different high
temperature which comes in to a pump and sup-
plied at required level. The aim is to design a double
pipe heat exchanger for an already existing suction
pool of pump in which hot hydrocarbons are pass-
ing after distillation. The heat recovered from high
temperature hydrocarbons is utilized to increase
the temperature of crude oil up to required limit.
The pool data, drawings, temperature of hydrocar-
bon and required temperature rise of crude oil were
given by industry.
Refinery Process Description
Introduction:
Every refinery begins with the separation of
crude oil into different fractions by distillation. The
fractions are further treated to convert them into
mixtures of more useful saleable products by vari-
ous methods such as cracking, reforming, alkyla-
tion, polymerization and isomerization. These mix-
tures of new compounds are then separated using
methods such as fractionation and solvent extrac-
tion. Impurities are removed by various methods,
e.G. Dehydration, desalting, sulphur removal and
hydrotreating. Refinery processes have developed in
response to changing market demands for certain
products. With the advent of the internal combus-
tion engine, the main task of refineries became the
production of petrol.
Distillation is the first step in the processing of crude
oil and it takes place in a tall steel tower called a
fractionation column. The inside of the column is
divided at intervals by horizontal trays. The column
is kept very hot at the bottom (the column is insu-
lated) but as different hydrocarbons boil at different
temperatures, the temperature gradually reduces
towards the top, so that each tray is a little cooler
than the one below.
The crude needs to be heated up before entering the
fractionation column and this is done at first in a
series of heat exchangers where heat is taken from
other process streams which require cooling be-
fore being sent to rundown. Heat is also exchanged
against condensing streams from the main column.
Typically, the crude will be heated up in this way up
to a temperature of 200 - 280 0C, before entering a
furnace.
As the raw crude oil arriving contains quite
a bit of water and salt, it is normally sent for salt
removing first, in a piece of equipment called a de-
salter. Upstream the desalter, the crude is mixed
with a water stream, typically about 4 - 6% on feed.
Intense mixing takes place over a mixing valve and
(optionally) as static mixer. The desalter, a large liq-
uid full vessel, uses an electric field to separate the
crude from the water droplets.
Distillation (Fractionation):
Because crude oil is a mixture of hydrocarbons with
different boiling temperatures, it can be separated
by distillation into groups of hydrocarbons that boil
between two specified boiling points. Two types of
distillation are performed: atmospheric and vacu-
um.
Design Aspects of Present Heat Exchanger
The thermal design is based upon a certain pro-
cess parameters, the thermal and physical proper-
ties of the process fluids and the basic governing
equations. Conventionally design method of heat
exchanger is largely based on the use of empiri-
cal equations as well as experimental data which
is available mostly in the form of graphs and chart.
Salient Features of Heat Exchanger
The heat exchanger considered for analysis here
has the following parameters.
Shell side.
Type of fluid: crude oil.
Inlet temperature =313K
Outlet temperature =553K.
Mass flow rate=0.320kg/s.
Diameter of shell=0.3m.

24
Tube side
Type of fluid: diesel oil.
Inlet temperature =618K
Outlet temperature =?.
Mass flow rate=145.6kg/s.
Specific gravity=0.874
Tube inside diameter =0.2027m.
Tube outside diameter=0.2191m
The properties of fluid are not available so with the
help of the specific gravity mentioned for the hot
fluid, obtained by API gravity equation 3.1. The
petroleum refining is a major industry, petroleum
products are an important fuel for power industry,
and petroleum derivates are starting point for many
syntheses in the chemical industry. Therefore given
common names or denoting the refinery operations
by which they were produced, and specific gravities
are defined by a scale established by the American
Petroleum Institute and termed either degrees API
or o
API. The o
API is related to the specific gravity by
After obtaining API gravity from table hot fluid is
identified as diesel. As cold fluid is crude oil.
Design of double pipe heat exchanger:
Thermal design calculations
For this the following data are required
Hot side(tube side)
Inlet temperature Thi
=618 K
Outlet temperature Tho
=?
Mass flow rate Mh
=145.6kg/s
Specific heat Cph
=3277.3J/kg K
Density =874kg/m3
Thermal conductivity k=0.1107 w/m K
Viscosity
-3 2
=4.5 10 Ns/m (or) pa-sµ ×
Thickness of fin t=0.002 m
Fin pitch s=0.142 m
Number of fins fN 34=
cold side(shell side)
Inlet temperature Tci
=313 K
Outlet temperature Tco
=553 K
Mass flow rate Mc
=0.320kg/s
Specific heat Cpc
=2491J/kg K
Density =698kg/m3
Thermal conductivity k=0.130 w/m K
Viscosity
-3 2
=0.75 10 Ns/m (or) pa-sµ ×
For counter flow LMTD
Flow area of fin
Consider as 10% fin cut so the area of cut is calcu-
lated by the following

25
Area of fin
Bare area (or) unfin area
Total fin area
Perimeter
Equivalent diameter
Velocity
Hence it is turbulent flow
Friction factor
Colburn factor
Prenatal number
Pressure drop
Geometry
The designed geometry under consideration in
this thesis is a double pipe heat exchanger type
or concentric tube heat exchanger with a circular
fins or baffles the domain is sub divided in to two
sections with a shell and tube channels. Figures
3.2 show schematic two-dimensional views of the
heat exchanger to be analyzed. This type of heat ex-
changer has been designed to recovery of heat from
hot source (hot fluid) which is flowing through the
tube and the shell side fluid is cold the flow is coun-
ter flow. The heat exchanger is one shell pass and
one tube pass based on these conditions the heat
exchanger is designed.

26
CFD ANALYSIS OF PLAIN TUBE
Heat exchanger without mesh
Heat Exchanger with mesh
Temperature variation on plane along the heat ex-
changer
Numerical Simulation Procedure
Results and Discussion
Over view
The present work involves the numerical analysis
of the heat exchanger with different materials with
varying fin thickness and by changing the mass flow
rates for cold fluid. Initially the simulation is car-
ried out with mass flow rate 0.320 Kg/s and shifted
to 0.220 And 0.120 Kg/s. The analysis was carried
out for steel, aluminum, and copper material for dif-
ferent thickness range of 0.002M to 0.005M in the
interval of 0.001M and the simulations and results
are discussed. These simulations are done as an
attempt for analysis of heat transfer and flow phe-
nomena in the shell side and tube side. The steady
state and unsteady simulations are done with inlet
conditions using turbulence model. The domain in
the present study is quite a complex 3-d geometry,
so it is quite diligent to present the flow physics in
the whole domain for discussion. The 2-d planes are
taken in the geometry for the discussion. The plane
and line along with the whole geometry and the co-
ordinate axes are shown in fig 6.1. The plane and
line are taken along the length of the heat exchang-
er in the x-y planes of constant z-coordinate. Plane
is taken in the centre of tubular section and a line
is at 0.220M from an outlet of the section. The de-
tails of fin materials along with different thickness
for comparison are presented in table 6.1.
Material/fin
thickness
Steel Aluminum Copper
t1
0.002 0.002 0.002
t2
0.003 0.003 0.003
t3
0.004 0.004 0.004
t4
0.005 0.005 0.005
Details of Comparative Study
The Plane and position of line in the flow domain.

27
Material Steel
Temperature variation on plane along the heat ex-
changer.
Temperature variation across Outlet for varying Fin
thickness
Material Aluminum
Temperature variations on plane along the heat ex-
changer
thickness.
Material copper.
Temperature variations on plane along the heat ex-
changer.
thickness.
Comparison of materials
Temperature variation on fin along the heat ex-
changer.
Variation of Heat Transfer with varying fin thick-
ness.
The above graph shows the relation between the
heat transfer and fin thickness with different ma-
terials. As the fin thickness increases the value of
heat transfer is increasing. For copper heat transfer
is maximum value when compared to other materi-
als and steel is having the least value of heat
Transfer.

28

29
(a) Varition of Friction factor with Reynolds number
(b) Varition of Heat Transfer Coefficient with Reyn-
olds number
Summary of results
Mass flow rates 0.320kg/s
Sr
no
Thick-
ness of
fin (m)
Tem-
perature
(k)
Pres-
sure
(Pascal)
Velocity
(m/s)
Heat trans-
fer (W)
1 0.002 526.65 37.65 0.14 167265.66
2 0.003 528.38 38 0.14 168600.05
3 0.004 529.72 38 0.14 169622.3
4 0.005 530.72 38 0.14 170435.08
Sr
no
Thick-
ness of
fin (m)
Tem-
perature
(k)
Pres-
sure
(Pascal)
Velocity
(m/s)
Heat trans-
fer (W)
1 0.002 538.39 37.7 0.14 176473.69
2 0.003 539.76 38 0.14 177524.04
3 0.004 540.55 38 0.14 178145.21
4 0.005 541.07 38 0.14 178549.9
Sr
no
Thick-
ness of
fin (m)
Tem-
perature
(k)
Pres-
sure
(Pascal)
Velocity
(m/s)
Heat trans-
fer (W)
1 0.002 540.46 38 0.14 178074.16
2 0.003 541.39 37.8 0.14 178820.6
3 0.004 541.88 38 0.14 179189.36
4 0.005 542.21 37.8 0.14 179464.3
Variation of properties with different thickness
(a) Steel (b) Aluminum (c) Copper
Sr
no
Thick-
ness of
fin (m)
Tem-
perature
(k)
Pres-
sure
(Pascal)
Velocity
(m/s)
Heat trans-
fer (W)
1 0.002 604.47 37.65 0.14 88704
2 0.003 605.12 38 0.14 88896
3 0.004 605.59 38 0.14 89088
4 0.005 605.96 38 0.14 89232
Sr
no
Thick-
ness of
fin (m)
Tem-
perature
(k)
Pres-
sure
(Pascal)
Velocity
(m/s)
Heat trans-
fer (W)
1 0.002 604.47 37.65 0.14 88704
2 0.003 605.12 38 0.14 88896
3 0.004 605.59 38 0.14 89088
4 0.005 605.96 38 0.14 89232
Sr
no
Thick-
ness of
fin (m)
Tem-
perature
(k)
Pres-
sure
(Pascal)
Velocity
(m/s)
Heat trans-
fer (W)
1 0.002 609.17 37.65 0.14 90208
2 0.003 609.47 38 0.14 90272
3 0.004 609.59 38 0.14 90304
4 0.005 609.69 38 0.14 90320
Sr
no
Thick-
ness of
fin (m)
Tem-
perature
(k)
Pres-
sure
(Pascal)
Velocity
(m/s)
Heat trans-
fer (W)
1 0.002 604.47 37.65 0.14 134432
2 0.003 605.12 38 0.14 135200
3 0.004 605.59 38 0.14 135744
4 0.005 605.96 38 0.14 136192
Sr
no
Thick-
ness of
fin (m)
Tem-
perature
(k)
Pres-
sure
(Pascal)
Velocity
(m/s)
Heat trans-
fer (W)
1 0.002 565.17 37.65 0.14 139648
2 0.003 575.88 38 0.14 140224
3 0.004 576.52 38 0.14 140560
4 0.005 576.93 38 0.14 140768
Sr
no
Thick-
ness of
fin (m)
Tem-
perature
(k)
Pres-
sure
(Pascal)
Velocity
(m/s)
Heat trans-
fer (W)
1 0.002 576.44 37.65 0.14 140512
2 0.003 577.18 38 0.14 140912
3 0.004 577.58 38 0.14 141136
4 0.005 577.83 38 0.14 141232
Conclusions
1. As we increase the fin thickness the temperature
of the cold fluid at the outlet of the heat exchanger
increases.
2. We get high temperature profile at outlet in case
of Aluminum and copper compared to steel mate-
rial.
3. There is very minor changes occur in the pres-
sure and velocity profile with increase of fin thick-
ness as well as change of material that is pressure
and velocity doesn’t get much affected by thickness
of fin and material of fin.

30
4. The simulated outlet temperature is 543k which
is very near to design outlet temperature 553k.
There is less than 3% variation occurs than design
value.
5. By decreasing the mass flow rate for there is in-
creasing the value of temperature up to 609k and
577k.
6. After 5min there is no variation in temperature
with respect to time.
Future Scope
1. Optimization of fin thickness and material for a
heat exchanger
2. Experimentation thermal analysis of double pipe
heat exchanger.
3. Numerical analysis of double pipe heat exchanger
using augmentation devices.
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Authors
Lakamana Satyabhaskar
Research Scholar
(mtech in Thermal Engineering)
Kits, Peddapuram(M) Tirupathi Village,
Divili 533-433,
Eg Dt,Andhra Pradesh,India.
K.koteswara Rao.
Assistant professor
Divili 533-433,
Eg Dt,Andhra Pradesh,India.
Y Dhana Shekar,
Assistant Professor ,
Divili 533-433,
Eg Dt,Andhra Pradesh, India

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