10 18186-Thermal 729149-1077824
10 18186-Thermal 729149-1077824
10 18186-Thermal 729149-1077824
ABSTRACT
The heat transfer, friction factor, pressure difference, Nusselt number of a helical coil tube using variable
pressure and velocity during inlet for various values of Dean number [ratio of coil diameter (D) to tube diameter (d)]
has been studied using commercially available computational tool. A validation is performed using the computational
tool through the experimental data and it was observed that the results are in good agreement. The helical coil of 0.3
m diameter with four (4) turns of inner diameter 0.01 m with length 3.77 has been modelled, meshed and analyzed
for both laminar and turbulent flows of constant wall temperature and heat flux. A grid independence test is also
performed. The results show that increase in Dean number increases the heat transfer of the helical tube. The
increases in pressure have less effect on heat transfer during laminar flow while adverse effect can be observed
during turbulent flow.
Keywords: Dean Number, Heat Transfer, Friction Factor, Helical Tubes, Nusselt Number
INTRODUCTION
Heat exchangers were an inevitable component in modern mechanical systems. In order to effectively use
energy being generated through various methods, various heat exchangers in various forms like, economizer, air
preheater, super heater, waste heat recovery boilers, etc were used. Even though heat exchangers serves the purpose
of transferring heat from one fluid to another, lack of effective heat transfer results in loss of heat from the fluid and
hence useful energy is being wasted. For this reason, various methodologies were being studied and adapted in
increasing the heat transfer effectiveness of various heat exchangers. In many cases where experimental study is not
feasible or economically viable, numerical study have been forecasted by many researchers to be a useful tool. The
thermal performance of vertical spiral ground heat exchangers (GHE) for extracting ground source heat using a heat
pump was performed for nine (9) spiral GHE and two (2) u-tube GHE with ore holes, using experimental method
and numerical method. The experiment was performed for all the test samples for 150hrs. The results of the
experiments were compared with predicted numerical results using commercially available solver COMSOL [1].
Another combined experimental and numerical approach was performed for investigating the heat transfer and
friction flow characteristics of three (3) mini channel regenerative heat exchangers with hydraulic diameter of the
channels as 1.5, 1 and 0.5 mm. The study was conducted for measuring the transient thermal responses and pressure
drop at the outlet and inlet of each of the heat exchangers. The authors concluded that heat exchanger with 0.5 mm
have the highest interstitial coefficient of heat transfer, which can be explained due to the increase in the specific
surface area of the heat exchanger [2]. Other combined study suggests that desiccant coated heat exchanger have
reduced heat transfer coefficient of 30%, as compared to conventional heat exchangers during heat transfer between
air and water. The researchers suggested that the reduction in the heat transfer is due to the resistance provided by the
desiccant coating [3]. Corrugated inner tubes with pitch of 5mm and depth 1.5mm have been found to have the
highest heat transfer and Nusselt number subjected to different flow rates of 0.03 to 0.13 kg/s and 0.04 to 0.14 kg/s
for cold and hot fluids respectively. The experimental result is verified by the prediction of artificial neural network
(ANN) which have R2 values of 0.99999, 0.999997 and 0.999993 for heat transfer, Nusselt number and Reynolds
number respectively [4].
This paper was recommended for publication in revised form by Regional Editor Baha Zafer
1
Department of Mechanical Engineering, National Institute of Technology Rourkela, India
2
Department of Mechanical Engineering, National Institute of Technology Manipur, India
3
Department of Mechanical Engineering, Rajeev Gandhi Memorial College of Engineering and Technology, Nandyal, India
4
Department of Mechanical Engineering, Maulana Azad National Institute of Technology Bhopal, India
*E-mail address: [email protected], [email protected]
Orcid id: 0000-0002-6555-3306, 0000-0002-6176-8211, 0000-0002-3884-8758
Manuscript Received 19 July 2018, Accepted 22 November 2018
Journal of Thermal Engineering, Research Article, Vol. 6, No. 2, Special Issue 11, pp. 128-139, March, 2020
The thermo hydraulic performance of air to water heat exchange on a double pipe heat exchanger with
helical fins (with fin spacing in the range of 0.05 to 2 m) was studied using commercially available numerical solver
ANSYS FLUENT [5]. The study have concluded that helical fin with fin spacing of 0.1 m provides the optimum
thermo hydraulic performance. The study also denotes the improvement of compactness and overall performance
with use of helical fins. Another study using the software proposed that helical wire inserts can increase the Nusselt
number by 1.77 times. Some studies also suggested that circular obstacles in heat exchangers can increase the overall
performance, compared to other form of obstacles like rectangular or triangular [6-7]. A study using CFD-segmented
heat exchanger model using open sourced solver Open FOAM have recommended that velocity scaling between
different fin geometries must be avoided. The maximum capacity loss observed was 9.75% from bare-tube heat
exchangers. They have concluded that the severity of the Mal-distribution of the refrigerant leads to larger capacity
loss in heat exchangers [8]. Other applications of CFD can be found in solving complex equations and geometry of
internal combustion engines. CFD solver such as Forte Reaction Design (Chemkin) has been used for studying 3-
dimension simulations of reactions. Engine emissions simulations were effectively being predicted using numerical
solver also [9-10]. Other studies on heat exchangers using commercial codes have been extensively studied by
various researchers [11-18 16] for different applications. They have found that commercial CFD codes and tools can
be used for studying the characteristics of heat exchangers. Other study involves thermal analysis and multi
dimensional modeling of various thermal systems including IC engines, emission dispersion studies, slurry flow,
flame study thermal comfort etc. [17-33].
In view of the above literatures, the authors have found that there are fewer studies in the combined effect of
Dean number, velocity and pressure inlet with conditions of constant wall temperature and heat flux on the heat
transfer, friction factor, pressure difference and Nusselt number of a helical tube. Hence a correlative study on the
combined effects has been studied numerically using commercially available tool, ANSYS. To increase the accuracy
in predicting the results, a validation has been performed using experimental results and the prediction holds good
for both values of heat transfer co-efficient and Nusselt number.
METHODOLOGY
Model Preparation and Geometry Creation
The helical tube has been modeled using commercial computational tool, ANSYS for which the dimensions
of 0.3 meter, 3.77 meter and 0.01 meter for diameter of coil (D), length of tube (L) and diameter of tube (d), has been
chosen for the study as shown in Fig. 1, since the present study will be helpful in analyzing compact heat exchange
systems. During the process of the study, four (4) other models were also created by changing the value of ‘d’,
keeping constant value of D and L in order to effectively study the effect of the change in dean number (D/d) on the
heat transfer and fluid flow characteristics. The circles are initially created and SWEEP procedure is followed for
generating the three dimensional model. The number of turns has been specified to be as four, while defining the
body type to be fluid for outer and innermost tube and solid for middle tube. The domain or the cell zone conditions
of the model have been defined as water- fluid & copper- solid. The tube of the heat exchanger is made up of copper
to facilitate maximum heat transfer due to its superior thermal conductivity. The properties of copper remained
constant throughout the analysis.
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The model is meshed using rectangular cells and grid independence test (GIT) was conducted on the model
while considering the model with no cells. Fig. 2 shows the meshing of the model in the computational domain.
Figure 2. (a) Grid of the computational domain and (b) frontal view of the meshing
4750
Outlet temperature
342.35
Pressure
342.30
4700
342.25
4650
342.20
4600 342.15
(a) (b)
292.00
291.94
291.92
291.90
291.88
291.86
(c)
Figure 3. (a) GIT based on inlet pressure of hot fluid, (b) GIT based on outlet temperature of hot fluid, (c) GIT based
on outlet temperature of cold fluid
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In the present study, initializing from D/d= 10 with assumptions of insulated outer wall, inlet velocity of hot
fluid as 1.5072 m/s (Re= 10000), temperature at 355K and variation of grid size from 65770 to 139770, the GIT is
performed based on inlet pressure of hot fluid, outlet temperature of hot fluid and outlet temperature of cold fluid.
From Fig. 3 (a), it can be observed that the results are independent after 137617, which shows that the results are
independent of the grid after the specified value. Also from Fig. 3 (b) and (c), it can be seen that the results are
independent after 138726 number of divisions, showing that the results are independent of the grid.
The following are the boundary conditions for the present study:
(a) The inlet velocity of the fluid are assumed to be 0.6 m/s, 0.8 m/s, 1 m/s and 1.2 m/s.
(b) The inlet gauge pressure are assumed to be 5000 N/m2, 10000 N/m2, 15000 N/m2 and 20000 N/m2
The flow was taken to be steady and incompressible and the density of the fluid is constant throughout the
computational domain. The effect of conduction on the tube material is small. SIMPLE algorithm is used for the
pressure correction approach and the relaxation factor has been kept to its default values (Pressure: 0.3; Momentum:
0.7; Energy: 01; Density: 01; Body force: 01). k-epsilon model is being used as the turbulence model. The governing
equations for the study we shown in equations (1) to (7)
Continuity equation
u v pw
0
x y z (1)
u u u 1 u v w
u v w px u
2
x y z x 3 x x y w (2)
Energy equation
T T T
C u v w u k 2T
x y z x y w (3)
where ∅ is the Rayleigh dissipation function and is given by
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u v w u v v w w u 2 u v w
2 ² ² ² ² ² ²
x y z y x z y x z 3 x y z (4)
T
k
h x
Tw T f
(5)
Nusselt number
T
dh
Nu x
Tw T f
(6)
Critical Reynolds number as per the correlation given by Schmidt (1967)
d 0.45
Recr 2300 1 8.6 (7)
D
400
15
Heat transfer coefficient
350
Nussult number
12
300
9
250
200
3
4000 6000 8000 10000 12000 14000 16000 18000 3000 6000 9000 12000 15000 18000
Reynolds number Reynolds number
(a) (b)
Figure 4. Validation of experimental and numerical results for (a) heat transfer coefficient and (b) Nusselt number
with Reynolds number
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Figure 5. (a) Pressure and (b) temperature contour distribution of tube for constant wall temperature
Fig. 5 shows the distribution of pressure and temperature contours respectively for the constant wall
temperature at inlet velocity of 0.6 m/s and turbulent flow. The Fig 5 (a) shows that the pressure distribution
(pascals) on the helical tubes are more on the upper region, while less effect is being observed in the lower regions.
Again, from Fig. 5 (b), the temperature (kelvin) contour shows that the whole length of the tube is subjected to the
heat.
Fig. 6 shows the variation of the variation of heat transfer coefficient, Nusselt number and Pressure with
Dean number for different pressure inlet, constant wall temperature and laminar flow. From the figure it can be noted
that there is slight change in the Nusselt number with change in the inlet pressure in Laminar flow. The heat transfer
is directly proportional to the Dean number and hence, maximum heat transfer is observed at maximum value of
Dean number, while gradual decrease in Nu is observed at all values of pressure with increasing Dean number. Less
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change is observed with variation in inlet pressure, though the overall effect in the increase of pressure difference is
observed with increase in Dean number during laminar flows.
The variation of heat transfer coefficient, Nusselt number and Pressure with Dean number for different
pressure inlet, constant wall temperature and turbulent flow is shown in Fig. 7. From the graph, is can be seen that
there is increase in Nusselt number with increase in Dean number and pressure. Accordingly, the heat transfer
coefficient also increases with increase in inlet pressure. Thus, helical tubes will have higher performance, with
increasing Dean number. In turbulent flow conditions, there is increase in all the parameters under study with
increase in Dean number. Heat transfer co-efficient increases with increase in pressure inlet while, reduction in
Nusselt number is observed. Increase in pressure difference with increase in inlet pressure is observed and for all
values of inlet pressure, the pressure difference increases with Dean number.
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The variation of heat transfer coefficient, Nusselt number and Pressure with Dean number for different
pressure inlet and constant heat flux is shown in Fig. 8 (laminar flow) and Fig. 9 (turbulent flow) respectively. The
computational study shows higher value of Nusselt number in helical tubes, as compared to straight tubes. During
constant heat flux conditions, in both laminar and turbulent flow conditions, the heat transfer co-efficient and
pressure difference increases with increase in Dean number. In laminar flow, it can be observed that the Nusselt
number for variable values of pressure inlet have less significant effect at lower Dean number. An increase in Nu is
observed in increasing Dean number.
The variation of heat transfer coefficient, Pressure difference, Nusselt number and friction factor with Dean
number at variable velocity and constant wall, laminar flow is shown in Fig. 10. There is slight change in the heat
transfer coefficient, with increase in Dean number. It can be observed that there is increase in pressure differences
with the flow with increasing Dean number and velocity of flow. From the graph between Nusselt number and Dean
number, it can be noted that the differences in the decrease in the Nusselt number due to increasing Dean number for
all flow of different velocity is identical. This shows that the changes in the Nusselt number are very low, when
increasing Dean number and variation of flow velocity. At lower flow velocity it can be observed that the effect of
Dean number is very less, while on the contrary very little change of from 5675 W/m2K at D/d of 12 is seen to
increase up to 6017 W/m2K at D/d of 20, while the value of heat transfer co-efficient is observed to be about 6176
W/m2K at D/d of 30. A similar reduction trend in Nu is observed while increasing the D/d ratio for all inlet velocity
values. While the friction factor increase with increase in flow velocity and decreases with increase in Dean number
at laminar flow with constant wall temperature.
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Fig. 11 shows the variation of heat transfer coefficient, Pressure difference, Nusselt number and friction
factor with Dean number at variable velocity and constant wall, turbulent flow. From the graph it is clear that there is
increase in Nusselt number, with increase in Dean number. Similar trend like laminar flow can also be observed in
turbulent flow for variable flow velocity at constant wall temperature, but Nu increases with increase in Dean
number and decreases with increasing flow velocity.
Fig. 12 shows the variation of Dean number with heat transfer coefficient, Pressure difference, Nusselt
number and friction factor at variable inlet and constant heat flux with laminar flow. It can be observed that the heat
transfer co-efficient increases with increase in Dean number for all values, while Nusselt number decreases with
increase in Dean number. The increase in velocity increases the parameters like heat transfer co-efficient and
pressure difference. Lower values of Nusselt number and friction factor is also observed with increase in pressure of
the fluid flow. The effect of variable velocity inlet at constant heat flux and laminar flow for heat transfer co-efficient
is seen to be negligible since at all velocity profiles, the heat transfer co-efficient is almost constant, though it
increase with increase in Dean number. The friction factor during laminar flow decrease with increase in velocity of
flow, yet increase with increasing Dean number.
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The variation of heat transfer coefficient, Pressure difference, Nusselt number and Friction factor at variable
inlet and constant heat flux with turbulent flow with Dean number is shown in Fig. 13. It can be observed that the
increase in Dean number results in increase in corresponding values. The increase in velocity increases the heat
transfer co-efficient and pressure difference. But the Nusselt number decreases with decrease in velocity. Similar
trend can be observed for Friction factor also.
CONCLUSION
Heat transfer phenomenon and fluid flow is studied using commercially available computational tool. The
corresponding effects of inlet mass flow rate, pressure at inlet and ratio of curvature (Dean number) is studied. The
following conclusions are drawn from the study:
The results of Nusselt number largely depends on the Dean number. The increase in Nusselt
number is observed with the increase in Dean number and mass flow rate.
The friction factor is more for Turbulent flow, as compared to laminar flow in all cases.
The computational tool can be used for studying complex and expensive study, which are rather
undesirable for experimental study.
NOMENCLATURE
Ac flow area, m2
As surface area, m2
Cp specific heat, J/kgK
d diameter of pipe, mm
dh hydraulic diameter, mm
D coil diameter, mm
De Dean Number
f friction factor
G mass velocity, m/s
h heat transfer coefficient, W/m2K
H pitch of coil, mm
j Colburn factor
k thermal conductivity, W/mK
L length of pipe, m
m mass flow rate, kg/s
n number of turns
Nu Nusselt Number
p pressure, N/m2
Pr Prandtl Number
Q heat flux, W/m2
Re Reynolds Number
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St Stanton Number
T Temperature, K
u, v, w velocity along X-axis, Y-axis and Z-axis, m/s
V flow velocity, m/s
Vs wetted volume, m3
x, y, z coordinates
X body force
Greek symbols
Subscripts
cr critical
d diameter
f fluid
w wall
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