Numerical Analysis of a Small Size Baffled Shell-and-Tube Heat Exchanger Using Different Nano-Fluids

In this study, numerical simulation was used to investigate the effect of adding different nano-particles into the fluid on the performance of a baffled shell-and-tube heat exchanger. A three-dimensional modeling approach was followed to analyze the effect of different nano-fluids, at various volume fractions, as applied in a baffled shell-and-tube heat exchanger. Once finished with validating the grid independency and results, we proceeded to obtain heat transfer rate, pressure drop, outlet shell temperature and exchanger effectiveness for different volume fractions and particle size of different nano-fluids. The studied nano-particles in the present work included Al₂O₃, CuO, Fe₂O₃, Cu, Fe, SiO₂, and Au, with water and ethylene glycol employed as base fluids. With constant mass flow rate for all cases, the results indicated that, the addition of nano-particles had reduced the heat transfer coefficient, pressure drop and the rate of heat transfer through the shell, even though it had increased outlet shell temperature. In other words, considering a constant heat transfer rate, the presence of nano-fluids in a baffled shell-and-tube heat exchanger is likely to be associated with increased outlet shell temperature. Another consequence presents that using ethylene glycol as base fluid leads to higher effectiveness compared with water as a base fluid in exchanger.     

Estimation of heat transfer coefficient and friction factor in the transition flow with low volume concentration of Al2O3 nanofluid flowing in a circular tube and with twisted tape insert

Experiments to evaluate heat transfer coefficient and friction factor for flow in a tube and with twisted tape inserts in the transition range of flow with Al₂O₃ nanofluid are conducted. The results showed considerable enhancement of convective heat transfer with Al₂O₃ nanofluids compared to flow with water. It is observed that the equation of Gleninski applicable in transitional flow range for single-phase fluids showed considerable deviation when compared with values obtained with nanofluid. The heat transfer coefficient of nanofluid flowing in a tube with 0.1% volume concentration is 23.7% higher when compared with water at number of 9000. Heat transfer coefficient and pressure drop with nanofluid has been experimentally determined with tapes of different twist ratios and found to deviate with values obtained from equations developed for single-phase flow. A regression equation is developed to estimate the Nusselt number valid for both water and nanofluid flowing in the transition flow Reynolds number range in circular plain tube and with tape inserts. The maximum friction factor with twisted tape at 0.1% nanofluid volume concentration is 1.21 times that of water flowing in a plain tube.     

Heat transfer and pressure drop performance of twisted oval tube heat exchanger

Twisted oval tube heat exchanger is a type of heat exchanger that aims at improving the heat transfer coefficient of the tube side and also decreasing the pressure drop of the shell side. In the present work, tube side and shell side heat transfer and pressure drop performances of a twisted oval tube heat exchanger has been experimentally studied. The tube side study shows that the tube side heat transfer coefficient and pressure drop in a twisted oval tube are both higher than in a smooth round tube. The shell side study shows that the lower the modified Froude number Fr_M, the higher the shell side heat transfer coefficient and pressure drop. In order to comparatively analyze its shell side performance of the heat exchanger, a rod baffle heat exchanger with similar size of the twisted oval tube heat exchanger is designed and its performance is calculated with Gentry's method. The comparative study shows that the heat transfer coefficient of the twisted oval tube heat exchanger is higher and the pressure drop is lower than the rod baffle heat exchanger. In order to evaluate the overall performance of the twisted oval tube heat exchanger, a performance evaluation criterion considering both the tube side and shell side performance of a heat exchanger is proposed and applied. The analyze of the overall performance of the twisted oval tube shows that the twisted oval tube heat exchangers works more effective at low tube side flow rate and high shell side flow rate.     

Convective gas cooling heat transfer and pressure drop characteristics of supercritical CO2/oil mixture in a minichannel tube

The effects of PAG oil concentration on the convective gas cooling heat transfer and the pressure drop characteristics of supercritical CO₂/oil mixture in minichannel tube were investigated. The test results showed that the average gas cooling heat transfer coefficient was decreased by 20.4% and the average pressure drop was increased by 4.8 times when the oil concentration was increased from 0 to 4 wt.%. The effects of the oil concentration on the convective gas cooling heat transfers and the pressure drops of the supercritical CO₂/oil mixture in minichannel tubes were experimentally confirmed to be significant.     

Heat transfer and flow characteristics of flow boiling of CO2‐oil mixtures in horizontal smooth and micro‐fin tubes

Experiments were carried out on the flow pattern, heat transfer, and pressure drop of flow boiling of pure CO₂ and CO₂‐oil mixtures in horizontal smooth and micro‐fin tubes. The smooth tube is a stainless steel tube with an inner diameter of 3.76 mm. The micro‐fin tube is a copper tube with a mean inner diameter of 3.75 mm. The experiments were carried out at mass velocities from 100 to 500 kg/(m²·s), saturation temperature of 10 °C, and the circulation ratio of lubricating oil (PAG) was from 0 to 1.0 mass%. Flow pattern observations mainly showed slug and wavy flow for the smooth tube, but annular flow for the micro‐fin tube. Compared with the flow patterns in the case of pure CO₂, an increase in frequency of slug occurrence in the slug flow region, and a decrease in the quantity of liquid at the top of the tube in the annular flow region were observed in the case of CO₂‐oil mixtures. With pure CO₂, the flow boiling heat transfer was dominated by nucleate boiling in the low vapor quality region, and the heat transfer coefficients for the micro‐fin tube were higher than those of the smooth tube. With CO₂‐oil mixtures, the flow boiling heat transfer was dominated by convective evaporation, especially in the high vapor quality region. In addition, the heat transfer coefficient decreased significantly when the oil circulation ratio was larger than 0.1 mass%. For the pressure drop characteristics, in the case of pure CO₂, the homogeneous flow model agreed with the experimental results within ±30% for the smooth tube. The pressure drops of the micro‐fin tube were 0–70% higher than those predicted with the homogeneous flow model, and the pressure drops increased for the high oil circulation ratio and high vapor quality conditions. The increases in the pressure drops were considered to be due to the increase in the thickness of the oil film and the decrease in the effective flow cross‐sectional area. © 2010 Wiley Periodicals, Inc. Heat Trans Asian Res; Published online in Wiley InterScience ( www.interscience.wiley.com ). DOI 10.1002/htj.20287     

Numerical simulation of condensation for R410A at varying saturation temperatures in mini/micro tubes

ABSTRACT

Heat transfer and pressure drop characteristics of condensation for R410A inside horizontal tubes (d_h = 0.25, 1, and 2 mm) at saturation temperatures Tsat = 310, 320, and 330 K are investigated numerically. The results indicate that local heat transfer coefficients and pressure drop gradients increase with increasing mass flux and vapor quality and with decreasing tube diameter and saturation temperature. Liquid film thickness also increases with increasing saturation temperature because of the lower surface tension at higher saturation temperature. When gravity dominates the condensation process, a vortex with its core lying at the bottom of the tube is found in the vapor phase region. For the annular flow regime, stream traces point from the symmetry plan to the liquid–vapor interface, where the vapor phase becomes the liquid phase. Numerical heat transfer coefficients and pressure drop gradients are compared to available empirical correlations. Two new models for heat transfer coefficients and frictional pressure drop gradients are developed based on the numerical work.     

Enhancement of shell side forced convective heat transfer in the shell tube‐type heat exchanger using thin plate‐type supports

The shell side heat transfer and pressure drop in counterflowing water were experimentally investigated on the basis of the overall heat transfer coefficient. The investigation was intended to identify ways to get higher performance for the cooler in a BWR nuclear power plant. The following three conclusions were reached in the study. (1) Predicted performance of the heat exchanger, using the overall heat transfer coefficient based on the outside area of the tube K_o, indicated an enhancement by 92% compared with the measured performance of the conventional segmental baffle‐type heat exchanger. (2) The tube side pressure drop ΔP_t=20 kPa and the shell side pressure drop ΔP_s=70 kPa were obtained, and were within the allowable value ΔP_a=80 kPa. The shell side pressure drop of the low‐pressure drop spacer could be decreased by 20% as compared with that of the standard spacer. (3) The enhancement constant of the shell side heat transfer using the low‐pressure drop spacer was about 1.2 times as large as that of the standard spacer, regardless of the pumping power. © 2003 Wiley Periodicals, Inc. Heat Trans Asian Res, 32(5): 455–471, 2003; Published online in Wiley InterScience ( www.interscience.wiley.com ). DOI 10.1002/htj.10097     

Experimental investigation of turbulent flow and convective heat transfer characteristics of alumina water nanofluids in fully developed flow regime

In this paper the convective heat transfer and friction factor of the nanofluids in a circular tube with constant wall temperature under turbulent flow conditions were investigated experimentally. Al₂O₃ nanoparticles with diameters of 40 nm dispersed in distilled water with volume concentrations of 0.1–2 vol.% were used as the test fluid. All physical properties of the Al₂O₃–water nanofluids needed to calculate the pressure drop and the convective heat transfer coefficient were measured. The results show that the heat transfer coefficient of nanofluid is higher than that of the base fluid and increased with increasing the particle concentrations. Moreover, the Reynolds number has a little effect on heat transfer enhancement. The experimental data were compared with traditional convective heat transfer and viscous pressure drop correlations for fully developed turbulent flow. It was found that if the measured thermal conductivities and viscosities of the nanofluids were used in calculating the Reynolds, Prandtl, and Nusselt numbers, the existing correlations perfectly predict the convective heat transfer and viscous pressure drop in tubes.     

Twisted bundle heat exchangers performance evaluation by CFD (CJ12/5054)

Shell and tube heat exchanger with single twisted tube bundle in five different twist angles, are studied using computational fluid dynamics (CFD) and compared to the conventional shell and tube heat exchanger with single segmental baffles. Effect of shell-side nozzles configurations on heat exchanger performance is studied as well. Heat transfer rate and pressure drop are the main issues investigated in the paper. The results show that, for the same shell-side flow rate, the heat transfer coefficient of heat exchanger with twisted tube bundle is lower than that of the heat exchanger with segmental baffles while shell-side pressure drop of the former is even much lower than that of the latter. The comparison of heat transfer rate per unit pressure drop versus shell-side mass flow rate shows that heat exchanger with twisted tube bundle in both cases of perpendicular and tangential shell-side nozzles, has significant performance advantages over the segmental baffled heat exchanger. Optimum bundle twist angles for such exchangers are found to be 65 and 55° for all shell side flow rates.     

Experimental study of Fe2O3/water and Fe2O3/ethylene glycol nanofluid heat transfer enhancement in a shell and tube heat exchanger

Heat transfer characteristics of Fe₂O₃/water and Fe₂O₃/EG nanofluids were measured in a shell and tube heat exchanger under laminar to turbulent flow condition. In the shell and tube heat exchanger, water and ethylene glycol-based Fe₂O₃ nanofluids with 0.02%, 0.04%, 0.06% and 0.08% volume fractions were used as working fluids for different flow rates of nanofluids. The effects of Reynold's number, volume concentration of suspended nanoparticles and different base fluids on the heat transfer characteristics were investigated. Based on the results, adding nanoparticles to the base fluid causes a significant enhancement of the heat transfer characteristics and thermal conductivity. This enhancement was investigated with regard to various factors; concentration of nanoparticles, types of base fluids, sonication time and temperature of fluids. In this paper, the effect of Fe₂O₃ nanoparticles on the thermal conductivity of base fluids like ethylene glycol and water was studied. The thermal conductivity measurement was made for different concentrations and temperatures. As the concentration of the nanoparticles increased, there was a significant enhancement in thermal conductivity and overall heat transfer due to more interaction between particles. It was also observed that there was an improvement in the thermal conductivity of the base fluid as the temperature increased. The measurements also showed that the pressure drop of nanofluid was higher than that of the base fluid in a turbulent flow regime. However, there was no significant increase in pressure drop at laminar flow.     

Thermally dependent viscosity and non-Newtonian flow in a double-pipe helical heat exchanger

A double-pipe helical heat exchanger was numerically studied to determine the effects of thermally dependent viscosity and non-Newtonian flows on heat transfer and pressure drop for laminar flow. Thermally dependent viscosities were found to have very little effect on the Nusselt number correlations for Newtonian fluids; however significant effects on the pressure drop in the heat exchanger were predicted. Changing the flow rate in the annulus can significantly affect the pressure drop in the inner tube, since the average viscosity of the fluid in the inner tube would change due to the change in the average temperature.The effects of non-Newtonian power law fluids on the heat transfer and the pressure drop were determined for laminar flow in the inner tube and in the annulus. The Nusselt number was correlated with the Péclet number for heat transfer in the inner tube. For the annulus, the Nusselt number was found to correlate best with the Péclet number and the curvature ratio. Pressure drop data were compared by using ratios of the pressure drop of the non-Newtonian fluid to a Newtonian fluid at identical mass flow rates and consistency indices.     

Effects of Different Fin Spacings on the Nusselt Number and Reynolds Number in Perforated Finned Heat Exchangers

In this study, the effect of holes placed on perforated finned heat exchangers on convective heat transfer was experimentally investigated. Six-millimeter-diameter holes were opened on each circular fin on a heating tube in order to increase convective heat transfer. These holes were placed on the circular fins in such a way as to follow each other at the same chosen angle. The holes created turbulence in a region near the heating tube surface on the bottom of the fin. Experiments were then performed to analyze the effect of this turbulence on heat transfer and pressure drop. These experiments were carried out at five different fin spacings at the angular locations of 30° and 60° in order to determine the optimum fin spacing. Moreover, further experiments were carried out for counterflow and parallel-flow arrangements to determine the effects of the flow directions of the heating fluid and heated fluid. Results show an increase in Nusselt number with increasing modified Reynolds number. In addition, when different fin spacing to heating tube external diameter ratios were examined, at a ratio of 0.414 and angular locations of 30° and 60°, 11% and 8.6% increase in heat transfer were obtained, respectively, for parallel-flow arrangement compared to counterflow. For parallel flow, pressure drop values were 3.5% and 3.8% lower at 30° and 60°, respectively.     

Heat Transfer and Pressure Drop Characteristics of Nanofluid Flows Inside Corrugated Tubes

An experimental investigation is carried out to study the heat transfer and pressure drop characteristics of multiwalled carbon nanotubes (MWCNTs)/heat transfer oil nanofluid flows inside horizontal corrugated tubes under uniform wall temperature condition. To provide the applied nanafluids, MWCNTs are dispersed in heat transfer oil with mass concentrations of 0.05, 0.1, and 0.2 wt%. The Reynolds number varies between 100 and 4,000. Three tubes with hydraulic diameters of 11.9, 13.2, and 15.5 mm are applied as the test section in the experimental setup. Tubes are corrugated four times on the cross section; that is, there are four different helices around the tube. Depths of the corrugations are chosen as 0.9, 1.1, and 1.3 mm, and pitch of corrugation is 14 mm. The acquired data confirm the increase of heat transfer rate as a result of utilizing nanofluids in comparison with the base fluid flow. However, corrugating the tubes decreases the heat transfer rate at low Reynolds numbers. The highest increase in heat transfer rate is observed for the Reynolds numbers for which the smooth tube is in the transition regime and the corrugated tube reaches the turbulent flow, that is, Reynolds number in the range of 1,000 to 3,000. Rough correlations are proposed to predict the Nusselt number and friction factor.     

Convective boiling heat transfer and two-phase flow characteristics inside a small horizontal helically coiled tubing once-through steam generator

The pressure drop and boiling heat transfer characteristics of steam-water two-phase flow were studied in a small horizontal helically coiled tubing once-through steam generator. The generator was constructed of a 9-mm ID 1Cr18Ni9Ti stainless steel tube with 292-mm coil diameter and 30-mm pitch. Experiments were performed in a range of steam qualities up to 0.95, system pressure 0.5-3.5 MPa, mass flux 236-943 kg/m²s and heat flux 0-900 kW/m². A new two-phase frictional pressure drop correlation was obtained from the experimental data using Chisholm’s B-coefficient method. The boiling heat transfer was found to be dependent on both of mass flux and heat flux. This implies that both the nucleation mechanism and the convection mechanism have the same importance to forced convective boiling heat transfer in a small horizontal helically coiled tube over the full range of steam qualities (pre-critical heat flux qualities of 0.1-0.9), which is different from the situations in larger helically coiled tube where the convection mechanism dominates at qualities typically >0.1. Traditional single parameter Lockhart-Martinelli type correlations failed to satisfactorily correlate present experimental data, and in this paper a new flow boiling heat transfer correlation was proposed to better correlate the experimental data.     

The effects of nanoparticle aggregation on the convection heat transfer investigated by a combined NDDM and DPM method

In this study, convective heat transfer of Al₂O3-water nanofluids (NFs) of various concentrations under laminar flow in a horizontal circular tube with and without considering particle aggregation was numerically investigated by a combined nanoparticle diameter distribution model (NDDM) with the Discrete Phase Model (DPM). Heat transfer coefficient (h), temperature distribution in axial and radial direction, and pressure drop (ΔP) were studied. It turns out that beside a slight pressure drop, heat transfer near the wall will significantly deteriorate when particle aggregation occurs. With an increase in Re numbers, the effects of particle aggregation on the heat transfer performance of the fluid will decrease.     

Pressure drop and heat transfer characteristics of air-rockbed thermal storage systems

Experiments were conducted to determine the pressure drop and heat transfer characteristics of rockbeds with air as the heat transfer medium. Both the pressure drop and the coefficient of volumetric heat transfer between the air and the rockbeds were found to depend upon the rock size and the air flow rate. In addition, the pressure drop also exhibited dependence on the rockbed porosity. The data, however; did not suggest any influence of rockbed porosity and inlet air and initial rockbed temperatures on the volumetric heat transfer coefficient. Relationships are proposed to estimate the pressure drop and volumetric heat transfer coefficients in rockbeds for the range of variables encountered in low temperature storage applications.     

Heat Transfer and Flow Characteristics of Al2O3/Water Nanofluid in Various Heat Exchangers: Experiments on Counter Flow

Abstract

On account of nanofluids influence on heat exchangers (HEs), a vigorous discussion can be made to concurrently contrast HEs to one another under the same conditions to detect maximum efficacy. Based on an extensive experimental study, this research is established to examine the effect of nanofluids on the performance of heterogeneous HEs with the same heat transfer surface area considering counter flow arrangement. A double pipe HE, a shell and tube HE and a plate HE are intended to accomplish the experiments. The experiments are executed under turbulent flow conditions using distilled water and Al₂O₃/water nanofluid with 0.2, 0.5, and 1% particle volume concentrations. From the results shown in the article, the double pipe HE revealed the best outcome for the heat transfer coefficient with a maximum enhancement of 60% while a maximum enhancement in the heat transfer coefficient of 11% was reported for the plate HE. Utilizing a nanofluid represented the lowest penalty in the pressure drop with a maximum enhancement of 27% for the plate HE while the highest penalty in the pressure drop with a maximum enhancement of 85% was observed in the double pipe and shell and tube HEs.     

Experimental investigation of twisted tape inserts performance on condensation heat transfer enhancement and pressure drop

A comprehensive experimental investigation is conducted on the augmentation of heat transfer coefficients and pressure drop during condensation of HFC-134a in a horizontal tube at the presence of different twisted tape inserts. The test section is a 1.04 m long double-tube counter-flow heat exchanger. The refrigerant flows in the inner copper and the cooling water flows in annulus. The experiments are performed for a plain tube and four tubes with twisted tapes inserts of 6, 9, 12 and 15 twist ratios. The pressure drop is directly measured by a differential pressure transducer. It is found that the twisted tape with twist ratio of 6 gives the highest enhancement in the heat transfer coefficient and the maximum pressure drop compared to the plain tube on a nominal area basis. For this case the enhancement in heat transfer and the pressure drop are increased by 40 and 240% in comparison with to the plain tube. It is observed that the twisted tape with the twist ratio of 9 has the best performance enhancing the heat transfer with the minimum pressure drop. Also empirical correlations are developed to predict smooth tube and swirl flow pressure drop. Predicted results are compared to experimental data and it is found that these correlations are reliable for pressure drop estimation.     

Numerical simulation on the performance of trisection helical baffle heat exchangers with small baffle incline angles

ABSTRACT

Numerical simulation was conducted on oil–water heat transfer in five circumferential overlap trisection helical baffle shell–and–tube heat exchangers (cothSTHXs) with 16 tubes and incline angles of 12°, 16°, 20°, 24°, and 28° and a segmental baffle heat exchanger of the identical tube layout for comparison under laminar flow calculation conditions. The local images represent shell-side flow patterns, and heat transfer properties are presented showing the detailed “secondary vortex flow” and “shortcut leakage flow” patterns to explain the different characteristics of the six schemes. The simulation curves of the heat transfer coefficient and pressure drop are compared with those of the experimental ones, with satisfactory agreement. The average values of the shell-side heat transfer coefficient and the comprehensive index h_o/Δp_o of the 12° helical scheme are respectively 47% and 51% higher than those of the segmental baffle scheme with about the same pressure drop.     

Effect of tube diameter on boiling heat transfer of R-134a in horizontal small-diameter tubes

The boiling heat transfer of refrigerant R-134a flow in horizontal small-diameter tubes with inner diameter of 0.51, 1.12, and 3.1 mm was experimentally investigated. Local heat transfer coefficient and pressure drop were measured for a heat flux ranging from 5 to 39 kW/m², mass flux from 150 to 450 kg/m² s, evaporating temperature from 278.15 to 288.15 K, and inlet vapor quality from 0 to 0.2. Flow patterns were observed by using a high-speed video camera through a sight glass at the entrance of an evaporator. Results showed that with decreasing tube diameter, the local heat transfer coefficient starts decreasing at lower vapor quality. Although the effect of mass flux on the local heat transfer coefficient decreased with decreasing tube diameter, the effect of heat flux was strong in all three tubes. The measured pressure drop for the 3.1-mm-ID tube agreed well with that predicted by the Lockhart–Martinelli correlation, but when the inner tube diameter was 0.51 mm, the measured pressure drop agreed well with that predicted by the homogenous pressure drop model. With decreasing tube diameter, the flow inside a tube approached homogeneous flow. The contribution of forced convective evaporation to the boiling heat transfer decreases with decreasing the inner tube diameter.