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Abstract
When the helix angle was varied from 00 to 200 for the heat exchanger containing 7 tubes of outer diameter 20 mm and a
600 mm long shell of inner diameter 90 mm, the simulation shows how the pressure vary in shell due to different
helix angle and flow rate. The heat transfer coefficient when recorded showed a very high value when the pressure inside
the heat exchanger registered a decline value and this incremental hike was found to be highly significant in the present
study. This might be due to the rotational and helical nature of flow pattern following the geometry change by the
introduction of continuous helical baffles in the shell side of the heat exchanger. The simulation results obtained with
Computational fluid dynamics tools for the baffle cut given to the modified heat exchanger are utilized for the calculation of
various parameters like the pressure decline, desired baffle inclination angle and mass flow rate, outlet temperature at the
shell side and recirculation at baffle side for the particular geometry of the heat exchanger. Small corners at variable angles
of the liquid flow are the result of introduction of segmental baffles which improves heat transfer and huge decline in
pressure thus increasing the fouling resistance. This recorded an effective heat transfer hike by the impact of helical baffle.
The most desirable heat transfer coefficient of the highest order and pressure decline of the lowest order are the result
generated in heat exchanger. Thus, the present study conclusively improved the performance of the heat exchanger by the use
of helical baffle in place of segmental baffle from the numerical experimentation results.
Keywords: Shell and tube heat exchanger, computational fluid dynamics tools, helix Baffles, Heat Transfer Coefficient,
Pressure Decline.
Introduction
Highest thermal performance is the key factor determining the
efficiency of any Shell and Tube Heat Exchanger. Hence, in the
design of Heat Exchanger, the foremost considerations should
be given to the cost and effectiveness so as to improve its
efficiency. The baffles of helical type instead of segmental type
when used in conjunction with changes in its geometry by
giving a full 3600 CFD model inclination, a higher decline in
pressure across the heat exchanger could be achieved using
Ansys tools. The temperature distribution and flow structure are
favorably obtained upon fine modelling the geometry
accurately. The present study is taken up with the major
objective of obtaining pressure decline at shell side and
consequent achievement of hike in heat transfer by design and
simulation of angle of helical baffles.
Lutcha and Nemcansky1 upon investigation of the flow field
patterns generated by various helix angles used in helical baffle
geometry found that the flow patterns obtained in their study are
similar to plug flow condition which is expected to decline
pressure at shell side and increase heat transfer process
significantly. Stehlik et al.2 studied the effect of optimized
segmental baffles and helical baffles in heat exchanger based on
Bell-Delaware method and demonstrated the heat transfer and
pressure decline correction factors for a heat exchanger. OilInternational Science Congress Association
1
RePr
x Kx T+y Ky T
Figure-1
Tube layout and arrangement
0.0
100.0
200.0 (mm)
50.0
150.0
Figure--2
Computational model of Shell and tube heat exchanger with
tubes and baffle inclination
Table-1
1
Geometric dimensions of shell and tube heat exchanger
Length of Heat exchanger, (L)
600 mm
Inner diameter of Shell (Di)
90 mm
Outer diameter of Tube (do)
20 mm
Tube bundle geometry and pitch (Triangular)
30 mm
Number of tubes (Nt)
7
Number of baffles (Nb)
6
Central baffle spacing B
86 mm
Baffle inclination angle ()
0 to 40
In order to get the correct velocity and thermal boundary layers
with much less computation, the hexahedral mesh elements
were utilized in discretizing the 3 D model in ICEM CFD. Fine
control near the wall surface on hexahedral mesh was ensured
so as to get
et the correct boundary layer gradient. In an effort to
get correct number of nodes, best control was obtained by
discretizing the shell and tube heat exchanger into solid and
fluid domains. For six baffles of the entire geometry divisions,
the fluid domains
ns are distinguished as Fluid Inlet, Fluid Outlet
and Fluid Shell and the solid domains are numbered from Solid
Baffle 1 to Solid Baffle 6. Fluid mesh finer than solid mesh is
used in the simulation of conjugate heat transfer process. In
order to capture velocity
elocity and thermal boundary layers, a fluid
domain which spans 100 microns is the height of the 1st cell
from the tube surface. A minimum angle and minimum
determinant of 180 and 4.12 respectively are found when the
discretized model is checked for quality.
qualit The minimum required
quality is met when the meshes are checked for errors and then
it is exported to the pre-processor
processor (ANSYS CFX).
Initially a relatively coarser mesh is generated with 1.8
Million cells. This mesh contains mixed cells (Tetra and
Hexahedral cells) having both triangular and quadrilateral
faces at the boundaries. Care is taken to use structured
cells (Hexahedral) as much as possible, for this reason the
geometry is divided into several parts for using automatic
methods available in the ANSYS meshing client. It is
0.000
0.200 (m)
0.100
Figure-3
Meshing diagram of shell and tube heat exchanger
299.96
307.94
305.28
302.63
313.24
310.59
337.10
334.44
331.79
329.14
326.49
323.84
321.19
318.54
315.89
345.05
342.40
339.75
353.00
350.35
347.70
Figure-4
Surface mesh with Helical Baffle and tube bundle of shell
and tube heat exchanger
Figure--5
Temperature Distribution across the tube and shell
10
307.94
305.28
302.63
299.96
313.24
310.59
321.19
318.54
315.89
337.10
334.44
331.79
329.14
326.49
323.84
345.05
342.40
339.75
350.35
347.70
Figure-6
Temperature Distribution for 100 baffle inclination
299.96
307.94
305.28
302.63
313.24
310.59
321.19
318.54
315.89
337.10
334.44
331.79
329.14
326.49
323.84
345.05
342.40
339.75
350.35
347.70
353.00
0.97
0.65
0.32
0.00
1.62
1.29
2.58
2.26
1.94
4.52
4.20
3.88
3.55
3.23
2.91
6.14
5.81
5.49
5.17
4.85
1.74
1.40
1.05
0.70
0.35
0.00
4.53
4.19
3.84
3.49
3.14
2.79
2.44
2.09
5.58
5.23
4.88
Figure--9
Velocity profile across the shell at 00 baffle inclination
6.63
6.26
5.93
6.98
Figure-7
Temperature Distribution of 200 baffle inclination
6.46
307.94
305.28
302.63
299.96
313.24
310.59
321.19
318.54
315.89
337.10
334.44
331.79
329.14
326.49
323.84
345.05
342.40
339.75
350.35
347.70
353.00
Figure--8
Temperature Distribution across Tube outlet in 00 baffle
inclination
Figure-10
10
Velocity profile across the shell at 100 baffle inclination
11
Figure-11
Velocity profile across the shell at 200 baffle inclination
1.38e5
1.26e5
1.15e5
1.03e5
9.18e4
8.04e4
6.89e4
5.75e4
4.60e4
3.46e4
2.31e4
1.17e4
2.26e2
-1.12e4
1.72e5
1.61e5
1.49e5
2.18e5
2.06e5
1.95e5
1.83e5
1.74
1.40
1.05
0.70
0.35
0.00
2.79
2.44
2.09
5.58
5.23
4.88
4.53
4.19
3.84
3.49
3.14
6.63
6.26
5.93
6.98
Figure-13
13
Pressure Distribution across the shell at 100 baffle
inclination
1.38e5
1.26e5
1.15e5
1.03e5
9.18e4
8.03e4
6.89e4
5.75e4
4.60e4
3.46e4
2.31e4
1.17e4
2.17e2
-1.12e4
1.72e5
1.60e5
1.49e5
2.18e5
2.06e5
1.95e5
1.83e5
2.13e5
2.02e5
1.90e5
1.79e5
1.67e5
1.55e5
1.44e5
1.32e5
1.21e5
1.09e5
9.78e4
8.63e4
7.47e4
6.32e4
5.16e4
4.01e4
2.86e4
1.70e4
5.51e3
-6.02e3
-1.76e4
14
Figure-14
Pressure Distribution across the shell at 200 baffle
inclination
Figure-12
Pressure Distribution across the shell at 00 baffles
inclination.
Table-2
Change in Outlet Temperature with respect to baffle inclination angle
Baffle Inclination Angle
Outlet Temperature of Shell side
Outlet Temperature of Tube side
(Degree)
(Kelvin)
(Kelvin)
0
346
317
10
347.5
319
20
349
320
12
Temperature
350
340
Shell
Outlet
330
320
310
300
0
10
20
Figure-15
Plot of Baffle inclination angle vs Outlet Temperature of
shell and tube side
It has been found that the increasing baffle inclination angle
from 00 to 200 affect the outlet temperature of shell side
significantly. Pressure Decline inside Shell with respect to
baffle inclination angle is provided in table 3.
Similar results were reported by Diaper and Hesler, 199014,
Sunil and Pancha15 and Zhang et al., 200816 using
Computational Fluid Dynamics software. Pressure Decline
inside Shell with respect to baffle inclination angle is provided
in figure-16.
16. Velocity inside the shell with respect to baffle
inclination angle from 00 to 200 is detailed in table 4 and figure17.
The shell-side
side pressure declines when the baffle inclination
angle is increased from 00 to 200. For shell and tube heat
exchanger a 100 baffle inclination angle results in pressure drop
of 4 per cent and 200 baffle inclination angle results in pressure
drop of 16 per cent when compared to the pressure drop at 00
baffle inclination angle as shown in figure-16. So, it is
generalized that with increase in baffle inclination, pressure
decline decreases, so that it affect in heat transfer rate, which is
increased.
Table-3
3
Pressure Decline inside Shell with respect to baffle
inclination angle
Baffle Inclination Angle
Pressure Decline Inside
(Degree)
Shell (kPA)
0
230.992
10
229.015
20
228.943
Table-4
4
Velocity inside Shell with respect to baffle inclination angle
Baffle Inclination Angle
Velocity inside shell
(Degree)
(m/sec)
0
4.2
10
5.8
20
6.2
Similar performance resulting from baffle inclinations in heat
exchangers are reported by Thirumarimurugan et al., 200817.
231.5
231
230.5
230
Pressure
229.5
229
228.5
228
227.5
0
10
20
Baffle angle
Figure-16
Plot of Baffle angle vs Pressure Decline
13
Table-5
Heat Transfer Rate across Tube side with respect to baffle
inclination angle
Baffle Inclination Angle
Heat Transfer Rate Across
(Degree)
Tube side (W/m2)
0
3557.7
10
3972.9
20
4182
Velocity (m/s)
6
5
4
3
Velocity
2
1
0
0
10
20
(W/m2)
Figure-17
Plot of Velocity profile inside shell
4300
4200
4100
4000
3900
3800
3700
3600
3500
3400
3300
3200
10
20
14
Baffle inclination
(in Degree)
00
100
200
Table-6
Overall Calculated value in Shell and Tube heat exchanger in simulation
Shell Outlet
Tube Outlet
Pressure
Heat Transfer
Temperature
Temperature
Drop
Rate(Q) (in W/m2)
(Kelvin)
(Kelvin)
346
317
230.992
3554.7
347.5
319
229.015
3972.9
349
320
228.943
4182
Outlet
Velocity(m/s)
4.2
5.8
6.2
Conclusion
The following are the salient points emerged from this study.
3.
4.
5.
6.
7.
8.
9.
th
References
1.
2.
15
16