Parametric study of gross flow maldistribution in a single-pass shell and tube heat exchanger in turbulent regime

Uniform distribution of flow in tube bundle of shell and tube heat exchangers is an arbitrary assumption in conventional heat exchanger design. Nevertheless, in practice, flow maldistribution may be an inevitable occurrence which may have severe impacts on thermal and mechanical performance of heat exchangers i.e. fouling. The present models for flow maldistribution in the tube-side deal only with the maximum possible velocity deviation. Other flow maldistribution models propose and recommend the use of a probability distribution, e.g. Gaussian distribution. None of these, nevertheless, estimate quantitatively the number of tubes that suffer from flow maldistribution. This study presents a mathematical model for predicting gross flow maldistribution in the tube-side of a single-pass shell and tube heat exchanger. It can quantitatively estimate the magnitude of flow maldistribution and the number of tubes which have been affected. The validation of the resultant model has been confirmed when compared with similar study using computational fluid dynamics (CFD).     

Numerical estimation of mixed convection heat transfer in vertical helically coiled tube heat exchangers

A numerical investigation of the mixed convection heat transfer from vertical helically coiled tubes in a cylindrical shell at various Reynolds and Rayleigh numbers, various coil‐to‐tube diameter ratios and non‐dimensional coil pitches was carried out. The particular difference in this study compared with other similar studies is the boundary conditions for the helical coil. Most studies focus on constant wall temperature or constant heat flux, whereas in this study it was a fluid‐to‐fluid heat exchanger. The purpose of this article is to assess the influence of the tube diameter, coil pitch and shell‐side mass flow rate on shell‐side heat transfer coefficient of the heat exchanger. Different characteristic lengths were used in the Nusselt number calculations to determine which length best fits the data and finally it has been shown that the normalized length of the shell‐side of the heat exchanger reasonably demonstrates the desired relation. Copyright © 2010 John Wiley & Sons, Ltd.     

Transient heat transfert in coflow heat exchanger

More than ever before, dynamic investigation techniques are becoming widely used in the control systems, parameter implementation and state estimators. Indeed, dynamical models describing the response of process systems that are subject to disturbances play a vital role in controlling and optimising these systems. Recently developed in literature, the method of step response analysis provides a promising means towards solving some of the problems associated with the characterisation of transient response of heat exchangers. In Abdelghani-Idrissi et al. (Int J Heat Mass Transfer 44:3721–3730, 2001), authors present analytical expressions of fluids temperatures response time of counter-current heat exchanger when hot fluid step change is applied in the internal tube. This paper describes the extension of this technique to a coflow heat exchanger for which the exact solution of its mathematical model is unavailable.     

Heat transfer characteristics of a new helically coiled crimped spiral finned tube heat exchanger

In the present study, the heat transfer characteristics in dry surface conditions of a new type of heat exchanger, namely a helically coiled finned tube heat exchanger, is experimentally investigated. The test section, which is a helically coiled fined tube heat exchanger, consists of a shell and a helical coil unit. The helical coil unit consists of four concentric helically coiled tubes of different diameters. Each tube is constructed by bending straight copper tube into a helical coil. Aluminium crimped spiral fins with thickness of 0.5 mm and outer diameter of 28.25 mm are placed around the tube. The edge of fin at the inner diameter is corrugated. Ambient air is used as a working fluid in the shell side while hot water is used for the tube-side. The test runs are done at air mass flow rates ranging between 0.04 and 0.13 kg/s. The water mass flow rates are between 0.2 and 0.4 kg/s. The water temperatures are between 40 and 50°C. The effects of the inlet conditions of both working fluids flowing through the heat exchanger on the heat transfer coefficients are discussed. The air-side heat transfer coefficient presented in term of the Colburn J factor is proportional to inlet-water temperature and water mass flow rate. The heat exchanger effectiveness tends to increase with increasing water mass flow rate and also slightly increases with increasing inlet water temperature.     

Measurement of heat transfer coefficient and axial dispersion coefficient using temperature oscillations

A periodic transient test technique based on the axial dispersion model is proposed for the determination of both heat transfer coefficients and axial dispersion coefficients in heat exchangers. The model uses a parameter called the axial dispersive Peclet number to account for the deviation of the flow pattern from ideal plug flow. It takes both axial dispersion in the fluid and axial heat conduction in the wall into account and is solved analytically by means of a complex Fourier transform. Experiments conducted on dented copper tubes show that axial dispersion has a significant effect on the dynamic temperature response of a heat exchanger.     

Quantitative infrared investigation of local heat transfer in a circular finned tube heat exchanger assembly

This work deals with the local heat transfer coefficient evaluation over the fin of the second row of a staggered circular finned tube heat exchanger assembly. The coefficient distribution is determined by using a transient technique and by calculating the energy balance during the fin cooling. The calculation model takes into account radiation with the surrounding and lateral heat conduction into the material. The method uses infrared measurements and integration between time bounds that depend on space. It is proposed to choose the integration bounds with an original criterion based on local heat transfer. Validation is performed on the reference case consisting in a thin plate in an aerodynamically and thermally developing channel flow. Then, distributions of Nusselt number on the circular fin are presented for several Reynolds numbers. The high resolution of the whole method and set-up allow detecting thermal imprints of developing horseshoe vortices. These imprints are analyzed by following their angular evolution around the tube.     

Thermal-economic multi-objective optimization of shell and tube heat exchanger using particle swarm optimization (PSO)

Many studies are performed by researchers about shell and tube heat exchanger (STHE) but the multi-objective particle swarm optimization (PSO) technique has never been used in such studies. This paper presents application of thermal-economic multi-objective optimization of STHE using PSO. For optimal design of a STHE, it was first thermally modeled using e-number of transfer units method while Bell–Delaware procedure was applied to estimate its shell side heat transfer coefficient and pressure drop. Multi objective PSO (MOPSO) method was applied to obtain the maximum effectiveness (heat recovery) and the minimum total cost as two objective functions. The results of optimal designs were a set of multiple optimum solutions, called ‘Pareto optimal solutions’. In order to show the accuracy of the algorithm, a comparison is made with the non-dominated sorting genetic algorithm (NSGA-II) and MOPSO which are developed for the same problem.     

Further understanding of twisted tape effects as tube insert for heat transfer enhancement

Tube inserts are used as heat transfer enhancement tool for both retrofit and new design of shell and tube heat exchangers. This paper discusses and reviews the characteristics and performance of twisted tapes. The theory and application are also addressed. Industrial case study was selected to illustrate the behaviour effect that the twisted tapes impose at various laminar, transition and turbulent flow regions. This effect was demonstrated by changing the inside tube diameter and twist ratio through evaluating selected exchanger design parameters such as: local heat transfer coefficient, friction factor and pressure drop. Testing the exponent powers for Re and Pr at both laminar and turbulent regions were carried out. General design considerations are outlined for the use of twisted tapes in shell and tube heat exchangers.     

Experimental studies of a double-pipe helical heat exchanger

An experimental study of a double-pipe helical heat exchanger was performed. Two heat exchanger sizes and both parallel flow and counterflow configurations were tested. Flow rates in the inner tube and in the annulus were varied and temperature data recorded. Overall heat transfer coefficients were calculated and heat transfer coefficients in the inner tube and the annulus were determined using Wilson plots. Nusselt numbers were calculated for the inner tube and the annulus. The inner Nusselt number was compared to the literature values. Though the boundary conditions were different, a reasonable comparison was found. The Nusselt number in the annulus was compared to the numerical data. The experimental data fit well with the numerical for the larger heat exchanger. But, there were some differences between the numerical and experimental data for the smaller coil; however these differences may have been due to the nature of the Wilson plots. Overall, for the most part the results confirmed the validation of previous numerical work.     

小管径管翅式换热器气压胀接成形机理研究

管翅式换热器是制冷行业中最常用的换热器形式,其换热管的胀接性能决定了换热器的传热性能.本文提出了管翅式换热器的三维流-固耦合模型,采用单向流固耦合瞬态数值模拟方法,对小管径管翅式换热器的流体和固体域的流动和变形特征开展了数值研究.计算结果表明:根据换热管和翅片的胀接成形要求和胀后管径要求,气压胀接压力的合理范围为P=12.5 MPa,与理论公式推导值一致.根据管翅应力随时间变化的规律可知,换热管接头处应力远大于其屈服极限66 MPa,翅片接头处应力刚好略大于其屈服极限132 MPa,满足胀接成形要求.胀后的换热管直径随着压力的增加其管径增大,换热管的径向位移在水平方向较小,垂直方向较大,其最大和最小位移差约为0.03 mm.探究了管翅间残余接触压力随胀接压力的变化,残余接触压力随胀接压力的变化可分为三个阶段.结果表明当胀接压力使得翅片内孔发生屈服后,继续增大胀接压力会导致胀接不完全.最后研究了保压时间的影响,结果表明保压时间的增加对胀接效果并没有明显影响.相关结果可为工程实际中小管径管翅式换热器气压胀接工艺提供理论指导.     

Modelluntersuchungen des Wärmeaustausches und Strömungswiderstandes an den Heizflächen mit Diagonalflossen

This paper presents the results of an experimental study on the heat transfer and pressure drop in diagonally finned tube banks. The investigations have been carried out using the napthalene analogy. The performance of a heat exchanger with fins arranged a certain angle to the flow direction with the plain tube heat exchanger have been compared.     

A review on transient test techniques for obtaining heat transfer design data of compact heat exchanger surfaces

Accurate and reliable dimensionless heat transfer characteristic is very essential for the analysis of heat exchangers. It is also required for the rating and sizing problems of heat exchangers. One of the important experimental methods used to determine the heat transfer coefficient between the heat transfer surface of the heat exchanger and the flowing fluid is transient test techniques. The transient test techniques are usually employed to establish Colburn factor versus Reynolds number characteristics of a high NTU heat exchanger surfaces like compact or matrix heat exchangers. In those situations, a single-blow test, where only one fluid is used, is employed to conduct the transient test. The transient technique may have the fluid inlet temperature having a step change, periodic or an arbitrary rise/drop. In this paper, various transient test techniques that are used for the determination of heat transfer characteristics of high NTU heat exchanger surfaces are discussed.     

Fouling resistance model for prediction of CaCO3 scaling in AISI 316 tubes

The term fouling is generally used to describe the deposition of unwanted (initially fluid) particles, which increases both resistance to heat transfer and pressure drop through the heat exchanger. CaCO₃ which is predominantly present in the cooling water, has inverse solubility characteristics i.e., it is less soluble in warm water, resulting in deposition of scales in heat transfer equipment. An experimental program is described in this paper to study the growth of fouling as a function of tube surface temperature, Reynolds number, tube diameter and the time for which the tube has been subjected to the scale forming solution. The data collected from the experiments are used to develop a fouling resistance model. In addition, the results obtained from the present study are also compared with those discussed earlier by several investigators with regard to CaCO₃ fouling.     

Experimental and numerical study on unsteady natural convection heat transfer in helically coiled tube heat exchangers

Both of experimental and numerical investigations were performed to understand unsteady natural convection from outer surface of helical coils. Four helical coils with two different curvature ratios were used. Each coil was mounted in the shell both vertically and horizontally. The cold water was entered the coil and the hot water in the shell was cooling by unsteady natural convection. A CFD code was developed to simulate natural convection heat transfer. Equations of tube and shell are solved simultaneously. Statistical analyses have been done on data points of temperature and natural convection Nusselt number. It was revealed that shell-side fluid temperature and the Nusselt number of the outer surface of coils are functions of in-tube fluid mass flow rate, specific heat of fluids and geometrical parameters including length, inner diameter of the tube and the volume of the shell, and time.     

换热器传热管在静水中的挤压膜阻尼研究

本文通过求解三维Navier-Stokes方程,导出计算挤压膜阻尼的公式,对Mulcahy所提出的模型作了改进,并提出了stokes数的间隙修正因子的概念. 改进后的挤压膜阻尼模型计及管子振幅的影响,在管子振幅很小的情况下,它与Mulcahy提出的模型相似,实际上可把Mulcahy提出的模型看成改进后模型的一个特例. 为了验证改进后的模型,对传热管在空气和静水介质中的阻尼进行了实验研究.结果表明理论计算值与实验测量值符合良好.     

Heat extraction characteristics of a single U-tube downhole heat exchanger with square cross section

The heat extraction rate from a stratum using a single U-tube downhole heat exchanger with square cross section was studied numerically. First, the present computer simulation program was made, and the computed results were checked with the field experimental data conducted by other researchers. After inspecting the effectiveness of the present computer simulation program, a numerical simulation was performed for a working 50-m full-scale model of in U-tube depth with this program. The effects of the flow rate of the heat extraction medium (water) and that of the tube material on the heat extraction rate were investigated for the case of a single U-tube. The computed results showed that increasing the flow rate of the working fluid of the heat extraction medium increases the heat extraction rate, and also suggests that the use of resin, such as polyethylene or polyvinyl chloride, for the tube is a possible alternative, even though a resin tube is inferior to a metal version with respect to heat transfer performance.     

Instantaneous Squeeze-Film Force Between a Heat Exchanger Tube and a Support Plate for Arbitrary Tube Motion

The instantaneous squeeze-film force between a heat exchanger tube and a support plate is studied. Based on a two-dimensional rectangular plate model, a short-sleeve squeeze-film model for arbitrary tube motion is developed. The instantaneous squeeze-film force is expressed in normal and tangential directions. The normal squeeze-film force consists of four nonlinear terms, the viscous, unsteady inertia, convective inertia and centripetal inertia terms. Three nonlinear terms, the viscous, unsteady inertia and Coriolis inertia terms, make up the tangential squeeze-film force. An experimental apparatus was developed in order to evaluate the theoretical models against measurements of a finite length squeeze film. A modified model based on the experimental data is obtained where the viscous terms for both directions are multiplied by the instantaneous Reynolds number. All the inertia terms are multiplied by constant coefficients. The modified model is in good agreement with most experimental cases for unsymmetrical linear motion, approximate circular motion and elliptical motion. The form of the modified model is suitable for predicting instantaneous squeeze-film forces in the simulation of heat exchanger tube vibration. Further work using different sized components and fluid properties is required in order to finalize coefficient values.     

Dynamic response of the crossflow heat exchanger with finite wall capacitance

This paper shows how the transient response of a cross-flow heat exchanger with finite wall capacitance may be calculated by analytical method. Making usual idealizations for the analysis of dynamic behavior of the heat exchanger, the model is based on three local energy balance equations which are solved by using the Laplace transform method for step change of the primary fluid inlet temperature. The solutions are found in the case of constant initial conditions and expressed in the explicit analytical form used to find temperature distributions of both fluids and the wall as well as the mean mixed fluid temperatures at the exit. Presented solutions are valid in cases where fluid velocities are different or equal and finite or infinite, respectively.The solutions can be very suitable for mathematical modeling systems containing such types of heat exchangers.     

Equations for transient behaviour of parallel-flow multichannel heat exchangers

A set of partial differential equations is formulated which describes the transient behaviour of parallel-flow multichannel heat exchangers. In the model, the heat capacitance of walls is neglected and heat is assumed to be transferred only in the direction perpendicular to the direction of flow of fluids. The set is solved by the MacCormack predictor-corrector method for a sample four-channel heat exchanger. Three cases of transient behaviour of the exchanger are investigated: uniform initial temperatures in all channels, a step change in flow rate in one channel, and a step change in inlet temperature of one fluid. In the last two cases, the exchanger is initially at steady state.     

Heat transfer and pressure loss of a very shallow fluidized-bed heat exchanger Part 2. Experiment with multirow tube banks

Experiments were carried out on heat transfer and pressure-loss characteristics of a low-pressure-loss fluidized-bed heat exchanger with an extremely small ststic bed height of glass beads. This heat exchanger was composed of a tube bankd in a staggered arrangement and a multislit distributor designed especially to reduce the pressure loss. The effect of the cross-sectional shape of the distributor, the particle size of the glass beads, the static bed height, and the number of rows on heat transfer performance were examined. The heat transfer and pressure-loss characteristics are compared with experimental data in terms of fan power consumption and the compactness of the heat exchanger.