The Testing and Model Validation of an Additively Manufactured Twisted Tube Heat Exchanger

2019 ◽  
Author(s):  
John D. Bernardin ◽  
Kyle Ferguson ◽  
David Sattler
Keyword(s):  
Heat Transfer ◽  
Heat Exchanger ◽  
Transfer Rate ◽  
Straight Tube ◽  
Cfd Model ◽  
Tube Heat Exchanger ◽  
Twisted Tube ◽  
Overall Heat Transfer Coefficient ◽  
Shell And Tube ◽  
Tube Shell

Abstract Performance enhancements in heat exchanger design and manufacturing have been achieved over the past several decades through a combination of improved thermal-hydraulic modeling and experimentation tools, enhancements in material formulations and associated property characterizations, and new manufacturing methods. Most recently, Additive Manufacturing (AM) methods have matured sufficiently that they are now being considered as realizable heat exchanger fabrication methods. More complex, compact, and efficient designs can be achieved with AM methods that could not be easily obtained through more traditional manufacturing techniques. This study expands upon a previous work [1] in which an optimized twisted tube shell and tube stainless steel heat exchanger was designed, analyzed, and fabricated with a Direct Metal Laser Sintering (DLMS) AM method. In that study, the twisted tube heat exchanger performance was a considerable improvement over that of a traditional straight tube shell and tube heat exchanger. In the present study, the AM twisted tube heat exchanger was subjected to thermal-hydraulic tests to measure its performance and to identify any necessary refinements to the previous CFD model. For the conditions used in this study, the experimental data will show how the previous CFD model over-predicted the twisted tube heat exchanger’s heat transfer rate of 2,297 W and under predicted its overall heat transfer coefficient of 1,008 W/m2/K. Interrogation of the CFD model found that this discrepancy was due to the utilization of a k-ε turbulence model. Once this turbulence characterization was replaced with a more suitable shear transport model, the numerical predictions and experimental measurements of total heat transfer rate and overall heat transfer coefficient were in very close (∼10%) agreement. When combined with the previous study, this current work reveals how a complex, twisted tube shell and tube heat exchanger can be designed with existing CFD modeling tools and efficiently manufactured with current AM technologies to significantly improve its performance over a more traditionally manufactured straight tube version of the heat exchanger.

scholarly journals Experimental Investigation Of Heat Transfer Characteristics Of Nanofluid Using Parallel Flow, Counter Flow And Shell And Tube Heat Exchanger

2015 ◽  
Vol 62 (4) ◽  
pp. 509-522 ◽  
Author(s):  
R. Dharmalingam ◽  
K.K. Sivagnanaprabhu ◽  
J. Yogaraja ◽  
S. Gunasekaran ◽  
R. Mohan
Keyword(s):  
Heat Transfer ◽  
Heat Transfer Coefficient ◽  
Heat Exchanger ◽  
Transfer Coefficient ◽  
Mass Flow Rate ◽  
Mass Flow ◽  
Flow Rate ◽  
Tube Heat Exchanger ◽  
Overall Heat Transfer Coefficient ◽  
Shell And Tube

Abstract Cooling is indispensable for maintaining the desired performance and reliability over a very huge variety of products like electronic devices, computer, automobiles, high power laser system etc. Apart from the heat load amplification and heat fluxes caused by many industrial products, cooling is one of the major technical challenges encountered by the industries like manufacturing sectors, transportation, microelectronics, etc. Normally water, ethylene glycol and oil are being used as the fluid to carry away the heat in these devices. The development of nanofluid generally shows a better heat transfer characteristics than the water. This research work summarizes the experimental study of the forced convective heat transfer and flow characteristics of a nanofluid consisting of water and 1% Al2O3 (volume concentration) nanoparticle flowing in a parallel flow, counter flow and shell and tube heat exchanger under laminar flow conditions. The Al2O3 nanoparticles of about 50 nm diameter are used in this work. Three different mass flow rates have been selected and the experiments have been conducted and their results are reported. This result portrays that the overall heat transfer coefficient and dimensionless Nusselt number of nanofluid is slightly higher than that of the base liquid at same mass flow rate at same inlet temperature. From the experimental result it is clear that the overall heat transfer coefficient of the nanofluid increases with an increase in the mass flow rate. It shows that whenever mass flow rate increases, the overall heat transfer coefficient along with Nusselt number eventually increases irrespective of flow direction. It was also found that during the increase in mass flow rate LMTD value ultimately decreases irrespective of flow direction. However, shell and tube heat exchanger provides better heat transfer characteristics than parallel and counter flow heat exchanger due to multi pass flow of nanofluid. The overall heat transfer coefficient, Nusselt number and logarithmic mean temperature difference of the water and Al2O3 /water nanofluid are also studied and the results are plotted graphically.

scholarly journals Performance Analysis of Shell and Tube Type Heat Exchanger Using Aluminium Oxide (Al2O3) Nano-Particle

2021 ◽  
Vol 9 (9) ◽  
pp. 157-164
Author(s):  
Paritosh Singh
Keyword(s):  
Heat Transfer ◽  
Thermal Conductivity ◽  
Heat Transfer Coefficient ◽  
Heat Exchanger ◽  
Transfer Coefficient ◽  
Solid Particles ◽  
Tube Heat Exchanger ◽  
Overall Heat Transfer Coefficient ◽  
Shell And Tube ◽  
Evacuated Tube

Abstract: Research in convective heat transfer using suspensions of nanometer sized solid particles in a base fluid started only over the past decade. Recent investigations on nanofluids, as such suspensions are often called, indicate that the suspended nanoparticles markedly change the transport properties and heat transfer characteristics of the suspension. The very first part of the research work summarizes about the various thermo physical properties of Al2O3 Nanofluid. In evacuated tube solar water heating system nanofluids are used as primary fluid and DM water as secondary fluid in Shell and Tube Heat Exchanger. The experimental analysis of Shell and Tube heat exchanger integrated with Evacuated tube solar collector have been carried out with two types of primary fluids. Research study of shell and tube heat exchanger is focused on heat transfer enhancement by usage of nano fluids. Conventional heat transfer fluids have inherently low thermal conductivity that greatly limits the heat exchange efficiency. The result of analysis shows that average relative variation in LMTD and overall heat transfer coefficient is 24.56% and 52.0% respectively. The payback period of system is reduced by 0.4 years due to saving is in replacement cost of Evacuated Tube Collector. Keywords: ETC; Nanofluid; LMTD; Thermal Conductivity; Overall heat transfer coefficient

Effectiveness study in shell and tube heat exchanger at various concentrations of CuO nanofluid for parallel flow

2021 ◽  
pp. 095440622110007
Author(s):  
Syed Sameer ◽  
SB Prakash ◽  
G Narayana Swamy
Keyword(s):  
Heat Transfer ◽  
Thermal Conductivity ◽  
Heat Transfer Coefficient ◽  
Heat Exchanger ◽  
Base Fluid ◽  
Cuo Nanoparticles ◽  
Parallel Flow ◽  
Tube Heat Exchanger ◽  
Overall Heat Transfer Coefficient ◽  
Shell And Tube

Nanoparticles enhances the heat transfer between particles and the fluids due to their high specific surface area and adjustable properties, including thermal conductivity and surface wettability, by varying particle volume concentrations in the base fluid to suit different applications. This article is an experimental study on the effectiveness and overall heat transfer coefficient in STHE (shell and tube heat exchanger), comprising baffle cut 25% with a nanofluid at 0.05, 0.1, and 0.2 percentage concentrations of CuO nanoparticles in the DW (distilled water) base-fluid. The inclusion of 0.15% SDBS (Sodium dodecyl-benzene sulphonate) by a two-step method as a surfactant improves the stability of dispersed CuO nanoparticles. The CuO/DW nanofluid thermo-physical properties such as thermal conductivity (k), density (ρ), and dynamic viscosity (μ), have increased. However, the nanofluid's specific heat (Cp) reduces as the nanoparticles proportion rises in the DW base fluid. There is an enhancement of the overall heat transfer coefficient and effectiveness compared to water during parallel flow variation. The maximum heat exchanger effectiveness was 3.01%, 4.01%, and 5.94% higher than water at 0.6 lpm mass flow rate and temperature T = 80 °C for volume fractions of 0.05, 0.1, and 0.2 percentage of CuO/DW nanofluid respectively during parallel flow.

scholarly journals Investigation on fluid flow heat transfer and frictional properties of Al2O3 nanofluids used in shell and tube heat exchanger

2020 ◽  
Author(s):  
sreejesh S R chandran ◽  
Debabrata Barik ◽  
ANSALAM RAJ T G ◽  
Reby ROY
Keyword(s):  
Heat Transfer ◽  
Heat Exchanger ◽  
Transfer Rate ◽  
Working Fluid ◽  
Flow Properties ◽  
Counter Flow ◽  
Tube Heat Exchanger ◽  
Frictional Properties ◽  
Flow Heat ◽  
Shell And Tube

Abstract Nanofluids are generally utilized in providing cooling, lubrication phenomenon, controlling the thermophysical properties of the working fluid. In this work, nanoparticles of Al2O3 are added to the base fluid which flows through the counter flow arrangement in a turbulent flow condition. The hot and cold fluids used are ethylbenzene and water respectively and have different velocities on both shell and tube side. This study emphasizes the analysis of flow properties, friction loss, and energy transfer in terms of heat using nanofluid in the heat exchanger. The heat transfer rate of present investigation with nanoparticle addition is 4.63% higher in comparision to Dittus Boelter correlation. Apart from this, the obtained friction factor is 0.0376 very much closer to Gnielinski and Blasius correlations. This investigation proved that appropriate nanoparticle additions and baffle inclinations have fabulous impact upon the performance of heat exchanger and its effectiveness.

scholarly journals Design and Analysis of double- stacked Heat Exchanger for Brewery Application

2020 ◽  
Vol 9 (1) ◽  
pp. 1793-1798
Keyword(s):  
Heat Transfer ◽  
Heat Exchanger ◽  
Pressure Drop ◽  
Heat Transfer Rate ◽  
Flow Rate ◽  
Transfer Rate ◽  
Working Fluid ◽  
Support Weight ◽  
Tube Heat Exchanger ◽  
Shell And Tube

A heat exchanger is a device intensively used for enhancing the transfer of heat energy between two or more working fluids at different temperature, which are in thermal contact. The optimal design and efficient operation of heat exchanger and heat transfer network are of a great significance in any of the process industry. The heat transfer efficiency depends on both design of heat exchanger and property of working fluid. From various types of heat exchanger, the double stacked shell and tube heat exchanger with straight tube and single pass is to be under study. Here the redesign of heat exchanger takes place with the key objectives of optimizing the pressure drop, optimizing the heat transfer rate and reducing the saddle support weight used for cooling purpose in brewery application. The design calculations are carried out using the Kerns and Bell Delwar method and other important parameters dealing with material selection and geometries are also taken into consideration. FEA analysis for optimizing the saddle support weight is carried out using Dassault systeme’s Solidworks while the CFD analysis for optimizing pressure drop and heat transfer rate is carried out using Dassault systeme’s Solidworks analysis software and the design and working of Shell and tube heat exchanger is determined in terms of variables such as pressure ,temperature ,mass flow rate ,flow rate ,energy input output that are of particular interest in Shell and tube heat exchanger analysis.

scholarly journals Heat transfer analysis in counter flow shell and tube heat exchanger using of design of experiments

2021 ◽  
pp. 77-77
Author(s):  
Sakthivel Perumal ◽  
Dinesh Sundaresan ◽  
Rajkumar Sivanraju ◽  
Nega Tesfie ◽  
Kamalakannan Ramalingam ◽  
...  
Keyword(s):  
Heat Transfer ◽  
Heat Transfer Coefficient ◽  
Heat Exchanger ◽  
Transfer Coefficient ◽  
Fluid Film ◽  
Heat Transfer Analysis ◽  
Counter Flow ◽  
Tube Heat Exchanger ◽  
Overall Heat Transfer Coefficient ◽  
Shell And Tube

In this research aimed to estimate the Overall heat transfer coefficient of counter flow Shell and Tube heat exchanger. Heat transfer is the phenomenon to analysis of heat transfer from one medium of fluid to another medium of fluid, it is considered as a major role in industrial applications. Numerous heat exchangers are available, in this research considered as shell and tube heat exchanger. Overall Heat Transfer Coefficient (OHTC) informed that three major factors are influenced as passing of fluid (film) media coefficient inside the tubes, circulating of fluid (film) media coefficient over in the shell and the resistance of wall made on metal. In this study Taguchi L9 Orthogonal array is executed to found the overall heat transfer coefficient with effective process parameters. Three major parameters are considered for this work are coil diameter (25 mm, 30 mm and 35 mm), Baffle thickness (15 mm, 20 mm and 25 mm) and Baffle gap (200 mm, 300 mm and 400 mm. Baffle plate thickness is highly significant factor for this experiment.

scholarly journals Experimental Investigation and Comparison of Shell Tube and Plate Heat Exchanger used in Water Chillers

2021 ◽  
Vol 23 (1) ◽  
Author(s):  
Shamkuwar S.C ◽  
◽  
Nitin Chopra ◽  
Mihir Kulkarni ◽  
Nikhil Ahire ◽  
...  
Keyword(s):  
Heat Transfer ◽  
Experimental Investigation ◽  
Heat Exchanger ◽  
Heat Exchangers ◽  
Plate Heat Exchanger ◽  
Working Fluid ◽  
Plate Heat ◽  
Tube Heat Exchanger ◽  
Overall Heat Transfer Coefficient ◽  
Shell And Tube

The main objective of the paper is to compare the performance of Shell and tube heat exchanger (STHE) and Plate heat exchanger (PHE) used in chillers. The paper deals with experimental investigation and comparison, which is based on actual testing of STHE and PHE. Both heat exchangers were designed and tested for a heat load of 6000 kcal/hr. In both types of heat exchangers, the primary working fluid used is Refrigerant R22 and secondary working fluid used is water. Theoretical analysis shows that PHE has a 9.67 % less heat transfer area than STHE. Experimental results show that overall heat transfer coefficient (OHTC) for PHE is higher than STHE by 30.96%. The paper also includes a comparison of the heat transfer rate (Q) of the two heat exchangers experimentally.

The Design, Analysis, and Fabrication of an Additively Manufactured Twisted Tube Heat Exchanger

2017 ◽  
Author(s):  
John D. Bernardin ◽  
Kyle Ferguson ◽  
David Sattler ◽  
Seung-Jun Kim
Keyword(s):  
Heat Transfer ◽  
Heat Transfer Coefficient ◽  
Heat Exchanger ◽  
Transfer Coefficient ◽  
Rapid Development ◽  
Steel Shell ◽  
Tube Heat Exchanger ◽  
Twisted Tube ◽  
Overall Heat Transfer Coefficient ◽  
Cfd Analyses

The rapid development of Additive Manufacturing (AM) technologies has provided engineers with new methods to design and fabricate complex mechanisms. AM offers unique methods to allow for integration and simplification of components, reduced manufacturing time, fabrication of complex-shaped objects, improvements upon existing designs, and extending the creative design space which engineers rely on for ingenuity. For many applications, heat exchanger performance can be improved by reducing its size, increasing the overall heat transfer coefficient and surface area, and making more efficient use of the mechanical structure for heat exchange. Traditional manufacturing often limits or prohibits many of these enhancements due to increased manufacturing and assembly costs. This study explored using AM to design and fabricate a compact twisted tube stainless steel shell and tube heat exchanger that would improve upon all of the features just mentioned. This paper discusses the design of the heat exchanger and the AM technique used to fabricate a prototype. The manuscript will show via CFD analyses, how the heat transfer area of the unit was improved 18% and the overall heat transfer coefficient as increased by 40% over a traditional round tube heat exchanger with an identical footprint. Further, the study will show how AM was leveraged to combine five manufacturing steps into one to fabricate a prototype, fully functional twisted tube heat exchanger.

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