CFD Analysis of Heat Transfer in A Helical Coil Heat Exchanger Using Fluent

CFD ANALYSIS OF HEAT TRANSFER IN
A HELICAL COIL HEAT EXCHANGER

USING FLUENT
A THESIS SUBMITTED IN PARTIAL FULFILLMENT OF THE
REQUIREMENTS FOR THE DEGREE OF
BACHELOR IN TECHNOLOGY
IN
MECHANICAL ENGINEERING
Department of Mechanical Engineering

National Institute of Technology, Rourkela
Rourkela 769008
CFD ANALYSIS OF HEAT TRANSFER IN A HELICAL COIL HEAT

EXCHANGER USING FLUENT
A thesis submitted in partial fulfillment of the requirements
for the degree of
Bachelor of technology
In
Mechanical engineering
By
Siddhartha Shankar Behera (109ME0258)
Under the guidance of
Dr. A. K. Satapathy

National Institute of Technology
Rourkela 769008
B.Tech Thesis 2013
CERTIFICATE
This is to certify that the work in this thesis entitled CFD analysis of heat
transfer in a helical coil heat exchanger using fluent by Siddhartha Shankar
Behera, has been carried out under my supervision in partial fulfillment of the
requirements for the degree of Bachelor of Technology in Mechanical
Engineering during session 2012-2013 in the Department of Mechanical
Engineering, National Institute of Technology, Rourkela.
To the best of my knowledge, this work has not been submitted
to any
other University/Institute for the award of any degree or diploma.
Date: 07/05/2013
Dr. Ashok Kumar Satapathy

(Supervisor)
Associate Professor
National Institute of Technology, Rourkela
DEPARTMENT OF MECHANICAL ENGINEERING

NATIONAL INSTITUTE OF TECHNOLOGY, ROURKELA
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B.Tech Thesis 2013
ACKNOWLEDGEMENT
I am extremely fortunate to be involved in an exciting and challenging research
project like CFD analysis of heat transfer in a helical coil heat exchanger using
fluent. It has enriched my life, giving me an opportunity to work in a new

environment of Fluent. This project increased my thinking and understanding
capability as I started the project from scratch. I would like to express my greatest
gratitude and respect to my Supervisor Dr. Ashok Kumar Satapathy, for his excellent
guidance, valuable suggestions and endless support. He has not only been a wonderful
supervisor but also a genuine person. I consider myself extremely lucky to be able to
work under the guidance of such a dynamic personality. Actually he is one of such
genuine person for whom my words will not be enough to express.
I am also thankful to Dr. K. P. Maity, H.O.D of Department of Mechanical
Engineering, National Institute of Technology, Rourkela for his constant support and
encouragement.
Last, but not the least I extend my sincere thanks to all faculty members of
Mechanical Engineering department for making my project a successful one, for their
valuable advice in every stage and also giving me absolute working environment
where I unlashed my potential. I would like to thank all whose direct and indirect
support helped me completing my thesis in time. I want to convey my heartiest
gratitude to my parents for their unfathomable encouragement.
Siddhartha Shankar Behera

109ME0258
Bachelor of Technology, Mechanical Engineering
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B.Tech Thesis 2013
Contents
Certificate
Acknowledgement
i
ii
List of Tables
iv
List of Figures
Abstract
vi
Nomenclature
1. Introduction About the Project
vii
1
1.1 Tubular Heat Exchangers
1.2 Double Pipe Heat Exchanger
1.3 Heat Transfer Coefficients
1.4 Advantages and Disadvantages
1.5 Applications
1.6 Aim of Present Work
1.7 Introduction to CFD
1.8 Organization of Thesis
2. Literature Survey
3. CFD Analysis
3.1 Geometry
9
12
13
3.1.1 Sketching
13
3.1.2 Sweep
13
3.1.3 Merging
13
3.2 Mesh
15
3.2.1 y+ Values
15
3.2.2 Named Selection
16
3.3 Solution
17
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3.3.1 Problem Setup
17
3.3.2 Models
17
3.3.3 Materials
17
3.3.4 Cell Zone Conditions
17
3.3.5 Boundary Conditions
18
3.3.6 Reference Values
18
3.3.7 Solution Methods
18
3.3.8 Solution Controls and Initialization
19
3.3.9 Measure of Convergence
19
3.3.10 Run Calculation
20
4. Results and Discussions
21
4.1 Mass Flow Rate and Total Heat Transfer Rate
22
4.2 Contours
23
4.3 Vectors
27
4.4 Plots
29
5. Conclusions
31
6. References
32
List of Tables
Figure Number
Caption
Page Number
Naming Of Various Parts of The Body
14
y+ Values for Different Wall Treatments
15
Boundary Conditions
18
Residuals
19
Mass Flow Rate
22
Total Heat Transfer Rate
22

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Figure Number
Caption
Page Number
Double Pipe Helical Coil
Close-Up of Double Pipe Coil
Wall Convection
Original Geometry
14
Geometry for Meshing
14
Mesh
16
Close-Up View of The Mesh
16
Named Selections
17
Contours of Dynamic Pressure In Pascal
23
Contours of Total Pressure In Pascal
23
10
Contours of Static Temperature
24
11
Contours of Turbulent Dissipation Rate
24
12
Contours of Turbulent Kinetic Energy
25
13
Contours of Effective Thermal Conductivity
25
14
Contours of Total Surface Heat Flux
26
15
Contours of Cell Reynolds Number
26
16
Contours of Effective Prandtl Number
27
17
Velocity Vectors Colored by Velocity Magnitude
27
(A)
1 (B)
18
Velocity Vectors Colored by Velocity Magnitude - Close

Up
28
19
Velocity Vectors Colored by Static Pressure
28
20
Scaled Reisduals
29
21
Wall Shear Stress Plot
29
22
Total Pressure Plot
30
23
Surface Nusselt Number
30

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ABSTRACT
Heat exchangers are the important engineering systems with wide variety of
applications including power plants, nuclear reactors, refrigeration and airconditioning systems, heat recovery systems, chemical processing and food industries.
Helical coil configuration is very effective for heat exchangers and chemical reactors
because they can accommodate a large heat transfer area in a small space, with high
heat transfer coefficients. This project deals with the analysis of the helical coiled heat
exchanger with various correlations given by different papers for specific conditions.
Although various configurations are available, the basic and most common design
consists of a series of stacked helically coiled tubes placed in a cylindrical outer cover.
The inner tube ends are connected to manifolds, which act as fluid entry and exit
locations. And the outer tube is also provided with inlet and outlet manifolds so that
cooling fluid can be passed through it. The tube bundle is constructed of a number of
tubes stacked atop each other, and the entire bundle is placed inside a helical casing, or
shell. The complex fluid-dynamic inside curved pipe heat exchangers gives them
important advantages over the performance of straight tubes in terms of area/volume
ratio and enhancing of heat transfer and mass transfer coefficient. Convective heat
transfer between a surface and the surrounding fluid in a heat exchanger has been a
major issue and a topic of study for a long time. The analysis of these various
correlations with certain defined data is presented in this project. In this study, an
attempt has been made to analyze the effect of counter-flow on the total heat transfer
from a helical tube. The temperature contours, velocity vectors, surface nusselt
number, total heat transfer rate from the wall of the tube was calculated and plotted
using ANSYS 13.0. Copper was chosen as the metal for the construction of the helical
tube. The fluid flowing through the inner tube and outer casing was taken as water.

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NOMENCLATURE
A = area of heat transfer (m2)
De= Dean Number
H = heat transfer coefficient (Wm2 K1)
H = tube pitch (m)
K = thermal conductivity (Wm1K1)
L= length of the pipe (m)
Nu= Nusselt number
Pr = Prandtl number
Q = heat transferred (W)
R= inner radius of the tube (m)
R = resistance the flow of thermal energy (W1m2K)
Rc = pitch circle radius of the pipe (m)
Re= Reynolds number
U = velocity (ms1)
U = overall heat transfer coefficient (Wm2K1)
V= volume (m3)
= helix angle (rad)
= curvature ratio
= (temperature) difference (K)
= viscosity (kgm1s1)
= density (kgm3)
av = average
i = internal
LM = log mean
o = external
ov = overall
w = wall

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Chapter 1
INTRODUCTION ABOUT THE PROJECT

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Heat exchange between flowing fluids is one of the most important physical process
of concern, and a variety of heat exchangers are used in different type of installations, as in
process industries, compact heat exchangers nuclear power plant, HVACs, food processing,
refrigeration, etc. The purpose of constructing a heat exchanger is to get an efficient method
of heat transfer from one fluid to another, by direct contact or by indirect contact. The heat
transfer occurs by three principles: conduction, convection and radiation. In a heat exchanger
the heat transfer through radiation is not taken into account as it is negligible in comparison
to conduction and convection. Conduction takes place when the heat from the high
temperature fluid flows through the surrounding solid wall. The conductive heat transfer can
be maximized by selecting a minimum thickness of wall of a highly conductive material. But
convection is plays the major role in the performance of a heat exchanger.
Forced convection in a heat exchanger transfers the heat from one moving stream to
another stream through the wall of the pipe. The cooler fluid removes heat from the hotter
fluid as it flows along or across it.
Classification of Heat Exchanger

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1.1 Tubular Heat Exchangers:
Tubular heat exchangers are built of mainly of circular tubes although some other
geometry has also been used in different applications. This type of construction offers a large
amount of flexibility in design as the designing parameters like the diameter, length and the
arrangement can be easily modified. This type is used for liquid-to-liquid (phase changing
like condensing or evaporation) heat transfer. Again this type is classified into shell and tube,
double pipe and spiral tube heat exchangers.
1.2 Double Pipe Heat Exchanger:

The double pipe or the tube in tube type heat exchanger consists of one pipe placed
concentrically inside another pipe having a greater diameter. The flow in this configuration
can be of two types: parallel flow and counter-flow. It can be arranged in a lot of series and
parallel configurations to meet the different heat transfer requirements. Of this the helically
arranged stands out as it has found its place in different industrial applications. As this
configuration is widely used, knowledge about the heat transfer coefficient, pressure drop,
and different flow patterns has been of much importance. The curvature in the tubes creates a
secondary flow, which is normal to the primary axial direction of flow. This secondary flow
increases the heat transfer between the wall and the flowing fluid. And they offer a greater
heat transfer area within a small space, with greater heat transfer coefficients. Study has been
done on the types of flows in the curved pipes, and the effect of Prandtl and Reynolds number
on the flow patterns and on Nusselt numbers. The two basic boundary conditions that are
faced in the applications are constant temperature and the constant heat flux of the wall.
Fig.1(a) Double pipe helical coil

Fig.1(b) Close-up of double pipe coil
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1.3 Heat Transfer Coefficient:
Convective heat transfer is the transfer of heat from one place to another by the
movement of fluids due to the difference in density across a film of the surrounding fluid
over the hot surface. Through this film heat transfer takes place by thermal conduction and as
thermal conductivity of most fluids is low, the main resistance lies there. Heat transfer
through the film can be enhanced by increasing the velocity of
the fluid flowing over the surface which results in reduction in
thickness of film. The equation for rate of heat transfer by
convection under steady state is given by,
Q = h A (Tw - Tatm)
Where, h-is the film coefficient or surface coefficient
(W/m2.K).
A is the area of the wall,
Tw is the wall temperature,
Tatm is surrounding temperature.
Figure 2 Wall Convection
The value of h depends upon the properties of fluid within the film region; hence it
is called Heat Transfer Coefficient. It depends on various properties of fluid, linear
dimensions of surface and fluid velocity (i.e. nature of flow).
The overall heat transfer coefficient is the overall transfer rate of a series or parallel
combination of convective and conductive walls. The overall Heat Transfer Coefficient is
expressed in terms of thermal resistances of each fluid stream. The summation of individual
resistances is the total thermal resistance and its inverse is the overall heat transfer
coefficient, U.
Where, U = overall heat transfer coefficient based on outside area of tube all
A = area of tube wall
h = convective heat transfer coefficient
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Rf = thermal resistance due to fouling
Rw= thermal resistance due to wall conduction and suffixes I and O refer to the
inner and outer tubes, respectively.
Due to existence of the secondary flow, the heat transfer rates (& the fluid pressure
drop) are greater in the case of a curved tube than in a corresponding straight tube at the same
flow rate and the same temperature and same boundary conditions.
1.4 Advantages & Disadvantages:

1.4.1 Advantages of coils:
1) Coils give better heat transfer performance, since they have lower wall resistance &
higher process side coefficient.
2) The whole surface area of the curved pipe is exposed to the moving fluid, which
eliminates the dead-zones that are a common drawback in the shell and tube type heat
exchanger.
3) A coil can provide a large surface area in a relatively small reactor volume.
4) The heat exchangers spring-like coil eliminates thermal expansion and thermal shock
problems, which helps in high pressure operations.
5) Fouling is comparatively less in helical coil type than shell and tube type because of
greater turbulence created inside the curved pipes.
1.4.2 Disadvantages of coils:
1) For highly reactive fluids or highly corrosive fluid coils cannot be used, instead
jackets are used.
2) Cleaning of vessels with coils is more difficult than the cleaning of shells and jackets.
3) Coils play a major role in selection of agitation system. Densely packed coils can
create unmixed regions by interfering with fluid flow.
4) The design of the helical tube in tube type heat exchanger is also a bit complex and
challenging.

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1.5 Applications:
Use of helical coils for heat transfer applications:
1) Used in hydro carbon processing, recovery of CO2, cooling of liquid hydrocarbons,
also used in polymer industries for cooling purposes.
2) Helical coils are used for transferring heat in chemical reactors because the heat
transfer coefficients are greater in helical coils as compared to other configurations.
This is especially important when chemical reactions have high heats of reaction are
carried out and the heat consumed has to be transferred rapidly to maintain the
temperature of the reaction. They are used widely in petroleum industries for different
applications.
3) Because of the compact configuration of helical coils, they can be readily used in heat
transfer application with space limitations, for example, marine cooling systems,
central cooling, cooling of lubrication oil, steam generations in marine and industrial
applications.
4) The helical coiled heat exchangers are used widely in food and beverage industries,
like in food processing and pre-heating, pasteurization of liquid food items, and for
storing them at desired temperatures.
5) Helical coil heat exchangers are often used as condensers in used in HVACs due to
their greater heat transfer rate and compact structure.
6) Helical coiled tubes have been and are used extensively in cryogenic industry for the
liquefaction of gases.
1.6 Aim of the Present Work:

The design of a helical coil tube in tube heat exchanger has been facing problems
because of the lack of experimental data available regarding the behavior of the fluid in
helical coils and also in case of heat transfer data, which is not the case in Shell & Tube Heat
Exchanger. So to the best of our effort, numerical analysis was carried out to determine the
heat transfer characteristics for a double-pipe helical heat exchanger by varying the different
parameters like different temperatures and diameters of pipe and coil and also to determine
the fluid flow pattern in helical coiled heat exchanger. The objective of the project is to
obtain a better and more quantitative insight into the heat transfer process that occurs when a
fluid flows in a helically coiled tube. The study also covered the different types of fluid flow
range extending from laminar flow through transition to turbulent flow. The materials for the
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study were decided and fluid taken was water and the material for the pipe was taken to be
copper for its better conducting properties.
1.7 Introduction to CFD:

Computational Fluid Dynamics, abbreviated as CFD, uses different numerical
methods and a number of computerized algorithms in order to solve and analyze problems
that involve the flow of fluids. The calculations required simulating the interaction of fluids
with surfaces defined by boundary conditions, and initial conditions are done by the ANSYS
Fluent v13.0. The Navier-Stokes equations form the basis of all CFD problems. Two equation
models are used for the simulations, and different models are discussed below.
The continuity equation, energy equation and the Navier-Stokes momentum equation
govern the flow of the fluid in the curve tubes
Continuity Equation gives the conservation of mass and is given by
And for constant density,

The momentum balance, (Navier-Stokes equations) follows Newtons 2nd law. The
two forces acting on the finite element are the body and the surface forces. In CFD programs,
the momentum equation is given as
The governing energy equation is:

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Turbulence is created because of the unstable nature of the fluid flow. The flow
becomes turbulent for higher Reynolds number. In this model the k- (turbulent kinetics
energy k and the turbulent dissipation ) model is used.
The physical interpretation of the equation is,

1. Accumulation of
2. Convection of by the mean velocity
3. Production of
4. Dissipation of
5. Diffusion of
The time constant for turbulence is calculated from the turbulent kinetic energy and
dissipation rate of turbulent kinetic energy.
1.8 Organization of Thesis:

The entire thesis is divided into 4 chapters:
First Chapter is all about the introduction about the project. It consists of the preideas related to the project. It includes the objective and the work division of the thesis.
Second Chapter consists of the literature survey done during the project work. It
includes the briefs of the important references from journals and papers that were referred in
course of the project.
Third Chapter tells the reader about the fundamentals of the CFD analysis. The
process of building geometry, meshing the geometric model, giving suitable cell-zone and
boundary conditions and solving the problem. It gives the complete description of the work.
It involves the methodology and the various steps taken to obtain the desired results.
Fourth Chapter lists all the results and contours-plots-vectors obtained after the
solving of the problem. The later parts list the conclusion, references used and the
nomenclature used in the thesis.

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Chapter 2
Literature review

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Daniel Flrez-Orrego, Walter Arias, Diego Lpez and Hctor Velsquez have worked
on the single phase cone shaped helical coil heat exchanger. The study showed the flow and
the heat transfer in the heat exchanger. An empirical correlation was proposed from the
experimental data for the average nusselt number and a deviation of 23% was found. For the
cone shaped helical coils an appreciable inclination of the velocity vector components in the
secondary flow was seen, even though the contours of velocity were similar. The study
showed that some of the deviations and errors were due to the non-uniform flame radiation
and condensed combustion products which modified the conditions of the constant wall heat
flux assumptions. The correlations for the nusselt number values were not totally reliable.
There was no proper data available for the effect of the taper in the local nusselt number and
also the effect of curvature ratio, vertical position and the pitch of the heat exchanger. [1]
J.S. Jayakumar observed that the use of constant values for the transfer and thermal
properties of the fluid resulted in inaccurate heat transfer coefficients. Based on the CFD
analysis results a correlation was developed in order to evaluate the heat transfer coefficient
of the coil. In this study, analysis was done for both the constant wall temperature and
constant wall heat flux boundary conditions. The nusselt numbers that were obtained were
found to be highest on the outer coil and lowest in the inner side. Various numerical analyses
were done so as to relate the coil parameters to heat transfer. The coil parameters like the
diameters of the pipes, the Pitch Circle Diameters have significant effect on the heat transfer
and the effect of the pitch is negligible. [2]
Timothy J. Rennie studied the heat transfer characteristics of a double pipe helical
heat exchanger for both counter and parallel flow. Both the boundary conditions of constant
heat flux and constant wall temperature were taken. The study showed that the results from
the simulations were within the range of the pre-obtained results. For dean numbers ranging
from 38 to 350 the overall heat transfer coefficients were determined. The results showed that
the overall heat transfer coefficients varied directly with the inner dean number but the fluid
flow conditions in the outer pipe had a major contribution on the overall heat transfer
coefficient. The study showed that during the design of a double pipe helical heat exchanger
the design of the outr pipe should get the highest priority in order to get a higher overall heat
transfer coefficient. [3]
J.S. Jayakumar, S.M. Mahajani, J.C. Mandal, Rohidas Bhoi studied the constant
thermal and transport properties of the heat transfer medium and their effect on the prediction
of heat transfer coefficients. Arbitrary boundary conditions were not applicable for the
determination of heat transfer for a fluid-to-fluid heat exchanger. An experimental setup was
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made for studying the heat transfer and also CFD was used for the simulation of the heat
transfer. The CFD simulation results were reasonably well within the range of the
experimental results. Based on both the experimental and simulation results a correlation was
established for the inner heat transfer coefficient. [4]
Usman Ur Rehman studied the heat transfer and flow distribution in a shell and tube
heat exchanger and compared them with the experimental results. The model showed an
average error of around 20% in the heat transfer and the pressure difference. The study
showed that the symmetry of the plane assumption worked well for the length of the heat
exchanger but not in the outlet and inlet regions. The model could be improved by using
Reynold Stress models instead of k- models. The heat transfer was found to be on the lower
side as there was not much interaction between the fluids. The design could be improved by
improving the cross flow regions instead of the parallel flow. [5]
Nawras H. Mostafa, Qusay R. Al-hagag studied on the mechanical and thermal
performance of elliptical tubes used for polymer heat exchangers. The mechanical analysis
showed that the streamlined shape of the outer tube had an optimal thermal performance. A
set of design curves were generated from which a number of geometries of the tube and
different materials can be easily selected in order to meet the deformation constraints. A
finite element solution was determined for strain as a function of the material of the tube. [6]

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Chapter 3
CFD analysis

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Computational fluid dynamics (CFD) study of the system starts with the construction
of desired geometry and mesh for modeling the dominion. Generally, geometry is simplified
for the CFD studies. Meshing is the discretization of the domain into small volumes where
the equations are solved by the help of iterative methods. Modeling starts with the describing
of the boundary and initial conditions for the dominion and leads to modeling of the entire
system. Finally, it is followed by the analysis of the results, discussions and conclusions.
3.1 Geometry:
Heat exchanger is built in the ANSYS workbench design module. It is a counter-flow
heat exchanger. First, the fluid flow (fluent) module from the workbench is selected. The
design modeler opens as a new window as the geometry is double clicked.
3.1.1 Sketching
Out of 3 planes, viz, XY-plane, YZ-plane and ZX-plane, the YZ-plane is selected for
the first sketch. A 4 inch line for the height of the helical structure is made. A new plane is
created in reference with the YZ-plane which is termed as plane 4. 4 new sketchers are added
under the new plane, i.e. plane 4. In sketch 2, a circle of diameter 0.545 inch at a distance of 3
inch from origin. In sketch 3, two circles of diameters 0.545 inch and 0.625 inch are made
concentric to previous circle. In sketch 4, two circles of diameters 0.625 inch and 0.785 inch
are made concentric to previous circles. In sketch 5, two circles of diameters 0.785 inch and
0.875 inch are made concentric to previous circles.
3.1.2 Sweep
Sketch 2, 3, 4 & 5 are swept along the line made in sketch made in sketch 1 using the
add frozen operation to construct the 3D model with different parts. The helical sweep is of
2 turns because the twist specification is defined in number of turns.
3.1.3 Merging
After sweep operation, it will show the model as 4 parts and 4 bodies. For merge
operation, all the 4 parts are selected using control and merged as 1 part. At the end it will
show as 1 part and 4 bodies. The 4 bodies within 1 part are named as follows:

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Table 1 Naming of various parts of the body with state type
Part number
Part Of The Model
State Type
Inner_Fluid
Fluid
Inner_Pipe
Solid
Outer_Fluid
Fluid
Outer_Pipe
Solid
Figure 3 Original Geometry
Figure 4 Geometry for Meshing

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Save the project at this point and close the window. Refresh and update the project on the
workbench.
3.2 Mesh:
Initially a relatively coarser mesh is generated. This mesh contains mixed cells (Tetra
and Hexahedral cells) having both triangular and quadrilateral faces at the boundaries. Care is
taken to use structured hexahedral cells as much as possible. It is meant to reduce numerical
diffusion as much as possible by structuring the mesh in a well manner, particularly near the
wall region. Later on, a fine mesh is generated. For this fine mesh, the edges and regions of
high temperature and pressure gradients are finely meshed.
3.2.1 y+ Values
y
values play a significant role in turbulence modeling for the near wall treatment.
y+ is a non-dimensional distance. It is often used to describe how coarse or fine a mesh is for
a particular flow pattern. It determines the proper size of the cells near domain walls. The
turbulence model wall laws have restrictions on the y+ value at the wall. For instance, the
standard K-epsilon model requires a wall y+ value between approximately 300 and 100. A
faster flow near the wall will produce higher values of y+, so the grid size near the wall must
be reduced. y+ values for different wall treatments are given in table 2
Table 2 y+ Values for Different Wall Treatments
Wall treatment method
Recommended y+ values
Used y+ values at tube walls
Standard wall functions
30 < y+ < 400
y+ < 5
Non-equilibrium wall functions
30 < y+ < 100
y+ < 5
Low Reynolds number model
y+ 1
y+ < 1
The mesh details view gave us the following information:
Relevance centre: fine meshing
Smoothing: high
Size: 4.033e-005m to 8.066e-005m
Pinch tolerance: 3.6297e-005m
Nodes: 586300
Elements: 53170

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Figure 5 Mesh
Figure 6 Close-up View of the Mesh
3.2.2 Named Selection

The different surfaces of the solid are named as per required inlets and outlets for
inner and outer fluids. The outer wall is named as insulation surface.

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Figure 7 Named Selections

Save project again at this point and close the window. Refresh and update project on
the workbench. Now open the setup. The ANSYS Fluent Launcher will open in a window.
Set dimension as 3D, option as Double Precision, processing as Serial type and hit OK. The
Fluent window will open.
3.3 Solution:
3.3.1 Problem Setup
The mesh is checked and quality is obtained. The analysis type is changed to Pressure
Based type. The velocity formulation is changed to absolute and time to steady state. Gravity
is defined as y = -9.81 m/s2
3.3.2 Models
Energy is set to ON position. Viscous model is selected as k- model (2 equations).
Radiation model is changed to Discrete Ordinates.
3.3.3 Materials
The create/edit option is clicked to add water-liquid and copper to the list of fluid and
solid respectively from the fluent database.
3.3.4 Cell zone conditions
The parts are assigned as water and copper as per fluid/solid parts.

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3.3.5 Boundary Conditions
Boundary conditions are used according to the need of the model. The inlet and outlet
conditions are defined as velocity inlet and pressure outlet. As this is a counter-flow with two
tubes so there are two inlets and two outlets. The walls are separately specified with
respective boundary conditions. No slip condition is considered for each wall. Except the
tube walls each wall is set to zero heat flux condition. The details about all boundary
conditions can be seen in the table 3 as given below.
Table 3 Boundary Conditions
Boundary
-
Condition
Type
Turbulent
Velocity
Turbulent
Magnitude
Kinetic Energy
0.9942 m/s
0.01 m2/s2
0.1 m2/s3
348 K
Dissipation
Temperature
Rate
Inner_Inlet
Velocity Inlet
Inner_Outlet
Pressure Outlet -
Outer_Inlet
Velocity Inlet
0.01 m2/s2
0.1 m2/s3
283 K
Outer_Outlet
Pressure Outlet -
1.8842 m/s
3.3.6 Reference Values

The inner_inlet is selected from the drop down list of compute from. The values are:
Area = 1 m2
Density = 998.2 kg/m3
Length = 39.37008 inch
Temperature = 348 K
Velocity = 0.9942 m/s
Viscosity = 0.001003 kg/m-s
Ratio of specific heats = 1.4
3.3.7 Solution Methods

The solution methods are specified as follows:
Scheme = Simple

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Gradient = Least Square Cell Based
Pressure = Standard
Momentum = Second Order Upwind
Turbulent Kinetic Energy = Second Order Upwind
Turbulent Dissipation Rate = Second Order Upwind
3.3.8 Solution Control and Initialization

Under relaxation factors the parameters are
Pressure = 0.3 Pascal
Density = 1 kg/m3
Body forces = 1 kg/m2s2
Momentum = 0.7 kg-m/s
Turbulent kinetic energy = 0.8 m2/s2
Then the solution initialization method is set to Standard Initialization whereas the
reference frame is set to Relative cell zone. The inner_inlet is selected from the compute from
drop down list and the solution is initialized.
3.3.9 Measure of Convergence
It is tried to have a nice convergence throughout the simulation and hence criteria is
made strict so as to get an accurate result. For this reason residuals are given as per the table 4
that follows.
Table 4 Residuals
Variable
Residual
x-velocity
10-6
y-velocity
10-6
z-velocity
10-6
Continuity
10-6
Specific dissipation energy/ dissipation energy
10-5
Turbulent kinetic energy
10-5
Energy
10-9

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3.3.10 Run Calculation
The number of iteration is set to 500 and the solution is calculated and various contours,
vectors and plots are obtained.

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Chapter 4
Results and discussionS

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4.1 Mass Flow Rate and Total Heat Transfer Rate
The mass flow rate and total heat transfer rate are given in the tables below.
Table 5 Mass Flow Rate

Mass Flow Rate
(kg/s)
inner_inlet
0.14690745
inner_outlet
-0.14690745
interior-part-inner_fluid
60.470463
interior-part-outer_fluid
-83.482896
outer_inlet
0.21353984
outer_outlet
-0.21353761
Net
2.2285868e-06
Table 6 Total Heat Transfer Rate

Total Heat Transfer Rate
(w)
inner_inlet
30626.679
inner_outlet
-23526.716
outer_inlet
-13529.476
outer_outlet
6429.4192
Net
-0.094444952

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4.2 Contours
The temperature, pressure and velocity distribution along the heat exchanger can be
seen through the contours.
Figure 8 Contours of Dynamic Pressure in Pascal
Figure 9 Contours of Total Pressure in Pascal

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Figure 10 Contours of Static Temperature in K
Figure 11 Contours of Turbulent Dissipation Rate (Epsilon) (m2/s3)

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Figure 12 Contours of Turbulent Kinetic Energy k (m2/s2)
Figure 13 Contours of Effective Thermal Conductivity (w/m-K)

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Figure 14 Contours of Total Surface Heat Flux (w/m2)
Figure 15 Contours of Cell Reynolds Number

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Figure 16 Contours of Effective Prandtl Number
4.3 Vectors
The plots give an idea of flow separation at several parts of the heat exchanger.
Figure 17 Velocity Vectors Colored by Velocity Magnitude (m/s)

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Figure 18 Close View of Velocity Vectors Colored by Velocity Magnitude (m/s)
Figure 19 Velocity Vectors Colored by Static Pressure (Pascal)

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4.4 Plots
Figure 20 Scaled Residuals
Figure 21 Wall Shear Stress Plot for Inner-wall And Outer-wall

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Figure 22 Total Pressure Plot for Inner-wall And Outer-wall
Figure 23 Surface Nusselt Number Plot for Inner-wall

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CONCLUSIONS
A CFD package (ANSYS FLUENT 13.0) was used for the numerical study of heat
transfer characteristics of a helical coiled double pipe heat exchanger for counter flow and the
results were then compared with that of the parallel flow. The CFD results when compared
with the experimental results from different studies were well within the error limits. The
study showed that there is not much difference in the heat transfer performances of the
parallel-flow configuration and the counter-flow configuration. Nusselt number at different
points along the pipe length was determined from the numerical data. The simulation was
carried out for water to water heat transfer characteristics and different inlet temperatures
were studied. Nusselt number for the pipes was found to be varying from 340-360.
Characteristics of the fluid flow were also studied for the constant temperature and
constant wall heat flux conditions. From the velocity vector plot it was found that the fluid
particles were undergoing an oscillatory motion inside both the pipes.
From the pressure and temperature contours it was found that along the outer side of
the pipes the velocity and pressure values were higher in comparison to the inner values.

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REFERENCES
1. Experimental and CFD study of a single phase cone-shaped helical coiled heat
exchanger: an empirical correlation. By Daniel Flrez-Orrego, ECOS June 26-29, 2012.
2. Helically Coiled Heat Exchangers by J.S.Jayakumar.
3. Numerical And Experimental Studies of a Double pipe Helical Heat Exchanger by
Timothy John Rennie, Dept. of Bio-resource Engg. McGill University, Montreal
August 2004.
4. Experimental and CFD estimation of heat transfer in helically coiled heat exchangers
by J.S. Jayakumar, S.M. Mahajani, J.C. Mandal, P.K. Vijayan, and Rohidas Bhoi,
2008, Chemical Engg Research and Design 221-232.
5. Heat Transfer Optimization of Shell-and-Tube Heat Exchanger through CFD Studies
by Usman Ur Rehman, 2011, Chalmers University of Technology.
6. Structural and Thermal Analysis of Heat Exchanger with Tubes of Elliptical Shape by
Nawras H. Mostafa Qusay R. Al-Hagag, IASJ, 2012,Vol-8 Issue-3.
7. Numerical analysis of forced convection heat transfer through helical channels Dr. K.
E. Reby Roy, IJEST, July-2012 vol-4.
8. Minton P.E., Designing Spiral Tube Heat Exchangers, Chemical Engineering, May
1970, p. 145.
9. Noble, M.A., Kamlani, J.S., and McKetta, J.J., Heat Transfer in Spiral Coils,
Petroleum Engineer, April 1952, p. 723.
Heat Transfer Analysis of Helical Coil Heat Exchanger with Circular and Square
Coiled Pattern by Ashok B. Korane, P.S. Purandare, K.V. Mali, IJESR, June 2012,
vol-2, issue-6.

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CFD ANALYSIS OF HEAT TRANSFER IN

A HELICAL COIL HEAT EXCHANGER

Department of Mechanical Engineering

CFD ANALYSIS OF HEAT TRANSFER IN A HELICAL COIL HEAT

Department of Mechanical Engineering

B.Tech Thesis 2013

To the best of my knowledge, this work has not been submitted

other University/Institute for the award of any degree or diploma.

Dr. Ashok Kumar Satapathy

DEPARTMENT OF MECHANICAL ENGINEERING

B.Tech Thesis 2013

fluent. It has enriched my life, giving me an opportunity to work in a new

Siddhartha Shankar Behera

B.Tech Thesis 2013

1.1 Tubular Heat Exchangers

1.2 Double Pipe Heat Exchanger

1.3 Heat Transfer Coefficients

1.4 Advantages and Disadvantages

1.6 Aim of Present Work

1.7 Introduction to CFD

1.8 Organization of Thesis

3.2.2 Named Selection

B.Tech Thesis 2013

3.3.4 Cell Zone Conditions

3.3.5 Boundary Conditions

3.3.6 Reference Values

3.3.7 Solution Methods

3.3.8 Solution Controls and Initialization

3.3.9 Measure of Convergence

3.3.10 Run Calculation

4. Results and Discussions

4.1 Mass Flow Rate and Total Heat Transfer Rate

Naming Of Various Parts of The Body

y+ Values for Different Wall Treatments

Mass Flow Rate

Total Heat Transfer Rate

DEPARTMENT OF MECHANICAL ENGINEERING

B.Tech Thesis 2013

Double Pipe Helical Coil

Close-Up of Double Pipe Coil

Geometry for Meshing

Close-Up View of The Mesh

Contours of Dynamic Pressure In Pascal

Contours of Total Pressure In Pascal

Contours of Static Temperature

Contours of Turbulent Dissipation Rate

Contours of Turbulent Kinetic Energy

Contours of Effective Thermal Conductivity

Contours of Total Surface Heat Flux

Contours of Cell Reynolds Number

Contours of Effective Prandtl Number

Velocity Vectors Colored by Velocity Magnitude

Velocity Vectors Colored by Velocity Magnitude - Close

Velocity Vectors Colored by Static Pressure

Wall Shear Stress Plot

Total Pressure Plot

Surface Nusselt Number

DEPARTMENT OF MECHANICAL ENGINEERING

B.Tech Thesis 2013