Heat Exchanger - Report

Shell-and-Tube Heat Exchanger
Author COMSOL
Report date Jun 9, 2018 4:20:06 PM
SUMMARY
Shell-and-tube heat exchangers are commonly used in oil refineries and other large-scale chemical
processes. In this example, two separated fluids at different temperatures flow through the heat
exchanger: one through the tubes (tube side) and the other through the shell around the tubes (shell
side). Several design parameters and operating conditions influence the optimal performance of a shell-
and-tube heat exchanger. This example shows the basic principles of setting up a heat exchanger model.
It can serve as a starting point for more sophisticated models involving parameter studies or additional
effects like corrosion, thermal stress, and vibration.
1
1.1 PARAMETERS 1
PARAMETERS
Name Expression Value Description
u_water 0.1[m/s] 0.1 m/s Inlet velocity, water
u_air 1[m/s] 1 m/s Inlet velocity, air
T_water 80[degC] 353.15 K Inlet temperature, water
T_air 5[degC] 278.15 K Inlet temperature, air
1.2 DEFINITIONS
Selection
1.2.1 Coordinate Systems
Boundary System 1
Coordinate system type Boundary system

Tag sys1
SETTINGS
First Second Third
t1 t2 n
2
1.3 GEOMETRY 1
Geometry 1
1.4 MATERIALS
1.4.1 Air
Air
3
1.4.2 Water, liquid
Water, liquid
1.4.3 Structural steel
EQUATIONS
4
1.4.4 Fluid Properties 1
Fluid Properties 1
SELECTION
Geometric entity level Domain
Selection Domains 1–2
EQUATIONS
5
1.4.5 Initial Values 1
Initial Values 1
SELECTION
1.4.6 Inlet 1: Water
6
Inlet 1: Water
EQUATIONS
Boundary condition
SETTINGS
Description Value
Boundary condition Velocity
Velocity field componentwise Normal inflow velocity
Normal inflow velocity u_water
Specify turbulent length scale and intensity
Turbulent intensity spf.IT_init
Turbulence length scale 0.07*5[cm]
1.4.7 Outlet 1: Water
Outlet 1: Water
7
EQUATIONS
Boundary condition
SETTINGS
Description Value
Boundary condition Pressure
Pressure 0
Normal flow On
Suppress backflow On
1.4.8 Inlet 2: Air
EQUATIONS
8
1.4.9 Outlet 2: Air
Outlet 2: Air
EQUATIONS
Boundary condition
SETTINGS
Description Value
Boundary condition Pressure
Pressure 0
Normal flow On
Suppress backflow On
9
EQUATIONS
1.4.10 Interior Wall 1
Interior Wall 1
10
EQUATIONS
Boundary condition
SETTINGS
Description Value
Boundary condition No slip
Translational velocity Automatic from frame
1.5 HEAT TRANSFER IN FLUIDS

USED PRODUCTS
COMSOL Multiphysics
Heat Transfer Module
Heat Transfer in Fluids
EQUATIONS
11
1.5.1 Fluid 1
EQUATIONS
Heat conduction, fluid
1.5.2 Initial Values 1
Initial Values 1
12
1.5.3 Thermal Insulation 1
Thermal Insulation 1
EQUATIONS
USED PRODUCTS
COMSOL Multiphysics
1.5.4 Inflow 1: Water
Inflow 1: Water
SELECTION
13
EQUATIONS
1.5.5 Inflow 2: Air
EQUATIONS
14
1.5.6 Outflow 1: Water
Outflow 1: Water
EQUATIONS
1.5.7 Outflow 2: Air
Outflow 2: Air
EQUATIONS
15
1.5.8 Symmetry 1
Symmetry 1
EQUATIONS
1.5.9 Thin Layer 1
EQUATIONS
16
1.6 MULTIPHYSICS
1.6.1 Nonisothermal Flow 1

USED PRODUCTS
COMSOL Multiphysics
Heat Transfer Module
Nonisothermal Flow 1
SELECTION
EQUATIONS
17
1.7 MESH 1
Mesh 1
Size 1
Stationary Solver 1 (s1)
GENERAL
Description Value
Defined by study step Stationary
LOG
18
48 constraints are merged/removed.
2 0.39 1.4e+005 0.3500000 0.39 19 14 14 55 0.00016 2
.1e-005
More inconsistent pointwise unidirectional constraints found...
3 0.35 1.6e+005 0.3500000 0.35 20 15 15 59 0.00015 1
.9e-005
Solution error estimates for segregated groups
0.13, 0.01, 0.33
Residual error estimates for segregated groups
1.8e+003, 1.3e+004, 1.8e+005
Pseudo time-stepping CFL-ratio:
0.12
Segregated solver iteration 6.
Velocity u, Pressure p
Iter SolEst Damping Stepsize #Res #Jac #Sol LinIt LinErr LinRes
1 0.21 0.5000000 0.21 12 6 6 43 0.00033 0.00018
Segregated Step 2
Iter SolEst Damping Stepsize #Res #Jac #Sol LinErr LinRes
1 0.013 0.8000000 0.013 12 6 6 5.2e-013 1.4e-014
Turbulence variables
Iter SolEst ResEst Damping Stepsize #Res #Jac #Sol LinIt LinErr
LinRes
1 0.33 2e+005 0.3500000 0.33 22 16 16 63 0.00035 4
.6e-005
2 0.28 2.2e+005 0.3500000 0.28 23 17 17 67 0.00011 1
.3e-005
3 0.24 2.4e+005 0.3500000 0.24 24 18 18 70 0.00089
0.00012
0.11, 0.01, 0.25
1.5e+003, 1.1e+004, 2.4e+005
0.12
1 0.17 0.5000000 0.17 14 7 7 50 0.0008 0.0004
Segregated Step 2
1 0.012 0.8000000 0.012 14 7 7 4.1e-013 1.4e-014
LinRes
1 0.22 2.7e+005 0.3500000 0.22 26 19 19 74 0.00028 3
.1e-005
2 0.18 2.6e+005 0.3500000 0.18 27 20 20 77 0.00073 9
.8e-005
3 0.15 2.5e+005 0.3500000 0.15 28 21 21 80 0.00073 9
.1e-005
0.085, 0.0097, 0.17
1.2e+003, 9.6e+003, 2.3e+005
0.12
19
1 0.16 0.5000000 0.16 16 8 8 56 0.00028 -
Segregated Step 2
1 0.015 0.8000000 0.015 16 8 8 4.8e-013 1.7e-014
LinRes
1 0.15 2.5e+005 0.3500000 0.15 30 22 22 84 0.00029 3
.5e-005
2 0.12 2.3e+005 0.3500000 0.12 31 23 23 87 0.00084
0.00012
3 0.1 2e+005 0.3500000 0.1 32 24 24 90 0.00084
0.00012
0.082, 0.012, 0.12
9e+002, 8.8e+003, 1.8e+005
0.14
1 0.15 0.5000000 0.15 18 9 9 61 0.00087 -
Segregated Step 2
1 0.016 0.8000000 0.016 18 9 9 4.2e-013 1.9e-014
LinRes
1 0.1 2e+005 0.3500000 0.1 34 25 25 94 0.00034 4
.4e-005
2 0.082 1.8e+005 0.3500000 0.082 35 26 26 97 0.00088
0.00013
3 0.064 1.6e+005 0.3500000 0.064 36 27 27 100 0.00088
0.00012
0.073, 0.013, 0.082
6.5e+002, 8.3e+003, 1.4e+005
0.16
1 0.13 0.5000000 0.13 20 10 10 66 0.00073 -
Segregated Step 2
1 0.018 0.8000000 0.018 20 10 10 4.2e-013 2.4e-014
LinRes
1 0.075 1.5e+005 0.3500000 0.075 38 28 28 104 0.00014
-
20
2 0.057 1.3e+005 0.3500000 0.057 39 29 29 107 0.00016
-
3 0.044 1.2e+005 0.3500000 0.044 40 30 30 109 0.00097
-
0.066, 0.015, 0.059
5.7e+002, 7.8e+003, 1e+005
0.18
1 0.12 0.5000000 0.12 22 11 11 71 0.00069 -
Segregated Step 2
1 0.02 0.8000000 0.02 22 11 11 4.1e-013 2.6e-014
LinRes
1 0.057 1.1e+005 0.3500000 0.057 42 31 31 112 0.00075
-
2 0.043 1e+005 0.3500000 0.043 43 32 32 114 0.00094
-
3 0.033 9e+004 0.3500000 0.033 44 33 33 116 0.00075
-
0.058, 0.016, 0.045
5.8e+002, 7.4e+003, 8.3e+004
0.2
1 0.1 0.5000000 0.1 24 12 12 76 0.00076 -
Segregated Step 2
1 0.021 0.8000000 0.021 24 12 12 4.3e-013 2.8e-014
LinRes
1 0.046 9e+004 0.3500000 0.046 46 34 34 119 0.00058
-
2 0.035 7.9e+004 0.3500000 0.035 47 35 35 121 0.00083
-
3 0.027 7e+004 0.3500000 0.027 48 36 36 123 0.00064
-
0.052, 0.017, 0.036
6.9e+002, 7.3e+003, 6.3e+004
0.21
21
1 0.09 0.5000000 0.09 26 13 13 81 0.0009 -
Segregated Step 2
1 0.021 0.8000000 0.021 26 13 13 4.2e-013 3.2e-014
LinRes
1 0.038 7.7e+004 0.3500000 0.038 50 37 37 126 0.0005
-
2 0.03 6.7e+004 0.3500000 0.03 51 38 38 128 0.00072
-
3 0.024 5.8e+004 0.3500000 0.024 52 39 39 130 0.00056
-
0.045, 0.017, 0.031
8.5e+002, 7.2e+003, 5.1e+004
0.23
1 0.077 0.5000000 0.077 28 14 14 87 0.00032 -
Segregated Step 2
1 0.02 0.8000000 0.02 28 14 14 4.3e-013 3.3e-014
LinRes
1 0.034 7e+004 0.3500000 0.034 54 40 40 133 0.00043
-
2 0.028 6e+004 0.3500000 0.028 55 41 41 135 0.00067
-
3 0.023 5.2e+004 0.3500000 0.023 56 42 42 137 0.00051
-
0.039, 0.016, 0.029
9.6e+002, 7.1e+003, 4.5e+004
0.24
1 0.073 0.5000000 0.073 30 15 15 93 0.00042 -
Segregated Step 2
1 0.018 0.8000000 0.018 30 15 15 4.2e-013 3.3e-014
LinRes
1 0.032 6.6e+004 0.3500000 0.032 58 43 43 140 0.00037
-
2 0.027 5.7e+004 0.3500000 0.027 59 44 44 142 0.00062
-
22
3 0.022 5e+004 0.3500000 0.022 60 45 45 144 0.00047
-
0.036, 0.014, 0.028
9.9e+002, 6.4e+003, 4.3e+004
0.26
1 0.056 0.5000000 0.056 32 16 16 99 0.00049 -
Segregated Step 2
1 0.014 0.8000000 0.014 32 16 16 4.5e-013 3.1e-014
LinRes
1 0.031 6.3e+004 0.3500000 0.031 62 46 46 147 0.00033
-
2 0.027 5.5e+004 0.3500000 0.027 63 47 47 149 0.00057
-
3 0.022 4.8e+004 0.3500000 0.022 64 48 48 151 0.00044
-
0.028, 0.012, 0.027
9.4e+002, 5.4e+003, 4.1e+004
0.27
1 0.048 0.5000000 0.048 34 17 17 105 0.00054 -
Segregated Step 2
1 0.012 0.8000000 0.012 34 17 17 4e-013 3.2e-014
LinRes
1 0.031 6.2e+004 0.3500000 0.031 66 49 49 154 0.00032
-
2 0.026 5.5e+004 0.3500000 0.026 67 50 50 156 0.00056
-
3 0.021 4.7e+004 0.3500000 0.021 68 51 51 158 0.00043
-
0.024, 0.0093, 0.027
8.5e+002, 4e+003, 4e+004
0.29
1 0.04 0.5000000 0.04 36 18 18 111 0.00054 -
23
Segregated Step 2
1 0.0086 0.8000000 0.0086 36 18 18 5.6e-013 3e-014
LinRes
1 0.03 6.2e+004 0.3500000 0.03 70 52 52 161 0.0003
-
2 0.025 5.4e+004 0.3500000 0.025 71 53 53 163 0.00053
-
3 0.02 4.7e+004 0.3500000 0.02 72 54 54 165 0.0004
-
0.02, 0.0069, 0.026
7.3e+002, 2.7e+003, 3.9e+004
0.3
1 0.035 0.5000000 0.035 38 19 19 117 0.00059 -
Segregated Step 2
1 0.0063 0.8000000 0.0063 38 19 19 4.2e-013 2.7e-014
LinRes
1 0.028 6.1e+004 0.3500000 0.028 74 55 55 168 0.00029
-
2 0.023 5.3e+004 0.3500000 0.023 75 56 56 170 0.00049
-
3 0.018 4.5e+004 0.3500000 0.018 76 57 57 172 0.00037
-
0.017, 0.005, 0.024
6e+002, 1.6e+003, 3.7e+004
0.32
1 0.031 0.5000000 0.031 40 20 20 123 0.00082 -
Segregated Step 2
1 0.0045 0.8000000 0.0045 40 20 20 3.9e-013 2.5e-014
LinRes
1 0.025 5.9e+004 0.3500000 0.025 78 58 58 175 0.00027
-
2 0.02 5.1e+004 0.3500000 0.02 79 59 59 177 0.00044
-
3 0.016 4.3e+004 0.3500000 0.016 80 60 60 179 0.00032
-
24
0.015, 0.0036, 0.021
5e+002, 8.7e+002, 3.5e+004
0.34
1 0.031 0.5000000 0.031 42 21 21 130 0.00081 -
Segregated Step 2
1 0.0033 0.8000000 0.0033 42 21 21 4.2e-013 2.3e-014
LinRes
1 0.022 5.5e+004 0.3500000 0.022 82 61 61 182 0.00024
-
2 0.017 4.7e+004 0.3500000 0.017 83 62 62 184 0.00036
-
3 0.013 3.9e+004 0.3500000 0.013 84 63 63 186 0.00025
-
0.015, 0.0026, 0.018
4.3e+002, 4.3e+002, 3.1e+004
0.36
1 0.032 0.5000000 0.032 44 22 22 138 0.00067 -
Segregated Step 2
1 0.0023 0.8000000 0.0023 44 22 22 7.3e-013 1.9e-014
LinRes
1 0.018 4.9e+004 0.3500000 0.018 86 64 64 189 0.00021
-
2 0.013 4.1e+004 0.3500000 0.013 87 65 65 191 0.00028
-
3 0.0094 3.3e+004 0.3500000 0.0094 88 66 66 193 0.00018
-
0.016, 0.0018, 0.014
3.6e+002, 2.2e+002, 2.6e+004
0.38
1 0.029 0.5000000 0.029 46 23 23 146 0.00094 -
Segregated Step 2
25
1 0.0015 0.8000000 0.0015 46 23 23 6e-013 1.7e-014
LinRes
1 0.013 4.1e+004 0.3500000 0.013 90 67 67 196 0.00018
-
2 0.0093 3.3e+004 0.3500000 0.0093 91 68 68 198 0.00021
-
3 0.0062 2.6e+004 0.3500000 0.0062 92 69 69 200 0.00013
-
0.014, 0.0012, 0.01
3.3e+002, 1.2e+002, 2e+004
0.4
1 0.026 0.5000000 0.026 48 24 24 154 0.00097 -
Segregated Step 2
1 0.00099 0.8000000 0.00099 48 24 24 4.6e-013 1.6e-014
LinRes
1 0.0092 3.3e+004 0.3500000 0.0092 94 70 70 203 0.00015
-
2 0.006 2.5e+004 0.3500000 0.006 95 71 71 205 0.00016
-
3 0.0037 1.9e+004 0.3500000 0.0037 96 72 72 207 0.00012
-
0.013, 0.00079, 0.0065
3.1e+002, 56, 1.4e+004
0.43
1 0.023 0.5000000 0.023 50 25 25 162 0.00071 -
Segregated Step 2
1 0.00054 0.8000000 0.00054 50 25 25 6.3e-013 1.5e-014
LinRes
1 0.0063 2.4e+004 0.3500000 0.0063 98 73 73 209 0.00092
-
2 0.0038 1.8e+004 0.3500000 0.0038 99 74 74 211 0.00015
-
3 0.0025 1.3e+004 0.3500000 0.0025 100 75 75 213 0.00012
-
0.012, 0.00043, 0.0042
26
2.6e+002, 30, 9.7e+003
0.46
1 0.019 0.5000000 0.019 52 26 26 170 0.00047 -
Segregated Step 2
1 0.00025 0.8000000 0.00025 52 26 26 6.2e-013 1.2e-014
LinRes
1 0.0046 1.8e+004 0.3500000 0.0046 102 76 76 215 0.00077
-
2 0.003 1.3e+004 0.3500000 0.003 103 77 77 217 0.00015
-
3 0.0025 9.4e+003 0.3500000 0.0025 104 78 78 219 0.00012
-
0.0093, 0.0002, 0.0034
2e+002, 25, 7.1e+003
0.49
1 0.014 0.5000000 0.014 54 27 27 177 0.00057 -
Segregated Step 2
1 9e-005 0.8000000 9e-005 54 27 27 7.4e-013 7.7e-015
LinRes
1 0.0038 1.3e+004 0.3500000 0.0038 106 79 79 221 0.00065
-
2 0.0029 9.6e+003 0.3500000 0.0029 107 80 80 223 0.00013
-
3 0.0026 7.5e+003 0.3500000 0.0026 108 81 81 225 0.00011
-
0.0068, 7.2e-005, 0.0031
1.5e+002, 21, 6.3e+003
0.53
1 0.0094 0.5000000 0.0094 56 28 28 182 0.00092 -
Segregated Step 2
1 2.4e-005 0.8000000 2.4e-005 56 28 28 8.2e-013 4.3e-015
27
LinRes
1 0.0032 1e+004 0.3500000 0.0032 110 82 82 227 0.00053
-
2 0.0027 7.9e+003 0.3500000 0.0027 111 83 83 229 0.00011
-
3 0.0024 6.7e+003 0.3500000 0.0024 112 84 84 230 0.00096
-
0.0047, 1.9e-005, 0.0029
1.1e+002, 14, 6e+003
0.57
1 0.0062 0.5000000 0.0062 58 29 29 187 0.00052 -
Segregated Step 2
1 1.2e-005 0.8000000 1.2e-005 58 29 29 6.6e-013 3.5e-015
LinRes
1 0.0026 8e+003 0.3500000 0.0026 114 85 85 232 0.00041
-
2 0.0022 6.7e+003 0.3500000 0.0022 115 86 86 233 0.00089
-
3 0.002 5.8e+003 0.3500000 0.002 116 87 87 234 0.00092
-
0.0031, 9.9e-006, 0.0024
77, 8.1, 5.3e+003
0.61
1 0.004 0.5000000 0.004 60 30 30 191 0.00086 -
Segregated Step 2
1 1.3e-005 0.8000000 1.3e-005 60 30 30 6.7e-013 3.8e-015
LinRes
1 0.002 6.4e+003 0.3500000 0.002 118 88 88 236 0.00031
-
2 0.0017 5.4e+003 0.3500000 0.0017 119 89 89 237 0.00068
-
3 0.0015 4.8e+003 0.3500000 0.0015 120 90 90 238 0.00069
-
0.002, 1e-005, 0.0018
54, 4.7, 4.3e+003
28
0.65
1 0.0027 0.5000000 0.0027 62 31 31 195 0.00057 -
Segregated Step 2
1 9.7e-006 0.8000000 9.7e-006 62 31 31 5.2e-013 3.8e-015
LinRes
1 0.0014 5e+003 0.3500000 0.0014 122 91 91 240 0.00022
-
2 0.0012 4.2e+003 0.3500000 0.0012 123 92 92 241 0.00048
-
3 0.001 3.7e+003 0.3500000 0.001 124 93 93 242 0.00049
-
0.0013, 7.8e-006, 0.0013
40, 4.4, 3.2e+003
0.7
1 0.0018 0.5000000 0.0018 64 32 32 199 0.00039 -
Segregated Step 2
1 6.5e-006 0.8000000 6.5e-006 64 32 32 5.6e-013 3.8e-015
LinRes
1 0.00094 3.7e+003 0.3500000 0.00094 126 94 94 244 0.00015
-
0.00091, 5.2e-006, 0.00061
25, 2.1, 3.1e+003
0.75
1 0.0012 0.5000000 0.0012 66 33 33 202 0.00097 -
Segregated Step 2
1 3e-006 0.8000000 3e-006 66 33 33 5.8e-013 3.6e-015
LinRes
1 0.00086 3.5e+003 0.3500000 0.00086 128 95 95 246 0.00015
-
0.00058, 2.4e-006, 0.00056
29
17, 1.5, 2.9e+003
0.82
1 0.00075 0.5000000 0.00075 68 34 34 205 0.00062 -
Segregated Step 2
1 1.7e-006 0.8000000 1.7e-006 68 34 34 4.2e-013 3.6e-015
LinRes
1 0.00076 3.2e+003 0.3500000 0.00076 130 96 96 248 0.00013
-
0.00038, 1.4e-006, 0.00049
13, 1.4, 2.6e+003
0.87
1 0.00049 0.5000000 0.00049 70 35 35 208 0.0004 -
Segregated Step 2
1 1.2e-006 0.8000000 1.2e-006 70 35 35 6.1e-013 3.8e-015
LinRes
1 0.00065 2.8e+003 0.3500000 0.00065 132 97 97 250 0.00011
-
0.00025, 9.4e-007, 0.00043
11, 1.3, 2.3e+003
0.92
1 0.00032 0.5000000 0.00032 72 36 36 210 0.00069 -
Segregated Step 2
1 8.9e-007 0.8000000 8.9e-007 72 36 36 4.3e-013 3.8e-015
LinRes
1 0.00055 2.4e+003 0.3500000 0.00055 134 98 98 251 0.00088
-
0.00016, 7.1e-007, 0.00036
9.4, 1.3, 2e+003
30
0.97
1 0.00024 0.5000000 0.00024 74 37 37 212 0.00046 -
Segregated Step 2
1 7.5e-007 0.8000000 7.5e-007 74 37 37 5.2e-013 4.3e-015
LinRes
1 0.00046 2.1e+003 0.3500000 0.00046 136 99 99 252 0.00079
-
0.00012, 6e-007, 0.0003
8.5, 1.2, 1.7e+003
1
Solution time: 3735 s. (1 hour, 2 minutes, 15 seconds)
Physical memory: 4.74 GB
Virtual memory: 5.99 GB
Ended at 1-Jun-2018 15:37:47.
----- Stationary Solver 1 in Study 1/Solution 1 (sol1) ------------------------>
Segregated 1 (se1)
GENERAL
Description Value
Maximum number of iterations 400
Stabilization and acceleration Pseudo time-stepping
Initial CFL number 3
Velocity u, Pressure p (ss1)
GENERAL
Description Value
Variables {Velocity field (comp1.u), Pressure (comp1.p)}
Linear solver Algebraic Multigrid Solver
METHOD AND TERMINATION

Description Value
Damping factor 0.5
Segregated Step 2 (ss2)
GENERAL
Description Value
Variables {Temperature (comp1.T), Wall temperature, downside (comp1.nitf1.TWall_d), Wall
31
Description Value
temperature, upside (comp1.nitf1.TWall_u)}
Linear solver Direct 1

Description Value
Damping factor 0.8
Turbulence variables (ss3)
GENERAL
Description Value
Variables {Turbulent kinetic energy (comp1.k), Turbulent dissipation rate (comp1.ep)}
Linear solver Algebraic Multigrid Solver 2

Description Value
Damping factor 0.35
Termination technique Iterations or tolerance
Number of iterations 3
Tolerance factor 1
Lower Limit 1 (ll1)
LOWER LIMIT
Description Value
Lower limits (field variables) comp1.k 0 comp1.ep 0 comp1.T 0
Algebraic Multigrid Solver (i1)
GENERAL
Description Value
Nonlinear-based error norm On
ERROR
Description Value
Factor in error estimate 20
Multigrid 1 (mg1)
GENERAL
Description Value
Solver Smoothed aggregation AMG
32
Description Value
Multigrid cycle F - cycle
Maximum number of DOFs at coarsest level 80000
Strength of connections 0.02
Construct prolongators componentwise On
Prolongator smoothing Off
Presmoother (pr)
SCGS 1 (sc1)
MAIN
Description Value
Sweep type SSOR
Vertex relaxation factor 0.7
Postsmoother (po)
SCGS 1 (sc1)
MAIN
Description Value
Sweep type SSOR
Vertex relaxation factor 0.7
Coarse Solver (cs)
Direct 1 (d1)
GENERAL
Description Value
Solver PARDISO
Direct 1 (d1)
GENERAL
Description Value
Solver PARDISO
Algebraic Multigrid Solver 2 (i2)
GENERAL
Description Value
Nonlinear-based error norm On
33
ERROR
Description Value
Factor in error estimate 20
Multigrid 1 (mg1)
GENERAL
Description Value
Solver Smoothed aggregation AMG
Maximum number of DOFs at coarsest level 50000
Construct prolongators componentwise On
Prolongator smoothing Off
Presmoother (pr)
SOR Line 1 (sl1)
MAIN
Description Value
Sweep type SSOR
Relaxation factor 0.7
Multivariable method Uncoupled
SECONDARY
Description Value
Postsmoother (po)
SOR Line 1 (sl1)
MAIN
Description Value
Sweep type SSOR
Multivariable method Uncoupled
SECONDARY
Description Value
34
Coarse Solver (cs)
Direct 1 (d1)
GENERAL
Description Value
Solver PARDISO
35
2 Results
2.1 DATA SETS
2.1.1 Study 1/Solution 1

SOLUTION
Description Value
Solution Solution 1
Component Save Point Geometry 1
Data set: Study 1/Solution 1
2.1.2 All Walls

DATA
Description Value
Data set Study 1/Solution 1
PARAMETERIZATION
Description Value
x- and y-axes Surface parameters
2.1.3 Exterior Walls

DATA
Description Value
36
PARAMETERIZATION
Description Value
2.1.4 Interior Walls

DATA
Description Value
PARAMETERIZATION
Description Value
2.1.5 Mirror 3D 1
DATA
Description Value
PLANE DATA
Description Value
Plane type Quick
Plane zx - planes
y-coordinate 0
2.2 DERIVED VALUES
2.2.1 Heat Transfer Coefficient

OUTPUT
Evaluated in Table 1
DATA
Description Value
COMMON
Expression Unit Description
aveop1(abs(nitf1.qwf_u))/(T_water-T_air) W/(m^2*K)
37
2.2.2 Inlet Pressure, Water
OUTPUT
DATA
Description Value
COMMON
p Pa Pressure
SETTINGS
Description Value
Integration order 4
2.2.3 Inlet Pressure, Air

OUTPUT
DATA
Description Value
COMMON
p Pa Pressure
SETTINGS
Description Value
Integration order 4
2.3 TABLES
2.3.1 Table 1
Heat Transfer Coefficient (aveop1(abs(nitf1.qwf_u))/(T_water-T_air))
TABLE 1
aveop1(abs(nitf1.qwf_u))/(T_water-T_air) (W/(m^2*K))
5.5924
38
2.3.2 Table 2
Inlet Pressure, Water (p)
TABLE 2
Pressure (Pa)
35.872
2.3.3 Table 3
Inlet Pressure, Air (p)
TABLE 3
Pressure (Pa)
13.092
2.4 PLOT GROUPS
2.4.1 Velocity (spf)
Slice: Velocity magnitude (m/s)
Fig 1.1
39
2.4.2 Pressure (spf)
Contour: Pressure (Pa) Contour: up(p) (Pa) Contour: down(p) (Pa)
Fig 1.2
2.4.3 Wall Resolution (spf)
Surface: Wall lift-off (mm)
Fig 1.3
40
2.4.4 Temperature (ht)
Surface: Temperature (degC)
Fig 1.4
2.4.5 Isothermal Contours (ht)
Isosurface: Temperature (K)
Fig 1.5
41
2.4.6 Velocity, Streamlines
Streamline: Velocity field
Fig 1.6
Report
A simulation of counter-current single pass Shell and tube heat exchanger is carried out in comsol. Here, the
air, entering the shell side is heated by hot water entering on the tube side. As the velocity of air in the shell
is in the turbulent region owing to the high inlet velocity and presence of baffles that not only guide the air
flow but also aid in maintaining the turbulence in the air flow. Turbulence is evident from fig 1.6 which
shows us the stream line velocity fields. We can see from fig 1.6 that though the air at the inlet of the shell
has uniform velocity, the rise in temperatures as it proceeds along the shell results in higher velocities,
primarily due to changes in density. As no external force exists for the fluid (air) to flow within the shell
(pumping of fluid into the shell is considered as inlet velocity), the changes in density due to presence of
temperature hot spots causes increase in velocities. The presence of baffles ensures good contact of the fluids
with the pipe surface, wherein the heat transfer occurs. However, fig 1.1, shows that the increase in velocities
of air has the highest values at the inlet where maximum shell fluid temperatures exists (refer fig 1.5). This
can be as stated earlier, due to changes in density of air resulting in velocities formed.
Fig 1.3 gives us an insight into analysis of wall effects on turbulent flows. Wall lift off are more at the baffles
surfaces. Turbulence formed nearer to the baffle walls due to temperature effects and flow direction changes
caused by presence of baffles. Wall lift offs show the presence of local turbulence nearer to walls. The plot
indicates regions of high turbulence which can cause vibration induced stresses on the tube wall close the
vicinity of turbulence and on the baffles themselves. Further reading on boundary layer effects in turbulence
and von-Karman theories will prove useful in better understanding .
Fig 1.5 tells us that effective heat transfer from the tubes to the shell fluid has taken place. This simulation
does not account for the losses due from shell surface not from tube surface.
42
43

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Shell-and-Tube Heat Exchanger

1.2.1 Coordinate Systems

Coordinate system type Boundary system

1.4.3 Structural steel

1.4.6 Inlet 1: Water

1.4.7 Outlet 1: Water

1.4.8 Inlet 2: Air

1.4.10 Interior Wall 1

1.5 HEAT TRANSFER IN FLUIDS

Heat Transfer in Fluids

Heat conduction, fluid

1.5.2 Initial Values 1

1.5.4 Inflow 1: Water

1.5.5 Inflow 2: Air

1.5.7 Outflow 2: Air

1.5.9 Thin Layer 1

1.6.1 Nonisothermal Flow 1

Stationary Solver 1 (s1)

Velocity u, Pressure p (ss1)

METHOD AND TERMINATION

Segregated Step 2 (ss2)

METHOD AND TERMINATION

Turbulence variables (ss3)

METHOD AND TERMINATION

Lower Limit 1 (ll1)

Algebraic Multigrid Solver (i1)

Coarse Solver (cs)

Algebraic Multigrid Solver 2 (i2)

SOR Line 1 (sl1)

SOR Line 1 (sl1)

2.1 DATA SETS

2.1.1 Study 1/Solution 1

Data set: Study 1/Solution 1

2.1.2 All Walls

2.1.3 Exterior Walls

2.1.4 Interior Walls

2.2 DERIVED VALUES

2.2.1 Heat Transfer Coefficient

2.2.3 Inlet Pressure, Air

2.4 PLOT GROUPS

2.4.1 Velocity (spf)

Slice: Velocity magnitude (m/s)

Contour: Pressure (Pa) Contour: up(p) (Pa) Contour: down(p) (Pa)

2.4.3 Wall Resolution (spf)

Surface: Wall lift-off (mm)

Surface: Temperature (degC)

2.4.5 Isothermal Contours (ht)

Isosurface: Temperature (K)

Streamline: Velocity field

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