COMPUTATIONAL ANALYSIS OF DOUBLE PIPE COUNTER FLOW HEAT

EXCHANGER USING FINS ATTACHED TO THE INNER PIPE

Jayaram Thumbe*1, Samuel Raju2, Rajath K3, Sai Suparna K4 , Raju Poojari5
*1
Associate Professor, 2,3,4,5 UG Students
Department of Mechanical Engineering
Srinivas Institute of Technology, Mangaluru, India
*[email protected]

ABSTRACT
Heat transfer enhancement in a heat exchanger can be improved by active and passive techniques. In the
present study, heat transfer rate from the hot fluid to cold fluid in a double pipe counter flow heat
exchanger having fins attached to the inner pipe along its length is analyzed. The whole analysis is carried
out by using commercial CFD code. The two fin configurations of rectangular and triangular fins are used
in the study. Computational analysis was carried on counter flow double pipe heat exchanger with
constant mass flow rate for hot and cold fluids for exit temperature. It is found that exit temperature of
the hot fluid is low and that of cold fluid is high for the rectangular fin. Using this exit temperature, the
heat transfer rate and fin effectiveness are calculated. The results show that heat transfer in a finned
configuration is comparatively greater than unfinned one. Among these fin configurations, the
rectangular fin shows improvement over triangular fin in terms of heat transfer rate, this is due to the
rectangular fin has the large surface area for a given volume and also the effectiveness of the fin show
the higher value than the triangular fin.

Keywords: double pipe heat exchanger, triangular fins, rectangular fins, mass flow rate

I. INTRODUCTION
The heat exchanger is a device in which the amount of space they occupy is relatively high.
efficient heat transfer from one fluid to another Enhancement of heat transfer in a heat
takes place. In the heat exchanger, two modes exchanger is done by several methods. These
of heat transfer occur such as convection and techniques are divided into active and passive
conduction. Usually, convection takes place in techniques. In active method, external input for
between fluids and conduction takes place the enhancement of heat transfer like jet
through the walls of the heat exchanger which impingement, induced vibrations etc. are used.
separated by the fluids. Overall heat transfer In passive method is something without the
coefficient, surface area, and logarithmic mean stimulation by external power such as surface
temperature difference play an important role in coating, surface roughness, and extended
the analysis of heat transfer. Reducing the heat surfaces. Double pipe heat exchanger uses one
transfer area of a heat exchanger is an heat exchanger pipe inside another. The pipe
opportunity to enhance the heat transfer rate sizes and a number of bends for the double pipe
and also it is getting Industrial importance. heat exchanger can be selected only after
energy, material and cost saving related to a determining the required heat exchanger
heat exchange process is supported by an surface area, for either parallel flow or counter
increase in the performance of the heat flow. Type of flow pattern in the heat exchanger
exchanger. Double pipe heat exchangers are the is an important factor in a double pipe heat
simplest of heat exchangers in which heat is exchanger design. The calculation of the log
transferred from the hot fluid to the cold fluid mean temperature difference is taken by the
through a separating cylindrical wall. Double flow pattern of a heat exchanger. An estimated
pipe heat exchangers have smaller diameters so overall heat transfer coefficient allows
they are primarily adapted to high pressure and calculation of the required heat transfer surface
high-temperature applications. They are fairly area. Hence pipe sizes, pipe lengths and a
cheap but compared to the other types the number of bends can be determined. In the

1
present study, the heat transfer enhancement is heat exchangers having different profiles of fin
carried out through a DPHE by using attached for their inner tube. The results
computational fluid dynamics using two types of obtained were plotted against one another for
fins such as Triangular, and Rectangular fins comparison. The graph of Temp vs length of
arranged on inner pipe surface which contains heat exchanger, Temp vs height of fin, Cold
cold process fluid i.e. water. The overall analysis water outlet temp vs mass flow rate of hot
is carried out by considering the system in a water, Cold water outlet temp vs cold water
steady state condition. mass flow rate, Heat transfer coefficient vs
CFD is essentially a branch of Continuum mass flow rate of cold water, Fin effectiveness
mechanics which deals with numerical vs mass flow rate, Pressure drop vs mass flow
simulation of fluid flow and heat transfer rate were plotted for selection of best
problems. Analyzing a fluid problem using CFD alternative. J. Manohar et al. [2] considered that
requires the following steps. First, Conversion of designing of heat exchangers is the one of the
the governing equations for a continuum important aspects to be considered while, to
medium in to a set of discrete algebraic increase the effectiveness of heat exchangers.
expressions using a process called discretization In their work heat transfer enhancement was
because the computer can only work with done using fins, which are attached to the inner
discrete numbers. Then finding the solutions of pipe of heat exchanger. Rectangular fins are
these discrete equations using a high-speed attached over inner tube along its length, for
digital computer to obtain the numerical solution various increase in surface area rate of heat
to desired level of accuracy. The three main transfer was calculated theoretically by
elements of CFD codes are: (1) A pre-processor logarithmic mean temperature difference
is used to input the problem geometry, grid method. In the experiment, the temperature
generation, define the flow parameters and the T1(hot water inlet), T2(hot water outlet), T3(cold
boundary conditions to the code. (2) A solver, water inlet), T4(cold water outlet) are noted,
for the conditions provided it solve the after achieving constant flow rate. The flow of
governing equations of the flow subject. four water is varied by adjusting the value, for various
different methods are used by a flow solver: (i) flow rate, the inlet and outlet of the hot and cold
finite difference method; (ii) finite element water temperatures were noted for doing
method, (iii) finite volume method, and (iv) calculation In designing part, it consists of a
spectral method. (3) A post-processor, is used stack of alternate flat plates called 4 parting
to show the results in graphical and easy to read sheets and corrugated rectangular fins brazed
format. Some of the attempts made by different together as a block to inner pipe, these fins are
persons making observations to increase characterized by high effectiveness,
thermal characteristics of heat exchanger are compactness, low weight and moderate cost.
Shiva Kumar et al. [1] have analysed concentric Streams exchange heat by flowing along the
tube heat exchanger with passive heat transfer passages made by the fins between the parting
technique. This performance is determined for sheets. Separating plate acts as the primary heat
different longitudinal fin profiles, rectangular, transfer surface and the projected part known
triangular, parabolic. Numerical analysis was as fins act as the secondary heat transfer
carried out in parallel flow double pipe heat surfaces intimately connected to the primary
exchanger for different profiles and for varied surface. Fins not only form the extended heat
mass flow rates. Here analysis was done by both transfer surfaces, but also work as strength
experimental and CFD method. In experimental supporting member against the internal
method, the setup of concentric tube double pressure. These fins are generally made up of
pipe heat exchanger the inner tube was made of alloy of aluminium or stainless steel and it is
copper and hot water flows from the geyser depending upon working temperature and
attached to it. The inlet temperature of cold and pressure. The setup consists of an inner tube
hot fluid was maintained at 303K and 323K. The and an outer tube. The inner tube is provided
mass flow rate of hot water was varied from with an external fin, to improve the active
0.02kg/s to 0.1kg/s with increase of 0.02kg/s surface area. Then hot fluid is passed through
each time by keeping mass flow rate of cold inner pipe, for various temperature of fluid,
water as constant (0.02kg/s). Similarly, length of pipe; Nusselt number, Heat transfer
experiment was conducted by varying mass coefficient, LMTD, Overall heat transfer rates
flow rate of cold water by keeping the mass flow are calculated. Then results are compared by
rate of hot water constant. These two iterations conducting experiment without using fins and
were conducted by using CFD technique for with using fins. Kanade Rahul H et al. [3] have

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carried out the heat transfer enhancement copper tube with inner tube and outer tube
through a DPHE by using computational fluid diameters of 15 mm and 25 mm, respectively.
dynamics using different types of baffles such The plain tubes with full-length twisted wires
as Semi-circular and Quarter-circular baffles and with regularly spaced twisted wires brush
arranged on inner pipe surface which contains inserts are tested. The twisted wires brush
cold process fluid i.e. water. These baffles are inserts are fabricated by winding 0.2 mm
arranged in such a manner that increases that diameter of the copper wires over 2 mm
retention time of fluid, pressure drop and diameter two twisted iron core-rods. They
turbulence inside the annulus which contains hot found the increased performance of concentric
process fluid i.e. water. Overall analysis is carried pipe heat exchanger with plain tube and tube
out by considering the DPHE in a steady state with twisted wire brush inserts having a plot
condition. Heat transfer rate, overall heat between tube side Nusselt number and
transfer coefficient and pressure drop are Reynolds number. Based on their experimental
determined for fully developed condition for results, The Nusselt number obtained for the
several Reynolds numbers based on the pipe tube with twisted wire brush inserts varied from
diameter and flow mean velocity with water as 1.55 to 2.35 times in comparison to those of the
working fluid. Kern method is used as a plain tube. The inner convective heat transfer
correlation for the design of heat exchanger. In coefficient for twisted wire brush inserts is
Grid generation, fine mesh size is selected, in approximately 9-11 % higher than that for plain
order to capture both thermal and velocity tube. The pressure drop for twisted wire brush
boundary layer with nodes of 64332 and 23100 inserts is 4- 5 % higher than that obtained for
elements. The analysis was carried out for a plain tube. The variation between theoretical
DPHE without baffles at 0.0583 m/s hot and Nusselt number and experimental Nusselt
0.116 m/s cold velocities and was validated with number is approximately 10-15 % because of
analytical design and it was found that the influence of viscosity effects and the
temperature variation was ≤ 1%. Heat exchanger experimental values are in reasonable
with quarter circular baffles arranged on outer agreement with predicted values. The friction
surface of inner pipe resulted in an increase of factor values for twisted wire brush inserts
heat transfer rate by 9.5% in comparison with no decrease than that for plain tube. It is 7-8% less
baffles. The performance of heat exchanger was than that obtained for plain tube.
increased by minimizing hot fluid temperature
and maximizing the cold fluid temperatures. The
optimal heat transfer rate was achieved for II. Numerical scheme
quarter-circular baffles with lower pressure
Double pipe heat exchanger without fins
drop and higher turbulence at 0.0583 m/s
velocity of hot fluid. Deepali Gaikwad et al. [4]
The geometric model of the double pipe heat
have done the experimental study to investigate
exchanger was constructed using work bench in
the heat transfer performance and friction
Ansys 16 environment. The complete domain
factor characteristics for laminar flow through a
consists of 54650 Elements. Grid independent
tube by means of twisted wire brush inserts. The
test was performed to check the validity of the
mass flow rates in inner tube and in annulus were
quality of the mesh on the solution as shown in
varied during experimentation. Air to water heat
the Fig. 1. Inlet temperature and mass flow rate
transfer study is performed and tested for
of the cold and hot fluid was specified. At the
counter flow configuration. Effect of inlet fluid
outlet, a pressure outlet boundary is enforced.
temperature and relevant parameters on heat
Pressure velocity coupling was resolved using
transfer characteristics and friction factor is
SIMPLE algorithm with a skewness correction
considered. Their study revealed that the
factor of 1. For pressure, linear discretization
twisted wire brush inserts provided significant
was used. For momentum, turbulent kinetic
enhancement of heat transfer with the
energy and turbulent dissipation rate with power
corresponding increase in friction factor, and
law scheme was used. For the energy equation
the pressure drop also slightly increases. Due to
second order upwind was used. Conservation
the turbulence created and swirl flow
equations were solved for the control volume to
generated, the convective heat transfer
yield the velocity and temperature fields for the
obtained from the tube with twisted wire brush
water flow in the heat exchanger. Convergence
inserts are higher than that with the plain tube
was affected when residuals fell below 10 −3 in
without twisted wire brush inserts. The twisted
the computational domain. A sample
wires brush inserts was made from straight
convergence plot is shown in the Fig. 2.

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Simulations were done by changing the mass temperature distribution at the outlet for both
flow rates of hot fluid as well as cold fluid. unfinned and finned (height = 6mm) heat
exchanger is shown in Fig .3 which clearly
350 indicates the increase in the average
temperature in the annulus for a finned tube.
Temperature(K)

340 Annulus fluid temperature along the length of

330 heat exchanger was plotted for different fin
heights and is as shown in Fig .4. It can be
320
observed that the temperature rise for the
310 finned heat exchanger is more than that of the
unfinned type. As the fin height increases the
300
average water temperature increased. But on
-5 5 15 25
comparing the temperature rise for different fin
Iterations heights, as the height increases, rise in average
temperature was found to be lower. Also, the
Fig-1: Variation of cold water outlet temperature curve shows that the temperature rise along the
with number of iterations length of exchanger is gradual and not steep. Fig
.5 represent the temperature plot along the
vertical length at the centre of the fin for 3mm,
6mm and 7mm height fins at a midsection of the
heat exchanger. Fin tip temperature for 3mm,
6mm and 7mm height fins are 326.84, 325 and
323.95K respectively. It indicates that there was
a decrease of temperature by 1.84K when the
height was increased from 3mm to 6mm and a
decrease of 1.05K when the height was
increased from 6mm to 7mm which indicates
the reduced fin performance on increasing the
fin height. Simultaneously increasing the fin
height increases the weight of the finned
assembly. Hence an optimum fin height of 6mm
was chosen for further comparison between
different profiles for fins.
Fig-2: Sample of Residual convergence plot for
the double pipe heat exchanger

Validation of the numerical results.

The Nusselt number obtained from the

numerical results of plain double pipe heat
exchanger is verified with the experimental
Nusselt number of Deepali Gaikwad et al. [4].
Fig. 3. Temperature distribution at the outlet
The error is found to be 12.2%.
surface for (a) unfinned (b) rectangular finned
Rectangular finned double pipe heat double pipe heat exchanger (6mm) for mh = 0.01
exchanger and mc = 0.02kg/s

A double pipe heat exchanger with rectangular

longitudinal fins was modeled in the Ansys work
bench environment. Base width of the fin was
2mm (18 degrees) kept constant throughout the
study. The simulation was done using different
fin heights 3mm, 6mm and 7mm. 12 fins were
placed circumferentially around the thickness of
the inner tube which remained constant
throughout the study. Simulation was carried
out for various mass flow rates of cold and hot
water. For mch = 0.01kg/s and mcc = 0.02kg/s

4
 330
Temperature (ºC) 328
320

Temperature(ºC)
326
310
324
300
322
0 0.5 1 1.5 2
0 0.005 0.01 0.015
Length along heat exchanger in m
Height of the fin in (m)
bare pipe
length 3m 3mm 6mm 7mm
length 6m
Fig. 5 Variation of temperature along the height of
fin at the mid-section of the heat exchanger mh =
Fig. 4 Variation of cold water temperature along
0.01 and mc = 0.02
the length of exchanger for different heights of
rectangular fins for mh = 0.01 and mc = 0.02kg/s

III. Results and discussions

Geometrical modelling of the heat exchanger
was constructed by changing the fin
configuration to tri-angular profile keeping the
fin base width, height and number of fins
constant as discussed in Section 3. Fig.6 shows
the different fin configurations undertaken in
the present study. Simulation was done for
different mass flow rates of hot water through Fig. 6 Different types of finned configurations (a)
the inner tube for a constant cold water flow triangular, (b) rectangular
rate of 0.02kg/s in the annulus. Fig .7 indicates
the temperature plot of all fin profiles with mch= 330
Temperature (ºC)

0.01kg/s and mcc = 0.02kg/s. It depicts that the 320

cold-water outlet temperature for the finned 310
tube is higher than the bare tube. Fins promote
300
boundary layer separation of the fluids and
0 0.5 1 1.5 2
disturb the whole bulk flow field inside circular
tubes. Separation and restarting of the Length of Heat exchanger in (m)
boundary layers increases the heat transfer rate.
Without fin
It can be further noted that the bulk of the fluid Triangular fin
layer is being disturbed the rise of temperature Rectangular fin
is also uneven along the length of the tube as
shown in Fig. 8. Temperature for triangular
Fig. 7 Variation of temperature along the length of
profile is slightly higher than the rectangular at
heat exchanger for different fin profiles at mh =
the entry of the heat exchanger, and as fluid 0.01 and mc = 0.02kg/s
progresses along the length of the heat
exchanger temperature for the rectangular Fig. 8 indicates the plot of cold water outlet
profile increases sharply than the triangular temperature Vs mass flow rates of the hot
profile and at the outlet it is marginally higher water. The outlet temperature for the
than triangular type. The fin form adjustment rectangular fin is 0.1% and 0.2% more that of
effects not only the mass of the heat exchanger, triangular shape for the highest mass flow rate
but also has an effect on the move liquid-like of hot water. Fig. 9 shows temperature rise
direction that causes the temperature changes along the length for a particular value of mch =
on the fin contact surfaces. 0.02kg/s and mcc = 0.01kg/s. It can be revealed
that rise in the temperature is higher for a finned
tube than the unfinned one. In case of finned
tube, the rise is not uniform and smooth as the
entire flow field is being disturbed along the
length. Rectangular finned tubes show a
marginal improvement over the other types.

5
 330 energy dissipated from the inner tube remains
Cold water outlet constant and hence as mcc is increased heat
temperature (ºC)
320
transfer rate is being increased due to the
310 increased turbulence, but the retention time of
300 the fluid in the exchanger will be reduced which
0 0.05 0.1 0.15 decreases the cold-water outlet temperature.
Mass flow rate of hot water (kg/s) Drop in outlet temperature or the rectangular
profile is marginally lesser than the other two
Without fin types showing its better performance.
Triangular fin
Rectangular fin

Outlet temperature of cold

320

Fig. 8 Variation of cold water outlet temperature 315

water (ºC)
with mass flow rates of hot water
310
330
305
Temperature (ºC)

320 0 0.05 0.1 0.15

310 Mass flow rate of cold water (kg/s)
300 Without fin
0 0.5 1 1.5 2 Triangular fin
Length of Heat exchanger in (m) Rectangular fin

Without fin Rectangular fin Fig. 10 Variation of cold water outlet temperature
with varying mass flow rates of cold water
Fig. 9 Variation of temperature along the length of
heat exchanger for rectangular fin profile at mh = Tab. 1 indicates the heat transfer rate for
0.01 and mc = 0.02kg/s different simulated conditions for the finned and
unfinned tubes. It can be revealed that heat
Fig. 10 shows the variation of outlet temperature transfer rate increases with the increase in mass
of cold water for varying mass flow rates of cold flow rate and finned tubes show higher value
than the unfinned condition. For a constant
S Conditio Mass Unfin Recta Triangu value of mc = 0.02kg/s and varying mc,
. n flow ned ngular lar rectangular finned tubes showed an average
N rate tube finned finned improvement of 6.1% over the triangular finned
o (kg/s (W) tube tube tube. Similarly, for a constant value of mh =
) (W) (W) 0.02kg/s and varying mcc, it showed an
1 mc 0.02 621 1069 1023 improvement by 2% over the triangular
2 consta 0.04 718 1430 1348
3 nt at 0.06 759 1620 1515 Table 1. Comparison of experimental and CFD
4 0.08 784 1741 1623 simulated results for unfinned the double pipe heat
0.02 exchanger
5 kg/s 0.1 800 1828 1700
and mh
varying Fig. 11 shows the variation of annulus heat
6 mh 0.02 621 1069 1023 transfer coefficient for different varied mcc
7 consta 0.04 841 1372 1284 keeping mch constant at 0.02kg/s. It is
8 nt at 0.06 992 1541 1487 observed that annular heat transfer coefficient
9 0.08 1102 1589 1507 is found to be reduced for finned structure since
0.02
1 0.1 1187 1680 1604 effective heat transfer coefficient is related to
kg/s the efficiency of the fin as Hannular = Fin
0
and mc efficiency × hnormal. Further on comparing the
varying values for different fin profiles it is observed that
water with mass flow rate of hot water being rectangular profiles the heat transfer coefficient
fixed. It indicates as the mass flow rate increases
the outlet temperature decreases for all profiles.
This is because for a fixed value of mch heat

6
is slightly higher than the others at all mass flow mass flow rate of hot liquid flowing inside the
rate conditions. inner tube should be maximum.

2000 2.5
Annulus heat transfer

Fin effectiveness
2
coefficient (W/m2)

1500
1.5
1000
1
500 0.5
0 0
0 0.05 0.1 0.15 0 0.05 0.1 0.15
Mass flow rate of cold water (kg/s) Mass flow rate (kg/s)
Without fin
Triangular fin Rectangular fin Triangular fin
Rectangular fin Rectangular fin Triangular fin

Fig. 11 Variation of annulus heat transfer Fig. 12 Variation of fin effectiveness with varying
coefficient with varying mass flow rates of cold mass flow rates of cold water and hot water
water
Fig. 13 represents the pressure drop variation for
Fig. 12 represents fin effectiveness for various unfinned and the finned tube for various mass
types of fins under different conditions. Fin flow rates of cold fluid. It can be seen that
Effectiveness was calculated by the simple pressure drop for unfinned tube is lesser than
relation fin effectiveness, ε=
with fin
For a the finned tube. In case of a finned tube pressure
without fin drop was highest for the fin with rectangular
constant value of mcc of 0.02kg/s, as mch was
shape. Higher pressure losses increase the
increased the effectiveness of the fins
pumping power. Since the pressure losses are
increased and rectangular fins showed highest
more in case of rectangular finned tube the
effectiveness among the different types.
pumping power required will be more when
Similarly, for a constant mh and as mc are varied
compared to the triangular finned tube.
fin effectiveness decreases as seen in the graph.
The rise in temperature for varying mcc
decreases for a finned tube compared with the 300
Pressure drop (Pa)

unfinned one. At higher mass flow rates the flow 250

field is being disturbed severely when compared 200
to the bare tube. Hence heat transfer capability 150
of the fins decreases causing reduction in fin 100
effectiveness. Hence in order to have a better 50
performance by the fins for heating a liquid 0
flowing in the annulus region, mass flow rate of 0 0.05 0.1 0.15
liquid in the annulus should be minimum and Mass flow rate of cold fluid (kg/s)
Without fin
Triangular fin
Rectangular fin

Fig. 13 Variation of pressure drop with varying

mass flow rates of cold water

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IV. Conclusion REFERENCES

In the present study, numerical simulation of [1] Shiva Kumar, K. Vasudev Karanth, Krishna
finned double pipe heat exchanger is carried out Murthy. (2015) “Numerical study of heat transfer
with hot fluid flowing in the inner tube and cold in a finned double pipe heat exchanger”, World
fluid in the annulus. The simulation was carried Journal of Modelling and Simulation, Vol. 11, No.
out using rectangular, triangular finned 1, pp. 43-54
configurations on the outer body of the inner [2] J. Manohar, J. Sundhar Singh Paul Joseph, J.
tube. Results indicated finned configuration Lakshmipathy & M. Sathishkumar. (2016),
gives overall better thermal qualities compared “Experimental study on Fabrication of finned
with unfinned one. Rectangular finned con- double counter flow heat exchanger”.
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The effectiveness value of the rectangular fin [3] Kanade Rahul H.1, Kailash B A, Gowreesh.
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Research Journal of Engineering and
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[4] Deepali Gaikwad, Kundlik Mali. (2014) “Heat
Transfer Enhancement for Double Pipe
Heat Exchanger Using Twisted Wire Brush
Inserts”, International Journal of Innovative
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