DESIGN AND FINITE ELEMENT ANALYSIS OF SHELL & TUBE

HEAT EXCHANGER USING NANO FLUIDS

A Major project report Submitted

In partial fulfillment of the requirements for the degree of

Mater of Technology in
THERMAL ENGINEERING
by
P GIRIBABU 18N31D2111

Under the esteemed guidance of

Dr. D. DAMODARA REDDY

(Associate Professor)

MALLA REDDY COLLEGE OF ENGINEERING & TECHNOLOGY

Department of mechanical Engineering
(Autonomous Institution- UGC, Govt. of India)
(Affiliated to JNTUH, Hyderabad, Approved by AICTE, NBA &NAAC with ‘A’ Grade)
Maisammaguda, Kompally, Dhulapally, Secunderabad – 500100
website: www.mrcet.ac.in

2018-2020
 MALLA REDDY COLLEGE OF ENGINEERING & TECHNOLOGY
(Autonomous Institution- UGC, Govt. of India)
(Affiliated to JNTUH, Hyderabad, Approved by AICTE, NBA &NAAC with ‘A’ Grade)
Maisammaguda, Kompally, Dhulapally, Secunderabad – 500100website: www.mrcet.ac.in

Department of Mechanical Engineering

CERTIFICATE

This is to certify that this is the bonafide record of the major project entitled “Design and Finite
Element Analysis of Shell & Tube Heat Exchanger Using Nano Fluids” submitted by
PADAMATINTI GIRIBABU (H.T.NO 18N31D2111), of M.Tech in the partial fulfillment for
the award of degree of Master of Technology in Thermal Engineering, Jawaharlal Nehru
Technological University ,Hyderabad during the academic year 2018 – 2020.

Dr.D.Damodara Reddy Dr.Srikar Potnuru

Internal Guide Head of the Department

External Examiner
 DECLARATION

I hereby declare that the major project titled “Design and Finite Element Analysis
of Shell & Tube Heat Exchanger Using Nano Fluids” submitted to Malla Reddy
College of Engineering and Technology (UGC Autonomous), affiliated to
Jawaharlal Nehru Technological University Hyderabad (JNTUH) for the award
of the degree of Master of Technology in Thermal Engineering is a result of
original research carried-out in this thesis. I understand my report may be made
electronically available to the public it is further declared that the project report
or any part thereof has not been previously submitted to any University or
Institute for the award of degree or diploma.

Name of the Student : Padamatinti Giribabu

Hall ticket number : 18N31D2111

Degree : Master of Technology in Thermal Engineering

Department : Mechanical Engineering

Title of the Project : Design and Finite Element Analysis of Shell&

Tube Heat Exchanger Using Nano Fluids.

Padamatinti Giribabu

Date :
 ACKNOWLEDGEMENT

I deeply thankful to our respected Principal of the college MRCET

Dr.S.Srinivasa Rao and Head of the Department MECH Dr.Srikar Potnuru,

Associate Professor of Thermal Dept and our internal guide Dr.D.Damodara

Reddy , whose help and interest where always with us during the execution of

the project .

Finally, I want to deeply acknowledgement all my classmates, friends who have

encouraged me during the preparation of my project.

iv
 TABLE OF CONTENTS

TABLE OF CONTENTS V
LIST OF FIGURES IX
LIST OF TABLES XI
NOMENCLATURE XI
ABSTRACT XII

CHAPTER I INTRODUCTION TO HEAT EXCHANGER 1-23

1.1 Introduction
1.1.1 History of Heat Exchanger 1
1.1.2 About Heat Exchanger 1
1.2 Shell and Tube Heat Exchanger 3
1.2.1 Theory and Application 3
1.2.2 Shell and Tube Heat Exchanger Types 4
1.2.2.1 U-Tubes 4
1.2.2.2 Straight-Tube 1-Pass 5
1.2.2.3 Straight-Tube 2-Pass 6
1.2.3 Selection of Tube Material 7
1.3 Nano Fluid 7
1.3.1 Introduction to Nano Fluid 7
1.3.2 History of Nano Fluid 8
1.3.3 Heat Conduction Mechanisms in Nano Fluid 8
1.3.4 Preparation of Nano Fluid 9
1.3.5 Types of Nano Fluid 9
1.4 Ti C(Tic) Nanoparticles 10
1.4.1 Introduction 10
1.4.2 Chemical Properties 10
1.4.3 Physical Properties 11
1.4.4 Thermal Properties 12
1.4.5 Applications 12
1.5 Ti N(Tin) Nanoparticles 12

v
 1.5.1 Introduction 12
1.5.2 Chemical Properties 13
1.5.3 Physical Properties 13
1.5.4 Thermal Properties 13
1.5.5 Applications 14
1.6 Zi O(ZnO) Nanoparticles 14
1.6.1 Introduction 14
1.6 2 Chemical Properties 14
1.6.3 Physical Properties 15
1.6.4 Thermal Properties 15
1.6.5 Applications 15
1.7 Calculations to Determine Properties of Nano Fluids by
Changing Volume Fractions 16
1.7.1 Nomenclature 16
1. 7.2 Nano Fluid Calculations for Titanium Carbide 16
1.7.2.1 Density of Nano Fluid 16
1.7.2.2 Specific Heat of Nano Fluid 17
1.7.2.3 Viscosity of Nano Fluid 17
1.7.2.4 Thermal Conductivity of Nano Fluid 18
1.7.3 Nano Fluid Calculations for Titanium Nitride 18
1.7.3.1 Density of Nano Fluid 18
1.7.3.2 Specific Heat of Nano Fluid 19
1.7.3.3 Viscosity of Nano Fluid 19
1.7.3.4 Thermal Conductivity of Nano Fluid 19
1.7.4 Nano Fluid Calculations for Zinc Oxide 20
1.7.4.1 Density of Nano Fluid 20
1.7.4.2 Specific Heat of Nano Fluid 21
1.7.4.3 Viscosity of Nano Fluid 21
1.7.4.4 Thermal Conductivity of Nano Fluid 21
CHAPTER II LITERATURE REVIEW 24-28
2.1 Introduction 24

2.2 Compact Heat Exchanger Using Nano Fluid 26

2.2.1 Why We Use Nano Fluid 27
2.3 Research Gap & Problem Description 27
vi
CHAPTER III INTRODUCTIONS TO MECHANICAL SOFTWARE 29-38
3.1 Introduction to CAD 29
3.2 Introduction to Pro/Engineer 30
3.2.1 Pro/Engineer Wildfire Benefits 30
3.2.2 Different Modules in Pro/Engineer 30
3.3 Introduction to FEA 31
3.3.1 Types of Engineering Analysis 33
3.3.2 Results of Finite Element Analysis 33
3.4 Introduction to Ansys 34
3.4.1 Steps Involved in Ansys 35
3.4.2 Thermal Analysis 35
3.5 Introduction to CFD 36
3.5.1 Boundary Conditions Considered for Thermal and CFD Analysis 37

CHAPTER IV CFD ANALYSIS OF SHELL & TUBE HEAT EXCHANGER 39-54

4.1 CFD Analysis Flow Chart 39
4.2 CFD Analysis for General STHE Using Hot Water and Cold-water 39
4.3 CFD Analysis on STHE Using Nano Fluids 42
4.3.1 Temperature Distribution along STHE Using Ti C 42
4.3.2 Heat Transfer Coefficient along the STHE Using Ti C 44
4.3.3 Total Heat transfer rate for Ti C nano fluid at various
volume fractions 45
4.3.4 Temperature Distribution along STHE Using Ti N 47
4.3.5 Heat Transfer Coefficient along the STHE Using Ti N 48
4.3.6 Total Heat transfer rate for Ti N nano fluid at various
volume fractions 48
4.3.7 Temperature Distribution along STHE Using Zi O 51
4.3.8 Heat Transfer Coefficient along the STHE Using Zi O 52
4.3.9 Total Heat transfer rate for Zi O nano fluid at various
volume fractions 53
CHAPTER V THERMAL ANALYSIS OF SHELL AND TUBE
HEAT EXCHANGER 55-62
5.1 Thermal Analysis Flow Chart 55
vii
5.2 Heat Flux Values for Aluminum STHE 57
5.2.1 Heat Flux Values for Aluminum STHE Using Ti C 57
5.2.2 Heat Flux Values for Aluminum STHE Using Ti N 58
5.2.3 Heat Flux Values for Aluminum STHE Using Zi O 59
5.3 Heat Flux Values for Copper STHE 60
5.3.1 Heat Flux Values for Copper STHE Using Ti C 60
5.3.2 Heat Flux Values for Copper STHE Using Ti N 61
5.3.3 Heat Flux Values for Copper STHE Using Zi O 62

CHAPTER VI RESULTS AND DISCUSSIONS 63-65

6.1 CFD Analysis Results 63
6.2 Thermal Analysis Results 65

CHAPTER VII CONCLUSION 68

REFERENCES 69-71

viii
 LIST OF FIGURES

Figure number Description Page Number

Figure1 1 Shell and Tube heat exchanger 3

Figure1. 2 U- Tube Heat Exchanger 5
Figure 1.3 Straight tube heat Exchanger (1-pass) 5
Figure 1.4 Straight tube heat Exchanger (2 -pass) 6
Figure 3.1 Shell and Tube heat Exchanger 3D model 38
Figure 3.2 Shell and Tube heat Exchanger 2D model 38
Figure 3.3 Shell and Tube heat Exchanger meshed 2D model 38
Figure 4.1 Flow Chart for CFD Analysis 39
Figure 4.2 2D geometry for hot water and cold water STHE 40
Figure 4.3 2D Meshed model for hot water and cold water STHE 40
Figure 4.4 Inputs and outputs of STHE 40
Figure 4.5 Selection of Fluid and its properties in CFD Analysis 41
Figure 4.6 Temperature distribution of STHE 42
Figure 4.7 Heat transfer coefficient of STHE 42
Figure 4.8 Temperature distribution of Ti C nanofluid at various volume fractions 44
Figure 4.9 Heat transfer Coefficient of Ti C nanofluid at various volume fractions 44
Figure 4.10 Temperature distribution of Ti N nanofluid at various volume fractions 48
Figure 4.11 Heat transfer Coefficient of Ti N nanofluid at various volume fractions 48
Figure 4.12 Temperature distribution of Zi O nanofluid at various volume fractions 52
Figure 4.13 Heat transfer Coefficient of Zi O nanofluid at various volume fractions 52
Figure 5.1 Thermal analysis flow chart 55
Figure 5.2 Imported model 56
Figure 5.3 Section view 56
Figure 5.4 Meshed Model 56
Figure 5.5 Heat flux values of Ti C at various volume fractions for Aluminum STHE 58
Figure 5.6 Heat flux values of Ti N at various volume fractions for Aluminum STHE 58
Figure 5.7 Heat flux values of Zi Oat various volume fractions for Aluminum STHE 59
Figure 5.8 Heat flux values of Ti C at various volume fractions for Copper STHE 60
Figure 5.9 Heat flux values of Ti N at various volume fractions for Copper STHE 61
Figure 5.10 Heat flux values of Zi O at various volume fractions for Copper STHE 62

ix
Figure 6.1 Comparison of Heat transfer coefficient between three nano fluids at
different volume fractions 64
Figure 6.2 Comparison Maximum temperatures between three nano fluids at
different volume fractions 64
Figure 6.3 Comparison of Total Heat transfer rate between three nano fluids at
different volume fractions 64
Figure 6.4 Comparison of Heat flux between three nano fluids at different
Volume fractions for Aluminum STHE 67

Figure 6.5 Comparison of Heat flux between three nano fluids at different
volume fractions for Copper STHE 67

x
 LIST OF TABLES

Table Number Table Description Page Number

Table 1.1 Titanium carbide nano fluid properties 22

Table 1.2 Titanium nitride nano fluid properties 22
Table 1.3 Zinc oxide nano fluid properties 23
Table 3.1 Geometric dimensions for Shell and Tube Heat Exchanger 37
Table 4.1 Boundary conditions 41
Table 6.1 CFD Analysis Results 63
Table 6.2 Thermal analysis results Aluminum STHE 65
Table 6.3 Thermal analysis results for Copper STHE 66

NOMENCLATURE
ρnf = Density of nano fluid (kg/m3)
ρs = Density of solid material (kg/m3)
ρw = Density of fluid material (water)
(kg/m3) Ф = Volume fraction
Cpw = Specific heat of fluid material (water) (j/kg-k)
Cps = Specific heat of solid material (j/kg-k)
µw = Viscosity of fluid (water) (poise)
µnf = Viscosity of Nano fluid (poise)
Kw = Thermal conductivity of fluid material (water)
(W/m-k)

Ks = Thermal conductivity of solid material (W/m-

k)

xi
DESIGN AND FINITE ELEMENT ANALYSIS OF SHELL & TUBE HEAT
EXCHANGER USING NANOFLUIDS

ABSTRACT

Shell and tube heat exchangers represent the most widely used vehicle for
the transfer of heat in industrial process applications. Shell and tube heat
exchangers have the ability to transfer large amounts of heat in relatively low cost,
serviceable designs. They can provide large amounts of effective tube surface
while minimizing the requirements of floor space, liquid volume and weight. A
decade ago, with the rapid development of modern nanotechnology, particles of
nanometer-size (normally less than 100 nm) are used instead of micrometer-size
for dispersing in base liquids, and they are called nanofluids.

In this thesis, analytical investigations are done on the shell and tube heat
exchanger, using forced convective heat transfer to determine flow characteristics
of nanofluids by varying volume fractions and mixed with water, the nanofluids
are Zinc Oxide, Titanium Oxide and Titanium Nitride nanofluids and different
volume concentrations (0.02,0.04,0.07and 0.15) % flowing under turbulent flow
conditions.

Thermal and CFD analysis are done on the heat exchanger by applying the
properties of the nanofluid with different volume fractions calculated using
theoretical calculations. 3D model of the heat exchanger will be done in
Pro/Engineer and analysis will be done in Ansys. The materials considered for
shell and tube heat exchanger are Aluminum and Copper.

xii
 CHAPTER I
INTRODUCTION TO HEAT EXCHANGER
1. INTRODUCTION
Heat exchanger is nothing but a device which transfers the energy from a hot
fluid medium to a cold fluid medium with maximum rate, minimum investment
and low running costs. Heat exchanger using nano fluid is a device in which the
heat transfer takes place by using nano fluid. In this the working fluid is nano
fluid. Nano fluid is made by the suspending nano particles in the fluid like
water, ethylene glycol and oil, hydrocarbons, fluorocarbons etc.
1.1.1 of Heat Exchanger
In the 1950s, aluminum heat exchangers made moderate inroad in the
automobile industry with the invention of the vacuum brazing technique, large
scale production of aluminum- based heat exchangers began to raise and grow
resulting from advantages of the controlled atmosphere brazing process
(Nocolok brazing process introduced by ALCAN). With increasing years
introduction of “long life” (highly corrosion resistant) alloys further improved
performance characteristics of aluminum heat exchangers. Extra demands for
aluminum heat exchangers increased mainly due to the growth of automobile air-
conditioning systems.
1.1.2 About Heat Exchanger
Heat exchangers are devices in which heat is transfer from one fluid to
another. The most commonly used type of heat exchanger is a shell-and-tube
heat exchanger. Shell-and-tube heat exchangers are used extensively in
engineering applications like power generations, refrigeration and air-
conditioning, petrochemical industries etc. These heat exchangers can be
designed for almost any capacity. The main purpose in the heat exchanger
design is given task for heat transfer measurement to govern the overall cost of
the heat exchanger. The heat exchanger was introduced in the early 1900s to
execute the needs in power plants for large heat exchanger surfaces as
condensers and feed water heaters capable of operating under relatively high
pressures. Both of these original applications of shell-and-tube heat
exchangers continued to be used; but the design have become highly
sophisticated and specialized, subject to various specific codes and practices.
1
The broad industrial use of shell-and-tube heat exchangers known today also
started in the 1900s to accommodate the demands of emerging oil industry.

The steadily increasing use of shell-and-tube heat exchangers and greater

demands on accuracy of performance prediction for a growing variety of
process conditions resulted in the explosion of research activities. These
included not only shell side flow but also, equally important, calculations of true
mean temperature difference and strength calculations of construction elements,
in particular tube sheets.
The objective of the thesis is to formulate the design algorithm and optimization
procedure for a shell-and-tube exchanger in which exchanger geometry is
determined from required performance for fixed pressure drops. First step in the
effective consideration of allowable pressure drops is to establish a quantitative
relationship between velocity, friction factors, pressure drop of the stream and
number of transfer units. The solution of this equation provides the core of such
an algorithm.

The heat transfer in a heat exchanger involves convection on each side of fluid
and conduction taking place through the wall which is separating the two fluids.
In a heat exchanger, the temperature of fluid keeps on changing as it passes
through the tubes and also the temperature of the dividing wall located between
the fluids varies along the length of heat exchanger.
Examples:
• Boilers, super heaters, reheaters, air preheaters.
• Radiators of an automobile.
• Oil coolers of heat engine.
• Refrigeration of gas turbine power plant.
• In waste heat recovery
system. Types:
1. Direct contact type of heat exchanger,
2. Non contact type of heat
exchanger. Direction of motion
of fluid:
1. Parallel flow,
2. Counter flow
2
3. Mixed flow.
1.2 SHELL AND TUBE HEAT EXCHANGER
A shell and tube heat exchanger is a class of heat exchanger designs. It is the
most common type of heat exchanger in oil refineries and other large chemical
processes, and is suited for higher-pressure and higher-temperature
applications. As its name implies, this type of heat exchanger consists of a
shell (a large pressure vessel) with a bundle of tubes inside it. One fluid runs
through the tubes, and another fluid flows over the tubes (through the shell) to
transfer heat between the two fluids. The set of tubes is called a tube bundle, and
may be composed by several types of tubes: plain, longitudinally finned, etc.

Fig. 1.1 Shell and Tube heat exchanger

A heat exchanger is a device for transferring heat from one fluid to another,
where a solid wall separates the fluids so that they never mix. They are widely
used in refrigeration, air conditioning, space heating, power production, and
chemical processing. One common example of a heat exchanger is the radiator in
a car, in which the hot radiator fluid is cooled by the flow of air over the radiator
surface.

1.2.1 Theory and Application

Two fluids, of different starting temperatures, flow through the heat exchanger.

3
One flows through the tubes (the tube side) and the other flows outside the tubes
but inside the shell (the shell side). Heat is transferred from one fluid to the
other through the tube walls, either from tube side to shell side or vice versa.
The fluids can be either liquids or

gases on either the shell or the tube side. In order to transfer heat efficiently, a
large heat transfer area should be used, leading to the use of many tubes. In this
way, waste heat can be put to use. This is an efficient way to conserve energy.

Heat exchangers with only one phase (liquid or gas) on each side can be called
one-phase or single-phase heat exchangers. Two-phase heat exchangers can be
used to heat a liquid to boil it into a gas (vapor), sometimes called boilers, or
cool a vapor to condense it into a liquid (called condensers), with the phase
change usually occurring on the shell side. Boilers in steam engine locomotives
are typically large, usually cylindrically-shaped shell- and-tube heat exchangers.
In large power plants with steam-driven turbines, shell- and-tube surface
condensers are used to condense the exhaust steam exiting the turbine into
condensate water which is recycled back to be turned into steam in the steam
generator.

1.2.2 Shell and tube heat exchanger Types

There can be many variations on the shell and tube design. Typically, the ends of
each tube are connected to plenums (sometimes called water boxes) through
holes in tube sheets. The tubes may be straight or bent in the shape of a U, called
U-tubes.

1.2.2.1 U-Tubes

The Shell and Tube (u-tube) is the most common type of heat exchanger used in
the process, petroleum, chemical and HVAC industries, it contains a number of
parallel u- tubes inside a shell. Shell Tube heat exchangers are used when a
process requires large amounts of fluid to be heated or cooled. Due to their
design, shell tube heat exchangers offer a large heat transfer area and provide
high heat transfer efficiency. In nuclear power plants called pressurized water
reactors; large heat exchangers called steam generators are two-phase, shell-and-

4
tube heat exchangers which typically have U-tubes. They are used to boil water
recycled from a surface condenser into steam to drive the turbine to produce
power. Most shell-and-tube heat exchangers are 1, 2, or 4 pass designs on the
tube side. This refers to the number of times the fluid in the tubes passes through
the fluid in the shell. In a single pass heat exchanger, the fluid goes in one end of
each tube and out the other. Surface condensers in power plants are often 1-pass
straight-tube heat exchangers.
Two and four pass designs are common because the fluid can enter and exit on the
same side. This makes construction much simpler.

Fig. 1.2 U- Tube Heat Exchanger

1.2.2.2 Straight-Tube 1-pass

Fig. 1.3 Straight tube heat Exchanger (1-pass)

5
 Fig. 1.4 Straight tube heat Exchanger (2 -pass)
One pass means that the fluid enter on one side and exit on the other side of the
heat exchanger There are often baffles directing flow through the shell side so
the fluid does not take a short cut through the shell side leaving ineffective low
flow volumes. Counter current heat exchangers are most efficient because they
allow the highest log mean temperature difference between the hot and cold
streams. Many companies however do not use single pass heat exchangers
because they can break easily in addition to being more expensive to build. Often
multiple heat exchangers can be used to simulate the counter current flow of a
single large exchanger.

1.2.2.3 Straight-Tube 2-pass

Two pass heat exchanger means that the fluid enters and exit on the same side of
the heat exchanger.

There are many different types or designs of shell and tube heat exchangers to
meet various process requirements. Shell and Tube heat exchangers can provide
steady heat transfer by utilizing multiple passes of one or both fluids. SEC shell
and tube heat exchangers come in two (2) and four (4) pass models standard,
and multi-pass custom models.

Shell and Tube heat exchangers use baffles on the shell-side fluid to
accomplished mixing or turbulence. Without the use of baffles, the fluid can
become stagnant in certain parts of the shell.

6
1.2.3 Selection of tube material

To be able to transfer heat well, the tube material should have good
thermal conductivity. Because heat is transferred from a hot to a cold side
through the tubes, there is a temperature difference through the width of the
tubes. Because of the tendency of the tube material to thermally expand
differently at various temperatures, thermal stresses occur during operation. This
is in addition to any stress from high pressures from the fluids themselves. The
tube material also should be compatible with both the shell and tube side fluids
for long periods under the operating conditions (temperatures, pressures, pH, etc.)
to minimize deterioration such as corrosion. All of these requirements call for
careful selection of strong, thermally-conductive, corrosion-resistant, high
quality tube materials, typically metals. Poor choice of tube material could
result in a leak through a tube between the shell and tube sides causing fluid
cross-contamination and possibly loss of pressure. Standard heat exchangers
particularly made for heavy duty ever with medium pressure ranges. The
composition can be made with different choice of materials; all sort of
combinations makes this type of exchangers versatile enough to solve any
problem of fluids, flows, even with high duty rating.

1.3 NANO FLUID

1.3.1 Introduction to nano fluid
Nano fluids are dilute liquid suspended nano particles which have only one
critical dimension smaller than ~100nm. Much research work has been made in
the past decade to this new type of material because of its high rated properties
and behavior associated with heat transfer (Masuda et al. 1993; Choi 1995), mass
transfer (Krishnamurthy et al. 2006, Olle et al. 2006).

The thermal behavior of nano fluids could provide a basis for an huge innovation
for heat transfer, which is a major importance to number of industrial sectors
including transportation, power generation, micro manufacturing, thermal
therapy for cancer treatment, chemical and metallurgical sectors, as well as
heating, cooling, ventilation and air-conditioning. Nano fluids are also important

7
for the production of nano structured materials (Kinloch et al. 2002), for the
engineering of complex fluids (Tohver et al. 2001), as well as for cleaning oil
from surfaces due to their excellent wetting and spreading behavior (Wasan &
Nikolov 2003).

1.3.2 History of nano fluid

The twenty-first century is an era of technological development and has already
seen many changes in almost every industry. The introduction of nano science
and technology is based on the famous phrase "There's Plenty of Room at the
Bottom" by the Nobel Prize-winning physicist Richard Feynman in 1959.
Feynman proposed this concept using a set of conventional-sized robot arms to
construct a replica of themselves but one-tenth the original size then using that
new set of arms to manufacture a even smaller set until the molecular scale is
reached Heat conduction mechanisms in nano fluid

Nano fluid is nothing but fluid particles which are less than even a micron
(nearly 10-9 times smaller) in diameter and highly reactive and efficient material
which can be used to increase factor like rate of reaction, thermal conductivity
of any metal or material, they are that much reactive and strong. Keblinski [1]
presented four possible methods in nano fluids which may contribute to thermal
conduction.
(a) Brownian motion of nano particles.
(b) Liquid layering at the liquid/particle interface.
(c) Ballistic nature of heat transport in nano particles.
(d) Nano particle clustering in nano fluids.

The Brownian motion of nano particles is too slow to transfer heat through a
nano fluid. This mechanism works well only when the particle clustering has
both the positive and negative effects of thermal conductivity which is obtained
indirectly through convection.

1.3.3 Preparation of nano fluid

The preparation of nano fluid is the first important step in using nano phase
particles to change the heat transfer rate of conventional fluids. Nano fluids are
mainly made up of metals, oxides, carbides and carbon nano tubes that can easily
8
be dispensed in heat transferring fluids, such as water, ethylene glycol,
hydrocarbons and fluorocarbons by addition of stabilizing agents. Nano particles
can also be produced from several processes namely gas condensation,
mechanical attribution or chemical precipitation. These nanoparticles can also be
produced under cleaner conditions and their surface can be protected from
unexpected coatings which may occur during the gas condensation process. The
main limitation of such method is that the all particles made by this method
occur with some incapability to produce pure metallic nano powders. The
formation of such a problem can be reduced by using a direct evaporation
condensation method [2, 3, and 4]. This method helps in controlling particle size
and produces particles for stable nano fluids without surfactants or any
electrostatic stabilizers, but has the disadvantage of oxidation of pure metals and
low vapor pressure fluids.
There are mainly four steps in the process of the direct evaporation -
condensation method also known as one step method.

1. A cylinder containing a heat transferring fluid such as water or ethylene

glycol is rotated inside so that a thin film of the fluid is constantly ejected out
through the top of the chamber.
2. A piece of metallic material is evaporated by heating on a crucible as the
source of the nano particles.
3. The fluid is allowed to cool at the bottom of the chamber to prevent any sort
of unwanted evaporation.
Another method for synthesis of nano fluid is the laser ablation method, which is
used to produce alumina nano fluids [5]. Pure chemical synthesis is also an
alternative method which has been used by Patel [6] to prepare gold and silver
nanofluids. Zhu et al [7] also used one-step pure chemical synthesis method for
preparing nanofluids using copper nano particles dispensed in ethylene glycol.
There are basically four ways for the synthesis of nano fluids or important
factors. They are basically,
1. Dispensing ability of nano particles
2. Stability factor of nano particles
3. Chemical compatibility associated to nano particles
4. Thermal stability of nano fluids

9
1.3.4 Types of nano fluid
Al2O3 + water
Cu O + water
Ti O + water
Ti C + water
Ti N+ water
Zi O+ water
CH3CH2OH + water

Out of these we are going to use Ti C + water, Ti N+ water, Zi O+ water as our

nano fluid in heat exchanger.

1.4 TITANIUM CARBIDE (TIC) NANOPARTICLES

1.4.1 Introduction

Scientific research on nanoparticles has discovered the most unexpected

behavior of elements by altering their atomic and molecular states. These
unexpected properties have found a variety of applications in fields such as
biomedicine, pharmaceuticals, electronics, optics, etc. This article deals with the
properties and applications of titanium carbide.

Titanium carbide (Ti C) nano particles show good chemical inertness and good
conductivity. These nanoparticles should be stored under vacuum, dry, cool and
stressfree conditions. Titanium belongs to Block D, Period 4 while carbon
belongs to Block P, Period 2 of the periodic table.

1.4.2 Chemical Properties

The following tables list the chemical properties of titanium carbide.

Chemical
data
Chemical symbol Ti C
CAS No 12070-08-
05
Titanium 4
Group Carbon 14
Titanium [Ar] 3d2
Electronic 4s2 Carbon [He]
configuration 2s2 2p2
10
 Element Content (%)
Chemical composition Titanium 79.9
carbon 1
20.3

1.4.3 Physical Properties

Titanium carbide nanoparticles appear in the form of a black powder having a

spherical surface area. The table below provides the physical properties of these
nanoparticles.

Properties Metric
Density 4.93 g/cm3
Molar Mass 59.89 g/mol

11
1.4.4 Thermal Properties

The thermal properties of titanium carbide nanoparticles are given in the table below:

Propertie Metri
s c
Thermal conductivity 330 W/m k
Specific heat 711 J/kg k

1.4.5 Applications
Given below are some of the chief applications of titanium carbide:

 In the manufacture of wear-resistant tools, cutting tools

 As a coating for abrasive steel bearings, wear resistant tools
 In the form of nano titanium carbide ceramic in optics applications
 Enhance the conductivity of materials and as a nucleating agent.

1.5 TITANIUM NITRIDE (TIN) NANOPARTICLES

1.5.1 Introduction

Nanoparticle research has become an area of interest to scientists due to the

unexpected results produced by altering the atomic and molecular properties of
elements. This article deals with the properties and applications of titanium
nitride nanoparticles.

Titanium nitride (Ti N) is available in coated, dispersed, high and ultra high
purity forms. Their high hardness, high temperature chemical stability, high
melting point, infrared absorption and UV shielding find a number of useful
applications. Titanium belongs to Block D, Period 4 while nitrogen belongs to
Block P, Period 2 of the periodic table. Some of the alternate names of titanium
nitride are tinite, nitride titanium and azanylidyne titanium. It is important to
maintain dryness while storing these nanoparticles and also avoid any stress on
them.

12
1.5.2 Chemical Properties

The following tables list the chemical properties of titanium nitride.

Chemical
data
Chemical symbol Ti N

CAS No 25583-20-4

Titanium 4
Group Nitrogen
15
Titanium [Ar] 3d2
Electronic 4s2 Nitrogen [He]
configuration
2s2 2p3
Element Content (%)
Chemical composition Titanium 77.4
Nitrogen 22.6

1.5.3 Physical Properties

Titanium nitride nanoparticles appear in the form of a brown powder having

a spherical surface area. The table below provides the physical properties of
these nanoparticles.
Properties Metric

Density 5.24 g/cm3

Molar Mass 61.87 g/mol

1.5.4 Thermal Properties

The thermal properties of titanium nitride nanoparticles are as below.

Propertie Metri
s c
Thermal conductivity 19.2 W/m-k

Specific heat 601.71 J/kg-k

13
1.5.5 Applications

Given below are some of the chief applications of titanium nitride.

 Making of plastic packaging materials like PET bottles

 In solar vacuum tube, due to high absorption of sunlight
 High temperature furnaces for energy consumption
 Making of artificial limbs, biological materials
 Used as alloy modificators in cemented carbides

1.6 ZINC OXIDE (ZNO) NANOPARTICLES

1.6.1 Introduction

Nanotechnology research has gained momentum in the recent years by

providing innovative solutions in the field of biomedical, materials science,
optics and electronics. Nanoparticles are essentially a varied form of basic
elements derived by altering their atomic and molecular properties of elements.
This article elaborates on the properties and applications of zinc oxide
Nanoparticles.
Zinc oxide (Zn O) nano powders are available as powders and dispersions.
These Nanoparticles exhibit antibacterial, anti-corrosive, antifungal and UV
filtering properties. Zinc is a Block D, Period 4 element while Oxygen is a Block
P, Period 2 element. Some of the synonyms of zinc oxide Nanoparticles are
oxydatum, zincioxicum, permanent white, ketozinc and oxozinc.

1.6.2 Chemical Properties

The chemical properties of zinc oxide nanoparticles are as per the table below.
Chemical data
Chemical Zn O
symbol
CAS No 1314-13-2

Group Zinc 12, Oxygen 16

Zinc [Ar] 3d10 4s2 Oxygen

Electronic configuration
[He] 2s2 2p4
Element Content (%)
Chemical composition ZincOxygen 80.34, 19.6

14
 1.6.3 Physical Properties

The table given below highlights the physical properties of zinc oxide nanopowders.

Properties Metric

Density 5600
kg/m3
Molar 81.40 g/mol
Mass

1.6.4 Thermal Properties

Given below are the thermal properties of zinc oxide nanoparticles.

Propertie Metri
s c
Melting point 1975°C

Boiling point 2360°C

1.6.5 Applications

Some of the applications of zinc oxide nanoparticles are given below.

 Zinc oxide is used in the manufacture of rubber and cigarettes (used as a

filter).
 Popularly known calamine lotion is made out of zinc oxide powder. It is
also used in a host of other creams and ointments that are used to treat
skin diseases.
 As an additive in the manufacture of concrete.
 Ceramic industry has a number of uses for zinc oxide powder.
 It is also used as an additive in food products such as breakfast cereals.
 Various paints use zinc oxide as a coating agent.

15
1.7 CALCULATIONS TO DETERMINE PROPERTIES OF NANO
FLUID BY CHANGING VOLUME FRACTIONS
1.7.1 Nomenclature
ρnf = Density of nano
fluid(kg/m3) ρs = Density of
solid material (kg/m3)
ρw = Density of fluid material
(water)(kg/m3)
Ф = Volume fraction
Cpw = Specific heat of fluid material (water)
(j/kg-k)
Cps = Specific heat of solid material(j/kg-k)
µw = Viscosity of fluid (water)(poise)
µnf = Viscosity of Nano fluid(poise)
Kw = Thermal conductivity of fluid material (water)
(W/m-k)

Ks = Thermal conductivity of solid material(W/m-k)

1. 7.2 Nano Fluid Calculations for Titanium Carbide

1.7.2.1 Density of Nano Fluid

ρnf = Ф×ρs + [(1-Ф) × ρw]

VOLUME FRACTION 0.02

ρnf = 0.02×4930 + [(1-0.02)×998.2]
ρnf = 1076.836 kg/m3
VOLUME
FRACTION 0.04
ρnf = 0.04×4930 + [(1-0.04)×998.2]
ρnf = 1155.472 kg/m3
VOLUME
FRACTION 0.07
ρnf = 0.07×4930 + [(1-0.07)×998.2]
16
 ρnf = 1273.426 kg/m3
VOLUME
FRACTION 0.15
ρnf = 0.15×4930 + [(1-0.15)×998.2]
ρnf = 1587.97 kg/m3

1.7.2.2 Specific Heat of Nano Fluid

Cp nf =

At Ф =0.02
Cp nf = 988.314
j/kg-k At Ф
=0.04
Cp nf = 1003.4207
j/kg-k At Ф
=0.07
Cp nf = 1013.0708
j/kg-k At Ф
=0.15
Cp nf = 1098.8511 j/kg-k

1.7.2.3 Viscosity of Nano Fluid

µnf =µw (1+2.5Ф)

At Ф =0.02
µnf = 1.05315×10-
3poise At Ф =0.04
µnf = 1.1033×10-3
poise At Ф =0.07
µnf = 1.178525×10-
3 poise At Ф =0.15
µnf = 1.379125×10-3 poise

17
1.7.2.4 Thermal Conductivity of Nano Fluid

Knf = × kw

β=0.1 taken from journal

At Ф =0.02
Knf = 0.644
W/m-k At Ф
=0.04
Knf = 0.7006
W/m-k At Ф
=0.07
Knf = 0.7838
W/m-k At Ф
=0.15
Knf = 1.04597 W/m-k

1.7.3 Nano Fluid Calculations for Titanium Nitride

1.7.3.1 Density of Nano Fluid

ρnf = Ф×ρs + [(1-Ф) × ρw]

VOLUME FRACTION 0.02

ρnf = 0.02×5240+ [(1-0.02)×998.2]
ρnf = 1083.036 kg/m3
VOLUME
FRACTION 0.04
ρnf = 0.04×5240 + [(1-0.04)×998.2]
ρnf = 1167.872 kg/m3

18
 VOLUME
FRACTION 0.07
ρnf = 0.07×5240+ [(1-0.07)×998.2]
ρnf = 1325.072 kg/m3
VOLUME
FRACTION 0.15
ρnf = 0.15×5240+ [(1-0.15)×998.2]
ρnf = 1744.272 kg/m3
1.7.3.2 Specific Heat of Nano Fluid

Cp nf =

At Ф =0.02
Cp nf = 3835.55316
J/kg-k At Ф =0.04
Cp nf = 3539.4391
J/kg-k At Ф =0.07
Cp nf = 3168.005
J/kg-k At Ф =0.15
Cp nf = 2460.2749 J/kg-k

1.7.3.3 Viscosity of Nano Fluid

µnf =µw (1+2.5Ф)

At Ф =0.02
µnf = 1.05315×10-
3 poise At Ф =0.04
µnf = 1.1033×10-3
poise At Ф =0.07
µnf = 1.178525×10-

19
 3 poise At Ф =0.15
µnf = 1.379125×10-3 poiseThermal Conductivity of Nano Fluid

Knf = × kw

β=0.1 taken from journal

At Ф =0.02
Knf = 0.6447

W/m-k At Ф
=0.04
Knf = 0.69182
W/m-k At Ф
=0.07
Knf = 0.7671
W/m-k At Ф
=0.15
Knf = 1.00057 W/m-k

1.7.4 Nano Fluid Calculations for Zinc Oxide

1.7.4.1 Density of Nano Fluid

ρnf = Ф×ρs + [(1-Ф) × ρw]

VOLUME FRACTION 0.02

ρnf = 1091.736 kg/m3
VOLUME
FRACTION 0.04
ρnf = 2175.27 kg/m3
VOLUME
20
 FRACTION 0.07
ρnf = 1325.576 kg/m3
VOLUME
FRACTION 0.15
ρnf = 2550.97 kg/m3

21
1.7.4.2 Specific Heat of Nano Fluid

Cp nf =

At Ф =0.02
Cp nf = 3798.58
J/kg-k At Ф
=0.04
Cp nf = 3475.68
J/kg-k At Ф
=0.07
Cp nf = 3076.77
J/kg-k At Ф
=0.15
Cp nf = 2334.98 J/kg-k

1.7.4.3 Viscosity of Nano Fluid

µnf =µw (1+2.5Ф)

At Ф =0.02
µnf = 1.05315×10-
3poise At Ф =0.04
µnf = 1.1033×10-3
poise At Ф =0.07
µnf = 1.178525×10-
3 poise At Ф =0.15
µnf = 1.379125×10-3 poise
1.7.4.4 Thermal Conductivity of Nano Fluid

Knf = × kw

β=0.1 taken from journal

22
 At Ф =0.02
Knf = 0.6447

W/m-k At Ф
=0.04
Knf = 0.69182
W/m-k At Ф
=0.07
Knf = 0.7671
W/m-k At Ф
=0.15
Knf = 1.00057 W/m-k
Table 1.1 Titanium carbide nano fluid properties

Volume Thermal Specific Density Viscosity

Fractio Conductivity Heat (Kg/m3) (Poise)
n (W/m-K) (J/Kg-K)
(Ф)
0.02 0.644 988.314 1076.83 1.05315×10-3
6
0.04 0.7006 1003.420 1155.47 1.10033×10-3
7 2
0.07 0.7838 1013.070 1273.42 1.178525×10-
8 6 3

0.15 1.0459 1098.851 1587.97 1.379125×10-

7 1 3

Table 1.2 Titanium nitride nano fluid properties

Volume Thermal Specific Density Viscosity

Fractio Conductivity Heat (Kg/m3) (Poise)
n (W/m-K) (J/Kg-K)
(Ф)
0.02 0.6447 3835.5531 1083.03 1.05315×10-3
6 6
0.04 0.6918 3539.4391 1167.87 1.10033×10-3
2 2
0.07 0.7671 3168.005 1325.07 1.178525×10-
2 3

23
 0.15 1.0005 2460.2749 1744.27 1.379125×10-
7 2 3

Table 1.3 Zinc oxide nano fluid properties

Volume Therma Specific Density Viscosity

Fractio l
Heat (Kg/m3) (Poise)
n (Ф) Conductivit
(J/Kg-K)
y (W/m-K)
0.02 25.32 3798.58 1091.73 1.05315×10-3
6
0.04 27.42 3475.68 2175.27 1.10033×10-3
0.07 31.868 3076.77 1325.57 1.178525×10-3
6
0.15 54.091 2334.98 2550.97 1.379125×10-3

24
 CHAPTER II
LITERATURE REVIEW

2.1 INTRODUCTION
A brief review of the work carried by various researchers on shell and tube heat
exchangers by using various nano fluids is presented following.
Prof. Alpesh Mehta et al. [29] have studied the improvement in
performance of STHE with Using of Nanofluids.
Jaafar Albadr et al. [30] have reported an experimental study on the
forced convective heat transfer and flow characteristics of a nanofluid consisting
of water and different volume concentrations of Al2O3 nanofluid (0.3–2) %
flowing in a horizontal shell and tube heat exchanger counter flow under
turbulent flow conditions are investigated.
S.Gh. Etemad et al. [31] have reported that the heat transfer
characteristics of nanofluid enhance significantly with increasing higher overall
heat transfer coefficient, convective heat transfer coefficient and Nusselt number
respectively.
Tuckerman and Pease [9] are the first to introduce this idea by using
microchannel heat sink (MCHS) as a source for cooling of electronic devices in
the year 1981. They experimentally narrated the MCHS capability and claimed
that they were able to dissipate heat flux at a rate of 790 W/cm2. They showed
that the convective heat transfer of single phase flows could be improved by
decreasing the width of the heat sink channels and increasing wetted area by the
heat transfer fluid.
The experimental and analytical studies by Wang et al. [10], Lee et al.
[11], Wang et al. [12] and Koo and Kleinstreuer [13] showed that nanofluid have
a higher thermal conductivity than that of pure fluids and therefore has great
affinity for heat transfer enhancement. Li and Xuan [14], Xuan and Li [15] and
Pak and Cho [16] experimentally showed the convection heat transfer and
pressure dropping for nano fluid tube flows. Their results show that heat
transfer coefficient was greatly incremented and it depends upon factors like
Reynolds number, particle size and shape, and particle volume fraction. They
25
also found that nano particles did not cause an extra pressure drop.
Another scientist named Donsheng and Yulog [17] studied practically the
convective heat transfer of nanofluid made up of ã-Al 2O3- water, flowing
through a tube made up of copper in the laminar flow region and showed a
considerable enhancement of convective heat transfer using the nanofluids.
The enhancement was particularly

significant in the entrance region as it was higher than that obtained solely due to
the enhancement on thermal conduction.

Seok and Choi [18] investigated numerically the cooling performance of

micro channel heat sink with nanofluids. They showed that the cooling
performance of a MCHS with water based nanofluids containing diamond (1%
volume fraction and 2 nm) at the fixed pumping power of 2.25 W is enhanced by
about 10% compared with that of a MCHS with water.
Joescon and Issam [19] performed experiments to explore the micro
channel cooling benefits of Al2O3-water nanofluid. They found that the high
thermal conductivity of nano particles enhance the single phase heat transfer
coefficient especially for laminar flow. Higher heat transfer coefficient was
achieved mostly in the entrance region of the micro channels and the
enhancement was weaker in the fully developed region, providing that nano
particles have an appreciable effect on thermal boundary layer development. It
was also observed that higher concentrations also produced greater sensitivity to
heat flux.
Mushtaq et al. [20] investigated the effect of channels geometry (the
size and shape of channels) on performance of counter flow micro channel heat
exchanger and used liquid water as a cooling fluid. They found that the
effectiveness of heat exchanger and pressure drop were increased by decreasing
the size of channels and claimed depending on the application of which type of
heat exchanger is used.
Mushtaq I. Hasan [21] numerically investigated the performance of
counter flow micro channel heat exchanger with MEPCM suspension as a
cooling fluid. He fund that using MEPCM suspension lead to improve thermal
performance of CFMCHE but also lead to extra increase in pressure drop and

26
resulting in decreasing the overall performance with using suspension as a
cooling medium.
For modelling, nano fluid is treated as a single-phase type fluid. This
assumption can be used since the particles are ultra fine and they are easily
fluidized [14, 15]. Also, the particle volume fraction in nano fluid is usually low.
Under such conditions the governing equations for the nano fluid flow and heat
transfer are simplified and local fluid and particles are in thermal equilibrium.
Schematic structure of the studied counter flow micro channel heat exchanger
with square channels. Due to the geometrical and thermal symmetry between
hot and cold channels rows, an individual heat exchanger unit consisting of two
channels containing hot and cold fluids and a separating wall is

considered as a model figure to represent the complete counter flow micro

channel heat exchanger since it gives an adequate indication about the
performance and the heat is transferred from hot to cold fluid through a thick
wall medium separating both fluids

2.1 Compact Heat Exchanger Using Nano Fluid

The necessity of compact heat exchangers (CHEs) has been seen in fields
like aerospace, automobile, gas turbine power plant and other industries for the
last 50 years and more. This is mainly due to several factors such as packaging
constraints, sometimes high performance requirements, low cost and using air or
gas as one of the fluids in the exchanger. For nearly twenty years additional
driving factors for heat exchangers design have been reducing energy
consumption for operation of heat exchangers and process plants, and
minimizing their overall capital investment. Figure 5 shows Heat Exchanger
area densities and hydraulic diameters; S+THX – Shell and tube heat exchanger;
PHE – Plate heat exchanger; PFHE – Plate fin heat exchanger; PCHE – Printed
circuit heat exchanger.

D.A. Reay [22] gives a general picture of the area density and typical
hydraulic diameters of a range of conventional and CHE 2. Kays et al.[23] and
Shah RK [24] defined CHE as having an area density which is greater than 700
m2/m3 when operating in gas streams, and in excess of 300 m2/m3 while
operating in liquid or two phase streams. They gave different geometries
27
surfaces of CHE: Plain fin, Louvered fin, Strip fin, Wavy fin, Pin fin and there
designation.

Compact Heat exchangers are becoming increasingly more and more

important elements in many industrial processes worldwide, both in their
original roles as contributors to increase energy efficiency and more recently as
the basis for novel intensified unit operations, such as compact reactors based on
PCHE fabrication techniques. CHEs, while accounting for 5 to 10% of the $15
billion plus worldwide market for heat exchangers, are seeing their sales increase
up about by 10% per annum compared to 1 % for all other types of heat
exchangers. Compact heat exchanger offer number of benefits which include:
 2 Improved effectiveness
 3 Smaller volumes
 4 Multi-stream and multi-pass configurations
 5 Tighter temperature controls
 6 Power savings
 7 Improved safety means protection Compact heat exchanger also deals
with application of Al2O3 + water nano fluid on compact heat exchanger
in comparison with conventional coolants.
2.2.1 Why we use nano fluid
The main goal or idea of using nano fluids is to attain highest possible
thermal properties at the smallest possible concentrations (preferably<1% by
volume) by uniform dispersion and stable suspension of nano particles
(preferably<10 nm) in hot fluids.

A nano fluid is a mixture of water and suspended metallic nano particles. Since
the thermal conductivity of metallic solids are typically orders of magnitude
higher than that of fluids it is expected that a solid/fluid mixture will have
higher effective thermal conductivity compared to the base fluid. Nano fluids are
extremely stable and exhibit no significant settling under static conditions, even
after weeks or months

2.2 RESEARCH GAP & PROBLEM DESCRIPTION

In the thesis, the shell and tube heat exchanger is taken in the water with various

28
temperatures. In this thesis, along with water, Titanium Carbide, Titanium
Nitride and Zinc Oxide nanofluids at different volume fractions (0.02, 0.04, 0.07
and 0.15) of the shell and tube heat exchanger is analyzed for heat transfer
properties, temperature, pressure, velocity and mass flow rates in CFD analysis.
In thermal analysis, two materials Copper and Aluminum are considered for heat
exchanger. Modeling is done in Pro/Engineer, Thermal analysis and CFD
analysis is done in Ansys. The boundary conditions for thermal analysis is
temperatures, for CFD analysis is pressure, velocity and temperature

29
 CHAPTER III
INTRODUCTION TO MECHANICAL SOFTWARE
3.1 INTRODUCTION TO CAD
Computer-aided design (CAD), also known as computer-aided design and
drafting (CADD), is the use of computer technology for the process of design
and design- documentation. Computer Aided Drafting describes the process of
drafting with a computer. CADD software, or environments, provides the user
with input-tools for the purpose of streamlining design processes; drafting,
documentation, and manufacturing processes. CADD output is often in the form
of electronic files for print or machining operations. The development of CADD-
based software is in direct correlation with the processes it seeks to economize;
industry-based software (construction, manufacturing, etc.) typically uses
vector-based (linear) environments whereas graphic-based software utilizes
raster-based (pixelated) environments.
CADD environments often involve more than just shapes. As in the manual
drafting of technical and engineering drawings, the output of CAD must convey
information, such as materials, processes, dimensions, and tolerances, according
to application-specific conventions. CAD may be used to design curves and
figures in two-dimensional (2D) space; or curves, surfaces, and solids in three-
dimensional (3D) objects.
CAD is an important industrial art extensively used in many applications,
including automotive, shipbuilding, and aerospace industries, industrial and
architectural design, prosthetics, and many more. CAD is also widely used to
produce computer animation for special effects in movies, advertising and
technical manuals. The modern ubiquity and power of computers means that
even perfume bottles and shampoo dispensers are designed using techniques
unheard of by engineers of the 1960s. Because of its enormous economic
importance, CAD has been a major driving force for research in computational
geometry, computer graphics (both hardware and software), and discrete
differentialgeometry.
The design of geometric models for object shapes, in particular, is often called
computer- aided geometric design (CAGD).
Current computer-aided design software packages range from 2D vector-based
30
drafting systems to 3D solid and surface modellers. Modern CAD packages can
also frequently allow rotations in three dimensions, allowing viewing of a
designed object from any desired angle, even from the inside looking out. Some
CAD software is capable of dynamic mathematic modeling, in which case it may
be marketed as CADD — computer- aided design and drafting.
CAD is used in the design of tools and machinery and in the drafting and design
of all types of buildings, from small residential types (houses) to the largest
commercial and industrial structures (hospitals and factories).
3.2 INTRODUCTION TO PRO/ENGINEER
Pro/ENGINEER Wildfire is the standard in 3D product design, featuring
industry-leading productivity tools that promote best practices in design while
ensuring compliance with your industry and company standards. Integrated
Pro/ENGINEER CAD/CAM/CAE solutions allow you to design faster than
ever, while maximizing innovation and quality to ultimately create exceptional
products.
Customer requirements may change and time pressures may continue to mount,
but your product design needs remain the same - regardless of your project's
scope, you need the powerful, easy-to-use, affordable solution that
Pro/ENGINEER provides.
3.2.1 Pro/Engineer Wildfire Benefits
•Unsurpassed geometry creation capabilities allow superior product
differentiation and manufacturability
•Fully integrated applications allow you to develop everything from
concept to manufacturing within one application
•Automatic propagation of design changes to all downstream deliverables
allows you to design with confidence
•Complete virtual simulation capabilities enable you to improve product
performance and exceed product quality goals
•Automated generation of associative tooling design, assembly instructions,
and machine code allow for maximum production efficiency
3.2.2 Different Modules in Pro/Engineer
 PART DESIGN
 ASSEMBLY

31
  DRAWING
 SHEETMETAL
3.3 INTRODUCTION TO FEA
Finite Element Analysis (FEA) was first developed in 1943 by R. Courant, who
utilized the Ritz method of numerical analysis and minimization of variational
calculus to obtain approximate solutions to vibration systems. Shortly
thereafter, a paper published in 1956 by M. J. Turner, R. W. Clough, H. C.
Martin, and L. J. Topp established a broader definition of numerical analysis.
The paper centered on the "stiffness and deflection of complex structures".
By the early 70's, FEA was limited to expensive mainframe computers generally
owned by the aeronautics, automotive, defense, and nuclear industries. Since the
rapid decline in the cost of computers and the phenomenal increase in computing
power, FEA has been developed to an incredible precision. Present day
supercomputers are now able to produce accurate results for all kinds of
parameters.
FEA consists of a computer model of a material or design that is stressed and
analyzed for specific results. It is used in new product design, and existing
product refinement. A company is able to verify a proposed design will be able
to perform to the client's specifications prior to manufacturing or construction.
Modifying an existing product or structure is utilized to qualify the product or
structure for a new service condition. In case of structural failure, FEA may be
used to help determine the design modifications to meet the new condition.
There are generally two types of analysis that are used in industry: 2-D
modeling, and 3- D modeling. While 2-D modeling conserves simplicity and
allows the analysis to be run on a relatively normal computer, it tends to yield
less accurate results. 3-D modeling, however, produces more accurate results
while sacrificing the ability to run on all but the fastest computers effectively.
Within each of these modeling schemes, the programmer can insert numerous
algorithms (functions) which may make the system behave linearly or non-
linearly. Linear systems are far less complex and generally do not take into
account plastic deformation. Non-linear systems do account for plastic
deformation, and many also are capable of testing a material all the way to
fracture.

32
FEA uses a complex system of points called nodes which make a grid called a
mesh. This mesh is programmed to contain the material and structural properties
which define how the structure will react to certain loading conditions. Nodes
are assigned at a certain density throughout the material depending on the
anticipated stress levels of a particular area. Regions which will receive large
amounts of stress usually have a higher node density than those which
experience little or no stress. Points of interest may consist of:

fracture point of previously tested material, fillets, corners, complex detail, and
high stress areas. The mesh acts like a spider web in that from each node, there
extends a mesh element to each of the adjacent nodes. This web of vectors is
what carries the material properties to the object, creating many elements.
A wide range of objective functions (variables within the system) are available
for minimization or maximization:
 Mass, volume, temperature
 Strain energy, stress strain
 Force, displacement, velocity, acceleration
 Synthetic (User defined)
There are multiple loading conditions which may be applied to a system. Some
examples are shown:
 Point, pressure, thermal, gravity, and centrifugal static loads
 Thermal loads from solution of heat transfer analysis
 Enforced displacements
 Heat flux and convection
 Point, pressure and gravity dynamic loads
Each FEA program may come with an element library, or one is constructed
over time. Some sample elements are:
 Rod elements
 Beam elements
 Plate/Shell/Composite elements
 Shear panel
 Solid elements
 Spring elements
 Mass elements

33
  Rigid elements
 Viscous damping elements
Many FEA programs also are equipped with the capability to use multiple
materials within the structure such as:
 Isotropic, identical throughout
 Orthotropic, identical at 90 degrees
3.3.1 General anisotropic, different throughout Types of Engineering Analysis
Structural analysis consists of linear and non-linear models. Linear models use
simple parameters and assume that the material is not plastically deformed. Non-
linear models consist of stressing the material past its elastic capabilities. The
stresses in the material then vary with the amount of deformation as in.
Vibration analysis is used to test a material against random vibrations, shock,
and impact. Each of these incidences may act on the natural vibrational
frequency of the material which, in turn, may cause resonance and subsequent
failure.
Fatigue analysis helps designers to predict the life of a material or structure by
showing the effects of cyclic loading on the specimen. Such analysis can show
the areas where crack propagation is most likely to occur. Failure due to fatigue
may also show the damage tolerance of the material.
Heat Transfer analysis models the conductivity or thermal fluid dynamics of
the material or structure. This may consist of a steady-state or transient transfer.
Steady-state transfer refers to constant thermo properties in the material that
yield linear heat diffusion.
3.3.2 Results of Finite Element Analysis
FEA has become a solution to the task of predicting failure due to unknown
stresses by showing problem areas in a material and allowing designers to
see all of the theoretical stresses within. This method of product design and
testing is far superior to the manufacturing costs which would accrue if each
sample was actually built and tested. In practice, a finite element analysis
usually consists of three principal steps:
1. Preprocessing: The user constructs a model of the part to be analyzed in
which the geometry is divided into a number of discrete sub regions, or
elements," connected at discrete points called nodes." Certain of these
nodes will have fixed displacements, and others will have prescribed
34
 loads. These models can be extremely time consuming to prepare, and
commercial codes vie with one another to have the most user-friendly
graphical “preprocessor" to assist in this rather tedious chore. Some of
these preprocessors can overlay a mesh on a preexisting CAD file, so that
finite element analysis can be done conveniently as part of the
computerized drafting-and-design process.
2. Analysis: The dataset prepared by the preprocessor is used as input to the
finite element code itself, which constructs and solves a system of linear
or nonlinear algebraic equations Kijuj = f

Where u and f are the displacements and externally applied forces at the nodal
points. The formation of the K matrix is dependent on the type of problem being
attacked, and this module will outline the approach for truss and linear elastic
stress analyses. Commercial codes may have very large element libraries, with
elements appropriate to a wide range of problem types. One of FEA's principal
advantages is that many problem types can be addressed with the same code,
merely by specifying the appropriate element types from the library.
3. Postprocessing: In the earlier days of finite element analysis, the user
would pore through reams of numbers generated by the code, listing
displacements and stresses at discrete positions within the model. It is
easy to miss important trends and hot spots this way, and modern codes
use graphical displays to assist in visualizing the results.
3.4 INTRODUCTION TO ANSYS
ANSYS is general-purpose finite element analysis (FEA) software package.
Finite Element Analysis is a numerical method of deconstructing a complex
system into very small pieces (of user-designated size) called elements. The
software implements equations that govern the behavior of these elements and
solves them all; creating a comprehensive explanation of how the system acts as
a whole. These results then can be presented in tabulated or graphical forms.
This type of analysis is typically used for the design and optimization of a
system far too complex to analyze by hand. Systems that may fit into this
category are too complex due to their geometry, scale, or governing equations.
ANSYS is the standard FEA teaching tool within the Mechanical Engineering
Department at many colleges. ANSYS is also used in Civil and Electrical
35
Engineering, as well as the Physics and Chemistry departments.
ANSYS provides a cost-effective way to explore the performance of products or
processes in a virtual environment. This type of product development is termed
virtual prototyping. With virtual prototyping techniques, users can iterate
various scenarios to optimize the product long before the manufacturing is
started. This enables a reduction in the level of risk, and in the cost of
ineffective designs. The multifaceted nature of ANSYS also provides a means to
ensure that users are able to see the effect of a design on the whole behavior of
the product, be it electromagnetic, thermal, mechanical etc.

3.4.1 Steps involved in ANSYS:

In general, a finite element solution can be broken into the
following these categories.
1. Preprocessing module: Defining the
problem The major steps in preprocessing
are given below
- defining key points /lines/areas/volumes
- define element type and material /geometric /properties
- mesh lines/areas/volumes/are required
The amount of detail required will depend on the dimensionality of the
analysis (i.e. 1D, 2D, axis, symmetric)
2. Solution processor module: assigning the loads, constraints and solving.
Here we specify the loads (point or pressure), constraints (translation,
rotational) and finally solve the resulting set of equations.
3. Post processing module: further processing and viewing
of results In this stage we can see:
List of nodal displacement
Elements forces and
moments Deflection plots
Stress contour diagrams
3.4.2 Thermal Analysis
ANSYS is capable of both steady state and transient analysis of any solid with
thermal boundary conditions. Steady-state thermal analyses calculate the effects
of steady thermal loads on a system or component. Users often perform a

36
 steady-state analysis before doing a transient thermal analysis, to help establish
initial conditions. A steady-state analysis also can be the last step of a transient
thermal analysis; performed after all transient effects have diminished. ANSYS
can be used to determine temperatures, thermal gradients, heat flow rates, and
heat fluxes in an object that are caused by thermal loads that do not vary over
time. Such loads include the following:
· Convection
· Radiation
· Heat flow rates
· Heat fluxes (heat flow per unit area)
· Heat generation rates (heat flow per unit volume)
· Constant temperature boundaries A steady-state thermal analysis may be either
linear, with constant material properties; or nonlinear, with material properties
that depend on temperature. The thermal properties of most material vary with
temperature. This temperature dependency being appreciable, the analysis
becomes nonlinear. Radiation boundary conditions also make the analysis
nonlinear. Transient calculations are time dependent and ANSYS can both solve
distributions as well as create video for time incremental displays of models.

3.5 INTRODUCTION TO CFD

Computational fluid dynamics, usually abbreviated as CFD, is a branch of fluid
mechanics that uses numerical methods and algorithms to solve and analyze
problems that involve fluid flows. Computers are used to perform the
calculations required to simulate the interaction of liquids and gases with
surfaces defined by boundary conditions. With high- speed supercomputers,
better solutions can be achieved. Ongoing research yields software that improves
the accuracy and speed of complex simulation scenarios such as transonic or
turbulent flows. Initial experimental validation of such software is performed
using a wind tunnel with the final validation coming in full-scale testing, e.g.
flight tests.
Methodology
In all of these approaches the same basic procedure is followed.
 During preprocessing
 The geometry (physical bounds) of the problem is defined.
37
  The volume occupied by the fluid is divided into discrete cells (the
mesh). The mesh may be uniform or non-uniform.
 The physical modeling is defined – for example, the equations of
motion
+ enthalpy + radiation + species conservation
 Boundary conditions are defined. This involves specifying the fluid
behavior and properties at the boundaries of the problem. For transient
problems, the initial conditions are also defined.
 The simulation is started and the equations are solved iteratively as a
steady-state or transient.
 Finally a postprocessor is used for the analysis and visualization of the
resulting solution.

3.5.1 Boundary Conditions Considered For Thermal and CFD Analysis

Ti C, Ti N and Zn O Nano fluid at four different volume fractions (0.02, 0.04,
0.07 and 0.15). In thermal analysis, the materials of shell and tube exchanger
considered are Aluminum and copper. The input for analysis is temperature. In
CFD analysis, the inputs are pressure, velocity and temperature

Table. 3.1 Geometric dimensions for Shell and Tube Heat Exchanger

Heat exchanger length, L 600 mm

Shell inner diameter, Di 90 mm
Tube outer diameter, do 20 mm
Tube bundle geometry and pitch Triangular 30 mm
Number of tubes, Nt 7
Number of baffles, Nb 6
Central baffle spacing, B 86 mm
Baffle inclination angle, θ 0 to 400

38
 Fig. 3.1 Shell and Tube heat Exchanger 3D model

Fig. 3.2 Shell and Tube heat Exchanger 2D model

Fig. 3.3 Shell and Tube heat Exchanger meshed 2D model

39
 CHAPTER IV
CFD ANALYSIS OF SHELL AND TUBE HEAT EXCHANGER

4.1 CFD ANALYSIS FLOW CHART

Here we have done CFD analysis by showing below flow chart. This shows that
different nano fluids with various volume fractions are used to obtain the results
are Temperature distribution, Heat transfer coefficient and heat transfer rate.

Temperature Distributions

Fig. 4.1 Flow Chart for CFD Analysis

4.2 CFD ANALYSIS FOR GENERAL STHE USING HOT WATER

AND COLD WATER

Ansys → workbench→ select analysis system → fluid flow fluent → double click

→→Select geometry → right click → import geometry → select browse

→open part → ok

40
→→ Select mesh on work bench → right click →edit → select mesh on left side part
tree
→ right click → generate mesh →

Fig. 4.2 2D geometry for hot water and cold water STHE

Fig. 4.3 2D Meshed model for hot water and cold water STHE

Fig. 4.4 Inputs and outputs of STHE

41
Select faces → right click → create named section → enter name → cold
fluid inlet Select faces → right click → create named section → enter name
→ cold fluid outlet Select faces → right click → create named section →
enter name → hot water inlet Select faces → right click → create named
section → enter name →hot water outlet
The above Pro E Model shows that input and output fluids with their
temperatures. Where ci, co, hi, ho represents cold fluid inlet, cold fluid outlet,
hot fluid inlet, hot fluid outlet respectively.
Update project>setup>edit>model>select>energy equation (on)>ok

Materials> Materials > new >create or edit >specify fluid material or specify
properties > ok
Select fluid

Fig. 4.5 Selection of Fluid and its properties in CFD

Analysis Table 4.1 Boundary

conditions

Inlet temperatures(T) 303k,353 k

Inlet pressure(P) 101325 pa

Inlet velocity(V) 1.4412 m/s

42
Solution > Solution Initialization > Hybrid Initialization >done
Run calculations > no of iterations = 100> calculate > calculation complete>ok
Results>edit>select contours>ok>select location (inlet, outlet,
wall.etc)>select pressure>apply

Fig. 4.6 Temperature distribution of STHE

Fig.4.7 Heat transfer coefficient of STHE

Table 4.2 Heat transfer rate

"Flux Report"

Total Heat Transfer Rate (w)

c_i 1042623.
8
c_o 0
h_i 9828294
h_o 0
wall-_trm_srf 0
wall-nanofluid-_trm_srf 0

Net 10870918
43
4.3 CFD ANALYSIS ON STHE USING NANO FLUIDS

The effect temperature distribution, Heat transfer coefficient and heat transfer
rate in shell and tube heat exchangers is observed in CFD analysis by using Ti C,
Ti N and Zn O with volume fractions of 0.02, 0.04, 0.07 and 0.15 are shown in
below.

4.3.1 Temparature Distribution along STHE using Ti C

Fig. 4.8 Temperature distribution of Titanium Carbide nanofluid at various

volume fractions

44
4.3.2 Heat Transfer Coefficient along the STHE using Ti C

Fig. 4.9 Heat transfer Coefficient of Titanium Carbide nanofluid at various

volume fractions

45
4.3.3. Total Heat transfer rate for Ti C nano fluid at various volume fractions

Total Heat transfer rate at Ф=0.02

""Flux Report"

Total Heat Transfer Rate (w)

c_i 1042580.6
c_o 0
h_i 9828294
h_o 0
wall-_trm_srf 0
wall-nanofluid-_trm_srf 0

Net 10870875

Total Heat transfer rate at Ф=0.04

""Flux Report"

Total Heat Transfer Rate

(w)

c_i 1042625.5
c_o 0
h_i 9828294
h_o 0
wall-_trm_srf 0
wall-nanofluid-_trm_srf 0

Net 10870920

46
 Total Heat transfer rate at Ф=0.07

""Flux Report"

Total Heat Transfer Rate (w)

c_i 1042709.8
c_o 0
h_i 9828294
h_o 0
wall-_trm_srf 0
wall-nanofluid-_trm_srf 0

Net 10871004

Total Heat transfer rate at Ф=0.15

"Flux Report"
Total Heat Transfer Rate (w)

c_i 1042770.9
c_o 0
h_i 9828294
h_o 0
wall-_trm_srf 0
wall-nanofluid-_trm_srf 0

Net 10871065

47
4.3.4 Temperature Distribution along STHE using Ti N

Fig. 4.10 Temperature distribution of Titanium Nitride nanofluid at various

volume fractions

48
4.3.5 Heat Transfer Coefficient along the STHE using Ti N

Fig. 4.11 Heat transfer Coefficient of Titanium Nitride nanofluid at various

volume fractions.

4.3.6 Total Heat transfer rate for Ti N nano fluid at various volume fractions

49
 Total Heat transfer rate at Ф=0.02

Flux Report"

Total Heat Transfer Rate (w)

c_i 1042634.1
c_o 0
h_i 9828295
h_o 0
wall-_trm_srf 0
wall-nanofluid-_trm_srf 0

Net 10870929

Total Heat transfer rate at Ф=0.04

"Flux Report"

Total Heat Transfer Rate (w)

c_i 1042703.2
c_o 0
h_i 9828294
h_o 0
wall-_trm_srf 0
wall-nanofluid-_trm_srf 0

Net 10870997

Total Heat transfer rate at Ф=0.07

"Flux Report"

50
Total Heat Transfer Rate (w)

c_i 1042775.5
c_o 0
h_i 9828294
h_o 0
wall-_trm_srf 0
wall-nanofluid-_trm_srf 0

Net 10871070

Total Heat transfer rate at Ф=0.15

"Flux Report"

Total Heat Transfer Rate (w)

c_i 1042787.9
c_o 0
h_i 9828294
h_o 0
wall-_trm_srf 0
wall-nanofluid-_trm_srf 0

Net 10871082

51
4.3.7 Temperature Distribution along STHE using Zi O

Fig. 4.12 Temperature distribution of Zinc oxide nanofluid at various volume

fractions

52
4.3.8 Heat Transfer Coefficient along the STHE using Zn O

Fig.4.13 Heat transfer Coefficient of Zinc oxide nanofluid at various volume

fractions

53
4.3.9 Total Heat transfer rate for Zi O nano fluid at various volume fractions

Total Heat transfer rate at Ф=0.02

"Flux Report"

Total Heat Transfer Rate (w)

c_i 1042576
c_o 0
h_i 9828293
h_o 0
wall-_trm_srf 0
wall-nanofluid-_trm_srf 0

Net 10870869

Total Heat transfer rate at Ф=0.04

"Flux Report"

Total Heat Transfer Rate (w)

c_i 1042622.3
c_o 0
h_i 9828293
h_o 0
wall-_trm_srf 0
wall-nanofluid-_trm_srf 0

Net 10870915

54
55
 Total Heat transfer rate at Ф=0.07

"Flux Report"

Total Heat Transfer Rate (w)

c_i 1042665.3
c_o 0
h_i 9828295
h_o 0
wall-_trm_srf 0
wall-nanofluid-_trm_srf 0

Net 10870960

Total Heat transfer rate at Ф=0.15

Flux Report"

Total Heat Transfer Rate (w)

c_i 1042737.8
c_o 0
h_i 9828294
h_o 0
wall-_trm_srf 0
wall-nanofluid-_trm_srf 0

Net 10871032

56
 CHAPTER V
THERMAL ANALYSIS OF SHELL AND TUBE HEAT
EXCHANGER

5.1 THERMAL ANALYSIS FLOW CHART

Here we have done Thermal analysis as followed by below showing flow

chart. This shows that different nano fluids with various volume fractions
are used to obtain the results are Temperature distribution, Heat flux.

Fig 5.1 Thermal analysis flow chart

57
Open work bench 14.5>select steady state thermal in analysis systems>select
geometry>right click on the geometry>import geometry>select IGES file>open

Fig 5.2 Imported model

Fig 5.3 Section view

Fig 5.4 Meshed Model

58
5.2 HEAT FLUX VALUES FOR ALUMINIUM STHE

The effect temperature distribution and Heat flux in shell and tube heat
exchangers is observed in CFD analysis by using Ti C, Ti N and Zn O with
volume fractions of 0.02, 0.04, 0.07 and 0.15 are shown in below.

5.2.1 Heat Flux Values for Aluminum STHE using Ti C

Fig. 5.5 Heat flux values of Titanium Carbide at various volume fractions for
Aluminum STHE

59
5.2.2 Heat Flux Values for Aluminum STHE using Ti N

Fig. 5.6Heat flux values of Titanium Nitride at various volume fractions for
Aluminum STHE

60
5.2.3 Heat Flux Values for Aluminum STHE using Zn O

Fig. 5.7 Heat flux values of Zinc oxide at various volume fractions for Aluminum
STHE

61
5.3 HEAT FLUX VALUES FOR COPPER STHE

5.3.1 Heat Flux Values for Copper STHE Using Ti C

Fig. 5.8 Heat flux values of Titanium Carbide at various volume fractions for
Copper STHE

62
5.3.2 Heat Flux Values for Copper STHE Using Ti N

Fig. 5.9 Heat flux values of Titanium Nitride at various volume fractions for
Copper STHE

63
5.3.3 Heat Flux Values for Copper STHE Using Zn O

Fig. 5.10 Heat flux values of Zinc oxide at various volume fractions for Copper
STHE

64
 CHAPTER VI
RESULTS AND DISCUSSIONS
6.1 CFD ANALYSIS RESULTS

We are using Titanium Carbide, Titanium Nitride and Zinc oxide nanofluids
with varying volume fractions of 0.02, 0.04, 0.07 and 0.15 with base fluid water.
We are going to analysis heat transfer coefficient and maximum temperature and
total heat transfer rate by using CFD analysis. After the analysis we are deciding
that the maximum heat transfer coefficient and maximum heat transfer rate is
achieved in 0.15 volume fraction where using Titanium Nitride. And also we
have observed that heat transfer coefficient is gradually increases when
increasing the volume fractions of nano fluids during CFD Analysis.

Table 6.1 CFD Analysis Results

Total
Heat Max
Type of Volum Heat
Transfer Tem
Nano e Transfer
Coefficient p (K)
Fluid Fractio Rat
(W/m2k) e
n
(W)
0.02 12900 353 1087087
5
Titanium 0.04 17700 353 1087092
Carbide 0
0.07 21000 358 1087100
4
1.15 24900 359 1087106
5
0.02 17300 353 1087092
9
Titanium 0.04 25400 354 1087099
Nitride 7
0.07 25500 354 1087107
0
1.15 28600 360 1087108
2
0.02 12700 353 1087086
9
Zinc 0.04 18300 353 1087091
Oxid 5
e 0.07 24900 354 1087096
0
1.15 27000 354 1087103
2

The above table 6.1 is extracted from CFD analysis results for shell and tube heat
exchanger. In CFD Analysis results are clearly indicating that the Titanium
65
Nitride nano fluid is better in heat transfer coefficient and heat transfer rate at
volume fraction of 0.15 comparing to titanium carbide and Zinc oxide
nanofluids. Because of titanium nitride nanofluids consist of better thermal
properties like thermal conductivity, specific heat is

35000
30000

Heat transfer coefficient

25000
20000
15000
10000
5000
0

Fig. 6.1 Comparison of Heat transfer coefficient between three nano fluids at
different volume fractions

362
Maximum Temparature

360
359
358 358
356
354
353 353
352
350
348
0.020.040.070.15

Fig. 6.2 Comparison Maximum temperature between three nano fluids at

different volume fractions

10871100
Total Heat Transfer Rate

10871050
10871000
10870950
10870900
10870850
10870800
10870750
0.02 0.04 0.07 0.15

Fig. 6.3 Comparison of Total Heat transfer rate between three nano fluids at
66
different volume fractions more than titanium carbide and zinc oxide. The
Comparison of Heat transfer coefficient between three nano fluids at
different volume fractions shown in fig6.1 and Fig 6.2, Fig.6.3 shows that
Comparison of maximum temperature and Total Heat transfer rate b/w three
nano fluids at different volume fractions in CFD Analysis.
6.2 THERMAL ANALYSIS RESULTS

In this thermal analysis also we have used Titanium Carbide, Titanium Nitride
and Zinc oxide nanofluids with varying volume fractions of 0.02, 0.04, 0.07 and
0.15 with base fluid water. But here we have used aluminum and copper
materials for shell and tube heat exchanger. Thermal analysis is done both
aluminum and copper heat exchangers. We are going to analysis heat flux and
maximum temperature. After the analysis we are deciding that the maximum
heat flux is achieved in 0.15 volume fraction where using Titanium Nitride. And
also we have observed that flux is gradually increases when increasing the
volume fractions of nano fluids during Thermal Analysis

Table 6.2 Thermal analysis results for Aluminum STHE

Aluminum
Type of Volume
Nano Fluid Fraction Max Temp Min Temp Heat Flux
(K) (K) (W/mm2)
0.02 353.1 295.1 2.8754
5 5
Titanium
0.04 353.1 295.1 2.8005
Carbide
5 5
0.07 353.1 295.1 2.9192
5 5
1.15 353.1 295.1 2.9651
5 5
0.02 353.1 295.1 2.8697
5 5
Titanium
0.04 353.1 295.1 2.9706
Nitride
5 5
0.07 353.1 295.1 2.9711
5 5
1.15 353.1 295.1 3.0042
5 5
0.02 353.1 295.1 2.797
5 5
Zinc
0.04 353.1 295.1 2.881
Oxide
5 5
0.07 353.1 295.1 2.965
5 5
67
1.15 353.1 295.1 2.987
5 5

68
 Table 6.3 Thermal analysis results for Copper STHE

Copper
Type of Volume
Nano Fluid Fraction Max Temp Min Temp Heat Flux
(K) (K) (W/mm2)
0.02 353.1 295.94 26.967
5
Titanium
0.04 353.1 296.69 27.279
Carbide
5
0.07 353.1 295.67 27.367
5
1.15 353.1 295.49 27.669
5
0.02 353.1 295.98 27.255
5
Titanium
0.04 353.1 295.47 27.694
Nitride
5
0.07 353.1 295.45 27.723
5
1.15 353.1 295.38 27.845
5
0.02 353.1 296.74 26.953
5
Zinc
0.04 353.1 295.9 27.201
Oxide
5
0.07 353.1 295.49 27.669
5
1.15 353.1 295.42 27.777
5

The table 6.2 is extracted from thermal analysis results for shell and tube heat
exchanger. In thermal Analysis results are clearly indicating that the Titanium
Nitride nano fluid is better in heat flux at volume fraction of 0.15 in both
aluminum and copper materials comparing to titanium carbide and Zinc oxide
nanofluids. Because of titanium nitride nanofluids consist of better thermal
properties like thermal conductivity, specific heat is more than titanium carbide
and zinc oxide. In which copper material gives more heat flux compared to
aluminum material. Because of copper material consist of high thermal
properties than aluminum. Fig.6.4 shows that Comparison of Total Heat transfer
rate between three nano fluids at different volume fractions and same way Fig
6.5 shows for copper material respectively.

69
 STHE Aluminium
3.05
3
2.95
2.9
Heat Flux

2.85
2.8
2.75
2.7
2.65
0.02 0.04 0.07 1.15
Fig. 6.4 Comparison of Heat flux between three nano fluids at different
volume fractions for Aluminum STHE

STHE Copper
28
27.8
27.6
27.4
Heat Flux

27.2
27
26.8
26.6
26.4
0.02 0.04 0.07 1.15
Fig. 6.5 Comparison of Heat flux between three nano fluids at different
volume fractions for Copper STHE

70
 CHAPTER VII
CONCLUSION AND FUTURE SCOPE

In this thesis, analytical investigations are done on the shell and tube heat
exchanger, using forced convective heat transfer to determine flow
characteristics of nanofluids by varying volume fractions and mixed with water,
the nanofluids are Zinc Oxide, Titanium Carbide and Titanium Nitride
nanofluids and different volume concentrations (0.02,0.04,0.07and 0.15)%
flowing under turbulent flow conditions.

By observing the CFD analysis results, temperature, heat transfer coefficient and
total heat transfer rates are increasing by increasing the volume fractions. The
values are more when Titanium Nitride is used than other two fluids.

Thermal analysis is done on the heat exchanger and the materials considered for
shell and tube heat exchanger are Aluminum and Copper. By observing the
results, the heat flux values are increasing by increasing the volume fractions.
The values are more when Titanium Nitride is used than other two fluids. When
the material Copper is used, heat flux is more. So heat transfer rate is more.

71
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