Ceb4053 Transport Phenomena CFD Project January 2023 Semester
Ceb4053 Transport Phenomena CFD Project January 2023 Semester
CFD PROJECT
A heat exchanger is a device that transfers heat between two fluids. Fluids can be of many
sorts, such as liquids or gases, and temperatures. Heat exchangers are utilised in a variety of
applications, including air conditioning, refrigeration, chemical processing, and power production.
The fundamental premise of a heat exchanger is to bring two fluids into contact while separating
them with a barrier that permits heat transfer. The barrier may be a solid wall or a collection of
tubes, depending on the heat exchanger's particular design. Momentum transport and heat transport
are two fundamental processes that occur in a heat exchanger during the transfer of heat from one
fluid to another.
Momentum transport refers to the transfer of momentum, or the force required to move a
fluid, between the two fluids flowing through the heat exchanger. This momentum transfer can be
caused by differences in fluid velocities, pressure gradients, and fluid viscosity. Momentum
transfer is important in heat exchangers because it affects the flow patterns and velocity profiles
of the fluids, which in turn can impact heat transfer efficiency.
Heat transport, on the other hand, refers to the transfer of thermal energy between the two
fluids flowing through the heat exchanger. Heat transfer can occur through three modes:
conduction, convection, and radiation. Conduction occurs when heat is transferred through a solid
medium, such as the heat exchanger walls. Convection occurs when heat is transferred through the
movement of fluids, either by forced convection (such as through a pump) or natural convection
(due to differences in temperature and density). Radiation occurs when heat is transferred through
electromagnetic waves.
In a heat exchanger, both momentum and heat transport are important considerations in the
design and operation of the device. Maximizing the transfer of thermal energy while minimizing
pressure drop and energy losses due to friction is a key goal in the design of efficient heat
exchangers.
There are various distinct forms of heat exchangers, including shell and tube, plate and
frame, and spiral. The selection of a heat exchanger depends on the individual application and
operating conditions, as each type has its own distinct benefits and drawbacks. The most common
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heat exchanger used in industry is shell and tube heat exchanger. Shell and tube heat exchanger is
a cylindrical shell that contains a network of tubes. One fluid travel through the tubes, while the
other flows in the shell outside the tubes.
The plate heat exchanger is the second type of heat exchanger. It's constructed out of thin
plates with corrugated designs. The plates are layered on top of each other, and the two fluids flow
between them in alternate channels.
The second heat exchanger is plate heat exchanger. It is made up of a series of thin plates
with corrugated patterns. The plates are stacked on top of each other, and the two fluids flow in
alternate channels between the plates. Next, finned tube heat exchanger, where it has a bundle of
tubes with fins attached to them. One fluid flows inside the tubes, while the other flows over the
fins, increasing the heat transfer surface area. Lastly, double pipe heat exchanger where it consists
of two pipes, one inside the other. One fluid flow through the inner pipe, while the other flows
through the outer pipe.
In a heat exchanger, a tube is a component that carries a fluid or gas and facilitates the
transfer of heat between two other fluids or gases. The shape of the tube can impact the efficiency
of heat transfer.
Circular tubes are tubes with a circular cross-section, which is the most common tube shape
in heat exchangers. The circular shape allows for easy fabrication and assembly, and it also
provides uniform flow of the fluid inside the tube, which helps to promote efficient heat transfer.
This configuration is often used for applications where the two fluids have a large temperature
differential, such as in refrigeration or air conditioning systems.
Ellipsoidal tubes, on the other hand, have an elliptical cross-section. This shape is used in
some heat exchanger designs because it allows for a larger surface area for heat transfer while still
maintaining a reasonable tube diameter. This can result in higher heat transfer rates and a more
compact heat exchanger design. However, ellipsoidal tubes are more difficult and expensive to
fabricate than circular tubes.
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GOVERNING EQUATIONS AND SIMULATION METHOD
Governing Equations
There are three properties of the flowing fluid that are of importance. They are momentum,
energy, and mass. The molecular momentum transfer in the bulk fluid can be explained by
Newton’s law of viscosity. It is empirically presented as Equation (1).
𝑑𝑣𝑥
𝜏𝑦𝑥 = −µ (1)
𝑑𝑦
Equation (1) states that the shearing force per unit area is proportional to the negative of
the velocity gradient (Byron et al., 2006). Based on the equation, it can be explained that x-
momentum is transferred to the adjacent layer of liquid which allows the motion in x-direction to
remain. In momentum transport, the driving force is the velocity gradient. For the fluid to flow,
force must be present. There are two types of force that would cause the fluid to flow, and they are
pressure as well as viscous force. The momentum can also be transferred through convective
transport, which is the bulk movement of the fluid. By taking into consideration all the three modes
of molecular momentum transfer, a combined momentum flux can be derived.
Another property to be considered is the energy of the fluid. In this case, the thermal energy
possessed by the fluid is of the most importance. Thermal energy can be transported through 3
different modes. They are conduction, convection, and radiation. In this case, however, thermal
energy transfer through radiation is irrelevant. Thus, only conduction and convection would be
discussed. Heat conduction can be explained by Fourier’s law. Where Equation (3) is its one-
dimensional form.
𝑑𝑇
𝑞𝑦 = −𝑘 𝑑𝑦 (3)
According to Fourier’s law, as molecules collide, heat energy is transferred from an area
of higher temperature to the lower one (Vedantu, 2023). It states that, heat transfer rate through a
material is proportional to the negative gradient present in the temperature, as well as to the area,
which is at right angles to the gradient, through which the heat flows (Vedantu, 2023). Whereas
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heat convection can be explained by Newton’s law of cooling. Newton’s law of cooling states that
the rate at which an object cools is proportional to the difference in temperature between the object
and the object’s surroundings (Carolina Biological Supply, 2022). Equation (4) is Newton’s law
of cooling equation.
𝑞 = ℎ𝐴(𝑇 − 𝑇𝑜 ) (4)
After considering heat conduction, convection and work done, the combined energy flux
vector would be as shown in Equation (5).
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𝑒 = 𝑞 + (2 𝜌𝑣 2 + 𝜌𝐻) 𝑣 + [𝜏. 𝑣] (5)
In the case of the project, the combined momentum flux equation is applicable to find the
velocity profile of the fluid flow inside the heat exchanger. The fluid used in the project is a
Newtonian fluid and it is assumed to be laminar, thus, it is applicable. Whereas the combined
energy flux, the Fourier’s law and Newton’s law of cooling is useful in determining the
temperature profile of the fluid. This is because both conduction and convection are present in this
case. The heat is transferred from the surface of the heater to the water and finally to the heat
exchanger wall by convection. Whereas the heat transfer within the heater’s wall is through
conduction. With all the 5 equations, the velocity and temperature of the water at a specific point
can be determined.
Simulation Method
Altair SimLab software was used to conduct the simulation and complete the CFD project. All the
procedures in completing the CFD simulation are summarized and shown below.
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1. First, select MKS (m kg N s) unit system 2. Create the rectangular body of heat
after opening the Altair Simlab. Make exchanger using ‘Create’ function based
sure the units are consistent. on the dimensions given in the problem
statement. Position the rectangular box
in the middle by changing center
dimensions.
Center: x=0m, y=0m, z=0m
Length: x=0.725m, y=0.2m, z=0.1m
3. Create another rectangular box at the 4. Create one rectangular box at the outlet
inlet of the heat exchanger using ‘Create’ of the heat exchanger using ‘Create’
function with dimensions below. function with dimensions below.
Center: x= -0.35m, y=0m, z= -0.0125m Center: x=0.2625m, y=0m, z=-0.0125m
Length: x=0.025m, y=0.2m, z=0.075m Length: x=0.2m, y=0.2m, z=0.075m
5. Create the first circle heater using 6. Repeat step 5 for the second circle heater.
cylinder based on the dimensions given. The distance between the heater is 10cm.
It is assumed that the distance of the first Center: x= -0.1875m, y=0m, z=0m
circle heater from the wall is 5cm. Height=0.2m, Outer radius=0.02m
Center: x= -0.2875m, y=0m, z=0m
Height=0.2m, Outer radius=0.02m
7. Go to ‘Sketch’ and select ‘New sketch’. 8. Sketch the ellipse based on the
Choose the ‘Ellipses’ and click on the dimensions given.
plane. Vertical=0.06m; Horizontal=0.04m
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9. Then, right click on the sketch at the 10. Create the surface mesh on the ellipse
assembly browser to realize the sketch as sketch with the element size of 0.005m.
single body. Choose ‘All Faces’.
11. Then, go to ‘Geometry’, ‘Create’ and 12. After extruding the body, right click on
choose ‘Extrude’. Extrude the ellipse the ‘SL_Body_1’ and duplicate another
body with a distance of 0.22m. Make ellipse body in the same model.
sure the distance is longer than the width
of the main body. After that, click ‘OK’.
13. Position the first ellipse heater 10cm next 14. Position the second ellipse heater 10cm
to the circle heater. next to the first ellipse heater.
Center: x= -0.0875m, y=0m, z=0m Center: x=0.0125m, y=0m, z=0m
15. Make sure all the heaters are within the 16. Then, remove the boxes and circles by
main body. To remove the boxes at the deleting them at the assembly browser.
inlet and outlet section, the boxes need to Right click on the box and choose
connect with the main body first. Click ‘Delete’. Then, click ‘Yes’. Repeat
on ‘Connect’ and select ‘Boolean’. Then, similar steps for the outlet and circle
select the main body as the target body heater. Then, the inlet section, outlet
while select all the cylinders and boxes section and both circle heaters are
as the tool bodies. Then, click ‘OK’. created.
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17. Create the surface mesh on the main 18. Then, connect the ellipses with the main
body with the element size of 0.005m so body. Go to ‘Geometry’, ‘Connect’ and
that they are in the same type of bodies select ‘Bodies’. Choose the main body
with the ellipses. and both ellipses. Then, click ‘Show
Body Pairs’ and ‘Select All’. Make sure
the ‘Body pair’ is selected for ‘On Row
Selection Display’. After that, click
‘Apply’.
19. Then, remove the ellipses by deleting 20. After that, break the main body into XZ
them at the assembly browser. Right plane. Go to ‘Geometry’, ‘Break’ and
click on the ellipses and choose ‘Delete’. click the ‘Define/Modify Plane’. Then,
Then, click ‘Yes’ and the ellipse heaters choose ‘XZ plane’ and choose the ‘Main
are created. Body’. Lastly, click ‘OK’.
21. Re-mesh the main body with the element 22. After that, go to ‘Mesh’ and ‘CFD’. For
size of 0.005m so that all the surfaces of the CFD mesh, select both the main body
the main body are meshed. For the as the ‘Fluid bodies’. For ‘Ignore BL
surface mesh output option, choose creation on faces’, the faces of the inlet,
‘Create the mesh in new model’. outlet and heaters’ insides are selected.
Then, click ‘Ok’.
23. After that, go to ‘Solutions’ and select 24. Then, go to ‘Analysis’ and choose ‘Inlet’.
‘Flow’. Select the main bodies and then Set the velocity value as given in the
choose ‘Laminar’ for the flow based on problem statement which is 0.05m/s and
the problem statement. Click ‘Include the temperature at 298.15K since water
Gravity’ to consider the gravity for the enters the heat exchanger at 25℃.
simulation.
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25. Then, go to ‘Outlet’ under ‘Analysis’. 26. Then, go to ‘Wall’ under ‘Analysis’.
Select both the outlet faces and click Select all the inner faces of all the
‘OK’. heaters. After that, set the temperature
value at 338.15K (65℃) as given in the
problem statement.
27. Define water as one of the materials. Go 28. Then, go to the assembly browser and
to ‘Material’ under ‘Analysis’, then input assign water as the material in the main
all the properties of the water based on bodies.
literature review.
Density = 1000 kg/m3
Specific heat = 4183 J/(kg.K)
Viscosity = 0.001 N.s/m2
Conductivity = 0.598 W/m.K
29. After that, go to solution browser, right 30. Lastly, right click on the ‘Results’ again
click on the ‘Results’ and choose and choose ‘View Solver Log’.
‘Update’.
31. After the simulation running is done, 32. Repeat similar steps for velocity profile.
view the results. Go to ‘Results’ and However, choose ‘Z’ for X data for
choose the ‘XY Plot’. Choose ‘XYZ’ for velocity magniture as Y data. Select the
the data type. Choose ‘X’ for X data for points vertically for velocity as shown
temperature as Y data. Select the points below.
horizontally for temperature as shown
below.
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RESULTS AND DISCUSSION
(a)
(b)
Figure 2: Temperature distributions (a) at the top of heat exchanger and (b) across heaters
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Figure 1 showed the temperature contour while Figure 2(a) depicted the
temperature distribution plotted from the inlet to the outlet of the heat exchanger without
passing across the heaters. The temperature remained constantly low until x=-100 cm, after
which the first and second heaters were situated. Beginning at x=-100 cm, the water
temperature increased gradually at which the ellipse heaters were located. It increased
considerably between x=160 cm and x=180 cm after the water passing through all the
heaters. The temperature then decreased to x= 240cm before increasing significantly till it
reached the maximum temperature of 313.499 K at x= 314 cm, which was at the outlet of
the heat exchanger. Both conduction and convection delivered heat from the heater to the
water. Therefore, heat transfer happened in the heat exchanger which caused the water to
receive heat energy and the outlet water temperature to increase.
Figure 2(b) depicted the temperature distribution against the x-axis for a 65°C
heater. The temperature at the middle of the heat exchanger was plotted along the length
of the heat exchanger across the heaters. The graph indicated that the maximum water
temperature at a heater temperature of 65°C was 338.15 K. Since the water entered the heat
exchanger at 25℃, temperature difference existed due to the presence of heaters at 65℃.
Therefore, heat transfer occurred due to the thermal gradient. As we could see the trend of
the graph, the temperature increases drastically to the maximum temperature at x=-
287.5cm which was the location of first heater. As the water approached nearer to the heater,
the temperature increased. Heat flowed from the heater with higher temperature to the
water through conduction and convection. The temperature was the highest at the surface
of the heater, but it decreased as water moved further away from the heater due to heat loss
of conduction and convection. Similar trends could be observed for the rest of the heaters.
According to Patil et al. (2015), the increase in heat transfer rate was less significant
under laminar flow conditions. As observed from the graph, the water entering at 298.15K
exited the heat exchanger at around 314K with a small difference of less than 16K.
Meanwhile, it could be observed that the temperature of water exiting the ellipse heater
was higher than that from the circle heater. It was reported that the use of elliptical tubes
enhanced the heat transfer capability of the heat exchanger as compared to circular tubes
(Yogesh et al., 2018).
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Part B: Velocity Profiles at 0.05 m/s; 0.12m/s; 0.2 m/s
i) v=0.05m/s,
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drag force were lower. The drag coefficient for a sphere is given with a range of values that
have been proven in equation (6) because drag on a sphere heavily depends on Reynolds
number (Jones & Knudsen).
𝐿𝑈
𝑅𝑒 = (6)
𝑣
Where;
Re : Reynolds number
ii) v = 0.12m/s,
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attained z = - 43.3512 but continued to rise until it came to z = 43.6309. In the case of z =
50, the velocity decreased dramatically. It was observed that as it transferred up the z - axis
of the heat exchanger, the fluid flow became steadily quicker as it approached the outlet.
On the other hand, there was no velocity, v=0 m/s across both heat exchanger walls where
z = -50 and z = 50. This was due to the fact that velocity was much higher within the point
of exit compared to the centre of the heat exchanger. As the velocity of the heat transfer
fluid inside the tubes was a critical factor in heat transfer performance for all arrangements
(Congedo, Colangelo, & Starace, 2012). Moreover, the amount of drag produced by an
object corresponds depending on its dimension. According to the objects with optimum
aerodynamic contours had a decreased coefficient of drag and drag force values. Based on
the strong relationship between the drag on a sphere and the Reynolds number, the drag
coefficient for spheres and ellipse can be obtained with a range of values that can be seen
equation (6) (Jones & Knudsen)
iii) v = 0.2m/s,
For velocity equals to 0.2 m/s, the velocity profile increased steeply between Z=-
50 to Z=-43. The velocity then steadily increased until Z=29. A slight drop in velocity was
observed at Z=33, followed by a sharp increase until Z=44. The velocity then dropped
tremendously at Z=50. The velocity profile continued to steadily increase up until point
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Z=29, then sharply increased until Z=44 due to the increasing driving force of the fluid
system. Moving up the heat exchanger, the fluid flowed faster as it was nearing the outlet,
where there is an opening. The closer the flow was to the center of the outlet, the greater
the velocity. This indicated that the center of the outlet had the least resistance. This might
be due to the flow’s path being clear of obstruction, hence less resistance. When going
down the heat exchanger, the resistance increased due to the drag force from the heat
exchanger wall. At both point Z=-50 and Z=50, the velocity was 0 as the wall was
stationary. Based on the velocity contour, it could be observed as well that the velocity of
the flow was generally higher near the outlet compared to the flow inside the heat
exchanger. This could be due to the reduced cross-sectional area. Based on Equation (7),
when the volumetric flowrate was kept constant, reduction in cross-sectional area resulted
in an increase in the velocity. Additionally, there was less resistance present near the outlet,
in comparison to inside the heat exchanger which contained the heaters.
𝑄 = 𝑉𝐴 (7)
0.2
Velocity (m/s)
0.15
V = 0.05 m/s
0.1 V = 0.12 m/s
V = 0.2 m/s
0.05
0
-60 -40 -20 0 20 40 60
Node Z
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Figure 6 showed the velocity profiles of the flow at 3 different inlet velocities. All
three different inlet velocities gave a similar profile. From the bottom of the heat exchanger,
the velocity showed a steep increase then a slight dip. It could be assumed that the steep
increase was due to the decreasing resistance as the flow was further from the wall. The
slight dip was due to the resistance caused by the ellipsoidal tube. This dip was more
obvious with the lower velocities. The flow with the highest velocity, which was V=0.2
m/s, had a less significant dip in the velocity. This was probably due to the velocity being
great enough to overcome most of the resistance caused by the ellipsoidal tube. As stated
by Lumen Candela (n.d), when a fluid increased in velocity, its kinetic energy increased as
well. Hence, fluid with greater velocity could overcome resistance better. It was
represented by Equation (8). The effect of greater flow velocity could also be seen by
comparing the increase of the velocity after the dip between flow with V=0.12 m/s and
V=0.05 m/s. As observed, the increase was greater with V=0.05 m/s than V=0.12 m/s. This
showed that resistance affected the velocity greater when the flow velocity was smaller.
Moving up the heat exchanger, the resistance from the ellipsoidal tube became less
significant. Thus, the increase in velocity could be observed with all 3 flow velocities.
Nearing the outlet opening of the heat exchanger, a drastic increase in temperature was
displayed by each flow velocity except V=0.05 m/s. This was probably due to the lack of
the flow’s ability to overcome the resistance imposed by the heat exchanger wall. Thus, it
could be concluded that the greater the flow velocity, the less significant the effect of
resistance on the velocity.
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𝐾𝐸 = 2 𝑚𝑣 2 (8)
According to Hall (2022), the geometry of an object influences the drag force
produced. Increasing the area and the drag coefficient, CD, would increase the drag force.
Equation (9) and (10) show the relation between drag force, drag coefficient, and surface
area respectively.
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𝐹𝐷 = 2 𝜌𝑉 2 𝐶𝐷 𝐴 (9)
𝐷
𝐶𝐷 = 1 (10)
𝑟𝑉 2 𝐴
2
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Thus, an object with a larger surface area and a more irregular shape would impose
a higher resistance on the surrounding fluid. This would then cause the fluid velocity to
have smaller flow velocity. This can be observed where the fluid is not hindered by the
heaters, it has a higher velocity. Hence, the sharp increase in the velocity at the outlet.
Whereas the fluid that flows past the heaters possesses a lower velocity. This is due to the
resistance produced by the tubes.
In terms of the general shape of the velocity profile, according to U.S. Department
of Energy (1992), for a laminar flow, the velocity distribution at a cross section will be
parabolic in shape with the maximum velocity at the center being about twice the average
velocity in the pipe. Whereas, for turbulent flow, the velocity profile would appear flatter
(U.S. Department of Energy, 1992). This can be observed where the flow is obstructed, the
velocity profile seems flatter whereas towards the opening of the outlet, it resembles the
parabolic shape better. This indicates that, due to the obstruction caused by the heaters, the
flow becomes turbulent.
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CONCLUSIONS
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