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Effects of Baffle Inclination Angle On Flow and Heat Transfer of A Heat Exchanger With Helical Baffles
Effects of Baffle Inclination Angle On Flow and Heat Transfer of A Heat Exchanger With Helical Baffles
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Abstract
Numerical simulations were carried out to study the impacts of various baffle inclination angles on fluid flow and heat transfer of heat exchangers
with helical baffles. The simulations were conducted for one period of seven baffle inclination angles by using periodic boundaries. Predicted flow
patterns from simulation results indicate that continual helical baffles can reduce or even eliminate dead regions in the shell side of shell-and-tube
heat exchangers. The average Nusselt number increases with the increase of the baffle inclination angle α when α < 30◦ . Whereas, the average
Nusselt number decreases with the increase of the baffle inclination angle when α > 30◦ . The pressure drop varies drastically with baffle inclination
angle and shell-side Reynolds number. The variation of the pressure drop is relatively large for small inclination angle. However, for α > 40◦ , the
effect of α on pressure drop is very small. Compared to the segmental heat exchangers, the heat exchangers with continual helical baffles have
higher heat transfer coefficients to the same pressure drop. Within the Reynolds number studied for the shell side, the optimal baffle inclination
angle is about 45◦ , with which the integrated heat transfer and pressure drop performance is the best. The detailed knowledge on the heat transfer
and flow distribution in this investigation provides the basis for further optimization of shell-and-tube heat exchangers.
© 2008 Elsevier B.V. All rights reserved.
Keywords: Heat transfer; Inclination angle; Helical baffle; Three-dimensional computation; Pressure drop; Optimization
0255-2701/$ – see front matter © 2008 Elsevier B.V. All rights reserved.
doi:10.1016/j.cep.2008.01.012
Y.-G. Lei et al. / Chemical Engineering and Processing 47 (2008) 2336–2345 2337
Table 2
Thermophysical properties of oil
Property Value
CP (J/kg K) 2316.2
Pr 110
μ (kg/m s) 0.006255
ρ (kg/m3 ) 814.3
λ (W/m K) 0.130
Table 1
Geometric parameters
Dimension Value
286 282 and 350 556 mesh points for the model with inclination
angle 30◦ . It was found that the difference in heat transfer coeffi-
cient between the results of grid system of 286 282 and 350 556
is 2%. Considering both convergent time and solution precision,
the grid system of 286 282 was adopted for the computational
model.
The computer code FLUENT was used to solve the fluid flow
and heat transfer in the computational domain [18]. The gov-
erning equations were iteratively solved by the finite volume
method using SIMPLE pressure–velocity coupling algorithm.
This numerical approach stores scalar variables at the center of
the control volume. The face values of scalar variables are also
required for the convection terms and their values are gained
from interpolation. As regards the solution algorithm, the seg-
regated approach is used to solve a single variable field by
considering all cells at the same time, and then solves the next
variable field by again considering all cells at the same time. Fig. 6. Predicted average Nusselt number versus Res compared with the result
The convective term in governing equations is discretized by of Wang [20].
the QUICK scheme with three-order precision. Because of the
nonlinearity of the equation set being solved by FLUENT, the Tmax − Tmin
T = (10)
iterative technique with under-relax predictions of velocity and ln(Tmax /Tmin )
pressure is used. Default under-relaxation factors of the solver
where Q is heat transfer rate; A, heat transfer area;
are used, which are 0.3 and 0.7 for the pressure and momentum.
Tmax = max(Tw − Tin , Tw − Tout ), and Tmin = min(Tw − Tin ,
The convergence criterion is that the normalized residuals are
Tw − Tout ).
less than 10−5 for the flow equations and 10−8 for the energy
equation. The present computations were carried in a Pentium
4 workstation with 4 GB RAM. Each simulation took approxi- 3. Model validation
mately 8–10 h to converge.
In order to verify the present numerical work, the model vali-
2.4. Performance parameter dation was conducted at first. Figs. 6 and 7 show the comparison
of the present numerical results and experimental measurements
The shell-side Reynolds number and friction factor are of Wang [20] for heat exchanger with baffle inclination angle of
defined by Eqs. (4) and (5) [19]: 15◦ . The comparisons were carried out for the average Nus-
selt number and friction factor. It can be observed from Fig. 6
ρude that the numerically predicted average Nusselt number is 3–10
Res = (4)
μ percent higher than the experimental results of Wang [20]. The
P de discrepancies between the simulating results and the experimen-
f = 2
· (5) tal data may be explained as follows. The baffles may have
1/2ρu L
qm
u= (6)
ρAmin
where u is the mean velocity at the minimum transverse area; de ,
the characteristic dimension which takes the value of the tube
diameter d; qm , the shell-side mass flow rate; ρ, the fluid density.
Amin is the minimum transverse area, which is determined by
1 d
Amin = BD 1 − (7)
2 p
Here, B is the axial distance of a period; D, the diameter of shell
side; p, the tube spacing.
The heat transfer coefficient and Nusselt number are defined
by Eqs. (8) and (9):
Q
h= (8)
AT
hde
Nu = (9) Fig. 7. Predicted friction factor versus Res compared with the result of Wang
λ [20].
2340 Y.-G. Lei et al. / Chemical Engineering and Processing 47 (2008) 2336–2345
Fig. 8. Stream lines in the shell side for different baffle inclination angles (Res = 1 000, Pr = 110): (a) α = 15◦ ; (b) α = 30◦ ; (c) α = 40◦ ; and (d) α = 50◦ .
significant bypass streams and leakage streams during exper- also computed in order to compare with the one with helical
iment due to manufacturing tolerances and quality control, so baffles.
the effective mass flow rate across the tube bundle decreases
due to the bypass and leakage. Thus, the experimental shell-side 4.1. Flow characteristics and heat transfer
heat transfer data are smaller than those predicted. However, in
our numerical simulations, the effects of the bypass and leakage The flow behavior in the shell side of the heat exchanger with
streams are not taken into account, and this leads to a higher continual helical baffles is different from that of a conventional
numerical prediction. The numerically predicted results might segmental heat exchanger. Fig. 8 shows the stream lines in the
be still acceptable as an engineering computation. As shown in shell side of heat exchanger with baffle inclination angles of
Fig. 7, the deviations of the numerical results of friction factor 15◦ , 30◦ , 40◦ , and 50◦ . The flow patterns inside the shell of the
from the experimental ones are 5–15%. Because of the effects heat exchangers with continual helical baffle have been revealed
of the bypass and leakage streams were not taken into account in rotational. The tube bundles are washed out by revolving fluid.
the numerical simulation, such an agreement should be regarded As can be seen from Fig. 8, the inclination angle of the path line
reasonable in the engineering computations. increases with the increase of baffle inclination angles. Because
of the effect of baffle inclination angle, the fluid flow in axial
4. Results and discussion direction is enhanced and the fluid flow is turned into a plug
flow.
In order to understand the flow field and heat transfer charac- Fig. 9 shows the velocity vectors in the cross-section plane
teristics of this problem, a total of 49 cases were considered in near the segmental baffle and helical baffle. As is shown in the
the present research. The effects of baffle inclination angles on figure, because of the zigzag flow pattern caused by the con-
the shell-side performances were studied. The performances of ventional segmental baffle, there are large dead spaces and a
a heat exchanger with 25% cut segmental vertical baffles were significant back mixing at the back of the baffle, where fluid
Y.-G. Lei et al. / Chemical Engineering and Processing 47 (2008) 2336–2345 2341
Fig. 9. Velocity vectors near the segmental baffle and helical baffle: (a) segmental baffle; and (b) helical baffle.
recirculates with low velocity and deteriorates heat transfer. distribution and gradient are different with different baffle incli-
The dead spaces result in inefficient use of the heat transfer nation angles, thus affect the heat exchange of the tubes in the
area. Fluid flow with helical baffles is continuous and the dead shell side.
place does not occur near the helical baffle. The spiral motion In the present study, the effect of the baffle inclination angle
brings about better mixing, and the heat transfer in this region on heat transfer has been investigated. The heat transfer coeffi-
is significantly enhanced. cient is evaluated by using the Nusselt number, which is defined
Fig. 10 illustrates some characteristics of the flow field. These by Eq. (9). The average Nusselt numbers of the tube bundle as
plots report the velocity vectors in the cross-section planes at the a function of the shell-side Reynolds number for different baf-
1/2 cycle of the heat exchanger with baffle inclinational angles fle inclination angles are given in Fig. 11. For all inclination
of 15◦ , 30◦ , 40◦ , and 50◦ . These planes are perpendicular to the angles, the value of Nu increase with the increase of shell-side
main flow direction. It can be seen that tubes are washed out Reynolds number, but the changes become less obvious when
by flow stream with velocity gradient. The reason for the large the baffle inclination angle are larger. For α < 30◦ , the increase
velocity gradient near the tube can be attributed to the helical of baffle inclination angle leads to the increase of Nu because
flow along the radius of shell and the free vortex generated by the tube in the shell side is washed out by a nonuniform velocity
the tangential velocity component. It is clear that the velocity profile with a certain velocity gradient mentioned above and the
Fig. 10. Velocity vectors in the cross-section plane at the 1/2 cycle for different baffle inclination angles (Res = 1 000, Pr = 110): (a) α = 15◦ ; (b) α = 30◦ ; (c) α = 40◦ ;
and (d) α = 50◦ .
2342 Y.-G. Lei et al. / Chemical Engineering and Processing 47 (2008) 2336–2345
Fig. 11. Average Nusselt number of the tube bundle versus Res for different Fig. 13. Average Nusselt number over tube 1, 2, and 3 versus Res for α = 30◦ .
baffle inclination angles.
Fig. 12. Average Nusselt number over tube 1, 2, and 3 versus Res for α = 15◦ . Fig. 15. Average Nusselt number over tube 1, 2, and 3 versus Res for α = 50◦ .
Y.-G. Lei et al. / Chemical Engineering and Processing 47 (2008) 2336–2345 2343
Fig. 16. Pressure drop versus Res for different baffle inclination angles
Fig. 17. Heat transfer coefficient versus pressure drop for different baffle incli-
nation angles
(1) The flow pattern in the shell side with continual helical Tw temperature of the tube (K)
baffle is near-plug flow. Therefore, the dead region is elim- u shell-side velocity (m s−1 )
inated and the heat transfer area is used more effectively.
The average Nusselt number of the tube bundle increases Greek symbols
with the increase of baffle inclination angle when α < 30◦ , α baffle inclination angle (◦ )
and decreases if the baffle inclination angle increases P pressure drop (Pa)
further. λ thermal conductivity (W m−1 K−1 )
(2) As the shell-side Reynolds number is increased, the pres- μ dynamic viscosity (Pa s)
sure drop increases for all the cases considered. For ρ density of oil (kg m−3 )
all helical baffle heat exchangers studied, the pressure
drops are lower than those of the conventional segmen- Subscripts
tal heat exchangers. The pressure drop decreases with the in inlet
increase of baffle inclination angle in all the cases con- max maximum
sidered. The change of the pressure drop is large in the min minimum
small inclination angle region. However, the effects of out outlet
baffle inclination angle on pressure drop are small when w wall
α > 40◦ .
(3) For all the helical baffle heat exchangers studied, the References
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