INVESTIGATION OF THE PERFORMANCE OF

COUNTER AND PARALLEL FLOW HEAT

EXCHANGER WITH DIFFERENT SHAPES OF
TUBES BY NUMERICAL ANALYSIS (Tentative)
A Thesis Submitted to the
Department of Mechanical and Production Engineering

AHSANULLAH UNIVERSITY OF SCIENCE AND TECHNOLOGY

By

Fahmid Rahman [16-01-08-051]

Shaan Rahatul Sakib Khan [15-02-08-040]

Under Supervision of
Mr. Fazlar Rahman
Assistant Professor
Department of Mechanical and Production Engineering

In the partial fulfillment of the

requirements for the degree

Of
Bachelor of Science in Mechanical Engineering
 CERTIFICATE OF ACCEPTANCE

The thesis entitled “INVESTIGATION OF PERFORMANCE OF A COUNTER AND

PARALLEL FLOW HEAT EXCHANGER WITH DIFFERENT SHAPES OF TUBES BY
CFD SIMULATION AND NUMERICAL ANALYSIS” submitted by the following students
have been accepted for partial fulfillment of the requirement for the degree of B.Sc. in
Mechanical Engineering on January 2021.

Fahmid Rahman 16.01.08.051

Shaan Rahatul Sakib Khan 15.02.08.040

Mr. Fazlar Rahman

Assistant Professor

Department of Mechanical and Production Engineering

Ahsanullah University of Science and Technology

Dhaka 1208, Bangladesh

Dr. Mahbubul Muttakin Dr. Md. Rejaul Haque

Assistant Professor Lecturer
Department of Mechanical and Production Department of Mechanical and Production
Engineering Engineering
Ahsanullah University of Science and Ahsanullah University of Science and
Technology Technology
Dhaka 1208, Bangladesh Dhaka 1208, Bangladesh

ii
 DECLARATION OF CANDIDATE

It is hereby declared that this thesis paper or any part of it has not been submitted elsewhere for
the award of any degree or diploma.

Fahmid Rahman 16-01-08-051 Signature :

Shaan Rahatul Sakib Khan 15-02-08-040 Signature :

iii
 ACKNOWLEDGMENT

First of all, thanks to the most merciful Allah for his kindness & blessings for allowing us to do
this research work under the supervision of Mr. Fazlar Rahman, Assistant Professor of the
Department of Mechanical & Production Engineering of Ahsanullah University of Science &
Technology for his continuous guidance & inspiration. The support he provided in so many ways
cannot be adequately expressed in words in these acknowledgments.

Finally, we wish to express our gratitude to our parents & all other family members for their
continuous support & utmost sacrifice without which this thesis work would not come into
reality.

iv
 ABSTRACT

Shell and tube heat exchanger is used in various industrial purposes and power generation
applications due to the high rate of heat transfer. It is used in industrial power plants for heating
or cooling down the fluids passing through the shell and tubes. The heat transfer rate of heat
exchangers can be increased by adding plates or pins, the fin on the tubes. In shell and tube type
heat exchanger, circular tubes are mostly used. But in this project, we are investigating the
performance of the heat exchanger by changing the shape of tubes and find the effect of the
shape of tubes on the effectiveness of the heat exchanger. To get the analytical values of
effectiveness and convective heat transfer coefficient for various geometrical shapes we have
done CFD simulation of double pipe heat exchanger for both counter and parallel flow. Here,
four cross-sections such as triangular, circular, square, hexagonal shapes are being studied by
keeping the same peripheral area.

Therefore, this study is aimed at investigating the effect of the shape of tube on the effectiveness
of a shell and tube type heat exchanger by numerical analysis. For this purpose, we have used
various shapes of tubes keeping cross-sectional area constant and find the effectiveness of the
heat exchanger by CFD simulation.

v
Table of Contents

Page No.

Acknowledgment ......................................................................................................................... [iv]

Abstract ..................................................................................................................................... [v]

List of Figures ........................................................................................................................[viii]

List of Tables ............................................................................................................................... [ix]

CHAPTER 1 Introduction ..................................................................................................[01-02]

1.1 Background ....................................................................................................................... [01]

1.2 Problem Statement ............................................................................................................ [01]

1.3 Objectives .......................................................................................................................... [02]

1.4 Scopes of this project ....................................................................................................... [02]

CHAPTER 2 Literature Review ........................................................................................[03-07]

2.1 Classifications of heat exchangers ................................................................................... [03]

2.1.1 Flow arrangements .......................................................................................................... [03]

2.1.2 Geometrical construction ................................................................................................ [04]

2.1.3 Heat transfer process ....................................................................................................... [04]

2.2 Basic constructions of shell & tube heat exchangers........................................................ [04]

2.3 The material used for shell & tube heat exchangers ......................................................... [05]

2.4 Applications of heat exchangers ...................................................................................... [06]

2.5 Previous research activities ............................................................................................... [06]

CHAPTER 3 Methodology ..................................................................................................... [08]

vi
CHAPTER 4 Design specifications and boundary conditions...............................................[09-23]

4.1 Calculation ........................................................................................................................ [09]

4.1.1 Calculations regarding the length of the tubes ............................................................... [09]

4.1.2 Calculation regarding the hydraulic diameter ................................................................ [10]

4.1.3 Calculation regarding the peripheral area of the tubes ................................................... [11]

4.1.4 Calculation regarding Reynolds number ........................................................................ [11]

4.1.5 Calculation regarding Nusselts number ......................................................................... [12]

4.2 Graphical representation for finding the exact tube length ............................................... [13]

4.3 Solid works design ............................................................................................................ [14]

4.4 Ansys geometry ................................................................................................................. [17]

4.5 Mesh ................................................................................................................................. [20]

4.6 Boundary conditions ......................................................................................................... [23]

CHAPTER 5 Performance analysis ...................................................................................[24-29]

5.1 Average inlet and outlet temperature ................................................................................ [24]

5.2 LMTD calculations ........................................................................................................... [26]

5.3 Effectiveness ..................................................................................................................... [27]

5.4 Overall analysis ................................................................................................................. [28]

CHAPTER 6 Results and Discussion.................................................................................[30-39]

6.1 Temperature contours ........................................................................................................ [30]

6.1 Temperature Vs Length ..................................................................................................... [34]

vii
 CHAPTER 7 Conclusions .................................................................................................... [40]

References ............................................................................................................................... [41]

viii
LIST OF FIGURES

Figure 2.1.1: Parallel & Counter Flow ........................................................................................................ 3

Figure 2.2: Heat exchanger parts ................................................................................................................ 5
Figure 3.1: Methodology ............................................................................................................................ 8
Figure 4.2.1: Graph ................................................................................................................................... 13
Figure 4.3.1: Heat exchanger setup with circular tube (Top view) .......................................................... 14
Figure 4.3.2: Heat exchanger setup with circular tube (Isometric view) .................................................. 14
Figure 4.3.3: Heat exchanger setup with square tube ............................................................................... 15
Figure 4.3.4: Heat exchanger setup with triangular tube .......................................................................... 15
Figure 4.3.5: Heat exchanger setup with hexagonal tube ......................................................................... 16
Figure 4.4.1: Circular Tube ....................................................................................................................... 17
Figure 4.4.2: Square Tube ......................................................................................................................... 17
Figure 4.4.3: Triangular Tube ................................................................................................................... 18
Figure 4.4.4: Hexagonal Tube .................................................................................................................. 18
Figure 6.1: Contour circular parallel flow .............................................................................................. 30
Figure 6.2: Contour circular counter flow ................................................................................................ 31
Figure 6.3: Contour square parallel flow .................................................................................................. 31
Figure 6.4: Contour square counter flow .................................................................................................. 32
Figure 6.5: Contour triangular parallel flow ............................................................................................. 32
Figure 6.6: Contour triangular counter flow ............................................................................................. 33
Figure 6.7: Contour hexagonal parallel flow ............................................................................................ 33
Figure 6.8: Contour hexagonal counter flow ............................................................................................ 34
Figure 6.9: Temp Vs Distance (Circular parallel) ................................................................................... 35
Figure 6.10: Temp Vs Distance (Circular counter) .................................................................................. 35
Figure 6.11: Temp Vs Distance (square parallel) ..................................................................................... 36
Figure 6.12: Temp Vs Distance (square counter) ..................................................................................... 37
Figure 6.13: Temp Vs Distance (triangular parallel) ................................................................................ 37
Figure 6.14: Temp Vs Distance (triangular counter) ................................................................................ 38
Figure 6.15: Temp Vs Distance (Hexagonal parallel) .............................................................................. 39
Figure 6.16: Temp Vs Distance (Hexagonal counter) .............................................................................. 39

ix
LIST OF TABLE

Table 1.1: Problem Statement ................................................................................................................................... 1

Table 2.1: Applications ............................................................................................................................................... 6
Table 4.1: Reynolds and Nusselt number for different shapes ................................................................................ 12
Table 4.2: Heat exchanger dimensions .................................................................................................................... 19
Table 4.3: Mesh data for circular counter flow........................................................................................................ 20
Table 4.4: Mesh data for circular parallel flow ........................................................................................................ 20
Table 4.5: Mesh data for square counter flow......................................................................................................... 20
Table 4.6: Mesh data for square parallel flow ......................................................................................................... 21
Table 4.7: Mesh data for triangular counter flow .................................................................................................... 21
Table 4.8: Mesh data for triangular parallel flow.................................................................................................... 21
Table 4.9: Mesh data for hexagonal counter flow ................................................................................................... 22
Table 4.10: Mesh data for hexagonal parallel flow.................................................................................................. 22
Table 4.11: Boundary conditions ............................................................................................................................. 23
Table 5.1: Input and output circular parallel ........................................................................................................... 24

Table 5.2: Input and output circular counter ......................................................................................................... 24

Table 5.3: Input and output square parallel ........................................................................................................... 25
Table 5.4: Input and output square counter ........................................................................................................... 25
Table 5.5: Input and output triangular parallel ....................................................................................................... 25
Table 5.6: Input and output triangular counter ...................................................................................................... 25
Table 5.7: Input and output Hexagonal parallel..................................................................................................... 24
Table 5.8: Input and output hexagonal counter ...................................................................................................... 24
Table 5.9: overall performance for parallel flow..................................................................................................... 28
Table 5.10: overall performance for counter flow ................................................................................................... 29

x
NOMENCLATURE

Q Volumetric flow rate (m3/sec)

μ Dynamic viscosity (kg/ms)

ρ Fluid density (kg/m3)

A Cross-sectional area (m2)

P Wetted perimeter (m)

DH Hydraulic diameter (m)

Nu Nusselt number

Red Reynolds number

Pr Prandtl number

v Fluid velocity (m/s)

𝞮 Effectiveness (%)

LTh Temp of hot fluid (0c)

LTc Temp of cold fluid (0c)

xi
 CHAPTER 1
INTRODUCTION

1.1 Background
The heat exchanger is a device which is used to transfer the thermal energy between two fluids
which are at different temperature. It mainly transmits the enthalpy or the thermal energy between
the two mediums. Among which one medium is cooled while the other end is heated.
In the early 1900s, to satisfy the requirements of power plants for large heat exchanger surfaces
such as condensers or feedwater heaters, the original structure of shell and tube heat exchangers
was introduced. A cylindrical shell with a bundle of tubes was present in these heat exchanges.
The tubes are made of thermally conductive materials that allow heat to be exchanged between the
hot fluids that flow outside the tubes and the coolant that flows through the tubes. In several
industries, particularly in refineries, shell and tube heat exchangers were widely used due to the
different advantages like efficiencies, size compact, etc. they provide over other heat exchangers
They are often used in space heating, cooling, air-conditioning, power plants, chemical plants,
refining of natural gas, cryogenic applications & treatments for sewage.

1.2 Problem Statement

The challenges that we met are as follows,
Table 1.1: Problem Statement
No Parameters Shell Tube

1 Fluid Type Water Water

2 Flow Velocity(m\s) 0.17 m\s 0.17 m\s

3 Inlet Temperature (K) 293 K 353 K

4 Material of Specimen Stainless Steel (SS) Aluminum (Al)

5 Flow Type Turbulent Turbulent

6 Turbulence Model K-epsilon Turbulence K-epsilon Turbulence

Model Model

1
1.3 Objectives
The main objectives of the present study are:

 To use a single tube heat exchanger with four different shapes of inner tubes having the
same peripheral area.
 To compare the convective heat transfer coefficient of the obtained & numerical values
through CFD simulations for different tubes.
 To compare the effectiveness of counter & parallel flow for different shapes of the tube.

At first, the intention was to do the project practically by making the setup in real life. But due to
the rise of the COVID-19 situation, the study was conducted through ANSYS simulation.

1.4 Scopes of this project

The project was aimed at finding out the convective heat transfer coefficient and the effectiveness
of a counter and parallel flow heat exchanger for various cross-sectional shapes of inner tubes
through CFD simulation.

2
 CHAPTER 2
LITERATURE REVIEW

2.1 Classifications of Heat Exchangers

The heat exchangers are often used in power generation application that requires heating or cooling
a large volume of fluids or gases. The Heat exchanger is classified based on the following
criteria:[1]

 According to the flow arrangements of fluid.

 According to the geometrical construction.
 According to the heat transfer process.

2.1.1 Flow Arrangements

According to their flow structure, heat exchangers are classified into two major terms. They are
counter-flow heat and parallel flow heat exchangers. The counter-flow heat exchanger is the most
efficient flow pattern between the two types. It leads to the lowest required heat exchanger surface
area cause the LMTD drop is the highest for a counter flow heat exchanger.

Figure 2.1: parallel and Counter Flow

3
LMTD means“ Log Mean Temperature Difference”.LMTD method could be used to determine
the overall heat transfer coefficient from experimental values using inlet and outlet temperatures
and their flow rates. With the inlet temperatures and the known value of the overall heat transfer
coefficient, the LMTD method is not suitable to determine the outlet temperature. In that case, the
effective NTU method is used to predict the outlet temperature.
On the other end, a double pipe heat exchanger can be worked in parallel flow mode. In roughly
parallel flow, a shell and tube heat exchanger can be controlled by making both fluids enter at one
end and exit at the other end. The temperature difference between the two fluids at the input end
is high with the parallel flow, but at the exit end, it becomes small as the temperature of the two
fluids reaches each other.

2.1.2 Geometrical Construction

According to the construction of geometry, heat exchangers are classified into four terms. They
are tabular, plate type, extended surface, and regenerative heat exchangers. Heat exchangers with
other constructions are also available as Shell and tube heat exchangers contain a series of the
tube and according to their shapes, these types of heat exchangers are used in the high-pressure
application.

2.1.3 Heat transfer Process

According to the heat transfer process, heat exchangers are classified into two patterns. They are
the direct contact type and indirect contact type. Heat transfer takes place in direct contact heat
exchangers between two immiscible fluids such as gas and liquid that come into close contact with
each other. For example, Cooling towers, water vapor jet condensers, and other vapors that use
water vapor.
On the other hand, the hot and cold fluids are separated in the indirect - contact form of heat
exchangers along with an exterior wall. There is no mixture of the two fluids. For example, an
Automobile radiator.

2.2 Basic Constructions of Shell and tube heat exchangers

Depending on the overall heat transfer coefficient and the output pressure drop performance, the
basic construction component of a shell and heat exchangers are given below,

Tubes: The core elements of a shell and tube heat exchangers are tubes. These tubes have a surface
for heat transfer between one fluid flowing within the tube and the other fluid flowing outside the

4
tube. Tubes with various diameters may be seamless or welded and most often made of alloys of
copper or steel.
Tube Bundles: Tube sheets and tubes consist of a tube bundle. Baffles and tie rods hold the bundle
of tubes together. With tube sheets that form the barrier between the tube and shell fluids, the tubes
are fixed. Ferrule and a soft metal packing ring may be used to fix the tubes with the tube board.
Shell: Shell is a shell-side fluid container including nozzles, inlet, and outlet ports. Here, the shell
usually has a circular cross-section and is generally made into a cylinder by rolling a metal plate
of suitable dimensions and welding the longitudinal joint and it is possible to build small diameter
shells by cutting the pipe to the correct length of the appropriate diameter.
Baffles: Baffles are mainly used to enhance the velocity of fluid by diverting the fluid flow to get
a better heat transfer coefficient across the tube bundles. The main functions of baffles are to
support the tubes in proper position during the operation period to avoid tube vibrations.

Figure 2.2: Heat Exchangers parts

2.3 Materials used for shell and tube heat exchangers

Based on the application criteria various materials are now used in the manufacturing process of
shell and tube heat exchanger. They are as follows:
 Titanium.
 Carbon Steel.
 Brass Alloys.
 Stainless Steel.
 Cupronickel Alloys.

5
But, Due to the lower corrosion-resistant application, Stainless Steel has become a widespread
alternative for the heat exchanger material. Here, in this project, we used stainless steel (SS) and
aluminum material for the same reason mentioned above.

2.4 Applications of Heat Exchangers

Applications of shell and tube heat exchangers in industries are as follows:

Table 2.1: Applications

No Industries Applications

1 Power Plants Pressurized water reactor in nuclear power plant,

Circuit cooling, radiators, oil coolers, heaters, and air
conditioners, electricity productions.

2 Foods and Beverage Heaters, cookers, food processing, preheating,

pasteurization of juices, milk fermentations

3 Pharmaceuticals Purifications of steam, water cooling, cryogenic

applications
4 Hydrocarbon processing Cooling of liquid hydrocarbons, preheating of
methanol
5 Marine Marine cooling systems, preheating of diesel fuel,
natural water distiller

2.5 Previous Research Activities

The heat exchangers are often used in power generation application that requires heating or cooling
a large volume of fluids or gases. From the above table, it is cleared that, the heat transfer process
is correlated in many industrial processes. In this project, Shell and Tube Heat exchanger is used
to estimate the heat transfer rate. There is a lot of research going on in this area, a few of them are
stated below,

6
 kakac, S.Sadik, and H.Liu et al.[2]: In this study, they have investigated the incompressible
turbulent flow of a fluid in a circular channel using CFD analysis. Experimentally \& numerically,
they did it in both cases by changing the circular channel with a series of conical hollows.
Compared to the traditional plain tube, a significant enhancement is found in the heat transfer from
the tube wall. They concluded that it is possible to achieve a better result by modifying the type of
inserts and position of installation.
Ender Ozden and Tari et al.[3]: In this paper, they have investigated the heat transfer coefficient
and pressure drop by modeling a tiny shell and tube heat exchanger. The effects of baffle spacing
on heat transfer and pressure drop are evaluated by considering two different baffle cut values.
Here, they performed a CFD analysis only on the shell side. Thus they compared this value with
the analytical one and concluded that a better argument can be obtained by the selection of baffle
cut.
Usman Ur Rehman et al.[4]: In this paper, through numerical modeling, he modeled an un-baffled
shell and tube heat exchanger to investigate the heat transfer coefficient and pressure drop. Here,
he claimed that his model can predict the heat transfer and the pressure drop with an average of
20\% error though it can be optimized by modifying this design either by decreasing the shell
diameter or by optimizing the tube spacing to get better results.

Kim, M.I., Lee, Y., Kim, B.W et al.[5]: In this paper, different shapes for a header type were
numerically studied to achieve the uniform distribution of gas-phase flow in the header of a shell-
and-tube heat exchanger. Here, the k-epsilon technique was adopted in numerical analysis and
found that, With header length, the uniformity of flow distribution increased, while it decreased
with the rate of gas flow. Besides, for a uniform distribution of a 1.3 m-length header, the optimal
position and shape of the inlet nozzle were suggested for a better argument.

Reza Amini, Mohsen Amini, Mehdi Kashfi et al.[6] In this paper, the thermal efficiency of a shell
and tube heat exchanger is numerically investigated under various conditions using ANSYS Fluent
and thus compared and checked with the value of the Bell-Delaware model. Finally, after changing
their design by adding helical tube fins it was thus found that the overall efficiency of a heat
exchanger was increased

7
 CHAPTER 3
METHODOLOGY

The methodology used for the analysis involves using the single tube heat exchanger and thus
comparing their corresponding values of effectiveness and convective heat transfer coefficient
with their theoretical ones. A simplified flow diagram explains the methodology of this study,

Figure 3.1: Methodology of this Project

8
 CHAPTER 4
DESIGN SPECIFICATIONS AND BOUNDARY
CONDITIONS

4.1 CALCULATION

The methodology adopted for the calculation of experimentation & theoretical evaluation of
overall heat transfer coefficient for shell & tube type heat exchanger for parallel & counter flow
arrangements are described in subsections 4.1.1, 4.1.2, 4.1.3, 4.1.4, 4.1.5

4.1.1 Calculation regarding the length of the tubes

We know, Nusselt Number, NuD = 0.023 x Re4/5 x Prn

Reynold’s Number, Re =ρ x V x d x 1
μ

Here, fluid density, ρ = 1000kg/m3

Diameter, d = 0.0381 m

Dynamic viscosity, μ=8.9 x 10-4 kg/m-s

Prandtl Number, Pr = 8 (From Appendix A.9)

n = 0.3 (For water to be cooled)

Radius, r = d/2

= 0.75 inch

= 0.01905 m

We know, volumetric flow rate, Q = A x V

Here, Q = 12 L/min
= 0.2 L/sec

= 0.0002 m3/sec

9
Area, A = ᴫ x r2 = 1.14 x 10-3 m2

V = Q/A =0.17 m/s

1
Again, We know, Nusselt Number, NuD =h x l x
k

Here, Conductive heat transfer, k =204 w/m-0c = 215 w/m-0k (For Aluminum @ 298k)

Here we have calculated various values of the convective co-efficient for various lengths.

[N.B: All the units are taken in SI units.]

4.1.2 Calculation regarding the hydraulic diameter

4𝐴
As we know, The hydraulic diameter, DH =
P
Where P = Wetted perimeter of the cross-section
A = Cross Sectional area of the flow

Circular tube:
4𝐴 2
DH = = 4𝜋𝑟 = 2r = d = 0.0381 m
𝑃 2𝜋𝑟
Square tube:
4𝐴 2
DH = = 4𝑎 = a = 0.0762m (where a is the arm length of the square)
𝑃 4𝑎

Triangle tube:
2√3⁄
DH = 4𝐴 =4𝑎 4
=
𝑎
= 0.1016m (where a is the arm length of the Triangle)
𝑃 3𝑎 √3

Hexagonal tube:
4𝐴 3√3⁄
2
DH = = 𝑎2 = √3 𝑎 = 0.051m (where a is the arm length of the Hexagonal)
𝑃 6𝑎 4

10
4.1.3 Calculation regarding the peripheral area of the tubes

All the shapes of the tubes have the same peripheral area, while the cross sectional area is
different.

For Tubes:
Here, we keep the same peripheral area for all four shapes of the tube. So the peripheral area is
constant here.
Circular:
Diameter, d = 1.5 Inch
So the peripheral Area = ᴫ X d = 4.713 Inch = 12 cm = 120 mm
Triangular: length per arm of triangle =12/3 cm = 4 cm =40 mm
Square: length per arm of square=12/4 cm = 3 cm = 30 mm
Hexagonal: length per arm of hexagon =12/6 cm = 2 cm = 20 mm

4.1.4 Calculation regarding the Reynolds Number of tubes

1
Circular: Reynold’s number, Re(Circular) = ρ x V x d x
μ

= 7277.53
1
Square: Reynold’s number, Re(Square) = ρ x V x a x
μ

= 14555.06
𝑎 1
Triangular: Reynold’s number, Re(Triangular) = ρ x V x x
√3 μ

= 11204.49
√3 1
Hexagonal: Reynold’s number, Re(Hexagonal) = ρ x V x 𝑎x
4 μ

= 4201.68

11
4.1.5 Calculation regarding the Nusselt Number of tubes

Circular:
Nusselt Number, NuD(Circular) = 0.023 x Re4/5 x Prn

=0.023 x (7277.53)4/5 x 80.3

= 52.75

Square:
Nusselt Number, NuD(Square) = 0.023 x Re4/5 x Prn

=0.023 x (14555.06)4/5 x 80.3

= 91.85

Triangular:
Nusselt Number, NuD(Triangular) = 0.023 x Re4/5 x Prn

=0.023 x (11204.49)4/5 x 80.3

= 74.50

Hexagonal:
Nusselt Number, NuD(Hexagonal) = 0.023 x Re4/5 x Prn

=0.023 x (4201.68)4/5 x 80.3

= 33.99≈34

Table 4.1: Reynolds and Nusselt number for four different shapes

Shapes Reynolds Number Nusselt Number

Circular 7277.53 52.75

Square 14555.06 91.85
Triangular 11204.49 74.50
Hexagonal 4201.68 34

12
4.2 GRAPHICAL REPRESENTATION FOR FINDING EXACT
LENGTH OF THE TUBE

The graph shown below is the graphical plot of convective heat transfer coefficient Vs length of
the tube. Where the length of the tube is plotted along the X-axis & convective heat transfer
coefficient along the Y-axis.

Figure 4.2.1: Convective heat transfer coefficient vs Length of tube graph

From this graph shown above, it can be seen that the convective heat transfer coefficient starts to
become lower and almost constantly linear at a length of 1.4 meters. So, this can be the optimum
length to get a temperature difference from the heat exchanger setup.

13
4.3 SOLIDWORKS DESIGN
Solidworks designs were made before making a practical setup. These are included in the report
to have an idea about how the setups may look in real life.

Figure 4.3.1: Heat exchanger with Circular tube (Top View)

Figure 4.3.2: Heat exchanger with Circular tube (Isometric View)

14
Figure 4.3.3: Heat exchanger setup with square tube

Figure 4.3.4: Heat exchanger setup with triangular tube

15
Figure 4.3.5: Heat exchanger setup with hexagonal tube

16
4.4 ANSYS GEOMETRY

Figure 4.4.1: Circular tube

Figure 4.4.2: Square tube

17
Figure 4.4.3: Triangular tube

Figure 4.4.4: Hexagonal tube

18
 Table 4.2: Heat Exchanger Dimensions
No Description Unit Dimension

1 Shell diameter(Circular for every setup) mm 76.20

2 Circular tube diameter mm 38.10
3 Square tube one arm length mm 76.20
4 Triangular tube one arm length mm 101.6
5 Hexagonal tube one arm length mm 50.8
6 Shell / Tube length mm 1400
7 The thickness for each shell and tube mm 2
8 Construction Material(shell) - Stainless steel
9 Construction Material(tube) - Aluminum

19
4.5 MESH

4.4.1 Mesh Data

Meshing is the most important part of a CFD analysis when it comes to the processing of a
geometry which needs to be divided into simple elements and these elements are used as discrete
local approximations of the larger domain. Fines mesh simulates the accuracy of the simulation.
Mesh data are necessary to examine the fineness of a mesh. In this particular simulation, 4
geometries were needed to mesh to get the ANSYS simulation. All the data related to the mesh
were generated in the post-processing and then exported.

Table 4.3: Mesh data for circular counterflow

Domain Nodes Elements

Coldwater domain 13140 8720
Hot water domain 16206 13952
Inner steel tube 8760 4360
Outer steel tube 8760 4360
All domains 46866 31392

Table 4.4: Mesh data for circular parallel flow

Domain Nodes Elements

Coldwater domain 13140 8720
Hot water domain 16206 13952
Inner steel tube 8760 4360
Outer steel tube 8760 4360
All domains 46866 31392

Table 4.5: Mesh data for Square counter flow

Domain Nodes Elements

Coldwater domain 27120 13440
Hot water domain 1013310 938964
Inner al tube 44000 32400
Outer steel tube 20064 9984
All domains 1080086 982692

20
 Table 4.6: Mesh data for Square parallel

Domain Nodes Elements

Coldwater domain 2712 1344
Hot water domain 8431 2021
Inner al pipe 2681 1803
Outer steel pipe 4680 2320
All domains 7644 3764

Table 4.7: Mesh data for Triangular counter

Domain Nodes Elements

Coldwater domain 1002478 942084
Hot water domain 137476 698379
Inner al tube 82718 43400
Outer steel tube 167552 85063
All domains 1390224 1768926

Table 4.8: Mesh data for Triangular parallel

Domain Nodes Elements

Coldwater domain 65939 56118
Hot water domain 15906 68799
Inner al tube 13488 6720
Outer steel tube 27168 13818
All domains 122501 145455

21
 Table 4.9: Mesh data for Hexagonal counter

Domain Nodes Elements

Coldwater domain 37356 27918
Hot water domain 268830 252586
Inner al tube 13488 6720
Outer steel tube 27168 13536
All domains 346842 300760

Table 4.10: Mesh data for Hexagonal parallel

Domain Nodes Elements

Coldwater domain 2941 1835
Hot water domain 3720 1845
Inner al tube 2520 1205
Outer steel tube 4680 2320
All domains 8946 4485

22
4.6 BOUNDARY CONDITIONS

Boundary conditions are set to analyze the simulation in ANSYS. It is necessary to adjust the
surrounding parameters to make the model. Mainly the temperatures, inlet velocity, and other
conditions are used to meet the criteria of making the model as per the experimental conditions.
This is done so that in the future, the practical values and the simulation values can be compared.

Table 4.11: Boundary conditions

Boundary Condition Shell Tube
type
Inlet Velocity-inlet 0.17 m/s 0.17 m/s
Outlet Pressure-outlet 0 0
Wall No-slip condition No heat flux Coupled
Temperature Inlet temperature 293 K 353 K
Turbulence Length scale 0.005 0.001

23
 CHAPTER 5
PERFORMANCE ANALYSIS

The performance analysis for the four shapes of the tube of the heat exchanger is done by obtaining
the average inlet and outlet temperatures of each of the tubes. The performance analysis explains
how the different shapes of tubes affect the exchanging of heat in the setups. Also, calculating the
effectiveness and the LMTD of the heat exchangers may help for further operations.

5.1 Average inlet and outlet temperature

Table 5.1: For circular shape and parallel flow, input and output temperatures

Cold input 293 K

Cold output 295.139 K
Hot input 353 K
Hot output 346.129 K

Table 5.2: For circular shape and counter flow, input and output temperatures
Cold input 293 K
Cold output 295.24028 K
Hot input 353 K
Hot output 346.51366 K

Table 5.3: For hexagonal shape and parallel flow, input and output temperatures
Cold input 293 K
Cold output 303.976 K
Hot input 353 K
Hot output 312.283 K

Table 5.4: For circular shape and counter flow, input and output temperature
Cold input 293 K
Cold output 295.50124 K
Hot input 353 K
Hot output 343.45246 K

24
Table 5.5: For square shape and parallel flow, input and output temperatures
Cold input 293 K
Cold output 303.24997 K
Hot input 353 K
Hot output 304.06792 K

Table 5.6: For square shape and counter flow, input and output temperatures
Cold input 293 K
Cold output 294.84059 K
Hot input 353 K
Hot output 343.43772 K

Table 5.7: For triangular shape and parallel flow, input and output temperatures
Cold input 293 K
Cold output 297.97657 K
Hot input 353 K
Hot output 328.5334 K

Table 5.8: For triangular shape and counter flow, input and output temperatures
Cold input 293 K
Cold output 295.14449 K
Hot input 353 K
Hot output 340.47298 K

25
 5.2 LMTD Calculation
Logarithmic mean temperature difference (LMTD) is determined to find the driving force of
temperature for a heat exchanger. It is found for most heat exchangers. It is the logarithmic average
between the temperatures of the hot and cold fluid domain. LMTD is different depending on the
flow type. That is why the formulas to obtain the LMTD are different for different flows.

For Parallel Flow,

(353−293)−(346.13−295.14) 60−50.99
LMTD(Circular) = 353−293 = 60 = 55.37 0C
ln[ ] ln( )
346.13−295.14 50.99

(353−293)−(304.07−303.25) 60−0.82
LMTD(Square) = 353−293 = 60 = 13.79 0C
ln[ ] ln( )
304.07−303.25 0.82

(353−293)−(328.53−293.98) 60−30.55
LMTD(Triangular) = 353−293 = 60 = 43.63 0C
ln[ ] ln( )
328.53−293.98 30.55

(353−293)−(312.28−303.98) 60−8.3
LMTD(Hexagonal) = 353−293 = 60 = 26.14 0C
ln[ ] ln( )
312.28−303.98 8.3

For CounterFlow,
(353−295.24)−(346.13−293) 57.76−53.513
LMTD(Circular) = 353−295.24 = 57.76 = 55.610C
ln[ ] ln( )
346.13−293 53.513

(353−294.84)−(343.44−293) 58.16−50.44
LMTD(Square) = 353−294.84 = 58.16 = 54.21 0C
ln[ ] ln( )
343.44−293 50.44

(353−295.5)−(343.45−293) 57.5−50.45
LMTD(Hexagonal) = 353−295.5 = 57.5 = 53.9 0C
ln[ ] ln( )
343.45−293 50.45

(353−295.15)−(340.47−293) 57.85−47.47
LMTD(Triangular) = 353−295.15 = 57.85 = 52.49 0C
ln[ ] ln( )
340.47−293 47.47

26
5.3 Effectiveness Calculation
In the most general way, the effectiveness of a heat exchanger is expressed as,

∆T(minimum Fluid)
Effectiveness, =
Maximum temp difference in the heat exchanger

Here, Minimum Fluid = The fluid experiencing the larger temperature difference

Maximum temperature Difference = Difference in inlet temperatures of the hot and cold fluid

5.3.1 Circular Shape

For Circular parallel flow, Minimum fluid = hot fluid

353−346.13
So, Effectiveness, (Circular Parallel) = = 0.1145 ≅ 11.45%
353−293

For Circular Counter flow, Minimum fluid = hot fluid

353−346.51
So, Effectiveness, (Circular Counter) = ≅ 10.82%
353−293

5.3.2 Square Shape

For Square parallel flow, Minimum fluid = hot fluid

353−304.07
Effectiveness, (Square Parallel) = ≅ 81.55%
353−293

For Square Counter flow, Minimum fluid = hot fluid

353−343.44
Effectiveness, (Square Counter) = ≅ 15.93%
353−293

27
5.3.3 Triangular Shape

For Triangular parallel flow, Minimum fluid = hot fluid

353−328.53
Effectiveness, (Triangular Parallel) = ≅ 40.78%
353−293

For Triangular counter flow, Minimum fluid = hot fluid

353−340.47
Effectiveness, (Triangular Counter) = ≅ 20.88%
353−293

5.3.4 Hexagonal Shape

For Hexagonal parallel flow, Minimum fluid = hot fluid
353−312.28
Effectiveness, (Hexagonal Parallel) = ≅ 67.87%
353−293

For Hexagonal counter flow, Minimum fluid = hot fluid

353−343.46
Effectiveness, (Hexagonal Counter) = ≅ 15.9%
353−293

5.4 Overall Analysis

Table 5.9: Overall performance for Parallel flow

Shape of tube Effectiveness (%) LMTD
Circular 11.45 55.37
Square 81.55 13.79
Hexagonal 67.87 26.14
Triangle 40.78 43.63

28
 Table 5.10: Overall performance for Counter flow
Shape of tube Effectiveness (%) LMTD
Circular 10.82 55.61
Square 15.93 54.21
Hexagonal 15.90 53.9
Triangle 20.88 52.49

So, the analysis shows the performance of each shape of the tubes. It just goes to show that for
counter flow, the effectiveness is comparatively less. While, for the parallel, the effectiveness
is higher. And the values of LMTD vary more for the counter flow rather than the parallel
flow.

29
 CHAPTER 6
RESULTS AND DISCUSSION

6.1 Temperature contours

The temperature distribution along the heat exchanger can be manifested through the side view on
the symmetry plane. For counter and parallel flow, 2 contour plots were generated for each of the
shapes of the tubes. All the plots were generated on the plane that was taken on the symmetry of
the setup. These plots show the temperature drop in the tube part, while temperature gain at the
shell part. All of the plots were taken at the Y-Z axis.

6.1.1 Contour plots for the circular shape

Figure 6.1: Temperature contour plot for circular at symmetry (for parallel flow)

30
 Figure 6.2: Temperature contour plot for circular at symmetry (for counter flow)

6.1.2 Contour plots for the square shape

Figure 6.3: Temperature contour plot for the square at symmetry (for parallel flow)

31
Figure 6.4: Temperature contour plot for the square at symmetry (for counter flow)

6.1.3 Contour plots for the triangular shape

Figure 6.5: Temperature contour plot for the triangle at symmetry (for parallel flow)

32
Figure 6.6: Temperature contour plot for the triangle at symmetry (for counter flow)

6.1.4 Contour plots for the hexagonal shape

Figure 6.7: Temperature contour plot for hexagon at symmetry (for parallel flow)

33
Figure 6.8: Temperature contour plot for hexagon at symmetry (for counter flow)

6.2 Temperature Vs Length Graph

Total 8 graph plots were generated for finding the temperatures against the length of the tube for
the four shapes of the tubes. Also, it was done for both the parallel and counter flow. At first, a
line was taken on the symmetrical plane of the cold fluid domain and another line on the hot
fluid domain along the length of each setup. Then two charts were generated for each of the
setup and flow types in ANSYS. Then, for the charts, the values of temperatures at a specific
distance along the length of the pipes were exported to the windows as excel files. Thus, the
values were put in the Excel file to generate the graph plots. These plots include the temperature
curve along the length for the cold fluid and hot fluid in the same graph at a specific line on the
symmetric plane of the geometry. The curves represent the temperature drop in hot fluid and the
temperature gain for the cold fluid.

34
6.2.1 Graphs for the circular shape

Figure 6.9: Shell and tube side temperatures for circular shape along the length of the setup.
(Parallel flow)

35
Figure 6.10: Shell and tube side temperatures for circular shape along the length of the setup. (Counter
flow)

6.2.2 Graphs for the square shape

Figure 6.11: Shell and tube side temperatures for square shape along the length of the setup.
(Parallel flow)

36
Figure 6.12: Shell and tube side temperatures for square shape along the length of the setup.
(Counter flow)

6.2.3 Graphs for the triangular shape

Figure 6.13: Shell and tube side temperatures for triangular shape along the length of the setup.
(Parallel flow)

37
Figure 6.14: Shell and tube side temperatures for triangular shape along the length of the setup. (Counter
flow)

38
6.2.4 Graphs for the hexagonal shape

Figure 6.15: Shell and tube side temperatures for hexagonal shape along the length of the setup.
(Parallel flow)

Figure 6.16: Shell and tube side temperatures for hexagonal shape along the length of the setup. (Counter
flow)

39
 CHAPTER 7
CONCLUSION

In this project, CFD models were developed successfully for each of the four shapes. With the
results that came onto the surface, later on, it is evident that heat exchanging is quite different
for the other shape of the tubes rather than the circular one. When the performances were
analyzed, it was seen that the square tube for the parallel flow shows the best result in terms of
effectiveness. While circular-shaped tubes are the most common, square- shaped tubes show
good results. Also, the hexagonal, triangle-shaped tubes brought some as well. The study was
initially meant to be a practical one, but later, due to the COVID 19 situation, ANSYS simulations
were done using ANSYS 2019 R3. In the future, this study has some lucrative scopes. This study
can be carried out practically to compare the results. Also, many other shapes of tubes, like an
octagon, can be used to test the heat transfer. Also, the fluid domain used in this experiment
was of water, while various other fluids can be used for the different shapes of the tubes to see
how they perform. The geometry was a simplified one. More complex geometries including
baffles can be tested as well. Also, only temperature analysis was done during the project.
There can be more analysis of the pressure in near future. So, indeed, this CFD analysis can
prove to be helpful for some future studies, both in real life and simulation.

40
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