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Author Name Giribabu

Title 2111
Paper/Submission ID 708812
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Total Pages 81
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60 Design and performance of a car radiator using Gd CeO2 and ZnO N By Student Paper
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61 Heat transfer and pressure drop studies on a PCM-heat exchanger module Publication
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106 redcol.minciencias.gov.co Publication

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107 Thermal-Hydraulic Analysis of the EU DEMO Helium-Cooled Pebble Publication

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51
DESIGN AND FINITE ELEMENT ANALYSIS OF SHELL & TUBE
HEAT EXCHANGER USING NANO FLUIDS
5
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)
74
MALLA REDDY COLLEGE OF ENGINEERING & TECHNOLOGY
Department of mechanical Engineering
5
(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
74 5
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
FiniteElement Analysis of Shell & Tube Heat Exchanger Using Nano Fluids” submitted by
5
PADAMATINTI GIRIBABU (H.T.NO 18N31D2111), of M.Tech in the partial
116
fulfillment forthe 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

5
Internal Guide Head of the Department
External Examiner
109
DECLARATION
5
I hereby declare that the major project titled “Design and Finite Element Analysis of Shell
5
& 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 madeelectronically 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 theDepartment 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 duringthe 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
15
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
1.5.2 Chemical Properties 13
1.6 Zi O(ZnO) Nanoparticles 14
1.6 2 Chemical Properties 14
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
1.7.4 Nano Fluid Calculations for Zinc Oxide 20
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
47
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
95
CHAPTER V THERMAL ANALYSIS OF SHELL AND TUBE
HEAT EXCHANGER 55-62
4
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

15
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
126
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
4
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
122 4
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
Figure 6.3 Comparison of Total Heat transfer rate between three nano fluids at
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

16
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
30
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
21
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)
µ w = Viscosity of fluid (water) (poise)
µ nf = 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
72
DESIGN AND FINITE ELEMENT ANALYSIS OF SHELL & TUBE HEAT
EXCHANGER USING NANOFLUIDS
ABSTRACT
23
Shell and tube heat exchangers are a popular choice for transferring heat in
various industrial processes. These heat exchangers offer a cost-effective design and
are capable of transferring large amounts of heat. They provide a significant amount
of effective tube surface while minimizing the need for floor space, liquid volume,
and weight. With the advancement of modern nanotechnology, the use of nanofluids
123
has become increasingly popular in recent years. Nanofluids consist of nanoparticles
with sizes less than 100 nm, which are dispersed in base liquids. This technology
23
offers an alternative to traditional micrometer-sized particles, providing enhanced
heat transfer properties.
The focus of this thesis is to conduct analytical investigations on the use of
shell and tube heat exchangers for forced convective heat transfer. Specifically, the
16
goal is to determine the flow characteristics of various nanofluids, including Zinc
Oxide, Titanium Oxide, and Titanium Nitride nanofluids mixed with water at
different volume concentrations (0.02, 0.04, 0.07, and 0.15) % under turbulent flow
conditions.
Thermal and CFD analysis will be performed on the heat exchanger using
theoretical calculations to determine the properties of the nanofluids with varying
volume fractions. The 3D model of the heat exchanger will be created using
139
Pro/Engineer, and the analysis will be carried out using Ansys. The materials
21
considered for the shell and tube heat exchanger are Aluminum and Copper.
xii
CHAPTER I
26
INTRODUCTION TO HEAT EXCHANGER
1. INTRODUCTION
16
A heat exchanger is a device designed to transfer energy from a hot fluid medium
to a cold fluid medium while ensuring maximum efficiency, minimal investment,
28
and low running costs. The use of nano fluid in heat exchangers involves the
transfer of heat through a fluid containing suspended nano particles. These
particles can be added to various fluids such as water, ethylene glycol, oil,
hydrocarbons, and fluorocarbons. The working fluid in a nano fluid heat
exchanger is the nano fluid itself.
1.1.1 of Heat Exchanger
During the 1950s, the automobile industry saw the introduction of aluminum heat
exchangers, which made moderate progress with the invention of vacuum brazing
73
techniques. Large-scale production of aluminum-based heat exchangers increased
14
as a result of the controlled atmosphere brazing process (Nocolok brazing process)
introduced by ALCAN. Over the years, the performance characteristics of
aluminum heat exchangers were further improved by the introduction of "long-
life" alloys that were highly resistant to corrosion. The growth of automobile air-
conditioning systems mainly contributed to the increased demand for aluminum
heat exchangers.
26
1.1.2 About Heat Exchanger
Heat exchangers are devices in which heat is transfer from one fluid to
40 10
another. The most commonly used type of heat exchanger is a shell-and-tube
heat exchanger. use of shell-and-tube heat exchangers has led to their
development for various applications. These heat exchangers consist of a shell
16 24
with a bundle of tubes inside. One fluid flow inside the tubes while the other
30
fluid flows over the tubes in the shell. The fluids can be either liquids or gases.
24
The design of a shell-and-tube heat exchanger depends on the specific
77
application and the desired performance characteristics, such as heat transfer
rate, pressure drop, and material compatibility. The materials used in the
24
construction of the heat exchanger can also vary depending on the fluids being
used and the operating conditions. As technology continues to advance, the
48 53
design of shell-and-tube heat exchangers will continue to evolve to meet the
needs of various industries. The development of heat exchangers can be traced
13
back to the early 1900s when the oil industry began to demand more efficient
heat transfer systems. As the use of shell-and-tube heat exchangers grew,
researchers focused on improving the accuracy of performance prediction for
various process conditions. This included calculations of true mean temperature
difference and strength calculations of construction elements, such as tube
sheets. The aim of this thesis is to create a design algorithm and optimization
procedure for a shell-and-tube exchanger, where the exchanger geometry is
determined by required performance for fixed pressure drops. To effectively
consider allowable pressure drops, a quantitative relationship must first be
established between velocity, friction factors, pressure drop of the stream, and
96
the number of transfer units. The heat transfer in a heat exchanger involves
53 24
convection on each side of the fluid and conduction through the wall separating
the two fluids. As fluids pass through the tubes, their temperatures change, and
111
the temperature of the dividing wall also varies along the length of the 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,
23
2. Non-contact type of heat
exchanger.
Direction of motion of fluid:

1. Parallel flow,
2. Counter flow
3. Mixed flow.
14
1.2 SHELL AND TUBE HEAT EXCHANGER
26 40
The shell and tube heat exchanger is a widely used type of heat exchanger design,
particularly in large chemical processes and oil refineries that require high
26
pressure and temperature capabilities. This type of heat exchanger consists of a
107
shell, which is a large pressure vessel, containing a bundle of tubes inside. The
133 21
heat transfer occurs between two fluids, with one fluid running through the tubes
24 30
and the other fluid flowing over the tubes through the shell. The set of tubes is
known as a tube bundle and may be comprised of various types of tubes, such as
plain or longitudinally finned tubes.
23
Fig. 1.1 Shell and Tube heat exchanger
62
A heat exchanger is an apparatus designed for the purpose of transferring heat
26
from one fluid to another, while keeping them separated by a solid wall to prevent
mixing. These devices are utilized in a variety of applications, including
39
refrigeration, air conditioning, space heating, power production, and chemical
21 39
processing. A familiar example of a heat exchanger is the radiator in a car, where
the flow of air over the radiator surface cools the hot radiator fluid.
1.2.1 Theory and Application

24
Heat exchangers facilitate the transfer of heat between two fluids that have
40
different starting temperatures. One fluid flows through the tubes (the tube side),
10
while 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
15
30
to shell side or vice versa. Both liquids and gases can flow on either the shell or
10
the tube side. Using a large heat transfer area with many tubes is an effective way
to transfer heat efficiently and to conserve energy.
Heat exchangers with only one phase (liquid or gas) on each side are called one-
phase or single-phase heat exchangers. Two-phase heat exchangers can be utilized
to heat a liquid and boil it into a gas (vapor), also known as boilers, or to cool a
vapor and condense it into a liquid, called condensers, with the phase change
generally occurring on the shell side. In steam engine locomotives, boilers are
typically large, cylindrical 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
then recycled back to be turned into steam in the steam generator.
23
1.2.2 Shell and tube heat exchanger Types
16
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
26 85
The Shell and Tube heat exchangers are widely used in various industries such as
process, petroleum, chemical, and HVAC. They are designed with a number of
40
parallel U-tubes inside a shell. These heat exchangers are ideal for processes that
72
require a large volume of fluid to be heated or cooled, as they provide a high heat
105
transfer efficiency due to their large heat transfer area. Steam generators, which
are used in nuclear power plants, are examples of two-phase, shell-and-tube heat
73
exchangers that typically have U-tubes. In most cases, shell-and-tube heat
48
exchangers are designed with 1, 2, or 4 passes on the tube side, which refers to the
21
number of times the fluid in the tubes passes through the fluid in the shell. Single
pass heat exchangers have the fluid going in one end of each tube and out the other,
while surface condensers in power plants are often 1-pass straight-tube heat
exchangers. Two and four pass designs are more common as they allow the fluid
16
to enter and exit on the same side, simplifying the construction process..
Fig. 1.2 U- Tube Heat Exchanger
1.2.2.2 Straight-Tube 1-pass
Fig. 1.3 Straight tube heat Exchanger (1-pass)
Fig. 1.4 Straight tube heat Exchanger (2 -pass)
17
26
One-pass heat exchangers are typically less efficient than multi-pass heat
exchangers due to their limited heat transfer surface area. Baffles are often used to
89
direct fluid flow and prevent short-circuiting, which can reduce heat transfer
efficiency. Counter-current flow is the most efficient arrangement, as it allows for
24
the largest temperature difference between the two fluids, resulting in greater heat
121
transfer rates. However, multi-pass heat exchangers are often preferred over
61
single-pass designs because they provide more heat transfer surface area and are
30
less susceptible to failure. Multiple heat exchangers can also be used in parallel or
series to achieve similar performance as a single, larger heat exchanger.
1.2.2.3 Straight-Tube 2-pass
Additionally, baffles help to increase the heat transfer coefficient by creating

61
turbulence, which promotes better mixing and distribution of the fluid. This is
135
important because a higher heat transfer coefficient means that the heat exchanger
can transfer heat more efficiently, leading to better performance and lower energy
costs.
23
Another design feature of shell and tube heat exchangers is the type of tube bundle
used. Tube bundles can be arranged in different patterns, such as in-line, rotated
square, or triangular, to provide different levels of turbulence and improve heat
transfer efficiency. Tube bundles can also be composed of different types of tubes,
30
such as plain or finned tubes, to increase the heat transfer surface area and improve
performance.
1.2.3 Selection of tube material
23
The selection of tube material is critical to ensure efficient and safe heat transfer in
a shell and tube heat exchanger. In addition to the requirements you mentioned,
48
tube material should also be able to withstand any potential fouling or scaling that
76
may occur from the fluids passing through them. Commonly used tube materials
79
include copper, stainless steel, titanium, and nickel alloys, each with their own
advantages and limitations. It's important to carefully consider the process
conditions and fluid properties when selecting the appropriate tube material for a
given application.
18
1.3 NANO FLUID
1.3.1 Introduction to nano fluid
83
Nano fluids exhibit improved thermal properties such as higher thermal
conductivity, heat transfer coefficients, and heat capacity compared to traditional
heat transfer fluids. These properties are due to the unique behavior of
nanoparticles at the nanoscale level, such as increased surface area and Brownian
132 70
motion. The improved thermal properties of nano fluids can lead to more efficient
and compact heat exchangers, which can result in energy savings and reduced
environmental impact.
Research on nano fluids is still ongoing, and further investigation is needed to fully
understand their properties and behavior. However, the potential benefits of using
137
nano fluids in heat transfer applications make them an exciting area of research
14
for future developments. 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 the
heat conduction mechanism.
28
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, theyare 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.
19
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.
1.3.2 Preparation of nano fluid

131
The Nano fluids are a type of liquid that contains suspended nanoparticles with a
16 119
critical dimension smaller than ~100nm. This material has attracted significant
62
research interest in recent years due to its unique properties and behavior,
23
particularly in relation to heat and mass transfer. Nano fluids have the potential to
76
revolutionize heat transfer, which is of great importance to a variety of industries,
10
including transportation, power generation, manufacturing, and more. They can
21
also be used in the production of nanostructured materials, complex fluids
engineering, and even in cleaning oil from surfaces due to their excellent wetting
and spreading behavior. The preparation of nano fluids involves dispersing metal,
oxide, carbide, or carbon nanotube particles into heat transferring fluids using
90
stabilizing agents. Nanoparticles can be produced using various methods, such as
gas condensation, mechanical attribution, or chemical precipitation, but the direct
evaporation-condensation method is preferred for producing stable nano fluids
without surfactants or electrostatic stabilizers, although it can result in the
oxidation of pure metals and low vapor pressure fluids.
20
2
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
103
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
58
nanofluids. Zhu et al [7] also used one-step pure chemical synthesis method for
preparing nanofluids using copper nano particles dispensed in ethylene glycol.
117 2
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
1.3.3 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

nanofluid 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,
21
pharmaceuticals, electronics, optics, etc. This article deals with the properties and
17
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

27
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 4s2Carbon [He]
configuration 2s2 2p2
Element Content (%)
Chemical composition Titanium 79.9
carbon 1
20.3
1.4.3 Physical Properties

58
Titanium carbide nanoparticles appear in the form of a black powder having a
2
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
22
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
17
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

88
1.5.1 Introduction
Nanoparticle research has become an area of interest to scientists due to the

2
unexpected results produced by altering the atomic and molecular properties of
elements. This article deals with the properties and applications of titanium nitride
nanoparticles.
27
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.
17 33
Titanium belongs to Block D, Period 4 while nitrogen belongs to Block P, Period
2 of the periodic table. Someof 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.
23
27
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 4s2Nitrogen [He]
configuration
2s2 2p3
Element Content (%)
Chemical composition Titanium 77.4
Nitrogen 22.6

58
Titanium nitride nanoparticles appear in the form of a brown powder having
2
a sphericalsurface area. The table below provides the physical properties of
these nanoparticles.
Properties Metric
Density 5.24 g/cm3
Molar Mass 61.87 g/mol
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
24
1.5.5 Applications
Given below are some of the chief applications of titanium nitride.

84
• 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
2
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.
108 2
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.
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
25
The table given below highlights the physical properties of zinc oxide nanopowders.
Properties Metric
Density 5600
kg/m3
Molar 81.40 g/mol
Mass
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 usedin 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.
26
1.7 CALCULATIONS TO DETERMINE PROPERTIES OF NANO
FLUID BYCHANGING VOLUME FRACTIONS
1.7.1 Nomenclature
ρ nf =
Density of nano
fluid(kg/m3)ρs = Density of
solid material (kg/m3)
ρ w = 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)
µ w = Viscosity of fluid (water)(poise)
µ nf = 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

ρ nf = 0.02×4930 + [(1-0.02)×998.2]
1076.836 kg/m3
ρ nf =
VOLUME
FRACTION 0.04
ρ nf = 0.04×4930 + [(1-0.04)×998.2]
1155.472 kg/m3
ρ nf =
VOLUME
FRACTION 0.07
ρ nf = 0.07×4930 + [(1-0.07)×998.2]
1273.426 kg/m3
ρ nf =
VOLUME
27
FRACTION 0.15
ρ nf = 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
µ nf = 1.05315×10-

3poise Ф =0.04
At
µnf = 1.1033×10-3
poiseAt
Ф =0.07
µ nf = 1.178525×10-
3 poiseAt
Ф =0.15
µ nf = 1.379125×10-3 poise
28
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-kAt
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

ρ nf =
Ф×ρs + [(1-Ф) × ρw]

ρ nf = 0.02×5240+ [(1-0.02)×998.2]
1083.036 kg/m3
ρ nf =
VOLUME
FRACTION 0.04
ρnf = 0.04×5240 + [(1-0.04)×998.2]
1167.872 kg/m3
ρ nf =
VOLUME
FRACTION 0.07
ρ nf = 0.07×5240+ [(1-0.07)×998.2]
29
1325.072 kg/m3
ρ nf =
VOLUME
FRACTION 0.15
ρ nf = 0.15×5240+ [(1-0.15)×998.2]
ρ nf = 1744.272 kg/m3
Cp nf =
At Ф =0.02
Cp nf = 3835.55316
J/kg-kAt
Ф =0.04
Cp nf = 3539.4391
J/kg-kAt
Ф =0.07
Cp nf = 3168.005
J/kg-kAt
Ф =0.15
Cp nf = 2460.2749 J/kg-k
µnf =µw (1+2.5Ф)
At Ф =0.02
µnf = 1.05315×10-
3 poiseAt
Ф =0.04
µnf = 1.1033×10-3
poiseAt
Ф =0.07
µ nf = 1.178525×10-
3 poiseAt
Ф =0.15
µnf = 1.379125×10-3 poiseThermal
Conductivity of Nano Fluid
30
Knf = × kw
At Ф =0.02
Knf = 0.6447
W/
m-kAt
Ф =0.04
Knf = 0.69182
W/m-kAt
Ф
=0.07
Knf = 0.7671
W/m-kAt
Ф
=0.15
Knf = 1.00057 W/m-k
1.7.4 Nano Fluid Calculations for Zinc Oxide

55
ρnf = Ф×ρ s + [(1-Ф) × ρ w ]

1091.736 kg/m3
ρ nf =
VOLUME
FRACTION 0.04
2175.27 kg/m3
ρ nf =
VOLUME
FRACTION 0.07
1325.576 kg/m3
ρ nf =
VOLUME
FRACTION 0.15
ρ nf = 2550.97 kg/m3
31
Cp nf =
At Ф =0.02
Cp nf =
3798.58
J/kg-kAt
Ф
=0.04
Cp nf = 3475.68
J/kg-kAt
Ф
=0.07
Cp nf = 3076.77
J/kg-kAt
Ф
=0.15
Cp nf = 2334.98 J/kg-k
µnf =µw (1+2.5Ф)
At Ф =0.02
µ nf = 1.05315×10-

3poiseAt
Ф =0.04
µnf = 1.1033×10-3
poiseAt
Ф =0.07
µ nf = 1.178525×10-
3 poiseAt
Ф =0.15
µ nf = 1.379125×10-3 poise
60
1.7.4.4 Thermal Conductivity of Nano Fluid
Knf = × kw
32
At Ф =0.02
Knf = 0.6447
W/
m-kAt
Ф =0.04
Knf = 0.69182
W/m-kAt
Ф
=0.07
Knf = 0.7671
W/m-kAt
Ф
=0.15
Knf = 1.00057 W/m-k
6
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
0.15 1.0005 2460.2749 1744.27 1.379125×10

7 2 -3
33
Table 1.3 Zinc oxide nano fluid properties
Volume Therma Specific Density Viscosity

l
Fractio 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
34
CHAPTER II
LITERATURE REVIEW
82
2.1 INTRODUCTION
41
Various researchers have conducted studies on the use of nanofluids in shell and
6
tube heat exchangers to improve their performance. For instance, Prof. Alpesh
Mehta et al. [29] investigated the use of nanofluids in improving the performance
32
of STHE. Jaafar Albadr et al. [30] carried out an experimental study on the flow
6
characteristics and forced convective heat transfer of nanofluids consisting of
water and varying volume concentrations of Al2O3 nanofluid in a horizontal shell
and tube heat exchanger counter flow. Wang et al. [10], Lee et al. [11], Wang et
75
al. [12], and Koo and Kleinstreuer [13] conducted analytical and experimental
32
studies that revealed that nanofluids have higher thermal conductivity than pure
138 129
fluids, which makes them suitable for heat transfer enhancement. The researchers
also found that factors such as Reynolds number, particle size and shape, and
54
particle volume fraction affected the heat transfer coefficient. In addition,
Donsheng and Yulog [17] studied the convective heat transfer of nanofluids made
up of ã-Al2O3-water, while Seok and Choi [18] investigated the cooling
140
performance of micro channel heat sink with nanofluids. Joescon and Issam [19]
performed experiments to explore the micro channel cooling benefits of Al2O3-
67
water nanofluid. Mushtaq et al. [20] investigated the effect of channels geometry
43
on the performance of counter flow micro channel heat exchanger. Finally,
6
Mushtaq I. Hasan [21] numerically investigated the performance of counter flow
micro channel heat exchanger with MEPCM suspension as a cooling fluid. To
model nanofluids, they are treated as a single-phase type of fluid, given that the
particles are ultrafine and easily fluidized, and their particle volume fraction is
43
usually low. The studied counter flow micro channel heat exchanger with square
channels was used as a model figure to represent the complete counter flow micro
channel heat exchanger, as it provides an adequate indication about the
performance, and heat is transferred from the hot to cold fluid through a thick wall
medium separating both fluids, due to the geometrical and thermal symmetry
between the hot and cold channels rows. fluids
60
2.1 Compact Heat Exchanger Using Nano Fluid
35
127
The necessity of compact heat exchangers (CHEs offer several advantages
92
over conventional heat exchangers, including a higher heat transfer rate per unit
68
volume, smaller footprint, lower weight, and reduced material usage. These
benefits translate into cost savings in terms of both capital and operating expenses.
In addition to their traditional applications in aerospace, automobile, and

gas turbine power plant industries, CHEs are also finding new applications in areas
such as renewable energy, chemical processing, and electronics cooling. For
134
example, CHEs are being used to improve the efficiency of solar thermal
113
collectors, to recover waste heat from industrial processes, and to cool high-power
electronics.
99
Overall, the increasing demand for energy efficiency and cost savings in
59
industrial processes is driving the growth of the CHE market. As new technologies
and materials are developed, the performance and versatility of CHEs are expected
to continue to improve, further expanding their range of applications.
6
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
87
Nano fluids are a promising area of research in the field of heat transfer and
thermal management. The goal is to improve the thermal properties of a fluid by
35
suspending metallic nanoparticles, such as copper or aluminum, in the fluid. This
is because the thermal conductivity of metallic solids is typically much higher than
54 32
that of fluids. By suspending the nanoparticles in the fluid, the effective thermal
conductivity of the mixture is expected to increase.
36
The use of nano fluids can provide significant benefits in a range of
applications, including cooling of electronics and machinery, heat exchangers, and
solar energy systems. However, it is important to ensure that the nanoparticles are
uniformly dispersed and stably suspended in the fluid, as settling can reduce the
effectiveness of the nano fluid.
The concentration of nanoparticles in the fluid is also important, as higher

concentrations can lead to increased viscosity and potential clogging of pipes or
channels. Ideally, concentrations of less than 1% by volume are preferred, with
nanoparticles less than 10 nm in size.
102
Overall, nano fluids have shown great potential for improving thermal
management in a range of applications, and research in this area is ongoing.
6
RESEARCH GAP & PROBLEM DESCRIPTION
In the thesis, the shell and tube heat exchanger are taken in the water with various
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.
100
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.
37
CHAPTER III
INTRODUCTION TO MECHANICAL SOFTWARE
49
3.1 INTRODUCTION TO CAD
Computer-aided design (CAD), also known as computer-aided design and
drafting (CADD). CAD, or computer-aided design, is a technology that uses
computer software to aid in the design and documentation of various objects,
35 98
structures, and systems. It has a wide range of applications in various industries,
including automotive, aerospace, architecture, and manufacturing. The software
used in CAD provides input tools for streamlining the design process, including
136
drafting, documentation, and manufacturing. The output of CAD is typically in the
75 69
form of electronic files that can be used for printing or machining operations.
CAD software can be used to design objects in two-dimensional or three-

dimensional space, including curves, surfaces, and solids. The software can also
25
allow rotations in three dimensions, allowing users to view a designed object from
any desired angle, including the inside looking out. Some CAD software is capable
of dynamic mathematical modeling, allowing for more advanced design
capabilities.
CAD has been a major driving force for research in computational geometry,
computer graphics, and discrete differential geometry due to its economic
importance. Current CAD software ranges from 2D vector-based drafting systems
to 3D solid and surface modelers, with some software marketed as computer-aided
design and drafting (CADD) due to its dynamic mathematical modeling
capabilities.
Overall, CAD is an important industrial art that has revolutionized the way objects,
8
structures, and systems are designed and created.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
38
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 qualityto 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.
34
3.1.1 Pro/Engineer Wildfire Benefits
• Unsurpassed geometry creation capabilities allow superior product
differentiation and manufacturability
8
• Fully integrated applications allow you to develop everything from
concept to manufacturing within one application
34
• Automatic propagation of design changes to all downstream deliverables
allows you to design with confidence
8
• Complete virtual simulation capabilities enable you to improve product
performance and exceed product quality goals
34
• Automated generation of associative tooling design, assembly instructions,
8
and machine code allow for maximum production efficiency
3.1.2 Different Modules in Pro/Engineer
➢ PART DESIGN
➢ ASSEMBLY
➢ DRAWING
➢ SHEETMETAL
39
3.2 INTRODUCTION TO FEA
Finite Element Analysis (FEA) is a powerful tool in the field of engineering and
is widely used in many industries. It allows engineers and designers to test and
optimize their designs without the need for physical prototyping, which can save
41
time and money. FEA can be used to simulate a wide range of physical
phenomena, including structural, thermal, fluid, and electromagnetic behavior. By
accurately modeling these phenomena, FEA can help engineers to optimize their
designs for maximum performance and reliability.
81
In addition to its use in product design and optimization, FEA is also used in failure
41
analysis and forensic investigations. When a product or structure fails, FEA can
be used to determine the cause of the failure and to develop recommendations for
preventing similar failures in the future.
59
While FEA has many benefits, it is important to note that it is only a tool and not
35
a substitute for engineering judgment and experience. Engineers must still have a
thorough understanding of the principles of physics and mechanics in order to
properly interpret FEA results and make informed design decisions. Additionally,
FEA is only as accurate as the input data and assumptions used in the model.
Careful attention must be paid to the selection of material properties, boundary
conditions, and other inputs in order to ensure that the FEA model accurately
reflects the real-world behavior of the system being analyzed.
8
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
examplesare shown:
• Point, pressure, thermal, gravity, and centrifugal static loads
• Thermal loads from solution of heat transfer analysis
• Enforced displacements
40
• Heat flux and convection
12 19
• 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:
45 37
• Rod elements
• Beam elements
• Plate/Shell/Composite elements
• Shear panel
• Solid elements
• Spring elements
• Mass elements
• Rigid elements
• Viscous damping elements
Many FEA programs also are equipped with the capability to use multiple
3
materialswithin the structure such as:
• Isotropic, identical throughout
41
• Orthotropic, identical at 90 degrees
19
3.2.1 General anisotropic, different throughout Types of Engineering Analysis
12
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 important for testing the durability and reliability of a
45
material or structure against random vibrations, shock, and impact. Fatigue
12
analysis, on the other hand, helps designers predict the lifespan of a material or
104
structure under cyclic loading, and can identify areas where cracks are likely to
form and propagate, ultimately leading to failure.
52 45
Heat Transfer analysis models the conductivity or thermal fluid dynamics of
12
the materialor 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.
19
3.2.2 Results of Finite Element Analysis
12
FEA has become a solution to the task of predicting failure due to unknown
52
stresses byshowing problem areas in a material and allowing designers to
12
see all of the theoreticalstresses within. This method of product design and
testing is far superior to the manufacturing costs which would accrue if each
3
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 loads.
These models can be extremely time consuming to prepare, and
commercial codes vie with one anotherto 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.
42
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.
3.3 INTRODUCTION TO ANSYS
ANSYS is a widely used software package for Finite Element Analysis (FEA) that
employs numerical methods to break down complex systems into small pieces
called elements. The software applies equations that describe the behavior of these
elements and then solves them to provide a detailed understanding of how the
entire system functions. The results of this analysis can be presented in graphical
or tabular formats. FEA is commonly used for designing and optimizing complex
systems that are too difficult to analyze manually due to their geometry, scale, or
governing equations. ANSYS is used as a teaching tool in many Mechanical
Engineering departments in universities, and it is also utilized in Civil and
Electrical Engineering as well as Physics and Chemistry departments. ANSYS
enables cost-effective virtual prototyping, which allows users to test and optimize
the performance of products or processes before manufacturing begins. This
approach reduces the risk of ineffective designs and lowers production costs.
Additionally, ANSYS is a versatile tool that enables users to analyze the impact
of design changes on various aspects of the product, such as electromagnetic,
thermal, and mechanical behavior. ANSYS is a widely used software package for
Finite Element Analysis (FEA) that employs numerical methods to break down
43
complex systems into small pieces called elements. The software applies equations
that describe the behavior of these elements and then solves them to provide a
detailed understanding of how the entire system functions. The results of this
analysis can be presented in graphical or tabular formats. FEA is commonly used
for designing and optimizing complex systems that are too difficult to analyze
manually due to their geometry, scale, or governing equations. ANSYS is used as
a teaching tool in many Mechanical Engineering departments in universities, and
it is also utilized in Civil and Electrical Engineering as well as Physics and
Chemistry departments. ANSYS enables cost-effective virtual prototyping, which
allows users to test and optimize the performance of products or processes before
manufacturing begins. This approach reduces the risk of ineffective designs and
lowers production costs. Additionally, ANSYS is a versatile tool that enables users
to analyze the impact of design changes on various aspects of the product, such as
electromagnetic, thermal, and mechanical behavior. 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 solvethe resulting set of equations.
3. Post processing module: further processing and viewing
of resultsIn this stage we can see:
List of nodal displacement
Elements forces and
momentsDeflection plots
Stress contour diagrams
3.4.2Thermal Analysis
44
ANSYS is a versatile software that can perform both steady state and transient
thermal analysis of solid objects subjected to thermal boundary conditions.
Steady-state thermal analysis is utilized to assess the impact of constant thermal
loads on a component or system. Typically, a steady-state analysis is performed as
a preliminary step to a transient thermal analysis, as it helps to establish the initial
conditions. Moreover, a steady-state analysis can also be conducted as the final
step in a transient thermal analysis, after all the transient effects have subsided.
With ANSYS, users can calculate important thermal parameters, such as
temperatures, heat fluxes, heat flow rates, and thermal gradients in an object
caused by constant thermal loads that do not vary over time. Such loads include
the following:
· Radiation
· Heat flow rates
· Heat fluxes (heat flow per unit area)
· Heat generation rates (heat flow per unit volume)
· Convection
45
· 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.
3.4 INTRODUCTION TO CFD

Computational Fluid Dynamics (CFD) is a field within fluid mechanics that
leverages numerical methods and algorithms to solve and investigate fluid flow
problems. By employing computer simulations, CFD is able to accurately model
the interaction of gases and liquids with surfaces under defined boundary
conditions. The use of high-speed supercomputers allows for faster and more
accurate solutions. Ongoing research and development of CFD software aim to
improve the accuracy and speed of simulations involving complex scenarios, such
as turbulent or transonic flows. The software is initially validated through
experimental testing in wind tunnels, with final validation coming from full-scale
testing, such as flight tests.
In all of these approaches the same basic procedure is followed.

• During preprocessing
• The geometry (physical bounds) of the problem is defined.
• The volume occupied by the fluid is divided into discrete cells (the
mesh). Themesh 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 initialconditions are also defined.
• The simulation is started and the equations are solved iteratively as a
46
steady-stateor transient.
• Finally, a postprocessor is used for the analysis and visualization of the
resulting solution.
3.4.1 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
47
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
48
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
differentnano 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 COLDWATER
Ansys → workbench→ select analysis system → fluid flow fluent → double click
→→Select geometry → right click → import geometry → select browse

→open part →ok
49
→→ 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
50
Select faces → right click → create named section → enter name → cold fluid
inlet Select faces → right click → create named section → enter name
→ cold fluid outletSelect 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. Whereci, 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
AnalysisTable 4.1 Boundary conditions
Inlet temperatures(T) 303k,353 k
Inlet pressure(P) 101325 pa
Inlet velocity(V) 1.4412 m/s
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,
51
wall.etc)>selectpressure>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
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.
52
4.3.1 Temparature Distribution along STHE using Ti C
Fig. 4.8 Temperature distribution of Titanium Carbide nanofluid at various

volumefractions
53
4.3.2 Heat Transfer Coefficient along the STHE using Ti C
Fig. 4.9 Heat transfer Coefficient of Titanium Carbide nanofluid at various

volumefractions
54
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"
c_i 1042580.6
c_o 0
h_i 9828294
h_o 0
wall-_trm_srf 0
Net 10870875
""Flux Report"
Total Heat Transfer Rate

(w)
c_i 1042625.5
c_o 0
h_i 9828294
h_o 0
wall-_trm_srf 0
Net 10870920
55
""Flux Report"
c_i 1042709.8
c_o 0
h_i 9828294
h_o 0
wall-_trm_srf 0
Net 10871004

"Flux Report"
c_i 1042770.9
c_o 0
h_i 9828294
h_o 0
wall-_trm_srf 0
Net 10871065
56
4.3.4 Temperature Distribution along STHE using Ti N
Fig. 4.10 Temperature distribution of Titanium Nitride nanofluid at various

volumefractions
57
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
58
Flux Report"
c_i 1042634.1
c_o 0
h_i 9828295
h_o 0
wall-_trm_srf 0
Net 10870929
"Flux Report"
c_i 1042703.2
c_o 0
h_i 9828294
h_o 0
wall-_trm_srf 0
Net 10870997
"Flux Report"
59
c_i 1042775.5
c_o 0
h_i 9828294
h_o 0
wall-_trm_srf 0
Net 10871070
"Flux Report"
c_i 1042787.9
c_o 0
h_i 9828294
h_o 0
wall-_trm_srf 0
Net 10871082
60
4.3.7 Temperature Distribution along STHE using Zi O
Fig. 4.12 Temperature distribution of Zinc oxide nanofluid at various volume

fractions
61
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
62
4.3.9 Total Heat transfer rate for Zi O nano fluid at various volume fractions
"Flux Report"
c_i 1042576
c_o 0
h_i 9828293
h_o 0
wall-_trm_srf 0
Net 10870869
"Flux Report"
c_i 1042622.3
c_o 0
h_i 9828293
h_o 0
wall-_trm_srf 0
Net 10870915
63
"Flux Report"
(w)
c_i 1042665.3
c_o 0
h_i 9828295
h_o 0
wall-_trm_srf 0
Net 10870960
Flux Report"
(w)
c_i 1042737.8
c_o 0
h_i 9828294
h_o 0
wall-_trm_srf 0
Net 10871032
64
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
65
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
66
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
AluminumSTHE
67
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
AluminumSTHE
68
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
69
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
CopperSTHE
70
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
CopperSTHE
71
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
72
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 analysisheat transfer coefficient and maximum temperature and total
heat transfer rate by using CFDanalysis. 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 whenincreasing 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 Nitride
73
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 consistof better thermal properties like thermal
conductivity, specific heat is
Fig. 6.1 Comparison of Heat transfer coefficient between three nano fluids at
differentvolume fractions
Fig. 6.2 Comparison Maximum temperature between three nano fluids at

differentvolume fractions
Fig. 6.3 Comparison of Total Heat transfer rate between three nano fluids at
different volume fractions more than titanium carbide and zinc oxide. The
74
Comparison of Heat transfer coefficientbetween 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
For this thermal analysis, we incorporated Titanium Carbide, Titanium Nitride,

and Zinc oxide nanofluids into the base fluid of water with varying volume
fractions of 0.02, 0.04, 0.07, and 0.15. We used aluminum and copper materials
for the shell and tube heat exchanger and performed a thermal analysis on both
materials. Our analysis focused on the heat flux and maximum temperature. Upon
completion of the analysis, we determined that the highest heat flux was achieved
with a volume fraction of 0.15, using Titanium Nitride. We also observed that the
flux increased gradually with the increase in volume fractions of the nanofluids
during the 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
1.15 353.1 295.1 2.987
5 5
75
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. The thermal analysis results clearly indicate that Titanium Nitride nano
fluid outperforms Titanium Carbide and Zinc oxide nanofluids in terms of heat
flux at a volume fraction of 0.15 for both aluminum and copper materials. This is
due to the superior thermal properties of titanium nitride nanofluids such as
thermal conductivity and specific heat, which are higher than those of titanium
carbide and zinc oxide. The heat flux is higher in copper material compared to
aluminum because copper material has higher thermal properties than aluminum.
Fig. 6.4 displays a comparison of the total heat transfer rate between the three
nanofluids at different volume fractions, while Fig. 6.5 shows the same
comparison for copper material.
76
STHE Aluminium
3.05
2.95
2.85
2.75
2.65
Fig. 6.4 Comparison of Heat flux between three nano fluids at different
volume fractionsfor Aluminum STHE
STHE Copper
27.8
27.6
27.4
27.2
26.8
26.6
26.4
Fig. 6.5 Comparison of Heat flux between three nano fluids at different
volume fractionsfor Copper STHE
77
CHAPTER VII
CONCLUSION AND FUTURE SCOPE
This thesis focuses on analytical investigations of a shell and tube heat exchanger
using forced convective heat transfer. The aim is to determine the flow
characteristics of nanofluids mixed with water at different volume fractions. The
nanofluids considered are Zinc Oxide, Titanium Carbide, and Titanium Nitride
nanofluids with volume concentrations of 0.02, 0.04, 0.07, and 0.15% under
turbulent flow conditions.
Based on the results of the CFD analysis, increasing the volume fractions of the
nanofluids led to an increase in temperature, heat transfer coefficient, and total
heat transfer rates. The values were found to be higher when using Titanium
Nitride compared to the other two fluids.
The heat exchanger materials considered were Aluminum and Copper. Thermal
analysis results showed that increasing the volume fractions of the nanofluids led
to an increase in heat flux values, with Titanium Nitride having the highest values
compared to the other two fluids. Moreover, using Copper material led to higher
heat flux values, resulting in higher heat transfer rates.
78
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