International Journal of Mechanical, Civil, Automobile and Structural Engineering (IJMCAS)

Vol. 1, Issue. 1, April 2015

ISSN (Online): 2395-6755

Comparison of Epoxy Composites using E-Glass/Carbon

Reinforcements
1
M.Arun Kumar, 2K.Dinesh Kumar, 3S.Karthick
Assistant Professor, Department of Mechanical Engineering, JIT Thopur, India
2,3
UG Students, Department of Mechanical Engineering, JIT Thopur, India

Abstract:- The computational fluid dynamics (CFD)

is the science of predicting fluid flow, heat transfer,
mass transfer, chemical reactions, and related
phenomena by solving the mathematical equations
which govern these processes using a numerical
process. Various researches are going on to avoid
scaling (or) fouling formation in shell and tube heat
exchanger and increase the rate of heat transfer. Here
we are introduce our concept to avoid scaling by
wounding the copper coil on the shell and tube in the
heat exchanger. Different case of heat exchangers are
analyzing by CFD simulation software and
comparing the result of rate of heat transfer.The
copper coil made with sharp edges wound on the
tube. So, it reduce the fouling formation 85-90% and
enhance the rate of heat transfer when compare to
other type of heat exchanger.

thermal analysis of shell and tube heat exchanger is

carried out by varying the tube materials. The
Tubular heat exchanger can be designed for high
pressures relative to environment and high pressure
differences between the fluids. It is used primarily for
liquid to liquid [3].The heat transfer enhancement in
a heat exchanger tube by installing seven different
baffle arrangements. The rate of heat transfer is
maximum for rectangular and triangular baffle
because behind maximum heat transfer rate was that
due to use of baffles, turbulence was increased as
they allow more mixing of fluid layers and resulted in
increase of heat transfer through the heat exchanger
tube [4]. The steady of increase in computing power
has enable model to react for multiphase flows in
realistic geometry with good resolution in [5]. This
system is used to study a fin-and-tube heat
exchanger. The purpose of the work was investigate
the possibilities of eventually using CFD calculations
for design of heat exchangers instead of expensive
experimental testing and prototype production. Here
created a model of a two-row fin and tube heat
exchanger by using open source Salome software in
[6]. Introducing continuous helical baffles in the shell
side of the heat exchanger and small corners at
variable angles of the liquid flow are the result of
introduction of segmental baffles which improves
heat transfer and huge decline in pressure thus
increasing the fouling resistance in [7].The optimum
pin shape based on minimum pressure drop and
maximizing the heat transfer across the automobile
engine body. The results indicate that the drop shaped
pin fins show improved results on the basis of heat
transfer and pressure drop by comparing other fins.
The reason behind the improvement in heat transfer
by drop shape pin fin was increased wetted surface
area and delay in thermal flow separation from drop
shape pin fin in [8].The phenomenon of forced
convection with turbulent flow of industrial processes
is complicated to develop analytically. The only key
to the problem is empirical models and numerical
solutions. The heat transfer coefficient (h) and
friction factor are very important parameters for fluid
flow systems due to their use in determining the heat
transfer rate and the pressure drop of the system

Keywords: CFD simulation software, copper coil

(plain and sharp), Shell and Tube type Heat
exchanger.
I.

INTRODUCTION

Computational Fluid Dynamics (CFD) as it is

popularly known is used to generate flow simulations
with the help of computer. CFD involves the solution
of the governing loss of fluid dynamics numerically.
The complex sets of partial differential equation of
solved on the geometrical domain divided into small
volumes, commonly known as a mesh or grid.
Different diameters of tube and different mass flow
rates are considered to examine the optimal flow
distribution and this problem has been subjected to
effect of materials (Aluminum, copper and alloys)
used for tube manufacturing on heat transfer
rate[1].To verify the shell and tube heat exchanger
designed with the use of the Kerns method by the
use of CFD. It is used to study the

Temperature and velocity profiles through the tubes

and the shell [2]. Using the ANSYS software, the

International Journal of Mechanical, Civil, Automobile and Structural Engineering (IJMCAS)

Vol. 1, Issue. 1, April 2015

ISSN (Online): 2395-6755

respectively. Then CFD simulation compared with

experimental data for air flow [9]. Heat transfer
enhancement by Plain and curved winglet type vertex
generators with punched holes, the flow resistance is
also lower in case of curved winglet type than
corresponding plain winglet vertex generators (VGs).
The best results for heat transfer enhancement is
obtained at high Reynolds number values (Re
>10000) by using VGs. This work presents a
numerically study on the mean nusselt number,
friction factor and heat enhancement characteristics
in a rectangular channel having a pair of winglet type
VGs under uniform heat flux of 416.67 w/m2. The
result indicate the advantages of using curved winglet
VGs with punched holes for heat transfer
enhancement [10].Comparative study between
Helical coil and Straight tube heat exchanger, here
present two conditions are, In the first conditionWhen cold water mass flow rate is constant and hot
water mass flow rate increased the effectiveness
decreases. Second condition-Increase in cold water
mass flow rate for constant hot water mass flow rate
in increase in effectiveness.Helical coil counter flow
is most effective in all these conditions and straight
tube parallel flow heat exchanger is least effective.
Because the helical coil tube heat exchanger, the
increased heat transfer coefficients are a consequence
of the curvature of the coil, which induces centrifugal
force to act on moving fluid, resulting in the
development of secondary flow. Due to the curvature
effect, the fluid streams in the outer side of the pipe
moves faster than the fluid streams in the inner side
of pipe in [11].

II.

A.

GEOMETRICAL
MODELING
MESH GENERATION

the geometry. Volume mesh is generated in TGrid which is a robust volume mesh generator.
Volume is dicretized using tetrahedron .Each and
every cell centroid is the co-ordinate at which the
navier-stokes system of equations are solved.
ANSYS-FLUENT was used as the solver. Here the
fluid flow is assumed to be three dimensional and
turbulent.Afterselection
of turbulence model
boundary conditions are specified. Fluent has
capability to store value of physical parameters for
any point in the domain for analysis. Seven points
were created to store the value of physical parameters
such as temperature, velocity, and pressure. FLUENT
is now ready to simulate flow problem. Finally, post
processing was done for result analysis.
B. Geometric Modeling:
Geometric model is generated in SOLIDWORKS which
is very popular modeling software. The generated model
is exported to the further process in the form of .IGES as
it is a third party format which can be taken into any other
tools. Here, Two type of copper coil is used (sharp and
flat edge) to create some kind of localized suction in
between the copper coils due to the condensation process.
So, it avoids the scale or fouling formation. The Sharp
edge copper coil is more efficient when compared with
the Flat edge copper coil.
C .Meshing Of CFD Domain:
After making the geometry of the domain, next step is to
mesh the domain. The CFD tool was used to create the
fine mesh quality. In considering case-1, case-2 (sharp
grooves) and case-3 (plain grooves), the surface and
volume mesh is generated with 5.25 and 18.89 lakhs, 5.09
and 18.96 lakhs,4.27 and 17.24 lakhs respectively. This
mesh contains tetrahedral cells having triangular faces at
the boundaries are shown in fig-1,2,3.The mesh details
are given below

AND

Methodology:

For CFD simulation, first of all, the geometry of the

shell and tube heat exchanger was created by using
SOLIDWORKS. The geometry of the heat
exchanger tube is in 3D view. After the geometry
creation, Extracting the fluid region is the next step in
which all the surfaces, which are in the contact of
fluid are taken alone and all other surfaces are
removed completely. To keep the domain air /water
tight some extra surfaces are created. This clean up is
done in ANSA meshing tool which is very robust
clean up tool.After cleaning up the geometry surface
mesh is generated in ANSA tool itself. All the
surfaces are discredited using tri surface element .As
the geometry has some complicated and skewed
surfaces tri surface elements are used to capture

International Journal of Mechanical, Civil, Automobile and Structural Engineering (IJMCAS)

Vol. 1, Issue. 1, April 2015

ISSN (Online): 2395-6755

This structure shows the layout of shell and tube heat
exchanger with wounding of sharp edged grooves in
meshed condition.

MESH DETAILS:
SURFACE
MODEL

BASE CASE
MODIFICA
TION 1
(SHARP
GROOVES)

MESH

Quality

525670

0.6

509450

0.6

Volume
MESH

1889715

1896024

MODIFICATION-2
Quality

0.8499

0.8599

MODIFICA

Figure-3 shell and tube heat exchanger with plain

edged grooves in meshed condition

TION2 (
PLAIN

427000

0.6

1724411

0.9324

This structure shows the layout of shell and tube heat

exchanger with wounding of plain edged grooves in
meshed condition.

GROOVES)

III. Boundary Conditions:

After mesh generation, boundary condition are
defined for CFD domain as shown in table 1. Specify
boundary condition icon is used to create
boundaries. In FLUENT launcher, both fluid and
solid can be defined.Generally, the copper materials
used in this analysis. The fluid used in this analysis is
water vapour. The material and fluid properties are
mentioned in table 2.

BASE CASE

Table 1: Fluid and Wall boundary conditions

Steam and coolant water Fluid zone
Figure-1Base case of shell and tube heat exchanger
Tube thickness and copper
Solid zone
wire
Velocity inlet
Coolant inlet
velocity
Coolant outlet
Pressure outlet

This structure shows the general layout of shell and

tube heat exchanger in meshed condition by using
ANSA tool.

with

varying

MODIFICATION-1
Steam inlet
Steam outlet
Coolant tube wall
Shell wall

Figure-2 Shell and tube heat exchanger with sharp

edged grooves in meshed condition

Mass flow inlet with mass flow

rate 0.5of 0.5 kg/s
Pressure outlet
No slip and conduction heat
transfer
No slip and adiabatic wall

International Journal of Mechanical, Civil, Automobile and Structural Engineering (IJMCAS)

Vol. 1, Issue. 1, April 2015

ISSN (Online): 2395-6755

Table 2: Fluid and Solid properties considered for

analysis

v)+

Properties
Fluids and
Density
Solids
Kg/m3
Steam

0.598

Specific Thermal conductivity

heat
W/mK
J/kg-K
1858.68 0.0261

Water

998.2

4182

0.6

Steel

8030

502.48

16.27

Copper

8978

381

387.6

IV. GOVERNING
DYNAMICS

vapour mass transfer (evaporation and condensation) is

governed by the vapour transport equation

EQUATIONS

v)=mlv mvlWhere,

v Vapour phase, - vapour volume fraction, v vapour

v
density,
vapourphasevelocity.mlvandmvl are the
rates of mass transfer due to evaporation and
condensation, respectively.These rates use units of
kg/s/m3.
As shown in the right side of Equation 5.6, ANSYS
FLUENT defines positive mass transfer as being from the
liquid to the vapour for evaporation-condensation
problems. Based on the following temperature regimes,
the mass transfer can be described as follows,

OF

FLUID

If T>Tsat Evaporation =mlvcoeff*ll (T-Tsat) / Tsat

If T<TsatCondensation=mvlcoeff*vv (T-Tsat) / Tsat

The basic governing equations 7.1 7.4, which describe

the fluid dynamics, are used to solve the steam and water
flow. The energy equation 7.5 was used to define the
conductive heat transfer across the fluid through the solid
region.
Conservation of Mass
+ div(
(7.1)
Conservation of X Momentum
+ div (
+ div(
Conservation of Y Momentum
+ div (

dP / dT = L/T(vg-vl)
The heat flux has units of kg/s/m3. P represents the partial
pressure of the vapour at the interface on the gas side in
KN/m2 and T is the temperature in K. The coefficient is
the accommodation coefficient that shows the portion of
vapour molecules going into the liquid surface and
absorbed by this surface. vgandvlare specific volume for
the gas and liquid respectively. L is the latent heatin J/kg.
Based on this differential expression, variations in
temperature can be obtained from variations of pressure
close to the saturation conditions.

SMx(7.2)

+ div (

SMy(7.3)

Conservation of Z Momentum
+div (

+div (

Coeff* is a coefficient () that needs to be fine tuned and

interpreted as a relaxation time. and are the phase
volume fraction and density respectively. The source term
for the energy equation can be obtained by multiplying
the rate of mass transfer by the latent heat.Consider the
Hertz Knudsen formula, which gives the evaporation condensation flux based on the kinetic theory for a flat
interface:

SMz(7.4)

V. Results and Discussion

Conservation of Energy
Internalenergy:

A. EVAPORATION-CONDENSATION MODEL

By completion of all the test runs in Fluent, from the

result we are understood the three cases of rate of heat
transfer characteristics in shell and tube heat exchanger.
By wounding the copper coil, it increases the turbulence
intensity. The turbulence intensity is measuring the
mixing of hot and cold fluid. So, the rate of heat transfer
rate is increased.

The evaporation-condensation model is a mechanistic

model with a physical basis. It is available with the
mixture and Eulerian multiphase models. The liquid-

A. Comparison of three different cases:

+div(
(7.5)

)+

International Journal of Mechanical, Civil, Automobile and Structural Engineering (IJMCAS)

Vol. 1, Issue. 1, April 2015

ISSN (Online): 2395-6755

The rate of heat transfer depends upon the turbulence

intensity, different cases [Base, Modification 1(sharp
groove), Modification 2(plain edge)] of rate of heat
transfer was analyzed in CFD simulation software.
Thedetails are mentioned in table 3.
TABLE-3

MODEL

BASE
MODEL
MODIFICAT
ION 1
(SHARP
GROOVES)

STATIC TEMPERATURE

TEMPERATURE(K)

STEAMINLET
TEMPERAT
URE (K)

STEAMOUTLET
TEMPERA
TURE (K)

373

321.09

Figure-5 Static temperature for modification-1 in fluent

layout
It represent the flow of static temperature range in the
Fluent of shell and tube heat exchanger for
modification-1.

373

317.67

373

319.41

MODIFICAT
ION2 (
PLAIN
GROOVES)

TURBULENT INTENSITY

RESULT OF MODIFICATION-1

Figure-6 Turbulent intensity for modification-1 in

fluent layout.

STATIC PRESSURE

It shows the maximum turbulentintensity in fluent

layout.
VELOCITY CONTOURS

Figure-4 Static pressure for modification-1in Fluent

analysis
It is the flow of static pressure Fluent layout of shell
and tube heat exchanger with wounding of sharp edged
grooves.

Figure-7 Velocity contours for modification-1 in

fluent layout
The velocity flow diagram is represented in ANSYS
Fluent. In this case represent the maximum velocity
contours.

International Journal of Mechanical, Civil, Automobile and Structural Engineering (IJMCAS)

Vol. 1, Issue. 1, April 2015

ISSN (Online): 2395-6755

Journal of engineering and applied sciences Vol.6,
NO. 7, July 2011, ISSN:1819-6608.

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