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abstract
Article history:
Received 2 June 2009
Received in revised form
11 September 2009
Accepted 20 September 2009
Available online 25 September 2009
In the present work, primarily two studies were carried out to ascertain the performance of coiled ow
inverter (CFI) as heat exchanger at pilot plant scale. In the rst study, performance of CFI heat exchanger
has been compared with conventional heat exchangers, i.e. shell and tube heat exchanger (SHE) and
plate type heat exchanger (PHE) under identical heat transfer area and process conditions. Experiments
were conducted with water owing under laminar ow regime within the ow range of 30300 kg/h in
the tube side of SHE and PHE. Friction factor and Nusselt number calculated from present experimental
study in SHE and PHE were compared with the experimental data previously reported for CFI heat
exchanger (Kumar et al., 2007). The Number of Transfer units (NTU) calculated in the present study for
CFI was nearly 3.77.5 times higher as compared to SHE and 22.5 times higher as compared to PHE. In
the second part of the study, experiments were performed rst time to investigate the pressure drop
and heat transfer of compressed air owing under turbulent ow condition in CFI heat exchanger at
pilot plant scale. Hot air at elevated pressures (1030 kg/cm2) in the tube side of CFI heat exchanger
with ow range 3 104 o NRe o 1.4 105 was cooled by either cooling water or ambient air. The friction
factor and Nusselt number values for compressed air owing in the CFI were also compared with the
experimental data reported in the literature for coiled tube at ambient conditions. On the basis of
experimental results, new correlations for friction factor and Nusselt number of compressed air owing
under turbulent ow condition in CFI heat exchanger have been developed.
& 2009 Elsevier Ltd. All rights reserved.
Keywords:
Coiled ow inverter heat exchanger
Heat transfer
Hydrodynamics
Turbulence
Transport processes
1. Introduction
Coiled tubes are commonly used in industries due to their
compact structure and high heat and mass transfer coefcient.
They are frequently encountered in practical applications, such as
heat exchangers, chemical reactors and piping systems. Numerous
studies (Adler, 1934; Ito, 1959; Kubair and Kuloor, 1966; Mori and
Nakayama, 1967; Shchukin, 1969; Dravid et al., 1971; Kalb and
Seader, 1972; Mishra and Gupta, 1979; Nigam and Saxena, 1986)
have been carried out to understand the transport phenomenon in
coiled tubes after the pioneering work of Dean (1927, 1928).
Several review papers have been published in order to understand
the hydrodynamics in curved tube for uid owing under laminar
and turbulent ow regime. Recently, Vashisth et al. (2008)
presented an exhaustive review paper dealing with uid ow,
heat transfer and mass transfer in curved tubes for wide range of
process conditions. They also reported limited studies on new
class of chaotic conguration introduced by Saxena and Nigam
(1984). The innovative CFI device developed by Saxena and Nigam
(1984) was based on the concept of multiple ow inversions
Corresponding author. Tel./fax: + 9111 26591020.
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Fig. 1. Experimental setup for compressed air system in the pilot plant of CFI heat exchanger.
the tube side of heat exchanger was varied from 16100 kg/h. An
inline electric resistance preheater (E-101) was designed for
handling pressure up to 40 kgf/cm2 and temperature range from
40 to 280 1C which heated the compressed air to the desirable
inlet temperature. The outlet temperature of the preheater was
regulated by an automatic PID regulator (TIC-101). Temperature
data were recorded at every 10 s. The T type thermocouples had
limits of error of 0.5 1C, when placed in a common water solution
the readings at steady state were all within 70.1 1C. All the
thermocouples were constructed from the same roll of thermocouple wire, and hence the repeatability of temperature readings
was high. Capacitance type pressure transmitter (PT-101 and 102)
which was calibrated to a span of 060 kgf/cm2 were used for
the pressure measurement of the tube side uid of the heat
exchanger.
An induced draft type cooling tower (CT-101) was used to
pump cooling water into the shell side of the CFI heat exchanger.
The ow rate of cooling water was measured by a magnetic
rotameter type ow meter (FI-201) with the range of 01000 kg/h.
The ow rate of cooling water in the shell side was varied from
100500 kg/h. Blower (B-101) was used for the case where the hot
uid was cooled by ambient air. The temperature was measured at
the inlet and outlet of tube as well as shell side of the heat
exchanger by copper-constantan thermocouples. These were T
type thermocouples with measuring range from 0 to 300 1C and
an accuracy of 0.5 1C or 0.4%. At the inlet of shell of the heat
exchanger, the cooling water temperature was 2530 1C and it was
raised by 511 1C at the outlet of the shell. During the experiments
the ambient temperature was 2228 1C, therefore, there was not
much heat loss from the outer wall of the heat exchanger.
Fig. 2 represents the schematic diagram of CFI heat exchanger
and CFI tube. The detailed description and design aspects of
the CFI heat exchanger were previously reported by Kumar
et al. (2007). Experiments with compressed air owing
under turbulent ow conditions in SHE and PHE could not be
carried out due to technical constraints in the design of pilot
plant.
Fig. 2. Schematic diagram of (a) CFI heat exchanger and (b) CFI tube [source:
Mridha and Nigam (2008b)].
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Fig. 3. Pressure drop at different values of ow rate of water owing in the tube
side of different heat exchangers.
Fig. 5. Overall heat transfer coefcient at different ow rates of water in the tube
side of SHE, PHE and CFI heat exchanger.
fCFI fS 1 0:0456NDe
Fig. 4. Friction factor versus Reynolds number of water in the tube side of different
heat exchangers.
DPd
G2t Ln
m cP DT
A DTLM
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0:7 0:4
NPr l
NNu 0:08825NRe
1003
Fig. 6. Variation of Nusselt number at low Reynolds number of water in the tube
side of SHE, PHE and CFI heat exchanger.
Fig. 7. Number of merit in CFI heat exchanger as compared to SHE and PHE.
Fig. 9. Pressure drop at different values of ow rate of compressed air owing with
different pressures in the tube side of CFI heat exchanger.
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Fig. 10. Friction factor versus Reynolds number of compressed air in the tube side
of CFI heat exchanger.
Fig. 11. Pressure drop at different values of ow rates of uid owing in the shell
side of CFI heat exchanger.
fCFI fS 1 0:051NDe
0:0075
p
9
10
11
The present experimental data of friction factor in tube side of CFI
heat exchanger were observed to be nearly 710% higher than the
data of Mishra and Gupta (1979). The friction factor correlation for
ambient air owing in the straight tube is also shown in the
gure. It can be seen that the friction factor in the present heat
exchanger is higher as compared to straight tubes.
Fig. 11 shows the variation of shell side pressure drop in the CFI
heat exchanger with ow rate of cooling water. The ow rate of
cooling water was varied from 100 kg/h to 500 kg/h. It can be seen
from the gure that the pressure drop increases with the increase
in ow rate of cooling water in the shell side of heat exchanger.
The friction factor in the shell side of the heat exchanger was
calculated on the basis of equivalent diameter of shell. This was
Fig. 12. Friction factor at various Reynolds number of uid owing in the shell side
of CFI heat exchanger.
done to take into account the effect of bafes which were present
in the shell side of the CFI heat exchanger. These bafes were used
to support the CFI tube and also provide turbulence to cooling
water owing in the shell side of heat exchanger. Fig. 12 shows the
experimental predictions of friction factor at various Reynolds
number in the shell side of heat exchanger. It was observed that
the friction factor decreases with increase in Reynolds number of
owing uid in the shell side of heat exchanger.
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Fig. 13. Overall heat transfer coefcient in CFI heat exchanger at various ow rates
of air at pressure of 20 kgf/cm2 in the tube side for different shell side ow rates of
cooling uid.
Fig. 14. Overall heat transfer coefcient in CFI heat exchanger at various tube ow
rate of compressed air for different pressures keeping constant cooling water ow
rate of 250 kg/h in the shell side of heat exchanger.
12
1005
Fig. 15. Variation of Nusselt number at high Reynolds number of compressed air in
the tube side of CFI heat exchanger.
Fig. 16. Overall heat transfer coefcient of CFI heat exchanger at different shell
side ow rates for various tube side ow rate of air at a pressure of 20 kg/cm2.
Re
2=3
fNRe l2 g1=5
26:2NPr 0:074
for 1 104 oNRe o2 105
13
It was observed that the Nusselt number calculated for CFI from
correlation was nearly 1214% higher than the data reported by
Mori and Nakayama (1967). This may be due to the effect of ow
inversion caused by 901 bends in CFI heat exchanger. The ow
inversions in CFI further increased the radial mixing of compressed air and enhance the heat transfer. The present experimental prediction for the heat transfer of compressed air in tube
side was also compared with the heat transfer of ambient air in
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4. Conclusions
Fig. 17. Nusselt number at different values of Reynolds number for uid at ambient
conditions in the shell side of CFI heat exchanger.
Notation
Fig. 18. Number of merit in CFI heat exchanger as compared to straight tube and
coiled tube.
straight tube. It was observed that the heat transfer in the present
heat exchanger is higher as compared to the straight tubes.
Fig. 16 shows the variation of overall heat transfer coefcient
for different ow rates of water in the shell side of heat exchanger.
The gure illustrates that the overall heat transfer coefcient
increases with the increase in shell side ow rates of water for any
given tube side ow rate. It was also observed that there was
increase in Uo as the ow rate of compressed air in tube side was
increased for any given shell side ow rate. There was nearly 1.76
folds increase in Uo when the tube side ow rate was increased
from 40 to 88 kg/h, at shell side ow rate of 320 kg/h. Nusselt
numbers in the shell side of heat exchanger were calculated using
the concept of equivalent diameter. Fig. 17 shows the Nusselt
number values of water at different Reynolds number in the shell
side of CFI heat exchanger. It can be seen from the gure that the
Nusselt number increases with increase in Reynolds number at
the shell side. There was 1.62 folds increase in Nusselt number as
the Reynolds number in shell side was increased from nearly 170
to 550. This could be due to the bafes tted at shell side which
created turbulence and minimized channeling of uid owing
through it.
Fig. 18 shows that the number of merit in CFI heat exchanger to
that of straight tube. It can be observed from gure that
enhancement in heat transfer in CFI heat exchanger is nearly
Cp
d
Dc
f
g
H
L
m
NDe
NHe
NNu
NPr
NRe
P
Rc
t
T
U
v
Greek letters
m
r
Subscripts
c
CFI
in
curved tube
coiled ow inverter
inlet
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out
s
sh
t
outlet
straight tube
shell side
tube side
Acknowledgment
The authors gratefully acknowledge the Ministry of Chemical
and Fertilizers, GOI, India for funding the project.
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