Literature Review

2.1. Introduction
The purpose of this chapter is to provide a literature review of past research effort such as
journals or articles related to shell and tube heat exchanger and computational fluid dynamics
(CFD) analysis whether on two dimension and three-dimension modelling. Moreover, review of
other relevant research studies is made to provide more information in order to understand more
on this research.
M.D. Rajkamal et. al. (2018) shell and tube heat exchanger study has been performed and A
helical coil heat exchanger with a helix angle of 30o using CREO software was designed and
fabricated. Nowadays copper is replaced by Carbon steel in industries. Presently the objective is
to use ANSYS CFX 15.0 software to infer the replicability of copper with two different inner
tube materials such as POCO HTC graphite and ASTM SA 179 carbon steel which also has
appreciable heat transfer characteristics and good corrosion resistance than copper. A laminar hot
fluid flow is the heat source medium. Also the increase in heat transfer rate with increase in mass
flow rate is also observed.

Shuvam Mohanty et. al. (2018) A numerical investigation of counter flow heat exchanger in a
particular tube in tube heat exchanger with reversing the flow is investigated in this paper. The
investigation includes the heat transfer and the pressure drop in the heat exchanger considering
water as a fluid. Many researchers have reported regarding the enhancement of counter flow heat
exchangers altering the fluid temperature and using different fluids. Here to foresee the outcome
of the heat exchanger in terms of temperature change and pressure drop due to variation of
temperature and mass flow rate a CFD program fluent has been used. A set of CFD simulation is
carried out for the double pipe counter flow heat exchanger and after validating the methodology
of CFD analysis the effects are established. The values and the results are case responsive to the
turbulence model section.

Ankush S. Patil et. al. (2017) Heat exchangers are the devices or equipment which are used to
transfer heat from one medium to another medium without mixing them. The objective may be
either to remove heat from a fluid or to add heat to a fluid. In great extent the research is going
on for further enhancing the heat transfer through heat exchangers. In this study research done by
various researchers to increase the effectiveness of heat exchanger has been discussed. Through
detailed analysis it has been observed that corrugated plate heat exchanger has maximum rate of
heat transfer.

Chandan Kumar Sethi (2017) This study is focused on the use of plate type heat exchanger for
seawater and engine oil as the working fluids. This examination work manages examination of
the plate-type heat exchanger with an assessment of convective heat transfer coefficient, overall
heat transfer coefficient, exchanger effectiveness, output temperatures of the fluids. Tests are led
by changing working parameters like mass flow rate, inlet temperatures of hot & cold fluids. The
analysis was done using ANSYS 12 CFD methodology. Distinctive parameters are figured from
the outcomes acquired and diagrams are plotted between different parameters. These charts have
been investigated and talked about to discover the ideal outcome for which the plate Heat
exchanger would give the best execution.

Deepa Shrivastava et. al. (2017) Computational Fluid Dynamics has been successfully used for
predicting flow and heat transfer characteristics in heat exchangers. In the present work a 3-
dimensional grid is generated for tube-in-tube heat exchanger using ANSYS. The continuity
equation, the momentum equation and the energy equations are solved using ANSYS. CFD
model is validated by comparing the results from experimentation, for both the parallel and
counter flow. The CFD result for heat transfer found to be in good agreement with the calculated
results from experimentation. The CFD based simulation carried out for Tube-in-Tube heat
exchanger using ANSYS software. The CFD results for heat transfer characteristics (Nusselt
number) are compared with result from the experimentation. The results are presented in
graphical form and they are found to be in good agreement with each other.

Dipankar De et. al. (2017) The aim of this work is to design of shell and tube type heat
exchanger with helical baffle and comparing with straight baffle with CFD analysis using
ANSYS FLUINT software tools. The model contains 7 Copper tubes each having 20 mm
external diameter and 17 mm internal diameter, length 600 mm and inner diameter of steel shell
is 90 mm and outer diameter 110 mm. 7 tubes are hold by 6 straight or helical aluminum baffle
and the helix angle of baffle is varying from 0º to 30º. All the models are design by using
CATIA software tools. In this paper how, the pressure drops and overall heat transfer coefficient
varies due to different helix angle has been studied when the flow rate remains same. The flow
pattern in the shell side of the heat exchanger with continuous helical baffles are forced to be
rotational and helical due to the geometry of the continuous helical baffles, which results in a
significant increase in heat transfer coefficient per unit pressure drop in the heat exchanger.

K. Venumadhav et. al. (2017) In the present study, Double Helical Circular Pipe Heat
Exchanger has been designed and analyzed to get maximum Effectiveness. Further, materials of
this design have also been varied and analyzed. The materials are considered as Steel,
Aluminum, and Copper. The design Double Helical Circular Pipe Heat Exchanger has been done
using SolidWorks software. Then analysis is carried out using ANSYS software. it is observed
Counterflow Heat Exchanger has greater Effectiveness than Parallel flow for all materials and
Copper is best suited material for the heat exchanger as it is giving more effectiveness than
Aluminum and Steel.

Mohammed Irshad et. al. (2017) The objective of this study is to design a shell and tube heat
exchanger with segmental baffles and to study the flow and temperatures inside the shell and
tubes using ANSYS software tool for the different baffle’s assemblies and orientation also
overall heat transfer is calculated for each design. This project totally contains 5 designs for
comparison. The process in solving simulation consists of modelling and meshing the basic
geometry of shell and tube heat exchanger using CFD package ANSYS 14.5. The heat exchanger
contains 7 tubes and 600mm length and 90mm shell diameter. In simulation we will show how
the temperature, pressure, velocity varies in shell due to different baffles orientation.

Q. Miao et. al. (2017) This study deals with the failure analysis of air heat exchanger. The
natural frequency and vibration mode of air heat exchanger are obtained based on a three-
dimensional finite element model. A flow-induced vibration is analyzed on the basis of modal
simulation results. A thermal-structural interaction simulation for air heat exchanger is carried
out by using the multi-physical field coupling method. The stress distribution and strain
distribution of air heat exchanger are calculated by using the results of temperature field
simulation. A Manson-Coffin model based on equivalent plastic strain range and cycle life is
used to describe fatigue life, and the equivalent plastic strain range was obtained by the thermal-
structural interaction simulation. The analysis results show that the major reason of fatigue
failure of air heat exchange tube bundle is the thermal stress and flow-induced vibration.

Raju et. al. (2017) This study consists of a simplified model of shell and tube type heat
exchanger having both interacting mediums as water and steam. In this paper we have first
designed a shell and tube heat exchanger to heat water from 40℃ to 70℃ by steam at 140℃
temperature. The design has been done using Kern’s method in order to obtain various
dimensions such as shell, tubes, baffles etc. A computer model using CATIA V5 has been
developed by using the derived dimensions of heat exchanger. Then the thermal simulation in
ANSYS has been performed by applying several thermal loads on different faces and edges. The
heat transfer capabilities of several thermal materials have been compared by assigning different
materials.

Samuel Raj et. al. (2017) The study deals with the CFD simulation of the shell and tube heat
exchanger by using a straight tube and a helical tube and comparing both of its performance
based on heat transfer. Straight tube heat exchanger (STHE) have large heat transfer surface
area-to-volume ratios to provide high heat transfer efficiency which are mostly used in
industries. But the Helical Coil Heat Exchanger (HCHE) is also widely used in industrial
applications because it can accommodate greater heat transfer area in a less space, with higher
heat transfer coefficients. So, both of the STHE and HCHE performances are compared to prove
that HCHE is better in usage and the analysis is done using ANSYS Fluent 14.5 software. The
model is created using CATIA V5 software.

Katarki et. al. (2017) an effort has been made to design a heat exchanger by modelling in
ANSYS software which is having an inner diameter of 330mm and outer diameter of 350mm for
shell. Similarly, for tube inner diameter is 21.18mm and outer diameter 25.4mm, length of tube
is 1500mm, contains 36 tubes. Here assembly of shell and tube are done with water and steam as
a medium. By using results, the design can be altered for better efficiency. Realizable k–ε (RKE)
model plies first-rate results. It is concluded that temperature of cold fluid increased from 356 to
359 ºK. Hot fluid decreases 404 – 403 ºK. Accomplished value of heat transfer rate for hot fluid
is 11475.76 KW and cold fluid is 64221.52 KW. Consequently, the comparisons of temperatures
of experimental value to the attained CFD value are valid.

B. S. Hasu et. al. (2016) An attempt is made in this study is for the Design of shell and tube heat
exchangers by modeling in UGNX8.0 by taking the Inner Diameter of shell is 600 mm, length of
the shell is 1000 mm and Outer diameter of tube is 12.5mm, length of Tube is1000mm and Shell
material as Steel 1008, Tube material as alloy materials to resist corrosive effect TP439and
AL29-4. By using modeling procedure Assembly Shell and Tube with water as medium is done.
By using ANSYS software, the thermal analysis of Shell and Tube heat exchangers is carried out
by varying the layout. Comparison is made between the Experimental results, ANSYS. With the
help of the available numerical results, the design of Shell and Tube heat exchangers can be
altered for better efficiency. This paper presents the variations in lay out with water as medium
with significant flow at the top level of exchanger and equal distribution of tubes pitch. Analysis
comparison with before layout and materials are observed.

Ashok reddy (2016) A review of shell and tube heat exchanger with different objective were
presented in this like helical baffle and study the flow and temperature field inside the shell using
ANSYS software tools, a nonlinear system of integro-partial differential algebraic equations,
modeling by using CATIA V5 software, thermal and hydraulic analysis, overall heat
coefficients. Two methods were applied in the suggested design model, Kern and Bell-Delaware,
in addition to the step by step technique.

Bala Bhaskara Rao et. al. (2016) Experimental and numerical simulations are carried for a
single shell and multiple pass heat exchangers with different tube geometries i.e. circular tubes to
elliptical tubes. The experiment was carried out with hot fluid in tube side and cold fluid in shell
side with circular tubes at 600 tube orientation and 25 % baffle cut. Heat transfer rates and
pressure drops are calculated for various Reynolds numbers from 4000 to 20000. Fluent software
is used for numerical investigations. Both circular and elliptical tube geometries with 450,600
and 900 orientations are used for the numerical studies. In addition to 25 % baffle cut, quarter
baffle cut and mirror quarter baffle cut arrangements are used for comparison. The experimental
values of heat transfer rates and pressure drops over shell side and tube side along the length of
STHE are compared with those obtained from fluent software.

VIJAY et. al. (2016) This study deals with the design and analysis of a heat exchanger (oil
cooler) by using pro E, hyper mesh and Ansys software’s, so as to satisfy the requirement data
collected from the source along with the design considerations of esteemed TEMA & ASME
standards. The main objective is to calculate the temperature distribution & stress value by using
Ansys. Within the present project, the thermal and pressure drop calculations are done by using
the empirical formula, as per TEMA and verified with HTRI software package (USA). The
pressure drops values on shell side and tube side at the same time, overall heat transfer
coefficient values are with a variation of 0.29%. 1.4% and 1.68% respectively and matching with
the HTRI software. The variation of LMTD and surface area with water inlet temperature
decreases and increases respectively and variation in overall heat transfer coefficient decreases
with the increase of fouling factor of oil. As the quantity of oil is varied increasingly the heat
load and the overall heat transfer coefficient also increases.

Digvendra singh et. al. (2016) The main objective of this study is to verify the heat exchanger
designed with the use of the Kern’s technique, by the use of Commercial Computational Fluid
Dynamics (CFD) software. For the simulation, purpose a symmetric view of the simplified
geometry of the heat exchanger is made using Solidworks software. In the present study, CFD
simulation is used to study the temperature and velocity profiles through the tubes and the shell.
It is found that the heat transfer through the length of the tube is not uniform. In the research
analysis shell and tube heat exchanger is designed and simulated by using Computational Fluid
Dynamic (CFD). The header selection for the heat exchanger has also been based on the
Computational Fluid Dynamic (CFD) simulation.

Mayank bhola et. al. (2015) Studied about CFD simulation of concentric tube heat exchanger
and concentric tube heat exchanger with insert used for heating air using ANSYS FLUENT
Software for steel. Design process for heat exchanger and insert has been carried out in
SOLIDWORKS, fluid domain is formed in ANSYS workbench, followed by meshing in default
mesh tool of ANSYS and solution is developed using ANSYS FLUENT software as FINITE
ELEMENT TOOL and the results are compared between the two designs for parallel flow. The
Reynolds number of air varied from 21000 to 100000. Inlet temperature of hot water and cold air
are 60̊ C and 26̊ C respectively. The work included the determination of Nusselt number, heat
transfer coefficient and friction factor for insert in parallel flow and counter flow.

Pankaj D. Lad et. al. (2015) The study work describes the optimization & FEA of concentric
pipe heat exchanger. It is proposed to study the abnormal behavior of concentric pipe heat
exchanger when hot & cold fluids are passed through pipes. The concentric pipe heat exchanger
using material SA 516 Grade 70 which is discussed in this report has covered making the
(thickness) optimization of inner pipe, tube sheets, and nozzles as per ASME Code in order to
reduce induced von-mises stress & deflection in the concentric pipe heat exchanger. Finally, at
different temperature the behaviour of heat exchanger is analyzed & compared ANSYS results
with experimental results for validation. It is observed that there is good agreement between
ANSYS & experimental results.

Roshan. V. Marode et. al. (2015) To measure the performance of different designs, its model is
suitably designed and fabricated so as to perform experimental tests. Thermal analysis has been
carried out for different design with two fluids and on the basis of comparative results is made
which one give the best heat transfer rates. This study shows the design and thermal analysis of
different tubes. Experimentally, same designs are made and results are evaluated. With relate to
same design tubes are thermally analyzed in ANSYS software and compared both the results.
After comparing the result for both water (Case-I) and water-Al2O3(Case-II) for four different
tubes we are in conclusion that twisted type of tube is giving high heat transfer coefficient as
compared to other i.e. 1.14 more. Along with effectiveness, twisted tube is at higher side by 1.17.
So according to my research one should go for twisted tube.

Saurabh Kumar et. al. (2015) Numerical simulation has been carried out for double tube helical
coil heat exchanger subjected to insulated outer wall condition using ANSYS FLUENT 15. The
graphs are plotted for Nusselt number and heat transfer coefficient for the water and nanofluids
in which flow condition is taken as turbulent. The finite volume method with k–ε standard
turbulent model was used to discretize the main governing equations. Result showed that the
value of Nusselt number for nanofluid is higher than that of the base fluid as water where the
SiO2 nanofluid yields the best heat transfer enhancement followed by CuO and Al2O3.
Enhancement in heat transfer is achieved by increasing the Dean Number and volumetric
concentration.

Sunil B. Revagade et. al. (2015) This study shows the design and thermal analysis of different
tubes. Experimentally, same designs are made and results are evaluated. With relate to same
design tubes are thermally analyzed in ANSYS software and compared both the results. After
comparing the result for both water (Case-I) and water-Al2O3(Case-II) for four different tubes
we are in conclusion that twisted type of tube is giving high heat transfer coefficient as compared
to other i.e 1.14 more. Along with effectiveness, twisted tube is at higher side by 1.17. So
according to my research one should go for twisted tube. However, a good understanding of the
underlying principles of exchanger design is needed to use this software effectively.

T. M Shaikh et. al. (2015) A computational study has been accomplished to determine the
effects of heat transfer in the helical coiled heat exchanger. It is concluded that the CFD analysis
results fairly matches with the Experimental Results. This shows that CFD Analysis is a
powerful tool to replace costly experiment and lengthy calculation. A comparison with
experimental results and CFD simulations has proven that for increasing mass.

Jayachandriah et. al. (2014) An attempt is made in this study is for the Design of shell and tube
heat exchangers by modeling in CATIA V5 by taking the Inner Diameter of shell is 400 mm,
length of the shell is 700 mm and Outer diameter of tube is 12.5mm, length of Tube is 800mm
and Shell material as Steel 1008, Tube material as Copper and Brass. By using modeling
procedure Assembly Shell and Tube with water as medium is done. By using ANSYS software,
the thermal analysis of Shell and Tube heat exchangers is carried out by varying the Tube
materials. Comparison is made between the Experimental results, ANSYS. With the help of the
available numerical results, the design of Shell and Tube heat exchangers can be altered for
better efficiency.

Dubey et. al. (2014) study consists of extensive thermal analysis of the effects of severe loading
conditions on the performance of the heat exchanger. To serve the purpose a simplified model of
shell and tube type heat exchanger has been designed using kern’s method to cool the water from
55°C to 45°C by using water at room temperature. Then we have carried out steady state thermal
analysis on ANSYS 14.0 to justify the design. After that the practical working model of the same
has been fabricated using the components of the exact dimensions as derived from the designing.
We have tested the heat exchanger under various flow conditions using the insulations of
aluminum foil, cotton wool, tape, foam, paper etc. We have also tested the heat exchanger under
various ambient temperatures to see its effect on the performance of the heat exchanger.
Moreover, we have tried to create the turbulence by closing the pump opening and observed its
effect on its effectiveness. All these observations along with their discussions have been
discussed in detail inside the study.
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