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Tutorial | Shell & Tube Heat Exchanger

CFD Simulation with ANSYS CFX

Atif Masood
Disclaimer
ANSYS and ANSYS CFX are registered trademarks or trademarks of ANSYS, Inc. or
its subsidiaries located in the United States or other countries. All registered
trademarks are property of their respective owners. This tutorial is not approved or
endorsed by ANSYS Inc., the owner/producer of the CFX software and owner of the
ANSYS® trade mark.
Summary
The primary objective of this tutorial is to guide the user using ANSYS CFX through
the thermal and flow simulation of shell and tube heat exchanger.

The objective of this simulation is to model the temperature and flow fields produced
inside a shell and tube heat exchanger.

Prerequisites
You will need to download following mesh file (.cfx5) freely available on FetchCFD at:
http://fetchcfd.com/view-project/797

- Shell-and-Tube-Heat-Exchanger-Mesh.cfx5
Problem Description
The sketch of the problem is shown below. The task is to model the heat exchange between two
fluids at different temperatures, flowing in opposite directions. In the shell of the heat exchanger,
water enters at a velocity of 0.5m/s and a temperature of 300°C, passing through the baffles and
leaving on the other side. Cooling water at 15°C is entering the tubes at a velocity of 0.5m/s.
Overview
Pre-processing Simulation Run Post-Processing

Importing mesh (.cfx5) Lauching the CFX-Solver Importing the results


files created in the ICEM and running the (.res) in CFD-post and
into the CFX pre- simulatoins. post-processing results.
processor. Defining the
problem and setting-up
boundary conditions.
Simulation Pre-processing
Step 1: Launch CFX Pre-processor (Windows > All apps > ANSYS 15.0 > CFX 15.0)

Note: In Working Directory set the path


a where you want to save your
b simulations

Step 2: Click: New Case > General

Note: In case of Information window


shows up just click ok
c

d
Mesh
Step 3: Mesh > Import Mesh > ICEM CFD

A: Import mesh file (.cfx5) for shell and tube heat


exchanger (Shell-and-Tube-Heat-Exchanger- a
Mesh.cfx5) into CFX pre-processor. Make sure b c
mesh units are mm.

Note: For this tutorial this mesh is fine


enough but for a simulation
analysis/study it is recommended to
perform mesh sensitivity study.

d
Defining Shell Side Domain
Step 4: Right click on the Default Domain and then select Rename. Enter “ShellSide” as new
name

b
Step 5: Right click on ShellSide and then left click on Edit
Select the mesh for the ShellSide by left clicking on Location tab
and then selecting “BODY2 from the Selection Dialog window.
Click OK to close this window. a
b

e
Step 6: Under Basic Settings select water as material from
Material library pop-up window.
Step 7: Click Fluid Models and under Option for Heat
Transfer select Thermal Energy. For Turbulence select
Shear Stress Transport. Initialize domain by click on
Initialization tab and selecting Domain Initialization. Finally
Click OK to finalize.

b
a

c e
e
f

g
Step 8: Right click on ShellSide then left click Insert and then Boundary

a
c
b

Type “ShellInlet” in the Inset Boundary pop-up d


window and click OK.
e
Step 9: Select the Boundary Type as Inlet and select for Location INLET2. Select for option under Mass
And Momentum Normal Speed and set a value of 0.5 m/s. For Heat Transfer Option select Static
Temperature and set a value of 100 C. Click OK to finalize.

b
c

e
Step 10: Right click on ShellSide then left click Insert and then Boundary

a
b c

Type “ShellOutlet” in the Inset Boundary pop-up d


window and click OK.
e
Step 11: Select the Boundary Type as Outlet and select for Location OUTLET2. Select for option
under Mass And Momentum Average Static Pressure and set a value of 0 Pa. Click OK to finalize.

b
c

d
Step 12: Right click on ShellSide then left click Insert and then Boundary

a
b c

Type “Baffles” in the Inset Boundary pop-up window d


and click OK.
e
Step 13: Select the Boundary Type as Wall. Click on the location tab and select (ctrl + left mouse
click) for Location Primitive 2D B and Primitive 2D D in the Selection Dialog window and click OK.
Click OK to finalize.

c
a

d
Defining Tube Side Domain
Step 14: Right click on the Default Domain and then select Rename. Enter “TubeSide” as new name

b
Step 15: Right click on TubeSide and then left click on Edit.
Make sure for mesh BODY is selected for Location and water for
Material as shown below.

a
c b

Note: It is possible that some of these values are already automatically


selected.
d
Step 16: Click Fluid Models and under Option for Heat Transfer select Thermal Energy. For
Turbulence select SST. Initialize domain by click on Initialization tab and selecting Domain
Initialization. Finally Click OK to finalize.

a e
e d
b

f
Step 17: Right click on TubeSide then left click Insert and then Boundary

b c

Type “TubeInlet” in the Inset Boundary pop-up d


window and click OK.
e
Step 18: Select the Boundary Type as Inlet and select for Location INLET1. Click on tab Boundary
Details. Select for option under Mass And Momentum Normal Speed and set a value of 0.5 m/s. For
Heat Transfer Option select Static Temperature and set a value of 288.18 K. Click OK to finalize.

a
c

b d

f
Step 19: Right click on TubeSide then left click Insert and then Boundary

b c

Type “TubeOutlet” in the Inset Boundary pop-up d


window and click OK.
e
Step 20: Select the Boundary Type as Outlet and select for Location OUTLET1. Click on Boundary
Details tab and select for option under Mass And Momentum Average Static Pressure and set a value
of 0 Pa. Click OK to finalize.

b c

e
Step 21: Double click on Default Fluid Fluid Interface in Outline
tree. Make sure all the parameters are set as shown below (see
b).

Step 22: Then click on tab Additional Interface Models and set
the parameters shown below (c, d and e).
a

c
d

e
Step 23: In Outline tree right click on the Solver Control and then left click on the Edit. Set Max.
Iterations in Convergence Control to 2500. Click OK to close.

a
b

d
Step 24: Save the project. File > Save Case As.

c
Step 25: In Outline tree right click on Simulation
Control, left click on start solver and then left click on
Define Run.

Write Solver Input File window will pop-up. Keep the


suggested name and click Save to save as .def file.

b c

a
d
Simulation Run
Step 26: CFX-Solver Manager will be launched.

Under Run Definition check the box in front of


Double Precision Parallel Environment. Set Run
Mode to Intel MPI Local Parallel. Set the number of
Partitions to an appropriate number.

All set! Hit the Start Run to start the simulations. b


a

Note: Partitions number depends on your computer on c


which you are running your simulations. If you have more
than two physical cores on your computer, you can set a
higher number.

d
Simulation will start and residual plots will be visible on the screen. Click on the tab to display all the
residual plot windows. Once the simulation run is complete a pop-up window will be shown informing
that simulation is complete and asking for post-process results. Select Post Process Results and click
OK.

Note: Depending on your


computer specs simulation
run could take up to several
hours or even more.

b
Post-process Results
Step 27: CFD Post will be launched along with a pop-up window asking for Domain selection. Keep the
suggested ones and click OK.
Step 28: Now insert Plane by clicking on the Location and then on Plane. Select YZ Plane in the Method,
Click on the tab Color and set the Mode to Variable and Variable to Temperature. Set the Range to
Local. Click Apply.

b
d
e
f
c g

h
Now you should see a plane showing temperature distribution
Step 29: Now insert Probe by clicking on the Probe tab (a). Select Temperature (b) as the Probe
variable.

b
Now left click on the location close to ShellInlet as shown below (a). Note down the temperature
displayed (b) as probe variable. Now left click on the location close to the ShellOutlet as pointed below
(c) and note down the temperature (d) again. By comparing the temperature it turns out that temperature
reduction of around 4 °C is achieved in case of shell side fluid. Repeat the same procedure for tube side
fluid as well to find out how much temperature increase is observed for cooling fluid.

b d
Step 30: Uncheck the Plane 1 from Outline tree. Now insert Surface Group by clicking on the Location
and then on Surface Group. Insert Surface Group window will pop-up. Keep the suggested name and
click OK. Next on the Geometry tab select All Domains for Domains and click on the locations tab and
select the parts as shown below (f) and click OK to close.

c
f
b d

e
g
Step 31: Now click on Color tab and set the Color to white. Next click on Render tab and set the
transparency to 0.3. Click Apply to finalize.

c
d

e
Step 32: Now insert streamlines by clicking on the Streamlines tab. Keep the suggested name and click
OK. Select ShellInlet in Start From and for # of Points set a value of 75. Click Apply to plot streamlines.

d
b

e
Now you should see velocity streamlines

Simulation files for this tutorial can be


downloaded for free from FetchCFD at:
http://fetchcfd.com/view-project/789
Reference/Source:

- Original shell and tube heat exchanger CAD


model by kaliraj:
https://grabcad.com/library/shell-and-tube-heat-
exchanger-4

- Shell and tube heat exchanger Mesh for CFD

That’s All, Simulation: http://fetchcfd.com/view-project/797

- Shell and tube heat exchanger CFD Simulation:

Thanks -
http://fetchcfd.com/view-project/789

ANSYS Inc. 2017: http://www.ansys.com/


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