NUMERICAL CONFIGURATION OF HEAT

TRANSFER AND FLUID FLOW IN PLAIN TUBE

BOILER AND TUBE BOILER INDUCED WITH RIBBED
Student: Abu Faiq Bin Abu Bakar
UiTM ID: 2016238794
Supervisor: Zainoor Hailmee Bin Solihin

ABSTRACT

Computational Fluid Dynamics (CFD) simulation of heat transfer and fluid flow analysis in the turbulent flow
regime in a plain tube and ribbed tube horizontal orientation are presented in this thesis. The problems in fluid
mechanics is the determination of the fluid flow characteristic represented by a circular cylinder. In particular,
the study of turbulent fluid flow characteristic in a tube is one of the most important subjects in industrial flow
applications. The objective of this project is to determine the fluid flow characteristics such as temperature and
velocity in a horizontal positioned plain tube and ribbed tube with the iteration of 1m length. The flow
characteristic of the plain tube shows that the temperature increases from 375K to 470K while the pressure drop
between inlet and outlet is equal to 741.34 Pa. Meanwhile, for the ribbed tube, the temperature is increasing from
375K to 580K, with the pressure drop is found to be 1655.5 Pa. It is clear that the temperature difference between
ribbed and smooth tube are equal to 95K and 205K, respectively. The high pressure drop and Nusselt number in
corrugated tube is due to the corrugated tube which not only has disturbed the flow but also causes swirling effect
near the wall. To perform the steady state CFD analysis for tube, the simulation is performed in ANSYS 15.0 and
is based on the use of governing equation of mass, momentum, energy and turbulence. k-ε turbulence model is
used for this assessment due to wide applications in internal flows. Between the two different geometric, the ribbed
tube has higher heat transfer efficiency than the smooth tube. This clearly shows that the characteristic of ribbed
tube is much better than smooth tube.

1.0 Introduction

Nowadays, the main concern is to increase the efficiency of water tube boiler by enhancing the heat transfer rate
in the boiler tube. Due to economic and environment demand, engineers must continuously focus on improving
the efficiency of the boiler and reducing emission. In real condition the boiler water tube are plane walled, due to
this the flow inside the tube is turbulance. Many studies have focused on turbulent flow, the laminar range is
particular interest in wide variety of engineering situations, including heat exchangers for viscous liquids in
chemical process and food industry. The use of smooth surface inside the tubes gives poor performances and new
geometries are needed to enhance the rate of heat transfer in tubes. Hence, the studies about flow characteristic in
tube boiler could be achieved by using CFD.

Computational Fluid Dynamics (CFD) is an engineering tool for modelling fluid flow, heat and mass transfer,
chemical reactions and related phenomena in complex geometries by solving the set of governing mathematical
equations. The main stages in a CFD study are divided into 3 stage. First, pre-processing. Formulate the problem,
governing equations and boundary conditions that construct computational mesh. Second, Solving. Numerical
solution of the governing equations. Third, post-processing. It is a process of plotting and analysis of results.

The solution to a flow problem (velocity, pressure, temperature etc.) is defined at nodes inside each cell. Both the
accuracy of a solution and its cost in terms of necessary computer hardware and calculation time are dependent
on the fineness of the grid. In general, the larger the number of cells in the grid the better the solution accuracy.
Optimal meshes are often non-uniform: finer in areas where large variations occur from point to point and rougher
in regions with relatively little change.
Rahman and Sukahar [7] presented about the Tube Temperature distribution in a water tube boiler through
application of finite element method (FEM). The Two-dimensional FEM models were developed and
axisymmetric triangular elements for the tube cross section area were employed. The results showed that the
temperature distribution at the tube wall decreases with increased mass flow rate of steam and increased scale
thickness.

Smith, J. W. et al. [1] The objective of this study was to experimentally measure the turbulent heat transfer and
temperature profiles in a rifled pipe. The rifled pipe was made by fitting snugly the continuous spiral rib inside a
smooth brass tube which had the inner diameter of 2.058 inch. The temperature profiles showed that the rifling
had reduced the resistance to heat transfer in the turbulent core which in the end the rifled tube offered a much
better heat transfer efficiency than in the smooth tube. Due to relatively uniform temperature profiles in the rifled
tube, the authors had suggested that the application of the rifled tube in tubular type reactors to ensure uniform
temperature distribution.
2.0 Methodology

The methodology of the present study can be divided into four stages of process flow which are geometry
modeling, pre-processing, processing and post-processing. Various steps in adopted methods are:

• Mathematical modeling of the system considered in present study.

• Developed the model in CATIA V5.

• Validation of present work and parameter with previous research.

• Run program to obtain the plots with plain boiler tube and tube boiler induced with ribbed parameters.

• Plotting & analysis of obtained plots.

2.1 Design and Modelling

The modeling software tool used to design the Boiler Tube and its geometry is CATIA V5. CATIA is
widely used to design and model 2D and 3D objects which are imported to numerical tools to carry out the
simulation. The modeling software has a wide range of accessibility and integrated with advanced design tools
which make it simple and little time consuming to design various objects for engineering applications. The tool
used to carry out the CFD analysis is ANSYS 15.0 and the solver chosen is CFX. The Continuity, Momentum
and Energy equations are the principle equations or laws used in CFD to solve for the require solution. The
ANSYS CFX tool is used to discretize the spatial domain using a mesh. The approximation accuracy is a function
of mesh spacing and the time step factor of higher order terms in the series expansion. ANSYS CFX uses shape
functions and second order approximations where the variations in each element such as tetrahedral, hexahedral,
pyramid and wedge are described by tri-linear shape functions

Parameter Dimension
Number of twist 99
Rib Width 10 mm
Rib height 1.9 mm
TABLE 1: Parameter corrugated ribbed tube

Fig. 1: 3D model of Corrugated ribbed tube

 Fig. 2: 3D model of plain tube

In this 3 dimensional CFD study, both tubes consider 26.7 mm outer diameter with a thickness of 3.9 mm and the
analysis was done for a length of 1000 mm. The commercial CFD software employs a control volume based
technique to convert the governing equations which are solved numerically using the implicit method. In the
segregated formulation the governing equations are solved sequentially, as it is segregated from one another.

2.2 Meshing & Simulation of Flow

The most important step in CFD analysis next to modeling is Meshing. Meshing decides the degree of
accuracy and time taken for analysis. There are many types of meshes like hex, tetra, staggered, etc.., of which
Triangular, Hex mesh and tetra mesh are important. Triangular and Hex meshes are mostly used for fluid analysis
where tetra meshes are used for solid boundaries. The developed 3D models as shown in the previous sections are
imported into the design module of the workbench. Later on using ICEM CFD the geometries are meshed. As
mesh quality decide time taken for analysis and accuracy, on each model grid independent test is conducted. Grid
independent test avoids the inappropriate results due to less number of elements or more number of elements.

Fig. 3: Mesh profile of corrugated tube

Fig. 4: Mesh profile of plain tube

The meshing is done in ICEM CFD 15.0 after modeling, the total number of elements is 36464 and the total
number of nodes is 27039 for Plain Tube and the total number of elements is 457026 and total number of nodes
is 430636 for corrugated tube. The element type is tetrahedral type. In order to capture both the thermal and
velocity boundary layers the entire model is discretized using tetrahedral type mesh elements which are accurate.
 2.3 Solver

The continuity, momentum and energy equations will be used by CFD and convert them to algebraic equations
by using Finite volume method and then run the solution by using implicit scheme second order upwind. Water
will be used as working fluid. Inside the tube with inner diameter (18.9 mm) and the thickness (3.9 mm) the
corrugated ribbed tube is consists of three additional parameters, which are Number of ribs, Height of ribs, and
Width of ribs. The CFD simulation is applied on Plain tube and corrugated ribbed tube under constant mass flow
rates. The following boundary conditions are given to the tubes in FLUENT 15.0.

The entire geometry was set up into fluid domain (water). In the present study, the k-epsilon standard model is
used with near wall treatment having standard wall functions. The two basis assumptions used in this study are:

a) The boundary condition for the inflow velocity at the tube inlet was assumed to be uniform.
b) No slip boundary condition.

Parameter
Mass flow rate 24 t/hr
Heated section temperature 1500 K
Velocity inlet 0.5 – 1 m/s
Temperature inlet 375K
Table 2: Parameter in boundary condition

The temperature of the heated section is 1500 K and heat transfer takes place to the water inside the tubes. The
temperature distribution in the boiler tube is affected by many variables such as mass flow rate of water, water
density, feed water temperature and area of tube boiler. Therefore, effect of these variables is also considered by
running a limited number of simulations by using the CFD simulation the result will contains the enhanced heat
transfer due to the increased wetted perimeter of the boiler tube and some other effects due to geometry.

During flow boiling water generated will flow through the water tube, may be in some region water may in contact
with the tube wall. In optimized tube geometry there will be a swirling flow and that centrifugal force will separate
steam and water, denser water will be taken away to the wall region by keeping less dense steam at the centre
region. This effect of optimized geometrical design of boiler tube will make the heat transfer more efficient than
ordinary plane boiler tube.
 2.4 Post-processor

At the end of this step we obtain the results in the form of contours, velocity vectors and residuals. In the present
study, the k-epsilon Realizable model is used with near wall treatment having standard wall functions. The solving
is done in FLUENT 15.0 and post processing is done in CFD-Post 15.0

Fig. 5: Flow chart showing the approach for solving the simulation
3.0 Results and Discussion

The mathematical model and methodology for solving the problem used in present work. This mathematical model
is studied, solved and validated using an ANSYS (FLUENT) programme in the present work. Present work also
includes parametric study of boiler tube geometry and obtaining heat transfer characteristics of boiler tube induced
with ribbed and compared it with the smooth tube. Simulations were carried out with constant mass flow rate for
both geometries considered here for boiler tube. The post processor was carried out in Fluent, and during the
process, the following observations were encountered.

3.1 Effect of corrugated geometry on heat transfer enhancement in tube boiler

Table below shows different parameters of heat transfer enhancement in boiler tube having smooth tube and
another different geometry. It has been observed that the total heat transfer rate and at the outlet of the channel is
increased significantly by applying corrugated geometry inside the tube of boiler. This is due to expanded
roughness surface area for similar mass flow inlet. Lower the low value of mass flow, inlet higher will be the
surface area and tube get heated consistently and in relatively minimum time as compare to large mass flow inlet
and smooth tube

Type Inlet Outlet

Temperature (K) 375 470
Heat Transfer Coefficient 4861.95
(W/m2-K)
Table 3: Different sets of boiler tube parameters having simple geometry

Type Inlet Outlet

Temperature (K) 375 540
Heat Transfer Coefficient 5922.15
(W/m2-K)
Table 4: Different sets of boiler tube parameters having corrugated ribbed geometry
 3.2 Temperature profile of boiler tube

When fluid to be heated enters into the tube, due to convective heat transfer the fluid inside the tube get heated.
Due to wall heat transfer coefficient and area product fluid get heated initially up to a certain length and after a
long time fluid reaches to a consistent temperature. Below are fig. 6 and fig. 7 showing temperature profile against
the position of the boiler tube. From the figure as shown above, it is been observed that the contour showing
temperature profile of smooth tube having simple geometry is not efficient as compared to the graph of other
figures having corrugated geometry. Temperature of smooth tube geometry goes up to 470 K from initial
temperature of 375 K while the temperature of corrugated tube geometry goes up to 540 K. The mean temperature
of the working fluid increases with the distance from the entrance as expected, as shown in both figure. Also
expected, the increase is rapid nearer the wall because of high heat transfer rates in this region due to higher
temperature differences between the wall surface and the fluid.

Fig. 6: Contour for static temperature on plane for corrugated tube (fluid domain)

Fig. 7: Contour for static temperature on plane for plain tube (fluid domain)

Fig. 6 and fig. 7 above show the comparison between the plain tube and corrugated ribbed tube fluid
domain temperature contours. The maximum fluid domain temperature in plain tube is approximately 197 °C and
for corrugated ribbed tube is around 267 °C. The study proves that the corrugated ribbed tube has better heat
transfer than plain tube and hence higher heat transfer rate than plain tube.
 3.3 Grid Independence study

In a grid independence study, the goal was to find the best mesh properties for accurate solution. The
process is to vary the mesh density to eventually provide a desired numerical accuracy for engineering purposes
at the same time achieving an optimum computational time.

Grid sensitivity study was conducted using a relevance factor for the entire tube boiler. The comparisons are
shown in Table 4.

MESH Relevance factor Number of nodes Number of element Temperature (K)

MESH 1 -80 283095 270900 490

MESH 2 -60 437950 1144740 515
MESH 3 -40 457026 430636 540
MESH 4 -20 525255 494474 588
MESH 5 0 766458 735591 590
MESH 6 20 811734 777594 595
MESH 7 40 1024521 3057592 600
Table 4: Grid sensitivity study

Fig. 8: Meshing element for (-80) relevance factor

Fig. 9: Meshing element for (-60) relevance factor

Fig. 10: Meshing element for (-40) relevance factor

Fig.11: Meshing element for (-20) relevance factor

Fig. 12: Meshing element for (0) relevance factor

Fig. 13: Meshing element for (20) relevance factor

Fig. 14: Meshing element for (40) relevance factor

 Temperature vs nodes
700

600

500
Temperature

400

300

200

100

0
0 200000 400000 600000 800000 1000000 1200000
Nodes

Temperature

Fig. 15: Comparison of temperature for 7 different meshes

Temperature for 7 different meshes were plotted (Fig. 15) and the change was observed to be less than 1% by
increasing the temperature between the Mesh 4 and Mesh 7 model. Therefore, any one of these meshes can be
chosen, but to save the computational time, the mesh with 525235 cells was selected. It is include enough mesh
detail around the corrugated ribbed geometry to ensure flow field and temperature accuracy.
4.0 Conclusion

The study carried out has been successfully met the goals of this project, that to determine the fluid flow
characteristics such as temperature and velocity in a horizontal positioned plain tube and ribbed tube with the
iteration of 1m length. The CFD study on heat enhancement characteristic of water flowing inside two types of
tube with different geometry were evaluated. Furthermore, it has been successfully define the mathematical
configuration for both tube with the best mesh properties. It also could differ the performance of corrugated tube
and plain tube. Therefore, CFD modelling with commercial CFD software, is a reliable method to be used to
predict heat transfer behaviour of flow.

The model was created using CATIA V5 and the flow analysis is done with ANSYS 15. The results
showing that the heat transfer is increased. The enthalpy and temperature increase with flow is advancing when
compare with normal boiler tube. Other than that, based on the results, the solution was concluded to be
independent of the number of cells. The grid generation started with coarse mesh. So the implementation of
Optimized corrugated ribbed boiler tube in this boiler is advisable. The study show that the improvement in
furnace heat transfer can be achieved by changing the internal plane surface to a corrugated ribbed geometry.
5.0 References

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[8] N. S. Gupte and A. W. Date, "Friction and heat transfer characteristics of helical turbulent air flow in annuli,"
Transaction of ASME Journal of Heat Transfer, Vol. 111, pp. 337–344, 1989.

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[10] Y. Chiu and J. Jang, "3D numerical and experimental analysis for thermal– hydraulic characteristics of air
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