HEAT TRANSFER ANALYSIS IN FINNED TUBE

HEAT-EXCHANGER WITH DESICCANT TABLET

A Project Report for

MINI PROJECT

























Submitted by:

AKARSH SONI (2011ME10648)

AMIT RANJAN (2011ME10653)



Under the esteemed guidance of

PROF. P.M.V. SUBBARAO



MECHANICAL ENGINEERING DEPARTMENT

INDIAN INSTITUTE OF TECHNOLOGY DELHI

HAUZ KHAS, NEW DELHI-110016
ACKNOWLEDGEMENT







I would like to express my gratitude to everyone who contributed, in
different ways, in completion of this project. My first thank has to go to my
supervisor- Prof. P.M.V. Subbarao for his keen interest, invaluable guidance
and timely supervision throughout the project work. Working with him was
more of a learning process which generated a lot of interest inside me
towards the project.

I also wish to extend my thanks to faculty members of Mechanical
Engineering Department for their support and continuous inspiration. I would
like to express my sincere regards to Mr. Raj for providing immense help in
completing this project and their assistance during various phase of project.



Finally thanks to my parents and friends for their direct or indirect
support and constant encouragement.





























April, 2014 Akarsh Soni & Amit Ranjan
INTRODUCTION AND THEORY






Adsorption refrigeration and heat pump have been thought as environment benign and cost
effective in waste recovery heat system. Adsorption working pair of calcium chloride-
ammonia has been proposed and developed for cooling.



Phase I : Initially reactor is cooled by a heat transfer fluid at Tm (ambient temperature). This
causes a drop in pressure in the reactor. When the pressure in the reactor reaches the
evaporator pressure the gas valve-1 connected to the evaporator is opened. The ammonia
gas at low pressure and temperature from evaporator is supplied to reactor and is adsorbed
by CaCl2 adsorbent.

The valve-1 is closed when there is equilibrium between evaporator and reactor pressure.

Phase II : After completion of phase I, reactor is heated by a heat transfer fluid because of
which adsorbed ammonia is released by CaCl2 in the form of ammonia vapours. The
heating is continued till the ammonia gas pressure reaches the condenser pressure. (The
temperature increase due to heating of ammonia and formation of ammonia vapours leads
to an increase in pressure inside the reactor.)

The valve-2 is opened when the ammonia gas pressure in reactor exceeds the
condenser pressure.
Stoichiometric equation for the reaction taking place in the reactor can be represented as:

2.3 + 1 2.(1)3 + 13

where, Hr = Enthalpy of transformation for reaction (J/mol)



The main motive of this mini project is to thermally analyse the finned tube heat
exchanger with two desiccant mixtures:

1. Calcium chloride only

2. Calcium chloride +activated carbon

These mixtures were used to conduct the experiment and to determine the overall heat
transfer coefficient of the heat exchangers. Also, see the effect of different parameters on it
like temperature of hot fluid, mass flow rate of the hot fluid and different amount of
activated carbon.

Activated carbon has lower value of thermal conductivity but it is mixed with
calcium chloride to improve mass transformation.
OBJECTIVE AND MOTIVATION






Objective:
Do heat transfer analysis in finned tube heat exchanger (solidified compound
adsorbent made by CaCl2 and activated carbon) and experimentally-
1. Compare the heat transfer through HX using "CaCl2" and "CaCl2 with Activated
carbon" as desiccant.
2. Compare the heat transfer through HX by varying the amount of activated carbon
in CaCl2.
3. See the effect of mass flow rate of hot fluid, different temperature of hot fluid
on the heat transfer through the HX.




Motivation:

Although some work has been done on problems related to swelling and smashing of the
CaCl2 adsorbent particles. Heat transfer analysis of the available system has not yet been
conducted. Use of the system without any proper heat transfer analysis can be termed as
brutal engineering because of the resources that would be wasted in doing so.

We intend to study the heat transfer analysis to extract maximum possible energy from
the waste energy (we intend to provide heat to HX through low grade heat sources) by
considering the factors affecting heat transfer and hence maximising the performance of
finned tube HX. This might also open the doors for use of low grade heat source for the
device.

SCHEMATIC
LITERATURE REVIEW




Following works had been studied for a better understanding of the project at hand and
the fundamental principles related to it.

Marcel Lacroix, University of Sherbrooke: He presented a theoretical model for
predicting the transient behaviour of a shell-and-tube storage unit with the PCM on the
shell side and the HTF circulating inside the tubes. A series of numerical experiments
were done to assess the effects of:
(1) The shell radius: On increasing radius, melting temperature of PCM is not reached,
only sensible heat is stored.
(2) The mass flow rate and inlet temperature of the HTF: Stored energy in PCM varies
linearly with inlet temperature and with an increasing slope for augmenting mass flow rate.
(3) The presence of fins attached to the inner tubes on the thermal behaviour of the
thermal unit: Annular fins were most effective for moderate mass flow rates and small inlet
temperatures.

L.W. Wang, R.Z. Wang, J.Y. Wu, K. Wang: Adsorption performances of three types of
adsorbents, CaCl2 with different expansion space, simple compound adsorbent and
solidified compound adsorbent made by CaCl2 and activated carbon, were tested, in which
ammonia was used as refrigerant.
The solidified compound adsorbent showed best performance for adsorption ice makers
on fishing boats for the larger filling quantity of adsorbent. The mass transfer performance
is improved by the addition of activated carbon in solidified compound adsorbent at the
condition of low evaporating temperature.

L. Wang, L. Chen, H.L. Wang, D. L. Liao: Study was conducted on the adsorption
characteristics of the adsorption refrigeration working pairs using alkaline-earth metal
chlorides as adsorbents and ammonia as refrigerant. The adsorption refrigeration
experiments of composite adsorbents were investigated. The study indicated that the
refrigeration capacity could be enhanced by compositing the adsorbents which
indicates that composite adsorbents can perform better in adsorption refrigeration, and
can be employed in adsorption refrigeration system using low-grade heat source.


Aytunc Erek, Dokuz Eylul University: He studied the heat transfer enhancement in
the thermal energy storage system by using radially finned tube. The solution of the system
consisted of solving the equations of the heat transfer fluid (HTF), the pipe wall and fin,
and the phase change material (PCM) as one domain. Fully developed velocity distribution
was taken in the HTF.
The results showed that solidification fronts can be significantly increased if the fin height is
increased. These results gave some knowledge for the design of the thermal energy storage
system.
FABRICATION OF HX WITH DESICCANT AND PROCEDURE



1. Manufacturing of finned tube heat exchanger:

The finned tube of following dimensions was used to conduct the
experiment: Length of finned tube = 25 inch = 63.5 cm

Inner diameter of tube = 16 mm
Outer diameter of tube = 17 mm

Diameter of fins = 35 mm (from the outer dia. Of
tube) Fin spacing = 5 mm

Fins per unit length = 29 per 5 inch = 2.29 per 1 cm
Thickness of fin = 0.5 mm

Manufactured finned tube were obtained from the industry directly and were used
to conduct the experiment.



















2. Preparing mixture of CaCl2 + Water or CaCl2 + Activated Carbon
+ Water:

Amount of water was calculated for the amount of CaCl2 used to fill the finned
tube considering CaCl2.3H2O

54 gm water (wt. of 3 molecule of water) in 111 gram of CaCl2 (wt. of 1 molecule of
CaCl2) Mixture was prepared by carefully mixing water in CaCl2 (or activated carbon
if used) as the reaction is exothermic in nature and large amount of heat is liberated
in preparing small amount of mixture.
2 + 3 2 2.3 2 + .










































3. Calibration of thermocouples:

Thermocouple wires (8 wires) were prepared (beads were made using Welder).
After this, they were dipped into ice (0C) and hot water (100C) respectively and
respective temperature were noted down from digital analogue.

For eg: Wire 1 showed temperature of ice and hot water--> -3C and 96C respectively

While they were at a temperature of 0 and 100 C respectively. So, error of thermocouple
wire 1 is [(-3)+(-4)]/2 = -3.5 Hence, 3.5 was added to the temperature shown by
thermocouple while doing the experiment. (Tactual = T thermo. + 3.5)






































4. Filling of finned tube with desiccant and removing water from it

After preparing the mixture of CaCl2, activated carbon and water. The mixture was filled
in the finned tube uniformly.





















As it is desiccant so it adsorbs water the surrounding and hence there is a need to heat
it in a furnace to desorb extra water molecules from the filled fin tube.




























Fig: Drying the paste after filling in finned tubes



5. Preparing experimental set-up

Experimental set-up consisted of:

Heat Exchanger:

It was a long tube made of mild steel with radial fins on the outer surface of it. Length
of finned tube was approx. 25 inch or 63.5 cm. Inner and outer diameter of tube were
16 and 17 mm respectively. Fins were of diameter 35 mm (from the outer dia. Of tube)
and 0.5 thickness with spacing of 5 mm in between.

The spacing between the fins was filled with desiccant mixture i.e. CaCl2 + Activated
carbon + Water uniformly.




































Fig: Heat Exchanger with high pressure tube Fig: Duct around HX



Duct: Heat exchanger was enclosed by a pipe to see the effect of natural and forced
convection. Used to guide the air flow over the heat exchanger. The ambient air
enters from the bottom and the heated air leaves the duct at the top.

High pressure tube: It was connected to the ends of the finned tube with m-seal
ensuring that there is no leakage from the ends. Hot flow from the water flow system
was passed through this high temp and high pressure pipe to the finned tube HX.

Water flow system: It consisted of tubes connecting tank, high pressure tube and pump.

To measure mass flow rate- Manometer was connected across the orifice plate to
obtain the pressure difference across orifice. Hence, calculating the mass flow rate of
hot water through the HX.

Heater- Heaters were used to vary the temperature of water flowing through the HX
(i.e. 60, 70, 80 C) And an electrical control system was provided to control the
temperature and maintain a steady value.

Pump: To circulate hot water through the Heat Exchanger.

Digital Analogue: Thermocouples from the different points of HX (along the HX at 0, 5, 10,
15, 20, 25 inch points from one end) were connected to the digital analogue and reading
were taken from it to get the temperature variation along the length of HX.




























Blower & Anemometer:

Blower was used to provide air velocity in the duct parallel to the HX i.e. along the
length of finned tube and test the HX for forced convection.

To measure the air flow velocity in the duct in which HX is placed. Hence, mass flow
rate of air can be calculated i.e.
=

6. Conducting experiment for different parameters

After achieving steady flow through the HX and constant hot water temperature, we
took observation i.e. temperature reading from the digital analogue for different sets:

1) CaCl2 2) CaCL2+Activated carbon (.125)* 3) CaCl2+Activated carbon (.2)*

*weight fraction of activated carbon in the desiccant mixture of CaCl2, activated
carbon and water.

All above HXs were tested for different parameters i.e. different temperature of hot
water, mass flow rate of hot water, free and forced convection.






































Figs: Full system including HX, Pump, Heater. Water Flow system,
Digital Analogue, High pressure tube, Manometer.
OBSERVATION AND CALCULATION



Dimension of fin tube:

Inner diameter of tube =15mm
Outer diameter of tube =17mm

Outer diameter of circular fins= 35mm
Finned tube length= 25inch= 63.5cm

No. of fins per unit length= 29fins/5inch = 2.28 fins/cm
Curved surface area of finned tube with desiccant=

=*outer dia of fin*length of finned tube
=*35mm*63.5cm

=.06982 sq m



OBSERVATION TABLES:

1. Desiccant = CaCl2 only

a) At 80 C

Mass Flow
rate (Kg/m3) 5 2.5 5
Flow type Free Free Forced
Points along
the length of Temperature Temperature Temperature
pipe(cm) (C) (C) (C)

Pipe outlet
25 77.6 80 78.9
20 78.1 80.3 79
15 78.6 80.7 79.3
10 79.1 81 79.8
5 79.7 81.2 80
0 80.2 81.7 80.7
Pipe inlet 80.8 82 81.6
Air velocity 0.1 0.1 5.7m/s
Ambient Temp.
36 36 36
Air outlet temp
40.1 41 39
Dia. Of
external pipe
(cm) 18 18 18


b) At 70 C

Mass
Flow
rate
(Kg/m3) 5 2.5 5
type Free Free Forced
Points along the Temperature Temperature Temperature
length of pipe (C) (C) (C)

Pipe outlet
0 68 68.3 67.4
5 68.3 68.6 67.9
10 68.6 68.8 68.2
15 68.9 69.1 68.8
20 69.3 69.4 69.1
25 69.6 69.8 69.5
Pipe inlet 70 70 70
Air velocity 6.2
Ambient Temp. 36 36 36
Air outlet temp 40 41 39
Dia. Of external
pipe 16 16 16
c) At 60 C



Mass
Flow
rate
(Kg/m3) 5 2.5 5
Flow
type Free Free Forced
Points along the Temperature Temperature Temperature
length of pipe (C) (C) (C)

Pipe outlet
25 58.3 58.5 58
20 58.6 58.8 58.4
15 58.9 59.2 58.9
10 59.3 59.5 59.3
5 59.6 59.7 59.6
0 60 60 60
Pipe inlet
Air velocity 5.9
Ambient Temp. 36 36 36
Air outlet temp 40 41 39
Dia. Of external
pipe 16 16 16


d) Desiccant = CaCl2 + Activated Carbon

a. At 60 C

Mass Flow Rate
(kg/s)

5 2.5 5
Flow type

FREE FREE FORCED



Points along pipe
TEMP

TEMP

TEMP


Outlet 25 59 59 58.5

20 59.3 59.2 58.8

15 59.5 59.4 59.1

10 59.5 59.8 59.4

5 59.7 60 59.7

Inlet 0 60 60 60
Duct diameter=17cm



Air outlet temp 42 43 42

a) At 70 C

Mass Flow Rate
(kg/s)

5 2.5 5
Flow type

FREE FREE FORCED



Points along
pipe
TEMP

TEMP

TEMP


Outlet 25 69 69 68

20 69.2 69.1 68.2

15 69.4 69.3 68.7

10 69.5 69.5 69.1

5 69.8 69.7 69.6

Inlet 0 70 70 70
Duct diameter=17cm



Air outlet temp 42 43 42

a) At 80 C

Mass Flow Rate
(kg/s)

5 2.5 5
Flow type

FREE FREE FORCED



Points along
pipe
TEMP

TEMP

TEMP


Outlet 25 79 79 78

20 79 79.2 78.4

15 79.3 79.3 78.6

10 79.6 79.6 79.1

5 79.7 79.8 79.6

Inlet 0 80 80 80
Duct diameter=17cm



Air outlet temp 42 43 42


SAMPLE CALCULATION

Calcium chloride desiccant at full opening valve forced convection:
Water inlet temp. = 80.8 C

Water outlet temp. = 77.6C
Orifice diameter= 18cm
Pipe diameter =65cm


Pressure difference in orifice section = 5mm of mercury
=5*13600*9.81/1000
=667.08 Pa

Volume flow rate through tube = Q
=Cd*A2*2*(P1-P2)/*(1D
2
2/D
2
1)

=.75**.18
2
/4 *2*667.08/1000(1-.18
2
/.65
2
)

=.229*10
-3
m
3
/s

Mass flow rate of water through tube = *Q

=1000*0.229*10
-3


=0.229 kg/s
Heat transferred = mw* Cp*(Tw2 Tw1)

=0.229*4.186*(80.8-77.6)*1000
=3080 W

Air intlet temp = 36C
Air outlet temp.= 39C

LMTD = [(80.8-36)-(77.6-39)]/ln[(80.8-36)/(77.6-39)]

=42.42C

Therefore, UASTln = 3080

Hence, U = 3080/(.06982*42.42)

=1039.92 W/m
2
C

RESULT TABLE 1: CaCl2 only

Type of
flow
Inlet
temperature

Outlet
Temperature

Mass
Flow
Rate
(kg/s)



Tlm
U(W/m
2
c)
Air inlet
temperature

Air inlet
temperature



Free 81.6 78.9 0.23 2021 41.25 701.7 36 41
Free 82 80 0.115 962.7 45.41 303.64 36 40
Forced 80.8 77.6 0.23 3080 42.42 1039.92 36 39


Forced 70 67.4 0.23 2503 30.32 1190 37 39
Forced 60 58 0.23 1925 20.93 1317.3 37 40


RESULT TABLE 2: CaCl2 + Activated Carbon

Type of
flow
Inlet
Temperature

Outlet
Temperature

Mass
Flow
Rate
(kg/s)


Air inlet
temperature
Air outlet
temperature Tln
U(W/m
2
C)



Free 80 79 0.115 481.39 40 43 17.92 181.63
Free 80 79 0.23 1925 40 42 38.48 716.49
Forced 80 78 0.23 1925 40 42 37.96 726.31


Forced 70 68 0.23 1925 40 42 27.95 986.43
Forced 60 68.5 0.23 1444.17 40 42 18.19 1137.11
















DISCUSSION




If we increase the mass flow rate of the hot water flowing through
tube then overall heat transfer co-efficient value of air side increases.
It can be explained as Cmin/Cmax ratio decreases while we increase
the value of mass flow rate and effectiveness value will not change
much more by changing the flow rate so we get a higher value of
Nusselt number implies higher value of overall heat transfer co-
efficient.


In case of blower we get higher value of overall heat transfer co-
efficient as it increases the convective heat transfer co-efficient which
depends strongly on air speed. Also increasing air speed will decrease
the value of Cmin/Cmax ratio which leads to increase in value of NTU
and so overall heat transfer co-efficient.

As we increase the hot water temperature flowing through tube we get
lower value of overall heat transfer coefficient. We are expecting it ti be
high as due to higher temperature difference between water
temperature and ambient temperature heat transfer magnitude should
be higher and so overall heat transfer coefficient.
It happens because of stability of desiccant. At higher temperature the
desiccant particles is not bounded together and it lose contact with the
finned tube and increasing the thermal resistance. So we get lower
value of overall heat transfer coefficient.

The overall heat transfer coefficient for desiccant with activated
carbon is lesser than with only calcium chloride as a desiccant. In our
experimental temperature range its value is around 8-20% lesser than
that of calcium chloride desiccant. But this heat exchanger is used in
adsorption refrigeration cycle where ammonia gas is adsorbed in
desiccant and by using calcium chloride with activated carbon its mass
transfer performance is improved appreciably which compensates for
its lower value of overall heat transfer co-efficient.
SOURCES OF ERROR




Calcium chloride as a desiccant starts adsorbing water from surrounding.
So its property will be altered. So some of the heat transfer fraction will be
used by water molecules latent heat of fusion and we get lower value of air
outlet temperature implies high value of LMTD and so lesser value of
overall heat transfer co-efficient. To improve this we can conduct
experiment in an evacuated chamber and passing dry air to the duct.


Thermocouples are not welded along the different sections of the
tube. During heating of the finned tube desiccant becomes softer and it
thermocouple may get misplaced.
REFERENCE




1. The adsorption refrigeration characteristics of alkaline-earth metal chlorides and
its composite adsorbents.
By- L. Wang, L. Chen*, H.L. Wang, D.L. Liao, The School of Chemistry and Chemical
Engineering, South China University of Technology, Guangzhou 510640, Guang
Dong, China.

2. Compound adsorbent for adsorption ice maker on fishing boats.
By- L.W. Wang, R.Z. Wang*, J.Y. Wu, K. Wang, Institute of Refrigeration and
Cryogenics, Shanghai Jiao Tong University, Shanghai, 200030, China.

3. Study of the heat transfer behaviour of a latent heat thermal energy storage unit
with a finned tube.
By- Marcel Lacroix, Department de genie mecanique, Universite de
Sherbrooke, Sherbrooke, Canada.

4. Phase change around a finned tube.
By- Aytun EREK, Dokuz Eyll niversitesi, Mhendislik Fakltesi, Makina
Mhendislii Blm, 35100-Bornova/zmir