Experimental Investigation on Effect on Heat

Transfer Rate by Cascading Spiral Inner Tube in

a Heat Exchanger

PME-753: PROJECT SYNOPSIS

By

Awadhesh Kumar Roy

Md. Nafis Ahsan
Mohd. Zaigam
Nidhi Bora

Project work carried out at

AMRAPALI INSTITUTE OF TECHNOLOGY AND SCIENCES

HALDWANI (UTTRAKHAND)

AMRAPALI INSTITUTE OF TECHNOLOGY & SCIENCE

HALDWANI (UTTRAKHAND)

December, 2016
 Experimental Investigation on Effect on Heat
Transfer Rate by Cascading Spiral Inner Tube in
a Heat Exchanger

PME-753: PROJECT SYNOPSIS

By
Awadhesh Kumar Roy
Md. Nafis Ahsan
Mohd. Zaigam
Nidhi Bora

Project work carried out at

AMRAPALI INSTITUTE OF TECHNOLOGY AND SCIENCES

HALDWANI (UTTRAKHAND)

Submitted in partial fulfillment of B.Tech Mechanical Engineering Degree programme

Under the Supervision of
Asst. Prof. Mayank Bhola
Amrapali Institute of Technology and Sciences, Haldwani (Uttrakhand)

AMRAPALI INSTITUTE OF TECHNOLOGY & SCIENCE

HALDWANI (UTTRAKHAND)

December, 2016

[II]
 CERTIFICATE

This is to certify that the Project Report entitled Experimental Investigation on Effect on
Heat Transfer Rate by Cascading Spiral Inner Tube in a Heat Exchanger and submitted by
Awadhesh Kumar Roy, Md. Nafis Ahsan, Mohd. Zaigam, Nidhi Bora for the partial
fulfillment of the requirements of B.Tech. Mechanical Engineering degree of Uttrakhand
Technical Univeristy, embodies the bonafide work done by him under my supervision.

Place: Haldwani Signature of the Project Guide

Date: 06/12/2016

Mr. Mayank Bhola

Assistant Professor

A.I.T.S. Haldwani

[I]
 Amrapali Institute of Technology & Science, Haldwani

Uttrakhand Technical University

Seventh Semester 2016-2017

PME-753 Project Synopsis

UNIVERSITYROLL NO. : 130030104026 130030104041

130030104042 130030104048

NAME OF THE STUDENT : Awadhesh Kumar Roy Md. Nafis Ahsan

Mohd. Zaigam Nidhi Bora

PROJECT CARRIED AT :Amrapali Institute of Technology &Sciences.

GUIDE NAME :Mr. Mayank Bhola

GUIDESS EMAIL ADDRESS : mayankkecua@gmail.com

DISSERTATION TITLE : Experimental Investigation on Effect on Heat Transfer

Rate by Cascading Spiral Inner Tube in a Heat Exchanger

[II]
 ABSTRACT
Heat Exchanger is a device used to exchange the heat from two fluids; having the temperature
gradient. This device is working on the principle of 2nd law of thermodynamics. To increase the
heat transfer rate, various methods were adopted in the past based on the research by including
the inserts Fins & Micro fins, Nano-fluids. Now we are including the design of inner pipe in
shape of spiral in the cascade.
For this purpose we have to change the design of inner tube of heat exchanger we use the
CATIA- V5 and to analyze the performance using the ANSYS software then compare the data
with the experimental one, on the different nature of fluid flow.

Broad Academic Area of Work: Heat and Mass Transfer, Fluid Mechanics

Key Words: New Design of inner pipe (spiral), CFD Analysis (ANSYS), Heat Transfer
enhancement through experimental performance

Signature of the Students

Date: 06-12-16
Signature of the Project Guide

Mr. Mayank Bhola

[III]
 ACKNOWLEDGEMENT

Words are indeed inadequate to convey my deep sense of gratitude to all those who helped me
through guiding this project to the best of my ability. Being a part of this project has certainly
been a unique and a very productive experience on my part.

I am really thankful to Mr. Mayank Bhola (project guide) with Mr. Hitendra Bankoti (project
coordinator) for making all kinds of support to carry the project successfully and for guiding
and helping me to solve all kinds of queries regarding the project work. The systematic way
of working and incomparable guidance has inspired the pace of the project to a great extent.

This project would not have been successful without the help of Mr. Ashish Saxena Head of
Dept. of Mechanical Engg. AITS, Haldwani

Last but not least I would like to thank all the Lab Attendant. Those who have directly or
indirectly helped me with their moral support for the completion of my project.

Sign

Awadhesh Kumar Roy

Sign.

Md. Nafis Ahsan

Sign.

Mohd. Zaigam

Sign.

Nidhi Bora

[IV]
 CONTENTS

Page no.

CERTIFICATE ......... [I]

ABSTRACT ... [II- III]
ACKNOWLEDGEMENT.......... [IV]
TABLE OF CONTENTS.................... [V]
LIST OF FIGURES .............. [VI]
LIST OF TABLES................ [VII]
ABBREVIATIONS......................................................................................................[VIII]
1 Introduction...........[1]
2 Literature Review .................[2-3]
2.1 Types of Heat Exchanger.............[2]
2.1.1 Transfer Type.......................[2]
2.1.2 Storage Type.............................[2]
2.1.3 Direct Type.......................[2]
2.2 Heat Transfer Enhancement....................[3]
2.3 The Overall Heat Transfer Coefficient........................[3]
2.4 Coefficient of friction..........[3]
2.5 Coefficient of velocity..................................................................................................[3]
2.6 Fluid flow rate.............................................................................................................[3]
3 Aim.............[4]
4 Methodology......[4-8]
4.1 Boundary Layer Effect...........[4]
4.2 Relative of Thermal &Momentum Boundary Layer....[4]
4.3 Heat Transfer coefficient..................[5]
4.4 Pressure Drop.......[6]
4.5 Analysis of Heat Exchanger...........................................................................[7]
4.6 Design Assumption.....[8]
5 Assumption..............................................[9]
6 Budget...................................... [11]
References .... [12]

[V]
 LIST OF FIGURES

Page no.

FIGURE 1 PARALLEL AND COUNTER FLOW HEAT EXCHANGER.......[8]

FIGURE 2 SINGLE SPIRAL PART DESIGN ON CATIA.......[9]
FIGURE 3 CASCADE SPIRAL PART DESIGN ON CATIA..... [10]

[VI]
 LIST OF TABLES

Page no.

Table 1.1: Budget..................................[11]

[VII]
 Abbreviation

A- Heat transfer area (m2)

- Specific heat capacity (KJ/kg K)
D- Equivalent hydraulic diameter (m)
F - Friction factor H Height of air channel (m)
h - Convective heat transfer coefficient(W/m2 C)
k - Thermal conductivity (W/m C)
m- Mass flow rate of air (kg/s)
Nu- Nusselt number
- Prandlt number
Q- Heat transfer rate (KW)
Re- Reynolds number
T- Temperature (C)
- Logarithmic mean temperature difference (C)
V - Average axial velocity (m/s)
- Dynamic viscosity
- Kinematic viscosity
- Minimum heat capacity
U- Overall heat transfer
NTU- No. of transfer unit

Subscripts
c- cold fluid
h- hot fluid
i- inlet
o- outlet

[VIII]
 1. Introduction
The analysis of heat exchanger is of great significance from engineering point of view due to
various engineering applications and implications dealt with it. Considerable significance has
been made on the development of various augmented heat transfer surfaces and devices, in
recent years. Energy and material saving reconsideration, space considerations as well as
economic incentives have led to the increased efforts aimed at producing more efficient and
reliable heat exchanger equipment through the augmentation of heat transfer [1][4]. Among
many techniques investigated for augmentation of heat transfer rates inside circular tubes, a
wide range of inserts have been utilized, particularly when turbulent flow is considered [1].
Enhanced performance of heat exchanger enables the size of the heat exchanger to be
decreased [4][2]. In tube heat exchanger design the tube often represents poor performance
when handling viscous liquids in laminar flow because near the tube wall, there is thermally
inefficient boundary layer with very little mixing. Since heat transfer is controlled principally
by the thickness of the boundary layer and its thermal conductivity. A very poor heat transfer
coefficient results, so need of augmentation is generated [3]. Therefore to achieve desired
heat transfer in an existing heat exchanger, several methods have been investigated in the
recent years. These methods are classified as

Passive technique of augmentation

Active techniques of augmentation
Instead, passive techniques employ special surface geometries or fluid additives which cause
heat transfer enhancement. On the other hand, active schemes such as surface vibration do
require external power for operation. The majority of commercially interesting enhancement
techniques are passive ones. Active techniques have attracted little commercial interest
because of the cost involved, and the problems that are associated with vibration or acoustic
noise. This work deals only with gas-side heat transfer enhancement using special surface
geometries. Special surface geometries provide enhancement by establishing a higher heat
transfer rate per unit base surface area. Clearly there are three basic ways of accomplishing
this:
1. Increase the effective heat transfer surface area per unit volume without appreciably
changing the heat transfer coefficient (h). Plane fin surfaces enhance heat transfer in
this manner.
2. Increase h without appreciably change in area. This is accomplished by using a special
geometrical shape, such as dimple, protruded or grooved mixing due to secondary flows and
[1]
boundary-layer separation within the channel. Vortex generation also increases h without a
significant area increase by creating longitudinal spiraling vortices exchange fluid between
the wall and core regions of flow, resulting in increased heat transfer.
3. Increase both h and A. Interrupted fins act this way. These surfaces increase the
effective surface area, and enhance heat transfer through repeated growth and destruction of
the boundary layers. Continuity equation, momentum equation, viscous model and energy
equations are used for solving the heat exchanger model.

2. Literature Review

A heat exchanger is a device that transfers thermal energy from a high temperature fluid to a
low-temperature fluid with both fluids moving through the device. Examples in practice in
which flowing fluids exchange heat are air intercoolers and pre-heaters, condensers and
boilers in steam plant, condensers and evaporators in refrigerator units, and many other
industrial processes in which a liquid or gas is required to be either cooled or heated (Eckert
and Drakes 1974).

2.1. Type of Heat exchangers

(2.1.1). Transfer type: In which both fluids pass through the exchanger and heat gets
transferred through the separating walls between the fluids.

(2.1.2). Storage type: In this, firstly the hot fluid passes through a medium having high heat
capacity and then cold fluid is passed through the medium to collect the heat. Thus hot and
cold fluids are alternately passed through the medium.

(2.1.3). Direct contact type: In this type, the fluids are not separated but they mix with each
other and heat passes directly from one fluid to the other. Transfer type heat exchangers are
the type most widely used.

In transfer type heat exchangers, three types of flow arrangements are used, viz. parallel,
counter or cross flow. In parallel flow, both the fluids flow in the same direction while in
counter flow; they flow in the opposite direction. In cross flow, they flow at right angles to
each other. The apparatus consists of two concentric tubes in which fluids pass. The hot fluid
is hot water which is obtained from an electric geyser. Hot water flows through the inner
tube, in one direction. Cold fluid is cold water which flows through the annulus. Control
valves are provided so that direction of cold water can be kept parallel or opposite to that of
hot water. Thus, the heat exchanger can be operated either as parallel or counter flow heat

[2]
exchanger. The temperatures are measured with temperature indicator. Thus, the heat transfer
rate, heat transfer coefficient, L.M.T.D. and effectiveness of heat exchanger can be calculated
for both parallel and counter flow.

2.2. Heat Transfer Enhancement

Heat transfer enhancement is the practice of modifying a heat transfer surface to increase the
heat transfer coefficient between the surface and a fluid. The effects of Heat Transfer
enhancement are:

To reduce the heat transfer surface area required for a given application and thus reduces
the heat transfer surface required for a given application which in term reduces the heat
exchanger size and cost.
Increase the heat duty of the exchanger.
Permit closer approach temperature. Reduce the fouling factors.
All of these can be visualized from the expression for heat duty for a heat exchanger.
2.3. The Overall Heat Transfer Coefficient
A heat exchanger typically involves two flowing fluids separated by a solid wall. Heat is first
transferred from the hot fluid to the wall by convection through the wall by conduction and
from the wall to the cold fluid again by convection. Any radiation effects are usually included
in the convection heat transfer coefficients (Holman 2002).
2.4. Coefficient of friction
A coefficient of friction is a value that shows the relationship b/w the force of friction b/w
two objects and the normal reaction b/w the objects.
=
2.5. Coefficient of velocity
The ratio of actual velocity of jet at vena-contractra, to the theoritical velocity of is known as
coeff. of velocity.
2.6. Fluid flow rate
The volumetric flow rate (also known as volume flow rate, rate of fluid flow or volume
velocity) is the volume of fluid which passes per unit time.
=

[3]
3. Aim

In this experiment we want to perform the heat transfer analysis by changing the shape of
inner tube to spherical helix shape and obtained the result for the various fluid flow nature
like laminar and turbulent flow and determining the flow providing best heat transfer effect
for such geometry.

4. Methodology

4.1. Boundary layer effect:- In order to increase the heat transfer, the techniques must
affect the boundary layer (laminar and buffer layers) by reducing its thickness, or increasing
its surface area, or increasing the turbulence. The boundary layer thickness may be reduced
by fitting protuberances to the heat transfer surface. These interrupt the fluid flow so that a
thick boundary layer cannot form. Alternatively a boundary layer thickness may be reduced
by imparting a rotational motion to a fluid flowing inside a tube. The boundary layer surface
area may be increased by extending the surface with fins, spines, coils and strips, etc. The
turbulence may be increased on the internal and external surfaces by artificial roughening,
or using special devices inside tubes known as turbulence promoters.

4.2. Relative thickness of the thermal and momentum boundary layers:-The thickness
of the momentum and thermal boundary layer are not necessarily the same. For many fluids
the viscous boundary layer is thicker than the thermal boundary layer. Liquid metals are
notable exceptions to this rule. The relationship is generally expressed in a dimensionless
group called the Prandtl number, after the great German physicist Ludwig Prandtl.

The Prandtl Number is defined simply as the ratio

=/

Where; = Kinematic viscosity of fluid

= Thermal diffusivity of fluid.

The kinematic viscosity is indicative of the rate at which momentum diffuses through a
fluid because of molecular motion. The thermal diffusivity is indicative of the rate of
diffusion of heat in the fluid. The ratio of these quantities is therefore a measure of the
relative magnitudes of diffusion of momentum and heat in the fluid. These diffusion rates
are precisely the quantities that determine how the thick boundary layer will be for a given
[4]
flow: large diffusivity means that viscous or temperature effects are expressed further out in
the flow.

The Prandtl number is therefore correction between the velocity field and the temperature
field.

Now

= / and = k/ ( Cp)

Then Pr= / = Cp / k

The common values of 0.7 < < 1 for many gases is striking. Also many liquids, apparently
dissimilar have a in range 2 to 4.

4.3. Heat transfer coefficient:-The rate of heat transferred q can be calculated very simply
from the equation

Q=hA( )

Where, q = rate of heat transferred

h = convective heat transfer coefficient

A = contact area for heat transfer between fluid and wall

= wall temperature and = Fluid free stream temperature.

Is both convenient and conventional to express the heat transfer in terms of yet another
dimensionless group, the Nusselt number Nu, after Wilhelm Nusselt, another note German
engineer and scientist active in developing the science of heat transfer in the 1930s. The
Nusselt number is composed of three elements:

= h.x/k

For Laminar flow in tube =h /k

.
For turbulent flow in smooth tube Nu =0.023

4.4. Pressure drop:-Pressure drop inside circular tube is given by fanning equation

p =

[5]
4.5 . Analysis of Heat Exchanger
Logarithmic Mean Temperature Difference The method used in the analysis of the heat
exchanger in this research work is the Logarithmic Mean Temperature Difference (LMTD),
and it is defined as that temperature difference which, if constant, would give the same rate of
heat transfer as actually occurs under variable conditions of temperature difference. In order
to derive expression for LMTD, the following assumptions were made: The overall heat
transfer coefficient U is constant, the flow conditions are steady, the specific heats and mass
flow rates of both fluids are constant, the is no loss of heat to the surroundings, there is no
change phase either of the fluid during the heat transfer, the change in potential and kinetic
energies are negligible, axial conduction along the tubes of the heat exchanger is negligible
(Saunders 1981).

In the recent years, considerable emphasis has been placed on the development of
various augmented heat transfer surfaces and devices. Among many techniques
investigated for augmentation of heat transfer rates inside circular tubes, awide range of
inserts have been utilized, particularly when turbulent flow is considered. The inserts studied
included twisted tape inserts, coil wire inserts, brush inserts, mesh inserts, strip inserts etc.

By virtue of this scope various researches have done on this topic to develop the efficient heat
exchange by increasing the co-efficient of friction, Reynolds No. and overall heat transfer co-
efficient. These increment is caused by the heat transfer area, high heat transfer co-efficient
and adapting the economic variable model. This experimental based design of spherical helix
heat exchanger having the compact size, for same mass flow rate having the greater
effectiveness by this way heat transfer co-efficient increases the Reynolds No. which is
solemnly responsible for increase in Heat transfer rate.

To Determine the effectiveness of the Heat exchanger we analyzed this system through two
methods by predict the outlet temperature of the hot and cold fluid stream in a specified heat
exchanger and mass flow rate by

1. Log mean Temperature difference (L.M.T.D)

2. Effectiveness- NTU (Net Transfer per Unit)

[6]
LMTD is defined as that temperature difference which if constant would give the same rate
of heat transfer across all over the system analysis, this occurs under variable condition of
temperature differences.

For parallel flow-

=
ln

For counter flow-

=
ln

NTU ( The No. of Transfer Unit) method is used to calculate the rate of Heat Transfer in Heat
Exchanger. (Especially counter current exchanger) When there is insufficient information to
calculate the LMTD.

Effectiveness of parallel flow Heat Exchanger-

1 exp[ (1 + )]
=
1+

Effectiveness of counter flow Heat Exchanger-

1 exp[ (1 )]
=
1 exp[ (1 )]

[7]
 Fig-1

4.6. . Design Assumption:-

In design of heat exchangers, several factors that need to be considered are;

1. Corrosion should be avoided.

2. Resistance to heat transfer should be minimized.

3. The equipment should be study.

4. Pumping cost should be kept low.

5. Space required should be kept low.

6. Required weight should be kept low.

7. Cost and material requirement should be kept low.

[8]
 5. Assumptions

No phase change occurs; both fluids are single phase and are unmixed,
Heat losses to surrounding are negligible,
The temperature in the fluid streams is uniform,
The fluids have constant specific heats.
The fouling resistance is negligible,
Pressure drop across heat exchanger is negligible.

Follow the various methods to adopt the practical result to compare and enhance the
efficiency of our well designed heat exchanger. Method to develop the system is as follow:-

Part design for the inner pipe is calculated and developed by using developed through
CATIA V5
Analysis of CFD on ANSYS to obtain the result in ideal condition for such contour
Based on this data the working model to compare between
1. Simple tube heat exchanger
2. Spiral tube with baffle heat exchanger.

Fig-2

[9]
 Fig-3

In which the Working fluid water to beat temp. 27c then calculate

The REYNOLDS No.

The NUSSELTNo.
Fluid flow rate
Coefficient of friction
Coefficient of velocity
Over all heat transfer coefficient

By adopting the reading data which refers through the various sensor like thermocouple. To
operate the sensor the voltage difference is maintain by the variac.

= ( )= = . =

=
= ( )=
=

. .
NUSSELT No. = 0.023 (Dittus- BoeltorEqn.)

Friction Factor = 0.046Re^0.2(Karman Nikuradse Eqn.)

[10]
6. Budget:

S. No. Material Quantity Unit Cost/Pc. Cost

1 Copper tube 3 Pc 280 840

2 Thermostat 2 Pc 360 720

3 Thermocouple 2 Meter 300 600

4 Variac 2 Pc 200 400

5 Iron stand (case) 1 Pc 2000 2000

6 Valve 2 Pc 100 200

7 Pump 2 Pc 600 1200

8 Insulation (glass wool & mineral wool) 4*4 Pc 80 640

9 Storage Tank 2 Pc 200 400

10 G.I Pipe 1 Pc 200 200

11 Manometer (u-tube)+ Rotameter 2+2 Pc 300 800

12 Indicators (Digital) 4 Pc 200 800

13 Travel Charge 1600

Grand Total 10,400/-

Table- 1

[8]
 REFRENCES

[1] S.N. Sarada, A.V.S.R. Raju and K.K. Radha, Experimental and Numerical Analysis of
Turbulent Flow Heat Transfer Enhancement in a Horizontal Circular Tube Using Mesh
Inserts Journal of Energy and Power Engineering, ISSN: 1934-8975

[2]Pardhi, Baredar, Performance Improvement of Double Pipe Heat Exchanger by Using

TurbulatorIJESAT, Vol. 2, Issue 4, ISSN: 2250-3676

[3]A.M.Patil, S.D.Patil, Analysis of Twisted Tape with Winglets to Improve the

Thermohydraulic Performance of Tube in Tube Heat Exchanger IJMEAR, Vol. 2, Issue 2,
ISSN: 2249-6564

[4]Bisht Priyanka, Joshi Manish, and Dr Gupta Anirudh, Comparison of heat transfer
between a circular and rectangular tube heat exchanger by using ANSYS FLUENT,
International Journal of thermal technologies Vol-3 ISSN: 2277 4114

[5]Frank P. Incropera, David P. DeWitt, Theodore L. Bergman and Adrienne S. Lavine,

Fundamentals of heat and mass transfer, sixth ed., 1988, pp.635- 636.

[9]