Design Analysis and Performance Evaluation

of Conical Coil in Coil Heat Exchanger at zero

Phase Shifts.
Bhushan. Pawar1, Akash Bhise2
1
P.G student, Heat Power Engineering, Department of Mechanical Engineering,
2
Assistant Professor, Department of Mechanical Engineering,
Dhole Patil College of Engineering,Wagholi,Pune

Abstract—The Conical tube heat exchanger design is a

challenge to manufacture so also difficult to clean over time for average mean temperature difference between the two fluids
maintenance. The problem of fouling can be dealt as proposed in for the entire heat exchanger. Due to the curvature of the tube,
our project , namely to prevent scaling and fouling by addition of a centrifugal force is generated as fluid flows through the
variable pitch where in the shape geometry of the spiral will be
curved tubes. Secondary flows produced by the centrifugal
changed from a flat spiral to a conical frustum . The geometry of
the tubes plays a significant part in design and development of force have great ability to enhance the heat transfer rate.
the heat exchanger. Project work discusses the development of Helical and spiral coils are the common known types of
such heat exchanger where in the copper tube is wound in a curved tubes which have been extensively used in a wide
conical shape and water to heated is always passed from top of variety of applications.
cone to bottom of cone , and the cones are connected in parallel.
The paper discusses the combined thermal and structural
analysis of the cone heat exchanger and also the testing of the
system in zero phase shift condition is discussed in the paper.

Index Terms—Conical coil tube heat exchanger, Fouling,

scaling, Thermal and structural analysis, Zero phase shift.

INTRODUCTION
1. A heat exchanger is a device used to transfer heat
between one or more fluids. The fluids are separated by
a solid wall to avoid intermixing or they may have
direct contact. They are widely used in space
heating, refrigeration, air-conditioning, , petrochemical
plants, chemical plants, petroleum refineries, natural-gas
processing, power stations heat recovery processes,
dairy processes and sewage treatment. The best real
world example of a heat exchanger is observed in
an internal combustion engine in which a circulating
fluid known as engine coolant flows
through radiator coils and air flows across the coils,
which cools the coolant and heats the incoming air. Heat
transfer in a heat exchanger there is usually convection
between each fluid and conduction through the wall
separating the two fluids. During the analysis of heat
exchangers, it is beneficial to work on overall heat
transfer coefficient U that accounts for the overall
contribution of all these effects on heat transfer. The
rate of heat transfer between the two fluids at any
location in a heat exchanger depends on the magnitude
of the temperature difference at that location, which
varies continuously along the length of heat exchanger.
In the analysis of heat exchangers, it is usually
convenient to work with the logarithmic mean
temperature difference LMTD, which is an equivalent
Figure No. 1 Conical Coil Heat Exchanger
2. LITERATURE REVIEW
N. D. Shirgire et al [1] studied about fluid to fluid heat
exchange is taken into consideration. Most of the
investigations and analysis on heat transfer coefficients are
for constant wall temperature or constant heat flux. The,
overall heat transfer coefficient, effectiveness, effect of cold
water flow rate on effectiveness of heat exchanger when hot
water mass flow rate is kept constant and effect of hot water
flow rate on effectiveness when cold water flow rate kept
constant are studied and compared for parallel flow, counter
flow arrangement of Helical coil and Straight tube heat
exchangers. All readings were taken at attainment of the
steady state condition of heat exchanger. The results indicates
that the heat transfer coefficient is influenced by the geometry
of the heat exchanger. The discussion suggests that Helical
coil heat exchanger are superior in all aspect studied here.
V.C. Momale et al [2] worked for the inside heat transfer
coefficient (hi) and outside heat transfer coefficient (ho) from
the different research paper were compared. For the
calculation of heat transfer coefficient MATLAB code is
developed for the same. The values of heat transfer coefficient
for inner side has agreement between each other, however
outside heat transfer coefficient has no agreement is found.
H. N. Deshpande et al [3] An attempt was made to change
the curvature ratio continuously throughout the coil by using a
conical shaped coil in order to decrease the critical Reynolds
number. Numerical results of conical coil are compared with
straight helical coil by using ANSYS fluent for mass flow rate
through coil 0.07kg/s and 0.05 kg/s through shell. From the
Numerical analysis it is observed that conical coil gives 8.71%
more heat transfer than straight coil. The various mass flow
rates through coil are taken as 0.01 kg/s, 0.02 kg/s, 0.05 kg/s,
0.07 kg/s, 0.09 kg/s, 0.1 kg/s keeping mass flow rate through
shell 0.05 kg/s constant also tube inlet and shell inlet
temperatures maintained same 42ºC and 27ºC respectively and
for same mass flow rate heat transfer rate calculated
numerically.
MOHAME ALIT et al [4] experimental study has been
made on steady state natural convection heat transfer from
vertical helical coiled tubes. Average heat transfer coefficients
were obtained for turbulent natural convection to water. The
experimental study has been carried out for four coil diameter
to tube diameter ratios, for five and ten coil turns, and for five
pitch to outer diameter ratios. The data is correlated and
compared with the Rayleigh number for two different coil
sets. The heat transfer coefficient decreases with coil length
for tube diameter d, = 0.012 m, but increases with coil length
for do = 0.00s m. A critical D/do is obtained for a maximum
heat transfer coefficient for tube diameter of 0.012 m with
either five or ten coil turns.
Yan Ke et al [5] the heat transfer characteristic of conical
spiral tube bundle was investigated with numerical simulation
method.
Different grid strategies and boundary layers were used and
the results of numerical simulation were verified via the
foregoing experiment data with a tolerance less than 5%. The
effect of structural parameters on heat transfer rates and
characteristic of conical spiral tube is studied and discussed.
The fluid flow characteristics inside the tube of different cross
sections was also studied. The results indicate that the cone
angle and cross section have significant effect on tube heat
transfer, while the helical pitch has little influence on heat
transfer enhancement. The contours of the fluid flow inside
the tube indicate that the center of the axial fluid flow offsets
to the outer surface of the tube, and the secondary fluid flow is
complicated. There exists four independent parts of secondary
flow in each cross section and the flow directions are different
from each other.
Timothy J. Rennie et al [6] an experimental study of a
double-pipe helical heat exchanger was performed. Two heat
exchanger sizes with both parallel flow and counter flow
arrangements were tested. Flow rates in the inner tube and in
the annulus were changed and temperature variation was
recorded. Overall heat transfer coefficients were calculated
and heat transfer coefficients in the inner tube and the annulus
region were determined using Wilson plots. Nusselt numbers
were determined for the inner tube and the annulus. The inner
Nusselt number as compared to the literature values. Though
the boundary conditions were different, a reasonable
comparison was found. The Nusselt number in the annulus
region was compared to the numerical data. The experimental
data fit well with the numerical study for the larger size heat
exchanger. But, some differences were observed between the
numerical and experimental data for the smaller size coil ;
however these differences may have been due to the nature of
the Wilson plots. Overall, for the most part in this study the
results confirmed the validation of previous numerical work.
Pramod S. Purandare et al [7] presents parametric analysis
of the helical coiled heat exchanger with various
correlations given by different researchers for specific
conditions. The analysis is carried out for laminar and
turbulent region separately for tube side heat transfer
coefficient and Nusselt number. The calculations are worked
out as per the data reduction procedure applied for helical
coil configuration and the results are tabulated for heat
transfer analysis.
Bibave Tejas et al [8] the methodology for the design of
helical cone coil heat exchanger is suggested. Available
correlation of heat transfer coefficient by different researchers
for calculation of heat transfer coefficient are used. The values
of heat transfer coefficient for inner side has agreement
between each other, however outside heat transfer coefficient
has no agreement. Also Computational fluid dynamics study
of the helical cone cool heat exchanger is carried out to
visualize the nature of fluid flow inside the coil and shell,
temperature variation from inlet to outlet for parallel and
counter flow arrangement for different mass flow rates and
Different inlet and outlet temperature conditions
Zaid S. Kareem et al [9] Studied about Computational Fluid
Dynamics approach employed for water flowing at Reynolds
number in an arrangement of spirally corrugated tubes. This
article aimed at the determination of the thermal performance
of unique smooth corrugation profile. The Performance
Evaluation Criteria were decided and calculated for corrugated
tubes, and the simulation results of both Nusselt number and
friction factor were compared with those of standard plain and
corrugated tubes for validation purposes. Results showed the
best thermal performance range of 1.8–2.3 for the tube which
has the severity of 45.455 · 10_3 for Reynolds number range
of 100–700. The heat transfer enhancement effective range
was 21.684%–60.5402% with friction factor increase of 19.2–
36.4%. This indicated that this creative
corrugation can enhance the heat transfer rates significantly
with appreciably increasing friction factor.
Ashkan Alimoradi et al [10] studied about calculations of the
heat transfer and entropy generation have been performed for
the steady state forced convection heat transfer in shell and
helically coiled tube heat exchangers. The effect of
geometrical parameters of the heat exchanger including: tube
diameter , coil diameter , diameter of the inlet of shell , shell
diameter (d, height of the coil , height of the shell , pitch and
the distance between the inlet and outlet of the shell on the
heat transfer rate and entropy generation has been investigated
simultaneously. The critical and optimal values of these
parameters have been obtained which minimize and maximize SPECIFICATIONS OF HEAT EXCHANGER
the COD (heat transfer rate per entropy generation), Outside diameter of inner tube 6.4 mm
respectively. Inside side diameter of inner tube 5.4 mm
Pitch diameter 125 mm
Radial pitch 30 mm
Inside diameter of shell 160 mm
3. OBJECTIVES
Outside diameter of shell 170 mm
it will be pertaining to the performance parameters of conical Overall length of shell 400 mm
coil copper tube heat exchanger and effect of phase angle Material of inner tube Copper
change and Testing of twin conical coil heat exchanger in Material of shell Copper
counter flow to determine
• LMTD
• Capacity ratio
• Effectiveness
• Overall Heat transfer Coefficient
To study the Graphs:
• LMTD Vs Flow rate of water (kg/sec)
• Capacity ratio Vs Flow rate of water (kg/sec)
• Effectiveness Vs Flow rate of water (kg/sec)
• Overall Heat transfer Coefficient Vs Flow rate of water
(kg/sec)
3.1 DESCRIPTION
The experiments will be carried out on the twin conical
copper coil heat exchanger initially without changing phase
angle and the different heat transfer characteristics will be
calculate and then the same is done by changing phase angle.
Experimentation on twin conical coil exchanger in counter
flow configuration to determine
Figure No 4 Steady State Thermal Analysis
LMTD
Capacity ratio
Effectiveness
Overall Heat transfer Coefficient

Figure No 2 Conical heat exchanger in parallel

Figure No 5 Total Heat Flux Analysis

Figure No 3 Conical heat exchanger in phase angle changed

 The total flux is 9.511 watt transferred from the coil. Graph of Temperature Gradient Vs mass flow rate

The temperature gradient is seen to gradually increase with

Fig No 6 Static Structural Analysis
Maximum combined stress induced is 243.73 Mpa which is
well below the maximum allowable stress of 400 Pa hence the
coil is safe.
4.EXPERIMENTAL SET UP
increase in mass flow rate due to better intermixing of
particles and lesser effect of boundary layer as the water
spirals down the cones.
Graph of Heat carried by water Vs mass flow rate

The heat carried by the water is seen to gradually increase

with increase in mass flow rate due to better intermixing of
particles and lesser effect of boundary layer as the water
spirals down the cones
Result Table :
Graph of Effectiveness vs. mass flow rate
SR. Mass Temperature Heat Effectiveness
NO. flow rate gradient carried by
Kg/sec water ( KJ)
1. 0.00469 17.8 0.82808727 0.220235977
2. 0.005051 19.2 1.00488 0.267255319
3. 0.005472 21..4 1.28005131 0.340439179
4. 0.005794 23.5 1.63994113 0.436154556
5. 0.006156 26 1.97932888 0.526417256

Effectiveness is the measure of performance of the coil in coil

system as to the ratio of the heat carried by the water as to the
heat input by the burner system, here in the effectiveness of
the system is seen to gradually increase with increase in mass
flow rate due to better intermixing of particles and lesser
effect of boundary layer as the water spirals down the cones.

CONCLUSION
 The temperature gradient is seen to gradually increase with
increase in mass flow rate due to better intermixing of
particles and lesser effect of boundary layer as the water
spirals down the cones.
 The temperature gradient is seen to gradually increase with
increase in mass flow rate due to better intermixing of
particles and lesser effect of boundary layer as the water
spirals down the cones.
 The effectiveness of the system is seen to gradually increase
with increase in mass flow rate due to better intermixing of
particles and lesser effect of boundary layer as the water
spirals down the cones

REFERENCES

Books:
[1] Yunus Cengel, “Heat Transfer: A Practical Approach”, Tata McGraw-
Hill.
[2] Ramesh K. Shah, Dusan P. Sekulic , “ Fundamentals of Heat Exchanger
Design”, Wiley-InterScience Publication.

Periodicals:
[1] N. D. Shirgire. et.al, “Comparative Study and Analysis between Helical
Coil and Straight Tube Heat Exchanger,” Int. Journal of Engineering Research
and Applications www.ijera.com ISSN : 2248-9622, Vol. 4, Issue 8 ( Version
2) , pp.130-133, August, 2014.

[2] V.C. Momale .et.al,“Analysis of Heat Transfer Coefficients for Helical

Coil Heat Exchanger,” International Journal on Theoretical and Applied
Research in Mechanical Engineering (IJTARME) Volume -6, Issue-1-2, 2017.

[3] H. N. Deshpande.et.al, “Comparative Numerical Analysis of Straight and

Conical Coil Heat Exchanger,” GRD Journals- Global Research and
Development Journal for Engineering | Volume 2 Issue 11 October, 2017.

[4] MOHAME ALIT .et.al, “Experimental investigation of natural convection

from vertical helical coiled tubes Helwan University,” Faculty of Engineering
and Technology, El-Mattaria, P.O. 11718, Cairo, Egypt Received 10 August
1992 and in final form 8 June, 1993.

[5] Yan Ke .et.al, “Numerical simulation on heat transfer characteristic of

conical spiral tube bundle,” ELSEVIER Applied Thermal Engineering 31,pp
284-292, 2011.

[6] Timothy J. Rennie et.al, Experimental studies of a double-pipe helical heat

exchanger, ELSEVIER Experimental Thermal and Fluid Science 29, pp 919–
924, 2005.

[7]P.S. Purandare et.al,“Parametric Analysis of Helical Coil Heat Exchanger,”

International Journal of Engineering Research & Technology Vol. 1 Issue 8,
October, 2012.

[8] Bibave Tejas et.al, “Design of conical coil heat exchanger”, Global journal
of engineering science and researches , February, 2016.