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| |
c c c
= |
|
c c c
\ .
(3)
Turbulent kinetic energy:
( ) ( )
i k eff
i j j
k
k ku Gk
t x x x
o c
| |
c c c c
+ = + + |
|
c c c c
\ .
(4)
Turbulent energy dissipation:
( ) ( )
2
*
1 2 i eff k
i j j
u C G C
t x x x k k
c c c
c c c
c c o
| |
c c c c
+ = + |
|
c c c c
\ .
(5)
where
eff t
= + ,
2
t
k
c
c
= ,
*
1 1 3
1
1
O
C C
c c
q
q
q
|q
| |
|
\ .
=
+
,
( )
1
2
2
ij ij
k
E E q
c
= ,
1
2
j
i
ij
j i
u
u
E
x x
( c
c
= +
(
c c
(
.
The empirical constants for the RNG k-model are assigned as
following(Smith and Woodruff, 1998)
0.0845 C
= ,
1
1.42 C
c
= ,
2
1.68 C
c
= , 0.012 | = , 4.38
o
q = , 1.39
k c
o o = = .
Now boundary conditions are presented. Non-slip boundary condition is
applied on the shell surface and thermal coupled condition is applied on the tube
surface in the computational domain. The standard wall function method is used to
simulate the flow in the near-wall region. The velocity-inlet and pressure-outlet
boundary condition(Smith and Woodruff, 1998) are applied on the inlet and outlet
sections, respectively.
2.3 SOLUTION PROCEDURE
The computational domain is discretized with unstructured tetrahedral grids, which
are generated by the commercial code GAMBIT. The region adjacent to the tube is
meshed much finer with the help of successive ratio scheme. Before any
computational result can be deemed enough to illuminate the physical phenomenon,
it must be justified by a grid independence test. Grid independence tests have been
carried out for each mesh model to ensure the optimized computational mesh. The
follow mesh modes having approximately 515983, 1029862, 1475661, 1936078,
2451194 elements are adequate for the 10-50tube STHXs, respectively.
The computer code FLUENT is used to calculate the fluid flow and heat
transfer characteristics of the STHXs. The governing equations are iteratively
solved by the finite-volume-method with SIMPLE pressure-velocity coupling
algorithm. Segregated approach is selected. It is used to solve a single variable field
4
International Journal of Food Engineering, Vol. 7 [2011], Iss. 4, Art. 7
http://www.bepress.com/ijfe/vol7/iss4/art7
DOI: 10.2202/1556-3758.2217
by considering all cells at the same time, and then solves the next variable field by
again considering all cells at the same time. The convective term in governing
equations are discretized by QUICK scheme with three-order precision. The
convergence criterion is that the normalized residuals are less than 10
-5
for the flow
equations and 10
-8
for the energy equation.
3. EXPERIMENTAL STUDY
3.1EXPERIMENTAL APPARATUS AND OPERATING PROCEDURE
In the present study, heat transfer performances of 10-50tube STHXs are studied
experimentally, respectively.
Fig.4.The experimental setup
The experimental setup of the study is shown in Fig.4. The system includes
a cooling air part and a heating air part. The heating air part consists of an air pump,
a volumetric flow meter, a heater, and a heat exchanger. Air is heated up by a heater
to reach a predetermined inlet temperature before entering the tube side of the heat
exchanger. Then it is pumped to the tube side to be cooled down. Finally, the cooled
air is pumped out off to the environment. The cooling air part consists of an air
pump, a volumetric flow meter and the heat exchanger. The cool air is pumped to
the shell side of the heat exchanger for heat-up. Then it is pumped out off to the
environment. To minimize heat loss of the facilities, 40mm thickness fibreglass
insulation is covered on the outer surface of the heat exchanger.
Measurements of inlet and outlet fluid temperature are carried out using
T-type thermal couples. The volumetric flow is measured with a flow meter at a
5
Jiang and Deng: Temperature Crossover in Shell and Tube Heat Exchangers
Published by Berkeley Electronic Press, 2011
range of 0-300m
3
/h. Data Acquisition System(Agilent HP3470A) records readings
of thermal couples.
The experiments are being conducted under steady state conditions. The
procedure is repeated a few times for different flow rates of the shell side ranging
from 20 to 200m
3
/h, while the flow rate of the tube is maintained constant. Prior to
each experiment, an energy balance test is conducted.. After reaching the stable
condition, temperatures are recorded by a Data Acquisition System for 10min
maintaining a span of 5s between two successive readings. At the same time, the
volumetric flow rate is recorded.
3.2 DATA REDUCTION
The shell-side Reynolds number is defined by equation (6)
s s s
s
s
de u
Re
=
(6)
Where
s
u is the mean velocity at the minimum transverse area;
s
de is the
characteristic dimension which takes the value of tube diameter d ;
s
is the fluid
density.
Before each experiment was carried out, a heat balance test was conducted.
The difference of heat duties between the hot air and cool air needs to be within
5.0%. The heat balance equation is
s t
ave
5.0%
Q Q
Q
s
(7)
s t
ave
2
Q Q
Q
+
=
(8)
( )
s s s p,s s,in s,out
Q v c T T =
(9)
( )
t t t p,t t,in t,out
Q v c T T =
(10)
where
s
Q and
t
Q are heat transfer rate of the shell side and the tube side;
s,in
T and
s,out
T are shell-side temperature at the inlet and outlet;
t,in
T and
t,out
T are tube-side
temperature at the inlet and outlet, respectively.
p,s
c and
p,t
c are special heat of the
cool air and hot air. The thermodynamic and transport properties of the hot air and
cool air are calculated according to average temperature values of the inlet and
outlet for the section.
6
International Journal of Food Engineering, Vol. 7 [2011], Iss. 4, Art. 7
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DOI: 10.2202/1556-3758.2217
2 1
LMTD
1
ln
T T
T
T
T
A A
A =
| |
A
|
A
\ .
(12)
1 , , t out s in
T T T A = ,
2 , , t in s out
T T T A = (13)
Heat transfer coefficient of the shell side is calculated with traditional Wilson plots
technique. The shell-side Nusselt numbers is computed by the following equation:
s
s
s
h d
Nu
= (14)
3.3 EXPERIMENT UNCERTAINTY
The experimental uncertainty of the present work is determined by using the
method presented by Kline and McClintock. The uncertainty calculation method
involves calculating derivatives of the desired variable with respect to individual
experimental quantities and applying known uncertainties. According to the
reference, the experimental uncertainty is defined as follows:
1 2 n
2 2 2
R
1 2 n
x x x
R R R
W W W W
x x x
| | | | | | c c c
= + + +
| | |
c c c
\ . \ . \ .
(15)
Where ( )
1 2
, ,...,
n
R f x x x = and
n
x is the variable that affects the results of R .
For10-50tube STHXs, the uncertainties of Nusselt number are 1.8%.
4. RESULTS AND DISSCUSSIONS
4.1MODEL VALIDATION
In order to verify the experimental setup, 10 tube STHX is used to investigate heat
transfer characteristics firstly. The heat transfer measurements of the present work
are compared with the data from Bell-Delaware method(Bell, 1988).
The overall heat transfer coefficient, K
m
, is defined as
ave
m
LMTD
Q
K
A T
=
A
(11)
where A is the surface area, and
LMTD
T A is the log mean temperature difference,
which is determined by
7
Jiang and Deng: Temperature Crossover in Shell and Tube Heat Exchangers
Published by Berkeley Electronic Press, 2011
Fig.5. Comparison of experiment results of Nusselt number with the data from Bell-Delaware
method for10tube STHX
The comparison of experimental results of Nusselt number in the shell side
with the data from Bell-Delaware method for 10tube STHX is presented in Fig.5. It
can be seen that the difference between the present experimental data and the
classical one is within 6%. The present experimental results are in great agreement
with the data from Bell-Delaware method. It indicates that the experimental setup is
reliable for the experimental research of 10-50tube STHXs.
4.2 EXPERIMENTAL RESULTS
As temperature crossover can be achieved or not is determined by many factors, in
order to simplify the problem, heat transfer performances of 10-50tube STHXs are
analyzed at the condition that average velocity is 10m/s both in the shell side and
the tube side.
Table3. Experimental and numerical results
The comparison between experimental results of the outlet temperature in
the shell side and tube side and the data from the numerical results for 10-50tube
STHXs is shown in Table3. It is seen from the table that the differences between the
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International Journal of Food Engineering, Vol. 7 [2011], Iss. 4, Art. 7
http://www.bepress.com/ijfe/vol7/iss4/art7
DOI: 10.2202/1556-3758.2217
present experimental data and the numerical results are within 7%. The numerical
results are in good agreement with the data from experiments. It indicates that the
simulation method is reliable.
From table3, it can be observed that when L/W4.62, the outlet temperature
of the cold air (
s,out
T ) is higher than that of the hot air (
t,out
T ), that means
temperature crossover can be achieved at the STHX with L/W4.62. But when
L/W3.08, outlet temperature of the cold air is lower than that of the hot air, which
means temperature crossover cant be achieved any more. The outlet temperature
of the cold air will equal to that of the hot air in STHX with L/W at the range of 3.08
to 4.62.
Fig.6. Heat transfer coefficient of 10-50tube STHXs
Fig.6 illustrates the comparison of experimental results of heat transfer
coefficient with the data from simulations for 10-50tube STHXs, respectively. It
can be seen that the deviation between the present experimental measurements and
the numerical results is within 7%. The present experimental results are in good
agreement with the numerical results. From Fig.6, it also can be clearly observed
that heat transfer coefficients decrease with the increase of tube numbers in STHXs.
In other words, heat transfer coefficients decrease with L/W decreasing. The reason
for this phenomenon appears to be as follows, the ratio of the cross flow area to the
whole area is 19.5% for 10tube STHX, but for 50tube STHX the ratio is 97.5%. As
the heat transfer efficient is higher when hot air and cold air exchange heat in
counter flow than in cross flow, the heat transfer coefficient will be getting smaller
when cross flow proportion is getting larger.
The inherent reason why heat transfer coefficient decrease with L/W
decreasing is distributions of temperature difference field (TDF) in 10-50tube
9
Jiang and Deng: Temperature Crossover in Shell and Tube Heat Exchangers
Published by Berkeley Electronic Press, 2011
STHXs become more and more uneven. It agrees with the principle of uniformity
of temperature different field (Guo et al., 2002).
Fig.7. Partition of sub-elements in 10tube STHX
A STHX can be divided into a lot of small elements (named sub-element)
and each sub-element is a small STHX. In Fig.7, 10-50 tube STHXs are divided
into numbers of the sub-elements with dimensions of 13mm100mm13mm in x,
y and z directions. Numbers of sub-elements in 10-50tube STHXs are 10121,
20121, 30121, 40121, 50121, respectively. Each sub-element is
numbered sequentially in x, y and z directions having a unique three-dimensional
coordinate (i, j, k). For example, the sub-element departed from the 10tube STHX
in Fig.7 is representative of (1, 1, 1). As there is only 1 sub-element in z direction,
k=1 for all sub-elements, so the three-dimensional coordinate (i, j, k) can be
simplified as two-dimensional coordinate (i, j). Then the sub-element departed
from the 10tube STHX in Fig.7 is representative of (1, 1). There is a characteristic
hot fluid temperature [
( ) ,
t
T i j
] and a characteristic cold fluid temperature [
( ) ,
s
T i j
]
for each sub-element. Their difference [
T A
] is named local characteristic
temperature difference. The aggregate of these local characteristic temperature
differences forms a temperature difference field of the heat exchanger.
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International Journal of Food Engineering, Vol. 7 [2011], Iss. 4, Art. 7
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DOI: 10.2202/1556-3758.2217
(a)
(b)
(c)
11
Jiang and Deng: Temperature Crossover in Shell and Tube Heat Exchangers
Published by Berkeley Electronic Press, 2011
(d)
(e)
Fig.8. TDF in 10-50 tube STHXs (a) 10tube (b) 20tube (c) 30tube (d) 40tube (e) 50tube
Fig.8 shows temperature difference fields acquired by the numerical
method in 10-50tube STHXs. From Fig.8, it can be observed that the local
temperature difference is almost uniform and the temperature difference is in the
range of 17.15-29.61K for 10tube STHX. But for 50tube STHX, the local
temperature difference is very uneven and the temperature difference ranges from 0
to 21.09K. The uniformity characteristics for 20-40tube STHXs are between
10tube STHX and 50tube STHX. Temperature difference becomes more and more
non-uniform with L/W decreasing.
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International Journal of Food Engineering, Vol. 7 [2011], Iss. 4, Art. 7
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DOI: 10.2202/1556-3758.2217
A parameter |
is defined as the uniformity factor of TDF.
( ) ( )
( ) ( )
1 1
2
1 1
[ , , ]
[ , , ]
M N
t s
i j
M N
t s
i j
T i j T i j
MN T i j T i j
|
= =
= =
(16)
Where ( ) ,
t
T i j and ( ) ,
s
T i j are the temperature distributions in the tube side and the
shell side, respectively; M and N are the numbers of sub-elements in length and
width directions. The uniformity factor of TDF in reality is at the range of 0-1, and
the more non-uniform the TDF, the smaller the uniformity factor of TDF.
Table4. Uniformity factor of TDF in five STHXs
Table 4 presents uniformity factors of TDF in 10-50tube STHXs. It is
clearly observed that the uniformity factor of TDF decreases with L/W decreasing.
Thats because the uniformity factor of TDF decreases (Guo et al., 1996).
5. CONCLUSIONS
The heat transfer characteristics of 10-50tube STHX have been studied on
experimental and numerical method. Heat transfer coefficients and outlet
temperatures of the hot air and the cold air in five STHXs are reported. Temperature
difference fields and uniformity factors of TDF acquired by the numerical method
in 10-50tube STHXs are depicted, respectively.
The conclusions are as follows:
(1)The heat transfer coefficient decreases with L/W decreasing. The reason
why heat transfer coefficient decrease with L/W decreasing is temperature
difference fields become less and less uniform. The uniformity of the temperature
difference field is in favour of increasing heat exchanger effectiveness.
(2)At the condition that average velocity is 10m/s in both the shell side and
the tube side, temperature crossover can be achieved in STHXs with L/W4.62. But
when L/W of STHXs is smaller than 3.08, temperature crossover cant be achieved
any more. =1 will be achieved in STHX with L/W in the range of 3.08 to 4.62.
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Jiang and Deng: Temperature Crossover in Shell and Tube Heat Exchangers
Published by Berkeley Electronic Press, 2011
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International Journal of Food Engineering, Vol. 7 [2011], Iss. 4, Art. 7
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Jiang and Deng: Temperature Crossover in Shell and Tube Heat Exchangers
Published by Berkeley Electronic Press, 2011