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Simulation of Fluid Flow and Heat Transfer Process in Heat Exchangers in Petroleum Industries
Abstract
Heat exchangers are very useful equipment in a wide range of industries, therefore ?the analysis of the internal flow in them is very important. In this study, a heat exchanger is modeled to solve the flow and temperature field. Three ?turbulence models have been tested for first and second order discretization using ?two different mesh densities, and the results are as follows. The effects of different parameters on the internal conditions of the converter have ?been simulated. The temperature changes decrease in proportion to the reduction of ?the heat transfer coefficient in viscous fluids, and the Reynolds number is greater ?than the Parantel number. For the tube with constant wall temperature and shell inlet, the heat transfer ?coefficient, pressure drop values and heat transfer rate are obtained. In another part, it is shown that the stabilization time of the fluid temperature has a ?direct relationship with the heat capacity of the pipes, and that the performance of ?the tubular heat exchanger with spiral walls is better than that of segmental walls. The intermittent temperature input has been investigated. It has been shown that ?the other flux will fluctuate with the same frequency, which it also proved our ? theoretical results.
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This study relates to an evaluation of the thermo-hydraulic performance for a state-of-the-art compact brazer plate heat exchanger (PHE) in 3kW for 3-plates. To improve heat transfer and pressure drop of the PHE, a lung pattern is designed at certain heights on the plate surface by using biomimetic approach in first time. It is known that human pulmonary system is one of the most effective heat exchanger devices in the nature. Its tree like structure provides good compactness, consequently better heat transfer rate per unit volume. By means of achievements in additive manufacturing technologies in recent years, a heat exchanger with any desired plate or fin geometry can be manufactured. In this study, plate surfaces have been designed as a 3D lung like structure in order to increase the heat transfer area. CFD simulations are then performed with Ansys-Fluent program in operating condition under supply temperatures of 90°C and 40°C with a mass flow rate of 0.5kg/s for hot and cold sides, respectively. The simulation is validated by the numerical and experimental results of an existing Chevron type compact brazed PHE. The results show that there is a 71.3% increase in heat transfer and a 67.8% decrease in pressure drop for 6.66% less volume compared to the reference PHE. The effectiveness of the lung patterned PHE is found to be 0.350. Fluid velocity in plate cavities on lung pattern is quite irregular due to turbulence formation at almost constant Reynolds numbers. This increases its effectiveness. Finally, lung patterned plates designed with biomimetric method is a guideline study to improve the performance of PHEs.
SPHERA v.9.0.0 (RSE SpA) is a FOSS CFD-SPH research code validated on the following application fields: floods with transport of solid bodies and bed-load transport; fast landslides and their interactions with water reservoirs; sediment removal from water bodies; fuel sloshing tanks; hydrodynamic lubrication for energy efficiency actions in the industrial sector. SPHERA is featured by several numerical schemes dealing with: transport of solid bodies in fluid flows; treatment of fixed and mobile solid boundaries; dense granular flows and an erosion criterion. The source and executable codes, the input files and the free numerical chain of SPHERA v.9.0.0 are presented. Some reference validations and applications are also provided. SPHERA is developed and distributed on a GitHub public repository.
Program summary
Program title: SPHERA v.9.0.0
Program files doi: http://dx.doi.org/10.17632/pwv9rsf3w8.1
Code Ocean capsule: https://doi.org/10.24433/CO.7457751.v1
Licensing provisions: GNU General Public License 3
Programming language: Fortran 95
Supplementary material: software documentation/guide, 34 tutorials
Nature of problem: SPHERA v.9.0.0 has been applied to free-surface and multi-phase flows involving the following application fields: floods (with transport of solid bodies, bed-load transport and a domain spatial coverage up to some hundreds of squared kilometres), fast landslides and wave motion, sediment removal from water reservoirs, fuel sloshing tanks, hydrodynamic lubrication.
Solution method: SPHERA v.9.0.0 is a research FOSS (“Free/Libre and Open-Source Software”) code based on the SPH (“Smoothed Particle Hydrodynamics”) technique, a mesh-less Computational Fluid Dynamics numerical method for free surface and multi-phase flows. The five numerical schemes featuring SPHERA v.9.0.0 deal with: dense granular flows; transport of solid bodies in free surface flows; boundary treatment for both mobile and fixed frontiers; 2D erosion criterion.
Additional comments including restrictions and unusual features: SPHERA v.9.0.0 is a 3D research FOSS (“Free/Libre and Open-Source Software”) code (developed under the subversion control system Git) with peculiar features for: floods (with transport of solid bodies, bed-load transport and a domain spatial coverage up to some hundreds of squared kilometres), fast landslides and wave motion, sediment removal from water reservoirs, fuel sloshing tanks, hydrodynamic lubrication. The whole numerical chain of SPHERA is made of FOSS, freeware and Open Data numerical tools.
References:
SPHERA (RSE SpA), https://github.com/AndreaAmicarelliRSE/SPHERA, last access on 28May2019
Amicarelli A., G. Agate, R. Guandalini; 2013; A 3D Fully Lagrangian Smoothed Particle Hydrodynamics model with both volume and surface discrete elements; International Journal for Numerical Methods in Engineering, 95: 419–450, DOI: 10.1002/nme.4514
Amicarelli A., R. Albano, D. Mirauda, G. Agate, A. Sole, R. Guandalini; 2015; A Smoothed Particle Hydrodynamics model for 3D solid body transport in free surface flows; Computers & Fluids, 116:205–228. DOI 10.1016/j.compfluid.2015.04.018
Amicarelli A., B. Kocak, S. Sibilla, J. Grabe; 2017; A 3D Smoothed Particle Hydrodynamics model for erosional dam-break floods; International Journal of Computational Fluid Dynamics, 31(10):413-434; DOI 10.1080/10618562.2017.1422731
Manenti S., S. Sibilla, M. Gallati, G. Agate, R. Guandalini; 2012; SPH Simulation of Sediment Flushing Induced by a Rapid Water Flow; Journal of Hydraulic Engineering ASCE 138(3): 227–311.
Di Monaco A., S. Manenti, M. Gallati, S. Sibilla, G. Agate, R. Guandalini; 2011; SPH modelling of solid boundaries through a semi-analytic approach. Engineering Applications of Computational Fluid Mechanics, 5(1):1-15.
As a part of vehicle thermal management, water-cooled intercoolers play an important role in engine efficiency. The incompressible simulation model was usually applied to estimate the performance of water-cooled intercoolers. In this paper, the computational fluid dynamics (CFD) compressible model is taken to analyze more accurate prediction models. The rate of section change, heat exchange, and the surface friction coefficient are used as the comparison basis of the compressible flow model and incompressible model on the pressurized air side of the water-cooled intercooler. By comparing the simulation results of the air side, it was found that the compressible simulation is closer to the experimental value than the incompressible simulation. Compared with the experiment, the compressible model heat transfer maximum value of deviation is 6.5%, and the pressure loss maximum deviation is 7.5%. This provides guidance to optimize the design of heat exchangers, in order to save on costs and shorten development times.
There are enormous tubes in large fixed tubesheet heat exchangers making it difficult to model all the tubes and tubesheet connections in detail for a finite element (FE) analysis. Alternatively, an equivalent solid plate with various simplified tube connections are employed in the FE modeling. But this fails to yield an accurate stress field around the connecting region of tubes and the tubesheet. Given that the maximum stress of the equivalent solid plate generally occurs adjacent to the solid tubesheet, a novel finite element modeling methodology is proposed in this paper. A two part process is used. The first part is a coarse FE model and the second part is a more detailed FE model. In the coarse FE model, the equivalent solid plate is employed in the central region of the tubesheet with simplified tube connections such as equivalent cylinder by multi-points contacting. And quasi detailed tube and tubesheet connections are used in the coarse FE model for the region adjacent to the solid plate, in which the tube and the tubesheet are simply connected with same nodes. This means that both tubesheet and tubes are established in this quasi detailed FE modeling region. Although both the weld and contacting condition between the tube and the tubesheet are not included, the coarse model is enough to yield a believable stress field for the determination of the maximum stress point of the quasi detailed FE modeling region. In the second part, the sub-model methodology is utilized in the predetermined maximum stress point, in which the detailed connecting structure of the tube and the tubesheet is included, such as the weld and the contact condition. The proposed modeling methodology is helpful to have an insight into the stress around the connecting region of the tube and tubesheet for the effective evaluation of the tubesheet and the connection.
Cost optimization, which is expressed as a set of analytical variables, is a key objective in economic design approaches of shell-and-tube heat exchangers. This study has provided new design techniques based on tube bundle effect on the economic optimization design of shell-and-tube heat exchangers. Also the objective of this paper is to develop the cost estimating for the new modified shell-and-tube heat exchangers by introducing new objective functions. According to the results the best configuration choice will obviously be the one with the least irreversibility, that is, with the lowest exergy destruction rate and lower annual capital cost. Also, the combined reduction of annual capital investment and operating cost by the new design technique led to a decrease in the overall costs of about 10% to 24% in comparison with original design. So the proposed design technique shows potential for improvement and economic optimization of shell-and-tube heat exchangers.
The purpose of this study is to explore the potential of using a general purpose CFD code to compute the characteristics of the flow field, and of the heat transfer augmentation in conduits with corrugated walls, encountered in commercial plate heat exchangers (PHE). The CFD code is used to simulate the performance of a PHE model comprised of stainless steel plates, following a herringbone design and assembled for single-pass countercurrent flow. The code is validated by comparing the numerical results with experimental data on pressure drop and overall temperature differences acquired for the countercurrent flow of water at both sides of the model PHE. The limited data published in the literature are also in fairly good agreement with the results of the present study. It is shown that the CFD code is an effective and reliable tool for studying the effect of various geometrical configurations on the optimum design of a PHE.
Heat exchangers have found extensive applications in the engineering sector owing to the crucial need for heat transfer and temperature regulation in the process industry. The performance analysis of a heat exchanger can either be investigated experimentally or utilizing computational fluid dynamics (CFD). The simulation of flow conditions based on CFD principles is considered as a contemporary approach for conducting performance analysis and design optimization of the heat exchanger. The paper aims to present how the performance optimization parameters of shell and tube heat exchanger effect its performance in terms of the extent of heat transfer achieved and fall in the shell outlet temperature. A standard model (Model 1) was initially defined, and seven subsequent models were created with one varying parameter as compared to Model 1 to carry out the comparative analysis. The results showed that decrease in inlet velocity, increase in thermal conductivity of the heat exchanger material, reduction in baffle spacing and use of triangular tube bundle arrangement has significant influence on the reduction of the condensate temperature. The effects of the same parameters on the temperature distribution and heat transfer rate have also been discussed.
Strong heterogeneity and anisotropy result in complex flow and relatively low oil recovery in fractured-vuggy reservoirs. In this work, we assess the Cahn-Hilliard phase field method (PFM) and the pairwise force smoothed particle hydrodynamics (PF-SPH) method in modeling 2D multiphase flow through fracture-vug medium, in terms of different capillary numbers, mobility ratios, gravity, and wettability. Comparing the results of numerical simulations and physical experiments, the results of the PF-SPH method are closer to the physical experimental displacement process than those of the PFM, and the PF-SPH method is found to be computationally more efficient and accurate than the PFM. The experimental and numerical results reveal that when the injection velocity, represented via logarithm of the capillary number (LCN), is not greater than -4 (gas phase case) or -2.3 (water phase case) in the fracture-vug medium, the gravitative differentiation of the oil-gas or oil-water is significant, and the oil-gas or oil-water flow is a stable stratified flow. When the injection velocity LCN exceeds -3 (gas phase case) or -1.3 (water phase case) in the vertical section, the gravitative differentiation of the oil-gas or oil-water is not obvious, and the fluid flow pattern appears as an unstable jet flow.
Strength calculation for tubesheets in floating-head heat exchangers in current standards is based on analytical theory which assumes that the two tubesheets are symmetrical with same thickness, same material. This assumption results in a design that is not optimized for the requirement of the floating-head heat exchangers. In this paper, a new analytical theory is proposed which is able to perform strength calculation for tubesheets of different size and materials in floating-head heat exchangers. Comparison of the analytical stresses with those obtained by finite element simulation shows that the new theory proposed here is reliable and applicable. In addition, this new theory covers the symmetric one adopted in current standards such as ASME and is effective for the optimization design of the floating tubesheet as well as other relevant elements in the floating-head heat exchangers.
The cross-flow heat exchanger is a special type of heat exchanger involving the exchange of heat in the case of two fluids flowing in an orthogonal direction. The heat exchanger often comprises of a number of cylinders carrying hot fluid, along with the colder fluid flowing across/over the tubes or cylinders. The system also comprises of additional fins across the tube cross-section along with delta winglets so as to generate the additional turbulence for increasing the rate of heat transfer. The addition of vortex generators helps in promoting system miniaturization. Moreover, the implementation of the passive techniques in cross-flow heat exchangers significantly escalates the pumping power requirement. Thereby, the objective of this paper is to carry out a review on the recent developments and their potential candidature for improving the thermal performance of heat exchanger. The latest state-of-the-art developments are deeply discussed with its evaluating parameters and some recommendations are made for further investigation in this area.
In the past decades have faced the challenges in meeting out the cooling demand due to the technological developments. More works are being carried out for optimum heat transfer in concentric heat exchangers, one among the double tube heat exchangers investigation is the triple tube heat exchangers (TTHE). Reported that the triple tube heat exchangers are more effective than double tube heat exchangers. In this paper, investigations carried out on triple tube heat exchangers are reviewed and the reports published by different researchers are critically analyzed in order to carry out the advanced research work on triple tube heat exchangers.
This research focus on the fluid flow and heat transfer of water inside the segmental baffle shell and tube heat exchanger (SB-STHE)optimization using combined baffle and longitudinal ribbed tube configuration. Triangular and circular ribbed tubes are employed with disk baffle shell and tube heat exchanger (DB-STHE)and combined segmental-disk baffle shell and tube heat exchanger (CSDB-STHE). The fluid domain is simulated by SOLIDWORKS Flow Simulation (Ver. 2015). Obtained results are compared with experimental data and numerical results available in literature. Based on the obtained results under maximum mass flow rates (2 kg/s), the average value of shell-side heat transfer coefficient of DB-TR and CSDB-TR are 26.6% and 31.9% higher than DB-CR and CSDB-CR, respectively. To evaluate the performance, Q/ΔP is selected at the same flow rate. A 42.8%, 40.5%, 24.2% and 7.12% difference over conventional baffles are represented by DB-TR, CSDB-TR, CSDB-CR and DB-CR respectively. In another criterion named as Performance evaluation criterion a 39%, 37%, and 13% performance difference over conventional baffles are represented by disk baffle shell and tube heat exchanger with longitudinal triangular ribbed tube (DB-TR), combined segmental-disk baffle shell and tube heat exchanger with longitudinal triangular ribbed tube (CSDB-TR), and combined segmental-disk baffle shell and tube heat exchanger with longitudinal circular ribbed tube (CSDB-CR)respectively.
Plate heat exchangers have been widely applied in numerous industrial applications since their first commercial exploitation in the 1920s. Enhancing the thermal-hydraulic performance of plate heat exchangers is of crucial importance for the energy conversion as well as for the improvement of the system economy, through savings in the capital investment. The efficiency of a plate heat exchanger can be improved either by optimizing its geometry or using heat transfer enhancement techniques. This paper provides a comprehensive review of previous works regarding the effects of chevron corrugation geometrical parameters on the performance of plate heat exchangers, and the application of heat transfer enhancement techniques in plate heat exchangers, focusing on passive surface techniques and the use of nanofluids. The objective of the paper is not only to describe relevant studies, but also to provide an understanding of the heat transfer mechanisms governing the results, and to evaluate and compare the different heat transfer enhancement techniques. In addition, prospective directions for future research are provided. The review indicates that for the chevron-type plate heat exchanger, the chevron angle is the most influential geometrical parameter by changing the flow structures in the single-phase heat transfer; meanwhile the chevron angle has a significant influence on the heat transfer regions characterized by convection in the two-phase heat transfer. An analysis based on the performance evaluation criteria suggests that the thermal-hydraulic performances of the studies with different geometrical parameters and enhancement techniques are generally higher at low Reynold numbers. Furthermore, the review and analysis indicate that the capsule-type embossing surface and the microstructured surface with a nano- and microporous layer are the enhancement techniques that present the highest performance in single-phase and two-phase heat transfer, respectively.
The pattern complexity (kinetics and uniformity) of bubble swarms governs the heat transfer performance in gas-liquid contact systems such as direct-contact boiling heat transfer process. An image analysis technique is developed for quantifying the complexity evolution of bubble pattern in the gas-liquid contact system based on entropy theory and algebraic topology (more precisely, Betti numbers) using organic Rankine cycle direct-contact heat exchangers. The Betti numbers method is associated with image segmentation using entropy theory, leading to a useful model to characterize the homogeneity of the mixture. Experimental results show such an effectiveness. This novel method may be applied the study of a variety of multiphase flows.
In this paperwork, a novel methodology of entropy generation minimization (EGM) for counter-current and co-current heat exchangers is developed. The methodology can be applied in general case for all types of the heat exchangers with the counter-current and co-current flow configuration. A number of entropy generation units (NEGU) function, along with its pressure drop and temperature difference components, are presented. Additionally, evaluated EGM can be easily incorporated into some optimization algorithms for industrial practice. Beside of the theoretical background, on an example and case study were proved that the EGM analysis could be useful in practical applications of heat exchanger optimization. Furthermore, the correlation between the minimum value of NEGU and minimum of total annual costs (operational and investment costs) have been shown. Based on the EGM methodology, on a case study was presented that pressure drop of the plate counter-current heat exchangers in series should be 36 kPa, in order to achieve minimal annual costs of the 456 EUR/year. The result corresponds to the heat exchangers in series with 2 sections and 46 plates per section.
A computational fluid dynamics model was implemented for studying the production of non-aerated sorbet in a scraped surface heat exchanger under different operating conditions. The coupled problem of fluid flow and heat transfer is solved by taking into account realistic values for the product physical properties as well as its complex rheology. The mathematical solution of the coupled problem represents a challenging task, among other reasons by the strong influence of temperature on product physical properties and rheology due to phase change. Fluid flow, heat transfer freezing and viscous dissipation phenomena are analyzed locally in the heat exchanger. The modeling approach is consistent, as indicated by comparisons between model predictions of the temperature profile along the heat exchanger and available experimental results.
The effects of the surface temperature distribution on the thermal resistance of a double U-tube Borehole Heat Exchanger (BHE) are studied by finite element simulations. It is shown that the thermal resistance of a BHE cross section is not influenced by the bulk-temperature difference between pairs of tubes, but is influenced by the thermal conductivity of the ground when the shank spacing is high. Then it is shown that, if the real mean values of the fluid bulk temperature and of the BHE external surface are considered, the 3D thermal resistance of the BHE coincides with the thermal resistance of a BHE cross section, provided that the latter is invariant along the BHE. Finally the difference between the BHE thermal resistance and the effective BHE thermal resistance, defined by replacing the real mean temperature of the fluid with the average of inlet and outlet temperature, is evaluated in some relevant cases.
Two novel shell-and-tube heat exchangers with louver baffles are invented and designed for energy conservation. A certain amount louver baffles at the inclination angle between shell side flow direction and louver baffle are equipped in shell side to support tube bundles. Numerical simulations are carried out to investigate the thermo-hydraulic performance of the two reformed shell-and-tube heat exchangers with louver baffles. For comparison, a shell-and-tube heat exchanger with conventional segmental baffles also studied in the paper. Fluid flow structures and temperature distributions are presented for the analysis of the physical behavior of fluid flow and heat transfer. Oblique flow is produced in the shell side of the shell-and-tube heat exchangers with louver baffles that decrease and eliminate the dead spaces and augment the local heat transfer. Compared with the shell-and-tube heat exchanger with segmental baffles, abrupt change of fluid flow is avoided that decrease the pressure drop in the shell side. The numerical results indicated that the heat transfer coefficient per pressure drop of both the shell-and-tube heat exchangers with louver baffles are higher than that of the shell-and-tube heat exchanger with segmental baffles. This implies that at the same heat transfer quantity, the pumping power of the shell-and-tube heat exchangers with louver baffles is lower than that of the shell-and-tube heat exchanger with conventional segmental baffles.
In this paper, the effects of number of inlets, tube length and diameter of cold outlet on temperature, flow rates passing through the vortex tube are investigated. The results including temperature of cold outlet and flow rates passing through the vortex tube are discussed. The effect of length, number of inlets, ranging from 1 to 5 inlets and the effect of cold outlet on the results are investigated. According to obtained results, we conclude that the passing flow rate from a cold outlet is increased as its diameter increase and by increasing the length of the vortex tube, the passing mass flow rates from the cold and hot cross-sections slightly increased and slightly increased, respectively. Also, the temperatures at both outlets decreased as the number of inlets increased, while increases were observed as the radius of cold outlet increased and the temperature of exiting gas is considerably higher than hot and cold outlets compared to the case where more number of inlets with reduced diameters is used. As shown, for L/D = 15 and as the radius of cold outlet is increased, the fraction of mass flow rate is decreased from 0.8 to 0.7 and then 0.6, from 0.65 to 0.58 and then 0.52, and from 0.42 to 0.32 and then 0.24 for n = 1, 3 and 5.
Smoothed Particle Hydrodynamics (SPH) is a relatively new meshless numerical approach which has at- tracted significant attention in the last two decades. Compared with the conventional mesh-based com- putational fluid dynamics (CFD) methods, the SPH approach exhibits some unique advantages in mod- eling multiphysic flows and associated transport phenomena due to its capabilities of handling complex boundary evolution as well as modeling complicated physics in a relatively simple manner. On the other hand, as SPH is still a developing CFD method, it is crucial to identify its advantages and limitations in modeling realistic multiphysic flow problems of real life and of industrial interest. Toward this end, this work aims at summarizing the motivations behind utilizing the SPH method in an industrial context, making the state-of-the-art of the present application of this method to industrial problems, as well as deriving general conclusions regarding its assets and limitations and stressing the remaining challenges in order to make it an hand-on computational tool.
An accurate description of the fluid flow and heat transfer within a fixed-bed reactor is desirable. The prevailing models of fluid flow invoke either a constant velocity (plug-flow) profile, or make use of a single axial velocity component with radial variation across the tube diameter. However, difficulties in predicting reactor performance and the wide disagreement between effective heat transfer coefficients suggest that these are oversimplified pictures of the real-flow situation. Computational fluid dynamics is a means that could improve our understanding of fixed-bed fluid flow and heat transfer, by solving the 3D Navier–Stokes equations. Simulations are presented for an improved geometry, compared to previous studies, of 10 solid spheres in a tube with a tube-to-particle ratio of 2.43, that includes both particle to particle and also wall to particle contacts. Simulations are also reported with heat generation from the spheres. The simulation results show strong flow components towards the wall and away from the wall, thereby transporting heat. The flow around the contact points themselves shows stagnant regions, due to the high shear of the solid surfaces. A high velocity gradient in the radial direction is observed between two layers of spheres, which clearly shows how the heat transfer is increased within the bed. Regions of back-flow are also observed, in qualitative agreement with literature experimental studies.
This paper presents a study about the design optimization of shell-and-tube heat exchangers. The formulated problem consists of the minimization of the thermal surface area for a certain service, involving discrete decision variables. Additional constraints represent geometrical features and velocity conditions which must be complied in order to reach a more realistic solution for the process task. The optimization algorithm is based on a search along the tube count table where the established constraints and the investigated design candidates are employed to eliminate nonoptimal alternatives, thus reducing the number of rating runs executed. The performance of the algorithm and its individual components are explored through two design examples. The obtained results illustrate the capacity of the proposed approach to direct the optimization towards more effective designs, considering important limitations usually ignored in the literature.
An analytical study on the effect of fouling and water quality on corrosion of kettle heat exchanger
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CFD Modeling of Real Scale Slab Reheating Furnace. 12th
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Co-rotating twin-screw extruders: Detailed analysis of conveying elements based on smoothed particle hydrodynamics. Part 1: Hydrodynamics
- A Eitzlmayr
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DOI: https://doi.org/10.15379/ijmst.v10i3.1672