Compact Heat Exchangers

Analysis, Design and Optimization using FEM and CFD Approach

AvC. Ranganayakulu,Kankanhalli N. Seetharamu

Inbunden, Engelska, 2018

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Beskrivning

A comprehensive source of generalized design data for most widely used fin surfaces in CHEsCompact Heat Exchanger Analysis, Design and Optimization: FEM and CFD Approach brings new concepts of design data generation numerically (which is more cost effective than generic design data) and can be used by design and practicing engineers more effectively. The numerical methods/techniques are introduced for estimation of performance deteriorations like flow non-uniformity, temperature non-uniformity, and longitudinal heat conduction effects using FEM in CHE unit level and Colburn j factors and Fanning friction f factors data generation method for various types of CHE fins using CFD. In addition, worked examples for single and two-phase flow CHEs are provided and the complete qualification tests are given for CHEs use in aerospace applications.Chapters cover: Basic Heat Transfer; Compact Heat Exchangers; Fundamentals of Finite Element and Finite Volume Methods; Finite Element Analysis of Compact Heat Exchangers; Generation of Design Data by CFD Analysis; Thermal and Mechanical Design of Compact Heat Exchanger; and Manufacturing and Qualification Testing of Compact Heat Exchanger. Provides complete information about basic design of Compact Heat ExchangersDesign and data generation is based on numerical techniques such as FEM and CFD methods rather than experimental or analytical onesIntricate design aspects included, covering complete cycle of design, manufacturing, and qualification of a Compact Heat ExchangerAppendices on basic essential fluid properties, metal characteristics, and derivation of Fourier series mathematical equationCompact Heat Exchanger Analysis, Design and Optimization: FEM and CFD Approach is ideal for senior undergraduate and graduate students studying equipment design and heat exchanger design.

Produktinformation

Utgivningsdatum:2018-03-09
Mått:178 x 246 x 33 mm
Vikt:1 111 g
Format:Inbunden
Språk:Engelska
Serie:Wiley-ASME Press Series
Antal sidor:544
Förlag:John Wiley & Sons Inc
ISBN:9781119424185

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Mer om författaren

C. Ranganayakulu, PhD, is an Outstanding Scientist and Group Director (GS-ECS) in the Aeronautical Development Agency, Ministry of Defence, India. Dr. Ranganayakulu is an Alexander von Humboldt re-visiting researcher at Helmut Schmidt University, Hamburg, and Leibniz University, Hannover, Germany, and Visiting Researcher at UNISA, Johannesburg, South Africa. K.N. Seetharamu, PhD, is a professor of Thermal Engineering at PES Institute of Technology, Bangalore, and is a member of the editorial board of a number of journals including the International Journal for Numerical Methods in Biomedical Engineering. He was a Professor of Mechanical Engineering at IIT Madras from 1980 to 1998.

Innehållsförteckning

Preface xiiiSeries Preface xv1 Basic Heat Transfer 11.1 Importance of Heat Transfer 11.2 Heat Transfer Modes 21.3 Laws of Heat Transfer 31.4 Steady-State Heat Conduction 41.4.1 One-Dimensional Heat Conduction 51.4.2 Three-Dimensional Heat Conduction Equation 71.4.3 Boundary and Initial Conditions 101.5 Transient Heat Conduction Analysis 111.5.1 Lumped Heat Capacity System 111.6 Heat Convection 131.6.1 Flat Plate in Parallel Flow 141.6.1.1 Laminar Flow Over an Isothermal Plate 141.6.1.2 Turbulent Flow over an Isothermal Plate 161.6.1.3 Boundary Layer Development Over Heated Plate 171.6.2 Internal Flow 181.6.2.1 Hydrodynamic Considerations 191.6.2.2 Flow Conditions 191.6.2.3 Mean Velocity 201.6.2.4 Velocity Profile in the Fully Developed Region 211.6.3 Forced Convection Relationships 231.7 Radiation 281.7.1 Radiation – Fundamental Concepts 301.8 Boiling Heat Transfer 351.8.1 Flow Boiling 361.9 Condensation 381.9.1 Film Condensation 391.9.2 Drop-wise Condensation 39Nomenclature 40Greek Symbols 42Subscripts 42References 432 Compact Heat Exchangers 452.1 Introduction 452.2 Motivation for Heat Transfer Enhancement 462.3 Comparison of Shell and Tube Heat Exchanger 482.4 Classification of Heat Exchangers 492.5 Heat Transfer Surfaces 512.5.1 Rectangular Plain Fin 522.5.2 Louvred-Fin 522.5.3 Strip-Fin or Lance and Offset Fin 532.5.4 Wavy-Fin 532.5.5 Pin-Fin 532.5.6 Rectangular Perforated Fin 542.5.7 Triangular Plain Fin 542.5.8 Triangular Perforated Fin 542.5.9 Vortex Generator 552.6 Heat Exchanger Analysis 562.6.1 Use of the Log Mean Temperature Difference 582.6.1.1 Parallel-Flow Heat Exchanger 592.6.1.2 Counter-Flow Heat Exchanger 622.6.2 Effectiveness-NTU Method 652.6.3 Effectiveness-NTU Relations 692.6.4 Evaluation of Heat Transfer and Pressure Drop Data 732.6.4.1 Flow Properties and Dimensionless Numbers 732.6.4.2 Data Curves for j andf 752.7 Plate-Fin Heat Exchanger 772.7.1 Description 772.7.2 Geometric Characteristics 782.7.3 Correlations for Offset Strip Fin (OSF) Geometry 812.8 Finned-Tube Heat Exchanger 812.8.1 Geometrical Characteristics 822.8.2 Correlations for Circular-Finned-Tube Geometry 842.8.3 Pressure Drop 852.8.4 Correlations for Louvred Plate-Fin Flat-Tube Geometry 862.8.5 Louvre-Fin-Type Flat-Tube Plate-Fin Heat Exchangers 902.8.5.1 Geometric Characteristics 912.8.5.2 Correlations for Louvre Fin Geometry 932.9 Plate-Fin Exchangers Operating Limits 932.10 Plate-Fin Exchangers – Monitoring and Maintenance 942.10.1 Advantage 952.10.2 Disadvantages 95Nomenclature 95Greek Symbols 97Subscripts 98References 983 Fundamentals of Finite Element and Finite Volume Methods 1013.1 Introduction 1013.2 Finite Element Method 1013.2.1 Finite Element Form of the Conduction Equation 1033.2.2 Elements and Shape Functions 1043.2.3 Two-Dimensional Linear Triangular Elements 1093.2.3.1 Area Coordinates 1123.2.4 Formulation for the Heat Conduction Equation 1143.2.4.1 Variational Approach 1153.2.4.2 Galerkin Method 1183.2.5 Requirements for Interpolation Functions 1193.2.6 Plane Wall with a Heat Source – Solution by Quadratic Element 1283.2.7 Two-Dimensional Plane Problems 1303.2.7.1 Triangular Elements 1313.2.8 Finite Element Method-Transient Heat Conduction 1413.2.8.1 Galerkin Method for Transient Heat Conduction 1423.2.9 Time Discretization using the Finite Element Method 1453.2.10 Finite Element Method for Heat Exchangers 1463.2.10.1 Governing Equations 1463.2.10.2 Finite Element Formulation 1483.3 Finite Volume Method 1643.3.1 Navier–Stokes Equations 1653.3.1.1 Conservation of Momentum 1683.3.1.2 Energy Equation 1713.3.1.3 Non-Dimensional Form of the Governing Equations 1733.3.1.4 Forced Convection 1743.3.1.5 Natural Convection (Buoyancy-Driven Convection) 1753.3.1.6 Mixed Convection 1773.3.1.7 Transient Convection – Diffusion Problem 1773.3.2 Boundary Conditions 178Nomenclature 178Greek Symbols 179Subscripts 179References 1794 Finite Element Analysis of Compact Heat Exchangers 1834.1 Introduction 1834.2 Finite Element Discretization 1844.3 Governing Equations 1844.4 Finite Element Formulation 1894.4.1 Cross Flow Plate-Fin Heat Exchanger 1894.4.2 Counter Flow/Parallel Flow Plate-Fin Heat Exchangers 1934.4.3 Cross Flow Tube-Fin Heat Exchanger 1944.5 Longitudinal Wall Heat Conduction Effects 1954.5.1 General 1954.5.2 Validation 1984.5.3 Cross Flow Plate-Fin Heat Exchanger 1994.5.4 Cross Flow Tube-Fin Heat Exchanger 2004.5.5 Parallel Flow Heat Exchanger 2064.5.6 Counter Flow Heat Exchanger 2064.5.7 Relative Comparison of Results 2074.6 Inlet Flow Non-Uniformity Effects 2074.6.1 General 2074.6.2 Validation 2144.6.3 Cross Flow Plate-Fin Heat Exchanger 2154.6.4 Cross Flow Tube-Fin Heat Exchanger 2214.6.5 Pressure Drop Variations – Flow Non-Uniformity 2244.7 Inlet Temperature Non-Uniformity Effects 2284.7.1 General 2284.7.2 Validation 2294.7.3 Cross Flow Plate-Fin Heat Exchanger 2294.7.4 Cross Flow Tube-Fin Heat Exchanger 2334.8 Combined Effects of Longitudinal Heat Conduction, Inlet Flow Non-Uniformity and Temperature Non-Uniformity 2354.8.1 General 2354.8.2 Validation 2374.8.3 Combined Effects of Longitudinal Wall Heat Conduction and Inlet Flow Non-Uniformity 2384.8.3.1 Cross Flow Plate-Fin Heat Exchanger – Combined Effects (LHC, FN) 2384.8.3.2 Cross Flow Tube-Fin Heat Exchanger – Combined Effects (LHC, FN) 2434.8.4 Combined Effects of Longitudinal Wall Heat Conduction, Inlet Flow Non-Uniformity and Temperature Non-Uniformity 2474.8.4.1 Cross Flow Plate-Fin Heat Exchanger – Combined Effects (LHC, FN, TN) 2514.8.4.2 Cross Flow Tube-Fin Heat Exchanger – Combined Effects (LHC, FN, TN) 2574.8.5 Combined Effects of Inlet Flow Non-Uniformity and Temperature Non-Uniformity 2604.8.5.1 Cross Flow Plate-Fin Heat Exchanger 2634.8.5.2 Cross Flow Tube-Fin Heat Exchanger 2674.9 FEM Analysis of Micro Compact Heat Exchangers 2734.9.1 Governing Equations and Finite Element Formulation 2774.10 Influence of Heat Conduction from Horizontal Tube in Pool Boiling 2824.10.1 General 2824.10.2 Governing Equations 2844.10.3 Finite Element Analysis 2854.10.3.1 One-Dimensional Case 2864.10.3.2 Two-Dimensional Case (Axial and Radial) 2864.10.3.3 Two-Dimensional Case (Azimuthal and Radial) 2874.10.3.4 Three-Dimensional Case 2874.10.4 Results 2884.10.4.1 One-Dimensional Heat Conduction Case 2904.10.4.2 Two-Dimensional Heat Conduction Case 2924.10.4.3 Three-Dimensional Heat Conduction Case 2934.11 Closure 298Nomenclature 299Greek Symbols 301Subscripts 302References 3035 Generation of Design Data – Finite Volume Analysis 3075.1 Introduction 3075.2 Plate Fin Heat Exchanger 3075.3 Heat Transfer Surfaces 3085.3.1 Lance and Offset Fins 3085.3.2 Wavy Fins 3085.3.3 Rectangular Plain Fins 3095.3.4 Rectangular Perforated Fins 3105.3.5 Triangular Plain Fins 3115.3.6 Triangular Perforated Fins 3115.4 Performance Characteristic Curves 3115.4.1 Working Fluids 3125.5 CFD Analysis 3125.5.1 Pre-Processor 3135.5.2 Main Solver 3135.5.3 Post-Processor 3135.5.4 Errors and Uncertainty in CFD Modelling 3135.6 CFD Approach 3145.6.1 Mathematical Model 3155.6.2 Governing Equations 3155.6.3 Assumptions 3165.6.4 Boundary Conditions 3165.6.4.1 Inlet Boundary Conditions 3175.6.4.2 Outlet Boundary Conditions 3175.6.4.3 Wall Boundary Conditions 3185.6.4.4 Constant Pressure Boundary Condition 3185.6.4.5 Symmetric Boundary Condition 3185.6.4.6 Periodic Boundary Condition 3185.6.5 Turbulence Models 3185.7 Numerical Simulation 3195.7.1 Transient Analysis 3205.7.1.1 Data Reduction and Validation 3215.7.2 Steady State Analysis 3285.7.2.1 Wavy Fin 3285.7.2.2 Offset Fins 3345.7.2.3 Rectangular Plain Fin 3375.7.2.4 Rectangular Perforated Fin 3445.7.2.5 Triangular Plain Fin Surface 3505.7.2.6 Triangular Perforated Fin Surface 3565.7.3 Flow Non-Uniformity Analysis 3625.7.4 Characterization of CHE Fins for Two-Phase Flow 3665.7.4.1 Experimental Set-Up 3675.7.4.2 Brazed Test Core 3685.7.4.3 Boiling Heat Transfer Coefficient 3705.7.4.4 Two-Phase Condensation 3745.7.5 Estimation of Endurance Life of Compact Heat Exchanger 3775.7.5.1 Computational Analysis 3785.7.5.2 CFD Analysis of CHE 3785.7.5.3 Endurance Life Estimation 3825.7.5.4 Fatigue Life Estimation 3825.7.5.5 Effect of Creep 3835.7.5.6 Results of Endurance Life 3845.8 Closure 385Nomenclature 388Greek Symbols 391Subscripts 391References 3926 Thermal and Mechanical Design of Compact Heat Exchanger 3996.1 Introduction 3996.2 Basic Concepts and Initial Size Assessment 4006.2.1 Effectiveness Method 4006.2.2 Inverse Relationships 4036.2.3 LMTD Method 4036.3 Overall Conductance 4076.3.1 Fin Efficiency and Surface Effectiveness 4096.4 Pressure Drop Analysis 4106.4.1 Single Phase Pressure Drop 4106.4.2 Two-Phase Pressure Loss 4136.4.2.1 Two-Phase Frictional Losses 4146.4.2.2 Two-Phase Momentum Losses – Change of Quality 4166.4.2.3 Two-Phase Gravitational Losses – Upward Flow (Boiling) 4166.4.2.4 Downward Flow (Condensation) 4176.5 Two-Phase Heat Transfer 4176.5.1 Condensation 4186.5.1.1 All Liquid Heat Transfer Coefficient 4186.5.1.2 Correction for the Vapour Volume 4186.5.1.3 Correction for the Multicomponent Streams 4196.5.2 Evaporation 4196.5.2.1 Reynolds Number Calculation 4206.5.2.2 Determine j and f Factors 4206.5.2.3 Heat Transfer Coefficient Calculation for Quality between 0 and 0.95 4206.5.2.4 Heat Transfer Coefficient for High and Low Values of Quality 4216.6 Useful Relations for Surface and Core Geometry 4216.7 Core Design (Mechanical Design) 4246.7.1 Fins 4246.7.2 Separating/Parting Sheets 4246.7.3 Cap Sheets 4246.7.4 Headers 4246.7.5 Supports 4256.7.6 Fin Minimum Thickness 4256.7.7 Parting/Separating and Cap Sheets Minimum Thickness 4266.7.8 Side-Bar Minimum Thickness 4266.7.9 Headers Minimum Thickness 4276.8 Procedure for Sizing a Heat Exchanger 4276.9 Design Procedure of a Typical Compact Heat Exchanger 4306.10 Worked Examples 4346.10.1 Example 1: Direct Transfer Heat Exchanger 4346.10.2 Example 2: Two-Pass Cross Flow Heat Exchanger 4426.10.3 Example 3: Compact Evaporator Design 4506.10.4 Example 4: Compact Condenser Design 451Nomenclature 454Greek Symbols 456Subscripts 457References 4577 Manufacturing and Qualification Testing of Compact Heat Exchangers 4617.1 Construction of Brazed Plate-Fin Heat Exchanger 4617.2 Construction of Diffusion-Bonded Plate-Fin Heat Exchanger 4617.3 Brazing 4647.3.1 Operations in Brazing 4657.3.2 Brazing Filler Metals 4697.3.3 Brazing Processes 4697.3.4 Vacuum Brazing 4707.3.4.1 Brazing of Aluminium and its Alloys 4707.3.4.2 Brazing of Stainless Steels 4747.3.4.3 Brazing of Super Alloys 4757.3.5 Vacuum Furnace Brazing Cycles 4767.3.5.1 Vacuum Level during Brazing 4777.3.5.2 Cooling Gases 4777.3.5.3 Post Brazing Inspection 4787.4 Influence of Brazing on Heat Transfer and Pressure Drop 4787.5 Testing and Qualification of Compact Heat Exchangers 4797.5.1 Acceptance Tests 4807.5.1.1 Thermal Performance and Pressure Drop Test 4807.5.1.2 Pressure Drop Test 4847.5.1.3 Leakage Test 4847.5.1.4 Proof Pressure Test 4847.5.2 Qualification Tests 4857.5.2.1 Vibration Test 4857.5.2.2 Combined Pressure, Temperature and Flow Cycling 4877.5.2.3 Experimental Evaluation of Endurance Life of Compact Heat Exchanger 4887.5.2.4 Pressure Cycling Test 4907.5.2.5 Thermal Shock Test 4917.5.2.6 Acceleration Test 4917.5.2.7 Shock Test 4917.5.2.8 Humidity Test 4927.5.2.9 Fungus Test 4937.5.2.10 Salt Fog Test 4937.5.2.11 Freeze and Thaw 4937.5.2.12 Rain Resistance 4937.5.2.13 Sand and Dust 4947.5.2.14 Shock Test (Arrestor Landing) 4947.5.2.15 Gunfire Vibration Test 4947.5.2.16 Burst Pressure Test 495References 496Appendices 497A.1 Derivation of Fourier Series Mathematical Equation 497A.2 Molar, Gas and Critical Properties 501A.3 Thermo-Physical Properties of Gases at Atmospheric Pressure 502A.4 Properties of Solid Materials 509A.5 Thermo-Physical Properties of Saturated Fluids 515A.6 Thermo-Physical Properties of Saturated Water 518A.7 Solar Radiative Properties of Selected Materials 521A.8 Thermo-Physical Properties of Fluids 522References 524Index 525