Designing & Developing a Porous based Box-Type Heat Exchanger for Enhanced Heat Transfer Rate

Abstract

The shell-and-tube heat exchanger\'s geometric configuration is optimized during the design development phase by taking into account various aspects like baffle spacing, tube arrangement, and overall system integration. Incorporating a blower into the system results in improved air circulation and effective heat transfer. By placing the band heater in a strategic location, air is heated precisely and locally, which helps to create a more responsive and controlled heating process. One essential tool for assessing the system\'s thermal and fluid dynamics is CFD analysis. The heat exchanger, blower, and band heater components\' fluid flow patterns, temperature distributions, and pressure gradients are investigated through simulations. The CFD analysis provides valuable insights that guide design modifications aimed at optimizing heat transfer rates, minimizing pressure drops, and improving the integrated system\'s overall performance.

Introduction

I. INTRODUCTION

The design and development of a shell-and-tube heat exchanger, coupled with a blower and band heater for hot air supply and a water motor for cold water supply, represent an innovative and versatile thermal system. This multifunctional design seeks to efficiently address diverse heating requirements by integrating a blower for enhanced air circulation, a band heater for localized water heating, and a water motor for controlled cold water supply.[2] The synergy of these components aims to optimize the heat exchange process, providing simultaneous hot air and water heating. The incorporation of Computational Fluid Dynamics (CFD) analysis into the design process further ensures a comprehensive understanding of fluid dynamics, thermal performance, and system efficiency. This integrated approach holds promise for applications across various industries, offering an adaptable and energy-efficient solution for the simultaneous provision of hot air and heated water.[1]

A. Problem Definition

The main difference between a normal heat exchanger and a porous-based heat exchanger lies in the nature of the heat transfer medium and how it affects heat exchange efficiency and other characteristics. In a normal heat exchanger, the heat transfer occurs through a solid wall or a direct contact interface between two fluids. The fluids do not mix, and the heat is conducted through the separating barrier. Heat transfer efficiency depends on the surface area of contact between the fluids and the thermal conductivity of the separating material. In general, normal heat exchangers are efficient for transferring heat between non-reacting fluids. Achieving higher heat transfer rate thorough porous & Nano particles. Normal heat exchangers may exhibit pressure drops due to changes in fluid direction, turbulence, and flow restrictions caused by the geometry of the heat exchange surfaces.

???????B. Objective  

1. To design and CFD analyse the heat transfer effect using Catia v5 & Ansys Workbench before manufacturing the proposed system.
2. To purchase, Fabricate the required frames as per the design modulation.
3. To increase the heat transfer rate with the available porous & nano particles material.
4. To maximize the temperature distributions by capturing the heat in porous bed form.
5. To conduct an experiential setup and note the reading upon time dependent factor.

II. LITERATURE SURVEY

Yue Hu1, Per Kvols Heiselberg [1] In this paper, a new window application—a ventilated window with a Phase Change Material (PCM) heat exchanger—is proposed. When ventilation pre-cooled air is available, the summertime night ventilation mode is used to release energy stored in PCM by the surrounding cold air, which can then be reloaded. The PCM ventilation system is assessed using numerical models that are constructed and validated through large-scale experiments.[1]

Because of their high latent heat, phase change materials (PCM) can store thermal energy over a narrow temperature range. In addition to thermal conductivity, density, and phase change enthalpy, viscosity based on temperature must be characterized when designing a thermal energy storage (TES) system with PCMs in order to account for natural convection.

Utilizing the resources of various research groups operating within a global network, a series of cooperative experiments were conducted to ascertain the viscosity of two PCMs—octadecane and the commercial paraffin RT70 HC—based on their respective temperatures.[2]

Buildings use an astounding amount of electricity—up to 45% of all energy used globally. One passive cooling method used in buildings to lower indoor heat input, enhance heat absorption, and prevent heat buildup is phase change materials (PCM). The use of PCM for thermal energy storage can raise a building's overall heat capacity. PCMs with enormous energy densities have sparked strong interest in developing high thermal inertia structures with significant energy savings.[3]

The current study focuses on the thermal performance of a heat exchanger based on encapsulated phase change material (PCM) for building thermal management in Indian settings.  Through experimental investigation, the encapsulated PCM-based heat exchanger's heat transfer characteristics are examined, and comparisons with radiant panel and thermally activated roof systems are made. The test chamber of an experiment is a small concrete cube with a window facing north.  It is discovered that an enclosed PCM-based heat exchanger can lower the mean air temperature by more than 6 C and the test chamber's heat gain by about 50%.[4]

III. PROPOSED SYSTEM

A. Working & Proposed Design

In order to maximize thermal performance and versatility, a methodical process is employed in the design development of a shell-and-tube heat exchanger integrated with a blower and band heater for air supply and water heating. First, the heat exchanger's geometry is designed, taking into account elements like the configuration of the tubes, the distance between the baffles, and the placement of the blower and band heater. While the band heater precisely and locally heats the air, the blower promotes improved air circulation. Durability, thermal efficiency, and corrosion resistance are all dependent on the choice of material and integration of components. Iterative improvements are made to the system with the goal of reaching the best possible heat exchange performance for both water and air.

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Conclusion

The design development and Computational Fluid Dynamics (CFD) analysis of a shell-and-tube heat exchanger can lead to several possible outcomes, impacting its efficiency, performance, and overall suitability for a given application. There are several possible results from the design, development, and computational fluid dynamics (CFD) study of a porous-based shell and tube heat exchanger with an air blower and band heater. Improved fluid distribution and surface area may lead to higher heat transfer rates when porous materials are used in the heat exchanger. An air blower improves heat exchange processes by facilitating effective air circulation. Furthermore, the band heater offers accurate temperature control, guaranteeing the appropriate air heating levels. The design may be fine-tuned for best performance by carefully studying several characteristics, including fluid flow patterns, temperature distributions, and pressure drops, using rigorous CFD research. In the end, this integrated system has the ability to effectively heat air and cool water at the same time, with potential uses in environmental control systems, industrial processes, and HVAC systems. A. Future Scope Future versions of the band heater and air blower-equipped porous-based shell and tube heat exchanger may investigate several options for improvement and modification. The use of sophisticated materials with enhanced thermal conductivity has the potential to enhance heat transfer efficiency and minimize energy usage. Smart sensor and feedback mechanism integration might allow for real-time control and monitoring, allowing performance to be optimized in response to changing operating circumstances. Further chances for even larger efficiency increases may arise from investigating alternate designs, such as multi-stage heat exchange or unique geometric layouts. Furthermore, improvements in computer power and CFD modeling methods may make it possible to conduct more thorough and precise assessments, exploring intricate fluid dynamics processes and optimizing design parameters. All things considered, the key to realizing the full potential of this integrated system for heating and cooling applications in many sectors is ongoing innovation and refinement in design, development, and CFD analysis.

References

[1] Peng, B., Wang, Q. W., Zhang, C., Xie, G. N., Luo, L. Q., Chen, Q. Y., & Zeng, M. (2007). An experimental study of shell-and-tube heat exchangers with continuous helical baffles. Journal of heat transfer, 129(10), 14251431. [2] Gay, B., Mackley, N. V., & Jenkins, J. D. (1976). Shell-side heat transfer in baffled cylindrical shell-and tube exchangers—an electrochemical mass-transfer modelling technique.International Journal of Heat and Mass Transfer, 19(9), 995-1002. [3] Kral, D., Stehlik, P., Van Der Ploeg, H. J., & Master, B. I. (1996). Helical baffles in shelland-tube heat exchangers, Part I: Experimental verification. Heat transfer engineering, 17(1), 93-101. [4] Gaddis, E. S., & Gnielinski, V. (1997). Pressure drop on the shell side of shell-and-tube heat exchangers with segmental baffles. Chemical Engineering and Processing: Process Intensification, 36(2), 149-159. [5] Li, H., & Kottke, V. (1998). Effect of baffle spacing on pressure drop and local heat transfer in shell-and-tube heat exchangers for staggered tube arrangement. International Journal of Heat and Mass Transfer, 41(10), 1303-1311. [6] Li, H., & Kottke, V. (1999). Analysis of local shellside heat and mass transfer in the shell-andtube heat exchanger with disc-and-doughnut baffles. International Journal of Heat and Mass Transfer, 42(18), 3509-3521. [7] Baghban, S. N., Moghiman, M., & Salehi, E. (2000). Thermal analysis of shell-side flow of shell-and-tube heat exchanger using experimental and theoretical methods. International Journal of Engineering, 13(1), 15-26 [8] Tandiroglu, A. (2006). Effect of flow geometry parameters on transient heat transfer for turbulent flow in a circular tube with baffle inserts. International Journal of Heat and Mass Transfer, 49(9-10), 1559-1567.

Copyright

Copyright © 2024 Bagade Sakshi Shashank, Kesapure Rushikesh Tulshiram, Kulkarni Malhar Atul, Rupali Prabhakar Shingate, Prof. Mr Polas Rohit Purushottam. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.