Heat Exchanger CFD
Heat Exchanger CFD
Heat Exchanger CFD
The aim of the project is to design and analyse the heat exchanger. A heat
exchanger is a piece of equipment built for efficient heat transfer from one
medium to another. The media may be separated by a solid wall, so that they
never mix, or they may be in direct contact. They are widely used in space
which the heat source, being a hot engine-cooling fluid, water, transfers heat to
air flowing through the radiator (i.e. the heat transfer medium).
CHAPTER I
INTRODUCTION
energy from the hot fluid to a cold fluid or vice versa, with maximum rate
and minimum investment and running cost. The heat exchanger is used to
without intermixing the fluids or changing the physical state of the fluids.
the point where it will become a liquid by the transfer of heat to another
fluid without intermixing the fluids. Water or air is used to condense the
vapour.
The figure given below shows a typical heat exchanger and its components
sheet
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3. Stationary Head Flange 18.Floating Head Baring
8. Shell External
Plates
17.Floating Head Flange
2.1 TYPES OF HEAT EXCHANGER
heat exchangers have been developed which are classified on the basis of
classifieds
as.
a. Regenerators.
b. Recuperator
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I. Direct Contact Heat Exchangers.
HOT WATER
Figure 2
direct mixing of hot and cold fluids and transfer of heat and mass takes
two fluids.
a. Regenerator
In a regenerator type of heat exchangers the hot and cold fluids pass
parameters
b. Recuperators
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These heat exchangers are used when two fluids cannot be allowed to
1. Easy construction
2. More economical
' In parallel flow heat exchanger as the name suggest the two fluid
streams (hot
and cold) travel in the same direction. The two streams enter at one end
and leave at the other end. The flow arrangements and variations of
temperatures of the fluid stream in case paralled flow heat exchangers are
difference between the hot and the cold fluid goes on decreasing from
inlet to outlet. Since this type of heat exchangers needs a large areas of
axis. FIGURE 3
direction. The hot and cold fluid enters the opposite ends. The flow
more or less nearly constant. This type of heat exchanger due to counter
flow gives maximum rate of heat transfer for a given surface area. Hence
such heat exchangers are most favored for heating and cooling fluids.
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ii. Cross Flow Heat Exchanger
In cross flow heat exchangers the two fluids (hot and cold) cross one
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COLD FLUID
(!N)
COLD FLUID
(UOT)
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COLD FLUID (UOT)
EXCHANGER Figure 5
Refer Figure : Hot fluid flow in the separate column and there is
mixing in the fluid streams. The cold fluid is perfectly mixed as its flow
uniform across any section, and will vary only in the directions of the
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Refer figure: In this case each of the fluid follows a prescribed path and is
i. Concentric Tubes
In this type, two concentric tubes are used each carrying one of the fluids.
The
In this type of heat exchanger one of the fluid flows through a bundle of
tube ' enclosed by a shell. The other fluid is forced through the shell and it
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Multiple parallel and counter flow passes are used for enhancing the
overall heat transfer. Multiple shell passes is possible where the fluid
flowing through the shell is re-routed. The shell side fluid is forced to
flow back and forth across the tubes in the by baffles. Multiple tube pass
exchangers are those which re-route the fluid through tubes opposite
direction
Figure 7
These are special purpose heat exchangers and have a very large
transfer surface area per unit volume of the exchanger. They are generally
the fluids is much smaller than that associated with the other fluid.
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4. PHYSICAL STATE OF FLUIDS.
Depending upon the physical state of the fluids the heat exchangers
i. Condenser
ii. Evaporators
i. Condenser
gradually increases from inlet to outlet. The hot fluid losses latent part of
ii. Evaporators
the temperature of the hot fluid gradually decreases from inlet to outlet.
curtailed
improper start up and shut down practices. Some common problems are :
shell
ii. Bending of the pass partition plate in the partition channel due to
slung
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flow from the tube inlet nozzle. Caused by rapid opening of the
channel
inlet valve.
iii. Introduction of tube side fluid in a fixed tube sheet heat exchanger
with
the shell side empty (since the resulting change in the tube metal
temperature may over stress the tube to tube sheet joint resulting in
the failure).
integral
avoid
pressure is the shell and the tube side pressure are always presents
simultaneously. The
is never violated. Including the period of start up and shut down, or the
vibration, rapid tube failure, corrosion and erosion of the tube wall, tube
joint failure, fluid level control difficulties and flanged joint leakage.
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Operating problems in heat exchangers may be broadly classified into
three groups.
i. Structural Problems
i. Structural Problems
Structural problems are the most serious; failure is often swift and
exchanger tubes over shadow all other structural failures. Tube to tube
in the tube sheet or cover in multiple pass design induces joint leakage.
structural problems.
Deposition of foul ants on the inside of the tube surface reduces the
available flow area and increase the skin friction, causing an increase in
tubes usually occur in units with low flow velocity design. Uneven
fouling may occur on the shell side of the tubes due to a poor baffling
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scheme. Which leads to a flow misdistribution. Highly non-uniform
welds joining pass partition plates to each other and to the channel.
Stress corrosion, galvanic corrosion, and erosion are the most requently
EXCHANGERS Advantages
1. Energy Savings.
operations.
Disadvantages
1. Friction losses
2.4 FOULING
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In a heat exchanger during normal operations the tube surface gets
covered by deposits of ash, soot, and dirt and scale etc. This phenomenon
fouling Processes
4. Corrosion fouling
5. Biological fouling
6. Freeze fouling
1. Velocity
2. Temperature
3. Water chemist
4. Tube materia]
Prevention of fouling
exchang*
1 Physical properties
.
2 Mechanical Properties
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3 Climatic Properties
.
4 Chemical Environment
.
5 Quality of Surface
. finish
6 Service File
.
7 Freedom from Noise
.
8 Reliability
.
Common failure to heat exchangers
tubes.
Inner surface,
Ui
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1/hi + ri/k In (ro /ri) + ri/ro x 1/ho
Outer surface
Uo
Where
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Ui Overall heat transfer coefficient inside the
tube
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Uo = Overall heat transfer coefficient outside the
tube
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Hi = Local convective heat transfer coefficient inside the
tube
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ho = Local convective heat transfer coefficient inside the
tube
ri = Inside radius of the
tube
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ro Outside radius of the
tube
k = Conductive heat transfer coefficient of tube material.
U.A. = UoAo
Where
0 o '
1 i n o Vn ) 1
hi Ai 2TTKL
h0A Figure 8
the thickness and thermal conductivity of the scale deposits, the effect of
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transfer coefficient hs. If hsj and hsQ be the heat transfer coefficient for
on the inside surface (RSj) and outside surface (RS0) are given
thus
defined as :
R f = ( l / h r ) = l / U H . t - 1/U .
There are various types of services in which tubular exchangers are used
in
fluid, which
the
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point where it will become a liquid by the transfer of heat to
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material, and there must be tensile stresses above some minimum
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Aluminum and stainless steel are well known for stress corrosion
components.
• Welding
• Fabrication
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• Improper design
• Improper materials
• Pitting
• Corrosion fatigue
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General corrosion
Crevice corrosion
Design errors
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Selective leaching, or
oying
dealt
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Erosion corrosion
Wear Failures
commonly used.
Adhesive wear
Erosive wear
surface due to relative motion in contact with a fluid that contains solid
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particles. More than one mechanism can be responsible for the wear
Pitting Corrosion
typified by the formation of holes or pits on the metal surface. Pitting can
Pits may be rather small and difficult to detect. In some cases pits may be
masked due to general corrosion. Pitting may take some time to initiate
methods for reducing the effects of pitting corrosion are listed below:
listed below:
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• Coatings
• Inhibitors
• Cathodic protection
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Figure.11 Uniform Corrosion
Corrosion Failures
deterioration of the material and its properties. This may result in failure
• Type of corrosion
• Corrosion rate
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necessitates a tensile stress, which may be caused by residual stresses, and
Aluminum and stainless steel are well known for stress corrosion
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Corrosion Failures Analysis.
to, foreign matter and/or surface layer of the metal is beneficial in failure
below:
• Uniform corrosion
• Pitting corrosion
• Intergranular
corrosion
» Crevice corrosion
• Galvanic corrosion
Fatigue Failures
the material. Metal fatigue cracks initiate and propagate in regions where
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Initial crack initiation
across
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Final sudden fracture of the remaining cross section
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Cycles to
Failure N
Stress
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Graph-1 S-N curve
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Schematic of S-N Curve, showing incr.ease in fatigue life with decreasing
stresses
Stress Ratio
The most commonly used stress ratio is R, the ratio of the minimum
•If the stresses are partially reversed, R = a negative number less than
1.
zero.
Variations in the stress ratios can significantly affect fatigue life. The
component will fail at lower alternating stress than it does under a fully
reversed stress.
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Preventing Fatigue Failure
improvements in design:
manufacturing.
loads below the static yield strength. This can result in an unexpected and
Creep occurs under load at high temperature. Boilers, gas turbine engines,
and ovens are some of the systems that have components that experience
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Failures involving creep are usually easy to identify due to the
Creep of Metals
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Fract
ure
1.
Strai
Initial
Load Time
----------
Graph-2 strain-time curve
period of time. The slope of the curve, identified in the above figure, is the
strain rate of the test during stage II or the creep rate of the material.
deformation takes place and the resistance to creep increases until stage II.
Stress Rupture
stresses used are higher than in a creep test. Stress rupture testing is
always done until failure of the material. In creep testing the main goal is
to determine the minimum creep rate in stage II. Once a designer knows
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the materials will creep and has accounted for this deformation a primary
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Stress
Typical
Stress M
W2 ir5 105 101 W Stress Rupture DataO
■ P i ' I I Tw,
rupture time, hr ters
Stress rupture tests are used to determine the time to cause failure.
extrapolate time to failure for longer times. Changes in slope of the stress
PARTS
Channel covers are usually circulars in design and fabricated out of the
same
plate material as the channel. The thickness of the flat channel covers in
against the channel cover. Only the code formula needs be considered.
measured at the bottom of the pass partition grove minus the tube side
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required to be provided with approximately 3/16 " (408m) deep groves
CHAPTERS CAUSES
OF FAILIURE
5.1 Vibration
phenomenon as
heat exchanger sizes and quantities of flow have increased .The shell side
flow
consideration
Vortex shelling
tubes may coincide with a natural frequency of tube and excite large
velocity exceed and the vibration then become self exited and grows in
Pressure fluctuation
5.2 Corrosion
causes corrosion.
is 229°c.
The heating fluid hot oil called Therminol passess through the
tubes. The inlet of hot oil is at top of the bundle and outlet is at the bottom
The inlet temperature of the hot oil is 320 °c. and the outlet temperature is
exchanger. During when the hot oil will be pass through the tubes this
state convective heat transfer (h) is less. This causes the top 120 ube
become overheat.
CHAPTER-6
TYPE OF FAILURE
6.1Tube bracking
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The corrosion and erosion in the tube can cause tube
brakeage
The clearance between the parallel and counter flow bundle can
6.3Tube bending
The clearance between the parallel and counter flow and over
'R'
two fluids)
P = (TCo-Tci)/ (Tho-
T c i ) = (230-217)/
(320-217) -0.126
R - (Tho-Thj)/ (Tco-
Tci) = (320-270)/
(230-217) = 3.8
=1 LMTD =1*68.87
=69.87°c
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A .consider flow inside the tube
viscosity) = (4*0.153)/
(3.14*0.01483*20* 10 ~4) =
6578.28
= 0.0238*Re08 Pr04
of hot oil)
(20*10"483.318*103)/0.H
08 = 59.89
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Nu = 0.023*6571.28 08*59.89 0 4
=138.9
(138.69*0.1108)/0.01
483 = 1036.2w/m2k
= (3*
10"4*2.356*103)/0.116
7 = 188.13
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3
Gr = (6.089 *0.00176*9.81 *71.5)/
( 11.34*10'3)2 =2.878*106
Where
'L'=6.689m (3 =
volumetric expansion=l/T
= 1/(295+273) = 1.760*
10"3k"'
(320+270)/2=295°c
temp =295-
((230+217)/2) =71.5°c
0.539*109
1/4
Nu = 0.53(Gr*Pr) for (104<
Gr*Pr>109) =0.53(0.539*109
*188.18)025 =87.42
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Nu=h0d0/k
h0 =(87.42*0.116)/ (19.05*10~3)
=494.74w/m2k
(0.01905/0.01483)) +
(1/494.724))
=290.0599w/m2oc
=2.356kj/kgoc Tco
Q =17.98*2.356*10 3*(230-217) =
550521.28w
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Heat transfer rate hot fluid
Q = mh cph (Th0-Thi)
Where mh
=0.153kg/sec
Cph =3.318kj/kg°c
Tco =320°c
=270°c
= 3045924w
Q =U* A* LMTD
A =Q/ (U*LMTD)
(29005*69.87) = 150.1m2
=3.14*.01905*6.689*360
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= 144.040m2 Actual area =144.040m2
design is safe
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ANALYSIS
determining and improving weak points, computing life and foreseeing probable
ANSYS software with its modular structure as seen in the table below gives
an opportunity for taking only needed features. ANSYS can work integrated with
other used engineering software on desktop by adding CAD and FEA connection
modules.
ANSYS can import CAD data and also enables to build a geometry with its
"preprocessing" abilities.
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Similarly in the same preprocessor, finite element model (a.k.a. mesh)
which is required for computation is generated. After defining loadings and carrying
ANSYS can carry out advanced engineering analyses quickly, safely and
practically by its variety of contact algorithms, time based loading features and
and parametric CAD systems with unique automation and performance. The power
Analysis procedure
Step1: Launch ANSYS, by going to the start-up menu and double clicking on
Step2: Once the program is launched it should look like as shown below. Go to
Step3: Next Double click on the Geometry. This stage is for getting the required
geometry read into the software; note that there is a blue question mark icon beside
the geometry text. Looking at the bottom of the window you will see two windows
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one having the title of Messages, this title confirms that the imported geometry has
no problems with it, the next window has the title Progress and that is necessary to
prove that state of the progress and if there is a problem it will state the problem.
Step4: Once ANSYS Workbench window is active you will get a window asking to
specify working units for the model dimension chose meters and press ok. For the
user this step might seem secondary in importance but as a matter of fact it’s of
great importance, because at later stages you will have to specify the box size
(discrete element dimension). Box size dimension leads to finer mesh, the finer the
used mesh is the more accurate is the captured data. The captured data term refers to
the fluid flow structures. Depending on case the selection of serial or parallel is
taken, also depending on the hardware provided in the computer lab dual core or
Step 6: A window having a title open will be visible to the user, choose File type
file .There are lots of software that are used to generate meshes, depending on the
software used the file extension text would be, to generate the mesh and then
exporting it in Parasolid format. A question comes to the mind of the student why do
I have to specify the file extension. The answer is that each mesh generation
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Step7: Looking at the Design Modeler window, we can’t see the imported geometry
yet, what is required next is to press on the generate icon that is represented by a
yellow thunder icon. The Design Modeler will read in the imported data file, and will
construct the required mesh. The imported Geometry Domain should look something
like this, still that doesn’t give any hints to the user, relating to the inner structure of
the domain. The geometry domain is viewed in the shaded exterior style.
Step8: go to view and chose wireframe. This step is necessary to view the inner
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Step 9a: Once the student gets to this stage, that means he has finished from the
Design Modeler and has to proceed to the Meshing part. Rotate the view and check
Step 9b: Go to the workbench and check that there is a green tick sign beside the
Geometry and then double click on the Mesh Icon. After finished from Design
Step 10a: The Meshing part of the project has started, notice that beside the Mesh
there is a yellow thunder icon. The scale shown at the bottom helps you make the
right decision on the box sizing, so that we can see that the largest value on the scale
Step 10b: right click on Mesh and chose Insert and then chose Method.at this stage
we come to the point where we have to choose what kind of mesh are we going to
Step 10c: click on the positive sign beside the Mesh you should get a tree sub branch
have automatic Method using the left button click on the grey box domain, as a
result it should by highlighted in green, then you see that the geometry text is
highlighted in blue press the apply. Choose the parallel option in the projection
mode, which will come handy later on, when you want to use the measure command
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Step 11: go to method and choose Tetrahedrons. This prepares the view for later
wanted operations.
Now that you have specified the mesh properties, you can proceed to the next step.
Step13: press the Update icon and then press on the Generate Mesh icon. For our
case we will want to now the dimensions of the inflow section of the pipe.
Step14: click on mesh, now it’s visible to the user the generated mesh. Click on the
Step15: Go to work bench, you will see there is a green tick beside the mesh
congratulations you can now proceed to the setup. Check the messages window if
there are any errors you will have to go back in steps and check where you went
wrong.
MESHING
Meshing involves division of the entire of model into small pieces called elements. It
is convenient to select the free mesh because the cylinder gasket has sharp curves,
so that shape of the object will not alter. To mesh the cylinder gasket the element
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type must be decided first. Here, the element type is solid 45. The element edge
length is taken as 5 mm. The numbers of elements are taken 2225 and the total
BOUNDARY CONDITIONS
The front eye of the cylinder gasket is coupled directly with a pin to the frame so
that the eye can rotate freely about the pin but no translation is occurred. The rear
eye of the spring is connected to the shackle which is a flexible link the other end
of the shackle is connected to the frame of the vehicle. The cylinder gasket is
totally fixed at the centre with the help of bottom plate to the axel of vehicle. The
force applied at both the eye end of cylinder gasket. The both eyes of the cylinder
gasket have the flexibility to slide along the X-direction when load applied on the
spring and also it can rotate about the pin in Z- direction. The link oscillates
during load applied and removed. So the displacement at the both eye is
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electromagnetic for engineers.
determining and improving weak points, computing life and foreseeing probable
ANSYS software with its modular structure as seen in the table below gives an
opportunity for taking only needed features. ANSYS can work integrated with
other used engineering software on desktop by adding CAD and FEA connection
modules.
72
ANSYS can import CAD data and also enables to build a geometry with
defining loadings and carrying out analyses, results can be viewed as numerical
and graphical.
ANSYS can carry out advanced engineering analyses quickly, safely and
73
and parametric CAD systems with unique automation and performance. The
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ANSYS Workbench is verification and improving of the product in virtual
environment.
especially PC, is more than an interface and anybody who has an ANSYS
RESEARCH METHODOLOGY
At present most inlet manifolds are designed by trial and error, method or
study through prototypes that takes much time and effort to reach an optimal
design and that there is a lack of a systematic process. To help design an inlet
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hour. Through the advancement of the computer system performance it is
made possible to run softwares that can analyze to give results of even the most
In this study, to develop a new framework for the design of inlet manifolds,
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PARALLEL FLOW
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79
COUNTER FLOW
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CONCLUSION
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A heat exchanger that works well in
design .
CHAPTER-11
REFERENCES
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1. Heat and Mass Trans.fer-R.K.Raj put
Rathore
kundwar
6. www.hocl.com
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