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CFD Simulation of a Double Pipe Heat Exchanges: Analysis Conduction and

Convection Heat Transfer

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International Journal of Scientific Research and Review ISSN NO: 2279-543X

CFD Simulation of a Double Pipe Heat

Exchanger: Analysis Conduction and
Convection Heat Transfer
Baru Debtera1, Ibsa Neme 1 and Venkatesa Prabhu, S*1
1
Department of Chemical Engineering, College of Biological and Chemical Engineering, Addis Ababa Science and

Technology University, Addis Ababa, Ethiopia.

Abstract —Simulation of heat transfer mechanisms in the heat exchangers is very important in different industrial process
to recover and minimize the wastage of thermal energy. Ansys Fluent is well-known software for computational fluid
dynamics (CFD) which is used to simulate and analyze heat transfer mechanisms in the heat exchanging system. In the
present work, a model of simulation for heat transfer rate observed from the double pipe heat exchanger (DPHE) has been
developed using Ansys Fluent 16.2 software. The DPHE setup was made with the tube length of 1m. The inner and outer
diameters of the tube were 0.05m and 0.055m, respectively. The annulus of the heat exchanger made with the inner and
outer diameters 0.08m and 0.085m, respectively. The objectives of this work are to study the hydrodynamic and thermal
behaviour of cold and hot fluids used in double pipe heat exchanger, and compare the actual heat transfer observed by
number of transfer unit method. Yet another objective is to simulate the obtained results using the CFD. In this approach,
a model developed by computational fluid dynamics has been validated by actual heat transfer. The results from the
numerical simulation of actual heat transfer well agreed with the effectiveness of heat transfer obtained from NTU method.
The actual heat transfer (Q) acquired by CFD simulation and the mathematical NTU method were respectively, 29.7 KW
and 30.5 KW. It clears that the percent error between the approaches, CFD simulation and effectiveness of heat transfer-
NTU method is 2.6%. It is less than the standard error (15%) and well acceptable.

Keywords— Double pipe heat exchanger, Ansys Fluent 16.2, Heat transfer, Temperature, Velocity profile.

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I. INTRODUCTION
A heat exchanger is equipment that used to transfer or exchange the heat energy for different purposes. In
the industries, heat exchangers are very important and play vital role to recover heat between two process fluids. The
most common heat transfer devices are concentric tube (double pipe), shell and tube and, plate heat exchanger [1].
The double pipe heat exchanger is basic and simplest heat exchanger equipment which is used to exchange the heat
energy either by parallel flow or counter flow arrangement [2]. When the required heat transfer area is small (up to 50
m2), the double pipe heat exchanger plays major role [3]. Here, the flow arrangement is important when one or both
of the process fluids are operated at high pressure, because of the smaller diameter of the pipes. While designing the
heat-transfer equipment it is to be noted that the trade-off between the two conflicting goals of low capital cost (high
overall heat-transfer coefficient with small heat-transfer area) and low operating cost (small stream pressure drop).
Already it is described by the use of different numerical methods such as NTU and LMTD methods. However, in
these methods are computationally time consuming, obtaining numerical errors during calculation and cannot be
predicted all thermal and hydraulic behaviors of fluids in the flow fields. To resolve these difficulties, computational
fluid dynamics (CFD) software can be used. CFD is the science of predicting fluid flow pattern, heat and mass transfer,
chemical reactions, and related phenomena by solving the set of governing mathematical equations such as
conservation of mass, conservation of momentum, conservation of energy, conservation of species, effects of body
forces, etc. [3]. It is a powerful tool for research and development in heat transfer simulation and modeling of heat
exchanger in the multiphase flow systems. Ansys Fluent is feasible and famous software that compute accurately the
conjugate heat transfer. Herewith realizable K-Epsilon, standard wall function mode can also be employed. This
simulation gives the values of pressure, temperature, heat transfer rate and velocity at various sections of the annulus
and pipe [5]. Convection within the fluids (natural and forced), conduction in solid regions, thermal radiation and
external heat gain or loss from the outer boundaries of the model can be computed using Ansys Fluent [6]. The
performance of parametric analysis on the average value of convective heat transfer coefficient is done based on results
of 3D in CFD simulations characterized by an average flow direction.
A significant advantages of CFD methods are evaluating thermal and hydrodynamics of the system that makes
possibility to analysis the geometric changes (different feed point layouts such as multiple entry points), selecting
operating conditions in lesser time (faster turnaround time). It can be reduced different expenses (flexibility for
changing design parameters without hardware changes). Another notable advantage is CFD provides more detailed
output information for trouble-shooting and far better understandings of the thermal and hydrodynamics performance.
This work designed about simulation, visualization, and the analysis on the conduction and convection heat transfer
mechanisms carried out in the laboratory double pipe exchanger. This work was carried out by the Ansys Fluent
software with CFD analysis to estimate the relationship between fluid velocity and heat transfer and to visualize the
fluid velocity profile and the temperature profile. The main objective of this work is to compare the numerical
effectiveness-NTU method with computational fluid dynamics (CFD) simulation of a double pipe heat exchanger
based on conduction and convection heat transfer mechanisms.

II. MATERIALS AND METHODS

Water was used as hot and cold fluids for heat transfer analysis in a double pipe heat exchanger. The physical
properties of hot and cold water are summarized in table 2.1.

Fluids properties Hot Fluid Cold Fluid

Density (kg/m3) 932.5 998.2
Thermal conductivity (W/m.K) 0.687 0.609
Temperature inlet (K) 415 300
Dynamics viscosity (kg/m.s) 0.000207 0.000841
Mass flow rate (kg/s) 0.87 0.9
Prandtl number 1.28 5.77
Specific heat transfer capacity(KJ/kg.K) 4.268 4.18

Table 1 Physical Characteristics hot and cold water

A. Effectiveness-Number of Transfer Unit
The heat transfer rate across a heat exchanger is usually expressed as given below.
.
Q  U A  T m …………… (1)

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Where: Q is heat transfer rate, U is overall heat transfer coefficient, A is area used to heat exchange, ΔTm is average
temperature difference between the fluids. The overall heat transfer coefficient (U) is a function of the flow geometry,
fluid properties and material composition of the heat exchanger. In general, the average temperature difference
between the fluids is a function of the fluid properties and flow geometry as well.
The overall heat transfer coefficient represents the inverse of total resistance to heat transfer from one fluid to another.
The functional form of U or the product of U and A, may be derived for any particular geometry by performing a
standard conduction analysis on the system of interest.
1 1 r 1 1 ...................... (2)
UA  [  ln( o )  ]
Ai hi 2 kL ri Ao ho
Where hi convective heat transfer coefficient on the tube is interior, Ai is interior surface area of one tube, ho is
convective heat transfer coefficient on the tube exterior, Ao is exterior surface area of one tube, ri is tube inner radius,
ro is tube outer radius, k is tube thermal conductivity and L is tube length. The heat transfer area on the interior of the
tubes is different from that on the exterior in cylindrical geometry, the product UA is normally used to describe heat
exchanger performance. Equation (2) represents the heat transfer across a small length segment (Δz) where the hot
and cold fluid temperatures can be considered constant. In reality, the hot and cold fluid temperatures change
continuously along the length of the heat exchanger [9]. The heat transfer rate from the hot fluid to the wall or
convection mechanism within the length defined by the length segment Δz is given by Newton’s Law of cooling as
given below [2].
q  2 ri zhc1[Th  Tc ] ……………………………… (3)

Fig.1 Heat transfer process representation through pipe line system.

The heat transfer mechanism in the tube is given in Fig.1. To calculate convective heat transfer coefficient in double
pipe heat exchanger for turbulent flow regime an be calculated from relation given below [1].
NuK , where Nu  0.027 Re 0.8 Pr 0.33 …………… (4)
h
d
Nu is Nusselt number, k is thermal conductivity of fluid, d is diameter of pipe, and Re is Reynold number and
Cp 
Pr  is Prandtl number. Reynold number for annulus flow was calculated from following relation.
K
.
 ud 4M ………………………….. (5)
Re  
  Dh 
Where ρ is density of fluid, Dh is hydraulic diameter, u is velocity of fluid and  is dynamics viscosity. For the tube
wall, the conduction equation was calculated by Fourier`s law as given below.
2 k z .....................……… (6)
q w [T  T ]
c
r
ln( o )
ri
In this numerical calculation work, an Effectiveness-NTU Method is preferable rather than LMD method, because of
two unknown (Tout ) hot , (Tout ) cold . It is more convenient method for predicting the outlet temperature by
application of an iterative approach. An advantage of the effectiveness-NTU method is its ability to calculate the outlet

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temperatures without resorting to a numerical iterative solution of a system of nonlinear equations. The heat exchanger
effectiveness ε is correlated as below
Q
 ................... (7)
Qmax
Where Q is an actual heat transfer rate, Qmax is the maximum possible heat transfer rate for given inlet temperatures
of the fluids.
Qmax  Cmin (Th,in  Tc,in ) .......……………………. (8)
Here Cmin is the smaller of the two heat capacity rates Cc and Ch . It is obtain from multiplication of mass flow rate
and specific heat capacity. The effectiveness ε depends on the heat exchanger geometry, flow pattern (parallel flow,
counter-flow, cross-flow, etc.) and the number of transfer units can be derived as
UA ......................... (9)
NTU 
Cmin
Relationships between the effectiveness and NTU have been investigated for a large variety of heat exchanger
configurations. Most of these relationships involve the ratio of C  Cmin . For a single pass heat exchanger with
r
Cmax
counter current flow regime the effectiveness is:
1  exp[ NTU (1  Cr )]
 ……………………… (10)
1  Cr exp[ NTU (1  Cr )]
Then Q actual is calculated from, Q   Qmax and easy to predicate the two outlet temperature. Table 3.2 gives a
manual calculation for effectiveness - NTU methods parameters to get actual heat transfer (Q).

B. CFD Software and Geometry

Computational Fluid Dynamics (CFD) is the finite element model technique which is great promise in the study
of the fluids flow, heat transfer and etc. Generally finite element model means the model of any body by dividing the
body into small parts known as elements. As the body has infinite particles it is impossible to study the action on the
each particle hence to avoid this difficulty the body is divided into small elements to get the results. This process is
known as the meshing. Meshing is the discretization of the domain into small volumes where the equations are solved
by the help of iterative methods. Modeling starts with describing the boundary and initial conditions for the dominion
and leads to modeling of the entire system. Finally it is followed by the analysis of the results.
The tool used to create the geometry is ANSYS Workbench Design Modular. ANSYS Design Modeler is used
for creating CAD models. In the present work, ANSYS Fluent version 16.2 was used to calculate temperature drop
across heat exchanger by performing CFD analysis. The outlet temperature for cold and hot pipes was measured and
analyzed with theoretical background. Theoretical Nu number and overall heat transfer coefficient also was correlated
with CFD results. The geometry with the actual size was drawn it consists of the major two parts large pipe (annulus)
and small pipe (tube). Fig.2.2 shows the geometrical configuration taken into consideration in this work. It consists
into a tube with length of 1.0 m and a circular section with the inner pipe diameter (ID) and (OD) equal to 0.05m and
0.055m, respectively. The annulus outer pipe diameter (ID) was 0.08m. This dimension of double pipe heat exchanger
between the standard range and 1m length was saved computational time during simulation. The process fluids, hot
fluid allowed at inner pipe and cold fluid operated at annulus. To compare, simulations were performed by utilizing
hot fluid at temperature 140℃. The flow and the thermal field are both assumed to be axial symmetrical.

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Fig.2 Representation of geometries of double pipe heat exchanger

Fig.2 represents the double pipe and meshed geometries of double pipe heat exchanger. Meshed model consists of the
discretization of the body into small parts known as elements. As the fluid flows through the pipe the domain used for
the analysis of the flow should be the volume in which the fluid is flowing. The meshed geometry is consist 23116
finite elements with 9.9 maximum aspect ratio with good quality mesh [11].
C. Software Validation
ANSYS FLUENT as a famous CFD tool for simulation of heat transfer process in the pipeline and for
optimization of the pipeline structure. Thus, it is adopted to simulate the fluid flow and temperature field in the
double pipe heat exchanger for validation of the software developed. In the present work, a model containing a
double pipe heat exchanger is created and analyzed with numerical simulation. In simulation, geometries were
created by Ansys work bench in the form of 3D geometry model of double pipe heat exchanger. The gird selected
has achieved its convergence through a steady state condition and Pressured-Based solver in steady heat transfer
approach was used for simulation. The standard k- model was adopted to model the turbulence in the pipe flow.
A turbulence model is a way to close the system of mean flow equations. It is among the Reynolds averaged
Navier-Stokes (RANS) based turbulence models, specifically standard k-ε model for the design double pipe heat
exchanger mentioned. Where k is the turbulent kinetic energy and ε is dissipation rate. The dissipation rate is correlated
with turbulent kinetic energy as given below:
3
K /2
 .....……………… (11) Where Lt is turbulence length [10].
Lt
Through the simulation, temperature gradient of the pipeline is obtained, and the heat loss within the pipeline system
was calculated according to the enthalpy difference between the fluids inlet and the outlet [7].
. .
Q  [M C p Tin  Tout ]hotfluid  [M C p Tout  Tin ]coldfluid …………… (12)
Here Q stands for the heat loss, T is temperature, Cp is specific heat capacity and m the mass flow rate. In this work
the comparison of results in manual heat transfer calculation by effectiveness-NTU method with CFD simulation of
Ansys Fluent were given the same values.

III. RESULTS AND DISCUSSION

A. Effectiveness-NTU method
A summary result of an effectiveness-number of transfer unit method was calculated and listed below.
Variables Values
Dimensionless (Re) Reynold for inner pipe (tube) 107011
Dimensionless (Re) Reynold for outer pipe (annulus) 54463
Inner convective heat transfer coefficient in W/m2k (hi) 3865.8
Outer convective heat transfer coefficient in W/m2k (ho) 2978.3
Overall heat transfer coefficient with heat transfer area in W/k (UA) 277.143
Number of transfer Unit dimensionless (NTU) 0.0746

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Specific heat ratio (Cr) 0.987

ε – effectiveness of counter current flow 0.07143
Qmax-maximum heat transfer (KW) 427
Q- actual heat transfer in (KW) 30.5

Table 2 The variable calculated with double pipe geometry

Table 2 shows variables calculated by using the given fluids properties and parameters exist in double pipe geometry.
These values were obtained after solving the above given equations denoted (2)  (10) for actual heat transfer.

B. CFD Software Simulation Method

Based on counter current flow pattern at steady state condition Computational Fluid Dynamics simulation of
Double Pipe Heat Exchanger expresses in three dimensions (3D).

Fig.3 Double Pipe Heat Exchanger Radial Temperature Profile

Fig.3 shows the temperature profile attained in the double pipe heat exchanger. It indicates the temperature variation
at left, middle and right sides. The left side position denotes a hot fluid inlet to inner pipe (tube) and outlet for a cold
fluid in the outer pipe (annulus). In this case, the temperature profile indicates less heat transfer to a cold fluid. Right
side position denotes a cold fluid inlet into annulus and outlet for a hot fluid at the tube. As shown in figure 3.1, the
temperature profile is unique from the rest curve. It indicates good heat transfer to cold fluid. The third curve at the
middle of double pipe heat exchanger in counter current flow explains the temperature profile curve which is given
between the left and right side curve.
C. Thermal and Hydraulic Result Analysis of the Tube and Annulus
1) Time-Averaged Simulation Results for Velocity Vectors

Fig.4 The velocity vector obtained from Simulation Results

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Fig.4 explicates the velocity vector at the left, middle and right sides for the double pipe heat exchanger simulated in
counter current flow at steady state condition. In the tube side, velocity profile indicates fully developed at the middle
and right sides position as given in Fig.4. Reynold number at the tube was calculated using (M) mass flow rate, (Di)
inner diameter of tube, and (µ) viscosity of hot fluid. It was assessed to be 107011. It reveals that the regime was
turbulent flow. Using hydraulic diameter the annulus Reynold number at annulus flow of fluid was calulaed to be
54463. It indicated flow regime was also turbulent.
2) Time-Averaged Simulation Results for Velocity Profile

Fig.5 velocity profiles at concentric heat exchanger

Fig.5 represents the velocity profiles at concentric heat exchanger. It shows the fully developed velocity character in
the heat exchanger. The inner curves are indicate velocity profile for inner pipe and it was traced at three difference
places such as left side (hot fluid inlet), middle (flow after 0.5m) and left side (hot fluid outlet). The left and right side
curves denote velocity profiles for annulus. Since there was no fluid flow it was observed that zero velocity boundary
layer at the wall of inner pipe. Also, two gabs were observed due to no fluid flow across the wall.
3) Time-Averaged Simulation Results for Temperature Distribution Profile
These results describe the relation between temperature and heat exchanger length. In addition, the analysis
deals the effect of turbulence flow on the linearity of temperature versus length of heat exchanger. The Fig.6 points
out the temperature distribution profile along the axial direction.

Fig.6 Simulation results for temperature along the length of heat exchanger

Fig.6 shows the results from simulation which describes the relation between temperature and length of heat
exchanger. This relation clearly explicates that the turbulence flow had negative effect on the linear equations.

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4) Contour and Path Lines for Time-Averaged Simulation of Temperatures Distribution

The contour and path lines for temperature variation within the heat exchanger are shown in Fig.7. The temperature
of heat transfer system is indicated by red color.

Fig.7 Time-averaged simulation results of temperature contour and path lines.

It explains the temperature contour and path lines of static temperature in double pipe heat exchanger. From Fig. 7,
the highest temperature value was represented by red arrow in color and decreases until ambient temperature as blue.
5) Time-Averaged Simulation Results for Residuals Graph

Fig.8 Time-averaged simulation results for scale residual graph

Fig.8 depicts the time-averaged simulation result for the scale of residual values which is monitor below the 10-6
tolerance error. It converged after 1373 iterations under steady state condition.

Table 3. Area-weighted average of static temperature results from Ansys Fluent simulation
Table 3 reveals the area weighted average of static temperature results obtained from Ansys Fluent simulation of
double pipe heat exchanger by counter current flow at steady state condition. Using the equation (12) and data in Table
3, heat transfer (Q) can be calculated. It was observed that the Q value to be 29.7 KW.

6) Inclined top views of Time-Averaged Simulation Results for Temperatures

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The Fig.9 shows the results of temperature variation in contour plots at the inclaned top views as subsections. From
the visualization, it was clearly detected that the heat transfer inside the double pipe heat exchanger.

Fig.9 Inclined top views of time-averaged simulation for temperatures

It discribes the countor plots of temperature through top to bottom of the double pipe heat exchanger. The array is
shown a direction of hot fluid through inner pipe and a cold fluid is opposite direction flow in the case of cuonter
current flow pattern.

III. CONCLUSION
The CFD software was implemented successfully to couple heat transfer model and standard k- turbulent
model in double pipe heat exchanger. The temperatures inlet in tube and annulus were maintained at 415K and 300K,
respectively for hot fluid in tube while cold fluids in annulus. In case of two unknown outlet temperatures, the
effectiveness-NTU method was performed to calculate actual heat transfer. Since the Ansys Fluent software has the
greater advancement to acquire more relevance information regards on thermals and hydrodynamics, the simulation
were carried out for time-averaged temperature variations along axial and radial directions, and also the velocity
profile in a concentric pipe. The actual heat transfer (Q) observed from CFD simulation result was 29.7KW. Then the
unknown two outlet temperatures were calculated to be 407.106K and 306.77K, represented hot and cold fluids
respectively. From the mathematical -NTU method, the actual heat transfer (Q) was assessed to be 30.5KW. The
percentage error between CFD simulation result and -NTU method was observed as 2.6% which is acceptable. When
the values are taken for scaling up to the industrial use, such type of the simulation studies in the heat exchangers
plays a great role.
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