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Optimization of Fin Type and Fin Per Inch On Heat Transfer and Pressure Drop of An Air Cooler

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World Academy of Science, Engineering and Technology

International Journal of Aerospace and Mechanical Engineering


Vol:9, No:9, 2015

Optimization of Fin Type and Fin per Inch on Heat


Transfer and Pressure Drop of an Air Cooler
A. Falavand Jozaei, A. Ghafouri

 serrated fins. These correlations were modified by ESCOA


Abstract—Operation enhancement in an air cooler depends on (Extended Surface Corporation of America) in order to obtain
rate of heat transfer, and pressure drop. In this paper for a given heat better predictive models [3].
duty, study of the effects of FPI (Fin Per Inch) and fin type (circular The objective of the present paper is the comparative
and hexagonal fins) on heat transfer, and pressure drop in an air
analysis of heat transfer and pressure drop models with
cooler in Iran, Arvand petrochemical. A program in EES
(Engineering Equations Solver) software moreover, Aspen B-JAC experimental data for circular and hexagonal fins and FPI in
an air cooler Heat Exchanger in Iran, Arvand petrochemical
International Science Index, Aerospace and Mechanical Engineering Vol:9, No:9, 2015 waset.org/Publication/10002571

and HTFS+ softwares are used for this purpose to solve governing
equations. At first the simulated results obtained from this program is on an industrial scale. The present paper shows a comparative
compared to the experimental data for two cases of FPI. The effects analysis of heat transfer and pressure drop models for fin type
of FPI from 3 to 15 over heat transfer (Q) to pressure drop ratio (circular and hexagonal fins) and FPI (fin per inch) in an air
(Q/Δp ratio). This ratio is one of the main parameters in design, and
cooler on an industrial scale. Heat transfer and pressure drop
simulation heat exchangers. The results show that heat transfer (Q)
and pressure drop increase with increasing FPI steadily, and the Q/Δp were evaluated with the models of equivalent circular fin
ratio increases to FPI=12 and then decreased gradually to FPI=15, method and sector method for hexagonal fins.
and Q/Δp ratio is maximum at FPI=12. The FPI value selection
between 8 and 12 obtained as a result to optimum heat transfer to II. THERMAL RATING
pressure drop ratio. Also by contrast, between circular and hexagonal
fins results, the Q/Δp ratio of hexagonal fins more than Q/Δp ratio of The thermal rating first requires a reasonable adaptation of
circular fins for FPI between 8 and 12 (optimum FPI). the means to be selected to the specified requirement. This
implies a certain experience. Shape, size, finning, and fin-tube
Keywords—Air cooler, circular and hexagonal fins, fin per inch, material must be suitable for the fluid to be cooled or
heat transfer and pressure drop. condensed and must be adapted to its physical properties. The
rating is then carried out by the following step-by-step
I. INTRODUCTION method.

A IR cooled heat exchangers are widely used in many


industrial areas such as chemical process, power
generation, petroleum refining, refrigeration, air-conditioning
A. Estimation of the Tube-Side Heat Transfer Coefficients
On the basis of the specified task, an initial guess of the
expected αi values may be made by means of tables [4]. The
and etc. Air cooled heat exchangers are used under conditions
indicated values refer to typical conditions of air coolers and
including high pressure and temperature, as well as corrosive
air condensers. When the tube-side conditions such as flow
fluids and environments. Common applications include gas re-
velocity and temperature of the streaming fluids or the
injection, gas lift and pipeline applications, cooling and
temperature difference of condensing or evaporating fluids are
condensing of hydrocarbon gases, and cooling of machinery
specified or known, the tube-side heat transfer coefficients
oil and heavy hydrocarbons. Air cooled steam condensers are
may be determined more exactly.
a special type of heat exchanger employed to condense steam
at the exhaust end of steam turbines for both power generation B. Selection of Fin Tubes
and mechanical drive applications. The estimated heat transfer coefficient gives a first idea of
In the open literature, there are many studies on compact the required and expedient surface area ratio A/Ai of the fin
heat exchangers and some of them are focused on helically tube to be chosen. The thermal and hydraulic data of the
finned tubes. The majority of the papers have studied solid selected fin tube should be available as a function of the
fins, [1]. Only a few papers focus on segmented fins, so there cooling air velocity u [1], according to (1) [6]:
are few correlations for heat transfer and pressure drop. One of
the most commonly used models was developed by [2], who R (1)
developed heat transfer and friction factor correlations for
different tube bundles (inline and staggered) with solid and C. Selection of the Cooling Air Velocity u
The cooling air velocity is fixed within rather narrow limits,
A. Falavand Jozaei is with the Department of Engineering, Ahvaz Branch, since the increase of the air-side pressure drop with growing
Islamic Azad University, Ahvaz, Iran. (corresponding author to provide velocity is almost square and due to the low static pressure of
phone: +986133348356; fax: +986133348356; e-mail: 100 to 200 Pa developed by conventional fans. It ranges
falavand@iauahvaz.ac.ir)
A. Ghafouri is with the Department of Engineering ,Ahvaz Branch, Islamic mostly from 2 to 4 m/s, depending on the face area, the
Azad University, Ahvaz, Iran (e-mail: a.ghafouri@iauahvaz.ac.ir).

International Scholarly and Scientific Research & Innovation 9(9) 2015 1657 scholar.waset.org/1307-6892/10002571
World Academy of Science, Engineering and Technology
International Journal of Aerospace and Mechanical Engineering
Vol:9, No:9, 2015

number of tube rows n, and on the admissible and feasible For optimum design it normally lies in the range of 0.8 <
temperature rise of the cooling air. NTU < 1.5. This quantity already represents a control value
for the available quantities u and nR.
D. Overall Heat Transfer Coefficient U
After the αi value and the cooling air velocity have been I. Coolant Thermal Number
determined, the overall heat transfer coefficient for a selected The dimensionless value ∆ /∆ for various
fin-tube system may be obtained from (1), when an additional types of flow in air coolers is given in [5]. For three typical
product-side fouling rfoul needs to be taken into account, the flow arrangements with air coolers: cross flow; cross-counter
actual service value is first determined, then: flow return bend; counter flow), is given by (8), (9), and
(11). Besides the known quantity NTU, the equations also
(2) contain the quantity ∆ /∆ , which must first be
estimated in order to obtain generally lies between 0
The fouling resistance rfoul may be taken from pertinent and 1, but may also be higher. For isothermal condensation,
manuals or gotten from experience. Generally, air-side fouling ∆ and are zero, so the same is obtained for all flow
need not be considered for the U value. Although relatively types.
International Science Index, Aerospace and Mechanical Engineering Vol:9, No:9, 2015 waset.org/Publication/10002571

high air-side fouling may adversely affect the air flow through
Arrangement I: Cross Flow
the unit and thus decrease the effective temperature difference,
it scarcely influences the U value because of the relatively On the tube side, one or more passes, side by side:
small air-side heat flux.
E. Number of Tube Rows (8)
The number of tube rows needed depends on both the Arrangement 2: Cross-Counter-Flow Return Bend
specific requirement and the efficiency of the selected fin-tube On the tube side two passes in the counter-flow direction to
system. Roughly estimated, these two factors can be expressed the air flow:
by a quantity a, which includes the temperature difference
between product and cooling air inlet as well as the value
U(A/S) of the fin tube[4]. 1 (9)

, , ∆
with
/ /
(3)
/
1 (10)
(4)
Arrangement 3: Counter Flow
where C1 = 24 for fin tubes of the kind, C2 = 0.49 On the tube side four or more passes in the counter flow
direction to the air flow:
F. Product Thermal Number
One auxiliary term for the further thermal rating is the (11)
dimensionless number
∆ , ,
The flow arrangements are selected according to the
∆ ,
(5) product volume to be cooled or condensed and the temperature
,

difference between the product and the cooling air.


It is used later to determine the effective mean temperature Arrangement 1 applies when large product volumes are to be
difference (EMTD) and the surface area needed. cooled or condensed or when high temperature differences are
G. Coolant Design Number involved. Arrangement 2 applies to liquid coolers with small
volumes and low temperature differences. Arrangement 3
The dimensionless design number applicable for one tube applies to high-pressure coolers or coolers where the
row is now calculated on the basis of the available results. temperatures of the two flows approach or overlap each other.
/
(6) J. Effective Mean Temperature Difference EMTD
The EMTD is obtained from the definition of NTU
where cP is the specific heat of air at constant pressure. according to (7) as follows:
H. NTU Number ∆ ∆
(12)
The dimensionless NTU number (number of transfer units)
is obtained by the product of the coolant design number and In order to simplify the calculation and avoid a trial-and-
the number of tube rows: error procedure, (8)-(11) can be rearranged to get:

(7) (13)

International Scholarly and Scientific Research & Innovation 9(9) 2015 1658 scholar.waset.org/1307-6892/10002571
World Academy of Science, Engineering and Technology
International Journal of Aerospace and Mechanical Engineering
Vol:9, No:9, 2015

which can be solved graphically as a function of ∆ and (circular and hexagonal fins). It can be found that for both
NTU. circular and hexagonal fins, the Q/Δp ratio increases to
FPI=12 and then decreased gradually to FPI=15 and the
K. Surface Area A Q/Δp ratio is maximum at FPI=12. Also by contrast,
The surface area needed is between circular and hexagonal fins at Fig. 4, the Q/Δp
ratio of hexagonal fins more than Q/Δp ratio of circular

.
(14) fins for FPI between 8 and 12 (optimum FPI).

where is the total heat transferred in the heat exchanger. IV. CONCLUSIONS
L. Face Area S Effects of FPI (fin per inch) on heat transfer and pressure
drop of an air cooler petrochemical industry with circular and
The coolant-side face area needed is obtained from
hexagonal fins is studied. Comparison of variation of heat
transfer and pressure drop in an air cooler, according to FPI
(15)
. (Figs. 1-4) shows that increase of FPI causes the increase of
surface per unit-finned tube, heat transfer and pressure
International Science Index, Aerospace and Mechanical Engineering Vol:9, No:9, 2015 waset.org/Publication/10002571

This face area is so apportioned to length and width that steadily. But the Q/Δp ratio increases to FPI=12 (for circular
reasonable bundle dimensions are obtained. fins about 47% and for hexagonal fins about 69%) and then
decreased gradually to FPI=15 for both fins (for circular fins
III. RESULTS AND DISCUSSION about 5% and for hexagonal fins about 8%), and Q/Δp ratio is
In this paper, the effects of FPI (fin per inch) and fin type maximum at FPI=12. The FPI value selection between 8 and
(circular and hexagonal fins) on rate of heat transfer, and 12 obtained as a result to optimum heat transfer to pressure
pressure drop are considered in an air cooler in Iran, Arvand drop ratio. Also by contrast, between circular and hexagonal
petrochemical with geometric parameters and thermophysical fins results, the Q/Δp ratio of hexagonal fins more than Q/Δp
properties. A program in EES (Engineering Equations Solver) ratio of circular fins for FPI between 8 and 12 (optimum FPI)
software moreover, Aspen B-JAC and HTFS+ softwares are
used for solve governing equations. For this purpose, 300
Surf/Unit‐Finned Tube (m²)

according to technical specifications and input fluids


250
conditions the program was run for that air cooler has 10 FPI
with circular fins. In this case output temperatures from this 200
program are 2.5 percent less than experimental temperatures. 150
To reconfirm the accuracy of the program, the number of FPI
100
became 12, and again output temperature from the program
was compared to experimental data. In this new case, output 50
temperatures from this program are 2 percent less than 0
experimental temperatures. After validation of numerical 0 5 10 15 20
model, the effect of FPI variations from 3 to 15 was FPI 
considered on heat transfer, and pressure drop. [7] From this
study we conclude that: Fig. 1 Surf/Unit-Finned Tube versus FPI
1- Variation of surface per unit-finned tube versus FPI is
400
shown in Fig. 1. It is found that with the increase of FPI, 380
surface per unit-finned tube increases, but after increasing 360
Heat Exchanged [kw]

FPI more than 12, variation in surface per unit-finned tube 340
is gradual (approximately 2 percent). 320
2- Fig. 2 shows heat exchanged versus FPI. It can be 300
observed in Fig. 1. The increase of FPI causes the 280
increase of heat transfer over tubes. The increase of FPI 260
from 3 to 12 causes the increase of heat exchanged about 240
50% (1.5 times). Moreover, increase of FPI from 12 to 15 220
causes the increase of heat exchanged about only 3%. 200
3- Pressure drop versus FPI is shown in Fig. 3. According to 0 2 4 6 8
FPI 
10 12 14 16
Fig. 3 with the increase of FPI, pressure drop increases.
The increase of FPI from 3 to 12 causes only a slight Fig. 2 Heat Exchanged versus FPI
increase of heat exchanged about 1%, but there is a sharp
increase between FPI=12 and FPI=15.
4- Fig. 4 shows that variation of heat transfer to pressure
drop ratio (Q/Δp ratio) versus FPI for two fin types

International Scholarly and Scientific Research & Innovation 9(9) 2015 1659 scholar.waset.org/1307-6892/10002571
World Academy of Science, Engineering and Technology
International Journal of Aerospace and Mechanical Engineering
Vol:9, No:9, 2015

0,21
0,205
Pressure Drop [bar]

0,2
0,195
0,19
0,185
0,18
0,175
0,17
0 2 4 6 8 10 12 14 16
FPI

Fig. 3 Pressure Drop versus FPI

2400
International Science Index, Aerospace and Mechanical Engineering Vol:9, No:9, 2015 waset.org/Publication/10002571

2200
heat transfer to pressure drop
ratio (Q/Δp ratio) [kw/bar]

2000
1800
Circular
1600
hexagonal
1400
1200
1000
3 4 5 6 7 8 9 10 11 12 13 14 15
FPI

Fig. 4 Heat transfer to pressure drop ratio (Q/Δp ratio) versus FPI

ACKNOWLEDGMENT
The authors thank the financial support from Ahvaz Branch,
Islamic Azad University and technical support from Arvand
petrochemical company.

REFERENCES
[1] B. Srbislav, M. Branislav, R. Jacimovic, R. Boris Latinovic, “Research
on air pressure drop in helically-finned tube heat exchangers,” Applied
Thermal Engineering, 2006, vol.26: pp. 478-485.
[2] C. Weierman, J. Taborek, W.J. Marner, “Comparison of the performance
of in-line and staggered banks of tubes with segmented fins.” The
American Institute of Chemical Engineers Symposium, 1978, 74 (174).
[3] V. Ganapathy, “Industrial Boilers and Heat Recovery Steam
Generators: Design, Applications and Calculations,” Marcel Dekker,
2003.
[4] R. K. Shah, D. Sekulic, “Fundamentals of Heat Exchanger Design” ,
New York: Wiley, 2003.
[5] A. D. Kraus, A. Aziz, J. Welty, “Extended Surface Heat Transfer,” John
Wiley & Sons, 2001.
[6] A. Bejan, A. D. Kraus, “Heat Transfer Hand Book,” New York: Wiley,
2003.
[7] API 661, “Standards of American Petroleum Institute,” March 2002,
Fifth Edition.

International Scholarly and Scientific Research & Innovation 9(9) 2015 1660 scholar.waset.org/1307-6892/10002571

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