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Design and Development of Spiral Tube Heat Exchanger Ajay S Hundiwale1, Samuel Raju2, Saikrishnan Ramesh3, Viraj shah4, Sulaiman Asankani5 1Assistant Professor, 2-4UG student, Dept. of Mechanical Engineering, SIES Graduate School of Technology, Nerul,

Navi Mumbai, Maharashtra, India. ---------------------------------------------------------------------***---------------------------------------------------------------------

Abstract – The Spiral Tube Heat exchanger consists of a

increase heat performance. The maintenance is easy since the tube bundle is one part and can be easily done.

spiral tube arranged in an array in which the liquid flows, the tubes are contained in a shell. The unique properties of a curved tube are double-flow which produces centrifugal force and thereby increasing heat transfer rate. The designed spiral tube model is for the liquid to liquid hear transfer. The spiral geometry is designed using Archimedean spiral geometry. The cold fluid flow in the curved path of the spiral tube and is heated in the spiral tube. The constant heating medium is used to heat the tube. To assess the performance the mathematical model is suitably designed and the CAD model was designed. The spiral coil is arranged in staggered array, 2 coil in set and two set connected to header tube forming the spiral tube bundle. The designed CAD model is conveniently programmed and analyzed on ANSYS Fluent. The standard k-epsilon model is used for analysis. The Nusselt correlation for the designed model was formulated by probability estimation based on the mathematical model. Simulation on a CFD model of the spiral coil bundle was conducted and the results obtained is compared to the mathematical model. The deviation of formulated correlation is in reasonable agreement with mathematical calculation. The change in Nusselt number concerning mass flow rate is selected as a comparison for the measure of performance.

2. LITERATURE REVIEW A spiral tube has a higher heat transfer coefficient than a straight tube. A spiral tube is more suitable for thermal expansion. The equation of friction factor is given by comparing various spiral coil tube[1]. The addition of fins, vortex generator, straight strip wire effect in heat transfer [4]. A theoretical model predicting the thermal performance of the spiral coil heat exchanger as a cooling and dehumidifying unit has been developed based on the assumption that the air is unmixed as it flows past each spiral coil turn. A theoretical model predicting the thermal performance of the spiral-coil heat exchanger as a cooling and dehumidifying unit has been developed [6]. Air mass flow rate and inlet-air temperature have a significant effect on the increase of outlet-air and water temperatures. The outlet-air and water temperatures decrease with increasing water mass flow rate. The enthalpy effectiveness and humidity effectiveness decrease as the air and water mass flow rates increase. The enthalpy effectiveness and humidity effectiveness increase as the inlet-air temperature increases [7]. The spirally coiled tube with three different curvature ratios of 0.02, 0.04, 0.05 under constant wall temperature is tested. The turbulent flow and heat transfer developments are simulated by using the k–e standard turbulence model. The turbulent kinetic energy, k, and turbulent kinetic energy dissipation, e, are coupled to the main governing equations via the turbulent viscosity relation. The outlet water temperature at the low curvature ratio is higher than the higher curvature ratio because the tube length for the lower curvature ratio is higher than the higher curvature ratio [8]. The induced centrifugal force in the spiral-coil tube has a significant effect on the enhancement of heat transfer. However, the pressure drop also increases. Due to the centrifugal force, the Nusselt number and pressure obtained from the spiral-coil Tube are 1.50 times higher than those from the straight tube [9]. The wire is used for increased heat transfer between coil and air. The longitudinal tube spacing still plays a major role in determining the magnitude of the Heat transfer coefficient as radial distance decrease heat transfer rate increased [10]. The use of LMTD method and equation for overall heat transfer and pressure drop in a spiral tube are formulated [11]. The spiral coil is more effective than using Nano-fluid to enhance the convection heat transfer coefficient. The addition of Nanoparticles affects the pressure drop by decreasing little [12]. The spiral

Key Words: Spiral tube Heat exchanger, Pancake coil, Staggered arrangement, Spiral tube bundle, Nusselt number formulation.

1.INTRODUCTION The Heat exchanger is one of the important components in the process industry. It has a broad range of application. Many industries require a certain temperature for their application and others require the temperature to run their machine efficiently. The heat is captured from byproduct with help of heat exchanger and it is used again which saves energy. The Spiral heat exchanger is known for its compactness, different arrangements combination, and high efficiency. The current system for the Spiral heat exchanger is in the developing stage. Recently a Spiral tube heat exchanger was made by SENTRY-EQUIP in which the Spiral are connected to the header by welding and arranged in-line. No plugging is used. The support and baffles are not attached since the bundle forms a stable structure. Due to a variety of parallel tube configurations (diameter, number and length), efficiency is not compromised by limited shell dimension and design which

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geometry can significantly enhance heat transfer compared to a straight channel. Greater flow rates have shown better thermal augmentation, a greater pressure drop is expected simultaneously. The entrance effects in short spiral channels could influence the pressure drop [13].

used. The support and baffles are not attached since the bundle forms a stable structure. Due to a variety of parallel tube configurations (diameter, number and length), efficiency is not compromised by limited shell dimension and design which increase heat performance. The maintenance is easy since the tube bundle is one part and can be easily done. Minimum material is used than in conventional [24].

The Nusselt number and the friction factors for a wide range of design parameters are obtained for the combined entry flows in spiral coils. With increasing Reynolds number, the heat transfer is enhanced 2-4 times over straight tubes of the same length due to secondary flow and centrifugal forces. The friction factor increases with spiral tube length [14]. As the curvature ratio increases, the heat transfer coefficient enhances. The intensity of secondary flow developed goes on increasing with an increase in curvature [15]. The spiral tube has better thermal performance (6‐7%) than the tapered tube and helical tube [16]. The effects of flow configuration on the heat transfer performance of a spiral wound heat exchanger were experimentally investigated. The spiralwound heat exchanger was made, three airflow configurations were tested, namely axial, radial, and mixed axial-radial flows. The overall heat transfer coefficient was determined from the experimental data and the shell-side convection heat transfer coefficient was calculated from the tube-side convection heat transfer coefficient and the total thermal resistance. The results showed that the mixed axial-radial flow configuration has the highest heat transfer coefficient and pressure drop followed by the axial and radial flow. The radial flow configuration has the lowest heat transfer coefficient and pressure drop [18]. An analytical model is developed for carrying out design simulations of the Pancake type heat exchanger. It is stated in the existing literature that each correlation is reasonable over a certain range of conditions, but for most engineering calculations one should not expect accuracy too much better than 20% [19]. The Nusselt number is highest for helical coil, whereas least for spiral coil, and for conical coil it reduces with increase in cone angle. The helical coil has a maximum ε whereas minimum in case of the spiral coil and conical coil, as cone angle increases ε decreases from helical to spiral [20]. The spiral tube for thermal energy storage purpose [21]. The obtained Nu and the heat transfer rate of a TSCTHE (triple spirally coiled tube heat exchanger) was greater than that of DSCTHE (double spirally coiled the tube heat exchanger) for both counter and parallel flow arrangements. Increasing the hot water inlet temperature increases the heat exchanger effectiveness while the Nu decreases. A considerable heat transfer enhancement was obtained by increasing the coil inclination angle from 45° to 90°. The thermo-hydraulic performance criteria η occurred at the minimum value and the maximum record values are 1.87 for counter flow and 1.72 for parallel flow pattern at coil inclination angles of 0°[23]. Recently a Spiral tube heat exchanger was made by SENTRY-EQUIP in which the Spiral are connected to the header by welding and arranged in-line. No plugging is

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3. PROPOSED SYSTEM The heat exchanger consists of CI Shell and SS Spiral tube. The flat spiral tube is arranged in stacking and in staggered order. The cold fluid passes through the spiral tube and heated sensibly by fluid in the shell, the shell fluid is heated by a heater to maintain a constant temperature. The fluid enters the first coil from outward to inward and then it enters the second coil from inward to outward both coils is connected, which forms one set likewise two sets is connected to the header where both inlet and outlet header is outside of the tube bundle

4. DESIGN OF EXPERIMENTAL SETUP The problem is to design a suitable spiral heat exchange system for liquid to liquid heat transfer and use this heat for a particular process industry. The basic selection done are 1. The selection of temperatures by survey or required in application. 2. Selecting of liquid properties based on mean or selected temperature. 3. Assumptions of inner diameter of spiral coil The spiral dimension are based on Archimedes spiral coil, using the equation of spiral (r = aθ, where a = p/2π and p = 2do) [26], the value of Ro and n is found out using equation and shell diameter is calculated using equation. Lsp = 1/2a × (Ro² - Ri²) n = (Ro – Ri) / p Di = (Ro + dh,o) × 2 + clearance This shell diameter is modified as per the nearest value available in TEMA standards. [5], [19] Ash = π/4 Di² - [(L×do) + (2×π/4×dh,o²) + (π/4×di²)] Re = (ρ × Vmax × di)/ μ. V = ṁ / (ρ × As) Vmax = ST / (ST – do) × V --- inline Vmax = ST / (2×(SD – do) × V --- staggered Several correlations, all based on experimental data, have been proposed for the average Nusselt number for cross flow over tube banks. More recently, Zukauskas (1987) has proposed correlations whose general form is [3] NuD = C× Rem × D × Prn ×(Pr/Prs)0.25

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Nomenclature : A surface area [m²] Cp specific heat [J/kg K] c capacity ratio [-] D coil diameter [m] d tube diameter [m] f friction factor [-] g gravitational acceleration [m/s²] h film heat transfer coefficient [W/m² K] k thermal conductivity [W/m K] L length of the tube [m] ṁ mass flow rate [kg/s] N number of pancake Nu Nusselt number [-] NuD Corrected Nusselt number NTU number of transfer units n number of turns P pressure [N/m²] Pr Prandtl number [-] p coil pitch [m] Q discharge [lit/s] q heat transfer rate [W] R radius of coil [m] Re Reynolds number [-] Rf fouling factor t thickness T temperature [C°]

U overall heat transfer coefficient [W/m² K] V fluid velocity [m/s] (r, θ) polar coordinates Greek symbols : Δ change in ε roughness factor [mm] η effectiveness [-] μ dynamic viscosity [N-s/m2] ρ density [kg/m³] Subscripts : avg average e exit h header lm logarithmic mean difference temperature (LMTD) i inner, inlet o outer, outlet s staggered sh shell sen sensible sp spiral st straight t tube w water

h = (NuD × k) / do The water side heat transfer coefficient is calculated, Assuming n pancakes Mounted on one header. For heating circulation fluid velocity is 1.3 – 3.0 m/s [25]. Re = (ρ × V × di)/ μ. Ai = π/4 × di² Q= ṁ/ρ ṁ = Ai×V×ρ

Calculation of overall heat Resistance(R) is given by [3],

(

{

–

)

( )

} )

((

0.5 ≤ Pr ≤ 2000 and

(

) (

√

}

(

)

LMTD for constant wall temperature is given by ΔTlm = (ΔTe – ΔTi)/ln(∆Te/∆Ti) where ∆Ti = Ts – Ti & ∆Te = Ts - Te

But Nusselt number for spiral coil is estimated using Mikheev correlation [1] : {

The number of pancakes required for sensible heating is [19],

when Ravg/di > 6

Ravg = (Ri + Ro)/2

( ) ( ) ( qsensible = ṁw ×Cpw × ∆Tw ; ∆Tw = Tt,i – Tt,o

The water side heat transfer coefficient can be calculated by

The NTU is given by [19],

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The surface temperature of tube is constant the exit temp from tube is given by Te = Ts - (Ts - Ti) exp(-UoAs / ṁ Cp) Te = Tt,o ; Ti = Tt,i ; As = Ao Total number of pancake required for final temperature,

)}

3 × 103 < Re < 5 × 106 Where f Colebrook equation : ( ) *( ) √

coefficient

Ai = πdiL Uo = 1/RAo ; Ao = πdoL

Using Gnielinski’s Correlation for Nusselt Number ; from pg 498, 497 & Table 8-3, [3]. {( ) (

transfer

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For constant surface temperature the effectiveness is given by : εeffectiveness = 1 - exp(-NTU) Pressure drop in spiral coil is given by,

Core diameter of pancake Outer diameter of pancake Angular position (θ) Radius of curvature (Rc) Shell dimensions

where De = dt,i ; [17], [19]

Table -2: Thermal Properties at varying velocity.

Pump work [3], Wpump = (ṁ@Q=1lit/s ∆P)/ρw

Parameters Solutions Velocity (V), m/s 1.5 2 2.5 3 Reynolds No. (Re) (×10³) 30.93 41.24 51.55 61.86 Discharge (Q), m³/s 0.15 0.20 0.25 0.30 Mass flow rate (ṁ), kg/s 0.15 0.2 0.25 0.3 friction factor (f) 0.023 0.022 0.021 0.020 Kinematic Viscosity (μ), N-s/m² (×10-3) 0.547 0.547 0.547 0.547 Nusselt No. (Nust) 164.7 224.7 285.3 346.3 Nusselt No. (Nusp) 207.1 282.5 358.8 435.5 Film Heat transfer coefficient (hsp), 1182 1613 2048 2486 W/m²K 5 3 5 8 Resistance (R) (×10-3) 0.58 0.47 0.41 0.37 Overall heat transfer coefficient (Uo) 7.168 8.766 1.007 1.116 (×10³) Outlet temperature (Te), °C 76.77 75.94 75.06 74.09 LMTD (∆TLMTD), °C 17.07 18.29 19.47 20.64 2928 3836 4693 5523 q sensible (W) 6 7 7 4 No. of Coils (N) 1 1 1 1 NTU 2.74 2.54 2.31 2.13 1173 1466 1759 8797 Dean's Number (De) 0 0 4 Pressure drop for one coil (∆p), bar 0.57 0.95 1.42 1.97

The pancakes are arranged in staggered array, the clearance between two pancake is 1.25 × dt,o. Since the staggered array header is added on both side i.e. 1inch pipe and 5mm clearance. The Dean number [27] : Where [26],

√

(

)

r = aθ, where a = p/2π , No. of turns, n = 5.5,since for 1 turn, θ is 2π r is the length of the radius from the centre, or beginning, of the spiral. θ is the angular position (amount of rotation) of the radius.

4.1 Problem solution The model was designed for the particular process industry, for design purpose, the milk pasteurization is considered where the required water temperature is 73°C, the water is heated by spiral tube bundle at constant wall temperature at 80°C, [2]. The available water is at room temperature at 30°C. The assumption taken is Steady operating conditions exist. The heat exchanger is well insulated so that heat loss to the surroundings is negligible. Changes in the kinetic and potential energies of fluid streams are negligible. Fluid properties are constant. There is no fouling. The fluid in the shell is heated by a heater and constant fluid temperature is maintained. Tube material of SS304, BWG 22 [5] of length 6m. The spiral pancake of core diameter of 204mm. The calculated shell diameter is 22inch. The number of pancakes required for heating is 1 with an effectiveness of 0.9.

4.2 Formulation of Nusselt number By analyzing Mikheev correlation Nusp = C × Re × Rc × Pr where C = constant The correlation for spiral tube can be given as Nu = C × Den × Prm , where dean’s number is product of Reynolds number and radius of curvature The constant C, m, n are found by probability analysis. By varying constant from 0 to 0.99 and the best fit is produced by using numerical python. The above problem is calculated for mass flow rate 0.15, 0.20, 0.25, 0.30 keeping all other parameters same. The probable the range of C, m, n are found at initial by plotting the Formulated correlation with constant from 0.1 to 0.9 with 0.1 interval the range for the actual value of Nusselt number is found between 0.5 to 0.65, taking C =0.5.

Table -1: Dimension of the spiral coil. Description Tube material Dimensions: Tube outer diameter Tube inner diameter Thermal Conductivity Roughness height (ε) Pitch (p) No. of turns, (n) Length of pipe Archimedes constant, (a) Length if radius from center (r)

204 mm 485.44 mm 11 π 139.5 mm 22 inch

Value SS304 ½ inch, BWG 22 12.7 mm 11.28 mm 17 W/mK 0.002 mm 25.4 mm 5.54 6m 4.0425 mm 139.699 mm

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Selecting interval 0.5 to 0.6 and choosing min value and close to 207, the value of m=0.53. Constant m value is plotted for interval 0.56 to 0.65 and minimum close value is selected.

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5. DESIGN

The arrangements of tubes are done in staggered array

Fig -1: Comparison of in-line and staggered Arrangements

Chart -1: a) Probability Analysis to find constant C. b) Probability Analysis to find constant m. c)Probability Analysis to find constant n1 d) Probability Analysis to find constant n2. e) Probability Analysis to find constant n3. f) Probability Analysis to find constant n4 Fig -2: Flow Diagram

Table -3: The probable value of formulated Nusselt No. Nusselt number Actual value Formulated value 207.12 207.84 282.58 271.5 358.8 340.35 435.58 419.5

5.1 CAD Model

Constant C m n 0.5 0.53 0.59 0.5 0.53 0.6 0.5 0.53 0.61 0.5 0.53 0.62

Formulated Nusselt number correlation for designed model. (

)

Where n = 0.59 to 0.60 for 6×10³ ≤ De ≤ 9×10³ n = 0.60 to 0.61 for 9×10³ ≤ De ≤ 12×10³ n = 0.61 to 0.62 for 12×10³ ≤ De ≤ 15×10³ n = 0.62 to 0.63 for 15×10³ ≤ De ≤ 18×10³ Fig -3: Isometric view of Spiral tube bundle.

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Outlet temperature (Te), °C Overall heat transfer coefficient (Uo) (×10³)

75.93 75.43 74.04

74.49

6.573 8.360 9.286 11.555

Resistance (R)(×10-3) 0.63 0.49 0.44 Film Heat transfer coefficient (hsp), W/m²K(×10³) 10.44 14.94 17.76

26.64

Nusselt No. (by CFD)

466.7

182.9 261.8 311.2

0.37

3. RESULTS AND DISCUSSIONS The analytical model outlet temperature is close to 75°C. There is a chance of error in the analysis since it is calculated for 3 iteration and mesh quality is maintained low. The average deviation between the Mikheev correlation and Formulated correlation is 3%. Due to double-flow, the heat transfer rate is also increased. The Nusselt number for the Spiral coil is 1.5-time Nusselt number of straight tube. The comparison is shown below :

Fig -4: Top view of Spiral tube bundle.

5.2 ANSYS Fluent Analysis

Chart -2: Comparison of Mikheev and formulated correlation with mass flow rate.

Fig -4: The temperature profile of the spiral tube bundle. The CAD model was imported to the workbench and it was segregated into parts and meshed. The Meshing for the inner domain is tetrahedral and for the tube the octahedral shape element. Total elements = 1,572,574. Total nodes = 468,969. The average skewness of element is 0.88. Average mesh quality is maintained up to 0.63. The model is calculated using the k-epsilon method. Limitations: Due to low processing power, the model is calculated for 3 iteration. Parameters Mass flow rate (ṁ), kg/s

Chart -3: Comparison of straight and spiral tube with mass flow rate.

Solutions 0.15

0.2

0.25

0.3

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formulated correlation for this model is obtained within 3%. Due to secondary flow and high Dean number, fully turbulent flow is observed which can decrease the scaling. There is uneven heating fluid due to change in Dean number as the diameter of spiral varies. The temperature profile observed is between is 74°C to 76°C. The deviation of Nusselt number between the mathematical model and Analyzed model is obtained within 12%. The Spiral heat exchanger works best for pure fluids. The staggering of spiral tubes reduces the size but increases complexity in connection. It is stated in the existing literature that each correlation is reasonable over a certain range of conditions, but for most engineering calculations one should not expect accuracy too much better than 20%.

Chart -4: Mass flow rate vs Dean No.

7. FUTURE SCOPE The standard design for the spiral tube heat exchanger can be developed. The experiment and analysis can be done by changing the material, curvature of the coil, the inner diameter of the pipe and coil. The spiral tube coil can be arranged in staggered by combining more than two. Using easy connection of coil so it can easily be removed if the coil is damaged. Internal core support can be given if the inner diameter of the coil is more. The spiral tube heat exchanger can be used where space is less also in a harsh environment like geo hot well. This heat exchanger removes the complex design of the shell since heat performance doesn’t depend on the shell. The pressure drop needs to be reduced. And more research to fully develop the industrial application model.

Chart -5: Mass flow rate vs overall heat transfer coefficient.

APPENDIX Properties of saturated water [3]. The Moody chart for friction factor [3]. Nusselt no. correlations for crossflow over tube banks [3]. Correction factor for tube banks [3]. Chart for Friction factor and Corrections factor [3].

REFERENCES [1]

Chart -4: Comparison of Analyzed and calculated Nusselt number with mass flow rate.

[2] [3]

6. CONCLUSIONS The spiral tube heat exchanger is analyzed for the heat transfer to water through shell and water through tubes. The deviation between the mathematical results and analytical values obtained are within 10%. The pressure drop estimated is also compared with actual values observed during analysis, which is found in an acceptable range. The deviation between the mathematical model and

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[4]

[5]

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J.C. Ho & N.E. Wijeysundera, “An unmixed-air flow model of a spiral coil cooling, Dehumidifying unit.”, Applied Thermal Engineering, Vol. 19, pp. 865-883, (1999). [7] Paisarn Naphon & Somchai Wongwises, “A study of the heat transfer characteristics of a compact spiral coil heat exchanger under wet-surface conditions.”, Experimental Thermal and Fluid Science 29, pp. 511– 521 (2005). [8] Paisarn Naphon & Jamnean Suwagrai, “Effect of curvature ratios on the heat transfer and flow developments in the horizontal spirally coiled tubes.”, International Journal of Heat and Mass Transfer 50, pp. 444-451, (2007). [9] Paisarn Naphon, ”Study on the heat transfer and flow characteristics in a spiral-coil tube.”, International Communications in Heat and Mass Transfer 38 , pp. 69–74 (2011). [10] Jader R. Barbosa JR. & Rodrigo A. Sigwalt, “Air-side Heat Transfer and Pressure Drop in Spiral Wire-ontube Condensers.”, International journal of Refrigeration, pp. 939-951.l, (2012). [11] Jay J. Bhavsar, V K. Matawala & S. Dixit, “Design and Experimental Analysis Of Spiral Tube Heat Exchanger”, International Journal of Mechanical and Production Engineering, ISSN: 2320-2092, Vol-1, Issue-1, (2013). [12] Milad Tajik Jamal-Abad, Amirhossein Zamzamian & Maziar Dehghan, “Experimental Studies on the Heat Transfer and Pressure Drop Characteristics of Cu– water and Al–water Nano fluids in a Spiral.”, Experimental Thermal and Fluid Science 47, pp. 206– 212 (2013). [13] M. Ghobadia & Y. S. Muzychkaa, “Heat transfer and pressure drop in a Spiral square channel.”, Experimental Heat Transfer: A Journal of Thermal Energy Generation, Transport, Storage and Heat conversion, (2014). [14] Zekeriya Altaç & Özge Altun, “Hydro-dynamically and thermally developing laminar flow in spiral Coil tubes.”, International Journal of Thermal Sciences 77, pp. 96-107, (2014). [15] Ruchal G. Humbare, Suraj R. Gurav, S. B. Trimbake, “Analysis of Heat Transfer Enhancement in Tube-intube Helical Coil Heat Exchangers.”, International Journal of Engineering and Advanced Technology (IJEAT), ISSN: 2249 – 8958, Vol-5 Issue-1, (2015). [16] Arun Gupta, Amit Sharma, Hardial Singh & Ashok K. Raghav, “Experimental and numerical investigation of taper helical and spiral tube thermal performance. ”, International Journal Energy Res., 10.1002/er.4186, 1 -12, (2018). [17] Zhongwei Huang, Gensheng Li, Shouceng Tian, Xianzhi Song, Mao SSheng Subhash Shah, “Abrasive Water Jet Perforation and Multi-Stage Fracturing”, Gulf Professional Publishing, pp. 191-203, ISBN: 9780-12-812807-7, (2018). [18] Mostafa H. Sharqawya, Sameh M.I. Saadb & Kazi K. Ahmedb, “Effect of flow configuration on the Performance of Spiral-wound Heat Exchanger.”, Applied Thermal Engineering Journal 161, 114157, (2019). [19] Dr. Madhukar S. Tandale & Sandeep M. Joshi, “Design of Heat Exchanger for waste heat recovery from

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[6]

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