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Research Update: Using CFD Simulation to Assess HTRI Predictions for Non-Newtonian Fluids
April 30, 2024
Designing effective heat exchangers requires understanding flow and heat transfer characteristics of fluids. Heat exchangers frequently use non-Newtonian fluids, and HTRI has conducted research to increase our knowledge of their behavior. In this webinar, we discuss the basics of non-Newtonian fluids and using power law to model the behavior. The timeline...
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TE-7 Review of Intube Static Mixers for Heat Transfer Applications
April 23, 2024
Inline static mixers promote the radial spreading of momentum and heat and are thus useful in enhancing heat transfer, especially in viscous laminar flows. After a brief review of the physics of plain tube laminar flow heat transfer, this report includes classifications of these mixers based on their construction and presents some...
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S-SS-3-30 Predictions of Single-phase Flow in TEMA F-shell Heat Exchanger: CFD vs. Xist
December 21, 2022
This report compares computational fluid dynamics (CFD) and Xist predictions of single-phase performance in a TEMA F-shell heat exchanger with a sealed longitudinal baffle. In the initial comparison, CFD underpredicted both duty (16% less) and pressure drop (over 50% less). We then represented an F shell in Xist using two E-shell...
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AC-20 Side Blockage Effects on Performance of Forced-draft Air-cooled Heat Exchangers
December 21, 2022
This report details a numerical study investigating the effects of blockages on the performance of an air-cooled heat exchanger. A high-fidelity computational fluid dynamics (CFD) model of HTRI’s Air-cooled Unit (ACU) is simulated and calibrated using experimental data from the unit. The validated CFD model is used to simulate five arrangements...
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Another way to think about heat transfer: Applying neural networks to HTRI
January 03, 2023
Parimah Kazemi, Numerical Analyst HTRI continues to expand our research capabilities to bring our members the latest information about heat transfer and process technology. Our Research & Technology Center (RTC) houses physical test units, while our computational fluid dynamics (CFD) simulations complement our experimental program and identify and resolve operational issues...
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BK1-18 A Parametric Study of Entrainment Using CFD Simulations
November 10, 2022
Accurate prediction of kettle entrainment is crucial for sizing kettles effectively, reducing equipment cost, and increasing column efficiency. Operating experience has informed the development of simple sizing rules. Two-phase CFD models can compute the amount of entrainment directly from the governing equations of motion. Two computational approaches are demonstrated: one uses...
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Pattern vs Performance
July 07, 2022
HTRI staff Salem Bouhairie and Syed Haq recently published an article, Pattern vs Performance, in the June issue of Hydrocarbon Engineering. This article discusses how airflow patterns within air-cooled heat exchangers degrade performance....
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Research Update Webinar: Industry Trends and Gaps in Process Heat Transfer
July 12, 2021
Webinar Overview HTRI's research program focuses on industry trends (e.g., lowering carbon footprint or assessing new technologies) and addresses gaps or areas where we need to learn more in process heat transfer (e.g., off-design performance). After summarizing the results from our research over the past year, this webinar provides...
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Case Study: Thermal Rating and Vibration Assessment of Disk-And-Doughnut Exchangers
July 08, 2020
Download Case Study PDF SUMMARY A fabrication company thermally re-rated two existing disk-and-doughnut heat exchangers for new process conditions at their acid plant. HTRI conducted research that improved their understanding and ability to model disk-and-doughnut heat exchangers. THE CHALLENGE Analyze heat exchanger performance Assess the potential for excessive vibration Flow pattern...
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Case Study - Reducing Hot Air Recirculation around Air-cooled Heat Exchangers
April 13, 2020
Download Case Study PDF SUMMARY An engineering, procurement, and construction company needed to enhance the performance of a bank of API 661 air-cooled heat exchangers (ACHEs) at a refinery. HTRI was asked to optimize the installation of two new forced-draft ACHEs, which were to be appended to seven existing induced-draft ACHEs....
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PHE-22 CFD Simulations of a Plate-and-shell Heat Exchanger
December 04, 2019
HTRI experimentally evaluated the thermal-hydraulic performance of a water-water plate-and-shell heat exchanger at the Research & Technology Center and then used the results to calibrate a solution approach through computational fluid dynamics. The tortuous flow paths through the corrugated channels of the plate pack were modeled effectively using porous media. Inertial resistance...
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Research Update: Insights from CFD Simulations of a Plate-and-Shell Heat Exchanger
November 07, 2019
HTRI gathered experimental data for a plate-and-shell exchanger at the Research & Technology Center (RTC). These data provided the opportunity for HTRI to extend its CFD simulation experience to plate heat exchanger types. The results provide additional insights about the flow distribution and port pressure drops. In this webinar, we discuss...
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Simulating air-cooler header and fan performance informs physical testing plans
June 05, 2019
Salem A. Bouhairie, Senior Project Engineer, Research Both tubeside and airside behavior affect the overall performance of an air cooler. Two concerns with air-cooled heat exchanger (ACHE) operation are two-phase process-side maldistribution in headers and misrated airside fan performance. At HTRI’s Research & Technology Center (RTC), we are developing plans to...
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Case study: Reducing shellside maldistribution in a condenser
October 16, 2018
Summary An engineering, procurement, and construction company asked HTRI to investigate methods—constrained by permissible pressure drop—to mitigate shellside flow maldistribution for an X-shell condenser, using cold seawater on the tube side to condense an off-gas on the shell side. Challenge Determine optimal geometric design modifications that minimize maldistribution and potential structural...
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Cooking up some CFD
January 24, 2018
Kevin J. Farrell, Principal Engineer, Computational Simulation & Validation Colleagues sometimes inquire about a challenging simulation they know I’m wrestling with. My short reply is generally, “It’s still cooking.” Sometimes explaining a complex topic with a simple analogy isn’t successful, but I think using a cooking analogy to describe CFD works...
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Air Cooler Testing at HTRI
February 14, 2017
HTRI is installing an industrial-scale ACHE this year to improve airflow predictions and enhance testing flexibility. Author Salem Bouhairie, Senior Project Engineer, Research Date February 8, 2017 HTRI’s air-cooled heat exchanger (ACHE) studies are a fundamental part of our research program. The most pressing concern expressed by our members about airside...
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Applications of Computational Fluid Dynamics
October 12, 2017
Kevin J. Farrell, Principal Engineer, Computational Simulation & Validation When heat exchangers perform ineffectively, engineers often turn to computational fluid dynamics (CFD) for insight. In fact, most companies use CFD in this reactive manner to validate and troubleshoot their operating exchangers. But innovative companies use CFD proactively to explore designs and...
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STG-21 Computational Simulation of Fluid Flow, Heat Transfer, and Temperature-induced Mechanical Stress in a Shell-and-tube Heat Exchanger
July 21, 2017
We completed a multiphysics computational simulation of a shell-and-tube exchanger, where simultaneous fluid flow and heat transfer of both fluid streams occurred. Temperature-induced mechanical stress also acted on the solid structures. A weak coupling of a finite-volume CFD Navier-Stokes model with a finite-element computational solid mechanics model underlies the multiphysics simulation....
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TPG-7 Challenges of Simulating Complete Intube Phase Change with CFD
March 13, 2017
Over the past several decades, the accuracy and usability of computational methods have substantially improved. This report reviews the complicated physics of two-phase flow and phase change, presents the equations of motion for a two-phase flow with various closure models, and compares current computational approaches. Although inadequate for the entire spectrum of...
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AC-18 Air-cooler Header Pressure Drop and Flow Maldistribution
February 08, 2017
In 2014 HTRI contracted with the Institute of Process and Environmental Engineering (IPEE) at Brno University of Technology, Brno, Czech Republic, to complete CFD simulations on six configurations of a two-pass horizontal air cooler, differing only in the number and type of inlet and outlet nozzles. Results showed the impact of...
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Detailed Interpretations of CFD Results
January 26, 2017
CFD simulations of heat exchangers and related components provide a wealth of high resolution insights about thermal-hydraulic performance. A simulation provides several million times more pieces of information about the flow and temperature fields than a typical experiment. Several post-processing techniques can offer valuable insight and possibly challenge our intuition: Streamlines,...
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AC-17 CFD Simulations of Airside Maldistribution Around API Air Cooler
September 12, 2016
Xace has limited capabilities for predicting maldistributed airside heat transfer because the software does not consider inter- and intra-air cooler proximity, turn-down and fan off/on operation, or ground effects. To improve our software methods, we examined the performance of an API-compliant air cooler through computational fluid dynamics (CFD) simulations, calibrating the...
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Research Update: CFD Simulations of Forced Draft Air Coolers with Air Maldistribution
January 16, 2017
API-compliant air coolers are modeled in two- and three-dimensional computational fluid dynamics (CFD) simulations to see what improvements are needed in Xace® with regard to the airside maldistribution. We validated the CFD model using Xace base cases. We then used CFD to simulate non-ideal airside flow situations that can potentially affect...
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Educational: A Layman’s Guide to CFD Webinar
January 16, 2017
Since the introduction of the digital computer in the 1950s, computational fluid dynamics (CFD) has increasingly been used to study and solve complex problems in fluid flow and heat transfer. With the rising popularity of sophisticated computing tools, many challenging engineering problems tend to be assigned to the CFD simulation world...
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Research Update: Air-cooler Headers: Predicting Pressure Drop and Flow Distribution
January 16, 2017
Header flow maldistribution and pressure loss in air-cooled heat exchangers may significantly affect performance. Most relevant literature focuses on plate-fin and cylindrical channel headers for tubular heat exchangers. The flow in the header is affected by its internal geometry, the orientation of the nozzles on the header, and inlet flow velocity....
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S-SS-3-29: CFD Simulations of Diabatic Shellside Viscous Flows
January 16, 2017
For shellside diabatic flows of highly viscous fluids, Xist can predict inconsistent pressure drops and heat transfer coefficients. HTRI examined the transition between forced and natural convection in single-segmental and double-segmental exchangers with Alta-Vis oil and an asphalt blend as test fluids. Comparisons were made between experimental data, open literature, computational...
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PFE-3 Prandtl Number Effect on Offset-strip Plate Fin via CFD
January 16, 2017
Using CFD simulations of laminar flow in an offset-strip fin geometry validated with experimental data, we have confirmed that the Colburn j-factor can be substantially overpredicted for fluids whose Prandtl number is significantly greater than that of air. In addition, we determined that the j-factor varies inversely with a Prandtl number...
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Research Update: CFD Modeling of Offset Strip Plate-fin Exchanger with Vapor and Liquid Services
January 16, 2017
Compact plate-fin heat exchangers are widely used for electronics, aerospace, and automotive cooling because of the light weight and small size. The majority of open-literature data use air as the test fluid; thus, the application of the ensuing air-based methods to higher Prandtl number, liquid services is dubious. In some applications,...
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S-SS-3-28 Optimal Application of Shellside Sealing Devices
January 16, 2017
This report documents two approaches to analyze the performance of different sealing devices. The first approach examines an exchanger with a fixed sealing device count and varied baffle spacing. The second approach considers an exchanger with fixed shellside geometry but different sealing device types and arrangements. Comparisons are made between experimental...
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S-SS-3-27 A Review of the A-stream Model of the Stream Analysis Method
January 16, 2017
After a brief overview of the evolution of the Stream Analysis Method, we use CFD simulation results to compare A-stream, tube-to-baffle leakage flow geometry and pressure drop models. We propose a modified A-stream pressure drop model for the refactored software that, contrary to current usage in HTRI Xchanger Suite 7, calculates...
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Research Update: Maldistribution in Shellside Laminar Viscous Flow
January 16, 2017
Xist® can predict unexpected performances of shellside viscous fluids in laminar regimes, where thermal maldistribution is present. The heat transfer of viscous flows across vertical baffles is analyzed by CFD to determine impact of such non-uniformity. Maldistribution can be monitored using a viscosity-independent Richardson number. The Richardson relates the impact of...
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STG-19 Design Guidance for Impingement Rods
January 16, 2017
Impingement rods are more effective than plates in protecting entrance tubes from damage. HTRI developed a method to assess the relative impact of a variety of competing flow conditions produced by each impingement configuration. For the conditions established in this study, a two-row grid of rods with a diameter slightly smaller...
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Research Update: Sealing Device Application
January 16, 2017
During this webinar, we discuss the basics of sealing devices, including common practices and design guidelines. Further, we review the basic flow resistance equation for sealing strips used in Xist® Version 7 and compare the measured performances of HTRI research-scale heat exchanger using sealing strips to CFD and Xist predictions....
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S-SS-3-25 Analysis of NTIW shellside performance using CFD and Xist
January 16, 2017
Using computational fluid dynamics (CFD) and Xist, HTRI simulated three configurations of no-tubes-in-window (NTIW) bundles in shell-and-tube heat exchangers. Our analysis of the trends in pressure drop and heat transfer underscores the importance of window friction and window momentum losses, even without tubes in this region, as well as the existence...
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Research Update: Analysis of NTIW Shellside Performance using CFD and Xist
January 16, 2017
This webinar will discuss Xist® and CFD predictions of three NTIW exchanger configurations – 2 baffle, 4 baffles, and 6 baffles. The discussion will focus on the contributions of crossflow and longitudinal flow on heat transfer, which is due to varied baffle spacing for the same baffle cut. During the webinar,...
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Research Update: Design and Construction of the Rotating Fouling Unit
January 16, 2017
HTRI currently runs fouling experiments on the High Temperature Fouling Unit (HTFU) which recirculates a 27 liter sample of crude for periods up to one month. As we plan to expand our crude oil fouling test program, we are investigating alternate test methods to screen crude oil fouling with smaller sample...
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S-ST-1-14 CFD Study of Single-Phase Laminar Mixed Convection in Inclined Tubes
January 16, 2017
To gain insight into the thermal-hydraulic phenomena associated with mixed convection in internal flows, we used computational fluid dynamics (CFD) to conduct a parametric study of single-phase laminar liquid flows in inclined tubes with isothermal, uniform wall temperatures (UWT). Both heating and cooling processes were simulated to isolate the effects of...
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CT-27 CFD Modeling of Intube Condensation
January 16, 2017
After briefly surveying the challenges of modeling condensation with computational fluid dynamics (CFD), we apply two relevant two-phase models in ANSYS® FLUENT® with varying degrees of success. Homogeneous nucleation in a Laval nozzle is well predicted, while the more interesting and relevant intube film condensation is plagued by grid resolution, model...
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S-SS-3-22 Stream Analysis in a Single-Segmentally Baffled Exchanger: CFD vs. Xist
January 16, 2017
HTRI conducted computational fluid dynamics (CFD) simulations to investigate leakage and bypass stream behavior under various flow regimes in an industrial-scale heat exchanger with single-segmental baffles. To cover a wide range of Reynolds numbers, the simulations tested single-phase water and Alta-Vis oil. Both concentric and eccentric configurations of the exchanger’s tube-to-baffle...
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S-SS-3-21 Disk-and-Doughnut Baffled Heat Exchangers: CFD Simulations and Methods
January 16, 2017
Disk-and-doughnut baffled heat exchangers can generate more heat transfer with less pressure drop than conventional segmental exchangers in certain industrial applications. Unfortunately, little information is available on these units in service. This report introduces new methods for analyzing and rating a disk-and-doughnut baffled heat exchanger. Using three-dimensional computational fluid dynamics (CFD)...
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S-ST-1-13 CFD Study of Diabatic Single-Phase Laminar Liquid Flow in Horizontal Tubes
January 16, 2017
To gain insight into the physical characteristics of single-phase liquid tubeside laminar diabatic flows, we used computational fluid dynamics (CFD) to analyze laminar data acquired with the HTRI Tubeside Single-Phase Unit (TSPU). This numerical approach generated local tubeside data that were validated by the associated experimental measurements. Twenty-seven experimental conditions for...
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AC-16 First Adaptation of Stream Analysis Method for Air-Cooled Heat Exchangers
January 16, 2017
A new Stream Analysis Method option is available in Xace® 6 to model flow bypassing in air-cooled heat exchangers with larger gaps at the edge of the bundle than those required by the API 661/ISO 13706-1:2005 standard. The heat transfer and pressure drop of the bundle can be less than predicted...
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BK1-12 Three-Dimensional CFD Simulations of Kettle Reboilers
January 16, 2017
Three-dimensional computational fluid dynamics (CFD) simulations of experimental kettle reboiler slices from the literature, as well as from the HTRI kettle reboiler, allow examination of fluid flow behavior on a fine spatial scale—significantly beyond the resolution of available experimental measurements. Interestingly, our simulations of kettle slices yield recirculation ratios that agree...
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Q14-4 Improved Heat Transfer Coefficients for Calculating Tubesheet Temperature
January 16, 2017
ASME Code 2007 Section VIII - Division 1 UHX requires an average tubesheet metal temperature for calculating the allowable thermal stresses between the shell and header flanges of a shell-and-tube heat exchanger. The Xist® tubesheet temperature calculations do not take into account the contribution of the heat transfer coefficients on both...
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Q14-3 Modeling Fans-Off Operation in Xace
January 16, 2017
During winter or in turndown conditions when full design duty is not required, air-cooled heat exchangers commonly run with one or more fans off. Xace® models this operation by allowing users to specify an inlet flow maldistribution. This article provides guidelines for modeling fans-off operation in Xace and describes a computational...
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STV-16 Calculating Fluidelastic Instability of U-Tubes Near Inlet Nozzles
January 16, 2017
The challenges of a rules-based vibration screening in Xist® have often led to excessive conservatism for U-tubes positioned near the inlet nozzle. In this study, we simulated shellside diabatic flow over the U-bend portion of the bundle for a number of nozzle locations using computational fluid dynamics (CFD). Using the simulation...
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S-SS-3-19 Improved Pressure Drop Method for Helical Quadrant Baffle Exchangers
January 16, 2017
A shellside helical flow path in a shell-and-tube exchanger can provide a number of distinct advantages over the reversing, serpentine flow path of conventional segmental baffles; however, current open literature prediction methods do not provide the confidence engineers need to make sound design decisions. Several fundamental geometric parameters either are not...
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Q13-1 Wall Functions for Turbulent Heat Transfer Modeling with CFD
January 16, 2017
Computational fluid dynamics solutions of the Reynolds-averaged Navier-Stokes equations often employ wall functions to capture the behavior of the near-wall boundary layer flow without excessive grid refinement. While the applicability of these functions has strong support from physical reasoning and dimensional arguments, they are nonetheless empirical. In this article, we review...
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F-17 Tubeside and Shellside Shear Stress for Single-Phase Flow
January 16, 2017
Anecdotal and laboratory evidence suggest that high shear stresses mitigate fouling. This report presents methods for calculating isothermal and diabatic shear stresses for single-phase fluids on both the tube side and the shell side of shell-and-tube heat exchangers. There are limitations to these methods, however. The tubeside shear stress calculation technique...
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BK1-11 Two-Dimensional CFD Simulations of Kettle Reboilers
January 16, 2017
To gain further insight into kettle reboiler operation and improve Xist® models, we simulated several kettle reboilers in two dimensions using CFD. The two-phase simulation results show good agreement with pressure drop and vapor volume fraction measurements from the literature. However, recirculation ratios calculated from the CFD results are substantially greater...
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S-SS-3-18 CFD Simulations of Single-Phase Turbulent Shellside Flow
January 16, 2017
High fidelity, tube-by-tube computational fluid dynamics (CFD) simulations of the turbulent, multistream shellside flow within a 9-crosspass, 591-mm diameter, 2276-mm long E shell were completed at four flow rates. The shellside water flow was heated by a full bundle at a uniform tube wall temperature. Computational results for duty and pressure...
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F-16 High Temperature Fouling Unit Redesign - Part I: Annular Test Section
January 16, 2017
Our ongoing analysis of the HTRI crude oil fouling data revealed an unacceptably high degree of scatter. A computational fluid dynamics (CFD) model of the High Temperature Fouling Unit (HTFU) test section demonstrated that the flow over the heated portion was undeveloped and asymmetrical, resulting in wall shear stress variations of...
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Q11-2 Simulating Nozzle Flow in Spiral Exchangers using CFD
January 16, 2017
Computational fluid dynamics (CFD) analysis was used to calculate the nozzle pressure drop K-values for spiral plate heat exchangers. Results of this analysis resolved the discrepancy between K-values from the Minton method and in PHE-11. The K-values from PHE-11 compared better with the CFD results in the region of Reynolds numbers...
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STV-15 Select Crossflow Velocity Distributions for Analyzing Tube Vibration Potential
January 16, 2017
Both the value and distribution of velocity along each span are important for proper assessment of tube vibration potential. Because of the disparity in spatial resolution between the small-scale finite element structural model of Xvib® and the larger scale incrementation scheme of Xist®, engineering judgment is required to populate the important...
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S-SS-3-17 Heat Transfer and Pressure Drop Methods for Square One Baffles
January 16, 2017
TRICO Metal Products, Inc. manufactures Square One™ baffles, a strip baffle or egg crate tube support technology for square pitch layouts. This report documents heat transfer and pressure drop methods for shellside flow using Square One baffles. Based on the existing Xist® window flow model, the methods have been adjusted for...
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TE-5 A CFD Study of Single-Phase Flows with Twisted Tape Inserts
January 16, 2017
To evaluate the thermal-hydraulic effectiveness of twisted tape inserts, we used computational fluid dynamics (CFD). After validating plain tube performance, we computed heat transfer (heating and cooling) and pressure drop for several twisted tape configurations in a 25.4-mm diameter tube with single-phase flow at laminar and turbulent Reynolds numbers from 102...
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Q10-1 The Benefits of Numerical Design Optimization
January 16, 2017
Numerical design optimization and the prerequisite statistical Design of Experiments (DOE) method lead to more effective CFD parametric studies and increase our confidence that the ensuing recommendations do indeed present the best design....
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STG-17 Annular distributors: A parametric design study
January 16, 2017
Unlike exchangers with conventional nozzles and nozzles with impingement devices, heat exchangers with annular distributors utilize full tube bundles while increasing end zone effectiveness and reducing the pressure drop and tube vibration potential. The uniformity of flow at the bundle entrance is controlled by the size and geometric aspect ratio of...
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AC-14 Longitudinal Pitch Effect on Pressure Drop and Heat Transfer in High-Finned Tubes
January 16, 2017
When increasing longitudinal pitch, methods for both pressure drop and heat transfer predictions for inline and staggered high-finned tube bundles are evaluated. When we compare the behavior simulated through computational fluid dynamics (CFD) to results from Xace and ESCOA for a characteristic tube geometry, the CFD results show that the effect...
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TPF-6 Multiphase CFD: U-Bends and Turnaround Headers
January 16, 2017
This report discusses multiphase computational fluid dynamics (CFD) simulations of turning flows in U-bends and turnaround headers. After brief descriptions of the numerical models, simulations of both single-phase and two-phase flows in the MBU serpentine test section are described to validate the CFD models for turning two-phase flows. The computed U-bend...
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S-SS-3-16 CFD Study of Flow Distribution in TEMA X Shells
January 16, 2017
Flow distribution in a TEMA X-shell exchanger was studied parametrically through computational fluid dynamics (CFD). Using design rules for manifolds and a lumped, linear circuit analysis of the exchanger, we identified the number of nozzles and the cross-sectional distribution area as key parameters. Our CFD results quantify the improvement in the...
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S-SS-3-14 CFD Study of NTIW Bundles
January 16, 2017
The thermal hydraulic performance of a gas-gas no-tubes-in-window (NTIW) field exchanger was studied parametrically using computational fluid dynamics (CFD). The tubes were modeled using porous media with velocity-dependent volumetric heat generation. An important performance indicator among the design variants was the ratio of the window velocity to the crossflow velocity. When...
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Q7-4 CFD Study of Inlet Zone Performance: Parallel vs. Perpendicular Segmental Baffle Cuts
January 16, 2017
Under contract from HTRI, university researchers simulated the fluid flow and heat transfer characteristics in the inlet zone of a shell-and-tube exchanger using computational fluid dynamics (CFD). Results revealed that the ratio of heat transfer to pressure drop for parallel baffle cut orientation was as low as 71 percent of that...
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STG-13 Computational Fluid Dynamics Study of Impingement Plates
January 16, 2017
The results of a computational fluid dynamics (CFD) study of impingement devices for inlet nozzles on shell-and-tube heat exchangers reveal the deleterious effects of increased velocity and pressure drop for a number of configurations. Simulations of entry flows with round and square solid plates as well as with rod grids were...
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