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35IJMPERDFEB201935

This research work investigates the flow field and the heat transfer characteristics of a Membrane Helical Coil Heat Exchanger for the cooling of syngas. Finite volume method based on FLUENT software practised and the RNG k–e turbulence model was adopted for modelling flow turbulent. The distribution of the resistance, the distribution of the heat source, and the porosity rate introduced to ANSYS R18.0 by coupling the user-defined function. The variation of local heat transfer,the pressure drop, and the temperature distribution studied under the effects of the syngas components and the operating pressure, and the impact of the arrangement of the membrane on the heat transfer investigated. The results show that higher operating temperature and pressure can improve the heat transfer, however, brings more significant pressure and temperature drop. The components of the syngas significantly affect the heat transfer and the pressure drop. The arrangement of the membrane influences the fluid flow.

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ISSN(P): 2249-6890; ISSN(E): 2249-8001

Vol. 9, Issue 1, Feb 2019, 365-372

© TJPRC Pvt. Ltd.

1

SAGAR. S. GADDAMWAR , ANAND N.PAWAR2 & PRAMOD A. NAIK3

1

PhD Research Scholar, Jawaharlal Darda Institute of Engineering and Technology, Yavatmal,Maharashtra State, India

2

Deputy Secretary, Maharashtra Board of Technical Education, Regional office Aurangabad, Maharashtra State, India

3

Joint Director Directorate of Technical Education, Mumbai, Maharashtra State, India

ABSTRACT

This research work investigates the flow field and the heat transfer characteristics of a Membrane Helical Coil Heat

Exchanger for the cooling of syngas. Finite volume method based on FLUENT software practised and the RNG k–e turbulence

model was adopted for modelling flow turbulent. The distribution of the resistance, the distribution of the heat source, and the

porosity rate introduced to ANSYS R18.0 by coupling the user-defined function. The variation of local heat transfer,the

pressure drop, and the temperature distribution studied under the effects of the syngas components and the operating pressure,

Original Article

and the impact of the arrangement of the membrane on the heat transfer investigated. The results show that higher operating

temperature and pressure can improve the heat transfer, however, brings more significant pressure and temperature drop.

The components of the syngas significantly affect the heat transfer and the pressure drop. The arrangement of the membrane

influences the fluid flow.

KEYWORDS: CFD, Syngas, Membrane Helical Coil Heat Exchanger, Heat transfer & Underground Coal Mines

Received: Nov 21, 2018; Accepted: Dec 11, 2018; Published: Jan 12, 2019; Paper Id.: IJMPERDFEB201935

INTRODUCTION

The global concerns are that the syngas will raise in the underground mines. The continually rising syngas in

underground mines are increasing the accident and diminishing the life of a worker who works in the underground

mines, discover methods to minimise the disaster and survival of a worker who works in the underground mines.

Membrane Helical Coil Heat Exchanger is a vital Heat Exchanger to reduce the high temperature and high pressure of

syngas in underground mines.

It recognised that in Underground Coal Mines, the coal gasification with the heat recovery membrane helical

coil heat exchanger shows high efficiency, so it is essential to understand the heat transfer characteristics of the heat

exchangers.

The scope of this research work is to investigate the flow field and the heat transfer characteristics of the

membrane helical coil heat exchanger for the cooling of syngas in underground coal mines by CFD simulation.

The membrane helical coil heat exchanger for the cooling of syngas in underground coal mines has two

characteristics:

366 Sagar. S. Gaddamwar, Anand N. Pawar & Pramod A. Naik

The calculated results were used to analyse the influence of syngas components, working pressure and the

arrangement of the membrane on heat transfer.

Delineation of the Geometry

Set of standard types of heat exchangers are used in heat transfer applications, the membrane helical coil heat

exchangers are still the most common type in use. They have more extensive heat transfer surface area-to-volume ratios

than most of the common types of heat exchangers, and they are manufactured efficiently for a large variety of sizes and

flow configurations. They are the cost-effective heat exchangers that can operate at high pressures, and their construction

facilitates disassembly for periodic maintenance and cleaning.

Impact Factor (JCC): 7.6197 SCOPUS Indexed Journal NAAS Rating: 3.11

CFD Analysis of Membrane Helical Coil for Optimization of High Pressure and 367

Temperature of Syngas in Underground Coal Mines

Figure 1 shows the zero and Figure 2 shows the geometries of the helical coil heat exchangers with three types of

membrane arrangements called configuration 1, configuration 2 and configuration 3, respectively. The syngas passes

through the tube side and the water falling on the tube. The U-tubes designed inside the tube which acts like a porous zone

through which the syngas passes that absorbs required heat to decrease the temperature of the syngas. The syngas passes

through the tube and gets cooled. The geometry parameters for membrane helical coil heat exchanger is given in Table 01.

Sr. No. Parameter Dimension

1. Length of heat exchanger tube 0.5m

2. Diameter of tube (d) 10mm

3. Radial pitch between helical coil (p1) 20 mm

4. Thickness of tube (t) 2mm

5. Inner Diameter of tube 8 mm

6. Diameter of inner helical coil (D) 150mm

To simplify numerical simulation while still keep the essential characteristics of the process, the following

assumptions are made:

• Heat transfer processes and Fluid flow are turbulent and in steady-state;

• Membrane Helical Coil Heat Exchanger is well-insulated hence the heat loss to the environment is ignored.

Mesh Generation

The 3D mesh system was established using the commercial code GAMBIT based on the 3D geometry.

The computational domain meshes with unstructured tetrahedral elements. The meshes of the computational model for

configuration1 are shown in Figure 03 and Figure 04. Grid independence tests are carried out to ensure that a near grid

independent solution can be obtained. The commercial code ANSYS R18.0 is adopted to simulate the flow and heat

transfer in the computational model.

368 Sagar. S. Gaddamwar, Anand N. Pawar & Pramod A. Naik

CFD Result

In a heat of syngas domain, we consider the following assumptions for getting the results of a temperature of

syngas domain-

Input Data

• Syngas Inlet

Temperature- 325.3

• Syngas Outlet

• Tube

Convection-500w/m2k

Material-Copper Tube

Impact Factor (JCC): 7.6197 SCOPUS Indexed Journal NAAS Rating: 3.11

CFD Analysis of Membrane Helical Coil for Optimization of High Pressure and 369

Temperature of Syngas in Underground Coal Mines

Figure 5: CFD Result of Membrane Helical Coil Heat Exchanger (Temperature of Syngas)

After completing the CFD simulations, we got the following results of Membrane Helical Coil Heat Exchanger in

the temperature of syngas domain are as follows-

In the temperature of water domain we consider the following assumptions for getting the results of the

temperature of water domain-

Input Data

• Water Inlet

Velocity- 1m/s

Temperature-311

• Water Outlet

• Tube

Convection-500w/m2k

Material-Copper

370 Sagar. S. Gaddamwar, Anand N. Pawar & Pramod A. Naik

Figure 6: CFD Result of Membrane Helical Coil Heat Exchanger (Temperature of Water)

After completing the CFD simulations, we got the following results of Membrane Helical Coil Heat Exchanger in

the temperature of the water domain are as follows-

In Pressure of syngas domain we consider the following assumptions for getting the results of the pressure of

syngas domain

Input Data

• Gas Inlet

Pressure- 245166Pa

• Gas Outlet

• Tube

Convection-500w/m2k

Material-Copper

Impact Factor (JCC): 7.6197 SCOPUS Indexed Journal NAAS Rating: 3.11

CFD Analysis of Membrane Helical Coil for Optimization of High Pressure and 371

Temperature of Syngas in Underground Coal Mines

Figure 7: CFD Result of Membrane Helical Coil Heat Exchanger (Pressure of Syngas)

After completing the CFD simulations, we got the following results of Membrane Helical Coil Heat Exchanger in

the pressure of syngas domain are as follows

CONCLUSIONS

In this research paper, three-dimensional numerical simulations for Membrane Helical Coil Heat Exchanger with

different membrane configuration and working condition are performed to reveal the effects of membrane configuration

and working condition on the temperature drop and heat transfer characteristics.

• Heat transfer analysis of a Membrane Helical Coil Heat Exchanger using CFD code ANSYS R18.0 has been

present in this paper.

• Higher operation pressure and temperature of syngas from underground coal mines, however, brings more

significant pressure drop because of the Membrane Helical Coil Heat Exchanger.

• The Membrane Helical Coil Heat Exchanger of the syngas significantly affect the pressure drop and the heat

transfer.

• The heat transfer increases with higher H2O percentage and lower H2 percentage. The pressure drop increases

with higher CO2 percentage and lower H2 percentage.

372 Sagar. S. Gaddamwar, Anand N. Pawar & Pramod A. Naik

ACKNOWLEDGMENTS

This work is financially supported by Gyro Drive Machinery Private Limited, Bangalore, Karnataka, India.

REFERENCES

1. D. Butterworth, A model for heat transfer during three-dimensional flow in tube bundles, in: Paper HX-6, Sixth International

Heat Transfer Conference, Toronto, 1978.

2. J.H. Nie, W.Q. Tao, Q.W. Wang, Three dimensional simulation of turbulence flow for heat exchanger head with complex

geometries, J. Xi’an Jiaotong Univ. 34 (5) (2000) 13–18.

3. S. Al-sanea, N. Rhodes, D.G. Tatchell, T.S. Wilkinson, A computer model for detailed calculation of the flow in power station

condenser, Inst. Chem. Eng. Symp. 75 (1983) 70–88.

4. Y.W. Chiu, J.Y. Jang, 3D numerical and experimental analysis for thermal–hydraulic characteristics of air flow inside a

circular tube with different tube inserts, Appl. Therm. Eng. 29 (2009) 250–258.

5. Sagar S. Gaddamwar, Aanad N. Pawar, Pramod A. Naik, Investigational Research of Heat Transmit Distinctiveness of High

Pressure Syngas In Coal Mines Used by Membrane Helical Coil, International Journal of Mechanical Engineering and

Technology (IJMET), Volume 9, Issue 1, January 2018, pp. 887–894

6. X.H. Huang, Q.J. Wang, Z. Lu, Three dimensional numerical simulation of fluid flow and heat transfer in shell-and-tube heat

exchanger, J. Chem. Ind. Eng. 51(3) (2000) 297–302.

7. X. Gu, Numerical Simulation of Shell-and-tube Heat Exchanger and Research on Sideling-flow Heat Exchanger, Zhengzhou

University, Zhengzhou, 2006.

8. R. D. Laranjo & N. M. Anacleto, Production of Fe-Cr-Ni-Mn Alloy by Direct Smelting of Mixed Low-Grade Chromite, Nickel

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10. B.O. Neeraas, A.O. Fredheim, B. Aunan, Experimental shell-side heat transfer and pressure drop in gas flow for spiral-wound

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12. S.S. Gaddamwar, A. N. Pawar, Pramod A. Naik, Similitude of Membrane Helical Coil With Membrane Serpentine Tube For

Characteristics of High-Pressure Syngas: A Review, AIP Conference Proceedings 1966, 020005 (2018).

13. C.H. Huang, I.C. Yuan, H.C. Ay, An experimental study in determining the local heat transfer coefficients for the plate finned-

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14. M. Prithiviraj, M.J. Andrews, Three-dimensional numerical simulation of shell and tube heat exchangers, Numer. Heat

Transfer A 33 (1998) 799–828.

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used in coal mines: A Review, International Journal of Science, Engineering and Technology (IJSET), pp 691-696.

Impact Factor (JCC): 7.6197 SCOPUS Indexed Journal NAAS Rating: 3.11

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