New Type of Heat Exchanger PDF

Mladen Bošnjaković, PhD, Assistant professor
Geel, Belgium, 22. March 2019.

Project is co-financed by the European Social Fund (ESF)
M. Bošnjaković, PhD, Assistant professor 2
BENEFICIARY:
College of Slavonski Brod (CSB)
Dr. Mile Budaka 1
35000 Slavonski Brod – Croatia
T: +385 35 492800
E: stemecoenergetics@gmail.com
W: https://www.vusb.hr
PARTNER:
Polytechnic in Požega (College of Požega, CP), Croatia
Vukovarska 17
34000 Požega – Croatia
T: +385 34 217018
E: ured@vup.hr
W: https://www.vup.hr
Project objectives:
 Increase the number of study programmes and curricula in English by
strengthening the competences of students as well as CSB and CP
staff which will improve the level of internationalization.
Target Group:
 22 members of teaching staff and 3 members of non-teaching staff of
CSB and CP including 106 students of CSB and CP
Project duration:
 10/2018 – 10/2020 (total 24 months)
Non-refundable funds:
 Project co-funded by the European Union under the European Social Fund in
amount of 100%

MLADEN BOŠNJAKOVIĆ
SHORT BIOGRAPHY
I am born on December 19, 1961 in Slavonski Brod.

From 1980 to 2002 I was employed in company Đuro Đaković where I worked in
the field of energy equipment design, quality control, technology preparation, and
as Project manager and as Production manager.
I graduated in 1989 at the Faculty of Mechanical Engineering and Naval

Architecture in Zagreb.
I received PhD at the Faculty of Mechanical Engineering of the University of Osijek
in 2018.
I am currently employed at College of Slavonski Brod as Head of Technical

Department.
Teaching experience - Programming of CNC Machines, Renewable Energy,

Environmental protection, Steam Generators, Heat Exchangers, Energy audits,
Hydraulic Machines, Quality Control, Material Management.
I am married and I have two children.

Where is Slavonski Brod?
Where is Croatia?
World Cup 2018 -

Welcome to Mario Manđukić

College of Slavonski Brod
(CSB)
College was established in 2006.

At the College studying about 1100 students.
CSB carries out the following professional undergraduate study programs:

Abbreviation of
Professional Undergraduate ECTS
academic title in Academic title
Study Program credits
Croatian / English
Plant Production
Orientation in: bacc. ing. agr. / Bachelor of Plant
180
- Horticulture B. Eng. Production
- Farming
bacc. oec. /
Management Bachelor of Economics 180
B. Econ.
bacc. ing. mech. / Bachelor of Mechanical

Production Engineering 180
B. Eng. Engineering
Each professional undergraduate study program is scheduled in six semesters

and completed by students upon defending of Bachelor thesis.
College of Slavonski Brod
(CSB)
CSB carries out the following professional graduate study programs:
Abbreviation of
Professional Graduate ECTS
academic title in Croatian Academic title
Study Program credits
/ English
struč. spec. oec./ Specialist of Applied

Management 120
M. App. Ec. Sciences in Economics
Ecology, Agriculture and struč. spec. ing. agr./ Specialist of Applied

120
Rural development prof. spec. eng. agr.) Sciences in Agriculture
Specialist of Applied
struč. spec. ing. mech./
Power engineering Sciences in Mechanical 120
prof. spec. eng. mech.)
engineering
Each professional graduate study program lasts four semesters. The students
complete the study upon successful defense of master thesis.

Development of new type
0
of Heat Exchanger
9
Content
1 Introduction
2 Geometric model of a new type of Heat exchanger
3 Numerical methods for solving problems
4 Foregoing numerical analysis
5 Processing and interpretation of numerical simulation results
6 Design of Heat exchanger model
7 Experimental testing of Heat exchanger model
8 The thermal calculation of the Heat exchanger model
9 Correlations for heat transfer and pressure drop
10 Results and discussion
11 Conslusion

1. Introduction
11
One of the important processes in mechanical engineering is heat and mass
transfer in Heat exchangers that are used in different areas such as electricity
generation, petroleum, chemical, food, automotive and computer industries,
heating, cooling, air conditioning and so on.
According to Newton's law of cooling the heat flux in the convective heat
transfer can be calculated as the product of the heat transfer coefficient, the
heat transfer surface area and the temperature difference between the surface
and the bulk fluid.
Attention is focused on increasing the heat transfer coefficient and the

thermal efficiency of the fin surface area.
By kind of the working fluid, gas - liquid heat exchangers are often used.
Typically, the heat resistance on the gas side makes 80% of the total heat
transfer resistance and designing the heat transfer on the gas side is a critical
point.
For increase of heat transfer coefficient - there are different passive and active
methods.
Active methods - have not found significant application in industry due to high
investment costs, large operating costs, and vibration and noise issues.
This paper - applying innovative fin geometry that increases turbulence of fluid
flow and mixing of fluid layers, thus the temperature boundary layer is periodically
interrupted, leading to more efficient heat and mass transfer.

Research Hypothesis
The aim of the research is to define and test a new geometric fin form, which will
enable more efficient heat transfer in the annular tube finned heat exchanger.
Hypothesis H0:
„Applaying a tube heat exchanger with innovative star shaped fin geometry, it is
possible to transfer a larger heat flux compared to existing tube heat exchanger
solutions."
Hypothesis H1:
"For tube heat exchanger with innovative star shaped fin geometry, it is possible to
determine the correlation for heat transfer (Nu)."
Hypothesis H2:
"For tube heat exchanger with innovative star shaped fin geometry, it is possible to
determine the correlation for pressure drop (Eu).“

Geometric model of a new type of
3.
Heat Exchanger
15
Geometric model of
a new type of Heat Exchanger

Geometric model
For the reference geometry, a round Ø40 fin of 0.5 mm thickness was taken. The
innovative fins are shown in the picture in the middle.
The diameter, thickness and step of the fin was selected according to the
literature recommendations.
Material: Stainless Steel

3. Numerical methods for solving problem
18
Numerical problem solving
There are three basic steps of each computer numerical simulation:

• Defining problems and generating mesh of control volumes
• Numerical solving
• Analysis of results
Real world
- Continuum
Physical model - Homogeneity
- Isotropy
(approximation - Monophase medium
of the real - Single Component
A set of integral-differential world) - Incompressible
equations and constituent relations - Stationarity
and boundary conditions - Viscous flow
Law of mass conservation Mathematical - Turbulent flow
Law of momentum conservation model - 3D
Law of energy conservation
Defining of Mathematical model
In order to perform numerical analyses of the finned tube heat exchanger is

necessary to choose the computational domain.
Figure: Mathematical model of computational domains for annular

finned tubes
Mathematical model defining
Software used: ANSYS FLUENT R17.2
Boundary condition: Symmetry
Boundary
condition: constant
temperature
Boundary condition: Symmetry

NUMERICAL ANALYSIS
Discretization of the geometric model creates the final Control Volumes (CV) that
interact with each other, but do not overlap and which fully meet the computational
domain. The final volume assembly is also called a geometric mesh.
Unstructured Structured
mesh mesh
In the boundary layer, the mesh should be dense

Outside the boundary layer - inviscid flow with small gradients - coarse mesh
What is Re larger boundary layer is thinner creating a geometric mesh depends on Re
NUMERICAL ANALYSIS
Min. the size of the element is 0,01

mm. Max. Tet Size is 2,0 mm
2 863 690 nodes i 9 422 252 CV eight

boundary layers
thickness of the first layer - 0,025 mm
Fin -3 boundary layers
Star-shaped fin
3 002 867 nodes and
10 910 150 CV

Determining the impact of network density on
the convergence of results
The check was performed for the star-type fin and for air velocity of 2.4 m/s.

NUMERICAL ANALYSIS
Step 2 involves defining the material properties, definition of boundary conditions,

turbulence model, ....
boundary conditions:
• the air speed at the entrance to the heat exchanger is uniformly distributed on cross-
section and value is from 1 m/s to 5 m/s;
• the amount of turbulence in the air inlet channel is 5%;
• the air temperature at the entrance to the channel is constant and is 288 K;
• the water temperature at the inlet of the tube is 353 K;
• temperature of the inner tube wall is constant and equal to the water temperature;
• the pressure gauge at the outlet of the channel is set to zero Pa
• hydraulically smooth surface tubes and fins;
• symmetry requirement is placed on the upper, lower, left and right sides of the domain.
• physical characteristics of fins and tubes material are constant (λc i ρc);
• it is assumed that the air acts as an ideal gas;
• the physical properties of air are defined as the polynomial function of the
temperature and thus set in the Fluent program.
• it is supposed incompressible flow

NUMERICAL ANALYSIS
The flow in the heat exchanger is

turbulent!
Characteristics of turbulent flow depends

on the geometry of HE and operating
flow conditions.
The problem - the choice of the

appropriate turbulence model that will
give the most accurate results for the
observed HE
Two models of turbulence have been

selected for use in this research :
REALISABLE 𝑘‐𝜀 model
SST 𝒌‐𝝎 model
`Turbulence is the most important unsolved

problem of classical physics.‘- Richard Feynman
Methods of solving and convergence criteria
Description Methods of solving /

convergence criteria
The calculation of the velocity field and SIMPLE algoritam
pressure field
Moment “Second-Order Upwind” numerical sheme
Kinetic energy of turbulence k “Second-Order Upwind” numerical sheme
Dissipation of turbulent kinetic energy ε,
Specific dissipation of turbulent kinetic “Second-Order Upwind” numerical sheme
energy ω
The equation of continuity, k, ω,
Default Convergence Criteria velocity in x, y, z: 1∙10-4
Energy: 1∙10-9
Convergence was achieved after 11,000 iterations. The convergence error was verified
on difference between the heat flow transmitted from the inner wall of the tube through the
outer surface of the tube and the fins and the heat flow which receiving air. The maximum
difference is 0,077 %.
NUMERICAL ANALYSIS RESULTS
Table 4.8 Output data for annular fins using k-ε Realizable model of turbulence
uz,1*=1,0 uz,1*=2,4 uz,1*=5,0
Description
m/s m/s m/s
The temperature at the outlet of HE Tz,2 K 327,3 315,4 307,1
Pressure at the inlet to the tube bundle pz,1 Pa 9,30 36,98 115,1
Pressure at the outlet of the tube bundle pz,2 Pa -1,35 -8,11 -31,13
Table 4.9 Output data for annular fins using k-ω SST model of turbulence
uz,1*=1,0 uz,1*=2,4 uz,1*=5,0

Description
m/s m/s m/s
The temperature at the outlet of HE Tz,2 K 327,6 314,8 306,5
Pressure at the inlet to the tube bundle pz,1 Pa 9,30 40,55 149,2
Pressure at the outlet of the tube bundle pz,2 Pa -1,85 -11,28 -49,85

PROCESSING AND INTERPRETATION OF
5.
NUMERICAL SIMULATION RESULTS
29
The values of the Eu number according to sources in the literature show
mutually significant differences of up to 25%.
Annular fins: Temperature field Star-shaped fins: Temperature field

The kinetic energy of turbulence
1. row 2. row 3. row 4. row 5. row 1. row 2. row 3. row 4. row 5. row
1. row
Annular fins Star-shaped fins

3. Row of tubes
Pressure
Density
Velocity

Comparison of the calculation results for annular fins
and star-shaped fins
Star-shaped
Annular fins
Star-shaped
Annular fins
Nu number is higher, about 13% of star-shaped fins then for annular fins

Star-shaped
Annular fins
Star-shaped
Annular fins
• Mass of star-shaped fin is 43.5% less than of annular fin

• Reduction of the exchanger bundle mass is 23.8%.
Efficiency of HE surface with star-shaped fins is greater than HE surface efficiency with
annular fin for 7,6 % at Re=2256 and 10 % at Re=11609.
Effectiveness of HE surface is higher for annular fin for 162% at Re=2256 and 99% at
Re=11609
Heat flux
Star-shaped
Annular fins
Star-shaped
Annular fins

Star-shaped
Annular fins
Heat flux per unit mass of the heat exchanger is greater for star-
shaped fins 12.1% at Re = 2255 and 15.5% at Re = 11608

HEAT EXCHANGER MODEL FOR
6.
LABORATORY TESTING
39
HEAT EXCHANGER MODEL
FOR LABORATORY TESTING
After the tube fins subassembly was made, the heat exchanger was
assembled and welded, followed by a pressure test.

HEAT EXCHANGER MODEL FOR
LABORATORY TESTING
Figure. Detail of annular fin cut off on EDM Machine Figure: Detail of the tube and annular fin joint

EXPERIMENTAL MODEL
7.
TESTING
42
EXPERIMENTAL MODEL TESTING
air conditioning
Boiler
Flow meter

Methodology of experimental testing
When it is estimated that a stationary state has been reached, it starts with a measurement
that lasts for 1 hour. The data of all measured values are taken every second and recorded
on a computer. For analysis, a 30 minute interval is used in which the air and water
temperature oscillations are at least.
Based on the considerations of Tatar and Lupia and Taylor, demands on stationarity have
been set :
• Change of inlet air temperature during the test < 0,5 °C,
• Change of inlet water temperature during the test < 1 °C,
• the deviation in the heat flow by the mean value during the measurement does not
exceed 5 %.
Furthermore, there is a requirement that the difference between the exchanged heat flow of
the air side and water is less than 8% (acc. ASME PTC 30-1991 standard less than 15 %).
The deviation of the mass flow of water and air should be less than 5%.

Methodology of experimental testing
The main goal of the test is to obtain relevant data on the basis of
which it is possible to compare the two thermodynamic respective
heat exchanger.
Therefore, the same test conditions for both heat exchangers

should be provided.
The measurement results always include a certain error or

measurement uncertainty.
However, as testing is carried out with the same equipment and in

(approximately) the same conditions it is assumed that the errors
are of the same size and the same sign.

Processing of measurement results
80
75
70
65 Water
Temperatura (°C)
60
55 Measured water and air
50
45
40
temperature for star-shaped
35
30
fins at air speed of 2.56 m/s
25 Air
20
15
142
189
236
283
330
377
424
471
518
565
612
659
706
753
800
847
894
941
988
1
1035
1082
1129
1176
1223
1270
1317
1364
1411
1458
1505
1552
1599
1646
1693
1740
1787
48
95
Time (s)(s)
Vrijeme
Temperatura zraka na ulazu Temperatura zraka na izlazu
Temperatura vode na ulazu Temperatura vode na izlazu
0,084
0,08
Air
0,076
0,072
Protok (kg/s)
0,068 Measured water and air

0,064 Water flow rate for star-shaped
0,06
0,056 fins at air speed of 2.56
0,052 m/s
142
189
236
283
330
377
424
471
518
565
612
659
706
753
800
847
894
941
988
1
1035
1082
1129
1176
1223
1270
1317
1364
1411
1458
1505
1552
1599
1646
1693
1740
1787
48
95
Vrijeme
Time (s)(s)
Maseni protok zraka Maseni protok vode

HEAT EXCHANGER MODEL
8.
HEAT CALCULATION
47
The physical model for testing heat exchanger

Analysis of heat transfer and pressure drop
Measured-Star-shaped
Measured-Annular
Comparison of Nu number obtained by laboratory model testing

and computed by correlation from literature
Mjereno-zvjezdaste
1,0 Briggs
ESDU
Ward and Young
0,9
PFR
Feten
0,8 Schmidt
mjereno-okrugle
HEDH
0,7 VDI-Warmeatlas
Eu
0,6
0,5
0,4
0,3
1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000
Re
Comparison of Eu number obtained by laboratory model testing and computed

by correlation from literature 50
M. Bošnjaković, PhD, Assistant professor
Measured-Star-shaped
Numerical-Star-shaped
Measured-Annular
Numerical-Annular
Figure 8.17 Comparison of Nu number obtained by laboratory model testing and

obtained by numerical analysis
1,00
0,90 Measured-Star-shaped
Mjereno - zvjezdaste
Num. analiza - zvjezdaste
0,80 Measured-Annular
Mjereno - okrugle
Num. analiza - okrugle
Numerical-Annular
0,70
Eu
0,60
0,50
0,40
0,30
1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000
Re
Figure 8.18 Comparison of Eu number obtained by laboratory model testing and obtained
by numerical analysis
85
80 Measured-Star-shaped
Mjereno - zvjezdaste
Measured-Annular
Mjereno - okrugle
75
70 Numerical-Annular
65
(%)
60
𝜂𝑓
55
50
45
40
1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000
Re
Figure 8.19 Comparison of fin efficiency obtained by laboratory model testing and
numerical analysis
3500
3000
2500
2000
qA (W/m2)
1500
1000 Measured-Star-shaped
Mjereno -zvjezdaste
500 Numerical-Annular
Measured-Annular
Mjereno - okrugle
0
1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000
Re
HE with star-shaped fins has a heat flux greater than 37% compared to HE with
annular fins.
For the same operating conditions and the same heat flux HE with star-shaped
fins can have a 37% smaller heat exchange surface.
CORRELATIONS FOR HEAT TRANSFER AND
9.
PRESSURE DROP FOR STAR-SHAPED FINS
55
A reasonable solution is correlation based on the results of the laboratory

testing, and additional information is obtained by numerical analysis.
-the thickness and spacing of the fins have been varied

Variant number
Step
Thickness
Velocity
Variant number
Step
Thickness
Velocity

Table: Results of numerical analysis for variants of analysed geometry
Results of
thermodynamic
calculations

Correlation for Nu number
for star-shaped fins
90
80
70
60
50
Nu
40
Izmjereno
Measured
30
20
Korelacija
Correlation
10 Numerička analiza
Numerical analysis
0
0 2000 4000 6000 8000 10000 12000 14000 16000
Re

Correlation for Eu number
for star-shaped fins
1,00
0,90
Izmjereno
Measured
0,80
Korelacija
Correlation
0,70
Eu
Numerička analiza
Numerical analysis
0,60
0,50
0,40
0,30
0 2000 4000 6000 8000 10000 12000 14000 16000
Re

RESULTS AND DISCUSSION
A new type of fins for the heat exchanger was proposed and analyzed. The analysis was
carried out using numerical analysis and experimental testing.
An important step is to create a quality mesh that is sufficient resolution to provide the
required accuracy of output results and at the same time to be able to process it on
available computing resources in a reasonable time.
Based on the results of numerical analysis, the Nu number is greater about 13% for star-
shaped fins compared to the Nu number for annular fins.
Efficiency of the HE surface with star-shaped fins is greater than the HE surface
efficiency with annular fins by 7.6% at Re = 2256 and 10% at Re = 11609
Heat flux is higher at the star-shaped fins more than 36.5%
Experimentaly obtained Nu and Eu numbers are well-matched with literature correlations
For all tested variants, the weight of the star-shaped fins relative to the mass of the
annular fins is lower by 43.5%

Conclusion
The results of numerical analysis and experimental testing

confirmed the assumption of increased turbulence caused
by the geometric shape of the star-shaped fin leading to a
higher heat transfer coefficient relative to the classic
annular fin.
Review of the hypothesis H0
„Applaying a tube heat exchanger with innovative star shaped fin geometry, it is possible
to transfer a larger heat flux compared to existing tube heat exchanger solutions."
An increase in the thermal flow by more than 36.5% was
achieved using the star-shaped fins instead of the annular
The increase of the heat transfer coefficient on the air side is

from 19.2% to 22.8%.

Thanks for you
atention
Literature:
Bošnjaković, M.; Čikić, A.; Muhič, S.; Stojkov, M. Development of a new type of
finned heat exchanger. Technical gazette 24 (2017) 06; 1785-1796,
doi.org/10.17559/TV-20171011071711
e-mail: mladenb@vusb.hr

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Mladen Bošnjaković, PhD, Assistant professor

Geel, Belgium, 22. March 2019.

M. Bošnjaković, PhD, Assistant professor 4

I am born on December 19, 1961 in Slavonski Brod.

I graduated in 1989 at the Faculty of Mechanical Engineering and Naval

I am currently employed at College of Slavonski Brod as Head of Technical

Teaching experience - Programming of CNC Machines, Renewable Energy,

I am married and I have two children.

M. Bošnjaković, PhD, Assistant professor 5

World Cup 2018 -

M. Bošnjaković, PhD, Assistant professor 6

College was established in 2006.

CSB carries out the following professional undergraduate study programs:

bacc. ing. mech. / Bachelor of Mechanical

Each professional undergraduate study program is scheduled in six semesters

CSB carries out the following professional graduate study programs:

struč. spec. oec./ Specialist of Applied

Ecology, Agriculture and struč. spec. ing. agr./ Specialist of Applied

M. Bošnjaković, PhD, Assistant professor 8

M. Bošnjaković, PhD, Assistant professor 10

Attention is focused on increasing the heat transfer coefficient and the

M. Bošnjaković, PhD, Assistant professor 13

M. Bošnjaković, PhD, Assistant professor 14

M. Bošnjaković, PhD, Assistant professor 16

Material: Stainless Steel

M. Bošnjaković, PhD, Assistant professor 17

There are three basic steps of each computer numerical simulation:

In order to perform numerical analyses of the finned tube heat exchanger is

Figure: Mathematical model of computational domains for annular

Software used: ANSYS FLUENT R17.2

Boundary condition: Symmetry

Boundary condition: Symmetry

M. Bošnjaković, PhD, Assistant professor 21

In the boundary layer, the mesh should be dense

Min. the size of the element is 0,01

2 863 690 nodes i 9 422 252 CV eight

M. Bošnjaković, PhD, Assistant professor 23

M. Bošnjaković, PhD, Assistant professor 24

Step 2 involves defining the material properties, definition of boundary conditions,

M. Bošnjaković, PhD, Assistant professor 25

The flow in the heat exchanger is

Characteristics of turbulent flow depends

The problem - the choice of the

Two models of turbulence have been

`Turbulence is the most important unsolved

Description Methods of solving /

uz,1*=1,0 uz,1*=2,4 uz,1*=5,0

M. Bošnjaković, PhD, Assistant professor 28

Annular fins: Temperature field Star-shaped fins: Temperature field

The kinetic energy of turbulence

Annular fins Star-shaped fins

M. Bošnjaković, PhD, Assistant professor 34

M. Bošnjaković, PhD, Assistant professor 35

• Mass of star-shaped fin is 43.5% less than of annular fin

M. Bošnjaković, PhD, Assistant professor 37

M. Bošnjaković, PhD, Assistant professor 38

M. Bošnjaković, PhD, Assistant professor 40

M. Bošnjaković, PhD, Assistant professor 41

M. Bošnjaković, PhD, Assistant professor 43

M. Bošnjaković, PhD, Assistant professor 44

Therefore, the same test conditions for both heat exchangers

The measurement results always include a certain error or

However, as testing is carried out with the same equipment and in

uz,1=1,0 uz,1=2,4 uz,1*=5,0