DESIGN AND FABRICATION OF DOUBLE PIPE

HEAT EXCHANGER WITH INCREASED

EFFECTIVENESS USING FINS
A Project Report Submitted
in Partial Fulfillment of the Requirements
for the Degree of
BACHELOR OF TECHNOLOGY
in
Mechanical Engineering

by
ABHISHEK PANDEY (1616440002)
ABHISHEK SHARMA (1616440005)
AMAN KHARE (1616440018)
ANURAG PATEL (1616440030)

Under the Supervision of

Mr. Bhola Chaurasia
(Assistant Professor)
Pranveer Singh Institute of Technology, Kanpur

to the
Faculty of Mechanical Engineering

DR. A. P. J. ABDUL KALAM TECHNICAL UNIVERSITY,

LUCKNOW
MARCH, 2020

i
DESIGN AND FABRICATION OF DOUBLE PIPE
HEAT EXCHANGER WITH INCREASED
EFFECTIVENESS USING FINS
A Project Report Submitted
in Partial Fulfillment of the Requirements
for the Degree of
BACHELOR OF TECHNOLOGY
in
Mechanical Engineering

by
ABHISHEK PANDEY (1616440002)
ABHISHEK SHARMA (1616440005)
AMAN KHARE (1616440018)
ANURAG PATEL (1616440030)

Under the Supervision of

Mr. Bhola Chaurasia
(Assistant Professor)
Pranveer Singh Institute of Technology, Kanpur

to the
Faculty of Mechanical Engineering

DR. A. P. J. ABDUL KALAM TECHNICAL UNIVERSITY,

LUCKNOW
MARCH, 2020

ii
 CERTIFICATE

Certified that Abhishek Sharma (1616440005) has carried out the project work presented in

this project report entitled “Design and Fabrication of Double Pipe Heat Exchanger with

Increased Effectiveness Using Fins” for the award of Bachelor of Technology from Dr. A.

P. J. Abdul Kalam Technical University, Lucknow, under my supervision. The project report

embodies results of original work, and studies are carried out by the student and the contents

of the thesis do not form the basis for the award of any other degree to the candidate or anybody

else from this or any other University / Institution.

Date: Mr. Bhola Chaurasia

Place: Assistant Professor
Department of Mechanical Engineering
PSIT, Kanpur

iii
 ABSTRACT

This work introduces a novel method that improves the thermal performance of a heat
exchanger. These performances can be in terms of effectiveness, efficiency, rate of work
produced and optimization in energy consumption. As Heat transfer is one of the most
important processes in industrial and consumer products, therefore by reduction in heat loss or
by increasing the rate of heat exchange we can be increasing the efficiency of a medium scale
industry by approximately 4-5%. In our process, we have replaced the conventional heat
exchanger with a finned tube so as to increase the area of contact and in turn the heat flow rate.
The most effective way to enhance the heat transfer on the air-side of a heat exchanger is to
modify the fin pattern and geometry by interrupting it periodically along the stream wise
direction. A double pipe heat exchanger will typically be either counter flow or parallel flow,
here we used counter flow type heat exchanger to get optimized result. In our process, we have
replaced the conventional heat exchanger with a finned tube so as to increase the area of contact
and in turn the heat flow rate. Now-a-days the fin inserts are also incorporated to increase
turbulence inside the tubes leading to forced convection and thus increasing rate of heat
transfer.
Here, we should a have to perform experiments so as to analyse the effectiveness of the fin that
can be helpful in increasing the efficiency of the industry (if rate of flow of heat increases). In
this work we have initialized by making a finned tube model of a heat exchanger along with
the conventional one.
After successful fabrication, we also performed practical experiment so as to do the further
analysis. Through the analysis, it is found that the heat flow rate via finned tube heat exchanger
should be greater than that of the conventional one. Thus, with increased effectiveness it has
various application in the industrial plants or factories where hot fluid is to be transferred
through a proper medium. Radiators are also a finned tube heat exchanger that has important
application in vehicles. All this is we can say is, a finned tube heat exchanger has better
efficiency when compared to that of conventional ones and also find their vital role in various
industrial plants in almost every manufacturing industry.

KEYWORDS: Effectiveness, Efficiency, Fins, Radiators.

iv
 ACKNOWLEDGEMENTS

It gives us a great sense of pleasure to present the report of the B. Tech Project undertaken
during B.Tech. Final Year. We owe a special debt of gratitude to Mr. Bhola Chaurasia,
Assistant Professor, Department of Mechanical Engineering, Pranveer Singh Institute of
Technology, Kanpur for his constant support and guidance throughout the course of our work.
His sincerity, thoroughness, and perseverance have been a constant source of inspiration for
us. It is only his cognizant efforts that our endeavours have seen the light of the day.
We also take the opportunity to acknowledge the contribution of Professor Nitin Srivastava,
Head, Department of Mechanical Engineering, Pranveer Singh Institute of Technology,
Kanpur, for his full support and assistance during the development of the project.
We also do not like to miss the opportunity to acknowledge the contribution of all faculty
members of the department for their kind assistance and cooperation during the development
of our project. Last but not the least; we acknowledge our family & friends for their
contribution to the completion of the project.

Signature: Signature:
Name: Abhishek Pandey Name: Abhishek Sharma
Roll No.: 1616440002 Roll No.: 1616440005
Date: Date:

Signature: Signature:
Name: Aman Khare Name: Anurag Patel
Roll No.: 1616440018 Roll No.: 1616440030
Date: Date:

v
 TABLE OF CONTENT

Content Page No.

Certificate iii
Abstract iv
Acknowledgements v
Table of Content vi
List of Tables viii
List of Figures ix

Chapter 1 INTRODUCTION 1-18

1.1 Overview 1
1.1.1 Overview of Heat Exchangers 3
1.1.2 Overview of Fins 5
1.1.3 Overview of Finned Heat Exchanger 7

1.2 Classification of Heat Exchanger 10

1.2.1 Parallel flow Heat Exchanger 12
1.2.2 Counter flow Heat Exchanger 12
1.2.3 Cross flow Heat Exchanger 13

1.3 Classification of Fins 14

1.3.1 Circular Cross section 14
1.3.2 Square Cross section 14
1.3.3 Rectangular Cross section 15

1.4 Applications of Heat Exchanger 16

1.5 Applications of Fins 17

CHAPTER 2 LITERATURE REVIEW 19-25

2.1 Findings from various Journals 20

2.1.1 Performance of Circular Fins 20
2.1.2 Advantage of using Aluminium Fins 21

vi
 2.1.3 Surface optimization of Plate-Fin surface 23

2.2 Methods of Enhancing Heat Transfer 24

2.3 Selection of optimum Fin Type 25

CHAPTER 3 DESIGN AND FABRICATION OF 26-34

DOUBLE PIPE HEAT EXCHANGER
3.1 Design and Calculations 26
3.1.1 Input Parameters 26
3.1.2 Design Parameters 26
3.2 CAD model of Heat Exchanger 27
3.3 Fabrication of Heat Exchanger 30
3.3.1 Components Used 30
3.3.2 Fabrication Methodology 34

CHAPTER 4 TESTING AND ANALYSIS 36-39

4.1 For Unfinned Heat Exchanger: Counter Flow 36
4.2 For Finned Heat Exchanger: Counter Flow 37
4.3 Comparison of Efficiency of two Heat Exchangers 38
4.4 Comparison of Effectiveness of two Heat Exchangers 39

CHAPTER 5: PROTOTYPE OF ACTUAL HEAT 41

EXCHANGERS

CHAPTER 6: RESULTS 42

CHAPTER 7: FUTURE SCOPE 43

CHAPTER 8: CONCLUSION 44

REFERENCES 45

vii
 LIST OF TABLES

Page No.
Table 1: - Industries and Applications of Heat Exchangers by Type 16
Table 2: - Comparison of Temperatures of various fin configurations 26
Table 3: - List of Components Used 31
Table No. 4: Unfinned Heat exchanger parameters 38
Table No. 5: Finned Heat exchanger parameters 39

viii
 LIST OF FIGURES
Page no.
Figure 1: - Shell and Tube Heat Exchanger 2
Figure 2: - Heat Exchanger with plate type Fins 5
Figure 3: - Recuperative Heat Exchanger 8
Figure 4: - Regenerative Heat Exchanger 8
Figure 5: - Direct Contact Type Heat Exchanger 9
Figure 6: - Parallel-flow and counter-flow heat exchanger 12
Figure 7: - Cross Flow Heat Exchangers 12
Figure 8: - Various geometries and configurations of fins 13
Figure 9: - Graph showing heat transfer by various fins boundary 14
conditions
Figure 10: -Various application of fins 17
Figure 11: -Schematic of an annular fin of uniform thickness 20
Figure 12: -Steady State Thermal Analysis of Circular Fins 24
Figure 13: -Steady State Thermal Analysis of Square Fins 24
Figure 14: Steady State Thermal Analysis of Rectangular Fins 25
Figure 15: Temperature Graph of various Fin Shapes 25
Figure 16: Rectangular cross section of annular fin 25
Figure 17: - 3D Model of Heat Exchanger 28
Figure 18: - Base Structure 28
Figure 19: - Finned Pipe 29
Figure 20: - PVC Shell 29
Figure 21: - Unfinned Pipe 29
Figure 22: - Valve 30
Figure 23: - Connecting Pipe 30
Figure 24: - Finned and Unfinned Pipe 32
Figure 25: - Aluminium Fins 32
Figure 26: - PVC Shell 33
Figure 27: - Water Pump 33
Figure 28: - Temperature sensing element 33
Figure 29: - Water Storage Tank 34
ix
Figure 30: - Heating Rod 34
Figure 31: - Valves 34
Figure 32: -Dimensions of Finned Pipe in mm 35
Figure 33: Counter Flow Heat exchanger Temperature diagram 36
Figure 34: - Actual prototype of Heat exchanger 37

x
 CHAPTER-1
INTRODUCTION
1.1 Overview
In this era the effective utilization of resources, minimum wastage of energy and increased
efficiency is the need of every industry. Heat exchanger has been playing a vital role in meeting
these demands, by effective transfer of energy from a hot fluid to a cold with maximum rate
and minimum investment and running costs. It helps in effective utilization of waste heat in
industries and also various machineries, in order to prevent overheating of the same. Heat
transfer enhancement is the process of improving the performance of a heat transfer system to
increasing the heat transfer coefficient. An increase in the heat transfer coefficient generally
leads to another advantage of reducing the temperature driving force, which increases the
efficiency of the industry. This increased coefficient can be attained by the techniques that are
used to augment heat transfer. The most effective way to enhance the heat transfer on the air-
side of a heat exchanger is to modify the fin pattern and geometry by interrupting it periodically
along the streamwise direction.
Now-a-days the fin inserts are also incorporated to increase turbulence inside the tubes leading
to forced convection and thus increasing rate of heat transfer.

A heat exchanger is a device which transfers heat from one medium to another, a Hydraulic
Oil Cooler or example will remove heat from hot oil by using cold water or air. Alternatively,
a Swimming Pool Heat Exchanger uses hot water from a boiler or solar heated water circuit to
heat the pool water. Heat is transferred by conduction through the exchanger materials which
separate the mediums being used. A shell and tube heat exchanger pass fluids through and over
tubes, where as an air-cooled heat exchanger passes cool air through a core of fins to cool a
liquid.

In double pipe heat exchanger design, an important factor is the type of flow pattern in the heat
exchanger. A double pipe heat exchanger will typically be either counterflow or parallel flow.
Crossflow just doesn’t work for a double pipe heat exchanger. The flow pattern and the required
heat exchange duty allows calculation of the log mean temperature difference. That together
with an estimated overall heat transfer coefficient allows calculation of the required heat
transfer surface area. Then pipe sizes, pipe lengths and number of bends can be determined.

1
A double pipe heat exchanger, in its simplest form is just one pipe inside another larger pipe.
One fluid flow through the inside pipe and the other flows through the annulus between the
two pipes. The wall of the inner pipe is the heat transfer surface. The pipes are usually doubled
back multiple times as shown in the diagram at the left, in order to make the overall unit more
compact.

Figure 1: Shell and Tube Heat Exchanger

2
1.1.1 Overview of Heat Exchangers
Heat exchangers are devices used to transfer heat between two or more fluid streams at different
temperatures. Heat exchangers find widespread use in power generation, chemical processing,
electronics cooling, air-conditioning, refrigeration, and automotive applications. In this chapter
we will examine the basic theory of heat exchangers and consider many applications. In
addition, we will examine various aspects of heat exchanger design and analysis.
A heat exchanger is a device that is used for transfer of thermal energy (enthalpy) between two
or more fluids, between a solid surface and a fluid, or between solid particulates and a fluid, at
differing temperatures and in thermal contact, usually without external heat and work
interactions. The fluids may be single compounds or mixtures. Typical applications involve
heating or cooling of a fluid stream of concern, evaporation or condensation of a single or
multicomponent fluid stream, and heat recovery or heat rejection from a system. In other
applications, the objective may be to sterilize, pasteurize, fractionate, distil, concentrate,
crystallize, or control process fluid. In some heat exchangers, the fluids exchanging heat are in
direct contact. In other heat exchangers, heat transfer between fluids takes place through a
separating wall or into and out of a wall in a transient manner. In most heat exchangers, the
fluids are separated by a heat transfer surface, and ideally, they do not mix. Such exchangers
are referred to as the direct transfer type, or simply recuperates. In contrast, exchangers in
which there is an intermittent heat exchange between the hot and cold fluids via thermal energy
storage and rejection through the exchanger surface or matrix--are referred to as the indirect
transfer type or storage type, or simply regenerators. Such exchangers usually have leakage
and fluid carryover from one stream to the other. A heat exchanger consists of heat exchanging
elements such as a core or a matrix containing the heat transfer surface, and fluid distribution
elements such as headers, manifolds, tanks, inlet and outlet nozzles or pipes, or seals. Usually
there are no moving parts in a heat exchanger; however, there are exceptions such as a rotary
regenerator (in which the matrix is mechanically driven to rotate at some design speed), a
scraped surface heat exchanger, agitated vessels, and stirred tank reactors. The heat transfer
surface is a surface of the exchanger core that is in direct contact with fluids and through which
heat is transferred by conduction. The portion of the surface that also separates the fluids is
referred to as the primary or direct surface. To increase heat transfer area, appendages known
as fins may be intimately connected to the primary surface to provide extended, secondary, or
indirect surface. Thus, the addition of fins reduces the thermal resistance on that side and
thereby increases the net heat transfer from/to the surface for the same temperature difference.

3
1.1.2 Overview of Fins
In this modern era of technology there could be many ways of enhancing the heat transfer rate
or doing optimum utilization of available energy without much wastage of it.
One of the ways to increase the heat transfer from the hot surface by increasing the surface area
in contact with environment. For this the surface area exposed to the surroundings is frequently
increased by the attachment of protrusion to the surfaces, and the arrangement provides a means
by which heat transfer rate can be substantially improved. These protrusions are called fins or
spines.
A “fin” is any external feature protruding into the stream of a moving fluid. Normally the fin
is used to remove heat from its host where the fin is hotter than the fluid. Heat passes from the
fin into (and through) the fluid by convection and radiation.
With fin cooling by natural convection, the fluid moves vertically by the buoyancy created by
having warmer, thinner fluid rising as it is heated and replaced with heavier, cooler fluid from
below.
With forced convection, a fluid is moved over the fin in any desired direction using a powered
fluid mover like a fan, pump, or blower.
In many engineering situations, means are often sought to improve heat dissipation from a
surface to its surrounding. Whenever the available surface is found inadequate transfer the
required quantity of heat with available temperature drop and convective heat transfer
coefficient, extended surfaces or fins are used.
Extended surfaces have fins attached to the primary surface on one side of a two-fluid or a
multifluid heat exchanger. Fins can be of a variety of geometry—plain, wavy or interrupted—
and can be attached to the inside, outside or to both sides of circular, flat or oval tubes, or
parting sheets. Fins are primarily used to increase the surface area (when the heat transfer
coefficient on that fluid side is relatively low) and consequently to increase the total rate of
heat transfer. In addition, enhanced fin geometries also increase the heat transfer coefficient
compared to that for a plain fin. Fins may also be used on the high heat transfer coefficient
fluid side in a heat exchanger primarily for structural strength (for example, for high pressure
water flow through a flat tube) or to provide a thorough mixing of a highly-viscous liquid (such
as for laminar oil flow in a flat or a round tube). Fins are attached to the primary surface by
brazing, soldering, welding, adhesive bonding or mechanical expansion, or extruded or
integrally connected to tubes.

4
Normally, there is an array of fins of identical size and shape to maximize the amount of heat
carried away from the host object.
Note that heat is also expelled from the fin by thermal (infrared) radiation. Gases are largely
transparent to radiation. Liquids are not.
Lastly, sometimes fins are used to warm its host. The concept is the same except heat moves
in the opposite direction.

Figure 2: Heat Exchanger with plate type Fins

5
1.1.3 Overview of Finned Heat Exchanger
Finned Tube Heat Exchangers is a type of heat exchanger design that uses plates and finned
chambers to transfer heat between fluids. It is often categorized as a compact heat exchanger
to emphasise its relatively high heat transfer surface area to volume ratio. The plate-fin heat
exchanger is widely used in many industries, including the aerospace industry for its compact
size and lightweight properties, as well as in cryogenics where its ability to facilitate heat
transfer with small temperature differences is utilized.
Heat exchangers with extended surfaces are widely used whenever heat is to be exchanged
between a medium that transports heat well (e.g. liquid, liquid with phase transition) and one
that does not (e.g. gas with small density). On the side of the medium transporting heat poorly,
the heat-transferring surface is enlarged by an arrangement of fins or other elements such as
pins or needles. These elements for enlarging the surface can be attached up to a relatively
great height to the surface, or they can be small and formed from the tube material itself. Fins
can be arranged in tubes on both the outside and the inside and mainly transversely or along
the sleeve shaft axis. From among the great abundance of possible arrangements, only tubes
with outside fins, arranged in an approximately orthogonal direction to the sleeve shaft, will be
considered here.
A high degree of flexibility is present in plate-fin heat exchanger design as they can operate
with any combination of gas, liquid, and two-phase fluids. Heat transfer between multiple
process streams is also accommodated.
Finned tubes are one of the most widely used means of passively enhancing the heat transfer
in circular tubes. Many investigators have proposed different correlations for predicting the
performance of such heat exchangers based on their experimental investigations. However, the
practical usage of such correlations is limited because of the variety of parameters that can
influence Nusselt number and friction factor. Most of the correlations either have been
developed with limited databases, or are geometry specific. Using CFD for analysing
performance of such heat exchangers is very computationally intensive and hence cannot be
used for design optimization purposes. On the other hand, empirical correlations have many
limitations in terms of their applicability. The objective of the present article is to present a
physically based model for evaluating heat transfer and frictional loss for an internally and / or
externally finned double pipe heat exchanger that can be applied in a wide range of operating
conditions of practical importance. This paper describes a simple semi-empirical-numerical
methodology to evaluate heat transfer and pressure drop characteristics in a finned tube heat

6
exchanger with internal and/or external fins. Conduction and turbulent forced convection are
the prominent modes of heat transfer. In order to resolve the operational characteristics of
double pipe finned heat exchangers, a numerical methodology is presented which uses well
known existing correlations for flow in a smooth pipe and flow over a flat plate. The method
of successive substitution is used to solve the problem numerically. The proposed methodology
is applied to some simple cases and the results compare well with existing data and correlations
available in the literature. It is found that the addition of fins to such double pipe heat
exchangers reduce the Nusselt Number; however, the corresponding heat transfer rate is
enhanced owing to the increase in the overall heat transfer area.
The main four type of fins are: plain, which refer to simple straight-finned triangular or
rectangular designs; herringbone, where the fins are placed sideways to provide a zig-zag path;
and serrated and perforated which refer to cuts and perforations in the fins to augment flow
distribution and improve heat transfer.
Specifications:
 Originally conceived by an Italian mechanic, Paolo Fruncillo.
 A plate-fin heat exchanger is made of layers of corrugated sheets separated by flat metal
plates, typically aluminium, to create a series of finned chambers.
 Separate hot and cold fluid streams flow through alternating layers of the heat
exchanger and are enclosed at the edges by side bars.
 Heat is transferred from one stream through the fin interface to the separator plate and
through the next set of fins into the adjacent fluid.
 The fins also serve to increase the structural integrity of the heat exchanger and allow
it to withstand high pressures while providing an extended surface area for heat transfer.

7
1.2 Classification of Heat Exchangers
1.Based on principle of operation heat exchangers
(a) Recuperative
In recuperative type of heat exchangers, cold and hot fluid flow through the unit without mixing
with each other. The transfer of heat occurs through the metal wall. Examples of recuperative
heat exchangers are boilers, heaters, coolers, vaporizers, condensers etc.

Figure 3: Recuperative Heat Exchanger

(b) Regenerative
Regenerative type of heat exchangers same heating surface is alternately exposed to hot and
cold fluid.
Heat associated with hot fluid is stored or absorbed by pickings or solids. The hot fluid supply
is then shut off and cold fluid is passed over pickings or solids to regenerate the heat.
Example of such type of heat exchangers is re generators of open-hearth furnace, glass melting
furnace etc. Recuperative and regenerative units can also be called as surface condensers.

Figure 4: Regenerative Heat Exchanger

8
(c) Direct contact
In direct contact type of heat exchangers hot and cold fluids are in direct contact and mixing
Occurs among them during the process of heat transfer. Mass transfer also occurs
simultaneously.
Examples of direct contact type of heat exchangers are spray columns cooling towers,
scrubbers etc.

Figure 5: Direct Contact Type Heat Exchanger

2. Based on flow pattern the heat exchangers

(a) Co-current
(b) Counter-current
(c) Cross flow
In co-current flow-arrangement hot and cold fluid flow in the same direction. It is also called
as parallel flow arrangement. In counter current flow arrangement hot and cold fluid moves in
opposite directions.
In cross flow arrangement hot and cold fluids move at right angles to each other.

9
3. Based on function of heat exchangers
(a) Chiller
(b) Heater
(c) Evaporator
(d) Cooler
(e) Partial condense
(f) Vaporizer
(g) Re-boiler
(h) Condenser
(i) Steam generator
(j) Waste heat boiler

4. Based on type of construction

(a) Shell and tube type
(b) Bayonet type
(c) Double pipe
(d) Air cooled
(e) Spiral type
(f) Plate type

10
1.2.1 Parallel Flow & Counter-flow Heat Exchangers

 Parallel-flow and counterflow

In the simplest heat exchanger, two fluids (one cold and one hot) move in the same or opposite
directions in a concentric tube configuration. When the fluids enter and leave at the same end
the arrangement is parallel-flow, whereas in the counterflow configuration, the fluids enter and
leave at the opposite end.
Co-current flow heat exchangers, also referred to as parallel flow heat exchangers, are heat
exchanging devices in which the fluids move parallel to and in the same direction as each other.
Although this configuration typically results in lower efficiencies than a counter flow
arrangement, it also allows for the greatest thermal uniformity across the walls of the heat
exchanger.
Countercurrent flow heat exchangers, also known as counter flow heat exchangers, are
designed such that the fluids move antiparallel (i.e., parallel but in opposite directions) to each
other within the heat exchanger. The most commonly employed of the flow configurations, a
counter flow arrangement typically exhibits the highest efficiencies as it allows for the greatest
amount of heat transference between fluids and, consequently, the greatest change in
temperature.
A counterflow heat exchanger has the hot fluid entering at one end of the heat exchanger flow
path and the cold fluid entering at the other end of the flow path. Counter flow is the most
common type of liquid-liquid heat exchanger, because it is the most efficient. A double pipe
heat exchanger is usually operated as a counter flow heat exchanger. The flow pattern in a shell
and tube heat exchanger with a single tube pass will be approximately counterflow if it is long
in comparison with its diameter. Because of the baffles and the need to distribute the flow of
the shell side fluid over the cross-section of the shell, the flow is not as close to counterflow in
a shell and tube heat exchanger as it is in a double pipe heat exchanger. The bottom diagram
on the left shows approximately counter flow in a straight tube, one tube pass shell, and tube
heat exchanger.

11
 Figure 6: Parallel-flow and counter-flow heat exchanger

 Cross flow Heat Exchangers

The fluids can also flow in perpendicular directions which is known as cross flow arrangement.
The two main types are finned and unfinned tubular. With a finned tubular heat
exchanger, both fluids are unmixed, the one between the fins is guided in a direction transverse
to the tube flow direction. In the unfinned exchanger heat can be exchanged in all directions,
and the fluid can mix.
A car radiator and an air conditioner evaporator coil are examples of crossflow heat exchangers.
In both cases heat transfer is taking place between a liquid flowing inside a tube or tubes and
air flowing past the tubes. With a car radiator, the hot water in the tubes is being cooled by air
flowing through the radiator between the tubes. With an air conditioner evaporator coil, air
flowing past the evaporator coils is cooled by the cold refrigerant flowing inside the tube(s) of
the coil. Crossflow heat exchangers are typically used for heat transfer between a gas and a
liquid as in these two examples.

Figure 7: Cross flow Heat Exchangers

12
1.3 Classification of Fins

 Types of Fins on Basis of Shape

Figure 8: Various geometries and configurations of fins

Various geometries and configurations are used to construct fins.

1. Each fin is shown attached to a wall or surface.
2. The end of the fin which is in contact with the surface is called the base while the free
end is called the tip.
3. The term straight is used to indicate that the base extends along the wall in a straight
fashion as shown in (a) and (b).
4. If the cross-sectional area of the fin changes as one move from the base towards the tip,
the fin is characterized as having a variable cross-sectional area. Examples are the fins
shown in (b), (c) and (d).
5. A spine or a pin fin is distinguished by a circular cross section as in (c). A variation of
the pin fin is a bar with a square or other cross-sectional geometry.
6. An annular or cylindrical fin is a disk which is mounted on a tube as shown in (d). Such
a disk can be either of uniform or variable thickness.

13
 Types of Fins Depending on Different Boundary Conditions

BOUNDARY CONDITIONS:

Case -1: Fin tip is insulated

Case -2: Fin is finite in length and also loses heat by convection from its tip (End not
insulated)

Case -3: Fin is infinitely long (very long fin)

When the fin is infinitely long then the temperature at the tip of the fin will be essentially that
of the fluid,

Figure 9: Graph showing heat transfer by various fins boundary conditions

It is justified from the above graph that for the same temperature conditions and same heat
transfer coefficient the Heat transferred in infinitely long fin is substantially greater than the
other two cases, but due to design and space constraints we’re bound to use the other two
types, yet we prefer the fin loosing heat at tip as it gives marginally greater heat transfer
under same conditions than the fin insulated at tip.

14
1.4 Applications of Heat Exchangers
Heat exchangers are devices used throughout industry for both heating and cooling processes.
Several variants of heat exchangers are available and find application in a wide range of
industries, including:

 ASME heat exchangers

 Automotive heat exchangers (typically as car radiators)
 Brewery heat exchangers
 Chemical heat exchangers
 Cryogenic heat exchangers
 Marine heat exchangers
 Power generation heat exchangers
 Refrigeration heat exchangers

Table 1 – Industries and Applications of Heat Exchangers by Type

Type of Heat Exchanger Common Industries and Applications
Shell and Tube  Oil refining
 Preheating
 Oil cooling
 Steam generation
 Boiler blowdown heat recovery
 Vapor recovery systems
 Industrial paint systems
Double Pipe  Industrial cooling processes
 Small heat transfer area requirements
Plate  Cryogenic
 Food processing
 Chemical processing
 Furnaces
 Closed loop to open loop water cooling
Condensers  Distillation and refinement processes
 Power plants

15
  Refrigeration
 HVAC
 Chemical processing
Evaporators/Boilers  Distillation and refinement processes
 Steam trains
 Refrigeration
 HVAC
Air Cooled/Fan Cooled  Limited access to cooling water
 Chemical plants and refineries
 Engines
 Power plants
Adiabatic Wheel  Chemical and petrochemical processing
 Petroleum refineries
 Food processing and pasteurization
 Power generation
 Cryogenics
 HVAC
 Aerospace
Compact  Limited space requirements (e.g., aircrafts and
automobiles)
 Oil cooling
 Automotive
 Cryogenics
 Electronics cooling

16
1.5 APPLICATION OF FINS

1. Fins are most commonly used in heat exchanging devices such as radiators in cars and
heat exchangers in power plants
2. They are also used in newer technology such as hydrogen fuel cells.
3. Nature has also taken advantage of the phenomena of fins.
4. The ears of jackrabbits and Fennec Foxes act as fins to release heat from the blood that
flows through them.

5. Common applications of finned surfaces are with, Cooling of electronics components.

6. Condensers and economisers of thermal powerplants.
7. Dry type cooling towers.
8. Air cooled cylinders of compressors, IC engines.
9. Evaporators and condensers of refrigeration and air conditioning system.
10. Electric motor and transformers.

Figure 10: Various application of fins

17
 CHAPTER-2

LITERATURE REVIEW

In this era the effective utilization of resources, minimum wastage of energy and increased
efficiency is the need of every industry. Heat exchanger has been playing a vital role in meeting
these demands, by effective transfer of energy from a hot fluid to a cold with maximum rate
and minimum investment and running costs. It helps in effective utilization of waste heat in
industries and also various machineries, in order to prevent overheating of the same. Heat
transfer enhancement is the process of improving the performance of a heat transfer system to
increasing the heat transfer coefficient. An increase in the heat transfer coefficient generally
leads to another advantage of reducing the temperature driving force, which increases the
efficiency of the industry. This increased coefficient can be attained by the techniques that are
used to augment heat transfer. The most effective way to enhance the heat transfer on the air-
side of a heat exchanger is to modify the fin pattern and geometry by interrupting it periodically
along the stream wise direction.

A heat exchanger is a device used to transfer heat between two or more fluids. The fluids can
be single or two phase and, depending on the exchanger type, may be separated or in direct
contact. Devices involving energy sources such as nuclear fuel pins or fired heaters are not
normally regarded as heat exchangers although many of the principles involved in their design
are the same.

In order to discuss heat exchangers, it is necessary to provide some form of categorization.

There are two approaches that are normally taken. The first considers the flow configuration
within the heat exchanger, while the second is based on the classification of equipment type
primarily by construction. Both are considered here.

Put simply, a heat exchanger is a device which transfers heat from one medium to another, a
Hydraulic Oil Cooler or example will remove heat from hot oil by using cold water or air.
Alternatively, a Swimming Pool Heat Exchanger uses hot water from a boiler or solar heated
water circuit to heat the pool water. Heat is transferred by conduction through the exchanger
materials which separate the mediums being used. A shell and tube heat exchanger passes fluids
through and over tubes, where as an air cooled heat exchanger passes cool air through a core
of fins to cool a liquid.
18
2.1 Findings from various Journals
 Performance investigation of plain and finned tube evaporative cooled heat
exchangers. (2002) A circular fin is easier to install and also the no. of fins that can be
attached also increases as compared to when using longitudinal fins, which in turn
increases effective contact surface area and hence heat transfer.

 International Journal of Mechanical Engineering and Robotics Research Vol. 7

(2018) Aluminium has high thermal conductivity, scaling, oxidation & corrosion is not
so effective in the performance of heat exchanger, and most importantly economical in
cost as compared to copper and competes with it in a better way.

 John E. Hessel Greaves, David A. Reay, in Compact Heat Exchangers (2017) The
increase in number of fins and decreasing the thickness to very small, as infinite small
thickness is not possible so it is chosen in such a way that it doesn’t affects the required
strength of fin as well, this enhances the total surface in contact and thus increases
effective heat transfer and hence effectiveness.

 International Journal of Engineering Research & Technology (IJERT) Vol. 5

Issue 08 (2016) The use of inserts in heat exchanger tubes increases the turbulence of
water flowing and thus causing forced convection and hence enhances the rate of heat
transfer between the two fluids.

2.1.1 Performance Of Circular Fins

Concentric annular or radial fins are employed to improve the rate of heat transfer from the
external surface of a circular tube. Such fins are commonly used in finned tube cross-flow heat
exchangers. The analysis of concentric annular fins with common profile shapes namely,
rectangular, triangular, concave and con-vex parabolic and hyperbolic are available in a
number of references. Substantial amount of research endeavours have also been made to find
out the optimal dimensions of radial fins so that the rate of heat transfer can be maximized for
a given fin volume or the fin volume can be minimized for a specified heat duty.
A circular fin is easier to install and also the no. of fins that can be attached also increases as
compared to when using longitudinal fins, which in turn increases effective contact surface
area and hence heat transfer.

19
 Figure 11: Schematic of an annular fin of uniform thickness

An annular fin of constant thickness 2t, inner radius r1 and outer radius r2 dissipating heat by
convection to a surrounding fluid is shown in Fig. 1. In the modelling, the most common
Murray–Gardner assumptions are adopted: steadiness in heat flow; constant thermal
conductivity k; uniform heat transfer coefficient h; unvarying fluid temperature T∞; prescribed
fin base temperature Tb; preponderance of radial temperature gradients over those in the 2
transversal direction; negligible heat transfers at the outermost fin section (i.e., adiabatic fin
tip); and null heat sources or sinks.

2.1.2 Advantage of using Aluminium Fins

According to the heat exchanger application and operation, there are various materials. The
common ones are Aluminium, Alloy, Copper, Brass, Nickel, Titanium, Stainless Steel, Carbon
Steel, etc., among which the aluminium and alloy are mostly used.

Aluminium has high thermal conductivity, scaling, oxidation & corrosion is not so effective in
the performance of heat exchanger, and most importantly economical in cost as compared to
copper and competes with it in a better way. The basic performance for fin tube heat exchange
should be with good solder ability and form ability, higher mechanical strength, good corrosion
resistance and thermal conductivity. In spite of these, aluminium and alloy are also featured in
extension and higher tensile strength increases under lower temperature. Around all world,
especially for low temperature and compact heat exchange, they are widely applied.

20
 Features of Aluminium

1. Low Density:

Aluminium is a very light metal with a specific weight of 2.7 g/cm3, about a third of
that of steel. This cuts the costs of manufacturing with aluminium. By alloying and
heat treatment, it can reach the structural of construction steel. Suitable for various
transportation, especially for small vehicle, reducing weight and consumption.

2. Good Corrosion Resistance:

When under harsh conditions, the materials oxide from aluminium is non-toxic. With
aluminium heat exchange, no worries that air or liquid inside will be destructed by oxide
after long time. In general, aluminium alloys are less corrosion-resistant than pure
aluminium, except for marine magnesium-aluminium alloys. Different types of surface
treatment such as anodising, painting or lacquering can further improve this property.

3. Good Thermal Conductivity:

Aluminium is an excellent heat and electricity conductor and in relation to its weight is
almost twice as good a conductor as copper. This has made aluminium the first choice
for major power transmission lines. It is also a superb heat sink for many applications
that require heat to be drained away rapidly, such as in computer motherboards and
LED lights. Especially suitable for radiating fin, heat transfer evaporator and condenser.

4. Recyclability:

Aluminium is 100% recyclable and recycled aluminium is identical to the virgin

product. This makes it a much more cost-effective source material for production runs.
The re-melting of aluminium requires little energy: only about 5% of the energy
required to produce the primary metal initially is needed in the recycling process.

21
2.1.3 Surface optimization of Plate-Fin surface

A proper selection of surface is one of the most important considerations in plate-fin heat
exchanger design. There is no such thing as surface that is best for all applications. The
particular application strongly influences the selection of the surface to be used. The objective
of the system in which the heat exchanger is to be used also influences the surface selection.
Both qualitative and quantitative considerations will be presented for surface selection. The
selection method, in the present study, is based on the Performance Evaluation Criteria (PEC)
of Webb (1981). The qualitative considerations for surface selection are the operating
temperatures, pressure, fluid contamination, cost, maintenance, and ruggedness. The problem
of heat exchanger design is very intricate. Because of a large number of qualitative judgments,
trade-offs and compromises, the heat exchanger design is more of an art at this stage.
As the practical demand of plate fin heat exchanger has increased experimental studies, have
been made by London and Shah in 1967 they been brought to a conclusion that small offset
spacing (length/dh), fin thickness and a large number of fins per inch gives better heat transfer.
In an another paper from Peng et al. in 2014, they investigated the flow and heat transfer
characteristics of an innovative offset strip fin both experimentally and numerically in the
Reynolds Number range of 500–5000. Results showed the dependence of fin length, fin pitch
and fin is the bent distance on the performance of the compact heat exchanger (CHE) and how
these results could directly be used to design CHEs’. Due to increasing demand of plate fin
heat exchanger in industry and research work every user is interested in high efficient plate fin
heat exchanger and this objective can be achieved with different approaches.
Fins used in a plate-fin heat exchangers exchanger are categorized as follows:
(1) plain (uncut surfaces) and straight fins;
(2) plain but wavy fins;
(3) interrupted fins such as strip, louver and perforated fins.
The increase in number of fins and decreasing the thickness to very small, as infinite small
thickness is not possible so it is chosen in such a way that it doesn’t affects the required strength
of fin as well, this enhances the total surface in contact and thus increases effective heat transfer
and hence effectiveness.

22
2.2 Methods of enhancing heat transfer
Heat transfer enhancement is the process of increasing the effectiveness of heat exchangers.
This can be achieved when the heat transfer power of a given device is increased or when the
pressure losses generated by the device are reduced. A variety of techniques can be applied to
this effect, including generating strong secondary flows or increasing boundary
layer turbulence.

In order to enhance the performance of the heat exchanger, the term, must be increased.

For achieving a reduced thermal resistance, the enhanced surface geometry may be used to

increase one or both terms in relation to the plain surfaces, leading to a reduced thermal

resistance per unit tube length, This reduced term may be used to achieve one of the

following three objectives:

1. Size reduction. maintaining the heat exchange rate (Q) constant, the length of the heat
exchanger may be reduced, providing a heat exchanger of smaller proportions.

2. Increased (UA).

 Reduced (Δtm): maintaining both (Q) and the length constant, Δtm can be reduced
increasing thermodynamic process efficiency leading to reduced operation costs.

 Increased heat exchange: Increasing and keeping a constant length will lead to an

increased (Q) for fixed fluid inlet temperature.

3. Reduced pumping power for fixed heat duty. This will require smaller velocities of operation
than the plain surface and a normally not desired, increased frontal area.

Depending on the objectives for the design, any of the three different performance
improvements can be used on an enhanced surface, and using any of the three mentioned
performance improvements it is fully possible to accomplish it.

Heat transfer enhancement, augmentation deals with the improvement of thermo-hydraulic

performance of heat exchangers. Different enhancements techniques have been broadly
classified as passive, active and compound techniques.

23
2.2.1 Active method
The active method involves external power input for the enhancement in heat transfer; for
examples it includes mechanical aids and the use of a magnetic field to disturb the light seeded
particles in a flowing stream, etc.

2.2.2 Passive Method

The Passive heat transfer augmentation methods does not need any external power input. In
the convective heat transfer one of the ways to enhance heat transfer rate is to increase the
effective surface area and residence time of the heat transfer fluids. By Using this technique
causes the swirl in the bulk of the fluids and disturbs the actual boundary layers which increase
effective surface area, residence time and simultaneously heat transfer coefficient increases in
an existing system. Following methods are generally used as Inserts, Extended surfaces,
Surface Modification, Use of Additives.

2.2.3 Compound Method

When any two or more techniques i.e. passive and active may be employed simultaneously to
enhance the heat transfer of any device, which is greater than that of produced by any of those
techniques separately, the term known as Compound enhancement technique.

2.3 Selection of Optimum Fin Type

Figure 12: Steady State Thermal Analysis Figure 13: Steady State Thermal Analysis
of Circular Fins of Square fins

24
 Figure 14: Steady State Thermal Analysis of Rectangular Fins

Figure 15: Temperature Graph of various Fin Shapes

After designing the fins and doing thermal analysis for equal volume of fin material, it is very
clear from the chart above and table below that the temperature difference is maximum in
case of rectangular fin and which means that the temperature gradient and hence, heat
transfer is maximum in case of rectangular fins.

Figure 16: Rectangular cross section of annular fin

25
Thus, the fin of rectangular cross section is considered to be the optimum fin for heat transfer
in heat exchangers.

Table 2: Comparison of Temperatures of various fin configurations

FIN MAXIMUM MINIMUM TEMPERATURE

CONFIGURATION TEMPERATURE TEMPERATURE DIFFERENCE

CIRCULAR 200°C 166.34°C 33.66°C

SQUARE 200°C 162.46°C 37.54°C

RECTANGULAR 200°C 155.62°C 44.38°C

26
 CHAPTER-3

DESIGN AND FABRICATION OF DOUBLE PIPE HEAT EXCHANGER

3.1 DESIGN AND CALCULATIONS

3.1.1 Input Parameters:

• Length of unfinned pipe = 1.5m

• Spacing between fins = 8-10 mm, for fins of thickness 0.5 to 1 mm and height of 1
acm.

• The above is selected to have considerable difference between the observed values
aof the two Heat Exchangers (i.e., Finned and Unfinned).

3.1.2 Design Parameters:

• Total distance between point on one fin to the adjacent point on the other fin is
aa(m=8) mm (approx.)

• Length of unfinned pipe (L) = 1.5m

• 750 mm of each finned pipe was joined to make one, for uniformity of analysis.

• Total number of fins (n) = L/m = 1500/8 = 187.5 ≅ (200) fins.

• Thus, n = 200.

27
3.2 CAD model of Heat Exchanger

Figure 17: 3D Model of Heat Exchanger

Figure 18: Base Structure

28
 Figure 19: Finned Pipe

Figure 20: Shell

Figure 21: Unfinned Pipe

29
 Figure 22: Valve

Figure 23: Connecting Pipe

30
3.3 Fabrication of Heat Exchanger
 Selecting the pipe and shell of designed length and material.
 Inner pipes into the shells.
 Fitting Valves & Nozzles.
 Attaching temperature sensors at terminals & display screen.
 Motor pump connections to valves via PVC pipes.
 Immersion rod placed into a tank for supply of hot water.
 Interconnection & fixing of all the materials.
 Leakage protection.

3.3.1 Components Used

Table 3 – List of Components Used

OBJECT MATERIAL PROPERTY

1. INNER PIPE MS 1.5 m Long

2. FINS ALUMINIUM 1 mm Thickness

3. SHELL PVC 0.18 W/mK

4. MOTOR PUMPS ABS 8 L/min flow rate

5. TEMPERATURE SENSORS Nickel Degree Celsius

6. HOT WATER TANK PVC 10 L (min)

7. IMMERSION HEATER NICHROME 1500W

8. VALVES BRASS 250 psi

31
1. Finned Pipe: A fin tube is a tube that has small fins around the outside surface. These fins
act as a filter and a mechanism to transfer heat from the material inside the tube to the outside
space or vice versa. A fin tube exchanger can be used as an industrial heat exchanger also.

Figure 24: Finned and Unfinned Pipe

2. Fins: The Fin is a major component used in many systems for increasing the rate of heat
transfer. In order to cool the system, fins are provided on the surface of the system to increase
the rate of heat transfer.

Figure 25: Aluminium Fins

3. PVC Pipe: Polyvinylchloride (PVC) has high hardness Traditional product PVC has a
maximum operating temperature around 140°F (60°C) when heat distortion begins to occur.
Thermal conductivity of PVC is 0.18 (W/mK).

32
 Figure 26: PVC Shell

4. Pump: A pump is a device that moves fluids (liquids or gases), or sometimes slurries, by
mechanical action.

Figure 27: Water Pump

5. Temperature sensing element: A temperature sensor is a device, typically, a thermocouple

or RTD, that provides for temperature measurement through an electrical signal. A
thermocouple is made from two dissimilar metal wires. The wires are joined together at one
end to form a measuring (hot) junction. The other end, known as the reference (cold) junction,
is connected across an electronic measurement device (controller or digital indicator).

Figure 28: Temperature sensing element

33
6. Hot Water Tank: Hot Water Tank is used to store useful amount of hot water which is
utilised for flow water through the inner pipe.

Figure 29: Water Storage Tank

7. Heating Element: A heating element converts electrical energy into heat through the
process of Joule heating. Electric current through the element encounters resistance, resulting
in heating of the element.

Figure 30: Heating Rod

8. Valves: Brass Ball Valves for use in residential and light commercial applications. Typical
services include; Multi-purpose shut-off valve for use in domestic hot and cold water systems,
natural or bottled gas and compressed air systems. Valve pressure rating 250 psi/17.2 bar non-
shock cold working pressure, Maximum service temperature 250°F.

Figure 31: Valves

34
3.3.2 Fabrication Methodology

 The heat exchanger used in this project is of shell and tube type. It consists of a shell which
is made up of Polyvinylchloride (PVC). The thermal conductivity of PVC pipe is 0.18
W/mK.
 The tubes are finned type and made up of mild steel. This Heat Exchanger consists of two
mild steel tubes each having an internal diameter of 16mm. Fins made up of aluminium
which is a very good conductor of heat and finned mild steel tubes means more dissipation
of heat to the surrounding.
 The cold water is supposed to flow through the finned tubes and gains its heat from the hot
water in the PVC shell as it progresses through the tube.
 A total of four holes are drilled on the PVC pipe, two for inlet and two for outlet of hot and
cold water.
 The inlet and outlet of hot water are drilled at the opposite extreme ends of the PVC shell
and are at an angle of 90 degrees with each other.
 The hot and cold water inlets and outlets are separated from each other with the help of two
circular baffles, one in between the two inlets and one in between the two outlets.
 Rotameters is used to control the concerned water and a set of thermocouple is used for the
observation of initial and final temperature.

35
 CHAPTER 4

TESTING AND ANALYSIS

Measurement of Temperatures at the inlet and outlet of all pipes.

 Th 1 = Inlet temperature of hot water

 Th2 = Outlet temperature of hot water
 Tc1 = Inlet temperature of cold water
 Tc2 = Outlet temperature of cold water
 U = Overall heat transfer coefficient
 Ch = Specific heat of hot water
 Cc = Specific heat of cold water
 Au = Area of Inner pipe
 Af = Area of finned pipe
 mh = Mass flow rate of hot water
 mc = Mass flow rate of cold water
 Qact = Actual heat transfer
 Qmax = Maximum possible heat transfer

Figure 32: Dimensions of Finned Pipe in mm

36
ANALYSIS AND CALCULATIONS:

Figure 33: Counter Flow Heat exchanger Temperature diagram

37
For Unfinned Heat Exchanger: Counter Flow

Table No. 4: Unfinned Heat exchanger parameters

Flow Rate of water Hot (ºC) Cold (ºC)

mh mc Inlet Outlet Inlet Outlet

0.1 kg/s 0.133 kg/s 80 65 30 40

Th1 = 80 ºC Th2 = 65 ºC
Tc1 = 30 ºC Tc2 = 40 ºC
mh = 6 lpm mc = 8 lpm

mh = 0.1 kg/s mc = 0.133 kg/s

Au = 0.0895 m2 U = 500 w/m2k

LMTD (Өm) = ((Th1- Tc2) - ((Th2- Tc1)) / ln ((Th1- Tc2) / (Th2- Tc1))
Өm = (40-35) / ln (40/35)
Өm = 37.44 ºC

Qact = U*Au*Өm
= 500*0.0895*37.44
Qact = 1675.44 W
Qmax = mh*Ch (Th1 - Th2)
= 0.1*4.18*15
Qmax = 6270 W
Efficiency = 1675.44 / 6270
= 26.72 %

38
For Finned Heat Exchanger: Counter Flow

Table No. 5: Finned Heat exchanger parameters

Flow Rate of water Hot (ºC) Cold (ºC)

mh mc Inlet Outlet Inlet Outlet

0.1 kg/s 0.133 kg/s 80 55 30 55

Th1 = 80 ºC Th2 = 55 ºC
Tc1 = 30 ºC Tc2 = 55 ºC
mh = 6 lpm mc = 8 lpm

mh = 0.1 kg/s mc = 0.133 kg/s

Af = 0.467 m2 U = 500 w/m2k

LMTD (Өm) = ((Th1- Tc2) - ((Th2- Tc1)) / ln ((Th1- Tc2) / (Th2- Tc1))
Өm = 25 ºC

Qact = U*Af*Өm
= 500*0.467*25
Qact = 5837.5 W
Qmax = mCp (Th1 - Th2)
= 0.1*4.18*25
Qmax = 10450 W
Efficiency = 5837.5 / 10450
= 55.86 %

39
Thus, we observe that the temperature difference increases in case of Finned
as compared to finned, the heat transfer rate and thus efficiency increases
by more than 20% by adding fins to the heat exchanger pipe.

Comparison of effectiveness of two Heat Exchangers:

For Unfinned Heat Exchanger: -

Effectiveness = Qact / Qmax

There, Ch= mh*ch= 0.1*4.18= cmin
Cc = mc*cc= 0.133*4.18
E= Ch (Th1-Th2) / Cmin (Th1-Tc1)
E1 = 0.3
For Finned Heat Exchanger: -

Effectiveness, E2 = (Th1-Th2) / (Th1-Tc1)

E2 = 0.5
Thus, we observe hereby, that the effectiveness of the heat exchanger is
marginally increased after attaching the fins onto the surface of the heat
exchanger.

40
 CHAPTER 5

PROTOTYPE OF ACTUAL HEAT EXCHANGER

The picture below shows the developed prototype of Fins attached to pipe.

Figure 34: Actual prototype of Heat exchanger

CHAPTER 6

41
 RESULTS

Through the obtained results of testing and analysis it is observed that the efficiency
and effectiveness of a heat exchanger can be enhanced to a much greater extent by simply
increasing the overall heat transfer surface area.

The efficiency of heat exchanger should increase by at least 25-40% including losses as it
also depend on the fluid type and velocity of flow, while in our project it was nearly 25%.

42
 CHAPTER-7

FUTURE SCOPE

Since heat exchangers are widely used in every field it is necessary to find out different methods
to improve their efficiency and that too in minimum cost. Efficiency of heat exchanger depends
on various factors, heat transfer rate being one of them.

The use of Nano fluids can be considered important for the future of heat exchangers, but the
validity of such claims is questionable with the lack of validation. Extensive research still needs
to be conducted on Newtonian fluids before progression onto other fluids.
Carbon Nanotubes (CNT) has impressive electrical and thermal properties (thermal
conductivity of 3000-6000 W/m K), so it’s no wonder that CNT heat sinks and copper CNT
composites would be the future. Graphene(CNT) is another one of those carbon based
metamaterials that have captivated the minds of scientists.

Now-a-days the fin inserts are also incorporated to increase turbulence inside the tubes leading
to forced convection and thus increasing rate of heat transfer. For improving efficiency is
turbulence of fluid experienced in tubes. we have replaced the conventional heat exchanger
with a finned tube so as to increase the area of contact and in turn the heat flow rate is objective
of this project. These simple techniques can improve efficiency of heat exchanger drastically
with minimum cost, so there is chance to improve these techniques to get optimized results in
future.

43
 CHAPTER-8

CONCLUSION

This project deals with the fabrication and analysis of conventional and novel heat exchanger.
During the analysis we observed the fins of rectangular cross section to be most feasible for
heat transfer thus used fins of same cross section. It can be seen through analysis that the
efficiency is marginally enhanced but simply adding fins to the heat exchanger. The most
effective way to enhance the heat transfer on the air-side of a heat exchanger is to modify the
fin pattern and geometry by interrupting it periodically along the stream wise direction. A
double pipe heat exchanger will typically be either counter flow or parallel flow, Crossflow
just doesn’t work for a double pipe heat exchanger. So, here we used counter flow type heat
exchanger to get optimized result.
Aluminium already being good conductor of heat it accelerates heat transfer. Aluminium also
has many qualities like rustproof, antifouling, corrosion free, cheap and easily available makes
it very useful for heat exchanger, therefore we used aluminium fins in our project.
With the increasing demand of exhaustible resources, it is required to have the effective
utilization of the available resources, this is where a finned heat exchanger dominates an
unfinned one and helps enhancing the overall efficiency of industry by 4-5%. The efficiency
of heat exchanger should increase by at least 25-40% including losses as it also depends on the
fluid type and velocity of flow, while in our project it was nearly 25%. Thus, these have
substantial role and should be used in industries.

44
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 PLAGIARISM SCAN REPORT

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This work introduces a novel method that improves the thermal performance of a heat exchanger. These performances can
be in terms of effectiveness, efficiency, rate of work produced and optimization in energy consumption. As Heat transfer is
one of the most important processes in industrial and consumer products, therefore by reduction in heat loss or by
increasing the rate of heat exchange we can be increasing the efficiency of a medium scale industry by approximately 4-5%. In
our process, we have replaced the conventional heat exchanger with a finned tube so as to increase the area of contact and in
turn the heat flow rate. The most effective way to enhance the heat transfer on the air-side of a heat exchanger is to modify
the fin pattern and geometry by interrupting it periodically along the stream wise direction. A double pipe heat exchanger will
typically be either counter flow or parallel flow, here we used counter flow type heat exchanger to get optimized result. In our
process, we have replaced the conventional heat exchanger with a finned tube so as to increase the area of contact and in
turn the heat flow rate. Now-a-days the fin inserts are also incorporated to increase turbulence inside the tubes leading to
forced convection and thus increasing rate of heat transfer. Here, we should a have to perform experiments so as to analyse
the effectiveness of the fin that can be helpful in increasing the efficiency of the industry (if rate of flow of heat increases). In
this work we have initialized by making a finned tube model of a heat exchanger along with the conventional one. After
successful fabrication, we also performed practical experiment so as to do the further analysis. Through the analysis, it is
found that the heat flow rate via finned tube heat exchanger should be greater than that of the conventional one. Thus, with
increased effectiveness it has various application in the industrial plants or factories where hot fluid is to be transferred
through a proper medium. Radiators are also a finned tube heat exchanger that has important application in vehicles. All this
is we can say is, a finned tube heat exchanger has better efficiency when compared to that of conventional ones and also find
their vital role in various industrial plants in almost every manufacturing industry. KEYWORDS: Effectiveness, Efficiency, Fins,
Radiators.

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