Course No: EEE 308: Electronic Properties of Materials

Section No: 1
Assignment

Cross flow heat exchanger using COMSOL

Date of Submission: 21 August 2023

Table of Contents
1. O BJECTIVE 1-2

2. S IMULATION PARAMETER TABLE 2-3

2.1 P ARAMETERS FROM COMSOL 2-3

3. P HYSICS 3

4. S IMULATED FIGURES 4-6

5. ANALYSIS 6

6. C ONCLUSION 6

7. R EFERENCES 6
 1. Objective
In this study I have used a computer program called COMSOL to make a model of a heat exchanger. A
cross flow heat exchanger is a heat exchanger used to transfer heat between two fluid streams that flow
perpendicular to each other. The device has many tubes that are twisted and not covered by anything. One
fluid flow across the tubes and another fluid flows inside the tubes. The computer program can predict
how the temperature changes in the device. The computer program can also show how the heat moves
from one fluid to another through the tubes. They are used in heat recovery systems to catch excess heat
from one system and deliver it to another. These types of heat exchangers are widely used in process
industries, such as food processing, refineries, and chemical plants.
The assignment will address the following course outcomes (CO):
1. CO3: Compare different materials and select the most appropriate one for a specific electrical
engineering application.
2. CO4: Demonstrate the capacity to extend learning beyond classroom lectures and activities.
I have compared two different materials which are Copper and Aluminum based on their thermal
conductivity, specific heat, density and corrosion resistance and found out appropriate one for cross flow
heat exchanger. Moreover, I will learn and use a new simulation platform for this assignment. So, these
activities will be helpful to address both course outcomes.

XY- View

YZ- View
Figure1: 3D representation of the geometry and the boundary conditions of a heat transfer device on
COMSOL

The model (Figure1) is created by using COMSOL Multiphysics. The model uses the Heat Transfer in
Solids interface to model conduction and convection in the solid domains, and the Laminar Flow interface
to model the fluid flow in the fluid domains. The model also uses different types of boundary conditions,
such as inlet, outlet, wall, symmetry, and insulation, to define the behavior of the heat exchanger.

2. Simulation parameter table

Temperature of Hot fluid flow, Th 330K
Temperature of Cold fluid flow, Tc 300K

Velocity of fluid flow, U1 0.5m/s

Used materials Aluminum and Copper

2.1 Parameters from COMSOL:

Material Contents of Aluminum (Used in COMSOL)

Material Contents of Copper (Used in COMSOL)

 3. Physics

Every substance has its own capacity to conduct heat. The thermal conductivity of a material is described
by the following formula:

K = (QL)/(AΔT)

Here,

 K is the thermal conductivity in W/m.K

 Q is the amount of heat transferred through the material in Joules/second or Watts
 L is the length of the piece of material
 A is the area of the surface in square meters
 ΔT is the difference in temperature in Kelvin

High thermal conductivity means the ability of a material to move heat quickly and efficiently. Materials
with high thermal conductivity can transfer heat rapidly from one location to another. They are used in
applications where fast heat transfer is important, such as in heat exchangers.

Again, the heat capacity of the metal affects the performance of the heat exchanger by influencing the
temperature difference between the fluids. A higher heat capacity means that the metal can store more
heat and maintain a higher temperature difference, which improves the heat transfer rate.

4. Simulated figures
Figure2: temperature distribution graph of cross flow heat exchanger Aluminum(left) and Copper(right).

Figure3: Changes of temperature with the increasing distance on Y-axis

Figure3: Isosurface temperature distribution graph of cross flow heat exchanger Aluminum(left) and
Copper(right).

Figure4: Velocity magnitude of fluid, Aluminum(left) and Copper(right)

Figure5: pressure distribution, Aluminum(left) and Copper(right)

5. Analysis
All the simulation graphs are almost similar for Aluminum and Copper. But the difference will be on heat
transfer rate. Copper will transfer heat faster and more efficiently than Aluminum. In figure1, Copper
transfer slightly more heat than Aluminum.
The equation for heat transfer rate, Q/t = kA∆T/d;
Here we can see, heat transfer rate(Q/t) is proportional to thermal conductivity(k). Lastly, if we want to
evaluate overall performance of a cross flow heat exchanger, we need to consider thermal conductivity,
corrosion resistance, Cost etc. during selection of metal. Copper is more corrosion resistant than
Aluminum, but Aluminum is low in cost for its low density.

6. Conclusion
In this assignment I have compared two different metals for cross flow heat exchanger on COMSOL
Multiphysics platform by simulating different graphs. Being familiar with COMSOL through this
assignment will be beneficial.

R EFERENCES
1. https://www.xometry.com/resources/materials/thermal-conductivity/
2. https://openstax.org/books/university-physics-volume-2/