Conjugate Heat Transfer Analysis for a Heat Exchanger

The Client:

A company involved into Design and Manufacturing of Heat Exchangers


To simulate the cross flow conditions for a heat exchanger using CFD Analysis and estimate the heat transfer parameters with consideration of the tube materials.

Client Expectations:

Client expected us to simulate various heat transfer parameters using CFD Analysis for the cross flow arrangement such as heat flux, temperature distribution etc for fluid and the tube materials. The hidden expectations (client needs) were to develop an accurate CFD model for CFD Analysis, to select appropriate boundary conditions and define them in the CFD environment.

CFD Analysis Project Challenges:

Conjugate Heat Transfer refers to the combination of heat transfer in fluids and in solids. It is also known as CHT problem in the CFD Analysis jargon and considered to be a complex CFD Analysis problem to solve. Getting the input data for the CFD Analysis and setting up valid boundary conditions were the biggest challenges for this project. Our CFD experts had to refer a lot of literature available on CFD Analysis for Conjugate Heat Transfer. Our CFD analyst had to make sure to scrutinize many models to define the CFD Analysis problem properly. Our CFD consultant had to verify the results with logical reasoning by referring and comparing the CFD Analysis results to the classical Fluid Dynamics results for a simplified CFD Analysis model.

CFD Analysis Project Deliverables:

CFD Analysis results provided the requisite information such as Temperature distribution, heat flux for various cases for the cross flow heat exchanger arrangement. This helped us client to further design and estimate the capacity of the heat exchanger. CFD Analysis results were embedded in the form of a well written CFD report which included the CFD results data in the form of tables and pictures.




CFD Analysis to predict Conjugate Heat Transfer for a Heat Exchanger

CFD Analysis Project Benefits:

The project saved the client overall of 8000 USD which includes the manpower and Testing resources required. In addition to the cost, CFD Analysis also helped the client to understand the flow characteristic and heat transfer characteristic of the heat transfer without developing a prototype. The use of CFD Analysis for predicting the Conjugate Heat Transfer phenomenon resulted in reduced Time to Market for the Heat Exchanger. The CFD Analysis project for Conjugate Heat Transfer also imparted a lot of learning to our CFD Analysis project team. Our CFD consultant could develop the best practices to conduct the CFD Analysis for Conjugate Heat Transfer problems.

CFD Analysis Project Hours:

  • CFD Analysis Model Preparation: 20 Hours
  • CFD Analysis Solving Time: 25 Hours
  • CFD Analysis Results Discussion: 4 Hours
  • CFD report preparation: 2 Hours

CFD Analysis Project Duration:

  • 8 days

CFD Analysis Project Team:

  • CFD Analyst
  • CFD Consultant
  • CFD Analysis Lead

Customer Delight Experience:

The client expected us to complete the CFD Analysis project within 15 working days which we delivered in 8 working days. Our CFD experts examined the project both from domain and CFD Analysis aspects. Our CFD analyst had referred a lot of literature for Conjugate Heat Transfer problem and incorporated the learning into the CFD Analysis report. Our CFD Consultant conducted a critical assessment of the CFD Analysis report and provided his feedback to include as recommendation for design to the client. The methodical approach to conduct the CFD Analysis was appreciated by the client.

Heat Exchanger Market Insights:

As indicative by the graph below, the global uptrend in the demand for Heat Exchangers suggest the requirements for new products in the heat exchanger domain. There may be challenges pertaining to the material of construction, standards to be referred (TEMA, ASME etc.) but the major aspect is the efficiency of the Heat Exchanger. In predicting or studying the efficiency even without building the heat exchanger, CFD Analysis proves to be a very much useful tool since using CFD Analysis results, design scrutiny can be done.

Heat Exchanger market in food & beverage industry

Similar Areas where CFD Analysis can be useful:

  • Conjugate Heat Transfer using CFD Analysis for Exhaust Manifold
  • Conjugate Heat Transfer using CFD Analysis for Radiators
  • Conjugate Heat Transfer using CFD Analysis for Evaporators
  • Conjugate Heat Transfer using CFD Analysis for Boilers
  • Conjugate Heat Transfer using CFD Analysis for Condensers
  • Conjugate Heat Transfer using CFD Analysis for Industrial Valves
  • Conjugate Heat Transfer using CFD Analysis for Cooling Tower
  • Conjugate Heat Transfer using CFD Analysis for Tanks
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