Failure Analysis of Heat Exchangers with a Valid CFD Simulation

Authors

  • Ádám Sass
    Affiliation
    KALL Ingredients Ltd., H-5211 Tiszapüspöki, 1 Fehértó part, Hungary
  • Alex Kummer
    Affiliation
    Department of Process Engineering, Faculty of Engineering, University of Pannonia, H-8200 Veszprém, 10 Egyetem Street, Hungary
  • Zsolt Ulbert
    Affiliation
    Department of Process Engineering, Faculty of Engineering, University of Pannonia, H-8200 Veszprém, 10 Egyetem Street, Hungary
  • Attila Egedy
    Affiliation
    Department of Process Engineering, Faculty of Engineering, University of Pannonia, H-8200 Veszprém, 10 Egyetem Street, Hungary
https://doi.org/10.3311/PPch.17095

Abstract

Energy efficiency, safety and stable operation of units are the most crucial aspects in every industrial process. In this study, Computational Fluid Dynamics (CFD) simulations were used to study heat transfer in a laboratory-sized tubular heat exchanger. A partly 2D axisymmetric and mainly 3D model of the heat exchanger was created and validated with several simulation in different operating points of heating capacity and volume flow. The results of the simulations were compared to experimental data to validate the model. The inlet and outlet temperatures were measured with Pt100 temperature probes, and the surface temperatures were measured with an infrared camera. The heat transfer coefficient was determined based on the surface measurements The validated model was applied for the investigation of performance losses of heat exchanger due to fouling caused by particle deposits along the tube which caused reduced heat transfer surface or performance and a failure of heating wire which caused reduced heating performance, hence altered heat and flow characteristics through the equipment. The results provide useful information not only in the design processes but the operational lifetime as well.

Keywords:

computational fluid dynamics, infrared camera, fouling, heating wire failure, performance analysis, validation

Citation data from Crossref and Scopus

Published Online

2021-08-26

How to Cite

Sass, Ádám, Kummer, A., Ulbert, Z., Egedy, A. “Failure Analysis of Heat Exchangers with a Valid CFD Simulation”, Periodica Polytechnica Chemical Engineering, 65(4), pp. 536–549, 2021. https://doi.org/10.3311/PPch.17095

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Articles