International Journal of Applied Engineering

Research and Development (IJAERD)

ISSN(P): 2250-1584 ISSN(E): 2278-9383
Vol. 4, Issue 6, Dec 2014, 1-10
TJPRC Pvt. Ltd.

ANALYSIS OF A CROSS FLOW HEAT EXCHANGER USING OPTIMIZATION

TECHNIQUES
SUBODH JAKKULA1 & G. SRINIVASA SHARMA2
1
2

Programmer Analyst, Cognizant Technology Solutions, Hyderabad, Telangana, India

Associate Professor, Department of Mechanical Engineering, MVSREC, Nadergul, Hyderabad, Telangana, India

ABSTRACT
Heat Exchangers are used mostly in process and heat recovery systems to exchange heat between hot and cold
fluids. The general design procedures streamlined and laid into practice from long time, but optimization and effective
utilization of surface area of Heat exchanger is always a challenging task for design and process engineers. In this paper, an
attempt is made to simulate the process parameters, and obtaining best feasible solution using multi-objective function.
This paper provides applicable based genetic algorithm for minimization of outlet temperature of hot fluid and
maximization of effectiveness of a cross flow heat exchanger. A Matlab code is developed for Optimization of operating
parameters of cross flow heat exchanger. The temperature and flow profiles at various sections are simulated using Ansys
Fluent.

KEYWORDS: NTU, THi, THo, TCi

Terminology
NTU= Number of Transfer units.
Effectiveness (), CR=Ratio of heat capacities of two fluids.
THi= Temperature of hot fluid at inlet.
THo= Temperature of Hot fluid at outlet.
TCi=Temperature of cold fluid at inlet.
TCo=Temperature of cold fluid at Outlet.
= Mass flow rate of hot fluid, kg/sec
= Mass flow rate of cold fluid, kg/sec
Ch= Heat capacity of hot fluid
Cc= Heat capacity of cold fluid
CR= Cc/Ch or Ch/Cc;
U=Overall Heat transfer coefficient. W/m2K
As= Surface Area. m2

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Subodh Jakkula & G. Srinivasa Sharma

INTRODUCTION
Heat exchangers are devices where two moving fluid streams exchange heat without mixing. Heat exchangers
may be classified according to transfer process, construction, flow arrangement, surface compactness, number of fluids and
heat transfer mechanisms or according to process functions. A cross flow type of heat exchanger in which fluids do not mix
with each other, basically consists of a stack of plates through which a certain number of tubes are placed perpendicularly.
A hot fluid is sent through the tubes whereas a cold fluid is made to flow outside the tubes, through the gaps between the
plates. Heat is transferred from the hot fluid to the cold one. Under steady operation, the mass flow rate of each fluid
stream flowing through a heat exchanger remains constant. w = 0, ke = 0, PE = 0. Heat exchangers are intended for heat
transfer between two fluids within the device. Usually, the entire heat exchanger is selected as the control volume and Q
becomes zero.

EXISTING ANALYTICAL APPROACHES AND PROBLEM STATEMENT

Known mass flow rates and temperatures of the fluids, the surface area is obtained by LMTD
(Log Mean temperature Difference Method), in which at least three temperatures are to be known and 4th temperature is
obtained by energy balance.

Steady State Fluid Flow Equation (Mass Flow Rate Balance):

Energy Balance:

Heat Transfer:

= U*As*LMTD* F (F= correction Factor)

LMTD =
Surface Area of the cross flow Heat exchanger is given by As=

Figure 1: Temperature Distribution in a Cross Flow Heat Exchanger

Actual scenario demands the following:

Case 1: The Heat exchanger working fluids are to be selected, with known outlet temperatures.

Case 2: The Outlet temperatures of both fluids are to be estimated with selected hot and cold fluids.

Impact Factor (JCC): 1.6842

Index Copernicus Value (ICV): 3.0

Analysis of a Cross Flow Heat Exchanger Using Optimization Techniques

Case 3: The Outlet temperatures and mass flow rates are to be estimated for selected fluids at maximum
effectiveness.

Case 4: The outlet Temperatures and mass flow rates are to be estimated for selected fluids at maximum
effectiveness, minimum surface area, minimum Outlet temperature of hot fluid outlet Temperature.
Case 1 and case 2 can be addressed from stand point of standard design procedures, where as case3 and case 4

involves arriving at a decision point by optimization of single objective function and multi-objective function. Hence, there
is a need to address this design procedure with Meta heuristic Algorithms such as genetic Algorithms.

OPTIMIZATION USING GENETIC ALGORTIHM

"A genetic Algorithm is an iterative procedure maintaining a population of structures that are candidate solutions
to specific domain challenges. During each temporal increment (called a generation), the structures in the current
population are rated for their effectiveness as domain solutions, and on the basis of these evaluations, a new population of
candidate solutions is formed using specific genetic operators such as reproduction, crossover, and mutation. Simulation
Optimization can efficiently handle a much larger number of scenarios than traditional optimization approaches, as well as
multiple sources and types of risk. Modern simulation optimization tools are designed to solve optimization problems of
the form: Minimize F(x)

(Objective function)

Subject to: Ax < b (Constraints on input variables)

(1)

gl < G(x) < gu (Constraints on output measures)

(2)

l< x < u

(3)

(Bounds)

Where the vector x of decision variables includes variables that range over continuous values and variables that
only take on discrete values (both integer values and values with arbitrary step sizes).The objective function F(x) is,
typically, highly complex. On the basis of both current and past evaluations, the method decides upon a new set of input
values.

IMPLEMENTATION PROCEDURE

Create Initial population using Random Number generators.

o

Mass flow rate of hot fluid and cold fluid are generated.

Specific heats of fluids are given as inputs.

Objective function is effectiveness of the heat exchanger which is ratio of actual Heat Transfer to maximum
possible Heat Transfer.
o

As per standard references ( Kays and London), the effectiveness of Heat exchanger in terms of U,As, Heat
Capacities and NTU are expressed as
o

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U= Over all Heat Transfer coefficient =

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Subodh Jakkula & G. Srinivasa Sharma

As = Surface Area

NTU=

CR=

[Note: Cmin = minimum of mhCh and mcCc].

Total Heat Transfer Rate,

Outlet temperatures of hot fluid and cold fluid are:

THo = THi+

TCo = TCi-

Hence outlet temperature is a function of THo=f(THi,NTU,CR,TCi).

MATHEMATICAL FORMULATION
The mathematical formulation of the tube fin heat exchanger is as follows.
Maximize: , effectiveness
Tho > Tco
Thi > Tci
0

Tho

SIMULATION
The Data for simulation is taken from Applied Thermodynamics Laboratory, at MVSREC, Hyderabad and
applied to developed Matlab code for implementation of Genetic Algorithm.
Table 1: Test Data Table: for Input Values to Code
Working Fluid
Air
Water

Impact Factor (JCC): 1.6842

Inlet Temperatures
20 0c
800c

Heat Capacities
(KJ/Kgk)
1005
4186

Index Copernicus Value (ICV): 3.0

Analysis of a Cross Flow Heat Exchanger Using Optimization Techniques

Figure 2: Implementation of Simulation Using GA

ANSYS FLUENT ANALYSIS

The below shown geometry in figure 3 represents the 3D model of a tube fin heat exchanger considered in this
project. Analysis of the above figure in Ansys Fluent is a time taking and a tedious process. To avoid wastage of resources
and to save time, a 2D model has been considered and analysis has been performed on it.

Figure 3: 3d Model

Figure 4: 2d View

Figure 5: Meshed Geometry

TEST RESULTS AND ESTIMATION OF EFFECTIVENESS USING GENETIC ALGORITHM

The Genetic Algorithm is run with test case data of 50 initial population, cross over probability of 0.6 and
mutation probability of .75. Re-insertion with a generation gap of .9 per generation is adopted. The stopping criteria for
genetic algorithm is taken as number of generations and if number of incremental generations exceed the Max Generations,
then Genetic algorithm stops. The convergence criterion for single function optimization is indicated in the figure with
a maximum effectiveness of 0.686. Values obtained using genetic algorithm in MATLAB
Table 2
Effectiveness
0.50109
0.50173
0.50379
0.50382
0.50454
0.50866
0.5121
0.51272
0.51323
0.51332
0.51702
0.51786
0.52278
0.52366
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NTU
13284.7
13924.9
13927.9
12540.3
14410.6
13416.5
14392.6
12767.5
12819.1
14298.5
12951.4
15912.9
16101.9
13839.9

Tho
89.8694
89.792
89.5449
89.5419
89.4555
88.9604
88.5478
88.4737
88.4121
88.402
87.9574
87.857
87.267
87.1608

Tco
123.09
88.4452
82.4763
90.9408
89.2934
107.464
149.998
68.8984
110.762
149.808
100.785
70.8304
138.895
145.654

Effectiveness
0.59509
0.59537
0.59609
0.59699
0.59751
0.5986
0.59934
0.59958
0.6028
0.60383
0.60438
0.60514
0.60638
0.60694

NTU
27737.9
22280.7
25622.8
27528.7
22367.1
19691.3
19450.9
23813.4
24265.7
19515.2
25136.8
25798
28395.8
26001.4

Tho
78.5898
78.5551
78.4691
78.3611
78.2991
78.1677
78.0789
78.0506
77.6643
77.5401
77.4745
77.3827
77.2344
77.1671

Tco
108.151
149.847
149.78
149.816
100.969
122.396
57.6102
149.994
65.4191
89.6245
91.9554
81.91
150
136.072
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Subodh Jakkula & G. Srinivasa Sharma

0.52381
0.52535
0.53579
0.54176
0.54516
0.5503
0.55063
0.55435
0.556
0.55838
0.55922
0.56415
0.56536
0.56819
0.56847
0.57054
0.57096
0.57137
0.57255
0.5729
0.57304
0.57636
0.57696
0.5785
0.58027
0.58113
0.58574
0.58819
0.58837
0.58955
0.59129
0.59144
0.5939
0.59439
0.59471

14164.7
13466
18040.3
18159.9
15687
17899.4
14869.4
18270.4
17622.4
19099.3
17665.7
17337.4
19342.2
16277.3
21434.1
21956.2
19252.8
21733.1
17957.7
16440.8
23010.6
17344
19060.4
18562.5
22387.6
22276
26021.3
24099.8
21878
17808.3
20720.5
22036.1
19317.4
23273.7
22601.9

87.1434
86.9582
85.7057
84.9889
84.5804
83.9637
83.9249
83.4786
83.28
82.9948
82.8941
82.3014
82.1566
81.817
81.7832
81.5352
81.4849
81.4356
81.2938
81.2514
81.2357
80.8368
80.7647
80.5798
80.3675
80.2645
79.7112
79.4177
79.3956
79.2543
79.0457
79.0268
78.7319
78.6728
78.6345

Table 2: Contd,
90.5725
0.61026
87.0502
0.6103
129.261
0.61253
63.2544
0.61316
137.204
0.61718
77.6176
0.61767
146.853
0.6179
102.214
0.61797
64.3813
0.61803
127.103
0.6242
90.7036
0.6252
144.308
0.62615
108.935
0.62834
144.602
0.62845
150
0.62973
77.841
0.63045
148.668
0.63123
149.245
0.63142
149.91
0.63373
53.7405
0.63374
77.0398
0.63436
102.729
0.63591
122.449
0.63613
92.9981
0.6362
114.37
0.64027
148.892
0.64143
63.4588
0.64243
94.8342
0.64325
126.38
0.6437
72.792
0.64459
84.2264
0.64515
84.9114
0.64548
149.998
0.64587
68.9303
0.64634
90.798
0.6466

29579.9
24639.7
31261.7
27114.3
30987.6
29986.7
26985.5
20299.4
26578.8
34363.9
31840.6
33320.3
24500.9
24440.3
35130.8
26994.1
32082.8
32675.3
28386.1
29433.3
21258.6
28441
30006.5
37451.3
37429.2
33366.5
38070.3
34426.7
37535.7
28687.9
29628.9
39059.9
28389.8
34341.6
24510

76.7693
76.7645
76.4961
76.421
75.9386
75.8793
75.8523
75.843
75.8366
75.0957
74.9756
74.8619
74.5987
74.5858
74.4318
74.346
74.2521
74.23
73.9518
73.9512
73.8763
73.691
73.6643
73.6565
73.1672
73.029
72.9085
72.8104
72.7555
72.6488
72.5817
72.5423
72.4953
72.4395
72.4082

130.425
89.8676
139.996
70.061
112.956
88.712
150
124.266
137.587
144.495
64.3479
117.137
51.5333
141.755
132.014
68.5563
149.995
138.089
89.7049
132.209
58.3021
126.445
65.2274
86.5038
79.7051
98.1783
93.2025
108.582
101.103
134.748
69.9595
104.003
102.625
80.4911
128.771

ANSYS Results
The 2D model has been subjected to various temperatures and plots for velocity, turbulence, transfer of heat
energy have been plotted. Hot fluid inlet temperature 80oC. After testing the 2D model for various hot fluid inlet
temperatures of 353, 363, 373, 383 K, it is observed that the air outlet temperature has decreased initially and then
increased gradually along the curve length where as the velocity of the air initially increased and then decreased. The wall
boundary temperature does not remain constant along the curve length instead it varies irregularly because of the set heat
flux.
Inlet Temperature of Hot Fluid 80oC: The below figure shows the variation of temperatures as hot and cold
fluids flow through it. It is observed that the hot fluid enters at 353K. The cold fluid enters at 293K, gradually gets heated
to 311K. The velocity contour shows the variation of velocity as the hot and cold fluids flow through the system.
The maximum velocity of 131m/sec is observed. The pressure contour shows the variation in static pressure of the system
as the hot and cold fluids flow through it. It is observed that the pressure gradually decreases.

Impact Factor (JCC): 1.6842

Index Copernicus Value (ICV): 3.0

Analysis of a Cross Flow Heat Exchanger Using Optimization Techniques

Figure 6
Inlet temperature of Hot Fluid 90oC: The below figure shows the variation of temperatures as hot and cold
fluids flow through it. It is observed that the hot fluid enters at 363K. The cold fluid enters at 293K, gradually gets heated
to 302K. The velocity contour shows the variation of velocity as the hot and cold fluids flow through the system.
The maximum velocity of 131m/sec is observed. The pressure contour shows the variation in static pressure of the system
as the hot and cold fluids flow through it. It is observed that the pressure gradually decreases.

Figure 7
Inlet Temperature of Hot Fluid 100oC: The below figure shows the variation of temperatures as hot and cold
fluids flow through it. It is observed that the hot fluid enters at 373K. The cold fluid enters at 293K, gradually gets heated
to 309K. The velocity contour shows the variation of velocity as the hot and cold fluids flow through the system.
The maximum velocity of 131m/sec is observed. The pressure contour shows the variation in static pressure of the system
as the hot and cold fluids flow through it. It is observed that the pressure gradually decreases.

Figure 8
Inlet Temperature of Hot Fluid 110oC: The below figure shows the variation of temperatures as hot and cold
fluids flow through it. It is observed that the hot fluid enters at 383K. The cold fluid enters at 293K, gradually gets heated
to 309K. The velocity contour shows the variation of velocity as the hot and cold fluids flow through the system.
The maximum velocity of 163m/sec is observed. The pressure contour shows the variation in static pressure of the system
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Subodh Jakkula & G. Srinivasa Sharma

as the hot and cold fluids flow through it. It is observed that the pressure gradually decreases.

Figure 9
Similarly, another 2D model of a plate fin heat exchanger which consists of a tube passage in be at the centre is
created and analysis is done using the same procedure. The velocity contour shows the variation of velocity as the hot and
cold fluids flow through the system. The velocity increases initially and gradually decreases. The maximum velocity of
281m/sec is observed. The pressure contour shows the variation in static pressure of the system as the hot and cold fluids
flow through it. It is observed that the pressure gradually decreases.

Figure 10

CONCLUSIONS
In the present paper, investigation of temperature distribution is carried out and optimization technique is applied
to cross flow heat exchanger and observed that effectiveness is maximized with optimum mass flow rate and temperature
at inlet and outlet are obtained. With the obtained inlet and outlet temperature, temperature distribution in cross flow heat
exchanger at various locations is obtained using ANSYS Fluent 13. The distribution of temperature is presented as contour
plot. The observations are satisfactory with the literature quoted in the references.

REFERENCES
1.

Mr. G. Srinivas Sharma and Ms. Aripala Lakshmi Kameswari, Optimization of process parameters of a shell and
tube Heat Exchanger using Genetic Algortihms, ICMS 2012

2.

Balas, E, (1998), Optimized Crossover-Based Genetic Algorithms for the Maximum Cardinality and Maximum
Weight Clique Problems, Journal of Heuristics, Vol. 4, pp.107-122.

3.

Advances in Industrial Heat Exchangers, HEE96, Institution of Chemical Engineers, London, 1996.ASME Boiler
and Pressure Vessel Code, Sec. VIII, Div.

4.

Rules for Construction of Pressure Vessels, American Society of Mechanical Engineers, New York, 1998.

Impact Factor (JCC): 1.6842

Index Copernicus Value (ICV): 3.0

Analysis of a Cross Flow Heat Exchanger Using Optimization Techniques

5.

Effectiveness Ntu Relationships for Design and Performance Evaluation of Multi-pass Cross flow Heat
Exchangers, Engineering Sciences Data Unit Item 87020, ESDU International, McLean, VA, October 1987.

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Standard of the Tubular Exchanger Manufacturers Association, 8th edn, TEMA, New York, 1999.

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M. Yilmaz, O.N. Sara, Performance evaluation criteria for heat exchanger based on second law analysis, Exergy.
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8.

A. Bejan, Entropy Generation through Heat & Fluid flow, Wiley, New York, 1982. 4. A. Bejan, Entropy
Generation Minimization, CRC Press, New York, 1995.

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J.V.C. Vargas, A. Bejan, D. L. Siems, Integrative thermodynamic optimization of the cross flow heat exchanger
for an aircraft environmental control system, Transaction of the ASME 123(2001) 760-769.

10. T. Kuppan, Heat Exchanger Design Handbook, New York, 2000.

11. .R.K. Shah, Fundamental of Heat Exchanger Designing, John Wiley & Sons. USA, 2003, pp. 735-804.
12. Antonio C. Caputo, Pacifico M. Peallagge, Heat exchanger design based on economic optimization, Applied
thermal engineering 28 (2008) 1151- 1155.

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