Heat exchangers are widely employed in numerous industrial applications to serve the heat recovery and cooling purpose. This work reports a performance analysis of a tube in tube heat exchanger for different flow configuration under variable operating conditions. The experimental investigation was performed on a U-shaped double pipe heat exchanger set up whereas Commercial Computational Fluid Dynamics code FLUENT along with k-ε turbulence modeling scheme was implemented for the simulation study. The flow solution was achieved by implementing k-ε turbulence modeling scheme and the simulation findings were compared with the experimental results. The experimental findings were in good agreement with the simulation results. The counter-flow configuration was found to be 29.4% more effective than the co-current one at low fluid flow rate. Direct relationship between heat transfer rate and flow rate is observed while effectiveness and LMTD showed inverse relationship with it. The significance of inlet temperature of hot and cold stream has been evaluated, they play crucial role in heat exchange process.

The disposal of ash in a thermal plant through the slurry pipe is subjected to some erosion wear due to the abrasive characteristics of the slurry. A simulation study of particle-liquid erosion of mild steel pipe wall based on CFD-FLUENT that considers the solid-liquid, solid-solid and solid-wall interaction is presented in this work.The multi-phase Euler-Lagrange model with standard k- ϵ turbulence modeling is adopted to predict the particulate erosion wear caused by the flow of bottom ash water suspension. Erosion rate for different particle size and concentration is evaluated at variable flow rate. It is observed that the pressure drop and erosion rate share direct relationships with flow velocity, particle size and concentration. The flow velocity is found to be the most influencing parameter. A model capable of predicting the erosion wear at variable operating conditions is presented.The simulation findings show good agreement with the published findings.