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Effect of wire coil inserts on heat transfer enhancement and fluid flow characteristics of a double-pipe heat exchanger

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Abstract

The need to reduce energy usage is one of the main issues with creating heat exchangers. This may be accomplished by increasing the heat transfer augmentation which results in the higher thermal performance factor (TPF). The aim of the present study is to experimentally determine the thermal hydraulic performance factor of DPHE with a novel wire coil insert. The experiments were performed in the range of Reynolds number (Re): 5500–15000, and the data were recorded for fifteen different combinations of wire coil (WC) inserts, including five different pitch ratios (P/Dc = 0.625, 1.25, 1.875, 2.5 and 3.125) and three wire diameters (d = 1, 1.5 and 2 mm). The application of WC inserts results in notable enhancement in heat transfer rate as compared to different TT. For the given range of Re, the heat transfer performance was improved to a maximum of 126.7% for pitch ratio (PR) P/Dc = 0.625 at wire diameter (d = 2 mm), while friction was recorded in the range of 2.67–4.71 times higher compared to PT. The TPF (η) with WC inserts for all combination was recorded greater than unity. The maximum value of TPF (η) obtained for wire coil inserts is 1.35 with PR (P/Dc = 0.625) and (d = 2 mm). Since TPF(η) in all cases is greater than 1.0 which shows that it is an effective approach.

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Abbreviations

A i :

Inner surface area of inner pipe (m2)

A o :

Outer surface area of inner pipe (m2)

ASHRAE:

American Society of Heating, Refrigeration and Air-conditioning Engineer

CPVC:

Chlorinated polyvinyl chloride

C p :

Specific heat capacity at constant pressure (J kg−1 K−1)

d i :

Inner copper pipe inner diameter (m)

d o :

Inner copper pipe outer diameter (m)

d :

Wire coil diameter

D c :

Coil diameter (m)

D i :

Outer CPVC pipe inner diameter (m)

D o :

Outer CPVC pipe outer diameter (m)

D h :

Hydraulic diameter (m)

f :

Friction factor (dimensionless)

\({f}_\text{t}\) :

Friction factor of the inner pipe with wire coil inserts (dimensionless)

f o :

Friction factor of the plain pipe (dimensionless)

\({h}_{{\text{i}}}\) :

Inner pipe average convective heat transfer coefficient (W m−2 K−1)

\({h}_{{\text{o}}}\) :

Outer pipe average convective heat transfer coefficient (W m−2  K−1)

\({h}_\text{p}\) :

Plain pipe average convective heat transfer coefficient (W m−2  K−1)

\({h}_\text{t}\) :

Average convective heat transfer coefficient of inner pipe with wire coil inserts (W/m−2 K−1)

\({k}_{{\text{i}}}\) :

Hot water thermal conductivity (W m−1 K−1)

\({k}_{{\text{p}}}\) :

Inner pipe material thermal conductivity (W m−1 K−1)

L :

Length of inner copper pipe (m)

\({{\text{Nu}}}_\text{o}\) :

Average Nusselt number of the plain tube (dimensionless)

\({{\text{Nu}}}_\text{t}\) :

Average Nusselt number of the inner tube with wire coil inserts (dimensionless)

P :

Pitch of the wire coil inserts

Pr:

Prandtl number

\({Q}_{{\text{h}}}\) :

Rate of heat transfer for the hot water in the inner tube (W)

\({Q}_{{\text{c}}}\) :

Rate of heat transfer for the cold water in the annulus tube (W)

\({Q}_{{\text{loss}}}\) :

Heat loss (W)

Re:

Reynolds number (dimensionless)

T b :

Mean bulk water temperature (K)

T c :

Cold water temperature (K)

T h :

Hot water temperature (K)

T w :

Mean wall temperature of inner pipe (K)

u :

Hot water velocity in the inner pipe (m s−1)

U i :

Overall heat transfer coefficient of inner pipe based on internal surface area (W m−2 K−1)

µ :

Dynamic viscosity of hot water (kg m−1 s−1)

ρ :

Mass density of hot water (kg m−3)

η :

Thermal performance factor (dimensionless)

ave:

Average

i:

Inlet

o:

Outlet

h:

Hot

c:

Cold

w:

Wall

b:

Bulk

\(\Delta P\) :

Difference in pressure between inlet and outlet of hot water (Pa)

\(\Delta {T}_{{\text{LMTD}}}\) :

Logarithmic mean temperature difference (K)

TT:

Twisted tape

TPF:

Thermal performance factor

NTU:

Number of transfer unit

WC:

Wire coil

PR:

Pitch ratio

VC:

Volume concentration

DPHE:

Double-pipe heat exchanger

HT:

Heat transfer

D-HST:

Double-helical screw tape

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Authors and Affiliations

  1. Department of Mechanical Engineering, Maulana Azad National Institute of Technology, Bhopal, Madhya Pradesh, 462003, India

    Brajesh Kumar Ahirwar & Arvind Kumar

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  1. Brajesh Kumar Ahirwar
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  2. Arvind Kumar
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Correspondence to Brajesh Kumar Ahirwar.

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Appendix: Uncertainty analysis

Appendix: Uncertainty analysis

The error has been calculated based on the sensitivity and the least count of the instruments used in this experiment.

Heat transfer coefficient

$$\left(\frac{\Delta h}{h}\right)= \sqrt{{\left(\frac{\Delta m}{m}\right)}^{2}+{\left(\frac{\Delta {T}_{\text{o}}}{{T}_{\text{o}}}\right)}^{2}+{\left(\frac{\Delta {T}_{\text{i}}}{{T}_{\text{i}}}\right)}^{2}+{\left(\frac{\Delta {T}_{\text{h}}}{{T}_{\text{h}}}\right)}^{2}}$$

Heat flux

$$\left(\frac{\Delta q}{q}\right)= \sqrt{{\left(\frac{\Delta I}{I}\right)}^{2}+{\left(\frac{\Delta V}{V}\right)}^{2}+{\left(\frac{\Delta L}{L}\right)}^{2}+{\left(\frac{\Delta D}{D}\right)}^{2}}$$

Nusselt number

$$\left(\frac{\Delta Nu}{Nu}\right)= \sqrt{{\left(\frac{\Delta h}{h}\right)}^{2}+{\left(\frac{\Delta D}{D}\right)}^{2}}$$

Reynolds number

$$\left(\frac{\Delta Re}{Re}\right)= \sqrt{{\left(\frac{\Delta m}{m}\right)}^{2}+{\left(\frac{\Delta D}{D}\right)}^{2}}$$

Friction factor

$$\left(\frac{\Delta f}{f}\right)= \sqrt{{\left(\frac{\Delta \left(\Delta p\right)}{\Delta p}\right)}^{2}+{\left(\frac{\Delta L}{L}\right)}^{2}+{\left(\frac{2\Delta Re}{Re}\right)}^{2}+{\left(\frac{3\Delta D}{D}\right)}^{2}}$$

Thermal performance factor

$$\left(\frac{3\Delta \eta}{\eta}\right)= \sqrt{{\left(\frac{3\Delta Nu}{Nu}\right)}^{2}+{\left(\frac{3\Delta {Nu}_{\text{o}}}{{Nu}_{\text{o}}}\right)}^{2}+{\left(\frac{\Delta f}{f}\right)}^{2}+{\left(\frac{{f}_{\text{o}}}{{f}_{\text{o}}}\right)}^{2}}$$

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Ahirwar, B.K., Kumar, A. Effect of wire coil inserts on heat transfer enhancement and fluid flow characteristics of a double-pipe heat exchanger. J Therm Anal Calorim 149, 3027–3042 (2024). https://doi.org/10.1007/s10973-024-12889-z

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