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Research Papers

Heat Transfer and Fluid Flow Characteristics in a Heat Exchanger Tube Fitted With Inserts

[+] Author and Article Information
Alaa E. Mahfouz

Mechanical Power Engineering Department,
Cairo University,
Giza 12613, Egypt
e-mail: eng_alaaomar2008@yahoo.com

Waleed A. Abdelmaksoud

Mechanical Power Engineering Department,
Cairo University,
Giza 12613, Egypt
e-mail: wamarouf@cu.edu.eg

Essam E. Khalil

Professor
Fellow ASME
Mechanical Power Engineering Department,
Cairo University,
Giza 12613, Egypt
e-mail: khalile1@asme.org

1Corresponding author.

Contributed by the Heat Transfer Division of ASME for publication in the JOURNAL OF THERMAL SCIENCE AND ENGINEERING APPLICATIONS. Manuscript received May 24, 2017; final manuscript received October 12, 2017; published online March 28, 2018. Assoc. Editor: Amir Jokar.

J. Thermal Sci. Eng. Appl 10(3), 031012 (Mar 28, 2018) (12 pages) Paper No: TSEA-17-1175; doi: 10.1115/1.4038707 History: Received May 24, 2017; Revised October 12, 2017

The aim of this study is to simulate and analyze the heat transfer and fluid flow characteristics for a tube of a heat exchanger fitted with inserts. The purpose of these inserts is to increase the heat transfer rate and improve the thermal performance of the heat exchanger. In this study, several types of tube inserts are simulated via a commercial computational fluid dynamics (CFD) solver. These insert types are presented as a single tube fitted with twisted tapes (TTs), twisted tapes with rod (TTR), and helical twisted tapes (HTT) with rod. To assess the performance of each insert type, the CFD results are presented in dimensionless form such as the Nusselt number (Nu), friction factor (f), and performance evaluation criteria (PEC). Additionally, useful dimensionless correlations are developed and presented in this paper to predict the performance of the heat exchanger over a wide range of Reynolds number and tape twist ratio. To ensure accurate CFD results, grid independence test and model validation study against previously reported experimental data were performed.

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Figures

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Fig. 1

Geometry of TT inside the tube

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Fig. 2

TT configuration at different twist ratios

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Fig. 3

TT configuration for the width (w) and axial length (y) description

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Fig. 4

Geometry of TTR inside the tube

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Fig. 5

Geometry of HTTR inside the tube

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Fig. 6

Mesh sizes for the grid independence study of the tube with TT

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Fig. 7

Predicted Nusselt number at different grid cells number for the simulation of tube with TT

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Fig. 8

Predicted friction factor at different grid cells number for the simulation of tube with TT

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Fig. 9

Validation of the predicted Nusselt number against the experimental data from Eiamsa-ard et al. [21]

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Fig. 10

Validation of the predicted friction factor against the experimental data from Eiamsa-ard et al. [21]

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Fig. 11

Velocity contours at cross-sectional plane in the middle of the tube for plane tube, tube with TT, tube with TTR, and tube with HTTR

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Fig. 15

Variation of PEC value against Reynolds number at twist ratios of y/w = 2.6, 2, and 1.75

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Fig. 14

Variation of friction factor against Reynolds number at different twist ratios

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Fig. 13

Variation of Nusselt number against Reynolds number at different twist ratios

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Fig. 12

Temperature contours at cross-sectional plane in the middle of the tube for plane tube, tube with TT, tube with TTR, and tube with HTTR

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Fig. 16

Nusselt number comparison between the TT and the TTR at twist ratios of y/w = 2.6 and 1.75

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Fig. 21

PEC comparison between the TT, the TTR, and the HTTR at twist ratio of y/D = 2.6

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Fig. 20

Friction factor comparison between the TT, the TTR, and the HTTR at twist ratio of y/D = 2.6

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Fig. 19

Nusselt number comparison between the TT, the TTR, and the HTT with rod HTTR at twist ratio of y/D = 2.6

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Fig. 18

PEC comparison between the TT and the TTR at twist ratios of y/w = 2.6 and 1.75

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Fig. 17

Friction factor comparison between the TT and the TTR at twist ratios of y/w = 2.6 and 1.75

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