Optimization of turbulent heat transfer in a heat exchanger with helical

corrugated tube
Abhishek Singh1, Mohan Gupta2*
1
United University, Rawatpur Jhalwa, Prayagraj, UP, India
2
*United College of Engineering and Research Naini, Prayagraj, (UP), India
*Corresponding author: email- [email protected]

Abstract- The increase in convective heat transfer has been studied in a one-stage non-stable run with
the aid of spirally ribbed pipe. Results of the slope-to-breadth proportion P/DH = “0.27, 0.18, and
0.22” and “slope-extent to breadth proportion” e/DH = “0.04, 0.06, and 0.02” of spirally fluted ducts
on the improvement of heat exchange, thermal presentation portion, and isothermal friction are found
and concluded in a coaxial duct hotness evaporator. Large volumes of unstable liquid flow with
Reynolds numbers varies from 5500 to 60,000. Compared to corrugated tubes, smooth tubes produce
less heat and transfer less heat. Heat conversion rate jumps from 123% to 232% in the test region. As
a result, because of the restraint dropping production, the value of the friction factor happens 1.46–
1.93 times on a flat tube in curved tubes. Additionally, probing data on the premises of curve
fitting of equations are applied to find the “Nusselt number, abrasion part”, and thermal
appearance section for the fluted duct in terms of slope ratio (P/DH), slope-extent fraction
(e/DH), “Reynolds number (Re), and Prandtl number (Pr)”.

Keywords: Corrugated tube, turbulent flow, Reynolds number, heat transfer, Nusselt number.

Introduction

In order to raise the heat production of heat exchangers, multiple tactics, such as energy transfer
modification approaches, is produced by lowering the heat exchanger's size and operating costs [4].
To put it another way, the HTE may be divided into two categories: the submissive process, which
does not need outside potential conception, and the operative process, which does [5]. In the
subservient procedure, temperature exchange profitability is improved by reducing the thermal limit
layer thickness to increase turbulence in the tube wall layer and by locating an additional fluid mix
with enhanced changed tubes, such as the tub with rib, the finned tube, the tube with uneven wall, the
fluted tube, the amoral tube, the helical tube, the elliptical axis, etc., shown in Fig. 1. Due to the
obvious suitability of the constraint fall accumulation, the heat exchange improvement in an unstable
one-stage run is much aided by the changed ducts, fluted duct, and duct.
[6]finds the immerse process in a grooved duct then by fitting and twisting put inside by visible
examination and also produced the exploratory relationship for immerse in both perpendicular
and almost parallel ducts. A unique method for calculating the hotness shift in stratified mist
liquefaction on an upright grooved tube was described by Dengliang et al. [7]. The phenomenon of
heat exchange in a “carbon-steel/copper curving grooved duct” was investigated by Wanga et al. [8].
Following analysis, it was found that the carbon steel spirally grooved duct provided a higher heat
exchange calculated than the carbon steel simple duct by around 17%, while the energy exchange
calculated by the copper ordinary duct is less than that of the curved hollowed channel, which is
approximately 50%. In several important technical applications, including as heat exchangers,
pipeline construction, the manufacturing of heavy metals, the marine, and the chemical sector,
corrugated tube is used.
The behavior of convective heat transfer and thermal efficiency in corrugated tubes at different pitch
ratios were described by Rainieri and Pagliarini [9]. a summary of their findings, the curved loop
considerably stimulated the eddy parts. According to Vicente et al. [10], is thermal friction. The
fluted ducts' abrasion portion measure is discovered to be around 250% to 300% more than that of the
plane duct in this technique of corrugated tube appearance [11]. The friction factor of plain duct is
2.45 times lower than that of corrugated tube. In their study, Rozzi et al. [12] examined how “heat
transfer and pressure drop” in a duct heat exchanger with Newtonian and non-Newtonian liquids as
the functional liquids occur as a result of wall corrugation in a shell. Vicente together with others [13]
Provides an explanation based on inspection that heat transfer takes place in fluted ducts for both
“turbulent and laminar” flow, with ethylene glycol and water serving as the functional liquids.
Following analysis, it is discovered that the fluted duct has a larger friction factor and heat
transmission than the plain duct, ranging from 25% to 30%. The usage of water and oil as the
operating fluid causes the heat exchange and abrasion part characteristics in a spirally fluted duct [14].
Their results are finalized. Following analysis, it was observed that the fluted duct's heat transfer
coefficient and friction factor were, in particular, greater than those of the flat duct, ranging from
120% to 160%. Using R-134a as the working liquid, give an investigative task for determining the
fluted ducts' extreme warmth interchange determine and limitation decrease [15]. Following
analysis, the loop slope provides a significant finding about the constraint fall conducts and the heat
exchange measure. The simple calculation method for a spiraling fluted duct, the heat exchanger
and erosion device combine with a deviated stripes explained by Zimparov [16, 17]. The results
show that the expected and investigative facts are almost identical.
More heat exchange measures in hotness evaporator structures have been achieved recently by the use
of different augmenting tubes, such as oval center line ducts, finned ducts, microfin ducts, and fluted
ducts, as the non-stable booster for upsetting the thermic surface. The term "conductive heat
exchange" refers to the optional oval center line duct described by Meng et al. [18]. Multiple
longitudinal vortices affected the relevance for heat transfer growth studies in the stagger oval center
line ducts. [19] Noted that “heat exchange and pressure drop” characteristics occur in a spirally
confused hotness evaporator and joined with a petal-shaped fluted duct for oil cooling. Al-Fahed et al.
[20] describe how a slack-stable/dense-stable perverted-strip inset causes the hotness shift measure
and constraint decrease in a micro finned tube. Following observation, it is discovered that tight-fit
tape has a greater thermal performance value than loose-fit tape.
Friction factor characteristics in tubes with an interior spiral-crack were pointed out by Webb et al.
[21]. The effects of the slope extent (0.33 to 0.55 mm), spiral gradient (25 to 45°), and crack start (18
to 45) on the heat exchange and friction factor was also discussed and shown.
The main goal of the current work is to determine the impact of changing the tube's surface on “heat
transfer enhancement”. Helically twisted tubes are often used to do this [22, 23].
Additionally, displayed are the true relationships between the abrasion element, thermic presentation
portion (η), and the Nusselt number (Nu).

Experimental facility:

Fig. 2 describes the present work that uses spirally corrugated tubes. The spirally fluted duct's interior
and exterior sides are depicted in the diagram. Helically corrugated tubes with pneumatic widths of
25, 25.5, and 24.5 mm, length of 1500 mm, and thickness of 2.5 mm were created using the copper
ducts. Nine scroll fluted ducts in a uniaxial duct hotness evaporator are employed for testing. There
are three different spirally fluted angles of P = 5.5, 4.5, and 6.5 mm and three different scroll fluted
slope-extents of e = “1.5, 1.0, and 0.5” mm (“slope-extent to width proportion”, e/DH = “0.06, 0.02,
and 0.04”).
 Figure 1. Surface design of various tubes

Fig. 3 displays a schematic representation for the coordinated duct heat exchanger that is being
provided for exploration. The two circular ducts in the coordinated duct hotness evaporator are the
cold-water flow that is utilized in the outside tube and the interior duct (also known as a plane duct or
“spirally fluted duct”) for the heated water flow. Serially, the simple tube's inner and outer radiuses
were 13mm and 14.3mm. The exterior duct was constructed out of “stainless steel”, and the inner tube
structure was composed of copper [1-3].
The exterior dimensions of the outer duct were appropriately enclosed to delay heat reduction to the
closer item. The test involves a continuous run for the chilled water that is employed as the cooler's
cooling agent. A cooling pillar rotated cooled water at a temp. of 28°C to control and keep the water's
constant temperature in the storage tank. An inverted U-tube manometer was used for the diffusive
abrasion testing, taking into account pressure decreases throughout the test portion. Two calibrated
rotameters provided the experimental water's titrate run rate.
Since the water tank was filled with water for the purpose of examination, the water was heated and
then released into a boiler when the “temperature goes to 70 °C”. The power tap was opened to let
warm water flow in before to the “internal duct of a coordinated duct” heat evaporator using a
rotameter. With the aid of 2 balance pressure gauges mounted on the duct's peak barrier, the
temperatures of the exit and the hot waters were noted in steady state conditions, and the pressure
drop was recorded. The entry and exit water temperatures were measured using the RTDs approach,
which is situated behind the warm water outflow. Measured from 5500 to 60,000, the Reynolds
number span was applied to the duct tube diameter.
 Figure 2. An illustration of a smooth, helically-corrugated pipe with an indication of
morphology

Data acquisition
The internal bore of the experiment duct are also depend on the average abrasion part and
Nusselt number. Heat taken by water is:
Q c=m˙c CpwTcout−Tcin
Q h=m˙h Cp;w Th;out−Th;in

Qc+Qh
Qaver=
2

Qave=UAiΔTLMTD

where
Ai=πDL:
1=U=1=hi + AilnðDo−DiÞ=2πkL+Ai=Aoho +R
1=U=1=hi +B
hi =CRem:
1=U=1=CRem+B=ARe—m+B:
hi =1=ð1=U−BÞ:
Nu=hiD= k:

Figure3. Simplified figure of exploratory structure.

Re=ρVD=μ
f=ΔP=ðL=DÞρV2=2

η=ðNua=NusÞ=ðfa=fs1=3

Results and Discussion

Experimental results- Effects on the “friction factor and the heat exchange” are displayed in the part
for the helically corrugated tube at varied “slope proportions” (P/DH = “0.22, 0.18, and 0.22”) and
“slope-extent to breadth proportions” (e/DH = “0.06, 0.04, and 0.02”). First, the value derived from
the quality relations was confirmed by measuring the heat transfer and friction factor using the current
plane duct in conjunction with an exploratory potential. The impacts of the slope ratio (P/DH) and
“slope-extent proportion” (e/DH) on the hotness evaporators' “abrasion, thermic presentation”, and
“heat exchange” characteristics are then displayed. Finally, the relationships between the abrasion
element, “Nusselt number, and thermal performance” are investigated.

Evaluation of the smooth pipe- The present observed information for the heat exchange rate and
pressure drop in terms of the Nu and friction factor of the plain tube are serially confirmed using
Petukhov Dittus- Boelter equations [19], as represents in Fig. 4(a) & 4(b). Lastly, the friction factor
has ±8% and the Nu, which has general equations, occurs in ±4% variances to fulfil the current
smooth tube consequence.

Result of slope proportion- For corrugated tubes, Fig. 5(a–b) explains how the Nusselt number and
Reynolds number are connected through the flat duct and many slope ratios, P/DH = 0.22, 0.27, and
0.18. Smooth tubes often exhibit lower Nusselt numbers than corrugated ducts for all Reynolds
numbers between 113 and 300%, as indicated by the slope angles (P/DH) rate that is measured. The
Nusselt number increases abruptly to about 230% above the flat valve in the case of the largest pitch
“proportion, P/DH = 0.27”, which occurs in twisted tube. This is more than P/DH = 0.22 and 0.18,
which occur around approximately 5% and 12%, respectively. It has been noted that when the pitch
ratio value rises, so does the Nusselt number. “Larger contact sides and corrugated surface
components” mix among the “fluid in the tube wall and the core” to produce this result; this is all due
to a significant effective turbulence/recirculation flow. Because the surface components are spirally
corrugated, the heat exchange value is more effective at lower Reynolds numbers. The main idea is
that the thermic limit surface's breadth matters; as the Reynolds number decreases, the surface
becomes broader, which leads to a more significant disarray of the thermic limit surface. In particular,
as shown in Fig. 6(a), the energy reduction that occurs in the friction factor reaches a large value at
lower Reynolds numbers.
Fig4. Demonstration of the planeduct

250

200
nUSSELT NUMBER

150

100

50

0
0 10000 20000 30000 40000 50000 60000 70000
REYNOLDS NUMBER

present work dittus and boelter equation

Fig 4(a). Nusselt number

present work Pethkhub Equation

0.04
0.035
Friction factor

0.03
0.025
0.02
0.015
0.01
0.005
0
0 10000 20000 30000 40000 50000 60000 70000
Reynolds Number

Fig 4(b) Abrasion part

 Fig.5 connection joining nusselt number and Reynolds number

450
400 smooth tube

350 P/DH-0.18.e/DH-0.02

300 P/DH-0.18,e/DH-0.04
Nusselt number

P/DH-0.18,e/DH-0.06
250
P/DH-0.22,e/DH-0.02
200
P/DH-0.22,e/DH-0.04
150
P/DH-0.22,e/DH-0.06
100 P/DH.27,e/DH-0.02
50 P/DH.27,e/DH-0.04
0 P/DH-0.27,e/DH-0.06
0 10000 20000 30000 40000 50000 60000 70000
reynolds number

Figure 5(a)

3
P / DH = 0.18, e / DH= 0.02
2.5 P / DH = 0.18 ,e/ DH -0.04
P/D H=0.18,e/DH - 0.06
2 P / DH - 0.22, e / DH - 0.02
P/DH- 0.22, e/DH - 0.04
Nu3/NuS

1.5
P/DH-0.22. e /DH- 0.06
1 P / DH- 0.27, e / DH -0.02
P/DH- 0.27, e/ DH -0.04
0.5 P/DH-0.27, e/DH- 0.06

0
0 20000 40000 60000 80000
REYNOLDS NUMBER

Figure 5(b) Nua / Nus

Figure 6(a) & 6(b) shows the effect of “pitch proportion through fluted duct” on diffusive abrasion
part characteristics at different Reynolds numbers. As the Re rises in the corrugated duct, the friction
factor, also known as the pressure drop, decreases. In particular, smooth tubes have lower friction
coefficients and Reynolds numbers than any corrugated tubes. Turbulence flows and recalculating
flows are caused by the fluid's pressure loss resulting from a significant viscosity drop that occurs
alongside the “duct wall from spirally fluted layers”. P/DH = 0.18, 0.22, and 0.27, the mean abrasion
part of the fluted ducts, are substituted by “1.93, 1.8, and 1.87” times on the plane duct, and P/DH =
0.27, which has the largest slope proportion, results in an average bigger abrasion part than “P/DH =
0.18 and 0.22”, which are around 3% and 7%, respectively.

Fig. 7 displays the thermodynamic presentation component (η) of the fluted duct with many pitch
proportions. This figure displays two inspections that are visible: First, the presentation component
increases as the pitch proportion increases, and second, the description part decreases as the Reynolds
number increases. It is recommended that fluted ducts be used for saving power at lower Reynolds
numbers. The fluted ducts with “P/DH = 0.18, 0.22, and 0.27” at e/DH = 0.06 provide the maximum
thermic presentation of 2.26, 2.33, and 2.15, sequentially. The average thermic presentation section of
the fluted duct, with a value of P/DH = 0.27, is found to be 4% and 9% greater than that of the less
pitched portions, P/DH = 0.22 and 0.18, based on the current work span.

Effect of rib-height ratio-

In Figs. 5(a) & 5(b) and 6(a) & 6(b), the pressure drop and heat exchange value are serially displayed
in place of the abrasion part and Nu as a result of the slope-extent to breadth proportions (e/DH =
0.04, 0.02, and 0.06) experienced in the fluted duct. The Nusselt number and the abrasion section of
the figure grow as the ratio of slope-extent to width increases. Owing to helical ribs that encourage
turbulence run adjacent to the duct wall and disruption of the thermic limit surface. In between the
range of 20–29% and 50–67%, respectively, the value of the magnified duct with e/DH = 0.06 the Re
value causes the Nusselt number value to become greater than the values with e/DH = 0.04 and 0.02.
Larger rib-heights can cause more peripheral flow, which increases the transitive heat exchange value.
In instance, the maximum valve thermal performances of 1.55, 1.89, and 2.33 are produced at P/DH =
0.27 by the enlarged ducts with e/DH = 0.06, 0.04, and 0.02.

Fig.6. connection Abrasin part and Reynolds number

Smooth tube P/DH-0.18,e/DH-0.02 P/DH-0.18,e/DH-0.04 P/DH-0.18,e/DH-0.06

P/DH-0.22,e/DH-0.02 P/DH-0.22,e/DH-0.04 P/DH-0.22. e /DH- 0.06 P / DH- 0.27, e / DH -0.02
P/DH- 0.27, e/ DH -0.04 P/DH-0.27, e/DH- 0.06
0.08

0.07

0.06
friction factor

0.05

0.04

0.03

0.02
0 10000 20000 30000 40000 50000 60000 70000
reynolds number

Figure 6(a) F
 P/DH-0.18,e/DH-0.02 P/DH-0.18,e/DH-0.04 P/DH-0.18,e/DH-0.06
P/DH-0.22,e/DH-0.02 P/DH-0.22,e/DH-0.04 P/DH-0.22. e /DH- 0.06
P / DH- 0.27, e / DH -0.02 P/DH- 0.27, e/ DH -0.04 P/DH-0.27, e/DH- 0.06
2.2

2.1

1.9

1.8

1.7
fa/fs

1.6

1.5

1.4

1.3

1.2
0 10000 20000 30000 40000 50000 60000 70000
reynolds number

Figure 6(b) fa /fs

P/DH-0.18,e/DH-0.02 P/DH-0.18,e/DH-0.04 P/DH-0.18,e/DH-0.06

P/DH-0.22,e/DH-0.02 P/DH-0.22,e/DH-0.04 P/DH-0.22. e /DH- 0.06
P / DH- 0.27, e / DH -0.02 P/DH- 0.27, e/ DH -0.04 P/DH-0.27, e/DH- 0.06

2.6

2.4

2.2
Thermal perfomance Factor

1.8

1.6

1.4

1.2

0.8
0 10000 20000 30000 40000 50000 60000
rynolds number

Fig 7. Connection joining thermic production element and Rynolds Number

Correlations-
The experimental heat transmission data importance, the “friction factor for single phase”
turbulent flow in scroll folded tubes, and the thermal stability for many slope-to-breadth
measurements “P/DH = 0.27, 0.18, and 0.22” and “slope-to-breadth” measurements (e/DH =
0.04, 0.06, and 0.02) are all included in the following instructions:

Fig.8 Demonstration of the Nusselt number Fig.9 Demonstration of the abrasion element
relation relation

It demonstrates that the pitch proportion (P/DH) and the Nusselt number (N) are only found in the
abrasion section, and that the slope-extent proportion (e/DH) is a major contributor to the necessary
space of thermal performance factor characteristics. It could have happened because the pitch ratio is
easier to determine than the slope-extent proportion on several. Figs. 8, 9, and 10 are categorized in a
sequential manner based on the division between the friction factor, thermal performance factor, and
the Nusselt number discovered by the present study with values determined by the current
relationship. The graphs illustrate that the mean deviations of the several regressions for thermal
performance, Nusselt number, and abrasion portion fall within about ±7%, ±9%, and ±4% ranges.
 Fig.10 Validation of thermal performance factor currection.

Conclusions-

This study examines and monitors the thermal potential, erosion element characteristics, and heat
transfer enhancement of a corrugated twisted tape. Nine spirally corrugated ducts that are processed
have three different slope-to-breadth proportions (P/DH = “0.27, 0.18, and 0.22”) as well as three
different slope-extent to breadth proportions (e/DH = “0.06, 0.02, and 0.04”). This unique outcome
indicates that when the slope angles (P/DH) and the slope-extent ratio (e/DH) increase, so does the
value of the abrasion element in the thermo graphic presentation section and the Nusselt number. The
boosted duct with slope ratio P/DH = 0.27 and “slope-extent proportion e/DH = 0.06” at lower Re,
where “friction factor and Nu are 2.14 and 3.01” times higher than the empty tube, is found to have
the highest thermal presentation part value in the current work, close to 2.33. Based on this, there is a
consistent empirical link between the friction factor, Nu and “thermal performance factor”.

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