enhancement of heat transfer in shell and tube heat exchanger · pdf file ·...

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International Journal of Mechanical Engineering and Technology (IJMET)

Volume 7, Issue 3, May–June 2016, pp.125–138, Article ID: IJMET_07_03_012

Available online at

http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=7&IType=3

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ISSN Print: 0976-6340 and ISSN Online: 0976-6359

© IAEME Publication

ENHANCEMENT OF HEAT TRANSFER IN

SHELL AND TUBE HEAT EXCHANGER

WITH TABULATOR AND NANOFLUID

Qasim S. Mahdi

Mechanical Engineering Department, College of Engineering,

Al–Mustansiriyah University, Baghdad, Iraq

Ali Abdulridha Hussein

Mechanical Engineering Department, College of Engineering,

Al–Mustansiriyah University, Baghdad, Iraq

ABSTRACT

The present work reported the use of variant twisted tapes fitted in a

double pipe heat exchanger to improve the fluid mixing that leads to higher

heat transfer rate with respect to that of the plain-twisted tape. Heat transfer,

flow friction and thermal enhancement factor characteristics in a double pipe

heat exchanger fitted with plain and variant twisted tapes using water as

working fluid are investigated experimentally. Tests are performed for laminar

flow ranges. The experimental data for a plain tube and plain-twisted tapes

are validated using the standard correlations available in the literature. Two

different variant twisted tapes which include V cut-twisted tape and Horizontal

wing cut-twisted tape with twist ratios of y = 2.0, 4.4 and 6.0 are used. In

addition, the variation of heat transfer coefficient of copper–nanofluids with

different of Reynold's number and volume concentration of nanoparticles in

plain tube without twisted tape. Based on these studies, the major conclusion

has been arrived the Nusselt number, friction factor and thermal enhancement

factor of variant twisted tapes are higher than that of plain twisted tape for the

twist ratios of 2.0, 4.4 and 6.0 respectively so among the variant twisted tapes

used in the present work, the horizontal wing cut-twisted tape give better

performance due to the effect of increased turbulence which improves the fluid

mixing near the wall of the test tube. By increasing volume concentration of

nanoparticles, thermal conductivity increases while the thermal boundary

layer thickness decreases. The Maximum thermal enhancement factor for P-

TT, V-TT and HW-TT are 3.903, 4.269 and 4.488 respectively and

enhancement plain twisted tape is better than CuO-nanofluid be three times.

Key words: Double Pipe Heat Exchanger, Twisted Tape Insert, Swirling,

Passive Methods, Heat Transfer Enhancement, Nanofluid, Turbulent, Laminar

Flow, Twist Ratio, Cuo Nanoparticles.

Qasim S. Mahdi and Ali Abdulridha Hussein


Cite this Article: Qasim S. Mahdi and Ali Abdulridha Hussein, Enhancement

of Heat Transfer In Shell and Tube Heat Exchanger with Tabulator and

Nanofluid. International Journal of Mechanical Engineering and Technology,

7(3), 2016, pp. 125–138.

http://www.iaeme.com/currentissue.asp?JType=IJMET&VType=7&IType=3

NOMENCLATURE

Symbol Description Units

Ac Tube cross-sectional area m2

As Tube surface area m2

Cp Specific heat J/kg.K

D Diameter of outer tube m

de Depth of cut mm

Dh Hydraulic diameter m

f Friction factor -------

F Correction factor -------

h Heat transfer coefficient W/m2.K

H Pitch length based on 180° m

h Heat transfer coefficient W/m2.K

kf Fluid thermal conductivity W/m.K

L Length m

m Mass kg

Mass flow rate kg/s

Nu Average Nusselt number -------

Pr Prandtl number -------

Q Heat transfer rate W

Re Reynolds number -------

Sw Swirling conductivity W/m.K

T Temperature C, K

t Time sec

u Velocity vector m/s

W Width of twisted tape mm

w Width of the cut mm

y Twist ratio -------

ΔP Pressure drop Pa

http://www.iaeme.com/currentissue.asp?JType=IJMET&VType=7&IType=2

Enhancement of Heat Transfer In Shell and Tube Heat Exchanger with Tabulator and

Nanofluid


Subscripts

Symbol Title

a annular

bf Base fluid

in inlet

m mean

nf Nanofluid

o Smooth tube

out outlet

p particle

pp Pumping power

ref Reference value

S Surface

w Wall

Greek Symbol

Symbol Title Units

Fluid Density kg/m

3

Dynamic viscosity kg/m.s

Kinematics viscosity m2/s

φ Volume concentration percentage

Ф Heat dissipation term

∆h Difference in level of manometric fluid m

ƞ Thermal enhancement factor

1. INTRODUCTION

Nowadays, thermal systems are some of the most important systems used in

engineering applications. Therefore, different methods have been researched and

developed to enhance heat exchange in these systems and reach a high performance

thermal operation. Heat transfer rate in conventional heat exchangers can be improved

through a variety of augmentation techniques that employs surface enhancements.

This improvement in heat transfer rate occurs as a result of the following conditions

that are created by the use of enhanced surfaces. These conditions are Interrupting of

boundary layer development and rising degree of turbulence, increasing heat transfer

area and Generating of swirling and/or secondary flows. Recently, many industrial

applications such as refrigeration, automotive and process industries have been

employing heat transfer enhancement techniques in order to improve the performance

of heat exchangers.

Enhancing heat transfer in heat exchangers could lead to many economic and

environmental benefits. Energy, material and cost savings are achieved through better

heat exchanger designs that reduce its size and improve its efficiency. Watcharin et

al. [2006] have studied the heat transfer and pressure drop in a concentric double pipe

heat exchanger with twisted tape insertion. The twist ratios used are Y = 5.0 and 7.0.

It was observed that the maximum Nusselt numbers over the range studied for using

the twisted tapes with ratios Y = 5.0 and 7.0 are 188% and 159%, respectively, when



compared to the plain tube. Yadav [2009] has studied the heat transfer and pressure

drop in a U-bend double pipe heat exchanger with half-length twisted tape insertion.

Half-length twisted tape was placed inside the inner tube of the heat exchanger in

order to introduce swirling flow. It was observed that the tape-induced swirl causes a

40% increase in the heat transfer coefficient of the half-length twisted-tape inserts

when compared to plain heat exchanger. However, the thermal performance of plain

heat exchanger was found to better than half-length twisted tape by (1.3-1.5) times.

Kapatkar et al. [2010] has examined the influences of fitting full length twisted tape

inserts in a plain tube for laminar flow on the heat transfer and friction factor. The

Reynolds number range was taken to be from 200 to 2000. Showed that full length

twisted tapes results in the following Nusselt number improvement are aluminum

tapes (50% to 100%), stainless steel tapes (40% to 94%) and insulated tapes (40% to

67%). The isothermal friction factor for the flow with the twisted tape inserts are

340% to 750 % higher as compared with those of smooth tube flow, in the given

range of twist ratios. A double pipe heat exchanger fitted with coil wire insert was

tested by Shashank and Taji [2013]. The wire is made up of three different

materials which are copper (Cu), aluminum (Al) and stainless steel. The study was

conducted over a Reynolds number of 4000 to 13000. The results showed that heat

transfer enhancements were 1.58, 1.41 and 1.31 for copper, aluminum and stainless

steel coils respectively. Moreover, the different coil wire inserts resulted in higher

friction factor than plain tube by 5.4 to 6.7 times for aluminum, 4.8 to 5.9 times for

stainless steel and 4.3 to 5.4 times for copper. Senthilraja and Vijayakumar [2013]

utilized a double pipe heat exchanger to experimentally measure the heat transfer

coefficient of CuO/Water nanofluid. A CuO nanoparticles were dispersed in a

deionized water to create a nanofluid. At room temperature, the nanofluid has a

diameter of 27nm at different volume concentrations (0.1% and 0.3%). It was found

that as time passes, the heat transfer coefficient increases while increasing the liquid

flow rate will result in an increase in the Nusslet number. The nanofluid with

concentration of 0.3% provided the highest heat transfer coefficient.

In the present study the effect of using twisted tape inserts and nanofluid

CuO/water will be investigated experimentally. Twisted tapes with variant twisted

tapes cut section and twist ratios as well as nanofluid with different volume

concentration were used for enhancement of heat transfer in double pipe heat

exchanger. Finally, an empirical correlations based on the experimental results of the

present study will be given for prediction the heat transfer (Nusselt number).

2. EXPERIMENTAL APPARATUAS AND PROCEDURE

2.1. Description of Test Rig

The external pipe: It is an insulated pipe which has been manufactured from copper

material of (51.78 mm) inner diameter, (1.5 m) length and (1.17 mm) thickness. It is

insulated from outside by glass wool. Insulation are used to reduce the heat losses to

the surrounding. A small hole was made in the external pipe for the thermocouples

wires that were installed on the external surface of the inner pipe. The hole was

patched with asphalt.

Internal pipe: It has been manufactured from copper material of (20.4 mm) inner

diameter (1530 mm) length and (0.88 mm) thickness. The pipe contains small vertical

(6 mm) ports at its inlet and outlet which are used to measure the difference in

pressure. The pressure sampling ports were welded using sliver brazing. The

thermocouples are fixed under these ports using metal support and screws to measure


Nanofluid


the inlet and outlet temperatures as shown in Figure (1). A valve is installed on the

outlet in order to control and stabilize the flow.

Twisted Tapes: In the test run, tapes are used with three different twist ratios y = 2.0,

4.4 and 6.0. Twisted tapes are made from copper strips of thickness 0.9 mm and width

17 mm as shown in table (1) and figure (2).

Table 1 Characteristic dimensions of the turbulators inserted tubes

Twist set δ

mm H mm

W

mm WR DR

No.

turn y=H/di Metal

P-TT 0.9 40.8 17 - - 37 2 Copper

P-TT 0.9 89.76 17 - - 17 4.4 Copper

P-TT 0.9 122.4 17 - - 13 6 Copper

V-TT 0.9 40.8 17 0.352 0.47 37 2 Copper

V-TT 0.9 89.76 17 0.352 0.47 17 4.4 Copper

V-TT 0.9 122.4 17 0.352 0.47 13 6 Copper

HW-TT 0.9 40.8 17 0.294 0.47 37 2 Copper

HW-TT 0.9 89.76 17 0.294 0.47 17 4.4 Copper

HW-TT 0.9 122.4 17 0.294 0.47 13 6 Copper

Figure 1 Schematic diagram of experimental test section



Figure 2 Shapes Twisted Tapes: (a) Plain-Twisted Tapes (P-TT), (b) V cut-Twisted Tapes

(V-TT), (c) Horizontal wing cut-twisted tape (HW-TT)

2.2. Test Procedure

In order to evaluate the thermal performance of double pipe heat exchanger, a series

of experiments was carried out at different operational and conformational

parameters. Operational parameters demonstrate: hot water flow rate of (0.008,

0.0109, 0.0137,0.0164,0.0192,0.019) kg/sec, cold water flow rate of (0.18) kg/sec,

inlet hot water temperature of ( C and inlet cold water temperature of

( C.

Runs heater tank of hot water after the water situation and wait for a while, then

we take our pump and control a flow rate on flow meter, it put exist after pump, and

in the mean time we take our water pump and wait by flow meter existing then, and

there many thermocouples at the inlet and outlet of the test tube for both hot and cold

tubes, starts registered record temperatures as well as the differential pressure

manometer score and when you reach a state of stability takes values recorded after

the transfer of the calculator by a small memory, and restore the same steps when

insert twisted tapes inside the tube.

2.3. Performance Parameters

Present study consists two fluid flow inside heat exchanger in counter flow

arrangement as shown in Figure (1). cold water is forced to flow through annuli and

hot de-ionized water is passes through inner tube. Steady state condition, insulated

outer surface of heat exchange and no phase changer have been assumed during the

analysis of present heat exchanger. Under these conditions the heat dissipation of both

sides Eiamsa-ard et al. [2006]:

Heat transferred to the cold water in the test section

Qc = c Cpc (Tc2 -Tc1) (1)

Heat transferred from the hot water in the test section

Qh = h Cph (Th1 -Th2) (2)

The percentage of heat loss

ɛ =

(3)

b a c


Nanofluid


The average heat transfer rate for hot and cold water side is taken for internal

convective heat transfer coefficient

Qavg =

(4)

The surface area of the inner tube

Ai = π di L (5)

Logarithmic mean temperature difference

(6)

The overall heat transfer coefficient

U =

(7)

The annulus side heat transfer coefficient annulus side heat transfer coefficient

(ha) is estimated using the correlation of Dittus –Boelter equation

Nua =

= 0.023 Rea0.8

Prc0.3 (8)

The inner tube side heat transfer coefficient (hi) is determined by neglecting the

conduction thermal resistance of copper tube wall:

(9)

The inner tube side Nusselt number

Nui =

(10)

The Reynolds Number is based on the different flow rates at the inlet of the test

section

Rei =

(11)

Friction factor and is related to pressure drop in the test section

f =

(12)

The thermal enhancement factor (ɳ)

ɳ =

= a Re-b

y-c

(13)

3. EXPERIMENTAL RESULT

3.1. Comparison of Experimental Results

The heat transfer data for the plain tube is compared with literature data obtained

using Sieder and Tate (1936) Equation (14) Cengel [2008]. The plain tube data are

matching with Sieder and Tate equation with the discrepancy of ± 3% as shown in

Figure (3).



(14)

The plain tube friction factor is shown in Figure (4) and these data are compared

with the data obtained using the Equation (15) Cengel [2008].

The experimental friction factors are matching with the deviation of ± 4% with the

results of the Equation (15).

(15)

In addition, the experimental data of the plain tube are correlated for Nusselt number

and friction factor respectively through Equations (16) and (17) as follow;

(16)

(17)

The Equations (16) and (17) are found to represent the experimental data within

±1% for Nusselt number ± 2% for the friction factor also.

3.2. Effect of Plain-Twisted tape

The experimental results of the tube fitted with P-TT are compared with the plain tube

and its results are validated using the correlations available in the literature for the

laminar flow at the inlet to test section. Otherness of Nusselt number, heat transfer

coefficient and friction factor with Reynolds number at the inlet to test section for the

tube fitted with P-TT of different twist ratios (y = 2.0, 4.4 and 6.0) and plain tube are

depicted in Figures (5) and (6) respectively.

By referring to the Figure (5) it can be observed that Nusselt number, heat transfer

coefficient increases with the increasing Reynolds number and also the result showed

that the use of lower twist ratio yields higher Nusselt number than that of the higher

twist ratio. This happens because the lower twist ratio creates stronger swirl flow

which makes the thinner boundary layer along the pipe wall. Therefore more heat transfer through the thinner boundary layer. The swirl flow also creates the fluctuation

of the energy between fluid layers and as a result the heat energy readily moves across

Figure 4 Experimental data verification of

friction factor for plain tube

Figure 3 Experimental data verification of

Nusselt number for plain tube


Nanofluid


the fluid layers. Moreover, the residential time of flow increases with stronger swirl

level which causes, the flow to have more time for exchanging the heat between the

core and the wall. Over the range studied, the mean Nusselt number for P-TT with

twist ratios y = 2.0, 4.4 and 6.0 are respectively 3.6467, 2.7001 and 2.4878 times

better than that for the plain tube.

Figure (6) shows that the friction factor decreases continuously with Reynolds

number and friction factor for lower twist ratio (y = 2.0) is significantly more than

that of the higher twist ratio (y = 4.4 and 6.0) due to stronger swirl flow offered by the

P-TT with lower twist ratio. From the experimental results, it can be observed that the

friction factors for the P-TT with twist ratio y = 2.0, 4.4 and 6.0 are respectively

6.80586, 4.3509 and 3.6079 times than that for the plain tube.

The experimental data are fitted by the following correlations:

(18)

(19)

The fitted values are agreeing with the experimental data within ±12% and -10%

for Nusselt number and friction factor respectively.

3.3. Effect of V Cut-Twisted Tape

This section is focused on the experimental study on the heat transfer and friction

factor for the horizontal concentric tube fitted with V-TT with different twist ratios y

= 2.0, 4.4 and 6.0 for laminar flow at the inlet of test section. The experimental results

of V-TT are compared with plain tube and P-TT.

Figure (7) shows the comparison between Nusselt number obtained from the tube

fitted with V-TT, P-TT and plain tube. It can be observed from the Figure (7) that, the

Nusselt number obtained from the V-TT is higher than those from the P-TT and plain

Figure 5 Nusselt number versus Reynolds

number for P-TT with different twist ratio(y)

and plain tube

Figure 6 Friction factor versus Reynolds

number for P-TT with different twist ratio(y)

and plain tube



tube. This means that V-TT generated the secondary flow along with main swirl flow

produced by P-TT. Mean Nusselt number for the tube fitted with V-TT of twist ratios

y = 2.0, 4.4 and 6.0 are respectively 4.1519, 3.005 and 2.7410 times better than that

for the plain tube and similarly 1.1385, 1.113 and 1.101 times higher than that of P-

TT.

The comparison of the friction factor between the V-TT, P-TT and plain tube with

the variations of inlet Reynolds number is shown in Figure (8) respectively. It can be

clearly seen that the friction factor continues to decrease with increase in hot water

Reynolds number. At a given Reynolds number, the friction factor for the tube with

V-TT is consistently higher than that of the P-TT and plain tube. This is because of

the additional disturbance to the main swirl flow in the form of turbulence which

increases the tangential contact between the fluid and the wall. Mean friction factor

for the tube fitted with V-TT of twist ratios y = 2.0, 4.4 and 6.0 are respectively 8.817,

5.7521 and 4.783 times higher than that for the plain tube and 1.29562, 1.322 and

1.325 times higher than that of P-TT with the same twist ratios. The experimental data

of heat transfer and friction factor for the tube with V-TT with different twist ratios (y

= 2.0, 4.4 and 6.0) are correlated as the function of Reynolds number, Prandtle

number and twist ratios are as follows:

(20)

(21)

The deviation between the predicted and experimental Nusselt number and

friction factor are respectively ±4% and ±8%.

3.4. Effect of Wing Cut-Twisted Tape

This section is mainly focussed on the study of the heat transfer enhancement effect

by fixing the depth and width ratios and the position of the wing-cut from horizontal

direction. The heat transfer and friction factor characteristics of the HW-TT is studied

for the twist ratios y = 2.0, 4.4 and 6.0 and the results are compared with those tube

Figure 7 Nusselt number versus Reynolds

number for V-TT, P-TT with different twist

ratio(y) and plain tube

Figure 8 Friction factor versus Reynolds

number for V-TT, P-TT with different twist

ratio(y) and plain tube


Nanofluid


fitted with and without P-TT. The experimental results from the HW-TT are

correlated for Nusselt number and friction factor.

Figure (9) shows the relationship between the Nusselt number and Reynolds

number for the tube with HW-TT, P-TT with different twist ratios, y = 2.0, 4.4 and

6.0 and also the plain tube respectively. In general, the HW-TT provide higher

Nusselt number than that of P-TT and plain tube depending on the twist ratios used.

HW-TT provides additional vortices to the fluid in the vicinity of the tube wall in

addition with swirl flow generated by the P-TT and thus leads to a higher heat transfer

enhancement in comparison with plain tube and P-TT.

On the other hand the use of HW-TT, mean Nusselt numbers for the twist ratios

2.0, 4.4 and 6.0 are respectively 4.3889, 3.242 and 2.895 times of that for the plain

tube and 1.1978, 1.2 and 1.1636 times of that for the tube fitted with P-TT. This may

be a consequence of better mixing between the core and the fluid wall due to the more

efficient turbulence offered by the HW-TT.

The friction factor characteristics at various Reynolds number based on the inlet

side of the tube fitted with HW-TT, P-TT and the plain tube is displayed in Figure

(10). At a given Reynolds number, the friction factors of all the HW-TT are

consistently higher than that of the tube with P-TT and plain tube due to an additional

blockage provided by the wings to the flowing fluid in the tube. For a tube with HW-

TT, the mean friction factors with twist ratios of 2.0, 4.4 and 6.0 are respectively

9.277, 6.419 and 5.207 times of those in the plain tube and 1.363, 1.4753 and 1.4432

times of those in the tube with the P-TT.

The experimental data of heat transfer and friction factor for a tube with the HW-

TT with different twist ratios are correlated as follows:

(22)

(23)

The deviation of the multiple regressions of Nusselt number and friction factor are

+12% and ±12%, respectively.

Figure (9) Nusselt number versus

Reynolds number for HW-TT, P-TT with

different twist ratio(y) and plain tube

Figure (10) Friction factor versus

Reynolds number for HW-TT, P-TT with

different twist ratio(y) and plain tube



3.5. Comparison of Variant Twisted Tape Inserts

The variant twisted tapes performances have been compared based on the thermal

enhancement factor because it relates the Nusselt number and friction factor

characteristics. Therefore, it is worthy to compare the performance using thermal

enhancement factor instead of making the comparisons of the Nussselt number and

friction factor of the variant twisted tape used in the present work separately.

Figure 11 Thermal enhancement factors versus Reynolds number for PTT, V-TT and HW-TT

Figure (11) present the comparison of the variant twisted tapes used in the present

work for the twist ratios y = 2.0, 4.4 and 6.0 respectively.

The thermal enhancement factor (ƞ for the P-TT, V-TT and HW-TT is expressed

in the equation (29), (30) and (31) respectively:

(24)

(25)

(26)

3.6. Inner Nusselt's Number with Nanofluids

Performance of double pipe heat exchanger with nanofluids has been studied to show

the effect of concentration on heat transfer enhancement. Water cold Reynold's

number has been selected as 3300 during nanofluids experiments. Figures (12) show the variation of the Nusselt's number with a Reynold's number of CuO nanofluids.

These figures clearly indicate that Nusselt's number increases with increasing both

Reynold's number and volume concentration of nanoparticles. The main reason of this

enhancement due to the increase in both thermal conductivity and heat transfer

coefficient of nanofluid.


Nanofluid


Figure 12 Variation Nusselt number of CuO/water Nanofluid with Reynolds Number for

various volume Concentration

Table (2) show the enhancement of Nusselt number with variation in volume of

copper-nanofluids.

Table 2 Enhancement in Nusselt number of CuO nanofluid

Concentration %

(lit/hr)

Enhancement

%

Concentration

%

(lit/hr)

Enhancement

%

0.2 30 7.92 0.2 60 5.3

0.4 30 10.2 0.4 60 6.41

0.6 30 12.38 0.6 60 8.41

0.2 40 7.31 0.2 70 4.48

0.4 40 9.78 0.4 70 6.49

0.6 40 11.32 0.6 70 7.65

0.2 50 5.87

0.4 50 8

0.6 50 9.68

4. CONCLUSIONS

The investigation on heat transfer and friction factor characteristics for variant twisted

tapes (P-TT, V-TT, HW-TT) fitted in the double pipe heat exchanger, with twist ratios

y = 2.0, 4.4 and 6.0 have been studied and presented. According to the past studies, it

is observed that modifications on the P-TT i.e. small cuts on the tape, will give an

assurance for enhancement of both heat transfer and thermal enhancement. The

variant twisted tapes are used based on the concept of introducing a small cuts on the

peripheral region of the tape (V-TT and HW-TT). The conclusion arrived the plain

tube data of Nusselt number and friction factor were verified with the standard

correlations in order to ensure the performance of the experimental set up for laminar



flow. The maximum deviation observed for both the experimental Nusselt number

and friction factor is ±4% and ±5% with the standard correlations values respectively.

The tape with lower twist ratio (y = 2.0) offered a better thermal enhancement than

the tape with higher twist ratio (y = 4.4 and 6.0). The V-TT provides improved heat

transfer enhancement than that of P-TT. In the group of variant twisted tapes, HW-TT

yields better thermal performance. The Nusselt number enhancement are (240, 183,

159)% for P-TT to y=(2.0, 4.4, 6.0) respectively also (326, 211, 181)% for V-TT to

y=(2.0, 4.4, 6.0) respectively in final the enhancement are (348, 232, 196)% for HW-

TT to y=(2.0, 4.4, 6.0).

REFERENCES

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and Pressure Drop Characteristics inside a Double Pipe U Bend Heat Exchanger,

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[3] Kapatkar V. N., A. S. Padalkar and Sanjay Kasbe, Experimental Investigation on

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pp. 32–39, 2013.

[5] Senthilraja S. and Vijayakumar KCK., Analysis of Heat Transfer Coefficient of

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heat transfer and flow friction in a circular tube fitted with regularly spaced

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[8] Mohd. Rehan Khan and Dr. Ajeet Kumar Rai, An Experimental Study of Exergy

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