Experimental investigation of convective heat transfer performance using sporadic flow divider type inserts

Year 2025, Volume: 11 Issue: 2, 331 - 343, 24.03.2025

Suryaji S. Kale Sanjaykumar S. Gawade

Abstract

The depletion of conventional energy resources highlights the growing need for efficient utilization of available energy sources. Heat exchangers play a vital role in transferring heat between two or more fluids, and enhancing their performance is crucial for improving energy efficiency. Various techniques, categorized as active, passive, or hybrid methods, can be employed to augment heat transfer in heat exchangers. This experimental study investigates the use of innovative sporadic flow divider inserts as a passive method for heat transfer enhancement. The experiments were conducted using inserts with different twist angles of 90°, 60°, 45°, and 30°, over a range of Reynolds numbers from 7000 to 21000. The effect of spacing between the inserts was also analyzed using different space ratios (0.19, 0.39, 0.59, 0.78) in combination with the various twist angles.
The results indicated that higher Reynolds numbers led to increased Nusselt numbers, a decrease in the Thermal Enhancement Factor (ψ), and a reduction in the Friction Factor (f). Among the tested configurations, the 45° twist angle insert exhibited the highest Thermal Enhancement Factor (ψ) and Overall Performance Criteria (η) across most conditions. Conversely, the 30° twist angle resulted in a significantly higher friction factor, impeding fluid flow. The optimal performance was achieved with a 45° twist angle and a space ratio of 0.59, yielding a 23% improvement in Thermal Enhancement Factor (ψ) and a 55% increase in Overall Performance Criteria (η) compared to a plain tube. These findings demonstrate that sporadic flow divider inserts can effectively enhance convective heat transfer with a moderate increase in friction, ultimately improving the Overall Performance Criteria (η).

Keywords

Flow Divider Type, Heat Transfer Enhancement, Inserts, Reynolds Number

References

• [1] Kumar N, Jhinge P. Effect of segmental baffles at different orientation on the performances of single pass shell and tube heat exchanger. Int J Eng Trends Technol 2014;15:423–428. [CrossRef]
• [2] Bichkar P, Dandgaval O, Dalvi P, Godase R, Dey T. Study of shell and tube heat exchanger with the effect of types of baffles. Procedia Manuf 2018;20:195–200. [CrossRef]
• [3] Ali MK, Naji S. Performance analysis of shell and tube heat exchanger parametric study. Case Stud Therm Eng 2018;12:563–568. [CrossRef]
• [4] Joemer CS, Thomas S, Rakesh D, Nidheesh P. Optimization of shell & tube heat exchanger by baffle inclination and baffle cut. Int J Innov Res Sci Eng Technol 2015;4:69–73.
• [5] Son Y, Shin J. Performance of a shell and tube heat exchanger with spiral baffles plates. KSME Int J 2001;15:1555–1562. [CrossRef]
• [6] Petrik M, Szepesi G. Shell side CFD analysis of a model shell and tube heat exchanger. Chem Eng. 2018;70:313–318.
• [7] Edward G, Volker G. Pressure drop on the shell side of shell-and-tube heat exchangers with segmental baffles. Chem Eng Process 1997;36:149–159. [CrossRef]
• [8] Gu X, Luo Y, Xiong X, Wang K, Wang Y. Numerical and experimental investigation of the heat exchanger with trapezoidal baffles. Int J Heat Mass Transf 2018;127:598–606. [CrossRef]
• [9] Akpbio E, Oboh I, Aluyor E. The effect of baffles in shell and tube heat exchangers. Adv Mater Res 2009;62–64:694–699. [CrossRef]
• [10] Singh G, Kumar H. Computational fluid dynamics analysis of shell and tube heat exchanger. J Civ Eng Environ Technol 2014;1:66–70.
• [11] Irshad M, Kaushar M, Rajmohan G. Design and CFD analysis of shell and tube heat exchanger. Int J Eng Sci Comput 2017;7:212452909.
• [12] Menni Y, Chamkha AJ, Ameur H, Mustafa. Enhancement of the hydrodynamic characteristics in shell-and-tube heat exchangers by using W-baffle vortex generators. Period Polytech Mech Eng 2020;64:212–223. [CrossRef]
• [13] Biçer N, Engin T, Yaşar H, Büyükkaya E, Aydın A, Topuz A. Design optimization of a shell-and-tube heat exchanger with novel three-zonal baffle by using CFD and Taguchi method. Int J Therm Sci 2020;155:106417. [CrossRef]
• [14] Feng H, Chen L, Wu Z, Xie Z. Constructal design of a shell-and-tube heat exchanger for organic fluid evaporation process. Int J Heat Mass Transf 2019;131:750–756. [CrossRef]
• [15] Arani AAA, Moradi R. Shell and tube heat exchanger optimization using new baffle and tube configuration. Appl Therm Eng 2019;157:113736. [CrossRef]
• [16] Marzouk SA, Abou Al-Sood MM, ElFakharany MK, El-Said EMS. Thermo-hydraulic study in a shell and tube heat exchanger using rod inserts consisting of wire-nails with air injection: experimental study. Int J Therm Sci 2020;161:106742. [CrossRef]
• [17] Safarian MR, Fazelpour F, Sham M. Numerical study of shell and tube heat exchanger with different cross-section tubes and combined tubes. Int J Energy Environ Eng 2019;10:33–46. [CrossRef]
• [18] Wildi-Tremblay P, Gosselin L. Minimizing shell-and-tube heat exchanger cost with genetic algorithms and considering maintenance. Int J Energy Res 2007:1272. [CrossRef]
• [19] Khan Z, Khan ZA. Experimental and numerical investigations of nano-additives enhanced paraffin in a shell-and-tube heat exchanger: a comparative study. Appl Therm Eng 2018:115436660. [CrossRef]
• [20] Fares M, AL-Mayyahi M, AL-Saad M. Heat transfer analysis of a shell and tube heat exchanger operated with graphene nanofluids. Case Stud Therm Eng 2020;18:100584. [CrossRef]
• [21] El-Saida EMS, Abou Al-Sood MM. Shell and tube heat exchanger with new segmental baffles configurations: a comparative experimental investigation. Appl Therm Eng 2019;150:039. [CrossRef]
• [22] Kale SS, Gawade SS. Heat transfer augmentation in forced convection with regularly spaced inserts—a review. Techno-Societal 2022 Proc 4th Int Conf Adv Technol Societal Appl Vol 2.
• [23] Kale SS, Gawade SS, Birajdar BR. Improving conversion efficiency of solar panel by cooling system. Techno-Societal 2022 Proc 4th Int Conf Adv Technol Societal Appl Vol 2.
• [24] Singh A, Gupta M, Tiwari DK, Verma RP. Utilization of aluminium helically corrugated twisted tape inserts for heat transfer enhancement of turbulent flow. Mater Today 2023;92:1623–1628. [CrossRef]
• [25] Yadav AS, Mishra A, Dwivedi K, Agrawal A, Galphat A, Sharma N. 4th International Conference on Advances in Mechanical Engineering and Nanotechnology. Mater Today 2022;63:726–730. [CrossRef]
• [26] Liaw KL, Kurnia JC, Putra ZA, Aziz M, Sasmito AP. Enhanced turbulent convective heat transfer in helical twisted multilobe tubes. Int J Heat Mass Transf 2023;202:123687. [CrossRef]
• [27] Hussen HM, Habeeb L, Kadhim ZK. Heat transfer enhancement by using twisted tape in horizontal and an inclined tube. J Mech Eng Res Dev 2020;43:106–124.
• [28] Chandrashekaraiah M, Nagappan B, Devarajan Y. Hybrid power generation: experimental investigation of PCM and TEG integration with photovoltaic systems. Int Res J Multidiscip Technovation 2024;6:225–231. [CrossRef]
• [29] Arulprakasajothi M, Poyyamozhi N, Saranya A, Elangovan K, Devarajan Y, Murugapoopathi S, Amesho KTT. An experimental investigation on winter heat storage in compact salinity gradient solar ponds with silicon dioxide particulates infused paraffin wax. J Energy Storage 2024;82:110503. [CrossRef]
• [30] Jothilingam M, Balakrishnan N, Kannan TK, Devarajan Y. Experimental investigation of a solar still system with a preheater and nanophase change materials. Proc Inst Mech Eng Part E J Process Mech Eng 2024:09544089241247455.
• [31] Thulasiram R, Murugapoopathi S, Surendarnath S, Nagappan B, Devarajan Y. RSM-based empirical modeling and thermodynamic analysis of a solar flat plate collector with diverse nanofluids. Process Integr Optim Sustain 2024;8:1–14. [CrossRef]
• [32] Nalavade S, Prabhune C, Sane N. Effect of novel flow divider type turbulators on fluid flow and heat transfer. Therm Sci Eng Prog 2018;9:322–331. [CrossRef]
• [33] White FM, Xue H. Fluid Mechanics. 9th ed. Tata McGraw-Hill; 2022.
• [34] Incropera FP, DeWitt DP, Bergman TL, Lavine AS. Incropera's principles of heat and mass transfer. 8th ed. New York: John Wiley & Sons; 2017.
• [35] Rahman MA, Dhiman SK. Thermo-fluid performance of a heat exchanger with a novel perforated flow deflector type conical baffles. J Therm Eng 2024;10:868–879. [CrossRef]
• [36] Attou Y, Bouhafs M, Feddal A. Numerical analysis of turbulent flow and heat transfer enhancement using V-shaped grooves mounted on the rotary kiln’s outer walls. J Therm Eng 2024;10:350–359. [CrossRef]
• [37] Raval P, Ramani B. Heat transfer enhancement techniques using different inserts in absorber tube of parabolic trough solar collector: a review. J Therm Eng 2024;10:1068–1091. [CrossRef]
• [38] Raja GA, Natarajan R, Gaikwad PR, Basil E, Borse SD, Sundararaj M. Heat enhancement in solar flat plate collectors—a review. J Therm Eng 2024;10:773–789. [CrossRef]