Heat Exchangers with Double Passive Enhancement€¦ · enhancements found by different authors....

Contemporary Engineering Sciences, Vol. 11, 2018, no. 70, 3445 - 3462

HIKARI Ltd, www.m-hikari.com

https://doi.org/10.12988/ces.2018.87321

Heat Exchangers with Double Passive

Enhancement

Miyer Valdes

Materiales Avanzados y Energía Research Group (MATyER), Instituto

Tecnológico Metropolitano, Calle 73 No. 76A – 354, Medellín, Colombia

Juan Gonzalo Ardila Marín

Department of Mechatronics, Materiales Avanzados y Energía Research Group

(MATyER), Instituto Tecnológico Metropolitano, Calle 73 No. 76A – 354,

Medellín Colombia

Copyright © 2018 Miyer Valdes and Juan Gonzalo Ardila Marín. This article is distributed under

the Creative Commons Attribution License, which permits unrestricted use, distribution, and

reproduction in any medium, provided the original work is properly cited.

Abstract

The use of passive enhancement for heat exchangers, as well as the interest of the

academic community in its study, has increased. It has been found that the

improvement of the transfer rate is the result of the formation of secondary flows,

the increase in turbulence or, simply, the increase in transfer area. In general terms,

when the contact between more particles and the transfer surface is enabled during

the passage through the tubes, heat transfer increases. As a result, a great deal of

studies is available, and a series of heat transfer correlations has been proposed.

Such correlations have been numerically or experimentally developed, and enable

to predict the convection and estimate the size of the exchangers, which makes them

a fundamental design tool. This article is a review of the most important studies

recently published in this field. It presents the geometries that provide single and

double passive enhancements and some of the correlations that are applied to heat

exchangers with double passive enhancement. In brief, this work constitutes a

thorough review of the results of numerical and/or experimental research—as well

as other reviews—in the field of heat exchangers in which the transfer phenomenon

has been improved by means of passive techniques.

Keywords: Heat transfer, Nusselt number, Dean number, Curved tube, Insert

3446 Miyer Valdes and Juan Gonzalo Ardila Marín

1 Introduction

Heat exchangers are devices used to transfer heat from one fluid to another

without mixing them. They are fundamental in many industrial applications such as

refrigeration, heating, air conditioning, agricultural production and vapor

generation systems, as well as cogeneration and chemical plants, among others [1].

The simplest type of exchanger is composed of two tube-in-tubes of different

diameters; this is called a double pipe exchanger. Probably, the most common type

in industrial applications is the shell and tube heat exchanger. These exchangers

contain a great number of tubes parallelly bundled inside a shell [2]. Enhancing the

performance of the exchangers is very important because it is related to energy

saving [1]. For this purpose, two main types of technique have been developed:

active and passive. The first requires external power, such as vibration or magnetic

fields; the second uses inserts or deformations in the surface of the tubing and no

external energy [3]. The passive technique with tube curving has been the most

widely used due to its compact size and high heat transfer coefficient produced by

the pattern of secondary flows studied by Dean since 1927 [4]. In turn, the single

enhancement techniques involve inserting springs, twisted and staggered tapes in

straight tubes, as well as corrugating or curving the latter [1], [5], [6]. Another

technique is the double improvement, i.e. a combination of two simple

enhancements [7] such as a curved tube with spring inserts, corrugation or baffles,

or a straight corrugated tube with tape inserts [8]–[11]. Passive enhancement is the

preferred technique and different geometries have been developed to increase heat

transfer. The following is a general overview of heat exchangers with passive

enhancement reported in the literature. The first section is a description of the

geometries of tubes with simple and double enhancements. Afterwards, the authors

that have conducted CFD studies of double enhancement exchangers are

mentioned. Subsequently, a table lists the heat transfer correlations of double

enhancements found by different authors. Finally, the heat transfer performance of

tubes with double enhancement is described.

2 Geometries of exchangers with simple passive enhancement

The use of an enhancement technique can be restricted to a specific application.

For example, corrugated and dimpled tubes are applicable in the food industry, but

inserts are not due to hygiene issues. In the petrochemical industry, the use of

mechanically bent tubes is not allowed for safety reasons. However, the use of

inserts does not pose any problem. In boilers and heat recovery systems, inserts are

often used because they are easily extracted for cleaning operations [6]. The

performance of many conventional heat exchange systems is generally poor due to

the development of the thermal boundary layer, which results in a low coefficient

of heat transfer by convection between the fluid and the hot surface. A thinner

boundary layer is needed on the heated surface to enhance heat transfer by

convection and reduce overall thermal resistance [12]. The heat transfer coefficient

in a turbulent flow is increased by mixing the flow at the boundary layer and by

Heat exchangers with double passive enhancement 3447

raising the level of turbulence of the flow [13]. In order to obtain such increases,

the surface of the tube is deformed or inserts are added. Skullong et al. studied

several inserts of staggered-winglet perforated tape and compared them to inserts

of non-perforated tape. Both types of tape maintained the same ratios of staggering

height and pitch to tube diameter, and the ratio of perforation area to total area was

equivalent to the porosity ratio of the insert [12] (Figure 1a). Li et al. studied three

combinations of twisted tape inserts: a tape the width of the tube; an internal tube

along with an insert; and an internal tube and four inserts. All these tapes had the

same tape pitch to width ratio [1] (Figure 1b).

Figure 1. Tape inserts. a) Staggered-winglet tape insert, adapted from [12]. b)

Twisted tape insert, adapted from [1].

Liu et al. compared smooth straight tubes and straight tubes with wire coil inserts

in a shell heat exchanger; the tube diameters were the same in both cases [14]

(Figure 2a). García et al. compared three tubes: smooth with wire coil insert,

corrugated and dimpled [6] (Figure 2b). Vicente et al. studied corrugated tubes with

different geometrical parameters by varying the corrugation depth and pitch and

maintaining the same tube diameter [13] (Figure 2c). Vulchanov and Zimparov

studied straight tubes with sand-type roughness with different ratios of roughness

depth to tube diameter and roughness depth to tube length [15].


Figure 2. Straight tubes with helical modifications. a) Wire coil insert, adapted

from [14]. b) Wire coil insert and dimpled tube, adapted from [6]. c) Corrugated

tube, adapted from [13].

Besides the enhancements presented above, the helically coiled exchanger has been

widely reported in the literature due to its high rate of heat transfer compared to

straight tubes—which is the result of its compact structure—and high heat transfer

coefficient [16], [17]. The most outstanding feature of the flow in helically coiled

exchangers is the secondary flow induced by centrifugal force—caused by the

curvature of the tubing—that pushes the particles of fluid towards the central region

and produces a secondary flow field that improves heat transfer [5], [18], [19]. As

a consequence, the heat transfer and friction factor of this type of exchangers are

significantly higher than straight tubing [20]–[22]. Based on the assumption of

smooth curves and low velocities, Dean raised the Navier-Stokes equations in

cylindrical coordinates and proposed a series of solutions for the secondary flow

function and for the axial velocity, from which arose the parameter known by its

name: Dean's number (De), which relates the centrifugal and inertial effects [23].

The following authors have studied helically coiled heat exchangers. Di Piazza and

Ciofalo compared a helically coiled tube with a straight tube, both of the same

length [24]. Kurnia et al. studied three configurations of tubes with square cross-

sections [5] (Figure 3) and compared them with a straight tube with identical cross-

section and length. Conté and Peng studied an internally and externally coiled tube

with a rectangular and curved pattern [25], as shown in Figure 4.


Figure 3. Configurations of tubes with square cross-section. a) Straight b) Conical

c) Helical d) In-plane, adapted from [5].

Figure 4. Coiled tube with rectangular pattern, adapted from [25].

The most exhaustively studied geometry is helically coiled tubes. There are many

types of configurations for this geometry, such as the one proposed by Zhao et al.,

who investigated a coiled tube with membrane [26] (Figure 5a). Different experts

have studied helically coiled tubes placed inside a storage tank [27]–[36] (Figure

5b). Rennie and Raghavan, as well as Zachár, studied a tube-in-tube helical heat

exchanger [18], [22] (Figure 5c).


Figure 5. Helically coiled tube. a) Tube with membrane, adapted from [26]. b)

Tube in storage tank, adapted from [19]. c) Tube-in-tube, adapted from [22].

3 Geometries of exchangers with double passive enhancement

Besides simple passive enhancement, there is double enhancement, i.e. the

combination of two simple improvements. The simultaneous use of two

enhancements has been researched by several authors. Bhattacharyya and Saha

studied a tube with integral helical rib roughness and a center-cleared twisted-tape

insert [37] (Figure 6a). Promvonge experimented with wire coil and twisted tape

placed inside it [10] (Figure 6b). Zimparov studied a helically corrugated tube with

twisted inserts [38]–[41] (Figure 6c). Wongcharee and S. Eiamsa-ard compared two

twisted insert arrangements, parallel and counter arrangements, relative to the

direction of the helical corrugation of the tube [42] (Figure 6d).

Ardila and Hincapié studied heat exchangers with double enhancement: curved and

twisted tubes [43], [44]. Khairul et al. experimented with a helically coiled heat

exchanger with helical corrugation as well [45]. Kumar et al. studied a tube-in-tube

helical exchanger with semi-circular baffles to provide turbulence and maintain the

curvature of the tubes [46] (Figure 7a). Mozafari et al., as well as Wongwises and

Polsongkram, experimented with tube-in-tube configurations and triangular

supports between the tubes, which induced a second passive enhancement [9], [47],

[48] (Figure 7b). Yildiz et al. studied a helically coiled tube with a wire coil insert


[49]. Rainieri et al. compared a straight helically corrugated tube to a helical

corrugated tube with the same type of corrugation [3], [7] (Figure 8a). Li et al. and

Zachár analyzed a helically coiled tube with two-turn helical corrugation [8], [11]

(Figure 8b). Ardila et al. made a comparison between helical smooth tube-in-tubes

and helical corrugated tubes of one and four inlets [50] (Figure 8c).

Figure 6. Double enhancement in straight tubes. a) Tube with integral helical rib

roughness and center-cleared twisted tape insert, adapted from [37]. b) Tube with

wire coil and tape, adapted from [10]. c) Helically corrugated tube with twisted

inserts, adapted from [40]. d) Twisted inserts in parallel and counter arrangement

relative to the direction of the helical corrugation, adapted from [42].


Figure 7. Helically coiled tubes. a) Tube-in-tube with semi-circular baffles,

adapted from [46]. b) Helical tube-in-tube with triangular supports, adapted from

[47].


Figure 8. Helically coiled tubes. a) Helically corrugated helical tube, adapted from

[7]. b) Two-turn helical corrugation, adapted from [8]. c) One- and four-inlet

helical tubes, adapted from [51].

4 CFD studies

Computational Fluid Dynamics (CFD) is a branch of fluid mechanics that uses

numerical methods, such as finite volume, to analyze phenomena of the fluids [50].

CFD programs enable to predict numerical results approximated to experimental

results. This validation has been widely reported in the literature [46]. The accuracy

of the results depends on the configuration of the simulation that adopts turbulence

models such as k-ε, k-ω, DNS, RSM, SST and algorithms like IMPLE, SIMPLEC,

PISO, etc. Some Italian researchers studied the incidence of turbulence models in

the results of simulations and reported that the RSM-ω model—for turbulent flows

greater than 14,000 Reynolds—yields excellent results compared to the

experiments [23]. Wang et al. concluded that the SST model provides the best

prediction of the experimental heat transfer coefficient, and the maximum error

between experimental data and the predictions of such model are in the 10% range

[36]. Besides, Jayakumar et al., as well as Rennie and Raghavan, numerically

studied the effects of the thermo-dependent properties of the fluid in heat

exchangers [17], [18]. Other authors found that the predictions of the CFD

reasonably match the experimental results [17], [20], [31], [35]. Additionally,

Jayakumar et al. confirmed that the CFD predictions matched the experimental

results within experimental error limits of 5% [17]. Kumar et al. concluded that the

numerical predictions for hydrodynamics and fully developed heat transfer were in

good agreement with the experimental results, with an error between 4% and 10%

[46].


5 Heat transfer correlations

Several authors have reported heat transfer correlations resulting from their

experimental and numerical studies. The nature of the correlations available in the

literature (Table 1) suggests that they are defined in terms of the Nusselt number

(Nu), as shown in Equation (1). This number provides a measurement of heat

transfer by convection. It is defined as a function of the Reynolds number,

represented by Equation (2), that establishes the relationship between inertial and

viscous forces in the flow and determines if the flow is turbulent or laminar based

on certain critical values. Sometimes, Re is replaced by the Dean number (De)

defined in Equation (3), which results from the product of Re and the square root

of the quotient of characteristic radii of a curved exchanger. The other typical

parameter, as a function of which Nu is correlated, is the Prandtl number in

Equation (4). Such number is the ratio of momentum diffusivity to thermal

diffusivity, a characteristic of the fluid that provides a measurement of the relative

effectivity of momentum and energy transfer by diffusion at thermal and

hydrodynamic boundary layers [44].

Pr,Defk

hDNu

f

(1)

Where h is the heat transfer coefficient; D , the hydraulic diameter of the

exchanger; and fk , the thermal conductivity of the fluid.

VDRe

(2)

Where is the fluid density; V the mean fluid velocity; and , the dynamic

viscosity of the fluid.

R

rDe Re

(3)

Where r is the hydraulic radius of the tube and R is the radius of the helix

curvature.

f

p

k

c Pr

(4)

Where pc is heat capacity.


Table 1. Correlations by different authors

Correlation Author 4.09112.0 Pr025.0 DeNu (5) [17]

For a straight tube with wire coil inserts 281.0Re012.0Nu (6)

[14] For a straight smooth tube

634.0Re0003.0Nu (7)

R

rNu 455.31PrRe00619.0 4.092.0

(8) [23]

22.04.077.0 1PrRe0061.0 Nu (9)

Where is nanofluid concentration.

[32]

192.0166.0

408.06688.0 Pr5855.0

D

p

D

hDeNu (10)

Where h is corrugation depth and p

is the helical pitch of the corrugation

[11]

Factorial design 3.050096.001646.0 Pr

1083514.2 s

DeVaNuosc

(11)

Where oscNu is the average oscillatory Nusselt and Va is the Valensi number.

2

2*2 rf

Where is the kinematic viscosity and f is the frequency

[4]

Uniform design 3.0

56388.0

01441.0 Pr10

03593.2

DeVaNuosc (12)

4.087.0 Pr280Re012.0 Nu (13) [41]

0238.0132.04055.5432.0 10*Pr98.6895 ttEqtp BoDeNu (14)

Where tpNu

is the two-phase Nusselt; eqDe

, the equivalent Dean; Bo , the

boiling number; and tt, the Martinelli parameter

[48]

44.074.025.0

2

Pr1500Re*

374.0

DphNu (15) [13]

Smooth tube 16.047.0 Pr1168.0 DeNu (16)

Corrugated tube 2.036.1 Pr0919.0 DeNu (17)

[3]

28.02.0 Pr08.2 DeNu for 100Pr18212 De (18)

[18]

46.058.0 Pr39.0 DeNu for 500Pr100212 De (19)

29.03.0 Pr7.2 DeNu for 4.0,2315Pr500212 DDe (20)

19.02.0 Pr27.5 DeNu for 6.0,1610Pr500212 DDe (21)


Table 1. (Continued): Correlations by different authors

38.0382.04.05.0 PrRe47.4 YCRNu (22)

Where CR is the ratio of the wire coil pitch dN and Y is the torsion ratio

wH

Where N is the wire coil pitch; d , the thickness of the wire coil; and w , the

thickness of the twisted tape.

[10]

Perforated tape 2536.03097.04.07682.0 PrPrRe1844.0 BrNu (23)

Where Br is the winglet blockage ratio Db

Where b is the thickness of the winglet.

Non-perforated tape 1714.04.07689.0 PrRe1949.0 BrNu (24)

[12]

4.08291.0Pr0506.0 DeNu (25) [31]

096856199.03.0834694285.0 PrRe02652604.0

MNu (26)

Where M is the gap ratio Dpp ie

Where ep is the pitch of the external helical diameter and ip is the pitch of the

internal helical diameter.

[27]

112.043356.00432.08144.07654.0 10*PrPr1352.0 BoDeNu ttlEqtp

(27)

Where lPr is the Prandtl number of the liquid.

[47]

6 Heat transfer

The following heat transfer results have been published regarding heat exchangers

with double passive enhancement: Mozafari et al. indicated that the average heat

transfer coefficient of a helical tube-in-tube is between 24% and 165%, greater than

that of a straight tube [9]. Rainieri et al. reported that a helical tube with corrugation

increases heat transfer up to 25 times, in contrast with a friction factor increase of

2.5 [3]. Rainieri et al. found that—for Re=1,000—helical corrugated tubes present

a Nusselt number 7 times higher than smooth straight tubes [7]. Wongwises and

Polsongkram found heat transfer with evaporation in a helical tube-in-tube presents

30 to 37% better performance than in a straight tube-in-tube [48]. They also found

that the coefficient of heat transfer with condensation in a helical tube-in-tube is

higher—33 to 53%—than in a straight tube [47]. Finally, Zachár concluded that the

heat transfer rate increases 100% more in a helical tube with helical corrugation

than in a smooth helical tube, both in a De number range from 30 to 1,400 [11].

7 Conclusions

This work reports a thorough review of the results of numerical and/or

experimental research—as well as other reviews—in the field of heat exchangers in which the transfer phenomenon has been improved by means of passive techniques.


Two types of research are differentiated: (1) studies conducted with exchangers

with simple enhancement provided by inserts—generally wires or tapes, in which

helical deformation is common—as well as curving or deforming the tubes or their

surfaces with metalwork and (2) studies conducted on heat exchangers with a

combination of two previously mentioned enhancements—i.e. double inserts or an

insert in addition to tube deformation. All the studies show the expected

enhancement effect after applying the technique. Such improvements vary with the

degree of deformation of the tube or insert, due to the increase in turbulence of the

fluids that results in greater contact of the particles with the transfer surfaces.

Besides, the formation of secondary flows is evaluated. The latter has been studied

by Dean since 1930 and it is associated with centrifugal forces caused by the

curvature of the tubes in the exchangers. Furthermore, many studies confirm that

the combination of passive techniques increases the improvement effect compared

to simple enhancement and to the traditional arrangement of straight smooth tubes.

Additionally, a complete collection of heat transfer correlations was presented in

terms of the Nusselt number given as a function of other dimensionless parameters

that characterize the flow based on features such as velocity, geometry (diameters,

lengths and curvature radii) and the fluid properties (most of them thermo-

dependent, such as density, viscosity, thermal conductivity and specific heat).

These correlations enable project engineers to establish the size of devices for

industrial applications and are useful to promote of the use of this technology that

increases energy recovery and plant efficiency.

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Heat Exchangers with Double Passive Enhancement€¦ · enhancements found by different authors....

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