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Applied Thermal Engineering 100 (2016) 227–236

Contents lists available at ScienceDirect

Applied Thermal Engineering


j o u r n a l h o m e p a g e : w w w. e l s e v i e r. c o m / l o c a t e / a p t h e r m e n g

Research Paper

Experimental investigation on thermal performance and fluid flow


characteristics in heat exchanger tube with solid hollow circular disk
inserts
Alok Kumar a,*, Sunil Chamoli b, Manoj Kumar b
a Mechanical Engineering Department, TULA’S Institute, Dehradun, Uttarakhand 248197, India
b Mechanical Engineering Department, DIT University, Dehradun, Uttarakhand 248009, India

H I G H L I G H T S

• Influence of “Solid hollow circular disk” on heat transfer is presented.


• Significant improvement in η is observed.
• Statistical correlations have been developed for Nu, f, and η.

A R T I C L E I N F O A B S T R A C T

Article history: Enhancement in heat transfer by generating turbulence in the fluid stream inside the heat exchanger
Received 2 September 2015 tube has become an innovative area of research for the researchers. Hence, many techniques have been
Accepted 16 January 2016 investigated and adopted on enhancement of heat transfer rate to reduce the size and cost of the heat
Available online 12 February 2016
exchangers. In the present study the effect of solid hollow circular disk (SHCD) turbulators on heat trans-
fer, friction factor and thermal performance factor of the heat exchanger is evaluated through
Keywords:
experimentation. The different parameters used for the experimentation include fixed thickness ratio (t/
Heat transfer
D) of SHCD, i.e. 0.0075, diameter ratios (d/D = 0.6, 0.7 and 0. 8) and pitch ratios (l/D = 1, 2, 3 and 4). The
Friction factor
Thermal performance factor experiments are conducted in the range of Reynolds number from 6500 to 23,000. The test setup com-
Solid hollow circular disk prises of the test section (1.4 m long) with a hydraulic diameter (D) of 68 mm. Constant heat flux is provided
in the test section with the help of a variable voltage transformer and coiled wire heater. On the basis
of experimental investigation, there is around 4.45 times enhancement in heat transfer in case of PR = 1
and DR = 0.6, and around 1.4 times enhancement in thermal performance factor for PR = 1 and DR = 0.8
when compared to smooth tube heat exchangers.
© 2016 Elsevier Ltd. All rights reserved.

1. Introduction same time it is also important to control the pressure drop due to
these disturbances which causes a rise in friction factor and finally
Heat exchangers are widely used in most of the thermal and me- affects the thermal performance of heat exchangers.
chanical devices. Its main purpose is the exchange of heat from one Different geometries with different geometrical and flow pa-
body to another, and hence it is used in both cooling and heating rameters have been used by different researchers for the
applications. Many researchers have been carried out in order to experimental investigation [2–23]. Bas and Ozceyhan [2] and Bhuiya
improve the heat transfer and thermal performance of heat ex- et al. [3,4] used single, double and triple twisted tapes with differ-
changers in order to reduce the cost and space required for its ent width ratios and twist ratios in their investigation. They found
installation and working. Among several methods used, passive that with a decrease in the value of twist ratio there is an increase
method [1] of heat transfer enhancement is the main area of in- in heat transfer. Some researchers like Eiamsa-ard et al. [5] and
vestigation for most of the researchers. Creating turbulence or Promvonge [6] used combination of twisted tape with circular ring
modifying the fluid stream by using some geometry as a hin- and wire coiled respectively in their experimentation, which showed
drance in the fluid path causes enhancement in heat transfer. At the better result as compared to smooth tube heat exchangers. Simi-
larly Promvonge and Eiamsa-ard [7,10] used conical ring with twisted
tape and serrated twisted tape, Eiamsa-ard and Promvonge [8,11]
* Corresponding author. Tel.: +91 9528657527. used double sided delta wing twisted tape and conical nozzle, Bhuiya
E-mail address: alok.protone@gmail.com (A. Kumar). et al. [9] used perforated twisted tape, and Kongkaitpaiboon et al.

http://dx.doi.org/10.1016/j.applthermaleng.2016.01.081
1359-4311/© 2016 Elsevier Ltd. All rights reserved.
228 A. Kumar et al./Applied Thermal Engineering 100 (2016) 227–236

Fig. 1. Schematic view of experimental setup.

[12,14] used perforated conical ring and circular ring turbulator in to avoid flow separation and stratification. Inlet section is fol-
their experimentation. Some of the other insert geometries used lowed by test section which is 1.4 m long. It comprises heating
were equilateral cross section coiled wire [13], twisted ring [15], arrangement which is made of coil wire heater made of Nichrome
inclined vortex ring [16], short length twisted tape [17], non- wire attached with variable voltage transformer, followed by insu-
uniform wire coil with twisted tape [18], V-nozzle [19], broken lation at the outer surface of the tube. Well calibrated T-type
twisted tape [20], conical nozzle [11], free spacing snail entry with thermocouples are placed near the tube wall, inlet and exit of the
conical nozzle [21], conical ring [22], perforated helical twisted tape flow stream to sense the wall and fluid temperature with the help
[23], etc. It is closely observed that the effect of all these geom- of a data logger with transient response of one second which is at-
etries used by different researchers, one thing is very common, i.e. tached to the computer with Labview software. For measuring
creating turbulence in fluid stream in order to enhance heat trans- pressure drop across the test section, a digital micromanometer is
fer. Some used geometries like twisted tapes which focus on core used, which is attached to tap placed at the inlet and exit of the
fluid disturbance, while some worked one surface modification by test section. Test section is followed by flow arrangement which com-
using coiled wire. Some researchers also investigated the combi- prises blower with 3 HP motor and 3 Φ power supply. In between
nation of both surface and core disturbance in fluid steam on heat blower and test section, a flow measurement device is attached. The
transfer. flow measurement device comprises orifice plate with U-Tube ma-
So, on the basis of previous research and looking at the litera- nometer filled with water as manometric fluid. Adjacent to blower,
ture gap for Kongkaitpaiboon et al. [14], it is decided to use solid flow control valve is attached to control the flow rate and to vary
hollow circular ring (SHCR) as insert geometry for the present work. the fluid flow rate during the experimentation. Schematic diagram
The different parameters used for the experimentation include fixed of the experimental test setup is shown in Fig. 1. The experimen-
thickness ratio (t/D) of SHCD, i.e. 0.0075, diameter ratio (d/D = 0.6, tal uncertainties in the measurement of various results are calculated
0.7 and 0.8) and pitch ratio (l/D = 1, 2, 3 and 4). The experiments using the methodology given by Kline and McClintock [24]. The
are conducted in the range of Reynolds number from 6500 to 23,000. maximum uncertainties calculated for the non-dimensional pa-
In the present work, the effect of SHCD insert on heat transfer and rameters are ±5.2% for Reynolds number, ±6.9% for Nusselt number
friction factor is studied through an experimental investigation. and ±7.4% for friction factor.
In this study, some assumptions are made in order to avoid minor As discussed above solid hollow circular disk is used as insert
losses during the experimentation. These assumptions are: geometry with different geometries and flow parameters in this
study. A photographic view of SHCD insert is shown in Fig. 2.
i. Test section is perfectly insulated, hence there is no heat loss
from the test section.
3. Data reduction and validation
ii. Heat flux is uniformly distributed throughout the test section.
iii. Heat transfer is taking place only through forced convection.
At the steady state condition of the experiment, it is assumed
that convective heat transfer from the wall surface of heat ex-
2. Research methodology changer tube is equal to the heat gain by the fluid circulating in the
tube. Hence the energy balance equation can be written as:
Experimental facility mainly comprised inlet section, also called
as calming section, test section, heating arrangement and air supply Q air = Q conv . (1)
system (blower). Inlet section is 2.5 m long and its main purpose
 Cp ( To − Ti )
where Q air = m (2)
is to allow fully developed flow to enter into the test section and
A. Kumar et al./Applied Thermal Engineering 100 (2016) 227–236 229

Fig. 2. Photographic view of solid hollow circular disk inserts.

And the convective heat transfer from the heat exchanger wall Re = ρVD μ (8)
is given by:
and the value of friction factor is obtained by:
Q conv = hA ( Twm − Tb ) (3)
f = ΔP {(L D) (ρV 2 2)} (9)
where Tb is bulk mean temperature of fluid and it is calculated by
the following equations: in which V is the mean velocity of the tube. All of the thermal prop-
erties of the tested fluid are determined at the bulk mean
Tb = ( To + Ti ) 2 (4)
temperature of fluid.
According to Webb and Kim [25] thermal performance factor is
and
defined as the Nusselt number ratio to the friction factor ratio at
Twm = ∑ Tw 12 (5) same pumping power, which is calculated by the following equa-
tion:
where ‘Tw’ is the local wall temperature at which thermocouple was
placed. ‘Twm’ is mean wall temperature, which was again the average Nu Nus
η= (10)
temperature of the total thermocouple placed on the wall surface. (f fs )1 3
It is assumed that temperature distribution is uniform through-
out the wall surface. The average heat transfer coefficient, ‘h’, and A thorough check of the instruments and the test set-up was fol-
the average Nusselt number, Nu, are estimated as follows: lowed by experimentation on conventional smooth pipe. The average
values of Nusselt number and friction factor were determined. These
 Cp ( To − Ti ) A ( Twm − Tb )
h=m (6) values are compared with the values obtained from the standard
correlation like Blasius equation for friction factor and Dittus–
and Boelter equation for Nusselt number in case of smooth tube. The
standard equations for friction factor and Nusselt number are given
Nu = hD k (7)
as:
The value of Reynolds number is obtained by standard equa-
tions mentioned below: Blasius equation

90
Nusselt Number (Nu)

80 Correlation
Experimental
70

60

50

40

0.031
0.030
0.029
Friction Factor (f)

0.028
0.027
0.026
0.025
0.024
0.023
0.022

10000 15000 20000 25000 30000 35000


Reynolds Number (Re)

Fig. 3. Validation of experimental setup.


230 A. Kumar et al./Applied Thermal Engineering 100 (2016) 227–236

270
DR=0.6, PR=1
DR=0.6, PR=2
240 DR=0.6, PR=3
DR=0.6, PR=4
DR=0.7, PR=1
DR=0.7, PR=2
210
DR=0.7, PR=3
DR=0.7, PR=4
Nusselt number (Nu) DR=0.8, PR=1
180 DR=0.8, PR=2
DR=0.8, PR=3
DR=0.8, PR=4
150

120

90

60

6000 9000 12000 15000 18000 21000 24000


Reynolds number (Re)
(a)

5.0

4.8 DR=0.6, PR=1 DR=0.6, PR=2 DR=0.6, PR=3 DR=0.6, PR=4


DR=0.7, PR=1 DR=0.7, PR=2 DR=0.7, PR=3 DR=0.7, PR=4
4.6 DR=0.8, PR=1 DR=0.8, PR=2 DR=0.8, PR=3 DR=0.8, PR=4

4.4

4.2

4.0
Nu/Nus

3.8

3.6

3.4

3.2

3.0

2.8

2.6
6000 9000 12000 15000 18000 21000 24000
Reynolds number (Re)
(b)
Fig. 4. (a) Variation in Nusselt number with Reynolds number. (b) Variation in Nu/Nus with Reynolds number.

f s = 0.316 × Re−0.25 (11) According to experimental value, Fig. 3 shows the validation of
friction factor and Nusselt number over the standard smooth tube
equation. Deviation of ±5% is seen in the case of Nusselt number
Dittus–Boelter equation
and ±7% in case of friction factor, as compared to smooth tube heat
exchanger. This small deviation in experimental result allows pro-
Nus = 0.023.Re0.8 .Pr 0.4 (12)
ceeding with the experimentation.
A. Kumar et al./Applied Thermal Engineering 100 (2016) 227–236 231

Fig. 5. Velocity vector contour and flow behavior.

4. Results and discussion smooth tube heat exchangers for the lower range of Reynolds
number.
On the basis of experimental investigation different results have
been obtained for different set of insert geometries. Variation of heat 4.2. Effect on friction factor
transfer and friction factor on the basis of different geometries and
flow parameters is obtained through experimental data. These data Friction factor (f) plays a dominant role in the efficient working
are further used to plot graphs which show variation of heat trans- of heat exchangers. For the higher values of friction factor the thermal
fer and friction factor with respect to different geometrical and flow performance decreases, so it is very necessary to control friction
parameters. factor in order to improve thermal performance. Fig. 6a and b shows
the effect of different geometries and flow parameters on the value
4.1. Effect on heat transfer of friction factor during experimentation.
It is observed that, with the increase in Reynolds number, fric-
The main objective of the experiment is to enhance heat trans- tion factor value decreases as it is inversely proportional to the square
fer compared to smooth tube heat exchangers. The effect of all insert of velocity. As the value of DR decreases, friction factor increases
geometries on heat transfer is shown in Fig. 4a and b. significantly. This is because of the increase in flow disturbances
It was noticed that as the value of diameter ratio decreases, heat due to lower diameter ratio. Because of densely populated insert
transfer increases significantly, and for DR = 0.6 heat transfer rate geometry in case of PR = 1, there is a frequent obstruction in the fluid
was maximum as compared to other diameter ratios. This happens flow, which leads to high friction factor. The physical behavior of
because of dominant jet impingement for the lower value of di- fluid flow can be observed in Fig. 5. Minimum friction factor value
ameter ratio. These dominant disturbances cause generation of eddy was observed at the higher range of Reynolds number for the insert
and vortex near the SHCD, which causes proper mixing of flow parameter PR = 3 and DR = 0.8.
stream, which leads to heat transfer enhancement. As the value of
DR increases these dominant disturbances also lose its effect, causing 4.3. Effect on thermal performance factor
decreases in heat transfer for higher diameter ratios. A similar effect
is observed for pitch ratio also. As the value of pitch ratio de- Thermal performance factor is a very important aspect for the
creases, heat transfer increases because of densely populated SHCD utilization of heat exchanger which is calculated by Eq. (10), which
in case of PR = 1. This leads to increase in frequency of eddy gen- is ratio of enhanced Nusselt number to the enhanced friction factor
eration across the SHCD, which causes an enhancement of heat as compared to plain tube and tube with insert. As there is tre-
transfer. These dominant disturbances can be clearly seen in Fig. 5, mendous increase found in the value heat transfer and friction factor
which is based on a CFD analysis done using ANSYS 14.2 software. for different insert geometries, it is very important to use only such
The K-epsilon model has been selected as a turbulence model for geometry in which thermal performance factor is maximum or more
the CFD analysis. The grid independent test was also being per- than unity (η ≥ 1).
formed during the analysis. The triangular grid system was used for It is found that thermal performance factor value is higher in the
grid independence test and it was found that after 724,000 mesh, lower range of Reynolds number and as the value of flow param-
grid system was behaving like independent of all the insert geom- eters increases, the thermal performance factor decreases
etries. The motive of this analysis was only to show the flow pattern significantly. Maximum thermal performance factor is observed for
of the fluid because of the obstruction produced due to the SHCD. the insert parameter of PR = 1 and DR = 0.8, and it is 1.4 times higher
Maximum augmentation in heat transfer was observed for PR = 1 as compared to smooth tube heat exchangers. As the value of PR
and DR = 0.6, which was around 4.5 times higher as compared to increases, the thermal performance factor decreases significantly,
232 A. Kumar et al./Applied Thermal Engineering 100 (2016) 227–236

2.2
DR=0.6, PR=1 DR=0.6, PR=2 DR=0.6, PR=3 DR=0.6, PR=4
DR=0.7, PR=1 DR=0.7, PR=2 DR=0.7, PR=3 DR=0.7, PR=4
2.0 DR=0.8, PR=1 DR=0.8, PR=2 DR=0.8, PR=3 DR=0.8, PR=4

1.8

1.6

Friction factor (f)


1.4

1.2

1.0

0.8

0.6

0.4

6000 9000 12000 15000 18000 21000 24000


Reynolds number (Re)
(a)

DR=0.6, PR=1 DR=0.6, PR=2 DR=0.6, PR=3 DR=0.6, PR=4


80
DR=0.7, PR=1 DR=0.7, PR=2 DR=0.7, PR=3 DR=0.7, PR=4
DR=0.8, PR=1 DR=0.8, PR=2 DR=0.8, PR=3 DR=0.8, PR=4
72

64

56

48
f/fs

40

32

24

16

6000 9000 12000 15000 18000 21000 24000


Reynolds number (Re)
(b)
Fig. 6. (a) Variation in friction factor with Reynolds number. (b) Variation in f/fs with Reynolds number.

and as the value of DR increases, the thermal performance factor be carried out by introducing perforation in solid disk. A single set
also increases. Effect of different parameters on the thermal per- of reading is taken with perforation and comparison is made
formance factor is shown in Fig. 7. between present and past work of Kongkaitpaiboon et al. [14],
which is shown in Fig. 8a and b. It is found that perforation shows
5. Future aspect tremendous impact on the thermal performance factor of the
heat exchanger tube. Also, this comparison shows that with de-
Looking at the future aspect of the present work and consider- creases in PR, significant improvement in thermal performance
ing high friction factor in case of solid disk insert future work can factor can be seen.
A. Kumar et al./Applied Thermal Engineering 100 (2016) 227–236 233

1.5
DR=0.6, PR=1 DR=0.6, PR=2 DR=0.6, PR=3 DR=0.6, PR=4
DR=0.7, PR=1 DR=0.7, PR=2 DR=0.7, PR=3 DR=0.7, PR=4
DR=0.8, PR=1 DR=0.8, PR=2 DR=0.8, PR=3 DR=0.8, PR=4
1.4

Thermal performance factor ( )


1.3

1.2

1.1

1.0

0.9
6000 9000 12000 15000 18000 21000 24000
Reynolds number (Re)

Fig. 7. Variation in thermal performance factor with Reynolds number.

6. Correlations " f = 0.1284 Re−0.1199 DR −4.2233 PR −0.2374 exp {0.0033 (ln PR 2 )} (14)

According to the experimental results obtained for Nusselt


• η = 5.1867 Re−0.1201 DR 0.8107 PR 0.0632 exp {−0.0952 (ln PR 2 )} (15)
number, friction factor and thermal performance factor with respect
to different flow and geometrical parameters of SHCD inserts, sta-
tistical correlations have been formulated. These correlations are 7. Comparison with previous work
entirely based on the experimental results obtained under the range
of temperature and pressure achieved in the present work and is According to the experimental study, a very significant augmen-
valid only for air as working fluid and the same kind of insert ge- tation of heat transfer and thermal performance factor can be
ometry, as used in the present work. Many investigators like Hans observed when SHCD is used as insert geometry. Comparison of the
et al. [26] and Singh et al. [27] used statistical methods to develop present work with some of the similar past work can be seen in
correlations for Nusselt number and friction factor and found that Table 1. The benefits of using SHCD over other insert geometries are
these statistical correlations are capable of predicting the perfor- many. It is very easy to manufacture SHCD as it can be simply made
mance of the roughened heat exchanger as the difference in the using punching and blanking operation using die and punch of a
predicted and experimental values is within acceptable limits. Sigma particular size. Cost of manufacturing is also very less as only single
plot-12 software has been used as a statistical tool for regression operation is used in making SHCD. Since very thin sheet metals are
analysis and to develop the correlations for Nusselt number, fric- used as raw materials, SHCD are not that costly as compared to
tion factor and thermal performance factor of the heat exchanger twisted tapes or conical rings. Manufacturing of other insert ge-
tube with SHCD insert. It is observed from experimental data that ometries like twisted tape has more complications as there is always
Nusselt number, friction factor and thermal performance factor are a chance of material wastage, as twist ratios have to be main-
strong functions of geometrical and flow parameters. It can be said tained uniformly throughout the twisted tape. Hence use of SHCD
that Nusselt number, friction factor and thermal performance factor can be advantageous as compared to other geometries used in such
are the functions of these parameters and can be written as: kind of study.

• Nu = Nu(Re, DR, PR)


• f = f(Re, DR, PR)
• η = η(Re, DR, PR) Table 1
Comparison of present work with some of similar past work.
On the basis of regression analysis and correlation obtained with S. No. Reference Enhanced heat Thermal
the help of sigma plot software, it is seen that the deviations of ex- transfer (Nu/Nus) performance
perimental and predicted values are ±5%, ±14% and ±8%, respectively, factor (η)

for heat transfer, friction factor, and thermal performance factor. 1. [5] 4.5 1.42
These deviations are shown in Figs. 9, 10 and 11 respectively. 2. [6] 6.5 1.54
3. [7] 3.67 1.95
On the basis of regression analysis, correlations obtained for
4. [12] 3.8 0.92
Nusselt number, friction factor and thermal performance factor are 5. [18] 3.7 1.25
given by the following equations: 6. [21] 4.1 1.1
7. [22] 3.3 1.8
• Nu = 0.1284 Re0.7253 DR −0.5792 PR −0.088 exp {−0.0246 (ln PR 2 )} (13) 8. Present work 4.45 1.4
234 A. Kumar et al./Applied Thermal Engineering 100 (2016) 227–236

1.35

Present work (DR=0.7, PR=1)


Future aspect using perforation (DR=0.7, PR=4)
1.30
Kongkaitpaiboon et al. (DR=0.7, PR=4)
Thermal performance factor ( )
1.25

1.20

1.15

1.10

1.05

1.00
6000 9000 12000 15000 18000 21000 24000
Reynolds number (Re)
(a)

Perforation in SHCD

(b)
Fig. 8. (a) Thermal performance factor comparison curve. (b) Perforated inset used for future aspect prediction.

8. Conclusions significantly with the decrease in PR, and for PR = 1, thermal


performance factor is maximum for all sets of geometrical
On the basis of experimentation and results obtained, the fol- parameters.
lowing conclusions are made: • Flow parameter also shows significant effect on heat transfer, fric-
tion factor and thermal performance factor respectively. With
• For DR, as the value of DR increases, there is a significant de- the increase in Reynolds number heat transfer increases for all
crease in the amount of heat transfer. The same trend is observed sets of geometries. But there is a decrease in the value of fric-
for friction factor also; for a higher range of DR, friction factor tion factor in the higher range of Reynolds number. Thermal
is less. But it shows different effect on thermal performance factor. performance factor was found to be maximum for all sets of ge-
As the value of DR increases, the thermal performance factor also ometrical parameters for the lower range of Reynolds number.
increases significantly, and for DR = 0. 8, thermal performance • On the basis of regression analysis and correlation obtained, it
factor is maximum. is seen that the deviations of experimental and predicted values
• For PR, increase in the amount of heat transfer is observed as are ±5%, ±14% and ±8%, respectively, for heat transfer, friction
there is decrease in the value of PR, and for PR = 1, heat factor, and thermal performance factor.
transfer is maximum. Similarly, as the value of PR increases, • SHCD can be used as insert geometry as its manufacturing is com-
friction factor decreases significantly, and for PR = 4, friction paratively easy and less costly. Also, it is easy to place it inside
factor is minimum. Thermal performance factor increases the tube.
A. Kumar et al./Applied Thermal Engineering 100 (2016) 227–236 235

300

250

+ 5%
Nupredicted 200

- 5%
150

100

50
50 100 150 200 250 300

Nuexperimental

Fig. 9. Plot for deviation between experimental and predicted values of Nu.

Acknowledgements
η Thermal performance factor
PR Pitch ratio
The author would like to gratefully acknowledge DIT Universi-
DR Diameter ratio
ty, Dehradun, Uttarakhand, India, for its support and facilities
Patm Atmospheric pressure (Pa)
provided for the research.

m Mass flow rate of fluid (kg/s)
D Hydraulic diameter (m)
Nomenclature
d Internal diameter of insert (m)
A Surface area of test section (m2)
Re Reynolds number
q Heat flux (W/m2)
Nu Nusselt number
Cd Coefficient of discharge
Pr Prandtl number
L Length of test section (m)
f Friction factor

2.0

1.8

1.6

1.4 + 14%
fpredicted

1.2

1.0
- 14%
0.8

0.6

0.4

0.2
0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0

fexperimental

Fig. 10. Plot for deviation between experimental and predicted values of f.
236 A. Kumar et al./Applied Thermal Engineering 100 (2016) 227–236

1.6

1.4
+ 8%
predicted

1.2

- 8%
1.0

0.8

0.8 1.0 1.2 1.4 1.6

experimental

Fig. 11. Plot for deviation between experimental and predicted values of η.

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