Mini Project Report

1.
Introduction
Energy conservation requires for reduction in consumption of primary resources,
environment protection and materials and manufacturing input savings. Methods of
improving the thermal and hydrodynamic performance of heat exchange devices are referred
to as heat transfer enhancement, and sometimes as augmentation or intensification (AE, 1998;
RM & AE, 2003). Heat transfer enhancement is one of the main research area in thermal
engineering domain, in which different methods to enhance the heat transfer are studied,
tested, and analyzed. Heat transfer enhancement is one of the challenging task in various
industries containing solar systems, electronic equipment, heat exchangers, and so on. Due to
the development of modern technology, the heat exchangers required in various industries for
high heat-flux cooling to the level of megawatt per meter square. At this level, cooling with
conventional fluids such as water and ethylene glycol are challenging because of their poor
thermal conductivity. Hence, it is necessary to increase the heat transfer performance of
working fluids in the heat transfer devices.
Due to lack of energy sources in many industrial applications, heat transfer

enhancement of thermal systems is one of the important problem. In the last few
decades, there is a significant growth in various industries such as electronics,
communication, and computing technologies and it will continue. Aerospace
applications, HEV, microprocessors heat fluxes etc. require high performance cooling
compact techniques. The essential thing in the energy conservation of heat transfer
equipment is its efficiency. Also, a more efficient heat exchanger can reduce the size of the
heat exchanger, thus reducing the costs associated with both material and manufacturing of
the heat exchanger (Tijing, Pak, Baek, & Lee, 2006). Improved heat transfer can make heat
exchangers smaller and more energy efficient (Eiamsa-Ard & Promvonge, 2005). In the last
few decades, significant efforts have been made to develop heat transfer techniques in order
to improve overall performance of heat exchangers. As there in increase energy cost, we can
expect that there will be a new growth phase in heat transfer enhancement field.
In the heat transfer process, heat exchanger plays an important role. Various heat
transfer enhancement techniques are developed to improve the thermal performance of heat
exchanger systems.
Heat transfer enhancement techniques are classified into three categories: Active
methods, Passive methods, and Compound methods. These techniques are used in various
areas such as thermal power plants, automobiles, refrigerators, heating and cooling in
evaporators etc. Heat transfer techniques can be as simple as change of the fluid velocity
inside the unit or as complex as the design of new surface geometries or the design of inserts
in the case of tubular geometry (Picon-Nunez, Melo-Gonzalez, & Garcia-Castillo, 2018).
Heat transfer enhancement is one of the fastest growing areas in heat transfer. These
heat transfer enhancement techniques include – 1. Active methods – mechanical aids, fluid
vibration, jet impingement, 2. Passive methods – extended surfaces, treated surfaces,
additives for fluids, swirl-flow devices, etc. and 3. Compound methods – rough-surface tube
with a twisted tape insert etc.
The active method involves addition of nanosized, high thermal conductivity, and
metallic powder to the base fluid, to increase the heat transfer rate. Active methods require
external power for instance like fluid vibrations etc. (Picon-Nunez, Melo-Gonzalez, &
Heat transfer enhancement methods for an heat exchanger Page 1

Garcia-Castillo, 2018). By increasing the surface area or by changing the boundary
conditions the rate of heat transfer can be increased passively. Comparatively passive
techniques are better where inserts are used to enhance heat transfer rate because the insert
manufacturing process is simple and they can be easily applied (Sonawane, Patil, & Chavan,
2016).
For the enhancement of heat transfer, active methods use external power while,
passive methods does not use any of the external power. The passive methods are mostly
preferred as there are simple and can be applied easily in various applications. Heat transfer
enhancement can also be termed as heat transfer augmentation or intensification. Heat
transfer enhancement techniques lead to increase in heat transfer coefficient but at the
expense of increase in pressure drop. So, while designing a heat exchanger using any of these
techniques, analysis of heat transfer rate & pressure drop has to be done (Dhumal, Kerkal, &
Pawale, 2017). Enhancing the performance of a heat transfer device is therefore of great
interest since it can result in energy, material and cost saving.
1.1. Heat exchanger
Heat exchanger is used to transfer heat between two fluids which are at different
temperatures. They are used in many engineering applications such as air-conditioning
systems, refrigeration systems, automobiles, power plants, food processing systems etc. Few
examples of heat exchangers are shell and tube heat exchangers, double pipe heat exchangers,
plate heat exchangers, economizers, evaporators, condensers, and cooling tower in thermal
plants.
In last few decades, the demand for efficient heat transfer in heat exchangers has increased.
Every heat exchanger works in steady state. Irrespective of the design all the heat exchangers
works under the basic fundamental laws – namely the Zeroth, First, and Second laws of
thermodynamics-which describe the transference of heat from one fluid to another fluid. The
most common materials used to construct the heat exchangers are tubes, coils, shells, fins,
plates.
The common metals used for constructing heat exchangers are titanium, copper due to their
high thermal conductivity. Depending on the required application other materials such as
graphite, ceramics, plastics or composites are also used in the construction of heat
exchangers. There are two types of heat transfer mechanisms employed by heat exchangers—
single-phase or two-phase heat transfer (Ronquillo). The required amount of thermal energy
needed for either heating or cooling is provided by the heat exchanger. To select a particular
type of heat exchanger, the rate of heat transfer is taken into consideration.

Fig. 1. Ceramic heat exchanger (CG Thermal, 2020)
1.2. Objectives of the work

This paper gives an idea about heat transfer rate in heat exchangers and various techniques
that are used to enhance the heat transfer rate in heat exchangers.
1.3. Motivation for the work

Due to increased demands by industry for heat exchange equipment, effort have been made to
produce more efficient heat exchangers by using different methods of heat transfer
enhancement. Savings in usage of energy and materials also produce strong motivation for
the advancing of better methods of enhancement.
1.4. Scope of the work

This report helps in designing a heat exchanger which helps to increase the heat transfer rate
and save the energy and cost.
2. Literature survey
(Ray & Jhinge, 2014) concludes that, wire coiled tube will be having higher pressure drop
when compared to an empty tube. The pressure drop depends on the geometry of the wire and
is always act a significant. Wire coil inserts will do better in turbulent and transition region
flow. Within the transition region, if wire coils are fitted in a smooth tube warmth exchanger,
heat transfer rate is often increased up to 200% keeping pumping power constant. In laminar
flow wire coil insert is not so effective and results shows that wire coils act like as a smooth
tube but accelerate transition to critical Reynolds numbers down to 700. In turbulent flow,
Wire coil leads a high drop increase which depends majorly on pitch to wire diameter ratio.
In the selection of the wire coil inserts, the form of the insert is important. Wire coil provides
better overall performance when the pressure drop penalty is considered.

(Shrikhande & Kriplani, 2014) concludes that various methods of enhancing the heat transfer rate
in automobile radiator by using various types of fluid flow rate, Reynolds number, nano
fluids and the volumetric concentration. Addition of various nano particles or additives to a
liquid slightly improves the viscosity and the thermal conductivity moderately. The
suspension of nano particles in the base liquid improves the heat transfer area and finally it
leads to the increase in the heat transfer due to the heat transfer rate depends upon the total
surface area available for transferring the heat. The thermal conductivity of the aluminium
oxide is lower when compared to copper oxide, titanium oxide and silicon oxide. From the
above study it is observed that with increasing the fluid flow rate particle concentration the
heat transfer rate increases with slight penalty of the pressure drop.
(Thianpong, Eiamsa-ard, Promvonge, & Eiamsa-ard, 2011) has gone through experimental
investigation on heat transfer and pressure drop nature of turbulent flow in a heating tube
consists of perforated twisted tapes with parallel wings for Reynolds number range in
between 5500 to 20500. he did the design of perforated twisted tape with the following -
 The wings consists an extra turbulence near tube wall which leads to disrupt the
thermal boundary layer efficiently.
 The pre-existing holes along a core tube decreases the pressure losses in the tube. The
different parameters investigated by him i.e. the hole diameter ratio and wing depth
ratio and also typical twisted tape was also been tested for the assessment. he
compared the results with the plain tube, the result says that the tubes having
perforated twisted tape heat transfer rate increases to 208 % and also with the twisted
tape the heat transfer icreases up to 190%. they check the overall performance during
experimentation under the similar pumping power with that of perforated twisted tape
with ratio of d/W and w/W which are equal to 0.11and 0.33 respectively, provides the
maximum thermal performance factor of 1.32, in the Reynolds number range of 5500.
(Matani & Dahake, 2013) says that, thermal nature in a tube fitted with twisted-tapes in co-
swirl arrangement with wire coil are shown in the present study. Results says that wire coil of
pitch ratio 0.88 is more higher to all twisted tapes. In twisted tape twin twisted tape acts as
counter swirl generator, which shows better performance than single twisted tape alone. The
work was conducted in the turbulent flow regime, Reynolds number from 5000 to 18,000
with air as the test fluid.
The results of the work can be noted as follows:
1. For the inserted tube, the pressure drop will increase with the rise in mass flow rate where
as the friction factor and performance factor has the opposite trends.
2. The compound enhancement system of the tube and the counter/co-swirl shows a slight
increase of heat transfer rate and thermal performance when compared to the smooth tube
acting alone, depending on twist ratios.

3. The counter/co-swirl tube yields larger friction factor and performance factor compared to
the smooth tube at low Reynolds number.
(Richard.T.L & Agilan.H, 2015) says that the experimental analysis in the work the enhancement
of heat transfer of fin for various materials is made and it can be increased. Fin efficiencies of
materials are 68%, 94%, 91% are achieved. And among all these materials from the analysis
says that copper has more thermal conductivity than aluminium and brass.
3. Heat transfer enhancement methods

Heat transfer enhancement helps in improving the thermo hydraulic performance of heat
exchangers. The performance of heat exchanger is defined by its thermal performance (i.e. by
improvement in convective heat transfer coefficient) and by its hydraulic performance (i.e.
amount of power consumed in pumping the fluid). Hence the term thermo hydraulic
performance is used as an indicator to heat exchanger performance (Saha, Tiwari, Sundén, &
Wu, 2016).
Various methods or techniques used for enhancing the heat transfer are – active methods,
passive methods, compound methods. Depending on the requirement of heat transfer rate we
use the suitable method. The method which leads to high heat transfer enhancement will be
accepted. Enhancement methods are primarily employed in a heat exchanger to reduce the
thermal resistance by producing higher heat transfer coefficients with or without surface area
increases; the latter is effected by fins or extended surfaces (Manglik, 2018).
These existing methods are broadly classified into two categories. In one category of
methods, the second law of thermodynamics is used and in another category of methods, the
first law of thermodynamics is used. The factors like safety, reliability, and ease of
manufacturing are taken into consideration while evaluating the method. In the present
situation, the need of energy-saving of heat transfer enhancement has acquired more
attention.
Table :1 classification of different active and passive methods
Active methods Passive methods

Mechanical aids Extended surfaces
Fluid vibration Treated surfaces
Surface vibration Rough surfaces
Jet impingement Swirl flow devices
Electrostatic fields Surface tension devices
Suction Displaced enhanced devices
Injection Additives for liquids
Induced flow stabilities Additives for gases
Rotation Coiled tubes

3.1. Active methods
For the enhancement in heat transfer, active methods use the external power input. Providing
external power is not easy in most of the applications; for this reason, the use of active
methods is limited. As there is necessity of external power input, the active methods are more
complex when compared to passive methods in the context of design and applications. Active
methods are not as common as passive methods. These methods are used in such places
where high and quick enhancement of heat transfer is needed. The heat transfer in active
methods is very high when compared to passive methods. Hence active methods are preferred
where high heat transfer enhancement is required.
The majority of commercially interesting techniques are mainly limited to passive techniques.
However, active techniques such as electro hydrodynamic (EHD) enhancement of boiling and
condensation indicate significant potential (Akira & Hiroshi, 1988). Active methods have
attracted little financially interest because of the costs involved. Active methods need extra
effort towards the development and design of an efficient heat exchanger.
These methods have great potential can control thermally. In scientific fields the use of
active methods is limited because, providing external power input in most of the applications
is not easy. Though active methods have acquired massive attention in research, their
applications have been limited. Let us go through various active methods that are responsible
for enhancing the heat transfer.
3.1.1. Electro hydrodynamics (EHD)
Electro hydrodynamic heat transfer enhancement uses interaction of electric field with
magnetic field in a dielectric fluid medium. This interaction, under certain conditions, results
in electrically induced fluid motion and/or interfacial instabilities, which are caused by an
electric body force (Saha, Tiwari, Sundén, & Wu, 2016). A high voltage and current is
applied to the fluid in this method. One of the major aims of this method is to convert
electrical energy into kinetic energy. The electric forces that are responsible for the
displacement of fluid are obtained by:
(1)
Where ,E the electric field strength( v/m), Fe is the electro hydrodynamic force ( N/m2 ), qc
is free electric charge density( C/m3 ), the fluid permittivity( F/m), q the fluid density(
kg/m3 ), and T the temperature in (K) (Jadhav, Awari, Bibe, Bramhane, & Mokashi, 2016).
The three terms in Eq. (1) stand for the electrophoretic, dielectrophoretic, and electrostrictive
components of the electric force (Saha, Tiwari, Sundén, & Wu, 2016).
This force can cause interfacial instabilities that force the liquid with higher permittivity to
move to the regions of higher electric field. This phenomenon is usually called as liquid
extraction phenomenon and is believed to be the primary mechanism responsible for flow
regime transitions which cause heat transfer enhancement (Saha, Tiwari, Sundén, & Wu,
2016). The first term of the equation, electrophoretic force, is the coulomb force. This force
occurs due to presence of net charge in the dielectric fluid medium. In single phase, the heat
transfer enhancement is mainly due to this force. The second term of the equation,

dielectrophoretic force, results as a change in permittivity of the fluid. Since the gradient in
the dielectric permittivity is very high at the liquid-vapour surface, this dielectrophoretic
force dominates in two-phase flows. The third term of the equation, electrostrictive force,
involves electrostriction based on the presence of different electric fields within the dielectric
fluid. The other point which is to be considered in this EHD method is the occurrence of
nucleate boiling in the material which increases the electrostatic force, which in turn
increases the heat transfer.
A wide range of applications for EHD method are reported in the literature consisting of:
pumping (Seyed-Yagoobi, 2005), single phase heat transfer (Alamgholilou & Esmaeilzadeh,
2012; Laohalertdecha, Naphon, & Wongwises, 2007), boiling (Cotton, Robinson, Shoukri, &
Chang, 2012; Liu, Li, Wang, & Yu, 2005), condensation (Laohalertdecha & Wongwises,
2006; Sadek, Ching, & Cotton, Characterization of Heat Transfer Modes of Tube Side
Convective Condensation under the Influence of an Applied DC Voltage, 2010), mixing
(Jalaal, Khorshidi, & Esmaeilzadeh, 2013). There are many studies regarding electro
hydrodynamic heat transfer enhancement. Grassi et al. studied heat transfer enhancement in
an annulus flow due to ion injection from sharp electrodes, experimentally (Grassi, Testi, &
Saputelli, Heat Transfer Enhancement in a Vertical Annulus by Electrophoretic Forces
Acting on a Dielectric Liquid, 2005) . N. Kasayapananad and T. Kiatsiriroat studied heat
transfer enhancement in a partially open square cavity with different wire electrode
arrangements (Kasayapanand & Kiatsiriroat, 2009).R. Baghaei Lakeh and M. Molki used a
corona jet to locally enhance natural convection heat transfer in a pipe (Lakeh & Molki,
2012). Sahebi and Alemrajabi studied EHD enhanced natural convection heat transfer of an
inclined heated plate with corona jet, experimentally (Sahebi & Alemrajabi, 2014). These
works proved that heat transfer can be enhanced significantly by EHD method.
The above mentioned papers considered ion-drag pumping, which is an EHD method. This
ion-drag pumping utilizes a wire-plate or needle-plate to generate the corona wind. Ion-drag
pumping deals with injection of ions from a sharp metal electrode into the fluid. This
injection of ions results in the degradation of the working fluid and electrode. A modern
concept, EHD conduction pumping is developed in contrary to the ion-drag pumping method.
It is associated with the nonequilibrium process of dissociation of neutral species and
recombination of generated ions in a finite thickness in the vicinity of electrodes which is
known as hetrocharge layer (Mirzaei & Saffar-Avval, 2018). This EHD conduction pumping
mechanism consumes lower power. Comparatively EHD conduction pumping mechanism is
better than ion-drag pumping mechanism.
Atten and Seyed-Yagoobi presented the first theoretical model of EHD conduction pumping
(Atten & Seyed-Yagoobi, 2003). This model was further developed in other researches. A
number of experimental studies in different electrode configurations are implemented by
different researchers on conduction pumping and the theoretical model is validated against
their results (Pearson & Seyed-Yagoobi, 2009; Siddiqui & Seyed-Yagoobi, 2009; Feng &
Seyed-Yagoobi, 2006). Publications related to EHD conduction pumping are very limited.
(Sadek, Robinson, Cotton, Ching, & Shoukri, 2006) have studied in-tube condensation of R134a
in a horizontal, single-pass, counter-current heat exchanger with a rod electrode placed in the
centre of the tube. In their study they have observed how the various characteristics like
overall heat transfer coefficient, enhancement ratio, over all pressure drop, pressure drop ratio
varies by varying applied voltage.

Fig.2. Effects of applied voltage on heat transfer coefficient and pressure drop at mass
flux of 83.4 kg/(m2s), heat flux of 10.2 kW/m2 and inlet quality of 66 %. (a) overall heat
transfer coefficient, (b) overall pressure drop (Sadek, Robinson, Cotton, Ching, & Shoukri,
2006).

From the graph, we can observe that over all heat transfer coefficient was increased by a
factor of 3.2 for EHD voltage of 8KV. The overall pressure drop was increased by a factor of
1.6 at same conditions of heat transfer enhancement. These results are obtained from their
study. The heat transfer enhancement is associated with strong EHD force. This EHD force
removes the condensate from the heat transfer surface, thus reducing the overall thermal
resistance and improving the heat transfer. EHD method is efficient for materials having
electrical properties. Hence EHD is one of the efficient method of heat transfer enhancement.
3.1.2. Jets
Jets are one of the most widely used phenomena because they exhibit free or wall-bounded
shear turbulent flows and large vortex structures which are essential in fluid dynamics and
engineering. Jets are used for various industrial applications such as cleaning, heating,
cutting, cooling, and jet and rocket propulsion. Many studies have been done on jets
phenomena because this method helps in enhancement of the heat transfer. Few literature
surveys on impingement heat transfer of jets are presented by (Viskanta, 1993; Oosthuizen &
Bassey, 1973). (Martin, 1977) examined heat and mass transfer for single round nozzle,
arrays of round and slot nozzles and provided extended reviews of heat transfer data .
A fluid flowing at high speed (jet) breaks the boundary layer and it get mixes near the surface
when projected towards a surface. This causes an increase in convective heat transfer
coefficient. Due to their high efficiency and ability to enhance the heat transfer, impinging
jets are used in variety of heating and cooling process. An effective cooling method for high
temperature surfaces is to use liquid jets impingement on the heated surface (Cardenas &
Narayanan, 2012). A bubble will nucleate on the surface, when liquid jets approach the
superheated surface. Turbulent mixing occurs in the vicinity of the wall. This occurs due to
alternately growing and collapsing of bubbles. The high degree of subcooling of the
surrounding liquid and the impinging flow prevent the bubbles from detaching from the wall,
due to which the entire boiling and condensation process limits to a boundary layer
phenomenon. A single bubble, while growing it is presumed that it will replace a hot fluid
volume near the wall which is consequently shifted into colder regions of the flow.
Momentum and heat exchange of such a deplaced fluid volume with the main flow will result
in a temperature drop in the fluid layer surrounding the bubble, leading to its collapse
immediately after it has reached its maximum radius (Saha, Tiwari, Sundén, & Wu, 2016).
Cold fluid will then be transported back to the heating wall and the process repeats. This
process is clearly shown in Fig. 3. (Timm, Weinzierl, & Leipertz, 2003)
Fig .3. Turbulence generation at the heating wall

The principle used by jets is, increase in projection of fluid at high velocity increases the heat
transfer coefficient (Jadhav, Awari, Bibe, Bramhane, & Mokashi, 2016). Based upon the
requirement of jets they are classified as follows, namely – single steady impingement jet,
multiple steady impingement jet, and unsteady jet (Léal, et al., 2013).
3.1.2.1. Single steady impingement jet
This single steady impingement jet uses only a single jet. It is the simplest method compared
to others. In the following figure we can observe how single jet works for heat transfer.
Fig. 4. Schema of the various flow zones in an impinging jet
The flow and heat transfer characteristics of a jet impinging on a surface orthogonal to the
main flow axis are shown in fig. 4. (Léal, et al., 2013). These different zones in the fig. 3. are
explained in (Oyakawa, Umeda, Islam, Saji, & Matsuda, 2009; Jambunathan, Lai, Moss, &
Button, 1992; Weigand & Spring, 2011):
(1) The zone 1 is known as flow development region. This region is made up of free jet
region and core region (Léal, et al., 2013). In the core region the velocity is
approximately equal to the nozzle exit bulk velocity. As the distance from the nozzle
increases, the free jet region gets widen.
(2) The zone 2 is known as fully developed region. It is present at the end of the core. As
the distance from the nozzle increases, the axial jet velocity gets reduced.
(3) The zone 3 is known as deflection region. It is present near the wall. This can be seen
as an increase in static pressure and a sharp decrease in the axial velocity. At the
centre of the deflection region, stagnation point is situated. To plot the Nusselt
number versus the distance from the stagnation point, (Jambunathan, Lai, Moss, &
Button, 1992) used the data from (Gardon & Carbonpue, 1962). When the distance
between the jet nozzle and the impingement plate is very less (H/D < 6), the flow
becomes a laminar flow near the stagnation point inducing a local minimum heat
transfer at the stagnation point. Maximum heat transfer is obtained at the stagnation
point when the impingement plate is situated at the end of the core region (H/D = 6).
When the distance between the jet nozzle and impingement plate increases (H /D > 6),
jet velocity decreases due to which heat transfer reduces at the stagnation point.
Hence heat transfer reduces as the distance from the centre increases.

(4) The zone 4 is known as wall jet region. This can be seen as the increase in the
transverse velocity, followed by a steady decrease. Due to this the flow changes from
laminar to turbulent. When the distance is less, this transition of flow from laminar to
turbulent causes increase in heat transfer and secondary peak is observed as the
Nusselt number varies. The effect of jet nozzle-to-impingement plate distance on the
Nusselt number is shown in the following figure. 5. (Lytle & Webb, 1994; Ganić,
1991).
Fig. 5. Radial variation of local Nusselt number for D =10.9mm
Hence heat transfer coefficient depends upon various factors such as nozzle-to-plate distance,
nozzle geometry, jet Reynolds number, velocity profiles, turbulence intensity.
The major conclusion that can be drawn from study of single jet impingement is, heat transfer
maximum at the impact zone, but gradually reduces away from it. To overcome this problem,
multiple jets are used which are described below.
3.1.2.2. Multiple steady impingement jet

Multiple jets are used to overcome the problems created by single jet. The regions are same
for multiple jets which are in single jet. The following figure shows a multiple jet
impingement system (Unnikrishnan, Kurian, & Johnson, 2018).

Fig. 6. Multiple jet impingement system
The heat transfer of multiple jet is same as that of single jet, when there is no interaction
between the jets. Heat transfer varies, when there is interaction between jets. This variation is
due to two factors – jet-to-jet interaction prior to impingement and head-on collision of
surface flow after impingement. Jet-to-jet interaction occurs due to the expansion of shear
layer. It occurs when the distance between the jets is small and high separation between jet
nozzle and impingement plate. Due to this type of interaction, strength of the jet get weak due
to which overall heat transfer on the impingement plate gets reduced when compared to the
case with no interaction between two jets prior to their impingement (Léal, et al., 2013). The
second factor, head-on collision of surface flow after impingement, also known as secondary
stagnation zone. This interaction causes fountain flow.
The heat transfer coefficient is high near the impingement zone. Hence, heat transfer
coefficient increases as the number of impingement zones increases.
3.1.2.3. Unsteady jet heat transfer
Due to flow instability and higher turbulence, thermal and hydrodynamic boundary layers get
disturbed, due to which heat transfer gets enhanced. Many studies have been done on
unsteady jet to evaluate the performance of heat transfer. (Xu, Yu, Qiu, Poh, & Mujumdar,
2010) recorded significant heat transfer enhancement due to intermittent fluctuation in a
turbulent impinging jet. They also observed that jet-to-plate distance and on-to-off jet time
ratio have significant effect on heat transfer enhancement. They have interpreted the heat
transfer enhancement mechanisms by different mechanisms – larger vortices, higher
turbulence, higher flow entrainment etc.
The parameters influencing the heat transfer characteristics are –

 Nozzle geometry
 Impingement plate geometry
 Nozzle-to-plate distance
 Heat flux
 Reynolds number of jet
 Turbulence intensity
 Velocity profile
 Shape of unsteadiness (ex: frequency)
(Zhou, Wang, Middelberg, & Herwig, 2009) studied heat transfer on smooth and non-smooth
surfaces. Out of the parameters tested, roughness has weak influence on heat transfer for
steady jets but, it has significant effect on heat transfer for unsteady jets. Few authors
acclaimed that, this result cannot be generalized unless and until the study of roughness
parameter on heat transfer on non-smooth plate. Recently one type of unsteady jets are
developed know as “synthetic jets”, in which net mass flux is zero.
3.1.3. Fluid vibration
This type of vibration enhancement is more experimental type because of mass of mass of
heat exchangers. To excite the fluids is easy than to create vibrations in heat exchangers
themselves. The range of frequency from 1Hz to ultrasound is used in exciting the fluids.

Because of its potential to enhance the reactions and mixing, the ultrasound has gained
attention in the recent years. The ability for heat exchangers is now less certain, although it
could be used to minimise fouling. Ultrasound is used to create in a rapid movement in a fluid
adjacent to a heat exchanger surface, rather than vibrating a surface directly. For example, the
effects of ultrasound can be seen in ultrasonic cleaning baths, for removing impurity from the
metal object surfaces. Ultrasound is still in its very beginnings, with regard to heat transfer
enhancement.
3.1.4. Surface vibration
Either at low or high frequency, surface vibration has been firstly used to enhance the single-
phase heat transfer. A piezoelectric device can be used to vibrate a surface.
3.1.5. Mechanical aids
Mechanical aids involve stirring of the fluid by either mechanical means or by rotating the
surface. They are applied to the liquid in a region close to the heat exchanger wall. Stirrers
are included in it. Mechanical scrapers, which are used for viscous liquids in chemical
industry, can also be applied to duct flow of gases (Bergles, 1988).
3.1.6. Spray
Spray contains the liquid droplets that are generated by air or pressure-assisted atomizer.
When the drops are impinged on the surface, they spread all over the surface, they get
evaporate or a thin film of fluid is formed due to which heat transfer get enhanced (Rini,
Chen, & Chow, 2001).
By evaporation, convection and secondary nucleation, heat transfer is more even at low
temperatures (Horacek, Kiger, & Kim, 2005). The heat transfer behaviour (heat flux versus
wall temperature) using spray cooling, confer the following attributes:
 At low wall temperature, the heating plate gets cooled by single-phase regime. As the
flow gets rapidly displaced from the heating surface, the liquid doesn’t get enough
time to warm up in this temperature range
 Below the saturation temperature, there might be an increase in curve slope due to the
evaporation thin liquid film formed on the surface (Yang, Chow, & Pais, 1996).
 When the liquid near the heating wall gets superheated, heat transfer coefficient gets
enhanced due to due to secondary nucleation and/or boiling (Rini, Chen, & Chow,
2001). Secondary nucleation occurs within the liquid. When the droplets enter the
liquid, nucleation sites will be formed, when adsorbed gas molecules surrounding
them gets dissolved. The number of nucleation sites are proportional to number of
liquid droplets forming the spray (Rini, Chen, & Chow, 2001). As the nucleation sites
increases, the heat transfer gets increased (Yang, Chow, & Pais, 1996). Boiling may
also begin at the wall at this temperature range (superheated liquid). Both secondary
nuclei and boiling can occur concurrently leading to higher heat transfer coefficients.
 When the flow increases additionally, the surface start to dry. Spray cooling has
higher heat flux.

Spray cooling depends on many factors like – droplet size, droplet density, droplet velocity,
nozzle-to-heating surface distance, air pressure, condensation etc. Hence spray cooling is
very complex (Horacek, Kiger, & Kim, 2005).
3.1.7. Suction
Suction involves either vapour removal through a porous heated surface in nucleate or film
boiling, or fluid withdrawal in single-phase flow through a porous heated surface (Bergles,
1988).
3.1.8. Injection
Injection involves supplying gas to a flowing liquid through a porous heat transfer surface or
injecting similar fluid upstream of or along the heat transfer section. It is mainly applied for
single-phase flow (Bergles, 1988).
3.1.9. Induced flow stabilities

At nearly low frequencies (<5Hz), improvement in heat transfer is observed by induced flow
stabilities. Induced flow stabilities are also known as pulses.
3.1.10. Rotation
Rotation is used to improve both heat and mass transfer. When a fluid is allowed to pass
across a rotating disc, improvement in heat transfer coefficients can be observed. In the last
decade, Spinning Disc Reactor (SDR), which utilizes the enhanced heat and mass transfer
was developed. The earliest significant work on rotating discs as heat transfer devices was
done firstly at Newcastle University and then at Protensive Ltd, until recently a PI equipment
manufacturer. For example, it is shown in the following figure. 7. (Reay, Ramshaw, &
Harvey, 2013).

Fig. 7. Structure of spinning disc heat transfer surface. A 0.5m diameter disc with delta T
20K will transfer 39kW, thanks to patented double spiral disc design, copper construction
(with chrome plating for corrosion resistance).
3.2. Passive Methods

Passive methods are one set of methods used for enhancement of heat transfer. Unlike active
methods, passive methods not require any external power input. The additional power
required to enhance the heat transfer is taken from the available power in the system, which
leads to a pressure drop in the fluid. Passive methods generally utilize geometrical or surface
modifications to the flow by additional devices or joining inserts.
These methods enhance the heat transfer by varying the flow treatment due to which pressure
drop also increases. One of the methods to enhance heat transfer is to increase the surface
area and residence time of the heat transfer fluids in the convective heat transfer. This method
causes the swirl in the bulk of the fluids and displaces the actual boundary layers which
increases the surface area, residence time due to which heat transfer coefficient increases.
Comparatively passive methods are less complex in the context of design and applications
than active methods. Heat transfer is less in passive methods than active methods. Some of
the passive methods are – extended surfaces, rough surfaces, coated surfaces, inserts,
nanofluids, swirl flow devices (turbulators). Out of all passive methods, inserts are popular
devices used for enhancement of heat transfer of heat exchangers used in industries. Many of
the passive methods are used to make shell and tube exchangers more compact.
The various passive methods are discussed in detail below –

3.2.1. Extended surfaces
Among all the enhancement methods, this one is the oldest technology of all. Extended
surfaces are also known as finned surfaces. When the available surface area is found
insufficient to transfer the required amount of heat with the available temperature drop,
extended surfaces are used (Sonawane, Patil, & Chavan, 2016). Fins are the most common
form of extended surfaces. They are associated with both tubular and plate-type heat
exchangers. For example, the car radiator is a highly compact finned unit. They provide
effective heat transfer enlargement.
Reduction of heat exchanger size might be an important objective for vehicular and heat
recovery processes. For these services, heat exchangers generally involve gases that have low
heat transfer coefficients. Extended surfaces, especially those with enhanced configurations,
are used to obtain size, weight, and cost reductions.
a. b
Fig. 8. Enhanced surfaces for gases
a. Offset strip fins used in plate-fin heat exchanger

b. Steel serrated fins welded to steel tube
In figure 1a, we can see the offset strip fin that normally exhibits an average heat transfer
coefficient 80 to 100 % higher than that of a plain fin of same area. In figure 1b, we can see
the steel serrated fins used for waste heat recovery boilers (Bergles, 1988).
By using segmented longitudinal fins inside circular tubes, heat transfer can be enhanced by
periodically displacing and restarting the boundary layer on the finned surface and perturbing
the bulk flow field (Prajapati, Mane, Mane, & Gaikwad, 2015). Finned surfaces provide a
large surface area density in plate fin or tube and plate fin type of compact heat exchangers.

Various types of finned surfaces are used namely – offset strip fins, perforated fins, wavy
fins, and louvered fins.
Fig. 9. Tubes with circumferential and strip fins on their outer surface
Most of the heat exchangers used in gas streams have fins to enhance the gas-side heat
transfer. Compact units like plate-fin heat exchangers have fins or secondary surfaces
between the pair of plates. In both natural and forced convection, fins are used. To enhance
the performance, plate-fin heat exchanger uses a variety of extended surfaces. Generally
finned heat exchangers are used as the basis of heat exchanger reactors where there is
frequently a need to used enhanced heat transfer control.
Porvair recently introduced a metal foam which can double as an extended surface into the
UK market. Foam can be characterized as an anisotropic three-dimensional extended surface.
One example of its use is in a gas-liquid heat exchanger, the tubes piercing the bulk of the
foam, which replace the conventional extended surfaces. Foam pore size was 0.1-5 mm.
Foam can be kept inside the tubes or between the plates, configuring a gas-gas heat
exchanger. Work is under way at Brunel university (Lu, Zhao, & Tassou, 2006).
Advantages of the foam include a choice of metals resistant to temperatures up to 1000°C,

low density, compact size and the potential to be formed into complex shapes. The foam can
be catalysed, a feature that could be highly relevant to heat exchanger reactors.

Fig. 10. An example of a tube filled with metal foam, tested at Brunel university
Fig. 11. Typical integral externally finned tubes

3.2.2. Treated surfaces
Treated surfaces have a comparatively fine scale variation to the surface fins, or have a
coating applied. These changes are naturally used to promote enhancement of boiling or
condensation. Treated surfaces involve usage of pits, cavities or scratches. These are usually
applicable in two phase transfer and they contain a variety of structured surfaces (continuous
or discontinuous integral surface roughness or alterations) and coatings. Though the treatment
provides a roughness to the surface, it is not large enough to effect single phase heat transfer.
There are various types of treated surfaces used –
1. Machined or grooved surfaces

2. Coated surfaces
3. Multilayered surfaces
4. Formed or modified low-fin surfaces
The principle of providing the treated surfaces for enhancement of boiling is to produce a
large number of vapour traps or nucleation sites on the surface. This is relevant for highly
wetting fluids like refrigerants, organic liquids, cryogens, and alkali metals where the normal
cavities are present on the heated surfaces. (Prajapati, Mane, Mane, & Gaikwad, 2015). For
less wetting or comparatively higher surface tension fluids, coatings of non-wetting material
(ex: Teflon) are given on either side of heated surface to improve stable nucleation. A fine-
scale porous coating may be used to enhance nucleate boiling.
Fig. 12. Illustration of cross section of porous boiling surface
A new process, surfi-sculpt, was developed at TWI, Cambridge, is a new development that
has considerable implications for PI where surface changes can enhance heat and/or mass
transfer.

Fig. 13. An example of the surface topography possible using Surfi -Sculpt, the process
developed at TWI
Surfi -Sculpt gives appreciable feature control by allowing projections to be built and shaped
as separate operations, letting a wide range of features to be formed on flat or curved
surfaces.
3.2.3. Rough surfaces
The simplest and oldest method, which is widely used in current practice, is the use of surface
roughness inside circular tubes (Webb, Eckert, & Goldstein, 1971). Roughness occurs
naturally in manufactured tubes and is very effective in enhancing turbulent flow convection
by displacing the viscous sub-layer in the near-wall turbulent flow structure to advance
higher momentum and heat transport. However, in laminar flows, small-scale roughness do
not show any significant effect.
Rough surfaces are produced in many configurations from sand-grain-type roughness to

discrete roughness. The configuration is naturally chosen to improve turbulence rather than
increase the heat transfer surface area. The application of rough surfaces is mainly towards
single-phase heat transfer. Integral roughness is formed by machining, or “restructuring” the
surface.
For enhanced heat transfer applications, rough surfaces have been employed on both inner
and outer surfaces of tubes in single-phase turbulent flows inside or over tube bundles. The
followings gives sampling of some such tubes that are used in various heat exchangers.

Fig. 14. Tubes with rough surfaces made up of structured two-dimensional helical ribs and
knurled three-dimensional diamond-shaped dimples
Fig. 15. Helical rib roughness tube
Comparatively heat transfer coefficient can be improved a lot that smooth tube turbulent flow
convection (Ravigururajan & Bergles, 1994; Ravigururajan & Bergles, 1996).
At present many commercial tubes are now produced with structured roughness made up of
ribs or surface indentations that are transversely or helically repeated along the length. Tubes
with ribs and indentations of different cross-sectional geometry, and wire-coil inserts that
provide helical ribs of circular cross section are shown in the following figure. 16
(Ravigururajan & Bergles, 1996). With a tube inside diameter di, the roughness profile
attributes are described by the protuberance height e, repeated-rib pitch p, spiral angle α in
degrees for helical ribs, and contact angle β in degrees of the roughness profile relative to the
flow direction.

Fig. 16. Geometrical descriptions of structured ribbed roughness and their profile shapes
3.2.4. Swirl flow devices
Methods for producing swirl flows to enhance heat transfer naturally consist of tube inserts,
axially twisted noncircular ducts, and tangential fluid entry arrangements in ducts (RM &
AE, 2003). Inserts need additional arrangements to make to fluid flow which enhance the
heat transfer. The various types of inserts used are – twisted tape, wire coils, ribs, baffle
plates, conical rings etc. Among these, twisted-tape inserts, are widely used to enhance forced
convection heat transfer inside circular tubes. Their usage in the shell-and-tube heat
exchangers, geometric features and characteristics (Manglik, 2018) are shown in the
following figure –
Fig. 17. Use of twisted-tape inserts in the tubes of a shell-and-tube heat exchanger, and
schematic representation of the geometric features a typical twist tape.

3.2.4.1. Twisted tapes
Twisted tapes are the metallic strips twisted using some of the suitable methods as per the
required shape and dimension, which are inserted in the flow to enhance the heat transfer.
The twisted tape inserts are most suitable and widely used in heat exchangers to enhance the
heat transfer.
Fig. 18. Twisted tape

Twisted tape inserts enhance the heat transfer rates with less friction factor. The use of
twisted tapes in a tube gives simple passive technique for enhancing the convective heat
transfer by making swirl into the heavy flow which displacing the boundary layer at the tube
surface due to sudden changes in the surface geometry which means, such type of tapes
induce turbulence and swirl flow which induces inside the boundary layer and which gives
better results of heat transfer coefficient and Nusselt number due to the changes in geometry
of twisted tape inserts. Concurrently, the pressure drop inside the tube will be increased when
using twisted-tape as an insert. For this most of the researchers have done by experimentally
and numerically to investigate the proper design to achieve the better thermal performance
with less frictional losses. The heat transfer enhancement of twisted tapes inserts depends on
the Pitch and Twist ratio.
Even so success has been observed when the twisted tapes are being used in heat exchangers
for heat transfer enhancement, still increased pumping power with the usage of insert devices
remains to be a concern. Investigation has been made to study the possibility of using
perforated helical twisted tape (P-HTTs) with a view to reduce pumping drawback (Saha,
Tiwari, Sundén, & Wu, 2016).
Fig. 19. Geometrical parameters of perforated helical twisted tape

Twisted tape may be altered by introducing V-cut in the plain twisted tape on both top and
bottom alternately in the peripheral region with different dimensions of depth and width to
improve the fluid mixing near the walls of the test section (Saha, Tiwari, Sundén, & Wu,
2016).
Fig.
20. Geometries V-cut twisted tapes
Fig. 21. Rectangular cut twisted tape inserts (Salam, Biswas, Saha, & Bhuiya, 2013)

Fig. 22. Twisted tapes with baffles (Mulla, Jangamashetti, Manoj, & K, 2014)
3.2.5. Displaced enhancement devices

These are generally found in engineering applications in the form of tube inserts. Their
intended usage is in thermal processing of viscous liquids in the chemical and food
processing industry. An example is shown in the following figure 23 (Manglik, 2018).
Fig. 23. A typical looped wire mesh insert for tubular exchangers and mixers used in the
chemical process industry
3.2.6. Coiled tubes
Coiled tubes are used in a variety of commercial heat exchangers. They not only increase the
heat transfer surface area per unit volume of the heat exchanger but also significantly enhance
the tube-side flow heat transfer coefficient (Manglik, 2018).
Fig. 24. Schematic representation of curved and coiled tubes and their geometric attributes

3.2.7. Additives (for liquids and gases)
A variety of additives can be used to enhance the heat transfer in both single-phase and two-
phase flows. Convective heat transfer in liquids can be improved by the addition of bubbles
or solid particles. Convective heat transfer in gases can be improved by the addition of fine
mists. The use of nano-particles to enhance the heat transfer is a recent development.
3.2.7.1. Nanofluids
Nanotechnology is concerned with the materials and systems whose structures and
components exhibit novel and significantly improved physical, chemical, and biological
properties, phenomena, and processes due to their nanoscale size. In the last two decades, the
application of nanofluids has drastically increased in enhancement of heat transfer.
Nanofluids have captivated the attention of researchers now-a-days.
Nanofluid is a colloidal mixture of nanoparticles in base fluid. They showed better thermal
characteristics than simple fluids. (CG, RA, J, & AJ, 1976) initially discovered ultrafine
particles, whose size is in nanometers. Later on, these ultrafine particles were named as
nanoparticles. Nanofluids are suspensions that can be obtained by dispersing different
nanoparticles in host fluids with the aim of enhanced thermal properties (France, Routbort, &
Choi, 2008). There are so many types of nanofluids used. Some of them are –
1. Al2 O3+ water

2. CuO + water
3. TiO + water
4. C H 3 C H 2 OH +water
(Albadr, SatinderTayal, & Alasadi, 2013) studied Al2O3+water nanofluid in different

concentration and find out the conductive heat transfer coefficient is higher than base liquid
at same mass flow rate at same inlet temp and heat transfer coefficient of nano fluid is also
increases in increase the concentration of Al2O3 in base liquid. Due to high thermal
conductivity, great improvement has seen in graphene water-based nanofluids (Balandin, et
al., 2008). Two methods are used in the preparation of nanofluids. They are single-step
process and two-step process.
Single-step process involves condensing of nanophase powders from the vapor phase directly
into a flowing low vapor-pressure liquid (nanoparticles are made and dispersed in liquid
simultaneously). The nanoparticles are prepared by either using physical vapour deposition
(PVD) technique or liquid chemical method (Y, J, S, E, & S, 2009). The initial PVD method,
known as VEROS (vacuum evaporation onto a running oil substrate), was founded to
produce nanoparticles. As it was difficult to separate the nanoparticles from the liquid, this
method didn’t last long. By applying slight modifications, (JA, US, S, LJ, & S, 1997)
developed a direct evaporation system where Cu vapour is directly condensed into
nanoparticles by contact with a flowing low-vapor-pressure liquid ethylene glycol. This
process does not involve drying, storage, transportation, and dispersion of nanoparticles, thus
during mixing agglomeration is minimized and fluid stability is higher. Only low vapour
fluids can be used in this process. This is the disadvantage of this process. Nanoparticles
shape can be varied from a spherical shape to octahedral shape by altering some synthesis
parameters.

In the two-step process (JA, US, S, LJ, & S, 1997) , nanoparticles are produced first and then
mixed with base fluids. Nanparticles are produced by either physical or chemical process.
Examples of physical process are inert-gas condensation (IGC), mechanical grinding.
Examples of chemical process are chemical vapour deposition (CVD), chemical precipitation,
thermal spray. Nanoparticles are generally produced in powder forms and dispersed in
aqueous and organic host liquids to produce nanofluids. This two-step process is cheaper
because nanopowders are commercially available now-a-days. Nanofluid with enhanced
thermal conductivity causes enhanced heat transfer.
3.3. Compound Methods

A compound technique consists of the pair of heat transfer enhancement methods (active
and/or passive) to extend the thermo hydraulic performance of heat exchangers. It can be
used simultaneously to generate an augmentation that increases the performance of the
system better than when either of the techniques operated independently. Preliminary studies
on compound passive augmentation technique of this type are quite encouraging.
It is well known that combination two or more of the existing techniques can be utilized
simultaneously to develop an enhancement larger than that produced by using single
technique. The pair of different techniques acting simultaneously is known as compound
enhancement. Interactions between different enhancement methods contribute to higher
values of the heat transfer coefficients compared to the sum of the corresponding values for
the individual techniques used alone. Preliminary studies in compound passive enhancement
techniques were encouraging. For example, many previous surveys indicated that the
corrugated tubes are among the most effective and practical methods for enhancing single-
phase heat transfer in tubes. It is reasonable to assume that a mixture of a corrugated tube
with twisted tape would be superior to either passive surface technique acting alone
( IntechOpen, 2018).
The following are some of the compound heat enhancement methods –
3.3.1. Helical-ribbed tube with double twisted tape inserts
In this method heat transfer characteristics of dual twisted tape insert and ribbed tube are
compared to those of the sleek and therefore the ribbed tube acting alone. This pair of the
twisted tapes and modified tubes has been investigated within the prospect of higher heat
transfer enhancement.
The test has been conducted within the flow regime, Re ranging from 6000 to 60,000 with
water as the test fluid (Saha, Tiwari, Sundén, & Wu, 2016). The small print of ribbed tube
and twin twisted tape has been shown (Saha, Tiwari, Sundén, & Wu, 2016) in the following
figure –

Fig. 25. Double twisted tapes and helically-ribbed tube with double twisted tape insert
It should be noted that the name is tube is named co-swirl when the ribbed tube is arranged in
similar directions of the helical swirl of the twisted tape and thus the helical rib motion.
Effects of the co-swirl motion of the ribbed tube and thus the double twisted tapes with
various twist ratios on heat transfer and friction characteristics were examined.
3.3.2. Ribbed tube with twin twisted tape
Nusselt number (Nu) variation with Reynolds number has been displayed Fig . 26(a) as the
heat transfer performance indicator for ribbed tube with twin twisted tape, the performance is
compared with ribbed tube and plain tube and is reflected within the form of Nu/Nu0 ratio
variation against Reynolds number Fig. 9(b). It is observed that Nu increases with the rise in
Re while, the Nu/Nu0 shows an opposite trend for all cases.
On the opposite hand, the combined technique i.e. ribbed tube having twin twisted tape
shows improved heat transfer rate results than the ribbed tube acting alone or the graceful
tube. This improved performance could also be attributed to the simpler stagnant layer
disruption capability of dual twisted tape assisted by the ribbed wall roughness, compared to
those caused by ribbed tube or plain tube individually. Heat transfer augmentation using
combined technique is found to enhance by 4–75 you bored with reference to the ribbed tube.
Of course, this variation is thanks to different combination of Re and twist ratio value. On the
opposite hand, the augmentation has been observed 150–320 yet one more compared to the
plain tube.

Fig. 26. Variation of Reynolds number with Nusselt number
3.3.3. Combination of nano fluids and wire coil insert for heat transfer
enhancement
Few researchers combined wire coil inserts with nanofluid to achieve a better heat transfer
rate in thermal devices. (M, S, & AC, 2010) and (M, MA, & M, 2012) investigated
experimentally the laminar heat transfer improvement and pressure loss of nanofluid flow
inside a pipe consists of wire coil inserts. (M, S, & AC, 2010) used Al2O3–water nanofluid,
while (M, MA, & M, 2012) employed CuO-based oil nanofluid. Both the researches
indicated that nanofluid has higher heat transfer efficiency as it flows through the pipes fitted
by wire coil inserts in lieu of flowing through the quality pipe. The higher thermal efficiency

of nanofluid with wire coil inserts is due to the influences of dispersion or back-mixing which
increases the gradient between the liquid and the surface (Malow, Wehrstedt, Schuurman, &
Hoeijmakers, 2014).
3.3.4. Combination of nanofluids and twisted tape inserts for heat transfer
improvement
Few researchers combined twisted tape inserts and nanofluid to realize a higher heat transfer
rate in thermal systems. Sharma has computed the friction factor and heat transfer coefficient
to a transitional nanofluid flow inside a circular pipe consists of twisted tape inserts. They
increased the heat transfer rate about 23.8 and 43.7% by using the nanofluid and twisted tape
insert, respectively, at Re = 9000.0. Moreover, they also reported that the highest friction
factor by twisted tape at 0.1% nanoparticle volume fraction is 1.20 times greater than the
friction factor obtained by pure water flow through a clear pipe.
(K & S, 2011) improved the heat transfer rate during a pipe by combine in twisted tape with
alternated axis and nanofluid. The twisted tapes with the alternated axis used by (K & S,
2011)are disclosed in figure. The results of earlier researches confirmed that the usage of
twisted tapes along with alternated axis provides higher heat transfer rate and thermal
efficiency. This may be supported by the fact that the alternated axis on twisted tapes changes
the flow pattern. This causes a disordered mixing between the fluid at the centre and the fluid
around the pipe surface.
Accordingly, this leads to a far better interruption of the thermal physical phenomenon in
comparison to the case of normal twisted tape, in which merely rotating flow is created. (K &
S, 2011) and proved that twisted tape with alternated axis has a greater value of heat transfer
(around 90%) as compared to the case of ordinary twisted tape.

Fig. 27. Twisted tape with alternated axis
(G & P, 2010) investigated numerically the combined effects of nanofluid and helical tape
inserts on the laminar heat transfer during a uniformly heated circular tube. The heat transfer
increment is about 5–30% by combining those two techniques. Note that the enhancement is
the function of the nanoparticle volume fraction and twist ratio.
(S, KP, & P, 2011) compared the thermal behaviours of the steady-state flows of alumina and
copper oxide–water nanofluids in a circular channel consists of helical screw tape inserts
displayed in figure 28. Note that Y represents a twist ratio (ratio of pitch of the helical screw
tape to the insert diameter). Their findings indicated that helical screw tape inserts have
higher thermal efficiency as equipped with copper oxide–water nanofluid.

Fig. 28. Helical screw tape inserts
(LS, NR, MT, & KV, 2012) investigated the combined influences of full-length twisted tape
inserts and magnetic nanofluid on the flow and thermal fields during a pipe. The heat transfer
rate is increases by 30.86% by using this type of nanofluid with a volume fraction of 0.60%
at Re = 22,000 for plain tube. An enhancement of 18.48% is obtained by using full-length
twisted tape inserts in comparison with the plain pipe at Re = 22,000 and u = 0.60%. Under
an equivalent condition, the friction factor is merely 1.122 times higher. (S & K, 2012)used
nanofluids in a microfin pipe equipped with single and dual twisted tapes as shown in figure
29. They reported that micro fin pipe equipped by dual twisted tapes has a significantly
higher thermal efficiency (up to 45.40%) in comparison with the one that equipped by a
single tape.

Fig. 29. Microfin pipe enhanced with single and dual twisted tapes

Fig. 30. Microfin pipe enhanced with single and dual twisted tapes
3.3.5. Combination of nanofluids and baffles for heat transfer enhancement
Other passive method used for heat transfer improvement is to employ baffles to change the
flow path. usually, these devices shifts the flow orientation and can also be employed in
several processes having water cooling, clarifying, clear wells, and reservoirs water treatment
equipment In thermal science, the usage of baffles interrupts both hydraulic and thermal
boundary layers and, accordingly causes improvement of the heat transfer rate indeed, the
flow passing around the baffles effects the duct surface, which can improve the local heat
transfer rate. Few researchers also combined this method with nanofluid to obtain a better
heat transfer rate in thermal devices.
(H, S, & PR, 2016) investigated numerically the combined effects of baffles and nanofluid on
the forced convection in the entry area of a duct. They considered the nanoparticle migration
in their simulation. Figure 31 shows the nanoparticle concentration contours between the
sixth and seventh baffles at Re = 400, dp = 10 nm and u = 4%. As shown in this figure, the
nanoparticle volume fraction reduces near the walls due to the thermophoresis phenomenon.
Note that the nanoparticles migrate from the region with higher temperature to the region
with lower temperature.

Fig. 31. Nanoparticle concentration contours between the sixth and seventh baffles at Re =
400, dp = 10 nm, and u = 4
(H, J, & M, 2012) studied numerically nanofluid natural convection in a cavity consists of a
conductive baffle. Their results shown that for a higher values of Rayleigh number, because
of the enhancement of convection, the average Nusselt number augments when one increases
the concentration of nanoparticles and other relocates the baffle towards the core of the
cavitation used segmental baffles and nanofluid in a shell and tube heat exchanger. He
investigated the effects of various nanoparticle shapes like cylindrical, bricks, platelets, and
blades and baffle angles on the performance of this system. They mentioned that the cylinder-
shaped nanoparticles have the better efficiency in comparison with all shapes for all baffle
angles.
Moreover, the 20 baffle angle has the best efficiency when compared to other angles.
Mohammed investigated numerically the mixed convection heat transfer of nanofluids on a
backward facing step inside a rectangular channel with a baffle. They came to know that a

small displacement of the baffle leads to an high change in the flow and temperature fields.
The optimized location of the baffle insert for heat transfer increment is related to the precise
flow and thermal conditions. In other research, (A, HA, & AN, 2014) again came through this
problem for a slotted and inclined baffle. Their findings states that the heat transfer increases
about 167 and 255% by combining nanofluid and a slotted baffle in comparison with
employing pure water for the cases with baffle and without baffle, respectively.
(A & A, 2014) checked various multiphase models to simulate and study the effects of
nanoparticles and baffles on the heat transfer increment. He used both single-phase model
and various multiphase models containing mixture, Eulerian, and volume of fluid models to
simulate this problem for Reynolds numbers in between 600 and 3000. He finalised that
multiphase models are more pinpointed for estimating the heat transfer of nanofluids.
Moreover, he showed that the baffle encompasses a larger influence on the heat transfer
improvement when compared to the nanofluid for higher values of the Reynolds number
(e.g., 2100–3000).
(Bahiraei M, 2015) investigated numerically the combined effects of nanofluid and helical
baffles on the energetic performance of a tube heat exchanger. Most of the baffles are
segmental types that the shell-side flow for moving along a zigzag pass to increase the
warmth transfer rate. Equipping this kind of baffles leads to some problems containing
creating dead areas in each portion in between two tandem baffles, and as a result, it
augments the fouling resistance. Another problem is the risk of vibration failure on the tube
surface as a result of intense zigzag flow structure.
Accordingly, helical baffles are introduced as a replacement for segmental type that almost
minimizes the above issues. They recommended that to get best heat transfer rate and a small
pressure loss, it's better to use helical baffles having small helix angle. Moreover, a high solid
volume fraction of nanoparticles can also be used without increasing too much the pressure
drop. (Bahiraei M, 2015) stated that the pressure drop increases about 150% as the volume
fraction increases in the range from 0 to 5%. (M, AR, Y, & R, 2016) used numerically
nanofluid and helical baffles in a twin pipe heat exchanger. A schematic of the twin pipe heat
exchanger with helical baffles simulated by (M, AR, Y, & R, 2016) is shown in figure 32.

Fig. 32. Schematic of double pipe heat exchanger equipped with helical baffles
(M, AR, Y, & R, 2016) used Cu, CuO, and CNT nanoparticles and employed water as the base
fluid. They concluded that increasing the nanoparticle volume fraction has the most
significant effect on the heat transfer for Cu nanoparticles in comparison with CuO and CNT
nanoparticles.
The nanoparticle concentration contours between the sixth and seventh baffles at Re = 400,
dp = 10 nm and u = 4%. the nanoparticle volume fraction decreases near the walls due to the
thermophoresis phenomenon. Note that the nanoparticles move from the region with high
temperature to the region with low temperature. Accordingly, a substrate with high values of
nanoparticle volume fraction appears over the baffles. They proved that the effect of the
nanoparticle diameters on PEC depends majorly on the value of the nanoparticle volume
fraction.
4. Conclusion
Energy crisis and environmental issues were the main factors given compulsory drive to
enhance the performance of heat exchangers that are sources for most power consumption
and affecting plant operating cost. In order to answer the performance issues of heat
exchangers, researchers have proposed various active, passive and compound methods.
Among them, active methods has gained huge popularity in the fields like medical
instruments, spacecraft engineering, marine applications and last but not the least all domains
where performance is prior but not cost. Needless to say, apart from the above mentioned
fields, a low cost solution to improve heat exchanger issue is highly desirable. Hence active
approach of enhancing performance is not preferred in industries because of its high
implementation cost and operating cost.

Active technique like electromagnetic fields and surface vibration require external power for
operation. Active methods are identified as a possibility for enhancement. The active method
depends on external power or activation, this method have power cost .power cost should be
considered and micro system designer has to carefully considered in their implementation
During nucleate boiling with EHD, heat transfer improvement is governed by various
mechanisms. The electric field is not so uniform in the liquid which is near to the interface as
density and temperature are not uniform. This develops electro restrictive forces. The electric
force of the liquid which is far from the heating wall is higher than the electric force of liquid
which is near the heating wall which generates electro convective movements .So that heat
transfer enhances. An important conclusion of single jet studies is that the heat transfer is
very high in the zone close to the impact zone, but decreases rapidly away from it.
Passive methods where flow is modified either by using insert devices or by altering the
channel geometry offers low cost solution to enhance heat exchange process. Compound
techniques, as discussed, are the most latest techniques of enhancing heat exchange process
and with this approach it would be possible to further decrease the geometry of the heat
exchangers without compromising the thermohydraulic performance. With the assist of
nanotechnology, it's further possible to enhance the performance of heat exchangers,
particularly dealing with low thermal conductivity fluids. Although it has been reported by
researchers that addition of nano particles significantly increases the pressure drop, yet this
new era brings many possibility to contribute.
We are aware that the heat transfer enhancement is possible by using treated surfaces, using
inserts, using extended surfaces which are the most important passive methods to improve
the heat transfer. By using treated surfaces we increase heat transfer rate which is applicable
for both boiling and condensing also. The twisted tape inserts are the most suitable and are
widely used in heat exchanger to increase the heat transfer. Twisted tape inserts generally
improves heat transfer rate with less friction factor. The coiled circular wire should be
applied in place of smooth one to achieve higher heat transfer. The heat transfer can also
done by extended surfaces that conclude that copper has higher thermal conductivity
compared to brass and aluminium.
A better improvement in the heat transfer rate was achieved by using vortex generator in pure
water, while a considerable development was achieved by using the vortex generator and
nanofluids at a time followed with a moderate rise in the friction factor. Usually, vortex

generators with winglets are more suitable to increase the heat transfer in modern thermal
devices because they have the ability to create longitudinal vertices and cause disruption to
the main flow field with lower pressure drop.
The geometrical properties of coil wires have a considerable effect on the thermal efficiency
of the whole thermal system. The heat transfer rate improves with increasing the coil
diameter. Usually, the secondary vectors have higher strength while using a coiled wire with
a larger diameter and this leads to more increase in the heat transfer rate. The heat transfer
increases as the ratio of wire coil inserts (the ratio of wire coil pitch to the inner diameter of
the pipe) decreases. A wire coil having sharp-edged shoe has higher heat transfer efficiency
when compared with the circular one.
The heat transfer enhancement generated by combining the use of nanofluid and twisted tapes
is greater at the pipe outlet ( when compared to inlet) as a result of the impact of the swirl
flow. The system performance can be increased without even increasing the size of the heat
exchanger. Nanofluid has higher heat transfer efficiency when equipped with r twisted strips.
The use of twisted tapes along with alternated axis improves the thermal efficiency when
compared to the base case with twisted tapes. The micro fin pipe increased by twin twisted
tapes has a considerably better thermal efficiency compared to the case with a single tape
alone. Usually, the twisted tapes are more efficient when compared with the wire coils to
increase heat transfer, while the wire coils lower pressure drop in comparison with twisted
tapes. Helical baffles were introduced as a substitution for segmental types. Even a small
small displacement of the baffle leads to a huge change in the flow and temperature fields. If
one wants to achieve higher heat transfer rates but small pressure drops, it is suggestable to
equip helical baffles with small helix angle.
5. Future scope
Further studies are essential for future to discover and optimizing geometries of different
inserts and vortex generators to enhance the thermal characteristics of heat exchangers.
Additionally, the recent boom in nanotechnology has widened a promising field in heat
transfer investigation. pair of inserts and nanofluids might be a kind of propitious idea to
increase the thermal systems performance which has been rarely reported in the open
literature. Numerous opportunities will be available when authors focus their efforts on
equipping nanofluids combined with various kinds of inserts in large as well as microscale
heat exchangers and heat sinks. The comparison of nanofluids and conventional fluids in

various shapes of compact heat exchangers and heat sinks in terms of heat transfer and
pressure drops has shown huge improvement.
As we know that the Passive heat transfer techniques does not require any external power
input and additional power required to enhance the heat transfer is absorbed from the
available power in the system. In the convective heat transfer one of the methods to enhance
the heat transfer rate is to increase the total effective surface area and residence time of the
heat transfer fluids. Using this technique causes the swirl in the bulk of the fluids and
interrupts the actual boundary layers which increase the total effective surface area, residence
time and along with heat transfer coefficient increases in the system. The primary condition
to improve the heat transfer is to achieve the swirl in the bulk of fluids and this can be done
by the passive heat transfer enhancement techniques. The heat enhancement techniques have
the easy installation and removal at the same time simple manufacturing process with
considerably low cost. We know that the heat transfer enhancement can be done by inserts
like wire coils, twisted tapes which are easily available and it has a simple process. we can
conclude that study on heat transfer enhancement methods offers a wide range of
applications.
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1.

Due to lack of energy sources in many industrial applications, heat transfer

Heat transfer enhancement methods for an heat exchanger Page 1

1.1. Heat exchanger

Heat transfer enhancement methods for an heat exchanger Page 2

1.2. Objectives of the work

1.3. Motivation for the work

1.4. Scope of the work

Heat transfer enhancement methods for an heat exchanger Page 3

The results of the work can be noted as follows:

Heat transfer enhancement methods for an heat exchanger Page 4

3. Heat transfer enhancement methods

Table :1 classification of different active and passive methods

Active methods Passive methods

Heat transfer enhancement methods for an heat exchanger Page 5

3.1.1. Electro hydrodynamics (EHD)

Heat transfer enhancement methods for an heat exchanger Page 6

Heat transfer enhancement methods for an heat exchanger Page 7

Heat transfer enhancement methods for an heat exchanger Page 8

Fig .3. Turbulence generation at the heating wall

Heat transfer enhancement methods for an heat exchanger Page 9

3.1.2.1. Single steady impingement jet

Fig. 4. Schema of the various flow zones in an impinging jet

Heat transfer enhancement methods for an heat exchanger Page 10

Fig. 5. Radial variation of local Nusselt number for D =10.9mm

3.1.2.2. Multiple steady impingement jet

Heat transfer enhancement methods for an heat exchanger Page 11

3.1.2.3. Unsteady jet heat transfer

The parameters influencing the heat transfer characteristics are –

3.1.3. Fluid vibration

Heat transfer enhancement methods for an heat exchanger Page 12

3.1.4. Surface vibration

3.1.5. Mechanical aids

Heat transfer enhancement methods for an heat exchanger Page 13

3.1.9. Induced flow stabilities

Heat transfer enhancement methods for an heat exchanger Page 14

3.2. Passive Methods

The various passive methods are discussed in detail below –

Heat transfer enhancement methods for an heat exchanger Page 15

Fig. 8. Enhanced surfaces for gases

a. Offset strip fins used in plate-fin heat exchanger

Heat transfer enhancement methods for an heat exchanger Page 16

Advantages of the foam include a choice of metals resistant to temperatures up to 1000°C,

Heat transfer enhancement methods for an heat exchanger Page 17

Fig. 11. Typical integral externally finned tubes

Heat transfer enhancement methods for an heat exchanger Page 18

1. Machined or grooved surfaces

Fig. 12. Illustration of cross section of porous boiling surface

Heat transfer enhancement methods for an heat exchanger Page 19

3.2.3. Rough surfaces

Rough surfaces are produced in many configurations from sand-grain-type roughness to

Heat transfer enhancement methods for an heat exchanger Page 20

Fig. 15. Helical rib roughness tube

Heat transfer enhancement methods for an heat exchanger Page 21

3.2.4. Swirl flow devices

Heat transfer enhancement methods for an heat exchanger Page 22

Fig. 18. Twisted tape

Fig. 19. Geometrical parameters of perforated helical twisted tape

Heat transfer enhancement methods for an heat exchanger Page 23

Heat transfer enhancement methods for an heat exchanger Page 24

3.2.5. Displaced enhancement devices

3.2.6. Coiled tubes