J. Inst. Eng. India Ser.
C (December 2019) 100(6):983–993
https://doi.org/10.1007/s40032-018-0493-z
ORIGINAL CONTRIBUTION
Numerical Investigations of the Convective Heat Transfer
from Turbulent Flow Over Staggered Tube Bank
H. A. Refaey1 • Asmaa M. Sultan1 • M. Moawad1 • M. A. Abdelrahman1
Received: 22 September 2017 / Accepted: 27 September 2018 / Published online: 15 October 2018
 The Institution of Engineers (India) 2018
Abstract The present work aims to introduce 2-D
numerical investigations of turbulent flow over staggered
tube bank by using a commercial CFD package (ANSYS-
Fluent). The realizable k-e turbulent model is applied. The
effect of the longitudinal pitch ratio (SL/D), transverse
pitch ratio (ST/D), Reynolds number, and tube shape on the
heat transfer and flow characteristics is studied. Due to
symmetry, half of the tube bank rows are considered. The
present simulation results are compared with the available
experimental data and previous analytical results, which
show acceptable agreement. The results of circular tube
bank show that there is an enhancement on the heat transfer
ranging from 1.02 to 8.8% when the longitudinal pitch ratio
changed from 1.25 to 3 at ST/D = 1.25 and 5000 B Re
B 50,000. Additionally, the friction factor decreases for ST/
D C 2 as the longitudinal pitch ratio increases but it
increases for ST/D B 1.5. For flat tube bank, the results
show that as the length ratio decreases the heat transfer
increases. Moreover, the flat tube diameter should be small
to obtain the highest heat transfer. Furthermore, two dif-
ferent correlations are obtained for Nusselt number for the
two tube banks.
Keywords Turbulent flow  Heat transfer  Tube bank 
Staggered  CFD  Flat tube
List of symbols
D Tube diameter (cm)
Dh Hydraulic diameter (m)
& H. A. Refaey
hassanein.refaey@feng.bu.edu.eg
1
Mechanical Engineering Department, Faculty of Engineering
at Shoubra, Benha University, Cairo 11629, Egypt
F Friction factor
L Tube length (m)
NL Number of tubes in longitudinal direction
p Pressure (Pa)
Pr Prandtl number
ReDh Reynolds number based on hydraulic diameter
(qVmaxDh/l)
SL Longitudinal distance between two consecutive
tubes (m)
ST Transverse distance between two consecutive tubes
(m)
U Fluid velocity in x-direction (m/s)
Umax Maximum velocity in minimum flow area (m/s)
Greek symbols
q Density (kg/m3)
l Dynamic viscosity (kg/ms)
Introduction
At present, the helically coiled heat exchangers are widely
used for lots of applications such as steam generators,
refinery condensers, and chemical reactions. For such heat
exchangers, the cooling fluid passes perpendicular to the
tube which produces a cross-flow over tube banks. The heat
transfer characteristics for the cooling fluid in this case are
enhanced compared with that fluid passing parallel to the
tube. Furthermore, there are two other parameters the tube
arrangement and flow characteristics effects on the heat
transfer. All these effects are important to predict the heat
transfer and in design procedures.
There are two main methods to investigate the heat
transfer and flow characteristics across tube banks: exper-
imental or numerical as well as their combination. Most of
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the earlier conducted experiments were conducted to air
flow. Earlier experimental studies have been done for
staggered and in-line arrangements of cross-flow over tube
banks [1–4]. The experimental data of Huge [2] and Pier-
son [3] for both in-line and staggered arrangements were
correlated by Grimison [4]. The empirical relation of
Grimison was valid for air only and pertains to tube banks
having 10 or more rows of tubes in the flow direction.
Hilpert [5] proposed an empirical correlation to obtain the
average Nusselt number of a single tube in cross-flow and
an empirical correlation was obtained. The same procedure
to obtain another empirical correlation was used by
Churchill and Bernstein [6]. Grimison’s correlation was
modified by Hausen [7], and the tube arrangement was
considered in an empirical formula. The flow and heat
transfer characteristics for a single tube in cross-flow were
investigated experimentally by Giedt [8]. The heat transfer
and flow structures for single tube and tube banks were
investigated experimentally and numerically by Žukauskas
[9]. A correlation for heat transfer coefficient was pro-
posed. Chen [10] analytically investigated the flow field
evaluation by increasing the flow Reynolds number. Wil-
son and Bassiouny [11] investigated numerically the heat
transfer and pressure drop for laminar and turbulent air
flow over tube bank for both in-line and staggered
arrangements. Recently, Khan et al. [12] analytically
investigated the heat transfer for in-line and staggered tube
banks under isothermal boundary condition. A correlation
of Nusselt number for both arrangements was obtained. An
experimental investigation of heat transfer and air flow
around sixteen tubes in-line flat tube banks with laminar
flow was carried out by Tahseen et al. [13]. A correlation
for Nusselt number has been presented, and it yielded good
predictions of the measured data. A numerical CFD sim-
ulation to study the effect of the length ratio and the height
ratio of flat tube banks heat exchangers on convection heat
transfer and friction coefficient was performed by Shareef
and Ramadhan [14].
From the literature review, it can be concluded that the
studies on the heat transfer of turbulent flow over tube bank
performed need more investigations. The main aim of the
present work is to extend the heat exchanger designer with
information about the staggered circular and flat tube
banks. Therefore, the present study numerically investi-
gates the heat transfer performance and flow characteristics
simultaneously by changing different parameters. The
study numerically investigates the effect of Reynolds
number, longitudinal and transverse pitch ratios on the heat
transfer and flow characteristics for two-dimensional tur-
bulent air flow over staggered circular and flat tube banks
arrangement.
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J. Inst. Eng. India Ser. C (December 2019) 100(6):983–993
Physical Model
The tube bank heat exchanger is arranged in two-dimen-
sional arrays called banks, or bundles. Generally, it is
characterized by tube diameter, cross-wise (transverse)
pitch, and stream-wise (longitudinal) pitch. Due to the
symmetry, half of the transverse pitch is taken for the CFD
simulation. The total length of the domain is also consid-
ered to be long to avoid the reverse flow condition.
Geometry
To reduce the calculation time, a simplified 2-D double
row geometry in the flow direction is used. The staggered
tube bank arrangement is considered with circular and flat
tube. The geometries for the two arrangements are pre-
sented in Fig. 1. The total number of geometries for cir-
cular tube bank arrangement is 25. The tube spacing in the
transverse, ST, and longitudinal, SL, directions is 1.25, 1.5,
2.0, 2.5, and 3.0 D, where the tube diameter, D, is equal to
1 cm. For flat tube bank, Dt is the flat tube diameter, H is
the height, and L is the length at which the exit temperature
is estimated. Table 1 represents the staggered flat tube bank
geometries used in the present study.
Numerical Approach
For the present study, the governing equations for conser-
vation of mass, momentum, and energy are used in the
CFD model. The detailed equations are represented in
Fluent [15]. Turbulent flow is assumed for all runs due to
high flow rates, leading to the Reynolds-averaged Navier–
Stokes equations (RANS), which are discretized by the
finite volume method. The fluid flow is assumed to be
turbulent and symmetry lines on both sides of the domain
as shown in Fig. 1. A 2-D grid generation system is used to
discrete the computational domain depicted in Fig. 1. The
mesh is refined to be denser around the tubes as this portion
is the interest of the study. The grid independence study is
done for all the present computational domains of the
studied cases. The flow variables and all turbulent quanti-
ties are discretized in a finite volume formulation using a
second-order upwind scheme.
Boundary Conditions
The heat transfer characteristics of circular and flat tube
banks with staggered arrangement have to be defined
properly. For the numerical approach of the problem, air is
used as the working fluid during all numerical work. The
flow is assumed to be 2-D incompressible, non-periodic
turbulent flow with constant properties calculated at inlet
J. Inst. Eng. India Ser. C (December 2019) 100(6):983–993 985

Fig. 1 Geometries for

D/2 Symmetry
a circular tube staggered
arrangement, b flat tube
1.2D 4D

ST /2
staggered arrangement, c three- Outlet
dimensional representation

SL Symmetry
(a)
D/2

0.5D D 3D Outlet
H Dt

L
(b)

Flow direcon in 3D case

(c)

Table 1 Staggered flat tube bank geometry details qUmax Dh

ReDh ¼ ; ð1Þ
Dt H/ L/D l
D
where m is the kinematic viscosity of the fluid and Dh is the
2 1.5 7 hydraulic diameter changes with changing ST which is
2 4 6 7 calculated according to the following equation [15]:
4 4 6 7 4Ac 4ðST =2Þð1Þ 2ST
2.5 2 6 7 8 Dh ¼ ¼ ¼ : ð2Þ
P 2ðST =2 þ 1Þ ðST þ 2Þ
4 6 7 8
3 2 6 7 8 The maximum velocity of the control volume happens
4 6 7 8 when the flow area is smallest. Considering the mass
conservation of an incompressible fluid in the control
volume, the maximum velocity is defined as in Wilson [11]
ST
flow temperature, Tin. The fluid region consists of the inlet, Umax ¼ p


U: ð3Þ
outlet, and tube bank zone. At the inlet, the air enters the ST  4 D
computational domain with constant temperature Tin- Finally, the friction factor can be obtained from flow over
= 300 K and uniform velocity Uin. The velocity compo- tube banks; it is the friction factor and is defined as in
nent in the y direction is zero. The outlet condition is Wilson [11]:
assumed to be pressure outlet. At the solid surfaces, no-slip
DP Dh 2
conditions for the velocity are specified. The tubes surface f ¼ 2
; ð4Þ
NL D qUmax
has constant temperature Tw = 348 K. To simplify the
calculation, the flow and thermal fields are assumed to be where DP is the total pressure drop. It is tubes resistance to
symmetric as shown in Fig. 1. flow over them.
The flow characteristics are dominated by the maximum
velocity Umax. The Reynolds number is defined based on Turbulence Model Selection and Validation
maximum velocity and hydraulic diameter
A comparison between different turbulence models and
analytical solution of the average Nusselt number pre-
sented by Khan et al. [12] is shown in Fig. 2. The CFD

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986 J. Inst. Eng. India Ser. C (December 2019) 100(6):983–993

500 realizable k–e model is chosen as the best turbulence model

Circular staggered tube bank fit with analytical and experimental results for the present
7 x 8, ST /D=2,S L /D=2
work simulation.
400 Khan [12]
Realizable κ−ε
RNG κ−ε Results and Discussion
Standard κ−ε
300
Staggered Circular Tube Bank Results
Nu

The effect of Reynolds number on the heat transfer is

200
studied for the staggered circular tube bank arrangement
with different longitudinal pitch ratios (SL/D from 1.25 to
3) as shown in Fig. 4. The longitudinal pitch ratio (SL/D) is
100
ranged from 1.25 to 3 at a constant transverse pitch ratio
(ST/D) of 1, 2, and 3. From these figs, it is observed that as
Reynolds number increases from 5000 to 100,000, the
0
0 20000 40000 60000 80000 100000 Nusselt number increases sharply. Also, it can be observed
Re that there is a small effect of increase in SL/D on Nu at low
Re and this effect increases at high Re. Consequently, it can
Fig. 2 Turbulence model selection be concluded that the Reynolds number has a great impact
on the heat transfer for all studied ranges of transverse and
results indicate that the realizable k–e turbulent model has
longitudinal pitch ratios.
good agreement with analytical solution of Khan et al. [12].
Figure 5 demonstrates the effect of longitudinal pitch
Furthermore, another validation has been done with pub-
ratio on Nusselt number for different Reynolds numbers
lished empirical correlations results as shown in Fig. 3.
(Re = 5000:100,000) and different transverse pitch ratios
The Fig. 3 shows a comparison between realizable k–e and
(ST/D = 1.25:3). For low ranges of Reynolds number, at all
different empirical correlations for Nu number for circular
transverse pitch ratios, there is no effect on Nusselt number
staggered tube bank arrangement with ST/D = 1.5 and SL/
by increasing longitudinal pitch ratio, while, for high val-
D = 2. The results indicated that, the realizable k–e gives
ues of Reynolds number (Re C 35,000), the Nusselt num-
good agreement with theoretical data obtained by Wilson
ber increases by increasing the longitudinal pitch ratio SL/
[11] and Gnielinski [16]. The results give an absolute dif-
D above the value (SL/D = 2) at ST/D = 1.25. Moreover, at
ference ranging from 0% to 21% for staggered arrangement
high transverse pitch ratio (ST/D = 2:3) there is no effect
between the present study and their works. Therefore, the
on the Nusselt number for all range of Reynolds number.
700
The temperature contours for circular tube configuration
Staggered arrangement 0.5 × 2 with ST/D = 1.5 and SL/D = 2 with different Reynolds
ST/D =1.5, SL/D = 2 numbers are shown in Fig. 6. It can be depicted that as
600
Gnilinsk [16] Reynolds number increases the temperature decreases, for
all Reynolds numbers. The decrease in temperature with an
500 Realizable K -ε
increase in Reynolds number leads to an increase in Nus-
Wilson[11] selt number with an increase in Reynolds number.
400

Nu Friction Factor
300
The effect of Reynolds number on friction factor for dif-
200 ferent longitudinal pitch ratios (SL/D = 1.25:3) and ST/
D = 1.5 is shown in Fig. 7a. From this figure, the gradient
100 of the friction factor is decreased by increasing Reynolds
number. This can be explained as follows: At relatively
0 high Reynolds number, the flow velocity increases and
0 20000 40000 60000 80000 100000 leads to a corresponding increase in the pressure drop. The
Re effect of longitudinal pitch ratio on friction factor for dif-
ferent Reynolds numbers (Re = 5000:100,000) and ST/
Fig. 3 Validation of the present work with different empirical
D = 1.5 is shown in Fig. 7b. The figure shows that the
correlations for staggered circular arrangement

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Fig. 4 Effect of Reynolds 800 800

number on Nusselt number for S T /D=1.25 ST /D=1.5
different SL/D (staggered SL /D=3 SL /D=1.25
SL /D=2.5 SL /D=1.5
circular tube arrangement)
SL /D=2 600 SL /D=2
600
SL /D=1.5 SL /D=2.5
SL /D=1.25 SL /D=3

Nu

Nu
400 400

200 200

0 0
0 20000 40000 60000 80000 100000 0 20000 40000 60000 80000 100000
Re Re
(a) (b)

800 800
S T /D=2 ST /D=2.5
SL /D=3 SL /D=3
SL /D=2.5 SL /D=2.5
SL /D=2 SL /D=2
600 600
SL /D=1.5 SL /D=1.5
SL /D=1.25 SL /D=1.25
Nu

Nu
400 400

200 200

0 0
0 20000 40000 60000 80000 100000 0 20000 40000 60000 80000 100000
Re Re
(c) (d)

800
ST /D=3
S L /D=3
S L /D=2.5
S L /D=2
600
S L /D=1.5
S L /D=1.25
Nu

400

200

0
0 20000 40000 60000 80000 100000
Re
(e)

friction factor increases by increasing longitudinal pitch high Reynolds number, increasing the flow velocity leads
ratio due to the increase in the pressure drop. The gradient to a corresponding increase in the pressure drop.
of the friction factor decreases by increasing Reynolds The velocity vectors for a staggered circular tube bank
number. This can be explained as follows: At relatively arrangement with ST/D = 1.5 and SL/D = 3 for different

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988 J. Inst. Eng. India Ser. C (December 2019) 100(6):983–993

Fig. 5 Effect of longitudinal 800 800

pitch ratio on Nusselt number ST /D=1.25 ST /D=1.5
with different Re (staggered
circular tube arrangement)
600 600

Nu

Nu
400 400

200 200

0 0
1 2 3 1 2 3
SL/D SL/D
(a) (b)

800 800
S T /D=2 ST /D=2.5

600 600
Nu

Nu
400 400

200 200

0 0
1 2 3 1 2 3
SL/D SL/D
(c) (d)

800
ST /D=3

600
Re=100000
Re=75000
Nu

400 Re=50000
Re=35000
Re=20000
200 Re=5000

0
1 2 3
SL/D

(e)

Reynolds numbers are shown in Fig. 9. It shows that the Staggered Flat Tube Bank Results
second tube influences redirecting the fluid flow, so high
velocity gradients are obtained by increasing the Reynolds In addition to the circular tube bank arrangement, the
number. staggered flat tube bank arrangement is studied. The

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J. Inst. Eng. India Ser. C (December 2019) 100(6):983–993 989

Fig. 6 Temperature contours

for ST/D = 1.5 and SL/D = 2

Re = 5000

Re = 20000

Re = 35000

Re = 50000

Re = 75000

Re = 100000

2 2
ST/D=1.5 ST /D=1.5
SL /D=3 Re =5000
SL /D=2.5 Re = 20000
SL /D=2 Re =35000
Re =50000
SL /D=1.5
Re =75000
Friction Factor, f
Friction Factor, f

SL /D=1.25
1.8 1.8 Re =100000

1.6 1.6

1.4 1.4
0 20000 40000 60000 80000 100000 1 2 3

Reynolds, Re Longitudinal Pitch Ratio, S L/D

(a) (b)
Fig. 7 Effect of both Reynolds number and longitudinal pitch ratios on friction factor for a staggered circular tube bank arrangement

following two sections represent the obtained results during
the study.
Effect of Reynolds Number and Length Ratio
on Heat Transfer
Herein, the effect of Reynolds number on heat transfer is
shown in Fig. 8 for different length ratios. Figure 8a, b
represents two figures for two different height ratios (H/
D) 2 and 4 and flat tube diameter (Dt) of 2. It could be seen
that Reynolds number has a great impact on the heat
transfer for all studied length ratios (L/D). The results
revealed that as the length ratio decreases the heat transfer
increases. The results show that the heat transfer is
enhanced by 42.5% at Re = 5000 and 36.4% at Re =
100,000 for the flat tube diameter Dt = 2 and H/D = 2.
However, the heat transfer is enhanced by 20.6% at Re =
100,000 for the flat tube diameter Dt = 2 and H/D = 4. In
addition, when increasing Dt, the amount of heat transfer
enhancement decreases. Therefore, it can be concluded that

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990 J. Inst. Eng. India Ser. C (December 2019) 100(6):983–993

Fig. 8 Effect of Re for different 600 600

length ratios (staggered flat tube D t =2 D t =2
arrangement) H/D=2,L/D=4 H/D=4,L/D=4
500 500
H/D=2,L/D=6 H/D=4,L/D=6
H/D=2,L/D=7 H/D=4,L/D=7
400 400

Nu
Nu
300 300

200 200

100 100

0 0
0 20000 40000 60000 80000 100000 0 20000 40000 60000 80000 100000
Re Re
(a) (b)
500 500
D t=2.5 D t=2.5
H/D=2,L/D=6 H/D=4,L/D=6
400 400
H/D=2,L/D=7 H/D=4,L/D=7
H/D=2,L/D=8 H/D=4,L/D=8
300 300
Nu

Nu
200 200

100 100

0 0
0 20000 40000 60000 80000 100000 0 20000 40000 60000 80000 100000
Re Re
(c) (d)
500 500
D t=3 D t=3
H/D=2,L/D=6 H/D=4,L/D=6
400 400
H/D=2,L/D=7 H/D=4,L/D=7
H/D=2,L/D=8 H/D=4,L/D=8
300 300
Nu

Nu

200 200

100 100

0 0
0 20000 40000 60000 80000 100000 0 20000 40000 60000 80000 100000
Re Re
(e) (f)

to obtain the highest heat transfer the tube diameter should
be small.
Figure 9 shows the temperature contours of different
Reynolds numbers on staggered flat tube bank with H/
D = 2 and L/D = 4. The figure indicates that as the value of
Reynolds number increases, the heat transfer increases.
Moreover, the temperature contours for L/D = 4, 6, and 7
at the same H/D = 2, Re = 500,000, and flat tube diameter
Dt = 2 are presented in Fig. 10.
Effect of Height Ratio on Heat Transfer
The following figure demonstrates the variation of Nusselt
number with Reynolds number for different height ratios
and length ratio = 7 with flat tube diameter of 2. Clearly,

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Re = 5000

Re = 50000

Re = 100000

Fig. 9 Temperature contour for H/D = 2 and L/D = 4 with different Re

Fig. 11 shows that for all studied height ratios, the Nusselt
number increases as Reynolds number increases. More-
over, the Nusselt number increases as the height ratio
decreases for the same value of Reynolds number. From
the figure, it can be declared that the height ratio has an
impact on the heat transfer. The augmentation is ranged
from 253.23 to 438.73 at Re = 100,000 as the height ratio
decreases from 4 to 1.5 with L/D = 7.
Comparison Between the Two Tube Bank
Arrangements
Figure 12 shows a comparison between the two tube bank
arrangements. The figure represents the variation of Nus-
selt number with Reynolds number for staggered circular
and two staggered flat tube bank arrangements. The fig-
ure demonstrates that for all studied Reynolds number
values, the Nusselt number values obtained for circular
tube bank arrangement are higher than those obtained for
staggered flat tube bank arrangements. This is due to that
circular tubes have minimum surface area than flat tubes,
which in turn reduces the design cost in many applications.
Correlations
The average Nusselt number is correlated as a function of
Reynolds number (5000 B Re B 100,000), longitudinal
pitch ratio, and transverse pitch ratio and SL/D = ST/
D = 1.25:3 for staggered circular tube bank at TS = 348 K
and Tin = 300 K. The deviation values are - 10.01% and
? 10.08% as shown in Fig. 13. The correlation is given as
follows:
Nu ¼ 0:137051Re0:738 ðST =DÞ0:2135 ðSL =DÞ0:01252 : ð5Þ
A second correlation for staggered flat tube bank
arrangement with Reynolds number
(5000 B Re B 10,000), L/D = 4, 6, 7, and 8, and H/
D = 1.5,2 and 4 is obtained. The deviation values are
- 12.86% and ? 9.02%, and the correlation is given as
follows:
Nu ¼ 0:15986Re0:7731 ðST =DÞ0:5913 ðSL =DÞ0:3468 : ð6Þ
Conclusions
Numerical CFD simulations with realizable k–e turbulence
model are employed in the present work. The effect of
change in Reynolds number, longitudinal and transverse
pitch ratios and tube shape on the heat transfer and friction

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992 J. Inst. Eng. India Ser. C (December 2019) 100(6):983–993

L/D=4

L/D=6

L/D=7

Fig. 10 Temperature contour for different L/D with H/D = 2 and Re = 50,000

500 600
Dt =2 Staggered Circular Tube [ST/D=3,SL/D=3]
H/D =1.5, L/D=7 Staggered Flat Tube [H/D=1.5,L/D=7]
H/D =2, L/D=7 Staggered Flat Tube [H/D=2,L/D=7]
400
H/D =4, L/D=7

400
300
Nu
Nu

200
200

100

0
0 0 20000 40000 60000 80000 100000
0 20000 40000 60000 80000 100000
Re
Re
Fig. 12 Comparison between the tube bank arrangements
Fig. 11 Variation of Nusselt number with Re number for different H/
D and length ratio = 7 with Dt = 2 • For staggered circular tube banks arrangement, it is
factor for 2-D turbulent air flow over staggered tube bank observed that there is a small difference in Nusselt
arrangement consists of two rows. Due to the symmetry, number when SL/D is more than 1.5.
half of the tube bank rows are considered where the tube • Reynolds number has a great influence on the heat
diameter (D) is equal to 1 cm. The major conclusions transfer for all studied tube bank arrangement cases.
drawn from this work can be summarized as follows: • For staggered circular tube bank arrangement, as the
longitudinal pitch ratio increases, the friction factor

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Fig. 13 Correlated average 700

Predicted - Nusselt number

Nusselt number versus
600
numerical Nusselt number:
a staggered circular tube bank 500
arrangement, b staggered flat +10.08%
400
tube bank arrangement -10.01%
300
200 Nu-CFD

100
0
0 100 200 300 400 500 600 700
Numerical - Nusselt number
(a) (b)

decreases for ST/D C 2. But, for ST/D B 1.5 as the
longitudinal pitch ratio increases, the friction factor
increases for all Reynolds number values.
• In case of flat tube bank arrangement, when the length
ratio (L/D) decreases and height ratio (H/D) remains
constant, the heat transfer rate is higher compared with
that obtained from increasing the length ratio (L/
D) values.
• Furthermore, for flat tube bank, the heat transfer is
enhanced by 36.4% at Re = 100,000, flat tube diameter
Dt = 2, and H/D = 2. Regarding H/D = 4, the heat
transfer is enhanced by 26.2% at Re = 100,000 with L/
D decreasing from 7 to 4.
• The smallest flat tube diameter gives the highest heat
transfer for staggered flat tube bank arrangement.
• Finally, from the correlations, it can be stated that
Reynolds number has great effect on heat transfer as
well as transverse pitch ratio (ST/D) than longitudinal
pitch ratio (SL/D).
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