EXPERIMENTAL INVESTIGATION OF HEAT TRANSFER ENHANCEMENT USING TWISTED TAPE INSERTS

IN A PIPE FLOW

ABSTRACT :

Heat transfer enhancement is the process of increasing the heat transfer rate and performance of a
system using various methods. The various methods include active, passive and compound methods.
Insertion of twisted tapes, which is a passive method is chosen for this experiment. Twisted tapes are
chosen for this experiment because insertion of these tapes into the tubes does not demand any
changes to be made in the cross section of the tube and also the usage of twisted tapes is more
economical as compared to other methods. The material of the twisted tapes is aluminium. Twisted
tapes with different number of Turns and notches (V - notch and Square notch) are inserted into the
forced convection apparatus and the heat transfer coefficient is calculated for the respective insert.
The effect of different twisted tapes on heat transfer rate is experimentally investigated. The
experiments for both the smooth tube and the typical twisted tape inserted tube are validated with
the literature

Keywords: Heat Transfer, Enhancement, Twisted tapes, Notches, Literature validation, Forced
Convection, Experimentation

INTRODUCTION :

In the field of thermal engineering, optimizing heat transfer processes is critical for improving
efficiency and performance in a variety of industrial applications. Heat Transfer enhancement
techniques are classified into three categories.

1)Active methods : Active methods involves addition of nano sized composites, high thermal
conductivity materials and metallic powders to the base fluid to increase the heat transfer rate and
also the enhancement rate. It requires external power input for enhancement in heat transfer.
Examples of active methods are mechanical injection and use of magnetic or electrostatic field to
disturb the light particles inserted in a flowing stream. The originality of design is not changed.

2)Passive methods : Passive heat transfer enhancement methods does not use any external power
input. In order to enhance the heat transfer performance by passive methods, the effective surface
area and the residence time is increased. It causes the swirl flow in bulk of fluids and disturbs the
actual boundary layer to increase the surface area, given time and similarly heat transfer coefficient
in existing system. It is commonly used in heating exchangers, evaporators, thermal power plants, air
conditioning, twisted tapes, wire coils, ribs, baffles.

3)Compound methods : It involves the usage of combination of methods i.e. active and passive
methods simultaneously for the heat transfer enhancement.
In this context, the use of twisted inserts in forced convection equipment emerges as a promising
technique for increasing heat transfer rates and thereby improving overall system efficacy. Traditional
forced convection arrangements may not achieve optimal heat transfer rates, leading to the need for
novel measures to improve performance. Twisted inserts offer an innovative solution to this
problem, utilizing fluid dynamics and turbulence enhancement concepts to facilitate heat transfer
throughout the system. These inserts, typically composed of helically twisted geometries deliberately
positioned along the fluid flow path, produce secondary flow patterns and break laminar boundary
layers.

This intensifies heat transmission methods such as convection and turbulence. The efficiency
of twisted inserts in heat transfer enhancement has been established in a number of experimental
and computational studies, with considerable improvements in heat transfer coefficients and
thermal performance indicators. Furthermore, the versatility of twisted inserts enables
customization based on individual application requirements, providing scalability and adaptability
across a variety of operating conditions and geometries.

In this study, we look at the fundamental concepts of heat transfer augmentation employing
twisted inserts in forced convection equipment. By reviewing existing literature, experimental
findings, and computational analyses, we hope to provide a comprehensive understanding of the
mechanisms underlying heat transfer augmentation with twisted inserts, as well as insights into
potential applications and implications for future research and industrial implementation. We hope
that this investigation will help to develop thermal engineering methods and optimize heat transfer
processes in a variety of engineering fields.

METHODOLOGY :

During the experimental research of heat transfer enhancement utilizing twisted inserts in pipe flow,
we used a systematic methodology structured around several key phases. Here's the step by step
methodology for the project.

1. Literature Review

Objective: To understand existing research on heat transfer enhancement techniques, focusing on

the use of twisted inserts in pipe flow.

Actions: Reviewed scientific articles, journals, and previous experimental studies related to heat
transfer, twisted inserts, and their efficiency in enhancing heat transfer in pipes.

2. Hypothesis Formulation

Objective: To develop hypothesis based on the literature review regarding how twisted inserts might
affect heat transfer in pipe flow.

Actions: Proposed how twisted inserts might enhance heat transfer, their potential effects on
pressure drop, and efficiency improvements and to find the relative heat transfer coefficient.

3. Experimental Design
Objective: To design an experiment to test the hypotheses.

Components:

Experimental Setup: Twisted tapes of varying number of turns(12,10,8 turns) and notches( Square
and V- shaped notch) were fabricated using aluminium strips. These various inserts were inserted in
the straight pipe of the forced convection apparatus and the respective readings of
temperature( using thermocouples) were tabulated.

Measurement Instruments: The placement of thermocouples is fixed in the forced convection

apparatus for temperature measurement, manometer for pressure drop measurement.

Twisted Inserts Specification: Defined the specifications of twisted inserts, such as material, twist
ratio (length per complete twist), width, and thickness.

4. Experimental Procedure

Objective: Carry out experiments to collect data on heat transfer coefficient and pressure drop.

Steps:

 Prepare the experimental setup and ensure all instruments are calibrated.
 Install a twisted insert into the pipe and ensure it is securely in place.
 Heat the fluid (using blower) and allow it to flow through the pipe.
 Record temperatures and pressure data for smooth tube(without inserts) first and then with
different inserts respectively.
 Repeat the experiment with different twisted insert designs (varying twist ratios, widths, and
materials).

5. Data Analysis

Objective: To assess how well twisted inserts operate in boosting the heat transfer coefficient,
analyse the data that has been gathered.

Actions: Use statistical and graphical methods to compare the heat transfer coefficient and pressure
drop with and without twisted inserts. Analyze the efficiency of heat transfer enhancement in
relation to the energy penalty of increased pressure drop.

6. Conclusions and Recommendations

Objective: Draw conclusions from the experimental data and make recommendations for practical
applications or further research.

Actions: Assess which twisted insert designs offer the best trade-off between heat transfer
enhancement and pressure drop. Discuss potential applications in industry and suggestions for
further research to optimize insert designs or explore alternative materials.

7. Reporting

Objective: Document the entire process, findings, and recommendations.

Components: Introduction, literature review, methodology, results, discussion, conclusions,

recommendations, and references.
This methodology offers a comprehensive framework for investigating the impact of twisted inserts
on heat transfer in pipe flow, encompassing from initial literature review through to final reporting,
ensuring a rigorous and systematic approach to the research project.

CONCLUSIONS :

This paper consists of review of work done in enhancement of heat transfer by using different
twisted tapes in the forced convection apparatus. A twisted tape and modified twisted tape
configurations creates swirl and turbulence.

The experiments likely demonstrated a significant enhancement in heat transfer rates when
twisted inserts were used in pipe flow. This enhancement can be attributed to the increased
turbulence and improved mixing induced by the twisted inserts, which disrupts the thermal
boundary layer and facilitates higher heat transfer coefficients.

Various Inserts Heat Transfer Co efficient value (h) W/m2K

Without Inserts (in a smooth tube) 25.029 W/m2K
With Inserts in a tube
 12 Turns 30.36 W/m2K
 10 Turns 29.87 W/m2K
 8 Turns 28.42 W/m2K
 Tape with V-shaped notch 28.88 W/m2K
 Tape with square shaped notch 32.55 W/m2K

The effectiveness of heat transfer enhancement could be quantitatively expressed in terms of the
Nusselt number increase compared to a baseline scenario without inserts. For example, twisted
inserts may have increased the heat transfer rate by 23.1%, as indicated by the experimental data.

REFERENCES :

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plain, perforated and dimpled twisted tape inserts (2021)
Toygun Dagdevir, Veysel Ozceyhan

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tape inserts: Experimental investigation and correlation development (2017)
Amar Raj Singh Suri, Anil Kumar

 Experimental study on effect of heat transfer enhancement for single-phase forced

convective flow with twisted tape inserts (2017)
Changzhong Man, Xiaogang Lv

 A comprehensive review on passive heat transfer enhancements in pipe exchangers (2012)

S. Liu ,M. Sakr
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