Comparative Experimental Study on Effect of Copper Wire Helical Wound Steel Tube with 2.5” Full Length Insert on Performance of Double Pipe Steel Tube Heat Exchanger

Abstract

A comparative experimental study was conducted to explore the hydrothermal behavior of a double tube heat exchanger with copper wire helical wound steel tubes and plane steel tubes with and without twisted tap inserts of pitch length 2.5 inches. In comparison to helical tubes, corrugated tubes, and many other more compact tube type heat exchangers, straight tube heat exchangers offer advantages since the construction of the heat exchanger tubes is easier. In the current work, the fluid-to-fluid heat exchange is considered, with a flow rate ranging from 15 to 75 liters/hour. Constant wall temperature or constant heat flux ideas are used in the majority of investigations on heat transfer coefficients. The efficiency, overall heat transfer coefficient, and impact of hot water flow rate with constant cold water flow rate for straight steel tube and copper wire helical wrapped steel tube heat exchangers in parallel flow and counter flow configurations were investigated and compared. Utilizing a 2.5\" full length clockwise twisted tape insert, both layouts were created. The measurements were carried out in a constant state. When the hot water flow rate is increased while maintaining the cold water flow rate constant, the efficiency of the heat exchanger drops for both the straight steel and the copper wire helical wound steel tube. Compared to a plane steel tube heat exchanger, the copper wire helical wound steel tube heat exchanger has a better efficiency. The test findings demonstrate that inserting inserts causes pressure drop. With 2.5\" clockwise twisted tape inserts wrapped in helical copper wire, steel tube was able to transmit heat more quickly than other arrangements.

Introduction

I. INTRODUCTION

The world's energy needs have significantly increased over the past ten years, which has led to much research on the best ways to use energy to address this problem [1]. Along with the rise in energy conservation, there has been a consistent and generous expansion in HE research and innovation, and many qualified professionals are still looking for ways to improve design and performance [2]. HE is frequently utilized in the industrial setting to transfer heat across various streams and temperatures. The most popular and often utilized HE in industry is concentrated-tube HE [3]. Twin tube heat exchangers, which can be utilized in a range of products, must be made more effective, efficient, and compact [4].

For single-phase and phase change heat transfer in a variety of applications, double tube heat exchangers are often used in power plants, the chemical industry, waste heat recovery systems, refrigeration and air conditioning systems, automotive, and process industries. The The hydro thermal properties of double tube heat exchangers have improved significantly. There are many active and passive strategies to improve the thermal performance of the double tube heat exchanger. In the active technique, additional power from outside sources, such as impinging jets, electrostatic fields, surface vibrations, etc., is required to accelerate the rate of heat transfer. In addition to not requiring any additional energy, passive technologies are also easy to make and inexpensive to use. As a result, heat exchangers are increasingly using the passive approach as a heating method [5].

In experimental and numerical investigations to assess the efficacy of tubular heat exchangers, the passive technique known as the enhancer is widely used [6–14].  The use of wire coil (WC) and twisted tape (TT) inserts as tabulators is one of the best methods for generating swirl flows in tubes and decreasing boundary layer thickness while boosting turbulent intensity [16]. The rate of heat transmission via the heat exchanger may be accelerated by employing inserts.

Conclusion

The mass flow rates inside and outside of straight steel and straight copper tube heat exchangers were adjusted in the heat and mass transfer lab during an experimental examination using parallel and counter flow configurations. 1) The efficiency of the heat exchanger is significantly impacted by both the hot and cold water flow rates. 2) Efficiency continuously declines when the mass flow rate of hot water is raised while the mass flow rate of cold water is kept at 45 LPH. 3) In all flow orientations, straight steel tube is more efficient and less effective in parallel flow. 4) The overall heat transfer coefficient rises as the mass flow rate of hot water does. 5) According to reports, the highest total heat transfer occurs at a hot water mass flow rate of 75 LPH at counter flow in a straight steel tube. 6) When the hot water flow rate varies while the cold water flow rate remains constant at 45 LPH in a straight steel tube with parallel flow, the LMTD is at least 15 LPH. 7) In this experimental arrangement, the heat exchanger tube is inexpensive and straight. 8) In this experimental arrangement, the heat exchanger tube is inexpensive and straight. It was discovered that the heat transfer rate increases with the volume flow rate of hot water in both the parallel and the counter flow examples, with the counter flow case displaying a higher heat transfer rate than the parallel flow case. The insert with a 2.5-inch pitch length was found to transmit heat more quickly than the other designs in both cases. The maximum rate of heat transfer, which was 638.52 Watt, was measured in a counter-flow configuration with a 2.5-inch insert. This rate is 24.58% higher than that of parallel flow in a steel tube enclosed by a helical copper coil and 22.99% higher than that of parallel flow in a parallel configuration with no insert. It denotes the volume flow rate variation of hot fluid, the pitch length of the twisted tape, and the rate of heat transfer on the relative direction of fluid motion. The counter flow configuration with a 2.5 inch clockwise insert was found to have the maximum effectiveness, measuring 0.690. This figure is greater by 19.27% and 23.04% than the highest effectiveness in counter flow arrangements for, respectively, plane steel tubes without inserts and helical bounded coil steel tubes without inserts. The greatest overall heat transfer coefficient for a 2.5-inch insert in a copper-bounded helical coil straight tube was determined to be 573.00 W/m2K, which is 33.07% and 18.28% greater than the maximum values for those two designs, respectively, in a parallel flow arrangement. It was discovered that when the volume flow rate of hot fluid increases, so does the value of the overall heat transfer coefficient. At 22.52 C, the plane steel tube in counter flow was found to have the highest value of LMTD, which was 17.53% higher than the value for the copper-bounded helical coil straight tube without insert and 20.91% higher than the value for the copper-bounded helical coil straight tube with 2.5\" insert in the parallel flow arrangement, respectively. It was discovered that as the volume flow rate of hot fluid increases, so does the value of LMTD. The lowest value of NTU was found in the case of no insert, where it was 1.433, which is 28.12% and 36.63% higher than the values discovered in 2.5 inch wise twist tape insert and copper-bounded helical coil straight tube without insert in parallel flow, respectively. The initial value of NTU was found to decrease with an increase in the volume flow rate of hot fluid.

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Copyright

Copyright © 2023 Udit Seryam, Aseem C Tiwari, Jeetendra Kushwaha. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.