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I. INTRODUCTION
In the past few decades, heat transfer enhancement technology has been developed and widely
applied in many engineering applications. Heating or cooling of viscous liquids in process industries, heating or cooling of oils, heating of circulating fluid in solar collectors, and heat transfer in
compact heat exchangers are a few example. Heat transfer augmentation techniques play a vital
role here since heat transfer coefficients are generally low for laminar flow in plain tubes. Insertion
of twisted tapes in tubes is one of such augmentation techniques.
Thus, research in this area has captivated the interest of a number of researchers, e.g., Eiamsa
and Promvonge.1 In passive technique, improvement is acquired without providing any extra flow
energy. In compound technique, two or more active or passive techniques may be utilized simultaneously to produce an enhancement that is much higher than that of the techniques operating
separately as presented by Yilmaz et al.2,3 Mamer and Bergles46 reported experimental data for
laminar flows of ethylene glycol with a twisted-tap ratio of 5.39 in an isothermal tube.
Mangilk and Bergles79 developed the generalized Nusslet number and friction factor correlations. Local convective-condensation measurements for four refrigerant fluidsR134a, R410A,
R125, and R32in a microfin tube were presented by Kedzierski and Goncalves.10 Their research
showed that R32 exhibits the highest heat transfer performance due to its high thermal conductivity. The turbulent mixed convection in a horizontal circular tube provided with an inserted strip
has been studied by Hsieh et al.11
Al-Fahed et al.12 compared pressure drop and heat transfer coefficients obtained from a plain
1941-7012/2011/32/023110/15/$30.00
3, 023110-1
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023110-2
M. Moawed
+#"**'#" -.(*
Test section
!"#$%&%'()"*
/)%0
Flaw$"-"#
meter
Flow
meter
Flaw
meter
Flow
meter
Ball valve
Heater
Cold water tank
Hot water tank
Pump
Pump
microfin and twisted tape inserted tubes. Sarma et al.13 presented a new approach for predicting
convective heat transfer coefficient of a tube equipped with twisted tape at different pitch to
diameter ratios. The predicted results were compared with empirical correlations. Recently, Sarma
et al.14 proposed generalized correlations for predicting friction factor and convective heat transfer
coefficient for twisted tapes in a tube. Reasonable agreement was obtained from comparison
between the predicted results and the measured data. Several investigations were carried out to
determine the effect of coiled wire or twisted tape elements on heat transfer and friction factor for
a long time.1517 This is because wire coil or twisted tape insert in a tube creates swirling flows
that modify the near wall velocity profile due to various vorticity distributions in the vortex core.
The fluid mixing between the tube core and the near wall region is enhanced because of swirl
induced tangential flow velocity component. However, accompanied with swirl induced heat transfer enhancement, the shear stress and pressure drag in a tube with coiled wire or twisted tape insert
are increased accordingly. For using compound turbulators, Promvonge and Eiamsa-ard1820 investigated the effects of conical-nozzle, conical-ring, or V-nozzle together with a swirl generator
decaying swirl on heat transfer and friction characteristics in a uniform heat flux tube and found
that using both enhancement devices, the increase in heat transfer rate is about 20%50% of using
a single enhancement device, but there is also a substantial rise in pressure loss.
A review of a previous work showed that there are no data on heat transfer and friction factor
inside elliptic tubes fitted with full length helical screw-tape inserts. So, the present paper reports
on the heat transfer and friction factor characteristics of laminar flow through circular and elliptic
tubes fitted with full length helical screw-tape inserts. Also, correlations based on the data gathered
during this work for predicting heat transfer coefficient and friction factor inside elliptic tubes
fitted with full length helical screw-tape inserts are proposed for practical applications.
II. EXPERIMENTAL APPARATUS
The experimental setup consists of a counterflow double pipe heat exchanger and a water flow
system with its accessories. As shown in Fig. 1, hot water circuit is arranged as follows: a hot
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023110-3
Heat transfer
Flow meter
(a)
Flow meter
H
w
dst
!b)
FIG. 2. a Cross section of the elliptic tube. b Configuration of the inserted tape.
water storage tank that provides multiple electrical heaters with rheostat, a half hp centrifugal
pump, a flow meter, a piping system with suitable valves, and an inner tube of heat exchanger. The
storage tank is perfectly insulated by 50 mm layer of glass wool and covered by a galvanized steel
sheet. The tank is fitted with suction, return, and vent pipes. The vent pipe has two functions: to
ensure that the storage tank is filled continuously with water to save heater elements and to prevent
accumulation of pressure inside the storage tank that may result from temperature rise or back
pressure. All hot pipes are insulated with suitable insulation thickness and secured with a galvanized steel cover. Cold water is supplied from city water passing through a calibrated flow meter
to the inside tube of the heat exchanger. Therefore, cold water flow rate could be changed while
hot water flow is constant and controlled using bypass system using a backflow branch and a
regulating valve, as shown in Fig. 1.
Two sets of double pipes are used separately in the present experiment as test sections. The
first one is double circular copper tube that has a length of 1500 mm. The inner tube has an inner
diameter of 38.1 mm and a thickness of 2 mm, while the outer tube diameter has an inner diameter
of 63.5 mm and a thickness of 2 mm. The second one is a double copper elliptic tube with the
same surface area as the first one and the same length of 1500 mm. The axis ratio
major/ minor = 2 for both inner and outer tubes with minor axis= 24 and 40 mm for inner and
outer tubes, respectively. The set of plain double circular tubes is used to compare against the
previous work and plain double elliptic tubes. The second set of double elliptic tubes is used with
different screw-tape inserts inside the inner elliptic tube. The helical screw-tape inserts with
various twist ratios are made by winding uniformly different strips in width over a 5 mm rod and
coated with chromium by electroplating to prevent corrosion Fig. 2. The twist ratio Y, which is
defined as the ratio of width of the strip w to the diameter of twist dst, is varied from 0.22 to
0.35 at a constant of pitch ratio S = 1. The pitch ratio is defined as the ratio of pitch H to the
diameter of twist dst and it ranged from 0.46 to 2.15 at a constant of twist ratio Y = 0.31. The
outer tube of the heat exchanger is perfectly insulated with a glass wool of 40 mm thick to
minimize heat loss.
Nine T-type calibrated thermocouples are inserted into the test section and distributed regularly. They are used to measure cold water, hot water, and wall temperature at the inlet, middle,
and exit of the test section, in addition to hot water in the storage tank. The thermocouples are
fixed in the surface of the tube by making a small notch at a specified location where the junction
of thermocouples is soldered. To get fluid bulk temperatures, groups of thermocouples are fixed at
different locations at the inlet and outlet of cold and hot water. The fluid bulk temperatures at the
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023110-4
M. Moawed
inlet and outlet of cold and hot water are calculated from the average of readings of fixed groups
of thermocouples. All instruments and measurements have certain general characteristics errors,
and uncertainties are inherent in both instrument and process of making the measurement. The
readings of thermocouples are taken by means of a multichannel digital thermometer with a
resolution of 0.1 C. The pressure drop across the inner tube is measured using pressure taps and
digital calibrated manometer. When steady state condition is established, water flow rates, pressure
drop, and all thermocouples temperatures have been recorded.
III. UNCERTAINTY ANALYSIS
Generally, the accuracy of the experimental results depends on the accuracy of individual
measuring instruments and manufacture accuracy of elliptic tubes. Also, the accuracy of an instrument is limited by its minimum division its sensitivity.
Based on uncertainties in the temperature 0.1 C, the elliptic tube surface areas 5%, and
heating power 5%, as well as those of geometrical parameters and consequences of their physical
parameters, uncertainties in thee average Nusselt number, friction factor, and Reynolds number are
estimated as a maximum of 3.8%, 2.6%, and 3.2% respectively.
IV. DATA REDUCTION
Using water on both sides of the heat exchanger can be performed with reasonable temperature difference between hot and cold sides. The flow velocities and the Reynolds number are
calculated from the measured flow rates based on the equivalent diameter. The tube equivalent
diameter is calculated from the volume of water required to fill a given length of tubing. Deq is
calculated in each case before turning on experiments by filling closed ended tested tube with
twisted tape inserts by water. The volume of water is measured by putting this water in a measuring flask, which equals the volume of space V between the twisted tape and the elliptic tube,
Deq = 4V/L0.5 .
The tube cross-sectional flow area of the tube, At, is calculated by using tube equivalent
2
/ 4. Reynolds number is calculated inside tubes as
diameter At = Deq
Re = Deq/v.
hC phThi Tho.
Qh = m
The heat losses from the test section to the surrounding are calculated and maximum heat losses
are found to be about 2% from the total heat.
The average heat transfer coefficient for inside tube, hc, is calculated from the following
equation:
hc = Qc/DeqLtm,
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023110-5
Heat transfer
12
10
Nu
2
400
600
800
1000
1200
1400
Re
FIG. 3. Comparison between the present work and the previous work Ref. 21.
Nu = hcDeqlkc .
Preliminary experiments have been performed on a smooth circular tube to compare the
results with the empirical correlations that was proposed by Hewitt et al.21 to validate the present
results. This correlation was stated as
Nu = 1.86Re Pr D/L0.33a/0.14
b .
10
The experimental Nu results of the present plain elliptic tube are compared with the present
plain circular tube and with Eq. 10 of the circular tube, as shown in Fig. 3. This figure represents
the variation of the average Nusselt number Nu with Reynolds number for three cases. The Nu
of the present experimental results of plain circular tube are found to agree within 5% with Eq.
10 of the plain circular tube approximately, while the present Nu results of the plain elliptic tube
are higher than that of both present and previous plain circular tubes.
Figures 48 show the relation of Nu with Re of the plain elliptic tube and an elliptic tube with
inserted swirl sheet of different Y and S. These figures show that Nu increases with an increase in
Re, but it changes dramatically with Y and S. The same general shape of curves can be seen from
these figures. The effect of Y on the Nu-S relation is shown in Fig. 8. These figures show that all
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023110-6
M. Moawed
24
No insertion
S = 2.15
S = 1.85
S = 1.38
S=1
S = 0.46
20
Nu
16
12
4
400
600
800
Re
1000
1200
1400
Nu results of the elliptic tube with an inserted swirl sheet with different S and Y are greater than
that of the plain elliptic tube. These figures show that Nu decreases with an increase in S and Y.
The behavior of flow inside the elliptic tube with an inserted swirl sheet is affected by an increase
in S or Y. The increase in S or Y leads to a decrease in the turbulence intensity of the flow inside
the elliptic tube with an inserted swirl sheet and, in turn, a decrease in Nu. Thus, insertion of a
helical screw sheet inside the tube makes swirls to flow and generates periodic disruptions to the
development of viscous boundary layer. This disturbance of main flow and viscous boundary
layers in a helical screw insert inside the tube enhances the heat transfer.
24
20
No insertion
S = 2.15
S = 1.85
S = 1.38
S=1
S = 0.46
Nu
16
12
8
4
400
600
800
Re
1000
1200
1400
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023110-7
Heat transfer
No insertion
S = 2.15
S = 1.85
S = 1.38
S=1
S = 0.46
16
Nu
12
4
400
600
800
Re
1000
1200
1400
Preliminary experiments have been performed on a smooth tube to compare the results with
empirical correlations that was proposed by Hewitt et al.21 to validate the present results. This
correlation is stated as
11
f = 64/Re.
18
16
14
No insertion
S = 2.15
S = 1.85
S = 1.38
S=1
S = 0.46
Nu
12
10
8
6
4
400
600
800
1000
1200
1400
Re
FIG. 7. Variation of Nu with Re of elliptic tube without and with different inserted swirl sheets at Y = 0.35.
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023110-8
M. Moawed
19
Y = 0.22
Y = 0.27
17
Y = 0.31
Y = 0.35
Nu
15
13
11
7
0
0.5
1.5
2.5
S
FIG. 8. Variation of Nu with S of elliptic tube at different Y and Re= 1279.
0.15
Present circular tube
Present ellipticie tube
0.13
0.11
0.09
0.07
0.05
0.03
400
550
700
850
1000
1150
1300
Re
FIG. 9. Comparison between the present work and the previous work Ref. 21.
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023110-9
Heat transfer
0.2
No insertion
S = 2.15
S = 1.85
S = 1.38
S=1
S = 0.46
0.18
0.16
0.14
0.12
0.1
0.08
0.06
0.04
400
600
800
1000
1200
1400
Re
FIG. 10. Variation of f with Re of elliptic tube at different S and Y = 0.22.
The experimental f results of the plain elliptic tube are compared with that of the plain
circular tube and Eq. 11 of the circular tube, as shown in Fig. 9. This figure represents the
variation of friction factor f with Reynolds number for three cases. The f of the present experimental results of the plain elliptic tube is slightly higher than that of the plain circular tube, while
the present results of the plain circular tube are found to agree within 7% with Eq. 11 of the
previous plain circular tube.
The effect of Y and S on the characteristics of friction factor inside an elliptic tube with and
without an inserted swirl sheet will be discussed in the present section. The experiments have been
performed at different Y and S to evaluate the direction of pressure drop. Figures 1013 show the
relation of f with Re for plain elliptic tube and elliptic tubes with inserted swirl sheets of different
Y and S. It is seen from these figures that the value of f decreases with an increase in Re, but it
decreases with an increase in S. The same general shape of curves can be seen from all figures.
The variation of f with S at different Y is shown in Fig. 14. This figure shows that the value of f
decreases with an increase in Y. The behavior of flow inside an elliptic tube with an inserted swirl
sheet is affected by an increase in S or Y. The increase in S or Y leads to a decrease in the
turbulence intensity of the flow inside the elliptic tube with an inserted swirl sheet and, in turn, a
decrease in f.
C. Correlation of the results
The experimental results are fitted, using power regression, to determine the following empirical correlations for elliptic tubes:
Nu = 1.35 Re0.21 s0.183Y 0.63
12
13
and
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023110-10
M. Moawed
0.18
No insertion
S = 2.15
S = 1.85
S = 1.38
S=1
S = 0.46
0.16
0.14
0.12
0.1
0.08
0.06
0.04
400
600
800
1000
1200
1400
Re
FIG. 11. Variation of f with Re of elliptic tube at different S and Y = 0.27.
D. Thermal performance
As shown in the present experimental results, there is an enhancement of the heat transfer
coefficient through elliptic tubes with an inserted swirl sheet, while an increment in friction
coefficient f occurs with a decrease in S and Y. The thermal performance factor is introduced
to indicate the percentage increase in Nu over the percentage increase in f. To get optimum
performance between Nu and f for S and Y, the variations of thermal performance parameter
0.18
No insertion
S = 2.15
S = 1.85
S = 1.38
S=1
S = 0.46
0.16
0.14
0.12
0.1
0.08
0.06
0.04
400
600
800
1000
1200
1400
Re
FIG. 12. Variation of f with Re of elliptic tube at different S and Y = 0.31.
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023110-11
Heat transfer
0.16
No insertion
S = 2.15
S = 1.85
S = 1.38
S=1
S = 0.46
0.14
0.12
f
0.1
0.08
0.06
0.04
400
600
800
1000
1200
1400
Re
FIG. 13. Variation of f with Re of elliptic tube at different S and Y = 0.35.
with S and Y are shown in Figs. 17 and 18, respectively. These figures show that the maximum
performance parameter occurs at S = 1 and Y = 0.22. This means that for the present experimental results, the optimum operating values of S and Y are 1 and 0.22, which give an enhancement in the performance parameter of 19.7% and 42.3%, respectively.
0.08
Y = 0.22
Y = 0.27
Y = 0.31
Y = 0.35
0.07
0.06
0.05
0
0.5
1.5
2.5
S
FIG. 14. Variation of f with S of elliptic tube at different Y and Re= 1279.
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023110-12
M. Moawed
20
18
+8%
Nucal
16
14
-8%
12
10
8
6
6
10
12
14
16
18
20
Nuexp
FIG. 15. Nucalc against Nuexpt for circular tube.
VI. CONCLUSION
Augmentation of laminar flow and heat transfer in elliptic tubes by means of helical screwtape inserts is investigated experimentally. The friction factor in the horizontal double pipes of
elliptic tubes with different parameters of S and Y is investigated. Cold and hot water are used as
working fluid in the tube side and shell side, respectively. The experiments covered a range of
Reynolds numbers, 5.7 102 Re 1.31 103. The effects of S and Y on heat transfer augmentation and friction factor have been presented.
The results of the present investigation can be summarized as follows.
0.2
0.18
0.16
+ !" %
f cal
0.14
0.12
- !" %
0.1
0.08
0.06
0.04
0.04
0.06
0.08
0.1
0.12
0.14
0.16
0.18
0.2
f exp
FIG. 16. f calc against f expt for flat tube.
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023110-13
Heat transfer
1.4
1.3
1.2
1.1
0.9
0.8
0
0.5
1.5
2.5
S
FIG. 17. Variation of with S at Y = 0.31 and Re= 1279.
1.6
1.5
1.4
1.3
1.2
1.1
1
0.9
0.8
0
0.1
0.2
0.3
0.4
0.5
Y
FIG. 18. Variation of with Y at S = 1 and Re= 1279.
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023110-14
M. Moawed
The results indicate that the helical screw element of different Y and S have an effect on the
results of heat transfer coefficient and friction factor.
The averaged Nusslet number Nu increases with an increase in the Reynolds number and
with a decrease in Y and S.
The Nu of the plain elliptic tube is greater than that of the plain circular tube and the Nu of
elliptic tubes containing a helical screw tapes is better than that of the plain elliptic tubes for
all Re, Y, and S.
For a fixed Reynolds number, the friction factor f increases with a decrease in Y and S for
the elliptic tubes.
The variation of thermal performance parameter with S and Y is presented. The
increases with an increase in S and Y until a point S = 1 and Y = 0.22, after that it gradually
decreases.
The maximum performance parameter gives the optimum values of S = 1 and Y = 0.22.
The correlations of the average Nusselt number and friction factor with Re, S, and Y are
presented.
NOMENCLATURE
Tube cross-sectional area m2
At
Specific heat capacity at constant pressure J kg1 K1
Cp
Diameter of the twisted insertion m
dst
Equivalent diameter m
Deq
f
Friction factor inside elliptic tube
L
Length of tube m
h
Heat transfer coefficient W m2 k1
H
Pitch between two turns of the twist sheet m
k
Thermal conductivity W m1 k1
m
Mass flow rate kg s1
Nu
Average Nusselt number
P
Pressure drop N m2
V
Volume of water filling the tested tube m3
Q
Heat transfer W
Re
Reynolds number
S
Pitch ratio pitch/diameter of twist, H / dst
T
Temperature K
Logarithmic mean temperature difference
tm
Velocity of water inside tube m s1
v
w
Width of twist sheet m
Y
Twist ratio width of twist sheet/diameter of twist, w / dst
Greek letters
a
b
Subscripts
c
h
i
o
s
w
Cold
Hot
Inside
Outside
Surface
Water
Plain tube
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023110-15
Heat transfer
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