Experimental study on a shell and tube heat

exchanger with novel self agitating inserts

Cite as: AIP Conference Proceedings 2200, 020039 (2019); https://doi.org/10.1063/1.5141209
Published Online: 20 December 2019

P. S. V. V. Srihari, P. S. V. V. S. Narayana, V. Hemanth Kumar, V. S. Surya Prakash, and P. Jaikishan

ARTICLES YOU MAY BE INTERESTED IN

Influence of slat and flaps arrangement on the performance of modified Darrieus wind turbine
AIP Conference Proceedings 2200, 020012 (2019); https://doi.org/10.1063/1.5141182

Thermal performance investigation of MMC heat sinks for low CTE electronic components
cooling
AIP Conference Proceedings 2200, 020024 (2019); https://doi.org/10.1063/1.5141194

Experimental study on vortex intensification of gravitational water vortex turbine with novel
conical basin
AIP Conference Proceedings 2200, 020082 (2019); https://doi.org/10.1063/1.5141252

AIP Conference Proceedings 2200, 020039 (2019); https://doi.org/10.1063/1.5141209 2200, 020039

© 2019 Author(s).
 Experimental Study On A Shell And Tube Heat Exchanger
With Novel Self Agitating Inserts
1, a)
P S V V Srihari, 2, b)P S V V S Narayana, 3V Hemanth Kumar,
4
V S Surya Prakash, 5 P Jaikishan
1,2,3,4,5
Assistant Professor, Department of Mechanical Engineering, Aditya College of Engineering and Technology,
Surampalem 533437, India
a)
psvvsrihari@gmail.com
b)psvvsnarayana@gmail.com

Abstract. The current experimental study investigates the effect of self-agitating inserts on the Shell and tube heat
exchanger (STHX) thermal performance. Three novel self-agitating inserts are proposed, namely rectangular agitating
insert (RAI), square agitating insert (SAI), and triangular agitating insert (TAI). The effect of these inserts is studied for
the Reynolds number ranging from 3000 to 7200. The improvement in friction factor, thermal performance factor (TPF),
and Nusselt number (Nu) are studied. Results showed the TAI has the best improvement in Nusselt number of 22.06%
compared to smooth pipe with maximum TPF of 2.32 RAI and SAI show 17.88 and 9.55% improvement in Nu with
maximum TPF of 1.81 and 1.6 respectively.

Keywords. Shell and tube heat exchanger, thermal performance factor, friction factor, Nusselt number.

INTRODUCTION

Pharmaceutical, air-conditioning, refrigeration, process, oil and gas industries widely use STHXs for multipurpose
applications. Increases in heat transfer increase the performance of heat exchanger and thereby decrease the cost and
size of systems. Passive or active techniques are employed to amplify heat exchanger’s heat transfer. Passive methods
such as using finned, fluted tubes and nanofluids don’t require external energy to enhance heat transfer. Turbulators
such as wire brushes, louvered, coiled wires falls under an active method that utilizes external energy [1].

Amar Raj et al. [2] studied f description and Nu of multiple square twisted tape perforated inserts (MSPT) in a
concentric tube heat exchanger. Twist ratio of 2.5, depth ratio of 0.042-0.167, 4 twisted tapes and 0.25 weight ratio
are the geometric parameters of the MSPT inserts. For the range of Re = 5000 to 27000, the effects of inserts are
studied. The f and Nu enhanced by 8.34 and 6.96 compared to tube without inserts. Nakhchi et al. [3] performed
numerical analysis for twisted tape with cross cuts (CCTA) in a circular duct and Cu-water nanofluid. Nine CCTA
geometries with different width ratio and length ratio ranging from 0.7 to 0.9 and 2 to 2.5, respectively, are tested for
Re ranging from 5000 to 15000 and 0 to 1.5% volume fraction of nanoparticles. There is 23.20% increase in the
coefficient of heat transfer as the nanoparticles volume fraction rise from 0 to 1.5%.

Hasanpour et al. [4] with the use of artificial neural networks along with genetic algorithm optimized heat transfer
of a corrugated tube heat exchanger with twisted tape inserts. U-notch and V-notch tape inserts twisted with twist
ratios of 3, 5 and 7 are used to conduct experiments with Re ranging from 5000 to 15000. U-notch twisted tape inserts
showed to have maximum heat transfer. Sompal et al. [5] investigated the heat exchanger thermal performance with
curved-winglet tapes (CWT) inserts on the tube side. CWT with 450 angle of attack, winglet pitch (0.5, 1, and 2) and

1st International Conference on Manufacturing, Material Science and Engineering (ICMMSE-2019)

AIP Conf. Proc. 2200, 020039-1–020039-6; https://doi.org/10.1063/1.5141209
Published by AIP Publishing. 978-0-7354-1951-3/$30.00

020039-1
winglet height (0.1, 0.2, and 0.3) are examined for Re = 4150 to 25400. CWT is modified to reduce the pressure loss
by punching to produce perforated-CWT (PCWT) with different hole diameters (1, 1.5, 2, 2.5, and 3) PCWTs showed
higher thermal performance factor (TEF) than CWT with maximum TEF of 1.76 higher than CWT.

Sarviya et al. [6] studied twisted tape inserts with continuous cut edges effect on the pressure drop and heat transfer
in a heat exchanger tube. Using twist ratios of 3 and 5, the heat transfer rate is amplified. Zahid et al. [7] worked on a
STHX with interstitial twisted tapes on the shell side. Propylene glycol with volume concentration varying from 0 to
40% in water solution is used as working fluid. The results are compared with a segmented baffle heat exchanger
which showed 20% increases in heat transfer rate.

No previous study is found on STHX with self-agitating inserts on the tube side. The current experimental work
focuses on STHX thermal performance evaluation with three different types of self-agitating inserts in the tube side.
Rectangular agitating insert (RAI), square agitating insert (SAI), and triangular agitating insert (TAI) are the three
different geometries of the agitating inserts. The results are compared with segmented baffle heat exchanger without
inserts.

EXPERIMENTAL DETAILS

The experimental setup consists of a STHX, heating tank, cold water tank, and pumps for circulation of working
fluid on both sides. Counter flow water/water loops are used to carry out experiments. Hot water flows on the shell
side whereas cold water flows inside the tubes. The hot water in closed loop configuration consists of a 200-liter
capacity tank with four 3kW electrical heaters and a centrifugal pump for hot water circulation. Two K-type
thermocouples record outlet and inlet temperatures. The shell is insulated to remove heat dissipation to the
surroundings. The cold water loop is in open circulation and contains two K-type thermocouples record outlet and
inlet temperatures and a centrifugal pump for water circulation. The pressure traps are arranged at the cold water outlet
and inlet and connected to a mercury manometer. Rotameters and ball valves are used for flow measurement and
control respectively. A data logger with Arduino board, display, and memory module are used for temperature logging.
The heat exchanger geometric details are shown in Table 1. Fig.1 shows the unassembled shell, tube bundle, and an
agitator. The experimental setup is shown in Fig. 2.

TABLE 1. Heat exchanger geometric details

Parameters Description
Shell parameters
‫ܦ‬௢ 60⁄54
ൗ‫݉݉( ܦ‬⁄݉݉)
௜
Material Mild Steel
Tube parameters
݀଴ 19⁄17
ൗ݀ (݉݉⁄݉݉)
௜
Material Mild Steel
Effective length (mm) 889
Tube pitch (mm) 27
Number of tubes 3
Layout pattern 300
Baffle parameters
Baffle Cut - Horizontal 20%
Thickness (mm) 3.1
Baffle pitch (mm) 57.15
Material Mild Steel
Number 13

020039-2
 FIGURE 1. Shell, tube, and agitating insert (RAI)

FIGURE 2. Experimental setup

The instrumentation used for data measurement is given in Table 4. The temperatures are measured with K-
type thermocouples of 60 mm in length and having 4 mm diameter. The inlet and outlet ports are equipped with these
thermocouples. The rotameters are used to measure the flow on both sides of the heat exchanger. Ball valves are used
to regulate the flow of working fluids. The differential pressure is measured by U tube differential mercury manometer
with the help of pressure traps located at the outlet and the inlet port of the heat exchanger tube side.

020039-3
 TABLE 2. Accuracy of instrumentation
Component Range Level of Accuracy
0
K-type thermocouples -50 to 150 C ± 0.10C
Differential manometer 0 to 200 mm of Hg ± 1%
Rotameter 5 to 50 L/min ± 5%
Heating tank circuit 15 to 90 0C ± 1 0C

DATA REDUCTION

The pressure drop on the tube side and the inlet and outlet temperature and fluid flow rate of shell and tube side
are the primary measurements. Fluid properties are evaluated at bulk mean temperature. All experiments are conducted
at steady state. The tube side performance is calculated as:

Re
UQ d i
1)
P

where Re = Reynolds number, U = density of the fluid,Q = velocity of flow, d i = inner tube diameter, and P =
dynamic viscosity. The Prandtl number is given by the equation

Pc p
Pr 2)
k
where c p = constant pressure heat capacity and k = thermal conductivity. The working fluid velocity is given by the
equation
§ ·
¨ m ¸§ N ·
Q ¨ i S d i U ¸¨ p N ¸
2
3)
¨ ¸© t ¹
© 4 ¹
where mi = fluid mass flow rate, N p = tube passes count, and N t = tubes count. Bell – Delaware method is used to
calculate Nusselt number as
Nu 0.024 Re 0.8 Pr 0.4 4)

The equation for friction factor is

2'PDh
f 5)
Uv 2 Leff

where 'P = differential pressure, Dh = hydraulic diameter, and Leff =effective tube length.
The thermal performance factor (TPF) is the measure of heat exchanger performance is given by the equation
Nu improved
Nu smooth
TPF 6)
'Pimproved
'Psmooth

020039-4
 RESULTS AND DISCUSSIONS

The experiments are conduction for the Re = 3000 to 7500. The readings are taken at steady state. Nu, f, and TPF
are evaluated from equations 4, 5, and 6.

FIGURE 3. Nu vs Re plots

The change in Nu with a change in Re is shown in Fig. 3. This variation is compared for all the four cases: smooth
pipe, rectangular agitating inserts (RAI), square agitating inserts (SAI), and triangular agitating inserts (TAI). The
maximum Nusselt number value of Nu = 41.5 is obtained for TAI, Nu = 40.8 for RAI, and Nu = 37.25 for SAI at Re
= 7200.

FIGURE 4. f vs Re plots

Fig. 4 shows the change in f with Re. The f decreases with increase in Re. At Re = 3200, the f is maximum for
TAI with f = 0.0525, for RAI f = 0.042, and for SAI f = 0.038. The TPF vs Re for all four cases is given in Fig. 5. The
maximum TPF of 2.32 is obtained for TAI at Re = 3200; for RAI, maximum TPF = 1.81; and for SAI, maximum TPF
= 1.6. As the Re increases the TPF decreases.

020039-5
 FIGURE 5. TPF vs Re plots

CONCLUSION

In the present experimental study on STHX, the Nu, f, and TPF are presented. There different types of inserts are
proposed: rectangular agitating inserts (RAI), square agitating inserts (SAI), and triangular agitating inserts (TAI).
The effect of these inserts on the heat exchanger thermal performance is relatively studied and presented. The
following conclusions are made from the study:
1. The heat exchanger performance can be increased by using self-agitating inserts.
2. The maximum Nu = 41.5 is obtained for TAI with maximum and minimum f values of 0.0525 and 0.034
respectively.
3. Nu = 40.08 and f = 0.042 are the maximum values for RAI whereas for SAI, the maximum Nu = 37.25 and f =
0.038.
4. The maximum value of TPF = 2.32 is obtained for TAI.
5. Compared to a smooth pipe, TAI, RAI, and SAI show 22.06%, 17.88%, and 9.55% improvement in Nu.

REFERENCES

1. Nemat Mashoofi, Saman Pourahmad, S.M.Pesteei, Study the effect of axially perforated twisted tapes on the
thermal performance enhancement factor of a double tube heat exchanger, Case Studies in Thermal Engineering
Volume 10, September 2017, Pages 161-168.
2. Amar Raj Singh Suri, Anil Kumar, Rajesh Maithani, Effect of square wings in multiple square perforated twisted
tapes on fluid flow and heat transfer of heat exchanger tube, Case Studies in Thermal Engineering, Volume 10,
September 2017, Pages 28-43.
3. M.E.Nakhchia, J.A.Esfahan, Cu-water nanofluid flow and heat transfer in a heat exchanger tube equipped with
cross-cut twisted tape, Powder Technology Volume 339, November 2018, Pages 985-994.
4. A.Hasanpour, M.Farhadi, K.Sedighi, Intensification of heat exchangers performance by modified and optimized
twisted tapes, Chemical Engineering and Processing - Process Intensification Volume 120, October 2017, Pages
276-285.
5. Sompol Skullong, Pongjet Promvonge, Chinaruk Thianpong, Nuthvipa Jayranaiwachira, MonsakPimsarn,
Thermal performance of heat exchanger tube inserted with curved-winglet tapes, Applied Thermal Engineering
Volume 129, 25 January 2018, Pages 1197-1211.
6. R.M.Sarviya, Veeresh Fuskele, Heat Transfer and Pressure Drop in a Circular Tube Fitted with Twisted Tape
Insert Having Continuous Cut Edges, Journal of Energy Storage Volume 19, October 2018, Pages 10-14.
7. Z.H. Ayub, D. Yang, T.S. Khan, E. Al-Hajri, A.H. Ayub, Performance characteristics of a novel STHX with
shell side interstitial twisted tapes for viscous fluids application, Applied Thermal Engineering Volume 134,
April 2018, Pages 248-255.

020039-6