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Heat Transfer Enhancement by Using Twisted Tape in Horizontal and An

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Journal of Mechanical Engineering Research and Developments
ISSN: 1024-1752
CODEN: JERDFO
Vol. 43, No. 3, pp. 106-124
Published Year 2020

Heat Transfer Enhancement by Using Twisted Tape in Horizontal

and An Inclined Tube
Areej Sami Mahdi†, Zena Khalefa Kadhim‡, Sanaa Turki Mousa Al- Musawi††*, Hasanen
Mohammed Hussain‡‡, & Laith Jaafer Habeeb†††
†
University of Technology, Training and Workshops Center
‡
Wasit University, College of Engineering, Mechanical engineering department
††
University of Baghdad, Department of Reconstruction and Projects,
‡‡
University of Technology, Mechanical Engineering Department
†††
University of Technology, Training and Workshops Center

*Email: [email protected]

ABSTRACT: This study investigate the heat transfer improvement in a single tube heat exchanger with and without
twisted tape insert with twist ratio (y/w = 4 and 6). The performance of the heat exchanger studied on the oblique and
horizontal tube. The laboratory work included fabricating a circular tube heat exchanger which made from copper
material of length (1000 mm) and inner and outer diameter of (23 and 25) mm, respectively. Distilled water under
laminar flow condition (Re =1056 - 2002) flows through insulated tube by using fiber glass at the outer surface to
reduce the thermal losses. The inserted tape was made from copper strip of thickness (0.8 mm) and full length inserted
in the test section. The results showed that the employ of inserted tape yield a considerable increase in the coefficient
of heat transfer about (16-27)% more than smooth tube. Empirical correlations for Nusselt number and friction factor
were developed during this work. The flow field and heat transfer are analyzed and simulated using ANSYS 15.0,
FLUENT package. A comparison of thermal performance for plain and twisted tape insert tubes was implemented
and gave good agreements between the experimental and numerical results with a maximum deviation of 10%.

KEYWORDS: Laminar flow, V-cut twisted tape, heat exchanger, twisted ratio.

LIST OF ABBREVIATIONS

CFD : Computational fluid dynamics

SIMPLE : Semi-Implicit Method for Pressure-Linked Equations

A : Tube surface area (m2)

Cpw : Water specific heat (kJ/kg. K)

f : Factor of friction

h : Coefficient of heat transfer (W/m2. K)

I : Alternative current (Amp.)

Kw : Water thermal conductivity (W/m. K)

L : Tube length (m)


m : Mass flow rate (kg/s)

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 Heat Transfer Enhancement by Using Twisted Tape in Horizontal and An Inclined Tube

Nu : Nusselt number

Δp : Pressure drop (N/m2)

Q : Overall heat power (W)

Rew : Water Reynolds number

T : Temperature degree (°C)

t : Thickness of tape (m)

V : Voltage (volt)

x, y, z : Cartesian coordinate (m)

vw : Water kinematic viscosity (m2/s)

ρw : Water density (kg/m3)

INTRODUCTION

Thermal systems are one of the important things which is used for engineering applications. Therefore, there are
several methods developed to improve heat exchange and reach to the optimum performance in these systems.
Different augmentation techniques that uses surface improvements have been used to enhance the rate of heat transfer
in conventional heat exchangers. This improvement resulting from the use of enhanced surfaces which minimize the
boundary layer development and increase the turbulence degree which leads to the creation of swirling and secondary
flows. Swirl flow devices are one of the passive techniques used in heat transfer enhancement. Swirl flow devices
cause swirl flow or secondary flow in the fluid. This effect can be caused by different types of devices such as tube
insert, duct geometry alterations as well as altered tube flow arrangements. In recent years, there has been considerable
effort in the development process of heat transfer augmentation techniques to increase the performance of heat
exchanger and to enhance inside tubes convective heat transfer coefficient.

Previous study experimentally the convective heat transfer and friction factor in a U-bend double pipe heat exchanger
equipped with half-length inserted tape to generate swirl flow. The result revealed that the use of inserted tape leads
to increase the heat transfer coefficient about 40% more than that of plain tube. However, the plain tube thermal
performance was found to be better than half-length twisted tape by (1.3-1.5) times. [1]

Then examined the utilization of reduced width twisted tape inserts in a horizontal circular tube in order to enhance
the heat transfer rate. The tube has an inside diameter of 27.5mm and air was employed as working fluid. The
experiments were conducted using twisted tapes with three different twist ratios (3, 4 and 5). Each of these tapes has
five different widths (26-full width, 22, 18, 14 and 10 mm). The range for the Reynolds number was from 6000 to
13500. They observed that as y/w ratio decreases, the heat transfer increases. [2]

A research carried out an experimental study to measure heat transfer coefficient of water on tube side for turbulent
flow. The tube is circular and is fitted with stainless steel twisted tape insert of 5.3 twist ratio. Nichrome wire covered
with fiber glass was wrapped around the test section in order to retain a uniform heat flux condition. The temperature
of the tube outer surface in the test section was measured at five different spots. T-type thermocouples were used to
measure the temperature with a thermometer placed in a mixing chapter at the outlet section. The study was conducted
over a range of 9500-20000 of Reynolds numbers. Heat flux was varied from 9 to 18 kW/m 2 for smooth tube and 15
to 31 kW/m2 for tube with twist tape insert. It was noticed that over the same Reynolds number, twist tape insert
caused an improvement in Nusselt number by 2.9 to 4 times when compared to the smooth tube. Results were
compared with Dittus and Boelter correlation and the error was -13% to 18%. [3]

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 Heat Transfer Enhancement by Using Twisted Tape in Horizontal and An Inclined Tube

Also analyzed the heat transfer performance of helical strip insert with regular space cut the passages generated a
turbulent flow in a circular pipe. The range of the Reynolds number used in the experiments was from 5000-30000.
Three different helical strips were used with helix angles of 30◦, 45◦ and 60◦. The experiments showed that with the
insertion of helical strips, the heat transfer rate is improved as a result of the turbulent flow generated in the circular
pipe. “The local heat transfer coefficients were found to be increasing to very high values along the downstream of
the helical strip, and then decreasing with the distance. Number of helical channels and the helix angle did not have a
big effect on the heat transfer. Overall, the helical tape led to a maximum 20% improvement in the heat transfer rate
depending on Reynolds number. With the increase of Reynolds number, the efficiency of heat transfer enhancement
decreased. [4]

A study modelled, simulated and analyzed the effect of Parabolic-Cut Twisted tape (PCT) inserts fitted in a circular
tube on the heat transfer rate using Computational Fluid Dynamics (CFD) modeling. A commercial CFD package
(FLUENT-6.3.26) was used to carry out the simulation. The modeled circular tube is a constant heat-fluxed tube
having a laminar flow. Three different twist tapes were considered in the simulation with twist ratio (y=2.93, 3.91and
4.89) and cut depth (w =0.5, 1 and 1.5 cm). It was discovered that the Nusselt number and the friction factor in the
tube fitted with PCT increase with the decrease of twist ratios (y) and cut depth (w). The CFD predicted results
matched with the literature correlations for plain tube for validation; with the discrepancy of less than ±8%for Nusselt
number and ±6.5 % for friction factor. [5]

The conducted an experiment for studying the flow and thermal characteristics of tube induced with various type of
twisted tape (Twisted tape with pins and twisted tape with pins bonded). Three different twist ratios have been used
during the study (3.33, 4.29, and 5.71). The experimental results revealed that the smaller twist ratio leads to higher
heat transfer values about 23.86% more than smooth tube and for twist ratios 4.29 and 5.71 the improvement was
19.9% and 14.4%, respectively. They also observed that the friction factor for twist ratio 3.33 is higher than those of
twist ratios 4.29, and 5.71 because of the less contact surface area of the turbulator. Empirical correlations have been
developed with maximum deviation of ±7.28, and ±7.16% for Nusselt number and friction factor, respectively. [6]

An investigated experimentally and numerically the most advantageous design parameters of helical coiled tube. A
helical tube (15 mm diameter) heat exchanger with the effects of insertion a coil wire of twisted tape into the helical
tube heat exchanger were examined. Dean number is in the range of 700 to 2000. Coiled wire with different insertion
of 15, 20 and 30 mm is used firstly, and then experiments were conducted at a constant pitch of 15 mm with different
sections circular of square thirdly, at constant insert pitch of 15 mm with different square wire thickness (a=1 and 2
mm). Nanoparticles of Al2O3 and TiO2 (d=80 nm,30 nm) respectively, dispersed in distilled water. The volume
concentrations were in the range of (0.08, 0.1, 0.2 and 0.3%) in order to simulate the flow of heat transfer in the helical
coil tube with nanofluids. A commercial program ANSYS Fluent 14.5 is used. The maximum heat transfer
enhancement resulting from using coil wire and nanofluid was exceeds over 120% as compared to smooth tube and
pure water. An empirical correlation for Nusselt number were developed with maximum deviation of (±20 %). [7]

An investigated and compared the thermal performance of Al2O3/water and CuO/water nanofluids when a helical
screw tape inserted in a straight circular duct. Three different helical screw tape were used with twist ratio of (y=1.78,
2.44 and 3). The experiment was carried out with a 0.1% volume concentration for both Al 2O3/water and CuO/water
nanofluids. The maximum increase in Nusselt number as a result of the use of water, Al2O3/water and CuO/water with
inserts compared to plain tube are 156.24%, 166.84%, 179.82% respectively at y= 1.78. [8]

A studied experimentally the influences of inducing inserted tape and using nanofluid in double pipe heat exchanger.
The internal pipe with inner diameter of 8mm and thickness 4 mm. The hot water flows in the inner tube while the
cold water was used in shell side. The inserted tape is 120 cm long and 5 mm wide and have a thickness of 1mm.
Aluminum sheet was used to make the twisted tapes. The nanofluid was prepared from Titanium dioxide with a volume
concentration of 0.01% and 30nm diameter. It was observed that using twisted tapes in addition to nanofluid will lead
to 10 to 25 percent increase in heat transfer coefficient. Furthermore, increasing mass flow rate and operating
temperature will increase the coefficient as well. Moreover, the experiment showed that friction factor and pressure
drop is higher with the use of twisted tapes. [9]

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 Heat Transfer Enhancement by Using Twisted Tape in Horizontal and An Inclined Tube

Based on a previous study then carried out experimental and numerical study to investigate the Nusselt number,
friction factor and index of thermal performance of a tube fitted with the typical and three modified strips (perforated,
notched and jagged) with constant width and a pitch length of 15 mm and 5 cm, respectively. In numerical part, the
simulation was implemented by using the CFD code FLUENT6.2. for one twist ratio of 2.94. The results revealed that
the high thermal performance resulting from using jagged insert with a maximum increase of 31% and 22% for Nusselt
number and the performance, respectively as compared to typical twisted tape. [10]

The Objectives and the benefits of the present work is to study the augmentation of heat transfer characteristics by
utilizing a swirl flow device in single pipe heat exchanger experimentally and numerically, under laminar flow with
constant heat flux condition. The procedure to design heat exchangers is more difficult, and more analysis of
efficiency, friction factor and heat transfer rate estimations apart from issues, such as the economic aspect of the
equipment and long-term performance. Therefore, any enhancement tool or methods used in the heat exchanger should
be optimized between the higher pumping cost and the benefits of heat transfer coefficient. Based on that, the variant
twisted tapes are designed to effectively improvement the fluid mixing with reasonable pressure drop resulting in the
thermal enhancement factor more than unity. This study includes investigation of the effectiveness of Reynolds
number and twisted ratios on the local Nusselt number, average Nusselt number, streamlines, velocity profile and
friction factor.

In the present study, the effect of using variant twisted tape inserts will be investigated. Twisted tapes with V-cut
twisted tape (V-TT), alternate axis twisted tape with variant twist ratio (y=4.0 and 6.0) were used for enhancement of
heat transfer in inclined and horizontal tube heat exchanger. The numerical analysis will be carried out using FLUENT
PACKAGE 15.0. Finally, an empirical correlation has been developed depending on the experimental data to predict
the heat transfer and friction factor in this work.

TEORETICAL ANALYSIS

Assumptions of single tube Heat Exchanger

Steady state condition and the fluid mass flow rate and its properties consider constant. The changes are negligible in
kinetic and potential energies. The water specific heat can be treated as constant. The heat transfer process by
conduction has been neglected along the tube because it is low. The tube outer surface is insulated and the heat
generation is negligible. There is no change in phase of flow inside the heat exchanger.

Data Reduction steps

Heat Transfer Rate

The electric power, that can be supplied on the outer surface wall of the tube to get heating effect, is calculated by:

(𝑒𝑙𝑒𝑐𝑡𝑟𝑖𝑐 𝑝𝑜𝑤𝑒𝑟) = I ∗ V (2-1)

or

(𝑒𝑙𝑒𝑐𝑡𝑟𝑖𝑐 𝑝𝑜𝑤𝑒𝑟)
=
Qh = m
 h Cph (Tho − Thi ) (2-2)

Inner Side Heat Transfer Coefficient (hi)

Qh = h i As (T s - Tm ) (2-3)

𝐴𝑠 = 𝜋𝑑𝑖 𝐿 (2-4)

Thi + Tho
Tm =
2 (2-5)

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 Heat Transfer Enhancement by Using Twisted Tape in Horizontal and An Inclined Tube

T1 + ..... + T3
Ts = (2-6)
3

Then average Nusselt number for the inner tube surface can be calculated as follows:

h idi
Nu i =
kh (2-7)

The internal flow is laminar for heated tube and the Reynolds number values range from 1056 to 2002 and its
evaluated by the equation:

4m
Re =
 di  (2-8)

Friction Factor

Depending on the experimental pressure drop, the Darcy friction coefficient can be calculated using the following
formula [11]:

2P di
f= (2-9)
L ρ V2

EXPERIMENTAL WORK

Experimental test was performed to investigate the heat transfer (Nusselt Number) and pressure drop (friction factor)
for laminar flow rate. Twisted tapes as enhancement device was used to investigate the enhancement level. Figure (1)
shows in details all the part of the test rig that is consist of three main parts: The hot water circuits, the test section and
the measuring devices. A water tank of (30) liter capacity has been connected to the cycle for supplying hot water
through a heat exchanger. It is made from galvanized material and insulated with glass wool insulation. Electrical
water heater (2.2 kW) having temperature controller and temperature sensor is designed and manufactured for this
purpose. One centrifugal pump was used for circulating the working fluid through experimental rig. The pipes were
made of (PVC) material which employed for test rig parts connecting because of the (PVC) flexibility and ease of
assembly after maintenance. Arm flux pipe sheet and roll are utilized to reduce heat losses from pipes across the cycle.

Flow meter is used to measure the flow rate circulation through the tube side. Simultaneously, the flow rate
measurement is completed by recording the time needed to collect a certain amount of working fluid by volume.
Different thermocouples are used during the experiment are K-Type, range (-50°C to 400°C). The thermocouple is
fixed to the pipe using an adhesive material. The thermocouple is covered with rubber for electrical insulation. All
thermocouples are connected with a digital reader data logger. MANOMETER ±2000 mbar range differential input
Model PM-9100 is used to measure the pressure difference along the tube. The test tube is made of copper metal of
inner and outer diameter (23 mm) and (25 mm) respectively, with tube length of (1000 mm). Small vertical taps of (6
mm) diameter are fixed at the outer tube surface at its inlet and outlet for measuring the pressure difference. Two
thermocouples are fixed under these holes for measuring the temperatures degree at the inlet and outlet section. In
order to control the flow on the outlet a valve was installed for this purpose. Figure (2) shows experimental test rig
schematic diagram.

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 Heat Transfer Enhancement by Using Twisted Tape in Horizontal and An Inclined Tube

Heat flux

Figure 1. Schematic diagram for the experimental rig setup.

Figure 2. Schematic diagram for test section with dimensions.

NUMERICAL SIMULATION

Numerical simulations allow us to analyze difficult phenomena without having to build an expensive prototype and
make complicated experimental measurements. The need to simulate the Navier-Stokes equation of complex fluid
flows arises in many engineering problems. The solution of conservation of mass, energy and momentum equations
is used to analyze the interaction between fluid flows, twisted tape inserts inside the plain tube. Numerical procedure
will be expressed in the following sections. The commercial CFD solver Fluent 15.0 was used to create the system
geometry simulations, based on finite volume method to solve the equations that describing flow in motion with a
segregated solver. The second-order upwind scheme was used for discretization of convection terms, energy, and
laminar kinetic and laminar dissipation energy. For the present cases, SIMPLE algorithm was used to resolve the
coupling between velocity and pressure fields [12]. It is essentially a gauss and correct procedure for calculation of

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 Heat Transfer Enhancement by Using Twisted Tape in Horizontal and An Inclined Tube

pressure. Grid independence test is carried out to obtain the most suitable computational grid for which the data results
don't change when the grid becomes finer. The suitable way for checking is to create a grid with more cells to compare
the solutions of the two models. The tests of grid refinement show that the average Nusselt number don't change as
the number of cells increase and a grid size of approximately (2) million cells provide enough accuracy and resolution,
therefore it is adopted as the standard for all cases. The grid independency test performed for V-cut twisted tape with
TR=4 configuration is shown in figure (3).

Figure 3. The grid independent solution test for V-cut twisted tape.

Governing Equations Describing Fluids in Motion

The differential equations used to describe the fluid flow are the continuity and the Navier-Stokes equations. For flows
including heat transfer phenomena, energy conservation equation should be enabled. The continuity equation is
derived from mass conservation balance to a small differential volume of the fluid. Three equations of the following
form are obtained to describe the flow in Cartesian coordinates.

Conservation of Mass

u v w
+ + =0 (4-1)
x y z

Navier-Stokes Equations

X-Momentum Equation:

p  2 2 
  u u +v u + wu  = − +    u +  u +  u 
2 (4-2)
 x y z  x
 x 2 y 2 z 2 

Y-Momentum Equation:

p  2 2 
  u v +v v + wv  = − +    v +  v +  v 
2 (4-3)
 x y z  y
 x 2 y 2 z 2 

Z-Momentum Equation:

p  2 2 
  u w+vw+ww  = − z +    w+ w+ w 
2 (4-4)
 x y z   x2 y2 z2 

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 Heat Transfer Enhancement by Using Twisted Tape in Horizontal and An Inclined Tube

Energy Equation

T T T  2Tnf 2Tnf 2Tnf  (4-5)

( C p )  u nf +v nf +w nf  = K 
 x2 + y2 + z2 

 x y z   

RESULTS AND DISCUSSION

Validation of Experimental Test Rig

Figure 4. Comparison between present work and Shah correlation at 𝒒"= 4457 W/m2, Re =1137.

The heat transfer and friction factor for smooth tube were investigated so as to verify the data obtained from the
experiments. Figure (4) indicates the local Nusselt number verses (Z/D) for the present test and the famous empirical
of Shah's equation [13] equation (5-1).

D (1 / 3) D
Nu ( x) = 1.953(Re . Pr . ) ; (Re . Pr . )  33.3 (5-1)
x x

Figure 5. Comparison between present work and Hagen correlation at 𝒒"=2421 W/m2.

The experimental data are in good agreement with Shah's equation and the maximum deviation of (12 %). Figure (5)
shows the agreement of friction factor with published Hagen-Poiseuille's equation [11], equation (5-2), with maximum
deviation of (6.6%).

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 Heat Transfer Enhancement by Using Twisted Tape in Horizontal and An Inclined Tube

64
f = (5-2)
Re
Analysis of Experimental Results

Influence of Tape Insert on the Characteristics of the Flow

Thermal Influence in Horizontal and Inclined Tube

Figure 6. The variation of local Nusselt number along the tube for the plain tube and the two types of twisted tape.

Figure 7. The influence of (Re) and twist ratio for on Nusselt number for V-cut twisted tape at 𝒒"=2421 W/m2.

In horizontal tube, the recorded data from the experiments were converted into local values of heat transfer coefficient
which in turn converted into local values of Nusselt number along the tube, as shown in figure (6). From this figure,
it is noticed that the values of Nusselt number are high at the thermal entrance region and then steadily decreases for
the types of twisted tape and the plain tube. The type of twisted tape causes an increase in the values of Nusselt number
for the same conditions because of the interruption in the fluid flow and decreasing the thermal boundary layer
thickness caused by the twisted tape. The shape of the curve indicates that the heat transfer becomes less when the
flow advances towards the end of the tube due to the increasing effect of boundary layer. The relationship between
Nusselt number and Reynolds number for smooth tube compared with the tube equipped with two types of inserted
tape are indicated in figures (7) and (8), respectively. In general, the value of Nusselt increases by increasing the value
of Reynolds and the Nusselt number value increases by decreasing the value of twist ratio for the types of twisted
tape.

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 Heat Transfer Enhancement by Using Twisted Tape in Horizontal and An Inclined Tube

Figure 8. The influence of (Re) and twist ratio for on Nusselt number for Alternate axis twisted tape at 𝒒"=2421
W/m2.

Figure 9. The influence of (Re) and twist ratio on (Nu) of V-cut twisted tape (TR=4, 6) for inclined tube at 𝒒"=2421
W/m2.

The experimental results of the inclined tube fitted with V-cut twisted tape are compared with the plain tube and its
results are validated using the experimental data in horizontal tube for the laminar flow regime. Otherness of Nusselt
number with Reynolds number at the inlet to test section for the tube fitted with V-cut twisted tape of twist ratios (y
= 4, 6) and plain tube are depicted in figure (9). With reference to this figure, it can note that the average Nusselt
number increases as Reynolds number increases, also the result revealed that the use of lower twist ratio gives higher
average Nusselt number than that of the higher twist ratio. This occurs because of the stronger swirl flow which
minimizes the boundary layer thickness near the wall of tube resulting from using lower twist ratio. The average
Nusselt number for V-cut twisted tape insert are 1.6 and 1.4 times better than that of plain tube for twist ratios y = 4
and 6, respectively.

Hydrodynamic Influence in Horizontal and Inclined Tube

In horizontal tube, the relationship between friction coefficient and Reynolds number for the smooth tube compared
with the two types of twisted tapes are shown in figures (10) and (11). Generally, the coefficient of friction tends to
decrease with increasing the value of Reynolds number and twist ratio for the types of twisted tapes. The smallest
twist ratio leads to high value of friction factor.

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 Heat Transfer Enhancement by Using Twisted Tape in Horizontal and An Inclined Tube

Figure 10. The effect of Reynolds number and twist ratio for V-cut twisted tape on friction factor for distilled water.

Figure 11. The influence of (Re) and twist ratio on friction factor for Alternate axis inserted tape.

Figure 12. The influence of (Re) and twist ratio on (f) of V-cut twisted tape (TR= 4, 6) for inclined tube at 𝒒"=2421
W/m2.

Figure (12) shows that the friction factor decreases as Reynolds number increases and friction factor for twist ratio (y
= 4) is larger than that of the twist ratio (y = 6) because of the stronger swirl flow produced by the V-cut twisted tape

116
 Heat Transfer Enhancement by Using Twisted Tape in Horizontal and An Inclined Tube

at lower twist ratio. The results revealed that the friction factors for the V-cut insert with twist ratio y = 4 and 6 are
respectively 1.3 and 1.1 times than that for the plain tube. Form this figure, we notice that the friction factor in inclined
tube is more than that in horizontal tube. In general, increasing the tube inclinations increases the flow acceleration
near the wall and, consequently, higher skin friction occurs. As a rule, we recommend that you stay away from using
the inclined tube in practical applications.

Heat Flux Influence in Horizontal Tube

Figure 13. Variation of Nusselt number for plain tube at different heat fluxes.

Figure (13) illustrates the variation of average Nusselt number of plain tube at different applied heat fluxes. It is noted
that, heat transfer enhancement rate for plain tube is almost the same and proportional directly with change in the heat
flux amount from (2420-12261 W/m2). The difference between the average wall temperature and the mean bulk fluid
temperature increases with constant value as the heat flux increases, also the physical properties of working fluid have
a constant change in their values and directly proportional to the heat flux changing. Therefore, there is no significant
effect for increasing the heat flux amount on smooth tube case at the same values of Reynolds number.

Correlations in Horizontal Tube

Empirical correlations of Nusselt number and friction factor were estimated from the experimental results. This is
accomplished by using multiple regression analysis method.

1-Correlations for Nusselt Number:

117
 Heat Transfer Enhancement by Using Twisted Tape in Horizontal and An Inclined Tube

Figure 14. Comparison between experimental results with regression equation of average (Nu) for V-cut twisted
tape.

Figure 15. Comparison between experimental results with regression equation of average (Nu) for Alternate axis
twisted tape.

The predicted correlations of average Nusselt number for V-cut and Alternate axis twisted tapes are represented in
equations (5-3) and (5-4), respectively. The fitted values are agreeing with the experimental data within ± 3% and ±
4% for V-cut and Alternate axis twisted tapes, as shown in figures (14) and (15), respectively.

Nu = 2.61 Re0.19 Pr0.83 y-0.05 (V-cut insert) (5-3)

Nu = 9.58 Re0.43 Pr0.79 y-0.011 (Alternate axis insert) (5-4)

2-Correlations for Friction Factor:

The fitted values of friction factor are represented by the equations (5-5) and (5-6) for V-cut and Alternate axis
twisted tapes, respectively. Figures (16) and (17) show the representation of the predicted correlations. The empirical
data are in good agreement with the experimental results with maximum deviation of ± 6% and ±7.2% for V-cut and
Alternate axis inserted tapes, respectively.

118
 Heat Transfer Enhancement by Using Twisted Tape in Horizontal and An Inclined Tube

Figure 16. Comparison of experimental data with regression equation of friction factor for tube with V-cut twisted
tape.

Figure 17. Comparison of experimental data with regression equation of friction factor for tube with Alternate axis
twisted tape.

f = 42.4 Re-0.95 y-0.1 (V-cut insert) (5-5)

f = 35.4 Re-0.94 y-0.18 (Alternate axis insert) (5-6)

Analysis of Numerical Results

119
 Heat Transfer Enhancement by Using Twisted Tape in Horizontal and An Inclined Tube

Figure 18. Numerical results for average Nusselt number versus Reynolds number for distilled water in a tube with
V-cut twisted tape at 𝒒"=2421 W/m2.

Figure 19. Numerical results for average Nusselt number versus Reynolds number for distilled water in a tube with
Alternate axis twisted tape at 𝒒"=2421 W/m2.

In horizontal tube, the numerical results obtained from using finite volume method single-phase model by commercial
CFD program ANSYS-Workbench 15.0, package are presented to show both the flow and heat transfer characteristics
for the present models. Numerical results of average Nusselt number versus Reynolds number for the types of twisted
tapes at different twist ratios are shown in figures (18) and (19) for V-cut and Alternate axis, respectively. The results
show the same behavior of Nusselt number with Reynolds number and twist ratio as that in the experimental result.

Velocity Vectors in Horizontal and Inclined Tube

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 Heat Transfer Enhancement by Using Twisted Tape in Horizontal and An Inclined Tube

V-cut Alternate axis

Figure 20. velocity vector in (m/s) at locations of V-cut and Alternate axis twisted tape along the test section with
(Re = 2002, TR=4).

Plain tube V- cut twisted tape

Figure 21. Velocity vector in (m/s) at different locations of inclined plain tube and tube fitted with V- cut inserted
tape at the end of the tube (Re =2002, 𝒒"=2421 W/m2).

In horizontal tube, figure (20) shows the velocity vector at section (Z=50 cm) along the tube for V-cut and Alternate
axis twisted tape, respectively. A secondary flow induced and a rotational movement is noticed along the tube which
will enhance the heat transfer in the tube. And, this secondary flow will increase with decrease in twist ratio.

In inclined tube, figure (21) shows velocity vector of inner tube for plain tube and tube induced with V-cut tape insert
at the end section. It is clearly seen that the secondary flow field contains larger velocities than the secondary flow of
the plain tube. This is because of the additionally induced swirling motion.

Temperature Contours in Horizontal and Inclined Tube

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 Heat Transfer Enhancement by Using Twisted Tape in Horizontal and An Inclined Tube

Plain tube

V-cut twisted tape Alternate axis

Figure 22. Temperature contours in (K) at locations of (Z= 50 cm) along the test section for plain tube, V-cut and
Alternate axis tape with (Re =2002) and (TR= 4).

In horizontal tube, figure (22) shows the temperature contours at locations of (Z=50cm) along the test section for plain
tube, V-cut and Alternate axis twisted tape, respectively. The temperature increases to the center of the tube and with
change of one twisted tape type or changing from plain tube to a tube fitted with twisted tape insert.

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 Heat Transfer Enhancement by Using Twisted Tape in Horizontal and An Inclined Tube

Plain tube V-cut twisted tape

Figure 23. Temperature contours in (oC) at the center of the test section for inclined plain tube and V-cut twisted
tape with (Re =2002, 𝒒"=2421 W/m2).

In inclined tube, figure (23) shows temperature contours at (Z=50cm) along the inclined tube for plain tube and V-cut
insert, respectively. From these figures, it can be seen gradient of temperature distribution along the sections of the
tube. Because of the particles swirling motion in the secondary flow field, It can be noted that the temperature field of
tube induced with twisted tape inserts is more homogeneous than the plain tube.

CONCLUSIONS AND RECOMMENDATIONS

The investigation on thermo hydraulic characteristics for two types of twisted tape (V-cut twisted tape, Alternate axis)
fitted in horizontal and inclined tube heat exchanger with (y = 4 and 6) have been studied experimentally and
numerically. The conclusion arrived from the present work are:

1. The experimental data of plain tube for Nusselt number and friction factor were verified with the predicted
empirical correlations and the maximum deviation are ±12% and ±6.6% for Nusselt number and friction
factor, respectively.

2. The lower twist ratio (y = 4) gave the highest value of heat transfer augmentation, about (12.6%).

3. Use twisted tape inserted in the present work offered higher thermal performance than smooth tube due to
the additional disturbance to the main swirl flow.

4. The alternate axis insert provides improved heat transfer performance more than that of V-cut insert. That is
because of the effective secondary flow, in addition with the main swirl flow.

5. An empirical correlation has been developed with a maximum error band of 4% and 6% with the experimental
data for Nusselt and friction factor, respectively.

6. Inclined tube introduced more friction factor than horizontal tube for all cases with lower Nusselt number
(about 9 %) than horizontal tube.

In order to know how fluid behaves for conditions other than the above tests, we recommend:

1- Change the tilt angle for the channel for wide ranges of inclination angles.

2- Test the inclination of channel for best performance for the system.

3- Using of porous media, combined with twisted tape.

4- Studying the effect of turbulators and nanofluids on other base fluid such (oil, glycol).

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 Heat Transfer Enhancement by Using Twisted Tape in Horizontal and An Inclined Tube

5- Perform the test at constant wall temperature conditions.

6- Study the flow and heat transfer characteristics of the magnetic nanofluid instead of distilled water.

7- Investigating the use of a two phase approach on heat transfer and flow.

8- Change the type of twisted tape material such as (aluminum and stainless steel).

REFERENCES

[1] A. S. Yadav, “Effect of Half Length Twisted-Tape Turbulators on Heat Transfer and Pressure Drop
Characteristics inside a Double Pipe U Bend Heat Exchanger”, Jordan Journal of Mechanical and Industrial
Engineering, Vol. 3, No. 1, pp. 17- 22, 2009.

[2] S.S. Naga, A. V. Sita Rama Raju, K. Kalyani Radha and L. Shyam Sunder, “Enhancement of heat transfer
using varying width twisted tape inserts”, International Journal of Engineering, Science and Technology, Vol.
2, No. 6, pp. 107-118, 2010.

[3] S. Bodius, B. Sumana and K. B. Muhammad Mostafa, “Heat Transfer Enhancement in a Tube Using Twisted
Tape Insert”, Proceedings of the 13th Asian Congress of Fluid Mechanics, pp. 835-838, 2010.

[4] B.D. Naresh, V.K. Mathew and S.D. Murtuza, “Heat Transfer Analysis of Helical Strip Insert with Regularly
Spaced Cut Sections Placed Inside A Circular Pipe”, International Journal of Modern Engineering Research
(IJMER), Vol. 2, Issue 5, pp. 3711-3716, 2012.

[5] D.S. Sami, H.K. Abdul Amir, S.T. Mohd and M. Bakar, “CFD Analysis of Heat Transfer and Friction Factor
Characteristics in a Circular Tube fitted with Parabolic-Cut Twisted Tape Inserts”, Australian Journal of Basic
and Applied Sciences, Vol. 7, No. 7, pp. 69-76, 2013.

[6] S. Selvam, P. Thiyagarajan, and S. Suresh, “Experimental Studies on Effect of Bonding the Twisted Tape with
Pins to The Inner Surface of The Circular Tube”, Thermal Science, Vol. 18, No. 4, pp. 1273-1283, 2014.

[7] M. J. Osama, “Parametric Investigation of Heat Transfer Enhancement in Helical Coil Tube by Using Vortex
Generators (Coil Wire inserts) and Nanofluids”, M.Sc. thesis Al–Mustansiriya University, Mechanical
Engineering Department, Baghdad, Iraq, 2014.

[8] S. Suresh, K.P. Venkitaraj, P.r. Selvakuma and M. Chandrasekar, “A comparison of thermal characteristics of
Al2O3/water and CuO/water nanofluids in transition flow through a straight circular duct fitted with helical
screw tape inserts”, Experimental Thermal and Fluid Science, Vol. 39, pp. 37–44, 2012.

[9] H. Maddah, A. Reza, F. Morshed, J. Shabnam and A. Khatere, “Effect of Twisted-Tape Turbulators and
Nanofluid on Heat Transfer in a Double Pipe Heat Exchanger”, Journal of Engineering, Vol. 2014, Article ID
920970.

[10] R. Masoud, S. Sayed Reza, and A.A. Ammar," Experimental and CFD Studies on Heat Transfer and Friction
Factor Characteristics of a Tube Equipped with Modified Twisted Tape Inserts", Chemical Engineering and
Processing, Vol. 48, PP. 762–770, 2009.

[11] F. M. White, "Fluid Mechanics", McGraw-Hill, 1999.

[12] H. K. Versteeg, and W. Malalasekera, "An Introduction to Computational Fluid Dynamics-The Finite Volume
Method", Longman group Ltd., 1995.

[13] R.K. Shah, A.L. London, "Laminar flow forced convection in ducts", Supplement to Advances in Heat Transfer,
Academic Press, New York, 1978.

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