Heat TransferEnhancement in Tube in Tube Heat Exchanger With Helical Wire Coil Inserts and CuO Nanofluid

IPASJ International Journal of Mechanical Engineering (IIJME)
Web Site: http://www.ipasj.org/IIJME/IIJME.htm

Email: editoriijme@ipasj.org
ISSN 2321-6441
A Publisher for Research Motivation........
Volume 3, Issue 5, May 2015
Heat TransferEnhancement in Tube in Tube

Heat Exchanger with Helical Wire Coil Inserts
and CuO Nanofluid
1
Sunil P. Kulkarni , Prof. S.M. Oak2
Student of M.E.(Master of engg.) in Heat Power Engg., VIT, No.666, Upper Indiranagar, Bibwewadi, Pune, Maharashtra
411037, India
2
Asso. Professor, VIT, No.666, Upper Indiranagar, Bibwewadi, Pune, Maharashtra 411037, India
ABSTRACT
In the present work, heat transfer enhancement in tube in tube counter flow heat exchanger with helical wire coil inserts and
CuO nanofluid for turbulent flow has been investigated. Different parameters affecting the heat transfer characteristics were
investigated so that the influence of each parameter can be determined. The Copper Oxide nanoparticles of 40nm size with
volumetric fractions of 0.25% are used to prepare the nanofluid for the experiment. The helical wire coil inserts of three
different pitch lengths of 14.2, 16.124 and 20.36 mm which correspond to pitch ratios of P/D = 1.29, 1.47 and 1.85 respectively
are used to strengthen the heat transfer efficiency for heat exchangers. The Reynolds number varied from 10000 to 35000, the
convective heat transfer coefficients were determined. The results gained in the study showed that dispersion of CuO
nanoparticles in water significantly increased the overall heat transfer coefficient and convective heat transfer coefficient. The
results also revealed that heat transfer improvement could be achieved by the coil having lower pitch ratio i.e. 1.29 as compared
with that of coils with P/D=1.47 and 1.85. The overall heat transfer coefficient, Nusselt number, convective heat transfer
coefficients for different configurations with and without inserting helical wire coil and nanofluid are compared.
Keywords: Enhancement in Heat exchanger, CuO Nanofluid, Helical wire coil inserts
1. INTRODUCTION
Heat exchangers are devices that facilitate the exchange of heat between two fluids that are at different temperatures
while keeping them from mixing with each other. Heat exchangers are commonly used in practice in a wide range of
applications, from heating and air-conditioning systems in a household, to chemical processing and power production
in large plants. Heat exchangers differ from mixing chambers in that they do not allow the two fluids involved to mix.
In a car radiator, for example, heat is transferred from the hot water flowing through the radiator tubes to the air
flowing through the closely spaced thin plates outside attached to the tubes. Some common examples include steam
generation, condensation in power, cogeneration plants, sensible heating and cooling in thermal processing of
chemical, pharmaceutical, agricultural products, fluid heating in manufacturing and waste heat recovery etc.
Some devices such as high speed microprocessors, laser application apparatus, super conducting magnets and optoelectronics re-quire high heat transfer cooling systems. Many techniques have been proposed to enhance the heat
transfer in these types of equipment. Enhancement in Heat exchangers performance can lead to more economical
design of heat exchanger which can help to make energy, material and cost savings related to a heat exchange process.
For decades, efforts have been done to enhance heat transfer, reduce the heat transfer time, minimize size of heat
exchangers, and finally increase energy and fuel efficiencies. These researches include passive and active methods, are
also termed as Heat transferAugmentation or referred as Heat transfer Enhancement or Intensification. Use of Heat
transfer enhancement techniques lead to increase in heat transfer coefficient but at the cost of increase in pressure drop.
So, while designing a heat exchanger using any of these techniques, analysis of heat transfer rate has to be done.
Geometry of Helical Coil:
The helical coils were made from aluminum material with wire diameter of 3.024 mm. These coils were fabricated in
workshop on Lathe Machine. Geometry of helical coil with three different pitch lengths of 14.2, 16.124 and 20.36 mm,
correspond to pitch ratios of P/D = 1.29, 1.47 and 1.85 respectively shown in Figure below.
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Fig. 1.1. Geometry of the Helical Coil

In this Figure, p is the pitch length; d is the wire diameter& D is the coil diameter
P/D=1.29
P/D=1.47
P/D=1.85
Fig. 1.2. image of the Helical Coil

Nanofluid Preparation:
For this work, sample containing CuO Nano powder(which was purchased from Sisco research Laboratories, Pvt. Ltd.,
Mumbai, Product Code-0340385 and Batch No: T-8390156 ) concentration of 0.25 % by weight was used, and sample
was stirred for half an hour with high speed mechanical stirrer. Samples are kept for 24 hour for sedimentation test.
After 24 hour no sedimentation of nanoparticles are found. These samples are ready for experimentations and used for
testing by pouring it into nanofluid.
2. EXPERIMENTAL SETUP
The experimental set up of tube-in-tube heat exchanger consists of nanofluid flow line and cooling water flow line with
counter flow heat exchanger. Different measuring devices like rotameter, thermocouples, and manometers are
connected in line. Flow control valves are used to get the required quantity of flow through test section. Nanofluid
heater is used to heat the fluid.
The different parts of experimental set-up are as below:
1. Nanofluid reservoir.
2. Nanofluid pump.
3. Nanofluid rotameter.
4. Cooling water rotameter.
5. Nanofluid heater.
6. Thermocouples with digital temperature indicator.
7. Differential manometer.
The required instruments selected as per their measuring range, accuracy and instrument availability in market. The
copper tubes are used because of higher thermal conductivity and the dimensions of pipe selected on the basis of
existing experimentation in literature. The two flow control valve is used to maintain flow rate of water as well as
nanofluid.
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Fig. 2.1 Line diagram for experimental setup
3. HEAT TRANSFER ANALYSIS

The heat transfer rate from the heating fluid (nanofluid) is calculated from:
Qnf = mnf.Cpnf.(T1-T2)nf
Where, Qnf is the heat transfer rate of the hot nanofluid, mnfis the flow rate of hot nanofluid, Cpnf is the specific heat of
hot nanofluid, T1 and T2 are inlet and outlet hot nanofluid temperatures respectively.
The heat transfer rate to the cooling water (heat gain by cooling water) is calculated as:
Qw = mw.Cpw.(T4-T3)w
where, Qw is the heat transfer rate to the cooling watermwis the flow rate of cold water, Cpwis the specific heat of water,
T4 and T3 are outlet and inlet cold water temperatures respectively.
The average heat transfer rate between the nanofluid and cooling water is calculated as follows:
Qavg = (Qw+Qnf)/2
Where,
Qavg is the average heat transfer rate between the cooling water and the nanofluid. The heat loss is minimized
by providing foam insulation over copper tube, test sections at hot zones.
The experimental overall heat transfer coefficient based on outer surface of copper tube is calculated as:
U o (exp)
Qavg
Ao . m
Where, A o = outer heat transfer surface of copper tube,

= log mean temperature difference of counter flow heat exchanger, = (T1-T4), and = (T2-T3).
The nanofluid heat transfer coefficient is calculated from Uo(exp)as below:
hnf
do
1
d . ln(d o / d i ) 1
di
o
U o (exp)
2.K co
ho
Where, Kco is thermal conductivity of copper tube material = 385 W/m2 oC.
do and di are outer and inner diameters of copper tube,
ho is outer heat transfer coefficient of water through annulus and calculated from the Dittus-Boelter equation as below:
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ISSN 2321-6441
Where Re and Pr are the Reynolds number and Prandtls number. The properties of fluid calculated at bulk fluid
temperature.
The outer heat transfer coefficient is calculated from the Nusselt number as below:
ho
Where
De
Nuo .K w
De
is the equivalent diameter of annulus for heat flow = = Di-do
Nano fluids Thermal and Flow Properties

The thermal and flow properties of water like Reynolds number, Prandtls number, conductivity are calculated at bulk
mean temperatures. The thermal and flow properties of nanofluid are calculated using different available correlations as
below:
Thermal conductivity using Timofeeva correlations as below [20]:
Knf 1 3 K w
Viscosity of nanofluid using Drew and Passman correlations as below [20]:
nf 1 2.5w
The density and specific heat using Pak and Cho correlations as below [20]
nf np (1 )w
Cpnf Cpnp (1 )Cpw
The Reynolds number and Prandtls number of nanofluid are calculated using following relations:
Renf
Prnf
nf .Vnf .di
nf
nf .Cpnf
Knf
Where, Vnf is the average velocity of nanofluid flowing through the copper tube.
Nusselt number of the nanofluid flow is computed from the following equation:
Nunf
hnf .di
Knf
4. COMPARATIVE STUDY OF DIFFERENT CONFIGURATION

Results of test conducted for water and CuO nanofluid with concentration of 0.25% by weight with and without helical
coil inserts studied. The overall heat transfer coefficient, convective heat transfer coefficient, Nusselt number, pressure
drop and finally friction factor with different Reynolds number are found and plotted.
Overall heat transfer coefficient
The values of overall heat transfer coefficient increases with increase in flow rate of hot fluid i.e. Reynolds number of
flow. Overall heat transfer coefficients for nanofluids are more than that of base fluid water. It indicates additions of
nanoparticles in the base fluid increases heat transfer rate of base fluid. This increase in heat transfer rate is mainly
contributed by increase in thermal conductivity of nanofluid by addition of nanoparticles. Also overall heat transfer
coefficient of nanofluid increases with decrease in pitch ratio of helical coil. It is mainly due to introduction of swirl
into the bulk fluid flow and disrupting the boundary layer at the tube surface due to repeated changes in the surface
geometry.
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Fig. 4.1 Overall heat transfer coefficient Vs Reynolds number for all configurations
Convective Heat transfer coefficient
The values of convective heat transfer coefficient increases with increase in flow rate of nanofluid i.e. Reynolds number
of flow. Convective heat transfer coefficients for nanofluids are more than that of base fluid water. It indicates additions
of nanoparticles in the base fluid increases heat transfer rate of base fluid. Convective heat transfer coefficient of
nanofluid increases with increase in its concentrations. This increase in heat transfer rate is mainly contributed by
increase in thermal conductivity of nanofluid by addition of nanoparticles and increased turbulence in the flow. The
improvement oh convective heat transfer with increasing Reynolds number is responsible by a decrease of thermal
boundary thickness due to the promoted turbulent intensity achieved by insertion of helical coil.
Fig. 4.2 Convective heat transfer coefficientVs Reynolds number for CuO-Water Nanofluid
Nusselt number
The values of Nusselt number of flow increases with increase in flow rate of nanofluid i.e. Reynolds number of flow.
Nusselt numbers of flow for nanofluids are more than that of base fluid water. Nusselt number of flow of nanofluid
increases decrease in pitch ratio of helical coil, this is mainly due to secondary fluid motion is generated by the tape
twist and the resulting twist mixing improves the convection heat transfer due to which Nusselt number is also get
affected. Nusselt number of the tube equipped with helical coil is improved when compared with that of the tube
without helical coil. This is due to the formation of swirl generated by a helical coil. In addition, Nusselt number
improves with decreasing pitch ratio of helical coil, as swirl intensity increases.
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Fig. 4.3 Nusselt number Vs Reynolds number for CuO-Water Nanofluid
5. CONCLUSION
Based on experiment investigation, important conclusions have been obtained and are summarized as follows:
1. Dispersion of the nanoparticles into the base liquid increases the thermal conductivity of the nanofluids and
collision of nanoparticles which are favourite factors for heat transfer enhancement.
2. Addition of nanoparticles into base fluid increases fluid viscosity which diminishes the fluid movement and thus
heat transfer rate.
3. The improvement of heat transfer with increasing Reynolds number is responsible by a decrease of thermal
boundary thickness due to the promoted turbulent intensity.
4. At a particle concentration of 0.25 % by weight, the use of CuO-water nanofluid increases convective heat transfer
coefficient up to 140.98 % than that of water at higher Reynolds number of 35000. Also at a particle concentration
of 0.25 % by weight CuO-water nanofluid with insertion of helical coil with pitch ratio 1.29 increases convective
heat transfer coefficient from 140.98 % to 249.45 % than that of water at same Reynolds number.
5. This significant increase in convective heat transfer coefficient is mainly contributed by increased thermal
conductivity of nanofluid and due to swirl generation because of insertion of helical coil.
6. Nusselt number of the flow also increases from 139.61 % to 247.45 % for CuO-water nanofluid for concentrations
0.25 % by weight without helical coil to same concentration with insertion of helical coil of pitch ratio 1.29.
7. Nusselt number increases with decrease in pitch ratio from 1.85 to 1.29. This is mainly due to the swirl generation.
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IPASJ International Journal of Mechanical Engineering (IIJME)

Web Site: http://www.ipasj.org/IIJME/IIJME.htm

A Publisher for Research Motivation........

Volume 3, Issue 5, May 2015