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Department of Mechanical Engineering, Faculty of Engineering, King Mongkuts Institute of Technology Ladkrabang,
Bangkok 10520, Thailand
Received 10 December 2003; received in revised form 13 September 2004; accepted 29 September 2004
Available online 20 November 2004
Abstract
Inuence of helical tapes inserted in a tube on heat transfer enhancement is studied experimentally. A helical tape is
inserted in the tube with a view to generating swirl ow that helps to increase the heat transfer rate of the tube. The ow
rate of the tube is considered in a range of Reynolds number between 2300 and 8800. The swirling ow devices con-
sisting of: (1) the full-length helical tape with or without a centered-rod, and (2) the regularly-spaced helical tape,
are inserted in the inner tube of a concentric tube heat exchanger. Hot air is passed through the inner tube whereas
cold water is owed in the annulus. The experimental data obtained are compared with those obtained from plain tubes
of published data. Experimental results conrmed that the use of helical tapes leads to a higher heat transfer rate over
the plain tube. The full-length helical tape with rod provides the highest heat transfer rate about 10% better than that
without rod but it increased the pressure drop. To overcome this, dierent free-spacing ratio (s = Ls/Lh) of 0.5, 1.0, 1.5,
and 2.0 were examined. It was found that the space ratio value should be about unity for Re < 4000. The regularly-
spaced helical tape inserts at s = 0.5 yields the highest Nusselt number which is about 50% above the plain tube.
2004 Elsevier Ltd. All rights reserved.
Keywords: Heat exchanger; Heat transfer; Pressure drop; Swirl ow devices; Helical tape insert
0038-092X/$ - see front matter 2004 Elsevier Ltd. All rights reserved.
doi:10.1016/j.solener.2004.09.021
484 S. Eiamsa-ard, P. Promvonge / Solar Energy 78 (2005) 483494
Nomenclature
Fig. 2. The inner tube tted with various helical geometries insert: (a) Full-length helical tape with a rod; (b) Full-length helical tape
without a rod; (c) Regularly-spaced helical tape without a rod.
popular than the helical tape despite higher heat transfer ber based on the inner tube diameter (Re) in a range of
rate (Bergles, 1985). However, at low values of Reynolds 23008800.
number the pressure drops for using both tapes are not
much dierent. In a solar water heater system, helical
tape insert can be well applied due to low Reynolds 2. Data reduction equations
number in the system. This helical tape can help to pro-
mote higher heat transfer exchange rate than the use of For uid ows in a concentric tube heat exchanger,
twisted-tape because of shorter pitch length which leads the heat transfer rate of the hot uid (air) in the inner
to stronger swirling ow and long residence time in the tube can be expressed as
tube as can be seen in Fig. 3. Thus, the aim of the pres- Q mC p T o T i 1
ent work is to reduce the pressure drop occurring from
using the tape insert in the tube which benets heat while the heat transfer of the cold uid (water) for the
transfer rate. This can be conducted by: (1) no rod at outer tube is
the core of the helical tape and (2) having a free-spacing
Q hA Te w T b 2
between the tapes. This arrangement leads to promoting
the swirl ow in continuous movement to the free space whereas,
of the following tape and this inuences on the heat T b T o T i =2 3
transfer and the pressure drop characteristics of the
tube. and
In the present study, the eect of swirling ow gener- X
ating by the helical tape insert on heat transfer and pres- Te w T w =15 4
sure drop characteristics in a concentric tube heat
exchanger is reported. In the experiment, a helical tape where Tw is the local wall temperature and evaluated at
was inserted into the inner tube with dierent helical the outer wall surface of the inner tube. It must be mea-
tape insert conditions: (1) the full-length helical tape sured at the depth from the outer surface of 0.5 mm. The
with or without a centered rod and (2) four regularly- average wall temperatures are calculated from 15 points,
spaced helical tape inserts, s = 0.5, 1.0, 1.5, and 2.0, as lined between the inlet and exit of the inner tube. The
seen in Figs. 2 and 4. All of the experiments were carried average heat transfer coecient and the mean Nusselt
out at the same inlet conditions with the Reynolds num- number are estimated as follows:
486 S. Eiamsa-ard, P. Promvonge / Solar Energy 78 (2005) 483494
Fig. 3. Relationship between Nusselt number and Reynolds number for the tube with the helical-tape and twisted-tape inserts.
Fig. 4. Geometry under investigation: (a) Full-length helical tape with a rod; (b) Full-length helical tape without a rod; (c) Regularly-
spaced helical tapes without a rod.
Fig. 5. A concentric tube heat exchanger tted with a helical tape and denition of geometric parameters of the helical tape.
ow rates of the hot air and cold water were adjusted by air was heated by an adjustable electrical heater. Both
control valves, situated before the inlet ports. The inlet the inlet and outlet temperatures of the hot air and the
488 S. Eiamsa-ard, P. Promvonge / Solar Energy 78 (2005) 483494
PC Computer
Flow out
Concentric Tube Heat Exchanger
Flow in
(Hot air)
Flow out
Rotameter
Rotameter
U-Manometer
Flow in with Water
(Cold water)
Chiller
Thermostat
with
Electrical Heater
Water
Reservoir
Blower
Centrifugal Pump
cold water were measured by multi-channel with iron- on the average tube wall temperature. The uncertainty in
Constantan thermocouple (type K). It was necessary the determined Nusselt number was estimated based on
to measure the temperature at 15 stations altogether at ANSI/ASME (1986). The overall uncertainty for the
the outer surface of the inner tube for nding out the Nusselt number was found in the range of 57%.
average Nusselt number. All fteen evaluated tempera-
ture probes were connected to the data logger sets.
The entrance and the exit of the inner-outer tubes were 4. Conrmatory tests
provided with pressure tapings for measuring the pres-
sure drop by connecting to the U-tube manometer. The present experimental results on heat and uid
For each test run, it was necessary to record the data ow characteristics in a tube without the helical tape
of temperature, volumetric ow rate and pressure drop insert were rst reported in the form of (1) Nusselt num-
of the hot air and the cold water at steady state condi- ber and (2) ow (friction factor, f). The results of the
tions. The inlet air temperature was maintained at plain tube were compared with the correlations of Dit-
80 C and the cold water was at 27 C during the exper- tusBoelter, Sieder and Tate, and Petukhov (Dittus
iment. The Reynolds number of the heated air was from and Boelter, 1930; Sieder and Tate, 1936; Petukhov,
2300 to 8800. The various characteristics of the ow and 1970; Moody, 1944) for the fully developed turbulent
the Nusselts number, the Reynolds numbers were based ow in circular tubes.
S. Eiamsa-ard, P. Promvonge / Solar Energy 78 (2005) 483494 489
Friction factor
f =8RePr 0.040
Nu
1:07 12:7f =81=2 Pr2=3 1
for 3000 6 Re 6 5 106 11
0.030
Friction factor correlations: Correlation from Moody
diagram (Moody, 1944) is of the form:
f 0:316Re1=4 for Re 6 2 104 12 0.020
30 Present work
5. Results and discussion
without a centered-rod
50 1000
Full-length helical
Full-length helical with a rod
45 900
with a rod
Full-length helical
40 Full-length helical 800 without a rod
without a rod
Plain tube
35 Plain tube 700
30 600
25 500
20 400
15 300
10 200
5 100
0 0
0 2000 4000 6000 8000 10000 0 2000 4000 6000 8000 10000
Reynolds Number Reynolds Number
Fig. 9. Relationship between Nusselt number and Reynolds Fig. 10. Relationship between the pressure drop and Reynolds
number for the tube with full-length helical tape inserts. number for the tube with full-length helical tape inserts.
In comparison between the full-length helical tape forces in the boundary layer. Also, the ow velocity is
with and without a centered-rod, it can be seen that larger since the motion is not in an axial direction.
the tape with rod yields higher heat transfer rate than It is obvious that the use of helical tape with rod gives
that without rod. This can be attributed to a ow mixing higher pressure drop than that of the helical tape with-
behavior between two streams from using the tape with- out a rod due to larger contact surface areas. Besides,
out rod: swirling ow around the tape and the axial ow the presence of helical tape with rod reduces ow areas,
along the tape core. This mixing gives rise to swirling resulting in a high speed rotating ow. This leads to the
ow weaker than that from using the tape with rod substantial pressure loss action of the uid (hot air) be-
which has a swirling ow only. In general, the average tween the rod surface and the inner tube wall higher
heat transfer rate for employing the tape with rod is than the case of the tape without rod. From the results
found to be 510% better than that for the tape without of the tape without rod, pressure loss could be reduced
rod. The corresponding increase in mean Nusselt num- around 30% in comparison with the full-length helical
bers in the heat exchanger is about 145% to 165% with tape with rod. As compromise the use of the tape with-
and without rod, respectively. out rod for Reynolds number less than 4000 is appropri-
Pressure drop: The relationship between the pressure ate as Nusselt number values remain nearly the same
drop and Reynolds number for using the full-length heli- especially.
cal tape with and without a centered-rod in a concentric
tube heat exchanger is presented in Fig. 10. In the gure, 5.2. Eect of the regularly-spaced helical tape
it is worth noting that pressure drop from the full-length
helical tape insert decreases at low Reynolds numbers Heat transfer: Fig. 11 shows the results obtained
due to weak swirling ow but increases substantially at from the hot air side experimental data, the variation
higher values of Reynolds number. It can be seen that of the Nusselt numbers with the Reynolds numbers were
the trend of pressure losses is similar for both the axial depicted for the regularly-spaced helical tape without a
ow (plain tube) and the swirl ow (helical tape inserts). centered-rod. In the gure, the trend of increasing Nus-
The pressure loss for the tube with the tape is substan- selt number with Reynolds number for the regulary-
tially higher than that for the plain tube because of a spaced helical tape is similar to that for the full-length
higher surface area and the dissipation of dynamic pres- helical tape. The use of small value of space ratio (s)
sure of the uid at high viscosity loss near the tube wall. yields a higher heat transfer rate than that of large value
Moreover, the pressure loss had high possibility to occur of space ratio (s). The large free-spacing between the
by the interaction of the pressure forces with inertial helical tapes for s = 1.0, 1.5 and 2.0 is found to be not
S. Eiamsa-ard, P. Promvonge / Solar Energy 78 (2005) 483494 491
40
30 Regularly-spaced
Nusselt Number
helical, s=0.5
25 Regularly spaced
helical, s=1.0
Regularly-spaced
20
helical, s=1.5
Regularly-spaced
15 helical, s=2.0
Plain tube
10
0
0 2000 4000 6000 8000 10000
Reynolds Number
Fig. 11. Relationship between Nusselt number and Reynolds number for the tube with regularly-spaced helical tape inserts without
rod.
sucient to maintain the swirl intensity to extent to the Pressure drop: Fig. 12 shows the relationship between
next helical tape. The swirling ow decays faster in the the pressure drop in the inner tube and Reynolds num-
large free-spacing before reaching the next helical tape ber values at various regulary-spaced helical tape with-
to build up swirling ow again. The optimum value of out a centered-rod in comparison with experiemental
the space ratio should be less than unity to get benet data of the full-length helical tape. In this arrangement
of a higher heat transfer rate and reduction of pressure of the helical tapes, the swirling ow can happen conti-
loss in comparison with the plain tube. nously in the free-spacing but at dierent swirl levels.
Throughout the experimental results, it is visible that The presence of the free-spacing region is to reduce the
using the smaller free space ratio (s = 0.5) yields the surface areas that aect considerably the pressure loss
higher values of heat transfer than the greater space of uid ow. Many space ratios are introduced to inves-
ratio (s = 1.0, 1.5 and 2.0) but lower than the full length tigate ow behaviours. In Fig. 12, the large pressure
helical tape (s = 0.0). In the gure, the regularly-spaced drop occuring from the full-length helical tape insert
helical tape without a centered rod for s = 0.5, s = 1.0, can be decreased substantially by using the regularly-
s = 1.5 and s = 20, gives the maximum heat transfer rate spaced helical tape. It can be seen that for the space ratio
at about 145%, 140%, 133% and 129% respectively, all of s = 0.5, s = 1.0, s = 1.5, and s = 2.0, the reduction of
compared with the plain tube. It is observed that at pressure drop is found to be about 45%, 52%, 58%
the small free-space ratio, s = 0.5, there are slight dier- and 62%, respectively. It can be seen that use of the reg-
ences in the heat transfer rate when compared with the ularly-spaced helical tape results in the decrease in pres-
full-length helical tape. This can be attributed to a sure loss considerably. The space ratio of 1 or lower is
strongly swirling ow remain for the small space ratio suggested especially at low Reynolds number.
while decaying swirling ows for the large space ratio.
Furthermore, the reductions of the Nusselt number
from using the regularly-spaced helical tape are 5%, 6. Flow visualization
10%, 17% and 21% for s = 0.5, s = 1.0, s = 1.5, and
s = 2.0, respectively, in comparison with the full-length Flow characteristics in a tube tted with a helical
helical tape. tape were studied by a visualization method. A particle
492 S. Eiamsa-ard, P. Promvonge / Solar Energy 78 (2005) 483494
600
Regularly-spcaed
400 helical, s=0.5
Regularly-spaced
helical, s=1.0
300 Regularly-spaced
helical, s=1.5
200 Regularly-spaced
helical, s=2.0
Plain tube
100
0
0 2000 4000 6000 8000 10000
Reynolds Number
Fig. 12. Relationship between the pressure drop and Reynolds number for the tube with regularly spaced helical tape inserts without
rod.
Fig. 13. Photograph of the ow in a circular tube tted with the helical tape.
image method was adopted to observe the ow eld in istics were taken at Reynolds number 4000. The photo-
the tube. The working uid is water, which is seeded graphs of the swirling ow through the helical tape
with a small amount of neutral-buoyancy particles. with and without a centered-rod along the tube length
The pictures of particle path lines are taken within the can be seen in Figs. 13 and 14(a). Fig. 14(b) shows that
transparent test section illuminated with a light sheet the swirling ow rapidly becomes a weak swirl ow at
to make visible of the whole ow structures in the swirl- the free-spacing between each tape element. Fig. 14(c)
ing ow eld. demonstrates the weak swirl ow from the free-spacing
Flow through the helical tape in the inner tube was changes to stronger swirl ow in the next helical tape.
observed as shown in Figs. 13 and 14. In the experiments, For the small space ratio, s = 0.5, the strong swirl
the helical tape was inserted into an acrylic circular tube ow still remains exist at the free-spacing while for the
having diameter equal to the inner tube of the concentric longer free-spacing length, s = 1.0, 1.5 and 2.0 the weak
tube heat exchanger. The photographs of ow character- swirl ow and some axial ow are observed.
S. Eiamsa-ard, P. Promvonge / Solar Energy 78 (2005) 483494 493
Fig. 14. Photograph of the ow in a circular tube tted the helical tape without a rod: (a) Swirling ow created by upstream helical
tape; (b) Swirling ow decaying in the free-space; (c) Swirling ow recreated by downstream helical tape.