Experimental Study of Heat Transfer Enhancement in A Pipe Using Twisted Tapes PDF

International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 INTERNATIONAL JOURNAL OF MECHANICAL ENGINEERING 6340(Print), ISSN
N 0976 6359(Online) Volume 4, Issue 2, March - April (2013) IAEME AND TECHNOLOGY (IJMET)
ISSN 0976 6340 (Print) ISSN 0976 6359 (Online) Volume 4, Issue 2, March - April (2013), pp. 100-111 IAEME: www.iaeme.com/ijmet.asp Journal Impact Factor (2013): 5.7731 (Calculated by GISI) www.jifactor.com
IJMET
IAEME
EXPERIMENTAL STUDY OF HEAT TRANSFER ENHANCEMENT IN A PIPE USING TWISTED TAPES AND WIRE COILS
Dr. A. G. Matani1, Swapnil A. Dahake2 Associate Professor, Mechanical Engineering Department, Government College of Engineering, Amravati, (M.S.) India 2 nd M.Tech. [2 Year Thermal Engineering], Government College of Engineering, Amravati, (M.S.) India.
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ABSTRACT In the proposed work, the heat transfer enhancement using twisted tapes and wire coil on pressure drop, Nusselt number (Nu), friction factor (f) and thermal enhancement index () are experimentally determined. The twisted tapes are used as swirl flow generators while wire coil along with twisted tapes used as co-swirl flow generators in a test section. The tests are conducted using the twisted tape with three different twist ratios (y/w = 3.5, 2.66 and 2.25) and wire coil along with twisted tapes, pitch ratio of 1.17 & 0.88 for Reynolds numbers range between 5000 and 18,000 under uniform heat flux conditions. Also double twist generating counter swirl are compared. The experiments using the twisted tape and with wire coil performed under similar operation test conditions, for comparison. The experimental results indicate that the tube with the various inserts provides considerable improvement of the heat transfer rate over the plain tube. The experimental results demonstrate that friction factor (f) and thermal enhancement index () increase with decreasing twist ratio (y/w) and Reynolds number. The results also show that the wire coils along with twisted tapes are more efficient than the twisted tapes for heat transfer enhancement. 1. INTRODUCTION Research is going on to investigate the level of heat transfer enhancement that can achieved by forced convection in which air is flow inside horizontal pipe. The comparison between bare tube and enhanced tube configuration are made on the basis of forced convection with air instabilities. These types of inserts increase the heat transfer coefficient
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 4, Issue 2, March - April (2013) IAEME
with respect to smooth tube. Differences among the enhanced configuration are also determined to observe which of them most stable and unstable one is. These inserts induced swirl flow heat transfer due to exponentially increasing heat input with exponential periods. In the last decades, significant effort has been made to develop heat transfer enhancement techniques in order to improve the overall performance of heat exchangers. The interest in these techniques is closely tied to energy prices and, it is expected that the heat transfer enhancement field will go through a new growth phase with the present increase in energy cost. Although there is need to develop novel technologies, experimental work on the older ones is still necessary. The knowledge of its performance shows a large degree of uncertainty which makes their industrial implementation difficult [6]. The efficiency of heat transfer equipment is essential in energy conservation. Furthermore, a more efficient heat exchanger can reduce the size of the heat exchanger, thus reducing the costs associated with both material and manufacturing of the heat exchanger [2]. Heat transfer enhancement technology has been widely applied to heat exchanger applications in refrigeration, automobile, process industries etc. There have been numerous attempts to reduce the size and cost of heat exchangers. Hence, there have been continuous attempts to improve the efficiency of heat exchangers by various methods. One of the best methods to achieve this is the use of augmented heat transfer surfaces. Improved heat transfer can make heat exchangers smaller and more energy efficient. The tube insert technology is one of the most common heat transfer enhancement technologies for shell and tube heat exchangers. Tube side enhancement techniques can be classified according to the following criteria: (1) additional devices which are incorporated into a plain round tube (twisted tapes, wire coils) and (2) non-plain round tube techniques such as surface modification of a plain tube (corrugated and dimpled tubes) [5] or manufacturing of special tube geometries (internally finned tubes) [6]. The dominant literature study usually mentions five types: wire coils, twisted tapes, extended surface devices, mesh inserts and displaced elements [7]. The main advantage of these types in respect to other enhancement techniques such as the artificial roughness by mechanical deformation or internal fin types is that they allow an easy installation in an existing smooth-tube heat exchanger. The various single and double twisted tapes are also used to generate swirl/co-swirl [9]. Due to its low cost, the insert devices which are most frequently used in engineering applications are wire coils and twisted tapes. Heat transfer enhancement techniques have been extensively developed to improve the thermal performance of heat exchanger systems with a view to reducing the size and cost of the systems. Swirl/vortex flow is the one of the enhancement techniques widely applied to heating/cooling systems in many engineering applications. The vortex flows can be classified into two types: continuous swirl and decaying swirl flows. The former represents the swirling motion that persists over the entire length of the duct for example helical/twisted tape and coiled wires inserts while the latter means the swirl created at the duct entrance and then decays along the flow path such as the tangential injection, the rib/baffle and the winglet vortex generators [10]. Swirl flow has been used in a wide range of applications from various engineering areas such as chemical and mechanical mixing and separation devices, combustion chambers, turbo machinery to pollution control devices. It is commonly known that the swirl flow enhances the heat transfer mainly due to the increased velocity in the swirl tube and the circulation of the fluid by forced convection [4].
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2. TWISTED TAPES & WIRE COIL TO GENERATE SWIRL The knowledge of heat transfer in a short circular tube with the twisted-tape insert tube is important to investigate the influence of the twist ratio of twisted tape on enhancement of critical heat flux. A lot of the experimental investigations were conducted with the heat transfer characteristics of the swirl flow. It was shown that the twisted-tape insert tube provided considerable enhancement of turbulent heat transfer for heating/cooling of fluid. The twisted-tape insert tubes are encountered in a number of important engineering and science systems such as plasma facing components in fusion experimental facilities, high power laser systems and etc. We believe that the enhancement of heat transfer for the twistedtape insert tube would be due to reduction of viscous sub-layer thickness on heated surface of test tube with an increase in liquid flow velocity from straight flow to swirl one even at a fixed mass velocity. Wire coil inserts are devices whose reliability and durability are widely contrasted. In extreme applications such as the tube-side of fuel pyrotubular boilers with great fouling problems and with high variations in temperature that produce great dilatations, wires are used without any problem. This is a cheap enhancement technique and it is completely viable for many industrial applications. This fact hinders a widespread use of wire coil inserts in industrial heat exchangers. The twisted tapes are made of mild steel and have tape width (w) of 10 mm, 15 mm & 20mm shown in Figure 1, tape thickness (d) of 0.8 mm, and tape length (l) of 900 mm. All tapes were prepared with different twist ratios, y/w = 3.5, 2.66 and 2.25 respectively where twist ratio is defined as twist length (l) to tape width (w). The double twisted tapes are manufactured by combining two single twisted tapes, which generate counter swirl in pipe shown in Figure 2. On the other hand, to avoid an additional friction in the system that might be caused the thicker tape. To produce the twisted tape, one end of a straight tape was clamped while another end was carefully twisted to ensure a desired twist length. Another insert, wire coil is made up of aluminum wire of 2 mm diameter having pitch of 30mm & 40 mm shown in Figure 3. These twisted tapes are fixed one by one inside the pipe having wire coil to generate co-swirl.
Figure 1: Single twisted tapes (y/w = 3.5, 2.66 & 2.25)
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 4, Issue 2, March Mar - April (2013) IAEME
Figure 2: Double twisted tape (y/w = 2.66)
Figure 3: Wire coil (p/d = 0.88)
3. TEST SECTION The test section is surrounded by nichrome heating wire, which is wrapped around the test section with a pitch distance of 5 mm. This pitch is good enough to provide a nearly uniform heating on the outer surface of the test section tube. The heating wire was powered by a variable AC power supply. The overall electrical power added to the heating section, Q, was calculated by measuring the voltage (0 (0200 200 V) and the electrical current (0 (02 A). To control the convection losses from the test section and other components, foam insulation and glass wool used. Four thermocouples are to be embedded on the test section to measure surface temperature of pipe and two thermocouples are placed in air stream at entrance and exist of test section to measure air temperature. To avoid floating voltage effects, the thermocouple bead is insulated from the electrically heated tube wall surface with a very thin sheet of mica between the thermocouple and the tube surface so as not to be effected from electricity. icity. Fig. 2 shows the schematic view of experimental set-up. set
Figure 4: Experimental set-up
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4. DATA REDUCTION In the experiments, the heat transfer rate in the tube is taken into account under a uniform heat flux (UHF) condition by using air as the test fluid. The heat transfer given by the hot surface to fluid (i.e. air) at any Reynolds number is Rate at which air is heated Qa = mCp (To - Ti) The convection heat transfer from the test section is given as Qc = hAs(Ts - Tm) At steady state condition, the heat transfer is assumed to be equal to the heat loss from the test section that can be drawn as Qa = Qc The mean temperature of the fluid in the test tube is given by Tm = (To + Ti) / 2 Ts is the mean temperature of surface wall temperature of the test tube. The average wall temperature is calculated from 4 points of local wall temperatures lined between the inlet and the exit of the test tube. The average heat transfer coefficient (h) and the mean Nusselt number (Nu) are estimated by h = mCp (To - Ti) / hA(Ts - Tm) The Nusselt number in terms of average heat transfer coefficient is defined as Nu = hD / k The Reynolds number is written as Re = UD / The experiment pressure losses, p across the test tube are arranged in non-dimensional form by using the following equation
in which U is mean velocity in the test tube and L is the test tube length. All of thermophysical properties of the air are determined at the overall mean air temperature (Tm). 5. EXPERIMENTAL RESULTS AND DISCUSSIONS In this section, the pressure drop, friction factor characteristics, heat transfer and thermal enhancement index in a tube fitted with twisted tapes, double twisted tape and wire coil (counter/co-swirl tape) are presented. The experiments are performed in the range of Reynolds number between 5000 and 18,000. The results obtained for the tube fitted with the single twisted tapes (ST), wire coil and the empty tube are used as the reference data for the performance evaluation of the modified tubes.
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5.1 Heat transfer result Experimental results of the Nusselt number (Nu) in plain tubes combined with a twisted tape (y/w = 3.5, 2.66, 2.25), double twisted tape (y/w = 3.5, 2.66) and wire coil (p/d = 1.17, 0.88) are presented in Figure 5. The Nusselt numbers for the plain tube acting alone are also plotted for comparison. The data show that the Nusselt number (therefore, the heat transfer coefficient) increases with increasing Reynolds number for the conventional turbulent tube flow. This is the most likely caused by a stronger turbulence and better contact between fluid and heating wall. It is noted that the increasing Nusselt number in the plain tube in common with a twisted tapes and wire coil is caused by the generating of pressure gradient along the radial direction, and this leads to redeveloping of thermal/hydrodynamic boundary layer. The higher increase of the Nusselt number in this style of both turbulence and swirl flows is a consequence of the higher reduction of boundary layer thickness and increase of resultant velocity. The variations of Nusselt number with Reynolds number for single and double twisted tapes with wire coil of pitch ratio (p/d = 1.17) shown in Figure 6 and with wire coil of pitch ratio (p/d = 0.88) shown in Figure 7. Nusselt number increases with the decrease of twist ratio and the increase of Reynolds number. The highest Nusselt number is achieved for twist ratio (y/w = 2.25) and pitch ratio (p/d =0.88). However, the heat transfer enhancement by twisted tapes is less efficient than that offered by wire coil indicated by the lower Nusselt number depending on operating condition.
smooth tube STT(y/w)=3.5 80 70 60 Nu 50 40 30 20 5000 7000 9000 11000 Re 13000 15000 17000 STT(y/w)=2.6 6 STT(y/w)=2.2 5 DTT(y/w)=3.5 DTT(y/w)=2.6 6 WC(p/d)=1.1 7
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Figure 5: Single twisted tape (y/w = 3.5, 2.66, 2.25), double twisted tape (y/w = 3.5, 2.66) and wire coil (p/d = 1.17, 0.88)
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STT(p/d)=1.17,(y/w)= 3.5 STT(p/d)=1.17,(y/w)= 2.66 STT(p/d)=1.17,(y/w)= 2.25 DTT(p/d)=1.17,(y/w)= 3.5 DTT(p/d)=1.17,(y/w)= 2.66
110 100 90 80 Nu 70 60 50 40 30 5000 10000 Re 15000
Figure 6: Single and double twisted tapes along with wire coil of pitch ratio (p/d = 1.17)
120 110 100 90 80 Nu 70 60 50 40 30 5000 7000 9000 11000 13000 Re 15000 17000 STT(p/d)=0.88,(y/w)=3. 5 STT(p/d)=0.88,(y/w)=2. 66 STT(p/d)=0.88,(y/w)=2. 25 DTT(p/d)=0.88,(y/w)=3. 5 DTT(p/d)=0.88,(y/w)=2. 66
Figure 7: Single and double twisted tapes with wire coil of pitch ratio (p/d = 0.88) 5.2 Friction factor results Experimental results of the friction factor (f) characteristics in plain tubes combined with a twisted tape (y/w = 3.5, 2.66, 2.25), double twisted tape (y/w = 3.5, 2.66) and wire coil (p/d = 1.17, 0.88) are presented in Figure 5. The friction factors of the plain tube acting alone are also plotted for comparison. Figure shows the influence of a plain tube combined with a twisted tape and wire coil on pressure loss, which indicates the friction in a heat exchanger.
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The relationship between pressure loss in terms of friction factor and Reynolds number for the tube with twisted tape (STT & DTT) and wire coil inserted and also for the plain tube is presented in Figure 5. It is found that using twisted tape and wire coil gives higher friction factor values than those from the plain tube as expected. The friction factor decreases with the increase of twist ratio and Reynolds number. The variations of friction factor with Reynolds number for single and double twisted tapes with wire coil of pitch ratio (p/d = 1.17) shown in Figure 9 and with wire coil of pitch ratio (p/d = 0.88) shown in Figure 10. The highest friction factor (or pressure loss) is obtained in case p/d = 0.88 & y/w = 2.66.
0.3 0.25 Friction factor (f) 0.2 smooth tube STT (y/w)=3.5 STT (y/w)=2.66 STT (y/w)=2.25 DTT (y/w)=3.5 DTT (y/w)=2.66
0.15 0.1
0.05 0 5000 7000 9000 11000 Re 13000 15000 17000
STT (p/d)=1.17,(y/w)=3.5 STT (p/d)=1.17,(y/w)=2.66 STT (p/d)=1.17,(y/w)=2.25 DTT (p/d)=1.17,(y/w)=3.5
0.5 0.45 0.4 Friction factor (f) 0.35 0.3 0.25 0.2 0.15 0.1 5000 7000 9000 11000 Re 13000 15000 17000
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0.6 0.55 0.5 0.45 Friction factor (f) 0.4 0.35 0.3 0.25 0.2 0.15 0.1 5000 7000 9000 11000 Re 13000 15000 17000
STT (p/d)=0.88,(y/w)=3.5 STT (p/d)=0.88,(y/w)=2.66 STT (p/d)=0.88,(y/w)=2.25 DTT (p/d)=0.88,(y/w)=3.5 DTT (p/d)=0.88,(y/w)=2.66
Figure 10: Single and double twisted tapes with wire coil of pitch ratio (p/d = 0.88) 5.3 Performance factor results Siva Rama Krishna, Govardhan Pathipaka, P. Sivashanmugam [3] proposed a performance evaluation analysis for the same pumping power and this method used for present study, the performance ratio is defined as
/
.
The performance analysis was made by above Eq. and the results are shown in Figure 11, 12, 13. In the present work, a thermal performance factor is evaluated since the factor is an important parameter indicating the potential of a twisted tape for practical applications. The thermal evaluation is considered under constant pumping power for each twisted tape with respect to the case without twisted tape (plain tube). The thermal performance factors for single twisted tape, double twisted tape and wire coil are presented in Figure 11. Apparently, a thermal performance factor decreases with increasing Reynolds number for all tape inserts. A larger pressure loss at a higher Reynolds number is responsible for the mentioned result. This suggests that the geometry of wire coil is more appropriate for practical use than the others in the view point of energy as well as operating cost savings.
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STT (y/w)=3.5 1.35 1.3 1.25 Performance factor 1.2 1.15 1.1 1.05 1 0.95 5000 7000 9000 11000 Re 13000 15000 17000 STT (y/w)=2.66 STT (y/w)=2.25 DTT (y/w)=3.5 DTT (y/w)=2.66 WC(p/d)=1.17
1.65 1.55 Performance factor 1.45 1.35 1.25 1.15 1.05 0.95 5000 7000 9000 11000 13000 Re 15000 17000
STT (p/d)=1.17,(y/w)=3.5 STT (p/d)=1.17,(y/w)=2.66 STT (p/d)=1.17,(y/w)=2.25 DTT (p/d)=1.17,(y/w)=3.5 DTT (p/d)=1.17,(y/w)=2.66
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1.75 1.65 Performance factor 1.55 1.45 1.35 1.25 1.15 1.05 0.95 5000 10000 Re 15000 STT (p/d)=0.88,(y/w)=3.5 STT (p/d)=0.88,(y/w)=2.66 STT (p/d)=0.88,(y/w)=2.25 DTT (p/d)=0.88,(y/w)=3.5
Figure 13: Single and double twisted tapes with wire coil of pitch ratio (p/d = 0.88) 6. CONCLUSIONS
Thermal characteristics in a tube fitted with twisted-tapes in co-swirl arrangement with wire coil are presented in the present study. The work has been conducted in the turbulent flow regime, Reynolds number from 5000 to 18,000 using air as the test fluid. The findings of the work can be drawn as follows: For the inserted tube, the pressure drop tends to increase with the rise in mass flow rate while the friction factor and performance factor give the opposite trends. The compound enhancement devices of the tube and the co-swirl show a considerable improvement of heat transfer rate and thermal performance relative to the smooth tube acting alone, depending on twist ratios. The co-swirl tube yields higher friction factor and performance factor than the smooth tube at low Reynolds number. The various inserts in pipe mixes the bulk flow well and therefore performs better in laminar flow. The result also shows twisted tape insert is more effective, if no pressure drop penalty is considered. Twisted tape in turbulent flow is effective up to a certain Reynolds number range. Swirl flow heat transfer is higher than non swirling flow.
NOMENCLATURE d wire diameter f Friction factor Performance factor Nu Nusselt number p pitch p/d pitch ratio Re Reynolds number w Width of tape y Twist length (y/w) twist ratio
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REFERENCES
1. Shou-Shing Hsieh, Feng-Yu Wu, Huang-Hsiu Tsai, Turbulent heat transfer and flow characteristics in a horizontal circular tube with Shou-Shing Hsieh, Feng-Yu Wu,Huang-Hsiu strip-type inserts, International Journal of Heat and Mass Transfer (2003),Vol. 46, pp. 823835. 2. Leonard D. Tijing, Bock Choon Pak, Byung Joon Baek, Dong Hwan Lee, A study on heat transfer enhancement using straight and twisted internal fin inserts, International Communications in Heat and Mass Transfer (2006), Vol. 33, pp. 719-726. 3. Siva Rama Krishna, Govardhan Pathipaka, P. Sivashanmugam, Heat transfer and pressure drop studies in a circular tube fitted with straight full twist, Experimental Thermal and Fluid Science (2009), Vol. 33, pp. 431438. 4. H. Gl a, D. Evinb, Heat transfer enhancement in circular tubes using helical swirl generator insert at the entrance, International Journal of Thermal Sciences (2007), Vol. 46, pp. 12971303. 5. Chinaruk Thianpong, Petpices Eiamsa-ard, Khwanchit Wongcharee, Smith Eiamsa-ard, Compound heat transfer enhancement of a dimpled tube with a twisted tape swirl generator, International Communications in Heat and Mass Transfer (2009), Vol. 36, pp. 698704. 6. Alberto Garcia, Pedro G. Vicente, Antonio Viedma, Experimental study of heat transfer enhancement with wire coil inserts in laminar-transition-turbulent regimes at different Prandtl numbers Experimental study of heat transfer enhancement with wire coil inserts in laminartransition-turbulent regimes at different Prandtl numbers, International Journal of Heat and Mass Transfer (2005), Vol. 48, pp. 4640-4651. 7. Alberto Garcia, Juan P. Solano, Pedro G. Vicente, Antonio Viedma, Enhancement of laminar and transitional flow heat transfer in tubes by means of wire coil inserts, International Journal of Heat and Mass Transfer (2007), Vol. 50, pp. 3176-3189. 8. Kumbhar D.G., Dr. Sane N.K., Heat Transfer Enhancement in a Circular Tube Twisted with Swirl Generator: A Review, Proc. of the 3rd International Conference on Advances in Mechanical Engineering, SVNIT Surat, January 4-6, 2010. 9. Panida Seemawute, Smith Eiamsa-ard, Thermohydraulics of turbulent flow through a round tube by a peripherally-cut twisted tape with an alternate axis, International Communications in Heat and Mass Transfer (2010), Vol. 37, pp. 652659. 10. Pongjet Promvonge, Somsak Pethkool, Monsak Pimsarn, Chinaruk Thianpong, Heat transfer augmentation in a helical-ribbed tube with double twisted tape inserts, International Communications in Heat and Mass Transfer (2012), Vol. 39, pp. 953-959. 11. S. Eiamsa-ard, C. Thianpong, P. Eiamsa-ard, Turbulent heat transfer enhancement by counter/co-swirling flow in a tube fitted with twin twisted tapes, Experimental Thermal and Fluid Science (2010), Vol. 34, pp. 5362. 12. Halit Bas, Veysel Ozceyhan, Heat transfer enhancement in a tube with twisted tape inserts placed separately from the tube wall, Experimental Thermal and Fluid Science (2012), Vol. 41, pp. 5158. 13. S. Eiamsa-ard , P. Seemawute, Decaying swirl flow in round tubes with short-length twisted tapes, International Communications in Heat and Mass Transfer (2012), Vol. 39, pp 649 656. 14. Er. Pardeep Kumar, Manoj Sain and Shweta Tripathi, Enhancement of Heat Transfer using Wire Coil Insert in Tubes International Journal of Mechanical Engineering & Technology (IJMET), Volume 3, Issue 2, 2012, pp. 796 - 805, ISSN Print: 0976 6340, ISSN Online: 0976 6359.
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 INTERNATIONAL JOURNAL OF MECHANICAL ENGINEERING 6340(Print), ISSN

Figure 1: Single twisted tapes (y/w = 3.5, 2.66 & 2.25)

Figure 2: Double twisted tape (y/w = 2.66)

Figure 3: Wire coil (p/d = 0.88)

Figure 4: Experimental set-up

110 100 90 80 Nu 70 60 50 40 30 5000 10000 Re 15000

0.05 0 5000 7000 9000 11000 Re 13000 15000 17000

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