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International Communications in Heat and Mass Transfer 37 (2010) 775781

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International Communications in Heat and Mass Transfer


j o u r n a l h o m e p a g e : w w w. e l s ev i e r. c o m / l o c a t e / i c h m t

An experimental study of thermal performance of shell-and-coil heat exchangers


Nasser Ghorbani a, Hessam Taherian b, Mod Gorji b, Hessam Mirgolbabaei c,
a
b
c

School of Mechanical Engineering, University of Leeds, Leeds, England


Department of Mechanical Engineering, Babol Noshirvani University of Technology, Babol 47144, Iran
Department of Mechanical Engineering, Islamic Azad University, Jouybar branch, Jouybar, Iran

a r t i c l e

i n f o

Available online 19 March 2010


Keywords:
Heat exchanger
Helical coil
Forced convection
Heat transfer

a b s t r a c t
In the present study an experimental investigation of the mixed convection heat transfer in a coil-in-shell
heat exchanger is reported for various Reynolds and Rayleigh numbers, various tube-to-coil diameter ratios
and dimensionless coil pitch. The purpose of this article is to assess the inuence of the tube diameter, coil
pitch, shell-side and tube-side mass ow rate over the performance coefcient and modied effectiveness of
vertical helical coiled tube heat exchangers. The calculations have been performed for the steady-state and
the experiments were conducted for both laminar and turbulent ow inside coil. It was found that the mass
ow rate of tube-side to shell-side ratio was effective on the axial temperature proles of heat exchanger.
The results also indicate that the NTU relation of the mixed convection heat exchangers was the same as
that of a pure counter-ow heat exchanger.
2010 Elsevier Ltd. All rights reserved.

1. Introduction
Reports on extensive numerical and experimental investigations
are available to be used for both laminar and turbulent ow in straight
tubes. However, ow through or over coiled pipes with curvature and
torsion is still under exploration. Heat exchangers are vastly used in
many industrial processes. Use of helical coils adds efciency to the
heat exchanger performance. Shell-and-coil heat exchangers have
been used mainly in solar domestic hot water (SDHW) systems
because of their high heat transfer and smaller space requirement,
their use in heat recovery systems for space heating also has been
reported [1]. Therefore, it is worthy to study heat transfer, pressure
drop and thermal performance of the shell side of helical or spiral
coil used in heat exchangers. In spite of numerical and experimental
studies which have been carried out in relation to tube-side heat
transfer coefcient, there are not many investigations on the shell-side
mixed convection heat transfer coefcient of shell-and-coil heat
exchangers.
The heat transfer and performance of a spirally coiled, nned-tube,
in a steel shell heat exchanger was investigated by Wongwises et al.
[2]. The spiral coil consists of a tube with 9.6 mm in diameter, having
four turns and six layers. Air and water were used for shell side and
tube side, respectively. They have illustrated that with increasing mass
ow rate in tube side the effectiveness of the heat exchanger decreased
and had a slight increase with increasing water mass ow rate.

Communicated by W.J. Minkowycz.


Corresponding author.
E-mail address: mirgolbabaei@gmail.com (H. Mirgolbabaei).
0735-1933/$ see front matter 2010 Elsevier Ltd. All rights reserved.
doi:10.1016/j.icheatmasstransfer.2010.02.001

Thermal performance and pressure drop of the helical coil with


and without ns of heat exchanger were investigated by Naphon [3].
Two different coil diameters with 9.5 mm diameter copper tube
having thirteen turns were used. Hot and cold water were used as
working uid in the range between 0.10 and 0.22 kg/s and between
0.02 and 0.12 kg/s, respectively. They have shown that with increasing
hot water mass ow rate friction factor decreased.
An extra parameter has been introduced by Kharat et al. [4] to
cover coil gap in multi helical coils in heat exchangers. A wide range of
Reynolds numbers from 20,000 to 150,000 has been analyzed. They
have also used Fluent 6.3.26 to compare data. Various helical coils
made of 12.5 mm ID tube with various coil diameters ranging from 92
to 1282 mm to determine friction factors have been investigated by
Srinivasan et al. [1]. Four different coil pitches of 2.5, 3.3, 6.6 and 13.2
tube diameters were tested and graphs of friction factors with respect
to the Dean number were produced. All the graphs showed breakpoints which were interpreted as the critical Reynolds number value
so that equation was found to describe this critical value for different
tube diameter to shell diameter ratio.
Tube in tube helical coil heat exchanger has been investigated
to study uid ow and heat transfer under turbulent condition by
Mandal and Nigam [5]. Hot air and cold water were used in inner tube
and outer tube as working uid. Moreover, the Reynolds number in
inner tube for air was ranged from 14,000 to 86,000. A CFD work
investigation has been done to cover the experimental data. Rogres
and Mayhew [6] concentrated their attention on heat transfer and
pressure loss in helically coiled tubes with turbulent ow having mean
diameters of 10.2, 12.5 and 190 mm, made of 9.45 mm ID copper tubes
heated by steam at slightly above atmospheric pressure. The heat
transfer data resulted in the empirical equation for the Reynolds

776

N. Ghorbani et al. / International Communications in Heat and Mass Transfer 37 (2010) 775781

Nomenclature
Ac,f
Ap
C
Cr
D, d
De
Dhx
g
h
H
He
k
L
LMTD

N
NTU
Nu
P
Pr
Q
Ra
Re
Rm
T
UA
V

Flow cross-section area, (m2)


Wetted surface area on the shell side, (m2)
Specic heat, (J/kgK)
Heat capacity ratio of the two uids (Cmin/Cmax)
Diameter, (m) s
 
Dt
Dean number, Re
Dc
4Ac;f H
Heat exchanger hydraulic diameter,
, (m)
Ap
2
Gravitational acceleration, (m/s )
Heat transfer coefcient, (W/m2K)
Heat exchanger height, (m)
"

 #1 = 2
p 2
Helical coil number, De 1 +
Dc
Thermal conductivity, (W/mK)
Total length of coils, (m)
Logarithmic mean temperature difference
Mass ow rate, (kg/s)
Number of coils turns
Number of (heat) transfer units
hD
Nusselt number,
k
Coil pitch, (m)

Prandtl number,

Heat transfer rate, (W)


gTD3
Rayleigh number,

VD
Reynolds number,

Tube-side to shell-side mass ow rate ratio (mc/ms,


mg/ms)
Temperature, (K)
Overall conductance of heat exchanger (W/K)
Velocity, (m/s)

Greek symbols

Thermal diffusivity, (m2/s)

Coefcient of volumetric thermal expansion, (1/K)

Heat exchanger effectiveness

Modied effectiveness

Kinematic viscosity, (m2/s)

Mass density, (kg/m3)

Subscripts
C
Coil
c
Cold water
h
Hot water
i
Inner, tube side
s
Shell
t
tube

number of104to 105 through which the ow was assumed turbulent.


Manlapaz and Churchill [7] have also worked on fully developed
laminar convection in helical coils. Reviewing and employing
previously published work of other authors, new correlations of
friction factor and Nusselt number in helical coiled tubes with constant
wall heat ux and constant wall temperature has been developed by
Manlapaz and Churchill [7]. Natural convection heat transfer in shellin-coil heat exchangers has been studied by Taherian and Allen [8], [9].
An aqueous solution of propylene glycol was pumped from a tank into

the coils through an electric heater and a distributor manifold and


recirculated after passing through rotameters. The effects of tube
diameter, coil diameter, coil surface and shell diameter on the shellside heat transfer coefcient of a shell-and-coil natural convection
heat exchanger which is commonly used in solar domestic hot water
(SDHW) systems, were studied. They found that the modied
effectiveness decreased with increasing mass ow rate ratio and
developed a correlation between these two factors and the shell-andcoil heat exchanger compactness ratio, for 0:3bRm H =L0:3 and
1:85 103 m g 34:3 103 kg =s . The NTU relation of the
natural convection heat exchangers was similar to those of a pure
counter-ow heat exchanger. The logarithmic mean temperature
difference was found to decrease with increasing the mass ow rate
ratio. They found that the ratio of the glycol to water mass ow rate
(Rm) was inuential on the axial temperature proles of heat
exchanger. For Rm greater than unity, the temperature proles were
of quadratic form from bottom to top of the heat exchanger. The
proles were linear for Rm close to unity and when the mass ow rate
ratio was considerably less than unity, the temperature proles were
of the logarithmic form. The effect of increasing the heat transfer rate
was to increase the slope of axial temperature proles. Fraser et al. [10]
assumed that the curves of the modied effectiveness versus the water
mass ow rate are universal when the shell-side mass ow rate is
xed. They made use of the assumption of universality in order to
develop an empirical model for natural convection heat exchangers in
SDHW systems. Mixed convection heat transfer from the vertical
helical coils was investigated numerically by Mirgolbabaei et al. [11].
It was concluded that coil pitch has signicant effect on shell-side
heat transfer coefcient. With increasing dimensionless coil pitch
in medium range, the heat transfer coefcient decreases while with
increasing pitch to 2 tube diameter, heat transfer coefcient is increased.
Also it was found that heat transfer coefcient decreases as the tube
diameter increases, for the same dimensionless coil pitch. Finally they
provided a correlation for Nusselt number on the shell-side. Moawed
[12] reported an experimental investigation of steady-state natural
convection heat transfer from uniformly heated helicoidal pipes
oriented vertically and horizontally. His experimental investigation
was conducted on four helicoidal pipes having different ratios of coil
diameter to pipe diameter, pitch to pipe diameter and length to pipe
diameter with the range of Rayleigh number1.5 103b Ra b 1.1 105. His
results showed that the overall Nusselt number increases with the
increase of coil to tube diameter ratio, dimensional pitch and length of
coil to tube diameter for the vertical helicoidal pipes. For the horizontal
helicoidal pipes, the overall Nusselt number increased with the increase
of dimensional pitch and length of coil to tube diameter, but it decreased
with the increase of coil to tube diameter ratio. He presented two
different equations to correlate the Nusselt number for horizontal and
vertical helicoidal pipes.
Different characteristic lengths to correlate the outside Reynolds
number with the Rayleigh number are investigated in natural convection heat transfer from helical coil by Prabhanjan et al. [13]. It was
nally found that the coil height has best t results for vertical coil. In
addition, they have developed a method of predicting the outlet
temperature from a coil, using the inlet temperature, bath temperature and coil dimensions.
Xin and Ebadian [14] have experimentally studied shell-in-coil
natural convection heat exchangers. Several correlations for Nusselt
number versus Rayleigh number based on different characteristic
lengths have been proposed.
Ajele [15] studied shell-and-coil natural convection heat exchangers
experimentally. Combinations of up to four coils, as well as single coil
were tested in a 100 mm inner diameter shell. He proposed a correlation for multiple coi1 tests of shell-and-coil natural convection heat
exchangers. Hollands and Brunger [16] pointed to the existence of an
optimum value for tube mass ow rate. Numerical investigations were
conducted to understand forced laminar uid ow over coiled pipes

N. Ghorbani et al. / International Communications in Heat and Mass Transfer 37 (2010) 775781

777

Fig. 1. a) Apparatus for heat exchanger experiments, b) Schematic diagram of a shell-and-coil mixed convection heat exchanger.

with circular cross-section by Conte et al. [17]. The focus of their study
was concentrated on exploring the convective heat transfer from conical
and helical coils with comparative studies. The same numerical
investigation method was applied to two differentially coiled pipes
(helical and conical) and for different Reynolds numbers corresponding
to ve cases of exterior ow arrangement. The results showed better
heat transfer performance for cases of conical coils whereas much ow
turbulence was observed due to an effective ow arrangement.
Although there are many works done in tube-side of helical coiled
tube heat exchangers also on the natural convection on shell-side,
there are not many investigations on forced and mixed convection
considering the both side of the heat exchanger. The present study
covers both laminar and turbulent ow regimes inside the coiled tube
depending on different mass ow rates.

2. Experimental apparatus and test section


Fig. 1 is a picture of the apparatus arranged for heat exchanger
experiments. The experimental procedure is the same as Ghorbani et al
[18]. Hot water was pumped to the tank, passing through six electric

Table 1
Geometrical characteristics of the heat exchanger.
No. Dt,o
(mm)

Dt,i
(mm)

Dc
(mm)

Ds,i
(mm)

Ds,o
(mm)

H
(mm)

p
(mm)

1
2
3

7.77
10.82
10.82

125.71
128.31
128.31

88.9
88.9
88.9

157
157
157

383
383
383

16.47
16.47
23.57

23.25
23.25
16.25

9.47
12.59
12.59

778

N. Ghorbani et al. / International Communications in Heat and Mass Transfer 37 (2010) 775781

Table 2
Experimental uncertainties of important parameters.
Parameter

Uncertainty

Parameter

Uncertainty

LMTD
NTU

5.8%
11.97%
1%
1%

1.6%
1%
2.47%

heaters and a valve that was installed at the inlet of the heat exchanger
to control the ow rate. Cold water in the shell side was taken from
urban water supply. The temperature of the inlet water of coiled tube to
the heat exchanger was controlled by a thermostat. Four different
constant temperatures of 50, 60, 70, and 80 C were considered for inlet
mass ow rate of coil. These temperatures are in accord with the outlet
temperature of a at plate solar collector. The temperature of shell-side
inlet was equal to the temperature of tap water. The ow rate was
measured using a calibrated measuring cylinder and a stopwatch
positioned at the outlet of heat exchanger. The mean mass ow rates of
shell-side and coil-side are 0.024, 0.05, 0.09 and 0.113 kg/s respectively.
These mass ow rates are selected according to the outlet mass ow
rate of a solar collector working in SDHW system [7].
The coil was formed carefully by using 9.52 and 12.5 mm OD
straight copper tubing. Care was taken to locate the coil into the
middle of the circular space between inner and outer shells of heat
exchanger. The specication of heat exchanger is shown in Table 1.
Temperatures were measured by four K-type thermocouples placed
at equally distanced locations in order to measure the coil surface and
the uid temperature. Four other thermocouples were located at inlets
and outlets of heat exchanger to measure the temperatures of the hot
and cold uids. A data acquisition device made by Advantech model USB
4718 having a capacity of 8 analog input channels was used to record all
temperature measurements. All tests were performed under steadystate conditions. A Visual Basic code was written to retrieve and store

Fig. 2. Temperature distribution for coil #1.

Fig. 3. Temperature distribution for coil #2.

Fig. 4. Temperature distribution for coil # 4.

temperature data and to perform calculations. The data acquisition


system scanned and stored data every 5 s and the measured values
were averaged over a period of 4 min. As with report of every experimental research, the analysis of the experimental uncertainties in
calculating the results must be given proper attention. The method
proposed by Kline and McClintock [19] seems to be widely accepted
among the authors of technical papers. The uncertainty in calculating
the major heat transfer and hydraulic parameters were evaluated based
on the mentioned method. The results are reported in Table 2.
3. Results and discussion
Figs. 24 show typical temperature distributions inside the heat
exchanger for xed inlet conditions(Rm 1 and Th,i = 80 C). In all
graphs of the axial temperature prole, the zero value on the abscissa
corresponds to the bottom of the exchanger whereas the value of one
indicates the top. The axial temperature prole is very close to linear
(R2 = 0.97) for all graphs.
Figs. 57 show typical temperature distributions inside the heat
exchanger for xed inlet conditions(Rm 0.21 and Th,i = 80C). The

Fig. 5. Temperature distribution for coil #1.

Fig. 6. Temperature distribution for coil #2.

N. Ghorbani et al. / International Communications in Heat and Mass Transfer 37 (2010) 775781

Fig. 7. Temperature distribution for coil #4.

axial temperature prole of the coil surface is far from being linear for
those gures. This deviation from a linear prole is inuenced by the
mass ow rate ratio. The nonlinearity is such that the proles tend to be
concave up, which means that the coil surface temperature is higher
than usual at the top and then it drops faster than usual while moving
towards the bottom of the heat exchanger. The value of Rm 1 seems to
be the critical point. For Rm signicantly less than unity the curves
deviate greatly from being linear whereas the curves are close to a
straight line for Rm 1. The linear temperature prole means that the
shell-side heat transfer coefcient is constant along the axis of the heat
exchanger. There is a notable drop in coil surface temperature. The
curves suggest that the shell-side heat transfer coefcient is no longer
constant. Since it is reasonable to assume that the heat ux is uniform,
the product (hoT) is constant along the coil surface. Therefore a
smaller temperature difference means a higher ho value. The magnitude
of ho starts from a low value at the top and gradually increases to
its highest value at the bottom of the heat exchanger. Obviously this
situation is not desirable since the hot stream forfeits its heat very
quickly and therefore the heat exchanger does not operate at its full

Fig. 10. Temperature distribution for coil #4.

capacity. It can be concluded that for such a low shell-side mass ow


rate, the heat exchanger is oversized in terms of the surface area.
Figs. 810 show typical temperature distributions inside the heat
exchanger for xed inlet conditions(Rm 4.7 and Th,i = 80 C). The
axial temperature prole of the shell-side water is far from being
linear for those gures. In these cases, the proles tend to be concave
down as opposed to the trend in Figs. 57. It can be seen that as the
mass ow rate ratio changes, the temperature prole changes from an
initially concave-up prole to concave-down one. In other words the
coil surface is colder than usual at the top part and its temperature
gradually decreases until it reaches its lowest value at the bottom of
heat exchanger.
The logarithmic mean temperature difference (LMTD) decreases
as the mass ow rate ratio increases for each heat ux. This is evident
from Fig. 11 which is typical of the behavior of LMTD. Also it is seen
that for a xed value of Rm, the effect of increased heat rate is to
increase the value of LMTD. Also each individual curve experiences a
attening effect as the mass ow rate ratio increases, especially for

Fig. 11. LMTD versus Rm for different heat transfer rates.


Fig. 8. Temperature distribution for coil #1.

Fig. 9. Temperature distribution for coil #2.

779

Fig. 12. Modied effectiveness for all test congurations.

780

N. Ghorbani et al. / International Communications in Heat and Mass Transfer 37 (2010) 775781

lower rates of heat transfer. In other words, further increment of the


tube-side mass ow rate, when the heat rate is relatively low, will not
decrease the value of LMTD further. This implies that the combination
of low heat rate and high tube-side mass ow rate will not result in an
increase of overall conductance of heat exchanger (UA) value.
Therefore the extra electrical power utilized by the tube-side loop
pump has not brought any extra performance to the heat transfer
process. This once again points to the existence of an optimum value
for shell-side mass ow rate as stated by Hollands and Brunger [16].
In Fig. 12 the modied effectiveness as dened by Eq. (1) is plotted
as a function of the mass ow rate ratio.
=

Th;i Tc;o
Th;i Tc;i

As can be seen in Fig. 12, the slope of the curve falls rapidly as the
value of the corrected mass ow rate increases. For all mass ow rate
ratios less than unity, a slight decrease will result in a considerable
improvement of heat exchanger effectiveness, while for values larger
than 2 the modied effectiveness remains nearly unchanged. This
means that for a certain heat exchanger, increment of tube-side mass
ow rate will always downgrade the effectiveness.
The data can be correlated by a simple power equation. Eq. (2) is
recommended for predicting the effectiveness of heat exchanger in
the range of Rm from 0.33 to 5.

= 0:4744

m s
m c

0:4627
2

The tube diameter has little effect on the modied effectiveness


since it does not appear in Eq. (2). This equation indicates that is a
strong function of the mass ow rate ratios. The shell-side water mass
ow rate has a favorable effect and tube-side mass ow rate has an
adverse effect on the modied effectiveness of the heat exchanger.
Physically, more shell-side water ow means more heat extracted
from the hot stream and therefore a greater temperature fall in that
stream which translates into better effectiveness. On the contrary,
more tube-side mass ow rate leads to less temperature fall in the hot
stream and consequently worsens the effectiveness of the heat
exchanger. The two mass ow rates, therefore act against each other
with the same strength.
Using the denition of the modied effectiveness and Eq. (2), one
can easily derive equations for predicting the tube-side and shell-side
outlet temperature.

Th;o = Th;i 0:4744

m s
m c

Tc;o = Tc;i + 0:4744

cp;c
cp;s

0:4627 

m c
m s

Th;i Tc;i

0:5373 

Th;i Tc;i

Fig. 13. Comparison of effectiveness data with standard heat exchanger congurations.


 0:8 h
i
D
Dt
0:8 0:4
Nui = 1 + 3:6 1 t
0:0023Rei Pri
Dc
Dc

In order to establish the effectivenessNTU relations for the shelland-coil heat exchangers, the data was plotted together with the plots
for some standard congurations in Fig. 13. As it could be observed in
Fig. 13, the NTU relationship for parallel and counter-ow
concentric tube heat exchangers, cross ow with both uids unmixed
and cross ow with the Cmin uid mixed are plotted for the case
Cr = 0.5 as an average value. In addition, for the sake of comparison
the general NTU for all heat exchangers with Cr = 0 has also been
presented in the same gure.
From Fig. 13 the effectiveness of the parallel-ow concentric tube
heat exchanger is the lowest of all and is far below the values observed
in current experiments. The case of Cr = 0 would over predict the
effectiveness if used for the current case. This case can be attributed to
the situation where the ow rate of one of the uids is so small that it
can be considered stagnant. If the relationship of the cross-ow type
heat exchanger with one of the uids mixed is used for current
situation, the data would be under predicted and therefore the
relationship is not suitable. Two cases that can closely predict the data
are the cross ow with both uids unmixed and the counter-ow
concentric tube heat exchangers. Among them, the counter-ow
conguration is closest in reality and also on the graph. In order to
double check this observation, Fig. 14 must be considered.

In general, the inlet temperatures are known, thus making the


prediction of the outlet temperatures possible by using Eqs. (3) and (4).
According to the research by Srinivasan et al. [1], the critical
Reynolds number for the helical pipe ow, which determines the ow
is laminar or turbulent, is related to the curvature ratio as follows:
h

i
d
0:5
Recrit: = 2100 1 + 12 =D

To calculate the Nusselt number for the laminar and turbulent


regimes, Eqs. (6) and (7) are used respectively [3,4]:
20
!3
!3 = 31 =
3
2
51 =
48
He
11
5
+
Nu = 4@
+ 1:816
1342
1:15
11
1 + PrHe2
1 + Pr

Fig. 14. The effectivenessNTU data compared with the counter-ow concentric tube
heat exchanger for different values of Cr.

N. Ghorbani et al. / International Communications in Heat and Mass Transfer 37 (2010) 775781

In Fig. 14, the results of the current experiment are compared with
the standard counter-ow relations for different Cr values of 0.2, 0.5
and 0.8. It can be resulted that the current data are reasonably
correlated by counter-ow relations. In conclusion, it is suggested to
use the NTU relations of counter-ow heat exchanger to predict
the effectiveness of the mixed convection shell-and-coil heat
exchangers and also for design purposes. The standard counter-ow
relation, taken from Kays and London [20] is reproduced here as
Eq. (8):
=

1 expNTU 1Cr 
:
1Cr expNTU 1Cr 

4. Conclusions
In the present study, an experimental investigation of the mixed
convection heat transfer in helically coiled tube heat exchanger, as
one of the most applicable compact heat exchangers is reported. The
mass ow rate of tube-side to shell-side ratio (Rm) was found to be
effective on the axial temperature proles of heat exchanger. The
results indicate that for Rm greater than unity, the temperature
proles were of quadratic form from bottom to top of the heat
exchanger. The proles were linear for Rm close to unity and when the
mass ow rate ratio was considerably less than unity, the temperature
proles were of the logarithmic form. With increasing mass ow rate
ratio the logarithmic mean temperature difference was decreased.
The modied effectiveness decreased with increasing mass ow rate
ratio. An equation was found to correlate the modied effectiveness
data to the mass ow rate ratio for 0.15 b Rm b 5. The NTU relation
of the mixed convection heat exchangers was same to those of a pure
counter-ow heat exchanger.
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