HEAT TRANSFER AND FRICTION FACTOR

CHARACTERISTICS OF VARIENT TWISTED TAPE

FITTED IN A DOUBLE PIPE HEAT EXCHANGER
A PROJECT REPORT

Submitted by

GOKULRAJ P 731616114017
JAYAMURUGAN K S 731616114027
KALEESWARAN D 731616114032
MOHANAKRISHNAN D 731616114049

in partial fulfillment for the award of the degree

of

BACHELOR OF ENGINEERING

In

MECHANICAL ENGINEERING

KSR INSTITUTE FOR ENGINEERING AND TECHNOLOGY

TIRUCHENGODE – 637 215

ANNA UNIVERSITY :: CHENNAI 600 025

MAY 2020
 ANNA UNIVERSITY : CHENNAI 600 025

BONAFIDE CERTIFICATE

Certified that this project report “HEAT TRANSFER AND FRICTION

CHARACTERISTICS OF VARIENT TWSITED FITTED IN A DOUBLE
PIPE HEAT EXCHANGER” is bonafide work of “GOKULRAJ P,
JAYAMURUGAN K S, KALEESWARAN D, MOHANAKRISHNAN D”
who carried out the project under my supervision.

SINGNATURE SINGNATURE
Dr. P.MURUGESAN, ME., Ph.D., Mr.R.VASANTHAKUMAR, ME.,
HEAD OF DEPARTMENT, SUPERVISOR,
Professor, Assistant Professor,
Department of Mechanical Engineering, Department of Mechanical Engineering,
KSR Institute for Engineering and KSR Institute for Engineering and
Technology, Technology,
Tiruchengode – 637 215 Tiruchengode – 637 215

Submitted for the Project report Viva-Voce Examination held on_____________

INTERNAL EXAMINER EXTERNAL EXAMINER

ii
 ACKNOWLEDGEMENT

We sincerely acknowledgement offering our word of thanks and gratitude to

the management and our beloved Founder and Chairman of our college Lion Dr.
K.S. RANGASAMY MJF, who provided all the facilities to us.

We would like to express our special gratitude and thanks to our beloved Vice
chairman Thiru. R. SRINIVASAN B.B.M, who provided all opportunity to do our
project.

We would like to express our sincere thanks to our Principal Dr. M.

VENKATESAN M.E., Ph.D., for forwarding us to do our project and offering
adequate duration in completing the project.

We are grateful to our Head of the Department, Department of Mechanical

Engineering Dr. P. MURUGESAN M.E., Ph.D., for his constructive suggestions
& encouragement during our project.

We wish to express our sincere and heartfelt thanks to our guide Mr. R.
VASANTHAKUMAR M.E., Assistant professor for his valuable guidance, support
and ideas throughout the entire work of our project.

We wish extend our sincere thanks to all faculties of our Mechanical

Engineering Department for their valuable suggestions, kind co-operation and
constant encouragement for successful completion of this project.

iii
 ABSTRACT

Heat exchanger is an important device which is widely used equipment in

different industries such as process, petroleum refining, chemicals, oil industries,
power plant and paper etc. Energy and material saving considerations as well as
environmental challenges in the industry have stimulated the demand for high
efficiency heat exchanger. To improve the efficiency of heat exchanger one must
think of heat transfer enhancement in heat exchanger.
Moreover, heat transfer enhancement enables the size of heat exchanger to be
considerably decreased. A high rate of heat transfer with minimum space
requirement is necessity for compact heat exchanger. The counter flow heat
exchanger is improving the heat transfer characteristic of the double pipe heat
exchanger is comparatively normal plain tube & plain twisted tape insert is used
improve the efficiency. To check the temperature difference in varying hot water
flow rates and predicts the Nusselt number, Reynolds number and Friction factor.
Furthermore, compare and select the best method of double pipe heat exchanger.
Simultaneously, validating the computational fluid dynamics in Ansys software.

iv
 TABLE OF CONTENTS

Chapter TITLE Page

No. No.
ABSTRACT iv
LIST OF TABLES vii
LIST OF FIGURES viii
1. INTRODUCTION 1
1.1 HEAT EXCHANGE METHOD 2
1.1.1 Direct heating systems 2
1.1.2 Indirect heating systems 2
1.1.2.1 Plate heat exchanger 3
1.1.2.2 Tubular heat exchangers 3
1.1.2.3 Scraped-surface exchangers 4
1.2 BASED ON FLUID ARRANGEMENT 5
1.2.1 Counter flow 5
1.2.2 Parallel flow 5
1.2.3 Cross flow 6
2. LITERATURE REVIEW 7
3. WORKING METHODOLOGY 10
4. PROBLEM IDENTIFICATION & TWISTED TAPE 11
INSERTS
4.1 PROBLEM IDENTIFICATION 11
4.2 TWISTED TAPE INSERTS 11
4.2.1 Benefits of Twisted Tape Inserts 11
5. MATERIAL SELECTION 13

v
 5.1 MATERIAL PROPERTIES 13
5.2 MILD STEEL MATERIAL 13
5.2.1 Uses of mild steel 14
5.3 COPPER MATERIAL 14
5.3.1 Types of Copper 15
5.4 ALUMINIUM MATERIAL 15
5.5 HOT & COLD-WATER PROPERTIES 16
6. EXPERIMENTAL INVESTIGATION SETUP AND 17
PROCEDURE
6.1 EXPERIMENTAL PROCEDURE 19
7. ANALYSIS OF DOUBLE PIPE HEAT EXCHANGER 20
7.1 INTRODUCTION OF FEM 20
7.1.1 FEA Works 20
7.1.2 Advantages of FEA Software 21
7.2 COMPUTATIONAL FLUID DYNAMICS 21
7.2.1 Performing a CFD Analysis 21
7.3 Plain Tube Analysis 22
7.4 Plain Twisted Tape Analysis 24
8. RESULT & DISCUSSION 26
8.1 Plain Tube 27
8.2 Twisted Tape 29
9. MODEL CALCULATION 31
10. CONCLUSION 35
REFERANCES 37
CONFERENCES
JOURNAL

vi
 LIST OF TABLES

Table TITLE Page

No. No.
5.1 Material Property 13
5.2 Hot & Cold-Water Properties 16
6.1 Experimental Setup Dimension 18
8.1 Overall Plain Tube Experimental Reading 27
8.2 Overall Plain Tube Analysis Reading 27
8.3 Overall Plain Twisted Tape Experimental Reading 29
8.4 Overall Plain Twisted Tape Analysis Reading 29
10.1 Comparative overall reading 35

vii
 LIST OF FIGURES

Figure TITLE Page

No. No.
1.1 Counter Flow Heat Exchanger 1
1.2 Plate heat exchangers 3
1.3 Tubular heat exchangers 4
1.4 Scraped-surface exchangers 4
1.5 Counter Flows 5
1.6 Parallel Flows 5
1.7 Cross Flows 6
5.1 Mild Steel Material 14
5.2 Copper Materials 14
5.3 Aluminium materials 16
6.1 Normal Plain Tube 17
6.2 Plain Twisted Tape Insert 17
6.3 Experimental setup of Double pipe heat exchanger 18
7.1 FEA works 20
7.2 Performing a CFD Analysis 22
7.3 Plain Tube Model in Ansys 22
7.4 Plain Tube Meshing in Ansys 23
7.5 Plain Tube Temperature Difference 23
7.6 Plain Twisted Tape Model in Ansys 24
7.7 Plain Twisted Tape Meshing in Ansys 24
7.8 Plain Twisted Tape Temperature Difference 25
8.1 Comparison of Plain Tube Nusselt Number 28

viii
8.2 Comparison of Plain Twisted Tape Nusselt Number 30
10.1 Comparison Overall Nusselt Number 36
10.2 Comparison of Friction Factor 36

ix
 CHAPTER 1

INTRODUCTION
The double pipe heat exchanger could be a method to simplify to exchange
heat b/w two fluids while not mixing at different temperature. In heat exchanger
two kinds of heat transfer happens like convection & conduction. Typically,
convection happens in each operating fluids & conduction through walls of heat
exchanger that separates the fluids.
The heat transfer coefficient improvement capability beside a minimum
loss in friction factor defines the inserts. Tube inserts are utilised for heat transfer
improvement in different industrial fields like fossil fuel refineries and chemical
plants of several years.
There may be several different flow patterns for a heat exchanger.
Common types of heat exchangers are counter flow, parallel flow, and cross flow.
The most effective flow method of the three is a counter flow heat exchanger.
A counter flow heat exchanger is the warm fluid that enters at one end of
the heat exchanger and the cold fluid that exits at the same end of the flow path.
Counter flow is the most popular type of fluid to fluid heat exchanger, since it is
the most effective type.

Fig. 1.1 Counter Flow Heat Exchanger

1
1.1 HEAT EXCHANGE METHOD
1.1.1 Direct heating systems
Direct systems have the advantage that the product is held at a high
temperature for a shorter period of time, thereby reducing the thermal damage for
the sensitive products such as milk. There are two groups of direct systems:
 Injection-based, where the high-pressure steam is injected into the
liquid, it allows fast heating and cooling, but is only suitable for
some products. As the product comes in contact with the hot nozzle,
there is a possibility of local overheating.
 Infusion-based, where the liquid is pumped through a nozzle into a
chamber with high-pressure steam at a relatively low concentration,
providing a large surface contact area, this method achieves near-
instantaneous heating and cooling and even distribution of
temperature, avoiding local overheating. It is suitable for liquids of
both low and high viscosity.
1.1.2 Indirect heating systems
In indirect systems, the product is heated by a solid heat exchanger similar
to those used for pasteurization. However, as higher temperatures are applied, it
is necessary to employ higher pressures in order to prevent boiling. There are
three types of exchangers in use:
 Plate exchangers,
 Tubular exchangers
 Scraped-surface exchangers
For higher efficiency, pressurized water or steam is used as the medium for
heating the exchangers themselves, accompanied with a regeneration unit which
allows reuse of the medium and energy saving.

2
1.1.2.1 Plate heat exchanger
A plate heat exchanger is a type of heat exchanger that uses metal plates to
transfer heat between two fluids. This has a major advantage over a conventional
heat exchanger in that the fluids are exposed to a much larger surface area because
the fluids are spread out over the plates. This facilitates the transfer of heat, and
greatly increases the speed of the temperature change. Plate heat exchangers are
now common and very small brazed versions are used in the hot-water sections
of millions of combination boilers. The high heat transfer efficiency for such a
small physical size has increased the domestic hot water (DHW) flow rate of
combination boilers. The small plate heat exchanger has made a great impact in
domestic heating and hot-water. Larger commercial versions use gaskets between
the plates, whereas smaller versions tend to be brazed.

Fig. 1.2 Plate heat exchangers

1.1.2.2 Tubular heat exchangers
These exchangers are generally built of circular tubes, although elliptical,
rectangular, or round/flat twisted tubes have also been used in some applications.
There is considerable flexibility in the design because the core geometry can be
varied easily by changing the tube diameter, length, and arrangement. Tubular
exchangers can be designed for high pressures relative to the environment and
high-pressure differences between the fluids.

3
 Tubular exchangers are used primarily for liquid-to-liquid and liquid-to-
phase change (condensing or evaporating) heat transfer applications. They are
used for gas-to-liquid and gas-to-gas heat transfer applications primarily when
the operating temperature and/ or pressure is very high or fouling is a severe
problem on at least one fluid side and no other types of exchangers would work.
These exchangers may be classified as shell-and tube, double-pipe, and spiral
tube exchangers. They are all prime surface exchangers except for exchangers
having fins outside/inside tubes.

Fig. 1.3 Tubular heat exchangers

1.1.2.3 Scraped-surface exchangers
The dynamic scraped surface heat exchangers incorporate an internal
mechanism which periodically removes the product from the heat transfer wall.
The product side is scraped by blades attached to a moving shaft or frame. The
blades are made of a rigid plastic material to prevent damage to the scraped
surface.

Fig. 1.4 Scraped-surface exchangers

4
1.2 BASED ON FLUID ARRANGEMENT
 Counter flow
 Parallel flow
 Cross flow
1.2.1 Counter Flow
A counter flow heat exchanger is one in which the direction of the flow of
one of the working fluids is opposite to the direction to the flow of the other fluid.
In a parallel flow exchanger, both fluids in the heat exchanger flow in the same
direction. The counter flow heat exchanger has three significant advantages over
the parallel flow design.

Fig. 1.5 Counter Flows

1.2.2 Parallel flow
A counter flow heat exchanger is one in which the direction of the flow of
one of the working fluids is opposite to the direction to the flow of the other fluid.
In a parallel flow exchanger, both fluid in the heat exchanger flow in the same
direction

Fig. 1.6 Parallel Flows

5
1.2.3 Cross flow
A cross flow heat exchanger exchanges thermal energy from one airstream
to another in an air handling unit (AHU). A cross flow heat exchanger is used in
a cooling and ventilation system that required heat to be transferred from one
airstream to another.

Fig. 1.7 Cross flow

6
 CHAPTER 2

LITERATURE REVIEW
Pragneshkumar Prajapati et al. (May 2016), large difference was
observed in Nusselt Number between the plain tube and in the heat exchanger
with twisted tape insert. The heat transfer improved by 22% to 33% in
temperature outlet at various Reynolds numbers with using inserts at y=45 and
heat transfer improved by 15% to 45% at various Reynolds number by using
inserts at y=15. So, it’s increase of pressure drop is more by using y=15
geometrical spacing pentagonal shape inserts in cold pipe of concentric tube type
heat exchanger compared to plane tube presented by Kanika Joshi et al. (May
2017).
Kalapala Lokesh et al. (May 2017), the more efficient the twisted tape
insert setup is because the twisted tape creates turbulence in the region where the
hot fluid flows. Through inserting twisted tapes, an improvement of about 30
percent in output is observed at low mass flow rates. The DPHE with various
angles of fins to research in the heat exchanger flow and temperature, Attempts
have been made to investigate the effects and heat transfer characteristics of
DPHE for six different fine inclinations: 0°, 5°, 10°, 15°, 20° and 25°. The heat
transfer rate is better for 20° helical fins in double pipe heat exchanger to say
Bandu et al. (Aug 2017).
Vijaya sagar & Appalanaidu (Aug 2017), The friction factor of 0.4%
ZnO Nano fluid flowing in a tube with H / D=3 twisted tape configuration
increases 12.16% at a Reynolds number of 3000 and 15.32% at a Re of 8000
compared to the same concentration liquid without warped tape inserts. The CFD
predictions match the experimental results within the limits of experimental
errors reasonably well. A correlation has been developed based on the results to
calculate the helical coil's internal heat transfer coefficient. Based on the
confidence gained in the predictions of the CFD, the results obtained under

7
different conditions can be further used to obtain a generalized correlation
applicable to different coil configurations developed by Jayakumar et al. (Oct
2017).
Yamini Pawar & Ashish Sarode (Dec 2017), the experimental
comparison of coils with circular diameter coil against coil with notches it was
also noted that inside Nu, heat transfer coefficient, Dean number these parameters
increases by 3.75% and hence here prove that coil with notches are superior than
simple circular tube coils. The heat transfer rate for helical wire insert rises to
74.7 percent. The rise for the twisted clip is 57.5 percent and for the corrugated
tube is 20.2 percent. For helical wire attachment, the overall heat transfer
coefficient increases to 95%. This increase for the twisted clip is 56.5 percent and
for the corrugated tube is 33 percent. For helical wire insert, which is 0.55 to say
the Deepak Sen & Alka Agrawal (Jan 2018), the Effectiveness quality is
optimum.
Sivasubramaniam Arthanari Ponnusamy , Mayilsamy Kavandappa
Goundar, Murugesan Perumal (Nov 2019), Nusselt numbers for the plain tube
fitted with Plain Tape (PT),Plain Tape Step Cut Arc (PT- SCA) and Plain Tape
Step Cut Rectangle (PT-SCR) are.056, 1.288& 1.460 times greater than that of
plain tube respectively. Friction factors in the tube with Plain Tape (PT), Plain
Tape Step Cut Arc (PT-SCA) and Plain Tape Step Cut Rectangle (PT-SCR) are
1.742, 2.537& 2.884 times higher than plain tube respectively. The thermal
enhancement factor (TEF) for the Plain Tape (PT), Plain Tape Step Cut Arc (PT-
SCA) and Plain Tape Step Cut Rectangle (PT-SCR) are 1.063, 1.236 & 1.382
times greater than that of plain tube. From the experimental results, it can be
concluded that the thermal enhancement factor (TEF) for the Plain Tape Step Cut
Rectangle (PT-SCR) is 23.08% higher than that of plain tube and the Plain Tape
Step Cut Rectangle (PT-SCR) insert gives the most improved performance in the
Double pipe heat exchanger compared to other profiles.

8
 Harsh Ladani et al. (April 2018), Through the use of finned tube, the
heat transfer rate and efficiency are low due to temperature reduction and pressure
drop in the heat exchanger. In the new model type heat exchanger is increased
over all heat transfer rate and also the heat exchanger's efficiency for circular fins
is increased by 4%-6%. The efficiency of the double pipe heat exchanger for
helical fine and Nano fluid is also increased by 12%-16%. It is also observed that
there is enhancement in heat transfer using helical and circular fin. The twist of
the internal tube was added from one to three turns; an increase up to 3% in the
Nusselt number was calculated. The biggest increase, up to 9% was calculated
when five turns were simulated to develop the Miyer Valdes et al. (May 2019).
Kola David & Abhishek kumar (May 2019), When we compare the
different geometries of radiator the helical type tube is the better model because
the heat transfer rate value is more for helical type tube radiator is better model.

9
 CHAPTER 3

WORKING METHODOLOGY

Need & Planning

Problem Identification

Material Selection

Double Pipe Heat Exchanger

(Experimental Setup & Analysis)

Normal DPHE Twisted Tape Insert

Comparative Varying Air

Flow Rates

Result & Comparison

Conclusion

10
 CHAPTER 4
PROBLEM IDENTIFICATION & TAPE INSERTS

4.1 PROBLEM IDENTIFICATION

The double pipe heat exchanger is already developed technology for quick
response of heat transfer. This method of heat transfer provided better results and
suitable for few applications in large scale industries. The advantages technology
should be applicable for all sectors to reduce the investment. So, the present work
has been processed under this area to improved heat transfer efficiency.

4.2 TWISTED TAPE INSERTS

A tape insert modifies flow stream characteristics to enhance heat transfer.
Here’s how to choose the optimal insert to meet process requirements.
Tape inserts are useful tools that improve tube side performance in heat
exchangers. Inserts are used for applications in which tube side heat transfer is
thermally limiting and an increase in pressure drop is allowed. The best insert
type and design for a particular application depends on flow conditions and fluid
properties.
Tape inserts can help increase heat transfer in environments with slow-
moving viscous fluids and a low Reynolds number.

4.2.1 Benefits of Twisted Tape Inserts

The use of tape inserts as a “process intensification” device makes them
widely accepted in the use of area reduction, and as such most practical design
examples will offer comparisons of the heat transfer area reduction (and often
reduction in number of shells) resulting from the use of a particular enhancement
technique. Whilst this section considers area reduction in most detail, due
primarily to the fact that it is a simple and accessible measure of insert

11
performance, the other principal design objectives (which are as appropriate to
retrofitting as they are to design from scratch) should be considered as a benefit
of twisted tape heat transfer enhancement. Apart from those already identified,
the use of twisted tape inserts may result in other benefits, including improved
plant control and fouling mitigation, both of which shall be considered in this
section.

12
 CHAPTER 5
MATERIAL SELECTION

5.1 Material Properties

Table 5.1 Material Property
Description Steel Copper Aluminium
Density (kg/m3) 8030 8978 2719
Specific Heat (j/kg K) 502.48 381 871
Thermal Conductivity
16.27 387.6 202.4
(w/m K)

5.2 Mild Steel Material

Galvanized steel was the standard piping material for water and wastewater
transport in the piping sector. This technology provided the metal pipe with a
reasonable level of internally and externally protection. This pipe used to cold
water flow in the process.
Mild steel contains approximately 0.05–0.25% carbon making it malleable
and ductile. Mild steel has a relatively low tensile strength, but it is cheap and
easy to form; surface hardness can be increased through carburizing.
Mild steel is very strong due to the low amount of carbon it contains. In materials
science, strength is a complicated term. Mild steel has a high resistance to
breakage. Mild steel, as opposed to higher carbon steels, is quite malleable, even
when cold.
The most important properties of steel are great formability and durability,
good tensile and yield strength and good thermal conductivity. As well as these
important properties the most characteristic of the stainless-steel properties is its
resistance to corrosion.

13
 Fig. 5.1 Mild Steel Material

5.2.1 Uses of mild steel

The major downside to mild steel is that it has a relatively low tensile
strength, meaning it'll break more easily under tension than other steels. Mild
steel has a relatively low tensile strength, but it is cheap and easy to form; surface
hardness can be increased through carburizing. That is why mild steel
called as mild or low carbon steel.
5.3 Copper Material
Copper tubing is almost widely used in hot and cold-water supply and as a
heat exchanger line. Furthermore, high thermal conductivity in the copper, it’s
used in the hot water flow process and Helical fins.
Copper tubing is most often used for the supply of hot and cold tap water,
and as a refrigerant line in HVAC systems. There are two basic types of copper
tubing, soft copper and rigid copper. Copper tubing is joined using flare
connection, compression connection, or solder. Copper offers a high level of
corrosion resistance but is becoming very costly.

Fig. 5.2 Copper Materials

14
5.3.1 Types of Copper
Soft copper
Soft (or ductile) copper tubing can be bent easily to travel around obstacles
in the path of the tubing. While the work hardening of the drawing process used
to size the tubing makes the copper hard or rigid, it is carefully annealed to make
it soft again; it is therefore more expensive to produce than non-annealed, rigid
copper tubing. It can be joined by any of the three methods used for rigid copper,
and it is the only type of copper tubing suitable for flare connections. Soft copper
is the most popular choice for refrigerant lines in split-system air conditioners and
heat pumps.
Rigid copper
Rigid copper is a popular choice for water lines. It is joined using a
solder/sweat, roll grooved, compression or crimped/pressed connection. Rigid
copper, rigid due to the work hardening of the drawing process, cannot be bent
and must use elbow fittings to go around corners or around obstacles. If heated
and allowed to cool in a process called annealing, rigid copper will become soft
and can be bent / formed without cracking.
5.4 Aluminium Material
To improve the temperature in the tube aluminium inserts with flat plate
profile are inserted into the copper tube.
Aluminium is the world’s most abundant metal and does the third most
common element comprise 8% of the earth’s crust. The versatility of aluminium
makes it the most widely used metal after steel. Aluminium is a chemical element
with the symbol Al and atomic number 13. It is a silvery-white, soft, non-
magnetic and ductile metal in the boron group. ... The chief ore of aluminium is
bauxite. Aluminium is derived from the mineral bauxite. Bauxite is converted
to aluminium oxide (alumina) via the Bayer Process. The alumina is then
converted to aluminium metal using electrolytic cells and the Hall-Heroult
Process.

15
 Aluminium is most commonly alloyed with copper, zinc, magnesium,
silicon, manganese and lithium. Small additions of chromium, titanium,
zirconium, lead, bismuth and nickel are also made and iron is invariably present
in small quantities.
Worldwide demand for aluminium is around 29 million tons per year.
About 22 million tons is new aluminium and 7 million tons is recycled aluminium
scrap. The use of recycled aluminium is economically and environmentally
compelling. It takes 14,000 kWh to produce 1 tonne of new aluminium.
Conversely it takes only 5% of this to recycle one tonne of aluminium. There is
no difference in quality between virgin and recycled aluminium alloys.

Fig. 5.3 Aluminium materials

5.5 Hot & Cold-Water Properties
Table 4.2 Hot & Cold-Water Properties
Cold Water Hot Water
Description
(30 ℃) (50 ℃)
Density (kg/m3) 997.5 990
Specific Heat (j/kg K) 4178 4180.5
Thermal Conductivity (w/m K) 0.6129 0.63965
Viscosity (kg/m s) 8.315e-7 5. 675e-7

16
 CHAPTER 6

EXPERIMENTAL INVESTIGATION SETUP AND PROCEDURE

A set of the experiments were carried out to investigate the turbulent flow
and heat transfer behavior in a double pipe counter water flow heat exchanger
with twisted tape on the inner tube.
The entire experimental setup model is one by one graphically represented
by Fig. 6.1, 6.2 & 6.3.

Fig. 6.1 Normal Plain Tube

Fig. 6.2 Plain Twisted Tape Insert

17
 Fig. 6.3 Experimental setup of Double pipe heat exchanger

The DPHE has selected according to the parameters taken as shown below.
The inner pipe, outer pipe and insert are available in market for that material as
well as its dimensions.
Table 6.1 Experimental Setup Dimension
Parameters Inner pipe Outer pipe Plain tape
Materials Copper Galvanised iron Aluminium
Length 2000 2000 2000
Inner diameter 25mm 52.5mm -
Outer diameter 28.5mm 60.3mm -
Width - - 23mm
Thickness 3.5mm 3.91mm 3mm

18
6.1 EXPERIMENTAL PROCEDURE

 The cold water and hot water mass flow rate is 10 LPM and 1.5 LPM
to 8 LPM respectively.
 The constant cold-water mass flow rate at 10LPM for each and every
experimental procedure.
 Check one as heat balance on the heat transfer between hot and cold
pipe.
 Measure the inlet, outlet temperatures of hot and cold water (Th1, Th2,
Tc1, and Tc2).
 Calculate the overall heat transfer coefficient, Nusselt number,
Reynolds number and thermal enhancement factor for plain tube and
with plain tape & plain twisted tape.
 Graphically the relationship between Reynolds number, Nusselt
number and thermal enhancement factor with experimental and
predicted under turbulent flow.

19
 CHAPTER 7
ANALYSIS OF DOUBLE PIPE HEAT EXCHANGER
7.1 INTRODUCTION OF FEM
The FEM is a mathematical performance for outcome nearby experimental
solutions to various computational domains. Numerical analysis done using FEM
is commonly mentioned as a finite element analysis (FEA). Typical FEA
applications consist of structural, thermal, electromagnetic and fluid field
problems. Engineers usage it to decrease the several physical models & tests &
optimize components in their design segment to improve better products, quicker.
ANSYS is preferred-purpose FEA software. FEA is a mathematical
method of discretizing a complicated design into very small pieces (of user-
specific length) known as factors. The software Implements equations that govern
the performance of these factors and solves all of them growing a comprehensive
clarification of how the device acts as an entire. Those consequences can be
supplied in tabulated or graphical forms.
7.1.1 FEA Works
FEA as useful in engineering possibly will be a machine tool for
performance arts engineering analysis. It consists of the operation of mesh
creation techniques for dividing a difficult problem into tiny parts, moreover
because of the use of software package program coded with FEM rule.

Fig. 7.1 FEA works

20
7.1.2 Advantages of FEA Software
 It reduces the amount of prototype testing, thereby saving the cost & time.
 It gives the graphical representation of the outcome of the analysis.
 The finite element modeling & analysis are performed in the pre-processor
& solution phases, which if done manually would consume a lot of time &
in some cases, might be impossible to perform.
 It helps optimize a design.
Purpose of the Mesh
 Equations area unit resolved at cell/nodal locations
 The domain is needed to be divided into separate cells (meshed)
Mesh Requirements
 Efficiency & Accuracy
 Refine (smaller cells) for high solution gradients & fine geometric detail.
 Coarse mesh (larger cells) elsewhere.
7.2 COMPUTATIONAL FLUID DYNAMICS
Computational fluid dynamics (CFD) is the numerical analysis of fluid
flow, heat transfer, and related phenomena. CFD solvers contain a complex set
of algorithms used for modeling and simulating the flow of fluids, gases, heat,
and electric currents. Many technological advances in aeronautics, automobiles,
and space would not be possible without CFD. Applications such as aerofoil
design in aeronautics drag simulation in automobile design, jet and thermal flow
in engine design, and cooling airflow in an electronic product use the CDF
methodology.
7.2.1 Performing a CFD Analysis
It is done in three stages: pre-processing, processing and post processing.
In pre-processing step, all the tasks that take place before the numerical solution
process, this includes problem thinking, meshing and generation of a
computational model. Processing involves using a computer to solve
mathematical equations of fluid flow. This is a very intensive process and usually

21
it requires the computer to solve many thousands of equations. In each case, the
equations are integrated and boundary conditions are applied to it. In post-
processing step, this program is used to make evaluation of the data generated by
CFD analysis. When the model has been solved, the results can be analysed both
numerically and graphically.
 FLUENT solvers are based on the finite volume method.
 Domain is discretized into a finite set of control volumes or cells.

Fig. 7.2 Performing a CFD Analysis

7.3 Plain Tube Analysis
Model

Fig. 7.3 Plain Tube Model in Ansys

22
Meshing

Fig. 7.4 Plain Tube Meshing in Ansys

Temperature Difference in Plain Tube

Fig. 7.5 Plain Tube Temperature Difference

23
7.4 Plain Twisted Tape Analysis
Model

Fig. 7.6 Plain Twisted Tape Model in Ansys

Meshing

Fig. 7.7 Plain Twisted Tape Meshing in Ansys

24
Temperature Difference in Plain Twisted Tape

Fig. 7.8 Plain Twisted Tape Temperature Difference

25
 CHAPTER 8
RESULT & DISCUSSION

In double pipe heat exchanger design, an important factor is the type of

flow pattern in the heat exchanger. A double pipe heat exchanger will typically
be either counter flow or parallel flow. Cross flow just doesn’t work for a double
pipe heat exchanger. The flow pattern and the required heat exchange duty allows
calculation of the log mean temperature difference. That together with an
estimated overall heat transfer coefficient allows calculation of the required heat
transfer surface area. Then pipe sizes, pipe lengths and number of bends can be
determined.
Nusselt number is a measure of the ratio between heat transfer by
convection (α) and heat transfer by conduction alone (λ/L). Convective heat
transfer relationships are usually expressed in terms of Nusselt number as a
function of Reynolds Number and Prandtl Number.
It is clear from earlier statement that the Nusselt number can never be less
than 1 because the convective flux can be zero but the molecular flux term will
be similar in the numerator and the denominator. Therefore, the minimum value
of Nusselt number is 1 when the convective flux is zero.
The larger the Nusselt number, the more effective the convection. A larger
Nusselt number corresponds to more effective convection, with turbulent flow
typically in the 100–1000 range. For turbulent flow, the Nusselt number is usually
a function of the Reynolds number and the Prandtl number.
It is also found that a flow in a pipe is laminar if the Reynolds Number
(based on diameter of the pipe) is less than 2100 and is turbulent if it is greater
than 4000.
The output results of the experimental performance are calculated by
mathematical calculations and the values of the parameters such as effectiveness,

26
 Nusselt number, overall heat transfer coefficient, and the output temperature are
shown in the table below.

8.1 Plain Tube

Table 8.1 Overall Plain Tube Experimental Reading

LPM Th1 Th2 Tc1 Tc2 Qc Qh Re Nu Hi F
1.5 50.2 43.2 30 30.7 487.23 731.15 2149.14 14.63 372.25 0.04936
2 50.2 43.65 30 30.9 626.44 912.20 2875.55 21.20 539.41 0.04823
2.5 50.25 44.3 30.1 31.15 730.85 1035.83 3614.10 26.82 682.83 0.04719
3 50.25 44.95 30.1 31.35 870.06 1107.23 4359.06 32.86 837.19 0.04668
3.5 50.25 45.45 30.1 31.5 974.47 1169.92 5105.60 38.59 983.66 0.04561
4 50.25 45.9 30.1 31.65 1078.88 1211.72 5855.74 44.48 1134.15 0.0445
4.5 50.25 46.25 30.1 31.8 1183.29 1253.51 6605.98 51.87 1322.92 0.04386
5 50.25 46.5 30.1 31.9 1252.89 1305.75 7354.55 59.34 1513.93 0.04284
5.5 50.3 46.8 30.1 32 1322.50 1340.59 8112.55 66.07 1686.21 0.04118
6 50.35 47 30.2 32.15 1357.30 1399.79 8867.70 74.65 1905.57 0.04051
6.5 50.35 47.2 30.2 32.2 1392.10 1425.92 9622.03 79.82 2037.88 0.03977
7 50.35 47.35 30.2 32.25 1426.91 1462.48 10374.62 87.36 2230.74 0.0382
7.5 50.35 47.5 30.2 32.3 1461.71 1488.61 11129.01 94.46 2412.37 0.03736
8 50.35 47.65 30.2 32.35 1496.51 1504.28 11885.22 100.76 2573.56 0.03777

Table 8.2 Overall Plain Tube Analysis Reading

LPM Th1 Th2 Tc1 Tc2 Qc Qh Re Nu Hi
1.5 50 42.14 30 30.86 598.60 820.94 2128.36 20.44 519.26
2 50 43.06 30 31.04 723.89 966.50 2858.00 26.84 682.54
2.5 50 44.07 30 31.25 870.06 1032.33 3600.60 32.30 822.21
3 50 44.52 30 31.33 925.75 1144.81 4335.91 38.14 971.08
3.5 50 44.93 30 31.42 988.39 1235.70 5074.81 44.47 1132.80
4 50 45.46 30 31.58 1099.76 1264.62 5823.96 50.86 1296.04
4.5 50 45.94 30 31.74 1211.13 1272.29 6576.78 57.06 1454.79
5 50 46.21 30 31.86 1294.66 1319.66 7323.14 66.47 1695.00
5.5 50 46.47 30 31.91 1329.46 1352.05 8072.06 71.09 1813.07
6 50 46.62 30 32.01 1399.07 1412.30 8816.36 84.87 2164.95
6.5 50 46.81 30 32.07 1440.83 1443.99 9565.47 93.22 2378.27
7 50 46.96 30 32.11 1468.67 1481.95 10313.57 101.90 2600.13
7.5 50 47.11 30 32.16 1503.47 1509.47 11063.45 111.34 2841.48
8 50 47.24 30 32.2 1531.32 1537.68 11813.24 121.07 3090.06

27
 160
Plain Tube Analysis
140 Plain Tube Experimental

120

100
Nusselt number

80

60

40

20

0
2000 4000 6000 8000 10000 12000

Reynolds number

Fig. 8.1 Comparison of Plain Tube Nusselt Number

It consists of two concentric tubes in which hot water flows through the
inner tube and cold water flows outer tube in flow through annulus. The outer
tube is made of a galvanized iron having inside and outside diameters of 52.5 mm
and 60.3 mm respectively. The inner tube made of a copper having inside and
outside diameters of 28.5 mm and 25 mm respectively. Water is supplied to the
pipe from the water loop, an electrical heater controlled by adjusting the voltage,
a stirrer and flow meter is placed in the path of the water supply.
The cold water is supplied from storage tank into the outer tube and hot
water is supplied in the inner tube. The flow meter and pressure gauge were used
to measure the mass flow rate of hot fluid and cold fluid flow. The volumetric
flow rates of the hot and cold fluid were adjusted by control valves, situated
before the inlet ports and experimental reading was taken with different flow rates
for obtained the different experimental data. The experimental data occurred for
plain tube & plain twisted tape.

28
8.2 Twisted Tape

Table 8.3 Overall Plain Twisted Tape Experimental Reading

LPM Th1 Th2 Tc1 Tc2 Qc Qh Re Nu Hi F
1.5 50.25 42.35 30.2 31.25 730.85 825.13 2135.90 24.28 617.19 0.13016
2 50.25 43 30.2 31.4 835.26 1009.67 2862.20 33.07 841.11 0.12653
2.5 50.25 43.6 30.2 31.5 904.87 1157.67 3594.44 41.22 1048.87 0.12214
3 50.2 44.25 30.1 31.55 1009.27 1242.99 4333.54 49.09 1249.71 0.11969
3.5 50.2 44.9 30.1 31.7 1113.68 1291.76 5081.58 56.60 1441.87 0.11751
4 50.2 45.35 30.1 31.8 1183.29 1350.97 5828.09 64.52 1644.25 0.115
4.5 50.2 45.75 30.1 31.9 1252.89 1394.51 6577.30 72.71 1853.65 0.11152
5 50.25 46.2 30.1 32 1322.50 1410.20 7337.07 78.14 1992.85 0.10763
5.5 50.25 46.5 30.1 32.1 1392.10 1436.33 8090.01 87.56 2233.82 0.10464
6 50.25 46.75 30.1 32.15 1426.91 1462.45 8843.02 93.54 2386.96 0.10154
6.5 50.25 46.95 30.1 32.2 1461.71 1493.80 9595.20 101.69 2595.29 0.09892
7 50.25 47.1 30.1 32.25 1496.51 1535.59 10345.66 113.83 2905.47 0.09626
7.5 50.3 47.3 30.2 32.4 1531.32 1566.94 11106.78 127.40 3252.54 0.09367
8 50.3 47.4 30.2 32.45 1566.12 1615.70 11856.71 148.50 3791.75 0.08978

Table 8.4 Overall Plain Twisted Tape Analysis Reading

LPM Th1 Th2 Tc1 Tc2 Qc Qh Re Nu Hi
1.5 50 41.45 30 31.14 793.50 892.99 2117.14 30.53 775.20
2 50 42.38 30 31.23 856.14 1061.18 2843.05 37.83 961.42
2.5 50 43.15 30 31.36 946.63 1192.46 3574.99 47.04 1196.20
3 50 43.84 30 31.49 1037.12 1286.84 4312.99 56.39 1434.76
3.5 50 44.61 30 31.64 1141.52 1313.68 5062.12 62.65 1595.14
4 50 45.12 30 31.76 1225.05 1359.31 5808.43 71.48 1820.99
4.5 50 45.51 30 31.83 1273.78 1407.03 6554.54 78.92 2011.24
5 50 45.92 30 31.95 1357.30 1420.62 7306.39 87.76 2237.10
5.5 50 46.21 30 32.01 1399.07 1451.62 8055.46 95.22 2428.04
6 50 46.49 30 32.08 1447.79 1466.61 8807.28 102.35 2610.38
6.5 50 46.69 30 32.13 1482.59 1498.30 9556.36 111.91 2854.74
7 50 46.83 30 32.18 1517.39 1545.32 10302.92 127.76 3259.62
7.5 50 46.99 30 32.22 1545.24 1572.14 11052.89 138.92 3544.74
8 50 47.09 30 32.28 1587.00 1621.24 11799.14 166.80 4256.62

29
 180
Plain Twisted Tape Analysis
160
Plain Twisted Tape Experimental
140

120
Nusselt number

100

80

60

40

20

0
2000 4000 6000 8000 10000 12000

Reynolds number

Fig. 8.2 Comparison of Plain Twisted Tape Nusselt Number

The comparison of Reynolds number and Nusselt number of experimental
data of plain tube, plain tape and plain twisted tape. It is seen that, the Nusselt
number with plain twisted tape inserts were gives higher values than the plain
tape inserts and plain tube. With increases of Reynolds number, the Nusselt
number also increased.

30
 CHAPTER 9
MODEL CALCULATION
Heat transfer calculation
Hot water flow rate (mh) = 3 LPM
Cold water flow rate (mc) = 10 LPM
Hot water inlet temperature (Th1) = 50.3 ℃
Cold water inlet temperature (Tc1) = 30.2 ℃
Hot water outlet temperature (Th2) = 44.45 ℃
Cold water outlet temperature (Tc2) = 31.55 ℃
Hot water properties
Bulk mean hot water temperature
𝑇ℎ1 +𝑇ℎ2 50.3+44.45
Tmh = =
2 2

= 47.375 ℃
Density = 991.312 kg/m3
Kinematic viscosity = 5.90994 x 10-7 m2/s
Prandtl Number (Prh) = 3.85325
Specific heat = 4179.843 J/kg K
Thermal conductivity = 0.63659 W/m K
Cold water properties
Bulk mean cold water temperature
𝑇𝑐1 +𝑇𝑐2 30.2+31.55
Tmc = =
2 2

= 30.875 ℃
Density = 997.281 kg/m3
Kinematic viscosity = 8.1623 x 10-7 m2/s
Prandtl Number (Prc) = 5.56275
Specific heat = 4178 J/kg K
Thermal conductivity = 0.61422 W/m K

31
Velocity of hot water (u1) at the inlet
mh = 3 LPM = 0.04998 kg/s
mh = ρAu1
ρh = 991.312 kg/m3
𝜋
A = x 𝑑𝑖 2
4

A = 0.000491 m2
𝑚ℎ 0.04998
𝑢1 = =
𝜌ℎ 𝐴 991.312 𝑥 0.000491

𝑢1 = 0.10268 m/s
Velocity of cold water (ua) at the annulus
mc = 10 LPM = 0.1666 kg/s
mc = ρAua
ρc = 997.281 kg/m3
𝜋
A = x (𝐷𝑖 2 − 𝑑𝑜 2 )
4

A = 0.785 (0.05452 – 0.02852)

A = 0.001694 m2
𝑚𝑐 0.1666
𝑢𝑎 = =
𝜌𝑐 𝐴 997.281 𝑥 0.001694

𝑢𝑎 = 0.09861 m/s
Heat transferred from the hot water in the test section (Qh)
Qh = mh Cph (Th1 – Th2)
Qh = 0.04998 x 4179.843 x (50.3 – 44.45)
Qh = 1222.115 W
Heat transferred from the cold water in the test section (Qc)
Qc = mc Cpc (Tc1 – Tc2)
Qc = 0.1666 x 4178 x (31.55 – 30.2)
Qc = 939.673 W
Percentage of heat loss (ε)
𝑄ℎ − 𝑄𝑐
ε= x 100
𝑄𝑐

32
 1222.115−939.673
ε= x 100
939.673

= 30.05 %
Average heat transfer rate (Qavg)
Qh + Qc
Qavg =
2
1222.115+939.673
Qavg =
2

Qavg = 1080.894 W
Logarithmic mean temperature difference (∆𝑻𝒍𝒎 )
((Th1 − Tc2 )−(Th2 − Tc1 ))
∆Tlm = (𝑇 − 𝑇 )
𝑙𝑛 ℎ1 𝑐2
(𝑇ℎ2 − 𝑇𝑐1 )

((50.3−31.55)−(44.45−30.2))
∆Tlm = (50.3−31.55)
𝑙𝑛
(44.45−30.2)

∆Tlm = 16.397 ℃
Overall heat transfer coefficient (U)
Qavg = U Ai ∆𝑇lm
𝑄𝑎𝑣𝑔
U=
𝐴𝑖 𝑥 ∆𝑇𝑙𝑚

Ai = 𝜋𝑑𝑖 𝐿
Ai = 3.14 x 0.025 x 2 = 0.157 m2
1080.894
U=
(0.157 𝑥 16.397)

U = 419.87 W/m2 K
Annulus side Reynolds number (𝑹𝒆𝒂 )
(𝑢𝑎 𝑥 𝐷ℎ )
𝑅𝑒𝑎 =
𝑉𝑐

𝑢𝑎 = 0.09861 m/s
𝐷ℎ = 0.0545 – 0.0285 = 0.026 m
𝑉𝑐 = 8.1623 x 10-7 m2/s
0.09861 𝑥 0.026
𝑅𝑒𝑎 =
8.1623 𝑥 10−7

𝑅𝑒𝑎 = 3141.09

33
Annulus side Nusselt number (Nua)
Nua = 0.023 Rea0.8 Prc0.4
Nua = 0.023 x 3141.09 0.8 x 5.56275 0.4
Nua = 28.675
Annulus side heat transfer coefficient (ha)
ℎ𝑎 𝐷ℎ
Nua =
𝑘𝑐
ℎ𝑎 𝑥 0.026
28.675 =
0.61422

ℎ𝑎 = 677.413 W/m2 K
Inner tube side heat transfer coefficient (hi)
1 1 1
= +
𝑈 ℎ𝑖 ℎ𝑎
1 1 1
= +
419.87 ℎ𝑖 677.413

ℎ𝑖 = 1104.97 W/m2 K
Inner tube side Nusselt number (Nui)
ℎ𝑖 𝑑𝑖
Nui =
𝑘ℎ
1104.97 𝑥 0.025
Nui =
0.63659

Nui = 43.394
Inlet Reynolds number (Re1)
(𝑢ℎ 𝑥 𝑑𝑖 )
𝑅𝑒𝑖 =
𝑉ℎ
0.10268 𝑥 0.025
𝑅𝑒𝑖 =
5.90994 x 10−7

𝑅𝑒𝑖 = 4343.529

CHAPTER 10
34
 CONCLUSION

The comprehensive study had been done on heat transfer in heat exchanger
using plain tube & twisted tape inserts. They concluded the twisted tape inserts
perform better in turbulent flow. It’s based on Nusselt number, Reynolds number
& friction factor.
Table 10.1 Comparative overall reading
Plain Tube Plain Twisted Tape
LPM Experimental Analysis Experimental Analysis
Nu Re f Nu Re Nu Re f Nu Re
1.5 14.63 2149.14 0.04936 20.44 2128.36 24.28 2135.9 0.13016 30.53 2117.14
2 21.2 2875.55 0.04823 26.84 2858 33.07 2862.2 0.12653 37.83 2843.05
2.5 26.82 3614.1 0.04719 32.3 3600.6 41.22 3594.44 0.12214 47.04 3574.99
3 32.86 4359.06 0.04668 38.14 4335.91 49.09 4333.54 0.11969 56.39 4312.99
3.5 38.59 5105.6 0.04561 44.47 5074.81 56.6 5081.58 0.11751 62.65 5062.12
4 44.48 5855.74 0.0445 50.86 5823.96 64.52 5828.09 0.115 71.48 5808.43
4.5 51.87 6605.98 0.04386 57.06 6576.78 72.71 6577.3 0.11152 78.92 6554.54
5 59.34 7354.55 0.04284 66.47 7323.14 78.14 7337.07 0.10763 87.76 7306.39
5.5 66.07 8112.55 0.04118 71.09 8072.06 87.56 8090.01 0.10464 95.22 8055.46
6 74.65 8867.7 0.04051 84.87 8816.36 93.54 8843.02 0.10154 102.35 8807.28
6.5 79.82 9622.03 0.03977 93.22 9565.47 101.69 9595.2 0.09892 111.91 9556.36
7 87.36 10374.62 0.0382 101.9 10313.57 113.83 10345.66 0.09626 127.76 10302.92
7.5 94.46 11129.01 0.03736 111.34 11063.45 127.4 11106.78 0.09367 138.92 11052.89
8 100.76 11885.22 0.03777 121.07 11813.24 148.5 11856.71 0.08978 166.8 11799.14

35
 180
Plain Twisted Tape Analysis
160 Plain Twisted Tape Experimental
Plain Tube Analysis
140
Plain Tube Experimental
120
Nusselt number

100

80

60

40

20

0
2000 4000 6000 8000 10000 12000
Reynolds number

Fig. 10.1 Comparison Overall Nusselt Number

0.28
Plain Twisted Tape Experimental
Plain Tube Experimental
0.24

0.2
Friction factor

0.16

0.12

0.08

0.04

0
2000 4000 6000 8000 10000 12000
Reynolds number

Fig. 10.2 Comparison of Friction Factor

36
REFERENCES

[1] Pragneshkumar Prajapati, Umang Soni, Ashvin Suthar (May 2016)

“Increase the Heat Transfer Rate of Double Pipe Heat Exchanger with
Quadratic Turbulator (Baffle) Attached Twisted Tape Insert” International
Journal of Advance Engineering and Research Development Vol. 3, Issue
5, pp. 204-212.
[2] Kanika Joshi, Shivasheesh Kaushik, Vijay Bisht (May 2017)
“Investigation on Heat Transfer Rate in Concentric Tube Heat Exchanger
Using Pentagonal Shape Inserts in ANSYS FLUENT 14.5 with Varying
Mass Flow Rate for Parallel Flow” International Journal of Scientific &
Engineering Research, Vol. 8, Issue 5, pp. 1092-1102
[3] Kalapala Lokesh, N. Somasankar, Sk. Azharuddin, K. Uma
Maheswara Rao, M. Hari Krishna, M. Siva Sankar Mani Kumar (May
2017) “Heat Transfer Enhancement of Double Pipe Heat Exchanger Using
Twisted Tape Inserts” International Journal of Mechanical Engineering
and Technology, Vol. 8, Issue 5, pp. 420-424.
[4] Bandu A. Mule1, D.N.Hatkar, M.S.Bembde (August 2017)
“Analysis of Double Pipe Heat Exchanger with Helical Fins” International
Research Journal of Engineering and Technology, Vol. 04, Issue 08, pp.
961-966
[5] T. Vijaya sagar, Dr.Y.Appalanaidu (August 2017) “Experimental
Investigation of Heat Transfer Coefficient and Friction Factor in a Double
Pipe Heat Exchanger With and Without Twisted Tape Inserts using ZNO-
Propylene Glycol Nano Fluid” International Journal of Mechanical
Engineering and Technology, Vol. 8, Issue 8, pp. 94-106.

37
[6] J.S. Jayakumar, S.M. Mahajani, J.C. Mandal, P.K. Vijayan, Rohidas
Bhoi (October 2017) “Experimental and CFD estimation of heat transfer
in helically coiled heat exchangers” Chemical Engineering Research and
Design, pp. 222-232.
[7] Yamini Pawar, Ashish Sarode (December 2017) “An
Experimentation of Helical Coil Tube Heat Exchanger with Different
Curvature Ratio and Geometry” International Conference Proceeding, pp.
176-185.
[8] Deepak Sen, Dr. Alka Agrawal, (January 2018) “Enhancing the Heat
Transfer Parameters in Double Pipe Heat Exchanger by Creating
Turbulence in Inner and Outer Tube” International Journal for Research in
Applied Science & Engineering Technology, Vol. 6, Issue I, pp. 2646-
2649.
[9] Harsh Ladani, Rajkamal Sanepara, Mayur Moradiya, Decent
Chopda, Prof.Vatsal Patel (April 2018) “Design and Fabrication of Double
Pipe Heat Exchanger Using Different Heat Transfer Enhancement
Techniques” International Journal of Technical Innovation in Modern
Engineering & Science, Vol. 4, Issue 4, pp. 112-120
[10] Miyer Valdes, Juan G. Ardila, Dario Colorado, and Beatris A.
Escobedo-Trujillo, (May 2019) “Computational Model to Evaluate the
Effect of Passive Techniques in Tube-In-Tube Helical Heat Exchanger”
energies, pp. 1-12.
[11] Kola David, Abhishek kumar (May 2019) “CFD and Heat Transfer
Analysis of Automobile Radiator Using Helical Tubes” International
Journal of Innovative Research in Science, Engineering and Technology,
Vol. 8, Issue 5, pp. 5988-6017.
[12] Sivasubramaniam Arthanari Ponnusamy , Mayilsamy Kavandappa
Goundar, Murugesan Perumal (November 2019) “Heat Transfer And

38
Friction Factor Characteristics Of Pipe-In-Pipe Heat Exchanger Fitted
With Varient Plain Tape Insert” Vol. 24, No. 1B, pp. 623-633.

39
 HEAT TRANSFER AND FRICTION FACTOR
CHARACTERSTICS OF VARIANT TWSITED
TAPE FITTED IN A DOUBLE PIPE HEAT
EXCHANGER
Vasanthakumar R1, Gokulraj P2, Jayamurugan K S3, Kaleeswaran D4, Mohanakrishnan D5
1
Assistant Professor,2345UG Students, Department of Mechanical Engineering,
KSR Institute for Engineering and Technology,
Tiruchengode,Tamil Nadu, India.

ABSTRACT— Heat exchanger is an important device which is widely used equipment in different
industries such as process, petroleum refining, chemicals, oil industries, power plant and paper etc. Energy
and material saving considerations as well as environmental challenges in the industry have stimulated the
demand for high efficiency heat exchanger. To improve the efficiency of heat exchanger one must think of
heat transfer enhancement in heat exchanger. Moreover, heat transfer enhancement enables the size of heat
exchanger to be considerably decreased. A high rate of heat transfer with minimum space requirement is
necessity for compact heat exchanger. The counter flow heat exchanger is improving the heat transfer
characteristic of the double pipe heat exchanger is comparatively normal plain tube & plain twisted tape insert
is used improve the efficiency. To check the temperature difference in varying hot water flow rates and predicts
the Nusselt number, Reynolds number and Friction factor. Furthermore, compare and select the best method
of double pipe heat exchanger. Simultaneously, validating the computational fluid dynamics in Ansys software.

Keywords—Heat transfer,Twisted Tape, CFD Analysis

I. INTRODUCTION

The double pipe heat exchanger could be a

method to simplify to exchange heat b/w two fluids
while not mixing at different temperature. In heat
exchanger two kinds of heat transfer happens like
convection & conduction. Typically, convection
happens in each operating fluids & conduction through
walls of heat exchanger that separates the fluids. The
heat transfer coefficient improvement capability
beside a minimum loss in friction factor defines the
inserts. Tube inserts are utilised for heat transfer
improvement in different industrial fields like fossil
fuel refineries and chemical plants of several years.
There may be several different flow patterns for a heat
exchanger. Common types of heat exchangers are
counter flow, parallel flow, and cross flow. The most
effective flow method of the three is a counter flow
heat exchanger. A counter flow heat exchanger is the
warm fluid that enters at one end of the heat exchanger
and the cold fluid that exits at the same end of the flow
path. Counter flow is the most popular type of fluid to
fluid heat exchanger, since it is the most effective type.
Fig. Counter Flow Heat Exchanger
II. LITERATURE REVIEW
Pragneshkumar Prajapati et al. (May 2016), large
difference was observed in Nusselt Number between
the plain tube and in the heat exchanger with twisted
tape insert. The heat transfer improved by 22% to 33%
in temperature outlet at various Reynolds numbers
with using inserts at y=45 and heat transfer improved
by 15% to 45% at various Reynolds number by using
inserts at y=15. So, it’s increase of pressure drop is
more by using y=15 geometrical spacing pentagonal
shape inserts in cold pipe of concentric tube type heat

1
exchanger compared to plane tube presented by
Kanika Joshi et al. (May 2017).
Kalapala Lokesh et al. (May 2017), the more
efficient the twisted tape insert setup is because the
twisted tape creates turbulence in the region where the
hot fluid flows. Through inserting twisted tapes, an
improvement of about 30 percent in output is observed
at low mass flow rates. The DPHE with various angles
of fins to research in the heat exchanger flow and
temperature, Attempts have been made to investigate
the effects and heat transfer characteristics of DPHE
for six different fine inclinations: 0°, 5°, 10°, 15°, 20°
and 25°. The heat transfer rate is better for 20° helical
fins in double pipe heat exchanger to say Bandu et al.
(Aug 2017).
Vijaya sagar & Appalanaidu (Aug 2017), The
friction factor of 0.4% ZnO Nano fluid flowing in a
tube with H / D=3 twisted tape configuration increases
12.16% at a Reynolds number of 3000 and 15.32% at
a Re of 8000 compared to the same concentration
liquid without warped tape inserts. The CFD
predictions match the experimental results within the
limits of experimental errors reasonably well. A
correlation has been developed based on the results to
calculate the helical coil's internal heat transfer
coefficient. Based on the confidence gained in the
predictions of the CFD, the results obtained under
different conditions can be further used to obtain a
generalized correlation applicable to different coil
configurations developed by Jayakumar et al. (Oct
2017).
low due to temperature reduction and pressure drop in
the heat exchanger. In the new model type heat
exchanger is increased over all heat transfer rate and
also the heat exchanger's efficiency for circular fins is
increased by 4%-6%. The efficiency of the double pipe
heat exchanger for helical fine and Nano fluid is also
increased by 12%-16%. It is also observed that there
is enhancement in heat transfer using helical and
circular fin. The twist of the internal tube was added
from one to three turns; an increase up to 3% in the
Nusselt number was calculated. The biggest increase,
up to 9% was calculated when five turns were
simulated to develop the Miyer Valdes et al. (May
2019).
Kola David & Abhishek kumar (May 2019), When
we compare the different geometries of radiator the
helical type tube is the better model because the heat
transfer rate value is more for helical type tube radiator
is better model.
III. PROBLEM INDENTIFICATION
The double pipe heat exchanger is already
developed technology for quick response of heat
transfer. The method of heat transfer provided better
results and suitable for few applications in large scale
industries. The advantages technology should be
applicable for all sectors to reduce the investment. So,
the present work has been processed under this area to
improved heat transfer efficiency.
IV. MATERIAL SELECTION

Yamini Pawar & Ashish Sarode (Dec 2017), the 1. Material Properties
experimental comparison of coils with circular Material Property
diameter coil against coil with notches it was also Description Steel Copper Aluminium
noted that inside Nu, heat transfer coefficient, Dean Density
number these parameters increases by 3.75% and 8030 8978 2719
(kg/m3)
hence here prove that coil with notches are superior Specific Heat
than simple circular tube coils. The heat transfer rate 502.48 381 871
(j/kg K)
for helical wire insert rises to 74.7 percent. The rise for
Thermal
the twisted clip is 57.5 percent and for the corrugated
Conductivity 16.27 387.6 202.4
tube is 20.2 percent. For helical wire attachment, the
(w/m K)
overall heat transfer coefficient increases to 95%. This
increase for the twisted clip is 56.5 percent and for the
corrugated tube is 33 percent. For helical wire insert, 2. Mild Steel Material
which is 0.55 to say the Deepak Sen & Alka Agrawal Galvanized steel was the standard piping material
(Jan 2018), the Effectiveness quality is optimum. for water and wastewater transport in the piping sector.
This technology provided the metal pipe with a
Harsh Ladani et al. (April 2018), Through the use reasonable level of internally and externally
of finned tube, the heat transfer rate and efficiency are protection. This pipe used to cold water flow in the

2
process. Mild steel contains approximately 0.05–
0.25% carbon making it malleable and ductile. Mild
steel has a relatively low tensile strength, but it is
cheap and easy to form; surface hardness can be
increased through carburizing. Mild steel is very
strong due to the low amount of carbon it contains. In
materials science, strength is a complicated term. Mild
steel has a high resistance to breakage. Mild steel, as
opposed to higher carbon steels, is quite malleable,
even when cold.
the boron group. The chief ore of aluminium is
bauxite. Aluminium is derived from the mineral
bauxite. Bauxite is converted to aluminium oxide
(alumina) via the Bayer Process. The alumina is then
converted to aluminium metal using electrolytic cells
and the Hall-Heroult Process. Aluminium is most
commonly alloyed with copper, zinc, magnesium,
silicon, manganese and lithium. Small additions of
chromium, titanium, zirconium, lead, bismuth and
nickel are also made and iron is invariably present in
small quantities.

Fig. 2.1 Mild Steel Material Fig. 4.1 Aluminium materials

3. Copper Material
Copper tubing is almost widely used in hot V. EXPERIMENTAL SETUP
and cold-water supply and as a heat exchanger line.
Furthermore, high thermal conductivity in the copper, EXPERIMENTAL SETUP DIMENSION
it’s used in the hot water flow process and Helical fins.
Copper tubing is most often used for the supply of hot
and cold tap water, and as a refrigerant line in HVAC
systems. There are two basic types of copper tubing,
soft copper and rigid copper. Copper tubing is joined
using flare connection, compression connection, or
solder. Copper offers a high level of corrosion
resistance but is becoming very costly.

Fig. Twisted Tape Insert

Parameter Inner Outer
Plain tape
s pipe pipe
Galvanise Aluminiu
Materials Copper
d iron m

Length 2000 2000 2000

Inner
25mm 52.5mm -
Fig. 3.1 Copper Materials diameter
Outer 28.5m
4.Aluminium Material 60.3mm -
diameter m
To improve the temperature in the tube
aluminium inserts with flat plate profile are inserted Width - - 23mm
into the copper tube. Aluminium is the world’s most
abundant metal and does the third most common Thickness 3.5mm 3.91mm 3mm
element comprise 8% of the earth’s crust. The
versatility of aluminium makes it the most widely used
metal after steel. Aluminium is a chemical element VI. EXPERIMENTAL PROCEDURE
with the symbol Al and atomic number 13. It is a  The cold water and hot water mass flow rate is 10.
silvery-white, soft, non-magnetic and ductile metal in

3
 LPM and 1.5 LPM to 8 LPM respectively.
 The constant cold-water mass flow rate at 10LPM VII. HOT & COLD-WATER PROPERTIES
for each and every experimental procedure.
 Check one as heat balance on the heat transfer Cold Water Hot Water
between hot and cold pipe. Description
(30 ℃) (50 ℃)
 Measure the inlet, outlet temperatures of hot and
Density (kg/m3) 997.5 990
cold water (Th1, Th2, Tc1, and Tc2).
Specific Heat (j/kg
 Calculate the overall heat transfer coefficient, 4178 4180.5
K)
Nusselt number, Reynolds number and thermal
Thermal
enhancement factor for plain tube and with plain
Conductivity (w/m 0.6129 0.63965
tape & plain twisted tape.
K)
 Graphically the relationship between Reynolds
Viscosity (kg/m s) 8.315e-7 5. 675e-7
number,Nusseltnumber and thermal enhancement
factor with experimental and predicted under
turbulent flow.

VIII. COMPARISON OF PLAIN TUBE AND PLAIN TWISTED TAPE NUSSELT NUMBER

160
Plain Tube Analysis
140 Plain Tube Experimental
120
100
Nusselt number

80
60
40
20
0
2000 4000 6000 8000 10000 12000
Reynolds number

Fig. Comparison Of Plain Tube Nusselt Number

It consists of two concentric tubes in which hot water flows through the inner tube and cold water flows
outer tube in flow through annulus. The outer tube is made of a galvanized iron having inside and outside diameters
of 52.5 mm and 60.3 mm respectively. The inner tube made of a copper having inside and outside diameters of
28.5 mm and 25 mm respectively. Water is supplied to the pipe from the water loop, an electrical heater controlled
by adjusting the voltage, a stirrer and flow meter is placed in the path of the water supply. The cold water is
supplied from storage tank into the outer tube and hot water is supplied in the inner tube. The flow meter and
pressure gauge were used to measure the mass flow rate of hot fluid and cold fluid flow. The volumetric flow
rates of the hot and cold fluid were adjusted by control valves, situated before the inlet ports and experimental
reading was taken with different flow rates for obtained the different experimental data. The experimental data
occurred for plain tube & plain twisted tape.

4
 180
Plain Twisted Tape Analysis
160
140
120
100
Nusselt number

80
60
40
20
0
2000 4000 6000 8000 10000 12000
Reynolds number

Fig. Comparison Of Plain Twisted Tape Nusselt Number

The comparison of Reynolds number and Nusselt number of experimental data of plain tube, plain tape
and plain twisted tape. It is seen that, the Nusselt number with plain twisted tape inserts were gives higher values
than the plain tape inserts and plain tube. With increases of Reynolds number, the Nusselt number also increased.

IX. CFD ANALYSIS OF DOUBLE PIPE HEAT EXCHANGER

PERFORMING A CFD ANALYSIS

It is done in three stages: pre-processing, processing and post processing. In pre-processing step, all the
tasks that take place before the numerical solution process, this includes problem thinking, meshing and generation
of a computational model. Processing involves using a computer to solve mathematical equations of fluid flow.
This is a very intensive process and usually it requires the computer to solve many thousands of equations. In each
case, the equations are integrated and boundary conditions are applied to it. In post-processing step, this program
is used to make evaluation of the data generated by CFD analysis. When the model has been solved, the results
can be analysed both numerically and graphically. It done by both FLUENT solver are based on finite volume
method and domain is discretized into a finite set control volumes or cells

CFD ANALYSIS

PLAIN TUBE TEMPERATURE PLAIN TWISTED TAPE TEMPERATURE

DIFFERENCE: DIFFERENCE:

5
 X. RESULT

In double pipe heat exchanger design, an important factor is the type of flow pattern in the heat exchanger. A
double pipe heat exchanger will typically be either counter flow or parallel flow. Cross flow just doesn’t work for
a double pipe heat exchanger. The flow pattern and the required heat exchange duty allows calculation of the log
mean temperature difference. That together with an estimated overall heat transfer coefficient allows calculation
of the required heat transfer surface area. Then pipe sizes, pipe lengths and number of bends can be determined.

180
Plain Twisted Tape Analysis
160 Plain Twisted Tape Experimental
Plain Tube Analysis
140
Plain Tube Experimental
120
Nusselt number

100

80

60

40

20

0
2000 4000 6000 8000 10000 12000
Reynolds number

Fig. Comparison Overall Nusselt Number

0.28 Plain Twisted Tape Experimental

Plain Tube Experimental
0.24

0.2
Friction factor

0.16

0.12

0.08

0.04

0
2000 4000 6000 8000 10000 12000
Reynolds number

Fig. Comparison of Friction Factor

XI. CONCULSION
The comprehensive study had been done on heat transfer in heat exchanger using plain tube & twisted tape
inserts. They concluded the twisted tape inserts perform better in turbulent flow. It’s based on Nusselt number,
Reynolds number & friction factor.

6
 XII. REFERENCE

1) Pragneshkumar Prajapati, Umang Soni, Ashvin Suthar (May 2016) “Increase the Heat Transfer Rate of
Double Pipe Heat Exchanger with Quadratic Turbulator (Baffle) Attached Twisted Tape Insert”
International Journal of Advance Engineering and Research Development Vol. 3, Issue 5, pp. 204-212.
2) Kanika Joshi, Shivasheesh Kaushik, Vijay Bisht (May 2017) “Investigation on Heat Transfer Rate in
Concentric Tube Heat Exchanger Using Pentagonal Shape Inserts in ANSYS FLUENT 14.5 with Varying
Mass Flow Rate for Parallel Flow” International Journal of Scientific & Engineering Research, Vol. 8, Issue
5, pp. 1092-1102
3) Kalapala Lokesh, N. Somasankar, Sk. Azharuddin, K. Uma Maheswara Rao, M. Hari Krishna, M. Siva
Sankar Mani Kumar (May 2017) “Heat Transfer Enhancement of Double Pipe Heat Exchanger Using
Twisted Tape Inserts” International Journal of Mechanical Engineering and Technology, Vol. 8, Issue 5, pp.
420-424.
4) Bandu A. Mule1, D.N.Hatkar, M.S.Bembde (August 2017) “Analysis of Double Pipe Heat Exchanger with
Helical Fins” International Research Journal of Engineering and Technology, Vol. 04, Issue 08, pp. 961-966
5) T. Vijaya sagar, Dr.Y.Appalanaidu (August 2017) “Experimental Investigation of Heat Transfer Coefficient
and Friction Factor in a Double Pipe Heat Exchanger With and Without Twisted Tape Inserts using ZNO-
Propylene Glycol Nano Fluid” International Journal of Mechanical Engineering and Technology, Vol. 8,
Issue 8, pp. 94-106.
6) J.S. Jayakumar, S.M. Mahajani, J.C. Mandal, P.K. Vijayan, Rohidas Bhoi (October 2017) “Experimental
and CFD estimation of heat transfer in helically coiled heat exchangers” Chemical Engineering Research
and Design, pp. 222-232.
7) Yamini Pawar, Ashish Sarode (December 2017) “An Experimentation of Helical Coil Tube Heat Exchanger
with Different Curvature Ratio and Geometry” International Conference Proceeding, pp. 176-185.
8) Deepak Sen, Dr. Alka Agrawal, (January 2018) “Enhancing the Heat Transfer Parameters in Double Pipe
Heat Exchanger by Creating Turbulence in Inner and Outer Tube” International Journal for Research in
Applied Science & Engineering Technology, Vol. 6, Issue I, pp. 2646-2649.
9) Harsh Ladani, Rajkamal Sanepara, Mayur Moradiya, Decent Chopda, Prof.Vatsal Patel (April 2018)
“Design and Fabrication of Double Pipe Heat Exchanger Using Different Heat Transfer Enhancement
Techniques” International Journal of Technical Innovation in Modern Engineering & Science, Vol. 4, Issue
4, pp. 112-120
10) Miyer Valdes, Juan G. Ardila, Dario Colorado, and Beatris A. Escobedo-Trujillo, (May 2019)
“Computational Model to Evaluate the Effect of Passive Techniques in Tube-In-Tube Helical Heat
Exchanger” energies, pp. 1-12.
11) Kola David, Abhishek kumar (May 2019) “CFD and Heat Transfer Analysis of Automobile Radiator Using
Helical Tubes” International Journal of Innovative Research in Science, Engineering and Technology, Vol.
8, Issue 5, pp. 5988-6017.
12) Sivasubramaniam Arthanari Ponnusamy , Mayilsamy Kavandappa Goundar, Murugesan Perumal
(November 2019) “Heat Transfer And Friction Factor Characteristics Of Pipe-In-Pipe Heat Exchanger
Fitted With Varient Plain Tape Insert” Vol. 24, No. 1B, pp. 623-633.