Enhancing thermal efficiency in helical heat exchangers: A CFD study on twisted tube configurations
Heat exchangers are crucial components for enhancing energy efficiency in various industrial applications. This study investigates the efficiency of a helical heat exchanger incorporating twisted tubes with different pitch lengths, focusing on their impact on thermal performance compared to traditio...
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| Format: | Article |
| Language: | English |
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Elsevier
2025-09-01
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| Series: | Case Studies in Thermal Engineering |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S2214157X25009542 |
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| author | Valiyollah Ghazanfari Fatemeh Mansourzade Armin Taheri Younes Amini Mohammad Mahdi Shadman |
| author_facet | Valiyollah Ghazanfari Fatemeh Mansourzade Armin Taheri Younes Amini Mohammad Mahdi Shadman |
| author_sort | Valiyollah Ghazanfari |
| collection | DOAJ |
| description | Heat exchangers are crucial components for enhancing energy efficiency in various industrial applications. This study investigates the efficiency of a helical heat exchanger incorporating twisted tubes with different pitch lengths, focusing on their impact on thermal performance compared to traditional circular tubes. Computational Fluid Dynamics (CFD) simulations were used to examine the Nusselt number, resistance factor, and Performance Evaluation Criteria (PEC) at Reynolds numbers of 1000, 1500, 2000, and 2500. Results indicate that twisted tubes enhance heat transfer efficiency, particularly at higher Reynolds numbers. At a Reynolds number of 2500, PEC index increases of approximately 20 %, 22 %, and 14 % were observed for pitch lengths of 17 mm, 27 mm, and 37 mm, respectively. However, at lower Reynolds numbers, the benefits diminish, with PEC increases generally below 15 %. The findings highlight the importance of optimizing pitch length to balance heat transfer enhancement with pressure drop, suggesting that a pitch length of 27 mm offers the most favorable performance. This study provides design guidelines for twisted tube heat exchangers to enhance thermal management in industrial applications. |
| format | Article |
| id | doaj-art-c99d52c13c7146318c50f0ba3db348ce |
| institution | Kabale University |
| issn | 2214-157X |
| language | English |
| publishDate | 2025-09-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Case Studies in Thermal Engineering |
| spelling | doaj-art-c99d52c13c7146318c50f0ba3db348ce2025-08-20T03:27:37ZengElsevierCase Studies in Thermal Engineering2214-157X2025-09-017310669410.1016/j.csite.2025.106694Enhancing thermal efficiency in helical heat exchangers: A CFD study on twisted tube configurationsValiyollah Ghazanfari0Fatemeh Mansourzade1Armin Taheri2Younes Amini3Mohammad Mahdi Shadman4Reactor and Nuclear Safety Research School, Nuclear Science and Technology Research Institute, Tehran, Iran; Corresponding author.Nuclear Fuel Cycle Research School, Nuclear Science and Technology Research Institute, Tehran, IranDepartment of Chemical Engineering, SR.C., Islamic Azad University, Tehran, IranNuclear Fuel Cycle Research School, Nuclear Science and Technology Research Institute, Tehran, IranNuclear Fuel Cycle Research School, Nuclear Science and Technology Research Institute, Tehran, IranHeat exchangers are crucial components for enhancing energy efficiency in various industrial applications. This study investigates the efficiency of a helical heat exchanger incorporating twisted tubes with different pitch lengths, focusing on their impact on thermal performance compared to traditional circular tubes. Computational Fluid Dynamics (CFD) simulations were used to examine the Nusselt number, resistance factor, and Performance Evaluation Criteria (PEC) at Reynolds numbers of 1000, 1500, 2000, and 2500. Results indicate that twisted tubes enhance heat transfer efficiency, particularly at higher Reynolds numbers. At a Reynolds number of 2500, PEC index increases of approximately 20 %, 22 %, and 14 % were observed for pitch lengths of 17 mm, 27 mm, and 37 mm, respectively. However, at lower Reynolds numbers, the benefits diminish, with PEC increases generally below 15 %. The findings highlight the importance of optimizing pitch length to balance heat transfer enhancement with pressure drop, suggesting that a pitch length of 27 mm offers the most favorable performance. This study provides design guidelines for twisted tube heat exchangers to enhance thermal management in industrial applications.http://www.sciencedirect.com/science/article/pii/S2214157X25009542Twisted tubesHelical heat exchangersThermal efficiencyReynolds numberCFD |
| spellingShingle | Valiyollah Ghazanfari Fatemeh Mansourzade Armin Taheri Younes Amini Mohammad Mahdi Shadman Enhancing thermal efficiency in helical heat exchangers: A CFD study on twisted tube configurations Case Studies in Thermal Engineering Twisted tubes Helical heat exchangers Thermal efficiency Reynolds number CFD |
| title | Enhancing thermal efficiency in helical heat exchangers: A CFD study on twisted tube configurations |
| title_full | Enhancing thermal efficiency in helical heat exchangers: A CFD study on twisted tube configurations |
| title_fullStr | Enhancing thermal efficiency in helical heat exchangers: A CFD study on twisted tube configurations |
| title_full_unstemmed | Enhancing thermal efficiency in helical heat exchangers: A CFD study on twisted tube configurations |
| title_short | Enhancing thermal efficiency in helical heat exchangers: A CFD study on twisted tube configurations |
| title_sort | enhancing thermal efficiency in helical heat exchangers a cfd study on twisted tube configurations |
| topic | Twisted tubes Helical heat exchangers Thermal efficiency Reynolds number CFD |
| url | http://www.sciencedirect.com/science/article/pii/S2214157X25009542 |
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