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Helical Coil Heat Exchanger Design and It's Performance Analysis

Experiment Findings · September 2023

DOI: 10.13140/RG.2.2.35691.52005

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 ME-310
Thermo-Fluid System Design

Helical Coil Heat Exchanger

Submitted by
1.Md. Tanzeem Hossain – 1910123
2.Md. Abdullah Al Mukit – 1910137
3.Md. Tanvir Anjum – 1910140
4.Md. Nazibul Islam – 1910142

Under the Supervision of

Md. Aminul Islam Olin

Department of Mechanical Engineering

BANGLADESH UNIVERSITY OF ENGINEERING &
TECHNOLOGY

Dhaka, 1000
1|Helical Tube Heat Exchanger

Acknowledgement

In the realm of education and hands-on learning, the role of teachers cannot be
overstated. As we celebrate the successful completion of our Helical Coil Tube Heat
Exchanger project, it is only fitting that we acknowledge the instrumental guidance and
unwavering support of our esteemed educators.

Our journey through the intricacies of heat exchanger design and fabrication was made
possible through the expertise and mentorship of Prof. Dr. A. K. M Monjur Morshed
Sir, Prof Dr. Arif Hasan Mamun Sir, Mr. Priom Das Sir and Md. Aminul Islam Sir.
Their profound understanding of thermodynamics, fluid dynamics, and heat transfer
laid the foundation for our project. Their patience in answering our questions, providing
insightful feedback, and encouraging us to think critically were indispensable. We are
deeply grateful for their dedication to our growth and development.

Additionally, we extend our heartfelt appreciation to Md. Aminul Islam Sir, whose
hands-on approach to teaching and laboratory experiments enriched our practical
knowledge. The opportunity to work alongside them on various experiments related to
heat exchangers not only expanded our skill set but also deepened our understanding
of real-world applications. Their commitment to fostering a strong foundation in
engineering principles has left an indelible mark on our learning experience.
In conclusion, the completion of the Helical Coil Tube Heat Exchanger project has
been a remarkable milestone in our academic journey. We owe our success to the
wisdom, mentorship, and dedication of our teachers. Their influence has not only
enhanced our technical competence but also inspired us to approach challenges with
enthusiasm and determination.
2|Helical Tube Heat Exchanger

Abstract
This study introduces a comprehensive investigation into the design and
performance optimization of helical tube heat exchangers. Helical tube
configurations present a promising alternative to conventional straight tube
designs due to their inherent advantages in heat transfer enhancement and
compactness. The research employs experimental validation to assess the
thermal performance of helical tube heat exchangers under various operating
conditions. Key design parameters, including pitch, diameter, and number of
helical turns, are systematically analyzed to identify their influence on heat
transfer efficiency and pressure drop characteristics. Furthermore, the study
explores advanced surface enhancement techniques, such as turbulators and
extended surfaces, to augment heat transfer rates within the helical tube
geometry.
Practical applications of helical tube heat exchangers are discussed,
encompassing industries ranging from HVAC systems to process industries,
where space constraints and energy efficiency are critical considerations.
Comparative analyses are conducted between helical tube designs and
conventional alternatives to demonstrate the superior performance and
compactness achieved through the helical configuration.
The study also addresses the challenges associated with manufacturing and
material selection for helical tube heat exchangers, emphasizing the importance
of selecting materials with high thermal conductivity and corrosion resistance.
Additionally, considerations for maintenance and cleaning procedures are
discussed to ensure the long-term operational effectiveness of the heat
exchanger.

Keywords: Effectiveness; Heat Transfer intensification; Helical Coil

3|Helical Tube Heat Exchanger

Introduction
Heat exchangers are essential devices designed to efficiently transfer heat from one
medium to another with or without direct mixing. They play a crucial role in various
aspects of our daily lives, impacting our comfort, safety, and convenience in numerous
ways.

Heat exchangers are ubiquitous in a wide range of industries, playing a vital role in
transferring thermal energy from one fluid to another. Among the diverse array of heat
exchanger designs, the helical coil tube heat exchanger stands out as a remarkable and
innovative solution.

Characterized by its distinctive helical coil configuration, this heat exchanger has
garnered significant attention for its enhanced heat transfer efficiency, compactness,
and versatility. Helically coiled tube heat exchangers are effective as heat transfer
equipment’s due to their compactness and increased heat transfer coefficients in
comparison with straight tube heat exchangers. They are used for thermal energy
exchange in air conditioning systems, nuclear power plants, refrigeration systems, and
pharmaceutical industry.

Most of the studies on helically coiled tube heat exchangers are focusing on either some
pre-specified boundary conditions e.g., constant heat flux, constant temperature
boundary conditions, or certain power input to the coil surface through DC current
input, or natural convection mechanism at the shell-side, rather than forced or mixed
convection mechanism. There have not been any comprehensive studies on the thermal
performance and heat transfer analysis of the shell-side of this type of compact heat
exchangers, by considering a fluid-to-fluid heat transfer mechanism.

The literature states that the heat transfer rates in helical coils are higher as compared
to straight tubes. Because of the compact structure and high heat transfer coefficient,
helical coil heat exchangers has its wide variety of applications in power generation,
nuclear reactors, air-conditioning, automotive industries, electronics, cryogenic
processes heat recovery systems, chemical processing steam power plants, food
4|Helical Tube Heat Exchanger

industry, cryogenic processes, transportation power systems, refrigeration units etc.,

The size of the heat exchanger is decreased considerably by heat transfer enhancement
techniques. The enhancement techniques are divided into two groups, active and
passive The active techniques require external forces like vibration of fluid, surface
vibration and electric field. The passive techniques use surface geometries. The
combination of two techniques is used to improve the heat transfer performance in
heat exchangers.

Figure: Helical coil Tube and Shell Heat Exchanger

The value of the Reynolds number helps to determine whether the flow is laminar or
turbulent where D is the inside diameter of the tube or pipe, V is the average velocity
of the fluid, 𝜌 is the density of the fluid, and μ is the dynamic viscosity. Kinematic
viscosity. The mass flow rate is related to volumetric flow rate Q, where m=Q*𝜌.
For the range of Re in the range if 𝑅𝑒 < 2300 the flow is laminar 2300<𝑅𝑒<4000 the
flow is transition and if 𝑅𝑒>4000 the flow is turbulent.
The turbulent flow is unsteady and time dependent fluctuations in pressure and velocity.
The general schematic diagram is given by fig2. The extent of centrifugal force depends
on the axial velocity of the particle and coil radius of curvature. The fluid particles flow
at the core of the pipe has higher velocity than that of near to the wall of the pipe. The
5|Helical Tube Heat Exchanger

stream drives the fluid towards the inner wall of the tube and causes counter-rotating
vortices called secondary flow. It provides the transport of the fluid over the pipe’s
cross section. This convective transport increases the heat transfer when compared to
straight tube. The effect of the curvature of the coil decreases the turbulent fluctuations.
Heat transfer augmentation technique is adopted to enhance heat transfer in single
phase.
6|Helical Tube Heat Exchanger

Nomenclature

Ao – Outer heat transfer surface area, m2

B – Mean diameter of coil, m
C – inner shell diameter, m
Cp – specific heat, J/kg-K
De – Dean number
Deq – shell side equivalent diameter, m
ODt – outside tube coil diameter, m
IDt – internal tube coil diameter, m
g – gravitational acceleration, m/s2
G – mass flow rate, kg/m2s
HTC – heat transfer coefficient
HX – heat exchangers
fc – friction factor for helical coil
fs – friction factor for straight pipe
F – fluid correction factor
T1 – Temperature difference in one end
T2 – Temperature difference in another end
H – height of shell, m
L – Total length of coil, m
LMTD – logarithmic mean temperature difference
m – mass flow rate, kg/s
N – number of turns of helical coil.
NTU – number of transfer units
7|Helical Tube Heat Exchanger

Nu – Nusselt number
p – distance between consecutive coil turns, m.
Pr – Prandtl number
ΔP – pressure drop, Pa.
Q – heat flux, W
qw – wall heat flux, W/m2
Ra – Rayleigh number
R – fouling factor, m2K/W
Re – Reynolds number
T – temperature, K
U – overall heat transfer coefficient, W/m2K
V – velocity, m/s
W – fluid heat capacity rate, W/K
K – thermal conductivity, W/m-K
µ – dynamic viscosity, Pa s

Subscript
Sh – Shell Side
t – Tube Side
c – Cold Fluid
h – Hot Fluid
eq – Equivalent
8|Helical Tube Heat Exchanger

Problem Statement

Design of a Helical Tube Heat Exchanger for two fluids Oil and Water. Hot unused
engine oil with a mass flow rate of 0.1 kg/s entering heat exchanger which has the
temperature of 65°C and leaving at 60°C. And the facility is being cooled by water with
inlet temperature at 30°C and leaving the facility at 40°C. We must design a helical tube
heat exchanger fulfilling the requirements and pressure drop below 70 KPa for safe
operation.

Parameters Hot Fluid (Engine Oil) Cold Fluid (Water)

Mass flow rate, (Kg/s) 0.1 -

Inlet Temperature, (°C) 65 30

Outlet Temperature, 60 40
(°C)
9|Helical Tube Heat Exchanger

Objectives

Helical coil tube heat exchangers serve various objectives in heat transfer applications,
and their design offers specific advantages for certain situations. The primary objectives
of using helical coil tube heat exchangers include:
Efficient Heat Transfer: This heat exchangers are designed to facilitate efficient heat
transfer between two fluids. The helical coil configuration increases the heat transfer
surface area, allowing for enhanced heat exchange.
Space Optimization: These heat exchangers are particularly useful in applications with
limited space. The helical coil design allows for a longer tube length within a compact
footprint, making them suitable for situations where space is at a premium.
High Turbulence and Heat Transfer: The spiral shape of the coil promotes
turbulent flow of the fluids, which is essential for maximizing heat transfer efficiency.
Turbulent flow enhances mixing and reduces the thermal boundary layer, allowing for
more effective heat transfer.
Temperature Control: Helical coil tube heat exchangers are employed in systems
where precise temperature control is essential. By exchanging heat between two fluids,
they can help maintain the desired temperature of one or both fluids.
Rapid Cooling or Heating: These heat exchangers are often used in applications that
require rapid cooling or heating of a fluid. The extended surface area and turbulent flow
characteristics facilitate quick heat exchange.
Thermal Recovery: In some processes, helical coil tube heat exchangers are utilized
to recover waste heat from one fluid and transfer it to another, improving overall energy
efficiency.
Versatility: Helical coil tube heat exchangers can be constructed from various
materials, allowing them to handle a wide range of fluids, including corrosive or
aggressive substances. This versatility makes them suitable for diverse industrial
applications.
Reduced Material Costs: Compared to some other heat exchanger designs, helical
coil tube heat exchangers can be more cost-effective due to their compact size and
efficient heat transfer capabilities. They often require less material for construction.
10 | H e l i c a l T u b e H e a t E x c h a n g e r

Compact Design: The helical coil design minimizes the footprint of the heat
exchanger, making it suitable for installations where space is limited or expensive.
Customization: These heat exchangers can be customized to meet specific process
requirements, including variations in coil diameter, tube material, and the number of
coils turns.
Heat Recovery: In some applications, such as in HVAC systems or industrial
processes, helical coil tube heat exchangers are used to recover heat from exhaust gases
or waste streams, reducing energy consumption and operating costs.
Chemical Processes: They are commonly used in chemical industries for tasks like
condensing vapors, cooling reactive chemicals, or heating process fluids.

In summary, the objectives of helical coil tube heat exchangers include enhancing heat
transfer efficiency, optimizing space utilization, and promoting turbulence for efficient
heat.
11 | H e l i c a l T u b e H e a t E x c h a n g e r

Mathematical Modeling

To conduct experimental research to verify the influence of surface modification on the

heat transfer coefficient of the coiled tube a reference heat exchanger model was
proposed. Heat transfer coefficient outside the coil was calculated based on the works
of methodology showed earlier. Helically coiled tubes show some peculiar
characteristics and phenomenological aspects of the thermohydraulic that are worthy
of a brief description. First, coiled pipes are compact, can well accommodate the
thermal expansions and have a high resistance to flow induced vibrations. Furthermore,
the fluid flowing in helical tubes develops secondary flows whose physical explanation
is represented in Fig. 1.

Figure 1: Shell Coil Heat Exchanger View (a) Centrifugal force acting on the flowing fluid and axial
speed. (b) Resulting secondary view

The curved shape of the inner tube of HX causes the fluid to experience a centrifugal force which
depends on its local axial velocity of Fig. (1b). Due to the boundary layer, the fluid particles flowing
12 | H e l i c a l T u b e H e a t E x c h a n g e r

close to the tube wall have a lower velocity with respect to the fluid flowing in the core of the tube
thus they are subject to a lower centrifugal force. Consequently, fluid from the core region is
pushed outwards forming a pair of recirculating counter-rotating vortices as presented in Fig. 1c.
In the Reynolds number range of 50 < Resh < 10000 the Nusselt number at shell side can be
expressed as,

Nush = 0.6Resh 0.5 Pr0.31

Where, Pr is the Prandl number, and for Resh > 10000,

Nush = 0.36Re0.55sh Pr 0.333(μ/μ p)0.14

Where, μ and μp are the dynamic viscosity of the wall and fluid, respectively. In shell side flow,
Reynolds number is calculated as the mass flow rate, Gsh, through equivalent diameter, Deq
𝐺𝑠ℎ 𝐷𝑒𝑞
Resh =
µ

Equivalent diameter depends on the volume of the annulus divided by heat exchanger length and
circumference.

4𝑉𝑠ℎ
𝐷𝑒𝑞 =
𝜋𝑂𝐷𝑡 𝐻

The volume available for the flow of fluid in the annulus, Vsh, can be calculated knowing
geometrical dimensions of the heat exchanger (Fig. 2)

𝜋 2 𝜋
𝑉𝑠ℎ = (𝐶 − 𝐵2 )𝑝𝑁 − 𝑂𝐷𝑡 2 𝐿
4 4

By determining Reynold’s number for both shell and coil side, we can calculate Nusselt
Number. Correlation for Nusselt number for shell side is already enlisted. Now, for helical
coil, Nusselt number can be determined from equation below,

4.343 3 𝐷𝑒
𝑁𝑢𝑡 = [(3.657 +
𝑥1
) + 1.158( 𝑥2 )0.5 ]
13 | H e l i c a l T u b e H e a t E x c h a n g e r

From these equations, we can easily find heat transfer co-efficient (h) for both shell and
tube side.

ℎ𝐷𝑒𝑞
𝑁𝑢 =
𝐾
Where, Deq changed according to Shell and Coil.

Then, LMTD method is used to find Heat duty and Overall heat transfer co-efficeint
subsequently.
𝑇1 − 𝑇2
𝐿𝑀𝑇𝐷 =
𝑇
ln ( 1 )
𝑇2

Corrected LMTD value is,

𝐿𝑀𝑇𝐷 = 𝐹. 𝐿𝑀𝑇𝐷

Overall heat transfer co-efficient,

1 1 1
= + + 𝑅𝑓−𝑐 + 𝑅𝑓−ℎ
𝑈 ℎ𝑡 ℎ𝑠ℎ
14 | H e l i c a l T u b e H e a t E x c h a n g e r

Figure: 2 Geometrical assumptions for designed helical heat exchanger.

Pressure Drop Calculation:

𝐿 𝑣2
∆𝑃 = 𝑓𝑐
𝐷 2𝑔
Where, fc is friction co-efficient for helical coil. f c Can be obtained from another co-
relation by White (1928)
11.6 0.45 2.2 −1
𝑓𝑐 = 𝑓𝑠 [1 − [1 − ( ) ] ]
𝐷𝑒
15 | H e l i c a l T u b e H e a t E x c h a n g e r

MATLAB Code

% Input Parameters

m_h = 0.1; % Hot fluid flow rate (in kg/s)

T_h_i = 65; % Hot fluid inlet temperature (in °C)
T_h_o = 60; % Hot fluid outlet temperature (in °C)
T_c_i = 30; % Cold fluid inlet temperature (in °C)
T_c_o = 40; % Cold fluid outlet temperature (in °C)
F = 0.97; % Correction factor
R_fh = 0.00088; % Fouling Factor for Hot Fluid (m^2.k/W)
R_fc = 0.00035; % Fouling Factor for Cold Fluid (m^2.k/W)
%PROPERTIES
%HOT FLUID
rho_h = 862.56;
Cp_h = 2058;
miu_h = 0.06683;
k_h = 0.1399;
Pr_h = 978.4;
%COLD FLUID
rho_c = 994;
Cp_c = 4178;
miu_c = 0.00072;
k_c = 0.623;
Pr_c = 4.33;
%LMTD
DT_1 = T_h_o - T_c_i ; % Change in temp
DT_2 = T_h_i - T_c_o ; % Change in temp
T_lm = (DT_1 - DT_2) / log(DT_1 / DT_2 );

%Heat Duty
Q_h = m_h*Cp_h*(T_h_i - T_h_o);
disp(Q_h);
Q_c = Q_h; %Heat Duty is equal
m_c = Q_c/(Cp_c*(T_c_o-T_c_i));
UA = Q_h/(F*T_lm);

%TUBE SIDE
%TUBE IS 3/8" BWG 17

%Tube Specs
ID_t = 0.0065786; % inner diameter in m
OD_t = 0.0095250; % outer diameter in m
A_t = (pi*ID_t*ID_t)/4; % cross sectional area
t = 0.0014732; % coil thickness in m
k = 390; %Conductive HT Co-eff (W/m-k)

V_t = m_c / (rho_c * A_t); % Velocity in inner tube;

% Assumptions!!!
% Overall heat transfer co-eff
U = 250;
16 | H e l i c a l T u b e H e a t E x c h a n g e r

A_o = UA / U; %Heat transfer area

%L = 3.0988;
L = A_o / (pi* OD_t);

% Coil Specs
N = 8 %input('Enter Coil Number:');
% No of coil
P = 0.035; % Pitch 0.035m
L_c = 0.2667; % Free length
D_in = 0.0936625; % Inner Diameter
D_out = 0.1143; % Outer Diameter
D_mean = (D_out + D_in) /2; % Mean Diameter
a = alpha(P,D_mean/2); % Heix angle
L = (pi* N* D_mean) / sin(a);
A_o = pi* OD_t * L; % Final HT Area
U = UA / A_o; % Overall HT Co-eff
% mass flow rate
G_t = m_c / A_t;
Re_t = (G_t* ID_t) / miu_c;
disp(Re_t)
a = OD_t /2;
R = D_mean / 2;
De = Dean_Number(Re_t, a, R);
x1 = X1(De, Pr_c);
x2 = X2(Pr_c);
Nu_t = Nusselt(x1, De, x2);
h_t = (Nu_t * k_c) / OD_t;
%Shell side
C = 0.127 % Shell Side inside dia
Lsh = 0.381 % Shell Length
Vsh = shell_vol(C, P, N, OD_t, Lsh); % Equivalent Shell Volume
Deq = (4*Vsh) / (pi* D_mean* Lsh);

v_sh = 2
% Economic Velocity
miu_p = miu_h;
Re_sh = (v_sh* rho_h * Deq) / miu_h ;
Nu_sh = 0.6* (Re_sh)^0.50 * (Pr_h)^0.31;
h_sh = (Nu_sh* k_h) / Deq;
U = ((h_sh)^-1 +(h_t)^-1 +R_fc + R_fh + t/k )^-1;

%PRESSURE DROP!!!
% e = 0.0025 assume to be drawn tubing
f_s = 0.03905; % For straight pipe, from Moody Diagram
f_c = coilfriction(f_s, De);
P = f_c*(L/ID_t)*(rho_c*(V_t)^2)/1000; %Pressure drop in KPa.
17 | H e l i c a l T u b e H e a t E x c h a n g e r

Calculations and Results

Table 1: Thermal Property

Properties Water Engine Oil
Inlet Temperature (°C) 30 65
Outlet Temperature (°C) 40 60
Average Temperature 35 62.5
(°C)
Specific Heat, Cp (J/kg- 4178 2058
k)
Dynamic Viscosity, µ 0.00072 0.06683
(Pa.s)
Thermal Conductivity, K 0.623 0.1393
(W/m-k)
Prandtl Number, Pr 4.33 978.4
Density, ρ (kg/m3) 994 862.56

Table 2: Geometric Parameters

Parameter Tube Side Shell Side

Material Copper
3
in BWG17 Mild Steel
8
Inner Diameter (mm) 6.5786 127
Outer Diameter (mm) 9.525 133
No. of Coil 8 –
Coil Mean Diameter 10.4 –
(cm)
Pitch (cm) 3.5 –
Total Length (m) 3.105 0.381
18 | H e l i c a l T u b e H e a t E x c h a n g e r

Table 3: Heat Transfer coefficient calculations

Fluid Velocity, v (ms-1) 0.729 2.0

Reynolds Number, Re 6621.56 2923.88
Nusselt Number, Nu 44.6421 274.1003
Heat Transfer Co- 2910 338.9836
efficient, h (W/m2K)
Fouling Factor, Rf 0.00035 0.00088

Table 4: Result from Rating Problem

Heat Duty, Q (W) 2487.4

Water Exit Temperature, Tw,exit (°C) 54.1956
Oil Exit Temperature, Toil,exit (°C) 52.5194

Table 5: Result from Designed HX

Overall Heat Transfer Co-efficient, U 220.9316

(W/m2K)
Pressure Drop, ∆P (Kpa) 48.4504
19 | H e l i c a l T u b e H e a t E x c h a n g e r

Pressure Test
20 | H e l i c a l T u b e H e a t E x c h a n g e r

Experimental Outcomes
21 | H e l i c a l T u b e H e a t E x c h a n g e r
22 | H e l i c a l T u b e H e a t E x c h a n g e r
23 | H e l i c a l T u b e H e a t E x c h a n g e r
24 | H e l i c a l T u b e H e a t E x c h a n g e r

Manufacturing process

SolidWorks Model:

Figure: Solid Works Model

25 | H e l i c a l T u b e H e a t E x c h a n g e r

Manufacturing:

Figure: Bending of Tube Figure: Helical Coil Tube

Figure: Complete Helical Coil

26 | H e l i c a l T u b e H e a t E x c h a n g e r

Figure: Welding of shell Fittings Figure: Helical Coil Tube Inside Shell

Figure: Caps enclosing the Coil Figure: Complete Heat Exchanger

27 | H e l i c a l T u b e H e a t E x c h a n g e r

Advantages
Helical coil tube heat exchangers offer several advantages in various heat transfer
applications due to their unique design. Here are some of the primary advantages of
using helical coil tube heat exchangers:

Efficient Heat Transfer: Helical coils provide an extended heat transfer surface area,
resulting in efficient heat exchange between two fluids. This design allows for improved
thermal performance.

Compact Design: The helical coil configuration minimizes the footprint of the heat
exchanger, making it suitable for installations with limited space or where space
optimization is crucial.

Enhanced Turbulence: The spiral shape promotes turbulent flow within the coil,
which is essential for efficient heat transfer. Turbulent flow enhances mixing and
reduces the thermal boundary layer, increasing heat exchange rates.

Rapid Temperature Change: Helical coil tube heat exchangers are capable of quickly
heating or cooling fluids due to their efficient heat transfer characteristics. This makes
them suitable for processes requiring rapid temperature changes.

Versatility: They can handle a wide range of fluids, including corrosive or aggressive
substances, thanks to the flexibility in material selection for the coil and tubing.

Customization: These heat exchangers can be customized to meet specific process

requirements, allowing variations in coil diameter, tube material, and the number of
coils turns to match the application.
Reduced Material Costs: Compared to some other heat exchanger designs, helical
coil tube heat exchangers often require less material for construction due to their
compact size.
28 | H e l i c a l T u b e H e a t E x c h a n g e r

Heat Recovery: They can recover waste heat from exhaust gases or other waste
streams, contributing to energy savings and reducing operating costs.

Precise Temperature Control: Helical coil tube heat exchangers are used in systems
requiring precise temperature control, as they can maintain the desired temperature of
one or both fluids effectively.

Low Maintenance: Depending on the design and materials used, they can be relatively
low maintenance, as long as proper cleaning and maintenance schedules are followed.

Chemical Processes: They are commonly employed in chemical industries for various
tasks, such as condensing vapors, cooling reactive chemicals, or heating process fluids.

Heat Exchanger Network Optimization: In industrial settings, helical coil tube heat
exchangers can be integrated into heat exchanger networks to optimize heat recovery
and improve overall energy efficiency.

Reduced Fouling: The coil design can help reduce fouling and scaling issues compared
to some other heat exchanger types, although proper maintenance is still essential.

Overall, the advantages of helical coil tube heat exchangers make them a valuable choice
for a wide range of applications, especially in situations where efficient heat transfer,
space optimization, and versatility are essential.
29 | H e l i c a l T u b e H e a t E x c h a n g e r

Disadvantages
While helical coil tube heat exchangers offer several advantages, they also have some
disadvantages and limitations that should be considered in their application. Here are
some of the disadvantages of helical coil tube heat exchangers:

Limited to Certain Applications: Helical coil tube heat exchangers may not be
suitable for all applications. Their design is better suited for specific situations where
space optimization and efficient heat transfer are essential.

Complex Cleaning and Maintenance: Cleaning the interior of helical coils can be
challenging, especially if they are tightly wound or have a complex geometry.
Disassembly may be required, making maintenance more time-consuming and costly.

Fouling and Scaling: Like other heat exchangers, helical coils are susceptible to
fouling and scaling over time, which can reduce heat transfer efficiency. Regular
cleaning and maintenance are necessary to prevent these issues.

Pressure Drop: The design of the coil and the flow rates can lead to a significant
pressure drop across the heat exchanger. High-pressure drops may require more
powerful pumps, increasing energy consumption and operating costs.

Cost: The manufacturing and installation of helical coil tube heat exchangers can be
more expensive compared to simpler heat exchanger designs. The cost can vary
depending on materials, customization, and other factors.

Limited Turbulent Flow Range: Achieving turbulent flow inside the coil is essential
for efficient heat transfer. If flow rates are too low, laminar flow can occur, reducing
heat exchange effectiveness. Proper sizing and flow rate control are crucial.
30 | H e l i c a l T u b e H e a t E x c h a n g e r

Material Compatibility: Careful consideration of materials is necessary to ensure

compatibility with the fluids being used. In some cases, specialized materials may be
required to resist corrosion or erosion.

Limited Flexibility: Once a helical coil heat exchanger is installed, it may be

challenging to modify or expand, making it less flexible compared to some other heat
exchanger designs.

Restricted Applications with High Temperature Differentials: Helical coil tube

heat exchangers may not be suitable for applications with extremely high temperature
differentials between the two fluids due to potential thermal stress and material
limitations.

Cleaning Accessibility: Depending on the installation and design, accessing and

cleaning the inner portions of the coil may be difficult, leading to potential cleanliness
and maintenance challenges.

Limited Flow Range: Some applications require a wide range of flow rates, which
may not be effectively accommodated by helical coil tube heat exchangers without
compromising efficiency.

In summary, while helical coil tube heat exchangers have advantages such as efficient
heat transfer and space optimization, they also have disadvantages, including challenges
related to cleaning, maintenance, pressure drop, and limited suitability for certain
applications. Careful consideration of these factors is essential when choosing this type
of heat exchanger for a specific task.
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Further improvement
Improving the heat transfer performance of helical coil tube heat exchangers can be
achieved through various strategies and enhancements. Here are some ways to further
improve the heat transfer efficiency of helical coil tube heat exchangers:

Increase Turbulence:
a. Increase Flow Velocity: Higher fluid flow rates can promote turbulence inside the
coil, leading to improved heat transfer. However, be cautious not to exceed the
allowable pressure drop or Reynolds number limits.
b. Use Inserts: Helical inserts or turbulators placed inside the coil can enhance fluid
mixing and turbulence, increasing heat transfer rates.

Optimize Coil Geometry:

a. Vary Coil Pitch: Adjusting the pitch (spacing between coil turns) can influence the
flow characteristics and heat transfer efficiency. Experiment with different pitch
configurations to find the optimal design.
b. Helix Angle: Altering the angle of the coil helix can impact the flow pattern within
the coil and affect heat transfer performance. Experiment with different helix angles to
optimize heat transfer.

Surface Enhancement:
a. Apply Heat Transfer Enhancements: Consider adding surface enhancements such as
fins, ridges, or extended surfaces to the coil tubing to increase the effective surface area
for heat transfer.

Use High-Conductivity Materials:

32 | H e l i c a l T u b e H e a t E x c h a n g e r

a. Select high thermal conductivity materials for the coil and tubing to enhance heat
transfer rates. Copper and aluminum are commonly used for their excellent thermal
properties.

Optimize Fluid Properties:

a. Use heat transfer fluids with higher thermal conductivity or heat capacity to improve
the overall heat transfer efficiency of the system.

Employ Baffles or Vortex Generators:

a. Internal baffles or vortex generators within the coil can enhance fluid mixing and
create turbulence, thereby improving heat transfer.

Control Flow Distribution:

a. Use flow distributors or flow control devices to ensure even distribution of the fluid
within the coil, preventing hot or cold spots and promoting uniform heat transfer.

Insulate the Exchanger:

a. Proper insulation of the heat exchanger can reduce heat losses to the surroundings
and improve overall thermal efficiency.

Monitor and Optimize:

a. Implement monitoring systems and control strategies to continuously optimize flow
rates, temperatures, and other parameters to maintain peak heat transfer efficiency.

Computational Fluid Dynamics (CFD) Analysis:

a. Utilize CFD simulations to model fluid flow and heat transfer within the coil. This
can help identify areas for improvement and guide design modifications.
33 | H e l i c a l T u b e H e a t E x c h a n g e r

Material Coatings:
a. Apply heat-conductive coatings or surface treatments to the inner surface of the coil
to enhance heat transfer.

Consider Phase Change:

a. In some applications, incorporating phase-change materials within the coil can
enhance heat transfer efficiency, especially during phase transitions.

Multiple Passes:
a. In some cases, multiple passes of the fluids through the coil can increase the contact
time and improve heat transfer.

Maintenance and Cleaning:

a. Regularly clean and maintain the heat exchanger to prevent fouling and scaling, which
can significantly reduce heat transfer efficiency over time.

When attempting to improve the heat transfer performance of a helical coil tube heat
exchanger, it is crucial to consider the specific requirements and constraints of the
application, perform thorough testing and analysis, and carefully balance trade-offs such
as pressure drop and energy consumption to achieve the desired efficiency
enhancements.
34 | H e l i c a l T u b e H e a t E x c h a n g e r

References

1. Jamshidi, N., Farhadi, M., Ganji, D., & Sedighi, K. (2013). Experimental analysis of heat

transfer enhancement in shell and helical tube heat exchangers. Applied Thermal

Engineering, 51(1–2), 644–652. https://doi.org/10.1016/j.applthermaleng.2012.10.008

2. Clark, G., & Van Der Werf, Y. D. (1998). Work in progress? The Industrious Revolution.

The Journal of Economic History, 58(3), 830–843.

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3. De Vries, J. (1994). The Industrial Revolution and the Industrious Revolution. The

Journal of Economic History, 54(2), 249–270.

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4. De Vries, J. (2008a). The Industrious Revolution.

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6. Jamshidi, N., Farhadi, M., Ganji, D., & Sedighi, K. (2013). Experimental analysis of heat

transfer enhancement in shell and helical tube heat exchangers. Applied Thermal

Engineering, 51(1–2), 644–652. https://doi.org/10.1016/j.applthermaleng.2012.10.008

7. Kumar, V., Saini, S., Sharma, M., & Nigam, K. (2006). Pressure drop and heat transfer

study in tube-in-tube helical heat exchanger. Chemical Engineering Science, 61(13),

4403–4416. https://doi.org/10.1016/j.ces.2006.01.039
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8. Litvine, A. (2014). THE INDUSTRIOUS REVOLUTION, THE INDUSTRIOUSNESS

DISCOURSE, AND THE DEVELOPMENT OF MODERN ECONOMIES. The

Historical Journal, 57(2), 531–570. https://doi.org/10.1017/s0018246x13000526

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Cambridge University Press.

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fins of air heat pump evaporator. Arch. Thermodyn. 37(2016), 3, 41–58,

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Microchannel cooling module. Appl. Therm. Eng. 93(2016), 1360–1366, DOI:

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