"Enhanced Heat Transfer Performance in Shell and Tube Heat Exchangers: A CFD Analysis of Twisted Tape Turbulators with Nanofluid Insertion"

International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 11 Issue: 02 | Feb 2024 www.irjet.net p-ISSN: 2395-0072
© 2024, IRJET | Impact Factor value: 8.226 | ISO 9001:2008 Certified Journal | Page 98
"Enhanced Heat Transfer Performance in Shell and Tube Heat
Exchangers: A CFD Analysis of Twisted Tape Turbulators with
Nanofluid Insertion"
Sudhanshu Bhushan1, Ajay Singh2, Parag Mishra3
1 Scholar, Department of Mechanical Engineering, Radharaman Institute of Technology and Science, Bhopal, M.P.,
India.
2Head and Prof., Department of Mechanical Engineering, Radharaman Institute of Technology and Science,
Bhopal, M.P., India.
3Assosiate Professor, Department of Mechanical Engineering, Radharaman Institute of Technology and Science,
Bhopal, M.P., India.
---------------------------------------------------------------------***---------------------------------------------------------------------
Abstract - This study presents a comprehensive
computational fluid dynamics (CFD) analysis of a shell and
tube heat exchanger with anovelenhancementtechnique - the
insertion of twisted tape turbulators within the tubeside - and
the incorporation of Aluminum Oxide (Al2O3) nanoparticles in
water as the base fluid. The primary objective is to investigate
and compare the heat transfer rate, convective heat transfer
coefficient, and pressure drop characteristics under various
operating conditions. The numerical simulations were
conducted using commercial CFD software, where the
governing equations of mass, momentum, and energy were
solved employing the finite volume method. Thek-εturbulence
model was adopted to account for turbulent flow behavior
inside the heat exchanger. The results obtained from the CFD
simulations were validated against experimental data,
ensuring the accuracy and reliability of the computational
approach. Subsequently, a parametricstudywasperformedto
explore the effects of varying nanoparticle concentrations,
flow velocities, and twist ratios of the tape turbulators on the
heat transfer and pressure drop characteristics. The findings
reveal that the incorporation of Al2O3 nanoparticles
significantly enhances the overall heat transfer rate, with
notable improvements observed at higher nanoparticle
concentrations. Moreover, the convective heat transfer
coefficient is found to be enhanced due to the presence of the
twisted tape turbulators, demonstrating a significant impact
on the overall performance of the heat exchanger. However, it
is also observed that an increase in nanoparticle
concentration leads to an augmentedpressuredropacrossthe
heat exchanger. Therefore, a trade-offbetweenenhancedheat
transfer and increased pressure dropneedstobeconsideredin
practical applications. In conclusion, this study provides
valuable insights into the use of twisted tape turbulators and
SiO2 nanofluids in shell and tube heat exchangers. The results
offer a fundamental understanding of the thermal and
hydrodynamic behavior and can aid in optimizing the design
and operational parameters to achieve an optimal balance
between enhanced heat transfer performance and acceptable
pressure drop levels in industrial applications.
Key Words: Heat Exchanger, Nanofluid, Twisted Tape
Turbulator, CFD Analysis, Thermal Analysis
1.INTRODUCTION
Heat exchangers play a pivotal roleinnumerousindustrial
processes and energy systems, facilitating efficient thermal
energy transfer between two fluid streams. Over the years,
researchers have explored various enhancementtechniques
to augment the heat transfer rate and improve the overall
efficiency of these heat exchangers. Among the prominent
techniques, the insertion of turbulators within the tube side
and the utilization of nanofluids have shown promising
results in enhancing heat transfer characteristics. In recent
years, computational fluid dynamics (CFD) hasemergedasa
powerful tool for investigating fluid flow and heat transfer
phenomena. CFD simulations provide detailed insights into
complex fluid dynamics and offer a cost-effective approach
to evaluate different heat exchanger configurations and
operating conditions. This study focuses on conducting a
comprehensive CFD analysis of a shell and tube heat
exchanger, which incorporates twisted tape turbulators
inside the tube and utilizes a nanofluid composed of silicon
dioxide (SiO2) nanoparticles dispersed in water as the base
fluid. The incorporation of twisted tape turbulators in the
tube side of heat exchangers has gained popularity due to
their ability to induce turbulence and enhance convective
heat transfer. Twisted tapes promote the formation of
secondary flow patterns, breaking the boundary layer and
leading to increased heat transfer rates. Consequently,these
turbulators have been widely adopted to improve the
thermal performance of heat exchangers, particularly in
applications involving high heat transfer requirements. In
addition to the use of turbulators, nanofluids have emerged
as a promising heat transfer enhancement medium.
Nanofluids are colloidal suspensions of nanoparticles in a
base fluid, which exhibit unique thermal properties
compared to conventional fluids.

2. LITERATURE SURVEY
In this experimental study, the Electro-Magnetic Vibration
(EMV) method utilizes a stretched string vibrating at its
natural frequency within a heated tube, induced by an AC
magnetic field.Thisnovelapproachgeneratesturbulenceand
radial flow, boosting heat transfer rates. Analysis involving
varying vibrating string turbulator (VST) diameters and
exciter positions, alongsidethermal performance evaluation
(TEF), revealed a potential enhancement factor of up to 1.47.
This underscores EMV's effectiveness in intensifying heat
exchanger performance through robust radial flow
generation [1]. This study introduces the Special Shape
Twisted TapeTurbulator (SSTT)withaDNA-likestructureto
enhance heat transfer in conduits. Through segmented
components, it induces swirling motion, showing a 125%
improvement over plain tubes at a 2mm pitch ratio.
Combining SSTT with a helical coiled wire turbulatoryieldsa
142% increase in heat transfer but also a 960% rise in
pressure drop, achieving a 20% enhancement in thermal
performance to 1.31 [2]. This research employed the
innovative electromagnetic vibration (EMV) technique in a
double-tube heat exchanger (DTHEX) for enhanced heat
transfer. Assessing factors like oscillator geometry, magnet
placement, nanofluids, and fluid flow, it achieved a
remarkable 277.5% improvement using CuO-water 1%
nanofluid compared to a standard heat exchanger. With the
potential to increase heat transfer by up to 13.3 times the
energy input, this method presents a transformative
opportunity in conserving materials, energy, and optimizing
heat exchanger and solar system designs [3]. This paper
explores renewable energyuseinresidentialandgreenhouse
heating/cooling, focusing on soil air conditioning systems.
Findings highlight air-driven ventilation as superior in
summer, with smaller pipe diameters and longer pipelines
enhancing performance. The study conducted infourIranian
cities demonstrates Rasht's system as highly effective for
heating and Abadan's for cooling. Additionally, cost
comparisons between soil cooling and conventional HVAC
systems were examined [4]. The study investigated heat
transfer and exergy losses in a double-tube heat exchanger
with corrugated inner tubes. Semi-elliptical corrugations on
the inner tubesignificantlyimpactedheattransferandexergy
losses, while modified corrugations, combining quarter-
elliptic shapes and inclined lines, delayed flow separation,
boosting heat transfer.However,heightenedheattransferled
to escalated exergy losses, emphasizing the trade-offs in
performance enhancement [5]. This paper delves into a
numerical investigation of a three-dimensional baffled shell
and tube heat exchanger, exploring the influence of physical
variables like baffle numbersand baffle type changesonheat
transfer and exergy using the SST turbulence model.
Analyzing oil and water as hot and cold fluids, the findings
reveal that increasing oil flowratesescalateheattransferand
exergy loss. Furthermore, augmenting baffles from 3 to 5
amplifies both heat transfer and exergylossinthesystem[6].
The study investigates enhanced thermal performance in
Shell and Helically CoiledTubeHeatExchangers(SHCTHEXs)
using an Al2O3-TiO2/water hybrid nanofluid. Simulations
reveal a 7.7% to 9% increase in heat transfer rates for the
horizontallyand vertically oriented SHCTHEXs, respectively.
The best performance is seen in the horizontally oriented
SHCTHEX with the hybrid nanofluid, providing superior
cooling compared to other configurations, emphasizing the
significant impact ofnanofluidutilizationonheattransfer[7].
This paper consolidates findings on enhancing
thermophysical properties of nanofluids by examining key
parameters like particle characteristics, base fluid,
temperature, additives, and pH. It serves as a valuable
resource amidst conflicting reports, aiding researchers in
navigating diverse studies. Additionally, it delves into
nanofluid applications,emphasizingtheiradvantagesinsolar
collectors and automotive heat exchangers, aiming to bridge
the gap between lab-scale research and practical industrial
implementation while outlining avenues for future
exploration [8]. The study constructed carbon nanotubes-
reinforced composite honeycomb sandwich panels via
silicone molding to enhance mechanical properties. The
results showcased a direct correlation between increased
nanotube content and wall thickness with higher
compressive and flexural strength, highlighting potential for
stronger sandwich panels with tailored properties [9]. The
manipulation of electrical and thermal conductivity in CNT-
modified polymeric composites (CNTMPCs) hinges on
various factors suchas chirality, length, type,fabrication,and
interface interactions. Molecular dynamics(MD)simulations
highlight how chirality impacts shorter CNTs more than
longer ones, with zigzag CNTs showing lower conductivity
than armchair types. Additionally, MD modeling
demonstrates a notable increase in thermal and electrical
conductivity with longer overlap lengths, underscoring the
potential for designing highly conductive CNTMPCs with
specificproperties,thoughfurthercomprehensivestudiesare
necessary due to the multitude of influencing factors [10].
The use of carbon nanotubes (CNTs) in silicone-molded
composites for honeycomb sandwich structures enhances
thermal stability and energy absorption. Increasing CNT
content up to 0.075 wt.% notablyraisedthermaldegradation
temperature by 14°C and improved energy absorption by
4.6%. Innovative dispersion techniques resulted in higher
thermal conductivity with lower CNT amounts compared to
prior studies, offering engineers an optimal strategy for
designing superior thermal properties in composite
structures [11]. In this research, a novel aerodynamically
designed perforated teardrop-shapedturbulator(PTST)was
numerically analyzed for its impact on hydro-thermal
parameters. Variations in hole geometry and area within the
PTST revealed significant effects on heat transfer and
pressure drop, highlighting a 1.39-fold increase in Thermal
Enhancement Factor (TEF) with a 5 mm diameter circular
hole. Comparatively, PTST and simple teardrop-shaped
turbulator (STST) showed 298% to 310.1% higher heat
transfer than a plain tube, while a correlation between TEF
and perforation area was established through curve fitting

[12]. This paper delves into enhancing the exergo-economic
performance of compact air heat exchangers by employing
passive techniques like TTI, PTTI, and DTTI with various
tripartite hybrid nanofluids. Simulation results show that
DTTI with THNF6 exhibits the highest overall heat transfer
coefficient (26%), 2.94% exergy efficiency, 5.04%
performance index,and a superiorsustainabilityindexatlow
Reynolds numbers, while THNF2, due to its high operating
cost, is less preferred despite a PEC range of 1.42–2.35 [13].
The study enhanced conventional Shell and Helically Coiled
Tube Heat Exchangers (SHCTHEXs) by integrating discs and
rings as baffles, elevating thermal performance. Numerical
simulations revealed a 7.1% increase in heat transfer and a
20% rise in overall heat transfer coefficient compared to the
conventional design. Experimental validationcloselyaligned
with simulations, showcasing a promising 2.4-3.5%
difference, affirming the success of the modified SHCTHEX
with circular baffles, achieving an overall heat transfer
coefficient of 1050-1400 W/m²K [14]. This study explores
enhancing U-type tubular heat exchanger (THEX) efficiency
by employingCuO-Al2O3/waterhybridnanofluid.Numerical
simulations and experimentalanalysesdemonstratethatthis
hybrid nanofluid significantly boosts overall heat transfer
coefficients in THEX compared to single-component
nanofluids. While fin additions elevate heat transfer, they
escalatepressuredropparticularlyinsmallerdiameterTHEX,
highlighting the efficacy of hybrid nanofluids in augmenting
thermal performance without such drawbacks [15]. This
paper explores an experimental analysis of a heat exchanger
tube using a newly devised perforated conical ring in
combination with twisted tape inserts.Itinvestigatesdiverse
geometric and flow parameters,spanningReynoldsnumbers
from 6000 to 30000, nanoparticle volume concentrations of
0.25-1.0%,and various ratiosfor inlet flow diameter toinner
print diameter of the ring,ringpitch,andtwistratios.Optimal
thermal-hydraulic performance (1.45) was achieved at
specific parameters, paving the way for empirical
correlations for Nusselt number and friction factor in
CuO/H2O nanofluids flow heat exchanger tubes with
perforated conical rings [16].
Table 1: Properties of base fluid, nanoparticles and
nanofluid
Vol.
Concen
tration
(%)
Thermal
Conductivit
y (W/mK)
Density
(kg/m3)
Specific
heat
(J/KgK)
Al2O3/H2O
(Nanofluid)
1 0.6327 1026 4046
2 0.65075 1055 3922
3 0.66915 1085 3804
SiO2/H2O
(Base Fluid)
- 32-36 3970-3990 760-870
3. OBJECTIVE OF PRESENT STUDY
The problem of performance of heat exchanger can be
improved by either creating a turbulence in the flow regime,
or by improving the quality of fluid flowing through the
system. Enhancement of the heat transfer enables the size of
the heat exchanger to be significantly decreased.
In the present work, passive techniques/twisted tape
turbulators (TTT) producing swirl motion are used to
improve the thermal performance characteristics of
concentric tube heatexchangerswithdifferentnanoparticles.
Thus, the effect of fluid quality improvement is studied in
double tube heat exchanger by addition of aluminum oxides
nano particles (Al2O3). A comparative analysis is done by
changing the concentration of nano particles in baseliquidof
water. The best concentration value of nanofluidwillprovide
the optimize qualities of nanofluid which keeping the shear
stress in controlled limits. A total of 4 readings are taken on
different values of mass flow rates in ordertoverifythetrend
of performance. The mass flow rate of cold nanofluid is kept
on 0.05, 0.1, 0.15, 0.20 kg/s respectively.
4. GEOMETRY OF THE HEAT EXCHANGER
Table 2 shows the geometry of the heat exchanger. Outside
diameter of the tube is 40 mm, inside dimeter of the tube is
41 mm. outside diameter if shell is 80mm and inside
diameter of shell is 82 mm
Table 2: Specifications Of Heat Exchanger
Sr.No. Parameter Value in mm Value in
meters
1 Outside Diameter of
Aluminum tube
40 mm 0.04 m
2 Inside Diameter of
Aluminum tube
41 mm 0.041 m
3 Outside Diameter of
Aluminum shell
80 mm 0.08 m
4 Inside Diameter of
Aluminum shell
82 mm 0.082 m
5 Effective Length of
Aluminum tube
1020mm 1.02 m
6 Effective Length of
Aluminum shell
1000mm 1.0 m
7 Heat Transfer Area 8.5316e+05
mm²
0.85
8 Sweep with number of turns 4, 8, 12 -

Figure 1: Geometry of Heat Exchanger with twisted tape
and meshing
The dataset presents details of analuminumtubeandshell
heat transfer system, featuring a tube with an outerdiameter
of 40 mm and an inner diameter of 41 mm, as well as a shell
with an outer diameter of 80 mm and an innerdiameterof82
mm. The effective lengths of the tube and shell are 1020 mm
and 1000 mm, respectively, with a heat transfer area of
853,160 mm². Additionally, the data mentions a parameter
called "Sweep with number of turns," which is 4, 8 and 12.
5. CFD REPORT
Table 3 shows the meshing report of the geometry. It
shows the element size, mesh quality, inflation information
and statistics like number of nodes and elements.
Table 3: Meshing Report
Object Name Mesh
State Solved
Display
Display Style Use Geometry Setting
Defaults
Physics Preference CFD
Solver Preference Fluent
Element Order Linear
Element Size 5.e-003 m
Export Format Standard
Export Preview Surface
Mesh
No
Sizing
Use Adaptive Sizing No
Growth Rate Default (1.2)
Max Size Default (1.e-002 m)
Mesh Defeaturing Yes
Defeature Size Default (2.5e-005 m)
Capture Curvature Yes
Curvature Min Size Default (5.e-005 m)
Curvature Normal Angle Default (18.0°)
Capture Proximity No
Bounding Box Diagonal 1.016 m
Average Surface Area 0.11282 m²
Minimum Edge Length 1.7279e-002 m
Quality
Check Mesh Quality Yes, Errors
Target Skewness Default (0.9)
Smoothing Medium
Mesh Metric Skewness
Min 1.79E-03
Max 0.8814
Average 0.34647
Standard Deviation 0.22805
Inflation
Use Automatic Inflation None
Inflation Option Smooth Transition
Transition Ratio 0.272
Maximum Layers 5
Growth Rate 1.2
Inflation Algorithm Pre
View Advanced Options No
Advanced
Number of CPUs for Parallel
Part Meshing
Program Controlled
Straight Sided Elements
Rigid Body Behavior Dimensionally Reduced
Triangle Surface Mesher Program Controlled
Topology Checking Yes
Pinch Tolerance Default (4.5e-005 m)
Generate Pinch on Refresh No
Statistics
Nodes 2364475
Elements 3916835
6. RESULT AND DISCUSSION
6.1. Heat Transfer Rate
Figure 2 shows the comparative values of heat transfer rates
of concentric circular plane tubes without any inserts, with

water flowingas hot fluid in both the cases but in case of cold
fluid, one arrangementhaswaterflowingascoldfluidandthe
next time, the Al2O3 nano fluid with volume fraction of 0.4 is
flowing as cold liquid respectively. The comparison shows
that the maximum value of heat transfer rate for the same
flow rates is achieved for water- nanofluid arrangement at
0.4 kg/s with a value of 8632.15 watts and Water-nanofluid
with insert (Noofturns-4)Water-nanofluidwithinsert(Noof
turns-8) and Water-nanofluid with insert (No of turns-12) is
6288.7 W, 8632.7 W and 9876.17 W.
Figure 2: Rate of Heat Transfer versus mass flow rate of
Hot Fluid in Counter Flow arrangement
6.2. Convective Heat Transfer Coefficient
Fig. 3 shows the comparative values of Overall Heat transfer
coefficient of concentric circular plane tubes without any
inserts, with water-water arrangement and water-nanofluid
arrangement respectively. The comparison shows that the
maximum value of Overall Heat transfer coefficient for the
same flow rates is achieved water-nanofluid arrangement at
0.2kg/s with a value of 2245.81 (Watts/(m2-K)).
Figure 3: Overall Heat transfer coefficient versus mass
flow rate of Cold Fluid in Counter Flow arrangement
6.3. LMTD
Fig 4 shows the comparative values of LMTD of concentric
circular plane tubes without any inserts, with water-water
and water-nanofluid arrangement respectively. The
comparison shows that the maximum value of LMTD for the
sameflow ratesisachievedforwater-nanofluidarrangement,
and it was at its maximum on0.2kg/swithavalueof9.21088.
This growth is due to the fact that temperature difference at
the inlet and exit increases. Since LMTD is directly
proportional tochange in temperatureatinletandexit. Thus,
it also shows increase w.r.t the mass flow rate.
Fig. 4: LMTD versus mass flow rate of cold Fluid in Counter
Flow arrangement
6.4. Effectiveness
Figure 5 shows the comparison of heat transfer rates among
water as a hot fluid and cold fluid, hot fluid as a water and
cold fluid as a nanofluid with different number of turnsofthe
insert like 4 turns, 8 turns and 12 turns. From the graph, it
can clearly be seen that as the thermal properties of the fluid
increases, rate of heat transfer increases due to high thermal
properties of nanofluid in comparison with water. But as we
put a insert of twisted tapeturbulator, it providesturbulence
in the fluid. Turbulenceincreasestheconvectiveheattransfer
coefficient of the fluid. And we know that convective heat
transfer coefficient of turbulent flow is greater than the
laminar.

Fig. 5: Effectiveness versus mass flow rate of Hot Fluid in
Counter Flow arrangement
7. CONCLUSION
1) In this research workthepropertiesofAl2O3nanofluid
were found out and defined in software for various values of
concentration factor. The performance of nanofluid is
observed to be optimum at concentration factorof0.4,which
was selected to calculate theperformance of heat exchanger.
2) In the present research work it is found out that the
overall heat transfer coefficientishavingamaximumvalueof
7624.53 Watts/m2k for the counter flow arrangement of
water-water type heat exchanger which is 42% less than the
value we obtained for water-nanofluid arrangement, which
has a value of 13039.99 Watts/m2K.
3) It is noted that LMTD for water-nanofluidarrangement
was found to be 9.21 K which is greater than water-water
arrangement by 24%.
4) The effectiveness of water-nanofluid arrangementwas
also found to be maximum with a value of 0.149 which is
more than that of water-water heat exchanger arrangement
by 56% at a volume flow rate of 0.2kg/s of cold water.
5) The maximum heat transfer rate was noted to be
increased by an amazing amount of 55% for a mass flow rate
of 0.2kg/swater-nanofluidarrangementincomparisontothe
water-water arrangement which had a value of 2219.11
Watts for the same working conditions.
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"Enhanced Heat Transfer Performance in Shell and Tube Heat Exchangers: A CFD Analysis of Twisted Tape Turbulators with Nanofluid Insertion"

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