Thermo-Hydrodynamics of a Helical Coil Heat Exchanger Operated with a Phase-Change Ice Slurry as a Refrigerant

The thermal performance of helical-coil heat exchangers can be significantly enhanced when operated with ice slurry as a phase-change refrigerant. It is essential to also consider the hydrodynamics of ice slurry flow to determine the overall performance of the heat exchanger. This study presents a detailed numerical investigation of the thermo-hydrodynamic performance of a helical coil heat exchanger operated with a laminar and non-Newtonian flow of ethyl-alcohol ice slurry subject to phase change. The Bingham plastic model is used to reflect the non-Newtonian behavior of ice slurry. The phase change of ice slurry is modelled using the enthalpy-porosity method. The pressure drop and heat transfer of ice slurry in a double-turn helical coil are determined in terms of ice mass fraction and Dean number. The results show that an increase in the ice mass fraction and Dean number results in an increase of the heat transfer rate. This is, however, associated with an increase in pressure drop. The entropy generation analysis is introduced to evaluate the overall performance of the heat exchanger, taking into account the opposing effects of heat transfer and pressure drop. It is evident that, at certain ice mass fractions, there exists an optimal value of the Dean number that leads to minimum irreversibility and maximum overall performance.     

Melting of ice slurry in a tube‐in‐tube heat exchanger

One of the main components of a closed ice slurry system is the heat exchanger in which ice slurry absorbs heat resulting in the melting ice crystals. Design calculations of heat exchangers are mainly based on heat transfer coefficient and pressure drop data. But experiments presented in this paper show the effect of ice slurry mass flux on heat transfer rate and heat transfer coefficient during melting. For the experiments, ice slurry was made from 6.5% ethylene glycol–water solution, flowing through a 16.91mm internal diameter, 1500mm long horizontal copper tube. The ice slurry was heated by hot water circulated at the annulus gap of the heat exchanger. Experiments of the melting process were conducted with changing the ice slurry mass flux and the ice fraction from 800 to 3500kgm^?2s^?1 and 0 to 25%, respectively. During the experiment, it was found that the measured heat transfer rates increase with the mass flow rate and ice fraction; however, the effect of ice fraction appears not to be significant at high mass flow rate. At the region of low mass flow rates, a sharp increase in the heat transfer coefficient was observed when the ice fraction was more than a certain value. Experiments were also conducted to investigate the effect of hot water temperature on the heat transfer coefficient. Copyright © 2006 John Wiley & Sons, Ltd.     

Thermal performance and pressure drop of the helical-coil heat exchangers with and without helically crimped fins

In the present study, the thermal performance and pressure drop of the helical-coil heat exchanger with and without helical crimped fins are studied. The heat exchanger consists of a shell and helically coiled tube unit with two different coil diameters. Each coil is fabricated by bending a 9.50 mm diameter straight copper tube into a helical-coil tube of thirteen turns. Cold and hot water are used as working fluids in shell side and tube side, respectively. The experiments are done at the cold and hot water mass flow rates ranging between 0.10 and 0.22 kg/s, and between 0.02 and 0.12 kg/s, respectively. The inlet temperatures of cold and hot water are between 15 and 25 °C, and between 35 and 45 °C, respectively. The cold water entering the heat exchanger at the outer channel flows across the helical tube and flows out at the inner channel. The hot water enters the heat exchanger at the inner helical-coil tube and flows along the helical tube. The effects of the inlet conditions of both working fluids flowing through the test section on the heat transfer characteristics are discussed.     

Optimal design of a metal hydride hydrogen storage bed using a helical coil heat exchanger along with a central return tube during the absorption process

Metal-hydride (MH) reactors are one of the most promising approaches for hydrogen storage because of their low operating pressure, high storage volumetric density and high security. However, the heat transfer performance of the MH reactor for high hydrogenation rate is inferior. In this study, the heat transfer and hydrogen absorption process of metal hydride tank performance in Mg₂Ni bed is analyzed numerically using commercial ANSYS-FLUENT software. The MH reactor is considered a cylindrical bed including a helical tube along with a central straight return tube for the cooling fluid. The effects of geometrical parameters including the tube diameter, the pitch size and the coil diameter as well as operational parameters on the heat exchanged and hydrogen absorption reactive time are evaluated comprehensively. The results showed that the helical heat exchanger along with central return tube could effectively improve heat exchanged between the cooling fluid and the metal alloy and reduce the temperature of the bed results in a higher rate of hydrogen absorption. For a proper configuration and geometry of the helical coil heat exchanger with a central return tube, the absorption reaction time is reduced by 24% to reach 90% of the storage capacity. After the optimization study of the geometrical parameters, a system with the heat exchanger tube diameter of 5 mm, coil diameter of 18 mm and the coil pitch value of 10 mm is recommended to have lower hydrogen absorption time and higher hydrogen storage capacity. The presented MH reactor can be applied for improvement of heat exchange and absorption process in industrial MH reactors.     

Pressure drop of flowing ice slurries in industrial heat exchangers

Experiments were conducted to determine the characteristics of ice flows through industrial heat exchangers (a Tetra Plex^® C6-SR and a Tetra Spiraflo^® MTC70/W-3). This type of equipment presents many problems with respect to cleaning and is therefore of particular interest when considering a pigging system using ice slurry. Moderately thick ice slurries (in the range 15–60% solids) were successfully pumped through commercial heat exchangers. Measured pressure drops were greater than those with water, and rose with increasing ice fraction and flow rate. Evidence was seen for an exponential dependence of pressure drop on ice fraction, in addition to a water-like dependence on the square of flow rate. Blocking events were observed at higher ice fractions, or when large crystal masses were thought to be present in the ice slurry. It is likely that the risks of this could be mitigated by better mixing of the bulk ice slurry prior to and during delivery. For some tests the ice crystals may have grown to almost 1 mm in diameter, which is close to the characteristic dimension of the flow channels in the PHE (mean width 4 mm), increasing the likelihood of blockages forming.     

Condensation heat transfer and pressure drop of HFC-134a in a helically coiled concentric tube-in-tube heat exchanger

The two-phase heat transfer coefficient and pressure drop of pure HFC-134a condensing inside a smooth helically coiled concentric tube-in-tube heat exchanger are experimentally investigated. The test section is a 5.786 m long helically coiled double tube with refrigerant flowing in the inner tube and cooling water flowing in the annulus. The inner tube is made from smooth copper tubing of 9.52 mm outer diameter and 8.3 mm inner diameter. The outer tube is made from smooth copper tubing of 23.2 mm outer diameter and 21.2 mm inner diameter. The heat exchanger is fabricated by bending a straight copper double-concentric tube into a helical coil of six turns. The diameter of coil is 305 mm. The pitch of coil is 35 mm. The test runs are done at average saturation condensing temperatures ranging between 40 and 50 °C. The mass fluxes are between 400 and 800 kg m⁻² s⁻¹ and the heat fluxes are between 5 and 10 kW m⁻². The pressure drop across the test section is directly measured by a differential pressure transducer. The quality of the refrigerant in the test section is calculated using the temperature and pressure obtained from the experiment. The average heat transfer coefficient of the refrigerant is determined by applying an energy balance based on the energy rejected from the test section. The effects of heat flux, mass flux and, condensation temperature on the heat transfer coefficients and pressure drop are also discussed. It is found that the percentage increase of the average heat transfer coefficient and the pressure drop of the helically coiled concentric tube-in-tube heat exchanger, compared with that of the straight tube-in-tube heat exchanger, are in the range of 33–53% and 29–46%, respectively. New correlations for the condensation heat transfer coefficient and pressure drop are proposed for practical applications.     

Effect of coil-wire insert on heat transfer enhancement and pressure drop of the horizontal concentric tubes

In the present study, the heat transfer characteristics and the pressure drop of the horizontal double pipe with coil-wire insert are investigated. The inner and outer diameters of the inner tube are 8.92 and 9.52 mm, respectively. The coiled wire is fabricated by bending a 1 mm diameter of the iron wire into a coil with a coil diameter of 7.80 mm. Cold and hot water are used as working fluids in the shell side and tube side, respectively. The test runs are performed at the cold and hot water mass flow rates ranging between 0.01 and 0.07 kg/s, and between 0.04 and 0.08 kg/s, respectively. The inlet cold and hot water temperatures are between 15 and 20 °C, and between 40 and 45 °C, respectively. The effect of the coil pitch and relevant parameters on heat transfer characteristics and pressure drop are considered. Coil-wire insert has significant effect on the enhancement of heat transfer especially on laminar flow region. Non-isothermal correlations for the heat transfer coefficient and friction factor are proposed. There is reasonable agreement between the measured data and predicted results.     

Heat transfer using a correlation by neural network for natural convection from vertical helical coil in oil and glycerol/water solution

A physical-empirical model is designed to describe heat transfer of helical coil in oil and glycerol/water solution. It includes an artificial neural network (ANN) model working with equations of continuity, momentum and energy in each flow. The discretized equations are coupled using an implicit step by step method. The natural convection heat transfer correlation based on ANN is developed and evaluated. This ANN considers Prandtl number, Rayleigh number, helical diameter and coils turns number as input parameters; and Nusselt number as output parameter. The best ANN model was obtained with four neurons in the hidden layer with good agreement (R > 0.98). Helical coil uses hot water for the inlet flow; heat transfer by conduction in the internal tube wall is also considered. The simulated outlet temperature is carried out and compared with the experimental database in steady-state. The numerical results for the simulations of the heat flux, for these 91 tests in steady-state, have a R ≥ 0.98 with regard to experimental results. One important outcome is that this ANN correlation is proposed to predict natural convection heat transfer coefficient from helical coil for both fluids: oil and glycerol/water solution, thus saving time and improving general system performance.     

An experimental investigation on the effects of surfactants on the thermal performance of hybrid nanofluids in helical coil heat exchangers

In the present study, the effects of surfactants on the thermal performance of the hybrid nanofluid (Alumina–Silver) at constant wall temperature and laminar flow have been experimentally studied in a helical coil heat exchanger. Different surfactants such as anionic Sodium Dodecyl Sulfate (SDS) and nonionic Poly Vinyl Pyrrolidone (PVP) in the concentration of range of 0.1–0.4 wt.% are employed. It is found that the thermal performance can be maximized by using the 0.2 vol.% hybrid nanofluid and 0.1 wt.% SDS anionic surfactant in the helical coil. The maximum thermal performance in the presence of hybrid Alumina–Silver nanofluid and SDS anionic surfactant is 16% higher than that of the pure distilled water. The presented results can have potential application in process intensification and optimum design of heat exchangers.     

Experimental study of closed‐loop thermosyphon with a different evaporator geometry

In this study, the effect of evaporator geometry on the loop thermosyphon's heat transfer coefficient is experimentally verified by using water as a working fluid with three filling ratios (50%, 70%, 90%), constant heat input (185 W), and condenser cooling water flow rate remaining constant at 2 Lpm. Three evaporator pipes are used (I: straight; II: helical coil evaporator with a diameter of 100‐mm coil and two turns; III: helical coil evaporator with a diameter of 50‐mm coil and four turns). From the experimental results, it can be observed that the performance of evaporator III is higher than the two other forms. A greater heat transfer coefficient value is found in case of type III evaporator and is equivalent to 2456 W/m²·°C. The maximum thermal resistance reduction occurs in the type III evaporator (37.32%), and the highest effective thermal conductivity for the same type is 6.123e + 05 W/m·°C. The experimental results demonstrate good agreement with the empirical equations.     

Experimental investigation of heat transfer coefficient and friction factor of ethylene glycol water based TiO2 nanofluid in double pipe heat exchanger with and without helical coil inserts

Heat transfer coefficient and friction factor of TiO₂ nanofluid flowing in a double pipe heat exchanger with and without helical coil inserts are studied experimentally. The experiments are conducted in the range of Reynolds number from 4000 to 15,000 and in the volume concentration range from 0.0004% to 0.02%. The base fluid is prepared by considering 40% of ethylene glycol and 60% of distilled water. The heat transfer coefficient and friction factor get enhanced by 10.73% and 8.73% for 0.02% volume concentration of nanofluid when compared to base fluid flowing in a tube. Heat transfer coefficient and friction factor further get enhanced by 13.85% and 10.69% respectively for 0.02% nanofluid when compared to base fluid flowing in a tube with helical coil insert of P/d = 2.5. The measured values of heat transfer coefficient and friction factor are compared with the published literature. Based on the experimental data, generalized correlations are proposed for Nusselt number and friction factor. The results are presented in graphical and tabular form. Uncertainty analysis is also carried out and the experimental error is in the range of ± 10%.     

Numerical investigation of heat transfer and pressure drop characteristics of tube–fin heat exchangers in ice slurry HVAC system

This paper analyzes the heat transfer and pressure drop characteristics of a tube–fin heat exchanger in ice slurry HVAC system. Ice slurry is a suspension of crystallized water based - ice solution with a freezing point depressant like ethylene glycol. The ice- slurry is pumpable, hence it is also called pumpable ice. The composition of ice slurry considered for analysis is 14% ice fraction, 16% ethylene glycol, and 70% water by volume. It is deduced that the ice slurry HVAC system results in 7.4% increase in temperature drop over the conventional chilled water system The latent heat absorbed by ice slurry on melting makes it an attractive choice for achieving high degree of cooling. The numerical analysis was conducted by simulating the ice slurry tube flow region and air flow region of tube–fin heat exchanger in the air-handling unit of HVAC system. For the simulation six different louver patterns with 10 to 55 louver angle were considered. The design of the tube–fin heat exchanger for optimal heat transfer and pressure drop characteristics was also determined with the optimization parameter like louver angle, fin pitch, and ice slurry flow velocity.     

Heat transfer characteristics in a tube fitted with helical screw-tape with/without core-rod inserts

Effects of insertion of a helical screw-tape with or without core-rod in a concentric double tube heat exchanger on heat transfer and flow friction characteristics are experimentally investigated. The heat exchanger has the outer and the inner tube diameters of 50 mm (D_o) and 25 mm (D) where the cold and the hot waters used as the test fluids are in shell and tube sides, respectively. The stainless steel helical screw-tape has the geometrical dimensions of width (W) 17 mm with the clearance to the tube wall (D − W) / 2 = 4 mm. Thus, the insertion of the screw-tape in the tube is considered as a loose-fit. In the experiment, the loose-fit helical tape with or without core-rod, is inserted in the inner tube of the heat exchanger and the hot water enters the tube based on its Reynolds number in a range of 2000 to 12,000. The experimental results show that the increases in average Nusselt number of using the loose-fit, helical tape with and without core-rod are found to be 230% and 340%, respectively, over the corresponding plain tube. It is worth noting that for the loose-fit, helical tape without core-rod, the friction factor is around 50% less than that for the one with core-rod while the Nusselt number is about 50% higher. Furthermore, the enhancement efficiency of the helical screw-tapes varies between 1.00 and 1.17, 1.98 and 2.14, for the tapes with and without core-rod, respectively.     

Hydrogen storage system based on hydride materials incorporating a helical-coil heat exchanger

Metal hydrides offer the potential to store hydrogen at modest pressures and temperatures with high volumetric efficiencies. The process of charging hydrogen into a metal powder to form the hydride is exothermic. The heat released by the reaction must be removed quickly in order to maintain a rapid charging rate. An effective method for heat removal is to embed a heat exchanger within the metal hydride bed. Here, we investigate the effectiveness of a helical coil heat exchanger tube to remove the heat generated during the absorption process. This paper presents a three-dimensional mathematical model formulated in Ansys Fluent 12.1 to evaluate the transient heat and mass transfer in a cylindrical metal hydride tank embedded with a helical-coil cooling tube. We present results from a parametric study of hydrogen storage efficiency as a function of helical coil pitch and convective heat transfer coefficient (h) within the cooling tube. We also explore the effect of adding aluminum foam to enhance the thermal conductivity of the metal hydride. The parametric study reveals that the mass of stored hydrogen is less sensitive to the coil pitch when aluminum foam is added. It is also found that the absorption rate increases with h as expected, although the rate of improvement diminishes at high values of h. Results were examined at filling times of 3 and 6 min to draw conclusions about the overall effectiveness of this hydrogen storage system. At 3 min, it is found that the addition of 5% Al foam is optimal, and h = 1000 W/m²-K is sufficient to bring the metal hydride to saturation; under these conditions a non-dimensional pitch of 0.5 maximizes the hydrogen absorption. Adding Al foam beyond 5% does not improve volumetric efficiency as the Al foam begins to displace the active hydrogen-absorbing material.     

Thermal analysis of slurry ice production system using direct contact heat transfer of carbon dioxide and water mixture

This research studies the heat transfer characteristic during ice formation of a direct contact heat transfer between carbon dioxide and water mixture. This research is divided into two parts. For the first part, the low temperature carbon dioxide, between − 15 and − 60 °C, is injected into water initially at 28 °C and exchanges heat directly. The flow rate of carbon dioxide is varied between 0.003 and 0.017 kg/s while the volume of water is between 1 and 3 L. From the experiment, it is found that the effectiveness of the direct contact heat transfer between the carbon dioxide and the water is closed to 100%. Moreover, the lumped model is found to be used for predicting the temperature of water and the mass of ice formation quite well.     

Mathematical Model for Predicting the Heat Transfer Characteristics of a Helical-Coiled,Crimped, Spiral,Finned-Tube Heat Exchanger

This paper is a continuation of the authors’ previous work. Theoretical and experimental studies of the heat transfer characteristics of a helical-coiled, crimped, spiral, finned-tube heat exchanger in dry surface conditions are presented. The test section is a helical-coiled, finned-tube heat exchanger. The coil unit is composed of four concentric helical-coiled tubes of different diameters. All tubes are constructed by bending straight copper tube into seven layers of helical coil. Aluminum crimped spiral fins, with an outer diameter of 28.25 mm and a thickness of 0.5 mm, are connected around the tube. Hot water is used as a working fluid for the tube side, while ambient air is used for the shell side. The test runs are done at air mass flow rates ranging between 0.04 and 0.13 kg/s. The water mass flow rates are between 0.2 and 0.4 kg/s. The water temperatures are between 40 and 50°C. A mathematical model is developed and the simulation results show reasonable agreement with the experimental data.     

Pipeline transport of biomass: Experimental development of wheat straw slurry pressure loss gradients

Pipeline transport in the form of a slurry can reduce the cost of transportation of biomass material to a biorefinery, as compared to trucks. This research experimentally studies the hydraulics of slurries of wheat straw with water for pipeline transport. Slurries with a range of particle sizes and saturated solid mass fractions are examined in a laboratory-scale 50 mm diameter carbon steel pipeline system. Slurries with particles approximately 3 mm long can flow with saturated solid mass fractions of up to 30%. Pressure loss gradients results suggest the influence of drag reducing fibre suspensions. This phenomenon enables slurry pressure losses to be below that of the carrier fluid alone (water) and be achieved with sufficiently long particle sizes, low saturated solid mass fractions and high velocities. Our results suggest that to reduce pressure losses per unit biomass material, slurries should have short particle sizes, to allow high saturated solid mass fractions to be pumped at low velocities. With the pipeline system and slurries examined in this study, slurries with particles approximately 3 mm long and saturated solid mass fractions of 20–30% pumped at 1.5 m s⁻¹ experience the lowest pressure losses. This result helps in the design and optimal operation of biomass slurry pipeline systems.     

Experimental studies on heat transfer and friction factor characteristics of turbulent flow through a circular tube fitted with regularly spaced helical screw-tape inserts

Experimental investigation of heat transfer and friction factor characteristics of circular tube fitted with full-length helical screw element of different twist ratio, and helical screw inserts with spacer length 100, 200, 300, and 400 mm have been studied with uniform heat flux under turbulent flow condition. The experimental data obtained are verified with those obtained from plain tube published data. The effect of spacer length on heat transfer augmentation and friction factor, and the effect of twist ratio on heat transfer augmentation and friction factor have been presented separately. The decrease in Nusselt number for the helical twist with spacer length is within 10% for each subsequent 100 mm increase in spacer length. The friction factor for helical twist insert with spacer length 100 mm is very much close to value of friction factor for full-length helical twist for all Reynolds number and decreases by 5% for each 100 mm increment space length indicating that there is no much reduction in pumping power. Hence the helical screw inserts with spacer can only be used for heat augmentation only in turbulent flow with less reduction in pumping power. Empirical correlation were formed for explaining data and found to fit experimental data within ±10%, and ±20%, respectively, for Nusselt number and friction factor.     

The performance of a cylindrical solar water heater

A cylindrical solar water heater is designed and manufactured in the Department of Mechanical Engineering, University of Bahrain. It consists of a cylindrical tube made from high quality glass having a length of 0.8, 0.14 m outer diameter and a thickness of 6 mm. A copper coil tube in the shape of spiral rings, with the tube inner diameter of 2 mm and outer diameter of 3.175 mm, painted black, serves as a collector to the incident solar energy on the cylinder wall. The thermal performance was evaluated extensively throughout the months of March and April 2002; a maximum temperature difference of 27.8 °C between inlet and outlet of the solar water heater at a mass flow rate of 9 kg/h was achieved. The efficiency of the cylindrical solar water heater was calculated. The maximum value during the experimental period was found to be 41.8%. This reveals a good capability of the system to convert solar energy to heat which can be used for heating water. An economic analysis has reveals that the cylindrical solar water heater compared with the flat plate collector is cost effective.     

The first and second law analysis of a lithium bromide/water coil absorber

The aim of this paper is to study the irreversibilities in a coil absorber using lithium bromide solution and to determine the variation of the second law efficiency with some variables such as cooling water flow rate, solution flow rate, cooling water temperature and solution concentration. The influence of absorber performance parameters is examined on the basis of the first and second laws of thermodynamics for parallel and counter-current types. In this regard, the heat and mass transfer, the second law efficiency, the magnitude and place of exergy losses in two types of absorbers are estimated and discussed comprehensively. The results showed that increasing the cooling water flow rate and decreasing the cooling water inlet temperature increase the heat and mass transfer, and decrease the second law efficiency. The effect of the solution concentration on the efficiency in general is small. Whereas the irreversibility for the counter-current mode is greater than that of the parallel-current mode, the heat-mass transfer 3–19% and the second law efficiency 1–12% are higher.