Journal of Thermal Analysis and Calorimetry

https://doi.org/10.1007/s10973-020-09395-3

Thermal performance of a helical shell and tube heat exchanger

without fin, with circular fins, and with V‑shaped circular fins applying
on the coil
Mehdi Miansari1 · Aghil Jafarzadeh1 · Hossein Arasteh2 · Davood Toghraie3

Received: 29 July 2019 / Accepted: 26 January 2020

© Akadémiai Kiadó, Budapest, Hungary 2020

Abstract
This numerical study analyzes the thermal performance of a helical shell and tube heat exchanger without a fin, with circu-
lar fins, and with cut (V-shaped) circular fins (with an angle of 15°) applying on the coil. The obtained results showed that
in both simple and circular finned heat exchangers when the fluid velocity (both hot and cold) on the shell side is higher
than the fluid velocity (both hot and cold) on the tube side, the heat transfer improves. It is also found that flowing the cold
water through the shell increases its velocity and flowing the hot fluid through the coil results in higher heat transfer values.
Moreover, the results revealed that the highest heat transfer magnitude designates the circular finned heat exchanger with
a cold water velocity of 3 m s−1 entering the shell and a hot water velocity of 1 m s−1 entering the tube. Finally, it is found
that the cut circular fins effects on the helical shell and tube heat exchanger efficiency and heat transfer are insignificant in
comparison with the circular fins.

Keywords  Helical coil · Shell and tube heat exchanger · Cut fin · V-shaped fin
List of symbols x, y, z Coordinate axes
cp Specific heat capacity (J kg−1 K−1) 𝜀 Turbulent dissipation rate ­(m2 s−3)
C1, C2 Model coefficients 𝜆 Thermal conductivity (W m−1 K−1)
D Diameter (m) 𝜇 Dynamic viscosity (kg m−1 s−1)
Gk Producing item of the k by the mean velocity 𝜈 Kinematics viscosity ­(m2 s−1)
gradient (kg m−1 s−3) 𝜌 Density (kg m−3)
h Heat transfer coefficient (W m−2 K−1) 𝜎k Turbulent Prandtl number for k
k Turbulent kinetic energy (m s−2) 𝜎ε Turbulent Prandtl number for 𝜀
L Heat exchanger length (m)
Subscripts
ṁ Mass flow rate (kg s−1)
i, j Tensor
Nu Nusselt number
avg Average
P Pressure (Pa)
c Cold
Q Heat transfer rate (W)
h Hot
Re Reynolds number
i Inlet
T Temperature (K)
o Outlet
U Velocity (m s−1)

* Mehdi Miansari Introduction

[email protected]
1
Department of Mechanical engineering, Qaemshahr Branch, Heat exchangers are almost the most widely used member
Islamic Azad University, Qaemshahr, Iran of the chemical and industrial processes and can be found in
2
Department of Mechanical Engineering, Isfahan University most industrial units such as refinery, power plants, food
of Technology, Isfahan, Iran industry and pharmaceuticals. The heat exchanger provides
3
Department of Mechanical Engineering, Khomeinishahr the ability to transfer heat energy between two or more fluids
Branch, Islamic Azad University, Khomeinishahr, Iran at different temperatures; this operation can be carried out

13
Vol.:(0123456789)
 M. Miansari et al.

between liquid–liquid, gas–gas or gas–liquid phases. Moreo- all helical strip types augment the heat transfer and pressure
ver, Heat exchangers are used in a wide range of applica- drop as well. Han et al. [16] performed a numerical simula-
tions, including power plants, refineries, petrochemicals, tion to study the flow direction effects on the helical strip
manufacturing industries, process industries, food and phar- performance. They reported the dimensionless optimum
maceutical industries, metal smelting, heating, air condition- magnitude geometrical parameters equal to 0.6. Liu et al.
ing, refrigeration systems and spatial applications [1–7]. [17] investigated the use of a helical tube in a shell and tube
Furthermore, heat exchangers are of great use in various exchanger comparing with a flat tube. They understood that
devices such as boilers, steam generators, condensers, evap- the one-pass helical tube model results in the highest hydro-
orators, cooling towers, fan coil preheaters, oil coolers and thermal efficiency. These researchers [18], in another work,
heaters, radiators, ovens and so forth. Rabienataj et al. [8] optimized a multi-objective double-tube heat exchanger with
performed an empirical study of a helical tube showing the an internal helical tube benefiting from the surface response
effect of alumina nanoparticles on the hydrothermal perfor- technique. Four geometrical parameters and Reynolds num-
mance of the channel. They deduced that higher heights and ber were investigated by them. Sadeghi et al. [19] evaluated
lower pitches of the groove of the helical tube lead to the different flow shapes effects in a double-pipe heat exchanger
optimum design. They also demonstrated that the heat trans- with helical tubes experimentally. In their work, six different
fer enhancement via the helical tube is higher than the nano- shape models with helical tubes experimented with reaching
particles’ improvement. Miansari et  al. [9] performed a the optimum case. Salimpour et al. [20] examined the ther-
numerical study to investigate the effect of adding circular mal performance of a helical tube employing the titanium
grooves on the shell of heat exchanger for improvement in oxide nanofluid. Three parameters of helical pitch, helical
the performance of shell and tube heat exchanger. Their depth and helical width at three surfaces and six geometric
obtained results showed that the groove increases the heat experiments were assessed. They revealed that the effect of
transfer rate up to 5% and does not affect the pressure drop a helical tube becomes more effective in high Reynolds num-
dramatically. Hajabdollahi et al. [10] examined the effects bers. Kareem et al. [21], in a numerical and empirical study,
of a tube fitted with twisted tape on the optimal design of a analyzed a one-way helical tube for water fluid in low Reyn-
fin-and-tube heat exchanger. All the physical parameters of olds numbers. They concluded that using helical tubes leads
the fin-and-tube heat exchanger were considered as design to a heat transfer improvement in 2.4–3.7 times higher than
parameters, and the optimization was performed using a a flat tube, and also a friction coefficient increase in 1.7–2.4
genetic algorithm for different mass flow rates of the tube times higher than a flat tube. Later, in another work, Han
side. They found that the Pareto front for the case of the et al. [22] carried out a study of heat transfer and turbulent
twisted tape tube was completely dominant over the PT for flow regime in an outer corrugated tube using the Reynolds
a lower mass flow rate. Milani et al. [11] experimentally stress model comparing to the direct simulation model
investigated a novel study on the heat transfer characteristics (DNS). The results included velocity and pressure profiles
in a shell and tube heat exchanger with a wavy cosine cor- at different sections, which were in good agreement with the
rugated wall in the structure of the tube bundle. They direct simulation results. Afterward, Panahi and Zamzamian
showed that the effectiveness and the overall heat transfer [23] analyzed a helical shell and tube heat exchanger with a
coefficient increase with the cold water flow rates, and wire turbulator. In their research, the wire turbulator is
enhancement of the wavy starting lengths decreases the heat within the coil and is simulated in two cases. In the first
exchanger effectiveness and the overall heat transfer coeffi- state, the coil side fluid is the gas, and in the second one, the
cient. Vicente et al. [12, 13] analyzed the pitch size and heli- coil side fluid is the water, and in both cases, the shell-side
cal height effects on nine cases in laminar, transient and fluid is water. Their obtained results revealed that the pres-
turbulent flow regime. Their obtained results showed that ence of wire enhances the heat transfer and the pressure drop
employing a helical tube decreases the transient Reynolds in the coil side. The effects of geometrical and operational
number to less than 1400. They also found that the groove parameters on heat transfer in a shell and coil tube heat
effects in laminar flow regimes are subtle; however, in the exchanger are performed by Zaboli et al. [24] and Afsharp-
turbulent flow regime, the heat transfer enhances by increas- anah et al. [25]. Wang et al. [26] carried out a numerical
ing the helical height and reducing the helical pitch. Naphon analysis and optimization study on shell-side performances
et al. [14] examined the hydrothermal performance of the of a shell and tube heat exchanger with staggered baffles
helical, considering the effect of the height-to-pitch ratio (STHX-ST). In this study, shell-side performance is com-
empirically. They realized that hydrothermal effects of the pared among three STHXs. They showed STHX-SG is not
heat exchanger are more affected by the helical height than always the best choice from the view of heat transfer
the helical pitch. Hassanpour et al. [15] evaluated the helical enhancement. Yu et al. [27] using RSM analysis proposed a
tubes, and helical strips use with three types of perforated, numerical study on turbulent heat transfer performance of a
U-shaped and V-shaped helical strips. They concluded that new parallel-flow shell and tube heat exchanger with

13
Thermal performance of a helical shell and tube heat exchanger without fin, with circular fins,…

clamping plate baffles and sinusoidal wavy tapes. Their But it should be noted that, along with this positive effect,
results revealed that the sinusoidal wavy tape could enhance applying circular fins can increase the overall mass of the heat
turbulent heat transfer effectively. Etghani and Baboli [28] exchanger and the friction effects due to the reduction in the
optimized the heat transfer and exergy losses numerically in useful flow of cross-sectional area. Therefore, in order to take
which the Taguchi’s method was employed to examine the advantage of the positive effects of circular fins in the heat
effective parameters of coil pitch, tube diameter and cold and exchanger and at the same time, reduce its negative effects,
hot fluid flow rates. They found that the tube diameter and this paper presents a new form of circular fins, termed cut
cold fluid flow rate were the most effective parameters. Mir- (v-shaped) circular fins. It is obvious that these types of fins
golbabaei [29] assessed the dimensions and conditions can reduce the overall mass of the heat exchanger, increase
affecting the helical shell and tube heat exchanger hydrother- the net flow cross-sectional area and then reduce the frictional
mal performance. These researchers investigated the effects effects. But the thermal performance of cut (v-shaped) cir-
of mass flow rate, helical pitch and tube diameter. Gou et al. cular fins in comparison with circular fins should be studied.
[30] proposed some correlations on the basis of empirical Then thermal performance analysis of applied circular fins and
data for helical coils. In their study, the proposed heat trans- cut (v-shaped) circular fins on the coil in a helical shell and
fer prediction models were examined with water fluid in both tube heat exchanger can be considered as a technological gap.
methods of single-phase and two-phase. Afterward, a Hence to bridge it, this numerical study aims to investigate
method to analyze the hydrothermal performance of a tube- the effects of different geometrical types of fins on the coil
in-tube helically coiled heat exchanger with a turbulator was on the thermal performance of the helical shell and tube heat
proposed by Mashoofi et al. [31]. Their obtained results exchangers.
showed an enhancement of Nusselt number to 81% by
employing the turbulators. Alimoradi et al. [32] carried out Mathematical modeling
an optimization study of a fin in a helical shell and tube heat
exchanger. In their research, ring-shaped fins were utilized In this study, the dimensions of the base helical shell and tube
on a coil as they revealed the heat transfer enhancement heat exchanger are based on the study by Alimoradi et al. [25],
equal to almost 44%. In another study, Alimoradi and Veysi as shown in Fig. 1. The coil is 10 mm in inner diameter with
[33] performed a numerical and empirical study of a helical circular fins, where there are 79 numbers of them with a height
shell and tube heat exchanger to analyze the heat transfer and of 2 mm. Furthermore, 1 mm thickness is considered for the
fluid flow characteristics. These researchers found that the coil. As it has been mentioned in the previous paragraph, in
Nusselt augments by helical pitch up to twice on the shell this research the effect of cut circular fins by eight times and
side; however, the Nusselt number enhances by only 0.8% angle of 15 degrees is compared to the simple circular fins on
on the tube side. Later in another paper, Alimoradi [34] ana- the coil side of the helical shell and tube heat exchanger as
lyzed the helical shell and tube heat exchanger effectiveness shown in Fig. 2.
variations with the number of thermal units (NTU). In their
work, the effectiveness values in various NTU and Cr mag- Governing equations
nitudes are nearly 12.6% lower than that of the parallel-flow
heat exchanger. Later a similar study is performed by Ali- Finite volume method by means of computational fluid
moradi [35] to investigate the geometricparameters and dynamics (CFD) is used for the simulation of the steady-state,
operating conditions using the exergy analysis. They showed single-phase forced convection heat transfer on both sides of
that the system thermal performance reduces linearly with the helical shell and tube heat exchanger and conductive heat
higher input temperature magnitudes, and moreover, an transfer in the solid fins. The governing equations (i.e., con-
enhancement in the number of rounds and a reduction in the tinuity, momentum and energy) are, respectively, as follows:
diameter of the coil result in an improvement in the heat
𝜕(𝜌uj )
exchanger thermal performance. Mahian et al. [36] proposed =0 (1)
a comprehensive review of the latest studies on 3D simula- 𝜕xj
tion of nanofluid flow in various regimes and configurations.
The numerical studies in the literature mostly focus on vari- (
𝜕 𝜌ui uj
)
𝜕ui 𝜕uj
( ( ))
𝜕p 𝜕
ous forms of heat exchangers. The effect of using different =− + 𝜇 + (2)
computational approaches on the flow and thermal perfor- 𝜕xj 𝜕xi 𝜕xj 𝜕xj 𝜕xi
mance predictions and the influence of the selected physical
model on the computational results are considered by them.
( )
𝜕 uj T
( )
𝜕 𝜆 𝜕T
The aforementioned literature review shows that applying = (3)
𝜕xj 𝜕xj 𝜌cp 𝜕xj
circular fins on the tube in the shell and tube heat exchanger
can improve the thermal performance of the heat exchangers.

13
 M. Miansari et al.

Fig. 1  Base helical shell and 120 mm

tube heat exchanger used in this 40 mm 12 mm
study provided by Alimoradi fin parameters
et al. [25]

t = 1mm

dsh = 120 mm

dc = 80 mm dt = 10 mm Hf

Pc = 20 mm

Fig. 2  Display of the present

study geometry in a simple, b
circular finned, c cut circular
finned heat exchangers and d,
e the front views of the two fin
types

The turbulent flow is considered for the both shell and tube
� �
𝜕(𝜌k) 𝜕 𝜌𝜀ui
�� � �
𝜕 𝜇 𝜕𝜀 𝜀2
sides; thus, a model should be selected for the consideration + = 𝜇+ t + 𝜌C1 E𝜀 − 𝜌C2
𝜕t 𝜕xi 𝜕xj 𝜎ε 𝜕xj
√
k + 𝜐𝜀
of the turbulence effects in addition to the other governing
(5)
equation. In comparison with standard k − 𝜀 model, the realiz-
able k − 𝜀 turbulence model can present better performance for where C1 and C2 are the model coefficients; 𝜎k and 𝜎ε are the
flows involving rotation, boundary layer under strong adverse turbulence Prandtl numbers for the k and 𝜀 , respectively; Gk
pressure gradients, separation and recirculation. Consequently represents the producing item of the k by the mean velocity
realizable k − 𝜀 is selected for the simulation of the turbulence gradient, and it can be calculated as follows:
effects. The transfer equations for this model are as follows 𝜕uj
[32]: Gk = −𝜌u�i u�j (6)
𝜕xi
( )
𝜕(𝜌k) 𝜕 𝜌kui
[( ) ]
𝜕 𝜇t 𝜕k
+ = 𝜇+ + Gk − 𝜌𝜀 (4)
𝜕t 𝜕xi 𝜕xj 𝜎k 𝜕xj

13
Thermal performance of a helical shell and tube heat exchanger without fin, with circular fins,…

Boundary conditions the mesh independence of the numerical results. Table 1 rep-
resents the results of the grid independency analysis, which
The water fluid with constant physical properties flows through reveals that the forth case with a number of meshes equal to
the coil and shell sides of the heat exchanger. The hot fluid 3,100,000 suffices for the following numerical simulations.
enters the coil side with the velocity of 1 m s−1 and tempera-
ture of 75 °C, and cold fluid enters the shell side with velocities Validation
of 0.75, 1.5 and 3 m s−1 and temperature of 25 °C.
The present numerical simulation results have been com-
Numerical procedures pared to the experimental data provided by Jamshidi et al.
[37] as displayed in Fig. 6. The case used is a 0.1041-m coil
For enhancement of the simulation accuracy of the current diameter and a 0.013-m pitch. It is visible that the current
three-dimensional and steady study, the governing equations numerical study has a desirable accuracy, and the maximum
are discretized with the finite volume formulation with the error is 5% occurring in the largest Reynolds numbers.
SIMPLE pressure–velocity coupling algorithm [36]. Further-
more, the second-order upwind scheme has been used for the
momentum, turbulent kinetic energy, turbulent dissipation rate Results and discussion
and energy, while the Presto scheme is used for the pressure.
No-slip condition is applied to all solid walls, and standard In this section, the effects of different parameters such as
wall functions are adopted as the near-wall treatment. It was changing the fluid temperature entering the coil and shell
also assumed that the fluids are incompressible and tube thick- sides with each other and inlet velocity in the coil and shell
ness, heat dissipation from the outer surfaces of the shell and sides on the heat transfer parameters of the helical shell and
radiation are negligible. When the solution converged, the of tube heat exchanger including the shell and tube outlet tem-
heat transfer rate is obtained as follows: perature, amount of heat transfer and the heat exchanger
Heat transfer rate of hot flow: thermal efficiency are examined quantitatively and also
qualitatively. The mentioned investigations are carried out
Qh = mc
̇ p (Th,i − Th,o ) (7) for the helical shell and tube heat exchanger without a fin,
with circular fins and with cut circular fins.
Total capacity of available heat transfer rate:
Different fluid flow and heat transfer characteristics of the
Qt = mc
̇ p (Th,i − Tc,i ) (8) simple, circular finned and cut circular finned helical shell
and tube heat exchanger are analyzed in nine tests and dis-
Thermal efficiency of heat exchanger can be defined as: played in Tables 2–4, respectively, in detail. In Table 2 and
(Th,i − Th,o ) case A, the cold water flows through the coil with a constant
Qh
𝜂= = (9) velocity while the hot water is at the shell side and contains
Qt (Th,i − Tc,i )
three values. Case B resembles case A but with different
velocity magnitudes at the coil side and a content velocity
Grid study value at the shell side. Also, case C is similar to case A, but
the cold and hot fluids are at shell and coil sides, respec-
According to the complexity of the present geometry, an tively. In Table 3, the cases D, E, and F look like cases A, B
unstructured mesh with a tetrahedron structure has been and C, respectively, but in the presence of circular fins on the
employed. It is necessary to produce a boundary layer mesh coil. Finally, in Table 4, the cases G and H resemble cases
with a first-order boundary layer height due to the nature of A and C, respectively, but in the presence of cut circular
the turbulent flow. The generated mesh has been displayed fins on the coil. So these tables are representing the effects
in Figs. 3–5 at shell and coil sides and also different views of various inlet velocities at both shell and tube sides and
of shell and coil. Five different sized grids are used to study also substituting the cold and hot fluids with each other on
the thermal performance of three types of heat exchangers.
After tabulating the results, now they need to be displayed
Fig. 3  The generated mesh on in figures purposefully. To investigate the effects of different
the shell
inlet velocities at both sides of shell and tube in simple and
circular finned heat exchangers on the heat transfer, Fig. 7 is
provided in which the data are based on cases A, B, D and E.
In these cases, the cold fluid is at the coil side, and in
cases A and D, the cold fluid is fixed at 1 m s−1, and the hot
fluid varies from 0.75 to 3 m s−1, while cases B and E are

13
 M. Miansari et al.

Fig. 4  The generated mesh on

the coil

Fig. 5  The generated mesh in

two different views

Table 1  Grid independency Case 1st 2nd 3rd 4th 5th

analysis
Number of elements 1,400,000 1,800,000 2,300,000 3,100,000 4,300,000
Heat flux/Wm−2 2180 2165 2195 2205 2210

13
Thermal performance of a helical shell and tube heat exchanger without fin, with circular fins,…

cases D and E, which means using fins doesn’t affect this

60
phenomenon. On the other hand, this figure reveals that
using fins enhances the heat transfer significantly by increas-
Present study
55 Jamshidi et. al. ing the heat transfer area. Moreover, increasing the veloc-
ity augments the heat transfer in all cases by enhancing the
advection effects as the convective heat transfer exists.
50
Since increasing the hot fluid velocity enhances the available
energy entering the heat exchanger, to find the optimum case, it
Nu

45
is better to analyze the heat exchanger efficiency [determined in
Eq. (9)]. So, the heat exchanger efficiency in cases A, B, D and
40
E is demonstrated in Fig. 8. This figure shows that increasing
the hot fluid (on shell side) velocity decreases the efficiency as
35
it decreases from 14.4 to 6.3% as velocity increases from 0.75
to 3 m s−1 while increasing the cold fluid (on coil side) velocity
30
in a similar rang enhances the efficiency from 11 to 14.4%. This
200 400 600 800 1000 1200 is because of higher available energy by entering hot fluid with
Re
higher velocity and not compensating the available energy by
the increased amount of heat transfer.
Fig. 6  Comparison of the current numerical results with the experi-
mental data of Jamshidi et al. [37] Figure 9 displays the effects of cases B, C, E and F with
different cold velocities in simple and circular finned heat
exchangers on the heat transfer. In these cases, the hot fluid
exactly the opposite. Comparing cases A and B shows those velocity is fixed at 1 m s−1, and the cold fluid varies from
higher velocities in the shell (containing hot fluid) than the 0.75 to 3 m s−1, while in cases B and E the cold fluid enters
tube (containing cold fluid) leads to higher amounts of heat the tube and in cases C and F cold fluid enters the shell, so
transfer in the heat exchanger. This is also true by comparing substituting the hot and cold water is taken into account in

Table 2  Results of the simple Case Test number Coil side Shell side Q/W
helical shell and tube heat
−1 −1
exchanger simulation U/m s Tin/K Tout/K U/m s Tin/K Tout/K

A 1 1 298.15 305 0.75 348.15 343 1780

2 1 298.15 307.1 1.5 348.15 344.8 2333
3 1 298.15 310.15 3 348.15 345.9 3135
B 4 0.75 298.15 307.6 1 348.15 344.2 1846
5 1.5 298.15 303.6 1 348.15 343.5 2158
6 3 298.15 301.2 1 348.15 342.9 2410
C 7 1 348.15 341.3 0.75 298.15 303.2 1780
8 1 348.15 339.2 1.5 298.15 301.5 2344
9 1 348.15 335.9 3 298.15 300.4 3189

Table 3  Results of the circular Case Test number Coil side Shell side Q/W
finned helical shell and tube
−1 −1
heat exchanger simulation U/m s Tin/K Tout/K U/m s Tin/K Tout/K

D 1 1 298.15 307.4 0.75 348.15 341.2 2418

2 1 298.15 310.1 1.5 348.15 343.7 3122
3 1 298.15 312.8 3 348.15 345.4 3834
E 4 0.75 298.15 310.8 1 348.15 342.8 2475
5 1.5 298.15 306 1 348.15 341.5 3059
6 3 298.15 302.7 1 348.15 340.5 3565
F 7 1 348.15 339.1 0.75 298.15 305 2361
8 1 348.15 336 1.5 298.15 302.6 3159
9 1 348.15 333.4 3 298.15 300.9 3842

13
 M. Miansari et al.

Table 4  Results of the cut Case Test number Coil side Shell side Q/W
circular finned helical shell and
−1 −1
tube heat exchanger simulation U/m s Tin/K Tout/K U/m s Tin/K Tout/K

G 1 1 298.15 307 0.75 348.15 341.4 2325

2 1 298.15 310 1.5 348.15 343.7 3090
3 1 298.15 312.5 3 348.15 345.5 3761
H 4 1 348.15 339.2 0.75 298.15 304.8 2328
5 1 348.15 336.6 1.5 298.15 302.45 3002
6 1 348.15 333.8 3 298.15 300.8 3737

4500 4500

Model A Model B
4000 Model B 4000 Model C
Model D Model E
Model E Model F
3500 3500
Q/W

Q/W
3000 3000

2500 2500

2000 2000

1500 1500
0.5 1.0 1.5 2.0 2.5 3.0 3.5 0.5 1.0 1.5 2.0 2.5 3.0 3.5
U/m s–1
UC/m s–1

Fig. 7  Variations of heat transfer with the fluid velocity in cases A, B,

D and E Fig. 9  Variations of heat transfer with the cold fluid velocity in cases
B, C, E and F

30 and cold) on the tube side, the heat transfer improves. As a

Model A result, it is better to flow the cold water through the shell and
25
Model B
Model D
increase its velocity and flow the hot fluid through the coil
Model E to reach higher heat transfer values. Another advantage of
this arrangement is that in reality, the thermal insulation of
20
the shell wall is not ideal, so if the problem aim is cooling,
η /%

entering the hot fluid to the coil prevents the energy from
15 escaping from the shell walls and total efficiency increases.
In addition, the positive effects of applying circular fins on
10 the coil on heat transfer are visible in this figure. Conse-
quently, the highest heat transfer magnitude designates the
5
circular finned heat exchanger with a cold water velocity of
0.5 1.0 1.5 2.0 2.5 3.0 3.5 3 m s−1 entering the shell and a hot water velocity of 1 m s−1
U/m s–1 entering the tube.
Figure 10 represents the effects of cases B, C, E and F
Fig. 8  Variations of heat exchanger efficiency with the fluid velocity with different cold velocities in simple and circular finned
in cases A, B, D and E
heat exchangers on its efficiency. Since just increasing the
cold water velocity is considered, the trend of this figure
this section. This figure states that in all cases, increasing the resembles Fig. 9. As it is observable that the more the fluid
cold water velocity enhances the heat transfer due to higher velocity on the shell side than the tube side, the more the
advection effects on the convective heat transfer. Further- heat exchanger efficiency increases. Also, employing cir-
more, it concludes that in both simple and circular finned cular fins on the coil side has been an increased efficiency.
heat exchangers, when the fluid velocity (both hot and cold) It also displays that increasing the cold water augments the
on the shell side is higher than the fluid velocity (both hot efficiency. As a result, the highest efficiency corresponds to

13
Thermal performance of a helical shell and tube heat exchanger without fin, with circular fins,…

30 22

Model B 20
Model C
25 Model E Model A
Model F 18 Model D
Model G
16
20
14

η /%
η /%

15 12

10

10 8

6
5
0.5 1.0 1.5 2.0 2.5 3.0 3.5 0.5 1.0 1.5 2.0 2.5 3.0 3.5

UC/m s–1 Uh/m s–1

Fig. 10  Variations of heat exchanger efficiency with the cold fluid Fig. 12  Variations of heat exchanger efficiency with the hot fluid
velocity in cases B, C, E and F velocity in cases A, D and G

the circular finned heat exchanger with a cold water veloc- transfer by about 35.84, 33.82 and 22.30% in hot fluid veloci-
ity of 3 m s−1 entering the shell and hot water velocity of ties of 0.75, 1.5 and 3 m s−1, respectively, in comparison
1 m s−1 entering the tube. The efficiency varies from 11.2 with the simple heat exchanger. Similar to this figure, Fig. 12
to 14.6% and 10.8 to 19.3% as the cold water increases and evaluates the variations of the efficiency of three types of
flows through the shell and tube, respectively. heat exchangers. As it was discussed, increasing the hot fluid
From now on, the cut circular finned helical shell and tube velocity reduces heat exchanger efficiency. In addition, there
heat exchanger thermal performance will be compared and are steeper slopes by applying fins that at lower velocities, the
assessed with the simple and circular finned ones. Figure 11 efficiency enhancement is about 30%, but at high velocities,
shows the effect of various inlet hot fluid velocities on the it is about 20%. It is also noteworthy that cut circular fins
shell side and a constant cold fluid velocity on the tube side effects on efficiency are insignificant in comparison with the
on the heat transfer. In addition, this figure illustrates that circular fins, and at higher velocities, their difference reduces.
applying cut circular fins increases the heat transfer by about Figure 13 demonstrates the variations of heat transfer
30.62, 32.45 and 19.97% in hot fluid velocities of 0.75, 1.5 with the cold fluid velocity on the shell side and the fixed
and 3 m s−1, respectively, in comparison with the simple heat hot fluid velocity on the coil side to compare the three types
exchanger. However, using circular fins increases the heat of heat exchangers. It shows that increasing the cold fluid

4500
4500
Model A
Model C
4000 Model D
4000 Model F
Model G
Model H

3500
3500
Q/W

3000
Q/W

3000

2500
2500

2000
2000

1500
1500
0.5 1.0 1.5 2.0 2.5 3.0 3.5 0.5 1.0 1.5 2.0 2.5 3.0 3.5
Uh/m s–1 UC/m s–1

Fig. 11  Variations of heat transfer with the hot fluid velocity in cases Fig. 13  Variations of heat transfer with the cold fluid velocity in
A, D and G cases C, F and H

13
 M. Miansari et al.

velocity enhances the heat transfer at three types of heat fluid velocity has enhanced the heat exchangers efficiencies
exchangers. It is also visible that using fins has positive and applying cut circular fins augments the heat exchanger
effects on heat transfer and the use of cut circular fins has efficiency by about 30.79, 28.07 and 17.18% in cold fluid
an almost similar (a slight lower) effect on heat transfer in velocities of 0.75, 1.5 and 3 m s−1, respectively, in compari-
comparison with the use of circular fins. A similar com- son with the simple heat exchanger. However, using circular
parison on the heat exchangers efficiency is displayed in fins increases the heat exchanger efficiency by about 32.64,
Fig. 14. It states that contrary to Fig. 12 increasing the cold 34.77 and 20.48% in cold fluid velocities of 0.75, 1.5 and
3 m s−1, respectively, in comparison with the simple heat
exchanger.
Figures 15 and 16 display the streamlines colored with
24 temperature magnitudes and flow contours in the mid-
Model C
Model F
dle section plane of the computational domain at simple,
22 Model H circular finned and cut circular finned helical shell and
20
tube heat exchangers, respectively. It shows that using
both types of fins enhances the mixing intensity while
18 the flow is passing the coil in the shell. So mixing the
η /%

16
fluid improves the heat transfer phenomenon as the fluid
with low cooling capacity near the coil is replaced with
14 the fluid with high cooling capacity near the shell walls,
to show these effects on the coil surface temperature,
12
as shown in Fig. 17. It states that the coil temperature
10 while the fins are applied is lower than the simple coil.
0.5 1.0 1.5 2.0 2.5 3.0 3.5
It is because of the enhanced heat transfer area and also
UC/m s–1
increased mixing intensity in the presence of cut circular
fins and circular ones.
Fig. 14  Variations of heat exchanger efficiency with the cold fluid
velocity in cases C, F and H

Fig. 15  Streamlines colored (a) (b)

with temperature magnitude in
Temperature Temperature
a simple, b circular finned and c Streamline 1 Streamline 1
cut circular finned helical shell 348 348
and tube heat exchangers
347 347

346 346

344 344

343 343
[K] [K]

(c) Temperature
Streamline 1
348

347

346

344

343
[K]

13
Thermal performance of a helical shell and tube heat exchanger without fin, with circular fins,…

Fig. 16  Flow contours in the (a) (b)

middle section plane of the
computational domain in a
simple, b circular finned and c
cut circular finned helical shell
Velocity
and tube heat exchangers Velocity
2.1
2.1

1.5 1.5

1.0 1.0

0.5 0.5

0.0 0.0
[m s^–1] [m s^–1]

(c)

Velocity
2.1

1.5

1.0

0.5

0.0
[m s^–1]

Fig. 17  Temperature contour (a) (b)

on the surface of a simple, b Temperature Temperature
circular finned and c cut circular coil fin shadow coil fin
348 348
finned coil
336 336

323 323

311 311

298 298
[K] [K]

(c)
Temperature
coil fin
348

336

323

311

298
[K]

13
 M. Miansari et al.

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exchanger with sinusoidal wavy tapes using RSM analysis. Appl jurisdictional claims in published maps and institutional affiliations.
Therm Eng. 2019;150:875–87.

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