6 II February 2018

http://doi.org/10.22214/ijraset.2018.2071
 International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 6.887
Volume 6 Issue II, February 2018- Available at www.ijraset.com

Review on Comparative Study between Straight

Tube Heat Exchanger and Helical Coil Heat
Exchanger
Vaibhav M. Samant1, Jayesh V. Bute2
1
(Student (Mechanical Engineering)/Pimpri Chinchwad College Of Engineering &Research, Pune, India)
2
(Asst. Prof./Pimpri Chinchwad College Of Engineering &Research, Pune, India)

Abstract: The main purpose of this study is to determine the relative advantage of using a helically coiled heat exchanger over a
straight tube heat exchanger. It is found that the heat transfer in helical circular tubes is higher as compared to Straight tube
due to their geometrical shape. Helical coils offer advantages over straight tubes due to their compactness and increased heat
transfer coefficient. The increased heat transfer coefficients are a consequence of the curvature of the coil, which induces
centrifugal forces to act on the moving fluid, resulting in the development of secondary flow. The curvature of the coil governs
the centrifugal force while the pitch (or helix angle) influences the torsion to which the fluid is subjected to. The difference in
velocity sets-in secondary flows. The fluid particles flowing at the core of the pipe have higher velocities than those flowing near
to the pipe wall. Thus the fluid particles flowing close to the tube wall experience a lower centrifugal force than the fluid
particles flowing in the tube core. This causes the fluid from the core region to be pushed towards the outer wall. This additional
convective transport increases heat transfer and the pressure drop when compared to that in a straight tube.
Keywords: Helical coil heat exchanger, heat transfer, secondary flow, straight tube heat exchanger,

I. INTRODUCTION
Several techniques are being used to increase the thermal performance of the heat exchanger. Active techniques, passive techniques
and compound techniques are used for enhancing the heat transfer. The active techniques require external forces like fluid vibration.
The passive techniques require special surface geometries. The compound technique is the combination of any two or more methods
of used for improving the performance of heat exchanger. Helical coiled tubes are superior to straight tube due to their compactness
and increased heat transfer coefficients. Flow in curved tube is different from the flow in straight tube because of the presence of the
centrifugal forces. It induces the secondary flow in liquid. The intensity of secondary flow developed in the tube is the function of
tube diameter (d) and coil diameter (D). Due to enhanced heat transfer in helical coiled configuration the study of flow and heat
transfer characteristics in the curved tube is of prime importance. The secondary fluid flow of helical tubes was first studied by
Dean with toroidal system. Based on the perturbation method, Germano solved the fluid flow equations of a helical duct with
elliptical cross section. This secondary flow pattern generally consists of two vortices, which move fluid from the inner wall of the
tube across the center of the tube to the outer wall. Upon reaching the outer wall it travels back to the inner wall. The secondary
flow increases heat transfer rates as it moves fluid across the temperature gradient. Thus, there is an additional convective heat
transfer mechanism, perpendicular to the axial flow, which does not exist in straight tube heat exchangers The amount of heat
transferred depends upon various factors like type of fluid flow, area of heat transfer, thermal conductivity of the separating wall etc.
There are three primary classifications of heat exchangers according to their flow arrangement. Parallel flow heat exchangers,
Counter-flow heat exchangers, Cross-current or cross-flow heat exchangers. Helical coil heat exchangers are of great use in
industrial applications such as power generation, nuclear industry, process plants, heat recovery systems, refrigeration, food
industry, etc due to its compact structure and high heat transfer coefficient. They are widely used in chemical and petrochemical
plants, refineries and sewage treatment.

II. LITERATURE REVIEW

The following research papers are studied in detail and the abstract of the work is presented here:
The intensity of secondary flow developed in the tube is the function of tube diameter (d) and coil diameter (D) as presented by
Dravid et al [1]. Due to enhanced heat transfer in helical coiled configuration the study of flow and heat transfer characteristics in
the curved tube is of prime importance. Developing fluid-to-fluid helical heat exchangers (fluid is present on both sides of the tube

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 International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 6.887
Volume 6 Issue II, February 2018- Available at www.ijraset.com

wall) requires a firm understanding of the heat transfer mechanism on both sides of the tube wall. Though much investigation has
been performed on heat transfer coefficients inside coiled tubes, little work has been reported on the outside heat transfer
coefficients. The result shows that the increasing of the coiled tube pitch decreases the inside Nusselt Number. He also studied that
helical coil have compact size and higher heat transfer coefficient they are widely used in industrial applications such as food
preservation, refrigeration, process plant, power generation etc.
Timothy J. Rennie, Vijaya G.S. Raghavan [2]Have done An experimental study of a double-pipe helical heat exchanger. Two heat
exchanger sizes and both parallel flow and counter flow configurations were tested. Flow rates in the inner tube and in the annulus
were varied and temperature data recorded. An attempt has been made to study the parallel flow and counter flow of inner higher
temperature fluid flow and lower temperature fluid flow, which are separated by copper surface in a helical coil heat exchanger.
Helical geometry allows the effective handling at higher temperatures and extreme temperature differentials without any highly
induced stress or expansion of joints. This type of heat exchanger consists of series of stacked helical coiled tubes and the tube ends
are connected by manifolds, which also acts as fluid entry and exit locations. In this paper, we focus on design parameters and heat
transfer conditions of a vaporizer or generator of a simple vapor absorption refrigeration system having flow condition of refrigerant
taken as laminar flow,
The research was done by Kondhalkar and Kapatkat [3] on performance analysis of spiral tube heat exchanger used in oil extraction
system . They discussed about the effective use of spiral tube heat exchanger in oil extraction process. They carried out research on
the performance analysis of spiral tube heat exchanger over the shell and tube type heat exchanger. They studied the Performance of
spiral tube heat exchanger and shell and tube heat exchanger for sugandhmantri oil emulsion. They found that the relation between
mass flow rate and effectiveness and found out that for the same mass flow rate effectiveness increases for the spiral tube heat
exchanger. Also it was observed that the heat transfer coefficient increased with increase in Reynolds number. Also they
investigated the relation between Reynolds numbers and Nusselt number and concluded that Nusselt number increases with increase
in Reynolds number. .
Zhengguo Zhang [4] et al.were made attempts to investigate the heat transfer characteristics of a helically baffled heat exchanger
combined with one three-dimensional finned tube. For the counter mode operation, experiments were carried out and overall heat
transfer coefficient determined using modified Wilson plot. The agreement with the numerical and experimental predictions of
Nusselt number and pressure drop values were well within 6.3% for Nusselt number and 9.8% for pressure drop in the shell side
respectively. Shinde D. &Dange M.[5] experimental investigation of heat transfer in cone shaped helical coil heat exchanger is
reported for various Reynolds number. The purpose of this article is to compare the heat transfer in cone shaped helical coil and
simple helical coil. The pitch, height and length of both the coils are kept same for comparative analysis. The calculations have been
performed for the steady state condition and experiments were conducted for different flow rates in laminar and turbulent flow
regime. The coil side flow rate is kept varying while the coil side flow rate is kept constant. It was observed that the effectiveness of
the heat exchanger for the cone shaped helical coil is more than that for the simple helical coil. Results show that the heat transfer
rates for the cone shaped helical coil are comparatively higher than that of the simple helical coil. It was found that the heat transfer
rates are 1.18 to 1.38 times more for the cone shaped helical coil than that of simple helical coil. Bibin Prasad et al. [6] helical pipes
are universally used for heat transfer enhancement in heat exchangers. In the present work, CFD simulations are carried out for a
counter flow double pipe helical heat exchanger byvarying the flow rates of a single fluid (water). The heat transfer characteristics
of the same are compared withthat of a counter flow double pipe straight tube heat exchanger for the same flow rates. The results
were interpreted by developing correlations between Nusselt number and Dean Number for both the inner and outer helical pipes
which shows a strong linear relationship.

A. Parameters to be taken into consideration for calculation of performance assessment of heat exchanger:
1) For the turbulent flow region (Re ≥ 104 ),
Nu = Re0.8 Pr1/3 (μ/μw)0.14
Where,
Nu = Nusselt Number = hd/k D0,Di =Outside and Inside diameter of the pipe
Re = Reynold’s Number = DVρ/μ V = average fluid velocity.
Pr = Prandtl Number = cpμ/k Cp,μ,ρ,k = Fluid properties at avg. bulk temperature.

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 International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 6.887
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It is observed that Nuincreases with increase in Re. This shows that the secondary’s developed in the fluid flow goes on increasing,
as Re increases, which increases the turbulence in the fluid flow. The increase in turbulence allows proper mixing of the fluid, which
enhances the Nu. And all the remaining parameters indirectly depend on Reynold’s number and Nusselt number.
2) Overall heat transfer coefficient: (U)
U= Q/A0ΔT
A0=π D0 L
3) The fouling factor for the exchanger is given as:
RD= RDi(Do/Di)+ RDo
Fouling could considerably impact on the thermal and mechanical performance of heat exchangers. It also impedes fluid flow,
accelerates corrosion and will increase pressure drop across heat exchangers. Helical geometry provides low fouling characteristics
which increases the schedule cleaning period of tube bundle.
4) Capacity Ratio

5) Number Of Transfer Units(NTU):

It is a dimensionless quantity and it is an indicator of size of heat transferring areas of heat exchanger. Large value of NTU means
large heat transferring area.
6) LMTD-Log mean temperature difference:
LMTD= (dTA – dTB)/ln(dTA/dTB)
dTA= Thot in –Tcold out
dTB=Thot out – Tcold in
For constant heat and mass transfer,
LMTDshell and tube>LMTDcounterflow > LMTD cross flow >LMTDparallel flow
7) Friction factor
f = 64/Re ..............(For laminar flow)
f= 0.4137 Re-0.2385.............(For turbulent flow)
This friction factor, f is a dimensionless factor that depends mainly on velocity v, diameter D, density and viscosity.
8) Effectiveness
€ = Q/Qmax
Q = Actual heat transfer rate
Qmax=Maximum possible heat transfer rate

B. Straight Tube Heat Exchanger

Fig 1.1 Simple shell and straight tube heat exchanger

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 International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 6.887
Volume 6 Issue II, February 2018- Available at www.ijraset.com

Shell-and-tube exchangers are classified and constructed in accordance with the widely used TEMA (Tubular Exchanger
Manufacturers Association). When the medium containing heat is a liquid or a vapour which heats another liquid, then the shell and
tube heat exchanger must be used since both paths must be sealed to contain the pressures of their respective fluid. The shell
contains the tube bundle, and usually internal baffles, to direct the fluid in the shell over the tubes in multiple passes. The shell is
inherently weaker than the tubes so that the higher-pressure fluid is circulated in the tubes while the lower pressure fluid flows
through the shell. Tube and shell heat exchangers are available in a wide range of standard sizes with many
combinations of materials for the tubes and shells. Heat transfer in straight tubes is governed by Reynolds and Prandtl Numbers,
under both laminar and turbulent flow conditions, and is usually presented in a form such as:
Nnu= c N ReaN prb ...............................(1)
Where, NNu is the Nusselt number, with the a, b, and c being constants, Re is the Reynolds number, pr is prandtl number. Heat
transfer rate of shell and tube heat exchanger depends on some of following parameters such as length of tube, number of baffles,
baffle cut. Generally the shell and heat type heat exchanger are widely used for various purposes having limitation to be designed
for maximum up to 15000 psi and 1000 0F.
There are few disadvantages concerned with shell and tube heat exchangers are: 1)Fixed tube sheet type exchanger having cleaning
issues as well as can be used for low temperature difference as there is no provision for the thermal expansion of the same.
2)Shell and tube heat exchanger are Subject to flow induced vibration which can lead to equipment failure. Subject to flow mal-
distribution especially with two phase inlet streams.
They can be designed for special operating conditions: vibration, heavy fouling, highly viscous fluids, erosion, corrosion.

C. Helical Coil Heat Exchanger

Fig. 2.1 helical coil heat exchanger Fig. 2.2 Cut section of helical coil
Helically coiled exchangers have compact size provides a distinct benefit. Helical geometry permits handling of high temperatures
and extreme temperature differentials without high induced stresses or costly expansion joints. High-pressure capability and the
ability to fully clean the service fluid flow area add to the exchanger’s advantages, Although various configurations of coil are
available. A typical shell and coiled tube heat exchanger is shown in Fig.2.1. In coiled tubes, the heat transfer coefficients are
higher due to the presence of secondary flow, which increases the extent of mixing. The difference between the heat transfer
coefficient (h) in coiled tubes and straight tubes is significant.
NNuc = NNus [1+ 3.5 (r / R)] ................................. (2)
Heat transfer rate of helical coil heat exchanger depends on some of following parameters such as coil pitch, Pitch circle diameter,
pipe diameter.

D. Comparison Between Straight Tube Heat Exchanger And Helical Coil Heat Exchanger
Variation of overall heat transfer coefficient for straight tube parallel flow, straight tube counter flow, helical coil parallel flow and
helical coil counter flow, when hot water mass flow rate is constant and cold water mass flow rate varied. As the mass flow rate
through the shell increases the overall heat transfer coefficient increases, and it is observed that hot mass flow rate inside tube

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 International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 6.887
Volume 6 Issue II, February 2018- Available at www.ijraset.com

increases the overall heat transfer coefficient also increases. Overall heat transfer coefficient of counter flow heat exchanger is high
compared to corresponding exchanger parallel flow. Helical coil counter flow has max. Overall heat transfer coefficient and straight
tube parallel flow has lowest overall heat transfer coefficient.

Fig. variation of overall heat transfer coefficient when mass flow rate inside the tube is 30 LPH

Overall heat transfer coefficient (U) in the helical heat exchanger is much higher than that in straight tubular heat exchangers. For
all values of Reynolds numbers, the overall heat transfer coefficient in the helical coils was larger than that in the straight tubes. The
overall heat transfer coefficient (U) in the helical heat exchanger increased with flow rate and approached a maximum value at
higher flow rates.

III. CONCLUSION
From study it is clear that, Helical coil counter flow is most effective in all these conditions and straight tube parallel flow heat
exchanger is least effective. There is some gap between results we are getting from current heat exchangers and results we should
get. This gap can be bridged by making use of helical coil heat exchangers with some design modifications for betterment of the
results. Overall heat transfer coefficient increases with increase in hot water mass flow rate and cold water mass flow rate. The
torsional forces induced by the pitch causes oscillations in the Nusselt number. However, the average Nusselt number is not affected
by the coil pitch. Unlike the flow through a straight pipe, the centrifugal force caused due to the curvature of the pipe causes heavier
fluid (water-phase) to flow along the outer side of the pipe. High velocity and high temperature are also observed along the outer
side.As the pitch is increased, higher velocity and higher temperature regions are on the bottom half of the pipe. Increase in pipe
diameter, keeping the inlet velocity constant, causes higher heat transfer coefficient and lower pressure drop. This effect is due to
the influence of secondary flows. By making use of helical geometry the centrifugal force and shear stress can be increased to
reduce the fouling effect. For a particular mass flow rate, helical tube heat exchanger provides an increase in heat transfer
coefficient by 10%. Heat exchangers used now a days have certain disadvantages such as less effectiveness, less heat transfer
coefficient. These demerits can be over comed by using multi pass helical coil heat exchangers.

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 International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 6.887
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REFERENCES
[1] Dravid, A. N., Smith., K. A., Merrill, E.A., and Brian, P.L.T., (1971).Effect of secondary fluid motion on laminar flow heat transfer in helically coiled tubes
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[2] Timothy J. Rennie, Vijaya G.S. Raghavan, 2005 Experimental studies of a double-pipe helical heat exchanger
[3] Kondhalkar G. E , Kapatkat V. N, “ Performance Analysis of Spiral Tube Heat Exchanger used in oil extraction system” International Journa,l of Modern
Engineering Research (IJMER), Vol.2, Issue.3, May-June 2012, PP-930-936.
[4] Zhengguo Zhang, Dabin Ma, Xiaoming Fang, XuenongGao, “Experimental and Numerical Heat Transfer in a Helically Baffled Heat Exchanger Combined
with One Three-Dimensional Finned Tube”, Chemical Engineering and Processing, Vol. 47, pp 1738–1743, 2008.
[5] Shinde D. &Dange M, 2013, ―Heat Transfer Analysis of a Cone Shaped Helical Coil Heat Exchangerǁ, International Journal of Innovations in Engineering and
Technology,Vol. 3 Issue 1, p. no. 56-62.
[6] Bibin Prasad, Sujith V, Mohammed Shaban K, SajuHaneef, Sandeep N, Vishnu Raj, 2013, ―Comparison of Heat Transfer between a Helical and Straight Tube
Heat Exchangerǁ, International Journal of Engineering Research and Technology, Vol. 6, Number 1, pp. 33-40.
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