Effect of the Width-Diameter Ratio of Twisted Tape Inserts in Heat Exchanger Tubes on Heat Transfer
Keywords:
Heat transfer enhancement, Thermal performance factor, Twisted tape, Width-to-diameter ratioAbstract
This study investigated how the width–diameter ratio of
twisted tape inserts and tube size influence heat transfer and
pressure loss in circular heat exchanger tubes under
turbulent air flow. A three-dimensional steady CFD model
with an SST k–omega turbulence closure simulated uniformly
heated tubes containing constant pitch tapes across multiple
diameters and ratios. Grid independence and literature
validation established numerical reliability. A mid-size tube
consistently delivered the best thermal performance, and
the largest tested width–diameter ratio produced the
highest Nusselt enhancement while keeping pressure
penalties manageable. The inserts markedly outperformed a
plain tube in overall heat transfer. Performance improves
because swirl from the tape strengthens core to wall mixing
and thins the thermal boundary layer without excessively
raising friction at suitable geometries. Findings guide
compact, energy-efficient exchanger design by identifying
geometry combinations that maximize heat transfer for
practical pumping power. Designers can apply the
framework across diverse operating conditions.
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