Applied Thermal Engineering: A. García, J.P. Solano, P.G. Vicente, A. Viedma
Applied Thermal Engineering: A. García, J.P. Solano, P.G. Vicente, A. Viedma
a r t i c l e i n f o a b s t r a c t
Article history: This work analyzes the thermalehydraulic behaviour of three types of enhancement technique based on
Received 7 June 2011 artificial roughness: corrugated tubes, dimpled tubes and wire coils. The comparison has been performed
Accepted 18 October 2011 from the three best specimens selected among the wide range of geometries investigated by the authors
Available online 25 October 2011
in previous works. Heat transfer and pressure drop experimental data in laminar, transition and
turbulent regimes are used in this investigation.
Keywords:
Results show that the shape of the artificial roughness exerts a greater influence on the pressure drop
Heat transfer enhancement
characteristics than on the heat transfer augmentation. Likewise, this shape strongly affects the advance
Wire coil inserts
Corrugated tubes
of the transition to turbulence and its characteristics: smooth or sudden. The study concludes that for
Dimpled tubes Reynolds numbers lower than 200, the use of smooth tubes is recommended. For Reynolds numbers
Turbulence promotion between 200 and 2000, the employment of wire coils is more advantageous, while for Reynolds numbers
higher than 2000, the use of corrugated and dimpled tubes is favoured over the wire coils because of the
lower pressure drop encountered for similar heat transfer coefficient levels.
Ó 2011 Elsevier Ltd. All rights reserved.
1359-4311/$ e see front matter Ó 2011 Elsevier Ltd. All rights reserved.
doi:10.1016/j.applthermaleng.2011.10.030
A. García et al. / Applied Thermal Engineering 35 (2012) 196e201 197
third of the XX century. The patent of the corrugated tubes dates the laminar regime: in viscous fluids, the flow can be laminar in the
back to 1977 [5]. The patent of a method for manufacturing dimpled entrance, where the fluid is cold and its viscosity is high. Transition
tubes by cold external deformation dates back to 1989 [6]. takes place at an undefined point of the heat exchanger. Because of
In the field of enhanced heat transfer, there are very few this, the transition point (critical Reynolds number) is an important
experimental studies on laminar flow. Here, the entrance effects parameter to bear in mind in all enhancement techniques.
and the secondary flow induced by buoyancy forces greatly The use of a surface roughness in the transition region
complicate the analysis. On wire coils, the work of Uttarwar and (Re ¼ 250e3000) can be very effective to increase heat transfer
Raja Rao [7] has been widely mentioned in the open literature [3,8]. [4,18]. Oliver and Shoji [19] studied different insert devices in the
However, their heat transfer results were strongly influenced by the laminar and transition region. Although their work only covered
entry region. Recently, Akhavan-Behabadi et al. [9] studied the heat Reynolds numbers below 700, it was proven that in this region,
transfer augmentation in laminar flow in tubes with different wire wire coils increase heat transfer in a much more efficient way than
coil inserts. The experiments were carried out in a double-pipe other insert devices such as mesh inserts and twisted tapes. Rav-
configuration with constant wall temperature, and did not igururajan and Bergles [20] and Li et al. [21] demonstrated through
account for entry region effects nor mixed convection. visualization experiments that the presence of artificial roughness
Barba et al. [10] published an experimental paper on heat promotes turbulent flow at Reynolds numbers below 2000. The
transfer enhancement in a corrugated tube for laminar and tran- paper of Olsson and Sundén [22] was focused on the laminar-
sitional flow. They reported pressure drop increases of 2.5 times for transitional region (Re ¼ 500e6000). They studied rib-
Re ¼ 800 and Nusselt number augmentations of about 17 times at roughened, dimpled and offset strip fin small tubes for radiators,
Pr ¼ 200, compared to the smooth tube. employing air as test fluid (Prz0.7). Their measurements were
Experimental studies on surface roughness enhancement highly influenced by the entry region. Since the flow behaviour
techniques have been usually carried out for turbulent flow at low presented a smooth transition, both friction factor and Nusselt
Prandtl numbers (water and air). Ravigururajan and Bergles [11] number results were fitted to Reynolds number by a simple power
compiled a great amount of experimental data from seventeen series correlation. To extend the validity of heat transfer results, it
sources and seven different enhanced tubes. They developed was assumed that Nusselt number was proportional to Pr1/3. Meyer
general correlations for the friction factor and for the Nusselt and Olivier [23,24] obtained heat transfer coefficients, and diabatic
number for turbulent flow. They concluded that roughness shape and adiabatic friction factor data for four helical finned tubes for
exerts a higher influence on pressure drop than on heat transfer. fully developed and developing flow, covering the laminar, transi-
Zhang et al. [12] obtained very similar results in wire coils of tional and fully turbulent flow. They analyzed the influence of
circular and square section. On the other hand, Zimparov et al. [13] secondary flows on the advance of transition, and the impact of
studied corrugated tubes with the same dimensionless geometrical different inlet geometries.
parameters but different shape and observed differences up to 25% Compound enhancement techniques have been recently studied
in the friction factor. Chen et al. [14] performed an experimental by several authors. Thianpong et al. [25] investigated the ther-
investigation of different dimpled tube geometries in turbulent malehydraulic performance of combinations of three twisted tapes
flow, providing accurate correlations for heat transfer and pressure and two dimpled tubes. They proposed experimental correlations
drop analysis. They concluded that the size and weight of the heat of heat transfer and pressure drop as a function of the pitch ratio
exchanger could be reduced by a factor of almost 2 without and twist ratio. The effects of the entrance length and mixed
affecting any other system conditions. Wang et al. [15] have studied convection were not considered. Saha adopted new configurations
the thermalehydraulic characteristics in tubes with outward- in square ribbed channels with wire coil inserts, and studied
facing and raised dimples in staggered and aligned configura- separately the laminar [26] and turbulent [27] flow regimes.
tions, for Reynolds number in the range 15000e60000 and using The aim of the present work is to perform a well-reasoned
air as working fluid. comparison of the thermalehydraulic behaviour of three types of
Further to the well known interest in using corrugated tubes in enhancement technique based on artificial roughness: corrugated
turbulent flow, the most interesting region is undoubtedly the tubes, dimpled tubes and wire coils. The authors have revisited
transition region [4,16,17]. A heat exchanger can partially work in their own results on dimpled tubes [28,29], corrugated tubes
198 A. García et al. / Applied Thermal Engineering 35 (2012) 196e201
[30,31] and wire coils [32], where a wide range of geometrical Table 1
parameters of each artificial roughness technique was investigated. Characteristic dimensions of the roughened tubes.
The specimens which yielded the best thermalehydraulic perfor- Enhancement d h (e) p l h/d p/d d2p/l
mance for each shape have been chosen in the present investiga- technique [mm] [mm] [mm] [mm] (e/d) [e] [e]
tion. The heat transfer and pressure drop experimental data [e]
obtained by the authors in laminar, transition and turbulent Dimpled, D05 16.0 1.83 14.50 9.02 0.114 0.906 1.957
Corrugated, C01 18.0 1.03 15.95 e 0.057 0.886 e
regimes have been analyzed on a comparative basis. The main
Wire coil, W01 18.0 1.34 21.12 e 0.074 1.173 e
advantage of this approach is that the range of Reynolds and
Prandtl numbers investigated is similar for the three techniques, as
well as the thermal boundary condition and development lengths.
pitch (p/d). Table 1 shows the geometrical and the dimensionless
This prevents an ambiguous interpretation when data from
parameters of the mechanically deformed tubes and the wire coil
different sources are analyzed. The criterion for the choice of the
analyzed in this work. The geometrical parameters analyzed in the
three specimens allows us to establish general conclusions on the
works from which the test specimens have been chosen, as deliv-
best eligibility of an artificial roughness shape with regard to the
ering the best thermalehydraulic performance, cover the next
flow regime.
ranges: for the corrugated tubes 0.024 < h/d < 0.057 and 0.608 < p/
d < 1.229; for the dimpled tubes 0.083 < h/d < 0.119 and
3. Artificial roughened tubes analyzed 1.650 < d2p/l < 2.639; for the wire coils 0.074 < e/d < 0.101 and
1.173 < p/d < 2.684. Further information on the measurement
Surface roughness is the most common and successful tech- technique, data reduction and uncertainties of the results can be
nique for enhancing tube-side heat transfer in single phase found in [28,29], [30,31] and [32].
turbulent flow. Large scale production of roughened tubes can be
manufactured through cold rolling. In corrugated and dimpled
tubes the roughness height and pitch are controlled by the roller 3.1. Pressure drop results
geometry, the feed rate and the pressure applied during the
process. A tube with a wire coil insert is another simple and cheap Fig. 2 shows the experimental results of isothermal pressure
method of creating a roughened tube. Fig. 1 shows a sketch of the drop for the wire coil, the corrugated tube and the dimpled tube
three enhancement techniques analyzed in this work: corrugated selected, obtained in the hydrodynamically developed region. The
tubes, dimpled tubes and wire coil inserts. experimental set-up was adjusted and verified through pressure
The dimensionless numbers characterizing the geometry of drop experiments with a smooth tube. Laminar results were
corrugated tubes are dimensionless roughness height (h/d) and compared to the analytical solution (fs ¼ 16/Re) while results in the
dimensionless pitch (p/d). For dimpled tubes, the dimensionless turbulent region were compared to Blasius equation
roughness height (h/d) and dimple density (d2/pl) are employed (fs ¼ 0.0791Re0.25). An excellent agreement with the mentioned
and for wire coil inserts, wire diameter (e/d) and dimensionless correlations is observed: 3% for 95% of the experimental data.
The three roughened tubes show the typical behaviour of arti-
ficial roughness techniques: advance of transition to turbulence
and high pressure drop increase in turbulent regime [33]. In
laminar regime, at Reynolds numbers below 350, the three devices
under study increase pressure drop around 30% as a result of an
increase of the skin friction drag: this is due to the reduction of the
cross-sectional area and to the increase of the wet perimeter
(decrease of the hydraulic diameter).
a At Reynolds numbers higher than 3000, the friction factor curve
corresponding to any of the three devices has the typical trend of
the turbulent flow in roughened tubes: fafRe0.2. This implies that
the flow is fully turbulent and the pressure drop is approximately
b
10
Friction factor, f
f=16/Re
c 10
10 10 10 10 10
Reynolds number, Re
Fig. 1. Types of surface roughness that this paper contemplates. (a) Wire coils: helical
pitch p, wire diameter e; (b) Corrugated tubes: corrugation pitch p, corrugation height Fig. 2. Fanning friction factor vs. Reynolds number. Experimental results for the wire
h; (c) Dimpled tubes: corrugation pitch p, length between dimples l, dimple height h. coil, the corrugated tube and the dimpled tube.
A. García et al. / Applied Thermal Engineering 35 (2012) 196e201 199
It can be stated that the three roughened tubes studied in this Pr=33.5
paper present similar behaviour both in pure laminar and turbulent Pr=74 Pr=2.8
Nusselt number, Nu
regimes. However, roughness shape plays an important role in how
transition occurs. During the performance of the pressure drop 10
experiments, it was observed that the transition to turbulence in LAMINAR FLOW
the dimpled tube took place with strong flow instabilities. These −−− Petukhov & Polyakov [35]
instabilities were not so strong in the experiments carried out in
the corrugated tube. In wire coils, transition occurred smoothly and
without any kind of fluctuation. Fig. 2 illustrates the different
behaviours: the friction factor curve of the dimpled tube presents
a high jump within a limited Reynolds number range, which goes 10
between 1200 and 1600. For the wire coil, the critical Reynolds
number cannot be clearly identified as the jump is very small and it
10 10 10 10
takes place within a wider Reynolds range that extends from 350 to
Reynolds number, Re
2000. However, flow visualization tests in this wire coil performed
by the authors [34] demonstrate that at Re ¼ 700 the flow has Fig. 3. Nusselt number vs. Reynolds number in laminar, transition and turbulent flow.
turbulent characteristics and that at Reynolds numbers between Experimental smooth tube results compared with Petukhov and Polyakov [35] and
350 and 700, the laminar flow is strongly disturbed. Gnielinski [36] equations.
Pressure drop results of the three roughened tubes are quali-
behaviour to that of the smooth tube. However, the onset of the
tatively different and it can be affirmed that this is due to the
buoyancy-driven recirculations is greatly affected by the roughness
roughness shape. Wire coils produce two effects in the flow
shape. In the wire coil, the appearance of a rotational component of
structure: rotation of the core flow and flow separation down-
the velocity was observed [34], which delays the appearance of the
stream of the wire. It is reasonable to affirm that corrugated tubes
mixed convection: it only occurs at Reynolds numbers below 200
produce a slight rotation of the core flow and no flow separation
and at higher Rayleigh numbers than for the smooth tube. In
downstream of the corrugations. On the other hand, the three-
corrugated tubes, this rotational component is weaker and mixed-
dimensional artificial roughness of dimpled tubes is similar to
convection flow does not occur at Reynolds numbers above 700.
natural roughness, which does not generate either rotating flow or
Finally, in the dimpled tube, viscous flow occurs in a similar way to
large-scale separations. It can be stated that the rotation of the core
the smooth tube, and there is not a significant delay in the devel-
flow affects mainly the advance of transition from laminar to
opment of mixed-convection flow.
turbulent flow and its characteristics: smooth or sudden. Moreover,
Figs. 4e6 clearly show great differences in how each enhanced
coil inserts of round wire shape produce flow separations that yield
tube promotes the transition (Region II) from laminar to turbulent
high friction factor coefficients in turbulent flow, suggesting that
regime. Transition from the fully laminar to the turbulent flow
bluff body drag exceeds the skin friction drag on the wall.
takes place smoothly in the wire coil in the Reynolds number range
from 200 to 700. Visualization tests showed that at Re ¼ 700 the
3.2. Heat transfer results
flow is turbulent. For Reynolds numbers between 200 and 700, the
flow remains laminar, but separation occurs downstream of the
This section aims to compare the increase in the heat transfer
wire. The fluid near the wall is mixed and the heat transfer coef-
coefficient produced by the different enhancement techniques in
ficient increases significantly. Conversely, in the dimpled tube, fully
laminar, transition and turbulent regimes. Experimental results are
developed laminar mixed-convection flow is found up to Reynolds
presented in terms of Nusselt number vs. Reynolds number. Firstly,
number 1200. The rotational component on the core flow produced
experimental results of Nusselt number for a smooth horizontal
tube are presented in Fig. 3.
Heat transfer in the laminar regime can occur either in forced
3
convection (continuous line) or in mixed convection (dashed line). 10
I II III
Experimental results in the laminar regime were obtained in mixed Pr=4.1
convection and at Rayleigh numbers from 2107 to 7.5107. These Pr=59 Pr=37
Pr=92
results agree with the correlation of Petukhov and Polyakov [35].
Experiments for the turbulent flow were carried out at five
different Prandtl numbers from 2.8 to 74. The results agree to 2
10
a great extent with the Gnielinski equation [36].
The different heat transfer regions for each of the three
enhanced tubes under study are illustrated in Fig. 4 (dimpled tube),
Fig. 5 (wire coil), and Fig. 6 (corrugated tube). Results are con-
D05: Pr=2.9, 4.1
fronted with the correlations for the smooth tube presented in D05: Pr=92, 59, 37
Fig. 2. 1 Smooth tube, Pr=2.9, 4.1
10 Smooth tube, Pr=92, 59, 37
In laminar flow, heat transfer in horizontal tubes can occur Smooth tube, Ra=constant
either in forced convection (entry region) or in mixed convection
2 3 4 5
(fully developed region), where the flow is affected by the existence 10 10 10 10
3 3
10 10
I II III
Nusselt number, Nu
oo
2 Sm
10
2
10
1
10 ed
Forc
Ra=7.5 10 W01: Pr=168, 23, 4.3 ube, Wire coil W01
oth T
Ra=2.0 10 Smo Corrugated tube C01
W01: Pr=76, 11, 2.8
Smooth tube, Pr=168, 23, 4.3 Dimpled tube D05
1
10 Smooth tube, Pr=76, 11, 2.8
Smooth tube, Ra=constant
0
2 3 4 5
10 1 2 3 4 5
10 10 10 10 10 10 10 10 10
Reynolds number, Re Reynolds number, Re
Fig. 5. Nusselt number vs. Reynolds number. Experimental results for the wire coil in Fig. 7. Nusselt number vs. Reynolds number. Experimental correlations for the wire
the: laminar region (I), transition region (II) and turbulent region (III). coil, the corrugated tube and the dimpled tube.
2
In the pure laminar region, heat transfer in roughened tubes is
10
very similar to that observed in smooth tubes. The rotational
velocity component induced in wire coils and corrugated tubes
hinders the appearance of mixed convection: for wire coils, the
buoyancy-driven recirculations only occur at Reynolds
C01: Pr=3, 6
Ra=15 10
Ra=7.5 10 C01: Pr=35, 60, 100
numbers below 200 and at high Rayleigh numbers. In corru-
1
Ra=3.6 10 Smooth tube, Pr=3, 6 gated tubes, mixed convection is not produced at Reynolds
10 Smooth tube, Pr=35, 60,100
Smooth tube, Ra=constant numbers above 700.
At Reynolds numbers above 2000 the three roughened tubes
2 3 4 5
10 10 10 10 produce similar heat transfer coefficients, but wire coils have
Reynolds number, Re
higher friction factor coefficients.
Fig. 6. Nusselt number vs. Reynolds number. Experimental results for the corrugated The roughness shape is the key factor in the selection of
tube in the: laminar region (I), transition region (II) and turbulent region (III). roughened tubes: at Reynolds numbers below 200, the use of
A. García et al. / Applied Thermal Engineering 35 (2012) 196e201 201
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