Thermohydraulic analysis of nanofluid flow in tubular heat exchangers with multi-blade turbulators: The adverse effects

Based on the significance of heat transfer in tubular flows, various methods of heat transfer enhancement have been developed by scholars. The use of turbulator inserts like twisted tapes is widely discussed and suggested by researchers, and many studies have concentrated on the positive influence of these devices. However, the question is whether these devices always positively impact heat transfer and fluid flow. In this study, efforts were made to find possible adverse impacts of using twisted tapes on the average Nusselt number (Nu), friction factor (f), flow behavior, and performance evaluation criterion (PEC) of water-titania nanofluid. Three-dimensional (3D) numerical methods were used to assess a combination of three different configurations of 156 cases with/without turbulators with different numbers of blades and pitch ratios (PR). Results suggest that at Reynolds number (Re) = 4000, 6000, and 8000, only 25%, 25%, and 22.9% of the examined cases led to PEC values over 1. Based on the results, while twisted tapes raised the Nu by up to 65.1%, the f can be increased by up to more than six times. Furthermore, streamlines and velocity magnitude contours were employed to discuss the fluid flow behavior in the presence of the turbulators. According to the findings, while with the best turbulator, the PEC value was increased by only 6.3%, some of the turbulators reduced this parameter by up to 11.8%, which is more severe. The worst performance was observed with the Case C (three-bladed) turbulator at a PR value of 11, which reduced the PEC by 11.8%. Based on the significance of heat transfer in tubular flows, various methods of heat transfer enhancement have been developed by scholars. The use of turbulator inserts like twisted tapes is widely discussed and suggested by researchers, and many studies have concentrated on the positive influence of these devices. However, the question is whether these devices always positively impact heat transfer and fluid flow. In this study, efforts were made to find possible adverse impacts of using twisted tapes on the average Nusselt number (Nu), friction factor (f), flow behavior, and performance evaluation criterion (PEC) of water-titania nanofluid. Three-dimensional (3D) numerical methods were used to assess a combination of three different configurations of 156 cases with/without turbulators with different numbers of blades and pitch ratios (PR). Results suggest that at Reynolds number (Re) = 4000, 6000, and 8000, only 25%, 25%, and 22.9% of the examined cases led to PEC values over 1. Based on the results, while twisted tapes raised the Nu by up to 65.1%, the f can be increased by up to more than six times. Furthermore, streamlines and velocity magnitude contours were employed to discuss the fluid flow behavior in the presence of the turbulators. According to the findings, while with the best turbulator, the PEC value was increased by only 6.3%, some of the turbulators reduced this parameter by up to 11.8%, which is more severe. The worst performance was observed with the Case C (three-bladed) turbulator at a PR value of 11, which reduced the PEC by 11.8%.