A novel integrated approach to heat transfer enhancement using baffles and inner fins in helical coil heat exchangers
Year: 2025
Type: article
Abstract: The global rise in energy demand has intensified the need for improved efficiency in thermal systems, particularly in industrial and high-load applications. Heat exchangers play a critical role in energy recovery, and enhancing their performance is essential for maximizing overall system efficiency. This study presents a numerical investigation of a shell-and-helical coil heat exchanger enhanced by the integration of shell-side baffles and tube-side internal fins. A three-dimensional model was developed to simulate turbulent flow and heat transfer across four structural configurations: a conventional design, a baffled configuration, an internally finned tube design, and a combined baffle–finned configuration. The simulation results indicate that the integrated configuration achieves the highest performance improvement, with up to a 33 percent increase in effectiveness compared to the conventional design, reaching a maximum effectiveness of 0.60. The same configuration also demonstrated a peak thermal-hydraulic performance value of approximately 1.60 at low flow rates, reflecting an effective balance between heat transfer enhancement and pressure loss. The numerical model was benchmarked against experimental data with a maximum deviation of about 2 percent, supporting its reliability. The study introduces a novel enhancement strategy that combines two geometric improvements into a single configuration, offering a compact and efficient solution for advanced thermal system applications.
Language: English
Subfield: Mechanical Engineering
Field: Engineering
Domain: Physical Sciences
Open Access status: gold
Estimated APC paid: $1,620
OpenAlex ID: W4417124424