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The influence of artificial roughness shape on heat transfer enhancement: corrugated tubes, dimpled tubes and wire coils
A. Garcíaa, J.P. Solano*,a, P.G. Vicenteb, A. Viedmaa
aUniversidad Politécnica de Cartagena, Departamento de Ingeniería Térmica y de Fluidos,
Campus Muralla del Mar, 30202 Cartagena, Spain bUniversidad Miguel Hernández, Departamento de Ingeniería de Sistemas Industriales, Avenida
de la Universidad, 03202 Elche, Spain
Abstract
This work analyzes the thermal-hydraulic behaviour of three types of enhancement
technique based on artificial roughness: corrugated tubes, dimpled tubes and wire coils.
The comparison has been performed from the three best specimens selected among the
wide range of geometries investigated by the authors in previous works. Heat transfer
and pressure drop experimental data in laminar, transition and turbulent regimes are
used in this investigation.
Results show that the shape of the artificial roughness exerts a greater influence on the
pressure drop characteristics than on the heat transfer augmentation. Likewise, this
shape strongly affects the advance of the transition to turbulence and its characteristics:
smooth or sudden. The study concludes that for Reynolds numbers lower than 200, the
use of smooth tubes is recommended. For Reynolds numbers 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.
* Corresponding author. Tel.: +34 968325938; fax: +34 968325999.
E-mail address: [email protected] (J.P. Solano)
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Keywords: Heat transfer enhancement, wire coil inserts, corrugated tubes, dimpled tubes, turbulence promotion.
Nomenclature
cp fluid specific heat (J kg-1 K-1)
d tube inner diameter (m)
e wire coil diameter (m)
h corrugation/dimple height (m)
l length between dimples (m)
lh length of the heat transfer test section (m)
lp length of the pressure drop test section (m)
p helical/corrugation/dimple pitch (m)
ΔP pressure drop across the test section (Pa)
Q overall electrical power added (W)
Qℓ heat losses in the test section (W)
q" heat flux (Q-Qℓ)/(πdlh) (W m-2)
v mean fluid velocity (m s-1)
Dimensionless groups
f Fanning friction factor, ΔP·d/(2ρv2lp )
Gr Grashof number, gβd4q"/υ2λ
Nu Nusselt number, αd/λ
Pr Prandtl number, μcp/ λ
Ra Rayleigh number, Gr·Pr
Re Reynolds number, ρvd/μ
Greek symbols
α heat transfer coefficient (W m-2 K-1)
β thermal expansion coefficient (K-1)
λ thermal conductivity (W m-1 K-1)
μ dynamic viscosity (kg m-1 s-1)
υ kinematic viscosity (m2 s-1)
ρ fluid density (kg m-3)
Subscripts
a augmented tube
s smooth tube
∞ asymptotic
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1. Introduction
Enhancement techniques based on artificial roughness are used in numerous
applications of heat exchangers. The choice of an enhancement technique depends on
variables such as: the flow regime (Reynolds number), the fluid properties (Prandtl
number), the existence or not of fouling, the allowable pressure drop and the existence
or absence of natural convection.
The use of an enhancement technique may be conditioned by the specific application:
for example, wire coils are not applicable in the food industry due to hygiene problems
but corrugated and dimpled tubes are. In the petrochemical industry, the use of
mechanically deformed tubes is not allowed for safety reasons. However, the use of
wire coils does not present any problem. In boilers and heat recovery systems, wire
coils are frequently used because of their easy removal for cleaning operations.
In the fully laminar regime, the use of artificial roughness techniques does not
significantly improve the heat transfer coefficients as they only promote mixing in the
boundary layer near the wall. Instead, devices that mix the gross flow are suitably
employed for heat transfer enhancement in this flow regime [1], [2].
In fully developed internal turbulent flow, the velocity and temperature profiles across
the tube are similar in shape and relatively flat until very close to the wall. Artificial
roughness techniques are particularly appropriate for heat transfer augmentation in this
flow regime, as they contribute to disturbing the thermal boundary layer.
With regard to the transition from laminar to turbulent flow, experimental evidence
proves that these techniques promote the advance of transition [3]. As a result of the
flow perturbation in the viscous sub-layer, turbulence spots at Reynolds numbers below
2300 lead to early turbulence phenomena. When the transition takes place, the heat
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transfer rate can be five times higher than the one for the laminar flow in a smooth tube
[4]. The use of the best enhancement technique will bring about an important increase
of the heat transfer rate in the transition region, this presenting a high potential in
applications with highly viscous fluids, e.g. in the petrochemical and food industries.
2. Background
The use of wire coils to enhance heat transfer in tubular heat exchangers goes back to
the works by Joule in the middle of the XIX century. In fact, those works are considered
the pioneers in the field of heat transfer enhancement. The technology which allows the
manufacture of low-cost deformed tubes was developed in the last third of the XX
century. The patent of the corrugated tubes dates back to 1977 [5]. The patent of a
method for manufacturing dimpled tubes by cold external deformation dates back to
1989 [6].
In the field of enhanced heat transfer, there are very few experimental studies on
laminar flow. Here, the entrance effects and the secondary flow induced by buoyancy
forces greatly complicate the analysis. On wire coils, the work of Uttarwar and Raja
Rao [7] has been widely mentioned in the open literature [3], [8]. However, their heat
transfer results were strongly influenced by the entry region. Recently, Akhavan-
Behabadi et al. [9] studied the heat transfer augmentation in laminar flow in tubes with
different wire coil inserts. The experiments were carried out in a double-pipe
configuration with constant wall temperature, and did not account for entry region
effects nor mixed convection.
Barba et al. [10] published an experimental paper on heat transfer enhancement in a
corrugated tube for laminar and transitional flow. They reported pressure drop increases
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of 2.5 times for Re=800 and Nusselt number augmentations of about 17 times at
Pr=200, compared to the smooth tube.
Experimental studies on surface roughness enhancement techniques have been usually
carried out for turbulent flow at low Prandtl numbers (water and air). Ravigururajan and
Bergles [11] compiled a great amount of experimental data from seventeen sources and
seven different enhanced tubes. They developed general correlations for the friction
factor and for the Nusselt number for turbulent flow. They concluded that roughness
shape exerts a higher influence on pressure drop than on heat transfer. Zhang et al. [12]
obtained very similar results in wire coils of circular and square section. On the other
hand, Zimparov et al. [13] studied corrugated tubes with the same dimensionless
geometrical parameters but different shape and observed differences up to 25% in the
friction factor. Chen el al. [14] performed an experimental investigation of different
dimpled tube geometries in turbulent flow, providing accurate correlations for heat
transfer and pressure drop analysis. They concluded that the size and weight of the heat
exchanger could be reduced by a factor of almost 2 without affecting any other system
conditions. Wang et al [15] have studied the thermal-hydraulic characteristics in tubes
with outward-facing and raised dimples in staggered and aligned configurations, for
Reynolds number in the range 15000-60000 and using air as working fluid.
Further to the well known interest in using corrugated tubes in turbulent flow, the most
interesting region is undoubtedly the transition region [4,16,17]. A heat exchanger can
partially work in the laminar regime: in viscous fluids, the flow can be laminar in the
entrance, where the fluid is cold and its viscosity is high. Transition takes place at an
undefined point of the heat exchanger. Because of this, the transition point (critical
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Reynolds number) is an important parameter to bear in mind in all enhancement
techniques.
The use of a surface roughness in the transition region (Re=250-3000) can be very
effective to increase heat transfer [4], [18]. Oliver and Shoji [19] studied different insert
devices in the laminar and transition region. Although their work only covered
Reynolds numbers below 700, it was proven that in this region, wire coils increase heat
transfer in a much more efficient way than other insert devices such as mesh inserts and
twisted tapes. Ravigururajan and Bergles [20] and Li et al. [21] demonstrated through
visualization experiments that the presence of artificial roughness promotes turbulent
flow at Reynolds numbers below 2000. The paper of Olsson and Sundén [22] was
focused on the laminar-transitional region (Re=500–6000). They studied rib-roughened,
dimpled and offset strip fin small tubes for radiators, employing air as test fluid
(Pr≈0.7). Their measurements were highly influenced by the entry region. Since the
flow behaviour presented a smooth transition, both friction factor and Nusselt number
results were fitted to Reynolds number by a simple power series correlation. To extend
the validity of heat transfer results, it was assumed that Nusselt number was
proportional to Pr1/3. Meyer and Olivier [23,24] obtained heat transfer coefficients, and
diabatic and adiabatic friction factor data for four helical finned tubes for fully
developed and developing flow, covering the laminar, transitional and fully turbulent
flow. They analyzed the influence of secondary flows on the advance of transition, and
the impact of different inlet geometries.
Compound enhancement techniques have been recently studied by several authors.
Thianpong et al [25] investigated the thermal-hydraulic performance of combinations of
three twisted tapes and two dimpled tubes. They found experimental correlations of heat
transfer and pressure drop as a function of the pitch ratio and twist ratio. The effects of
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the entrance length and mixed convection were not considered. Saha adopted new
configurations in square ribbed channels with wire coil inserts, and studied separately
the laminar [26] and turbulent [27] flow regimes.
The aim of the present work is to perform a well-reasoned comparison of the thermal-
hydraulic behaviour of three types of enhancement technique based on artificial
roughness: corrugated tubes, dimpled tubes and wire coils. The authors have revisited
their own results on dimpled tubes [28,29], corrugated tubes [30,31] and wire coils [32],
where a wide range of geometrical parameters of each artificial roughness technique
was investigated. The specimens which yielded the best thermal-hydraulic performance
for each shape have been chosen in the present investigation. The heat transfer and
pressure drop experimental data obtained by the authors in laminar, transition and
turbulent regimes have been analyzed on a comparative basis. The main 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. This prevents an ambiguous interpretation when data from different sources are
analyzed. The criterion for the choice of the three specimens allows us to establish
general conclusions on the best eligibility of an artificial roughness shape with regard to
the flow regime.
3. Artificial roughened tubes analyzed
Surface roughness is the most common and successful technique for enhancing tube-
side heat transfer in single phase 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 geometry, the feed rate and the
pressure applied during the process. A tube with a wire coil insert is another simple and
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cheap method of creating a roughened tube. Fig. 1 shows a sketch of the three
enhancement techniques analyzed in this work: corrugated tubes, dimpled tubes and
wire coil inserts.
The dimensionless numbers characterizing the geometry of corrugated tubes are
dimensionless roughness height (h/d) and dimensionless pitch (p/d). For dimpled tubes,
the dimensionless roughness height (h/d) and dimple density (d²/pl) are employed and
for wire coil inserts, wire diameter (e/d) and dimensionless pitch (p/d). Table 1 shows
the geometrical and the dimensionless parameters of the mechanically deformed tubes
and the wire coil analyzed in this work. The geometrical parameters analyzed in the
works from which the test specimens have been chosen, as delivering the best thermal-
hydraulic performance, cover the next 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
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 technique, data reduction and uncertainties of the
results can be found in [28,29],[30,31] and [32].
3.1. Pressure drop results
Fig. 2 shows the experimental results of isothermal pressure drop for the wire coil, the
corrugated tube and the dimpled tube selected, obtained in the hydrodynamically
developed region. The experimental set-up was adjusted and verified through pressure
drop experiments with a smooth tube. Laminar results were compared to the analytical
solution (fs=16/Re) while results in the turbulent region were compared to Blasius
equation (fs=0.0791Re-0.25). An excellent agreement with the mentioned correlations is
observed: ±3% for 95% of the experimental data.
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The three roughened tubes show the typical behaviour of artificial 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).
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: fa ∝
Re−0.2. This implies that the flow is fully turbulent and the pressure drop is
approximately proportional to the square of the flow velocity. The wire coil produces
higher pressure drop than the deformed tubes: at Re=10000, the friction factor increase
is fa/fs=5 as compared to fa/fs=3.7 obtained in corrugated and dimpled tubes.
It can be stated that the three roughened tubes studied in this paper present similar
behaviour both in pure laminar and turbulent regimes. However, roughness shape plays
an important role in how transition occurs. During the performance of the pressure drop
experiments, it was observed that the transition to turbulence in the dimpled tube took
place with strong flow instabilities. These 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 between 1200 and 1600. For the wire coil, the
critical Reynolds number cannot be clearly identified as the jump is very small and it
takes place within a wider Reynolds range that extends from 350 to 2000. However,
flow visualization tests in this wire coil performed by the authors [34] demonstrate that
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at Re=700 the flow has turbulent characteristics and that at Reynolds numbers between
350 an 700, the laminar flow is strongly disturbed.
Pressure drop results of the three roughened tubes are qualitatively different and it can
be affirmed that this is due to the roughness shape. Wire coils produce two effects in the
flow structure: rotation of the core flow and flow separation downstream of the wire. It
is reasonable to affirm that corrugated tubes produce a slight rotation of the core flow
and no flow separation downstream of the corrugations. On the other hand, the three-
dimensional artificial roughness of dimpled tubes is similar to natural roughness, which
does not generate either rotating flow or large-scale separations. It can be stated that the
rotation of the core flow affects mainly the advance of transition from laminar to
turbulent flow and its characteristics: smooth or sudden. Moreover, coil inserts of round
wire shape produce flow separations that yield high friction factor coefficients in
turbulent flow, suggesting that bluff body drag exceeds the skin friction drag on the
wall.
3.2. Heat transfer results
This section aims to compare the increase in the heat transfer coefficient produced by
the different enhancement techniques in laminar, transition and turbulent regimes.
Experimental results are presented in terms of Nusselt number versus Reynolds number.
Firstly, 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 convection (continuous
line) or in mixed convection (dashed line). Experimental results in the laminar regime
were obtained in mixed convection and at Rayleigh numbers from 2 ⋅107 to 7.5⋅107 .
These results agree with the correlation of Petukhov and Polyakov [35]. Experiments
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for the turbulent flow were carried out at five different Prandtl numbers from 2.8 to 74.
The results agree to 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 confronted with the correlations for the smooth tube presented in Fig. 2.
In laminar flow, heat transfer in horizontal tubes can occur either in forced convection
(entry region) or in mixed convection (fully developed region), where the flow is
affected by the existence of two buoyancy-driven recirculations. The results shown in
Figs. 4-6 for the pure laminar region (Region I) are for mixed convection flow. Here,
the three roughened tubes have a similar behavior to that of the smooth tube. However,
the onset of the buoyancy-driven recirculations is greatly affected by the roughness
shape. In the wire coil, the appearance of a rotational component of the velocity was
observed [34], which delays the appearance of the mixed convection: it only occurs at
Reynolds numbers below 200 and at higher Rayleigh numbers than for the smooth tube.
In corrugated tubes, this rotational component is weaker and mixed convection flow
does not occur at Reynolds numbers above 700. Finally, in the dimpled tube, viscous
flow occurs in a similar way to the smooth tube, and there is not a significant delay in
the development of mixed convection flow.
Figs. 4-6 clearly show great differences in how each enhanced tube promotes the
transition (Region II) from laminar to turbulent regime. Transition from the fully
laminar to the turbulent flow takes place smoothly in the wire coil in the Reynolds
number range from 200 to 700. Visualization tests showed that at Re=700 the flow is
turbulent. For Reynolds numbers between 200 and 700, the flow remains laminar, but
separation occurs downstream of the wire. The fluid near the wall is mixed and the heat
transfer coefficient increases significantly. Conversely, in the dimpled tube, fully
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developed laminar mixed-convection flow is found up to Reynolds number 1200. The
rotational component on the core flow produced in corrugated tubes hinders the
establishment of the two buoyancy-driven recirculations: at Reynolds numbers above
700 heat transfer takes place under forced convection.
In the turbulent regime at Reynolds numbers above 2000 (Region III), the assertions by
Ravigururajan and Rabas [37] are validated: wire coil inserts have approximately the
same heat transfer coefficient as integral surface roughness. Bergles [38] affirms that
with these techniques, maximum Nusselt number augmentations of 250% can be
expected at low Prandtl numbers.
4. Discussion of results and conclusions
Fig. 7 presents the Nusselt number correlations proposed by the authors [28-32] for the
corrugated tube, the dimpled tube and the wire coil at Prandtl number 200 in the
Reynolds number range from 20 to 20000.
At Reynolds numbers below 200, the use of roughened tubes will not produce higher
heat transfer coefficients than those produced by smooth tubes. Moreover, wire coils
and to a lesser extent corrugated tubes, can even reduce the heat transfer rate when they
delay the establishment of mixed convection flow. Therefore the use of these
enhancement techniques is not recommended within this range of Reynolds numbers.
For Reynolds numbers between 200 and 2000, the authors recommend the use of wire
coil inserts. In this region, Nusselt number and friction factor curves are continuous and
therefore it is possible to obtain reliable correlations. Wire coils are the best choice for
heat exchangers working in this region since they produce the best heat transfer
enhancement and they have a predictable behaviour.
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At Reynolds numbers above 2000, the deformed tubes produce slightly higher heat
transfer coefficients than the wire coil: at Re=10000 and Pr=200, Nua/Nus = 2.9 for
mechanically deformed tubes and Nua/Nus = 2.4 for the wire coil. The correlations
employed offer the next influence of Prandtl number on Nua/Nus: for dimpled tubes,
01.0sa PrNuNu ; for corrugated tubes, 05.0
sa PrNuNu ; for wire coils, 02.0sa PrNuNu
. These relations yield negligible differences between the heat transfer augmentations
reported above and the values averaged over the range of Prandtl number investigated.
Since wire coil inserts produce the highest friction factor coefficients in the turbulent
regime, it is obvious that they perform worse than corrugated and dimpled tubes. In any
case, wire coils would find use in many applications since they are easy to install on
existing smooth-tube heat exchangers.
The conclusions of this comparative analysis can be summarized in the next points:
The roughness shape determines the existence or absence of a rotational velocity
component in the flow and its magnitude. The core flow rotation affects mainly
the advance of transition from laminar to turbulent flow and its characteristics:
smooth or sudden.
In coil inserts, transition from the fully laminar to the turbulent flow takes place
smoothly. In the Reynolds number range from 200 to 700 the flow remains
laminar, but separation occurs downstream of the wire. This separation promotes
heat transfer enhancement and eventually yields bluff body drag and high
friction factors in turbulent flow.
In the pure laminar region, heat transfer in roughened tubes is 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 numbers
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below 200 and at high Rayleigh numbers. In corrugated tubes, mixed convection
is not produced at Reynolds numbers above 700.
At Reynolds numbers above 2000 the three roughened tubes produce similar
heat transfer coefficients, but wire coils have higher friction factor coefficients.
The roughness shape is the key factor in the selection of roughened tubes: at
Reynolds numbers below 200, the use of roughened tube is not recommended:
smooth tubes will produce the same results; at Reynolds numbers between 200
and 2000, the use of wire coils is recommended; at Reynolds numbers above
2000, the use of corrugated and dimpled tubes is recommended. In any case,
wire coils would find use in many applications since they are easy to install on
existing smooth-tube heat exchangers.
The conclusions reported in this work aim to ease the eligibility of an artificial
roughness technique for a given application, provided that the flow conditions are
known. For example, this knowledge is being at present employed for the tube-side
enhancement of flat plate solar collectors with coil inserts [39], that typically operate
with transitional flow Reynolds numbers.
Acknowledgements
This research has been partially financed by the DPI2007-66551-C02 grant of the
Spanish Ministery of Science and the company ”HRS Spiratube”.
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[37] T.S. Ravigururajan, T.J. Rabas, Turbulent flow in integrally enhanced tubes, Part 1:
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(1996) 19-29.
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Experimental Thermal and Fluid Science, 26 (2002) 335-344.
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Simulation of an enhanced flat-plate solar liquid collector with wire-coil insert devices,
Solar Energy 85-3 (2011) 455-469.
20
Figure captions
Figure 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 h; (c) Dimpled tubes: corrugation pitch p, length between dimples l, dimple
height h.
Figure 2. Fanning friction factor vs. Reynolds number. Experimental results for the wire
coil, the corrugated tube and the dimpled tube.
Figure 3. Nusselt number vs. Reynolds number in laminar, transition and turbulent flow.
Experimental smooth tube results compared with Petukhov and Polyakov [19] and
Gnielinski [20] equations.
Figure 4. Nusselt number vs. Reynolds number. Experimental results for the dimpled
tube in the: laminar region (I), transition region (II) and turbulent region (III).
Figure 5. Nusselt number vs. Reynolds number. Experimental results for the wire coil in
the: laminar region (I), transition region (II) and turbulent region (III).
Figure 6. Nusselt number vs. Reynolds number. Experimental results for the corrugated
tube in the: laminar region (I), transition region (II) and turbulent region (III).
Figure 7. Nusselt number vs. Reynolds number. Experimental correlations for the wire
coil, the corrugated tube and the dimpled tube.
Enhancement
technique
d
[mm]
h (e)
[mm]
p
[mm]
l
[mm]
h/d (e/d)
[-]
p/d
[-]
d2p/l
[-]
dimpled, D05 16.0 1.83 14.50 9.02 0.114 0.906 1.957
corrugated, C01 18.0 1.03 15.95 - 0.057 0.886 -
wire-coil, W01 18.0 1.34 21.12 - 0.074 1.173 -
Table(s)
101
102
103
104
105
10−3
10−2
10−1
Reynolds number, Re
Fric
tion
fact
or, f
f=16/Re
f=0.079 Re
Wire coil: W01Dimpled tube: D05Corrugated tube: C01Smooth tube −0.25
Figure(s)
102
103
104
105
101
102
103
Reynolds number, Re
Nus
selt
num
ber,
Nu
Pr=74Pr=33.5
Pr=16.8Pr=4.4
Pr=2.8
− − −
Ra=2.0−7.5 107 , Nu=15.4−19.5
Gnielinski [36]
TURBULENT FLOW
LAMINAR FLOW
Petukhov & Polyakov [35]
Figure(s)
102
103
104
105
101
102
103
Reynolds number, Re
Nus
selt
num
ber,
Nu
D05: Pr=2.9, 4.1D05: Pr=92, 59, 37Smooth tube, Pr=2.9, 4.1Smooth tube, Pr=92, 59, 37Smooth tube, Ra=constant
Pr=92Pr=59 Pr=37
Pr=4.1Pr=2.9
Ra=15 10Ra=7.4 10Ra=3.5 10
6
66
IIIIII
Figure(s)