Enhancing Thermal Performance in Double Pipe Heat Exchangers Using Combined Twisted Tape and Helical Tape Inserts: A Comprehensive Review and Research Framework

Abstract

This research explores the potential of systematic review and research framework to improve how efficiently heat is transferred in double pipe heat exchangers (DPHEs) using combined passive techniques—internal twisted tape inserts placed inside the pipe and helical tapes wrapped around the outside. Despite extensive studies on individual enhancement methods, a significant research gap exists in understanding their synergistic effects. This review synthesizes key findings from numerical and experimental studies on twisted tape geometries, thermal performance factors (TPF), and entropy generation. It identifies critical gaps, including the lack of empirical correlations for combined inserts and insufficient analysis of thermodynamic efficiency. The proposed research aims to evaluate how the Nusselt number and friction factor change with different Reynolds numbers develop empirical correlations for design optimization, and conduct entropy generation analysis to minimize irreversibility. The findings will contribute to the design of energy-efficient DPHEs for real-world industrial uses.

Introduction

Heat exchangers are essential components in industries such as power generation, chemical processing, HVAC, and refrigeration. Enhancing their thermal performance is critical for energy efficiency, cost reduction, and compact system design. Passive heat transfer enhancement methods—like twisted tapes (TT) and helical tapes (HT)—have gained attention for their ability to disrupt the boundary layer and induce swirling flows, thereby improving heat transfer. However, the combined use of internal TT and external HT in double-pipe heat exchangers (DPHEs) remains underexplored.

Key Points:

1. Literature Review:

   • Surveys advancements in individual use of TT and HT.

   • Identifies research gaps in combined configurations.

   • Establishes a research framework to optimize DPHE performance for better efficiency and cost-effectiveness.

   • Emphasis on sustainability, energy conservation, and compact designs.

2. Thermal Enhancement Techniques:

   • Passive methods like fins, twisted tapes, baffles, and nanofluids.

   • Compound techniques (e.g., TT + HT, or nanofluid + tape inserts) show higher performance than single methods.

   • Systematic integration of these can reduce size, enhance energy efficiency, and lower operational costs.

3. Numerical Analyses:

   • Xiong et al. studied various turbulator geometries in DPHEs using CFD simulations.

     • Circular pipes with fusiform turbulators showed the highest heat transfer.

     • Some rectangular pipe configurations also outperformed plain circular pipes under specific conditions.

   • Square ducts with twisted tapes showed better thermo-hydraulic performance than circular ones under certain flow conditions.

   • Microplate heat exchangers with dimple patterns (validated experimentally and numerically) outperformed conventional designs, especially under turbulent flow.

   • Double-V Baffles (DVBs) created vortex flows that significantly improved heat transfer, with a maximum thermal enhancement factor of 3.55.

   • Use of Twisted Tape Inserts (TTI), Perforated TTIs (PTTI), and Double TTIs (DTTI) with ternary hybrid nanofluids (THNFs) enhanced thermal efficiency while reducing CO? emissions and costs.

   • W-cut twisted tape inserts showed significant improvement in heat transfer at higher Reynolds numbers, but increased pressure drop required balancing with performance gains.

Conclusion

The research on entropy generation in heat exchangers highlights the effectiveness of geometrical modifications—such as twisted tapes, helical coils, and turbulators—and nanofluid integration in enhancing heat transfer. These enhancements lead to significant increases in Nusselt number and overall thermal performance, though often accompanied by higher frictional losses. Thermodynamic indicators like the Bejan number and exergy efficiency have been instrumental in evaluating these trade-offs and guiding the design of more efficient systems. Nanofluids, especially those based on graphene and hybrid nanoparticles, have shown strong potential in improving thermal conductivity while reducing entropy generation under optimized conditions. Research on twisted tape inserts consistently highlights that key parameters—such as twist ratio, tape width, geometry (including V-cut, U-cut, and perforated designs), and tape length—play a critical role in influencing both heat transfer and flow resistance. In general, lower twist ratios and narrower tapes tend to improve thermal performance by promoting stronger swirl flows, although this typically results in higher pressure drops. More advanced configurations, such as helical screw tapes or compound geometries, have shown even greater effectiveness by further enhancing turbulence and mixing. When these optimized insert designs are used in conjunction with nanofluids, the combined effect can significantly boost heat transfer efficiency while minimizing entropy generation. This synergy offers promising potential for the design of high-performance heat exchangers, particularly in applications focused on energy recovery and industrial thermal management.

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Copyright © 2025 Harsh Narayan Shukla, Rakesh Kumar Patel, Bhrant Kumar Dandoutiya, Abhay Agrawal. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.