Bonfring International Journal of Industrial Engineering and Management Science, Vol. 8, No.
1, March 2018 1
Enhancement of Turbulent Heat Transfer Using
Copper Twisted Tape
G. Gokulnath, R. Govindaraj, K.M. Eazhil and L. Senthilkumar
Abstract--- Augmentation of turbulent flow heat transfer in
a horizontal tube by means of twisted tape inserts with air as
the working fluid. In order to reduce excessive pressure drops
associated with full width twisted tape inserts, with less
corresponding reduction in heat transfer coefficients, width of
twisted tape is reduced from 25mm. The drill holes will be
provided additionally in the twisted copper tape which allows
more air inside than the aluminium pipe, thus the copper tape
tends to increases heat transfer rate effectively. Our paper
carried out for plain tube with or without twisted tape insert at
constant wall heat flux and different mass flow rates. Both
heat transfer coefficient and pressure drop are calculated and
the results are compared with those of plain tube. It is
observed that the enhancement of heat transfer increases as
the varying width of the twisted tape compared with plan tube.
Keywords--- Heat Transfer, Horizontal Tube, Copper
Twisted Tape, Heat Transfer Coefficient.
I. INTRODUCTION
H EAT transfer is a discipline of thermal engineering that
concerns the generation, use, conversion and exchange of
thermal energy and heat between physical systems. Heat is an
irreversible, non equilibrium process from the point of view of
thermodynamics. The losses of available work from the
assigned energy resources due to process irreversibility Heat
transfer is classified into various mechanisms:-
1.1. Convection
Convection heat transfer is the transfer of thermal energy
by the mixing and motion a fluid or gas. It is the transfer of
heat from one place to of another movement of fluids.
Convection heat transfer is often the dominant and the most
effective mode of heat transfer in industrial, commercial, and
domestic applications such as space heating, electronics
cooling and especially compact the at exchanger.
1.2. Natural Convection
If the fluid motion occurs as a result of the density
difference produced by the temperature difference, the process
is called free or natural convection
G. Gokulnath, UG Scholar, Department of Mechanical Engineering, SNS
College of Engineering, Coimbatore.
R. Govindaraj, Assistant Professors, Department of Mechanical
Engineering, SNS College of Engineering, Coimbatore.
K.M. Eazhil, Assistant Professors, Department of Mechanical
Engineering, SNS College of Engineering, Coimbatore.
L. Senthilkumar, Assistant Professors, Department of Mechanical
Engineering, SNS College of Engineering, Coimbatore.
DOI:10.9756/BIJIEMS.8360
ISSN 2277-5056 | © 2018 Bonfring
1.3. Forced Convection
If the fluid motion is induced by a pump , a blower , a fan
,or some similar device, the process is called force or general
the magnitude of the circulation in Forced convection is
greater, and higher rate of heat transfer obtained than
convection
1.4. Radiation
Radiation is the transfer of thermal energy by the emission.
The transfer of energy to or from a body by means of the
emission or absorption of electromagnetic radiation. Thermal
radiation occurs through a vacuum or any transparent medium
(solid or fluid).It is the transfer of energy by means of photons
and electromagnetic waves.
Thermal radiation is a direct result of the random
movement's of atoms and molecules in matter. Since these
atoms and molecules are composed of charged particles
(protons and electrons), their movement results in the emission
of electromagnetic radiation, which carries energy away from
the surface
1.5. Advection
The transfer of energy from one location to another as a
side effect of physically moving an object containing that
energy. It is moved by the physical transfer of a hot or cold
object from one place to another.
II. LITERATURE SURVEY
Influences of that twisted tape insertion on heat transfer
and flow friction characteristics in a concentric double pipe
heat exchanger have been studied experimentally [1].In the
experiments the swirling flow was introduced by using twisted
tape placed inside the inner test tube of the heat exchanger
with different ratios, y=5.0 and 7.0.The experimental result
revealed that the increasing heat transfer rate of twisted tape
insert is found to be strongly influenced by tape induced swirl
[2]
. Over the range investigation the maximum nusselt numbers
for using the enhancement with y=5.0 and 7.0 are 188% and
159% respectively, higher than that of the plain tube. In
addition, the effects of twisted tape on the heat transfer
enhancement efficiency are also investigation [3]. Heat
exchanger is the apparatus providing heat transfer between
two or more fluids, and they can be classified according to the
mode of flow of fluid or their construction method [4]. Heat
exchangers with the convective heat transfer of fluid inside the
tubes are frequently used in many engineering applications [5].
Augmentation of heat transfer in connection with fluid mixing
or non-mixing, is also involved which most heat exchangers
have no contact between the fluids [6]. At present the
technology of the twisted tape inserts is widely used in various
Bonfring International Journal of Industrial Engineering and Management Science, Vol. 8, No. 1, March 2018 2

industries. Insertion of twisted tapes in a tube provides a Figure 1: Twisted Tape

simple passive techniques for enhancing the convective heat COMPONENTS SPECIFICATIONS
transfer by introducing swirl into the bulk flow and by BAND HEATER
disrupting the boundary layer at the tube surface due to Zinc
Material Used: 200C
repeated changes in the surface geometry [7]. It has been Temperature Range: 220V,5A
explained that such tapes induced turbulence superimpose Power Supply:
vortex motion. causing a thinner boundary layer and HEATPIPE
Stainless Steel
constantly resulting in a high heat transfer co-efficient and Material Used
nusselt number due to repeated changes in the twisted tape THERMOCOUPLE
J
Type:
geometry. On consideration of the heat transfer enhancement, Grade :
32F to 392F, 0C to 200C
It can be considered through bringing the twisted tape to insert THERMOSTAT
while the pressure drop inside the tube is higher. Because of To maintain the constant temperature
Usage:
0-300C
low asserts and easy setting up, it is widely used, especially in Range:
230V,15A
compact heat exchanger [8]. A Heat transfer enhancement Power Supply:
concept in which swirl was introduced in the flow was FLANGECOUPLING
Cast Iron
Material Used:
proposed by Kreit and Margolis (1959).In this concept, part of Dimension:
50mmdia(with4holes)
the fluid enters axially while the remainder is injected VALVE
tangentially at various locations along the tube axis. The radial Ball Valve
Type:
Mica
pressure gradient results in thermal boundary layer with an Material Used
accompanying improvement in heat transfer [9]. Most of the
swirl flows were created by the insertion of a twisted tape in III. EXPERIMENTAL SETUP
the tube. Twisted tapes, when inserted into tubes, tend and
The Supply is given to the blower motor and the valve is
promote turbulence as well as to intensity mixing of the hot
opened slightly. A heat input of 40w is given to the zinc
fluid and cold fluid. Thin in turn improves the heat transfer
heating wire wound on the test section by adjusting the
process [10].
dimmer stat. The thermocouples are forced on the plan
1.6. Specifications Twisted Tape surface. Thermocouples used for experimentation are J type
Material Used:-Copper with accuracy of +/-0.2%.The readings of the thermocouples
are observed every 5 minutes until they show the constant
Dimension:-600x25x3mm values.
Hole diameter:-5mm Under steady state condition, the reading of the thermo
Twisted Ratio:-3 couples amoted. The fluid properties were calculated as the
average between the inlet and outlet bulk temperatures .The
experiment is carried out in similar fashion with straight tape
inserts with twisted tape inserts (twist ratios) for the width of
25mm.The mass flow rates considered for the constant heat
input of 40w in terms of water level difference in U tube water
manometer are viewed. The presence of the insert in the pipe
causes resistance to flow and increases turbulence.

BLOWER

BALL VALVE

BAND HEATER

THERMOCOUPLE

DISPLAY UNIT

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Bonfring International Journal of Industrial Engineering and Management Science, Vol. 8, No. 1, March 2018 3

1.7. Working Methodology 1.11. Twisted Tape

The apparatus consists of a blower unit fitted with a pipe, Twisted tape is main component in our project to
which is connected to the test section located in horizontal augmentation of turbulent flow heat transfer in horizontal
orientation. Zinc band heater encloses the test section. Two tube. The material selected for this twisted tape is copper strip
Thermocouples T1,T2 are placed at equidistant from the origin to withstand the high heat resistance. The plain copper strip
of heating zone are embedded on the walls of the tube. The available in the market. The tape can be twisted by heating the
pipe system consists of a valve, which controls the air flow strip. After heating, strip is fixed at one end by means of vice
rate through it and an orifice meter to find the volume flow and tape id twisted using cutting blade.
rate of air through the system. 1.12. Band Heater
Two Calibrated pressure gauges are provided to measure The band heater is a device that used to heat the pipe and
the pressure drops across the test section. Input to the heater is then it transfer to inside the pipe. This type of heater is not
given through dimmer stat. Display unit consists of voltmeter, readily available in the market and then it given order as per
ammeter and the temperature indicator. The circuit was specification. The material selected for heater is zinc with the
designed for a load voltage of 0-220V, with a maximum range of the temperature (0-2000c).In this band heater, there is
current of 10A. Difference in the levels of manometer fluid a two connection with phase and neutral. The wire is
represents the variations in the flow rate of air.The velocity of connected with thickness of 2.5 sq.mm with 220V and 5A.
airflow in the tube is measured with the help of orifice plate
and the water manometer fitted on forced convection
apparatus.
1.8. Fabrication Work
After the completion of the design calculations and the 3-D
models, the fabrication works were started. The materials
required for each and every components were thoroughly
analyzed and properly planned for the complete utilization of
the material resources..The materials were purchased .Some
components like blower, thermocouple, stainless steel pipe are Figure 3: Band heater
readily available so that the work became easier. The tedious 1.13. Thermocouple
process in the fabrication work is the collection of the required
The thermocouple is a device that used to measure the
components and resources. The details of the components and
temperature inside the pipe. It is readily available in the
its fabrication methods were discussed below.
market with different range. The type of thermocouple used in
1.9. Heat Pipe our project is J type with range of (0-2000c).The digital
The heat pipe is one of the heat transfer device which has display with four varying indicator to indicate the temperature
been used to transfer heat between the inlet and outlet. The (T1, T2, T3, T4).
material selected for this heat pipe is stainless steel pipe that
readily available in the market with OD 48mm at the length of
2000mm.The SS pipe were cut into the no. of pieces as per
dimension using electric cutter.
1.10. Blower
The blower is one of important component in our project
to resource the air as working fluid. The blower is readily
available in the market with OD of 48mm.there is a machining
work done as coupling to fit pipe with blower using lathe.

Figure 2: Blower
Figure 4: Thermocouple

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Bonfring International Journal of Industrial Engineering and Management Science, Vol. 8, No. 1, March 2018 4

1.14. Capillary Thermostat with different range with specification of (0-3000c), 230V and
It is a device that used to regulate the band heater for 15A.It can’t be directly connected into the switch and it can be
particular temperature. It is readily available in the market connected with the phase and band heater.

Figure 5: Thermostat
1.15. Ball Valve the port is in line with both ends of the valve, flow will occur.
Reading is analyzed by varying the flow using ball valve by
It is a device that used to control the flow of the air from
moving it different position.
the blower. The gate valve type used in our project is ball
valve. A ball valve is a valve with a spherical disc in which
the sphere as a hole or port through the middle so that when

Figure 6: Ball Valve

1.16. Base 3. Heat transfer rate can be increased by using copper
material.
The base is used in our project is plywood to hold the
assembly of our apparatus. Plywood is a wood panel that 1.18. Applications
consist of no. of sheets or glued together to resist the 1. This method can be applicable in Power generation.
shrinkage an its less expensive. 2. These heat transfer techniques are also used in
1.17. Advantages food Industries.
1. Tape material cost can be reduced by reducing the
IV. RESULT AND DISCUSSION
width of it.
2. Manual pumping power can be saved by using blower. This review has considered heat transfer of twisted tape
placed in the heat exchanger. All the possible subjects’ results

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Bonfring International Journal of Industrial Engineering and Management Science, Vol. 8, No. 1, March 2018 5

are summarized, such as heat transfer studies according to

drilled twisted tape. In case of twisted tape more turbulence is
created during the swirl of fluid and gives higher heat transfer
rate.

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