Effects of multi-spring wires on hydrothermal performance of double tube heat exchanger

Double-tube heat exchangers play a vital role in industries by facilitating efficient heat transfer between two fluids while keeping them physically separated. Their design offers versatility, reliability, and ease of maintenance, contributing to improved process efficiency, energy conservation, and cost savings across a wide range of applications. This study investigates the influence of multi-spring wires on the performance of double-tube heat exchangers using A CFD turbulence model. The analysis covers friction factor, Nusselt number, and exergy efficiency across Reynolds numbers spanning from 4500 to 7500. Employing a steel spring wire of 2 mm diameter and 1000 mm length in three configurations (1, 2, and 3 springs), the results reveal a consistent increase in Nusselt number with rising Reynolds number. Notably, a 3-wire configuration demonstrates a 112 % enhancement in Nusselt number compared to plain tubes, with a maximum friction factor increase of 134 %. Exergy efficiency experiences significant improvement, rising by 61 % with the 3-wire setup compared to plain tubes. Additionally, the study predicts temperature, pressure, and velocity distributions along the tube through numerical analysis of the results. This study improves the energy efficiency and sustainability of double-tube heat exchangers using multi-spring inserts, lowering emissions and costs while advancing thermal management systems.