Cited by 8Heat Transfer and OptimizationHeat Transfer MechanismsHeat transfer and supercritical fluids

In the Study of the Effects of the Pipe Design of a Heat Exchanger on the Thermo-Fluid Characteristics and Exergy Destruction

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Rostami, Sadra, Ahmadi, Nima·2025·Processes

Abstract

This study investigates the effects of novel pipe cross-section designs on the thermal, hydraulic, and exergetic performance of a double-pipe heat exchanger, aiming to identify the most efficient design for industrial applications. Four novel cross-sections are proposed: Case 1 (rounded square), Case 2 (hexagonal), Case 3 (triangular), and Case 4 (star-like), all maintaining the same inlet area as the base model (circular). A 3D CFD model using the Finite Volume Method and realizable k-ε turbulence model is employed to analyze performance under turbulent flow conditions (Re = 3000–20,000). Key metrics, including the Nusselt number, overall heat transfer coefficient, pressure drop, and exergy destruction, are evaluated. The results show that Case 2 achieves a 7% increase in the Nusselt number at Re = 3000 and a 2% increase at Re = 20,000, while Case 4 exhibits a 180% improvement in the overall heat transfer coefficient at Re = 13,100. However, Case 4’s higher pressure drop reduces its performance compared to the base model. Case 2 demonstrates the best thermal characteristics, making it the most suitable for industrial applications.

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References 29 · Cited by 8

Authors
Rostami, S., & Ahmadi, N.
Affiliations
Technical and Vocational University (IR)
Corresponding author
Ahmadi, Nima
Venue
Processes
Publisher
MDPI AG
Published
2025-03-12
Volume
13
Issue
3
Pages
835
ISSN
2227-9717 (ISSN-L)
OpenAlex
W4408362463
Cited by
8
References
29
Citations by year
2026: 4 · 2025: 4
FWCI
2.32
Type
journal article
Language
en
Open access
Locations
Processes (publishedVersion, cc-by)
Topics
  • Physical Sciences › Engineering › Mechanical Engineering › Heat Transfer and Optimization
  • Physical Sciences › Engineering › Mechanical Engineering › Heat Transfer Mechanisms
  • Physical Sciences › Engineering › Computational Mechanics › Heat transfer and supercritical fluids
Keywords
double pipe heat exchanger, non-circular tubes, hexagonal tubes, triangular tubes, Nusselt number, thermal transmittance, pressure drop, exergy destruction, turbulent flow, heat transfer enhancement

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