Thermo-hydraulic performance of concentric tube heat exchangers with turbulent flow: Predictive correlations and iterative methods for pumping power and heat transfer

Abstract

This research addresses the problem of predicting the thermo-hydraulic performance of concentric tube heat exchangers (CTHE) under turbulent flow conditions, a critical aspect in energy-efficient industrial systems such as HVAC, power generation, and chemical processing. Existing studies often lack accurate predictive methods for balancing heat transfer performance with pumping power requirements. To tackle this issue, novel correlations and an iterative Newton–Raphson method were developed for predicting pumping power and heat transfer rates. Three-dimensional CFD simulations of a water-to-water counter-flow CTHE were conducted, with Reynolds numbers ranging from 4000 to 8000 for both the hot and cold fluids. The simulations employed the Reynolds-Averaged Navier–Stokes (RANS) equations with the $k-\omega$ SST turbulence model. The results demonstrated that increasing the Reynolds number enhances both heat transfer rates and pumping power, with the cold fluid requiring consistently higher pumping power. New correlations were developed to predict pumping power, capturing the impact of both entry and fully developed flow regions. These correlations showed an average error of less than 2.33% when compared with the CFD data. The iterative Newton–Raphson method for predicting heat transfer rates demonstrated high accuracy, with an average error of 0.66% for heat transfer rate, 0.03% for hot fluid outlet temperature, and 0.01% for cold fluid outlet temperature. Additionally, we identified optimal operating conditions for efficient cooling and heating based on the heat capacity ratio ($C_r$). The novelty of this work lies in the development of new, highly accurate predictive correlations and iterative methods for optimizing CTHE performance, going beyond existing literature by providing comprehensive insights into the relationship between pumping power, heat transfer efficiency, and flow conditions.