Design correlations for a novel enhanced compact heat exchanger with offset circular fins

A novel core geometry for compact heat exchangers, termed “circular offset fins (cOF)”, is proposed and experimentally investigated in the present work. This core design resembles the well-known offset strip fins used in efficient compact heat exchangers, with a key difference that instead of having rectangular fluid flow passages between deflections, this design features circular paths, resulting in fins with semicircular profiles. An experimental study examined heat transfer and pressure drop characteristics for five different core geometries. These geometries varied in passage diameters, lengths, and degrees of obstruction. The experiments were carried out over Reynolds numbers ranging from 500 to 3000 at different core wall temperatures. Data was analyzed using Kays and London's steady-state steam-to-air heat transfer technique to determine the empirical Colburn factor. The empirical Fanning friction factors for these geometries were also obtained. The asymptotic behavior of the Colburn and Fanning friction factor data allowed for the development of correlations in the function of Reynolds number and geometry dimensionless parameters. The proposed correlations predict data within ±6 % and ±8 %, respectively. The impact of different geometric parameters on core performance was assessed using the Colburn and Fanning friction factors, as well as area and volume goodness factors, and compared to rectangular offset strip fins. Direct comparisons showed that circular offset fins consistently exhibited a lower friction factor than rectangular fins. Although its Colburn factor was lower than rectangular fins up to a Reynolds number of 2000, circular fins it surpassed that of rectangular fins beyond this point. For the area goodness factor, their performance was comparable at a Reynolds number of 500, with circular fins outperforming after this point, achieving a 1.8-fold advantage at a Reynolds number of 3000. In terms of the volume goodness factor, both types of fins performed similarly up to a Reynolds number of 1000. Beyond this threshold, circular offset fins demonstrated a 1.3-fold improvement at a Reynolds number of 3000, underscoring the potential of the novel core geometry for compact heat exchanger applications.