A comparison of thermal-hydraulic performance of various fin patterns using 3D CFD simulations

The objective of the present numerical study is to investigate the thermal-hydraulic characteristics of various circular (plain circular fin, crimped spiral fin, serrated fin) and plate fins [plain plate fin, wavy fin and fin with punched delta winglet pair (DWP)]. The geometrical parameters are, tube outer diameter (OD) = 7 mm, fin spacing (S) = 3-7 mm, fin height (hf) = 5 mm, number of tube rows (Nr) = 2, transverse tube pitch (Pt) = 23 mm and longitudinal tube pitch (Pl) = 18 mm. The Reynolds number based on hydraulic diameter has been considered in the range of 2500 ⩽ Reh ⩽ 4000. The circular fins outdo the plate fin in terms of the heat transfer coefficient and the heat transfer per unit pumping power for the circular fins has been found to be 140-170% higher as compared to the plate fins for a fixed Reynolds number. Local Nusselt number around the periphery of the tubes showed that fin patterns affect the wake region formation and flow separation on the tube surface. It has been observed that heat transfer coefficient decreases with an increase in the fin spacing due to increase in bypass flow rate through the heat exchanger at a constant Reynolds number. The heat transfer per unit pumping power showed an increase of more than 100% with an increase in the fin spacing from 3 to 6 mm. The flow patterns have been studied in detail for serrated fin, crimped fin and fin with DWP. The vortices generated by the fins merge with the horseshoe vortices and enhances the heat transfer in the domain. The fin efficiency has been found to be in the range of 77-83% for the circular fins and 55-66% for the plate fins for a range of 2500 ⩽ Reh ⩽ 4000. Only one circular fin design i.e., crimped fin provides higher volume goodness factor as compared to the plate fins. In general it has been observed that more compact heat exchanger can be designed using plate fins but at a higher pumping power cost.