International Journal of Heat and Mass Transfer 79 (2014) 551–560

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International Journal of Heat and Mass Transfer

journal homepage: www.elsevier.com/locate/ijhmt

Heat transfer and friction factor characteristics of turbulent flow through

a circular tube fitted with vortex generator inserts
Prashant W. Deshmukh ⇑, Rajendra P. Vedula
Department of Mechanical Engineering, Indian Institute of Technology, Bombay, India

a r t i c l e i n f o a b s t r a c t

Article history: Local heat transfer coefficients and average pressure drop measurements for turbulent flow in a circular
Received 4 June 2014 tube fitted with a nonconventional insert are presented here. The insert was fabricated with a central rod
Received in revised form 5 August 2014 on which curved delta wing vortex generators were attached on opposite sides at specific axial locations.
Accepted 15 August 2014
The influence of pitch to projected length ratio (p/pl), height to tube inner diameter ratio (e/d) and angle
Available online 7 September 2014
of attack (a) on the heat transfer performance are reported here. Air was used as the working fluid and
local heat transfer measurements for both smooth and rough surface sides of the tube are reported for
Keywords:
fully developed turbulent flow with Reynolds number (Re) varying between 10,000 and 45,000. The
Heat transfer enhancement
Vortex generators
average Nusselt number ratio with and without the insert (Nua/Nus), at constant Reynolds number (Re)
Local Nusselt number is found to be in the range of 1.3–5.0. The Nusselt number ratio (Nua/Nuc), based on equal pumping power
Turbulent flow is found to be in the range of 1.0–1.8. Empirical correlations are developed for Nusselt Number and
Circular pipe friction factor in terms of Reynolds number (Re), pitch to projected length ratio (p/pl), height to tube inner
diameter ratio (e/d) and angle of attack (a).
Ó 2014 Elsevier Ltd. All rights reserved.

1. Introduction Nusselt number ratio at constant pumping power, i.e. performance

The heat transfer performance of conventional heat exchanger
devices can be substantially improved by a number of heat transfer
enhancement techniques. Passive techniques for increasing heat
transfer coefficients use different types of obstructions which
disturb the flow. Results for twisted tape and wire coil inserts have
been widely reported in the literature to enhance the heat transfer
coefficients in laminar and turbulent flows in circular cross-section
tube geometries. In the current work the heat transfer performance
of a different type of insert based on curved delta wing vortex
generators is reported but a brief review of the existing inserts is
presented in this section for the sake of completeness.
Manglik and Bergles et al. [6] reported experimental data for
heat transfer and isothermal pressure drop in tube side flow with
twisted tape inserts under laminar and turbulent flow conditions.
They presented correlations which are widely used for the heat
transfer performance. The heat transfer enhancement was
approximately 40% when compared to the smooth tube and the
⇑ Corresponding author. Address: Department of Mechanical Engineering, Indian
Institute of Technology, Bombay Powai, Mumbai 400 076, India. Tel.: +91 22
25767547; fax: +91 22 2572 6875/3480.
E-mail addresses: pwdeshmukh25@gmail.com (P.W. Deshmukh), rpv@me.iitb.
ac.in (R.P. Vedula).
ratio R3, was found to be nearly unity for a Reynolds number range
between 10,000 and 45,000. The influence of various parameter
variations for regular twisted tape and several modifications of it
has been studied in the literature for enhancing heat transfer coef-
ficients. Chang et al. [1] proposed the use of spiky twisted tapes
and also provided an exhaustive review of the modifications to
the conventional twisted tapes proposed by different authors that
could enhance the thermal performance of the twisted tape inserts.
They reported the performance ratio, R3 for their best geometry to
vary from 1.5 to 1.1 for the Reynolds number increasing from 4000
to 35,000. Eiamsa-ard et al. [8] reported data for segmented
twisted tapes with uniform and non uniform alternate axes and
lengths. The performance ratio was reported to monotonically
reduce from 1.4 to 1.2 for Reynolds number increasing from
5000 to 20,000. In addition, they compiled literature available on
twisted tape with various modifications and found the Nusselt
number ratio Nua/Nus for these inserts for turbulent flow condi-
tions to be in the range of 0.8–2.5 and the performance ratio, R3
to be in the range of 0.8–1.4.
Shivashanmugam et al. [5], Eiamsa-ard et al. [11] reported the
use of a different type of insert called the helical screw tape insert.
These inserts have a twisted tape wound on a central rod which
gives the flow a screw like churning motion. The performance
ratio, at constant pumping power was reported to reduce from

http://dx.doi.org/10.1016/j.ijheatmasstransfer.2014.08.042
0017-9310/Ó 2014 Elsevier Ltd. All rights reserved.
552 P.W. Deshmukh, R.P. Vedula / International Journal of Heat and Mass Transfer 79 (2014) 551–560
Nomenclature
Symbol Meaning
A inside surface area of test section (pdL) (m2)
b base of vortex generator (refer Fig. 1a) (m)
c vortex generator length (refer Fig. 1a) (m)
DP pressure drop of fluid (N/m2)
d inside diameter of test section (m)
e height of vortex generator (e = c sin a) (m)
k thermal conductivity of the material (W/m K)
L heated length of test section (m)
l length of the tube between the pressure taps (m)
m mass flow rate of fluid (kg/s)
p pitch of vortex generator (refer Fig. 1c) (m)
pl projected length of vortex generator (pl = c cos a) (m)
r, h, z cylindrical coordinates
T temperature (K)
V voltage (V)
I current (A)
Cp specific heat at constant pressure (J/kg K)
Greek symbols
a angle of attack, degrees (refer Fig. 1) for vortex genera-
tors, a = a sin (e/c) and helix angle for helical wire coil
K vortex generator aspect ratio, K = 2 b/c (refer Fig. 1a)
2.0 to 1.5 when the Reynolds number increased from 5000 to
13,000.
Another passive technique for heat transfer enhancement for
flow inside tubes well reported in the literature is the use of wire
coil inserts. Garcia et al. [2] studied the thermo-hydraulic behav-
iour of different configurations of helical wire coil inserts in the
laminar, transition and turbulent flow regimes. They reported that
the best helical wire coil produces a heat transfer enhancement of
2.5 at Reynolds number 10,000 and this enhancement gradually
decreases with the Reynolds number. The performance ratio, R3
at constant pumping power was reported to vary from about 1.5
at an equivalent Reynolds number of 10,000 to almost unity at
an equivalent Reynolds number of 100,000.
Liu et al. [7] reviewed the various passive heat transfer
enhancement options available in the literature. They indicated
that the twisted tape inserts perform better in laminar flow condi-
tions whereas wire coil inserts perform better in turbulent flow.
Discrete vortex generators have been reported for square and
rectangular geometries for heat transfer enhancement. Feibig
et al. [4] reported heat transfer and drag measurements using delta
wing type of longitudinal vortex generators for rectangular chan-
nel flow. They concluded that Nusselt number enhancement Nua/
Nus is a function of the vortex generator aspect ratio, K, angle of
attack, a, and Reynolds number, Re. A higher angle of attack a
and aspect ratio, K results in enhancement in both heat transfer
and pressure drop. Yakut et al. [3] experimentally investigated
the dependence of geometrical parameters of delta winglet vortex
generators on heat transfer, pressure drop and flow induced vibra-
tions characteristics in internal flow through a pipe. They used
tapes with delta winglets on both sides inserted in the round tube.
Liou et al.[10] reported data for heat transfer enhancement in a
square duct with 12 different shaped vortex generators at
Re = 12,000. Among these configurations studied, they concluded
that delta wing vortex generator provide highest heat transfer aug-
mentation at constant pumping power.
A new type of enhancement device for tube flow is proposed in
this study. All the delta wing type vortex generators that have been
reported were used on flat surfaces and were therefore flat. The
q density of fluid (kg/m3)
Subscripts
a augmented case
b bulk fluid
c equivalent smooth tube at constant pumping power
L loss
o outlet of test section
i inlet of test section
s smooth Tube at constant Reynolds number
w wall
Dimensionless parameters
Re Reynolds number, qlv d
R3 Nusselt number ratio at equal pumping power
Pr
lC
Prandtl number, k p
f average friction factor
Nu local/average Nusselt number
p/pl ratio of pitch to projected length of vortex generator
e/d ratio of vortex generator height to inside diameter of
tube
current device is manufactured using curved delta wing type vor-
tex generators to form an insert that can be used in tubes and
pipes. The curvature is provided to ensure proper contact with
the tube wall. Experimental data for the heat transfer performance
of the proposed insert is presented in this article.
2. Geometric details of vortex generator insert
The details of the vortex generator insert used in the present
study are shown in Fig. 1. A 0.5 mm thick aluminum sheet
was bent in the form of a hollow cone having included angle equal
to twice the desired angle of attack of vortex generator as shown in
Fig. 1(a). The diameter of the base of the cone was made equal to
the inner diameter of the tube in which the enhancement
device is to be placed. The curved triangular shaped vortex
generator with base ‘b’, included angle ‘b’ and length ‘c’ was cut
from this cone.
A 1 mm diameter steel pin as shown in Fig. 1(b), was bent such
that it has three parts, lying in a single plane. The first part is hor-
izontal, the second part is perpendicular to first and third part is at
an angle ‘a’ equal to desired angle of attack, to the first part. The
delta wing shaped curved vortex generator was then glued to the
third part in a manner such that the projected area of the curved
vortex generator on a plane normal to that containing the steel
pin is maximum. These steel pins were periodically glued on a
2 mm diameter rod to make the required insert as shown in
Fig. 1(c). A cotton string was used to tie the part 1 to the central
rod for additional strength. The length of the first part of the steel
pin is not important but the length of the second part is such that
the base of the vortex generator is in good contact with the inner
wall of the tube. The length of third part of the steel pin is also
not very important and is kept equal to vortex generator length
‘c’, shown in Fig. 1(a).
Initial data was obtained with the delta wing pins glued to the
central rod with epoxy glue but the strength at the attachment
point was very poor and therefore, the joint was fortified using a
string. A comparison of the data obtained with and without the
string indicated differences well within the uncertainty limits of
 P.W. Deshmukh, R.P. Vedula / International Journal of Heat and Mass Transfer 79 (2014) 551–560 553

Fig. 1. Geometrical details of delta wing vortex generator.

the experimentation. This was a laboratory scale insert and an
industrial scale insert could be manufactured using joining
techniques like brazing or welding. A photograph of the insert
being inserted into the tube is shown in Fig. 1(d).
The diameter of the central rod and the steel pins are not
important but must be as small as possible to prevent large
pressure drop due to the insert, but large enough to provide struc-
tural rigidity to the insert. The end view of the tube with the insert
along with the circumferential and flow directions, h, z respectively
are shown in the Fig. 1(e). The circumference of the tube is divided
into two regions for the sake of convenient data representation:
region with vortex generators (0° < h < 85°, 180° < h < 265°) and
554 P.W. Deshmukh, R.P. Vedula / International Journal of Heat and Mass Transfer 79 (2014) 551–560

Table 1 stainless steel tube of wall thickness 0.25 mm and an outside

Characteristics dimensions of vortex generator insert. diameter equal to 25 mm. A length equal to forty pipe diameters
Angle of attack, Pitch to projected length, Height to tube inner dia. ratio, was provided upstream of the test section for the flow to develop.
a p/pl e/d Two copper sleeves soldered at each end of the test section were
15 1.4 0.09 connected to a DC power supply and current was passed through
15 2.9 0.09 the test section wall to heat it. The test section was painted with
15 5.8 0.09 black board paint to achieve uniform emissivity all over the surface
30 1.6 0.17
30 2.1 0.17
and the local temperature of the test section wall was measured by
30 3.2 0.17 a thermal camera (Mikron make, Model No. M7600 PRO). Air was
30 6.4 0.17 forced through the test section by a centrifugal blower and the flow
45 1.6 0.25 rate of air was regulated using an inlet and a by-pass valve.
45 2.0 0.25
The flow rate was calculated by measuring the differential pres-
45 3.9 0.25
45 7.9 0.25 sure head, using a manometer, across a calibrated venturimeter
located upstream of the test section. The bulk temperature of air
in the test section was measured using pre calibrated Chromel–
Alumel K-type thermocouples connected to a data acquisition sys-
tem (Agilent make, Model No. 34970A). The temperature at the
region without the vortex generators (85° < h < 180°). There are inlet and exit locations were computed as the average of measured
several geometrical parameters that affect the heat transfer char- temperatures of three thermocouples positioned in the flow field.
acteristics of the insert with vortex generators. These parameters The exit temperature measurement location was at the end of a
include pitch to projected length ratio of vortex generator (p/pl), 0.5 m long unheated, well insulated section with passive mixing
height to inside tube diameter ratio (e/d), vortex generator aspect elements after the test section. The DC power supply was adjusted
ratio (K), angle of attack (a) and the arrangement of vortex gener- such that the temperature difference between inlet and outlet bulk
ators (either inline or staggered). The parameters used for the pres- temperature at each Reynolds number reading, was at least 20 °C
ent experimental study are shown in Table 1. and the system was allowed to reach steady state for each heat flux
The measurements were made for a constant aspect ratio, K value. The pressure drop, DP was measured across the inlet and
equal to 3.8, for different pitch to projected length ratio, p/pl and exit locations of the test section and at each location, four pressure
three different angles of attack a. Among these different vortex taps 90° circumferentially apart, were connected together to obtain
generator configurations the best configuration was identified an average pressure. The friction factor was computed using the
based on the performance ratio R3. The Reynolds number based following equation:
on inner diameter of the test section was varied from 10,000 to
45,000. The present study was limited to the inline arrangement p2 DPd5 q
f ¼ 2
ð01Þ
of vortex generators i.e. there was no circumferential ‘h’, variation 32lm
in the location of successive vortex generators in the axial The total electrical power input, Qin to the test section and the heat
direction. carried, Qout by the fluid flowing through the test section were
calculated using:
3. Experimental setup and methodologies
Q in ¼ V  I; Q out ¼ mC P ðT bo  T bi Þ ð02Þ
A schematic of the facility to measure local heat transfer A separate set of experiments were conducted to measure the heat
coefficients is shown in Fig. 2. The test section is a 1000 mm long loss, Qloss, from the outside surface of the test section which is

1 – Thermocouples K type
2 – Thermal Camera

Fig. 2. Schematic of local experimental test set up.

 P.W. Deshmukh, R.P. Vedula / International Journal of Heat and Mass Transfer 79 (2014) 551–560 555

Fig. 3. Nu(z)/Nus variation for Re = 25,000 (p/pl = 12.8, a 30° i.e. e/d 0.17, K = 3.8).

Front View Side View

(a) Test Section with Insert

(b)
Fig. 4. (a) Stream wise section of surface with vortex generators (b) circumferential distribution of local Nusselt number ratio, Nu(z, h)/Nus around the vortex generator at
Re = 35,000 (p/pl 12.8, angle of attack, a 30°, e/d 0.17).

exposed to the ambient to permit temperature measurements by
thermal camera. The electrical power required to maintain the test
section at a given temperature with no flow through the test section
was measured and considered equal to Qloss. The experiment was
repeated at different values of electrical power and a curve fit was
obtained for heat loss as a function of temperature difference
between the wall and ambient.
Energy imbalance Qimbalance was calculated as:
Q imbalance ¼ Q in  Q out  Q loss ð03Þ
The energy imbalance calculated as percentage of the electrical
power input was always less than 10% for all the experiments
performed. This imbalance is due to the uncertainties in the mea-
surement of electrical current and voltage, flow rate, temperatures
at inlet, outlet and wall.
556 P.W. Deshmukh, R.P. Vedula / International Journal of Heat and Mass Transfer 79 (2014) 551–560

Nua
Nuc ¼ 0:023Re0:8
c Pr
0:4
; R3 ¼ ð11Þ
Nuc
The experimental uncertainties, within a 99.7% confidence interval,
were calculated to be 15.6% for Nusselt number and 8.7% for friction
factor measurements.
The maximum heat transfer to the fluid due to the fin effect is
estimated to be 6.8% of the total heat input, for the case with
highest number of fins and highest heat transfer coefficients by
using the standard fin analysis for triangular fins. However, since
the fins are manually made, the physical contact between the wall
and fin is poor resulting in a high thermal contact resistance. In
addition, there is only a line and not an area contact between the
fin and the wall, the maximum effect due to the fin is, therefore
likely to be much smaller than the above estimated maximum
value and is, therefore considered insignificant.

Fig. 5. Schematic of the flow across the vortex generator. 4. Results and discussions

The thermal image was used to obtain the local temperature on The experimental data of Nusselt number and pressure drop for
the test section wall. The bulk temperature at different axial smooth tube flow at different Reynolds numbers was compared
locations was computed by assuming a linear variation between with the relations given in Eq. (10) and the mismatch between
the inlet and exit locations since a uniform heat flux at the wall average Nusselt number, Nu and friction factor, f was less than
was imposed. The local Nusselt number Nu(z, h), Circumferential 10% and 5% respectively. Additionally, since a new type of insert
averaged Nusselt number at any axial location for rough and has been proposed in the current study, the experimental method-
smooth surfaces, Nu1(z), Nu2(z) respectively, of the test section ologies were tested against the wire coil insert data reported by
and their corresponding average Nusselt number values, Nu(1) Garcia et al. [2] by replicating one of the cases giving the best per-
and Nu(2) were obtained as formance and the maximum deviation from their data was noticed
to be less than 10% – the comparison is presented in Figs. 9–11.
Q out  d
Nuðz; hÞ ¼ ð04Þ These results provided the confidence in the experimental
A½T w ðz; hÞ  T b ðzÞ  k
R 85 methodologies and procedures adopted in the present study.
0
Nuðz; hÞ  dh Fig. 3 shows the axial variation of the circumferentially
Nu1 ðzÞ ¼ R 85 ð05Þ
dh averaged Nusselt number ratio, Nu(z)/Nus along the length of test
0
R 180 section for the first four vortex generators having p/pl and e/d
85
Nuðz; hÞ  dh ratios equal to 12.8 and 0.17 respectively. The exact physical
Nu2 ðzÞ ¼ R 180 ð06Þ
85
dh location of the four vortex generators inside the tube is also
RL indicated in the figure.
0
Nu1 ðzÞ  dz
Nuð1Þ ¼ RL ð07Þ The flow first encounters the leading edge of the vortex
0
dz generator where the heat transfer coefficient begins to rise. This
RL
Nu2 ðzÞ  dz increase continues along the stream wise direction underneath
0
Nuð2Þ ¼ RL ð08Þ the vortex generator, reaching a maximum at the trailing edge.
0
dz
R In the region downstream of the trailing edge the heat transfer
NuðzhÞdzdh coefficient values rapidly decrease but before the heat transfer
Nua ¼ R ð09Þ
dzdh coefficients drop to the smooth tube values the flow encounters
the next vortex generator and the process repeats. It can be noticed
The overall average Nusselt number, Nua was calculated as the
that the flow becomes developed, i.e. heat transfer coefficient
arithmetic average of the smooth and rough surface average Nusselt
reaches a constant value, after the first vortex generator itself.
numbers Nu(1) and Nu(2). The performance of a heat transfer
The flow became developed after the first one or two vortex gener-
augmentation device is described by Bergles et al.[9] and several
ator elements for all the geometric variations studied here.
others by using the criterion R3 (Nua/Nuc) where Nusselt number,
There is also a significant variation in the circumferential Nus-
Nuc is evaluated at the equivalent smooth tube Reynolds number
selt numbers at different stream wise (i.e. z) locations. The loca-
Rec for equal pumping power and equal heat exchange surface area.
tions are labelled as A, B, C, D, E, F, as shown in Fig. 4(a). The
The Nusselt number and friction factor for the smooth tube for pres-
locations are equally spaced between the leading edge of the one
ent study were obtained by the following well established
vortex generator and the trailing edge of the subsequent vortex
equations:
generator. The corresponding Nusselt number variations are
NuS ¼ 0:023Re0:8
S Pr
0:4
ðDittus BoelterÞ; f S ¼ 0:079Re0:25
S ðBlasiusÞ shown in Fig. 4(b). The heat transfer coefficients are highest along
ð10Þ the centreline of the vortex generator (i.e. h = 42.5°) and reduce on
either side of the centre line.
The friction factor fa, for a given augmented tube Reynolds number A schematic of the possible mechanism is shown in Fig. 5. The
Rea, was used to obtain the equivalent smooth tube Reynolds fresh mainstream fluid is directed towards the pipe wall by
number Rec evaluated using: the vortex generator and simultaneously exits from underneath
the vortex generator in the circumferential direction. This causes
Re3a
f a  Re3a ¼ f s  Re3c ) Re2:75
c ¼ fa  high heat transfer coefficients at the centerline (h = 42.5°) with a
0:079 progressive decrease on either side. The circumferential region of
The Nusselt number for the smooth tube was evaluated at this the tube without the vortex generator (85° < h < 180°) experiences
equivalent Reynolds number. elevated heat transfer coefficients over the smooth tube values due
 P.W. Deshmukh, R.P. Vedula / International Journal of Heat and Mass Transfer 79 (2014) 551–560 557

Fig. 6. Contour plot for local Nua/Nus over the tube surface (a) with VGs (b) without VGs for Re = 25,000 (p/pl = 12.8, a 30° i.e. e/d 0.17, K = 3.8).

Fig. 7. Contour plot for local Nua/Nus over the tube surface (a) with VGs (b) without Gs for Re = 45,000 (p/pl = 6.4, a 30° i.e. e/d 0.17, K = 3.8).
558 P.W. Deshmukh, R.P. Vedula / International Journal of Heat and Mass Transfer 79 (2014) 551–560

Fig. 8. Average Nua/Nus with pitch to projected length ratio, P/Pl for Re = 35,000.

Fig. 9. Average Nua/Nus v/s Reynolds number, Re for vortex generator inserts and helical wire coil.

to the cross stream flows from underneath the vortex generator
towards this region. Mainstream fluid moving towards the wall
beneath the vortex generators progressively enhances the heat
transfer coefficients from the leading edge to the trailing edge.
The region downstream of the trailing edge also has fresh main-
stream fluid moving towards the wall resulting in high heat trans-
fer coefficients there as well. There are likely to be longitudinal
vortices at low angles of attack and a mixing region due to a wake
at large angles of attack in the region downstream of the vortex
generator. The heat transfer coefficients progressively decrease as
the disturbance dissipates in the zone downstream of the trailing
edge. Figs. 6 and 7 correspond to a projected part of circular test
section on a two dimensional plane which contain the thermal
camera image. Figures show the distribution of local Nusselt num-
ber enhancement ratio, Nua/Nus, of the smooth and rough surfaces.
Fig. 8 shows the variation of Nusselt number ratio, Nua/Nus with
p/pl at a given Reynolds number. At very low p/pl values, the main-
stream flow is unable to penetrate the region between successive
vortex generators, due to the larger resistance offered by the vortex
generators resulting in reduced heat transfer coefficients. At very
high values of p/pl ratios, the heat transfer enhancement is reduced
due to reduction in number of vortex generators per unit length
which results in a smaller amount of fresh mainstream fluid being
directed towards the heated tube wall. An optimum value of p/pl
ratio therefore exists where, heat transfer enhancement is maxi-
mum. Optimum values for the e/d = 0.17 and 0.1 could be obtained
but experimental limitations prevented obtaining data for p/pl
values lower than 1.6 for e/d = 0.25 in the present investigation.
The optimum value of p/pl is noticed to reduce progressively as
e/d increases.
The Nusselt number and friction factor ratios with respect to
the corresponding smooth tube values, Nua/Nus as a function of
Reynolds number for all different configurations are presented in
Fig. 9. The figure also includes the data obtained from the current
experimental apparatus for the wire coil insert geometry reported
by Garcia et al. [2] to give the best performance and the compari-
son can be noted to be good. The vortex generator configuration
having angle of attack, a 15° i.e. e/d ratio 0.09, has the lowest Nus-
selt number augmentation. The configurations with angle of attack
a equal to 30° and 45° show a Nusselt number augmentation,
between 2.5 and 5.0, for the Reynolds number ranging from
10,000 to 45,000. The Nusselt number augmentation, Nua/Nus is
 P.W. Deshmukh, R.P. Vedula / International Journal of Heat and Mass Transfer 79 (2014) 551–560 559

Fig. 10. Average fa/fs v/s Reynolds number, Re for vortex generator inserts and helical wire coil.

Fig. 11. Average performance ratio, R3 v/s equivalent Reynolds number, Rec for vortex generator inserts and helical wire coil.

Fig. 12. Comparison of empirical fitted Nusselt number, Nua with experimental values.
560 P.W. Deshmukh, R.P. Vedula / International Journal of Heat and Mass Transfer 79 (2014) 551–560
Fig. 13. Comparison of empirical fitted friction factor, fa with experimental values.
maximum for the vortex generator configuration having p/pl ratio
1.6, angle of attack, a equal to 45° i.e. e/d ratio 0.25 for entire
Reynolds number range studied. Fig. 10 shows the variation of fric-
tion factor ratio, with Reynolds number, Re. The pressure drop
increases with increasing angle of attack, a and decreasing p/pl.
Fig. 11, shows the variation of performance ratio R3, with equiv-
alent Reynolds number, Rec for all the configurations studied. It is
observed that all the configurations show the value of performance
ratio, R3 greater than 1.0, except for the configuration of vortex
generator having p/pl ratio 1.4, e/d ratio 0.09, angle of attack, a
equal to 15°.
Empirical correlations for Nusselt number Nu, friction factor f,
have been developed for tubes with vortex generator inserts for
Reynolds number range between 10,000 and 45,000, angle of
attack a between 15° and 45° i.e. e/d ratio 0.09–0.25, p/pl ratio of
1.4–7.9 for aspect ratio, K of 3.8
 0:125
0:17 0:79 2
Nu ¼ 0:46Re0:77 ðp=plÞ ðe=dÞ 0:125  ðe=dÞ
 0:7
0:59 1:22 2
f ¼ 0:77Re0:14 ðp=plÞ ðe=dÞ 0:125  ðe=dÞ
Figs. 12 and 13 show comparison between the predicted experi-
mental data and the present predictions by the Eqs. (12) and (13)
above. In the figures, calculations using the present correlations
agree reasonably (within ±20%) with experimental data for the fric-
tion factor and Nusselt number.
5. Conclusions
A new insert has been proposed for enhancing heat transfer
coefficients for turbulent flows in a pipe. The local heat transfer
and average pressure drop for turbulent flow in a circular tube fit-
ted with this vortex generator insert, have been measured under
uniform heat flux conditions with air as a working fluid for differ-
ent geometric parameters. Vortex generator inserts of almost all
the configurations show Nusselt number values about 150–500%
higher than the corresponding smooth tube values. The aspect
ratio of the vortex generator was not varied in the current study.
The inserts with e/d = 0.25, p/pl = 1.6, a = 45° and e/d = 0.17,
p/pl = 2.1, a = 30°, were observed to produce the best enhancement
at constant pumping power.
The average heat transfer enhancement for the surface with
vortex generators is found to be much higher than that for the
surface without vortex generators. In general, the average heat
transfer characteristics of the vortex generator insert are found
to be superior to the conventional helical wire coil insert. The vor-
tex generator insert induces secondary flows only at the localized
areas and therefore heat transfer enhancements at specific
locations can be easily produced. However, large variations of heat
transfer coefficients exist over the surface of the tube.
Conflict of interest
None declared.
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