International Journal of Thermal Sciences 145 (2019) 106016

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International Journal of Thermal Sciences

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Parametric study on thermal enhancement and flow characteristics in a heat T

exchanger tube installed with protruded baffle bundles
S. Eiamsa-arda,∗, K. Ruengpayungsaka, C. Thianpongb, M. Pimsarnb, V. Chuwattanakulb
a
Department of Mechanical Engineering, Faculty of Engineering, Mahanakorn University of Technology, Bangkok 10530, Thailand
b
Faculty of Engineering, King Mongkut’s Institute of Technology Ladkrabang, Bangkok 10520, Thailand

ARTICLE INFO ABSTRACT

Keywords: Influence of protruded baffle turbulators (P-BTs) on turbulent convective heat transfer rate and thermal per-
Heat transfer enhancement formance behavior in round tubes was experimentally studied. The following geometrical parameters of P-BTs
Turbulator were considered (i) spacing ratio (SR = s/Dob = 1.0–3.0), (ii) diameter ratio (DR = d/Dob = 0.2–0.4), (iii) baffle
Protruded baffle orientation angle (θ = 0° (without rotation), 60°, 120° and 180°), and (iv) Reynolds number (Re = 6000 to
Turbulent promoter
20,000). Air was used as working fluid at Prandtl number of Pr = 0.71. The plain tube data was examined for
comparison with tube installed with protruded baffle turbulators (P-BTs). The experimental results obvious that
increasing baffle orientation angle (θ), increasing diameter ratio (DR) and decreasing spacing ratio (SR) lead to
the significant increases in heat transfer (Nu) and pressure loss (f). It can be also reveal that thermal performance
(η) at a given Re considerably increases with the increasing spacing ratio (SR) and the reduction of diameter ratio
(DR) and baffle orientation angle. The P-BTs with larger baffle orientation angle, induce stronger vortex ring and
longitudinal vortex behind the baffles, give higher the thermal performance. Furthermore, all of empirical
correlations (Nu, f and η) were derived as a function of Re and the protruded baffle turbulator (P-BT) geometry
parameters including spacing ratio (SR), and protrusion-diameter ratio (DR).

1. Introduction
Techniques of heat transfer augmentation (passive, active and
combined techniques) are extensively applied and continuously devel-
oped. The aims of development are not only to improve heat transfer
rate, but also to save energy, materials and equipment cost. In passive
methods, several inserts with different geometries were applied to
modify fluid flow and consequently enhance heat transfer. It is well
known that the inserts or turbulators installed in the flow passage fa-
cilitate heat transfer between the fluid flow and tube surface by in-
creasing turbulence intensity.
Several types of the turbulators were proposed for heat transfer
augmentation in the open literature. Sözen and Kuzay [1] carried out
experiments to study heat transfer rate using rolled copper mesh inserts.
Their results suggested that the heat transfer enhancement with mesh
inserts caused a large pressure drop which limited its applications.
Yakut and Sahin [2] examined the thermal performance in heat ex-
changer tubes installed with conical-ring bundles. The maximum heat
transfer was obtained by using the turbulator with the smallest pitch.
Akansu [3] numerically studied the heat transfer in round tubes in-
stalled with porous ring inserts by using the shear-stress transport k-ω
model. They obvious that heat transfer rate decreased as a distance
between rings (L) increased and a ring height (H) decreased. In addi-
tion, turbulators with different designs and geometries have been ex-
tensively developed for heat transfer enhancement such as transverse
ribs [4], V-nozzle [5], short helical tape [6], circular cross sectional
rings [7], conical-nozzles [8], propeller [9] coiled circular/square wire
[10], helical tape with centered-rod [11], conical-ring [12], twisted
wire brushe [13], circular-ring [14], straight tapes with double-sided
delta wings [15], coiled wire with triangular cross section [16], coiled
wire [17], longitudinal strip [18], triple helical tapes [19], wire coil
[20], conical cut-out combined with internal fins [21], louvered strip
[22], diverging conical rings [23], wire-rod [24], helical blade rotors.
[25], ball turbulators [26,27], small pipe inserts [28], wound woven
wire matrix [29], conical strip [30], detached circular ring [31], per-
forated rectangular strips [32,33], wires [34], and helical wire [35].
The use of turbulator results in both desired heat transfer en-
hancement and undesired friction loss penalty. For more practical use,
new turbulators have been designed to optimize both effect in order to
maximize the thermal performance that considered under the constant
pumping power. Influences of the eccentricity on thermal performance
were reported by Zade et al. [36]. Their results revealed that the helical

∗
Corresponding author.
E-mail address: smith@mut.ac.th (S. Eiamsa-ard).

https://doi.org/10.1016/j.ijthermalsci.2019.106016
Received 25 November 2017; Received in revised form 5 July 2019; Accepted 6 July 2019
1290-0729/ © 2019 Elsevier Masson SAS. All rights reserved.
S. Eiamsa-ard, et al. International Journal of Thermal Sciences 145 (2019) 106016

Nomenclature SR spacing ratio, s/Dob

t thickness of tube, m
A heat transfer area, m2 T temperature, °C
Cp specific heat, J kg−1 K−1 u average velocity in tube, m s− 1

d protrusion diameter, m
D test tube diameter, m symbol
Dob outer diameter of baffle, m
Dib inner diameter of baffle, m θ baffle orientation angle, degree
DR diameter ratio, d/Dob ν kinematic viscosity, m2 s−1
f friction factor η thermal performance factor
GCI grid convergence index ρ density, kg m− 3
Gk production of turbulence kinetic energy (TKE)
Gb production of TKE due to the buoyancy Subscripts
h heat transfer coefficient, W m− 2 K− 1
ka thermal conductivity, W m− 1 K− 1 b bulk
l axial pitch length, m conv convection
L test section length, m pp pumping power
m air mass flow rate, kg s−1 t turbulence
Nu Nusselt number w wall
p static pressure, Pa
Pr Prandtl number Abbreviations
Q heat transfer rate, W
Re Reynolds number, ρuD/μ BT baffle turbulator
s baffle spacing, m P-BT protruded baffle turbulator

screw tape can be improved the thermal performance up to 33% over Fig. 1 is study under periodic flow condition. In the present study, the
those of the plain tube. The curved-winglet turbulators with different air flows through a tube and then flows through a protruded baffle
winglet height ratios (b/D) and winglet pitch ratios (P/D) were de- turbulators (P-BTs) placed in tube. The effects of (1) spacing ratio
signed by Skullong et al. [37] to increase thermal enhancement in heat (SR = s/Dob = 1.0, 2.0 and 3.0), (2) diameter ratio (DR = d/Dob = 0.2,
exchanger tubes. The experimental results showed that the maximum 0.3 and 0.4), and (3) baffle orientation angle (θ = 0° (without rotation),
thermal enhancement factor of 1.62 was obtained using the turbulators 60°, 120° and 180°) were examined. The fluid field and thermal beha-
with BR = 0.1 and PR = 1.0. Acır et al. [38] reported that the thermal viors in a tube installed with protruded baffle turbulators (P-BTs) were
performance as high as 1.8 was achieved by using circular ring turbu- also examined with the finite volume technique under different pro-
lators. Ruengpayungsak et al. [39] studied the heat transfer rate and truded baffle configurations. The flows near the wall region were
thermal performance in a circular tube mounted with gear-ring turbu- treated by an enhanced wall function.
lators. The gear-ring turbulators was designed by focusing in mini- Continuity equation:
mizing reduced the pressure loss (f) in order to maximize thermal
performance factor. Their results reported that thermal performance (ui ) = 0
strongly dependent on number of holes (N) and spacing ratio (SR) of the xi (1)
gear-ring. The highest thermal enhancement factor of 1.3 was found at
Momentum equation:
N = 24 and SR = 3.0. Sheikholeslami and Ganji [40,41] reported that
thermal performance of the tube installed with perforated helical fin
p ui
and the one inserted with perforated circular-ring increased as open ( ui uj ) = + µ ui uj
xj xi xj xj (2)
area ratio (λ) increased.
Regarding to the recently literature review above, the different in-
Energy equation:
serts possess different heat transfer enhancement performances. The
geometries of turbulators and conditions applied of the relevant works
T
are summarized in Table 1. In common, the inserts giving better heat ( ui T ) =
xi xj xj (3)
transfer rates usually cause more significant friction penalty. However,
appropriate design and configuration of inserts are important factors for
The diffusivities is written as
a reasonable tradeoff between heat transfer rate and pressure loss. This
report aims the heat transfer enhancement by using protruded baffle µ µt
= and t =
turbulators (P-BTs). The influences of the geometrical parameters in- Pr Prt (4)
cluding spacing ratio (SR), protrusion-diameter ratio (DR), and baffle
orientation angle (θ) on thermal performance factor are examined. This where
work was carried out using the air as the test fluid with flow rates
ui uj 2 ui
corresponding to Reynolds numbers (6000 ≤ Re ≤ 20,000). The system u i u j = µt + k + µt ij
without P-BTs was also tested as the reference case. In the present re- xj xi 3 xi (5)
port, the correlations expressing the present results are also given.
The realizable k-ε model is expressed as

2. Flow configuration ( k) ( kuj ) µt k

+ = µ+ + Gk + Gb + + Sk
t xj xj k xj (6)
The heat transfer and flow of experimental system of investigation is
a tube installed protruded baffle turbulators (P-BTs) as depicted in and

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S. Eiamsa-ard, et al. International Journal of Thermal Sciences 145 (2019) 106016

Table 1
Summarized of the previous turbulator geometries and test conditions.
No. Author and year Test fluid Flow region Types Geometry

1 Sözen and Kuzay (1996) Water Turbulent (6000 ≤ Re ≤ 19,000) Rolled copper mesh –
2 Yakut and Sahin (2004) Air Turbulent (5000 ≤ Re ≤ 38,000) Conical-ring

3 Akansu (2006) Air Turbulent (5000 ≤ Re ≤ 45,000) Porous ring

4 San and Huang (2006) Air Turbulent (4608 ≤ Re ≤ 12,936) Transverse rib

5 Eiamsa-ard and Promvonge Air Turbulent (8000 ≤ Re ≤ 18,000) V-nozzle

(2006)

6 Gül and Evin (2007) Water Turbulent (5000 ≤ Re ≤ 30,000) Helical tape

7 Ozceyhan et al. (2008) Air Turbulent (4475 ≤ Re ≤ 43,725) Circular cross sectional ring

8 Eiamsa-ard and Promvonge Air Turbulent (8000 ≤ Re ≤ 18,000) Free-spacing snail entry and conical-
(2007) nozzle

9 Eiamsa-ard et al. (2009) Air Turbulent (4000 ≤ Re ≤ 21,000) Propeller type swirl generator

10 Promvonge et al. (2008) Air Turbulent (5000 ≤ Re ≤ 25,000) Coiled wire and snail

11 Eiamsa-ard and Promvonge Air Transition-Turbulent Regularly-spaced helical tape

(2005) (2300 ≤ Re ≤ 88,000)

12 Promvonge and Eiamsa-ard Air Turbulent (6000 ≤ Re ≤ 26,000) Conical-ring and twisted-tape
(2007)

13 Naphon and Suchana (2011) Water Turbulent (6000 ≤ Re ≤ 22,000) Twisted wires brush

14 Kongkaitpaiboon et al. (2010) Air Turbulent (4000 ≤ Re ≤ 20,000) Circular-ring

15 Eiamsa-ard and Promvonge Air Turbulent (4000 ≤ Re ≤ 20,000) Double-sided delta-wing tape
(2011)

16 Gunes et al. (2010) Air Transition-Turbulent Triangle cross sectioned coiled-wire

(3500 ≤ Re ≤ 27,700)

17 Akhavan-Behabadi et al. (2009) R-134a Turbulent (−) Coiled wire –

18 Sundar and Sharma (2010) Al2O3/ Transition-Turbulent Longitudinal strip –
water (3000 ≤ Re ≤ 22,000)
19 Bhuiya et al. (2012) Air Turbulent (22,000 ≤ Re ≤ 51,000) Triple helical tape

20 Eiamsa-ard et al. (2012) Air Turbulent (4000 ≤ Re ≤ 25,000) Tandem wire coil

(continued on next page)

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S. Eiamsa-ard, et al. International Journal of Thermal Sciences 145 (2019) 106016

Table 1 (continued)

No. Author and year Test fluid Flow region Types Geometry

21 Muthusamy et al. (2013) Air Turbulent (6800 ≤ Re ≤ 97000) Conical cut-out

22 Fan et al. (2012) Air Turbulent (12,000 ≤ Re ≤ 42,500) Louvered strip

23 Karakaya and Durmuş (2013) Air Turbulent (10,000 ≤ Re ≤ 34,000) Conical spring

24 Nanan et al. (2013) Air Turbulent (6000 ≤ Re ≤ 20,000) Wire-rod

25 Zhang et al. (2013) Water Turbulent (13,000 ≤ Re ≤ 27,000) Helical blade rotor

26 Jasiński (2014) Water Turbulent (10,000 ≤ Re ≤ 300,000) Ball

27 Jasiński (2014) Water Turbulent (10,000 ≤ Re ≤ 300,000) Ball

28 Tu et al. (2014) Water Turbulent (4000 ≤ Re ≤ 18,000) Pipe inserts

29 Costa et al. (2014) – Laminar (4 ≤ Re ≤ 450) Stacked woven wire matrix

30 You et al. (2015) Air Laminar (300 ≤ Re ≤ 18000) Conical strip

31 Buyukalaca et al. (2012) Air Turbulent (4350 ≤ Re ≤ 24,920) Detached circular ring

32 Bhuiya et al. (2012) Air Turbulent (15,000 ≤ Re ≤ 47,000) Perforated strip

33 Bhuiya et al. (2014) Air Turbulent (14,000 ≤ Re ≤ 47,000) Perforated rectangular strip –
34 Zohir et al. (2015) Water Turbulent (4000 ≤ Re ≤ 14,000) Coiled circular wire

35 Panahi and Zamzamian (2017) Water Turbulent (100 ≤ De ≤ 400) Helical wire

36 Zade et al. (2017) – Turbulent (5000 ≤ Re ≤ 12000) Helical screw tape

37 Skullong et al. (2018) Air Turbulent (4150 ≤ Re ≤ 25,400) Curved-winglet tape

38 Acır et al. (2016) Air Transition-Turbulent (3000 ≤ Re ≤ 7500) Circular ring

(continued on next page)

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S. Eiamsa-ard, et al. International Journal of Thermal Sciences 145 (2019) 106016

Table 1 (continued)

No. Author and year Test fluid Flow region Types Geometry

39 Ruengpayungsak et al. (2017) Air Turbulent (6000 ≤ Re ≤ 20,000) Gear-ring

40 Sheikholeslami and Ganji (2016) Air Turbulent (6000 ≤ Re ≤ 12,000) Discontinuous helical

41 Sheikholeslami and Ganji (2016) Air Turbulent (6000 ≤ Re ≤ 12,000) Perforated turbulator

42 Yaningsih et al. (2018) Water Turbulent (5300 ≤ Re ≤ 17,500) Louvered strip

from 1.0 mm thick aluminum strips. The following geometrical para-

meters were investigated (i) spacing ratio defined as baffle spacing to
Dob ratio (SR = s/Dob = 1.0 (31 P-BTs), 2.0 (16 P-BTs) and 3.0 (11 P-
BTs), where s = 64, 128 and 192 mm, respectively), (ii) protrusion-
diameter ratio defined as protrusion-diameter to outer diameter of
baffle (DR = d/Dob = 0.2, 0.3 and 0.4 where d = 12.8, 19.2 and
25.6 mm, respectively) (iii) baffle orientation angles (θ = 0° (without
rotation), 60°, 120° and 180°).

3.2. Experimental apparatus and procedure

The schematic diagram of experimental heat transfer and flow fa-

Fig. 1. Geometry details of tube installed with baffle turbulator and computa-
tional domain of periodic tube flow.
( ) ( uj ) µt
+ = µ+ + C1 S C2
t xj xj xj k+
+ C1 C3 Gb + S
k (7)
The SIMPLE algorithm and finite volume approach with QUICK
scheme are used to solve the numerical problem. In the simulation, the
grid adoptions for y+ = 2.27 was settled for the tube installed with
protruded baffle turbulators (P-BTs). It was obvious that the variation
in Nusselt number and friction factor values for the protruded baffle (P-
BTs) with spacing (SR = 1.0), diameter ratio (DR = 0.2) at Re = 6000
is marginal when increasing the cell numbers from 502,150 to 855,350,
the grid system of 502,150 cells was adopted for the present study. The
heat flux around the tube walls is kept up at 700 W/m2. The mass flow
rate at the inlet tube was kept constant at 300 K with Pr = 0.707 by
using air as the test fluid. At the exit condition, the outlet pressure value
was set to be 1.013 × 105 Pa. The comparisons showed that the pre-
dicted result is in good agreement with the present data with deviations
within 7–14% depending on each case of protruded baffle (P-BTs) ar-
rangements.
3. Experimental facility
3.1. Protruded baffle turbulators (P-BTs)
The protruded baffle turbulators (P-BTs) and their geometrical
parameters are shown in Fig. 2(a–f). All protruded baffle turbulators (P-
BTs) having inner diameters of 51 mm (Dib = 0.8Dob) were fabricated
cility is demonstrated in Fig. 2(g). Experimental apparatus mainly
consisted of entry and calming sections (with a length of 2000 mm), test
section (2000 mm long), and outlet section (with a length of 800 mm).
A heating section had covered with an electrical heater wire which
covered by insulator to prevent leakages from the tube. During in each
experiments, the electrical current was supplied at the constant rate of 3
amps with a variac transformer. The calibration of heat loss test or
2
thermal equilibrium test was carried out at various power supplies,
which the heat input (QIV = IV) by electrical heater around the wall and
the heat absorbed by the air (Qa) were measured and checked before
running the regular experiments.
In each running the regular experiments above, the entry bulk air
(working fluid) at constant temperature from a 10 hp blower was di-
rected the entry and calming sections. In the current investigation, six
P-BTs elements were installed in the calming section to promote the
fully developed flow of the working fluid before entering the testing
section. Then the air flow from the calm section was directed through
the test section. Each of experiment. The volumetric air flow rates were
measure by the orifice air flow meter that placed before the calm sec-
tion then the temperature is constant of all Reynolds number studied
which the Reynolds number is fixed at the entry of calm section. The
volumetric flow rate (V ) was varied by adjusted the motor speed
through the three phase inverter. The entry air temperature was mea-
sure by a resistance temperature detector (RTD) at placed before the
calm section while the average outlet air temperature was also mea-
sured by 3 resistance temperature detectors (RTDs) that placed in dif-
ferent radius locations in the mixing chamber and all of the resistance
temperature detectors (RTDs) were calibrated within ± 0.1 °C deviation
via thermostat. During the flow very mixing in the heating section via
the protruded baffle turbulators (P-BTs), then the bulk air (Tb) in the
heating section can be calculated via equation (12). In each test run, the
local wall temperatures (Tw) were measured by using type-T thermo-
couples that installed in 17 stations along the test section which each
station two type-T thermocouples were taped on different opposite
tube-side. All of the temperature (air temperature and wall

5
S. Eiamsa-ard, et al. International Journal of Thermal Sciences 145 (2019) 106016

Fig. 2. a. Typical baffle and protrusion baffles of different protrusion diameters (d). b. Photograph of BT inserts at different spacing ratios (SR). c. Photograph of P-BT
inserts with fixed baffle orientation angle θ = 0°/360°. d. Photograph of P-BT inserts at baffle orientation angle, θ = 60°. e. Photograph of P-BT inserts at baffle
orientation angle, θ = 120°. f. Photograph of P-BT inserts at baffle orientation angle, θ = 180°. (a) diagram of experimental apparatus g. Detail of experimental heat
transfer apparatus. (b) inlet and heat transfer sections g. Detail of experimental heat transfer apparatus. (a) stream line and fluid temperature field (b) local wall
temperature (c) local Nusselt number.

temperature) were recorded via the data acquisition system. The Rey- In this work, the thermal equilibrium can be determined as,
nolds number of the present work is tested in turbulent flow regime
QIV Qair
between 6000 and 20,000. Isothermal pressure losses were measured × 100% 8%
and record by a differential pressure digital gauge and it was calibrated
QIV (10)
via an inclined U-tube manometers. Thus, it can be estimated that
Qair = Qconv (11)
4. Data reduction
where the bulk air can be calculated as,
In the heat exchanger tube under steady state, heat transfer received Tb = (To + Ti )/2 (12)
by air (Qair) and the heat supplied via electrical heater can be written as
and
Qair = mCp, a (To Ti ) (8)
T˜w = Tw/17 (13)
Qconv = hA (T˜w Tb) (9)
The h of each test is evaluated by compounding equations (9)–(11)

6
S. Eiamsa-ard, et al. International Journal of Thermal Sciences 145 (2019) 106016

Fig. 2. (continued)

as below, Re = uD / (19)

h = mCp, a (To Ti )/ A (T˜w Tb ) (14) Similarly, a relationship for the pressure loss (f) of tube installed
with protruded baffle turbulator (P-BT) inserts can be written as a
then, the average Nu is evaluated as,
function of spacing ratio (SR), protrusion-diameter ratio (DR), baffle
Nu = hD /ka (15) orientation angle (θ), Prandtl number, and Reynolds number as

and isothermal f is determined as, f = f (Re, (SR), (DR), ( )) (20)

dP
dx
D In the experimental results, the thermal performance factors (η)
f= 1
2
u2 (16) were calculated via equation (21) that consideration on a base of under
the same pumping power per unit mass of fluid which it is the first
where dP/dx is pressure gradient and u is the average velocity in the primary design to guide the selection of a heat transfer enhancement
test section via an orifice flow meter tube. technique. By adopting the same pumping power criterion for thermal
To describe the influences of the P-BT geometry and test condition performance, the following relationship is obtained
parameters of Prantl number (Pr), spacing ratio (SR), protrusion-dia-
meter ratios (DR), baffle orientation angles (θ), and Reynolds number = (Nut / Nup)(ft / fp ) 1/3
(21)
(Re) on heat transfer in heating tube installed with protruded baffle
turbulators (P-BTs) which placed in tandem arrangement, the mean
heat transfer enhancement (Nu) can be expressed as:
Nu = f (Re, Pr, (SR), (DR), ( )) (17) 5. Uncertainty of experimental data

Prandtl number (Pr) can be determined as
Pr = Cp µ/ k
The Reynolds number (Re) is expressed as
To be sure the experimental data, the uncertainties were determined
via ref. [42–44]. The data uncertainties were expressed as below. The
(18)
uncertainties are presented in Table 2.
Nusselt Number:

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S. Eiamsa-ard, et al. International Journal of Thermal Sciences 145 (2019) 106016

Fig. 2. (continued)

{ } { } { }
Table 2 2 2 2 0.5
Nu 1
Summarized of the present experimental uncertainties for the relevant vari- = (Nu) h + (Nu) D + (Nu) ka
Nu Nu h D k
ables.
2 2 0.5
h D
Variables Uncertainties = +
h D (22)
Ammeter (I) 1.4%
Kinematic viscosity of air (from tables) 0.06% q
Pressure (P) 4.8%
where h = Tw Tb
.
Bulk temperature (oC) 0.18%
Manometer (m) 4.2% 2 2 2 0.5
h 1 h h h
Temperature indicator 3.2% = q + Tw + Tb
Thermal conductivity (k) 0.4% h h q Tw Tb
Velocity (U) 5.4% 2 2 2 0.5
Voltmeter (V) 1.7% q Tw Tb
= + +
q Tw Tb Tw Tb (23)

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S. Eiamsa-ard, et al. International Journal of Thermal Sciences 145 (2019) 106016

Fig. 3. Effect of spacing ratio (SR) on contour of 2D flow, fluid temperature, 3D flow in longitudinal plane, wall temperature and Nusselt number in tube with BT for
Re = 5000.

where q = Tbi )]. 6. Experimental results and discussion

0.5
DLh
[(V 2/ R) + mCp (Tbo

Friction Factor: The study of heat transfer rate and pressure loss behaviors in a
constant heat flux tube with protruded baffle turbulator (P-BT) inserts
2 0.5
{ } +{
} + { D} + { }
2
f
=
1 f
( P)
f
L
2 f 2 f
Re of the different arrangements: spacing ratios (SR = s/Dob), protrusion-
f f ( P) L D (Re)
diameter ratios (DR = d/Dob), and baffle orientation angles (θ) are ex-
amined. The present results on thermohydraulic behaviors are pre-
0.5
= { ( P) 2
P } +{ } +{ } +{ }
L
L 2 3 D 2
D
2 Re 2
Re (24) sented as mentioned below.
0.5
where
( P)
P
= h
h
and
Re
Re
= ( ) +( )
m 2
m
D 2
D
.

9
S. Eiamsa-ard, et al.
Fig. 4. Influence of protrusion-diameter ratio (DR) on contour of 2D flow and
fluid temperature field in tube with P-BT for Re = 5000 and SR = 1.0.
Fig. 5. Influence of protrusion-diameter ratio (DR) on 3D flow and wall tem-
perature in tube with P-BT for Re = 5000 and SR = 1.0.
10
International Journal of Thermal Sciences 145 (2019) 106016
Fig. 6. Influence of protrusion-diameter ratio (DR) on local Nusselt number in
tube with P-BT for Re = 5000 and SR = 1.0. (a) Nu (b) f.
6.1. Flow and thermal structure
The numerical results of the flow structure, temperature distribution
and local Nusselt number in a round tube with protruded baffle tur-
bulator (P-BT) inserts at Re = 6000, SR = 1.0, 2.0 and 3.0, and
DR = 0.2, 0.3 and 0.4 are showed in Figs. 3–6. The results were vali-
dated with the experimental ones under the same condition. The
comparisons showed that the results are in good agreement with the
experimental data with the deviations within ± 12% for heat transfer
rate and within ± 8% for friction loss depending on protruded baffle (P-
BTs) arrangement.
6.1.1. Effect of spacing ratios
Streamline, fluid temperature field, local surface wall temperature
and distribution of Nusselt number around the test tube with baffle
turbulators (BTs) at three different spacing ratios (SR = 1.0, 2.0 and
3.0) were presented in Fig. 4(a–c). Apparently, the reverse/recircula-
tion flow in mainly forward direction is generated behind baffle tur-
bulators (BTs). In addition, the reverse/recirculation intensity trends to
increase with decreasing spacing ratio (SR), this improves the homo-
geneous of fluid temperature field and local wall temperature (see in
Fig. 4(a and b)). Consequently, the lower wall temperature fields and
higher local Nusselt numbers are detected as SR decreases due to the
higher contact between the surface tube wall and the core fluid regions.
6.1.2. Effect of protruded baffle turbulator (P-BT) and protrusion-diameter
ratio
Fig. 5(a–d) presents the contour plots of 2D flow and fluid tem-
perature fields of tube installed with baffle turbulators (BTs) and pro-
truded baffle turbulator (P-BT) at Re = 6000 and SR = 1.0. Evidently,
both baffle turbulators (BTs) and protruded baffle turbulator (P-BT)
induce recirculation flows behind the baffles. However, the protruded
baffle turbulators (P-BTs) generate larger/longer recirculation flow.
S. Eiamsa-ard, et al.
Fig. 7. Confirmatory test of present work. (a) Nu (b) Nu/Nup.
The baffles with larger protrusion-diameter ratios (DR) give better fluid
mixing notified by the lower core fluid temperatures. Fig. 6(a–d) de-
monstrated the effect of protrusion-diameter ratio (DR) on 3D flow in
longitudinal plane and wall temperature of tube installed with pro-
truded baffle turbulators (P-BTs). Interestingly, protruded baffle tur-
bulators (P-BTs) generate secondary vortex flow behind the baffles.
Moreover, as DR increases, the secondary vortex flow becomes stronger
resulting in lower wall temperatures. Note that the secondary vortex
flow is not observed in tube with baffle turbulators (BTs). According to
Fig. 7(a–d), protruded baffle turbulators (P-BTs) give higher local wall
Nusselt number than baffle turbulators (BTs). The protruded baffle
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International Journal of Thermal Sciences 145 (2019) 106016
turbulators (P-BTs) with larger DR give better heat transfer rate than
the ones with smaller DR. The use of protruded baffle turbulators (P-
BTs) with larger DR leads to higher mean velocity and thus effective
axial air flow (Re) and then lead to reduce the flow cross-sectional area.
Moreover, the secondary flow enhances boundary layer eruption,
leading in better heat transfer enhancement.
6.2. Thermohydraulic results
6.2.1. Validation test
The validity test was performed on the plain tube for assessing the
reliability of the experimental apparatus. The results are compared with
Dittus-Boelter correlation and Blasius, under similar conditions.
The standard correlations of Dittus-Boelter and Blasius [45] are
shown below.
Nusselt number correlation:
Nu = 0.023 Re4/5 Pr0.4 (25)
The standard correlations of Blasius [45] are shown below.
Friction factor correlation:
f = 0.316 Re 1/4
(26)
Fig. 7 reveals the comparison between the present work results and
earlier correlations in the open literature [45]. The present experi-
mental data are seen to be in good agreement with above correlations
[45]. The average percentage deviations of the present data of Nu and f
are within ± 6.01% (maximum deviation is ± 9.9%) and ± 2.64%
(maximum deviation = ± 7.91%), respectively. The Nu, f and the
thermal performance behaviors of tubes installed with protruded baffle
turbulator (P-BT) inserts are discussed in the following subsections.
6.2.2. Effect of baffle spacing ratio (SR)
Fig. 8(a) shows the relationship between Nu and Re of a tube in-
stalled with protruded baffle turbulators (P-BTs) at SR = 1.0, 2.0 and
3.0 and also the plain tube. As expected, the heat transfer rate increases
with increasing Re in all reports. The Nu/Nup is also plotted as showed
in Fig. 8(b). Apparently, Nu/Nup slightly decreases with the rise of
Reynolds number, for all inserted tubes. All heat transfer enhancement
ratios (Nu/Nup) are above unity, indicating the better heat transfer rate
in a tube installed with P-BTs as compared in the plain tube. The pre-
sence of the P-BTs performs rise to a reverse flow in the space between
two successive protruded baffle turbulators (P-BTs) which reduced the
thermal boundary layer leading to improves fluid mixing and increase
the rate of enhanced heat transfer rate. The protruded baffle turbulators
(P-BTs) with the lowest baffle pitch ratio (SR = s/Dob = 1.0) offer the
maximum Nu/Nup due to the strongest overall heat transfer intensity
[26,27,46]. At constant DR of 0.2, the Nu/Nup values for the tubes with
protruded baffle turbulators (P-BTs) at SR = 1.0, 2.0 and 3.0 are
2.74–3.1, 2.54–2.86 and 2.34–2.6 times, respectively.
The effects of baffle spacing ratio (SR) and Reynolds number on
pressure loss (f) are displayed in Fig. 9(a and b). Fig. 9(a) shows that
friction factor (f) decreases with increasing Re due to the suppression of
viscous sub-layer. It is observed that the friction losses in a tube in-
stalled with protruded baffle turbulators (P-BTs) gives higher than
those the plain tube alone. And it is also seen that the friction factor
increases with decreasing spacing ratio (SR). Fig. 9(b) shows that f/fp
trends to increase with increasing Re and decreasing SR. At constant DR
of 0.2, f/fp is observed to be around 23.77–31.49, 16.03–21.62 and
11.12–14.97 times for SR = 1.0, 2.0 and 3.0, respectively. This implies
that the tube installed with baffles with larger spacing ratio value can
help to decrease pressure drop considerably.
The thermal performance represents the comparative performance
S. Eiamsa-ard, et al.
Fig. 8. Influence of baffle spacing ratio (SR) and protrusion-diameter ratio (DR) on Nusselt number. (a) f (b) f/fp.
of a tube with enhancement device to the plain tube alone. The thermal
performance calculated via Eq. (14), is plotted versus Re in Fig. 10.
Fig. 10 also shows that thermal performance factor associated with for
the protruded baffle turbulator (P-BT) inserts decreases with increasing
Re. This relates to the thickness of thermal boundary layer. At similar
conditions, thermal performance factor increases as SR decreases. At
constant DR of 0.2, thermal performance factors are varied between
0.87 and 1.08, 0.91 and 1.13, and 0.95 and 1.16 for SR = 1.0, 2.0 and
3.0, respectively. The similar effect of SR on thermal performance factor
12
International Journal of Thermal Sciences 145 (2019) 106016
is also found at DR = 0.3 and 0.4. Note that baffle turbulator (BT) in-
serts yield higher the thermal performance factor than protruded baffle
turbulator (P-BT) inserts, owing to lower pressure loss across the test
section.
6.2.3. Effect of protrusion-diameter ratio
The effect of the protrusion-diameter to outside baffle diameter
ratios (DR = d/Dob = 0.2, 0.3 and 0.4) on the heat transfer character-
istics in tube is showed in Fig. 8(a and b). The heat transfer rate (Nu)
S. Eiamsa-ard, et al.
Fig. 9. Influence of baffle spacing ratio (SR) and protrusion-diameter ratio (DR) on friction factor.
increases with increasing protrusion-diameter ratio (DR), due to the
better mixing of the fluid flow between the tube surface and core re-
gions. Based on the experimental results, the protruded baffle turbu-
lators (P-BTs) with DR = 0.4, yield over the heat transfer (Nu) than the
ones with DR = 0.2 and 0.3 by around 9.24–30.9% and 4.7–17.3%,
respectively.
The influence of the baffle diameter ratio (DR) on the pressure loss
(f) is displayed in Fig. 8(a-b). Obviously, pressure loss (f) increases with
increasing protrusion-diameter ratio. This can be explained that the
13
International Journal of Thermal Sciences 145 (2019) 106016
baffles with large protrusion-diameter possess more flow disturbance
effect, giving strong turbulent intensity and thus higher friction factor.
The protruded baffle turbulators (P-BTs) with the largest protrusion-
diameter ratio (DR = 0.4) cause friction losses higher than those with
DR = 0.2 and 0.3 by around 122–226% and 58–95%, depending on Re.
The friction losses in the tube installed with protruded baffle turbula-
tors (P-BTs) with DR = 0.2, 0.3 and 0.4, are found to be 11.1–31.5,
15.6–53.2 and 24.7–100.9 times of the plain tube.
Thermal performance (η) increases as DR decreases (Fig. 10). As
S. Eiamsa-ard, et al. International Journal of Thermal Sciences 145 (2019) 106016

Fig. 10. Influence of baffle spacing ratio (SR) and protrusion-diameter ratio (DR) on thermal performance factor. (a) DR = 0.2 (b) DR = 0.3 (c) DR = 0.4.

seen, the thermal performance associated with the tube installed with orientation angle (θ) of 60°, 120° and 180° are 1.17, 1.173 and 1.178
protruded baffle turbulators (P-BTs) at DR = 0.2, 0.3 and 0.4 are found respectively.
to be around 0.87–1.17, 0.85–1.1, and 0.76–0.99, respectively. In other
words, the protruded baffle turbulators (P-BTs) with DR = 0.2 perform
7. Empirical correlation of the present data
thermal performances over than the ones with DR = 0.3 and 0.4 by
2.65–9% and 13–20.8%, respectively. The higher thermal performance
In the present report, the correlations of the present data were de-
factors at smaller DR is mainly attributed to the lower friction loss.
veloped by using regression analysis. The resultant correlations of the
tubes with baffle turbulators (BT) and protruded baffle turbulator (P-
6.2.4. Effect of baffle orientation angle
BT) inserts in terms of spacing ratio (s/Dob), protrusion-diameter ratios
The variation of Nusselt number with Re at three various baffle
(d/Dob) are shown as follows. However, due to the very small influence
orientation angles (θ = 00 (without rotation), 600, 1200 and 1800) is
of the baffle orientation angles (θ) on the Nusselt number and pressure
shown in Fig. 11. As shown, heat transfer slightly increases with in-
loss, this parameter is neglected in the present correlations.
creasing baffle orientation angles (θ). The mean Nusselt number values
Empirical correlation for baffle turbulator (BT):
at baffle orientation angles (θ) of 0°, 60° and 120° are lower than that at
baffle rotation angle (θ) of 180°. This can be explained that the baffles Nu = 0.078 Re0.768 Pr0.4SR 0.136 (27)
with smaller angle gives slightly weaker secondary vortex flow intensity
resulting to lower fluid mixing and lower temperature gradients near f = 0.788 Re 0.051 SR 0.486
(28)
the tube wall (Figs. 12–14).
Influence of baffle orientation angle on pressure loss (f) is depicted
= 5.531 Re 0.175 SR 0.026
(29)
in Fig. 15. Evidently, the protruded baffle turbulators (P-BTs) with
larger orientation angle cause higher pressure loss (f) than the ones Empirical correlation for protruded baffle turbulator (P-BT):
with smaller orientation angle. Friction loss is mainly caused by the
interaction of pressure forces with inertial forces in the boundary layer. Nu = 0.069 Re0.755 Pr0.4SR 0.222 (1 + DR)1.036 (30)
Based on the experimental results the friction factors of tube with P-BTs
at θ = 180° are higher than those at θ = 60° and 120° by around f = 0.527 Re 0.058 SR 0.821 (1 + DR)6.202 (31)
0.43–2.55% and 0.16–1.27%, respectively.
Thermal performance factors of P-BT at different baffle orientation = 5.922 Re 0.173 SR 0.054 (1 + DR) 1.009
(32)
angles (θ = 60°, 120°and 180°) are reported in Fig. 16. Obviously, the
protruded baffle turbulator (P-BT) with baffle orientation (θ = 180°) Fig. 17(a–c) presents the comparison between the predicted data
performs slightly better than the protruded baffle turbulator (P-BT) from correlations and experimental data of the present works. For baffle
without baffle rotation (θ = 00). The thermal performance of protruded turbulators (BTs), the deviations of the predicted data are within ±
baffle turbulator (P-BT) at orientation angle (θ) of 180° are higher than 7%, ± 13% and ± 3% for Nu, f and η, respectively. For protruded
those at θ = 60° and 120° by around 0.04–1.31% and 0.01–0.81%, baffle turbulators (P-BTs), the deviations are within ± 8% for Nusselt
respectively. Furthermore, the highest thermal performance factors of number, ± 13% for friction factor and ± 5%, and for thermal perfor-
the tubes installed with protruded baffle turbulators (P-BTs) at mance factor.

14
S. Eiamsa-ard, et al. International Journal of Thermal Sciences 145 (2019) 106016

Fig. 11. Influence of baffle orientation angles (θ) on Nusselt number ratio.

15
S. Eiamsa-ard, et al. International Journal of Thermal Sciences 145 (2019) 106016

Fig. 14. Influence of baffle orientation angles (θ) on local Nusselt number in
Fig. 12. Influence of baffle orientation angles (θ) on contour of 2D flow and
tube with P-BT for Re = 5000, SR = 1.0 and DR = 0.2. (a) DR = 0.2 (b)
fluid temperature field in tube with P-BT for Re = 5000, SR = 1.0 and
DR = 0.3 (c) DR = 0.4.
DR = 0.2.

8. Conclusions

Experimental works have been examined to report the influence of

protruded baffle turbulators (P-BTs) on thermohydraulic performance
behavior. The study encompasses baffle spacing ratios (SR = 1.0, 2.0
and 3.0), protrusion-diameter ratios (DR = 0.2, 0.3 and 0.4), and baffle
orientation angles (θ = 00 (without rotation), 60°, 120° and 180°). It
can be concluded as follows.

1. Protruded baffle turbulators (P-BTs) in tandem along the heat ex-

changer tube has significant effect on the heat transfer which is
accompanied with the increased pressure loss. The effect is mainly
attributed to the induced secondary flow which helps to augment
the fluid mixing between the wall and core regions.
2. The enhancement of heat transfer rate and pressure loss of pro-
truded baffle turbulators (P-BTs) increases with increasing protru-
sion-diameter ratio (DR), baffle orientation angles (θ) and de-
creasing baffle spacing ratio (SR).
3. At constant DR of 0.4 mean enhanced heat transfer rates at
SR = 1.0, 2.0, and 3.0 are found to be 303%, 226%, and 189%,
respectively while mean increased friction losses are 101, 53, and 34
times, respectively, over than that the plain tube alone.
4. The maximum heat transfer and friction factor are obtained by using
the protruded baffle turbulators (P-BTs) at the smallest baffle spa-
cing ratio (SR = 1.0), largest baffle orientation angle (θ = 180°) and
largest protrusion-diameter ratio (DR = 0.4) which are up to 3.57
and 4.06 times of the plain tube alone and 78 and 102 of the tube
installed with the baffle turbulators (BTs).
5. The thermal performance (η) increases with decreasing Re and the
maximum value of thermal performance of 1.18 is obtained by the
Fig. 13. Influence of baffle orientation angles (θ) on 3D flow in longitudinal protruded baffle turbulators (P-BTs) at the smallest protrusion-dia-
plane and wall temperature in tube with P-BT for Re = 5000, SR = 1.0 and meter ratio (DR = 0.2) and baffle orientation angles (θ = 1800) at
DR = 0.2. largest spacing ratio (SR = 3.0).

16
S. Eiamsa-ard, et al. International Journal of Thermal Sciences 145 (2019) 106016

Fig. 15. Influence of baffle orientation angles (θ) on friction factor ratio. (a) DR = 0.2 (b) DR = 0.3 (c) DR = 0.4.

17
S. Eiamsa-ard, et al. International Journal of Thermal Sciences 145 (2019) 106016

Fig. 16. Influence of baffle orientation angles (θ) on thermal performance factor. (a) Nusselt number (b) friction factor.

18
S. Eiamsa-ard, et al.
Fig. 17. Comparison between experimental and predicted works. (c) thermal performance factor.
Acknowledgements
The authors would like to acknowledge the software support from
King Mongkut's Institute of Technology Ladkrabang (KMITL) and the
help of Associate Professor Pongjet Promvonge and Associate Professor
Jarruwat Charoensuk for their technical assistance on ANSYS FLUENT,
particularly in the post processing of analysis results.
Appendix A. Supplementary data
Supplementary data to this article can be found online at https://
doi.org/10.1016/j.ijthermalsci.2019.106016.
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