Authors : Hemavathi P.; Vijaya Kumar Reddy K.

Volume/Issue : Volume 11 - 2026, Issue 4 - April

Google Scholar : https://tinyurl.com/3arkcye6

Scribd : https://tinyurl.com/4d2pk8h8

DOI : https://doi.org/10.38124/ijisrt/26apr2362

Note : A published paper may take 4-5 working days from the publication date to appear in PlumX Metrics, Semantic Scholar, and ResearchGate.

Abstract : In the current decade, heat exchangers play an important role in optimizing energy utilization, improving HVCE performance, and reducing carbon emissions in a variety of sectors. Shell and tube heat are frequently utilized to achieve this. Using a 40° helical baffle in the shell side and twist tape in the tube, the shell and tube heat exchanger is studied numerically to enhance heat transmission. The investigation is carried out using twisted tape inserts with pitches of 50, 100, 150, and 200 mm, as well as varied mass flow rates. The results display flow and thermal parameters, including pressure drop, friction factor, heat transfer coefficient, Nusselt number, and thermal performance. When compared to the traditional design, the Nu increases by 10.84%, 17.55%, 23.52%, and 31.21% as the twist tape pitch increases. The creation of swirl flow in the tube causes the fluid to mix well. Also, when the mass flow rate and twist pitch length rise, the factor of friction decreases. The rate of increase in friction factor is 70.81%, 47.04%, 37.43%, and 31.34% for twist pitches of 50, 100, 150, and 200 mm. However, the performance evaluation criterion (PEC) reveals that best thermo-hydraulic performance is reached at a twist tape pitch of 150 mm, which is 19.60% higher than the other values. It is shown that using helical baffles in conjunction with twisted tape inserts is a great and useful way to improve heat exchanger thermal efficiency.

Keywords : Shell-and-Tube Heat Exchanger; Twisted Tape Inserts; Helical Baffles; Heat Transfer Enhancement; Pressure Drop; PEC.

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