Enhancing heat exchanger efficiency with novel perforated cone-shaped turbulators and nanofluids: a computational study

Abstract The present paper presents a numerical investigation of heat transfer in an exchanger fitted with a modified conical-shaped turbulator containing water/Fe2O3 nanofluid. The study aims to address the critical need for improved heat exchanger efficiency, a vital component in various industries, including the chemical, power generation, and food industries. The work focuses on achieving enhanced heat transfer performance within a smaller volume, a primary goal of modern technology and industrial processes. The innovation in this study lies in the design and analysis of a novel conical turbulator, which has not been explored extensively in the context of heat exchangers fitted with nanofluids. Unlike traditional methods, which often rely on active or semi-active means to enhance heat transfer, this research introduces a passive approach through the incorporation of turbulators. Specifically, the study investigates the use of perforated cone-shaped turbulators in conjunction with nanofluids to boost heat transfer performance. The research employs state-of-the-art computational fluid dynamics (CFD) models, allowing for a comprehensive evaluation of the turbulator’s performance across a wide range of Reynolds numbers (Re = 4000–20,000). It further examines the influence of various turbulator parameters, nanoparticle content, and geometry on heat transfer efficiency. Key findings indicate that the modified turbulator exhibits exceptional performance, increasing Nusselt numbers by 3.4–5.4 times and friction coefficients by 2.3–1.8 times compared to smooth pipes. Particularly noteworthy is the 92 % increase in the Nusselt number achieved with a mere 2 % increase in the Fe2O3 nanoparticle content. The present study introduces a novel passive heat transfer enhancement method using perforated cone-shaped turbulators and nanofluids, filling a significant gap in existing research. The innovative turbulator design and its substantial performance improvements offer promising prospects for achieving higher heat exchanger efficiency, making it a valuable contribution to thermal systems and heat transfer engineering.