Effect of spring-wire turbulators with different shapes on heat transfer improvement of solar air heaters; A numerical simulation

This study evaluates the heat transfer and performance characteristics of a solar air heater (SAH) equipped with spring-wire turbulators using a 3D verified CFD simulation process. Five different shapes of spring-wire (as shown in the graphical abstract) are investigated and compared to a flat SAH (without turbulator). The effects of helical diameter, pitch, and wire diameter on the performance of the system are comprehensively analyzed for all five mentioned geometries. The results reveal that the turbulator significantly enhances the thermal efficiency of the SAH within the absorber section. Rectangular cross section shape shows higher enhanced Nu number compared to the other cross section shapes. However, considering both heat transfer and pressure drop, the circular turbulator exhibits the optimal performance. Larger helical diameter, helical pitch and wire diameter, augments, decreases and increases the value of Nu/Nu_s respectively. Generally, higher increased Nu number also shows higher pumping power as well and that is why thermohydraulic performance parameter (THPP) is considered as well. Larger helical diameter, and helical pitch decreases and increases thermohydraulic performance respectively. For instance, the circular turbulator's THPP rises by approximately 17.5% as the pitch increases from 50 mm to 250 mm. However, the impact of wire diameter on THPP does not show a unified curve trend and depends on the shape of the turbulator. This study is remarkably useful for optimizing the performance of SAHs with turbulators, paving the way for enhanced device efficiency.