Investigation of Hydrodynamic Flow Characteristics in Helical Coils with Ovality and Wrinkles

The forming of helical coils using a rolling process results in geometrical irregularities (wrinkles and ovality) that are likely to influence the hydrodynamic behaviour of the flow field inside the coil in applications such as air generators. In this study, the above behaviour was investigated by experimental and numerical analyses considering the heat exchanger used in dry air generators. In experimental analysis, a three-turn copper helical coil with wrinkles and ovality was investigated to estimate the global hydrodynamic characteristics inside the helical coil. The results were compared with that of the ideal geometry of a coil without wrinkles and ovality. The effect of wrinkles was assessed through friction factor, and the corresponding equivalent surface roughness was found to increase by 5.7 times, owing to the presence of wrinkles in the helical coil. Numerical simulation was conducted to determine the pressure distribution, velocity distribution, and secondary flow inside the helical coil; the results were validated with experimental data. A critical portion of the helical coil with multiple wrinkles was considered for numerical simulation to investigate the localized effects of wrinkles on the flow field behaviour. The analysis in the vicinity of wrinkles revealed negative pressure development during flow, which in turn would cause re-circulation and cavitation that are undesirable.

Optimal Design of a Helical Coil Support for Dewars in Fuel Cell Applications

Fuel cells are gaining popularity because of their efficient energy production without causing environmental pollution. Recently DRDO, has developed a fuel cell-based fuel cell-based Air Independent Propulsion (AIP) system. In this system, the hydrogen is produced onboard while oxygen is carried in liquified form (LOX) from the land in specially designed insulated storage vessels called dewars. Such vessels are needed because LOX has low boiling point (NBP ~ 90K) and heat of vaporization (~213 kJ/kg) due to which it boils off easily even when there is small amount of heat inleak from the ambient. A typical dewar consists of two vessels separated by insulation. Support members are used to hold the two vessels together. Heat inleak through the supports and the insulation of the dewar causes the boiling of LOX. The vessels are subjected to dynamic loads during the voyage as well as due to the filling and consumption of LOX. Therefore, the support system should be designed so that it can withstand the dynamic loads experienced by the dewar. While the support system should have enough mechanical strength to withstand the loads it is subjected to, it should also restrict the heat inleak from the ambient to minimize the LOX boil-off. To meet this requirement, we need to optimize the support system design. Design optimization of support systems is especially critical in submarines to reduce the snorkeling frequency. Even though the dewars are available commercially for various applications, their design methodologies are not available in the open literature. Cylindrical rods are generally used as support members. In earlier studies, the authors have shown that helical coils give better thermal performance than tension rods as dewar supports. These two support systems involve different design criteria. It is important to evolve an optimal design of the support system to maximize the mechanical strength of the support while minimizing the heat inleak through the support. In this paper we are presenting a design methodology for optimizing a helical support. We have proposed a modified optimization technique derived from the classical genetic algorithm (GA) for this purpose. The modification has been done by ensuring design feasibility of the coil at each step of the algorithm. The proposed optimization technique has been tested on a LOX dewar and an optimal design of the helical coil support has been obtained.

Numerical study of the effects of geometric parameters and nanofluid properties on heat transfer and pressure drop in helical tubes

In this research the geometric parameters and nanofluid properties effects on heat transfer and pressure drop in helical tube, by using alumina-water nanofluid as cooling fluid, are numerically investigated. Friction factor and heat transfer coefficient are calculated by considering the effects of nanofluid properties, including nanoparticle diameter, nanofluid temperature, Reynolds number, and volume fraction, on the one hand, and the impact of geometric parameters, including tube diameter, coils diameter and coils pitch, on the other hand. Numerical analysis is performed in the Ansys Fluent 19.2 software using the SST k-ω turbulence model. By increasing the nanofluid volume fraction the heat transfer coefficient and pressure drop in helical coils increase, the same as the nanoparticle diameter reduction. The reduction of nanoparticle diameter causes an enhancement of heat transfer and friction factor, the best results happen in dp = 5 nm and φ = 4%, where the it was ~ 40.64% more efficient than base fluid. This amounts for φ = 3%, φ = 2% and φ = 1% are 31.80%, 18.02% and 8.83%, respectively. Finally, the performance evaluation criteria (PEC) is compared for different cases, the maximum value was happen on φ = 4% and dp = 5 nm, which it is 1.86 times higher than the base fluid. The results indicate that the thermal efficiency of the heat exchanger improve largely by using helical coils and nanofluids, rather than the base fluid, and direct tubes. In addition, increasing coil pitch and curvature ratio enhance heat transfer and reduce friction factor.