Thermodynamic optimization of a heat exchanger tube mounted with integrated-winglet twisted-tapes

Thermodynamic optimization of a heat exchanger tube mounted with integrated-winglet twisted-tapes | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Article Thermodynamic optimization of a heat exchanger tube mounted with integrated-winglet twisted-tapes Sathaporn Liengsirikul, Monsak Pimsarn, Varesa Chuwattanakul, and 2 more This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-7800619/v1 This work is licensed under a CC BY 4.0 License Status: Posted Version 1 posted You are reading this latest preprint version Abstract This study introduces integrated-winglet twisted tapes (IWTTs) as passive enhancers for constant-flux air flow in a circular tube, targeting simultaneous gains in both first- and second-law metrics. A realizable k-ε RANS model with second‑order spatial discretization, tight residual criteria, and grid‑independence checks was employed over 5,000 ≤ Re ≤ 20,000. The results are benchmarked against a plain tube (PT) and a traditional twisted tape (TTT). Eleven cases were assessed, spanning three winglet lengths and lifts. Among them, the IWTT-Lr0.033-Hr0.017 consistently delivered the best integrated performance. First‑law evaluation shows a peak thermal performance factor ( TPF ) = 1.58 at Re = 5,000. The TPF for the IWTT-Lr0.033-Hr0.017 remains above unity (1.58→1.01) throughout the range. For the same case, the Nusselt number increases from 51.39 to 91.64 across the examined window, with Nu/Nu₀ values of up to 2.82, exceeding the TTT counterpart by 8% at Re = 5,000. Second‑law indicators corroborate these gains. Exergy destruction is reduced from 316.52 W (PT) to 79.89 W (Lr0.033-Hr0.017) at Re = 5,000 (a 75% reduction) and remains 7–12% lower than the TTT over the range. Total entropy generation for the Lr0.033-Hr0.017 remains low and weakly varies ( S total ≈ 0.266–0.304), while the Bejan number is high (≈ 0.9997–0.9875), indicating the dominance of heat‑transfer over frictional irreversibility. This performance is attributed to winglet‑induced secondary swirl flow that disrupts the near‑wall boundary layer and augments convection while moderating pressure penalties under cube‑root weighting in TPF . Collectively, these findings establish the IWTT‑ Lr0.033-Hr0.017 as the most effective option in the present matrix and a promising insert for compact, air‑cooled heat exchangers where dual‑law (energy and exergy) improvements are required. Physical sciences/Energy science and technology Physical sciences/Engineering Physical sciences/Mathematics and computing Physical sciences/Physics Heat transfer integrated winglet twisted tape total entropy generation twisted tape Full Text Additional Declarations No competing interests reported. Cite Share Download PDF Status: Posted Version 1 posted You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. Our growing team is made up of researchers and industry professionals working together to solve the most critical problems facing scientific publishing. Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-7800619","acceptedTermsAndConditions":true,"allowDirectSubmit":true,"archivedVersions":[],"articleType":"Article","associatedPublications":[],"authors":[{"id":542628737,"identity":"a11d48d9-1f22-459a-9eb4-ddaa075af816","order_by":0,"name":"Sathaporn Liengsirikul","email":"","orcid":"","institution":"Mahanakorn University of Technology","correspondingAuthor":false,"prefix":"","firstName":"Sathaporn","middleName":"","lastName":"Liengsirikul","suffix":""},{"id":542628738,"identity":"2a725382-00fb-4d67-b2bc-8b36b2c2d6de","order_by":1,"name":"Monsak Pimsarn","email":"","orcid":"","institution":"King Mongkut’s Institute of Technology 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twisted-tapes","fulltext":[],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":false,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":false,"hideJournal":true,"highlight":"","institution":"","isAcceptedByJournal":false,"isAuthorSuppliedPdf":true,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":false,"isPdf":true,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"researchsquare","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":true,"externalIdentity":"","sideBox":"","snPcode":"","submissionUrl":"/submission","title":"Research Square","twitterHandle":"researchsquare","acdcEnabled":true,"dfaEnabled":false,"editorialSystem":"","reportingPortfolio":"","inReviewEnabled":false,"inReviewRevisionsEnabled":true},"keywords":"Heat transfer, integrated winglet twisted tape, total entropy generation, twisted tape","lastPublishedDoi":"10.21203/rs.3.rs-7800619/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-7800619/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"\u003cp\u003eThis study introduces integrated-winglet twisted tapes (IWTTs) as passive enhancers for constant-flux air flow in a circular tube, targeting simultaneous gains in both first- and second-law metrics. A realizable k-ε RANS model with second‑order spatial discretization, tight residual criteria, and grid‑independence checks was employed over 5,000\u0026thinsp;\u0026le;\u0026thinsp;\u003cem\u003eRe\u003c/em\u003e\u0026thinsp;\u0026le;\u0026thinsp;20,000. The results are benchmarked against a plain tube (PT) and a traditional twisted tape (TTT). Eleven cases were assessed, spanning three winglet lengths and lifts. Among them, the IWTT-Lr0.033-Hr0.017 consistently delivered the best integrated performance. First‑law evaluation shows a peak thermal performance factor (\u003cem\u003eTPF\u003c/em\u003e)\u0026thinsp;=\u0026thinsp;1.58 at \u003cem\u003eRe\u003c/em\u003e\u0026thinsp;=\u0026thinsp;5,000. The \u003cem\u003eTPF\u003c/em\u003e for the IWTT-Lr0.033-Hr0.017 remains above unity (1.58\u0026rarr;1.01) throughout the range. For the same case, the Nusselt number increases from 51.39 to 91.64 across the examined window, with \u003cem\u003eNu/Nu₀\u003c/em\u003e values of up to 2.82, exceeding the TTT counterpart by 8% at \u003cem\u003eRe\u003c/em\u003e\u0026thinsp;=\u0026thinsp;5,000. Second‑law indicators corroborate these gains. Exergy destruction is reduced from 316.52 W (PT) to 79.89 W (Lr0.033-Hr0.017) at \u003cem\u003eRe\u003c/em\u003e\u0026thinsp;=\u0026thinsp;5,000 (a 75% reduction) and remains 7\u0026ndash;12% lower than the TTT over the range. Total entropy generation for the Lr0.033-Hr0.017 remains low and weakly varies (\u003cem\u003eS\u003c/em\u003e\u003csub\u003e\u003cem\u003etotal\u003c/em\u003e\u003c/sub\u003e \u0026asymp; 0.266\u0026ndash;0.304), while the Bejan number is high (\u0026asymp;\u0026thinsp;0.9997\u0026ndash;0.9875), indicating the dominance of heat‑transfer over frictional irreversibility. This performance is attributed to winglet‑induced secondary swirl flow that disrupts the near‑wall boundary layer and augments convection while moderating pressure penalties under cube‑root weighting in \u003cem\u003eTPF\u003c/em\u003e. Collectively, these findings establish the IWTT‑ Lr0.033-Hr0.017 as the most effective option in the present matrix and a promising insert for compact, air‑cooled heat exchangers where dual‑law (energy and exergy) improvements are required.\u003c/p\u003e","manuscriptTitle":"Thermodynamic optimization of a heat exchanger tube mounted with integrated-winglet twisted-tapes","msid":"","msnumber":"","nonDraftVersions":[{"code":1,"date":"2025-11-11 20:02:38","doi":"10.21203/rs.3.rs-7800619/v1","editorialEvents":[{"type":"communityComments","content":0}],"status":"published","journal":{"display":true,"email":"[email protected]","identity":"researchsquare","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":true,"externalIdentity":"","sideBox":"","snPcode":"","submissionUrl":"/submission","title":"Research Square","twitterHandle":"researchsquare","acdcEnabled":true,"dfaEnabled":false,"editorialSystem":"","reportingPortfolio":"","inReviewEnabled":false,"inReviewRevisionsEnabled":true}}],"origin":"","ownerIdentity":"154f2f1e-b3a9-48a1-8cb7-52cf61e0dd17","owner":[],"postedDate":"November 11th, 2025","published":true,"recentEditorialEvents":[],"rejectedJournal":[],"revision":"","amendment":"","status":"posted","subjectAreas":[{"id":57724765,"name":"Physical sciences/Energy science and technology"},{"id":57724766,"name":"Physical sciences/Engineering"},{"id":57724767,"name":"Physical sciences/Mathematics and computing"},{"id":57724768,"name":"Physical sciences/Physics"}],"tags":[],"updatedAt":"2026-01-28T19:25:04+00:00","versionOfRecord":[],"versionCreatedAt":"2025-11-11 20:02:38","video":"","vorDoi":"","vorDoiUrl":"","workflowStages":[]},"version":"v1","identity":"rs-7800619","journalConfig":"researchsquare"},"__N_SSP":true},"page":"/article/[identity]/[[...version]]","query":{"redirect":"/article/rs-7800619","identity":"rs-7800619","version":["v1"]},"buildId":"8U1c8b4HqxoKbykW_rLl7","isFallback":false,"isExperimentalCompile":false,"dynamicIds":[84888],"gssp":true,"scriptLoader":[]}