Abstract
This study investigates the effects of air injection on heat transfer performance in helical coil tube heat
exchangers. Experiments were conducted varying air injection rates (0-50 L/min), injection locations
(0%, 33%, 66% of coil length), coil diameters (300 mm, 450 mm), and water flow rates (0.1-0.5 kg/s).
Results show significant heat transfer enhancement with air injection, achieving a maximum Nusselt
number increase of 84.7% (±4.4%) at 50 L/min air injection. The optimal configuration, balancing heat
transfer enhancement and pressure drop, occurred at 30 L/min air injection, 33% injection location, and
300 mm coil diameter, yielding a 62.2% (±3.8%) increase in Nusselt number and a thermal performance
factor of 1.32. Air injection efficacy was inversely proportional to water flow rate, with the thermal
performance factor decreasing from 1.45 to 1.18 as water flow increased from 0.1 to 0.5 kg/s. Novel
correlations for Nusselt number and friction factor were developed, valid for Reynolds numbers 5,000-
50,000 and Prandtl numbers 3.5-6.5, with mean absolute errors of 7.2% and 8.5% respectively. For a 10
kW heat duty, the optimized air-injected system required 38.3% less heat transfer area compared to a
conventional helical coil heat exchanger, at the cost of 34.9% higher pumping power. These findings
provide valuable insights for designing and optimizing air-injected helical coil heat exchangers,
potentially improving energy efficiency in various industrial applications
exchangers. Experiments were conducted varying air injection rates (0-50 L/min), injection locations
(0%, 33%, 66% of coil length), coil diameters (300 mm, 450 mm), and water flow rates (0.1-0.5 kg/s).
Results show significant heat transfer enhancement with air injection, achieving a maximum Nusselt
number increase of 84.7% (±4.4%) at 50 L/min air injection. The optimal configuration, balancing heat
transfer enhancement and pressure drop, occurred at 30 L/min air injection, 33% injection location, and
300 mm coil diameter, yielding a 62.2% (±3.8%) increase in Nusselt number and a thermal performance
factor of 1.32. Air injection efficacy was inversely proportional to water flow rate, with the thermal
performance factor decreasing from 1.45 to 1.18 as water flow increased from 0.1 to 0.5 kg/s. Novel
correlations for Nusselt number and friction factor were developed, valid for Reynolds numbers 5,000-
50,000 and Prandtl numbers 3.5-6.5, with mean absolute errors of 7.2% and 8.5% respectively. For a 10
kW heat duty, the optimized air-injected system required 38.3% less heat transfer area compared to a
conventional helical coil heat exchanger, at the cost of 34.9% higher pumping power. These findings
provide valuable insights for designing and optimizing air-injected helical coil heat exchangers,
potentially improving energy efficiency in various industrial applications
Keywords
Air Injection
Heat exchangers
heat transfer
Nusselt number
Optimization