Design Optimization, Thermohydraulic, and Enviro-Economic Analysis of Twisted Perforated Tape Insert-Based Heat Exchanger With Nanofluid Using Computational Fluid Dynamics and Taguchi Grey Method

Abstract

Abstract In this paper, the effect of perforated twisted tape insert (PTTI)-based heat exchanger (HX) utilizing nanofluid as working fluid undercooling, turbulent flow model has been investigated numerically. Parameters, i.e., nanofluid mass flow rates (0.018–0.038 kg/s), perforated pitches (20 mm–40 mm), and perforated diameters (2 mm–4 mm) variation effects on fluid outlet temperature, Nusselt ratio, Friction ratio, pressure drop, overall thermal performance, CO2 discharge, and heat exchanger operating cost (HXOC) have been investigated. This work also focuses on design optimization with three different factors and three levels for higher heat transfer coefficient (HTC) and minimum pressure drop based on the Taguchi–Grey method. Computational fluid dynamics (CFD) output is used as an input value for statistical analysis. Results revealed that the PTTI in HX successfully achieved overall heat transfer enhancement in the range of 19.2% to 28.5%, but at the cost of pressure penalty of 126% to 163% higher than the plain tube. Critical Reynolds number 7927, above which PTTI in HX is least suitable for heat transfer enhancement as fluid velocity dominates over heat transfer and 1.7–2.5 times higher carbon discharge to the environment and HXOC. Preference sets of geometrical and fluid parameters are obtained using Grey analysis. Based on statistical analysis, in the considered levels, a group of parameters to attain higher HTC and minimum pressure drop are mass flow rate of 0.018 kg/s, a perforated pitch of 20 mm, and a perforated diameter of 4 mm.