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Helical coil tubes are essential in a variety of engineering applications due to their improved heat transfer and compact shape. The current study presents an experimental and numerical investigation of geometrical optimization for helical coil elliptic tubes. Four distinct coil pitch values are examined with a constant perimeter for all geometries and three aspect ratio values (1, 0.75, 0.5) utilizing water as the working fluid across varying the volume flow rates. The helical coil has the same surface area as the tube for each coil. The numerical simulation is conducted using the ANSYS FLUENT CFD software (Version 19.2). The experimental and numerical results indicate that the increase in heat transfer due to an increase in mass flow rate is significantly greater than the improvement gained by changing the aspect ratios. Increasing the volume flow rate to 3 L/min significantly improves the average heat transfer coefficient, with a 66.6 % increase found at a maximum coil pitch of 0.08 m and an aspect ratio of 0.5. Furthermore, a helical coil with an aspect ratio of one (circular cross-section) exhibits the best compromise between pressure drop penalty and heat transfer enhancement, resulting in the greatest hydraulic thermal performance parameter.

NuScale Power has completed a series of full-length helical coil steam generator tests at SIET Laboratories in Piacenza, Italy. The test program included an investigation of the onset and evolution of density wave oscillations (DWOs). This paper describes the mechanisms leading to the onset of DWOs. A semi-empirical DWO stability correlation was developed from first principles using data from tests performed in the full-height (2015) TF-2 counterflow test facility. This research supports the concept that the onset of DWOs is caused by liquid bridging inside the boiling length of the tubes. A DWO onset correlation is obtained by performing a steady-state momentum balance on the liquid slug created by liquid bridging in annular flow. This yields a momentum balance equation in terms of a set of dimensionless superficial velocities, a corresponding dimensionless pressure drop term, and an average void fraction. Envelope theory is then used to obtain a critical void fraction, which is substituted into the dimensionless momentum balance to obtain a DWO onset correlation similar to the Wallis countercurrent flooding correlation. Predictions using the DWO stability correlation have been compared to DWO experiments from the (2022) TF-2, TF-1, and Polimi. The predictions for the onset and termination of DWOs show excellent agreement with the data. [ABSTRACT FROM AUTHOR]

This numerical study examines the thermal-hydraulic performance of helical coil heat exchangers (HCHEs) using twisted tubes versus conventional circular tubes. The effects of Reynolds number (Re = 10,000 to 100,000), pitch length (11, 7.2, 5.5, 3.6 mm), and twisted tube orientation (co-current, counter-current) on heat transfer efficiency and pressure drop were investigated. The results show that higher Reynolds numbers can reduce the Resistance factor by approximately 25 % and improve heat transfer by approximately 35 %. An optimal pitch length of 5.5 mm was found to balance enhanced heat transfer and manageable pumping costs. Twisted tubes demonstrate significant performance advantages at lower Re, with 20–33 % higher Performance Evaluation Criterion (PEC) values compared to circular tubes. However, the benefit diminishes at higher Re, with less than 10 % PEC increase. Implementing counter-current twisted tube configurations leads to approximately 13 % higher Nusselt number and 11 % higher Resistance factor, resulting in a 10 % overall PEC improvement. These findings highlight the superior thermal-hydraulic performance of twisted tubes in HCHE applications, especially at lower Reynolds numbers. Future work could explore different fluids, advanced optimization, energy analysis, cost assessment, and additional geometric parameters to further enhance twisted tube heat exchanger design and performance.

Low-temperature stratification, high-volumetric storage capacity, and less-complicated material processing make phase-changing materials (PCMs) very suitable candidates for solar energy storage applications. However, their poor heat diffusivities and suboptimal containment designs severely limit their decent storage capabilities. In these systems, the arrangement of tubes conveying the heat transport fluid (HTF) plays a crucial role in heat communication between the PCM and HTF during phase transition. This study investigates a helical coil tube-and-shell thermal storage system integrated with a novel central return tube to enhance heat transfer effectiveness. Three-dimensional computational fluid dynamics simulations compare the proposed design against a baseline helical coil system without a return tube under equivalent conditions. Outcomes quantify the return tube's efficacy in augmenting heat transfer uniformity and accelerating phase transition. Adding the return tube markedly boosts heat storage and recovery rates, increasing charging by 88% and discharging by 56% versus the baseline. Moreover, total phase transition time reduces by 48% for melting and 36% for solidification with the return tube. The accelerated charging stems from sustained convective heat transfer inside the return tube even as the molten layer thickens. Meanwhile, enhanced solidification results from ongoing cooling of inner regions. Isotherm analysis visualizes the return tube's efficacy in maintaining thermal uniformity throughout the phase transition process. Overall, the return tube significantly improves PCM thermal response, demonstrating a novel but straightforward approach to address heat transfer limitations in latent thermal storage systems.

Inductive power transfer (IPT) systems often encounter limitations in efficiency and transmission distance due to near-field magnetic coupling characteristics. Increasing the inductance can enhance the transmission distance, but it also raises the system’s Q factor, leading to several issues. This study aimed to optimize the magnetic core design of helical coils to enhance magnetic coupling in IPT systems while minimizing the increase in self-inductance. Through finite element analysis, various core placements were evaluated, leading to a proposed core design process that integrates inner and lower cores at optimal angles. The proposed design was compared with conventional cores, and its performance was validated in an IPT system. The results demonstrate that the proposed core design significantly enhances the coupling coefficient (k) and extends power transmission distance compared with conventional planar and U-shaped core structures without substantially increasing self-inductance (L). This design effectively balances the trade-off between increasing inductance and maintaining system stability, thereby improving transmission efficiency while minimizing frequency instability and voltage stress.

The aim of this study is to utilize waste thermal energy from industries into useful heat for water and air heating. In this paper, the thermal modeling and performance of three fluid heat exchangers (TFHE) have been experimentally investigated. The TFHE considered here is an enhanced version of the double‐pipe heat exchanger. A novel TFHE having fin (1 mm thin copper wire of 10 mm pitch) acts as a roughness element, which is wrapped on the helical coil's outer surface for increasing heat transfer (HT) rate and the turbulence effect for normal water, and this outer surface finned helical coil is inserted between two concentric straight tubes. The innermost tube carries atmospheric air, the finned helical coil tube carries waste hot fluid while normal water flows in the inner annulus of the outermost tube. The coiled‐side Reynolds number is varied in the range of 7000–30,000, while the curvature ratio of 0.1315, pitch‐to‐inside diameter ratio of 2.88 and wire‐to‐tube diameter e/d=0.182 $e/d=0.182$ of the helical tube is kept constant. A counterflow arrangement has been made for experimentation. Nusselt number is calculated using the traditional Wilson plot method that is compared and validated with results available in the literature. The overall HT coefficient is found to increase by increasing the volume flow rate of fluids, while effectiveness decreases or increases depending on residence time and capacity ratio. The percentage increment in the Nusselt number, maximum friction factor, overall HT coefficient between waste hot fluid to normal water, effectiveness is found to be 21.10%–23.88%, 90.91%, 3.40%–29.45%, 3.40%–25.33%, respectively, for the coil side. TFHE is thus proposed for heating water and space simultaneously. [ABSTRACT FROM AUTHOR]

High temperature gas reactors (HTGRs) have broad application prospects in power supply, seawater desalination and hydrogen production. Helical coil steam generators have the advantages of compact structure, high heat transfer efficiency and resistance to expansion thermal stress, which was widely used in energy supply, power engineering, petrochemical and other fields. The steam generator of HTGRs has complex structure and severe operating conditions. It is very important to accurately predict its thermalhydraulic characteristics under normal operation and typical transient conditions for the safety of HTGR. Based on this, a general and accurate heat transfer model was established by using homogeneous flow model, the system thermalhydraulic analysis code for high temperature gas reactor helical coil oncethrough steam generator (STAGS) was developed. Based on THTR300 reactor steam generator, the outlet temperatures of tube and shell side predicted by the system code were compared with the experimental data, and the calculation error of both sides is less than 3 K. It is proved that the system code can effectively predict the thermalhydraulic characteristics of helical coil steam generator in HTGRs under normal operation conditions. Taking high temperature gas cooled pebblebed module (HTRPM) reactor as the research object, the characteristics of the helical coil steam generator under full power condition were analyzed, and the distribution of key thermalhydraulic parameters along the helical tube was obtained. The results show that the thermal resistance of the tube side increases sharply after entering the liquiddeficient area, and the thermal resistance of the shell side is greater than the thermal resistance of the tube side and the tube wall at different positions of the heat exchange tube bundles, which has a major impact on the heat transfer. A study was carried out on the influence of the fluid mass flow at the shell and tube sides on the operating characteristics of HTRPM steam generator. The results show that the maximum value of the heat transfer coefficient at the tube side is greatly affected by the tube side fluid mass flow. Then the response of the key parameters of the steam generator when the thermalhydraulic parameters of two sides inlet was disturbed was studied. The results show that the change of the thermalhydraulic parameters of the shellside helium has a severe impact on the heat transfer power of the steam generator. When the shell side helium mass flow drops by 10% and the inlet temperature increases by 20 K, the heat transfer power of steam generator decreases by 968 kW and increases by 664 kW respectively. This work has reference significance for design and safety analysis of helical coil steam generator in high temperature gas reactors.

To numerically investigate the flow and heat transfer characteristics of a water/Al2O3 nanofluid in a double-pipe helical coil heat exchanger, we simulated a two-phase Eulerian model to predict the heat transfer coefficient, Nusselt number, and pressure drop at various concentrations (i.e., volume fraction) and under diverse flow rates at the steady state. In this simulation, we used the k-epsilon turbulence model with an enhanced wall treatment method. The performance factor of the nanofluid was evaluated by accounting for the heat transfer and pressure drop characteristics. As a result, the heat transfer was enhanced by increasing the nanofluid concentration. The 1.0 vol.% nanofluid (i.e., the highest concentration) showed a heat transfer coefficient 1.43 times greater than water and a Nusselt number of 1.38 times greater than water. The pressure drop of nanofluids was greater than that of water due to the increased density and viscosity induced using nanoparticles. Based on the relationship between the Nusselt number and pressure drop, the 1.0 vol.% nanofluid was calculated to have a performance factor of 1.4 relative to water, indicating that the enhancement rate in heat transfer performance was greater than that in the pressure drop. In conclusion, the Al2O3 nanofluid shows potential as an enhanced working fluid in diverse heat transfer applications.

Inductive power transfer (IPT) systems often encounter limitations in efficiency and transmission distance due to near-field magnetic coupling characteristics. Increasing the inductance can enhance the transmission distance, but it also raises the system's Q factor, leading to several issues. This study aimed to optimize the magnetic core design of helical coils to enhance magnetic coupling in IPT systems while minimizing the increase in self-inductance. Through finite element analysis, various core placements were evaluated, leading to a proposed core design process that integrates inner and lower cores at optimal angles. The proposed design was compared with conventional cores, and its performance was validated in an IPT system. The results demonstrate that the proposed core design significantly enhances the coupling coefficient (k) and extends power transmission distance compared with conventional planar and U-shaped core structures without substantially increasing self-inductance (L). This design effectively balances the trade-off between increasing inductance and maintaining system stability, thereby improving transmission efficiency while minimizing frequency instability and voltage stress. [ABSTRACT FROM AUTHOR]

The helical coil heat exchanger (HCHX) is one of the most popular heat transfer devices in heat pump water heaters. In this study, the Computational Fluid Dynamics (CFD) software, ANSYS FLUENT, was employed to predict the thermohydraulic performance of an HCHX, including the overall heat transfer coefficient and Fanning friction factor. Using different sizes of the HCHX, comparing the CFD results with experimental data or correlations available in the literature revealed that both results on thermohydraulic performance agreed well. The objective of this study was to choose the Taguchi method coupled with grey relational analysis (GRA) to optimize the HCHX design with the improvement of thermohydraulic performance. Among the selected three factors in the optimization process, it was found that the coil pitch and coil diameter were the two most important factors in influencing the thermohydraulic performance of HCHXs, while the outer diameter of the helical tube had little impact. Consequently, the optimal design of the HCHX increased the overall heat transfer coefficient by 131% and decreased the friction fanning factor by 6%, resulting in the increase of heat transfer rate by 47% and the reduction of pumping work by 72%. Moreover, the predicted optimal thermohydraulic performance was verified by the predictive formula of the Taguchi method.