Numerical study of an exhaust heat recovery system using corrugated tubes and twisted tape inserts

Abstract

Diesel engine generators are the major power source for small communities in cold regions. Diesel generators waste about 1/3 of their fuel energy in the form of heat through exhaust gas. The primary goal of this work is to capture part of the heat from the exhaust and improve the efficiency of the system. A gas to liquid heat transfer performance of a concentric tube heat exchanger with corrugated tubes and twisted tape inserts is investigated by considering its effects on engine performance and economics. This type of heat exchanger is expected to be inexpensive to install and effective in heat transfer, with minimal effect on exhaust emissions of diesel engines. Most previous research has investigated liquid to liquid heat transfer in corrugated tubes at low Reynolds, not gas to liquid heat transfer. The SolidWorks Flow Simulation computer program was used to perform these studies. The program is first validated by comparing simulation results with renowned correlations and field measurements. Simulations are then conducted for a concentric tube heat exchanger with corrugated tubes and twisted tapes of different configurations to determine the optimal design. The maximum enhancement in the rate of heat transfer was found in an annularly corrugated tube heat exchanger with twisted tape inserts. This exchanger transfers about 235.3% and 67.26 % more heat compared to plain tube and annularly corrugated tube heat exchangers without twisted tapes, respectively. Based on optimal results, for a 120 kWe diesel generator, the application of an annularly corrugated tube heat exchanger with twisted tape inserts can save 2,250 gallons of fuel annually (a cost of approximately $11,330) expected payback of initial cost in one month. In addition, saving heating fuel also reduces CO₂ emissions by 23 metric tons per year.