Numerical analysis of flow resistance and heat transfer in the transitional regime of pipe flow with twisted-tape turbulators

In this paper, we present the numerical analysis of the fully developed ow and heat transfer in pipes equipped with twisted-tape inserts in the laminar to transitional flow regime. The flow Reynolds number ranges from 210 to 3100 based on the pipe diameter, whereas the Prandtl number of the working fluid, a 40% mixture of water and ethylene glycol, is about 45 at the average film temperature. The numerical study is carried out via Scale Adaptive Simulations (SAS) where the k-ω SST model is employed for turbulence modeling. Using SAS and low-dissipation discretization schemes, the present study shows that it is possible to capture the transition from the laminar regime to the pulsating or pseudo-laminar flow regime induced by the twisted-tape at low Reynolds numbers, as well as the transition to moderate turbulent regime at the higher, yet non-turbulent for smooth pipes, range of Reynolds numbers. Numerical results, validated against experiments performed in a dedicated test rig, show very good agreement with measured data and an increase of the friction factor and Nusselt number in the range of 4 to 7 times and 6 to 15 times, respectively, of the values for an empty pipe.