Performance Analysis and Optimization of Double Pipe Heat Exchanger

Abstract

Double pipe heat exchangers are widely used in industrial applications due to their simple design, ease of maintenance, and reliable thermal performance. This study presents a comprehensive analysis of the thermal and hydraulic performance of a double pipe heat exchanger under varying flow conditions and configurations. Both counterflow and parallel flow arrangements are experimentally investigated using water as the working fluid. Parameters such as the overall heat transfer coefficient, effectiveness, pressure drop, and Nusselt number are analyzed. The experimental results are validated using theoretical calculations and simulation models developed in ANSYS Fluent. Additionally, the effects of flow rate, temperature difference, and pipe material on heat transfer performance are studied. The study also explores potential enhancements such as extended surface areas and turbulence promoters. The findings suggest that counterflow configuration offers higher thermal efficiency, and that optimization of flow rates and pipe materials significantly improves heat exchanger performance. This research contributes to the design and operation of compact and efficient heat exchangers in energy systems, HVAC, and process industries. This study presents the performance analysis and optimization of a double pipe heat exchanger under varying flow conditions. Experimental and simulation-based methods are employed to evaluate heat transfer rates, pressure drop, and overall thermal efficiency. The effects of flow arrangement, Reynolds number, and fluid properties are systematically analyzed. Optimization is carried out by modifying design and operating parameters to maximize heat transfer while minimizing pumping power. The findings provide useful guidelines for efficient thermal system design and industrial applications.

Cite as:

Bharat Y Bhosale. (2025). Bharat Y Bhosale. Recent Trends in Thermodynamics and Thermal Energy System, 1(3), 1–9. 

https://doi.org/10.5281/zenodo.17440469