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Thermal Enhancement of Double Pipe Heat Exchanger Using Diamond Shaped Fins Configuration and Geometric Optimization

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Abstract:

Heat exchangers are widely recognized as eco-friendly devices that transfer heat between two or more fluids without mixing. Double Pipe Heat Exchangers (DPHE) are used in many industrial applications such as power generation, chemical processing, HVAC, and renewable energy systems. Traditional DPHEs are simple and reliable, however, they often face limitations in heat transfer. Improving the thermal performance of DPHE can significantly enhance the operational efficiency of thermal energy systems. This study presents a novel fin arrangement to the traditional DPHE using different diamond-shaped fins to improve its thermal performance. The thermal and hydraulic properties of DPHE with different diamond-shaped fin configurations are investigated using CFD analysis. The optimization process is carried out using the Response Surface Method (RSM) for optimal diamond-shaped fin design. The results indicate that novel diamond-shaped fins improve thermal performance, particularly at high mass flow rates. The thermal enhancement factor (TEF), overall heat transfer coefficient, and pressure drop are used to evaluate the thermal performance of DPHE. The diamond-shaped fins exhibit a 55% increase in overall heat transfer coefficient compared to conventional DPHE. The TEF for diamond-shaped fin configurations is higher than 1 with a maximum value of 1.63 for DPHE-HF45 depicting a 63% increase in thermal enhancement. The optimization results show that the optimal fin design achieves a desirability of 81.3%, with a pressure drop of 870.726 Pa and an overall heat transfer coefficient of 2199.85 W/m2K at a mass flow rate of 2.711 lit/min.

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Periodical:

Diffusion Foundations and Materials Applications (Volume 39)

Pages:

129-152

DOI:

https://doi.org/10.4028/p-6O60Sp

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Online since:

January 2026

Authors:

Muhammad Aadil*, Kareem Akhtar, Muhammad Anas Wazir, Zia Ul Haq, Naseer Iqbal, Ghulam Mustafa

Keywords:

CFD Analysis, Double Pipe Heat Exchanger, Heat Transfer, RSM, TEF

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© 2026 Trans Tech Publications Ltd. All Rights Reserved

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* - Corresponding Author

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