Optimizing thermal performance in tube-in-tube heat exchangers with metal foam inserts: experimental and RSM analysis

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ABSTRACT This study investigates tube-in-tube heat exchanger performance under steady-state conditions, examining co-current and counter-current flows. It explores various configurations, including metal foam enhancements, to optimize heat transfer efficiency and minimize pressure drop. Driven by the potential of metal foam to enhance heat transfer, the study aims to demonstrate significant improvements in thermal performance compared to conventional designs. Experimental methods involve testing four configurations with Nickel foam (10 PPI, 0.90 porosity) inserts, evaluating temperatures and pressure drops across flow rates of 25 to 50 LPH. Hot water at 65°C flows in the annulus, while normal water at 31°C flows in the outer annulus. Results show metal foam’s substantial enhancement in heat transfer, with counter-current metal foam configurations achieving up to 3.71 times greater efficiency than parallel flow setups. Moreover, comprehensive performance evaluation reveals that the counter-flow heat exchanger with metal foam is 2.03 times more efficient than the conventional co-current flow without metal foam. Conclusions highlight metal foam’s effectiveness in improving heat transfer performance and optimizing thermal systems through systematic parameter optimization using response surface methodology.