Metal foam is a porous medium with high porosity, convoluted flow pathways, strength-to-weight ratio, and thermal conductivity employed in heat exchanges and other engineering applications because of its properties. Therefore, a novel circular tube filled with aluminum metallic foam is proposed to improve hydraulic thermal performance and reduce pumping power losses and metal foam volume. The current work considers the Brinkman-Forchheimer Extended Darcy model for forced convection flow and the local thermal equilibrium (LTE) model for heat transfer under a constant thermal boundary condition. The governing equations are solved using the finite volume method (FVM). The variable parameters are the pore per inch (PPI) of 10–50, the porosity εrange of 0.79–0.95, and the Reynolds number range of 2500–7000. The results show that the performance index (PI) has its maximum value of 6.8 at 10PPI and ε =0.95 in the heat exchanger; this enhancement at 10PPI is 13% and 34.48% more as compared to the PI value at ε =0.85 and ε =0.79 and at a fixed inner annulus Re of 7000. The average Nusselt number (Nu) increased by 81.63%, 104.3%, and 120% compared to the foamless tube at 10, 20, and 30PPI andε =0.95, respectively, in an intermediate tube. Heat transfer coefficients (HTC) considerably increase compared to foamless tubes nearly 3.2 times, 3.8 times, and 4.2 times at 10, 20, and 30PPI, respectively, at 2500 Re and 144%, 175% and 200% more at 7000 Re. The maximum reduction ratio in normalized friction factor ratio (fP/fNoP) at 10PPI is approximately 50% compared to (fP/fNoP) at 30PPI and 25% at 20PPI; it occurs at 7000 Re. The normalized area goodness factor ratio has the maximum value at 10PPI and ε =0.95, which is 5.8, and for 20 and 30PPI, it is 3.5 and 2.3, respectively. This shows that aluminum metal foam in triple tube heat exchanger's intermediate tube at 10PPI and porosity of 0.95 can be the optimized results for performance enhancement.
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