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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. [ABSTRACT FROM AUTHOR]

This research investigates the use of metal foam inserts to enhance the thermal-hydraulic performance of double-tube heat exchangers, relevant for energy-efficient systems such as solar flat plate collectors. Motivated by the need for improved heat transfer efficiency, this study hypothesizes that metal foam integration can significantly boost performance. Through systematic experimental study, the impact of metal foam inserts on heat transfer and pressure drop characteristics is comprehensively evaluated across various configurations, spanning horizontal and vertical orientations. Experimental evaluations were conducted on four configurations, including both conventional and metal foam-integrated heat exchangers in horizontal and vertical orientations, using water as the working fluid and Nickel metal foam with 0.9 porosity and 10 PPI in the annular space. The findings highlight significant enhancements in heat transfer performance with metal foam integration across both horizontal and vertical heat exchanger configurations compared to conventional counterparts, particularly showcasing superior effectiveness and efficiency in the horizontal configuration. Results show that metal foam integration substantially enhances heat transfer, with horizontal configurations exhibiting a 14.56% higher heat transfer coefficient than vertical ones. Additionally, the comprehensive performance index improved by 1.17 times, indicating a better balance between heat transfer enhancement and pressure loss. These findings were validated against established correlations from the literature, confirming the superior effectiveness of horizontal metal foam heat exchangers. [ABSTRACT FROM AUTHOR]