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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]

AbstractIn this research, a parametric analysis of partially filled high-porosity metallic foams within a double-tube heat exchanger integrated into a solar flat plate collector is conducted. The primary objective is to comprehensively analyze the thermal and fluid flow behavior in this complex system through numerical simulations employing ANSYS Fluent v2021, with water as the working fluid. The study encompasses three distinct metal foam materials—Nickel, Copper, and Aluminum—each investigated across six cases with varying porosities (ranging from 0.80 to 0.90) and pore densities (ranging from 10 to 30). The investigation also explores changes in the internal diameter of the foams adjacent to the conduit wall and the external diameter of the foam within the tube core, resulting in multiple test cases. Rigorous validation of simulation results against experimental data enhances the credibility of the findings. To simulate fluid flow and heat transfer phenomena within the metal foam heat exchanger’s intricate geometry, the research leverages the Reynolds-Averaged Navier-Stokes (RANS) equations coupled with the k-epsilon model, treating the metal foam as a porous medium. The outcomes reveal intriguing insights, such as the close thermal performance match between 10 PPI aluminum foam and the more costly 10 PPI copper foam. The highest performance factor is observed for 30 PPI aluminum foam, highlighting its efficiency. However, the performance factor exhibits variations, with values of 2.03, 3.15, and 3.73 for 100 PPI, 20 PPI, and 30 PPI foams, respectively, and their corresponding porosities of 0.90, 0.85, and 0.80 in case 1, case 2, and case 3, all at a lower Reynolds number of 3,000. This performance factor decreases progressively with increasing fluid flow rates. Additionally, the research evaluates key parameters, including average wall temperature, average Nusselt number, and Colburn j factor, to identify the optimal performance characteristics within the investigated configurations. This study provides valuable insights into the potential for enhancing the efficiency of heat exchangers in solar flat plate collectors through the strategic utilization of high-porosity metallic foams. [ABSTRACT FROM AUTHOR]