Thermal-hydraulic analysis of wetted airside plain fin flat tube heat exchangers and the role of vortex generators

This study addresses the demand for efficient and compact heat exchange solutions in industrial applications. Unlike previous studies that predominantly focused on round tube configurations, this research investigates the impact of vortex generators and geometrical parameters on plain-fin flat-tube designs. Using ANSYS Fluent, the study evaluated the effects of fin geometry, vortex generators, and flow conditions on thermal–hydraulic performance. The key findings revealed that vortex generators enhanced heat transfer by 5–48% by promoting fluid mixing and turbulence but also leading to an increment in friction losses reaching 35–62%, depending upon the number of vortex generators. Condensation rates increased downstream of vortex generators due to enhanced mixing with cooler surfaces. In terms of thermal–hydraulic performance, specific plain-fin configurations outperformed others, offering efficient heat transfer with relatively lower friction losses, even when compactness was considered. Some configurations were recommended for applications where heat exchanger size is less important, but high heat transfer is crucial. Lastly, it was discovered that the effect of vortex generators is more pronounced for lower to intermediate pumping powers per unit area. New empirical correlations were also derived to predict thermal–hydraulic behavior based on geometry and vortex generator placement. A comparison with the literature revealed significantly higher performance as compared to convex/concave vortex generators. Lastly, it was discovered that the effect of vortex generators is more pronounced for lower to intermediate pumping powers per unit area. Empirical correlations for “j” and “f” were correlated with all geometric parameters.