5th European Thermal-Sciences Conference, The Netherlands, 2008

PERFORMANCE EVALUATION OF SOLID AND SERRATED

FINNED-TUBE BUNDLES WITH DIFFERENT
FIN GEOMETRIES IN FORCED CONVECTION
R. Hofmann, F. Frasz, K. Ponweiser
Vienna University of Technology, Institute for Thermodynamics and Energy Conversion,
AUSTRIA

Abstract

Experimental investigations have been carried out for heat transfer and pressure drop at turbulent
flow of combustion gases at solid and serrated finned-tube heat exchanger in counter cross-flow to
optimize the heat exchanger. Three different shaped fin geometries were considered, where the
geometrical constants for the fins, i.e. fin height, fin pitch, fin thickness, and fin width were varied.
The solid I-shaped as well as the serrated I- and U-shaped fin tubes are arranged staggered at the
equal transverse and longitudinal pitch. The developed correlations for the Nusselt number and the
pressure drop coefficient were compared with the experimental results and equations from
literature. As an example, the correlation of Escoa (1979) and Weierman (1976) were used.
Additionally, a performance evaluation criterion for single-phase flows, developed by Webb (1994)
was carried out for different fin geometries. The Generalized Lvque-Equation-Analogy, in Martin
and Gnielinski (2000) was used to evaluate the uncertainty of the pressure drop measurement.

Nomenclature (optional)
hf average fin height [m] tq transverse tube pitch [m]
L diagonal pitch [m] Ts average fin temperature [K]
NR number of tubes in the flow-direction [-] xF factor for Lvque-Equation [-]
s average fin thickness [m] r fin efficiency [-]
t fin pitch [m] pressure drop coefficient [-]
tl longitudinal tube pitch [m] j Colburn factor [-]

Indices i inside
0 characteristic length at da I, U shape of finned-tube
1, 2 inlet, outlet m average mean
8R, 1R 8 tube rows, single tube row min minimum net free area in a tube row
a outside r fin
b calculation condition s I serrated tube
c converted sf fin fixed
ch channel tot total
e net free area of a row w water
f fix sol solid
g gas ser serrated
h hydraulic

1 Introduction

Whenever gas/water heat exchangers are used, the heat transfer coefficient at the gas-side of a heat
exchanger is inherently lower than at the water-side. There are many possibilities to improve a low
 5th European Thermal-Sciences Conference, The Netherlands, 2008

heat transfer coefficient, e.g. by increasing the total surface or turbulences. Therefore, elements like
fins, pins or needles can be used. This increase of the total outside tube surface allows transferring
more heat from hot gas, but the demand on smaller installation sizes and lower costs requires
smaller fin pitch with larger fin height and segmented fins. Finned-tubes with segmented fins show
a somewhat higher turbulence than those with smooth fins, because the boundary layer has to be
built up anew at each segment, Frasz (2005). Experimental investigations of solid and serrated
finned-tubes have been analyzed extensively by Weierman (1976), Weierman and Taborek (1978),
Nir (1991), Frasz (1994), Kawaguchi (2005), Nss (2005), and Genic (2006). Reid and Taborek
(1994) compared the different influences of solid and segmented fins. The staggered arrangement of
tubes in the flow-channel can cause a higher pressure drop. Weierman and Taborek (1978)
investigated the performance of in-line and staggered tube arrangement of segmented fin-tubes.
They found that in-line arrangement should only be used for special cases, because of the
disadvantage of any bypass flow between the tube bundles. Numerous heat transfer and pressure
drop correlations of serrated/solid fin tubes have been developed by Nir (1991), Kawaguchi (2005),
Weierman (1976) and Escoa (1979). Genic (2006) investigated experimentally the pressure drop of
in-line and staggered arrangements and compared these correlations with literature. To optimize a
finned-tube heat exchanger means to maximize the heat transfer rate with the simultaneous
minimization of the pumping power. Webb (1994) as well as Stephan and Mitrovi (1984)
developed criterions to evaluate the performance of heat exchangers. In the actual study, an
experimental investigation of solid and serrated finned-tubes is presented. Especially the influence
of the fin height on the heat transfer and pressure drop was analyzed.

2 Experimental Setup and Measurement Procedure

A test rig for heat transfer and pressure drop measurements at finned tube bundles in cross-flow is
in operation at the laboratory of the Institute for Thermodynamics and Energy Conversion, at the
Vienna University of Technology. This test facility allows measuring at Reynolds numbers in the
range between 4500 and 35000 with a flue gas mass-flow from 0.6 to 4.5 kg/s; the layout is shown
in figure 1. The finned-tube bundle is admitted with hot gas up to 400 C, which is generated by
combustion of natural gas. For air intake either a Venturi nozzle or a smaller ISA 1932 inlet nozzle
for low Re-numbers is implemented. Those are used for mass flow measurement of combustion air.
Following a connecting piece with a bend, a variable incidence entry vane is mounted in front of the
radial fan for mass flow regulation of the air. The radial fan can produce a maximum pressure
height of 5000 Pa and generates 45000 Nm/h at 3500 Pa. The burner is designed as a duct burner,
with a maximum burner power of 1 MW.

Figure 1: Layout of the test facility.

Behind the burner and after two 90 bends static mixers are installed. After a transition piece to a
rectangular cross-section, a flow rectifier consisting of three fine wire meshes in close arrangement
is installed. After the flow rectifier, which rectifies the vortices; caused by mixers and redirecting
 5th European Thermal-Sciences Conference, The Netherlands, 2008

pipes, a 2000 mm long inlet channel follows, to calm the fully developed turbulent flow. The finned
tube heat exchanger with a tube length of approx. 500 mm is built into a 1500 mm channel piece.
The heat exchanger consists of a rectangular sheet steel channel in which the finned tubes are
arranged horizontally with a given transverse and longitudinal pitch. All connecting pipes are
arranged outside of the channel. This is the only arrangement allowing exact measurements of heat
transfer at the small test section width of the tube banks. With this arrangement any bypass flow
between the tube bundle and the wall can be avoided. The tube bundle consists of 88 tubes, which
are arranged in 8 consecutive columns, consisting of 11 horizontal tubes. An even cooling water
flow distribution in the tubes is achieved using orifices after the inlet collector. For more details see
Frasz (2005). Three different finned tube geometries have been investigated. The geometrical
constants of the solid finned tubes with I-shape as well as serrated I- and U-shaped fin tubes are
specified in table 1. For all tubes, the transverse and the longitudinal pitch are equal. As seen in
table 1, the fin height varies most.
Table 1: Specifications of the investigated finned-tubes.
Fin Geometry I-solid I-serrated U-serrated
Bare tube diameter da 38.0 mm 38.0 mm 38.0 mm
Tube thickness st 2.6 mm 4 mm 3.2 mm
Number of fins per m nr 276 276 295
Average fin height hf 15 mm 15.5 mm 20.0 mm
Average fin thickness s 1.0 mm 1.0 mm 0.8 mm
Average tube length l 500 mm 500 mm 495 mm
Average segment width hs - 4.5 mm 4.3 mm
Reduced fin height hred 18.6569 mm 16.7685 mm 21.5 mm
Number of tubes in the direction of the flow NR 8 8 8
Number of tubes per row NT 11 11 11
Longitudinal tube pitch tl 79 mm 79 mm 79 mm
Transverse tube pitch tq 85 mm 85 mm 85 mm
Total outside surface area of the bundle Atot 67.0582 m 64.047 m 84.4815 m
Fin material - St 4 St 37.2 DC01
Tube material - St 35.8 St 35.8 St 35.8
Net free area in a tube row Amin 0.23421 m 0.23269 m 0.2292 m

The main advantages of the U-fin geometry are a higher contact area between fin and tube for a
better heat conduction and, as a result of the U-shape, smaller fin spacing possibilities, see figure 2.
This allows a higher total outside surface area of the bundle at equal or smaller installation size of
the overall heat exchanger. The volume-flow of water is constant with VW=14.1 m/h at pW=2.7 bar
for all measurements.

Figure 2: Comparison of finned-tubes with I- and U-fins.

4 Data Reduction Methods for Heat Transfer and Pressure Drop

To calculate the heat transfer of a finned tube, the convection and the conduction has to be
considered. Therefore, the fin efficiency is introduced, by which the actual heat transfer coefficient
is multiplied in order to get the apparent heat transfer coefficient. This is calculated, according to
 5th European Thermal-Sciences Conference, The Netherlands, 2008

the laws of heat conduction, under the assumption, that the actual heat transfer coefficient is
uniformly distributed across the fin surface, Frasz (2005). With the help of the fin efficiency the
actual (external) heat transfer coefficient at the surface is
hA tot
h0 = . (1)
A tube + r A fin
The dimensionless number Nu0 with a characteristic dimension l = d a at the medium gas
temperature is calculated with
h 0d a
Nu 0 = . (2)
k gm
For all finned tubes the Nusselt number was calculated at an average mean boundary-layer
temperature. The total pressure drop of the channel with inserts (tube bundle) is calculated with
2
M& 1
p = N R
g
A min 2gm
, (3)

where gm is the arithmetic mean density in the net free area of a row. The pressure drop
coefficients of the channel ch were correlated with the Konakov (1954) equation. The properties for
the physical quantities are based on the arithmetic mean temperature of hot gas between inlet and
outlet. By considering the pressure variation as a result of the temperature change over the bundle,
the pressure drop coefficient for the finned-tube bundle is calculated by
2
1
M&
1 2 L
= p . (4)
g
8 R 2 ch
A ch g g w 2
DH
1 2
gm E

5 Comparison with the Literature

5.1 Equations for the Heat Transfer

For the determination of the external heat transfer, some correlations in the literature exist for solid
or serrated finned tubes. Only some equations for finned tubes with serrated and solid fins were
developed by e.g. Escoa (Extended Surface Corporation of America) as well as by Nir (1991). The
correlation of Escoa (1979) for serrated and solid fins in staggered tube arrangement is defined by
1/ 4 1/ 2
1 Tgm d a + 2h f
Nu = Re 0.65 Pr 1/ 3 C3 C5 (5)
4 Ts da
For the definition of C3, C3sol, and C5 see Escoa (1979) and Weierman (1976). Therein C3sol instead
of C3 is applied for the calculation of solid finned-tubes. Since
Nu = f (Re, Pr, Tgm , Ts , d a , h f , t , s, t q , t l ) (7)
and the heat conduction through the tube and the fin is different for the investigated geometries, the
formula for the Nusselt number has to be converted for the same conditions. Each point of the
diagram is obtained at different temperatures. For further calculations a new average reference
temperature for gas and fin has to be set. The Nusselt number changes then to
1/ 4
Tgf

T
sf I d a + 2h fI C 3I . (8)
Nu c = Nu U
Tgm
1/ 4
d a + 2h fU C 3U

T
s U
As the comparison of the solid and serrated fin tubes in figure 3 shows, the dimensionless heat
transfer coefficient for eight serrated fin tube rows in staggered arrangement is higher than that for
the solid tube bundle. The fin segmentation increases turbulence, whereby the gas penetration to the
fin root area is improved, Reid and Taborek (1994). The heat transfer coefficient of the serrated I-
 5th European Thermal-Sciences Conference, The Netherlands, 2008

fin tube is somewhat higher than that of the U-fin tube. All fin-characteristics show approximately
same gradients. The Nu-exponents vary from 0.59 to 0.65. The Nu-correlations in figure 3 are
calculated at constant Pr-numbers. The variation of Pr at test conditions is small and can therefore
be neglected for further calculation. The uncertainty of the pressure difference measuring at low Re-
numbers is in the range of about 15 %. The different exponents in the Nu-correlation could be
caused by this uncertainty. All measured values show good congruence with the equations of Escoa.
C3 directly influences the heat transfer. C3 and C3sol are functions with the negative factor hf/(t-s) in
the exponent. Using this exponent hf/(t-s), a comparison of serrated and solid I-fin show an increase
of C3; and the overall heat transfer rises up about 22 %. Figure 4 shows this comparison of Nu at
serrated and solid I-fin, using the correlation of Escoa, for 13 validated measurement points.

200 Nu I_ser/Nu I_sol ESCOA

NuEscoa_I_ser=0.187 * Re0.6479 Mean Nu I_ser/Nu I_sol measurement
NuEscoa_U_ser=0.1844 * Re0.6492 Nu I_ser/Nu I_sol measurement
NuEscoa_I_sol=0.1479 * Re0.6512 1.3
NuU_ser=0.3516 * Re0.5883

Nu_ser/Nu_sol
102 NuI_ser=0.3522 * Re0.5961
log(Nu)

90 NuI_sol=0.195 * Re0.63
80 1.2
70

60
U_ser_fin
50 I_ser_fin 1.1
I_sol_fin
40 ESCOA U_ser_fin comp
ESCOA I_ser_fin comp
ESCOA I_sol_fin comp
30 1.0
3000 4000 5000 6000 8000 20000 30000 40000
104 0 2 4 6 8
log(Re) h/(t-s)

Figure 3: Heat transfer for 8 tube rows, Pr=0.71. Figure 4: Comp. of serrated and solid I- fins.

For a given fin height at hf/(t-s) = 5.718 a scatter plot, marked with , is shown. This variation
occurs due to a measurement uncertainty when calculating the heat transfer rate. The calculated
mean value for a comparison of the two different fin types show good prediction for rising the
heat transfer rate, according to Escoa. The heat transfer coefficient declines with increasing fin
height and fin pitch. For an optimal fin height, the pressure drop has to be minimized. The pressure
drop coefficient rises even more for small hf/(t-s), Frasz (1994). Yet with an increasing fin height,
the total outside heating surface increases. There could be a gain from the heating surface, by
increasing hf. Especially the Nu-numbers of the U or I serrated fin tubes are almost the same. After
analyzing the effect of the pressure drop variation, using the performance evaluation criterion by
Webb (1994), an optimum caused by the total outside heating surface for the U fin type has been
detected. The effect on heat transfer for a variation of the fin height, fin pitch, fin thickness, gas
velocity, transverse and longitudinal pitch is shown in Frasz (2005). The low effect of varying the
fin height, using the formula of Escoa shows similar characteristics as in Frasz (2005). During
manufacturing, the solid fin is stretched on the outside and compressed or shaped in a wave-like
manner on the inside. Therefore, the choice of the strip steel for the fins is restricted to very ductile
materials. Serrated fin tubes are easier to manufacture by the high-frequency resistance welding
technique. Between pressure drop and heat transfer a correlation for tube bundles exist. If the
pressure drop is known, the heat transfer could be calculated using the Generalized Lvque-
Equation, in Martin and Gnielinski (2000)
1/ 3
Nu 2 d
1/ 3
= 0.404 x f 1R Re h h , (9)
Pr L
where, xf = 0.46 is a factor, 1R is the pressure drop coefficient for a single tube row, dh the
hydraulic diameter, and L is a characteristic length for staggered arrangement. For more details see
Martin and Gnielinski (2000). In figure 5 the characteristics for all investigated finned-tube bundles,
based on 1 and 2, are presented. The exponents of the Nu correlations for the U-finned tubes are
 5th European Thermal-Sciences Conference, The Netherlands, 2008

well predicted. The differences between the exponents of the calculated heat transfer correlations
and the Lvque-equations of serrated I-finned tubes can be identified in the uncertainty of the
pressure difference measurement for Re<10000. This underestimates the heat transfer for
Re<10000. For the solid finned tubes, heat transfer is overestimated for Re<20000. By taking into
account the high measurement uncertainty for low Re-numbers, a comparison of figures 3 and 5
shows an agreement with the prediction of heat transfer correlations, according to the Lvque-
equation.

20.0 U fin_ser_(zeta 1) I fin_ser_(zeta2)

300
NuUzeta1=0.3274 * Reh0.6026 U fin_ser_(zeta 2) ESCOA I fin_ser
ESCOA U fin_ser I fin_sol_(zeta1)
NuUzeta2=0.2919 * Reh0.6061
ESCOA I fin_ser_comp I fin_sol_(zeta2)
NuI_ser_zeta1=0.1244 *Reh0.6958 I fin_ser_(zeta1) ESCOA I fin_sol
200
NuI_ser_zeta2=0.1155 *Reh0.6944
NuI_sol_zeta1=0.2962 * Reh0.6043

log(NR=8)
NuI_sol_zeta2=0.2791 * Reh0.6036
log(Nu)

10.0
9.0
8.0
102
U fin Leveque equ.(zeta1) 7.0
90
80
U fin Leveque equ.(zeta2)
6.0
I serrated fin Leveque equ.(zeta1)
70
I serrated fin Leveque equ.(zeta2)
5.0
60 I solid fin Leveque equ.(zeta1)
I solid fin Leveque equ.(zeta2)
50 4.0
6000 8000 20000 30000 40000 50000 4000 5000 6000 8000 20000 30000 40000
104 104
log(Reh) log(Re)

Figure 5: Nu according to Lvque-equations. Figure 6: Pressure drop for 8 tube rows.

5.2 Equations for the Pressure Drop

The pressure drop coefficient correlation of Escoa for serrated and solid fins is defined by
1/ 2
d + 2h f
= 4 a C2 C4 C6 (10)
da
For the definition of C2, C4, and C6 see Escoa (1979) and Weierman (1976). A comparison of the
serrated U and I geometries of the heat exchanger is only possible at same conditions. The objective
function of pressure drop is
= f (Re, N R , d a , h, t , s, t l , t q ) . (11)
Therein dimensionless groups, tube row number, and geometry are considered. For c, the equation
1/ 2
d + 2h fI C4I
c = U a (12)
d a + 2h fU C4U
is obtained. Figure 6 represents the pressure drop coefficient for eight tube rows in staggered
arrangement. 1 (zeta1) is calculated from the static pressure differences and 2 (zeta2) is calculated
from total pressure differences in the center of the channel. Any flow separation and bypass flow
have not been detected. The investigations were made under hot conditions, so that the effect of the
pressure recovery through the tube bundle had to be considered. The pressure drop coefficients of
all fin tubes have similar characteristics at Re>10000. A high uncertainty in pressure drop
measurement can be observed for Re<10000 for solid/serrated I-fin tubes. The measured results of
the serrated U- and solid I-fin tubes have the same gradients as the correlations of Escoa. After a
transformation, no considerable difference between the serrated U- and I fin tube can be observed.
This is due to the almost same net free area in a single tube row (= 0.65 % difference). All
investigated fin tubes show a small increase for Re15000, then, at 25000<Re<35000, the pressure
drop coefficient tends to show a constant value. According to the correlations of Escoa, the fin
height indicates an increase of the pressure drop coefficient at the same installation size. The
pressure drop changes, according to equation (4), because wE is influenced by a smaller net free
area in a single tube row.
 5th European Thermal-Sciences Conference, The Netherlands, 2008

6 Performance Evaluation of Investigated Finned-Tubes

For the evaluation of the performance of the investigated finned-tubes the criterion for single phase
flow, developed by Webb (1994) was used.
h A hA
=
j j
=
(St
Pr )
2/3
(St Pr )2 / 3 (13)
(P P ) (A A )
1/ 3 2/3
( )
1/ 3
( )
1/ 3

The terms on the left side of this equation are part of the Colburn-factor ratio for heat transfer and
the pressure drop ratio. There are three different possibilities which are quantified with this
criterion: (I) (h*A*)/(hA)maximizing the heat transfer rate for equal P*/P and A*/A; (II)
P*/Pminimizing the pumping power for equal (h*A*)/(hA) and A*/A; (III) A*/A minimizing the
overall heat exchanger size for equal P*/P and (h*A*)/(hA). To optimize the heat exchanger with the
help of the performance criterion means to maximize the heat transfer rate with the simultaneous
minimization of the pressure drop and the heat exchanger size. As presented in figure 7, the heat
transfer rate for serrated I-shaped fins tends to increase for Re<10000 and Re>20000. This effect is
higher for low Re-numbers. Between 10000<Re<20000, no significant difference between serrated
U- and I-fin tubes can be identified. A comparison of serrated and solid I fin tubes shows higher
enhancement for low Re-numbers. The pumping power (figure 8) for the serrated I-finned tubes is
smaller for Re<10000 and Re>20000. In the range of 10000<Re<20000, the pumping power has the
same characteristic between serrated U- and I-fin tubes. The solid finned tubes show higher P. This
tube has a relatively low h and almost equal Asol compared to Aser. To satisfy condition (II) for
equal (h*A*)/(hA) and A*/A, the pumping power will rise. This effect could be intensified by the
high measurement uncertainty at low Re-numbers, as mentioned above. The small difference
between the modification of the net-free area in a tube row for these tube geometries was neglected.

2.0 h*Atot(zeta1)I_ser/h*Atot(zeta1)U_ser 2.0

h*Atot(zeta2)I_ser/h*Atot(zeta2)U_ser
h*Atot(zeta1)I_ser/h*Atot(zeta1)I_sol
h*Atot(zeta2)I_ser/h*Atot(zeta2)I_sol
log(hAtot()*/hAtot())

1.0
log((P())*/(P()))

0.8
0.7
0.6
0.5
0.4

0.3

1.0 (P(zeta1))I_ser/(P(zeta1))U_ser
0.2
(P(zeta2))I_ser/(P(zeta2))U_ser
0.9 (P(zeta1))I_ser/(P(zeta1))I_sol
(P(zeta2))I_ser/(P(zeta2))I_sol
4000 5000 6000 70008000 20000 30000
104 4000 5000 6000 70008000
104 20000 30000
log(Re) log(Re)

Figure 7: (h*A*)/(hA) for equal P*/P and A*/A. Figure 8: P*/P for equal (h*A*)/(hA) and A*/A
2.0 2.0
Atot(zeta1)I_ser/Atot(zeta1)U_ser NuI_ser/NuU_ser
Atot(zeta2)I_ser/Atot(zeta2)U_ser NuI_ser/NuI_sol
Atot(zeta1)I_ser/Atot(zeta1)I_sol
Atot(zeta2)I_ser/Atot(zeta2)I_sol
log(Atot()*/Atot())

log(Nu*/Nu)

1.0
0.9
0.8

0.7

0.6 1.0
0.5 0.9

4000 5000 6000 70008000 20000 30000 4000 5000 6000 70008000 20000 30000
104 104
log(Re) log(Re)

Figure 9: A*/A for equal P*/P and (h*A*)/(hA). Figure 10: Nu-ratio of test tubes.
 5th European Thermal-Sciences Conference, The Netherlands, 2008

In figure 9 the ratio of the total outside surface area of the bundles is presented. The h values for the
two serrated heat exchangers have only a small variation. For an enhancement of heat transfer it is
necessary to enlarge the tube surface area and/or improve heat conduction. At serrated fin tubes in
the range Re<10000 and Re>20000 the installation size of the heat exchanger with U-fins is
improved. In the range of 10000<Re<20000 no improvement of the heat exchanger size is possible.
In figure 10 the ratio of Nu-numbers for the test tubes is shown. I-serrated finned tubes tend to
improve heat transfer for Re<10000 and Re>20000. In the range between 10000<Re<20000 the
heat exchangers are almost similar, this is the field where no advantage of the pumping power and
the heat exchanger surface area can be observed. A comparison between the solid and serrated I-fins
shows an enhancement by using fins with segmentation. As an optimal range 15000<Re<25000 can
be identified, because of a relatively high heat transfer at relatively low pressure drop.

7 Conclusion
Experimental studies have been performed to compare heat transfer and pressure drop correlations
for serrated and solid finned-tubes. A comparison with some correlations from the literature shows
good agreement with small uncertainty. Exemplary the geometry parameter fin height was chosen
to analyze the influence on the performance. A performance criterion was applied to characterize
the efficiency of the different finned-tube bundles. Three areas, Re<10000, 10000<Re<20000, and
Re>20000, as result of the comparison between serrated U- and I-fin were identified. The
performance evaluation between serrated and solid I-fin shows an optimal range of
15000<Re<25000. Despite the varying fin height and fin pitch of the two different serrated
geometries, no substantial difference tendencies have been observed by use of these equations.

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