Heat transfer augmentation procedures, such as Heat Transfer Enhancement and Intensification, are commonly used in heat exchanger systems to enhance thermal performance by decreasing thermal resistance and increasing convective heat transfer rates. Swirl-flow devices, such as coiled tubes, twisted-tape inserts, and other geometric alterations, are commonly used to create secondary flow and improve the efficiency of heat transfer. This study aimed to explore the performance of a heat exchanger by comparing its performance with and without the use of twisted-tape inserts. The setup consisted of a copper inner tube measuring 13 mm in inner diameter and 15 mm in outer diameter, together with an outer pipe measuring 23 mm in inner diameter and 25 mm in outer diameter. Mild steel twisted tapes with dimensions of 2 mm thickness, 1.2 cm width, and twist ratios of 4.3 and 7.2 were utilised. The findings indicated that the heat transfer coefficient was 192.99 W/m² °C when twisted-tape inserts were used, while it was 276.40 W/m² °C without any inserts. The experimental results closely aligned with the theoretical assumptions, demonstrating a substantial enhancement in heat transfer performance by the utilisation of twisted-tape inserts. The study provides evidence that the utilisation of twisted-tape inserts resulted in a nearly two times increase in the heat transfer coefficient, hence demonstrating their efficacy in augmenting heat transfer.

Global energy agencies and commissions report a sharp increase in energy demand based on commercial, industrial, and residential activities. At this point, we need energy-efficient and high-performance systems to maintain a sustainable environment. More than 30% of the generated electricity has been consumed by HVAC-R units, and heat exchangers are the main components affecting the overall performance. This study combines experimental measurements, numerical investigations, and ANN-aided optimization studies to determine the optimal operating conditions of an industrial shell and tube heat exchanger system. The cold/hot stream temperature level is varied between 10 ℃ and 50 ℃ during the experiments and numerical investigations. Furthermore, the flow rates are altered in a range of 50–500 L/h to investigate the thermal and hydraulic performance under laminar and turbulent regime conditions. The experimental and numerical results indicate that U-tube bundles dominantly affect the total pumping power; therefore, the energy consumption experienced at the cold side is about ten times greater the one at the hot side. Once the required data sets are gathered via the experiments and numerical investigations, ANN-aided stochastic optimization algorithms detected the C10H50 scenario as the optimal operating case when the cold and hot stream flow rates are at 100 L/h and 500 L/h, respectively.