Energy efficiency enhancement with a chaotic helix exchanger

Optimizing the performance of heat exchangers is essential for achieving energy-efficient and carbon-free industrial processes. In this experimental study, a Chaotic Helix Exchanger (CHE) based on the concept of chaotic advection is proposed. The present work examines the overall performances of the CHE compared to a conventional Helical Heat Exchanger (HHE) of the same exchange surface, for Reynolds numbers ranging from 350 to 8600. The overall energy efficiency of the exchanges is assessed by comparing the thermal enhancement with the pressure drops, using performance criteria, PEC and L f . It is found that CHE boosts heat transfer rates while energy consumption (pressure drop) remains equivalent, resulting in a significant improvement in overall energy efficiency. The PEC values raise up to 7 when comparing CHE with a reference straight tube, and up to 2.5 when comparing with HHE. The performance enhancement increases with the Reynolds number in its lower limit, is optimal in the transitional regime and levels off at a value slightly below the optimal value in the higher limit studied. This implies that CHE has great potential for industrial applications in all flow conditions studied. Optimal enhancement can be achieved when transitional intermediate Reynolds regimes are expected. • Performance of a Chaotic Helix Exchanger is experimentally investigated. • Heat transfer is quantified with temperature differences and Nusselt number. • Friction factor is found equivalent to that of an helical exchanger. • Maximal efficiency enhancement is reported in the transitional regime.