A novel integrated approach to heat transfer enhancement using baffles and inner fins in helical coil heat exchangers

The global rise in energy demand has intensified the need for improved efficiency in thermal systems, particularly in industrial and high-load applications. Heat exchangers play a critical role in energy recovery, and enhancing their performance is essential for maximizing overall system efficiency. This study presents a numerical investigation of a shell-and-helical coil heat exchanger enhanced by the integration of shell-side baffles and tube-side internal fins. A three-dimensional model was developed to simulate turbulent flow and heat transfer across four structural configurations: a conventional design, a baffled configuration, an internally finned tube design, and a combined baffle–finned configuration. The simulation results indicate that the integrated configuration achieves the highest performance improvement, with up to a 33 percent increase in effectiveness compared to the conventional design, reaching a maximum effectiveness of 0.60. The same configuration also demonstrated a peak thermal-hydraulic performance value of approximately 1.60 at low flow rates, reflecting an effective balance between heat transfer enhancement and pressure loss. The numerical model was benchmarked against experimental data with a maximum deviation of about 2 percent, supporting its reliability. The study introduces a novel enhancement strategy that combines two geometric improvements into a single configuration, offering a compact and efficient solution for advanced thermal system applications.