Heat Transfer Enhancement and Flow Resistance Characteristics in a Tube with Alternating Corrugated-Smooth Segments

To mitigate the inherent high flow resistance of conventional corrugated tubes, a novel design with alternating clockwise/counterclockwise corrugated segments separated by smooth sections is proposed. A 3D numerical model was developed to systematically evaluate the thermal-hydraulic performance of the novel tube against smooth and conventional corrugated tubes, with simulations conducted at Reynolds number (Re) = 9952–35,827. Results show both corrugated configurations enhanced heat transfer significantly relative to the smooth tube: the conventional tube had the highest Nusselt number (Nu) (1.76–1.79 times that of the smooth tube), while the novel tube achieved Nu = 1.61–1.65 times that of the smooth tube. Notably, the novel tube reduced flow resistance substantially—at Re = 35,827, its friction factor (f) was only 65.2% of the conventional tube’s. Parametric studies revealed that more corrugated segments improved heat transfer but increased pressure drop: the 72-12 configuration exhibited the best heat transfer, while the 72-2 configuration reduced f by 40.7%. The novel tube showed superior overall performance (Performance Evaluation Criterion (PEC) > 1.24 for all Re), as corrugated segments generated periodic vortices to disrupt the thermal boundary layer, while smooth segments enabled flow redevelopment and pressure recovery. This study provides valuable guidance for designing high-efficiency, low-resistance heat exchange elements.