Influence of Epoxy-Based Thermally Conductive Polymer Composites on the Thermo-Hydraulic Performance of Finned Helical Coil Heat Exchangers Across Flow Regimes

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Year : 2026 | Volume : 14 | 02 | Page :
    By

    Ayush Patel,

  • Sairaj Gujar,

  • Yogesh Bhalerao,

  • Pramod P. Kothmire,

  1. UG Scholar, Department of Mechanical Engineering, MIT Academy of Engineering, Pune, Maharashtra, India
  2. UG Scholar, Department of Mechanical Engineering, MIT Academy of Engineering, Pune, Maharashtra, India
  3. Associate Professor, School of Engineering, Mathematics and Physics, University of East Anglia, Norwich Research Park, Norwich, , United Kingdom
  4. Associate Professor, Department of Mechanical Engineering, MIT Academy of Engineering, Pune, Maharashtra, India

Abstract

The use of polymer composites in heat exchanger applications has gained increasing attention due to their advantages in weight reduction, corrosion resistance, and design flexibility. However, their relatively low thermal conductivity compared to conventional metallic materials remains a key limitation for efficient heat transfer. In this study, the thermo-hydraulic performance of a finned helical coil heat exchanger is investigated with particular focus on epoxy-based polymer composites reinforced with thermally conductive fillers such as graphite nano platelets and boron nitride. A three-dimensional computational model of the heat exchanger is developed and analyzed using computational fluid dynamics under steady-state conditions. The material domain is extended beyond conventional metallic configurations by incorporating polymer composite properties with varying effective thermal conductivity in the range of 0.2–20 W/m·K, representing different filler loading conditions. A parametric study is conducted by varying the hot fluid mass flow rate, enabling evaluation across laminar, transitional, and turbulent flow regimes. The results show that thermal performance is strongly influenced by the interaction between material conductivity and flow-induced convection. While low-conductivity polymer matrices introduce additional thermal resistance, the combined effect of finned surfaces and curvature-induced secondary flows significantly enhances convective heat transfer. An improvement of approximately 20–35% in Nusselt number is observed for the finned helical configuration compared to the plain tube. This enhancement is accompanied by an increase in pressure drop; however, the thermo-hydraulic performance factor remains greater than unity for most operating conditions. Furthermore, a distinct flow-regime-dependent behavior is observed, with optimal performance occurring at intermediate mass flow rates where a balance between residence time, convective enhancement, and hydraulic losses is achieved. The study demonstrates that epoxy-based thermally enhanced polymer composites, when integrated with appropriate geometric design, can serve as viable alternatives to conventional metallic materials in compact heat exchanger applications.

Keywords: Epoxy based Composite, Helical coil heat exchanger, CFD, finned tube, heat transfer, pressure drop.

How to cite this article:
Ayush Patel, Sairaj Gujar, Yogesh Bhalerao, Pramod P. Kothmire. Influence of Epoxy-Based Thermally Conductive Polymer Composites on the Thermo-Hydraulic Performance of Finned Helical Coil Heat Exchangers Across Flow Regimes. Journal of Polymer & Composites. 2026; 14(02):-.
How to cite this URL:
Ayush Patel, Sairaj Gujar, Yogesh Bhalerao, Pramod P. Kothmire. Influence of Epoxy-Based Thermally Conductive Polymer Composites on the Thermo-Hydraulic Performance of Finned Helical Coil Heat Exchangers Across Flow Regimes. Journal of Polymer & Composites. 2026; 14(02):-. Available from: https://journals.stmjournals.com/jopc/article=2026/view=241288


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Ahead of Print Subscription Original Research
Volume 14
02
Received 06/04/2026
Accepted 25/04/2026
Published 29/04/2026
Publication Time 23 Days
26

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