Abstract A 3D numerical analysis of the flow and mass transfer in helical pipes is presented. The interpretation of the flow patterns and their impact on mass transfer is shown to require a non-orthogonal pseudo-stream function based visualization. The strong coupling between torsion and curvature effects, and the resulting secondary flow regimes are well characterized by a parameter combining both the Dean (Dn) and Germano numbers (Gn). For membrane separation applications, helical modules combining high curvature with low torsion would alleviate concentration polarization and yield appreciable flux improvement.