The combined effects of wall longitudinal heat conduction and inlet fluid flow maldistribution in crossflow plate-fin heat exchangers

An analysis of a crossflow plate-fin compact heat exchanger, accounting for the combined effect of two-dimensional longitudinal heat conduction through the exchanger wall and nonuniform inlet fluid flow distribution on both hot and cold fluid sides is carried out using a finite element method. Using the fluid flow maldistribution models, the exchanger effectiveness and its deterioration due to the combined effects of longitudinal heat conduction and flow nonuniformity are calculated for various design and operating conditions of the exchanger. It was found that the performance deteriorations are quite significant in some typical applications due to the combined effects of wall longitudinal heat conduction and inlet fluid flow nonuniformity on crossflow plate-fin heat exchanger. Received on 20 May 1999     

Experimental investigation of the flow pattern,pressure drop and void fraction of two-phase flow in the corrugated gap of a plate heat exchanger

The two-phase flow in the corrugated gap created by two adjacent plates of a plate heat exchanger was investigated experimentally. One setup consisting of a transparent corrugated gap was used to visualize the two-phase flow pattern and study the local phenomena of phase distribution, pressure drop and void fraction. Saturated two-phase R365mfc and an air-water mixture were used as working fluids.In a second experimental setup, the heat transfer coefficients and the pressure drop inside an industrial plate heat exchanger during the condensation process of R134a are determined. Both experimental setups use the same type of plates, so the experimental results can be connected and a flow pattern model for the condensation in plate heat exchangers can be derived. In this work the results of the flow pattern visualization, the two-phase pressure drop in the corrugated gap and the void fraction analysis by measurement of the electrical capacity are presented. A new pressure drop correlation is derived, which takes into account different flow patterns, that appear during condensation. The mean deviation of the presented pressure drop model compared to the experimental data and data from other experimental works is 18.9%. 81.7% of the calculated pressure drop lies within ±30% compared to the experimental data.     

The combined effects of inlet fluid flow and temperature nonuniformity in cross flow plate-fin compact heat exchanger using finite element method

An analysis of a crossflow plate-fin heat exchanger accouning for the combined effects of inlet fluid flow nonuniformity and temperature nonuniformity on both hot and cold fluid sides is carried out using a Finite Element Model. A mathematical equation is developed to generate different types of fluid flow/temperature maldistribution models considering the possible deviations in inlet fluid flow. Using these fluid flow maldistribution models, the exchanger effectiveness and its deteriorations due to flow/temperature nonuniformity are calculated for entire range of design and operating conditions. It was found that the performance deteriorations are quite significant in some typical applications due to inlet fluid flow/temperature nonuniformity.     

Two-phase flow distributors for fuel cell flow channels

All existing proton exchange membrane （PEM） fuel cell gas flow fields have been designed on the basis of single-phase gas flow distribution. The presence of liquid water in the flow causes non-uniform gas distribution, leading to poor cell performance. This paper demonstrates that a gas flow restrictor/distributor, as is commonly used in two-phase flow to stabilize multiphase transport lines and multiphase reactors, can improve the gas flow distribution by significantly reducing gas real-distribution caused by either non-uniform water formation in parallel flow channels or flow instability associated with negative-slope pressure drop characteristic of two-phase horizontal flow systems.     

Distribution of air–water mixtures in parallel vertical channels as an effect of the header geometry

Uneven phase distribution in heat exchangers is a cause of severe reductions in thermal performances of refrigeration equipment. To date, no general design rules are available to avoid phase separation in manifolds with several outlet channels, and even predicting the phase and mass distribution in parallel channels is a demanding task. In the present paper, measurements of two-phase air–water distributions are reported with reference to a horizontal header supplying 16 vertical upward channels. The effects of the operating conditions, the header geometry and the inlet port nozzle were investigated in the ranges of liquid and gas superficial velocities of 0.2–1.2 and 1.5–16.5 m/s, respectively. Among the fitting devices used, the insertion of a co-axial, multi-hole distributor inside the header confirmed the possibility of greatly improving the liquid and gas flow distribution by the proper selection of position, diameter and number of the flow openings between the supplying distributor and the system of parallel channels connected to the header.     

Heat transfer and pressure loss of a very shallow fluidized-bed heat exchanger Part 2. Experiment with multirow tube banks

Experiments were carried out on heat transfer and pressure-loss characteristics of a low-pressure-loss fluidized-bed heat exchanger with an extremely small ststic bed height of glass beads. This heat exchanger was composed of a tube bankd in a staggered arrangement and a multislit distributor designed especially to reduce the pressure loss. The effect of the cross-sectional shape of the distributor, the particle size of the glass beads, the static bed height, and the number of rows on heat transfer performance were examined. The heat transfer and pressure-loss characteristics are compared with experimental data in terms of fan power consumption and the compactness of the heat exchanger.     

Equal quality distribution of gas–liquid two-phase flow by partial separation method

This paper proposes a new method for equal quality distribution of gas–liquid two-phase flow by partial separate-phase distribution with a dual-header distributor. The upper and liquid (lower) headers are interconnected with five vertical downward arms. A gas–liquid two-phase mixture enters the distributor from the upper header where most of the liquid of the mixture is removed through the downward arms into the liquid header. Hence, firstly, the remaining gas-rich fluid can be uniformly distributed into the outlet branches, and then secondly, the liquid collected in the liquid header can be uniformly re-distributed into the individual outlet branches. Because both distribution processes are conducted in the condition of single or near single-phase flow, mal-distribution of the two-phase flow is essentially eliminated, and a satisfactory equal quality distribution of gas–liquid two-phase flow is reached. Experiments were conducted in an air–water two-phase flow test loop. The inner diameter of the inlet pipe was 60 mm, the superficial velocity ranges of gas and liquid were 3–32 m/s and 0.02–0.17 m/s respectively, and the quality ranged from 0.02 to 0.44. The flow pattern in the inlet pipe included stratified flow, wavy stratified, slug flow, and annular flow. The experimental results showed that this new method could significantly improve the distribution performance of the two-phase flow. The maximum quality deviation between each outlet branch and the inlet pipe is less than ±1% under the conditions of stratified, wavy stratified and slug flows in the upper header, and less than ±5% in annular flow.     

THERMAL BOUNDARY LAYER IN CFB BOILER RISER

Measurement of temperature profiles of gas-solid two-phase flow at different heights in commercial-scale circulating fluidized bed (CFB) boilers was carried out. Experimental results showed that the thickness of thermal boundary layer was generally independent of the distance from the air distributor, except when close to the riser outlet. Through analysis of flow and combustion characteristics in the riser, it was found that the main reasons for the phenomena were: 1) the hydrodynamic boundary layer was thinner than the thermal layer and hardly changed along the CFB boiler height, and 2) both radial and axial mass and heat exchanges were strong in the CFB boiler. Numerical simulation of gas flow in the outlet zone confirmed that the distribution of the thermal boundary layer was dominated by the flow field characteristics.     

Analysis of frictionless two-phase flow in tubes under centrifugal acceleration and minimum heating for choked flow

To determine the void fraction in a tube of a rotating heat exchanger, an analytical investigation was undertaken to model frictionless two-phase flow boiling. Steady, one-dimensional separated two-phase conservation equations in differential form, were first applied to a stationary system. The equations were integrated between the inlet and exit of the flow channel to yield three coupled algebraic equations. The algebraic equations were then modified to represent rotating systems. To obtain closure, the velocity ratio, mass quality and void fraction are defined as a function of pressure.

A numerical technique was used to solve the equations. Sample results are presented in a graph of mass quality versus void fraction. The graph demonstrates that a minimum heat input must be exceeded to change from a single-phase flow to saturated two-phase flow boiling. Also, the void fraction was found to increase for increasing heat input, decreasing mass flow rate, increasing inlet mass quality and decreasing pressure difference between the inlet and exit.     

Evaporation in parallel pipes––splitting characteristics

Utilizing solar power using parabolic trough collectors for energy is considered most proven and lowest cost for large-scale solar power technology. So far commercial plants used oil as the primary heated fluid and steam was produced in a secondary heat exchanger. This seem to be a very inefficient process due to the need of extra heat exchangers and extra losses incurred while heat is transferred from oil to steam. The reason oil is used as the primary heated fluid is partially due to the reluctance of the designer to deal with the behavior of two-phase, water steam, in parallel pipes owing to the possible uneven flow distribution and instability related problems.Analysis of a system of two parallel pipes with common inlet and outlet manifolds that undergoes a process of heating and evaporation shows that multiple steady state solutions for the flow distribution in the two pipes may be obtained. A simplified stability analysis backed by new experimental results allows the determination of the actual physical solutions that take place. Design considerations are discussed and suggestions for optimal operation are included.     

Vortex shedding and fluidelastic instability in a normal square tube array excited by two-phase cross-flow

Laboratory experiments were conducted to determine the flow-induced vibration (FIV) response and fluidelastic stability threshold of a model heat exchanger tube bundle subjected to a cross-flow of refrigerant 11. The tube bundle consisted of a normal square array of 12 tubes with outer tube diameters of 7.11 mm and a pitch over diameter ratio of 1.485. The experiments were conducted in a flow-loop that was capable of generating single- and two-phase cross-flows over a variety of mass fluxes and void fractions. The primary intent of the research was to improve our understanding of the FIVs of heat exchanger tube arrays subjected to two-phase cross-flow. Of particular concern was the effect of array pattern geometry on fluidelastic instability. The experimental results are analysed and compared with existing data from the literature using various methods of parameter definition. Comparison of tube vibration response in liquid flow with previous results shows a similar occurrence of symmetric vortex shedding that validates the scale model approach in single-phase flow. It was found that the introduction of a small amount of bubbles in the flow disrupted the vortex shedding and thereby caused a significant reduction in streamwise vibration amplitude. The fluidelastic stability thresholds for the present array agree well with results from previous studies. Furthermore, a good collapse of the stability data from various investigations is obtained when the fluid density is defined using the slip model of Feenstra et al. and when an effective two-phase flow velocity is defined using the interfacial velocity model of Nakamura et al.     

Heat Transfer and Pressure loss of a very shallow fluidized-bed heat exchanger Part 1. Experiment with a single row of tubes

A novel gas fluidized-bed heat exchanger with a very small static bed height has been developed for a heat-exchanging system using a low-pressure fan. This fluidized bed is composed of a multislit distributor, a single row of 8 mm diameter tubes, and glass beads 48–195 μm in diameter. The measured performance of heat transfer is excellent and that of fluidization is satisfactory, in spite of the static bed height being as small as 13 mm. In the best case, the test fluidized bed exhibited a heat transfer performance comparable to that of a conventional fluidized bed with a perforated plate distributor and a static bed height of 150 mm, and showed one-fourteenth the pressure loss.     

3D Numerical heat transfer and fluid flow analysis in plate-fin and tube heat exchangers with electrohydrodynamic enhancement

Three-dimensional laminar fluid flow and heat transfer over a four-row plate-fin and tube heat exchanger with electrohydrodynamic (EHD) wire electrodes are studied numerically. The effects of different electrode arrangements (square and diagonal), tube pitch arrangements (in-line and staggered) and applied voltage (V_E=0–16 kV) are investigated in detail for the Reynolds number range (based on the fin spacing and frontal velocity) ranging from 100 to 1,000. It is found that the EHD enhancement is more effective for lower Re and higher applied voltage. The case of staggered tube pitch with square wire electrode arrangement gives the best heat transfer augmentation. For V_E=16 kV and Re = 100, this study identifies a maximum improvement of 218% in the average Nusselt number and a reduction in fin area of 56% as compared that without EHD enhancement.     

Analysis of evaporative cooling and enhancement of condenser efficiency and of coefficient of performance

The graphical method to determine with the aid of a Mollier i - x diagram (psychrometric chart) combined heat and mass transfer is simulated by a computer program. Heat rejection rates from a plate-fin tube type condenser are determined for various flow rates and inlet state conditions of air and for different degrees of wetting of the heat transfer surfaces. The presence of water and the cooling by latent heat makes it possible to exchange more heat than the unwetted exchanger would even for idealized conditions of infinite heat transfer coefficient of the air. The evaporative cooled condenser also can exchange heat with ambient air which has much higher temperature than the condensing fluid. Evaporative cooling increases heat transfer by a factor of more than three for saturated inlet air and greater than five for lower inlet humidities. Wetted heat exchangers require less extended surfaces and can operate effectively with bare tubes only. Wetting the condenser of a refrigeration or heat pump system makes it possible to exchange the condenser load at lower temperatures. This yields an increase of COP of the order of 30 to 60% and therefore a substantial decrease in compressor power and its energy consumption.     

A simple and accurate numerical network flow model for bionic micro heat exchangers

Heat exchangers are often associated with drawbacks like a large pressure drop or a non-uniform flow distribution. Recent research shows that bionic structures can provide possible improvements. We considered a set of such structures that were designed with M. Hermann’s FracTherm^® algorithm. In order to optimize and compare them with conventional heat exchangers, we developed a numerical method to determine their performance. We simulated the flow in the heat exchanger applying a network model and coupled these results with a finite volume method to determine the heat distribution in the heat exchanger.     

INVESTIGATION INTO MALDISTRIBUTION IN A CIRCULATING FLUIDIZED BED

1. Introduction The design of gas distributor has a major influence on gas flow patterns, dumping and dead zones. It has been demonstrated that maldistribution will occur if the distribu-tor has a low pressure drop, that is, some parts of the bed will receive much less gas than others, and may be tem-porarily or permanently defluidized, while the gas forms semi-permanent spouts or channels in other parts. There-fore, maldistribution is undesirable in industry. For example, the temperature in a…     

Parametric study of gross flow maldistribution in a single-pass shell and tube heat exchanger in turbulent regime

Uniform distribution of flow in tube bundle of shell and tube heat exchangers is an arbitrary assumption in conventional heat exchanger design. Nevertheless, in practice, flow maldistribution may be an inevitable occurrence which may have severe impacts on thermal and mechanical performance of heat exchangers i.e. fouling. The present models for flow maldistribution in the tube-side deal only with the maximum possible velocity deviation. Other flow maldistribution models propose and recommend the use of a probability distribution, e.g. Gaussian distribution. None of these, nevertheless, estimate quantitatively the number of tubes that suffer from flow maldistribution. This study presents a mathematical model for predicting gross flow maldistribution in the tube-side of a single-pass shell and tube heat exchanger. It can quantitatively estimate the magnitude of flow maldistribution and the number of tubes which have been affected. The validation of the resultant model has been confirmed when compared with similar study using computational fluid dynamics (CFD).     

Experiments on two-phase flow distribution inside parallel channels of compact heat exchangers

Uneven distribution in heat exchangers is a cause of reduction in both thermal and fluid-dynamic performances. Many papers have dealt with single-phase flow and both flow distribution data and analytical or numerical models are available for header design. With regard to two-phase flow, phase separation in manifolds with several outlets is so complicated that, to date, there is no general way to predict the distribution of two-phase mixtures at header-channel junctions. The design of headers for new generation compact heat exchangers and multi-microchannel evaporators is still based on an empirical approach, as a number of variables act together: geometrical parameters and orientation of the manifolds and of the channels, operating conditions, fluid physical properties.     

Predict the temperature distribution in gas-to-gas heat pipe heat exchanger

A theoretical model has been developed to investigate the thermal performance of a continuous finned circular tubing of an air-to-air thermosyphon-based heat pipe heat exchanger. The model has been used to determine the heat transfer capacity, which expresses the thermal performance of heat pipe heat exchanger. The model predicts the temperature distribution in the flow direction for both evaporator and condenser sections and also the saturation temperature of the heat pipes. The approach used for the present study considers row-by-row heat-transfer in evaporator and condenser sections of the heat pipe heat exchanger.     

MODELLING TWO-PHASE FLOW-EXCITED DAMPING AND FLUIDELASTIC INSTABILITY IN TUBE ARRAYS

This paper reports the results of an experimental study of the flow-induced vibration of a heat exchanger tube array subjected to two-phase cross-flow of refrigerant 11. The primary concern of the research was to develop a methodology for predicting the critical flow velocities for fluidelastic instability which better characterize the physics of two-phase flows. A new method is proposed for calculating the average fluid density and equivalent flow velocity of the two-phase fluid, using a newly developed void fraction model to account for the difference in velocity between the gas and liquid phases. Additionally, damping measurements in two-phase flow were made and compared with the data of other researchers who used a variety of modelling fluids. The results show that the two-phase damping follows a similar trend with respect to homogeneous void fraction, and when normalized, agree well with the data in the literature. The fluidelastic threshold data of several researchers who used a variety of fluids, is re-examined using the proposed void fraction model, and the results show a remarkable change in trend with flow regime. The data corresponding to the bubbly flow regime shows no significant deviation from the trend established by Connors' theory. However, the data corresponding to the intermittent flow regime show a significant decrease in stability which is nearly independent of the mass-damping parameter. It is believed that the velocity fluctuations that are inherent in the intermittent flow regime are responsible for tripping the instability, causing lower than expected stability of the bundle.