Three-dimensional numerical investigation of heat transfer for plate fin heat exchangers

In the present study, the potential of rectangular fins with 30° and 90° angle and 10 mm offset from the horizontal direction for heat transfer enhancement in a plate fin heat exchanger is numerically evaluated with conjugated heat transfer approach. The rectangular fins are mounted on the flat plate channel. The numerical computations are performed by solving a steady, three-dimensional Navier–Stokes equation and an energy equation by using Fluent software program. Air is taken as working fluid. The study is carried out at Re = 400 and inlet temperatures, velocities of cold and hot air are fixed as 300, 600 K and 1.338, 0.69 m/s, respectively. Colburn factor j versus Re design data is presented by using Fluent. The results show that the heat transfer is increased by 10 % at the exit of channel with fin angle of 30° when compared to channel without fin for counter flow. The heat transfer enhancement with fins of 30° and 90° for different values of Reynolds number with 300, 500 and 800 and for varying fin heights, fin intervals and also temperature distributions of fluids on the top and bottom surface of the channel are investigated for parallel and counter flow.     

Experimental study of the effect of spray inclination on ultrafast cooling of a hot steel plate

The ultrafast cooling that occurs during high mass flux air-atomized spray impingement on a hot 6 mm thick stainless steel plate has been studied experimentally in terms of the nozzle inclination between 0° and 60°. The average mass flux of water used in the study accounts to 510 kg/m² s. The coolants used in the study are pure water and surfactant water of 600 ppm concentration. The initial temperature of the plate has been maintained at 900 °C, which is the temperature of a hot strip on run-out table in steel industry. The transient surface heat flux and temperature histories have been estimated by an inverse heat solver using measured temperature input data. Heat transfer results demonstrates that optimum cooling efficiency (~2.76 MW/m², 194 °C/s) for pure water has been achieved at 30° nozzle orientation. The inclined nozzle has not been found beneficial when surfactant water is used as the coolant.     

Heat transfer from a flat surface to an inclined impinging jet

An experimental study was carried out to investigate the effect of the inclination jet on convection heat transfer to horizontal flat plate. Local heat transfer determined as a function is of three parameters including inclination angle of the air jet relative to the plate in range of 90° ≤ θ ≤ 45°, jet-to-plate spacing in range of 2 ≤ L/D ≤ 8 and Reynolds number in range of 1,500 ≤ Re ≤ 30,000. The results show that the maximum heat transfer point moves towards the uphill side of the plate and the maximum heat transfer decreases as the inclination angle decreases. The correlations were conducted to predict maximum and local Nusselt number as a function of Re, θ, L/D, and x/D for a specific three regions.     

Large area impingement spray cooling from multiple normal and inclined spray nozzles

An inclined spray chamber with four multiple nozzles to cool a 1 kW 6U electronic test card has been designed and tested in this study. The multiple inclined sprays can cover the same heated surface area as that with the multiple normal sprays but halve the volume of the spray chamber. The spray cooling system used R134a as a working fluid in a modified refrigeration cycle. It is observed that increasing mass flow rate and pressure drop across the nozzles improved the heat transfer coefficient with a maximum enhancement of 117 %, and reduced the maximum temperature difference at the heated surface from 13.8 to 8.4 °C in the inclined spray chamber with a heat flux of 5.25 W/cm², while the heat transfer coefficient of the normal spray increased with a maximum enhancement of 215 % and the maximum temperature difference decreased from 10.8 to 5.4 °C under similar operating conditions. We conclude that the multiple inclined sprays could produce a higher heat transfer coefficient but with an increase in non-uniformity of the surface temperature compared with the multiple normal sprays.     

Enhanced heat transfer performances of molten salt mixed convection in a vertical annular duct

The mixed convection heat transfer of upward molten salt flow in a vertical annular duct is experimentally and numerically studied. The heat transfer performances of mixed convection are measured under Reynolds number 2,500–12,000 and inlet temperature 300–400 °C, and Nusselt number of molten salt flow with cooled inner wall monotonically increases with buoyancy number. The mixed convection is further simulated by low-Reynolds number k-ε model and variable properties, and the heat transfer tendency from numerical results agrees with that from experiments. At low Reynolds number, the natural convection plays more important role in the mixed convection. As the buoyancy number rises, the thickness of flow boundary layer near the inner wall increases, while the effective thermal conductivity remarkably rises, so the enhanced heat transfer of mixed convection is mainly affected by the effective thermal conductivity due to turbulent diffusion.     

Heat transfer characteristics of multi-walled carbon nanotubes suspension in a developing channel flow

The present study experimentally investigates the effect of multi wall carbon nanotubes (MWCNT) suspensions on the convective heat transfer coefficients. The MWCNT suspensions used in this study were prepared by dispersing MWCNTs in deionized water 0.25 wt% arab gum solution. The heat transfer characteristics were measured for thermally developing laminar flow in a finite length horizontal circular pipe under isothermal wall conditions. The study was conducted over a range of Reynolds number of 300–2,300, based on 0.8 mm tube diameter. Results indicate enhancements of the convective heat transfer coefficient as a function of Reynolds number and volume fractions. An average enhancement of heat transfer coefficient of 50 % was observed over the base fluid. An overall increase of pumping force varying from 20 to 30 % over the flowing range is observed. The results suggest an optimum MWCNT volume fraction point of 0.1 % which gives the best heat transfer enhancement.     

The effect of pre-thermal history on shear and uniaxial elongational viscosity of a tetrafluoroethylene/hexafluoropropylene copolymer near the crystal melting transition

The melt rheology of a commercially available tetrafluoroethylene/hexafluoropropylene copolymer, which is known as Teflon FEP copolymer, was studied to examine the effect of pre-thermal history during sample preparation conditions on dynamic shear and uniaxial elongational measurements. The first experimental series includes the sample preparation under hot press at 320 °C followed by a rapid cooling. The master curves were successfully obtained at 300 °C from the time-temperature superposition principle. The loss modulus G″ was found to be proportional to the angular frequency in a double-logarithmic plot toward 0.01 (rad/s), while the slope of the storage modulus G′ did not become 2. The elongational viscosity as a function of time under constant strain rates showed weak strain-hardening, which was enhanced with larger strain rates. The second experimental series contain three kinds of samples with different pre-thermal history to control rheological properties. All samples were hot-pressed at 320 °C followed by a rapid cooling to room temperature for the sample A and a slow cooling for the sample B and C. The dynamic shear and elongational measurements were performed at 270 °C for all samples, which were heated from room temperature for the sample A and B, but heated up to 280 °C and cooled down to 270 °C for the sample C. The distance between G″ and G′ become narrower in the order of the sample C, B, and A. In the same order, unexpectedly, the strain-hardening in the elongational viscosity measurements became the strain-softening. These unusual properties were discussed from a residual crystallinity.     

Heat transfer and fluid flow analysis of artificially roughened ducts having rib and groove roughness

Artificially roughness is one of the well known methods of enhancing heat transfer from the heat transfer surface in the form of repeated ribs, grooves or combination of ribs and groove (compound turbulators). The artificial roughness produced on the heat transferring surface is used in cooling of gas turbine blades, nuclear reactor, solar air heating systems etc. Solar air heaters have wide applications in low to moderate temperature range, namely, drying of foods, agricultural crops, seasoning of wood and space heating etc. Solar air heaters have low value of convective heat transfer coefficient between the working fluid (air) and the heat transferring surface, due to the formation of thin laminar viscous sub-layer on its surface. The heat transfer from the surface can be increased by breaking this laminar viscous sub layer. Hence, in the present work compound turbulators in the form of integral wedge shaped ribs with grooves are used on the heat transfer surface, to study its effect on the heat transfer coefficient (Nusselt number) and friction factor in the range of Reynolds number 3,000–18,000. The roughness produced on the absorber plate forms the wetted side of upper broad wall of the rectangular duct of solar air heater. The relative groove position (g/p) was varied from 0.4 to 0.8 and the wedge angle (Φ) was varied from 10° to 25°, relative roughness pitch (p/e) and relative roughness height (e/D) was maintained as 8.0 and 0.033 respectively. The aspect ratio of the rectangular duct was maintained as 8. The Nusselt number and friction factor of the artificially roughened ducts were determined experimentally and the corresponding values were compared with that of smooth surface duct. It is observed that wedge-groove roughened surface shows more enhancement in heat transfer compared to only rib roughened surface arrangement. The investigation revealed that Nusselt number increases 1.5–3 times, while the friction factor increases two to three folds that of the smooth surface duct in the range of operating parameters. It is also observed that in rib–groove roughness arrangement with relative groove position of 0.65 shows the maximum enhancement in the heat transfer compared to the other rib-groove roughness arrangements. Statistical correlations for the Nusselt number and friction factor have been developed by the regression method in terms of the operating and roughness parameters. A program was also developed in MATLAB for the calculation of thermal efficiency and thermal effectiveness. It was observed that the thermal efficiency is more for wedge angle of 15° and relative groove position of 0.65 and its value ranges from 42 to 73 %. The uncertainties in the measurements due to various instruments for the Reynolds number, Nusselt number, and friction factor have been estimated as ±3.8, ±4.54 and ±7.6 % respectively in the range of investigation made.     

Heat transfer characteristics of staggered wing-shaped tubes bundle at different angles of attack

An experimental and numerical study has been conducted to clarify heat transfer characteristics and effectiveness of a cross-flow heat exchanger employing staggered wing-shaped tubes at different angels of attack. The water-side Re_w and the air-side Re_a were at 5 × 10² and at from 1.8 × 10³ to 9.7 × 10³, respectively. The tubes arrangements were employed with various angles of attack θ_1,2,3 from 0° to 330° at the considered Re_a range. Correlation of Nu, St, as well as the heat transfer per unit pumping power (ε) in terms of Re_a and design parameters for the studied bundle were presented. The temperature fields around the staggered wing-shaped tubes bundle were predicted by using commercial CFD FLUENT 6.3.26 software package. Results indicated that the heat transfer increased with the angle of attack in the range from 0° to 45°, while the opposite was true for angles of attack from 135° to 180°. The best thermal performance and hence the efficiency η of studied bundle occurred at the lowest Re_a and/or zero angle of attack. Comparisons between the experimental and numerical results of the present study and those, previously, obtained for similar available studies showed good agreements.     

Experimental and numerical investigations on slot air jet impingement cooling of a heated cylindrical concave surface

Experimental and numerical studies have been carried out for slot air jet impingement on a heated concave surface of a partially opened-top horizontal cylinder of length L = 20 cm. The slot jet is situated at the symmetry line of the partially opened-top cylinder along the gravity vector and impinges to the bottom of the cylinder which is designated as θ = 0°. The width of the opening at the top of the horizontal cylinder is W = 3 cm which corresponds to a circumferential angle Δθ = 50.8°. The experiments are performed by a Mach–Zehnder interferometer which enables to measure the local convection heat transfer coefficient. Also, a finite volume method based on the SIMPLE algorithm and non-orthogonal grid discretization scheme is used to solve the continuity, momentum, and energy equations. The Poisson equations are solved for (x, y) to find the grid points which are distributed in a non-uniform manner with higher concentration close to the solid regions. The effects of jet Reynolds number (Re _j) in the range from 190 to 1,600 and the ratio of spacing between nozzle and cylinder surface to the jet width from H = 1.5 to H = 10.7 on the local and average Nusselt numbers are examined. It is observed that maximum Nusselt number occurs at the stagnation point at (θ = 0°) and the local heat transfer coefficient decreases on the circumferential surface of the cylinder with increase of θ as a result of thermal boundary layer thickness growth. Also results show that the local and average heat transfer coefficients are raised by increasing the jet Reynolds number and by decreasing the nozzle-to-surface spacing.     

Numerical computation of natural convection in an isosceles triangular cavity with a partially active base and filled with a Cu–water nanofluid

This paper discusses the results of a study related to natural convection cooling of a heat source located on the bottom wall of an inclined isosceles triangular enclosure filled with a Cu water-nanofluid. The right and left walls of the enclosure are both maintained cold at constant equal temperatures, while the remaining parts of the bottom wall are insulated. The study has been carried out for a Rayleigh number in the range 10⁴ ≤ Ra ≤ 10⁶, for a heat source length in the range 0.2 ≤ ε ≤0.8, for a solid volume fraction in the range 0 ≤ ?≤0.06 and for an inclination angle in the range 0° ≤ δ≤45°. Results are presented in the form of streamline contours, isotherms, maximum temperature at the heat source surface and average Nusselt number. It is noticed that the addition of Cu nanoparticles enhances the heat transfer rate and therefore cooling effectiveness for all values of Rayleigh number, especially at low values of Ra. The effect of the inclination angle becomes more noticeable as one increases the value of Ra. For high Rayleigh numbers, a critical value for the inclination angle of δ = 15° is found for which the heat source maximum temperature is highest.     

Lattice Boltzmann simulation of natural convection in nanofluid-filled 2D long enclosures at presence of magnetic field

In this paper, the effects of a magnetic field on natural convection flow in filled long enclosures with Cu/water nanofluid have been analyzed by lattice Boltzmann method. This study has been carried out for the pertinent parameters in the following ranges: the Rayleigh number of base fluid, Ra = 10³–10⁵, the volumetric fraction of nanoparticles between 0 and 6 %, the aspect ratio of the enclosure between A = 0.5 and 2. The Hartmann number has been varied from Ha = 0 to 90 with interval 30 while the magnetic field is considered at inclination angles of θ = 0°, 30°, 60° and 90°. Results show that the heat transfer decreases by the increment of Hartmann number for various Rayleigh numbers and the aspect ratios. Heat transfer decreases with the growth of the aspect ratio but this growth causes the effect of the nanoparticles to increase. The magnetic field augments the effect of the nanoparticles at high Rayleigh numbers (Ra = 10⁵). The effect of the nanoparticles rises for high Hartmann numbers when the aspect ratio increases. The rise in the magnetic field inclination improves heat transfer at aspect ratio of A = 0.5.     

Experimental investigation of heat transfer and flow pattern from heated horizontal rectangular fin array under natural convection

This paper presents results of the experimental study conducted on heated horizontal rectangular fin array under natural convection. The temperature mapping and the prediction of the flow patterns over the fin array with variable fin spacing is carried out. Dimensionless fin spacing to height (S/H) ratio is varied from 0.05 to 0.3 and length to height ratio (L/H) = 5 is kept constant. The heater input to the fin array assembly is varied from 25 to 100 W. The single chimney flow pattern is observed from 8 to 12 mm fin spacing. The end flow is choked below 6 mm fin spacing. The single chimney flow pattern changes to sliding or end flow choking at 6 mm fin spacing. The average heat transfer coefficient (h_a) is very small (2.52–5.78 W/m² K) at 100 W for S = 5–12 mm. The h_a is very small (1.12–1.8 W/m² K) at 100 W for 2–4 mm fin spacing due to choked fin array end condition. The end flow is not sufficient to reach up to central portion of fin array and in the middle portion there is an unsteady down and up flow pattern resulting in sliding chimney. The central bottom portion of fin array channel does not contribute much in heat dissipation for S = 2–4 mm. The h_a has significantly improved at higher spacing as compared to lower spacing region. The single chimney flow pattern is preferred from heat transfer point of view. The optimum spacing is confirmed in the range of 8–10 mm. The average heat transfer results are compared with previous literature and showed similar trend and satisfactory agreement. An empirical equation has been proposed to correlate the average Nusselt number as a function of Grashof number and fin spacing to height ratio. The average error for this equation is ?0.32 %.     

L- and U-shaped heat pipes thermal modules with twin fans for cooling of electronic system under variable heat source areas

This study utilizes a versatile superposition method with thermal resistance network analysis to design and experiment on a thermal module with embedded six L-shaped or two U-shaped heat pipes and plate fins under different fan speeds and heat source areas. This type of heat pipes-heat sink module successively transfer heat capacity from a heat source to the heat pipes, the heat sink and their surroundings, and are suitable for cooling electronic systems via forced convection mechanism. The thermal resistances contain all major components from the thermal interface through the heat pipes and fins. Thermal performance testing shows that the lowest thermal resistances of the representative L- and U-shaped heat pipes-heat sink thermal modules are respectively 0.25 and 0.17 °C/W under twin fans of 3,000 RPM and 30 × 30 mm² heat sources. The result of this work is a useful thermal management method to facilitate rapid analysis.     

Heat transfer performance comparison of steam and air in gas turbine cooling channels with different rib angles

Using steam as working fluid to replace compressed air is a promising cooling technology for internal cooling passages of blades and vanes. The local heat transfer characteristics and the thermal performance of steam flow in wide aspect ratio channels (W/H = 2) with different angled ribs on two opposite walls have been experimentally investigated in this paper. The averaged Nusselt number ratios and the friction factor ratios of steam and air in four ribbed channels were also measured under the same test conditions for comparison. The Reynolds number range is 6,000–70,000. The rib angles are 90°, 60°, 45°, and 30°, respectively. The rib height to hydraulic diameter ratio is 0.047. The pitch-to-rib height ratio is 10. The results show that the Nusselt number ratios of steam are 1.19–1.32 times greater than those of air over the range of Reynolds numbers studied. For wide aspect ratio channels using steam as the coolant, the 60° angled ribs has the best heat transfer performance and is recommended for cooling design.     

Convective heat transfer from molten salt droplets in a direct contact heat exchanger

This paper presents a new predictive model of droplet flow and heat transfer from molten salt droplets in a direct contact heat exchanger. The process is designed to recover heat from molten CuCl in a thermochemical copper–chlorine (Cu–Cl) cycle of hydrogen production. This heat recovery occurs through the physical interaction between high temperature CuCl droplets and air. Convective heat transfer between droplets and air is analyzed in a counter-current spray flow heat exchanger. Numerical results for the variations of temperature, velocity and heat transfer rate are presented for two cases of CuCl flow. The optimal dimensions of the heat exchanger are found to be a diameter of 0.13 m, with a height of 0.6 and 0.8 m, for 1 and 0.5 mm droplet diameters, respectively. Additional results are presented and discussed for the heat transfer effectiveness and droplet solidification during heat recovery from the molten CuCl droplets.     

The cooling heat transfer characteristics of the supercritical CO2 in micro-fin tube

This study intended to verify the cooling heat transfer characteristics of supercritical gas for refrigerating and air-conditioning devices that use CO₂, a natural refrigerant, as the operating fluid. Experiments were performed with a gas cooler, which was the test part. The gas cooler was a heat exchanger made of a micro-fin tube with an inner diameter of 4.6 mm and an outer diameter of 5.0 mm. The experiment results are summarized as follows. The heat transfer coefficient, according to the mass flux, peaked at the low cooling pressure of 8.0 MPa in the gas cooler, and reached its minimum at the high pressure of 10.0 MPa. Furthermore, when the mass flux of the refrigerant increased, the coefficient increased faster with the lower cooling pressure in the gas cooler. The heat transfer coefficient, according to the shape of the heat transfer tube, showed that the maximum values of the CO₂ cooling heat transfer coefficients of the smooth tube and the micro-fin tube were found at 44.7 °C, which were the pseudo-critical temperatures for the entrance pressures. It was found that the cooling heat transfer coefficient of the micro-fin tube increased by 12–39 % more than that of the smooth tube. The experiment results for the CO₂ heat transfer coefficients of the smooth tube and the micro-fin tube were compared with the results estimated from previous correlations. It was found that the experiment values generally significantly differed from and the experiment values greater than the estimated values. The differences were especially greater in the vicinity of the critical temperature points. Based on these results, a new correlation was suggested that includes the density ratio and the specific heat ratio.     

Computation of heat transfer enhancement in a plate‐fin heat exchanger with triangular inserts and delta wing vortex generator

Longitudinal vortices disrupt the growth of the thermal boundary layer, thereby the vortex generators producing the longitudinal vortices are well known for the enhancement of heat transfer in compact heat exchangers. The present investigation determines the heat transfer characteristics with secondary flow analysis in plate fin triangular ducts with delta wing vortex generators. This geometrical configuration is investigated for various angles of attack of the wing i.e. 15°, 20°, 26° and 37° and Reynolds numbers 100 and 200. The constant wall temperature boundary condition is used. The solution of the complete Navier Stokes equation and the energy equation is carried out using the staggered grid arrangement. The performance of the combination of triangular secondary fins and delta wing with stamping on slant surfaces has also been studied. Copyright © 2009 John Wiley & Sons, Ltd.     

Performance evaluation and optimization of semi-dimpled slit fin

In this paper, the semi-dimpled slit fin is proposed and the characteristics of heat transfer and fluid flow are analyzed based on the orthogonal experiment design method. A serial studies on the effects of fin pitch, arrangement of semi-dimple, dimple radius on heat transfer and flow characteristics of semi-dimpled slit fin are investigated. The computational results show fin pitch (Fp) has significantly effected on the performance of heat transfer and fluid flow, the influence of arrangement of semi-dimple, the dimple radius (R) and the opening direction of semi-dimples dwindle. At the same time, compared to the general semi-dimpled slit fin, the heat transfer coefficient and JF factors of the optimized fin increase by 10.7–25.1 and 2.6–7.7 %, respectively. When Re ≤ 1,521, the overall performance of slit fin is better than that of optimized fin; while Re > 1,521, the overall performance of optimized fin is better than that of slit fin. Finally, the performance evaluation plot of enhanced heat transfer of heat exchanger is applied to analyze the optimized fin, it can be seen that optimization fin have better heat transfer performance under the same power consumption.     

Experimental study on the evaporative cooling of an air-cooled condenser with humidifying air

Using six different materials to construct a water curtain, this study aims to determine the most effective spray cooling of an air cooled heat exchanger under wet conditions. The experiments were carried out at a mass flow rate of 0.005–0.01 kg/s (spraying water), an airspeed of 0.6–2.4 m/s and a run time of 0–72 h for the material degradation tests. The experimental results indicate that the cooling efficiency, the heat rejection, and the sprinkling density increase as the amount of spraying water increases, but, the air-flow of the condenser is reduced at the same time. In addition, the cooling efficiency of the pads decreases with an increase of the inlet air velocity. In terms of experimental range, the natural wood pulp fiberscan can reach 42.7–66 % for cooling efficiency and 17.17–24.48 % for increases of heat rejection. This means that the natural wood pulp fiberscan pad most effectively enhances cooling performance, followed in terms of cooling effectiveness by the special non-woven rayon pad, the woollen blanket, biochemistry cotton and kapok, non-woven cloth of rayon cotton and kapok, and white cotton pad, respectively. However, the natural wood pulp fiberscan and special non-woven rayon display a relatively greater degradation of the cooling efficiency than the other test pads used in the material degradation tests.