Measurement of heat transfer coefficient and axial dispersion coefficient using temperature oscillations

A periodic transient test technique based on the axial dispersion model is proposed for the determination of both heat transfer coefficients and axial dispersion coefficients in heat exchangers. The model uses a parameter called the axial dispersive Peclet number to account for the deviation of the flow pattern from ideal plug flow. It takes both axial dispersion in the fluid and axial heat conduction in the wall into account and is solved analytically by means of a complex Fourier transform. Experiments conducted on dented copper tubes show that axial dispersion has a significant effect on the dynamic temperature response of a heat exchanger.     

Monitoring the thermal efficiency of fouled heat exchangers: A simplified method

Fouling is a problem whether we are aware of it or not. In an industrial plant, it is important not only to be able to measure the buildup of unwanted deposits, but also to do it in the simplest and most economically possible way. This paper addresses the question of monitoring fouling in an oil refinery plant, where the high number of heat exchanger units and the variability of the feedstock charge pose additional problems in terms of the practicability of following the energetic performance of such equipment. In this case, the flow rates and quality of the fluids flowing through the heat exchangers do not usually correspond to the design conditions, because they change with time. Therefore, to assess the fouling level of the exchangers, the day-to-day measured thermal efficiency should not be compared with the efficiency predicted in the design calculations. The latter should be recalculated by introducing whenever necessary new values of flow rates, physical properties, and so forth, and by evaluating new heat transfer coefficients. However, the procedures are too time consuming to be applied frequently. The present work describes a simplified method for following heat exchanger performances, based on the assessment of the number of transfer units and thermal efficiencies, where the effects of changing the feedstock charge, particularly the flow rates of the fluids, are taken into account. The only data that need to be collected are the four inlet/outlet temperatures of the heat exchanger unit and one of the flow rates. Several heat exchanger units in an oil refinery were successfully monitored by means of this method, and it was found that the variations in the physical properties did not significantly affect the results obtained for the particular plant under study.     

Convective heat transfer characteristics of high-pressure gas in heat exchanger with membrane helical coils and membrane serpentine tubes

Since the heat transfer performance of syngas cooler affects the efficiency of the power generating system with integrated coal gasification combined cycle (IGCC) directly, it is important to obtain the heat transfer characteristics of high-pressure syngas in the cooler. Heat transfer in convection cooling section of pressurized coal gasifier with the membrane helical coils and membrane serpentine tubes under high pressure is experimentally investigated. High pressure single gas (He or N₂) and their mixture (He + N₂) gas serve as the test media in the test pressure range from 0.5 MPa to 3.0 MPa. The results show that the convection heat transfer coefficient of high pressure gas is influenced by the working pressure, gas composition and symmetry of flow around the coil, of which the working pressure is the most significant factor. The average convection heat transfer coefficients for various gases in heat exchangers are systematically analyzed, and the correlations between Nu and Re for two kinds of membrane heat exchangers are obtained. The heat transfer coefficient of heat exchanger with membrane helical coils is greater than that of the membrane serpentine-tube heat exchanger under the same conditions. The heat transfer coefficient increment of the membrane helical-coil heat exchanger is greater than that of the membrane serpentine-tube heat exchanger with the increase of gas pressure and velocity.     

Further understanding of twisted tape effects as tube insert for heat transfer enhancement

Tube inserts are used as heat transfer enhancement tool for both retrofit and new design of shell and tube heat exchangers. This paper discusses and reviews the characteristics and performance of twisted tapes. The theory and application are also addressed. Industrial case study was selected to illustrate the behaviour effect that the twisted tapes impose at various laminar, transition and turbulent flow regions. This effect was demonstrated by changing the inside tube diameter and twist ratio through evaluating selected exchanger design parameters such as: local heat transfer coefficient, friction factor and pressure drop. Testing the exponent powers for Re and Pr at both laminar and turbulent regions were carried out. General design considerations are outlined for the use of twisted tapes in shell and tube heat exchangers.     

Periodic flow and heat transfer using unstructured meshes

A numerical scheme has been developed for computing fluid flow and heat transfer in periodically repeating geometries. Unstructured solution-adaptive meshes are used in a cell-centred finite volume formulation. The SIMPLE algorithm is used for pressure‒velocity coupling. For periodic flows the static pressure is decomposed into a periodic component and one that varies linearly in the streamwise direction. The latter is computed from the imposition of overall mass balance at the periodic boundary. A subiteration between the periodic pressure correction equation and the correction to the linear component is used. For heat transfer a formulation using the physical rather than the scaled temperature is employed. The scheme is applied to both laminar and turbulent computations of periodic flow and heat transfer in a variety of heat exchanger geometries; comparison with published computations and experimental data is found to be satisfactory. © 1997 John Wiley & Sons, Ltd.     

Flow boiling heat transfer of R134a in the multiport minichannel heat exchangers

The flow boiling heat transfer characteristics of R134a in the multiport minichannel heat exchangers are presented. The heat exchanger was designed as the counter flow tube-in-tube heat exchanger with refrigerant flowing in the inner tube and hot water in the gap between the outer and inner tubes. Two inner tubes were made from extruded multiport aluminium with the internal hydraulic diameter of 1.1 mm for 14 numbers of channels and 1.2 mm for eight numbers of channels. The outer surface areas of two inner test sections are 5979 mm² and 6171 m², while the inner surface areas are 13,545 mm² and 8856 mm² for 14 and eight numbers of channels, respectively. The outer tube of heat exchanger was made from circular acrylic tube with an internal hydraulic diameter of 25.4 mm. The experiments were performed at the heat fluxes between 15 and 65 kW/m², mass flux of refrigerant between 300 and 800 kg/m² s and saturation pressure ranging from 4 to 6 bar. For instance the boiling curve, average heat transfer coefficients are discussed. The comparison results of two test sections with different the number of channels are investigated. The results are also compared with nine existing correlations. The new correlation for predicting the heat transfer coefficient was also proposed.     

Evaluating the results of the single-blow transient heat exchanger test

Single-blow test data are often used as the basis for fundamental convective heat transfer correlations. However, if the heat transfer model used to relate the measured temperature history to an avergge heat transfer coefficient does not accurately describe the experiment, then the accuracy of the data may be low.

The results of simulations are presented that quantify the error in the estimated heat transfer coefficient due to specific common mismatches between the model and the experiment. The areas of mismatches include inlett fluid temper history, longitudinal conduction in the solid, variable local convective coefficient, and effective core mass.

One symptom of a mismatch between the model and the experiment is that different criteria for comparing the measured and predicted temperature histories may yield different estimates for the performance of the same heat exchanger. The results obtained using direct temperature history and derivative and integral evaluation criteria are compared. It is shown that even if two different crit yield similar estimates for the average heat transfer coefficient, these estimates may be far from correct.

The results presented in this paper lead to the recommendation that singl-blow facilities be calibrated with tests on a core of known performance to demonstrate the appropriateness of the model as well as the accuracy of the measurements and thus establish a minimum level of confidence in new data.     

Determination of heat transfer correlations for plate-fin-and-tube heat exchangers

This paper presents a numerical method for determining heat transfer coefficients in cross-flow heat exchangers with extended heat exchange surfaces. Coefficients in the correlations defining heat transfer on the liquid- and air-side were determined using a non-linear regression method. Correlation coefficients were determined from the condition that the sum of squared fluid temperature differences at the heat exchanger outlet, obtained by measurements and those calculated, achieved minimum. Minimum of the sum of the squares was found using the Levenberg-Marquardt method. The outlet temperature of the fluid leaving the heat exchanger was calculated using the mathematical model describing the heat transfer in the heat exchanger. Since the conditions at the liquid-side and those at the air-side are identified simultaneously, the derived correlations are valid in a wide range of flow rate changes of the air and liquid. This is especially important for partial loads of the exchanger, when the heat transfer rate is lower than the nominal load. The correlation for the average heat transfer coefficient on the air-side based on the experimental data was compared with the correlation obtained from numerical simulation of 3D fluid and heat flow, performed by means of the commercially available CFD code. The numerical predictions are in good agreement with the experimental data.     

Heat transfer augmentation and pumping power in double-pipe heat exchangers

One of the criteria for evaluating the performance of a heat exchanger with extended surfaces is the pumping power required for a specified heat duty. The results of an experimental project to relate the pumping power to heat transfer augmentation in a double-pipe heat exchanger are reported. The inner, electrically heated pipe was provided with external, rectangular, axial extended surfaces with interruptions. Heat transfer augmentation and friction factors were determined for different configurations with air as the fluid. Starting with continuous fins, cuts were introduced in the fins to give four ratios of the finssegment length to the gap between the segments, and finally all the fins were removed, which resulted in smooth pipes. Five different mass flow rates in two different inner pipes were employed. Lengths, surface areas, and pumping powers for finned pipes are compared with those for smooth pipes. The average heat transfer coefficient increases with an increase in the frequency of the interruptions. For equal heat transfer rates a significant reduction in the lengths can be achieved by interrupted fins. In many cases the reduction in the length is also accompanied by a reduction in the pumping power.     

Transient heat transfert in coflow heat exchanger

More than ever before, dynamic investigation techniques are becoming widely used in the control systems, parameter implementation and state estimators. Indeed, dynamical models describing the response of process systems that are subject to disturbances play a vital role in controlling and optimising these systems. Recently developed in literature, the method of step response analysis provides a promising means towards solving some of the problems associated with the characterisation of transient response of heat exchangers. In Abdelghani-Idrissi et al. (Int J Heat Mass Transfer 44:3721–3730, 2001), authors present analytical expressions of fluids temperatures response time of counter-current heat exchanger when hot fluid step change is applied in the internal tube. This paper describes the extension of this technique to a coflow heat exchanger for which the exact solution of its mathematical model is unavailable.     

Comparisons of the heat transfer and pressure drop of the microchannel and minichannel heat exchangers

The present study investigated the comparisons of the heat transfer and pressure drop of the microchannel and minichannel heat exchangers, both numerically and experimentally. The results obtained from this study indicated that the heat transfer rate obtained from microchannel heat exchanger was higher than those obtained from the minichannel heat exchangers; however, the pressure drops obtained from the microchannel heat exchanger were also higher than those obtained from the minichannel heat exchangers. As a result, the microchannel heat exchanger should be selected for the systems where high heat transfer rates are needed. In addition, at the same average velocity of water in the channels used in this study, the effectiveness obtained from the microchannel heat exchanger was 1.2–1.53 times of that obtained from the minichannel heat exchanger. Furthermore, the results obtained from the experiments were in good agreement with those obtained from the design theory and the numerical analyses.     

An experimental investigation of heat transfer and flow friction characteristics of louvered fin surfaces by the modified single blow technique

This paper describes the development of an experimental facility to determine the heat transfer and flow friction characteristics of heat exchange surfaces by the modified single blow technique and the application of this transient technique to evaluate the performance characteristics of louvered fin heat exchangers. The reliability of implementing the modified single blow technique on the developed test facility is borne out by the good agreement in the heat transfer and flow friction data for the parallel plate test core when compared with theoretical and empirical correlations available in the literature. Performance evaluation of two louvered fin surfaces used mainly for cooling of large land and marine based electrical power generator sets is carried out and compared with similar louvered fin surfaces available in the literature. On the basis of dimensionless area and power factors, it was found that the flat fin is slightly superior in overall performance than its corrugated counterpart for low Reynolds numbers. Both surfaces are however inferior in performance when compared with the flat fin surface of Achaichia and Cowell and the corrugated fin surface of Davenport. Use of the j/f ratio as an approximate figure of merit led to an inaccurate assessment of the performance of the louvered fin heat exchanger surfaces evaluated in this study. Received on 8 May 1998     

Equations for transient behaviour of parallel-flow multichannel heat exchangers

A set of partial differential equations is formulated which describes the transient behaviour of parallel-flow multichannel heat exchangers. In the model, the heat capacitance of walls is neglected and heat is assumed to be transferred only in the direction perpendicular to the direction of flow of fluids. The set is solved by the MacCormack predictor-corrector method for a sample four-channel heat exchanger. Three cases of transient behaviour of the exchanger are investigated: uniform initial temperatures in all channels, a step change in flow rate in one channel, and a step change in inlet temperature of one fluid. In the last two cases, the exchanger is initially at steady state.     

Numerical characterization of micro heat exchangers using experimentally tested porous aluminum layers

A microporous heat exchanger device is being developed for cooling high-power electronics. The device uses a mechanically compressed aluminum porous layer to improve the heat transfer at the coolant/solid interface and to provide more uniform cooling of the electronics. The hydraulic characteristics (porosity, permeability, and Forchheimer coefficient) of nine distinct compressed layers are obtained experimentally. These layers have porosity from 0.3 to 0.7 and permeability from 1.8 × 10⁻¹⁰ m2 to 1.2 × 10⁻⁹ m2. The inertia coefficient varies from 0.3 to 0.9. These hydraulic characteristics are used in the numerical simulations of a real microporous heat exchanger for cooling phased-array radars in development. Thermal and hydraulic performances are illustrated in terms of total pressure drop across the heat exchanger, maximum temperature difference in the direction transverse to the electronic modules, and maximum temperature within the coolant passage. Results indicate that the proposed design is capable of achieving a maximum transverse temperature difference of 2°C using polyalphaolephin as coolant.     

Experimental distribution of phases and pressure drop in a two-phase offset strip fin type compact heat exchanger

Uniform distribution of fluids is crucial to obtain high performance in compact heat exchangers. Maldistribution has been studied by many authors, especially for parallel channels heat exchangers. But theoretical models and experimental studies for predicting flow maldistribution in offset strip fins exchangers are scarce. Offset strip fins, besides their higher thermal hydraulic performances, favour lateral distribution due to their geometry. In this work, an experimental investigation has been carried out for this type of heat exchanger. The experimental set-up consists in a flat vertical compact heat exchanger (1 m × 1 m area and 7.13 mm thickness) equipped with offset strip fins with a hydraulic diameter of 1.397 mm. Air and water are the working fluids. The flow rates of each phase in seven zones regularly distributed at the outlet have been measured as well as the pressures at the inlet, the outlet and two intermediate positions. These measurements were completed with visualisations using a high-speed camera.     

Dynamic response of the crossflow heat exchanger with finite wall capacitance

This paper shows how the transient response of a cross-flow heat exchanger with finite wall capacitance may be calculated by analytical method. Making usual idealizations for the analysis of dynamic behavior of the heat exchanger, the model is based on three local energy balance equations which are solved by using the Laplace transform method for step change of the primary fluid inlet temperature. The solutions are found in the case of constant initial conditions and expressed in the explicit analytical form used to find temperature distributions of both fluids and the wall as well as the mean mixed fluid temperatures at the exit. Presented solutions are valid in cases where fluid velocities are different or equal and finite or infinite, respectively.The solutions can be very suitable for mathematical modeling systems containing such types of heat exchangers.     

Numerical estimation of mixed convection heat transfer in vertical helically coiled tube heat exchangers

A numerical investigation of the mixed convection heat transfer from vertical helically coiled tubes in a cylindrical shell at various Reynolds and Rayleigh numbers, various coil‐to‐tube diameter ratios and non‐dimensional coil pitches was carried out. The particular difference in this study compared with other similar studies is the boundary conditions for the helical coil. Most studies focus on constant wall temperature or constant heat flux, whereas in this study it was a fluid‐to‐fluid heat exchanger. The purpose of this article is to assess the influence of the tube diameter, coil pitch and shell‐side mass flow rate on shell‐side heat transfer coefficient of the heat exchanger. Different characteristic lengths were used in the Nusselt number calculations to determine which length best fits the data and finally it has been shown that the normalized length of the shell‐side of the heat exchanger reasonably demonstrates the desired relation. Copyright © 2010 John Wiley & Sons, Ltd.     

Influence of the position and number of decay heat exchangers on the thermal hydraulics of a slab test facility A comparison of analytical and experimental data

To assess the capability of passive decay heat removal systems of an advanced pool-type liquid-metal cooled reactor, natural circulation experiments have been performed to investigate the in-vessel cooling modes caused by the position and number of decay heat exchangers in operation. The rather simple slab test facility AQUARIUS is equipped with an electrically heated core and decay heat exchangers. Four different arrangements of heat exchangers are under consideration to study the temperature distribution and the flow behavior in the apparatus during both symmetrical and asymmetrical heat removal. The experiments have been carried out in water under laminar flow conditions.

Temperatures have been measured under quasi-steady-state conditions. The observed flow paths have been documented photographically. In case of asymmetrical heat removal, especially when a single heat exchanger is operated in one of both upper plena, the temperature distribution and the flow behavior are different from symmetrical cooling modes. A comparison of analytically predicted temperatures using the COMMIX-2(V) computer program with experimental data shows reasonably matches the findings. The results of the numerically determined velocity fields are in good agreement with the visual observations.     

A study on the correlation between the thermal contact conductance and effective factors in fin–tube heat exchangers with 9.52 mm tube

The thermal contact resistance is a principal parameter interfering with heat transfer in a fin–tube heat exchanger. However, the thermal contact resistance in the interface between tubes and fins has not been clearly investigated. The objective of the present study is to examine the thermal contact conductance for various fin–tube heat exchangers with tube diameter of 9.52 mm and to find a correlation between the thermal contact conductance and effective factors such as expansion ratio, fin type, fin spacing and hydrophilic coating. In this study, experiments have been conducted only to measure heat transfer rate between hot and cold water. To minimize heat loss to the ambient air by the natural convection fin–tube heat exchangers have been placed in an insulated vacuum chamber. Also, a numerical scheme has been employed to calculate the thermal contact conductance with the experimental data. As a result, a new correlation including the influences of expansion ratio, slit of fin and fin coating has been introduced, and the portion of each thermal resistance has been estimated in the fin–tube heat exchangers with 9.52 mm tube.     

3D numerical simulation on fluid flow and heat transfer characteristics in multistage heat exchanger with slit fins

In this paper, a numerical investigation is performed for three-stage heat exchangers with plain plate fins and slit fins respectively, with a three-dimensional laminar conjugated model. The tubes are arranged in a staggered way, and heat conduction in fins is considered. In order to save the computer resource and speed up the numerical simulation, the numerical modeling is carried out stage by stage. In order to avoid the large pressure drop penalty in enhancing heat transfer, a slit fin is presented with the strip arrangement of “front coarse and rear dense” along the flow direction. The numerical simulation shows that, compared to the plain plate fin heat exchanger, the increase in the heat transfer in the slit fin heat exchanger is higher than that of the pressure drop, which proves the excellent performance of this slit fin. The fluid flow and heat transfer performance along the stages is also provided.