Numerical simulations of heat transfer distribution of a two-pass square channel with V-rib turbulator and bleed holes

The blade tip region in gas turbine encounters high thermal loads due to temperature difference and hence efforts for high durability and safe operations are essential. Improved and robust methods of cooling are required to downgrade heat transfer rate to turbine blades. The blade tip regions, which are exposed to high gas flow, suffers high local thermal load which are due to external tip leakage. Jet impingement, pin cooling etc. are techniques used for cooling blades. A more usual way is to use serpentine passage with 180-degree turn. In this study, numerical simulation of heat transfer distribution of a two-pass square channel with rib turbulators and bleed holes were done. Periodical rib turbulators and bleed holes were used in the channel. The ribs arrangement were 60 degree V rib, 60 degree inverted V ribs, combination of 60 degree V rib at inlet and 60 inverted V rib at outlet section and combination of Inverted V at inlet and V rib at the outlet. The results were numerically computed using Fluent with Reynolds number of 12,500 and 28,500. Turbulence models used for computations were k-ω-SST and RSM. Temperature based and shear stress based techniques were used for heat transfer distribution prediction. The results for 60 degree V rib, 60 degree inverted V ribs were compared with the experimental results for validation of the results obtained. Detailed distribution shows distinctive peaks in heat transfer around bleed holes and rib turbulator. Comparisons of the overall performance of the models with different orientation of rib turbulator are presented. It is found that due to the combination of 60 degree inverted V rib in inlet and 60 V rib in outlet with bleed holes provides better heat treatment. It is suggested that the use of rib turbulator with bleed holes provides suitable for augmenting blade cooling to achieve an optimal balance between thermal and mechanical design requirements.     

Developing and fully developed turbulent flow in ribbed channels

Wall-mounted roughness features, such as ribs, are often placed along the walls of a channel to increase the convective surface area and to augment heat transfer and mixing by increasing turbulence. Depending on the relative roughness size and orientation, the ribs also have varying degrees of increased pressure losses. Designs that use ribs to promote heat transfer encompass the full range of having only a few streamwise ribs, which do not allow fully developed flow conditions, to multiple streamwise ribs, which do allow the flow to become fully developed. The majority of previous studies have focused on perturbing the geometry of the rib with little attention to the spatially and temporally varying flow characteristics and their dependence on the Reynolds number. A staggered rib-roughened channel study was performed using time-resolved digital particle image velocimetry (TRDPIV). Both the developing (entry region) and a fully developed region were interrogated for three Reynolds numbers of 2,500, 10,000, and 20,000. The results indicate that the flow was more sensitive to Reynolds number at the inlet than within the fully developed region. Despite having a similar mean-averaged flowfield structure over the full Reynolds number range investigated, the population and distribution of coherent structures and turbulent dissipation within the fully developed region were also found to be Reynolds number dependent. Exploring the time-accurate flow characteristics revealed that in addition to vortices shed from the rib shear layer, the region of the rib wake was governed by a periodic process of bursting of the wake vortices resulting in the intermittent ejection of the inter-rib recirculation region into the core flow. This periodic process was the driving mechanism resulting in mixing and heat transfer augmentation. A quadrant-splitting burst analysis was also performed to determine the characteristic frequency and duration of inter-rib bursting as well as the wake shedding frequency, both of which were determined to be Reynolds number dependent.     

Experimental study of heat transfer due to interaction of two separated flows of different scales

This paper describes an experimental study of heat transfer in a channel behind a backward-facing step in the presence of a disturbance in front of it in the form of a single rib in the range of the Reynolds numbers Re = 5000-15 000. The influence of the rib position and height on heat transfer intensity behind the backward-facing step is investigated. It is shown that reattachment of the flow disturbed by the obstacle intensifies the heat transfer on the surface behind the backward-facing step.     

Heat transfer and pressure drop measurements in rib-roughened rectangular ducts

In the present study, the thermal and hydraulic performance of three rib-roughened rectangular ducts is investigated. The aspect ratio of the ducts was 1 to 8, and the ribs were arranged staggered on the two wide walls. Three rib configurations were tested: parallel ribs and V-shaped ribs pointing upstream or downstream of the main flow direction. For all cases, the rib height-to-hydraulic diameter ratio was 0.06, with an attack angle of 60° and a pitch-to-height ratio of 10. The Reynolds number range was from 1000 to 6000. Liquid crystal thermography was employed in the heat transfer experiment to demonstrate detailed temperature distribution between a pair of ribs on the ribbed surfaces. The secondary flows caused by the inclined ribs create a significant spanwise variation of the heat transfer coefficients on the rib-roughened wall with high heat transfer coefficient at one end of the rib and low value at the other. In the streamwise direction between two consecutive ribs, the temperature distribution shows a sawtooth fashion because of flow reattachment. Based on the local heat transfer coefficients, the average Nusselt numbers were estimated as weighted mean values. Isothermal pressure drop data were taken and presented as Fanning friction factors. The ducts are compared to each other by considering both heat transfer and friction factor performance.     

Heat (mass) transfer and friction loss in two-pass ducts with various parallel rib arrangements

The present study investigated the effects of four parallel rib arrangements on heat/mass transfer and pressure drop characteristics in rotating two-pass ducts. The experiments of mass transfer and pressure measurement are performed to obtain heat transfer distributions and friction losses. The highest averaged heat (mass) transfer and friction loss in each region appeared in the turning region in the stationary cases, but appeared in the upstream region of the second pass in the rotating cases. Among the tested rib arrangements, the averaged heat (mass) transfer and the friction factor in the second pass in the stationary ducts were high in the cases with the NN- and PP-type ribs; however, in the rotating ducts, they were high in the cases with the NN- and PN-type ribs. The thermal performance in the four different rib arrangements was almost the same.     

Heat transfer and flow temperature measurements in a rotating triangular channel with various rib arrangements

In the present study, the regionally-averaged heat transfer coefficients and flow temperature distributions were measured in an equilateral triangular channel with three different rib arrangements (α = 45, 90 and 135°). To measure regionally-averaged heat transfer coefficients in the channel, two rows of copper blocks and a single heater were installed on two ribbed walls. The fluid temperature distributions were obtained using a thermocouple-array. The rotation number ranged from 0.0 to 0.1 with a fixed Reynolds number of 10,000. For the 90° ribs, the heat transfer coefficients on the pressure side surface were increased significantly with rotation, while the suction side surface had lower heat transfer coefficients than the stationary channel. For the angled ribs, rib-induced secondary flow dominated the heat transfer characteristics and high heat transfer rates were observed on the regions near the inner wall for the 45° angled ribs and near the leading edge for the 135° angled ribs.     

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.     

Experimental investigation of local heat transfer in a square duct with various-shaped ribs

In the present study, experimental studies are carried out to investigate the heat transfer and friction characteristics in a square duct roughened by various-shaped ribs on one wall. The ribs are oriented transversely to the main stream in a periodic arrangement. Liquid crystal thermography is employed to measure the local and average heat transfer coefficient on the ribbed surface. The rib height-to-duct hydraulic diameter ratio is fixed at 0.1; the rib pitch-to-height ratio varies from 8 to 15 and the test Reynolds number spans from 8,000 to 20,000. The results show that the trapezoidal-shaped ribs with decreasing height in the flow direction (case C) provide the highest heat transfer enhancement factor and are likely to be used to suppress the local hot spot which usually occurs in the region just behind the ribs.     

Thermal and friction characteristics of turbulent flow through rectangular and square ducts with transverse ribs and wire-coil inserts

The heat transfer and the pressure drop characteristics of turbulent flow of air through rectangular and square ducts with internal transverse rib turbulators on two opposite surfaces of the ducts and with wire-coil inserts have been studied experimentally. Circular duct has also been used. The transverse ribs in combination with wire-coil inserts have been found to perform better than either ribs or wire-coil inserts acting alone. The flow friction and thermal characteristics are governed by duct aspect ratio, coil helix angle and wire diameter of the coil, rib height and rib spacing, Reynolds number and Prandtl number. Correlations developed for friction factor and Nusselt number have predicted the experimental data satisfactorily. It has been found that on the basis of constant pumping power, up to 35% heat duty increase occurs for the combined ribs and wire-coil inserts case compared to the individual ribs and wire-coil inserts cases in the measured experimental parameters space. On the constant heat duty basis, the pumping power has been reduced up to 20% for the combined enhancement geometry than the individual enhancement geometries.     

Direct Numerical Simulation of Flow in a Ribbed Channel

The issue of turbine lifetime is an important one, particularly for modern turbines operating at high temperature regimes. A cooling design such as ribs may achieve an improved lifetime and complex mechanisms of heat transfer need to be well studied. In this paper, a Direct Numerical Simulation (DNS) is presented for a 3-D channel flow with two square ribs on the lower wall. The full unsteady compressible Navier-Stokes equations are solved with an original hybrid finite difference/finite element scheme. The Reynolds number of the simulation is 7 000 based on the bulk velocity at the inlet and the channel height. The present study is mainly devoted to understand the mechanism of heat transfer at the wall through the topological analysis of the flow and the temperature flux. Results show that the large-scale structures generated by obstacles splash onto the lower surface and induce longitudinal vortices which enhance heat transfer at the wall. A comprehensive data base including 56 correlations was set up for testing and improving turbulence models for this complex, separated flow.     

Experimental study of flow and heat transfer in rib-roughened rectangular channels

Secondary flow patterns, pressure drop and heat transfer in rib-roughened rectangular channels have been investigated. The aspect ratio of the channels is 1–8, and ribs are attached to the wide channel walls in order to set up swirling motions. The geometries tested consist of channels having cross ribs, parallel ribs, cross V-ribs, parallel V-ribs, and multiple V-ribs (Swirl Flow Tube). The flow patterns were investigated using smoke wire visualization and LDV measurements. The smoke wire experiments have been performed at Re=1100 and the LDV measurements at Re=3000 at periodic fully developed conditions. The heat transfer and pressure drop are described by j and f factors for Reynolds numbers from 500 to 15 000. The distributions of axial mean velocity and turbulent fluctuations are strongly influenced by the secondary flows. Large mean velocities and small fluctuations are found in regions where the secondary flow is directed towards a surface, while small mean velocities and large fluctuations are found in regions where the secondary flow is directed away from a surface. The Swirl Flow Tube provides a significant increase in the j factor at Reynolds numbers from 1000 to 2000, but unfortunately also an increase in the f factor. At higher Reynolds numbers, the j and f factors of the Swirl Flow Tube are of the same order of magnitude as for the other rib-roughened channels. It is found that the flow direction in a channel with parallel V-ribs has important influence on the j/f ratio. At Reynolds numbers above 4000, this channel provides the highest j/f ratio if the V-ribs are pointing upstream; while it provides the lowest j/f ratio of all rib configurations, if the V-ribs are pointing downstream.     

Heat/mass transfer and pressure drop in a triangular-rib-roughened rectangular channel

In this paper, the heat/mass transfer analogy was used to investigate the heat transfer and pressure drop in a square channel with triangular ribs on its two opposite walls. Reynolds number varied from 1 × 10⁴ to 7 × 10⁴; the dimensionless heights of the triangular ribs H/W were 0.04, 0.07, and 0.1; and their dimensionless pitches S/W were 0.45, 0.63, 1.0, 1.37, 1.55, and 2.1. Experimental results showed that the heat transfer coefficients of the wall with triangular rib were about 1 to 2.3 times larger than those of a smooth-channel wall, and the pressure drops along this roughened channel were about 1 to 10 times larger than those for a smooth channel. Correlations of heat transfer and pressure drop were obtained, which are useful for practical designs.     

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.     

Optimization of a buoyancy chimney with a heated ribbed wall

Heat and mass transfer in natural convection vertical channels was investigated by means of two-dimensional CFD simulations aided by optimization algorithms. The channel was immersed in air, enclosed between an adiabatic smooth wall and an isothermally heated ribbed wall. The ribs were perpendicular to the fluid flow and their height, width, pitch, thermal conductivity and lateral wall inclination were variable. Also the smooth heated wall channel was studied and compared with the ribbed one. The existence of an optimal channel width for a given channel height and rib geometry was shown. A sensitivity analysis was carried out for the ribbed and the smooth channels. Optimization was applied to the ribbed channel problem in order to maximize the heat and the mass transfer through a multi-objective genetic algorithm. It was found that the presence of the ribs penalizes the channel performance so that no ribbed channel over-performed the smooth one.     

Heat/Mass transfer in a two-pass rotating rectangular duct with and without 70°-angled ribs

The present study investigates convective heat/mass transfer and flow characteristics inside a cooling passage of rotating gas-turbine blades. The rotating duct with and without rib turbulators are used. The ribs of 70° attack angle are attached on leading and trailing surfaces in a staggered arrangement. A naphthalene sublimation technique is employed to determine detailed local heat transfer coefficients using the heat and mass transfer analogy. Additional numerical calculations are conducted to analyze the flow patterns in the cooling. The local heat/mass transfer and the flow pattern in the passage are changed significantly according to rib configurations, duct turning geometry and duct rotation speed. The results show that the duct rotation generates the heat transfer discrepancy between the leading and trailing walls due to the secondary flows induced by the Coriolis force. The heat/mass transfer on the ribbed duct shows 80% higher than the smooth duct because the ribs attached on the walls disturb the mainflow resulting in recirculation and secondary flows near the rib with the secondary flow generated by rotation. The overall heat transfer pattern on the leading and trailing walls for the first and second passes depend on the rotating speed and the turning geometry, but the local heat transfer trend is affected mainly by the rib arrangeements.     

Thermal and friction characteristics of laminar flow through rectangular and square ducts with transverse ribs and wire coil inserts

The heat transfer and the pressure drop characteristics of laminar flow of viscous oil (195 < Pr < 525) through rectangular and square ducts with internal transverse rib turbulators on two opposite surfaces of the ducts and with wire coil inserts have been studied experimentally. Circular duct has also been used. The transverse ribs in combination with wire coil inserts have been found to perform better than either ribs or wire coil inserts acting alone. The heat transfer and the pressure drop measurements have been taken in separate test sections. Heat transfer tests were carried out in electrically heated stainless steel ducts incorporating uniform wall heat flux boundary conditions. Pressure drop tests were carried out in acrylic ducts. The flow friction and thermal characteristics are governed by duct aspect ratio, coil helix angle and wire diameter of the coil, rib height and rib spacing, Reynolds number and Prandtl number. Correlations developed for friction factor and Nusselt number have predicted the experimental data satisfactorily. The performance of the geometry under investigation has been evaluated. It has been found that on the basis of constant pumping power, up to fifty per cent heat duty increase occurs for the combined ribs and wire coil inserts case compared to the individual ribs and wire coil inserts cases in the measured experimental parameters space. On the constant heat duty basis, the pumping power has been reduced up to forty per cent for the combined enhancement geometry than the individual enhancement geometries.     

Effects of cross ribs on heat/mass transfer in a two-pass rotating duct

Two-pass internal cooling passage with rib turbulators has been investigated for convective heat/mass transfer under rotating conditions. The flow and heat transfer characteristics in the cooling passage are very complicated so that it is required the detail analysis to design more efficient gas turbine blades. A naphthalene sublimation technique is employed to determine detailed local heat transfer coefficients using the heat and mass transfer analogy. The local heat/mass transfer and flow pattern in the cooling passage are changed significantly according to rib configurations, duct turning geometries and duct rotation speeds. Four different rib configurations are investigated to obtain the combined effects of the angled rib, duct turning and rotation. The results show that the duct rotation generates the heat/mass transfer discrepancy between the leading and trailing walls due to the secondary flows induced by the Coriolis force. The angled ribs generate a single rotating secondary flow with the cross-rib arrangement and the duct turning makes a strong Dean-type vortex. These vortices affect significantly the heat/mass transfer on the duct wall. The overall heat transfer pattern on the leading and trailing surfaces for the first and second passes are dependent on the duct rotation, but the local heat transfer trend is affected mainly by the rib arrangements. In addition, the present study observes the rotating effect in the two-pass smooth duct to obtain the baseline data in comparison with the ribbed duct for various rib arrangements.     

On flow structure, heat transfer and pressure drop in varying aspect ratio two-pass rectangular channel with ribs at 45°

To increase the thermal efficiency of gas turbines, inlet temperature of gas is increased. This results in the requirement of cooling of gas turbine blades and vanes. Internal cooling of gas turbine blades and vanes is one of several options. Two-pass channels are provided with ribs to enhance heat transfer at the expense of an increased pressure drop. The space in the blade is limited and requires channels with small aspect ratios. Numerical simulations have been performed to investigate heat transfer, flow field and pressure loss in a two-pass channel equipped with 45° ribs with aspect ratio (W_in/H) equal to 1:3 in the inlet pass and 1:1 in the outlet pass with both connected together with a 180° bend. The results are compared with a higher aspect ratio channel (W_in/H = 1:2, inlet pass). In the ribbed channel, a decrease in pressure drop was observed with a decrease in the aspect ratio of the channel. The smaller aspect ratio channel not only allows using more cooling channels in the blade, but also results in more heat transfer enhancement. The divider-to-tip wall distance (W_el) has influence on the pressure drop, as well as on the heat transfer enhancement at the bend and outlet pass. Heat transfer decreases with decrease in aspect ratio of the inlet pass of the two-pass channel. With increase in divider-to-tip wall distance, heat transfer tries to attain a constant value.     

Shape optimization of staggered ribs in a rotating equilateral triangular cooling channel

A rotating equilateral triangular cooling channel with staggered square ribs inside the leading edge of a turbine blade has been optimized in this work based on surrogate modeling. The fluid flow and heat transfer in the channel have been analyzed using three-dimensional Reynolds-averaged Navier–Stokes (RANS) equations under uniform heat flux condition. Shear stress transport turbulence model has been used as a turbulence closure. Computational results for area-averaged Nusselt number have been validated compared to the experimental data. The objectives related to the heat transfer rate and pressure drop has been linearly combined with a weighting factor to define the objective function. The angle of the rib, the rib pitch-to-hydraulic diameter ratio, and the rib width-to-hydraulic diameter ratio have been selected as the design variables. Twenty-two design points have been generated by Latin Hypercube sampling, and the values of the objective function have been calculated by the RANS analysis at these points. The surrogate model for the objective function has been constructed using the radial basis neural network method. Through the optimization, the objective function value has been improved by 21.5 % compared to that of the reference geometry.     

An experimental investigation of heat transfer characteristics for turbulent flow over staggered ribs in a square duct

An experimental study of developing and fully developed turbulent air flow in a square duct with two opposite rib-roughened walls in which the ribs are attached in a staggered fashion was conducted to determine the heat transfer characteristics. The rib height-to-hydraulic diameter ratio (e/D_H) was 0.19, the rib pitch-to-height ratio (p/e) was 5.31. The streamwise temperature distribution was measured, and a law of the wall for the thermal boundary layer at each free-stream turbulence level was obtained. The effects of free-stream turbulence intensity with variations of 4–11% on heat transfer coefficients were also examined. Finally, the relationship between Nusselt number and Reynolds number was correlated. The results might be used in the design of turbine blade cooling channels.