Experimental investigation of the reverse heat transfer of R134a flow through non-adiabatic coiled capillary tubes

This research represents an experimental investigation of the metastable flow and re-condensation phenomenon through non-adiabatic lateral helical capillary tubes and suction tube heat exchanger. The results show that mass flux ratio has a vital role: It affects metastable flow and also reverse heat transfer phenomenon through non-adiabatic helical capillary tube. Therefore, by increasing of the mass flux ratio, the rate of heat transfer between them decreases. In contrast to the strong rate condition of heat transfer between them, reverse heat transfer or re-condensation maybe happen. Moreover, experimental results show that for R134 flow with mass flux ratio more than 57.84, metastable flow exists in non-adiabatic capillary tube with 0.9144 mm inner diameter, 30 mm coil diameter, 6.18 m length, 4 mm inner diameter of compressor suction tube.

     

Formability evaluation of dimple forming process based on numerical and experimental approach

Exhaust gas recirculation (EGR) cooler consists of a number of heat transfer tubes that have relatively larger net area than that of flat type tubes. The surface of the tubes is made up with lots of grooves and protrusions for enlarging the net heat transfer area. Most tubes are manufactured through forming processes, such as bending, spinning, roll forming, stamping and so on. Therefore, a series of fracture or defect can occur during the various forming processes. In this study, the manufacturing process of a dimple-type rectangular heat transfer tube used for an EGR cooler system is investigated based on the numerical simulation and the experimental approach. A prototype of the tube is designed and modified to a newly designed tube considering the conservation of the net heat transfer area based on the numerical and analytical approach. Formability evaluation of the tube sheet is carried out by using forming limit curves based on the plastic instability conditions. Strain- and stress-based forming limit curves are utilized to ensure the strain path independence. The newly designed tube having a number of dimples on the both sides are manufactured by the press forming process. Thickness distributions for the principal cross-sections are observed from both the simulation and the experiment and compared each other. From the results, it is confirmed that the forming process is robust to manufacture the dimple type rectangular tubes with the comparison of thickness, and application of the forming limit curves.     

An experimental study on heat exchange effectiveness in the diesel engine EGR coolers

Both reducing nitrogen oxides (NOx) and particulate matter (PM) emissions from diesel engine and improving fuel consumption are important in meeting government regulations and society needs. Use of the Cooled Exhaust Gas Recirculation (EGR) system is one of the most effective techniques currently available for reducing NOx and PM emissions. However, the EGR system has a trade-off between NOx and PM emissions at high loads. In the present study, engine dynamometer experiments have been performed to investigate the heat exchange effectiveness of EGR coolers with shell & tube-type and stack-type. The results show that the heat transfer effectiveness of the stack-type EGR cooler is 25–50 % higher than that of the shell & tube type due to an increased surface area and a better mixing of the exhaust gas flow.     

Determination of deposit thickness in natural gas cooler based on the measurements of gas cooling degree

An original method for estimating fouled deposit thickness on the inside surfaces of natural gas cooler tubes is presented. This method does not require opening and inspecting a cooler as it is based on the measurement of gas cooling degree, i.e. the gas temperature difference between the cooler inlet and discharge. The deposit layer on the internal heat transfer surfaces is of semi-liquid consistency and its thermal conductivity coefficient has not been investigated until now. This paper describes the experimental determination of the deposit thermal conductivity coefficient. This parameter enables determination of a cooler’s performance as a function of current deposit thickness. Practical application of the method is illustrated in the case of CH_R cooler working in the KS01 compressor station in Vel’ké Kapušany, Slovakia. For this type of cooler, a diagram for deposit thickness as a function of the gas cooling degree is presented.     

A study of the fouling characteristics of EGR coolers in diesel engines

Diesel emission regulations have recently become more severe. An important goal in diesel engine research is the development of methods to reduce the emissions of NOx and PM (particulate matter). Cooled EGR (exhaust gas recirculation) system has been widely used to reduce the NOx and PM emissions of light-duty diesel engines. In this study, numerical analyses, rig tests and engine tests were performed to assess how changes in internal shape characteristics can improve the heat exchange efficiencies of EGR coolers. The heat exchange efficiencies of EGR coolers have been numerically and experimentally measured during a fouling process. The results show that the second type of oval EGR cooler tested (oval #2) exhibited better heat exchange efficiency than either the first type of oval EGR cooler was tested (oval #1) or the shell and tube cooler examined. The turbulence generated in exhaust gas flows by the wavy-finned design of the oval EGR coolers facilitated PM desorption that allows these coolers to self-purify. With respect to the two similar oval EGR coolers, the cooler with fin pitch 4 mm has better efficiency than the cooler with fin pitch 6 mm due to differences in the heat transfer areas of these coolers. Both CFD analyses involving extreme conditions of engine operation and engine fouling tests involving conditions experienced during vehicular operation indicate that the two oval coolers differed by less than 4% with respect to both initial heat transfer efficiency and heat transfer efficiency after a 78-hour fouling test.     

Experimental study on heat transfer characteristics of water-spray-bed heat exchanger

An experimental study was conducted on a water-spray-bed heat exchanger to investigate the heat transfer characteristics. A laboratory-scale test rig was built and its heat transfer characteristics were investigated with respect to various design and operation parameters such as the water spray flow rate, exhaust gas flow rate and number of tube rows. It was found that the implementation of the water spray increased the heat transfer rate to about 1.3 - 2.2 times that of a heat exchanger without water spray, although with a slight increase in the pressure loss. It was thus confirmed that the water spray was effective for enhancing condensing heat recovery from an exhaust gas.

     

天然气发动机EGR冷却器性能研究试验

基于发动机实际工况的EGR冷却器性能评估,探究水流量和EGR冷却器进水温度对EGR冷却器性能指标和可靠性指标的影响;探究不同结构EGR冷却器的性能差别.     

炼油厂钢管及其管道内部黑色沉积物的气相色谱-质谱分析

利用气相色谱 -质谱 ( GC/MS)技术和环境扫描电镜 ( ESEM)能谱分析 ,对炼油装置中发生管道“爆裂”的热交换器管道内部黑色沉积物进行了成分与来源分析。黑色沉积物含有碳、铁的氧化物、卤素、钾、镁、盐类和饱和脂肪烃。结果表明 :管道气体在炼制装置开停机的阶段 ,发生蒸汽冷凝沉积现象。沉积物与管道内壁发生化学反应 ,管壁受到严重腐蚀 ,使得热交换介质发生变化 ,不能再承受正常的应力负荷是发生爆裂的重要原因     

Determination of optimum winglet height of longitudinal vortex generators for the best thermo-hydraulic performance of compact heat exchangers

The effect of winglet height on the thermal-hydraulic performance of finned tube heat exchanger (FTHE) is investigated numerically. The rectangular winglet pairs (RWPs) having 5° attack angle are placed in common flow up (CFU) manner adjacent to the tubes for analysis. The air-side performance evaluation has been done based on the area goodness factor (j/f). The working fluid (air) is considered as incompressible fluid. Additionally, MOORA (multi objective optimization on the basis of ratio analysis) method is employed to get the best performance order of various configurations by taking Nusselt number (Nu) and area goodness factor (j/f) as beneficial attributes and friction factor (f) as a non-beneficial attribute having equal significances. The present study reveals that the rectangular vortex generators having 60 % of the channel height provides the better thermal hydraulic performance compared to the other considered cases.

     

An experimental study on the pressure drop and heat transfer through straight and curved small diameter tubes

A tube type heat exchanger is often the only solution when minimum pressure loss is a requirement. In addition, small diameter tubes are preferable because of an increased heat transfer area within an acceptable pressure loss limit. The present work reports on both an analytic model and experimental results with regards to the pressure drop and heat transfer characteristics of compact straight, C-curved, and U-curved tubes. The inner diameter of the tube (D) for our selected heat exchanger type was 1.26 mm with a thickness of 0.12 mm and a total length of 150.8 D. For the experiment, pressurized nitrogen gas bottles were used rather than an air compressor system in order to simplify the test facility. Hence the pressure conditions were easily set at 10, 30, and 50 bar corresponding to a range of Reynolds numbers from 10000 to 50000. To elevate the air temperature outside the tube (from 100°C to 400°C), an electric furnace was installed around the “test tube”. An analytic model to determine the pressure loss through curved tubes-referred to as the modified friction factor- is proposed. Good agreement was found between the modified friction factor and existing correlations, thus confirming the suitability of this model for determining pressure losses for different shape of tubes. The average measured Nusselt numbers were within 10- 15% of the Dittus-Boelter and Gnielinski correlations.     

Numerical investigations on swirl intensity decay rate for turbulent swirling flow in a fixed pipe

Due to the importance of predicting the SIDR¹ associated with engineering problems such as combustion chambers, draft tube of the Francis and Kaplan turbines, heat exchanger tubes, separators and so forth, in this research the trend of SIDR and its affecting factors, through a turbulent swirl decay pipe flow have been investigated. The swirling flow is created by means of a rotating honeycomb which produces solid body rotation at the inlet of a fixed pipe. First of all, turbulent swirling decay flow has been numerically surveyed using different flow conditions at the pipe inlet. The numerical results have been validated and compared with the existing experimental data and mathematical relations, showing satisfactory coincide. The obtained results show that, the SIDR depends mainly on the Reynolds number of the passing flow. On this basis, correlations have been proposed in order to improve the predictions of swirl intensity decay rate at upstream regions as well as those with high swirl intensity. In addition, conducted analyses demonstrates (analyses have been made to demonstrate) that the previous developed correlations for predicting swirl intensity decay rate, agree with those provided in this study only for regions far enough from downstream having the low swirl intensity. This implies that the swirl intensity decay rate should be a function of the type of swirl generator at the pipe inlet.     

An experimental study on accelerated fouling of aluminum oxide and ferric oxide particles in internally enhanced tubes

This paper describes the results of accelerated particulate fouling tests performed on three enhanced tubes and a plain tube. The tests were performed using ferric oxide and aluminum oxide as foulant materials. Three enhanced tubes included 25 start, 10 start helically ribbed tubes and a ripple tube. Effects of the water velocity (0.9 to 1.8 m/s) and foulant concentration (750 to 2500 ppm) were investigated. At 750 ppm, the enhanced tubes fouled almost the same as the plain tube for the entire velocity range tested (0.9 to 1.8 m/s). The enhanced tube fouled faster than the plain tube for cases of high concentration combined with low velocities. Of the three enhanced tubes, the 25 start helically ribbed tube fouled faster than the ripple and the 10 start helically ribbed tubes. One thing to be noted is that the fouling concentrations used in the tests are significantly higher than would be expected in commercial heat exchangers. Also, the velocity range investigated is lower than would be expected in heat exchanger operation.

     

Vertically installed Venturi tubes for wet-gas flow measurement: Possible improvements to ISO/TR 11583 to extend its range of applicability

Venturi tubes are commonly used for wet-gas flow measurement, and the majority of commercial wet-gas flow meters generally include a Venturi tube installed vertically with embedded secondary instrumentation. The presence of the liquid causes an increase in the measured differential pressure and results in the Venturi tube over-reading the actual amount of gas passing through the meter. Most of the research in the literature is focused on the investigation of the over-reading for horizontally oriented Venturi tubes, thus limiting the development of over-reading correlations for vertical installation. An experimental campaign was recently conducted at the TÜV SÜD National Engineering Laboratory (NEL) high-pressure wet-gas loop, where three Venturi tubes of the same nominal diameter (4”) but different throat to inlet diameter ratio (0.4, 0.6, 0.75) were tested, installed vertically after a blind tee. The results of this experimental campaign are presented in this paper and the effects of various parameters (line pressure, gas Froude number, diameter ratio) on the over-reading are briefly discussed. It is shown that the over-reading correlation included in the ISO/TR 11583:2012 and developed for horizontally oriented Venturis, is not applicable to vertically oriented Venturis. However, if modified, the correlation included in the ISO/TR 11583 is capable of meeting its stated uncertainty limits for the experimental data presented here for vertically installed Venturis.     

Convective heat transfer behaviour of water-ethylene glycol-mixture with silver nanoparticles under laminar flow conditions

In this work, we report the forced convective heat transfer performance and pressure drop of aqueous ethylene glycol seeded with silver nanoparticles for low temperature applications. Experiments were performed in a tube in tube counter-current heat exchanger using silver nanofluid as the hot fluid under laminar flow conditions. In this study, water-ethylene glycol mixture with 70:30 volume percent was used as the base medium. Silver nanofluid was allowed to flow through inner tube of the heat exchanger for varying nanofluid mass flow rates from 5 g/s to 30 g/s and three inlet temperatures of nanofluid viz. 2 °C, 5 °C and 10 °C. The increments in thermal diffusivity and viscosity are found to be ~37 % and ~69 % at 0.45 vol%, respectively. The enhancement in heat transfer coefficient at highest mass flow rate is found to be ~94 % for 0.45 vol%. The pressure drop in the silver nanofluid increases with respect to increase in volume percentage of nanoparticles due to increase in viscosity.

     

In Situ Lubrication with Boric Acid: Powder Delivery of an Environmentally Benign Solid Lubricant

In situ deposition of boric acid in dry powder form is investigated as a potential environmentally benign solid lubricant for sliding metal contacts. Boric acid is widely used in industrial processes and agriculture, is not classified as a pollutant by EPA, and produces no serious illnesses or carcinogenic effects from exposure to solutions or aerosols. In this study, boric acid powder is aerosolized and entrained in a low-velocity jet of nitrogen gas, which is directed at a self-mated 302 SS sliding contact in a rotating pin-on-disc tribometer. The effects of powder flow rate, sliding speed, normal load, and track diameter on coefficient of friction and wear rate are investigated. Friction coefficients below μ = 0.1 can be consistently reached and maintained as long as the powder flow continues. Wear rates are reduced over 2 orders of magnitude.     

Heat transfer in countercurrent gas-solid flow inside the vertical pipes

Heat transfer characteristics of the countercurrent gas-solid flow inside verical pipes has been investigated with the shell and tube type heat exchanger. Sand particles having the average particle diameter of 1.0 and 1.7mm were used. The effect of gas velocity and sand paticle flow rate on the heat transfer rate and the pressure drop were examined. At room temperatures, the predicted pressure drop agrees well with the experimental results when the larger sand particles are used. The results shows that there exists an optimum sand particle flow rate at which the heat transfer rate become maximum. The increase in the heat transfer coefficient due to sand particles was obtained up to 62%.     

CO_2气体冷却器的性能分析与试验研究

CO2气体冷却器的型式和换热效果对CO2跨临界循环的性能影响较大,有必要对其换热性能进行分析。通过对气体冷却器划分微元,建立了传热过程计算模型,用间接法计算了划分微元与不划分微元时CO2侧冷却换热系数,并与几个所选换热关联式的计算值进行了比较,结果发现划分微元时的值几乎都高于关联式计算值。综合分析选择了较合适的换热关联式,为系统及气体冷却器的模拟优化提供了依据。进而新建了CO2热泵实验台,对新气体冷却器的性能进行了测试和比较。结果表明,新CO2气体冷却器的性能比原换热器有了大幅提高。通过优化达到了改善换热器和系统性能的目的。     

Two-dimensional two-fluid model for air-oil wavy flow in horizontal tube

This study concerns the development of a two-dimensional two-fluid model for wavy flows in horizontal tubes. To deal with the curved walls of the liquid and gas phases and the gas-liquid interface simultaneously, the bipolar coordinate system was used. Experiments on air-oil mixture flow in horizontal tubes with diameters of 20 and 40 mm were conducted to observe wavy flow patterns accompanying the two-dimensional (2D) and Kelvin-Helmholtz (KH) waves and to measure the pressure gradient under different flow conditions. Two different previous correlations for the interfacial friction factor were employed in the model for predicting the wavy flows with 2D and KH waves. Predictions of the model of the liquid film height, the average values of wall shear stresses of each phase, and the average interfacial shear stress were compared for different diameters and different superficial gas and liquid Reynolds numbers. Also presented are detailed predictions of the model for four different flow conditions, including the local values of interfacial shear stress, wall shear stress of the liquid phase, interfacial friction factor, liquid film height, and two-dimensional velocity distribution in the liquid phase at the cross-section of the tube.

     

高温CO_2冷风机的数值计算

用分布参数法建立数学模型,对CO2冷风机在高温工况下进行仿真模拟计算。分析计算了管内制冷剂侧的传热特性,以及管间距与翅片间距对换热系数和压降的影响。结果表明,由于随着干度的增加,管内CO2流型不断发生变化,管内侧换热系数和压降也随之变化。在设计冷风机时,应综合考虑翅片间距与管间距对冷风机总换热系数及空气侧压降的影响。     

二氧化碳跨临界循环放热过程换热性能研究

二氧化碳跨临界循环放热过程处于超临界区，由于在准临界点附近CO2的热物理参数变化非常剧烈，超临界区流体的换热有别于传统制冷剂，气体冷却器的换热优劣对系统性能影响较大。为了能设计出高效的气体冷却器，应该对这一过程的换热性能作一全面了解。本文主要讨论了制冷剂CO2在气体冷却器中的换热特点，以及流体温度、高压侧压力、质量流速、热流密度、管径和含油量等因素对换热的影响，最后探讨了换热关联式和气体冷却器型式的研究进展。