Heat Transfer and Entropy Generation Analysis of an Intermediate Heat Exchanger in ADS

The intermediate heat exchanger for enhancement heat transfer is the important equipment in the usage of nuclear energy. In the present work, heat transfer and entropy generation of an intermediate heat exchanger (IHX) in the accelerator driven subcritical system (ADS) are investigated experimentally. The variation of entropy generation number with performance parameters of the IHX is analyzed, and effects of inlet conditions of the IHX on entropy generation number and heat transfer are discussed. Compared with the results at two working conditions of the constant mass flow rates of liquid lead-bismuth eutectic (LBE) and helium gas, the total pumping power all tends to reduce with the decreasing entropy generation number, but the variations of the effectiveness, number of transfer units and thermal capacity rate ratio are inconsistent, and need to analyze respectively. With the increasing inlet mass flow rate or LBE inlet temperature, the entropy generation number increases and the heat transfer is enhanced, while the opposite trend occurs with the increasing helium gas inlet temperature. The further study is necessary for obtaining the optimized operation parameters of the IHX to minimize entropy generation and enhance heat transfer.     

Conflation of ε-Ntu and EGM design methods for heat exchangers with uniform wall temperature

This paper conflates two heat exchanger design approaches – the ε-N_tu (effectiveness–number of transfer units) and the EGM (entropy generation minimization) – focusing on heat exchangers with uniform wall temperature, i.e. condensers and evaporators. An algebraic formulation which expresses the dimensionless rate of entropy generation as a function of the heat exchanger geometry (number of transfer units), the thermal-hydraulic characteristics (friction factor and Colburn j-factor), and the operating conditions (heat transfer duty, core velocity, surface temperature, and fluid properties) is derived. It is shown that there does exist a particular number of transfer units which minimizes the dimensionless rate of entropy generation. An algebraic expression for the optimum heat exchanger effectiveness, based on the working conditions, heat exchanger geometry and fluid properties, is also presented. The theoretical analysis led to the conclusion that a high effectiveness heat exchanger design does not necessarily provide the best thermal-hydraulic performance.     

Exergetic Optimization of Shell-and-Tube Heat Exchangers Using NSGA-II

In this article, a multi-objective exergy-based optimization through a genetic algorithm method is conducted to study and improve the performance of shell-and-tube type heat recovery heat exchangers, by considering two key parameters, such as exergy efficiency and cost. The total cost includes the capital investment for equipment (heat exchanger surface area) and operating cost (energy expenditures related to pumping). The design parameters of this study are chosen as tube arrangement, tube diameters, tube pitch ratio, tube length, tube number, baffle spacing ratio, and baffle cut ratio. In addition, for optimal design of a shell-and-tube heat exchanger, the method and Bell–Delaware procedure are followed to estimate its pressure drop and heat transfer coefficient. A fast and elitist nondominated sorting genetic algorithm (NSGA-II) with continuous and discrete variables is applied to obtain maximum exergy efficiency with minimum exergy destruction and minimum total cost as two objective functions. The results of optimal designs are a set of multiple optimum solutions, called “Pareto optimal solutions.” The results clearly reveal the conflict between two objective functions and also any geometrical changes that increase the exergy efficiency (decrease the exergy destruction) lead to an increase in the total cost and vice versa. In addition, optimization of the heat exchanger based on exergy analysis revealed that irreversibility like pressure drop and high temperature differences between the hot and cold stream play a key role in exergy destruction. Therefore, increasing the component efficiency of a shell-and-tube heat exchanger increases the cost of heat exchanger. Finally, the sensitivity analysis of change in optimum exergy efficiency, exergy destruction, and total cost with change in decision variables of the shell-and-tube heat exchanger is also performed.     

Optimal design analysis of a tubular heat exchanger network with extended surfaces using multi-objective constructal optimization

The present work aims to investigate the influence of extended surfaces (fins) on the multi-objective optimization of a tubular heat exchanger network (THEN). An increase in the heat transfer area using various extended surfaces (fins) to enhance the performance of the heat exchanger was used while considering the effectiveness and total heat transfer area as two objective functions. In addition to the simulation of simple fins, a new set of fins, called constructal fins, was designed based on the constructal theory. Tubular heat exchanger network design parameters were chosen as optimization variables, and optimization results were achieved in such a way as to enhance the effectiveness and decrease the total heat transfer area. The results show the importance of constructal fins in improving the objective functions of heat exchangers. For instance, the simple fins case enhances the effectiveness by up to 5.3% compared to that without fins (usual heat exchanger) while using constructal fins, in addition to the 7% increment of effectiveness, reduces the total heat transfer area by 9.47%. In order to optimize the heat exchanger, the heat transfer rate and cold fluid temperature must increase, and at the same time, the hot exiting fluid temperature should decrease at the same constant total heat transfer area, which is higher in the constructal fins case. Finally, optimized design variables were studied for different cases, and the effects of various fins were reported.     

Design and optimization of a downhole coaxial heat exchanger for an enhanced geothermal system (EGS)

The present study considers the design, performance analysis and optimization of a downhole coaxial heat exchanger for an enhanced geothermal system (EGS). The optimum mass flow rate of the geothermal fluid for minimum pumping power and maximum extracted heat energy was determined. In addition, the coaxial pipes of the downhole heat exchanger were sized based on the optimum geothermal mass flow rate and steady-state operation. Transient effect or time-dependent cooling of the Earth underground, and the optimum amount and size of perforations at the inner pipe entrance region to regulate the flow of the geothermal fluid were disregarded to simplify the analysis. The paper consists of an analytical and numerical thermodynamic optimization of a downhole coaxial heat exchanger used to extract the maximum possible energy from the Earth's deep underground (2 km and deeper below the surface) for direct usage, and subject to a nearly linear increase in geothermal gradient with depth. The thermodynamic optimization process and entropy generation minimization (EGM) analysis were performed to minimize heat transfer and fluid friction irreversibilities. An optimum diameter ratio of the coaxial pipes for minimum pressure drop in both limits of the fully turbulent and laminar fully-developed flow regime was determined and observed to be nearly the same irrespective of the flow regime. Furthermore, an optimum geothermal mass flow rate and an optimum geometry of the downhole coaxial heat exchanger were determined for maximum net power output. Conducting an energetic and exergetic analysis to evaluate the performance of binary power cycle, higher Earth's temperature gradient and lower geofluid rejection temperatures were observed to yield maximum first- and second-law efficiencies.     

Entropy generation and pumping power in a turbulent fluid flow through a smooth pipe subjected to constant heat flux

In a heat exchange process, heat transfer and pumping power requirements are the two main considerations. Efforts made to increase heat transfer in a fluid flow usually cause increase in the pumping power requirement. In an effort to avoid inefficient utilization of energy through excessive entropy generation, a thermodynamic analysis of turbulent fluid flow through a smooth duct subjected to constant heat flux has been made in this study. The temperature dependence of the viscosity was taken into consideration in determining the heat transfer coefficient and friction factor. It was shown that the viscosity variation has a considerable effect on both the entropy generation and the pumping power. Pumping power to heat transfer ratio and the entropy generation per unit heat transfer can become very large especially for low heat flux conditions.     

Numerical Analysis of a Small Size Baffled Shell-and-Tube Heat Exchanger Using Different Nano-Fluids

In this study, numerical simulation was used to investigate the effect of adding different nano-particles into the fluid on the performance of a baffled shell-and-tube heat exchanger. A three-dimensional modeling approach was followed to analyze the effect of different nano-fluids, at various volume fractions, as applied in a baffled shell-and-tube heat exchanger. Once finished with validating the grid independency and results, we proceeded to obtain heat transfer rate, pressure drop, outlet shell temperature and exchanger effectiveness for different volume fractions and particle size of different nano-fluids. The studied nano-particles in the present work included Al₂O₃, CuO, Fe₂O₃, Cu, Fe, SiO₂, and Au, with water and ethylene glycol employed as base fluids. With constant mass flow rate for all cases, the results indicated that, the addition of nano-particles had reduced the heat transfer coefficient, pressure drop and the rate of heat transfer through the shell, even though it had increased outlet shell temperature. In other words, considering a constant heat transfer rate, the presence of nano-fluids in a baffled shell-and-tube heat exchanger is likely to be associated with increased outlet shell temperature. Another consequence presents that using ethylene glycol as base fluid leads to higher effectiveness compared with water as a base fluid in exchanger.     

Energetic and Exergetic Performances of Plate Heat Exchanger Using Brine-Based Hybrid Nanofluid for Milk Chilling Application

Abstract

Theoretical study on the energetic and exergetic performances of a counter-flow corrugated plate heat exchanger using hybrid nanofluids for the milk chilling application has been done in the present investigation. Magnesia-silver and Alumina-silver nanoparticles have been dispersed in the ethylene glycol–water mixture and propylene glycol–water mixture (20:80 brine solutions) with different particle volume concentration separately. Effect of particle volume concentration and flow rate of the hybrid nanofluid on the heat transfer rate, convective, and overall heat transfer coefficients, mass flow rate of milk, pressure drop, pumping power, entropy generation rate, second law efficiency, irreversibility, irreversibility distribution ratio, non-dimensional exergy (NDE) destruction, and performance index have been studied. It has been observed that heat transfer rate, convective and overall heat transfer coefficients, pressure drop, pumping power, irreversibility, entropy generation rate, second law efficiency, and milk flow rate increase; while NDE destruction, performance index, and irreversibility distribution ratio decrease with the hybrid nanofluid flow rate and the volume concentration of the nanofluid. Within studied ranges, the hybrid nanofluid yields the maximum improvement of heat transfer rate and convective heat transfer coefficient of about 1.6% and 9.4%, respectively, compared to base fluid. It has also been found that silver?+?alumina shows slightly better performance improvement and hence hybrid nanofluid is recommended as a suitable alternative for the milk chilling units.     

Design optimization of shell-and-tube heat exchanger using particle swarm optimization technique

Shell-and-tube heat exchangers (STHEs) are the most common type of heat exchangers that find widespread use in numerous industrial applications. Cost minimization of these heat exchangers is a key objective for both designer and users. Heat exchanger design involves complex processes, including selection of geometrical parameters and operating parameters. The traditional design approach for shell-and-tube heat exchangers involves rating a large number of different exchanger geometries to identify those that satisfy a given heat duty and a set of geometric and operational constraints. However, this approach is time-consuming and does not assure an optimal solution. Hence the present study explores the use of a non-traditional optimization technique; called particle swarm optimization (PSO), for design optimization of shell-and-tube heat exchangers from economic view point. Minimization of total annual cost is considered as an objective function. Three design variables such as shell internal diameter, outer tube diameter and baffle spacing are considered for optimization. Two tube layouts viz. triangle and square are also considered for optimization. Four different case studies are presented to demonstrate the effectiveness and accuracy of the proposed algorithm. The results of optimization using PSO technique are compared with those obtained by using genetic algorithm (GA).     

Entropy generation and Carnot efficiency comparisons of high temperature heat transfer fluid candidates for CSP plants

Heat transfer fluid is a critical component in a concentrating solar power plant. A large quantity of heat transfer fluid is required to transfer heat between the solar collector and the power block, thus it is crucial to select the most appropriate heat transfer fluid in order to maximize the system performance. The present study compared the performances of five molten-salt eutectic mixtures in regarding with the entropy generation rate and the Carnot efficiency of using them as heat transfer fluids. All the five molten-salt eutectic mixtures have thermal stability temperatures above 600 °C. Effects of the tube lengths in the steam generation heat exchanger and the receiver heat exchanger as well as the heat transfer fluid flow rate on both the entropy generation rate and the Carnot cycle efficiency were investigated. The results indicate that the carbonate salts has the worst performances compared to the other eutectic mixtures. The three chloride salts have slightly higher entropy generation rate and 5% higher Carnot efficiency than the Solar Salt. Therefore the three chloride salts are suggested to be used in advanced concentrating solar power tower plants as potential high temperature heat transfer fluids.     

Multiobjective thermo‐economic and thermodynamics optimization of a plate–fin heat exchanger

In the present work, a multiobjective heat transfer search (MOHTS) algorithm is proposed and investigated for thermo‐economic and thermodynamic optimization of a plate–fin heat exchanger (PFHX). Heat exchanger effectiveness and total annual cost (TAC) are considered as thermo‐economic objective functions. Similarly, entropy generation rate and heat exchanger effectiveness are considered as thermodynamic objective functions. Six design variables including flow length of cold and hot streams, no flow length, fin height, fin pitch, and fin offset length are considered as decision variables. Effectiveness and accuracy of the proposed algorithm are evaluated by analyzing application examples of a PFHX. The results obtained using the proposed algorithm for thermo‐economic considerations are compared with the available results of NSGA‐II and TLBO in the literature. Results show that 3.56% to 10.29% reductions in TAC with 0.48% to 0.81% higher effectiveness are observed using the proposed approach compared to TLBO and NSGA‐II approaches. Additionally, the distribution of each design variable in its allowable range is also shown for thermo‐economic consideration to identify the level of conflict on objective functions. The sensitivity analyses of design variables on the objective functions value are also performed in detail.     

Second law analysis and heat transfer in a cross-flow heat exchanger with a new winglet-type vortex generator

In this paper a second law analysis of a cross-flow heat exchanger (HX) is studied in the presence of a balance between the entropy generation due to heat transfer and fluid friction. The entropy generation in a cross-flow HX with a new winglet-type convergent–divergent longitudinal vortex generator (CDLVG) is investigated. Optimization of HX channel geometry and effect of design parameters regarding the overall system performance are presented. For the HX flow lengths and CDLVGs the optimization model was developed on the basis of the entropy generation minimization (EGM). It was found that increasing the cross-flow fluid velocity enhances the heat transfer rate and reduces the heat transfer irreversibility. The test results demonstrate that the CDLVGs are potential candidate procedure to improve the disorderly mixing in channel flows of the cross-flow type HX for large values of the Reynolds number.     

Effect of nanoparticle shape on the heat transfer and thermodynamic performance of a shell and tube heat exchanger

Nanofluid is a heat transfer fluid that can improve the performance of heat exchanger systems. Different parameters such as particle size, shape, and volume concentration affect the performance of these systems. The objective of this paper is to study the effect of different nanoparticle shapes (such as cylindrical, bricks, blades, platelets, and spherical) on the performance of a shell and tube heat exchanger operating with nanofluid analytically. Boehmite alumina (γ-AlOOH) nanoparticles of different shapes were dispersed in a mixture of water/ethylene glycol as the nanofluid. The thermodynamic performance of the shell and tube heat exchanger that is used in a waste heat recovery system was analysed in terms of heat transfer rate and entropy generation. Established correlations were used to measure the thermal conductivity, heat transfer coefficient and rate and entropy generation of nanofluid. The results show an increase in both the heat transfer and thermodynamic performance of the system. However, among the five nanoparticle shapes, cylindrical shape exhibited better heat transfer characteristics and heat transfer rate. On the other hand, entropy generation for nanofluids containing cylindrical shaped nanoparticles was higher in comparison with the other nanoparticle shapes. However, the increased percentage of entropy was below 1%. Therefore, this greater entropy generation could be deemed negligible and cylindrical shaped nanoparticles are recommended to be utilized in heat exchanger systems working with nanofluids.     

Optimization for a heat exchanger couple based on the minimum thermal resistance principle

Following the brief introduction to the concept of a physical quantity, entransy, the equivalent thermal resistance of a heat exchanger couple is defined based on the entransy dissipation. The minimum thermal resistance principle is applied to obtain the optimal heat capacity rate of the medium fluid and the optimal allocation of heat exchangers thermal conductance, which correspond to the maximum heat transfer rate in the heat exchanger couple. In addition, analytical expression for the optimal heat capacity rate of the medium fluid is derived, whose reciprocal equals the sum of the reciprocal of the individual heat capacity rate of the hot and cold fluids, just like the case of two electrical capacitors in series. Numerical results in the variation of the thermal resistance and the heat transfer rate with the medium fluid heat capacity rate or the thermal conductance allocation agree with the theoretical analyses. Finally, for comparison, the entropy generation rate is also calculated to obtain its relation with the thermal performance of the heat exchanger couple. The results show that there is no one-to-one correspondence of the minimum entropy generation rate and the maximum heat transfer rate. This indicates that the minimum entropy generation principle cannot be used for optimizing the heat exchanger couple.     

Different Strategies to Improve Industrial Heat Exchange

A variety of different strategies are available to process and equipment designers to improve industrial heat transfer. These range from the use of efficient forms of individual heat exchangers to the optimum utilization of the individual units in a network, generally referred to as "process integration." This article attempts to review these strategies with reference to the conventional and more recent forms of shell-and-tube heat exchangers. In the context of a heat exchanger network, process heat transfer intensification ( global intensification ), i.e., network design for maximum energy recovery, is a first important step. This needs to be then combined with heat transfer intensification in individual units/shells ( local intensification ). The benefits of global and local intensification are illustrated with examples of a helically baffled heat exchanger ( Helixchanger ), as a representative of a more recent form of shell-and-tube exchanger. Some aspects concerning the use of multistream heat exchangers are discussed, and finally, an example for optimization of a plate-type heat exchanger is presented.     

The application of field synergy number in shell-and-tube heat exchanger optimization design

In the present work the field synergy principle is applied to the optimization design of the shell-and-tube heat exchanger with segmental baffles. The field synergy number which is defined as the indicator of the synergy between the velocity field and the heat flow is taken as the objective function. The genetic algorithm is employed to solve the heat exchanger optimization problems with multiple design variables. The field synergy number maximization approach for heat exchanger optimization design is thus formulated. In comparison with the initial design, the optimal design leads to a significant cost cut on the one hand and an improvement of the heat exchanger performance on the other hand. The comparison with the traditional heat exchanger optimization design approach with the total cost as the objective function shows that the field synergy number maximization approach is more advantageous.     

Influence of nanofluids on parallel flow square microchannel heat exchanger performance

The effects of using various types of nanofluids and Reynolds numbers on heat transfer and fluid flow characteristics in a square shaped microchannel heat exchanger (MCHE) is numerically investigated in this study. The performance of an aluminum MCHE with four different types of nanofluids (aluminum oxide (Al₂O₃), silicon dioxide (SiO₂), silver (Ag), and titanium dioxide (TiO₂)), with three different nanoparticle volume fractions of 2%, 5% and 10% using water as base fluid is comprehensively analyzed. The three-dimensional steady, laminar developing flow and conjugate heat transfer governing equations of a balanced MCHE are solved using the finite volume method. The MCHE performance is evaluated in terms of temperature profile, heat transfer rate, heat transfer coefficient, pressure drop, wall shear stress pumping power, effectiveness, and overall performance index. The results reveal that nanofluids can enhance the thermal properties and performance of the heat exchanger while having a slight increase in pressure drop. It was also found that increasing the Reynolds number causes the pumping power to increase and the effectiveness to decrease.     

Performance analysis of finned tube and unbaffled shell-and-tube heat exchangers

This work considers an optimum design problem for the different constraints involved in the designing of a shell-and-tube heat exchanger consisting of longitudinally finned tubes. A Matlab simulation has been employed using the Kern's method of design of extended surface heat exchanger to determine the behavior on varying the values of the constraints and studying the overall behavior of the heat exchanger with their variation for both cases of triangular and square pitch arrangements, along with the values of pressure drop. It was found out that an optimum fin height existed for particular values of shell and tube diameters when the heat transfer rate was the maximum. Moreover it was found out that the optimum fin height increased linearly with the increase in tube outer diameter. Further studies were also performed with the variation of other important heat exchanger design features and their effects were studied on the behavior of overall performance of the shell-and-tube heat exchanger. The results were thereby summarized which would proclaim to the best performance of the heat exchanger and therefore capable of giving a good idea to the designer about the dimensional characteristics to be used for designing of a particular shell and tube heat exchanger.     

Performance Evaluation of Some Tube Inserts as Heat Transfer Enhancement Techniques

Different heat transfer enhancement techniques can be used successfully in the retrofit design of shell-and-tube heat exchangers that can lead to significant cost savings. Tube inserts are frequently used in such applications. Twisted tapes, wire coils, helically coiled ribbons (as tube inserts in smooth pipes), and rifled pipes have been evaluated as heat transfer enhancement techniques. To assess the benefit of using these kinds of techniques, extended performance evaluation criteria (PEC) have been implemented under different constraints. The decrease in entropy generation can be combined with the relative increase in the heat transfer rate or decrease of the heat transfer area to determine the geometrical parameters of the tubes for optimal thermodynamics performance.     

Application of EoEP principle with variable heat transfer coefficient in minimizing entropy production in heat exchangers

A more realistic application of the entropy minimization principle EoEP is presented. This principle dictates uniform local entropy generations along the heat exchanger in order to minimize the total entropy generation rate due only to heat transfer. For a certain heat duty and area of an existing exchanger, this is done by changing the temperatures of one fluid while the temperatures of the other fluid are held constant. Since the heat duty is fixed, the change in the temperatures of the fluid after the change, however, may sometimes cause a drastic change in its flow rate. This may cause considerable changes in the overall heat transfer coefficient (U) and, consequently, in the entropy generation rate. Depending on the choice of the fluid for changing, the new entropy generation rates may be higher or lower than those based on constant U as is the case in papers recently published. So, the classical application of the EoEP principle needs to be modified to achieve more realistic entropy generation rates. In this study, the principle of EoEP with variable U is applied to some cases of heat exchange, and a simple method is presented as a criterion for the proper choice of the fluid to be changed.