Laminar flow and heat transfer in a periodic serpentine channel with semi-circular cross-section

Computational fluid dynamics (CFD) has been used to study fully developed laminar flow and heat transfer behaviour in periodic serpentine channels with a semi-circular cross-section. The serpentine elements are characterised by their wavelength (2L), channel diameter (d) and radius of curvature of bends (R_c), with results reported for Reynolds numbers (Re) up to 450, as well as for a range of geometric configurations (3 < L/d < 12.5, 0.525 < R_c/d < 2.25) at Re = 110. The flow in these channels is characterised by the formation of Dean vortices following each bend. As the Reynolds number is increased, more complex vortical flow patterns emerge and the flow domain becomes increasingly dominated by these vortices. Alignment of flow with vorticity leads to efficient fluid mixing and high rates of heat transfer.Constant wall heat flux (H2) and constant wall temperature (T) boundary conditions and a range of fluid Prandtl numbers (0.7 < Pr < 100) have been examined. High rates of heat transfer and low pressure loss are found relative to fully-developed flow in a straight pipe, with heat transfer enhancements greater than 10 for a Prandtl number of 100.As part of this work, we also obtain an accurate value for the Nusselt number for fully-developed flows in straight semi-circular passages with constant wall temperature, Nu_T = 3.323(±0.001).     

Fluid Dynamics and Transfer Processes in Bended Microchannels

Abstract

The understanding of the flow processes in microchannels and micromixers is essential for the design of microfluidic devices like microreactors or analytical equipment. We have performed a systematic numerical CFD-study of mixing and mass transfer in sharp 90° bends and heat transfer in T-joints to obtain a detailed insight into the flow patterns and corresponding transfer processes in a wide range of Reynolds numbers. With increasing flow velocity, the straight laminar flow starts to form symmetrical vortices in the bend, at the entrance of the mixing channel, and in T-joints. The vortices enhance the transport processes like heat and mass transfer in the channels significantly. The influence of the geometry and the flow conditions is shown by an analytical estimation of the relevant forces. The appearance of convective transport processes is used for the definition of microflows, which are controlled by viscous forces and diffusive transfer processes.     

Numerical simulation of the power-based efficiency in vanadium redox flow battery with different serpentine channel size

We present numerical investigations on the power-based efficiency of vanadium redox flow battery (VRFB). A three-dimensional numerical model is developed to capture the complexities of electrochemical reactions and fluid dynamics when considering different serpentine channel sizes and electrolyte flow rates. It is shown that the reduced channel size and increased electrolyte flow rate improve the electrochemical performance of the VRFB due to the enhanced distribution of molar centration at the electrodes. Nonetheless, the channel size reduction and increased electrolyte flow rate also increases pressure drop between inlet and outlet of the serpentine channels for negative and positive sides. In this, we calculate the power-based efficiency by considering the generated power of VRFB and power loss due to overpotentials, ohmic loss, and required pump power. The maximum power-based efficiency of 96.6% is calculated with the channel size of 1.9 mm at 60 mL min⁻¹, while it is 95.5% with 9.6 mm in channel size at 100 mL min⁻¹. The proposed numerical approach can be useful to determine the channel size with optimized electrolyte flow rate and maximum VRFB efficiency.     

Heat transfer enhancement of finned-tube heat exchanger using nozzle- and diffuser-shaped fins instead of straight fins

In this paper, a new method has been used to improve the heat transfer rate in the finned-tube heat exchanger with nozzle- and diffuser-shaped arrangement. For this study, the effect of several parameters was studied numerically. For the computational fluid dynamics simulation, the continuity, momentum, and energy equations were solved by the finite volume method using the standard k–ԑ model. The rate of heat transfer increases with the decreasing of fin bend radius (15 < R_fb < 20) for both nozzle-shaped fin and diffuser-shaped fin. By increasing of side temperature (600 < T_side < 900) and side Reynolds number (2000 < Re_side < 5000) the heat transfer rate increased for both nozzle- and diffuser-shaped fins. Results showed that a nozzle-shaped fin with a fin bend radius of 15 mm under the condition of Re_in = 20,000, T_side = 900 K, and Re_side = 3400 has a higher effect on heat transfer in comparison with the other types of fins. The maximum heat transfer rate was almost 39% and 35% for the nozzle-shaped fin with a bend radius of 15 mm and diffuser-shaped fin with a bend radius of 15 mm compared with the simple tube, respectively. Finally, correlational equations have been suggested to forecast the average Nu number as functions of various parameters of the tube equipped with different types of outer fins involving nozzle- and diffuser-shaped.     

Heat transfer of gas–liquid mixture in micro-channel heat sink

The main objective of the present investigation is to study heat transfer in parallel micro-channels of 0.1 mm in size. Comparison of the results of this study to the ones obtained for two-phase flow in “conventional” size channels provides information on the complex phenomena associated with heat transfer in micro-channel heat sinks. Two-phase flow in parallel micro-channels, feeding from a common manifold shows that different flow patterns occur simultaneously in the different micro-channels: liquid alone (or single-phase flow), bubbly flow, slug flow, and annular flow (gas core with a thin liquid film, and a gas core with a thick liquid film). Although the gas core may occupy almost the entire cross-section of the triangular channel, making the side walls partially dry, the liquid phase always remained continuous due to the liquid, which is drawn into the triangular corners by surface tension. With increasing superficial gas velocity, a gas core with a thin liquid film is observed. The visual observation showed that as the air velocity increased, the liquid droplets entrained in the gas core disappeared such that the flow became annular. The probability of appearance of different flow patterns should be taken into account for developing flow pattern maps. The dependence of the Nusselt number, on liquid and gas Reynolds numbers, based on liquid and gas superficial velocity, respectively, was determined in the range of Re_LS = 4–56 and Re_GS = 4.7–270. It was shown that an increase in the superficial liquid velocity involves an increase in heat transfer (Nu_L). This effect is reduced with increasing superficial gas velocity, in contrast to the results reported on two-phase heat transfer in “conventional size” channels.     

Influence of geometry change on creep failure life of 90° pressurised pipe bends with no initial ovality

The influence of the geometry change during creep on the failure life of 90° pipe bends, subjected to internal pressure, was investigated using finite element creep damage analyses. The bends were considered to be circular in shape with no initial ovality. The failure lives obtained using the material properties for a CrMoV pipe steel at 640 °C clearly show a significant life reduction when the geometry change is included. In the range of the pipe bend dimension ratios investigated, it was found that the failure lives could be reduced to between 65 and 78% of those obtained from constant geometry cases, indicating that the influence of geometry change may need to be appraised for detailed numerical analysis. The results were compared with those of the corresponding straight pipes and their relevance considered. It has been shown that under constant geometry conditions, the failure life for pipe bends is about 30% lower than that for the straight pipes.     

Limit and plastic collapse loads for un-reinforced mitred bends under pressure and bending

Approximate limit and plastic collapse load solutions for un-reinforced mitred bends under internal pressure and under bending are proposed in this paper, based on three-dimensional finite element analysis and approximate solutions for smooth bends. Solutions are given for single- and multi-mitred bends (mainly for single and double segmented bends) with the pipe mean radius-to-thickness ratio (r/t) ranging from r/t = 5 to r/t = 50, and the bend radius-to-mean radius ratio (R/r) from R/r = 2 to R/r = 4. Internal pressure, in-plane bending and out-of-plane bending loads are considered, but not their combination. It is found that the essential features of limit and plastic collapse loads for mitred bends are similar to those for smooth bends, and thus existing solutions for smooth elbows can be used to construct limit loads and plastic collapse for mitred bends.     

Condensation heat-transfer and pressure drop characteristics of refrigerant R-290/R-600a–oil mixtures in serpentine small-diameter U-tubes

Flow condensing experiments for refrigerant R-290, and R-600a mixed with the lubricating oil (EMKARATE RL 32H) in serpentine small-diameter (2.46 mm) U-tubes are reported. The tests were run at the saturation temperature of 40 °C, vapor qualities of 0.41–0.82, mass flux of 300–600 (kg/m²s) and inlet oil concentrations from 0 to 5 mass% oil. It was found that the condensation heat-transfer coefficients increased as mass flux values, vapor quality and the number of tube bends increased, but it decreased as the oil concentration increased. In addition, the two-phase pressure drops increased with increases in mass flux values, the number of tube bends and the oil concentration.     

Curvature Ratio Effect on Two-Phase Pressure Drops in Horizontal Return Bends: Experimental Data for R134a

This article presents 154 pressure drop data points measured during two-phase flow of R-134a in horizontal return bends. The tube diameter is constant at 10.85 mm and the curvature ratio is either 7.74 or 5.53. Saturation temperature varies from 15 to 20°C, vapor quality from 0.05 and 0.95, and mass velocity ranges from 300 to 600 kg m^?2 s^?1. Return bend pressure drops are calculated by subtracting the straight tube pressure drop from the total measured pressure drop along the bend. The perturbations induced up- and downstream of the singularity are taken into account in the measurements. The comparison of the pressure drops for the two configurations (curvature ratio of 5.53 and 7.74) showed that they are greater (about 10%) for the larger curvature ratio. This can be attributed to the effect of the developed length on the pressure drop; on the other side the pressure gradients are larger for the lower curvature ratio, which can be explained by the effect of the centrifugal force and the perturbations up- and downstream of the return bend. The experimental data are compared against four prediction methods available in the literature. The Domanski and Hermès correlation is the best at predicting the present data.     

Heat transfer and fluid flow in shrouded pin fin arrays with and without tip clearance

Shrouded pin fin arrays with tip clearances (Cg) up to 25% of pin height were experimentally evaluated. Pressure loss was measured (2 × 10² < Re_D < 2 × 10⁴) and liquid crystal thermography was employed to obtain temperature distributions from which the impact of Cg on the mean heat transfer rate was determined for 2 × 10² < Re_D < 1 × 10⁴. Cg was found to influence pressure drop performance to the greatest extent at low Re_D, (<5 × 10³), with the effect being significantly diminished by Re_D = 1.5 × 10⁴. On a per unit pumping power basis, higher heat transfer rates were observed for dimensionless clearances (Cg/D) less than 0.2 as compared to the non-clearance case.     

Experimental investigation on the convective heat transfer in straight and coiled corrugated tubes for highly viscous fluids: Preliminary results

The forced convective heat transfer in straight and coiled tubes, having smooth and corrugated wall, was experimentally investigated in two ranges of the Reynolds number: a lower one (5 < Re < 13) obtained with Glycerol and a higher one (150 < Re < 1500) obtained with Ethylene Glycol. The aim of the research was to verify the effectiveness of these passive heat transfer enhancement techniques when highly viscous fluids are treated. This issue is particularly crucial in applications in which the thermal processing of high Prandtl number fluids is required, such as in the food, chemical, pharmaceutical and cosmetics industries. In the present note, preliminary results, obtained by considering a given geometrical configuration characterized by a tube diameter of 14 mm, a curvature ratio of 0.06, a corrugation depth of 1 mm and a corrugation pitch of 16 mm, are presented. The main conclusion is that the wall curvature enhances heat transfer at all Re, whereas the wall corrugation enhances heat transfer only in the higher Re range; moreover the wall corrugation is totally ineffective in the low Re range and, if helical coils are present, it also destroys the benefit induced by the wall curvature. The largest increment in heat transfer rates is thus obtained by using smooth helical coils at low Re, and corrugated helical coils at larger Re. The results, although of preliminary nature, suggest interesting applications of the passive heat transfer enhancement technique based on smooth wall coiled tubes in the very low Reynolds number values range, while the combined passive technique based on wall corrugation and curvature represents an interesting solution for Reynolds number values in the range 150–1500.     

Mass transfer and mixing by pulsatile three-dimensional chaotic flow in alternating curved pipes

We present an experimental and numerical study of three-dimensional pulsatile flow in a twisted pipe in order to show the effects of chaotic advection on mixing in this flow configuration. The numerical study is done by CFD code with a pulsatile velocity field imposed as an inlet condition. The experimental setup is composed principally of a “Scotch-yoke” pulsatile flow generator and a twisted duct. The twisted duct consists of six 90° bends of circular cross-section; the plane of curvature of each bend is at 90° to that of its neighbors. The secondary flow, generated by centrifugal force, the pulsating velocity field and also due to the change in curvature plane, leads to irregular fluid particle trajectories. Velocity measurements were made for a range of stationary Reynolds numbers (300 ? Re_st ? 1200) and frequency parameters (1 ? α < 20) and for two velocity-amplitude ratios (β); agreement between the numerical and experimental results is satisfactory. In the first bend, for certain control parameter values, the secondary flow becomes more complex due to the pulsation, and in some cases Lyne instability and a siphon phenomenon appear. However, in the other bends, one passes from four cells (Lyne instability) in the first bend with two cells in the other bends. The numerical and experimental study revealed modifications in the trajectories’ evolution due to pulsation. The superposition of an oscillating flow on a stationary curved-pipe flow, in some cases, causes the destruction of the trapping zones (KAM structures). The number of regular zones that disappear with an increase in the number of bends decrease with pulsation frequency and velocity-amplitude ratio. Both these phenomena contribute to the mixing and mass transfer enhancement in the flow.     

Unstable vortex flow and new inertia-driven vortex rolls resulting from an air jet impinging onto a confined heated horizontal disk

An experiment combining flow visualization and temperature measurement is carried out here to investigate the possible presence of new inertia-driven vortex rolls and some unique characteristics of the time-dependent mixed convective vortex flow in a high-speed round air jet impinging onto a heated horizontal circular disk confined in a vertical cylindrical chamber. How the jet Reynolds and Rayleigh numbers and jet-to-disk separation distance affect the unique vortex flow characteristics is examined in detail. Specifically, the experiment is conducted for the jet Reynolds number varying from 0 to 1623 and Rayleigh number from 0 to 63,420 for the jet-to-disk separation distance fixed at 10.0, 20.0 and 30.0 mm. The results indicate that at sufficiently high Re_j the inertia-driven tertiary and quaternary rolls can be induced aside from the primary and secondary rolls. At an even higher Re_j the vortex flow becomes unstable due to the inertia-driven flow instability. Only for H = 20.0 mm the flow is also subjected to the buoyancy-driven instability for the ranges of the parameters covered here. Because of the simultaneous presence of the inertia- and buoyancy-driven flow instabilities, a reverse flow transition can take place in the chamber with H = 20.0 mm. At the large H of 30.0 mm the flow unsteadiness results from the mutual pushing and squeezing of the inertia- and buoyancy-driven rolls since they are relatively large and contact with each other. It is also noted that the critical Re_j for the onset of unsteady flow increases with ΔT for H = 10.0 and 20.0 mm. But for H = 30.0 mm the opposite is true and raising ΔT can destabilize the vortex flow. Based on the present data, flow regime maps delineating the temporal state of the flow are provided and correlating equations for the boundaries separating various flow regimes are proposed.     

Experimental Investigation of Local Heat Transfer and Skin Friction in Tube Coils

Local heat transfer and skin friction around the tube perimeter of coils were studied in airflow. The heat transfer experiments were performed with two different coils D/d = 23 and 15.6, and skin friction experiments were performed with three different coils D/d = 25, 13.3 and 6.67 In the wide range of Re number from 4×103 till 105 . Variation of the local heat transfer around the perimeter and along the tube was defined. The behavior of the shear stresses at the wall and of the flow modes were studied. Investigations of the heat transfer indicated that with the increase of D/d the difference between heat transfer in the initial thermal section and the stabilized heat transfer increases. Investigations of the shear stress and its fluctuations indicated that, in large-curvature coils, the transition from laminar-vortex flow to turbulent flow around the tube perimeter takes place at different values of Re. In the region of the external generatrix of the bend, the transition occurs at smaller Re, whereas a     

Water-to-water heat transfer in tube–tube heat exchanger: Experimental and analytical study

Tube–tube heat exchanger (TTHE) is a low cost, vented double wall heat exchanger which increases reliability by avoiding mixing of fluids exchanging heat. It can be potentially used for heat recovery from engine cooling circuit, oil cooling, desuperheating in refrigeration and air conditioning, dairy, and pharmaceutical industry, chemical industry, refinery, etc. These tube–tube heat exchangers are successfully demonstrated for superheat recovery water heating applications, condenser and evaporator in heat pumps, lube oil cooler for shipboard gas turbines, milk chilling and pasteurizing application. This paper presents an experimental study on various layouts of TTHE for water-to-water heat transfer. The theoretical and experimental results on this type of heat exchanger configuration could not be located in literature. Overall heat transfer coefficient and pumping power were experimentally determined for a fixed tube length and surface area of serpentine layouts with different number of bends and results are compared with straight tube TTHE. In the case investigated, serpentine layout TTHE with seven bends has shown optimum performance, with overall heat transfer coefficient 17% higher than straight tube TTHE. Two out of five serpentine layout TTHE have shown poor heat transfer performance than straight tube TTHE. The experimental results also indicate that there is a definite optimum for a number of bends in serpentine layout TTHE. An analytical model for prediction of thermo-hydraulic performance of straight layout has been developed and validated experimentally.     

Influence of oil on R-410A two-phase frictional pressure drop in a small U-type wavy tube

This study presents single-phase and two-phase pressure drop data with oil concentration C = 0, 1, 3 and 5% in a copper wavy tube having an inner diameter of 3.25 mm and a curvature radius of 6.35 mm. The ratio of frictional factor between U-bend in wavy tube and straight tube (f_C/f_S) is about 1.5 to 2.5 for Re = 2500 ∼ 25000. The effect of secondary flow is very crucial in the U-bend that it increases the pressure drop considerably. However, the effect of oil concentration on friction factor is negligible provided the properties are based on mixture. The ratio between two-phase pressure gradients of U-bend and straight tube is about 3. This ratio is increased with oil concentration and vapor quality. The oil effect on two-phase pressure drop is especially pronounced at high vapor quality because the effective oil concentration in liquid mixture is increased with vapor quality. The frictional two-phase multiplier for straight tube can be fairly correlated by using the Chisholm correlation. A modified two-phase friction factor based on the Geary correlation is also utilized to predict the frictional two-phase pressure gradient in U-bend. The predictions give a good agreement to the present oil–refrigerant data with a mean deviation of 12.92%.     

Two-phase flow behaviour and pressure drop of R134a in a smooth hairpin

Adiabatic two-phase flow of refrigerant R-134a in a hairpin was studied. The hairpin consists of a smooth tube with an inner diameter of 8 mm and with a bend radius of 11 mm. Because of the forces exerted on the flow in the bend, the flow needs to redevelop downstream of the U-bend. The effects of this phenomenon on the pressure drop are studied and linked to visual observations of the flow. Pressure drop and videos of the flow behaviour are recorded in the straight sections upstream and downstream of the bend. These are then compared to the flow and pressure drop for developed flow. The pressure drop downstream of the bend was consistently higher than that for developed flow. It exceeded the pressure drop for developed flow by an average of 30% for all data points. Each video of the flow behaviour was reduced to a single image by calculating the standard deviation of the time signal of each pixel. The standard deviation profiles were compared in order to quantitatively evaluate the change of the flow behaviour. The flow recovery downstream of the bend stretches out over more than 30 tube diameters.     

Investigation of dimpled fins for heat transfer enhancement in compact heat exchangers

Direct and Large-Eddy simulations are conducted in a fin bank with dimples and protrusions over a Reynolds number range of Re_H = 200 to 15,000, encompassing laminar, transitional and fully turbulent regimes. Two dimple-protrusion geometries are studied in which the same imprint pattern is investigated for two different channel heights or fin pitches, Case 1 with twice the fin pitch of Case 2. The smaller fin pitch configuration (Case 2) develops flow instabilities at Re_H = 450, whereas Case 1 undergoes transition at Re_H = 900. Case 2, exhibits higher Nusselt numbers and friction coefficients in the low Reynolds number regime before Case 1 transitions to turbulence, after which, the differences between the two decreases considerably in the fully turbulent regime. Vorticity generated within the dimple cavity and at the dimple rim contribute substantially to heat transfer augmentation on the dimple side, whereas flow impingement and acceleration between protrusions contribute substantially on the protrusion side. While friction drag dominates losses in Case 1 at low Reynolds numbers, both form and friction drag contributed equally in Case 2. As the Reynolds number increases to fully turbulent flow, form drag dominates in both cases, contributing about 80% to the total losses. While both geometries are viable and competitive with other augmentation surfaces in the turbulent regime, Case 2 with larger feature sizes with respect to the fin pitch is more appropriate in the low Reynolds number regime Re_H < 2000, which makes up most of the operating range of typical compact heat exchangers.     

Endwall heat transfer and fluid flow around an inclined short cylinder

Measurements of endwall heat transfer and flow field around a short single cylinder have been performed to examine the influence of cylinder inclination at low Reynolds number (Re_D = 1.0 × 10⁴). Both ends of the cylinder are attached to the endwalls and the length-to-diameter ratio of the cylinder varies from 2.7 to 4, depending on the inclination angle. Endwall heat transfer contours (obtained from transient liquid crystals) and endwall flow visualization results consistently indicate that the interaction between the horseshoe vortices around the cylinder and the wakes shed from the cylinder varies with the inclination. Spanwise pressure gradient induced by the inclination causes: (i) skewing of the upstream main flow as it approaches the cylinder; (ii) formation of a jet-like flow immediately downstream of the cylinder, followed by its impingement onto the endwall; and (iii) skewed separation line along the cylinder span from the cylinder axis.     

A general implementation of the H1 boundary condition in CFD simulations of heat transfer in swept passages

A methodology has been developed to study laminar flow and heat transfer behaviour in periodic non-straight passages with a heat transfer boundary condition of constant axial heat flux and constant peripheral temperature (H1). The technique uses Newton iteration to determine the wall temperature distribution required to satisfy the H1 boundary condition. The methodology is validated for hydrodynamically developed and thermally developing flow, as well as for hydrodynamically and thermally developed flow in straight ducts with various cross-sections. The methodology is extended to study fully developed flow in a periodic serpentine channel, consisting of a number of bends and straight sections, with a semi-circular cross-section. The results show the existence of a non-monotonic temperature distribution along the serpentine channels which exists because increased rates of heat transfer at bends lead to reductions in the local wall temperature in order to maintain a constant axial heat flux. Hot spots within the passage cross-section, typical of the H2 boundary condition, are removed in the H1 case.