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.     

Design and multi-objective optimization of heat exchangers for refrigerators

In this study, a detailed thermodynamic model for a refrigerator based on an irreversible Carnot cycle is developed with the focus on forced-air heat-exchangers. A multi-objective optimization procedure is implemented to find optimal design values for design variables. Minimizations of energy consumption and material cost were the two objectives considered. Since these objectives are conflicting, no single design will satisfy both simultaneously. The result of this research is a set of multiple optimum solutions, which are called ‘Pareto optimal solutions’. Air and refrigerant side correlations were combined with an elemental approach to model the heat exchangers. This paper presents a detailed design model development. A limited validation is presented with experimental test-data obtained from a typical household refrigerator. Detailed simulation models are typically complex and computationally demanding. An optimization algorithm requires several evaluations of such models. Response surface based metamodels for objective functions were used to save computational effort. A genetic-algorithm based optimization tool is used for multi-criteria optimization.     

Multi-objective optimization of a multi water-to-water heat pump system using evolutionary algorithm

This paper deals with the energy recovery in the dairy industry. Thermodynamic, economic and environmental optimization of three water-to-water heat pumps has been studied in order to replace totally or partially a fuel boiler used to produce heat at different temperature levels in a cheese factory. These heat pumps have their evaporators connected to one effluents source and two of them are equipped by storage tanks at the condenser side. Multi-objective optimization permits optimal repartition of mass flow rates of effluents and optimal choice of electrical power of the compressors and volumes of storage tanks. The thermodynamic objective is based on the exergy destruction in the whole system. The economic objective is based on the investment cost and the operating cost obtained with the heat pump system. The environmental impact objective has been defined and expressed in cost terms by considering a CO₂ taxation (carbon tax) on the GHG emissions. This objective has been integrated with the economic objective. Multi-objective genetic algorithms are used for Pareto approach optimization.     

A Modified Entropy Generation Number for Heat Exchangers

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Prediction of heat transfer rates for shell-and-tube heat exchangers by artificial neural networks approach

This work used artificial neural network(ANN)to predict the heat transfer rates of shell-and-tube heatexchangers with segmental baffles or continuous helical baffles,based on limited experimental data.The BackPropagation (BP) algorithm was used in training the networks.Different network configurations were alsostudied.The deviation between the predicted results and experimental data was less than 2%.Comparison withcorrelation for prediction shows ANN superiority.It is recommended that ANN can be easily used to predict theperformances of thermal systems in engineering applications,especially to model heat exchangers for heattransfer analysis.     

The control of a refrigeration system using a compact plate heat exchanger as an evaporator

This paper will show some of the problems that may be encountered when using a compact plate exchanger as an evaporator in a refrigeration system which utilizes a thermostatic expansion valve as its controlling device.     

A study on the effects of CO-tubes insertion on the emission characteristics of a compact heat exchanger

The effects of CO-tubes insertion on NO_x (nitrogen oxides) and CO emissions from a compact heat exchanger were numerically simulated using a quasi one-dimensional premixed flame model, and the results were compared to experiments with a laboratory-scale heat exchanger and a commercial compact condensing boiler with a heat exchanger installed. The “CO-tubes” means that pre-cooling tubes were inserted between the burner and the main heat exchanger to reduce CO concentration. In the numerical results, the outlet concentration of NO increased as the distance between the burner and the CO-tubes was increased up to 3 cm. However, NO concentration was little affected by the CO-tubes when the distance was greater than 3 cm. Additionally, the concentration of CO reached a minimum at the distance of 3 cm. CO concentration increased when the distance from the burner to the CO-tubes was increased or decreased between 2 cm and 3 cm. These simulated results showed good agreement with the experimental results using a laboratory-scale heat exchanger. However, the maximum and minimum distances for NO and CO concentrations were different. When the CO-tubes were subsequently applied in a working commercial boiler, CO concentration was dramatically reduced by the CO-tubes and NO concentration was also slightly decreased.     

A computationally efficient hybrid time step methodology for simulation of ground heat exchangers

Ground heat exchanger design tools have become increasingly important for the sizing of energy-efficient heating and cooling systems. Most such heat exchanger design tools incorporate a simulation that uses both long and short timesteps (a “hybrid timestep” procedure). Current tools typically expect engineers to exercise judgment to determine the magnitude and duration of the shorter timestep. This paper proposes an accurate and efficient methodology for developing this hybrid timestep formulation, which is validated against hourly simulations for a set of three building types. Overall, the method performs well for design purposes, with the error in ground heat exchanger sizing averaging less than 1% and always less than 8%.     

Multi-objective optimization of HVAC system with an evolutionary computation algorithm

A data-mining approach for the optimization of a HVAC (heating, ventilation, and air conditioning) system is presented. A predictive model of the HVAC system is derived by data-mining algorithms, using a dataset collected from an experiment conducted at a research facility. To minimize the energy while maintaining the corresponding IAQ (indoor air quality) within a user-defined range, a multi-objective optimization model is developed. The solutions of this model are set points of the control system derived with an evolutionary computation algorithm. The controllable input variables — supply air temperature and supply air duct static pressure set points — are generated to reduce the energy use. The results produced by the evolutionary computation algorithm show that the control strategy saves energy by optimizing operations of an HVAC system.     

Optimization of energy systems based on Evolutionary and Social metaphors

Optimization problems that arise in energy systems design often have several features that hinder the use of many optimization techniques. These optimization problems have non-continuous mixed variable definition domains, are heavily constrained, are multimodal (i.e. have many local optima) and, foremost, the functions used to define the engineering optimization problem are often computationally intensive. Three methods are tested here: (a) a Struggle Genetic Algorithm (StrGA), (b) a Particle Swarm Optimization Algorithm (PSOA), and (c) a PSOA with Struggle Selection (PSOStr). The last is a hybrid of the evolutionary StrGA and the socially inspired PSOA. They are tested in four purely mathematical and three energy systems thermoeconomic optimization problems. All of the methods solved successfully all the problems. The PSOStr, however, outperformed the other methods in terms of both solution accuracy and computational cost (i.e. function evaluations).     

Second-law performance of heat exchangers for waste heat recovery

Exergy change rate in an ideal gas flow or an incompressible flow can be divided into a thermal exergy change rate and a mechanical exergy loss rate. The mechanical exergy loss rates in the two flows were generalized using a pressure-drop factor. For heat exchangers using in waste heat recovery, the consumed mechanical exergy is usually more valuable than the recovered thermal exergy. A weighing factor was proposed to modify the pressure-drop factor. An exergy recovery index (η_II) was defined and it was expressed as a function of effectiveness (?), ratio of modified heat capacity rates (C^∗), hot stream-to-dead-state temperature ratio, cold stream-to-dead-state temperature ratio and modified overall pressure-drop factor. This η_II–? relation can be used to find the η_II value of a heat exchanger with any flow arrangement. The η_II−Ntu and η_II−Ntu_h relations of cross-flow heat exchanger with both fluids unmixed were established respectively. The former provides a minimum Ntu design principle and the latter provides a minimum Ntu_h design principle. A numerical example showed that, at a fixed heat capacity rate of the hot stream, the heat exchanger size yielded by the minimum Ntu_h principle is smaller than that yielded by the minimum Ntu principle.     

Planning the optimum cleaning schedule based on simulation of heat exchangers under fouling

An investigation of variations in outlet temperatures of heat exchangers under fouling was carried out. The simulation of heat exchangers was performed by employing a linear fouling deposit function. The formation of deposits reduces heat exchangers effectiveness. There is inherently a linear nature between outlet and inlet temperatures of heat exchangers. The outlet temperatures can also be affected by up‐stream exchangers serving the same streams, and the up‐stream influence can be transferred in the heat system. The mathematical model of the cleaning cycle was outlined, based on the objective function of minimizing cost in unit operation time. According to the results, some heat exchangers can be given cleaning priority when the system is shut down, in order to maximize economic benefit. © 2011 Wiley Periodicals, Inc. Heat Trans Asian Res; Published online in Wiley Online Library ( wileyonlinelibrary.com/journal/htj ). DOI 10.1002/htj.20384     

A finite line‐source model for boreholes in geothermal heat exchangers

An analytical solution of the transient temperature response in a semi‐infinite medium with a line source of finite length has been derived, which is a more appropriate model for boreholes in geothermal heat exchangers, especially for their long‐duration operation. The steady‐state temperature distribution has also been obtained as a limit of this solution. An erratic approach to this problem that appears in some handbooks and textbooks is indicated. Two representative steady‐state borehole wall temperatures, the middle point temperature and the integral mean temperature, are defined. Differences between them are compared, and concise expressions for both are presented for engineering applications. On this basis the influence of the annual imbalance between heating and cooling loads of the geothermal heat exchangers is discussed regarding their long‐term performance. © 2002 Wiley Periodicals, Inc. Heat Trans Asian Res, 31(7): 558–567, 2002; Published online in Wiley InterScience ( www.interscience.wiley.com ). DOI 10.1002/htj.10057     

Computer simulation of borehole ground heat exchangers for geothermal heat pump systems

Computer simulation of borehole ground heat exchangers used in geothermal heat pump systems was conducted using three-dimensional implicit finite difference method with rectangular coordinate system. Each borehole was approximated by a square column circumscribed by the borehole radius. Borehole loading profile calculated numerically based on the prescribed borehole temperature profile under quasi-steady state conditions was used to determine the ground temperature and the borehole temperature profile. The two coupled solutions were solved iteratively at each time step. The simulated ground temperature was calibrated using a cylindrical source model by adjusting the grid spacing and adopting a load factor of 1.047 in the difference equation. With constant load applied to a single borehole, neither the borehole temperature nor the borehole loading was constant along the borehole. The ground temperature profiles were not similar at different distances from the borehole. This meant that a single finite difference scheme was not sufficient to estimate the performance of a borefield by superposition. The entire borefield should be discretized simultaneously. Comparison was made between the present method and the finite line source model with superposition. The discrepancies between the results from the two methods increased with the scale of borefield. The introduction of time schedule revealed a discrepancy between the load applied to the ground heat exchanger and that transferred from the borehole to the ground, which was usually assumed to be the same when using analytical models. Hence, in designing a large borefield, the present method should give more precise results in dynamic simulation.     

Impact of scale build‐up models on energy utilization in heat exchangers

In this paper an energy utilization index is presented. It is used to investigate the impact of scale build‐up in heat exchange equipment. The investigation is carried out using several scale build‐up models. The models employed in this paper are the linear, logarithmic, and the asymptotic one. It has been demonstrated by a realistic example that the type of scale build‐up model assumed greatly affects energy utilization and maintenance scheduling for heat exchange equipment. Copyright © 1999 John Wiley & Sons, Ltd.     

径向热管换热器壳程压降数值模拟及参数优化

通过对径向热管换热器壳程压力场的数值模拟,分析入口烟气速度对换热器压降的影响规律,并对换热器结构参数进行优化。结果表明:换热器迎风侧压力高于背风侧压力,沿烟气流动方向压力逐渐降低且呈线性分布;换热器压降随入口烟气速度的增加而增加,且其增加速率也相应增大。通过改变换热器结构参数,对换热器壳程压降进行分析研究,得到其结构优化参数:翅片高度小于26.5mm,翅片间距大于6.5mm,热管横向间距108～111mm,纵向间距120～125mm。     

Optimal design of plate-and-frame heat exchangers for efficient heat recovery in process industries

The developments in design theory of plate heat exchangers, as a tool to increase heat recovery and efficiency of energy usage, are discussed. The optimal design of a multi-pass plate-and-frame heat exchanger with mixed grouping of plates is considered. The optimizing variables include the number of passes for both streams, the numbers of plates with different corrugation geometries in each pass, and the plate type and size. To estimate the value of the objective function in a space of optimizing variables the mathematical model of a plate heat exchanger is developed. To account for the multi-pass arrangement, the heat exchanger is presented as a number of plate packs with co- and counter-current directions of streams, for which the system of algebraic equations in matrix form is readily obtainable. To account for the thermal and hydraulic performance of channels between plates with different geometrical forms of corrugations, the exponents and coefficients in formulas to calculate the heat transfer coefficients and friction factors are used as model parameters. These parameters are reported for a number of industrially manufactured plates. The described approach is implemented in software for plate heat exchangers calculation.     

A new approach for thermal performance calculation of cross-flow heat exchangers

A new numerical methodology for thermal performance calculation in cross-flow heat exchangers is developed. Effectiveness-number of transfer units (ε-NTU) data for several standard and complex flow arrangements are obtained using this methodology. The results are validated through comparison with analytical solutions for one-pass cross-flow heat exchangers with one to four rows and with approximate series solution for an unmixed-unmixed heat exchanger, obtaining in all cases very small errors. New effectiveness data for some complex configurations are provided.     

A new fuzzy adaptive particle swarm optimization for non-smooth economic dispatch

This paper proposes a novel method for solving the Non-convex Economic Dispatch (NED) problems, by the Fuzzy Adaptive Modified Particle Swarm Optimization (FAMPSO). Practical ED problems have non-smooth cost functions with equality and inequality constraints when generator valve-point loading effects are taken into account. Modern heuristic optimization techniques have been given much attention by many researchers due to their ability to find an almost global optimal solution for ED problems. PSO is one of modern heuristic algorithms, in which particles change place to get close to the best position and find the global minimum point. However, the classic PSO may converge to a local optimum solution and the performance of the PSO highly depends on the internal parameters. To overcome these drawbacks, in this paper, a new mutation is proposed to improve the global searching capability and prevent the convergence to local minima. Also, a fuzzy system is used to tune its parameters such as inertia weight and learning factors.     

Adaptive particle swarm optimization approach for static and dynamic economic load dispatch

This paper presents a novel heuristic optimization approach to constrained economic load dispatch (ELD) problems using the adaptive–variable population – PSO technique. The proposed methodology easily takes care of different constraints like transmission losses, dynamic operation constraints (ramp rate limits) and prohibited operating zones and also accounts for non-smoothness of cost functions arising due to the use of multiple fuels. Simulations were performed over various systems with different numbers of generating units, and comparisons are performed with other existing relevant approaches. The findings affirmed the robustness, fast convergence and proficiency of the proposed methodology over other existing techniques.