Thermodynamic assessment of solid oxide fuel cell system integrated with bioethanol purification unit

A solid oxide fuel cell system integrated with a distillation column (SOFC–DIS) has been proposed in this article. The integrated SOFC system consists of a distillation column, an EtOH/H₂O heater, an air heater, an anode preheater, a reformer, an SOFC stack and an afterburner. Bioethanol with 5 mol% ethanol was purified in a distillation column to obtain a desired concentration necessary for SOFC operation. The SOFC stack was operated under isothermal conditions. The heat generated from the stack and the afterburner was supplied to the reformer and three heaters. The net remaining heat from the SOFC system (Q_SOFC,Net) was then provided to the reboiler of the distillation column. The effects of fuel utilization and operating voltage on the net energy (Q_Net), which equals Q_SOFC,Net minus the distillation energy (Q_D), were examined. It was found that the system could become more energy sufficient when operating at lower fuel utilization or lower voltage but at the expense of less electricity produced. Moreover, it was found that there were some operating conditions, which yielded Q_Net of zero. At this point, the integrated system provides the maximum electrical power without requiring an additional heat source. The effects of ethanol concentration and ethanol recovery on the electrical performance at zero Q_Net for different fuel utilizations were investigated. With the appropriate operating conditions (e.g. C_EtOH = 41%, U_f = 80% and EtOH recovery = 80%), the overall electrical efficiency and power density are 33.3% (LHV) and 0.32 W cm⁻², respectively.     

Energy and exergy analyses of an externally fired gas turbine (EFGT) cycle integrated with biomass gasifier for distributed power generation

Biomass based decentralized power generation using externally fired gas turbine (EFGT) can be a technically feasible option. In this work, thermal performance and sizing of such plants have been analyzed at different cycle pressure ratio (r_p = 2−8), turbine inlet temperature (TIT = 1050–1350 K) and the heat exchanger cold end temperature difference (CETD = 200–300 K). It is found that the thermal efficiency of the EFGT plant reaches a maximum at an optimum pressure ratio depending upon the TIT and heat exchanger CETD. For a particular pressure ratio, thermal efficiency increases either with the increase in TIT or with the decrease in heat exchanger CETD. The specific air flow, associated with the size of the plant equipment, decreases with the increase in pressure ratio. This decrease is rapid at the lower end of the pressure ratio (r_p < 4) but levels-off at higher r_p values. An increase in the TIT reduces the specific air flow, while a change in the heat exchanger CETD has no influence on it. Based on this comparison, the performance of a 100 kW EFGT plant has been analyzed for three sets of operating parameters and a trade-off in the operating condition is reached.     

Working fluids for low-temperature organic Rankine cycles

A thermodynamic screening of 31 pure component working fluids for organic Rankine cycles (ORC) is given using BACKONE equation of state. The fluids are alkanes, fluorinated alkanes, ethers and fluorinated ethers. The ORC cycles operate between 100 and 30 °C typical for geothermal power plants at pressures mostly limited to 20 bar, but in some cases supercritical pressures are also considered. Thermal efficiencies η_th are presented for cycles of different types. In case of subcritical pressure processes one has to distinguish (1) whether the shape of the saturated vapour line in the T,s-diagram is bell-shaped or overhanging, and (2) whether the vapour entering the turbine is saturated or superheated. Moreover, in case that the vapour leaving the turbine is superheated, an internal heat exchanger (IHE) may be used. The highest η_th-values are obtained for the high boiling substances with overhanging saturated vapour line in subcritical processes with an IHE, e.g., for n-butane η_th=0.130. On the other hand, a pinch analysis for the heat transfer from the heat carrier with maximum temperature of 120 °C to the working fluid shows that the largest amount of heat can be transferred to a supercritical fluid and the least to a high-boiling subcritical fluid.     

The micro-tube heat transfer and fluid flow of water based Al2O3 nanofluid with viscous dissipation

The numerical modeling of the conjugate heat transfer and fluid flow of Al₂O₃/water nanofluid through the micro-tube was presented in the paper. The laminar flow regime was considered along with viscous dissipation effect. The diameter ratio of the micro-tube was D_i/D_o = 0.1/0.3 mm with a tube length L = 100 mm. The heat transfer rate was fixed to Q = 0.5 W with three different Br = 0.1, 0.5 and 1. The water based Al₂O₃ nanofluid was considered with various volume concentrations of Al₂O₃ particles ? = 1, 4, 6, 9% and two diameters of the particles D_p = 10 nm and 47 nm. The analysis was performed on the results for local heat transfer coefficient.     

Heat transfer augmentation in a helical-ribbed tube with double twisted tape inserts

Turbulent convective heat transfer characteristics in a helical-ribbed tube fitted with twin twisted tapes have been investigated experimentally. The experiment was carried out in a double tube heat exchanger using the helical-ribbed tube having a single rib-height to tube-diameter ratio, e/D_H = 0.06 and rib-pitch to diameter ratio, P/D_H = 0.27 as the tested section. The insertion of the double twisted tapes with twist ratio, Y, in the range of 2.17 to 9.39 is to create vortex flows inside the tube. The inserted ribbed tube is arranged in similar directions of the helical swirl of the twisted tape and the helical rib motion of the tube (called co-swirl). Effects of the co-swirl motion of the ribbed tube and the double twisted tapes with various twist ratios on heat transfer and friction characteristics are examined. The results obtained from the ribbed tube and the twin twisted tape insert are compared with those from the smooth tube and the ribbed tube acting alone. The experimental results reveal that the co-swirling inserted tube performs much better than the ribbed/smooth tube alone at a similar operating condition. The co-swirl tube at Y ≈ 8 yields the highest thermal performance at lower Reynolds number (Re). In addition, the correlations of Nusselt number and friction factor as functions of Re, Pr and Y are also proposed.     

Hydrogen diffusion and hydrogen influenced critical stress intensity in an API X70 pipeline steel welded joint – Experiments and FE simulations

An API X70 pipeline steel has been investigated with respect to hydrogen diffusion and fracture mechanics properties. A finite element cohesive element approach has been applied to simulate the onset of hydrogen-induced fracture. Base metal, weld simulated heat affected zone and weld metal have been investigated. The electrochemical permeation technique was used to study hydrogen diffusion properties, while in situ fracture mechanics testing was performed in order to establish the hydrogen influenced threshold stress intensity. The average effective diffusion coefficient at room temperature was 7.60 × 10⁻¹¹ m²/s for the base metal, 4.01 × 10⁻¹¹ m²/s for weld metal and 1.26 × 10⁻¹¹ m²/s for the weld simulated heat affected zone. Hydrogen susceptibility was proved to be pronounced for the heat affected zone samples. Fracture toughness samples failed at a net section stress level of 0.65 times the yield strength; whereas the base metal samples did not fail at net section stresses lower than the ultimate tensile strength. The initial cohesive parameters which best fitted the experimental results were σ_c = 1500 MPa (3.1·σ_y) for the base metal, σ_c = 1800 MPa (3.0·σ_y) for weld metal and σ_c = 1840 MPa (2.3·σ_y) for heat affected zone. Threshold stress intensities K_Ic,HE were in the range 143–149 MPa√m.     

Experimental prediction of total thermal resistance of a closed loop EAHE for greenhouse cooling system

The design of an earth to air heat exchanger (EAHE) requires knowledge of its total thermal resistance (R_Tot) for heating and cooling applications. In this research, a 47 m long horizontal, 56 cm nominal diameter U-bend buried galvanized was studied experimental EAHE used for the determination and evaluation of thermal properties of heat exchanger. This system was designed and installed in the Solar Energy Institute, Ege University, Izmir, Turkey. Based on the experimental results, generalized relationships were developed for predicting of thermal resistance of the heat exchanger. Average total heat exchanger thermal resistance was estimated to be 0.021 K-m/W as a constant value under steady state condition.     

Enhancement of heat transfer in a tube with regularly-spaced helical tape swirl generators

Influence of helical tapes inserted in a tube on heat transfer enhancement is studied experimentally. A helical tape is inserted in the tube with a view to generating swirl flow that helps to increase the heat transfer rate of the tube. The flow rate of the tube is considered in a range of Reynolds number between 2300 and 8800. The swirling flow devices consisting of: (1) the full-length helical tape with or without a centered-rod, and (2) the regularly-spaced helical tape, are inserted in the inner tube of a concentric tube heat exchanger. Hot air is passed through the inner tube whereas cold water is flowed in the annulus. The experimental data obtained are compared with those obtained from plain tubes of published data. Experimental results confirmed that the use of helical tapes leads to a higher heat transfer rate over the plain tube. The full-length helical tape with rod provides the highest heat transfer rate about 10% better than that without rod but it increased the pressure drop. To overcome this, different free-spacing ratio (s = L_s/L_h) of 0.5, 1.0, 1.5, and 2.0 were examined. It was found that the space ratio value should be about unity for Re < 4000. The regularly-spaced helical tape inserts at s = 0.5 yields the highest Nusselt number which is about 50% above the plain tube.     

Heat transfer characteristics in a tube fitted with helical screw-tape with/without core-rod inserts

Effects of insertion of a helical screw-tape with or without core-rod in a concentric double tube heat exchanger on heat transfer and flow friction characteristics are experimentally investigated. The heat exchanger has the outer and the inner tube diameters of 50 mm (D_o) and 25 mm (D) where the cold and the hot waters used as the test fluids are in shell and tube sides, respectively. The stainless steel helical screw-tape has the geometrical dimensions of width (W) 17 mm with the clearance to the tube wall (D − W) / 2 = 4 mm. Thus, the insertion of the screw-tape in the tube is considered as a loose-fit. In the experiment, the loose-fit helical tape with or without core-rod, is inserted in the inner tube of the heat exchanger and the hot water enters the tube based on its Reynolds number in a range of 2000 to 12,000. The experimental results show that the increases in average Nusselt number of using the loose-fit, helical tape with and without core-rod are found to be 230% and 340%, respectively, over the corresponding plain tube. It is worth noting that for the loose-fit, helical tape without core-rod, the friction factor is around 50% less than that for the one with core-rod while the Nusselt number is about 50% higher. Furthermore, the enhancement efficiency of the helical screw-tapes varies between 1.00 and 1.17, 1.98 and 2.14, for the tapes with and without core-rod, respectively.     

Effect of interface layer on the cooling performance of a single thermoelement

The resultant thermoelectric (TE) figure of merit Z, the coefficient of performance (COP), the heat pumping capacity per unit area (Q_c/S) were derived analytically as functions of l₀, ρ_c, κ_c and s_c for a single thermoelement (STE) by taking into account the interface layers, where l₀ is a length of a TE material, ρ_c the electrical interface resistivity, κ_c the thermal interface conductivity and s_c the ratio of the Seebeck coefficient of an interface layer to that of a TE material. As a result, it was first revealed that the increase in Z₀T of a TE material is not necessarily reflected in the increase in ZT of an STE as long as the interface layers are present. The COP and Q_c/S are lowered remarkably for s_c = 0 and κ_c ? 10⁴ W/m² K. However, it was clarified that even for low values of κ_c, the COP and Q_c/S return to the original high values (obtained for κ_c ? 10⁵ W/m² K) at s_c = 0.45 and 0.90, respectively. The definite criterion of s_c whether or not the boundary Seebeck coefficient has an effect on the enhancement of the cooling performance was indicated quantitatively for an STE with interface layers.     

Performances of a heat exchanger and pilot boiler for the development of a condensing gas boiler

In this research, design factors for a heat exchanger and boiler were investigated using a simplified model of a heat exchanger and pilot condensing boiler, respectively. Specifications of each heat exchanger component (e.g., upper heat exchanger (UHE) and lower heat exchanger (LHE); coil heat exchanger (CHE); baffles) were investigated using a model apparatus, and the comprehensive performance of the pilot gas boiler was examined experimentally. The heating efficiency of the boiler developed was about 90% when using the optimal designed heat exchangers. Compared to a conventional Bunsen-type boiler, the heating efficiency was improved about 10%. Additionally, NO_x and CO emissions were about 30 ppm and 160 ppm, respectively, based on a 0% O₂ basis at an equivalence ratio of 0.70, which is an appropriate operating condition. However, the pollutant emission of the boiler developed is satisfactory considering the emission performance of a condensing boiler, even though CO emission must be reduced.     

Species heat and mass transfer in a human upper airway model

Steady 3-D airflow and scalar transport of ultrafine particles, d_p<0.1 μm, and fuel vapors within the human upper airways are simulated and analyzed for laminar as well as locally turbulent flow conditions. Presently, our respiratory system consists of two major segments of a simplified human cast replica, i.e., a representative oral airway from mouth to trachea (Generation 0) and a symmetric four-generation upper bronchial tree model (G0-G3). The simulation has been validated with experimental data in terms of ultrafine particle deposition efficiencies. The present computational results show the following: (1) At low breathing rates (Q_in≈15 l/min), ambient temperature variations (ΔT_max=47 °C) influence the local velocity fields and vapor concentrations; however, the total and segmental deposition fractions of fuel vapor in the upper airway are essentially unaffected. (2) The inlet flow rate has a significant effect on vapor deposition, i.e., the higher the flow rate the lower the deposition fraction. (3) The convective heat transfer coefficient averaged over an individual bifurcation unit can be correlated as Nu=0.568(RePr)^0.495 (600 < Re < 6000). (4) Two new Sherwood number correlations capture the convective mass transfer for the oral airway and individual bifurcations.The methodology outlined and physical insight provided can be also applied to other intake configurations, such as engine ports and inlets to air-breathing propulsion systems.     

Working fluids for high-temperature organic Rankine cycles

Alkanes, aromates and linear siloxanes are considered as working fluids for high-temperature organic Rankine cycles (ORCs). Case studies are performed using the molecular based equations of state BACKONE and PC-SAFT. First, “isolated” ORC processes with maximum temperatures of 250 °C and 300 °C are studied at sub- or supercritical maximum pressures. With internal heat recovery, the thermal efficiencies η_th averaged over all substances amount to about 70% of the Carnot efficiency and increase with the critical temperature. Second, we include a pinch analysis for the heat transfer from the heat carrier to the ORC working fluid by an external heat exchanger (EHE). The question is for the least heat capacity flow rates of the heat carrier required for 1 MW net power output. For the heat carrier inlet temperatures of 280 °C and 350 °C are considered. Rankings based on the thermal efficiency of the ORC and on the heat capacity flow rates of the heat carrier as well as on the volume and the heat flow rates show cyclopentane to be the best working fluid for all cases studied.     

Experimental investigation of convective heat transfer and pressure loss in a round tube fitted with circular-ring turbulators

This paper presents the effect of the circular-ring turbulator (CRT) on the heat transfer and fluid friction characteristics in a heat exchanger tube. The experiments were conducted by insertion of CRTs with various geometries, including three different diameter ratios (DR = d/D = 0.5, 0.6 and 0.7) and three different pitch ratios (PR = p/D = 6, 8 and 12). During the test air at 27 °C was passed through the test tube which was controlled under uniform wall heat flux condition. The Reynolds number was varied from 4000 to 20,000. According to the experimental results, heat transfer rates in the tube fitted with CRTs are augmented around 57% to 195% compared to that in the plain tube, depending upon operating conditions. In addition, the results also reveal the CRT with the smallest pitch and diameter ratios offers the highest heat transfer rate in accompany with the largest pressure loss.     

Experimental investigation of heat transfer and turbulent flow friction in a tube fitted with perforated conical-rings

Perforated conical-ring (PCR) is one of the turbulence-promoter/turbulator devices for enhancing the heat transfer rate in a heat exchanger system. In the present paper, the influences of the PCR on the turbulent convective heat transfer (Nu), friction factor (f) and thermal performance factor (η) characteristics have been investigated experimentally. The perforated conical-rings (PCRs) used are of three different pitch ratios (PR = p/D = 4, 6 and 12) and three different numbers of perforated holes (N = 4, 6 and 8 holes). The experiment conducted in the range of Reynolds number between 4000 and 20,000, under uniform wall heat flux condition and using air as the testing fluid. The experimental results obtained by using the plain tube and the tube equipped with the typical conical-ring (CR) are also reported for comparison. It is found that the PCR considerably diminishes the development of thermal boundary layer, leading to the heat transfer rate up to about 137% over that in the plain tube. Evidently, the PCRs can enhance heat transfer more efficient than the typical CR on the basis of thermal performance factor of around 0.92 at the same pumping power. Over the range investigated, the maximum thermal performance factor of around 0.92 is found at PR = 4 and N = 8 holes with Reynolds number of 4000.     

Analysis of heat transfer and pressure drop characteristics in an offset strip fin heat exchanger

A steady-state three-dimensional numerical model was used to study the heat transfer and pressure drop characteristics of an offset strip fin heat exchanger. Water was the heat transfer medium, and the Reynolds number Re_dh ranged from 10 to 3500. Variations in the Fanning friction factor f and the Colburn heat transfer factor j relative to Re_dh were observed. General correlations for the f and j factors were derived, and these could be used to analyze fluid flow and heat transfer characteristics of offset strip fins in the laminar, transition, and turbulent regions. Finally, three performance criteria (j/f, j/f^1/3, and JF) were adopted, and the best performance criteria for the cases Pr = 7 and Pr = 50 were chosen to be JF and j/f^1/3, respectively.     

Non-premixed acoustically perturbed swirling flame dynamics

An investigation into the response of non-premixed swirling flames to acoustic perturbations at various frequencies (f_p = 0-315 Hz) and swirl intensities (S = 0.09 and 0.34) is carried out. Perturbations are generated using a loudspeaker at the base of an atmospheric co-flow burner with resulting velocity oscillation amplitudes |u′/U_avg| in the 0.03-0.30 range. The dependence of flame dynamics on the relative richness of the flame is investigated by studying various constant fuel flow rate flame configurations. Flame heat release rate is quantitatively measured using a photomultiplier with a 430 nm bandpass filter for observing CH∗ chemiluminescence which is simultaneously imaged with a phase-locked CCD camera. The flame response is observed to exhibit a low-pass filter characteristic with minimal flame response beyond pulsing frequencies of 200 Hz. Flames at lower fuel flow rates are observed to remain attached to the central fuel pipe at all acoustic pulsing frequencies. PIV imaging of the associated isothermal fields show the amplification in flame aspect ratio is caused by the narrowing of the inner recirculation zone (IRZ). Good correlation is observed between the estimated flame surface area and the heat release rate signature at higher swirl intensity flame configurations. A flame response index analogous to the Rayleigh criterion in non-forced flames is used to assess the potential for a strong flame response at specific perturbation configurations and is found to be a good predictor of highly responsive modes. Phase conditioned analysis of the flame dynamics yield additional criteria in highly responsive modes to include the effective amplitude of velocity oscillations induced by the acoustic pulsing. In addition, highly responsive modes were characterized by velocity to heat release rate phase differences in the ±π/2 range. A final observed characteristic in highly responsive flames is a Strouhal number between 1 and 3.5 based on the burner co-flow annulus diameter (St = f_pU_avg/d_m). Finally, wavelet analyses of heat release rate perturbations indicate highly responsive modes are characterized by sustained low frequency oscillations which accompany the high amplitude velocity perturbations at these modes. Higher intensity low frequency heat release rate oscillations are observed for lean flame/low pulsing frequency conditions.     

Local heat transfer characteristics of array impinging jets from elongated orifices

The aim of this research is to enhance the heat transfer on an impinged surface under an impinging jet array by minimizing a cross-flow effect. Conventional round orifices (aspect ratio, AR = 1) are substituted by the elongated orifices with aspect ratio AR = 4 and 8 with the same jet exit area. Two types of orifice arrangements; in-line and staggered arrays are compared. The experimental investigation was carried out at constant distance from orifice plate to impinged surface H = 2D_E (D_E is equivalent diameter of orifice). The heat transfer characteristic was visualized using thermochromic liquid crystal sheet (TLCs) and the Nusselt number distribution was evaluated by an image processing technique. The flow characteristic on the impinged surface was also visualized by oil film technique. The results show that the cross-flow in a case of the jets issued from the orifices with AR = 4 is considerably less significant than that in cases of the ones delivered from the orifices with AR = 1 and 8. At Reynolds number of 13,400, the Nusselt numbers for the jet arrays issued from the elongated orifices with AR = 4 with in-line and staggered arrangements are respectively 6.04% and 12.52% higher than those for the case of AR = 1.     

Analysis of fluid flow and heat transfer in a rib grit roughened surface solar air heater using CFD

This paper presents the study of fluid flow and heat transfer in a solar air heater by using Computational Fluid Dynamics (CFD) which reduces time and cost. Lower side of collector plate is made rough with metal ribs of circular, square and triangular cross-section, having 60° inclinations to the air flow. The grit rib elements are fixed on the surface in staggered manner to form defined grid. The system and operating parameters studied are: e/D_h = 0.044, p/e = 17.5 and l/s = 1.72, for the Reynolds number range 3600-17,000. To validate CFD results, experimental investigations were carried out in the laboratory. It is found that experimental and CFD analysis results give the good agreement. The optimization of rib geometry and its angle of attack is also done. The square cross-section ribs with 58° angle of attack give maximum heat transfer. The percentage enhancement in the heat transfer for square plate over smooth surface is 30%.