Heat transfer analysis of blast furnace stave

The three-dimensional mathematical model of temperature and thermal stress field of the blast furnace stave is built. The radiation heat transmitted from solid materials (coke and ore) to inner surface of the stave, which has been neglected by other studies, is taken into account. The cast steel stave is studied and the finite element method is used to perform the computational analysis with soft ANSYS. Numerical calculations show very good agreement with the results of experiment. Heat transfer analysis is made of the effect of the cooling water velocity and temperature, the cooling channel inter-distance and diameter, the lining material, the cooling water scale, the coating layer on the external surface of the cooling water pipe as well as the gas clearance on the maximum temperature and thermal stress of the stave hot surface. It is found that reducing the water temperature and increasing the water velocity would be uneconomical. The heat transfer and hence the maximum temperature and thermal stress in the stave can be controlled by properly adjusting operating conditions of the blast furnace, such as the gas flow, cooling channel inter-distance and diameter, lining material, coating layer and gas clearance.     

ANALYSIS OF TRANSIENT THERMAL BENDING MOMENTS AND STRESSES OF THE WORKPIECE DURING SURFACE GRINDING

Geometrical inaccuracy is often induced by heat generated during grinding. Furthermore, the transient thermal process is the main cause for the residual stresses on theground surface. The objective of this article is to investigate the three-dimensional transient temperature distribution of the workpiece using the finite difference method,and based on the acquired temperature and beam theory, the thermal moment and thermoelastic stress as calculated using Simpson's multiple numerical integral method. The energypartition is the key factor in accurately predicting the temperature distribution, on which the solution of the thermal moment and stress rely. As the heat conductivity of the workpiece decreases, the stress and moment increase near the wheel-workpiece contact zone and the peaks move closer to the contact position. A smaller thickness results in higher thermal stress and lower thermal moment. Enhancing cooling in grinding effectively reduces temperature and the induced stress.     

柴油机冷却水套中无水冷却液的数值模拟分析

运用FLUENT软件对某型号柴油机冷却水套三种无水冷却液在不同温度下的冷却效果进行数值模拟分析.模拟结果表明:由于冷却液表面换热系数的变化受冷却液粘度及导热率的影响,而这两个因素随温度的变化而变化;温度较低时,冷却液的导热率的影响占主导地位,表面换热系数随温度的增大而减小;温度较高时,冷却液粘度的影响占主导地位,表面换热系数随温度的升高而增大.     

Performance Analysis and Optimization of a Single-Barrier Solid-State Thermionic Refrigerator With External Heat Transfer

A model of a single-barrier solid-state thermionic refrigerator with external heat transfer is established in this paper. The performance of the refrigerator is analyzed and optimized by using the combination of finite-time thermodynamics and nonequilibrium thermodynamics. The general expressions for cooling load and coefficient of performance (COP) of the refrigerator are derived. The optimum regions of cooling load and COP are obtained and the effects of the heat reservoir temperature and thermal conductance of the barrier material on the performance of the refrigerator are analyzed by detailed numerical examples. The results obtained are compared with those obtained by using traditional analysis without considering external heat transfer. For the fixed total heat transfer surface area of two heat exchangers, the ratios of the heat transfer surface area of the hot-side heat exchanger to the total heat transfer surface area of the heat exchangers are optimized for maximizing the cooling load and COP of the refrigerator, respectively. The effects of the total heat transfer surface area and the applied voltage on the optimum performance of the refrigerator are analyzed. The results obtained herein may provide some theoretical guidelines for the design and application of practical solid-state thermionic refrigerators.     

Reciprocating liquid‐assisted system for electronic cooling applications

Increasing the power density and heat dissipation in electronic equipment and their need for an efficient thermal management system have made the liquid cooling techniques inevitable in recent years. In most applications, liquid cooling systems work in conjunction with more traditional cooling methods, such as conduction and convection heat transfer, using air cooling systems. In this study, the performance of Reciprocating Mechanism‐Driven Heat Loop (RMDHL) for electronic and power electronic cooling applications has been studied and compared with that of a conventional Dynamic Pump‐Driven Heat Loop (DPDHL). A numerical model using moving boundaries in Ansys Fluent commercial code has been developed to generate the reciprocating motion of working fluid with desired frequency and amplitude. The temperature distribution contours and Nusselt numbers show the superior performance of the RMDHL system in terms of heat transfer and temperature uniformity of the heated surface. The results show that, for the same average mass flow rate in the cooling loops the average surface temperature in the RMDHL loop is considerably lower than that of DPDHL especially at higher reciprocating frequency. The results also indicate that similar to the effect of the oscillatory frequency, increasing the amplitude also increases the heat transfer rate in the RMDHL loop. In addition, the Nusselt number shows a linear increment with the increase of both oscillatory amplitude and frequency. Uniform temperature distribution and efficiency of thermal management systems based on RMDHL loop could decrease the resultant thermal stress in electronic devices and increase the reliability of them.     

An experimental investigation of film cooling performance of louver scheme

An experimental investigation of the film cooling performance of louver schemes using Thermochromic Liquid Crystal technique is presented in this paper. The louver scheme allows the cooling flow to pass through a bend and encroach with the blade material (impingement effect), then exit to the outer surface of the aerofoil through the film cooling hole. The cooling performance of the louver scheme was analyzed for blowing ratios ranging from 0.5 to 1.5 and for a density ratio of 0.94. The results showed that the louver scheme enhances the local and the average film cooling effectiveness, and the net heat flux reduction better than other published film hole configurations. The louver scheme also provides a wide extensive spread of the secondary flow over the outer surface, thus enhancing the lateral film cooling performance over the downstream surface area. Moreover, the louver scheme produces a lower heat transfer ratio than other film hole geometries at low and high blowing ratios. As a result, the louver scheme is expected to reduce the gas turbine airfoil’s outer surface temperature by provide superior cooling performance than other film cooling schemes hence increasing the airfoil life time.     

3-D CONJUGATE ANALYSIS OF COOLED COATED PLATES AND HOMOGENIZATION OF THEIR THERMAL PROPERTIES

To predict the aerothermal behavior of a transpiration cooled plate, a multiscale approach based on the homogenization method of periodic material structures is presented here. This method allows calculation of effective equivalent thermophysical properties either for each layer or for the multilayer of superalloy, bondcoat, and thermal barrier coating (TBC). From the 3-D conjugate flow and heat transfer analysis, the stationary state is extracted and transferred to the microscale unit cell discretized by finite elements. The analysis proves for different cooling configurations a significant decrease in the amount of cooling fluid to obtain a desired superalloy temperature. Beyond, the hole outlet shaping leads to a reduction of the thermal gradients on the multilayer. The effect of the different cooling designs on the effective conductivities are discussed then. Finally, the influence of the selection of the unit cell position on these effective thermal properties is investigated.     

COMBINED MACROSCOPIC AND MICROSCOPIC ANALYSIS OF THERMOELASTOPLASTIC STRESSES OF A FUNCTIONALLY GRADED MATERIAL PLATE

This article discusses the elastoplastic thermal stresses induced in a ceramic-metal functionally graded material plate (FGP) subjected to a thermal load taking the fabrication process into consideration. The FGP is divided into three regions. The first region near the cooling, metal, surface of the FGP is produced by ceramic particle-reinforced metal; while the second region near the heat-resistant, ceramic, surface is the opposite; and the third middle region is perfectly mixed by the metal and the ceramic. The first and second regions are governed by the particle-reinforced thermoelastoplastic constitutive equation, while the third region is expressed by the macroscopic analysis. Three cases of the temperature condition are studied: cooling from the fabricated temperature to room temperature, heating from the room temperature, and heating after cooling from the fabricated temperature. The temperature-dependent material properties are considered, and the particle volume fraction is assumed to vary according to a power function along the thickness direction of the FGP. The effect of the distribution parameter of the composition on the macroscopic stress, the stress in the matrix, and the stress in the particle in the FGP are discussed and illustrated in figures. Also, the effect of the fabricated temperature on the maximum tensile matrix stress is discussed.     

Cooling of spherical products: Part II—heat transfer parameters

This paper presents a study on the determination of the heat transfer parameters, namely surface heat transfer coefficients, thermal conductivities, thermal diffusivities, specific heats and Biot numbers, for the individual product being cooled with water and with air. An analytical model was developed to determine the surface heat transfer coefficients of the products depending on the thermal properties and cooling process parameters. The results of the present study indicate that surface heat transfer coefficients decrease with increasing batch weight in water cooling and increase with increasing air flow velocity in air cooling. The proposed model can be used to determine easily and accurately surface heat transfer coefficients of different spherically shaped objects subjected to cooling.     

Numerical analysis of heat transfer and flow field around cross-flow heat exchanger tube with fouling

Fouling is one of the main problems of heat transfer which can be described as the accumulation on the heat exchanger tubes, i.e.; ash deposits on the heat exchanger unit of the boiler. A decrease in heat transfer rate by this deposition causes loss in system efficiency and leads to increasing in operating and maintenance costs. This problem concerns with the coupling among conduction heat transfer mode between solid of different types, conjugate heat transfer at the interface of solid and fluid, and the conduction/convection heat transfer mode in the fluid which can not be solved analytically. In this paper, fouling effect on heat transfer around a cylinder in cross flow has been studied numerically by using conjugate heat transfer approach. Unlike other numerical techniques in existing literatures, an unstructured control volume finite element method (CVFEM) has been developed in this present work. The study deals with laminar flow where the Reynolds number is limited in the range that the flow field over the cylinder is laminar and steady. We concern the fouling shape as an eccentric annulus with constant thermal properties. The local heat transfer coefficient, temperature distribution and mean heat transfer coefficient along the fouling surface are given for concentric and eccentric cases. From the results, we have found that the heat transfer rate of cross-flow heat exchanger depends on the eccentricity and thermal conductivity ratio between the fouling material and fluid. The effect of eccentric is dominant in the region near the front stagnation point due to high temperature and velocity gradients. The mean Nusselt number varies in asymptotic fashion with the thermal conductivity ratio. Fluid Prandtl number has a prominent effect on the distribution of local Nusselt number and the temperature along the fouling surface.     

叶型表面曲率对离散孔气膜冷却性能的影响

由于型面曲率的影响,涡轮叶片前缘和吸力面的冷却气膜易于脱离型面,气膜冷却效果下降。本研究将叶片型线分段拟合,建立了多个单一曲率的曲面模型(R/D=-30、-75、120、∞),研究涡轮叶片表面曲率对于气膜冷却的影响。流动与传热的数值模拟采用Fluent软件,湍流模型选择RNGk-ε模型,模拟方法经平板流动进行的结果验证是可靠的。在不同吹风比(M=0.5、1.2、2.0)条件下,计算比较了不同曲率曲面上气膜单孔下游的壁面传热系数以及局部平均气膜冷却效率。结果表明:涡轮叶片型面曲率对气膜冷却效果的影响与吹风比有关。不同曲率的型线部分,应该设计采用不同的吹风比,气膜冷却效果可能取得最佳。低吹风比M<1时,凹面曲率对气膜换热系数是强化,凸面基本没有作用。高吹风比M>1时,曲率不影响换热能力,冷却效果则取决与气膜相对于型面的流动状态和与主流的掺混能力。     

Experimental investigations on overall cooling effect of ribbed channel with air bleeds

An experimental investigation on overall heat transfer performance of a rectangular channel, in which one wall has periodically placed oblique ribs to enhance heat exchange and cylindrical film holes to bleed cooling air, has been carried out in a hot wind tunnel at different mainstream temperatures, hot mainstream Reynolds numbers, coolant Reynolds numbers and blowing ratios. To describe the cooling effect of combined external coolant film with the internal heat convection enhanced by the ribs, the overall cooling effectiveness at the surface exposed in the mainstream with high temperature was calculated by the surface temperatures measured with an infrared thermal imaging system. The total mass flow rate of cooling air through the coolant channel was regulated by a digital mass flow rate controller, and the blowing ratio passing through the total film holes was calculated based on the measurements of another digital-type mass flow meter. The detailed distributions of overall cooling effectiveness show distinctive peaks in heat transfer levels near the film holes, remarkable inner convective heat transfer effect over entire channel surface, and visible conductive heat transfer effect through the channel wall; but only when the coolant Reynolds number is large enough, the oblique rib effect can be detected from the overall cooling effectiveness; and the oblique bleeding hole effect shows the more obvious trend with increasing blowing ratios. Based on the experimental data, the overall cooling effectiveness is correlated as the functions of Re_m (Reynolds number of hot mainstream) and Re_c (Reynolds number of internal coolant flow at entrance) for the parametric conditions examined.     

Vortical structures and heat transfer augmentation of a cooling channel in a gas turbine blade with various arrangements of tip bleed holes

Abstract

This study investigates the internal cooling processes affected by the tip bleed holes in gas turbine blades. Double bleed holes are fixed at the center of the blade tip near the pressure side and suction side, respectively. Five different arrangements of the holes along the center line of the tip are studied. The purely double holes are set as the Baseline. The purpose of the present study is to provide a new perspective of the tip film cooling to understand the internal flow processes, vorticity evolution and the mechanism of the heat transfer augmentation. A topological analysis and the boundary layer analysis methods are introduced to better understand the tip heat transfer. The total extraction area and volume is kept at the same level for all the studied cases. The results show that the Dean vortices and the near-wall vortices induced by the secondary flow contribute to the high heat transfer coefficient on the tip surface. The mixing effect of the Dean vortices and the hole extraction helps to enhance heat transfer upstream of the tip. Different arrangement of the bleed holes can affect the internal flow processes and heat transfer performance. The suction effect of the center-line bleed hole can accelerate the near-hole flow and reduce the thickness of the boundary layer. The center-line hole fitted at the middle of the tip affects significantly the rear side of the hole. Thus, the holes aligned in the middle of the tip provide the highest heat transfer and thermal performance. The thermal performance is enhanced by up to 4.7% compared with the Baseline.     

Cooling of Laser Slab by Forced Convection through a Heat Sink

The present study addresses a novel cooling scheme for the high-power solid-state laser slab. The scheme cools the laser slab by forced convection in a narrow channel through a heat sink. Numerical simulations were conducted to investigate the thermal effects of a Nd:YAG laser slab for heat sinks of different materials, including the undoped YAG, sapphire, and diamond. The results show that the convective heat transfer coefficient is non-uniform along the fluid flow direction due to the thermal entrance effect, causing a non-uniform temperature distribution in the slab. The heat sink lying between the coolant fluid and the pumped surface of the slab works to alleviate this non-uniformity and consequently improve the thermal stress distribution and reduce the maximum thermal stress of the slab. The diamond heat sink was found to be effective in reducing both the highest temperature and the maximum thermal stress; the sapphire heat sink was able to reduce the maximum thermal stress but not as effective in reducing the highest temperature; and the undoped YAG heat sink reduced the maximum thermal stress but tended to increase the highest temperature. Therefore, cooling with the diamond heat sink is most effective, and that with the sapphire heat sink follows; cooling with the undoped YAG heat sink may not apply if the highest temperature is a concern.     

Transpiration cooling of a nose cone by various foreign gases

The transpiration cooling mechanisms used for thermal protection of a nose cone was investigated experimentally and numerically for various cooling gases. The effects of injection rates, model geometry, inlet temperature and Reynolds number of the main stream were studied for air, nitrogen, argon, carbon dioxide and helium. The experiments used a hot gas wind tunnel with T_∞ = 375 K and 425 K and Re_∞ = 4630–10,000. The experimental results indicated that even a small amount of coolant injection drastically reduced the heat transfer from the hot gases with the cooling effectiveness increasing with increasing injection rate, although the increases became smaller as the gas injection rate was further increased. The temperature and cooling effectiveness distribution along the transpiration surface of the nose cone model exhibited similar tendencies for all the coolants employed in present experimental research. The temperature decreased from the stagnation point towards the downstream region, then increased because of the non-uniform mass flow distribution of the coolant and thermal conduction from the metal backplane, whereas the cooling effectiveness variation was the reverse. The local cooling effectivenesses and thermal capacities were found to depend on the coolant thermophysical properties. Two-dimensional numerical simulations using the RNG κ?ε turbulence model for the main stream flow and the Darcy–Brinkman–Forchheimer momentum equations and thermal equilibrium model for the porous zone compared well with the general features in the experiments.     

Methodology for predicting spray quenching of thick-walled metal alloy tubes

This paper explores the parametric influences of spray quenching for thick-walled metal alloy tubes. Using the point-source depiction of a spray, an analytical model is derived to determine the shape and size of the spray impact zone, as well as the distribution of volumetric flux across the same zone. This distribution is incorporated into heat transfer correlations for all spray boiling regimes to generate a complete boiling curve for every location across the impact zone. By setting boundary conditions for both the sprayed and unsprayed portions of the tube surface, a heat diffusion model is constructed for a unit cell of the tube for both aluminum alloy and steel. This model is used to construct spray quench curves for every point along the sprayed surface and within the wall. Increasing nozzle pressure drop or decreasing orifice-to-surface distance are shown to increase the magnitude of volumetric flux, which hastens the onset of the rapid cooling stages of the quench as well as improves overall cooling effectiveness. The sprayed surface is characterized by fast thermal response to the spray, while regions within the wall display more gradual response due to heat diffusion delays. With their superior thermal diffusivity, aluminum alloy tubes transmit the cooling effect through the wall faster than steel tubes. For steel, the cooling effect is more concentrated near the sprayed surface, causing the sprayed surface to cool much faster and locations within the wall much slower than for aluminum alloy. The predictive approach presented in this paper facilitates the determination of surface temperature gradients in the quenched part to guard against stress concentration. Also, when combined with metallurgical transformation models for the alloy, it may be possible to predict material properties such as hardness and strength.     

Parameter survey of thermally highly loaded,porous and cooled multi-layer systems for turbine blades

This study is an advanced investigation for the cooling of high temperature turbine vanes and blades.The efficientheat exchanging near the surface of a blade may be achieved by forcing a cooling air flow emitting out of a thinlayer of the porous metal which is pasted on the structural high strength metal.The contents include the consid-eration on the computational model of heat transfer through a layer of porous material,the concrete modeling andthe analysis of the model,the numerical survey of key parameters for both the two-layer porous materials and theheat transfer fluid flow passing through the model channels.The results revealed that the constructed system isreasonable.Proposed an evaluation formula for the porous material heat transfer efficiency.     

Effects of chemical reaction caused by cooling stream on film cooling effectiveness

With the increase of inlet temperature of gas turbines, the benefits by using the conventional methods are likely to approach their limits. Therefore, it is essential to study novel film cooling methods for surpassing these current limits. Based on the theory of heat transfer enhancement, a film cooling method with chemical reaction by cool- ing stream is proposed. In order to test the feasibility of the proposed method, numerical simulations have been conducted. The classic flat plate structure with a 30 degree hole is used for the simulation. In the present study, the effects of the parameters in relation to the chemical reaction on film cooling effectiveness, such as chemical heat sink, volume changes, and reaction rate, are investigated numerically. The conventional film cooling is also calculated for the comparison. The results show that film cooling effectiveness is improved obviously due to the chemical reaction, and the reaction heat and reaction rate of cooling stream have an important effect on film ef- fectiveness. However, the effect of volume changes can be ignored.     

Improvement of film cooling performance by trenched holes on turbine leading-edge models

The present study aims to improve cooling performance over the leading edge surface with the high temperature and high thermal stress by the introduction of trenched holes. Three staggered rows of leading-edge film cooling holes with different trench arrangements and hole orientations are included under blowing ratios of 0.5, 1.0, 1.5, and 2.0, compared with round-hole cases. Under the conditions of leading-edge flow patterns and convex curvature, the trenched hole with 2D width plays a role of “protection” of coolant against the impinging hot gas at a large range of blowing ratios. This contributes to the better lateral spread of coolant and cooling performance. Besides, the trenched holes narrow the regions with a high heat transfer coefficient and reduce the detrimental heating on the surface. Compared with round holes, the trenched holes guarantee the downstream coolant coverage and higher cooling performance at a larger inclined angle, in spite of the changed compound angles.     

Impact of variation of nanoparticle shape on free convective MHD water-based flow of Hamilton–Crosser model radiative nanofluids over a permeable surface

The present analysis explores the impact of shape of the nanoparticles on the conducting nanofluids past a porous surface. The electrically conducting fluid possesses enhanced physical properties due to the thermal buoyancy, and the radiative heat energy enhances the thermal properties of the water-based nanofluid. The suitable choice of a nanoparticle, that is, considering the metal particle like copper (Cu) and oxide particle such as TiO₂ in conjunction with the Hamilton–Crosser model thermal conductivity, augments the heat transfer properties. The appropriate transformation of similarity variable and the stream function helps to convert the leading partial differential equations to nonlinear ordinary differential equations (ODEs). Furthermore, these distorted ODEs are handled by using numerical technique such as Runge–Kutta–Fehlberg along with the shooting technique. The graphical presentation of the profiles of flow phenomena due to the interaction of relevant parameters is deployed for the physical significance, and the comparison of the present investigation shows a good agreement with the earlier results. However, the major outcomes are as follows; backflow occurs near the surface region due to the impermeable surface also increasing shape of the nanoparticle decelerates the fluid temperature and it is useful by considering the spherical shaped nanoparticles for the enhanced heat transfer.