Laminar flow and heat transfer in plate-fin triangular ducts in thermally developing entry region

Laminar forced flow and heat transfer in plate-fin isosceles triangular ducts encountered in compact heat exchangers is investigated. The flow is hydrodynamically fully developed, but developing thermally under uniform temperature conditions. Heat conduction in the fin of finite conductance and convection in the fluid are analyzed simultaneously as a conjugate problem. The study covers a wide range of apex angles from 30° to 120°, and fin conductance parameters from 0 to infinitely large. Nusselt numbers in the developing and fully developed regions for various apex angles and fin conductance parameters are obtained, which can be used in estimation of heat transfer characteristics in plate-fin compact heat exchangers with fins of various conductivities and thickness.     

Experimental Determination of the Heat Transfer Coefficient of a Plate-Fin Heat Exchanger

Heat transfer in compact plate-fin heat exchangers is augmented by the introduction of complex fin patterns in the channels. Kays and London presented a lot of experimental data for several types of fin configurations, and many authors followed their example with other types of fins. For some fin types, the heat transfer correlation for the Nusselt number cannot be found in literature. Most of the data are given for large scale model fins in good controlled laboratory environments—little data is available for real heat exchangers.

A test rig was constructed at Ghent University to verify the performance of several fin types. Measurements were done on a real heat exchanger and not on a large scale model in order to determine the performance under real operational conditions.

The measurement setup consists of a hot water circuit and an air circuit with a fan. In the heat exchanger, 40 thermocouples are introduced on the air side and the wall. This way, the convection coefficient of the fins can be determined for a broad range of Reynolds numbers.

In the paper the measurement set-up is discussed and the measurements are presented. An in depth error analysis is performed on the measurements. This way a heat transfer correlation is provided with a tight error margin for compact plate-fin air coolers.     

Heat and mass transfer in plate-fin enthalpy exchangers with different plate and fin materials

Enthalpy exchangers have been used as an efficient means to recover both sensible heat and moisture from exhaust ventilation air. A cross-flow plate-fin structure is the most popular arrangement for the exchanger core due to its compactness and high mechanical strength even with very small channel wall thickness. Traditionally, hygroscopic paper is selected as the plate and fin materials. Though the sensible effectiveness with this material is satisfactorily high, the latent effectiveness is disappointingly low due to the low moisture diffusivity in paper. To solve this problem, in this study, a novel concept is proposed to augment moisture transfer in the exchanger. Plates and fins are made with different materials. A novel membrane – the composite supported liquid membrane (CSLM) is used as the plate material. Paper is still used as the fin material for its cheapness and high support strength. To make comparisons, two cores, one is paper-fin and paper-plate, and another one is paper-fin and membrane-plate, are constructed and tested for heat and moisture recovery. Simultaneous heat and moisture transfer in the plate-fin core is studied. Mathematical model governing the heat and moisture transfer in the cores is set up and numerically solved. Both the experimental data and numerical results indicate that the latent effectiveness of the paper-fin and membrane-plate core is 60% higher than the traditional paper-fin and paper-plate core, due to the high moisture diffusivity in the CSLM.     

Studies on pumping power in terms of pressure drop and heat transfer characteristics of compact plate-fin heat exchangers—A review

Renewable energy sources like solar energy, wind energy, etc. are profusely available without any limitation. Heat exchanger is a device to transfer the energy from one fluid to other fluid for many applications in buildings, industries and automotives. The optimum design of heat exchanger for minimum pumping power (i.e., minimum pressure drop) and efficient heat transfer is a great challenge in terms of energy savings point of view. This review focuses on the research and developments of compact offset and wavy plate-fin heat exchangers. The review is summarized under three major sections. They are offset fin characteristics, wavy fin characteristics and non-uniformity of the inlet fluid flow. The various research aspects relating to internal single phase flow studied in offset and wavy fins by the researchers are compared and summarized. Further, the works done on the non-uniformity of this fluid flow at the inlet of the compact heat exchangers are addressed and the methods available to minimize these effects are compared.     

Design of Plate-Fin Tube Dehumidifiers for Humidification–Dehumidification Desalination Systems

A two-dimensional numerical model of a plate-fin tube heat exchanger for use as a dehumidifier in humidification–dehumidification (HDH) desalination systems is developed, because typical heating, ventilating, and air conditioning (HVAC) dehumidifier models and plate-fin tube dehumidifier geometries are not intended for the considerably higher temperature and humidity ratio differences that drive heat and mass transfer in HDH desalination applications. The experimentally validated model is used to investigate the influence of various heat exchanger design parameters. Potential improvements on common plate-fin tube dehumidifier designs are identified by examining various methods of optimizing tube diameter and longitudinal and transverse tube spacing to achieve maximum heat flow for a given quantity of fin material at a typical HDH operating point. Thicker fins are recommended than for HVAC geometries, as the thermal conductive resistance of HVAC fins restricts dehumidifier performance under HDH operating conditions.     

Numerical study of flow patterns of compact plate-fin heat exchangers and generation of design data for offset and wavy fins

Thermo-hydraulic design of compact heat exchangers (CHEs) is strongly dependent upon the predicted/measured dimensionless performance (Colburn factor j and Fanning friction factor f vs. Reynolds number Re) of heat transfer surfaces. Also, air (gas) flow maldistribution in the headers, caused by the orientation of inlet and outlet nozzles in the heat exchanger, affects the exchanger performance. Three typical compact plate-fin heat exchangers have been analyzed using Fluent software for quantification of flow maldistribution effects with ideal and real cases. The headers have modified by providing suitable baffle plates for improvement in flow distribution. Three offset strip fin and 16 wavy fin geometries used in the compact plate-fin heat exchangers have also been analyzed numerically. The j and f vs. Re design data are generated using CFD analysis only for turbulent flow region. For the validation of the numerical analysis conducted in the present study, a rectangular fin geometry having same dimensions as that of the wavy fin has been analyzed. The results of the wavy fin have been compared with the analytical results of a rectangular fin and found good agreement. Similarly, the numerical results of offset strip fin are compared with the correlations available in the open literature and found good agreement with most of the earlier findings.     

The performance of a new gas to gas heat exchanger with strip fin

A compact gas to gas heat exchanger needs large heat transfer areas on both fluid sides. This can be realised by adding secondary surfaces. The secondary surfaces are plate fin, strip fin, and louvered fin, etc. The fins extend the heat transfer surfaces and promote turbulence.This paper presents a gas to gas heat exchanger with strip fins. The heat exchanger design and construction are based on a method to seal rectangular strip fins in slots in opposite walls of a rectangular pipe. Fins are fixed and sealed to the walls simultaneously by high temperature brazing of glass mixed with metals in a furnace. The additional advantage of glass is that it forms a coating on the heat transfer surface to protect the surface from corrosion.A number of measurements were carried out to test the performance of this heat exchanger. Not surprisingly, the measurement results indicate that heat transfer coefficient and pressure drop increase with the ratio of heat transfer area to volume (fin density). Colburn factor and friction factor versus Reynolds number are presented.     

换热技术从大型化向微小化的发展

在分析传统换热器结构特点的基础上,具体分析了目前常用紧凑式换热器的结构、性能及应用情况,阐述了微型化学（化工）机械系统的发展及应用情况。以氨冷器为例,分别进行了板翅式换热器和另一种高效的小型换热装置——热管换热器的设计,表明板翅式换热器具有更加高效的换热效率和紧凑的结构,由此综合说明了换热技术从大型化向紧凑化、微小化发展的必然趋势。进一步以典型的微型化换热器装置——微通道换热器、微通道蒸发器和微通道加热器为例,具体分析了微型换热技术广阔的应用前号。     

Numerical investigation of fluid flow and heat transfer over louvered fins in compact heat exchanger

Numerical investigation of fluid flow and heat transfer characteristics over louvered fins and flat tube in compact heat exchangers is presented in this study. Three-dimensional simulations of single and double row tubes with louvered fins have been conducted. Simulations are performed for different geometries with varying louver pitch, louver angle, fin pitch and tube pitch and for different Reynolds number. Conjugate heat transfer and conduction through the fins are considered. The air-side performance of heat exchanger is evaluated by calculating Stanton number and friction factor. The results are compared with experiment and a good agreement is observed. The local Nusselt number variation along the top surface of the louver is calculated and effects of geometrical parameters on the average heat transfer coefficient is computed. Design curves are obtained which can used to predict the heat transfer and the pressure drop for a given louver geometry.     

Reflux condensation in narrow rectangular channels with perforated fins

Reflux condensation is an industrial process that aims to reduce the content of the less volatile component or to eliminate the non-condensable phase of a vapour mixture, by the means of separation. Separation consists in condensing the less volatile phase and to recover the condensate while simultaneously, the non-condensable species are recuperated at the top of the system. Compact plate-fin heat exchangers can be used in gas separation processes. The aim of this study is to test the process of reflux condensation of an air–steam mixture in the channels of a plate fin heat exchanger with a hydraulic diameter of 1.63 mm. The experimental study shows that reflux condensation occurs in specific parts of the heat exchanger, the other parts remaining dry.Moist air condensation is modelled by the film theory and the results show that the model is well adapted to simulating the heat and mass transfer.     

Multidisciplinary optimization of a pin-fin radial heat sink for LED lighting applications

In this study, the cooling performance and mass of a pin-fin radial heat sink were optimized. A radial heat sink with pin fins was examined numerically to obtain a lighter heat sink while maintaining a similar cooling performance to that of a plate-fin heat sink investigated in a previous study. Both natural convection and radiation heat transfer were considered. Experiments were performed to validate the numerical model. The average temperature and mass of the heat sink for various types of fin arrays were compared to determine an appropriate reference configuration. The effects of various geometric parameters on the thermal resistance and mass of the heat sink were investigated; these indicated that the system was sensitive to the number of fin arrays, as well as the length of the long and middle fins. Multidisciplinary optimization was carried out using the three design variables to minimize the thermal resistance and mass simultaneously, and Pareto fronts were obtained with various weighting factors. A design for the optimum radial heat sink is proposed, which reduces the mass by more than 30% while maintaining a similar cooling performance to that of a plate-fin heat sink.     

Development of Colburn j Factor and Fanning Friction Factor Correlations for Compact Surfaces of the Triangular Perforated Fins Using CFD

The necessity of increased heat transfer surface area has resulted in the development of compact heat exchangers, which are widely used in the aerospace and automobile industries. Hence perforations are made on triangular plain fins to study the effects on the heat transfer coefficient. A numerical model has been developed for the perforated fin of a triangular plate fin heat exchanger. Perforated fin performance has been analyzed with the help of computational fluid dynamics (CFD) by changing the various parameters of the fin. The Colburn j factor and the Fanning friction factor are calculated for different Reynolds numbers. The values of the Colburn j factor and the Fanning friction factor are validated for known geometric fins with available data in the literature and extended to triangular perforated fins. The correlations have been developed between Reynolds number, Colburn j factor, and Fanning friction factor by taking into account fin height, fin thickness, and fin spacing. The present numerical analysis is carried out for air media.     

WINGLET-TYPE VORTEX GENERATORS FOR PLATE-FIN HEAT EXCHANGERS USING TRIANGULAR FINS

Vortex generators in the form of delta winglet pairs have already been proposed by many researchers for enhancement of the heat transfer rate in plate-fin heat exchangers. In this work, the enhancement potential of triangular fins (which are widely used inserts between the plates of the plate-fin heat exchanger) having delta winglets mounted on their slant surfaces has been computed. The performance of this combination is evaluated for varying angles of attack of the winglet and different thermal boundary conditions. The performance of the combination of triangular fins and winglets with stamping on the slant surfaces also has been evaluated.     

Experimental Investigation on Fluid Flow Maldistribution in Plate-Fin Heat Exchangers

The plate-fin heat exchanger is normally designed with the assumption that the fluid is uniformly divided among all the parallel passages. In practice, however, the design of the exchanger, the heat transfer process, the operation of the external system, etc., may create high flow maldistribution. The performance deterioration of plate-fin heat exchangers due to flow maldistribution may be serious. In this review, the flow distribution performance in a plate-fin heat exchanger has been experimentally studied and the distribution performance of different distributors' inlet angles has been measured. The combined effects of the inlet angle and mass flow rate on flow maldistribution have been studied. The study is useful in the optimum design of plate-fin heat exchangers.     

Fin Pattern Effects on Air-Side Heat Transfer and Friction Characteristics of Fin-and-Tube Heat Exchangers with Large Number of Large-Diameter Tube Rows

Air-side heat transfer and friction characteristics of nine kinds of fin-and-tube heat exchangers, with a large number of tube rows (6, 9, and 12, respectively) and large diameter of tubes (18 mm), are experimentally investigated. The test samples consist of three types of fin configurations: plain fin, slit fin, and fin with delta-wing longitudinal vortex generators. The working fluid in the tube is steam. Results show that when the number of tube is larger than 6, the heat transfer and friction performance for three kinds of fins is independent of the number of tube rows, and slit fin provides higher heat transfer and pressure drop than the other two fins. The heat transfer and friction factor correlations for all the heat exchangers were acquired with Reynolds numbers ranging from 4000 to 10000. The air-side performance of heat exchangers with plain fin, slit fin, and longitudinal vortex-generator fin were evaluated under three sets of criteria, and the results showed that the heat exchanger with slit fin has better performance than that with vortex-generator fin, especially at high Reynolds numbers.     

Numerical computation for parallel plate thermoacoustic heat exchangers in standing wave oscillatory flow

A simplified computational method for studying the heat transfer characteristics of parallel plate thermoacoustic heat exchangers is presented. The model integrates the thermoacoustic equations of the standard linear theory into an energy balance-based numerical calculus scheme. Details of the time-averaged temperature and heat flux density distributions within a representative domain of the heat exchangers and adjoining stack are given. The effect of operation conditions and geometrical parameters on the heat exchanger performance is investigated and main conclusions relevant for HX design are drawn as far as fin length, fin spacing, blockage ratio, gas and secondary fluid-side heat transfer coefficients are concerned. Most relevant is that the fin length and spacing affect in conjunction the heat exchanger behavior and have to be simultaneously optimized to minimize thermal losses localized at the HX-stack junctions. Model predictions fit experimental data found in literature within 36% and 49% respectively at moderate and high acoustic Reynolds numbers.     

Cooling enhancement in an air-cooled finned heat exchanger by thin water film evaporation

A theoretical analysis on the cooling enhancement by applying evaporative cooling to an air-cooled finned heat exchanger is presented in this work. A two-dimensional model on the heat and mass transfer in a finned channel is developed adopting a porous medium approach. Based on this model, the characteristics of the heat and mass transfer are investigated in a plate-fin heat exchanger with the interstitial surface fully covered by thin water film. Assuming that the Lewis number is unity and the water vapor saturation curve is linear, exact solutions to the energy and vapor concentration equations are obtained. The cooling effect with application of evaporative cooling was found to be improved considerably compared with that in the sensible cooler. This is because the thermal conductance between the fin and the air increases due to the latent heat transfer caused by the water evaporation from the fin surface. It is also found that the cooling enhancement depends greatly on the fin thickness. If the fin is not sufficiently thick, the cooling enhancement by the evaporative cooling decreases since the fin efficiency drops considerably due to the water evaporation from the fin surface. The fin thickness in the evaporative cooler should be increased larger than that in the sensible cooler to take full advantage of the cooling enhancement by the water evaporation.     

Optimization of peripheral finned-tube evaporators using entropy generation minimization

The peripheral finned-tube (PFT) is a new geometry for enhanced air-side heat transfer under moisture condensate blockage (evaporators). It consists of individual hexagonal (peripheral) fin arrangements with radial fins whose bases are attached to the tubes and tips are interconnected with the peripheral fins. In this paper, experimentally validated semi-empirical models for the air-side heat transfer and pressure drop are combined with the entropy generation minimization theory to determine the optimal characteristics of PFT heat exchangers. The analysis is based on three independent parameters, i.e., porosity, equivalent particle diameter and particle-based Reynolds number. The total heat transfer rate is a fixed constraint. The optimal heat exchanger configurations, i.e., those in which the entropy generation number reaches a minimum, are calculated for constant heat flux and constant tube wall temperature boundary conditions. Performance evaluation criteria of fixed geometry, fixed face area and variable geometry were implemented. In all cases, it was possible to determine a combination of independent parameters that provided a minimum entropy generation rate.     

Calculation of Two-Phase Convective Heat Transfer Coefficients of Cryogenic Nitrogen Flow in Plate-Fin Type Heat Exchangers

The two-phase convective heat transfer coefficients for nitrogen inside the flow path of plate-fin type heat exchangers operating at cryogenic temperatures are calculated using CFX Release 13.0. Using a homogeneous two-phase model, the governing equations are solved to find pressure, velocity, and enthalpy distributions for three types of fin geometries: plain, wavy, and serrated. The results are further processed to evaluate the wall shear stress and heat flux, which in turn yield the friction coefficients and convective heat transfer coefficients. The coefficients are presented as functions of system pressure, flow rate, and local quality. The results can be used for the design of plate-fin type exchangers with the same fin configurations and operating conditions as the calculation.     

Fluid Flow Distribution and Heat Transfer in Plate-Fin Heat Exchangers

Single-phase and two-phase flow distribution in plate-fin heat exchangers and the influence of nonuniform fluid flow distribution on the thermal performance of such heat exchangers were experimentally investigated. The experimental results show that flow maldistribution can be a serious problem in plate-fin heat exchangers because of nonoptimized header configurations. The uneven distribution of two-phase flow in plate-fin heat exchangers is more pronounced than that of single-phase flow. It is shown that the uneven distributions result in a significant deterioration of the heat transfer performance. The relationship between the flow maldistribution characteristics and the resulting loss in heat exchanger effectiveness has been studied in this work. Certain improved header configurations with perforated plates were proposed in order to solve the maldistribution problem. It was found that the new header configurations could effectively improve the thermal performance of plate-fin heat exchangers. By changing the header configuration, the degree of flow and temperature nonuniformity in the plate-fin heat exchanger was reduced to 16.8% and 74.8%, respectively, under the main test condition.