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At least 55 records · Page 3

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DOE OSTI2022

Computational Fluid Dynamics and Heat Transfer Modeling of a Dimpled Heat Exchanger

Multiphysics and analytical calculations were conducted for a heat exchanger with passive, natural circulation flow. A glycol/water working fluid convects the heat to a dimpled heat exchanger shell, which subsequently transfers the heat to the soil, which acts as the ultimate heat sink. Because the system is fully-passive, it is not subject to the expenses, maintenance, and mechanical breakdowns associated with moving parts. Density, heat capacity, and thermal conductivity material properties were measured for various soil samples, and subsequently included as input for the soil heat conduction model. The soil model was coupled to a computational fluid dynamics (CFD) heat exchanger model that included the dynamic Smagorinsky large eddy simulation and k- omega turbulence models. The analysis showed that the fluid dynamics and heat transfer models worked properly, albeit at a slow pace. Nevertheless, the coupled CFD/heat conduction simulation ran long enough to determine a key parameter—the amount of heat conducted from the heat exchanger to the ground. This unique performance value, along with experimental data, was used as input for stand-alone, fast-running CFD models, as well as boundaries to obtain solutions to partial differential equations for soil heat conduction.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2020

Conjugate Heat Transfer Analysis of the Supercritical CO2 Based Counter Flow Compact 3D Heat Exchangers

Compact heat exchangers using supercritical fluids such as CO2 are preferred due to their high heat transfer capacity and smaller footprint. Three-dimensional conjugate forced convection heat transfer analysis was performed on several shell-and-tube counter-flow microchannel heat exchangers. Numerical simulations were conducted to test effect of change in mass flow rate, hydraulic diameter and various cross sections on the heat transfer. Increasing mass flow rate improved heat transfer up to a maximum value and then decreased downstream with increasing turbulence. Maximum heat transfer was obtained for the micro channel with the smallest hydraulic diameter. Amongst the cross sections analyzed (circular, square, circular with radial ribs, and square with radial ribs), the most uniform distribution of temperature and maximum heat transfer were obtained for circular cross section with radial ribs. An optimally efficient operation of such a heat exchanger can be attained by considering these factors during multi-objective constrained optimization of geometric parameters and requirements for additive manufacturing of such compact heat exchangers.

Chitale, Janhavi↗

DOE OSTI2020

Conjugate Heat Transfer Analysis of the Supercritical CO2 Based Counter Flow Compact 3D Heat Exchangers

Chitale, Janhavi↗

DOE OSTI2022

Non-Equilibrium Law-of-the-wall Modeling for Improved Heat Transfer Predictions: Model Development and Validation.

Abstract not provided.

Perini, Federico↗

DOE OSTI2021

Review of heat transfer enhancement techniques in two-phase flows for highly efficient and sustainable cooling

We show that two-phase internal flow is ubiquitous to many systems due to its ability to transfer large amounts of heat effectively. Recent advances motivated by sustainability have pushed towards augmenting the heat transfer between the tube and the two-phase working fluid. Augmenting heat transfer in two-phase flows enables process intensification, and compactness leading to reduced cost and material consumption. This review investigates the effect of heat transfer enhancement techniques on different fluids including R134a, R407C, R22, etc … The techniques are categorized into passive and active and focus on durable enhancement methods which do not include surface structuring or coating. Passive techniques utilize geometrical and surface modifications to induce better mixing. Several passive techniques are analyzed including fins, inserts, and more. In analyzing these techniques, the effect of changing geometric parameters is studied, and the limitations are highlighted. Further, active techniques that enable heat transfer enhancement through applying power are also investigated. Electrohydrodynamic approaches are analyzed and compared to passive techniques. Additionally, the implications of heat exchange enhancement in the context of global energy are discussed. An energy analysis discretized by the use sector is conducted, with an emphasis on predicting the future potential for renewable and sustainable development. Moreover, although active approaches provide the highest heat transfer enhancement, due to implementation difficulties, passive techniques are more frequently adopted. The review ends with discussion of next-generation heat exchangers which will rely more on additive manufacturing due to its flexibility and reduced cost per part as the technology matures.

Nusselt number↗

DOE OSTI2021

Review and Analysis of Heat Transfer Correlations For Horizontal Pseudocritical CO 2 Heat Exchanger Applications

There is significant interest in the development of supercritical carbon dioxide (sCO 2 ) power cycles because of the potential for smaller and more energy efficient systems than a steam Rankine cycle. Heat exchanger designs typically use empirical correlations, but the applicability of these correlations near the CO 2 critical point is a potential issue. Though numerous correlations have been proposed in the literature, there are some disagreements when it comes to the accuracy. The current work recognizes the role of thermophysical properties, and its impacts on the heat transfer correlations and cycle efficiency. Heat transfer correlations proposed for horizontal flow inside circular pipes were analyzed with the help of numerical simulations. Steady state RANS simulations were performed using SST k-w turbulence model to evaluate the Nusselt number empirical correlations. It was found that the most of correlations (except Yoon) produced a Nusselt number that differed significantly with the one predicted numerically. Some of the correlations were developed for pure forced convection regime and as mentioned in Lin et al. do not account for mixed convection or free convection effects. Based on the limited observation, it appears that Yoon et al. predictions match well with the numerically predicted Nusselt Numbers. However, further analysis is required understand the applicability of various correlations and is contingent on accurate measurements or predictions of wall temperature profiles in the axial and the circumferential directions.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2020

Heat transfer unit for prefabricated vessel

Vessel assemblies, heat transfer units for prefabricated vessels, and methods for heat transfer prefabricated vessel are provided. A heat transfer unit includes a central rod, and a plurality of peripheral rods surrounding the central rod and connected to the central rod. The plurality of peripheral rods are movable between a first collapsed position and a second bowed position, wherein in the second bowed position a midpoint of each of the plurality of peripheral rods is spaced from the central rod relative to in the first position. The heat transfer unit further includes a heat transfer element connected to one of the plurality of peripheral rods.

Tamburello, David A.↗

DOE OSTI2021

High flux boiling heat transfer enhancement using triangle shaped vertical walls in two-phase microchannel heat exchangers

Two-phase heat exchangers allow heat loads to be dissipated with lower fluid flow rates without inducing thermal gradients, and high surface area microchannels further reduce the thermal resistance of these heat exchangers. However, there are many practical limits that prevent widespread use of two-phase microchannel heat exchangers. Many authors have looked to address these practical limits by treating the channel floors or creating artificial nucleation sites. Few works look to enhance heat transfer in the walls of channels with hydraulic diameters below 200 μm. This work is aimed at increasing the efficacy of high aspect ratio silicon microchannels that use R134a as the working fluid. The 125 parallel channels are 40 μm wide, 200 μm deep, and 2 mm long and contain a 15 μm wide, 150 μm long restriction at each inlet. The thermal resistance and dryout characteristics of traditional, plain-walled channels are compared to channels with 2 area enhancement patterns each of which increases the area available for heat transfer by 41%. Furthermore, a resistance to dryout is seen in both area-enhanced test sections, and a 15.5% reduction in thermal resistance is shown for the area-enhanced part with a 6 μm triangular pitch. Only a 7.8% performance increase is seen in the test section with a 3 μm pitch. Both area enhancement patterns induce an average 27% increase in pressure drop for all tests. Heat transfer characteristics are solved for using a finite element analysis (FEA) model. By examining heat transfer coefficients and local heat fluxes, it is postulated that the area enhancement reduces heat transfer coefficients and the performance increase is caused by increasing the number of active nucleation sites.

42 ENGINEERING↗

DOE OSTI2023

Heat transfer module

A heat transfer module can include an envelope sealed to define an internal volume that contains a working fluid and a wick disposed on an internal surface of the envelope. The wick and envelope each has a first portion extending through an evaporator region and a second portion extending through adiabatic and condenser regions. The first portion of the wick is a metal hydride. The first portion of the envelope includes a metal liner surrounding the first portion of the wick, a first diffusion barrier layer disposed between the first portion of the wick and the metal liner, and a ceramic matrix composite cladding surrounding the metal liner. The second portions of the wick and envelope each includes a refractory metal and/or stainless steel.

Stauff, Nicolas E.↗

DOE OSTI2025

Numerical simulation of frost formation and heat transfer on fin-and-tube heat exchangers in turbulent cross-flow

Frost formation in fin-and-tube heat exchangers in turbulent cross-flow presents significant challenges in industrial refrigeration applications, affecting heat transfer efficiency and operational reliability. The purpose of this work is to investigate frost deposition and growth on a staggered bank of a fin-and-tube freezer coil under turbulent forced convection conditions. The focus here is on investigating conditions that closely replicate real-world scenarios in large walk-in industrial freezers. Using a direct numerical simulation approach, we examine the flow dynamics and thermal behaviour in the presence of frost, considering turbulent regimes characterized by a Reynolds number in the range 1050 ≤ R e D , avg ≤ 4800 , with the characteristic length being the outer diameter of the tube and the velocity being the bulk fluid velocity between the plates (fins). Computational fluid dynamics simulations are employed to resolve the interactions between turbulent airflow and the frost layer. Our approach incorporates a modified immersed boundary method and a slow-time acceleration technique to address the complex dynamic interface between the continuously evolving frost layer and the flowing air stream. Our findings indicate that frost forms more on the sides of the finned surfaces (plates) and less on the tubes themselves. This article is part of the theme issue ‘Heat and mass transfer in frost and ice’.

Science & Technology - Other Topics↗

DOE OSTI2022

Numerical simulation of falling film sensible heat transfer over round horizontal tubes

Numerical simulations are performed to explore the heat transfer characteristics of falling films over horizontal round tubes with uniform heat flux imposed for a range of Reynolds numbers spanning the droplet, jet, and sheet regimes. Simulations results agree well with available experimental measurements. The study analyzes the local as well as average heat transfer behavior under the different flow modes. The numerical results show that the local Nusselt number (Nu) distribution depends on the flow features in each mode and varies substantially in all directions for the respective mode. In the droplet mode, the Nu value varies significantly as the droplet impinges and the remnant liquid-bridge retracts (peak instantaneous Nu near 6), followed by wave propagation over the tube surface with peak Nu around 0.25. For the jet modes, the local maximum in the heat transfer occurs off-center to the impingement location with magnitudes of peak Nu = 3.1 for the inline jet mode and Nu = 2.7 for the staggered jet mode, while on the rest of the tube surface, it has an inverse relation with the liquid film thickness. Substantial variations in the heat transfer value are also recorded in the middle of the two impinging jets with Nu = 0.95 in the inline jet mode where the neighboring jets do not interact, and Nu = 0.60 in the crest region of the staggered jet mode where the neighboring jets interact with each other. In the sheet mode, the Nu was seen to depend on the thickness of the liquid waves traversing over the tube surface. Lower Nu values were recorded beneath the crest location of the liquid waves, which increases (1.4–11.6% depending on circumferential location) abruptly in magnitude at the advancing fronts of the waves. The temperature distribution in the liquid film in each of the modes was examined to evaluate the mechanism of heat transfer process. This study also compares the local heat transfer coefficient distribution with the analytical heat transfer models derived to predict heat transfer performance over horizontal tube surfaces.

42 ENGINEERING↗

DOE OSTI2025

Enhanced pool boiling heat transfer using novel inverted trapezoid microgroove structures

Pool boiling heat transfer improvements with enhanced surfaces have been extensively studied for various hydrofluorocarbon (HFC) refrigerants. However, there is a limited number of studies in the open literature that focus on the pool boiling heat transfer characteristics of hydrofluoroolefin (HFO) refrigerants on enhanced surfaces. This study aims to address this gap by analyzing the pool boiling behavior of HFO refrigerants, specifically R1234yf and R1234ze(E). Experiments were conducted on both plain surfaces and novel inverted trapezoid microgroove structures. Further, the experimental results indicate that the microgroove structures can improve heat transfer coefficients by up to 80% compared to plain surfaces. Additionally, the performance of R1234yf and R1234ze(E) was compared to that of R134. It was observed that R1234yf exhibited comparable performance to R134a, while R1234ze(E) showed slightly lower performance. To assess the influence of saturation temperature on pool boiling heat transfer, tests were conducted at different saturation temperatures of 15℃, 25℃, and 35℃. The findings revealed that the pool boiling heat transfer coefficient increases with rising saturation temperature.

42 ENGINEERING↗

DOE OSTI2019

Development and Validation of Predictive Models for In-Cylinder Radiation and Wall Heat Transfer

The lack of accurate submodels for in-cylinder radiation and heat transfer has been identified as a key shortcoming in developing truly predictive, physics-based computational fluid dynamics (CFD) models that can be used to develop and design combustion systems for advanced high-efficiency, low-emissions engines. Measurements of wall boundary layers in engines show discrepancies of up to 100% with respect to standard CFD boundary layer models. And analysis of in-cylinder radiation based on the most recent spectral property databases and high-fidelity radiative transfer equation solvers has shown that at operating pressures and exhaust-gas recirculation levels typical of modern compression-ignition truck engines, molecular gas radiation (mainly carbon dioxide and water vapor) can be more important than soot particle radiation, and that a significant fraction of the emitted radiation (50% or more) can be reabsorbed before reaching the walls, thereby acting to redistribute energy in the combustion chamber. In this project, an integrated experimental and simulation approach has been used to generate new physical insight into in-cylinder heat-transfer processes in engines, and to develop computationally practicable CFD-based models that accurately represent the physics. New experimental data have been taken in an optically accessible single-cylinder research engine, and in a multi-cylinder production engine. Those data have provided new insight into the radiative environment in engines. New CFD models have been developed and validated for in-cylinder heat transfer, focusing mainly on radiative heat transfer and coupling between turbulent boundary layer wall heat transfer and radiative heat transfer. The CFD models have been developed and implemented in an open-source software framework that can be shared with other researchers. The models are compatible both with unsteady Reynolds-averaged Navier Stokes (URANS) formulations and with large-eddy simulations (LES) of in-cylinder processes in engines.

02 PETROLEUM↗

DOE OSTI2022

Advanced metal hydride heat transfer system utilizing an electrochemical hydrogen compressor

An electrochemical heat transfer device for a hot water tank utilizes an electrochemical hydrogen compressor to pump hydrogen into and out of a tank having a metal hydride forming alloy therein. The absorption of hydrogen by the metal hydride forming alloy is exothermic, produces heat, and the desorption of the hydrogen from the metal hydride forming alloy is endothermic and draws heat in. An electrochemical hydrogen compressor may be configured between to tanks and pump hydrogen back and forth to form a heat transfer device, such as a hot water heater. A heat transfer device may be coupled with the tank or may comprise the outer surface of the tank to transfer heat to an object or to the surroundings. A closed loop may be configured having two tanks and one or two electrochemical hydrogen compressors to pump the hydrogen in a loop around the system.

Bahar, Bamdad↗

DOE OSTI2020

Measurement of Convective Heat Transfer Coefficients With Supercritical CO 2 Using the Wilson-Plot Technique

This paper describes the measurement of convective heat transfer coefficients and friction factors for sCO 2 flowing in a smooth tube and compares the results with published correlations for validation. The paper also describes the Heat Exchange and Experimental Testing (HEET) rig recently designed and built at the U.S. Department of Energy’s (DoE’s) National Energy Technology Laboratory (NETL) in Morgantown, WV. Here, the Wilson-plot technique used for measuring the heat transfer coefficients is described along with the data reduction process. The Wilson-plot technique was chosen as the basis for the design of NETL’s HEET rig. Advantages of the Wilson-plot technique include the (1) ability to measure high convective heat transfer coefficients accurately, (2) ability to measure average heat transfer coefficient for complicated heat exchange geometries like those produced using additive manufacturing, (3) ability to measure heat transfer coefficients on both sides of a heat exchanger independently, and (4) simplicity of experimental setup. Capabilities of the HEET rig include pressure to 24 MPa (3500 psig), temperature to 538 °C (1000 °F), mass flow rate to 1.5 kg/s (3 lb/s), and Re to 500,000. The rig is designed to operate with pure CO 2 or a mixture of CO 2 and up to 10% N2 by volume to study the impact of gas mixtures typical of direct-fired sCO 2 power cycles on the convective heat transfer and pressure drop. Preliminary tests in the HEET rig were performed with smooth stainless-steel tube and pure CO 2 , and the results were compared with published correlations for Nusselt number (Nu) and friction factor. Over a Reynolds number (Re) range from 58,000 to 228,000, measured Nu was compared to predictions using the Dittus and Boelter equation (Kreith and Bohn, 1993, “Principles of Heat Transfer, West Publishing Company”) within 5% and measured friction factors were compared to predictions using the McAdams correlation (“McAdams, 1954, “Heat Transmission,” 3rd ed., McGraw Hill, New York)” for smooth tube to be within 5%.

42 ENGINEERING↗

DOE OSTI2023

Role of heating and turbulent heat transfer in HE burning and detonation

Enhanced heat transfer model has been developed due to the turbulence in the cracks and pores in the burning fractured HE. This turbulence then serves in the initialization of the turbulence in the product gas. Enhanced heat transfer is also modeled in the turbulent product gas. Numerical simulations of the onset of HE burning and transition to detonation have been performed with and without the turbulent heat transfer model. Computational results indicate that onset of chemical reactions and transition to detonation is induced by the shockwave formed by the pressure rise caused by the heating. In other words, processes similar to shock-to-detonation transition (SDT) could become the driving mechanism for HE explosion and detonation in the case of heating rather than the temperature alone.

45 MILITARY TECHNOLOGY, WEAPONRY, AND NATIONAL DEF↗

DOE OSTI2025

A Finite Element Method for Compressible and Turbulent Multiphase Flow Instabilities with Heat Transfer

We present a new finite element framework for modeling compressible, turbulent multiphase flows with heat transfer. For two-fluid systems with a free surface, the Volume of Fluid (VOF) method is implemented without the need for interface reconstruction, while turbulence is resolved using a dynamic Vreman large eddy simulation (LES) model. Unlike most two-phase VOF studies, which neglect heat transfer, the present approach incorporates energy transport equations within the VOF formulation to account for heat exchange, an effect particularly important in turbulent flows. Conjugate heat transfer is often challenging in finite volume methods, which require explicit specification of heat fluxes at the solid–fluid interface, limiting accuracy and predictive capability. By contrast, the finite element formulation does not require heat flux inputs, allowing more accurate and robust simulation of heat transfer between solids and fluids. The method is demonstrated through three representative cases. First, a two-fluid instability with a single-mode perturbation is simulated and validated against analytical growth rates. Second, conjugate heat transfer is examined in a high-temperature flow over a cold metal cylinder, with validation performed both quantitatively—via pressure coefficient comparisons with experimental data—and qualitatively using vector field topology. Finally, compressible spray injection and breakup are modeled, demonstrating the ability of the framework to capture interfacial dynamics and atomization under turbulent, high-speed conditions. In the compressible spray injection and breakup case, the results indicate that the finite element formulation achieved higher predictive accuracy and robustness than the finite-volume method. With the same mesh resolution, the FEM reduced the root mean square error (RMSE) and mean absolute percentage error (MAPE) from 6.96 mm and 26.0% (for the FVM) to 4.85 mm and 12.7%, respectively, demonstrating improved accuracy and robustness in capturing interfacial dynamics and heat transfer. The study also introduced vector field topology to visualize and interpret coherent flow structures and instabilities, offering insights beyond conventional scalar-field analyses.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2024

An Experimental Investigation of Sintered Particle Effect on Heat Transfer Performance in an “Annular Flow” Evaporation Tube

Wicking structures have been widely used within passive heat transfer devices with high heat fluxes, such as heat pipes, to enhance their thermal performance. While wicking structures promote capillary pumping of the working fluid and thin film evaporation, they can result in capillary evaporation and further enhance the evaporation heat transfer. In this study, a 0.5 mm thick layer of 105 µm sintered copper particles was added to the inner wall of a copper tube, aiming to form an “annular flow” and enhance the heat transfer characteristics by taking advantage of thin film and capillary evaporation. Acetone was chosen as the working fluid, and the performance of an evaporation tube was tested for power inputs of 10, 30, 50, and 70 W. For each power input, trials were run at inclination angles varying from -90 deg to 90 deg to investigate the capillary effects. The temperature measurements showed that the temperature distribution along the evaporation tube is always downward sloping, meaning the temperature at the fluid inlet is larger than the outlet. In conclusion, results show that an “annular flow” formed by a thin layer of sintered particles can promote thin film and capillary evaporation and, therefore, boost the evaporation heat transfer coefficient.

42 ENGINEERING↗