Dissertations / Theses on the topic 'Tube and Shell Condenser'

Etude de la réponse axisymétrique d'un tube circulaire à une onde de pression le parcourant longitudinalement. Rappel de la méthode analytique, et prise en compte des comportements rhéologiques viscoélastiques linéaires. Ainsi ce travail peut-il s'appliquer aux problèmes de sécurité industrielle relatifs aux confinements des matières explosibles, mais aussi contribuer à l'étude de la rhéologie des matériaux charges à haute vitesse de sollicitation ou à la détonique des mélanges gazeux

Enhanced Finned-Tube Condenser Design and Optimization Susan W. Stewart 173 pages Directed by Dr. Sam V. Shelton Finned-tube heat exchangers are widely used in space conditioning systems, as well as any other application requiring heat exchange between liquids and gases. Their most widespread use is in residential air conditioning systems. Residential systems dictate peak demand on the U.S. national grid, which occurs on the hot summer afternoons, and thereby sets the expensive infrastructure requirement of the nations power plant and electrical distribution system. In addition to peak demand, residential air conditioners are major energy users that dominate residential electrical costs and environmental impact. The only significant opportunity for electrical power use reduction of residential air conditioners is in technology improvement of the finned-tube heat exchangers, i.e., condenser and evaporator coils. With the oncoming redesign of these systems in the next five years to comply with the regulatory elimination of R-22 used in residential air conditioners today, improvement in the design technology of these systems is timely. An air conditioner condenser finned-tube coil design optimization methodology is derived and shown to lead to improved residential air conditioner efficiency at fixed equipment cost. This nonlinear optimization of the 14 required design parameters is impractical by systematic experimental testing and iteration of tens of thousands condenser coils in an air conditioning system. The developed methodology and results can be used in the redesign of residential systems for the new mandated environmentally friendly refrigerants and to meet increasing regulatory minimum system efficiencies. Additionally, plain fins and augmented fins, (louvered), are compared using the developed model and optimization scheme to show the effect of the augmentation on system performance. Furthermore, an isolated condenser model was developed using condenser entropy generation minimization as the figure of merit to minimize the model complexity and computation time. Isolated model optimizations are compared with the system model optimum designs.

A new test facility, with a vertical reflux condenser of 1500mm overall length and 45mm internal diameter, has been commissioned and tested and methods developed for measuring key process parameters. An experimental study of reflux condensation in a single tube using n-pentane and iso-octane and binary mixtures of these single component hydrocarbons has been undertaken. Using water as the cooling medium, a correlation was developed for determining the coolant-side heat transfer coefficient in the reflux condenser based on the Wilson plot method. The composition of binary liquid mixture samples from the test facility was determined using an empirical correlation developed using density measurements from a vibrating u-tube densitometer. The single components were condensed in the range 32.0-48.4°C and 0.106-1.515bara by adjusting the test condenser heat load for fixed conditions on the coolant side to investigate how the condensate-film heat transfer coefficient varied with the condensate film Reynolds number. The results show good agreement with the method recommended by HTFS for correcting the Nusselt theory for the effects of waves. A further small correction was made to improve the fit to the data. The binary hydrocarbon mixtures were condensed across the range 65.9-90.1°C and 0.729-1.531bara by conducting similar experiments where the feed vapour contained 50% and 70% n-pentane. Composition measurements of the condensate and vapour leaving the test condenser were made to examine the separation of components during partial reflux condensation. The results suggest that this separation is influenced by heat flux and that it would be improved if the test condenser were operated at a lower heat flux. Further experimental work is needed to verify this, and to investigate how this influences the number of thermodynamic stages, which was found to be less than one with the conditions reported here. Analysis of the heat transfer resistances on the vapour side showed that the standard procedure of using a dry-gas heat transfer coefficient, with or without a mass transfer correction term based on the film theory, poorly predicted the experimental values. These predictions were improved by the use of an enhancement factor, which may be more relevant in counter-current than co-current condensing situations. The results indicate that use of a dry-gas heat transfer coefficient with the film theory correction factor, over-predicts the mass transfer resistance. Comparison was made between the data and predictions based on the integral condensation curve, as might be used in Silver's method for condenser thermal design. It was shown that this method poorly predicted the surface area and the separation achieved in the test condenser. The results indicate that the heat and mass transfer coefficients obtained in a plain tube are significantly higher than those based on using a dry-gas heat transfer coefficient corrected by film theory. Implications for the design of reflux condensers have been presented.

Thesis (MEng)--Stellenbosch University, 2015.
ENGLISH ABSTRACT: In this study, one and two-dimensional models are developed for the evaluation of the thermal performance of a delugeable flat tube bundle to be incorporated in the second stage of an induced draft hybrid (dry/wet) dephlegmator (HDWD) of a direct air-cooled steam condenser (ACSC). Both models are presented by a set of differential equations. The one-dimensional model is analysed analytically by using three methods of analysis which are: Poppe, Merkel, and heat and mass transfer analogy. The two-dimensional model is analysed numerically by means of heat and mass transfer analogy method of analysis whereby, the governing differential equations are discretised into algebraic equations using linear upwind differencing scheme. The two-dimensional model’s accuracy is verified through a comparison of the two dimensional solutions to one dimensional solutions. Satisfactory correlation between the one and two-dimensional results is reached. However, there is a slight discrepancy in the solutions, which is mainly due to the assumptions made in one-dimensional model. The effect of tube height, tube pitch, tube width, deluge water mass flow rate, frontal air velocity, steam, and air operating conditions on the heat transfer rate and air-side pressure drop for both wet and dry operating modes are investigated. The long tube height, large tube width, small tube pitch, and high frontal air velocity are found to increase the tube bundle’s performance. However, this performance is associated with a high airside pressure drop. The performance of the deluged flat tube bundle is found to be less sensitive to the changes in the deluge water mass flow rate and air operating conditions. Furthermore, the best configuration of a delugeable flat tube bundle is identified through a comparison to round tube bundle presented by Anderson (2014). The performance of the round tube bundle is found to be around 2 times, and 1.5 times of that of flat tube bundle, when both bundles operate as an evaporative and dry air-cooled condenser respectively.
AFRIKAANSE OPSOMMING: In hierdie studie is een en twee-dimensionele modelle ontwikkel vir die evaluering van die termiese prestasie van 'n benatbare plat buis bundel in die tweede stadium van 'n geïnduseerde ontwerp hibriede (droë / nat ) deflegmator van 'n direkte lugverkoelde stoom kondensator. Beide modelle is aangebied deur 'n stel van differensiaalvergelykings. Die een-dimensionele model is analities ontleed deur die gebruik van drie metodes van analise wat: Poppe, Merkel, en die hitte en massa-oordrag analogie. Die twee-dimensionele model is numeries ontleed deur middel van hitte en massa-oordrag analogie metode van analise waardeur , die regerende differensiaalvergelykings gediskretiseer in algebraïese vergelykings met behulp van lineêre windop differensievorming skema. Die tweedimensionele model se akkuraatheid is geverifieer deur 'n vergelyking van die twee dimensionele oplossings te een dimensionele oplossings. Bevredigende korrelasie tussen die een en twee-dimensionele resultate bereik word. Maar daar is 'n effense verskil in die oplossings, wat is hoofsaaklik te wyte aan die aannames wat gemaak in een-dimensional model. Die effek van buis hoogte, buis toonhoogte, buis breedte, vloed water massa-vloeitempo, frontale lug snelheid, stoom, en in die lug werktoestande op die hitte oordrag snelheid en lug - kant drukval vir beide nat en droë maatskappy modi word ondersoek. Die lang buis hoogte, groot buis breedte, klein buisie toonhoogte, en 'n hoë frontale lug snelheid gevind die buis bundel se prestasie te verhoog. Tog is hierdie prestasie wat verband hou met 'n hoë lug - kant drukval. Die prestasie van die oorstroom plat buis bundel gevind word minder sensitief vir die veranderinge in die vloed water massa-vloeitempo en lug werktoestande. Verder is die beste opset van 'n benatbare plat buis bundel geïdentifiseer deur 'n vergelyking met ronde buis bundel aangebied deur Anderson (2014). Die prestasie van die ronde buis bundel gevind word om 2 keer, en 1.5 keer van daardie plat buis bundel , wanneer beide bundels funksioneer as 'n damp en droë lugverkoelde kondensor onderskeidelik.

Traditionally Shell-and-tube heat exchangers are designed using correlation based approaches like Kern method and Bell-Delaware method. With the advances in Computational Fluid Dynamics (CFD) software, it is now possible to design small heat exchangers using CFD. In this thesis, shell-and-tube heat exchangers are modeled and numerically analyzed using a commercial finite volume package. The modeled heat exchangers are relatively small, have single shell and tube passes. The leakage effects are not taken into account in the design process. Therefore, there is no leakage from baffle orifices and no gap between baffles and the shell. This study is focused on shell side flow phenomena. First, only shell side is modeled and shell side heat transfer and flow characteristics are analyzed with a series of CFD simulations. Various turbulence models are tried for the first and second order discretization schemes using different mesh densities. CFD predictions of the shell side pressure drop and the heat transfer coefficient are obtained and compared with correlation based method results. After selecting the best modeling approach, the sensitivity of the results to the flow rate, the baffle spacing and baffle cut height are investigated. Then, a simple double pipe heat exchanger is modeled. For the double pipe heat exchanger, both the shell (annulus) side and the tube side are modeled. Last, analyses are performed for a full shell-and-tube heat exchanger model. For that last model, a small laminar educational heat exchanger setup is used. The results are compared with the available experimental results obtained from the setup. Overall, it is observed that the flow and temperature fields obtained from CFD simulations can provide valuable information about the parts of the heat exchanger design that need improvement. The correlation based approaches may indicate the existence of a weakness in design, but CFD simulations can also pin point the source and the location of the weakness.

Please read the abstract (Summary) in the 00front part of this document
Dissertation (M Eng (Mechanical Engineering))--University of Pretoria, 2006.
Mechanical and Aeronautical Engineering
unrestricted

A numerical analysis of flow maldistribution and shell side flow on heat in a shell and tube heat exchanger is presented. The flow field at the inlet and in the headers was obtained by solving conservation equations of mass and momentum by employing k-ε turbulence model. As the flow maldistribution in the header affects the heat transfer performance of the STHE, pressure drop and velocity distribution of the fluid inside the header were analyzed. Two types of headers were considered with varying header length for a Reynolds number range of 1000 to 3000. As the header length was increased to 1500 mm the flow maldistribution decreased and the static pressure was almost equal for all the tubes in case of a conical header. Also, the numerical simulations show that the conical header with 1500 mm header length has less flow maldistribution when compared to other models. The Shell side flow was modeled as a flow along a twisted tube with a diameter D and a length 30D using Catia V519. Four different models of the twisted tube with pitch varying between 4D and 5.5D were studied for a range of Reynolds number Re = 75-750. The analysis was carried out for three different wall temperatures of the twisted tube such as 343 K, 363 K and 383 K. The pressure drop increased with increase in Reynolds number, while the pressure drop and outlet fluid temperature increased with decrease in the pitch of the tube. But the convective heat transfer decreased with reduction in pitch. With a decrease in pitch, the energy transfer between the fluid and the adjacent tubes increases resulting in increased outlet fluid temperature.
Thesis (M.S.)--Wichita State University, College of Engineering, Dept. of Mechanical Engineering.

This PhD work has been dedicated to the improvement of the modelling of air condensers of both round tube and fins (RTPFs) and Minichannel technologies. The calculation platform employed is IMST-ART. This is a dedicated software for the design of refrigeration, air-conditioning and heat pump equipment following the vapor compression cycle. The model implemented in IMST-ART for condensers and evaporators is the combination of a segment-by-segment approach with the numerical method SEWTLE (Semi Explicit method for Wall Temperature Linked Equations) for the solution of the resulting system of equations. The target of the first part of this thesis was the comparative analysis of the empirical correlations aimed at the evaluation of the heat transfer coefficients and pressure drop in both the air and refrigerant sides of a condenser. The Literature review pointed out the presence of many studies concerning the condensation modelling. Therefore, after selecting the most interesting to compare, the first objective of this first part of the PhD became the identification of a suitable methodology for defining the best combination of correlations for the estimation of the thermo-hydraulic performance of the condensers. After an in-depth analysis of different possibilities, a well-defined methodology was identified as the best for the purpose. In the thesis, it was successfully applied to the identification of the best set of correlations for the heat transfer coefficients and friction factors for both the round-tube and minichannel condensers. The second part of the PhD was targeted to the improvement of the condensation modelling. In particular, the attention was focused on the analysis of the phenomena taking place at the beginning of the condensation process, when the superheated vapor finds the wall of the condenser being at a temperature lower than the refrigerant saturation temperature, i.e. convective condensation superheated vapor zone (CSH zone). It is well known that, in this zone, the condensation starts with some kind of droplet/thin film condensation on the walls. Afterwards, the bulk of the refrigerant flow reaches the saturation temperature and the condensation occurs at saturated conditions. Hence, the PhD thesis has been dedicated to the implementation in the general model for condensers (in IMST-ART software) of this CSH zone, which it was found to have an important effect on the prediction of the wall temperatures distribution in the tested air condensers. Two different numerical solutions were implemented and compared, i.e. Temperature and Enthalpy approaches, and validated against experimental results. Prediction results are very similar, thus the Enthalpy approach was selected because it required lower computational time. The final part of thesis was oriented towards the study of the effect of airflow maldistribution on the performance of air condensers. An innovative experimental methodology for generating and measuring any uneven air velocity profile at the inlet of a heat exchanger was first developed in a dedicated wind tunnel and then applied for the analysis of the performance degradation of one sample of condenser of each RTPFs and Minichannel technologies. Three different velocity profiles were produced and tested along a wide set of operating conditions, including different refrigerant charges and hence subcoolings. The experimental results showed that, although differences in wall temperature distribution were significant, the effect of air maldistribution on the performance of the two tested condensers was small. The improved model was validated against the experimental results and also showed little effect on condenser performance. Finally, the agreement between the results of the simulation and the experimental results was very satisfactory.
Este trabajo de doctorado se ha dedicado a la mejora del modelado de condensadores de aire, con tecnología de tubos y aletas o minicanales. La plataforma de software empleada es IMST-ART, que es un software dedicado a asistir el diseño de equipos de refrigeración, aire acondicionado y bomba de calor, basados en el ciclo de compresión de vapor. El modelo de IMST-ART para condensadores y evaporadores se basa en una aproximación segmento a segmento combinada con el método numérico SEWTLE (Semi Explicit method for Wall Temperature Linked Equations) para la solución del sistema de ecuaciones resultante. El objetivo de la primera parte de esta tesis fue el análisis comparativo de las correlaciones empíricas destinadas a evaluar los coeficientes de transferencia de calor y la caída de presión para condensadores de aire, tanto para el lado del aire como para el del refrigerante. La revisión de la Literatura mostró la existencia de numerosos estudios sobre el modelado de la condensación en este tipo de intercambiadores. Por lo tanto, después de la selección de las correlaciones más interesantes a comparar, el primer objetivo de esta primera parte de la tesis resultó el encontrar la metodología más adecuada para la identificación de cuáles eran las correlaciones que mejor estimaban el comportamiento termo-hidráulico de los condensadores. Después de un análisis en profundidad de diferentes posibilidades, se encontró la metodología claramente más adecuada y se pasó a aplicarla a la identificación del mejor conjunto de correlaciones para los coeficientes de transferencia de calor y factores de fricción para condensadores de aire. La segunda parte del doctorado se dirigió a la mejora del modelado del comienzo del proceso de condensación cuando el vapor sobrecalentado encuentra la pared del condensador a una temperatura que está por debajo de la temperatura de saturación del refrigerante en lo que se puede denominar como condensación convectiva en la zona de vapor sobrecalentado (zona CSH). Es bien sabido que la condensación comienza en esta zona con algún tipo de condensación de gotas/película delgada sobre las paredes antes de que el núcleo del flujo de refrigerante alcance la temperatura de saturación y la condensación se produzca en condiciones saturadas. La segunda parte del doctorado se ha dedicado a la implementación en el modelo general de condensadores (en el software IMST-ART) de esta zona CSH, que se encontró que tenía un efecto importante en la predicción de la distribución de las temperaturas de la pared en los condensadores de aire ensayados. Se implementaron y compararon dos soluciones numéricas diferentes, denominados aproximación de temperatura y aproximación de entalpía respectivamente, y se validaron por comparación con resultados experimentales. La predicción resultó ser muy similar con ambas aproximaciones por lo que finalmente se seleccionó la aproximación de entalpía por ser considerablemente más rápida. La parte final de la tesis se orientó hacia el estudio del efecto de la mala distribución del flujo de aire en el rendimiento de los condensadores de aire. Para este fin se desarrolló una metodología experimental innovadora capaz de generar y medir cualquier perfil de velocidad de aire no uniforme a la entrada de un intercambiador de calor. El desarrollo se llevó a cabo primero en un túnel de viento específicamente dedicado a este propósito y luego se aplicó para el análisis de la degradación de las prestaciones de dos muestras de condensador de cada una de las tecnologías estudiades: RTPFs y Minicanal. Mediante la metodología desarrollado se generaron tres perfiles de velocidad diferentes que se ensayaron a lo largo de un amplio conjunto de condiciones de funcionamiento, incluyendo diferentes cargas de refrigerante y, por tanto, grados de subenfriamiento en el refrigerante. Los resultados experimentales mostraron que el efecto de la mala distrib
Aquest treball de doctorat s'ha dedicat a la millora de la modelització de condensadors d'aire, amb tecnologia de tubs i aletes o minicanals. La plataforma de software emprada és IMST-ART, que és un software dedicat a assistir el disseny d'equips de refrigeració, aire condicionat i bomba de calor, basats en el cicle de compressió de vapor. El model de IMST-ART per condensadors i evaporadors es basa en una aproximació segment a segment combinada amb el mètode numèric SEWTLE (Semi Explicit method for Wall Temperature Linked Equations) per a la solució del sistema d'equacions resultant. L'objectiu de la primera part d'aquesta tesi va ser l'anàlisi comparativa de les correlacions empíriques destinades a avaluar els coeficients de transferència de calor i la caiguda de pressió per condensadors d'aire, tant per al costat de l'aire com per al del refrigerant. La revisió de la Literatura va mostrar l'existència de nombrosos estudis sobre la modelització de la condensació en aquest tipus d'intercanviadors. Per tant, després de la selecció de les correlacions més interessants a comparar, el primer objectiu d'aquesta primera part de la tesi va resultar el trobar la metodologia més adequada per a la identificació de quines eren les correlacions que millor estimaven el comportament termo-hidràulic dels condensadors. Després d'una anàlisi en profunditat de diferents possibilitats, es va trobar la metodologia clarament més adequada i es va passar a aplicar-la a la identificació del millor conjunt de correlacions per als coeficients de transferència de calor i factors de fricció per condensadors d'aire. La segona part del doctorat es va dirigir a la millora de la modelització del començament del procés de condensació quan el vapor sobreescalfat troba la paret del condensador a una temperatura que està per sota de la temperatura de saturació del refrigerant, en el que es pot denominar com condensació convectiva a la zona de vapor sobreescalfat (zona CSH). És ben sabut que la condensació comença en aquesta zona amb algun tipus de condensació de gotes/pel·lícula sobre les parets abans que el nucli del flux de refrigerant arribi a la temperatura de saturació i la condensació es produeixi en condicions saturades. La segona part del doctorat s'ha dedicat a la implementació en el model general de condensadors (en el programari IMST-ART) d'aquesta zona CSH, que es va trobar que tenia un efecte important en la predicció de la distribució de les temperatures de la paret en els condensadors d'aire assajats. Es van implementar i van comparar dues solucions numèriques diferents, denominades aproximació de temperatura i aproximació d'entalpia respectivament, i es van validar per comparació amb resultats experimentals. La predicció va resultar ser molt semblant amb les dues aproximacions pel que finalment es va seleccionar l'aproximació d'entalpia per ser considerablement més ràpida. La part final de la tesi es va orientar cap a l'estudi de l'efecte de la mala distribució del flux d'aire en el rendiment dels condensadors d'aire. Amb aquesta finalitat es va desenvolupar una metodologia experimental innovadora capaç de generar i mesurar qualsevol perfil de velocitat d'aire no uniforme a l'entrada d'un intercanviador de calor. El desenvolupament es va dur a terme primer en un túnel de vent específicament dedicat a aquest propòsit i després es va aplicar per a l'anàlisi de la degradació de les prestacions de dues mostres de condensador de cadascuna de les tecnologies estudiades: RTPFs i Minicanal. Mitjançant la metodologia desenvolupada es van generar tres perfils de velocitat diferents que es van assajar al llarg d'un ampli conjunt de condicions de funcionament, incloent càrregues diferents de refrigerant i, per tant, graus de subrefredament en el refrigerant. Els resultats experimentals van mostrar que l'efecte de la mala distribució de l'aire en les prestacions dels dos condensadors provats va
Pisano, A. (2017). Analysis of the condensation process and air maldistribution in finned tube and minichannel condensers [Tesis doctoral no publicada]. Universitat Politècnica de València. https://doi.org/10.4995/Thesis/10251/86182
TESIS

Thesis (MScEng (Mechanical and Mechatronic Engineering))--University of Stellenbosch, 2009.
ENGLISH ABSTRACT: Air-cooled steam condensers are used in arid regions where adequate cooling water is not available or very expensive. In this thesis the effect of steam-side and air-side effects on the condenser performance, steam distribution and critical dephlegmator length is investigated for air-cooled steam condensers as found in power plants. Solutions are found so that no backflow is present in the condenser. Both single and two-row condensers are investigated. The tube inlet loss coefficients have the largest impact on the critical dephlegmator tube length in both the single and two-row condensers. The critical dephlegmator tube lengths were determined for different dividing header inlet geometries and it was found that a step at the inlet to the dividing header resulted in the shortest tubes. Different ambient conditions were found to affect the inlet steam temperature, the steam flow distribution, heat rejection distribution and the critical dephlegmator length for the single and two-row condensers. There were differences in the steam mass flow distributions for the single and two-row condensers with opposite trends being present in parts of the condenser. The single-row condenser’s critical dephlegmator tube lengths were shorter than those of the two-row condenser for the same ambient conditions. Areas of potential backflow change with different ambient conditions and also differ between a single and two-row condenser. The two-row condenser always have an area of potential backflow for the first row at the first condenser fan unit.
AFRIKAANSE OPSOMMING: Droë lug-verkoelde stoom kondensors word gebruik in droë gebiede waar genoegsame verkoelingswater nie beskikbaar is nie of baie duur is. In hierdie tesis word die effek van stoomkant en lugkant effekte op die vermoë van die kondensor, die stoomvloeiverdeling en kritiese deflegmator lengte ondersoek vir lug-verkoelde stoom kondensors soos gevind in kragstasies. Dit word opgelos sodat daar geen terugvloei in enige van die buise is nie. ʼn Enkel- en dubbelry kondensor word ondersoek. Die inlaatverlieskoëffisiënte van die buise het die grootste impak op die lengte van die kritiese deflegmator buise in beide die enkel- en dubbelry kondensors. Die kritiese deflegmator buis lengtes is bereken vir verskillende verdeelingspyp inlaat geometrië en dit is gevind dat ʼn trap by die inlaat van die verdeelingspyp die kortste buise lewer. Dit is gesien dat verskillende omgewingskondisies die inlaat stoom temperatuur, die stoomvloeiverdeling, die warmteoordrag verdeling en die kritiese lengte van die deflegmator buise vir die enkel- en dubbelry kondensor. Daar was verskille tussen die stoomvloeiverdelings vir die enkel- en dubbelry met teenoorgestelde neigings in dele van die kondensor. Die kritiese deflegmator buis lengte vir die enkelry kondensor was korter as die vir die dubbelry kondensor vir dieselfde omgewingskondisies. Die areas in die kondensor waar terugvloei moontlik kan plaasvind in die kondensor verander met ongewingskondisies en verskil vir die enkel- en dubbelry kondensers. Die dubbelry kondensor het altyd ʼn area van moontlike terugvloei vir die eerste buisry by die eerste kondensor waaiereenheid.

In shell-and-tube heat exchangers there is an unavoidable clearance between the tube bundle and the shell wall. This clearance has a relatively low flow resistance and hence a relatively large proportion of the shell-side flow will pass through it, bypassing the tube bundle and thus avoiding the heat transfer surface. The clearance can be blocked by sealingstrips, which eliminate the gap and divert the bypassing flow back into the tube bundle. This thesis details an investigation of bypass lanes in shell-and-tube heat exchangers and the use of sealing-strips. A model exchanger was designed and built to represent a rectangular tube bank in which the bypass lane width could be varied, sealing-strips could be inserted at various positions along the bypass to block completely the bypass wall-to-tube bundle clearance. For four different tube arrays, the pressure drop and exit bypass mass flow fraction were found for isothermal air flow over a range of total flow rates. Three different tube bank geometries were investigated, i) with no bypass lane (ideal bundle), ii) for a range of bypass lane widths, iii) for a range of bypass lane widths blocked by various numbers of sealing-strips. For one tube array type, flow distributions upstream of the tube bank were found using a hot-wire anemometer; from these results the inlet bypass flow fractions were estimated. From these studies it was found that ESDU generally overestimates the pressure drop coefficients when bypassing is present. Bell's (1960) correction factor generally underestimates the pressure drop coefficient when bypassing is present and overestimates the effect of sealing-strips in increasing the pressure drop over the bank. The rectangular tube bank model was modified to represent a section of a cylindrical exchanger. The effect on the pressure drop over a bank with a non-uniform bypass lane width, in the flow direction, was investigated. It was found that the inverse root mean square of the bypass clearances best characterised the "effective" bypass clearance of the whole bank. Flow visualisation studies were undertaken of shell-side flow in a cylindrical exchanger made of glass in which all leakage flows, except bypassing, were eliminated. From the dye traces produced, the shell-side flow was seen to be highly complex. For the geometries examined it appeared that there was little interchange of flow between the bypass and crossflow stream over the crossflow section of the exchanger, but that the bypass stream became crossflow at each window region, with crossflow transferring into the bypass lane. Sealing-strips were seen to produce a thorough mixing of the bypass and crossflow streams

A common technique to improve the performance of shell and tube heat exchangers (STHE) is by redirecting the flow in the shell side with a series of baffles. A key aspect in this technique is to understand the interaction of the fluid dynamics and heat transfer. Computational fluid dynamics simulations and experiments were performed to analysis the 3-dimensional flow and heat transfer on the shell side of an STHE with and without baffles. Although, it was found that there was a small difference in the average exit temperature between the two cases, the heat transfer coefficient was locally enhanced in the baffled case due to flow structures. The flow in the unbaffled case was highly streamed, while for the baffled case the flow was a highly complex flow with vortex structures formed by the tip of the baffles, the tubes, and the interaction of flow with the shell wall.

Dans les recherches réalisées pour ce projet de thèse, il est démontré qu’une traverse existante de train d’atterrissage d’hélicoptère à patins fabriquée par pliage et érosion chimique, pourrait être remplacée par une autre traverse, dont la forme innovante est fabricable par le procédé d’hydroformage de tubes. Ce procédé présente par exemple l’avantage d’être plus respectueux de l’environnement que le procédé de fabrication actuel, car il ne nécessite pas l’utilisation de produits chimiques polluant. De plus, la méthodologie développée dans le cadre des recherches réalisées permet de prendre en compte l’histoire du matériau de la traverse dans toutes les étapes de son processus de fabrication. Les performances d’un train d’atterrissage équipé de la nouvelle traverse ont été évaluées numériquement. Des travaux, développés avec le logiciel de calculs par éléments finis ABAQUS, ont permis de mettre en évidence l’intérêt d’utiliser des éléments finis de coque solides fiables et précis. Ces éléments sont en effet capables de prendre en compte le comportement dans l’épaisseur de structures minces avec une seule couche d’éléments. Une nouvelle technique de lissage appelé «Smoothed finite element method» ou «SFEM» a retenu l’attention pour sa simplicité de mise en œuvre et son insensibilité à la distorsion de maillage parfois rencontrée dans les simulations de formage de formes complexes. Un élément de coque solide résultant linéaire développé en utilisant cette méthode SFEM pour traiter de la cinématique en membrane et en flexion a été testé avec succès au travers d’exemples classiques identifiés dans la littérature. Ce nouvel élément a montré un niveau de précision souvent supérieur à celui d’autres éléments déjà existants. En outre, un élément de coque solide à intégration réduite, capable de fonctionner avec la plupart des lois de comportement en trois dimensions et cela même en présence de structures minces a été développé. Cet élément, libre de tout blocage a montré un bon niveau de précision par rapport aux éléments existants dans le cas de problèmes implicites géométriquement linéaires et non-linéaires. L’élément a été étendu en formulation explicite puis couplé avec une loi de comportement hyper élastoplastique en trois dimensions. Il a enfin été testé dans une simulation d’hydroformage de tubes en présence de pressions élevées, de frottement et de grandes déformations.
In the current work, it is shown that an existing helicopter skid landing gear cross tube, made by tube bending and chemical milling, could be replaced by another cross tube, whose innovative shape is producible by tube hydroforming. This method has for example the advantage of being more environmentally friendly than the current manufacturing process, because it does not require the use of hazardous chemicals. In addition, the methodology developed in this project takes into account the cross tube material’s history throughout the manufacturing process. Moreover, the performance of a skid landing gear equipped with this new cross tube has been evaluated numerically. This thesis simulation work has been developed with the finite element analysis software ABAQUS. It highlights the potential gains of using a reliable and accurate solid-shell finite element which is capable to take into account the through-thickness behavior of thin structures with a single layer of elements. A new smoothing technique called «Smoothed finite element method» or «SFEM» has been considered for its simplicity and insensitivity to mesh distortion, sometimes encountered while simulating complex shapes forming. A new resultant linear solid-shell element using this SFEM to deal with membrane and bending kinematics has been developed and successfully tested through classical benchmark problems found in the literature. This new element has often shown much greater level of accuracy than other existing elements. In addition, a novel reduced integration solid-shell element, able to work with most three dimensions constitutive laws even in the presence of thin structures is also discussed. This element, free of locking, shows a good accuracy level with respect to existing elements in implicit geometrically linear and non-linear benchmark problems. Its extension to explicit formulation is coupled with a three dimensions hyper elastoplastic constitutive law and tested in a tube hydroforming simulation involving high pressures, friction and large deformations.

Flow obstructions are used as a passive design element in heat exchangers to enhance heattransfer. Further, a change in flow structure can also have a positive effect on the heat transfer. Avertical shell and tube heat exchanger, used to recover heat in the greywater stream, isinvestigated in this study. The heat exchanger consists of flow obstructions such as annulargrooves and a helical string. The flow structure can be modified to a swirling film flow byadding a passive design element, called a Cyclone generator. This study aims to experimentallyvalidate a periodic heat transfer CFD model of a shell and tube heat exchanger, with uniformflow at steady-state laminar conditions. The study further analyses the heat transfercharacteristics of the annular grooves and the helical string, and the modified flow due to aswirling film. A calibrated test rig is constructed to consist of a heat source and a heat sink, as well as a meansfor measuring the flow and temperature of a vertical heat exchanger at elevated temperatures.The experimental results were evaluated using the Ɛ -NTU method and uncertainty analysis ofone standard deviation. The heat exchanger geometry had periodically repeating sectionsbetween the inlet and the outlet. Hence the large geometry was simplified to a smaller periodicmodule. The module was subjected to periodic boundary conditions and was simulated using apressure-based coupled algorithm on ANSYS Fluent. Further, the distribution of pressure andvelocity flow fields are examined for uniform flow in CFD. The experiment investigated the heattransfer of a swirling flow at a wide range of flow rates. The CFD model could not be validated by the experiment due to a difference between the overallheat transfer coefficients, calculated in the model and the experiment. The error in validationcould be pointed to an ambiguous energy result in one of the streams. However, the model couldsimulate real-life pressure drop conditions. It was found that the helical string contributed to asubstantial increase in the local turbulence, which translates to an increase in heat transfer. Theheat transfer was also increased in the presence of the annular grooves. From the experiment, a higher heat transfer is noticed at the entrance region of the heatexchanger compared to the middle section. The heat transfer characteristics of the swirling filmwere found to be significantly higher than that of the uniform flow. Finally, for uniform andswirling flows, the heat exchanger effectiveness, Ɛ, can be described as a single logarithmicfunction of the NTU.

The thesis describes the results of a research programme involving both experimental and modelling work to study evaporation on the shellside of shell-and-tube heat exchangers. The particular focus is on the study of evaporation over a range of mass fluxes typical of operating practice. Current design procedures make simplifying assumptions (such as a uniform gas/liquid distribution across the entire cross section of the shellside) which are thought to be inaccurate. The experimental work was conducted on a TEMA E-type shell and tube evaporator. The evaporator has 97 tubes of length 1240 mm, and the unit is large enough to represent full-scale industrial exchangers. Geometrical considerations such as baffle orientation and presence of sealing strips were also tested. The results show that there is a drop in the heat transfer performance at lower mass fluxes and higher vapour outlet qualities. It is suggested that the sudden drop in heat transfer performance at lower mass fluxes is caused by a change in flow pattern on the shellside of the heat exchanger. Evidence suggests that there is a possible transition from a homogeneous to a stratified two-phase flow. Support for this conclusion is that the transition in heat transfer performance appears to coincide with a change in the behaviour of the measured two-phase pressure drop multiplier. The thesis also describes the development of a model for shellside heat transfer and pressure drop which allows for the effects of separated flow and also attempts to predict the apparent transition in two-phase flow pattern. Knowledge of the existence of the transition and its prediction is important in avoiding unexpected poor performance in practice. A close correspondence is found when the predictions from the developed model are compared with the data from the experimental programme.

Sasol Limited experiences extremely high particulate fouling rates inside shell-and-tube heat exchangers that utilize process cooling water. The water and foulants are obtained from various natural and process sources and have irregular fluid properties. The fouling eventually obstructs flow on the shell side of the heat exchanger to such an extent that the tube bundles have to be replaced every nine months. Sasol requested that certain aspects of this issue be addressed. To better understand the problem, the effects of various tube and baffle configurations on the sedimentation rate in a shell-and-tube heat exchanger were numerically investigated. Single-segmental, double-segmental and disc-and-doughnut baffle configurations, in combination with square and rotated triangular tube configurations, were simulated by using the CFD software package, STAR-CCM+. In total, six configurations were investigated. The solution methodology was divided into two parts. Firstly, steady-state solutions of the six configurations were used to identify the best performing model in terms of large areas with high velocity flow. The results identified both single-segmental baffle configurations to have the best performance. Secondly, transient multiphase simulations were conducted to investigate the sedimentation characteristics of the two single-segmental baffle configurations. It was established that the current state of available technology cannot adequately solve the detailed simulations in a reasonable amount of time and results could only be obtained for a time period of a few seconds. By simulating the flow fields for various geometries in steady-state conditions, many of the observations and findings of literature were verified. The single-segmental baffle configurations have higher pressure drops than double-segmental and disc-and-doughnut configurations. In similar fashion, the rotated triangular tube configuration has a higher pressure drop than the square arrangement. The single-segmental configurations have on average higher flow velocities and reduced cross-flow mass flow fractions. It was concluded from this study that the single-segmental baffle with rotated triangular tube configuration had the best steady-state performance. Some results were extracted from the transient multiphase simulations. The transient multiphase flow simulation of the single-segmental baffle configurations showed larger concentrations of stagnant sediment for the rotated triangular tube configuration versus larger concentrations of suspended/flowing sediment in the square tube configuration. This result was offset by the observation that the downstream movement of sediment was quicker for the rotated triangular tube configuration. No definitive results could be obtained, but from the available results, it can be concluded that the configuration currently implemented at Sasol is best suited to handle sedimentation. This needs to be verified in future studies by using advanced computational resources and experimental results.
Thesis (MIng (Mechanical Engineering))--North-West University, Potchefstroom Campus, 2013

Background Nuclear reactors utilizing molten fuels rather than solid fuels show a massive advantage in energy yield, waste handling and safety features. The only successful reactor utilizing a molten fuel was called the ‘Molten Salt Reactor Experiment’ (MSRE), built and operated in the Oak Ridge national laboratory (ORNL) in Tennessee, U.S.A. during the 1960s. The molten salts in question are fluoride compounds under the name of “FLiBe”. In this thesis, the heat exchangers of the MSRE are modelled and simulated, with the aim to test whether current computational fluid dynamics (CFD) software and mathematical models can accurately predict molten salt heat transfer behaviour.  Methods All programs used are open-source and/or free-access to facilitate open collaboration between researchers in this growing field. All models and findings produced in this thesis are free to use for future research. The program Onshape was used to draw CAD-models based on hand-drawn technical documents released by ORNL. Several programs, e.g., Simscale and Salome, were used to create high detailed meshes of the heat exchangers. The CFD software Simscale and OpenFOAM have been used to simulate the heat exchangers, using the 𝑘 − 𝜔 𝑆𝑆𝑇 Reynolds averaged Navier-Stokes (RANS) turbulence model to perform a multiregion conjugate heat transfer (CHT) analysis. The program Paraview has been used for all post-processing on the large datasets.  Results A working toolchain with open-source programs for CFD has been identified. Highly detailed, full-scale and accurate CAD-drawings of the two heat exchangers have been produced. Models have been finely meshed, containing tens of millions of cells, with good quality measures. The simulations produced physically sound and valuable data: Great heat transfer predictive capability with high accuracy to the data presented by ORNL. Pressure data showed a consistent over-prediction with a factor of ~2. Possibility of error within the MSRE measurement.  Conclusions CHT using modern turbulence methods work well for the intended purpose and can be used by industry to simulate molten salt heat transfer. Open-source programs perform well and can be used by researchers to share ideas and progress. Doubts around certain measurements from the MSRE, showing large uncertainties. Future projects have been outlined to continue the work performed in this thesis. Molten salt reactors show fantastic promise as an energy generation method and should be seriously considered for the future of clean, reliable energy.

Transport Membrane Condenser (TMC) is an innovative technology based on the property of a nano-scale porous material which can extract both waste heat and water from exhaust gases. This technology tremendously improves the efficiency of boilers and gas/coal combustors by lowering waste heat and increasing water recovery. Contaminants in the flue gases, such as CO2, O2, NOx, and SO2 are inhibited from passing through the membrane by the membrane’s high selectivity. The condensed water through these tubes is highly pure and can be used as the makeup water for many industrial applications. The goal of this research is to investigate the heat transfer, condensation rate, pressure drop and overall performance of crossflow heat exchangers. In this research, a numerical model has been developed to predict condensation of water vapor over and inside of nano-porous layers. Both capillary condensation inside the nanoscale porous structure of the TMC and the surface condensation were considered in the proposed method using a semi-empirical model. The transport of the water vapor and the latent heat of condensation were applied in the numerical model using the pertinent mass, momentum, turbulence and energy equations. By using the proposed model and simulation procedure, the effect of various inlet parameters such as inlet mass flow rate, inlet temperature, and water vapor content of the inlet flow on the performance of the cross-flow TMC heat exchanger was studied to obtain the optimum performance of the heat exchangers at different working conditions. The performance of the TMC heat exchangers for inlet flue gas rate 40 to 120 kg/h, inlet water rate 60 to 140 kg/h, inlet flue gas relative humidity 20 to 90%, and tube pitch ratio 0.25 to 2.25 has been studied. The obtained results show that the water condensation flux continuously increases with the increase of the inlet flue-gas flow rate, water flow rate, and the flue-gas humidity. The total heat flux also follows the same trend due to the pronounced effect of the latent heat transfer from the condensation process. The water condensation flux and the overall heat transfer increase at the beginning for small values of the tube pitches and then decreases as the tube pitch increases furthermore. In addition to the cross-flow TMC heat exchangers, the performance of a shell and tube TMC heat exchanger for high pressure and temperature oxy-combustion applications has been investigated. The performance analysis for a 6-heat exchanger TMC unit shows that heat transfer of the 2-stage TMC unit is higher than the 2-stage with the same number of the heat exchanger in each unit.

At present, people already fully aware of how expensive it is energy dependence on fossil fuels. Trying to reduce this dependence goes hand in hand with environmental limits, which restrict the production of dangerous compounds. Biomass is a fuel that does not create large amounts of sulfur and carbon dioxide generated during combustion is in a closed cycle. Different types of biomass have different calorific value, and therefore different demands on the quantity needed to produce MWh. It is therefore necessary to choose the fuel with regard to the availability of in the site.

The purpose of this research project is the design and optimization of complex chemical engineering problems, by employing evolutionary algorithms (EAs). EAs are optimization techniques which mimic the principles of genetics and natural selection. Given their population-based approach, EAs are well suited for solving multiobjective optimization problems (MOOPs) to determine Pareto-optimal solutions. The Pareto front refers to the set of non-dominated solutions which highlight trade-offs among the different objectives. A broad range of applications have been studied, all of which are drawn from the chemical engineering field. The design of an industrial packed bed styrene reactor is initially studied with the goal of maximizing the productivity, yield and selectivity of styrene. The dual population evolutionary algorithm (DPEA) was used to circumscribe the Pareto domain of two and three objective optimization case studies for three different configurations of the reactor: adiabatic, steam-injected and isothermal. The Pareto domains were then ranked using the net flow method (NFM), a ranking algorithm that incorporates the knowledge and preferences of an expert into the optimization routine. Next, a multiobjective optimization of the heat transfer area and pumping power of a shell-and-tube heat exchanger is considered to provide the designer with multiple Pareto-optimal solutions which capture the trade-off between the two objectives. The optimization was performed using the fast and elitist non-dominated sorting genetic algorithm (NSGA-II) on two case studies from the open literature. The algorithm was also used to determine the impact of using discrete standard values of the tube length, diameter and thickness rather than using continuous values to obtain the optimal heat transfer area and pumping power. In addition, a new hybrid algorithm called the FP-NSGA-II, is developed in this thesis by combining a front prediction algorithm with the fast and elitist non-dominated sorting genetic algorithm-II (NSGA-II). Due to the significant computational time of evaluating objective functions in real life engineering problems, the aim of this hybrid approach is to better approximate the Pareto front of difficult constrained and unconstrained problems while keeping the computational cost similar to NSGA-II. The new algorithm is tested on benchmark problems from the literature and on a heat exchanger network problem.

Orientador: André Luiz Seixlack
Banca: Emanuel Rocha Woiski
Banca: José Roberto Simões Moreira
Resumo: Neste trabalho apresenta-se um modelo numérico para a simulação do escoamento transiente de fluidos refrigerantes ao longo de condensadores do tipo arame-sobre-tubo, comumente usados em refrigeradores domésticos que empregam o ciclo de compressão de vapor. A análise envolve o escoamento do fluido refrigerante no interior do tubo e a transferência de calor por convecção natural e radiação entre a superfície externa do tubo, as aletas em forma de arames cilíndricos e o ar externo. No interior do tubo o escoamento é considerado unidimensional e dividido em uma região monofásica de vapor superaquecido, uma região bifásica líquido-vapor e outra em que o refrigerante encontra-se no estado de líquido subresfriado. A queda de pressão no interior do tubo é também considerada. Na região bifásica o escoamento é considerado homogêneo, ou seja, são consideradas condições de equilíbrio térmico e hidrodinâmico entre as fases. Inicialmente, condições de regime permanente serão assumidas e posteriormente será analisada a resposta dinâmica do condensador às variações das condições de operação do sistema. A simulação do escoamento ao longo do condensador é obtida a partir da solução numérica das equações de conservação da massa, da quantidade de movimento e de conservação de energia. Para a parede do condensador, a equação de conservação de energia é resolvida para determinar a sua distribuição de temperatura. O método de Volumes Finitos é usado na discretização das equações governantes. O modelo permite a determinação, nos regimes permanente e transiente, das distribuições de pressão, título, temperatura do refrigerante e temperatura do tubo ao longo do condensador, em função da geometria do condensador e das condições de operação. O modelo proposto é analisado e os resultados obtidos são discutidos e comparados... (Resumo completo, clicar acesso eletrônico abaixo)
Abstract: This work presents a numerical model to simulate the unsteady refrigerant fluid flow along wire-on-tube condensers, commonly used in vapor compression cycle based domestic refrigerators. The model considers the refrigerant flow inside the tube and the heat transfer from the outer surfaces of the wires and tubes to the surrounding air by free convection and radiation. The refrigerant flow along the condenser is divided into a vapor superheated singlephase region, a two-phase liquid-vapor flow region and a subcooled liquid region. The refrigerant pressure drop is taking into account. The homogeneous model is employed for the two-phase flow region, i.e. the hydrodynamic and thermal equilibrium between the phases are considered. Initially the steady state condition is considered and later condenser unsteady behavior is analyzed. The mass conservation, momentum and energy conservation equations for the refrigerant flow are solved in order to evaluate the distributions of mass flux, pressure and temperature of the refrigerant fluid, respectively. Also, the energy conservation equation for the tube wall is solved to determine the wall temperature distribution. The system of differential equations is solved using the Finite Volume method. The model is analyzed and the obtained results are compared with data available in the open literature.
Mestre

This master’s thesis deals with the design of heat recovery system from melting furnace waste gases. The first part is devoted to a brief description of heat exchangers, with the special importance being placed on the shell-and-tube heat exchanger. The second part contains a calculation of stoichiometric combustion, design of geometrical dimensions, calculation of pressure drops and power. At the end of the thesis there are various possibilities of utilization of the obtained waste heat and their basic economic assessment.

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Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)
Neste trabalho apresenta-se um modelo numérico para a simulação do escoamento transiente de fluidos refrigerantes ao longo de condensadores do tipo arame-sobre-tubo, comumente usados em refrigeradores domésticos que empregam o ciclo de compressão de vapor. A análise envolve o escoamento do fluido refrigerante no interior do tubo e a transferência de calor por convecção natural e radiação entre a superfície externa do tubo, as aletas em forma de arames cilíndricos e o ar externo. No interior do tubo o escoamento é considerado unidimensional e dividido em uma região monofásica de vapor superaquecido, uma região bifásica líquido-vapor e outra em que o refrigerante encontra-se no estado de líquido subresfriado. A queda de pressão no interior do tubo é também considerada. Na região bifásica o escoamento é considerado homogêneo, ou seja, são consideradas condições de equilíbrio térmico e hidrodinâmico entre as fases. Inicialmente, condições de regime permanente serão assumidas e posteriormente será analisada a resposta dinâmica do condensador às variações das condições de operação do sistema. A simulação do escoamento ao longo do condensador é obtida a partir da solução numérica das equações de conservação da massa, da quantidade de movimento e de conservação de energia. Para a parede do condensador, a equação de conservação de energia é resolvida para determinar a sua distribuição de temperatura. O método de Volumes Finitos é usado na discretização das equações governantes. O modelo permite a determinação, nos regimes permanente e transiente, das distribuições de pressão, título, temperatura do refrigerante e temperatura do tubo ao longo do condensador, em função da geometria do condensador e das condições de operação. O modelo proposto é analisado e os resultados obtidos são discutidos e comparados...
This work presents a numerical model to simulate the unsteady refrigerant fluid flow along wire-on-tube condensers, commonly used in vapor compression cycle based domestic refrigerators. The model considers the refrigerant flow inside the tube and the heat transfer from the outer surfaces of the wires and tubes to the surrounding air by free convection and radiation. The refrigerant flow along the condenser is divided into a vapor superheated singlephase region, a two-phase liquid-vapor flow region and a subcooled liquid region. The refrigerant pressure drop is taking into account. The homogeneous model is employed for the two-phase flow region, i.e. the hydrodynamic and thermal equilibrium between the phases are considered. Initially the steady state condition is considered and later condenser unsteady behavior is analyzed. The mass conservation, momentum and energy conservation equations for the refrigerant flow are solved in order to evaluate the distributions of mass flux, pressure and temperature of the refrigerant fluid, respectively. Also, the energy conservation equation for the tube wall is solved to determine the wall temperature distribution. The system of differential equations is solved using the Finite Volume method. The model is analyzed and the obtained results are compared with data available in the open literature.

L'utilisation de nouveaux fluides frigorigenes respectueux de notre environnement remet en cause les connaissances etablies pour le dimensionnement des installations frigorifiques et de conditionnement d'air. Les condenseurs de type tema x, largement utilises dans de telles applications, sont composes d'un faisceau de tubes horizontaux ameliores a l'exterieur desquels vient se condenser la vapeur de fluide frigorigene. Le dimensionnement optimal d'un tel echangeur necessite la prise en compte de l'effet d'inondation du condensat le long des rangees de tubes du faisceau. L'approche experimentale reste dans ce domaine un moyen privilegie d'amelioration des connaissances. L'experimentation est realisee sur une maquette simulant une partie du condenseur. Les mesures locales effectuees pour deux fluides frigorigenes et deux geometries de tubes ameliores ont permis d'etablir un nombre important de donnees experimentales. Leur confrontation avec divers modeles de la litterature permet de choisir le mieux adapte au cas de la condensation de fluides frigorigenes. Par la suite, afin de mettre a disposition des fabricants et utilisateurs d'echangeurs les principaux resultats de ce travail, le logiciel cetuc a ete etendu au cas des condenseurs de type tema x

In order to increase the efficiency of a preheating system as temperatures increase, without using seawater as a coolant, an additional heat exchanger is required to be installed into the system. The purpose of the study is therefore to investigate how the temperatures of fuel oils can be increased while minimising the loss of energy and costs. The study was conducted in Karlshamn Power Station's (kvt) preheating system on Block 3. The study was conducted via Design for six sigma (DFSS) according to the primary design concept SG2 to guarantee the study's understanding of empirical data, and the development of solutions. The study resulted in two variants of heat exchangers where one is an identical Shell and Tube heat exchanger from Siljan Allards AB and the other one is a Supermax Shell and Plate heat exchanger from Tranter International.

This master’s thesis is focused on the description and processing of the cell method, which is generally recommended for prediction of fluids temperature profiles in heat exchanger. In the thesis the basic equations for calculating heat transfer are presented and is also described the current situation in the field of computational prediction of fluids temperature profiles in heat exchangers. The cell method is solved by using the software Maple and is applied to the specific case of industrial heat exchangers. The results obtained by the cell method are compared with the results obtained by educational version of software HTRI Xchanger Suite. By this comparison explicitness of the cell method is assessed.

In dieser Arbeit werden neuartige Flachrohre für die Verwendung als Rückwandverflüssiger in der Haushaltskältetechnik mit numerischen und dynamischen Simulationen sowie Experimenten untersucht. Dabei kommen unterschiedliche überströmte Längen sowie der Einfluss horizontaler Abstände auf den Wärmeübergang durch freie Konvektion zur Betrachtung. Realisiert wird die numerische Strömungssimulation mit der Software Fluent 3.6.26, wobei das RNG-k-epsilon- als Turbulenzmodell und diskrete Ordinaten zur zusätzlichen Modellierung des Strahlungswärmeübergangs verwendet werden. Zur Verifizierung werden experimentelle Untersuchungen mit natürlicher Konvektion durchgeführt. Ebenso kommt ein kompakter Verflüssiger bei erzwungener Konvektion zur experimentellen Analyse. Mit einem neuen Verflüssigermodell wird außerdem ein Haushaltskühlschrank in Modelica 2.2.1 dynamisch simuliert. Diese Arbeit zeigt, dass die Verwendung eines Flachrohrverflüssigers großes Potenzial einer konkurrenzfähigen Alternative zu konventionellen Verflüssigern besitzt
In this work novel flat tubes used as rear panel condensers in the household refrigeration technology are examined with numerical and dynamic simulations as well as experiments. Therefore different overflowed lengths and the influence of horizontal spacing on the heat transfer by free convection are taken into consideration. The CFD calculations are realized with the software Fluent 3.6.26, where the RNG-k-epsilon turbulence model and discrete ordinates for an additional modelling of radiation heat transfer are applied. For the verification, experimental studies with natural convection are carried out. Likewise, a compact condenser is experimentally analysed in forced convection. With a new model for the liquefier a domestic refrigerator is also dynamically simulated in Modelica 2.2.1. This work shows that the use of a flat tube condenser has a great potential of a competitive alternative to conventional liquefiers

This diploma thesis deals with the design of a feedwater heater. The aim of the work is to perform thermal, hydraulic and stress analysis. A preliminary technical documentation is also part of this work. The first part contains a summary of basic types of heat exchangers and processes of heat transfer. The main part is focused on thermal analysis to determine the main parameters of the heat exchanger. Next part is followed up by hydraulic analysis to determine the pressure drop of the heating water. After that is created design of heat exchanger with stress analysis of the proposed wall thicknesses of the shell, water chambers and tubesheet. Achieved results are summarized and evaluated at the end of the diploma thesis.

Shell and tube heat exchangers and their use in cooling processes are the major topic of this thesis. The theoretical part of the thesis starts with the mechanisms of heat transfer and then deals with shell and tube heat exchangers. Their position, design specifications and equations for calculations are given. In the experimental part, the heat transfer on semi-operating shell and tube heat exchangers with baffles and glass or silicon carbide heat exchange surface is examined by cooling the humid air by 50% propylene glycol in tubes. For four or five coolant flows and three airflows, input and output flow temperatures including relative air humidity were measured. Differences in exchanged heat between the exchangers were negligible due to the low local air heat transfer coefficient, although silicon carbide has two orders of magnitude better thermal conductivity than glass. Much higher efficiency was performed by the carbide heat exchanger because the difference between air outlet temperature and liquid inlet temperature was one and half times higher for the glass heat exchanger. That was reflected in a decrease in mean temperature difference, which resulted in a 16 % higher experimental heat transfer coefficient compared with the glass surface. The theoretical model using the j factor, the correction factors for the baffles, and the correction for air humidity condensation have proven to be appropriate. For the glass surface, for the highest air flow rates the model gives an appropriate heat-transfer coefficient; at lower flow rates it gives slightly higher values. For the silicon carbide surface, it gives a lower heat-transfer coefficient because the model failed to consider a lower mean temperature difference. The results also evaluate the heat loss through the shell and the heat exchanged in addition by air humidity condensation.

The Master´s thesis is dealing with water-cooled condensers and is splitted into three main parts. The first section provides general knowledge about condensers and heat exchangers, including the basic information of hydrophobic surfaces. These surfaces were used during verifying the impact of hydrophobicity on the heat exchange in water steam. The second section describes an experimental testing. It shows the difference between hydrophobic and nonhydrophobic surfaces and their impact on the heat exchange. The third and the last part of this thesis is design and calculation of water-cooled condenser. The design of the condenser is supported by drawings placed in attachement.

La condensation de melanges non azeotropiques a l'interieur de tubes lisses horizontaux a ete analysee par une approche theorique ainsi que par une approche experimentale. Une etude bibliographique a permis de trouver des modeles physiques de calcul specifiques aux melanges. Cette etape a ete suivie d'une modelisation numerique des methodes decrites. Nous avons utilise egalement le logiciel de conception d'echangeurs a tubes et calandre cetuc, dans lequel ont ete introduites les differentes methodes de calcul des coefficients de transfert de chaleur a travers le film de condensat. Les codes de calcul qui ont fait l'objet de la simulation ont ete valides par des experimentations adaptees. L'accord entre les resultats theoriques et experimentaux est satisfaisant. Cependant une des theories utilisees (la theorie du film) rend mieux compte des resultats experimentaux

Sabe-se que o Método dos Elementos Finitos em sua forma convencional é uma ferramenta poderosa no cálculo estrutural moderno. Porém, se o problema apresenta singularidades, como os efeitos de borda tipicamente introduzidos pelos vínculos nas estruturas em casca, a análise pode exigir alto refinamento da malha. Procurando resolver mais eficientemente esse tipo de problema, especificamente em estruturas com simetria de revolução como os tubos cilíndricos e as cascas esféricas, apresentam-se neste trabalho alternativas não convencionais para o emprego do Método dos Elementos Finitos. Dadas as simetrias de forma e carregamento, a abordagem pode ser feita em campo unidimensional. São apresentadas as respostas analíticas, em termos de deslocamentos e esforços, para as estruturas citadas, partindo-se de suas equações diferenciais governantes. Em seguida, as formas fracas correspondentes são resolvidas pelo Método dos Elementos Finitos, incorporando-se alguns tipos de enriquecimento que aproveitam a estrutura deste método. Por fim, são comparados os resultados aproximados entre si e com relação aos analíticos, comprovando o grande potencial das alternativas sugeridas.
It is known that the Finite Element Method in its conventional form is a powerful technique in the modern structural calculus. However, if the problem has singularities, as boundary effects typically introduced by the support into shell structures, the analysis may demand high refinement of the mesh. In order to resolve this type of problem more efficiently, particularly in structures with symmetry of revolution as cylindrical tubes and spherical shells, this dissertation presents non-conventional alternatives for the employment of the Finite Element Method. Due to the form and load symmetry, the treatment can be made in one-dimensional system. The analytical responses, in terms of displacements and efforts, are recovered to the mentioned structures, from their governing differential equations. Next, corresponding weak forms are resolved by the Finite Element Method and some types of enrichment that utilize the structure of this method are incorporated. Finally, the approach results are compared among themselves and with analytical results, proving the great potential of the suggested alternatives

Cette étude concerne la compréhension des mécanismes de transfert de chaleur et le développement d’un système de stockage pour la valorisation de la chaleur fatale industrielle. L’utilisation de Matériaux à Changement de Phase (MCP) permet d’atteindre une densité énergétique élevée et de restituer la chaleur à température constante. Cependant, leur faible conductivité thermique impose d’améliorer les transferts thermiques, notamment par l’utilisation d’échangeurs à surface augmentée. Le but est de comprendre le comportement de tels échangeurs en régime transitoire au contact de MCP. Une étude expérimentale à basse température, où quatre échangeurs de type tube-calandre ont été testés avec différentes orientations (horizontale/verticale) et injections (haut/bas), a mis en évidence des phénomènes de transfert thermique importants, comme la convection naturelle à la charge et la contraction volumique à la décharge. Ces observations ont été validées par un modèle CFD tridimensionnel. Une méthode de comparaison des performances basée sur un calcul d’énergie par le biais d’un maillage expérimental est proposée et permet de sélectionner un échangeur selon les critères de densités énergétiques, de temps caractéristique et de coût. Trois MCP, envisagés pour l’application, ont alors été testés à température réelle (100-200 °C) au contact d’un échangeur tube inox à ailettes transverses en aluminium pour évaluer leur cyclabilité et comparer leur comportement. Le mélange de sels, H105 (Tfusion = 122 °C), n’est pas retenu pour l’application à cause de sa faible densité énergétique (≈ 56 kWh/m3) et sa plage de fusion trop étalée. L’acide sébacique (Tfusion = 132 °C) a un comportement répétable au cours des cycles et une densité énergétique plus élevée (≈ 66 kWh/m3). L’alcool de sucre, l’érythritol (Tfusion = 118 °C), présente de bonnes thermo-physiques (128 kWh/m3) mais la maîtrise de sa cristallisation est un point clé pour l’utiliser en tant que MCP
This PhD thesis deals with the understanding of the heat transfer mechanisms and with the development of thermal energy storage system for the industrial waste heat recovery application. The use of Phase Change Materials (PCM) is attractive for its high storage density and its possibility to deliver heat at constant temperature. However, the PCM low thermal conductivity leads to develop heat transfer improvement methods, such as heat exchangers with increased heat transfer surface. The goal is to characterize the behavior of such heat exchangers An experimental study, where four several heat exchangers have been tested with different orientations (horizontal/vertical) and injection types (upward/downward), highlighted the impact of natural convection during the melting process and the volume contraction one during the solidification. These results have been validated through a 3D numerical model. A performance comparison method based on an energy calculation through an experimental mesh is proposed and enables to select a heat exchanger on criteria such as the storage density, the characteristic time and the cost. Three PCM, adapted to our application, have been tested at the intended temperature (100-200 °C) by integrating them into a storage system made of a stainless steel tube with aluminum circular fins. Their ability to resist to repeated cycles has been assessed and their behavior has been compared. The salts mixture, H105 (Tmelting = 122 °C), is not selected for the application because of it low storage density (≈ 56 kWh/m3) and its large melting area. The sebacic acid (Tmelting = 132 °C) has a repeatable behavior with cycles and a higher storage density (≈ 66 kWh/m3) and is appropriate as storage material. The sugar alcohol, erythritol (Tmelting = 118 °C), has good thermo-physical properties (128 kWh/m3) but the crystallization control is a key point to use it as a PCM

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Neste trabalho, desenvolve-se uma nova abordagem de otimização do projeto de um trocador de calor casco e tubos. O algoritmo Otimizador por Lobo Cinzento (GWO) é aplicado para minimizar a função objetivo custo total do trocador de calor proposto. As variáveis de otimização adotadas são: número de passes nos tubos, diâmetro externo dos tubos, diâmetro interno do casco, espaçamento dos defletores e corte dos defletores. O método Bell-Delaware e o método de Kern são utilizados para calcular o coeficiente de transferência de calor e a perda de pressão para o lado do casco. Os resultados da otimização são comparados com o projeto original do trocador de calor e também com os resultados alcançados por outros algoritmos de otimização da literatura. Além disso, o algoritmo GWO é comparado com outras meta-heurísticas de otimização em três funções de teste distintas. Os resultados da comparação do algoritmo GWO nas funções de teste mostram um desempenho competitivo, comparado com o Algoritmo Genético, Otimização por Enxame de Partículas, algoritmo Evolução Diferencial e Algoritmo do Vaga-Lume. Os resultados da otimização do trocador de calor utilizando o método de Kern mostra um bom desempenho, com a redução do investimento de capital em 11,95%, 7,93%, 6,24%, 2,37% e 0,19% comparado ao projeto original, GA, ICA, PSO e GSA respectivamente. Além disso, o custo operacional total descontado foi menor que o projeto original e o restante das metaheurísticas exceto para o algoritmo GSA onde o algoritmo GWO obteve resultado 22,33 %, superior. No geral, a redução combinada do investimento de capital e do custo operacional total descontado obtido pela aplicação do algoritmo GWO levaram a uma redução de custo total de 20,80%, 7,28%, 6,07% e 4,06% comparado ao projeto original, GA, ICA e PSO respectivamente. Por fim, os resultados da otimização do trocador de calor utilizando o método Bell-Delaware comparado ao projeto original mostram desempenho satisfatório com redução do investimento de capital em 13,32%. O custo operacional total foi menor em 32,56%. Neste caso, a redução combinada do investimento de capital e do custo operacional total descontado com o GWO levaram a uma redução de custo total de 17,19%.
In this work, a new approach to optimizing the design of a shell and tube heat exchanger is developed. The Grey Wolf Optimizer algorithm (GWO) is applied to minimize the objective total cost function of the proposed heat exchanger. The optimization variables adopted are: number of tubes passes, tube outside diameter, shell inside diameter, baffles spacing and baffle cut. The Bell-Delaware method and the Kern method are used to calculate the heat transfer coefficient and the pressure drop from the shell side. The results of the optimization are compared with the original design and with other optimization algorithms in the literature. In addition, the GWO algorithm is compared with other optimization meta-heuristics in three different test functions. The results of the comparison of the GWO algorithm in the test functions show a competitive performance compared to the Genetic Algorithm, Particle Swarm Optimization, Differential Evolution algorithm and Firefly Algorithm. Already, the results of the optimization of the heat exchanger using the Kern method shows a good performance, with the reduction of capital investment by 11.95%, 7.93%, 6.24%, 2.37% and 0.19% compared to the original project, GA, ICA, PSO and GSA, respectively. In addition, the total discounted operating cost was lower than the original project and the rest of the metaheuristics except for the GSA algorithm where the GWO algorithm obtained 22.33% higher result. Overall, the combined reduction in capital investment and total discounted operating cost obtained by applying the GWO algorithm led to a total cost reduction of 20.80%, 7.28%, 6.07% and 4.06% compared to the original project, GA, ICA and PSO, respectively. Finally, the results of optimization of the heat exchanger using the Bell-Delaware method compared to the original design show satisfactory performance with reduction of capital investment by 13.32 %. The total discounted operating cost was lower by 32.56%. In this case, the combined reduction in capital investment and discounted total operating cost obtained by applying the GWO algorithm led to a total cost reduction of 17.19%.

Subject of this work is a development of an integrated software environment for mechanical design and check of shell and tube heat exchangers. Processes of mechanical design and checks well as software which perform these processes are broken down to basic methods and parts. Mechanical design is usually performed according to some standards. In this work, ČSN EN 13445 is used. This standard describes mostly design check calculations which can be easily algorithmized. On the contrary, design calculations are described to some extent in few simple cases and mechanical design of shell and tube heat exchanger has not been fully algorithmized yet. Subject of this work is design of software, which will be capable of automatically performing mechanical design from datasheet as an input. Based on breakdown of design and check processes, requirements for key software features are derived. Important part of presented work is design and implementation of key modules – data model of shell and tube heat exchanger, module for mechanical design check according to ČSN EN 13445. These modules form basis of the software which will be developed further in future work.

Main object of the work is stress analysis of specific parts of tube and shell heat exchanger by using MKP. Each part is judged by two different computation methods. The method based on computation values and the method nearing real condition of operation of device. To approach real load are in the work made basic heat transfer computations for entire device and for analyzed part are computed boundary conductance by using CFD.

O presente trabalho descreve e introduz uma metodologia numérica de simulação térmica de trocadores de calor de fluxo cruzado e de casco e tubo. A metodologia computacional é utilizada para simular doze configurações de arranjos de escoamento de trocadores de calor de fluxo cruzado com número de passes e tubos por passe arbitrários, assim como diversas condições de mistura de ambos os fluidos. O procedimento computacional é desenvolvido, baseado em diversos trabalhos da literatura, para calcular a efetividade de temperatura e o fator de correção da diferença média logarítmica de temperatura para trocadores de calor de fluxo cruzado em escoamentos contracorrente e paralelo. Novos dados da efetividade de temperatura e do fator de correção para configurações complexas de trocadores de calor são apresentados em diversas tabelas e figuras. As condições de mistura do fluido interno depois de cada passe são analisadas e caracterizadas por três configurações: misturado, não misturado com uma ordem idêntica das fileiras e não misturado com uma ordem inversa das fileiras. A influência da mistura do fluido externo entre os tubos do trocador de calor também é analisada. A metodologia computacional também é utilizada para trocadores de calor de casco e tubo tipo TEMA E com um passe de ambos os fluidos (fluidos do casco e dos tubos) em escoamentos contracorrente e paralelo de acordo com as entradas do trocador de calor. O algoritmo é baseado em diversas hipóteses e considerações de modelagem adotadas em diversos trabalhos de trocadores de calor de fluxo cruzado e de casco e tubo. Cada seção entre as chicanas é idealizada como um trocador de calor não misturado - não misturado. Além disso, este estudo fornece um sumário de correlações matemáticas exatas e aproximadas para algumas configurações de trocadores de calor de fluxo cruzado e de casco e tubo, que são muito apropriadas para análises computacionais e que facilitam o cálculo de efetividade de temperatura e do fator de correção. Os resultados encontrados são comparados com o algoritmo HETE e com soluções e relações matemáticas disponíveis em outras literaturas e mostram a capacidade dos algoritmos desenvolvidos.
The present thesis describes and introduces the numerical simulation methodologies for thermal modeling of crossflow and shell-and-tube heat exchangers. The computational methodology is used for simulating twelve general flow arrangement configurations of crossflow heat exchangers with arbitrary number of passes and tubes per pass, as well as, several mixture conditions of both fluids. The computational procedures are developed, based on some works from literature, to calculate the temperature effectiveness and the mean logarithm temperature difference (MLTD) correction factor for crossflow and parallel and counter-crossflow heat exchangers. New temperature effectiveness and correction factor data for the treated complex flow arrangements configurations are provided and showed in various tables and plots. Tube fluid mixing conditions after each pass, characterized by three types of configuration: tube fluid mixed; tube fluid unmixed keeping identical order of the rows; and tube fluid unmixed with inverted order of the rows, are analyzed. The influence of external fluid mixing between tube rows along the heat exchanger configurations is also addressed. The computational methodology is also addressed to TEMA E shell-and-tube heat exchangers type with one-pass of both fluids (in-tube and shell side) flowing in counterflow and parallel regarding the heat exchangers inlets. The algorithm is based on various assumptions and modelling considerations adopted in several works of crossflow and shell-and-tube heat exchangers. Each section between two baffles is idealized as an unmixed-unmixed crossflow heat exchanger. In addition, this study provides a summary of exact and approximate correlations for some configurations of crossflow and shell-and-tube heat exchangers, that are very appropriate for computerized analysis and that facilitate the computation of both parameters, the temperature effectiveness and the mean logarithmic temperature difference correction factor. The results found are compared to algorithm HETE and with available relations and solutions of other works and show the capability of the developed algorithm.

This thesis is devoted to thermal-hydraulic design and rating of heat exchangers with the specialized commercial software HTRI. These heat exchangers are solved for real high-temperature applications, where the hot fluid is a flue gas with high temperature (above 500 °C). In the thesis is made a brief analysis of the conventional design of heat exchangers usable for high-temperature aplications, description of the basic relations, description and brief user manual of software HTRI. Further, work includes a comparative study of methods for calculation of pressure drop of the fluid at 180° elbows, as support analysis for solution of required applications characterized by low pressure drop of process fluids.

Ce projet porte, dans un souci d’efficacité énergétique, sur la récupération d’énergie des rejets thermiques à basse température. Une analyse d’optimisation des technologies dans le but d’obtenir un système de revalorisation de chaleur rentable fait objet de cette recherche. Le but sera de soutirer la chaleur des rejets thermiques et de la réappliquer à un procédé industriel. Réduire la consommation énergétique d’une usine entre habituellement en conflit avec l’investissement requis pour les équipements de revalorisation de chaleur. Ce projet de maitrise porte sur l’application d’optimisations multiobjectives par algorithme génétique (GA) pour faciliter le design en retrofit des systèmes de revalorisation de chaleur industrielle. L’originalité de cette approche consiste à l’emploi du «fast non-dominant sorting genetic algorithm» ou NSGA-II dans le but de trouver les solutions optimales entre la valeur capitale et les pertes exergétiques des réseaux d’échangeurs de chaleur et de pompes à chaleur. Identifier les solutions optimales entre le coût et l’efficacité exergétique peut ensuite aider dans le processus de sélection d’un design approprié en considérant les coûts énergétiques. Afin de tester cette approche, une étude de cas est proposée pour la récupération de chaleur dans une usine de pâte et papier. Ceci inclut l’intégration d’échangeur de chaleur Shell&tube, d’échangeur à contact direct et de pompe à chaleur au réseau thermique existant. Pour l’étude de cas, le projet en collaboration avec Cascades est constitué de deux étapes, soit de ciblage et d’optimisation de solutions de retrofit du réseau d’échangeur de chaleur de l’usine de tissus Cascades à Kinsley Falls. L’étape de ciblage, basée sur la méthode d’analyse du pincement, permet d’identifier et de sélectionner les modifications de topologie du réseau d’échangeurs existant en y ajoutant de nouveaux équipements. Les scénarios résultants passent ensuite à l’étape d’optimisation où les modèles mathématiques pour chaque nouvel équipement sont optimisés afin de produire une courbe d’échange optimal entre le critère économique et exergétique. Pourquoi doubler l’analyse économique d’un critère d’exergie? D’abord, parce que les modèles économiques sont par définition de nature imprécise. Coupler les résultats des modèles économiques avec un critère exergétique permet d’identifier des solutions de retrofit plus efficaces sans trop s’éloigner d’un optimum économique. Ensuite, le rendement exergétique permet d’identifier les designs utilisant l’énergie de haute qualité, telle que l’électricité ou la vapeur, de façon plus efficace lorsque des sources d’énergie de basse qualité, telles que les effluents thermiques, sont disponibles. Ainsi en choisissant un design qui détruit moins d’exergie, il demandera un coût énergétique moindre. Les résultats de l’étude de cas publiés dans l’article montrent une possibilité de réduction des coûts en demande de vapeur de 89% tout en réduisant la destruction d’exergie de 82%. Dans certains cas de retrofit, la solution la plus justifiable économiquement est également très proche de la solution à destruction d’exergie minimale. L’analyse du réseau d’échangeurs et l’amélioration de son rendement exergétique permettront de justifier l’intégration de ces systèmes dans l’usine. Les diverses options pourront ensuite être considérées par Cascades pour leurs faisabilités technologiques et économiques sachant qu’elles ont été optimisées.

In the industrial sector, it is possible to observe unexpected behaviours of processes, which were not anticipated in the design stage. Such is the case of a secondary cooling process existing within a tobacco manufacturing plant, which was initially designed to cool and recover clean process water with chilled water for posterior recirculation into the main cooling process. It has been observed that under the design flowrates the plate and frame heat exchanger where the process water is cooled is rapidly clogged by suspended solids coming from the main cooling process, resulting in both high maintenance costs and frequent product ion downtime due to necessary intervention for mechanical cleaning. The aim of this thesis project is to evaluate and design process improvements providing sustainable solutions, reducing the operative costs existing nowadays and avoiding any damage on the plate and frame heat exchanger. Any process design solution asks for a capital investment, which was also considered in the overall analysis of the alternatives within this study. Within the evaluation of the possible modifications, solid/liquid separation was mostly studied, together with the selection and design of an appropriate heat exchanger for the given process. After a preliminary screening, a reduced number of alternatives were analysed in detail to assess their possible application. Few alternatives to solving the problem have been studied, in spite of having a wide variety of options.