Transitional fluid flow numerical modelling in sinusoidal heat exchanger channels

The study focuses on modelling heat transfer and fluid flow in a sinusoidal plate-fin heat exchanger channel at 10 ≤ Re ≤ 1000. The aim is to investigate the modelling of unsteady flows from ≈200, a regime that promotes fluid mixing and improves heat transfer [1]. The channel geometry is taken from a study by Zhang et al. [2], in which steady state simulations were presented. Steady and unsteady numerical simulations are undertaken; with the impact of different turbulence modelling assumptions considered. Predictions for Re > 200 were made using k – ω SST turbulence model. Results obtained agree to the observations by Rush et al. [1]. The study includes exploring and verifying simulation approaches for this regime. A further aim of the study is to compare Computational Fluid Dynamics (CFD) codes OpenFOAM and Ansys Fluent

A multi-scale conjugate heat transfer modelling approach for corrugated heat exchangers

The paper compares two serrated plate-fin Heat Exchanger (HE) corrugation modelling methods using Computational Fluid Dynamics (CFD). The first method follows closely recent literature studies and models a finite length single channel of a corrugation layer inside the HE core. The second method utilises the conjugate heat transfer methodology and models a section of the HE core with both cold and hot fluid streams separated by a solid conducting wall (HE corrugation). The results of latter model are then extrapolated for the full dimensions of a HE core layer to obtain flow and heat transfer characteristics. The conjugate heat transfer analysis methodology presented is novel and eliminates the need for analytical/empirical modelling currently widely used within industry. Furthermore, it provides more detailed information about the flow and heat transfer inside the HE core enabling potential for more efficient HE designs. Predictions at the corrugation level were carried out at with mesh independence studies completed for all the computational domains. The results obtained in the HE corrugation predictions were then implemented to the multi-scale HE unit model where the flow inside the HE core was modelled using two porous media simplifications whilst the heat transfer was simplified using the effectiveness source term. The HE unit predictions were validated against industrial experimental data with good agreement found between the numerical and experimental results. All the simulations were completed using the open-source CFD package OpenFOAM

Experimental and numerical study of the additive layer manufactured inter-layer channel heat exchanger

In this paper the performance of a recently patented additive layer manufactured (ALM) concept inter-layer heat exchanger (HE) is evaluated experimentally and numerically. Two numerical HE models are developed using the conjugate heat transfer (CHT) methodology. The first is an idealised HE core model, consisting of a single period width HE corrugation section (termed superchannel). The second approach uses a fully detailed HE unit model which resolves the flow and heat transfer inside the complete HE unit. A close agreement was found between the HE unit simulations and the experimentally obtained results, such that the fully detailed HE model could be validated. It was also shown that, a full CHT approach is necessary to accurately evaluate complex inter-layer ALM HE core flow and heat transfer behaviour and can serve as an approach for optimising HE designs. The results also reinforce the occurrence of the inter-layer flow mixing inside the HE core of the same flow streams and allows the mass flow to redistribute inside the HE core which is impossible with the current HE generation geometries. The superchannel model results in a slight over-estimation in heat transfer ( K on average) making the simplified model acceptable as a conservative estimate. Using validated simulations a parametric study was conducted by changing the solid properties of the full CHT HE model to aluminium to investigate the effects of a significantly more conductive material. This resulted in higher heat transfer effectiveness () of the HE unit. All the simulations were carried out using CFD package OpenFOAM

Numerical simulation of crust freezing in processed meat: A fully coupled solid–fluid approach

We present a numerical model for the simulation of continuous impinge ment freezing of processed food products. This model is capable of fully describing the fluid dynamics of the non-isothermal flow field, including turbulence with conjugate heat transfer (CHT). The motion of the solid region is captured by advecting the solid rathe than employing a moving mesh algorithm, resulting in a model that is more computationally efficient. This methodology is implemented as a numerical solver using the well-known open-source library OpenFOAM. Our results confirm that the proposed model can provide detailed insight on the freezing process at a minimum computational cost.The authors would like to thank University of Nottingham Hermes fund for sponsoring the research

A numerical evaluation of next generation additive layer manufactured inter-layer channel heat exchanger

A Concept Heat Exchanger (HE) design manufactured using the Additive Layer Manufacturing (ALM) technique Selective Laser Melting (SLM) is proposed and numerically evaluated. It is composed of a HE corrugation which introduces inter-layer flow conduits between the parallel HE layers of the same fluid. These pathways are provided by hollow elliptical tubes which serve several functions: to disturb the flow to promote heat transfer, to provide additional heat transfer area and to minimise flow maldistribution inside the HE core. The corrugation is incorporated into a counter-flow prototype HE unit model meaning to exploit the installation volume and design freedom made possible via ALM. Three Computational Fluid Dynamics (CFD) models are utilised to evaluate the performance of the proposed HE unit. Firstly, a traditional two step HE design methodology is utilised which works by initially evaluating a fully symmetric channel of the proposed HE corrugation (termed single channel). Then the results this model are incorporated into a simplified HE unit model. The second approach evaluates the HE unit performance based on a fully detailed CFD analysis that fully resolves flow and heat transfer inside the HE core. The third modelling approach involves splitting the inter-layer HE unit model into parts, which results in HE header models and allows simplification of the HE core into a single corrugation period width HE core model (termed superchannel). The results of these models are then compared to a conventional pin–fin HE unit model, formed by blocking the elliptical inter-layer conduits. It was found that in all the HE unit models the pressure drop is similar whilst the heat transfer was enhanced by between 7% and 13% in terms of the overall ΔT by the inter-layer channels (increasing with the Reynolds number). All simulations were completed using a CFD package OpenFOAM

Design and operation of a Rayleigh Ohnesorge Jetting Extensional Rheometer (ROJER) to study extensional properties of low viscosity polymer solutions

The Rayleigh Ohnesorge Jetting Extensional Rheometer (ROJER) enables measurement of very short relaxation times of low viscosity complex fluids such as those encountered in ink-jet printing and spraying applications. This paper focuses on the design and operation of the ROJER. The performance of two nozzle designs are compared using Newtonian fluids alongside a study using computational fluid dynamics (CFD). Subsequently a disposable nozzle is developed that overcomes issues of blockage and cleaning. The operability of this design is subject to a focused study where low viscosity polymer solutions are characterised. The test fluid materials are ethyl hydroxy-ethyl cellulose (EHEC) and poly ethylene oxide (PEO) mixed with water/glycerol solutions. Results obtained by the disposable nozzle are encouraging, paving the way for a more cost-efficient and robust ROJER setup

Unsteady Flow Modelling in Plate-Fin Heat Exchanger Channels

A methodology using Computational Fluid Dynamics (CFD) was developed to predict the flow and heat transfer performance of a single two dimensional sinusoidal channel of a Heat Exchanger (HE) at a Reynolds number (Re) range of ≤ Re ≤ 500. The impact of different modelling assumptions was thoroughly evaluated which has not has been done in detail before. Two computational domains were used: a single period sinusoidal channel for fully periodic flow predictions and finite length channel consisting of 6 sinusoidal channel periods. Mesh and time independence was achieved for both domains whilst results with periodic domain were compared to numerical results in the literature. Laminar, k - e and k - w SST predictions were assessed throughout the Reynolds range with unsteady flow onset detected at Re ≈ 200 using laminar and k-w SST models. The impact of different accuracy numerical discretisation schemes is assessed throughout the Re range and it was found that second order accuracy schemes should be used to fully capture the unsteady flow. Comparison between open-source CFD package OpenFOAM and Ansys was Fluent was performed and agreement was‘ found

Numerical simulation of crust freezing in processed meat: A fully coupled solid–fluid approach

We present a numerical model for the simulation of continuous impinge ment freezing of processed food products. This model is capable of fully describing the fluid dynamics of the non-isothermal flow field, including turbulence with conjugate heat transfer (CHT). The motion of the solid region is captured by advecting the solid rathe than employing a moving mesh algorithm, resulting in a model that is more computationally efficient. This methodology is implemented as a numerical solver using the well-known open-source library OpenFOAM. Our results confirm that the proposed model can provide detailed insight on the freezing process at a minimum computational cost.The authors would like to thank University of Nottingham Hermes fund for sponsoring the research