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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 55 records · Page 3
All sourcesNASA NTRSDOE OSTI
DOE OSTI2020

A hybrid porous model for full reactor core scale CFD investigation of a prismatic HTGR

Three-dimensional (3-D) Computational Fluid Dynamics (CFD) analysis of a whole nuclear reactor core is a tremendous challenge due to the large geometric volume and complex structures. Here, this research presents a hybrid porous (HP) model to simplify a prismatic High Temperature Gas-cooled Reactor (HTGR) core, so 3-D CFD investigation can be performed on a full reactor core scale. In the HP model, the prototypic small coolant channels in the nuclear fuel blocks are lumped together to form multiple equivalent large coolant channels, and then the porous medium flow model is applied to each of them. Therefore, heat transfer in fuel blocks is computed by a hybrid combination of solid energy and porous flow energy equations. The similarity between the HP model and prototypic model is achieved by deriving the porous flow permeability, inertial resistance factor, and artificial thermophysical properties. Compared with the widely used whole porous (WP) flow model, the HP model preserves more realistic geometric structures, and therefore more accurate physical processes. The General Atomics' Modular High Temperature Gas-cooled Reactor (MHTGR) design was chosen as a prototype to demonstrate the methodology. Simulations were performed using the prototypic CFD model and HP model at steady-state forced circulation, steady-state natural circulation, and transient conditions that correspond to normal operation, extended period of pressurized cool down, and short-term transients after reactor shutdown, respectively. The comparison shows good agreement between the HP model and prototypic model in the maximum fuel temperature, average solid temperature, and helium flow rate, which demonstrates the potential applicability of the HP model for a full reactor core scale simulation in the future. As a benefit, the HP model reduces the mesh quantity by a factor of 50 from a prototypic model. Correspondingly, the computation time was reduced by a factor of at least 30.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Role of Inlet Boundary Conditions on Fuel-Air Mixing at Supercritical Conditions

Advanced engine design and alternative fuels present the possibility of fuel injection at purely supercritical conditions in diesel engines and gas turbines. The complex interactions that govern this phenomenon still need significant research, particularly the boundary conditions for fuel injection are critical for accurate simulation. However, the flow inside the injector itself is often omitted to reduce the computational efforts, and thus, velocity, mass flux, or total pressure is specified at the injector exit (or domain inlet), often with simplified velocity profiles and turbulence levels. This simplified inlet boundary treatment has minimal effects on results for conventional fuel injection conditions, however, the validity of this approach at supercritical conditions has not been assessed. Comprehensive real-gas and binary fluid mixing models have been implemented for computational fluid dynamics (CFD) analysis of fuel-air mixing at supercritical conditions. The model is verified using prior CFD results from the literature. The model is used to investigate the effects of the shape of axial velocity and mass fraction profiles at the inlet boundary with the goal to improve the comparison of predictions to experimental data. Results show that the boundary conditions have a significant effect on the predictions, and none of the cases match precisely with experimental data. Furthermore, the study reveals that the physical location of the inlet boundary might be difficult to infer correctly from the experiments and highlights the need for high-quality, repeatable measurements at supercritical conditions to support the development of relevant high-fidelity models for fuel-air mixing.

02 PETROLEUM↗
DOE OSTI2024

Exploring the Feasibility of INCONEL® ALLOY 740H® for Power Plant Headers: Integrating Machine Learning with Computational Fluid Dynamics (CFD)

This keynote presentation explores the behavior of headers—essential components of pipeline systems—using ANSYS simulation software and machine learning techniques. The study aims to predict the thermal and mechanical performance of headers under diverse conditions through both steady-state and transient simulations. We investigate critical parameters such as heat transfer coefficient, fluid velocity, and temperature to optimize header design. Conducted as part of a DOE project led by NCAT in collaboration with UNC Charlotte, this research encompasses multiple key topics. The initial section focuses on the behavior of header systems under steady-state conditions using ANSYS simulation. It underscores the importance of headers in industrial infrastructure, especially in the energy sector, and examines the implications of material selection and flow direction on heat transfer dynamics. Methodologically, we employ Computational Fluid Dynamics (CFD) analysis through ANSYS, detailing the development of models, material properties, geometry specifications, boundary conditions, and meshing strategies. Our simulations explore various operational parameters, including temperature and mass flow rates, crucial for predicting heat transfer coefficients and enhancing header design. Results from the study include parametric investigations into mesh sensitivity, viscosity model evaluations, and the effects of heat transfer locations, all validated against theoretical calculations. We conclude with insights on mesh optimization, the suitability of viscosity models, and recommendations for future research aimed at improving header system efficiency and sustainability in industrial applications.

20 FOSSIL-FUELED POWER PLANTS↗
DOE OSTI2021

CFD-Guided Evaluation of Spark-Assisted Gasoline Compression Ignition for Cold Idle Operation

A closed-cycle, three-dimensional (3D) computational fluid dynamics (CFD) analysis campaign was conducted to evaluate the performance of using spark plugs to assist gasoline compression ignition (GCI) combustion during cold idle operations. A conventional spark plug using single-sided J-strap design was put at a location on the cylinder head to facilitate spray-guided spark assistance. Ignition was modeled with an L-type energy distribution to depict the breakdown and the arc-to-glow phases during the energy discharge process. Several key design parameters were investigated, including injector clocking, number of nozzle holes, spray inclusion angle, number of fuel injections, fuel split ratio, and fuel injection timings. The study emphasized the region around the spark gap, focusing on flame kernel formation and development and local equivalence ratio distribution. Flame kernel development and the ignition process were found to correlate strongly with the fuel stratification and the flow velocity near the spark gap. The analysis results showed that the flame kernel development followed the direction of the local flow field. In addition, the local fuel stratification notably influenced early-stage flame kernel development due to varying injection spray patterns and the fuel injection strategies. Among these design parameters, the number of nozzle holes and fuel injection timing had the most significant effects on the engine combustion performance.

42 ENGINEERING↗
DOE OSTI2023

Flow Induced Corrosion in 6061-T6 Aluminum Pipes in De-Ionized Water Environments

Flow induced corrosion/erosion of 6061-T6 aluminum in de-ionized (DI) water environments has not been studied widely. Especially, the long-term effects of corrosion/erosion in seemingly benign flow velocity, temperature, and resistivity ranges of 8 ft/s, 85 oF, 3-5 MOhm-cm, respectively. This study concludes that the flow induced corrosion/erosion in the above parameter ranges is minimal. This is detailed by presenting a literature survey, measuring pipe wall samples from a system that has operated in the above parameter range, predict the loss of material in mm/year at the above velocities and at higher temperatures using electric potential values from other experimental studies coupled with wall shear stress simulated using Computational Fluid Dynamic (CFD) analysis.

72 PHYSICS OF ELEMENTARY PARTICLES AND FIELDS↗
DOE OSTI2021

DESIGN AND PROTOYPING OF A FISSILE-BEARING CHLORIDE SALT IRRADIATION EXPERIMENT

Limited data exists on the properties of irradiated fueled chloride-based salts for use in advanced nuclear reactors. The design and prototyping of a salt irradiation experiment is underway. Mechanical design will integrate the experiment into existing assemblies in TRIGA type cores. Neutronics modeling demonstrated how targeted power densities can be reached and provide insight on radionuclide source term generation within the experiment. Thermal-hydraulic and computational fluid dynamics (CFD) analysis indicated that temperature ranges in the salt can satisfy both safety and programmatic requirements. Initial prototyping tests provided confidence in the ability to extract the salt post-irradiation, and in the heater performance. Future planned prototyping will provide an integral assessment of the proposed design prior to insertion in the reactor.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2024

Large eddy simulation of a pressurized reactive fluid–particle system: single-particle dynamics analysis

Pressurized oxy-combustion (POC) is a promising candidate to reduce carbon emissions in power generation. Designing an effective burner plays a vital role in developing new combustion technologies. Because of the high pressure, the volume fraction of particles in a pressurized oxy-combustor could be higher than that in the conventional combustor, therefore, the particle dynamics in the pressurized vessel need to be evaluated accordingly. The present computational work is to predict the influence of the particle size and particle injection location on the particle trajectory. The Stokes number based on turbulence fluctuation, St, is adopted to evaluate the impact of the gas phase on the particulate phase. A large eddy simulation (LES) with the environment pressure of 15 bar and the thermal input of the fuel particle of 100 kWth has been performed by means of the commercial CFD package. It is shown that that in this pressurized environment St << 1 for the 25 µm particles, St ~ 1 for the 100 µm particles, while for the particles exceeding 200 µm St >> 1. The trajectories of the sampling particles from the LES results support this conclusion: the particles less than 100 µm tend to be uniformly distributed in the space while the particles exceeding 200 µm tend to concentrate in the combustor.

Li, Lei↗
DOE OSTI2023

ECAR-7210 Rev 0 Steady-state Thermo-mechanical Analysis of the MARVEL Fuel Bundle

This document reports the steady-state thermal-hydraulic and static mechanical analyses of the MARVEL micro-reactor core. The objective of this work is to investigate whether fuel-to-fuel contact could occur due to the thermal deformation of the fuel cladding during the normal operation and to assess the resulting impact on the peak cladding temperatures (PCT) if contact occurs. The scope of the work consists of three computational tasks. First, a conjugate heat transfer analysis using computational fluid dynamics (CFD) model was performed to evaluate the PCTs during normal operating conditions. Second, a finite element analysis (FEA) using the cladding temperature field obtained from the CFD analysis was performed to evaluate the thermal deformation of cladding and determine the occurrence of fuel-to-fuel contact. Finally, a CFD analysis of FEA-informed fuel-to-fuel gap (represented by a conservative 0.05 mm uniform gap) was performed to evaluate whether the PCT exceeds the safety criteria.

21 - SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLAN↗
DOE OSTI2024

Identification of Dynamic Force Coefficients for an Additively Manufactured Hermetic Squeeze Film Bearing Support Damper Utilizing a Pass-Through Channel

Abstract The following paper presents breakthrough experimental results for a new hermetic squeeze film damper (HSFD) concept that is integrally designed within an externally pressurized tilting-pad radial gas bearing support. The flexibly damped gas bearing module was designed for a 7.2″ (183 mm) diameter shaft and fabricated using direct metal laser melting (DMLM); also known as additive manufacturing. The bearing and HSFD were sized based on ongoing studies for oil-free supercritical carbon dioxide (sCO2) power turbines in the 8.5 MW–10 MW power range. The development of the new damper concept was motivated by past dynamic testing on HSFD, which generated frequency-dependent stiffness and damping force coefficients. In efforts to eliminate the frequency dependency, a new HSFD architecture was conceived that adds accumulator volumes and a pass-through channel to previously conceived HSFD flow network designs. The other motivation for the work is the need to develop a cost-effective and reliable oil-free bearing technology that is scalable to large power turbomachinery applications. There were several objectives for the following work. The first objective was to successfully design and fabricate a single piece bearing-damper using additive manufacturing, while dimensionally controlling critical design features. The paper discusses the manufacturing steps and shows cut-ups that reveal adequate clearance control capability with internal damper clearances. The second objective was to perform experimental testing with the new HSFD design in efforts to extract stiffness and damping coefficients for excitation frequencies within 20–160 Hz and peak vibration amplitudes between 0.25 mils (6.35 microns) to 1 mil (25.4 microns). The test results for a single HSFD bearing module indicated that the design modifications to the HSFD architecture were successful in eliminating nearly all the frequency dependencies for the stiffness force coefficient. The dynamic tests yielded a stiffness coefficient that varied between 112 klb/in. (19.6 MN/m) and 96 klb/in. (16.8 MN/m). The damping force coefficient however, exhibited relatively more variation with frequency with values residing between 175 lb-s/in. (31 kN-s/m) to 214 lb-s/in. (37 kN-s/m). Finally, the paper advances a three-dimensional fluid-structure interaction (FSI) model using transient finite element analysis (FEA) coupled to a computational fluid dynamics (CFD) model. The FSI analysis performed between 20 Hz and 80 Hz was used to predict the stiffness and damping of the HSFD using a quarter-section model of the damper. The FSI analysis was able to support test results by showing only a 6–7.4% change in the magnitude of force coefficients. Stiffness predictions agree reasonably well with experiments whereas damping is underpredicted.

Engineering↗
DOE OSTI2022

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

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

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2020

HYDRODYNAMIC ANALYSIS OF MACROALGAE LOCAL MODEL USING COMPUTATIONAL FLUID DYNAMICS

In this article, a local scale, fully nonlinear coupled fluid-structural interaction (FSI) sugar kelp model has been developed using a computational fluid dynamics (CFD) method. In this model, to be consistent with available experimental data, the sugar kelp is approximated as elongated rectangles with smoothed isosceles triangles at the ends and a single kelp model with one end fixed in a channel with constant current model is developed. Several different current speeds are simulated, and the resulting drag forces and calculated drag coefficients are validated by comparison with experimental data from the literature. In a previous study, a global scale model was developed using a computational structural dynamics (CSD) method to simulate macroalgae farming system and guide the system configuration design. In the global scale model, the hydrodynamic forces are calculated using Morison’s equation and the kinematics and dynamics of the sugar kelp are simplified and the group of kelps attached to the long line is modeled as a slender structure with the same length and an effective diameter such that the volumes are consistent with the real physical system. This simplified model matches the weight and buoyancy but adjusting the hydrodynamic properties when the general hydrodynamic coefficients are employed. Therefore, optimal hydrodynamic coefficients used in global scale model were determined to obtain the hydrodynamic force more accurately. The validated local scale model is then be applied to determine the hydrodynamic coefficients of the simplified sugar kelp model for global dynamic analysis.

hydrodynamic modeling, macroalgae, CFD model↗
DOE OSTI2025

Spin-on deposition of amorphous zeolitic imidazolate framework films for lithography applications

Amorphous zeolitic imidazolate framework (aZIF) films have been recently introduced as resists for electron beam and extreme ultraviolet lithography. aZIFs are also being considered for separation applications, including thin film membranes. However, the reported methods for aZIF deposition are currently based on highly empirical trial-and-error approaches that hinder control of film composition, thickness and uniformity as well as scale-up and transferability to different coating geometries. This work presents a method for depositing aZIF films with controllable thickness using dilute precursors mixed immediately before encountering the substrate. Importantly, the method is amenable to quantitative analysis by computational fluid dynamics to extract intrinsic deposition rates and limiting reactant transport diffusivities, enabling predictive physics-based modeling of the deposition process. This allows the deposition method to be adapted for spin coating on silicon wafers to prepare high-quality aZIF films with consistently controlled thickness. Using this approach, high-resolution resist performance and wafer-scale use for beyond extreme-ultraviolet lithography of aZIF films is demonstrated.

75 CONDENSED MATTER PHYSICS, SUPERCONDUCTIVITY AND↗
DOE OSTI2021

Numerical Analysis of Fuel Effects on Advanced Compression Ignition Using a Cooperative Fuel Research Engine Computational Fluid Dynamics Model

Growing environmental concerns and demand for a better fuel economy are driving forces that motivate the research for more advanced engines. Multi-mode combustion strategies have gained attention for their potential to provide high thermal efficiency and low emissions for light-duty applications. These strategies target optimizing the engine performance by correlating different combustion modes to load operating conditions. The extension from boosted spark ignition (SI) mode at high loads to advanced compression ignition (ACI) mode at low loads can be achieved by increasing the compression ratio and utilizing intake air heating. Further, in order to enable an accurate control of intake charge condition for ACI mode and rapid mode-switches, it is essential to gain fundamental insights into the autoignition process. Within the scope of ACI, homogeneous charge compression ignition (HCCI) mode is of significant interest. It is known for its potential benefits, operation at low fuel consumption, low NOx, and particulate matter (PM) emissions. In the present work, a virtual Cooperative Fuel Research (CFR) engine model is used to analyze fuel effects on ACI combustion. In particular, the effect of fuel octane sensitivity (S) (at constant Research Octane Number (RON)) on autoignition propensity is assessed under beyond-RON (BRON) and beyond-MON (BMON) ACI conditions. The three-dimensional CFR engine computational fluid dynamics (CFD) model employs a finite-rate chemistry approach with a multi-zone binning strategy to capture autoignition. Two binary blends with Research Octane Number (RON) of 90 are chosen for this study: primary reference fuel (PRF) with S = 0 and toluene–heptane (TH) blend with S = 10.8, representing paraffinic and aromatic gasoline surrogates. Reduced mechanisms for these blends are generated from a detailed gasoline surrogate kinetic mechanism. Simulation results with the reduced mechanisms are validated against experimental data from an in-house CFR engine, with respect to in-cylinder pressure, heat release rate, and combustion phasing. Thereafter, the sensitivity of combustion behavior to ACI operating condition (BRON versus BMON), air-fuel ratio (λ = 2 and 3), and engine speed (600 and 900 rpm) is analyzed for both fuels. It is shown that the sensitivity of a fuel’s autoignition characteristics to λ and engine speed significantly differs at BRON and BMON conditions. Moreover, this sensitivity is found to vary among fuels, despite the same RON. It is also observed that the presence of low-temperature heat release (LTHR) under BRON condition leads to more sequential autoignition and longer combustion duration than BMON condition. Finally, the study indicates that the octane index (OI) fails to capture the trend in the variation of autoignition propensity with S under the BMON condition.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2023

Conjugate Heat Transfer Analysis in Pressurized Helium Gas Cooling Channels

Los Alamos National Laboratory (LANL) is working with NorthStar Medical Radioisotopes (NMR) on their efforts to produce Mo-99 from the irradiation of Mo-100 targets. The NMR target consists of an Inconel window that allows the electron beam to penetrate and irradiate a stack of Mo-100 disks. The irradiation process generates large amounts of heat and is cooled using pressurized helium gas flowing at 400 g/s. LANL provides both numerical analysis support and experimental support. Computational fluid dynamics (CFD) and conjugate heat transfer (CHT) analysis are performed on the NMR target to analyze the helium flow and volumetric heating through the NMR system. In this iteration of numerical analysis, we update the Mo-100 disk thickness to 0.74 mm and the gap between the Inconel window and the first disk to 0.69 mm. Estimates of the heat flux from the electron beams from Monte Carlo N-Particle code (MCNP) analysis were combined with CFD to perform the CHT analysis. The pressure drop through the targets, force applied on the first disk, beam window and target disk temperatures are some of the quantities estimated using the simulations. The pressure drop through the target was estimated as 0.198 MPa, while the force due to venturi effects across the first disk was estimated to be 100 N. The results show maximum window temperatures over 600 °C and peak disk temperatures over 1600 °C. Past work has shown that beyond 650-700 °C, the Inconel window becomes susceptible to yield and rupture. The increased temperature in these results reduces the margin of error possible on beam spot size. The disk temperatures showed a sinusoidal distribution with the 6 th – 8 th disk from each window exhibiting highest disk temperatures. The peak temperature of the stainless steel housing was close to 316 °C and that of the laminations and spacers was approximately 582 °C.

43 PARTICLE ACCELERATORS↗
DOE OSTI2023

Numerical Analysis of Novel Plate Type Heat Exchanger with Oval-Twisted Channels

The novel heat exchanger (HX) designs implementing geometrical and surface modification combinations are expected to perform better than traditional HX technologies. Applied enhancement techniques seek to achieve (1) higher overall heat transfer performance, (2) increased compactness, and (3) simplified or comparable manufacturability. One innovative enhancement technique is to generate swirling flow vortices induced by channel or tube twisting. The turbulence generated by the twisted cross-section greatly enhances the heat transfer rate with minimal increases in pressure drop. Plate-type HXs and Printed Circuit Heat Exchangers (PCHXs) are compact designs that achieve high heat transfer rates per unit volume by utilizing several small channels, which maximizes the heat transfer surface area between the hot and cold fluids. Currently, advanced manufacturing technologies enable the design and fabrication of compact-type units with complicated channel geometries to achieve the highest performance and meet the compactness criteria of innovative HX technology. The proposed HX design concept combines the compactness of plate-type HXs and twisted channels, which provide additional turbulence and flow swirl enhancement. The plate-type oval-twisted HX (PTOTHX) is a crossflow configuration, with 16 short channels on one side (for hot fluid) and 8 long channels on the perpendicular side (for cold fluid). The inlet plenums have flow guide vanes to redirect flow and produce uniformity across the various flow paths. The compact size and purportedly improved heat transfer performance of the PTOTHX investigated herein prove its viability in various applications. Some notable potential nuclear applications of the PTOTHX include reactor core, spent fuel cooling, and residual heat dissipation. To establish a reference case, circular channels (PTCHX) are also considered in the present study for comparison with (PTOTHX). This paper aims to outline the numerical analysis procedures for determining the viability of the PTOTHX by comparing its heat transfer performance with the PTCHX units. The computational study used STAR-CCM+, a commercial computational fluid dynamics (CFD) code. Sensitivity analysis and model selection studies are conducted to determine the appropriate mesh density and turbulence model to provide the reported results. Numerical analyses comparing the Nusselt number (Nu) of the PTOTHX design with a comparable HX unit, including a circular cross-section and no twisting (PTCHX), show an overall heat transfer performance increase of 29-55% for balanced flow and 29-59% for imbalanced flow. Oval-cross-sectional twisted channels induce swirling flow vortices, enhancing the working fluid's convective heat transfer capabilities.

25 ENERGY STORAGE↗
DOE OSTI2025

Thermal Analysis of a Solid Particle Light-Trapping Planar Cavity Receiver Using Computational Fluid Dynamics

Concentrated solar power (CSP) is one of the most effective ways of harnessing solar power to create efficient, durable, and resilient energy systems. This study entails thermal modeling and analysis of a novel central tower receiver configuration. This receiver uses solid particles as the heat transfer fluid (HTF), a promising option for third-generation CSP systems. The configuration considered here is the light-trapping planar cavity receiver (LTPCR) introduced by the National Renewable Energy Laboratory. While heat transfer studies of various LTPCR subsystems have been done, system-level thermal analysis of the LTPCR receiver has not been attempted. This study also presents important sensitivity analyses of the operating parameters of the CSP system, which can help guide the design of future central tower receivers. This study employs Ansys Fluent as a computational fluid dynamics (CFD) tool to model fluid dynamics and heat transfer in the receiver, intending to quantify its thermal performance. The model seamlessly integrates Monte Carlo ray tracing data, which generates absorbed solar flux profiles from the heliostat field design, with the heat transfer characteristics of the fluidized particle bed. This unified model is designed to accurately predict the thermal behavior of the LTPCR. Analysis of preliminary results reveals that the primary loss mechanisms are radiative and natural convective losses, in that order. Based on observations from a baseline case, several strategies are suggested and numerically tested. These solutions include selective cooling of high-temperature regions and manipulation of particle bed parameters. Selective cooling of high-temperature regions reduced the peak temperature by 151 degrees C and decreased thermal losses by 0.9%. Improving the particle-wall heat transfer coefficient (P-W HTC) of the particle bed decreased the thermal losses by 1.7% and decreased the peak temperatures by 57 degrees C. Decreasing the particle inlet temperature (PIT) also reduced thermal losses by 3.5% and decreased peak temperatures by 29 degrees C. Compounding these strategies improved the thermal losses of the receiver from 13.5% in the baseline case to 7.5%. Additionally, the study explores the variation in thermal performance across different locations of the receiver, where a variation of thermal losses from 12.9% to 17.3% is found. This allows a comprehensive evaluation of potential improvements in efficiency and temperature management.

computational fluid dynamics↗
DOE OSTI2022

Multi-scale and multi-physics analysis, design optimization, and experimental validation of heat exchangers utilizing high performance, non-round tubes

Air-to-refrigerant heat exchangers (HXs) are fundamental components in HVAC&R systems, and considerable research has been dedicated designing continually smaller, lighter, and more efficient HX designs. In recent years, researchers have leveraged advancements in Computational Fluid Dynamics (CFD), Finite Element Analysis (FEA), and optimization algorithms to consider primary tube shape and topology optimization to design highly compact, high performance HXs for a multitude of applications. In this research, we present a computationally efficient, comprehensive, multi-scale, and multi-physics analysis and optimization method for air-to-refrigerant HXs featuring automated CFD and FEA simulations and approximation-assisted optimization. This methodology was utilized to design HXs with shape-optimized, non-round tubes which outperform current state-of-the-art tube-fin HXs without compromising structural integrity. The optimal HXs were shown to deliver similar thermal performance to the baseline HXs while also achieving more than 20% reductions in airside pressure drop and core envelope volume and more than 30% reduction in internal volume. Comprehensive experimental validation of the optimization methodology was conducted through the testing of two prototypes in a standardized wind tunnel facility under multiple operating conditions. For prototype #1 under dry evaporator conditions, the predicted heat load agreed within ± 10% of measured values and the predicted airside pressure drop agreed within ± 30%, while for dehumidifying conditions, the predicted sensible and latent heat loads agreed within ± 10% and ± 20% of the measured values, respectively. For prototype #2, the predicted condenser heat load agreed within ± 3.0% of measured values, and the predicted airside pressure drop agreed within ± 27%. The acceptable agreement between simulation and experimental results for the present application highlights the flexibility of the novel optimization methodology to design next generation HXs with improved performance and reduced volume, weight, and environmental impact.

42 ENGINEERING↗