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The presentation and supporting information provide data on the performance of an engineering-scale cross-flow heat exchanger used in hydrothermal liquefaction (HTL). Temperature profiles are provide for the process of waste water treatment sludges and a food waste. The data can be used to model larger-scale heat exchangers used in HTL.
Frost formation in fin-and-tube heat exchangers in turbulent cross-flow presents significant challenges in industrial refrigeration applications, affecting heat transfer efficiency and operational reliability. The purpose of this work is to investigate frost deposition and growth on a staggered bank of a fin-and-tube freezer coil under turbulent forced convection conditions. The focus here is on investigating conditions that closely replicate real-world scenarios in large walk-in industrial freezers. Using a direct numerical simulation approach, we examine the flow dynamics and thermal behaviour in the presence of frost, considering turbulent regimes characterized by a Reynolds number in the range 1050 ≤ R e D , avg ≤ 4800 , with the characteristic length being the outer diameter of the tube and the velocity being the bulk fluid velocity between the plates (fins). Computational fluid dynamics simulations are employed to resolve the interactions between turbulent airflow and the frost layer. Our approach incorporates a modified immersed boundary method and a slow-time acceleration technique to address the complex dynamic interface between the continuously evolving frost layer and the flowing air stream. Our findings indicate that frost forms more on the sides of the finned surfaces (plates) and less on the tubes themselves. This article is part of the theme issue ‘Heat and mass transfer in frost and ice’.
The status of research on the transient behavior of finned coil cross-flow heat exchangers using single phase fluids is reviewed. Applications with available analytical or numerical solutions are discussed. Investigation of water-to-air type cross-flow finned tube heat exchangers is examined through the use of simplified governing equations and an up-wind finite difference scheme. The degenerate case of zero air-side capacitance rate is compared with available exact solution. Generalization of the numerical model is discussed for application to multi-row multi-circuit heat exchangers.
In this article, we develop a generalized and scalable statistical model for accurate prediction of fouling resistance using commonly measured parameters of industrial heat exchangers. This prediction model is based on deep learning where a scalable algorithmic architecture learns non-linear functional relationships between a set of target and predictor variables from large number of training samples. Here, the efficacy of this modeling approach is demonstrated for predicting fouling in an analytically modeled cross-flow heat exchanger, designed for waste heat recovery from flue-gas using room temperature water. The performance results of the trained models demonstrate that the mean absolute prediction errors are under 10 –4 KW –1 for flue-gas side, water side and overall fouling resistances. The coefficients of determination (R 2 ), which characterize the goodness of fit between the predictions and observed data, are over 99%. Even under varying levels of measurement noise in the inputs, we demonstrate that predictions over an ensemble of multiple neural networks achieves better accuracy and robustness to noise. We find that the proposed deep-learning fouling prediction framework learns to follow heat exchanger flow and heat transfer physics, which we confirm using locally interpretable model agnostic explanations around randomly selected operating points. Overall, we provide a robust algorithmic framework for fouling prediction that can be generalized and scaled to various types of industrial heat exchangers.
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This work presents a first study of novel air conditioning system based on quasi isothermal dehumidification combined with dew-point evaporative cooling through the Maisotsenko cycle (M-Cycle). The dehumidification process is realized in desiccant coated heat exchanger with heat rejection system. The key idea behind the solution is to maximize the cooling effectiveness by creating favourable conditions for dehumidification and evaporative cooling process. This is achieved by rejecting the heat of sorption in the desiccant system and providing cold and dry air for M-Cycle air cooler, which allows the system to be powered by using low-grade heat energy at 50 °C. The analysis is performed on the basis of experimentally validated numerical models of each component combined in a unified model of the system. The goal of the study is to determine the performance of the solution under different operational conditions. In addition two types of M-Cycle air coolers (i.e. cross-flow and regenerative unit) are compared to establish which unit is more suitable as the source of cooling energy for the system. It was established that proposed system is able to provide comfortable room parameters (supply air temperature equal 17 °C and humidity ratio equal 0.010 kg/kg-da) for outdoor air temperatures ranging from 28 to 36 °C and outdoor air humidity ranging from 0.010 to 0.018 kg/kg-da. This means that the proposed solution is able to provide comfortable conditions in temperate and humid climates. Results also indicate that the system consisting of the regenerative M-Cycle HMX allows better cooling load management, offers higher thermal Coefficient of Performance (COP th ) and uses less water compared to the system with the cross-flow HMX. However, the system with cross-flow heat and mass exchanger (HMX) has a relatively greater electrical Coefficient of Performance (COP el ) in most cases.
The helically-coiled heat exchanger (HCSG) offers advantages over straight tubes such as compactness in geometry, increased heat transfer coefficients, and capability to absorb thermal expansion. In this study, the time-resolved velocity field data of shell-side crossflow over a five-layer helically coiled steam generator geometry was obtained using Particle Image Velocimetry (PIV) between adjacent rods in four regions with up to 5000 frames per second (5 kHz) at approximately Re u = 3600. The slant rod bundle created different flow patterns in different regions. Proper Orthogonal Decomposition (POD) revealed high-energy-mode flow structures. Due to the confined flow channel geometry, the large flow structures were not advected resulting in no strong POD mode paring. Continuous Wavelet Transform (CWT) visualized the characteristics of flow fluctuation in time and frequency domain simultaneously, which ranged in Strouhal number, S u , between 0.03 and 1.17. In the wake regions of the rods, flows changed in both pattern and magnitude over time. Once a pattern formed, it continued for relatively shorter than straight tube arrays, before changing the pattern again. The histograms of the POD time coefficients presented this multimodal flow characteristics. The current study focuses more on whole flow field analyses in the selected regions rather than local point-wise analyses. Finally, this study revealed that various Strouhal numbers can exist in the helically coiled heat exchanger geometry, which was not observed in straight tube arrays. In particular, Strouhal numbers smaller than 0.1 do not seem to be caused by vortex shedding but seem to be the result of the combination of complex geometry and possible multimodal trends. Based on the current observation, further works would involve intensive instantaneous point-wise analyses on the interactions between important locations such as separation points, stagnation points, shear layers, etc.
This paper presents a first numerical analysis of the cross-flow Maisotsenko cycle (M-Cycle) below dew-point evaporative cooler for humid climates with model including the water vapor condensation phenomenon. Proposed solution allows to cool ambient air below its dew-point temperature, by utilizing cooling energy in air extracted from the building, due to that it can be used as effective pre-cooling solution for traditional systems. Proposed unit has significant advantage over traditional counter and cross-flow units operating in heat recovery mode, hence it is almost insensitive on temperature of exhaust air. This is caused by effective pre-cooling of the exhaust air in its initial part. Operation in humid climates using cold extracted air results in condensation occurrence in the primary air channels, and hence partial dehumidification of the primary airflow (which allows to cool the air before its dew- point temperature). The Maisotsenko cycle exchanger used to recover heat in the air-conditioning system is compared with Maisotsenko exchanger that operates only on the ambient airflow and does not allow to recover heat from the exhaust airflow from a conditioned space. Achieved results showed that M-Cycle below dew-point air cooler can operate more effectively in humid climates than traditional cross-flow Maisotsenko cycle exchanger.
Flow across tube banks was investigated by surveys of total dynamic and static pressure by visualization of the flow through the use of titanium tetrachloride smoke, by thermocouple surveys of heated tubes, and by hot-wire surveys of both heated and unheated tubes. It was found that turbulence increased as the depth of the bank increased and that the broad wake behind each tube affected flow over the succeeding tubes.
Data repository for the paper: Molerus and Wirth's Heat Transfer Model for Bubbling Fluidized Beds: Proposal for an Extended Model Including Immersed Tube Banks and Particle Cross-Flow Powder Technology 2025
Improved heat exchangers according to several embodiments are provided. The heat exchangers provide improved heat transfer for air flow in wet and dry operating conditions, while minimizing pressure drop across the heat exchanger in some applications. According to one embodiment, an improved heat exchanger includes a plurality of metal foam fins between adjacent heat exchange conduits, the heat exchange conduits being arranged parallel to each other to define parallel flow paths between an inlet header and an outlet header. The metal foam fins occupy a cross-flow region between adjacent conduits, the fins having a fixed angular orientation or being rotatable in unison to vary the thermal capacitance of the heat exchanger.
The objective of this project was to design and develop a 20kW range small-scale solid oxide fuel cells (SOFC) power system for applications such as data centers and commercial buildings. The original plan included a 5,000 hours demonstration and a Techno-Economic Analysis (TEA) which were dropped as part of project termination. The original project plan was to use a stack with a cross-flow cell design which had previously been tested for 500 hours at a community college in Malta, NY. However, it was decided to move to the advanced R-SOFC co-flow cell developed under Department of Energy Award DE-FE0031971. The advanced cell design has the advantage of a larger active area for the same manufacturing footprint which results in fewer required cells for the same stack power, hence a higher volumetric power density (kW/L) and lower cost per kW than the original cross-flow cell design. A full SOFC system Simulink model was developed and calibrated with testing data from a fuel cell stack and BOP (balance of plant) components. The simulation results from the calibrated model showed an acceptable match with the experimental data. A structural analysis conducted for various load scenarios indicated no high stress areas for all spatial directions. Major electrical system components were acquired, built and successfully tested. System sensors were verified and validated against controls. Safety checks, a diagnostic check, PID tuning, and control software commissioning tasks were also conducted. The power electronics prototype was delivered and trial testing completed. Balance of Plant component testing and simulation work was conducted to characterize Reformer-Heat Exchanger heat transfer and backpressure and reformer catalyst methane conversion and product selectivity. Simulations were conducted to design the Anode and Cathode fluid passages and size the air-air and fuel-fuel heat exchangers. A Burner operation map was created from test data and the Anode Gas Recirculation blower was tested to evaluate its durability. The SOFC system used a horizontal style design where components sit directly on a casting with a direct connection to the skid. This design has efficient packaging and a small footprint with approximate dimensions of 750 mm x 700 mm x 1700 mm. An SOFC system was built and successfully tested at the Malta, NY facility The system for over 500 hours under load of which over 300 hours was at full load of 20 kW.
Membrane-based dehumidification is currently being considered as a promising solution for the building application due to its low cost and very limited energy consumption. Developing a simple and efficient open-source code simulation tool is important for boosting the optimization and evaluation of such device in HVAC community. This paper reports a first-order physics based model which accounts for the fundamental heat and mass transfer of humid-air vapor at feed side to flow stream at permeate side. The current model comprises two membrane mass transfer submodels (i.e. microstructure model and performance map model); and it adopts a segment-by-segment methodology for discretizing heat and mass transfer governing equations. The model is capable of simulating both dehumidifiers and energy recovery ventilators with parallel-flow cross-flow, and counter-flow configurations. The model was validated with the measurements at appropriate device. The practices in dehumidification and energy recovery exchangers are also discussed. The model and open-source codes are expected to become a solid fundament for developing a more comprehensive and accurate membrane-based dehumidification in the future.
The overall purpose of this project was to reduce the Reversible-Solid Oxide Fuel Cell (R-SOFC) system cost by developing two technologies, an improved cell design and the incorporation of an ejector in the fuel recycle loop instead of a blower. A Simulink model of the baseline SOFC system was developed and calibrated with experimental test data. The R-SOFC system model was built by integrating GT Suite developed models of the steam generation components into the baseline Simulink SOFC system model. The ability to run the stack in SOEC operating mode was also added to the model. The system model was used to explore the ability of the R-SOFC system to meet operational constraints on Steam/Carbon ratio and H2 concentration on the fuel side electrode. A CFD ejector model was developed and used to explore a range of ejector design parameters, leading to the final ejector design that was prototyped for testing. A prototype steam ejector was first tested in a laboratory environment using room temperature air. The steam ejector was subsequently tested using the full hot recycle loop with all relevant heat exchangers and steam generation components. The test conditions utilized temperatures, pressures, and flow rates expected in an R-SOFC application. Throughout the experimental testing work, ejector performance test data was used to improve and then validate the CFD ejector model. A CFD cell model was developed and used to optimize thermal gradients, voltage, and cost of a new cell substrate design. A CFD comparison of co-flow and cross-flow cell designs informed the decision to use a co-flow design for the new cell substrate. Multiple rounds of CFD simulation were used to improve the cell design to minimize the variation in air and fuel distribution across cell channels and to minimize the variation in air and fuel distribution across different cells in the stack. A few prototypes of the new cell substrate design were produced and validated in a laboratory environment by thermally spraying and verifying that they met established manufacturing specifications. The cell manufacturing process was adjusted in order to bring these metrics within acceptable tolerances. Cummins’ internal calculations show that the new cell design reduces cost ~50% compared to the baseline cell, while the ejector + superheater/boiler concept reduces cost of the recycle loop by ~40%. The impact of these cost reductions on the cost of producing H2 will depend on the specific system where they are applied. Therefore, a Techno-Economic Analysis was completed using system cost as a variable, and showing how the NREL Current and Future system costs translate into H2 production cost.
The paper addresses individual-radiator performance results of the prototype Space Erectable Radiator System (SERS) in both ambient and thermal vacuum environments. The radiator design utilizing a two-phase fluid loop is outlined, along with SERS design requirements, radiator panel hardware, and whiffletree clamp hardware providing a dry-contact interface of the SERS panel with the heat exchanger of the thermal bus. It is observed that throughout integrated thermal-bus tests, SERS panels managed the load demands whether interfacing with twin condensers, in parallel-flow configuration, or with shear-flow condensers, in a cross-flow configuration. It is found that the insulation losses in the integrated and stand-alone test points are approximately 2 to 6 pct. The motorized whiffletree clamp is seen as performing satisfactorily during remote operations as well as maintaining 28,800-lb force throughout the test duration without requiring further adjustments.