Thesis (PhD)--Stellenbosch University, 2013. / ENGLISH ABSTRACT: The steam-side side operation of a practical air-cooled steam condenser is investigated using a combination of CFD, numerical, analytical and experimental methods. Particular attention is directed towards the vapor flow distribution in the primary condensers and dephlegmator performance. Analysis of the vapor flow in the distributing manifold, connecting the steam turbine exhaust to the air-cooled heat exchangers, highlights the importance of careful design of the guide vanes in the manifold bends and junctions. Improved guide vane design and configuration can reduce the steam-side pressure drop over the manifold and improve the vapor flow distribution, which may be beneficial to condenser operation. The vapor flow in the primary condensers is shown to exhibit a non-uniform distribution amongst the heat exchanger tubes. The vapor flow distribution is strongly linked to the distribution of tube inlet loss coefficients through the heat exchanger bundles. The non-uniform flow distribution places an additional demand on dephlegmator performance, over and above the demands of row effects in the case of multi-row primary condenser bundles. Row effects are shown to account for as much as 70 % of available dephlegmator capacity in this case. Simultaneously, inlet loss coefficient distributions can account for up to 30 % of dephlegmator capacity. In some situations then, the dephlegmator is fully utilized under ideal operating conditions and there is no margin of safety to cope with non-ideal operation of the primary condensers. The upstream regions of the primary condensers are therefore exposed to a high risk of undesirable noncondensable gas accumulation. Reduced dephlegmator capacity due to insufficient ejector performance may further compound this problem. Single-row primary condenser bundles eliminate row effects and thereby significantly reduce the demands on dephlegmator performance. The use of such bundles in the dephlegmator would also measurably reduce ejector loading. In light of the findings of this study, it is recommended that single-row bundles be considered as the primary option for future air-cooled condenser applications. A hybrid (dry/wet) dephlegmator concept is analysed and shown to be able to provide measurably enhanced dephlegmator performance when operating in wet mode, while consuming only a small amount of water. The enhanced dephlegmator cooling translates to an increase in total air-cooled condenser capacity of up to 30 % at high ambient temperatures in this case. The benefit of this enhanced cooling capacity to steam turbine output may be significant. The hybrid dephlegmator concept therefore offers a simple, cost-effective and sustainable solution to the issue of reduced air-cooled condenser performance during hot periods. Careful design of the first and second stage bundle configurations in the hybrid dephlegmator is necessary to avoid flooding in the first stage during wet operation of the second. Furthermore, the slightly poorer dry-operation performance of the hybrid dephlegmator results in increased risk of non-condensable gas accumulation in multi-row primary condensers. Again, single-row primary condenser bundles would lay rest to such concerns. / AFRIKAANSE OPSOMMING: Die bedryf aan die stoom-kant van ʼn praktiese lugverkoelde-stoomkondensor word ondersoek met behulp van 'n kombinasie van berekeningsvloeimeganika, numeriese, analitiese en eksperimentele metodes. ʼn Spesifieke fokus word geplaas op die dampvloeiverspreiding in die primêre kondensors asook die deflegmatorwerksverrigting. Ontleding van die damp vloei in die verdeelspruitstuk, wat die uitlaat van die stoomturbine aan die lugverkoelde-stoomkondensor koppel, beklemtoon die belangrikheid van noukeurige ontwerp van die leilemme in die spruitstukdraaie en aansluitings. Verbeterde leilemontwerp en opstelling kan die drukval aan die stoom-kant van die draaie en aansluitings verminder en die dampvloeiverspreiding verbeter. Dit kan gevolglik lei tot verbeterde werksverrigting van die kondensor. Die studie toon dat ʼn nie-eenvormige dampvloeiverspreiding in die warmteruilerbuise van die primêre kondensors bestaan. Die verspreiding van buisinlaat-verlieskoëffisiënte deur die bundels van die warmteruiler is sterk afhanklik van die voorgenome dampvloeiverspreiding. Die nie-eenvormige vloeiverspreiding veroorsaak 'n groter aanvraag na deflegmator-werksverrigting, bo-en-behalwe nog vereistes van ry-effekte in die geval waar multi-ry-bundels vir primêre kondensors gebruik word. Ry-effekte is verantwoordelik vir so veel as 70 % van die beskikbare deflegmator kapasiteit. Terselfdertyd kan die verspreiding van inlaat-verlieskoëffisiënte verantwoordelik wees vir tot 30 % van die deflegmator kapasiteit. In sommige gevalle is die deflegmator dus ten volle aangewend onder ideale bedryfstoestande, en bestaan daar geen band van veiligheid om nie-ideale werksverrigting van die primêre kondensor te hanteer nie. Sekere dele van die stroom-op primêre kondensors word dus blootgestel aan 'n hoë risiko vir die opbou van ongewenste nie-kondenseerbare gasse. Verder kan ‘n vermindering in deflegmator kapasiteit, weens onvoldoende werksverrigting van die vakuumpompe, dié probleem vererger. Enkel-ry-bundels vir primêre kondensors vermy ry-effekte en lei sodoende tot ʼn aansienlike vermindering in die aanvraag na deflegmator-werksverrigting. Die gebruik van sulke bundels in die deflegmator sou die vakuumpomplas ook meetbaar verminder. Uit die bevindinge van hierdie studie word dit aanbeveel dat enkel-ry bundels beskou word as die primêre opsie vir toekomstige lugverkoelde-kondensor aansoeke. ’n Konsep vir ’n hibriede-deflegmator (droog/nat) word ontleed. Die studie toon dat, deur hierdie konsep in die nat-modus te gebruik, ’n meetbare verbetering in deflegmator-werksverrigting gesien kan word, ten koste van net ʼn klein hoeveelheid waterverbruik. Die verbetering in verkoelingsvermoë van die deflegmator beteken ʼn toename van tot 30 % in die totale verkoelingsvermoë van die lugverkoelde-kondensor gedurende periodes wanneer hoë omgewingstemperature heersend is. Die voordeel van hierdie verbeterde verkoelingsvermoë op die werksuitset van die stoomturbine kan beduidend wees. Die konsep vir ’n hibriede-deflegmator bied dus 'n eenvoudige, koste-effektiewe en volhoubare oplossing vir warm atmosferiese periodes, wanneer die lugverkoelde-kondensor se verkoelingsvermoë afneem. Noukeurige ontwerp van die eerste en tweede fase bundelkonfigurasies in die hibriede-deflegmator is nodig om oorstroming in die eerste fase, tydens nat werking van die tweede fase, te verhoed. Verder veroorsaak die effens swakker werksverrigting, gedurende die bedryf van die hibriede-deflegmator in die droog-modus, ʼn verhoogde risiko vir die opbou van nie-kondenseerbare gasse in multi-ry primêre kondensors. Weereens sal enkel-ry-bundels in primêre kondensors hierdie probleem oplos.

Significant maldistribution negatively influences performance of equipment containing dense tube bundles and, moreover, it can cause a wide range of operating issues. This thesis therefore focuses on analysis of fluid flow in complete distribution systems via computational fluid dynamics (CFD). Data obtained from simulations carried out using the software ANSYS Fluent were also statistically analysed. Influence of system arrangement, tube bundle parameters and operating parameters on flow distribution non-uniformity and pressure drop was investigated. According to the results, system arrangement is the crucial differentiating parameter in terms of flow distribution as well as pressure drop. Additionally, data obtained via the classical CFD approach were compared with those yielded by a simplified CFD model for three selected distribution systems. Simplified CFD approach can - given its low computational demand - be utilised in optimization algorithms as well as in the course of the initial stage of equipment design process. Furthermore, this thesis discusses a simulation tool which is based on the simplified CFD approach. Although this tool is still being developed, the results it yields are very promising.

Flow distribution has big importance in equipment with limited tube rows because it provides correct operation and sometimes specific flow distribution for technology purposes is needed. This thesis is focusing on flow analysis in these units using computational fluid dynamics (CFD). For analysis of such systems models with varying tube rows and varying perforated segment lengths were created. Analysis showed significant impact of flow manifold layout along with tube layout and number of tubes. Simplified 1D model using static pressure regain coefficient was created which provides much shorter computational times. Comparison of 1D and CFD models was made to determine field of their usage.

Tato diplomová práce se zaměřuje na modelování proudění tekutiny v paralelních distribučních systémech, kde hraje důležitou roli rovnoměrnost distribuce tekutin. Pro tento účel je vytvořen vlastní CFD kód. Kód je napsán v programovacím jazyce Java a používá ke zlepšení výkonu knihovny třetích stran, které se vyznačují přímým přístupem ke hardwarovým a systémovým prostředkům. Kód se také vyznačuje určitými zjednodušeními, u nichž se očekává, že sníží výpočetní časy. Vliv použitých zjednodušujících opatření je vyhodnocen porovnáním výsledků simulací proudění na několika geometriích s údaji získanými z podrobných modelů CFD. Geometrie použitých svazků trubek se odlišují různými uspořádáními toku a trubek a také různým počtem trubek.

Fluid flow maldistribution plays a key role in equipment used in process and energy industries, although its evaluation is often underestimated or fully neglected. Uneven flow distribution may cause thermal or mechanical load on the tube bundle, and in extreme scenarios, it can also have an adverse effect on the process efficiency. This thesis aims to find the optimal computational tools for flow distribution prediction suitable for the initial stage of the equipment design process and to identify suitable settings of these tools for their subsequent industrial deployment. The results of simplified analytical models, detailed numerical simulations, and experimental measurements were compared for the dividing header and the U-type distribution system. It was found that the results provided by simplified mathematical models, the solution of which is also significantly less time-consuming compared to detailed CFD simulations, best correspond to the measured experimental values in all modeled configurations. For arrangements with higher lateral resistance coefficient, both computational approaches provide approximately equally accurate results. However, for arrangements with lower lateral resistance coefficient, the deviation of the results obtained by CFD calculations from the experimental data is significantly larger.

The increase in truck traffic on highways has brought many problems and challenges to transportation planning and traffic operation, including traffic congestion, transportation system deficiency (insufficient truck parking, etc.), safety, infrastructure deterioration, environmental impacts (air quality and noise), economic development, and so forth. Along with the increase in truck traffic, the need for developing a statewide truck freight demand model has grown so that a state can estimate truck traffic at any point on its highways. The most significant hurdle to including freight transportation in the transportation modeling process is that most of the demand forecasting methodologies currently available were developed for passenger trips, not freight trips. This type of modeling methodology usually makes an assumption that freight trips follow the same behavioral mechanism as passenger trips. In order to overcome the weakness of using a typical four-step demand forecasting modeling process, the concept of commodity flow models (CFMs) can be used to develop a truck freight flow model. It is widely accepted that focusing on the freights enables CFMs to capture more accurately the fundamental economic mechanisms that drive freight movements. The type of commodity being carried is one of the most important characteristics of truck movements, and it is sometimes a challenge to obtain such information from the carriers. Thus, lately, the integration of the freight flow modeling and land use modeling has emerged as an alternate tool to estimate freight movements than the previously developed models. In this study, county-level multiple regression models relating land use to commodity flow were developed using a geographical information system and statistics. Then, a statistical/mathematical statewide commodity flow distribution model was developed by using a physical friction factor (physical distance), a statistical friction factor (Euclidean distance), and economic factors (differences of population and difference of employment among the counties). The commodity flow distributed among truck traffic analysis zones (TTAZs) by the statewide commodity flow distribution model were converted to truck trips and the resulting truck trips were assigned to Utah's truck routes using the all-or-nothing assignment procedure of TransCAD and a genetic algorithm. Truck freight data from the US Census Bureau's Commodity Flow Surveys, which have become available to the public for free via the Internet, enabled the development of a commodity flow based statewide truck freight demand model. It was found that the integration of the freight flow and land use data could be a practical method for modeling tuck traffic demand on state-wide truck routes although the current level of data availability on commodity flow and land use data still constrains the full capability of this type of modeling.

New emission legislation regarding air pollution control, as instructed by the Department of Environmental Affairs (DEA) to Eskom Generation Power Stations, implies a particulate emission limit of 100 mg/Nm3 for all existing power stations by 2015 and 50 mg/Nm3 for all new and existing power stations by the year 2020. Some of Eskom’s power stations which are equipped with Electrostatic Precipitators (ESP’s) were not designed for this stringent legislation. It is also experienced that ESP’s and coal quality in Eskom have deteriorated over time, resulting in the performance of the ESP’s not meeting the legislative requirements. Eskom is in the process of introducing various ESP enhancement projects to improve performance and aligning the operating philosophy to comply with the more stringent particulate emission legislation. An ESP efficiency test was conducted at Lethabo Power Station to determine the current state of the plant and performance. The results of the test were compared with the original design base specifications to determine the relevant deficiencies which contribute to high emissions and poor ESP performance. It was aimed to develop an ESP simulation model and validate the outputs with the test data. This study endeavours to demonstrate the greater impact on ESP performance when the ESP is operated outside the design specification. It is further aimed to demonstrate that a solution to the problem of high emissions is not only contributed by the variables within the ESP itself. This study is a coal to stack evaluation considering the ESP variables and the upstream conditions of the ESP that form part of the entire process. The intention of this study is to demonstrate the importance of operating an ESP at the designed parameters and highlight the significance of proper maintenance. It was learned that before any ESP enhancement technology can be implemented, the ESP and upstream conditions must be in accordance with design specifications. The implementation of an ESP enhancement technology will have no merit or justification on a unit that is being operated outside of its design specifications. The results obtained from the ESP simulation model correlated well with the ESP efficiency test data. The expectation of the model to assist operators and engineers to operate ESP’s according to the designer’s specifications was conceded. / MIng (Mechanical Engineering), North-West University, Potchefstroom Campus, 2014

New emission legislation regarding air pollution control, as instructed by the Department of Environmental Affairs (DEA) to Eskom Generation Power Stations, implies a particulate emission limit of 100 mg/Nm3 for all existing power stations by 2015 and 50 mg/Nm3 for all new and existing power stations by the year 2020. Some of Eskom’s power stations which are equipped with Electrostatic Precipitators (ESP’s) were not designed for this stringent legislation. It is also experienced that ESP’s and coal quality in Eskom have deteriorated over time, resulting in the performance of the ESP’s not meeting the legislative requirements. Eskom is in the process of introducing various ESP enhancement projects to improve performance and aligning the operating philosophy to comply with the more stringent particulate emission legislation. An ESP efficiency test was conducted at Lethabo Power Station to determine the current state of the plant and performance. The results of the test were compared with the original design base specifications to determine the relevant deficiencies which contribute to high emissions and poor ESP performance. It was aimed to develop an ESP simulation model and validate the outputs with the test data. This study endeavours to demonstrate the greater impact on ESP performance when the ESP is operated outside the design specification. It is further aimed to demonstrate that a solution to the problem of high emissions is not only contributed by the variables within the ESP itself. This study is a coal to stack evaluation considering the ESP variables and the upstream conditions of the ESP that form part of the entire process. The intention of this study is to demonstrate the importance of operating an ESP at the designed parameters and highlight the significance of proper maintenance. It was learned that before any ESP enhancement technology can be implemented, the ESP and upstream conditions must be in accordance with design specifications. The implementation of an ESP enhancement technology will have no merit or justification on a unit that is being operated outside of its design specifications. The results obtained from the ESP simulation model correlated well with the ESP efficiency test data. The expectation of the model to assist operators and engineers to operate ESP’s according to the designer’s specifications was conceded. / MIng (Mechanical Engineering), North-West University, Potchefstroom Campus, 2014

Les échangeurs de chaleur constitués de microcanaux parallèles sont considérés une bonne solution technologique pour dissiper de grands flux de chaleur dans les composants et les systèmes miniaturisés. D’une manière générale cette réduction de taille permet une diminution des coûts des matériaux et l'utilisation de plus faible quantité de fluides frigorigènes pour les systèmes de refroidissement. Cette étude est divisée en deux parties complémentaires A et B. Elles visent à étudier le comportement thermo-hydraulique dans les échangeurs de chaleur constitués de microcanaux pour une meilleure compréhension des transferts de chaleur et des écoulements diphasiques dans les évaporateurs miniatures. Dans la partie A, nous étudions l'ébullition convective du réfrigérant R134a dans un mini échangeur composé de neuf microcanaux parallèles de section transversale circulaire, placés horizontalement, avec un diamètre interne de 0,77 mm et longueur et 150 mm. Les résultats expérimentaux montrent que la configuration d'écoulement a une forte influence sur le coefficient de transfert de chaleur, et que différents mécanismes de transfert de chaleur ont lieu dans chacune de ces configurations d'écoulement. En revanche la perte de pression est une fonction directe de la vitesse massique, du titre de vapeur et de la pression du système. La partie B, porte sur l’analyse de la distribution de l'écoulement diphasique en l’absence de transferts de chaleur et de changement de phase liquide-vapeur. A partir de ces résultats nous montrons que les effets du titre de gaz sur la répartition du liquide change considérablement selon la position de l'ensemble (tube d'alimentation, distributeur-canaux). / Heat exchangers consisting of parallel micro-channels are considered a good technological solution in response to the increasing demand for compact systems, which require high heat flux dissipation, ensuring a decrease in the material costs and the use of a lower quantity of refrigerants. The aim of this study was to investigate the thermo-hydraulic behavior inside these components provided by microchannels. This study is divided into two experimental studies (A and B) which are complementary. In part A, the convective boiling of the refrigerant R134a is analyzed within nine parallel microchannels of circular cross section, positioned horizontally, with internal diameter and length of 0.77 mm and 150 mm, respectively. The experimental results show that the flow pattern has a strong influence on the heat transfer coefficient, and that different heat transfer mechanisms are associated with each of the flow patterns observed, whereas the frictional pressure drop is a direct function of the mass velocity, vapor quality and pressure of the system. In part B, the two-phase flow distribution, using as the working fluid a mixture of air and water, is analyzed inside a circular header coupled to nine branched parallel microchannels of circular cross-section with internal diameter and length of 0.8 mm and 150 mm, respectively. The results show that the effect of the gas quality on the liquid distribution changes considerably depending on the configuration (feeder tube-header-channels).

Hlavním cílem této práce je seznámit se s požadavky specifické procesní aplikace a návrhem výměníku tepla s křížovým tokem pracovních látek a zhodnotit návrh předmětného výměníku pomocí simulačního softwaru. Nejprve jsou v práci prozkoumány provozní podmínky rekuperace odpadního tepla a obecné možnosti návrhu a jsou uvedeny základní rovnice pro tepelný a hydraulický výpočet. Hlavní část práce se zaměřuje na modulární trubkový výměník tepla s křížovým tokem pracovních látek navržený pro experimentální výzkum rekuperace tepla a zanášení ze znečištěných spalin produkovaných spalováním alternativních paliv na VUT v Brně (VUT) na Ústavu procesního inženýrství (UPI). Nejprve je stručně představena situace v testovací laboratoři. Poté je popsán postup návrhu předmětného tepelného výměníku pomocí softwaru HTRI a výsledky jsou shrnuty a porovnány s cílovými požadavky. Následně je analyzována distribuce toku vody v trubkovém prostoru uvnitř jednoho ze čtyř identických modulů výměníku tepla užitím softwaru CDF pomocí tří různých simulačních přístupů. Jsou popsány dva přístupy využívající model turbulence k--SST a jeden přístup využívající model turbulence k--Realizable turbulence. Nakonec jsou diskutovány rozdíly mezi přístupy a výsledky simulací distribuce toku.