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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.

In this thesis. a three dimensional heat transfer model of heated airflow through the upper human respiratory tract consisting of nasal, oral, trachea, and the first two generations of bronchi is developed using computational fluid dynamics simulation software. Various studies have been carried out in the literature investigating the heat and mass transfer characteristics in the upper human respiratory tract, and the study focuses on assessing the injury taking place in the upper human respiratory tract and identifying acute tissue damage based on level of exposure. The model considered is for the simultaneous oronasal breathing during the inspiration phase with high volumetric flow rate of 90/liters minute and a surrounding air temperature of 100 degrees centigrade. The study of the heat and mass transfer, aerosol deposition and flow characteristics in the upper human respiratory tract using computational fluid mechanics simulation requires access to a two dimensional or three dimensional model for the human respiratory tract. Depicting an exact model is a complex task since it involves the prolonged use of imaging devices on the human body. Hence a three dimensional geometric representation of the human upper respiratory tract is developed consisting of nasal cavity, oral cavity, nasopharynx, pharynx, oropharynx, trachea and first two generations of the bronchi. The respiratory tract is modeled circular in cross-section and varying diameter for various portions as identified in this study. The dimensions are referenced from the literature herein. Based on the dimensions, a simplified model representing the human upper respiratory tract is generated.This model will be useful in studying the flow characteristics and could assist in treatment of injuries to the human respiratory tract as well as help optimize drug delivery mechanism and dosages. Also a methodology is proposed to measure the characteristic dimension of the human nasal and oral cavity at the inlet/outlet points which are classified as internal measurements.

Thermoelectric generators (TEGs) are currently a topic of interest in the field of energy harvesting for automobiles. In applying TEGs to the outside of the exhaust tailpipe of a vehicle, the difference in temperature between the hot exhaust gases and the automobile coolant can be used to generate a small amount of electrical power to be used in the vehicle. The amount of power is anticipated to be a few hundred watts based on the temperatures expected and the properties of the materials for the TEG. This study focuses on developing efficient heat exchanger modules for the cold side of the TEG through the analysis of experimental data. The experimental set up mimics conditions that were previously used in a computational fluid dynamics (CFD) model. This model tested several different geometries of cold side sections for the heat exchanger at standard coolant and exhaust temperatures for a typical car. The test section uses the same temperatures as the CFD model, but the geometry is a 1/5th scaled down model compared to an full-size engine and was fabricated using a metal-based rapid prototyping process. The temperatures from the CFD model are validated through thermocouple measurements, which provide the distribution of the temperatures across the TEG. All of these measurements are compared to the CFD model for trends and temperatures to ensure that the model is accurate. Two cold side geometries, a baseline geometry and an impingement geometry, are compared to determine which will produce the greater temperature gradient across the TEG. / Master of Science

Heat transfer inside rotating coolant channels have a significant impact in design of gas turbine airfoils and other rotating components such as generator windings.  The effects of the Coriolis acceleration and centrifugal buoyancy have a significant impact on heat transfer behavior inside such rotating coolant channels due to the complex flow patterns of coolant.  Detailed heat transfer knowledge greatly enhances the designers\' ability to validate numerical models of newly designed channels. A rotating experimental rig was designed and built to model scaled up coolant channels at speeds up to 750 rotations per minute (rpm).  A camera is mounted onto the rotating test section and a transient liquid crystal technique is used to measure detailed heat transfer coefficients on a surface of interest.  The experimental set-up is innovative, as it involves no surface heating of the test section, very little instrumentation beyond a few thermocouples and a spray coating of thermochromic liquid crystals on the test surface.  To validate the test rig and the experimental method, multipass coolant channels with rib turbulators, large diameter radially outward channels with rib turbulators, and jet impingement cooling schemes are studied during rotation.  90deg, W, and M-shaped rib enhancements are studied and detailed heat transfer measurements clearly capture the heat transfer enhancement mechanisms with and without rotation.  Jet impingement schemes with single and double rows, normal and off-angle jets, and a cross flow outlet condition are all studied under rotation.  Non-rotating studies are also performed for baseline comparisons to rotating conditions.  Large aspect ratio, diverging channels with dimple and rib turbulators are studied in a stationary condition.  Results for all different test geometries show good comparisons with published studies indicating that the rotating rig and experimental method are valid.  Jet impingement schemes produce higher heat transfer compared to the two-pass channels with ribs, however pressure losses are significantly higher.  The fewer the jets and H/d=1 produces the highest pressure losses with no significant gain in heat transfer.  Off angle jets at H/d=1 produces very high pressure losses with no heat transfer advantage.  A final study with radially outward coolant channels is performed with the highest rotation speeds.  The structure, test section, and camera are thoroughly designed to withstand the exceptional g-forces.  Heat transfer in the radial channels with and without rotation show very little effect of rotation due to the small rotation number. / Ph. D.

Green roofs can be an effective and appealing way to increase the energy efficiency of buildings by providing active insulation. As plants in the green roof transpire, there is a reduction in heat flux that is conducted through the green roof. The R-value, or thermal resistance, of a green roof is an effective measurement of thermal performance because it can be easily included in building energy calculations applicable to many different buildings and situations. The purpose of this study was to determine if an increase in ambient temperature would cause an increase in the R-value of green roofs. Test trays containing green roof materials were tested in a low speed wind tunnel equipped to determine the R-value of the trays. Three different plant species were tested in this study, ryegrass (Lolium perenne), sedum (Sedum hispanicum), and vinca (Vinca minor). For each test in this study the relative humidity was maintained at 45% and the soil was saturated with water. The trays were tested at four different ambient temperatures, ranging from room temperature to 120ºF. The resulting R-values for sedum ranged from 1.37 to 3.28 ft²h°F/BTU, for ryegrass the R-values ranged from 2.15 to 3.62 ft²h°F/BTU, and for vinca the R-values ranged from 3.15 to 5.19 ft²h°F/BTU. The average R-value for all the tests in this study was 3.20 ft²h°F/BTU. The results showed an increase in R-value with increasing temperature. Applying an ANOVA analysis to the data, the relationship between temperature and R-value for all three plant species was found to be statistically significant.

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This work reports on the design, fabrication and testing of a thermal switch wherein the open and closed states are actuated by shape memory alloy elements while heat is transferred by a heat-pipe. The motivation for such a switch comes from NASA's need for thermal management in advanced spaceport applications associated with future lunar and Mars missions. For example, as the temperature can approximately vary between 40 K to 400 K during lunar day/night cycles, such a switch can reject heat from a cryogen tank in to space during the night cycle while providing thermal isolation during the day cycle. By utilizing shape memory alloy elements in the thermal switch, the need for complicated sensors and active control systems are eliminated while offering superior thermal isolation in the open state. Nickel-Titanium-Iron (Ni-Ti-Fe) shape memory springs are used as the sensing and actuating elements. Iron (Fe) lowers the phase transformation temperatures to cryogenic regimes of operation while introducing an intermediate, low hysteretic, trigonal R-phase in addition to the usual cubic and monoclinic phases typically observed in binary NiTi. The R-phase to cubic phase transformation is used in this application. The methodology of shape memory spring design and fabrication from wire including shape setting is described. Heat transfer is accomplished via heat acquisition, transport and rejection in a variable length heat pipe with pentane and R-134a as working fluids. The approach used to design the shape memory elements, quantify the heat transfer at both ends of the heat pipe and the pressures and stresses associated with the actuation are outlined. Testing of the switch is accomplished in a vacuum bell jar with instrumentation feedthroughs using valves to control the flow of liquid nitrogen and heaters to simulate the temperature changes. Various iv performance parameters are measured and reported under both transient and steady-state conditions. Funding from NASA Kennedy Space Center for this work is gratefully acknowledged.

Advancement in turbine technology has far reaching effects on today's society and environment. With more than 90% of electricity and 100% of commercial air transport being produced by the usage of gas turbine, any advancement in turbine technology can have an impact on fuel used, pollutants and carbon dioxide emitted to the environment. Within the turbine engine, fully understanding film cooling is critical to reliability of a turbine engine. Film cooling is an efficient way to protect the engine surface from the extremely hot incoming gas, which is at a temperature much higher than allowable temperature of even the most advanced super alloy used in turbine. Film cooling performance is affected by many factors: geometrical factors and as well as flow conditions. In most of the film cooling literature, film effectiveness has been used as criterion to judge and/or compare between film cooling designs. Film uniformity is also a critical factor, since it determines how well the coolant spread out downstream to protect the hot-gas-path surface of a gas turbine engine. Even after consideration of all geometrical factors and flow conditions, the film effectiveness is still affected by the stator-rotor interaction, in particular by the moving wakes produced by upstream airfoils. A complete analysis of end wall film cooling inside turbine is required to fully understand the phenomena. This full analysis is almost impossible in the academic arena. Therefore, a simplified but critical experimental rig and computational fluid model were designed to capture the effect of wake on film cooling inside an annular test section. The moving wakes are created by rotating a wheel iv with 12 spokes or rods with a variable speed motor. Thus changing the motor speed will alter the wake passing frequency. This design is an advancement over most previous studies in rectangular duct, which cannot simulate wakes in an annular passage as in an engine. This rig also includes film injection that allows study of impact of moving wakes on film cooling. This wake is a simplified representation of the trailing edge created by an upstream airfoil. An annulus with 30° pitch test section is considered in this study. This experimental rig is based on an existing flat plate film cooling (BFC) rig that has been validated in the past. Measurement of velocity profiles within the moving wake downstream from the wake generator is used to validate the CFD rotating wake model. The open literature on film cooling and past experiments performed in the laboratory validated the CFD film cooling model. With these validations completed, the full CFD model predicts the wake and film cooling interaction. Nine CFD cases were considered by varying the film cooling blowing ratio and the wake Strouhal number. The results indicated that wakes highly enhance film cooling effectiveness near film cooling holes and degrades the film blanket downstream of the film injection, at the moment of wake passing. However, the time-averaged film cooling effectiveness is more or less the same with or without wake

Flow boiling heat transfer allows for the dissipation of large amounts of heat. In this work, the effect of heat flux and pressure on flow boiling of liquid refrigerant R-134a is studied in a vertical thin channel. The experimental setup mimics a refrigeration cycle and specifically looks at the effect of pressure and wall heat flux on the departure size and bubble generation rate. The experimental setup consists of a closed loop which includes a vertical narrow rectangular channel and two synchronized high speed cameras for optical measurements at either sides of the channel. The setup is built to employ an accurate measurement technique to define wall temperatures of the representative flow boiling process. Instead of using thermocouples on the surface channel, the thermochromic liquid crystallography (TLC) technique is used to determine non-invasively the heater surface temperature at high temporal and spatial resolution. The TLC interval range is 30-50°C. The TLC is attached to a Fecralloy heating section. The high speed Prosilica cameras simultaneously capture, colored TLC images as well as bubble nucleation and departure at very high frame rates. Experiments on subcooled flow boiling heat transfer have been conducted with refrigerant R-134a under a mass flux range of 484.838 kg/m2 s to 1212.1 kg/m2 s. With the low mass flux, the wall heat flux ranged from 167.2 to 672.1 kW/m2 , the inlet subcooling ranged from 0.35°C to 16.55 °C, the system pressure ranged from 621 kPa to 1034 kPa. At high mass flux, the wall heat flux ranged from 329.8 kW/m2 to 744 kW/m2 , the iv inlet subcooling from 0.16°C to 17.21 °C, and the system pressure from 621 kPa to 1034 kPa. A parametric study was done by maintaining various input parameters constant. From the high speed images, bubble parameters such as size and frequency are calculated. Temperature contours are utilized to determine the surface wall temperature at specific points. Sequential wall temperatures are traced over a short period of time to understand the cooling effects. The bubble propagation and coalescence are also visualized. Results show that bubble size and frequency increased with heat flux at any particular pressure. At higher pressure, the trend would be for the bubble size to decrease; however, the inlet subcooling and heat flux also affect bubble size. The bubble frequency is also seen to be affected by the inlet subcooling and the heat flux. Even though the inlet subcooling is maintained approximately constant, any slight decrease in subcooling increased bubble growth rate. Another trend that is observed is that at higher the heat flux, the bubble generation frequency is faster; however no specific trend is observed for wall superheat. With an increase in heat flux, the wall superheats are expected to increase; however, the localized nature of the nucleation activity sites is seen to affect the results. The variables are non-dimensionalized to note trends in parameters. In summary, the data analysis demonstrates that both heat flux and pressure significantly influence the bubble generation rate, size, propagation and coalescence.