The present work seeks to investigate the thermal hydraulic (heat transfer and fluid dynamics) behavior of supercritical (Sc) fluids at both the fundamental and applied levels. The thermal hydraulics of these fluids is not very well known although they have been used in various applications. There are drastic changes in the thermal and hydraulic properties of fluids at supercritical conditions. There has been a lot of focus to effectively utilize these properties changes in many applications such as heat exchangers. This work focuses on studying the forced convective heat transfer of Sc-CO2 in a series of mini semi-circular horizontal tubes and a zig-zag shaped horizontal channel. The problems were investigated numerically by second-order finite volume method using a commercial software FLUENT. Three dimensional Computational Fluid Dynamics (CFD) models were developed to simulate the flow and heat transfer for three different geometries – a single semi-circular channel, a series of nine parallel semi-circular channels and a zig-zag channel. Grid and accuracy refinement studies were carried out to assess numerical errors. All the computational meshes developed for this study incorporated the first node cell within the viscous sub-layer i.e. y <1. Since the flow is turbulent, an appropriate choice of turbulence model is highly desirable. Henceforth, various turbulence models were used to study their impact on the heat transfer solution for these problems. The present numerical work focuses on improving the CFD model and methodologies in order to capture the experimental data of the heat transfer spike at the super critical conditions. Local and average heat transfer coefficients near the critical point were determined from measured wall temperatures and calculated local bulk temperatures. The numerical results are compared with the experiments. The numerical predictions do not convincingly agree with the experiments. This could be because of the incapability of turbulent models to capture the flow physics accurately due to the rapid changes in the fluid properties near critical conditions.

In the present study, the local heat transfer coefficient over the surface of the tube row of a fin-and-tube heat exchanger is to measure. The test cases including the tube row arrangement of staggered and in-line, Reynolds number range of 2000 to 9000, and transverse tube pitch of S=2.0D, 2.5D and 2.8D, are studied and discussed. Experimental models of heat exchangers are constructed according to similarity principles. Complete distribution of local heat transfer coefficients are measured over the full surface of the tube row of a fin-and-tube heat exchanger by the transient heat transfer method with thermochromic liquid crystal used as the surface thermometer. And using micro video camera assembled in the experimental system to obtain the experimental image. Software, LCIA(Liquid Crystal Image Analysis), is used to obtain the temporal history of the surface temperature used to determined the local heat transfer coefficient. The results show that the heat transfer coefficient over the surface of the fin tube row increases with the Reynolds number. And the heat transfer coefficient for staggered cases is larger than that for in-line cases. The heat transfer coefficient on the surface of the tube row with transverse tube pitch S=2.0D is similar to the case with S=2.5D, and is larger than the case with S=2.8D. Therefore, there should exist an optimum geometry of the plate fin for a fin-and tube heat exchanger.

This report discusses the use of micro-fabrication techniques for creating experimental test sections containing trees of micro-finned conducting pathways, also referred to as constructal trees, for cooling a heat generating substrate. These trees are made of copper and contain branches that bifurcate at 90° angles to form constructal patterns. The patterns for the finalized test sections were created using photolithography techniques, and copper was deposited via thermal evaporation onto a 1 cm² substrate to create the trees. Certain test section design parameters were varied including the geometric complexity of the constructal trees, the volume of copper used between tree complexities, choice of material for the substrate, and the height, or thickness, of the trees. Also described in this report is an experimental methodology and testing apparatus designed to assess the cooling performance of the test sections. This methodology includes using controlled uniform heating applied to the bottom of each test section, while cooled nitrogen is impinged on the tip of the constructal tree to create a heat sink. / text

Accurate values of thermophysical transport properties of particle beds are necessary to accurately model heat and mass transfer processes in particle beds that under-go preferred processes and changes. The objective of this study is to use a proven analytical/numerical methodology to estimate the unknown transport properties within test cells filled with silicagel particles and compare the results with the previously published data. An experimental test cell was designed and constructed to carry out transient heat transfer tests for both step change conduction and convection heat transfer within a packed bed of silicagel particles. For a known step change in the test cell temperature boundary condition, the temporal temperature distribution within the bed during heat conduction depends only on the effective heat conduction coefficient and the thermal capacity of the particle bed. The central problem is to, using only the boundary conditions and a few time-varying temperature sensors in the test cell of particles, determine the effective thermal conductivity of the test bed and specify the resulting measurement uncertainty. A similar problem occurs when the heat convection coefficient is sought after a step change in the airflow inlet temperature for the test cell. These types of problems are known as inverse heat transfer problems (IHTP). In this thesis, IHTP method was used to estimate the convective heat transfer coefficient. Good agreement was seen in experimental and numerical temperature profiles, which were modeled by using the estimated convective heat transfer coefficient. The same methodology was used to estimate the effective thermal conductivity of the particle bed. Comparison between the experimental temperature distribution and numerical temperature distribution, which was modeled by using the estimated effective conductivity, illustrated good agreement. On the other side, applying the effective thermal conductivity, obtained from a direct steady state measurement, in the numerical simulation could not present agreement between the numerical and experimental results. It was concluded that the IHTP methodology was a successful approach to find the thermophysical properties of the particle beds, which were hard to measure directly.

The development of a sustainable manufacturing process requires a comprehensive evaluation method and fundamental understanding of the processes. Coolant application is a critical sustainability concern in the widely used machining process. Cryogenic machining is considered a candidate for sustainable coolant application. However, the lack of comprehensive evaluation methods leaves significant uncertainties about the overall sustainability performance of cryogenic machining. Also, the lack of practical application guidelines based on scientific understanding of the heat transfer mechanism in cryogenic machining limits the process optimization from achieving the most sustainable performance. In this dissertation, based on a proposed Process Sustainability Index (ProcSI) methodology, the sustainability performance of the cryogenic machining process is optimized with application guidelines established by scientific modeling of the heat transfer mechanism in the process. Based on the experimental results, the process optimization is carried out with Genetic Algorithm (GA). The metrics-based ProcSI method considers all three major aspects of sustainable manufacturing, namely economy, environment and society, based on the 6R concept and the total life-cycle aspect. There are sixty five metrics, categorized into six major clusters. Data for all relavant metrics are collected, normalized, weighted, and then aggregated to form the ProcSI score, as an overall judgment for the sustainability performance of the process. The ProcSI method focuses on the process design as a manufacturer’s aspect, hoping to improve the sustainability performance of the manufactured products and the manufacturing system. A heat transfer analysis of cryogenic machining for a flank-side liquid nitrogen jet delivery is carried out. This is performed by micro-scale high-speed temperature measurement experiments. The experimental results are processed with an innovative inverse heat transfer solution method to calculate the surface heat transfer coefficient at various locations throughout a wide temperature range. Based on the results, the application guidelines, including suggestions of a minimal, but sufficient, coolant flow rate are established. Cryogenic machining experiments are carried out, and ProcSI evaluation is applied to the experimental scenario. Based on the ProcSI evaluation, the optimization process implemented with GA provides optimal machining process parameters for minimum manufacturing cost, minimal energy consumption, or the best sustainability performance.

Taking into account the expected increase in global energy demands and increasing climate change issues, there is a pressing need to develop new environmentally sustainable energy systems. Nuclear energy will play a major role in being part of the energy mix since it offers a relatively clean, safe and reliable source of electrical energy. However, opportunities for building new generation nuclear systems will depend on their economic and safety attractiveness as well as their flexibility in design to adapt in different countries and situations. Keeping these objectives in mind, a framework for international cooperation was set forth in a charter of Generation IV International Forum (GIF) (GIF Charter, 2002) and six design concepts were selected for further development. To achieve high thermal efficiencies of up to 45 ??? 50%, the use of SuperCritical Fluids (SCFs) as working fluids in heat transfer cycles is proposed Generation IV designs. An important aspect towards development of SCF applications in novel Gen IV Nuclear Power Plant (NPP) designs is to understand the thermodynamic behavior and prediction of Heat Transfer Coefficients (HTCs) at supercritical (SC) conditions. In addition to the nuclear power industry applications; SCFs are also expected to play a vital role in a number of other important technologies such as refrigeration systems, and geothermal systems, to name a few. Given the potential for vast number of applications of SCFs in industry, the objective of this work was to gain an understanding on the behavior of SCFs and to develop a fundamental knowledge of the heat-transfer processes and correlations for SC Water and SC CO2 flowing in bare circular tubes. Experimental datasets for SC Water and SC CO2 were compiled and used to obtain a basic 1-D empirical correlation that can predict HTC in bare circular tubes during the transient phases. The accuracy of these correlations was also analyzed using statistical techniques. Limitations and applications for 1-D correlations are discussed as well. The new correlations showed promising results for HTC and Tw calculations for the reference dataset with uncertainty of about ??25% for HTC values and about ??10-15% for the calculated wall temperature.

The aim of this research is to increase the current density of electrical machines by improving the heat transfer from the stator. Hence, this research investigates key heat transfer parameters that limit convective and conductive heat transfer. The current density is interdependent on temperature and parameters governing heat transfer. Therefore, thermal analysis of electrical machines is important to design high current density electrical machines. This research starts by investigating the role air-cooled axial flux machines in the context of electric transportation. These are found to suffer from thermal limitations, forcing the propulsive power to be distributed among several wheels. The machine topology is found to play an important role in the heat transfer limits. The internal rotor topology suffers from heat transfer limits from the casing while the internal stator topology suffers from heat transfer in the rotor-stator gap. Addressing the latter is more challenging. This research does this by investigating a novel evaporative cooling mechanism to transport heat from the machine's internal stator to the outer rotor. A proof of concept was experimentally established and the challenges for adopting this mechanism to an electrical machine are investigated. The research focus is turned to direct oil-cooled machines. These do not suffer from the same thermal limits as they use an external radiator to expel heat. However, direct liquid cooled machines suffer from a non-uniform flow distribution, which affects the stator temperature distribution. To investigate this problem, an efficient thermo-fluid model was developed to predict the flow and temperature distribution in an oil-cooled stator. This was compared to CFD models and validated to within 6% of experimental results. The stator temperature distribution is improved by carefully controlling the flow distribution. The hot spot temperature is reduced by 13 K, doubling the insulation lifetime, or for the same hot spot temperature increasing the current density by 7%. The heat transfer coefficient an oil-cooled machine was measured by adapting the double layer thin film heat flux gauge technique. Correlations for the heat transfer coefficient on the pole piece surfaces are established and compared with analytical and CFD predictions. Finally the focus is turned to conductive heat transfer in concentrated windings. These are shown to suffer from a severe temperature gradient. Heat is transferred from one winding layer to the next and a hotspot is formed on the layer with the longest thermal path. The hotspot limits the current density of the machine. A lumped parameter thermal model was developed to predict the value and location of the hotspot in concentrated windings. To shorten the thermal path of the windings, a heat sink was interleaved between the windings. The new construction offers a reduction in hotspot temperature by up to 70 K. For the same maximum temperature the current density is increased by 30%. This thesis revisits flat windings and addresses their manufacturing challenges. Lastly, the relevance of thermal contact resistances is broadened to the general thermal design of electrical machines. This research shows that modeling the thermal resistance at the interface of concentric geometry by a constant parameter is an oversimplification. This was experimentally demonstrates to change with heat flux, contact pressure and material properties.

High combustion temperatures are required in gas-turbine engines to achieve high cycle efficiencies. With increasing temperature, however, the life span of the turbine components are reduced. The ability to accurately predict engine component temperature as a function of combustion temperature is required to strike this balance correctly. An experimental heat transfer measurement technique is developed in this thesis, which builds on a large body of existing literature. The technique enables a detailed quantification of turbine heat transfer on test rigs which closely represent gas-turbine engine configurations. Fundamental improvements are made to existing methods, in the definition of the ‘semi- infinite limit’ for transient measurement techniques, in Infra-red camera calibration, and in thermal effusivity measurement. The improvements were developed from first principles, verified experimentally, and have been used on a world leading heat transfer rig (the FACTOR combustor-turbine interaction rig, run on the NG-Turb facility at DLR Göttingen). It was found that optimisation of a number of measurement parameters was required to minimise the measurement uncertainty. It is shown that the optimum measurement parameters are dependant, and sensitive to the specific configuration of the test rig. An experimental procedure was developed and tested, which has been ‘tuned’ for measurements on the FACTOR test rig. Despite the challenging measurement environment on the FACTOR rig, it was found that state-of-the-art heat transfer measurement uncertainties of approximately 5%, could nevertheless still be achieved, by using the new methods. General principles and rules are established which can be used to guide the design of future heat transfer measurements, with the aim of minimising measurement uncertainty.

The effect of surface modification and high intensity electric field (uniform and non – uniform) acting separately or in combination on pool boiling of R-123 is presented in this thesis. The effect of surface modification was investigated on saturated pool boiling of R-123 for five horizontal copper surfaces modified by different treatments, namely: an emery polished surface, a fine sandblasted surface, a rough sandblasted surface, an electron beam (EB) enhanced surface and a sintered surface. Each 40 mm diameter heating surface formed the upper face of an oxygen-free copper block, electrically heated by embedded cartridge heaters. The experiments were performed from the convective heat transfer regime to the critical heat flux, with both increasing and decreasing heat flux, at 1.01 bar, and additionally at 2 bar and 4 bar for the emery polished surface. Significant enhancement of heat transfer with increasing surface modification was demonstrated, particularly for the EB enhanced and sintered surfaces. The emery polished and sandblasted surface results are compared with nucleate boiling correlations and other published data. The effect of uniform and non-uniform electric fields on saturated pool boiling of R-123 at 1.01 bar pressure was also examined. This method of heat transfer enhancement is known as electrohydrodynamic abbreviated as EHD-enhancement. A high voltage potential was applied at the electrode located above the heating surface, which was earthed. The voltage was varied from 0 to 30 kV. The uniform electric field was provided through a 40 mm diameter circular electrode of stainless steel 304 wire mesh having an aperture of 5.1 mm, while the non-uniform electric field was obtained by using a 40 mm diameter circular rod electrode with rods 5 and 8 mm apart. The effect of uniform electric field was investigated using all five modified surfaces, i.e. emery polished, fine sandblasted, rough sandblasted, EB enhanced and sintered surfaces, while non – uniform electric field was tested using the emery polished, fine sandblasted, EB enhanced and sintered surfaces. The effect of pressure on EHD enhancement was also examined using emery polished surface at saturation pressure of 2 and 4 bars while the electric field was fix at 20 kV corresponding to 2 MV/m. Further, the bubble dynamics is presented for the emery polished surface obtained using a high-speed high – resolution camera.

There is interest concerning the energy performance of buildings in the United States. Buildings, whether residential, commercial or institutional, generally underperform in terms of energy efficiency when compared to buildings that are constructed following sustainably and energy efficiency standards. A substantial percentage of energy loss in these buildings is associated with the thermal efficiency of its envelope (exterior walls, windows roof, floors and doors). The objective of this study will evaluate the results of three energy modeling techniques developed to investigate the energy transfer through the envelope of existing campus buildings. The techniques employed are solving the heat transfer calculations using spreadsheets, using a stand-alone modeling software (OpenStudio) and using an integrated building energy modeling software (eQuest) employed in Autodesk Revit. The first technique is somewhat different from the other two because it does not require a 3D representation of the building to be generated as the first step in the modeling process. It is the application of a mathematical methodology employing heat transfer algorithms entered into the spreadsheet’s cells to estimate the heat transfer through the building envelope. Data needed for this technique are weather data of the buildings location, surface area of the building envelope, and the overall heat transfer coefficient (U-value) of each component of the building envelope. The OpenStudio technique involves a 3D representation of the building. The building is drawn on a 3D modeling computer program called SketchupPro, which communicates directly to the OpenStudio energy modelling interface. The building operations as well as the building characteristics, such as the composition and type of the elements that made up the building envelop, the thermal zone, occupancy schedule and the space type was inputted in the OpenStudio engine. The OpenStudio engine runs the simulation and generates a detail result about the energy usage and energy transfer in the building. The third method that employs AutoCAD Revit software is a standalone technique that does not require an external software for sketching the building model. Revit the ability to draw the model as well as perform the energy analysis at the same time with the aid of inbuilt eQuest modeling engine. The model in Revit is generated with the right building envelope characteristics as the existing building and the weather file. The process is somewhat similar to the OpenStudio technique; the main difference is the level of detail and limitation provided by both the energy modeling engine (eQuest and EnergyPlus). At the end of the simulation, the building energy modeling using Autodesk Revit presents a detailed result of the energy usage and energy flow in the building. The underlying reason of the comparison of three techniques is to understand the simplest, most efficient, accurate method to quantify heat transfer through the building envelope. By the end of this study, the most efficient technique for investigating the building envelope will be expected to be the EnergyPlus technique because of the usage simplicity, ability to take in a lot of details required for simulation and the periodical software updates.