In this work, we study the enhanced endwall heat transfer for flow past non conducting pin fin arrays. The aim is to resolve the controversy over the heat transfer that is taking place from the endwall and the pin surface.Various parameters were studied and results were obtained. Our results are found to be consistent with some of the results that have been previously published. The results were surprisingly found to be dependent on the height of the pin fin.

<p>This research presents the results of numerical study of heat transfer and pressure drop in a heat exchanger that is designed with different shape pin fins. The heat exchanger used for this research consists of a rectangular duct fitted with different shape pin fins, and is heated from the lower plate. The pin shape and the compact heat exchanger (CHE) configuration were numerically studied to maximize the heat transfer and minimize the pressure drop across the heat exchanger. A three dimensional finite volume based numerical model using FLUENT© was used to analyze the heat transfer characteristics of various pin fin heat exchangers. The simulation applied to estimate the heat transfer coefficient and pressure drop for a wide range of Reynolds numbers with different pin fins. Circular pin configuration variations included changes in pin spacing, axial pitch and pin height ratio. Rectangular and drop-shaped pin variations also included changes in length and aspect ratio. Correlations for Nusselt number and friction factor were developed. The optimum drop shaped pin array was shown to match the heat transfer rates obtained by the optimum circular pin configuration while incurring less than one third the specific fluid friction power losses. The data and conclusions of this study can be applied to the optimization of different heat exchangers which are used in industry, especially oil cooler in power transformers which are currently working with low cooling efficiency. It can also be used in the design of electronic components, turbine blade cooling or in other high heat flux dissipation applications requiring a low-profile, high area-density based micro-heat exchanger design. This study also shows that numerical models backed with experimental analysis can reduce both the time and money required to create and evaluate engineering concepts, especially those that deal with fluid flow and heat transfer. In the following chapters, first the problems which are encountered by power transformer suppliers are described. Then pin fin technology is studied with more details as a novel solution to the oil cooling problem. Some studies on behavior of power transformer coolers are also conducted to make their problems more clear. Available experimental data in the Iran Transfo company have been used for validation of these studies. They are presented as separated papers at the end of thesis. Finally the results of pin fin studies are presented and horizontal continuous casting (HCC) is explained as a manufacturing method for pin fins production. A separate paper which is based on experimental study on HCC is also included at the end of thesis.</p> / <p>Forskningen presenterad är ett resultat av en numerisk studie av värmeöverföring och tryckfall i en värmeväxlare designad med olika former av Kylflänsar. Värmeväxlaren består av ett rektangulärt kanal utrustat med olika former av Kylflänsar och är uppvärmd underifrån. Kylflänsar forma och den kompakta värmeväxlarens utformning är studerade numeriskt för att maximera värmeöverföringen och minimera tryckfallet över värmeväxlaren.En tredimensionell finit volym baserad på en numerisk modell i FLUENT© användes för att analysera värmeöverföringsegenskaper för olika Kylflänsar konfigurationer. Genom simuleringar uppskattades värmegenomgångstalet och tryckfallet för olika Reynolds tal och Kylflänsar konfigureringar. Cirkulära Kylflänsar konfigurationer inkluderar variation av avstånd mellan Kylflänsar, och förhållandet mellan axiellt avstånd och höjd. Rektangulära och droppformade Kylflänsar inkluderade även variation för längd och aspekt förhållande. Korrelation mellan Nusselts tal och friktionsfaktor utvecklades. Optimal matris för hur droppformade Kylflänsar placerades visades överensstämma med optimal överföring för cirkulära Kylflänsar men bara med en tredjedel av friktionsförlusterna för fluiden. Data och slutsatser från studien kan användas inom för optimering av värmeväxlare använda i industrin, speciellt oljekylda högspänningstransformatorer som har låg effektivitet i kylningen. Resultaten kan även användas inom design av elektronikkomponenter, kylning av turbinblad eller andra komponenter med högt värmeflöde där låg profil, och stor ytdensitet behövs. Studien visar att kombinationen av numeriska modeller som valideras genom experiment kan reducera både tid och kostnad vid utveckling och utvärdering av ingenjörsverktyg, speciellt inom fluidmekanik och värmeöverföring. I följande kapitel beskrivs först problem som identifierats av tillverkare av högspänningstransformatorer. Kylflänsar studeras i detalj som en ny lösning till de identifierade problemen med oljekylning. Några studier har genomförts för att ytterligare belysa problemen kring högspänningstransformatorers kylning. Tillgängliga data från Iran Transfo company har använts för validering av resultat från studierna. Studierna presenteras som separata artiklar i slutet av avhandlingen. Avslutningsvis presenteras resultat från studierna av Kylflänsar och en horisontell kontinuerlig gjutprocess (HCC) för tillverkning av Kylflänsar. HCC-studien presenteras som en separat artikel inkluderad sist i avhandlingen.</p>

This research presents the results of numerical study of heat transfer and pressure drop in a heat exchanger that is designed with different shape pin fins. The heat exchanger used for this research consists of a rectangular duct fitted with different shape pin fins, and is heated from the lower plate. The pin shape and the compact heat exchanger (CHE) configuration were numerically studied to maximize the heat transfer and minimize the pressure drop across the heat exchanger. A three dimensional finite volume based numerical model using FLUENT© was used to analyze the heat transfer characteristics of various pin fin heat exchangers. The simulation applied to estimate the heat transfer coefficient and pressure drop for a wide range of Reynolds numbers with different pin fins. Circular pin configuration variations included changes in pin spacing, axial pitch and pin height ratio. Rectangular and drop-shaped pin variations also included changes in length and aspect ratio. Correlations for Nusselt number and friction factor were developed. The optimum drop shaped pin array was shown to match the heat transfer rates obtained by the optimum circular pin configuration while incurring less than one third the specific fluid friction power losses. The data and conclusions of this study can be applied to the optimization of different heat exchangers which are used in industry, especially oil cooler in power transformers which are currently working with low cooling efficiency. It can also be used in the design of electronic components, turbine blade cooling or in other high heat flux dissipation applications requiring a low-profile, high area-density based micro-heat exchanger design. This study also shows that numerical models backed with experimental analysis can reduce both the time and money required to create and evaluate engineering concepts, especially those that deal with fluid flow and heat transfer. In the following chapters, first the problems which are encountered by power transformer suppliers are described. Then pin fin technology is studied with more details as a novel solution to the oil cooling problem. Some studies on behavior of power transformer coolers are also conducted to make their problems more clear. Available experimental data in the Iran Transfo company have been used for validation of these studies. They are presented as separated papers at the end of thesis. Finally the results of pin fin studies are presented and horizontal continuous casting (HCC) is explained as a manufacturing method for pin fins production. A separate paper which is based on experimental study on HCC is also included at the end of thesis. / Forskningen presenterad är ett resultat av en numerisk studie av värmeöverföring och tryckfall i en värmeväxlare designad med olika former av Kylflänsar. Värmeväxlaren består av ett rektangulärt kanal utrustat med olika former av Kylflänsar och är uppvärmd underifrån. Kylflänsar forma och den kompakta värmeväxlarens utformning är studerade numeriskt för att maximera värmeöverföringen och minimera tryckfallet över värmeväxlaren.En tredimensionell finit volym baserad på en numerisk modell i FLUENT© användes för att analysera värmeöverföringsegenskaper för olika Kylflänsar konfigurationer. Genom simuleringar uppskattades värmegenomgångstalet och tryckfallet för olika Reynolds tal och Kylflänsar konfigureringar. Cirkulära Kylflänsar konfigurationer inkluderar variation av avstånd mellan Kylflänsar, och förhållandet mellan axiellt avstånd och höjd. Rektangulära och droppformade Kylflänsar inkluderade även variation för längd och aspekt förhållande. Korrelation mellan Nusselts tal och friktionsfaktor utvecklades. Optimal matris för hur droppformade Kylflänsar placerades visades överensstämma med optimal överföring för cirkulära Kylflänsar men bara med en tredjedel av friktionsförlusterna för fluiden. Data och slutsatser från studien kan användas inom för optimering av värmeväxlare använda i industrin, speciellt oljekylda högspänningstransformatorer som har låg effektivitet i kylningen. Resultaten kan även användas inom design av elektronikkomponenter, kylning av turbinblad eller andra komponenter med högt värmeflöde där låg profil, och stor ytdensitet behövs. Studien visar att kombinationen av numeriska modeller som valideras genom experiment kan reducera både tid och kostnad vid utveckling och utvärdering av ingenjörsverktyg, speciellt inom fluidmekanik och värmeöverföring. I följande kapitel beskrivs först problem som identifierats av tillverkare av högspänningstransformatorer. Kylflänsar studeras i detalj som en ny lösning till de identifierade problemen med oljekylning. Några studier har genomförts för att ytterligare belysa problemen kring högspänningstransformatorers kylning. Tillgängliga data från Iran Transfo company har använts för validering av resultat från studierna. Studierna presenteras som separata artiklar i slutet av avhandlingen. Avslutningsvis presenteras resultat från studierna av Kylflänsar och en horisontell kontinuerlig gjutprocess (HCC) för tillverkning av Kylflänsar. HCC-studien presenteras som en separat artikel inkluderad sist i avhandlingen.

Magnetic confinement fusion has the potential to provide a nearly inexhaustible source of energy. Current fusion energy research projects involve conceptual "Tokamak" reactors, inside of which contaminants are "diverted" along magnetic field lines onto collection surfaces called divertor plates. Approximately 15% of the reactor's thermal power is focused on the divertor plates, creating a need for an effective cooling mechanism. Current extrapolations suggest that divertor plates will need to withstand heat fluxes of more than 10 MW/m2. The cooling mechanism will need to use a coolant compatible with the blanket system; currently helium, and use a minimal fraction of the reactor's available pumping power; ie: will need to experience minimal pressure drops. A leading cooling concept is the Helium Cooled Flat Plate Divertor (HCFP). This thesis experimentally examines four variations of the HCFP. The objectives are to: 1. Experimentally determine the thermal performance of the HCFP with a hexagonal pin-fin array in the gap between the impinging jet and the cooled surface over a range of flow rates and incident heat fluxes; 2. Experimentally measure the pressure drop associated with the hexagonal pin-fin array over a range of flow conditions; 3. Determine and compare the thermal performance of and pressure drop associated with the HCFP for two different slot widths, 0.5 mm and 2 mm over a range of flow rates and incident heat fluxes; 4. Compare the performance of the HCFP with a hexagonal pin-fin array with that of the HCFP with a metal-foam insert and the original HCFP; 5. Provide an experimental data set which can be used to validate numerical models of the HCFP design and its variants. 6. Analytically determine the maximum heat flux which the HCFP can be expected to withstand at theoretical operating conditions in the original and pin-fin array configurations.

The transport of particulates within both a fully developed and developing pin fin arrays is explored using computational fluid dynamics (CFD) simulations. The simulations are carried out using the LES solver, GenIDLEST, for the fluid (carrier) phase and a Langragian approach for the particle (dispersed) phase. A grid independency study and validation case versus relevant experiments are given to lend confidence to the numerical simulations. Various Stokes numbers (0.78, 3.1 and 19.5) are explored as well as three nondimensional particle softening temperatures (θ_ST = 0, 0.37 and 0.67). The deposition is shown to increase with decreasing particle Stokes number and thus decreasing size from 0.005% for St_p = 19.5 to 13.4% for St_p = 0.78 and is almost completely concentrated on the channel walls (99.6% - 100%). The erosion potential is shown to increase with Stokes number and is highest on the pin faces. As is to be expected, the deposition increases with decreasing softening temperature from 13.4% at θ_ST = 0.67 to 79% for θ_ST =0. Overall, the channel walls of the array show the greatest potential for deposition. On the other hand, the pin faces show the greatest potential for erosion. Similarly, the higher Stokes number particles have more erosion potential while the lower Stokes number particles have a higher potential for erosion. / Master of Science

Approved for public release, distribution is unlimited / This study concentrates on the empirical characterization of a staggered pin-fin array heat exchanger placed in a modular, rectangular wind tunnel. A full analysis of the heat transfer and pressure drop behavior was conducted on various pin-fin shapes, sizes, and configurations. The study was based on airflow over a wide range of Reynolds numbers in the laminar regime. The empirical data gathered can be used to corroborate and develop better numerical models to characterize the performance of such heat exchangers as well as scale down to the micro level for comparison with micro-heat exchangers. / Lieutenant, United States Navy

One of the most important industrial processes is heat transfer, carried out by heat exchangers in single and multiphase flow applications. Despite the existence of well-developed theoretical models for different heat transfer mechanisms, the expanding need for industrial applications requiring the design and optimization of heat exchangers, has created a solid demand for experimental work and effort. This thesis concerns the use of numerical approaches to analyze and optimize heat transfer and fluid flow in power generation industry, with emphasis on pin fin technology. This research begins with a review on heat transfer characteristics in surfaces with pin fins. Different pin fins shapes with various flow boundaries were studied, and thermal and hydraulic performances were investigated. The impact of parameters such as inlet boundary conditions, pin fin shapes, and duct cross-section characteristics on both flow and heat transfer were examined. Two important applications in power generation industry were considered for this study: power transformer cooling, and condenser for CO2 capturing application in oxy-fuel power plants. Available experimental data and correlations in the literature have been used for models validation. For each case, a model based on current configuration was built and verified, and was then used for optimization and new design suggestions. All numerical modeling was performed using commercial CFD software. A basic condenser design was suggested and examined, supplemented by the use of pin fin technology to influence the condensation rate of water vapour from a CO2/H2O flue gas flow. Moreover an extensive review of numerical modeling approaches concerning this condensation issue was conducted and presented. The analysis results show that the drop-shaped pin fin configuration has heat transfer rates approximating those of the circular pin configuration, and the drop-shaped pressure losses are less than one third those of the circular. Results for the power transformer cooling system show those geometrical defects in the existing system are easily found using modeling. Also, it was found that the installation of pin fins in an internal cooling passage can have the same effect as doubling the radiator’s height, which means a more compact cooling system could be designed. Results show that a condensation model based on boundary layer theory gives a close value to experimental correlations. Considering a constant wall temperature, any increase in CO2 concentration results in lower heat transfer coefficients. This is a subsequence of increased diffusivity resistance between combustion gas and condensing boundary layer. Also it was shown that sensitivity of heat transfer rate to inlet temperatures and velocity values decreased when these parameters increased. The application of numerical methods concerning the condensation process for CO2 capturing required significant effort and running time as the complexity of multiphase flow was involved. Also data validation for the CO2/H2O condenser was challenging since this is quite a new application and less experimental data (and theoretical correlations) exist. However, it is shown that models based on numerical approaches are capable of predicting trends in the condensation process as well as the effect of the non-condensable CO2 presence in the flue gas. The resulting data, conclusions, applied methodology can be applied to the design and optimization of similar industrial heat exchangers, such as oil coolers which are currently working at low efficiency levels. It can also be used in the design of electronic components, cooling of turbine blades, or in other design applications requiring high heat flux dissipation. Finally, the finding on water vapour condensation from a binary mixture gas can be referenced for further research and development in this field.

In this study, an entropy generation minimization procedure is employed to optimize the overall performance (thermal and hydrodynamic) of isolated fin geometries and pin-fin heat sinks. This allows the combined effects of thermal resistance and pressure drop to be assessed simultaneously as the heat sink interacts with the surrounding flow field. New general expressions for the entropy generation rate are developed using mass, energy, and entropy balances over an appropriate control volume. The formulation for the dimensionless entropy generation rate is obtained in terms of fin geometry, longitudinal and transverse pitches, pin-fin aspect ratio, thermal conductivity, arrangement of pin-fins, Reynolds and Prandtl numbers. It is shown that the entropy generation rate depends on two main performance parameters, i. e. , thermal resistance and the pressure drop, which in turn depend on the average heat transfer and friction coefficients. These coefficients can be taken from fluid flow and heat transfer models. An extensive literature survey reveals that no comprehensive analytical model for any one of them exists that can be used for a wide range of Reynolds number, Prandtl number, longitudinal and transverse pitches, and thermal conductivity. This study is one of the first attempts to develop analytical models for the fluid flow and heat transfer from single pins (circular and elliptical) with and without blockage as well as pin-fin arrays (in-line and staggered). These models can be used for the entire laminar flow range, longitudinal and transverse pitches, any material (from plastic composites to copper), and any fluid having Prandtl numbers (&ge;0. 71). In developing these models, it is assumed that the flow is steady, laminar, and fully developed. Furthermore, the heat sink is fully shrouded and the thermophysical properties are taken to be temperature independent. Using an energy balance over the same control volume, the average heat transfer coefficient for the heat sink is also developed, which is a function of the heat sink material, fluid properties, fin geometry, pin-fin arrangement, and longitudinal and transverse pitches. The hydrodynamic and thermal analyses of both in-line and staggered pin-fin heat sinks are performed using parametric variation of each design variable including pin diameter, pin height, approach velocity, number of pin-fins, and thermal conductivity of the material. The present analytical results for single pins (circular and elliptical) and pin-fin-arrays are in good agreement with the existing experimental/numerical data obtained by other investigators. It is shown that the present models of heat transfer and pressure drop can be applied for a wide range of Reynolds and Prandtl numbers, longitudinal and transverse pitches, aspect ratios, and thermal conductivity. Furthermore, selected numerical simulations for a single circular cylinder and in-line pin-fin heat sink are also carried out to validate the present analytical models. Results of present numerical simulations are also found to be in good agreement.

In this study, an entropy generation minimization procedure is employed to optimize the overall performance (thermal and hydrodynamic) of isolated fin geometries and pin-fin heat sinks. This allows the combined effects of thermal resistance and pressure drop to be assessed simultaneously as the heat sink interacts with the surrounding flow field. New general expressions for the entropy generation rate are developed using mass, energy, and entropy balances over an appropriate control volume. The formulation for the dimensionless entropy generation rate is obtained in terms of fin geometry, longitudinal and transverse pitches, pin-fin aspect ratio, thermal conductivity, arrangement of pin-fins, Reynolds and Prandtl numbers. It is shown that the entropy generation rate depends on two main performance parameters, i. e. , thermal resistance and the pressure drop, which in turn depend on the average heat transfer and friction coefficients. These coefficients can be taken from fluid flow and heat transfer models. An extensive literature survey reveals that no comprehensive analytical model for any one of them exists that can be used for a wide range of Reynolds number, Prandtl number, longitudinal and transverse pitches, and thermal conductivity. This study is one of the first attempts to develop analytical models for the fluid flow and heat transfer from single pins (circular and elliptical) with and without blockage as well as pin-fin arrays (in-line and staggered). These models can be used for the entire laminar flow range, longitudinal and transverse pitches, any material (from plastic composites to copper), and any fluid having Prandtl numbers (&ge;0. 71). In developing these models, it is assumed that the flow is steady, laminar, and fully developed. Furthermore, the heat sink is fully shrouded and the thermophysical properties are taken to be temperature independent. Using an energy balance over the same control volume, the average heat transfer coefficient for the heat sink is also developed, which is a function of the heat sink material, fluid properties, fin geometry, pin-fin arrangement, and longitudinal and transverse pitches. The hydrodynamic and thermal analyses of both in-line and staggered pin-fin heat sinks are performed using parametric variation of each design variable including pin diameter, pin height, approach velocity, number of pin-fins, and thermal conductivity of the material. The present analytical results for single pins (circular and elliptical) and pin-fin-arrays are in good agreement with the existing experimental/numerical data obtained by other investigators. It is shown that the present models of heat transfer and pressure drop can be applied for a wide range of Reynolds and Prandtl numbers, longitudinal and transverse pitches, aspect ratios, and thermal conductivity. Furthermore, selected numerical simulations for a single circular cylinder and in-line pin-fin heat sink are also carried out to validate the present analytical models. Results of present numerical simulations are also found to be in good agreement.

In modern microprocessors, thermal management has become one of the main hurdles in continued performance enhancement. Cooling schemes utilizing single phase microfluidics have been investigated extensively for enhanced heat dissipation from microprocessors. However, two-phase fluidic cooling devices are becoming a promising approach, and are less understood. This study aims to examine two-phase flow and heat transfer within a pin-fin enhanced micro-gap. The pin-fin array covered an area of 1cm x 1cm and had a pin diameter, height and pitch of 150μm, 200μm and 225μm, respectively, (aspect ratio of 1.33). This study covers both uniformly and partially heated scenarios. The working fluid used was R245fa. The average heat transfer coefficient and high speed flow visualization results indicated a rapid transition to the annular flow regime with a strong dependence on heat flux. Also, unique, conically-shaped two-phase wakes were observed, demonstrating the lateral spreading capability of the pin-fin array geometry.