Se ha desarrollado y construido una infraestructura experimental orientada a la validación de modelos de intercambiadores compactos de aletas y tubos y sistemas de refrigeración con sobrealimentación de líquido. El objetivo ha sido la obtención de datos experimentales fiables, con condiciones geométricas y de contorno exactamente definidas, para poder compararlos inequívocamente con resultados de simulaciones numéricas. Se presentan los modelos matemáticos, objetivo de la validación, y una descripción detallada del circuito de aire, del refrigerante líquido, y del refrigerante de cambio de fase, que integran la infraestructura.Estos tres circuitos están encargados de asegurar condiciones estables y controladas para los prototipos ensayados y para el sistema de refrigeración con sobrealimentación de líquido, en un amplio rango de temperaturas, flujos másicos y potencias. El diseño permite el ensayo de prototipos de intercambiadores de calor con diferentes geometrías y dimensiones. Se presentan detalladamente los instrumentos de medida con sus precisiones, montaje, se describen también los componentes y los parámetros de la unidad de adquisición de datos.Especial atención se ha dedicado a la calibración de los instrumentos de medida como parte esencial del proceso de preparación de los ensayos. Se describe el proceso de estimación de las incertidumbres sistemáticas de los sensores calibrados. Se expone en detalle la formulación y la metodología adoptada para el análisis de incertidumbre de los resultados experimentales.El procesamiento y el análisis de los datos experimentales se ha realizado en forma automática con un código computacional especialmente desarrollado, encargado de calcular los resultados a partir de las variablas medidas, de llevar a cabo el análisis de incertidumbres detallado, y de comparar los resultados numéricos y experimentales.Se presentan resultados experimentales obtenidos con la infraestructura experimental desarrollada. Se presentan estudios detallados de intercambiadores de calor compactos en condiciones de enfriamiento de aire, utilizando refrigerante líquido y de cambio de fase. Se presentan también resultados del estudio experimental del sistema de refrigeración con sobrealimentación de líquido. Los resultados han sido comprobados y verificados a través de balances energéticos en todos los componentes, donde la misma magnitud física ha sido evaluada de mediciones independientes. Con el objetivo de permitir el uso mas general de los resultados experimentales se presentan también los datos crudos de las variables medidas durante los ensayos.Se ha propuesto una metodología de validación para el modelo de intercambiadores compactos, basada en comparaciones sistemáticas de resultados numéricos y experimentales. Estas comparaciones han sido analizadas en términos estadísticos con el objetivo de cuantificar las diferencias observadas y dar una evaluación global de las prestaciones del modelo numérico en las condiciones ensayadas. La metodología propuesta para la validación del modelo de intercambiadores compactos puede ser utilizada como base para metodologías de validación en general. / Experimental infrastructures intended for validation of compact heat exchanger models, and models of liquid overfeed refrigeration systems have been developed and constructed. The aim has been the obtaining of reliable experimental data from tests at exactly defined geometrical and boundary conditions, permitting the unequivocal comparisons with numerical simulation results. The mathematical models are presented and detailed description of the airhandling, the liquid refrigerant, and phase-changing refrigerant circuits integrating the experimental infrastructure is given.These three circuits are encharged to provide stable controlled conditions for the tested prototypes and the liquid overfeed system in the desired range of temperatures, fluid flows, and capacities. The design permits the accommodation of heat exchanger prototypes with different geometry and sizes.Detailed overview of the measuring instruments is presented, with their accuracies and mounting, and the components and parameters of the data acquisition system are described.Special attention has been paid to the calibration of the measuring instruments as an essential part of the test preparation. The process of estimation of the systematic uncertainties in the calibrated sensors measurements is described. The formulation and the methodology adopted for the uncertainty analysis of the experimental results is exposed in detail.The experimental data processing and analysis has been performed automatically with a specially developed program encharged with the calculation of the experimental results from the measured variables, the detailed uncertainty analysis, and the numerical to experimental results comparisons.Experimental results obtained with the developed infrastructure are presented. Detailed studies of compact heat exchangers under cooling conditions, using liquid and phase-changing refrigerants, are performed and presented. Results from the experimental studies of the liquid overfeed refrigeration system are also presented. The results have been checked and verified through energy balance checks for all the components where measurements of the same physical magnitude can be contrasted with independent measurements. In order to give more general use of the obtained experimental data, the raw measured variables during the tests are also presented.An experimental validation methodology for the compact heat exchanger model has been proposed, based on systematic comparisons between numerical and experimental results. The comparisons have been analysed in statistical terms in order to quantify the observed differences and to give global evaluation of the numerical model performance in the tested conditions. The methodology proposed for validation of the heat exchanger model can be used as a basis for validation methodology for numerical models in general.

The work presents investigations into the development of a fuel-powered compact SMA actuator system. For the final SMA actuator, the K-alloy SMA strip (0.9 mm x 2.5 mm), actuated by a forced convection heat transfer mechanism, was embedded in a rectangular channel. In this channel, a rectangular piston, with a slot to accommodate the SMA strip, ran along the strip and was utilized to prevent mixing between the hot and the cold fluid in order to increase the energy density of the system. The fuel, such as propane, was utilized as main energy source in order to achieve high energy and power densities of the SMA actuator system. Numerical analysis was carried out to determine optimal channel geometry and to estimate maximum available force, strain and actuation frequency. Multi-channel combustor/heat exchanger and micro-tube heat exchanger were designed and tested to achieve high heat transfer rate and high compactness. The final SMA actuator system was composed of pumps, valves, bellows, multi-channel combustor/heat exchanger, micro-tube heat exchanger and control unit. The experimental tests of the final system resulted in 250 N force with 2 mm displacement and 1.0 Hz actuation frequency in closed-loop operation, in which the hot and the cold fluid were re-circulated by pumps.

Sasol Limited experiences extremely high particulate fouling rates inside shell-and-tube heat exchangers that utilize process cooling water. The water and foulants are obtained from various natural and process sources and have irregular fluid properties. The fouling eventually obstructs flow on the shell side of the heat exchanger to such an extent that the tube bundles have to be replaced every nine months. Sasol requested that certain aspects of this issue be addressed. To better understand the problem, the effects of various tube and baffle configurations on the sedimentation rate in a shell-and-tube heat exchanger were numerically investigated. Single-segmental, double-segmental and disc-and-doughnut baffle configurations, in combination with square and rotated triangular tube configurations, were simulated by using the CFD software package, STAR-CCM+. In total, six configurations were investigated. The solution methodology was divided into two parts. Firstly, steady-state solutions of the six configurations were used to identify the best performing model in terms of large areas with high velocity flow. The results identified both single-segmental baffle configurations to have the best performance. Secondly, transient multiphase simulations were conducted to investigate the sedimentation characteristics of the two single-segmental baffle configurations. It was established that the current state of available technology cannot adequately solve the detailed simulations in a reasonable amount of time and results could only be obtained for a time period of a few seconds. By simulating the flow fields for various geometries in steady-state conditions, many of the observations and findings of literature were verified. The single-segmental baffle configurations have higher pressure drops than double-segmental and disc-and-doughnut configurations. In similar fashion, the rotated triangular tube configuration has a higher pressure drop than the square arrangement. The single-segmental configurations have on average higher flow velocities and reduced cross-flow mass flow fractions. It was concluded from this study that the single-segmental baffle with rotated triangular tube configuration had the best steady-state performance. Some results were extracted from the transient multiphase simulations. The transient multiphase flow simulation of the single-segmental baffle configurations showed larger concentrations of stagnant sediment for the rotated triangular tube configuration versus larger concentrations of suspended/flowing sediment in the square tube configuration. This result was offset by the observation that the downstream movement of sediment was quicker for the rotated triangular tube configuration. No definitive results could be obtained, but from the available results, it can be concluded that the configuration currently implemented at Sasol is best suited to handle sedimentation. This needs to be verified in future studies by using advanced computational resources and experimental results. / Thesis (MIng (Mechanical Engineering))--North-West University, Potchefstroom Campus, 2013

Sasol Limited experiences extremely high particulate fouling rates inside shell-and-tube heat exchangers that utilize process cooling water. The water and foulants are obtained from various natural and process sources and have irregular fluid properties. The fouling eventually obstructs flow on the shell side of the heat exchanger to such an extent that the tube bundles have to be replaced every nine months. Sasol requested that certain aspects of this issue be addressed. To better understand the problem, the effects of various tube and baffle configurations on the sedimentation rate in a shell-and-tube heat exchanger were numerically investigated. Single-segmental, double-segmental and disc-and-doughnut baffle configurations, in combination with square and rotated triangular tube configurations, were simulated by using the CFD software package, STAR-CCM+. In total, six configurations were investigated. The solution methodology was divided into two parts. Firstly, steady-state solutions of the six configurations were used to identify the best performing model in terms of large areas with high velocity flow. The results identified both single-segmental baffle configurations to have the best performance. Secondly, transient multiphase simulations were conducted to investigate the sedimentation characteristics of the two single-segmental baffle configurations. It was established that the current state of available technology cannot adequately solve the detailed simulations in a reasonable amount of time and results could only be obtained for a time period of a few seconds. By simulating the flow fields for various geometries in steady-state conditions, many of the observations and findings of literature were verified. The single-segmental baffle configurations have higher pressure drops than double-segmental and disc-and-doughnut configurations. In similar fashion, the rotated triangular tube configuration has a higher pressure drop than the square arrangement. The single-segmental configurations have on average higher flow velocities and reduced cross-flow mass flow fractions. It was concluded from this study that the single-segmental baffle with rotated triangular tube configuration had the best steady-state performance. Some results were extracted from the transient multiphase simulations. The transient multiphase flow simulation of the single-segmental baffle configurations showed larger concentrations of stagnant sediment for the rotated triangular tube configuration versus larger concentrations of suspended/flowing sediment in the square tube configuration. This result was offset by the observation that the downstream movement of sediment was quicker for the rotated triangular tube configuration. No definitive results could be obtained, but from the available results, it can be concluded that the configuration currently implemented at Sasol is best suited to handle sedimentation. This needs to be verified in future studies by using advanced computational resources and experimental results. / Thesis (MIng (Mechanical Engineering))--North-West University, Potchefstroom Campus, 2013

Shell and tube heat exchangers and their use in cooling processes are the major topic of this thesis. The theoretical part of the thesis starts with the mechanisms of heat transfer and then deals with shell and tube heat exchangers. Their position, design specifications and equations for calculations are given. In the experimental part, the heat transfer on semi-operating shell and tube heat exchangers with baffles and glass or silicon carbide heat exchange surface is examined by cooling the humid air by 50% propylene glycol in tubes. For four or five coolant flows and three airflows, input and output flow temperatures including relative air humidity were measured. Differences in exchanged heat between the exchangers were negligible due to the low local air heat transfer coefficient, although silicon carbide has two orders of magnitude better thermal conductivity than glass. Much higher efficiency was performed by the carbide heat exchanger because the difference between air outlet temperature and liquid inlet temperature was one and half times higher for the glass heat exchanger. That was reflected in a decrease in mean temperature difference, which resulted in a 16 % higher experimental heat transfer coefficient compared with the glass surface. The theoretical model using the j factor, the correction factors for the baffles, and the correction for air humidity condensation have proven to be appropriate. For the glass surface, for the highest air flow rates the model gives an appropriate heat-transfer coefficient; at lower flow rates it gives slightly higher values. For the silicon carbide surface, it gives a lower heat-transfer coefficient because the model failed to consider a lower mean temperature difference. The results also evaluate the heat loss through the shell and the heat exchanged in addition by air humidity condensation.

This diploma thesis deals with the design of a feedwater heater. The aim of the work is to perform thermal, hydraulic and stress analysis. A preliminary technical documentation is also part of this work. The first part contains a summary of basic types of heat exchangers and processes of heat transfer. The main part is focused on thermal analysis to determine the main parameters of the heat exchanger. Next part is followed up by hydraulic analysis to determine the pressure drop of the heating water. After that is created design of heat exchanger with stress analysis of the proposed wall thicknesses of the shell, water chambers and tubesheet. Achieved results are summarized and evaluated at the end of the diploma thesis.

This study numerically examines the heat transfer and pressure drop performance of finned tube heat exchangers with staggered and inline tube layout for a range of tube pitch. The first part of the thesis considers the case where the heat exchanger is placed in fully ducted airflow. The simulations indicate that the performance reduced considerably for the staggered tube layout with an increase in the tube pitch, but a minimal difference for the inline tube arrangement. The effects of other geometrical parameters like fin pitch and the number of tube rows are then presented. Finally, a correlation for fin and tube heat exchangers with inline tube layout is proposed based on 280 simulations for 70 different configurations. The proposed heat transfer correlation can describe the database within ±8% discrepancy while the friction factor correlation can correlate the dataset within a ±10% discrepancy. The mean deviations for heat transfer and friction factor correlations are 4.3% and 5.4%. An important factor that influences the performance of flat plate and finned tube heat exchangers is when there is bypass flow around the heat exchanger. The next section of this thesis numerically investigates the partially ducted inline fin and tube heat exchanger with side bypass. The effects of the side clearance and the Reynolds number on the heat transfer and the pressure drop performance of the heat exchanger are presented. The simulations indicate that the heat transfer performance depreciates by more than 25% for infinite side clearance. The study then compares the pressure difference observed for entry, exit and the friction pressure drop with the various correlations available in the literature. Finally, the heat transfer and pressure drop performance for staggered and inline tube layouts are compared. / Thesis / Master of Applied Science (MASc)

This experimental study explores the heat transfer from heated bare and finned tubular surfaces to particulates in packed bed cross flow. The results from this experiment will be used to help select the type of particulates that will be used. Additionally, these results will assist in estimating heat transfer in prototype and commercial particle to fluid heat exchangers (PFHX). This research is part of larger effort in the use of particulates in concentrating solar power technology. These solid particles are heated by concentrated sunlight to very high temperatures at which they are a suitable heat source for various thermal power and thermochemical cycles. Furthermore, one of the advantages of this concept is the ability to store thermal energy in the solid particles at relatively low cost. However, an important feature of any Particle Heat Receiver (PHR) system is the PFHX, which is the interface between the solar energy system and the thermal power or chemical system. In order to create this system material data is needed for the design and optimization of this PFHX. The paper focuses on the heat transfer properties of particulates to solid surfaces under plug flow conditions. The particulates will be evaluated for three grain sizes of sand and two grain sizes of proppants. These two materials will be tested at one, five and ten millimeters per second in order to see how the various flow rates, which will be required for different loads, will affect the heat transfer coefficient. Finally the heat transfer coefficient will also be evaluated for both finned and non-finned heat exchangers to see the effect that changes in the surface geometry and surface area have on the heat transfer coefficient. The heat transfer coefficient will help determine the appropriate material that will be used in the PHR system.

Subject of this work is a development of an integrated software environment for mechanical design and check of shell and tube heat exchangers. Processes of mechanical design and checks well as software which perform these processes are broken down to basic methods and parts. Mechanical design is usually performed according to some standards. In this work, ČSN EN 13445 is used. This standard describes mostly design check calculations which can be easily algorithmized. On the contrary, design calculations are described to some extent in few simple cases and mechanical design of shell and tube heat exchanger has not been fully algorithmized yet. Subject of this work is design of software, which will be capable of automatically performing mechanical design from datasheet as an input. Based on breakdown of design and check processes, requirements for key software features are derived. Important part of presented work is design and implementation of key modules – data model of shell and tube heat exchanger, module for mechanical design check according to ČSN EN 13445. These modules form basis of the software which will be developed further in future work.

The proposed master´s thesis looks into the aspects of tubular heat exchangers modeling using available software tools. In the first – theoretical part there is a description of distribution and types of heat exchangers, including a detailed description of the industrial heat exchanger solved in this thesis. Another chapter is devoted to the main computational relations and calculation methods used in the context of thermo-hydraulic calculation. The main part of thesis consists of chapters, which are devoted to selected available software and perform calculations using the software in the specific industrial case. Finally, there is summary of the various software and a recommendation for the specific program for the need.