With increasing global energy consumption, stringent environmental protection legislation and safety regulations in industrialised nations, energy saving has been put under high priority. One of the most efficient ways of energy reduction is through heat transfer enhancement for additional heat recovery. Applying compact heat exchanger is one of the main strategies of heat transfer enhancement. However, the application of compact heat exchangers is prohibited by the lack of design methodology. Therefore, the aim of this research is to tackle the problem of developing optimisation methodologies of plate/plate-fin heat exchanger design. A mathematical model of plate-fin heat exchanger design is proposed to consider fin type selection with detailed geometry and imposed constraints simultaneously. The concept of mix-and-match fin type combinations is put forward to include all possible fin type combinations in a heat exchanger. The mixed integer nonlinear programming (MINLP) model can be converted to a nonlinear programming (NLP) model by employing continuous heat transfer and pressure drop correlations and considering the basic fin geometric parameters as continuous variables. The whole optimisation is based on volumetric minimisation or capital cost minimisation and completed by CONOPT solver in GAMS. Case studies are carried out to demonstrate the effectiveness and benefits of the new proposed methodology. For plate heat exchangers, the design methodology is developed on the basis of plate-fin heat exchanger methodology, and takes phase change, plate pattern selection, flow arrangement and pressure drop constraints simultaneously. The phase change problem is tackled by dividing the whole process into several subsections and considering constant physical properties in each subsection. The performances of various flow arrangements are evaluated by correction factors of logarithmic mean temperature difference. For two-phase conditions, the heat transfer and pressure drop performance are predicted by continuous two-phase Nusselt number and Fanning friction factor correlations to avoid the MINLP problem. The optimisation is solved by CONOPT solver as well. The feasibility and accuracy of the new proposed methodology is examined by case studies.

Diploma thesis titled Regeneration of heat and water for paper drying process analyzes use of waste hot air ventilated from drying section of paper mill. Moreover is described detailed design process of recuperation heat exchanger, which should be part of regeneration loop of paper mill. Designed heat exchanger is plate-fin crossflow heat exchanger. For deasign is used – NTU method.

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Ce mémoire de thèse traite de l’analyse, l’intensification et l’optimisation du transfert thermique convectif dans les échangeurs à plaques et ailettes à pas décalés utilisés notamment dans le domaine automobile comme refroidisseurs d’air de suralimentation. Deux approches complémentaires sont abordées dans cette étude : des simulations numériques visant à l’analyse fine locale des caractéristiques de l’écoulement et des mécanismes de transfert, et une modélisation de type nodale permettant une caractérisation globale des performances thermo-aérauliques. Sur la gamme de Reynolds considérée différentes modélisations de la turbulence sont mises en œuvre et comparées. Ainsi des simulations aux grandes échelles (LES) permettent de qualifier des simulations de type RANS classiquement utilisées jusque-là : de fortes différences tant au niveau structuration de l’écoulement qu’au niveau performances globales sont ainsi mises en évidence selon le régime d’écoulement considéré. La mise au point d’un modèle nodal est ensuite abordée dans le but de mener des optimisations de géométries d’échangeurs non-conventionnels à pas décalés. Les différents scénarii d’optimisation considérés montrent l’intérêt de cette approche autorisant l’évaluation d’un nombre élevé de configurations géométriques. Dans une dernière partie une nouvelle géométrie innovante permettant de générer des tourbillons longitudinaux sur ce type d’ailettes est proposée et étudiée. / This thesis deals with the analysis, intensification and optimization of convective heat transfer in offset strip fins (OSF) heat exchangers used, for example, in the automotive field as water-cooled charge air coolers. Two complementary approaches are carried out in this study: CFD simulations to perform local fine analysis of the flow characteristics and transfer mechanisms, and a nodal type modeling allowing calculation of global aerothermal performance. Over the range of Reynolds numbers considered, different turbulence modeling approaches are implemented and compared: Large Eddy Simulations (LES) and RANS simulations which are usually used. The qualification of the RANS models shows that strong differences, both in the flow structure and at the overall performance evaluation level, may beobserved, depending on the flow regime considered. Then the development of a nodal model is presented. It aims at carrying out rapid optimization of geometries of unconventional OSF heat exchangers. The various optimization scenarios considered show the interest of this approach allowing the evaluation of a large number of geometric configurations. In a last part, an innovative new geometry that generates longitudinal vortices on this type of fins is proposed and studied.

Le contexte industriel est favorable aux échangeurs-réacteurs catalytiques intensifiés puisqu’ils permettent une diminution des limitations aux transferts de matière et de chaleur comparé aux réacteurs conventionnels. Toutefois, l'industrialisation de ces unités est problématique à cause de l'absence de logiciel d’ingénierie de prédiction et d’optimisation de leurs performances. Afin de construire un tel outil, les écoulements, les transferts de matière interne et externe liés aux réactions catalytiques hétérogènes, les transferts de chaleur convectif, conductif, diffusif et par rayonnement sont d’abord analysés, permettant de formuler des hypothèses simplificatrices. Les phénomènes pertinents identifiés sont ensuite mis en équations pour créer la base physique de ProSec Réaction, le nouveau logiciel de simulation des échangeurs-réacteurs. Ce logiciel est validé par comparaison avec les résultats expérimentaux du pilote de vaporeformage du méthane d'Air Liquide et par confrontation avec des simulations tri-dimensionnelles de celui-ci (CFD). L'excellente adéquation entre les résultats expérimentaux et numériques démontre le potentiel de prédiction du modèle mono-dimensionnel développé. Dans le cas particulier des échangeurs-réacteurs à plaques et ailettes catalytiques (wash-coat), une représentation bi-dimensionnelle discrète est construite et permet de tenir compte des effets thermiques radiaux intrinsèques à ces échangeurs particuliers. Enfin, ProSec Réaction est exploité pour évaluer les perspectives d'optimisation géométrique des canaux de l'échangeur-réacteur du pilote d'Air Liquide. Celles-ci montrent la flexibilité et l'intérêt de ce nouvel outil de simulation / Intensified heat exchanger reactors are promising technologies in the current industrial context because of their high potential to significantly reduce heat and mass transfer limitations compared to conventional reactors. However, the absence of simulation software for predicting their performances and optimising their geometry inside a flowsheet is limiting the industrialisation of these units. Preliminary to the development of such a simulation tool, flow characteristics, internal and external mass transfers inherent to heterogeneous catalytic reactions, convective, conductive, diffusive and radiative heat transfers are analysed, allowing the definition of simplifying assumptions. The identified relevant phenomena are then modelled and constitute the physical base of ProSec Reaction, the new heat exchanger-reactor simulation software. This software is validated by comparing the predicted values to the Air Liquide steam reforming pilot plant results and to three-dimensional simulation results as well (CFD). The excellent consistency between numerical and experimental results demonstrates the accuracy and the predictive potential of the developed one-dimensional model. In the specific case of wall-coated plate-fin heat exchanger reactors, a discrete two-dimensional model is built and allows the representation of radial temperature gradients in the material, which are intrinsic to these specific heat exchangers. Finally, optimisation perspectives of the Air Liquide pilot plant heat exchanger reactor channel geometry are evaluated thanks to ProSec Reaction. They demonstrate the flexibility and the benefits of this new simulation tool