MODELLING COMPACT HEAT EXCHANGER SURFACE MOHD FADZIL BIN HASHIM g in fulfillment of the ‘This report submitted to Faculty of Mechanical Engineerit requirements for the award of the Bachelor of Mechanical E1 (Thermo-Fluids) Faculty of Mechanical Engineering Kolej Universiti Teknikal Kebangsaan Malaysia November, 2005ABSTRACT Compact heat exchanger surface is one equipment for heat transfer, that have a compress surface is compact heat exchanger surface. The thermal resistance at ‘compact heat exchanger depend for air flow tough the fin surface. ‘The main point of this research is to study the fin surface to increase the efficiency of fin surface for heat transfer to the air. For the purpose the experiment in the Computational Fluid Dynamic (CFD) is using to sce and know the real result. ‘This research must completed by draw fin louvered in the surface of the radiator fin on many dimension and followed by simulation CFD software to find the result.vi ABSTRAK “Compact Heat Exchanger Surface” adalah satu alat permindahan haba yang mempunyai permukaan yang telah dimampatkan didalam satu alat yang dipanggil “compact Heat Exchanger”. Pengaruh rintangan haba pada “compact Heat Exchanger” bergantung kepada aliran udara yang bersentuhan dengan permukaan sirip. Kajian kecekapan sirip untuk memindahkan haba kepada udara. Untuk tujuan ini, ujikaji bertujuan mengkaji permukaan sirip bagi menambahkan lagi perlu dilakukan dengan menggunakan “Computational Fluid Dynamic (CFD)” bagi melihat dengan lebih teliti keputusan yang diperlukan. Kajian ini perlu melukis “fin-louvered” dalam permukaan sirip radiator dalam dalam CFD software untuk mendapatkan pelbagai dimensi and buat simulasi keputusan.CHAPTER 1 INTRODUCTION In the manufacturing process, have a many type of compact heat exchanger. That is use for heat transfer from system to air for decrease or increase the temperature of the system depend on the purpose for example automotive, heating and conditioning. For the automotive system, radiator will use to decrease the temperature. In the part of radiation there is some part with have their own function. One of the part is fin where it is important part in the radiator system. The function of fin in radiator is to free the heat which was trap in the air. At the surface of the fin, there is a louvered which the function is to add some efficient for the fin to get free the heat. In this thesis, the writer should make a design and make a research on the efficiency of the louvered. To use the Computational Fluid Dynamics (CFD), to create and design the model of a heat transfer surface according to exact geometrical values. To simulate the air flow and heat transfer behavior through these surfaces. To identify the characteristic of these flow patterns.1.1 Project Title “Modeling Compact Heat Exchanger Surface”. To model heat exchanger surface and simulate air flow through these surfaces using Computational Fluid Dynamics (CED) software package. 1.2 Objective 1. Todevelop air flow and heat transfer, character or pattern in heat exchangers. 2. Use suitable Computational Fluid Dynamics (CFD) software package to model actual geometries of heat exchanger surface. 3. To compare numerical prediction with published experimental data. 13 Scope of Project Scope project is to survey of Computational Fluid Dynamics (CFD) software package viable. Use an viable available Computational Fluid Dynamics (CFD) software package to model actual geometries of heat exchanger surfaces and simulate air and heat flow over these surfaces. Compare data with existing predictions.1.4 Problem of Statement 1. To study flow or heat transfer trough surfaces. >. Determine heat exchanger performance and characteristic. 3, Accumulate automotive performance data for better design. 1.5 Problem Analysis In this project, to study flow or heat transfer trough surfaces, Computational Fluid Dynamics (CFD) software package must to use for determine heat exchanger performance and characteristic. Accumulate automotive radiator, check the surface and dimensions the surface. ‘Afier that design in the Computational Fluid Dynamics (CFD) software package and run in the predi ulation for the performance data checking, Compare result with existing ns.CHAPTER 2 LITERATURE REVIEW Understanding the mechanisms that difference heat transfer in a louvered fin heat ‘exchanger provides the potential for reducing the heat exchanger’s size and surface design. This reduction in size can clearly benefit many industries, including automotive, heating, and air conditioning. A Thole (2003) Because more than 85% of the total thermal resistance in a typical air-cooled heat exchanger occurs on the air side, the performance of compact heat exchangers depends highly on the heat transfer occurring on the air side. Compact heat exchangers are usually characterized by a large heat transfer surface per unit of volume. Louvered fins, rather than continuous fins, are commonly used in compact exchangers to break up boundary growth along the fins and increase the air side heat transfer surface area. The increase in surface area results because of the fin thickness that is exposed as a result of the louvers being stamped out of the fins. Typical geometry for a louvered fin heat exchanger used in the trucking industry as a truck radiator from A.Tole (2003).Oe eaten teeny nme NNN ves a, Louver Piton, Lp Figure 2.1 : Typical geometry for a louvered fin heat exchanger used in the trucking industry as a truck radiator from A. Tole (2003) The design compact heat exchanger geometry comprised of louvered fins, where air passes along. The studies was to understand the fundamental radiator affecting the heat transfer along the louvered surfaces in this complicated flow and thermal field. The Current study explores the local heat transfer characteristics of louvered fin arrays to determine how geometry and Reynolds numbers affect the heat transfer performance. The majority of the data currently available for compact heat exchangers focuses on the heat exchanger as an entire system. As such, these heat exchangers are characterized using the Number of Transfer Units. As previously mentioned, the current Study focuses on the local heat transfer on louver surfaces. Although most of the Published data is for heat exchanger tests using Computational Fluid Dynamics (CFD) Software package, To design of a compact heat exchanger, strategies must be proposed 0 reduce the air side resistance. However, before any strategies to augment the air side heat transfer can be proposed, a thorough insight of the current mechanisms that govern alr side heat transfer is required.Marthinuss (2002), in there research is Air Cooled Compact Heat Exchanger Design For Electronics Cooling explain the plate fins surface In the engineering study, have are many type of the fins and the function. Types of fin depend for function and the suitability. There are many factors 10 consider in the selection of fins style and ‘geometry. This approach produces a design that works, but is hardly optimized for any of the considerations involved in designing the compact heat exchanger. Figure below show five common plate fin type and the critical fin dimensions. (staign Fins {oerea Fins: wip Fins (anved Onvets Figure 2.2: Plate Fins Types from Kays & London,(1964)The heat transfer and pressure drop by picking off the j-Colbum factor and friction factor at the proper Reynolds number for a certain configuration, but it is unknown whether the proper design was chosen from a size and efficieney standpoint. ‘The first thing the thermal engineer needs to do is prioritize the design factors. Pressure drop, heat transfer, size, weight and cost must be placed in order of importance. Hence, figures of merit were developed in an effort to compare the different fin configurations. Size is generally an important factor in the heat exchanger design. If size is the overall driving design factor then a good figure of merit is heat transfer per unit height. Figure 2.3 provides a comparison if size or height is the critical factor in the heat exchanger design. From a purely standpoint, pin fin offer the smallest design for the best heat transfer while straight fins are the most inefficient from a heat transfer and smallest size constraint. 0.09, straignt Fi 0.08 J (eotburnftrletion) ° 2000 © 4000» 6000» 000 Reynolds Number Figure 2.3: Heat transfer/pressure drop FOM from Kays & London (1964)Stephan et al (2002). Approximately 85% of the total thermal resistance oceurs on the air side of the heat exchanger. The results of the experimental study showed that the hot thermal wakes formed at the entrance louver have an adverse effect on the heat transfer of downstream louvers. Measuring the adiabatic wall temperature of the louvers in the aray showed the effet of these thermal wakes. The experimental study showed that the optimal louver geometry was Reynolds number dependent, Perrotin, et al (2003) in there research is Fin efficiency calculation in enhanced fin and tube heat exchangers in dry conditions, explain for the evaluation of the finned surface performance or for the determination of the air-side heat transfer coefficient from experimental data. High efficiency heat exchangers use enhanced fin geometry (louvered and slit fins) for which the fin efficiency could be overestimated by usual formulations and more precisely equivalent circular fin and conventional 1-D sector methods. Because the slits (or louvers) alter the conduction path through the fin, the assumption of radial heat flow pattern is no more valid, and the actual fin efficiency could only be determined by numerically solving the multi-dimensional heat conduction equation. Modtech (1999) in there Wet site title is Heat Transfer say, The third and last form of heat transfer we shall consider is that of radiation, which in this context means light (visible or not). This is the means by which heat is transferred, for example, from the sun to the earth through mostly empty space-such a transfer cannot occur via convection nor conduction, which require the movement of material from one place to another or the collisions of molecules within the material.2.1 Review The Latest Research Using CED. Marthinuss et al(2002), in there research is Air Cooled Compact Heat Exchanger Design For Electronics Cooling explain the plate fins surface In the engineering study, have are many type of the fins and the funetion. Types of fin depend for function and the suitability, There are many factors to consider in the selection of fins style and geometry. This approach produces a design that works, but is hardly optimized for any of the considerations involved in designing the compact heat exchanger. ‘A. Stephan (2002). Approximately 85% of the total thermal resistance occurs on the air side of the heat exchanger. The results of the experimental study showed that the hot thermal wakes formed at the entrance louver have an adverse effect on the heat transfer of downstream louvers. Measuring the adiabatic wall temperature of the louvers in the array showed the effect of these thermal wakes. The experimental study showed that the optimal louver geometry was Reynolds number dependent. Vega et al (2002), in there research Simulation of compact heat exchangers using global regression and soft computing is explain the dissertation investigates enhancement in accuracy of heat rate predictions in compact fin-tube heat exchangers. ‘These include the idealized assumptions in the procedure by which correlations are found, the data compression that occurs through the correlation process, and the multiplicity of solutions for @ proposed correlating function obtained using local regression. In there conclusion of the steady state performance of plate fin-tube compact heat exchangers. Two types of techniques have been used. ‘The first encompasses global optimization methods that are used to find the parameters of a given functional form. ‘The second is a adaptive function itself which belongs to the soft computing methodology.10 Quadir et al (2001), in Analysis of micro channel heat exchangers using FEM. temperature, the fluid temperature and Was present method is able to predict the surfa thus the total thermal resistance of the micro channel heat sink satisfactorily. The present methodology has an added advantage in that non-uniform surface heat flux distribution over the package base can also be analyses easily. The method used in the present analysis is an alternative to massive CFD calculations.a CHAPTER 3 METODOLOGY In the research of Compact Heat Exchanger Surface, the main point is to search value heat transfer from the fin, At the surface of the fin there is a louvered where the function is to increase the efficiency of the heat transfer at fin. There is many types of fin in the compact heat exchanger depends on the functional and the purpose that the system wants. Figure below shown types of louvered. LAR an Very Ue? SALLE rN“ a — 7 COO? “YS 7 Louver Lower Louver Pitch ily) Louver Not 2-drecten is ormata pase Figure 3.1: Side View of Louvered12 ‘There are many types of method to run the research where it is depends on the collecting data. In the experiment wind tunnel can be used but the surface of louvered rust be on the big scale. Even though, there is some information that cannot be taken. For example air flow pattern cannot be taken specifically at the definite part because there is some air flow pattern cannot be shown although using gas or tint air. It most like temperature pattern where it is released by the louvered. From that way one of the computational fluid dynamic software is chosen to make this experiment success. 3.1 Chosen Method Experiment Louvered is drawn in 2D shape Definite the grid Data is set iv. Conduct the simulation v. Data is taken vi. Louvered is drawn again in 3D shape1B 32 Radiator Surface To Be Modeling tn the radiator found a lot of fins that already compile interrupt tube. ‘The fins function to disengage heat and every fin have a louvered, that purpose to heat exchanger and increase efficiency fins. In my research, | must to design the louvered and test there efficiency in the Computational Fluid Dynamic for example CFX software package. Figure 3.2: Typical louvered-fin compact heat exchanger Figure 3.3: AssemblyBee pees APSSSSSSN — iets BA ALLL EOC INSNNSSNNSSN So - “oar faaem COPECO? Gian bebe mE Figure 3.4: ide View of Louvered Louver Angle (1) 27 Fin Pitch to Louver Pitch (Fp/ls) 0.76 Fin Thickness to Louver Pitch (Vi) | 0.08 Number of Louvers. Channel depth to Louver Pitch (d/l 20 ‘Scale factor for testing Table 3: Summary of Louvered Fin Geometry 33 Fluids ca A fluid is a substance that will flow, and is usually a liquid or gas. The ‘mechanics of fluids is the application of the general principle of mechanics to liquids and gases: Conservation of matter. ii, Conservation of energy. Newton's laws of motion,15 3.4 Conservation of matter (com i. Fora fixed region Mass entering = mass leaving + mass remaining ji, For steady flow (no variation with time) Mass entering = mass leaving Within a stream tube: m= pi Ar=p2V2A2 p= density kg/m? V=velocity m/s A= Area m? m= mass flow kg/s 3.5 Conservation of energy i, For steady, incompressible (constant density), in viscid (no viscosity), flow with no heat or work transfer: OYE 7 Pt ply Bt CONSTANT P= pressure N/m2 = acceleration due to gravity m/s2 Z= elevation above datum. Mji, For viscous flow pve +P + pail + Losses “These are known as non-Newtonian fluids equation non drip paint is a pseudo — plastic fluid in which the viscosity decreases as the rate of shear increases. Where; In turbulent flow inertia forces within the fluid dominate the viscous forces, which results in random, fluctuating unsteady flow; Figure 3.6: Turbulent Flow In such a flow there is an apparent viscosity which results from the transfer of momentum jin the flow, and which is known as the turbulent or eddy viscosity. Boussin-esq proposed a relationship for the total shear stress; moa)7 CHAPTER 4 EXPECTED RESULT T. Perrotin et al (2003), The surface area, the flow conditions and the geometry of the flow passage influence the heat transfer rate and the airside heat transfer coefficient, Louvered fins are composed of several inter-rupted surfaces that interact with the boundary layer and generate complex air-flow patterns. Louvered fin design has been extensively studied experimentally and, more recently, numerically with CFD codes using finite element geometry or finite volume methods such as CFX. At higher Reynolds number, the boundary layers are thinner and the flow is almost aligned with the louvers. The intermediate Reynolds numbers at which the flow becomes lotiver-directed is still a challenging question and CFD helps to understand this phenomenon. Figure 4.1; Cut of a refrigerant-to-air heat exchanger with louvered fins and channels18 This model, 2 complete element of the actual airside condenser geometry and includes the tube and the fin with the unlouvered zone. To reduce the computational domain size, only half of the fin and half of the tube were represented and symmetry conditions were assumed on both sides of the domain, Figure 4.2: Computational domain of the 3D model CED analysis permits calculation of the actual fin efficiency corresponding to the proposed fin design, taking into account the heat transfer coefficient variations over the fin surface. Figure 4.3: Temperature distribution within the fin,19 ‘The velocity and temperature profiles at a low Reynolds number when the flow reaches steady state. Figure 4.4: Velocity magnitude distribution (left scale) This appears early outside the louver bank for a Reynolds number of around 600. ‘The instability progresses upstream in the louver bank as the Reynolds number is increased. Figure perature contours of an unstable laminar flow at Re=648.0 ‘These are characterized by waves and vortices that appear between the boundary layer of the louver and the secondary wake passing over the louver, which are two fluid streams of different velocities and densities.20 |e. ay Figure 4.6: Instantaneous temperature contours ofan unstable laminar flow at Re864.0 All these phenomena have profound effect on the heat transfer characteristics and heat transfer coefficient enhancement is observed where waves and vortices impact on the heat transfer surface Figure 4.7: Instantaneous Nusselt number for the 3 last louvers of the fin at Re=864.0CHAPTER 5 COMPUTATIONAL METHODOLOGY ‘Three-dimensional computational simulations were completed using the commercial package (CFX 5.7.1). CFX is a pressure-based, incompressible flow solver that can be used with structured or unstructured grids. CFD predictions were obtained by solving the momentum equations, energy equation, and the radiation transport equation (RTE). ‘The flow was simulated as three-dimensional or two-dimensional, laminar, and steady. To replicate the experiments, a single row of 13 stream wise louvers, including ‘one entrance louver, one reversal louver, and one exit louver, made up the computational domain. Periodic boundary conditions were used to computationally simulate the infinite stack of louvers, faa et to the computational domain was located 5 louver pitches upstream of the entrance louver while the exit was located $ louver pitches downstream of the exit louver. A constant velocity boundary condition was applied to the inlet at the matched Reynolds numbers. The exit to the fin channel was assigned an outflow boundary condition. A constant heat flux was applied to the fin (flat plate) surface. Since the effectiveness of the louvers was calculated to be small, the base of the louvers was considered to be adiabatic. To ensure a high quality mesh, several steps2 vpere taken First 2 quarilateral grid was atached along the tube wall surface, This grid attowed for higher resolution along the heat transfer surface while capturing the tube wall boundary layer. Through previous simulations, the tube wall boundary layer thickness was computed: thus, the depth of quadrilateral meshing was known. Second, the volume of the channel was meshed using an unstructured scheme with constant grid density. Grid insensitivity was obtained through a number of grid density studies. These studies included repeatability of the predictions of the heat transfer atthe tube wall. The convergence criterion used was that residuals for u,v, w, and continuity dropped by four orders of magnitude and seven orders of magnitude for energy and radiation intensity. |All computations were performed in parallel and required approximately 100 iterations to ensure convergence. 5.1 Computational Fluid Dynamic (CFD) This software that be able to study the dynamics of things that flow. Using CFD, ‘you build a computational model that represents a system or device that must to study. ‘Then you apply the fluid flow physics to this virtual prototype, and the software outputs a prediction of the fluid dynamics. CFD is a sophisticated analysis technique. It not only predicts fluid flow behavior, but also the transfer of heat, mass (such as in perspiration or dissolution), phase change (such as in freezing or boiling), chemical reaction (such as combustion), mechanical movement (such as an impeller turning), and stress or deformation of related solid structures (such as a mast bending in the wind). In my research this must be use program to crate the design two dimensions and three dimensions, fin-louvers to run the simulation to provide a standard configuration and general purpose CFD solution. Workbench launches the standard application-Pre,23 solver and Poston the advanced CFD tab within Workbench, With sub tabs used to select witch application is displayed. The overall workflow is managed through the sporkbench project page. As each step of the CFD process generates resulting file, the ser ean select the various operations that can be performed with those files to continues the process or modify the model. In my study, the total of air flow will be simulated first and later heat transfer added. This is for measure the co efficiency of @ fin-louvers in they design and characteristics. Before that, a course grid will be used first in two dimensions and later find grid inthe three dimensions will be generated. This part for make sure the operation or simulation will be run on the progress. ‘After that, other geometries (different thickness, width or louvered angles of fins. piteh/spacing) can be created and simulation will be run to make information for studying in the detail result. All the results will be compared with publish experimental data. The purpose is to know the co efficiencies the design compare the experimental data, 52 A Working Definition of CFD First, break down the words: i. Computational - having to do with mathematics, computation ii. Fluid Dynamics - the dynamics of things that flow This is CFD - a computational technology that enables you to study the dynamics of things that flow. Using CFD, you bui system or de ‘a computational mode! that represents a that you want to study. Then you apply the fluid flow physics to this24 vjrtual prototype, and the software outputs a prediction of the fluid dynamics. CFD is a sophisticated analysis technique. It not only predicts fluid flow behavior, but also the transfer of heat, mass (such as in perspiration or dissolution), phase change (such as in freezing or boiling), chemical reaction (such as combustion), mechanical movement (such as an impeller turning), and stress or deformation of related solid structures (such ‘as.a mast bending in the wind). 53 The Benefits of CFD. Basically, the compelling reasons to use CFD are these three: Insight There are many devices and systems that are very difficult to prototype. Often, CED analysis shows you parts of the system or phenomena happening within the system that would not otherwise be ible through any other means. CFD gives you a means of visual and enhanced understanding of your designs.