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Proceedings of the ASME 2010 10th Biennial Conference on Engineering Systems Design and Analysis

ESDA2010
July 12-14, 2010, Istanbul, Turkey
Proceedings of the ASME 2010 10th Biennial Conference on Engineering Systems Design and Analysis
ESDA2010
July 12-14, 2010, Istanbul, Turkey

ESDA2010-
ESDA2010-24362

IMPINGING JET COOLING OPTIMIZATION FOR OBTAINING UNIFORM HEAT FLUX

Farshad Kowsary Hamed Gholamian


Professor, Faculty of Mechanical Engineering, M.S. Student, Faculty of Mechanical Engineering,
University of Tehran, University of Tehran,
Tehran, Iran Tehran, Iran

Mehran Rajaeeian Hoonejani


Ph.D. Student, Department of Mechanical Engineering,
University of California, Santa Barbara
Santa Barbara, CA

ABSTRACT H i* separation distance between the exit plane of the jets


In this study obtaining a uniform heat flux over a target and the design plate
surface was investigated by means of using characteristics of k Thermal conductivity of the air
jet impingement heat transfer. Conjugate Gradients Method L1 Design surface length
(CGM) was utilized to minimize the objective function defined Non-dimensional design surface length
on the basis of the squared differences between the target heat L*1
flux and the calculated ones. Design variables were taken to be L2 Isothermal bottom wall length
jets’ Reynolds numbers, separation distance between the exit Non-dimensional Isothermal bottom wall length
L*2
plane of the jets and the target plate, as well as inter-jet
spacing. Air single phase jets were used in this study. The N Number of nodes on design surface
problem was solved for the cases of 4 and 6 jets. Temperature Nu Design surface Nusselt number
difference between the jet exit and the target plate is 100ºC, and p Local pressure
a steady state condition was assumed. The Finite Volume p∞ Operating pressure (kPa)
Method and an unstructured mesh were used for direct solution
P* Non-dimensional local pressure
of the jet impingement heat transfer problem for a laminar jets
Pr Prandtl number
impingement to a flat plate with constant temperature.
qd Desired heat flux on the design surface
r
NOMENCLATURE qc Calculated surface heat flux vector
r
D Design variables vector qcn Calculated surface heat flux on i’th node
Dh Hydraulic Diameter Re Reynolds number
erms The root mean square of relative error of estimated T Static temperature
heat flux TW Static Temperature of bottom wall
f Objective function u,v Velocity component in x and y directions
G Inter jet spacing U * ,V * Non-dimensional velocity component in x and y
G * Non-dimensional inter jet spacing directions
Convective heat transfer coefficient V0 Characteristic velocity
h
H The upper wall height W The jet width
* Non-dimensional upper wall height x, y Horizontal and vertical coordinate
H
Hi separation distance between the exit plane of the jets X * , Y * Non-dimensional horizontal and vertical coordinates
and the design plate

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heated metallic foils is investigated in 1986 by C.K. Carlson
Greek symbols and E.M. Sparrow [7].
α Thermal diffusivity of the fluid Some studies were performed to achieve the uniform heat
µ Viscosity flux in the case of convective heat transfer. W. Roetzel and M.
ν Kinematic Viscosity Newman [8] performed an investigation in which a uniform
θ *
Non-dimensional temperature heat flux among the surface of the drum in a paper dryer is
desirable. To obtain this goal, a specific wall profile was
ρ Density developed. On the other hand, S. Chander and A. Ray [9]
experimentally studied characteristics of three interacting
Subscripts methane/air flame jets arranged in a triangular configuration
d Relative to the desired condition impinging normally on a flat surface to obtain uniform heat
i Relative to the number of the jet flux. N. Radifi and W. Blasiak [10] experimentally investigated
j Relative to the jets the various modes of heat transfer and the effect of the HiTAC
n Relative to the number of the node on design surface flame characteristics on heat transfer intensity and uniformity
inside a semi-industrial test furnace using various industrial
regenerative burners and various flame configurations namely;
INTRODUCTION single-flame, twin-flame counter, twin-flame parallel and twin-
One of the main objectives in industrial heating or cooling flame stagger.
processes is achieving a spatially uniform heat flux over the As mentioned most of the previous researches on achieving
cooled or the heated surface. Temperature Uniformity Control heat flux uniformity have utilized the radiation heat transfer
(TUC) as well as Heat Flux Uniformity Control (HFUC) has mode. In the present work for the first time by using a classical
received considerable attention in recent years. Inverse heat optimization technique the optimal arrangement of jets are
transfer techniques provide an efficient procedure to design determined in order to achieve heat flux uniformity over a
configuration which lead to achieving such goals. design surface. Using jet impingement techniques one can
In the most investigations the heat transfer mode used to attain potentially high heat fluxes for both heating as well as
obtain uniform temperature or heat flux distribution, is cooling. As this is a preliminary study of the sort, laminar jets
radiation. S. M. Hoseini Sarvari and S. H. Mansouri [1] studied are taken into consideration for simplicity; even though low
the Inverse design of a two-dimensional heat source speed (i.e., laminar) jets by themselves are potentially useful in
distribution, having the desired temperature and heat flux applications where there is limitation on the pressure exerted by
profiles for a design surface of an irregular enclosure with jets upon the design surface.
participating media. The other approach to these types of
problems is the shape design problems. K.J. Daun, D.P.
Morton, J.R. Howell [2] presented an optimization
methodology for designing radiant enclosures containing DESIGN SURFACE AND JETS GEOMETRY
specularly-reflecting surfaces. The optimization process works The schematic of two-dimensional impinging jets and
by making intelligent perturbations to the enclosure geometry design surface for both cases of 4 and 6 jets and the symmetry
at each design iteration using specialized numerical algorithms. line are shown in Fig. 1. In these configurations, design surface
P.J. Timans [3] Studied the evolution of RTP (Rapid Thermal with the length of L1 and bottom surface with the length of L2
Processing) system design to include concepts such as wafer are kept at a constant temperature of Th. The locations of jet
rotation, axisymmetric heater design and multiple point outlets are shown. The left vertical wall is symmetry line and
dynamic temperature control. The problem with use of radiative the right vertical wall is outlet. Jets vertical walls and the
heat transfer for achieving heat flux uniformity is the fact that it remaining parts of the upper horizontal wall are insulated as
can not be readily used for cooling application. shown in Fig. 1.
Pourshaghaghy et al. [4] studied the inverse radiative
design problem in which the objective is to determine the
spatial distribution of heat source strengths which produces a
desired temperature and heat flux distribution on the design
surface. Birla et al. [5] in 2004 studied the uniform heating of
fruits by means of radio frequency treatments. Using a
particular mathematical method Zareifard et al. [6] in 2006
designed an oven to achieve the goal of uniform heat flux to
minimize the Losses of bakery products.
Few investigations were carried out to obtain uniform
temperature or heat flux focus on conduction heat transfer
mode. For instance, Heat flux uniformity at thin, electrically

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DIRECT PROBLEM FORMULATION
The system is considered to be two dimensional, steady a)
and laminar with air as the working Newtonian fluid. The
continuity, Navier-Stokes and energy equations for
incompressible fluid without considering the radiation and free
convection heat transfer modes can be described in the
Cartesian coordinate system as follows

∂U * ∂V *
+ =0 (1)
∂X ∂Y
∂U * ∂U * 1 ⎛⎜ ∂ 2U * ∂ 2U * ⎞⎟
∂P *
U* +V * =− + + (2)
∂X *
∂Y *
∂X Re ⎜⎝ ∂X * 2 ∂Y * 2 ⎟⎠
*

b)
∂V * * ∂V
*
∂P * 1 ⎛⎜ ∂ 2V * ∂ 2V * ⎞⎟
U* + V = − + + (3)
∂X * ∂Y * ∂Y * Re ⎜⎝ ∂X * 2 ∂Y * 2 ⎟⎠
∂θ * ∂θ * 1 ⎛⎜ ∂ 2θ * ∂ 2θ * ⎞⎟
U* +V * = + (4)
∂X *
∂Y * Re Pr ⎜⎝ ∂X * 2 ∂Y * 2 ⎟⎠
The governing equations listed above are non-
dimensionalized with the following parameters. The definition
of characteristic velocityV0 differs for the case of 4jets to that of
the case of 6 jets.
For the case of 4 jets

V0 = v j1 + v j 2 (5) Figure 1. SCHEMATIC CONFIGURATION OF THE PROBLEM

And for the case of 6 jets The boundary conditions, shown in Fig. 1, are defined as
follows:
V0 = v j1 + v j 2 + v j 3 ●On the jets inlet walls
(6)
V * = −V J , U * = 0 , θ * = 0 (9)
The following parameters are defined for the cases of 4 and
●For the adiabatic walls
6 jets with the corresponding V0
∂θ *
x y p − p∞ V* =0 , U* = 0 , =0 (10)
Dh = 2W , X * = , Y* = , P* = , ∂Y *
Dh Dh ρV02 ●On the bottom wall and design surface
T − Tj u v ρV D
θ* = , U* = ,V * = , Re = 0 h , V * = 0 , U* = 0 , θ * =1 (11)
TW − T j V0 V 0 µ
ρv jiW ν (7) ●On the symmetry line
Rei = , Pr = ,
µ α ∂V * ∂θ *
U* = 0 , =0 , =0 (12)
h X Dh ∂θ * ∂X * ∂X *
Nu = ∝− *
k ∂n Design Surface
●On the right wall

P* = 0
The geometric dimensionless parameters are defined as (13)
if U < 0 (inflow) → θ * = 1 , V * = 0
*

, H i = i ( i = 1,2,3) , L*1 = 1
H H L
H* = *
Where p∞ = 101.3 kPa considered as operating pressure.
Dh Dh Dh
(8) ●Other variables on the right wall (outlet) are extrapolated
L2 G from inside.
L*2 = , G* =
Dh Dh

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BENCHMARKING OF THE DIRECT SOLUTION flux on the design surface is qd. Therefore surface is discretized
Single phase air jets were used in this study. The Finite into N nodes and their corresponding heat fluxes resulting from
Volume Method with an unstructured mesh using commercial direct solution are represented by a vector
CFD code, FLUENT, was applied for direct solution of the
laminar confined jets impingement heat transfer to a flat plate
r
with constant temperature. The obtained results were compared qc = [qc1 qc 2 L qcN ]T (16)
with the previous literature [11] this comparison was presented
in [12] and because of space limitations it is not discussed here. A
Selection of the appropriate grid size is essential due to the 20
large number of direct problems to be solved in the course of 18
nonlinear search procedure. The grid independency test was 16
performed for a benchmark problem described in reference [11] 14
and results are shown in table 1 and Fig. 2a. So the optimum 12
grid size of 55 × 170 was chosen. The utilized grid is shown in 10

Nu
40x100
Fig. 2b. 8 45x120
6 55x170
4 65x200
INVERSE PROBLEM FORMULATION 2
The formulation of the inverse problem is described by 0
referring to Fig. 1. As it is desirable to have a specific spatially
0 0.5 1 1.5 2
uniform heat flux on the design surface, the design variables for Dimensionles Position X
the inverse problem are jets’ Reynolds numbers, separation
distance between the exit plane of the jets and the design B
surface as well as inter-jet spacing. For the case of 4 jets the
design variables vector is given as
r
D = ⎡⎣ Re1 Re2 H 1* H 2* G * ⎤⎦ T (14)
,

and for the case of 6 jets the design variables vector is defined
by
r
D = ⎡⎣ Re1 Re2 Re3 H 1* H 2* H 3* G * ⎤⎦ T (15)

The corresponding constrains are


●For the jets’ Reynolds number
0 ≤ Re j ≤ 1000
●For the separation between the exit plane of the jets and Figure 2. REPRESENTATIVE GRID FOR THE BENCHMARK
PROBLEM
design surface
0.6 ≤ H *j ≤ 3
●For the inter-jet spacing In order to estimate the design variables, the temperature
of design surface is set to be the actual boundary condition of
0.05 ≤ G * ≤ 1
the direct problem. Then by assuming an initial guess for the
design variables, heat flux distribution on the design surface is
The optimization problem is defined to determine the r
calculated. The calculated values of qc are then compared with
design variables such that it satisfies the desired conditions on
the design surface and mentioned constraints. The required heat the desired value of the heat flux on the design surface, and if

Table 1. CONVERGENCE OF MEAN NUSSELT NUMBER IN THE DESIGN SURFACE WITH DECREASING THE GRID SIZE
nodes in Y direction nodes in X direction Mean Nusselt number on design surface
40 100 12.3233
45 125 12.2291
55 170 12.1331
65 200 12.0624

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necessary, the design variables is varied and the procedure is counter as i = 1 .
Table 2. DESIGN VARIABLES AT INITIAL AND FINAL RESULTING POINT AS WELL AS CORRESPONDING erms FOR THE CASE OF 4 JETS.
Desired Uniform Nusselt = 8.333 Desired Uniform Nusselt = 11.667 Desired Uniform Nusselt = 15
Parameter Initial Final Initial Final Initial Final
Re1 215.06 163.43 477.90 194.36 645.17 201.52
Re 2 645.17 201.36 716.85 713.68 645.17 488.13

H1* 1.8 1.3216


2
1.1147 0.9 0.7503

H 2* 1.8 2.0981
2
2.0566 0.9 1.1044
* 0.2 0.0501 0.0502 0.1 0.0500
G 0.5
erms 45.11 9.90 46.42 7.85 57.84 10.95

repeated until sufficient proximity between the “calculated” and 2) Calculate the gradient of the objective function and
the “desired” value of the heat flux is reached. This procedure
r
− ∇f D1 ( )
is performed by considering an objective function f assume the
( )
r as the first search vector.
∇f D1
3) Calculate the optimum step size for the current search
( ) ∑ (q
r N
f D = d − qcn )2 (17) vector by means of golden section method.
n=1
r 4) Check the new point for optimality, if it is the optimal
The problem is then to find the vector V which minimizes point, terminate the iteration. otherwise continue to the
the function f. next step.
5) Calculate the gradient of the objective function and
The optimal point of function f corresponds to the solution normalize it.
r 6) Find the new search vector according to CGM.
D of the problem. The computational algorithm of this
procedure consists of two main parts; the direct problem 7) Consider the iteration counter to be i = i + 1 then go
solving and the optimization procedure. As explained, for the to step 3
first part the FVM is employed in this work, while for latter
part the Conjugate Gradients Method (CGM) is used as the RESULTS AND DISCUSSION
main optimization method to minimize function f. Details of In the cases of 4 and 6 jets the problem is solved for three
this algorithm is not discussed here; interested readers are different desired Nusselt numbers. The required Nusselt
referred to Ref. [13] for CGM details. In the CGM method for numbers on the design surface for both cases are 8.333, 11.667
obtaining the optimum step size λ the Golden Section and 15. The initial guess and the final solution for each case as
algorithm is employed. well as objective function and related errors, are reported in
The iterative algorithm for finding design variables can be table 2 and 3. Local Nusselt number distribution on the design
described as follows: surface as well as the convergence history for the root mean
r square of relative error of estimated heat flux is depicted in Fig.
1) Start with an initial guess of D1 and set the iteration 3 and 4. The latter parameter is defined as

Table 3. DESIGN VARIABLES AT INITIAL AND FINAL RESULTING POINT AS WELL AS CORRESPONDING erms FOR THE CASE OF 6 JETS.
Desired Uniform Nusselt = 8.333 Desired Uniform Nusselt = 11.667 Desired Uniform Nusselt = 15
Parameter Initial Final Initial Final Initial Final
Re1 215.06 64.96 322.59 136.79 322.59 192.62
Re 2 215.06 50.62 322.59 303.28 322.59 572.18
Re3 215.06 127.83 322.59 327.35 322.59 458.43

H1* 0.75 0.6901 0.9 0.8412 0.9 0.6625

H 2* 0.75 0.8026 1.2 1.2082 1.2 1.0843

H 3* 0.75 0.7982 1.5 1.4898 1.5 1.4391


* 0.1 0.0584 0.15 0.0500 0.15 0.0505
G
erms 75.08 3.49 35.06 5.69 24.45632 9.77

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2 geometric parameters are assumed
1
N
⎛ qci − qd ⎞
erms =
N ∑ ⎜⎜
i =1 ⎝
qd
× 100 ⎟⎟

(18)
W = 0.05 m , H * = 3 , L*1 = 2 , L*2 = 8 (19)
As it is seen in Fig. 3 and 4 left columns, almost in all
Moreover, stream lines and temperature contours for all of
cases the method converges in less than 10 steps and the
the six cases at final answer points are presented in Fig. 6.
resulting erms is less than 10% which is acceptable for most
For the both cases the following fixed non-dimensional

A)
50 14
12
40
10
erms

30 8

Nu
20 6
Iteration 1
4 Iteration 5
10 Iteration 10
2
Desired Nusselt (8.33)
0 0
0 2 4 6 8 10 12 0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
Iteration Dimensionless Position X

B)
50 20
18
40 16
14
30
12
erms

Nu

20 10
8 Iteration 1
10 Iteration 4
6
Iteration 9
4 Desired Nusselt (11.667)
0
2
0 2 4 6 8 10 12
0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
Iteration
Dimensionless Position X

C)
70 32

60 28

50 24
40 20
erms

Nu

30 16
20 12 Iteration 1
Iteration 6
10 8 Iteration 9
Uniform Nusselt (15)
0 4
0 2 4 6 8 10 12 0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
Iteration Dimensionless Position X
Figure 3. CONVERGENCE HISTORY (ON THE LEFT COLUMN) AND LOCAL NUSSELT DISTRIBUTION (ON THE RIGHT COLUMN) FOR
DIFFERENT OBJECTIVE NUSSELT NUMBERS IN CASE OF 4 JETS WITH ࡴ‫ כ‬ൌ ૛, ࡸ૚‫= כ‬2 AND ࡸ૛‫= כ‬8 (A) Nu=8.33 , (B) Nu=11.667 , (C) Nu=15.

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engineering applications. to increasing the number of design variables that allows the
Due to the nonlinear behavior of the problem, during the CGM method to fine tune them more effectively.
study it is observed that the number of the iterations and the Almost in all cases it is seen from Fig. 5 that the separation
resulting erms depend on the initial guess point of the algorithm. occurs on the bottom isotherm wall that causes distortion on
Also it can be seen from tables 2 and 3 that for most of cases, isotherms. But in Fig. 5f the isotherms are not distorted and the
by increasing the desired Nusselt number the error variance flow is not separated.
increases. Also the left column of the Fig. 5 Shows that by increasing
Table 3 and 4 show that by using 6 jets instead of 4 jets the the desired Nusselt number, the isotherms become denser above
purpose of the problem is achieved more accurately. This is due the design surface. The temperature gradients decrease away
A)
20
80
70
60 15

50

Nu
10
erms

40
30
Itration 1
20 5 Itration 4
Itration 9
10 Uniform Nusselr (8.333)
0 0
0 2 4 6 8 10 0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2

Iteration Dimensionless Position X

B)
40 30
35
25
30
25 20

20
Nu
erms

15
15 Iteration 1
10 Iteration 4
10 Iteration 9
5 Desired Nusselt (11.667)
5
0 0
0 2 4 6 8 10 0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2
Iteration Dimensionless Position X
C)
30
20
25

20 15
erms

15
Nu

10
10 Iteration 1
Iteration 4
5 Iteration 7
5 Desired Nusselt (15)

0 0
0 2 4 6 8 10 0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2

Iteration Dimensionless Position X

Figure 4. CONVERGENCE HISTORY (ON THE LEFT COLUMN) AND LOCAL NUSSELT DISTRIBUTION (ON THE RIGHT COLUMN) FOR
DIFFERENT OBJECTIVE NUSSELT NUMBERS IN CASE OF 6 JETS WITH ࡴ‫ כ‬ൌ ૛, ࡸ૚‫= כ‬2 AND ࡸ૛‫= כ‬8 (A) Nu=8.333 , (B) Nu=11.667 , (C) Nu=15.

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from bottom surface. a uniform heat flux over the design surface. It is also seen that
Distribution of local Nusselt number on design surface, in the final solution the outer jet heights are greater than those
depicted in right column of Fig. 3 and 4, shows that the error in of the interior ones.
the beginning and ending parts of the design surface is higher
than middle parts. CONCLUSION
Table 2 and 3 show that in final answer point of the various In this paper by use of the computational fluid dynamics
cases the Reynolds number of the outer jet is more than others. and the conjugate gradients method a systematic procedure is
This way the outer jet decreases the horizontal velocity of the developed to achieve an optimal jet configuration for which a
inner jet near its point of impact, while boosting up the uniform heat flux condition can be attained on an isothermal
momentum of its outer low the velocity part. This also leads to surface. A variance error of 10% was reached for a low Nusselt
A)

B)

C)

D)

E)

F)

Figure 5. ISOTHERMS (ON THE LEFT COLUMN) AND STREAMLINES (ON THE RIGHT COLUMN) FOR THE FINAL ANSWER POINT (A)4 JETS
Nu=8.333 (B) 4 JETS Nu=11.667 (C) 4 JETS Nu=15 (D) 6 JETS Nu=8.333 (E) 6 JETS Nu=11.667 (F) 6 JETS Nu=15.

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number which can be reduced further by increasing the number [7] Sparrow, E.M. and Carlson, C.K., 1987, “Experimental
of jets. It was concluded that as the variance error increases investigation of heat flux uniformity of thin electrically heated
when the target Nusselt number increases. To remedy this metallic foils”, Int. J. Heat Mass Transfer, 30(3), March, pp.
problem once again one can utilize larger number of jets. 601-604.

[8] Roetzel, W. and Newman, M., 1975, “Uniform heat flux in a


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[1] Hosseini Sarvari, S.M. and Mansouri, S.H., 2004,“Inverse operating under rimming conditions”, Int. J. Heat Mass
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media”, Numerical Heat Transfer Part B, 46(3), September, pp.
[9] Chander, S. and Ray, A., 2007, “Heat transfer characteristics
283–300.
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surface”, Int. J. Heat and Mass Transfer, 50(3), February, pp.
[2] Daun, K.J., Morton, D.P. and Howell, J.R., 2003,
640-653.
”Geometric optimization of radiant enclosures containing
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pp. 845–851. characteristics of HiTAC heating furnace using regenerative
burners”, Applied Thermal Engineering, 26(16), November,
[3] Timans, P.J., 1998, “Rapid thermal processing technology pp. 2027-2034.
for the 21st century”, Materials Science in Semiconductor
Processing 1 , 1(3-4), December, pp. 169-179. [11] Dagtekin, I. and Oztop, H.F., 2008,” Heat transfer due to
double laminar slot jets impingement onto an isothermal wall
[4] Pourshaghaghy, A., Pooladvand, K., Kowsary, F. and within one side closed long duct”, International
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scattering media”, International Communications in Heat and
Mass Transfer, 33(3), March, pp. 381-390. [12] Rajaeeian Hoonejani, M., 2009. “Impinging Jet Cooling
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[5] Birla, S. L., Wang, S., Tang, J. and Hallman, G., 2004, University of Tehran, Tehean, Iran, August.
”Improving heating uniformity of fresh fruit in radio frequency
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Technology, 33(2), August, pp. 205-217. Taylor and Francis, New York, 2000 chapters 2 & 5.

[6] Zareifard, M.R., Marcotte, M. and Dostie, M., 2006, ”A


method for balancing heat fluxes validated for a newly
designed pilot plant oven”, Journal of Food Engineering, 76(3),
October, pp. 303-312.

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