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Description
Plate fin and tube heat exchangers (PFTHE) have plenty applications in heating and cooling technics e.g. cooling towers, dry coolers and air coolers in the food industry, oil coolers in car engines, air coolers and heaters in ventilation, refrigerant coolers and heat pumps in air conditioning. Is it possible to optimize the construction of the PFTHE? It would seem that the current process of design of PFTHE cannot be more optimal.
The classical method of calculating PFTHE is based on the average logarithmic difference of medium temperatures. It assumes that the air-side heat transfer coefficient on every row of PFTHE is constant. Computational fluid dynamics (CFD) simulation studies and experimental results show that there are significant differences in coefficient between an individual row of tubes. This is true especially if air velocity in front of PFTHE is smaller than 2.5 m/s. It is possible to consider different coefficients on each row of tubes. Taking into account these dependencies between heat transfer coefficient and the row’s position will allow optimal PFTHE design e.g. it will eliminate 4-row PFTHEs in favour of 1- or 2-row PFTHEs. Following optimization gives us a chance to significantly reduce materials for building PFTHEs.
The main objective of the research is to create a new method of calculation and experimental studies of cross-flow heat exchanger made from tubes with individual or continuous fins. This new method will be determined based on experimental and numerical research. An analytical and numerical model of 2-row and 4-row PFTHE will be developed. New method can be used during the cross-flow heat exchanger design or optimization.
The test facility will be built for the needs of experimental determination of the Nusselt number for air-side and water-side in PFTHEs. The stand will allow aerodynamic, hydraulic and thermal tests in steady and transient conditions.
Summary of project results
The project aimed to address the need for improved performance and understanding of heat exchanger systems. Heat exchangers are instrumental in a variety of industrial processes, from power generation to HVAC systems, but their optimisation and performance improvement remain major challenges. The project aimed to develop advanced computational and analytical methods for the analysis and optimisation of tubular cross-flow heat exchangers.
The project involved several crucial activities, including computational fluid dynamics (CFD) modelling, development of new numerical methods, experimental validation and analytical modelling. These activities were essential for a better understanding of heat exchanger processes. The main result of the project was the development of advanced computational and analytical tools for analyzing and optimizing cross-flow tubular heat exchangers. This included the proposal of two novel numerical methods, determination of individual air-side Nusselt number correlations, and experimental validation of the developed models. Additionally, the project led to insights into the variations in air-side heat transfer coefficients for different tube rows, highlighting the importance of considering individual correlations for accurate predictions.
The project has brought significant benefits to end beneficiaries by improving the efficiency, reliability and performance of heat exchanger systems. By providing advanced computational tools and methodologies, the project has enabled final consumers to optimise heat exchanger designs, leading to improved energy efficiency, reduced operating costs and increased productivity across a range of industry sectors.The importance of the project lies in its long-term impact on energy efficiency, sustainability and industrial competitiveness. By improving the understanding and optimisation of heat exchanger systems, the project contributes to global efforts to reduce energy consumption and greenhouse gas emissions. Furthermore, the methodologies and tools developed have the potential to drive innovation and progress in heat exchanger technology, benefiting industries worldwide for years to come.