Analysis and optimization of heat loss for water-cooled furnace roller

A heat transfer model of furnace roller cooling process was established based on analysis of furnace roller＇s structure. The complicated model was solved with iteration planning algorithm based on Newton search. The model is proved logical and credible by comparing calculated results and measured data. Then, the relationship between water flow velocity, inlet water temperature, furnace temperature and roller cross section temperature, outlet water temperature, water temperature rise, cooling water heat absorption was studied. The conclusions and recommendations are mainly as follows： l） Cooling water temperature rise decreases with the increase of water flow velocity, but it has small relationship with inlet water temperature; 2） In order to get little water scale, inlet water temperature should be controlled below 30 ℃. 3） The cooling water flow velocity should be greater than critical velocity. The critical velocity is 0.07 m/s and water flow velocity should be controlled within 0.4-0.8 m/s. Within this velocity range, water cooling efficiency is high and water temperature rise is little. If cooling water velocity increases again, heat loss will increase, leading to energy wasting.

Design of Balanced Reactor Welded with Water-Cooled Aluminum Busbars

A new process of welding aluminum water-cooled busbars is proposed, It can not only reduce the weight and cost, but also improve the dynamic and thermal stability. Furthermore~ both finite element method analysis and a prototype test testify the advantages of the design which is not limited by load current and provides a new approach for water-cooled reactors.

Numerical Simulation on Subcooled Boiling Heat Transfer Characteristics of Water-Cooled W/Cu Divertors

In order to realize safe and stable operation of a water-cooled W/Cu divertor under high heating condition,the exact knowledge of its subcooled boiling heat transfer characteristics under different design parameters is crucial.In this paper,subcooled boiling heat transfer in a water-cooled W/Cu divertor was numerically investigated based on computational fluid dynamic（CFD）.The boiling heat transfer was simulated based on the Euler homogeneous phase model,and local differences of liquid physical properties were considered under one-sided high heating conditions.The calculated wall temperature was in good agreement with experimental results,with the maximum error of 5%only.On this basis,the void fraction distribution,flow field and heat transfer coefficient（HTC）distribution were obtained.The effects of heat flux,inlet velocity and inlet temperature on temperature distribution and pressure drop of a water-cooled W/Cu divertor were also investigated.These results provide a valuable reference for the thermal-hydraulic design of a water-cooled W/Cu divertor.

Optimization of the Water-Cooled Structure for the Divertor Plates in EAST Based on an Orthogonal Theory

An orthogoual experimental scheme was designed for optimizing a water-cooled structure of the divertor plate. There were three influencing factors： the radius R of the water- cooled pipe, and the pipe spacing L1 and L3. The influence rule of different factors on the cooling effect and thermal stress of the plate were studied, for which the influence rank was respectively R 〉 L1 〉 L3 and L3 〉 R 〉 L1. The highest temperature value decreased when R and L1 increased~ and the maximum thermal stress value dropped when R, L1 and L3 increased. The final optimized results can be summarized as： R equals 6 mm or 7 mm, L1 equals 19 mm, and L3 equals 20 mm. Compared with the initial design, the highest temperature value had a small decline~ and the maximum thermal stress value dropped by 19~ to 24~. So it was not ideal to improve the cooling effect by optimizing the geometry sizes of the water-cooled structure, even worse than increasing the flow speed, but it was very effective for dropping the maximum thermal stress value. The orthogoaal experimental method reduces the number of experiments by 80%, and thus it is feasible and effective to optimize the water-cooled structure of the divertor plate with the orthogonal theory.

Preparation of Al-Zn-Mg-Cu alloy semisolid slurry through a water-cooled serpentine pouring channel

The semisolid slurry of Al-Zn-Mg-Cu alloy was prepared through a self-designed water-cooled copper serpentine pouring channel(WSPC) machine. Influences of pouring temperature, the number of turns and the cooling water flow rate on the microstructure of the semisolid Al-Zn-Mg-Cu alloy slurry were investigated. The results show that the semisolid Al-Zn-Mg-Cu alloy slurry with satisfactory quality can be generated by the WSPC when the pouring temperature is in the range between 680 ℃ and 700 ℃. At a given pouring temperature, the average grain size of primary α-Al decreases and the shape factor increases with the increase of the number of turns. When the cooling water flow rate is 450 L·h^(-1), the obtained semisolid slurry is optimal. During the preparation of the semisolid Al-Zn-Mg-Cu alloy slurry with low superheat pouring, the alloy melt has mixed inhibition and convection flow characteristics by "self-stirring". When the alloy melt flows through the serpentine channel, the chilling effect of the inner wall of the channel, the convection and mixed inhibition of the alloy melt greatly promote the heterogeneous nucleation and grain segregation. This effect destroys the dendrite growth mode under traditional solidification conditions, and the primary nuclei gradually evolve into spherical or nearspherical grains.

Analysis of surface cracking in water-cooled rolls and heat transfer between furnace chamber and rolls in a direct flame furnace

In the direct fired furnace of a continuous annealing line, seal rolls are susceptible to deformation that leads to surface defects of steel strips. According to failure analysis, the reasons include improper structural design and heat imbalance. An improved design has been proposed to reduce stress concentration and thermal radiation. A heat transfer model has been employed to determine the proper water flow rate for roll cooling. Industrial application proves that seal rolls with the new design has less deformation and longer service life.

Fully Immersing Water-Cooled Radial Slab Laser and its Incoherent Beam Combination

A novel scheme of fully immersing water cooling is proposed for a Nd：glass radial slab laser. The slab medium is entirely immersed in the circulating water Ailing the pumping cavity, which enables much lower temperature and reasonably smaller thermal gradient in the slab medium. The radial slab is symmetrically and synchronously pumped by eight flash lamps, and produces multi-output beams with a total energy of 469md. Incoherent beam combination property of the multi-output beams is also investigated. The approach suggested here provides a way of scaling the slab lasers to much higher output levels and also a convenience for beam combinations.

The Corrected Simulation Method of Critical Heat Flux Prediction for Water-Cooled Divertor Based on Euler Homogeneous Model

An accurate critical heat flux（CHF） prediction method is the key factor for realizing the steady-state operation of a water-cooled divertor that works under one-sided high heating flux conditions.An improved CHF prediction method based on Euler＇s homogeneous model for flow boiling combined with realizable k-ε model for single-phase flow is adopted in this paper in which time relaxation coefficients are corrected by the Hertz-Knudsen formula in order to improve the calculation accuracy of vapor-liquid conversion efficiency under high heating flux conditions.Moreover,local large differences of liquid physical properties due to the extreme nonuniform heating flux on cooling wall along the circumference direction are revised by formula IAPWSIF97.Therefore,this method can improve the calculation accuracy of heat and mass transfer between liquid phase and vapor phase in a CHF prediction simulation of water-cooled divertors under the one-sided high heating condition.An experimental example is simulated based on the improved and the uncorrected methods.The simulation results,such as temperature,void fraction and heat transfer coefficient,are analyzed to achieve the CHF prediction.The results show that the maximum error of CHF based on the improved method is 23.7%,while that of CHF based on uncorrected method is up to 188%,as compared with the experiment results of Ref.[12].Finally,this method is verified by comparison with the experimental data obtained by International Thermonuclear Experimental Reactor（ITER）,with a maximum error of 6% only.This method provides an efficient tool for the CHF prediction of water-cooled divertors.

Creation and Development of Turbo-generators with Water-Cooled Stator and Rotor Windings in Shanghai Electrical Machinery Mfg Works

1. An Overview of Manufacture and Operation A turbine generator utilizing a new technology of electrical machinery industry, i.e. the windings of its stator and rotor all being inner water-cooled, was first successfully created in China and was known afterwards as a turbine generator with watercooled stator and rotor windings (Abbrev, TGWSR). The teachers from Zhejiang University came to Shanghai between

Progress of the 10 J water-cooled Yb:YAG laser system in RCLF

The high repetition rate 10 J/10 ns Yb:YAG laser system and its key techniques are reported.The amplifiers in this system have a multi-pass V-shape structure and the heat in the amplifiers is removed by means of laminar water flow.In the main amplifier,the laser is four-pass,and an approximately 8.5 J/1 Hz/10 ns output is achieved in the primary test.The far-field of the output beam is approximately 10 times the diffraction limit.Because of the higher levels of amplified spontaneous emission(ASE) in the main amplifier,the output energy is lower than expected.At the end we discuss some measures that can improve the properties of the laser system.

Numerical study of macrosegregation formation of ingot cast in normal sand mold and water-cooled sand mold

Formation of macrosegregation of 5 t steel ingots cast in sand molds with and without water-cooled copper tube is simulated by solving macroscopic mass, momentum, species and energy conservation equations with the consideration of shrinkage formation. Predicted macrosegregation pattern of the ingots shows a fair agreement with the experimental data. Both calculations and experiments reveal that some positive segregation patches are formed at the bottom of ingot. With the water-cooled copper tube inserted in the sand mold, the ingot cast has a less intensive macrosegregation. Mechanisms of macrosegregation formation are numerically analyzed. Explanations regarding the influences of fluid flow and temperature change upon the segregation formation are provided.

Atomic resolution scanning tunneling microscope imaging up to 27 T in a water-cooled magnet

We report the first atomically resolved scanning tunneling microscope （STM） imaging in a water-cooled magnet （WM）, for which extremely harsh vibrations and noise have been the major challenge. This custom WM-STM features an ultra-rigid and compact scan head in which the coarse approach is driven by our newly designed TunaDrive piezoelectric motor. A three-level spring hanging system is used for vibration isolation. Room-temperature raw-data images of graphite with quality atomic resolution were acquired in the presence of very strong magnetic fields, with a field strength up to 27 T, in a 32-mm-diameter bore WM with a maximum field strength of 27.5 T at a power rating of 10 MW, calibrated by nuclear magnetic resonance （NMR）. This record field strength of 27 T exceeds the maximal field strength achieved by the conventional supercon- ducting magnets. Besides, our WM-STM has paved the way to STM imaging using a 45 T, 32-mm-diameter bore hybrid magnet, which is the world＇s flagship magnet, producing the strongest steady magnetic field.

Effects of water-cooled cover on physiological and production parameters of farrowing sows under hot and humid climates

The hot and humid climates,as encountered in the southern region of China with the open housing,can adversely impact the sows undergoing heat stress during the most vulnerable period at lactation.Hence,a water-cooled cover system(WCCs)for local cooling has essential practical value to improve productivity.The WCCs was developed for the sow crate of lactating sows separately,which performance was validated with the cooling efficiency in the sow occupied zone(SOZ)and physiological parameters.The results showed that the WCCs for the farrowing sows using aluminium plastic tubes connected in series could reach an appropriate cooling performance in adjacent units.The WCCs could decrease the SOZ air temperature by 3.0-4.5℃under the extremely hot climate when the indoor air temperature was 37℃,and maintain a suitable range(25-30℃)under the typical hot climate(<35℃).The respiration rate and skin temperature of farrowing sows had no significant difference between treatment group(WCC)and control group(sprinkle cooling)when the air temperature was below 30℃,but had a significant difference(p<0.05)when air temperature rose above 30℃.The control sows drank more during hot weather,and the feed intake was significantly lower than the sows with the WCCs(p<0.01).It was concluded that the WCCs could alleviate the heat stress of farrowing sows during typical hot climate.

Numerical calculation for circulating current in stator transposition bars of large water-cooled turbo-generators

Accurate calculation of circulating current is one of the key problems for stator transposition bars in the design of turbo-generators. Aimed at limitation that analytical algorithm of circulating current could not reflect the local electromagnetic field distribution and difficulty that overlaps easily exist in solid modeling process of stator transposition bars, a simplified physical model of transposition bars is established. A three-dimensional(3-D) numerical method for circulating current in stator transposition bars of large water-cooled turbo-generators is investigated, which is combined with field-circuit coupling method. Taking stator bars less than 540° transposition with void model of a 600-MW water-cooled turbo-generator as the research object, the magnetic flux density distribution, current density distribution and circulating current distribution of transposition strands are obtained by numerical calculation. Compared with calculation results of the improved analytical algorithm, the correctness of the numerical calculation for circulating current is demonstrated, the calculation value difference for the maximum current of strands is obtained. The numerical calculation for circulating current will provide an appropriate basis for the reasonable calculation of local overheating of stator transposition bars and the design of safety margin for turbo-generators.

Design and thermal analysis of a water-cooled DSC module

Elevated working temperatures reduce the efficiency of dye-sensitized solar cells （DSCs）, and effective temperature regulation protects them from the undesirable efficiency loss. In this work, a semi-transparent DSC module equipped with a cooling sys- tem was designed and constructed for application in buildings, the temperature and output performance of the modules with or without cooling treatment were investigated. The test results showed the cooling system could noticeably improve the power generation and reduce the module temperature. Moreover, we established a mathematical model to analyze the modules＇ ther- mal performances, and introduced the concept of cooling efficiency to evaluate the cooling effect. The model accuracy have been validated utilizing measured data, and the effects of channel depth and mass flow rate on the module temperature and cooling efficiency were further theoretically studied. The combined DSC module has been found to have a good application prospect in building integrated photovoltaic （BIPV）, and the numerical results are important in system design.

Flow Field and Temperature Field of Water-Cooling-Type Magnetic Coupling

At present, the water-cooling simulation of the water-cooled magnetic coupler is based on the water-cooled motor and the hydraulic coupler, which cannot accurately characterize the temperature distribution of the rotating watercooled coupling of the coupler. Focusing on rotating water cooling radiating, the present paper proposes simulating the water cooling temperature field as well as the flow field through the method of combining fluid-solid coupled heat transfer and MRF(Multiphase Reference Frame). In addition, taking an 800 kW magnetic coupling as an example, the paper optimizes the shape, number, cooling water inlet speed? and so on? of the cooling channel. Considering factors such as the complete machine’s temperature, and drag torque, it is proved that the cooling e ect is best when there are 36 involute curved channels and when the inlet speed is 3 m/s. Further, through experiments, the actual temperature values at six di erent positions when 50 kW and 70 kW thermal losses di er are measured. The measured values agree with the simulation results, proving the correctness of the proposed method. Further, data have been collected during the entire experimental procedure? and the variation in the coupling’s temperature is analyzed in depth, with the objective of laying a foundation for the estimation of the inner temperature rise as well as for the optimization of the structural design.

DEVELOPMENT OF SINGLE-PHASED WATER-COOLING RADIATOR FOR COMPUTER CHIP

In order to cool computer chip efficiently with the least noise, a single phase water-cooling radiator for computer chip driven by piezoelectric pump with two parallel-connection chambers is developed. The structure and work principle of this radiator is described. Material, processing method and design principles of whole radiator are also explained. Finite element analysis （FEA） software, ANSYS, is used to simulate the heat distribution in the radiator. Testing equipments for water-cooling radiator are also listed. By experimental tests, influences of flowrate inside the cooling system and fan on chip cooling are explicated. This water-cooling radiator is proved more efficient than current air-cooling radiator with comparison experiments. During cooling the heater which simulates the working of computer chip with different power, the water-cooling radiator needs shorter time to reach lower steady temperatures than current air-cooling radiator.

Mathematical model on heat transfer of water-cooling steel-stick bottom electrode of DC electric arc furnace

For predicting and controlling the melted depth of bottomelectrode during the process of steelmaking, the water-cooling steel-stick electrode is taken as an example, to analyze the process ofheat transfer, then 3D mathematical model by control capacity methodis built. At the same time, the measurement on the melted depth ofbottom electrode is conducted which verified the correctness of thebuilt mathematical model. On the base of verification, all kinds ofkey parameters are calculated through the application and a series ofresults are simulated. Finally, the optimum parameters are found andthe service life of bottom electrode is prolonged.

Research on the Flow and Heat Transfer Characteristics of a Water-Cooling Plate in a Heat Dissipation System

The water-cooling heat dissipation technology can solve the heat dissipation and noise problems of the calculation plate.Therefore,the structural design of the water-cooling plate directly affects its flow and heat transfer characteristics,which restricts the promotion and application of the technology.To this end,the water-cooling plate of a heat dissipation system was taken as the research object,and its flow and heat transfer characteristics were numerical simulated and experimental studied.Through comparative analysis,the rationality of the numerical simulation method was verified.Based on this,three improved schemes of water-cooling plate structure were proposed and numerical simulation was carried out,and the optimal model was verified by experiments.The results of the study show that compared with the original water-cooling plate,the optimized water-cooling plate has increased internal flow velocity and distributes uniformly,increased heat transfer amount by 4.2%,and the average temperature of the calculation plate decreased by 5.3%.

Cooling System Design and Thermal Analysis of Modular Stator Hybrid Excitation Synchronous Motor

Hybrid excitation synchronous motor has the advantages of uniform and adjustable electromagnetic field, wide speed range and high power density. It has broad application prospects in new energy electric vehicles, wind power generation and other fields. This paper introduces the basic structure of hybrid excitation motor with modular stator, and analyzes the operation principle of hybrid excitation motor. The cooling structure of the water-cooled plate is designed, and the effects of the thickness of the water-cooled plate and the number of water channels in the water-cooled plate on the heat dissipation capacity of the water-cooled plate are analyzed by theoretical and computational fluid dynamics methods. The effects of different water cooling plate structures on water velocity, pressure drop, water pump power consumption and heat dissipation capacity were compared and analyzed. The influence of different inlet flow velocity on the maximum temperature rise of each part of the motor is analyzed, and the temperature of each part of the motor under the optimal water flow is analyzed. The influence of the traditional spiral water jacket cooling structure and the water-cooled plate cooling structure on the maximum temperature rise of the motor components is compared and analyzed. The results show that the water-cooled plate cooling structure is more suitable for the modular stator motor studied in this paper. Based on the water-cooled plate cooling structure, the air-water composite cooling structure is designed, and the effects of the air-water composite cooling structure and the water-cooled plate cooling structure on the maximum temperature rise of each component of the motor are compared and analyzed. The results show that the maximum temperature rise of each component of the motor is reduced under the air-water composite cooling structure.