Performance Investigation of Capillary Tubes for Machine Tool Coolers Retrofitted with HFC-407C Refrigerant

The machine tool coolers are the best managers of coolant temperature in avoiding the deviation of spindle centerline for machine tools. However, the machine coolers are facing the compressed schedule to phase out the HCFC （hydro-chloro-floro-carbon） refrigerant and little attention has been paid to comparative study on sizing capillary tube for retrofitted HFC （hydro-floro-carbon） refrigerant. In this paper, the adiabatic flow in capillary tube is analyzed and modeled for retrofitting of HFC-407C refrigerant in a machine tool cooler system. A computer code including determining the length of sub-cooled flow region and the two phase region of capillary tube is developed. Comparative study of HCFC-22 and HFC-407C in a capillary tube is derived and conducted to simplify the traditional trial-and-error method of predicting the length of capillary tubes. Besides, experimental investigation is carried out by field tests to verify the simulation model and cooling performance of the machine tool cooler system. The results from the experiments reveal that the numerical model provides an effective approach to determine the performance data of capillary tube specific for retrofitting a HFC-407C machine tool cooler. The developed machine tool cooler system is not only directly compatible with new HFC-407C refrigerant, but can also perform a cost-effective temperature control specific for industrial machines.

Reliability Investigation of Semiconductor Coolers

The tests on the thermoelectric shock of semiconductor coolers show that the life of semiconductor coolers follows the Weibull distribution. After the early failed devices are removed, the failure rule of the devices can be described as an exponential distribution. The main failure mode is tile crack between electric couple material and welding pad. The failure mechanism is the orientated incline and easy splitting of the thermoelectric materials and the stress of substrate deformation due to the temperature difference between the two sides of the cooler. The reliability of the devices can be improved by using multi-layer metalization in electric couple welding.

Influence of syngas components and ash particles on the radiative heat transfer in a radiant syngas cooler

Radiant syngas cooler(RSC)is widely used as a waste heat recovery equipment in industrial gasification.In this work,an RSC with radiation screens is established and the impact of gaseous radiative property models,gas components,and ash particles on heat transfer is investigated by the numerical simulation method.Considering the syngas components and the pressure environment of the RSC,a modified weighted-sum-of-gray-gases model was developed.The modified model shows high accuracy in validation.In computational fluid dynamics simulation,the calculated steam production is only 0.63%in error with the industrial data.Compared with Smith's model,the temperature decay along the axial direction calculated by the modified model is faster.Syngas components are of great significance to heat recovery capacity,especially when the absorbing gas fraction is less than 10%.After considering the influence of particles,the outlet temperature and the proportion of radiative heat transfer are less affected,but the difference in steam output reaches 2.7 t·h^(-1).The particle deposition on the wall greatly reduces the heat recovery performance of an RSC.

Analysis of the Erosion-Corrosion Mechanism of the Air Cooler in a Hydrocracking Unit:A Numerical and Experimental Study

Corrosion leakages often occur in the air cooler of a hydrocracking unit,with the failure sites mainly located in the entrance area of the tubes.An analysis of the macroscopic morphology and corrosion products confirmed that the damage was caused by erosion-corrosion(E-C).Numerical and experimental methods were applied to investigate the E-C mechanism in the air cooler.Computational fluid dynamics(CFD)was used to calculate the hydrodynamic parameters of the air cooler.The results showed that there was a biased flow in the air cooler,which led to a significant increase in velocity,turbulent kinetic energy and wall shear within 0.2 m of the tube entrance.A visualization experiment was then performed to determine the principles of migration and transformation of multiphase flow in the air cooler tubes.Various flow patterns(pure droplet flow,mist flow,and annular flow)and their evolutionary processes were clearly depicted experimentally.The initiation mechanism and processes leading to the development of E-C in the air cooler were also determined.This study provided a comprehensive explanation for the E-C failures that occur in air coolers during operation.

CFD performance analysis of finned-tube CO_(2)gas coolers with various inlet air flow patterns

A detailed model of three-dimensional computational fluid dynamics(CFD)on a finned-tube CO_(2)gas cooler has been developed and validated.The model is then applied to investigate the effect of uniform and mal-distribution inlet airflow profiles on the coil performance.The airflow mal-distribution velocity profiles include linear-up,linear-down and parabolic while the effected coil performance parameters contain airside pressure drop,average airside heat transfer coefficient,approach temperature and coil heating capacity.The model also enables to predict the CO_(2)refrigerant temperature profile along the coil pipes from refrigerant inlet to outlet at different operation conditions.The simulation results reveal that different types of inlet airflow velocity profiles have significant effects on the gas cooler performance.The uniform airflow velocity profile case shows the best thermal performance of gas cooler.Compared with the cases of linear-up and parabolic air velocity profiles,the linear-down airflow profile can influence more on the coil heat transfer performance.Due to the thermal conduction between neighbour tubes through coil fins,reversed heat transfer phenomenon exists which can be detected and simulated by the CFD model.It is predicted that the linear-down airflow profile can increase greatly the reversed heat transfer phenomenon and thus lead to the highest approach temperature and the lowest heating capacity amongst these four types of airflow profiles.The research method and outcomes presented in this paper can have great potentials to optimize the performance of a CO_(2)gas cooler and its associated refrigeration system.

Experimental Study on the Thermal Performances of a Tube-Type Indirect Evaporative Cooler

The so-called indirect evaporative cooling technology is widely used in air conditioning applications.The thermal characterization of tube-type indirect evaporative coolers,however,still presents challenges which need to be addressed to make this technology more reliable and easy to implement.This experimental study deals with the performances of a tube-type indirect evaporative cooler based on an aluminum tube with a 10 mm diameter.In particular,the required tests were carried out considering a range of dry-bulb temperatures between 16℃ and 18℃ and a temperature difference between the wet-bulb and dry-bulb temperature of 2℃∼4℃.The integrated convective heat transfer coefficient inside the tube in the drenching condition has been found to lie in the range between 36.10 and 437.4(W/(m^(2)⋅K)).

Effect of sinter layer porosity distribution on flow and temperature fields in a sinter cooler

When sinters are filled into the sinter cooler from the sintering machine, it is commonly seen that, due to segregation effects, sinters of larger size usually accumulate closer to the inner wall of the sinter cooler, whereas those of smaller size are to the outer wall. This nonuniform distribution of sinters has led to uneven cooling effect throughout the cooler. This causes the sinters leaving the cooler at a large temperature difference. This undesired temperature difference leads to the deformation and even the destruction of the conveyors. The computational fluid dynamics （CFD） technique was used in the present work to investigate the heat and fluid flow phenomena within the sinter cooler corresponding to the different distribution of sinter layer porosity, which was highly dependent on the arrangement and orientation of sinters within the sinter cooler. It is confirmed that a high mass flow rate within the sinter layer causes a low temperature region and vice versa. The flow fields for vertically reducing porosity distribution and random distribution are almost identical indicating the relative insignificance of convective heat transfer mechanism.

Optimum design and layout of the cooling apparatus for long compaignship blast furnace

Generally, the cooler life can determine the blast furnace life. Theslag-metal skull frozen on the cooler can separate the cooler from the hot gas flow in blastfurnace. The key problem is how to freeze liquid slag-metal on the cooler, and the main measure isto decrease the hot surface temperature of the cooler. The computational technology of heat transferwas practically used for long campaign blast furnace design. The optimum design of the cast ironstave, copper stave, plate-stave combined system and flange stave was given by the computingresults. According to the results, the optimum arrangement of different coolers (cast iron or copperstave, flange stave and plate-stave combined system) on different height of blast furnace wall canbe found through all these temperature fields.

Designing for Long Campaign Life Blast Furnace (1)──The Mathematical Model of Temperature Field for Blast Furnace Lining and Cooling Apparatus and New Concept of Long Campaignship Blast Furnace Cooler Design

The physical and mathematical model of temperature field for blast furnace stave coolers was established. The computation results show that the heat resistance of 2-6 mm water scale within the cooling pipe is about 7%-20% of the total heat resistance of cooling stave body, as for drilling duct type, the heat resistance of 2-6 mm water scale is about 88%-98% of the total heat resistance. Using drilling duct or full cast pipe can eliminate gas clearance and coating layer between pipes and cast iron body and reduce the heat resistance of the cooler sharply and improve the coefficient of heat transfer to a great extent. The water velocity within coolers can be kept at the 1evel of 0.5- 1 .5 m/s, the higher water velocity can not decrease the hot surface temperature, but can increase energy consumption for cooling water.

Ammonium Salt Deposition Characteristics in an Air Cooler System Based on the Coupling of Fluid Flow and Heat Transfer Simulation

The ammonium salt corrosion is a typical failure mode for the hydrogenation reaction effluent air cooler(REAC) system. In order to investigate the corrosion characteristics in the REAC system, numerical simulations were performed by using the mixture model, the heating transfer model, and the particles tracking model. The results show that the differences between the temperature and the velocity at each cross section of the first-row and second-row tubes are small. The inertia of the particles plays an important role in the particle’s deposition, and the smaller particles distribute more uniformly in the air cooler. However, for larger particles, they prefer falling from the inner side of the vertical elbow, and preferentially depositing at the inlet header and pipes before saturation. In the heat exchanger tubes, the particle deposition number is larger in the second-row tubes than that in the first-row tubes, and the high-risk tubes mainly concentrate on the middle and right side of the air cooler. The kinetic parameters of the particles are in accordance with the blocking-prone position in many real operating conditions.

Designing for Long Campaign Life Blast Furnace (2)-The Simulation of Temperature Field of Lining and Cooling Apparatus

Through the numerical modeling of temperature field for Blast Furnace (BF) lining and stave coolers, it can tell designers how to design a cooler which the hot surface temperature is less than its critical temperature under very high heat flux. Applying low heat re- sistance lining and staves cooler to BF is good for a layer of slag skull frozen on the hot surface of cooling stave. As long as the slag skull can stand, the furnace wall is stable and the heat loss of furnace does not increase. This is the basic principle for designing long campa- ignship BF.

Experimental and Numerical Investigation on Erosion Corrosion of the Air Cooler Tube Bundle in a Residue Hydrotreating Unit

Corrosion leakage occurred in the 14th tube bundle in the first row of a residual oil hydrotreating air cooler after operating for two years.The failure location was 0.5 m from the outlet header box.In this paper,the erosion corrosion of the air cooler tube bundle was investigated by experimental and numerical methods.Visual inspection,scanning electron microscopy(SEM),and X-ray diffraction(XRD)experiments were performed,and the failure morphology and material composition confirmed that the damage was caused by erosion corrosion.The shear stress transport k–ωturbulence model(SST-k–ω)was then used to investigate the flow and erosion corrosion characteristics,combined with mass transfer,corrosion rate,and ionization equilibrium models.The numerical simulation results revealed that the water phase volume fraction increased with flow and heat transfer in the fluid,which increased the mass flow rate and concentration of hydrogen sulfide.The mass transfer coefficient and corrosion rate were proposed as important parameters to characterize erosion corrosion.Moreover,the local concentration of wall shear stress was found to increase the risk of erosion corrosion.The predicted high-risk area was consistent with the actual failure area,which verified that this failure incident was attributable to erosion corrosion by the water phase.

Design of an efficient collector for the HIAF electron cooling system

A collector with high perveance,efficient recu-peration,and low secondary emissions is required for the 450-keV electron cooler in the HIAF accelerator complex.To optimize the collection efficiency of the collector,a simulation program,based on the Monte Carlo simulations,was developed in the world’s first attempt to calculate the electron collection efficiency.In this program,the backscattering electrons and secondary electrons generated on the collector surface are calculated using a Monte Carlo approach,and all electron trajectories in the collector region are tracked by the Runge–Kutta method.In this paper,the features and structure of our program are described.The backscattering electron yields,with various collector surface materials,are calculated using our pro-gram.Moreover,the collector efficiencies for various col-lector structures and electromagnetic fields are simulated and optimized.The measurement results of the collection efficiency of the HIAF collector prototype and the CSRm synchrotron are also reported.These experimental results were in good agreement with the simulation results of our program.

Functional Link Neural Network for Predicting Crystallization Temperature of Ammonium Chloride in Air Cooler System

The air cooler is an important equipment in the petroleum refining industry.Ammonium chloride(NH4 Cl)deposition-induced corrosion is one of its main failure forms.In this study,the ammonium salt crystallization temperature is chosen as the key decision variable of NH4 Cl deposition-induced corrosion through in-depth mechanism research and experimental analysis.The functional link neural network(FLNN)is adopted as the basic algorithm for modeling because of its advantages in dealing with non-linear problems and its fast-computational ability.A hybrid FLNN attached to a small norm is built to improve the generalization performance of the model.Then,the trained model is used to predict the NH4 Cl salt crystallization temperature in the air cooler of a sour water stripper plant.Experimental results show the proposed improved FLNN algorithm can achieve better generalization performance than the PLS,the back propagation neural network,and the conventional FLNN models.

Numerical Simulation and Optimization of Perforated Tube Trolley in Circular Cooler

Three symmetrically perforated tubes were arranged in the circular cooler trolley as auxiliary cooling inlet to improve the cooling performance of the sintered body during the production process. Fluent 15.0 has been used to simulate the process;the study shows that the perforated tube structure trolley has changed the temperature field within the sintering area, thereby improving the sintering area of the cooling effect and uniformity, also greatly reducing the cooling time. Compared with the traditional trolley, the best structure of the porous tube trolley has reduced 41% cooling time and increased 50% waste heat recovery.

表面冷却器的设计性计算程序处理

表冷器的热工计算分为二种类型.一种是设计性的;即根据已知被处理空气的初,终状态来选用表冷器型号;另一种是校核性的;即对于已选用好了表冷器,来校核其能将某种初状态的空气处理到什么样程度的终状态.

Enhancement of electron–ion recombination rates at low energy range in the heavy ion storage ring CSRm

Recombination of Ar^(14+), Ar^(15+), Ca^(16+), and Ni^(19+) ions with electrons has been investigated at low energy range based on the merged-beam method at the main cooler storage ring CSRm in the Institute of Modern Physics, Lanzhou,China. For each ion, the absolute recombination rate coefficients have been measured with electron–ion collision energies from 0 meV to 1000 meV which include the radiative recombination(RR) and also dielectronic recombination(DR)processes. In order to interpret the measured results, RR cross sections were obtained from a modified version of the semiclassical Bethe and Salpeter formula for hydrogenic ions. DR cross sections were calculated by a relativistic configuration interaction method using the flexible atomic code(FAC) and AUTOSTRUCTURE code in this energy range. The calculated RR + DR rate coefficients show a good agreement with the measured value at the collision energy above 100 meV.However, large discrepancies have been found at low energy range especially below 10 meV, and the experimental results show a strong enhancement relative to the theoretical RR rate coefficients. For the electron–ion collision energy below 1 meV, it was found that the experimentally observed recombination rates are higher than the theoretically predicted and fitted rates by a factor of 1.5 to 3.9. The strong dependence of RR rate coefficient enhancement on the charge state of the ions has been found with the scaling rule of q^(3.0), reproducing the low-energy recombination enhancement effects found in other previous experiments.

Experimental Investigation of Capacity Control Scheme on System Performance for a Machine Tool Cooler

Highly accurate manufacture in machining industry can only be obtained with precise temperature control of the coolant （oil or water）.Machine tool with more accurate,stable and advanced the precision of the working component cannot be developed without appropriate cooling.However,the machine tool coolers are facing the control hunting of cooling temperature and the dramatic variation of heat load in high-accuracy machining.The main objective of this study is to evaluate the influence of the hot-gas by-pass scheme and suction regulation for capacity control of a machine tool cooler system.In this study,experimental investigation on both hot-gas by-pass scheme and suction valve regulation for capacity control has been proposed.Effects of using capillary tube and thermostatic expansion valve along with different capacity control scheme have been investigated extensively in an environmental testing room.Cooling performance and power consumption of the cooler system have been measured and analyzed as well by comparing with different opening percentage of throttling valve under specific coolant temperature.The experimental results reveal that the power consumption will reduce slightly by capacity control using the hot-gas by-pass scheme but the coefficient of performance （COP） of the overall system will decrease.Lower coolant temperature will result in higher compressor power consumption as well.While conducting suction valve regulating for capacity control,energy-saving at 10%-12% can be obtained by using thermostatic expansion valve under different evaporator load.It also reveals that suction valve regulation along with adequate choice of thermostatic expansion valve can provide alternative choice for steady capacity control and substantial energy-saving.The proposed cooler systems with different capacity control schemes are not only more cost-effective than inverter driven system,but also can perform energy-saving and precise temperature control specific for high-accuracy machine tool cooling.

Numerical Simulation and Experimental Studies of Air Treatment Process with Water Spray of One Row Counter Flow

The present work is focused on heat and mass transfer in a direct evaporative air cooler of one row counter flow spray. Models of the two-phase flow in such a air treatment system have been developed. The fields of temperature and relative humidity in spray chamber, as well as the trajectories of sprayed drops have been obtained by numerical method. Experiments aiming at quantifying the system performance and its influence factors have been conducted. It indicates that the increase of air velocity and water/air ratio while the decrease of nozzle density are favorable. The performance of the system of parallel flow spray and counter flow spray have been compared by means of humidifying efficiency. Comparison between numerical simulation and experimental results demonstrate good agreement for outlet air temperature with a maximum error of 8% observed for air relative humidity.

MATERIALS FOR RETENTION OF LIQUID CRYOGENS CONTAINED IN SPACE QUALIFIED COOLER

A new kind of material used in liquid cryogen cooler has been found and investigated in our group It is anticipated that the materials can be applied in the conditions of launching, rotation in any orientation and weightlessness. The mechanism on which the material relies is similar to 'sponge' trapping the liquid cryogens within its micro-pores with surface tension. Preliminary tests have been performed on wicking. Also,we apply the materials to the cryogenic optical cooler whjch needs to be maintained within the temperuture range of 80-100 K. The results are satisfactory.