Implementation of heat exchanger performance testing system of heat transfer and flow resistance

A heat transfer performance testing system is presented with its hardware structure, operation principle, and software control and measurement system. Working fluids of the subsystem include thermal conducting oil, compressed air, glycol water solution and water as the heating fluids, and air and water as the cooling fluids. The heat transfer performance testing of heat exchangers can be conducted not only for a conventional one heating fluid to one cooling fluid, but also for a compound air cooling heat exchanger with two or three heating fluids in parallel or in series. The control and measurement system is implemented based on a LabVIEW software platform, consisting of the data acquisition and process system, and the automotive operation and control system. By using advanced measuring instruments combined with sound computer software control, the testing system has characteristics of a compact structure, high accuracy, a wide range of testing scope and a friendly operation interface. The uncertainty of the total heat transfer coefficient K is less than 5%. The testing system provides a reliable performance testing platform for designing and developing new heat exchangers.

Strategy for Synthesis of Flexible Heat Exchanger Networks Embedded with System Reliability Analysis

System reliability can produce a strong influence on the performance of the heat exchanger network(HEN).In this paper,an optimization method with system reliability analysis for flexible HEN by genetic/simulated annealing algorithms(GA/SA) is presented.Initial flexible arrangements of HEN is received by pseudo-temperature enthalpy diagram.For determining system reliability of HEN,the connections of heat exchangers(HEXs) and independent subsystems in the HEN are analyzed by the connection sequence matrix(CSM),and the system reliability is measured by the independent subsystem including maximum number of HEXs in the HEN.As for the HEN that did not meet system reliability,HEN decoupling is applied and the independent subsystems in the HEN are changed by removing decoupling HEX,and thus the system reliability is elevated.After that,heat duty redistribution based on the relevant elements of the heat load loops and HEX areas are optimized in GA/SA.Then,the favorable network configuration,which matches both the most economical cost and system reliability criterion,is located.Moreover,particular features belonging to suitable decoupling HEX are extracted from calculations.Corresponding numerical example is presented to verify that the proposed strategy is effective to formulate optimal flexible HEN with system reliability measurement.

Corrosion risk analysis of tube-and-shell heat exchangers and design of outlet temperature control system

This study deals with the high-risk shell-and-tube heat exchangers in the effluent system of hydrogenation reaction of the petrochemical industry.The process of hydroprocessing reactor effluent system is simulated in Aspen Plus to study the distribution of corrosive medium in the three phases of oil,gas and water.The least-squares method is utilized to calculate the ammonium salt crystallization temperature.Then,the heat exchanger with risk of ammonium salt crystal corrosion is identified.Dynamic mathematical modeling of the heat exchanger is established to determine the transfer function.A temperature control system with proportional integral derivative(PID)control of the heat exchanger outlet is designed,and fuzzy logic is used to implement self-tuning of PID parameters.After MATLAB simulation,the results show the control system can achieve rapid control of the heat exchanger outlet temperature.

Modeling and Optimization for Heat Exchanger Networks Synthesis Based on Expert System and Genetic Algorithm

A new superstructure form of heat exchanger networks (HEN) isproposed based on expert system system (ES). The new superstructureform is combined with the practical engineering. The differentinvestment cost formula for Different heat exchanger is alsopresented based on ES. The mathematical model for the simultaneousoptimization Of network configuration is established and solved by agenetic algorithm. This method can deal with larger scale HENsynthesis and the optimal HEN configuration is obtainedautomatically. Finally, a case study is presented to Demonstrate theeffectiveness of the method.

A systematic strategy for multi-period heat exchanger network retrofit under multiple practical restrictions

A systematic strategy for retrofit of the multi-period heat exchanger network （HEN） on the basis of the multi- objective optimization is developed. In this three-stage procedure, a simplified multi-objective optimization model of the multi-period lIEN is first established and then solved to target the retrofit, aiming to minimizing the total annual cost and total annual CO2 emissions. The obtained Pareto front represents series of retrofit targets under different emission limitations, from which the most desirable one can be selected. The matching of the existing and the required heat exchangers is further implemented to finalize the retrofit, which will meet the practical retrofit requirements and matching restrictions. The application of the proposed procedure is illustrated through a case study of a HEN in a vacuum gas oil hydro-treating unit.

A numerical study on heat transfer enhancement and design of a heat exchanger with porous media in continuous hydrothermal flow synthesis system

The aim of this study is to use a new configuration of porous media in a heat exchanger in continuous hydrothermal flow synthesis(CHFS)system to enhance the heat transfer and minimize the required length of the heat exchanger.For this purpose,numerous numerical simulations are performed to investigate performance of the system with porous media.First,the numerical simulation for the heat exchanger in CHFS system is validated by experimental data.Then,porous media is added to the system and six different thicknesses for the porous media are examined to obtain the optimum thickness,based on the minimum required length of the heat exchanger.Finally,by changing the flow rate and inlet temperature of the product as well as the cooling water flow rate,the minimum required length of the heat exchanger with porous media for various inlet conditions is assessed.The investigations indicate that using porous media with the proper thickness in the heat exchanger increases the cooling rate of the product by almost 40% and reduces the required length of the heat exchanger by approximately 35%.The results also illustrate that the most proper thickness of the porous media is approximately equal to 90% of the product tube's thickness.Results of this study lead to design a porous heat exchanger in CHFS system for various inlet conditions.

Energy Efficient Air Conditioning System Using Geothermal Cooling-Solar Heating in Gujarat, India

It is well known that one unit of electrical energy saved is equal to more than two units produced. One way of economizing the power is utilization of energy efficient systems at all locations. In the present study, the air conditioning system is analysed and an innovative way is suggested. We use natural low temperature of shallow sub surface (1 - 3 m) of the earth—geothermal cooling system. It is known that majority of the households and the apartment complexes in India have two tanks for water storage. One is the underground water sump and the other is the overhead water tank. In our study, we use these two water storage systems for space cooling during summer and also for heating during winter. The main aim of our paper is air-conditioning of the space in an economic way to save electricity. It is based on a simple idea of transferring the low temperature from underground water sump to the room in the house using water as a mode of transport. Since India is a tropical country located at low latitude, most of the year, the air temperature is high and demands space cooling. However, for a couple of months during severe winter months (Dec.-Jan.) at Ahmedabad, heating of the space is required. For heating the space, we suggest to use the well-known solar water heater. Effective use of heat exchanger is shown through computation, modelling schemes and lab experiment. We recommend geothermal cooling for 10 months in a year and solar hot water system during 2 months of winter. It is observed that the ambient air temperature of 35°C - 40°C in the room can be brought down to 26°C without much consumption of electricity. In a similar manner, the room temperature at night (13°C) during winter in Ahmedabad can be increased to 27°C through circulation of water from solar water heater in the heat exchanger.

Investigating Two Configurations of a Heat Exchanger in an Indirect Heating Integrated Collector Storage Solar Water Heating System

Due to the environmental impact of energy usage and increased price of fusel fuel, consumers need to be encouraged to use renewable energy sources. The IHICSSWHS （indirect heating integrated collector storage solar water heater system） is one of the most economical systems. It incorporates the collection of a solar energy component and a hot water storage component in one unit. The objective of this study was to investigate ways to enhance the thermal performance of the system. Two configurations of the system were studied： system with double row HX （heat exchanger） and tube length of 16.2 m, and system with single row HX and tube length of 8.1 m and 10.8 m. The service water tube inside diameter was also varied to 10.7 mm and 17.1 mm The steady state continuity, momentum and energy equations were numerically solved, using FLUENT software. A standard k-w turbulent model and surface-to-surface radiation model were used. The result showed that the system of 10.8 m tube length and single row HX provided higher outlet temperature than the system of 16.2 m and double row HX. Therefore, a significant reduction in cost and power usage can be achieved by using a single row HX.

Strong self-flushing technique for heat exchanger of sewage source heat pump system

To better remove the contamination on the surface of a heat-exchanger in urban sewage source heat pump system （USSHPS）, this paper analyzes the feasibility of strong self-flushing on the basis of experiments and presents a new on-line self-flushing technique, which alternately flushes part of heat transfer tubes. In addition, operation principles and the structure of the new heat-exchanger are introduced and the feasible economi- cal and technological cleaning plans are given by design calculation and scheme comparison. The result shows that keeping each tube washed for one minute with 5 m/s, the operating cost is lower than ￥5 and when one flushing pump ahemately flushes 10-20 heat exchangers, the saved costs of flushing 10 tubes alternately are over 4 times of the increased costs.

CFD-Based Optimization of a Diesel Engine Waste Heat Recycle System

A dedicated heat exchanger model is introduced for the optimization of heavy-duty diesel engines.The model is a prerequisite for the execution of CFD simulations,which are used to improve waste heat recovery in these systems.Several optimization methods coupled with different types of working fluids are compared in terms of exergy efficiency and heat exchanger complicity.The three considered optimization methods all lead to significant improvements in the R245fa and R1233zd systems with a comparatively low evaporation temperature.The optimal R245fa system has the highest efficiency increase(77.49%).The cyclopentane system displays the highest efficiency among the optimized ORC(Organic Rankine Cycle)systems,yet achieved by using a much heavier evaporator HEC(Heat Exchanging Core).In contrast,the 96.84%efficiency increase for the optimized R1233zd is achieved with only 68.96%evaporator weight.

Optimal design of the first stage of the platefin heat exchanger for the EAST cryogenic system

The size of the heat exchanger is an important factor determining the dimensions of the cold box in helium cryogenic systems. In this paper, a counter-flow multi-stream plate-fin heat exchanger is optimized by means of a spatial interpolation method coupled with a hybrid genetic algorithm.Compared with empirical correlations, this spatial interpolation algorithm based on a kriging model can be adopted to more precisely predict the Colburn heat transfer factors and Fanning friction factors of offset-strip fins. Moreover, strict computational fluid dynamics simulations can be carried out to predict the heat transfer and friction performance in the absence of reliable experimental data. Within the constraints of heat exchange requirements, maximum allowable pressure drop, existing manufacturing techniques and structural strength, a mathematical model of an optimized design with discrete and continuous variables based on a hybrid genetic algorithm is established in order to minimize the volume. The results show that for the first-stage heat exchanger in the EAST refrigerator, the structural size could be decreased from the original2.200？×？0.600？×？0.627（m^3） to the optimized 1.854？×？0.420？×？0.340（m3）, with a large reduction in volume. The current work demonstrates that the proposed method could be a useful tool to achieve optimization in an actual engineering project during the practical design process.

The heat recovery simulation in the system of dry granulation of the steel slag

In present,the wet-based pattern is mainly adopted to deal with the steel slag by steel plant at home and abroad,the wet-based technology has some defects;Wasting of water,pollution of the environment,and the slag has not been fully recycled.This paper presents a new method,which is aimed to realize dry granulation,waste heat recovery and comprehensive utilizing the steel slag.According to the ideas of wind quenching granulation,the heating slag from the converter furnace,was bring to the granulation heat exchange system,through the process of breaking in a container,the granulation heat exchange system has the functions of feeding continuously and heat exchange.The heat air,through the diversion tubes,could be recycled in removing the dust.The granulation slag could be bring to a confined roller,granulating and cooling secondarily.The roller export was connected to a magnetic separator.The separated iron could be recycled,and the remaining slag could also be reused as building materials,in process of stabilization and secondary magnetic separation.The heated air could be guided into the boiler to generate the steam,which can be used to generate electricity,or use as cleaned energy,realizing the target to recycle the waste heat in steel slag.The highlights of the new method are dry granulation and waste heat recovery.This paper states the process of heat exchange between the air and the steel slag in the system of granulation heat exchange in the new technical process.In theory,it has been proved reasonable with the the system of granulation heat exchange,and also the work conditions has been optimized.

A Pole Assignment Design Method of Process Control System for Tubular Heat Exchanger

This Paper has first studied the simplified model of tubular heat exchanger which is widely used in the industry and other field.On the basis of reference 2,a new pole assignment design method of pro-cess control system with derivative control action is found.For the above system,the method and the for-mation which calculate the feedback matrix K and gain matrix L is given,and the simulation of the system is made.

Optimizing Grids Demand Reduction through Enhanced Heat Transfer in Low-Temperature Waste Heat Driven ORC Systems

With increasing awareness of energy conservation and environmental protection, the Organic Rankine Cycle (ORC) system has gained significant attention. This technology enables the recovery of industrial waste heat, waste incineration heat, and renewable energy sources such as geothermal heat, biomass energy, and solar energy at lower temperatures. However, the low-grade heat source utilized in ORC systems faces a challenge to achieving high power generation efficiency and output power. Therefore, enhancing the power generation capacity of ORC systems is a key research focus in this field. An entranced heat exchanger ORC system with the screw expander driven by the low-temperature heat source is established to investigate the relevant performance. Hot water temperature from 77°C to 132°C is adopted for performance analysis, while the environmental temperature is approximately 25°C. Refrigerant R245fa is selected as the working fluid, and the screw expander is employed for power generation. It is worth noting that the entranced heat exchanger ORC system has significant potential for low-temperature heat recovery. Experimental results indicate that the maximum power output is 12.83 kW, which is obtained at around 105°C hot water inlet temperature. Correspondingly, the average power output remains 11.75 kW, revealing the system’s high stability for power generation. The implementation of a plate heat exchanger for enhanced heat transfer has enabled a 50% reduction in system size compared to traditional shell-tube type ORC systems. Besides, economic calculations demonstrate substantial benefits associated with the ORC system. The calculations indicate an internal benefit of 560,000 RMB/year, accompanied by notable external benefits such as an energy saving and emission reduction potential of up to 784 t CO2 per year. Moreover, the payback period is 2.23 years. It shows a remarkable improvement in terms of performance and excellent economic benefits. As a result, the novel ORC presents a promising alternative for low-grade heat utilization as compared to conventional small-scale ORC systems.

Comparison and Performance Analysis of Heat Storage Equipment in Solar Heating System

Solar heating system is widely used recently. Heat storage equipment is the guarantee for steady performance of solar heating system. A design of latent heat storage exchanger with submerged coil was introduced with the structure, working principle, and the main advantages. This heat exchanger was integrated into solar heating system as the heat storage equipment. Advantage comparison of the designed heat exchanger in solar heating system with hot water tank was carried out. The analysis results show that the latent heat storage exchanger is superior to hot water tank obviously. The heat exchanger performance parameters and variations of these parameters are got： （1） with the increase of phase change material （PCM） volume ratio, heat storage equipment volume ratio decreases; （2） heat storage efficiency has the same varying tendency with outdoor and air temperature; while the bigger PCM volume ratio is, the weaker the effect of outdoor air temperature on heat storage efficiency is; （3） heat storage capacity and heat storage efficiency increase together; when PCM volume ratio is big, heat storage efficiency is high and the system can begin operating effcienfly and quickly; （4） with the increase of heat storage capacity, life cyde operation cost （LCOC） of system increases gradually in high speed; but with the increase of PCM volume ratio, the difference between the two systems LCOCs becomes smaller and smaller; （5） the reasonable range of PCM volume ratio is 0.5 - 0.7. Temperature characteristic analysis shows that, with the filled PCM, heat storage medium temperature presents several segments at different time, under conditions of different heat storage capacity and different PCM state.

Heat Exchanging Process of Metal Target under Millisecond Pulsed Laser Shocking

Laser plays an important role in synthesizing nanometer material. A three-dimensional mathematical model is established in this paper when single pulsed millisecond laser shocks the surface of the metal target at a liquid-solid interface. By changing laser power density and target size, the temperature field variation of the metal target is investigated. Results show that the generation process of nanoparticles includes heating, melting and boiloff.

Thermal Characterization of Lauric Acid and Stearic Acid Binary Eutectic Mixture in Latent Heat Thermal Storage Systems with Tube and Fins

In order to obtain the suitable phase change material（PCM） with low phase change temperature and improve its heat transfer rate, experimental investigation was conducted. Firstly, different mass ratios of lauric acid（LA） and stearic acid（SA） eutectic mixtures were prepared and characterized by differential scanning calorimetry（DSC）. Then, the performance of eutectic mixture during charging process under different fin widths in vertical condition, and performance during charging and discharging processes under different inlet temperature heat transfer fluid（HTF） in horizontal condition were investigated, respectively. The results revealed that the LA-SA eutectic mixture had the suitable phase change temperature and desired latent heat for low-temperature water floor heating system. Wide fins and high inlet temperature HTF significantly enhanced the transfer rate and decreased the melting time.

Research on shell-side heat and mass transfer with multi-component in LNG spiral-wound heat exchanger under sloshing conditions

The spiral-wound heat exchanger(SWHE) is the primary low-temperature heat exchanger for large-scale LNG plants due to its high-pressure resistance, compact structure, and high heat exchange efficiency. This paper studied the shell-side heat and mass transfer characteristics of vapor-liquid two-phase mixed refrigerants in an SWHE by combining a multi-component model in FLUENT software with a customized multicomponent mass transfer model. Besides, the mathematical model under the sloshing condition was obtained through mathematical derivation, and the corresponding UDF code was loaded into FLUENT as the momentum source term. The results under the sloshing conditions were compared with the relevant parameters under the steady-state condition. The shell-side heat and mass transfer characteristics of the SWHE were investigated by adjusting the component ratio and other working conditions. It was found that the sloshing conditions enhance the heat transfer performance and sometimes have insignificant effects. The sloshing condition is beneficial to reduce the flow resistance. The comprehensive performance of multi-component refrigerants has been improved and the improvement is more significant under sloshing conditions, considering both the heat transfer and pressure drop.These results will provide theoretical support for the research and design of multi-component heat and mass transfer enhancement of LNG SWHE under ocean sloshing conditions.

Topology Optimization of Two Fluid Heat Transfer Problems for Heat Exchanger Design

Topology optimization of thermal-fluid coupling problems has received widespread attention.This article proposes a novel topology optimization method for laminar two-fluid heat exchanger design.The proposed method utilizes an artificial density field to create two permeability interpolation functions that exhibit opposing trends,ensuring separation between the two fluid domains.Additionally,a Gaussian function is employed to construct an interpolation function for the thermal conductivity coefficient.Furthermore,a computational program has been developed on the OpenFOAM platform for the topology optimization of two-fluid heat exchangers.This program leverages parallel computing,significantly reducing the time required for the topology optimization process.To enhance computational speed and reduce the number of constraint conditions,we replaced the conventional pressure drop constraint condition in the optimization problem with a pressure inlet/outlet boundary condition.The 3D optimization results demonstrate the characteristic features of a surface structure,providing valuable guidance for designing heat exchangers that achieve high heat exchange efficiency while minimizing excessive pressure loss.At the same time,a new structure appears in large-scale topology optimization,which proves the effectiveness and stability of the topology optimization program written in this paper in large-scale calculation.

Combining reinforcement learning with mathematical programming:An approach for optimal design of heat exchanger networks

Heat integration is important for energy-saving in the process industry.It is linked to the persistently challenging task of optimal design of heat exchanger networks(HEN).Due to the inherent highly nonconvex nonlinear and combinatorial nature of the HEN problem,it is not easy to find solutions of high quality for large-scale problems.The reinforcement learning(RL)method,which learns strategies through ongoing exploration and exploitation,reveals advantages in such area.However,due to the complexity of the HEN design problem,the RL method for HEN should be dedicated and designed.A hybrid strategy combining RL with mathematical programming is proposed to take better advantage of both methods.An insightful state representation of the HEN structure as well as a customized reward function is introduced.A Q-learning algorithm is applied to update the HEN structure using theε-greedy strategy.Better results are obtained from three literature cases of different scales.