Simulation Study on the Heat Transfer Characteristics of a Spray-Cooled Single-Pipe Cooling Tower

The current study focuses on spray cooling applied to the heat exchange components of a cooling tower.An optimization of such processes is attempted by assessing different spray flow rates and droplet sizes.For simplicity,the heat exchanger of the cooling tower is modeled as a horizontal round tube and a cooling tower spray cooling model is developed accordingly using a computational fluid dynamics(CFD)software.The study examines the influence of varying spray flow rates and droplet sizes on the heat flow intensity between the liquid layer on the surface of the cylindrical tube and the surrounding air,taking into account the number of nozzles.It is observed that on increasing the spray flow strength,the heat flow intensity and extent of the liquid film in the system are enhanced accordingly.Moreover,the magnitude of droplet size significantly impacts heat transfer.A larger droplet size decreases evaporation in the air and enhances the deposition of droplets on the round tube.This facilitates the creation of the liquid film and enhances the passage of heat between the liquid film and air.Increasing the number of nozzles,while maintaining a constant spray flow rate,results in a decrease in the flow rate of each individual nozzle.This decrease is not favorable in terms of heat transfer.

Designing an Experimental Device for Swinging Excitation Spray Cooling

In this paper,we introduce the design principle of the oscillating excited spray cooling experimental device.We then designed an oscillating excited spray cooling experimental device.By using the device,the swaying motion can be realized through the control system,and the motion of the droplet under different vibration frequencies can be observed.By measuring the liquid flow rate and pressure,the changes in liquid flow rate,pressure,and temperature with time under different vibration frequencies were studied.The trajectory of the droplet and the temperature distribution of the droplet under different vibration frequencies could be observed.The device has a simple structure,is easy to control,and can achieve continuous observation of the spray cooling process.

The Use of Single-Phase Immersion Cooling by Using Two Types of Dielectric Fluid for Data Center Energy Savings

Data centers are recognized as one of the most important aspects of the fourth industrial revolution since conventional data centers are inefficient and have dependency on high energy consumption,in which the cooling is responsible for 40%of the usage.Therefore,this research proposes the immersion cooling method to solving the high energy consumption of data centers by cooling its component using two types of dielectric fluids.Four stages of experimentalmethods are used,such as fluid types,cooling effectiveness,optimization,and durability.Furthermore,benchmark software is used to measure the CPU maximum work with the temperature data performed for 24 h.The results of this study show that the immersion cooling reduces 13℃ lower temperature than the conventional cooling method which means it saves more energy consumption in the data center.The most optimum variable used to decrease the temperature is 1.5 lpm of flow rate and 800 rpm of fan rotation.Furthermore,the cooling performance of the dielectric fluids shows that the mineral oil(MO)is better than the virgin coconut oil(VCO).In durability experiment,there are no components damage after five months immersed in the fluid.

Development of Energy-storing High Pressure Spray Cooling System

The greenhouse has been increasingly used in the breeding industry. However, the high temperature inside the greenhouse in summer has not been effectively addressed. The spray cooling system sprays tiny droplets into the air. Thus the water molecules will be vaporized, absorbing heat and reducing ambient temperature. It is the only cooling method that can be used to cool the uneasily-sealed flexible greenhouse. We developed an energy-storing high pressure spray cooling system. The ordinary water pump is used as the source of high-pressure water. The partial kinetic energy is stored in the energy-storing tubes. When the water pump is stopped, the energy produced by releasing the compressed air can still be used to maintain the spray. And thus the use-cost and systematic wear would be reduced. The cooling system only requires 1 kilowatt hour of power per day. It has been widely used in summer to cool the breeding sheds. After a recent continuous improvement, its functions have been extended to disinfection, removing dust, humidifying and immunizing animals. In addition, it can also be used for the cooling and humidifying of squares, venues and streets in summer. The energy-storing high pressure spray cooling system has a broad application prospect.

Numerical Simulation of Three-dimensional Heat and Mass Transfer in Spray Cooling of Converter Gas in a Venturi Scrubber

In order to predict the pressure drop, collection efficiency, velocity, temperature and mole fraction of vapor in an industrial venturi scrubber with water spraying for converter gas cooling, a three-dimensional model of heat and mass transfer with phase change is established. The gas flow and liquid droplets are treated as a continuous phase with a Eulerian approach and as a discrete phase with a Lagrangian approach, respectively. The coupled problem of heat, force, and mass transfers between gas flow and liquid droplets is solved by a commercial computational fluid dynamics（CFD） package, FLUENT. The numerical results show that the water injections have an important influence on the distributions of pressure, velocity, temperature, and mole fraction of vapor, especially for the spraying region in the throat. In the spraying region, the pressure drop is higher and the velocity is lower than in other regions due to the gas-droplet drag, while the temperature is lower because the droplet absorbs large amounts of heat from the high temperature gas and the mole fraction of vapor is higher due to the phase change of the liquid droplet. A number of cases with different Water-to-gas volume flow ratios and baffle openings were simulated. The dependence of pressure drop, velocity, temperature, mole fraction of vapor, and collection efficiency on both the water-to-gas volume flow ratio and baffle opening are analyzed. The good agreements between simulation results and experiment data of pressure drop, temperature, and collection efficiency validate the model. The model should facilitate optimization of the venturi scrubber design in order to give better performance with lower pressure drops and higher collection efficiency.

Transient Heat Transfer Study of Direct Contact Condensation of Steam in Spray Cooling Water

We conducted a transient experimental investigation of steam–water direct contact condensation in the absence of noncondensible gas in a laboratory-scale column with the inner diameter of 325 mm and the height of 1045 mm. We applied a new analysis method for the steam state equation to analyze the molar quantity change in steam over the course of the experiment and determined the transient steam variation. We also investigated the influence of flow rates and temperatures ofcooling water on the efficiency ofsteam condensation. Our experimental results show that appropriate increasing of the cooling water flow rate can significantly accelerate the steam condensation. We achieved a rapid increase in the total volumetric heat transfer coefficient by increasing the flow rate of cooling water, which indicated a higher thermal convection between the steam and the cooling water with higher flow rates. We found that the temperature ofcooling water did not play an important role on steam condensation. This method was confirmed to be effective for rapid recovering ofsteam.

Experiment on Spray Cooling Performance with Different Additives of Different Mass Fraction

As an efficient cooling method for high heat flux field,spray cooling has a great application potential on aircraft directed energy weapon cooling.Based on previous research results,an experimental system of open-loop spray cooling was established,and the potassium chloride aqueous solutions and ethylene glycol aqueous solutions with different mass fractions were applied to investigate the influence of different additives on spray cooling system performance.Besides,theoretical analysis was conducted according to the droplet breakage principle and the characteristic parameters of fluid mechanics.The results indicate that heat transfer can be enhanced by adding potassium chloride up to a certain concentration and then decrease with higher concentration.Heat transfer is deteriorated with the increase of ethylene glycol concentration.Both of the two additives can reduce the freezing point of the system,and ethylene glycol is preferred to improve the application range of the system in consideration of the corrosion of salt solution.

Ultra Fast Spray Cooling and Critical Droplet Daimeter Estimation from Cooling Rate

Spray cooling is an effective tool to dissipate high heat fluxes from hot surfaces. This paper thoroughly investigates the effects of spray parameters on the cooling time and cooling rate under varying inlet pressure using water as the coolant. Cylindrical samples of stainless steel with constant diameter, D = 25 mm, and thickness δ: 8.5 mm, 13 mm, 17.5 mm and 22 mm were investigated. Critical droplet diameter to achieve an ultrafast cooling rate of 300°C/s was estimated by using analytical model for samples of varying thickness. At an inlet pressure of 0.8 MPa, maximum cooling rates of 424.2°C/s, 502.81°C/s and 573.1°C/s were achieved for wall super heat ΔT = 600°C, 700°C and 800°C respectively.

Experimental Study on Spray Cooling Performance of Pressure Atomizing Nozzle

Aiming at the problem of air-cooled condenser output limit, a spray humidification system was presented to reduce the inlet air temperature. The pressure atomizing nozzle TF8 was chosen for inlet air spray cooling, and the spray cooling experiment with different layouts of nozzles were conducted. Through heat and mass transfer analysis, the cooling effect fitting correlation was acquired with evaporative cooling being the major cooling mechanism. The experimental results under different nozzle layouts show that when the product of dry ball and wet ball temperature difference and spray rate is smaller than 75 ~C-m3/h, opening the TF8 nozzles in row 1 and row 2 （row distance is 500 mm） has better cooling effect than those in row 1 and row 3 （row distance is 1 000 mm）, while when the product is larger than 75 ~C＇m3/h, opening the TF8 nozzles in row 1 and row 3 is superior in cooling effect to those in row 1 and row 2.

Effects of air-atomized water spray cooling device structure on the quenching process,microstructure,and properties of wear-resistant steel

With its high strength and hardness, wear-resistant steel has become an important material in the field of construction machinery manufacturing.Given that quenching technology is a crucial component of wear-resistant steel production, the selection of the cooling method to be used during this process is important.In this study, the feasibility of quenching wear-resistant steel by air-atomized water spray cooling was studied, and the cooling rate, microstructure, and hardness of wear-resistant steel under various cooling device structures were analyzed.The results reveal that the air-atomized water spray cooling method is an effective technique in quenching wear-resistant steel.Furthermore, martensite and uniform hardness were obtained by the air-atomized water spray cooling technique.As the space between the nozzles in each row in the device increased, the cooling rate was reduced during quenching.Meanwhile, the martensite content decreased, and more carbides were observed in the martensitic structure.A mixture comprising self-tempered martensite and bainite was formed at a large distance over a longer period of time.All these factors resulted in lower hardness and worse property uniformity.

Nozzle Spray Diffusivity Changing Law for Ultra Fast Cooling in Hot Strip Mill

Slot nozzle and intensive nozzle can be used in ultra fast cooling equipment. The spray cooling method with higher water pressure can be taken in order to achieve ultra fast cooling for hot rolled strip. Water will be diffused after it is sprayed out from ultra fast cooling nozzle. Spray diffusivity will affect water velocity and penetrability of water into residual water layer on top of the strip,and then it will affect strip cooling effect. Water spraying process can be simulated by Fluent and some conclusions were obtained. Slot nozzle width and outlet velocity within setting range could not affect the length of potential core zone and the spray diffusivity. Intensive nozzle diameter and outlet velocity will affect the length of potential core zone and the spray diffusivity with different extent. These conclusions will provide referenced role for confirming ultra fast cooling nozzle size and distance between ultra fast cooling nozzle and hot rolled strip.

Spray Effect on the Thermal Performances of a Dry Cooling Tower

Pre-cooling the inlet air of a dry cooling tower by means of a spray can improve the tower performance during periods of high temperature.To study the spray effect on the thermal performance of natural draft dry cooling towers(NDDCTs),in this study 3-D numerical simulations of such a process have been conducted using Fluent 16.2(a two-way coupled Eulerian-Lagrangian approach).The considered NDDCT is 120 m high and only half system is simulated due to its structural symmetry.Three different spray strategies have been investigated at a typical crosswind speed of 4 m/s,which is the most frequent wind speed.The results have shown that:(1)The three implemented spray strategies can improve the thermal performance of the studied NDDCT with a vary-ing degree of success.In one case,the heat rejection rate can be increased by 35.2%,and the tower outlet water temperature can be decreased by 2.1℃ when compared with the no spray case;(2)To improve the thermal per-formance of the NDDCT using a small amount of water,the design of the spray pre-cooling system must include more nozzles on the windward and fewer or even no nozzles on the leeward sides of the NDDCT.

Controlled Cooling of Hot Rolled Steel Channels by Water Spraying on the Final Cooling Bed

The objective of this research is to design an effective and relatively simple method for controlled cooling of hot rolled steel channels by water spraying on the final cooling bed after continuous cast steel billets passing through reheating furnace and sequential rolls to form channels. The need for this research arose as the channels were being cooled by forced air draft and natural convection which brought the temperature of the channels to about 270°C (518°F) at the shear stand. Steel at this temperature is too hot for convenient handling by the operators. Additional cooling by water spraying would be an acceptable solution but such cooling should be designed to enable an acceptable microstructure to be developed in the channel, as the microstructure of steel is strongly affected by nonequilibrium cooling through the eutectoid range: the mechanical properties of steel are a consequence of the microstructure. The approach followed in this investigation was first to develop a finite element method (FEM) to determine the temperature profiles in the channel subjected to cooling by water spraying and natural convection and arrive at suitable water spray rates to bring the temperature of the channel at the shear stand to levels suitable for convenient handling. PATRAN was used for preprocessing and ABAQUS for processing and post processing. Next, laboratory experiments were conducted to determine the microstructure and hardness of channels at the spray rates found suitable through FEM, to suggest the water spray rate most suitable for providing a temperature convenient for handling and for developing a desirable microstructure.

Heat Transfer during Spray Cooling of Flat Surfaces with Water at Large Reynolds Numbers

We present a new Nusselt number correlation for spray cooling at large Reynolds numbers and high surface temperatures for water sprays impinging perpendicularly onto a flat plate. A large set of experimental data on spray cooling of hot surfaces with water has been analyzed, including the water temperature effects. For large-scale cooling, such as in industrial processes, large number of injection parameters such as number, type, pressure, and angle of the spray injection has led to a multitude of correlations that are difficult for general and practical applications. However, by synthesizing a set of experimental data where all of the above parameters have been varied, we find that the Nusselt number and therefore the heat transfer coefficient can be cast accurately as a function of the Reynolds number. Water is widely used as the coolant during spray cooling, and has a specific phase change characteristic. At large Reynolds number (Re > 100,000) and surface temperature (Ts > 600°C) ranges, which are of interest in large-scale spray cooling, the effect of water temperature is quite significant as it affects the film boiling close to the surface. This effect also has been parameterized using experimental data.

The mechanics and deformation of high temperature steel frame rapidly cooled by spray water in fire fighting

A finite element is established for analyzing the dynamical mechanics and deformation of steel frame at high temperature when it is rapidly cooled down by spray water in fire fighting, The simulation result shows that remarkable mechanical coupling effects are produced in the process, and the sectional stress in rapid cooling down is found considerably larger than that in heating-up. Meanwhile, the stress and deformation of a beam mainly related to cooling rate and location are much larger than those of a column in rapid cooling, In fire fighting, the structure on the first or second floor was more dangerous than those on other floors in rapid cooling, These results could provide a theoretical reference for the design of steel structure and fire fighting.

Evaporative Cooling Applied in Thermal Power Plants:A Review of the State-ofthe-Art and Typical Case Studies

A review is conducted about the application of the evaporative cooling technology in thermal power plants.Different case studies are considered,namely,evaporative air conditioners,evaporative cooling in direct air-cooled systems,gas turbine inlet cooling,wet cooling towers,and hybrid cooling towers with a crosswind effect.Some effort is provided to describe the advantages related to direct evaporative cooling when it is applied in thermal power plants and illustrate the research gaps,which have not been filled yet.In particular,typical case studies are intentionally used to compare the cooling performances when direct evaporative cooling is implemented in different types of cooling towers,including the natural draft wet cooling tower(NDWCT)and the pre-cooled natural draft dry cooling tower(NDDCT).It is shown that the NDWCT provides the best cooling performance in terms of power station cooling,followed by the pre-cooled NDDCT,and the NDDCT;moreover,the evaporative pre-cooling is able to enhance the cooling performance of NDDCT.Besides,on a yearly basis,better NDDCT cooling performances can be obtained by means of a spray-based pre-cooling approach with respect to wet media pre-cooling.Therefore,the use of nozzle spray is suggested for improvement in the performance of indirect/direct air-cooling systems with controlled water consumption.

Transient performance and intelligent combination control of a novel spray cooling loop system

Effective thermal control systems are essential for the reliable working of insulated gate bipolar transistors （IGBTs） in many applications. A novel spray cooling loop system with integrated sintered porous copper wick （SCLS-SPC） is proposed to meet the requirements of higher device level heat fluxes and the harsh environments in some applications such as hybrid, fuel cell vehicles and aerospace. Fuzzy logic and proportional-integral-derivative （PID） policies are applied to adjust the electronic temperature within a safe working range. To evaluate the thermal control effect, a mathematical model of a 4-node thermal network and pump are established for predicting the dynamics of the SCLS-SPC. Moreover, the transient response of the 4 nodes and vapor mass flowrate under no control, PID and Fuzzy-PID are numerically investigated and discussed in detail.

Recent Advances in Closed Loop Spray Cooling and its Application in Airborne Systems

In recent years,the problem of heat dissipation in airborne directed energy weapons has attracted considerable research interest.Spray cooling can be applied to cool airborne directed energy weapons,owing to its several advantages such as a large heat transfer coefficient,absence of boiling hysteresis and uniform surface temperature.To examine the potential of an airborne spray cooling system,the typical high heat flux dissipation methods were compared,and the state of the art research on spray cooling was reviewed.This review was focused on studies related to the spray cooling hydrodynamic mechanism,experimental studies of closed loop spray cooling,numerical simulation studies about spray cooling and the identification of the factors influencing spray cooling systems,and investigations related to the multiple nozzle spray cooling technology and heat transfer correlation predictions.Overall,there is a need for further research to investigate the failure phenomenon after the critical state,matching operation of the total system and microscopic characteristics of airborne specific parameters.

Visualization of Film Wavelike Characteristics and Measurement of Film Thickness in Spray Cooling

An experimental investigation was performed to study the heat transfer in an eight-nozzle spray cooling system with de-ionized water as the working fluid. Visualization of the liquid-solid contact area and the flow near the heated surface was made using a microscopic lens system in conjunction with an advanced high-speed camera. The film thickness and film wavelike characteristics under liquid volume flow rates ranged from 2.78×10 -6 m 3 /s to 1.39×10 -5 m 3 /s and surface temperatures between 22℃ and 78.2℃ were examined respectively. The development process of the liquid film on the heated surface was observed. The local mean film thickness, the film wavelike characteristics and the behavior of the bubbles appeared in the liquid film were captured using an image processing technique. It is discovered that there exists a climax of local mean film thickness during the starting process of spray cooling. When the liquid film reaches the dynamic stable state, the dimensionless mean film thickness decreases with the increase of the liquid volume flow rate, and increases with the increase of surface temperature generally. Besides, the volume flow rate has a more significant impact on the wavelength and amplitude of the liquid film compared to the surface temperature.

Ground experimental investigations into an ejected spray cooling system for space closed-loop application

Spray cooling has proved its superior heat transfer performance in removing high heat flux for ground applications. However, the dissipation of vapor liquid mixture from the heat sur- face and the closed-loop circulation of the coolant are two challenges in reduced or zero gravity space enviromnents. In this paper, an ejected spray cooling system for space closed-loop application was proposed and the negative pressure in the ejected condenser chamber was applied to sucking the two-phase mixture from the spray chamber. Its ground experimental setup was built and exper- imental investigations on the smooth circle heat surface with a diameter of 5 mm were conducted with distilled water as the coolant spraying from a nozzle of 0.51 mm orifice diameter at the inlet temperatures of 69.2 ℃ and 78.2 ℃ under the conditions of heat flux ranging from 69.76 W/cm2 to 311.45 W/cm2, volume flow through the spray nozzle varying from 11,22 L：h to 15.76 L·h. Work performance of the spray nozzle and heat transfer performance of the spray cooling system were analyzed; results show that this ejected spray cooling system has a good heat transfer performance and provides valid foundation for space closed-loop application in the near future.