Artificial Intelligence‐Based Heat Exchanger Design and Optimization

Design of heat exchanger for the production of zinc imidazole framework-8 (ZIF-8) particles

Design and CFD analysis of hair pin heat exchanger using aluminium and titanium carbide nanofluids

Chapter 3 - Heat exchanger for solar thermal energy

Thermal interactions among vertical geothermal borehole fields

Additive manufacturing (AM) can enable complex and novel designs that are otherwise infeasible with traditional metal manufacturing techniques. In low-volume production scenarios, particularly for specialized applications which can benefit from customized designs, traditional metal manufacturing techniques may be limited by costs associated with tooling. The ability to produce novel designs is particularly interesting in heat exchanger (HX) design where performance is often largely based on the achievable geometry. However, consequences of the AM process such as surface roughness, deviation from specified dimensions, and defects such as cracks and voids could also affect HX performance. These effects may vary between identically designed AM parts based on AM machine settings. The goal of this work is to gain a better understanding of the performance variations across several different implementations of the same heat exchanger design. More specifically, the objective of this work is to experimentally compare the thermal and hydraulic performances of a traditionally manufactured, stamped-aluminum aircraft oil cooler and three geometrically equivalent, additively manufactured counterparts. Compared to the traditionally manufactured heat exchanger, the AM HXs exhibited significantly higher air-side pressure loss and higher heat transfer despite having nominally similar geometries. Between AM HXs, there were slight differences in surface roughness characteristics based on optimal profilometry measurements. In addition, the thickness of the air-side fins varied as much as 15 percent between the AM HXs. The net effect, without the contribution of each cause clear, was higher air-side pressure loss and slightly higher heat transfer for the AM HX with thicker fins. This study indicates that functional heat exchangers built using AM vary in performance even when the same digital model is used to print them, and that AM HXs as a group perform considerably differently than their traditional counterparts. Thus, there is a need to account for anticipated surface roughness, geometric deviations, and potential defects when designing HXs. Proper consideration could result in improved thermal performance for future heat exchangers.

Design of condensation heat exchanger for the PAFS (Passive Auxiliary Feedwater System) of APR+ (Advanced Power Reactor Plus)

Design and modeling of a multiscale porous ceramic heat exchanger for high temperature applications with ultrahigh power density

Investigations of heat transfer and hydrodynamics in heat exchangers with compact arrangements of tubes

Air-to-fluid heat exchangers (HXs) play a critical role as the main heat transfer component in Heating, Ventilation, Air-Conditioning, and Refrigeration (HVAC&R) systems. However, their airside thermal resistance significantly inhibits their overall performance. Furthermore, these HXs must be continually more compact to meet the latest refrigerant charge limits to reduce emissions. Recent literature suggests that traditional HX geometries (e.g., round or flat tubes with fins), have reached their limits, and more sophisticated shape- and topology-optimized designs are required to achieve the next jump in performance. This research sheds light on the next generation of air-to-refrigerant HXs and aims to address several practical issues to commercialization such as novelty challenges (improved performance for significant charge reduction; modeling expertise & time investment), manufacturing challenges (non-round tube manufacturing; tube-header integration; product qualification, e.g., burst pressure testing, extreme operational environment, etc.), and operational challenges (flow maldistribution, fouling & wetting, noise & vibration). For example, a >20% improvement on one (or more) HX-level performance metrics (e.g., envelope volume, airside pressure drop, face area, capacity, refrigerant charge, weight, cost, etc.) must be achieved before a HX design is considered for commercialization. We present a new, comprehensive and experimentally validated air-to-refrigerant HX optimization framework with simultaneous thermal-hydraulic performance and mechanical strength considerations for novel, non-round, shape- and topology-optimized tubes capable of optimizing single and two-phase HX designs for any refrigerant choice and performance requirement with significant engineering time savings compared to conventional design practices. The framework was exercised for a wide range of applications and refrigerants, resulting in HXs which achieved greater than 20% improved performance, 20% reductions in size, and 25% reductions in refrigerant charge. To enable non-round tube bundle use in next generation HVAC&R equipment, novel manufacturing techniques were investigated, including the development of conventional manufacturing methods for small diameter, non-round tubes and novel tube-header integration strategies. In total, ten HX prototypes were manufactured, nine using conventional methods directly attributed to this project and one using advanced additive manufacturing methods. The five-year manufacturing feasibility of the proposed HXs was found to have a good outlook. The non-round tube HX simulated performance was validated through comprehensive experimental testing, including nine in-house component-level tests, one independent component-level test at an industry partner laboratory, and in-house system-level tests of using a commercially-available, residential packaged A/C unit which was retrofitted with a non-round tube prototype HX. It was found that HX designs proposed by the new framework can successfully predict experimental thermal-hydraulic performance within ±10-20% the first time with no manual design changes, eliminating the need for time-consuming and expensive prototyping efforts. This work will accelerate design and time to market for next generation HXs while simultaneously facilitating industry transition to new refrigerants at lower charge.

Flat tube heat exchangers: Experimental analysis of frosting and water retention

This research focuses on enhancing the efficiency of Bi2Te3-based thermoelectric generators (TEGs) in ocean thermal energy conversion (OTEC) systems through innovative heat exchanger designs. Our comparative study uses computer simulations to evaluate three types of heat exchangers: cavity, plate-fins, and longitudinal vortex generators (LVGs). We analyze their impact on thermoelectric conversion performance, considering the thermal energy transfer from warm surface seawater to TEGs. The results demonstrate that heat exchangers with plate-fins and LVGs significantly outperform the cavity heat exchanger regarding thermal energy transfer efficiency. Specifically, plate-fins increase TEG output power by approximately 22.92% and enhance thermoelectric conversion efficiency by 38.20%. Similarly, LVGs lead to a 13.02% increase in output power and a 16.83% improvement in conversion efficiency. These advancements are contingent upon specific conditions such as seawater flow rates, fin heights, LVG tilt angles, and locations. The study underscores the importance of optimizing heat exchanger designs in OTEC systems, balancing enhanced heat transfer against the required pump power. Our findings contribute to a broader understanding of materials science in sustainable energy technologies.

Due to limitations imposed by manufacturing processes, heat exchanger designs previously were composed of tubes and fins (and several variants of these two geometric shapes).Recent advances in additive manufacturing techniques have led to the use of multi-objective topology optimization (TopOpt) to generate organic heat exchanger designs that satisfy mission-specific requirements.TopOpt-based heat exchanger design frameworks were initially developed assuming laminar flow.However, for a multitude of applications, the gaseous flow is often turbulent.The purpose of this paper is to develop a machine-learned (ML) model that can be incorporated into a TopOpt framework to design heat exchangers.Specifically, design inputs include domain size (10 10), temperature, and flow rates of hot (80 o C, 11 L/min) and cold fluids (55 o C, 67 m/s) and constraints based on energy density, pressure loss, and manufacturability.The hot and cold fluids are an aqueous solution of 50-50 ethylene glycol and air, respectively.A ML-based turbulence model is developed by first simulating the flow and heat transfer on 10 preliminary heat exchanger designs using two-equation, realizable -based steady RANS (Reynolds-Averaged Navier-Stokes) calculations.Then, a Gaussian Process machine learning model is trained to calculate the turbulent viscosity using area density as the input variable.The model is validated by performing an RANS calculation using a 0-equation eddy viscosity model with the eddy viscosity predicted by the GP model and comparing it with the test data.The outlet temperatures of both calculations were within 2% of each other.The next step is to incorporate this model into the TopOpt framework.

Optimization of heat exchanger designs in metal hydride based hydrogen storage systems

In this study, the additive manufacturing technique has been utilized to fabricate air-water heat exchangers for the application of thermoelectric power plants. Additive manufacturing is a powerful fabrication method that has enabled fabrication of complex geometries that are either challenging or impossible to fabricate based on conventional techniques. Three manifold-microchannel heat exchangers with different interior designs were fabricated by additive manufacturing and from stainless steel. The heat exchangers were tested at different air flow rates and different inlet water temperatures. One heat exchanger was designed and fabricated based on an original design of the manifold-microchannel heat exchanger. Two other heat exchangers were designed with some modifications compared to the original design. In one modified heat exchanger, cylindrical pin arrays were considered on air manifold walls in order to enhance air disturbance, and thus, increase heat transfer between water and air. The second modified heat exchanger contained same pins and also had microchannels in the perpendicular orientation compared to the original design in the outlet manifolds. This design modification was done in order to reduce air-side pressure drop in the heat exchanger. The heat transfer characteristics along with air-side pressure drop were measured and compared with the original design of the manifold-microchannel heat exchanger. Results indicated that the heat flow rate, convection heat transfer coefficient, and pressure drop did not significantly change in modified heat exchangers. For air Reynolds number between around 800 and 4,000, the heat flow rates obtained in the original heat exchanger (type A) and for 50° C water inlet temperature were between 63.9 and 228 W for the lowest and the highest air flow rates, respectively. For the same inlet water temperature, these heat flow rates were between 64.2 and 211 W for the lowest and the highest air flow rates and in one of the modified heat exchangers (type B), respectively. Similarly, while the highest air-side pressure drop in the original heat exchanger was 3458 Pa, this property was measured at 3525 (type B) and 3884 (type C) for the two modified heat exchangers.

Coupling effect between tunnel lining heat exchanger and subway thermal environment