1. Introduction and Literature Review
Thermoacoustic systems are usually divided into engines and refrigerators depending on the direction of energy conversion between the acoustic and thermal energy. The working principle of the thermoacoustic refrigerator is illustrated in
Figure 1. The acoustic driver at the end of the resonator supplies acoustic power,
, to the working gas inside the resonator. The standing wave acoustic field induces oscillatory motion of “gas parcels” coupled with their cyclic compression and expansion. Internal structures such as heat exchangers and stacks are placed at a location where the oscillating pressure and velocity are non-zero. A fragment of a single stack plate has been magnified at the bottom of
Figure 1 together with a gas parcel undergoing an acoustic oscillation. The gas parcel is compressed as it moves to the right and the parcel temperature increases to be slightly higher than the plate temperature. Consequently, heat is being transferred from the parcel to the plate. As the flow reverses, the gas parcel expands and the temperature drops slightly lower than that of the plate. As a result, heat is being absorbed from the plate and the parcel returns to its original thermodynamic state. This completes the thermodynamic cycle. In essence, the acoustic wave provides power that allows the heat to be pumped up the temperature gradient. Conversely, if a high enough temperature gradient is imposed across the stack/regenerator, an acoustic power will be self-excited and useful energy will be produced [
1]. This in turn could be extracted by a linear alternator to produce electricity, or used to drive a coupled thermoacoustic cooler.
The challenges in achieving efficient thermoacoustic devices were discussed comprehensively by Swift [
1]. The difficulties with complex flows across the porous structures (stack, regenerator, and heat exchangers) that form the core of the thermoacoustic device have been raised as important research issues. Understanding phenomena such as vortex flow at the end of stacks [
2], entrance effects [
3], joining conditions [
1], and streaming [
4], is important as these could hold the key to an efficient device operation.
The structure of the vortex pattern, as observed for example by Mao et al. [
5], is expected to influence the flow and possibly induce losses that may affect the efficiency of thermoacoustic systems. This has been illustrated through the observations of streamlines and viscous dissipation presented in the numerical investigation of Worlikar and Knio [
6]. The viscous dissipation represents mechanical energy losses within the model. The choice of location for the stack/heat exchanger and blockage ratio (gap between plates) were reported as factors that influence mechanical energy losses.
The same group has made several improvements to their model [
7,
8,
9]. These involve adiabatic stacks and heat exchangers, all working in a thermoacoustic standing wave environment. In all models, a simplified periodic configuration was used covering the area between the plates and some open area next to the plates to include the possible contribution from the vortex shedding phenomenon. The natural convection was assumed to be very small compared to the oscillatory flow magnitude, and was hence neglected. The effect of natural convection in an oscillatory flow has been previously tested in an experiment involving a heated wire located in an empty resonator [
10]. The natural convection was found to dominate the flow under a small velocity regime. This result, however, is not very conclusive because the temperature difference investigated was not widely varied. Furthermore, it is speculated that the presence of additional structures such as the stack and heat exchanger may alter the influence of the natural convection effect on the flow even when the velocity is relatively small [
11].
It is important to highlight that most numerical modelling work presented in this review applies a simplified model whereby a thin plate or a pair of adjacent plates with an implementation of periodic boundary conditions to replicate the array of plates is considered. In modelling, a periodic boundary condition means that the flows at the matching periodic boundary are linked so that flow conditions are shared at this boundary. As a result the flow will be duplicated for all other channels in a periodic manner [
12]. While this has advantages in terms of computational cost, it must be carefully applied as it might give misleading information pertaining to the flow structure. This has been demonstrated experimentally by Guillaume and LaRue [
13]. Their experimental results were later compared to a numerical model developed using commercial software, Fluent [
14], using the same number of plates as in the experiment. Their works show that, for a structure with an array of plates, the flow structures at the end and in the middle of the plates are influenced by the adjacent plates. The Strouhal number (the ratio of a product of a characteristic length and the frequency of the vortex shedding to a reference velocity) is reported to have changed in magnitude when a comparison was made between the two arrangements. It is important to highlight here that the investigations reported in [
13,
14] were carried out in steady flow and might not be directly applicable to the oscillatory condition, but they do give an idea of possible sources of discrepancy if investigations of an array of plates are carried out using single plate approximation. The observation of asymmetry and non-periodic development of vortex structures at the end of a plate array was also reported by Mao et al. [
5]. This suggests that a physical periodic structure (array of plates) does not guarantee that the flow structures are periodic. Hence modelling a single plate may not be adequate to describe the physics of flow around a structure with an array of plates.
Similarly, considering a single plate, the flow structures at two ends may not be identical in practice for reciprocating flows. Most investigations (cf., [
7,
9,
12]) assumed that flows at the two ends are actually symmetrical and therefore the analysis was mainly focused on just one end. This seems reasonable for investigations that do not involve a temperature gradient (adiabatic stack). However, the presence of a temperature gradient on solid boundaries is necessary for the thermoacoustic effect to take place. Temperature effects must be considered to account for additional phenomena such as temperature-driven buoyancy [
11,
15,
16,
17,
18] and non-linear effects [
4] that could affect the flow symmetry. Experimental studies often reveal signs of nonlinearities that are insufficiently addressed by the linear model [
1,
11]. In most numerical studies (cf. [
7,
9,
18]) the natural convection effect was neglected. This effect however was observed in many experimental works [
1,
11,
17].
Current computational fluid dynamics (CFD) study aims to improve the understanding of physical processes involved in the phenomena reported in the earlier experimental work of Shi et al. [
17]. However, bearing in mind more complex operating conditions (e.g., tilted-angle solar powered systems [
19,
20] or space applications), the scope of CFD is somewhat wider and extends to include gravity effects and effects of the device orientation on the physics of thermo-fluid processes across the heat exchanger plates. The novelty of this study stems from the fact that the model used attempts to take into account a far wider range of physical effects which are commonly neglected in numerical works related to thermoacoustics (i.e., natural convection or the use of a full array of plates to handle asymmetrical flow features). This is undertaken to explain the phenomena reported in [
11,
17]. In addition, the study of device orientation provides a new perspective of the importance of considering such seemingly minor details in modelling heat transfer phenomena in thermoacoustics.
2. Computational Model
A two-dimensional computational domain based on the experimental setup of [
11,
17] is shown by the red-dashed box in
Figure 2a. It covers a rectangular area of 0.132 m × 7.4 m of the quarter-wavelength resonator. The mesh is designed to be denser within the vicinity of the heat exchanger (300 mm to the left and right from the heat exchangers) to resolve vortex structures issuing from and returning into the heat exchanger assembly. Elsewhere, a much coarser mesh is adopted as the problem consists of solving the governing equations for an empty resonator. The coarse mesh is illustrated in
Figure 2b and the fine mesh in
Figure 2c. This approach was validated against the theoretical predictions of linear thermoacoustic theory [
1]: 300 mm away from the heat exchanger, the pressure and velocity simply follow the linear model. A structured mesh of quadrilateral type was used for this model; the long computational domain is divided into several parts so that the distribution of mesh sizes could be made with acceptable quality. The minimum orthogonal quality was recorded to be 0.74 with maximum skewness of 0.31 (i.e., close to 1 for minimum orthogonality and close to 0 for maximum skewness [
15]). The minimum mesh spacing in the
x- and
y-directions is 0.08 mm and 0.25 mm, respectively.
The plates of the hot and cold heat exchangers (subsequently denoted as HHX for “hot heat exchanger” and CHX for “cold heat exchanger” throughout the paper) have thickness,
, of 3 mm and are arranged in a parallel configuration with the spacing,
, of 6 mm between them. This is shown in
Figure 2d as a magnified view of a single channel between a pair of hot and cold plates; point ‘m’ is the location of the joint where the hot and cold plates meet. The HHX and CHX are located next to each other with a joint positioned at
from the pressure antinode. The wavelength,
, is defined as
, where
is the speed of sound and
is the frequency of the flow (13.1 Hz). Location of the pressure antinode for this 1/4-wavelength rig is at the end wall—cf.
Figure 2a. The arrangement of the heat exchanger plates (10 pairs) follows the physical setup with five pairs of heated/cooled fins and five pairs of unheated ones, treated as adiabatic plates. The unheated plates provide consistent porosities for the flow (cf., [
17]).
The model extends over the whole height of the resonator to resolve the flow asymmetries observed experimentally [
17]. The use of symmetry or periodic boundary conditions is inappropriate due to the presence of temperature-driven buoyancy effects. In addition, the experimental data are based on phases determined by comparing the phase of the velocity between the plates to the phase of the pressure at the pressure antinode. As the intention was to replicate as closely as possible the phenomena taking place in the physical apparatus, a full two-dimensional model was chosen.
The boundary condition at the right end of the resonator is defined as a moving wall to replicate the acoustic displacement induced by the loudspeaker. The displacement,
, is simply modelled as:
Here,
,
,
,
, and
are the angular velocity, mean density, speed of sound, wave number, and time, respectively. The term
is the oscillating pressure at the location of the pressure antinode and
is the distance from the joint to the pressure antinode (shown as 4.6 m in
Figure 2a). The mean pressure,
, is 0.1 MPa. The drive ratio,
, of the low amplitude flow investigated throughout this paper is 0.3%. The resonator wall was treated as adiabatic. The model was solved for two thermal conditions. In the first, the walls of heat exchangers are treated as adiabatic to replicate the experiments with no temperature gradient imposed on the heat exchangers (essentially ambient laboratory conditions), mainly to make comparisons between the experimental and numerical results for vortex structures. In the second, the temperature distributions were based on experiments using a linear interpolation of experimental data reported by Shi et al. [
17], as shown in
Figure 3, mainly for validation of the CFD model itself. Further extended studies into the system behaviour under arbitrary conditions assumed “flat” temperature profiles (as explained later).
The flow is modelled in ANSYS FLUENT [
12] using two-dimensional Navier–Stokes equations as described by:
The fluid used in this study is nitrogen modelled as an ideal gas with temperature-dependent properties. A power law model suggested by Swift [
1] is used for the temperature-dependent viscosity while a seventh order polynomial model suggested by Abramenko et al. [
21] is selected to model the temperature-dependent thermal conductivity:
In Equations (2) to (5),
,
,
,
,
,
,
,
,
,
,
and
are density, velocity vector, time, pressure, gravity, energy, thermal conductivity, temperature, reference temperature (300 K), stress tensor, gas constant and viscosity, respectively [
12].
Viscous heating (the second term on the right-hand-side of Equation (4)) is taken into account in this model because of the presence of heat exchangers with large surface areas. The flow is assumed to be laminar due to the small Reynolds number involved in the case investigated. The Pressure-Implicit with Splitting Operators (PISO) algorithm is selected for pressure-velocity coupling as the algorithm provides better solutions for transient cases [
12,
22,
23,
24,
25].
A first order implicit scheme is used for the discretisation of time due to the presence of the moving wall [
12]. The momentum and energy equations are discretised using a second order upwind scheme with the convergence set to the absolute values of 1 × 10
−4 for the continuity and momentum equation, and 1 × 10
−7 for energy equation. The density is calculated using the second order upwind numerical scheme. Density is related to pressure and temperature by using the equation of state as shown in Equation (5). The transient solution of the flow problem is solved in a segregated way using the pressure-based solver [
12,
25]. The time step size was chosen so that solution converged within 15 to 18 iterations in every time step. If the time step size was too large, the solution was found not to converge in every time step. If the size was too small, convergence occurred too fast within a certain time step (sometimes only requiring one iteration in one time step). The best time step for convergence was determined and set at 1200 steps per acoustic cycle. The area-weighted-average of pressure at the end wall, known as the pressure antinode, was monitored until a steady state oscillatory flow was obtained. This is defined as a state when pressure, velocity, and temperature do not change much from cycle to cycle. By way of example,
Figure 4 shows the history of oscillating pressure and velocity monitored for location “m” as defined in
Figure 2. A steady oscillatory flow condition is achieved after six flow cycles. However, as will be discussed later, results presented in this paper are obtained after 70 flow cycles, when both the flow and thermal oscillatory flow conditions have reached a steady oscillatory state. The solutions are also monitored so that they converge in every time step at every flow cycle (through the selection of the time step size).
When the steady oscillatory state condition is reached, the model is validated and used for analysis. In this study, the development of flow within one oscillatory cycle is investigated according to the time frame defined in
Figure 5. The cycle is subdivided into twenty phases starting from the first phase,
1. The relationship between pressure, velocity, and gas displacement, for the 20 phases of a flow cycle is illustrated. Phase
1 is set for the maximum value of the oscillating pressure at the location of the pressure antinode (rigid wall of the resonator). The period of one cycle is the inverse of the operating frequency—13.1 Hz.
The model was solved using the SPECTRE High Performance Computing facility at the University of Leicester (4 login nodes for solving one model, with 28 cores of 56 threads and 256 GB memory per one login node). With this computing facility, the 2D unsteady calculation for one cycle takes about 30 min. Therefore the solution for 490 cycles (as discussed later) takes about 9.5 days.
2.1. Grid Independency
The grid independency tests are illustrated in
Figure 6. In essence, the mesh was progressively refined in the part of the domain surrounding the heat exchangers (there was practically no need to do this in an empty resonator). The description of mesh density is given as cell counts in
Figure 6a for five cases. Here, the velocity values at point “m” for phases 6 and 16 are taken as test variables (+ve and −ve values due to the change of direction). Similarly, the resulting axial velocity profiles (from the wall to channel centre), for selected phases in the cycle are further illustrated in
Figure 6b. For clarity, velocity profiles are shown only for three cell counts. At low mesh density, the velocity profile is slightly over-predicted at all 6 phases shown. The velocity within the boundary layer appears to be the same for all cases because the mesh is always designed to be denser in that area. It is found that the model with a total of 45,910 cells is sufficient to provide a grid-independent solution.
2.2. CFD Model Validation
The velocity amplitude obtained from the converged model that reaches a steady oscillatory state is compared to the experimental result to validate the model. The velocity amplitudes shown in
Figure 7a,b are for the location at the centre of the gap between the plates of the heat exchanger, 1 mm away from the joint—cf.,
Figure 2c—for all 20 phases in a cycle. In both graphs, the line denoted as “Theory_dT = 0” represents the theoretical/analytical solution for oscillatory velocity calculated from the general thermoacoustic theory as given by [
1]:
where
,
, and
are the angular velocity, mean density, and the pressure gradient of the oscillatory flow, respectively. The term
is a viscous shape factor which varies according to the geometry of the internal structure involved in the system. The shape factor for parallel plate geometry is given as [
1]:
The shape factor defines the viscous, , or thermal, , effects depending on the definition of the penetration depths used. The terms: , , and are the distance from the centre of the gap to the wall of the plate, the centre of the gap, and the thermal () or viscous () penetration depth.
Figure 7a, for the adiabatic case, compares the experimental results of Shi et al. [
11] (“Experiment_dT = 0”) with the current numerical results (“CFD_Laminar_dT = 0”). The theoretical solution is calculated for the mean density taken at 300 K. A good match between the experiment, CFD, and analytical solution can be seen. Maximum discrepancies between the three methods appear at phases
6 and
16 representing the highest velocity values for the two parts of the flow cycle. Comparison between the theory and experiment shows that the theoretical value is 9.3% lower than the experimental value at
6, and 2.6% lower at
16. However, CFD results differ from the experimental results only by 0.3% and 1.8% for
6 and
16, respectively.
Figure 7b shows the velocity oscillations obtained from the experiment and CFD for the case with imposed temperature difference (the theoretical adiabatic solution is only plotted for reference). Experimental and CFD results show that, with the imposed wall temperature condition, the flow in the second half of the cycle exhibits a larger amplitude of velocity compared to the first half of the cycle. This is counterintuitive since one would expect that a hotter fluid would travel with higher velocity in the first half of the cycle, while cold fluid would flow with a lower velocity in the second half of the cycle. However it is possible that there is a mean flow along the channels (streaming effect) due to the convective currents as discussed later in
Section 3.2.2.
Figure 8 shows the validation of temperature profiles for a location 15 mm from the joint—cf.,
Figure 2c—above both the cold and hot plates. The maximum relative discrepancies of 6% were found between the numerical and experimental values when using the absolute temperature scale (17 K on the HHX and 18 K on CHX). However these discrepancies need to be seen in the context of high experimental uncertainty of the temperature field when using acetone based planar laser induced fluorescence (PLIF) method (16 K reported in [
17]) as well as a large temperature span between the heated and cooled plates—cf.
Figure 3. Clearly, the trend of the temperature profiles agrees very well qualitatively with the experimental values. Indeed, the original PLIF experiments were more concerned with temperature gradients than absolute temperature values in order to calculate surface heat fluxes.
Of course, even if the temperature measurement had zero error, there would still inevitably be discrepancies in CFD arising from the inability to model all aspects of the physical process. For example, in reality the walls of the rig are not adiabatic, and in addition they do accumulate heat and tend to induce thermal inertia processes with the scale of hours. The role of the three-dimensional flow effects within the system is also unclear—unfortunately, the experiment could only provide “planar” results close to the resonator centreline.
4. Conclusions
The two-dimensional ANSYS FLUENT CFD model has been set up to investigate the oscillatory flow across the parallel-plate heat exchanger at the low drive ratio of 0.3%. The flow, as represented by the velocity profiles, is well predicted by the model. For example, the velocity amplitudes at the centre of the heat exchanger channel have a maximum discrepancy of 1.8% compared to the experimental data. On the other hand, the numerically calculated temperatures have the maximum discrepancies of 6% compared to the experimental values. The differences noted in the temperature profiles and the resulting heat fluxes are likely to be the result of the combination of factors related to experimental uncertainties and the inability of the model to capture all the complexities of the real experimental setup. Overall, the current model under-predicts the space-time-averaged wall heat transfer by up to 30% in comparison to the experimental values.
The investigation of the effect of initial temperature on the flow and heat transfer helps explain the selection of an appropriate initial temperature that best suits the model. The current approaches of prescribing the initial temperature fields showed that the initialisation procedure influences both the magnitude of heat flux and velocity profiles within the structures. The investigation suggests that the current model is best initialised at 300 K. The model initialised with a temperature field defined more closely to the experimental conditions resulted in a change of the flow character, incongruent with the real flow behaviour. It can be speculated that the reason for this is the type of boundary conditions imposed on the model, which may not fully represent the reality of the experiment with its long time-history (hours), far beyond the capabilities of the current CFD model.
The imposed temperature boundary conditions (on the heat exchanger plates) is shown to cause asymmetry to the flow seemingly related to the nonlinearity caused by the combined effects of the temperature-dependent density and viscosity and the temperature-driven flow (buoyancy). The change in fluid density with respect to the temperature results in lower velocity amplitudes during the first part of the cycle and relatively higher magnitudes of velocity for the second part of the cycle. Here, an “asymmetrical boundary” creates asymmetries in the temperature and velocity fields. In addition, the temperature-driven buoyancy flow creates further “distortions” to the already asymmetrical features of the velocity and temperature fields. The results indicate that there are “net flows” through channels (or in other words “streaming”). These effects are well illustrated through changing the orientation of the device relative to the gravity field.
Temperature-dependent gravity effects influence the magnitudes of velocity profiles and temperature profiles between the plates depending on the direction of the flow and the locations of the CHX/HHX. Consequently, the heat fluxes also change. The presence of the imposed temperature field is shown to influence the velocity profile and gas displacement across the plates, hence breaking the symmetry of the flow. The vortex structures at the end of the plates, and the shear layer within the area bounded by the plates, change with temperature. Device orientation influences the flow and heat transfer due to temperature-driven buoyancy effects.
The viscous dissipation is also affected. The vertical arrangement is shown to provide a lower viscous dissipation but care should also be taken when dealing with this kind of arrangement because the temperature-driven flow changes the temperature and velocity field within the channel.