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32 pages, 572 KB  
Review
Convective Heat Transfer in Gas-Cooled Nuclear Reactors—A Review
by Patryk Jasik, Wojciech Malinowski, Jan Marchewka, Jakub Pelczarski and Piotr Kolasiński
Energies 2026, 19(7), 1668; https://doi.org/10.3390/en19071668 (registering DOI) - 28 Mar 2026
Abstract
Gas-cooled reactors are highly sophisticated energy systems in which numerous physical phenomena take place at the same time. Among these, the effective removal of heat from the reactor core is of great importance. In gas-cooled reactors, convective heat transfer and the conditions under [...] Read more.
Gas-cooled reactors are highly sophisticated energy systems in which numerous physical phenomena take place at the same time. Among these, the effective removal of heat from the reactor core is of great importance. In gas-cooled reactors, convective heat transfer and the conditions under which it occurs are critical to both the performance and safety of these reactors. Convective heat transfer in gas-cooled reactors is particularly complex due to the thermo-physical properties of gaseous coolants, high operating temperatures, and diverse flow regimes. It is commonly characterized using empirical and semi-empirical correlations. Each correlation is valid only within specific ranges of operating and geometric conditions, making the appropriate selection of correlations essential for accurate reactor design and reliable safety assessment. The aim of this review is to provide a comprehensive evaluation of the models and correlations applicable to the description and modeling of convective heat transfer in selected types of gas-cooled reactors. For each reactor type, the relevant correlations are categorized and summarized in tables, along with their ranges of applicability and inherent limitations. In total 154 correlations were reviewed. The findings highlight that convective heat transfer in different types of gas-cooled reactors is described differently. This article offer a consolidated reference of correlations useful for engineers and researchers working in the field of heat transfer and nuclear reactor engineering. In addition, remaining challenges are discussed and future research directions are proposed to support improved heat transfer modeling for current and next-generation gas-cooled reactor technologies. Full article
(This article belongs to the Section J1: Heat and Mass Transfer)
17 pages, 4938 KB  
Article
Oil-Based Phase Change Emulsions Endowed with High Thermal Conductivity and Responsive Rheological Behavior
by Yihua Qian, Qing Wang, Yaohong Zhao and Zhi Li
Materials 2026, 19(7), 1330; https://doi.org/10.3390/ma19071330 - 27 Mar 2026
Abstract
To overcome the low thermal conductivity and flow channel clogging inherent in traditional phase change materials (PCMs) for immersion cooling, this study develops a novel oil-based phase change emulsion (PCE) integrating high thermal transport with adaptive rheological behavior. A liquid thermal conductivity enhancer [...] Read more.
To overcome the low thermal conductivity and flow channel clogging inherent in traditional phase change materials (PCMs) for immersion cooling, this study develops a novel oil-based phase change emulsion (PCE) integrating high thermal transport with adaptive rheological behavior. A liquid thermal conductivity enhancer was synthesized by modifying epoxidized soybean oil with LiTFSI and blending it with a synthetic ester to form a dielectric base fluid. A mid-to-low-temperature PCM (Span65) was then incorporated via surfactant-free ultrasonic emulsification. The resulting PCE exhibits a tunable phase-change window (25~40 °C) driven by interfacial confinement effects and a multiscale lamellar network. It achieves significantly enhanced thermal conductivity (15% increase over base oil) while maintaining excellent electrical insulation (<10−9 S/cm). Rheologically, the emulsion transitions from shear-thinning in the solid state to near-Newtonian in the liquid state, optimizing both suspension stability and pumping efficiency. This work establishes a strategy for designing high-performance, safe, and energy-efficient dielectric coolants, offering a robust solution for next-generation electronic and battery thermal management systems. Full article
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24 pages, 17492 KB  
Article
Thermal Exposure Risks in the City: Supply and Demand Disparity Between Urban Shade and Pedestrian Flows Using Mobile Signaling Data
by Wenxin Cai, Fei Yang and Jiawei Yi
Land 2026, 15(4), 548; https://doi.org/10.3390/land15040548 - 27 Mar 2026
Viewed by 26
Abstract
Extreme heat poses growing health risks in high-density cities, yet static assessments often fail to capture dynamic pedestrian exposure. This study quantifies the supply and demand disparity between urban shade provision and actual pedestrian demand in Fuzhou, China, during a specific extreme heat [...] Read more.
Extreme heat poses growing health risks in high-density cities, yet static assessments often fail to capture dynamic pedestrian exposure. This study quantifies the supply and demand disparity between urban shade provision and actual pedestrian demand in Fuzhou, China, during a specific extreme heat event. Integrating high-resolution mobile signaling data with dynamic urban shade simulations, we classified the road network into risk quadrants and analyzed behavioral drivers using XGBoost and SHAP algorithms. Results show a pronounced disparity: high-risk zones carry the highest pedestrian flows (a mean daily volume of 28.6 pedestrian trajectories per segment) but exhibit minimal shade coverage (3.14%), while comfort zones provide 5.5 times greater shading coverage for comparable activity levels. In contrast, surplus zones exhibit substantial shading capacity but limited pedestrian use, indicating inefficient spatial allocation of cooling resources. Further analysis shows that pedestrian accumulation in high-risk zones is primarily driven by functional necessity, whereas pedestrian flows in comfort zones are more sensitive to thermal conditions. These findings reveal structurally embedded thermal exposure risk and support a shift from static metrics toward dynamic urban planning to protect vulnerable pedestrian flows. Full article
(This article belongs to the Section Urban Contexts and Urban-Rural Interactions)
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25 pages, 1373 KB  
Article
Modelling the Effect of Vertical Alternating Current Electric Field on the Evaporation of Sessile Droplets
by Yuhang Li and Yanguang Shan
Processes 2026, 14(7), 1066; https://doi.org/10.3390/pr14071066 - 26 Mar 2026
Viewed by 131
Abstract
We developed an arbitrary Lagrangian–Eulerian (ALE)-based multiphysics model for evaporation from a contact-line-pinned sessile drop of neat water subject to a vertically oriented sinusoidal alternating current (AC) electric field applied across parallel-plate electrodes. The framework fully couples electrostatics, incompressible flow, heat transfer with [...] Read more.
We developed an arbitrary Lagrangian–Eulerian (ALE)-based multiphysics model for evaporation from a contact-line-pinned sessile drop of neat water subject to a vertically oriented sinusoidal alternating current (AC) electric field applied across parallel-plate electrodes. The framework fully couples electrostatics, incompressible flow, heat transfer with evaporative cooling, and transient vapour transport in air, and includes an instantaneous, voltage-controlled electrowetting contact-angle response under constant-contact-radius conditions. Validation against published data shows that the model captures both pinned-droplet evaporation and electrically induced deformation. Because Maxwell traction scales with the squared electric-field magnitude, droplet height and contact angle exhibit a robust 2:1 frequency-doubled response, producing two peak–trough events per voltage period. The resulting periodic deformation drives oscillatory interfacial shear and internal recirculation, yielding a synchronous double-peaked evaporative-flux waveform. Gas-side analysis quantifies a time-varying diffusion-layer thickness via a characteristic diffusion length; two thinning events per period coincide with flux maxima, indicating that AC enhancement is dominated by periodic compression of the vapour boundary layer and reduced gas-side mass-transfer resistance. Increasing voltage amplitude (0–60 kV) strongly accelerates volume loss, while frequency has a secondary effect: the cycle-averaged flux rises from 1 to 10 Hz but decreases slightly at 20 Hz due to phase lag and weaker boundary-layer modulation. Full article
(This article belongs to the Section Energy Systems)
20 pages, 5855 KB  
Article
Internal Flow, Vibration, and Noise Characteristics of a Magnetic Pump at Different Rotational Speeds
by Fei Zhao, Bin Xia and Fanyu Kong
Water 2026, 18(7), 784; https://doi.org/10.3390/w18070784 - 26 Mar 2026
Viewed by 122
Abstract
A high-speed magnetic pump rated at 7800 r/min was studied. A numerical model was established, and a hydraulic, vibration, and noise testing system was set up to conduct flow simulations, noise, and vibration experiments at different speeds. The results show that increasing speed [...] Read more.
A high-speed magnetic pump rated at 7800 r/min was studied. A numerical model was established, and a hydraulic, vibration, and noise testing system was set up to conduct flow simulations, noise, and vibration experiments at different speeds. The results show that increasing speed leads to a higher pressure difference between the pump chamber and the cooling circuit. Meanwhile, the turbulent kinetic energy at the impeller outlet increases. Despite an increase in energy loss, the loss ratio decreases, and overall efficiency improves. The internal flow noise collected by the outlet hydrophone mainly comes from Rotor–Stator Interference (RSI), and it can sensitively capture changes in rotational speed. The dominant frequency of the outlet noise agrees well with the blade frequency calculated from the set speed, with a maximum deviation of 0.26%. As the speed increases, the overall sound pressure level (OASPL) at the inlet and outlet and the Root Mean Square (RMS) acceleration values at the outlet and pump body generally increase, while the acceleration at the motor base shows a decreasing trend. The conclusions are helpful for the design and optimization of rotary machinery such as high-speed magnetic pumps. Full article
(This article belongs to the Section Hydraulics and Hydrodynamics)
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25 pages, 17827 KB  
Article
Synergistic PCM–Liquid Thermal Management for Large-Format Cylindrical Batteries Under High-Rate Discharge
by Chunyun Shen, Chengxuan Su, Zheming Zhang, Fang Wang, Zekun Wang and Shiming Wang
Appl. Sci. 2026, 16(7), 3200; https://doi.org/10.3390/app16073200 - 26 Mar 2026
Viewed by 114
Abstract
The push for higher energy density in electric vehicles has resulted in large-sized lithium-ion batteries, but their geometric upscaling exacts a heavy thermal price. Under high-rate discharge, these massive cells become heat traps, risking thermal runaway. To tame this instability, this paper engineered [...] Read more.
The push for higher energy density in electric vehicles has resulted in large-sized lithium-ion batteries, but their geometric upscaling exacts a heavy thermal price. Under high-rate discharge, these massive cells become heat traps, risking thermal runaway. To tame this instability, this paper engineered a hybrid management strategy fusing liquid cooling, Phase Change Materials (PCMs), and flow deflectors. With a primary focus on the structural optimization of the cooling channel, a three-dimensional numerical model, calibrated using experimentally determined thermophysical properties, was developed to overcome the thermal bottlenecks of conventional cooling architectures. Results indicated that the initial channel optimization effectively reduced the maximum temperature to 327.7 K, but it still remained near the safety threshold. Integrating PCM radically altered the thermal landscape, slashing the outlet temperature differential by 41.67% (from 2.76 K to 1.61 K) compared to pure liquid cooling and blunting peak thermal spikes. Furthermore, to overcome laminar stagnation, strategic deflector baffles were introduced to agitate the coolant, enhancing heat dissipation. Specifically, the optimal half-coverage (L = 1/2) baffle configuration successfully lowered the maximum temperature to 322.42 K while substantially reducing the system pressure drop from 948.16 Pa to 627.57 Pa, achieving a 33.33% reduction compared to the full-coverage scheme. Finally, a multi-variable sensitivity analysis confirmed the extraordinary engineering robustness of the optimized configuration, demonstrating a negligible maximum temperature fluctuation of less than 0.5% despite ±10% operational and material uncertainties. This synergistic system actively stabilizes the thermal envelope, offering a robust engineering blueprint for next-generation high-power battery packs. Full article
(This article belongs to the Section Applied Thermal Engineering)
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24 pages, 4226 KB  
Article
Development of RP-3 Surrogate Fuels via Multi-Objective Genetic Algorithm for Regenerative Cooling CFD with Supercritical Property Fidelity
by Sangho Ko, Yuchang Gil and Sungwoo Park
Aerospace 2026, 13(4), 307; https://doi.org/10.3390/aerospace13040307 - 25 Mar 2026
Viewed by 204
Abstract
Supercritical heat transfer in regenerative cooling channels is strongly influenced by thermophysical property variations near the pseudo-critical temperature, yet their direct implications for cooling performance have not been fully addressed. This study investigates how incorporating supercritical property considerations into surrogate fuel formulation affects [...] Read more.
Supercritical heat transfer in regenerative cooling channels is strongly influenced by thermophysical property variations near the pseudo-critical temperature, yet their direct implications for cooling performance have not been fully addressed. This study investigates how incorporating supercritical property considerations into surrogate fuel formulation affects heat transfer behavior in a regenerative cooling channel. RP-3 surrogate fuels were constructed using a genetic algorithm by matching both temperature-independent properties and temperature-dependent properties under supercritical conditions. Unlike previous approaches employing distillation curves as a secondary objective, the present formulation adopted supercritical density distribution and pseudo-critical temperature (Tpc) as optimization targets. The formulated surrogate fuels were evaluated in a regenerative cooling channel model surrounding a combustor, and their flow and heat transfer characteristics were compared with those of literature-based surrogate fuels. The results show that differences in Tpc and density variation trends significantly influence buoyancy-induced asymmetric flow structures and the onset of heat transfer deterioration. Surrogate fuels with lower Tpc exhibit earlier density reduction and earlier development of asymmetric flow, whereas fuels with higher Tpc demonstrate relatively mitigated wall temperature rise. The results of the present study suggest that surrogate fuel formulation based on supercritical thermophysical properties can have a significant influence on the predicted heat transfer behavior in regenerative cooling channels under the operating conditions considered. Full article
(This article belongs to the Section Astronautics & Space Science)
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15 pages, 7154 KB  
Article
The Process of Pressure, Temperature, and Phase State Changes Within Supercritical CO2 Buried Pipelines During Micro-Leakage
by Xu Jiang, Junliang Huo, Yuhua Feng, Guangbin Li, Fei Qian, Lei Chen and Wenjing Yang
Processes 2026, 14(7), 1039; https://doi.org/10.3390/pr14071039 - 25 Mar 2026
Viewed by 145
Abstract
Within the carbon capture, utilization and storage (CCUS) chain, buried CO2 pipelines are an indispensable engineering solution under complex topographic conditions. Experimental investigations show that leakage from buried supercritical CO2 (sCO2) pipelines features a two-stage pressure decline: an initial [...] Read more.
Within the carbon capture, utilization and storage (CCUS) chain, buried CO2 pipelines are an indispensable engineering solution under complex topographic conditions. Experimental investigations show that leakage from buried supercritical CO2 (sCO2) pipelines features a two-stage pressure decline: an initial rapid drop driven by high leaking medium mass flow, followed by a linear decrease governed by homogeneous liquid CO2 vaporization. Notably, the choking flow effect homogenizes linear pressure drop rates across distinct experimental conditions. Leakage orifice diameter is a dominant factor for pipeline temperature distribution: small orifices yield consistent temperature drop rates at different vertical pipeline positions, while larger ones cause faster cooling at the pipeline bottom, forming significant vertical temperature gradients that intensify closer to the leakage orifice. Leakage direction and initial pipeline pressure are key regulators of leakage dynamics: vertical upward leakage (0°) leads to faster pressure drops due to the reduced soil resistance, and elevated initial pressure not only intensifies the pressure drop rate and amplifies CO2’s endothermic effect but also modulates the phase transition pathway of sCO2 during leakage. Full article
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25 pages, 10863 KB  
Article
Study on the Influence of Inflow Direction on the Entrainment Effect of Blockages in the Open Intake Channel of Nuclear Power Plants
by Lulu Hao, Xiao Qin and Xiaoli Chen
Processes 2026, 14(7), 1036; https://doi.org/10.3390/pr14071036 - 24 Mar 2026
Viewed by 71
Abstract
In recent years, frequent blockage of water intake structures at nuclear power plants (NPPs) by marine organisms has increased the risk of cooling source loss for the plants. Optimizing the layout of water intake structure to actively avoid or divert blockages near the [...] Read more.
In recent years, frequent blockage of water intake structures at nuclear power plants (NPPs) by marine organisms has increased the risk of cooling source loss for the plants. Optimizing the layout of water intake structure to actively avoid or divert blockages near the intake entrance is one of the effective measures for cooling source risk prevention and control, and relevant research remains scarce at present. Taking a certain NPP as the research object, this paper simulates the flow field and particle transport in the sea area around the water intake based on a hydrodynamic-particle coupling model. A method for determining the maximum water source range and critical tidal conditions under risk source uncertainty is proposed. The flow pattern and entrainment risks of different open channel inlet types are compared. The results show that when the water intake open channel is arranged perpendicular to the ambient flow, a large recirculation zone exists at the intake entrance. Simply increasing the width at the intake entrance by expanding the local opening has an insignificant effect on reducing the water intake velocity and entrainment risk, while adopting additional side opening intake plays a certain role in dispersing the water intake entrainment intensity. The research results provide a basis for the optimal design and operation of water intake at NPPs. Full article
(This article belongs to the Special Issue Advances in Hydrodynamics, Pollution and Bioavailable Transfers)
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19 pages, 1844 KB  
Article
Physics-Informed Dynamic Resilience Assessment and Reconfiguration Strategy for Zonal Ship Central Cooling Systems
by Xin Wu, Ping Zhang, Pan Su, Jiechang Wu and Luo Yuchen
J. Mar. Sci. Eng. 2026, 14(7), 598; https://doi.org/10.3390/jmse14070598 (registering DOI) - 24 Mar 2026
Viewed by 65
Abstract
Zonal ship central cooling systems, which are primarily implemented in naval platforms and advanced specialized vessels to ensure high survivability, exhibit complex fluid–thermal interactions and multi-level valve networks, challenging conventional resilience analysis, especially under large-scale fault scenarios and dynamic topology reconfiguration. This paper [...] Read more.
Zonal ship central cooling systems, which are primarily implemented in naval platforms and advanced specialized vessels to ensure high survivability, exhibit complex fluid–thermal interactions and multi-level valve networks, challenging conventional resilience analysis, especially under large-scale fault scenarios and dynamic topology reconfiguration. This paper presents a physics-informed dynamic resilience assessment and reconfiguration optimization method tailored for such systems. To address the high-dimensional reconfiguration search space, a physics-informed pruning mechanism combining topological reachability filtering and nodal continuity-based feasible-flow verification is introduced, eliminating 42.6% of invalid topologies and reducing optimization time by approximately 38%. Additionally, a cumulative thermal severity (CTS) metric is developed to capture transient thermal shock risks, quantitatively assessing deviation from the 50 °C system safety boundary at the most critical node. Simulation results for a main seawater pump failure scenario demonstrate that the proposed reconfiguration strategy, which coordinates cross-zone tie valves and leverages healthy zones’ pressure margins, shortens recovery time by 47%, suppresses peak temperature from 51.5 °C to 50.2 °C, reduces maximum over-temperature from 1.5 °C to 0.2 °C, and decreases CTS from 8.5 °C·s to 0.1 °C·s (a 98.8% reduction). These findings demonstrate that physics-informed pruning substantially reduces the computational burden of high-dimensional reconfiguration, while the proposed CTS metric enables quantitative assessment of transient thermal-shock risk. Together, they offer robust methodological guidance for resilience-oriented decision support and fault-tolerant design in complex shipboard fluid–thermal systems. Full article
(This article belongs to the Section Ocean Engineering)
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22 pages, 5428 KB  
Article
Impact of Cascaded and Series/Parallel Configurations on the Thermal Performance of Flat-Plate Phase-Change Thermal Energy Storage Systems
by Shizhao Yan, Juan Shi and Zhenqian Chen
Energies 2026, 19(6), 1559; https://doi.org/10.3390/en19061559 - 21 Mar 2026
Viewed by 165
Abstract
This study investigates the thermal performance of a flat-plate phase-change thermal energy storage system, focusing on two structural innovations: a cascaded arrangement of multiple phase-change materials (PCMs) with varying melting points, and the implementation of series/parallel flow configurations. A combined numerical and experimental [...] Read more.
This study investigates the thermal performance of a flat-plate phase-change thermal energy storage system, focusing on two structural innovations: a cascaded arrangement of multiple phase-change materials (PCMs) with varying melting points, and the implementation of series/parallel flow configurations. A combined numerical and experimental approach is employed to analyze dynamic charging/discharging behavior. Quantitative results indicate that the cascaded configuration (three PCMs) reduces phase-change completion time by 13% and increases cooling energy storage power from 2.00 kW to 2.43 kW during charging compared to single-PCM systems. Flow configuration significantly impacts thermal response: the parallel layout delivers more stable cooling output, while the series layout achieves faster initial cooling (reaching 6.24 °C within 1200 s, 31% faster than the parallel layout). Experimental results reveal that inlet water temperature is the most critical operating parameter, with each 2 °C increase significantly prolonging charging time. This work offers practical guidance for the design and optimization of efficient cascaded PCM thermal storage systems. Full article
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24 pages, 4666 KB  
Article
Numerical Study on Heat Transfer Characteristics of Microchannel with Ferrofluid Under Influence of Magnetic Intensity
by Seong-Guk Hwang, Tai Duc Le and Moo-Yeon Lee
Micromachines 2026, 17(3), 383; https://doi.org/10.3390/mi17030383 - 21 Mar 2026
Viewed by 209
Abstract
Effective thermal management is critical for high-power lithium-ion batteries to mitigate excessive heat generation and ensure operational reliability. Failure to maintain a uniform temperature distribution can lead to accelerated capacity fading and severe safety risks, such as thermal runaway. In this study, a [...] Read more.
Effective thermal management is critical for high-power lithium-ion batteries to mitigate excessive heat generation and ensure operational reliability. Failure to maintain a uniform temperature distribution can lead to accelerated capacity fading and severe safety risks, such as thermal runaway. In this study, a ferrofluid-based magnetohydrodynamic (MHD) microchannel cooling system was numerically investigated to elucidate the influence of magnetic intensity, magnet geometry, and electrical boundary conditions on flow behavior and heat transfer performance for battery cooling applications. A fully coupled multiphysics model incorporating electromagnetic, fluid flow, and heat transfer phenomena was developed and validated against experimental and numerical data from the literature. The results show that increasing the applied voltage enhances current density and Lorentz force almost linearly, leading to significant flow acceleration and improved convective heat transfer. Electrical insulation effectively suppresses current leakage into the channel walls, increasing the average current density by up to 222% and the Lorentz force by more than 300%. Compared with a cylindrical magnet, a rectangular magnet provides a more uniform magnetic field distribution and stronger near-wall Lorentz forcing, resulting in superior cooling performance. Under a 4C discharge condition, the insulated rectangular magnet reduces the maximum battery temperature by approximately 30% and increases the average Nusselt number by up to 103% relative to the non-insulated case. The findings reveal the critical roles of magnetic-field-controlled flow symmetry and near-wall forcing in MHD-driven microchannels, and provide practical design guidelines for battery cooling systems with no moving mechanical parts and active electromagnetic flow control. Full article
(This article belongs to the Special Issue Complex Fluid Flows in Microfluidics)
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24 pages, 3321 KB  
Article
Investigation of the Influence of Wetting Ability of the Sprayed Surface of the Heat Exchanger on the Process of Evaporative Cooling
by Ivan Ignatkin, Nikolay Shevkun and Dmitry Skorokhodov
Thermo 2026, 6(1), 20; https://doi.org/10.3390/thermo6010020 - 20 Mar 2026
Viewed by 190
Abstract
Ensuring the required microclimate parameters is the most critical task in hot climates. In pig farms, air cooling is provided by means of steam-compression chillers or evaporative cooling, which is the simplest way to cool the air. The implementation of evaporative cooling depends [...] Read more.
Ensuring the required microclimate parameters is the most critical task in hot climates. In pig farms, air cooling is provided by means of steam-compression chillers or evaporative cooling, which is the simplest way to cool the air. The implementation of evaporative cooling depends largely on the interaction of the media involved in this process. This paper considers the process of interaction of cooling water with the surface of a cellular polycarbonate heat exchanger. A mathematical model describing the process of wetting the sprayed surface of the heat exchanger is obtained. The authors determined the theoretical water flow rate required to provide air cooling for a given operation mode. Experimental trials of a recuperative heat recovery unit with a heat exchanger made of cellular polycarbonate equipped with a water evaporative cooling system were carried out. The authors conducted a comparative assessment to evaluate the effectiveness of evaporative cooling in a heat recovery unit equipped with a polycarbonate heat exchanger versus panel evaporative systems using wetted paper pads at pig farms in the Vladimir and Tambov regions of Russia. The panel evaporative coolers provided a temperature reduction of 11.3 °C without any splashing effect. Under the same operating conditions, the heat recovery unit achieved an inlet air temperature reduction of 10.5 °C, accompanied by splashing. When the water flow rate supplied for evaporation was reduced until the splashing ceased, the cooling temperature drop decreased to 10.1 °C, which is 11% lower, compared with the paper pads. The study revealed characteristic operating modes for the unit that ensure effective air cooling, depending on the cooling water flow rate. Since the prevailing temperature during the system’s main operating time is significantly lower than the design temperature (the absolute temperature maximum), to achieve effective cooling of the supply air without splashing or excessive water waste, the cooling circuit water should circulate at a flow rate within 40 to 63% of the maximum design value. Alternatively, an automated control system should be employed to regulate the water supply based on outdoor air temperature and humidity. Full article
(This article belongs to the Topic Clean Energy Technologies and Assessment, 2nd Edition)
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29 pages, 3082 KB  
Article
Multi-Objective Optimization of Thermal and Mechanical Performance of Prismatic Aluminum Shell Lithium Battery Module with Integrated Biomimetic Liquid Cooling Plate
by Yi Zheng and Xu Zhang
Batteries 2026, 12(3), 106; https://doi.org/10.3390/batteries12030106 - 19 Mar 2026
Viewed by 234
Abstract
Addressing the thermal management challenges of prismatic aluminum shell lithium battery modules in electric vehicles under high-rate charge–discharge conditions, this study proposes a multi-objective optimization design method for integrated biomimetic liquid cooling plates. By integrating various highly efficient heat transfer structures from nature, [...] Read more.
Addressing the thermal management challenges of prismatic aluminum shell lithium battery modules in electric vehicles under high-rate charge–discharge conditions, this study proposes a multi-objective optimization design method for integrated biomimetic liquid cooling plates. By integrating various highly efficient heat transfer structures from nature, including fractal-tree-like networks, leaf vein branching systems, and spider web radial distribution, a novel biomimetic liquid cooling plate topology was constructed. A multi-physics coupled numerical model considering electrochemical heat generation, thermal conduction, convective heat transfer, and thermal stress deformation was established. The NSGA-II algorithm was employed to globally optimize 12 design variables including channel geometric parameters, operating conditions, and structural dimensions, achieving collaborative optimization objectives of maximum temperature minimization, temperature uniformity maximization, pressure drop minimization, and structural lightweighting. The weight coefficients for the four optimization objectives were determined through the Analytic Hierarchy Process (AHP) with verified consistency (CR = 0.02 < 0.10), ensuring rational priority allocation aligned with automotive safety standards. The optimization results demonstrated that compared to the initial design, the optimal solution reduced the maximum temperature under 3C discharge conditions by 9.9% to 34.7 °C, decreased the temperature difference by 31.3% to 3.3 °C, lowered the pressure drop by 24.6% to 2150 Pa, reduced structural mass by 4.0%, and decreased maximum stress by 16.7%. Quantitative comparison with single biomimetic structures under identical boundary conditions showed that the integrated design achieved a 3.3% lower maximum temperature and 25.7% better flow uniformity than the best-performing single structure, demonstrating the synergistic advantages of multi-biomimetic integration. These synergistic performance improvements can be attributed to the hierarchical multi-scale architecture where fractal networks provide macro-scale flow distribution, leaf vein branches ensure meso-scale coverage, and spider web radials achieve micro-scale thermal matching. Long-term cycling tests conducted at 1C/1C rate with 25 ± 1 °C ambient temperature showed that the optimized design maintained a capacity retention rate of 92.3% after 1000 charge–discharge cycles, demonstrating excellent durability. The complex biomimetic channel structure can be fabricated using selective laser melting technology with minimum feature sizes below 0.3 mm, indicating promising manufacturing feasibility. The research findings provide theoretical guidance and technical support for the engineering design of high-performance battery thermal management systems. Full article
(This article belongs to the Section Battery Modelling, Simulation, Management and Application)
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23 pages, 14312 KB  
Article
Gradient Flow Field Designing to Enhance Mass and Heat Transfer for Air-Cooled Proton Exchange Membrane Fuel Cell Using the Modeling Frame
by Xuemei Li, Beibei Chen, Fei Wang, Zhijun Deng, Yajun Wang and Chen Zhao
Batteries 2026, 12(3), 105; https://doi.org/10.3390/batteries12030105 - 19 Mar 2026
Viewed by 222
Abstract
Structural optimization of the cathode flow field is a viable approach to homogenize multi-physical field distributions and boost the output of air-cooled proton exchange membrane fuel cells (PEMFCs). This work develops a three-dimensional non-isothermal model to systematically evaluate the performance of graded flow [...] Read more.
Structural optimization of the cathode flow field is a viable approach to homogenize multi-physical field distributions and boost the output of air-cooled proton exchange membrane fuel cells (PEMFCs). This work develops a three-dimensional non-isothermal model to systematically evaluate the performance of graded flow channel designs. The results indicate that the graded structure promotes fluid transport in the central zone, thereby improving oxygen distribution uniformity at the gas diffusion layer/catalyst layer (GDL/CL) interface. Compared to the traditional parallel flow channel (with an average oxygen mass fraction of 0.051% and a uniformity index of 0.779), this configuration yields a 6.4% increase in the average oxygen mass fraction and a 0.96% enhancement in distribution uniformity. However, increased gradient flow reduces the flow velocity within the channels and raises the operating temperature, posing challenges for water and thermal management. The curved channel design, featuring longer channels at the ends and shorter channels in the center, compensates for the uneven air supply caused by the fan, thus balancing the flow distribution. Among the tested configurations, the 10° curved structure exhibits optimal performance, achieving the best compromise between gas distribution and liquid water removal. It effectively promotes oxygen diffusion and uniform water distribution, significantly alleviating mass transfer polarization and yielding a more uniform interface temperature distribution due to evaporative cooling. Both excessively small and large curvature angles lead to performance degradation, primarily due to inadequate water removal and flow separation, accompanied by excessive pressure drop, respectively. In contrast, the 10° curved channel strikes an optimal balance, offering significant advantages in overall cell performance and water–thermal management, which provides critical guidance for optimizing PEMFC flow field designs. Full article
(This article belongs to the Special Issue Fuel Cell for Portal and Stationary Applications)
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