Search Results (356)

A two-phase closed thermosyphon (TPCT), a gravity-assisted heat pipe, is a highly efficient heat transmitter involving liquid–vapor phase change. It is used in many applications, including heat spreading, thermal management and control, and energy saving. The main objective of this study is to investigate the effects of the operating conditions for a thermosyphon used in solar water heaters. The study particularly focuses on the influence of the inclination angle. Thus, a comprehensive simulation model is developed using the volume of fluid (VOF) approach. Complex and related phenomena, including two-phase flow, phase change, and heat exchange, are taken into account. To implement the model, an open-source CFD toolbox based on finite volume formulation, OpenFOAM, is used. The model is then validated by comparing numerical results to the experimental data from the literature. The obtained results show that the simulation model is reliable for investigating the effects of various operating conditions on the transient and steady-state behavior of the thermosyphon. In fact, bubble creation, growth, and advection can be tracked correctly in the liquid pool at the evaporator. The effects of the designed operating conditions on the heat transfer parameters are also discussed. In particular, the optimal tilt angle is shown to be 60° for the intermediate saturation temperature (<50 °C) and 90° for the larger saturation temperature (>60 °C). Full article

In this study, the optimal design of the central pipe in a middle-deep geothermal heat pump (MD-GHP) system is studied using the response surface method to improve the system’s coefficient of performance (COP) and operational reliability. Firstly, a model describing the energy transfer and conversion mechanisms of the MD-GHP system, incorporating unsteady heat transfer in the central pipe, is established and validated using field test data. Secondly, taking the inner diameter, wall thickness, and effective thermal conductivity of the central pipe as design variables, the effects of these parameters on the COP of a 2700 m deep MD-GHP system are analyzed and optimized via the response surface method. The resulting optimal parameters are as follows: an inner diameter of 88 mm, a wall thickness of 14 mm, and an effective thermal conductivity of 0.2 W/(m·K). Based on these results, a composite central pipe composed of high-density polyethylene (HDPE), silica aerogels, and glass fiber tape is designed and fabricated. The developed pipe achieves an effective thermal conductivity of 0.13 W/(m·K) and an axial tensile force of 29,000 N at 105 °C. Compared with conventional PE and vacuum-insulated pipes, the composite central pipe improves the COP by 11% and 7%, respectively. This study proposes an optimization-based design approach for central pipe configuration in MD-GHP systems and presents a new composite pipe with enhanced thermal insulation and mechanical performance. Full article

This study presents an experimental evaluation of the thermal and exergetic performance of an air-to-air heat pipe heat exchanger using a cobalt oxide (Co₃O₄)-based non-Newtonian nanofluid, with the additional incorporation of carbon black (CB). Nanofluids were synthesized via a two-step method and tested under turbulent flow conditions across varying Reynolds numbers. The results demonstrated that increasing the Co₃O₄ nanoparticle concentration and adding CB substantially improved both the thermal and exergetic performance compared to deionized water. Specifically, maximum thermal efficiency improvements of 62.7% and 75.4% were recorded for nanofluids containing 1% and 2% Co₃O₄, respectively. The addition of CB further enhanced the thermal efficiency, achieving a maximum improvement of 79.2%. Furthermore, the maximum reduction in thermal resistance reached 61.4% with CB incorporation, while the 2% Co₃O₄ nanofluid achieved a maximum decrease of 50.2%. The use of nanofluids led to a significant reduction in exergy loss, with exergy-saving efficiencies reaching up to 33.6%. These findings highlight the considerable potential of Co₃O₄- and CB-based hybrid nanofluids in advancing waste heat recovery technologies and enhancing the thermodynamic performance of air-to-air heat pipe heat exchanger systems. Full article

This work presents the implementation of a dual-extended Kalman filter (DEKF) in a double pipe counter-current heat exchanger. The DEKF aims to estimate online the heat transfer coefficient (HTC) to monitor the process. Some investigations estimate parameters in heat exchangers to detect fouling. However, there is limited research on online estimation using DEKF. The tests were performed at two operating conditions: in the first condition, the inlet temperatures were without perturbation; meanwhile, in the second operating condition, the cold-water inlet temperature was perturbed by the environmental heat. The experimental tests were carried out at different cold mass flow rates, which impact the temperatures and vary the heat transfer coefficient of the heat exchanger. The results showed adequate agreement between the estimated values of the heat transfer coefficients and those calculated with algebraic equations. This adequate agreement indicates that the DEKF method is conducive to detecting some problems in heat exchanger applications, such as poor heat transfer performance caused by fouling. Full article

A significant portion of energy losses in industrial systems arises from the inefficient use of high-temperature exhaust gases, emphasizing the need for enhanced heat recovery strategies. This study aims to improve energy efficiency by examining the effects of radiation-intensifying inserts on combined radiative and convective heat transfer in flue-gas heated channels. A systematic literature review revealed a research gap in understanding the interaction between these mechanisms in flue-gas heat exchangers. To address this, analytical calculations were conducted for two geometries: a radiation-intensifying plate between parallel plates and the same insert in a circular pipe. The analysis covered a range of gas-flue and wall temperatures (560–1460 K and 303–393 K, respectively), flow velocities, and spectral emissivity values. Key performance metrics included Reynolds and Nusselt numbers to assess flow resistance and heat transfer. Results indicated that flue-gas temperature has the most significant effect on total rate of heat transfer, and the insert significantly enhanced radiative heat transfer by over 60%, increasing flow resistance. A local Nusselt number minimum at a length-to-diameter ratio of approximately 26 suggested transitional flow behavior. These results provide valuable insights for the design of high-temperature heat exchangers, with future work planned to validate the findings experimentally. Full article

Thermoelectric generator (TEG) has emerged as a critical technology for automotive exhaust energy recovery, yet there is still a lack of reviews analyzing automotive TEG structure design and optimization methods simultaneously. Therefore, this review consolidates structure design and methods for improving thermoelectric conversion efficiency, focusing on three core components: thermoelectric module (TEM), heat exchanger (HEX), and heat sink (HSK). For TEM, research and development efforts have primarily centered on material innovation and structural optimization, with segmented, non-segmented, and multi-stage configurations emerging as the three primary structural types. HEX development spans external geometries, including plate, polygonal, and annular designs, and internal enhancements such as fin, heat pipe, metal foam, and baffle to augment heat transfer. HSK leverages active, passive, or hybrid cooling systems, with water-cooling designs prevalent in automotive TEG for cold-side thermal management. Optimization methods encompass theoretical analysis, numerical simulation, experimental testing, and hybrid methods, with strategies devised to balance computational efficiency and accuracy based on system complexity and resource availability. This review provides a systematic framework to guide the design and optimization of automotive TEG. Full article

This study presents an innovative hybrid geothermal air conditioning system that combines conventional air-based heat exchange with ground heat exchange technology. The system features a ground heat exchanger placed downstream from the outdoor unit heat exchanger, requiring minimal modifications to conventional air conditioners through the addition of bypass flow paths and a four-way valve. This design ensures that the ground heat exchanger consistently operates after the outdoor unit heat exchanger in both cooling and heating modes. The researchers evaluated the proposed system’s performance through both computational simulation (1D-CAE) and experimental testing. Simulation results demonstrated significant efficiency improvements, with the hybrid system achieving a coefficient of performance (COP) of 4.51 compared to just 1.24 for conventional air conditioners under extreme temperature conditions (38 °C). The experimental validation with a shallow-buried (20 cm) ground heat exchanger confirmed an approximately 20% COP improvement across various ambient temperatures. The main advantages of this hybrid system over conventional geothermal systems include reduced installation costs due to shorter borehole lengths, separate air conditioning units and underground piping, and compatibility with existing control systems. The design addresses skilled labor shortages while enabling large-scale demonstration operations with minimal initial investment. Future work will focus on optimizing the burial depth and conducting long-term durability testing to advance practical implementation. Full article

Hydrogen-powered aircraft constitute a transformative innovation in aviation, motivated by the imperative for sustainable and environmentally friendly transportation solutions. This paper aims to concentrate on the design of hydrogen powertrains employing a system approach to propose representative design models for distribution and propulsion systems. Initially, the requirements for powertrain design are formalized, and a use-case-driven analysis is conducted to determine the functional and physical architectures. Subsequently, for each component pertinent to preliminary design, an analytical model is proposed for multidisciplinary analysis and optimization for powertrain sizing. A double-wall pipe model, incorporating foam and vacuum multi-layer insulation, was developed. The internal and outer pipes sizing were performed in accordance with standards for hydrogen piping design. Valves sizing is also considered in the present study, following current standards and using data available in the literature. Furthermore, models for booster pumps to compensate pressure drop and high-pressure pumps to elevate pressure at the combustion chamber entrance are proposed. Heat exchanger and evaporator models are also included and connected to a burning hydrogen engine in the sizing process. An optimal liner pipe diameter was identified, which minimizes distribution systems weight. We also expect a reduction in engine length and weight while maintaining equivalent thrust. Full article

The traditional finite element method deals with the temperature field around the cooling tube due to the computational efficiency problems caused by grid division and the uncertainty of the convective heat transfer coefficient, resulting in inaccurate calculation results around the cooling tube. We conducted experiments to study the thermal stress and temperature gradient caused by various factors such as different materials of cooling pipes, pipe diameters, cooling water temperatures, and flow rates. The results showed that aluminum alloy pipes had the highest cooling efficiency but also produced a large temperature gradient. Pipe diameter had the most significant impact on cooling efficiency. Additionally, it is recommended that the cooling water flow velocity is not less than 0.6 m/s to achieve the best efficiency for the cooling pipe of any pipe diameter. The influence range of the cooling pipe on concrete could vary with pipe material, flow rate, and ambient factors. Our experimental results were compared with other heat transfer formulas (the Dittus–Boelter formula and the Yang Joo-Kyoung formula). According to the measured results, the formula is modified). The modified formula can estimate the heat transfer coefficient more accurately according to the flow rate and pipeline characteristics. Finally, the applicability of the formula is further verified by comparing the concrete on the bottom plate of a dam. The proposed heat transfer prediction model can estimate the heat transfer coefficient according to the flow rate and pipeline characteristics, The accuracy of the convection coefficient under different working conditions is improved by 10–25%. It is convenient to predict concrete temperature in practical engineering. Full article

Cleaning operations in narrow pipelines are often hindered by limited maneuverability and low efficiency, necessitating the development of a high-performance and highly adaptable robotic solution. To address this challenge, this study proposes a pipeline-cleaning robot specifically designed for the heat-exchange tubes of industrial heat exchangers. The robot features a dual-wheel cross-drive configuration to enhance motion stability and integrates a gear–rack-based alignment mechanism with a cam-based propulsion system to enable autonomous deployment and cleaning via a flexible arm. The robot adopts a modular architecture with a separated body and cleaning arm, allowing for rapid assembly and maintenance through bolted connections. A vision-guided control system is implemented to support accurate positioning and task scheduling within the primary pipeline. Experimental results demonstrate that the robot can stably execute automatic navigation and sub-pipe cleaning, achieving pipe-switching times of less than 30 s. The system operates reliably and significantly improves cleaning efficiency. The proposed robotic system exhibits strong adaptability and generalizability, offering an effective solution for automated cleaning in confined pipeline environments. Full article

In this work, a novel type of shell and helically coiled heat exchangers (SHCHEXs) that are used extensively in numerous applications has been numerically and experimentally studied. A low-cost and easily applicable design for enhancing the heat exchange rate in a shell and helically coiled heat exchanger has been developed within the scope of this study. In this context, a SHCHEX has been developed with an internal guiding pipe and spirally formed fins with the purpose of leading the fluid in the cold loop over the coil where hot fluid flows inside it. Numerical simulations were carried out in this study for determining how the new changes including nonporous and porous spiral fins affected heat transfer in the system. In the experimental part of the current research, a heat exchanger with a guiding pipe and nonporous spiral fins has been fabricated and its thermal behavior tested at various conditions utilizing water and MnFe₂O₄-ZnFe₂O₄/water hybrid-type nanofluid. Both numerical and experimental findings of this research exhibited positive effects of using new modifications including spiral fin integration. Overall findings of this work clearly exhibited a significant effect of the spiral fin medication and MnFe₂O₄-ZnFe₂O₄/water-hybrid magnetic nanofluid utilization on the thermal performance improvement in the heat exchanger. Experimentally determined findings showed that using MnFe₂O₄-ZnFe₂O₄/water in the hot loop of the SHCHEX improved the heat transfer coefficient of the heat exchanger by an average ratio of 16.2%. In addition, mean variation between the experimentally obtained exit temperature and numerically achieved one was 3.9%. Full article

With the high penetration of renewable energy, the imbalance between heat supply and demand is becoming increasingly severe. Installing additional heat storage bypass pipelines in the heating network can significantly enhance the heat storage capacity of the system, and regulating the supply and demand balance of heat stations can achieve a stable heat supply for users. This paper proposes a heat storage bypass configuration scheme and a dual-valve-coordinated control system. Based on the control valves’ ideal and operational flow characteristics, this paper delves into the minimum and maximum control impedance mechanisms in control valves, analyzing their impact on operational performance. Aiming at the fluctuation in the water supply temperature in the secondary pipe network (dead zone of 1%), the influence of control valve parameters on the dynamic response was systematically analyzed. The optimal parameter-matching scheme of the bypass control valve and the heat exchange control valve was finally determined through an optimization analysis. We verified its correctness based on the measured engineering data. This study improves the stability and operational efficiency of the supply and demand balance and decoupling control of the heating heat exchange unit, thereby establishing a critical technical foundation for advancing the high-efficiency integration of renewable energy sources within urban energy systems. Full article

Cylindrical joints serve as critical pathways for heat flow in various applications, including heat pipes, electronic devices, and fin-tube heat exchangers. Despite their significance, research has predominantly focused on flat joints, with limited investigation into cylindrical joints, especially on how cylindrical thermal contact conductance (TCC) changes in response to temperature and heat flux, a feature distinctive to cylindrical joints. This study provides a comprehensive theoretical and numerical investigation of cylindrical TCC behavior across various material combinations and heat flux directions. We identified three response modes for outward heat flux and six for inward heat flux, classified by the relative thermal expansion coefficients and heat flux direction. Notably, under inward heat flux, we discovered a previously unreported phenomenon: two possible contact states occurring at identical interfacial temperature, heat flux, and material conditions, with TCC values differing by more than an order of magnitude. The study covers a wide range of conditions (temperatures from 293 K to 1400 K and heat fluxes from 10⁴ to 10⁶ W/m²), confirming that the identified response patterns are broadly applicable and governed by general principles rather than specific material properties or geometric parameters. These findings provide new insights into cylindrical joint behavior and offer valuable guidelines for optimizing the design and performance of thermal systems involving cylindrical interfaces. Full article

A new evaporative condensation refrigerant pump heat pipe air-conditioning unit based on a microchannel heat pipe heat exchanger is proposed. Performance experiments were conducted on the unit, and the experimental results show that the cooling capacity of the unit in the dry, wet, and mixed modes can reach 112.1, 105.8, and 115.4 kW, respectively, the optimal airflow ratio of the secondary/primary airflow is 2.2, 1.8, and 1.8, respectively, and the EER decreases with increasing airflow ratio. With increasing dry- and wet-bulb temperatures of the secondary-side inlet air, the cooling capacity and energy efficiency ratio of the unit decrease, and the energy efficiency ratio in the wet mode is higher than that in the dry mode, which can prolong the operating hours of the wet mode within the operating temperature range of the dry mode and improve the energy efficiency of the unit. A new calculation method for the refrigerant charge is proposed, and the optimal refrigerant charge is 32 kg based on the experimental results, which agrees with the theoretical calculation results. Full article

A novel design of a proton exchange membrane electrolyzer is presented. In contrast to previous designs, the flow field plates are round and oriented horizontally with the feed water entering from a central hole and spreading evenly outward over the anode flow field in radial, interdigitated flow channels. The cathode flow field consists of a spiral channel with an outlet hole near the outside of the bipolar plate. This results in anode and cathode flow channels that run perpendicular to avoid shear stresses. The novel sealing concept requires only o-rings, which press against the electrolyte membrane and are countered by circular gaskets that are placed over the flow channels to prevent the membrane from penetrating the channels, which makes for a much more economical sealing concept compared to prior designs using custom-made gaskets. Hydrogen leaves the electrolyzer through a vertical outward pipe placed off-center on top of the electrolyzer. The electrolyzer stack is housed in a cylinder to capture the oxygen and water vapor, which is then guided into a heat exchanger section, located underneath the electrolyzer partition. The function of the heat exchanger is to preheat the incoming fresh water and condense the escape water, thus improving the efficiency. It also serves as internal phase separator in that a level sensor controls the water level and triggers a recirculation pump for the condensate, while the oxygen outlet is located above the water level and can be connected to a vacuum pump to allow for electrolyzer operation at sub-ambient pressure to further increase efficiency and/or reduce the iridium loading. Full article