Search Results (167)

This study addresses the thermal hazards that arise during the initial engagement stage of wet clutches, where rapid heat generation within the transient lubricating film may cause premature film rupture, torque instability, and accelerated wear. To overcome these challenges, a coupled thermo–fluid model was developed to capture oil film flow, heat transfer, and viscous torque behavior under varying groove structures. A novelty of this work is the first integration of computational fluid dynamics (CFD) with response surface methodology (RSM) to systematically reveal how groove geometry—cross-sectional shape, number, and inclination angle—collectively influences peak temperature and viscous torque during the lubricating film stage. Simulation results show that spiral semi-circular grooves provide superior thermal management, reducing the peak friction plate temperature to 75.5 °C, while the optimized design obtained via RSM (groove depth of 0.89 mm, 19 grooves, and a 5.28° inclination angle) further lowers the maximum temperature to 68.2 °C and sustains torque transmission above 18.5 N·m. These findings demonstrate that rational groove design, guided by multi-objective optimization, can mitigate thermal risks while maintaining torque stability, offering new insights for the high-performance design of wet clutches. Full article

Supercritical carbon dioxide (Sc-CO₂) thermal shock fracturing emerges as an innovative rock fragmentation technology combining environmental sustainability with operational efficiency. This study establishes a thermo-hydro-mechanical coupled model to elucidate how in situ stress magnitude and anisotropy critically govern damage progression and fluid dynamics during Sc-CO₂ thermal shock fracturing. Key novel findings reveal the following: (1) The fracturing mechanism integrates transient hydrodynamic shock with quasi-static pressure loading, generating characteristic bimodal pressure curves where secondary peak amplification specifically indicates inhibited interwell fracture coalescence under anisotropic stress configurations. (2) Fracture paths undergo spatiotemporal reorientation—initial propagation aligns with in situ stress orientation, while subsequent growth follows thermal shock-induced principal stress trajectories. (3) Stress heterogeneity modulates fracture network complexity through confinement effects: elevated normal stresses perpendicular to fracture planes reduce pressure gradients (compared to isotropic conditions) and delay crack initiation, yet sustain higher pressure plateaus by constraining fracture connectivity despite fluid leakage. Numerical simulations systematically demonstrate that stress anisotropy plays a dual role—enhancing peak pressures while limiting fracture network development. This demonstrates the dual roles of the technology in enhancing environmental sustainability through waterless operations and reducing carbon footprint. Full article

In this study, a computational thermo-fluid dynamics simulation of a wide-slot jet impingement heating process is performed. The present configuration consists of a turbulent incompressible air jet impinging orthogonally on an isothermal cold plate at a Reynolds number of around 11,000. The two-dimensional mean turbulent flow field is numerically predicted by solving Reynolds-averaged Navier–Stokes (RANS) equations, where the two-equation eddy viscosity k-$\omega$ model is utilized for turbulence closure. As the commonly used shear stress transport variant overpredicts heat transfer at the plate due to excessive turbulent diffusion, the recently developed generalized k-$\omega$ (GEKO) model is considered for the present analysis, where the primary model coefficients are suitably tuned. Through a comparative analysis of the various solutions against one another, in addition to reference experimental and numerical data, the effectiveness of the generalized procedure in predicting both the jet flow characteristics and the heat transfer at the plate is thoroughly evaluated, while determining the optimal set of model parameters. By improving accuracy within the RANS framework, the importance of model adaptability and parameter tuning for this specific fluid engineering application is demonstrated. This study offers valuable insights for improving predictive capability in turbulent jet simulations with broad engineering implications, particularly for industrial heating or cooling systems relying on wide-slot jet impingement. Full article

A solar air heater (SAH) converts solar energy into heated air without causing environmental pollution. It features a low initial cost and easy maintenance due to its simple design. However, owing to air’s poor thermal conductivity, its thermal efficiency is relatively low compared to that of other solar systems. To improve its thermal performance, previous studies have aimed at either enlarging the heat transfer surface or increasing the convective heat transfer coefficient. In this study, a novel SAH with fins and sequentially placed obstacles on the fin surface—designed to achieve both surface extension through a finned channel and enhancement of the heat transfer coefficient via the obstacles—was investigated using computational fluid dynamics analysis. The results confirmed that the obstacles enhanced heat transfer performance by up to 2.602 times in the finned channel. However, the obstacles also caused a pressure loss. Therefore, the thermo-hydraulic performance was discussed, and it was concluded that the obstacles with a relative height of 0.12 and a relative pitch of 10 yielded the maximum THP values among the investigated conditions. Additionally, correlations for the Nusselt number and friction factor were derived and predicted the simulation values with good agreement. Full article

Combustion modeling using computational fluid dynamics (CFD) offers detailed insights into the flame structure and thermo-chemical processes. Furthermore, it has been extensively used in the past to optimize industrial furnaces. Despite the increasing computational power, the prediction of the reaction kinetics in flames is still related to high calculation times, which is a major drawback for large-scale combustion systems. To speed-up the simulation, artificial neural networks (ANNs) were applied in this study to calculate the chemical source terms in the flame instead of using a chemistry solver. Since one ANN may lack accuracy for the entire input feature space (temperature, species concentrations), the space is sub-divided into four regions/ANNs. The ANNs were tested for different fuel mixtures, degrees of turbulence, and air-fuel/oxy-fuel combustion. It was found that the shape of the flame and its position were well predicted in all cases with regard to the temperature and CO. However, at low temperature levels (<800 K), in some cases, the ANNs under-predicted the source terms. Additionally, in oxy-fuel combustion, the temperature was too high. Nevertheless, an overall high accuracy and a speed-up factor for all simulations of 12 was observed, which makes the approach suitable for large-scale furnaces. Full article

Laser-based powder bed fusion of metals (PBF-LB/M) is one of the most promising additive manufacturing technologies to fabricate complex-structured metal parts. However, its corresponding applications have been limited by technical bottlenecks and increasingly strict industrial requirements. Process optimization, a scientific issue, urgently needs to be solved. In this paper, a three-phase transient model based on the level-set method is established to examine the heat transfer and melt pool behavior in PBF-LB/M. Surface tension, the Marangoni effect, and recoil pressure are implemented in the model, and evaporation-induced mass and thermal loss are fully considered in the computing element. The results show that the surface roughness and density of metal parts induced by heat transfer and melt pool behavior are closely related to process parameters such as laser power, layer thickness, scanning speed, etc. When the volumetric energy density is low, the insufficient fusion of metal particles leads to pore defects. When the line energy density is high, the melt track is smooth with low porosity, resulting in the high density of the products. Additionally, the partial melting of powder particles at the beginning and end of the melting track usually contributes to pore formation. These findings provide valuable insights for improving the quality and reliability of metal additive manufacturing. Full article

Exploring the dynamics of nonlinear nanofluidic flow-induced vibrations, this work focuses on single-walled branched carbon nanotubes (SWCNTs) operating in a thermal–magnetic environment. Carbon nanotubes (CNTs), renowned for their exceptional strength, conductivity, and flexibility, are modeled using Euler–Bernoulli beam theory alongside Eringen’s nonlocal elasticity to capture nanoscale effects for varying downstream angles. The intricate interactions between nanofluids and SWCNTs are analyzed using the Differential Transform Method (DTM) and validated through ANSYS simulations, where modal analysis reveals the vibrational characteristics of various geometries. To enhance predictive accuracy and system stability, machine learning algorithms, including XGBoost, CATBoost, Random Forest, and Artificial Neural Networks, are employed, offering a robust comparison for optimizing vibrational and thermo-magnetic performance. Key parameters such as nanotube geometry, magnetic flux density, and fluid flow dynamics are identified as critical to minimizing vibrational noise and improving structural stability. These insights advance applications in energy harvesting, biomedical devices like artificial muscles and nanosensors, and nanoscale fluid control systems. Overall, the study demonstrates the significant advantages of integrating machine learning with physics-based simulations for next-generation nanotechnology solutions. Full article

In the automotive industry, the increasing stringent standards to reduce fuel consumption and pollutant emissions has driven significant advancements in turbocharging systems. The centrifugal compressor, as the most widely used power-absorbing machinery, plays a crucial role but remains one of the most complex components to study and design. While most numerical studies rely on adiabatic models, this work analyses several Computational Fluid Dynamics (CFD) models with conjugate heat transfer (CHT) of varying complexity, incorporating real solid components. This approach allowed a sensitivity analysis of the performance obtained from the different models compared to the adiabatic case, highlighting the effects of internal heat exchange losses. Moreover, an analysis of the temperature distribution of the wheel was conducted, along with a thermal assessment of the various heat flux contributions across the different components, to gain a deeper understanding of the performance differences. The impact of including the seal plate has been evaluated and different boundary conditions on the seal plate have been tested to assess the uncertainty in the results. Finally, the influence of heat exchange between the shroud and the external environment is also examined to further refine the model’s accuracy. One of the objectives of this work is to obtain a correct temperature profile of the rotor for a subsequent thermo-mechanical analysis. Full article

COVID-19 restricted the number of employees. Operational data showed that traditional methods of modeling heat consumption are not correct anymore. The aim is to model the energy demand of an office building during COVID-19 limitations and showcase improvements after a new controller or suggested alternatives are applied. After an actual heat consumption profile was simulated, energy conservation scenarios were considered: the usage of thermostatic radiator valves (TRVs); accounting impacts of solar radiation and wind; changing mass flow rates based on the indoor temperature; adopting an additional control, changing the temperature setpoint; introducing night and day setbacks. After implementing new design and operational methods, the overheating of indoor spaces was alleviated, and the average indoor temperature was reduced from 23.5 °C to 20.4 °C. The annual specific heat consumption decreased to 174 kWh/m² (20.2% lower). The methodology ensured thermal comfort and high energy-saving potential. If operating parameters were adjusted, the total saving effect in energy demand was 119.8 MWh, with an energy-saving rate of 19.8%. Employing TRV-related savings and considering thermal inertia provided more stable indoor temperatures and higher energy performance. The minimum saving effect corresponded to the optimal operation and ensuring the indoor environment by considering wind and the maximum one-to-night setbacks. The fluctuations in indoor temperature became smoother. Full article

The accelerated urbanisation that is occurring in many regions of the world is resulting in a corresponding increase in the volume of sewage sludge. This sludge is then stored in specialised landfills, the area of which is increasing annually. One of the methods of utilising this sludge is through its combustion in power plants, where it serves to generate heat. However, due to the low calorific value of sewage sludge, it is recommended to combust it in conjunction with high-calorific fuel. To improve energy efficiency of sewage residue biomass utilisation by co-combustion with coal, it is necessary to determine the main combustion parameters and mass fraction in the mixture. The objective of this study is to estimate the primary parameters of combustion of sewage sludge and coal by employing the synchronous thermal analysis method, in addition to determining the concentrations of gaseous substances formed during the combustion process. A comprehensive technical and elemental analysis of the fuels was conducted, and their thermal properties were thoroughly determined. The inorganic residue from sewage sludge combustion was analysed by scanning electron microscopy for the content of trace elements and basic oxides. Thermogravimetric analysis (TGA) of fuels was conducted in an oxidising medium, utilising a 6 mg suspension with a heating rate of 20 °C/min. The profiles of TG, DTG, and DSC curves were then utilised to determine the ignition and burnout temperatures, maximum mass loss rate, combustion index, and synergistic effects. The mixture of coal with 25% sewage sludge was found to have the most energy-efficient performance compared to other mixtures, with a 3% reduction in ignition temperature compared to coal. Concentrations of carbon dioxide, carbon monoxide, nitrogen oxides, and sulphur oxides were also determined. Full article

Efficient cooling and heat recovery systems are becoming increasingly critical in large-scale commercial and industrial facilities, especially with the rising demand for sustainable energy solutions. Traditional air-conditioning and refrigeration systems often dissipate significant amounts of waste heat, which remains underutilized. This study addresses the challenge of harnessing low-potential waste heat from such systems to support fifth-generation district heating and cooling (5GDHC) networks, particularly in moderate-temperate regions like Flanders, Belgium. To evaluate the technical and economic feasibility of waste heat recovery, a methodology is developed that integrates established performance metrics—such as the energy efficiency ratio (EER), power usage effectiveness (PUE), and specific cooling demand (kW/t)—with capital (CapEx) and operational expenditure (OpEx) assessments. Empirical correlations, including regression analysis based on manufacturer data and operational case studies, are used to estimate equipment sizing and system performance across three operational modes. The study includes detailed modeling of data centers, cold storage facilities, and large supermarkets, taking into account climatic conditions, load factors, and thermal capacities. Results indicate that average cooling loads typically reach 58% of peak demand, with seasonal coefficient of performance (SCOP) values ranging from 6.1 to a maximum of 10.3. Waste heat recovery potential varies significantly across building types, with conversion rates from 33% to 68%, averaging at 59%. In data centers using water-to-water heat pumps, energy production reaches 10.1 GWh/year in heat pump mode and 8.6 GWh/year in heat exchanger mode. Despite variations in system complexity and building characteristics, OpEx and CapEx values converge closely (within 2.5%), demonstrating a well-balanced configuration. Simulations also confirm that large buildings operating above a 55% capacity factor provide the most favorable conditions for integrating waste heat into 5GDHC systems. In conclusion, the proposed approach enables the scalable and efficient integration of low-grade waste heat into district energy networks. While climatic and technical constraints exist, especially concerning temperature thresholds and equipment design, the results show strong potential for energy savings up to 40% in well-optimized systems. This highlights the viability of retrofitting large-scale cooling systems for dual-purpose operation, offering both environmental and economic benefits. Full article

This study aims to improve the operational efficiency of district heating (DH) systems by introducing a novel control method based on variable flow rate control, without compromising indoor comfort. The novelty of this work lies in its integrated analysis of flow control and substation configurations in DH networks, linking real-world operational strategies with mathematical modeling to improve energy efficiency and infrastructure costs. Using a case study from Omsk, Russia, where supply temperatures and energy demand profiles are traditionally rigid, the proposed approach utilizes operational data, including outdoor temperature, supply/return temperature, and hourly consumption patterns, to optimize heat delivery. A combination of flow rate adjustments, bypass line implementation, and selective control strategies for transitional seasons (fall and spring) was modeled and analyzed. The methodology integrates heat meter data, indoor temperature tracking, and Supervisory Control and Data Acquisition (SCADA)-like system inputs to dynamically adapt supply temperatures while avoiding overheating and reducing distribution losses. The results show a significant reduction in excess heat supply during warm days, with improvements in heat demand prediction accuracy (17.3% average error) compared to standard models. Notably, the optimized configuration led to a 21% reduction in total greenhouse gas (GHG) emissions (including 6537 tons of CO₂ annually), a 55.3% decrease in annualized operational costs, and a positive net present value (NPV) by year nine, with an internal rate of return (IRR) of 25.4%. Compared to conventional scenarios, the proposed solution offers better economic performance without requiring extensive infrastructure upgrades. These findings demonstrate that flexible, data-driven DH control is a feasible and sustainable alternative for aging networks in cold-climate regions. Full article

Additive manufacturing is revolutionizing the production of thermo-fluidic devices by enabling the creation of a wide variety of complex architectures, significantly enhancing performance and efficiency. Nevertheless, the range of structural types investigated to date remains limited, with most studies employing simplified methodologies and constrained operating conditions. This study explores the thermo-hydraulic performance of water-cooled annular channels incorporating BCC, Octahedral, and gyroid structures fabricated from AISI 316L stainless steel using Laser Powder Bed Fusion. The samples were experimentally tested across a broad spectrum of mass flow rates using a custom-designed test rig to evaluate heat transfer and pressure loss performance, and extensive morphological characterization was conducted to correlate the thermo-fluid dynamic behavior with the geometric and surface features specific to the manufacturing process. The investigation revealed that reticular configurations are preferable when low pressure losses are required, whereas gyroids are more suitable for high thermal loads. The topology of the structures was shown to be a key factor influencing overall performance, emphasizing the importance of selecting the appropriate structure for each specific application and the significant potential for performance improvements through the development of tailored metamaterials. Full article

This study investigates improving district heating (DH) systems by analyzing the effects of low-temperature operation on network efficiency, heat losses, and indoor temperature stability. A mathematical model is developed to simulate building heat performance under different supply temperatures, substation connection types, and envelope materials. The methodology involves detailed hourly heat load simulations and optimization techniques to assess the impact of temperature flexibility and heat accumulation within buildings. The results reveal that a 10 °C reduction in supply temperature leads to a heat loss decrease of up to 20%, significantly improving system efficiency. Moreover, buildings with higher thermal inertia and indirect substation connections exhibit better resilience to short-term temperature fluctuations, ensuring more stable indoor conditions. The analysis also demonstrates that optimizing temperature control can reduce operational costs by 19%, primarily by minimizing excessive heat supply and utilizing stored thermal energy effectively. Despite slight temperature fluctuations in extreme conditions, the system maintains indoor comfort levels within acceptable limits. This study concludes that transitioning to a lower-temperature DH system is feasible without compromising reliability, provided heat accumulation effects and supply flexibility are carefully managed. These findings offer a replicable approach for improving DH efficiency in networks with diverse building configurations. Full article

The use of supercritical carbon dioxide (SC-CO₂) coiled tubing drilling technology for developing heavy oil and other special reservoirs offers significant advantages, including non-pollution of oil layers, prevention of clay swelling, avoidance of reservoir damage, compact footprint, and enhanced oil recovery, making it a highly promising innovative drilling technology. The thermo-hydraulic coupling characteristics of SC-CO₂ in helical coiled tubes are critical to the design of SC-CO₂ coiled tubing drilling systems. However, existing models often neglect thermal conduction, variable thermophysical properties, and friction-compression coupling effects, leading to significant deviations in the prediction of temperature and pressure variations. Considering heat transmission and fluid dynamics, a coiled tube heat-transfer model which considers varying properties of both pressure and temperature has been developed based on an optimized convective heat-transfer coefficient. Then, the physical parameters of the carbon dioxide in the helical coiled tubing were researched. Results indicated that the temperature change of carbon dioxide in helical coiled tubing was small due to the low temperature difference between the carbon dioxide and the air as well as the existence of an air interlayer and low natural convective heat-transfer efficiency. The drop in pressure of the carbon dioxide increased with increasing coiled tubing length, and the pressure was half that of the conventional drilling fluid in the same condition due to its low viscosity. The density of carbon dioxide in the helical coiled tubing changed from 1078 kg/m³ to 1047 kg/m³ with increasing coiled tubing length under the conditions stated herein, and the carbon dioxide remained liquid throughout the whole process. Full article