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Hydrodynamics and Heat Transfer Characteristics of A Novel Heat Exchanger With Delta-Winglet Vortex Generators - 2010
Hydrodynamics and Heat Transfer Characteristics of A Novel Heat Exchanger With Delta-Winglet Vortex Generators - 2010
a r t i c l e in fo
abstract
Article history:
Received 16 June 2008
Received in revised form
28 August 2009
Accepted 21 October 2009
Available online 6 November 2009
The effects of vortex generators on heat transfer and pressure drop of a novel heat exchanger are
investigated using computational uid dynamics (CFD) method. The Reynolds numbers based on n
collar outside diameter varied from 600 to 2600, the attack angle from 101 to 501, and the aspect ratio
from 1 to 4. The numerical results are also analyzed from the view point of eld synergy principle,
according to which the reduction of the intersection between velocity and temperature gradient is the
basic mechanism for augmentation of heat transfer. The results indicate that the enhanced
congurations produce the longitudinal vortices and accelerate the ow, which result in signicant
augmentations of heat transfer with modest pressure drop penalties. It was found that the deltawinglet vortex generator with an attack angle of 201and an aspect ratio of 2 provides the best integrated
performance over the range of Reynolds number computed. The Colburn j-factor of the optimal
conguration is shown to increase by 35.145.2% with a corresponding increase of 19.334.5% in the
friction factor.
& 2009 Elsevier Ltd. All rights reserved.
Keywords:
Heat transfer
Heat exchanger
Vortex generator
Computational uid dynamics (CFD)
Field synergy principle
1. Introduction
Fin-and-tube heat exchangers are widely used in various elds
such as chemical process, power generation, air-conditioning and
automobile. For n-and-tube heat exchangers, the dominant
thermal resistance is usually on the air side. Therefore, the
enhancement of heat transfer in n surface is critical to improve
the overall performance of heat exchangers. In order to reduce the
thermal resistance on the air side, many variants of the n
patterns like wave, slit and louver are widely used (Beecher and
Fagan, 1987; Achaichia and Cowell, 1988; Chang and Wang, 1997;
Wang et al., 1997; Kim and Bullard, 2002; Wongwises and
Chokeman, 2005). However, with signicantly improving the heat
transfer performance, the associated penalty of pressure drop is
also tremendous (Webb, 1994; Kays and London, 1998). However,
a secondary ow enhancement method, which uses vortex
generators to increase the heat transfer coefcient, only leads to
small increase in pressure drop. Using this method, the longitudinal vortex is generated by the vortex generators to cause ow
swirling and destabilizing, boundary layer modication and bulk
uid mixing. (Jacobi and Shah, 1995; Fiebig, 1998).
In general, the conguration of vortex generator on the n
surface-tube bank can be divided into common-ow-down
conguration and common-ow-up conguration. For common-ow-down conguration, the VGs (vortex generators) pairs
are usually mounted behind the tube such that the VGs enhance
the mixing of the hot and cold uid and improve the poor heat
transfer in the wake region. In common-ow-up conguration,
the VGs are placed further upstream adjacent to the tube in
order to create a nozzle-like ow passage, which brings about
separation delay and narrows the wake. Many experimental
investigations were devoted to the hydrodynamics and heat
transfer characteristics of n-and-tube heat exchanger with
vortex generator in common-ow-down conguration. Fiebig
et al. (1993) experimentally investigated the inuence of the
wing-type vortex generators on heat transfer and pressure drop of
a n-and-tube heat exchanger. In their chosen geometry, the
vortex generators increase the heat transfer by 55% to 65% for the
inline tube arrangement with a corresponding increase of 2045%
in the apparent friction factor. Fiebig et al. (1994) also studied
local heat transfer and pressure drop of n-and-tube heat
exchanger with winglet vortex generators. According to their
results, much stronger vortex-induced heat transfer enhancement
for the staggered arrangement of at tubes than with round tubes.
Wang et al. (2002a) utilized a dye-injection technique to visualize
the ow structure for enlarged n-and-tube heat exchangers with
annular and delta-winglet vortex generators. They found that for
the same winglet height, the delta winglet shows more intensive
vertical motion and ow unsteadiness than those of the annular
winglet. However, the corresponding pressure drops of the delta
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winglet are lower than those of the annular winglet at the same
Reynolds number. Wang et al. (2002b) investigated the local and
average heat transfer characteristics over a complete at tube-n
element with four vortex generators. The experiments were
performed using the naphthalene sublimation technique. They
pointed out that mean heat transfer enhancement observed was
as high as 47.5% over the no-winglet case. Leu et al. (2004) studied
the heat transfer and ow in the n-and-tube heat exchangers
with rectangular winglet-type vortex generators mounted behind
the tube. They found that the proposed technique is able to
generate longitudinal vortices and to improve the heat transfer
performance in the wake regions, and the case of a = 451 provides
the best heat transfer enhancement. Zhang et al. (2004)
conducted an experimental investigation of the effect of span
position of vortex generators on the local heat transfer coefcient
of three-row at tube bank n. They revealed that the vortex
generators should be mounted as close as possible to the tube
wall; the vortices generated by the upstream vortex generators
converge at wake region of the at tube. OBrien et al. (2004);
OBrien and Sohal (2005) tested local heat transfer in a narrow
rectangular duct tted with a circular tube, and/or delta-winglet
vortex generators. The duct was designed to simulate a single
passage in a n-and-tube heat exchanger. Joardar and Jacobi
(2005) carried out an experimental study of the effectiveness of
leading edge delta wings in a louvered-n compact heat
exchanger under both dry and wet surface conditions. They
reported an average heat transfer increases over the baseline case
of 21% for dry conditions and 23.4% for wet conditions, with a
pressure drop penalty smaller than 7%.
The investigations presented in the foregoing paper are aimed
at augmenting the heat transfer of heat exchangers by vortex
generators in common-ow-down conguration. More recently,
some experimental studies of a new type heat exchanger with
vortex generator in common-ow-up conguration are also
reported in the open literatures. Torii et al. (2002) proposed a
novel strategy that can augment heat transfer while reducing
pressure drop penalty in a n-and-tube heat exchanger at
relatively low Reynolds number ow conditions. In their studies,
delta-winglet-type vortex generators with common-ow-up conguration were deployed on the n surface. They found that, for
three-row tube bundles in a staggered arrangement with commonup-ow winglet pair built only in the rst row, the heat transfer
was increased by 1030%, and yet the pressure loss was reduced by
3455%. In a further study, Kwak et al. (2003) experimentally
investigated the performance of heat exchangers with various
numbers of transverse rows in staggered tube bundles. The winglet
pairs are placed beside the front row of the tube bundle. They
reported that the three rows of tube bundles provide the largest
pressure loss penalty. Allison and Dally (2007) conducted an
experimental study to investigate the effects of delta-winglet
vortex generators on the performance of a n-and-tube radiator. In
their studies, the winglets were arranged in ow-up conguration.
The results showed that the winglet surface had 87% of the heat
transfer capacity but only 53% of the pressure drop of the louver n
surface. Joardar and Jacobi (2008) experimentally studied the
characteristics of multirow inline-tube heat exchangers with two
different winglet congurations in common-ow-up arrangement.
They reported that vortex generator arrays can signicantly
enhance the performance of n-tube heat exchangers with ow
depths and n densities typical to those used in air-cooling and
refrigeration applications.
A comprehensive experimental investigation of a heat exchanger is very expensive because of the high equipment cost.
Although experimental data can be used for design and validating
numerical simulation results, the high cost of experiments
severely restricts its application. In comparison with experimen-
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2. Model description
2.1. Computational domain
The schematic diagram of core region of a plain n-and-tube
heat exchanger is shown in Fig. 1(a) with two rows of tubes along
the ow direction. The airow direction is x-direction, n span
wise direction is y-direction, and n thickness direction is
z-direction. As the total n construction has the symmetry
characters in the y-direction, a calculation element was dened
as the shadowed part of the gure. In the present study, heat
exchangers with different winglet geometries (attack angle and
aspect ratio) are computed. The geometric dimensions of the heat
exchangers are listed in Table 1. The isometric view of deltawinglet vortex generators on the n surface-tube bank is shown
in Fig. 1(b). The delta winglet is arranged in common-ow-up
conguration in the gure. The position and geometry of deltawinglet vortex generators are presented schematically in Fig. 1(c).
There are three geometrical parameters to describe a delta
winglet: angle of attack (b), aspect ratio (L), and winglet
thickness. As shown in Fig. 1(c), b is the angle of the winglet
with respect to the incoming ow direction. L is based on the
relative side lengths of the delta winglet and is dened as L = b/a.
In the present study, all of the winglets have equal heights b of
0.8Fp whereby the winglet length (a) is altered to vary L. The
values of b used in this investigation are 101, 201, 301, 401 and 501.
The chosen values of L are 1, 2, 3 and 4. For all cases, the thickness
of the delta winglet is kept constant at 0.2 mm. Fig. 1(d) presents
the pictorial view of the computational domain, where the
upstream and downstream parts of the computation domain are
not presented proportionately in order to save the space. The
domain was extended 5 times relative to the original heat transfer
zone for the exit section to ensure that no ow recirculation exists
at the outlet and the local one-way ow boundary condition can
1553
Momentum:
@
@
@u
@p
rui uk
m k
@xi
@xi
@xi
@xk
Energy:
@
@
k @T
rui T
@xi
@xi Cp @xi
v w 0;
T Tin const
4a
0; w 0;
0
@z
@z
@z
At the front and back boundaries:
@u
@w
0;
@y
@y
v 0;
@T
0
@y
4b
4c
0;
@z
@z
w 0;
@T
0
@z
5a
0;
@y
@y
v 0;
@T
0
@y
5b
0
@x
@x
@x
@x
5c
6a
0;
@y
@y
v 0;
@T
0
@y
6b
@T
0
@y
6c
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1554
Fig. 1. Schematic diagram of a n-and-tube heat exchanger with delta-winglet vortex generators and computation domain: (a) schematic of core region of a plain n-andtube heat exchanger, (b) isometric view of delta-winglet vortex generators on the n surface-tube bank, (c) dimensions and position of the vortex generators and (d)
computational domain.
Table 1
Geometric dimension for the studied heat exchangers.
Dimension
Value
2
10.23
25.4
22
3.2
0.13
44
10, 20, 30, 40, 50
1, 2, 3, 4
Tube region:
u v w 0;
T Twt const
6d
3. Solution method
3.1. Grid generation and independency validation
The geometry and the uid ow of the heat exchangers
with delta-winglet vortex generators are complex. The
quality and quantity of the meshes are very important for the
accuracy and time of the numerical simulations. Therefore,
the grid system must be generated with great care and effort
so that the near-wall gradients are appropriately resolved,
and the second ow pattern can be captured. The computational
meshes were generated using Gambit, which is packaged
with FLUENT software. The computational domain was
divided into three parts in the ow direction: the upstreamextended region, the n coil region and the upstream-extended
region. The mesh topologies are given in Fig. 2. Structured meshes
were used in the upstream-extended and downstream-extended
regions, while unstructured meshes were employed in the n coil
region. The regions adjacent to the tubes, ns and delta-winglet
vortex generators were meshed much ner with the help of
successive ratio scheme in GAMBIT. It is believed that these
efforts are required in order to capture the correct ow and heat
transfer eld. In this study, a very large difference in cell volume
between adjacent cells was avoided and a very high quality of
mesh (skewnesso 0.7) has been ensured throughout the
computational domain. Before any computational result can be
deemed enough to illuminate the physical phenomenon, the
computational results must be justied through the grid
independence test. In the present computation, a series of grid
independence tests have been conducted to mesh models to
ensure that optimized computational mesh was obtained. Four
different grid densities of about 150 000, 250 000, 400 000 and
600 000 cells were used for both the baseline and enhance
conguration. It was found that the difference in heat transfer
coefcient between the two highest grid densities was within 2%.
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1555
Fig. 2. Mesh topology: (a) side view of the upstream-extended region, (b) irregular
meshing of the n coil region and (c) detail of the grid on the vortex generator.
Q
Ao LMTD
Tw T in Tw T out
lnTw T in =Tw T out
Dp p in p out
11
12
y cos1
@T
@T
U @T
@x V @y W @z
~ jjgradTj
jU
13
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numerical integration,
P
y dv
ym Pi;j;k i;j;k
dvi;j;k
14
where dvi, j, k is the volume element of the control volume (i, j, k).
4.2. Model validation
In order to verify the present numerical work, the model
validation was conducted with the help of a n-and-tube heat
exchanger without winglet at rst. The heat exchanger has the
same diameter as that used by Wang et al. (1996). The geometric
parameters of the heat exchanger are listed as follows: the n
collar outside diameter of 10.23 mm, the n pitch of 3.2 mm,
transverse pitch of 25.4 mm and longitudinal pitch of 22 mm. The
Re number ranges from 600 to 2600, corresponding to the frontal
air velocity that ranges from 0.53 to 2.30 m/s. Fig. 3(a) shows the
comparison of Colburn j-factor between numerical prediction and
experimental results. It can be observed that the numerically
predicted Colburn j-factor is about 1.57.8% higher than the
experimental results of Wang et al. (1996). The comparison of
0.030
0.025
Experimental
Numerical
0.020
0.015
0.010
0.005
0.000
500
1000
1500
2000
2500
3000
Re
Fig. 4. Longitudinal vortex structure.
0.10
Experimental
Numerical
0.08
0.06
0.04
0.02
0.00
500
1000
1500
2000
2500
3000
Re
Fig. 3. Comparison of Colburn j-factor and friction factor between numerical and
experimental results: (a) Colburn j-factor and (b) friction factor.
Fig. 5. Velocity vectors on the plane close to a bottom plane: (a) the pain n
geometry and (b) vortex generator with b = 20o and L = 2.
%
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Y.-G. Lei et al. / Chemical Engineering Science 65 (2010) 15511562
55
50
without vortex generators
with vortex generators
45
40
Nu (x)
1557
35
30
25
20
15
10
10
20
x, mm
30
40
50
Fig. 6. Temperature distribution of the outlet surface (x= 44 mm) at Re =1000 for: (a) the plain(nandita, plain or pain?)n geometry and (b) the vortex generator with b = 201
and L =2.
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1558
the hot and cold uid. This is the reason why the local Nusselt
number behind the delta winglet is greatly improved.
89
100
h (W m-2 K-1)
80
60
40
Re = 600
Re = 1400
Re = 2200
10
20
30
attack angle ()
40
50
intersection angle ()
87
86
85
84
10
20
30
attack angle ()
40
50
3.5
Re = 600
Re = 1400
Re = 2200
3.0
2.5
M x104 (Ks-1)
20
Re = 600
Re = 1400
Re = 2200
88
2.0
1.5
1.0
0.5
0.0
10
20
30
attack angle ()
40
50
Fig. 9. Variations of average intersection angle and module production with attack
angle: (a) variation of intersection angle and (b) variation of module production.
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Y.-G. Lei et al. / Chemical Engineering Science 65 (2010) 15511562
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0.50
0.035
VG0
VG10
VG20
VG30
VG40
VG50
0.03
0.025
0.45
0.40
0.35
j/f
0.02
VG0
VG10
VG20
VG30
VG40
VG50
0.015
0.30
0.25
0.01
0.20
500
1000
1500
500
1000
Re
1500
Re
2000
2500
3000
Fig. 11. j/f versus Re for vortex generators and plain n geometry.
0.10
0.08
0.06
80
h (W m-1K-1)
100
VG0
VG10
VG20
VG30
VG40
VG50
0.04
60
40
0.02
500
1000
1500
2000
Re = 600
Re = 1400
Re = 2200
2500 3000
Re
Fig. 10. Colburn j-factor and friction factor versus Re for vortex generators and
plain n geometry: (a) j versus Re and (b) f versus Re.
20
2
3
aspect ratio
5. Conclusions
In this paper, the heat transfer and uid ow performance of nand-tube heat exchangers with delta-winglet vortex generators were
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0.04
88.0
Re = 600
Re = 1400
Re = 2200
87.5
87.0
= 1.0
= 2.0
= 3.0
= 4.0
0.03
0.025
86.5
86.0
intersection angle ()
0.035
0.02
85.5
0.015
85.0
84.5
84.0
2
3
aspect ratio
0.01
500
1500
Re
0.1
3.0
2.5
= 1.0
= 2.0
= 3.0
= 4.0
0.08
Re = 600
Re = 1400
Re = 2200
2.0
M x104 (Ks-1)
1000
1.5
0.06
1.0
0.5
0.0
0.04
500
0
2
3
aspect ratio
Fig. 13. Variations of average intersection angle and module production with
respect ratio: (a) variation of intersection angle and (b) variation of module
production.
1000
1500
Re
Fig. 14. Colburn j-factor and friction factor versus Re for vortex generators with
different aspect ratios (b = 201): (a) j versus Re and (b) f versus Re.
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In addition, the improvements of j/f ratio compared to the unenhanced heat exchanger are smaller and smaller with increase
in Reynolds number. It implies that the vortex generators placed
in common-ow-up arrangement are more effective for lower
Reynolds numbers than for higher Reynolds numbers.
(6) For the Reynolds number range under consideration, the
= 2 provides
= 201 and E
delta-winglet vortex generator with a
the best ratio of j/f. The optimal conguration increases the
Colburn j-factor by 35.145.2%, and simultaneously increases
the friction factor by 19.334.5%.
Notation
total heat transfer area, m2
Ao
Ac
minimum free ow area, m2
a
winglet length, m
b
winglet height, m
specic heat, J/(kg K)
Cp
Dc
n collar outside diameter (Do + 2d), m
tube outside diameter, m
Do
f
friction factor
n pitch, m
Fp
h
heat transfer coefcient, W/(m2 K)
j
Colburn j-factor
k
thermal conductivity, W/(m K)
LMTD log-mean temperature difference, K
M
module production
N
the number of control volume or point
Nu
Nusselt number
p
pressure, Pa
pressure drop in ow direction, Pa
Dp
Pr
Prandtl number
Q
heat transfer capacity, W
Re
Reynolds number based on n collar outside diameter
S1
span wise tube pitch, m
longitudinal tube pitch, m
S2
T
temperature, K
U, V, Wx, y, z velocity components, m/s
velocity at the minimum cross-section area, m/s
Uc
~
velocity vector
U
x, y, z Cartesian coordinates
Greek symbols
b
d
y
m
r
Subscripts
ave
in
out
w
average value
inlet parameter
outlet parameter
wall conditions
Acknowledgements
This work is supported by the Key Project of National Natural
Science Foundation of China (No.U0934005), and the National
Basic Research Program of China (973 Program) (2007CB206902).
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