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Procedia Manufacturing 22 (2018) 714–721
Procedia Manufacturing 00 (2017) 000–000
11th International Conference Interdisciplinarity in Engineering, INTER-ENG 2017, 5-6 October
www.elsevier.com/locate/procedia
2017, Tirgu-Mures, Romania
11th International Conference Interdisciplinarity in Engineering, INTER-ENG 2017, 5-6 October
2017, Tirgu-Mures, Romania
Energy efficient heat pipe heat exchanger for waste heat recovery in
Energy efficient
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Engineering pipe heat buildings
exchanger
International Conference for2017,
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28-30 June
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Andrei Burlacua, *, Gavril Sosoia, Robert Ștefan Vizitiua, Marinela Bărbuțăa, Constantin
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Abstract a
University of Minho, 4800-058 Guimarães, Portugal
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Unochapecó, 89809-000 Chapecó, SC, Brazil
Abstract
This study presents a Computational Fluid Dynamics (CFD) Heat Transfer Analysis for an originally designed Energy Efficient
Heat Pipe Heat Exchanger for Waste Heat Recovery in Buildings. The research is focused on developing a heat pipe heat
This study presents
exchanger a Computational
for domestic hot water and Fluid Dynamics
thermal (CFD)
agent Heat Transfer
preparation, Analysis
preheating for an the
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ventilation Efficient
systems in
Abstract
Heat Pipe Heat Exchanger for Waste Heat Recovery in Buildings. The research is focused on developing a heat
buildings, using as a primary agent the return of the existing heating system. The proposed device has a lot of advantages as high pipe heat
exchanger for
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domestic hotlow
recovery, water
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be increasingly interconnected,
has a lot of advantages as high
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© 2018 The Authors. Published by Elsevier B.V.
Indeed,
© 2018 Thelean
Engineering. management
Authors. Publishedand continuous
by Elsevier B.V. improvement approaches suggest capacity optimization instead of
Peer-review under responsibility of the scientific committee of the 11th International Conference Interdisciplinarity in Engineering.
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Keywords: Heat Pipe; both theHeat
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Zero Energy This Energy
Building (NZEB); paper Performance
presents and discusses
of Building; a mathematical
CFD Analysis.
model for capacity management based on different costing models (ABC and TDABC). A generic model has been
Keywords: Heat Pipe; Heat Pipe Heat Exchanger; Nearly Zero Energy Building (NZEB); Energy Performance of Building; CFD Analysis.
developed and it was used to analyze idle capacity and to design strategies towards the maximization of organization’s
1. Introduction
value. The trade-off capacity maximization vs operational efficiency is highlighted and it is shown that capacity
optimization might hide operational inefficiency.
1. Introduction
In the
© 2017 Thepresent, buildingsbyare
Authors. Published responsible
Elsevier B.V. for approximately 40% of energy consumption and 36% of CO 2 R R

emissions in the European Union (EU).

Peer-review under responsibility of the scientific committee of the Manufacturing Engineering Society International Conference
In the present, buildings are responsible for approximately 40% of energy consumption and 36% of CO 2
2017. R R

emissions in the European Union (EU).

Keywords: Cost Models; ABC; TDABC; Capacity Management; Idle Capacity; Operational Efficiency

* Corresponding author. Tel.: +40 232-701-258; fax: +40-232-233-368.

1.E-mail
Introduction
address: andrei.burlacu@tuiasi.ro
* Corresponding author. Tel.: +40 232-701-258; fax: +40-232-233-368.
The cost
E-mail
2351-9789 of idle
address:
© 2018 capacity is a fundamental
andrei.burlacu@tuiasi.ro
The Authors. Published by Elsevier information
B.V. for companies and their management of extreme importance
in modern under
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Peer-review underTel.:
* Paulo Afonso. responsibility
+351 253of the761;
510 scientific committee
fax: +351 253 604of741
the 11th International Conference Interdisciplinarity in Engineering.
E-mail address: psafonso@dps.uminho.pt

2351-9789 © 2017 The Authors. Published by Elsevier B.V.

Peer-review under responsibility of the scientific committee of the Manufacturing Engineering Society International Conference 2017.
2351-9789 © 2018 The Authors. Published by Elsevier B.V.
Peer-review under responsibility of the scientific committee of the 11th International Conference Interdisciplinarity in Engineering.
10.1016/j.promfg.2018.03.103
 Andrei Burlacu et al. / Procedia Manufacturing 22 (2018) 714–721 715
722 Andrei Burlacu et al. / Procedia Manufacturing 00 (2018) 721–728

While new buildings generally need fewer than three to five liters of heating oil per square meter per year, older
buildings consume about 25 liters on average. Some buildings even require up to 60 liters. [1]
The European Commission has presented some package of measures in order to increase the energy
performances of buildings and keep the European Union competitive as the clean energy transition is changing
global energy markets.
The most important Directives covering the reduction of the energy consumption of buildings are The Energy
Performance of Buildings Directive (2010/31/EU, 19 May 2010) and the Energy Efficiency Directive (2012/27/EU,
25 October 2012) of the European Parliament and of the Council. [2, 3]
The target for the Commission is to lead to the clean energy transition, not only to adapt it. For this reason the EU
has committed to cut CO 2 emissions by at least 40% by 2030 while modernising the EU's economy and delivering
on jobs and growth for all European citizens. Today's proposals have three main goals: putting energy efficiency
first, achieving global leadership in renewable energies and providing a fair deal for consumers. [4]

Nomenclature

HP Heat Pipe
HPHE Heat Pipe Heat Exchanger
NZEB Nearly Zero Energy Building
EU European Union
T Temperature, [oC]
T op Operating temperature, [oC]
Lv Latent heat of vaporization [kJ/kg]
Cp Specific heat of vapour, constant pressure [kJ/kg∙ oC]
Pv Vapour pressure [bar]
ρv Vapour density [kg/m3]
ρl Liquid density [kg/m3]
λ Thermal conductivity, [W/(m∙ oC)]
l hp Length of the heat pipe, [m]
d hp Diameter of the heat pipe, [m]
l ev Length of the evaporator, [m]
d ev Diameter of the evaporator, [m]
l co Length of the condensed, [m]
d co Diameter of the condenser, [m]
l HPHE Length of the heat pipe heat exchanger, [m]
d HPHE Diameter of the heat pipe heat exchanger, [m]

Romania also adopted in 2010, the Directives 2010/31/EU and 2012/27/EU and recently the European legislation
on Nearly Zero Energy Buildings (NZEB), Government Ordinance No. 13/2016 of 27.01.2016 which states that over
only 3 years the buildings will receive authorizations only if they will achieve the nearly zero energy buildings
targets: "New buildings for which reception on completion shall be based on the building authorization issued from
31 December 2020 will be buildings whose energy consumption is almost zero." [5]
This new adopted Directives have a very important economic impact for the EU and determines the promotion of
some urgent actions regarding the improving of the energy performances of buildings. This should be mandatory and
determines the implementation of new innovative types of heat exchangers with higher performances for energy
recovery. According to the literature review, one of the methods is to recover the waste energy from different
industrial processes or from the commercial, public and residential buildings. [6 - 15]
From this category, heat pipe heat exchangers have become very efficient because are very compact and have the
possibility for adjusting the transferred heat flux and also can be used for preheating or heating the air from air
conditioning systems, heating or producing the domestic hot water. [6 - 8, 13, 15 - 17, 19 - 21]. Even if they still
have relatively higher costs compared to the classical heat exchangers it is evident they will have a fast development
716 Andrei Burlacu et al. / Procedia Manufacturing 22 (2018) 714–721
Andrei Burlacu et al. / Procedia Manufacturing 00 (2018) 721–728 723

and penetration of the market. [6 - 14, 18, 22]. One of the most commonly and widely used classic heat exchanger in
the present is for waste heat recovery from the heating systems from buildings [6, 7, 9, 13, 18].
The promotion of the new heat pipe heat exchangers will provide energy savings and most important the
reduction of Greenhouse Gasses emissions and environmental protection. This research domain can be very fast
developed by using the new technologies and more powerful workstations for simulating and testing before the
manufacturing. The investors will benefit for a high efficient products for energy recovery with a short payback
periods of time for the initial investments.

1.1. Research methodologies

This study presents an originally designed Heat Pipe Heat Exchanger for Waste Heat Recovery in residential,
public or commercial buildings using as a primary agent the return of the existing heating system.
The recovered heat can be used for domestic hot water and thermal agent preparation or preheating / heating the
air from the ventilation system.
To achieve the objectives of the proposed paper, a 3D model for our designed Heat Pipe Heat Exchanger was
created using Autodesk Inventor Software. In order to determine the energy performances and the feasibility of the
proposed system, the analysis and simulations were performed in different hypothesis using Autodesk Simulation
CFD software.

2. Experimental and Numerical Results

2.1. Description of the numerical model for the Energy Efficient Heat Pipe Heat Exchanger

The 3D numerical model for the proposed system was realized using Autodesk Inventor Software at the real scale
geometry. The constructive details of the Energy Efficient Heat Pipe Heat Exchanger are presented in Fig. 1.

Fig. 1. Heat Pipe Heat Exchanger (HPHE).

1-Evaporator, 2-Condenser, 3-Heat Pipe, 4-Heat transfer ring, Type 1, 5-Heat transfer ring, Type 2,
6-Separation flange, 7-Primary agent inlet, 8-Primary agent outlet, 9-Secondary agent inlet, 10-Secondary agent outlet

The heat pipe heat exchanger has a modular and compact design and it is formed by two main parts, the
evaporator and the condenser, separated by a separation flange. The heat pipes are introduced vertically through the
separation flange for recovering the heat from the primary agent (the return of the existing heating system) and
 Andrei Burlacu et al. / Procedia Manufacturing 22 (2018) 714–721 717
724 Andrei Burlacu et al. / Procedia Manufacturing 00 (2018) 721–728

heating the secondary agent (cold water). For increasing the performances of heat pipe heat exchanger we have
introduced five heat transfer rings in the condenser part. The heat transfer rings are placed so that the water
circulation inside the condenser to be guided along the heat pipes thus resulting a better heat transfer.
The geometry was created with the following dimensions:

• Evaporator:𝑙𝑙𝑒𝑒𝑒𝑒 = 0.700𝑚𝑚, 𝑑𝑑𝑒𝑒𝑒𝑒 = 0.250𝑚𝑚

• Condenser: 𝑙𝑙𝑐𝑐𝑐𝑐 = 0.400𝑚𝑚, 𝑑𝑑𝑐𝑐𝑐𝑐 = 0.250𝑚𝑚
• HPHE: 𝑙𝑙𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻 = 1.100𝑚𝑚, 𝑑𝑑𝐻𝐻𝐻𝐻𝐻𝐻𝐻𝐻 = 0.250𝑚𝑚
• Heat Pipe: 𝑙𝑙ℎ𝑝𝑝 = 1.000𝑚𝑚, 𝑑𝑑ℎ𝑝𝑝 = 0.010𝑚𝑚
• Separation flange: 𝑑𝑑𝑠𝑠𝑠𝑠 = 0.300𝑚𝑚
• Heat transfer ring type 1 diameter (interior/exterior): 𝑑𝑑ℎ𝑡𝑡𝑡𝑡1𝑖𝑖𝑖𝑖𝑖𝑖 = 0.011𝑚𝑚 , 𝑑𝑑ℎ𝑡𝑡𝑡𝑡1𝑒𝑒𝑒𝑒𝑒𝑒 = 0.150𝑚𝑚
• Heat transfer ring type 2 diameter (interior/exterior): 𝑑𝑑ℎ𝑡𝑡𝑡𝑡2𝑖𝑖𝑖𝑖𝑡𝑡 = 0.150𝑚𝑚 , 𝑑𝑑ℎ𝑡𝑡𝑡𝑡2𝑒𝑒𝑒𝑒𝑒𝑒 = 0.248𝑚𝑚
• Primary agent (hot water) inlet diameter: 𝑑𝑑ℎ𝑤𝑤 = 0.027𝑚𝑚
• Secondary agent (cold water) inlet diameter: 𝑑𝑑𝑐𝑐𝑐𝑐 = 0.027𝑚𝑚

The Heat pipes were acquired from nPowerTek Company from Taiwan and operates with water as a working
fluid and are made from Copper. The most important characteristics are presented in Table 1.

Table 1. nPowerTek Heat pipes.

Heat pipe proprieties Symbol Value Units
Length of the heat pipe l hp 1.00 [m]
Diameter of the heat pipe d hp 0.01 [m]
Operating temperature T op +5…+ 230 [oC]
o
Latent heat of vaporization at 70 C Lv 2334 [kJ/kg]
o
Specific heat of vapour, constant pressure at 70 C Cp 1.936 [kJ/kg∙ oC]
o
Liquid density at 70 C ρl 977.5 [kg/m3]
o
Vapour density at 70 C ρv 0.198 [kg/m3]
o
Thermal conductivity of operating fluid at 70 C λw 0.663 [W/m∙ oC]
Thermal conductivity of heat pipe container (Copper) λ cu 394.0 [W/m∙ oC]

2.2. Boundary Conditions

To cover a lot of operating conditions the simulation program was structured with constant volume flow rate, Q 1
and temperature, T 1,in , for the primary agent in the Evaporator and variable temperature, T 2,in , and constant volume
flow rate, Q 2 , for the secondary agent in the Condenser, as follows, Table 2.

Table 2. Description of the case studies.

Case Description
Case 1 Q 1 =10 [l/min]; T 1,in = 70 [oC]; Q 2 = 6 [l/min], T 2,in =10 [oC];
Case 2 Q 1 =10 [l/min]; T 1,in = 70 [oC]; Q 2 = 10 [l/min], T 2,in =10 [oC];
Case 3 Q 1 =10 [l/min]; T 1,in = 70 [oC]; Q 2 = 15 [l/min], T 2,in =10 [oC];
Case 4 Q 1 =10 [l/min]; T 1,in = 70 [oC]; Q 2 = 20 [l/min], T 2,in =10 [oC];
Case 5 Q 1 =10 [l/min]; T 1,in = 70 [oC]; Q 2 = 30 [l/min], T 2,in =10 [oC];

Also, for a complete evaluation of the efficiency of the heat pipe heat exchanger we have also reanalyzed all the
cases for a reduced temperature, T 1,in , for the primary agent maintaining constant the volume flow rate, Q 1 as
presented in Table 3.
718 Andrei Burlacu et al. / Procedia Manufacturing 22 (2018) 714–721
Andrei Burlacu et al. / Procedia Manufacturing 00 (2018) 721–728 725

Table 3. Description of the case studies.

Case Description
Case 1 Q 1 =10 [l/min]; T 1,in = 60 [oC]; Q 2 = 6 [l/min], T 2,in =10 [oC];
Case 2 Q 1 =10 [l/min]; T 1,in = 60 [oC]; Q 2 = 10 [l/min], T 2,in =10 [oC];
Case 3 Q 1 =10 [l/min]; T 1,in = 60 [oC]; Q 2 = 15 [l/min], T 2,in =10 [oC];
Case 4 Q 1 =10 [l/min]; T 1,in = 60 [oC]; Q 2 = 20 [l/min], T 2,in =10 [oC];
Case 5 Q 1 =10 [l/min]; T 1,in = 60 [oC]; Q 2 = 30 [l/min], T 2,in =10 [oC];

2.3. Creating the Mesh

After applying the boundary conditions we have created the geometry mesh, and it resulted a number of 940000
elements (Fig. 2).

Fig. 2. Heat Pipe Heat Exchanger (HPHE): Mesh size.

2.4. Numerical Results

The numerical modeling achieved with Autodesk Simulation CFD software package revealed the quality and
quantity of thermal heat flux in various assumptions of the configuration through 2D and 3D contours of static
temperatures (Fig. 3, Fig. 4, Fig. 5 and Fig. 6).

The results for all the study cases are presented in Table 4 and Fig. 7.

Table 4. Results for all the cases – HPHE [oC]

Primary agent temperature Case 1 Case 2 Case 3 Case 4 Case 5
o o o o o
T 1,in [ C] T 2,out [ C] T 2,out [ C] T 2,out [ C] T 2,out [ C] T 2,out [oC]
70 59.6 57.4 54.2 50.1 47.6
60 48.7 46.3 43.5 40.7 38.2
 Andrei Burlacu et al. / Procedia Manufacturing 22 (2018) 714–721 719
726 Andrei Burlacu et al. / Procedia Manufacturing 00 (2018) 721–728

Fig. 3. Contours of static temperature for all the cases - 2D – HPHE – 70 [oC].

Fig. 4. Contours of static temperature for all the cases - 2D – HPHE – 60 [oC].

Fig. 5. Contours of static temperature for all the cases - 3D – HPHE – 70 [oC].
720 Andrei Burlacu et al. / Procedia Manufacturing 22 (2018) 714–721
Andrei Burlacu et al. / Procedia Manufacturing 00 (2018) 721–728 727

Fig. 6. Contours of static temperature for all the cases - 3D – HPHE – 60 [oC].

Fig. 7. Results for all the cases – HPHE [oC].

Analyzing the results it is obvious that the maximum temperature T 2,out =59.6 [oC] for the secondary agent it is
obtained corresponding to the Case 1 with Q 1 =10 [l/min], T 1,in = 70 [oC], Q 2 =6 [l/min] and T 2,in =10 [oC]. This is
normal considering the reduced volume flow rate for the secondary agent but we can observe that in all the other
cases the results are very good, even in the Case 5 where the volume flow rate of the secondary agent is 5 times
higher, Q 2 =30 [l/min], the resulted temperature for the secondary agent is T 2,out =47.6 [oC].
In the case of using a reduced temperature for the primary agent, T 1,in =60 [oC], and maintaining all the other
parameters the same we still have obtained good results for the secondary agent, T 2,out =48.7 [oC] for the volume
flow rate Q 2 =6 [l/min] and T 2,out =38.2 [oC] for the volume flow rate Q 2 =30 [l/min] proving the feasibility of the
designed heat pipe heat exchanger.
This is very encouraging and demonstrate that our designed heat pipe heat exchanger can also operate with
higher volume flow rates for the secondary agent or with lower temperatures for the primary agent.
Also we can observe the utility of introducing the heat transfer rings inside the condenser favouring the heat
transfer from the heat pipes to the secondary agent.

3. Conclusions

The results of the numerical simulations for the originally designed Energy Efficient Heat Pipe Heat Exchanger
for Waste Heat Recovery in Buildings confirmed our assumptions and demonstrate the feasibility for the proposed
 Andrei Burlacu et al. / Procedia Manufacturing 22 (2018) 714–721 721
728 Andrei Burlacu et al. / Procedia Manufacturing 00 (2018) 721–728

system to operate using as primary agent the return of the existing heating system. The recovered heat can be used
for domestic hot water and thermal agent preparation, preheating / heating the air from ventilation systems in
buildings.
By implementing our proposed system for a residential, public or industrial building we can increase the energy
performances of the building simultaneously with the decreasing of CO 2 emissions, which represents a grate
positive impact upon the environment.
The results of our study are in close correlation with the European Directives covering the improving the energy
efficiency and the reduction of the energy consumption of buildings.

References

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