Journal of Molecular Structure 1212 (2020) 127927

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Journal of Molecular Structure

journal homepage: http://www.elsevier.com/locate/molstruc

Design and production of high temperature heat pipe heat recovery

units
Emin Taner Elmas
Vocational School of Higher Education for Technical Sciences, Division of Motor Vehicles and Transportation Technologies, Department of Automotive

dır University, 76000, Ig
Technology, Ig
dır, Turkey

a r t i c l e i n f o a b s t r a c t

Article history: By this study; it has been aimed to determine the design parameters and to manufacture a heat recovery
Received 6 June 2019 unit using “heat pipe technology” in order to recover the energy of high temperature waste flue gases
Received in revised form which are the exhaust product of a water-tube steam boiler, fire-tube steam boiler, superheated water
17 December 2019
boiler, hot water boiler, incinerator, any equipment producing heat energy or any power unit and
Accepted 17 February 2020
Available online 24 March 2020
machine.
After having determined the scope of the Project, it has been decided that the system to be designed
shall be a prototype “Heat Pipe Air Recuperator”. Thus, the heat energy of the high temperature waste
Keywords:
Heat pipe
flue gases which are the exhaust product of a boiler or of an equipment producing heat energy shall be
Heat pipe air recuperator recovered through the use of the “Heat Pipe Air Recuperator” to be designed. A heat exchange between
Energy saving the exhaust gases and the fresh air shall realize, and so, the air shall be heated as free of charge.
Energy efficiency As well as this is a new technical profit, by the technical application of the Project, by implementing
Waste heat recovery waste heat recovery in such a way, an important energy efficiency and great profit shall be provided for
Exhaust gases the companies, industrial plants and also for the country economy by saving energy and fuel.
© 2020 Elsevier B.V. All rights reserved.

1. Introduction implementing waste heat recovery in such a way, an important and

For some industrial applications, the waste heat can be recov-
ered through the installation of economizers and can be used either
feed water heating or similar purposes. If the flow rate and the
temperature of the waste heat are high-enough (e.g. the exhaust
gas of a gas turbine or steam boiler), the waste heat can be trans-
ferred directly to a waste heat recovery boiler, therefore hot water,
superheated water, saturated steam or superheated steam can be
produced by use of such an engineering application.
Within the scope of our project, “heat pipe” sytem, a novel
technique has been implemented in order to be able to recover the
heat energy of waste exhaust gas, instead of using a conventional
recovery unit. The optimum design parameters has been deter-
mined by analyzing the capacity calculations and the optimal heat
pipe heat recovery unit is designed, and manufactured thereafter.
Develeopment of such a project shall provide an achievement of
a novel industrial technique, besides, as well as this is a new
technical profit, by the technical application of the Project, by
E-mail address: e.taner.elmas@igdir.edu.tr.
great profit shall be provided for the companies, industrial plants
and also for the country economy by saving energy and fuel.
The scope of the project has been determined and it has been
regarded that the heat recovery unit to be developed shall be a
prototype “Heat Pipe Air Recuperator” which is a kind of heat
-exchanger. By this study, the waste heat of exhaust gases coming
from a boiler or heat-production equipment, shall be recovered by
means of this “Heat Pipe Air Recuperator” and hot-air production
can be realized as free of charge through the use of this energy
recovery method.
2. Materials and methods
2.1. Project systematic, methods and design parameters
The project systematic, methods and design parameters can be
summarized as follows: At the beginning, the heat pipe material,
working fluid, wick material, and wick structure is specified and
determined [1]. The diameter and wall thickness of the heat pipe is
selected [2]. The fin structure and fin geometry of the heat pipe is
designated, fin dimensions and fin material is specified [3,4]. After

https://doi.org/10.1016/j.molstruc.2020.127927
0022-2860/© 2020 Elsevier B.V. All rights reserved.
2 E. Taner Elmas / Journal of Molecular Structure 1212 (2020) 127927

that, the operating temperature of the working fluid inside the heat
pipe is identified. The composition of waste exhaust gas to be used DPc ¼ DPv þ DPl þ DPg
for heat pipe air recuperator, the gas flow rate, inlet and outlet le þ lc
temperatures of waste exhaust gas are designated. The flow rate, leff ¼ la þ (7)
2
inlet and outlet temperatures of the air to be heated by means of
leff 473 mm ¼ 0:473 m
the energy recovered with the help of heat pipe air recuperator is
determined [5e9]. The materials and wall thicknesses for the body If 200 mesh stainless steel wick is used inside the heat pipe, the
and shell of heat pipe air recuperator are specified. The theoretical calculations shall be as follows [26e28]:
backgound is described, the calculations for the power-capacity The general equation DPc ¼ DPv þ DPl þ DPg is re-organized and
rates that can be achieved by each recuperator heat pipe which then the following balance is achieved:
have different mesh -wick configurations, so the maximum thermal

 h i
power capacity obtained by each heat pipe can be calculated. The 1 2sl cos q
convenience of the thermal capacity rates are verified by analyzing m_ ¼ 

 x  r l g l eff sin 4 (8)
8mv leff ml rc
the heat pipe limitation values, i.e. capillary limitation, boiling rv prv4 þ r Kl effAw
l
limitation, sonic limitation, entrainment limitation, viscous limi-
tation and condenser limitation [10e17]. The total thermal power m_ ¼ 2:007063138681  105 kg=s
capacity of complete heat pipe air recuperator is calculated. The The above calculated mass flow rate is considered and the po-
technical values for fin structure, the total heat transfer surface area wer capacity rate is determined accordingly and described as
of finned tubes within the recuperator, the ratio of finned surface to follows:
total surface, are identified. The layout geometry of the finned tubes
within the recuperator is adjusted. The mechanical constructive Q max ¼ m_ max x L .
design of the heat pipe air recuperator is established, production m_ max ¼ 2:007063138681  105 kg s (9)
drawings for manufacturing process are prepared and the projects
Q ma ¼ 44:7956421922,W
are drawn. The calculation for verification of fully developed flow
stream condition for exhaust gas at the inlet of heat pipe air The above power capacity rate is calculated by applying single-
recuperator is realized. The flow velocities of waste exhaust gas layer of stainless steel 200 mesh wick material. However, this ca-
stream and air stream ducts are checked if they are proportionally pacity may be increased and the double-layer of 200 mesh stainless
suitable for design limits. The amount of working fluid to be steel wick material can be composed instead of single-layer. Then,
capsulized into each heat pipe is calculated [18e23]. the power capacity rate is re-calculated and a comparison can be
made between the new and previous values.
2.2. The calculations of thermal power-capacity rates for heat pipe Hence the mass flow rate re-calculated as below and is found to
air recuperator be;
.
In order to determine the total thermal power capacity rate of m_ max ¼ 4:01411543  105 kg s
the heat pipe air recuperator, it is necessary to calculate the
maximum power-capacity rates that can be achieved by each By regarding the new mass flow rate, the thermal power ca-
recuperator heat pipe. Thefore, the maximum capacity of the pacity rate is re-calculated accordingly and is found as follows:
complete recuperator can be specifed [24,25].
The basic equation to be used for the calculation of heat pipe Q max ¼ m_ maks  LQ
power-capacity rate is as follows: Q max ¼ 89:59104228  103 kj=s
Q max ¼ 89:59104228 w
DPc ¼ DPv þ DPl þ DPg (1)
As it can be clearly seen by the above calculations, the new
where DPc is the pressure drop due to capillary effect, DPv is the power capacity rate is nearly two times higher than the first one.
pressure drop causing the flow of vapor from evaporator to the Therefore, a better value is now obtained. However, as a third step,
condenser, DPl is the pressure drop causing the flow of liquid from it is possible to think that the power capacity rate may be much
condenser to evaporator and DPg is the pressure drop due to more better and therefore increased. In order to increase the ca-
gravitational head. pacity, double-layer of 120 mesh stainless steel wick structure is
Each parameter can be defined by below equations: added on the double-layer of 200 mesh stainless steel wick and so,
a new four-layer stainless steel wick structure is obtained [29,30].
2 sl cos q Hence, the new power capacity rate can be obtained as follows:
Dpc ¼ (2)
re
Q max ¼ m_ max  L

 m_ max ¼ 6:527003514  104 kg=s
8 mv m_ le þ lc
Dpv ¼ þ la (3) Q max ¼ 1:456761914 kj=s ðkwÞ
rv p rv4 2 Q max ¼ 1456:761914 W
This new wick structure has four-layer composed of having two-
ml leff m_
Dp1 ðDarcy LawÞ (4) layer of 200 mesh stainless steel wick and two-layer of 120 mesh
rl K Aw
stainless steel wick.
As a result, the power capacity rate of a heat pipe is calculated as
Dpg ¼ rl g leff sin 4 (5) 1456.761914 W finally and it is obviously possible to say that this is
a much better value than the first and second rates. Consequently, it
Q max ¼ m_ max x L (6) is logical to use heat pipes having a thermal power capacity of
1456.761914 W of each for the design of complete heat pipe air
L ¼ ðhsb Þ Latent heat of vaporization recuperator unit.
 E. Taner Elmas / Journal of Molecular Structure 1212 (2020) 127927 3

Before confirming the value of 1456.761914 W, it is necessary to    

make some controls and required to verify the convenience of the AFT ¼ 455x103  174:25x103
thermal power capacity rate by analyzing that if the heat pipe
limitation values, i.e. capillary limitation, boiling limitation, sonic AFT ¼ 0:07928375 m2
limitation, entrainment limitation, viscous limitation and ma ¼ rair x AFT x Vair;i
condenser limitation are suitable.
At this step, all these limitation values must be compared with 0:274794776 ¼ 1:1614  Vair;i
the calculated thermal capacity power rate, the decision for the 
Vair;i ¼ 2:984299919 m s
suitability of limitations is made after the comparison. If the ther-
mal power capacity rate is out of the limitation values, the capacity ST
Vmax ¼ x Vair;i
calculation must be re-considered. Finally, for our study, all these ST dd dH
calculations and comparisons are made many times leading to ST ¼ 75 mm
achieve the most optimal value and the maximum thermal power
rate compatible with all these limitations is determined as Q SL ¼ 75 mm
max ¼ 1456.761914 W [31,32]. dd ¼ 31:8 mm
The Calculation of Total Thermal Power Capacity Rate for the
Complete Heat Pipe Air Recuperator Unit.
dH ¼ 14:20502901 mm
The total number of heat pipes included within the heat pipe air 75x103
recuperator unit is 18 ea [33e44]. Vmax ¼   x 2:984299919
3
75x10 31:8x103 0:014205029
The total heat amount to be transferred can be calculated by the
following equation: Vmax ¼ 7:719355674 m=s

Q Total ¼ Q max  Nb (10) The Reynolds number is calculated as follows [61e68]:

r air x Vmax x dd Vmax x dd

ReD;max ¼
m air n air
Q Total, the total thermal power capacity rate of the heat pipe air .
recuperator, kW vair ¼ 15:89  106 m2 s
Q max, the thermal power capacity rate for each heat pipe, KW
7:719355674 x 31:8  103
Nb , the total quantity - number of heat pipes included within the ReD;max ¼
heat pipe air recuperator, ea. 15:89  106
ReD;max ¼ 15448:42734
Q max ¼ 1456:761914 W
Then the Nusselt Number can be calculated as follows:
Q max ¼ 1:45676191:KW
NuD ¼ 1:13 C2 C1 Rem
D;max Pr
1=3
Hence, the total thermal power capacity rate of the heat pipe air
recuperator unit can be calculated as follows:
ReD;max ¼ 1544842734
Q Total ¼ Q max  Nb
Q Total ¼ 1:456761914  18 ST 75
Q Total ¼ 26:22171445 KW ¼ ¼ 2:358490566
dd 31:8
After this step, the energy balance for the heat pipe air recu-
perator unit must be established considering the values of tem- SL 75
¼ ¼ 2:358490566
perature and flow rate for both the waste exhaust gas as the heating dd 31:8
hot fluid and also the air as the heated cold fluid, so the logarithmic
The layout and cross-sections of four-layer wick structure to be
mean temperature difference should be calculated. The results are
located inside the heat pipe are detailed by Fig. 1.
tabulated at Table 1. Then, the waste exhaust gas mass flow rate is
Therefore, the water amount to be filled into the heat pipe shall
calculated [45e52].
be as follows [69e79]:
Therefore, for the fluid flow; Duct Sectional Width is 455 mm
and Duct Sectional Height is 174.25 mm [53e60];
mwater ¼ 0.013267604 kg
Vwater, working fluid water volume, ml
Table 1 rl ¼ 952:15 kg=m3
For the heat pipe air recuperator; the inlet and outlet temperatures, logarithmic Vwater¼13.93436328 ml (Calculated volume)
mean temperature difference for both the waste exhaust gas as the heating hot fluid Vwater¼20 ml (Selected volume)
and also the air as the heated cold fluid.

AFT ¼ ½Duct Sectional Width  ½Duct Sectional Height (11) Finally; it has been decided that Vwater¼20 ml of water (dem-
ineralized boiler feed water) is the amount of working fluid to be
filled into each heat pipe [80,81].
Temperature Parameter Numerical Value of Temperature Temperature Unit

Tgi 260 C
Tgo 177 
C 3. Results and discussion

Tai 27 C

Tao 122 C Each heat pipe is consisting of a inner four-layer stainless steel
DTlm 143.9166 
C
wick structure which has double-layer of 120 mesh stainless steel
4 E. Taner Elmas / Journal of Molecular Structure 1212 (2020) 127927

The number of fins and fin pitch both for exhauts gas side and air
side must be considered accordingly.

Fig. 1. The layout detail and the cross sections of four-layer wick structure located
within the heat pipe.

wick and double-layer of 200 mesh stainless steel wick on it.

(double-layer of 120 mesh is added on the double-layer of 200
mesh) [82,83].
As a result, the thermal power capacity rate of a heat pipe is Fig. 2. The 3-D solid model of the finned heat pipes.
calculated as 1456.761914 W finally and it is obviously possible to
say that this is a much better value than the first and second rates.
Consequently, it is logical to use heat pipes having a thermal power
capacity of 1456.761914 W of each for the design of complete heat
pipe air recuperator. The total number of heat pipes included
within the heat pipe air recuperator is 18 ea.
The convenience of the thermal capacity rates are verified by
analyzing the heat pipe limitation values, i.e. capillary limitation,
boiling limitation, sonic limitation, entrainment limitation, viscous
limitation and condenser limitation. The total power capacity of
complete heat pipe air recuperator is calculated and is found to be
as 26.22171445 kW.
In spite of the fact that it is possible to increase the thermal
power capacity rate of each heat pipe, the limitation values are very
critical at this step. Each limitation value must be compared with
the calculated thermal power capacity rate of a heat pipe. Each
limitation value must be higher than the maximum capacity rate of
a heat pipe, so the energy transfer can be achieved between the
evaporator and condenser sections [84,85]. Fig. 3. The solid model of heat pipe air recuperator prototype. (The body shell is
The wick configuration is very important in order to achieve the closed).
energy transfer within a heat pipe. The layer configuration of wick
structure may be changed in order to increase the capacity of each
heat pipe, however if the heat pipe capacity exceeds even one of
those limitation values, the required thermodynamical cycle does
not realize, thus the heat pipe does now work and the energy can
not be transferred from evaporator section to condenser section.
The wick material should be selected durable for the working
fluid flow.
The material of the heat pipe walls are also important since the
pipes are exposed to high temperature exhaust gases. The high
temperature exhaust gases are also corrosive, therefore the pipe
material should be selected accordingly. The working fluid inside
the heat pipe is also another important issue and it should also be
selected properly for high temperature applications [86,87].
The outside diameter and wall thickness should also be
considered appropriate for whole heat pipe air recuperator since
the number of total heat pipes are determined according to the
total thermal power capacity rate of heat pipe air recuperator
system. The fin structure, dimensions and the fin configuration
Fig. 4. The solid model of heat pipe air recuperator prototype. (The body shell is open).
must also be considered for the calculations.
 E. Taner Elmas / Journal of Molecular Structure 1212 (2020) 127927 5

The material for recuperator casing, exhaust duct and air duct
must also be appropriate for the application.
Heat pipe length, position, amount, working fluid quality must
also be considered for the design and production of heat pipe
recuperator system.
The amount of working fluid to be filled into each heat pipe
must also be calculated since the proper energy transfer can only be
achived on condition that the synchronized evaporation and
condensation is maintained. The temperature of the working fluid
is also critical.
The configuration of total number of heat pipes should also be
solid modelled in order to provide the acceptable pressure drop
rates of exhaut gas and air flow within the recuperator system. The
fluid flow ducts for both the exhaust gas and air must have the
corrrect dimensions, the hydrodynamic and thermal inlet and
outlet lengths have to provide the fully developed flow conditions.
The chemical compositions of exhaust gases are also considered
for the capacity rates. The heat transfer coefficients are also
determined for the proper calculation of heat flux rates [88,89].
The mass flow rates for exhaust gas, air and working fluid are
important for the design calculations.
The inlet and outlet temperatures of both exhauts gas and air
must be determined accordingly.
After all these parameters discussed in this section are deter-
mined and selected properly, the real thermal power capacity rate
of each heat pipe can be calculated, and therefore the expected total
power capacity rate of heat pipe air recuperator can be reached
[90,91].
The figures of 3-D solid models of the heat pipe air recuperator,
the prototype and the complete system are represented by Fig. 2,
Fig. 3, Fig. 4 and Fig. 5.

4. Conclusion

The Summary Table for Design Parameters of Complete Heat

Fig. 5. The solid model of heat pipe air recuperator prototype and complete installed
system including all connection flow stream ducts.
Pipe Air Recuperator Unit.
After having finished the design and production of heat pipe air
recuperator, the design parameters can be summarized as a
conclusion. The chemical composition of high temperature waste
flue gases which are the exhaust product of a boiler or of an
equipment consist of CO2, SO2, N2, O2 and H2O and the amount of
each constituent are given by Table 2. These constituents are based

Table 2
Heat pipe air recuperator unit design paramaters summary table.

The Chemical Composition of Waste Exhaust Gas

Constituent Amount - kg/kg Amount - m3/m3

CO2 0.1309 0.0819

SO2 0.0 0.0
N2 0.7273 0.7193
O2 0.0287 0.0248
H2O 0.1131 0.174

mg 0.274794776 kg/s Mass flow rate of waste exhaust gas, kg/s

ma 0.274794776 kg/s Mass flow rate of the air to be heated kg/s

Tgi 260  C The inlet temperature of waste exhaust gas to heat pipe air recuperator
Tgo 177  C The outlet temperature of waste exhaust gas from heat pipe air recuperator
qTai 27  C The inlet temperature of the cold air to be heated
Tao 122  C The outlet temperature of the heated air

Q max 1456.761914 W 1.456761914 kW Thermal power capacity for each heat pipe
Q Total 26,222 W 26.222 kW Total thermal power capacity of complete heat pipe air
recuperator unit
Tv 108-109  C The operating temperature of working fluid within the heat pipes
Vwater 20 ml. The volume of working fluid to be filled into the heat pipe
Working Fluid Water (Soft, Demineralized)

Wick Structure 2 layers - 200 Mesh SST 304 and 2 layers - 120 Total four-layer wick structure
Mesh SST 304
wicks (304 quality stainless steel)
Heat Pipe Ø 31.8 mm  3.6 mm. Finned Tube Pipe: St 35.8.I, Fin: Carbon steel-145  34  2.5 mm
Quantity of Heat Pipes (3  3 aligned - layout double-finned tube 3  2  3 ¼ 18 ea. Total number of heat pipes
structure)
Heat Pipe Layout Position Vertical position 90
Heat Pipe Length 473 mm
Air Recuperator Body-Shell Frame St 37 Carbon steel 730  565  473 mm
Number of fins and fin pitch (Air Side) 15 ea. X 11 mm
Number of fins and fin pitch (Exhauts 15 ea. X 11 mm
Gas Side)
6 E. Taner Elmas / Journal of Molecular Structure 1212 (2020) 127927
on for the calculations of heat pipe air recuperator which is a
prototype kind of heat -exchanger for high temperature heat pipe
heat recovery unit.
The mass flow rate of waste exhaust gas is selected equal to the
mass flow rate of the air to be heated in order to reach a proper
balanced thermal design. Both of these mass flow rates, are
0.274794776 kg/s. The inlet temperature of waste exhaust gas to
heat pipe air recuperator, outlet temperature of waste exhaust gas
from heat pipe air recuperator, inlet temperature of the cold air to
be heated, outlet temperature of the heated air are 260  C, 177  C,
27  C and 122  C, respectively. Thermal power capacity for each
heat pipe is 1.456761914 kW and the total thermal power capacity
of complete heat pipe air recuperator unit is 26.222 kW. The
operating temperature of working fluid within the heat pipes is
108e109  C, the volume of working fluid to be filled into the heat
pipes is 20 ml. The working fluid of heat pipe is soft, demineralized
water. The wick structure for each heat pipe is designed consisting
of 2 layers - 200 Mesh SST 304 and 2 layers - 120 Mesh SST 304
wicks (304 quality stainless steel), forming totally four-layer wick
structure. The dimension of each heat pipe is Ø 31.8 mm  3.6 mm
and they are finned-tubes. The pipe material is St 35.8. I, the fin
material is carbon steel and fin dimensions are 145  34  2.5 mm.
The number of fins and fin pitch both for exhauts gas and air sides
are equal and 15 ea. X 11 mm, respectively. The total number of heat
pipes used to produce the heat pipe air recuperator is 18 ea. (3  3
aligned - layout double-finned tube structure gives 3  2  3 ¼ 18
ea.). The heat pipe layout is vertical position-90 . The length of each
heat pipe is 473 mm. The air recuperator body-shell and frame are
made of St 37-carbon steel, the dimensions for the recuperator is
730  565  473 mm.
All design parameters of complete heat pipe air recuperator unit
mentioned in this section are summarized by Table 2.
Author contribution statement
As the only author of my article, I made the following individual
contributions by myself: Conceptualization, Data curation, Formal
analysis, Funding acquisition, Investigation, Methodology, Project
administration, Resources, Supervision, Validation, Visualization,
Roles/Writing - original draft, Writing - review & editing.
Declaration of competing interests
The authors declare that they have no known competing
financial interests or personal relationships that could have
appeared to influence the work reported in this paper.
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