Three-dimensional Numerical Simulation of Fluid Flow and Heat Transfer in Fin-and-tube Heat Exchangers at Different Flow Regimes

Book excerpt: This thesis aims at unifying two distinct branches of work within the Heat Transfer Technological Center (CTTC). On one side, extensive experimental work has been done during the past years by the researchers of the laboratory. This experimental work has been complemented with numerical models for the calculation of fin and tube heat exchangers thermal and fluid dynamic behavior. Such numerical models can be referred to as fast numerical tool which can be used for industrial rating and design purposes. On the other hand, the scientists working at the research center have successfully developed a general purpose multi-physics Computational Fluid Dynamics (CFD) code (TermoFluids). This high performance CFD solver has been extensively used by the co-workers of the group mainly to predict complex flows of great academic interest. The idea of bringing together this two branches, comes from the necessity of a reliable numerical platform with detailed local data of the flow and heat transfer on diverse heat exchanger applications. Being able to use local heat transfer coefficients as an input on the rating and design tool will lead to affordable and accurate prediction of industrial devices performance, by which the center can propose enhanced alternatives to its industrial partners. To accomplish these goals, several contributions have been made to the existing TermoFluids software which is in continuous evolution in order to meet the competitive requirements. The most significant problematics to adequately attack this problem are analyzed and quite interesting recommendations are given. Some of the challenging arising issues involve the generation of suitable and affordable meshes, the implementation and validation of three dimensional periodic boundary condition and coupling of different domains with important adjustments for the study of cases with different flow physics like time steps and thermal development. Turbulence is present in most of engineering flows, and refrigeration evaporator heat exchangers are not an exception. The presence of many tubes (acting like bluff bodies for the flow) arranged in different configurations and the fact that the flow is also confined by fins, create complex three dimensional flow features that have usually turbulent or transition to turbulent regime. Therefore, three dimensional turbulent forced convection in a matrix of wall-bounded pins is analyzed. Large Eddy Simulations (LES) are performed in order to assess the performance of three different subgrid-scale models, namely WALE, QR and VMS. The Reynolds numbers of the study were set to 3000, 10000 and 30000. Some of the main results included are the pressure coefficient around the cylinders, the averaged Nusselt number at the endwalls and vorticity of the flow. The final part of the thesis is devoted to study the three dimensional fluid flow and conjugated heat transfer parameters encountered in a plate fin and tube heat exchanger used for no-frost refrigeration. The numerical code and post processing tools are validated with a very similar but smaller case of a heat exchanger with two rows of tubes at low Reynolds for which experimental data is available. The next analysis presented is a typical configuration for no-frost evaporators with double fin spacing (for which very few numerical data is reported in the scientific literature). Conjugated convective heat transfer in the flow field and heat conduction in the fins are coupled and considered. The influence of some geometrical and flow regime parameters is analyzed for design purposes. In conclusion, the implementations and general contributions of the present thesis together with the previous existent multi-physics computational code, has proved to be capable to perform successful top edge three dimensional simulations of the flow features and heat transfer mechanisms observed on heat exchanger devices.