Numerical modeling and experimental validation of heat and mass transfer inside charge air coolers with water condensation

Abstract

A numerical model was developed for predicting the heat and mass transfer during condensation within a charge air cooler under different operating conditions. Numerical modeling of the charge air cooler was performed in a commercial CFD software with the condensation model implemented as a User Code. The semi-theoretical condensation model is based on the most common film condensation models and predicts the local condensation rate and the mass of the accumulated condensate. The validation of the numerical model was carried out using an experimental setup designed especially for this purpose. The measured and calculated values of the condensation rate and the mass of the accumulated condensate are in good agreement: the numerical model predicts the measured condensation rate within a mean deviation of 9.9% and the measured mass of the accumulated condensate within a mean deviation of 11.2%.