Compact Heat Exchangers Research Articles

Experimental study of enhanced convection in mini-tube with jet chamber insert using infrared thermometry

Enhancing single-phase convection in mini-tubes is essential for improving the efficiency and compactness of heat exchangers. Conventional mini-tube inserts, such as twisted tapes and helical screws, suffer from limited fluid mixing and significant pressure drops. These limitations restrict their effectiveness in achieving high heat transfer efficiency, especially in compact systems where space and energy are constrained. To overcome these challenges, this study introduces a novel mini-tube insert design featuring linked jet chambers to promote adequate spatial fluid mixing and significantly boost convective heat transfer. Experimental results demonstrate that at a Reynolds number (Re) of 300, the new insert increases the Nusselt number (Nu) by 67 % over a tube without inserts. Infrared thermometry further reveals that this enhancement leads to a 15.1 °C reduction in average wall temperature. The performance evaluation criterion (PEC) for the jet chamber insert reaches 1.66 at Re = 300, representing an 18.5 % improvement compared to traditional helical screw inserts. Beyond heat transfer, the insert design also improves temperature uniformity along the flow direction and stabilizes the outlet fluid temperature, addressing critical performance metrics for practical applications. The findings highlight its potential to improve energy efficiency and thermal performance in systems where space and thermal management are crucial.

Design and optimization of additive manufactured Fischer-Koch-structured heat exchanger for enhanced heat transfer efficiency

The study explores using triply periodic minimal surfaces (TPMS) to enhance heat exchanger efficiency and reduce flow resistance. By leveraging TPMS's high surface area and minimal curvature, a range of compact heat exchangers with different unit cell sizes was developed for thermal-hydraulic analysis. The Fischer-Koch (FK) S structure, a TPMS model, was used to precisely control design parameters like porosity and surface area. Selective Laser Melting (SLM) facilitated the creation of complex geometries, which were analyzed through numerical simulations and experiments. Results showed a strong link between Nusselt (Nu) and Reynolds (Re) numbers for the FK structure. The smallest unit cell (6 mm) achieved the highest heat transfer rate and specific volume heat transfer of 140 W/cm3, a notable industry advancement. A “Light” configuration reduced the heat exchanger's volume by 28 % without affecting thermal performance, indicating a new direction for efficient, lightweight designs.

Experimental investigation on combined flow and temperature non-uniformity for three-fluid compact heat exchanger with cross flow configuration

ABSTRACT Non-uniformities in flow and temperature are the most conspicuous reason behind diminishing efficacy in heat exchangers. Cross-flow three-fluid heat exchanger being a pivotal component in cryogenics, is experimentally investigated under imposed flow and temperature non-uniformities in central hot fluid. The interaction of combined flow and temperature non-uniformity invariably precipitates a degradation in the efficacy of both adjacent fluids. About 7.3% and 6.2% of efficacy degradation is encountered in fluid “a” (for C 2 configuration) and fluid “c” (for C 1 configuration), respectively, for F N 1 + T N III model. In many cases, C 1 configuration and T N III model is inimical to fluid “c” performance.

Design of a Thermal Performance Test Equipment for a High-Temperature and High-Pressure Heat Exchanger in an Aero-Engine

For next-generation power systems, particularly aero-gas turbine engines, ultra-light and highly efficient heat exchangers are considered key enabling technologies for realizing advanced cycles. Consequently, the development of efficient and accurate aero-engine heat exchanger test equipment is essential to support future gas turbine heat exchanger advancements. This paper presents the development of a high-pressure and high-temperature (HPHT) heat exchanger test facility designed for aero-engine heat exchangers. The maximum temperature and pressure of the test facility were configured to simulate the conditions of the last-stage compressor of a large civil engine, specifically 1000 K and 5.5 MPa. These conditions were achieved using multiple electric heater systems in conjunction with an air compression system consisting of three turbo compressor units and a reciprocating compressor unit. A commissioning test was conducted using a compact tubular heat exchanger, and the results indicate that the test facility operates stably and that the measured data closely align with the predicted performance of the heat exchanger. A commissioning test of the tubular heat exchanger showed a thermal imbalance of 1.02% between the high-pressure (HP) and low-pressure (LP) lines. This level of imbalance is consistent with the ISO standard uncertainty of ±2.3% for heat dissipation. In addition, CFD simulation results indicated an average deviation of approximately 1.4% in the low-pressure outlet temperature. The close alignment between experimental and CFD results confirms the theoretical reliability of the test bench. The HPHT thermal performance test facility will be expected to serve as a critical test bed for evaluating heat exchangers for current and future gas turbine applications.

Dynamics and heat transfer characteristics on tube side and shell side of micro-tube compact air-to-air heat exchanger

Applied to the design and selection of compact micro-tube heat exchangers for aviation, an experimental study on the flow and heat transfer performance on both the tube side and shell side of micro-tube heat exchangers was conducted based on the Wilson plot method. The results demonstrated that, although the fluid on the tube side entered the hydraulically smooth region earlier at Reh = 3000, the enhancement in the heat transfer performance and drag reduction characteristics was primarily manifested on the shell side. Compared with traditional empirical correlations, the shell-side Nusselt number showed a maximum enhancement of 47.99 %, and the flow resistance was reduced by a maximum of 59.84 %. Furthermore, a new evaluation index was employed to verify the performance of the heat exchanger. The results indicated that the heat exchanger exhibited advantages in designs requiring low flow resistance, compactness, and lightweight compactness.

The Effect of Channel Surface Roughness on Two–Phase Flow Patterns: A Review

This review article highlights the critical impact of surface roughness in modifying the structure of two-phase flow within mini- and microchannels, particularly in processes such as boiling and condensation. Channel surface roughness enhances flow resistance, affects the distribution of vapor bubbles, and enhances heat transfer by providing additional nucleation sites. Several experiments have shown that while increased surface roughness enhances the efficiency of heat transfer, increased flow resistance may hurt system performance. This is so because too high a surface roughness negatively impacts flow resistance, a factor of importance in the optimization for a balance between heat transfer and flow resistance, especially in high-performance compact heat exchangers. Furthermore, the review identifies that higher-degree measurement and characterization techniques of the surface roughness are increasingly required, as traditional 2D parameters may not fully represent the actual physics of complex surface interactions in two-phase flow systems. Consequently, the article calls for further research that can examine the exact relationship between roughness, flow structure, and thermal performance with the aim of improving design strategies for future heat exchanger technologies.

Heat Transfer Enhancement of Nano Al2O3 Mixed with Regular Coolant Blends in Compact Heat Exchanger

Heat Transfer Enhancement of Nano Al2O3 Mixed with Regular Coolant Blends in Compact Heat Exchanger

Experimental Study on Heat Transfer Characteristics on Intersecting Spiral Finned Tube Type on Heat Exchanger

Compact heat exchangers play an important role in the industrial world, one of their applications being in thermal machines to dissipate heat generated during mechanical processes. To improve the performance of heat exchangers, many studies have been conducted, including the addition of spiral fins, and the spacing of these fins on the outer surface. This study examines the heat transfer characteristics of the outer surface. The heat exchanger is made of galvanized pipe with an inner diameter of 20 mm and an outer diameter of 22 mm. It has a passage length of 300 mm with a sharp turn of 81 mm. The spiral fins are made of aluminum, with a thickness of 0.3 mm, a spiral fin height of 10 mm, and a distance of 30 mm between the spiral fins. The cross-section of the spiral fins varies, including options without spiral fins, without spiral fins, without intersecting spiral fins, with intersecting 2 mm spiral fins, intersecting 5mm spiral fins, and intersecting 7mm spiral fins. Heat exchangers are supplied with hot at a constant inlet temperature of 80C and a flow rate of 0.57 kg/s. The fan operates at speeds of 3.59 m/s, 4.45 m/s and 5.07 m/s. The results show that the highest heat transfer rate and heat transfer coefficient are produced by the heat exchanger with a cross-section of 5 mm intersecting spiral fins, specifically 11,682.7 W and 604 W/m2.K.

A Review on Heat Transfer Enhancement in a Heat Exchanger

Compact heat exchanger is commonly used in car radiators which is normally small with low flowrate. To produce a large surface area, thin plates or corrugated fins are attached closely separating the two fluids. Compact heat exchanger is normally used in applications where weight and volume are the significant factors for the enhancement of heat transfer. This paper reviews the research related to the characteristics, advantages and findings on various type of compact heat exchanger. It is found that the geometric parameters such as fin shape, tube shape, fin pitch, tube pitch, tube arrangement, tube angle and vortex generators affect the heat transfer performance in general. The air inlet angle of 45° and common flow upstream gives the optimum heat enhancement in most studies while the most suitable air flow is between 1.8 – 3.8 m/s.

Design correlations for a novel enhanced compact heat exchanger with offset circular fins

A novel core geometry for compact heat exchangers, termed “circular offset fins (cOF)”, is proposed and experimentally investigated in the present work. This core design resembles the well-known offset strip fins used in efficient compact heat exchangers, with a key difference that instead of having rectangular fluid flow passages between deflections, this design features circular paths, resulting in fins with semicircular profiles. An experimental study examined heat transfer and pressure drop characteristics for five different core geometries. These geometries varied in passage diameters, lengths, and degrees of obstruction. The experiments were carried out over Reynolds numbers ranging from 500 to 3000 at different core wall temperatures. Data was analyzed using Kays and London's steady-state steam-to-air heat transfer technique to determine the empirical Colburn factor. The empirical Fanning friction factors for these geometries were also obtained. The asymptotic behavior of the Colburn and Fanning friction factor data allowed for the development of correlations in the function of Reynolds number and geometry dimensionless parameters. The proposed correlations predict data within ±6 % and ±8 %, respectively. The impact of different geometric parameters on core performance was assessed using the Colburn and Fanning friction factors, as well as area and volume goodness factors, and compared to rectangular offset strip fins. Direct comparisons showed that circular offset fins consistently exhibited a lower friction factor than rectangular fins. Although its Colburn factor was lower than rectangular fins up to a Reynolds number of 2000, circular fins it surpassed that of rectangular fins beyond this point. For the area goodness factor, their performance was comparable at a Reynolds number of 500, with circular fins outperforming after this point, achieving a 1.8-fold advantage at a Reynolds number of 3000. In terms of the volume goodness factor, both types of fins performed similarly up to a Reynolds number of 1000. Beyond this threshold, circular offset fins demonstrated a 1.3-fold improvement at a Reynolds number of 3000, underscoring the potential of the novel core geometry for compact heat exchanger applications.

Comparative analysis of inlet and outlet cavity designs on the thermal-hydraulic performance of compact heat exchangers for combustion engine exhaust heat recovery

ABSTRACT Improving the Internal Combustion Engines (ICEs) overall thermal efficiency is crucial to reduce fuel consumption and emissions. To achieve this goal, waste heat recovery from exhaust gases remains the most promising strategy, which involves the utilization of compact heat exchangers. This study evaluates the performance of novel Monolithic Integrated Thermal Exchange Matrixes (MITEMs) designs for recovering exhaust heat from a 70 hp diesel engine, focusing on the impact of inlet/outlet cavities. Computational Fluid Dynamics simulations were employed to analyze the heat transfer rate, pressure drop, and overall thermal-hydraulic performance of different MITEM designs. The Rectangular Channels with Large Cavities (RCLC) design exhibited superior performance, enhancing the heat transfer rate by 14.7% compared to the baseline design while limiting pressure drop increase to 9.2%. The RCLC design increased local Nusselt numbers and heat transfer coefficients by up to 60%, achieving peak velocities of 98 m/s within cross-sectional planes. These findings provide valuable insights for optimizing exhaust heat recovery systems in diesel engines.

Thermal-hydraulic analysis of wetted airside plain fin flat tube heat exchangers and the role of vortex generators

This study addresses the demand for efficient and compact heat exchange solutions in industrial applications. Unlike previous studies that predominantly focused on round tube configurations, this research investigates the impact of vortex generators and geometrical parameters on plain-fin flat-tube designs. Using ANSYS Fluent, the study evaluated the effects of fin geometry, vortex generators, and flow conditions on thermal–hydraulic performance. The key findings revealed that vortex generators enhanced heat transfer by 5–48% by promoting fluid mixing and turbulence but also leading to an increment in friction losses reaching 35–62%, depending upon the number of vortex generators. Condensation rates increased downstream of vortex generators due to enhanced mixing with cooler surfaces. In terms of thermal–hydraulic performance, specific plain-fin configurations outperformed others, offering efficient heat transfer with relatively lower friction losses, even when compactness was considered. Some configurations were recommended for applications where heat exchanger size is less important, but high heat transfer is crucial. Lastly, it was discovered that the effect of vortex generators is more pronounced for lower to intermediate pumping powers per unit area. New empirical correlations were also derived to predict thermal–hydraulic behavior based on geometry and vortex generator placement. A comparison with the literature revealed significantly higher performance as compared to convex/concave vortex generators. Lastly, it was discovered that the effect of vortex generators is more pronounced for lower to intermediate pumping powers per unit area. Empirical correlations for “j” and “f” were correlated with all geometric parameters.

Adaptability analysis of flow and heat transfer multi-scale numerical method for printed circuit heat exchanger

The printed circuit heat exchanger (PCHE) is a high-efficiency and compact mini-channel heat exchanger. Due to the large number of fine channels, it is difficult to conduct the flow and heat transfer numerical simulation of the entire heat exchanger based on the actual channels, which requires a lot of computational resource and time. In this paper, a simplified multi-scale numerical method with a non-equilibrium porous media model (NOPM) is proposed to study the flow and heat transfer performance of PCHE at high temperature and pressure. The pressure field, velocity field and temperature field of NOPM and actual multi-channel model (MC) under different working conditions are compared to study the adaptability of NOPM for the PCHE. The results indicate that the NOPM can accurately predict the flow and heat transfer performance under PCHE configurations with a large number of channels. However, as the channel number decreases, the relative errors in the temperature and pressure prediction significantly increase due to the increased flow maldistribution. Similarly, the NOPM can well predict the overall temperature distribution of the PCHE solid when the channel number is numerous. This work could support accurate thermal design, and provide accurate temperature field for the thermal stress analysis of PCHE.

Numerical and experimental investigation of additive manufactured heat exchanger using triply periodic minimal surfaces (TPMS)

With the increasing demand for high-efficiency compact heat exchangers in automobiles and spacecraft, lighter and more efficient metamaterials hold promise as advanced materials for cooling applications but remain beyond reach. Triply Periodic Minimal Surface (TPMS) structures, characterized by their smooth surfaces and significantly huge volumetric surface area, represent ideal internal structures for heat exchangers, and the development of additive manufacturing has made their design and production possible. This study focuses on designing heat exchangers based on seven TPMS structures (Fischer-Koch S, Gyroid, SplitP, Diamond, I-WP, F-RD, Primitive) and prints the finished heat exchangers using AlSi10Mg material based on numerical investigation results. Comprehensive evaluation metrics are used to rank the results. The findings reveal that the internal interleaved channels have varying effects on different structures, with Fischer-Koch S exhibiting the highest heat transfer capability of up to 269 W/K. Gyroid and I-WP demonstrate the best fluidity, with resistance only 23.44 % of Primitive’s. Gyroid has the best overall evaluation metrics, with a 54 % efficiency improvement over traditional plate heat exchangers. Additionally, this study proposes the use of the Voronoi algorithm to handle the channels of TPMS and identifies the asymmetric characteristics of heat exchangers on both sides, and it is believed that there is still greater optimization potential for the performance of TPMS heat exchangers.

Heat Transfer Enhancement in a 3D-Printed Compact Heat Exchanger

The study describes experimental data on thermal tests during the condensation of HFE7100 refrigerant in a compact heat exchanger. The heat exchanger was manufactured using the additive 3D printing in metal. The material is AISI 316L steel. MPCM slurry was used as the heat exchanger coolant, and water was used as the reference medium. The refrigerant was condensed on a bundle of circular tubes made of steel with an internal/external diameter of di/de = 2/3 mm, while a mixture of water and phase change materials as the coolant flowed through the channels. Few studies consider the heat exchange in condensation using phase change materials; furthermore, there is also a lack of description of heat exchange in small-sized exchangers printed from metal. Most papers deal with computer research, including flow simulations of heat exchange. The study describes the process of heat exchange enhancement using the phase transition of coolant. Experimental data for the mPCM slurry coolant flow was compared to the data of pure water flow as a reference liquid. The tests were carried out under the following thermal and flow conditions: G = 10–450 [kg m−² s−1], q = 2000–25,000 [W m−²], and ts = 30–40 [°C]. The conducted research provided many quantities describing the heat exchange in compact heat exchangers, including heat exchanger heat power, heat exchange coefficient, and heat exchange coefficients for working media. Based on these factors, the thermal performance of the heat exchanger was described. External characteristics include the value of the thermal power and the heat exchange coefficient as a function of the mass flow density of the working medium and the average logarithmic temperature difference. The performance of the heat exchanger was presented as the dependencies of the heat exchange coefficients on the mass flux density and the heat flux density on the heat exchange surface. The thickness of the refrigerant’s condensate film was also determined. Furthermore, a model was proposed to determine the heat exchange coefficient value for the condensing HFE7100 refrigerant on the outer surface of a bundle of smooth tubes inside a compact heat exchanger. According to experimental data, the calculation results were in good agreement with each other, with a range of 25%. These data can be used to design mini condensers that are widely used in practice.

Precision micro-particle removal from through-holes via laser-induced plasma shockwaves in additive manufacturing

This study introduces a novel Laser-Induced Plasma (LIP) technique for the non-contact, rapid removal of nano and microparticles from through-holes in Additive Manufacturing (AM) components. This method is crucial for high-value applications, such as medical devices, compact heat exchangers, and aerospace engineering, which require efficient cleaning of intricate parts with holes and channels to address high failure costs. The technique leverages shockwaves generated by LIP to target and clean these complex geometries. The research focuses on two main areas: (i) characterizing the effects of shockwaves in semi-cylindrical channels to understand interactions with complex geometries, and (ii) quantitatively analyzing the removal of Fe-271 microparticles from semi-cylindrical channels of silicon (Si) wafers, selected for their consistent surface properties compared to the rough textures of AM-produced surfaces. Utilizing the experimental set-up Laser-Induced Plasma LIP Cleaning for Additive Manufacturing (LIPCAM), the study demonstrates that complete microparticle removal is achievable up to 20 mm from the plasma source with variable laser pulses. The results indicate that particles larger than 27 μm are entirely removed after a single pulse, and particles larger than 21 μm are removed after 50 pulses. These findings highlight the method's effectiveness in achieving high particle removal efficiency across different distances and particle sizes, thus ensuring thorough decontamination of complex internal structures. The study underscores the potential of this method to enhance the reliability and safety of critical AM builds, making it a viable solution for industries where precision and cleanliness are paramount.

Thermal Stress Analysis of Compact Heat Exchanger Produced by Additive Manufacturing

Abstract Compact heat exchangers are renowned for their high heat transfer rates and efficiency, achieved by incorporating mini and micro-channels in their core design. However, operating under conditions of high-pressure fluctuations and significant temperature differences between hot and cold streams can potentially induce fatigue failure. To the best of our knowledge, this study represents the first investigation into the thermal stresses experienced by heat exchanger samples manufactured by selective laser melting technology, focusing on circular channels. Experiments were conducted using hot water in the inner channel, while the remaining channels and the sample surface were subjected to natural convection in ambient air. Strain gauges, thermocouples, and RTDs were employed to measure strain and temperature variations over time. These data were utilized as inputs for a numerical model based on finite element method. The strain measurements were compared with those obtained from the numerical model, revealing an average difference of approximately 20%. Lastly, a thermal fatigue analysis based on the maximum equivalent stresses predicted by the numerical model is presented. The evaluation considered both S-N curves: outlined in the ASME standard and the one obtained with specimens produced through selective laser melting. In the case of circular channels manufactured through additive manufacturing evaluated in this work, thermal stresses alone are insufficient to cause component failure due to fatigue. However, significant pressure cycles superimposed on the model can reverse this situation, making the combined effect of thermal and mechanical stresses influential in determining the component's fatigue behavior.

Numerical analysis of free convection under the influence of radiation and inclined MHD in a triangular cavity filled with hybrid nanofluid and a porous fin

This study presents a novel investigation into the thermal behavior of a hybrid nanofluid (MgO − Ag − H2O) in natural convection around a porous fin in a triangular enclosure under the influence of radiation and magnetohydrodynamic effects. The research uniquely combines these complex phenomena, addressing a significant gap in the literature. This configuration has potential applications in advanced solar thermal collectors, electronic cooling systems for high-power devices, and compact heat exchangers in various industries. The main objectives are to understand how various parameters influence heat transfer and fluid flow behavior and to optimize the design for enhanced thermal performance. The study considers a range of variables including Rayleigh number (103 − − 106), Hartmann number (0 – 50), Aspect ratio (0.3 – 0.6), radiation parameters (Rd = 1 − − 5, λ = 1 − 5), and volume concentration (0- 0.05), which have been numerically analyzed using the finite element method (FEM). The findings reveal that increasing the Darcy number (Da) enhances heat transfer at low Rayleigh numbers (Ra = 103,104). However, at higher Ra (Ra = 106), the impact of Da becomes more complex, with a critical Da beyond which heat transfer efficiency decreases due to an increase in flow resistance. The nanoparticle volume concentration plays a vital role, as higher concentrations lead to improved heat transfer efficiency, especially at higher Ra, through enhanced thermal conductivity and thermal dispersion. The length of the porous fin greatly impacts fluid flow patterns and heat transfer rates, with longer fins creating more complex flow patterns, promoting enhanced heat transfer and stronger thermal plumes. Thermal radiation, represented by the radiation parameters (Rd and λ), significantly influences both the heat transfer rate and the convective flow patterns within the enclosure. This study also incorporates a comprehensive entropy generation analysis, providing novel insights into system irreversibilities and optimization potential. The entropy analysis reveals the complex interplay between various parameters and their impact on system efficiency, offering valuable guidance for designing high-performance thermal management systems.

Design framework based on implicit modeling for a compact heat exchanger with triply periodic minimal surface structures

Design framework based on implicit modeling for a compact heat exchanger with triply periodic minimal surface structures

Microscale channels produced by micro friction stir channeling (μFSC)

The current literature lacks comprehensive research on the processing limits of the Friction Stir Channeling process (FSC) for creating the smallest continuous and integral channels, using tools with threaded probes 2 mm in diameter or smaller. This study pioneers the exploration of the extreme limits of the microscale FSC process, with potential applications in the development of ultra-compact heat exchangers, seeking to enhance the efficiency and sustainability of these systems. Customized tools were designed and manufactured, with predefined dimensions and geometries to establish a set of parameters that consistently produce continuous microchannels, maximizing the hydraulic diameter within the constraints of each tool's specifications and geometry. Comprehensive evaluations—including continuity, watertightness, micro-computed tomography, neutron computed tomography, microhardness testing, and thermal measurements—were conducted to ensure the channels' structural integrity and suitability for super-compact heating and cooling applications. Internal channels were successfully created using tools with threaded probes measuring 2.0, 1.0, and 0.5 mm in diameter, and corresponding shoulder diameters of 5, 4, and 3.5 mm, within 5 mm thick AW1050-H111 aluminum alloy plates. The smallest channel achieved a hydraulic diameter of 191 μm, using a 0.5 mm diameter threaded probe, thus qualifying it as a microchannel. The thermal performance of a compact heat exchanger model was also tested, demonstrating that despite the high cost associated with tool production, particularly due to the specialized manufacturing processes required, the FSC process remains viable, reliable, and repeatable for the production of mini- and micro-channels.