Heat Transfer Model Research Articles

DEM analysis of heat generation and transfer during granular flow in a rotating drum

In many granular material handling processes, heat generation, and subsequent temperature rise, due to contacts between particles and surfaces is common. Aiming to explore this phenomenon, friction-induced heat generation and heat transfer models are developed and implemented into a Discrete Element Method (DEM) in this paper. The DEM models are validated qualitatively for the temperature distribution pattern and quantitatively for the evolution of particle temperature rise using data obtained experimentally. Moreover, the temperature distribution of the drum end plates obtained in the simulations shows the same annulus pattern observed in experiments. It is also found that increasing the rotation speed of the drum leads to an increase in the annular heated region of drum and in the net heat that particles obtain. In addition, a higher rotation speed leads to higher absolute fluctuations and lower relative variability of particle temperature.

Hydrogen-fueled PFI SI engine investigation for near-zero NOx emissions in de-throttled and supercharged ultra-lean burn conditions

This study investigates the efficiency and combustion characteristics of a hydrogen port fuel injection (PFI) spark ignition (SI) engine under various load levels, excess air ratios and intake pressures. Experiments were conducted on a single-cylinder research engine to evaluate the effects of throttle opening and supercharging on pumping work and combustion parameters. The key findings indicate that abnormal combustion events are more closely related to the relative air-fuel ratio (λ) than to load, further limiting load increases during de-throttled operation. Additionally, combustion variability compromised mixture enleanment in both naturally aspirated and supercharged conditions. The gross indicated efficiency was approximately 40.7% across the range of 2.2 < λ < 3.5 with minimal variation. Efficiency gains were linked to reduced heat transfer losses in lean conditions, as validated by computational heat transfer, thermodynamic and fluid dynamic models on Gamma Technologies GT-ISE software. Moreover, nitrogen oxides (NOx) emissions were nearly zero for all test conditions when λ was above 2.2. These findings provide crucial insights into optimizing hydrogen engine performance under various intake pressures, highlighting the potential for achieving high efficiency and low emissions.

On Possibility of Controlling of Temperature of Gases and Liquids in a Transportation System by Local Cooling or Heating

In this paper we consider an approach of changing the temperature of liquids and gases in the pipeline by local heating and cooling. We introduce a model of heat transfer with account forced convection. Also we introduce an analytical approach for prognosis of heat transfer.

Mathematical model for heat transfer during underground coal gasification process

Purpose. To develop a mathematical model of the “coal-gas” medium heat transfer during underground coal gasification to predict the combustion face advance velocity and the duration of gasification column mining. Methodology. To detect the temperature fields in the coal seam and gas, depending on the displacement length of the phase transition boundary, a boundary-value problem of mathematical physics has been developed. To solve this boundary-value problem, Boltzmann transformations, as well as methods for solving ordinary differential equations, are used. Newton-Raphson method, which has quadratic convergence, is used to find the roots of the transcendental equation. Findings. Tendencies in the formation of mathematical models when studying temperature fields around an underground gasifier have been analyzed, with highlighting their disadvantages. A mathematical model of heat transfer during underground gasification has been developed, taking into account the phase transition boundaries of the “coal-gas” medium. A computational experiment was conducted to determine the temperature of the phase transition boundary based on the length of the gasification column and the duration of the process. Originality. A mathematical model for heat transfer during coal gasification in the form of a boundary-value problem of mathematical physics, which consists of parabolic heat-transfer equations, the Stefan condition at the phase transition boundary, and the Dirichlet boundary conditions, has been constructed. As a result of solving the boundary-value problem, a self-similar solution has been obtained for the distribution of the coal seam and gas temperature fields, as well as the position of the phase transition boundary depending on the gasification duration and on the medium density, thermal conductivity coefficients, specific heat capacity of gas and coal, specific calorific value and temperature of coal combustion, initial coal temperature and constant temperature of the gasification process. The conducted analysis of numerical calculations provides a deeper understanding of the dynamics of underground coal gasification process and makes necessary corrections to achieve the maximum process efficiency. Practical value. A methodology for determining the displacement length of the phase transition boundary of the “coal-gas” medium has been developed, taking into account the change in the combustion face temperature along the gasification zone length depending on the duration of this process. Application of the methodology makes it possible to predict the time of mining the gasified coal column for drawing up a calendar plan for mining operations.

A Review of Comprehensive Guidelines for Computational Fluid Dynamics (CFD) Validation in Solar Chimney Power Plants: Methodology and Manzanares Prototype Case Study

This review provides a comprehensive examination of CFD modeling procedures for SCPP, with an emphasis on the detailed methodologies and a case study of the Manzanares prototype in Spain. The introduction delineates the historical context and physical modeling principles of solar chimneys, while highlighting their potential in industrial applications. The governing equations are meticulously discussed, covering assumptions in both 2D and 3D CFD modeling, the continuity and momentum equations, and the selection and accuracy of turbulence models, particularly the k-ε equations. The review also delves into heat transfer modeling, encompassing the energy equation and radiation modeling. Analytical evaluations of turbine pressure drop ratios and performance metrics for power generation efficiency are critically analyzed. The establishment of boundary conditions in solar chimney applications, including sky temperature assessments and distinctions between 2D and 3D boundary conditions, is extensively explored. Mesh generation techniques for both 2D and 3D CFD models are presented, supported by case studies. Parametric studies and experimental investigations are scrutinized to elucidate their impact on the performance of solar chimneys. The temperature–entropy diagram for an idealized Brayton cycle is introduced as a conceptual framework for efficiency analysis. Validation of the CFD codes, both 2D and 3D, against experimental data is performed to ensure model accuracy. The review further examines energy balance approaches in modeling solar chimneys, presenting state-of-the-art CFD results and discussing their implications in both 2D and 3D contexts. The synthesis of these findings culminates in a comprehensive conclusion, offering insights into the future directions and potential advancements in the CFD modeling of solar chimneys. This work aims to serve as a definitive reference for researchers and practitioners in the field, providing a robust foundation for the development and optimization of SCPP technology.

Modeling the interaction between powder particles and laser heat sources

This study investigates the spheroidization of titanium Ti-6Al-4V powder particles using numerical models developed in Abaqus and OpenFOAM. Spherical particles are crucial in powder-based additive manufacturing due to their superior flowability, packing density, and mechanical properties, enhancing printing precision and the quality of final products. While conventional techniques such as gas atomization and plasma spheroidization have been extensively researched, the potential of laser spheroidization remains underexplored. To address this gap, detailed numerical analyses of laser spheroidization were conducted, modeling heat transfer from the laser to powder particles using a transient uncoupled heat transfer method with latent heat considerations, while particle deformation was simulated with a phase-fraction-based interface-capturing approach integrated with Navier-Stokes equations. The results, validated against analytical models, indicate that particles within the 20–80 μm range experience optimal spheroidization within a 0.005-second residence time under laser heating, with particles smaller than 30 μm reaching evaporation temperatures of 5,000°C, while larger particles reshape without evaporating under a typical heat flux of 94 MW/m2 (1.8 kW laser power). This study demonstrates that laser spheroidization of Ti-6Al-4V powder can potentially increase powder yield by 10%, offering higher power density and shorter melting times compared to plasma spheroidization, thus presenting a more efficient alternative for achieving spherical particles of specific sizes.

Optimizing cold storage for uniform airflow and temperature distribution in apple preservation using CFD simulation

Apples are preserved in cold storage within standard size crates to avoid injury during handling and are stacked in a specific manner to promote adequate air circulation. This research builds an air flow and heat transfer model of a cold room (5.75 m × 3.83 m × 3.75 m) with apple filled crates (0.55 m × 0.37 m × 0.3 m) modeled as a porous media and uses CFD simulation to study how alternate stacking impacts airflow distribution and product temperature. The conventional arrangement of crates, termed CS1, was simulated, and the resulting temperature distribution data were used to validate the model with published experimental data, a root mean square error of 1.13 °C indicates good match. The model is extended to examine temperature distribution for two additional arrangements of crates (CS2 and CS3) with changed orientations and spacing, in accordance with a specific strategy. CS3, featuring larger spacing along the z-direction, showed higher average air velocity compared to CS2 and CS1 by 7.4% and 3.7% respectively. CS3 also improved cooling rate by 25.2% and increased the number of chilled crates by 20% within 40 h, along with a reduced temperature heterogeneity (3.59 °C). The model could predict hot spots in various stacking configurations, aiding in optimal arrangement.

Innovative passive techniques and PCM integration in building envelopes for enhanced energy efficiency in desert regions

Rising energy demands in buildings for heating, cooling and operating appliances underscore the importance of implementing energy-efficient solutions. Passive cooling techniques provide a sustainable alternative to conventional, energy-intensive cooling systems, promising reduced energy consumption in buildings. Using a dynamic heat transfer model validated with ANSYS Fluent, this study examined three configurations: integrating phase change materials at the brick's centerline with cavities filled with air, EPS insulation, and emissivity coating. Additionally, the benefits of combining all three passive methods were evaluated. Results indicated that among the evaluated PCMs, capric acid demonstrated superior performance. While each passive method studied offers distinct advantages in enhancing thermal performance and achieving energy efficiency, assessing their combined effects revealed significant insights. Specifically, integrating capric acid at the brick's centerline, while simultaneously configuring EPS insulation in the upper cavities and emissivity coating in the lower cavities, yielded superior performance. This configuration significantly reduced inner surface temperature by approximately 6.6 °C and minimized heat flux by about 58.4 % compared to traditional bricks. Achieving energy savings of 56.24 %, this configuration shows potential to enhance both thermal comfort and energy efficiency in building applications.

Study on the effect of variable laser power on residual stress distribution in laser directed energy deposition of Ti6Al4V

In the laser directed energy deposition (LDED) process, cyclic thermal stress loading induces significant temperature variations on the surface and subsurface of the workpiece during repeated heating, leading to the formation of residual tensile stress during cooling. This adversely affects the mechanical properties of the parts, causing deformation and defects. In this study, a heat transfer model and a three-dimensional stress model were established based on finite element analysis. A variable laser power (VLP) deposition strategy was proposed to dynamically simulate the temperature and stress fields of Ti6Al4V titanium alloy under different deposition strategies. The model was validated by collecting substrate temperature variations using thermocouples and measuring residual stress with an X-ray diffractometer (XRD). Experimental results showed that the temperature error between the simulation and the experiment ranged from 6.25 % to 10.12 %, with an average stress simulation error of 6.92 %. Among the four strategies, the samples using the VLP strategy showed a reduction in the average substrate temperature by 12.68 % to 15.08 % compared to the other three strategies. The maximum principal stress in the layer was reduced by 7.8 % to 32.14 %, and the residual stress distribution was more uniform in all directions. The microstructure of the deposition layer further indicated that the VLP strategy improves residual stress distribution and leading to better deposition quality.

Modelling of cracking during beam oscillation laser welding of a creep-resistant nickel alloy

During high power laser welding of Inconel 740H, horizontal solidification cracks form at locations between approximately 70–80% of the weld depth. With the integration of circular beam oscillation, the laser energy density distribution and underlying thermo-mechanical conditions were altered. By coupling three-dimensional heat transfer, fluid flow, and stress modelling tools, the role that circular beam oscillation plays in the formation of the strain rates and stresses driving this cracking phenomenon was identified. While the addition of a circular oscillation pattern appeared to lower the stress levels along the solidification front, it did not eliminate the appearance of horizontal cracking. Only when the beam amplitudes reached 1.6 mm did solidification cracking disappear, but the weld depths were also significantly reduced.

Particle resolved DNS and URANS simulations of turbulent heat transfer in packed structures

An accurate prediction of turbulent heat transfer in packed-bed reactors is fundamental for the design and performance of such reactors. Various classes of Reynolds-Averaged Navier-Stokes models are available in the literature for predicting turbulent heat transfer via closing the Reynolds stress and Turbulent Heat Flux terms. In this work, we investigate the accuracy of representative unsteady RANS turbulence models in modeling heat transfer characteristics in packed-bed reactors. For this accuracy assessment, the performance of the examined unsteady RANS models is compared with particle-resolved Direct Numerical Simulations including heat transfer. The simulations are conducted in a three dimensional periodic domain consisting of randomly arranged cylindrical particles for Reynolds number Rep=1000. The extracted mean quantities (e.g. velocity and temperature), turbulent heat flux components and turbulent kinetic energy are used as a reference for the RANS models' accuracy assessment. The SST k−ω and Spalart-Allmaras models performed well in predicting mean fields. However, all models tended to mispredicted the turbulent quantities including the turbulent viscosity and heat flux vector. The thermal field calculations rely on the turbulent viscosity based Simple Gradient Diffusion Hypothesis for modeling turbulent heat flux, which introduce challenges in capturing the coupling between thermal and turbulent fields.

The effect of non-uniform skelp temperature on X70 steel coil cooling

This study explored the effect of varying steel skelp temperature (500 °C–600 °C) on the subsequent temperature-time ( T- t) profile during and after coiling of low C (0.05 wt. %) X70 microalloyed steels. Three industrially produced steel coils with similar rough rolling temperatures (∼1050 °C) and finish rolling temperatures (∼850 °C) but different coiling temperatures (500 °C–600 °C) and different skelp thicknesses (19 mm and 25 mm) were studied. The surface temperature of each coil was measured using an infrared video camera. A three-dimensional heat transfer model was developed to predict the T- t profiles. A lower (∼60 °C) initial skelp temperature near the head and tail of the skelp led to a reduced coil temperature. A higher (∼50 °C) temperature near the head and tail region of the skelp resulted in a more uniform coil temperature (a difference of ∼10 °C instead of ∼50 °C).

Thermal resistance capacity model for transient simulation of capillary-box heat exchangers

In this paper, a novel simplified hybrid model is developed to simulate the transient thermal behaviors of capillary-box heat exchangers (CBHEs) buried in the seabed, serving as the front-end heat exchangers in seawater source heat pump system (SWHPs). The thermal resistance and capacity (TRC) approach is applied for derivation of the governing equations inside and outside the heat exchangers. Also, an analytical solution is integrated to model heat transfer in the seabed base. The effects of seawater seepage on the thermal performance of CBHEs are taken into account in the present model. The state-space representation is used to solve the governing equations. The model is verified against experimental data, achieving very good agreement with the mean bias error (MBE) of 7.2 %. A comparison with a three-dimensional computational fluid dynamic (CFD) model indicates that the TRC model's maximum relative error and MBE are 0.7 % and 2.0 % lower than those of the CFD model. Additionally, the ratio of the time required by the CFD and TRC models for a 31-day run was 138. These results demonstrate that the TRC model is sufficiently accurate and fast in the thermal simulation of CBHEs. Furthermore, the thermal properties of CBHEs are examined using the present model. The model in this study provides practical implications for heat transfer analysis and design improvement of CBHEs utilized in SWHPs.

New generalized expressions for forced convective heat transfer coefficients across the flat plate

This study presents a novel generalized model for forced convective heat transfer coefficients (CHTC) over flat plates, addressing key limitations in existing models. Current expressions often provide averaged values and fail to capture the local variations in heat transfer, leading to inaccuracies, particularly in transitional zones. Moreover, there is no consensus on boundary layer classifications, which further complicates the development of reliable CHTC models. To address these issues, we conduct extensive CFD simulations to systematically analyze the combined effects of plate length (L), wind velocity (v), position along the plate (x), and temperature difference (Δt) on local CHTC. The simulations span a wide range of conditions (0.25 m ≤ L ≤ 8 m, 3 m/s ≤ v ≤ 25 m/s, and 5 °C ≤ Δt ≤ 80 °C), creating a comprehensive database of local CHTC values. Based on this data, a new generalized CHTC expression is derived as a function of L, v, x, and Δt, accurately predicting CHTC across laminar, transitional, and turbulent zones of flat plats. The accuracy of proposed CHTC expression is verified through thorough in-sample and out-of-sample evaluations, achieving R2 values between 0.973 and 0.999, with maximum deviations ranging from 2.6 % to 8.5 %. These research methods and conclusions can provide valuable references for optimizing thermal processes in applications such as industrial heat exchangers, electronics cooling, and building heating systems, where precise heat transfer modeling is critical for enhancing efficiency and system design.

Modeling of turbulent flows through annuli with smooth and rough walls; drag reduction and heat transfer

A model of a turbulent flow in an annular channel with rough walls is developed. An effect of roughness on hydraulic resistance of the channel is accounted for through the formal dimensionless negative velocity shift at the wall by using an empirical function linking this velocity shift to the dimensionless sandgrain wall roughness. The developed annular flow model is validated by experimental data found in literature for both smooth walls, both rough walls, smooth outer wall and rough inner wall as well as vice versa. The same flow model is applied also to a polymer solution turbulent flow in annular channel with hydraulically smooth walls. A turbulent drag reduction effect, observed in this case, is accounted for by a positive velocity shift at the wall determined for a certain drag reduction chemical from experiments in a round cross-section pipe. Also, an engineering approach for modeling heat transfer through either outer or inner wall of an annular channel with rough walls is suggested. This approach is based on the known analogy of heat transfer in a hydraulically smooth annular channel and a pipe. This analogy is extended to an annular channel with rough walls by using the developed flow model. The heat transfer model developed is validated, discussed and illustrated by calculation examples. Key attention is paid to analyzing an effect of the Reynolds number on both a Nusselt number increase and an efficiency change for different wall roughening cases.

Development of a Single Vial Mass Flow Rate Monitor to Assess Pharmaceutical Freeze Drying Heterogeneity.

During pharmaceutical lyophilization processes, inter-vial drying heterogeneity remains a significant obstacle. Due to differences in heat and mass transfer based on vial position within the freeze drier, edge vials freeze differently, are typically warmer and dry faster than center vials. This vial position-dependent heterogeneity within the freeze dryer leads to tradeoffs during process development. During primary drying, process developers must be careful to avoid shelf temperatures that would result in overheating of edge vials causing the product sublimation interface temperature to rise above the critical (collapse) temperature. However, at lower shelf temperatures, center vials require longer to complete primary drying, risking collapse or melt-back due to incomplete drying. Both situations may result in poor product quality affecting drug stability, activity, and reconstitution times. We present a new approach for monitoring vial location-specific water vapor mass flow based on Tunable Diode Laser Absorption Spectroscopy (TDLAS). The single vial monitor enables measurement of the gas flow velocity, water vapor temperature, and gas concentration from the sublimating ice, enabling the calculation of the mass flow rate which can be used in combination with a heat and mass transfer model to determine vial heat transfer coefficients and product resistance to drying. These parameters can in turn be used for robust and rapid process development and control.

Device Model for a Solid‐State Barocaloric Refrigerator

Solid‐state refrigeration represents a promising alternative to vapor compression cooling systems. Solid‐state devices based on magnetocaloric, electrocaloric, and elastocaloric effects have demonstrated the ability to achieve high‐efficiency, reliable, and environment‐friendly refrigeration. Cooling devices based on the barocaloric (BC) effect—entropy change due to applied hydrostatic pressure, however, has not yet been realized despite the significant promise shown in material‐level studies. As a step toward demonstrating a practical cooling system, this work presents a thermodynamic and heat transfer model for a BC refrigerator The model simulates transient thermal transport within the solid refrigerant and heat exchange with hot and cold thermal reservoirs during reversed Brayton refrigeration cycle operation. The model is used to evaluate the specific cooling power (SCP) and coefficient of performance (COP) of the device comprising nitrile butadiene rubber (NBR) as a representative BC refrigerant. Experimentally validated BC properties of NBR are used to quantify the contribution of different operating parameters including cycle frequency, applied pressure, operating temperatures, and heat transfer coefficient. The results show that a BC refrigerator operating with a temperature span of 2.4 K and 0.1 GPa applied pressure can achieve an SCP of 0.024 W g−1 at 10 mHz cycle frequency and a COP as high as 5.5 at 1 mHz cycle frequency—exceeding that of conventional vapor compression refrigerators. In addition, to identify key refrigerant properties, the effect of bulk modulus, thermal expansion coefficient, heat capacity, and thermal conductivity on device performance are quantified. The results highlight the trade‐off between different material properties to maximize the BC response, while minimizing mechanical work and improving thermal transport. This work demonstrates the promise of solid‐state cooling devices based on soft BC materials and provides a framework to quantify its performance at the device‐level.

Research and clearance analysis on of steam twin-screw expander employed in indutrial waste heat recovery

In actual factories, screw expanders frequently operate under partial loads.To address the lack of theoretical research and the risks of errors in engineering design associated with steam pressure differential power generation under these conditions,a simulation of the twin-screw expander's working process was developed. The rotor profile was designed, geometric variables such as rotor mesh clearance were calculated, and models for leakage and heat transfer were established. A suction pressure correction model was proposed for the suction process under partial loads, along with correction parameters to simplify simulations.Experimental results demonstrate that the twin-screw expander operates stably under highly fluctuating conditions, demonstrating excellent variable load performance.As the load decreases, the loss of suction pressure reduces the expander's pressure differential, leading to lower leakage and improved efficiency. When the load is reduced from 100 % to 65 %, the volumetric efficiency increases from 78.87 % to 84.76 %, and the isentropic efficiency rises from 66.81 % to 74.25 %.Compared to experimental data, the flow calculation error of the suction pressure correction model presented in this study is controlled within 3 %.This model addresses performance calculations under partial loads, ensuring that theoretical models better align with real-world applications and supporting accurate selection of twin-screw expanders.This model enables appropriate selection of expanders to reduce pressure losses and enhance economic efficiency.

Thermal performance of pipe-type energy piles with open-ended heat exchange tubes

This paper examines the thermal performance of pipe-type energy piles with open-ended heat exchange tubes (abbreviation as: open-tube energy pile). This study compares the thermal performance of U-tube energy piles with open-tube energy piles through model testing. The analysis focused on heat exchange efficiency, temperature changes at inlet and outlet points, and the piles’ and surrounding soil’s temperature response characteristics. An analytical model using Laplace transform was developed for the open-tube energy pile, with simulations conducted to analyze it at full scale. Results indicate that, under the same cases, the open-tube energy pile exhibits higher heat exchange efficiency than the U-tube energy pile. Additionally, the pile and surrounding soil show more pronounced temperature responses during testing with the open-tube configuration. Compared to existing models, the heat transfer model proposed in this paper is more suitable for analyzing the heat transfer of open-tube energy pile. Moreover, changes in the thermophysical properties of the pipe pile and soil will have different effects on the heat transfer between the pile and the soil.

Comparison of interfacial injected energy between simulated lightning return stroke experiment and common Joule heat & Arc heat model application

A previous study has shown that the thermal damage of the Joule thermal arc heat transfer model is lighter than that of a natural lightning strike. Therefore, this paper focuses on the return stroke current and proposes an improved experimental method of simulated return damage without using arc-inducing wire. Combining the data with the inversion model of injected energy, the energy transfer characteristics of the samples are characterized. Furthermore, a data dimensionality reduction method based on multiple correlation coefficients is used to discuss the impact of the current peak/rise rate/wave tail time on the injected energy discrepancy. The results indicate a positive correlation between the current peak and current rise rate with the injected energy discrepancy. When the tail time exceeds 15 microseconds, the injected energy discrepancy decreases as the tail time increases. The thermal source characteristics of energy transfer during the return stroke process are determined. During the initial phase of the return stroke current, interfacial energy transfer includes contributions from ion enthalpy flux, Joule heating, and electronic enthalpy flux. When the tail time exceeds 15 microseconds, the contribution of ion enthalpy flux to the injected energy diminishes with increasing tail time.