Microchannel Heat Exchanger Research Articles

Research on large-scale microchannel heat exchangers in domestic heat pump air conditioning applications

Research on large-scale microchannel heat exchangers in domestic heat pump air conditioning applications

Effect of Channel Shape on Heat Transfer and Mechanical Properties of Supercritical CO2 Microchannel Heat Exchanger

The heat exchanger plays a key role in the S-CO2 power cycle of power generation systems based on waste heat and has a large impact on their cost control and compactness. In this paper, we take the channel shape of a microchannel heat exchanger as the research object and combine orthogonal tests and numerical simulation, taking the microchannel cross-section length/short-axis ratio, volume ratio and filling rate as independent variables, to numerically study multi-channel thermal–fluid–solid coupling and explore the effects of different microchannel cross-section length/short-axis ratios, volume ratios and filling rates on the thermal hydraulic and mechanical properties of the heat exchanger. The results show that a change in the channel volume ratio has a greater impact on the thermal hydraulic performance of the heat exchanger and that its heat transfer performance is only marginally affected by a change in the channel filling rate. Additionally, when other geometric parameters are kept to a certain level, the closer the shape of the channel is to a circle, the better its mechanical properties are. Within the range of permissible designs, a change in the channel volume ratio does not have an obvious impact on the mechanical properties of the microchannels, while the channel filling rate has the most significant impact. The most significant effect of the channel filling rate on the mechanical properties occurs through the channel volume ratio.

Dynamic response characteristics of microchannel evaporator in a mechanically pumped two-phase loop under hypergravity environment

The unique hypergravity environment and severe heat-dissipation requirements of modern fighter aircrafts pose serious challenges to the potential utilization of mechanically pumped two-phase loops (MPTLs), which are an efficient cooling technology. The microchannel evaporator is a key component of the MPTL system, and understanding its startup and operation characteristics is of great significance for design and optimization. In this context, an experimental MPTL system is built and fixed on a rotating platform, which is designed to generate hypergravity ranging from 0 g0 to 15.0 g0 (g0 = 9.8 m·s−2). The dynamic-response characteristics of the temperature, pressure, and flow rates during the startup and operation of the microchannel evaporator under various hypergravity conditions are investigated. The results indicate that different startup modes, namely gradual startup under low hypergravity and overshoot startup under high hypergravity, are achieved on the microchannel evaporator, even if the flow rate and heat flux are not changed, which is completely different from that under normal gravity. These two startup modes can be quantitatively recognized by two dimensionless numbers: the boiling number (Bo) and Froude number (Fr). A larger Bo or 1/Fr, which corresponds to a larger heat flux or hypergravity; both conditions contribute to the startup mode of the microchannel evaporator shifting from gradual to overshoot startup. During the operation of a microchannel evaporator, the competition between the elevated saturation temperature of the fluid and the induced Coriolis and centrifugal forces caused by hypergravity determines the wall-temperature variation of the evaporator. The dynamic wall temperature decreases under hypergravity below 2.5 g0, is stable with small fluctuations under hypergravity from 4.7 g0 to 7.5 g0, and increases for hypergravity larger than 11.0 g0.

Thermal performance of a two-pass microchannel evaporator

Microchannel evaporator is one of the key components in many thermal systems such as heat exchanger of HAVC and refrigeration system. The evaporation heat transfer performance of microchannel evaporator, which usually has many flow paths, is highly affected by the distribution of liquid flow that will seriously deteriorate the flow boiling performance due to the lack of liquid supply, local dryout, etc. In this study, a novel two-pass microchannel evaporator (L × W × H = 103 × 64 × 20 mm) is designed and fabricated. The width, height and length of each individual channel are 0.6, 1 and 65 mm, respectively. To significantly improve liquid redistribution after the first-pass, evenly distributed spacers with different diameter holes were placed in the connecting flow path. Additionally, the channel number ratio between the first and second pass plays an important role. Therefore, three different channel ratios of 1:1, 1:2, and 3:5 were selected in this study. The heat transfer and flow characteristics of the two-pass microchannel evaporator using working fluid HFE-7100 were experimentally studied for flow rate varying from 30 ml/min to 110 ml/min. The inlet subcooling keeps about 30 K. Also, visualization studies were conducted for the explanations. The experimental results indicate that the thermal performance is superior in microchannel evaporator with channel ratio of 1:2. By considering Reynolds number of each channel in the first pass, microchannel evaporator with channel ratio of 1:1 outperforms other two evaporators. Furthermore, the wall temperature uniformity of this evaporator is better than others. The achieved heat flux of 20 W/cm2 is much higher than the reported studies. The overall two-phase HTC of this microchannel evaporator is about 4.5 kW/m2K.

Numerical investigation on dynamic flow characteristics of methane condensation in microchannels

Microchannel condensers play an essential role in cryogenic two-phase heat management systems due to their efficient heat transfer characteristics. Thus, it is worth conducting an in-depth study on microscale condensation characteristics of cryogenic fluids. This paper delves into the flow condensation process of methane in microchannels. A two-dimensional transient model with high accuracy for cryogenic fluids has been developed by combining a self-defined program for the source term of the phase transition model. The model fully considers the boundary layer thickness and accurately explores the mesh accuracy. The complete condensation flow patterns are captured for various vapor quality, mass flux, and wall subcooling degrees. The injection flow is a unique flow regime for condensation in microchannels. The decrease in wall subcooling degree and increase in mass flux leads to the separation point at the neck of the injected flow moving towards the exit, while the annular flow region is expanding and the flow pattern transition is lagging. The mass flux improves the heat transfer coefficient more significantly at high vapor quality. During injection and bubble flow, the wall shear stress and local heat transfer coefficient are subject to bouncing and oscillations, which may induce fluctuations in the upstream annular flow. The prediction performance of six classical heat transfer correlations is evaluated. The results indicate that the Nie et al. correlation has the highest comprehensive prediction accuracy with MRD and MARD of -5.00 % and 15.83 %, respectively.

A Microchannel Heat Exchanger Produced From a Metal Matrix Composite by Hybrid Laser Powder Bed Fusion and Inkjet Printing

Abstract This paper explores the production of an oxide dispersion strengthened (ODS) 304L stainless steel microchannel heat exchanger (HX) using a hybrid additive manufacturing process of laser powder bed fusion and inkjet printing. The study investigates the capabilities and economics of the hybrid inkjet-laser powder bed fusion (LPBF) process and evaluates the dimensional accuracy, functionality, and mechanical properties of the resulting ODS alloy. The effectiveness and pressure drop of the ODS heat exchangers produced by the hybrid LPBF tool are also determined. Results show that the inkjet-doped samples have a lower mean channel height with higher standard deviation than samples produced by LPBF alone. This is attributed to greater absorption of laser energy for the powder coated with the oxide precursor. The economic analysis shows that the hybrid process has a potential for reducing the unit cost of the heat exchanger based on cost modeling assumptions.

Optimization of louver fin geometries for miniature microchannel condenser by Taguchi and CFD method

Optimization of louver fin geometries for miniature microchannel condenser by Taguchi and CFD method

A new paradigm in critical flow analysis: Combining Buckingham Pi theorem with neural network for improved predictions in microchannels

Critical flow phenomena are prevalent in many chemical engineering processes, such as microchannel heat exchangers, nuclear safety analysis, jet pump modeling, and industrial systems utilizing subcooled or two-phase pressurized fluids. Understanding the impact of various physical parameters on critical flow and accurately predicting critical flow mass flux is essential in these processes. This article collects extensive experimental data on subcooled water two-phase critical flow and supplements it with additional experimental data from actual micro-cracked channels, constructing a comprehensive benchmark database. The database covers an inlet pressure range of 1.82–16.29 MPa, an inlet subcooling range of 0.3–119.35 K, and a microchannel hydraulic diameter range of 0.09–2.2 mm. By integrating the classical Buckingham Pi theorem with a data-driven active subspace method, the dominant dimensionless numbers in subcooled water two-phase critical flow were identified, addressing some limitations of the Buckingham Pi theorem by ranking the influences of these dimensionless numbers. Based on these dominant dimensionless numbers, the impact of physical quantities on two-phase critical flow was accurately identified, leading to a concise predictive correlation for critical flow mass flux with a mean absolute percentage error of 20.3 % across 1071 experimental data points, outperforming commonly used critical flow models. Furthermore, leveraging the dominant dimensionless numbers improved existing model results, enhancing the Henry-Fauske model’s overall prediction accuracy from a mean absolute percentage error of 47.6 % to 17.8 %. This study outlines a promising path for discovering physical characteristics and mechanisms in data-driven critical flow, facilitating a deeper understanding of critical flow phenomena.

Numerical simulation and thermodynamic test analysis of plate heat exchanger based on topology optimization

Efficient heat transfer in PHEs relies on optimizing flow distribution to minimize thermal dead zones. Existing studies have predominantly focused on single-phase fluids as working media and employed density-based methods for structural optimization of microchannel heat exchangers at small scales. In this study, the Brinkman term from the porous media flow model is introduced in an innovative manner, along with the utilization of a material density interpolation model, which builds upon the density-based approach. A novel two-phase fluid topology optimization method is proposed, specifically tailored for large-scale PHE operating conditions, resulting in the successful design of a new PHE topology. To compare the performance of the two heat exchangers, finite element simulation, visualization experiments, and thermodynamic performance testing are conducted. The simulation results reveal that the heat transfer capacity of the topological PHE is 810 W with pressure drops of 18.8 kPa, while the dimple PHE exhibits heat transfer capacity of 652 W with pressure drops of 25.9 kPa. Compared to the dimple PHE, the topological PHE demonstrates 24.2 % improvement in heat transfer performance and 27.8 % reduction in pressure drop. The dimensionless comprehensive heat transfer coefficient (j/f) indicates that the overall performance of the topological PHE significantly surpasses that of the traditional PHE. Furthermore, the visualization experiment results demonstrate that the complex texture structure of the topological PHE effectively induces fluid motion, compelling the fluid to flow along the texture direction. This significantly mitigates the issue of uneven flow within the PHE, thus enhancing heat transfer efficiency. Specifically, the topological PHE exhibits inlet–outlet temperature difference of 10.3 °C and pressure drops of 11.2 kPa, while the dimple PHE shows inlet–outlet temperature difference of 6 °C and pressure drops of 12.9 kPa. The findings of this study provide guidance for future research endeavors aimed at evaluating potential solutions to advance heat transfer in PHEs and facilitate the implementation of thermal management strategies.

An Experimental Approach to Overcome the Fouling Issue in Micro Heat Exchangers

AbstractMicro heat exchangers improve heat and mass transfer compared to conventional heat exchangers, enabling more energy‐efficient applications. However, their sensitivity to fouling limits broader industrial application. This approach presents a combined investigation of fouling and cleaning in microscale heat exchangers using two test rigs. Individual sets of analysis methods are developed to improve the understanding of heat and mass transfer on the microscale. In addition to known methods, such as pressure loss analysis, newly developed and established image analysis techniques are used to monitor fouling and cleaning. Based on the presented methods, it is possible to predict the initial position of thermally induced fouling and to demonstrate the applicability of automated cleaning on the microscale.

Investigations on Microchannel Heat Exchanger using Numerical, Experimental, and ANN Techniques

Investigations on Microchannel Heat Exchanger using Numerical, Experimental, and ANN Techniques

IMPROVEMENT OF THE METHODOLOGY FOR CALCULATING THE HYDRODYNAMICS OF COILED HEAT EXCHANGERS FOR CRYOGENIC PLANTS OPERATING ON THE J-T CYCLE

The widespread use of cryogenic plants operating on the J-T (Joule-Thomson) cycle is associated with low operating costs, reliability, and long service life. One of the main elements of the plant is a recuperative heat exchanger made in the form of a single- or multi-layer coiled heat exchange surface. The ability to compensate for temperature and mechanical stresses due to the twisted design ensures long-term and trouble-free operation of the heat exchange equipment. The importance of determining the characteristics of the hydrodynamics of the flow of liquids or gases is primarily associated with a conscious choice of methods for solving heat and mass transfer problems, the use of certain methods of process intensification, and optimization of equipment design. The purpose of creating efficient equipment is to determine the maximum heat transfer rate at moderate values of hydraulic resistance. The analysis of known empirical dependencies does not provide a definitive answer regarding the development of a generalized methodology for calculating Hampson-type microheat exchangers used in cryogenic installations. The aim of this work is to improve the methodology for calculating the hydrodynamics of coiled heat exchangers by modifying the calculated correlations. This is possible by introducing appropriate corrections to them that take into account the influence of the geometric characteristics of the tube bundle on its resistance. The experimental study of hydrodynamic processes during forced gas convection in a coiled heat exchanger made it possible to establish the dependence of the Euler number Eu on the main geometric characteristics of the heat exchanger: the relative coil pitch, the gap between the heat exchanger tube and the outer and inner surfaces of the body. Based on the research results, the corrections in the dimensionless form eкр and eз, which are used to perform variational calculations of the structures of coiled heat exchangers located in annular channels, were determined in order to optimize their geometric characteristics. Bibl. 19, Fig. 5.

Performance of dual-row condenser using microplate and conventional folded multiport extruded tube: A prospective pilot study

Microchannel heat exchangers (MCHXs) are typically manufactured using multiport extruded tubes and serpentine louvered fins, which exhibit deficiencies in corrosion resistance. Tubes made of multilayered aluminum have been shown to improve the corrosion performance. This study explored the thermal–hydraulic performance of a novel microplate heat exchanger (MPHX) with a dual-row design that utilizes advanced materials such as multilayer aluminum through comparison with conventional folded MCHXs. The results indicate that the heat transfer rate of the dual-row MPHX was at most 30 % higher compared to that of conventional folded MCHX for the same frame size. However, heat transfer of the MPHX was approximately 10 % lower than that of the conventional folded MCHX for the same effective face area. Additionally, the conventional folded MCHX is highly sensitive to the installation orientation and flow configuration; it fails to function when installed vertically and in co-current flows owing to issues such as liquid blockage. Such phenomena were not observed in the dual-row MPHXs. On the refrigerant side, the MPHXs exhibited pressure drops that were three to four times higher than that of a conventional folded MCHX.

Quantification of two-phase flow in a microchannel heat exchanger header based on capacitance measurement

The two-phase distribution has always been one of the research focuses of microchannel heat exchangers, because the maldistribution could seriously affect the heat transfer performance. This paper developed a capacitive method to quantify the two-phase distribution of vapor-liquid flow in the aluminum header of a microchannel heat exchanger. A flexible capacitance sensor was used to quantify the two-phase distribution with R134a. The inlet mass fluxes vary from 17.47 kg m−2 s−1 to 52.42 kg m−2 s−1 and inlet vapor qualities range from 0.2 to 0.6. The normalized time-averaged capacitance signal was processed by a Gaussian function to obtain the mathematical expectation and the standard deviation. The local vapor quality in the header was solved for using a correlation derived from the pre-experiments. The distribution of local vapor quality showed that gases were concentrated upstream of the header, while liquids were concentrated in the middle and lower reaches. The local vapor quality reached a minimum and remained constant at 0.1 in the middle and lower reaches, unaffected by changes in inlet conditions. As the mass flux increased, both the local vapor quality maximum point and the minimum point in the header were shifted back toward the downstream. Additionally, the increase of mass flux caused the fluctuation of the standard deviation increased, which meant the stability of the flow decreased. The two-phase flow measurement technique based on flexible capacitance sensors proposed in this study realized the extension of the capacitive method from the experimental stage to the industrial application stage.

Experimental study of the two-phase flow distribution in helical-structured vertical headers

A vertical header is a crucial component of a microchannel heat exchanger that facilitates the distribution of the two phases of the refrigerant into horizontally aligned channels. Ensuring an even distribution of the refrigerant into the channels is imperative for achieving the designed optimal performance. Previous studies have indicated that the distribution characteristics of the vertical header are contingent upon the mass flow rate and geometric properties of the header. This study aims to investigate the distribution characteristics of two-phase flow resulting from structural modifications in the header, specifically by implementing a vertical header with a helical structure. Hence, an experimental device simulating a microchannel heat exchanger found in a commercial air conditioning system was employed. The distribution characteristics of the vertically oriented header with a helical structure were measured by varying the inlet conditions (mass flow rate: 50–100 kg h−1; vapor quality: 0.1–0.2). The measured distribution characteristics were compared with those obtained from a conventional straight vertical header possessing the same cross-sectional properties. The experimental findings demonstrated that the helical structure induced a distinctive flow pattern and facilitated the mixing of the two phases. Furthermore, this helical structure exhibited reduced inertial forces compared to the simple vertical header, leading to improved distribution performance.

Comparative Study of Straight and Venturi Channel Cross-Sections of Microchannel Heat Exchangers

Abstract This study provides extensive research on fluid flow and heat transfer for 4-layered ceramic-compact counterflow microchannel heat exchangers (CFMCHE) using CFD-ACE®, a computational fluid dynamics (CFD) package. The goal is to build and expand upon previous studies in this area to identify a more efficient channel shape for better performance of the microchannel cross-section through numerical analysis under the same operating conditions. To develop the methodology for numerical analysis, a three-dimensional (3D) computational model of the CFMCHE was developed and validated with published and experimentally tested results with a percentage difference in outlet temperatures of 3-5% for hot fluids and 6-12% for cold fluids across the entire design of experiments (DoEs). Microchannel heat exchangers (MCHEs) exhibit high heat transfer rates and area-to-volume ratios, making them suitable for industrial applications. In this study, various design options for channel cross sections in a venturi shape were assessed numerically using a validated methodology in a segmented venturi CFMCHE to enhance performance. The steady-state performance of the Venturi CFMCHE was compared to that of the straight CFMCHE baseline design under the same bucket volume, area, and operating conditions. It was found that the venturi CFMCHE showed a ∼4-9% improvement as compared to the straight CFMCHE, but same time the pumping power was also 15-40% under the same operating conditions.

An overview of conjugate heat transfer augmentation methods for thermal management and recent advancements in microchannel heat sink overall performance

Recent technological advancement creates high-dense circuits development which creates colossal cooling demand requirements. In the future, advanced technology and scientific applications need to balance heat fluxes beyond limitation that catalyse the research opportunities further to achieve cooling requirements. Conventional cooling equipment is inappropriate for extracting heat from microchips within the minimal surface area. Microchannel technology appeared as a next-generation heat exchanger for the given heat duty. In the classical case of accounting, micro-heat exchangers both axial and transverse wall conduction effects is usually neglected. However, from the year 2005 onwards, researchers identified conduction dominance at fluid velocity is zero zones at the interface, which created balance between conduction–convection currents, finally included axial wall/heat conduction effects to a general model. This present study made a comparative evaluation fluid flow, heat transfer characteristics, thermal performance (TP) based on geometrical parameters, substrate materials and discusses previous issues, and current issues-based future research directions. Till today, based on applications of microchannels in thermal management, several experimental and numerical investigations have been reported for further improvement in TP. However, many researchers are still trying to accomplish things over a long period. Therefore, an overview of previous studies is furnished in the present study to assist researchers in this area much useful for further improvement.

Exploring the influence of crystallization fouling on microscale heat exchangers through machine learning analysis

Crystallization deposition within micro-scale heat exchangers poses significant challenges to their efficiency and functionality, stemming from the accumulation of crystalline residues on heat transfer surfaces. This study employs advanced machine learning methodologies, including GRU, LSTM, RNN, and CNN models, to explore the underlying factors influencing micro heat exchanger performance. Through meticulous analysis of key parameters such as Reynolds number, sedimentation coefficient, flow rate, and channel dimensions, the study aims to delineate the foundational factors shaping heat exchanger performance at the microscopic level. Results reveal the exceptional accuracy of CNN model in forecasting experimental outcomes, surpassing 99% accuracy and demonstrating superior performance compared to traditional numerical methods. Temperature emerges as a pivotal determinant, profoundly influencing crystallization dynamics, with its intricate interplay with solute solubility elucidated through rigorous analysis. Furthermore, comparative assessment of training times highlights the CNN model’s efficiency, attributed to its specialized architecture suited for spatial data processing. This study provides valuable insights into the impact of crystallization deposition on microscale heat exchangers, showcasing the transformative potential of machine learning in optimizing heat exchanger performance and addressing operational challenges in industrial applications.

Optimized Model for Heat Transfer and Entropy Generation in Micro-Heat Exchanger Induced by Walls Injection Using Design of Experiments

The improvement of heat transfer in MEMS remains today a major challenge because its importance in many engineering applications and industry. The objective of this paper is to analyze heat transfer and irreversibility in micro flows. The case of heated horizontal microchannel filled with nanoliquid in the slip flow regime is investigated by means of the LBM method. The slip velocity and the temperature jump conditions are applied to lower and upper walls. The flow is induced by wall injection. The effects of quadratic combination of several design factors such as Reynolds number (Re), Knudsen number (Kn), volume fraction (Vf) and nanoparticles diameter (Dp) on heat transfer enhancement and volumetric entropy generation were reported and a polynomial regression for the interaction between these parameters is determinate based on response surface methodology.

Frosting characteristics of microchannel heat exchangers: Parametric studies and correlation development

Recently, microchannel heat exchangers (MCHX) have been widely used in heat pump systems due to their high surface-to-volume ratio and high efficiency of heat transfer. However, when the MCHX operates in frosting conditions, its performance is adversely affected. To study the frost formation and distribution characteristics of MCHX, a comprehensive parametric study was performed for the MCHX with a larger fin pitch. The effects of fin geometries and environmental parameters on the frosting characteristics of MCHX were studied. Fin height (Fh) can effectively inhibit frost formation, which is due to the increase of surface temperature with the increase of Fh. When Fh increased from 6.0 mm to 11.8 mm, the frost time increased by 30.5 %. However, the increase in Fh also brings the penalty of reduced heat transfer rate. The effect of fin depth (Fd) on frost formation performance is small because the frost is mainly deposited in the front part, resulting in the rear fin cannot work efficiently. Fin pitch (Fp) is the most significant structural parameter affecting frosting performance. When Fp increases from 1.6 mm to 4 mm, the frosting time increases by 4 times and frost mass increased by 2.2 times. This is because with the increase of Fp, the frost blocking in the front part can be effectively delayed, and the distribution uniformity of the frost layer is improved. Lower surface temperature and higher humidity ratio significantly promote frost formation and reduce the uniformity of frost distribution. When the inlet temperature is reduced from −5 °C to −8 °C, the frosting time is shortened by 2.15 times, and the frost mass is reduced by 55.7 %. When the relative humidity increases from 76 % to 92 %, the frosting time is shortened by 2.15 times, and the frost mass is reduced by 42.5 %. The air velocity has a minor impact on the growth rate of frost in the front part. However, as the air velocity increases, the uniformity of frost distribution is significantly improved. When the air velocity increased from 1.1 m s−1 to 2.2 m s−1, the mass of accumulated frost increased by 29.5 %. Furthermore, frost thickness and air-side heat transfer coefficient correlations were developed by testing 12 samples. The developed heat transfer coefficient correlation can accurately capture the changing trend of the j-factor. This study provides a fundamental understanding of the frosting characteristics of MCHX and can effectively guide the louvered fin optimization.