Numerical analysis of heat transfer and the optimisation of regenerators

To optimize a regenerator’s structure and its operation parameters and, consequently, to increase the efficiency of heat recovery and to save energy, a computational approach is used to study the unsteady three-dimensional flow and heat transfer. The simulation is performed in two steps. In the first step, the gas flow and heat transfer in a typical sphere-bed unit is simulated to deduce a dimensionless equation of heat transfer between gas and sphere. In the second step, a model is developed to simplify the prototype and to simulate the gas flow and heat transfer in the whole regenerator. The heat exchange process in regenerators and the effects of the regenerator’s structure and operation parameters, such as gas mass flux, reversal time, regenerator height, sphere diameter, and thermophysical properties of the spheres, are studied with the model to determine efficiency of heat recovery.

Suppression of natural convection heat transfer coefficients in an attic shaped enclosure

The use of convection suppression devices has been widely discussed in the literature as a means of reducing natural convection heat loss from enclosed spaces. In this study the use of a single baffle was examined as a possible low cost means of suppressing heat loss by natural convection in an attic shaped enclosure.

Recently the authors experimentally demonstrated that the natural convection heat transfer for an attic shaped enclosure with Grashof Numbers in the range of 107 to 109 [1] could be predicted using a correlation in the literature developed for Grashof Numbers in the range 105 and 106 [2]. However, in this study the impact of adding a single baffle to the enclosure was examined. It was found that the heat transfer coefficient changes with increasing baffle length, and can be predicted using a modified form of the correlation presented in [1], as shown in Eq. (1).

Particle dynamics and heat transfer at workpiece surface in heat treatment fluidised beds

The particle behaviour in a heat treatment fluidised bed was studied by the analysis of particle images taken with a high speed CCD digital video camera. The comparison of particle dynamics was performed for the fluidised beds without part, with single part and with multi-parts. The results show that there are significant differences in particle behaviours both in different beds and at different locations of part surfaces. The total and radiative heat transfer coefficients at different surfaces of a metallic part in a fluidised bed were measured by a heat transfer probe developed in the present work. The structure of the probe was optimized with numerical simulation of energy conservation for measuring the heat transfer coefficient of 150-600 W/m2K. The relationship between the particle dynamics and the heat transfer was analysed to form the basis for future more rational designs of fluidised beds as well as for improved quality control.

Investigations into hydrodynamics and heat transfer in vacuum fluidised beds.

Investigations into vacuum fluidised beds has improved understanding of heat transfer and hydrodynamics which will enable optimization of various industrial processes. Significant contributions were made in theoretical and experimental analysis.

Analytical thermal study on nonlinear fundamental heat transfer cases using a novel computational technique

In this paper a novel computational technique called Parameterized Perturbation Method (PPM) is used to obtain the solutions of nonlinear fundamental heat conduction equations. Three well known problems in the area of heat transfer are addressed to be solved. An analytical investigation is carried out for: (a) the temperature distribution in a fin with a temperature-dependent thermal conductivity, (b) the cooling of the lumped system with variable specific heat, and (c) the temperature distribution of a convective-radiative fin. The validity of the results of PPM solution was verified via comparison with numerical results obtained using a fourth order Runge-Kutta method. These comparisons revealed that PPM is a powerful approach for solving these problems. Also, the results showed that the main attributions of this method are very straightforward calculations and low computational burden compared to previous analytical and numerical approaches.

Numerical simulation of heat and mass transfer in fluidised bed heat treatment furnaces

In this paper, a novel combined theoretical and computational model is developed to simulate the heat and mass transfer between a fluidised bed and a workpiece surface, and within the workpiece by considering the fluidised bed as a medium consisting of a double-particle layer and an even porous layer. The heat and mass-transfer flux from the fluidised bed to the workpiece surface is contributed by dense and bubble phases, respectively. The convective heat and mass transfer is simulated by analysing the gas dynamics in the fluidised bed, while radiative heat transfer is modelled by simulating photon emission in a three-dimensional particle array. The simulation shows that convection is approximately constant, while radiation contributes significantly to the heat transfer. The heat-transfer coefficient on an immersed surface near particles is about 6–10 times that on other areas. The transient heat and mass-transfer coefficient, heat and mass-transfer flux on any surface of the workpiece, transient temperature and carbon distributions at any position of the workpiece during the metal carburising process are studied with the simulation.

Heat and mass transfer in fluidised-bed heat-treatment furnaces

The mechanisms of heat and mass transfers between heat-treatment fluidised beds and immersed workpiece were studied by using computational simulation and experimental validation. A model called Double Particle-layer and Porous Medium was developed to simulate the gas flow and heat transfer between fluidised beds and immersed workpiece.

Combustion simulations for a self controlling variable compression ratio connecting rod

Variable compression ratio enables an engine to achieve increased efficiency at part loads, where the majority of driving occurs, without sacrificing full load power requirements or increasing the risk of engine knock. Although over 100 patents and patent applications exist none of these systems has been commercialized yet due to issues related to feasibility, cost and frictional loss. A new approach of a self controlling variable compression ratio connecting rod is presented that does not need a friction intensive external activation and that could even be retrofitted. The potential in fuel consumption and exhaust emission reduction as well as increased power and torque output for this concept has been verified in combustion simulations utilizing the latest research results related to the dynamic heat transfer in the combustion chamber from Professor Kleinschmidt from the University of Siegen, Germany. The self controlling variable compression ratio connecting rod allows the con rod to compress at high load conditions thereby increasing cylinder volume to alleviate combustion pressures and temperatures and therefore limit knock onset. The biggest efficiency gains can be achieved at medium load where the reduction of heat loss during the compression of the connecting rod plays a major role additional to the well known efficiency gains of an increased compression ratio. The combustion simulation results shows fuel consumption can be reduced by between 3% and 5% during part load and wide open throttle operation at various engine speeds. Emissions are also reduced significantly; particularly NOx and CO emissions were reduced by up to 35%.The self controlling variable compression ratio connecting rod allows the con rod to compress at high load conditions thereby increasing cylinder volume to alleviate combustion pressures and temperatures and therefore limit knock onset. The biggest efficiency gains can be achieved at medium load where the reduction of heat loss during the compression of the connecting rod plays a major role additional to the well known efficiency gains of an increased compression ratio.The combustion simulation results shows fuel consumption can be reduced by between 3% and 5% during part load and wide open throttle operation at various engine speeds. Emissions are also reduced significantly; particularly NOx and CO emissions were reduced by up to 35%.

A novel exhaust heat recovery system to reduce fuel consumption

Internal combustion engines release about 1/3 of the energy bound in the fuel as exhaust waste gas energy and another 1/3 energy is wasted through heat transfer into the ambient. On the other hand losses through friction are the third largest root cause for energy loss in internal combustion engines. During city driving frictional losses can be of the same size as the effective work, and during cold start these losses are even bigger. Therefore it is obvious to utilise wasted exhaust energy to warm up the engine oil directly. Frictional losses of any engine can be reduced during part load. Sensitivity analyses have been conducted for different concepts that utilise exhaust energy to reduce engine viscosity and friction. For a new system with an exhaust gas/oil heat exchanger the following benefits have been demonstrated:

• Fuel consumption reductions of over 7% measured as an average over 5 NEDC tests
compared to the standard system configuration.
• Significant reductions in exhaust emissions, mainly CO and NOx have been achieved
• Significantly higher oil temperatures during cold start indicate large potential to
reduce engine wear through reduced water condensation in the crankcase
• Fuel consumption reductions of further 3.3% to 4.6% compared to the 7% measured
over the NEDC test can be expected under real world customer usage conditions at
lower ambient temperatures.

Oil temperature measurements and analysis resulted in the idea of a novel system with further potential to reduce fuel consumption. This Oil Viscosity Energy Recovery System (OVER 7™) consists of 3 key features that add significant synergies if combined in a certain way: an oil warm up circuit/bypass, including oil pressure control and Exhaust Gas/Oil Heat Exchanger. The system separates the thermal inertias of the oil in the engine galleries and the oil pan, reduces hydraulic pumping losses, increases the heat transfer from the cylinder head to the oil, and utilises the exhaust heat to reduce oil friction.

The project demonstrated that sensitivity analysis is an important tool for the evaluation of different concepts. Especially for new concepts that include transient heat transfer such a qualitative approach in combination with accurate experiments and measurements can be faster and more efficient in leading to the desired improvements compared to time consuming detailed simulations.