Effects of Fin Parameters on Gas-Side Heat Transfer Performance of H-Type Finned Tube Bundle in a Waste Heat Recovery Boiler

Alfa Laval Aalborg Oy designs and manufactures waste heat recovery systems utilizing extended surfaces. The waste heat recovery boiler considered in this thesis is a water-tube boiler where exhaust gas is used as the convective heat transfer medium and water or steam flowing inside the tubes is subject to cross-flow. This thesis aims to contribute to the design of waste heat recovery boiler unit by developing a numerical model of the H-type finned tube bundle currently used by Alfa Laval Aalborg Oy to evaluate the gas-side heat transfer performance. The main objective is to identify weaknesses and potential areas of development in the current H-type finned tube design. In addition, numerical simulations for a total of 15 cases with varying geometric parameters are conducted to investigate the heat transfer and pressure drop performance dependent on H-type fin geometry. The investigated geometric parameters include fin width and height, fin spacing, and fin thickness. Comparison between single and double tube type configuration is also conducted. Based on the simulation results, the local heat transfer and flow behaviour of the H-type finned tube is presented including boundary layer development between the fins, the formation of recirculation zone behind the tubes, and the local variations of flow velocity and temperature within the tube bundle and on the fin surface. Moreover, an evaluation of the effects of various fin parameters on heat transfer and pressure drop performance of H-type finned tube bundle has been provided. It was concluded that from the studied parameters fin spacing and fin width had the most significant effect on tube bundle performance and the effect of fin thickness was the least important. Furthermore, the results suggested that the heat transfer performance would increase due to enhanced turbulence if the current double tube configuration is replaced with single tube configuration, but further investigation and experimental measurements are required in order to validate the results.

Computational fluid dynamics evaluation of liquid food thermal process in a brick shaped package

Food processes must ensure safety and high-quality products for a growing demand consumer creating the need for better knowledge of its unit operations. The Computational Fluid Dynamics (CFD) has been widely used for better understanding the food thermal processes, and it is one of the safest and most frequently used methods for food preservation. However, there is no single study in the literature describing thermal process of liquid foods in a brick shaped package. The present study evaluated such process and the influence of its orientation on the process lethality. It demonstrated the potential of using CFD to evaluate thermal processes of liquid foods and the importance of rheological characterization and convection in thermal processing of liquid foods. It also showed that packaging orientation does not result in different sterilization values during thermal process of the evaluated fluids in the brick shaped package.

Pyörivän palopään suunnittelu

Työssä suunniteltiin pienten kiinteistöjen keskuslämmityksen käyttöön kiinteää polttoainetta käyttävä palopää, jossa palopään pyörimisliike sekoittaa polttoainetta palamisen aikana. Polttoaineen sekoittamisella pyritään parantamaan palamisen hyötysuhdetta ja vähentämään haitallisia päästöjä. Laitteen suunnittelu toteutettiin systemaattista koneensuunnittelun metodia mukaillen. Työn aihe rajattiin koskemaan ainoastaan palopään mekaniikan suunnittelua ja mitoitusta. Suunnittelussa pyrittiin huomioimaan valmistusystävällisyys ja minimoimaan kustannukset. Laitteen suunnittelussa käytettiin SolidWorks 2014 – ohjelmaa.

Analysis of Phase Separator Design Criteria Using Computational Fluid Dynamics

Gravitational phase separation is a common unit operation found in most large-scale chemical processes. The need for phase separation can arise e.g. from product purification or protection of downstream equipment. In gravitational phase separation, the phases separate without the application of an external force. This is achieved in vessels where the flow velocity is lowered substantially compared to pipe flow. If the velocity is low enough, the denser phase settles towards the bottom of the vessel while the lighter phase rises. To find optimal configurations for gravitational phase separator vessels, several different geometrical and internal design features were evaluated based on simulations using OpenFOAM computational fluid dynamics (CFD) software. The studied features included inlet distributors, vessel dimensions, demister configurations and gas phase outlet configurations. Simulations were conducted as single phase steady state calculations. For comparison, additional simulations were performed as dynamic single and two-phase calculations. The steady state single phase calculations provided indications on preferred configurations for most above mentioned features. The results of the dynamic simulations supported the utilization of the computationally faster steady state model as a practical engineering tool. However, the two-phase model provides more truthful results especially with flows where a single phase does not determine the flow characteristics.

Design of traction transmission and suspension systems for an omni-directional mobile robot

This project aims to design and manufacture a mobile robot with two Universal Robot UR10 mainly used indoors. In order to obtain omni-directional maneuverability, the mobile robot is constructed with Mecanum wheels. The Mecanum wheel can move in any direction with a series of rollers attached to itself. These rollers are angled at 45º about the hub’s circumference. This type of wheels can be used in both driving and steering with their any-direction property. This paper is focused on the design of traction system and suspension system, and the velocity control of Mecanum wheels in the close-loop control system. The mechanical design includes selection of bearing housing, couplers which are act as connection between shafts, motor parts, and other needed components. The 3D design software SolidWorks is utilized to assemble all the components in order to get correct tolerance. The driving shaft is designed based on assembled structure via the software as well. The design of suspension system is to compensate the assembly error of Mecanum wheels to guarantee the stability of the robot. The control system of motor drivers is realized through the Robot Operating System (ROS) on Ubuntu Linux. The purpose of inverse kinematics is to obtain the relationship among the movements of all Mecanum wheels. Via programming and interacting with the computer, the robot could move with required speed and direction.

Höyryturbiinin ulosvirtauskanaviston kokeellinen tutkimus pienoismallilla

Diplomityössä tutkittiin höyryturbiinin ulosvirtauskanavistojen kokeellisia tutkimusmenetelmiä ja suoritettiin käytännön mittauksia Fortum Oyj:n Loviisan ydinvoimalaitoksen höyryturbiinien huuvan pienoismallilla. Kirjallisuusselvityksen perusteella todettiin, että pienoismallitutkimuksella on ollut keskeinen asema ulosvirtauskanavistojen suunnittelussa. Kokeellisten menetelmien perusongelmana on höyryturbiinin ulosvirtausolosuhteiden jäljitteleminen. Käytetyt mittausmenetelmät perustuvat pääosin tavanomaisiin paine- ja nopeusmittauksiin. Lisäainepartikkeleihin ja laser-valaisuun perustuva PIV (particle image velocimetry) todettiin lupaavaksi menetelmäksi ulosvirtauskanavistojen tutkimuksen saralla. Työn käytännön osuudessa tehtiin mittauksia mittasuhteessa 1:8 rakennetulle höyryturbiinin huuvan pienoismallille. Mittauksilla tutkittiin virtausta mallin sisääntulo- ja ulostulotasoissa. Lisäksi mitattiin staattisen paineen jakauma huuvan sisällä. Kokonaispainetta mittaava kiel-putki todettiin käytännölliseksi työkaluksi huuvan virtauskentän tutkimuksessa. Tuloksista käy hyvin ilmi huuvan ulostuloon syntyvien pyörteiden muodostuminen ja ulostulon epätasainen nopeusjakauma. Staattinen paine huuvan sisällä havaittiin epätasaisesti jakautuneeksi. Ulostulotason ja staattisen paineen mittauksilla saadut tulokset sopivat hyvin yhteen kirjallisuudesta löytyvien tutkimustulosten kanssa ja tukevat Loviisan ulosvirtauskanavistosta aiemmin tehtyjä CFD-simulointeja.

Dynamic modeling and simulation of the airflow cleaning device

The objective of the work is to study the flow behavior and to support the design of air cleaner by dynamic simulation.In a paper printing industry, it is necessary to monitor the quality of paper when the paper is being produced. During the production, the quality of the paper can be monitored by camera. Therefore, it is necessary to keep the camera lens clean as wood particles may fall from the paper and lie on the camera lens. In this work, the behavior of the air flow and effect of the airflow on the particles at different inlet angles are simulated. Geometries of a different inlet angles of single-channel and double-channel case were constructed using ANSYS CFD Software. All the simulations were performed in ANSYS Fluent. The simulation results of single-channel and double-channel case revealed significant differences in the behavior of the flow and the particle velocity. The main conclusion from this work are in following. 1) For the single channel case the best angle was 0 degree because in that case, the air flow can keep 60% of the particles away from the lens which would otherwise stay on lens. 2) For the double channel case, the best solution was found when the angle of the first inlet was 0 degree and the angle of second inlet was 45 degree . In that case, the airflow can keep 91% of particles away from the lens which would otherwise stay on lens.

Heat-transfer improvements in an axial-flux permanent-magnet synchronous machine

Axial-flux machines tend to have cooling difficulties since it is difficult to arrange continuous heat path between the stator stack and the frame. One important reason for this is that no shrink fitting of the stator is possible in an axial-flux machine. Using of liquid-cooled end shields does not alone solve this issue. Cooling of the rotor and the end windings may also be difficult at least in case of two-stator-single-rotor construction where air circulation in the rotor and in the end-winding areas may be difficult to arrange. If the rotor has significant losses air circulation via the rotor and behind the stator yokes should be arranged which, again, weakens the stator cooling. In this paper we study a novel way of using copper bars as extra heat transfer paths between the stator teeth and liquid cooling pools in the end shields. After this the end windings still suffer of low thermal conductivity and means for improving this by high-heat-conductance material was also studied. The design principle of each cooling system is presented in details. Thermal models based on Computational Fluid Dynamics (CFD) are used to analyse the temperature distribution in the machine. Measurement results are provided from different versions of the machine. The results show that significant improvements in the cooling can be gained by these steps.

A computational fluid dynamic study on the filtering mechanics in suspension feeding marine invertebrates

Les suspensivores ont la tâche importante de séparer les particules de l'eau. Bien qu'une grande gamme de morphologies existe pour les structures d'alimentation, elles sont pratiquement toutes constituées de rangées de cylindres qui interagissent avec leur environnement fluide. Le mécanisme de capture des particules utilisé dépend des contraintes morphologiques, des besoins énergétiques et des conditions d'écoulement. Comme nos objectifs étaient de comprendre ces relations, nous avons eu recours à des études de comparaison pour interpréter les tendances en nature et pour comprendre les conditions qui provoquent de nouveaux fonctionnements. Nous avons utilisé la dynamique des fluides numérique (computational fluid dynamics, CFD) pour créer des expériences contrôlées et pour simplifier les analyses. Notre première étude démontre que les coûts énergétiques associés au pompage dans les espaces petits sont élevés. De plus, le CFD suggère que les fentes branchiales des ptérobranches sont des structures rudimentaires, d'un ancêtre plus grande. Ce dernier point confirme l'hypothèse qu'un ver se nourrit par filtration tel que l'ancêtre des deuterostomes. Notre deuxième étude détermine la gamme du nombre de Reynolds number critique où la performance d'un filtre de balane change. Quand le Re est très bas, les différences morphologiques n'ont pas un grand effet sur le fonctionnement. Cependant, une pagaie devient une passoire lorsque le Re se trouve entre 1 et 3,5. Le CFD s’est dévoilé être un outil très utile qui a permis d’obtenir des détails sur les microfluides. Ces études montrent comment la morphologie et les dynamiques des fluides interagissent avec la mécanisme de capture ou de structures utilisées, ainsi que comment des petits changements de taille, de forme, ou de vitesse d'écoulement peuvent conduire à un nouveau fonctionnement.

Development of solar air heaters & thermal energy storage system for drying applications in food processing industries

In the present work, the author has designed and developed all types of solar air heaters called porous and nonporous collectors. The developed solar air heaters were subjected to different air mass flow rates in order to standardize the flow per unit area of the collector. Much attention was given to investigate the performance of the solar air heaters fitted with baffles. The output obtained from the experiments on pilot models, helped the installation of solar air heating system for industrial drying applications also. Apart from these, various types of solar dryers, for small and medium scale drying applications, were also built up. The feasibility of ‘latent heat thermal energy storage system’ based on Phase Change Material was also undertaken. The application of solar greenhouse for drying industrial effluent was analyzed in the present study and a solar greenhouse was developed. The effectiveness of Computational Fluid Dynamics (CFD) in the field of solar air heaters was also analyzed. The thesis is divided into eight chapters.

Numerical Simulation of Two-Part Underwater Towing System

The motion instability is an important issue that occurs during the operation of towed underwater vehicles (TUV), which considerably affects the accuracy of high precision acoustic instrumentations housed inside the same. Out of the various parameters responsible for this, the disturbances from the tow-ship are the most significant one. The present study focus on the motion dynamics of an underwater towing system with ship induced disturbances as the input. The study focus on an innovative system called two-part towing. The methodology involves numerical modeling of the tow system, which consists of modeling of the tow-cables and vehicles formulation. Previous study in this direction used a segmental approach for the modeling of the cable. Even though, the model was successful in predicting the heave response of the tow-body, instabilities were observed in the numerical solution. The present study devises a simple approach called lumped mass spring model (LMSM) for the cable formulation. In this work, the traditional LMSM has been modified in two ways. First, by implementing advanced time integration procedures and secondly, use of a modified beam model which uses only translational degrees of freedoms for solving beam equation. A number of time integration procedures, such as Euler, Houbolt, Newmark and HHT-α were implemented in the traditional LMSM and the strength and weakness of each scheme were numerically estimated. In most of the previous studies, hydrodynamic forces acting on the tow-system such as drag and lift etc. are approximated as analytical expression of velocities. This approach restricts these models to use simple cylindrical shaped towed bodies and may not be applicable modern tow systems which are diversed in shape and complexity. Hence, this particular study, hydrodynamic parameters such as drag and lift of the tow-system are estimated using CFD techniques. To achieve this, a RANS based CFD code has been developed. Further, a new convection interpolation scheme for CFD simulation, called BNCUS, which is blend of cell based and node based formulation, was proposed in the study and numerically tested. To account for the fact that simulation takes considerable time in solving fluid dynamic equations, a dedicated parallel computing setup has been developed. Two types of computational parallelisms are explored in the current study, viz; the model for shared memory processors and distributed memory processors. In the present study, shared memory model was used for structural dynamic analysis of towing system, distributed memory one was devised in solving fluid dynamic equations.

Untersuchungen zum thermisch induzierten Luftwechselpotential von Kippfenstern

Die sogenannte natürliche Lüftung - Lüftung infolge Temperatur- und Windeinfluss - über geöffnete Fenster und Türen ist im Wohnbereich noch immer die häufigste Form des Lüftens. Die Wirkung des Lüftens wird einerseits von den baulichen Gegebenheiten, z.B. der Fenstergröße, Öffnungsfläche und Laibungstiefe sowie andererseits durch den Nutzer, der z.B. eine Gardine oder Rollos anbringt, beeinflusst. Über den genauen Einfluss von verschiedenen Faktoren auf den Luftwechsel existieren zur Zeit noch keine gesicherten Erkenntnisse. Die Kenntnis des Luftwechsels ist jedoch für die Planung und Ausführung von Gebäuden in Hinblick auf das energiesparende Bauen sowie unter bauphysikalischen und hygienischen Aspekten wichtig. Der Einsatz von Dreh-Kippfenstern sowie das Lüften über die Kippstellung ist in Deutschland üblich, so dass die Bestimmung des Luftwechsels über Kippfenster von großem Interesse ist. Ziel dieser Arbeit ist es, den thermisch induzierten Luftwechsel über ein Kippfenster unter Berücksichtigung verschiedener Randbedingungen zu beschreiben. Hierbei werden Variationen der Kippweite, Laibungs- und Heizungsanordnung berücksichtigt. Die Arbeit gliedert sich in drei Teile: im ersten Teil werden messtechnische Untersuchungen durchgeführt, im zweiten Teil exemplarisch einige messtechnisch untersuchten Varianten mit CFD simuliert und im dritten Teil ein verbesserter Modellansatz zur Beschreibung des Luftwechsels aus den Messwerten abgeleitet. Die messtechnischen Untersuchungen bei einer Kippweite von 10 cm zeigen, dass bei dem Vorhandensein einer raumseitigen Laibung oder einem unterhalb des Fensters angeordneten Heizkörpers mit einer Reduktion des Volumenstroms von rund 20 Prozent gegenüber einem Fenster ohne Laibung bzw. ohne Heizkörper gerechnet werden muss. Die Kombination von raumseitiger Laibung und Heizung vermindert das Luftwechselpotential um ca. 40 Prozent. Simuliert wird die Variante ohne Laibung und ohne Heizung für die Kippweiten 6 cm und 10 cm. Die Ergebnisse der mit CFD simulierten Tracergas-Messung weisen für beide Kippweiten im Mittel rund 13 Prozent höhere Zuluftvolumenströme im Vergleich zu den Messwerten auf. Die eigenen Messdaten bilden die Grundlage für die Anpassung eines Rechenmodells. Werden vor Ort die lichte Fensterhöhe und -breite, die Kippweite, die Rahmen- und Laibungstiefe sowie die Abstände der Laibung zum Flügelrahmen gemessen, kann die Öffnungsfläche in Abhängigkeit von der Einbausituation bestimmt werden. Der Einfluss der Heizung - bei einer Anordnung unterhalb des Fensters - wird über den entsprechenden Cd-Wert berücksichtigt.

Numerische Untersuchungen zur Bewertung von Rührbehältern und Flotationsapparaten

Diese Arbeit behandelt die numerische Simulation von Rührbehältern und Flotationszellen mit Hilfe kommerzieller Software basierend auf einer Finite-Volumen-Methode. Ziel der Untersuchungen ist es, ein Verfahren zu entwickeln, das eine Beurteilung der Anlagen in Abhängigkeit verschiedener geometrischer und strömungsmechanischer Parameter ermöglicht und so unterstützend zur Prozessauslegung beiträgt. An zwei einfachen Geometrien (Strömungsrohr, Scheibenrührer) werden grundsätzliche Parameter und Fragestellungen erläutert, welche für die Simulation von Bedeutung sind und der Verifzierung des eingesetzten Programmpakets dienen. Die Betrachtung industriell eingesetzter Flotationsmaschinen erfolgt beispielhaft an zwei Anlagen mit unterschiedlichen Rotor-Stator-Systemen. Eine Modellzelle im Labormaßstab dient zur Berechnung der Verweilzeitverteilung und zur Charakterisierung wichtiger Einflussgrößen (Drehzahl, Volumenstrom, Durchströmungskonfiguration, Partikelmasse, Randbedingung). Die numerisch gewonnenen Ergebnisse werden dabei erfolgreich mit Experimenten validiert. Ein Flotationssegment in Originalgröße liefert weitere Ergebnisse zur Hydrodynamik. Die Berechnung wird stationär und transient vorgenommen, um die Bedeutung der Zeitabhängigkeit bewerten zu können. Damit ist ferner eine Aussage zum Einlaufverhalten der Strömung möglich, indem das Drehmoment am Rührer als Funktion der Zeit ausgewertet wird. Eine Bewertung erfolgt über die Bestimmung der Verweilzeitverteilung in Abhängigkeit verschiedener Strömungskonfigurationen.

Simultaneous Drying and Separation of Composite Agricultural Material for Hay Processing

In composite agricultural materials such as grass, tee, medicinal plants; leaves and stems have a different drying time. By this behavior, after leaving the dryer, the stems may have greater moisture content than desired, while the leaves one minor, which can cause either the appearance of fungi or the collapse of the over-dried material. Taking into account that a lot of grass is dehydrated in forced air dryers, especially rotary drum dryers, this research was developed in order to establish conditions enabling to make a separation of the components during the drying process in order to provide a homogeneous product at the end. For this, a rotary dryer consisting of three concentric cylinders and a circular sieve aligned with the more internal cylinder was proposed; so that, once material enters into the dryer in the area of the inner cylinder, stems pass through sieve to the middle and then continue towards the external cylinder, while the leaves continue by the inner cylinder. For this project, a mixture of Ryegrass and White Clover was used. The characteristics of the components of a mixture were: Drying Rate in thin layer and in rotation, Bulk density, Projected Area, Terminal velocity, weight/Area Ratio, Flux through Rotary sieve. Three drying temperatures; 40°C, 60° C and 80° C, and three rotation speeds; 10 rpm, 20 rpm and 40 rpm were evaluated. It was found that the differences in drying time are the less at 80 °C when the dryer rotates at 40 rpm. Above this speed, the material adheres to the walls of the dryer or sieve and does not flow. According to the measurements of terminal velocity of stems and leaves of the components of the mixture, the speed of the air should be less than 1.5 m s-1 in the inner drum for the leaves and less than 4.5 m s-1 in middle and outer drums for stems, in such way that only the rotational movement of the dryer moves the material and achieves a greater residence time. In other hand, the best rotary sieve separation efficiencies were achieved when the material is dry, but the results are good in all the moisture contents. The best rotary speed of sieve is within the critical rotational speed, i.e. 20 rpm. However, the rotational speed of the dryer, including the sieve in line with the inner cylinder should be 10 rpm or less in order to achieve the greatest residence times of the material inside the dryer and the best agitation through the use of lifting flights. With a finite element analysis of a dryer prototype, using an air flow allowing speeds of air already stated, I was found that the best performance occurs when, through a cover, air enters the dryer front of the Middle cylinder and when the inner cylinder is formed in its entirety through a sieve. This way, air flows in almost equal amounts by both the middle and external cylinders, while part of the air in the Middle cylinder passes through the sieve towards the inner cylinder. With this, leaves do not adhere to the sieve and flow along drier, thanks to the rotating movement of the drums and the showering caused by the lifting flights. In these conditions, the differences in drying time are reduced to 60 minutes, but the residence time is higher for the stems than for leaves, therefore the components of the mixture of grass run out of the dryer with the same desired moisture content.