Rotary Heat Exchanger, Effect of Mass Flow Rate CFD Simulation

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  • The problem numerically simulates a Rotary Heat Exchanger, Effect of Mass Flow Rate on heat transfer coefficient in ANSYS Fluent software.
  • The 2D geometry of the model is created in Design Modeler software.
  • The model is meshed in ANSYS Meshing creating  86,598 elements.
  • The Standard k-epsilon model is used to describe turbulency of the flow.
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Description

Rotary Heat Exchanger, Effect of Mass Flow Rate on Heat Transfer Coefficient CFD Simulation, ANSYS Fluent

Description

In this project, the simulation of a 2D rotary heat exchanger is performed. The rotary heat exchanger, also known as a rotary regenerator, is a type of heat recovery system that recovers heat from a hot gas stream. This equipment is commonly used in various industries, including power generation and HVAC systems, to improve energy efficiency. The simulation model developed here aims to provide an accurate representation of the thermal performance of a 2D rotary heat exchanger. The model is based on fundamental principles of heat transfer and fluid dynamics, and it can be used to predict the performance of the exchanger under various operating conditions.
The geometry of the heat exchanger is designed in Design Modeler software. The model consists of 2 regions. One is dedicated to the hot fluid and the other one is designed for the cold one. Next, the model is meshed in ANSYS Meshing software. A structured grid is generated and the total number of elements is 86,598.

Methodology

The aim of the study is to study the effect of mass flow rate on the heat transfer coefficient. Four different mass flows are studied including 0.02, 0.04, 0.06 and 0.08 kg/s. The hot Co2 with 700°C temperature flows into the hot domain and on the other side, cold water vapor with 30°C flows. Due to symmetrical physics, only half of the heat exchanger is modeled and instead, the axisymmetric boundary type is used. The rod inside is rotating with a constant rotational velocity of 100rpm. Also The Standard k-epsilon model is used to describe turbulence of the flow.

Conclusion

After the simulation process, velocity and temperature contours are extracted. In order to study the effect of mass flow rate on heat transfer, heat transfer coefficient is reported in each case. The following table represents the correlation between mass flow and heat transfer. As the data indicates, even though the mass flow rate increases linearly, the heat transfer demonstrates non-linear behavior.

Mass Flow Rate(kg/s) h (W/m2.K) Changes(%)
0.02 33.7
0.04 90.1 167.35905
0.06 155.6 72.6970033
0.08 224.6 44.344473

 

Reviews

  1. Avatar Of Lonzo Wisoky

    Lonzo Wisoky

    I really appreciated how the mass flow rate’s effect on the heat transfer coefficient was highlighted. The non-linear relationship insights were particularly valuable for understanding the complex behavior of heat transfer in a rotary heat exchanger.

    • Avatar Of Mr Cfd Support

      MR CFD Support

      We are pleased to read that you found the effect of the mass flow rate on the heat transfer coefficient insightful. It is great to know that the data provided useful information on the complex heat transfer characteristics of the rotary heat exchanger. Thank you for your positive comment!

  2. Avatar Of Porter Collier

    Porter Collier

    The simulation helped me understand the performance complexities of rotary heat exchangers. Could you explain how changing the mass flow rate impacts the heat transfer coefficient significantly and causes a non-linear relationship, as shown in the results?

    • Avatar Of Mr Cfd Support

      MR CFD Support

      In the simulation, as mass flow rate increases, more mass carries heat through the exchanger per unit time, which enhances the overall heat transfer. However, this relationship is non-linear due to several factors such as fluid properties, flow turbulence and the heat exchanger’s geometric characteristics. As flow rate increases, turbulence generally increases, which can improve heat transfer. But this relationship is complex due to mixed convective heat transfer mechanisms and possible changes in the boundary layer thickness affecting overall heat transfer.

  3. Avatar Of Korey Moore

    Korey Moore

    I am thrilled with the clarity of the results from the simulation! Especially how the correlation between mass flow and heat transfer coefficient was non-linear, which was unexpected. It goes to show the dynamism in heat exchange systems.

    • Avatar Of Mr Cfd Support

      MR CFD Support

      Thank you for your feedback! We appreciate the time you have taken to compliment our simulation. It’s great to hear that the results met your expectations and provided you with clear insights into the thermal dynamics of the heat exchanger. If you have any further questions or need more information, don’t hesitate to reach out.

  4. Avatar Of Sebastian Weimann

    Sebastian Weimann

    The analysis of how mass flow rate affects the heat transfer is fascinating. Could you please explain why the relationship between mass flow rate and heat transfer coefficient isn’t linear?

    • Avatar Of Mr Cfd Support

      MR CFD Support

      The relationship between mass flow rate and heat transfer coefficient is not linear due to the complexity of the heat transfer mechanisms involved in the process. As the mass flow rate increases, the ability of the fluid to absorb or transfer heat changes, and this interplay of variables leads to a non-linear response. Additionally, factors such as turbulence, flow velocity, and temperature gradients can dramatically influence the heat transfer coefficient, contributing to its non-linear behavior.

  5. Avatar Of Andreanne Kshlerin

    Andreanne Kshlerin

    I’ve gone through the project on the 2D rotary heat exchanger simulation, and I am really impressed with the detail in results! I’m curious though, how is turbulence affecting the heat transfer at different mass flow rates?

    • Avatar Of Mr Cfd Support

      MR CFD Support

      Hello and thank you for your positive feedback! The turbulence in the flow plays a significant role in enhancing the heat transfer process by promoting mixing of the fluid particles. As the mass flow rate increases, the turbulent kinetic energy increases, which assists in disturbing the thermal boundary layer, thereby improving the convective heat transfer. This correlates with the increase in the heat transfer coefficient as the mass flow rate rises. Additionally, the use of the Standard k-epsilon model in the simulation accounts for the average effects of turbulence, providing a more reliable approximation for these changes in the heat transfer coefficient at different mass flow rates.

  6. Avatar Of Prof. Erika Stracke

    Prof. Erika Stracke

    I was impressed with how the influence of varying mass flow rates on heat transfer was explored. The detailed methodology and specific rapid rotation incorporated in the simulation made it interesting. Could you explain the reason behind the observed non-linear relationship between mass flow rate and the heat transfer coefficient?

    • Avatar Of Mr Cfd Support

      MR CFD Support

      The non-linear relationship between mass flow rate and heat transfer coefficient is due to the complex interplay between increased fluid velocity energizing the boundary layer and accelerating convective heat transfer, and the limits imposed by the thermophysical properties of the fluids as flow rates change. As mass flow rate increases, the convective heat transfer coefficient initially rises due to enhanced mixing and higher Reynolds number, but this relationship is not simply proportional as other factors such as turbulence and boundary layer characteristics dominate at different flow regimes, leading to the non-linear trend observed in the simulation findings.

  7. Avatar Of Zion Crooks

    Zion Crooks

    I’ve been curious about the rotary heat exchanger after going through the CFD simulation. Could you provide some clarity on why the heat transfer coefficient doesn’t increase linearly with mass flow rate?

    • Avatar Of Mr Cfd Support

      MR CFD Support

      The heat transfer coefficient doesn’t increase linearly with mass flow rate due to the complex relationship between flow properties and heat transfer dynamics. Factors such as turbulent mixing, flow velocity, and temperature gradients all influence heat transfer. As mass flow rate increases, each of these factors is affected differently, leading to a non-linear relationship between mass flow rate and heat transfer coefficient.

  8. Avatar Of Marlene Bednar

    Marlene Bednar

    The simulation really helped me comprehend the relationship between mass flow rate and heat transfer coefficient. But I’m curious, how is the rotational velocity of 100rpm applied to the model inside ANSYS Fluent, and does it affect the turbulence model settings?

    • Avatar Of Mr Cfd Support

      MR CFD Support

      The rotational velocity of 100rpm is applied within ANSYS Fluent using a moving reference frame or by defining a rotating wall boundary condition. Indeed, this setting can affect turbulence in the analysis. By specifying the rotational speed of the rod, the solver adjusts the velocity field calculations accordingly. The turbulence model settings, like the k-epsilon model used here, include empirical constants that account for rotational effects, ensuring that predictions of turbulence-driven transfer phenomena remain accurate, even in spinning applications. The rotation influences the formation of local turbulent structures and, consequently, the heat transfer between the fluids and the rotating parts of the heat exchanger.

  9. Avatar Of Junius Reichert

    Junius Reichert

    The project review was fantastic! I’m highly impressed by the detailed analysis performed on the rotary heat exchanger and the effects of varying mass flow rates. It really highlights the practical application of CFD in optimizing such critical components in the industry. The simulated correlation between mass flow and heat transfer is particularly valuable; it provides a clear understanding of the system’s efficiency based on real operational changes.

    • Avatar Of Mr Cfd Support

      MR CFD Support

      Thank you so much for your positive feedback! We are pleased to hear that our CFD simulation met your expectations and provided insightful data for your understanding of the rotary heat exchanger. It’s great to know that the detailed report on heat transfer variabilities with respect to mass flow rates was helpful. We always strive to offer practical and clear CFD analyses to support industry professionals in optimizing their designs and processes. Your satisfaction is our main goal!

  10. Avatar Of Mr. Dino Fahey Jr.

    Mr. Dino Fahey Jr.

    I was very intrigued by the clear relationship between mass flow rate and heat transfer coefficient shown in the results. What applications would particularly benefit from understanding this correlation in a rotary heat exchanger context?

    • Avatar Of Mr Cfd Support

      MR CFD Support

      Industries such as power generation, waste heat recovery systems, and HVAC systems can greatly benefit from understanding the correlation between mass flow rate and heat transfer coefficient. These insights enable optimizing energy efficiency and performance in these systems.

  11. Avatar Of Erin Predovic

    Erin Predovic

    The product seems highly detailed and precise, but I’m curious about the numerical settings for achieving convergence. Can you please provide insight into the convergence criteria and relaxation factors used in these simulations?

    • Avatar Of Mr Cfd Support

      MR CFD Support

      The convergence criteria typically aim for the residual value for all the equations below 1E-3, which is a common benchmark ensuring the solution’s stability and accuracy. The specific relaxation factors are adjusted towards more conservative values for complex simulations, possibly around 0.3 to 0.7 range, to ensure steady convergence without fluctuations caused by rapid changes in the computational domain. Exact values might vary based on the simulation requirements and are gauged through trial runs.

  12. Avatar Of Mrs. Mariam Murray

    Mrs. Mariam Murray

    Wow, impressive report on the rotary heat exchanger! The level of detail in the simulation methodology is greatly appreciated. Testing varying mass flow rates to analyze the thermal efficiency could definitely aid in optimizing HVAC systems.

    • Avatar Of Mr Cfd Support

      MR CFD Support

      Thank you for your kind words! We’re thrilled you found the report on the rotary heat exchanger simulation insightful. It’s always our goal to provide an in-depth analysis that can help improve energy efficiency in real-world applications. We appreciate you taking the time to review our product!

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