Multi-scale and multi-physics analysis, design optimization, and experimental validation of heat exchangers utilizing high performance, non-round tubes

Journal Article · Fri Jul 08 00:00:00 EDT 2022 · Applied Thermal Engineering

DOI:https://doi.org/10.1016/j.applthermaleng.2022.118965· OSTI ID:2418602

Tancabel, James ^[1]; Aute, Vikrant ^[2]; Klein, Ellery ^[2]; Lee, Cheng-Yi ^[2]; Hwang, Yunho ^[2]; Ling, Jiazhen ^[2]; Muehlbauer, Jan ^[2]; Radermacher, Reinhard ^[2]

---

1. Univ. of Maryland, College Park, MD (United States); OSTI
2. Univ. of Maryland, College Park, MD (United States)

Air-to-refrigerant heat exchangers (HXs) are fundamental components in HVAC&R systems, and considerable research has been dedicated designing continually smaller, lighter, and more efficient HX designs. In recent years, researchers have leveraged advancements in Computational Fluid Dynamics (CFD), Finite Element Analysis (FEA), and optimization algorithms to consider primary tube shape and topology optimization to design highly compact, high performance HXs for a multitude of applications. In this research, we present a computationally efficient, comprehensive, multi-scale, and multi-physics analysis and optimization method for air-to-refrigerant HXs featuring automated CFD and FEA simulations and approximation-assisted optimization. This methodology was utilized to design HXs with shape-optimized, non-round tubes which outperform current state-of-the-art tube-fin HXs without compromising structural integrity. The optimal HXs were shown to deliver similar thermal performance to the baseline HXs while also achieving more than 20% reductions in airside pressure drop and core envelope volume and more than 30% reduction in internal volume. Comprehensive experimental validation of the optimization methodology was conducted through the testing of two prototypes in a standardized wind tunnel facility under multiple operating conditions. For prototype #1 under dry evaporator conditions, the predicted heat load agreed within ± 10% of measured values and the predicted airside pressure drop agreed within ± 30%, while for dehumidifying conditions, the predicted sensible and latent heat loads agreed within ± 10% and ± 20% of the measured values, respectively. For prototype #2, the predicted condenser heat load agreed within ± 3.0% of measured values, and the predicted airside pressure drop agreed within ± 27%. The acceptable agreement between simulation and experimental results for the present application highlights the flexibility of the novel optimization methodology to design next generation HXs with improved performance and reduced volume, weight, and environmental impact.

• Research Organization: Univ. of Maryland, College Park, MD (United States)
• Sponsoring Organization: USDOE Office of Energy Efficiency and Renewable Energy (EERE); USDOE Office of Energy Efficiency and Renewable Energy (EERE), Energy Efficiency Office. Building Technologies Office
• Grant/Contract Number: EE0008221
• OSTI ID: 2418602
• Alternate ID(s): OSTI ID: 1882749
• Journal Information: Applied Thermal Engineering, Journal Name: Applied Thermal Engineering Vol. 216; ISSN 1359-4311
• Publisher: Elsevier
• Country of Publication: United States
• Language: English

Related Subjects

42 ENGINEERING
Experimental validation
Heat exchanger
NURBS
Optimization
Shape optimization