Fluid Mechanics & Aerodynamics

Fluid Mechanics & Aerodynamics

Increasing the Mechanical and Thermal Performance of Liquid-Gas Micro Heat Exchangers with Cosine-Shaped and NACA0012 Airfoil Wall Geometries and Fouling Reduction

Document Type : Original Article

Authors
mohsen rostami 1
Ahmadreza Rahmati 2
amirhamzeh farajollahi 3
Javad Deldarsheikhi 2
1 Assistant Professor, Imam Ali University, Tehran, Iran
2 Master's degree, Imam Ali University, Tehran, Iran
3 Associate Professor, Imam Ali University, Tehran, Iran
Abstract
The significance of employing micro- and nano-scale dimensions is increasingly recognized, with one key advantage being the reduction in overall radiator weight. Furthermore, utilizing micro-scale dimensions facilitates achieving higher heat transfer rates compared to conventional industrial scales, particularly in cooling processes involving liquid and gas fluids. This research primarily aims to investigate crucial dimensionless fluid flow parameters such as the friction factor and Nusselt number. These parameters are compared across various flow rates and geometries, ultimately identifying the geometry with the most favorable thermal performance. One approach to enhance heat transfer performance in microchannels involves novel geometries. In this study, a sinusoidal corrugated microchannel was employed. To improve heat transfer, geometric parameters such as wavelength, wave amplitude, and aperture height were investigated. Subsequently, this optimized geometry with misaligned walls was compared against both aligned-wall corrugated geometries and an airfoil-shaped geometry based on the NACA0012 profile. For the investigation, different geometries were initially designed using CATIA simulation software. Subsequently, they were analyzed using FLUENT software, employing numerical solution methods and applying the conservation equations for mass, momentum, and energy. The analysis assumes steady, laminar, and incompressible flow conditions. The dimensions of the microchannel are 0.3 mm x 20 mm x 310 mm. Water, as the working fluid, was introduced at various flow rates ranging from 1.5 to 9 cubic meters per hour, implemented as an equivalent velocity boundary condition. The outlet was subjected to a pressure outlet boundary condition, and the walls experienced a no-slip condition and convective heat transfer from the surrounding 300 K cold air. In the corrugated microchannel radiators examined in this study, heat transfer enhancement of 200% to 350% was achieved compared to mini-channel dimensions, along with a 58% weight reduction compared to a reference radiator. The airfoil-shaped geometry exhibited a 33% improvement in thermal performance compared to the aligned-wall geometry and a 49% improvement in fluid-dynamic performance compared to the misaligned corrugated geometry. Furthermore, a study of fouling, comparing average velocities at a distance of 150 micrometers near the microchannel wall, revealed values 6.6 times higher than those observed in the mini-channel walls.
Keywords
Microheat Exchanger
Performance Enhancement
Wavy Wall
Airfoil Wall
Fouling

Smiley face

[1]     Ghachem K, Aich W, Kolsi L. Computational analysis of hybrid nanofluid enhanced heat transfer in cross flow micro heat exchanger with rectangular wavy channels. Case Studies in Thermal Engineering.2020;24:100822. DOI:10.1016/j.csite.2020.100822
[2]     Zia Ullah Khan M, Younis Y.M, Akram N Akbar B, Rajput U.A, Bhutta R.A, Uddin E, Jamil M.A, García M´ arquez F.P, Zahid F.B. Investigation of heat transfer in wavy and dual wavy micro-channel heat sink using alumina nanoparticles. Case Studies in Thermal Engineering.2021;28:1011515. DOI: 10.1016/j.csite.2021.101515
[3]     Kumar Dey T, Saxena R, Gupta A. Analytical study of fluid flow and thermal characteristics of flow in micro channel heat sinks with working fluid as water and alumina & water nanofluid. Materials Today:Proceedings.2022;74:213-217. DOI:10.1016/j.matpr.2022.08.054
[4]     Hatami, M., Jafaryar, M., Zhou J., and Jing, D. Investigation of Engines Radiator Heat Recovery Using Different Shapes of Nanoparticles in H2O/(CH2OH)2 Based Nanofluids, International Journal of Hydrogen Energy.2017;42:10891. DOI:10.1016/j.ijhydene.2017.01.196
[5]     Esfe, M.H., Rostamian, H., Toghraie, D., Hekmatifar, M., and Khalil Abad, A.T. Numerical Study of Heat Transfer of U-Shaped Enclosure Containing Nanofluids in a Porous Medium Using Two-Phase Mixture Method , Case Studies in Thermal Engineering. 2022;38:102150. DOI:10.1016/j.csite.2022.102150
[6]     Elsaid, A.M. Experimental Study on the Heat Transfer Performance and Friction Factor Characteristics of Co3O4 and Al2O3 based H2O/(CH2OH)2 Nanofluids in a Vehicle Engine Radiator, International Communications in Heat and Mass Transfer. 2019;108:104263. DOI:10.1016/j.icheatmasstransfer.2019.05.009
[7]     Peyghambarzadeh, S.M., Hashemabadi, S.H., Hoseini, S.M., and Seifi Jamnani, M. Experimental study of Heat Transfer Enhancement Using Water/Ethylene Glycol Based Nanofluids as a New Coolant for Car Radiators, International Communications in Heat and Mass Transfer.2011;38:1283. DOI:10.1016/j.icheatmasstransfer.2011.07.001
[8]     Goudarzi, K. and H. Jamali, Heat Transfer Enhancement of Al2O3-EG Nanofluid in a Car Radiator with Wire Coil Inserts, Applied Thermal Engineering.2017;118:510. DOI:10.1016/j.applthermaleng.2017.03.016
[9]     Shah, A.P., and Gaurvadkar, A. Design and Development of Automotive Radiator for Better Cooling Efficiency, Materials Today: Proceedings.2022;72:1028. DOI:10.1016/j.matpr.2022.09.153
[10]  Incropera, DeWitt, Bergman, Lavine. Introduction to heat transfer. Fifth Edition.
[11]  Ismael T, Bu Yun S, Ulugbek F. Radiator heat dissipation performance. Electronics Cooling and Thermal Control. 2016;6:88. DOI:10.4236/jectc.2016.62008
[12]  [12] Shankara R.P, Banapurmath N.R, D’Souza A, Sajjan A.M, Ayachit N.H, Yunus Khan T.M, Badruddin I.A, Kamangar S. An insight into the performance of radiator system using ethylene glycol-water based graphene oxide nanofluids. Alexandria Engineering. 2021;61:5155. DOI:10.1016/j.aej.2021.10.037
[13]  Kumar A, Hasan M.A, Chand P. Heat transport in nanofluid coolant car radiator with louvered fins. Powder Technology.2020;376:631. DOI:10.1016/j.powtec.2020.08.047
[14]  Han C, Xin j, Han F, Bao S, Yang D, Li X. Study on the three-dimensional heat flow field of supercritical nitrogen in a micro-channel plate heat exchanger.Cryogenics.2022;126:103545. DOI:10.1016/j.cryogenics.2022.103545
[15]  He B, Li L, He G, Tian M, Zhang Y, Tong W, Jian Q, Yu X. Experimental study on heat transfer performance of micro-grooved I-shaped aluminum heat pipe for heat pipe heat exchangers. Applied Thermal Engineering.2024;253:123773. DOI:10.1016/j.applthermaleng.2024.123773
[16]  Wang L, Quan Z, Zhao Y, Yang M, Jing H. Heat transfer process analysis and performance research of micro heat pipe array applied for the thermal management of proton exchange membrane fuel cells. Applied Thermal Engineering.2023;219:119531. DOI:10.1016/j.applthermaleng.2022.119531
[17]  Jamil M.A, Yaqoob H, Imteyaz B, Ali H.M, Allahyar K, Goraya T.S, Shahzad M.W, Alkasmoul F. On design and analysis of a concentric tube micro fin heat exchanger for applications of tire pyrolysis lube oil cooling. International Communications in Heat and Mass Transfer.2023;146:106896. DOI:10.1016/j.icheatmasstransfer.2023.106896
[18]  Godi N.Y. Heat transfer augmentation in heat sink with fin-bars inserted in cooling channel. Results in Engineering.2024;23:102650. DOI:10.1016/j.rineng.2024.102650
[19]  Sakkay M, Ghandouri I.E, Maakoul A.E, Saadeddine S, Meziane M, Dani A. Enhancing heat transfer efficiency and entropy generation minimization in Micro-Channel Heat Sinks through pillar spacing and diameter optimization. International Journal of Heat and Fluid Flow.2024;108:109492. DOI:10.1016/j.ijheatfluidflow.2024.109492
[20]  Marseglia G, Giorgi M.G, Carvalho D.S, Pontes P, Souza R.R, Moreira A.L.N, Moita A.S. Experimental investigation on the effects of the geometry of microchannels based heat sinks on the flow boiling of HFE-7100. Applied Thermal Engineering.2024;236:121479. DOI:10.1016/j.applthermaleng.2023.121479
[21]  Ali N, Srivastava S, Haque I, Yadav J, Alam T, Siddiqui T.U, Siddiqui M.I.H, Cuce E. Heat dissipation and fluid flow in micro-channel heat sink equipped with semi-elliptical pin-fin structures: A numerical study. International Communications in Heat and Mass Transfer.2024;155:107492. DOI:10.1016/j.icheatmasstransfer.2024.107492
[22]  Acharya N. Magnetically driven MWCNT-Fe3O4-water hybrid nanofluidic transport through a micro-wavy channel: A novel MEMS design for drug delivery application. Materials Today Communications.2020;24:100822. DOI:10.1016/j.mtcomm.2023.107844
[23]  kumar V.A, Arivazhagan S, Balaji T. Experimental investigation of an automobile radiator using carbon based hybrid nano coolant. International Journal of Thermal Sciences.2023;193:108497. DOI:10.1016/j.ijthermalsci.2023.108497
[24]  Hajialibabaei M, Saghir M.Z, Dincer I, Bicer Y. Optimization of heat dissipation in novel design wavy channel heat sinks for better performance. Energy.2024;297:131155. DOI:10.1016/j.energy.2024.131155
[25]  Khoshvaght-Aliabadi M, Ghodrati P, Mortazavi H, Kang Y.T. Numerical analysis of heat transfer and flow characteristics of supercritical CO2-cooled wavy mini-channel heat sinks. Case Studies in Thermal Engineering.2023;226:120307. DOI: 10.1016/j.applthermaleng.2023.120307
[26]  Amiri H.A, Afsharpanah F, Moshafi S, Asiaei S. Thermal management of an asymmetrical wavy microchannel heat sink via Ag/water nanofluid. Case Studies in Thermal Engineering.2024;53:103857. DOI:10.1016/j.csite.2023.103857
[27]  Gibreel M, Zhang X, Elmouazen H. Enhancement of heat transfer and hydrogen fuel flow characteristics in a wavy cooling channel with secondary branch design. International Journal of Thermal Sciences.2023;193:108513. DOI:10.1016/j.ijthermalsci.2023.108513
[28]  Hajialibabaei M, Saghir M.Z, Dincer I, Bicer Y. Experimental and numerical study on heat transfer performance of wavy channel heat sink with varying channel heights. International Communications in Heat and Mass Transfer.2023;148:107044. DOI:10.1016/j.icheatmasstransfer.2023.107044
[29]  Gibreel M, Zhang X, Elmouazen H. Serpentine and furrowed wavy channels-based enhancement in heat transfer for a rocket engine chamber. International Journal of Thermal Sciences.2023;185:108074. DOI:10.1016/j.ijthermalsci.2022.108074
[30]  Kumar B.R, Vigneshwaran K, Antony D.A. CFD analysis of different radiator surfaces to optimize heat transfer coefficient. Materials Today: Proceedings.2022;68:2334-2341. DOI:10.1016/j.matpr.2022.09.045
[31]  Pourhammati S, Hossainpour S. Improving the hydrothermal characteristics of wavy microchannel heat sink by modification of wavelength and wave amplitude. International Communications in Heat and Mass Transfer.2022;130:105805. DOI:10.1016/j.icheatmasstransfer.2021.105805
[32]  Rostami M, Farajollahi A.H, Ghanbari M, Naderi A. Numerical Simulation of the Effect of Using a Finned Tube on the Thermal Efficiency of Heat Exchangers. Journal of Aerospace Mechanics.2022;18:53-76. DOI:20.1001.1.26455323.1401.18.1.4.2
[33]  WrightS.J, Dixon-Hardy D.W, Heggs P.J. Aircraft air conditioning heat exchangers and atmospheric fouling. Thermal Science and Engineering Progress.2018;7:184. DOI:10.1016/j.tsep.2018.06.007
[34]  Padmanabhan S, Reddy O.Y, Yadav K.V.A.K, Raja V.K.B, Palanikumar K. Heat transfer analysis of double tube heat exchanger with helical inserts. Materials Today: Proceedings.2021;46:3588. DOI:10.1016/j.matpr.2021.01.337
[35]  Pang L, Luo K, Yuan Y, Mao X, Fang Y. Thermal performance of helicopter air conditioning system with lube oil source (LOS) heat pump. Energy.2019;190:116446. DOI:10.1016/j.energy.2019.116446
[36]  Farajollahi A.H, Mokhtari A, Rostami M, Imani K, Salimi M. Numerical study of using perforated conical turbulators and added nanoparticles to enhance heat transfer performance in heat exchangers. Scientia Iranica. 2023; 30:1027. DOI:10.24200/sci.2022.59717.6394
[37]  Sarafraz M.M, Arjomandi M. Thermal performance analysis of a microchannel heat sink cooling with copper oxide-indium (CuO/In) nano-suspensions at high-temperatures. Applied Thermal Engineering.2018;137:700. DOI:10.1016/j.applthermaleng.2018.04.024
[38]  Zhao Y, Li G, Dang C, Wu H. Research on the thermal performance of the condenser in a loop heat pipe anti-icing system. Frontiers in Energy Research.2023;24:1306563. DOI:10.3389/fenrg.2023.1306563
[39]  Tang J, Xie Y, Wu H, Fang Z, Yu J, McCluskey D.  Experimental and numerical investigation on conjugate performance of fan and heat exchanger of helicopter oil cooling system. Thermal Science and Engineering Progress.2022;35:101472. DOI:10.1016/j.tsep.2022.101472
[40]  Khaled M, Elhage H, Elmarakbi A, Peerhossaini H, Harambat F. Aerothermal Management of Vehicle Heat Exchangers: Parametric Analysis. ASME 2013 Fluids Engineering.2013;11:16148. DOI:10.1115/FEDSM2013-16148
[41]  Faraj A, Faraj J, Harika E, Hachem F, Khaled M. Development of a new method for estimating the overall heat transfer coefficient of heat exchangers – Validation in automotive applications. Case Studies in Thermal Engineering.2021;28:101434. DOI:10.1016/j.csite.2021.101434
[42]  Farajollahi A.H, Yahyaabadi M.M, Pourseifi M. Numerical Investigation of Heat Transfer Enhancement in an Automotive Radiator Utilizing Mini-Channel Tubes and Tubes Configuration. Fluid mechanics and aerodynamics in imam hussein university.1401;11:37. DOR:https://dor.isc.ac/dor/20.1001.1.23223278.1401.11.2.4.8
[43]  Bejan, A., Convective Heat Transfer”, Fourth Edition ed. Unites States of America: Wiley, 2013.
Fluid Mechanics & Aerodynamics
Volume 14, Issue 1 - Serial Number 35
Spring and summer
September 2025
Pages 105-122

  • Receive Date 07 June 2025
  • Revise Date 21 July 2025
  • Accept Date 15 August 2025
  • Publish Date 23 August 2025