In the last 50 years, the technology of rotary heat exchangers has not changed considerably. A reliable simulation can help improve the design of this technology. In this work, a simulation for rotary heat exchangers was developed and validated with multiple experimental data. This simulation takes an innovative approach based on locally calculated heat transfer coefficients and considers the entry region effect. This approach proved to be accurate since the average difference between the experimental results and the proposed model with a constant heat boundary condition is 0.1% and the maximum absolute deviation 1%. Experimental, as well as simulation results, indicate that lower empty tube gas velocity (1 m/s) and higher rotational speed (12 rpm) improve thermal efficiency compared to commonly used operating conditions. Additionally, a new model for predicting the local internal Nusselt number for sine ducts in the rotor channels is proposed, which considers the entry region effect.
Rotary heat exchangers have been widely used in paint shops, combustion power plants, and in heating, ventilation, and air conditioning systems in buildings. For these processes, many types of heat exchangers are available in the market: Tube-shell heat exchangers, plate heat exchangers, and rotary heat exchangers, among others. For the rotary heat exchangers, the problem is that there is no net present value method and lifecycle assessment method-based optimization found in the literature. In this work, we address this issue: An optimization is carried out with help of an empirically validated simulation model, a life-cycle assessment model, an economical assessment, and an optimization algorithm. The objective function of the optimization simultaneously considers economic and environmental aspects by using different CO2 pricing. Different CO2 pricing scenarios lead to different optimization results. The ambient air empty tube velocity va, 2.1 optimum was found at 1.2 m/s, which corresponds to a specific mass flow msp of 5.4 kg/(m2·h). For the wave angle β, the optimum was found in the range between 58° and 60°. For the wave height h* the optimum values were found to be between 2.64 mm and 2.77 mm. Finally, for the rotary heat exchanger length l, the optimum was found to be between 220 mm and 236 mm. The optimization results show that there is still potential for technical improvements in the design and operation of rotary heat exchangers. In general terms, we recommend that the optimized rotary heat exchanger should cause less pressure drop while resulting in similar heat recovery efficiency. This is because the life cycle assessment shows that the use phase for rotary heat exchangers has the biggest impact on greenhouse gases, specifically by saving on Scope 2 emissions.
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