Plate fin-tube heat exchangers are widely used in air conditioning and refrigeration systems and other industry fields. Various errors made in the manufacturing process can result in the formation of an air gap between the tube and fin. Several numerical simulations were carried out for a symmetric section of plate fin-tube heat exchanger to study the influence of air gap on heat transfer under periodic flow conditions. Different locations and sizes of an air gap spanning 1/2 circumference of the tube were considered for the range of airflow velocities. Velocity and temperature fields for cases with air gap were compared with ideal thermal contact cases. Blocking of heat flow by the gap leads to the reduction of heat transfer rate. Fin discontinuity in the front of the tube causes the smallest reduction of the heat transfer rate in comparison to the ideal tube-fin contact, especially for thin slits. The rear gap position is the worst in the smallest gap range. Therefore, reversing the flow direction can lead to up to a 15% heat transfer increase, if mainly the rear gaps are present. The introduction of a thin slit in the front of the tube leads to convective heat transfer enhancement, which should be further investigated.
The present study is devoted to the modeling, design, and experimental study of a heat pipe heat exchanger utilized as a recuperator in small air conditioning systems (airflow ≈ 300–500 m3/h), comprised of individually finned heat pipes. A thermal heat pipe heat exchanger model was developed, based on available correlations. Based on the previous experimental works of authors, refrigerant R404A was recognized as the best working fluid with a 20% heat pipe filling ratio. An engineering analysis of parametric calculations performed with the aid of the computational model concluded 20 rows of finned heat pipes in the staggered arrangement as a guarantee of stable heat exchanger effectiveness ≈ 60%. The optimization of the overall cost function by the “brute-force” method has backed up the choice of the best heat exchanger parameters. The 0.05 m traversal (finned pipes in contact with each other) and 0.062 m longitudinal distance were optimized to maximize effectiveness (up to 66%) and minimize pressure drop (less than 150 Pa). The designed heat exchanger was constructed and tested on the experimental rig. The experimental data yielded a good level of agreement with the model—relative difference within 10%.
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